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Carrier – Ops And Service For X Series Trailer & Rail Refrigeration

1. STA RT RUN f N N A OFF MessageCenter eo HEAT COOL DEFROST START STOP C OW TINUOUS SETPOINT BOX TEMPERATURE STATUS OK DEFAULT MESSAGE MAY BE REPLACED BY USER DEFINED MESSAGE MANUAL ALARMLI smresrop SELECT DEFROST J O DISPLAY and KEYPAD MODULE 2 47 62 10683 The Display 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 inst
2. PAB F6B B1 P33 POS LB G B FS 3A o OUTPUT POWER SR C11 papers l B T Ipsi L MONO gt aJ E IE QC SE PONENTS AFAR E ris B 30 87 TO SP1 F17 ENG BLOCK GR 5 3 3 3 3 3 3 3 3 3 3 3 3 3 F4 7 5A u SPK24 A B F3 7 5A F LEGEND AUTOFRESH AIR RELAY AUTO RESTART LIGHT HEAT LIGHT SV4 CONTROL SV1 CONTROL FUEL HEATER RELAY FAULT LIGHT OUT OF RANGE LIGHT DEFROST LIGHT COOL LIGHT BUZZER SV3 CONTROL SV2 CONTROL NLOADER 2 CONTROL NLOADER 1 CONTROL A B F2 10A e ENSCU 16 N10 PENNE B El RELAY POWER TO SPKSIBAl i e TO 1MP26 E4 30 87 GPR Saa aa 30030 ONMOWUNIBRNO MPQCB Plo HC8 NMNNN qUN 0
3. 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 9 8 Micro Diagnostic Tree Cond 4 Unit Will Not Run In High Speed 9 15 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 v Check functional parameter settings for air flow Does the setting show high NO y Does the unit have IntelliSet options YES Y Is ProductShield High YES Air configured on y 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 setpoint y Is setpoint 10 4F or Is setpoint 10 5F or lower higher T Is return air temperature equal to or colder than YES setpoint l Is selected probe te
4. y l Is the Inspect and repair NO system he 3 wiring T l operat harnesses for the a 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 y cable from the back El 9 Oban NO i roblems with MicroProgrammer System OK of the display to the dx Y EM display itself and the if using a PC to upgrade software ne oe m StarTrak if ribbon cable from Did the software load correctly Cebu disconnected the keypad to the lt votage earlier board Did you find Did the loading should read 11 and correct the of the software E or higher Is condition correct the voltage roblem ithi 2 within range NO 5 MPR Code 2 y 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 in order to verify repa above tests with your y MPR Code 1 Did you find and correct the supervisor If necessary aio correct the condition condition go to the beginning of the NO table amp test again System OK Y 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 r
5. ZONE NORMALLY CLOSED CONTACTS TCH SYMBOL INDICATES MOMENTARY CONTACTS SPLICE PACK INDICATES A SOLDERED SPLICE POINT PIN CONNECTION a COMPONENT CONNECTION NUMBER OR LET HC1 OR C MULTIPLE PLUG CONNECTION NUMBER INDICATES A CONNECTION WIRE LUG ETC SYMBOL DESCRIPTION ZONE E PTION NORMALLY OPEN CONTACTS INDICATES A WIRE GROUND INDICATES CONNECTION INDICATES A CHASSIS GROUND NO WIRE AAT AMBIENT AIR TEMPERATURE FAR AUTOFRESH AIR EXCHANGER RELAY COPTION ON XTC FAS AUTOFRESH AIR EXCHANGER SOLENOID COPTION ON XTC LT ALTERNATOR RL AUTO RESTART LIGHT LIGHT BAR BUZZER BATTERY DP COMPRESSOR DISCHARGE PRESSURE DT COMPRESSOR DISCHARGE TEMPERATURE COOL LIGHT LIGHT BAR CLUTCH UTCH RELAY PRESSOR SUCTION PRESSURE PRESSOR SUCTION ODULATION VALVE XTC A RRENT TRANSFORMER GH PRESSURE CUT OUT SWITCH N C FROST AIR SWITCH 1 JUMPER FROST LIGHT CLIGHT BAR 112 K11 LIGHT BAR OR SWITCH ICROPROCESSOR BOARD FROST TERMINATION TEMPERATURE 4 H3 H2 MICROPROCESSOR QUICKCONNECT GINE COOLANT LEVEL SWITCH OUT OF RANGE LIGHT LIGHT BAR GINE COOLANT TEMPERATURE C ETURN AIR TEMPERATURE GINE OIL LEVEL SWITCH EMOTE SWITCH GINE OIL PRESSURE SWITCH N 0 OTE SENSOR R I R GIN P R RELAY OR PLUG C SAT SUPPLY AIR TEMPERATURE 7 5 AMPERE SATELLITE COMMUNICATION 6 SPEED CONTROL SOLENOID 5 S S c EATER OPTIONAL EATER
6. 30 he F8 ERR SP25 9 HC16 e4 A B 301187 ENG BLOCK 6RD 20A ZONE RMALLY CLOSED CONTACTS SWITCH SYMBOL INDICATES MOMENTARY CONTACTS SPLICE PACK INDICATES A SOLDERED SPLICE POINT PIN CONNECTION DICATES CONNECTION INDICATES A CHASSIS GROUND NO WIRED COMPONENT CONNECTION NUMBER OR LETTER oR X E LTIPLE PLUG CONNECTION NUMBER e INDICATES A CONNECTION WIRE LUG ETC SYMBOL DESCRIPTION ZONE DESCRIPTIO RMALLY OPEN CONTACTS INDICATES A WIRE GROUND AAT AMBI AFAR AUTO AFAS AUTO ALTE AUTO BUZZ BATT CO CO T AIR TEMPERATURE 7 M17 FUEL HEATER COPTIONAL RESH AIR EXCHANGER RELAY COPTION ON XTC 7 K14 FUEL HEATER RELAY OPTIONAL RESH AIR EXCHANGER SOLENOID OPTION ON X FUEL HEATER TEMP SWITCH COPTIO ATOR FAULT LIGHT LIGHT BAR RESTART LIGHT LIGHT BAR FUEL LEVEL SWITCH R FUEL PUMP RY FUEL AND SPEED ACTUATOR ESSO HARGE PRESSURE ANUAL GLOW CRANK SWITCH COPTIO ESSO HARGE TEMPERATURE GLOW PLUG U R Zr e LIGH BAR PLUG RELAY H RENT PLUG H RELA ESSO PRESSURE ESSO MODULATION VALVE XTC GHT LIGHT BAR RENT T ER ESSURE CUT OUT SWITCH N C ROST AIR H PER ROST LIGHT LIGHT BAR PER R SWITCH AR ROST TERMINATION TEMPERATURE OCESSOR BOARD ENGINE COOLANT LEVEL SWITCH OCESSOR QUICKCONNECT ENGINE COOLANT PERATURE F RANGE LIGHT LIGHT BAR OIL LEVEL SWITCH AIR TEMPERATURE E OIL PRESS
7. i START RUN O OFF s MessageCenter When first powered up the microprocessor controller will run a selftest All ofthe mode lights will light all ofthe segments on the display will turn on all of the Liquid Crystal Display LCDs in the MessageCenter will turn on to verify their operation The display will then show the setpoint temperature in the left four characters and the refrigerated compartment temperature in the right four characters 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 message unless there is an alarm s stored in the controller If there is an alarm s stored in the controller INACTIVE ALARMS IN MEMORY will be displayed on the MessageCenter and the Alarm LED will flash for five seconds then turn off CHECK AT NEXT SERVICE INTERVAL will then be displayed if there are any active non shutdown alarms present Total engine hours total switch on hours See 1 Place the START RUN OFF switch to START RUN position Section 5 2 1 and the Active IntelliSet Refer to Section 3 19 1 will also be shown when configured The suction modulation valve CSMV will go through a proce
8. 62 10683 6 2 MessageCenter MESSAGES 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 5 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 5 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 Micro Alarm list which have not yet been cleared out INSTALLED REMOVE CARD XX An Option PC card has been inserted into the PC card slot and the option has been installed in the Micro The PC card may safely be removed from the slot XX indicates 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 Micro DO NOT REMO
9. 5 20 5 6 1 Microprocessor Replacement o occocccocccor e mn 5 20 5 6 2 MICrOprocessor Setup sod gu eile re ds CERDUUCPOEE fas 5 21 5 6 3 Configurations Via Keypad ooooooccccoccccnc he 5 22 5 6 4 Functional Parameters Via Keypad 0 ccc e nh 5 22 5 6 6 Engine And Switch on Hourmeters Via ReeferManager PC Program Luue 5 23 5 6 7 Configuration IntelliSet PC Card sisssssssssssessee e n 5 23 iii 62 10683 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page MESSAGECENTER MESSAGES 0cocccccccccc een n nnne 6 1 ALARM TROUBLESHOOTING ccc cece eect ehh n nnn nnn 7 1 7 1 INTRODUCTION TO ALARM TROUBLESHOOTING GUIDE 00 0 e eee eee 7 1 2 NOTES dna homes teet edere d ete pieta ebd Vulev e Race ug dad er cea tete 7 2 7 3 DRIVER OPERATOR ALARMS 00 c cece cece nnn nnn nnn 7 3 1 LOW FUEL LEVEL WARNING for units with Low Fuel Level 096 to 10096 Sensor fuel level is display IN Data lito lt ct hates DOLEUPAITQENEMPC MIR ME aU UE ERI ERU ENERGIE E 7 4 1 LOW FUEL LEVEL WARNING for units with Low Fuel Level switch no fuel level display in Data list 7 5 2 EOW ENGINE OIL LEVEL 2 caida nn ttt bracket Da moe dco d La md tion Rte d und 7 6 3 LOW GOOLANT LEVEE scarico a dar eoe EP RE EO Rd 7 7 7 ASHUTDOWN ALARMS I9 ee nee A eee ee 7 8 11 LOW ENGINE OIL PRESSURE coocccccccccccc hn 7 8 12 HIGH COOLANT TEMPERATURE a recica rha aaa h a e eee eee
10. 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 6 NEVER POUR COLD WATER INTO A HOT ENGINE however hot water can always be added to a cold engine Ultima XTC KAV90910334 a Verify that the wiring to sensor is correct See wiring schematic in Section 10 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 4X 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 0 inHg Bar Discharge Pressure 0 Bar PSIG Engine RPM 0 8 6 3 Lube Oil Filters After warming up the engine stop engine place shallow drain pan un
11. v Check System discharge pressure at compressor Is discharge pressure 435PSI or higher NO v Y Check system suction pressure at compressor Is suction pressure 5PSI or lower YES gt System OK y NO Check engine coolant temperature Is coolant temperature 77 F or below YES YES Is the ambient temp 80 NO Is unit in iaher Has th it been in defrost L YES or higher as the unit bee efros v defrost for less than 30 seconds System OK YES and suction pressure is less A NO Has the unit been in NO than 10 PSI OR Has the unit _ Does the unit have a door defrost for more than been in defrost for up to switch or remote switch 5 1 2 minutes po 5 1 2 minutes and the YES suction pressure is more m YES gt v 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 4 y Did you find and correct the condition YES gt i Are alarms A122 and A123 Is setpoint 10 F or lower both ee Check funtional parameter settings for high speed delay _ gt gt NO NO NO minutes for continuous run gt Has the unit been running less that the l selected high YES gt y Check
12. ISTART DEFROST EM ANS 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 t TO SCROLL THEN TO SAVE will show in the MessageCenter 4 Pressthe key to select Sleep Mode Settings 5 SLEEP MODE YES OR NO will show in the MessageCenter Press either UP or DOWN ARROW key to change the Sleep Mode to YES 62 10683 3 10 3 8 SLEEP MODE OFF e e e e 9 e HEAT COOL DEFROST START STOP CONTINUOUS SETPOINT BOX TEMPERATURE SLEEP MODE SETTINGS MANUAL ALARM LIST Ic E SELECT DEFROST dps O 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 t TO SCROLL THEN TO SAVE will show in the MessageCenter 4 Press the key to select Sleep Mode Settings 5 SLEEP MODE YES OR NO will show in the MessageCenter Press either the UP or DOWN ARROW key to change the Sleep Mode to NO OR Sleep Mode OFF STA RT RUN 1 To take the unit out of Sleep Mode place the START RUN OFF switch ii to the OFF position then back to Start Run 3 11 62 10683 SLEEP MODE ON Continued
13. 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 maintenance on the unit place the Mode switch in MAIN TENANCE MODE After the unit is serviced return the Mode switch to REMOTE ON Refer to Section 3 19 3 for more detailed in formation on two way communication 4X WARNING Under no circumstances should ether or any other starting aids be used to start en gine 44 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 circuitis shorted to ground due to one ofthe mentioned components being defec tive or a worn wire the MessageCenter will show Suction Pressure 29 9inHg 1 Bar Discharge Pressure 0 Bar PSIG Engine RPM 0 62 10683 1 2 OWN Te 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 MW Te Do not start unit without installing the evapo rator panels as unit damage or body harm may result MW Te Do not use a nitrogen cylinder without a
14. 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 diesel engine will not shut down except for safeties or if the engine stalls Refer to Section 4 3 for more detailed information on Continuous Run operation Start Stop and Continuous operation may be tied to the setpoint 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 5 2 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 device three consecutive times without running a minimum of 15 minutes between shutdowns the 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 7 SLEEP MODE ON e e e e e e HEAT COOL DEFROST START STOP CONTINUOUS SETPOINT BOX TEMPERATURE SLEEP MODE SETTINGS MANUAL ALARM List
15. 3 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 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 5 Check refrigerant charge See Section 8 12 1 Checking Refrigerant Charge a Check for undercharged system Level must be above lower sight glass 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 10 __ c Check superheat of valve Refer to Section 2 10 62 10683 7 98 NO 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 4 4 8 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 mod
16. ALTERNATOR CHECK SHUT YES NO YES When the alternator is not charging alarm DOWN 51 is active turn the alarm light on and shut the unit down NO When the alternator is not charging alarm 51 is active turn the alarm light on and the unit will continue to run ENGINE OIL LEVEL SWITCH YES NO YES This unit has a low engine oil level switch installed NO This unit does not have a low engine oil level switch installed 62 10683 5 4 CONFIGURATION SELECTIONS DESCRIPTION LOW COOLANT LEVEL YES NO YES A Low Coolant Level sensor is installed in the coolant system NO There is no Low Coolant Level sensor installed in the coolant system FUEL TANK NO DEVICE NO DEVICE There is no Low Fuel Level sensor SWITCH installed in the fuel tank INSTALLED SWITCH INSTALLED A Low Fuel Level switch is 0 TO 100 SEN installed in the fuel tank SOR 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 FUEL TANK SIZE OFF OFF No Low Fuel Level Switch or 0 to 10096 30 GALLONS Sensor is installed in the tank OR 50 GALLONS TEE 75 GALLONS A Low Fuel Level switch or a 0 to 10096 sensor is 100 GALLONS installed in the tank but the unit will not shutdown 120 GALLONS 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 ti
17. FUSIBLE PLUG EQUALIZER TXV 4 BULB Y BYPASS RECEIVER CHECK A VALVE S EVAPORATOR lt HEAT EXCHANGER lt LIQUID LINE VIBRASORBER y CDP HPS LIQUID LINE SERVICE VALVE E FILTER NS DRYER Y SUBCOOLER B COMPRESSOR h CHECK VALVE DISCHARGE A VIBRASORBER gt CONDENSER Figure 2 16 Refrigerant Circuit During Heating And Defrost 2 27 62 10683 SECTION 3 OPERATION 3 1 STARTING UNIT AUTO MODE LIGHTS DISPLAY O HEAT COOL DEFROST ALARM N O O O START STOP CON TINUOU 200 3245 F BOX TEMPERATURE SETPOINT ER EEEE 2i E E EE E o 2
18. 3 Check door switch a Check switch operation Contacts must Open amp Close as door is opened and closed 4 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 62 10683 7 46 ANO Steps ALARM CAUSE CORRECTIVE ACTION 7 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 3 Check circuit with the steps below as necessary E a Check amperage draw on Speed Relay Refer to Section 2 12 circuit Check unit operation a Did unit shut down Yes Check F3 No Check F2 b Check amperage draw on Run Relay Refer to Section 2 12 circuit 72 BAD F4 OR F6 FUSE Check fuses Ja Locate blown fuse s Will have open circuit 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 valves Buzzer amp Fuel He
19. 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 STANDARD LIGHT BAR d Door and Remote Switches The unit has provisions to install a Door switch DS and upto two remote switches REMS1 and 2 and connect them to the microprocessor so that when the door is opened or a remote switch is turned on off either an alarm is displayed or the unit may be programmed to shut down Either event may also be recorded by the DataRecorder Because different door switches are available there are provisions within the Configuration list to configure the microprocessor to correctly read the type of switch that is installed The microprocessor will recognize switches with contacts that are either open when the door is open or that are closed when the door is open Additionally the Configuration 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 no alarm and only record door openings and closings in the DataRecorder If the Door switch or Remote switches are configured to shut the unit down when either the door or remote switches is open the unit will shut down for a minimum ofthree minutes Additionally there is an Override Door switc
20. 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 5 1 or with a Download PC card refer to Section 5 3 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 18 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 See Configuration List Section 5 2 1 62 10683 3 32 3 19 OPTIONS 3 19 1 IntelliSet e HEAT O COOL 340 SETPOINT APPLES e DEFROST MANUAL DEFROST ALARM LIST OS SEAN DURING START UP e e START STOP CONTINUOUS 3945 F BOX TEMPERATURE ACTIVE d SELECT CONTINUOU O 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 key to view current IntelliSet IntelliSet Hot Key must be enabled in configurations See Section 5 2 1 Press either t
21. b Slowly open king valve and purge air through the drier Tighten drier outlet side fitting c Leak test drier connections d Check refrigerant level e Check unit operation by running Pretrip Refer to Sec tion 3 3 8 18 THERMOSTATIC EXPANSION VALVE 44 CAUTION Service mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating Refer to Section 5 2 3 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 19 3 for more information on two way communication 62 10683 8 28 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 refrigerant flow to match the evaporator load and b prevention of liquid refrigerant entering the compressor Unless the valve is defective it seldom requires any maintenance 8 18 1 Replacing Expansion Valve a
22. 2 C NOTE Delta t logic is not used or available when unit is configured for GO TO CONTINUOUS b ProductShield High Air High air mode allows the unit to provide increased airflow generally with a reduced delta T under the pre programmed criteria This can maximize product protection under 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 at normal High Speed or Low Speed depending on how far the compartment temperature is away from set point as long as the ambient air temperature is inside the pre programmed temperature range 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 and supply air sensors as an additional criteria for switching to high air When the delta T setting is used the unit must bring the delta t above this 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 e The ProductShield High Air ambient air temperature range is def
23. 2037 Select the correct year HOURS Select the correct hour 0 11 is AM 12 23 is PM MINUTES LOW ENGINE SPEED 5 9 62 10683 CONFIGURATION SELECTIONS LIGHT BAR Indicates the type of light bar installed 8 HR ADDITIONAL DATA DECIMAL HIGH SPEED DELAY 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 VEHICLE ID This is only available when Unit Op eration Rail is selected in above configuration RAIL SHUTDOWN OVERRIDE RAIL OVERRIDE RESTART This is only available when Unit Op eration Rail is selected in above configuration ENABLE INTELLISET AT KEY CONFIGS COMPLETE TO EXIT 62 10683 DISPLAYED NOT DISPLAYED 1 MIN O TO 10 MINUTES IN 0 5 MINUTE IN CREMENTS QUALCOMM OTHER STANDARD RAIL DESCRIPTION YES When the START RUN OFF switch is turned OFF the data recorder will continue to record sensor data for an additional 8 hours NO When the START RUN OFF switch is turned OFF the data recorder will stop recording all data DISPLAYED setpoint will be shown with a deci mal and temperatures may be selected to a tenth of a degree NOT DISPLAYED setpoint will not be shown with
24. Check wiring to DPT 8 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 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 for Check SV2 Circuit Alarm a Check for alarm 97 or P192 Alarm conditions must be corrected and the alarm cleared to continue Check for Check UL1 alarm a Check for alarm 85 or P144 Alarm conditions must be corrected and the alarm cleared to continue 5 Check UL1 operation Unit must be running See Note 10 See Section 8 15 Unloader Checkout Procedure a a Energize UL1 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 c
25. MANUAL DEFROST OM ALARM LIST START STOP ONTINUOUS 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 ALARM LIST Key The ALARM LIST key allows you to view the alarms stored in the microprocessor 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 viewthe inactive alarm list Refer to Section 3 12 START STOP CONTINUOUS Key This key allows you to change from Start Stop operation to Continuous Run operation In Start Stop operation when the controller is in Off Cycle mode the unit will not be running During Off Cycle mode the microprocessor monitors refrigerated compartment temperature battery voltage and engine coolant temperature and will restart the unit when needed SELECT O SELECT Key Press the SELECT key to scroll through the menu selections One of the five standard and one optional menu selections will appear when the SELECT key
26. NO If alarm 39 Check Engine RPM is active turn the alarm light on and allow the unit to continue LOW PRESSURE SHUTDOWN 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 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 YES If the unit is running and the suction pres sure rises to 98 PSIG 6 67 Bars or higher for 10 minutes alarm 27 is active the unit will shut down NO High suction pressure will not shut down the REFRIGERATION SYS YES When the unit is running and the discharge SHUTDOWN pressure is not at least 5 PSIG 0 34 Bar higher than the suction pressure alarm 28 is active shut the unit down NO When the unit is running do not shut the unit down if the above condition exists YES The unit will shutdown and not restart when eu E A alarms 13 17 18 27 28 29 or 56 occur three 4 ae times within two hours Special activation required NO Normal shutdown rules for above alarms CURRENT FOR S S SHUTOFF Charging amps must be lower than this for start stop off cycle in 5A increments VOLTAGE FOR S S RESTART 12 2A This value will be used during START STOP OFF 2 12 0 TO 12 8 VDC cycles If battery voltage falls below this value the in 5A increments unit will restart
27. OPERATION 4 SERVICE for X SERIES Trailer and Rail Refrigeration Units With Advance Microprocessor 62 10683 Rev B TRANSICOLD OPERATION AND SERVICE MANUAL NOSEMOUNT TRAILER AND RAIL REFRIGERATION UNITS WITH ADVANCE MICROPROCESSOR TABLE OF CONTENTS PARAGRAPH NUMBER Page SAFETY PRECAUTIONS reini aa an a a 1 1 11 SAFETY PRECAUTIONS Zy titi taa O tee E 1 1 1 2 SPECIFIC WARNING AND CAUTION STATEMENTS ssssssee eese 1 1 T9 SAFETY DEGALS eon a Masi eae heen dda dream da aor 1 4 UNIT DESCRIPTION 365 sedi ete eek eta Weeds cate dd cen een 2 1 2 1 GINTRODUGTION ct exe IHE REV ewe newest EA 2 1 2 2 GENERAL DESCRIPTION 5 copio arica E ie ie ea 2 1 23 CONDENSING SECTION suasana eer n 2 9 2 931 ENQING ci Mani oa des achat ee a ea a are oa ag e hae Pe fa 2 9 2 9 2 Alternator Regulator 2 ce be ana make Ee Rider Rob E Ait doit rei Soe ale Mate ate 2 10 2 9 3 Compressor A e preter ADR RO dienes eed es bee oes Ales RR LR 2 11 2 9 4 Compressor UnloaderS ousceziesenssseebuifegrexkgebenstebkur erd ee See eed Se oes 2 11 2 9 5 ME DEIeE x ate tat Oa ee eet teas ete a a a sd ed eL a od nd ex 2 12 2 3 6 IRGCCIVED widen cena dL Re n a edd Ead md ete aaa eed ge rt 2 12 2 9 7 Tr nsducers and SernsotsS iaaa dy ees eee eles ces ed Oe EE bled e ere 2 13 2 8 EVAPORATOR SECTION sssssssseess enr hn ns 2 18 2 4 1 Thermal Expansion Valve ssssseeseseeee nnn ene 2 13 2 4 2 H
28. Refer to Section 2 12 for complete resistance chart Sensor See Note 6 10k Ohms 77 F 25 C b Inspect harness amp control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins schematic 7 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 Numb
29. Refer to Section 8 9 1 d Calibrate new discharge transducer before installing Frontseat both suction and discharge service valves in compressor Refer to Section 8 20 1 to isolate compressor e Install new discharge transducer being careful to ob b Equalize compressor discharge and suction pres tain the correct transducer for your unit R 404A sures through the service valve gauge set Slowly CDPs have a red dot on the side See Figure 8 17 purge off the high side pressure to 0 Bar PSIG c Disconnect wiring from defective transducer and re move The CDP is located at the side of the center A CAUTION compressor cylinder head See Figure 8 20 Service mode MUST be used whenever re moving refrigerant charge refrigerant leak A WARNING checking or evacuating Refer to Section The Compressor 5 2 3 Discharge Pressure Transducer does not have a Schrader valve f Evacuate and dehydrate the compressor Refer to in the connecting fitting Any discharge Section 8 11 Pull down to 500 microns pressure remaining in the compressor will g Check unit operation by running Pretrip Refer to Sec be released when removing the CDP tion 3 3 8 31 62 10683 8 21 COMPRESSOR SUCTION PRESSURE TRANSDUCER CSP CTD P N 12 00352 03 BLUE 8 21 1 Calibrating Compressor Suction Pressure Transducer The Compressor Suction Pressure Transducer CSP has a range of 29 9 inHg to 100 PSIG 1 to 6 8 Bars Because of this much s
30. b Check Supply Air Sensor resistance Refer to Section 8 29 for complete resistance chart SO 10 000 Ohms 77 F 25 C a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic 3 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 Na Check supply air sensor wiring 7 57 62 10683 NOT 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 occ
31. key to enter that number for the month i Now press the Up Arrow key to go to day Using the same key presses as in h and i 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 show PRESS TO SAVE TIME CHANGES NOTE If you do not press the key none of the time changes you just made will be saved NOTE If a Configuration card will be used to configure the microprocessor skip ahead to CONFIGU RATION CARD Section 5 6 7 If the Configura tions and Functional Parameters will be set from the keypad continue with following steps 5 6 3 and 5 6 4 5 6 3 Configurations Via Keypad Refer to Section 5 2 for list of available microprocessor configurations NOTE Units equipped with IntelliSet MUST have the settings installed using ReeferManager and a Configuration PC card IntelliSet settings CAN NOT be installed by using either the keypad or by using a laptop computer IntelliSet settings CANNOT be installed by us ing either the keypad or by using a laptop computer 62 10683 5 22 5 6 4 Functional Parameters via Keypad Refer to Section 3 15 for the list of available Microprocessor Functional Parameters and for directions on how to access them 5 6 5 Data Recorder Via ReeferManager PC Program NOTE If the factory settings are used you can sk
