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OPERATION & SERVICE - Sunbelt Transport Refrigeration

1. J 1 Place the START RUN OFF switch to START RUN position MessageCenter 62 10683 3 2 MANUAL START GLOW AND CRANK IF EQUIPPED WARNING Under no circumstances should ether or any other starting aids be used to start engine O COOL DEFROST START STOP CON TINUOU 20 a BOX TEMPERATURE START RUN 1 Hold GLOW CRANK switch in the GLOW position GLOW CRANK q SS Back of Control 27 The GLOW CRANK switch was removed from units built after April 2007 When the micro powers up MANUAL START MODE SELECTED will appear in the MessageCenter and the Alarm LED will blink for five seconds If the GLOW CRANK switch is held in the GLOW position before the START RUN OFF switch is placed in the START RUN position when the START RUN OFF switch is in the START RUN position the unit Start mode is changed to MANUAL START and the unit operation mode is set to CONTINUOUS RUN When the engine is running this switch is disabled 62 10683 3 2 2 Place START RUN OFF switch to the START RUN position 3 Continue to hold GLOW CRANK switch in the GLOW position for up to 15 seconds 4 Then crank the engine by
2. D JIC AFAR ee Pos B 30 87 TO 5 1 F17 95 N ENG BLOCK GR S 3 3 3 3 3 3 3 3 3 3 3 3 3 FAC 5A SPK24 A B F3 7 SA T m F LEGEND mmm mMm mMm mMm mm mm TI mm AUTOFRESH AIR RELAY AUTO RESTART LIGHT HEAT LIGHT SV4 CONTROL SV1 CONTROL FUEL HEATER RELAY FAULT LIGHT OUT OF RANGE LIGHT DEFROST LIGHT COOL L BUZZE SV3 SV2 C UNLOADER 2 CONTROL UNLOADER CONTROL A B F2 10A e ENSCU 16 10 ak B RELAY POWER TO SPKSIB4 RU eO 1MP26 E4 30 87 MPQC8 HC8 Ome 00 107 o TTL m mom om omoamoamam IE 30 87 NN WN SP25 e TO N13 FH ENG BLOCK GRD ZONE NORMALLY CLOSED CONTACTS CH SYMBOL INDICATES MOMENTARY CONTACTS SPLICE PACK NORMALLY OPEN CONTACTS INDICATES A SOLDERED SPLICE POINT W N PIN CONNECTION INDICATES CONNECTION NDICATES A CHASSIS GROUND NO WIRE N COMPONENT CONNECTI
3. SSR F DISPLAY KEYPAD TO FLSC B y RE 5 23 B 209 RE 1 DS A TO HC9 MP P33 CONTROL BOX pad ULTIMA XTC AND ULTRA XTC P11 P22 csp P12 5MPA9 TO HC6 B3 5MPA10 856555 TO SMPA1 5MPA11 7 MPQCS TO 2MP25 E7 TO ENSCU 3 Re NNNNNNNNNNNNNND DDO ODD O O lt F6B B1 PAS P33 Pog P20 P32 LB G B F9 OUTPUT POWER rai gt 20 202 One E
4. NON ESC ENGINE Figure 9 1 Priming Fuel Pump 9 11 62 10683 9 7 SERVICING FUEL PUMP 9 7 1 Mechanical Pump See Figure 9 2 The fuel filter may become plugged or restricted with foreign particles or wax as a result of using the wrong grade of fuel or untreated fuel in cold weather This will cause the engine to lose capacity The filter must be cleaned on a regular schedule such as unit pre trip or when the oil and fuel filters are changed Refer to Section 9 1 1 Nut 2 Banjo 3 Filter 4 Copper Rings Figure 9 2 Mechanical Fuel Pump a Turn nut counter clockwise to loosen and remove nut Item 1 Figure 9 2 Use container to catch draining fuel b Remove banjo fitting Item 2 and let it hang loose c Turn filter Item 3 counter clockwise and remove Check and clean d Replace copper rings Item 4 e To install reverse above steps 62 10683 9 12 9 8 ENGINE SERVICE AND COMPONENTS 9 8 1 Cooling System flows through the condenser radiator The condenser radiator must be internally and externally clean for adequate cooling The water pump V belt must be adjusted periodically to provide maximum air flow Refer to Section 9 9 2 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
5. Cap Spring Gasket Stem Seat Body Figure 9 23 Discharge Check Valve Serviceable Prior to S N JAW90756460 gt 07 00457 00 Figure 9 24 Discharge Check Valve Non Serviceable Beginning With S N JAW90756460 Figure 9 25 Hot Gas Check Valve Non Serviceable 9 15 1To Service Check Valve See Figure 9 23 a Store the refrigerant in an evacuated container Refer to Section NO TAG a b Replace necessary parts c Evacuate and dehydrate unit Refer to Section NO TAG d Addrefrigerantcharge RefertoSectionNO TAG 9 15 2To Replace Check Valve See Figure 9 24 and Figure 9 25 a Store the refrigerant in an evacuated container Refer to Section NO TAG b Using a pipe cutter cut the valve stub outs and unsweatthe remaining stub outfrom the connect ing copper NOTE Inert brazing techniques MUST be followed during replacement of valves NOTE Place magnetic discharge check valve tool Carrier Transicold P N 07 00457 00 ontop ofdischargecheckvalve Figure 9 24 topull the plunger from the body seat c Replace valve d Evacuate and dehydrate unit Refer to Section NO TAG e Addrefrigerantcharge RefertoSectionNO TAG f Check unit operation by running Pretrip Refer to Section 3 4 9 16 CHECKING A
6. 3 G SEE NOTE 4 5 3 3 3 3 3 3 3 3 3 3 3 3 3 F4 7 SA A B F3C 5A R 5 B FSH A e F RESH AIR RELAY 5 Po FSP BE TART LIGHT z L rm T m F2 10A mm d ENCLS anc 2MP15 E6 B RELAY POWER TO SPKS 84 Ro eO IMP2GLE4 Sx SPK6 30 87 Tras 30 87 ons A e OO 0001 A NOUO MPQC8 HC8 0 040 lt lt NW gt FH ETE ETE Mm FTU FT FTU FTU FT TI TI TI UO TIT NN WN HC14 LOADER 1 CONTROL F8 FHR SP25 W AUTOFRESH ONLY V HC16 4 gt FH je A B 30 Is ENG BLOCK GRD 20A ZONE RMALLY CLOSED CONTACTS ITCH SYMBOL INDICATES MOMENTARY CONTACTS SPLICE PACK INDICATES A SOLDERED SPLICE POINT PIN CONNECTION DICATES CONNECTION INDICATES A CHASSIS GROUND NO WIRED RMALLY OPEN CONTACTS INDICATES A WIRE GROUND COMPONENT CONNECTION NUMBER OR LETTER OR c LTIPLE PLUG CONNECTION NUMBER INDICATES A
7. 6 20 6 7 ADVANCE MICROPROCESSOR REPLACEMENT amp CONFIGURATION SETUP 6 22 6 7 1 Microprocessor Replacement 0 eaa eaa eens 6 23 6 7 2 Microprocessor Setup 0 00 sh 6 24 6 7 8 Configurations Via Keypad 6 25 6 7 4 Functional Parameters via Keypad 6 25 6 7 5 DataRecorder Via ReeferManager PC Program 6 25 6 7 6 Engine And Switch on Hourmeters Via ReeferManager PC Program 6 26 6 7 7 Configuration IntelliSet PC Card cee 6 26 6 7 8 Microprocessor Final Checkout c cece ees 6 26 6 7 9 Replacing Display Bezel Assembly 6 27 nennt Me wrote ee Dee ees pene ea Se 7 1 7 1 MessageCenter MESSAGES 7 1 ALARM TROUBLESHOOTING nnn nn eee eee anh 8 1 8 1 INTRODUCTION TO ALARM TROUBLESHOOTING GUIDE 8 1 8 2 NOTES DA A 8 2 8 3 DRIVER OPERATOR ALARMS ssssssssssees esr 8 3 1 LOW FUEL LEVEL WARNING for units with Low Fuel Level 0 to 100 Sensor fuel level is displayed in Data list 8 3 1 LOW FUEL LEVEL WARNING for units with Low Fuel Level switch no fuel level display in Data list 8 4 LOW ENGINE OIL LEVER
8. 1 8 2 Clear the inactive alarms All alarms cleared 62 10683 8 112 SECTION 9 SERVICE PARAGRAPH NUMBER Page 9 1 MAINTENANCE SCHEDULE 0 0 0 cece 9 1 9 2 PRETRIPINSPECTION eect ete 9 4 9 3 GRILLE INSERT REMOVAL be eed ee ERRAT IEEE CE RERO I RS 9 8 9 4 SURROUND REMOVAL ERA RETE ER Pham Qed ee 9 9 9 5 DOORLATCH MAINTENANCE AND REPLACEMENT 9 10 9 6 PRIMING F ELE SYSTEM e Y eb EUER OPERARI Ria 9 11 9 7 SERVICING FUEL PUMP a 9 12 9 8 ENGINE SERVICE AND COMPONENTS 9 12 9 9 SERVICING AND ADJUSTING V BELTS 9 17 9 10 FANSHAFT ASSEMBLY Recte bln ead ete e As 9 21 9 11 THERMOSTATIC EXPANSION VALVE I ees 9 24 9 12 REPLACING THE COMPRESSOR n 9 28 9 13 CHECKING COMPRESSOR OIL LEVEL 9 30 9 14 COMPRESSOR UNLOADER VALVE 9 31 9 15 REPLACING OR SERVICING CHECK VALVE 9 32 9 16 CHECKING AND REPLACING FILTER DRIER 9 33 9 17 CHECKING AND REPLACING HIGH PRESSURE CUTOUT SWITCH HPS 9 33 9 18 COMPRESSOR DISCHARGE PRESSURE TRANSDUCER CDP 9 35 9 19 COMPRESSOR SUCTIO
9. 2 12 2 9 6 Piter Drier eet Pep eret Padded ORAL atre 2 13 2 9 7 RECCIVER i cos eese t Ree eee Ee UY et Y RAUS Y Rn 2 13 2 3 8 Compressor Transducers and Sensors 2 14 2 4 EVAPORATOR SECTION 2 14 2 4 1 Thermal Expansion Valve ssssseesseee e men 2 14 2 4 2 Heat Exchanger E puce Eod EET iad ies gabe EDUC PER gues 2 14 2 4 3 Evaporator Gale e bc s 2 14 2 4 4 Evaporator Transducers and Sensors 2 15 2 5 SYSTEM OPERATING CONTROLS AND COMPONENTS 2 15 2 5 1 Multiple Languages cee HH 2 15 2 5 2 Special EeatUres co cv ie seed ded een E lees 2 15 2 5 8 Component Description And Location 2 16 2 5 4 Handling of PC Cards 00 e 2 22 2 6 OPTIONS hors eee ek fae a adic ented T fer ege e vus 2 22 2 61 Eight Bal 24 oo e E ep EN EE Eu Dee eer 2 22 2 6 2 Door and Remote Switches 0 ccc cece 2 23 26 3 Range Alarm event GALa 2 24 2 4 ENGINE DATA Het A eC re e Rc ele ae 2 25 2 7 1 Lubrication Systemerne UE Ue PEG FEN 2 25 2 8 ENGINE SCREW THREADS cee nhe 2 26 2 9 ENGINE AIR SYSTEM meyer ba Re a Vinee can deen Baa es 2
10. LED been illuminated for Start Run Off switch second on and 1 2 second off more than 5 minutes off Remove the Program card and try again NO N y o Micro does ot recognize the card Try another Wait at least 5 minutes program card or use MicroProgrammer Figure 10 12 Micro Diagnostic Tree Cond 8 Programming Problems With PC Cards 10 21 62 10683 START HERE vgg Does the MessageCenter say Once 04 00 is installed into the micro it Are you trying to load any version of OLD SOFTWARE CANNOT s no longer possible to load any version software that is older than 04 00 00 LOAD of 03 or previous software Newer versions be loaded as released If NO NO loading 04 00 or 04 02 and the micro has 03 xx or previoius software incrementally upgrade the software Only MicroProgrammer version 3 14 is to be used to See Bulletin SERO4 47 for instructions properly install 04 00 00 and later software Earlier versions of MicroProgrammer should be discarded NO MicroProgrammer only runs on Windows 95 98 It will not run on Windows 2000 or XP Are you using version 3 14 on a Windows 95 98 machine Obtain MicroProgrammer 3 14 and Windows YES 95 98 for software installation When downloading with a cable make sure cable Did you find and correct the condition Did you find and connections are secure and tight Turn off all
11. D EMULATION REGULATOR D Emulation Orange Not Used on Advance 10 24 AC Terminal 10 24 Ground Screw 1 4 20 Positive Output Cable Figure 2 11 Alternator and Regulator RONA 2 11 62 10683 2 3 4 Compressor The compressor assembly includes the refrigerant com pressor suction and discharge service valves high pressure switch and the suction and discharge pres sure transducers The compressor draws refrigerant gas from the evaporator and delivers it to the condenser at an increased pressure The pressure is such that refrigerant heat can be absorbed by the surrounding air at ordinary temperatures 2 3 5 Compressor Unloaders The refrigeration compressor used is a 41 cfm model 05G equipped with unloaders as standard equipment Unloaders are used as a compressor capacity control to unload the compressor during periods of reduced loads This provides closer temperature control and reduces power required to operate the compressor thus reducing fuel consumption a Major Working Parts e Solenoid and valve system Spring loaded piston type bypass control valve Spring loaded discharge check valve Solenoid Valve Valve Stem Gas Bypass Port Spring Guide Spring Piston Piston Bypass Valve Bleed Orifice o Lied b Unloaded Operation Figure 2 12 Pressure from the discharge manifold Item 15 passes through the strainer 9 and bleed orifice 8 to the back
12. Check that Maintenance Hour Meter Reset Interval in Configuration list as required 4 interval is set for your requirements b Reset Maintenance Hour Meter 4 for Hour Meter is reset in the Functional Parameter list the next service interval Follow maintenance interval recommendations in Section 9 1 a See Note 1 Page 8 2 Clear the inactive alarms 8 105 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 230 SERVICE SOON PM 5 DUE TRIGGER ON The Maintenance Hour Meter 5 time has expired UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via keypad Check Unit Maintenance Records a Schedule unit into service facility for Must be done soon maintenance 2 Perform Maintenance BN Perform appropriate engine amp unit Follow instructions on proper maintenance form maintenance IN Maintenance Hour Meter 5 ame Check that Maintenance Hour Meter Reset Interval in Configuration list as required 5 interval is set for your requirements b Reset Maintenance Hour Meter 5 for Hour Meter is reset in the Functional Parameter list the next service interval Follow maintenance interval recommendations in Section 9 1 See Note 1 8 2 a Clear the inactive alarms All alarms cleared 62 10683 8 106 ANO Steps ALARM CAUSE CORRECTIVE ACTION 8 11 MICROPROCESSOR ALARMS 232 SETPOINT ERROR TRIGGER ON There is an
13. Replace ENSCU Did you find and correct the condition Check high speed mechanical stop on injection pump assembly for loose screws or tampering Are the screws loose ENSCU is not the fault YES Y Set proper high speed RPM per this manual Did you find and correct the condition YES Y System OK v v Check for proper internal mechanical operation of injection pump assembly and governor assembly Did you find and correct the condition Replace ENSSN Did you find and correct the condition NO YES NO Review results of above tests with your super visor If necessary go to the beginning of the table amp test again Remove new ENSSN and re install old ENSSN back into unit ENSSN is not the fault Review results of above tests with your supervisor If necessary go to the beginning of the table amp test again Figure 10 1 ESC Diagnostic Tree 1 Long 1 Short LED Code 10 9 62 10683 START HERE Verify unit starts go into i high speed and stall after running for a few seconds Using jumper wire verify there is at least 11 Check for high resistance or an Verify there is at least 11 open in the VDC going into the ENSSNG ground ENSSN 12 V terminal circuit Did you find and correct the condition
14. TIP When alarms are cleared from the Inactive Alarm list both active and inactive alarm lists are cleared If there is a safety shutdown UNIT SHUTDOWN SEE ALARM LIST will be shown Pressing the Alarm List key will bring any Active Alarms into the MessageCenter Refer to Section 8 fora complete list of Alarms and their descriptions NOTE The Inactive Alarm list is also called the Techni cians List Only qualified refrigeration techni cians should access the inactive list It is not in tended for the use of drivers or operators Table 3 1 Shutdown Alarms SHUTDOWN ALARMS SHUTDOWN ALARM ONLY or may be configured as SHUTDOWN see configuration list Section 6 2 1 i 12 13 15 16 17 18 19 20 Maximum Compressor Alarms Optional 27 28 29 30 3i 32 35 39 4 5 53 56 57 58 6i 72 122 123 204 232 233 237 238 242 243 246 248 249 MirprcesorEmr Z Oo lf Alarms 122 and 123 are both active and setpoint is in the perishable range 10 4 F 12 and higher the unit will shut down Otherwise alarm only 3 19 62 10683 3 14 UNIT DATA e e HEAT COOL DEFROST START STOP CONTINUOUS 20 45 F SETPOINT BOX TEMPERATURE PRESS 1 TO VIEW DATA 1 Press the SELECT key until the MessageCenter displays PRESS 1 TO VIEW DATA 2 By pressing the UP ARROW key you will move through the Data List beginning at
15. Turn the START RUN OFF switch to OFF and dis connect the negative battery cable Loosen the fan belt idler and remove upper drive belt Remove the top eight bolts four along top edge and two down each side that hold fan shroud to condens er frame Remove the three bolts that thread through the back of the clutch rotor pulley forward into the condenser fan hub Carefully remove the condenser fan and hub assembly from unit Placethe three pins of the spanner wrench CTD P N 07 00396 01 into the holes on the face of the clutch armature Place the tool handle between the fan shaft frame support and pod 10 o clock position to provide hands free anti rotation Loosen and remove the ar mature retaining bolt and washer NOTE The armature retaining bolt is a LEFT HAND THREAD BOLT Remove the clutch armature A standard 5 8 11 X 1 right hand thread bolt can be threaded through the center to jack the armature off the shaft if needed Use spanner socket CTD P N 07 00303 02 to re move the spanner nut that secures the clutch rotor NOTE The armature retaining bolt is a LEFT HAND NYLOCK THREAD BOLT h Slide the clutch rotor pulley off and remove If the rotor will not slide off easily remove the condenser fan hub adapter from the fan Place the adapter backwards against the fan shaft hub and thread three 5 16 18 X 2 3 4 long bolts from the back of the rotor forward into the hub adapter Tighten the bolts
16. lt S 2 27 62 10683 2 13 COMPONENT RESISTANCE AND CURRENT DRAW Table 2 8 Component Resistance and Current Draw Component Ohms SV1 7 8 x 0 3 Ohms 0 10 to 2 0 Amps SV2 and 4 10 6 0 3 Ohms 0 75 to 2 0 Amps AFAS Auto Fresh Air Pull in 0 36 Ohms 10 Pull in 29 Amps Solenoid Hold 14 4 Ohms 10 Hold 0 83 Amps Unloader 10 6 0 3 Ohms 1 0 to 2 0 Amps Clutch 2 5 0 2 Ohms 3 0 to 5 0 Amps Speed solenoid Units with 1 5 to 2 5 Ohms 3 0 8 0 Amps out ESC Fuel solenoid 11 1 Ohms to 13 4 Ohms 0 25 to 2 0 Amps Red Black wires White Black wires Can not be accurately measured with Coil 30 0 to 40 0 Amps Commander in circuit Engine Speed Sensor Units 22 mAmps Max with ESC 12VDC Relay 72 Ohms 10 0 14 0 18 Amps GPR SSR FHR 12VDC Relay 80 Ohms 15 0 12 0 17 Amps RCR Indicator lights 8 Light Bar 4 8 0 2 Ohms NA Only Compressor Suction Modu lation Valve Resistance 92 ohms 10 for any two windings 62 10683 2 28 2 14 REFRIGERANT CIRCUIT DURING COOLING See Figure 2 16 When cooling the unit operates as a vapor compression refrigeration system The main components of the system are the 1 reciprocating compressor 2 air cooled condenser 3 expansion valve and 4 direct expansion evaporator The compressor raises the pressure and the temperature of the refrigerant and forces it through the discharge check valve and into the conde
17. NSTRUCTIONS UNIT DAILY PRIOR TO OPERATION REMOVE ANY OREIGN MATERIAL ENSURE FACTORY LED ENCLOSURES AND PROTECTIVE EQUPMENT ARE PLACE AND IN WORKING CONDITION 62 11282 00 REV n 62 10683 1 6 p WARNING TP F PAN BLADES WARNING START AUTOMATICALLY 62 02509 00 REV A J puo CAUTION SYSTEM DO NOT REMOVE CAP WHEN HOT 62 10794 00 REV A DO NOT FILL BOTTLE ABOVE MAX LINE CAP AND SENSOR TO BE HAND TIGHTENED ONLY Ay CAUTION n ricrross TOP COOLANT INTO REMOVE RECOVERY BOTTLE ONLY FILL EMPTY FILLER CAP RADIATOR THROUGH FILLER NECK SLOWLY SLOWLY TO AVOID 62 02142 01 REV B AIR ENTRAPMENT 62 10683 SECTION 2 UNIT DESCRIPTION PARAGRAPH NUMBER Page 2 1 JINTRODUCTION keel beue a eiut 2 1 2 2 GENERAL DESCRIPTION 0 000 cece enhn 2 2 2 3 CONDENSING SECTION tice eae bal cay bole ste bale ee eb oe ile eee nee es 2 10 2 9 1 Condenser Goll icc ian aie ated Shaan Gade MN aed Fhe aed MEN 2 10 21312 scettur tet Soden head bod penu Sattar ns 2 10 2 3 3 Alternator Regulator a a a a hn 2 11 2 9 4 Gompressor ies x epu eR hex ig Res ey uon e ep anie eee wallet at 2 12 2 8 5 Compressor Unloaders
18. SELF TEST When first powered up The microprocessor will run a self test All of the mode lights will light All of the segments on the display will turn on All of the Liquid Crystal diodes LCDs in the Mes sageCenter will turn on to verify their operation The display will then show the set point tempera ture in the left four characters and the refrigerated compartment temperature in the right four charac ters The last character after the degree symbol shows the temperature units as C Centigrade or F Fahrenheit When set for F there is a decimal in the compartment Temperature When set for C there is a comma in the compartment Temperature The MessageCenter will display the default mes sage unless there is an alarm s stored in the micro processor If there is an alarm s stored in the micro processor INACTIVE ALARMS IN MEMORY will be dis played on the MessageCenter and the Alarm LED will flash for 5 seconds then turn off CHECK AT NEXT SERVICE INTERVAL will then be displayed if there are any active non shutdown alarms present Any hourmeters that are configured ON will also be displayed The MessageCenter will show STATUS OK as the microprocessor begins to position the CSMV to unit starting positions n engine operation after the refrigeration valves open the intake air heater will energize as required the buzzer will sound and the diesel engine will start
19. cece e nn 5 5 5 9 CARGO PROTECT MODE 1 Sede Tac ties ead TI amu mE 5 5 5 10 ENGINE SPEED OPERATION deine ter ub Ep Rite be 5 8 511 DEFROST ie et ade 5 8 5 11 1 Evaporator Temperature Criteria For Defrost 5 8 5 11 2 Defrost Initiation tenet tenes 5 8 5 11 3 Normal Defrost Operation eens 5 9 5 11 4 Normal Defrost Termination 5 9 5 11 5 Normal Defrost Termination Sequence 5 9 5 11 6 High Ambient Defrost Operation 5 10 5 11 7 High Ambient Defrost Termination Sequence 5 10 5 11 8 High Ambient Defrost Termination 0 ccc eect eee 5 11 5 11 9 High Ambient Defrost Termination Sequence 5 11 5 12 UNLOADER CONTROL OPERATION cece eens 5 11 5 13 SV1 OPERATIONS eet Rebeca 5 11 5 14 SV2 OPERATION es CER ee ea bees ee 5 11 5 15 TEMPERATURE RANGE LOCK 1 amp 2 eects 5 12 5 16 ProductShield emo bee een ea Pa ete ame eee ee War e ee 5 14 5 16 1 ProductShield Modes cbr teat ER td anes tees 5 14 5 17 UNLOADER CONTROL OVERRIDES sssssssesees eee 5 18 5 18 MAXIMUM SUCTION OPERATING PRESSURE COOL ONLY 5 19 5 19 MAXIMUM
20. ee ed 3 31 3 18 STOPPING UNIT ced mage dees 3 32 3 19 DATA BEGCORBDING 44 Seiten meen ale EA d hus 3 33 3 19 1 Microprocessor Information e 3 33 3 19 27 coe obs Dev EHE De DEDERE 3 33 3 19 3 Sensor and Event Data ssssssssssssssse ses 3 33 3 19 4 Data Downloading me 3 34 3 19 5 DataRecorder PowerUp een 3 34 3 20 OPTIONS ie ERES Re E AR eet Ae C re t c Ud 3 35 9 201 IntelliSet sas cass wise oh Had oe oh wet LI PEG FEN 3 35 3 20 2 DataTrakt for Advance Microprocessors 3 37 3 20 3 Two Way Remote Communication 00 c ccc eet nen 3 37 3 20 4 AutoFresh Air Exchange eee he 3 38 SECTION 3 OPERATION WARNING 3 1 STARTING UNIT AUTO Under no circumstances should ether or any other starting aids be used to start engine MODE LIGHTS DISPLAY 7 N O O O COOL DEFROST ALARM START STOP CON TINUOU 20 341 F SETPOINT BOX TEMPERATURE G E
21. 8 17 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 28 CHECK REFRIGERATION SYSTEM TRIGGER ON Discharge pressure is not at least 5 PSIG 0 34 Bar higher than Suction pressure for more than 10 minutes UNIT CONTROL Alarm Only or Unit Shutdown amp Alarm if configured RESET CONDITION Auto reset when discharge pressure is more than 20 PSIG 1 36 Bars above the suction pressure for five minutes or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check System Pressures a Install Manifold Test Set and check and Suction amp Discharge Pressures must have the same compare compressor discharge amp reading 5 PSIG 0 34 Bar on gauges amp on micro suction pressures with those shown on display the microprocessor display Check Compressor Drive Coupling a Verify that compressor coupling is Compressor crankshaft must be turning intact and that the compressor crankshaft is turning Perform Pretrip Check a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding Check compressor reed valves amp gaskets a Remove compressor h
22. COMPRESSOR h DISCHARGE CHECK VALVE LIQUID LINE SERVICE VALVE FILTER N C DRYER SUBCOOLER B jdee VIBRASORBER CONDENSER Figure 2 16 Refrigerant Circuit During Cooling 2 29 62 10683 2 15 REFRIGERANT CIRCUIT HEATING AND DEFROSTING See Figure 2 17 When vapor refrigerant is compressed to a high pressure and temperature in a reciprocating compressor the mechanical energy necessary to operate the compressor is transferred to the gas as it is being compressed This energy is referred to as the heat of compression and is used as the source of heat during the heating cycle When the microprocessor calls for heating the hot gas solenoid valve SV4 opens and the condenser pressure control solenoid valve SV1 closes The condenser coil then fills with refrigerant and hot gas from the compressor enters the evaporator Also the liquid line solenoid valve SV2 will remain energized valve open until the compressor discharge pressure increases to predetermined setting the microprocessor The microprocessor de energizes the liquid line solenoid valve SV2 and the valve closes to stop the flow of refrigerant to the expansion
23. The suction modulation valve CSMV will go through a procedure to close itself The micropro cessor starts out giving the CSMV the command to close completely The display will show SMV CLOSING WAIT XX SECONDS where xx is the number of seconds until the valve is fully closed The CSMV will then open to a predetermined posi tion according to the ambient and compartment tem peratures The display will show SETTING SMV XX The start sequence will start at 30 After the CSMV reaches 30 the glow plugs will energize as required the buzzer will sound and the diesel engine will start NOTE Placing the unit in either Continuous Run or Start Stop will automatically put the unit into Auto Start operation 62 10683 3 4 PRETRIP e HEAT COOL DEFROST PPPP SETPOINT TEST 1 ajv START STOP CONTINUOUS BOX TEMPERATURE MANUAL ALARM LIST DEFROST ze I A MIU SELECT CONTINUOU 1 Press the SELECT key until the MessageCenter displays PRESS THE KEY TO START PRETRIP 2 Press the key to start PRETRIP 3 Verify that during TEST 1 the complete display is turned on that the buzzer comes on and that all lights on the Light Bar come on 4 The remainder of Pretrip will take 7 to 15 minutes and will run itself automatically The PRETRIP mode is for checking unit operation and evaluating operation of all modes It will indicate a failure when one is detected
24. a Serial Number Cut Offs Ultra XTC KAV90910396 Ultima XTC KAV90910334 b Testing a Verify that the wiring to sensor is correct See wiring schematic in Section 11 b Check voltage at the RPM Sensor connector with the Run Relay energized Unit running Unit off Manual Start mode selected and test must be completed within five minutes before the Failed To Start Manu al mode occurs or Component Test mode will ener gize the Run Relay for five minutes without starting the unit c Voltage between ENRPMA 2MP31 and ENRPMC 2MP7 should be 5 0 VDC d Check continuity between ENRPMB and 2MP18 e If the above tests check OK read warning below If the RPM display is still not correct replace the RPM sensor WARNING The 5 0 VDC terminal B is common be tween the compressor discharge pressure transducer the compressor suction pres sure transducer and the RPM sensor If this circuit is shorted to ground due to one of the mentioned components being defec tive or a frayed wire the MessageCenter will show Suction Pressure 14 7 PSIG Bar Discharge Pressure 0 PSIG Bar Engine RPM 0 9 13 62 10683 9 8 4 Engine Oil And Oil Filter To check the engine oil level Run the unit to bring the engine up to operating temperature shut the unit off and unscrew Dipstick the cap dipstick Wipe the dip stick clean and insert the cap into the oil fill tube without threading it into the oil fill
25. 137 16 62 kg 5 5 pints 2 8 L Oil Charge Approved OII Mobil Arctic EAL 68 62 10683 2 11 REFRIGERATION SYSTEM DATA Table 2 6 Refrigeration System Data Gearbox Oil Mobil SHC 75 90W 150z 0 43 kg Fanshaft Oil Mobil SHC 630 3 20z 0 09 kg a Compressor Discharge Pressure Transducer CDP Range 0 to 500 psig 0 to 34 bar b Compressor Suction Pressure Transducer CSP Range 29 93 inHg 14 7 psig to 100 psig 1 to 6 9 bar c Defrost Air Switch DAS Initiates Defrost 1 40 07 inch 85 1 8 mm WG d Defrost Timer microprocessor controlled 1 5h 3h 6h or 12 hours e Defrost Termination Thermistor DTT Allows defrost initiation at temperatures below 40 F 4 4 C Terminates defrost cycle at 55 12 8 C f Receiver Fusible Plug Setting 430 F 221 C Melting Point 9 High Pressure Switch HPS Opens on a pressure rise at 465 10 psig 34 0 7 bar Closes on a pressure fall at 350 10 psig 24 0 7 bar h Unit Dry Weight Approximate 1600 Ib 725 kg i Expansion Valve MOP Ultima and X2 2500 105 PSIG 7 1 Bars Ultra and X2 2100 55 PSIG 3 7 Bars j Expansion Valve Superheat Setting 8 to 10 F 4 4 to 5 6 C at O F 17 8 C refrigerated compartment temperature Change 09 11 2 12 SAFETY DEVICES System components are protected from damage caused by unsafe operating conditions by automatic shut down of the unit when such conditions occur This is accompl
26. 2 Check Engine Oil Level Switch 9 Inspect engine oil level switch amp No physical damage to switch connector pins amp terminals No damaged or corroded pins in plug b Check engine oil level switch operation Contacts open when level is more than 7 qts low Contacts closed when level is less than 4 qts low Check Engine Oil eval Switch Harness Em Inspect harness control box No physical damage to harness connector pins amp See wiring No damaged or corroded pins schematic Section 11 b Check for shorted circuit in harness Place unit in PC mode or in Manual Start mode see Note and continuity through the harness Note 4 DO NOT START UNIT Battery reading 12 13 VDC between wires in plug 4 Check Oil Level Switch 2 5 Drain oil level to Ha 2 8 to 3 4 quarts Ha liters low Remove switch b Visually and physically inspect upper Must be securely fastened to center rod and lower float stops 8 5 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION LOW COOLANT LEVEL TRIGGER ON Engine coolant level is 1 or more quarts 95 or more liters low for more than 30 seconds UNIT CONTROL Alarm only RESET CONDITION Auto reset if engine coolant level is at the full mark for more than 30 seconds Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found On
27. 3 20 2 DataTrak for Advance Microprocessors DataTrak allows remote communication providers cellular satellite etc to request data from the Advance microprocessor and have it transmitted via their equipment to another location This is typically done via the internet to any destination in the world Some providers can also send commands via their equipment to the Advance microprocessor to change settings and the way the controller is operating the unit DataTrak is an optional feature The DataTrak option is installed by inserting a DataTrak PC Card into the PC Card slot of the microprocessor and following the on screen instructions on the keypad The DataTrak Option installation can be confirmed by scrolling through the Unit Data List see Section 3 14 DataTrak will be listed under the Installed Options heading if it is installed Once DataTrak is installed the Advance Microprocessor must be properly configured for the provider that will be connecting to it This is done in the configuration list see section 6 2 1 The Satellite Com configuration can be set for Qualcomm or Other If the provider is Qualcomm then this selection must be made All other communications providers use the Other selection Carrier Transicold has worked with approved communication providers with recommended installation locations and wiring connections to Carrier units Instructions for installing this equipment is supplied by i
28. 51 22 s SP11 k 4 02 a gt sm SET i SPK4 CSP SPK4 Od GD GD L 1 T 2 2 C2 6 17 11 1 62 10683 Plugs used with Schematic 62 04102 Rev and 62 10300 Rev A ESC Engine 1 MP Natural 24 1 SMV D NCLS NOPS NSCU SMV A NOLS SMV B C R C R E D E E E HPS jesMv B 32 8 79 G9 62 10683 11 2 CDP Fu 30 5 16 HC Plug For All Units Component 12vdc Input from SPK3 to Fuel Heater Relay Coil 1 12vdc Output from MPQC3 to ENSCU 16 12vdc Output from transformer to starter motor SM 12vdc Input unswitched Power from Battery BTY To Main Power In MPQCI 12vdc Output from MPQC4 to SPK20 it id 12vdc Output to Glow Plugs GP 12vdc Input Ground from Battery GRD 12vdc Output to Fuel Heater Circuit FHTS 12vdc Output to Fuel Heater Relay Coil FHR Unused Teminals 10 12 13 18 amp 19 NOTE Terminal 11 used only with units with J 1 Jumper 11 3 62 10683 ADVANCE MICRO DISPLAY HARNESS CONNECTIONS TesPomt Pin Color Pns Red Groun
29. 9 c 8 MATCH MARK Pry the adapter back toward the engine flywheel or use 5 16 18 x 2 1 2 Ig bolts 3 in every other hole of adapter and take up evenly on the bolts until the 5 16 18 x 1 Ig bolts engage engine flywheel Apply thread sealer Loctite 2262 to the bolts used to se cure adapter to flywheel Take up on all bolts evenly and then torque to a value of 28 ft Ib 3 87 Mkg Place V belt on the gearbox sheave and adjust belt tension as indicated in Table 9 3 Install V belt guard DO NOT START UNIT UNTIL V BELT GUARD IS INSTALLED Reconnect negative battery cable Start unit and run for 10 minutes to allow for belt stretch Disconnect battery Turn unit off remove belt and re check belt tension Install belt guard NEW BELT ADAPTER FLYWHEEL SLIDE ADAPTER Figure B Figure 9 13 Removing V Belt from Engine Adapter Drive Sheave 62 10683 9 20 9 10 FANSHAFT ASSEMBLY SEE FIGURE 9 14 AX WARNING Beware of V belts and belt driven compo nents as the unit may start automatically Before servicing unit make sure the START RUN OFF switch is in the OFF posi tion or the unit is in Maintenance mode Also disconnect the negative battery cable 9 10 1 Clutch Removal a f g CAUTION Do not get anti seize oil compound onto clutch contact surfaces Thoroughly clean off oil compound with contact or brake cleaner if this occurs
30. Check for high resistance or an open between NO ENSCU terminal v pisi Using jumper wire check for Did you find 5 VDC at ENSCU terminal and 10 Do you have 5 VDC at the condition terminal 10 VDC at ENSCU terminal 25 Replace ENSCU Did you find and correct the condition i Remove new ENSCU Check for open or high and re install old resistance on circuit ENSCU back into between ENSSN and ENSCU unit ENSCU is not Did you find and correct the condition the fault Review results of above tests with your supervisor If necessary go to the beginning of the table amp test again Replace ENSSN Did you find and correct the condition Remove new ENSSN and re install old ENSSN back into unit ENSSN is not the fault Review results of above tests with your supervisor If necessary go to the beginning of the table amp test again Figure 10 2 ESC Diagnostic Tree 2 Long 1 Short LED Code 62 10683 10 10 START HERE Does the engine starter engage amp turn the engine over Go to Advance Micro diagnostic table Figure 10 6 YES Verify the proper voltage going into FSA terminal 1 12 VDC when Start Run Off switch is first turned on for the pull in voltage 1 VDC for hold in
31. at ENSCU terminal Must be above 11 5 VDC C ce for ground at ENSCU terminal No damage or high resistance 19 3 Starter Relay Circuit a Check of starter solenoid START RUN OFF switch START RUN position Manual Start mode See Note Note 4 Relay Beene closed when un switch is ON b Check S socket amp terminals No signs of discoloration from overheating T corrosion c Check voltage to Starter Solenoid Negative lead on 85 Positive lead on 86 12 VDC Relay Negative lead on Gnd Positive lead on 87 amp 30 12 VDC d Inspect wiring to starter solenoid amp No physical damage to wiring or battery cable end starter motor No damaged or corroded terminals e Check voltage to starter solenoid Must be above 11 5 VDC Check voltage to starter motor Must be above 10 VDC while cranking WEIT Fuel and Speed Actuator FSA amp circuit ESC Engines Only 6 Check Run Relay LED LED 28 must be ON b Check for 12 VDC on the Run Relay Must be 0 VDC circuit c Check SPK20 for voltage Must be 12 VDC d Check ENSCU terminals 13 amp 15 for Must be 12 VDC voltage 2 Check FSA plunge 5 Check Starter a procu starter and wiring No damage or corrosion cable must be clean and tight steps onthenextpage O S 8 25 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 35 CHECK STARTER CIRCUIT Continued Check Battery Voltage
32. harness plug between pins Check Remote Sensor Switch Connector 8 9 Locate and inspect 10 way connector Connector must have cap on for optional sensors and switches No corrosion or moisture inside connector If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink 8 59 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 126 CHECK FUEL SENSOR CIRCUIT TRIGGER ON The Low Fuel Shutdown is configured as a 0 to 10096 sensor and the fuel level reading in the data list is less than 296 for 30 seconds UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when fuel level is sensed above 496 for 30 seconds or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check For Low Fuel Level aM a Check fuel level in the fuel tank Add fuel as needed to the fuel tank Check Fuel Level Sensor a Inspect fuel level sensor amp connector No physical damage to sensor pins amp terminals No damaged or corroded pins in plug b Check fuel level sens
33. o Place new coil over enclosing tube and retainer and connect wiring Check unit operation by running Pretrip Refer to tion 3 4 Note When installing coil make sure roll pin is fitted into stem nut and coil seats properly onto pin to keep it from rotating Use tool torque stem nut to 2 8 to 20 22 ft lbs 30 Torque 3 Bolts to 12 16 ft lbs 16 to 22 Nm Figure 9 22 Unloader Valve 1 Coil Assembly 9 Pin Anti Rotation fits 2 Stem Enclosing Tube into top of stem nut Assy 10 Bolts Valve Body 8 3 Installation Removal 11 Washers 3 Tool 12 Piston use only with 4 Spring Plunger hot gas bypass 5 Plunger Assembly unloaders 6 O Ring 7 Valve Body 8 Gasket Valve Body 62 10683 CAUTION Service mode MUST be used whenever moving refrigerant charge refrigerant leak checking or evacuating Refer to Section 6 2 3 9 15 REPLACING OR SERVICING CHECK VALVE A check valve allows the hot gas to travel in one direction only The function of the Hot Gas Bypass check valve is to raise the receiver pressure when the ambient temperature is low so that refrigerant can flow from the receiver to the evaporator when the unit is in heating or defrost The function of the Discharge Line check valve is to prevent any liquid refrigerant from migrating into the compressor during the unit off cycle
34. seed ike e E REIS ert Red ect te caer ie tes 8 5 3 LOW COOLANT LEVEL xc E Ree ua Rha ena alae es 8 6 62 10683 iv TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page ALARM TROUBLESHOOTING Cont 8 4 SHUTDOWN ALARMS oy cai acct ete ee a x ee ee ee eee ee eee ee ae 8 7 11 LOW ENGINE OIL PRESSURE ri dosne uia tai DE 8 7 12 HIGH COOLANT TEMPERATURE rr 8 8 13 DISCHARGE PRESSURE 0000 cece rn 8 9 13 HIGH DISCHARGE PRESSURE Continued usasa sannana 8 10 15 BATTERY VOLTAGE TOO HIGH rh 8 11 16 BATTERY VOLTAGE TOO 1 nei a iE a a eh 8 11 17 COMP DISCHARGE TEMP rh 8 12 17 HIGH COMP DISCHARGE TEMP Continued cece eee eh 8 13 18 LOW REFRIGERANT PRESSURE n 8 14 19 LOW FUEL SHUTDOWN for units with Low Fuel Level 0 to 100 Sensor fuel level is dsplayed in Data list 8 15 19 LOW FUEL SHUTDOWN for units with Low Fuel Level Switch no fuel level display in Data 1 5 8 15 20 MAXIMUM COMPRESSOR ALARMS eens 8 16 21 TECHNICIAN RESET REQUIRED eect tte eens 8 16 27 HIGH SUCTION PRESSURE ndisse iu ak a bea debe HER eR E ee 8 17 28 CHECK REFRIGERATION SYSTEM n 8 18 29 GEEGKEEAT CYCLE npe LENS noU p E bbb Hess
35. Auto Mode alarm is activated NOTE If the Engine Coolant Temperature Sensor alarm is Active the glow time for temperatures less than 32 F 0 C will be used 4 2 2 Variable Glow Time The glow time for the first start attempt will vary in duration based on engine coolant temperature and how the microprocessor is configured Short or Long as follows Table 4 1 Glow Time Glow Time in Sec onds Short Cet 4 2 Engine Coolant Temper ature Less than 32 F 0 C 15 2 10 33 F to 50 F 1 C to 10 C 51 F to 77 F 11 C to 0 5 25 C Greater than 78 F 26 30 The second start attempt has five seconds of glow time added to the time shown in the table The third start attempt will have 10 seconds added If the coolant temperature sensor is defective the microprocessor assumes a temperature of less than 32 F 0 C for the glow timing 5 62 10683 REPEAT A 10 Seconds GLOW THIRD ATTEMPT 15 Seconds STOP REPEAT A 5 Seconds GLOW SECOND ATTEMPT 15 Seconds STOP MAXIMUM 10 Seconds Checked at 2 Seconds FIRST ATTEMPT A VARIABLE 0 to 55 SECONDS GLOW HOMING CSMV Figure 4 1 Auto Start Sequence 62 10683 4 2 4 2 3 Engine Running The engine is considered to be running when a Engine RPM are greater than 1000 and b The engine oil pressure switch contacts are closed within 15 seconds of the engine starting OR if the RPM sensor i
36. Trailer amp Rail Refrigeration OPERATION amp SERVICE for X SERIES Trailer and Rail Refrigeration Units With Advance Microprocessor 62 10683 Rev C Change 09 11 TRANSICOLD OPERATION AND SERVICE MANUAL NOSEMOUNT TRAILER AND RAIL REFRIGERATION UNITS WITH ADVANCE MICROPROCESSOR How to use this manual Please take a few minutes to read this page It explains the content and structure of this manual This will make it easier for you to find the information that you need Section 1 Safety Precautions This section contains the Safety Precautions Safety Decals and Microprocessor cautions Read this section before working on the unit Section 2 Unit Description This section describes the unit listed in the Model Chart Table 2 1 Section 3 Operation This section shows you how to configure and operate the Carrier Advance Microprocessor Section 4 Engine and Standby Motor This section describes operation of the engine and the standby motor Section 5 Temperature Control This section describes the temperature control Section 6 Technician Interface This section describes various testing and downloading functions available to a technician Section 7 Message Center This section describes all the messages and alarms which can be displayed on the MessageCenter Section 8 Alarm Troubleshooting This section provides information on the probable causes of the alarm codes given by the mi
37. connector pins amp terminals See wiring No damaged or corroded pins schematic Section 11 8 27 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 37 CHECK LOW SPEED RPM TRIGGER ON Controller is set for low engine speed operation and RPM being read by the microprocessor are not correct The correct RPM for low speed are different for different models as shown below Less than 1325 or greater than 1625 for Ultima XTC and X2 2500A R or Less than 1200 or greater than 1500 for Ultra XTC and X2 2100A R for more than 60 seconds 120 seconds when the microprocessor calls for a change from high speed to low speed or when the unit first starts UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if controller is set for low engine speed operation and RPM are Between 1375 to 1575 for Ultima XTC and X2 2500A R or Between 1250 to 1400 for Ultra XTC and X2 2100A R for 60 seconds or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Model Number a Verify that the model number on the Enter the correct number in the data list Refer to Section unit data label matches the model 3 14 number shown in t
38. de ener 10096 Open i gized gized i c High Ambient Defrost Termination Once the Defrost Termination Temperature Sensor DTT and Supply Air Tem perature SAT reach 55 F 12 8 C the high ambient defrost cycle will terminate 5 11 7 High Ambient Defrost Termination Sequence The following sequence will be used for High Ambient Defrost Termination The unit will remain in High Speed and will reset the CSMV position to the position it was in at the start of defrost The microprocessor will open de energize SV1 and open energize SV2 and unload energize UL1 When suction pressure has risen 10 PSIG 0 7 Bar above start point or after 15 seconds the microprocessor will place the unit in Low Speed close de energize SV4 and unload energize UL2 e After 5 seconds the clutch will be engaged After an additional 5 seconds the microprocessor will return to normal temperature control The data recorder will record a Defrost Termination Event NOTE If the Ambient Air temperature is below 80 F 26 7 C then the Normal Defrost Operation will be used When the Ambient Air temperature is above 80 F 26 7 C the High Ambient Defrost Operation will be used 62 10683 5 10 5 11 8 High Ambient Defrost Termination Once the Defrost Termination Temperature Sensor DTT and Supply Air Temperature SAT reach 55 F 12 8 C the defrost cycle will terminate 5 11 9 High Ambient Defrost Termination Sequence The following seq
39. move before the timer is started 4 F may be used for very critical tem perature products 7 F may be used for less critical products The alarm may be turned off by selecting the OFF setting 3 27 62 10683 FUNCTIONAL The NORMAL selection allows the unit to cycle from High Speed to Low Speed depending on how close the compartment temperature is to setpoint Some products generate a considerable amount of heat NORMAL heat of respiration during transportation This frequently occurs with AIR FLOW HIGH produce The HIGH selection can be used for these loads since continuous high air flow may be required to keep the entire load at a constant tem perature The engine will remain in High Speed when High is selected NOTE HIGH AIR FLOW does not work with set points below 10 4 F 12 0 C FRESH PROTECT OFF OFF Fresh Protect is turned off A 2TO5 F 1 1 thru E determines the allowable temperature SAT can go below set 2 8 C point when the unit is operating in Continuous Run Cool FreshProtect a a 7 F 2 2TO does not operate in Start Stop See Section 5 8 C 6 to 9 F 3 3 TO 5 0 C D 8to 11 F 4 4 TO 61 C E 10 to 13 F 5 6 TO 7 2 CLOSED AutoFresh Air Exchange assembly will be closed except for pretrip and component test mode OPEN Assembly will be open if the engine is running and the set point is greater than 28 F 2 2 C and the unit is not defrosting 0 CLOSE
40. ride Temperature After the Minimum Off Time has expired the micropro cessor continually monitors the refrigerated compart ment temperature If the refrigerated compartment tem perature goes more than 3 6 F 2 0 C away from set point above or below set point in the Perishable range or above set point in the Frozen range the unit will re start The Minimum Off Time is selected in the micropro cessor Functional Parameter List Refer to Section 3 17 The default setting is 20 minutes 62 10683 3 Engine coolant temperature drops below 34 F 1 C If the Engine Coolant Temperature drops below 34 F 1 C the unit will restart and will run until all conditions for shutdown are met If Alarm 129 CHECK ENG COOLANT SENSOR is act ive the unit will restart if the ambient air temperature drops to 32 F 0 C after the unit has been in the OFF cycle for 60 minutes Ifthe unit restarts due to this condi tion the Minimum Run Time will be at least 20 minutes regardless of the setting in the Functional Parameter list 4 Battery voltage falls below voltage selected in the configuration list See Section 6 2 1 The selectable range is between 12 0 to 12 8 VDC The factory setting is 12 2 VDC TIP While the unit is running the status of the unit battery can be readily checked by reading the Battery Voltage in the Data List If O K ap pears after the voltage reading battery volts is sufficient to allow the un
41. 2 Start Run Off Switch On Unit Operates But Not Properly 10 15 62 10683 START HERE Is the unit equipped with StarTrak Turn the Start Run Off switch to the OFF position Does the engine continue to run There a problem with the StarTrak system Repair as necessary YE YES S Replace Start Run Off switch Did you find and correct the condition Y Check for defective Disconnect StarTrak Start Run Off switch from the unit and install Is Switch defective J1 Jumper This will eliminate StarTrak NO from the system System OK Re install Check wiring to Start Run Off switch for an open or short Did you find StarTrak if and correct the condition disconnected T earlier NO A Verify the Run Relay de energizes when the Start Run Off switch is in the OFF position Replace Run Relay Did Unplug fuel solenoid or fuel you find and puo pn actuator Does x the condition Is the relay YES defective Check wiring for fuel NO solenoid of fuel and speed Y actuator for a short Did Check wiring to Run Relay you find and correct the for an open or short Did you condition find and correct the condition Verify correct fuel solenoid or fuel and speed actuator ope
42. 8 bleed orifice to the solenoid valve stem 2 chamber and then 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 3 Vip dear We Solenoid Valve Valve Stem Gas Bypass Port Spring Guide Spring Piston Piston Bypass Valve Bleed Orifice 6 closing the gas bypass from the discharge manifold to the suction manifold 10 Cylinder discharge pressure will force open the discharge piston check valve assembly 14 Refrigerant gas will pass into the compressor discharge manifold The loaded cylinder bank will continue to operate fully loaded until the solenoid valve control device is energized and the gas bypass port is opened Refer to Section 5 12 for more information on Loaded Operation n oo s See EN wis T 9 Strainer 10 Suction Manifold 11 Cylinder Discharge Valve 12 Valve Plate 13 Cylinder Suction Valve 14 Discharge Piston Check Valve Assembly 15 Discharge Manifold Figure 2 13 Compressor Cylinder Head Loaded 2 3 6 Filter Drier The drier is a cylinder shell containing a drying agent and screen It is installed in the liquid line and functions to keepthe system clean and remove moisture from the refrigerant 2 3 7 Receiver Liquid refrigerant from the condenser drains
43. 9 43 Thermal Expansion Valve 2 14 Thermostatic Expansion Valve 9 24 Trip Start 3 16 Troubleshooting 8 1 Troubleshooting Software Loading 6 19 Two Way Remote Communication 3 37 U UltraFreeze Offset 5 4 UltraFreeze Start Stop 5 4 UltraFresh 3 Temperature Control 5 3 5 4 Unidrive torque Requirements 9 47 Unit Data 3 20 Unit Startup Engine Road and Electric Standby 3 3 Unloader 9 31 Unloader Checkout Procedure 9 31 Unloader Control Operation 5 11 Unloader Control Overrides 5 18 Using ReeferManager to Install Software 6 19 Using The DataShare Program PC Card 6 18 V V Belts 9 17 Variable Glow Time 4 1 View Active Alarms 3 17 View Hourmeters 3 24 View Inactive Alarms 3 18 W Water Pump V Belt 9 18 Index 4 TRANSICOLD North America Central America Carrier Transicold and Mexico 700 Olympic Drive Ejercito Nacional No 418 Athens GA 30601 USA Piso 9 Torre Yumal Tel 1 706 357 7223 Col Chapultepec Morales Fax 1 706 355 5435 11570 Mexico D F Tel 5255 9126 0300 Fax 5255 9126 0373 A member of the United Technologies Corporation family Stock symbol UTX 2009 Carrier Corporation Printed in U S A 1009 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
44. A 1 CSMV SP24 0 ENOPS TO K10 ENRPM we G CDP MP gt CONTROL BOX 3 GCS ULTIMA ULTIMA XTC AND_ULTRA XIC NNNNNNNNNNNNNNDD DO DODD O O lt TO HC6 B3 TO SMPA1 TO 2 25 F6B B1 LB G B OUTPUT POWER C1 E alale One 2 MONG e 202 D DIG AFAR pU SL a B 30 87 TO SP1 F17 D S NOT ON XTC UNITS or DTT2 F4 7 SA A B F3 7 SA F LEGEND R IIS eee FSH A B a 230 4 ENG BLOCK GR 5 3 3 3 3 3 3 3 3 3 3 3 3 3 AUTOFRESH AIR RELAY AUTO RESTART LIGHT HEAT LIGHT SV4 CONTROL SV1 CONTR
45. INDICATION TROUBLE POSSIBLE CAUSES REFERENCE SECTION 10 1 3Starter Motor Malfunction crank or turns slowly Starter motor turns Pinion or ring gear obstructed or worn Clean both but pinion does not engage remove burrs or replace Glow Crank switch defective Replace at wich was depressed after switch was depressed Starter motor Engine is already running Check Starter motor does not disengage after engine is starts Defective starter Engine Manual 10 1 4Malfunction In The Engine Starting Circuit molor solenoid SS does not energize or does Run relay RR defective not remain energized 62 10683 10 2 INDICATION ACTION TROUBLE POSSIBLE CAUSES REFERENCE SECTION 10 1 5 Miscellaneous Engine Troubleshooting 98 Loss of power Defective fuel injection pump Engine Manuall Defective injector s or incorrect type Engine Manual Incorrect fuel injection pump timing Engine Manuall Incorrect valve timing Engine Manual Engine Manual cre Engine shockmounts defective Vibration Engine Manual 9 8 8 Removel Engine Manual 9 8 1 8 5 1 replace Engine Manual Engine Manual 9 8 9 Restriction in air cleaner Exhaust pipe restriction Restriction in water jacket Restriction in radiator Coolant level too low Loose water pump Defective thermostat Defective water pump belt Plugged crankcase breather line Overheating Excessive
46. No moisture damaged or corroded pins 1MP Plug is connected tightly to microprocessor No wires are pushed back through plug b Check Return Air Sensor resistance 10 000 Ohms 77 F 25 C See section 2 13 for See Note 4 Page 8 2 complete table of temperatures and resistance values 2_ be removed and each individual wire separated from the others terminated and insulated with heat shrink 8 75 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION P154 CHECK SUPPLY AIR SENSOR TRIGGER ON Supply Air Sensor is not within the maximum range of 53 F to 158 F 47 C to 70 C UNIT CONTROL Pretrip will abort and PRETRIP FAILED IN TEST 3 will be displayed in MessageCenter Defrost termination will be as described in Section 5 11 RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Supply Air Temperature Sensor SAT 1 a Inspect Supply Air Sensor amp connector No physical damage to harness No moisture damaged or corroded pins 1MP Plug is connected tightly to microprocessor No wires are pushed back through plug b Check Supply Air Sensor resistance 10
47. TIP A Pretrip can be started when the refrigerated compartment is at any temperature The MessageCenter displays the current test and the complete of the test When the Pretrip tests are complete the MessageCenter will display one of three different messages PRETRIP PASS OR PRETRIP FAIL IN TEST X OR PRETRIP FAILED amp COMPLETE Alarm light will be on Press the ALARM LIST key to review the alarms triggered by the Pretrip tests 62 10683 TIP The Pretrip test PASS results message will stay displayed until a key is pressed or until the Start Run Off switch is placed in the OFF posi tion The Pretrip test FAIL results message will stay displayed until the alarms are cleared Once Pretrip is started the control panel keys are disabled until Pretrip is completed TIP If CAN NOT START PRETRIP is displayed in the MessageCenter check to see if the unit is in PC mode Defrost Refer to Section 6 1 or check the alarm list Section 3 12 for active shutdown alarms 8 4 PRETRIP Continued NOTES NOTE 1 Pretrip may be initiated any time the unit is running or when the unit is off but the START RUN OFF switch is in the START RUN position Pretrip will not start if there is an active shutdown alarm or if the unit is in PC mode or in defrost NOTE 2 Pretrip will run until completed unless an alarm occurs that causes Pretrip to be aborted Only alarms that will result in other erroneou
48. Test specific gravity of battery Check for battery specifications e Perform load test on battery Follow Check for battery specifications battery manufacturer s procedure Check Voltage At Microprocessor Check voltage reading Must be above 11 VDC microprocessor input MPQC1 MPQC2 b Check voltage reading on Must be within 0 5 VDC of reading obtained in 3a above microprocessor display 8 11 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 17 HIGH COMP DISCHARGE TEMP TRIGGER ON Ambient temp below 120 F 48 9 C discharge temp was between 310 F 349 F 154 4 C 176 7 C for three minutes or Ambient temp above 120 F 48 9 C Discharge temp was between 340 F 349 F 171 1 C 176 7 C for three minutes or Discharge temp ever reaches 350 F 176 7 C UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset after 15 minutes with Ambient temp below 120 F 48 9 C the discharge temp falls below 300 F 148 8 C or Auto Reset after 15 minutes with Ambient temp above 120 F 48 9 C the discharge temp falls below 330 F 65 4 C or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Contin
49. above or below set point Unit will restart when compartment temperature is above or below set point by the restart value Restart value during the Minimum Off Time is the Override Temperature se lected in the Functional parameter list Restart value following the Mini mum Off Time is 3 6F 2 0C When the compartment tempera ture is near setpoint the unit will operate in Cool with UltraFreeze operating at compartment tempera tures more than 3 F 1 7 C below setpoint Continuous High Air Flow is not al lowed when the compartment tem perature is less than 3 2F 1 8C above setpoint ProductShield High Air is available Compartment temperature criteria is satisfied when the temperature is within 0 5 F 0 3 C above setpoint Unit will restart when compartment temperature is above setpoint by the restart value Restart value dur ing the Minimum Off Time is the Override Temperature selected in the Functional parameter list Re start value following the Minimum Off Time is 3 6F 2 0C ree Unit will operate in low speed six Unit will shut down cylinder cool 62 10683 5 3 PULLDOWN PULL UP MODE During pulldown mode the unit will run in high speed and high speed capacity unless there is a high speed override Refer to Section 4 4 5 3 1 Pulldown or Pull up will be initiated in any of the following conditions a f At engine start Set point change Operational mode ch
50. and all lights on the Light Bar This test will last five seconds All segments of the display all LEDs on the microprocessor all lights of the Light Bar and the buzzer will be on during this test This is the only portion of the Pretrip check that requires the operator to determine PASS or FAIL A defective display and sound test is indicated if any LCD LED segments are not visible any LEDs or lights do not come on or the buzzer does not sound Anything that fails during this test should be repaired at the conclusion ofthe Pretrip cycle Pretrip will continue regardless of the outcome of this test A faulty display light bar or buzzer will not affect the operation of the unit but will affect what is displayed during unit operation Test2 Amperage Check of Electrical Components Check the amperage current draw of the following components e Battery DC Current All Components Turned Off e Auto Fresh Air Solenoid e Auto Fresh Air Solenoid e Evap Cond Fan Clutch e Front Unloader e UL2 Rear Unloader e Speed Solenoid or ESC module SVI e SV2 e SV4 e Glow Plugs e Fuel Solenoid or ESC module Most components will be energized for four seconds at which time the amperage reading is taken There is a two second rest period between each component The glow plugs will be energized for 15 seconds at which time the amperage reading is taken Test 2 will last approximately two minutes If a problem is detected w
51. and the Engine Oil Pressure switch is closed oil pressure good and engine RPM are sensed at less than 1000 RPM or The ambient is below 32 F 0 C and the DC amp draw is more than 2 amps and this is the 2nd or 3rd start attempt and engine RPM are sensed at less than 1000 RPM or With the unit in Manual Start The ambient temperature is above 32 F 0 C and this is the 2nd or 3rd start attempt and the Engine Oil Pressure switch is closed oil pressure good engine RPM are sensed at less than 50 RPM or The ambient is below 32 F 0 C and the DC amp draw is more than 2 amps and this is the 2nd or 3rd start attempt and engine RPM are sensed at less than 50 RPM NOTE This alarm can only be triggered on during the engine starting sequence and the 20 seconds immediately following UNIT CONTROL Alarm Only Engine will be considered running RESET CONDITION With the unit in Auto Start Auto Reset in Auto Start when engine RPM are greater than 1 000 or With the unit in Manual Start Auto Reset in Auto Start when engine RPM are greater than 1 000 or when Oil Pressure switch contacts OPEN or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the ste
52. and until the ambient air temperature drops below 110 F 43 3 C 5 11 DEFROST Defrost is an independent cycle overriding cooling and heating functions in order to de ice the evaporator as required When the unit is in Defrost the DEFROST LED will be on the MessageCenter will display DEFROST CYCLE STARTED for the first 5 seconds then the default message will be displayed for the rest of the Defrost Cycle The compartment temperature section of the Main Display will show dF The set point will continue to be displayed on the left side Compartment temperature will not be displayed during Defrost The CSMV will always be 100 open during Defrost Mode NOTE The unit will operate in high speed in the defrost mode except during pump down in high ambient defrost 5 11 1 Evaporator Temperature Criteria For Defrost Before a defrost cycle can be initiated DTT Defrost Termination Temperature sensor and SAT Supply Air Temperature sensor must be below 40 F 4 4 C OR SAT must be below 45 F 7 2 C If the DTT2and SAT alarms are active then the RAT Return Air Temperature sensor must be below 45 F 7 2 C 5 11 2 Defrost Initiation When one of the applicable criteria is met defrost may be initiated by any of four different methods a Defrost Interval Timer The microprocessor contains an internal Defrost Timer adjustable in the Functional Param eter list which can be set using the keyboard Refer to Section 3 16 Functional C
53. in 0 5 increments This message will only appear if ProductShield is installed The information set in the following config urations can be read in the Unit Data list GO TO START STOP Allows unit to be set for and operate in Continuous Run until ambient tem perature falls within a user defined range when unit will go to Start Stop This allows fuel savings while offering Continuous Run operation protection when ambient is outside range Unit will return to Continuous Run when ambient goes beyond range GO TO CONTINUOUS Allows unit to be set for and operate in Start Stop until ambient tempera ture falls outside a user defined range when unit will go to Continuous Run This provides continuous air flow and good product protection for extreme ambient temperatures Unit will return to Start Stop when ambient comes back inside range The minimum range allowed for this selection is 10 F 5 5 C This means that the MIN temperature will never be closer to the MAX temperature than 10 OFF There is no lower limit for this parameter Select the lower limit of the ambient range desired for this parameter Refer to Section 5 16 for more information on Econo Min Temp OFF There is no upper limit for this parameter Select the upper limit of the ambient range desired for this parameter Refer to Section 5 16 for more information on Econo Max Temp OFF Delta T is not used for determining the ac tivation de activation o
54. k Start Stop Frozen Range In Start Stop Mode with the setpoint in the frozen range i e below 10 4 F 12 C and minimum runtime has expired and the refrigerated compartment temperature is not yet down to setpoint the engine will be forced to high speed operation High Speed Delay When operating in low speed there is adelay when switching to high speed The de fault delay is one minute Refer to Configuration Mode Section 6 2 Whenever the unit is operating in low speed there may be a delay before switching to high speed This delay is selected in the Configuration List Refer to Configuration Mode Section 6 2 SECTION 5 TEMPERATURE CONTROL PARAGRAPH NUMBER Page 51 INTRODUCTION eau te ala 5 1 5 2 PERISHABLE AND FROZEN SET POINT RANGES 5 1 big PULLDOWN PULL UP MODE ue bole sts pale he eb op ile eee bale es 5 2 5 4 HEAT MODE ORERATION EIE MEO 5 2 5 5 COOL MODE OPERATION cee hr 5 2 5 6 UltraFresh 3 TEMPERATURE eee nnn 5 3 5 6 1 Heat Cool Null Switching Operation 5 3 5 6 2 Null Mode Operation 0 eens 5 4 5 7 UltraFreeze TEMPERATURE CONTROL 0 0 cece eee nn 5 4 5 7 1 UltraFreeze Offset 0 hn 5 4 5 7 2 UltraFreeze Start Stop 0 0 eee hn 5 4 5 8 FreshProtectt SUPPLY AIR CONTROL
55. lower roadside door The control module contains replaceable relays and fuses which are externally accessible LEDs are located next to the three relays plugged into the control module to indicate relay operation Additional LEDs indicate operation of the FETs Field Effect Transistors The control module includes the logic board program memory FETs PC card slot and necessary input output circuitry to interface with the unit The logic board is located within the control module and does not contain any serviceable components CAUTION Under no circumstances should anyone attempt to repair the Logic or Display boards Should problem develop with either of these components contact your nearest Carrier Transicold dealer for replacement QC5 CLUTCH RELAY K3 GROUND STRAP PC CARD FAULT LED RED 1 WHITE PC CARD SLO 2MP BLACK CARD STATUS LED GREEN MICROPROCESSOR STATUS LED GREEN 3MP GREY ry FET LEDs RUN RELAY 2 LED28 F3 7 5A SPEED RELAY 1 QC3 LED27 F2 10A RELAY POWER QC8 12 VDC AUTOFRESH AIR RELAY DC CURRENT SENSOR LED30 GPR LED31 SSR 6MP DISPLAY KEYPAD CIRCUIT 5MP START CRANK GLOW CIRCUIT AMP NOT USED QC2 MICROPROCESSOR GROUND QC1 SYSTEM POWER 12 VDC F1 7 5A Figure 2 14 Control Module
56. snapshot is recommended for pressure voltage amperage amp RPM f When the setup is correct press the Send button to send the new settings to the microprocessor g From the Confirm Send Information Pop Up check the data you want to send and un check the data you don t want to send Click the OK button h Verify that the settings were sent by waiting for the confirmation pop up message NOTE If the DataRecorder date and time were not set earlier they can be set from this screen by click ing on DataRecorder Tools Set Date and Time i Leavethe microprocessor powered up as you contin ue with the next section 62 10683 6 7 6 Engine And Switch on Hourmeters Via ReeferManager PC Program a Start the ReeferManager program Go to the Serial Operations Tab b Click on DataRecorder Microprocessor Setup but ton c In the upper left menu bar click on MicroprocessorTools gt Set New Micro Hours d At this screen enter the hours that were recorded in step b of Section 6 7 1 Send the new readings to the microprocessor NOTE Hours can only be entered into the micropro cessor until either the Total Engine Hours or the Total Switch On Hours reach 25 However in the case of incorrect hours being entered changes can be made for 60 minutes after the initial change has been made regardless of the number of hours entered Once the 60 min utes has expired and either of the total hour meters
57. 0 C the unit will run for 20 minutes minimum run time then restart every 60 minutes maximum off time Battery voltage and amperage will be monitored nor mally NOTE Units equipped with IntelliSet option can select Sleep Mode by choosing IntelliSleep See Sec tion 3 20 1 IntelliSleep can ONLY be exited by selecting a different IntelliSet 3 10 DEFROST 3 10 1 Manual Defrost DEFROST LIGHT e e e e HEAT COOL DEFROST START STOP CONTINUOUS 124 dF SETPOINT BOX TEMPERATURE DEFROST CYCLE STARTED MANUAL List srART sTOP 1 SELECT DEFROST din ma 1 Press the MANUAL DEFROST key The DEFROST light will come on and the Messa geCenter will display DEFROST CYCLE STARTED for five seconds or flash CAN NOT START DEFROST CYCLE for five seconds When Defrost mode CANNOT be manually initiated NOTE CANNOT START DEFROST CYCLE is displayed in the MessageCenter This will occur when Refer to Section 5 11 for more detailed information on manual and automatic defrost initiation and termination e DTT2 is above 40 F 4 4 C and SAT is above 45 F 7 2 C OR TIP The engine has not run a minimum of15 The Manual Defrost Key can be used at any seconds after starting OR time to start a Defrost Cycle The unit is in PC mode OR e unit is in Pretrip OR e There is an active shutdown Alarm 3 15 62 10683 3 11 TRIP START HEAT COOL DEFROST START STOP CONT
58. 10 3 13 Expansion Valve Malfunction c cece 10 7 10 3 14 Compressor Suction Modulation Valve CSMV Malfunction 10 8 10 3 15 Solenoid Valve Malfunction SV1 2 OR 4 10 8 10 4 ELECTRONIC SPEED CONTROL TROUBLESHOOTING 10 8 10 4 1 Advance Microprocessor Troubleshooting Guide 10 13 10 5 COMPRESSOR TROUBLESHOOTING GUIDE 10 23 WIRING SCHEMATIC tes 11 1 PLUGS USED WITH SCHEMATIC 62 10499 REV V STANDARD 11 1 PLUGS USED WITH SCHEMATIC 62 04102 REV ESC ENGINE 11 2 PLUGS USED WITH SCHEMATIC 62 10300 REV A ESC ENGINE 11 2 HC PLUG FORCALELUNLEEDS D Ee T RR etes 10 3 ADVANCE MICRO DISPLAY HARNESS CONNECTIONS 10 4 VOLTAGE TESTS iste ite 10 4 INDEX Index 1 62 10683 LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figure 2 1 Front View Of Unit With Non ESC Engine 2 3 Figure 2 2 Curbside Non ESC Engine cece 2 4 Figure 2 3 Roadside Non ESC Engine cece eee nn 2 4 Figure 2 4 Front View Of Unit With Electronic Speed Control Electronic Speed Control 2 5 F
59. 155 os 18 980 aso 170 7 1 040 38 9 80 711 16 940 360 1822 920 367 6 789 15 450 370 187 8 830 37 8 767 14 070 1933 740 38 9 794 12 870 390 198 9 670 40 0 ez eo ane eo 41 1 850 10 750 410 210 0 540 420 2156 400 43 3 906 9 050 490 221 1 450 EXEIEGEUES 460 104 4 6 1072 5 230 110 0 5 130 500 260 0 240 28 4 EHE 1183 4 185 es em wma fa aferta aT n Ene ES 22 se 233 570 7 7 221 280 89 209 670 198 760 108 11 1 188 490 EX 133 169 700 o me se 15 5 16 6 Hur 200 ERI 222 23 3 20 lt 2 189 9 2 167 799 180 4 156 7 Der o as eue ne sn Tar ms seme ms 060 50 0 662 690 o as o ae se o9 519500_ e pee eisio js s11 stero Foro 1s 14 4 12 2 25 522 99 200 _ _ 128 53 3 31 850 amo J EET aoo EXE T 106 108 114 16 118 138 120 36 100 126 128 130 62 10683 9 46 9 29 UNIDRIVE TORQUE REQUIREMENTS FIGURE 9 35 Extensive damage may occur if the proper hardware and procedures are not followed Periodic inspection of hardware and bolt torque is recommended to insure the integrity of the unidrive NOTE Thread locking sealant 5 16 flat washer and 5 16 lock was
60. 2 5 to 3 0 Rotor Shim Condenser Fan Hub Adapter Clutch Rotor Clutch Armature 10 to 11 ft Ibs 1 4 to 1 5 Mkg Spanner Nut 24 f 80 to 85 ft lbs 11 1 to 11 5 Clutch Coil Figure 9 14 Fanshaft Assembly 62 10683 9 22 9 10 4 Blower Wheel Installation a Make sure key is properly placed in keyway Slide d Slowly and evenly torque blower wheel bushing bolts blower wheel and bushing onto shaft to 10 to 11 ft lbs 1 4 to 1 5 e Position nozzle cover so that blower wheel is cen sembly forward until blower wheel touches pod This 20 in Ibs 0 23 Mkg will set approximate clearance between blower wheel and pod f Rotate blower wheel and check that clearance is approximately 1 4 Adjust nozzle cover and or blow c Loosely attach the nozzle cover to pod with retaining er wheel if necessary bolts Install SAT with at least 1 2 of sensor in the g Reinstall evaporator panel reattach air chute and nozzle Reattach DTT bulkhead if so equipped Fanshaft Seal Ring Clamp Fanshaft Nozzle Cover Bolts Blower Wheel Bushing Nozzle Cover Gasket Blower Wheel A Nozzle Cover Spring Clip Figure 9 15 Blower Wheel And Nozzle Cover Assembly 9 23 62 10683 9 10 5 Clutch Installation NOTE The orientation of the clutch coil MUST be on the bottom Secure the harness to the lower right fan shaft mounting bolt using the cushion clamp provided a Place clu
61. 25 Test voltage at alternator output Must be between 12 16 VDC terminal with unit off b Test voltage at alternator output Must be between 12 16 VDC terminal with unit running Check Voltage At Microprocessor EN Check voltage reading at Must be between 12 16 VDC microprocessor input QC1 to QC2 b Check voltage reading on Must be within 0 5 VDC of reading obtained in 3 Amp microprocessor display above 16 BATTERY VOLTAGE TOO LOW TRIGGER ON Voltage at the microprocessor is less than 10 VDC except when the engine starter is engaged UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset after 15 minutes when the voltage at the microprocessor is between 11 14 VDC or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check For Alternator Not Charging Alarm a Check for alarm 51 Alarm conditions must be corrected and the alarm cleared to continue 2 Check Battery Voltage 2 te Inspect battery cable ends and posts Must be clean and tight b Test voltage at battery with unit off Must be above 11 VDC c Test voltage at battery with unit Must be above 11 VDC running d
62. 3 14 e Check amp draw of each glow plug Refer to Section 2 13 for amp values Use ammeter 2 Check Glow Plug Circuit Wiring s Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section 2 8 73 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION P152 CHECK FUEL SOLENOID CIRC TRIGGER ON Normal Amps for the Fuel Solenoid Hold Circuit is 0 42 to 3 5 Amps 0 2 to 4 5 Amps for ESC units for non Electronic Speed Controlled ESC engines and 0 2 to 4 5 Amps for ESC engines including possible electric fuel pump The circuit tests outside this range UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 1 Check For Bad F2 Or F3 Fuse Alarm feme ume to continue a b Check amp draw of fuel solenoid Use Component Test Mode Section 6 2 2 to test Refer to Section 2 13 for amp values View current draw in the Unit Data list Refer to Section 3 14 Check Fuel And Speed Actuator FSA ESC engines only a Check resistance of FSA Refer to
63. 3 SAFETY DECALS Q ADANGER KEEP CLEAR OF ROTATING BELTS e AND PULLEYS WARNING UNIT MAY START AUTOMATICALLY 62 02146 02 REV C 62 03958 00 Heat Warning THIS UNIT IS CONTROLLED VIA SATELLITE IT CAN START OR STOP AT ANY TIME BY REMOTE COMMAND PRIOR TO PERFORMING ANY MAINTENANCE PLACE THE MAINTENANCE SWITCH IN THE MAINTENANCE MODE POSITION TO PREVENT REMOTE STARTING CAPABILITY LBLO20 ONLY USED ON UNITS WITH TWO WAY COMMUNICATION CAPABILITIES 1 5 UNIT MAY START AT ANY TIME IF THE RUN STOP SWITCH IS IN THE RUN POSITION 62 02450 00 REV C 62 10683 A WARNING DISCONNECT BATTERIES BEFORE DOING ANY ELECTRICAL WELDING ON UNIT OR CHASSIS TO WHICH UNIT IS ATTACHED TRAILER CONTAINER RAIL CAR METAL BUILDING ETC THIS UNIT HAS A EGATIVE GROUND SYSTEM NOT REVERSE POLARITY ERSED POLARITY WILL CAUSE IMMEDIATE FAILURE OF ELECTRICAL SYSTEM 62 02139 01 REV_B CONTAINS HOT SURFACES THAT WILL IGNIT M FLAMMABLE MATERIAL S SUCH AS BIRD NESTS LEAVES E LIMBS OR MAINTENANCE MA S SUCH AS SHOP RAGS DO_NOT OPERATE PECTION FIRES AND SERIOUS INJURIES MAY E COMBUSTIBLES ES
64. 30 is not also active or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Fan Belts Check upper fan belt tension amp Refer to Section 9 9 for belt tensions condition No Glazing no cracking no slipping b Check lower fan belt tension amp Refer to Section 9 9 for belt tensions condition No Glazing no cracking no slipping 2 Check Evaporator Air Flow b Check evaporator section condition of Good Air Flow evaporator blower wheels return air Return air not restricted bulkhead air chute cleanliness of Air chute in good condition evap coil No damage to blower wheel Evap coil clean a Check evaporator fan clutch Must be engaged suction pressures with those shown on the microprocessor controller Lt me Refrigerant Charge e Check for undercharged system Level must be above lower sight glass E Perform Pretrip Check Any active alarms must be corrected and cleared before ies Check SV4 a Check SV4 for leakage when closed Check System Pressures Em Install Manifold Test Set and check and Suction amp Discharge Pressures must have the same compare compressor discharge amp reading on gauge
65. 30 minutes the unit will return to Start Stop when the ambient temperature has fallen within the pre programmed temperature range by 3 6 F 2 C NOTE Delta T logic is not used or available when unit is configured for GO TO CONTINUOUS ProductShield ECONO GO TO CONTINUOUS EXAMPLES 1 Ifthe Econo Minimum Temperature is set to 0 F 17 8 C and the Econo Maximum Temperature is set to 90 F 32 2 C and the ambient air temperature falls outside these temperatures the unit operation can change to Econo Continuous Run 2 Ifthe Econo Minimum Temperature is set to O F 17 8 C and the Econo Maximum Temperature is set to OFF and the ambient air temperature falls below 0 F 17 8 C the unit operation can change to Econo Continuous Run 3 If the Econo Minimum Temperature is set to OFF and the Econo Maximum Temperature is set to 90 F 32 2 C and the ambient air temperature rises above 90 F 32 2 C the unit operation can change to Econo Continuous Run 4 If both the Econo Minimum and Econo Maximum Temperatures are set to OFF ProductShield Econo Go To Continuous can not operate because no range has been defined and it is therefore impossible for the ambient temperature to be outside of range 62 10683 5 16 b ProductShield High Air ProductShield High Air mode allows the unit to provide increased airflow by operating the engine in high speed This generally results in a reduced Delta T This can maximize product protection un
66. 5 1 Bars for five minutes if configured for alarm only or Auto Reset after 15 minutes if configured as a Shutdown Alarm or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check System Pressures Check and compare compressor Suction amp Discharge Pressures must have the same discharge amp suction pressures with reading 5 PSIG 0 34 Bar on gauges amp on micro those shown on the microprocessor display controller 2 Check Compressor Drive Coupling a Verify that compressor coupling is Compressor crankshaft must be turning intact and that the compressor crankshaft is turning Perform Pretrip Check a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding 4 Check compressor reed valves amp gaskets a Remove compressor heads amp inspect Must be in good condition condition of all reeds amp gaskets 5 Check compressor pistons and connecting rods Check compressor pistons Must be in good condition connecting rods See Refrigeration Trouble Shooting Section 10 3 ng y a NK por La NE 61
67. 5 4 5 7 2 UltraFreeze Start Stop enn 5 4 5 8 FreshProtectt SUPPLY AIR CONTROL ssssssssses eese mn 5 5 5 9 CARGO PROTEC MODE EE et sis 5 5 5 10 ENGINE SPEED OPERATION hh 5 8 5211 s DEFROST iie newer eee IC beled a Geek Dee Saag pints De Sb oleae Gente Oey eine 5 8 5 11 1 Evaporator Temperature Criteria For Defrost 5 8 5 11 2 Defrost Initiation cee RR hh 5 8 5 11 3 Normal Defrost Operation ccc nn 5 9 5 11 4 Normal Defrost Termination 0 00 cece tenes 5 9 5 11 5 Normal Defrost Termination Sequence 5 9 5 11 6 High Ambient Defrost Operation 5 10 5 11 7 High Ambient Defrost Termination Sequence 5 10 5 11 8 High Ambient Defrost Termination 5 11 5 11 9 High Ambient Defrost Termination Sequence 5 11 5 12 UNLOADER CONTROL OPERATION cece n mn 5 11 5 13 SVIMOPERATION 1032 en epe EE Meere AE PME eo 5 11 5 14 SVZ OPERATION ius RE RARE e ORE Ae dee ee RR ble sh ade sae esa 5 11 5 15 TEMPERATURE RANGE LOCK 1 amp 2 ssussssssesssess en 5 12 5 16 ProduetShield 2 A A A EUM Ee LI 5 14 5 16 1 ProductShield Modes 0 00 cece eee tenet ene 5 14 5 17 UNLOADER CONTROL OV
68. 5 Amps The circuit tests outside this range UNIT CONTROL Pretrip will abort and PRETRIP FAILED IN TEST 2 will be displayed in MessageCenter RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE eee the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with he duin below as necessary 1 Check For Bad F4 Or F6 Fuse Alarm Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue Check SV1 g a Check resistance of SV1 Refer to Section 2 13 b Check amp draw of SV1 Use Component Test mode Section 6 2 2 to test Refer to Section 2 13 for amp values View current draw in the Unit Data list Refer to Section 3 14 Check SV1 amp Circuit a Inspect SV1 and wiring No physical damage to harness No damaged or corroded pins b Start unit setpoint more than 10 F Unit running in Heat Cycle 5 5 C above box temperature and set above 11 F 11 5 C See note Note 9 c Check operation of SV1 FET 10 LED must be ON d Check voltage to SV1 Must be 11 VDC or higher across the 2 wires 4 SV1 Circuit Wiring A Inspect harness amp control box No physical damage to harness connector pins amp termina
69. 6 5 INSTALLING NEW SOFTWARE 0c cece eee n 6 17 6 5 1 Software Version Numbers n 6 17 6 5 2 Using The Program PC Card ccc eee 6 18 6 5 3 Using ReeferManager to Install Software 6 19 6 5 4 Troubleshooting Software Loading Problems 6 19 6 6 RE SETTING PM PREVENTATIVE MAINTENANCE HOURMETERS 6 20 6 7 ADVANCE MICROPROCESSOR REPLACEMENT amp CONFIGURATION SETUP 6 22 6 7 1 Microprocessor Replacement sssaaa naana anaana 6 23 6 7 2 Microprocessor ete eens 6 24 6 7 3 Configurations Via Keypad 6 25 6 7 4 Functional Parameters via Keypad 6 25 6 7 5 DataRecorder Via ReeferManager PC Program 6 25 6 7 6 Engine And Switch on Hourmeters Via ReeferManager PC Program 6 26 6 7 7 Configuration IntelliSet PC Card eect ees 6 26 6 7 8 Microprocessor Final Checkout cece cette eens 6 26 6 7 9 Replacing Display Bezel Assembly 6 27 SECTION 6 TECHNICIAN INTERFACE 6 1 MODE DOWNLOAD PORT PC mode allows the user to access and download data using a computer when the unit is not running and without starting the eight hour DataRecorder timer Connecting a download cable P N 22 01737 00 6 Long or 2
70. 62 10683 Figure 2 14 shows the control module The control module has three relays and four fuses that are user accessible There are three 7 5 amp fuses and one 10 amp fuse The PC card slot is also shown in Figure 2 14 This card slot is used with all Carrier Transicold PC cards The microprocessor automatically detects the presence and type of PC card inserted and responds accordingly The different types of PC cards are e Download PC card for downloading unit data Option PC card for installing optional software programs e Configuration card microprocessor functions DataRecorder configurations e Program PC card for upgrading the microprocessor software There are three LEDs associated with the function of the PC card slot These are e Agreen Microprocessor Status LED which will blink steadily once per second indicating that the microprocessor is operating and will blink every 0 5 seconds if there is no software or if itis loading software A green PC Card Status LED which comes on when there is a PC card inserted in the slot This LED will 1 Blink every 0 5 seconds when data is being trans ferred to or from the PC card and will be on steady when the operation is complete and the PC card may be removed 2 During download the light will blink once per second and will blink every 1 5 seconds when the download is complete the and for setting configurations 2 17 A red PC Card Fault LED bli