32. pm 62 10683 7 108 SECTION 8 SERVICE MW Te 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 MW Te 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 19 3 for more information on two way communication 44 CAUTION Unit uses R404A and POE oil The use of in ertgas brazing proceduresis 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 44 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 NOTE To avoid damage to the earth s ozone layer use arefrigerant recovery sys
33. 0c cece eect es 8 32 Table 8 5 CSMV Connections es ese cortaron de 8 37 Table 8 6 Sensor Resistance ENCT RAT SAT ATT DTT2 0 00 cece n 8 41 Table 8 7 Sensor Resistance CDT 0 ccc cece e hen 8 42 Table 8 8 R 404A Temperature Pressure Chart ooccccccccccc eese 8 46 xi LIST OF ILLUSTRATIONS Continued 62 10683 SECTION 1 SAFETY PRECAUTIONS 1 1 SAFETY PRECAUTIONS Your Carrier Transicold refrigeration unit has been designed with the safety ofthe 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 44 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 44 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 44 C
34. 1 3 C 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 once the unit enters UltraFresh 3 Mode it will remain in that modeuntil the box temperature rises to 3 6 F 2 0 C above setpoint at which point it will go to HighSpeed 6 Cylinder Cool Figure 4 3 Start Stop Temperature Control Operating Sequence Perishable Range High Speed 6 Cylinder Cool 3 2 F 1 8 C Low Speed 6 Cylinder Cool 0 5 F 0 3 C Start Stop Off Cycle CSMV CONTROL FALLING BOX h o 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 4 4 Start Stop Temperature Control Operating Sequence Frozen Range 4 9 62 10683 4 4 5 ULTRAFRESH 3 TEMPERATURE CONTROL UltraFresh 3 is an advanced method of temperature control for both Perishable or Frozen ranges It produces a reduced capacity state by throttling down the CSMV and pulsing the SV
35. 44 CAUTION Service mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating Refer to Section 5 2 3 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 19 3 for more information on two way communication 44 CAUTION Do not vapor charge R 404A Only liquid charging through the receiver outlet king valve is acceptable 8 12 1 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 8 21 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 approximatel
36. 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 Continue with the steps below as necessary 1 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 2 Check refrigerant charge a Check for undercharged system Level must be above lower sight glass 3 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
37. Check Ambient Air Temperature sensor AAT a Inspect Ambient Air Sensor 8 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 Ambient Air Sensor resistance 10 000 Ohms 77 F 25 C See section 2 12 for See Note 4 complete table of temperatures and resistance values 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 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 7 77 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 c
38. Correct this situation before performing step 2 pest 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 44 WARNING UNITS EQUIPPED WITH STAR TRAK TWO WAY COMMUNICATION CAPABILITIES MAY HAVE THE ABILITY TO BE STARTED OR c After 3 5 minutes of defrost operation turn the unit off TURNED OFF REMOTELY EVEN IF THE and wait 5 15 seconds Observe the compressor oil START RUN OFF SWITCH IS IN THE OFF level in the sight glass See Figure 8 19 Oil level should be between the Minimum and Maximum 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 Minimum fer to Section 3 19 3 for more information on two way communication Maximum Figure 8 19 Oil Level in Sight Glass 62 10683 8 24 8 14 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 O
39. High Air Flow Start Stop Off Cycle Start Stop Restart 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 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 Minimum 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 during 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 00 Cargo Protect Mode Both RAT Unit will operate in low speed
40. LOW ENGINE OIL LEVEL 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 Check engine oil level switch a 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 level switch harness a Inspect harness amp control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins schematic b Check for shorted circuit in harness Place unit in PC mode or in Manual Start mode see Note and continuity through the harness 4 DO NOT START UNIT Batter
41. P192 CHECK SV2 CIRCUIT cuco edu Duk eR Dac ae ea AH edad eect 7 89 P194 HIGH SUCTION PRESSURE 0 0 ccc hh e 7 90 P195 LOW SUCTION PRESSURE ius cerae e pU ERR EIER E ERAT OE ERE ed de 7 91 P196 HIGH DISCHARGE PRESSURE sssseeeee ee 7 93 P198 LOW DISCHARGE PRESSURE 00 cece eee hn 7 94 P200 CHECK UL1 CYLINDERS 00 center Aa a TA 7 95 P201 CHECK UL CYLINDERS zi o aa es a e rake A hate eM RR Ti a IR anes 7 96 P202 FIIGH SIDE LEAK 3 iei eere eese ore Re neos eg em Maw re a RR P S Many aul 7 96 P203 CHK DISCHARGE CHECK VALVE sssssssseee e hme 7 97 P204 LOW SUCTION PRESSURE cirea nig kag Da pea e r me 7 98 P205 CHK DEFROST TERM 2 SENSOR 0 cece en 7 99 7 10 MAINTENANCE ALARMS 00 ccc cece eee eee n n nnn 7 100 223 ENGINE MAINTENANCE DUE 0 0 I nee enna 7 100 225 GENERAL MAINTENANCE DUE 00 00 cece I e eee 7 100 226 SERVICE SOON PM 1 DUE II teen ened 7 101 227 SERVICE SOON PM 2 DUE 0 ented 7 101 228 SERVICE SOON PM 3 DUE nosite i I nnn een nnn 7 102 229 SERVICE SOON PM 4 DUE II nnn een nae 7 102 230 SERVICE SOON PM 5 DUE ttn een nee 7 103 62 10683 vi TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page 7 11 MICROPROCESSOR ALARMS ooo cree arr nr n mr hh nnn 7 104 232 SETPOINT ERROR casein seus ane di dd Mk ter disp ado Adde eins 7 104 239 MODELS ERROR uuo eer do Reve a ere
42. TOTAL ENGINE HOURS 0 HRS MANUAL aLaRMLisT sTaRT sTop _ SELECT DEFROST deuten O 00 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 5 2 1 Typical displayed meters are TOTAL ENGINE HOURS and TOTAL SWITCH ON HOURS 4 Pressing the key will access all other meters when OTHER METERS AND COUNTERS is displayed 5 The selected hourmeter will remain in the MessageCenter for 10 seconds and then the default message STATUS OK 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 e Meters listed in Step 3 above that were not previously displayed Engine Protect Hours e Switch On Protect Hours e Engine Sleep Hours e High Speed Hours e Clutch Cycles e Start Cycles 3 23 62 10683 3 15 FUNCTIONAL CHANGE PARAMETERS O e e e e e HEAT COOL DEFROST START STOP CONTINUOUS 200 4I45 F SETPOINT BOX TEMPERATURE PRESS 1 TO VIEW SETTINGS MANUAL SELECT ALARM Ex START
43. 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 NOTE Remanufactured compressors are shipped without oil Do not start unit without adding oil See Section 2 9 for correct charge n Start unit and check for noncondensibles v Check compressor oil level Refer to Section 8 14 Add oil if necessary Check compressor unloader operation Refer to Section 8 15 x Check refrigerant cycles by running a unit Pretrip Refer to Section 3 3 W 8 23 62 10683 Compressor Bolts Compressor Bell Housing Key Compressor Drive Gear Locking Tab Nylon Drive Gear Drive Sheave Bolts V Belt Engine Adapter Drive Sheave VOCONDARON gt o Figure 8 18 Compressor Drive Assembly 8 14 CHECKING COMPRESSOR OIL LEVEL 8 14 1 To Check The Oil Level In The Compressor a Operate the unit in high speea 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 44 CAUTION Service mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating Refer to Section 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
44. 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 This sensor may be calibrated if necessary GROUND SUPPLY VOLTAGE OUTPUT Figure 8 3 Fuel Level Sensor Wiring 8 5 1 Testing The 0 To 100 Fuel Level Sensor a Verify that the wiring to sensor is correct 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 nat 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 O 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 8 6 ENGINE SERVICE AND COMPONENTS 8 6 1 Cooling System 8 6 2 Testing The RPM Sensor Units beginning with below serial numbers and ALL X2 units Refer to Air flows through the condenser radiator The Section 8 6 5 for information on units with Elec condenser radiator must be internally and externally tronic Speed Control clean fo
45. displayed in the Data List Also verify that the correct date and time is 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 62 10683 SECTION 6 MessageCenter 6 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 7 for a list of alarm messages Referto Section 3 13 for a list of Unit Data messages Refer to Section 3 15 for a list of Functional Parameter messages Refer to Section 5 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 amp 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 keys 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 keys 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 to install the option into the Micro The numbe
46. 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 __ a Check for alarm 1 Must be cleared Lie Check fuel level intake Must be above 1 4 tank Fill as needed E Check accuracy of sensor LUE penes Sensor accuracy See Section 8 5 for sensor testing and calibration PUSE E be calibrated accurately Check wiring to sensor No physical damage to sensor No damaged or corroded pins s fuel level sensor harness Em Inspect harness amp control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins schematic 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 4 Battery voltage reading 12 13 VDC between 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
47. 1 Continuous Run Temperature Control Operating Sequence Perishable Range 4 8 Figure 4 2 Continuous Run Temperature Control Operating Sequence Frozen Range 4 8 Figure 4 3 Start Stop Temperature Control Operating Sequence Perishable Range 4 9 Figure 4 4 Start Stop Temperature Control Operating Sequence Frozen Range 4 9 Figure 8 1 Priming Fuel Pump 2 cece eee eee teen m aa 8 5 Figure 8 2 Mechanical Fuel Pump 0 00 ccc eee 8 6 Figure 8 3 Fuel Level Sensor Wiring 0 0 ccc cece ese m 8 6 Figure 8 4 Fuel System Diagram 0 0 ccc nen teens 8 8 Figure 8 5 Lube Oil Flow Diagram 0 0 m RI III HH m n 8 8 Figure 8 6 Speed Control Solenoid 0 n 8 8 Figure 8 7 Electronic Speed Control Components o occccccccc ees 8 9 Figure 8 8 Frame Mounted Engine Speed Control Unit ENSCU 000s 8 9 Figure 8 9 DI Engine Crankcase Breather 000 cece es 8 10 Figure 8 10 Belt Tension Gauge sssssssssssses esee mn 8 10 Figure 8 11 V Belt Arrangement Non ESC Engine o o ococcccccccncccc enne 8 11 Figure 8 12 V Belt Arrangement Electronic Speed Control Engine 00 cece ee eee 8 12 Figure 8 13 Removing V Belt from Engine Adapter Drive Sheave sssellssssesessn 8 13 Figure 8 14 Fanshaft Assembly ooocccccccccco sehr n 8 15 Figure 8 15 Blower Wheel And
48. 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 42 0 C 2 7 F 1 5 C 1 5 F 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 modeuntil the box temperature rises to 3 6 F 2 0 C above setpoint at which point it will go to HighSpeed 6 Cylinder Cool Figure 4 1 Continuous Run Temperature Control Operating Sequence Perishable Range High Speed 6 Cylinder Cool 2 F 41 8 di 61861 Low Speed 6 Cylinder Cool 2 3 F 1 3 C UltraFreeze 2 Cylinder Cool Null FALLING BOX TEMPERATURE RISING BOX TEMPERATURE 3 6 F 42 0 C 2 7 F 1 5 C Figure 4 2 Continuous Run Temperature Control Operating Sequence Frozen Range 62 10683 4 8 High Speed 6 Cylinder Cool 3 2 F 1 8C Low Speed 6 Cylinder Cool 2 3 F 1 3 C Low Speed 2 Cylinder Cool CSMV CONTROL 0 5 F 0 3 C Start Stop Off Cycle Low Speed 2 Cylinder Heat P e I 2 o 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 C 2 7 F 1 5 C 0 5 F 0 3 C 2 3 F
49. 1 5 RESET INTERVAL This is not displayed unless the PM meter is assigned to a counter in the previous configuration PRODUCTSHIELD SETUP NOTE ProductShield is only avail able when IntelliSet is installed Refer to Section 4 5 2 for more information on the following settings PRODUCTSHIELD ECONO 62 10683 OFF ENGINE HOURS SWITCH ON HOURS CLUTCH CYCLES START CYCLES HIGH SPEED HOURS ENGINE HOURS OFF or 50 TO 30 000 HRS in 50 hr increments OFF or SWITCH ON HOURS 50 TO 30 000 HRS in 50 hr increments OFF or CLUTCH CYCLES 1 000 TO 90 000 CYCLES in 1 000 cycle incre ments OFF or START CYCLES 1 000 TO 90 000 CYCLES in 1 000 cycle incre ments OFF or HIGH SPEED HOURS 50 30000 HRS in 50 hr increments OFF GO TO START STOP GO TO CONTINUOUS 5 6 OFF The PM 1 5 Maintenance hourmeter s is turned off ENGINE HOURS PM meter will count engine hours until the next service interval SWITCH ON HOURS PM meter will count Switch On Hours until the next service interval CLUTCH CYCLES PM meter will count how many times the fan clutch cycled on off until the next service interval START CYCLES PM meter will count how many times the engine has started until the next service interval HIGH SPEED HOURS PM meter will count how many hours the unit operated in high speed until the next service interval OFF PM 1 5 is not being used ENGINE HOURS PM 1 5 is connecte
50. 12 C the unit will operate in Cool and UltraFreeze see Section 4 4 5 For set points above 65 F 18 4 C the unit will operate in Cool and Heat but will not operate in UltraFresh 3 4 4 3 Heat Mode Operation In the Heat Mode the microprocessor will operate the unit controls as follows SV1 SV2 Engine Speed re ULA UL2 CSMV Refer to SV2 Refer to Refer to UL1 Refer to UL2 100 4 4 4 Cool Mode Operation In the Cool Mode the microprocessor will operate the unit controls as follows svi sv2 Engine Speed Sunat UL1 UL2 CSMV Refer to Section 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 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 4 7 for maximum suction pressure limits during each mode of op eration in Cool Mode 4 7 62 10683 Note The following temperature control operating sequence diagrams are after pulldown and do not show overrides High Speed 6 Cylinder Cool 3 2 F 1 8 C Low Speed 6 Cylinder Cool 2 3 F 1 3 C Low Speed 2 Cylinder Cool 1 5 F 0 8 C UltraFresh 3 Low Speed 2 Cylinder Null CSMV CONTROL 1 8 F 1 0 C Low Speed 2 Cylinder Heat 2 7 F
51. 15 Mkg 3 8 24 x 1 00 Ig Grade 8 28 ft lbs 3 87 Mkg DIRECT DRIVE 90 ft lbs 12 45 Mkg M12 x 1 25 x 25 mm lg 8 Required 65 ft Ibs 8 99 Mkg 3 8 16 x 1 lg Grade 5 12 Required 28 ft Ibs 3 87 Mkg Figure 8 34 Unidrive Torque Requirements Electronic Speed Control Engine 8 45 62 10683 62 10683 Table 8 8 R 404A Temperature Pressure Chart Temperature Pressure eC F Bars PSIG 34 30 0 68 9 91 Le e 177 256 a 6 188 273 ae 226 328 4 6 268 389 a3 8 285 41 1 9 16 347 504 8 18 365 529 6 22 401 581 4 4 420 609 3 479 695 Temperature Pressure eC F Bars PSIG 6 s 500 725 3 34 821 786 a 549 788 3 38 566 8 amp 1 4 40 90 855 6 42 614 890 T 4 e3 025 8 45 amp 63 2 9 amp s9 00 9 0 0 7 15 1087 s 55 796 154 1e 60 869 126 1 e 65 9 47 1974 2i 70 1030 494 Ca 75 11 18 62 1 27 80 1210 1755 2 85 13 07 189 6 32 90 14 10 2045 35 95 15 18 2202 38 100 16 38 236 8 at 105 17 58 2542 48 110 1878 2724 46 115 20 11 291 6 49 120 21 50 9113 s2 125 22 95 332 9 54 180 24 48 355 0 a7 185 26 07 78 1 eo 140 27 74 4023 63 145 29 48 427 5 66 150 3 30 4540 8 46 SECTION 9 UNIT TROUBLESHOOTING 44 CAUTION Under no circumstances should anyone
52. 3 PSIG 0 2 Bar compare compressor discharge amp f suction pressures with those shown on Suction amp Discharge Pressures must have the same the microprocessor controller reading on gauges amp on micro display a Check for undercharged system Level must be above lower sight glass 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 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 NN Perform Pretrip Check a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding 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 10 c Check superheat of valve Refer to Section 2 10 7 15 62 10683 NOT 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 10 or less for more than 1 minute UNIT CONTROL Unit shutdown and Alarm RESET CONDITION Auto reset when fuel level is above 12
53. 4 5 minutes and the refrigerated compartment tempera tureis 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 Chargethe systemuntil the refrigerant levelis 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 3 8 12 3 Adding Full Charge 44 CAUTION Do not vapor charge R 404A Only liquid charging through the receiver outlet king valve is acceptable Q 2 a Dehydrate unit to 500 microns and leave in deep vac uum Refer to Section 8 11 3 o Place drum of refrigerant on scale and connect charg ing line from drum to king valve Purge charging line at king valve c Note weight of drum and refrigerant d Open liquid valve on drum Midseat king valve and al low the liquid refrigerant to flow into the unit until the correct weight of refrigerant has been added as indi cated by scales Correct charge will be found in Table 2 1 NOTE Itis possible that all liquid may not be pulled into the receiver as outlined in step d In this case frontseat the receiver outlet valve king valve and run the unit in cooling until the correct a
54. 62 10683 7 24 ANO 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 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 engine running i a Verify that engine is still running Engine should not be running Check for Bad Engine RPM Sensor alarm 4 a Check for alarm 130 Alarm conditions must be corrected and the alarm cleared to continue 3 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 a In
55. Air Thermistor SAT 9 co NO 62 10683 2 6 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 Solenoid Relay SSR 5 Fuse F7 5 Amp 12 Glow Plug Relay GPR Figure 2 8 Control Box Short Box 2 7 62 10683 1 Control Module Microprocessor 6 Fuse F7 5 Amp Refer to Section 2 5 3 7 AutoFresh Relay AFAR Location Only 2 Fuse F1 7 5 Amp Located next to control 8 Fuse F5 80 Amp module 9 Fuel Heater Relay FHR Location Only 3 Fuse F10 40 Amp Optional Auto Fresh Air 10 Starter Solenoid Relay SSR Exchange Location Only 11 Glow Plug Relay GPR 4 Fuse F6 15 Amp 12 Glow Crank Switch GCS If equipped 5 Fuse F8 20 Amp Optional Fuel Heater Figure 2 9 Control Box Redesigned Tall Box 62 10683 2 8 2 3 CONDENSING SECTION The condensing section consists of aan engine compressor drive package condenser fan condenser radiator coil refrigerant controls piping wiring defrost air switch and associated components 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 compres
56. 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 16 Check battery voltage NEN a Test voltage at battery with unit off Must be between12 16 VDC b Test voltage at battery with unit Must be between12 16 VDC running Check alternator voltage a 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 a Check voltage reading at START RUN OFF switch in START RUN position Manual microprocessor input QC1 to QC2 Start mode See Note 4 Must be between 12 16 VDC b Check voltage reading on Must be within 0 5 VDC of reading obtained in 3 Amp microprocessor display above 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
57. CONTROL 000ccccccc een nnn nnn nnn nnn 4 1 4d AUTO STARHT SEQUENGE crue inertes pe rr tage d dees ea dre M 4 1 4 1 1 Variable Glow Time ssssssesssese RR hh he 4 1 4 12 Engine RUNNING iee daraan eR Dee eeu eager iuda each eise nu 4 2 4 1 3 Initial Engine Operation 0 eR mh 4 2 42 START STOP OPERATION unire he a a Rh hh nn 4 3 4231 Start Stop Mode iin e eR e a EEUU NER Gale cate Dees 4 3 4 2 2 gt RESTON c sci LT cer E KE PRG ee IS Sorat Phe NER MERE RR ROT ME eR DES 4 3 4 3 CONTINUOUS RUN OPERATION 0 0000 cece eee m 4 5 62 10683 ii TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page 4 4 TEMPERATURE CONTROL siie ciara i paaa E REA A hh hs 4 6 4 4 1 Perishable and Frozen Setpoint Ranges 0 0c cece eee esee 4 6 4 4 2 Pulldown Pul up Mode 0 00 cece teen eens 4 6 4 4 3 Heat Mode Operation 4 7 4 4 4 Cool Mode Operation 4 7 4 4 5 Ultrafresh 3 Temperature Control o o occcoocccccccocc eee en 4 10 4 4 6 Cargo Protect Mode 0 ccc cece hh 4 11 4 4 7 Engine Speed Operation 0 00 ccc nn 4 11 4 4 8 Defrost iios bt wid yew a ds 4 12 4 4 9 Unloader Control Operation oooocccocccccco arc 4 15 4 5 SMA Operation i xiii aeter e Mei Ad tr hades goin Mete ic was moe Me pre ice Th 4 15 4 5 1 Temperature Range Lock 1 amp 2 uuusssssesssessesesess ens 4 16 4 5 2 Prod ctShleld 5 nose Deubseceesenescep AA O OE C hee Ae esd de Tee 4 18 4 5 3 Prod
58. Fusible Plug 2 23 G Gearbox Oil 2 23 Glow Plugs 8 10 Glow Crank Switch GCS 2 18 H Heat Mode Operation 4 7 Heat Cool Null Switching Operation 4 10 Heating Cycle 8 39 High Pressure Switch 2 23 8 29 Indicator LEDs 2 18 3 31 Installing New Software 5 14 Integral Voltage Regulator Operation 12 VDO 2 10 IntelliSet 3 33 K Key Descriptions 2 19 Index L Language Selection 3 29 Lube Oil And Flow Diagrams 8 8 Lube Oil Filter 8 7 Lube Oil Flow Diagram 8 8 Lubrication System 2 22 Maintenance Schedule 8 1 Manual Defrost 3 14 Manual Start Glow amp Crank 3 2 Max Operating Pressureoverride Heat And Defrost Only 4 24 MessageCenter 2 18 MessageCenter 6 1 Microprocessor Replacement 5 20 N Null Band Operation 4 10 O Output Overrides 4 22 P PC Mode 5 1 Pretrip 3 3 Pretrip Inspection 8 4 Priming Fuel System 8 5 ProductShield 4 18 Pulldown Pull up Mode 4 6 Pumping Unit Down 8 17 Index 2 Index R Re Setting PM Hourmeters 5 18 Receiver Sight Glass 8 33 Refrigerant Charge 8 17 8 21 Refrigerant Circuit Cooling 2 26 Refrigerant Circuit Heating Defrosting 2 27 Refrigerant Leak Checking 8 18 Refrigeration Charge 2 23 Refrigeration System Data 2 23 Remote Switches 2 21 Remove Jumper Mode 5 2 Replacing Check Valve 8 26 Replacing the Compressor 8 22 RPM Sensor 8 7 S Safety Decals 1 5 Safety Devices 2 24 Saf
59. Hot Gas Bypass check valve is to raise the receiver pressure when the ambient temperature is low so that refrigerant can flow from the dead 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 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 3 0 Mkg 4 2 gt 9 10 Torque 3 Bolts to 12 16 ft Ibs Figure 8 21 Unloader Coil 1 Coil Assembly 9 Pin Anti Rotation fits 2 Stem Enclosing Tube into top of stem nut Assy 10 Bolts Valve Body 3 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 Cap Spring Gasket Stem Seat Body Figure 8 22 Discharge Check Valve Serviceable Prior to S N JAW90756460 DARAN a 07 00457 00 Figure 8 23 Discharge Check Valve Non Serviceable Beginning With S N JAW90756460 Figure 8 24
60. 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 WARNING Under no circumstances should ether or any other starting aids be used to start en gine 62 10683 3 2 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 Placingtheunitin Start Stop will automatically put it back into Auto Start operation Manual Start mode will automatically be can celled when the START RUN OFF switch is toggled to OFF and then back to START RUN Refer to Section 4 1 1 for glow times 3 3 PRETRIP e O e Ld O O HEAT COOL DEFROST START STOP CONTINUOUS SETPOINT BOX TEMPERATURE TEST 1 ajv MANUAL ALarm List starT sTOP SELECT DEFROST disi O o JAN 1 Press the SELECT key
61. 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 19 3 for more information on two way communication 8 8 1 Clutch Removal 44 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 a Turn the START RUN OFF switch to OFF and dis connect the negative battery cable o Loosen the fan belt idler and remove upper drive belt Remove the top eight bolts four along top edge and o 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 Place the 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 62 10683 2 NOTE The armature retaining bolt is a LEFT HAND THREAD BOLT Remove the clutch armature A standard 5 8 11 X 1 8 a o right hand thread bolt can be threaded through the center to jack the armature off the shaft if needed Use spanner
62. 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 2007 Carrier Corporation e Printed in U S A 1007 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
63. 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 8 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 select 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 e Month e Day Year e Hour e Minute NOTE Theclock is a 24 hour clock Hours 1 thru 12 are AM and hours 13 thru 24 are PM RUN 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 WAKE is set to YES theunit will wake up at the 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
64. OK 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 Slee mode WARNING NO TEMP CONTROL will flash in the MessageCenter and the main display setpoint and compartment temperature will be turned off This is because compartment temperature does not have to be at setpoint 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 While the unit is cycled off in Sleep mode SLEEP MODE OFF ON TO WAKE will be displayed in the MessageCenter The display backlight will turn off after five minutes Sleep mode may be exited by either N 62 10683 turning the START RUN OFF switch to the OFF position then back to the ON position or by accessing the Functional Parameter list and selecting SLEEP MODE OFF While in Sleep mode 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 setpoint 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 batte
65. Refer to Section 2 6 for conditions Must be correct for ambient conditions S Check engine exhaust system Ta Inspect the exhaust system Must be clear and unobstructed SSS ee e EE E 62 10683 7 22 ANO 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 GCS Units built after April 2007 do not have CS Unis buite er Apt to Section 3 2 For units without a GCS check the wiring that would for location of switch connect to the switch if it were present for shorts It is not possible to place the unit in Manual Start Mode without energizing this circuit Figure 9 1 thru Figure 9 4 There must be no LED Ill ie alarm codes occurring to continue Operator failed to crank engine a Manually start unit Engine starts and runs Check fuel level in tank a Check fuel g