71. 9 33 Figure 9 26 Typical Setup for Testing High Pressure Switch 9 34 Figure 9 27 Discharge Pressure Transducer Values 9 35 Figure 9 28 Suction Pressure Transducer Values 9 37 Figure 9 29 SV2 SV4 Solenoid Valves 0 0 emn 9 38 Figure 9 30 SV 2 SV 4 MARKING m n 9 39 Figure 9 31 SV1 Solenoid Valve 9 40 Figure 9 32 Suction modulation valve CSMV sssusssssessssessee e n 9 41 Figure 9 33 CSMV Remy Ace REP Ret RUM eR Da d ere cce RR rec e 9 42 Figure 9 34 Defrost Air Switch Test Setup 9 44 Figure 9 35 Unidrive Torque Requirements Non ESC Engine 9 48 Figure 9 36 Unidrive Torque Requirements Electronic Speed Control Engine 9 49 Figure 10 1 ESC Diagnostic Tree 1 Long 1 Short LED Code 10 9 Figure 10 2 ESC Diagnostic Tree 2 Long 1 Short LED Code 10 10 Figure 10 3 ESC Diagnostic Tree 2 Long Short LED Code 10 11 Figure 10 4 ESC Diagnostic Tree 2 Long 7 Short LED Code 10 12 Figure 10 5 Micro Diagnostic Tree Cond 1 Start Run Off Switch On Unit Does Not Operate
72. AutoFresh Air Exchange Relay output from the micro is negative so the circuit will not be shorted to ground but is shorted either within the relay itself or to a positive wire Alarm may be manually reset via Keypad or by turning the unit off then back on again UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when AFEX current amp draw is normal or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Autofresh Air Exchange Relay AFAR a Inspect AFAR amp socket No damage to relay No damage to socket b Check resistance of relay coil Refer to Section 2 13 Check Afar Wiring Inspect harness amp control See Notes Note 3 Note 4 amp Note 8 connector pins amp terminals See wiring No physical damage to harness schematic Section 11 No damaged or corroded pins Check Afar Current Draw a Use Component Test mode Refer to Refer to Section 2 13 for normal current values Section 6 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 14 62 10683 8 54 NO Steps ALARM CAUSE CORRECTIVE ACTION 93 CHECK START UP BU
73. C of actual temperature 2 System Pressures a Install Manifold Test Set and check and Suction pressure must be above 3 PSIG 0 2 Bar compare compressor discharge amp suction pressures with those shown on Suction amp Discharge Pressures must have the same the microprocessor controller reading on gauges amp on micro display Refrigerant Charge 3 2 Check for undercharged system Level must be above lower sight glass F Check SV1 Operation See Section 9 21 2 Checking SV1 a Check the operation of the SV1 valve Must perform correctly portesi procedure Correct any problems found before proceeding 5 Check Compressor For Ability To Pump Up Pressure a Check the operation of the high side of Discharge pressure must rise a minimum of 50 to 100 psig the compressor by covering the 3 4 to 6 9 bars condenser inlet air b Remove compressor heads amp inspect Must be in good condition condition of all reeds amp gaskets 8 97 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION P200 CHECK UL1 CYLINDERS TRIGGER ON A problem has been detected inside the front cylinder head of the compressor with a suction reed discharge reed head gasket or valve plate gasket UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found
74. CARD STATUS LED will flash 4 When the copy is complete COPY COMPLETE REMOVE CARD X is the number of empty spaces remaining on the card will show in the MessageCenter The PC Card Status LED will be solid You may then remove the PC card Do not remove the card until prompted to do so 5 When the card is removed the MessageCenter will return to the default message 6 If any other messages appear refer to Section 7 1 MessageCenter for an explanation of the error message If there is an error the PC CARD FAULT LED will be on until the card is removed 7 Data must be copied from the Download Card onto a computer drive before it can be viewed e e e START STOP CONTINUOUS BOX TEMPERATURE COPYING DATA PLEASE WAIT MANUAL ALARM LIST START STO SELECT DEFROST NOH rr 5j j 62 10683 6 5 INSTALLING NEW SOFTWARE NOTE All units should have the Controller software upgraded to 04 05 00 04 07 00 for X2 units or above It is no longer possible to load any versions of 03 software into that microprocessor Newer versions can be loaded as they are released 6 5 1 Software Version Numbers The first two digits of the software revision number e g 04 indicate the major release Major releases occur when significant changes are made to the software Whenever a major change to software is made and that software is installed into a microprocessor it is not possible to downgrade the software back to any low
75. CONNECTION WIRE LUG ETC SYMBOL DESCRIPTION ZONE SYMBOL PTION AAT AMBI AFAR AUTO AFAS AUTO ALT ALTE ARL AUTO BUZZ BATT CO CO m T AIR TEMPERATURE RESH AIR EXCHANGER RELAY OPTION ON XTC RESH AIR EXCHANGER SOLENOID OPTION ON X TOR EATER OPTIONAL FHR EATER RELAY OPTIONAL EATER TEMP SWITCH COPTIO LT LIGHT LIGHT BAR LEVEL SWITCH U OLENOID GLOW CRANK SWITCH LUG U R RESTART LIGHT LIGHT BAR R RY 550 HARGE PRESSURE ESSO HARGE TEMPERATURE LIGH HT BAR H H RE ESSO ION PRESSURE ESSO IO ODULATION VALVE XTC RENT T RMER ROST AIR SWITC ROST LIGHT LIGHT BAR R SWITCH DEFROST TERMINATION TEMPERATURE ENGINE COOLANT LEVEL SWITCH ENGINE COOLANT TEMPERATURE ENGINE OIL LEVEL SWITCH ENGINE OIL PRESSURE SWITCH N 0 ENGINE RPM EVAPORATOR PLUG FUSE MP 7 5 AMPERE FUSE SR 10 AMPERE FUSE RR 7 5 AMPERE FUSE CLHR 7 5 AMPERE L2 FUSE MAXI FUSE 80 AMPERE A2 D2 B6 D9 D10 FUSE SV amp UL 15 AMPERE 1 D15 M14 J11 J16 FUSE SROS 5 AMPERE 0 M15 F17 FUSE FHR 20 AMPERE OPTIONAL B3 B6 D8 D10 FUSE LB 3 AMPERE L11 L13 M14 M16 FUSE AFAR 10 AMPERE DUAL ELEMENT SLOW BLOW COPTION ON XTC UJ w pum dw JUIN AAA co 16 LUG RELAY RENT PLUG Hin JA Boies L14 J14 114 17 2020000 DD mm a7 m LIGHT LIGHT BAR PRESSURE CUT OUT SWITCH N C J 1 JUMPER IGHT BAR ICROPROCESSOR BOARD ICROPROCESSOR QUICKCO
76. CSMV Malfunction 10 8 10 3 15 Solenoid Valve Malfunction SV1 2 OR 4 10 8 10 4 ELECTRONIC SPEED CONTROL TROUBLESHOOTING 10 8 10 4 1 Advance Microprocessor Troubleshooting Guide 10 13 10 5 COMPRESSOR TROUBLESHOOTING GUIDE 10 23 SECTION 10 UNIT TROUBLESHOOTING CAUTION Under no circumstances should anyone attempt to service the Advance Microprocessor See Sec tion 10 4 1 for microprocessor troubleshooting Should a problem develop with the Advance Micro processor contact your nearest Carrier Transicold dealer for replacement NOTE Run a Pretrip and Check all active alarms before continuing with troubleshooting ACTION INDICATION TROUBLE POSSIBLE CAUSES REFERENCE SECTION 10 1 DIESEL ENGINE See Table 10 1 and Figure 10 1 thru Figure 10 4 for ESC troubleshooting 10 1 1Engine Will Not Start pees Airinfuelsystem 96 Starter motor cranks but engine fails to start Plugged fuel filter s Plugged fuel lines to injector s ESC defective 10 4 Starter cranks engages Voltage drop in battery cable s Check but dies after a few seconds Engine lube oil too heavy 2 7 1 10 1 2Engine Starts Then Stops Fuel supply restricted Check No fuel in tank Check Leak in fuel system Check Side Fuel pump FP malfunction 96 10 1 62 10683 ACTION
77. CSMV wind ings in an attempt to rotate the valve or irre parable damage will occur 9 41 9 22 2 CSMV Diagnostics If the CSMV is suspected to be faulty the first thing the operator should do is perform a Pretrip test Refer to Section 3 4 Some symptoms that could indicate a faulty CSMV are eUnusually high suction pressure in COOL mode A27 HIGH SUCTION PRESSURE ALARM may be generated eUnusually low suction pressure A18 LOW REFRIGERANT ALARM may be gen erated temperature control Compartment temperature deviates from set point If the unit fails Test 10 during pretrip P180 CHECK SUCTION MOD VALVE the CSMV could be faulty The CSMV could have become mechanically jammed or it could have failed electrically in the power head or it may not be receiving the proper signal from the microprocessor There are several steps the operator should make in addition to the unit Pretrip to further diagnose the valve a The CSMV may be stuck in some position other than completely closed and the stepper motor cannot move the piston To check if the valve is stuck first start the unit and run in cool mode with manifold gauges attached to the compressor b Allow the suction pressure to pull down to 0 psig bar AX WARNING Carrier Transicold does not recommend al lowing the compressor to pull less than 0 psig bar at any time Once the unit has reached suction pressure of 0 psig bar place
78. Check For Any Pretrip Alarms a Scroll the Alarm list for any Active Alarm conditions must be corrected and the alarm cleared Pretrip alarms to continue Rerun Pretrip Check If Desired a Clear Active Alarm List then run Unit running in Pretrip mode Check for any new alarms Pretrip amp check for any new alarms b Allow to terminate automatically Pretrip cycle operates normally P143 CHECK CLUTCH CIRCUIT TRIGGER ON Normal Amps for the Clutch Circuit is 2 0 to 7 Amps The circuit tests outside this range UNIT CONTROL Pretrip will abort and PRETRIP FAILED IN TEST 2 will be displayed in MessageCenter RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check For Bad F4 Or F6 Fuse Alarm a Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue Check Clutch a Check resistance of clutch coil Refer to Section 2 13 b Check amp draw of clutch coil Use Component Test mode Section 6 2 2 to test Refer to Section 2 13 for amp values View current draw in the Unit Data list Refer to Section 3 14 Check Clutch amp Circuit a Ins
79. Clean Broken capillary element bulb charge Low superheat and liquid Pin and seat of expansion valve eroded or Clean held open by foreign material Fluctuating suction Improper bulb location or installation Figure 9 16 pressure Low superheat setting 9 11 2 High superheat Broken capillary 10 7 62 10683 INDICATION ACTION TROUBLE POSSIBLE CAUSES REFERENCE SECTION 10 3 14 Compressor Suction Modulation Valve CSMV Malfunction Coil not seated properly Coil defective Check and Re place Loose connector Check and Tighten CSMV not controlling correctly CSP defective Check and Re CDT defective Check and Re place CDP defective Check and Re place 10 3 15 Solenoid Valve Malfunction SV1 2 OR 4 ee en function properly Movement of plunger restricted due to a Corroded or worn parts b Foreign material lodged in valve c Bent or dented enclosing tub Foreign material lodged under seat olenoid valve closes but refrigerant continues to flow Defective seat 10 4 ELECTRONIC SPEED CONTROL TROUBLESHOOTING Table 10 1 ENSCU LED Fault Chart See following pages for troubleshooting trees tenm Engine Over Speed more than 2 530 RPM oe 2906 008 ENSSN mechanical engine engine problem No signal from ENSSN for 2 seconds after RPM Two Lang o ENSSN or wiring problem is greater than 1 000 RPM for 10 seconds OR for 5 seconds while engine cranking no voltage at pin
80. Component Test Mode 6 12 Compressor 2 12 Compressor Data 2 26 Compressor Discharge Pressure Transducer 2 14 2 26 9 35 Compressor Discharge Temperature Trans ducer 2 14 Compressor Oil Level 9 30 Compressor Suction Modulation Valve 2 14 Compressor Suction Modulation Valve CSMV 9 41 Compressor Suction Pressure Transducer 2 14 2 26 9 37 Compressor Transducers 2 14 Compressor Troubleshooting Guide 10 23 Index 1 Compressor Unloader 2 12 9 31 Condenser Coil 9 45 Condenser Subcooler 2 10 Config and Tech Test Modes 6 2 Configuration Mode 6 3 Continuous Run Mode 4 5 Continuous Run Operation 3 11 Cool Mode Operation 5 2 CSMV Control 5 4 CSMV Diagnostics 9 41 D Data Ohms And Amps 2 28 Data Recording 3 33 Defrost 5 8 Defrost Air Switch 9 43 9 44 Defrost Cycle 9 43 Defrost Initiation 5 8 Defrost Temperature Sensor 2 15 Defrost Termination Thermistor 2 26 Defrost Timer 2 26 Display 2 19 Display Bezel Assembly 6 27 Display Bezel Assembly Installation 6 27 Door Latch Maintenance 9 10 Door Switches amp Remote Switches 2 23 2 24 Download Port 6 1 Downloading Data With The PC Card 6 16 Drive Gear 9 47 62 10683 E Electronic Modules 2 22 Electronic Speed Control 9 16 Emergency CSMV repair procedures 9 43 Engine 2 10 Engine Air Filter 9 16 Engine Air Filter Inspection 9 16 Engine Air System 2 26 Engine Coolant Level Sensor 2 10 Engine C
81. Ee Dee pe E 8 18 8 5 START UP ENGINE ALARMS 2 les ae m lm aa a eee x eee eke need alee nixa 8 19 30 FAILED TO RUN MINIMUM TIME ssee RR HH 8 19 31 FAILED TO START AUTO ees 8 20 32 FAILED TO START MANUAL 8 22 34 ENGINE FAILED 5 eee eG ee pee 8 24 35 CHECK STARTER CIRCUIT ett eee aes 8 25 36 CHECK COOLANT TEMPERATURE cece eee eee e eens 8 27 37 SPEED RPM sss 8 28 38 CHECK HIGH SPEED RPM eere OR Se Hadden aces Mal A Wek eig RR a DEIRA Ih 8 30 39 CHECK ENGINE RPM cede ten fe RR Erde bea eben 8 32 40 CHECK GLOW PLUGS eee xp ER RM EGRE EG Exe pac ex n 8 34 41 ENGINE STAPLED cece eau ces re essa ew eats e o bf ie LIED 8 35 8 6 WARNING STATUS ALARMS n n n n n nnn n n nnn 8 37 51 ALTERNATOR NOT CHARGING 8 37 53 BOX TEMP OUIEOF RANGE uae Gaede heed RU MCI RR RUP ROI MENOR AIRE 8 38 54 DEFROST NOT COMPLETE 8 40 55 CHECK DEFROST AIR SWITCH tee e teen eens 8 41 56 CHECK EVAPORATOR AIRFLOW 00 cee eect eee eens 8 42 57 CHECK REMOTE SWITCH 1 eens 8 43 58 CHECK RE
82. Engine Oil And Oil Filter re nean eet eens 9 14 9 8 5 Fube OIlFIlters cese rt een ree ieee natin eed a kaw Lt Gece ed 9 14 9 8 6 Speed Control Solenoid And Linkage 9 15 9 8 7 Electronic Speed Control ESC cee 9 16 9 8 8 gt Engine Air Biter 222 832 cts ecg ce enne eee dae 9 16 9 8 9 Engine Crankcase Breather 9 17 9 8 10 Glow PIUGS s etae Dee e doe ie Pen Reb RUP dears 9 17 62 10683 viii TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page SERVICE Cont 9 9 SERVICING AND ADJUSTING V BELTS eee n 9 17 9 9 1 Belt Tension Gauge 0 ccc ened tenes 9 17 9 9 2 Water Pump Alternator Crankshaft 9 18 9 10 sFANSHAPT ASSEMBLY ai CIR I ERI Bere Riles eel uted venue eee eens 9 21 9 1 0 1 Clutch Removal srian Gad eee M DH he 9 21 9 10 2 Blower Wheel And Fanshaft Removal 9 21 9 10 3 Fanshaft Installation IH n 9 22 9 10 4 Blower Wheel 1 5 9 23 9 10 5 Clutch Installation cee III Hn 9 24 9 11 THERMOSTATIC EXPANSION VALVE mn 9 24 9 11 1 Replacing Expansion Valve amp Screen 9 24 9
83. Harness FSA Harness on ESC Engines Inspect harness amp control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins or terminals schematic Section 11 b Check resistance of speed solenoid Refer to Section 2 13 With the FSA disconnected check FSA on ESC units the FSA coil resistance Spec is 3 4 ohms 10 c Check amp draw of speed solenoid Refer to Section 2 13 Use Component Test Mode Refer to Section 6 2 2 to test Refer to Section 2 13 for amp values View current draw in the Unit Data List Section 3 14 Additional steps on the next page 62 10683 8 30 NO Steps ALARM CAUSE CORRECTIVE ACTION 38 CHECK HIGH SPEED RPM Continued Force High Speed operation See note Note 9 microprocessor is not calling for High Speed operation Check Speed Overrides in Section 4 4 for more information Check voltage to speed solenoid On Must be 12 14 VDC ESC engines check voltage on the engine speed control unit ENSCU pin 16 6 Engine RPM a Check actual engine RPM using hand Refer to Section 2 7 held tachometer Adjust engine linkage setting as needed b Compare actual RPM with those Both readings within 50 RPM shown on display Check Engine Air Intake System a Check air filter indicator Flag must not be visible a Place unit in continuous run and adjust Controller will call for High Speed operation
84. I and the alarm number message 3 Press the ALARM LIST or UP or DOWN key to scroll through the list of alarms 4 When you reach the end of the alarm list LIST END TO CLEAR ALARMS is displayed for five seconds 5 To clear the active and inactive alarm list press the key while LIST END TO CLEAR ALARMS is being displayed ALL ALARMS CLEAR is displayed The microprocessor can hold up to 16 alarms in the combined Active and Inactive Alarm lists The lists can be read via the MessageCenter or using the ReeferManager PC program There are two sections in the Alarm list an Active Alarm section and Inactive Alarm section Alarms in these sections are in the order which the alarms activate and deactivate respectively On startup all alarms are marked as inactive in the entire list If an inactive alarm becomes active the alarm is moved from the Inactive Alarm list to the Active Alarm list As additional alarms occur they will be placed first in the Active Alarm list Each alarm can only be present in either the Active or Inactive Alarm List at any given time As conditions change alarms may be moved from the Active Alarm list to the Inactive alarm list and back Alarms are also recorded in the data recorder They are recorded at the time they occur become active and the time they become inactive For a complete list of alarms and troubleshooting information refer to Section 8 1 62 10683
85. LIGHT BAR and the Remote Heat light circuit to the Light Bar circuit is shorted The Heat Light output from the micro is negative so the circuit will not be shorted to ground but is shorted either within the Heat Light itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when Heat light current amp draw is normal or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Heat Light a Inspect Heat light amp socket No damage to bulb No damaged or corroded pins b Check resistance of light bulb Refer to Section 2 13 Check Heat Light Wiring a Inspect harness amp control See Notes Note 3 Note 4 amp Note 8 connector pins amp terminals See wiring No physical damage to harness schematic Section 11 No damaged or corroded pins Check Heat Light Current Draw a Use Component Test mode Refer to Refer to Section 2 13 for normal current values Section 6 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 14 88 CHECK REMOTE COOL LIGHT TRIGGER ON The micro Light Bar configuration is set for an 8 L
86. Latch Lower Cable Removal 62 10683 9 6 PRIMING FUEL SYSTEM 9 6 1 Mechanical Fuel Pump The mechanical fuel lift pump is mounted on the engine next to the injection pump This pump has a manual plunger for priming the fuel system when the fuel tank has been run dry See Figure 9 1 To prime the fuel system use the following steps a b Turn the bleed valve red counter clockwise until fully opened Turn the top of the manual fuel pump plunger counter clockwise to unlock it S L O W L Y up down once per second pump the manual plunger until positive pressure resistance is felt This may take up to 200 strokes This will indicate fuel flow Red Fuel Bleed Valve Manual Fuel Pump Plunger ENGINE WITH ELECTRONIC SPEED CONTROL C Continue to pump S L O W L Y up down once per second approximately 100 more strokes to fill the filter and bleed the air out of the lines Start engine It may be necessary to continue to pump until the engine starts Depress and turn the top of the manual plunger clockwise to lock in place When engine is running smoothly turn bleed valve clockwise until fully closed Red Fuel Bleed Valve Manual Fuel Pump Plunger
87. NO Steps ALARM CAUSE CORRECTIVE ACTION 125 CHECK COMP DISCH SENSOR TRIGGER ON Compressor Discharge Sensor circuit has failed open or shorted If shorted the data list will display 392 F 200 C If the circuit is open the data list will show the temperature as 40 F 40 C UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when Compressor Discharge Sensor is in range or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Compressor Discharge Temperature Sensor CDT 2 Inspect Compressor Discharge No damage to sensor Sensor amp connector No damage moisture or corrosion in connector b Check Compressor Discharge Sensor Refer to Section 9 28 for complete resistance chart resistance See Note Note 6 000 Ohms 77 F 25 2 Check Compressor Discharge Sensor Wiring EN Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section 2 b Power microprocessor up See Voltage should be 2 5 VDC volts at harness plug between Note 5 Page 8 2 Disconnect sensor pins from harness Check for voltage at
88. No kinks or other obstructions No holes Connected to correct nipple Check Condition Of Evaporator a Visually inspect evaporator following Coil must be clean and cleared of ice or any other defrost material Perform Pretrip a Clear Active Alarm list then run Pretrip Any active alarms must be corrected and cleared before amp check for any new alarms proceeding Check Evaporator Pressure Drop a Check pressure reading with Refer to Section 2 11 Magnehelic Gauge Check Evaporator Fan Clutch a Check Evap Fan Clutch operation in Must disengage fan defrost Check Condition Of Refrigerated Compartment amp Load a Check condition of refrigerated Doors must be closed and door seals must seal and compartment doors amp seals prevent outside air from leaking in 3 4 5 7 b Check condition of product If it is warm and moist frequent defrost cycles can be expected 8 41 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 56 CHECK EVAPORATOR AIRFLOW TRIGGER ON In the Cool mode the Supply Air temperature is 5 F 2 8 C or more warmer than Return Air Temperature for five minutes or In the Heat mode the Suction pressure has been higher than 100 PSIG 6 8 Bars for more than 60 seconds NOTE For this alarm the unit must be running This alarm will not occur in either the Defrost or Pretrip cycles UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset in 15 minutes IF Alarm
89. OPERATING PRESSURE MOP OVERRIDE HEAT AND DEFROST ONLY 00000 c cece eee mn 5 19 5 20 SUCTION PRESSURE OPERATION I 5 20 5 1 INTRODUCTION SECTION 5 TEMPERATURE CONTROL Temperature control is achieved by controlling engine speed compressor UL1 and UL2 unloaders and solenoid valves SV1 SV2 SV4 and the CSMV Temperature control attempts to maintain the compartment temperature at the chosen set point At times the compartment temperature may not be equal to the set point This may be due to the unit is still in the process of pulling down or up to set point OR ethe unit is in Start Stop OFF mode ethe unit has recently terminated defrost the compartment door is open the product was not at set point when loaded 5 2 PERISHABLE AND FROZEN SET POINT RANGES There are two ranges defined for set point a Setpoints above 10 4 F 12 C are considered Perishable b Setpoints of 10 4 F 12 C or below are considered Frozen _ Perishable omn Temperature Control High Air Flow Start Stop Off Cycle Start Stop Restart Cargo Protect Mode Both RAT and SAT sensor alarms are active When the compartment tempera ture is near setpoint the unit will cycle from Heat to Cool to Heat to maintain temperature Continuous High Air Functional Pa rameter is Available ProductShield High Air is Available Compartment temperature criteria is satisfied when the temperature is 0 5 F 0 3 C
90. Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with is steps below as necessary Check Refrigerant Charge a Check for undercharged system Level must be above lower sight glass Manually Test Refrigeration System See Note 9 Page 8 2 a Run Check Must pass all tests p eee any problems found before proceeding b P Sn tac ei ronn and compare compressor Suction Pressure must have the same reading on gauge amp suction P Sn tac ei ronn with pressure shown on micro display on the microprocessor controller Check Compressor Front Head Reed Valves amp Gaskets a Remove ue ecd front head amp Must be in good condition inspect condition of all reeds amp ue ecd 62 10683 8 98 ANO Steps ALARM CAUSE CORRECTIVE ACTION P201 CHECK UL2 CYLINDERS TRIGGER ON A problem has been detected inside the rear cylinder head of the compressor with a suction reed discharge reed head gasket or valve plate gasket UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue wi
91. Remote Auto light circuit to the Light Bar circuit is shorted The Auto Light output from the micro is negative so the circuit will not be shorted to ground but is shorted either within the Auto Light itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when Auto light current amp draw is normal or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Auto Light a Inspect Auto light amp socket No damage to bulb No damaged or corroded pins b Check resistance of light bulb Refer to Section 2 13 Check Auto Light Wiring a Inspect harness amp control box See Notes Note 3 Note 4 amp Note 8 connector pins amp terminals See wiring No physical damage to harness schematic Section 11 No damaged or corroded pins Check Auto Light Current Draw a Use Component Test mode Refer to Refer to Section 2 13 for normal current values Section 6 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 14 90 AUTOFRESH AIR EXCHANGE RELAY TRIGGER ON AutoFresh Air Exchange circuit to the relay coil is shorted The
92. Section 2 13 With FSA unplugged ohm spec is 3 4 ohms 10 b Check amp draw between MPQC4 amp Use Component Test Mode Section 6 2 2 to test terminal 13 and 15 of the ENSCU Refer to Section 2 13 for amp values Check Fuel Solenoid amp Circuit Non ESC engines only a Inspect fuel solenoid and wiring No physical damage to harness No damaged or corroded pins No damage to solenoid b Check operation of Run Relay Start Run Off switch in Start Run Manual Start Operation See Note 2 LED 28 must be ON c Check voltage to fuel solenoid Start Run Off switch in Start Run Manual Start Mode See Note 2 12 VDC between FSCC ground amp FSHA hold With Manual Crank Switch in crank position 12 VDC between FSCC ground amp FSPB pick Check FSA amp Circuits ESC only a Inspect FSA and wiring No physical damage to harness No damaged or corroded pins No damage to solenoid b Check operation of Run Relay Start Run Off switch in Start Run Manual Start Operation See Note 2 LED 28 must be ON c Check voltage to FSA Start Run Off switch in Start Run Manual Start Mode See Note 2 OR component test mode run relay 12 VDC between engine speed control unit ENSCU pins 13 and 19 12 VDC between ENSCU pins 13 and 19 With Manual Crank Switch in crank position 12 VDC between ENSCU pins 15 and 19 Check Fuel Solenoid Circuit Wiring a Inspect harness amp control box No physical damage to harness connector pins am
93. Solenoid Relay SSR 5 Fuse F7 5 Amp 12 Glow Plug Relay GPR Figure 2 8 Control Box Short Box 62 10683 2 8 1 Control Module Microprocessor 7 AutoFresh Relay AFAR Location Only Refer to Section 2 5 3 8 Fuse F5 80 Amp 2 Fuse F1 7 5 Amp Located next to control 9 Fuel Heater Relay FHR Location Only module 10 Starter Solenoid Relay SSR 3 Fuse F10 40 Amp Optional Auto Fresh Air 11 Glow Plug Relay GPR Exchange Location Only 12 Glow Crank Switch GCS on side of box If 4 Fuse F6 15 Amp equipped 5 Fuse F8 20 Amp Optional Fuel Heater 6 Fuse F7 5 Amp Figure 2 9 Control Box Redesigned Tall Box 2 9 62 10683 2 3 CONDENSING SECTION The condensing section consists of engine compressor drive package condenser fan condenser radiator coil refrigerant controls piping wiring The drive equipment includes the engine clutch air cleaner muffler coolant overflow bottle and drive belts Refrigeration components mounted in the condensing section include the compressor defrost air switch suc tion modulation valve filter drier and receiver 2 3 1 Condenser Coil The condenser coil is a tube in fin type and acts as a heat exchanger in which the compressed refrigerant gas is lowered in temperature and condensed into a liquid Air movement over the condenser is provided by an electric motor driven fan mounted in the condensing section 2 3 2 Engine The diesel engine
94. TO ENGINE Number of engine hours until the next programmed engine maintenance MAINT 3 21 62 10683 Table 3 2 UNIT DATA Also appear in Configurations May or may not be displayed depending on functional parameter settings HOURS TO UNIT MAINT Number of switch on hours until the next programmed general unit main tenance TIME LEFT TO PM 1 5 Number of hours until the next programmed maintenance PRODUCTSHIELD SETUP Indicates that unit has IntelliSet installed and displays ProductShield set ings PRODUCTSHIELD Indicates if ProductShield Econo is OFF OR Go To Start Stop OR Go ECONO To Continuous Run ECONO MIN TEMP Minimum ambient temperature of range for activation of ProductShield Econo Will only be displayed if Econo is NOT OFF ECONO MAX TEMP _ Maximum ambient temperature of range for activation of ProductShield Econo Will only be displayed if Econo is NOT OFF ECONO DELTA T Delta T value for activation of ProductShield Econo Will only be dis played if Econo is NOT OFF PRODUCTSHIELD HIGH Indicates if Product Shield High Air is ON or OFF AIR HIGH AIR MIN TEMP Minimum ambient temperature of range for activation of Product Shield High Air Will only be displayed if High Air is ON HIGH AIR MAX TEMP Maximum ambient temperature of range for activation of Product Shield High Air Will only be displayed if High Air is ON HIGH AIR DELTA T Delta T value for activation of Product Shield High Air Will only be dis
95. TRIGGER ON Battery voltage is less than 11 VDC or greater than 17 VDC UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check For Battery Voltage Too High Alarm a Check for alarm 15 Alarm conditions must be corrected and the alarm cleared to continue Check For Battery Voltage Too Low Alarm a Check for alarm A16 Alarm conditions must be corrected and the alarm cleared to continue 8 77 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION P157 CHECK BATTERY CURRENT TRIGGER ON With all circuits off current flow of more than 1 5 or 2 Amps is detected in the electrical circuits NOTE If this alarm occurs Pretrip Test 2 will not be performed You will need to run Pretrip again UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if
96. The number of installs remaining on the PC card will be shown ACTIVE This message will appear in the MessageCenter along with the cur rent IntelliSet indicating that the IntelliSet is active and none of its settings have been modified ACTIVE ALARM LIST CLEARED The list of active alarms in the microprocessor alarm lists has been erased This does not remove alarms from the data recorder ALL ALARMS CLEARED The list of active and inactive alarms in the microprocessor alarm lists have been erased This does not remove alarms from the data recorder ALL INFO LOADED REMOVE CARD All data has been loaded into the microprocessor from the PC card The card may be safely removed from the microprocessor ARL LIGHT OFF IN X MINS The Auto Restart Light circuit to the Operator s Light Bar has been energized in Component Test mode The ARL circuit will continue to be energized for the number of minutes shown BACK TO CONFIGS Pressing the key with this message showing will return the user to the main microprocessor Configuration list BACK TO FUNC PARAMS Pressing the key with this message showing will return the user to the main Functional Parameter list BAD PC CARD OR CARD SLOT The microprocessor has detected a problem with either the PC card or the PC card slot BUZZER OFF IN X MINS The Buzzer circuit has been energized in Component Test mode The Buzzer circuit will continue to be energized for the number of minutes shown CALIBRATIO
97. The user has selected manual start mode The diesel engine must be started using the manual GLOW CRANK switch This is avail able only on units that have a Glow Crank Switch MAX SETPOINT HAS BEEN REACHED Maximum set point allowed by configuration settings has been reached 7 3 62 10683 MessageCenter MESSAGES MIN SETPOINT HAS BEEN REACHED Minimum set point allowed by configuration settings has been reached MODIFIED This message will appear in the MessageCenter along with the cur rent IntelliSet indicating that the IntelliSet is active and one or more of its settings have been modified NEW SW LOAD TO CANCEL A Program PC card has been inserted into the PC card slot and the program on the PC card is a newer version than what is already loaded in the microprocessor Press the key to load the program NO ACTION TAKEN REMOVE CARD A Program PC card has been inserted into the PC card slot and no key presses have been made to install the program into the micro processor The PC card may be safely removed from the slot NO ACTIVE ALARMS There are no active alarms in the microprocessor alarm list NO DATA ON CARD REMOVE CARD A Program or Configuration PC card has been inserted into the PC card slot and no valid data is present on the PC card The PC card may safely be removed from the unit NO DATA TO COPY REMOVE CARD A Download PC card has been inserted into the PC card slot and there is no va
98. This selection will be used as the label text when displaying Trailer Asset Car ID for modification NO When Alarm 30 or Alarm 31 occur the unit will not automatically restart until the Alarms are cleared YES When Alarm 30 or Alarm 31 occur the unit will automatically restart after 4 hours If Rail is selected for Unit Operation and the Rail Shutdown Override is in effect this indicates the number of restarts allowed NO Pressing the SELECT key will allow the user to access the IntelliSet Menu YES Pressing the key will allow the user to ac cess the IntelliSet Menu to return to the Configuration Main Menu When the Rail Shutdown Override con figuration is set to YES the unit will restart and at tempt to continue to run when the unit has shut down 3 times OR the unit has failed to start after 3 start attempts AND either Alarm 30 or Alarm 31 is active AND the unit has been off for 4 hours e Rail Override Restart is the number of times the unit can clear Alarms 30 or 31 after the unit has been off for the 4 hour off time The factory setting is 3 Setting this number too high may result in a discharged or damaged battery if the unit never actually starts or fails to run long enough to charge the battery prior to shutting down again 62 10683 6 2 2 Component Test Mode NOTE To enter Component Test mode refer to Section 6 2 Component Test Mode allows the Technician to energize individual circuits
99. YES theunit will wake up atthe designated time automat ically run Pretrip and then control to setpoint PRETRIP PASS FAIL will remain in the Message Center until it is manually cleared If Sleep Mode is selected when the unit is not running Start Stop OFF Cycle any remaining Minimum Off Time will be ignored and the engine will start It will run for four minutes minimum until the engine coolant temperature is above 122 F 50 C and the battery is fully charged O K appears in the Data list voltage line and charging amps are less than amps set in the Configuration list While the unit is running in Sleep mode SLEEP WARNING NO TEMP CONTROL will flash in the MessageCenter and the main display set point and compartment temperature will be turned off This is because the refrigerated compartment temperature does not have to be at set point to allow the unit to cycle off go to sleep If the unit is already running when Sleep Mode is selected it will continue to run until the conditions described above are met then shut off go to sleep There is NO TEMPERATURE CONTROL in Sleep Mode and it should never be used for hauling perishable or frozen products 62 10683 While the unit is cycled off in Sleep mode SLEEP MODE OFF ON TO WAKE will be displayed inthe MessageCenter The display backlight will turn off after five minutes Sleep Mode may be exited by either turning the Start Run Off switch to the OFF posi
100. a Install two keys into the shaft keyways d Install the fan shaft into the unit with the four fan shaft mounting bolts and torque bolts to 28 to 30 ft Ib 3 9 to 4 1 Mkg making sure the plug for the vent is pointing NOTE up If itis necessary to drive the keys into place be sure to support the shaft while tapping the keys NOTE To aid in fan shaft alignment install two 3 8 16 b Position the fan shaft so that the housing is in the nor x 1 1 2 studs bolts with heads cut off into the mal mounting position with the shaft horizontal and fan shaft mounting hub Once the first two fan the vent hole facing directly up Remove both pipe shaft mounting bolts are loosely installed re plugs 1 8 NPT from fan shaft move the studs and install bolts c Ensure oil in fan shaft is at proper level If not fill the fan shaft with oil 07 00373 00 until oil is at the bot tom of the level hole approximately 3 0z 89 ml Ap ply pipe thread sealant to the pipe plug on the side of f Apply caulk to the fan shaft seal and place on the fan fan shaft housing and tighten Reinstall pipe plug on shaft Place fan shaft seal ring clamp on seal and hub to prevent oil spillage tighten e Apply pipe thread sealant to barb fitting and install into vent hole Slide hose vent onto barb fitting Retaining Bolt 3 Bolts LEFT HAND THREAD Installation See Clutch Installation Step 6 A 25 to 30 ft lbs 3 5 to 4 1 p 18 to 22 ft lbs
101. and clean Evaporator Section check coil s for cleanliness and clear of debris Check air chute if applicable Check bulkhead and return air screen Defrost Water Drains No debris amp drain properly Place in Continuous Run and start unit 62 10683 9 4 IMMEDIATELY AFTER STARTING ENGINE Fuel Leaks Check fuel lines filters for leaks ADJUST Oil Leaks Check oil lines filters for leaks Coolant System Check for leaks Exhaust System Check for leaks Condenser Fan Check for proper airflow O Evaporator Fan Check for proper airflow O Ensure clutch engages properly no slip or unusual noises Check for unusual noises alternator fan shaft water pump idler and gearbox bear ings PRETRIP List any Pretrip alarms List Alarms occurring during Pretrip ADJUST AFTER OPERATING UNIT FOR 15 MINUTES OR MOR Initiate defrost and allow to terminate automatically Allow Defrost to terminate automatically ending the Pretrip 9 5 62 10683 OPERATE IN HIGH SPEED COOL AND RECORD from Microprocessor Unit Data List SUCTION PRESSURE DISCHARGE PRESSURE ENGINE COOLANT
102. and front doors d Reverse above steps to install new surround SURROUND MOUNTING BOLTS REMOVE DECAL PLATE TO ACCESS UNIT MOUNTING STUD SURROUND MOUNTING BOLTS Figure 9 2 Surround Removal 9 9 62 10683 9 5 DOOR LATCH MAINTENANCE AND REPLACEMENT Proper maintenance is important for smooth operation of the latch assembly and the latch pins that are moun ted on the unit s frame See Figure 9 1 In order to keep the movable parts clean and lubricated CTD re commends the use of a de greasing cleaner and LPS 2 lubricant This lubricant should be available at any local automobile and truck parts suppliers 9 5 1 Front Door Latch Cable Replacement a Remove circular clip that secures the cable to the paddle assembly b Slide cable from paddle and rotate other end out of latch assembly c Reverse above steps to install new cable UPPER CABLE F b E UN THREAD THE LOWER CABLE FROM THE UPPER CABLE AND LATCH ASSEMBLY 9 5 2 Side Door Latch Cable Replacement a Remove circular clip that secures the cable to the paddle assembly b Remove the lower cable from the paddle assembly and the lower latch NOTE The lower cable is threaded through the upper cable eyelet and the lower latch assembly See Figure 9 3 c Remove the upper cable from the upper latch d Reverse above steps to install new cable REMOVE CIRCULAR CLIP PADDLE ASSEMBLY Figure 9 3 Side Door
103. any active alarm occurs Continue with the steps below as necessary Check Battery Current Draw aa 7 3 Check Individual Circuits raw Check For Parasitic Loads Electrical current being used by a non refrigeration unit 3 E component a Check for electrical loads that are Check for non factory installed electrical devices such as drawing current with all circuits OFF lift gates inside lights satellite systems etc These must have zero amps during Pretrip 62 10683 8 78 ANO Steps ALARM CAUSE CORRECTIVE ACTION P158 CHECK AMBIENT AIR SENSOR TRIGGER ON Ambient Air Sensor is not within the maximum range of 53 F to 158 F 47 C to 70 C UNIT CONTROL Pretrip will abort and PRETRIP FAILED IN TEST 3 will be displayed in MessageCenter RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Ambient Air Temperature sensor AAT Check ambient air sensor wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section 1 Check remo
104. b Reset Engine Maintenance Hour Meter Hour Meter is reset in the Functional Parameter list for the next service interval Follow maintenance interval recommendations in Section 9 1 1 8 2 Clear the inactive alarms 225 GENERAL MAINTENANCE DUE TRIGGER ON The General Maintenance Hour Meter time has expired UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via keypad Check Unit Maintenance Records a Schedule unit into service facility for Must be done soon maintenance 2 Perform Maintenance BN Perform appropriate engine amp unit Follow instructions on proper maintenance form maintenance EN General Maintenance Hour Meter 8 Check that the General Maintenance Reset Interval in Configuration list as required Hour Meter interval is set for your requirements b Reset General Maintenance Hour Hour Meter is reset in the Functional Parameter list Meter for the next service interval Follow maintenance interval recommendations in Section 9 1 See Note 1 Page 8 2 a Clear the inactive alarms All alarms cleared 8 103 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 226 SERVICE SOON PM 1 DUE TRIGGER ON The Maintenance Hour Meter 1 time has expired UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via keypad Check Unit Maintenance Recor
105. be ON d Check voltage to SV 4 Must be 11 VDC or higher across the 2 wires 4 Check SVA Circuit Wiring As Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section 62 10683 8 72 NO Steps ALARM CAUSE CORRECTIVE ACTION P151 CHECK GLOW PLUG CIRCUIT TRIGGER ON Normal Amps for the Glow Plugs Circuit is 23 to 35 Amps after 15 seconds The circuit tests outside this range UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Glow Plug Circuit a glow plug relay amp socket No of discoloration from overheating oe oe NE cR Ez corrosion b Check operation of Glow Plug Relay START RUN OFF switch in START RUN Manual Start Operation See Note Note 4 Glow Crank switch in Glow position LED 30 must be ON c Check voltage to glow plugs Must be 11 VDC or higher d Check Glow Plug circuit Amps Use Component Test mode Section 6 2 2 to test Refer to Section 2 13 for amp values View current draw in the Unit Data list Refer to Section
106. card adaptor must be used to accomplish this task c Uninstall earlier versions of ReeferManager And Reports as follows All previous version of both ReeferManager and Reports must be uninstalled prior to installing newer versions of these programs NOTE These instructions are intended to be generic and not specific to any computer Because ReeferManager can be installed on any com puter with any operating system excluding Vista there will be some differences within those operating systems from one version to another The wording may not be exactly the same however the procedure below will work for all operating systems mentioned e Click the Start button located at the lower left corner of your computer screen e Move the mouse pointer up to Settings A secondary menu will slide out to the right Move the mouse pointer over and click on Control Panel e With the pop up box there is an icon or line item named Add Remove Programs Double Click it e In the next pop up box scroll down until you find ReeferManager and click it once to highlight it e Click on the Add Remove button A Confirm File Deletion or and InstallShield Wizard will appear If you are certain you have selected the correct program click Yes Next or OK buttons and follow the on screen instructions e When ReeferManager has been uninstalled you will receive a confirmation pop up message Clear it d Auto Install ReeferManager NOT
107. changes and Defrost Initiation and Termination and also records all data values including temperature and pressure sensors in either averaged or snapshot format The details are provided below 3 19 1 Microprocessor Information The microprocessor Information that is available to be recorded is as follows DataRecorder Setup Sensor Being Recorded Logging Intervals Events and Sensors DataRecorder Time Clock Date Time Setpoints And all setpoint changes ID Number Unit Serial Number Unit Model Number Current System Mode Functional Parameters Microprocessor Configurations 3 19 2 Data Recording The DataRecorder data comes from four general categories of information a Microprocessor Information as described in Section 3 19 1 above b Sensor Data This information is recorded at predetermined intervals as snapshot of the sensor at the time of the recording or an averaged reading of the sensor readings since the last recording The user can determine which sensor s will be recorded at what intervals and whether snapshot or averaged readings are preferred Snapshot readings of sensors are also taken at the time of a shutdown alarm c Event Occurrences This information is any additional data that is recorded on a when it occurs basis Events are recorded by the recorder as they occur An Event is defined as something that happens i e set point changed Defrost Cycle Started or Main Power On etc Hourme
108. compressor and remove bolts from valve flanges f Remove fuel filter bracket if necessary from the The service replacement compressor is sold compressor bell housing o at E g Disconnect wiring to unloader valve assemblies PAVE PACS cu DENSA ER ON Compressor Discharge Temperature Sensor CDT moved compressor prior to return shipping Compressor Discharge Pressure Transducer CDP Customer should retain the original capacity Compressor Suction Pressure Transducer CSP unloader valves for use on replacement com and the wiring to the high pressure cutout switch pressor Check oil level in service replacement HPS Identify wiring and switches if necessary See compressor Refer to Section 9 13 Figure 9 18 62 10683 9 28 Remove 10 bolts from the engine compressor bell housing Disconnect ground strap from frame Remove Suction Pressure Transducer from suction line Attach sling or other device to the compressor Slide compressor enough to clear nylon drive gear as shown in Figure 9 19 and remove compressor from unit m Drain oil from defective compressor before shipping n The original unloader valves must be transferred to the replacement compressor The plug arrangement removed from the replacement is installed in the origi nal compressor as a seal If piston is stuck it may be extracted by threading socket head cap screw into top of piston A small Teflon seat
109. detected Test 4 in Heat Pretrip may last up to 12 minutes depending on ambient and compartment temperatures and unit condition For very low compartment temperature the unit may operate in six cylinder low speed heat Test 5 UL2 Rear Unloader With the unit still running the same as it was in Test 4 the operation of UL2 Unloader is tested If suction and discharge pressures do not change when UL2 is energized and de energized the CHECK UL2 alarm will be displayed Test 5 will last about 20 seconds Test 6 UL1 Front Unloader With the unit still running the same as it was in Test 5 the operation of UL1 is tested If suction and discharge pressures do not change when UL1 the CHECK UL1 alarm will be displayed Test 6 will last about 20 seconds Test 7 8 and 9 Engine High and Low Speeds The engine will go from Low Speed to High Speed then back to Low Speed during these tests Engine RPM will be checked If the engine is not operating within the operating range either the CHECK LOW SPEED RPM or CHECK HIGH SPEED RPM alarm will be displayed Tests 7 8 and 9 will last about 30 seconds 62 10683 3 6 Test 10 Check Suction Modulation Valve CSMV This test ensures that the CSMV is opening and closing properly If suction pressure doesn t change as expected with CSMV closed then CHECK SUCTION MOD VALVE alarm will be displayed This test may take several minutes Test 11 SV1 Cool Pretr
110. drives the compressor directly through a nylon drive gear and adapter The adapter also includes a V belt sheave which drives the gearbox The condenser evaporator fan shaft is driven with a V belt from the gearbox The water pump V belt drives the alternator a Engine Transducers and Sensors 1 Engine RPM Sensor ENRPM Non ESC engines only Non ESC Engines Provides microprocessor with engine RPM information to be displayed and recorded in the DataRecorder It is located on the rear of the engine in the flywheel housing ESC Engines Provides the ENSCU with the engine RPM information for speed control of the engine The ENSCU then sends the information to the micropro cessor to be displayed in the unit Data List and then to be recorded in the Data Recorder It is located in the tim ing case cover of the engine above the oil filter 2 Engine Oil Pressure Switch ENOPS This normally open switch allows the engine to operate when oil pressure is above 15 2 PSIG 1 02 0 1 Bars The switch will open and automatically stop the engine 5 seconds after pressure drops below 15 2 PSIG 1 02 0 1 Bars There is a 15 second delay after the engine starts to allow the oil pressure to build up before the microprocessor looks at the input from this switch The switch is located on the front of the engine below the fuel solenoid 3 Engine Oil Level Switch ENOLS Optional ENOLS sets off alarm when oil level is low Located on
111. eG 4 1 4 2 Engine Cranking sic su esc nee hee a be eet eed scene oleate beeen id eed 4 1 4 2 2 Variable Glow Time csc in csc teed eed a cae Lee eee led L ERRUEdaS 4 1 4 2 3 Engine RUNNING 63 acer uet up beeen ter eatin aren te ele 4 3 4 2 4 Initial Engine Operation cee eee n 4 3 4 3 RUNNING MODES eee teed ents eed ees da ee pi 4 3 4 3 1 Start Stop Mode eet ete ees 4 3 4 3 2 CONTINUOUS RUN MODE hr 4 5 4 4 SPEED CONTROL OVERRIDES 0 ccc ccc 4 6 62 10683 ii TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page TEMPERATURE CONTROL ccc es le Se eee Shee eee eee NTA 5 1 512 INTRODUCTION ob eer ee eee Mae ete DEDE EET ebat eas 5 1 5 2 PERISHABLE AND FROZEN SET POINT RANGES 5 1 5 3 PULLDOWN PULL UP MODE easa een ae a a a a aa na 5 2 5 4 CHEAT MODE OPERATION i 3 ceeds up REIR yee QU 5 2 bib COOLMODE OPERATION iirin sraa pice ee ees WA aah Plas a D h 5 2 5 6 UltraFresh 3 TEMPERATURE CONTROL sssssssses sese hn 5 3 5 6 1 Heat Cool Null Switching Operation 5 3 5 6 2 Null Mode Operation eens 5 4 5 7 UltraFreeze TEMPERATURE CONTROL 00 00 cece ene hn 5 4 5 754 UltraFreeze Offset eise Ee Rire geb Mee oe waa ROI ds
112. eee a Refer s Refer to UL1 Refer to UL2 Refer to NOTE The CSMV maintains the maximum suction pressure of the refrigeration system The selected controlling sensor determines if the unit is running in high speed or low speed and six or four or two cylinders The control ling sensor may be RAT or SAT depending if the the microprocessor is configured for Return Air Control or Supply Air Control Refer to Chart in Section 5 18 for maximum suction pressure limits during each mode of operation in Cool Mode 62 10683 5 2 5 6 UltraFresh 3 TEMPERATURE CONTROL UltraFresh 3 is an advanced method of temperature control for set points in both Perishable and Frozen ranges It produces a reduced capacity state by throttling down the CSMV and pulsing the SV4 valve SV4 Pulse Mode or mixing heating and cooling modes Pulsed Null Mode UltraFresh 3 uses the supply or return air sensor to control compartment temperature while insuring that the supply air temperature does not get too cold when a perishable set point is chosen The sensor that is selected under the Functional Parameters for temperature control is shown below as the selected probe The Temperature Control Probe is the sensor actually used by the microprocessor to perform the temperature control In the case of a bad probe the remaining probe will be used for temperature control If both probes are bad the unit will run in Cargo Protect Mode SELECTED PROBE TEMPERATURE CON
113. error in the Setpoint that is stored in the microprocessor memory or in the memory sector of the microprocessor that the Setpoint is stored in UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset when a valid Setpoint is entered or Alarm may be manually reset by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Set Point a Check set point setting Must be between 22 89 6 30 C 32 C b Enter new set point Reset Microprocessor a Turn the Start Run Off switch off for 30 The microprocessor powers up OK and the latest setpoint seconds and then turn back on appears in the display b Valid set point can not be entered Replace microprocessor See Note 1 Page 8 2 a Clear the inactive alarms All alarms cleared 233 MODEL ERROR TRIGGER ON There is an error in the Model Number that is stored in the microprocessor memory or in the memory sector of the microprocessor that the Model Number is stored in UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset only when a valid Model number is entered NOTE Follow the steps below until a problem is found Once a repair or correction has bee
114. family must be identified for the correct model num ber to be displayed in the next selection UNIT MODEL NUMBER NDL93N ABO The correct model number must be selected for NDL93P ABO proper operation and control This is also part of the Unit Data where user can read the information This list contains many selections NDL93R ABO Configuration mode is the only way user can write Only those covered by this manual NDL93S ABO information are shown here NDL93S ABA Pick one of these models from the X NDL93U ABA series model family NDL93V ABO UNIT SERIAL NUMBER The unit S N may be entered This may be up to 11 characters long Numbers letters and a space are available by scrolling through the available list TRAILER ID The ID number may be entered This may be up to 10 characters long Numbers letters and a space are available by scrolling through the available list Hours from existing microprocessor can be installed into replacement micro NOTE Changes to these values may be made for SET NEW HOURS up to 60 minutes based on the real time clock This configuration only appears in the list until an hourmeter reaches 25 hours LONG SHORT LONG Longer glow times may be used for units GLOW TIME in colder ambient conditions SHORT Shorter glow times are used as the facto ry setting for all engines NOTE Refer to Section 4 2 1 for glow time table 6 3 62 10683 CONFIGURATION SELECTIONS DESCRIPTION YES When the c
115. for high speed delay ee NO NO minutes for continuous run Has the unit been running less that the selected high YES gt Y Check funtional parameter settings for speed delay minutes Is the unit in Start Stop YES high speed delay minutes for start stop NO operation Check the configurations for high speed delay Is the setpoint 10 5 F NO Is the setpoint further away from the selected or higher probe temp for less than the selected minutes NO YES Y Is selected probe temp within YES Is return air temp equal to or N po e colder than setpoint setpoint Is speed relay LED27 Check the F2 circuit illuminated on micro for excess amp draw or short to ground Did YES you find and correct the condition The micro is calling for low speed operation If you believe this is not Is the F2 fuse blown correct review your testing with your supervisor before changing NO microprocessor Is there voltage at QC3 NO NO Replace relay Did you YES Check for proper operation of the NO find and correct the condition T YES speed relay Is the relay Review the test results with your operating properly y supervisor If necess
116. full automatic control of the engine or compressor starting and stopping by monitoring refrigerated com partment temperature battery charging amps battery voltage and engine coolant temperature Engine Road only The main function of automatic cycling is to turn off the refrigeration system near set point to provide an energy efficient temperature control system and to initi ate a restart sequence when certain conditions are met The Start Stop Continuous key is pressed to select be tween Continuous Run and Start Stop operating modes Refer to Section 4 3 1 for more detailed infor mation on Start Stop Mode 3 9 If the unit fails to start after three start attempts the FAILED TO START AUTO MODE alarm will be activated While running if the unit shuts down on a safety or fails to run for the minimum run time three consecutive times the FAILED TO RUN MINIMUM TIME Alarm will be activated The shutdown counter is cleared when the unit has run for 15 minutes or when the unit cycles off normally NOTE FreshProtect is not enabled in Start Stop mode See Functional Parameters List Table 3 3 62 10683 3 6 1 Start Stop Parameters The selectable Start Stop parameters in the Functional Parameter list can be applied to Start Stop operation so that The same settings apply to any set point or The settings can be specified to be different depend ing on whether the set point is inthe perishable range
117. glow plugs Must be 11 VDC or higher 2 Glow Plug Circuit Wiring Inspect harness amp control box physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins schematic ae Glow Plugs Check amp draw of each glow plug 62 10683 8 34 NO Steps ALARM CAUSE CORRECTIVE ACTION 41 ENGINE STALLED TRIGGER ON The engine is running RPM sensor is good and engine speed is less than 10 RPM or The engine is running RPM sensor alarm is ON and the Oil Pressure switch contacts are open UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Restart after 15 minutes or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with he 2 below as necessary 1 Check For Alarm 130 Check RPM Sensor e Check for alarm 130 When Alarms 130 and 41 occur at the same time generally the engine has run out or is running out of fuel This causes the engine RPM to surge and drop Check fuel tank and add fuel as necessary Check fuel lines between the fuel tank and the fuel pump inlet for drawing air in Check For Flash Code On Engine Speed Control Unit ENSCU Applies to ESC engines only a Check for flash codes on t
118. gt CONDENSER Figure 2 17 Refrigerant Circuit During Heating And Defrost 62 10683 2 30 SECTION 3 OPERATION PARAGRAPH NUMBER Page 3 1 STARTING UNIT AUTO cee e nr 3 1 3 2 MANUAL START GLOW AND CRANK IF 3 2 3 3 Unit Startup Self UP e t ie Ge ae eee ate eile des 3 3 3 4 SPRETBIP r aae eee Pies Ge MENU a Wek Meat 3 4 3 5 CHANGING SET POINT mn 3 8 3 6 START STOP OPERBATION a E E 3 9 3 7 CONTINUOUS RUN OPERATION nn 3 11 3 83 SLEEP MODE ON 5 emt be ea Gaia Veet ben end Hanada es 3 12 3 9 SLEEP MODE eren bere Te peris ute bet IRI Macte pe dele LR Dus 3 13 3 10 DEFROST irre YR re ales Reve ee de 3 15 9 10 1 Manudal Defrost Sac eins Saeed eb ERES OR RR DE Se UE eR E PES 3 15 3st TRIPSSTABTS fad eser estt b Se a d sse A 3 16 3 12 VIEW ACTIVE ALARMS cece ec ehh hen 3 17 3 19 VIEW INACTIVE ALARMS e EERSUEDC ERE UA Wide halk be CEP DVve eee lees 3 18 3 14 UNIT DATA Re Ro bale ek ards me RR eio wale nana ale be 3 20 3 15 VIEW HOURMETERS e Dc unl Nace Roten dite 3 24 3 16 FUNCTIONAL CHANGE PARAMETERS 3 25 3 17 LANGUAGE SELECTION cece ences bis ee ee Ge
119. have contributed to the occurrence of the first alarm The first alarm that appears is the last alarm that was recorded The check items in the troubleshooting guide are listed in order of their likeliness of occurrence and ease of testing We recommend that you follow the order in which they are presented however there may be times when situations or experience directs you to use a different order For example if the trailer or rail car is loaded you may want to perform all the condensing unit checks first even though some evaporator section checks may be listed before them As you go through the troubleshooting steps you will find the cause of the problem When you find and correct the problem it is not necessary to continue through the remainder of the steps Some active alarms will clear inactivate themselves automatically once the cause has been corrected You then only need to go to the inactive list to clear all alarms before verifying the remainder of the unit operation Alarms that do not inactivate themselves automatically must be cleared manually See Note 1 Page 8 2 When you are finished making repairs run the unit through a Pretrip cycle and verify that no further active alarms occur Also both Alarm lists should be cleared sothat there are no old alarms in memory when the unit leaves your repair facility If the message CHECK MICROPROCESSOR appears in the MessageCenter there is a communication error betw
120. higher the CDT limits are increased to 340 F 171 C for three minutes d Compressor Suction Modulation Valve CSMV The CSMV opens and closes as required for capacity control of the refrigeration system cooling cycle It is located in the suction line at the exit of the evaporator pod e Ambient Air Temperature Sensor AAT AAT is a temperature control probe which provides the microprocessor with ambient air temperature informa tion to be displayed recorded in the DataRecorder and used to control the refrigeration system It is located behind the condenser grille 2 4 EVAPORATOR SECTION The evaporator fits into a rectangular opening in the upper portion of the front wall of the refrigerated compartment front wall When installed the evaporator section is located inside this compartment and the condensing section is outside The evaporator assembly consists of an evaporator coil an evaporator fan motor a thermal expansion valve a heat exchanger a defrost termination sensor DTT supply SAT and return RAT air sensors See Figure 2 7 2 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 du
121. inspections ofthe unit Failure to follow the recommended maintenance schedule may affect the life and reliability of the refrigeration unit 9 3 62 10683 9 2 PRETRIP INSPECTION AX WARNING Inspect battery cables for signs of wear abrasion or damage at every Pre Trip inspection and replace if necessary Also check battery cable routing to ensure that clamps are secure and that cables are not pinched or chafing against any components The following pretrip inspection should be performed before every trip and at regular maintenance intervals ADJUST REPLACE BEFORE STARTING ENGINE Drain water from bottom of fuel tank Drain water from water separator on fuel filter if applicable Check radiator coolant level Condenser Coil Cleanliness Check the coil for cleanliness straighten fins if ne cessary Radiator Coil Cleanliness Check the coil for cleanliness straighten fins if necessary Air Cleaner Hoses insure they re secure with no leaks Air Cleaner Indicator check operation if applicable Engine Oil Level check and add if neces sary Check condition and tension of belts Check all fan and idler bearings Door Latches Hinges Check for proper operation Condenser Fan Blades Check condition Check battery fluid level if applicable Battery cables and terminals are secured
122. is shorted either within the SV2 coil itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when unit calls for Heat or Defrost and the SV2 coil current amp draw is normal or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check SV2 Coil terminals No damaged or corroded pins Check SV2 Wiring a Inspect harness amp control box See Notes Note 3 Note 4 amp Note 8 connector pins amp terminals See No physical damage to harness wiring schematic Section 11 No damaged or corroded pins Check SV2 Current Draw a Use Component Test mode Refer to Refer to Section 2 13 for normal current values Section 6 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 14 8 55 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 8 8 SENSOR ALARMS 121 CHECK AMBIENT AIR SENSOR TRIGGER ON Ambient Air Sensor circuit has failed open or shorted If shorted the data list will display 158 F 70 C If the circuit is open the data list will show the temperature as 52 6 F 47 C UNIT CONTROL A default value of 122 F 50 C w
123. locally and there can be no two way communication when the Mode switch on the Remote Monitoring Control Box is in MAINTENANCE MODE Therefore when performing maintenance on the unit place the Mode switch in MAIN TENANCE MODE After the unit is serviced return the Mode switch to REMOTE ON Re fer to Section 3 20 3 for more detailed infor mation on two way communication WARNING Inspect battery cables for signs of wear ab rasion or damage at every Pre Trip inspec tion and replace if necessary Also check battery cable routing to ensure that clamps are secure and that cables are not pinched or chafing against any components WARNING Under no circumstances should ether or any other starting aids be used to start en gine WARNING Do Not Allow Configuration Jumper Wire To Touch Any Ground 62 10683 1 2 WARNING The 5 0 VDC terminal B is common be tween the Compressor Discharge Pressure Transducer the Compressor Suction Pres sure Transducer and the RPM sensor If this circuit is shorted to ground due to one of the mentioned components being defec tive or a worn wire the MessageCenter will show Suction Pressure 14 7 PSIG 1 Bar Discharge Pressure 0 PSIG Bar Engine RPM 0 WARNING Keep hands and arms away from unit when operating without belt guard in place Nev er release a unit for service without the belt guard securely tightened in place WARNING
124. lower than this value Select the highest temperature that will ever be used as set point Set point can not be set higher than this value Indicates if the Auto Fresh Air Exchange is installed If AutoFresh Air hardware is not installed this configuration needs to be set to NOT INSTALLED to prevent alarms from occurring CONFIGURATION SELECTIONS DESCRIPTION SETPOINT SETPOINT Once the compartment temperature has reached set point 1 5 F 0 8 C the Auto Fresh Air Exchange system will start to operate based on the parameters selected in the Functional Parameter list AUTO FRESH AIR DELAY 0 48 HOURS IN 0 to 48 Hours After this length of time AutoFresh 1 HOUR Air Exchange will begin if the unit is no longer run ning in pull down mode Refer to Section 5 3 even INCREMENTS though the compartment temperature has never reached set point TOGETHER TOGETHER When the Minimum Run Time Mini mum Off Time Maximum Off Time and Override Temperatures are set in the Functional Parameter List the same values will be used for both Frozen S S PARAMETERS and Perishable set points SEPARATE SEPARATE When the Minimum Run Time Mini mum Off Time Maximum Off Time and Override Temperatures are set in the Functional Parameter List different values may be entered for Perishable and Frozen set points ON A remote sensor has been added to the unit REMOTE TEMP SENSOR 1 3 and connected into the wire harness at Remote Optiona
125. microprocessor controller 62 10683 8 100 NO Steps ALARM CAUSE CORRECTIVE ACTION P204 LOW SUCTION PRESSURE TRIGGER ON Suction Pressure is less than 10inHg 0 34 Bar for more than 30 continuous seconds or less than 16inHg 0 54 Bar for more than 5 seconds at any time during Pretrip UNIT CONTROL Pretrip will abort and PRETRIP FAILED IN TEST X will be displayed in MessageCenter indicating in which test the suction pressure was too low RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Fan Belts a Check upper fan belt tension amp Refer to Section 9 9 for belt tensions condition No Glazing no cracking no slipping b Check lower fan belt tension amp Refer to Section 9 9 for belt tensions condition No Glazing no cracking no slipping suction pressures with those shown on reading on gauges amp on micro display the microprocessor controller Manually Defrost Unit a Defrost unit and terminate Typical defrost cycle time is 5 20 minutes automatically Suction pressure should rise gradually during cycle Check Evaporator Air Flow a Che
126. minutes between shutdowns the Alarm 30 FAILED TO RUN MINIMUM TIME Alarm will be activated The shutdown counter is cleared when the unit has run for 15 minutes NOTE FreshProtect is enabled in Continuous Run mode See Functional Parameters List Table 3 3 62 10683 3 8 SLEEP MODE ON e e e HEAT COOL DEFROST START STOP CONTINUOUS SETPOINT BOX TEMPERATURE SLEEP MODE SETTINGS MANUAL ALARM LIST ISTART DEFROST epi JAN 1 Press the SELECT key until the MessageCenter displays PRESS 1 TO VIEW SETTINGS 2 By pressing the UP or DOWN ARROW key you will move through the Function List until SLEEP MODE SETTINGS appears in the MessageCenter 3 Press the key 1 TO SCROLL THEN TO SAVE will show in the MessageCenter 4 Press the key to select Sleep Mode Settings 5 SLEEP MODE YES OR will show in the MessageCenter Press either UP or DOWN ARROW key to change the Sleep Mode to YES 62 10683 3 12 3 9 SLEEP MODE OFF e e e e HEAT COOL DEFROST START STOP CONTINUOUS SETPOINT BOX TEMPERATURE SLEEP MODE SETTINGS MANUAL ALARM EM py z dp deum 1 Press the SELECT key until the MessageCenter displays PRESS 1 TO VIEW SETTINGS 2 By pressing the UP or DOWN ARROW key you will move through the Function List until SLEEP MODE SETTINGS appears in the MessageCenter 3 Press the key 1 TO SCROLL THEN TO SAVE will show in the MessageCen
127. necessary Due to the time involved in adjusting the superheat replace the valve rather than adjusting it 9 11 3Measuring Superheat NOTE The expansion valve and bulb location are shown in Figure 2 7 a Remove evaporator panel from rear of unit and then pull loose the Presstite insulation from one end of the expansion valve bulb b Loosen one TXV bulb clamp and make sure area un der clamp above TXV bulb is clean c Place thermocouple above parallel with TXV bulb and then secure loosened clamp making sure both bulbs are firmly secured to suction line as shown in Figure 9 16 Use Presstite insulation to completely cover both bulbs 9 25 1 Suction Line 2 TXV Bulb Clamp 3 Nut and Bolt Clamp 4 Thermocouple 5 TXV Bulb Figure 9 16 Thermostatic Expansion Valve Bulb and Thermocouple NOTE When conducting this test the suction pressure must be at least 6 PSIG 0 41 Bar below ex pansion valve maximum operating pressure MOP For MOP Refer to Section 2 11 Connect an accurate gauge to the 1 4 0 01mm port on the suction service valve Run unit until stabilized Set controller 10 F 5 5 C below refrigerated compartment temperature From the temperature pressure chart Refer to Table 9 9 determine the saturation temperature cor responding to the evaporator outlet pressure Note the temperature of the suction gas at the expan sion valve bulb Subtract the saturation te
128. open or shorted If shorted the data list will display 158 F 70 C If the circuit is open the data list will show the temperature as 52 6 F 47 C UNIT CONTROL Alarm only RESET CONDITION Auto Reset when Remote Temperature Sensor 1 is in range or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Remote Temperature Sensor 1 REMSN1 a Verify that Remote Temperature Remote Temperature Sensor 1 is installed Sensor 1 has been installed and is Wires are connected to 10 pin connector at cavities E amp F correctly wired to the unit If sensor is not present change micro configuration to OFF 2 Check Remote Temperature Sensor 1 E Inspect Remote Temperature Sensor 1 No damage to sensor amp connector No damage moisture or corrosion in connector b Check Remote Temperature Sensor 1 Refer to Section 9 28 for complete resistance chart resistance See Note Note 6 5 000 Ohms 77 F 25 C Check Remote Temperature Sensor 1 Wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section 1
129. operating in low speed and the suction pressure is greater than 65 PSIG 4 4 Bars both unloaders are unloaded As the suction pressure drops below 64 PSIG 4 4 Bars the UL2 unloader is loaded If the suction pressure drops below 35 PSIG 2 4 Bars the UL1 unloader is loaded b At ambient temperatures of 90 F 32 2 C or higher At ambient temperatures of 90 F 32 2 C or higher the unloading suction pressure settings relative to ambient temperatures follow a descending straight line Refer to following chart REFRIGERATION SYSTEM SUCTION PRESSURES FOR LOADING AND UNLOADING UL1 FRONT UNLOADER UL2 REAR UNLOADER SUCTION NN ABOVE THE LINE UNLOADED PRESSURE BELOW THE LINE LOADED 80 00 90 00 100 00 110 00 120 00 130 00 F AMBIENT TEMPERATURE 62 10683 5 20 SECTION 6 TECHNICIAN INTERFACE PARAGRAPH NUMBER Page 6 1 MODE DOWNLOAD PORT 000 cece cent ene eae 6 1 6 2 MICROPROCESSOR CONFIGURATION AND TECHNICIAN TEST MODES 6 2 6 2 1 Configuration Mode cen tee spend peels bE beanies DERE 6 3 6 2 2 Component Test Mode 6 12 6 2 3 5 MOC eich coer eden DER Ead Nette Ree 6 13 6 3 PC SUPPOHT SOFTWARE ren ta deat ee tas ee 6 14 6 3 1 ReeferManager And Reports cece cee een n 6 14 6 4 DOWNLOADING DATA WITH THE PC CARD 6 16
130. or PRETRIP FAIL IN TEST if the Pretrip cycle was aborted by an alarm before it was completed 3 7 62 10683 3 5 CHANGING SET POINT HEAT e COOL 20 SETPOINT e DEFROST t MANUAL DEFROST mil ALARM LIST e e START STOP CONTINUOUS 145 F BOX TEMPERATURE TO SCROLL THEN TO SAVE SELECT CONTINUOU 1 With the setpoint displayed press the UP ARROW or DOWN ARROW key to change the setpoint to the desired value The MessageCenter will show 1 TO SCROLL THEN TO SAVE 2 Press the key to save the Set points of 22 F to 89 6 F 30 C to 32 C may be entered via the keypad The microprocessor always re tains the last entered set point in memory Depending on microprocessor set up the set point may be changed up or down in either 0 1 one tenth of a degree or 1 one full degree increments by pressing and releasing either the UP ARROW or DOWN ARROW key NOTE The microprocessor Configurations allow a minimum and maximum setpoint to be entered so that only set points within that range may be selected MAX SETPOINT HAS BEEN REACHED or MIN SETPOINT HAS BEEN REACHED will appear in the MessageCenter when either of these conditions are met 62 10683 3 8 Set point may be changed any time the Start Stop Off switch is inthe START RUN position or when the unit in PC Mode EXCEPT when Viewing the Alarm List Data List or Functional Par
131. outlet valve king valve and run the unit in cooling until the correct amount of refrigerant is added When scale indicates that the correct charge has been added close liquid line valve on drum and back seat the king valve Remove charging hose Start unit and check for noncondensibles and run a unit Pretrip Refer to Section 3 4 Figure 9 18 Pressure Switch and Sensor 9 12 REPLACING THE COMPRESSOR CAUTION Service mode MUST be used whenever moving refrigerant charge refrigerant leak checking or evacuating Refer to Section 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 Section NO TAG If compressor does not operate frontseat both suction and discharge service valves and remove refrigerant charge from compressor Refer to Section NO TAG 6 2 3 a Disconnect negative battery cable b Remove the two rear compressor bracket mounting bolts compressor shockmount end NOTE BI Service replacement compressors are shipped eee without oil d Back out suction and discharge service bolt valve flange by two complete revolutions and leave threads 9 12 1 Removal and Replacement of Compressor engaged e Break seal between service valves and
132. pressure shown on micro display on the microprocessor controller c With manifold gauges connected to the Monitor manifold gauges with the unit off The suction and compressor discharge and suction discharge pressures should not equalize for several valves and the unit running in Cool minutes slowly front seatthe King Valve until the suction pressure reaches 5 psig 3 Correct any problems before proceeding bar then shut the engine off 8 99 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION P203 CHK DISCHARGE CHECK VALVE TRIGGER ON Refrigerant is leaking backwards through the Discharge Check Valve UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the below as necessary 1 Check Discharge Check Valve e Test Discharge Check Valve for Must not leak leakage Manually Test Refrigeration System See Note 9 Page 8 2 a Run O Check Must Er E __ all tests Pee 777 any found before proceeding b Check and compare compressor Suction Pressure must have the same reading on gauge amp suction pressure with pressure shown on micro display on the
133. ring at bottom of pis ton must be removed Remove the complete High Pressure switch assem bly HPS See Figure 9 18 and install on new com pressor after checking switch settings Remove Compressor Discharge Temperature sensor CDT Compressor Discharge Pressure transducer CDP and Compressor Suction Pressure transducer CSP and install on new compressor Install compressor frame to new compressor if removed with defective compressor p mi W X Install compressor in unit by reversing step 4 12 b through n The use of new locknuts is recommended when replacing compressor Torque bolts to a value of 46 ft lb 6 4 Install new gaskets on service valves and tighten bolts uniformly Refer to Section 9 29 1 drive gear installation Attach two lines with hand valves near vacuum pump to the suction and discharge service valves Leak test then dehydrate and evacuate compressor to 500 microns 29 90 Hg vacuum 75 9 cm Hg vac uum Turn off valves on both lines to pump Fully backseat open both suction and discharge service valves Remove vacuum pump lines and install manifold gauges Check refrigerant level Start unit and check for noncondensibles Check compressor oil level Refer to Section 9 13 Add oil if necessary Check compressor unloader operation Refer to Section 9 14 Check refrigerant cycles by running a unit Pretrip Refer to Section 3 4 Compressor Bo
134. same The correct wire plug to each transducer must be connected to the proper transducer Check for Check UL1 alarm a Check for alarm 85 or P144 Alarm conditions must be corrected and the alarm cleared to continue Check system pressures Check and compare compressor Suction amp Discharge Pressures must have the same discharge amp suction pressures with reading 5 PSIG 0 34 Bar on gauges amp on micro those shown on the microprocessor display controller Check for Check SV2 Circuit Alarm a Check for alarm 97 or P192 Alarm conditions must be corrected and the alarm cleared to continue Check Front Unloader UL1 Operation Unit must be running See Note 9 Page 8 2 See Section 9 14 Unloader Checkout Procedure a Energize UL 1 coil Pressures must change within 3 4 seconds of coil being energized or de energized Suction pressure must raise slightly Discharge pressure must drop slightly b De energize UL1 coil Suction pressure must drop slightly Discharge pressure must raise slightly Check for Check UL2 Unloader alarm a Check for alarm P191 Alarm conditions must be corrected and the alarm cleared to continue Check SV1 for being closed a Check voltage to SV1 coil Must be 0 VDC b Check pressure differential between Must be less than 25 PSIG 1 70 Bars compressor discharge port and receiver king valve Check the compressor center head snubber tee a Check snubber restrictor inside the
135. seconds of coil being energized or de energized Suction pressure must raise slightly Discharge pressure must drop slightly Check snubber b De energize UL2 coil Suction pressure must drop slightly Discharge pressure must raise slightly 5 Check The Compressor Center Head Snubber Tee a Check snubber restrictor inside the Tee must be open and not blocked or overly restricted If tee assembly for HPS and CDP doubt remove the snubber restrictor with a hammer sensors and small punch then restart pretrip BN NE B E 8 91 62 10683 NO Steps ALARM CAUSE CORRECTIVE ACTION P192 CHECK SV2 CIRCUIT TRIGGER ON Normal Amps for the SV2 Circuit is 0 75 to 2 0 Amps The circuit tests outside this range UNIT CONTROL Pretrip will abort and PRETRIP FAILED IN TEST 2 will be displayed in MessageCenter RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check For Bad F4 Or F6 Fuse Alarm a Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue Check SV2 a Check resistance of SV2 Refer to Section 2 13 b Check amp draw of SV2 Use Componen
136. set Purge lines Connect a second manifold test set discharge gauge to the king valve 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 Open the LIQUID valve on drum and purge all hoses Start the unit Adjust the setpoint so that the unit will run in high speed cool mode Run the unit for approximately ten minutes until the refrigeration system is warmed up and the refriger ated compartment temperature is less than 45 F 7 2C Check the appropriate sight glass to determine charge See Step g for determination of charge If undercharged proceed with step e Frontseat the king valve and monitor the second set of manifold gauges When the king valve pressure drops below the pressure in the refrigerant drum open the manifold gauge set discharge valve and al low liquid refrigerant to flow into the system While monitoring the appropriate sight glass careful ly weigh the refrigerant into the system Because the unit is in this charging state it is not possible to accu rately determine when the system is full Therefore never allow more than 3 lbs 1 4 kg of refrigerant into the system at a time After metering 3 lbs 1 4 kg of refrigerant into the sys tem close the valve of the manifold gauge set con nected to the king valve Open the king valve and al low the system to balance out appr