66. Speed Actuator ESC engines a Check Run Relay LED LED 28 must be ON b Check voltage to fuel solenoid or ESC START RUN OFF switch in START RUN position Manual module Start mode See Note 4 More than 11 VDC positive and good ground c Inspect solenoid amp connector pins amp No damage to solenoid Fuel Speed Actuator ESC terminals for non ESC engines module or wires __Inspect ESC module connector pins amp No damaged or corroded pins terminals for ESC engines 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 10 e Check resistance of solenoid Refer to Section 2 12 f Check operation of solenoid Plunger must move in when energized 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 Additional steps on the next page 62 10683 7 34 li ALARM CAUSE CORRECTIVE ACTION 41 ENGINE STALLED Continued 1 1 1 11 1 111 1 STALLED 41 ENGINE STALLED Continued 1 1 1 11 1 111 1 E Check Engine Speed Sensor ENSSN Units With Electronic Speed Control ESC engines Only a Inspect harness control box No physical damage to h
67. Temperature Sensor ENCT Provides micro 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 4 Injector e Engine Coolant Level Sensor ENCLS Optional Sets off alarm when coolant level is low Located in the coolant bottle f Engine Speed Control Unit ENSCU ESC only See Figure 2 10 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 See Section 9 4 for information on diagnosing failures 2 9 Figure 2 10 Frame Mounted Engine Speed Control Unit ENSCU g 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 h 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 62 10683 2 3 2 Alternator Regulator Electrical power for the control system and for charging the battery is provided by the 12 VDC alternator a Alternator Operation 44 CAUTION Observe proper polarity when installing battery Negative battery terminal must be grounded Reverse polarity will destroy the rectifier diode
68. The condenser pres sure control solenoid SV1 closes and suction pres sure will rise approximately 10 to 15 PSIG 0 68 to1 02 Bars after five minutes on unit operation Re fer to Section 8 23 2 if unit does not heat properly O Unit should remain in defrost until DTT2 located on the center tube sheet below the evaporator reaches 55 F 12 8 C Atthis point the defrost cycle will ter minate and the unit will resume automatic operation 8 25 2 Defrost Air Switch DAS 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 ne manner operates all components involved in de rost NOTE If DTT2 is above 40 F 4 4 C the MessageCenter will show CANNOT START DEFROST CYCLE b Unit should remain in defrost until DTT2 reaches 55 F 12 8 C At this point the defrost cycle will ter minate 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 8 26 8 25 3 Electronic Defrost Timer Refer to Section 4 4 8 for description 8 26 CHECKING CALIBRATION OF DEFROST AIR SWITCH a b D OQ 8 39 Ohmmeter or Continuity Device Adjustment Screw 0 050 socket head size Low Side Connection
69. 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 6 1 for a 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 l Micro is not the fault Replace micro and operate system in order to verify repair Did you find and correct the condition NO y Micro is not the fault Remove new micro amp re install old micro defective Turn power off and verify status light is not blinking Check for bent pins in the card slot amp straighten 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 strai
70. _ YES 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 Check for open or high resistance on circuit between FSA and ENSCU With the FSA disconnected check the resistance of the FSA coil Spec is Did you find and correct 2 8 ohms 10 the condition Is ohm reading within spec NO es Remove the FSA from the NO Replace ENSCU Did you find and correct the condition NO engine amp inspect FSA should l Remove new ENSCU and re install old ENSCU back into unit move freely without binding and shaft should be straight Is FSA functioning properly Review results of above tests Replace the FSA Did you find and correct the condition 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 lt nno YES Review results of above tests with your super visor If necessary go to the beginning of the table amp test again ENSCU is not the fault Review results of above tests with your supervisor If necessary go to the beginning
71. a Ensure that the new microprocessor is in place all wires connected and the negative battery cable is re connected Place the START RUN OFF switch in the START RUN position The controller will immediately go into the Configuration List so that the correct model num ber 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 appears 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 keys 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 LAD90887654 Press the Up Arrow key again and the ID field will ap pear Press the key then the Up Arrow key You will see a blinking cursor in the field Using the Up or Down Arrow keys scroll through the Number Letter list until the first letter number of the ID you recorded above appears Press the key to enter that number letter and advance the cursor
72. 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 active alarm occurs Continue with the steps below as necessary Check trailer or rail compartment doors 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 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 Perform pretrip check a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceed
73. air switch DAS out of calibration 8 26 DTT2 is above 40 F 4 4 C Cool Box Down Defrost air switch DAS defective 8 25 amp 8 26 Loose terminal connections Tighten Air sensing tubes defective or disconnected Check Microprocessor defective Replace Loose terminal connections Tighten DTT2 is above 40 F 4 4 C Cool Box Down Unit has been running less than 15 seconds Try again Low refrigerant charge 8 12 Solenoid valve malfunction 9 3 12 Clutch Gearbox defective Replace Defrost air switch DAS out of adjustment 8 25 amp 8 26 Wet load Normal Low refrigerant charge 8 12 Defrost air switch DAS out of adjustment 8 25 amp 8 26 9 3 7 Abnormal Pressure a Cooling High discharge pressure Low discharge pressure High suction pressure Low suction pressure Suction and discharge pressures tend to equalize when unit is operating 62 10683 Condenser coil dirty Condenser fan defective V belt broken or loose Discharge check valve restricted Noncondensibles or refrigerant overcharge Solenoid valve SV1 malfunction SVA leaking by Compressor valves s worn or broken SVA leaking by Compressor valves s worn or broken Compressor gasket s defective Suction service valve partially closed King valve partially closed Filter drier partially plugged Low refrigerant charge Expansion valve malfunction No evaporator air flow or restricted air flow Excessive frost on coil Solenoid valve SV2 defective Clutch Fa
74. 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 battery current draw a Note amp draw on display Must show 1 5 to 2 Amps See Note 3 Check individual circuits EN a Isolate individual circuits and test amp Must be in range Refer to Section 2 12 draw 3 Check For parasitic loads electrical current being used by a non refrigeration unit 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 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
75. be eb eet et Bee a Ee Pelt ee DA arn ees 7 68 P145 CHECK SPEED SOL CIRCUIT 0 0 I e 7 69 P148 GHECK SV CIRCUIT 2r eer eae at neck ted rd A ae PUM ee is 7 70 P150 CHECK SV4 CIRGUIT cri ovnis wee een e eae CUm ERE EDO LR RR ee Sas ERIS 7 71 P151 CHECK GLOW PLUG CIRCUIT 0 m 7 72 P152 CHECK FUEL SOLENOID CIRC 0 eens 7 73 P153 CHECK RETURN AIR SENSOR 000s ccc hm 7 74 P154 CHECK SUPPLY AIR SENSOR 00 ccc rr 7 75 P155 CHECK COOLANT TEMP SENSOR 0 ccc eee n 7 76 P156 CHECK BATTERY VOLTS osito cito eet ON Rete Le etc dl ail ce P DR et els 7 76 P157 CHECK BATTERY CURRENT oder bis ee Roe een A a 7 77 P158 CHECK AMBIENT AIR SENSOR 00 cece eens 7 77 P160 CHECK DISCH TEMP SENSOR ssssssseee e he 7 78 P162 CHECK AUTO FRESH AIR EXCHANGE SOLENOID AFAS CIRCUIT 000000 7 78 P164 CHECK ULZ CIRCUIT cocina pain aa RR RR on cg ence eo aor c pete ea 7 79 P165 CANNOT PUMP DOWN 000 orina peed an a A da a ad 7 80 P174 CHECK LOW SPEED RPM 0occcccccccccc nnn nee nnn 7 81 P175 CHECK HIGH SPEED RPM ooo 7 82 P178 CHECK ULT 1 4 ee iia a efe ree a REO dad hike a ea acie dd Ver eed ie es 7 84 P180 CHECK SUCTION MODULATION VALVE ssseeee e 7 85 P181 CHECK SVA VALVES zer RET Ive RT DEA cep Tas a 7 86 P182 CHECK SVI VALVE e peg ier ex er oriente es aol ate or etes 7 87 P191 CHECK UL rater ei p imei ea ref oe i IH EI PRATER E A Fra d RR eoa 7 88
76. belt tensions A z Check radiator fan belt No Glazing no cracking no slipping d Check water pump belt tension amp condition Check engine cooling system PR a E A e to Temperature must be within 20 F 11 1 C b Test operation of engine coolant Refer to Section 2 6 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 7 9 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 13 HIGH DISCHARGE PRESSURE TRIGGER ON Compressor discharge pressure is over 465 PSIG 31 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 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 pretri
77. 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 anumber associated with them When filling out the MPR tag that will be attached to the returned part write the step number on the upper half of the tag 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 table was used and the path that was followed to determine the micro was at fault 9 11 62 10683 Disconnect StarTrak from unit and in
78. clean oil if possible If the filters are not primed the engine may operate for a period with no oil supplied to the bearings 44 CAUTION Service Mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating 1 3 44 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 44 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 44 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 44 CAUTION Unit uses R404A and POE oil 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 Procedure 98 50553 00 Inert Gas Brazing 44 CAUTION Do not get anti seize oil compound onto clutch contact surfaces Tho
79. contacts will close and initiate a de frost cycle The Defrost Air Switch requires periodic testing and calibration Refer to Section 8 26 In the case where the switch is out of adjustment it will either not put the 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 the DTT2 and SAT temperatures are below the range defined above by pushing the MANUAL DEFROST key Refer to Section 3 9 Normal Defrost Operation sv S2 CLOSE RefertoSV2 RREN mam DISENGAGE e e io e 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 De
80. 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 62 10683 2 5 1 Multiple Languages Messages in the MessageCenter can be displayed in English French or Spanish 2 5 2 Special Features The following special features are incorporated into the Carrier Transicold Advance Microprocessor A MessageCenter which clearly displays all 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 62 10683 2 14 Automated Micro Self test DataRecorder DataRecorder date and time can be set from the keypad Auto Start Stop Trip Start to record date time of trip in DataRecorder memory PC card functionality for downloading data upgrading programming and configuration set up See 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 ke
81. engine coolant temperature is above 122 F 50 C Ifthe 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 am bient temperature sensor alarm is also active the unit will run for a minimum of 20 minutes before allowing an OFF cycle c The battery voltage is high enough Provisions are made to sense when the battery voltage is correct A good bat tery is defined as having 13 4 VDC at 75 F 23 9 C This voltage varies with ambient temperature d 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 changed 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 4 2 6 NOTE When conditions b c and d are all met OK will appear in the Unit Data List for battery voltage Table 4 2 Battery Voltages a ee Unit wil
82. 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 3 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 desired point and additional cooling capacity is required Table 4 3 FreshProtect For Return Air Temperatures less than 10 F 5 6 C above set point Below Setpoint A 2TOSF 4TO28C COo 8 4TOZFB2T0390 COo Db sonras E 30019 56T0720 OFF NOLMT X j 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 whe
83. funtional parameter settings for speed delay minutes Is the unit in Start Stop Ygs high speed delay minutes for start stop NO operation y 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 NO a po e colder than setpoint li 2865 ol setpoint Is speed relay LED27 Check the F2 circuit N illuminated on micro for excess amp draw or short to ground Did t YES you find and Y 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 v 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 necessary go to y ee An the beginning of the table and Micro is calling for high speed ls yes od or FSA Is the test again there 12V at the speed control solenoid actuator solenoid or FSA operating properly
84. is pressed These are PRETRIP DATA FUNCTION CHANGE TRIP START or PRINT or one optional selection IntelliSet will appear in the MessageCenter Repeated presses of the SELECT key will sequence the menu through the selections The menu will wrap around Press the SELECT key until the desired menu selection appears in the MessageCenter The five standard selections are PRETRIP Used to initiate a Pretrip DATA Displays Unit Data Refer to Section 3 13 FUNCTION CHANGE Displays unit Functional Parameter settings Refer to Functional Change Parameters Section 3 15 TRIP START This menu selection is only used with the DataRecorder It is used to record a Trip Start event which is logged in the DataRecorder This records the time and date of the beginning of the trip Data can then be downloaded and reviewed by trip making data review much easier PRINT Enables the user to use hand held Strip Print printer kit P N 12 00543 10 The optional selection is INTELLISET Refer to Section 3 19 1 62 10683 c 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 onthe front of a rail car They are controlled by the microprocessor These lights correspond to the microprocessor LEDs HEAT COOL DEFROST TRANSICOLD E iW y Pag ome CE A ENGINE AUTO START OUT OF RANGE OPTION DOWN LED LIGHT BAR 62 10683 2 20
85. microprocessor controller 7 97 62 10683 NOT 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 4 Refer to Section 8 7 for belt tensions condition No Glazing no cracking no slipping b Check lower fan belt tension amp Refer to Section 8 7 for belt tensions condition No Glazing no cracking no slipping 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 suction pressures with those shown on reading on gauges amp on micro display the microprocessor controller
86. mode Refer to Section 5 2 2 b 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 c Asecond method is to disconnect the wire connection to the plug and test the resistance from the plug toa ground on the engine block The reading should be 0 7 to 1 2 ohms if the plug is good Table 8 2 Belt Tension See Figure 8 11 BELTS Water Pump Alternator Crankshaft 45 to 55 6 2 to 7 6 Gearbox to Fan shaft 70 to 80 9 7 to 11 1 Engine to Gearbox 70 to 80 9 7 to 11 1 62 10683 8 10 8 7 SERVICING AND ADJUSTING V BELTS 44 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 8 7 1 Belt Tension Gauge Use a belt tension gauge tester P N 07 00253 shown in Figure 8 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 causes slippage and excessive belt wear It is also important to keep belts and sheaves free of any fore
87. 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 12 Check heat light wiring a Inspect harness amp control box See Notes 3 4 amp 9 connector pins amp terminals See wiring No physical damage to harness schematic No damaged or corroded pins Check heat light current draw a Use Component Test mode Refer to Refer to Section 2 12 for normal current values Section 5 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 13 88 CHECK REMOTE COOL LIGHT TRIGGER ON The micro Light Bar configuration is set for an 8 LIGHT 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 n
88. nozzle s defective Engine Manual Injection pump defective Engine Manual Air cleaner or hose restricted 8 6 6 Safety device open 2 11 Fuel solenoid defective Engine Manual Fuel pump FP malfunction 8 3 9 1 3 Starter Motor Malfunction Starter motor will not Battery insufficiently charged Check crank or turns slowly Battery cable connections loose or oxidized Check Battery cables defective Replace Starter brushes shorted out Engine Manual Starter brushes hang up or have no contact Engine Manual Starter solenoid damaged Engine Manual Glow Crank switch defective Replace Engine lube oil too heavy 2 6 9 1 62 10683 INDICATION TROUBLE Starter motor turns but pinion does not engage POSSIBLE CAUSES Pinion or ring gear obstructed or worn Starter motor does not disengage Glow Crank switch defective after switch was depressed Starter motor solenoid defective Engine is already running ACTION REFERENCE SECTION Clean both remove burrs or replace Replace Engine Manual Check Pinion does not disengage Defective starter Engine Manual after engine is released 9 1 4 Malfunction In The Engine Starting Circuit No power to starter Battery defective Check Loose electrical connections Tighten motor solenoid SS Fuel solenoid does not energize or does not remain energized 9 2 ALTERNATOR 12 Volt DC Alternator fails to charge Low or unsteady charging rate Battery defective Loose electrical connecti
89. of hours until the next programmed maintenance PRODUCTSHIELD SETUP Indicates that unit has IntelliSet installed and displays ProductShield settings 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 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 displayed if High Air is ON PRODUCTSHIELD Indicates the ambient temperature below which ProductShield Winter will WINTER xx operate Will only be displayed if WINTER is NOT OFF RANGE 1 LOCK OFF Temperature Range 1 Lock is turned off CONTINUOUS When the setpoint is set between Range 1 Minimum and Maximum Temperatures the unit is set to operate only in Continu o
90. 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 operational alarms occurred Pretrip will show FAIL and the tech
91. or use MicroProgrammer Figure 9 12 Micro Diagnostic Tree Cond 8 Programming Problems With PC Cards 9 19 62 10683 START AERE vs 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 can be loaded as released If NO NO loading 04 00 or 04 02 and the micro y 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 y 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 mid 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 screen correct the condition savers and power saver options on the laptop These YES System OK options can interfere with software download Did you A find and correct the condition NO y Make sure you are not using USB or 9 pin adapters on the computer Did you
92. 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 4 Check fuel solenoid 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 b Check operation of solenoid Plunger must move in when energized 1 B 3A B 3 7 73 62 10683 NOT 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 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 Ee Check Return Air Temperature sensor RAT a Inspect Return 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 Return Air Sensor resistance 10 000 Ohms 77 F 25 C See section 2 12 for See Not
93. position Manual Start mode all electrical circuits off See Note 5 Must be 2 0 to 1 5 Amps with no load us b Check direction of wire through current Must be in correct direction See arrow on current sensor sensor c Check amp current value with O 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 13 Check alternator belt a Check alternator belt tension amp Refer to Section 8 7 for belt tensions condition No Glazing no cracking no slipping Check alternator wiring a Check output amp 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 4 Must have 11 or more VDC with switch ON 4 Check AUX D terminal Must have less than 3 VDC with unit OFF a Inspect harness amp control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins schematic le Check output wire unit running Must have 13 or more VDC when tested against battery post EP Check ground wire unit running Must have 13 or move VDC when tested against battery post Check for add on equipment drawing too mu
94. 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 1 Check UL2 Rear unloader coil a Inspect UL2 Unloader coil amp terminals No damage to coil No damaged or corroded pins C b Check resistance of coil Refer to Section 2 12 Check amp draw of coil Refer to Section 2 12 Use ammeter Check UL2 coil wiring a Inspect harness amp control box See Notes 3 4 amp 9 connector pins amp terminals See wiring No physical damage to harness schematic No damaged or corroded pins 3 Check UL2 current draw a Use Component Test mode Refer to Refer to Section 2 12 for normal current values Section 5 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 13 7 51 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 87 CHECK REMOTE HEAT LIGHT TRIGGER ON The micro Light Bar configuration is set for an 8 LIGHT BAR and the Remote Heat light circuit to the Light Bar circuit is shorted The Heat Light output from the micro is
95. pressure regulator Cylinder pressure is approximately 159 9 Bars 2350 PSIG Do not use oxygen in or near a refrigerant sys tem as an explosion may occur See Figure 8 26 MW Te 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 MW Te Carrier Transicold does not recommend al lowing the compressor to pull less than 0 Bar PSIG at any time 44 CAUTION Observe proper polarity when installing battery negative battery terminal must be grounded Reverse polarity will destroy the rectifier diodes in alternator As a precau tionary measure disconnect positive bat tery terminal when charging battery in unit Connecting charger in reverse will destroy the rectifier diodes in alternator 44 CAUTION Use only ethylene glycol anti freeze with inhibitors in system as glycol by itself will damage the cooling system Always add pre mixed 50 50 anti freeze and water to 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 which is Dexcool approved and has 5 150 5 years 150 000 miles on the label 44 CAUTION When changing oil filters the new filters should be primed partially filled with
96. read in the Unit Data list 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 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 micro can be installed into re placement micro NOTE Changes to these values may be made for up to 60 minutes This configuration only appears in the list until an hourmeter reaches 25 hours LONG Longer glow times may be used for units in colder ambient conditions SHORT Shorter glow times are used as the facto ry setting for all engines NOTE Refer to Section 4 1 for glow time table 62 10683 CONFIGURATION SELECTIONS DESCRIPTION OUT OF RANGE SHUTDOWN YES When the compartment 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 PARAMETERS LOCKOUT YES All Functional Parameters in the function list are locked in place NO All Functional Parameters in the function list can be changed using the keypad unless individu ally locked out by ReeferManager RPM ALARM SHUTDOWN YES If alarm 39 Check Engine RPM is active turn the alarm light on and shut the engine off
97. set for 17 8 to 30 C 28 to 55 F 2 2 to 12 8 C 23 3 17 8 12 2 In the same example as above Range 1 or Range 2 can be changed to lock the unit operation into Start Stop The primary time that it is important to determine which range is to be Range 1 and which is to be Range 2 is when the ranges overlap each other In example 2 Refer to Figure below the ranges will be set to lock all setpoints into Start Stop except for a small range between 0 and 5 6 C 32 and 42 F where the unit will always operate in Continuous Run Range 1 Minimum Temperature will be set for 0 C 32 F and Maximum Temperature of 5 6 C 42 F Range 2 will be set for a Minimum Temperature of 30 C 22 F and a Maximum Temperature of 32 C 89 6 F 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 Set for Continuous 30 to 32 C 23 3 17 8 12 2 4 17 62 10683 4 5 2 ProductShield ProductShield is a group of configuration settings within the microprocessor that work together with the IntelliSet option to allow improved operating efficiency while providing customized product protection for up to 31 different commodities There are three modes to ProductShield a ProductShield Econo ProductShield Econo allows the unit to have the ability to automatically switch from Start Stop operation to Continuous run or
98. 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 Slide off and remove the clutch rotor pulley 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 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 8 2 Blower Wheel And Fanshaft Removal Remove bulkhead and air chute if so equipped Re move evaporator back panel Remove the bolts that secure DTT2 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 Inse
99. solenoid FSA on ESC Must move in and out freely plunger b Check engine speed arm amp linkage Must move freely Force high speed operation See note10 a 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 voltage to speed solenoid FSA Must be 12 14 VDC on ESC d Check resistance of speed solenoid Refer to Section 2 12 FSA on ESC e Check amp draw of speed solenoid Use Component Test Mode Section 5 2 2 to test FSA on ESC Refer to Section 2 12 for amp values View current draw in the Unit Data list Refer to Section 3 13 f Inspect harness amp control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins or terminals schematic g 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 micro a Check voltage at pin 16 with unit Must be O VDC for all units running 4 Check engine RPM a Check actual engine RPM using hand Refer to Section 2 6 held tachometer Adjust engine linkage setting as needed b Compare actual RPM with tho
100. 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 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 4 DO NOT START UNIT c Check for voltage at harness plug Voltage should be approximately 12VDC at harness 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 C to the checking for continuity Must be less than 10 ohms microprocessor plug 2MP04 3 Check circuits with test substitute switch a Substitute known good sensor and clear er Start unit and run for 30 Alarm should not come on Install new switch if seconds IE necessary b Check to see if alarm re occurs 7 5 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION
101. tests with your super visor If necessary go to the beginning of the table amp test again Figure 9 4 ESC Diagnostic Tree 2 Long 7 Short LED Code 62 10683 9 10 9 4 1 Advance 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 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
102. than 1 quart low 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 7 and shutdown YS pio Opens at 15 amps Door Open Door Switch or Remote Switch See Trigger On criteria for May be configured for alarm only or alarm Alarms 57 58 and 61 in Sec and shutdown tion 7 Refrigerated compartment temperature Out Microprocessor See Trigger On criteria for Of Range Alarm 53 in Section 7 May be configured for alarm only or alarm and shutdown 62 10683 2 24 2 12 COMPONENT RESISTANCE AND CURRENT DRAW Table 2 7 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 Cannot be accurately measured Pull in 29 Amps Solenoid with coil commander in circuit Hold 0 83 Amps 10 6 0 3 Ohms 1 0to 2 0 Amps 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 Units without 11 1 Ohms to 13 4 Ohms 0 25 to 2 0 Amps ESC Red Black wires Fuel and Speed Actuator 2 8 Ohms 10 68 F 20 C Units with ESC 4 Amps Max Engine Speed Sensor Units 22 mAmps Max with ESC 12VD
103. to pull less than 0 Bar PSIG at any time c Once the unit has reached suction pressure of 0 Bar PSIG switch the unitto OFF using the START RUN OFF switch 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 8 37 62 10683 o D Wait about two minutes after the engine stops to en sure the valve is fully shut and then energize SV2 with 12 VDC manually If the CSMV is fully shut the suction pressure should still read O Bar PSIG after energizing SV2 If the valve is stuck at some position other than fully closed or it cannot fully close for any reason the suction pres sure during this test will rise 1 If the suction pressure holds to O go to Step f 2 If the suction pressure rises go to Step g f 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 g or there is something ob structing the refri
104. to test Refer to Section 2 12 for amp values View current draw in the Unit Data list Refer to Section 3 13 e Check amp draw of each glow plug Refer to Section 2 12 for amp values Use ammeter Check glow plug 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 62 10683 7 72 NO 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 Check for bad F2 or F3 fuse alarm a Check for alarm 71 Alarm conditions must be corrected and the alarm cleared to continue 2A Check fuel solenoid non ESC engines only a Check resistance of fuel solenoid Refer to Section 2 12 b Check amp draw of fuel s
105. to the next place Repeat this process until the entire ID number is entered If the cursor is still blinking in a blank space after you are finished slowly wait two to three sec onds between presses press the key to leave blanks in the remaining spaces When you reach the end the message y TO SCROLL THEN TO SELECT will appear i e XYZ5678 Press the Up Arrow key again and SET NEW HOURS appears Press the key then the Up Arrow key to enter that menu 5 21 f 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 O zero just press the key to enter O 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 keys 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 Engine Protect than the number of Switch On Hours NOTE None ofthe Total hourmeters are listed When the hours for all the hour
106. tube retainer and con nect wiring A CAUTION Service mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating 1 Coil Assembly 5 Seal 2 Retainer 6 Piston Assy 3 Enclosing Tube Assy 7 Body 4 Plunger Assy 8 Bracket Adapter Figure 8 27 SV2 SV4 Solenoid Valves 62 10683 8 34 To service the liquid line solenoid valve SV 2 orthe hot gas solenoid valve SV 4 first pump the unit down Refer to Section 8 9 1 Remove and store the refrigerant charge in an evacuated container Refer to Section 8 9 2 1 Remove coil retainer and coil assembly from valve 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 8 28 DIMPLES Figure 8 28 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 8 10 5 Install coil assembly and retainer 6 Start unit and check refrigerant charge Refer to Sec tion 8 12 7 Check refrigeration cycles 8 Run Pretrip Refer to Section 3 3 8 23 2 Solenoid Valve SV1 a Replacing the Coil NOTE The coil may be re
107. 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 9 13 Micro Diagnostic Tree Cond 9 Programming Problems With MicroProgrammer 62 10683 9 20 SECTION 10 WIRING Plugs used with Schematic 62 10499 Rev V Standard Engine 1 MP Natural 2 MP Black PS 24 pl Did 12 Y Terminal R R femina Termina REMSN1 SATCOM C 32 i CI me 32 SLP A FHR O gt n ES m lt 02 z Y oo 2 il O J Fr E g n Mii Oja Na S CO N AQUI ol o o 3 wW kes C N eoe n e iC pus o 10 1 62 10683 zm SEMEN SP23 REMSN2 SP23 REMSN3 ENCT N T Q w aj C2 N pO 2 2 aj A C O cd o h h Ti m Z O Qo PM NM P 0 oO 3 HC 17 I U n AR EIS E N S E NC N S S N MS1 RPM MV D MS2 LS PS ENRPM MV C MV A
108. 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 TIP evaluating operation of all modes It will indicate a failure The Pretrip test results message will stay dis When eS played until a key is pressed or until the TIP START RUN OFF switch is moved to the OFF A Pretrip can be started with any compartment position temperature The MessageCenter displays the current test and the Once Pretrip is started the control panel keys are complete of the test When the Pretrip tests are disabled until Pretrip is completed complete the MessageCenter will display one of three different messages e PRETRIP PASS or e PRETRIP FAIL IN TEST X or TIP If CAN NOT START PRETRIP is displayed in the MessageCenter check to see if the unit is in e PRETRIP FAILED amp COMPLETE PC mode Refer to Section 5 1 or check the Press the ALARM LIST key to review the alarms alarm list Section 3 11 for active shutdown triggered by the Pretrip tests alarms 3 3 62 10683 PRETRIP Continued NOTES NOTE 1 Pretrip may be initiated any time the unit is running or when the unit is off but the START
109. 0 Compressor Discharge Temperature Trans ducer 2 13 Compressor Oil Level 8 24 Compressor Suction Modulation Valve 2 13 8 37 Compressor Suction Pressure Transducer 2 13 8 32 Compressor Unloader 2 11 8 26 Condenser Coil 8 40 Config and Tech Test Modes 5 2 Configuration Mode 5 3 Continuous Run Operation 3 9 4 5 Controller Sensor 8 40 Cool Mode Operation 4 7 D Data Ohms And Amps 2 25 Data Recording 3 31 Defrost 4 12 Defrost Air Switch 2 23 8 39 Defrost Cycle 8 39 Dehydration 8 19 Display 2 18 Door Switches amp Remote Switches 2 21 Download Port 5 1 Downloading Data With The PC Card 5 13 E Electronic Speed Control 8 9 Engine Air Cleaner 8 9 Engine Air System 2 23 Engine Coolant Level Sensor 2 9 Engine Coolant Temperature Sensor 2 9 Engine Cooling System 8 7 Engine Crankcase Breather 8 10 Engine Data 2 22 Engine Oil 2 22 Engine Oil Level Switch 2 9 Engine Oil Pressure Switch 2 9 Engine RPM Sensor 2 9 Engine Screw Thread 2 23 Engine Speed Control Unit 2 9 Engine Speed Operation 4 11 Engine to Gearbox V Belt 8 13 Evacuation 8 19 Evaporator Coil 2 13 8 40 Expansion Valve 2 23 8 28 Index 1 F Failed To Start Auto Mode 4 4 Fan Clutch Air Gap 2 23 Fan Shaft V Belt 8 13 Fanshaft 8 14 Fanshaft Oil 2 23 Filter Drier 8 28 FreshProtect 4 21 Fuel and Speed Actuator 2 9 Fuel Level Sensor 8 6 Functional Change Parameters 3 24
110. 0 cece II eee 7 50 85 CHECK ULT CIRCUIT pirrer iiei ranr iea n rr tee lent al as ER Id 7 51 86 CHECK ULZ CIRCUIT socia A dada mai ube hs 7 51 87 CHECK REMOTE HEAT LIGHT 0 cnt 7 52 88 CHECK REMOTE COOL LIGHT iae e re e eee ek an eee dedi ede ne ek 7 52 89 CHECK REMOTE AUTO LIGHT nipona eya nts 7 53 90 AUTOFRESH AIR EXCHANGE RELAY 000 ccc rr 7 53 93 CHECK START UP BUZZER ek air ta Dh 7 54 97 CHECK SVZ GIRGUIT iuc AR i Gales daa e c dci cea d aN RR c DR a 7 54 7 8 SENSOR ALARMS ie eaa aa enhn n n nnn n nnn 7 55 121 CHECK AMBIENT AIR SENSOR ssssssseee e 7 55 122 CHECK RETURN AIR SENSOR ssssssssssee me 7 56 123 CHECK SUPPLY AIR SENSOR 0 02 he 7 57 125 CHECK COMP DISCH SENSOR siae taima y iaa e me 7 58 126 CHECK FUEL SENSOR CIRCUIT 0 0 e e 7 59 129 CHECK ENG COOLANT SENSOR ssssssee e nen es 7 60 130 CHECK ENGINE RPM SENSOR 0 0 cece e 7 61 132 CHECK DEFROST TERM 2 SENSOR ssseeeeeee n 7 63 133 CHECK REMOTE TEMP SENSOR 1 ssssssseseee en 7 64 134 CHECK REMOTE TEMP SENSOR 2 000ccccccccccc n 7 65 135 CHECK REMOTE TEMP SENSOR 8 0 e 7 66 X 62 10683 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page 7 9 PRET RIP ALARMS 1h a a e xA Ree IER a RA eee ni ie we 7 67 P141 PRETRIP STOPPED BY USER i oil cc ee pee ale a a A ea ERU HE que 7 67 P143 CHECK CLUTCH CIRCUIT ooo 7 67 P144 CHECK ULT CIRCUIT 2 Reed a SA
111. 1 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 open 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 bel
112. 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 1 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 8 29 for complete resistance chart See Note 6 10 000 Ohms 9 77 F 25 C 2 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 3 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 p
113. 180 00 or connect an insulated jumper wire between plug terminals A and B 62 10683 5 2 Insulated Jumper Download Port Jumper P N 22 50180 00 WHITE WIRE WARNING DO NOT ALLOW JUMPER WIRE TO TOUCH ANY GROUND e Turn the START RUN OFF switch to the START f RUN position The ALARM LED will come on the set point will appear but the refrigerated compartment temperature will not and REMOVE JUMPER will appear in the MessageCenter for 10 seconds Remove the jumper at this time TO SCROLL THEN TO SELECT will appear in the MessageCenter for 10 seconds or until either the UP or DOWN ARROW keys are pressed Press the UP ARROW key to scroll through the Main 5 2 1 Configuration Mode NOTE To enter Configuration mode refer to Section 5 2 a t TO SCROLL THEN TO SELECT will appear in the MessageCenter b Press the UP ARROW key to scroll through the Con figuration list beginning at the top Press the DOWN ARROW key to scroll through the Configuration list beginning at the bottom c To read through the Configuration list continue to press either the UP or DOWN ARROW keys The list is circular meaning that once the end is reached it is repeated from the beginning Menu beginning at the top Press the DOWN ARROW key to scroll through the Main Menu beginning at the bottom g Select the mode you wish to access and press the key See the following pages for i
114. 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 Setpoint setting Must be between 22 F to 89 6 F 30 C to 32 C Jb Enter new Setpoint Must be between 22 F to 89 6 F 30 C to 32 C Reset microprocessor AAA 30 seconds then turn back on TE Alarm 246 remains active Replace microprocessor See Note 1 a Clear the inactive alarms All alarms cleared 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 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 Setpoint setting Must be between 22 F to 89
115. 4 valve SV4 Pulse Mode or mixing heating and cooling modes Pulsed Null Mode UltraFresh 3 uses both the supply and return air sensors to control compartment temperature The sensor that is selected under the Functional Parameters for the temperature control is known as the Selected Probe This is the probe that will be used to determine when the temperature is at setpoint The Active Probe is the sensor actually used by the microprocessor to perform the temperature control It is the same as the Selected Probe unless that sensor is not installed or is defective or if supply is the selected probe in Frozen Range SELECTED PROBE ACTIVE PROBE Return Air Sensor Return Air Sensor only Supply Air Sensor Perishable Range Supply Air Sensor Return Air Sensor Frozen Range In the case of a bad probe the remaining probe will be used for temperature control a Heat Cool Null Switching Operation There are three possible modes for UltraFresh 3 control temperatures These are Heat Cool and Null When not in pulldown UltraFresh 3 controls the unit based on the following Refer to the temperature control operating sequence diagrams 1 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 setpoint 2 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 setpoint 3 To exit cool and en
116. 5 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 4 Cap Screw 11 Rail Cap Assembly refrigerated compartment dirty air may be drawn into 5 Gasket 12 Rail Bracket the air stream and 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 36 AIR OPENINGS POINT DOWN TO PREVENT RAIN WATER ENTRY Figure 3 2 AutoFresh in Closed Position Figure 3 3 AutoFresh in Open Position 3 37 62 10683 SECTION 4 ENGINE AND TEMPERATURE CONTROL 4 1 AUTO START SEQUENCE When the starting conditions are met the start sequence will begin by fully closing 0 Open the Compressor Suction Modulation Valve CSMV The CSMV will then open When it reaches 30 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 powe
117. 6 F 30 C to 32 C b Enter new Setpoint Must be between 22 F to 89 6 F 30 C to 32 C Wi 1 All settings must be valid Reset microprocessor NAAA RUE 30 seconds then turn back on b Alam48remainsadive Replace microprocessor See Note 1 __ a Clear the inactive alarms All alarms cleared 7 107 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 necessary Check microprocessor a Check Temperature Sensor Data Must be valid reading for RAT SAT AAT etc b Check for any Active Sensor Alarms Must all be cleared Check microprocessor amp unit Wiring a Check Wiring to Micro and at input Must not be miss wired to allow 12 VDC on any of the devices to the micro sensor input circuits a Turn START RUN OFF switch off for Microprocessor powers up OK 30 seconds then turn back on a Alarm 249 remains active Replace microprocessor See Note 1 a Clear the inactive alarms All alarms cleared E E
118. 6 ENGINE DATA Table 2 3 Engine Data CT4 134DI V2203 DI E2B Engine Model in 2 gallons 7 6 liters 50 50 mix never to exceed 60 40 Winter Diesel No 1 Summer Diesel No 2 7 0 amps per plug at 10 5 VDC nominal A CAUTION 2 6 1 Lubrication System a Oil Pressure 40 to 60 PSIG 2 7 To 4 1 Bars Use only ethylene glycol anti freeze with Engine in high speed inhibitors in system as glycol by itself will b Oil Pressure Safety Switch Setting Closes damage the cooling system Always add 15 3 PSIG 1 02 2 Bars pre mixed 50 50 anti freeze and water to ra 4 NS MEM CES p c Lube Oil Viscosity diator engine Never exceed more than a 60 concentration of anti freeze Use a low Outdoor Temperature 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 which is Dexcool approved and has 5 150 5 years 150 000 miles on the label Centigrade Fahrenheit 0 Below 32 TOW or TEWA0 Extended Service Interval ESI packages are standard on X units beginning with S N JAB90602792 The ESI package reduces the frequency of scheduled service intervals The two tables below reflect the differences between standard and ESI packages Oil Change Intervals Standard Service Interval API MOBIL Class Cl or higher DELVAC 1 2000 Hours or 1 yr 4000 Hours or 1 yr Oil Change Intervals Ext
119. 7 589 25 27 8 600 24 614 23 300 622 23 31 4 633 22 32 2 644 2 656 20 344 05 600 ss os 19980 aso 1707 1 040 EJE 711 16 940 360 182 2 920 367 6 789 15 450 370 187 8 830 378 767 14 070 380 1933 740 38 9 794 12 870 390 198 9 670 40 0 ez eo ao ane 00 41 1 850 10 750 410 210 0 540 420 2156 400 43 3 906 9 050 490 221 1 450 En no eso mo 2007 eo 460 ERES hou 104 4 6 107 2 5 230 110 0 5 130 600 260 0 240 28 4 EHE 118 3 4 121 1 3 185 es am 100 ma fa 14 fs sima n ENE ES 22 EX se 233 570 L7 221 260 89 209 670 198 760 108 11 1 188 490 EJE 183 169 700 o are aero se wa 155 16 6 Hur 200 ERI 222 29 3 HENE 2 189 9 2 167 709 180 4 ase 7 ED EIE Der E o as eue ne 407 eim Tar ms seme ms a ETA 060 50 0 662 690 o as o a an se e o9 519500_ e pee eisio js s11 stero 107 600 1s 14 4 12 2 120 522 38 200 _ 128 53 3 31 850 amo J ES aoo EXE T 106 108 114 16 118 138 120 36 100 126 128 130 62 10683 8 42 8 30 UNIDRIVE TORQUE REQUIREMENTS FIGURE 8 33 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 t
120. 7 3 1 2517 eae a gt 62 10683 8 32 8 21 3 Replacing Compressor Suction Pressure o O Transducer WA TE 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 19 3 for more information on two way communication Pump down the unit at the king valve until the suc tion pressure is approximately 5 PSIG 0 34 Bar Refer to Section 8 9 1 Disconnect wiring from defective transducer Slowly remove the transducer The pressure remaining in the suction line will be held in place by a Schrader valve located inside the fitting The CSP is located on the suction line just above the suction service valve See Figure 2 4 Install new suction transducer being careful to obtain the correct transducer for your unit R 404A CSPs have a blue dot on the side Check for leaks Open the king valve and check operation 44 CAUTION Service mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating Evacuate and
121. 7 38 NO 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 Check evaporator fan clutch a Check Evap Fan Clutch operation in Must disengage fan defrost 2 Check refrigerant level a Visually check refrigerant level in Must be at correct level receiver tank 3 Check for low refrigerant pressure alarm a Check for alarm 18 Alarm conditions must be corrected and the alarm cleared to continue 4 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 5 Check accuracy of DTT2 and SAT temperature r
122. 71 Check for Bad F2 or F3 Fuse alarm to continue 40 Check Glow Plugs alarm 35 Check Starter Circuit alarm 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 5 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 control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins schematic 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 5 2 2 In both cases there must be more than 11 VDC 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 7 21 62 10683 5 7 EIL ALARM CAUSE CORRECTIVE ACTION FAILED TO START AUTO MODE Continued 8 Check for correct engine oil A Check for correct oil viscosity weight
123. 8 6 6 Engine Air Filter ble ERRERE A MU WERE A ue Du Rr cent 8 9 8 6 7 Engine Crankcase Breather ooocooocccocccccccc en 8 10 8 6 8 Servicing Glow Plugs ssssusesessee eem mn 8 10 8 7 SERVICING AND ADJUSTING V BELTS oooccccccccccc e he 8 10 8 21 Belt Tension Gauges es ead Sia ee EE AD EIE RA ac dea En i Rus 8 10 8 7 2 Water Pump Alternator Crankshaft V Belt sssssssssssssesess eh 8 11 8 8 FANSHAEF T ASSEMBLY ie A hoe DAs Pd UE Rete T PRU UAT hate PEP 8 14 8 8 1 Clutch Removal ucro ner re TS me UU E ADIRE RR Ire DU RA Re DR Se 8 14 8 8 2 Blower Wheel And Fanshaft Removal 000s cece eee een 8 14 9 9 3 Fanshaft Installation arcos caca ri en ees patie eee Mew Ico S dee DERI oases 8 15 8 8 4 Blower Wheel Installation 0 0 eee ete teens 8 16 8 8 5 Gluteh Installation o e eg ie ee es Gee ig Soe AMOUR RC e pet 8 17 8 9 PUMPING UNIT DOWN OR REMOVING REFRIGERANT CHARGE 20 0005 8 17 8 9 7 Pumping Down The Unit muta A ae PGR Ge ab Th 8 18 8 9 2 Removing The Refrigerant Charge 0 eee nnn 8 18 8 10 REFRIGERANT LEAK CHECKING ssssssee ene eens 8 18 8 11 EVACUATION AND DEHYDRATION 0ooccccccccccc eee he 8 19 8 112 PreparatiO toti gaat lynne ordi t ratu Pai aol e ga a atin 8 19 8 11 3 Procedure For Evacuation And Dehydrating System 0 0 cece eee eee 8 19 vii 62 10683 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page 8 12 ADDI
124. ANNOT ENTER TRIP START Cannot enter trip start A problem has been detected within the DataRecorder CANNOT START DEFROST CYCLE Cannot start defrost cycle Refer to Defrost Sections 3 9 4 4 8 2 14 and 8 25 CANNOT START PRETRIP Cannot start pretrip Refer to Pretrip Section 3 3 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 the Micro You may safely remove the PC card from the slot 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 6 1 62 10683 MessageCenter MESSAGES CARD REMOVED DATA NOT COPIED The PC card was removed before all data recorder data was cop ied 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 A Configuration card has been inserted into the PC card slot Press to load configurations or IntelliSets into microprocessor CHANGE INTELLISET TO EXIT The unit is operating in Sleep mode and IntelliSleep is active CHARGE MODE HOLD TO EXIT Service mode has the refrigeration system set so that it c
125. AUTION 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 damage 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 requ
126. C Mode Pressing the key will cause the new displayed setpoint value to become active and SET POINT CHANGED is displayed If the display is flashing and the new value is not entered after five seconds of no keyboard activity the entire display and Light Bar will flash and the buzzer will sound for 15 seconds with SET POINT NOT CHANGED displayed and then revert back to the active setpoint All other keys are active at this time and if pushed while the display is flashing will stop the flashing and perform the requested function TIP You may press and hold the UP ARROW or DOWN ARROW key to quickly change the set point The longer the key is held the faster the setting will change 62 10683 3 5 START STOP OPERATION e e e HEAT COOL DEFROST 200 SETPOINT ALARM START STOP 0 START STOP CONTINUOUS 32945 F BOX TEMPERATURE START STOP MODE SELECTED MANUAL DEFROST ALARM LIST o SEPAN Arii SELECT CONTINUOU O 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 gives the microprocessor automatic control of starting and stopping the diesel engine as required The main function of Automatic Start Stop is to turn off the refrigeration system near the setpoint
127. C Relay 72 Ohms 10 0 14 0 18 Amps 10 00328 00 12VDC Relay 80 Ohms 15 0 12 0 17 Amps 10 00385 00 12VDC Relay 97 Ohms 10 0 11 0 14 Amps 10 00328 02 White Black wires Can not be accurately measured with Coil 30 0 to 40 0 Amps Commander in circuit Indicator lights 8 Light Bar 4 8 0 2 Ohms Onl y 2 25 62 10683 2 13 REFRIGERANT CIRCUIT DURING COOLING See Figure 2 15 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 condenser tubes The condenser fan circulates surrounding air over the outside of the condenser tubes The tubes have fins designed to improve the transfer of heat from 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 ma
128. 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 4 wire connections No damage to buzzer No damaged or corroded pins __ b Check resistance of buzzer Refer to Section 2 12 Check buzzer wiring a Inspect harness amp control box See Notes 3 4 amp 9 connector pins amp terminals See wiring No physical damage to harness schematic No damaged or corroded pins Check buzzer current draw a Use Component Test mode Refer to Refer to Section 2 12 for normal current values Section 5 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 13 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 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 turni
129. Center will show COPYING DATA PLEASE WAIT While the data is being copied the green PC CARD STATUS LED will flash on for one second then off for one second in tandem with the Micro Status LED 4 When the copy is complete COPY COMPLETE REMOVE CARD X X is the number of empty spaces remaining on the card will show in the MessageCenter The PC card Status LED will stop blinking but be on 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 6 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 NOTE Data must be downloaded off of the Download PC card onto a computer drive before it can be viewed O Ld COOL DEFROST SETPOINT BOX TEMPERATURE COPYING DATA PLEASE WAIT Pb MANUAL f ALARM E sTART sTOP SELECT DEFROST cd OM 62 10683 5 4 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 5 4 1 Software Version Numbers The first two digits of the software revision number e g 04 indicates the major release Major releases o
130. Coil Resistance Spec 2 8 ohm 10 Short ENSCU supply voltage is greater than 26V Do Long Seven ENSCU or alternator problem hort 62 10683 9 6 START HERE Start unit y NOTE Ensure the run relay is energized during test With ENSSN unplugged during testing unit will stall 8 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 y Check for high resistance or an open between ENSCU terminal 258 L yves_ gt 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 ENSSNG 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 Replace ENSCU Did you find and correct the condition Check high speed mechanical s
131. DUE E Eben eue 9 3 9 3 2 Unit Runs But Has Insufficient Cooling lisse 9 3 9 3 3 System Will Not Pump Down sssessser RI hm rh 9 3 9 3 4 Unit Operates Long Or Continuously In Cooling oocoocccccocccnc or 9 3 9 3 5 Unit Will Not Heat Or Has Insufficient Heating 0 0 ccc tees 9 3 9 3 6 Defrost Cycle Malfunction sssssessssesesee mh 9 4 9 9 7 Abnormal Pressure 2 vrbe UID ria IR RELATA ENT 9 4 9 3 8 Abnormal NOISe o RETE RE Dn ep DR eu uU uates 9 5 9 3 9 Control System Malfunction 000 cc hh 9 5 9 3 10 No Evaporator Air Flow Or Restricted Air Flow 0 00 cece eee eens 9 5 9 3 11 Expansion Valve Malfunction 0 00 cece e mm 9 5 9 3 12 Solenoid Valve Malfunction ssssssssssesssee sm 9 6 9 4 Electronic Speed Control Troubleshooting 0 00sec Ih 9 6 9 4 1 Advance Microprocessor Troubleshooting Guide aseenaan neeaae 9 11 WIRING SCHEMATIC 22 cemere A wie shaw es eee eats 10 1 PLUGS USED WITH SCHEMATIC 62 10499 REV V STANDARD ENGINE 0005 10 1 PLUGS USED WITH SCHEMATIC 62 04102 REV ESC ENGINE s sese 10 2 HG PLUG EOR AEL UNLITS ru uh A a P dac ets 10 3 ADVANCE MICRO DISPLAY HARNESS CONNECTIONS sssssssesee ee nen 10 4 VOLTAGE TESTS tesoro OR E NH ER Henn 10 4 ix 62 10683 LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figure 2 1 Front View Of Unit With Non ESC Engine o occ