137. set point to at least 15 degrees away from box temperature and a temperature greater than 20 F 5 6 C If the unit does not immediately go into High Speed set the AIRFLOW Functional Parameter to HIGH Check operation of Speed Relay LED LED 27 must be ON If LED 27 is not on the b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Check Engine Exhaust System a Inspect the exhaust system Must be clear and unobstructed 8 31 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 39 CHECK ENGINE RPM TRIGGER ON Engine RPM have been Less than 1200 or greater than 2500 for Ultima XTC and X2 2500A R or Less than 1100 or greater than 2000 for Ultra XTC and X2 2100A R for more than five minutes UNIT CONTROL Alarm Only or Unit Shutdown amp Alarm if configured RESET CONDITION Auto Reset if unit is set for Alarm Only when engine RPM are Between 1200 to 2500 for Ultima XTC and X2 2500A R or Between 1100 to 2000 for Ultra XTC and X2 2100A R for more than five minutes or After 15 minutes if the unit is set for RPM Shutdown or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below
138. show INSTALL COMPLETE REMOVE CARD At the same time the Card Status LED will stop blinking and be on solid indicating that the software install is complete 6 When the card is removed the Microprocessor will power up as it was prior to inserting the card PC mode or unit running Allow the Micro to completely power up Main Display and MessageCenter displaying appropriate messages once after installing the new software before turning the power off or removing the PC mode jumper DO NOT TURN THE START RUN OFF SWITCH OFF DURING THE INITIAL START FOLLOWING A SOFTWARE UPGRADE 62 10683 6 18 6 5 3 Using ReeferManager to Install Software 44 CAUTION It is important that communications be tween the Microprocessor and the comput er not be disturbed during the software loading process If using a laptop comput er turn all energy saving features off Turn off any screen saver or any hard drive time out settings NOTE 04 10 software and above can be installed us ing either the preferred previously described Program PC card method or by using a minim um of ReeferManager 03 07 and a computer Existing Program PC cards may be upgraded to the latest software version by using the Reefer Manager program The ReeferManager version 03 07 program is designed to be installed and operated on the fol lowing Windows operating systems Windows 95 98 ME 2000 and XP The programs will not operate on Windows Vista Prepare the PC t
139. software loading process de pending on the version of software currently in the controller DO NOT INTERRUPT THE SOFTWARE INSTALLATION PROCESS ONCE IT HAS STARTED 1 Place the Microprocessor in PC mode Refer to Section 6 1 or place the START RUN OFF switch in the START RUN position 2 Insert a Program PC card into the PC card slot on the front of the microprocessor Be certain that the instruction label on Program PC card is facing the Caution label on the microprocessor Do not force card into slot Hold the Program PC card at the end opposite the plug end Do not squeeze the card in the middle while inserting See Section 2 5 4 for PC card care 3 The MessageCenter will show one of three different messages Same SW to Load 1 To Cancel Old SW to Load 1 To Cancel New SW to Load 1 To Cancel 4 Verify by the message that you are upgrading downgrading the software according to your intentions 5 Press the key to load the program The MessageCenter will show ENGINE AND MICRO WILL STOP NOW If the engine is running it will shut down After about 45 seconds the MessageCenter backlight will dim and the message INSTALLING PROGRAM SOFTWARE will be displayed The Card Status LED adjacent to the PC card slot will blink together with the Micro Status LED at a rate of 1 2 second on then 1 2 second off during this installation process Once the entire program has been loaded the MessageCenter will
140. speed RPM in Test 8 by Between 450 and 925 for Ultima XTC and X2 2500A R or Between 150 and 525 for Ultra XTC and X2 2100A R UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Speed Solenoid amp Linkage On Non electronic Speed Controlled ESC Engines And The Fuel And Speed Actuator On ESC Engines a Check speed solenoid FSA on ESC Must move in and out freely plunger b Check engine speed arm amp linkage Must move freely Force Low Speed Operation See Note 9 Page 8 2 a Set Functional Parameter LOW LED 27 must be OFF SPEED START for a high number 30 to 90 then start the unit Set Functional Parameter back to original setting after completing repairs b Check operation of Speed Relay LED LED 27 must be OFF c Check voltage to speed solenoid FSA Must be 0 VDC on ESC d On X2 2500 units ONLY check for Must be 12 VDC voltage on engine speed control unit ENSCU pin 22 3 Check For Proper Voltage To The Engine Speed Control Unit ENSCU Pin 16 Based On Requested Speed From The Microprocessor a Check voltage at pin 16 with un
141. strainer located in the inlet of the discharge check valve should also be removed and inspected 10 27 62 10683 SECTION 11 WIRING PARAGRAPH NUMBER Page PLUGS USED WITH SCHEMATIC 62 10499 REV V STANDARD ENGINE 11 1 PLUGS USED WITH SCHEMATIC 62 04102 REV ESC ENGINE 11 2 PLUGS USED WITH SCHEMATIC 62 10300 REV A ESC ENGINE 11 2 HC PLUG FORALL UNITS eiie rper Dep Geis chc Aid Phat 10 3 ADVANCE MICRO DISPLAY HARNESS CONNECTIONS 10 4 VOLTAGE TESTS nies ae Len ae ade reb ap er adis bis 10 4 SECTION 11 WIRING Plugs used with Schematic 62 10499 Rev V Standard Engine 1 MP Natural 24 Temi REMSN1 REMSN2 SEMEN SP23 4 REMSN2 SP23 SATCOM MS1 RPM MV D MS2 LS ENRPM MV C MV A LS RPM MV B wo e gt g ojs a Aw MS 3983 m 2 E n E Q 528 7 FHR HC 17 an 70 n I 1 ee a Gl msg O O1 C3 C2 UL2 Rear SATCOM A SLP B
142. supervisor If necessary go to the beginning of the table amp test again Review results of above tests with your super visor If necessary go to the beginning of the table amp test again Figure 10 4 ESC Diagnostic Tree 2 Long 7 Short LED Code 62 10683 10 12 10 4 1Advance Microprocessor Troubleshooting Guide The purpose of the following procedure is to provide a logical and straightforward guide to be used when troubleshooting operational or other problems occurring with the microprocessor Often users and technicians have mistakenly worked to correct a problem that has ended up being normal operation The microprocessor has several different conditions contributing to operating parameters These conditions are called out in the various diagnostic charts to aid the technician in pinpointing the problem or in realizing that the unit is performing normally When using these tables it is important to verify the reported symptom or problem and then correctly identify the appropriate table for that particular condition Using the incorrect table will lead to an incorrect diagnosis A table of contents is included to easily identify the correct table to use When using these Diagnostic Tables it is very important not to skip any steps Follow the flow of the tables in the order that they are laid out These tables are formatted into a logical troubleshooting sequence Skipping around
143. terminals and If the START RUN OFF switch is placed in the START RUN position the microprocessor will go to normal operation If the unit is shut down with the PC cable or jumper still in place the engine will shut down and the microprocessor will remain powered up 4 WARNING Do not place the START RUN OFF Switch in the START RUN position or the unit will start 6 2 MICROPROCESSOR CONFIGURATION AND TECHNICIAN TEST MODES REMOVE JUMPER MODE c Place the START RUN OFF switch in the OFF posi tion d With the unit off locate the download port Remove the protective plug to gain access to the wire termi nals Plug in jumper P N 22 50180 00 or connect an insulated jumper wire between plug terminals A and B 62 10683 6 2 Insulated Jumper Download Port Jumper P N 22 50180 00 WHITE WIRE AX WARNING Do Not Allow Jumper Wire To Touch Any Ground e Place the START RUN OFF switch in the START RUN position The ALARM LED will come on and the set point will appear but the refrigerated com partment temperature will not and REMOVE JUMPER will appear in the MessageCenter for 10 seconds Remove the jumper at this time 1 TO SCROLL THEN TO SELECT will appear in the MessageCenter for 10 seconds or until either the UP or DOWN ARROW keys is pressed f Press the UP ARROW key to scroll through the Main Menu beginning at the top Press the DOWN ARROW key to scroll through the Main Menu
144. the DataRecorder to be set The time set here can be read in the unit data list Indicates the type of light bar installed YES NO YES When the START RUN OFF switch is turned OFF the data recorder will continue to record sensor data for an additional eight hours YES NO YES When the START RUN OFF switch is turned ROA OFF the data recorder will continue to record sensor data for an additional eight hours NO When the START RUN OFF switch is turned OFF the data recorder will stop recording all data DISPLAYED DISPLAYED Set point will be shown with a deci mal and temperatures may be selected to a tenth of a degree DECIMAL ee NOT DISPLAYED NOT DISPLAYED Set point will not be shown with a decimal All other temperatures will still be displayed with a decimal 62 10683 6 10 CONFIGURATION SELECTIONS DESCRIPTION HIGH SPEED DELAY 1 MIN 10 MINUTES IN 0 5 MINUTE IN CREMENTS SATELLITE COMM Optional This configuration is only visible in the microprocessor configuration list when the DataTrak option is installed in the microprocessor It is always visible in the configuration list in ReeferManager although it is non functional until the DataTrak op tion is installed UNIT OPERATION See Note on Following Page VEHICLE ID This is only available when Unit Op eration Rail is selected in above configuration RAIL SHUTDOWN OVERRIDE This is only available when Unit Op era
145. the Start Run Off switch in the the OFF position After the engine shuts down the micro processor will fully close the CSMV NOTE Carefully listen to the valve When the unit is off and the valve is closing the valve will make a ratcheting noise that may be heard or felt as itis closing If this can be heard or felt it indicates that the microprocessor is attempting to close the valve and may serve as a quick indication that the drive module is in working order It is not however an indication that the valve piston is actually working d Wait about 2 minutes after the engine stops to ensure the valve is fully shut 62 10683 e If the CSMV is fully shut the suction pressure should still read 0 psig bar If the valve is stuck at some posi tion other than fully closed or it cannot fully close for any reason the suction pressure during this test will rise 1 If the suction pressure holds at 0 go to Step f 2 If the suction pressure rises go to Step NO TAG Use the Stepper Motor Tester CTD special tool P N 07 00375 00 to manually open the valve The suc tion pressure on the manifold gauge should go up If the suction pressure does not go up the CSMV is stuck closed go to Step NO TAG or there is some thing obstructing the refrigerant NOTE Opening the valve can also be accomplished by using the microprocessor Place the Start Run Off switch in the START RUN position The mi croprocessor will go through it
146. the oil pan next to the fill 4 Engine Coolant Temperature Sensor ENCT Provides microprocessor with engine coolant temperature information to be displayed and recorded in the DataRecorder The sensor is located on the starter side of the engine near the 74 Injector 5 Engine Coolant Level Sensor ENCLS Optional 62 10683 Sets off alarm when coolant level is more than 1 quart low Located in the coolant bottle 6 Engine Speed Control Unit ENSCU ESC only See Figure 2 10 The ENSCU is mounted on the roadside frame behind the upper door See Figure 2 4 It provides the RPM signalto the microprocessor The unit has an alarm LED incorporated within it which is used to diagnose failures within the ESC system See Section 10 4 for information on diagnosing failures Figure 2 10 Engine Speed Control Unit ENSCU 7 Fuel and Speed Actuator FSA ESC only The FSA combines the fuel shutoff solenoid and speed control solenoid into one component Engine speed is controlled by varying rod position 8 Engine Speed Sensor ENSSN ESC only The ENSSN provides the RPM signal to the ENSCU for speed control It is located on the front of the engine in the gear case cover 2 3 3 Alternator Regulator The alternator converts mechanical and magnetic energy to alternating current AC and voltage by the Electrical power for the control system and for charging rotation of an electromagnetic field rotor inside
147. the standard Defrost Timer setting A54 DEFROST NOT COMPLETE Alarm will be activated NOTE If the Defrost Air Switch DAS contacts are still closed at defrost termination or if the DAS calls for a defrost cycle within eight minutes of the previous defrost cycle termination in two consecutive defrost cycles the fol lowing will occur The Defrost Air Switch DAS is ignored for defrost initiation until the unit has completed another defrost cycle in which the DAS contacts were open at termination The manual defrost switch can always start a new Defrost cycle A55 CHECK DEFROST AIR SWITCH Alarm is activated A Defrost Override timer is activated which will initiate another defrost cycle in 1 5 hours regardless of the standard Defrost Timer setting 5 11 5 Normal Defrost Termination Sequence The following sequence will be used to perform a transition from defrost to normal temperature control a The microprocessor will place the engine in Low Speed and Open de energize SV1 and Open energize SV2 and SVA b The microprocessor will return the CSMV to the same it was prior to the initiation of defrost c The SV4 will close de energize d After afew seconds the Clutch will be engaged energized There will be a short delay before the engine can return to High Speed e At this point the microprocessor will return to normal temperature control The data recorder will record a Defrost Termination Event 5 9 62 10683
148. the tables will most likely lead to errors in diagnosis Throughout the tables the steps will point the technician to areas to look at or check for a problem Most of the steps will lead the technician to a circuit or other area of the unit to check test and possibly repair other than the microprocessor Some steps will point to a possible problem with the microprocessor Whenever reaching one of these steps it is a very good practice to install the new microprocessor then verify unit operation PRIOR TO writing hours Trailer ID Unit Serial Number etc into the new microprocessor Once the technician is satisfied that a new microprocessor is required the hours trailer ID unit serial number customer configurations or IntelliSets etc should be entered Should the problem remain even with the new microprocessor in place once all repairs are made the original microprocessor is to be reinstalled into the unit to avoid unnecessary costs to the customer or having the Warranty Request rejected if there is no problem found with the returned microprocessor All steps leading to replacement of the microprocessor have a number associated with them When filling out the MPR tagthat will be attached to the returned part write the step number on the upper half of thetag inthe Failure Description Field Include the same information in the Failure Description Field when entering the warranty claim information on line This will show which diagnostic tabl
149. the top and moving toward the bottom or by pressing the DOWN ARROW key you will move through the Data List beginning at the bottom and moving toward the top 3 The selected Data Item will remain in the MessageCenter for ten seconds then the default message STATUS or other customer specified message will appear 4 To lock an item in the MessageCenter for continuous viewing press the key The Data item will flash continuously to indicate it is locked 5 Pressing the UP or DOWN ARROW key will unlock that item and move i to the next data item Pressing the key will unlock the item After ten seconds the default message will be displayed 62 10683 3 20 Table 3 2 UNIT DATA Also appear in Configurations May or may not be displayed depending on functional parameter settings SUCTION PRESSURE Compressor suction pressure Return air entering evaporator air temperature Supply air leaving evaporator air temperature Ambient air entering condenser air temperature FUEL LEVEL of fuel in tank This is only shown when 0 100 sensor is config ured ON SUCTION MOD VALVE open of CSMV START MODE AUTO if the engine will start automatically MANUAL if the engine must be started manually INSTALLED OPTIONS Applies only if unit has any one or more of these options installed INTELLISET INSTALLED DATATRAK INSTALLED COMPRESSOR ALARM SHUTDOWN ID as entered by the user Trailer Car or Asset ID 4 HOURS
150. the unit will continue to run YES NO YES When the A11 LOW ENGINE OIL PRES SURE alarm has been activated three times in the last two hours of engine operation the A21 ENGINE OIL PRESS SHUTDOWN TECHNICIAN RESET REQUIRED alarm will be activated NO A21 will not be activated YES NO YES When the A12 HIGH COOLANT TEM PERATURE alarm has been activated three times in the last two hours of engine operation the A21 HIGH ENGINE TEMP SHUTDOWN TECHNICIAN RESET REQUIRED alarm will be activated NO A21 will not be activated Change 09 11 62 10689 CONFIGURATION SELECTIONS DESCRIPTION LOW COOLANT LEVEL FUEL TANK FUEL TANK SIZE DISPLAY TOTAL ENGINE HR DISPLAY TOTAL SWITCH ON HR DIESEL RESET VALUE Refer to Section 2 7 for oil change intervals SWITCH ON RESET VALUE NO DEVICE SWITCH INSTALLED 0 TO 100 SEN SOR OFF 30 GALLONS 50 GALLONS 75 GALLONS 100 GALLONS 120 GALLONS NO YES OFF 50 TO 30 000 HRS OFF 50 TO 30 000 HRS 6 5 YES A Low Coolant Level sensor is installed in the coolant system ius xc There is no Low Coolant Level sensor installed in the coolant ius xc i NO DEVICE There is no Low Fuel Level sensor installed in the fuel tank SWITCH INSTALLED A Low Fuel Level switch is installed in the fuel tank 0 to 100 SENSOR A Low Fuel Level sensor is installed in the fuel tank The fuel level may be read in the unit data list OFF No Low F
151. the unloaders to maintain a Maximum Operating Pressure MOP The CSMV is always at 100 open in heat and defrost modes A Compressor Suction Pressure CSP transducer is used to provide this information to the microprocessor This MOP is calculated based on suction pressure ambient air temperature and mode of operation From this the microprocessor will be able to determine the system load The system load will correspond to a maximum horse power discharge pressure and coolant temperature which the unit can operate within By overriding temperature control and unloading cylinder banks on the compressor these conditions can be maintained at the appropriate levels When the compressor is fully loaded it is operating on six cylinders When the front unloader UL1 is UNLOADED energized the unit operates on four cylinders When UL1 and the rear unloader UL2 are UNLOADED energized the unit operates on two cylinders The front unloader UL1 always unloads before the rear unloader UL2 5 19 62 10683 5 20 SUCTION PRESSURE OPERATION 5 20 1 Directions For Reading the Chart Below a At ambient temperatures of 90 F 32 2 C or below When the system is operating in high speed and the suction pressure is greater than 63 PSIG 4 3 Bars both unloaders are unloaded As the suction pressure drops below 63 PSIG 4 3 Bars the UL2 unloader is loaded If the suction pressure drops below 32 PSIG 2 2 Bars the UL1 unloader is loaded When the system is
152. to1 02 Bars after five minutes on unit operation Refer to Section 9 21 2 if unit does not heat properly c Unit should remain in defrost until DTT located onthe center tube sheet below the evaporator reaches 55 F 12 8 C At this point the defrost cycle will ter minate and the unit will resume automatic operation 9 25 DEFROST AIR SWITCH DAS 9 25 1 Testing The Defrost Air Switch And Circuit a To check the Defrost Air switch run unit in high speed cooling and place a jumper across the air switch termi nals This will start the defrost cycle as it simulates the action of the defrost air switch Bypassing the switch in this manner operates all components involved in de frost NOTE If DTT is above 40 F 4 4 C the MessageCenter will show CANNOT START DEFROST CYCLE b Unit should remain in defrost until DTT reaches 55 F 12 8 C At this point the defrost cycle will terminate and the unit will resume automatic operation c If the above test indicates satisfactory operation test Defrost Air switch DAS settings using a magnehelic gauge Refer to Section 9 25 2 9 43 62 10683 9 25 2 Checking Calibration Of Defrost Air Switch 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 00 High Side Connection gt oo Figure 9 34 Defrost Air Switch Test Setup a Ma
153. valve When additional heating capacity is required the microprocessor opens the Liquid Line Solenoid valve SV2 to allow additional refrigerant to be metered into the hot gas cycle through the expansion valve When in engine operation and the discharge pressure exceeds pressure settings detailed in Section 2 11 the pressure cutout switch HPS opens to de energize the run relay coil RR When the RR coil is de energized the RR contacts open stopping the engine The function of the hot gas bypass line is to raise the receiver pressure when the ambient temperature is low below 17 8 C 0 F so that refrigerant flows from the receiver to the evaporator when needed EXTERNAL EQUALIZER FUSIBLE PLUG lt EVAPORATOR gt BYPASS CHECK VALVE RECEIVER HEAT EXCHANGER IL ON lt LIQUID LINE VIBRASORBER CDP HPS COMPRESSOR m DISCHARGE CHECK VALVE LIQUID LINE SERVICE VALVE z FILTER DRYER SUBCOOLER dAe VIBRASORBER
154. will not shut down the unit REFRIGERATION SYS YES NO YES Alarm 28 is Alarm and Shut Down SHUTDOWN NO Alarm 28 is Alarm only YES The unit will shutdown and not restart when COMPRESSOR ALARM SHUTDOWN YES NO Alarms 13 17 18 27 28 29 or 56 occur three times within two hours Special activation required NO Normal shutdown rules for above alarms CURRENT FOR S S SHUTOFF 6 5A REDEEM amps must be lower than this for start 1A TO 10A stop off cycle in 5A increments VOLTAGE FOR S S RESTART 12 2A This value will be used during Start Stop Off cycles 12 0 TO 12 8 VDC If battery voltage falls below this value the unit will in 5A increments restart YES When the alternator is not charging Alarm 51 is active turn the alarm light on and shut the ALTERNATOR CHECK SHUT YES NO unit down DOWN NO When the alternator is not charging Alarm 51 is active turn the alarm light on and the unit will continue to run YES This unit has a low engine oil level switch installed ENGINE OIE FEVER TERNO NO This unit does not have a low engine oil level switch installed OUT OF RANGE SHUTDOWN YES NO 62 10683 6 4 CONFIGURATION SELECTIONS DESCRIPTION ENGINE OIL LEVEL SHUTDOWN YES NO YES When the A2 LOW ENGINE OIL LEVEL alarm is activated the alarm light will illuminate and the unit will shutdown NO When the A2 LOW ENGINE OIL LEVEL alarm is activated the alarm light will illuminate and
155. 000 Ohms 77 F 25 C See section 2 13 for See Note 4 Page 8 2 complete table of temperatures and resistance values Check Supply Air Sensor Wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section a Check Remote Sensor Switch Connector a Locate and inspect 10 way connector Connector must have cap on for optional sensors and switches No corrosion or moisture inside connector If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink Check Remote Sensor Switch Connector a Locate and inspect 10 way connector Connector must have cap on for optional sensors and switches No corrosion or moisture inside connector If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink 62 10683 8 76 ANO Steps ALARM CAUSE CORRECTIVE ACTION P155 CHECK COOLANT TEMP SENSOR TRIGGER ON Engine Coolant Temp Sensor is not within the maximum range of 58 F to 266 F 50 C to 130 C UNIT CONTROL Pretrip will abort and PRETRIP FAILED IN TEST 3 will be displayed in MessageCenter RESET CONDITIO
156. 1 b Check 10 way connector for all No physical damage moisture or corrosion to connector remote sensors and switches Cavity plugs are in place for unused circuits 8 65 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 134 CHECK REMOTE TEMP SENSOR 2 TRIGGER ON Remote Temperature Sensor 2 circuit is configured on and has failed open or shorted If shorted the data list will display 158 F 70 C If the circuit is open the data list will show the temperature as 52 6 F 47 C UNIT CONTROL Alarm only RESET CONDITION Auto Reset when Remote Temperature Sensor 2 is in range or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Remote Temperature Sensor 2 REMSN2 a Verify that Remote Temperature Remote Temperature Sensor 2 is installed Sensor 2 has been installed and is Wires are connected to 10 pin connector at cavities G amp H correctly wired to the unit If sensor is not present change micro configuration to OFF 2 remote temperature sensor 2 2 Inspect Remote Temperature Sensor 2 No damage to sensor amp connector No damage moisture or corrosion in connect
157. 1 1 SAFETY PRECAU IONS er cen Let Dc ae 1 1 1 2 SPECIFIC WARNING AND CAUTION STATEMENTS 1 1 1 5 1 3 SAFETY DECALS SECTION 1 SAFETY PRECAUTIONS 1 1 SAFETY PRECAUTIONS Your Carrier Transicold refrigeration unit has been designed with the safety of the operator in mind During normal operation all moving parts are fully enclosed to help prevent injury During all pre trip inspections daily inspections and problem troubleshooting you may be exposed to moving parts Please stay clear of all moving parts when the unit is in operation and when the unit main power switch is in the START RUN position CAUTION Under no circumstances should anyone at tempt to repair the Logic or Display boards Should a problem develop with these com ponent contact your nearest Carrier Transicold dealer for replacement 4 CAUTION Under no circumstances should a techni cian electrically probe the processor at any point other than the connector terminals where the harness attaches Micropro cessor components operate at different voltage levels and at extremely low current levels Improper use of voltmeters jumper wires continuity testers etc could per manently damage the processor CAUTION Most electronic components are suscept ible to damage caused by electrical static discharge ESD In certain cases the hu man body can have enough static electri city to cause resultant d
158. 1 6 Bars UNIT CONTROL Immediate Unit Shutdown amp Alarm RESET CONDITION Auto Reset after 15 minutes if the compressor discharge pressure falls below 350 PSIG 23 8 Bars or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 If Alarm Occurs During Pretrip Test 11 12 Or 13 a Check discharge snubber tee Remove and inspect tee If snubber restrictor is in place remove it reinstall tee and re test for alarm b Check SV1 for opening During pretrip tests 11 12 and 13 SV1 may be energized for 1 second to reduce head pressure during tests If SV1 fails to actually open during the 1 second that it is de energized this alarm may occur Repair SV1 as needed 2 Check Fan Belts a Check upper fan belt tension amp Refer to Section 9 9 for belt tensions condition No Glazing no cracking no slipping b Check lower fan belt tension amp Refer to Section 9 9 for belt tensions condition No Glazing no cracking no slipping 3 Check Wiring a Visually Inspect wiring to HPS SV4 amp Wires must be connected properly amp securely to each both Compressor Unloaders component 4 Check Airflow Through Con
159. 10 14 Figure 10 6 Micro Diagnostic Tree Cond 2 Start Run Off Switch On Unit Operates But Not Properly 10 15 Figure 10 7 Micro Diagnostic Tree Cond 3 Start Run Off Switch Off Unit Fails To Stop 10 16 Figure 10 8 Micro Diagnostic Tree Cond 4 Unit Will Not Run In High Speed 10 17 Figure 10 9 Micro Diagnostic Tree Cond 5 Unit Will Not Run In Low Speed 10 18 Figure 10 10 Micro Diagnostic Tree Cond 6 Data Recorder Data Download Problems When Using ReeferManager and a Download Cable Data File Analysis Problems Using Reports eee Yee er Y RR eU ER ve cU WAR e M e d 10 19 Figure 10 11 Microprocessor Diagnostic Tree PC Card 10 20 Figure 10 12 Micro Diagnostic Tree Cond 8 Programming Problems With PC Cards 10 21 Figure 10 13 Micro Diagnostic Tree Cond 9 Programming Problems With MicroProgrammer 10 22 Figure 10 14 Compressor Diagnostics eee n 10 26 LIST OF ILLUSTRATIONS Continued 62 10683 xiii LIST OF TABLES TABLE NUMBER Page Table 2 1 Model Charten uo or vain Nae de Eg R CET AO 2 1 Table 2 2 Additional Support Manuals ssssssssesessee e rn 2 1 Table 2 3 Field Effect Transistors ee rn 2 21 Table 2 4 Engine Data emm ee eee Ed ace e a Rata 2 25 Table 2 5 Compressor Data 22 esm
160. 11 2 Checking Superheat deni nn 9 25 9 11 3 Measuring Superheat 0 eee tenes 9 25 9 11 4 Checking The Refrigerant Charge 9 27 9 11 95 Partial Charge metal Ci etse tutes 9 27 9 11 6 Adding Full Charge siasii kaei teen rh 9 28 9 12 REPLACING THE COMPRESSOR n 9 28 9 12 1 Removal and Replacement of Compressor 9 28 9 13 CHECKING COMPRESSOR OIL LEVEL ssesssesr ee nn 9 30 9 13 1 To Check The Oil Level In The Compressor 9 30 9 13 2 Adding Oil With Compressor In System 9 30 9 13 3 Adding Oil To Service Replacement Compressor 9 30 9 13 4 To Remove Oil From The Compressor 9 31 9 14 COMPRESSOR UNLOADER VALVE eee mn 9 31 9 14 1 Unloader Checkout Procedure 9 31 9 14 2 Replacing Unloader Valve Internal Parts 9 31 9 14 3 Unloader Coil Replacement ete 9 32 9 15 REPLACING OR SERVICING CHECK VALVE ccc cece tenet eee 9 32 9 15 1 To Service Check Valve sssssssssssesse een 9 33 9 15 2 To Replace Check Valve ssssssssesssse sh 9 33 9 16 CHECKING AND REPLACING FILTER DRI
161. 18 of ENSCU Actuator FSA wiring disconnected or open ius FSA or wiring problem circuit Coil Resistance Spec 2 8 ohm 10 ENSCU supply voltage is greater than 26V Two Lang Seve ENSCU or alternator problem 62 10683 10 8 START HERE Start unit NOTE Ensure the run relay is energized during test With ENSSN unplugged during testing unit will stall amp go through start sequence again Unit will not start This is normal Verify there is at least 11 VDC going into the ENSSN 12V terminal NO Check for high resistance or an open between ENSCU terminal 25 amp veg y ENSSN 12V terminal Did you find and correct the condition Using strobe light 07 00177 01 or equivalent check engine RPM Is RPM equal to or over 2 530 Check for high resistance or an open in the ENSSN ground circuit Did you find and correct the condition Remove new ENSCU and re install old ENSCU back into unit Review results of above tests with your Using jumper wire check for 5 VDC at ENSCU terminal 10 Do you have 5 VDC at terminal 10 Check for open or high resistance on circuit between ENSSN and ENSCU Did you find and correct the condition v supervisor If necessary go to the beginning of the table amp test again
162. 2 6 2 3 Service Mode 4 CAUTION Service Mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating NOTE The START RUN OFF switch MUST be in the START RUN position to keep the unit in Service Mode If the switch is placed in the OFF posi tion the unit exits Service Mode and closes the CSMV to 0 open and de energizes UL1 Scroll through the Main Menu then press the key when SERVICE MODE appears in the MessageCenter ENTERING SERVICE will appear in the MessageCenter and OFF will be displayed in the main display The CSMV will be set to 100 open and the Front Unloader UL1 will be energized Once the CSMV is 100 open RECOVER LEAK CHK EVAC is displayed in the MessageCenter Refrigerant recovery leak checking or evacuation may be performed on the unit at this time Refer to Service Procedures in Section NO TAG When the refrigeration system is evacuated the system pressure will go into adeep vacuum While this is occurring the MessageCenter will change to EVAC CHARGE MODE The position of the CSMV and UL1 does not change in this mode To prevent refrigerant migration to the compressor during charging if all pressure transducers CSP and CDP drop below 9 8 psig or 20 inHg 0 68 bar and then 2 of the 3 pressure transducers rise above 5 psig 0 34 bar the microprocessor will close the CSMV to 0 open and de energize UL1 When the valves are
163. 2 01737 04 20 Long to the download port with the START RUN OFF switch in the OFF position allows the Advance Microprocessor to power up and communicate with the computer All functions available from the keypad may be viewed or changed using the ReeferManager and a personal computer PC connected to the download port Using the PC will provide additional programming and configuring capabilities that will not be available through the keypad The DataRecorder may also be configured and downloaded through the download port using the ReeferManager program 62 10683 PC mode can be used for Changing set point for the next load Changing any of the functional parameters for the next load Reading Engine hourmeters Reading Maintenance hourmeters Resetting Maintenance hourmeters Viewing the Active and Inactive alarm lists Entering a Trip Start Keeping the microprocessor powered up after turning the START RUN OFF switch to the OFF position Demonstrating the operation of the microprocessor without the engine running Use any of the PC cards Download Program Configuration or Option To better utilize PC mode aPC Mode jumper CTD P N 22 50180 01 is available This jumper looks similar to the Configuration jumper refer to Section 6 2 buthasa GREEN WIRE on it With the unit off locate the download port Remove the protective plug to gain access to the wire terminals Plug in jumper or connect an insulated jumper wire to
164. 242 DIS PRESS CALIBRATE ERROR hn 8 110 243 SUCT EVAP CALIBRATE ERROR ssssssssssesss sse 8 110 246 EEPROM WRITE FAILURE a Ee Ree EE ME ME RE dns 8 111 248 CONF HP2 ERROR cece esses 8 111 249 MICROPROCESSOR ERROR ssssssssseseses sn rn 8 112 ERUIT 9 1 9 1 MAINTENANCE SCHEDULE m 9 1 9 2 PRETRIPINSPEGTION pane ee EUER Dae 9 4 9 3 GRILLE INSERT REMOVAL hs 9 8 9 4 SURROUND REMOVAL eese hh hn 9 9 9 5 DOOR LATCH MAINTENANCE AND REPLACEMENT 9 10 9 5 1 Front Door Latch Cable Replacement 9 10 9 5 2 Side Door Latch Cable Replacement 9 10 9 6 PRIMING FUEL SYSTEM 9 11 9 6 1 Mechanical Fuel Pump 00 cece emn 9 11 9 7 SERVICING FUEL PUMP hs 9 12 9 7 1 Mechanical Pump See Figure 9 2 9 12 9 8 ENGINE SERVICE AND COMPONENTS 00 eee eee n 9 12 9 8 1 GOolINg SYSTEM 2 ctu eee rae eee eie LRA uae 9 12 9 8 2 Fuel Level Sensor eee LG ube oa aa 9 13 9 8 3 The RPM Sensor hen eed scan 9 13 9 8 4
165. 26 2 10 COMPRESSOR IQ ees 2 26 2 11 REFRIGERATION SYSTEM DATA 000 cece ttt 2 26 212 SAFETY DEVICES etn rei ete eue 2 27 2 13 COMPONENT RESISTANCE AND CURRENT DRAW 2 28 2 14 REFRIGERANT CIRCUIT DURING COOLING 2 29 2 15 REFRIGERANT CIRCUIT HEATING AND DEFROSTING 2 30 SECTION 2 UNIT DESCRIPTION 2 1 INTRODUCTION AX WARNING Beware of V belts and belt driven compo nents as the unit may start automatically Before servicing unit make sure the Start Run Off switch is in the OFF position or the unit is in Maintenance mode Also discon nect the negative battery cable AX WARNING UNITS EQUIPPED WITH REMOTE TWO WAY COMMUNICATION CAPABILITIES HAVE THE ABILITY TO BE STARTED OR TURNED OFF REMOTELY REGARDLESS OF THE SETTING OF THE START RUN OFF SWITCH The unit is controlled locally and there can be no two way communication when the Mode Switch on the Remote Monitoring Control Box is in MAINTENANCE MODE Therefore when performing any work on the unit place the mode switch in MAINTE NANCE MODE After the unit is serviced re turn the mode switch to REMOTE ON This manual contains Operating Data Electrical Data and Service Instructions for the refrigeration units listed in Table 2 1 Additional support manuals are listed in Table 2 2 The model serial numb
166. 5 11 6 High Ambient Defrost Operation NOTE If the Ambient Air temperature is below 80 F 26 7 C then the Normal Defrost Operation will be used When the Ambient Air temperature is above 80 F 26 7 C the High Ambient Defrost Operation will be used If the discharge pressure rises to 340 psig 23 1 Bar UL1 will energize and unload for the remainder of the defrost cycle If the discharge pressure rises to 350 psig the SV1 valve will de energize open for 1 second to reduce the discharge pressure If the discharge pressure remains at 350 psig 23 8 Bar the SV1 valve may de energize open again ad much as twice a minute The High Ambient Defrost Cycle has three separate modes a Pump Down Mode The Pump Down Mode pumps the low side of the refrigeration system down to a lower suction pressure and reduces the engine load normally seen at the beginning of a Defrost um Engine Clutch OPEN CLOSE CLOSE LOW ES peel ng de ener ehe EE dis 100 gize ergize gize gize The unit will remain in the Pump Down Mode until the following conditions are met A minimum of 30 seconds and the suction pressure is less than 10 PSIG 0 68 Bar or OR A maximum of 5 1 2 minutes regardless of suction pressure b High Ambient Defrost Mode Following the Pump Down Mode the Defrost Cycle will begin The unit controls will be opened closed as follows Engine Clutch DISENGAGE UNLOAD Refer to SV2 Operation de ener
167. 654 Press the UP ARROW key again and the ID field will appear Press the key then the UP ARROW key You will see a blinking cursor in the field Using the UP or DOWN ARROW key scroll through the Num ber Letter list until the first letter number ofthe ID you recorded above appears Press the key to enter that number letter and advance the cursor to the next place Repeat this process until the entire ID number is entered Ifthe cursor is still blinking in a blank space after you are finished slowly wait 2 to 3 seconds be tween presses press the key to leave blanks in the remaining spaces When you reach the end the mes sage TO SCROLL THEN TO SELECT will appear i e 25678 Now press the DOWN ARROW key until SET TIME appears Press the key then the UP ARROW key to enter that menu 62 10683 6 24 f g h x CAUTION certain that the clock you are using is ac curate and is showing the correct time Also some customers are located in differ ent time zones from where the repair is be ing made If you know what time zone they use enter that time If you don t then enter the current time where you are located When MONTH appears press the key then the UP ARROW key The MessageCenter will begin to flash indicating that it is ready to accept changes Use the UP or DOWN ARROW key to scroll through the num ber list until the correct number of the current month app
168. 9 C or above the unit will run in low speed for a minimum of 2 minutes and until the ambient drops below 110 F 43 3 C This applies to Heat and Cool modes only not Defrost b Low Suction Pressure High Discharge Pressure UL1 has been energized unloaded and the suction pressure is less than 0 PSIG Bar for at least 30 seconds or the discharge pressure is greater than 435 PSIG 29 6 Bars for more than five seconds the engine will be forced to run in low speed for a minimum of five minutes After five minutes the engine can return to high speed if suction pressure is greater than 5 PSIG 0 34 Bar for 30 seconds or discharge pressure is less than 410 PSIG 28 0 Bar for 30 seconds c Low Speed Engine Coolant Warm up If engine Coolant Temperature Sensor Alarm is not active the engine will run in low speed until the coolant is above 79 F 26 C The engine will run in low speed while the engine warms up until the coolant is above 79 F 26 C d Defrost The unit Is generally in High Speed but will run in low speed during Stage 1 pump down mode of High Ambient Defrost It will also run at low speed at the end of the defrost cycle when the clutch is re engaged e Door Remote Switch Configurable for Low Speed Alarm The unit will be forced into low speed if the optional door switch Remote Switch 1 or Remote Switch 2 alarm is active and is configured for the unit to operate in Low Speed when the door is ope
169. ART RUN position Manual and continuity through the harness Start mode See Note Note 4 or PC mode Battery voltage reading 12 13 VDC between wires in plug Check Engine Oil Pressure WE a Connect mechanical oil gauge Oil pressure must be greater than 15 PSIG 1 02 Bars b Check engine oil level Oil must be in safe range on dipstick 8 7 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 12 HIGH COOLANT TEMPERATURE TRIGGER ON For ambient temperatures below 120 F 48 9 C Engine coolant temperature is above 230 F 110 C or Ambient temperatures above 120 F 48 9 C engine coolant temp is over 241 F 116 C or Engine coolant temperature is between 230 F and 241 F 110 C and 116 C for more than five minutes UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset after 15 minutes if the engine coolant temp falls below 212 F 100 C or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Coolant Level a Check coolant level in overflow bottle Level must be in the Normal range b Check coolant level in radiator Level must be at the top of the radiator fill tube Do not r
170. ATION VALVE CSMV 9 41 9 22 Funcion scribo DIU Madea tanita abodes PRA Meis 9 41 9 22 2 CSMV Diagnostics Sora a ene Re RA Dn RR RO tec ee 9 41 9 22 3 Replacing The CSMV Power Head 9 42 9 23 2 HGHT BAR EUER suat s 9 43 9 23 1 Light Bar Operation and 9 43 9 24 CHECKING DEFROST OR HEATING 2 ees nn 9 43 9 24 1 Hot Gas Solenoid Valve SV1 amp SV4 Heating and Defrosting 9 43 9 25 DEFROST AIR SWITCH DAS sssssssssesesse emn 9 43 9 25 1 Testing The Defrost Air Switch And Circuit 9 43 9 25 2 Checking Calibration Of Defrost Air Switch 9 44 9 26 EVAPORATOR COIL CLEANING eem n 9 44 9 27 CONDENSER COIL CLEANING em mn 9 45 9 28 MICROPROCESSOR SENSOR CHECKOUT 9 45 9 29 UNIDRIVE TORQUE REQUIREMENTS 20 c cece eee 9 47 9 2921 Drive Gear olga wo EA E NR LOUER 9 47 UNIT TROUBLESHOOTING sassoni rr n Mireles ae wee ees he tees ead eee n ee 10 1 10 41 7 DIESEL ENGINE IX ERR Re 10 1 10 1 1 Engine Will Not Start e mn 10 1 10 1 2 Engine Starts Then Stops 0 c cece enn 10 1 10 1 3 Starter Mo
171. Air Exchange parameter is used to choose the type of fresh air control The AutoFresh Air Control parameter is used to select the cycling of the assembly if CFM CONTROL has been set The air exchange rate can be adjusted from zero to the maximum at the microprocessor Maximum rate is 50 CFM AutoFresh Air Exchange controls the amount of CFM exchanged based on a 20 minute duty cycle The duty cycle timer is reset whenever the START RUN OFF switch is turned OFF then back ON or if the unit is shut down by either a Door or Remote switch shutdown When the ambient air temperature is below 36 F 2 2 C and the AutoFresh Air Exchange functional parameter is set for OPEN the AutoFresh Solenoid AFAS will always be closed for the last 15 seconds of each 20 minute time block and then reopen Closing and opening the vent periodically prevents ice buildup from freezing the solenoid or air door into the open position The AutoFresh solenoid current draw is tested during Pretrip Test 2 however it is a good idea for the technician to visually verify that the solenoid actually pushes the air assembly open then closed again This 1 Solenoid 8 Outlet Hose operation is visible from ground level by looking up at 2 Jam Nut 9 Sleeve the curbside of the unit See Figure 3 2 and Figure 3 3 3 Washer 10 Push In Fastener With the introduction of unfiltered air into the S pM 1 ran Cap Assembly refrigerated compartment dirty air may be dr
172. Ambi ent Air temperature is above 80 F 26 7 C the High Ambient Defrost Operation will be used If the discharge pressure rises to 340 psig 23 1 Bar UL1 will energize and unload for the remainder of the defrost cycle If the discharge pressure rises to 350 psig 23 8 Bar the SV1 valve will de energize open for 1 second to reduce the discharge pressure If the discharge pressure remains at 350 psig 23 8 Bar the SV1 valve may de energize open again ad much as twice a minute 5 11 4 Normal Defrost Termination Defrost Termination Defrost will be terminated once any of the following conditions are met a When the defrost termination temperature DTT and Supply Air Temperature SAT are both above 55 F 12 8 C and the sensors are working properly If both DTT and SAT sensors are bad then defrost will terminate in 10 minutes A sensor alarm indicates that the sensor is bad b A54 DEFROST NOT COMPLETE ALARM The microprocessor also has a Defrost Cycle Timer which monitors the total time of the Defrost cycle This is the amount of time that the system is actually defrosting This timer starts every time a Defrost Cycle is initiated and it keeps track of the time that the system is actually defrosting If the Defrost cycle does not complete within 45 minutes the following will occur The Defrost cycle will be terminated Defrost Override timer is activated which will initiate another defrost cycle in 1 5 hours regardless of
173. CIRC rosan 2 ee e 8 74 P153 CHECK RETURN AIR SENSOR he 8 75 P154 CHECK SUPPLY AIR SENSOR e 8 76 P155 CHECK COOLANT TEMP SENSOR e e 8 77 P156 CHECK BATTERY VOLTS nem e Ue Dtm e b e e POL vue sada ae is 8 77 P157 CHECK BATTERY CURRENT esae RR RE Ra ERG ea due ck hee 8 78 P158 CHECK AMBIENT AIR SENSOR 2 e 8 79 P160 CHECK DISCH TEMP SENSOR 8 80 P162 CHECK AUTO FRESH AIR EXCHANGE SOLENOID AFAS CIRCUIT 8 81 P164 GHECK UL2 CIRCUNT Deere 8 82 P165 CANNOT PUMP DOWN i xe eR Rec x e ees 8 83 P174 CHEGK LOW SPEED RPM Ded et CERE ERE eor een itn 8 84 P475 CHECK HIGHSPEED RPM cere rrr ek Ree Ec iR FU Re ROCA Pau a I d 8 85 P175 CHECK HIGH SPEED RPM Continued II 8 86 PA178 GBHEGK ULI eoe eeu Fee cO ep Kaw eec da gre ed eis 8 87 P180 CHECK SUCTION MOD VALVE e m 8 88 P181 CHECK SVA VALVE iro yea eme ead ge ere Re aa ac a hae 8 89 P182 CHECK SVT VALVE iier err repe RR EH af eq eC ERU REA 8 90 P191 CHECK UL issue oer eR ride cedo Alaa deir t e D a e ae Sate 8 91 P192 CHECK SV2 CIRGULT nr ek eye eer PERI Ree ek ee aoa ee atr eS 8 92 P194 HIGH SUCTION PRESSURE hh aE 8 93 P195 LOW SUCTION PRESSURE cacao he 8 94 P196 HIGH DISCHARGE PRESSUR
174. CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Visually Inspect Unit a 1 compressor turning with engine Compressor must turn with engine Check System Pressure Check and compare compressor Suction amp Discharge Pressures must have the same discharge amp suction pressures with reading 5 PSIG 0 34 Bar on gauges amp on micro those shown on the microprocessor display controller Manually Test Refrigeration System See Note 9 Page 8 2 See Refrigeration Troubleshooting Must pass all tests Section 10 3 System Will Not Pump Correct any problems found before proceeding Down b Run Quick Check Correct any problems found before proceeding 8 83 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION P174 CHECK LOW SPEED RPM e TRIGGER ON in Test 7 With Speed Relay turned off speed solenoid de energized engine RPM are NOT Between 1375 and 1600 for Ultima XTC and X2 2500A R or Between 1275 and 1500 for Ultra XTC and X2 2100A R TRIGGER ON in Test 9 15 seconds after the High Speed Test engine RPM have NOT dropped from the high
175. Check download port on unit Plug 1 in jumper and see if you can put YES Make sure you wait at least 5 minutes for E micro into configuration mode peel No N Ried lf Ni gt us Will mi into configuration mode urn the unit off for 30 seconds Exit out of the MicroProgrammer Turn unit back on YES Restart MicroProgrammer and try again NO If you are at this table for a second time Problem is with Y program micro using Program PC card computer Try Repair faulty wiring or damaged loading software download port Did you find and YES with another correct the condition computer Figure 10 13 Micro Diagnostic Tree Cond 9 Programming Problems With MicroProgrammer 62 10683 10 22 10 5 Compressor Troubleshooting Guide The purpose of the following procedure is to provide a logical and systematic method of determining whether 060 compressor repair or replacement is required A Checkout Procedure For Determining If Compressor Repair Or Replacement Is Required Certain operating conditions or refrigeration system components may be misdiagnosed and subsequently lead to the determination that the compressor is bad These conditions or components must be checked prior to replacing a compressor and must be checked after a replacement compressor is installed to prevent replacement compressor damage 1 2 3 7 Check refrigerant level per Section 9 11 4 En
176. Clear the inactive alarms 62 10683 8 104 NO Steps ALARM CAUSE CORRECTIVE ACTION 228 SERVICE SOON PM 3 DUE TRIGGER ON The Maintenance Hour Meter 3 time has expired UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via keypad Check Unit Maintenance Records a Schedule unit into service facility for Must be done soon maintenance 2 Perform Maintenance BN Perform appropriate engine amp unit Follow instructions on proper maintenance form maintenance Maintenance Hour Meter 3 Check that Maintenance Hour Meter Reset Interval in Configuration list as required 3 interval is set for your requirements b Reset Maintenance Hour Meter 3 for Hour Meter is reset in the Functional Parameter list the next service interval Follow maintenance interval recommendations in Section 9 1 See Note 1 8 2 Clear the inactive alarms All alarms cleared 229 SERVICE SOON PM 4 DUE TRIGGER ON The Maintenance Hour Meter 4 time has expired UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via keypad Check Unit Maintenance Records a Schedule unit into service facility for Must be done soon maintenance 2 Perform Maintenance EE Perform appropriate engine amp unit Follow instructions on proper maintenance form maintenance EN Maintenance Hour Meter 4
177. D CFM CONTROL Assembly will be cycled open and closed over a 20 AUTO FRESH AIR 1 OPEN minute time period The length of time the assembly is opened or 2 CFM CONTROL closed is based on the Auto Fresh Air Control Functional Parameter The CFM CONTROL will only be active for setpoints greater than 28 F 2 2 C and in Continuous Run mode or Auto Start Stop mode when the engine is running The assembly will be closed when the setpoint is less than 28 F 2 2 C or during defrost or during the off cycle of Start Stop mode AUTO FRESH AIR 5TO50CFMIN5 When CFM CONTROL is selected this parameter is visible When CONTROL CFM INCREMENTS CFM CONTROL is used the solenoid will open and close in 20 minute 25 CFM time blocks to control the amount of air being exchanged so that the amount of air exchanged averages the CFM setting During the first portion of the 20 minute block the solenoid will be open allowing fresh air in and exhausting stale air Once sufficient air has been exchanged the solenoid will close until the beginning of the next 20 minute block 62 10683 3 28 LOW SPEED START UP MINUTES CONTINUOUS OFF or Allows user to set the number of minutes the unit will run in low speed 1 to 255 minutes every time the engine starts START STOP OFF or 1 to 255 minutes 10 min UNLOADER Std The recommended setting for this is Std This setting should not be PRESSURE 5 changed unless discussed with a Carrier Transicold Factory Serv
178. Do not start unit without installing the evapo rator panels as unit damage or body harm may result WARNING Do not use a nitrogen cylinder without a pressure regulator Cylinder pressure is approximately 2350 psig 159 9 bar Do not use oxygen in or near a refrigerant system as an explosion may occur See Figure 9 26 4 amp WARNING The Compressor Discharge Pressure Transducer does not have a Schrader valve in the connecting fitting Any discharge pressure remaining in the compressor will be released when removing the CDP WARNING Carrier Transicold does not recommend al lowing the compressor to pull less than 0 PSIG Bar at any time 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 CAUTION Use only ethylene glycol anti freeze with inhibitors in system as glycol by itself will damage the cooling system Always add pre mixed 50 50 anti freeze and water to ra diator engine Never exceed more than a 60 concentration of anti freeze Usea low silicate anti freeze meeting GM specifica tions GM 6038M for standard life coolant or use Texaco Havoline extended life coolant or any other extended life coolant whi
179. E he 8 96 P198 LOW DISCHARGE PRESSURE a A nr a eects 8 97 P200 CHECK ULT CYLINDERS e 8 98 P201 CHECK ULZ CYLINDERS o Lene eer alee na dalle eed o qose sie Moses 8 99 P202 HIGE SIDE LEAK aiina d RC Sce Rt Re RCM eet ACIE OU Rea a 8 99 P203 CHK DISCHARGE CHECK VALVE cece e 8 100 P204 LOW SUCTION PRESSURE 0 0 cece nets 8 101 P205 CHK DEFROST TERM 2 SENSOR 0 cece e 8 102 vii 62 10683 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page ALARM TROUBLESHOOTING Cont 8 10 MAINTENANCE ALARMS Lit a ul ak Me ead Beale ee eke Sea lex 8 103 223 ENGINE MAINTENANCE DUE n m 8 103 225 GENERAL MAINTENANCE DUE hn 8 103 226 SERVICE SOON 1 DUE hm 8 104 227 SERVICE SOON 2 DUE sssssesesese eh rn 8 104 228 SERVICE SOON PM 3 DUE een hn 8 105 229 SERVICE SOON PM 4 DUE ete eens 8 105 230 SERVICE SOON 5 DUE cette eens 8 106 8 11 MICROPROCESSOR ALARMS nnns hn nn hrs 8 107 232 SETPOINT ERRORHR 4 E Rete eA ARS 8 107 283 MODEL ERROR eR E RR ERE RR EAR RE Rede e RU 8 107 237 FUNCTIONAL PARAMETERS eee een 8 108 238 CONFIGURATIONS 1 ERROR ie eh rn 8 109
180. E If this is the first time that ReeferManager has been installed onto a particular computer Carri er Communications CCN must first be in stalled If an earlier version of CCN has already been installed onto this computer AND the pro gram communications between the computer and the Advance Microprocessor worked cor rectly it is not necessary to uninstall and rein stall CCN If the communications between the computer and the microprocessor did not work uninstall and reinstall CCN 6 15 Close all programs and applications that are currently running Insert the ReeferManager CD ROM into the appropriate drive usually D The CD ROM will start running and automatically start the install program Click the button to install ReeferManager Follow the on screen instructions using the default settings Click the Finish button to close the install program Remove the CD from the drive and store for future use Reboot the computer to enable the programs 62 10683 6 4 DOWNLOADING DATA WITH THE PC CARD 1 Place the microprocessor in PC Mode Refer to Section 6 1 or place the START RUN OFF switch in the START RUN Position 2 Insert Download Card into the PC card slot on the front of the microprocessor Be certain that the instruction label is facing the Caution la bel Do not force card into slot 3 The MessageCenter will show COPYING DATA PLEASE WAIT While the data is being copied the green PC
181. E CARD XX An Option PC card has been inserted into the PC card slot and the option has been installed in the microprocessor The PC card may safely be removed from the slot XX indicates the number of option installations remaining on card INSTALLING OPTION PLEASE WAIT An Option PC card has been inserted into the PC card slot and the option is being installed in the microprocessor DO NOT REMOVE THE CARD WHILE THIS MESSAGE IS BEING DISPLAYED INSTALL STOPPED REINSERT CARD An Option PC card has been inserted into the PC card slot and the install process has been stopped been stopped by the PC card not being fully inserted in the slot or by being removed Remove and reinsert PC card to continue If any keys are pressed while UNIT BATTERY xx V message is being displayed this message will be displayed as a warning that no KEYPAD LOCKED BATTERY TOO LOW changes can be made and information can not be viewed until the battery voltage is brought back up above 10 volts for more than 10 seconds LIST END TO CLEAR ALARMS The end of the Alarm list has been reached Pressing the key will clear the Alarm list LOADING INFO A Configuration PC card has been inserted into the PC card slot and information from the Configuration card is being loaded into the microprocessor DO NOT REMOVE THE CARD WHILE THIS MESSAGE IS BEING DISPLAYED MAIN MENU Consists of Configuration mode Component Test mode and Ser Vice modes MANUAL START MODE SELECTED
182. ED will start blinking at the rate of 0 5 seconds on and 0 5 seconds off The 6 complete value on the computer screen will in crement itself as the program is loaded The com plete will stop several times during the loading pro cess for up to 15 seconds This is normal DO NOT STOP THE PROCESS The time to load the program is dependent upon the speed of the computer This will generally take from 4 to 6 minutes It is important that the program is not interrupted from thetime the Program Micro button is clicked until the program is completely loaded Once the 6 complete reaches 10096 the shutdown box will appear Click the OK button The microprocessor will power up and the unit will start Allow the engine to start completely the first time after loading software DO NOT PLACE THE START RUN OFF SWITCH IN THE OFF POSITION DURING THE INITIAL START FOL LOWING A SOFTWARE UPGRADE 6 5 4 Troubleshooting Software Loading Problems If after loading the software program the microprocessor does not power up or the engine does not start use the following to isolate the problem a Did the unit perform properly prior to loading the soft ware If not the problem most likely is not a result of the software loading process Check the Microprocessor Status LED near the PC Card slot on the microprocessor It should be blinking continuously at the rate of 1 second on and 1 second off This is the normal heartbeat rate o
183. ER nnn 9 33 9 16 1 To Check Filter Drier cece III 9 33 9 17 CHECKING AND REPLACING HIGH PRESSURE CUTOUT SWITCH HPS 9 33 9 17 1 Checking High Pressure Switch 9 33 9 17 2 Replacing High Pressure Switch 0 0 neeaae 9 34 9 18 COMPRESSOR DISCHARGE PRESSURE TRANSDUCER 9 35 9 18 1 Testing Compressor Discharge Pressure 9 35 9 18 2 Calibrating Compressor Discharge Pressure lt 9 35 9 18 3 Replacing Compressor Discharge Pressure Transducer 9 36 ix 62 10683 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page SERVICE Cont 9 19 COMPRESSOR SUCTION PRESSURE TRANSDUCER 9 37 9 19 1 Testing Compressor Suction Pressure Transducer 9 37 9 19 2 Calibrating Compressor Suction Pressure Transducer 9 37 9 19 3 Replacing Compressor Suction Pressure Transducer 9 37 9 20 Replacing Receiver Sight Glass Assembly Or Fusible Plug 9 38 9 21 SERVICING SOLENOID seem 9 38 9 21 1 Solenoid Valve SV2 SV4 ssssssssessese es hn 9 38 9 21 2 Solenoid Valve SV1 eee ees 9 39 9 22 COMPRESSOR SUCTION MODUL
184. ER RELAY OPTIONAL FUEL HEATER TEMP SWITCH COPTIO FAULT LIGHT LIGHT BAR FUEL LEVEL SWITCH FUEL PUMP FUEL SOLENOID ANUAL GLOW CRANK SWITCH GLOW PLUG GLOW PLUG RELAY HIGH CURRENT PLUG en AD wo UJ Ww e oe cA JUIN AAA 60 550 HARGE TEMPERATURE COOL LIGH HT BAR CLUTCH CLUTCH RE PRESSO ION PRESSURE PRESSO ION MODULATION VALVE XTC CURRENT T RMER ROST AIR SWITCH ROST LIGHT LIGHT BAR R SWITCH ROST TERMINATION TEMPERATURE ENGINE COOLANT LEVEL SWITCH ENGINE COOLANT TEMPERATURE ENGINE OIL LEVEL SWITCH ENGINE OIL PRESSURE SWITCH N 0 ENGINE RPM EVAPORATOR PLUG FUSE MP 7 5 AMPERE FUSE SR 10 AMPERE FUSE RR 7 5 AMPERE FUSE CLHR 7 5 AMPERE FUSE MAXI FUSE 80 AMPERE A2 D2 B6 D9 D10 FUSE SV amp UL 15 AMPERE 1 D15 M14 J11 J16 FUSE SROS 5 AMPERE 0 M1S F17 FUSE FHR 20 AMPERE OPTIONAL B3 B6 D8 D10 FUSE LB 3 AMPERE L11 L13 M14 M16 FUSE AFAR 40 AMPERE DUAL ELEMENT SLOW BLOW H COPTION ON XTC B3 wo CELO Qo Qo TT TT Tm E 0000 16 H1 J2 B3 L3 L11 L14 J14 114 L16 J17 DO S mc Cu HEAT LIGHT LIGHT BAR HIGH PRESSURE CUT OUT SWITCH N C J 1 JUMPER 2 K11 LIGHT BAR ICROPROCESSOR BOARD 4 H3 H2 ICROPROCESSOR QUICKCONNECT OUT OF RANGE LIGHT LIGHT BAR RETURN AIR TEMPERATURE REMOTE SWITCH REMOTE SENSOR RUN RELAY SUPPLY AIR TEMPERATURE SATELLITE COMMUNICATION SPEED CONTROL SOLENOID SERIAL PORT STAR
185. ERRIDES n 5 18 5 18 MAXIMUM SUCTION OPERATING PRESSURE COOL ONLY 5 19 5 19 MAXIMUM OPERATING PRESSURE MOP OVERRIDE HEAT AND DEFROST ONLY 5 19 5 20 SUCTION PRESSURE OPERATION cece cette ete mn 5 20 iii 62 10683 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page TECHNICIAN INTERFACE piece ee eed eee eek De ee ed ex RN ERANT KE 6 1 6 1 sha cate engin ce PESE Ge Saree ead ten Een 6 1 6 2 MICROPROCESSOR CONFIGURATION AND TECHNICIAN TEST MODES 6 2 6 2 1 Configuration Mode rh 6 3 6 2 2 Component Test Mode ene teens 6 12 6 2 3 Semice Mode e ee Sis eh ea TM PG GS 6 13 6 3 PC SUPPORT SOFPTWAREs cler Reed aue ee ig eee RE DUE 6 14 6 3 1 ReeferManager And Reports cece ees n 6 14 6 4 DOWNLOADING DATA WITH THE PC CARD cece ne 6 16 6 5 INSTALLING NEW SOFTWARE rn 6 17 6 5 1 Software Version Numbers c cece ene 6 17 6 5 2 Using The Program PC ssssssssssssesesess en 6 18 6 5 3 Using ReeferManager to Install Software 6 19 6 5 4 Troubleshooting Software Loading Problems 6 19 6 6 RE SETTING PM PREVENTATIVE MAINTENANCE HOURMETERS
186. ETPOINT MAX SETPOINT AUTO FRESH AIR EXCHANGE 62 10683 6 8 DESCRIPTION OFF There is no upper limit for this parameter Select the upper limit of the ambient range desired for this parameter Refer to Section 5 16 for more information on High Air Max Temp OFF Delta T is not used for determining the ac tivation de activation of High Air Delta T 3 6 F to 27 F Select the desired Delta T value for activation of 2 to 15 C ProductShield High Air 0 5 increments OFF OFF ProductShield Winter is disabled Select the desired ambient temperature below which ProductShield Winter will operate forced Continuous Run operation OFF If both Range 1 amp Range 2 locks are off Start Stop or Continuous Run may be selected If either Range 1 or Range 2 is not OFF the unit will operate in the selected mode whenever the set point is within that range START STOP The unit will always operate in Start Stop whenever the set point is between the minimum amp maximum temperatures for that range see below CONTINUOUS The unit will always operate in Continuous Run whenever the set point is between the minimum amp maximum temperatures for that range see below Select the lowest temperature desired for either Range 1 and or Range 2 Select the highest temperature desired for either Range 1 and or Range 2 Select the lowest temperature that will ever be used as set point Set point can not be set
187. FROST ALARM START STOP CON TINUOU SETPOIN BOX TEMPERATURE a H START RUN OFF 1 To stop the unit place the START RUN OFF switch in the OFF position The diesel engine will stop and the microprocessor will NOTE turn off The Microprocessor Main Display The CSMV will close to 0 when START MessageCenter and all indicator LEDs will also turn off RUN OFF switch is switched to OFF NOTE Due to internal processing within the micro processor turning the START RUN OFF switch OFF then back to START RUN will re sult in a 4 to 50 second delay between the display going off and coming back on again 62 10683 3 32 3 19 DATA RECORDING The Advance microprocessor contains a_ built in DataRecorder with 512K of memory The recorded data can be downloaded from the DataRecorder using either ReeferManager a PC software program or a Download PC card The DataRecorder reads the same input information as the microprocessor Functional Parameters Configurations and Unit Data at all times The DataRecorder records events as they occur such as set point
188. IGGER ON The High Engine Temp Shutdown Configuration and or Engine Oil Pressure Shutdown Configuration is are set to YES and either Alarm 11 Low Engine Oil Pressure or Alarm 12 High Coolant Temperature has become active and shut the unit down three times within the past 2 hours e UNIT CONTROL Unit shutdown and alarm RESET CONDITION Reset from inactive alarm list only Can not be reset by turning switch OFF and then ON again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Determine Which Alarm Caused This Alarm To Be Active a Check active alarm list for One or more of these alarms will be present Alarm 5 11 12 b Follow the steps for the alarm s found All alarms condition must be corrected above and correct the alarm condition Reset Alarm Reset all alarms from the inactive alarm All alarms must be cleared to start unit list 62 10683 8 16 Change 09 11 NO Steps ALARM CAUSE CORRECTIVE ACTION 27 HIGH SUCTION PRESSURE TRIGGER ON Suction pressure has been greater than 98 PSIG 6 7 Bars for more than 10 minutes UNIT CONTROL Alarm Only or Unit Shutdown amp Alarm if configured RESET CONDITION Auto reset when suction pressure is less than 75 PSIG
189. IGHT BAR and the Remote Cool light circuit to the Light Bar circuit is shorted The Cool Light output from the micro is negative so the circuit will not be shorted to ground but is shorted either within the Cool Light itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when Cool light current amp draw is normal or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Cool Light a Inspect Cool light amp socket No damage to bulb No damaged or corroded pins b Check resistance of light bulb Refer to Section 2 13 Check Cool Light Wiring a Inspect harness amp control See Notes Note 3 Note 4 amp Note 8 connector pins amp terminals See wiring No physical damage to harness schematic No damaged or corroded pins Check Cool Light Current Draw a Use Component Test mode Refer to Refer to Section 2 13 for normal current values Section 6 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 14 8 53 62 10683 NO Steps ALARM CAUSE CORRECTIVE ACTION 89 CHECK REMOTE AUTO LIGHT TRIGGER ON
190. INUOUS 20 45 F TRIP START ENTERED MANUAL ALARM LIST TART STOP SELECT DEFROST Sato rrj 1 To mark the start of a trip in the data recorder press the SELECT key until The MessageCenter displays PRESS TO ENTER TRIP START 2 Press the key 3 If trip start is acknowledged by the data recorder TRIP START ENTERED will be dis played for five seconds and then the display will revert back to the normal display Other wise CANNOT ENTER TRIP START will flash and then the display will revert back to the normal display Trip Start places a time stamped events in the data recorder memory to allow easy review of the data from the last trip and to allow downloading data from a specific trip A trip begins at a Trip Start and ends at the next Trip Start Trip Start tells the data recorder that the present date and time is the beginning of a new trip 62 10683 3 16 3 12 VIEW ACTIVE ALARMS ALARM LIGHT HEAT COOL DEFROST START STOP CONTINUOUS 20 3245 F SETPOINT BOX TEMPERATURE NO ACTIVE ALARMS Pb MANUAL ALARM LIST SELECT DEFROST CONTINUOUS Q Press the ALARM LIST key If there are no active alarms the display will say NO ACTIVE ALARMS for five seconds If there are active alarms the display will be A and the alarm number and message The last alarm that occurred will be the fir
191. IT ETE TIC C2 C202 02 O2 C2 OO COO OO COO OQ gt 22 22 27 m 2 20201112 202 m lt a U NOWNNNDDADS A2 D2 B6 D9 D10 D11 D15 M14 J11 J16 RE 10 M15 F17 AMPERE B3 B6 08 010 AMPERE L11 L13 M14 M16 LICE PACK SPEED RELAY START RUN OFF SWITCH STARTER SOLENOID STARTER SOLENOID CONTACTOR STARTER SOLENOID RELAY SOLENOID VALVE UNLOADER USE SV amp UL USE SROS 5 A HR 20 A B 3 AMPE cO CO Ow C RE OPTIONAL L AFAR 40 AMPERE COPTION ON XTC HEATER OPTIONAL H H 00511 69 NO Q3S VH Ummm Co mam Lip EATER RELAY OPTIONAL EATER TEMP SWITCH OPTIONAL CC 0000 00 0000 00 COD 0 0 0 Index A Advance Microprocessor Troubleshooting Guide 10 13 Air Filter Service Procedure 9 16 Air Switch 9 44 Alternator Operation 2 11 Alternator Regulator 2 11 Ambient Air Temperature Sensor 2 14 Auto Fresh Air Exchange AFAX 3 38 Automatic Defrost 3 15 B Belt Tension Gauge 9 17 Blower Wheel And Fanshaft Removal 9 21 Blower Wheel Installation 9 23 Calibrating Compressor Suction Pressure Transducer 9 37 Cargo Protect Mode 5 5 Changing IntelliSets 3 36 Changing Setpoint 3 8 Charging Amps 3 10 Checking for a Defective Glow Plug 9 17 Checking High Pressure Switch 9 33 Checking Superheat 9 25 Clutch Installation 9 24 Clutch Removal 9 21
192. LARMS e 8 3 8 4 SHUTDOWN ALARMS mel Phas wake be RECETA cR le 8 7 8 5 START UP ENGINE ALARMS n 8 19 8 6 WARNING STATUS ALARMS 00 cece e 8 37 8 7 EEECTRICAL ALARMS x x eget tees ue RAP Gh pude Ed epa ees osx 8 48 8 8 SENSOR ALARMS osni amie det ende cte as D eR er Gee Owed 8 56 8 9 PRETRIP ALARMS recu et EORR Je E ePi e RR RC RE RI RR EUR AEA Pis 8 68 8 10 MAINTENANCE ALARMS cece e 8 103 8 11 MICROPROCESSOR ALARMS en 8 107 SECTION 8 ALARM TROUBLESHOOTING 8 1 INTRODUCTION TO ALARM TROUBLE SHOOTING GUIDE The Alarm Troubleshooting Guide should be used whenever an alarm occurs Alarms will appear in the MessageCenter and will begin with the alarm number Alarms are listed in the Troubleshooting Guide by alarm number When an alarm occurs look through both Active and Inactive Alarm lists in the microprocessor See Note Note 1 Section 8 2 and make note of all alarms Before beginning to actually troubleshoot a unit visually inspect the unit in particular the area of the unit that is causing a problem In many cases the cause of the problem will be obvious once a visual inspection is performed For those cases where the cause of the problem is not obvious this troubleshooting guide will be of assistance Usually you should begin troubleshooting with the first alarm that appears in the active Alarm list Other alarms in the list may
193. MOTE SWITCH 2 0 0 ett eee eee eee 8 44 59 DATALOGGER NOT RECORDING cece cece eect eee ee eens 8 45 60 DATALOGGER TIME WRONG teen eens 8 46 61 DOOR OPEN xe Se e Ga e eed d eda e VG eh ee ae 8 47 Change 09 11 62 10683 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page ALARM TROUBLESHOOTING Cont 8 7 ELECTRICAL ALARMS 0 ccc eee eee n n nnn 8 48 71 2 ORCES EUSE OSEE DSL 8 48 72 BADFAORHEG FUSE 8 48 78 CHECK SV1TCIRCUIT gt iui eels amas 8 49 79 wh rk WE ep T ui i ERR ER Es 8 49 81 CHECK FHR CIRGUE oki esee Ie RE Daum edt eet ted Cadeau 8 50 82 CHECK REMOTE OUT RANGE LIGHT eect eens 8 50 83 CHECK REMOTE DEFROST LIGHT eens 8 51 84 CHECK REMOTE ALARM LIGHT nee 8 51 85 CHECK ULT GIRGUIT ael aer packs Mice eas nes 8 52 86 CHECK UL2 CIRCUIT cre Moana tone a hn any ales aly Ales 8 52 87 CHECK REMOTE HEAT LIGHT incer eene ek em ede e 8 53 88 CHECK REMOTE COOL LIGHT ttn teens 8 53 89 CHECK REMOTE AUTO LIGHT tnt 8 54 90 AUTOFRESH AIR EXCHANGE RELAY teeta 8 54 93 CHECK START UP BUZZER ir cte b eee lh i o Rte
194. N Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary za Check Engine Coolant Temperature Sensor ENCT Inspect Engine Coolant Sensor amp No damage to sensor connector No moisture damage or corrosion in connector 1MP Plug is connected tightly to microprocessor No wires are pushed back through plug b Check Engine Coolant Sensor 10 000 Ohms 77 F 25 C See section 2 13 for resistance See Note 4 Page 8 2 complete table of temperatures and resistance values Check Engine Coolant Sensor Wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section ds remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink 3 Remote Sensor Switch Connector a Locate and inspect 10 way connector Connector must have cap on for optional sensors and switches No corrosion or moisture inside connector If there is a problem with the connector and there are no P156 CHECK BATTERY VOLTS
195. N PRESSURE TRANSDUCER CSP 9 37 9 21 SERVICING SOLENOID VALVES 0 0 ccc 9 38 9 22 COMPRESSOR SUCTION MODULATION VALVE CSMV 9 41 9 23 LIGHT eigen ue eon bo eb ene noel Tt eee es 9 43 9 24 CHECKING DEFROST OR HEATING CYCLE 9 43 9 25 DEFROST AIR SWITCH DAS 9 43 9 26 EVAPORATOR COIL CLEANING cece tenes 9 44 9 27 CONDENSER COIL CLEANING III eens 9 45 9 28 MICROPROCESSOR SENSOR CHECKOUT 9 45 9 29 UNIDRIVE TORQUE REQUIREMENTS 9 47 SECTION 9 SERVICE WARNING Beware of V belts and belt driven compo nents as the unit may start automatically Before servicing unit make sure the START RUN OFF switch is in the OFF posi tion or the unit is in Maintenance mode Also disconnect the negative battery cable CAUTION Use only Carrier Transicold approved Poly ol Ester Oil POE Buy quantities of one quart or less When using this hygroscopic oil immediately reseal Do not leave con tainer of oil open or contamination will oc cur CAUTION Unit uses R404A and POE The use of in ert gas brazing procedures is mandatory for all Carrier Transicold refrigeration units otherwise compressor failure will occur For more information refer to Technical Procedur
196. N UNSUCCESSFUL Attempt to calibrate discharge transducer failed CANNOT ENTER TRIP START Cannot enter trip start A problem has been detected within the Da taRecorder CANNOT START DEFROST CYCLE Cannot start defrost cycle Refer to Defrost Sections 3 10 5 11 2 15 and 9 24 CANNOT START PRETRIP Cannot start pretrip Refer to Pretrip Section 3 4 Data cannot be downloaded and software upgrades are prohibited CANNOT DOWNLOAD BATTERY DEAD when battery voltage is below 7 0 volts This message will be dis played until the serial cable is removed CARD FULL REMOVE CARD The PC Download card is full There is no additional room to down load information from the microprocessor You may safely remove the PC card from the slot 7 1 62 10683 MessageCenter MESSAGES CARD LOCKED REMOVE CARD The lock switch on the PC card is in the Locked position To use the PC card move the switch to the Unlocked position CARD REMOVED DATA NOT COPIED The PC card was removed before all data was copied onto the card CARD REMOVED REINSERT CARD The PC card was removed from the card slot before the operation was completed Reinsert the PC card into the card slot to perform the operation CFG TO LOAD 1 TO CANCEL CHANGE INTELLISET TO EXIT CHARGE MODE HOLD TO EXIT CHECK AT NEXT SERVICE INTERVAL A Configuration card has been inserted into the PC card slot Press the key to load configurations or In
197. ND REPLACING FILTER DRIER 9 16 1 To Check Filter Drier Theunit must be running in Coolforthis test Check fora 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 9 16 2 To Replace Filter Drier a Pump down the unit per section NO TAG Remove bracket then replace drier Tighten inlet side fitting b Slowly open king valve and purge air through the drier Tighten drier outlet side fitting c Close the king valve d Leak test drier connections e Remove the refrigerant pressure from the low side of the system according to Step NO TAG of Section NO TAG f Evacuate the low side of the system according to Section NO TAG g Check refrigerant level h Check unit operation by running Pretrip Refer to Sec tion 3 4 9 17 CHECKING AND REPLACING HIGH PRES SURE CUTOUT SWITCH HPS 9 17 1 Checking High Pressure Switch AX WARNING Do not use a nitrogen cylinder without a pressure regulator Cylinder pressure is approximately 2350 PSIG 159 9 Bars Do not use oxygen in or near a refrigerant sys tem as an explosion may occur See Figure 9 26 9 33 62 10683 1 Cylinder Valve and Gauge Pressure Regulator Nitrogen Cylinder Pressure Gauge 0 400 PSIG 0 to 27 2 Bars Bleed Off Valve 1 4 inch Connection Figure 9 26 Typical Setup for Tes
198. NNECT OUT OF RANGE LIGHT LIGHT BAR RETURN AIR TEMPERATURE RE ITCH RE SOR RU X SU R TEMPERATURE SATELLITE COMMUNICATION SPEED CONTROL SOLENOID SERIAL PORT STARTER MOTOR SPLICE POINT gt monn ANDO gt JE s 0p Jd Ul on 63 2 9 4 TI T N or 5 Uc E N C0C0 C0 COCOCO22 Z2 22 220 OO gt U 66 01 9 DMC NO GAsva ILU SPLICE PAC SPEED RELAY START RUN OFF SWITCH STARTER SOLENOID STARTER SOLENOID CONTACTOR STARTER SOLENOID RELAY SOLENOID VALVE UNLOADER 000000 00 00 9 CD 20 6 01 SPK3 L11 NOTES OUTPUT UNIT SHOWN IN OFF POSITION POWER s WIRE IDENTIFICATION SYSTEM COLOR WHITE DC CONTROL CIRCUITS f E BLACK GROUNDS SP1 TO 5P2 K10 55 ADDRESS SYSTEM EXAMPLE 9 2 25 9 5 QO DO INDICATES A WIRE BETWEEN PLUG HC A PIN 9 MICROPROCESSOR PLUG2 PIN 25 F7 MPQC1 TO ENSCU 18 N11 r T0 8 27 4 He TO SSR86 J9 l op 4 ED Boel EE SYSTEM POWER GCS SPKs o ROS LOCATED IN ENGINE HARNESS WWW
199. OL FUEL HEATER RELAY FAULT LIGHT OUT OF RANGE LIGHT DEFROST LIGHT COOL LIGHT BUZZER SV3 CONTROL SV2 CONTROL UNLOADER 2 CONTROL UNLOADER 1 CONTROL RELAY POWER TO a P26 E4 SSR SPK6 55 30 15 R lt MPQC8 TIT mmm FTU FTT mmm mm mm FTT BOND Re C N 30 ie F8 PHR SP25 W AUTOFRESH ONLY 6 9 HCTE f gt N13 oga B 301187 ENG BLOCK GRD ZONE NORMALLY CLOSED CONTACTS ITCH SYMBOL INDICATES MOMENTARY CONTACTS SPLICE PACK INDICATES A SOLDERED SPLICE POINT a NORMALLY OPEN CONTACTS INDICATES A WIRE GROUND PIN CONNECTION INDICATES CONNECTION INDICATES A CHASSIS GROUND NO WIRE COMPONENT CONNECTION NUMBER OR LETTER lt lt MULTIPLE PLUG CONNECTION NUMBER INDICATES A CONNECTION WIRE LUG ETC SYMBOL DESCRIPTION ZONE DESCRIPTION AAT AMBI FAR AUTO FAS AUTO ET ALTE RL AUTO BUZZER BATTERY ENT AIR TEMPERATURE R E E COMPRESSO HARGE PRESSURE R C C R RESH AIR EXCHANGER RELAY ON XTC RESH AIR EXCHANGER SOLENOID COPTION ON XTC ATOR RESTART LIGHT LIGHT BAR FUEL HEATER OPTIONAL FUEL HEAT
200. ON SYSTEM OPERATION REFERENCE SECTION a Daily Maintenance Pre Trip Inspection before starting Check Engine Hours Check Engine Oil Level b Every Service Interval or Annually 1 Check unit mounting bolts 2 Check engine and compressor mount bolts 3 Check door latches amp hinges 4 Check gauges switches and electrical connections 5 Check all belt tensions 6 Check control box 7 Check gearbox and fan shaft for oil leaks 8 Check fan shaft idler and gearbox bearings 9 Check clutch air gap and adjust as required 1 Check oil filter change interval refer to section f of this table 2 Check for oil leaks 3 Check low oil pressure safety 4 Clean crankcase breather 5 Check engine speeds for units without electronic speed control Fuel System 1 Clean fuel pump strainer 2 Change fuel filter s refer to section f of this table 3 Check fuel heater optional Cooling 1 Clean radiator condenser fin surface System 2 Check antifreeze concentration 3 Check water pump 4 Check water temperature sensor functions 2 7 Exhaust 1 Check mounting hardware Check System 2 Check muffler and exhaust pipes Check Air Intake 1 Change air cleaner element Check System 2 Check and replace air filter indicator if needed 9 8 8 Starting 1 Check battery condition Check Replace System 2 Clean battery connections and cable ends Check Replace 3 Check battery hold down clamps Check 4 Check starter operatio
201. ON NUMBER OR LETTER OR lt MULTIPLE PLUG CONNECTION NUMBER SYMBOL DESCRIPTION ZONE PTION CATES A WIRE GROUND CATES A CONNECTION WIRE LUG ETC AAT AMBI FAR AUTO FAS AUTO LT ALTE RL AUTO BUZZER BATT COMP COMP COOL L CLUT CLUT T AIR TEMPERATURE J12 RESH AIR EXCHANGER RELAY ON XTC L15 RESH AIR EXCHANGER SOLENOID OPTION ON XTC J14 R 8 ART LIGHT LIGHT BAR B3 LIGHT LIGHT BAR EVEL SWITCH UMP D SPEED ACTUATOR GLOW CRANK SWITCH COPTIOND LUG LUG RELAY RENT PLUG f o gt 7 9 K16 HARGE PRESSURE J2 E3 L3 HARGE TEMPERATURE 0 L11 L14 J14 I14 HT BAR 5 L16 J17 n OUUOCQO UI IGHT LIGHT BAR RESSURE CUT OUT SWITCH N C TON PRESSURE JUMPER IO MODULATION VALVE XTC UMPER CURRENT RMER E BAR ROST AIR SWITCH PROCESSOR BOARD ROST LIGHT LIGHT BAR F ICROPROCESSOR QUICKCONNECT R SWITCH T RANGE LIGHT LIGHT BAR DEFROST TERMINATION TEMPERATURE AIR TEMPERATURE ENGINE COOLANT TEMPERATURE SWITCH ENGINE OIL LEVEL SWITCH E SENSOR ENGINE OIL PRESSURE SWITCH N 0 LAY ENGINE SPEED CONTROL UNIT Y AIR TEMPERATURE ENGINE SPEED SE LITE COMMUNICATION EVAPORATOR PLUG L PORT FUSE MP 7 5 AMP ARTER MOTOR FUSE SR 10 AMPE SPLICE POINT FUSE RR 7 5 AMP FUSE CLHR 7 5 A FUSE MAXI FUSE 5 P P R 220 Damm 2 1111 I
202. ON UNSUCCESSFUL e When DISCHARGE PRESSURE 0 0 BAR PSIG appears the offset has been saved into the micropro cessor memory and the calibration is complete f If the calibration was unsuccessful either there is more than 0 Bar PSIG on the transducer or the trans ducer is further away from 0 than an offset will allow The transducer must be replaced 9 35 62 10683 Table 9 4 Compressor Discharge Pressure Transducer Bars PSIG Voltage Bars PSIG Voltage Bars PSIG 0 1 5 1 NOTE Pump down compressor per Section NO TAG The 5 0 VDC terminal B is common between Frontseat both suction and discharge service valves the Compressor Discharge Pressure Trans to isolate compressor ducer the Compressor Suction Pressure b Transducer and the RPM sensor for non ESC engines or ENSSN for engines with electronic speed control If this circuit is shorted to ground Slowly equalize compressor pressure through the service valve gauge ports c Recover refrigerant remaining in compressor to 0 due to one of the mentioned components being psig bar defective or a worn wire the MessageCenter will show d Disconnect wiring from defective transducer and re Suction Pressure 14 7 PSIG 1 0 Bar move the transducer The CDP is located on the top Discharge Pressure 0 PSIG Bar cylinder head Engine REMO e Connect wiring and calibrate the transducer per Sec tion 9 18 2 9 18 3 Replacing Compressor Dis
203. ORRECTIVE ACTION 40 CHECK GLOW PLUGS TRIGGER ON Glow Plug amperage is less than 30 Amps or greater than 43 Amps after 14 seconds of glow time NOTE In auto start this can only occur when the Engine Coolant Temperature is below 32 F 0 C and the glow time is configured SHORT UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if glow plug amperage is between 30 to 43 amps for at least 14 seconds during the glow cycle or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Glow Plug Circuit a Inspect glow plug relay amp socket No signs of discoloration from overheating No corrosion b Check operation of Glow Plug Relay START RUN OFF switch in START RUN position Manual Start Operation See Note Note 4 Glow Crank switch in Glow position OR use Component Test Mode to energize the Glow Plug Relay Refer to Section 6 2 2 LED 30 must be ON c Check Non Amps View Current Draw in Data list posu eb to Section 2 13 d Check Glow Plug circuit amperage Current Draw Non Running Amps Glow Plug Amps In Component Test Mode only the Glow Plug Amps will be displayed e Check voltage to
204. P Suction service valve Fuel filter Engine oil drain Starter motor Lube oil fill and dipstick Lube oil filter Oil Pressure Switch OP Mechanical fuel pump Fuel bleed valve Speed Control Solenoid SCS Water Temperature Sensor WTS Ambient Temperature Sensor ATS Figure 2 1 Front View Of Unit With Non ESC Engine 62 10683 Condenser Pressure Control Solenoid Valve SV1 Defrost Air Switch DAS Filter Drier Receiver Receiver sight glass Liquid Line Solenoid Valve SV2 Battery location Figure 2 2 Curbside Non ESC Engine NOo ROI 62 10683 2 4 Condenser Radiator Radiator fill neck Radiator overflow reservoir Engine air cleaner Alternator See Figure 2 11 Model Serial No Location Control box See Figure 2 8 gt Figure 2 3 Roadside Non ESC Engine Bom 7omonugoo Liquid line service valve Hot Gas Solenoid Valve SV4 Suction Modulation Valve CSMV High Pressure Cutout Switch HPS Compres sor Discharge Transducer CDT and Unloader Solenoid Valve Discharge service valve Compressor 05G Compressor sight glass Suction Pressure Transducer CSP Suction service valve Engine oil drain Starter motor Lube oil fill and dipstick Lube oil filter Mechanical fuel pump Engine Oil Pressure Switch ENOPS Engine Speed Sensor ENSSN Fuel and Speed Actuator FSA and Alternator Fuel bleed valve Engine air cleaner Fuel filt
205. RD IS INSTALLED 3 Loosen idler pulley 4 5 6 7 Remove old belt and replace with new belt See Figure 9 11 Using a belt tension gauge Figure 9 10 on the belt rotate idler pulley so that the gauge reads the correct tension Refer to Table 9 3 Tighten idler carriage bolt and bolts NOTE The tension of both belts must be checked and adjusted if necessary after a brief break in pe riod See step 6 Reconnect negative battery cable and install belt guard and operate unit in high speed for 5 10 min utes Remove guard and disconnect battery Repeat steps 4 and 5 62 10683 9 9 4 Engine To Gearbox V Belt a 1 2 To Replace V belt Disconnect negative battery cable and remove V belt guard and then loosen idler bolt Match mark adapter to engine flywheel See Figure 9 13A for ease of assembly Remove six bolts 5 16 18 x 1 Ig securing adapter drive sheave to engine flywheel Figure 9 13A Insert two of the six bolts 5 16 18 x 1 Ig into the threaded holes jacking holes provided on engine adapter Jack adapter from engine flywheel Re move the two screws from adapter Insert a pry bar between engine flywheel and adapter Figure 9 13A and slide the adapter sheave toward the compres sor enough to change the V belt as shown in Figure 9 13B Replace V belt FLYWHEEL ATTACHING SCREWS Figure A 5
206. RE 5 23 65 RE 05 DISPLAY KEYPAD K3 K2 CLHR RR PCMCIA SPKS SP24 Q Eu ENOPS TO ENCLSC J TO HC9 K ENRPM GE G CDP MP P33 POS CONTROL BOX a ULTIMA ULTIMA XTC Pes AND ULTRA P35 P11 P22 P12 5MPA9 TO HC6 B3 5MPA10 8555885 TO 5MPA1 E3 5 11 2MP25 E7 NNNNNNNNNNNNNNDD DODD O O lt PAS TO 6 81 P33 POS P20 P32 LB G B F9 OUTPUT POWER C1 ng SOON e 20 E JL IL NOT ON XTC UNITS Cm DTT2 AFAR mec 5 1 F17 2 3
207. RECEIVED anias Toer opa ee ovn HI DP RI EUR ove epa Eat pese epus 2 13 2 3 8 Compressor Transducers and Sensors 2 14 2 4 EVAPORATOR SECTION METRE 2 14 2 4 1 Thermal Expansion Valve ssssssseeee e mm 2 14 24 2 Heat Exchanger ss ei ESAE RETE EE LES UEM TESTE AS 2 14 2 43 Evaporator Coll zs curb DER Loa UE HE LE PEU INE 2 14 2 4 4 Evaporator Transducers and Sensors 2 15 2 5 SYSTEM OPERATING CONTROLS AND COMPONENTS 2 15 2 5 1 Multiple Language Seeerei erea eda ee ea ee ENER EAE E nent 2 15 2 5 2 Special Features sinrego aaea Re ea LA bee aia 2 15 2 5 3 Component Description And Location 2 16 2 5 4 Handling of PC Cards enn 2 22 2 6 OPTIONS use EUER alien dee Sie eu s pu Ga leh ee a 2 22 2 6 1 Light peeks ceeds 2 22 2 6 2 Door and Remote Switches 2 23 2 6 3 of Range Alarm cee tenet ene 2 24 217 ENGINE DATA ess tener ee seta th ee i 2 25 2 7 1 Lubrication System eee 2 25 2 8 ENGINE SCREW THREADS ene 2 26 2 9 ENGINE AIECSYSTEM FREIER bane Per make AGS Mc in Roe A re ERI 2 26 2 10 COMPRESSOR DATA rre ex Re
208. RIVE 90 ft lbs 12 45 Mkg M12 x 1 25 x 25 mm 19 8 Required 65 ft Ibs 8 99 Mkg 3 8 16 x 1 lg Grade 5 12 Required 28 ft lbs 3 87 Mkg Figure 9 36 Unidrive Torque Requirements Electronic Speed Control Engine 9 49 62 10683 62 10683 Table 9 9 R404A Temperature Pressure Chart Temperature Pressure eC F Bars PSIG 34 3 068 9 9 2 e 177 256 6 185 273 ae 226 328 14 6 265 389 3 8 285 411 9 16 347 504 8 18 3 65 529 6 22 401 58 1 4 4 420 609 3 479 695 Temperature Pressure Bars PSIG of 32 50 725 S21 756 e 35 545 788 3 565 81 4 40 59 855 e 2 614 890 7 638 925 e 4 665 962 o 68 999 30 50 7 15 1037 38 55 798 15 36 amp 6 126 38 6 9ar 1374 L2 70 1630 149 4 728 75 11181621 ar 12 10 1785 29 85 13 7 189 6 90 14 10 2045 35 95 15 18 2202 100 1633 2368 at 105 1753 2542 110 1878 2724 115 20 1 291 6 a 120 21 50 311 8 52 126 22 95 3329 54 130 24 48 355 0 Ls 185 26 07 378 1 60 140 27774 4023 145 29 48 427 6 150 31 30 4540 9 50 SECTION 10 UNIT TROUBLESHOOTING PARAGRAPH NUMBER Page 10 1 DIESEL ENGINE a a ae E iA 10 1 10 1 1 Engine Will Not Start eee nee ae 10 1 10 1 2 Engine Starts T
209. ROL Alarm Only RESET CONDITION Auto Reset when light current amp draw is normal or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Out Of Range Light a Inspect Out of Range light amp socket No damage to bulb No damaged or corroded pins b Check resistance of light bulb Refer to Section 2 13 Check Out Of Range Light Wiring a Inspect harness amp control Notes Note 3 Note 4 amp Note 8 connector pins amp terminals See wiring No physical damage to harness schematic No damaged or corroded pins Check Out Of Range Light Current Draw Use Component Test mode See Refer to Section 2 13 for normal current values Section 6 2 6 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 14 62 10683 8 50 NO Steps ALARM CAUSE CORRECTIVE ACTION 83 CHECK REMOTE DEFROST LIGHT TRIGGER ON The micro Light Bar configuration is set for an 8 LIGHT BAR and the Defrost light circuit to the Light Bar circuit is shorted The Defrost Light output from the micro is negative so the circuit will not be short
210. RT CYCLES START CYCLES PM Meter is connected to the meter is assigned to a counter in the 1 000 TO 90 000 clutch cycle meter This meter counts every time previous configuration CYCLES in 1 000 the engine starter engages The reset interval will cycle increments be 1 000 to 90 000 cycles HIGH SPEED HIGH SPEED HOURS PM Meter is connected to HOURS the high engine speed hourmeter which counts 50 30000 HRS only high speed engine hours The reset interval will in 50 hr increments be 50 30 000 hrs MAINTENANCE MAINTENANCE DAYS PM 1 5 is connected to DAYS the real time clock which counts only days The 0 to 99 999 DAYS reset interval will be 10 99 999 days in 10 day incre ments 62 10683 6 6 CONFIGURATION ee DESCRIPTION PRODUCTSHIELD SETUP NOTE ProductShield is only avail able when IntelliSet is installed Refer to Section 5 16 for more information on the following settings OFF OFF ProductShield Econo is OFF ePRODUCTSHIELD ECONO ePRODUCTSHIELD ECONO MIN TEMP ePRODUCTSHIELD ECONO MAX TEMP PRODUCTSHIELD ECONO DELTA T PRODUCTSHIELD HIGH AIR PRODUCTSHIELD HIGH AIR MIN TEMP GO TO START STOP GO TO CONTINUOUS 19 F to 119 F 28 3 C to 48 3 C in 0 5 F or C increments Default 119 F 48 3 C 19 F to 119 F 28 3 C to 48 3 C in 0 5 F or C increments Default 119 F 48 3 C 3 6 F to 27 F 2 15 C
211. Range 1 Maximum Temperature of 55 F 12 8 C Should Continuous Run operation ALWAYS also be required with set points between 22 F 30 C and 0 F 17 8 C then Range 2 will be set for Continuous Run witha Range 2 Minimum Temperature of 22 F 30 C and a Range 2 Maximum Temperature of 0 F 17 8 C Any set point outside of Range 1 or Range 2 will allow the user to change unit operation between Start Stop and Continuous Run 62 10683 5 12 Range Lock 1 amp 2 Range 2 is set for 0 to 22 F Range 1 is set for 17 8 to 30 C 28 to 55 F 2 2 to 12 8 C 23 3 17 8 12 2 Figure 5 5 Range Lock 1 Inthe example shown in Figure 5 5 Range 1 or Range 2 can be changed to lock the unit operation into Start Stop It is primarily important to determine which range is to be Range 1 and which is to be Range 2 is when the ranges overlap In the example shown in Figure 5 6 the ranges will be set to lock all set points into Start Stop except for a small range between 32 and 42 F 0 and 5 6 C during which the unit will always operate in Continuous Run Range 1 Minimum Temperature will be set for 32 F 0 C and Maximum Temperature of 42 F 5 6 C Range 2 will be set for a Minimum Temperature of 22 F 30 C and a Maximum Temperature of 89 6 F 32 C Range 1 always has priority when Range 1 amp 2 overlap Range 1 is set for 32 to 42 F Range 2 is set for 22 to 0 to 5 6 C 89 6 F Se
212. SP is located on the fitting on the crankcase of the compressor e Install new CSP and reconnect wiring Evacuate and dehydrate the compressor Refer to Section NO TAG NOTE Evacuation and dehydration is necessary only in the event that the compressor has reached atmospheric pressure during this procedure Check unit operation by running Pretrip Refer to Sec tion 3 4 a 9 37 62 10683 9 20 REPLACING RECEIVER SIGHT GLASS AS a b o Q SEMBLY OR FUSIBLE PLUG CAUTION Service mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating Refer to Section 6 2 3 Remove the refrigerant from the complete system Refer to Section NO TAG Unscrew the sight glass assembly or fusible plug and discard Wrap threads of new sight glass or plug with Teflon tape or spread some sealing compound on pipe threads of new sight glass assembly or plug and install Torque the sight glass to 15 to 25 ft Ibs 20 to 34 Nm Torque the fuse plug to 4 to 8 ft Ibs 5 to 11 Nm Using a trace amount of refrigerant removed from the system in Step a bring the pressure of the system up to about 10 psig xxx Add dry nitrogen to increase the pressure to 100 psig 6 9 bar Leak check receiv er sight glass or fusible plug Section NO TAG After leak checking unit release the refrigerant nitro gen to atmosphere and evacuate and dehydrate as outlined in S
213. Sensor 3 has been installed and is Wires are connected to 10 pin connector at cavities J amp K correctly wired to the unit If sensor is not present change micro configuration to OFF 2 Check remote temperature sensor 3 EM Inspect Remote Temperature Sensor 3 No damage to sensor amp connector No damage moisture or corrosion in connector b Check Remote Temperature Sensor 3 Refer to Section 9 28 for complete resistance chart resistance See Note Note 6 io 000 Ohms 77 F 25 C Check remote temperature sensor 3 wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section 11 b Check 10 way connector for all No physical damage moisture or corrosion to connector remote sensors and switches Cavity plugs are in place for unused circuits 8 67 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 8 9 PRETRIP ALARMS P141 PRETRIP STOPPED BY USER TRIGGER ON Pretrip cycle was stopped before the Pretrip cycle ended automatically UNIT CONTROL Alarm Only RESET CONDITION Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary
214. T CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check For SV4 Alarm BRI Check for alarms 79 P150 Alarm conditions must be corrected and the alarm cleared to continue System Pressures 2 2 Check and compare compressor Suction amp Discharge Pressures must have the same discharge amp suction pressures with reading 5 PSIG 0 34 Bar on gauges amp on micro those shown on the microprocessor display controller Check SV4 Operation Unit Must Be Running In Heat Cycle See Note 9 Page 8 2 ENS Section 9 21 1 Checking SV4 a Set unit to run in high speed cool After 60 seconds note suction and discharge pressures b SVA coil Hot gas hissing sound will begin immediately Suction pressure must rise slightly Discharge pressure must drop slightly c De energize SV4 coil Hot gas hissing sound will stop immediately Suction pressure must drop slightly pressure must rise slightly 4 Manually Test Refrigeration System a Run Quick Check Must pass all tests Correct any problems found before proceeding 8 89 62 10683 NOT Steps ALARM CAUSE CORREC
215. TE GASKET IS NOTCHED FOR CLEARANCE AROUND DETENTS MOUNTING BRACKET CONTROL BOX GASKET Figure 6 1 Display Module Assembly 6 27 62 10683 SECTION 7 MessageCenter PARAGRAPH NUMBER Page 7 1 MessageCenter MESSAGES 0 00 ccc enna 7 1 SECTION 7 MessageCenter 7 1 MessageCenter MESSAGES The following table lists all of the messages that do not appear in other lists in this manual and a description of their meaning Refer to Section 8 for a list of alarm messages Refer to Section 3 14 for a list of Unit Data messages Refer to Section 3 16 for a list of Functional Parameter messages Refer to Section 6 2 1 for a list of Configuration messages MessageCenter MESSAGES TO SCROLL THEN TO LOCK This message is used when viewing Unit Data Use the UP and DOWN arrow keys to move through the data list Press the key to lock a data item in the MessageCenter TO SCROLL THEN TO SAVE Press the UP or DOWN arrow key to scroll through menu selec tions available in this mode When you reach the desired selection press the key to store new value in microprocessor s memory TO SCROLL THEN TO SELECT Press the UP or DOWN arrow key to scroll through menu selec tions available in this mode When you reach the desired selection press the key to select it TO INSTALL INSTALLS LEFT XX An Option PC card has been inserted into the PC card slot Press the key to install the option into the microprocessor
216. TEMP RETURN AIR TEMP SUPPLY AIR TEMP AMBIENT AIR TEMP DEFROST TERM TEMP 2 COMP DISCH TEMP CSMV BATTERY VOLTAGE DC CURRENT DRAW ENGINE RPM SOFTWARE REVISION CONTROL SERIAL UNIT MODEL HOURS TO ENGINE MAINTENANCE HOURS TO UNIT MAINTENANCE TIME LEFT TO PM1 TIME LEFT TO PM2 TIME LEFT TO PM3 TIME LEFT TO PM4 TIME LEFT TO PM5 DATALOGGER TIME AND DATE Download recorder data if required Enter Trip Start in microprocessor 62 10683 9 6 Table 9 2 CHECK AND RECORD THE FOLLOWING Defrost Timer Set For SSS SOS FmznShudwmOfe SSCS Ha EEUU pr Out of Range Alarm Unloader Pressure Control 9 7 62 10683 9 3 GRILLE INSERT REMOVAL See Figure 9 1 b Remove the 2 bolts on top of the grille insert Removal of insert will ease in condenser coil cleaning Refer to Section 9 27 a Remove the 3 bolts on each side of the grille insert d Reverse above steps to install new grille insert c Swing insert down and lift out of locating holes GRILLE INSERT MOUNTING BOLTS SURROUND GRILLE INSERT LUBRICATE LATCHES AND PINS Figure 9 1 Grille Insert Removal And Door Latch Maintenance 62 10683 9 8 9 4 SURROUND REMOVAL a Place the Start Run Off switch in the OFF position c Remove the bolts that secure the surround to the unit and disconnect the starter b Open both side
217. TER MOTOR SPLICE POINT ae wo AND ma ES 02 0 O2 O OUUUU 22 2222 27 2 Cg ABUT QD N on UW NN 000 UO OZ Z220 20D gt 660 69 NO Q3sva 2720 SPLICE PAC SPEED RELAY START RUN OFF SWITCH STARTER SOLENOID STARTER SOLENOID CONTACTOR STARTER SOLENOID RELAY SOLENOID VALVE UNLOADER mmm m mm m mn m mM 0020000000000 00 2 f NOTES OUTPUT UNIT SHOWN IN OFF POSITION POWER FERES WIRE IDENTIFICATION SYSTEM OLOR WHITE DC CONTROL CIRCUITS B BLACK GROUNDS t5 ADDRESS SYSTEM EXAMPLE HC9 2MP25 TX DICATES A WIRE BETWEEN PLUG HC B A IN 9 MICROPROCESSOR PLUG2 IN 25 A B TO SP2 K10 V3 NOT SUED WITH ULTIMA XTC D ULTRA X r 9 8 P27 F1 7 SA LOCATED IN ENGINE HARNESS HC6 55886 V9 WWW U SYSTEM POWER GPR SSR F Ale TO FLSC 5y
218. TIVE ACTION P182 CHECK SV1 VALVE TRIGGER ON Discharge pressure did not decrease when SV1 was de energized opened as expected in Heat Pretrip Mode or discharge pressure did not increase as expected when SV1 was energized closed in Cool Pretrip Mode UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for SV1 Alarm Lo Check for alarms 80 P148 Alarm conditions must be corrected and the alarm cleared to continue E System Pressures 28 Check and compare compressor Suction amp Discharge Pressures must have the same discharge amp suction pressures with reading 5 PSIG 0 34 Bar on gauges amp on micro those shown on the microprocessor display controller EN Check Sv1 Operation Unit Must Be Running In Heat Cycle See Note 9 Page 8 2 EN Section 9 21 2 Checking SV1 a Set unit to operate in high speed heat After 3 minutes note discharge and suction pressures b De c SV1 coil Compressor discharge pressure will drop eee ene tank pressure will raise slightly 4 Manually Test Refrigeration System Run Quick Check Must p
219. TROL Alarm Only RESET CONDITION Auto Reset when the UL1 Coil current amp draw is normal or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Front Unloader UL1 Coil Inspect Front Unloader UL1 coil amp No damage to coil terminals No damaged or corroded pins b poro c resistance of coil Refer to Section 2 13 Cannot be opened infinite ohms posu BS Zero Ohms or shorted to ground c Check amp draw of coil Refer to Section 2 13 Use ammeter 2 Check Front Unloader UL1 Current Draw a Use Component Test mode Refer to Refer to Section 2 13 for normal current values Section 6 2 2 to test id current View current draw in the Unit Data list Refer to Section draw of the circuit 3 14 Check Front Unloader UL1 Coil Wiring a Inspect harness amp control box See Notes Note 3 Note 4 amp Note 8 connector pins amp terminals See wiring No physical damage to harness schematic Section 11 No damaged or corroded pins 86 CHECK UL2 CIRCUIT TRIGGER ON UL2 Rear Unloader Coil circuit is shorted The UL2 output from the micro is negative so the circuit will not be shorted
220. TROL PROBE Return Air Sensor Return Air Sensor for perishable and frozen set points Supply Air Sensor for perishable set points Return Air Sensor for frozen set points Supply Air Sensor 5 6 1 Heat Cool Null Switching Operation There are three possible modes for UltraFresh 3 control temperatures These are HEAT COOL and NULL Refer to Sections 5 4 and 5 5 for descriptions of HEAT and COOL modes When notin pulldown UltraFresh 3 controls the unit based on the following Refer to the temperature control operating sequence diagrams a To exit NULL and enter COOL while in Continuous Run the control temperature must be greater than or equal to 3 6 F 2 C above set point b To exit NULL and enter COOL while in Start Stop the control temperature must be greater than or equal to 1 8 F 1 C above set point To exit COOL and enter NULL while in either Continuous Run or Start Stop the control temperature must be less than 1 5 F 0 8 C above set point d To exit NULL and enter HEAT the control temperature must be more than or equal to 1 8 F 1 C below set point e To exit heat and enter NULL the control temperature must be less than 1 5 F 0 8 C below set point 5 3 62 10683 5 6 2 Null Mode Operation Null Band consists of a Pulsed Null Mode Operation Reduced capacity is produced between the HEAT and COOL Modes by a mode known as Pulsed Null This mode is not a constant operating mode but only operates f
221. Tee must be open and not blocked or overly restricted If tee assembly for HPS and CDP doubt remove the snubber restrictor with a hammer sensors and small punch then restart pretrip 8 87 62 10683 NO Steps ALARM CAUSE CORRECTIVE ACTION P180 CHECK SUCTION MOD VALVE TRIGGER ON Suction pressure did not drop as expected during Test 10 in Pretrip when the CSMV was changing position UNIT CONTROL Alarm only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Software Revision Level Upgrade software Revision level must be 04 06 00 or higher Check connector to the suction modulation valve a Inspect CSMV and wiring No damage or corrosion Connector fits together tightly No moisture inside Check operation of suction modulation valve Nl a See CSMV troubleshooting Section Must pass all tests 9 22 2 62 10683 8 88 NO Steps ALARM CAUSE CORRECTIVE ACTION P181 CHECK SV4 VALVE TRIGGER ON Suction pressure did not rise within range amp discharge pressure did not drop within range when SV4 was energized opened UNIT CONTROL Alarm Only RESE
222. VE ACTION DATALOGGER NOT RECORDING TRIGGER ON No data is being recorded by the data recorder UNIT CONTROL Alarm Only RESET CONDITION Alarm may be manually reset via keypad NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with ie steps below as necessary 1 Clear Alarm a Clear Active Alarm s Alarms Alarms Clear b Check for Active nS reoccurrence Inactive download all data amp retain If Active go to next step Microprocessor Defective a Download previous data using Data retrieval OK Download PC Card or ReeferManager Program b Replace microprocessor amp set New microprocessor in place Configurations Functional Parameters Enter hours from removed microprocessor set Maintenance Hour Meters and Data Recorder Setup NOTE Specific configurations or IntelliSet settings may be found on the TransCentral Website Authorized Carrier Transicold Dealers only 8 45 62 10683 PNG see ALARM CAUSE CORRECTIVE ACTION DATALOGGER TIME WRONG e TRIGGER ON The real time clock in the Data Recorder does not contain a valid date UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when the Data Recorder Real Time Clock is reset or Alarm may be manually reset by turning the unit off then back on again NOTE Follow the
223. XX indicates the number of empty download slots remaining on the card COPYING DATA PLEASE WAIT A DownLoad PC card has been inserted into the PC card slot and all data from the data recorder is being copied onto the PC card DO NOT REMOVE THE CARD WHILE THIS MESSAGE IS BE ING DISPLAYED DATA RECORDER FAILURE The microprocessor has stopped recording unit data DEFROST CYCLE STARTED The unit has gone into defrost DOOR OPEN The trailer or rail compartment door is open DOOR OPEN LOW SPEED The trailer or rail compartment door is open forcing the unit to run in low speed ENTERING SERVICE MODE The initial message for Service mode See Section 6 2 3 EVAC CHARGE MODE The unit is in Service Mode and the refrigeration system is ready to be evacuated or changed with refrigerant See Section 6 2 3 EXITING PRETRIP MODE Pretrip has been aborted either by user or by a pretrip alarm EXITING SERVICE MODE Service mode has been turned off and unit is returning to normal operation FUNCTION NOT CHANGED The key was not pressed in the allotted amount of time to select the new Functional Parameter setting The new setting was not stored and the old setting will be used HOUR METERS NOT CHANGED Indicates that no changes have been made to the hourmeters in either the configuration or functional parameter lists INACTIVE ALARMS IN MEMORY There are inactive alarms in the microprocessor alarm list which have not yet been cleared INSTALLED REMOV
224. ZZER TRIGGER ON The Buzzer circuit is shorted The Buzzer output from the micro is negative so the circuit will not be shorted to ground but is shorted either within the Buzzer itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when Buzzer amp draw is normal or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Buzzer a Inspect Buzzer amp wire connections No damage to buzzer No damaged or corroded pins b Check resistance of buzzer Refer to Section 2 13 Check Buzzer Wiring Inspect harness amp control See Notes Note 3 Note 4 amp Note 8 connector pins amp terminals See wiring No physical damage to harness schematic Section 11 No damaged or corroded pins Check Buzzer Current Draw a Use Component Test mode Refer to Refer to Section 2 13 for normal current values Section 6 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 14 97 CHECK SV2 CIRCUIT TRIGGER ON SV2 coil circuit is shorted The SV2 output from the Micro is negative so the circuit will not be shorted to ground but
225. a meters OR When the unit is in PreTrip OR When the unit is in Sleep Mode Pressing the key will cause the new displayed set point value to become active and SETPOINT CHANGED will be displayed If the key is not pressed and there is no keyboard activity for 5 seconds the entire display and Light Bar will flash for 15 seconds and SETPOINT NOT CHANGED will be displayed The microprocessor setting will then revert back to the last entered set point All other keys are active while the display is flashing and if pushed while the display is flashing will cause the flashing to stop and perform the requested function TIP The set point may be changed quickly by press ing and holding the UP ARROW or DOWN AR ROW key The longer the key is held the faster the setting will change 3 6 START STOP OPERATION HEAT COOL 20 SETPOINT DEFROST ALARM START STOP LIGHT START STOP CONTINUOUS H4 F BOX TEMPERATURE START STOP MODE SELECTED MANUAL DEFROST 705 ALARM LIST SELECT CONTINUOU 1 Press the START STOP CONTINUOUS key until the START STOP Light on the controller illuminates 2 Verify that START STOP MODE SELECTED is displayed on the MessageCenter and that the Start Stop light is illuminated The unit is now in Start Stop operation Automatic Start Stop is provided to permit starting stopping restarting of the unit as required This feature allows
226. a Inspect battery cable ends and posts Must be clean and tight No corrosion b Test voltage at battery with unit off Must be above 11 VDC C Test specific gravity of battery Cheek o SE d Perform load test on battery Follow ek ooo battery manufacturer s procedure 7 Checkfor correct engine oil ILE Check for correct viscosity for Refer to Section 2 7 conditions Must be correct for ambient conditions 62 10683 8 26 ANO Steps ALARM CAUSE CORRECTIVE ACTION 36 CHECK COOLANT TEMPERATURE TRIGGER ON Coolant temperature is below 32 F 0 C after the engine has been running for five minutes UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when Coolant temp rises above 36 F 2 2 C or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Coolant Temperature a Check temperature of coolant or upper Must be above 32 F 0 C radiator hose Check Engine Coolant Sensor a Check resistance of Engine Coolant Refer to Section 2 13 for complete resistance chart Sensor See Note 6 10k Ohms 77 F 25 C amp b Inspect harness control box No physical damage to harness
227. a three the battery is provided by the 12 VDC alternator phase stator assembly The alternating current and voltage is changed to direct current and voltage by a Alternator Operation passing AC energy through a three phase full wave rectifier system Six silicon rectifier diodes are used The regulator is an electronic switching device It senses the system voltage level and switches the voltage applied to the field in order to maintain proper A CAUTION system voltage b Integral Voltage Regulator Operation 12 VDC Observe proper polarity when installing The regulator is an all electronic transistorized device battery Negative battery terminal must be 9 No mechanical contacts or relays are used to perform grounded Reverse polarity will destroy the the voltage regulation of the alternator system The rectifier diodes in alternator As a precau electronic circuitry should never require adjustment and tionary measure disconnect positive bat the solid state active elements used have proved tery terminal when charging battery in unit reliable enough to warrant a sealed unit The system is Connecting charger in reverse will destroy temperature compensated to permit the ideal charging the rectifier diodes in alternator rate at all temperatures Yellow O POS OUTPUT GRN ees NEGATIVE GRN OUTPUT
228. ace unit in Manual Start mode Check Voltage to transducer Voltage reading be tween A negative and B positive should be 5 0 VDC d Check wire continuity C output to microprocessor and 1MP6 e Place 5 0 VDC on transducer terminal B and 5 0 VDC on transducer terminal A Test voltage between and The reading should be as shown in table be low 9 19 2 Calibrating Compressor Suction Pressure Transducer The Compressor Suction Pressure Transducer CSP has a range of 14 7 to100 psig 1 to 6 8 bar Calibration is not required because the range is so small NOTE The 5 0 VDC terminal B is common between the Compressor Discharge Pressure Trans ducer the Compressor Suction Pressure Transducer and the RPM sensor for non ESC engines or ENSSN for engines with electronic speed control If this circuit is shorted to ground due to one of the mentioned components being defective or a worn wire the MessageCenter will show Suction Pressure 14 7 PSIG Bar Discharge Pressure 0 PSIG Bar Engine RPM 0 9 19 3 Replacing Compressor Suction Pressure Transducer a Pump down compressor per Section NO TAG Frontseat both suction and discharge service valves to isolate compressor b Slowly equalize compressor pressure through the service valve gauge ports c Recover refrigerant remaining in compressor to 0 psig bar d Disconnect wiring from defective transducer and re move old transducer The C
229. actuates at correct gauge reading After switch is adjusted place a small amount of paint or fingernail polish on the adjusting screw so that vibration will not change switch setting Q 5 9 26 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 sometimes as often as after each trip the accumulation can be great enough to restrict air flow cause coil icing repetitive defrosts and loss of unit capacity Due to the washing action of normal defrost the fiber dust and particles may not be visible on the face of the coil but may accumulate deep within Clean the evaporator coil on a regular basis not only to remove cardboard dust but also 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 necessary a Remove rubber check valves Kazoo from drain lines front of refrigerated compartment b Remove evaporator bulkhead and back panel then spray coil with a mild detergent solution such as Oakite 164 or any good commercial grade autom
230. al function automatic expan 62 10683 2 14 sion control and prevention of liquid return to the com pressor 2 4 2 Heat Exchanger The heat exchanger is the tube in tube type and is con nected in the main suction line and liquid line The cold suction gas is used to cool the warm liquid refrigerant within the heat exchanger This results in greater sys tem capacity and efficiency 2 4 3 Evaporator Coil The unit evaporator is a tube and fin type The operation of the compressor maintains a reduced pressure within the coil At this reduced pressure the liquid refrigerant evaporates at a temperature sufficiently low enough to absorb heat from the air Heating is accomplished by circulating hot gas directly from the compressor to the evaporator coil Solenoid valves control the refrigerant circuit to operate the heating cooling system Automatic evaporator coil defrosting is initiated by either sensing the air pressure drop across the coil with a differential air switch or with the defrost timer in the microprocessor As perishable products respire they consume oxygen O2 and give off carbon dioxide COs This will eventually cause the atmosphere within a refrigerated compartment to have higher levels of and lower levels of Oo This may adversely affect the shelf life of some sensitive perishable products When transporting these products it may be desirable to maintain normal atmospheric conditions prevent the bui
231. al test temperature at the sensor is an ice bath at 32 F 0 C or a calibrated temperature tester PETC c onms ohms F Ohms 26 7 9 200 60 0 2 88 300 8057 ree o sees 90 sez 7394 _ Foe sse 6354 Fes 6 000 amp e 23 000 amp s 20 000 222 110 500 21 103600 15 905 92 o s 65400 Le 155 15316 L6 aaa 70729 s 53 6546 es 188 19 100 20 12490 6 89 5200 9 45 62 10683 Epe _ orms co _ 7 8 189 690 67 461 170 5 6 434 790 356 umm e 148 9 EN 194 136 138 o 140 o 144 146 we 155 160 165 o 170 o 175 o 180 185 oa fasa 307970 ea 353 Ea 76 78 80 _82_ 86 ES 90 70 040 150 ES man m 98 0 100 102 104 106 o 110 o 112 11a E EE emaa 18 20 22 24 4 26 3 IER 32 21 171 96 40 44 267 E 48 0 2 o 54 o 56 o 62 6a 68 o 70 o 72 74 re EE 244 56 7 28 25 6 578 27 267 589 25 27 8 600 24 614 300 622 23 31 4 633 22 322 644 2 656 20 344 05 600
232. alarms Did you find and correct the with MicroProgrammer condition if using a PC to upgrade Md software Did the software load correctly z Y n Verify function settings configurations and IntelliSet settings are installed amp correct Did NO you find and correct the condition Y Review the results of above tests with your Use Pre Trip to check for any alarms supervisor If Use the Component Test Mode Section necessary go to the 6 2 2 to beginning of the table verify operation Did you find and correct amp test again the condition Use this manual to check for correct operation Did you find and correct the condition y Download data recorder amp review unit operation Did you find and correct the condition Remove new micro amp re install Are you sure unit is not operating old micro back in the unit Micro properly Operate the system Did you is not the fault Review results find and correct the condition of above tests with your supervisor If necessary go to NO beginning of table amp test again MPR Code 5 Y Replace micro and operate system in order to verify repair Did you find and correct the condition Figure 10 6 Micro Diagnostic Tree Cond
233. alize the SV4 or bypass check valve must be repaired Any repair of these valves also requires further inspection of the compressor Section B if all refrigeration system components check out it will be necessary to follow the compressor inspection proced ure Section B 10 23 62 10683 B Compressor Inspection Procedure NOTE Only conduct this procedure after running Pretrip The system must be OFF during the following procedure 1 Refrigerant Recovery a Close frontseat the suction and discharge service valves b Reclaim the refrigerant by using an approved refrigerant recovery machine and reduce the compressor pressure to PSIG Refer to Section NO TAG NOTE To avoid damage to the earth s ozone layer use a refrigerant recovery system whenever removing refrigerant When working with refrigerants you must comply with all local government environmental laws U S A EPA sec tion 608 CAUTION Service mode MUST be used whenever removing refrigerant charge refrigerant leak checking evacuating Refer to Section 6 2 3 When compressor disassembly is required for compressor inspection disconnect electrical wires order to isolate power from compressor 2 Compressor Inspection a Start with the front cylinder head of the compressor b Remove the cylinder head of the compressor and observe the following cautions CAUTION Leave two cylinder head bolts loose with threads engaged the crankcase u
234. amage to the com ponents by touch This is especially true of the integrated circuits found on the truck trailer microprocessor 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 when the START RUN OFF switch SROS is in the START RUN position A buzzer will sound for five 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 SROS is in the OFF position 1 1 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 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 the refrigeration system of 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 whenever your unit requires service of the refrigeration system you contact your nearest Carrier Transicold authorized repair facility for service Battery This unit is equipped with a lead acid type battery The battery no
235. ange or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Supply Air Temperature Sensor SAT 5 Inspect Air Sensor amp connector rec Een damage moisture or corrosion in connector b EN Supply Air viaa resistance Refer to Section 9 28 for complete resistance chart 2 Supply Air Sensor Wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section 11 b Power microprocessor See Voltage should be 2 5 VDC volts at harness plug between Note 5 Page 8 2 Disconnect sensor pins from harness Check for voltage at harness plug between pins Check Remote Sensor Switch Connector a Locate and inspect 10 way connector Connector must have cap on for optional sensors and switches No corrosion or moisture inside connector If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink 62 10683 8 58
236. ange such as Start Stop Continuous Operation Defrost termination If the system is running in Start Stop Run Mode the minimum run time has expired and other conditions for shutdown are met except that the compartment temperature has not reached set point Pretrip termination 5 3 2 Pulldown or Pull up will end in the following conditions a b For Continuous Run Mode When the RAT and SAT are equally spaced above and below set point AND SAT RAT equals set point for set 2 points below 65 F 18 4 C AND both supply and return air sensors are good For START STOP Mode When the selected Control Probe Temperature is within 0 5 F 0 3 C of set point NOTE When the system leaves Pulldown COOL or Pull up HEAT modes it will enter UltraFresh 3 temperature Control Mode see Section 5 6 when the set point is between 10 4 F and 65 F 12 C to 18 4 C For set points at or below 10 4 F 12 C the unit will operate in COOL and UltraFreeze see Section 5 6 For set points above 65 F 18 4 C the unit will operate in COOL HEAT and PULSED NULL modes but will not oper ate in UltraFresh 3 5 4 HEAT MODE OPERATION In HEAT Mode the microprocessor will operate the unit controls as follows Refer to SV2 Refer to Refer to UL1 Refer to UL2 10096 HEAT mode is not used for frozen set points 5 5 COOL MODE OPERATION In COOL Mode the microprocessor will operate the unit controls as follows
237. arness plug between pins A and B between pins A and B d Check continuity of the wire from the Place START RUN OFF switch in OFF position prior to harness plug pin to the checking for continuity Must be less than 10 ohms microprocessor plug 2MP04 Check Circuits With Test Substitute Switch a Substitute known good sensor and clear alarm Start unit and run for 30 Alarm should not come on Install new switch if seconds necessary b Check to see if alarm re occurs 62 10683 8 4 ANO Steps ALARM CAUSE CORRECTIVE ACTION 2 LOW ENGINE OIL LEVEL Note This is an optional alarm which will not occur unless an oil level sensor is present and configured ON TRIGGER ON Engine oil level is sensed approx 7 or more qts 6 62 or more liters low for longer than 30 seconds UNIT CONTROL Alarm Only or may be configured to shut unit down on some models RESET CONDITION Auto reset if engine oil level is above 4 qt 3 79 liters low for more than 30 seconds or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Engine Oil Level a Check engine oil dipstick Add engine oil as needed to fill
238. ary go to Y the beginning the table and Micro is calling for high speed 1 ygs colored or FSA Is the test again there 12V at the speed control solenoid actuator solenoid or FSA operating properly NO pno NO Check wiring and connections from QC3 to speed control Repair or replace solenoid or solenoid or FSA Did you find and correct the condition actuator as needed Figure 10 8 Micro Diagnostic Tree Cond 4 Unit Will Not Run In High Speed 10 17 62 10683 START HERE Is the unit operating in defrost T NO Y Unit may be running old software Upgrade software from http www transcentral carrier com Did you find and correct the condition T NO Check functional parameter settings for air flow Does the setting show high Does the unit have IntelliSet options YES Y Is ProductShield High YES Air configured on What is the version of software in the micro Software Rev 04 02 00 Software Rev 04 03 00 and earlier and later Y Y Check to see if the ambient is inside the Min Max range Did you find and correct the Check to see if the ambient is outside the Min Max range Did you find and correct the condition condition v NO Check setpo
239. as necessary Check Model Number a Verify that the model number on the Enter the correct number in the data list Refer to Section unit data label matches the model 3 14 number shown in the micro unit data list 2 Check For Flash Code On Engine Speed Control Unit ENSCU Applies to ESC engines only a Check for flash codes on the ENSCU Refer to Electronic Speed Control Diagnostic tables Figure 10 1 thru Figure 10 4 On All Units With ESC Refer To Electronic Speed Control Diagnostic Tables a Check speed solenoid plunger on non Must move in and out freely ESC engines Fuel and speed actuator on ESC engines b Check engine speed arm amp linkage Must move freely Check Fuel System a Check for Alarm 1 Fill tank as needed b Check fuel flow Unrestricted fuel flow through system Fuel not gelled c Check fuel system prime No air in fuel system Check Engine Air Intake System a Check air filter indicator Flag must not be visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions c Check voltage to speed solenoid Must be 0 VDC Force Low Speed Operation See Note 9 a Using Functional Parameters set the Unit will run in low speed RPM must be within range High Speed Delay for at least 10 shown above for each specific model Adjust speed minutes so the unit starts in low speed linkage as needed b Check operation of Speed Relay LED LED 27 must be OFF when t
240. ass all tests Correct any problems found before proceeding 62 10683 8 90 NO Steps ALARM CAUSE CORRECTIVE ACTION P191 CHECK UL2 TRIGGER ON The pressure differential between discharge and suction pressures did not change as expected when the UL2 Rear Unloader was loaded de energized or unloaded energized UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check For SV2 Circuit Alarm a Check for alarm 97 or P192 Alarm conditions must be corrected and the alarm cleared to continue 2 Check For Check UL2 Unloader Alarm a Check for alarm 85 or P144 Alarm conditions must be corrected and the alarm cleared to continue 3 Check System Pressures a Check and compare compressor Suction amp Discharge Pressures must have the same discharge amp suction pressures with reading 5 PSIG 0 34 Bar on gauges amp on micro those shown on the microprocessor display controller Check UL2 Operation Unit Must Be Running See Note 9 Page 8 2 See Section 9 14 Checking Unloaders a Energize UL2 coil Pressures must change within 3 4
241. ate and dehydrate the compressor Refer to Section NO TAG NOTE Evacuation and dehydration is necessary only in the event that the compressor has reached atmospheric pressure during this procedure Check unit operation by running Pretrip Refer to Sec tion 3 4 9 18 COMPRESSOR DISCHARGE PRESSURE TRANSDUCER CDP CTD P N 12 00352 04 RED HIGH RANGE PRESSURE TRANSDUCER lt H o gt 5 a E 2 5V SUPPLY VOLTS PRESSURE PSIG Figure 9 27 Discharge Pressure Transducer Values 9 18 1 Testing Compressor Discharge Pressure Transducer a Verify that the wiring to the transducer is correct See wiring diagram Section 11 b Power up the transducer circuit Place unit into PC Mode Refer to Section 6 1 c Check Voltage to transducer connector Voltage reading between A negative and B positive should be 5 0 VDC d Check wire resistance between C output to micro processor and 1MP05 e Place 5 0 VDC on transducer terminal B and 5 0 VDC ontransducer terminal A Disconnect C from the microprocessor Test voltage between B and C The reading should be as shown in table below 9 18 2 Calibrating Compressor Discharge Pressure Transducer The compressor discharge pressure transducer CDP has arange of 0 to 500 PSIG 0 to 34 02 Bars With this large of a pressure range some transducers will not read exactly the same as the next To allow for variations in transd
242. ately0 020 0 51mm Reinstallclutch assembly and re measure to verify air gap Installcushionclamponcoilharnessapproximate ly 3 from coil to prevent harness from rubbing on rotor Q 5 Reattach the condenser fan and hub assembly to theclutchrotor Threadthethree bolts from behind the clutch rotor into the condenser fan hub and torque the bolts to 18 22 ft lb 2 5 to 3 0 Mkg Reinstallthe upper drive belt and adjustidler to at tain a belt tension of 70 80 ft Ib 9 7 to 11 1 Mkg 62 10683 j Remove condenser fan shroud spacer supports that may have been inserted Reinstall upper eight bolts that hold shroud to condenser frame k Plug the clutch coil connector back into the wiring harness Tie wrap harness as needed to secure 1 Re connect negative battery cable m Check unit for proper clutch operation AX WARNING Do not start unit without installing the evapo rator panels as unit damage or body harm may result n Check for proper unit operation by running Pretrip Refer to Section 3 4 9 11 THERMOSTATIC EXPANSION VALVE CAUTION Service mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating Refer to Section 6 2 3 The thermostatic expansion valve TXV is an automatic device which maintains constant superheat of the refrigerant gas leaving the evaporator regardless of suction pressure The valve functions are a automatic response of refr
243. atic dish washer detergent such as Electrosol or Cascade and let the solution stand for a few minutes and re 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 Replace evaporator back panel and run unit until de frost mode can be initiated to check for proper drain ing from drain pan 9 27 CONDENSER COIL CLEANING Remove all foreign material from the condenser coil by reversing the normal air flow is pulled in through the front and discharges over the engine Use an FDA approved cleaning agent whenever possible However compressed air or water may be used as a cleaning agent It may be necessary to use warm water mixed with any good commercial dishwasher detergent Rinse coil with fresh water if a detergent is used 9 28 MICROPROCESSOR SENSOR CHECKOUT An accurate ohmmeter must be used to check resistance values shown in Table 9 7 Due to variations and inaccuracies in ohmmeters thermometers or other test equipment a reading within 2 of the chart value would indicate a good sensor If a sensor is bad the resistance reading will usually be much higher or lower than the resistance values given in Table 9 7 At least one lead from the sensor must be disconnected from the unit electrical system before any reading is taken Not doing so will result in a false reading Two preferred methods of determining the actu
244. atures the unit operation can change to High Air 2 Ifthe High Air Minimum Temperature is set to 0 F 17 8 C and the High Air Maximum Temperature is set to OFF and the ambient air temperature falls below O F 17 8 C the unit operation can change to High Air 3 If the High Air Minimum Temperature is set to OFF and the High Air Maximum Temperature is set to 90 F 32 2 C and the ambient air temperature rises above 90 F 32 2 C the unit operation can change to High Air 4 IfboththeHigh Air Minimum and High Air Maximum Temperatures are setto OFF ProductShield Econo High air can not operate as no range is defined and it is impossible for the ambient temperature to be outside of range If the unit shuts down in Auto Start Stop during High Air it will not be in High Air when it restarts and will return to normal operation for a minimum of 15 minutes The original activation conditions must then be met in order for the unit to return to High Air c ProductShield Winter When the unit is set for Start Stop operation ProductShield Winter allows it to switch to continuous run when the ambient air temperature falls below a pre programmed temperature falling between 32 to 20 F 0 to 29 C This helps protect the unit from the possibility of fuel gelling and other cold weather issues NOTE When the unit is operating in Continuous Run the unit will not switch into ProductShield Winter When the unit is operating in Start Stop and t
245. auses slippage and excessive belt wear It is also important to keep belts and sheaves free of any foreign material which may cause the belts to slip The belt tension gauge can be used to adjust all belts The readings which we specify for Carrier Transicold units are applicable only for our belts and application as the tension is dependent on the size of the belt and distance between sheaves When using this gauge it should be placed as close as possible to the midpoint between two sheaves See Figure 9 11 The V belts must be kept in good condition with the proper tension to provide adequate air movement across the coils 9 17 62 10683 Table 9 3 Belt Tension See Figure 9 11 Water Pump Alternator Crankshaft Part No 07 00253 9 9 2 Water Pump Alternator Crankshaft V Belt The water pump alternator crankshaft V belt is driven c Check the center alignment of the engine drive alter by a sheave on the engine crankshaft Frayed cracked nator and water pump sheaves to ensure proper or worn belts must be replaced Adjustment is achieved alignment Pulley misalignment will create excess by altering the position of the front side idler alternator belt wear and shorten alternator bearing life The cen When replacing a V belt avoid excessive force when ter line of all three sheaves must be in line applying tension to the V belt to prevent damage to the water pump bearings Refer to Table 9 3 d Pivot alternator to p
246. away from set point above or below set point in the perishable range or above set point in the frozen range the unit will restart The Minimum Off Time is selected in the microprocessor Functional Parameter List Refer to Section 3 17 The default setting is 20 minutes c Engine coolant temperature drops below 34 F 1 C If the Engine Coolant Temperature drops below 34 F 1 C the unit will restart and will run until all conditions for shut down are met If Alarm 129 CHECK ENG COOLANT SENSOR is active the unit will restart if the ambient air temperature drops to 32 F 0 C after the unit has been in the OFF cycle for 60 minutes Ifthe unit restarts due to this condition the Minimum Run Time will be at least 20 minutes regardless of the setting in the Functional Parameter list d Battery voltage falls below voltage selected in the configuration list See Section 6 2 1 In some ambient conditions there are times when the unit may be off for very long periods of time To ensure that the load stays within safe temperature ranges the Maximum Off Time may be used to force the unit to restart regardless of any change in refrigerated compartment temperature Maximum Off Time is selected in the microprocessor Functional Parameter List The default setting is OFF When the unit restarts it will return to Continuous Run operation for a minimum of 15 minutes or the Minimum Run Time as selected in the Functional Parameter list whichever t
247. awn into 5 Gasket 12 Bracket the air stream be deposited onto the fan blades 6 Hose Clamp Assembly reducing the airflow and ventilation Periodically the fan 7 Inlet Hose blades must be inspected and cleaned if necessary to maintain optimum air flow and air exchange performance Figure 3 1 AutoFresh Air Exchange 62 10683 3 38 AIR OPENINGS POINT DOWN TO PREVENT RAIN WATER ENTRY Figure 3 2 AutoFresh in Closed Position Figure 3 3 AutoFresh in Open Position 3 39 62 10683 SECTION 4 ENGINE PARAGRAPH NUMBER Page 4T INTRODUCTION tee De e deer mea vege a ll 4 1 4 2 ENGINE START UP iius xe uU ae See ge AREA eR S 4 1 4 271 Engine ie ele UDCIMVERRaR DE 4 1 4 2 2 Variable Glow Time hn 4 1 4 2 3 Engine Running m mr 4 3 4 2 4 Initial Engine Operation 4 3 43 RUNNING MODES mnn 4 3 4 3 1 Start Stop Mode ssim e mec dae 4 3 4 3 2 CONTINUOUS RUN MODE 000 ccc eects 4 5 4 4 SPEED CONTROL OVERRIDES cee eee 4 6 SECTION 4 ENGINE 4 1 INTRODUCTION This section describes the engine operation and the re frigeration system running modes known as automatic Start Stop and Continuous Run 4 2 ENGINE START UP 4 2 1 Engine Cranking Whenthe starting conditions are met the start sequence will begin by ful
248. beginning at the bottom g Select the mode you wish to access and press the key See the following pages for information on these test modes Configuration Mode Component Test Mode Service Mode 6 2 1 Configuration Mode is circular meaning that once the end is reached it is repeated from the beginning d To change one of the configurations bring the Config NOTE uration to change into the MessageCenter and press To enter Configuration mode refer to Section 6 2 TO SCROLL THEN TO SAVE will show inthe MessageCenter for 10 seconds Then the selected Configuration will flash showing the current value 1 TO SCROLL THEN TO SELECT will appear in Press the UP or DOWN ARROW key to scroll through the MessageCenter the list of available selections for this Configuration b Press the UP ARROW key to scroll through the Con e Once new value is showing in the MessageCenter figuration list beginning at the top press the key to save the selection The Press the DOWN ARROW key to scroll through the MessageCenter will stop flashing The new value is Configuration list beginning at the bottom now in memory c To read through the Configuration list continue to f Press the UP ARROW key to continue to scroll press either the UP or DOWN ARROW keys The list through the Configuration list CONFIGURATION SELECTIONS DESCRIPTION UNIT MODEL FAMILY ULTRA ULTIMA Units models are grouped into families The correct VECTOR
249. blinking 1 second on amp 1 second off Verify the integrity of the download cable and connections Did you find and Did you have a communication Go to Condition 1 correct the condition failure during a download Unit does not operate When viewing down Use the configuration loaded data does all jumper to verify that the data appear on Intermittent communication download port wiring is Jan 01 1970 problem Ensure AC cord is correct and doesn t have an properly connected or PC batter open high resistance or a is fully charged Did you find short See Section XXX Did and correct the condition When viewing the DataRecorder date amp download in Reports a time have never been set specific sensor or event Set date amp time Operate Verify the correct com port is does not show in the the system in order to Verify PC power saving features selected in the PC software See data file The verify the repair are OFF I E screen saver monitor Help gt Contents gt PC Setup for Reports data filter time out hard disc time out auto additional information Did you settings may be set power down sleep mode find and correct the condition incorrectly or specific Did you find and correct the condition sensors and events may not be recorded DataRecorder is not Verify com port configured properly availability I E infrared Use the Reports Data Verify the integrity of the devices turned off PDA Filter p
250. btain maximum use of the evaporator heat transfer surface The refrigerant pressure drop caused by the expansion valve is accompanied by a drop in temperature so the low pressure low temperature fluid that flows into the evaporator tubes is colder than the air that is circulated over the evaporator tubes by the evaporator fan The evaporator tubes have aluminum fins to increase heat transfer therefore heat is removed from the air circulated over the evaporator This cold air is circulated throughout the refrigerated compartment 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 compressor through the Suction Modulation Valve CSMV The CSMV controls the compressor suction pressure thereby matching the compressor capacity to the load FUSIBLE PLUG EXTERNAL EQUALIZER o lt TXV lt ry ee BULB 1 EVAPORATOR BYPASS CHECK VALVE RECEIVER HEAT EXCHANGER LIQUID LINE VIBRASORBER
251. by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Defrost Termination Temperature Sensor 2 DTT2 a Inspect Defrost Termination No damage to sensor Temperature Sensor 2 amp connector No damage moisture or corrosion in connector b Check Defrost Termination Refer to Section 9 28 for complete resistance chart Temperature Sensor 2 resistance 10 000 Ohms 77 F 25 C See Note Note 6 2 Check Defrost Termination Temperature Sensor 2 Wiring Inspect harness amp control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins schematic Section 11 3 a Locate and inspect 10 way connector Connector must have cap on for optional sensors and switches No corrosion or moisture inside connector If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink 62 10683 8 64 NO Steps ALARM CAUSE CORRECTIVE ACTION 133 CHECK REMOTE TEMP SENSOR 1 TRIGGER ON Remote Temperature Sensor 1 circuit is configured on and has failed
252. ca 8 55 97 GCHECKSV2 CIRGUIT ek esie aad Deka Dea HE aka dari 8 55 8 8 SENSOR ALARMS 11liiw9 ed Quae ea d aaa cr eei a dar ER TEX PG MATRE 8 56 121 CHECK AMBIENT AIR SENSOR e ene 8 56 122 CHECK RETURN AIR SENSOR tantr tigreen iue nea 8 57 123 CHECK SUPPLY AIR SENSOR oi 8 58 125 CHECK COMP DISCH SENSOR e m 8 59 126 CHECK FUEL SENSOR CIRCUIT eens 8 60 129 CHECK ENG COOLANT SENSOR 0 cece nee 8 61 130 CHECK ENGINE RPM SENSOR 00 cece eens 8 62 132 CHECK DEFROST TERM 2 SENSOR cece eens 8 64 133 CHECK REMOTE TEMP SENSOR 1 00 n 8 65 134 CHECK REMOTE TEMP SENSOR 2 nn 8 66 135 CHECK REMOTE TEMP SENSOR 3 e 8 67 62 10683 vi TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page ALARM TROUBLESHOOTING Cont 8 9 PRETRIP ALARMS 00sec eee eee ee Henn hh n enn nnn 8 68 P141 PRETRIP STOPPED BY USER Lon ELE e nace predecir CUR pires 8 68 P143 CHECK CLUTCH CIRCUIT s e m eme 8 68 P144 CHECK ULT CIRCUIT ee eee per be Ve LE ERR I debe wre ELE LE EE eid 8 69 P145 CHECK SPEED SOE CIRGUIT kr RUE TA RR RR M re TR PAG we 8 70 P148 CHECK SV1 CIRCUIT I m n 8 71 P150 CHECK SVA CIRCUIT e RD ER TA a ee aer es 8 72 P151 CHECK GLOW PLUG CIRCUIT m e 8 73 P152 CHECK FUEL SOLENOID
253. ce a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check For Low Coolant Level a Check engine coolant level in the Add coolant as needed to the coolant reservoir and to the coolant bottle fill tube on the radiator b Check coolant hoses for leaks or Repair all leaks and breaks as necessary breaks Add coolant as needed to the coolant reservoir and to the fill tube on the radiator a b Check harness wiring to plug Verify wires are in correct plug orifice c Check engine coolant level switch Place unit in Component Test mode Run Relay On or in operation Manual Start mode see Note Note 4 DO NOT START UNIT d Check for voltage at harness plug Voltage should be 12 volts at harness plug between pins A between pins A and B and B e Check continuity of the wire from the Place START RUN OFF switch in OFF position prior to harness plug pin to the checking for continuity Must be less than 10 ohms microprocessor plug 2MP15 Check Circuits With Test Substitute Switch a Substitute known good sensor and clear alarm Start unit and run for 30 seconds b Check to see if alarm re occurs Alarm should not come on Install new sensor Check Engine Coolant Level Switch Inspect engine coolant level switch amp No physical damage to switch connect
254. ch is Dexcool approved and has 5 150 5 years 150 000 miles on the label CAUTION When changing oil filters the new filters should be primed partially filled with clean oil if possible If the filters are not primed the engine may operate for a period with no oil supplied to the bearings CAUTION Service Mode MUST be used whenever moving refrigerant charge refrigerant leak checking or evacuating 1 3 CAUTION The display and MessageCenter may be have differently during the software loading process depending on the version of soft ware currently in the controller DO NOT IN TERRUPT THE SOFTWARE INSTALLATION PROCESS ONCE IT HAS STARTED CAUTION It is important that communications be tween the Micro and the computer are not disturbed during the software loading pro cess If using a laptop computer turn all en ergy saving features off Turn off any screen saver or any hard drive time out settings CAUTION Be certain thatthe clock you are using is ac curate and is showing the correct time Also some customers are located in differ ent time zones from where the repair is be ing made If you know what time zone they use enter that time If you don t then enter the current time where you are located CAUTION Do not over torque display screws Torque all screws to 11in Ibs 1 2 Nm CAUTION Unit uses R404A and POE The use of in ert gas brazing proce
255. charge Pressure f Install new CDP and reconnect wiring Transducer Evacuate and dehydrate the compressor Refer to Section NO TAG NOTE WARNING a Evacuation and dehydration is necessary only in the event that the compressor has reached atmospheric pressure during this procedure Q The Compressor Discharge Pressure Transducer does not have a Schrader valve in the connecting fitting Any discharge pressure remaining in the compressor will h Check unit operation by running Pretrip Refer to Sec be released when removing the CDP tion 3 4 Table 9 5 Compressor Suction Pressure Transducer Voltage PSIG Bare Volage vollage ss ws eet _ Co 18 re oa seat 39 s 49 395m 9 18 mem 9 a mna ew 3 1 wes 45 mr is me 3 62 10683 9 36 9 19 COMPRESSOR SUCTION PRESSURE TRANSDUCER CSP CTD P N 12 00352 03 BLUE lt a gt 2 a E 2 5V SUPPLY VOLTS PRESSURE PSIG Figure 9 28 Suction Pressure Transducer Values 9 19 1 Testing Compressor Suction Pressure Transducer Verify that the wiring the transducer is correct See wiring diagram Section 11 b Power up the transducer circuit Place unit into PC mode Refer to Section 6 1 or pl
256. ck by pass check valve Check SV2 Check king valve Check compressor 9 12 9 21 1 9 15 9 21 1 10 3 4Unit Operates Long Or Continuously In Cooling Hot Load Pre cool product Defective box insulation or air leak Correct Refrigeration system Refrigerated Compartment 62 10683 10 4 INDICATION ACTION TROUBLE POSSIBLE CAUSES REFERENCE SECTION 10 3 5 Unit Will Not Terminate Cooling Temperature sensor malfunction Check set point Check whether Microprocessor improperly set microprocessor is set at C or Unit fails to stop cooling 10 3 6Unit Will Not Heat Or Has Insufficient Heating Refrigeration EI does ROC Woven Unit fais to stop heating Temperature sensor malfunction 10 3 8Defrost Cycle Malfunction Defrost air switch DAS out of calibration 9 25 2 DTT2 is above 40 F 4 4 C Cool Box Down Will not initiate defrost Defrost air switch DAS defective 9 24 amp 9 25 2 automatically BODIE Sd Initiates but does not defrost OO a Frequent defrost Does not terminate or Low refrigerant charge NO TAG cycles on defrost Defrost air switch DAS out of adjustment 9 24 amp 9 25 2 pU Load Allow time to pull down Compartment or insufficient refrigerated compartment insula Correct tion or air leak 10 5 62 10683 INDICATION ACTION TROUBLE POSSIBLE CAUSES REFERENCE SECTION 10 3 9Abnormal Pressure a Cooling Vbetbrkenorone o High discharge pres
257. ck evap fan clutch Must be engaged Check System Pressures a Install Manifold Test Set and check and Suction pressure must be above 3 PSIG 0 2 Bar compare compressor discharge amp Suction amp Discharge Pressures must have the same b Check evaporator section return air Good Air Flow bulkhead air chute cleanliness of Return air not restricted evap coil Air chute in good condition No damage to blower wheel Evap coil clean Check Refrigerant Charge See Section 9 11 4 Checking Refrigerant Charge 5 un a Check for undercharged system Level must be above lower sight glass 6 Check Expansion Valve TXV a Visually inspect valve Bulb must be clamped tightly on the suction line and insulated b Check MOP of valve Refer to Section 2 11 c Check superheat of valve Refer to Section 2 11 8 101 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION P205 CHK DEFROST TERM 2 SENSOR TRIGGER ON Defrost Termination Temperature Sensor 2 is not within the maximum range of 53 F to 158 F 47 C to 70 C UNIT CONTROL Alarm and defrost cycle will terminate as described in section 5 11 RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see i
258. cle time is 5 20 minutes automatically Suction pressure should rise gradually during cycle 8 system pressures a Check and compare compressor Suction amp Discharge Pressures must have the same discharge amp suction pressures with reading 5 PSIG 0 34 Bar on gauges amp on micro those shown on the microprocessor display controller Additional steps on the next page 62 10683 8 94 NO Steps ALARM CAUSE CORRECTIVE ACTION P195 LOW SUCTION PRESSURE Continued NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with he sesh below as necessary 9 Manually Test Refrigeration System See Note 9 Page 8 2 a Run pol Check Must pass all tests bs MEE 7 any problems found before proceeding b See Refrigeration Troubleshooting Section 10 3 9 Low Suction Pressure 10 Check Expansion Valve TXV es pc inspect valve Bulb must be clamped tightly on the suction line and pu E deum b Check MOP of valve Refer to Section 2 11 c Verify that correct TXV is in unit Must have correct valve d Check superheat of valve Refer to Section 2 11 11 Check For Damage To The Suction Line pe Visually inspect suction line for any No damage to line kinks restrictions or other damage For Restricted Compressor Suction Scr
259. closed CHARGE MODE HOLD TO EXIT is displayed in the MessageCenter The key must be pressed and held for six seconds to exit Service mode or the START RUN OFF switch can be be placed in the OFF position and then back in the START RUN position If the unit shifts to Charge Mode and CHARGE MODE HOLD TO EXIT is displayed inthe MessageCenter while you are still recovering refrigerant leak testing or evacuating the refrigeration system DO NOT CONTINUE Exit Service Mode and then re enter making sure that RECOVER LEAK CHK EVAC is displayed in the MessageCenter before performing any of these services To exit Service Mode at any time press and hold the key for 5 seconds EXITING SERVICE MODE will then appear in the MessageCenter When exiting Service Mode the microprocessor closes the CSMV to 0 open and de energizes UL1 62 10683 6 3 PC SUPPORT SOFTWARE 6 3 1 ReeferManager And Reports a ReeferManager enables the user to do the following e Monitor in real time via the download port an RS 232 connection the current status of the microprocessor inputs outputs refrigeration electrical engine and temperature sensors and alarms Record sensor data to a file for diagnostic purposes Download microprocessor and DataRecorder data via serial port communications Display edit and send unit model number serial number and trailer ID to the microprocessor Display edit and send functional
260. control have no RPM sensor speed or fuel solenoids Engine speed is controlled by three components the engine speed control unit ENSCU the fuel and speed actuator FSA and the engine speed sensor ENSSN The ENSCU is mounted on the roadside frame behind the upper door It provides the RPM signal to the microprocessor The unit has an alarm LED incorporated within it which is used to diagnose failures within the ESC system 62 10683 9 16 Figure 9 8 Frame Mounted Engine Speed Control Unit ENSCU The FSA combines the fuel shutoff solenoid and speed control solenoid into one component Engine speed is controlled by varying rod position The ENSSN provides the RPM signal to the ENSCU for speed control It is located on the front of the engine in the gear case cover 9 8 8 Engine Air Filter a Engine Air Filter Inspection The dry type air filter should be inspected regularly for leaks A damaged air filter or hose can seriously affect the performance and life of the engine The air filter is designed to effectively remove contaminants from the air stream entering the engine An excessive accumulation of these contaminants in the air filter will impair its operation therefore a service schedule should be set up and followed The air cleaner filter element requires replacement when dirty 1 Check all connections for mechanical tightness Be sure filter outlet pipe is not fractured 2 Incase of leakage and if adjust
261. crankcase pressure 10 2 ALTERNATOR 12 Volt DC Check Check Limited charging system operating time Battery condition Alternator belt loose broken Loose dirty corroded terminals or broken leads Check Repair Alternator fails to charge Excessively worn open or defective brushes Open blocking diode Regulator faulty Check Open isolation diode Check Open rotor field coil Replace Alternator belt loose Loose dirty corroded terminals or broken leads Check Repair Excessive charging rate Regulator leads loose dirty corroded terminals or Clean Repair as evidenced by battery wires broken requiring too frequent refilling or amp reading shows constant Defective regulator Check high amp charge 10 3 62 10683 INDICATION ACTION TROUBLE POSSIBLE CAUSES REFERENCE SECTION 10 2 ALTERNATOR 12 Volt DC cont Defective or badly worn V belt olsy alternator Misaligned belt or pulley 99 pulley 10 3 REFRIGERATION TEMPERATURE CONTROL 10 3 1Unit Will Not Cool Compressor drive defective 9 12 Compressor malfunction Refrigeration system Check system for non condensables NO TAG 10 3 2Unit Runs But Has Insufficient Cooling Compressor valves defective Unloader malfunction 9 14 Abnormal pressure 10 3 9 Refrigeration system Clutch Failure 9 10 5 Engine does not Speed control linkage 9 8 6 develop full rpm Engine malfunction 10 1 10 3 3System Will Not Pump Down Check SV4 Che
262. cream ICE 3 35 CREAM is selected With each selection the micropro cessor automatically re programs the settings to pro vide the best temperature control fuel economy and performance for that particular product NOTE IntelliSet 31 is pre programmed as IntelliSleep which allows Sleep Mode See Section 3 8 to be entered by simply changing to that IntelliSet The ONLY way to exit from IntelliSleep is to se lect a different IntelliSet NOTE The above settings are examples of possible settings Factory IntelliSets are available from the Information Website through your author ized Truck Trailer dealer 62 10683 a Changing IntelliSets HEAT COOL DEFROST START STOP CONTINUOUS 20 494 F SETPOINT BOX TEMPERATURE PRESS 1 TO VIEW INTELLISETS a wi MANUAL ALARM LIST TART STOP 1 SELECT DEFROST dp 1 PRESS Key to display current IntelliSet Enable IntelliSet at Key must configured ON See Section 6 2 1 If the Key is not enabled press the Select Key until the MessageCenter shows PRESS 1 TO VIEW INTELLISETS 2 Press the UP or DOWN ARROW key to move through the IntelliSet List The current IntelliSet will have either ACTIVE or MODIFIED to the right of the name 3 To use a different IntelliSet or to change the current IntelliSet from MODIFIED to ACTIVE bring the IntelliSet you wish to use into the MessageCenter and press Key 62 10683 3 36
263. croprocessor controller Section 9 Service This section describes the service procedures for the unit Section 10 Unit Troubleshooting This section provides information on the probable causes for unit troubleshooting Section 11 Wiring This section contains Electrical Schematics and Plug Information the model covered in this book 62 10683 TABLE OF CONTENTS PARAGRAPH NUMBER Page e es Seared eee Stee ee EE 1 1 Tt SAFETY PRECAUTIONS Zy tenni exten Wide eee de eal e RE T OEC eg n EN 1 1 1 2 SPECIFIC WARNING AND CAUTION STATEMENTS 1 1 1 3 SAFETY DECALS dda Ea SEP MEE got 1 5 UNIT DESCRIPTION err te ee itt Rem tmt ER rex nah 2 1 2 1 INTRODUCTION ez ue nutu rere UR IDE ir heri cates ERE UD a E Led e 2 1 2 2 GENERAL DESGHRIBP TION e epe Rp UR M POSU BURKE ME pecus OA 2 2 2 3 CONDENSING SECTION ee rm 2 10 2 94 Gondenser Goil 2 E sce pata be ae EI E ERG Die ee eee dead Seen eee df 2 10 2 9 2 Engines zen Lab Poe oL Eee Lb ELO RE 2 10 2 3 3 Alternator Regulator ccc ees hn 2 11 2 9 4 COITIDIOSSOF 1c week 2 12 2 8 5 Compressor Unloaders e nnn 2 12 2 3 6 Filter Diera ei Dune Dto 2 13 2 9 4
264. ct valve plates unloaders reed No broken or missing parts valves amp gaskets 62 10683 8 96 E 5 Check For Refrigerant Overcharge NO Steps ALARM CAUSE CORRECTIVE ACTION P198 LOW DISCHARGE PRESSURE TRIGGER ON In the Heat Pretrip mode the Compressor Discharge Pressure did not rise to normal The minimum Normal discharge pressure for systems operating in the Heat Pretrip Mode can be estimated by taking the temperature of the air entering the condenser coil Ambient Air Temperature AAT and looking at a pressure temperature chart see table Table 9 9 for the corresponding pressure then adding 80 psig 5 5bars to it UNIT CONTROL Pretrip will abort and PRETRIP FAILED IN TEST 4 will be displayed in MessageCenter RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the seps below as necessary 1 Check For Ambient Sensor Alarm Check for alarm s 121 and P158 Alarm conditions must be corrected and the alarm cleared to continue b Check Ambient Sensor calibration Must be within 10 F 5 5 C Must be within 10 F 5 5 C of actual temperature actual Must be within 10 F 5 5
265. ction 11 Check Fuel System a Check fuel system prime No air in fuel system b Check fuel flow Unrestricted fuel flow through system c Check fuel system check valve from Check valve must hold fuel and not leak back filter to injection pump Check Engine Air Intake System a Check air filter indicator Flag must not be visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Check For Correct Engine Oil a Check for correct oil viscosity weight Refer to Section 2 7 for conditions Must be correct for ambient conditions Check Engine Exhaust System a Inspect the exhaust system Must be clear and unobstructed Check Engine a Check engine compression Compression must be above 400 PSIG 27 22 Bar 8 23 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 34 ENGINE FAILED TO STOP TRIGGER ON Engine is turning more than 500 RPM or the micro input shows that the engine is turning more than 500 RPM for 20 seconds after unit was turned off shut down on an alarm or cycled off in a Start Stop Off Cycle or Oil Pressure Switch contacts are closed longer than 20 seconds after unit was turned off shut down on an alarm or cycled off in a Start Stop Off Cycle UNIT CONTROL Alarm Only RESET CONDITION Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has bee
266. ctions TO RESET followed by the number of hours or cycles that will be used for the next service interval Press the key to reset the hourmeter to the new value shown The name of the hourmeter and RESET will be displayed indicating that the reset was successful Repeat steps 5 7 to Reset additional PM hourmeters 62 10683 6 20 SETTING PM PREVENTATIVE MAINTENANCE HOURMETERS Continued NOTE The hourmeters must first be configured ON Refer to Section 6 2 1 PM Preventative Maintenance hourmeters are provided to track unit operation and to notify the user when periodic preventative maintenance is due Within the Advance Microprocessor there are seven PM hourmeters available for use Engine Switch On Five programmable hourmeters The programmable PM hourmeters PM1 5 can be configured to count any of the following Engine Hours Switch On Hours Clutch Cycles Start Cycles High Speed Hours The PM hourmeters are activated and the reset interval is selected from the Configuration List To turn on the Engine PM hourmeter select the desired maintenance interval in hours and enter as the DIESEL RESET VALUE in the Configuration list Selecting OFF will completely turn the Engine PM hourmeter off The reset value selected here will be the value used when the PM hourmeter is reset from the Functional Parameter List To turn on the Switch On PM hourmeter select the desi
267. d RPM are Between 2050 to 2350 for Ultima XTC X2 2500A R or Between 1550 to 1850 for Ultra XTC X2 2100A R for 60 seconds or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Model Number a Verify that the model number on the Enter the correct number in the data list Refer to Section unit data label matches the model 3 14 number shown in the micro unit data list EE Check For Proper Voltage To The Engine Speed Control Unit ENSCU Pin 22 Based On The Model Check For Proper Voltage With Unit Running ESC Engine Only Ultima XTC X2 2500A Verify 12 VDC at terminal 16 of the ENSCU Verify 12 VDC at terminal 22 of the ENSCU b Ultra XTC and X2 2100A Verify 12 VDC at terminal 16 of the ENSCU Verify 0 VDC at terminal 22 of the ENSCU c Check circuit from ENSCU terminal 16 Must be 12 VDC to micro connection MPQC3 Check Speed Solenoid amp Linkage On Non ESC Engines a Check speed solenoid plunger on non Must move in and out freely ESC engines Fuel and speed actuator on ESC engines b Check engine speed arm amp linkage Must move freely non ESC engines Check Speed Solenoid
268. d pins schematic Section 11 b Check for shorted circuit in harness START RUN OFF switch in START RUN position Manual and continuity through the harness Start mode See Note Note 4 Battery voltage reading 12 13 VDC between wires in plug 9 Perform Check I Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding Lae Refrigeration Trouble Shooting Discharge Pressure must be in normal range for the Section 10 3 current ambient and box temperature conditions 62 10683 8 10 NO Steps ALARM CAUSE CORRECTIVE ACTION 15 BATTERY VOLTAGE TOO HIGH TRIGGER ON Voltage at the microprocessor is greater than 17 VDC UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset after 15 minutes when the voltage at the microprocessor is between 11 14 VDC or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Battery Voltage e Test voltage at battery with unit off Must be between12 16 Must be 12 16 VDC b Test voltage at battery with unit Must be between12 16 DIST E running 2 Check Alternator Voltage
269. denser Coil a Inspect condenser radiator fins Fins must be straight 9096 or more of the coil surface must be undamaged No dead air spaces Condenser Radiator coil must be clean b Check airflow with unit running Even airflow through the entire coil No dead spots 5 Check System Pressures a Install Manifold Test Set and check and Suction amp Discharge Pressures must have the same compare compressor discharge amp reading on gauges amp on micro display Ku ss udi NRE M Pressures must be in the normal range for ambient amp box temperature conditions Check For Refrigerant Overcharge a Check refrigerant level in the receiver Level must be between upper amp lower sight glasses tank 7 Check HPS Switch a Inspect switch amp connector pins amp physical damage to switch terminals No damaged or corroded pins in plug b Check switch operation Contacts open when compressor discharge pressure is Refer to Section 2 11 for pressure above cut out point 10 PSIG 0 68 Bar settings Contacts closed when compressor discharge pressure is below cut in point 10 PSIG 0 68 Bar Additional steps on the next page 8 9 62 10683 PNG tone ALARM CAUSE CORRECTIVE ACTION HIGH DISCHARGE PRESSURE Continued 8 HPS Switch Harness Inspect harness amp control box physical damage to harness connector pins amp terminals See wiring No damaged or corrode
270. der coil energizes and the suction and discharge pressures do not change the un loader assembly must be checked o c 9 14 2 Replacing Unloader Valve Internal Parts See Figure 9 22 a Pump down the unit Refer to Section NO TAG Frontseat both service valves to isolate the compres sor Remove coil retaining cap if equipped and coil Remove enclosing tube collar item 2 Figure 9 22 using installation removal tool supplied with repair kit item 3 d Check plunger for restriction due to a Corroded or worn parts 5 Foreign material lodged in valve Bent or dented enclosing tube e Install new parts Do not over tighten enclosing tube assembly Torque to a value of 8 ft pounds 1 1 Mkg Remove supplied installation removal tool Install coil and voltage plate Evacuate and dehydrate the compressor Refer to Section NO TAG Start unit and check unloader operation Refer to Section 9 14 1 i Check unit operation by running Pretrip Refer to Sec tion 3 4 2 62 10683 9 14 3 Unloader Coil Replacement NOTE The coil may be removed without pumping the unit down a Disconnect leads Remove retainer if equipped Lift off coil See Figure 9 22 b Check unloader coil resistance with an ohm meter Correct resistance should be between 7 5 and 10 5 ohms Verify coil type voltage and frequency of old and new coil This information appears on the coil housing
271. der difficult conditions while allowing the unit to operate more efficiently during less demanding conditions When the Air Flow parameter in the Functional Parameter list is set for NORMAL ProductShield High Air allows the unit to run as required either High Speed or Low Speed depending on e How far the compartment temperature is away from set point AND e Speed Override Conditions Refer to Section 4 4 When the ambient temperature falls outside the pre programmed temperature range ProductShield High Air mode will be enabled and the engine will go to high speed to provide high air flow within the refrigerated compartment The operator can also optionally pre program a maximum evaporator coil temperature differential Delta T between the return air 1RAT and supply air 1SAT sensors as an additional criteria for switching to ProductShield High Air Whenthe Delta T setting is used the unit must bring the Delta T above this pre programmed setting before going to High Air Mode The Delta T setting is used to prevent ProductShield High Air from operating when the heat load on the refrigeration unit is low NOTE In ProductShield High Air the Delta T must be higher than the value selected in order to enter the mode ProductShield ECONO HIGH AIR EXAMPLES 1 Ifthe High Air Minimum Temperature is set to O F 17 8 C and the High Air Maximum Temperature is set to 90 F 32 2 C and the ambient air temperature falls outside these temper