132. ERRIDE TEMP PERISHABLE MAXIMUM OFF TIME FROZEN MINIMUM RUN TIME FROZEN MINIMUM OFF TIME FROZEN OVERRIDE TEMP FROZEN MAXIMUM OFF TIME FROZEN SHUTDOWN OFFSET NOTE Inthe eventthat different values for both Perishable and Frozen Start Stop times are selected in the Function al Parameter list then the Configuration is changed from Separate to Together The values from the Perish able times will be the ones that will be used 4 2 6 Charging Amps A Configuration for Start Stop Shutoff Configuration exists which allows the microprocessor to monitor battery charging amperage in addition to battery voltage The battery charging rate as seen in the Data list must be belowthe 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 the alternator is putting a high charging rate into it then not be sufficiently 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 requi
133. 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 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 2 Check freeze point of aon NE Use Coolant tester check Must be between 4096 to 6096 Ethylene Glycol to water concentration of D A IUS mixture IN airflow through radiator condenser coil a Inspect condenser amp 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 Check condenser amp water pump belts a Check upper fan belt tension amp condition b Check lower fan belt tension amp condition Refer to Section 8 7 for
134. 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 62 10683 4 24 4 8 1 Suction Pressure Operation 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 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
135. G He C SEONG MICROPROCESSOR PLUG2 B TO SP2 K10 NOT SUPPLIED WITH ULTIMA XTC D ULTRA XTC TO GPR86 K9 HC6 TO SSR86 J9 Al LOCATED IN ENGINE HARNESS F1 7 5A PSA SYSTEM POWER GPR SSR F DISPLAY KEYPAD 1B 1A B l 2B CSMV XTC 2A MP 35 CONTROL BOX GCS ULTIMA ULTIMA XTC AND_ULTRA XTC NNNNNNNNNNNNNND DD DDD WD O TO HC6IB3 TO SMPA1 E3 E gt TO 2MP25 E7 2 gt TO F6B B1 LB G B O gel F9 3A OUTPUT PO
136. GER 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 4 4 8 RESET CONDITION Auto Reset when Defrost Termination 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 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 8 29 for complete resistance chart Temperature Sensor 2 resistance 10 000 Ohms 77 F 25 C See Note 6 Check defrost termination temperature Sensor 2 wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins schematic Check remote sensor switch connector a Locate and inspect 10 way connector Connector must have cap on for optional sensor
137. HE 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 Refer to Section 3 19 3 for more detailed informa tion on two way communication 62 10683 7 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 will clear or inactivate the alarms This moves the alarm to the Inactive Alarm list ifthe 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 I 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 I
138. Hot Gas Check Valve Non Serviceable 8 16 1To Service Check Valve See Figure 8 22 Store the refrigerant in an evacuated container Refer to Section 8 9 a b Replace necessary parts C d a and dehydrate unit Refer to Section 8 11 Add refrigerant charge Refer to Section 8 12 8 16 2To Replace Check Valve See Figure 8 23 a b 8 27 and Figure 8 24 Store the refrigerant in an evacuated container Refer to Section 8 9 Using a pipe cutter cut the valve stub outs and unsweat the remaining stub out from 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 8 23 topull the plunger from the body seat Replace valve Evacuate and dehydrate unit Refer to Section 8 11 Add refrigerant charge Refer to Section 8 12 Check unit operation by running Pretrip Refer to Section 3 3 62 10683 8 17 CHECKING AND REPLACING FILTER DRIER 8 17 1 To Check Filter Drier Check for a restricted or plugged filter drier by feeling the liquid line inlet and outlet connections of the drier cartridge If the outlet side feels cooler than the inlet side then the filter drier should be changed 8 17 2 To Replace Filter Drier a Pump down the unit per section 8 9 1 Remove brack et then replace drier Tighten inlet side fitting
139. ION 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 3 29 62 10683 3 17 STOPPING UNIT 7 gt O O O O O O O HEAT COOL DEFROST ALARM START STOP CON TINUOU 200 3245 F SETPOIN BOX TEMPERATURE EH H START RUN O OFF 1 To stop the unit place the START RUN OFF switch in the OFF position The diesel engine will stop and the microprocessor NOTE controller will 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 30 3 18 DATA RECORDING The Advance microprocessor contains a built in DataRecorder with 512K of memory The recorded data can be downloaded from
140. IRCUIT AMP NOT USED QC2 MICRO GROUND QC1 SYSTEM POWER 12 VDC Figure 2 14 Control Module 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 controller 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 e Option PC card for installing optional software programs e Configuration PC card for microprocessor functions DataRecorder configurations setting the configurations and 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 Micro 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 it is loading software e 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 d
141. LED on the Keypad and the Fault light on the light bar will flash on and off once a second a 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 refrigeration system pressures This will occur only once during an Off Cycle but may be repeated during subsequent Off Cycles 4 2 5 Start Stop Parameters The selectable Start Stop parameters in the Functional Parameter list can be applied to Start Stop operation so that a The same settings apply to any setpoint or b The settings can be specified to be different depending on whether the setpoint is above 10 4 F 12 C in the per ishable range or 10 4 F 12 C or below in the frozen range The decision as to whether the same settings will be used together for all setpoints or if they will be separated between perishable and frozen is made in the Configuration list refer to Section 5 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 62 10683 4 4 If SEPARATE is selected in the Configuration list then the following Functional Parameter values will be available for use PERISHABLE MINIMUM RUN TIME e PERISHABLE MINIMUM OFF TIME PERISHABLE OV
142. 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 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 13 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 9 1 thru Figure 9 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 link
143. MPLETE TO EXIT The user has reached the end of the Configurations list Pressing the t or arrow keys will start list over Press to exit Configura tion list CONFIGURATION MODE Press to enter Configuration mode CONFIGURATION NOT CHANGED New configuration selection was not entered saved CONTINUOUS LOCKED The current setpoint is within a range that has been locked into the Continuous Run mode Start Stop can not be selected CONTINUOUS RUN MODE SELECTED The unit operating mode has been changed from Start Stop to Continuous Run COPY COMPLETE REMOVE CARD XX A DownLoad PC card has been inserted into the PC card slot and all data from the data recorder has been copied onto the PC card You may safely remove PC card from the slot XX number of empty download slots remaining on the card 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 XX num ber 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 controller has stopped recording unit data DEFROST CYCLE STARTED The unit has gone into defrost
144. N YES Allows operator to override remote switch 1 and or 2 and allow the unit to continue to run even with the remote switch in the ON position or the door is open LANGUAGE ENGLISH ENGLISH All information displayed in the MessageCenter will be IDIOMAS ESPANOL shown in English LANGUE FRANGAIS a FRAN AIS All information displayed in the MessageCenter will be LINGUAGEM PORTUGUES shown in French ESPANOL All information displayed in the MessageCenter will be shown in Spanish 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 Functional Parameter may not appear in the list for your unit depending on how the microprocessor has been configured 62 10683 3 28 3 16 LANGUAGE SELECTION e e e e e e HEAT COOL DEFROST ALARM START STOP CONTINUOUS 200 3345 F SETPOINT BOX TEMPERATURE ESPANOL MANUAL ALARM EN START STO Fel DEFROST cong 00 1 Press and hold the SELECT key for six seconds until MessageCenter displays current language ENGLISH ESPANOL FRANCAIS or 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 FUNCT
145. NG REFRIGERANT TO SYSTEM oocccccccccccc ene 8 21 8 12 1 Checking The Refrigerant Charge ssssssssssessse eee nn 8 21 8 12 2 Partial Charge u c RR a DA ae SR ele 8 21 8 12 3 Adding Full Charge 0 ccc Rm mh 8 22 8 18 REPLACING THE COMPRESSOR sssssesesse eese mn 8 22 8 14 CHECKING COMPRESSOR OIL LEVEL sessssesse e en 8 24 8 14 1 To Check The Oil Level In The Compressor sssssssssees ene 8 24 8 14 2 Adding Oil With Compressor In System 0 eese 8 25 8 14 3 Adding Oil To Service Replacement Compressor 00000 cece esee 8 25 8 14 4 To Remove Oil From The Compressor 000 cece nn 8 25 8 15 COMPRESSOR UNLOADER VALVE sssssssesess hm 8 26 8 15 1 Gheckout Procedure e sscercpie stepie cce fere iR dan DIR RP Ub4 DERRTG GDLDRET ba Pi 8 26 8 15 2 Unloader Coil Replacement oooooccccoccccccc hn 8 26 8 15 3 Replacing Valve Internal Parts seei reiro e o ene 8 26 8 16 REPLACING OR SERVICING CHECK VALVE ssssssssssess een 8 26 8 16 1 To Service Check Valve ssusssessesssesss ee hh 8 27 8 16 2 To Replace Check Valve ssssssesssesse eee hh 8 27 8 17 CHECKING AND REPLACING FILTER DRIER ssssssssee eee n 8 28 8 17 1 To Check Filter Drier iuteeoc certe eer rp E EE a A A dee Pg 8 28 8 18 THERMOSTATIC EXPANSION VALVE ssssssssesse eee mn 8 28 8 18 1 Replacing Expansion Valve amp Screen uuus
146. Nozzle Cover Assembly sssssssssee eee 8 16 Figure 8 16 Vacuum Pump Connection 0 nent eee nes 8 20 Figure 8 17 Pressure Switch and Sensor 0 0 0 cece enn 8 23 Figure 8 18 Compressor Drive Assembly sssssssssssssesess emn 8 24 Figure 8 19 Oil Level in Sight Glass oooooocccconocnn eese n 8 24 Figure 8 20 Compressor vico a eR ee ees Rer ae A Dr eae RE ee RS 8 25 Figure 8 21 Unloader Goll 69 mener tee ie E ee ee ew eer ie 8 27 Figure 8 22 Discharge Check Valve Serviceable Prior to S N JAW90756460 ssesee 8 27 62 10683 z FIGURE NUMBER Page Figure 8 23 Discharge Check Valve Non Serviceable Beginning With S N JAW90756460 8 27 Figure 8 24 Hot Gas Check Valve Non Serviceable ooocococcccccococcn sene 8 27 Figure 8 25 Thermostatic Expansion Valve Bulb and Thermocouple 00 cece eee eee eee 8 29 Figure 8 26 Typical Setup for Testing High Pressure Switch 0 0 00 cece eee eee 8 30 Figure 8 27 SV2 SV4 Solenoid Valves 0 0 eee n 8 34 Figure 8 28 SV 2 SV 4 MARKING 000 cece eee s 8 35 Figure 8 29 SV1 Solenoid Valve oooooccccocornr hh 8 36 Figure 8 30 Compressor Suction Modulation Valve CSMV 0 cect eee ere 8 37 Figure 8 31 CSMV Coil Bi Polar Design 00 cece eee eee 8 37 Figure 8 32 Defrost Air Switch Test Setup ooooocccococcccn teen eens 8 39 Figure 8 33 Unidrive T
147. O O O WJ al oo ENS Nm Dd RY N slalalalslalelalaleials w e m w o N or m zu m nm Z w w w co ooo 2 lD u aj TJT zo _ Co 2 a 4 4 15 33 17 6 8 7 0 9 1 10 16 n 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 A 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 10 3 62 10683 ADVANCE MICRO DISPLAY HARNESS CONNECTIONS TesPomt Pin Coo Beseipion TPis Pns Red GroundforBackighingandindicatorLEDs Ten Display groun TP10 TX the serial communications from the control to the display RX the serial communications from the display to the control VOLTAGE TESTS pe pets E EEES Lea qe EA eR 8 fo 62 10683 10 4 SPK3 111 NOTES OUTPUT 1 UNIT SHOWN IN OFF POSITION POWER EUEN FS 80A 2 WIRE IDENTIFICATION SYSTEM COLOR WHITE DC CONTROL CIRCUITS A A BLACK GROUNDS SATCOM G RX TX f CATES A WIRE BETWEEN PLU
148. ON 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 7 17 62 10683 NOT 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 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 of
149. Operation e 5 10096 Open c High Ambient Defrost Termination Once the Defrost Termination Temperature Sensor DTT2 and Supply Air Tem perature SAT reach 55 F 12 8 C the high ambient defrost cycle will terminate 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 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 4 14 High Ambient Defrost Termination Once the Defrost Termination Temperature Sensor DTT2 and Supply Air Temperature SAT reach 55 F 12 8 C the defrost cycle will terminate High Ambient Defrost Termination Sequence The following sequence will be used for High A
150. Pressure Line or Aspirator Bulb P N 07 00177 01 Magnehelic Gauge P N 07 00177 00 High Side Connection Figure 8 32 Defrost Air Switch Test Setup Make sure magnehelic gauge is in proper calibration NOTE The magnehelic gauge may be used in any position but must be re zeroed if position of gauge is changed from vertical to horizontal or vice versa USE ONLY IN POSITION FOR WHICH IT IS CALIBRATED The Defrost Air switch MUST be in the same orientation as it will be in when installed in the unit Bom oo With air switch in vertical position connect high pres sure side of magnehelic gauge to high side connec tion of air switch See Figure 8 32 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 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 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 O Any hesitation in the ohmmeter in dicates a possible problem with the switch and it should be replaced Referto Section 2 10 for switch settings If switch fails to actuate at correct gauge reading ad
151. RELAY OPTIONAL EATER TEMP SWITCH OPTIO LIGHT LIGHT BAR LEVEL SWITCH UMP OLENOID L GLOW CRANK SWITCH PLUG LUG RELAY URRENT PLUG n E a C AGI pa wo wo ea B x Zur w A Gr O ABRUOMNNN K16 a TE Grasas TI TIT TI TI 1 QBVow a 2 B3 L3 4 314 114 7 m H1 J 1 41 6 31 FE LIGHT LIGHT BAR dC f wo lt lt Ea uper d a mommKcoor Aw Y e op O ay e wo nrmrmmmocoocoooo ETRAS C e OOO C CET es r o TU TU wo mmmmn a EU 10 AMPERE 7 5 AMPERE RIAL PORT R 7 5 AMPERE ARTER MOTOR I FUSE 80 AMPERE A2 D2 B6 D9 D10 LICE POINT 8 UL 15 AMPERE 1 015 M14 J11 J16 S 5 AMPERE 0 M15 F17 20 AMPERE OPTIONAL B3 B6 D8 D10 3 AMPERE L11 L13 M14 M16 FAR 10 AMPERE DUAL ELEMENT SLOW BLOW COPTION ON XTC U ITUccCrIIn T gt 0T00O0OTO SPLICE PAC SPEED RELAY START RUN OFF SWITCH STARTER SOLENOID STARTER SOLENOID CONTACTOR STARTER SOLENOID RELAY SOLENOID VALVE UNLOADER Zt pv Uc A DO oO wn CC O02C0 00 0000 C0 CO C A B C D E F G H I J K L M N 0 P o 5 82 10499 ART9 S9 R M al SPK3LL11 NOTES OUTPUT UNIT SHOWN IN OFF POSITION POWER deis FS 804 WIRE IDENTIFICATION SYSTEM FB 15 COLOR WHITE DC CONTROL CIRCUITS A B BLACK GROUNDS o SSC y ADDRESS SYSTEM EXAMPLE HC9 2MP25 RX TX
152. RPM in Test 28 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 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 1 b Check engine speed arm amp linkage Must move freely 2 Force low speed operation See note 10 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 i D 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 micro a Check voltage at pin 16 with unit M
153. RPM MV B E W e m N C E o To UL2 Rear F Fr CO N Oo SATCOM A SLP B N OJN o MN a oO SV4 Al mAAA e op I lt r O O0O N 0 w S o a SR Se T S 6 3 7 wo eo 6 17 Plugs used with Schematic 62 04102 Rev ESC Engine 1 MP Natural 2 MP Black 24 x Uh E E Terminal Femina REMSN1 Soe Terminal SATCOM C i O gt n T A SLP C O D m vl zx 62 z N A 2 UO a NIO TIT 0 J O AI co N o UL1 Front SLP E PEERS e m Oja oo O O C SATCOM B N TO 0 h h A E Q m 4 SLP A FHR HC 17 N 00 CSMV B 32 8 19 00 62 10683 10 2 S E U ep l T EL REMS1 CSMV D REMS2 ENCLS DS ENOPS ENSCU CSMV C CSMV A ENOLS CSMV B C2 N iini UL2 Rear 3 SATCOM A SLP B N e o o r lt lt T z R DTT2 SP11 AAT SAT SP12 V AT 35 23 N e Kes wj j C2 NI N 9izci i oa o aj A O l
154. 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 erroneous 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 micro will shut the unit down by de energizing the fuel solenoid non ESC engines or the fuel and speed actuator ESC If the unit is not running and the suction modulation valve CSMV has reached its fully closed position Pretrip will begin TIP It is always a good idea to clear all alarms from both Alarm Lists before starting Pretrip This practice allows the technician to know that any alarms present following Pretrip had to occur during Pretrip and are not old alarms that had simply never been cleared out before NOTE The operator MUST be present and validate this test by watching the micro display during Test 1 Display Test The micro will turn on all segments of the LCD and LED display Test 1 Display And Sound Test The microprocessor activates the LCD LED display and all lights on th
155. Recorder Setup NOTE Specific configurations or IntelliSet settings may be found on the TransCentral Website Authorized Carrier Transicold Dealers only 7 45 62 10683 NOT 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 configuration is set for Rail and the unit is operating in Sleep Mode Shut 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 trailer or rail compartment side or rear door is open a Inspect trailer or rail car compartment Trailer or rail car compartment door s must be closed doors 2 Check wiring El a Visually inspect wiring to door switch Wiring must be connected b Visually inspect condition of switch Must not be damaged
156. SAT 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 10 000 Ohms 77 F 25 C See section 2 12 for See Note 4 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 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 others terminated and insulated with heat shrink T 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 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 7 75 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION P155 CHECK COOLANT TEMP
157. 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 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 e zoe below as necessary 1 Check Engine Coolant Temperature sensor ENCT 8 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 NN Check Engine Coolant Sensor 10 000 Ohms 77 F 25 C See section 2 12 for resistance See Note 4 complete table of temperatures and resistance values Ms engine coolant sensor wiring B Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic be removed and each individual wire separated from the mE remote sensor switch connector Em Locate and inspect 10 way connector Connector must have cap on for optional sensors and switches No corrosion or moisture inside connec
158. STO DEFROST tonnou il OM 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 TO SCROLL THEN TO SAVE will show in the MessageCenter Pressing either 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 UP or DOWN ARROW key until the desired value is showing 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 shown If no further keys are pressed the default message will be displayed after10 seconds NOTE Any function that is shown with a padlock symbol cannot be changed from the keypad 62 10683 3 24 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 de
159. T Steps ALARM CAUSE CORRECTIVE ACTION 38 CHECK HIGH SPEED RPM Continued Force High Speed operation See note 10 a Place unit in continuous run and adjust Controller will call for High Speed operation setpoint 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 microprocessor is not calling for High Speed operation Check Speed Overrides in section 4 6 1 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 Check engine RPM a Check actual engine RPM using hand Refer to Section 2 6 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 aM 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 Must be clear and unobstructed 62 10683 7 30 NO 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
160. T 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 Check 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 10 See Section 8 15 Checking Unloaders a Energize UL2 coil Pressures must change within 3 4 seconds of coil being energized or de energized Suction pressure must raise slight
161. TINGS appears in the MessageCenter 2 Press the UP ARROW key or the DOWN ARROW key until RESET PM HOURMETERS is displayed Press key ft TO SCROLL THEN TO SELECT will show in the MessageCenter If NO HOURMETERS TO RESET appears there are none to reset Press UP or DOWN ARROW key until the PM hourmeter you wish to reset is shown The MessageCenter will show the hourmeter name with the instructions TO RESET followed by the number of hours or cycles that will be used for the next service interval Press 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 NOTE PM Preventative Maintenance hourmeters are First the hourmeters must be configured ON Refer to Section 5 2 1 hourmeters available for use Engine e Switch On Five programmable hourmeters 62 10683 5 18 provided to track unit operation and to notify the user when periodic preventative maintenance is due Within the Advance Microprocessor there are seven PM SETTING PM PREVENTATIVE MAINTENANCE HOURMETERS Continued The programmable PM hourmeters PM1 PM5 that 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 fr
162. TROL 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 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 SV4 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 12 c Check amp draw of coil Refer to Section 2 12 Use ammeter 2 Check SV4 wiring a Inspect harness amp control box See Notes 3 4 amp 9 connector pins amp terminals See wiring No physical damage to harness schematic No damaged or corroded pins 3 Check SV4 current draw a Use Component Test mode Refer to Refer to Section 2 12 for normal current values Section 5 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 13 current draw of the circuit 62 10683 7 48 ANO 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 gr
163. Temp setting with no upper limit When ProductShield Econo Max Temp is set for a temperature and ProductShield Econo Min Temp 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 Max Temp is set for OFF and ProductShield Econo Min Temp is set for OFF the ambient air temperature will be considered to be inside the range at any ambient air temperature When the unit is set for Start Stop ProductShield Econo allows the unit to run in Continuous Run when e ProductShield Econo configuration is set to GO TO CONTINUOUS See Section 5 2 1 AND e Theunithas run in Start Stop for a minimum of 15 minutes OR the Minimum Run Time whichever is longer as set in the Functional Parameter list See Section Table 3 3 AND e The ambient temperature falls outside a pre programmed temperature range and the ProductShield Winter ambient condition is not met See Section c below NOTE If unit is set for Start Stop and ProductShield Econo is configured for GO TO START STOP the unit will re main in Start Stop 62 10683 4 18 Once the micro 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 30 minutes the unit will return to Start Stop after the ambient temperature has fallen within the pre programmed temperature range by 3 6 F
164. UNIT SHUTDOWN SEE ALARM LIST An active shutdown alarm has shut the unit down UNIT SHUTDOWN RMS1 2 The unit has shut down because switch is open May be connected to a door or a remote control switch 2 UNKNOWN CARD REMOVE CARD A defective or different type of PC Card has been inserted into the PC Card slot The Micro can not recognize any data on the card The card may be safely removed from the Micro 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 Micro 6 5 62 10683 SECTION 7 ALARM TROUBLESHOOTING 7 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 inthe Troubleshooting Guide by alarm number When an alarm occurs look through both Active and Inactive Alarm lists in the microprocessor see Note 1 Section 7 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 obvio
165. 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 eren centem oe ANY ELECTRICAL WEL UNIT OR CHAS FORE DOING DING ON SIS TO WHICH UNIT ER CONTAINER VILDING 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 IS ATTACHED TRAIL RAIL CAR METAL A CAUTION 62 10683 Z Ay WARNING T F FAN BLADES WARNING ay START AUTOMATICALLY 62 02509 00 REV A J xe Ay 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 instructions TOP COOLANT INTO REMOVE RECOVERY BOTTLE FILLER CAP FILL EMPTY RADIATOR THROUGH FILLER NECK SLOWLY SLOWLY TO AVOID 62 02142 01 REV B AIR ENTRAPMENT 1 7 62 10683 SECTION 2 UNIT DESCRIPTION 2 1 INTRODUCTION This manual contains Operating Data Electrical Data and Service Instructions for the refrigeration units listed in Table 2 1 4 amp WARNING Additional support manuals are listed
166. URE SWITCH N 0 SWITCH SPEED CONTROL UNIT SENSOR E SPEED SENSOR AY RATOR PLUG AIR TEMPERATURE P 7 5 AMPERE ITE COMMUNICATION SR 10 AMPERE PORT RR 7 5 AMPERE MOTOR CLHR 7 5 AMPERE POINT AXI FUSE 80 AMPERE SV amp UL 15 AMPERE SROS 5 AMPERE FHR 20 AMPERE OPTIONAL LB 3 AMPERE AFAR 10 AMPERE DUAL ELEMENT SLOW BLOW COPTION ON XTC VVOO Damm anm nomma rnn mmrmmmrnrnrmrmadgtsgo dododoocoooouJU0z7 Q 0 X0 Ul I CUN lt OO CO CO COL Z0 220220 O gt VNNNNNVIIIVO OF N los W NWO ep AS O U 7N SPLICE PACK SPEED RELAY START RUN OFF SWITCH STARTER SOLENOID STARTER SOLENOID CONTACTOR STARTER SOLENOID RELAY SOLENOID VALVE UNLOADER a OO IT Ww D D w N lt 0 poj aud ow O A B C D E F G H I J K L M N 0 P 9 62 04102 ART1 51 R Index A Advance Microprocessor Troubleshooting Guide 9 11 Air Switch 2 23 8 39 Alternator Operation 2 10 Ambient Air Temperature Sensor 2 13 Auto Fresh Air Exchange AFAX 3 36 Auto Start Sequence 4 1 Automatic Defrost 3 14 B Belt Tension Gauge 8 10 C Cargo Protect Mode 4 11 Changing IntelliSets 3 34 Changing Setpoint 3 7 Charging Amps 4 5 Checking For Noncondensibles 8 33 Component Test Mode 5 11 Compressor Data 2 23 Compressor Discharge Pressure Transducer 2 13 8 3
167. V 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 mi cro with ambient air temperature information to be dis played recorded in the DataRecorder and used to con trol 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 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 evaporator fan expansion valve a defrost thermostat termination switch The location of the thermostat is shown in Figure 2 7 The return air sensor is also shown in 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 dual function automatic expan sion control and prevention of liquid return to the com pressor 2 4 2 Heat Exchanger The heat exchanger