272. dforBackighingandindicatorLEDs Ten Display ground TP10 TX the serial communications from the control to the display RX the serial communications from the display to the control VOLTAGE TESTS g Se aren 8 fo 62 10683 11 4 SPK3 L11 NOTES OUTPUT UNIT SHOWN IN OFF POSITION POWER IRE IDENTIFICATION SYSTEM 15 OLOR WHITE DC CONTROL CIRCUITS 5 LHS BLACK GROUNDS 5 EN ADDRESS SYSTEM EXAMPLE HC9 2MP25 DO TX DICATES A WIRE BETWEEN PLUG HC A IN 8 AND MICROPROCESSOR PLUG2 IN 25 spi B SP2 K10 SP 1 F7 SA MPQC1 V3 NOT SUPPLIED WITH ULTIMA XTC D ULTRA XTC r T0 8 3MP27 F1 7 5 gt LOCATED IN ENGINE HARNESS 55886 197 WWW 5 SYSTEM POWER GPR SSR F DISPLAY KEYPAD TO FLSC 5 RE SP POS RE DS A k3 k2 PCMCIA A reer ENCLS
273. ds a Schedule unit into service facility for Must be done soon maintenance 2 Perform Maintenance BN Perform appropriate engine amp unit Follow instructions on proper maintenance form maintenance EN Maintenance Hour Meter 1 8 Check that Maintenance Hour Meter Reset Interval in Configuration list as required 1 interval is set for your requirements b Reset Maintenance Hour Meter 1 for Hour Meter is reset in the Functional Parameter list the next service interval Follow maintenance interval recommendations in Section 9 1 See Note 1 8 2 Clear the inactive alarms All alarms cleared 227 SERVICE SOON PM 2 DUE TRIGGER ON The Maintenance Hour Meter 2 time has expired UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via keypad Check Unit Maintenance Records LJ Schedule unit into service facility for Must be done soon maintenance Maintenance BN Perform appropriate engine amp unit Follow instructions on proper maintenance form maintenance EN Maintenance Hour Meter 2 S18 Check that Maintenance Hour Meter Reset Interval in Configuration list as required 2 interval is set for your requirements b Reset Maintenance Hour Meter 2 for Hour Meter is reset in the Functional Parameter list the next service interval Follow maintenance interval recommendations in Section 9 1 See Note 1 8 2
274. ds of time requires a temperature range of 4 to 149 F 20 to 65 C When PC cards are exposed to temperatures outside of this range for several days data contained on the card may be damaged PC cards should never be Dropped Bent Twisted Squeezed Submersed in any liquid Exposed to electrostatic discharge Exposed to intense ultraviolet light Exposed to nearby magnetic or electromagnetic fields Low X Ray exposure i e that experienced while passing through a security screen should not harm the card data High X Ray exposure i e that experienced in a medical or dental environment may damage the card data PC cards should not be kept in a shirt pocket contained a pocket screwdriver with a magnetic end PC cards should be kept in a hard plastic jewel case when not in use Replacement cases P N 58 50109 00 are available from Carrier Transicold s Performance Parts Group 62 10683 2 22 2 6 OPTIONS 2 6 1 Light Bar The Light Bar is an external set of indicator lights that can be seen in the mirror from the cab of a truck or on the front of a rail car They are controlled by the microprocessor a Eight Light Light Bar These lights correspond to the microprocessor LEDs HEAT COOL DEFROST START STOP and ALARM The ENGINE AUTO START light is only illuminated when the unit is operating in Start Stop The OUT OF RANGE light is illuminated when the Out of Range Alarm is active b Two Light Light Bar T
275. dures is mandatory for all Carrier Transicold refrigeration units otherwise compressor failure will occur For more information Refer to Technical Procedure 98 50553 00 Inert Gas Brazing CAUTION Do not get anti seize oil compound onto clutch contact surfaces Thoroughly clean off oil compound with contact or brake cleaner if this occurs 62 10683 CAUTION Only a refrigerant drum containing R404a should be connected to units covered by this manual in order to pressurize the sys tem Any other gas or vapor will contami nate the system which will require addi tional purging and evacuation of the high side discharge of the system CAUTION Do not vapor charge R404A systems Only liquid charging through the receiver outlet King valve is acceptable CAUTION Do not over tighten or damage the SV2 or SV4 enclosing tube assembly Torque to 17 ft pounds 2 4 Mkg Also make sure all parts are placed on the enclosing tube in proper sequence to avoid premature coil burnout 62 10683 1 4 CAUTION When adding oil to the compressor ex treme care must be taken to ensure the hose is immersed in the oil at all times Otherwise airand moisture will be drawn into the com pressor CAUTION When removing the compressor cylinder head leave two cylinder head bolts loose with threads engaged in the crankcase until cylinder head is completely loosened to prevent any residual crankcase pressure 1
276. e Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check engine RPM sensor wiring non ESC engines only a Inspect harness amp control box See Note NO TAG connector pins amp terminals See No physical damage to harness wiring schematic Section 11 No damaged or corroded pins b Check RPM wiring Place unit in Manual Start mode see Note Note 4 OR Use Component Test Mode to energize the Run Relay DO NOT START UNIT Refer to Section 6 2 2 c Check voltage reading between plug With lead on A and lead on C reading should be 5 VDC terminals A amp B 2 volts If it is not check for grounded positive circuit at CSP and CDP transducers Check circuits with test sensor a Substitute known good sensor and Must be within 20 RPM or reading on tachometer check Unit Data List reading Refer to Section 3 14 8 63 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 132 CHECK DEFROST TERM 2 SENSOR TRIGGER ON Defrost Termination Temperature Sensor 2 circuit has failed open or shorted If shorted the data list will display 158 F 70 C If the circuit is open the data list will show the temperature as 52 6 F 47 C UNIT CONTROL Use RAT or SAT for defrost initiation criteria See Defrost mode Section 5 11 RESET CONDITION Auto Reset when Defrost Termination Temperature Sensor 2 is in range or Alarm may be manually reset via keypad or
277. e peat as required to ensure proper oil level High Pressure Switch Connection Suction Service Valve Oil Fill Plug Bottom Plate Oil Drain Plug Oil Level Sight Glass Oil Pump Unloader Solenoid Discharge Thermistor Connection Discharge Service Valve Figure 9 21 Compressor 9 14 COMPRESSOR UNLOADER VALVE See Figure 9 22 The compressor unloaders located on the compressor cylinder heads are controlled by the Advance Microprocessor Refer to Section 2 3 5 9 14 1 Unloader Checkout Procedure a Connect manifold gauges to the compressor suction and discharge service valves and start unit in cooling with the refrigerated compartment temperature at least 5 F 2 8 C above set point and the compressor will be fully loaded both unloader coils are de ener gized Note suction pressure Unplug both unloader coils Using cable included in the test kit CTD P N 07 50006 00 energize front unloader Note dis charge and suction pressures A rise of approximate ly 3 psig 0 2 bar will be noted on the suction pressure gauge Discharge pressure should drop approxi mately 5 to 15 psig 0 4 to 1 0 bar d Disconnect UL1 and note pressures Suction pres sure should drop and discharge pressure should rise by same amount as in step c above e Repeat steps c amp d for UL2 rear unloader At the end of the test plug both unloaders back in NOTE If either unloa
278. e 98 50553 00 Inert Gas Brazing CAUTION 9 1 WARNING UNITS EQUIPPED WITH STAR TRAK TWO WAY COMMUNICATION CAPABILITIES MAY HAVE THE ABILITY TO BE STARTED OR TURNED OFF REMOTELY REGARDLESS OF THE SETTING OF THE START RUN OFF SWITCH The unit is controlled locally and there can be no two way communication when the mode switch on the Remote Monitoring control box is in MAINTENANCE MODE Therefore when performing any work on the unit place the mode switch in MAINTE NANCE MODE After the unit is serviced re turn the mode switch to REMOTE ON Re fer to Section 3 20 3 for more information on two way communication NOTE To avoid damage to the earth s ozone layer use arefrigerant recovery system whenever remov ing refrigerant When working with refrigerants you must comply with all local government envi ronmental laws U S A EPA section 608 MAINTENANCE SCHEDULE For the most reliable operation and for maximum life your unit requires regular maintenance This includes oil and filter changes fuel and air filter replacement coolant replacement and pretrip inspections Maintenance should be performed according to the schedule on the following page When changing oil filters the new filters should be primed partially filled with clean oil if possible If the filters are not primed the engine may operate for a period with no oil supplied to the bearings 62 10683 Table 9 1 Maintenance Schedule ACTI
279. e PC cards on one particular micro take those same suspect PC cards and try them on another micro If the cards function properly on the second micro it proves the first micro is not reading the PC cards properly Is the micro at fault The card Write Protect Switch is ON Unlock PC Card by sliding Write Protect switch to the OFF position amp re insert the card Operate the System in order to verify the repair Download card has no more empty memory space Use ReeferManager to extract downloaded data amp then erase card Operate the system in order to verify the repair See Section 7 1 fora list of MessageCenter error messages Find your specific error message and follow the directions in the description column Repair as needed Operate the system in order to verify the repair PC Card is not seated properly Remove card from slot wait 10 seconds amp re insert card Did you find and correct the condition YES PC card slot may be NO Micro is the fault Replace micro and operate system in order to verify repair Did you find and correct the condition Y Micro is not the fault Remove new micro amp re install old micro i defective Turn power off and verify status light is not blinking Check for bent pins in the card slot amp straigh
280. e actual RPM with those Both readings within 50 RPM shown on display Additional steps on the next page 8 85 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION P175 CHECK HIGH SPEED RPM Continued 5 Check engine air intake system 5 Check air filter indicator must not be must not Flag must not be visible visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions 6 Check engine exhaust system E a Inspect the exhaust system Must be clear and unobstructed 62 10683 8 86 NO Steps ALARM CAUSE CORRECTIVE ACTION P178 CHECK UL1 TRIGGER ON The pressure differential between suction and discharge pressures did not change as expected when the UL1 Front Unloader was loaded de energized or unloaded energized UNIT CONTROL If alarm A191 is already on then Pretrip will be aborted amp display will read PRETRIP FAILED IN TEST 6 RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Wiring To DPT amp SPT a Verify that correct wires are connected Plugs to transducers are the
281. e appropriate modes to see if any active alarm occurs Continue with us dus below as necessary 1 Check for bad F4 or F6 fuse alarm LU Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue Lo Rear Unloader UL2 E a Check resistance of UL2 Refer to Section 2 13 b Check amp draw of UL2 Use Component Test mode Section 6 2 2 to test Refer to Section 2 13 for amp values View current draw in the Unit Data list Refer to Section 3 14 Rear Unloader UL2 And Circuit EN Inspect Rear Unloader UL2 and damage or corrosion wiring Connector fits together tightly no moisture inside b Check operation of Rear Unloader START RUN OFF switch in START RUN Manual Start UL2 FET 22 Operation See Note Note 4 LED must be ON c Check voltage to UL2 Must be 11 VDC or higher across the 2 wires 4 Rear Unloader UL2 Circuit Wiring is Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section ib 62 10683 8 82 ANO Steps ALARM CAUSE CORRECTIVE ACTION P165 CANNOT PUMP DOWN TRIGGER ON With SV1 SV2 amp SV4 in the closed position the compressor is not able to pull the low side of the refrigerant system down to 10 PSIG 0 68 Bar UNIT CONTROL Pretrip will abort and PRETRIP FAILED IN TEST 11 12 or 13 will be displayed in MessageCenter RESET
282. e compartment temperature is within 0 5 F 0 3 C of setpoint for set points in the Perishable range or is less than 0 5 F 40 3 C above set point for set points in the Frozen range 2 Theunit has run for the Minimum Run Time The Minimum Run Time is selected in the microproces sor Functional Parameter List Refer to Section 3 16 The default setting is 4 minutes The purpose ofthis is to force the unit to run long enough to completely circulate the air inside the compartment and to ensure that the product temperature is at set point 3 Theengine coolant temperature is above 122 F 50 C The engine coolant temperature is above 122 F 50 C If the unit can not cycle off it will operate as if in Continuous Run mode The engine coolant temperature will override the minimum off time and out of range condition to force engine restarting when the engine coolant temperature drops below 34 F 1 C If the engine coolant sensor alarm is active and the ambient temperature is above 32 F 0 C the engine coolant temperature will be ignored for the OFF cycle If the engine coolant sensor alarm is active and the ambient temperature is below 32 F 0 C or the ambient temperature sensor alarm is also active the unit will run for a minimum of 20 minutes before allowing an OFF cycle 62 10683 4 The battery voltage is high enough Provisions are made to sense when the battery voltage is correct A good battery is defined as
283. e during Component Test Mode are the ALARM and SELECT keys The alarm list is available for viewing any active or inactive alarms The SELECT key will only allow access to the Amp Current Draw for the item in the Data List When Component Test mode is selected the Main Display will show OFF The following components may be tested during the Component Test mode Component Menu List FETLED Board LED Cool Light Heat Light Defrost Light COOL LIGHT OFF IN X MINS Ee HEAT LIGHT OFF IN X MINS DEFROST LIGHT OFF IN X MINS Auto Restart Light ARL LIGHT OFF IN X MINS Out Of Range Light ORL LIGHT OFF IN X MINS Fault Light FAULT LIGHT OFF IN X MINS Unloader 1 front Unloader 2 rear UL1 OFF IN X MINS UL2 OFF IN X MINS SV1 SV1 OFF IN X MINS SV2 SV2 OFF IN X MINS duc Rey QHROFFINXMNS Speed Relay SROFFINXMNS RunRehy _ RROFFINXMNS 1 Glow Plug Relay Glow Plug Relay GPR OFF IN X MINS m AutoFresh Air Exchange Relay AFAR OFF IN X MINS Main Menu To access Component Test mode or Configuration mode These are for the Light Bar only The FET LED will illuminate however the corresponding indicator LED on the Display will not illuminate SV4 OFF IN X MINS Co ior NOTE Electronic speed control modules can not be tested through the microprocessor Refer to Section 10 4 1 for Troubleshooting guide for units with Electronic Speed Control Engines 62 10683 6 1
284. e enn 9 17 Figure 9 10 Belt Tension cece nents 9 18 Figure 9 11 V Belt Arrangement None ESC Engine 9 18 Figure 9 12 V Belt Arrangement Electronic Speed Control Engine 9 19 Figure 9 13 Removing V Belt from Engine Adapter Drive Sheave 9 20 Figure 9 14 Fanshaft Assembly seems 9 22 62 10683 xii FIGURE NUMBER Page Figure 9 15 Blower Wheel And Nozzle Cover Assembly 9 23 Figure 9 16 Thermostatic Expansion Valve Bulb and Thermocouple 9 25 Figure 9 17 Vacuum Pump Connection 9 26 Figure 9 18 Pressure Switch and Sensor c cece cee nen 9 28 Figure 9 19 Compressor Drive Assembly cece eee hn 9 29 Figure 9 20 Oil Level in Sight Glass eR mn 9 30 Figure 9 21 Compressor cfs ined weenie dentate t rls red err DekRPUDC GENIS 9 31 Figure 9 22 Unloader Valve EL ELE TAa ages Manton EUER Re PROPERE T Are ra DR 9 32 Figure 9 23 Discharge Check Valve Serviceable Prior to S N JAW90756460 9 32 Figure 9 24 Discharge Check Valve Non Serviceable Beginning With S N JAW90756460 9 32 Figure 9 25 Hot Gas Check Valve Non Serviceable
285. e if any active alarm occurs Continue with the steps below as necessary Check Wiring To DPT amp SPT a Verify that correct wires are connected Plugs to transducers are the same The correct wire plug to each transducer must be connected to the proper transducer Check Fan Belts a Check upper fan belt tension amp Refer to Section 9 9 for belt tensions condition No Glazing no cracking no slipping b Check lower fan belt tension amp Refer to Section 9 9 for belt tensions condition No Glazing no cracking no slipping Check Evaporator Air Flow See Note 9 Page 8 2 a Check evap fan clutch Must be engaged b Check evaporator section return air Good Air Flow bulkhead air chute cleanliness of Return air not restricted evap coil Air chute in good condition No damage to blower wheel Evap coil clean i 4 Check For SV2 Circuit Alarm a Check for alarm 97 or P192 Alarm conditions must be corrected and the alarm cleared to continue 5 Check System Pressures Check and compare compressor Suction amp Discharge Pressures must have the same discharge amp suction pressures with reading 5 PSIG 0 34 Bar on gauges amp on micro those shown on the microprocessor display controller Check Refrigerant Charge a Check for undercharged system See Level must be above lower sight glass Section 9 11 4 Checking Refrigerant Charge 7 Manually Defrost Unit a Defrost unit and terminate Typical defrost cy
286. e prompted to press either the key or the UP or DOWN ARROW to scroll through list of IntelliSets The current IntelliSet will have either the word ACTIVE or MOD IFIED after it MODIFIED indicates that one or more of the IntelliSet settings other than set point have been changed To change MODIFIED to AC TIVE press key while the IntelliSet is shown in the MessageCenter The Advance Microprocessor offers over 48 parame ters that may be set depending on the product being car ried IntelliSet allows the owner to pre program specific product settings into the microprocessor and give the settings a name The operator may then call up these settings by simply selecting the IntelliSet name For example Apples may require continuous operation at 35 F 1 7 C with a defrost every hours while a load of cheese may require the same operation with set points ranging from 35 F to 42 F 1 7 C to 5 6 C anda load of ice cream requires Start Stop operation at 22 F 30 C with defrost at 12 hour intervals The set tings required for each product may be entered into the microprocessor and then locked so they cannot be changed In the case of the cheese the range of set points may be locked leaving the operator the ability to change the set point within the locked range When aload of apples is going to be picked up the oper ator simply selects APPLES from the IntelliSet menu for cheese CHEESE is selected for ice
287. e tests with your super visor If necessary go to the beginning of the table amp test again es NO Review results of above tests with your super visor If necessary go to the beginning of the table amp test again Figure 10 3 ESC Diagnostic Tree 2 Long 3 Short LED Code 10 11 62 10683 Replace ENSCU Did you find and correct the condition START HERE With the Start Run Off switch ON and the ENSCU wire 13 removed from the connector connector plugged in check voltage at ENSCU terminal 13 Is voltage 26 VDC or higher NOTE With connector unplugged unit will not start but will crank Check voltage while unit is cranking Check voltage output at alternator Is voltage 26 VDC or higher Remove new ENSCU and re install old ENSCU back into unit ENSCU is not the fault Review results of above tests with your supervisor If necessary go to the Starting at terminal 13 at the ENSCU check circuit for induced voltage creating the 26 VDC signal Did you find and correct the condition YES a Replace alternator Did you find and correct the condition NO Remove new alternator and re install old alternator back into unit alternator is not beginning of the fault Review the table amp test again results of above tests with your
288. e than 2 7 F 1 5 C Control Temp is less than 2 3 F 1 3 C below setpoint below setpoint COOL Control Temp is more than 3 6 F 2 C Control Temp is less than 1 4 F 0 8 C Frozen above setpoint above setpoint When the compressor is fully loaded it is operating on six cylinders When the front unloader UL1 is Unloaded ener gized the unit operates on four cylinders When UL1 and the rear unloader UL2 are both unloaded energized the unit operates on two cylinders UL2 always unloads before UL1 HEAT 5 13SV1 OPERATION The SV1 valve will be open de energized whenever the system is operating in the Cool Cycle s SV1 valve will be closed energized during Heat and Defrost Cycles When the system is operating in the Defrost Cycle and the Dis charge Pressure reaches 350 PSIG 23 8 Bars during Defrost SV1 opens de energizes for 1 second then closes energizes again to help control Discharge Pressure 5 14 SV2 OPERATION The SV2 valve will be open energized whenever the system is operating in the Cool Cycle The SV2 valve will open and close during the Heat and Defrost Cycles to control Discharge and Suction pressures The following SV2 control is used during the Heat and Defrost cycles 1 If the Discharge Pressure is greater than the SV2 closed value shown in the table below SV2 is de energized closed 2 If the Discharge Pressure is less than the SV2 open value SV2 is energized open SV2 closed and
289. e unit is serviced re turn the Mode switch to REMOTE ON Refer to Section 3 20 3 for more detailed informa tion on two way communication 62 10683 8 2 NOTES Note 1 Note 2 Note 3 Note 4 Active alarms will always be in the Alarm list They will have an A in front of the alarm number Active alarms may be inactivated by going to the end of the Active Alarm list LIST END TO CLEAR ALARMS will appear in the MessageCenter Pressing the key will clear or inactivate the alarms This moves the alarm to the Inactive Alarm list if the condition that caused the alarm has been corrected When Shutdown Alarms are cleared the unit will attempt to restart if the micro is set for auto start When non Shutdown Alarms are cleared there will be no noticeable change in the unit s operation The Inactive Alarm list is reached by first pressing and holding the Alarm list key then the UP Key and holding both of them for six seconds Alarms in this list will begin with 1 Inactive followed by the alarm number Clearing alarms from the Inactive Alarm list will also clear alarms from the Active Alarm list Go to the end of the Inactive Alarm List LIST END TO CLEAR ALARMS will show in the Message Center Press to clear all alarms from both lists For units with a Glow Crank switch refer to Note 4 Note 5 and Note 9 To test electrical circuits when unit is without a glow crank switch locate the 3
290. e used as a refrigerated compartment door switch The switch contacts will be OPEN whenever the door is OPEN DOOR OPEN DOOR OPEN SWITCH CLOSED The Remote REMOTE SWITCH 1 2 SWITCH CLOSED switch will be used as a refrigerated compartment Optional door switch The switch contacts will be CLOSED NOTE Sensor s on DataRecorder whenever the door is OPEN must also be set SWITCH ON SWITCH ON CONTACTS OPEN The Remote CONTACTS OPEN switch will be used as a remote control switch The switch contacts will be OPEN whenever the switch is in the ON position SWITCH ON CON SWITCH ON CONTACTS CLOSE D The Re TACTS CLOSE D mote switch will be used as a remote control switch The switch contacts will be CLOSED whenever the switch is in the ON position ALARM ONLY ALARM ONLY When Door switch indicates that the door is open a warning alarm will be displayed in the MessageCenter UNIT SHUTDOWN UNIT SHUTDOWN When Door switch indicates that the door is open a warning alarm will be dis played in the MessageCenter and the unit will shut REMOTE SWITCH 1 2 down Optional LOW ENGINE LOW ENGINE SPEED When Door switch indi SPEED cates that the door is open the engine will be forced to low speed ONLY DATA RECORDER DATA RECORDER ONLY The data recorder will record every time the door is opened or closed There will be no alarms or messages displayed in the MessageCenter The following will allow the Real Time Clock in
291. e values 2 Check Software Version Check Microprocessor Software ver Upgrade to the latest version of software Newer versions sion of ReeferManager may contain configurations that were not present in older versions of Microprocessor software Reconfigure Microprocessor a Send settings to Microprocessor Using ReeferManager and a Configuration PC Card write the desired configuration file to the PC Card then load the file into the Microprocessor Allow the Microprocessor to reboot itself 4 Reset microprocessor Turn Start Run Off switch off for 30 Microprocessor powers up OK seconds then turn back on b Check for valid Configurations in Data Valid number is present List Alarm is cleared c Valid Configurations can be Replace microprocessor entered See Note 1 Page 8 2 Ja Clear the inactive alarm 8 109 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 242 DIS PRESS CALIBRATE ERROR TRIGGER ON There is an error in the Discharge Pressure Sensor Calibration value stored inthe microprocessor memory or in the memory sector of the microprocessor that the calibration value is stored in UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset when the Discharge Pressure Sensor is calibrated successfully or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correct
292. e was used and the path that was followed to determine the micro was at fault 10 13 62 10683 Disconnect StarTrak from unit and install J1 jumper This will eliminate StarTrak from the system START HERE Is unit equipped with StarTrak NO Is Micro Status NO nana mE LED blinking Check the F1 fuse Check Micro Status Is the fuse blown LED blink rate YES Replace the fuse Did you find and correct the condition Return to the top of this sae Micro Status LED Micro Status LED is blinking N is blinking at 1 at 1 2 second ON amp 1 2 second amp 1 second OFF ES second OFF Inspect and repair poor Check the Glow Crank switch batten star connections at the micro and wiring for shorting Is the and display Did you find Switch or circuit shorted engine block and and correct the condition inside the control box Did you find and NO NO correct the condition th it nsure the operator is waiting Replace NO long enough by turning the Load current version Switch and Start Run Off switch ON and of software from http pns Check voltage waiting 2minutes for the display www transcentral between 1 amp 2 to on Did you find and carrier com Did the Voltage should read correct the condition current version of 11 volts or higher sof
293. eads amp inspect Must be in good condition condition of all reeds amp gaskets Check compressor pistons and connecting rods a Check compressor pistons Must be in good condition connecting rods See Refrigeration System Troubleshooting Section 10 3 29 CHECK HEAT CYCLE TRIGGER ON The unit has been operating in the heat cycle for more than 5 minutes and the SAT is more than 5 5 F 3 C colder than the RAT constantly for more than 60 seconds Unit is actually cooling the air going through the evaporator UNIT CONTROL Unit shutdown and alarm RESET CONDITION Auto reset after 15 minutes or alarm may be manually reset via keypad or by turning the START RUN OFF switch OFF and then back On again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Perform Pretrip Check a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding See Troubleshooting Section 10 3 Refrigeration System Not Heating 62 10683 8 18 ANO Steps ALARM CAUSE CORRECTIVE ACTION 8 5 START UP ENGINE ALARMS FAILED TO RUN MINIMUM TIME 30 TRIGGER ON Engine has shut down on an alarm 3 times without having run for at least 15 minutes between each shutd
294. ears Press the key to enter that number for the month Press the UP ARROW key to go to Day Using the same key presses as in f and g above continue to enter the correct numerical value for the Day Year Hour and Minute Hours are displayed and entered as a 24 hour clock 0 to 12 is AM 13 to 24 is PM When you are finished the MessageCenter will diis play PRESS TO SAVE TIME CHANGES NOTE If you do not press the key none of the time changes you just made will be saved j Press the UP ARROW key to go to SET NEW HOURS Press the key then the Up Ar row key to enter that menu The first hourmeter is Engine Protect Hours Press the key to select this meter The cursor will be blink ing on the ten thousands place Press the UP or DOWN ARROW key to select the correct value then press the key If the correct number in any of the locations is 0 zero just press the key to enter 0 as the value and move the cursor to the next place For example if you are entering 567 hours you will press the key twice to leave a 0 for the first two numbers then use the UP and DOWN ARROW key to scroll through the numbers to enter the correct hours When the correct hours for Engine Protect Hours has been entered press the key to advance to the next hourmeter If an invalid number is entered a warning message will flash in the MessageCenter For exam ple you can not enter a higher number of hours for E
295. ecommended that the adjust ment be made so that the available capacity is slightly larger than the load the unit will cycle OFF and ON i Once repair parts become available repair as re quired 9 23 LIGHT BAR 9 23 1 Light Bar Operation and Test a The green LEDs illuminate when 12 volts is applied to Pin G and ground is applied to Pin B b The amber LEDs will illuminate when 12 volts is ap plied to Pin G and ground is applied to Pin B and Pin H c Use an Ohmmeter to test light bar operation PIN B should be open to other terminals and PIN G should have 325 to 550 ohms to PIN H 9 24 CHECKING DEFROST OR HEATING CYCLE NOTE DTT must be 40 F 4 4 C or lower before any checks can be made 9 24 1 Hot Gas Solenoid Valve SV1 amp SV4 Heating and Defrosting a Connect a discharge pressure gauge to the manual shut off valve king valve and another gauge to the compressor discharge service valve Connect a gauge to the compressor suction service valve b Start unit with controller set at least 10 F 5 5 C be low indicated refrigerated compartment temperature to obtain high speed cooling Press the MANUAL DE FROST key to initiate defrost DTT must be at or be low 40 F 4 4 C The hot gas solenoid valve SV4 will energize and the hot gas line will be hot to touch on both sides of the valve The condenser pressure control solenoid SV1 closes and suction pressure will rise approximately 10 to 15 PSIG 0 68
296. ection NO TAG Add refrigerant charge Refer to Section NO TAG Check unit operation by running Pretrip Refer to Section 3 4 9 21 SERVICING SOLENOID VALVES 9 21 1 Solenoid Valve SV2 SVA CAUTION Do not over tighten or damage the enclos ing tube assembly Torque to 17 ft pounds 2 4 Mkg Also make sure all parts are placed on the enclosing tube in proper se quence to avoid premature coil burnout Replacing the SV2 SV4 Coil NOTE The coil may be replaced without removing the refrigerant or pumping the unit down 1 Unplug from wiring harness remove coil retainer and coil assembly 2 Verify coil type voltage and frequency This informa tion appears on the coil housing 3 Place new coil over enclosing tube retainer and con nect wiring 62 10683 9 38 b Replacing SV2 SVA internal parts CAUTION Service mode MUST be used whenever moving refrigerant charge refrigerant leak checking or evacuating Refer to Section 6 2 3 1 Coil Assembly 5 Seal 2 Retainer 6 Piston Assy 3 Enclosing Tube Assy 7 Body 4 Plunger Assy 8 Bracket Adapter Figure 9 29 SV2 SV4 Solenoid Valves To service the liquid line solenoid valve SV2 or the hot gas solenoid valve SV4 first pump the unit down Refer to Section NO TAG Remove and store the refrigerant charge in an evacuated container Refer to Section NO TAG 1 Remove coil retainer and coil assembly from val
297. ed here will be the number of hours between Switch On service intervals 62 10683 CONFIGURATION SELECTIONS DESCRIPTION OFF The PM 1 5 Maintenance is turned off ENGINE HOURS ENGINE HOURS PM meter will count engine hours until the next service interval SWITCH ON SWITCH ON HOURS PM meter will count Switch HOURS On Hours until the next service interval CLUTCH CYCLES CLUTCH CYCLES PM meter will count how many times the fan clutch cycled on off until the next service interval START CYCLES START CYCLES PM meter will count how many times the engine has started until the next service interval HIGH SPEED HIGH SPEED HOURS PM meter will count how HOURS many hours the unit operated in high speed until the next service interval MAINTENANCE MAINTENANCE DAYS PM meter will count how DAYS many days until the next service interval OFF The PM 1 5 Maintenance hourmeter s is turned off ENGINE HOURS ENGINE HOURS PM Meter will count engine hours until the next service interval SWITCH ON SWITCH ON HOURS PM Meter will count Switch HOURS On Hours until the next service interval CLUTCH CYCLES CLUTCH CYCLES PM Meter is connected to the 1 000 TO 90 000 clutch cycle meter This meter counts every time CYCLES in 1 000 the fan clutch engages The reset interval will be PM 1 5 RESET INTERVAL cycle increments 1 000 to 90 000 cycles This is not displayed unless the PM STA
298. ed to ground but is shorted either within the Defrost Light itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when Defrost light current amp draw is normal or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Defrost Light a Inspect Defrost light amp socket No damage to bulb No damaged or corroded pins b Check resistance of light bulb Refer to Section 2 13 Check Defrost Light Wiring Inspect harness amp control box See Notes Note 3 Note 4 amp Note 8 connector pins amp terminals See wiring No physical damage to harness schematic No damaged or corroded pins Check Defrost Light Current Draw a Use Component Test mode Refer to Refer to Section 2 13 for normal current values Section 6 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 14 84 CHECK REMOTE ALARM LIGHT TRIGGER ON Remote Alarm light circuit to the Light Bar circuit is shorted The Alarm Light output from the micro is negative so the circuit will not be shorted to ground but is shorted either within the Alarm Light itsel
299. ed when set ting the microprocessor up from the keypad Generally the microprocessor can be setup us ing a Configuration PC card however certain parameters can not be set using a Configura tion PC card Those parameters can be entered using the keypad or the ReeferManager pro gram The steps below detail entering the data using the keypad a Ensure that the new microprocessor is in place all o wires connected and the negative battery cable is re connected Place the START RUN OFF switch in the START RUN position The microprocessor will immediately go into the Configuration List so that the correct mod el number can be selected Using the UP or DOWN ARROW keys scroll through the list until the correct Model Family appears and press the key Use the Up or Down Arrow keys to scroll through the list of model numbers until the correct model number ap pears verify the model serial plate on the unit Press the key to enter the new model number Press the UP ARROW key again and the unit serial number field will appear Press the key then the UP ARROW key You will see a blinking cursor in the field Now using the UP or DOWN ARROW key scroll through the Number Letter list until the first letter of the serial number you recorded above appears Press the key to enter that letter and advance the cursor to the next place Repeat this process until the entire unit serial number is entered i e LAD90887
300. eed solenoid FSA ESC Must move and out freely plunger b Check engine speed arm amp linkage Must move freely 2 Force high speed operation See Note 9 Page 8 2 Set Functional Parameter LOW LED 27 must be ON SPEED START to zero and adjust setpoint at least 10 F 5 6 C above or below box temperature then start the unit Set Functional Parameter back to original setting after completing repairs b Check operation of Speed Relay LED 27 must be ON c Check oe to speed solenoid FSA Must be 12 14 VDC on ESC d Check Sus of speed solenoid Refer to Section 2 13 FSA on ESC e Check amp draw of speed solenoid Use Component Test Mode Section 6 2 2 to test FSA on ESC Refer to Section 2 13 for amp values View current draw in the Unit Data list Refer to Section 3 14 f Inspect harness amp control physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins or terminals schematic Section 11 g On X2 2500 units ONLY check for Must be 12 VDC voltage on engine speed control unit ENSCU pin 22 EEG For Proper Voltage To The Engine Speed Control Unit ENSCU Pin 16 Based On Requested Speed From The Microprocessor Check voltage at pin 16 with unit Must be 0 VDC for all units running Check Engine RPM a Check actual engine RPM using hand Refer to Section 2 7 held tachometer Adjust engine linkage setting as needed b Compar
301. een 5 Visually inspect compressor suction Must be clean and unobstructed inlet screen for material 8 95 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION P196 HIGH DISCHARGE PRESSURE TRIGGER ON This alarm is generated during Test 4 of Cool Pretrip Discharge pressure is higher than normal Normal discharge pressure for systems operating in the Cool Mode can be estimated by taking the temperature of the air entering the condenser coil Ambient Air Temperature AAT and adding 30 F 16 6 C to it then looking at a pressure temperature chart see Table 9 9 for the corresponding pressure UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Fan Belts a Check upper fan belt tension amp Refer to Section 9 9 for belt tensions condition No Glazing no cracking no slipping b Check lower fan belt tension amp Refer to Section 9 9 for belt tensions condition No Glazing no cracking no slipping 2 Check Wiring a Visually Inspect wiring to SV4 amp both Wires must be connected properly amp securely to each Compressor Unloader
302. een the keypad and the microprocessor With no communication there will not be an associated alarm Should this occur check the wire connections for the wiring that connects connector 6 on the microprocessor to the connector at the Keypad Display assembly In later model units this message will read CHK WIRES FROM MICRO TO KEYPAD When working on the refrigeration system an accurately calibrated manifold test set should always be installed It is also a good idea to connect an additional high pressure gauge to the king valve In high or low ambients it may be necessary to cool or warm the box temperature before performing specific tests providing that the trailer or rail compartment is not loaded with perishable product AX WARNING Beware of V belts and belt driven compo nents as the unit may start automatically Before servicing unit make sure the START RUN OFF switch is in the OFF posi tion or the unit is in the Maintenance mode Also disconnect the negative battery cable WARNING UNITS EQUIPPED WITH STAR TRAK TWO WAY COMMUNICATION CAPABILITIES MAY HAVE THE ABILITY TO BE STARTED OR TURNED OFF REMOTELY REGARDLESS OF THE SETTING OF THE START RUN OFF SWITCH The unit is controlled locally and there can be no two way communication when the Mode switch on the Remote Monitoring Control Box is in MAINTENANCE MODE Therefore when performing any work on the unit place the Mode switch in MAINTE NANCE MODE After th
303. emove the cap from a hot radiator if the cap must be removed do so very slowly in order to release the pressure without spray 2 Check Freeze Point Of Coolant a Use Coolant tester to check Must be between 40 to 60 Ethylene Glycol to water concentration of anti freeze mixture mixture 3 Check Airflow Through Radiator Condenser Coil a Inspect condenser amp radiator fins Fins must be straight 90 or more of the coil surface must be undamaged No dead air spaces Condenser Radiator coil must be clean 4 Check Condenser And Water Pump Belts Check upper fan belt tension amp condition b Check lower fan belt tension amp condition Refer to Section 9 9 for belt tensions No Glazing no cracking no slippin c Check radiator fan belt 9 9 pping d Check water pump belt tension amp condition 5 Check engine cooling system a Compare actual engine temperature to thin 209 44 1 the microprocessor reading Temperature must be within 20 F x11 1 C b Test operation of engine coolant Refer to Section 2 7 for coolant thermostat specifications thermostat c Check water pump operation Must not leak impeller attached tightly to shaft d Check water pump bypass hose to Must be clear and open thermostat housing for internal blockage 62 10683 8 8 NO Steps ALARM CAUSE CORRECTIVE ACTION 13 HIGH DISCHARGE PRESSURE TRIGGER ON Compressor discharge pressure is over 465 PSIG 3
304. ep Hours e Switch On Sleep Hours High Speed Hours e Clutch Hours Start Cycles e Date And Time 6 23 d Remove PC jumper or turn START RUN OFF switch to Off Remove negative battery cable from battery Remove Connectors 1MP 2MP amp 3MP from the out side of the control box Open keypad door by removing the screws at the bot tom Open control box door and use the retaining rod to hold the door open Remove Connectors 5MP amp 6MP inside the control box Remove all wires from the Micro i Locate wire to 80A fuse that runs through the Current Sensor Note the orientation of the wire through the Current Sensor to be certain that the wire is rein stalled through the new Current Sensor in the same direction Inserting the wire through the Current Sen sor in the opposite direction will result in erroneous current readings Remove wire from fuse holder and gently pull through the Current Sensor Remove the screws holding the sides of the Micro into the control box Remove the single screw holding the top of the Micro in place Pull the Micro back and twist out of the control box Install the new Micro by reversing steps a thru 62 10683 6 7 2 Microprocessor Setup NOTE Before starting the unit the microprocessor must be configured for the correct unit model family and model number This can be done at the unit keypad or by using the ReeferManager program The steps below are us
305. er Engine Speed Control Unit ENSCU Water Temperature Sensor WTS Ambient Temperature Sensor AAT Figure 2 4 Front View Of Unit With Electronic Speed Control Electronic Speed Control 62 10683 nO Gg ROI Condenser Pressure Control Solenoid Valve SV1 Defrost Air Switch DAS Filter Drier Receiver sight glass Receiver Liquid Line Solenoid Valve SV2 Battery location Figure 2 5 Curbside Electronic Speed Control 62 10683 2 6 o om Condenser Radiator Pressurized coolant system Control box See Figure 2 8 Serial Port Download Plug SLP Model Serial No Location Figure 2 6 Roadside Electronic Speed Control UM rum ke ee BS Evaporator fan Expansion valve Heat exchanger Nozzle cover Return Air Thermistor RAT AutoFresh Air Exchange See Sections Evaporator coil 2 4 3 and 3 20 4 Figure 2 7 Evaporator Section Panels and Grille Removed Defrost Termination Thermostat DTT Supply Air Thermistor SAT 2 7 62 10683 1 Serial Port Download Plug SLP 6 Fuse F6 15 Amp Fuel Pump 2 Control module Microprocessor 7 Fuse F8 20 Amp Optional Fuel Heater Refer to Section 2 5 3 8 AutoFresh Relay AFAR 3 Fuse F1 7 5 Amp 9 Fuse F5 80 Amp 4 Fuse F10 40 Amp Optional Auto Fresh Air 10 Fuel Heater Relay FHR Exchange 11 Starter
306. er major release version The second two digits e g 05 indicate a minor release Minor releases occur when new features new models or other enhancements are added to the software Software versions of newer or older minor versions can be installed into a microprocessor as needed 6 17 The third set of digits e g 00 is the actual release number Production software is generally 00 Test and experimental versions will have a different number The third digit does not affect the major or minor designation therefore the software can still be installed into a microprocessor as needed NOTE Some test or experimental versions may be the ONLY current version that will operate correctly in a particular unit Until a new production ver sion is announced changing the software may result in incorrect unit operation 62 10683 6 5 2 Using The Program PC Card TIP Whenever performing a major operation to a microprocessor such as installing new operating software it is always a good idea to start the unit and give it a quick check over prior to performing the operation NOTE Once the unit shuts down to begin the software install process the Compressor Suction Modulation Valve CSMV closing process begins The software installation processes will not begin until the CSMV is com pletely closed which will delay the actual process for about 45 seconds CAUTION The display and MessageCenter may behave differently during the
307. er plate is located inside the unit on the frame as shown in Figure 2 3 Table 2 1 Model Chart Advance Models Ultra XTC NDL 93NN Ultra XTC Rail Edition NDL 93NR Ultra XTC with Tier 2 Engine NDL 93VN Ultima XTC NDL 93PN Ultima XTC Rail Edition NDX 93PR Ultima XTC with Tier 2 Engine NDL 93RN X2 2100A and R NDL93S X2 2500A and R NDL93U LB 20 C Engine Speed ompressor High Low 1700 1350 CT4 134 DI 05G 41cfm 2200 1475 V2203 DI 1700 1350 ESC 2200 1450 Table 2 2 Additional Support Manuals Manual Number 62 10671 62 11171 62 10646 62 10682 62 10295 62 10863 62 11168 62 10301 62 10865 62 11167 62 10299 62 11053 62 02756 62 11052 Equipment Covered Ultra Ultima XTC Engine Tier 2 Engine Electronic Speed Control Engine Tier 2 Engine Electronic Speed Control Compressor Compressor 05G TWINPORT Compressor Compressor 05G TWINPORT Type of Manual Parts List Parts List Operator s Manual Easy To Run Parts List Parts List Parts List Workshop Workshop Workshop Parts List Parts List Service Service 62 10683 2 2 GENERAL DESCRIPTION The refrigeration units described in this manual are one piece self contained fully charged pre wired refrigeration heating nosemount diesel powered units for use on insulated trailers or rail cars to maintain cargo temperatures within very close limits Automatic evaporator coil defrosting is initiated by either sensin
308. erature Control Operating Sequence Frozen Range 5 6 Figure 5 3 Start Stop Temperature Control Operating Sequence Perishable Range 5 7 Figure 5 4 Start Stop Temperature Control Operating Sequence Frozen Range 5 7 Figure 5 75 Range Lock 1 35 epp epe xu eatin Oe ies Gah a SLR CL ah 5 13 Figure 5 6 Range bock 2 ic ac oboe d t ce we ten tae IR ean ate ede 5 13 Figure 6 1 Display Module Assembly 6 27 Figure 9 1 Grille Insert Removal And Door Latch Maintenance 9 8 Figure 9 2 Surround Removal een hh n 9 9 Figure 9 3 Side Door Latch Lower Cable Removal 9 10 Figure 9 1 Priming Fuel Pump m m m N 9 11 Figure 9 2 Mechanical Fuel Pump m m 9 12 Figure 9 3 Fuel Level Sensor Wiring 9 13 Figure 9 4 Fuel System Diagram shes 9 14 Figure 9 5 Lube Oil Flow Diagram eR mH m he 9 15 Figure 9 6 Speed Control Solenoid eens 9 15 Figure 9 7 Electronic Speed Control Components 00 ce eects 9 16 Figure 9 8 Frame Mounted Engine Speed Control Unit ENSCU 9 16 Figure 9 9 DI Engine Crankcase Breather cec
309. ervice Mode and the system is ready for recovery and leak testing REMOVE CARD BATTERY TOO LOW If a PC card is inserted when battery is below 7 0 volts this mes sage will be displayed until card is removed REMOTE SWITCH 1 2 OPEN Remote switch is open May be connected to a trailer or rail car compartment door or a remote control switch REMOTE SWITCH 1 2 OPEN LOW Shows that the remote switch is open and that the unit is running in SPEED low speed Switch may be connected to a trailer or rail car compart ment door or a remote control switch REMOVE JUMPER The Configuration Technician Test mode has been entered Re move the jumper wire before continuing SAME SW TO LOAD 1 TO CANCEL A Program PC card has been inserted into the PC card slot and the program on the PC card is the same as the program currently in the microprocessor Press the key to reload the same program or press the UP ARROW key to cancel and remove card SERVICE MODE Indicates that this selection has been made in Configuration and Test Modes which allows servicing of the refrigeration system SETPOINT CHANGED The new set point has been entered saved into microprocessor memory The new set point will be used SETPOINT NOT CHANGED The new set point has NOT been entered NOT saved into micro processor memory The old set point will be used SETTING SMV XXX 96 The START RUN OFF position has been placed in the START RUN positi
310. es periodic testing and calibration Refer to Section 9 25 2 In the case where the switch is out of adjustment it will either not putthe unit into defrost as soon as needed or it will attempt to put the unit into defrost prematurely In the first case the defrost timer will help correct any icing problem TIP Ice is not the only thing that will cause the air differential to increase across the evaporator coil Shrink wrap paper plastic bags and other such items when caught in the return air stream and pulled up against the evap orator coil or the return air grill can also cause the Defrost Air Switch contacts to close When looking at a unit for a Defrost Air Switch problem be sure to also inspect the condition and cleanliness of the evaporator coil and the return air area c Manual Defrost The Defrost cycle may be started at any time providing that evaporator temperature criteria as defined in Section 5 11 1 have been met by pushing the MANUAL DEFROST key Refer to Section 3 10 62 10683 5 8 5 11 3 Normal Defrost Operation Vi CLOSE Refertosv2 Qnes DISENGAGE e n dioe 100 energized Operation gized de energized ergized ergized Open When the ambient air temperature is greater than 35 F 1 7 C the compressor discharge pressure will be monitored during the defrost cycle NOTE If the Ambient Air temperature is below 80 F 26 7 C the Normal Defrost Operation will be used When the
311. esired point and additional cooling capacity is required Table 4 2 FreshProtect For Return Air Temperatures less than 10 F 5 6 C above set point Below Setpoint A 2T0SF 4TO28C 4TO7FB2T0390 801i F44TOG1 0 10019 656T0720 p _ OFF The process of refrigeration causes the cargo area air to be drawn into the Return Air inlet of the evaporator section From there it is directed through the evaporator coil where it is cooled off then discharged through the Supply Air blower housing and back into the cargo area The warmer the Return Air temperature is in relationship to setpoint the more cooling capacity is needed to bring the air temperature down to setpoint As cooling capacity is increased the Supply Air temperature drops as additional heat is removed from the air If left uncontrolled the Supply Air temperature can fall as much as 20 F 11 1 C or more below the Return Air temperature When the RAT approaches setpoint the SAT will also approach setpoint The SAT may then be closer to setpoint than shown in Table 4 2 When FreshProtect is set for OFF the system runs with FreshProtect off and the SAT will operate as far below setpoint as needed to bring the RAT to setpoint as quickly as possible All other FreshProtect settings enable FreshProtect Supply Air Temperature control and the controller watches the Supply Air Temperature as well as the Return Air Temperature while the sys
312. evel should be between the Minimum and Maximum marks Maximum Minimum Figure 9 20 Oil Level in Sight Glass 62 10683 9 30 9 13 2 Adding Oil With Compressor In System Two methods for adding oil are the oil pump method and closed system method a Oil Pump Method One compressor oil pump that may be purchased is a Robinair part no 14388 This oil pump adapts to a one U S gallon 3 785 liters metal refrigeration oil container and pumps 2 1 2 ounces 0 0725 liters per stroke when connected tothe oil fill tem 3 Figure 9 21 There is no need to remove pump from can after each use When the compressor is in operation the pump check valve prevents the loss of refrigerant while allowing the technician to develop sufficient pressure to overcome the operating suction pressure to add oil as necessary Backseat suction service valve and connect oil charging hose to oil fill Item 3 Figure 9 21 Purge the oil hose at oil pump Add oil as necessary Refer to Section 2 10 b Closed System Method CAUTION Extreme care must be taken to ensure the hose is immersed in the oil at all times Otherwise air and moisture will be drawn into the compressor When an oil pump is not available oil may be drawn into the compressor through the oil fill port or through the suction service valve 1 Connect the suction connection of the gauge manifold to the compressor suction service valve port and the common connect
313. evenly to pull the rotor off the fan shaft hub Unplug the clutch coil connector from the wiring har ness then remove the clutch coil Be sure to retain all shims on fan shaft hub correctly positioned on Fanshaft pin Remove the vent hose and 1 8 barb fitting from fan shaft hub Install a plug to prevent oil from spilling out vent hole while removing fan shaft 9 10 2 Blower Wheel And Fanshaft Removal a Remove bulkhead and air chute if so equipped Re move evaporator back panel Remove the bolts that secure DTT and SAT to the nozzle cover Care should be taken to prevent cutting wires on evaporator coil Remove the remaining bolts in the nozzle cover and carefully remove it from the pod NOTE The nozzle cover CTD P N 58 04469 00 is sealed with a gasket CTD P N 42 00506 00 If the gasket is damaged during removal it MUST be replaced Remove the two 1 4 20 X 1 long bolts from the blow er wheel split taper bushing Insert them into the threaded holes Tighten bolts evenly to push the blower wheel away from the bushing Remove the fan shaft seal ring clamp and carefully peel seal from pod use a putty knife if needed NOTE The fan shaft seal CTD P N 42 00372 00 is caulked to the pod If seal is damaged during re moval it MUST be replaced f Remove the four 3 8 bolts from the fan shaft 9 21 Remove fan shaft from unit 62 10683 9 10 3 Fanshaft Installation
314. extra wires inside the control panel that were used to connect to the glow crank switch before April 2007 Use either a jumper wire to energize the circuits or connect a temporary GCS into the circuit to continue To test electrical circuits when the unit is equipped with a glow crank switch place the unit in Manual Start Operation To dothis first turn the unit off Press and hold the Glow Crank switch in the Glow position Place the Start Run Off Switch in Start Run position Continue to hold the Glow Crank switch until the setpoint and box temperature are shown in the display then release it The MessageCenter will show Manual Start Mode Selected and the Run Relay will be energized See Unit non running amps below for current draw in this state 62 10683 Note 5 Note 6 Note 7 Note 8 Note 9 Many checks wil be made with the microprocessor powered up but with no outputs to the unit components The unit may be put into PC Mode to do this For additional information see PC Mode Section 6 1 For units with a Glow Crank switch an alternative method to power up the microprocessor with no load hold the Glow Crank switch in the glow position and place the START RUN OFF switch in START RUN Continue to hold the Glow Crank switch for two seconds after the self test begins then release This is before the setpoint and box temp values are show The Message Center will show Manual Start Mode Selected however n
315. f or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when Alarm light current amp draw is normal or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Alarm Light a Inspect Remote Alarm light amp socket No damage to bulb No damaged or corroded pins b Check resistance of light bulb Refer to Section 2 13 Check Alarm Light Wiring a Inspect harness amp control See Notes Note 3 Note 4 amp Note 8 connector pins amp terminals See wiring No physical damage to harness schematic No damaged or corroded pins Check Alarm Light Current Draw a Use Component Test mode Refer to Refer to Section 2 13 for normal current values Section 6 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 14 8 51 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 85 CHECK UL1 CIRCUIT TRIGGER ON UL1 Front Unloader Coil circuit is shorted The UL1 output from the micro is negative so the circuit will not be shorted to ground but is shorted either within the UL1 itself or to a positive wire UNIT CON
316. f ProductShield Econo Go To Start Stop mode Select the desired Delta T value for activation of ProductShield Econo Go To Start Stop mode OFF The unit will operate normally in high and low speeds ON The unit will operate in high speed when the ambient air temperature falls OUTSIDE the mini mum maximum temperature range selected set tings for HIGH AIR MIN TEMP HIGH AIR MAX TEMP AND HIGH AIR DELTA T see below OFF There is no lower limit for this parameter 19 F to 119 F 28 3 C to 48 3 C in 0 5 F or C increments Default 119 F 48 3 C 6 7 Select the lower limit of the ambient range desired for this parameter Refer to Section 5 16 for more information on High Air Min Temp 62 10683 CONFIGURATION SELECTIONS 19 F to 119 F 28 3 C to 48 3 C in 0 5 F or C increments Default 119 F 48 3 C PRODUCTSHIELD HIGH AIR MAX TEMP ePRODUCTSHIELD HIGH AIR DELTA T 20 F to 32 F 28 9 C to 0 C in 0 5 C or F incre ments PRODUCTSHIELD WINTER xx RANGE 1 2 LOCK START STOP CONTINUOUS F 22 F TO 89 6 30 C to 32 C in 0 1 incre ments 89 6 F 30 C to 32 C in 0 1 incre ments 22 F TO 89 6 F 30 C to 32 C in 0 1 incre ments 22 F TO 89 6 F 30 C to 32 C in 0 1 incre ments NOT INSTALLED STAN DARD RANGE 1 2 MINIMUM TEMP RANGE 1 2 MAXIMUM TEMP MIN S
317. f any active alarm occurs Continue with is below as necessary Temperature Sensor 2 resistance complete table of temperatures and resistance values See Note 4 Page 8 2 2 Check Defrost Termination Temperature Sensor 2 Wiring BH Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section 1 1 Check Defrost Termination Temperature Sensor 2 DTT2 Inspect Defrost Termination No damage to sensor Temperature Sensor 2 amp connector No damage or corrosion in connector 1MP plug is connected tightly to microprocessor No wires are pushed back through plug b Check Defrost Termination 10 000 Ohms 77 F 25 C See section 2 13 for 62 10683 8 102 ANO Steps ALARM CAUSE CORRECTIVE ACTION 8 10 MAINTENANCE ALARMS 223 ENGINE MAINTENANCE DUE TRIGGER ON The Engine Maintenance Hour Meter time has expired UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via keypad Check Unit Maintenance Records Schedule unit into service facility for Must be done soon maintenance Maintenance me Perform appropriate engine amp unit Follow instructions on proper maintenance form maintenance EN Engine Maintenance Hour Meter EENI Check that the Engine Maintenance Reset Interval in Configuration list as required Hour Meter interval is set for your requirements
318. f the micro processor If the Microprocessor Status LED is blinking at the rate of 5 seconds on and 5 seconds off the micro processor is still in Program Mode and the software is not fully loaded into memory Load the software again being careful to follow each step completely in sequence If the Microprocessor Status LED is not on at all check voltage to QC1 amp QC2 Also check for voltage from the START RUN OFF switch at 5MPA 1 If volt age and grounds check OK the microprocessor may be dead and require replacement 62 10683 6 6 RE SETTING PM PREVENTATIVE MAINTENANCE HOURMETERS TIP PM hourmeters may be reset for the next maintenance interval from the Functional Parameter list using the keypad HEAT COOL DEFROST START STOP CONTINUOUS 20 3245 F SETPOINT BOX TEMPERATURE PRESS 1 TO VIEW SETTINGS Pb MANUAL srART sTOP SELECT DEFROST ER deis o J LA j ZA aA 1 Press the SELECT key until PRESS 1 TO VIEW SETTINGS appears in the MessageCenter 2 Press the UP ARROW key or the DOWN ARROW key until RESET PM HOURMETERS is displayed Press the key 7 TO SCROLL THEN TO SELECT will be displayed in the MessageCenter If NO HOURMETERS TO RESET appears there are none to reset Press the UP or DOWN ARROW key until the PM hourmeter you wish to reset is shown The MessageCenter will show the hourmeter name with the instru
319. for five minutes at a time while the unit isn t running The engine cannot start when the microprocessor is in Component Test Mode From the Main Menu select Component Test Mode and press the key Use the UP or Down arrow keys to scroll through the list when TO SCROLL THEN TO SELECT appears in the MessageCenter Press the key to select the component desired for testing For example if the Front Unloader UL1 Light is selected the UL1 coil will be energized and the MessageCenter will display UL1 OFF IN 5 MINUTES The minutes will count down to 0 at which time the UL1 circuit will be de energized and the MessageCenter will display the last component tested The test may be stopped at any time by placing the START RUN OFF switch in the OFF position or by pressing and holding the key for 6 seconds Should you need more than 5 minutes the timer may be resetto 5 minutes anytime during the test by pressing the key Thetimer may only be reset once during each test After the 5 minute timer expires the MessageCenter will return to the Component Test Mode Menu and display the last component tested To retest the same component and circuit again press the key To select another component to test press the UP or DOWN Arrow key to view other components and press the key to select the desired component To go to Service Mode or Configuration Mode select the Main Menu and press the key The only keys that operat
320. frigerated compartment temperature in both Centigrade and Fahrenheit is one tenth degree The user has the option as to whether to have the setpoint displayed with a decimal or comma Only setpoint is affected by this selection All other temperatures and pressures will continue to be displayed with either a decimal or comma Refer to Configurations Section 6 2 2 19 Indicator LEDs The display has six LEDs across the top to indicate operation status These indicators are Cool Indicator Green Turned on when the unit is in Cool mode Heat Indicator Amber Turned on when the unit is in Heat mode Defrost Indicator Amber Turned on when the unit is in Defrost mode Start Stop Indicator Green Turned on when the Start Stop mode has been selected Continuous Indicator Green Turned on when the Continuous mode has been selected Alarm Indicator Red Off or flashes at a rate of 0 5 seconds NOTE When the unit is in PULSED NULL mode fan only the mode indicators COOL HEAT and DEFROST are all off NOTE There is an opening between the Alarm and Start Stop LEDs that is not used at this time 62 10683 MessageCenter The MessageCenter is used to show messages Details of the messages are described in Section 7 1 MessageCenter Switch Descriptions START RUN OFF Switch SROS START RUN START RUN OFF Switch f N START RUN OFF switch is a 12 VDC 7 input to the microprocesso
321. g PC Mode are met the START RUN OFF switch is OFF the PC mode Jumper is con nected and the engine is not running PC Mode allows the user to access and download data using a computer when the unit is not running and without starting the 8 hour data recorder timer Refer to Section 6 1 PM DUE Preventative Maintenance is now due on the unit PM HOUR METER NOT CHANGED The last change for the PM hourmeter was not received by the mi croprocessor PRESS 1 TO VIEW DATA Press the UP or DOWN ARROW key to scroll through the Data list PRESS 1 TO VIEW SETTINGS Press the UP or DOWN ARROW key to scroll through Functional Parameter settings PRESS 1 TO VIEW PRINT MENU Press the UP or DOWN ARROW key to view the strip print setup menu 62 10683 7 4 MessageCenter MESSAGES PRETRIP FAIL IN TEST XX nn of the pretrip tests did not pass and the pretrip was not com pleted PRETRIP PASS All of the pretrip tests were OK PRODUCT SHIELD HIGH AIR ON The unit is operating in ProductShield High Air which overrides nor mal unit operation Refer to Section 5 16 1 b PRODUCT SHIELD WINTER ON The unit is operating in ProductShield Winter which overrides nor mal unit operation Refer to Section 5 16 1 c PRODUCT SHIELD ECONO ON The unit is operating in ProductShield Econo which overrides nor mal unit operation Refer to Section 5 16 1 a RECOVER LEAK CHK EVAC MODE This message will be displayed when the unit is in S
322. g the air pressure drop across the coil with a dif ferential air switch or with the defrost timer in the micro processor The control box includes manual switches micropro cessor fuses and associated wiring The unit can be equipped with an optional remote light bar which mounts separately on the front roadside corner of the refriger ated compartment 62 10683 The temperature controller is a solid state micropro cessor Refer to Section 2 5 Once the microprocessor is set at the desired temperature the unit will operate automatically to maintain the desired temperature with in very close limits The control system automatically se lects high and low speed cooling or high and low speed heating as necessary to maintain the desired tempera ture within the refrigerated compartment The auto Start Stop operation provides automatic cycl ing of the diesel engine which in turn offers an energy efficient alternative to continuous operation of the en gine with control of temperature by alternate cooling and heating ofthe supply air evaporator outlet air The auto Start Stop feature is standard equipment Liquid line service valve Hot Gas Solenoid Valve SV4 Suction Modulation Valve CSMV High Pressure Cutout Switch HPS Discharge service valve Unloader solenoid valve Compressor Discharge Transducer CDT Compressor 05G Compressor sight glass Suction Pressure Transducer CS
323. ge the current language selection See Section 3 16 for more information on Language Selection 2 5 2 Special Features The following special features are incorporated into the Carrier Transicold Advance Microprocessor A MessageCenter which clearly displays information in dot matrix form Unit Operation and Alarms are displayed in English not in codes UltraFresh 3 Large LCD display Unit Data and Functional Parameters Programmable Maintenance hourmeters PM Hourmeters are resettable from the keypad Bright LED alarm light Bright LED mode lights Fully automated Pretrip Automated microprocessor Self test e DataRecorder e DataRecorder date and time can be set from the keypad e Auto Start Stop e Trip Start to record date time of trip in DataRecorder memory PC card functionality for downloading data upgrading programming and setting up Configurations Refer to Section 2 5 4 FETs Field Effect Transistors for switching components on and off and checking circuit current Automatic Engine Starting Manual engine starting exists in units built before April 2007 Functional Parameter locks Alarms are stored in microprocessor memory for future reference New menu system to simplify keyboard and enhance functionality 62 10683 2 5 3 Component Description And Location a Control Module The control module is housed in the control box on the lower roadside right corner of the unit just inside the
324. ger battery life 3 7 CONTINUOUS RUN OPERATION e HEAT e COOL 20 SETPOINT e DEFROST e ALARM CONTINUOUS RUN LIGHT START STOP CONTINUOUS 4I45 BOX TEMPERATURE CONTINUOUS RUN MODE SELECTED Pb E MANUAL DEFROST 705 1 Press the START STOP CONTINUOUS key until the CONTINUOUS RUN Light on the microprocessor illuminates 2 Verify that CONTINUOUS RUN MODE SELECTED is displayed on the MessageCenter and that the CONTINUOUS RUN light is illuminated The unit is now in Continuous Run operation In the Continuous Run mode the unit will not shut down except for safeties or if the engine stalls Refer to Section 4 3 2 for more detailed information on Continuous Run operation Start Stop and Continuous operation may be tied to the set point ranges for frozen and perishable loads The START STOP CONTINUOUS key is locked out if START STOP LOCKED appears in the MessageCenter when the key is pressed and the unit is in Start Stop mode or CONTINUOUS LOCKED appears in the MessageCenter when the key is pressed and the unit is in Continuous Run mode Refer to the configuration table Section 6 2 If the unit fails to start after three start attempts Alarm 31 FAILED TO START AUTO will be activ ated While running if the unit shuts down an internal counter keeps track of the shutdowns Should the unit shut down three consecutive times without running a minimum of 15
325. h when disconnected from the switch Check Fuel And Speed Actuator FSA amp Circuit ESC Engines Only Check Relay LED LED 28 must be OFF b Check for 12 VDC on the Run Relay Must be 0 VDC circuit c Check SPK20 for voltage Must be 0 VDC d Check ENSCU terminals 13 amp 15 for Must be 0 VDC voltage Check FSA plunger 6B Check Fuel Solenoid non Electronic Speed Controlled ESC engines amp Circuit EX Check Run Relay LED LED 28 must be OFF b Check voltage at harness to fuel Must be 0 VDC solenoid non ESC engines c Check fuel solenoid plunger Must be free to move 62 10683 8 24 NO Steps ALARM CAUSE CORRECTIVE ACTION 35 CHECK STARTER CIRCUIT TRIGGER ON Engine speed failed to reach 50 RPM during 2 start attempts UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with ite below as necessary Check Engine Start Up JP Does engine E snoi star run for afew If NO continue with step 2 below Wii a If Unit Has Electronic speed Control Flash Gode ESC Engines Only alee Speed Control Unit ENSCU Figure 10 1 thru Figure 10 4 b Check for
326. hange or the ReeferManage PC Program The Defrost Timer may be set for 1 5 3 0 6 0 or 12 0 hour intervals When the unit has run for the selec ted amount of time a defrost cycle will be initiated if the evaporator temperature criteria as defined in Section 5 11 1 have been met The Defrost Timer is reset to zero whenever a defrost cycle ends regardless of how it was initiated and begins counting down until the next defrost cycle The microprocessor holds in memory the last entered Defrost Timer interval The Defrost Timer only counts time when the engine and compressor are running and evaporator temperature cri teria as defined in Section 5 11 1 have been met Whenthe START RUN OFF switch is placed inthe OFF position the defrost timer will be reset to zero Units running in Start Stop will not increment the timer during off cycles For this reason the defrost timer can not attempt to initiate a defrost cycle during an OFF cycle However it is possible that the unit will go into a defrost cycle very shortly after restarting from a Start Stop OFF Cycle if the timer expires at that point b Defrost Air Switch A Defrost Air Switch DAS measures the air restriction through the evaporator coil As ice forms and builds up the air flow is restricted Once enough ice builds up the switch contacts will close and initiate a de frost cycle f the evaporator temperature criteria as defined in Section 5 11 1 have been met The Defrost Air Switch requir
327. harness side of the CSMV connector Locate the wires labeled CSMVA CSMVB CSMVC and CSMVD These will correlate to the connector pins labeled A B C and D See Figure 9 33 Place the Start Run Off switch in the START RUN position DO NOT ALLOW THE UNIT TO START When the MessageCenter displays SMV CLOSING WAIT XXX SECONDS measure the AC voltage be tween pins A and B and then between C and D usinga voltmeter that is set to read AC volts The digital volt meter should read from 10 to 16 VAC for each pair of wires If this test passes there is a good signal com ing from the microprocessor If a reading of 10 to 16 VAC is not present on one or both of the wire pairs check the wiring between the microprocessor and the CSMV connector or check the microprocessor for proper model number configu ration If all the above tests pass the CSMV is operating properly and the abnormal unit operation can be con tributed to something other than the CSMV CSMV Power Head 14 00263 20 Pump the unit down at the king valve Refer to Sec tion NO TAG CAUTION Service mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating Refer to Section 6 2 3 Unplug the CSMV connector from the engine har ness Loosen the 2 1 8 nut on the CSMV and remove the power head assembly See NO TAG Install the new CSMV power head The power head should be set to 100 Open whe
328. hat will be used with ReeferManager as follows The screen saver must be turned off The battery should be capable of running the PC for 30 minutes or the PC should be plugged into an electrical outlet All battery saver features hard drive time out monitor time out etc should be set to more than 30 minutes The download cable must be connected to a 9 pin COM port on the PC USB to COM Port adaptors will not work Follow these steps to use ReeferManager a Connect the computer to the microprocessor using a Download Cable Once the cable is connected to the download port the microprocessor will power up and show PC MODE Start the program by double clicking on the MicroProgrammer icon on your computer desktop Click on the Load File button The Open box will ap pear on the screen Using the mouse select the file you want to load this will be a bex file by clicking once on it to highlight it 6 19 e Click the OK button Watch the lower left message area of the program Once the file is validated the Program Micro button will become active Place the START RUN OFF switch in the START RUN position Wait for the Main Display and MessageCenter to power up Click on the Program Micro button The MessageCenter will go blank If the engine was run ning it will shut down Nothing will happen for the first 5 10 seconds then the software will begin to load The Microprocessor Status L
329. having 13 4 VDC at 75 F 23 9 C This voltage varies with ambient tem perature 5 The battery charging amps are low enough Provisions are made to sense when the battery charging amps are low enough to indicate that the battery is sufficiently charged The battery is sufficiently charged when the charging rate is below that selected in the Configuration List The selectable range is 1 0 to 10 0 amps in 0 5A increments The factory setting is 6 5 Amps See Section 3 6 2 NOTE When conditions 3 thru 5 are met will appear in the Unit Data List for battery voltage b Start Stop Mode Cycle On Conditions A restart will be initiated when one of the following conditions occurs 1 Normal restart 1 The Refrigerated Compart ment Temperature Has Exceeded Selectable Over ride Temperature The microprocessor continually monitors the refriger ated compartment temperature during the Minimum Off Time The unit will restart if the refrigerated compart ment temperature goes beyond the Override Temperat ure above or below set point in the Perishable range or above set point in the Frozen range The Minimum Off Time and the Override Temperatures are selected in the microprocessor Functional Parameter List Refer to Section 3 17 The default value is 20 minutes for the Minimum Off Time and 11 0 F 6 C for the Override Temperature 2 Normal restart 2 The Refrigerated Compart ment Temperature Has Exceeded Standard Over
330. he ENSCU Refer to Electronic Speed Control Diagnostic tables Figure 10 1 thru Figure 10 4 All flash codes must be cleared before continuing Lom Engine Shut Off Manually EN Check for external cause Check for Bad F2 or F3 Fuse Alarm ME pessum for alarm 71 Alarm conditions must be corrected and the alarm cleared pessum T B continue Check Fuel System a Check for Alarm 1 Fill tank as needed b ae fuel flow Unrestricted fuel flow through system ee ee not gelled c Check fuel system prime No air in fuel system d Check fuel system check valve from Check valve must hold fuel and not leak back filter to injection pump 6 Check Fuel Solenoid non ESC engines or Fuel Speed Actuator ESC engines E a Check Run Relay LED LED 28 must be ON b Check voltage to fuel solenoid or START RUN OFF switch in START RUN position Manual ENSCU module Start mode See Note Note 4 More than 11 VDC positive and good ground c Inspect solenoid amp connector pins amp No damage to solenoid or wires terminals for non ESC engines No damaged or corroded pins __Inspect ENSCU module connector pins Wires plugged in amp terminals for ESC engines ENSCU module or wires No damaged or corroded pins Wires plugged in d Inspect harness amp control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins schematic See Wiring Schematic Section 11 e Check resistance of s
331. he alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Microprocessor a Check set point settin E 3 Must be between 22 F to 89 6 F 30 C to 32 C b Enter new set point Reset Microprocessor a Turn START RUN OFF switch off for Microprocessor powers up OK 30 seconds then turn back on b Alarm 248 remains active Replace microprocessor See Note 1 Page 8 2 __ a Clear the inactive alarms All alarms cleared 8 111 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 249 MICROPROCESSOR ERROR TRIGGER ON Microprocessor Input Conversion Error UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset when input conversions are valid or Alarm may be manually reset by turning the unit off then back on again Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as 1 Check Microprocessor a Check Temperature Sensor Data Mi b Check for any Active Sensor Alarms Must all be cleared all be cleared BL Microprecessor amp Unit Wiring devices to the micro sensor input circuits Le Microprocessor 30 seconds then turn back on E b Alarm 249 remains active Replace microprocessor 1 microprocessor
332. he alternator is putting a high charging rate into it then not be sufficient ly charged to restart the engine at the end of a Start Stop Off Cycle The factory setting for this configuration is 6 5 amps This is a general setting that may need to be adjusted for the operating environment of the unit Units operated in colder ambient temperatures may want to decrease this setting to force a higher charge in the battery prior to Start Stop Off Cycle Units operated in warmer ambient temperatures may use a higher setting As a battery ages it is normal for it to require longer re charging periods If the running time is gradually in creasing in Start Stop operation due to the battery re quiring a longer charging period this run time may be shortened by raising the amp setting This may be seen by reviewing downloaded data and looking at the amp reading during prolonged engine Start Stop On Cycles 3 6 3 Restart Voltage A configuration for Start Stop Restart on Battery Volt age allows the microprocessor to restart the unit when the voltage selection has been reached The Configuration may be set from 12 0 to 12 8 Volts in 0 1V increments The factory setting for this configura tion is 12 2V A lower voltage selection may result in a longer off cycle based on battery voltage and possibly overall shorter battery life A higher voltage selection may result in a shorter off cycle based on battery voltage and possibly overall lon
333. he green LED indicates STATUS OK The amber LED indicates CHECK UNIT Amber follows the mi croprocessor fault light and alarms can be read on the microprocessor display 2 6 2 Door and Remote Switches A unit has provisions to connect a Door Switch DS and or two remote switches REMS1 and 2 directly to the microprocessor The microprocessor will recognize switches with con tacts that are either open when the door is open or that are closed when the door is open Additionally the Con figuration List gives you the ability to determine whether the switch will enable the alarm only enable the alarm and also shut the unit down enable the alarm and put the unit into low speed while the door is open or to have TRANSIGOLD ENGINE COOL AUTO Ex ET OUT DEFROST OF TWO LIGHT LED LIGHT BAR no alarm and only record door openings and closings in the Data Recorder If the door or remote switch is configured to shut the unit down when the door is open the unit will shut down fora minimum of three minutes Additionally there is an Override Door Remote Switch in the Functional Para meters Refer to Functional Parameter List Section 3 16 When this parameter is set to YES the Door Re mote Switch Alarm will come on when the door is open However the unit will not shut down This feature is in cluded in the event of a door switch failure EIGHT LIGHT BAR 62 10683 2 6 3 Out of Range Alarm The Out Of Range Alarm is i
334. he micro unit data list ES For Proper Voltage To The Engine Speed Control Unit ENSCU Pin 22 Based On The Model Check For Proper Voltage With Unit Running ESC Engine only SE Ultima XTC and X2 2500A Verify O VDC at terminal 16 of the ENSCU Verify 12 VDC at terminal 22 of the ENSCU b Ultra nc I I NE and X2 2100A Verify 0 VDC at terminal 16 of the ENSCU posce ls 0 VDC at terminal 22 of the ENSCU EXC Speed Solenoid amp Linkage On Non electronic Speed Controlled ESC Engines Fuel and Speed Actuator on ESC engines E Check speed solenoid on standard Must move in and out freely engines Fuel and speed actuator on ESC plunger b Check engine speed arm and linkage Must move freely 4 Force Low Speed Operation See Note 9 Em P Li speed San 10 Functional Parameters set the Unit will run in low speed RPM must be within range Low P Li speed San 10 Start Up Delay to 10 shown above for each specific model Adjust speed minutes linkage as needed b Check operation of Speed Relay LED LED 27 must be OFF c Check voltage at engine speed control Must be 0 VDC unit ENSCU pin 16 5 Check Engine RPM a Check actual engine RPM using hand Refer to Section 2 7 held tachometer Adjust engine linkage setting as needed b Compare actual RPM with those Both readings within 50 RPM shown on display 6 Engine Air Intake System Check air filter indicator Flag must not be vis
335. he microprocessor detects that the ambient temperature has dropped below the pre programmed temperature the unit will switch into ProductShield Winter mode which will force the unit to operate in Continuous Run The unit will continue to operate in Continuous Run for a minimum of 30 minutes After 30 minutes the unit will return to auto Start Stop if the ambient temperature has risen more than 3 6 F 2 C above the pre programmed ProductShield Winter temperature NOTE All of the ProductShield settings may be viewed in the Data List Refer to Section 3 14 For units with Intelli Sets the Data List will reflect the ProductShield settings for the IntelliSet that is currently active 5 17 62 10683 5 17 UNLOADER CONTROL OVERRIDES The compressor unloaders will operate in either a de energized loaded or energized unloaded position depending on current operating conditions The list below shows the conditions that will control the operation of the unloaders in addition to the unloader control used by the temperature control described in section 5 12 There is a delay of 10 seconds between LOADING de energizing compressor cylinders under all operating conditions except engine starting The overrides will be allowed in Cargo Protect Mode if the override does not use the return or supply temperature Unloader Overrides in priority order If an override only applies or takes effect for one unloader continue down the priority list for the ot
336. he microprocessor is calling for Low Speed c Check voltage to speed solenoid FSA Must be 0 VDC voltage cannot be checked on ESC Additional steps on the next page 62 10683 8 32 NO Steps ALARM CAUSE CORRECTIVE ACTION 39 CHECK ENGINE RPM Continued Check Low Speed Engine RPM a Check actual engine RPM using hand Refer to Section 2 7 held tachometer Adjust engine linkage setting as needed b Compare actual RPM with those Both readings within 50 RPM shown on display 8 high speed operation Note9 Check Speed Overrides section 4 4 for more information c Check voltage to speed solenoid on Must be 12 14 VDC standard engines FSA cannot be checked on ESC engines Check High Speed Engine RPM actual engine RPM using hand Refer to Section 2 7 tachometer Adjust engine linkage setting as needed d actual RPM with those Both readings within 50 RPM gros on ur d a Place unit in continuous run and adjust Controller will call for High Speed operation set point to at least 15 degrees away from box temperature and a temperature greater than 20 F 5 6 C If the unit does not immediately go into High Speed set the AIRFLOW Functional Parameter to HIGH b Check operation of Speed Relay LED LED 27 must be ON If LED 27 is not on the microprocessor is not calling for High Speed operation 9 8 33 62 10683 NOT Steps ALARM CAUSE C
337. he minimum length of time the unit will remain off whenever the unit cycles off in Auto Start Stop modes This selects the override restart temperature for the Auto Start Stop Off Cycle During the Minimum Off Time should the refrigerated com partment temperature drift this far above or below setpoint in the Per ishable Range or above set point in the Frozen Range the unit will override the Minimum Off Time and restart OFF There is no maximum off time When a minute value is selected this is the longest amount of time the unit will remain off during a Perishable or Frozen or both Auto Start Stop Off Cycle When this time expires the unit will restart and run for the Minimum Run Time regardless of any temperature change inside the refrigerated compartment This only applies to Frozen set points in Start Stop operation This offset is the number of degrees below set point that the unit will run before cycling off This will allow for a lower average refrigerated compartment temperature when considering temperature rises during off cycles The unit has both a Return Air Sensor and a Supply Air Sensor This selection determines which sensor temperature will be used for set point selections above 10 4 F 12 C to determine when set point is reached Return Air is generally selected for most products Products that are sensitive to small temperature changes may use the Supply Air set ting Supply Air limits the temperature
338. hen Stops en 10 1 10 1 3 Starter Motor Malfunction ccc teen eens 10 2 10 1 4 Malfunction In The Engine Starting Circuit 10 2 10 1 5 Miscellaneous Engine Troubleshooting 10 3 10 2 ALTERNATOR 12 Volt DO 00 ett tenes 10 3 10 3 REFRIGERATION TEMPERATURE CONTROL 10 4 COOL ss ree emt te pe cep diner Wide eei IR Eus 10 4 10 3 2 Unit Runs But Has Insufficient Cooling 10 4 10 3 3 System Will Not Pump Down IH mn 10 4 10 3 4 Unit Operates Long Or Continuously In Cooling 10 4 10 3 5 Unit Will Not Terminate Cooling 10 5 10 3 6 Unit Will Not Heat Or Has Insufficient Heating 10 5 10 3 7 Unit Will Not Terminate Heating 10 5 10 3 8 Defrost Cycle Malfunction n 10 5 10 3 9 Abnormal Press re A De ete Ae ee a aie ee 10 6 10 3 10 Abnormal ch rp e Rr ce x epe t ruo ga epe e e anaes 10 7 10 3 11 Control System Malfunction 0 nh 10 7 10 3 12 No Evaporator Air Flow Or Restricted Air Flow 10 7 10 3 13 Expansion Valve Malfunction 0 0000 cece nh 10 7 10 3 14 Compressor Suction Modulation Valve
339. her must be used on bolts be tween the compressor mounting flange and the engine bell housing The recommended seal ant is Loctite Threadlocker 262 The following figures show the torque value size and grade of the hardware to be used when reassembling the unidrive assembly 9 29 1 Drive Gear When installing a nylon drive gear always a Install with black dot facing steel gear b Use new bolts and locking tabs included in drive gear kit Use Loctite or a similar thread locking compound on threads of drive gear bolts d DO NOT use Never Seez or any other lubricating compound on the nylon drive gear or compressor steel gear The gear must be assembled dry e Torque the 6 bolt nylon drive gear bolts to 30 ft lbs 9 47 62 10683 M8 x 1 25 x 20 mm 19 4 Required 28 ft lbs 3 87 Mkg 5 16 18 x 3 4 lg Grade 8 or 3 8 16 x 1 3 4 lg Grade 5 4 Required 25 ft lbs 3 46 6 Required 30 ft lbs 4 15 3 8 24 x 1 00 Ig Grade 8 28 ft Ibs 3 87 Mkg i jJ Wa a a 90 ft lbs 12 45 M12 x 1 25 x 25 mm lg 8 Required 65 ft Ibs 8 99 Mkg 3 8 16 x 1 lg Grade 5 10 Required 28 ft Ibs 3 87 Mkg NNI TAPI Figure 9 35 Unidrive Torque Requirements Non ESC Engine 62 10683 9 48 M8 x 1 25 x 20 mm 19 6 Required 28 ft Ibs 3 87 Mkg 3 8 16 x 1 3 4 lg Grade 5 6 Required 30 ft Ibs 4 15 Mkg 3 8 24 x 1 00 Ig Grade 8 28 ft lbs 3 87 DIRECT D
340. her unloader a High Ambient If the ambient temperature is above 120 F 48 9 C when the engine starts UL1 and UL2 will both be unloaded for a minimum of 2 minutes and until the ambient air temperature drops below 110 F 43 3 C b Mop Override Maximum Operating Pressure Control UL1 and UL2 will be energized and de energized based on Compressor Suction Pressure CSP Refer to MOP Override Section 5 19 If the unit is operating in Defrost or in HEAT the MOP Override can only UNLOAD the UL1 The UL2 must remain LOADED c Low Suction Pressure High Discharge Pressure Unloading is used along with low speed to increase the suction pressure or decrease the discharge pressure These steps in capacity reduction are taken in the following order 6 cylinder high speed to 4 cylinder high speed to 4 cylinder low speed to 2 cylinder low speed Unloading will take place if the following conditions occur discharge pressure is greater than 435 PSIG 29 6 Bars for 5 seconds or suction pressure is less than 0 PSIG OBar for 30 seconds Therefore if the engine is running at high speed 6 cylinder operation and one of the conditions listed above occurs the compressor will be unloaded from 6 to 4 cylinders UL1 will be energized and the engine will remain in high speed If the condition discharge pressure greater than 435 PSIG or suction pressure less than 0 PSIG does not change to at least a drop in discharge pressure to less than 410 PSIG or an i
341. his message is being displayed will allow user access to Component Test mode COMPONENT TEST MODE MENU SELECTIONS The selections following this message are the components avail able for energizing during Component Test mode CONFIG ERROR REMOVE CARD There was an error configuring the microprocessor with the Config uration PC card Remove the PC card from the slot CONFIGS COMPLETE TO EXIT The user has reached the end of the Configurations list Pressing the UP or DOWN ARROW key will start list over Press the key to exit Configuration list CONFIGURATION MODE Press the key to enter Configuration mode CONFIGURATION NOT CHANGED New configuration selection was not entered saved CONTINUOUS LOCKED CONTINUOUS RUN MODE SELECTED The current set point is within a range that has been locked into the Continuous Run mode Start Stop can not be selected Continuous run mode is selected COPY COMPLETE REMOVE CARD XX 62 10683 A DownLoad PC card has been inserted into the PC card slot and all data from the DataRecorder has been copied onto the PC card You may safely remove PC card from the slot XX indicates the number of empty download slots remaining on the card MessageCenter MESSAGES COPY ERROR REMOVE CARD XX A DownLoad PC card has been inserted into the PC card slot and an error occurred while the data was being copied onto the PC card You may safely remove the PC card from the slot
342. holding the GLOW CRANK switch in the CRANK position until the engine starts This may take up to 10 seconds The GLOW CRANK switch when held in the GLOW position tells the microprocessor to energize the glow plug relay which powers the glow plugs in the engine to preheat the combustion chamber The CRANK position of the switch tells the microprocessor to engage the engine starter If the switch is held in the CRANK position the starter will engage after a short delay of up to one second for a maximum 10 seconds NOTE Manual Start will automatically put the unit in Continuous Run mode Placing the unit in Start Stop will automatically put it back into Auto Start operation Manual Start mode will automatically be can celed when the START RUN OFF switch is toggled to OFF and then back to START RUN Refer to Section 4 2 2 for glow times 3 3 Unit Startup SELF TEST O HEAT COOL DEFROST ALARM START STOP TINUOU SETPONT MAK BOX TEMPERATURE STANDBY ENGINE START RUN
343. ible must not Flag must not be visible visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Additional steps on the next page 62 10683 8 28 PNG se ALARM CAUSE CORRECTIVE ACTION E LOW SPEED RPM Continued 7 Engine Fuel System ER a Check fuel tank level Must have enough fuel to run engine b pasce Ud fuel lines Connections are tight and not leaking No kinks or sharp bends in the lines c Check fuel screen Fuel screen is located in the inlet fitting to the lift pump must be clean d Check fuel filters Fuel filters must be clean and allow full flow of fuel through eee ieee Engine Exhaust Check Engine Exhaust System 1 OE 8 Inspect the exhaust system Must be clear and unobstructed 8 29 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 38 CHECK HIGH SPEED RPM TRIGGER ON Controller is set for high engine speed operation and RPM being read by the microprocessor are not correct The correct RPM for low speed are different for different models as shown below Less than 2000 or greater than 2400 for Ultima XTC and X2 2500A R or Less than 1500 or greater than 1900 for Ultra XTC and X2 2100A R for more than 60 seconds 120 seconds when the microprocessor calls for a change from low speed to high speed UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if controller is set for high engine speed operation an
344. ically as the control system makes adjustments in the system s capacity to maintain compartment temperature when it is close to setpoint 62 10683 5 18 5 18 MAXIMUM SUCTION OPERATING PRESSURE COOL ONLY In Cool Mode the CSMV is used to control Suction Pressure to these MAXIMUM operating limits determined by the compressor speed and number of loaded cylinders as shown in the following table Pressures may be lower depending on ambient and control temperatures etc Table 4 3 Suction MOP Ambient Air Temperatures Ambient Air Temperatures below 108 5 F 42 5 C above 110 3 F 43 5 C 6 Cylinders 4Cylinders 2Cylinders 6Cylinders 4Cylinders 2 Cylinders Ultima XTC and X2 2500 25 PSIG 40 PSIG 76 PSIG 19 PSIG 30 PSIG 70 PSIG 1 7 Bars 2 7 Bars 5 2 Bars 1 3 Bars 2 0 Bars 4 8 Bars igh Spee Ultima XTC 35 PSIG 50 PSIG 76 PSIG 21 PSIG 35 PSIG 60 PSIG and X2 2500 24Bars 1 5Bars 6 2Bars 1 4Bars 24Bars 4 1 Bars Low Speed Ultra XTC a X2 2100 31 PSIG 50 PSIG 76 PSIG 20 PSIG 40 PSIG 70 PSIG Speed 2 1 Bars 1 5 Bars 5 2 Bars 1 4 Bars 2 7 Bars 4 8 Bars igh Spee Ultra XTC and X2 2100 35 PSIG 50 PSIG 76 PSIG 20 PSIG 30 PSIG 60 PSIG 2 4 Bars 1 5 Bars 5 2 Bars 1 4 Bars 2 0 Bars 4 1 Bars Low Speed 5 19 MAXIMUM OPERATING PRESSURE MOP OVERRIDE HEAT AND DEFROST ONLY The microprocessor monitors the suction pressure of the refrigeration system and controls
345. ice CONTROL 5 Engineer or Field Service Engineer SLEEP MODE SETTINGS The following sub menus determine whether sleep mode is to be used and what the settings will be SLEEP MODE NO is the normal operating selection and no further selections will be The following available two sub menu selections will be YES selects Sleep Mode In this mode the unit will operate only as FUNCTIONAL available if YES needed to keep the engine warm and the battery charged There is is selected NO TEMPERATURE CONTROL in Sleep Mode The following Sleep Mode parameters were added in Software Version 04 07 00 NO the unit will remain in Sleep Mode until it is taken out manually NO This can be accomplished either through the Functional Parameter list YES or by turning the START RUN OFF switch to OFF and then back to MORER NE START RUN YES the SET WAKE UP TIME sub menu vill be available SET WAKE UP TIME This setting is used to set Sleep Mode wake up time The clock is a 24 hour clock Hours 1 thru 12 are AM and 13 thru 24 are PM The wake up time must be at least 1 hour and no more than 8 days from the time the clock is set 3 29 62 10683 FUNCTIONAL NO The unit will wake up at the designated time and control to set point RUN PRETRIP YES The unit will wake up at the designated time automatically run AT WAKE Pretrip and then control to set point The Pretrip Pass Fail message will remain in the MessageCenter until the me
346. id Ms Ton YES or FSA and linkage for correct operation PAMAN TANS CENTA carrier cor S Did you find and correct Did you find and correct the condition the condition NO Check System discharge pressure at compressor Is discharge pressure 435PSI or higher NO Check system suction pressure at compressor Is suction pressure 5PSI lower gt System OK v Check engine coolant temperature Is coolant temperature 77 F or below YES YES Is the ambient temp 80 F NO Is unit in igher Has th it been in defrost YES or higher as the unit bee efros v defrost for less than 30 seconds System OK YES and suction pressure is less NO Has the unit been in NO gt than 10 PSI OR Has the unit _ Does the unit have door defrost for more than been in defrost for up to switch or remote switch 5 1 2 minutes 5 1 2 minutes and the YES suction pressure is more m YES gt Is the door open Lihan 10 PSI NO Is the switch configured for low speed NO NO NO Check door switch wiring for an open Did you find and correct the condition YES gt i Are alarms A122 and A123 Is setpoint 10 F or lower Doth ee Check funtional parameter settings
347. igerant flow to match the evaporator load and b prevention of liquid refrigerant entering the compressor Unless the valve is defective it seldom requires any maintenance 9 11 1 Replacing Expansion Valve amp Screen a Pump down the unit by closing the king valve Refer to Section NO TAG b Remove insulation Presstite from expansion valve bulb and then remove bulb from suction line c Remove Presstite from the expansion valve power head Unscrew power head only if the element is be ing changed and replace by reversing steps a through c Use a wet rag to keep TXV cool whenever brazing Heat inlet outlet and equalizer connections to valve body and remove valve Clean all tube stubs so new valve fits on easily e Reverse steps a through d to install new valve and screen with cone of screen pointing into liquid line at inlet to the valve f The thermal bulb is located below the center of the suction line See Figure 9 16 This area must be clean to ensure positive bulb contact Firmly tighten the straps around the thermal bulb and suction line and insulate both with Presstite Evacuate by placing vacuum pump on suction ser vice valve Draw down to 500 microns o Q 9 24 h Open king valve and then check refrigerant level See Section 9 11 4 i Check unit operation by running Pretrip Refer to Sec tion 3 4 9 11 2 Checking Superheat NOTE Do not adjust expansion valve unless abso lutely
348. igure 2 5 Curbside Electronic Speed Control c eect tenet eens 2 6 Figure 2 6 Roadside Electronic Speed Control c cece eens 2 6 Figure 2 7 Evaporator Section Panels and Grille 2 7 Figure 2 8 Control Box Short Box mn 2 8 Figure 2 9 Control Box Redesigned Tall eects 2 9 Figure 2 10 Engine Speed Control Unit ENSCU 0 0 2 eens 2 10 Figure 2 11 Alternator and Regulator ect m 2 11 Figure 2 12 Compressor Cylinder Head Unloaded 2 12 Figure 2 13 Compressor Cylinder Head Loaded 2 13 Figure 2 14 Control Module mr 2 16 Figure 2 15 Display and Keypad ear i a oe T EEEO ee mm 2 18 Figure 2 16 Refrigerant Circuit During Cooling 0 c cece eee eens 2 29 Figure 2 17 Refrigerant Circuit During Heating And Defrost 2 30 Figure 3 1 AutoFresh Air Exchange ee mm 3 38 Figure 3 2 AutoFresh in Closed Position tenets 3 39 Figure 3 3 AutoFresh in Open Position lssssessssssesese emn 3 39 Figure 4 1 Auto Start Sequence cece een 4 2 Figure 5 1 Continuous Run Temperature Control Operating Sequence Perishable Range 5 6 Figure 5 2 Continuous Run Temp
349. ill be used for any calculations RESET CONDITION Auto Reset when Ambient Air Sensor is in range or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Ambient Air Temperature Sensor AAT a Inspect Ambient Air Sensor amp No damage to sensor connector No damage moisture or corrosion in connector b Check Ambient Air Sensor resistance Refer to Section 9 28 for complete resistance chart See Note Note 6 10 000 Ohms 77 F 25 C Check Ambient Air Sensor Wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section 11 b Power microprocessor up See Voltage should be 2 5 VDC volts at harness plug between Note 5 Page 8 2 Disconnect sensor pins from harness Check for voltage at harness plug between pins FROM VECTOR Check Remote Sensor Switch Connector a Locate and inspect 10 way connector Connector must have cap on for optional sensors and switches No corrosion or moisture inside connector If there is a problem with the connector and there are no remote sensors or switches in the uni
350. ime is longer The same ProductShield Econo Go To Start Stop activation conditions must again be met in order for the unit to cycle OFF again While the unit is running and the set point is between 32 and 65 1 F 0 and 18 4 C the FreshProtect settings as selected in the Functional Parameter list will be effective When ProductShield Econo Maximum Temperature is set for OFF and ProductShield Econo Minimum Temperature is set for atemperature the ambient air temperature will be considered to be inside the range whenever the ambient air temperature is higher than the Minimum Temperature setting with no upper limit When ProductShield Econo Maximum Temperature is set for a temperature and ProductShield Econo Minimum Temperature is set for OFF the ambient air temperature will be considered to be inside the range whenever the ambient air temperature is lower than the Max Temp setting with no lower limit When ProductShield Econo Maximum Temperature is set for OFF and ProductShield Econo Minimum Temperature is set for OFF the ambient air temperature will be considered to be inside the range at any ambient air temperature ProductShield ECONO GO TO START STOP EXAMPLES The following examples apply in situations where all other Start Stop conditions have been met Refer to Section 4 3 1 1 If the Econo Minimum Temperature is set to 30 F 1 1 C and the Econo Maximum Temperature is set to 40 F 4 4 C and the ambient air temperat
351. int Is setpoint 10 4F or Is setpoint 10 5F or lower higher Tm Is return air temperature equal to or colder than YES setpoint Is selected probe tem greater NO than 3 6F from setpoint Is speed relay LED27 NO illuminated on the YES micro Did you find and correct the condition Is there a voltage of 12V or higher at QC3 v Check wiring for high resist ance or shorted NO nections Did you find and correct the condition System OK Is there 12V or higher at the Speed Solenoid or FSA v YES Check the speed solenoid or FSA I p and linkage for binding Did you find and correct the condition Review the test results with your supervisor If necessary go to the beginning of the table and test again Figure 10 9 Micro Diagnostic Tree Cond 5 Unit Will Not Run In Low Speed 62 10683 10 18 START HERE What does the CONNECTION OK ReeferManager program NOT CONNECTED display on the bottom of the screen of your PC Are the dates for the data the download There is no screen serial connection Data Recorder date amp time may be set wrong Set the correct date amp time Did you find and correct the condiditon Is the micro status light
352. 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 The receiver is provided with two sight glasses for the observation of liquid level and a fusible plug 62 10683 2 3 8 Compressor Transducers and Sensors a Compressor Suction Pressure Transducer CSP Provides microprocessor with suction pressure information to be displayed recorded the DataRecorder and used to control the refrigeration system It cannot be calibrated It is located near the oil pump on the compressor b Compressor Discharge Pressure Transducer CDP Provides microprocessor with discharge pressure information to be displayed recorded the DataRecorder and used to control the refrigeration system It can be calibrated It is located on the center cylinder head of the compressor c Compressor Discharge Temperature Sensor Transducer CDT Provides microprocessor with compressor discharge temperature information to be displayed recorded in the DataRecorder and used to control the refrigeration system It is located on the center cylinder head of the compressor It will shut the unit down if center compressor head discharge temperature reaches 310 F 154 C for three minutes or 350 F 177 C If ambient temperature sensor AAT is at 120 F 49 C or
353. ion has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active occurs Continue with the steps below as necessary Dome Discharge Pressure Reading EN Check Discharge Pressure Reading Must read valid data 2 Calibrate Discharge Pressure Sensor as a Calibrate Discharge Pressure Sensor Calibration successful successful successfully calibrated 0 A Clear the inactive alarms All All alarms cleared cleared 243 SUCT EVAP CALIBRATE ERROR TRIGGER ON There is an error in the Suction Evaporator Pressure Sensor Calibration value stored in the microprocessor memory or in the memory sector of the microprocessor that the calibration value is stored in UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset when the Suction Evaporator Pressure Sensor is calibrated successfully or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Suction Evaporator Pressure Reading a Check Suction Evaporator Pressure Must read valid data Reading Calibrate Suction Evaporato
354. ion of the gauge manifold to a vacu um pump Remove the discharge hose from the gauge manifold connect one end to the compressor oil fill port and immerse the other end in an open container of refrigeration oil Start the vacuum pump and pull the compressor into a 10 15 vacuum Stop the pump Watch the oil level in the sight glass As it reaches the minimum mark stop the flow of oil from the container Refer to Section 2 10 2 Break any remaining vacuum raise to 0 Bar PSIG with refrigerant remaining in the system crack open the suction service valve or from a fresh drum of re frigerant Replace the oil port plug and evacuate the compressor crankcase Open both service valves before starting the unit 9 13 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 2 10 through the suction service valve flange cavity or by removing the oil fill plug See Figure 9 21 9 13 4 To Remove Oil From The Compressor a Close suction service valve frontseat and pump unit down to 0 07 to 1 to 2 PSIG 0 1 Bar Frontseat dis charge service valve and slowly bleed remaining re frigerant Slowly remove the drain plug from the compressor and drain the proper amount of oil Replace the plug securely back into the compressor Open service valves and run unit to check level r
355. iously displayed Engine Protect Hours e Switch On Protect Hours e Engine Sleep Hours e High Speed Hours e Clutch Cycles e Start Cycles 62 10683 3 24 3 16 FUNCTIONAL CHANGE PARAMETERS e e e e e HEAT COOL DEFROST START STOP CONTINUOUS 20 32345 F SETPOINT BOX TEMPERATURE PRESS TO VIEW SETTINGS MANUAL ALARM LIST SELECT DEFROST oul CONTINUOU mat 1 Press the SELECT key until the MessageCenter displays PRESS 1 TO VIEW SETTINGS 2 By pressing the UP ARROW key you will move through the Function List beginning at the top or by pressing the DOWN ARROW key you will move through the Function List beginning at the bottom 3 To change one of the functions bring the function you wish to change into the MessageCenter and press key f TO SCROLL THEN TO SAVE will show the MessageCenter Pressing either the UP or DOWN ARROW key will begin to change the function setting The MessageCenter will flash indicating that a change has been made that has not been entered into memory Continue pressing the UP or DOWN ARROW key until the desired value is displayed then press the key The MessageCenter will stop flashing The new value is now in memory If the key is not pressed within 10 seconds the MessageCenter will change to FUNCTION NOT CHANGED This will appear for five seconds then return to the last Functional Parameter displayed If no further keys are pres
356. ip Only With the unit running in two cylinder Low Speed Cool the operation of SV1 will be tested for opening and closing If the valve does not operate correctly the CHECK SV1 VALVE alarm will be displayed This test may last up to three minutes Test 12 Check SV4 NOTE The Cool and Heat Pretrip modes will merge to gether at this step With the unit running in two cylinder Low Speed Heat SVA is tested for opening and closing If the valve does not operate correctly the CHECK SV4 VALVE alarm will be displayed This test may last up to eight minutes Test 13 Low Side Pump Down With the unit running in two cylinder Low Speed SV2 and SV4 will all be closed to pump the low side of the unit down If a problem is detected the alarm CANNOT PUMP DOWN LOW SIDE will be displayed Test 13 may last up to eight minutes Test 14 High to Low Side Leakage The unit will shut down and check for pressure equalization between the high and low sides If any leakage is detected the HIGH SIDE LEAK alarm will be displayed This test will last one minute Test 15 Check Discharge Check Valve With the unit off the discharge check valve is checked for leakage If any leakage is detected the CHECK DISCHARGE CHECK VALVE alarm will be displayed Test 15 will last 40 seconds Test 16 Check for Other Alarms The alarm list is checked for any non pretrip alarms that may have occurred during the Pretrip test If any operatio
357. is is the current Date and Time that the DataRecorder is using This may be different than your actual time depending on the Time Zone and Daylight Savings Time selections made by the owner of the unit 3 23 62 10683 3 15 VIEW HOURMETERS e e HEAT COOL DEFROST START STOP CONTINUOUS 20 3245 F SETPOINT BOX TEMPERATURE TOTAL ENGINE HOURS 0 HRS MANUAL 1 alarm List 5 SELECT DEFROST die J 1 Press the SELECT key until the MessageCenter displays PRESS 1 TO VIEW HOURMETERS 2 Press the UP or DOWN ARROW key to move through the Hourmeter List 3 Displayed hourmeters will depend on unit configurations See Section 6 2 1 Typical displayed meters are TOTAL ENGINE HOURS and TOTAL SWITCH ON HOURS 4 Pressing the key will access all other meters and display OTHER METERS AND COUNTERS 5 The selected hourmeter will remain in the MessageCenter for 10 seconds and then the default message STATUS or other customer specified message will appear 6 To lock an hourmeter in the MessageCenter for continuous viewing press the key The hourmeter will flash continuously to indicate it is locked 7 Pressing any key on the keypad will unlock the item Pressing the UP or DOWN ARROW key will move to the next hourmeter Hourmeters available when OTHER METERS AND COUNTERS is chosen are Meters listed in Step 3 above that were not prev
358. is section UltraFreeze operates the same as UltraFresh UltraFreeze control will be used anytime a frozen set point is selected in either continuous or Start Stop operation 62 10683 5 4 5 8 FreshProtect SUPPLY AIR CONTROL FreshProtect operates between set points of 32 0 F 0 C and 65 1 F 18 4 C only When the unit is operating in Start Stop FreshProtect is only functional after the Return Air Temperature is within 0 5 F of set point and criteria for shutdown other than compartment temperature has not yet been reached When the unit is operating in Continuous Run FreshProtect becomes functional once the Return Air Temperature RAT is approximately 10 F 5 6 C above setpoint NOTE FreshProtect only operates when the unit is set for Return Air Control See Table 3 3 for more informa tion on setting controls It does not operate when the unit is in Supply Air Control nor when the unit is in Heat or Defrost cycles FreshProtect places a flexible limit on how far below setpoint the SAT can drop while the unit is operating in Cool Mode Table 4 2 below shows the functional parameter settings and the corresponding ranges below setpoint that the Supply Air Temperature can go when the RAT is 10 F 5 6 C or less above setpoint Whenever the RAT is more than 10 F 5 6 C above setpoint it is possible for the SAT to be lower than the shown range since the air temperature within the cargo area is a considerable distance from its d
359. ished by the safety devices listed in Table 2 7 Table 2 7 Safety Devices Unit Shutdown Safety Devices Unsafe Conditions Safety Device Device Setting High engine cooling water temperature Engine coolant temp ENCT Refer to section 2 7 microprocessor reset Opens at 7 1 2 amps Opens at 10 amps Opens at 7 1 2 amps Opens at 7 1 2 amps Excessive current draw by glow plug circuit Fuse F5 Opens at 80 amps control circuit or starter solenoid SS Excessive current draw by all solenoid Fuse F Opens at 15 amps valves and unloaders and light bar F 6 Excessive current draw by glow crank Fuse F7 Opens at 5 amps switch and START RUN OFF switch Glow Crank switch removed in units built after April 2007 9 Excessive current draw by fuel heater Fuse F8 Optional Opens at 20 amps Excessive current draw by light bar Opens at 3 amps Excessive current draw by Fresh Air Relay Fuse F10 Optional Opens at 40 amps Excessive compressor discharge pressure High pressure cutout switch Refer to section 2 3 8 HPS automatic reset Unsafe Conditions Safety Device Low Engine Oil Level Low Engine Oil Level Switch Engine oil level is more than 7 May be configured for alarm only or alarm ENOLS quarts low and shutdown Low Fuel Level Low Fuel Level Switch or See Trigger On criteria for May be configured for alarm only or alarm Low Fuel Level Sensor alarms 1 and 19 in Section 8 and shutdown 2 o wn 2
360. isplay and Keypad module is located for operator access at the lower roadside corner of the unit The display board is mounted in the Keypad and Display module The display board includes the LCD display keypad and keypad interface The Display and Keypad module provides the user with a panel to view and control the functions of the refrigeration unit The module consists of a switch keypad MessageCenter and main display Setpoints and other system information are selected using the keypad The previous figure shows the Display and Keypad module Display The main display has nine characters seven seven segment characters and two nine segment characters two decimal points two commas and a degree symbol The display is used to provide the user a setpoint and refrigerated compartment temperature either in degrees Centigrade or Fahrenheit The comma symbols are used as the decimal indicators in Europe When Metric Units is selected in the Functional Parameters the two comma icons are used instead of decimal points When English Units is selected in the Functional Parameters decimal points are used Temperature display is right justified with unused digits blank A negative sign will be displayed for all setpoint and refrigerated compartment temperatures below Zero A positive sign will be displayed for all setpoint and refrigerated compartment temperatures above 0 which will not have a sign in front of it The resolution for re
361. isplayed recorded in the data recorder and used to control the refrigeration system It is located in the center of the return air grille c Supply Air Temperature Sensor SAT The SAT is a temperature control probe which provides microprocessor with supply air temperature information to be displayed recorded in the data recorder and used to control the refrigeration system It is located in the supply air nozzle 2 5 SYSTEM OPERATING CONTROLS AND COMPONENTS The temperature controller is a Carrier Transicold Advance Microprocessor Refer to Section 2 5 3 and 3 Once the microprocessor is set at the desired temperature the unit will operate automatically to maintain the desired temperature within very close limits The microprocessor consists of two modules the con trol module See Figure 2 14 and the display and key pad module See Figure 2 15 The control box includes manual switches a microprocessor fuses and associated wiring Standard equipment includes an Auto Start Stop feature This feature provides automatic cycling of the diesel engine which in turn offers an energy efficient alternative to continuous operation of the engine with control of temperature by alternate cooling and heating of the supply air evaporator outlet air 2 15 2 5 1 Multiple Languages Messages in the MessageCenter can be displayed in English French Portuguese or Spanish Press and hold the Select Key for 6 seconds to view or chan
362. it Must be O VDC for all units running Check Engine RPM a Check actual engine RPM using hand Refer to Section 2 7 held tachometer Adjust engine linkage setting as needed b Compare actual RPM with those Both readings within 50 RPM shown on display Check Engine Air Intake System a Check air filter indicator Flag must not be visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions 6 Check Engine Exhaust System _ a Inspect the exhaust system Must be clear and unobstructed 62 10683 8 84 NO Steps ALARM CAUSE CORRECTIVE ACTION P175 CHECK HIGH SPEED RPM TRIGGER ON With Speed Relay turned on voltage at the speed solenoid Engine Speed Control Unit for high speed operation engine RPM are NOT Between 2000 and 2300 for Ultima XTC X2 2500A R or Between 1700 and 2000 for Ultra XTC X2 2100A R UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with hc ILE below as necessary BE Speed Solenoid amp Linkage On Non Electronic Speed Controlled ESC Engines Or The fuel And Speed Actuator On ESC Engines Check sp
363. it is in pullup mode RAT is still far away from set point and the unit is operating in heat and the SAT is the same temperature or colder than RAT 2 7 ENGINE DATA Table 2 4 Engine Data 2 gallons 7 6 liters 50 50 mix never to exceed 60 40 15 quarts 14 liters Winter Diesel No 1 Summer Diesel No 2 7 0 amps per plug at 10 5 VDC nominal Engine Model Displacement No Cylinders Weight Coolant Capacity Oil Capacity with Filter Fuel Glow Plug Amperage CAUTION Use only ethylene glycol anti freeze with 2 7 1 Lubrication System a Oil Pressure 40 to 60 PSIG 2 7 To 4 1 Bars inhibitors in system as glycol by itself will damage the cooling system Always add pre mixed 50 50 anti freeze and water to ra diator engine Never exceed more than a 60 concentration of anti freeze Use a low silicate anti freeze meeting GM specifica tions GM 6038M for standard life coolant or Engine in high speed b Oil Pressure Safety Switch Setting Closes 15 3 PSIG 1 02 2 Bars c Lube Oil Viscosity Outdoor Temperature use Texaco Havoline extended life coolant or any other extended life coolant which is Dexcool approved and has 5 150 5 years 150 000 miles on the label Fahrenheit Centigrade Mobil Delvac 1 BW 400r 15W40 uu Extended Service Interval ESI packages are standard on X units beginning with S N JAB90602792 The ESI package reduces the frequency of scheduled service interval
364. it to cycle off If O K does not appear this condition has not been met and the unit is not ready to cycle off 5 The Maximum Off Time has expired In some ambient conditions there are times when the unit may be off for very long periods of time To ensure that the load stays within safe temperature ranges the Maximum Off Time may be used to force the unit to re start regardless of any change in refrigerated compart ment temperature Maximum Off Time is selected in the microprocessor Functional Parameter List The default setting is OFF NOTE The unit may remain in low speed for some time after engine start up when in the Start Stop Mode due to the High Speed Delay Functional Parameter The High Speed Delay is selected in the microprocessor Functional Parameter List Refer to Section 3 17 The default value is 10 minutes c Start Stop Indicator To indicate that the unit is in the Start Stop mode the Start Stop LED indicator on the keypad will be illumi nated d Failed To Start Auto Mode If the unit fails to start after three start attempts the Alarm A31 FAILED START AUTO MODE will ap pear in the MessageCenter and the Alarm LED on the Keypad will flash on and off once a second NOTE X2 units only During a Start Stop OFF cycle the micro continues to monitor the ambient air temperature If the ambient air temperature rises to115 F 46 C SV4 will energize for 45 seconds to equalize the refrige
365. it will go to High Speed 6 Cylinder Cool Figure 5 1 Continuous Run Temperature Control Operating Sequence Perishable Range 3 2 1 8 2 3 F 1 3 C le a l o O 2 o FALLING BOX TEMPERATURE High Speed 6 Cylinder Cool Low Speed 6 Cylinder Cool UltraFreeze 2 Cylinder Cool Null RISING BOX TEMPERATURE 3 6 F 42 0 C 2 7 F 1 5 Figure 5 2 Continuous Run Temperature Control Operating Sequence Frozen Range 62 10683 5 6 High Speed 6 Cylinder Cool 3 2 F 1 8 C Low Speed 6 Cylinder Cool 2 3 F 1 3 2 3 F 1 3 C Low Speed 2 Cylinder Cool CSMV CONTROL 0 5 0 3 C Start Stop Off Cycle Low Speed 2 Cylinder Heat P e gt o 2 7 F 1 5 C Low Speed 6 Cylinder Heat 3 6 F 2 0 C High Speed 6 Cylinder Heat FALLING BOX TEMPERATURE RISING BOX TEMPERATURE 3 6 F 2 0 2 7 F 1 5 0 5 F 0 3 C 2 3 F 1 3 3 2 F 1 8 C Once the Minimum Run Time has expired the compressor will operate in 6 cylinders depending on suction pressure During the Minimum Off Time the unit will restart at Override Temperature selected in the Functional Parameter List Note System can change from Low Speed 2 Cylinder Cool to Low Speed 6 Cylinder Cool when the box temperature rises However o
366. itch is forcing the unit into a Shut down this alarm may be temporarily overridden by setting the correct Func tional Parameter 8 47 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 8 7 ELECTRICAL ALARMS 71 BAD F2 OR F3 FUSE TRIGGER ON One or more of the following fuse circuits have been open for more than 2 seconds F2 Speed Relay output circuit or F3 Run relay output circuit UNIT CONTROL Alarm Only RESET CONDITION Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Unit Operation a Did unit shut down Yes Check F3 No Check F2 Check Fuses a Locate blown fuse s Will have open circuit b Verify fuse size Refer to Section 2 12 Must be correct rating for circuit see wiring diagram c Inspect fuse amp fuse holder Terminals tight No signs of overheating melting or discoloration Check Circuit a Check amperage draw on Speed Relay Refer to Section 2 13 circuit b Check amperage draw on Run Relay Refer to Section 2 13 circuit 72 BAD F4 OR F6 FUSE TRIGGER ON One or more of the following fuse circuits have been open for more than 2 seconds F4 Clutch Relay output circuit or F6 SV amp UL va
367. ith any of the listed components the corresponding alarm will be displayed Test 3 Temperature and Pressure Sensor Check Check the condition of the following sensors e Return Air Sensor e Supply Air Sensor e Engine Coolant Sensor e Battery Voltage Sensor e Ambient Air Sensor e Defrost Termination Sensor e Compressor Discharge Sensor Test 3 will last approximately five seconds If a problem is detected with any of the listed components the corresponding alarm will be displayed 62 10683 PRETRIP Continued Test 4 Warm Up The engine is started automatically and the ambient air sensor is read The Pretrip splits into two modes at this point as the engine and compressor are allowed to run and be warmed up If the ambient temperature is above 32 F 0 C the unit will operate in the Cool Pretrip mode If the ambient temperature is at or below 32 F 0 C the unit will operate in the Heat Pretrip mode In the Cool Pretrip mode the unit will operate in two cylinder Low Speed Cool The compressor suction and discharge pressures will be tested Appropriate alarms will be displayed if any problem is detected Test 4 in Cool Pretrip will last approximately 60 seconds In the Heat Pretrip mode the unit will operate in four cylinder Low Speed Heat The micro will check for a rise in compressor discharge pressure fan clutch operation and SV1 operation Appropriate alarms will be displayed if any problem is
368. k to see if the unit has a For units with a GCS continue with Step 2 below Ss SEEN BS 2007 do PA For units without a GCS check the wiring that would connect to the switch if it were present for shorts It is not for location of switch possible to place the unit in Manual Start Mode without energizing this circuit 2 Check For Flash Code On Engine Speed Control Unit ENSCU Applies to ESC engines only a Check for flash codes on the ENSCU Refer to Electronic Speed Control Diagnostic tables Figure 10 1 thru Figure 10 4 There must be no LED flashing alarm codes occurring to continue Operator Failed To Crank Engine aM a Manually start unit Engine starts and runs Check Fuel Level In Tank __ a Check fuel gauge on tank Fill tank as needed Check For Check Glow Plugs Alarm a Check for alarm 40 Alarm conditions must be corrected and the alarm cleared to continue 6 Manual Glow Crank Switch GCS Only for units with a GCS a Check the glow crank switch No damaged or corroded pins No physical damage b Check voltage to glow crank switch START RUN OFF switch in START RUN position Manual Voltmeter lead on Battery post Start mode See Note Note 4 Voltmeter lead on switch terminals ws With wires connected to switch Position Terminals vDo min 2 amp 3 0 V min Glow 1 amp 3 10 1 2 V min 2 0 V min Disconnect wire to Starter Solenoid before checking Crank 1 amp 2 11 1 2V
369. ke 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 ZEROED The Defrost Air switch MUST be in the same orientation as it will be in when installed in the unit 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 9 34 c Install tee in pressure line to high side connection Tee should be approximately halfway 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 62 10683 9 44 With the gauge reading at zero apply air pressure very slowly to the air switch An ohmmeter will indi cate continuity when switch actuates The switch contacts should close and the ohmmeter needle move rapidly to 0 Any hesitation in the ohmmeter in dicates a possible problem with the switch and it should be replaced Referto Section 2 11 for switch settings If switch fails to actuate at correct gauge reading adjust switch by turn ing adjusting screw clockwise to increase setting or counterclockwise to decrease setting Repeat checkout procedure until switch
370. kly but will begin to rise to a minimum of 250 PSIG 17 0 Bars within 15 to 20 minutes If suction and discharge pressures remain low and the receiver level does not drop the valve may be inoperative and can be checked by the following method 1 Verify the solenoid coil has proper voltage and is en ergized in heating and defrosting 2 Connect a discharge pressure gauge to the compres sor discharge service valve and connect a gauge to the manual shut off valve king valve leaving the re ceiver tank 3 With the refrigerated compartment temperature at 35 F 1 7 C or lower operate the unit in high speed cool and remove or disconnect the GND wire lead ing to the SV1 coil 4 With a separate 12 VDC negative ground wire energize SV1 with the unit in high speed cooling and observe the discharge and receiver pressures If the valve is closing properly compressor discharge pres sure will begin to rise and the receiver pressure will remain the same or begin to drop slowly If the valve is not seating properly both discharge and receiver pressure will rise slowly or remain the same 5 Operate the unit until discharge pressure reaches 200 PSIG 13 61 Bars and disconnect jumper wire to SV1 valve Discharge and receiver pressure should be within 5 to 15PSIG 0 34 to 1 02 Bars of each oth er b Replacing the SV1 Coil NOTE The coil may be replaced without removing the refrigerant or pumping the unit down 1 Rem
371. l ON OFF Temp Sensor 1 3 plug This enables Remote NOTE Sensor s on DataRecorder pon Sensor 1 3 to be read through the Data must also be set RE OFF There is no Remote Sensor 1 3 in this unit SWITCH NOT SWITCH NOT INSTALLED There is no door INSTALLED switch in this compartment OPEN SWITCH DOOR OPEN SWITCH OPEN A door switch has DOOR SWITCH OPEN been installed on one of the refrigerated compart Optional ment doors The switch contacts will be OPEN NOTE Door Switch must be set to whenever the door is OPEN be recorded on DataRecorder OPEN SWITCH DOOR OPEN SWITCH CLOSED A door switch CLOSED has been installed on one of the refrigerated compartment doors The switch contacts will be CLOSED whenever the door is OPEN ALARM ONLY ALARM ONLY When Door switch indicates that the door is open a warning alarm will be displayed in the MessageCenter UNIT SHUTDOWN UNIT SHUTDOWN When Door switch indicates that the door is open a warning alarm will be dis DOOR SWITCH UNIT played in the MessageCenter and the unit will shut SHUTDOWN down Optional Optional LOW ENGINE LOW ENGINE SPEED When Door switch indi SPEED cates that the door is open the engine will be forced to low speed DATA RECORDER ONLY 6 9 62 10683 CONFIGURATION SELECTIONS DESCRIPTION NOT INSTALLED NOT INSTALLED This remote switch is not installed in this unit DOOR OPEN DOOR OPEN SWITCH OPEN The Remote SWITCH OPEN switch will b
372. lace tension on belt using hand by ey force only Do not use pry bar or excessive force as it a Make sure negative battery terminal 15 disconnected may cause bearing failure For correct belt tension and remove old belt see Table 9 3 Tighten pivot and adjustment bolts b Place V belt on alternator sheave and then install al ternator with two bolts loosely in position e Reinstall negative battery cable Gearbox to Fan Shaft Belt Torque to 80 ft lbs 11 1 Engine to Gearbox Belt Alternator Torque to 15 to 16 ft lbs 2 1 to 2 2 Mkg Water Pump Alternator Crank shaft Belt Figure 9 11 V Belt Arrangement None ESC Engine 62 10683 9 18 Gearbox to Fan Shaft Belt Engine to Gearbox Belt Torque to 80 ft lbs 11 1 Alternator Torque to 15 to 16 ft lbs 2 1 to 2 2 Mkg Water Pump Alternator Crank shaft Belt Figure 9 12 V Belt Arrangement Electronic Speed Control Engine 9 9 3 Gearbox To Fan Shaft V Belt AX WARNING Keep hands and arms away from unit when operating without belt guard in place Never release a unit for service without the belt guard securely tightened in place a To Replace V belt 1 Disconnect negative battery cable and remove V belt guard 2 DO NOT START UNIT UNTIL V BELT GUA
373. larms Any active alarms must be corrected and cleared before proceeding 6 Check Delta T a Calculate SAT minus RAT or check In cool SAT must be at least 1 F 0 6 C than RAT Delta T value in Data list In heat SAT must be at least the same temperature as RAT or warmer Perform Pretrip Check plur xc Re S 8 39 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 54 DEFROST NOT COMPLETE TRIGGER ON Defrost cycle did not terminate automatically DTT2 and SAT did not reach termination temperature of 55 F 12 8 C within 45 minutes UNIT CONTROL Alarm Only While this alarm is active the Defrost Timer will be temporarily set to initiate a defrost cycle 90 minutes 1 5 hours of unit running time after the alarm comes on RESET CONDITION Auto Reset when defrost cycle is started again or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Perform Pretrip Check a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding 2 Check For Defective Defrost Sensor Location Correct Installation a Has sensor fallen from location Must be corrected to co
374. ld up of CO and the depletion of by using fresh air exchange in addition to accurate temperature control AutoFresh Air Exchange provides the ability to control the amount of fresh air without the need for manual intervention while in transit AutoFresh Air Exchange can also be used to lower the humidity level within a refrigerated compartment IF the ambient air has a lower humidity level AutoFresh Air Exchange is a factory installed option as it requires a modified evaporator pod See Figure 2 7 When AutoFresh Air Exchange is operational and ON two air ports open The upper port allows fresh ambient air to enter while stale air exits through the lower port AutoFresh Air Exchange is available for all setpoints at or above 28 F 2 2 C AutoFresh Air Exchange is not operational when the setpoint is set below 28 F 2 2 C or when the unit is in Defrost or when the unit has cycled off in Auto Start Stop Refer to Section 3 20 4 for more information on AutoFresh Air Exchange 2 4 4 Evaporator Transducers and Sensors a Defrost Termination Temperature Sensor DTT The DTT is located on the curbside evaporator support bracket above the coil It senses the temperature of the evaporator and allows defrost initiation once the tem perature falls below 40 F 4 4 C b Return Air Temperature Sensor RAT The RAT is atemperature control probe which provides microprocessor with return air temperature information to be d
375. lection 3 31 LIGHT BAR 2 22 9 43 Light Bar Operation and Test 9 43 Lube Oil And Flow Diagrams 9 14 Lube Oil Filter 9 14 Lube Oil Flow Diagram 9 15 Lubrication System 2 25 Maintenance Schedule 9 1 Manual Defrost 3 15 Manual Start Glow amp Crank 3 2 Max Operating Pressureoverride 5 19 Measuring Superheat 9 25 MessageCenter 2 20 MessageCenter 7 1 Microprocessor Replacement 6 22 Microprocessor Sensor Checkout 9 45 N Normal Defrost Operation 5 9 Normal Defrost Termination 5 9 Normal Defrost Termination Sequence 5 9 Null Mode Operation 5 4 Oil Filter 9 14 PC Mode 6 1 PC Support Software 6 14 Perishable Set Point Ranges 5 1 Pretrip 3 4 Pretrip Inspection 9 4 Priming Fuel System 9 11 ProductShield 5 14 Pulldown Pull up Mode 5 2 Pulsed Null Mode Operation 5 4 R Re Setting PM Hourmeters 6 20 Receiver 2 13 Receiver Fuse Plug Setting 2 26 Receiver Sight Glass 9 38 ReeferManager 6 14 Refrigerant Circuit Cooling 2 29 Refrigerant Circuit Heating amp Defrosting 2 30 Refrigeration System Data 2 26 Remote Switches 2 23 Remove Jumper Mode 6 2 REPLACING CHECK VALVE 9 32 Replacing Compressor Discharge Pressure Transducer 9 36 Replacing Compressor Suction Pressure Transducer 9 37 Replacing Display Bezel Assembly 6 27 Replacing Expansion Valve amp Screen 9 24 Replacing SV1 Internal Components 9 40 Replacing SV2 SV4 internal par
376. lid data in the data recorder to copy onto the PC card The PC card may safely be removed from the unit NO INACTIVE ALARMS There are no inactive alarms in the Alarm list NO INSTALLS LEFT REMOVE CARD An Option PC card has been inserted into the PC card slot and all install options have been used The PC card may safely be re moved from the unit OLD INTELLISETS USE REEFERMAN _ The IntelliSets that are on the Configuration PC Card were written with too old of a PC Program like ServiceManager The software in the microprocessor requires IntelliSets to be written to the Configu ration PC Card using ReeferManager Rewrite the information to the card using ReeferManager then use it in the microprocessor again OLD SW CANNOT LOAD REMOVE A Program PC Card has been inserted into the PC Card slot and CARD the major version of the program on the PC Card is an older vers ion than what is already loaded in the microprocessor Software with older major versions can not be loaded into the micropro cessor Remove the PC Card Refer to Section 6 5 1 for software version description OLD SW LOAD 1 TO CANCEL A Program PC Card has been inserted into the PC Card slot and the minor version of the program on the PC Card is an older ver sion than what is already loaded in the microprocessor Press the key to load the older program Refer to Section 6 5 1 for software version description PC MODE Indicates that the conditions for enterin
377. ls See No damaged or corroded pins wiring schematic Section iD 8 71 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION P150 CHECK SV4 CIRCUIT TRIGGER ON Normal Amps for the SV4 Circuit is 0 75 to 2 0 Amps The circuit tests outside this range UNIT CONTROL Pretrip will abort and PRETRIP FAILED IN TEST 2 will be displayed in MessageCenter RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE T the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with ne as below as necessary 1 Check For Bad F4 Or F6 Fuse Alarm Ie Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue E Check SV4 E a Check resistance of SV4 Refer to Section 2 13 b Check amp draw of SV4 Use Component Test mode Section 6 2 2 to test Refer to Section 2 13 for amp values View current draw in the Unit Data list Refer to Section 3 14 SV4 amp Circuit a Inspect SV4 and wiring No physical damage to harness No damaged or corroded pins b Start unit with setpoint more than 10 F Unit running in Heat Cycle 5 5 C above box temperature and set above 11 F 11 6 C See note Note 9 c Check operation of SV 4 FET 9 LED must
378. lts Compressor Bell Housing Key Compressor Drive Gear Locking Tab Nylon Drive Gear Drive Sheave Bolts V Belt Engine Adapter Drive Sheave 1 2 3 4 5 6 7 8 9 Figure 9 19 Compressor Drive Assembly 9 29 62 10683 9 13 CHECKING COMPRESSOR OIL LEVEL CAUTION Service mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating Refer to Section 6 2 3 9 13 1 To Check The Oil Level In The Compressor a Operate the unit in high speed fully loaded cool for at least 15 minutes Unplug wires to the unloaders if necessary to ensure six cylinder operation NOTE Check the oil sight glass on the compressor to ensure that no foaming of the oil is present after 15 minutes of operation If the oil is foaming check the refrigerant system for flood back of liquid refrigerant Correct this situation before performing step 2 b After 15 minutes initiate a defrost cycle This will al low any residual oil to be returned to the compressor NOTE Operate the unit in defrost for 3 5 minutes only Do not allow the unit to terminate defrost automatically The sudden reduction of crank case pressure at defrost termination could cause a temporary increase in oil circulation and gave a false oil level reading c After 3 5 minutes of defrost operation turn the unit off and wait 5 15 seconds Observe the compressor oil level in the sight glass See Figure 9 20 Oil l
379. lue selected in order to enter Start Stop NOTE Ifthe unitis set for Continuous Run and ProductShield Econo is configured for GO TO CONTINUOUS or OFF the unit will remain in Continuous Run 62 10683 5 14 Once the microprocessor detects that the above criteria have been met the unit will switch from Continuous Run toa Start Stop Off Cycle and remain Off for the Minimum Off Time as set in the Functional Parameter list A restart will be initiated when one of the following four conditions occurs a Normal restart 1 The Refrigerated Compartment Temperature Has Exceeded Selectable Override Tem perature The microprocessor continually monitors the refrigerated compartment temperature during the Minimum Off Time The unit will restart if the refrigerated compartment temperature goes beyond the Override Temperature above or be low set point in the perishable range or above set point in the frozen range The Minimum Off Time and the Override Temperatures are selected in the microprocessor Functional Parameter List Refer to Section 3 17 The default value is 20 minutes for the Minimum Off Time and 11 0 F 6 C for the Override Temperature b Normal restart 2 The Refrigerated Compartment Temperature Has Exceeded Standard Override Tem perature After the Minimum Off Time has expired the microprocessor continually monitors the refrigerated compartment tem perature If the refrigerated compartment temperature goes more than 3 6 F 2 0 C
380. lug 1MP26 Check Circuits With Test Substitute Sensor a Substitute known good sensor and clear alarm Start unit and run for 30 Alarm should not come on Install new sensor if seconds necessary b Check to see if alarm re occurs 8 3 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION LOW FUEL LEVEL WARNING for units with Low Fuel Level switch no fuel level display in Data list TRIGGER ON Fuel level is less than 1 8 of a tank for more than 30 seconds UNIT CONTROL Alarm only RESET CONDITION Auto reset when fuel level is above 1 4 tank for more than 30 seconds Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check For Low Fuel Level aM a Check fuel level in the fuel tank Add fuel as needed to the fuel tank Check Fuel Level Switch a Inspect fuel level switch amp connector No physical damage to switch pins amp terminals No damaged or corroded pins in plug b Check fuel level switch operation Place unit in Component Test Mode Run Relay On or in Manual Start Mode see Note Note 4 DO NOT START UNIT c Check for voltage at harness plug Voltage should be approximately 12VDC at h
381. lves Buzzer amp Fuel Heater Relay coil circuit UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset when the fuse is replaced and the unit is powered up or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Fuse a Locate blown fuse Will have open circuit b Verify fuse size Refer to Section 2 12 Must be correct rating for circuit see wiring diagram c Inspect fuse amp fuse holder Terminals tight No signs of overheating melting or discoloration Check Circuit a Check amperage draw on clutch circuit Refer to Section 2 13 b Check amperage draw on F6 circuit Refer to Section 2 13 See wiring schematic 62 10683 8 48 NO Steps ALARM CAUSE CORRECTIVE ACTION 78 CHECK SV1 CIRCUIT TRIGGER ON In either the Heat Null or Defrost cycles the SV1 coil circuit is shorted The SV1 output from the micro is negative so the circuit will not be shorted to ground but is shorted either within the SV1 coil itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when unit calls for Heat or Defrost and the SV1 coil current amp draw is normal or Alarm ma
382. ly closing 0 Open the Compressor Suction Modulation Valve CSMV The CSMV will then open When it reaches 3096 the starting sequence continues by energizing the Run and Clutch relays along with the solenoid valve SV2 and both unloaders UL1 and UL2 After 5 seconds the Glow Plug Relay GPR will energize to supply power to the glow plugs and the buzzer will sound for 5 seconds before the starter is energized On initial power up there will be a 5 second delay before the starting sequence begins Ifthe required glow time is zero warm engine short glow time the microprocessor will energize the starter after a 5 second delay The engine will crank for a maximum of 10 seconds or until the engine is running The glow relay will also be de energized at the same time the starter disengages If the engine does not start a 15 second rest period will elapse before the next start attempt The Run Relay Clutch Relay both unloaders and SV2 will remain energized and CSMV will remain in pre start position until the next starting sequence Before beginning another starting sequence the oil pressure is checked to determine if the engine is running or the RPM sensor has failed For the second and third start attempts the glow time is increased by 5 seconds over the glow time of the first attempt listed below The microprocessor allows three start attempts without the engine starting before the starting is locked out and the Failed To Start
383. ment does not correct the trouble replace necessary parts or gaskets Swelled or distorted gaskets must always be re placed 3 Air Filter Service Indicator The air filter indicator is connected to the engine air intake manifold and its function is to indicate when the air filter requires replacement During operation when a plugged air cleaner causes the intake manifold pressure to drop to 20 500 mm WG the indicator will move to the red line The air cleaner should then be replaced and the indicator reset by pressing the reset button b Air Filter Service Procedure 1 Release 2 clips on air cleaner housing and remove bottom cover 2 Remove filter element wipe inside of air cleaner housing clean and install new filter element 3 Wipe inside of bottom cover clean and re install 4 Re secure 2 clips on air cleaner housing and close roadside door 9 8 9 Engine Crankcase Breather The engine uses a closed type breather with the breather line attached to the cylinder head cover See Figure 9 9 The breather assembly should be cleaned once a year or at every 2000 hours maintenance interval whichever comes first See Table 9 1 1 Screw 2 Breather Cover 3 Breather Valve 4 Breather Tube Figure 9 9 DI Engine Crankcase Breather 9 8 10 Glow Plugs a Servicing Glow Plugs The total circuit amp draw for the glow plug circuit is checked during a Pretrip cycle The glow plugs when energized draw a nomi
384. min 3 0 V min min c Check voltage to glow plugs Glow Plug switch ON Manual Start mode More than 11 VDC d Check voltage to starter solenoid Crank switch ON Manual Start Mode More than 11 VDC Check Glow Crank Switch Harness All Units a Inspect harness amp control box physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins schematic Additional steps on the next page 62 10683 8 22 32 FAILE al Mis ERE ALARM CAUSE CORRECTIVE ACTION D TO START MANUAL Continued Check Fuel Solenoid Applies to non ESC engines only a Check Run Relay LED LED 28 must be ON b Check voltage to fuel solenoid START RUN OFF switch in START RUN position Manual Start mode See Note Note 4 More than 11 VDC positive and good ground c Inspect solenoid amp connector pins amp No damage to solenoid or wires terminals No damaged or corroded pins Wires plugged in amp d Inspect harness control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins schematic See Wiring Schematic Section 11 e Check resistance of solenoid Refer to Section 2 13 f Check operation of solenoid Plunger must move in when energized Check Fuel Solenoid Harness a Inspect harness amp control box No physical damage to harness connector pins amp terminals See Wiring No damaged or corroded pins Schematic Se
385. modes to see if any active alarm occurs Continue with us dus below as necessary 1 Check For Bad F2 Or F3 Fuse Alarm NS Check for alarm 71 Alarm conditions must be corrected and the alarm cleared to continue Ms Speed Solenoid Non ESC engines Ex Check resistance of speed solenoid Refer to Section 2 13 b Check amp draw of speed solenoid Use Component Test mode Section 6 2 2 to test Refer to Section 2 13 for amp values View current draw in the Unit Data list Refer to Section 3 14 2B Check Circuit For High Resistance ESC engines EE Check amp draw of engine speed Use Component Test mode Section 6 2 2 to test control circuit ENSCU pin 16 and Refer to Section 2 13 for amp values on the micro View current draw in the Unit Data list Refer to Section 3 14 Check Speed Solenoid amp Circuit RE pe speed solenoid and wiring No physical damage to harness No damaged or corroded pins pm damage to solenoid b Check operation of Speed Relay LED LED 27must be ON c Check voltage to speed solenoid Must be 11 VDC or higher across the 2 wires 4 Check Speed Solenoid Circuit Wiring BH Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section ib 62 10683 8 70 NO Steps ALARM CAUSE CORRECTIVE ACTION P148 CHECK SV1 CIRCUIT TRIGGER ON Normal Amps for the SV1 Circuit is 0 75 to 2
386. move the 4 5mm x 20mm lg hex head bolts holding the bezel assembly to the bracket Care fully separate the bezel assembly from the bracket Disconnect the wiring harness from the display board and the START RUN OFF switch Display Bezel Assembly Installation CTD P N 91 00312 02SV 4 CAUTION Do not over torque screws Torque all screws to 11in Ibs 1 2 Nm g NOTE Eleven Phillips head screws are used to retain the keypad to the bezel 8 3 4 Lg screws around the perimeter of the keypad and 3 3 8 Lg blunttip screws in the center of the keypad Four 3 8 Lg Phillips head screws are used to retain the display board to the keypad Remove the old gasket from the door mounting bracket Ensure that the surface is completely free of any old gasket material and apply the new gasket included in the kit to the bracket Plugthe wire harness into the new display board and reconnect the wires to the START RUN OFF switch Secure the bezel to the control door with the 4 5mm X 20mm Ig hex head bolts Torque bolts to 26 in Ibs 2 9 Nm Fasten bezel and bracket assembly to unit side door using 4 hex head 1 4 20 bolts Reconnect wire harness 10 pin connector from the microprocessor Reconnect negative battery cable and run Pretrip to check unit operation DISPLAY WINDOW DETENT SPRINGS DETENTS KEYPAD DOOR WINDOW GASKET DISPLAY BOARD KEYPAD BOARD DISPLAY BEZEL WINDOW GASKET NO
387. mperature determined in Step f from the average temperature measured in Step g The difference is the superheat of the suction gas 62 10683 62 10683 Refrigerant Recovery Unit Refrigerant Cylinder Manifold Gauge Set Valve Evacuation Manifold Vacuum Pump Vacuum Gauge King Valve Receiver 10 Condenser 11 Evaporator 12Discharge Service Valve 13 Suction Service Valve 14 Compressor 15 Compressor Suction Modulation Valve CSMV Figure 9 17 Vacuum Pump Connection 9 26 4 CAUTION Service mode MUST be used whenever moving refrigerant charge refrigerant leak checking or evacuating Refer to Section 6 2 3 CAUTION Do not vapor charge R404A Only liquid charging through the receiver outlet king valve is acceptable 9 11 4 Checking The Refrigerant Charge NOTE High speed operation at some conditions may create high turbulence inside the receiver If itis difficult to see the refrigerant settling properly in the receiver sight glass unplug the speed sole noid forcing low speed operation There should be less turbulence in the receiver and the liquid refrigerant should settle properly Checking Refrigerant Level on Units With S N Prior to JAR90710713 NOTE The ambient air entering the condenser air temperature should be above 40 F 4 4 C a Start unit in cooling mode Run app
388. n 62 10683 f Cargo Protect Mode If the setpoint is in the frozen range i e below 10 4 F 12 C and both RAT and SAT sensor alarms are active the unit will run in low speed cool g Frozen Setpoint If the setpoint is in the frozen range i e below 10 4 F 12 C and the refrigerated compartment temperature is below setpoint the unit will run in low speed h High Air Flow For Perishable setpoints the AIR FLOW Functional Parameter will force the unit to operate in continuous High Speed operation when AIR FLOW HIGH is selected When AIR FLOW NORMAL is selected the unit will cycle normally between high and low speeds High Air is NOT available for setpoints in the frozen range i e below 10 4 F 12 C i Product Shield High Air The engine is forced to High Speed if Product Shield High Air Configuration is set to ON and the ambient temperature falls outside the selected range and the temperature difference between the supply air and the return air is greater than the selected value Refer to Section 5 16 for more information on Product Shield j Adjustable High Speed Delay on Engine Start up Whenever the engine starts the unit will remain in low speed according to the selection made in the Functional Parameter list for High Speed Delay for Continuous or Start Stop modes A different setting is allowed for each mode Refer to Functional Parameters Section 3 16 for additional information
389. n received from the warehouse This is to ensure the Teflon valve seal is not damaged when it is installed Ensure the valve is fully open by using Stepper Motor Tester CTD special tool P N 07 00375 00 to manu ally open the valve to 100 before it is installed f Torque the 2 1 8 nut to 35 to 40 ft lbs 47 4 to 54 2 Nm g Reconnect the CSMV connector to the engine har ness h Evacuate the low side of the refrigeration system Refer to Section NO TAG i Open the liquid line service valve run the unit for approximately 10 minutes and initiate a pretrip Emergency CSMV Repair Procedures In the event that the CSMV system has a failure and replacement components are not readily available in an emergency A LIMP HOME procedure can be done as follows a Attach a manifold gauge set b Perform a low side pump down per Section NO TAG When the unit has reached 0 to 5 psig 0 to 0 34 bar close the suction service valve and turn the unit OFF c Remove CSMV power head by loosening the 2 1 8 inch diameter nut see NO TAG and sliding the power head out d Remove the piston by loosening the Allen screw and removing the piston and screw e Install the power head assembly without the piston torque to 35 to 40 foot Ibs 47 4 to 54 2 Nm f Open all valves g Start the unit h Adjust the suction service valve so that the approxi mate temperature OR current limit is maintained For perishable loads it is r
390. n Check Charging 1 Check alternator brushes and replace if necessary Check System 2 Check alternator output 2 13 62 10683 9 2 ACTION SYSTEM OPERATION REFERENCE SECTION b Every Service Interval or Annually Continued Refrigera Check air switch amp calibrate tion Check amp clean evaporator coil and defrost drain hoses System Check operating refrigerant pressure Check all sensor calibrations Check manual defrost operation Check Compressor drive coupling Perform Pre Trip inspection c Every 6000 Hour Maintenance Normal Operating Conditions with conventional coolant Cooling 1 Drain and flush cooling system 12 000 hours with Extended Life System Coolant ection 9 9 d Every 10 000 Hour Maintenance Perform complete 2000 and 3000 hour Preventive Maintenance and the following Fuel System 1 Clean and adjust injector nozzles Engine Service Guide e Every 12 000 Hour Maintenance with extended life coolant Cooling 1 Drain and flush cooling system 6 000 hours with Conventional System Coolant ection 9 9 f Oil And Filter Change Intervals Oil amp Filter Change Interval us API Class CG engine oil ing Mobil Delvac 1 engine oil Soin p aon eases o Mobil Delvac1 is the only approved synthetic oil Maximum oil drain interval is two 2 years New oil filter required at 1 yr interval These maintenance schedules are based on the use of approved oils and regular pretrip
391. n back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Engine Coolant Temperature Sensor ENCT b Check Engine Coolant Sensor Refer to Section 9 28 for complete resistance chart resistance See Note Note 6 10 000 Ohms 77 F 25 C Check Engine Coolant Sensor Wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section 3 Remote Sensor Switch Connector a Locate and inspect 10 way connector Connector must have cap on for optional sensors and switches No corrosion or moisture inside connector If there is a problem with the connector and there are no Inspect Engine Coolant Sensor amp No damage to sensor connector No damage moisture or corrosion in connector remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink 8 61 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 130 CHECK ENGINE RPM SENSOR TRIGGER ON With the unit in Auto Start The ambient temperature is above 32 F 0 C and this is the 2nd or 3rd start attempt
392. n be down loaded and reviewed by trip making data re view much easier Refer to Section 3 11 PRESS TO VIEW PRINT MENU En ables the user to use hand held Strip Print printer kit P N 12 00543 10 The optional selection is PRESS 1 TO VIEW INTELLISETS Re fer to Section 3 20 1 Table 2 3 FIELD EFFECT TRANSISTORS Transistors not listed are spares STANDARD ET DESIGNATION FET6 Auto Fresh Air Relay FET FETS FETS FETIO FETI2 FETI4 FETIS FETC F FETI7 FETIS FET2 FET22 FET23 Front unloader UL 1 Out Of Range Light 2 21 62 10683 2 5 4 Handling of PC Cards PC cards can be used to upgrade software Section 6 5 2 download recorder data Section 6 7 1 set configurations Section 6 2 1 and Functional Parameters Section 6 7 7 and install optional features While these cards are constructed for a rugged environment they are not intended to be stored ina technician s toolbox The label on each card clearly states that the card is to be handled with care not to be bent dropped or exposed to impact Heat moisture and direct sunlight should be avoided PC cards are designed to be used in a wide temperature range of 40 to 185 F 40 to 85 C Whena PC card is connected to an Advance microprocessor or computer at temperatures outside this range data transmission between the card and the other device may not be performed correctly Retention of programmed data for extended perio
393. n input signal to the microprocessor as to the of fuel remaining in the fuel tank The microprocessor then turns on the Check Fuel Level alarm when the level reaches 15 and if configured to do so turns the engine off when the level reaches 10 The sensor has the capability of sending from 0 to 100 of the fuel level to the microprocessor The fuel tank level will be displayed in the Unit Data list Some units may have sensors that may be calibrated if necessary GROUND SUPPLY VOLTAGE OUTPUT Figure 9 3 Fuel Level Sensor Wiring a Verify that the wiring to sensor is correct and connec ted properly b Check voltage at the Fuel Level Sensor with the START RUN OFF switch in the START RUN posi tion Unit running or Unit off and Manual Start mode selected c Voltage between red wire positive and black wire negative should be 12 5 to 13 5 VDC Do not dis connect the red or black wires from the switch d Disconnect the white wire output from the sensor Voltage between black wire negative and white wire output should be 0 VDC when the switch is dry and out of the fuel e When the switch is immersed into fuel the voltage reading between black wire negative and white wire output increase up to 5 VDC when fuel has reached the full mark 9 8 3 The RPM Sensor Units beginning with below serial numbers and ALL X2 units Refer to Section 9 8 7 for information on units with Electronic Speed Control
394. n made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check For Engine Running a Verify that engine is still running Engine should not be running Check RPM Sensor a Check actual engine RPM using hand Adjust engine linkage setting as needed held tachometer b Compare actual RPM with those Both readings within 50 RPM shown on display Check For Bad Engine RPM Sensor Alarm BN Check for Alarm 130 Alarm conditions must be corrected and the alarm cleared to continue 2 Engine Oil Pressure Switch 2 5 Inspect switch amp connector pins amp No physical damage to switch terminals No damaged or corroded pins in plug b Check engine oil switch operation Contacts closed when oil pressure is above 15 PSIG 1 02 Bars Contacts open when oil pressure is below 12 PSIG 0 82 Bar 5 Check Engine Oil Switch Harness a Inspect harness control box No physical damage to harness connector pins amp EB See wiring No damaged or corroded pins schematic b Check for shorted circuit in harness Start Run Off Switch in Start Run position Manual Start and continuity through the harness Mode See Note Note 4 for units with GCS only For ie without a GCS use Component Test Mode to energize the Run Relay Refer to Section 6 2 2 Battery voltage reading 12 13 VDC between wires in plug to Oil Pressure Switc
395. n made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Model Number a Check Model Number in Must be a valid Model Number from Configuration List microprocessor aM b Enter correct Model Number From Configuration List select correct Model Number Reset Microprocessor a Turn Start Run Off switch off for 30 Microprocessor powers up OK seconds then turn back on b Check for valid Model number in Data Valid number is present List Alarm is cleared c Valid model number can not be microprocessor entered See Note 1 Page 8 2 a Clear the inactive alarms All alarms cleared 8 107 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 237 FUNCTIONAL PARAMETERS ERROR TRIGGER ON There is an error in one or more of the Functional Parameters that are stored in the microprocessor memory or in the memory sector of the microprocessor that the Functional Parameters are stored in UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset when valid Functional Parameters are entered or Alarm may be manually reset by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through
396. nal 6 to 9 amps each at 10 5 vdc When servicing the glow plug is to be fitted carefully into the cylinder head to prevent damage to glow plug Torque value for the glow plug is 14 to 18 ft lb 1 9 to 2 5 Mkg b Checking for a Defective Glow Plug 1 The entire circuit may be tested using Component Test mode Refer to Section 6 2 2 2 To test individual glow plugs disconnect all glow plugs from each other and place an ammeter or clip on ammeter in series with each glow plug and ener gize the plugs Each plug if good should show 6 to 9 amps draw at 12 VDC 3 Asecond methodiis to disconnect the wire connection to the plug and test the resistance from the plug to a ground on the engine block The reading should be 0 7 to 1 2 ohms if the plug is good 9 9 SERVICING AND ADJUSTING V BELTS AX WARNING Beware of V belts and belt driven compo nents as the unit may start automatically Before servicing unit make sure the START RUN OFF switch is in the OFF posi tion or the unit is in Maintenance mode Also disconnect the negative battery cable 9 9 1 Belt Tension Gauge Use a belt tension gauge tester P N 07 00253 shown in Figure 9 10 whenever V belts are adjusted or replaced A belt tension gauge provides an accurate and easy method of adjusting belts to their proper tension Properly adjusted belts give long lasting and efficient service Too much tension SHORTENS belt and bearing life and too little tension c
397. nal alarms occurred Pretrip will show FAIL and the technician will need to review the Alarm List and take necessary and appropriate action to clear them see list below Test 16 will last about five seconds Test 16 Check For Other Alarms That May Be Present Check for the following alarms Alarm Alarm Description No LOW FUEL LEVEL WARNING for units with Low Fuel Level switch no fuel level display in Data List LOW FUEL LEVEL WARNING for units with Low Fuel Level 0 to 100 Sensor fuel level is dis played in Data List LOW ENGINE OIL LEVEL LOW COOLANT LEVEL 18 LOW REFRIGERANT PRESSURE 27 SUCTION PRESSURE 28 CHECK REFRIGERATION SYSTEM ENGINE FAILED TO STOP 36 CHECK COOLANT TEMPERATURE ALTERNATOR NOT CHARGING DEFROST NOT COMPLETE 55 CHECK DEFROST AIR SWITCH 59 DATALOGGER NOT RECORDING DATALOGGER TIME WRONG 71 BAD F2 OR F3 FUSE 81 CHECK FHR CIRCUIT 82 CHECK REMOTE OUT RANGE LIGHT 223 thru If any Maintenance alarms are active Pretrip will not pass 230 232 thru If any Microprocessor alarms are active Pretrip will not pass 249 Pretrip Termination When the Pretrip cycle is completed the unit will return to normal temperature control operation PRETRIP PASS will be shown in the display until the operator presses any key In the event that the Pretrip test triggered an alarm s the display will show either PRETRIP FAIL and COMPLETE if the entire Pretrip cycle was completed