168. VE 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 Once the battery voltage goes below 7 0 Volts for 10 seconds all KEYPAD LOCKED BATTERY TOO LOW of the keys on the keypad will be locked LIST END TO CLEAR ALARMS You have reached the end of the Alarm list 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 Micro 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 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 setpoint allowed by configuration settings has been reached MIN SETPOINT HAS BEEN REACHED Minimum setpoint allowed by configuration settings has been reached MODIFIED This message will appear in the MessageCenter along with the current IntelliSet indicating that the IntelliSet is active and one or more of its settings have been modif
169. WER C1 Y gt a E OO o SE EncT 4 Cepr B NOT ON 3MP11 DTT1 XTC UNITS orm 3MP22 3MP34 DTT2 F4 7 5A 3MP18 CLHR ero AFAR DE z E TD qe ENG BLOCK GRD Sp lt w SEE NOTE 4 2 ER 8 TO SP1 F17 HC1 SAT A B F3C 5A MPQCS m QD m D RAT CAAT REMBNI TO 2MP15 E6 REMSNI 3 C A B lt REMSN2 RELAY POWER TO SPK5 B4 UTOFRESH AIR RELAY RESTART LIGHT LIGHT ONTROL ONTROL HEATER RELAY LIGHT F RANGE LIGHT ST LIGHT LIGHT ZZER V3 CONTROL T V2 CONTROL G LOADER 2 CONTROL gt LOADER 1 CONTROL A B F2C10A Ci c m Ty 30 Oo m n a o omc om e NNWODO MmMMNMUUTI gt gt REMSN2 H MPOCB z ai REMSN3 lt J 30 REMSN3 lt F8 FHR W AUTOFRESH ONLY e HCI6 gt A B 301187 ENG BLOCK GRD TO F10 N13 204
170. a a a 7 9 13 HIGH DISCHARGE PRESSURE 000 cece eet eee eens 7 10 15 BATTERY VOLTAGE TOO HIGH sssssssssssssss eee hn 7 12 16 BATTERY VOLTAGE TOO LOW sssssssssssss teen rh 7 12 17 HIGH COMP DISCHARGE TEMP 0000 nananana 7 13 18 LOW REFRIGERANT PRESSURE 0000 cece eee hn 7 15 LOW FUEL SHUTDOWN for units with Low Fuel Level 0 to 100 Sensor fuel level is displayin pod ist 19 LOW FUEL SHUTDOWN for units with Low Fuel Level Switch no fuel level display in Data list 7 16 20 MAXIMUM COMPRESSOR ALARMS sssssssssss sse eeee eee 7 17 27 HIGH SUCTION PRESSURE oa ea a erai a dea a aa aaa sse ee enna 7 18 28 CHECK REFRIGERATION SYSTEM 0ooccccccccccccccc eee eee eens 7 19 297 gt CHECK HEAT CYGLE x certe iix tie er nets teed a dat ca ra dined a 7 19 7 5 START UP ENGINE ALARMS 00 ccc eee cece eee n n nh hh nn nnn 7 20 30 FAILED TO RUN MINIMUM TIME sssss RR II III teen eens 7 20 31 FAILED TO START AUTO MODE 0ccccccocc hn 7 21 32 FAILED TO START MANUAL ssssssssssss sss a N a 7 23 34 ENGINE FAILED TO STOP rata boh Rao ERRARE RT HEC hen Deae diuum 7 25 35 CHECK STARTER CIRCUIT et a 7 26 36 CHECK COOLANT TEMPERATURE 0oooccccccccccccccc eee eee eee eens 7 27 37 CHECK LOW SPEED RPM i p xurcu e RR oda GR T EY 7 28 38 CHECK HIGH SPEED RPM 0 00 esse 7 29 39 CHECK ENGINE RPM kou abra ba dad Pase sedem bg
171. a decimal All other temperatures will still be dis played with a decimal 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 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 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 3 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 Press to return to the Configuration Main Menu 5 2 2 Component Test Mode NOTE To enter Component Test mode refer to Section 5 2 Component Test mode allows the Technician to energize individual circuits for five minutes at a time while the
172. a 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 air a Inspect switch amp connector pins amp No damaged or corroded pins terminals b Check defrost air switch setting with Refer to Section 2 10 Magnehelic Gauge and check the Contacts closed with pressure applied to high side resistance of switch contacts Contacts open with no pressure applied Check switch wiring a Inspect harness amp control box See Note 7 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 No kinks or other obstructions No holes Connected to correct nipple Check evaporator pressure drop a Check pressure reading with Refer to Section 2 10 Magnehelic Gauge Check evaporator fan clutch a Check Evap Fan Clutch operation in Must disengage fan defrost Check condition of trailer and rail compartment amp load a Check condition of trailer and rail Doors must be closed and door seals must seal and compartment doors amp seals prevent outside air from leaking in b Check condition of product If it is warm and moist
173. 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 MN Check for low fuel level warning a EO Ja Check for alarm 1 Must be cleared be cleared 62 10683 7 16 Al 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 Evaporator 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 13 for information on Unit Data list UNIT CONTROL Unit shutdown and Alarm RESET CONDITI
174. 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 F10 fuse a Check circuit current All conditions must be corrected in circuit Check Auto Fresh Air Exchange Solenoid AFAS a Check amp draw of AFAS Use Component Test Mode Section 5 2 2 to test Refer to Section 2 12 for amp values View current draw in the Unit Data List Check AFAS and circuit a Inspect AFAS and wiring No physical damage to harness No damaged or corroded pins No damage to solenoid b Check operation of AutoFresh Air AFAS turned on and LED12 on Exchange Relay AFAR AFAR energized c Check voltage to AFAS 12VDC between AFAS B ground and AFAS A 12VDC when AFAR is energized 62 10683 7 78 ANO 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 Follo
175. age Must move freely Check fuel system a Check for Alarm 1 Fill tank as needed b Check fuel flow Unrestricted fuel flow through system 3 4 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 10 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 the 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 5 7 81 62 10683 NOT 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 6 held tachometer Adjust engine linkage setting as needed b Compare actual RPM with those Both readings within 50 RPM shown on display Force high speed operation See note 10 a Place unit in continuous run and adjust Controller will call for High Speed operation set point to
176. ally seized P E the condition 2 y Load current version of software from http www transcentral carrier com Did the software load correctly YES No 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 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 Figure 9 7 Micro Diagnostic Tree Cond 3 Start Run Off Switch Off Unit Fails To Stop 62 10683 9 14 Unit may be running old soft START HERE Check the Speed Solenoid NP Ms ani iic from YES or FSA and linkage for correct operation Da WN TANS CENTA carrier cor i eN Did you find and correct 2 Did you find and correct the condition the condition NO
177. am ICE CREAM is selected With each selection the microprocessor automatically reprograms the settings to provide 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 7 to be entered by simply changing to that IntelliSet NOTE The above settings are examples of possible settings Except for IntelliSleep IntelliSets are not factory set They are developed by individu al customers 62 10683 a Changing IntelliSets Ld HEAT COOL DEFROST SETPOINT BOX TEMPERATURE PRESS 1 TO VIEW INTELLISETS MANUAL ALARM LIST TART STOP SELECT DEFROST diede OM 1 PRESS Key to display current IntelliSet Enable IntelliSet at Key must configured ON See Section 5 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 34 3 19 2 DataTrak for Advance Microprocessors DataTrak allows remote communication providers cellular satellite etc to request data from the Advan
178. an be charged with refrigerant through the king valve Press the key to manually exit or wait until the charging is complete CHECK AT NEXT SERVICE INTERVAL 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 The engine coolant level is not full CHECK DOOR Door switch indicates that trailer or rail car compartment door is not closed CHECK ENGINE OIL LEVEL The oil level in the diesel engine is low CHECK FUEL LEVEL The level in the fuel tank is very close to empty CHECK MICROPROCESSOR There is a communication signal lost between the keypad display and the micro Check and test the wiring to the keypad display CHK WIRES FROM MICRO TO KEYPAD There is a communication signal lost between the keypad display and the micro Check and test the wiring to the keypad display CLHR OFF IN X MINS 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 while this message is being displayed will allow user access to Component Test mode COMPONENT TEST MODE MENU The selections following this message will be the components avail SELECTIONS able for energizing during Component Test mode CONFIG ERROR REMOVE CARD There was an error configuring the Micro with the Configuration PC card Remove the PC card from the slot CONFIGS CO
179. 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 5 Check DTT2 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 13 Perform Pretrip Check a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding 7 Check compressor 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 7 13 62 10683 NOT 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 10 c Check superheat of valve Refer to Section 2 10 9 Check system for non condensables a Check refrigeration system for No non condensable gas e
180. arness connector pins amp tonis See wiring No damaged or corroded pins schematic 9 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 engine exhaust system i 22 11 Check engine m a Tp check engine vale adustment Rocker arm dearance must be coves e Gheck engine compression Compression must be above 272 Bars 00 PSIG EE cr a Check discharge amp suction pressures 7 35 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 7 6 WARNING STATUS ALARMS 51 ALTERNATOR NOT CHARGING TRIGGER ON Unit is running either engine or standby 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 steps below as necessary Check Microprocessor Current Sensor a Check micro Current Value START RUN OFF switch in START RUN
181. arts List 62 11053 Compressor 05G TWINPORT Parts List 62 0276 Service 82 1052 Compressor 05G TWINPORT 2 1 62 10683 h King 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 CSP Suction Service Valve TOCONDOROM 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 1 Condenser Pressure Control Solenoid Valve SV1 Defrost Air Switch Filter Drier Receiver Receiver Sight Glass Liquid Line Solenoid Valve SV2 Battery Location Figure 2 2 Curbside Non ESC Engine NOOR WP 2 3 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 Nou Rwy gt Figure 2 3 Roadside Non ESC Engine 62 10683 PONS To ogouoo King Valve Hot Gas Solenoid Valve SV4 Suction Modulation Valve CSMV High Pressure Cutout Switch HPS Compres sor Discharge Transducer CDT and Unloader Solenoid Valve D
182. as necessary 1 Check for low engine oil level alarm a Check for alarm 2 Alarm conditions must be corrected and the alarm cleared to continue b Check engine oil level Oil must be in safe range on dipstick Check engine oil pressure switch 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 3 Check engine oil switch harness a Inspect switch amp connector pins amp No physical damage to switch terminals No damaged or corroded pins in plug a Inspect harness amp control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins schematic A 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 4 or PC mode Battery voltage reading 12 13 VDC between wires in plug 4 Ta 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 62 10683 7 8 ANO 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
183. asses tank Check HPS switch a Inspect switch 8 connector pins amp No 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 10 for pressure above cut out point 10 PSIG 0 68 Bar settings Contacts closed when compressor discharge pressure is below cut in point x 10 PSIG x0 68 Bar Additional steps on the next page 62 10683 7 10 NO Steps ALARM CAUSE CORRECTIVE ACTION 13 HIGH DISCHARGE PRESSURE Continued 8 Check HPS switch harness B Inspect harness amp control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins schematic Ms Check for shorted circuit in harness START RUN OFF switch in START RUN position Manual and continuity through the harness Start mode See Note 4 Battery voltage reading 12 13 VDC between wires in plug 9 Perform Pretrip Check BE Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding EE Refrigeration Trouble Shooting Discharge Pressure must be in normal range for the Section 9 3 current ambient and box temperature conditions 7 11 62 10683 NOT 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
184. at Cycle 5 5 C above box temperature and set above 11 F 11 6 C See note 10 c Check operation of SV 4 FET 9 LED must be ON d Check voltage to SV 4 Must be 11 VDC or higher across the 2 wires 4 Check SV4 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 7 71 62 10683 NOT 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 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 Manual Start Operation See 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 5 2 2
185. 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 8 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 Check Speed Overrides in section 4 6 1 for more information 9 c Check voltage to speed solenoid on Must be 12 14 VDC standard engines FSA voltage cannot be checked on ESC engines Check high speed engine RPM a Check actual engine RPM using hand Refer to Section 2 6 held tachometer Adjust engine linkage setting as needed b Compare actual RPM with those Both readings within 50 RPM shown on display 62 10683 7 32 40 Steps ALARM CAUSE CORRECTIVE ACTION 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 clea
186. ater Relay coil circuit b Verify fuse size Refer to Section 2 11 Must be correct rating for circuit see wiring diagram c Inspect fuse amp fuse holder Terminals tight No signs of overheating melting or discoloration 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 11 Must be correct rating for circuit see wiring diagram i 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 12 b Check amperage draw on F6 circuit Refer to Section 2 12 See wiring schematic 7 47 62 10683 NOT 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
187. ation system Defrost cycle did not terminate Abnormal pressure Solenoid valve malfunction Clutch Failure 9 3 2 Unit Runs But Has Insufficient Cooling Compressor Compressor valves defective 13 Unloader malfunction 15 7 5 8 1 8 1 Refrigeration system Abnormal pressure 9 3 Unloader malfunction 8 1 Expansion valve malfunction 3 1 No or restricted evaporator airflow 3 1 Clutch Failure 8 6 Engine does not Speed control linkage 8 6 develop full rpm Engine malfunction 9 1 9 3 3 System Will Not Pump Down IO LEC 5257 Fy ass check vale 9 3 4 Unit Operates Long Or Continuously In Cooling Trailer or Rail Car Hot Load product Defective box insulation or air leak Correct Refrigeration system Abnormal pressure 9 Temperature controller malfunction 9 9 3 5 Unit Will Not Heat Or Has Insufficient Heating Refrigeration Abnormal pressure Temperature controller malfunction Solenoid valve malfunction 1 4 check valve bypass defective Clutch Failure Compressor Compressor drive defective Compressor defective 3 3 7 9 Engine does not develop Engine malfunction full rom FSA malfunction Diagnostic code on ENSCU 9 3 62 10683 INDICATION ACTION TROUBLE POSSIBLE CAUSES REFERENCE SECTION 9 3 6 Defrost Cycle Malfunction Will not initiate defrost automatically Will not initiate defrost manually Initiates but does not defrost Frequent defrost Does not terminate or cycles on defrost Defrost
188. attempt to service the Advance Microprocessor See Sec tion 9 4 1 for microprocessor troubleshooting Should a problem develop with the Advance Micro processor contact your nearest Carrier Transicold dealer for replacement INDICATION ACTION TROUBLE POSSIBLE CAUSES REFERENCE SECTION 9 1 DIESEL ENGINE See Table 9 1 and Figure 8 33 thru Figure 9 4 for ESC troubleshooting 9 1 1 Engine Will Not Start Starter motor will not Battery insufficiently charged Check crank or low cranking speed Battery terminal post dirty or defective Check Bad electrical connections at starter Check Starter motor malfunctions 9 1 3 Starter motor solenoid defective Engine Manual Open starting circuit 9 1 4 Incorrect grade of lubricating oil Unloaders not unloaded High refrigeration suction pressure Starter motor cranks No fuel in tank but engine fails to start Air in fuel system Water in fuel system Drain Sump Plugged fuel filter s Replace Plugged fuel lines to injector s Check Fuel control operation erratic Engine Manual Glow plug s defective 8 6 8 Fuel solenoid defective eens aie Fuel pump FP malfunction Starter cranks engages Engine lube oil too heavy 2 6 but dies after a few seconds Voltage drop in battery cable s Check 9 1 2 Engine Starts Then Stops Engine stops after Fuel supply restricted Check several rotations No fuel in tank Check Leak in fuel system Check Faulty fuel control operation Engine Fuel filter restricted Replace Injector
189. auge 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 Check 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 4 Voltmeter lead on switch terminals With wires connected to switch Position Terminals VDC Off 1 11 V min 283 0 V min Glow 183 10 1 2 V min 2 0 V min Disconnect wire to Starter Solenoid before checking Crank 1 amp 2 11 1 2V min 3 O V 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 sak tena Sco wina harness amp control box No physical damage to harness connector sak tena Sco itn amp terminals See wiring No damaged or corroded pins schematic Additional steps on the next page 1111 111 11 11 111111 7 23 62 10683 Lu ALARM CAUSE CORRECTIVE ACTION FAILED TO START MANUAL Continued 8 Check Fuel Solenoid Applies to non ESC engines only a a Check Run Relay LED LED 28 must be ON b Check voltage to fuel solenoid START RUN OFF switch in START RUN po
190. b Visually inspect condition of switch Must not be damaged 4 Check Remote Switch 2 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 7 43 62 10683 PRG suo ALARM CAUSE CORRECTIVE 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 the steps below as necessary HS a Clear Active Alarm s Alarms Clear b Check for Active Alarm reoccurrence If 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 Author
191. 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 Check battery voltage a 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 Test specific gravity of battery Check for battery specifications e Perform load test on battery Follow Check for battery specifications battery manufacturer s procedure 3 Check voltage at microprocessor a Check voltage reading at START RUN OFF switch in START RUN position Manual microprocessor input MPQC1 to Start mode See Note 4 MPQC2 Must be above 11 VDC b Check voltage reading on Must be within 5 VDC of reading obtained in 3a above microprocessor display ERA E a Ba 62 10683 7 12 NO 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
192. bolts to 20 in Ibs 0 23 Mko f Rotate blower wheel and check that clearance is approximately 1 4 Adjust nozzle cover and or blow er wheel if necessary g Reinstall evaporator panel reattach air chute and bulkhead if so equipped Fanshaft Seal Fanshaft Spring Clip Figure 8 15 Blower Wheel And Nozzle Cover Assembly 62 10683 8 8 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 clutch 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 b Install rotor spacer and rotor onto the fan shaft c 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 a LEFT HAND NYLOCK THREAD NUT d 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 t
193. cccccccccoccccnc eee 2 2 Figure 2 2 Curbside Non ESC Engine ssssssssssssssesess ee nnn 2 3 Figure 2 3 Roadside Non ESC Engine 0 cece eee n 2 3 Figure 2 4 Front View Of Unit With Electronic Speed Control Electronic Speed Control 2 4 Figure 2 5 Curbside Electronic Speed Control o ooocoocccccccnccnc ee 2 5 Figure 2 6 Roadside Electronic Speed Control 0 0 0 cece 2 5 Figure 2 7 Evaporator Section Panels and Grille Removed 0 00 cece eee 2 6 Figure 2 8 Control Box Short Box 0 ccc tne 2 7 Figure 2 9 Control Box Redesigned Tall Box ssssssssssesesss eI nn 2 8 Figure 2 10 Frame Mounted Engine Speed Control Unit ENSCU 0 eee 2 9 Figure 2 11 Alternator and Regulator 0 cece nee nen m 2 10 Figure 2 12 Compressor Cylinder Head Unloaded 0 0 cece cece eee eh 2 11 Figure 2 13 Compressor Cylinder Head Loaded 0 c cece es 2 12 Figure 2 14 Control Module 0 een n ene 2 15 Figure 2 15 Refrigerant Circuit During Cooling o ococococcccccncnnc III 2 26 Figure 2 16 Refrigerant Circuit During Heating And Defrost 0 00 cece eee eee 2 27 Figure 3 1 AutoFresh Air Exchange 00 cee eect ent ms 3 36 Figure 3 2 AutoFresh in Closed Position oooccccoccccccccncr eee eens 3 37 Figure 3 3 AutoFresh in Open Position 0 00 ccc eet eee teens 3 37 Figure 4
194. ccur 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 lower 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 62 10683 5 14 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 5 4 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 Oncethe unit shuts down to begin the software install process the Suction Modulation Valve closing process begins The software ins
195. ce microprocessor and have it transmitted via their equipment to another location This is typically done via the internet to any destination in the world 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 13 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 5 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 each individual provider and not by Carrier Transicold Communications electrical harnesses and serial port splitters are available from Carrier Transicold Re
196. ce rotates the rotor and causes the valve to open one step The windings are energized and polarized in the reverse sequence to close the valve one step RED 2B Figure 8 31 CSMV Coil Bi Polar Design 8 24 1 CSMV Diagnostics If the CSMV is suspected to be faulty the first thing the operator should do is perform a unit Pretrip Refer to Section 3 3 Some symptoms that could indicate a faulty CSMV are e Unusually high suction pressure in COOL mode e A27 High Suction Pressure alarm may be generated e Unusually low suction pressure e A18 Low Refrigerant alarm may be generated e Poor temperature control e Refrigerated compartment temperature devi ates from setpoint 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 receivingthe proper signalfromthemicro Thereare severalsteps the operator should makeinadditionto the unit Pretrip to further diagnose the valve a The CSMV may be stuck in some position other thancompletelyclosedandthestepper motorcan not move the piston To check if the valve is stuck firststartthe unitandrunincoolmodewithmanifold gauges attached to the compressor b Unplug SV2 coil and allow the suction pressure to pull down to 0 Bar PSIG 44 WARNING Carrier Transicold does not recommend al lowing the compressor
197. ce is still bad one or both ofthe coils could be faulty Replace the CSMV power head as sembly Refer to Section 8 24 2 Locate the wires on the engine 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 Table 8 5 Place the START RUN OFF switch in the START RUN position DO NOT ALLOW THE UNIT TO START When the MessageCenter displays SMV CLOSING measure the AC voltage between pins A and B and then between C and D A reading of 10 to 62 10683 8 38 x 8 24 2 Replacing The CSMV Power a b O o a Q 2 16 VAC should be read by the digital voltmeter for each pair of wires If this test passes there is a good signal coming from the microprocessor Ifthe reading of 10to 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 Head 14 00263 20 Pump the unit down at the king valve Refer to Sec tion 8 9 1 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 Figure 8 30 Install the new CSMV power head The p
198. ch current a Check amperage of added on All add on components amp accessories must draw less components amp accessories than 20 Amps 6 Perform Pretrip Check a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding 62 10683 7 36 NO 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 for 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
199. cle 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 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 Place into Pretrip mode Unit running in Pretrip mode 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 a
200. 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 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 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 12 c Check amp draw of coil Refer to Section 2 12 Use ammeter Check SV1 wiring a Inspect harness amp control box See Notes 3 4 amp 9 connector pins amp terminals See wiring No physical damage to harness schematic No damaged or corroded pins Check SV1 current draw a Use Component Test mode Refer to Refer to Section 2 12 for normal current values View Section 5 2 2 to test actual current current draw in Data list draw of the circuit 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 CON
201. conds 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 atthe next Trip Start Trip Start tells the data recorder that the present date and time is the beginning of a new trip 3 15 62 10683 3 11 VIEW ACTIVE ALARMS ALARM LIGHT e e e e e HEAT COOL DEFROST SETPOINT BOX TEMPERATURE NO ACTIVE ALARMS MANUAL ALARM LIST START STO SELECT DEFROST CONTINUOUS AN 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 first 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 being displayed ACTIVE ALARMS LIST CLEAR is displayed This will move all Alarms to the Inactive Alarm list Alarms that occur are stored in the Alarm list in the TIP c
202. 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 2 5 SYSTEM OPERATING CONTROLS AND COMPONENTS The temperature controler is a Carrier Transicold Advance Microprocessor controller Refer to Section 2 5 3 and 3 Once the controller is set at the desired temperature the unit will operate automatically to maintain the desired temperature within very close limits The control box includes manual switches microprocessor fuses and associated wiring Also the unit can be equipped with an optional remote light bar which mounts separately and can be seen in the mirror from the cab of a truck or on the front of a rail car Standard equipment includes an Auto Start Stop feature This feature provides automatic cycling of the