398. nce the unit enters UltraFresh 3 Mode it will remain in that mode until the box temperature rises to 3 6 F 2 0 C above setpoint at which point it will go to High Speed 6 Cylinder Cool Figure 5 3 Start Stop Temperature Control Operating Sequence Perishable Range High Speed 6 Cylinder Cool 3 2 1 8 C Low Speed 6 Cylinder Cool 0 5 F 0 3 C Start Stop Off Cycle CSMV CONTROL FALLING BOX E TEMPERATURE RISING BOX TEMPERATURE 3 6 F 2 0 C Once the Minimum Run Time has expired the compressor will operate in 6 cylinders depending on suction pressure During the Minimum Off Time the unit will restart at Override Temperature selected in the Functional Parameter List Figure 5 4 Start Stop Temperature Control Operating Sequence Frozen Range 5 7 62 10683 5 10 ENGINE SPEED OPERATION The engine will operate the compressor at two different speeds low and high Speed Control is based on the differences of Controlling Temperature and set point as follows HGHSPEED LOW SPEED COOL Control Temp is more than 3 6 F 2 0 C Control Temp is less than 3 F 1 8 C above above setpoint setpoint HEAT Control Temp is more than 3 6 F 2 0 C Control Temp is less than 3 F 1 8 C below setpoint below setpoint NULL NOTE For X2 units only When the ambient air temperature reaches 120 F 48 9 C the engine will go to low speed for a minimum of two minutes
399. ncrease in suction pressure to above 5 PSIG the engine will shift to low speed and the compressor will remain running on 4 cylinders If the condition still does not change UL2 will energize and the compressor will operate on 2 cylinders still in low speed operation Once the engine shifts to low speed or one or both of the unloaders energize due to these conditions the unit will remain in low speed and the unloader s will remain energized for a minimum of 5 minutes d Defrost Refer to defrost control Refer to Section 5 11 In a Normal Defrost cycle both unloaders will be loaded de energized In a High Ambient Defrost Cycle both unloaders will be unloaded energized during the Stage 1 pumpdown mode The remainder of the Defrost Cycle will have UL1 unloaded energized UL2 loaded de energized e Cargo Protect Mode If the setpoint is in the frozen range below 10 4 F 12 C and both RAT and SAT sensor alarms are active the unit will run fully loaded UL1 and UL2 de energized f Start Stop Override If the system is running in Start Stop Run Mode and the minimum run time has expired and the compartment temperature is not at setpoint and the Return Air Temperature is less than 50 F 10 C both unloaders will be LOADED de energized to increase the unit capacity so that set point may be reached more quickly and allow an Off Cycle g Continuous Run Low Speed Null Mode UL1 and UL2 will load and unload period
400. nctional Parameter list whichever time is longer AND The ambient temperature falls within the pre programmed temperature range AND e The unit is not already running in ProductShield Winter mode which forces the unit to operate in Continuous Run only Refer to Section c below AND Allthe normal criteria for a Start Stop Off Cycle box temperature at set point engine coolant temperature battery volts and charging amps are met e Optionally if the Econo Delta T configuration is set for a numerical value and not set to OFF the operator can pre program a maximum evaporator coil temperature differential Delta T between the return air 1 RAT and supply air 1SAT sensors as an additional criteria for switching to Start Stop In this case the unit must bring the Delta T below this pre programmed setting before going to Start Stop The product is probably cooled close to set point if the Delta T is pre programmed for a relatively low temperature 4 to 6 F 2 2 to 3 3 C and that setting has been reached Reaching the low Delta T setting is an indication that not much heat is being removed from the product in order to maintain the Return Air Temperature Setting the Delta T for a higher value 8 to 27 F 4 4 to 15 C or leaving the setting OFF enables the unit to cycle into an OFF cycle whether or not the unit is cooling at a higher capacity NOTE In ProductShield Econo Go to Start Stop the Delta T must be lower than the va
401. ndividual providers and not by Carrier Transicold Communications electrical harnesses and serial port splitters are available from Carrier Transicold Performance Parts Group PPG Communication Providers will connect into the wiring harness at the SATCOM port and possibly at the J1 connector Testing the SATCOM port may be done using a serial port to PC cable 22 01690 00 and the ReeferManager program If ReeferManager can communicate with the microprocessor the unit wiring and microprocessor are performing normally and any communication problem is with the provider s equipment 3 37 3 20 3 Two Way Remote Communication There are several different Telematics providers whose systems are approved for one way or possibly two way communications with Carrier Transicold Truck Trailer Rail refrigeration equipment Current information on each of these systems is available on the Carrier Transicold TransCentral Information Center Please visit www transcentral carrier com 62 10683 0 AutoFresh Alr Exchange ITEMS 6 7 AND 8 ARE NOT ACTUALLY To activate AutoFresh operation the AutoFresh Air SHOWN ONLY LOCATIONS ARE INDICATED Exchange configuration needs to be set See Section 6 2 1 A second configuration AutoFresh Air Delay 5 can be used to delay the start of AutoFresh operation by up to 48 hours after engine start up Two functional parameters See Table 3 3 are used to choose the type of fresh air exchange The AutoFresh
402. ne starts ANO Steps ALARM CAUSE CORRECTIVE ACTION 8 3 DRIVER OPERATOR ALARMS 1 LOW FUEL LEVEL WARNING for units with Low Fuel Level 0 to 100 Sensor fuel level is displayed in Data list Note This is an optional alarm which will not occur unless a fuel level sensor is present and configured ON TRIGGER ON Fuel level is 15 or less for more than 30 seconds UNIT CONTROL Alarm only RESET CONDITION Auto reset when the fuel level is above 1796 for more than 30 seconds or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check For Low Fuel Level a Check fuel level in the fuel tank pins amp terminals No damaged or corroded pins in plug c Check for voltage at the harness plug Voltage should be approximately12VDC between pins for BLACK SP24 negative and RED SPK5 positive wires d Check for voltage at harness plug Voltage should be greater than 0 VDC and less than 5 negative and WHITE 1MP26 e Check continuity of the wire from the Place START RUN OFF Switch in OFF position prior to harness plug pin the checking for continuity Must be less than 10 ohms microprocessor p
403. ngine Protect than the number of Switch On Hours NOTE None of the Total hourmeters are listed When the hours for all the hourmeters are entered the microprocessor will add the correct hours to gether and calculate the Total Engine Hours and Total Switch On Hours When the end ofthe list is reached PRESS TO SAVE HOURS will be displayed Pressing the key will save the hours and return you to the configuration list If you do not press the key none of the time hours or cycles you just entered will be saved Hourmeters may be changed for 60 minutes fol lowing the initial hour entry If an error has been made be certain to correct it within the 60 min ute time period Following that time the hour meters will count the appropriate hours because the unit switch is on and the unit is op erating and no further manual changes will be allowed NOTE After the configuration settings are complete use the UP or DOWN ARROW keys until CONFIGS COMPLETE TO EXIT is dis played in the MessageCenter Press the key to save NOTE If a Configuration card will be used to configure the microprocessor skip ahead to CONFIGU RATION CARD Section 6 7 7 If the Configura tions and Functional Parameters will be set from the keypad continue with following steps 6 7 3 and 6 7 4 6 7 3 Configurations Via Keypad Refer to Section 6 2 for a list of available microprocessor configurations Refer to Section 6 2 1 for instr
404. nks if there is a problem transferring data from the PC card that has been plugged into the PC card slot The red LED will continue to blink until the PC card is removed The LED will also blink if there is an error reading the card The LED will blink every 0 5 seconds during a software change either an upgrade or downgrade It will blink every 1 0 seconds during data download to PC card It will blink every 2 0 seconds when either the Program or Configuration or Option cards is inserted and no action is taken Check the MessageCenter for description of error 62 10683 b Display and Keypad MODE LIGHTS DISPLAY CON TINUOUS HEAT COOL DEFROST ALARM START STOP 20 1341 BOX TEMPERATURE START RUN f N N OFF MessageCenter COOL DEFROST START STOP 20 1341 SETPOINT BOX TEMPERATURE STATUS OK CONTINUOUS DEFAULT MESSAGE MAY BE REPLACED BY USER DEFINED MESSAGE DISPLAY and KEYPAD MODULE Figure 2 15 Display and Keypad 62 10683 2 18 The D
405. noid 4 Linkage Speed 2 Bolt 5 Clip 3 Solenoid Bracket Figure 9 6 Speed Control Solenoid Change 09 11 9 15 a Hold the speed lever against the low speed stop and check the RPM Adjust the low speed stop screw if necessary b Check engine speed using microprocessor data list c Check for proper operation by running Pretrip Re fer to Section 3 4 High Speed Adjustment a Loosen but do not remove the 4 speed solenoid mounting nuts b Turnthe jacking nut allowing the solenoid to move along the slots until the desired high speed is reached Tighten the solenoid mounting bolts and verify correct high and low speed RPM 4 Check for proper unit operation by running Pretrip Refer to Section 3 4 NOTE LE Low Emission DI engines are delivered with a tamper resistant high speed adjustment screw on the engine High speed adjustments are made using the slotted holes in the solenoid mounting bracket and the speed solenoid ad justing bracket with solenoid adjusting bolt and lockout on the bracket 62 10683 9 8 7 Electronic Speed Control ESC Units begin ning with below serial numbers and ALL X2 units a Serial Number Cut Offs Ultra XTC KAV90910396 Ultima XTC KAV90910334 Refer to Section 11 for schematic wiring diagram Refer to Section 10 for ESC diagnostic alarms and diagnostic trees Figure 9 7 Electronic Speed Control Components b Description Engines with electronic speed
406. not be visible must not Flag must not be visible visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Additional steps on the next page 62 10683 8 20 NO Steps ALARM CAUSE CORRECTIVE ACTION 31 FAILED TO START AUTO MODE Continued Check For Correct Engine Oil 7 a Check for correct oil viscosity weight Refer to Section 2 7 for conditions Must be correct for ambient conditions Check Engine Exhaust System a Inspect the exhaust system Must be clear and unobstructed S OOOO OOS a Check engine compresson RefertoSedong7 i 8 21 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 32 FAILED TO START MANUAL TRIGGER ON The unit was placed in Manual Start mode and the engine was not manually started within five minutes or The user has tried to start the engine three times unsuccessfully in the Manual Start mode UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Reset by changing to Auto Start mode or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check If Unit Has A Glow Crank Switch GCS a Visually chec
407. ns schematic b Check for shorted circuit in harness START RUN OFF switch in START RUN position and continuity through the harness Battery voltage reading 12 13 VDC between A and B wires in plug 19 LOW FUEL SHUTDOWN for units with Low Fuel Level Switch no fuel level display in Data list TRIGGER ON Alarm 1 LOW FUEL LEVEL has been on past the allowed run time See chart below UNIT CONTROL Unit shutdown and Alarm RESET CONDITION Auto reset when fuel level is above 1 4 tank for more than 30 seconds or Alarm may be manually reset via keypad or by turning the unit off then back on again 30 gal Fuel tank 30 Minutes 50 gal Fuel tank 60 Minutes 75 gal Fuel tank 90 Minutes 100 gal Fuel tank 120 Minutes 120 gal Fuel tank 150 Minutes NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check For Low Fuel Level Warning Alarm a Check for alarm 1 Must be cleared 8 15 62 10683 ALARM CAUSE CORRECTIVE ACTION MAXIMUM COMPRESSOR ALARMS TRIGGER ON One of the following alarms 13 High Discharge Pressure 17 High Compressor Discharge Temperature 18 Low Refrigerant Pressure 27 High Suction Pressure 28 Check Refrigerant System 29 Check Heat Cycle 56 Check Eva
408. nser tubes The condenser fan circulates surrounding air over the outside of the condenser tubes The tubes have fins designed to improve the transfer of heat from the refrigerant gas to the air This removal of heat causes the refrigerant to liquify Liquid refrigerant leaves the condenser and flows through the solenoid valve SV1 normally open and to the receiver The receiver stores the additional charge necessary for low ambient operation and for the heating and defrost modes The receiver is equipped with a fusible plug which melts if the refrigerant temperature is abnormally high and releases the refrigerant charge The refrigerant leaves the receiver and flows through the manual liquid line service valve King valve to the subcooler The subcooler occupies a portion of the main condensing coil surface and gives off further heat to the passing air The refrigerant then flows through a filter drier where an absorbent keeps the refrigerant clean and dry and the electrically controlled liquid line solenoid valve SV2 normally closed which starts or stops the flow of liquid refrigerant The refrigerant flows to the Liquid suction heat exchanger Here the liquid is further reduced in temperature by giving off some of its heat to the suction gas The liquid then flows to an externally equalized thermostatic expansion valve which reduces the pressure of the liquid and meters the flow of liquid refrigerant to the evaporator to o
409. ntended to notify the driver when the refrigerated compartment temperature has moved away from set point or when the unit is operating at low cooling capacity and the compartment temperat ure is not pulling down toward set point The Out Of Range Alarm may be configured as an Alarm Only or as an Alarm and Unit Shutdown Refer to Section 6 2 Con figuration Mode If the unit shuts down due to a shutdown alarm the Out Of Range Alarm will come on when the refrigerated compartment temperature has been out of range for 30 to 45 minutes regardless if the refrigerated compart ment temperature was ever within set point range or not Generally when the unit is running the refrigerated compartment temperature must have first been In Range before the Out of Range Alarm can be triggered In Range is defined as the temperature of the refrigerated compartment having been within 2 7 F 1 5 C of set point in the Perishable Range or within 2 7 F 1 5 C of set point in the Frozen Range The point at which the actual Out of Range Alarm comes on is determined by the Out of Range Functional Pa rameter setting Selections of 4 F 2 C 5 5 F 3 C 7 F 4 C and OFF are available The OFF setting dis ables the Out of Range Alarm All other settings allow the user to determine how far away from set point the re frigerated compartment temperature will move before turning on the Alarm The alarm will be activated after 30 minutes if the
410. ntil cylinder head is completely loosened to prevent any residual crankcase pressure c Remove the valve plate NOTE Do not pry the valve plate in order to remove it from the crankcase If necessary remove 2 bolts from the dis charge valve stop Remove the valve stop Using one of the discharge valve stop bolts as a jacking screw lift the valve plate from the dowel pins pushing the head off the crankcase d Inspect the parts of the cylinder head and or the valve plate 1 Inspect cylinder head gaskets for proper alignment and center web blow out 2 Inspect the discharge valves for loose or damaged valve stops or any debris that may affect the proper opera tion of the valves 3 Inspect for broken cracked or chipped discharge reeds 4 If applicable inspect the discharge check valve to ensure the piston moves and contacts the plate 5 Inspect for broken cracked or chipped suction valves 6 7 Inspect valve plate gaskets for damage and wear Inspect the valve plate and the cylinder head for cracks e Remove oil in the cylinders on top of the pistons to avoid unnecessary clean up Inspect the top of the piston for damage Check for debris burned and carbonized oil sludge or mechanical failure f Inspect cylinder bores for excessive wear Excessive wear for cylinder bores is defined as heavy and uneven scratches gouges or chipping of the internal wall of the cylinder with a depth greater than 0 025 inch which are caused b
411. ntinue 3 Check Evaporator Fan Clutch a Check Evap Fan Clutch operation in Must disengage fan defrost 4 Check Refrigerant Level a Visually check refrigerant level in Must be at correct level receiver tank 5 Check For Low Refrigerant Pressure Alarm a Check for alarm 18 Alarm conditions must be corrected and the alarm cleared to continue 6 Verify Temperature Of DTT2 a Using a service Test thermometer Must be within 2 F 1 C check temperature of Evaporator tube sheet at DTT2 and compare with DTT2 temperature in Data list b Check DTT2 and RAT wiring Verify that RAT temperature is being displayed as RAT in unit Data list and that DTT2 is being displayed as DTT2 Correct wiring if required Refer to Section 3 14 7 Check Accuracy Of DTT2 And SAT Temperature Readings a Check DTT2 resistance and Refer to Section 2 13 for complete resistance chart Check SAT resistance See Note Note 6 10K Ohms 77 F 25 C Check DTT2 For Proper Mounting a Inspect DTT2 Should be screwed tightly in place Flat area of DTT2 must be against metal surface See Troubleshooting Section 10 3 6 Refrigeration System Not Heating 62 10683 8 40 NO Steps ALARM CAUSE CORRECTIVE ACTION 55 CHECK DEFROST AIR SWITCH TRIGGER ON The defrost air switch has called for a defrost cycle within eight minutes of a defrost termination for two consecutive defrost cycles The air switch contact must be closed contin
412. o 48 Nm d The failed compressor may have pumped oil into the system Do not charge more oil until you install the new com pressor and run the unit to determine if oil level is correct Areminder when shipping for warranty credit a When shipping the failed compressor for warranty credit include the completed field failure diagnostic report and the bottled oil sample for the purpose of further analysis Electrical testing of the compressor a Check current draw of the motor winding with a current meter while the motor is running Each of the 3 legs should draw an equal amount of current within 10 The rated load current at 460VAC is 17 5 amps for a high efficiency 41CFM compressor b Check the resistance of each winding while compressor is off and power is isolated and disconnected from any source The resistance will be approximately 10hm and should be equal across all legs c Check the resistance to ground from each leg while compressor power is isolated and disconnected from any source There should be low resistance to ground open with standard ohmmeter Because oil and refrigerant fluids are conductors the use of amegohmeter may show variations in resistance to ground through the case of the com pressor using higher test voltages 10 25 62 10683 START HERE Gone through the system diagnostics No system or other component defect dis covered The system is OFF Recover refrigerant Start the compres
413. o approximate ambient tem peratures Remember the engine compartment temperatures are generally higher than actual ambient air temper atures A fast reading digital thermometer such as 07 00269 is helpful in determining ambient temperatures NOTE The amount of time required to pump the unit down to 0 PSIG is not by itself an indicator that the compressor is bad A longer than normal pumpdown time necessitates additional checks to determine the cause b Ifthe suction discharge and receiver pressures do not rapidly equalize SV4 discharge and bypass check valves are in good condition Further compressor evaluation can only be done by following the compressor inspection pro cedure Section B If the suction discharge and receiver pressures equalize above saturated pressure SV4 discharge and bypass check valves must be checked before determining whether further compressor inspection is required To determine the cause of suction discharge and receiver pressure equalization start the unit with the king valve closed and slowly close the suction service valve until suction pressure reaches 0 psig bar Turn the unit off and open the hand valves between the suction and discharge gauges a If the pressures equalize to above saturated pressure the discharge check valve is not holding and must be re paired Once the discharge check valve is repaired the compressor must be inspected further Section B a If the pressures do not equ
414. o electrical circuits will be energized Current draw in this state is O 0 5 Amps Sensors and sensor circuits may be tested at the 1MP plug Remove plug from microprocessor and using the 1MP Plug Map and an ohmmeter test resistance of circuits See Section 9 28 for chart of resistances for different sensors When checking the Defrost Air switch RPM Sensor Standard Engine Only Engine Oil Level switch Door switch or HPS unplug 2MP at the microprocessor Using the 2MP Plug Map and wiring diagram check for voltage at the appropriate terminal When checking the light bar Solenoid Valves amp Unloader circuits unplug 3MP at the microprocessor Using the 3MP Plug Map and wiring diagram check for voltage at terminal of the circuit you are testing Should be battery voltage Some tests can only be conducted while the unit is operating The unit may be started automatically by placing the START RUN OFF switch in the START RUN position Units with a Glow Crank switch can be started manually by pressing and holding the Glow Crank switch in the Glow position Place the START RUN OFF switch in START RUN Continue to hold the Glow Crank switch until the setpoint and box temperature are shown in the display then release it after glowing the engine for the appropriate time required for the ambient temperature The MessageCenter will show Manual Start Mode Selected Hold the Glow Crank switch in the Crank position until the engi
415. of coil Use Component Test mode Section 6 2 2 to test Refer to Section 2 13 for amp values View current draw in the Unit Data list Refer to Section 3 14 b Check resistance of Front Unloader Refer to Section 2 13 UL1 coil Check Front Unloader UL1 And Circuit I Inspect Front Unloader UL1 and damage or corrosion wiring Connector fits together tightly no moisture inside b Check operation of UL1 FET 23 START RUN OFF switch in Start Run Manual Start Operation See Note Note 4 LED must be ON Check voltage to Front Unloader UL1 Must be 11 VDC or higher across the 2 wires 4 Check Front Unloader UL1 Circuit Wiring B Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section zm 8 69 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION P145 CHECK SPEED SOL CIRCUIT TRIGGER ON Normal Amps for the Speed Solenoid Circuit is 3 0 to 9 0 Amps for non Electronic Speed Controlled ESC engines or 0 to 1 0 Amps for ESC engines The circuit tests outsidethis range UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE cse the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate
416. of the air leaving the evaporator to the setpoint setting NOTE Whenever the setpoint is below 10 4 F 12 C the unit will ALWAYS be controlled by the Return Air Sensor regardless of the selection made here 62 10683 3 26 FUNCTIONAL DISPLAY TEMPS ENGLISH UNITS Temperatures will display in either English F or Metric C IN METRIC UNITS FAHRENHEIT CEL CIUS DISPLAY ENGLISH UNITS Pressures will display in either English psig or Metric bar PRESSURE IN METRIC UNITS PSIG BAR RESET PM HOURMETERS Maintenance hourmeters that have expired will appear in this list ENGINE If there are no active maintenance hourmeters this menu item will not appear in the Functional Parameters If there are active maintenance hourmeters and none have expired SWITCH ON and turned the alarm on the MessageCenter will display RESET NO HOURMETERS TO RESET When any maintenance hourmeter has timed out and preventative 1 Thru 5 maintenance has been performed selecting RESET and pressing the key will de activate the alarm and reset the hourmeter for the next service interval OUT OF RANGE English Metric Once the unit is at set point then drifted away for more than 15 min ALARM OFF OFF utes an Out Of Range Alarm will come on Or if configured for Out AF 2 Of Range Shutdown after 45 minutes the unit will shut down This 5 F 3 C setting determines how far away from set point the temperature must 7 4
417. 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 because the rate of bleed through the gas bypass port is greater than the rate of bleed through the bleed orifice 8 When the pressure behind the piston has been reduced sufficiently the valve spring will force the piston bypass valve back opening the gas bypass from the discharge manifold to the suction manifold Discharge pressure in the discharge manifold will close the discharge piston check valve assembly 14 isolating the compressor discharge manifold from the individual cylinder bank manifold The unloaded cylinder bank will continue to operate fully unloaded until the solenoid valve control device is de energized and the gas bypass port is closed E 9 Strainer 10 Suction Manifold 11 Cylinder Discharge Valve 12 Valve Plate 13 Cylinder Suction Valve 14 Discharge Piston Check Valve Assembly 15 Discharge Manifold Figure 2 12 Compressor Cylinder Head Unloaded 62 10683 2 12 c Loaded Operation Figure 2 13 Discharge pressure bleeds from the discharge manifold Item 15 through the strainer 9 and
418. of time For example high ambients and low set points may cause the CSMV to open higher than 30 5 7 UltraFreeze TEMPERATURE CONTROL For frozen setpoints a modified UltraFresh 3 temperature control is used to keep the unit from over cooling and driving the box temperature far below setpoint UltraFreeze operates similar to UltraFresh 3 except as noted in this section UltraFreeze control will be used anytime a frozen setpoint is selected in both continuous and start stop operation When UltraFreeze is active it is normal to hear the refrigerant solenoid valves energize and de energize every few seconds 5 7 1 UltraFreeze Offset In UltraFreeze the unit will control the box temperature between setpoint and up to 3 F 1 6 C below setpoint while the unit is running 5 7 2 UltraFreeze Start Stop In start stop operation the micro will control to setpoint by cycling the unit off when the box temperature is within 0 5 F 0 3 C of setpoint Should the unit be required to continue to run after the box temperature is satisfied due to either low battery voltage or low engine coolant temperature the UltraFreeze logic will control to the 3 F 1 6 below set point offset until all conditions for an off cycle are met and the unit cycles off For frozen set points a modified UltraFresh 3 temperature control is used to keep the unit from over cooling and driving the compartment temperature far below set point Except as noted in th
419. olenoid or FSA Refer to Section 2 13 f Check operation of solenoid or FSA Plunger must move in when energized Additional steps on the next page 8 35 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 41 ENGINE STALLED Continued Check RPM Sensor Standard Engines Only a Check Engine RPM in Data list Must be Steady Accurate Reading b Check wiring from RPM Sensor to No physical damage to harness Control Box Connectors and Pins See No damaged or corroded pins Wiring Schematic Plug connection fits tightly Check Engine Speed Sensor ENSSN Units With Electronic Speed Control ESC engines Only IN a Inspect harness amp control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins schematic Section 11 9 Engine Air Intake System a Check air filter indicator Flag must not be visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Check Engine Exhaust System a Inspect the exhaust system Check Engine a Check Injection pump timing b Check engine valve adjustment c Check engine compression Compression must be above 27 2 Bars 400 PSIG a Check discharge amp suction pressures 62 10683 8 36 ANO Steps ALARM CAUSE CORRECTIVE ACTION 8 6 WARNING STATUS ALARMS 51 ALTERNATOR NOT CHARGING TRIGGER ON Unit is running either engine or standb
420. ompartment temperature has been out of range for 30 minutes the alarm light will come on and the unit will shut down NO When the compartment temperature has been out of range for 15 minutes the alarm light will come on and the unit will continue to run YES All Functional Parameters in the function list are locked in place PARAMETERS LOCKOUT YES NO NO All Functional Parameters in the function list can be changed using the keypad unless individu ally locked out by ReeferManager YES If Alarm 39 Check Engine RPM is active turn the alarm light on and shut the engine off RPM ALARM SHUTDOWN YES NO NO If Alarm 39 Check Engine RPM is active turn the alarm light on and allow the unit to continue to run YES When low refrigerant pressure is sensed in the system alarm 18 is active turn the alarm light on and shut the unit down after the time delay in LOW PRESSURE SHUTDOWN YES NO the following selection NO When low refrigerant pressure is sensed in the system Alarm 18 is active turn the alarm light on and the unit will continue to run LP SHUTDOWN DELAY 120SECS After the Low Pressure signal is received how long 0 255 seconds shall the unit continue to run before it is shut down YES If the unit is running and the suction pres sure rises to 98 psig 6 67 Bars or higher for 10 HIGH SUCT PRESS SHUTDOWN YES NO minutes Alarm 27 is active the unit will shut down NO High suction pressure
421. on NO Once the unit shuts down to begin the software installation process the suction modulation valve closing process begins The software installation processes will not begin Can the card be read by the YES py until the CSMV is completely closed which ReeferManager program will delay the actual process for about 45 seconds Did you find and correct the J YE TN Place card back Possible condition NO into the micro and defective try again Did this PC card Retry solve the problem operation with another card Micro display will show ENGINE AND MICRO WILL STOP NOW and engine will stop Did you find and correct YES the condition Y System OK NO The display will show INSTALLING PROGRAM SOFTWARE Make sure you wait until the display shows INSTALLL COMPLETE before removing card Did you find and correct the condition Using the ReeferManager pos Programy install Program Does MessageCenter display CARD DATA CORRUPT CANNOT LOAD card into computer and re install the correct bex file Software has finished e YES Is the card status LED on solid loading NO There is problem loading Has the card status the software Turn unit the card st tus
422. on and the CSMV is opening SLEEP MODE OFF ON TO WAKE The unit is cycled off in Sleep Mode Place the START RUN OFF switch in the OFF position then back to the START RUN position to wake the microprocessor up SLEEP WARNING DOOR OPEN The rail unit is in Sleep Mode and a rail car compartment door is open The unit will start as needed for Sleep Mode SLEEP WARNING NO TEMP CONTROL The unit is running in Sleep mode SLEEP WARNING REMS1 2 OPEN The rail unit is in Sleep mode and a remote switch is open Switch may be connected to a door or a remote control switch The unit will start as needed for Sleep mode SMV CLOSING WAIT xxx SECONDS Microprocessor is powering up and CSMV is closing XX indicates the number of seconds remaining until valve is fully closed START MODE AUTO or MANUAL Indicates whether the unit is in Auto Start or Manual Start mode START STOP LOCKED The set point has been locked into the Start Stop mode Continu ous Run can not be selected START STOP MODE SELECTED Start Stop Mode has been selected STATUS OK The unit is working correctly TECHNICIAN RESET REQUIRED A21 AL11 Low Engine Oil Pressure or AL12 High Coolant Temperat ure has been activated three times in the last two hours and the unit has been locked out The unit must be brought to a Carrier Transicold Dealer for Service TEST 1 to 16 Pretrip is currently running this test and is x complete TIME SELECTION NOT CHANGED A time change was star
423. oolant Temperature 3 10 Engine Coolant Temperature Sensor 2 10 Engine Cooling System 9 12 Engine Crankcase Breather 9 17 Engine Cranking 4 1 Engine Data 2 25 Engine Oil 2 25 9 14 Engine Oil Level Switch 2 10 Engine Oil Pressure Switch 2 10 Engine RPM Sensor 2 10 Engine Screw Thread 2 26 Engine Sensors 2 10 Engine Speed Control Unit 2 10 Engine Speed Operation 5 8 Engine To Gearbox V Belt 9 20 Engine Transducers 2 10 Evaporator Coil 2 14 9 44 Evaporator Sensors 2 15 Evaporator Transducers 2 15 Events 3 33 Expansion Valve 9 24 F Failed To Start Auto Mode 4 5 Fanshaft 9 21 Fanshaft Installation 9 22 Fanshaft Oil 2 26 Filter Drier 2 13 Filter Drier 9 33 FreshProtect 5 5 Fuel and Speed Actuator 2 10 Fuel Level Sensor 9 13 Functional Change Parameters 3 25 62 10683 Index Fusible Plug 2 26 G Gearbox Oil 2 26 Gearbox To Fan Shaft V Belt 9 19 Glow Plugs 9 17 Grille Insert Removal 9 8 H Heat Exchanger 2 14 Heat Mode Operation 5 2 Heat Cool Null Switching Operation 5 3 Heating Cycle 9 43 High Ambient Defrost Operation 5 10 High Ambient Defrost Termination Sequence 5 10 5 11 High Pressure Cutout Switch 9 33 High Pressure Switch 2 26 9 33 Indicator LEDs 2 19 3 33 Installing New Software 6 17 Integral Voltage Regulator Operation 12 VDO 2 11 IntelliSet 3 35 K Key Descriptions 2 20 Index 2 Index L Language Se
424. open pressure settings are based on the model number as follows Model No SV2 OPEN SV2 CLOSE Ultima XTC and X2 2500 190 PSIG 250 PSIG 12 9 Bars 17 Bars Ultra XTC and X2 2100 200 PSIG 300 PSIG 13 6 Bars 20 4 Bars 5 11 62 10683 5 15 TEMPERATURE RANGE LOCK 1 amp 2 See Figure 5 5 and Figure 5 6 The unit can be locked into Start Stop or Continuous Run operation for various set points Two independent ranges are available for selection Each range can be set to lock the unit into either Start Stop or Continuous Run based on the current set point Each Range has its own selectable minimum and maximum temperatures which define the span of the range If some set point temperatures are contained in both ranges due to range overlap the unit operation specified for Range 1 will always have priority over the unit operation specified for Range 2 Typically both Range 1 and Range 2 are used to control different set point ranges when the unit is not equipped with the IntelliSet option For units with IntelliSet because each IntelliSet is generally programmed for a specific product only Range Lock 1 is used to hold the unit in either the Start Stop or Continuous Run Mode and Range Lock 2 is left OFF For example if Continuous Run operation is ALWAYS required whenever the set point is between 28 F and 55 F 2 2 C and 12 8 C Range 1 will be set for Continuous Run with a Range 1 Minimum Temperature of 28 F 2 2 C and a
425. or b Check Remote Temperature Sensor 2 Refer to Section 9 28 for complete resistance chart resistance See Note Note 6 1o 000 Ohms 77 F 25 C Check remote temperature sensor 2 wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section 11 b Check 10 way connector for all No physical damage moisture or corrosion to connector remote sensors and switches Cavity plugs are in place for unused circuits 62 10683 8 66 NO Steps ALARM CAUSE CORRECTIVE ACTION 135 CHECK REMOTE TEMP SENSOR 3 TRIGGER ON Remote Temperature Sensor 3 circuit is configured on and has failed open or shorted If shorted the data list will display 158 F 70 C If the circuit is open the data list will show the temperature as 52 6 F 47 C UNIT CONTROL Alarm only RESET CONDITION Auto Reset when Remote Temperature Sensor 3 is in range or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Remote Temperature Sensor 3 REMSN3 a Verify that Remote Temperature Remote Temperature Sensor 3 is installed
426. or The alarm list is displayed in the MessageCenter Pressing the ALARM LIST key once displays the active alarm list Each successive press cycles through the list to the end To view the inactive alarm list Refer to Section 3 13 START STOP CONTINUOUS Key This key allows you to change from Start Stop operation to Continuous Run operation In Start Stop operation when the microprocessor is in Off Cycle mode the unit will not be running During Off Cycle mode the microprocessor monitors refrigerated compartment temperature battery volage and engine coolant temperature and will restart the unit when needed SELECT Key Press the SELECT key to scroll through the menu selections One of the five standard and one optional menu selections will appear in the MessageCenter when the SELECT key is pressed The five standard selections are PRESS 1 TO VIEW HOURMETERS Displays the hours for individual hour me ters Refer to Section 3 15 PRESS 1 TO START PRETRIP Used to initiate a pretrip Refer to Section 3 4 PRESS 1 TO VIEW DATA Displays Unit Data Refer to Section 3 14 PRESS TO VIEW SETTINGS Dis plays unit Functional Parameter settings Refer to Section 3 16 PRESS 1 MARK TRIP START This menu selection is only used with the Data Recorder It is used to record a Trip Start event which is logged in the Data Recorder This records the time and date of the begin ning of the trip Data can the
427. or a few seconds at a time During Pulsed Null the HEAT and COOL valves are opened simultaneously to reduce either the heating or cooling capacity In the Null Mode Refer to the following charts the unit will pulse between COOL and NULL or HEAT and NULL in 10 second increments The capacity in the NULL Mode is varied by adjusting the pulse rate Cool Mode Engine Clutch OPEN OPEN CLOSED ENGAGE UNLOAD UNLOAD Referto CSMV Control Null Mode Engine Clutch OPEN OPEN OPEN ENGAGE UNLOAD UNLOAD Refer to CSMV Control Heat Mode Engine Clutch Refer to SV2 CLOSED opora OPEN LOW ENGAGE UNLOAD UNLOAD Refer to CSMV Control Section 5 14 Pulsed Null Mode operation will modify the length of each Mode in 10 second cycles That is if the unit is in the COOL NULL Pulse band the unit may run in COOL for up to nine seconds then NULL for one second if the Control Temperature is away from set point As the Control Temperature comes closer to set point the length of COOL time will decrease and the amount of NULL time will increase However the combination of the two will always equal 10 seconds The same is true for the HEAT NULL Pulse band b CSMV Control The CSMV will automatically go to 30 when it enters Ultra Fresh 3 at 1 5 F 0 8 C above set point The CSMV will usually control between 30 and 4 depending on the controlling probe and Suction Pressure However it can go above 30 for short periods
428. or in the frozen range The decision as to whether the same settings will be used together for all set points or if they will be separated between Perishable and Frozen is made in the Configura tion List Refer to Section 6 2 If TOGETHER is selected in the Configuration List then the following Functional Parameter values will be available for use MINIMUM RUN TIME MINIMUM OFF TIME OVERRIDE TEMP MAXIMUM OFF TIME FROZEN SHUTDOWN OFFSET If SEPARATE is selected in the Configuration List then the following Functional Parameter values will be available for use PERISHABLE MINIMUM RUN TIME PERISHABLE MINIMUM OFF TIME PERISHABLE OVERRIDE TEMP PERISHABLE MAXIMUM OFF TIME FROZEN MINIMUM RUN TIME FROZEN MINIMUM OFF TIME FROZEN OVERRIDE TEMP FROZEN MAXIMUM OFF TIME FROZEN SHUTDOWN OFFSET NOTE In the event that the Configuration is changed from Separate to Together the values from the Perishable Functional Parameters are the ones that will be used 62 10683 3 6 2 Charging Amps A Configuration for Start Stop Shutoff exists which al lows the microprocessor to monitor battery charging amperage in addition to battery voltage The battery charging rate as seen in the Data List must be below the selected amp setting to allow the unit to cycle off The Configuration may be set from 1 0 to 10 0 Amps in 0 5 amp increments A weak or defective battery may show a suitable voltage charge while t
429. or operation Place unit in Manual Start mode see Note Note 4 OR Use Component Test Mode to energize the Run Relay DO NOT START UNIT Refer to Section 6 2 2 c Check for voltage at harness plug Voltage should be 12 volts at harness plug between pins between pins for BLACK SP24 and for BLACK SP24 and RED SPK5 wires RED SPK5 wires d Check continuity of the wire from the START RUN OFF switch in OFF position prior to checking harness plug pin C to the for continuity Must be less than 10 ohms microprocessor plug 1MP26 e With the Fuel Level Sensor Voltage must be between 0 0 5 0 VDC reconnected check the voltage at the microprocessor plug 1MP26 Check Fuel Level Sensor Calibration __ a Check fuel level sensor calibration See Section 9 8 2 Check Circuits With Test Substitute Sensor a Substitute known good sensor and clear alarm Start unit and run for 30 seconds b Check to see if alarm re occurs Alarm should not come on Install new sensor 62 10683 8 60 ANO Steps ALARM CAUSE CORRECTIVE ACTION 129 CHECK ENG COOLANT SENSOR TRIGGER ON Engine Coolant Sensor circuit has failed open or shorted If shorted the data list will display 266 F 130 C If the circuit is open the data list will show the temperature as 58 F 50 C UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when Engine Coolant Sensor is in range or Alarm may be manually reset via keypad or by turning the unit off the
430. or pins amp terminals No damaged or corroded pins in plug 62 10683 8 6 ANO Steps ALARM CAUSE CORRECTIVE ACTION 8 4 SHUTDOWN ALARMS 11 LOW ENGINE OIL PRESSURE TRIGGER ON Engine oil pressure is below 12 PSIG 0 82 Bar for longer than five seconds while the engine is running UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset after 15 minutes or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the active alarm s See Note 1 Operate the unit through the appropriate modes to see if any active active alarm occurs Continue with the steps below as necessary Check For Low Engine Oil Level Alarm a Check for alarm 2 Alarm conditions must be corrected and the alarm cleared to continue Check Engine Oil Pressure Switch a Inspect switch amp connector pins amp No physical damage to switch terminals No damaged or corroded pins in plug b Check engine oil switch operation Contacts closed when oil pressure is above 15 PSIG 1 02 Bars Contacts open when oil pressure is below 12 PSIG 0 82 Bar Check Engine Oil Switch Harness Inspect harness amp control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins schematic Section 11 b Check for shorted circuit in harness START RUN OFF switch in ST
431. ort fae dE Glee wed Reg LH Qu ESTHER 2 26 Table 2 6 Refrigeration System Data ssssssssssssesses ees hen 2 26 Table 2 8 Component Resistance and Current Draw 2 28 Table 3 1 Shutdown Alarms EE LUE EU eee ee ES 3 19 Table 3 3 Functional Parameters Rr 3 26 Table 4 1 Time sre mee Ie zin rang ema ona eee dm da ete DE 4 1 Table 4 3 Suctlom MOP teure ICE EUN petet Fire oic Rated its ree EORR e pe M ada 5 19 Table 6 1 Connection Point Voltage eee nn 6 22 Table 9 1 Maintenance Schedule ssssessesesess sn 9 2 Table 9 3 2 Belt TensiOre Leo oou ELE een bu ehe nie EU EOS 9 18 Table 9 4 Compressor Discharge Pressure Transducer 9 36 Table 9 5 Compressor Suction Pressure 9 36 Table 9 6 CSMV Connections rh nn 9 41 Table 9 7 Sensor Resistance ENCT RAT SAT ATT DTT 9 45 Table 9 8 Sensor Resistance CDT 2 0 cece ehe 9 46 Table 9 9 R404A Temperature Pressure Chart cece cette nn 9 50 Table 10 1 ENSCU LED Fault Chart eed pees ike dente ees 10 8 62 10683 xiv SECTION 1 SAFETY PRECAUTIONS PARAGRAPH NUMBER Page
432. ove top locknut spacer cup and nameplate 2 Disconnect wiring and remove coil 3 Replace coil by reversing steps 1 and 2 9 39 62 10683 c Replacing SV1 Internal Components See Figure 9 31 CAUTION Service mode MUST be used whenever moving refrigerant charge refrigerant leak checking or evacuating Refer to Section 6 2 3 lt Remove and store the refrigerant charge in an eva cuated container Refer to Section NO TAG Remove the top locknut spacer cup nameplate coil assembly and spacer Using a 12 point 1 3 8 inch box wrench loosen the enclosing tube locknut and bleed off remaining re frigerant Remove enclosing tube and locknut assembly The gasket is inside the enclosing tube e gt o Remove seat disc from inside of body and check for obstructions and foreign material 9 Placethe seat disc into the valve body with the small er diameter end facing up a Place the enclosing tube locknut over the enclosing tube Install spacer over enclosing tube making sure it is seated properly in the enclosing tube locknut Tighten enclosing tube locknut to a torque value of 20 ft lb 2 78 Mkg Do not over tighten Locknut Screw 6 Enclosing Tube Lock 1 8 Install coil assembly nameplate and top locknut or 2 Spacer Cup nut screw 3 Nameplate 7 Enclosing Tube 9 Dehydrate and evacuate the system Refer to sec 4 Coil 8 Seal tion NO TAG Charge unit with ref
433. own not including Door or Remote switch shut downs UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Alarm may be manually reset via keypad or by turning the unit off then back on again e If Unit Operation mode is set for Rail this alarm will automatically reset after 4 hours NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue alarm s with ie seus below as necessary 1 Check For Alarms 1 Check for shut down alarms Alarm conditions must be corrected and the alarm s cleared to continue 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 31 FAILED TO START AUTO MODE TRIGGER ON Engine has tried to start three times unsuccessfully in the auto start mode UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE See the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with ie ses below as necessary Check For Flash Code On Engine Speed Control Unit ENSCU Applies to ESC engines only for flash codes on the ENSCU Refer Electronic Speed Control Diagnostic tables Figure 10 1 th
434. oximately 4 5 minutes and the refrigerated compartment tempera ture is less than 45 F 7 2C Check sight glass es to determine charge Units With S N Prior to JAR90710713 Once the refrigerant level is at centerline of the lower sight glass weigh in another 3 Ibs 1 4 kg of refrigerant Units With S N Beginning With JAR90710713 Charge the system until the refrigerant level is at cent erline of the lower sight glass THE LOWER SIGHT GLASS SHOULD NOT BE EMPTY AND THE UP PER SIGHT GLASS SHOULD NOT BE FULL Start unit and check for noncondensibles and run a unit Pretrip Refer to Section 3 4 62 10683 9 11 6 Adding Full Charge CAUTION Do not vapor charge R404A Only liquid charging through the receiver outlet king valve is acceptable Dehydrate unit to 500 microns and leave in deep vac uum Refer to Section Table 9 9 Place drum of refrigerant on scale and connect charg ing line from drum to king valve Purge charging line at king valve Note weight of drum and refrigerant Open liquid valve on drum Midseat king valve and al low the liquid refrigerant to flow into the unit until the me E e f 9 COMPRESSOR correct weight of refrigerant has been added as indi cated by scales Correct charge will be found in Table 2 1 NOTE It is possible that all liquid may not be pulled into the receiver as outlined in step d In this case frontseat the receiver
435. p ground wire unit OFF Negative lead on Ground terminal Positive lead on Output terminal same as battery voltage b Check exciter wire if used START RUN OFF switch in START RUN position Manual Start mode See Note Note 4 Must have or more VDC s switch ON Check Aux D Termina Must have less than 3 VDC with unit OFF a Inspect harness control box No physical damage to harness connector pins amp Ga See wiring No damaged or corroded pins schematic b Check output wire running Must have 13 or more VDC when tested against battery peer ee c Check wire unit running Must have 13 or move VDC when tested against post Check For Add On ee Drawing Too Much Current Check amperage added on All add on components amp accessories must draw less components amp po M than 20 Amps Perform Pretrip Check a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding 8 37 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 53 BOX TEMP OUT OF RANGE TRIGGER ON UNIT CONTROL Alarm Only The box temperature has been in range within 2 7 F 1 5 C of setpoint for perishable and frozen at least once since the unit was started Sleep Model and Component Test Modes excluded and is now further away from setpoint than the limit set in the functional parameters 4 5 5 or 7 F 2 3 or 4 C for this unit for more than 15 minutes or fo
436. p terminals See No damaged or corroded pins wiring schematic Section 11 b Check operation of solenoid Plunger must move in when energized 62 10683 8 74 NO Steps ALARM CAUSE CORRECTIVE ACTION P153 CHECK RETURN AIR SENSOR TRIGGER ON Return Air Sensor is not within the maximum range of 53 F to 158 F 47 C to 70 C UNIT CONTROL Pretrip will abort and PRETRIP FAILED IN TEST S will be displayed in MessageCenter RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Return Air Temperature sensor RAT Check Return Air Sensor Wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section i Check Remote Sensor Switch Connector a Locate and inspect 10 way connector Connector must have cap on for optional sensors and switches No corrosion or moisture inside connector If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may E a Inspect Return Air Sensor amp connector No physical damage to harness
437. parameters and configuration settings to the microprocessor and data recorder Transfer hour meter values to replacement microprocessors Initiate Pretrip and Defrost operations Support Download Configuration and Program PC Card operations Provide a security log on system controlled by a System Administrator b The Reports Program enables the user to do the following Read DCX download files from the Advance microprocessor Create various customized reports that include set point sensors and events Create various customized graphical reports Print numerical graphical and event reports View and print refrigeration system historical settings and changes Filter download data by date range and desired sensors and events Search for a sensor or event of interest Synchronize multiple graphical and numerical windows to better understand historical operation PC Setup enables the user to select how to display various parameters for use in the graph and text window Easily adjust x and y axis and color scheme to accommodate various data Export data to a spreadsheet friendly format such as MS Excel 62 10683 6 14 NOTE The ReeferManager program does not support USB port serial connections In the event that a notebook PC does not have a DB 9 serial port connector an RS 232 serial port type Il PCMCIA card adaptor may be used to adapt the notebook PC to the Carrier download cable For desktop PCs a PCI bus RS 232 serial
438. pect clutch and wiring No damage or corrosion Connector fits together tightly no moisture inside b Inspect clutch relay amp socket No signs of discoloration from overheating No corrosion c Check operation of Clutch Relay START RUN OFF switch in START RUN Manual Start Operation See Note Note 4 LED 29 must be ON d Check voltage to clutch Must be 11 5 VDC or higher Check Clutch Circuit Wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section 11 62 10683 8 68 ANO Steps ALARM CAUSE CORRECTIVE ACTION P144 CHECK UL1 CIRCUIT TRIGGER ON Normal Amps for the UL1 Front Unloader Circuit is 0 75 to 2 0 Amps The circuit tests outside this range UNIT CONTROL Pretrip will abort and PRETRIP FAILED IN TEST 2 will be displayed in MessageCenter RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE reo the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with he duin below as necessary 1 Check For Bad F4 Or F6 Fuse Alarm poc for alarm 72 Alarm conditions must be corrected and the alarm cleared purum continue Lire Front Unloader UL1 8 Check amp draw
439. ped with the IntelliSet option this file will need to be on a Config Card in order to install the IntelliSet parameters into the replacement microprocessor A computer is needed to enter the engine and switch on hours into the new microprocessor All settings including unit model number Trailer ID unit serial number and operating hours and cycles from the old microprocessor can be installed into the new microprocessor using either the keypad or a computer with the ReeferManager program NOTE A single set of configurations functional parameters and data recorder settings can be sent serially to the microprocessor using the ReeferManager program Multiple sets of set tings IntelliSets can only be sent to the micro processor by using a Configuration PC card 6 7 1 Microprocessor Replacement a If possible power the microprocessor up either using a PC mode jumper or by placing the START RUN OFF switch in the START RUN position If the micro processor will not power up skip ahead to step d Insert a Download PC card into the PC card slot and download all data from the data recorder If a Down load PC card is not available data may also be down loaded using a download cable and the ReeferManager PC Program Scroll through the DataList and make note of the fol lowing from the MessageCenter ID Number Unit Serial Number Unit Model Number Engine Protect Hours e Switch On Protect Hours Engine Sle
440. perature Sensor CDT a Inspect Compressor Discharge Temp No damage to sensor Sensor amp connector No damage or corrosion in connector 1MP Plug is connected tightly to microprocessor No wires are pushed back through plug b Check Compressor Discharge Temp 100 000 Ohms 77 F 25 C See section 2 13 for Sensor resistance complete table of and resistance values See Note 4 Page 8 2 2 Check Compressor Discharge Temp Sensor Wiring Em Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section 1 Check Remote Sensor Switch Connector a Locate and inspect 10 way connector Connector must have cap on for optional sensors and switches No corrosion or moisture inside connector If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink 62 10683 8 80 ANO Steps ALARM CAUSE CORRECTIVE ACTION P162 CHECK AUTO FRESH AIR EXCHANGE SOLENOID AFAS CIRCUIT TRIGGER ON Normal Amps for the AFAX Circuit is 0 4 to 2 5 Amps The circuit tests outside this range UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a p
441. played if High Air is ON PRODUCTSHIELD Indicates the ambient temperature that is controlling ProductShield Win WINTER xx ter Will only be displayed if WINTER is NOT OFF RANGE 1 LOCK OFF Temperature Range 1 Lock is turned off CONTINUOUS The unit is set to operate only in Continuous Run when t the set point is set between Range 1 Minimum and Maximum Tempera tures START STOP The unit is set to operate only in Start Stop when the set point is set between Range 1 Minimum and Maximum Temperatures RANGE 1 MINIMUM TEMP This is the lower limit for Range 1 RANGE 1 MAXIMUM TEMP This is the upper limit for Range 1 RANGE 2 LOCK OFF Temperature Range 2 Lock is turned off CONTINUOUS The unit is set to operate only in Continuous Run when the setpoint is set between Range 2 Minimum and Maximum Tempera tures START STOP The unit is set to operate only in Start Stop when the setpoint is set between Range 2 Minimum and Maximum Temperatures RANGE 2 MIN TEMP This is the lower limit for Range 2 T RANGE 2 MAX TEMP This is the upper limit for Range 2 62 10683 3 22 Table 3 2 UNIT DATA Also appear in Configurations May or may not be displayed depending on functional parameter settings REMOTE SENSOR 1 3 This is the temperature at remote Temperature Sensor 1 2 and 3 These sensors are optional and may not be applicable to your unit Up to three remote sensors may be listed DATALOGGER Th
442. porator Airflow has occurred three times during the last two hours of actual unit operation off cycle time is not included AND this alarm Alarm 20 has been enabled in this microprocessor Test 6 or Compressor Alarm Shutdown appears in the Installed Options List in Unit Data AND Compressor Alarm Shutdown in the configuration list has been set to YES Refer to Section 3 14 for information on Unit Data list UNIT CONTROL Unit shutdown and Alarm RESET CONDITION This alarm can only be cleared from the Inactive Alarm list It can not be cleared from the Active Alarm list and it will not clear when the START RUN Stop switch is turned Off then On again This is so that drivers and other operators can not reset the alarm The unit MUST be taken to a repair shop for inspection and repair NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check for trigger on alarms a Check the Active Alarm list to see See steps for the active alarm so that the alarm can be which of the following alarms is also cleared present A13 A17 A18 A27 A28 All Alarm s from the above list must be cleared to A29 A56 continue Reset Alarm 20 from the Inactive Alarm list 21 TECHNICIAN RESET REQUIRED TR
443. ps below as necessary Check Alarm List a Check for A41 When Alarms 41 and 130 occur at the same time generally the engine has run out or is running out of fuel This causes the engine to surge Check fuel tank and add fuel as neces sary Check fuel lines between the fuel tank and the fuel pump inlet for drawing air in Check Engine rpm Sensor Non ESC engines only a Inspect Engine RPM Sensor amp No damage to sensor connector No damage moisture or corrosion in connector b Compare actual engine RPM with Must be 20 RPM those shown on the display using hand Must be a steady reading held tachometer b thaw oe apy rand actual engine RPM with Must be 20 RPM those shown on the display using hand Must be a steady reading held tachometer c Check for 12 VDC between ENSSN 12 Must be 12 VDC V terminal amp ENSSN SC SE d Check for 12 VDC at ENSCU terminal Must be 12 VDC 25 to ground Additional steps on the next page EE Check Engine Speed Sensor ENSSN ESC engines Only a Inspect circuit from ENSCU terminal 3 No damage to unit to micro connection 2MP18 amp damage moisture or corrosion in connector connector 62 10683 8 62 NO Steps ALARM CAUSE CORRECTIVE ACTION 130 CHECK ENGINE RPM SENSOR Continued NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition abov
444. r When placed in the START RUN position this switch provides power to the microprocessor The microprocessor performs self test all segments of display are illuminated Then set point and refrigerated compartment temperature are displayed To stop the unit or remove power from the microprocessor place the SROS to the OFF position GLOW CRANK Switch GCS Removed from units built after April 2007 The GLOW CRANK switch is located on the back of the control box and is easily reachable from under the control box OFF 7 EN GLOW CRANK NOTE The GLOW CRANK switch will energize the glow and crank circuits only when the START RUN OFF switch is in the RUN posi tion and after the microprocessor has gone through the self test Key Descriptions MANUAL DEFROST macy UP ARROW and DOWN ARROW Keys These keys allow you to change the setpoints or other displayed data of the system They also allow you to scroll through the Unit Data list Function Parameters list Alarm list etc EQUAL Key ENTER The EQUAL key is used for many things including entering a setpoint changing a Functional Parameter clearing alarms and locking the data menu MANUAL DEFROST Key The MANUAL DEFROST key is used to initiate a defrost cycle when the proper conditions are met 62 10683 ALARM LIST START STOP ONTINUOUS Q ALARM LIST Key The ALARM LIST key allows you to view the alarms stored in the microprocess
445. r Pressure Sensor a Calibrate Suction Evaporator Pressure Calibration successful Sensor b Suction Evaporator Pressure Sensor Replace microprocessor can not be successfully calibrated See Note 1 Page 8 2 a Clear the inactive alarms All alarms cleared 62 10683 8 110 NO Steps ALARM CAUSE CORRECTIVE ACTION 246 EEPROM WRITE FAILURE TRIGGER ON There is an error in the ability to write information to be stored in the memory UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Microprocessor a Check set point settin 2 Must be between 22 F to 89 6 F 30 C to 32 C b Enter new set point Reset Microprocessor 30 seconds then turn back on b Alarm 246 remains active See Note 1 Page 8 2 is a Clear the inactive alarms 248 CONF MODE HP2 ERROR TRIGGER ON Microprocessor internal operational program error UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset only when valid info is available for the microprocessor are entered Follow the steps below until a problem is found Once a repair or correction has been made clear t
446. r more than 30 minutes immediately following the end of a defrost cycle OR If a unit Shutdown alarm occurs and the box temperature is further away from setpoint than the limit set in the functional parameters 4 5 5 or 7 F 2 3 or 4 C for more than 30 minutes regardless if the box temperature has been in range The box temperature has not been in range and the unit is operating in Pulldown Cool and the DeltaT SAT minus RAT is less than 1 F 0 56 C OR The unit is operating in Pullup Heat and the SAT is the same temperature or colder than the RAT for more than 30 minutes Alarm 122 CHECK RETURN AIR SENSOR and Alarm 123 CHECK SUPPLY AIR SENSOR must not be active Shut Down amp Alarm The box temperature has been in range within 2 7 F 1 5 C of setpoint for perishable and frozen at least once since the unit was started Sleep mode Diagnostic and Component Test modes excluded and is now further away from setpoint than the limit set in the functional parameters for this unit for more than 45 minutes UNIT CONTROL Alarm Only or Unit Shutdown amp Alarm if configured RESET CONDITION Auto Reset or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any ac
447. ration amp replace if needed Fuel solenoid or fuel and Operate system in order to verity speed actuator is defective repair Did you find and correct YES or mechanically seized P E the condition y Load current version of software from http www transcentral carrier com Did the software load correctly YES Noy NO YES Go To Condition 8 Remove new fuel solenoid or fuel and speed actuator amp re install old component Old component is not the fault Did the loading of the software correct the problem System OK Re install StarTrak if disconnected earlier Remove connectors from unit one at a time to determine if any other devices are providing power feedback causing the micro to remain powered Did you find and correct the condition Review the results of above tests with your supervisor If necessary go to the beginning of the table amp test again Figure 10 7 Micro Diagnostic Tree Cond 3 Start Run Off Switch Off Unit Fails To Stop 62 10683 10 16 Programming Problems with PC Cards if using a PC Card to upgrade software or Condition 9 Programming Problems with MicroProgrammer if using a PC to upgrade software Did the software load correctly Unit may be running old soft START HERE Check the Speed Soleno
448. ration system pressures This will occur only once during an Off Cycle but may be repeated during subse quent Off Cycles 4 3 2 CONTINUOUS RUN MODE In the Continuous Run mode the engine will not shut down except for shut down alarms or if the engine stalls Continuous Run mode is normally used for fresh produce and other temperature sensitive product loads The Start Stop Continuous key is pressed to switch between Con tinuous Run and Start Stop operating modes NOTE The microprocessor may be locked so that the unit will always operate in Start Stop or in Con tinuous Run whenever the set point is within a specific range Refer to Section 5 15 Range Lock for additional information NOTE The unit will remain in low speed until the engine coolant temperature reads 79 F 26 C in Con tinuous Run Mode High Speed Delay can be changed from OFF or from 1 to 255 minutes Referto Functional Parameters in Section 3 16 62 10683 4 4 SPEED CONTROL OVERRIDES NOTE With the complex control systems in use with the Advance Microprocessor there are many different reasons the engine may be operating in either High Speed or Low Speed besides how far the refrigerated compartment temperature is away from set point This section lists the dif ferent factors that determine the speed of the engine in the order of their priority Speed Control Solenoid Overrides in priority order a High Ambient If ambient temperature is 120 F 48
449. reaches 25 hours no further changes can be made The 60 minute grace period is based on the Real Time Clock in the DataRecorder That is why it is important that the Real Time Clock is set to the correct time prior to setting the hour meters e Your computer may now be disconnected and turned off or you can continue setting up the configurations 62 10683 6 26 6 7 7 Configuration IntelliSet PC Card a Place the START RUN OFF switch in the OFF posi tion to power down the microprocessor and to take it out of Configuration mode Power the microprocessor up by either placing the START RUN OFF switch inthe START RUN position Manual Start Operation can be used if the unit is so equipped or by inserting a PC mode jumper into the download port Insert the Configuration PC card into the PC card slot in the microprocessor and watch the MessageCenter When the MessageCenter shows CFG TO LOAD 1 TO CANCEL press the key It will take 10 15 seconds to load the Intelli Sets from the card LOADING INFO will be dis played during this time When finished the Message Center will show ALL INFO LOADED REMOVE CARD Remove the Configuration PC card The MessageCenter will show MICRO WILL RESET AND RESTART NOW the display will go blank then come back on after a few seconds NOTE When the microprocessor powers up the dis play will show PRESS TO VIEW INTELLISETS The unit will not sta
450. red maintenance interval in hours and enter as the SWITCH ON RESET VALUE in the Configuration list Selecting OFF will completely turn the switch on PM hourmeter off 6 21 To turn on any of the Programmable PM hourmeters they must first be programmed to count one of the available parameters from the list above For example PM 1 may be programmed to count Clutch Cycles Selecting OFF will completely disable the PM hourmeter Once a selection is made then a reset interval may be selected For hours the PM hourmeter may be set in 50 hour increments anywhere from 50 to 30 000 hours For cycles the PM hourmeter may be set in 1 000 cycle increments anywhere from 1 000 to 90 000 cycles Selecting OFF instead of an interval will also disable the PM hourmeter Maintenance Days are also available for customers who service their equipment by calendar days instead of operating hours or cycles Once the PM hourmeters are activated from the Configuration List they can only be turned OFF or RESET for a new interval from the Functional Parameter List The PM Hourmeters may be reset using either a PC and the ReeferManager program or the keypad RESET is only available when the accumulated hours are more than 95 of the reset value for that Hourmeter For example the Engine PM Hourmeter Reset Interval is 1000 hrs Reset will be allowed anytime after 950 hours have expired TIP Factory default is OFF for all PM hourmeters To rese
451. reed valves amp gaskets a Remove compressor heads amp inspect Must be in good condition condition of all reeds amp gaskets Additional steps on the next page 62 10683 8 12 ANO Steps ALARM CAUSE CORRECTIVE ACTION 17 HIGH COMP DISCHARGE TEMP Continued 8 Check Expansion Valve TXV a Visually inspect valve Bulb must be clamped tightly on the suction line and insulated No physical damage to bulb capillary tube of valve body aM b Check MOP of valve Refer to Section 2 11 Check superheat of valve Refer to Section 2 11 9 Check system for non condensables a Check refrigeration system for No non condensable gas es may be present non condensable gas es 8 13 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 18 LOW REFRIGERANT PRESSURE TRIGGER ON Suction Pressure is less than 6 inHg 0 2 Bar for more than 120 seconds when the RAT is above 10 F 23 3 C or If the Suction Pressure is less than 16 inHg 0 41 Bar for more than 120 seconds at any RAT temperature UNIT CONTROL Alarm Only or Unit Shutdown amp Alarm if configured RESET CONDITION Auto Reset after 15 minutes if Suction Pressure is more than 4 inHg 0 41 Bar or if RAT falls below 10 F 23 3 C or Alarm may be manually reset via keypad or by turning the unit off then back on again Time may be set from 0 255 seconds in the configuration list Refer to section 6 2 1 NOTE Follow
452. reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check SVA Coil a Inspect SV4 coil amp connector pins amp No damage to coil terminals No damaged or corroded pins b Check resistance of coil Refer to Section 2 13 c Check amp draw of coil Refer to Section 2 13 Use ammeter Check SV4 Wiring a Inspect harness amp control box See Notes Note 3 Note 4 amp Note 8 connector pins amp terminals See wiring No physical damage to harness schematic No damaged or corroded pins Check SV4 Current Draw a Use Component Test mode Refer to Refer to Section 2 13 for normal current values Section 6 2 2 and Alarms 81 thru 90 View current draw in the Unit Data list Refer to Section and Alarms 93 and 97 to test actual 3 14 current draw of the circuit 8 49 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 81 CHECK FHR CIRCUIT TRIGGER ON Fuel Heater Relay circuit is shorted The Fuel Heater Relay output from the micro is negative so the circuit will not be shorted to ground but is shorted either within the Fuel Heater Relay coil itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Rese
453. rigerant per sec 5 Spacer 9 Seat Disc tions NO TAG 10 Body 10 Start unit and check operation 11 Run Pretrip Refer to Section 3 4 Figure 9 31 SV1 Solenoid Valve 62 10683 9 40 9 22 COMPRESSOR SUCTION MODULATION VALVE CSMV The purpose of the CSMV is to control suction pressure maintain the compressor within normal operating range and maximize unit capacity and fuel economy At initial startup the microprocessor will go through a self test When the test is complete the MessageCenter will display SMV CLOSING When closing is complete the MessageCenter will display SETTING SMV XXX The XX will count up to a predetermined percentage depending on ambient temperature and compartment temperature The unit will then go through its normal start procedure 2 1 8 inch Nut Figure 9 32 Suction modulation valve CSMV 9 22 1 Function The CSMV coil consists of two windings labeled 1 and 2 Each winding has two poles labeled A and B Both poles of both windings have a wire connected back to the microprocessor Looking at the 4 pin connector on the CSMV coil the wiring is as follow Table 9 6 CSMV Connections Winding Pole 2 B 0 Refer to Section 2 13 for resistance value There is no common connection point between the two windings The microprocessor opens and closes the CSMV by sending a series of electrical pulses to the coil 4 CAUTION Do not connect 12 VDC to the
454. rmally 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 1 2 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 Warns against an immediate hazard which WILL result in severe personal injury or death WARNING Warns against hazards or unsafe condi tions which COULD result in severe personal injury or death CAUTION Warns against potential hazard or unsafe practice which could result in minor personal injury or product or property damage The statements listed below are specifically applicable to this refrigeration unit and appear elsewhere in this manual These recommended precautions must be un derstood and applied during operation and maintenance of the equipment covered herein 62 10683 WARNING Beware of V belts and belt driven compo nents as the unit may start automatically Before servicing unit make sure the START RUN OFF switch is in the OFF posi tion or the unit is in Maintenance mode Also disconnect the negative battery cable WARNING UNITS EQUIPPED WITH STAR TRAK TWO WAY COMMUNICATION CAPABILITIES MAY HAVE THE ABILITY TO BE STARTED OR TURNED OFF REMOTELY REGARDLESS OF THE SETTING OF THE START RUN OFF SWITCH The unit is controlled
455. roblem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the LB below as necessary Comes For Bad F10 Fuse 8 Check circuit current All conditions must be corrected in circuit Check Auto Fresh Air Exchange Solenoid AFAS draw of AFAS Use Component Test Mode Section 6 2 2 to test Refer to Section 2 13 for amp values current draw in the Unit Data List Wa AFAS And Circuit 28 oo AFAS and wiring No physical damage to harness No damaged or corroded pins pamm S damage to solenoid b Check EI uM of AutoFresh Air AFAS turned on and LED12 on EI uM Relay AFAR AFAR energized c Check voltage to AFAS 12VDC between AFAS B ground and AFAS A 12VDC when AFAR is energized 8 81 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION P164 CHECK UL2 CIRCUIT TRIGGER ON Normal Amps for the UL2 Rear Unloader Circuit is 0 75 to 2 0 Amps The circuit tests outside this range UNIT CONTROL Pretrip will abort and PRETRIP FAILED IN TEST 3 will be displayed in MessageCenter RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE T the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through th
456. roximately ten minutes until the refrigeration system is warmed up and the refrigerated compartment temperature is less than 45 F 7 2C Check the lower sight glass on the receiver to deter mine charge The system is correctly charged when refrigerant level is at centerline of sight glass then weigh in another 3 Ibs 1 4 kg of refrigerant Checking Refrigerant Level on Units With S N Beginning With JAR90710713 NOTE The ambient air entering the condenser air temperature should be above 40 F 4 4 C a Start unit in cooling mode Run approximately ten minutes until the refrigeration system is warmed up and the refrigerated compartment temperature is less than 45 F 7 2C Check the lower sight glass to determine charge The system is correctly charged when the lower sight glass is not empty and the upper sight glass is not full c Ifthe system appears to be overcharged Remove re frigerant through the king valve to correct refrigerant level Ifthe refrigerant system appears to be undercharged Add refrigerant through the king valve 9 11 5 Partial Charge h 9 27 4 CAUTION Do not vapor charge R404A Only liquid charging through the receiver outlet king valve is acceptable NOTE The ambient air entering the condenser air temperature should be above 40 F 4 4 C Place drum of refrigerant on scale and note weight Backseat discharge and suction service valves and install a manifold gauge
457. rrected and alarm cleared to proceed 2 Check System Pressures Check and compare compressor Suction amp Discharge Pressures must have the same discharge amp suction pressures with reading 5 PSIG 0 34 Bar on gauges amp on micro those shown on the microprocessor display controller 3 a Test MOP of Expansion valve b Verify that correct TXV is in unit 4 Must pass all tests Correct any problems found before proceeding 8 93 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION P195 LOW SUCTION PRESSURE TRIGGER ON This alarm is generated during Test 4 of Cool Pretrip Suction pressure is lower than normal using the lesser value of the two following calculations Minimum suction pressure should be 15 PSIG 1Bar less than TXV MOP see section 2 11 for MOP values OR RAT minus 40 F 22 C Calculate suction pressure using a Temperature Pressure chart See Table 9 9 For example if the RAT is 45 F you would take 45 F minus 40 F which equals 5 F Look up the saturated suction pressure for 5 F See Table 9 9 UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to se
458. rt until one of the new IntelliSets has been selected Press the UP or DOWN ARROW key to scroll through the list of IntelliSets Pressing the UP ARROW key will bring the first IntelliSet name into the Message Center Move to the desired IntelliSet and press the key The desired IntelliSet will automatically become act ive and the unit will be able to be started 6 7 8 Microprocessor Final Checkout a While the unit is running scroll through the Data List Start the unit and allow it to run for a few minutes of the microprocessor Verify that all the data that was recorded in Step b of Section 6 7 1 is now accurately displayed in the Data List Also verify that the correct date and time are being displayed Initiate a Pretrip test Allow the unit to complete the Pretrip and check for any alarms Make any neces sary repairs before returning the unit into service 6 7 9 Replacing Display Bezel Assembly Display Bezel Assembly Removal a Place the START RUN OFF switch in the OFF posi tion and disconnect the negative battery cable At tach a grounded wrist strap CTD P N 07 00304 00 and ground it to a good unit frame ground b Open the roadside side door containing the Keypad Display Assembly Unplug the display cable from the 10 pin harness c Loosen and remove the 4 hex head 1 4 20 bolts holding the bezel bracket to the door and lay the bezel assembly on a clean work surface d Loosen and re
459. ru Figure 10 4 There must be no LED alarm codes occurring to continue Wia Fuel Level In Tank E Check fuel gauge on tank Fill tank as needed Check For Alarms 28 Check for the following alarms Alarm conditions must be corrected and the alarm cleared 71 Check for Bad F2 or F3 Fuse alarm to continue 40 Check Glow Plugs alarm 35 Check Starter Circuit alarm 4 Check Fuel Solenoid Applies to non ESC engines only a Check Run Relay LED Must be ON b Check voltage to fuel solenoid Energize Run Relay in Component Test Mode Refer to section 6 2 2 to energize the fuel solenoid Must have 12 VDC between FSC C ground amp FSH A hold With Manual Crank Switch in crank position for units with GCS only 12 VDC between FSC C ground amp FSP B pick For units without GCS check FSC B pick circuit between fuel solenoid and starter motor c Inspect solenoid amp connector pins amp No damage to solenoid terminals No damaged or corroded pins d Inspect harness amp control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins schematic mL c Check voltage to glow plugs Glow Plug switch ON Manual Start Mode units with GCS only Units without GCS energize Glow Plug Relay in Component Test Mode Refer to section 6 2 2 In both cases there must be more than 11 VDC 6 Check Engine Air Intake System 2 5 Check air filter indicator Flag must
460. s Replace filter s and add lube oil Refer to Section 2 7 Warm up engine and check for leaks a Lube Oil And Fuel Flow Diagrams Fuel Tank Fuel Supply Line 7 Fuel Bleed Valve 8 Fuel Pump Optional 9 0 1 Injection Pump Injector Nozzles Fuel Leak off Line Fuel Return Line Mechanical Lift Pump Fuel Filter Fuel Warmer Optional Figure 9 4 Fuel System Diagram DARN Engine Block Oil Pan Full Flow Oil Filter Engine Oil Connection Oil Pressure Switch Figure 9 5 Lube Oil Flow Diagram 9 8 6 Speed Control Solenoid And Linkage Non b Servicing the Speed Control Solenoid and Linkage NOTE Check operation of speed solenoid before re placement If solenoid is sticking clean and lub ricate the solenoid in accordance with Technical Instruction 98 50234 1 Solenoid Removal Replacement 8 Disconnect wiring to solenoid Disconnect linkage arm Item 4 Figure 9 6 from solenoid Remove mounting hardware from solenoid and then remove solenoid b Install replacement solenoid and mounting hard ware Do not tighten at this time c Attach linkage to solenoid and install the clip to the linkage rod ESC engines only Units beginning with below 2 Low Speed Adjustment serial numbers and ALL X2 units Refer to Section 9 8 7 for information on units with Electronic Speed Control a Serial Number Cut Offs Ultra XTC KAV90910396 Ultima XTC KAV90910334 1 Sole
461. s Refer to Section 9 1 for instructions on service intervals 4 CAUTION When changing oil filters the new filters should be primed partially filled with clean oil if possible If the filters are not primed the engine may operate for a period with no oil supplied to the bearings Change 09 11 2 25 62 10683 2 8 ENGINE SCREW THREADS All threads used on the diesel engine are metric 2 9 ENGINE AIR SYSTEM The air cleaner is installed on the engine to prolong its life and performance by preventing dirt and grit from getting into the engine causing excessive wear on all operating parts It is the responsibility of the operator to give the air cleaner equipment regular and constant attention in accordance with the instructions Refer to section 9 8 8 Clean air is supplied to the engine through the air cleaner The air is necessary for complete combustion and scavenging of the exhaust gases As the engine piston goes through the intake stroke the piston draws clean fresh air down into the cylinder for the compression and power strokes As the engine goes through its exhaust stroke the upward movement of the piston forces the hot exhaust gases out of the cylinders through the exhaust valves and the exhaust manifold If the air filter is allowed to become dirty the operation of the engine would be impaired 2 10 COMPRESSOR DATA Table 2 5 Compressor Data Compressor Model 058 NoOyides 6 No Unlcaders
462. s amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Section 11 b Power microprocessor up See Voltage should be 2 5 VDC volts at harness plug between Note 5 Page 8 2 Disconnect sensor pins from harness Check for voltage at harness plug between pins Check Remote Sensor Switch Connector a Locate and inspect 10 way connector Connector must have cap on for optional sensors and switches No corrosion or moisture inside connector If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink 8 57 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 123 CHECK SUPPLY AIR SENSOR TRIGGER ON Supply Air Sensor circuit has failed open or shorted If shorted the data list will display 158 F 70 C If the circuit is open the data list will show the temperature as 52 6 F 47 C UNIT CONTROL Use Return Air Sensor reading minus 3 6 F 2 C If Return Air Sensor Alarm is on and setpoint is at or below 10 4 F 12 C unit will run in Low Speed Cool only If setpoint is above 10 4 F 12 C unit will shut down If Alarm 132 CHECK DEFROST TERM 2 SENSOR is also active Defrost termination will be as described in section 5 11 RESET CONDITION Auto Reset when Supply Air Sensor is in r
463. s amp on micro display 62 10683 8 42 NO Steps ALARM CAUSE CORRECTIVE ACTION 57 CHECK REMOTE SWITCH 1 TRIGGER ON Remote Switch 1 is set to trigger alarm contacts open or contacts closed depending on set up in configuration list for Remote Switch 1 for more than five seconds NOTE This alarm is disabled for Shutdown when the Unit Operation configuration is set for Rail and the unit is operating in Sleep Mode eShut down may be overridden in the Functional Parameter list UNIT CONTROL Alarm Only or may be configured to shut unit down RESET CONDITION Alarm Only Auto Reset after Remote Switch 1 has been set to allow unit to run for more than five seconds Unit Shutdown Auto Reset after three minutes minimum off time for Remote switch shutdown condition and Remote Switch 1 has been set to allow unit to run for more than five seconds NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Determine What Remote Switch 1 Is Controlled By a Remote Switch 1 may be connected to Find and locate Remote Switch 1 a refrigerated compartment door or some other device and used to remotely control the unit 2 Check To See If Refrigerated Compartment Side Or Rear Door Is Open Or If The Device Tha
464. s alarms or will affect future Pretrip tests will allow Pretrip to be aborted TIP Pretrip may be stopped by the user by either turning the unit off then back on again or by pressing and holding the key for five seconds PRETRIP STOPPED BY USER will appear in the MessageCenter Once Pretrip is started If the unit is running the microprocessor will shut the unit down If the unit is not running and the suction modulation valve CSMV has reached its fully closed position Pretrip will begin NOTE Before completing PreTrip the microprocessor looks at the status of alarms and if certain alarms are active for example Low Fuel Warn ing Check Engine Oil Level Check Coolant Level Check Coolant Temperature PreTrip will show FAILED indicating that the unit is not ready to be sent out for a load butthat the alarm list should be checked and all present alarm si tuations corrected TIP It is always a good idea to clear all alarms from both Alarm Lists before starting Pretrip The technician will then know that any alarms pres ent following Pretrip occurred during Pretrip and are not old alarms that had not been cleared NOTE The operator MUST be present and validate this test by watching the microprocessor dis play during Test 1 Display Test The micropro cessor will turn on all segments of the LCD and LED display Test 1 Display And Sound Test The microprocessor activates the LCD LED display
465. s component 3 Check Airflow Through Condenser Coil See Note 9 Page 8 2 a Inspect condenser radiator fins Fins must be straight 9096 or more of the coil surface must be undamaged No dead air spaces Condenser Radiator coil must be clean b Check airflow with unit running Even airflow through the entire coil No dead spots 4 Check System Pressures a Install Manifold Test Set and check and Suction amp Discharge Pressures must have the same compare compressor discharge amp reading on gauges amp on micro display Pressures must be suction pressures with those shown on in the normal range for ambient amp box temperature the microprocessor controller conditions a Check refrigerant level in the receiver Level must be between upper amp lower sight glasses tank Check Discharge Check Valve Check that discharge check valve Must open fully with unit running opens fully b Check discharge check valve screen Must be clean of any debris 7 Manually Test Refrigeration System See Note 9 Page 8 2 a Run Quick Check Must pass all tests Correct any problems found before proceeding Check System For Non Condensables a Check refrigeration system for No non condensable gas es may be present non condensable gas es b See Refrigeration Troubleshooting Section 10 3 9 High Discharge Pressure Check Compressor a Remove all Compressor heads and Must be in good condition inspe
466. s ke WAN Ree ER UU E Ale ACCU Ele Ala TR 2 26 2 11 REFRIGERATION SYSTEM DATA een hn 2 26 2 12 SAFETY DEVICES Bead i ben eb omo tee hd er Aad tis 2 27 2 13 COMPONENT RESISTANCE AND CURRENT 2 28 2 14 REFRIGERANT CIRCUIT DURING COOLING sssssseeees nen 2 29 2 15 REFRIGERANT CIRCUIT HEATING AND DEFROSTING 2 30 i 62 10683 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page OPERATION Ae es ie sse bv ihe gue LM ead Shall lk 3 1 94 STARTINGUNIT 9 AUTO iste I EE EVEN 3 1 3 2 MANUAL START GLOW AND CRANK IF EQUIPPED 3 2 3 9 Unit Startup Self Test sso sss iad herein tt POIL ERG WE FERRE 3 3 3 45 exte Preis etatis to eite deter bm tur octo tee 3 4 3 5 CHANGING SET POINT rns 3 8 3 6 START STOP OPERATION pa rr 3 9 3 7 CONTINUOUS RUN OPERATION n mn 3 11 3 8 SLEEP MODE a eR RES ee Race rede dale 3 12 3 9 SLEEP MODE OFF xe RERUM Ree ES Rb rede ede ima 3 13 3 10 DEFROST 1 sk ERREUR Ra ree e eb redde e RATS 3 15 3 10 1 Manual Defrost hh hn 3 15 TRIP START sae eds bis dears br RR Hane dole ee dale eA ee dee adie 3 16 3 12 VIEW ACTIVE ALARMS
467. s not reading correctly and the engine is being started for the second or third attempt the engine is considered to be running when a For ambient temperatures at or above 32 F 0 C the engine oil pressure switch contacts are closed b For ambient temperatures below 32 F 0 C the alternator charging amps are more than 2 amps NOTE If either of these two cases occurs alarm 130 CHECK ENGINE RPM SENSOR will be ac tivated NOTE While the starter is engaged if the engine speed is less than 50 RPM for more than 3 seconds the SSR will de energize to stop the starter 4 2 4 Initial Engine Operation If a unit is started when the Engine Coolant Tempera ture is 79 F 26 C or below after the engine starts the unit will immediately go to low speed 4 cylinder opera tion until the water temperature reaches 79 F 26 C or for a minimum of 15 seconds The CSMV will control suction pressure to 78 PSIG 5 3 Bars Max during low speed 4 cylinder operation Refer to Chart Section 5 18 Once the water temperature is greater than 79 F 26 C the unit will run at high speed 4 cylinder opera tion and the CSMV will control to a maximum suction pressure of 42 PSIG 2 9 Bars Refer to chart When the RAT reaches 50 F 10 C the unit will go to 6 cylin der cool operation and the CSMV will control to a maxi mum suction pressure of 27 PSIG 1 8 Bars The unit will continue in high speed 6 cylinder cool until the con
468. s self test and the display will show SMV CLOSING WAIT XXX SECONDS The valve is obviously closed at this point but the microprocessor is programmed to always close the CSMV every time the microprocessor is powered up The display will then show SET TING SMV XXX Refer to 9 22 above If the suction pressure does not go up the CSMV is stuck closed go to Step NO TAG or there is something obstructing the refrigerant NOTE If the valve passes steps a through f the valve is operating properly g If the suction pressure rises during Step e or if the valve is determined to be stuck closed in Step f turn the unit Off by placing the Start Run Off switch in the OFF position and unplug the 4 pin connector to the CSMV With a reliable digital ohmmeter check the winding resistance between 1A Black wire and the 1B White wire AND between the 2A Green wire and the 2B Red wire Refer to Section 2 13 for standard resistance in normal ambient temperatures If this resistance is confirmed proceed to Step 8 If an infinite or zero ohm reading occurs first check the wires atthe connector for good contact If the connec tor is in good condition and the resistance is still bad one or both of the coils could be faulty Replace the CSMV power head assembly P N 14 00263 20 Re fer to Section 9 22 3 62 10683 9 42 h 9 22 3 Replacing The a oon Figure 9 33 CSMV Coil Locate the wires on the engine
469. screen correct the condition savers and power saver options on the laptop These YES System OK options can interfere with software download Did you find and correct the condition Make sure you are not using USB or 9 pin adapters on the computer Did you find and correct the condition NOH Y Problem is with Did the MicroProgrammer program launch computer Try load properly on your computer ing software with another computer YES System OK A Y Veri loadi When you loaded the problem file erify you are loading a Load the correct does it say FILE VALID on the correct BEX file and try again bottom of the screen Advance micro Are you i loading the correct file Try again using n a good cable Close MicroProgrammer The PROGRAM MICRO button is not and start over again OR use Program PC card active Click on the button Is the NO software loading NO Check the integrity of Y Did you achieve the download cable 19 vgg Did you get a Is the Percent the cable Communication Error Complete 100 download i message increasing
470. sed the default message will be displayed after 10 seconds NOTE Any function that is shown with a padlock symbol cannot be changed from the keypad 3 25 62 10683 Table 3 3 Functional Parameters FUNCTIONAL PARAMETER DEFROST TIMER SET FOR SET S S PARAMETERS These may be displayed individually 8 parameters as PERISH and FROZEN or combined 4 parameters with no designation PERISH FROZEN MIN RUN TIME PERISH FROZEN MIN OFF TIME PERISH FROZEN OVERRIDE TEMP e PERISH FROZEN MAX OFF TIME FROZEN SHUT DOWN OFFSET TEMP CONTROL 60MINS in one minute increments 90MINS 20MINS in one minute increments 3 6 F 2 C TO 18 F 10 C 11 F 6 C 0 5 F or C increments OFF 10MINS TO 255MINS in one minute increments 0 F 0 C RETURN AIR SUPPLY AIR The defrost timer will automatically put the unit into the defrost cycle at the interval selected if evaporator is below 40 F 4 4 C Shorter times are generally used for warm humid products like pro duce Longer times can be used for dry and frozen products Time and Temperature values that control the Automatic Start Stop operation are set in this section When TOGETHER is selected in Configurations only Perishable Settings are used This determines the minimum length of time the unit will run every time the unit starts in Auto Start Stop modes This determines t
471. sor inspection with front cylinder head Remove the cylinder head Inspect the parts of the head and the valve plate Inspect pistons Inspect the cylinder bores Check the compressor rotation Next center or rear cylinder heads NO Done for all heads Hu Repair Replace or repair the compressor Replace Follow repair procedures Follow replacement procedures Figure 10 14 Compressor Diagnostics 62 10683 10 26 C Procedure After Compressor Repair Or Replacement 1 Run Pretrip to ensure all refrigeration components function properly 2 In addition to ensure the repair of the original compressor or the reliability of the replacement compressor check the following a Verify proper air switch setting using 07 00177 magnehelic gauge or equal b Verify that air switch will initiate defrost by momentarily jumping the air switch contacts c Check all switches and sensors for proper operation 3 See Section 9 13 for compressor oil level check procedure 4 Perform refrigerant and compressor oil moisture acid tests per instructions with test kits change oil or reclaim refri gerant as required Refer to 98 50037 for system cleanup procedures 5 If a compressor failure such as broken valves had the possibility of releasing large particles into the system the discharge
472. ssage is manually cleared This will only appear when a compartment door switch is configured in the Configuration List OVERRIDE NO Allows the door switch to shut the unit down whenever the com DOOR partment door is opened and the door switch is configured for shut SHUTDOWN down YES Allows operator to over ride the compartment door shutdown switch and allow the unit to continue to run even with the compart ment door open NOTE This will only appear when a remote switch REMS1 or REMS2 is configured ON in the Configuration List OVERRIDE NO Allows remote switch 1 and or 2 to shut the unit down whenev REMS 1 2 NO er door is open or the switch is turned ON YES Allows operator to override remote switch 1 and or 2 and al low the unit to continue to run even with the remote switch in the ON position or the door is open ENGLISH ENGLISH All information displayed in the MessageCenter will be shown in English FRANGAIS FRAN AIS All information displayed in the MessageCenter will be LANGUAGE shown in French IDIOMAS ESPANOL ESPANOL All information displayed in the MessageCenter will be LANGUE shown in Spanish LINGUAGEM PORTUGU S PORTUGU S All information displayed in the MessageCenter will be shown in Portuguese NOTE This parameter can be quickly accessed by pressing and holding the Select key for six seconds Selections in BOLD are the factory settings This Func
473. ssociated approxi mate 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 These should be worn whenever han dling a microprocessor Table 6 1 Connection Point Voltage Connection Point Approximate Voltage AAT CDT DTT ENCT 2 5 VDC Variable RAT SAT 62 10683 6 22 Although there is less danger of electrical static dis charge ESD damage in the outdoor environment or in a repair shop where the processor is likely to be han dled proper board handling techniques should always be stressed Advance Microprocessors should always be handled by the plastic cover and not the exposed printed circuit board This not only precludes the possi bility of ESD damage but also lowers the possibility of physical damage to the electronic components When field diagnosis of a Carrier Transicold Vector 6500 refrigeration unit determines that an Advance Microprocessor is not performing properly and must be replaced the following steps MUST be taken to ensure correct operation of the unit following the repair Prior to beginning work on the unit be certain that the current configuration file has been downloaded for the customer from the Carrier Transicold Information Center and written onto a Configuration PC Card using the ReeferManager Program If the original microprocessor was equip
474. st alarm displayed and so on 3 Press the ALARM LIST or UP ARROW key to scroll through the list of alarms 4 When you reach the end of the alarm list LIST END TO CLEAR ALARMS is displayed for five seconds 5 To clear the active alarm list press the key while LIST END TO CLEAR ALARMS is be ing displayed ACTIVE ALARMS LIST CLEAR is displayed This will move all Alarms to the Inactive Alarm list Alarms are stored in the Alarm list in the TIP microprocessor Stored alarms may be viewed on the The message CHECK MICROPROCESSOR MessageCenter on earlier microprocessors or CHK WIRES For a complete list of alarms their meanings and FROM MICRO TO KEYPAD on newer micro troubleshooting refer to Section 8 1 processors means there is a wiring problem TIP between the microprocessor and the display Another way to clear active alarms is to turn the module microprocessor OFF and then back ON using the START RUN OFF switch 3 17 62 10683 3 13 VIEW INACTIVE ALARMS HEAT COOL 20 SETPOINT e DEFROST START STOP CONTINUOUS 32345 F BOX TEMPERATURE NO INACTIVE ALARMS MANUAL DEFROST 1 Press and hold both the ALARM LIST key and the UP ARROW key for six seconds If there are no inactive alarms the display will read NO INACTIVE ALARMS for five seconds ALARM LIST d SELECT CONTINUOU 2 If there are inactive alarms the display will be
475. steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Real Time Clock a Check Real Time Clock in the Data list Must show correct date and time Change as needed or using ReeferManager Configuration list 2 Microprocessor 248 Turn main switch off for 30 seconds Microprocessor powers up OK then turn on b Check for valid Real Time Clock read Valid date and time in memory ing in Data list Alarm is cleared automatically c Real Time Clock can not be changed Replace microprocessor Microprocessor Defective a Download previous data using Data retrieval OK Download PC Card or ReeferManager Program b Replace microprocessor amp set New microprocessor in place Configurations Functional Parameters Enter hours from removed microprocessor set Maintenance Hour Meters and Data Recorder Setup NOTE Specific configurations or IntelliSet settings may be found on the TransCentral Website Authorized Carrier Transicold Dealers only 62 10683 8 46 NO Steps ALARM CAUSE CORRECTIVE ACTION 61 DOOR OPEN TRIGGER ON Trailer or rail car compartment door has been open for more than five seconds NOTE This alarm is disabled for Shutdown when the Unit Operation configura
476. sure Non condensables or refrigerant overcharge NO TAG and Table 2 1 SV1 Solenoid valve SV1 malfunction RR Sp Suction and discharge Compressor valves defective 9 12 pressures tend to equalize when unit is operating Compressor gasket s defective 9 12 10318 Vbetsbokenorkom 99 NO TAG Low discharge pressure Solenoid valve SV1 malfunction Solenoid SV1 open 62 10683 10 6 INDICATION ACTION TROUBLE POSSIBLE CAUSES REFERENCE SECTION 10 3 10 Abnormal Noise Tighten 9 12 Compressor 9 12 103 13 Insufficient oil 9 13 Condenser or Loose or striking shroud evaporator fan Bearings defective Defective Replace Clutch Gearbox V belts Cracked or worn 10 3 11 Control System Malfunction Sensor defective 9 28 Will not control Relay s defective Check Microprocessor malfunction Check 10 3 12No Evaporator Air Flow Or Restricted Air Flow E t il blocked Frost on coil vaporator coil blocke Dirty coil V belt broken or loose Clutch Gearbox defective evaporator Evaporator fan loose or defective 9 24 9 26 Evaporator fan rotating backwards Evaporator air flow blocked in refrigerated compartment 10 3 13 Expansion Valve Malfunction Low refrigerant charge NO TAG NO TAG External equalizer line plugged y Ice formation at valve seat NO TAG agua Wax dirt plugging valve or orifice Clean high superheat Wax oil or dirt plugging valve or orifice
477. sure that the compressor crankshaft is turning and that the compressor drive gears are in good condition Install gauges on the suction and discharge service valves A separate gauge should be connected to the unit liquid line king valve in order to determine pressures in other steps Check unloaders as follows a With the unit operating in high speed cool check the status of the front and rear cylinder unloaders The micropro cessor energizes the unloaders independently based on suction pressure If one or both unloaders are energized unplug or disconnect the power source separately for the front and rear unloaders b Using a separate 12V power source energize and de energize each unloader separately Note the suction pres sure change as each unloader is energized or de energized Both unloaders should show a rise in suction pressure rise of 3 to 6 PSIG 0 2 to 0 4 bar when energized and a drop of 3 to 6 PSIG when de energized If little or no change is noticed for either unloader the cylinder head s must be removed for further inspection See Section B for in spection procedure Perform unit pumpdown per Section NO TAG a Shut the unit off and observe the suction discharge and receiver pressure Receiver pressure should drop very slowly and suction and discharge pressure will slowly equalize to within a nominal saturated pressure range Refer tothe refrigerant pressure temperature chart Table 9 9 for pressures corresponding t
478. t Remote Switch 1 Is Connected To Is Set To Trigger The Alarm E a Inspect refrigerated compartment Refrigerated compartment door s must be closed doors b Check device at Remote Switch 1 Must have switch in position that allows unit to operate Check Wiring a Visually inspect wiring to switch Wiring must be connected b Visually inspect condition of switch Must not be damaged Check Remote Switch 1 a Check switch operation Contacts must Open amp Close as switch is opened and closed Door is open switch contacts are Check Configurations a Verify that Configuration is set for the Must be correct for type of Remote switch being used type of switch being used i e when closed etc 8 43 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 58 CHECK REMOTE SWITCH 2 TRIGGER ON Remote Switch 2 is set to trigger alarm contacts open or contacts closed depending on set up in configuration list for Remote Switch 2 for more than five seconds NOTE This alarm is disabled for Shutdown when the Unit Operation configuration is set for Rail and the unit is operating in Sleep Mode eShut down may be overridden in the Functional Parameter list UNIT CONTROL Alarm Only or may be configured to shut unit down RESET CONDITION Alarm Only Auto Reset after Remote Switch 2 has been set to allow unit to run for more than five seconds Shutdown Auto Reset after three minutes minimum off time for Remote switch sh
479. t the connector may be removed and each individual wire separated from the others terminated and insulated with heat shrink 62 10683 8 56 NO Steps ALARM CAUSE CORRECTIVE ACTION 122 CHECK RETURN AIR SENSOR TRIGGER ON Return Air Sensor circuit has failed open or shorted If shorted the data list will display 158 F 70 C If the circuit is open the data list will show the temperature as 52 6 F 47 C UNIT CONTROL Use Supply Air Sensor reading plus 3 6 F 2 C If Supply Air Sensor Alarm is on and setpoint is at or below 10 4 F 12 C unit will run in Low Speed Cool only If setpoint is above 10 4 F 12 C unit will shut down RESET CONDITION Auto Reset when Return Air Sensor is in range or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Return Air Temperature Sensor RAT a Inspect Return Air Sensor amp connector No damage to sensor No damage moisture or corrosion in connector b Check Return Air Sensor resistance Refer to Section 9 28 for complete resistance chart See Note Note 6 10 000 Ohms 77 F 25 C Check Return Air Sensor Wiring a Inspect harnes
480. t Test mode Section 6 2 2 to test Refer to Section 2 13 for amp values View current draw in the Unit Data list Refer to Section 3 14 Check SV2 amp Circuit a Inspect SV2 and wiring No damage or corrosion Connector fits together tightly no moisture inside b Check operation of SV2 FET 21 START RUN OFF switch in START RUN Manual Start Operation See Note Note 4 LED must be ON c Check voltage to SV2 Must be 11 VDC or higher across the 2 wires Check SV2 Circuit Wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins schematic Section 11 62 10683 8 92 ANO Steps ALARM CAUSE CORRECTIVE ACTION P194 HIGH SUCTION PRESSURE TRIGGER ON This alarm is generated during Test 4 of Cool Pretrip Suction pressure is higher than normal Maximum suction pressure should be approximate MOP of TXV or a little bit higher during this test UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for SV4 Alarm a Check for alarm P181 Condition must be co
481. t a PM hourmeter that has not expired and is not found in the Functional Parameter list a From the Configuration list select the PM hourmeter Press the key to change Select OFF for the interval Press the key to enter Press the key to change Select the correct interval Press the key to enter Place the START RUN OFF switch in the OFF posi tion then back to START RUN Check the Data list The correct number of hours should be showing as HOURS TO ENGINE MAINT 2o o0o0o0c 62 10683 6 7 ADVANCE MICROPROCESSOR REPLACE MENT amp CONFIGURATION SETUP CAUTION Under no circumstances should a techni cian electrically probe the processor at any point other than the connector terminals where the harness attaches Microproces sor components operate at different volt age levels and at extremely low current lev els Improper use of voltmeters jumper wires continuity testers etc could perma nently damage the processor CAUTION Most electronic components are suscepti ble to damage caused by electrical static discharge ESD In certain cases the hu man body can have enough static electric ity to cause resultant damage to the compo nents by touch This is especially true of the integrated circuits found on the trailer mi croprocessor As mentioned above some microprocessor inputs op erate at voltage levels other than the conventional 12 VDC Connection points and the a
482. t for Continuous 30 to 32 C Set for Start Stop 23 3 17 8 12 2 Figure 5 6 Range Lock 2 5 13 62 10683 5 16 ProductShield NOTE ProductShield does not operate within Sleep Mode ProductShield is a group of configuration settings within the microprocessor that are available in all Advance Micropro cessors that have the IntelliSet option installed The ProductShield Modes work together with the various IntelliSets to allow improved operating efficiency while providing customized product protection for up to 31 different commodities Each ProductShield setting allows the user to select an ambient temperature range in which to operate The Minimum and Maximum range values can be set to OFF or any value from 20 to 119 F 28 9 to 48 4 C 5 16 1 ProductShield Modes a ProductShield Econo Go To Start Stop and Go To Continuous Run ProductShield Econo allows the unit to automatically switch from Start Stop operation to Continuous run or vice versa based on a change in the ambient air temperature This allows for maximum product protection while providing for fuel savings depending on ambient conditions 1 When the unit is set for Continuous Run ProductShield Econo allows the unit to cycle OFF in Start Stop when e ProductShield Econo configuration is set to GO TO S S Refer to Section 6 2 1 AND e Theunit has run in Continuous Run for a minimum of either 15 minutes or the Minimum Run Time as selected inthe Fu
483. t when Fuel Heater Relay current amp draw is normal or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Fuel Heater Relay a Inspect Fuel Heater Relay amp socket No damage to relay No damaged or corroded pins b Check resistance of relay coil Refer to Section 2 13 Check Fuel Heater Relay Wiring Inspect harness amp control box See Notes Note 3 Note 4 amp Note 8 connector pins amp terminals See wiring No physical damage to harness schematic No damaged or corroded pins Check Fuel Heater Relay Current Draw a Use Component Test mode Refer to Refer to Section 2 13 for normal current values Section 6 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 14 82 CHECK REMOTE OUT RANGE LIGHT TRIGGER ON The micro Light Bar configuration is set for an 8 LIGHT BAR and the Out of Range light circuit to the Light Bar circuit is shorted The Out Of Range Light output from the micro is negative so the circuit will not be shorted to ground but is shorted either within the Out Of Range Light itself or to a positive wire UNIT CONT
484. ta Downloading The data within the DataRecorder can be downloaded from the DataRecorder by using either the ReeferManager a PC software program and a download cable connected to the download port refer to Section 6 1 or with a Download PC card refer to Section 6 4 If a PC card is used the ReeferManager program is then used to extract the data from the PC card and place it on the computer hard disk 3 19 5 DataRecorder Power Up The DataRecorder records data the entire time the START RUN OFF switch is in the Run position A configuration exists which allows the user to select either an additional eight hours of data to be recorded after the START RUN OFF switch is placed in the OFF position or to stop recording at the same time the START RUN OFF switch is turned to the Off position The factory setting is to include the additional 8 hours of data See Configuration List Section 6 2 1 3 20 OPTIONS 3 20 1 IntelliSet e HEAT e COOL 324 SETPOINT APPLES e DEFROST ALARM MANUAL D DURING START UP ALARM E START STOP CONTINUOUS 3345 F BOX TEMPERATURE ACTIVE START SELECT CONTINUOU Observe the MessageCenter during the power up process If the unit is equipped with IntelliSet the name of the active or modified IntelliSet will be displayed for approximately 10 seconds before the engine starts DURING OPERATION Press the SELECT key to view current IntelliSet You will b
485. tch coil onto fan shaft hub with coil harness on top Make sure all original shims are correctly positioned on fan shaft pin and then slide coil onto hub so fan shaft pin fits into notch in coil NOTE The fan shaft pin is used to position the coil to properly secure the wire harness to the frame Install rotor spacer and rotor onto the fan shaft Install the new spanner nut included in mounting ac cessory kit CTD P N 50 00236 21 Use CTD span ner socket 07 00303 02 and torque to 80 85 ft lbs 11 1 to 11 5 Mkg NOTE The spanner nut is LEFT HAND NYLOCK THREAD NUT Q Slide the armature into place on the fan shaft making sure the key is in place and the keyway lines up cor rectly with the shaft key e Install the new armature retaining bolt and washer Use spanner wrench CTD P N 07 00396 01 at the 2 o clock position to hold the armature then torque the retaining bolt to 25 30 ft lb 3 5 to 4 1 NOTE The armature retaining bolt is a LEFT HAND THREAD BOLT f Measure the clutch air gap with the air gap tool CTD P N 07 00432 00 The gap should be be tween0 015and0 090inches 0 38and2 3mm If it is not remove entire clutch If gap is less than 0 015 0 38 mm remove enough ofthe fan shaft hub shims to increase the gap to approximately 0 020 0 51mm Shims CTD P N 50 00232 30 are 0 010 0 25mm each Ifthe gapis morethan 0 090 2 3 mm add enough shims to reduce gap toapproxim
486. te sensor switch connector a Locate and inspect 10 way connector Connector must have cap on for optional sensors and switches No corrosion or moisture inside connector If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may 1 a Inspect Ambient Air Sensor amp damage to sensor connector No moisture damage or corrosion in connector 1MP Plug is connected tightly to microprocessor No wires are pushed back through plug b Check Ambient Air Sensor resistance 10 000 Ohms 77 F 25 C See section 2 13 for See Note 4 Page 8 2 complete table of temperatures and resistance values 2 be removed and each individual wire separated from the others terminated and insulated with heat shrink 8 79 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION P160 CHECK DISCH TEMP SENSOR TRIGGER ON Compressor Discharge Temp Sensor is not within the maximum range of 40 F to 392 F 40 C to 200 C UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Compressor Discharge Tem
487. ted but not entered in Configuration list Change 09 11 7 5 62 10683 MessageCenter MESSAGES Message Description TRIP START ENTERED The Trip Start marker has been placed in the DataRecorder UNIT BATTERY LOW The unit battery has dropped below 7 volts for more than 10 seconds UNIT SHUTDOWN DOOR OPEN The unit has shut down because the trailer or rail compartment door is open UNIT SHUTDOWN SEE ALARM LIST An active shutdown alarm has shut the unit down UNIT SHUTDOWN 1 2 The unit has shut down because switch is open May be connected to a door or a remote control switch UNKNOWN CARD REMOVE CARD A defective or different type of PC Card has been inserted into the PC Card slot The microprocessor can not recognize any data on the card The card may be safely removed from the micropro cessor WARNING NO TEMP CONTROL Both RAT and SAT alarms are on and unit is running with a set point in the frozen range in low speed six cylinder cool WRONG UNIT TYPE REMOVE CARD A Configuration PC Card has been inserted into the PC Card slot The unit model type on the PC card is not in the same unit family type as the controller The card may be safely removed from the microprocessor 62 10683 7 6 Change 09 11 SECTION 8 ALARM TROUBLESHOOTING PARAGRAPH NUMBER Page 8 31 INTRODUCTION TO ALARM TROUBLESHOOTING GUIDE 8 1 8 27 NOTES zoe che x ce ett uU Ra eee eee eo OS 8 2 83 DRIVER OPERATOR A
488. telliSets into microprocessor The IntelliSleep Intelliset is active Alternates with INTELLI SLEEP MODE at 5 second interval whether unit is run ning or not Service mode has the refrigeration system set so that it can be charged with refrigerant through the king valve Press the key to manually exit or wait until the charging is complete The unit needs to be checked at next service interval There is currently an active non shutdown alarm in the Alarm list CHECK COOLANT LEVEL Requires Optional Sensor CHECK DOOR CHECK ENGINE OIL LEVEL Requires Optional Sensor The engine coolant level is not full Door switch indicates that trailer or rail car compartment door is not closed The oil level in the diesel engine is low CHECK FUEL LEVEL Requires Optional Sensor The level in the fuel tank is very close to empty CHECK MICROPROCESSOR Earlier Units Only There is a communication signal lost between the keypad display and the microprocessor Check and test the wiring to the keypad display CHK WIRES FROM MICRO TO KEYPAD Later Units CLHR OFF IN X MINS There is a communication signal lost between the keypad display and the microprocessor Check and test the wiring to the keypad display The Clutch Relay circuit has been energized in Component Test mode The Clutch Relay circuit will continue to be energized for the number of minutes shown COMPONENT TEST MODE Pressing the key while t
489. tem is operating in the Cool Mode 5 9 CARGO PROTECT MODE When both the return air sensor RAT alarm and the supply air sensor SAT alarm are active the unit will enter Cargo Protect Mode for temperature control When the set point is in the frozen set point range the unit will run low speed loaded cool WARNING NO TEMP CONTROL will be displayed in the MessageCenter The unit will shutdown when the set point is in the perishable range See section 5 2 for definition of perishable amp frozen set points 5 5 62 10683 Note The following temperature control operating sequence diagrams are after pulldown and do not show overrides 3 2 F 1 8 C 2 3 1 3 1 5 F 0 8 C CSMV CONTROL 1 8 F 1 0 C 2 7 F 1 5 3 6 F 2 0 FALLING BOX TEMPERATURE High Speed 6 Cylinder Cool Low Speed 6 Cylinder Cool Low Speed 2 Cylinder Cool UltraFresh 3 Low Speed 2 Cylinder Null Low Speed 2 Cylinder Heat Low Speed 6 Cylinder Heat High Speed 6 Cylinder Heat RISING BOX TEMPERATURE 3 6 F 42 0 C 2 7 F 1 5 1 5 0 8 C 2 3 F 1 3 C 3 2 F 1 8 C Note System can change from Low Speed 2 Cylinder Cool to Low Speed 6 Cylinder Cool when the box temperature rises However once the unit enters UltraFresh 3 Mode it will remain in that mode until the box temperature rises to 3 6 F 2 0 above setpoint at which point
490. ten as needed Did you find and correct the condition Review the test results with your supervisor If necessary go to the 62 10683 beginning of the table and test again YES MPR Code 4 NO Y Are pins unable to be straightened or pins broken 10 20 Figure 10 11 Microprocessor Diagnostic Tree PC Card Problems START HERE Are you trying to load any version of Does the MessageCenter say software that is older than 04 00 00 OLD SOFTWARE CANNOT LOAD T NO Insert the PC Card into the PC Card slot the front of the micro Be certain that the instructions label on the download card is facing the Caution label on the micro Do Once 04 00 is installed into the micro it is no not force the card into the slot Handle the longer possible to load any version of 03 or card from the edges Did you find and previous software Newer versions can be correct the condition loaded as released If loading 04 00 or 04 02 and the micro has 03 xx or previoius software NO incrementally upgrade the software See Bulletin SERO4 47 for instructions Does the MessageCenter acknowledge a program card was nstalled by displaying Verify you are using a Progra PC card and not OLD SOFTWARE NEW SOFTWARE another PC card Did you find and correct the or SAME SOFTWARE conditi
491. ter 4 Press the key to select Sleep Mode Settings 5 SLEEP MODE YES OR will show in the MessageCenter Press either the UP or DOWN ARROW key to change the Sleep Mode to NO OR Sleep Mode OFF START RUN 1 To take the unit out of Sleep Mode place the START RUN OFF switch to the OFF position then back to Start Run NOTE If IntelliSleep is active the only way to exit Sleep Mode is to activate another IntelliSet 3 13 62 10683 SLEEP MODE ON Continued No further menu selections are available when NO is selected from the SLEEP MODE YES OF NO menu The following sub menus are available when YES is selected 1 WAKE UP TIME a When WAKE UP TIME is set to NO the unit will remain in Sleep Mode until it is taken out manually per Section 3 9 b When WAKE UP TIME is set to YES the SET WAKEUP TIME menu will become available Pressing the key will allow the user to se lect the time the unit is to automatically wake up The wake up time must be at least 1 hour and no more than 8 days from the time the clock is set The following inform ation can be entered Month Day Year Hour Minute NOTE Theclock is a 24 hour clock Hours 1 thru 12 are AM and hours 13 thru 24 are PM HUN PRETRIP TEST AT WAKE a When PRETRIP TEST AT WAKE is set to NO the unit will wake up at the designated time and con trol to setpoint b When PRETRIP TEST AT is set to
492. ters are recorded at midnight or the first time of day the switch is turned to the ON position d User Area Data The user or service technician is able to enter a comment into the DataRecorder using the ReeferManager program 3 33 3 19 3 Sensor and Event Data Sensors The following sensors may be recorded either with an averaged reading or snapshot or may not be recorded at all Return Air Temperature Supply Air Temperature Ambient Air Temperature Compressor Discharge Temperature Engine Coolant Temperature Compressor Discharge Pressure Compressor Suction Pressure Battery Voltage Battery DC Current Engine RPM Events Selectable User may determine whether the following events are recorded All other events such as ON OFF Defrost start will be recorded Pretrip Start Pretrip End Trailer ID Unit S N Unit Mode Control Mode Transducer Calibration Optional Sensors and Events In addition to the above Sensors and Events the DataRecorder also has the capabilities to record the following Remote Temperature Sensor 1 Remote Temperature Sensor 2 e Remote Temperature Sensor 3 Remote Switch 1 Remote Switch 2 Door Switch Fuel Tank Level 62 10683 DATA RECORDING CONTINUED Time Intervals The following intervals are available for sensor recording e 2 Minutes e 5 Minutes e 10 Minutes e 15 Minutes 30 Minutes 1 Hour e 2 4Hours 62 10683 3 34 3 19 4 Da
493. th the steps below as necessary Manually Test Refrigeration System See Note 9 Page 8 2 a Run Quick Check Must pass all tests Correct any problems found before proceeding b Check and compare compressor Suction Pressure must have the same reading on gauge amp suction pressure with pressure shown on micro display on the microprocessor controller Check Compressor Rear Head Reed Valves amp Gaskets a Remove compressor rear head amp Must be in good condition inspect condition of all reeds amp gaskets P202 HIGH SIDE LEAK TRIGGER ON With the Low Pressure Side of the refrigeration system forced to low pressure refrigerant pressure is leaking past one of the components in the High Pressure Side of the refrigeration system into the Low Pressure Side UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Manually Test Refrigeration System See Note 9 Page 8 2 a Run Quick Check Must pass all tests Correct any problems found before proceeding b Check and compare compressor Suction Pressure must have the same reading on gauge amp suction pressure with
494. the appropriate modes to see if any active occurs Continue with the steps below as necessary cerk Functional Parameters 7 Check Functional Parameters All must be set for selectable values 2 Microprocessor 28 Turn Start Run Off switch off for 30 Microprocessor powers OK seconds then turn back on b Check for valid Functional Parameters Valid number is set for all parameters in Functional Parameters List Alarm is cleared c Valid Functional Parameter s can not Replace microprocessor be entered See Note 1 Page 8 2 Clear the inactive alarms All All alarms cleared ss cleared 62 10683 8 108 ANO Steps ALARM CAUSE CORRECTIVE ACTION 238 CONFIGURATIONS 1 ERROR TRIGGER ON There is an error in Configuration Group 1 that is stored in the microprocessor memory or in the memory sector of the microprocessor that the Configurations are stored in UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset when valid Configuration s are entered or Alarm may be manually reset by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Configurations a Check Configurations All must be set for selectabl
495. the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Fan Belts a Check upper fan belt tension amp Refer to Section 9 9 for belt tensions condition No Glazing no cracking no slipping 2 Check System Pressures a Install Manifold Test Set and check and Suction pressure must be above 3 PSIG 0 2 Bar compare compressor discharge amp suction pressures with those shown on Suction amp Discharge Pressures must have the same the microprocessor controller reading on gauges amp on micro display 3 Check Refrigerant Charge a Check for undercharged system Level must be above lower sight glass 4 Manually Defrost Unit a Defrost unit and terminate Typical defrost cycle time is 5 20 minutes automatically Suction pressure should rise gradually during cycle 5 Check Evaporator Airflow a Check evaporator fan clutch Must be engaged b Check evaporator section blower Good Air Flow wheel return air bulkhead air chute Return air not restricted and cleanliness of evaporator coil Air chute in good condition No damage to blower wheel Evap coil clean Perform Pretrip Check a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding 7 Check E
496. ting High Pressure Switch Remove switch as outlined in Section 9 17 2 Connect ohmmeter or continuity light across switch terminals Ohmmeter will indicate resistance and continuity light will be lit if switch closes after relieving pressure Connect switch to a cylinder of dry nitrogen See Figure 9 26 Set nitrogen pressure regulator higher than cutout point on switch being tested Pressure switch open and close points are shown in Section 2 11 Close valve on cylinder and open bleed off valve Openoylinder valve Slowly close bleed off valve and increase pressure until the switch opens If a continu ity light is used it will go out 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 The light will light or the ohmmeter indicator will move 62 10683 9 34 9 17 2 Replacing High Pressure Switch a Pump down compressor per Section NO TAG Frontseat both suction and discharge service valves to isolate compressor Slowly equalize compressor pressure through the service valve gauge ports Recover refrigerant remaining in compressor to 0 psig bar Disconnect wiring from defective switch and remove old switch The HPS is located on the top cylinder head See Figure 9 21 Install new HPS after verifying switch settings and re connect wiring Refer to Section 9 17 1 Evacu
497. tion Rail is selected in above configuration See Note on Following Page RAIL OVERRIDE RESTART This is only available when Unit Op eration Rail is selected in above configuration ASSET TRAILER CAR N ENABLE INTELLISET AT KEY YE CONFIGS COMPLETE EXIT Press NOTE The following changes occur in the unit s per formance when Rail Mode is selected The Trailer ID can now be changed in order to more accurately define the vehicle carrying the unit The choices ae ASSET CAR or TRAILER e Rail Shutdown Override can be selected When the Rail Shutdown Override con figuration is set to NO the unit will remain off until all alarm s are manually reset in cases where the unit has unsuccessfully attempted to start 3 times OR the unit has shut down on an alarm 3 times 6 11 QUALCOMM OTHER STANDARD RAIL NO YES 1 20 3 Select the length of time unit remains in low speed before transitioning to high speed QUALCOMM The microprocessor is set to send Qualcomm communication messages OTHER The microprocessor is set to send com munication messages to communication telematics companies other than Qualcomm STANDARD The microprocessor is set to control over the road trailer refrigeration operation RAIL The microprocessor is set to control Rail refrigeration operation If Rail is selected for Unit Operation this indicates type of vehicle in use
498. tion then back to the START RUN position or by accessing the Functional Parameter list and selecting SLEEP MODE While in Sleep mode the Unit Data and Alarm lists may be viewed and Functional Parameters may be viewed and changed as necessary However Start Stop Continuous Run selections and set point can not be changed Manual Defrost and Pretrip can be initiated The unit will restart when engine coolant temperature drops below 34 F 1 C or if the battery voltage drops below the battery restart value selected in the configurations See 6 2 1 Sleep mode is generally used in cold ambients when the trailer or rail car may be parked or not used and the unit is OFF for an extended period of time one day to several weeks with no product inside the refrigerated compartment Many times units are very difficult to start due to a discharged battery thickened engine oil etc after that time in cold ambients In Sleep mode the unit will Wake Up periodically and run to keep the battery charged and the engine warm In Sleep Mode the unit will Wake Up periodically and run to keep the battery charged and the engine warm NOTE In the event that the Engine Coolant Tempera ture sensor fails Sleep mode will operate as fol lows In ambients above 32 F 0 C the unit will run as above and will monitor battery voltage and charging amps only according to the configura tion setting In ambients below 32 F
499. tion is set for Rail and the unit is operating in Sleep Mode eShut down may be overridden in the Functional Parameter list UNIT CONTROL Alarm Only or may be configured to shut unit down RESET CONDITION Alarm Only Auto Reset after the door has been closed for more than five seconds Shutdown Auto Reset after three minutes minimum off time for door open condition and the door has been closed for more than five seconds NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check To See If Refrigerated Compartment Side Or Rear Door Is Open Inspect refrigerated compartment Refrigerated compartment door s must be closed doors 2 Check Wiring CeO O a Visually inspect wiring to door switch b Visually inspect condition of switch 3 a Check switch operation Contacts must Open amp Close as door is opened and closed Check Configurations a Verify that Configuration is set for the Must be correct for type of door switch type of switch being used i e when Door is open switch contacts are closed etc Temporary Solution Tip a In the event of a defective switch that In the Functional Parameter list set OVERRIDE DOOR can not be repaired or replaced and SHUTDOWN to YES the sw
500. tional Parameter may not appear in the list for your unit depending on how the microprocessor has been configured NOTE If the padlock is visible when accessing language from the Functional Parameter List the language cannot be changed However when accessing the language using the hot key press and hold the Select Key for 6 seconds the language can be changed regardless if the padlock is shown or not 62 10683 3 30 3 17 LANGUAGE SELECTION HEAT COOL DEFROST ALARM START STOP CONTINUOUS 20 3345 F SETPOINT BOX TEMPERATURE ESPANOL MANUAL ALARM Ed START STO TO um 1 Press and hold the SELECT key for six seconds until MessageCenter displays current language ENGLISH ESPANOL FRANCAIS PORTUGUES 2 Press the UP or DOWN ARROW key until the MessageCenter indicates the desired language Press the key The new language will now be active If the key is not pressed within 10 seconds the MessageCenter will change to FUNCTION NOT CHANGED This will flash for five seconds then return to the current language If no further keys are pressed the default display will return in another 10 seconds TIP If the language is set to one that the user does not understand press and hold the SELECT key for 6 seconds to bring up the Language Parameter so that it can be changed 3 31 62 10683 3 18 STOPPING UNIT O COOL DE
501. tive alarm occurs Continue with the steps below as necessary NOTE The temperature criteria for this alarm is reset and the box temperature must again go In Range before this alarm can be triggered if any of the following occur Pretrip is started Setpoint is changed eA door switch or remote switch is installed and configured as a door switch NOTE The 15 30 or 45 minute timer is reset and starts again whenever The unit cycles off and restarts in Start Stop The unit goes into and comes out of Defrost NOTE This alarm does not go into the Inactive Alarm list when it becomes inactive or is cleared NOTE This alarm will not be used in Sleep mode Check Trailer Or Rail Compartment Doors IH a Inspect all trailer or rail compartment Must be closed no air leakage doors Check For Low Refrigerant Pressure Alarm a Check for alarm 18 Alarm conditions must be corrected and the alarm cleared to continue Additional steps on the next page 62 10683 8 38 NO Steps ALARM CAUSE CORRECTIVE ACTION 53 BOX TEMP OUT OF RANGE Continued Check Refrigerant Level a Visually check refrigerant level in Must be at correct level receiver tank Check system pressures a Install Manifold Test Set and check Suction amp Discharge Pressures must be in the normal system pressures range Suction amp Discharge Pressures must have the same reading on gauges amp on micro display a Run Pretrip amp check for a
502. to ground but is shorted either within the UL2 itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when the UL2 Coil current amp draw is normal or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check Rear Unloader UL2 Coil a Inspect Rear Unloader UL2 coil amp No damage to coil terminals No damaged or corroded pins b Check resistance of coil Refer to Section 2 13 c Check amp draw of coil Refer to Section 2 13 Use ammeter Check Rear Unloader UL2 Current Draw a Use Component Test mode Refer to Refer to Section 2 13 for normal current values Section 6 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 14 Check Rear Unloader UL2 Coil Wiring a Inspect harness amp control box See Notes Note 3 Note 4 amp Note 8 connector pins amp terminals See wiring No physical damage to harness schematic Section 11 No damaged or corroded pins 62 10683 8 52 NO Steps ALARM CAUSE CORRECTIVE ACTION 87 CHECK REMOTE HEAT LIGHT TRIGGER ON The micro Light Bar configuration is set for an 8
503. tor Malfunction ccc teens 10 2 10 1 4 Malfunction In The Engine Starting Circuit 10 2 10 1 5 Miscellaneous Engine Troubleshooting 10 3 10 2 ALTERNATOR 12 Volt DG elc Rr Re Dee RR eee are 10 3 62 10683 x TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page UNIT TROUBLESHOOTING Cont 10 3 REFRIGERATION TEMPERATURE CONTROL 000 cece en 10 4 10 3 1 Unit Will Not Cool IH hm rh 10 4 10 3 2 Unit Runs But Has Insufficient Cooling 10 4 10 3 3 System Will Not Pump Down sssssesee e II Hm 10 4 10 3 4 Unit Operates Long Or Continuously In Cooling 10 4 10 3 5 Unit Will Not Terminate Cooling ccc III 10 5 10 3 6 Unit Will Not Heat Or Has Insufficient Heating 10 5 10 3 7 Unit Will Not Terminate Heating 10 5 10 3 8 Defrost Cycle Malfunction ccc e n 10 5 10 3 9 Abnormal Pressure 10 6 Cooling u hee aa ada a e ERES 10 6 b Heating ace poete Rer TRIS EAT Mate re A Peine Ex db 10 6 10 3 10 Abnormal Noise mh 10 7 10 3 11 Control System Malfunction 0 0 cece 10 7 10 3 12 No Evaporator Air Flow Or Restricted Air Flow 10 7
504. trolling temperature is 3 2 F 1 8 C away from setpoint The microprocessor will then follow the operating se quence logic on Figure 5 2 4 3 RUNNING MODES Two running modes are possible automatic Start Stop and Continuous Run modes The user can toggle between the two modes by pressing the appropriate key on the keypad Refer to Sections 3 6 and 3 7 NOTE The microprocessor may be locked so that the unit will always operate in Start Stop whenever the set point is within a specific range Refer to Range Lock Section 5 15 and ProductShield Section 5 16 for additional information 4 3 1 Start Stop Mode Start Stop mode is provided to allow fuel efficient con trol of refrigerated compartment temperature while in suring that the refrigerated compartment temperature does not drift too far away from set point When the refri gerated compartment temperature gets close the set point the refrigeration system will shut off This allows the diesel engine to shut down saving fuel As the refri gerated compartment temperature drifts away from set point the refrigeration system and the engine will turn back on a Start Stop Mode Cycle Off Conditions Whenever the unit starts in Start Stop Mode it will con tinue to run until all five of the following criteria have been satisfied 1 The refrigerated compartment temperature is near set point After the Minimum Run Time expires the unit will go into an Off Cycle when th
505. ts 9 38 Replacing the Compressor 9 28 Replacing The CSMV Power Head 9 42 Replacing the SV1 Coil 9 39 Replacing the SV2 SV4 Coil 9 38 Replacing Unloader Valve Internal Parts 9 31 Restart Voltage 3 10 Return Air Temperature Sensor 2 15 RPM Sensor 9 13 Running Modes 4 3 Index 3 62 10683 Index S Safety Decals 1 5 Safety Devices 2 27 Safety Precautions 1 1 Sensor Checkout 9 45 Serial Number Cut Offs 9 15 9 16 Service Mode 6 13 Servicing Check Valve 9 32 Servicing Fuel Pump 9 12 Servicing Glow Plugs 9 17 Servicing Solenoid Valves 9 38 Servicing the Speed Control Solenoid and Linkage 9 15 Sleep Mode On 3 12 3 13 Solenoid Valve SV1 Checkout 9 39 Sortware Version Numbers 6 17 Speed Control Overrides 4 6 Speed Control Solenoid And Linkage 9 15 Start Run Off Switch 2 20 Start Stop Indicator 4 4 Start Stop Mode 4 3 Start Stop Mode Cycle Off Conditions 4 3 Start Stop Mode Cycle On Conditions 4 4 Start Stop Operation 3 9 Starting Unit Auto 3 1 Stopping Unit 3 32 Suction MOP Cool Only 5 19 Suction Pressure Operation 5 20 Supply Air Temperature Sensor 2 15 Surround Removal 9 9 SV1 9 39 SV1 Operation Defrost Only 5 11 SV2 Operation Heating and Defrost 5 11 SV2 SVA 9 38 Switch Descriptions 2 20 62 10683 T Temperature Range Lock 1 amp 2 5 12 Testing Compressor Suction Pressure Trans ducer 9 37 Testing The Defrost Air Switch
506. tube Remove the dipstick again and check oil level DO NOT add oil ifthe level is in the safe range If needed add oil as indicated by markings on dipstick until level is in the safe range SAFET a To Change Engine Oil and Filter 1 Warm up the engine and then stop it by placing the Start Run Off switch in the OFF position 2 Remove drain plug from oil pan and drain engine oil using Oil Drain Tool CTD P N 68 15763 00 3 Lightly oil gasket on new filter before installing Tight en 3 4 to 1 of a turn after the seal makes contact CAUTION When changing oil filters the new filters should be primed partially filled with clean oil if possible If the filters are not primed the engine may operate for a period with no oil supplied to the bearings 4 Replace filter and add lube oil Refer to Section 2 7 Warm up engine and check for leaks b Replace filter and add lube oil Refer to Section 2 7 Warm up engine and check for leaks 62 10683 9 14 9 8 5 Lube Oil Filters After warming up the engine stop engine place shallow drain pan under filter and remove filter Lightly oil gasket on new filter before installing Tighten per the filter manufacturer s directions CAUTION When changing oil filters the new filters should be primed partially filled with clean oil if possible If the filters are not primed the engine may operate for a period with no oil supplied to the bearing
507. tware load correctly you find and Is voltage within range NO correct the problem Is the Inspect and repair NO system he 3 wiring T operat harnesses for the Check Wiring for high ing OK micro and display Go To Condition 8 resistance or an open now the cable from the Programming Problems Did you find and S micro to the back of with PC Cards if using a PC correct the condition YES the display the Card to upgrade software or i cable from the back 9 a p NO i roblems with MicroProgrammer System OK of the display to the Y SO display itself and the if using a PC to upgrade software ine oe m StarTrak if ribbon cable from Did the software load correctly disconnected the keypad to the votage earlier board Did you find Did the loading should read 11 and correct the of the software ie or higher Is condition correct the voltage roblem ithi 2 within range NO 5 MPR Code 42 Y Check Wiring for high Replace micro and operate n resistance or an open NO tem in order to verify repair Review the results of Did vou find and System order to verify above tests with your y MPR Code 1 Did you find and correct the supervisor If necessary correct the condition condition go to the beginning of the NO table amp test again S
508. ucers and still display an accurate pressure reading in the Data list a calibration feature for the CDP built into the microprocessor To calibrate the CDP it must be removed from the compressor and exposed to atmosphere During the calibration process the microprocessor measures the difference between what the transducer is sending and what the microprocessor was expecting for a zero reading The difference between these two is called an offset This offset is then stored in the microprocessor s memory and is used in all future calculations for displaying compressor discharge pressure NOTE The Compressor Discharge Pressure on the microprocessor Data list will never read less than 0 Bar PSIG even if itis exposed to a vacu um such as when evacuating the system Consequently a transducer reading of 0 does not indicate accurate calibration Every dis charge transducer must be calibrated before being installed into a compressor a Power up the transducer circuit Place unit into PC mode Refer to Section 6 1 or place unit in Manual Start mode b Press the Select key until Press to View Data ap pears in the MessageCenter o Press the Up Arrow until Discharge Pressure is dis played in the MessageCenter d Press and hold the Equal key for six seconds The MessageCenter will blink 5 times When it stops blink ing the display will either show DISCHARGE PRESSURE 0 0 BAR PSIG or the message CALIBRATI
509. uctions on how to access them NOTE Units equipped with IntelliSet MUST have the settings installed using ReeferManager and a Configuration PC card IntelliSet settings CANNOT be installed by us ing either the keypad or by using a laptop com puter 6 25 6 7 4 Functional Parameters via Keypad a Refer to Section 3 16 for the list of available Micropro cessor Functional Parameters and for directions on how to access them b Leave the microprocessor powered up as you contin ue with the next section 6 7 5 DataRecorder Via ReeferManager PC Program NOTE If the factory settings are used you can skip this section and proceed to hourmeter Setup a Refer to Section 3 19 for list of DataRecorder Setups b Power up the microprocessor If it is not already pow ered up refer to directions under Microprocessor Setup Functional Parameters via keypad Section 6 7 4 above c Connect your computer to the download port of the unit use cable 22 001737 and start the ReeferManager program You will need ReeferMan ager version 03 07 00 or higher NOTE ReeferManager 03 07 00 is REQUIRED in or der to view change and send new features to and from the microprocessor d In ReeferManager go to the Serial Operations Tab and then click on DataRecorder Microprocessor set up button e Select the Sensors to be recorded and whether you wish averaged or snapshot recordings averaged is recommended for all temperature sensors
510. ue with the steps below as necessary If Alarm Occurs During Pretrip a Pump down low side of refrigeration Verify that system will pump down to 0 PSIG and will hold system without leak back Check Refrigerant Charge a Check for undercharged system Level must be above lower sight glass Check Airflow Through Condenser Coil a Inspect condenser radiator fins Fins must be straight 9096 or more of the coil surface must be undamaged No dead air spaces Condenser Radiator coil must be clean b Check airflow with unit running Even airflow through the entire coil No dead spots Check system pressures a Install Manifold Test Set and check and Suction amp Discharge Pressures must have the same compare compressor discharge amp reading on gauges amp on micro display suction pressures with those shown on the microprocessor controller E E Check 2 a Visually inspect the mounting and Must be mounted tightly to the evaporator section with the orientation of DTT2 long flat surface of DTT2 in contact with the metal surface b Verify the temperature of DTT2 Use a test temperature reading device infrared independent thermometer etc to verify that DTT2 temperature is the same as that being displayed in the Unit Data list Refer to Section 3 14 Perform Pretrip Check a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding Check compressor
511. uel Level Switch or 0 to 100 Sensor is installed in the tank OR A Low Fuel Level switch or a 0 to 10096 sensor is installed in the tank but the unit will not shutdown due to a Low Fuel Level alarm 30 120 GALLONS When a Low Fuel Level switch is installed and the LOW FUEL LEVEL WARNING Alarm 1 is on the unit will shutdown Alarm 19 after a time delay Refer to chart below 30 gallon 30 min 50 gallon 60 min 75 gallon 90 min 100 gallon 120 min 120 gallon 150 min OR If a 0 to 100 sensor is installed the low fuel level WARNING Alarm 1 will come on when the level reaches 15 or less and the unit will shutdown Alarm 19 when the level reaches 10 YES This hourmeter will be displayed during the startup messaging sequence and will be in hour meter menu NO This hourmeter will not be displayed during the startup messaging sequence and will be shown with the other meters and counters lists YES This hourmeter will be displayed during the startup messaging sequence and will be in hour meter menu NO This hourmeter will not be displayed during the startup messaging sequence and will be shown with the other meters and counters lists OFF The Engine Maintenance hourmeter is turned off 50 30 000 hrs The value selected here will be the number of hours between engine service inter vals OFF The Switch On Maintenance hourmeter is turned off 50 30 000 hrs The value select
512. uence will be used for High Ambient Defrost Termination a The unit will remain in High Speed and will reset the CSMV position to the position it was in at the start of defrost b The microprocessor will open de energize SV1 and open energize SV2 and unload energize UL1 c When suction pressure has risen 10 PSIG 0 68 Bar above start point or after 15 seconds the microprocessor will place the unit in Low Speed close de energize SV4 and unload energize UL2 d After 5 seconds the clutch will be engaged e After an additional 5 seconds the microprocessor will return to normal temperature control The data recorder will record a Defrost Termination Event NOTE Refer to Section 2 15 for more on the defrost mode 5 12 UNLOADER CONTROL OPERATION To LOAD or de energize a compressor unloader increases the capacity of the system by increasing the number of cylinders pumping refrigerant in the compressor To UNLOAD or energize a compressor unloader decreases the capacity of the system by decreasing the number of cylinders pumping refrigerant Refer to Section 2 3 4 for more information on compressor unloaders Unloaders will use the differences of Controlling Temperature and set point as follows LOAD de energize UL1 and UL2 UNLOAD energize UL1 and UL2 COOL Control Temp is more than 3 6 F 2 C above Control Temp is less than 2 3 F 1 3 C Perishable setpoint above setpoint Control Temp is mor
513. ull down menu to download cable and applications turned off set sensors amp events to connections Did you find i i computer has 9 pin serial be viewed OR use and correct the ondition port ME Service Manager or USB port Did you find dide e NM and correct the condition parameters Operate the system in order to verify the repair Use PC Download Card Use PC to download Download Card data to download data Figure 10 10 Micro Diagnostic Tree Cond 6 Data Recorder Data Download Problems When Using ReeferManager and a Download Cable Data File Analysis Problems Using Reports 10 19 62 10683 START HERE Make sure the Start Run Off switch is ON or the micro is Usint either a PC card or computer with a download cable hooked into the serial port download plug load current version of in PC Mode See Section 6 1 the software into micro Insert PC into the PC card slot on the micro What does the MessageCenter display say about the PC Card UNKNOWN CARD CARD LOCKED REMOVE CARD CARD FULL REMOVE CARD MessageCenter has addition PC Card error messages Doesn t acknowledge that a PC Card has been inserted Card may be defective Try a different card Did you find and correct condition NO Y If you have tried 2 or mor
514. unit is still more than the number of de grees selected in the Functional Parameter list away from set point if the alarm is configured for Alarm Only The alarm will be activated and the unit will shutdown after 45 minutes if the alarm is configured for Alarm and Shutdown 62 10683 2 24 In Sleep Mode Pretrip Component Test Mode or if the unit has a Door Switch or Remote Switch configured as a Door Switch and the door has been opened the Out of Range Alarm is disabled and will not come on After exiting any of these modes or closing the refrigerated compartment door the refrigerated compartment tem perature must again come In Range of the set point be fore the Out of Range Alarm can be activated The internal timer is inactive in Defrost or in a Start Stop Off Cycle Once the unit leaves these modes and goes into a temperature control mode HEAT COOL or PULSED NULL the Out of Range internal timer not start until the temperature is out of range of set point Once the compartment temperature is out of range the timer will start allowing the unit time to bring the refriger ated compartment temperature into range before the Out of Range Alarm can be activated If the unit is not heating or cooling correctly the Out of Range alarm may come on when The unit is in cool and in pulldown mode RAT is still far away from set point and if the Delta T SAT minus RAT is not at least 1 0 F 0 56 C for 30 minutes OR The un
515. uously for 15 seconds before the defrost cycle is started UNIT CONTROL Alarm ON While this alarm is active the defrost air switch will NOT be used to initiate a defrost cycle however the Defrost Timer will initiate a defrost cycle 90 minutes after the alarm comes on and the manual defrost switch will remain operative RESET CONDITION Auto Reset when defrost cycle terminates correctly and the air switch does not call for a defrost cycle within the eight minutes following defrost termination or Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Defrost Air Switch Inspect switch amp connector pins amp No damaged or corroded pins terminals b Check defrost air switch setting with Refer to Section 2 11 Magnehelic Gauge and check the Contacts closed with pressure applied to high side resistance of switch contacts Contacts open with no pressure applied 2 Check Switch Wiring Inspect harness amp control box See Note NO TAG connector pins amp terminals See wiring No physical damage to harness schematic No damaged or corroded pins Check Air Switch Hoses a Inspect air hoses to switch
516. ure falls between these temperatures the unit operation can change to Econo Start Stop 2 Ifthe Econo Minimum Temperature is set to 30 F 1 1 C and the Econo Maximum Temperature is set to OFF and the ambient air temperature is anywhere above 30 F 1 1 C the unit operation can change to Econo Start Stop 3 Ifthe Econo Minimum Temperature is set to OFF and the Econo Maximum Temperature is set to 40 F 4 4 C and the ambient air temperature falls anywhere below 40 F 1 7 C the unit operation can change to Econo Start Stop 4 If both the Econo Minimum and Econo Maximum Temperatures are set to OFF unit operation can change to Econo Start Stop at any ambient temperature 5 15 62 10683 2 When the unit is set for Start Stop ProductShield Econo allows the unit to run in Continuous Run when ProductShield Econo configuration is set to GO TO CONTINUOUS Refer to Section 6 2 1 AND e Theunithasrunin Start Stop for a minimum of 15 minutes OR the Minimum Run Time whichever is longer as set in the Functional Parameter list See Table 3 3 AND e The ambient temperature falls outside the pre programmed temperature range NOTE If unit is set for Start Stop and ProductShield Econo is configured for GO TO START STOP or OFF the unit will remain in Start Stop Once the microprocessor detects that the above criteria have been met the unit will switch from Start Stop to Continuous Run for a minimum of 30 minutes After
517. utdown condition and Re mote Switch 2 has been set to allow unit to run for more than five seconds NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Determine What Remote Switch 2 Is Controlled By a Remote Switch 2 may be connected to Find and locate Remote Switch 2 a refrigerated compartment door or some other device and used to remotely control the unit 2 Check To See If Refrigerated Compartment Side Or Rear Door Is Open Or If The Device That Remote Switch 2 Is Connected To Is Set To Trigger The Alarm Inspect refrigerated compartment Refrigerated compartment door s must be closed doors b Check device at Remote Switch 2 Must have switch in position that allows unit to operate Check Wiring a Visually inspect wiring to switch Wiring must be connected b Visually inspect condition of switch Must not be damaged 4 Check Remote Switch 2 ui a Check switch operation Contacts must Open amp Close as switch is opened and closed 5 Check Configurations a Verify that Configuration is set for the Must be correct for type of Remote switch being used type of switch being used i e when Door is open switch contacts are closed etc 62 10683 8 44 kd E ALARM CAUSE CORRECTI
518. ve Remove enclosing tube assembly and related items 2 Check for foreign material in valve body 3 Install new parts NOTE Rebuild kit P N 14 00150 51 contains both a black neoprene seal and a white Teflon seal Use the one that matches seal in existing valve The valve with the Teflon seal can be identified by two dimples in the housing See Figure 9 30 DIMPLES Figure 9 30 SV 2 SV 4 MARKING 4 Tighten enclosing tube assembly to a torque value of 17 ft pounds 2 4 Mkg and leak check the valve Re fer to Section NO TAG 5 Install coil assembly and retainer 6 Start unit and check refrigerant charge Refer to Sec tion NO TAG 7 Check refrigeration cycles 8 Run Pretrip Refer to Section 3 4 9 21 2 Solenoid Valve SV1 a Solenoid Valve SV1 Checkout Procedure To obtain proper heating and defrost the normally open N O SV1 solenoid valve must energize and close tightly during the heat and defrost cycles If the valve does not close tightly due to physical damage foreign material or wear refrigerant leakage through the valve can reduce heating capacity During normal heat or defrost cycles the following conditions will be observed when the valve is Operating properly 1 Receiver refrigerant level will drop quickly at the initia tion of heating or defrost mode 2 Suction pressure will rise slowly to 90 100 PSIG 6 12 to 6 80 Bar 3 Discharge pressure will drop quic
519. voltage amp 0 8 VDC during starter engagement Do you have the correct NO voltage pee pm YES With the FSA disconnected check the resistance of the FSA coil Spec is 2 8 ohms 10 Check for high resistance or an open on the FSA ground circuit terminal 2 Did you find and correct the condition Using jumper wire are the proper voltages present at ENSCU terminal 7 YES 1 Check for open or high resistance on circuit between FSA and ENSCU Did you find and correct the condition Replace ENSCU Did you find and correct the condition Is ohm reading within spec NO Replace the FSA Did you find and correct the condition NO Remove the FSA from the engine amp inspect FSA should move freely without binding and shaft should be straight Is FSA functioning properly No Remove new ENSCU and re install old ENSCU back into unit ENSCU is not the fault Review results of above YES tests with your supervisor If necessary NO Remove new FSA and re install old FSA back into unit FSA is not the fault Review results of above tests with your supervisor If necessary go to the beginning of the table amp test again go to the beginning of the table amp test again Review results of abov
520. water to ra diator engine Never exceed more than a 60 concentration of anti freeze Use a low silicate anti freeze meeting GM specifica tions GM 6038M for standard life coolant or use an extended life coolant which is Dexcool approved and has 5 150 5 years 150 000 miles on the label a Servicing the Cooling System 1 Remove all foreign material from the condenser ra diator coil Compressed air or water may be used as a cleaning agent It may be necessary to use warm wa ter mixed with any good commercial dishwasher de tergent Rinse coil with fresh water if a detergent is used NOTE Draining the coolant from the engine petcock will leave approximately 1 quart 9 liters of coolant in the block 2 Drain coolant completely by removing lower radiator hose and radiator cap 3 Install hose and fill system with clean untreated wa ter to which 3 5 of an alkaline based radiator clean er is added 6 oz 151 grams to 1 gallon 3 78 liters of water 4 Run engine and drain while warm Rinse system three times after it has cooled down Refill system with water 5 Run engine to operating temperature Drain system again and fill with 50 50 water anti freeze mixture Unit coolant capacity is 1 67 U S gallons see Cau tion Note and Refer to Section 2 7 NEVER POUR COLD WATER INTO A HOT ENGINE however hot water can always be added to a cold engine 9 8 2 Fuel Level Sensor An optional fuel level sensor supplies a
521. xpansion Valve TXV a Visually inspect valve Bulb must be clamped tightly on the suction line and insulated b Check MOP of valve Refer to Section 2 11 c Check superheat of valve Refer to Section 2 11 62 10683 8 14 NO Steps ALARM CAUSE CORRECTIVE ACTION 19 LOW FUEL SHUTDOWN for units with Low Fuel Level 0 to 100 Sensor fuel level is displayed in Data list TRIGGER ON Fuel level is 1096 or less for more than 1 minute UNIT CONTROL Unit shutdown and Alarm RESET CONDITION Auto reset when fuel level is above 1296 for more than 1 minute or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check For Low Fuel Level Warning Alarm N a Check for alarm 1 Must be cleared b Check fuel level intake Must be above 1 4 tank Fill as needed Check accuracy of sensor __ a Verify sensor accuracy See Section 9 8 2 for sensor testing b Check wiring to sensor No physical damage to sensor No damaged or corroded pins Check fuel level sensor harness Inspect harness amp control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pi
522. y and the current flow is more than 1 0 Amps discharge between the alternator to the battery for three continuous minutes UNIT CONTROL Alarm Only or Unit Shutdown amp Alarm if configured RESET CONDITION Auto Reset if not shut down when alternator is charging or alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the below as necessary Check Microprocessor Current Sensor a micro Current Value START RUN OFF switch in START RUN position Manual Start mode all electrical circuits off See Note Note 5 pomme e Rn be 2 0 to 1 5 Amps with no load b Check direction of wire current Must be in correct direction See arrow current sensor Check amp current value with 0 amps Disconnect and remove the wire going through the current going through the current sensor sensor then reconnect it to the fuse holder Power up micro and check CURRENT DRAW in the Unit Data List The value must be between 1 0 and 1 0 Amps Refer to Section 3 14 Check Alternator Belt Check alternator belt tension amp Refer to Section 9 9 for belt tensions condition No Glazing no cracking no slipping Check Alternator Wiring a Check output am
523. y be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check SV1 Coil a Inspect SV1 coil amp connector pins amp No damage to coil terminals No damaged or corroded pins b Check resistance of coil Refer to Section 2 13 c Check amp draw of coil Refer to Section 2 13 Use ammeter 2 SV1 Wiring 5 Inspect harness amp control Notes Note 3 Note 4 amp Note 8 connector pins amp terminals See wiring No physical damage to harness schematic No damaged or corroded pins Check SV1 Current Draw Se Use Component Test mode Refer to Refer to Section 2 13 for normal current values View Section 6 2 2 to test current current draw in Data list draw of the et 79 CHECK SV4 CIRCUIT TRIGGER ON In either the Heat or Defrost cycles the SV4 coil circuit is shorted The SV4 output from the micro is negative so the circuit will not be shorted to ground but is shorted either within the SV4 coil itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when unit calls for Heat or Defrost and the SV4 coil current amp draw is normal or Alarm may be manually
524. y foreign objects other than a normal reciprocating movement of the pistons and piston rings 62 10683 10 24 4 5 7 g Check compressor rotation 1 Unplug the fuel solenoid 2 Rotate the compressor by hand if possible or by using the engine starter to bump the compressor NOTE Bumping the compressor means to momentarily energize the starter motor without ignition of the engine 3 All pistons should move freely and smoothly up and down without any inconsistent resistance or seizure h Repeat Steps 2 b thru 2 g for the center head and the rear head Decision to repair or replace The compressor should be REPAIRED if no defects are found or if the only defects found are in Steps 2 4 1 4 5 or 6 b The compressor should be REPLACED if it failed the examination of 2 f 2 g 2 h or has broken discharge valves Replacement of the compressor a Refer to Section 9 12 for compressor replacement procedures b Drain and measure the compressor oil and put it in a plastic bottle Follow Carrier Transicold instructions for re turning the oil with the compressor Repair of the compressor a Replace gaskets in addition to all replacement parts b The torque required to reassemble the screws of the valve stop on the valve plate is 12 ft lbs 16 3 Nm c Replace anew valve plate or a cylinder head only when it is defective The torque required for the bolts of the cylin der head is 35 to 55 ft 16 40 t
525. ystem OK Re install Remove new micro and re install old micro System OK StarTrak if back into the unit Micro is not the fault Re install disconnected Review results of above tests with your StarTrak if earlier supervisor If necessary go to the beginning disconnected of the table amp test again earlier NO Figure 10 5 Micro Diagnostic Tree Cond 1 Start Run Off Switch On Unit Does Not Operate 62 10683 10 14 START HERE Wrong Chart The unit See Condition 1 starts amp runs Micro may not be configured properly NO Verify correct model number is selected in the micro via unit data Did you find and correct the condition Unit may be running on old software Upgrade software to current version Did the software load correctly Did the loading of the software correct the problem NO Y Y Go To Check ground connectors at the Condition 8 battery starter engine block and Programming Problems inside the control box Did you find with PC Cards if using a and correct the condition PC Card to upgrade NO v software or Check for active amp inactive alarms Condition 9 Refer to Section 8 for troubleshooting Programming Problems
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OPERATION & SERVICE - Sunbelt Transport Refrigeration

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OPERATION &amp; SERVICE - Sunbelt Transport Refrigeration

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OPERATION & SERVICE - Sunbelt Transport Refrigeration