203. cro memory The new setpoint will be used SETPOINT NOT CHANGED The new setpoint has NOT been entered NOT saved into Micro memory The old setpoint will be used SETTING SMV XXX The START RUN OFF position has been placed in the START RUN position and the power is up and CSMV is opening SLEEP MODE OFF ON TO WAKE The unit is cycled off in Sleep mode Turn the START RUN OFF Switch OFF then back ON to wake the Micro 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 Power Up and CSMV is closing XX is number of seconds remain ing until valve is fully closed START MODE AUTO or MANUAL This Data Message tells the user if the unit is in Auto Start or Manual Start mode START STOP LOCKED The setpoint has been locked into the Start Stop mode Continuous Run can not be selected START STOP MODE SELECTED Us O mode has been changed from Continuous Run to Start Stop STATUS OK TEST 1 to 16 TIME SELECTION NOT CHANGED TRIP START ENTERED UNIT SHUTDOWN DOOR OPEN The unit has shut down because the trailer or rail compartment door is open
204. ctive alarms 7 101 62 10683 NOT 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 Perform maintenance a Perform appropriate engine amp unit Follow instructions on proper maintenance form maintenance Reset maintenance hour meter 3 3 a 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 8 1 pa See Note 1 pa a 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 NE Perform appropriate engine amp unit Follow instructions on proper maintenance form maintenance 3 Reset maintenance hour meter 4 8 Check that Mainte
205. d m Fuel Bleed Valve Manual Fuel Pump Plunger NON ESC ENGINE Figure 8 1 Priming Fuel Pump 62 10683 8 4 SERVICING FUEL PUMP 8 4 1 Mechanical Pump See Figure 8 2 Due to foreign particles in the fuel and wax as a result of using the wrong grade of fuel or untreated fuel in cold weather the fuel filter may become plugged or restricted and the engine will lose capacity The filter must be cleaned on a regular schedule such as when the oil filter is changed Refer to Section 8 1 1 Nut 2 Banjo 3 Filter 4 Copper Rings Figure 8 2 Mechanical Fuel Pump a Turn nut counter clockwise to loosen and remove nut item 1 Figure 8 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 steps 1 through 3 62 10683 8 5 FUEL LEVEL SENSOR An optional fuel level sensor p n 12 00548 07 or new sensor 12 00548 06 supplies an 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
206. d 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 Power up the transducer circuit Place unit into PC mode Refer to Section 5 1 or place unit in Manual Start mode Press the Select key until Press 1 to View Data ap pears in the MessageCenter Press the Up Arrow until Discharge Pressure is showing in the MessageCenter Press and hold the Equal key for six seconds The MessageCenter will blink five times When it stops blinking the display will either show Discharge Pressure 0 0 Bar PSIG or the message Calibration Unsuccessful When Discharge Pressure 0 0 Bar PSIG appears the offset has been saved into the microprocessor memory and the calibration is complete If the calibration was unsuccessful either there is more than 0 Bar PSIG on the transducer or the trans ducer is further away from O than an offset will allow The transducer must be replaced 8 20 2 Testing Compressor Discharge Pressure Transducer oO a Verify that the wiring to the transducer is correct See wiring diagram Section 10 Power u
207. d or Range 2 Select the lowest temperature that will ever be used as setpoint Setpoint can not be set lower than this value Select the highest temperature that will ever be used as setpoint Setpoint 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 SETPOINT Once the compartment temperature has reached setpoint 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 0 to 48 Hours After this length of time AutoFresh Air Exchange will begin if the unit is no longer run ning in pull down mode See Section 4 4 2 even though the compartment temperature has never reached setpoint 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 and Perishable setpoints 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 setpoints ON A remote sensor has been added to the unit and connected into the wire harness at Remote Temp Sensor 1 3 plug This enables Remote Temp Sensor 1 3 to be read t
208. d to the engine hourmeter The reset interval will be 50 30 000 hrs SWITCH ON HOURS PM 1 5 is connected to the switch on hourmeter The reset interval will be 50 30 000 hrs CLUTCH CYCLES PM 1 5 is connected to the clutch cycle meter This meter counts every time the fan clutch engages The reset interval will be 1 000 to 90 000 cycles START CYCLES PM 1 5 is connected to the clutch cycle meter This meter counts every time the engine starter engages The reset interval will be 1 000 to 90 000 cycles HIGH SPEED HOURS PM 1 5 is connected to the high engine speed hourmeter which counts only high speed engine hours The reset interval will be 50 30 000 hrs 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 OFF ProductShield Econo is OFF 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 sav ings while offering Continuous Run operation protection when ambient is outside range Unit will return to Continuous Run when ambient goes be yond range GO TO CONTINUOUS Allows unit to be set for and operate in START STOP until ambient temper ature falls outside a user defined range when unit will go to Continuous Run This provides continuous air flow and good
209. de clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with he below as necessary Check refrigerant charge a Check for undercharged system Level must be above lower sight glass must be above lower Level must be above lower sight glass glass EE and compare compressor Suction Pressure must have the same reading on gauge amp suction ETTIT E with pressure shown on micro display on the microprocessor controller Check compressor front head reed valves amp gaskets a Remove re oe front head amp Must be in good condition inspect condition of all reeds amp re oe 2 Manually test refrigeration system See note 10 EE Run EA Check Must pass all tests Correct any problems found before proceeding 7 95 62 10683 NOT 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 with t
210. defrost cycle in 1 5 hours regardless of 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 Normal Defrost Termination Sequence The following sequence will be used to perform a Normal Defrost Termination a The micro will place the engine in Low Speed and Open de energize SV1 and Open energize SV2 and SV4 b The micro 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 High Ambient Defrost Operatio
211. dehydrate the compressor Refer to Section 8 11 Check unit operation by running Pretrip Refer to Sec tion 3 3 8 22 REPLACING RECEIVER SIGHT GLASS AS a b O e SEMBLY OR FUSIBLE PLUG 44 CAUTION Service mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating Store the refrigerant in an evacuated container Re fer to Section 8 9 1 Unscrew the sight glass assembly Wrap threads with Teflon tape or spread some sealing compound on pipe threads of new sight glass assembly or plug and install The torque value for either the sight glass as sembly or the plug is 20 25 ft lbs 2 8 to 3 5 Mkg Leak check receiver sight glass or fusible plug per Section 8 10 After leak checking unit evacuate and dehydrate as outlined in Section 8 10 Add refrigerant charge Refer to Section 8 12 Checking For Noncondensibles To check for noncondensibles proceed as follows 4 8 33 Stabilize system to equalize pressure between the suction and discharge side of the system The en gine needs to be off for several hours Measure temperature at any of the copper tubing in the condenser Check pressure at the compressor discharge ser vice valve Determine saturation pressure as it corresponds to the condenser temperature using the Temperature Pressure Chart Table 8 8 If gauge reading is 3 psig 0 2 BAR or higher than the calculated P T pressure i
212. der filter and remove filter Lightly oil gasket on new filter before installing Tighten per the filter manufacturer s directions 44 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 Replace filter s and add lube oil Refer to Section 2 6 Warm up engine and check for leaks 8 7 62 10683 Lube Oil And Fuel Flow Diagrams 8 6 4 Servicing The Speed Control Solenoid And Linkage Non ESC engines only Units begin ning with below serial numbers and ALL X2 units Refer to Section 8 6 5 for information on units with Electronic Speed Control Serial Number Cut Offs e Ultra XTC KAV90910396 e Ultima XTC KAV90910334 1 Solenoid 4 Linkage Speed 2 Bolt 5 Clip 3 Solenoid Bracket 1 Fuel Tank 7 Fuel Bleed Valve 2 Fuel Supply Line 8 Injection Pump Figure 8 6 Speed Control Solenoid 3 Fuel Pump Optional 9 Injector Nozzles 4 Mechanical Lift Pump 10 Fuel Leak off Line a Solenoid Removal Replacement o ae Fue Return Gne 1 Disconnect wiring to solenoid Disconnect linkage 6 Fuel Warmer Optional arm Item 4 Figure 8 6 from solenoid Remove mounting hardware from solenoid and then remove solenoid Figure 8 4 Fuel System Diagram 2 Install replacement solenoid and mounting hard ware Do not tighten at this time 3 Attach linkage to sole
213. dler pulley 4 5 Remove old belt and replace with new belt See Figure 8 11 Using a belt tension gauge Figure 8 10 on the belt rotate idler pulley so that the gauge reads the correct tension Refer to Table 8 2 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 FLYWHEEL ATTACHING SCREWS Figure A b 2 MATCH MARK Engine To Gearbox V Belt 1 Disconnect negative battery cable and remove V belt guard and then loosen idler bolt Match mark adapter to engine flywheel See Figure 8 13A for ease of assembly Remove six bolts 5 16 18 x 1 Ig securing adapter drive sheave to engine flywheel Figure 8 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 8 13A and slide the adapter sheave toward the compres sor enough to change the V belt as shown in Figure 8 13B Replace V belt Pry the adapter back toward the engine flywheel or use 5 16 18 x 2 1 2 Ig bol
214. driven compressor as required This feature allows full automatic control ofthe engine starting and stopping by monitoring refrigerated compartment temperature battery charging amps and engine coolant temperature The main function of automatic engine cycling is to turn off the refrigeration system near setpoint to provide a fuel efficient temperature control system and to initiate a restart sequence after certain conditions are met The Start Stop Continuous key is pressed to select between Continuous Run and Start Stop operating modes NOTE The microprocessor may be locked so that the unit will always operate in Start Stop whenever the setpoint is within a specific range Referto Range Lock Section 4 5 1 and ProductShield Section 4 5 2 for additional information 4 2 1 Start Stop Mode Whenever the unit starts in Start Stop Mode it will continue to run until all five of the following criteria have been satisfied a It has run for the predetermined Minimum Run Time The Minimum Run Time is selected in the microprocessor Functional Parameter list Refer to Section 3 15 The purpose ofthis is to force the unit to run long enough to com pletely circulate the air inside the compartment and to ensure that the product temperature is at setpoint This may be set for any value between four minutes and 60 minutes in one minute intervals The engine must run for the Mini mum Run Time before cycling off The factory setting is four minutes b The
215. dure to close itself The microprocessor 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 position according to the ambient and compartment temperatures The display will show SETTING SMV XX The start sequence will start at 30 WARNING Under no circumstances should ether or any other starting aids be used to start en gine After the CSMV reaches 30 the glow plugs will energize as required the buzzer will sound and the diesel engine will start 62 10683 3 2 MANUAL START GLOW AND CRANK IF EQUIPPED 7 O O O HEAT COOL DEFROST O ALARM O O START STOP CON TINUOU S O 200 HAD F STA RT RUN OFF 1 Hold GLOW CRANK switch in the GLOW position GLOW CRANK Back of Control Box 2 Place START RUN OFF switch to the START RUN position 3 Continue to hold GLOW CRANK switch in the GLOW md position for up to 15 seconds 4 Then crank the engine by holding the GLOW CRANK switch in the CRANK position until the engine starts This may take up to 10 seconds NOTE 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
216. e 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 up inthe 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 pull down menu to download cable and applications turned off set sensors amp events to connections Did you find i i de computer has 9 pin serial be viewed OR use and correct the c ondition port as NOT ME Service Manager or USB port Did you
217. e 4 complete table of temperatures and resistance values 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 3 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 7 74 NO 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 4 4 8 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 Supply Air Temperature sensor
218. e 8 26 Set nitrogen pressure regulator higher than cutout point on switch being tested Pressure switch cutout and cut in points are shown in Section 2 10 Close valve on cylinder and open bleed off valve Open cylinder valve Slowly close bleed off valve and increase pressure until the switch opens If a 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 c ou The light will light or the ohmmeter will close 62 10683 8 30 8 20 COMPRESSOR DISCHARGE PRESSURE TRANSDUCER CDP CTD P N 12 00352 04 RED 8 20 1 Calibrating Compressor Discharge Pressure Transducer The compressor discharge pressure transducer CDP has a range 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 transducers and still display an accurate pressure reading in the Data list there is a calibration feature for the CDP built into the microprocessor To calibrate the CDP it must be removed from the compressor and be exposed to 0 Bar PSIG 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 an
219. e 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 of the 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 62 10683 Test 2 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 UL1 Front Unloader e UL2 Rear Unloader e Speed Solenoid or ESC module e 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 with any
220. e Program Micro button The MessageCenter will go show ENGINE AND MICRO WILL STOP NOW for a few seconds If the engine was running it will shut down Nothing will happen for the first 5 10 seconds then the software will begin to load The MessageCenter backlight will go dim and INSTALLING PROGRAM SOFTWARE will be dis played Micro Status LED will start blinking at the rate of 0 5 seconds on 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 one or two 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 four to six minutes Itis important that the program is not interrupted from thetime the Program Micro button is clicked until the program is completely loaded Once the complete reaches 10096 The MessageCenter will show INSTALL COMPLETE and the shutdown box will appear Click the OK button j The microprocessor will power up and the unit will start Allow the engine to start completely the first time after loadingsoftware DONOTTURNTHESTART RUN OFF SWITCH OFF DURING THE INITIAL START FOLLOWING A SOFTWARE UPGRADE 5 4 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 f
221. e cen ter line of all three sheaves must be in line d Pivot alternator to place tension on belt using hand force only Do not use pry bar or excessive force as it may cause bearing failure For correct belt tension see Table 8 2 Tighten pivot and adjustment bolts e Reinstall negative battery cable Torque to 80 ft lbs 11 1 Mkg Alternator SY Sa E onn Torque to 15 to 16 ft lbs 2 1 to 2 2 Mkg Water Pump Alternator Crank shaft Belt N Ure B EJ AA A d Figure 8 11 V Belt Arrangement Non ESC Engine 8 11 62 10683 Gearbox to Fan Shaft Belt Torque to 80 ft lbs 11 1 Mkg 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 8 12 V Belt Arrangement Electronic Speed Control Engine 62 10683 8 12 8 7 3 Gearbox To Fan Shaft And Engine To Gearbox V Belt a Gearbox to Fan Shaft V Belt 44 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 To Replace V belt 1 2 Disconnect negative battery cable and remove V belt guard DO NOT START UNIT UNTIL V BELT GUARD IS INSTALLED 3 Loosen i
222. e 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 actual test temperature at the sensor is an ice bath at 32 F 0 C or a calibrated temperature tester e omms c ohms e Ohms F Ohms Fe 267 9 200 0 600 2 488 Fa soo 8057 sr o sees 90 s22 7308 Los sse 6 564 Fes 367 6068 a amp e 23 000 Fas amp s 20 900 a 222 110 500 rs 211 10300 es e06 902 o 178 85400 eo 155 15316 6 144 70720 s 53 6546 es 189 10100 ree 200 12490 rie 89 52090 8 41 62 10683 CEJA C orms co EEE 7 8 189 690 67 461 170 5 6 434 790 356 umm e 148 9 EN o 194 o 136 o 138 o 140 o 144 o 146 73 80 148 o 155 o 160 o 165 o 170 o 175 o 180 185 Las soso ea aso 307970 ea 353 Ea 76 78 80 82 86 ES EN 70 040 150 ES man m 98 o 100 o 102 o 104 106 o 110 o 112 11a 118 eo 4 EE emaa E 18 20 22 ESE es EN EM 32 21 171 96 98 40 44 267 rhim e os E 46 48 0 52 o 54 o 56 60 o 62 64 68 o 70 o 72 o 74 c e 24 41 567 28 25 6 57 8 27 26
223. e the seat disc into the valve body with the small er diameter end facing up 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 Install coil assembly nameplate and top locknut or screw Dehydrate and evacuate the system Refer to sec tion 8 11 Charge unit with refrigerant per sections 8 12 10 Start unit and check operation 11 Run Pretrip Refer to Section 3 3 62 10683 1 Locknut Screw 6 Enclosing Tube Lock 2 Spacer Cup nut 3 Nameplate 7 Enclosing Tube 4 Coil 8 Seal 5 Spacer 9 Seat Disc 10 Body Figure 8 29 SV1 Solenoid Valve 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 a Receiver refrigerant level will drop quickly at the initia tion of heating or defrost mode b Suction pressure will rise slowly to 90 100 PSIG 6 12 to 6 80 Bar c Discharge pressure will drop quickly but
224. ead 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 refrigerated 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 5 2 Indicator LEDs The display has six LEDs across the top to indicate operation status These indicators are e Cool Indicator Green Turned on when the unit is in Cool mode e Heat Indicator Amber Turned on when the unit is in Heat mode e 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 e Continuous Indicator Green Turned on when the Continuous mode has been selected e Alarm Indicator Red Off or flashes at a rate of 0 5 seconds NOTE There is an opening between the Alarm and Start Stop LEDs that is
225. eadings a Check DTT2 resistance and Refer to Section 2 12 for complete resistance chart heck SAT resist eee Note 6 iis 10K Ohms 77 F 25 C a Inspect DTT2 Should be screwed tightly in place oo M Flat area of DTT2 must be against metal surface 7 a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding See Troubleshooting Section 9 3 5 Refrigeration System Not Heating 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 13 7 39 62 10683 NOT 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 continuously 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 vi
226. eat Exchlanger Aaa 2 13 24 3 Evaporator Coll tec E A dp ee oed pes 2 13 2 5 SYSTEM OPERATING CONTROLS AND COMPONENTS 0occccccccccc esee 2 13 2 51 Multiple Languages vent TI pepe RR et cae eee a A 2 14 2 5 2 Special Features coner k scat A pas UR eed 2 14 2 5 3 Component Description And Location 0 00 cece cee nets 2 15 2 5 4 Handling of PC Cards petise ented 2 16 2 6 ENGINE DATA tocata ria da dot 2 22 236 1 Lubrication SOM A a PAG ean i 2 22 2 7 ENGINE SCREW THREADS sianida aadar n a tenet hn 2 23 2 89 ENGINE AIR SYSTEM wcccmi ni cot pP tie Ae il RUE ELE 2 23 2 9 COMPRESSOR DATA 0 000 cece ene rh 2 23 2 10 REFRIGERATION SYSTEM DATA ooccccccccccc eer s 2 23 2 11 SAFETY DEVIGES Seducir ais petites A tweet deer ete ihe 2 24 2 12 COMPONENT RESISTANCE AND CURRENT DRAW 00000 0c cece nes 2 25 2 13 REFRIGERANT CIRCUIT DURING COOLING cccccccccccccc nen 2 26 2 14 REFRIGERANT CIRCUIT HEATING AND DEFROSTING 0 0c cece eee eee 2 27 i 62 10683 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page OPERATION nas A RR 3 1 3 17 STARTINGIUNIT AUTO anios coa vs Sen y eee daa 3 1 3 2 MANUAL START GLOW AND CRANK IF EQUIPPED sssssssee III 3 2 3 9 PRETRIP a cire 4S thee rac A hen edad ERE am eU IARE Tae 3 3 9 4 CHANGING SETPOINT 45 2 2 x uve ERRIRS ratas er obey wees ni 3 7 3 5 START STOP OPERATION A A EK EVE 3 8 3 6 CONTINUOUS RUN OPERATION sssss
227. eck for Did you find 5 VDC at ENSCU terminal and r Sireci 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 9 2 ESC Diagnostic Tree 2 Long 1 Short LED Code 62 10683 9 8 START HERE Does the engine starter engage amp turn the engine over Goto Advance Micro diagnostic table Figure 9 6 YES y Verify the proper voltage going into FSA terminal YES 1 12 VDC when Start Run Off switch is first turned on for the pull in voltage 1 VDC for hold in voltage amp 0 8 VDC during starter engagement Do you have the correct NO voltage
228. em 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 Solenoid Valve Valve Stem Gas Bypass Port Spring Guide Spring Piston Piston Bypass Valve Bleed Orifice ONOOIROM 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 2 11 62 10683 c Loaded Operation Discharge pressure bleeds from the discharge manifold Figure 2 13 item 15 through the strainer 9 and 8 bleed orifice to the solenoid valve stem 2 chamber and the back of the pist
229. emove evaporator panel from rear of unit and then pull loose the Presstite insulation from one end ofthe expansion valve bulb Loosen one TXV bulb clamp and make sure area un der clamp above TXV bulb is clean 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 8 25 Use Presstite insulation to completely cover both bulbs 1 Suction Line 2 TXV Bulb Clamp 3 Nut and Bolt Clamp 4 Thermocouple 5 TXV Bulb Figure 8 25 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 10 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 8 8 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 temperature determined in Step f from the average temperature measured in Step g The difference is the superheat of the suction gas 8 19 CHECKING AND REPLACING HIGH PRES SURE CUTOUT SWITCH HPS 8 19 1 Replacing High Pressure Sw
230. en High is selected NOTE HIGH AIR FLOW does not work with setpoints below 10 4 F 12 0 C FRESH PROTECT OFF OFF Fresh Protect is turned off A 2TOS5F 11TO Athru E determines the allowable temperature SAT can go below 2 8 C setpoint when the unit is operating in Continuous Run Cool FreshPro B 4TO7 F 2 2TO tect does not operate in Start Stop See Section 4 5 4 3 9 C C 6 to 9 F 3 3 TO 5 0 C D 8to 11 F 4 4 TO 6 1 C E 10 to 13 F 5 6 TO 7 2 AUTO FRESH AIR 0 CLOSED CLOSED AutoFresh Air Exchange assembly will be closed except 1 OPEN for pretrip and component test mode AOFM CONTROL 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 CFM CONTROL Assembly will be cycled open and closed over a 20 minute time period The length of time the assembly is opened or 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 5 TO 50 CFM IN 5 When CFM CONTROL is selected this parameter is visible When CFM INCREMENTS CFM CONTROL is used the solenoid will open and close in 20 minute 25 CFM time block
231. ended Service Interval MOBIL API Class CG or higher DELVAC 1 3000 Hours or 2 yr 4000 Hours or 2 yr 44 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 62 10683 2 22 NOTE The maximum oil change interval is one year for CG oil or two years for Mobil Delvac 1 unless units are equipped with Extended Service Inter val Packages The only approved synthetic lube oil is Mobil Delvac 1 The normal oil change intervals should be reduced if the equipment is operated under extreme conditions such as in dirty environments Refer to Section 8 1 for more detailed information on service intervals 2 7 ENGINE SCREW THREADS All threads used on the diesel engine are metric 2 8 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 However 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 8 6 6 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
232. er 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 13 number shown in the micro unit data list Check for proper voltage to the Engine Speed Control Unit ENSCU pin 22 based on the model Check for proper voltage with unit running a 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 XTC and X2 2100A Verify O VDC at terminal 16 of the ENSCU Verify O VDC at terminal 22 of the ENSCU Check speed solenoid amp linkage on non Electronic Speed Controlled ESC engines Fuel and Speed Actuator on ESC engines a Check speed solenoid on standard Must move in and out freely engines Fuel and speed actuator on ESC plunger b Check engine speed arm 4 linkage Must move freely a Using Functional Parameters set the Unit will run in low speed RPM must be within range Low Speed 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 Check engine RPM a Check actual engine RPM using hand Refer to Section 2 6 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 fi
233. er list RESET is only available when the accumulated hours or cycles 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 reset 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 to change Select Off for the interval Press to enter Press to change Select the correct interval Press to enter Turn the START RUN OFF switch off then back to START RUN Check the Data list The correct num ber of hours should be showing as HOURS TO ENGINE MAINT Ja DaAND ST 62 10683 5 6 ADVANCE MICROPROCESSOR REPLACE MENT amp CONFIGURATION SETUP When field diagnosis of a Carrier Transicold Trailer or Rail 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 equipped with the IntelliSet option this fi
234. es View current draw in the Unit Data list Refer to Section 3 13 a ES 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 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 7 89 62 10683 NOT 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 check SV4 alarm a Check for alarm P181 Condition must be corrected and alarm cleared to proceed 2 Check system pressures a Check and compare co
235. es to see if any active alarm occurs Continue with the seps below as necessary 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 IT Check Defrost Termination 10 000 Ohms 77 F 25 C See section 2 12 for ert Sensor 2 resistance complete table of temperatures and resistance values ee Note 4 2 Check defrost termination temperature sensor 2 wiring 28 Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic 7 99 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 223 225 7 10 MAINTENANCE ALARMS 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 1 Check unit maintenance records a Schedule unit into service facility for Must be done soon maintenance 2 Perform maintenance a Perform appropriate engine amp unit Follow instructions on proper maintenance form maintenance Reset engine maintenance hour meter a Check that the Engine Maintenance Reset Interval in Configuration list as required Hour Meter interval is set for your re
236. essary d Midseat the refrigerant system service valves e Open the vacuum pump and electronic vacuum gauge valves if they are not already open Start the vacuum pump Evacuate unit until the electronic vac uum gauge indicates 2000 microns Close the elec tronic vacuum gauge and vacuum pump valves Shut off the vacuum pump Wait a few minutes to be sure the vacuum holds f Break the vacuum with dry nitrogen Raise system pressure to approximately 2 PSIG 0 14 Bar g Purge nitrogen from system h Repeat steps e through g one time i Evacuate unit to 500 microns Close off vacuum pump valve and stop pump Wait five minutes to see if vacuum holds This checks for residual moisture and or leaks j With a vacuum still in the unit the refrigerant charge may be drawn into the system from a refrigerant con tainer on weight scales The correct amount of refrig erant may be added by observing the scales Correct charge will be found in Table 2 1 8 19 62 10683 62 10683 Refrigerant Recovery Unit Refrigerant Cylinder Evacuation Manifold Valve Vacuum Pump Vacuum Gauge King Valve Receiver Condenser OMNOARWD Evaporator Discharge Service Valve Suction Service Valve Compressor Compressor Suction Modulation Valve CSMV Figure 8 16 Vacuum Pump Connection 8 20 8 12 ADDING REFRIGERANT TO SYSTEM
237. esults of above tests with your StarTrak if earlier supervisor If necessary go to the beginning disconnected of the table amp test again earlier NO y Figure 9 5 Micro Diagnostic Tree Cond 1 Start Run Off Switch On Unit Does Not Operate 62 10683 9 12 START HERE Wrong Chart The unit See Condition 1 starts amp runs i 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 T NO 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 a or Check for active amp inactive alarms Condition 9 Refer to Section 7 for troubleshooting Programming Problems alarms Did you find and correct the with MicroProgrammer condition if using a PC to upgrade Ma software Did the software load correctly z 2 y gt Verify func
238. ety Precautions 1 1 Service Mode 5 12 Servicing Check Valve 8 26 Servicing Fuel Pump 8 6 Servicing Solenoid Valves 8 34 Sleep Mode On 3 10 3 11 Solenoid Valve SV1 Checkout 8 36 Sortware Version Numbers 5 14 Speed Control Solenoid 8 8 Speed Control Solenoid SCS Overrides 4 22 Start Stop Indicator 4 4 Start Stop Operation 3 8 4 3 Start Stop Parameters 4 4 Stopping Unit 3 30 Suction MOP Cool Only 4 24 Suction Pressure Operation 4 25 SV1 Operation Defrost Only 4 15 SV2 Operation Heating and Defrost 4 15 Switch Descriptions 2 18 T Temperature Control 4 6 Temperature Range Lock 1 amp 2 4 16 Thermostatic Expansion Valve 2 23 8 28 Trip Start 3 15 Troubleshooting 7 1 Troubleshooting Software Loading 5 17 Two Way Remote Communication 3 35 U UltraFresh 3 Temperature Control 4 10 Unidrive torque Requirements 8 43 Unit Data 3 19 Unit Weight 2 23 Unloader 2 11 8 26 Unloader Control Operation 4 15 Unloader Control Priority 4 23 Using Microprogrammer 5 16 Using The DataShare Program PC Card 5 15 V V Belts 8 10 Variable Glow Time 4 1 View Active Alarms 3 16 VIEW HOURMETERS 3 23 View Inactive Alarms 3 17 W Water Pump V Belt 8 11 Index 3 TRANSICOLD VA North America Central America Carrier Transicold and Mexico 700 Olympic Drive Ejercito Nacional No 418 Athens GA 30601 USA Piso 9 Torre Yumal Tel 1 706 357 7223 Col Chapultepec
239. f 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 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 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 a Check compressor pistons and Must be in good condition connecting rods See Refrigeration Trouble Shooting Section 9 3 IUE u BEER M Ie ey z E M erg 62 10683 7 18 NO 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 mi
240. f 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 4 4 8 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 and 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 periodically as the control system makes adjustments in the system s capacity to maintain compartment temperature when it is close to setpoint 4 23 62 10683 4 7 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 comp
241. figuration 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 shutdown condition and Remote 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 1 Determine what Remote Switch 2 is controlled by a Remote Switch 2 may be connected to Find and locate Remote Switch 2 a trailer or rail compartment door or some other device and used to remotely control the unit Check to see if trailer or rail compartment side or rear door is open or if the device that Remote Switch 2 is connected to is set to trigger the alarm a Inspect trailer or rail compartment Trailer or rail car compartment door s must be closed doors ie gt b Check device at Remote Switch 2 Must have switch in position that allows unit to operate Check wiring aM a Visually inspect wiring to switch Wiring must be connected
242. find side el 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 9 10 Micro Diagnostic Tree Cond 6 Data Recorder Data Download Problems When Using ReeferManager and a Download Cable Data File Analysis Problems Using Reports 9 17 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 5 1 the software into micro Insert PC card into the PC card slot on the micro l 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 PC Card may be defective Try a different card Did you find and correct condition NO y If you have tried 2 or more 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
243. find and correct the condition NO 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 fle tonne 4 file and try again bottom of the screen Advance micro Are you i y agal loading the correct file l Try again using YES a good cable Close MicroProgrammer The PROGRAM MICRO button is not and start over again OR use Program PC card zk active Click on the button Is the NO software loading NO p NO Check the integrity of Y Did you achieve the download cable Is4 yes Did you get a Is the Percent nt daas dl the cable OK Communication Error Complete 10096 download i message increasing 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 No lid Ried i Le Ni g gt us Will mi into configuration mode urn the unit off for 30 seconds Exit out of GTO AN the MicroProgrammer Turn
244. frequent defrost cycles can be expected 62 10683 7 40 ANO 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 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 a Check upper fan belt tension 4 Refer to Section 8 7 for belt tensions condition No Glazing no cracking no slipping b Check lower fan belt tension amp Refer to Section 8 7 for belt tensions condition No Glazing no cracking no slipping Check evaporator air flow a Check evaporator fan clutch Must be engaged b Check evaporator section condition of Good Air Flow evaporator blower wheels return air Return air not restricted bulkhead air chute cleanline
245. 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 9 COMPRESSOR DATA Table 2 4 Compressor Data Compressor Model 058 No Oylinders 6 No Unloaders 187 Tbs 62 kg Oil Charge 5 5 pints 2 8 L Mobil Arctic EAL 68 Approved OII 2 23 2 10 REFRIGERATION SYSTEM DATA Table 2 5 Refrigeration System Data Defrost Air Switch 1 40 07 inch 35 DAS Initiates Defrost mm WG Expansion Valve Setting 8 to 10 F Superheat 4 4 to 5 6 C Setting at O F 17 8 C refrigerated compart ment temperature 105 PSIG 7 1 Bars Ultima and X2 2500 Expansion Valve MOP 55 PSIG 3 7 Bars Ultra and X2 2100 Fan Clutch Air Gap 0 015 to 0 095 208 to 220 F 97 8 to 104 4 C Cutout 465 10 PSIG 32 7 0 7 Bars Cut in 350 10 PSIG 24 6 0 7 Bars Refrigeration Charge Refer to Table 2 1 Gearbox Oil Mobil SHC 75 90W 150z 0 43 kg Fanshaft Oil Mobil SHC 630 3 20z 0 09 kg Unit Weight Approximate 1600 Ib 725 kg Fusible Plug Setting High Pressure Switch HP1 62 10683 2 11 SAFETY DEVICES System components are protected from damage caused by unsafe operating cond
246. frost Operation will be used When the Am bient Air temperature is above 80 F 26 7 C the High Ambient Defrost Operation will be used Ifthe discharge pressure rises to 340 psig 23 1 Bar UL1 will energize and unload for the remainder of the de frost cycle If the discharge pressure rises to 350 psig the SV1 valve will de energize open for 1 second to reduce the discharge pressure Ifthe discharge pressure remains at 350 psig 23 8 Bar the SV1 valve may de energize open again ad much as twice a minute 62 10683 4 12 Normal Defrost Termination Defrost Termination Defrost will be terminated once any of the following conditions are met a When the defrost termination temperature DTT2 and Supply Air Temperature SAT are both above 55 F 12 8 C and the sensors are working properly If both DTT2 and SAT sensors are bad then defrost will terminate in 10 minutes A sensor alarm indicates that the sensor is bad b Defrost Terminated By Time 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 It is used to terminate Defrost after a maximum time of 45 minutes 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
247. g ReeferManager Rewrite the information to the card using ReeferManager then use it in the micro again OLD SW CANNOT LOAD REMOVE CARD A Program PC Card has been inserted into the PC Card slot and the major version of the program on the PC Card is an older vers ion than what is already loaded in the Micro Software with older major versions can not be loaded into the Micro Remove the PC Card Refer to Section 5 4 1 for software version description OLD SW TO LOAD t 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 Micro Press to load the older program Refer to Section 5 4 1 for software version de scription PC MODE START RUN OFF switch is OFF the PC mode Jumper is con nected and engine is not running in order to enter PC mode 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 micro 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 Pa rameter settings PRETRIP FAIL IN TEST XX Some 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 When unit is equipped w
248. gerant between the SV2 valve and the CSMV NOTE Opening the valve can also be accomplished by using the microprocessor To open the CSMV valve reconnect SV2 to the engine harness Place the START RUN OFF switch in the START RUN position The microprocessor will go through its self test and the display will show SMV CLOSING The valve is obviously closed at this point but the microprocessor still has to home the CSMV valve every time the microprocessor is powered up The display will then show SETTING SMV XX Refer to 8 24 above If the suction pressure does not go up the CSMV is stuck closed go to Step g or there is something obstructing the refrigerant between the SV2 valve and the CSMV 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 2 valve is determined to be stuck closed in Step f turn theunit 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 onmmeter checkthe winding resistance between 1A black wire and the 1B white wire AND between the 2A green wire and the 2B red wire In normal ambient each winding should have 72 to 84 ohms If this resistance is con firmed proceed to Step 8 If an infinite or zero ohm reading occurs first check the wires at the connector for good contact If the connector is in good condition andthe resistan
249. ghtened or pins broken 9 18 Figure 9 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 Y Insert the PC Card into the PC Card slot on 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 condition 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 until the CSMV
250. gil INDICATES A WIRE BETWEEN PLUG HC C A PIN 9 AND MICROPROCESSOR PLUG2 PIN 25 B TO SP2 K10 TO ENSCU 18 N11 L T0 CPR86 K9 LOCATED IN ENGINE HARNESS ES SA C6 TO SSR88 J9 WWW QJ 7 5A 9 SYSTEM POWER GPR SSR F DISPLAY KEYPAD TO FLSC 2 op y RE 9 SP23 B Iy LOS RE l En lo k3 k2 ki CLHR RR SR PCMC DS A A A B q Ad B ENCLS ERU E SPK20 J14 SPK24 o BIA ENOPS TO HCO K10 MP TO ENSCU 3 M10 CONTROL BOX ULTIMA XTC AND ULTRA XTC a d amp NNNNNNNNNNNNNNDDD C 0 0 DD X PAS TO HC6IB3 PATO 85 86 TO SMPA1 E3 SMPA11 MPQCS gt TO 2MP25 E7 Ul gi
251. h in the functional parameters Refer to Functional Parameter List Section 3 15 When this switch is turned OFF the Door switch or Remote Switch Alarm s will come on as needed however the unit will not shut down e Out of Range Alarm The Out Of Range Alarm is intended to notify the driver when the refrigerated compartment temperature is moving away from the setpoint The Out Of Range Alarm may be configured as an Alarm Only or as an Alarm and Unit Shutdown Refer to Section 5 2 Configuration mode Generally before the Out of Range Alarm can be triggered the refrigerated compartment temperature must have first been In Range In Range is defined as the refrigerated compartment temperature having been within 2 7 F 1 5 C of setpoint in the Perishable Range or within 2 7 F 1 5 C of setpoint in the Frozen Range If the unit shuts down due to a shutdown alarm the Out Of Range alarm will come on after the timer expires 30 or 45 minutes and when the refrigerated compartment temperature goes out of range regardless if the refrigerated compartment temperature was ever within setpoint range or not 2 21 Out of Range is determined by the Functional Parameter setting Selections of 4 F 2 C 5 5 F 3 C 7 F 4 C and OFF are available The OFF setting disables the Out of Range alarm All other settings allow the user to determine how far away from setpoint the refrigerated compartment temperature may move befo
252. h to continuous run when the ambient temperature falls below a pre programmed temperature This helps protect the unit from the possibility of fuel gelling and other cold weather issues NOTE ProductShield Winter mode is not available when the unit is operating in Continuous Run Once the micro 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 All of the ProductShield settings may be viewed in the Data List Refer to Section 3 13 For units with IntelliSets the Data List will reflect the ProductShield settings for the IntelliSet that is currently active NOTE ProductShield does not operate within Sleep Mode 4 19 62 10683 4 5 3 ProductShield Temperature Ranges 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 The examples below all use the same settings and illustrate the differences in unit operation for the various ProductShield selections a ProductShield Econo Go To Start S
253. he PQ card slot will blink together with the Micro Status LED at a rate of 1 2 second on then 1 2 second of during this installation process Once the entire program has been loaded the MessageCenter will 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 Micro 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 5 15 62 10683 5 4 3 Using MicroProgrammer 44 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 NOTE 04 05 00 04 06 00 for X2 units software and above can be installed using either the pre ferred previously described Program PC card method or by using MicroProgrammer 3 14 and acomputer Existing Program PC cards may be upgraded to 04 05 00 or 04 06 00 by using the ReeferManager program NOTE Only MicroProgrammer version 3 14 is to be used
254. he SAT temperature to below 45 F 7 2 C and then restart defrost Should the defrost cycle not complete within 45 minutes the defrost cycle will be terminated and DEFROST NOT COMPLETE will be displayed in the MessageCenter The microprocessor will initiate another Defrost Cycle in 1 5 hours of engine running time Pressing the manual defrost key will override this mode and start another defrost cycle 62 10683 Defrost termination conditions When DTT2 and SAT are above 55 F 12 8 C When a shutdown alarm occurs If the CDT rises to 310 F 154 4 C for more than a minute when the unit has been in the defrost cycle for more than four minutes If both the DTT2 and SAT sensor alarms are active the unit will stop defrost after 10 minutes NOTE Refer to Section 4 4 8 for more detailed information on manual and automatic defrost initiation and termination TIP The Manual Defrost Key can be used at any time to start a Defrost Cycle 3 10 TRIP START e e e e e HEAT COOL DEFROST START STOP CONTINUOUS 200 HAD F SETPOINT BOX TEMPERATURE TRIP START ENTERED MANUAL ALARM List START STOP SELECT DEFROST dpi TM j 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 se
255. he Up or Down Arrow key to scroll through the list of IntelliSets The current IntelliSet will have either the word ACTIVE or MODIFIED after it MODIFIED indicates that one or more of the IntelliSet settings within the microprocessor has been changed To change MODIFIED to ACTIVE press key while the IntelliSet is shown in the MessageCenter The Advance microprocessor offers over 48 parameters that may be set depending on the product being carried 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 three hours while a load of cheese may require the same operation with setpoints ranging from 35 F to 42 F 1 7 C to 5 6 C and a load of ice cream requires Start Stop operation at 22 F 30 with defrost at 12 hour intervals The settings 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 setpoints may be locked leaving the operator the ability to change the setpoint within the locked range When a load of apples is going to be picked up the operator simply selects APPLES from the IntelliSet menu for cheese CHEESE is selected and the 3 33 setpoint reset as required for ice cre
256. he 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 9 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 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 SO0NNADO ADN _ Figure 8 20 Compressor 8 14 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 9 through the suction service valve flange cavity or by removing the oil fill plug See Figure 8 20 8 14 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 b Slowly remove the oil drain plug from the compressor and drain the proper amount of oil Replace the plug securely back into the compressor c Open service valves and run unit to check oil level re peat as required to en
257. he steps below as necessary 1 Manually test refrigeration system See note 10 BS Run A Check Must e a EET all tests AP eee any a dl found before proceeding EN 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 2 Check compressor rear head reed valves amp gaskets 2 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 1 Manually test refrigeration system See note10 D Run Quick Check Must pass all tests Correct any problems found before proceeding LE Check and compare compressor Suction Pressure must have the same reading on gauge amp suction press
258. he unidrive NOTE Thread locking sealant 5 16 flat washer and 5 16 lock washer 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 8 30 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 O 8 43 62 10683 M8 x 1 25 x 20 mm lg 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 Mkg 6 Required 30 ft lbs 4 15 Mkg 3 8 24 x 1 00 Ig Grade 8 28 ft lbs 3 87 Mkg WANN i Jj m E i EN L2 90 ft lbs 12 45 rog M12 x 1 25 x 25 mm lg 3 Required 65 ft lbs 8 99 Mkg 3 8 16 x 1 lg Grade 5 10 Required 28 ft lbs 3 87 Mkg NNI Z gj mas Figure 8 33 Unidrive Torque Requirements Non ESC Engine 62 10683 8 44 M8 x 1 25 x 20 mm lg 6 Required 28 ft lbs 3 87 Mkg 3 8 16 x 1 3 4 lg Grade 5 6 Required 30 ft lbs 4
259. he 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 F2 or F3 fuse alarm a Check for alarm 71 Alarm conditions must be corrected and the alarm cleared to continue Check speed solenoid non ESC engines a Check resistance of speed solenoid Refer to Section 2 12 b Check amp draw of speed solenoid Use Component Test mode Section 5 2 2 to test Refer to Section 2 12 for amp values View current draw in the Unit Data list Refer to Section 3 13 Check circuit for high resistance ESC engines Nu a Check amp draw of engine speed Use Component Test mode Section 5 2 2 to test control circuit ENSCU pin 16 and Refer to Section 2 12 for amp values MPQCS3 on the micro View current draw in the Unit Data list Refer to Section 3 13 Check speed solenoid amp circuit a Inspect speed solenoid and wiring No physical damage to harness No damaged or corroded pins No 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 Check speed solenoid circuit wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded
260. high 8 18 9 5 62 10683 INDICATION ACTION TROUBLE POSSIBLE CAUSES REFERENCE SECTION Low superheat and liquid Superheat setting too low slugging in compressor External equalizer line plugged Ice holding valve open Foreign material in valve Pin and seat of expansion valve eroded or held open by foreign material Fluctuating suction Improper bulb location or installation pressure Low superheat setting High superheat Broken capillary 9 3 12 Solenoid Valve Malfunction Solenoid valve does not No power to valve function properly Improper wiring or loose connections Coil defective Valve improperly assembled Coil or coil sleeve improperly assembled Movement of plunger restricted due to a Corroded or worn parts b Foreign material lodged in valve c Bent or dented enclosing tub Solenoid valve closes but Foreign material lodged under seat refrigerant continues to flow Defective seat 9 4 Electronic Speed Control Troubleshooting Table 9 1 ENSCU LED Fault Chart See following pages for troubleshooting trees tenm Engine Over Speed more than 2 530 RPM Engine Over Speed more than 2 530 RPM Hes eee ENSSN or mechanical engine problem No signal from ENSSN for 2 seconds after RPM ee TU ENSSN or wiring problem is greater than 1 000 RPM for 10 seconds OR for 5 seconds while engine cranking no voltage at pin 18 of ENSCU Actuator FSA wiring disconnected or open Two Long Three FSA or wiring problem circuit
261. his can be accomplished either through the Functional Parameter list or by turning the Run Stop switch to STOP and then back to RUN YES the SET WAKE UP TIME sub menu will 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 27 62 10683 FUNCTIONAL RUN PRETRIP NO NO The unit will wake up at the designated time and control to set AT WAKE YES point YES The unit will wake up at the designated time automatically run Pretrip and then control to setpoint The Pretrip Pass Fail message will remain in the MessageCenter until the message is manually cleared OVERRIDE NO This will only appear when a compartment door switch is configured DOOR YES ON in the Configuration List SHUTDOWN NO Allows the door switch to shut the unit down whenever the com partment door is opened and the door switch is configured for shut 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 OVERRIDE NO NOTE This will only appear when a remote switch REMS1 or REMS 1 2 YES REMS2 is configured ON in the Configuration List SERIO NO Allows remote switch 1 and or 2 to shut the unit down whenev er door is open or the switch is turned O
262. hometer c Check for 12 VDC between ENSSN 12 Must be 12 VDC V terminal amp ENSSN ground d Check for 12 VDC at ENSCU terminal Must be 12 VDC 25 to ground Additional steps on the next page 7 61 62 10683 NOT 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 above 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 7 connector pins amp terminals See No physical damage to harness wiring schematic No damaged or corroded pins b Check RPM wiring Place unit in Manual Start mode see Note 4 OR Use Component Test Mode to energize the Run Relay DO NOT START UNIT Refer to Section 5 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 13 62 10683 7 62 ANO Steps ALARM CAUSE CORRECTIVE ACTION 132 CHECK DEFROST TERM 2 SENSOR TRIG
263. hrough the Data List OFF There is no Remote Sensor 1 3 in this unit SWITCH NOT INSTALLED There is no door switch in this compartment DOOR OPEN SWITCH OPEN A door switch has been installed on one of the refrigerated compart ment doors The switch contacts will be OPEN whenever the door is OPEN DOOR OPEN SWITCH CLOSED A door switch has been installed on one of the refrigerated compartment doors The switch contacts will be CLOSED whenever the door is OPEN CONFIGURATION SELECTIONS DESCRIPTION ALARM ONLY ALARM ONLY When Door switch indicates that the door is open a warning alarm will be displayed in the MessageCenter 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 down DOOR SWITCH LOW ENGINE SPEED When Door switch indi Optional ERE INE cates that the door is open the engine will be forced to low speed DATA RECORDER ONLY The data recorder will DATA RECORDER record every time the door is opened or closed ONLY There will be no alarms or messages displayed in the MessageCenter UNIT SHUTDOWN REMOTE SWITCH 1 2 NOT INSTALLED NOT INSTALLED This remote switch is not Optional DOOR OPEN installed in this unit NOTE Sensor s on DataRecorder SWITCH OPEN DOOR OPEN SWITCH OPEN The Remote must also be set DOOR OPEN switch will be used as a refrigerated compartment SWITCH CLOSED door switch The sw
264. i 7 31 40 CHECK GLOW PLUGS r eiectieben cde tbe perbr OR AGER I UE ARP CDM RERO HR Ur Ne 7 33 41 ENGINE STALLED Rex Re rh a Kc UR Re AT XU s 7 34 62 10683 iv TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page 7 6 WARNING STATUS ALARMS ccc cece certs n nnn nnn 7 36 51 ALTERNATOR NOT CHARGING 0 000 cece e 7 36 53 BOX TEMP OUT OF RANGE 2 cece cece m eee e enna 7 37 54 DEFROST NOT COMPLETE 1 e ra ties iene aera ae E nes 7 39 55 CHECK DEFROST AIR SWITCH 2 cece ented 7 40 56 CHECK EVAPORATOR AIRFLOW oii mieni 0 00 cece I 7 41 57 CHECK REMOTE SWITCH 1 cette arera 7 42 58 CHECK REMOTE SWITCH 2 i cec oe tae ea ere EUER DUE eee ES 7 43 59 DATALOGGER NOT RECORDING sssssss cece nen ened 7 44 60 DATALOGGER TIME WRONG iiao crae diania barean nent tenes 7 45 61 DOOR OPEN 26 Ier rere A A Ad A AA T i a e Te 7 46 7 7 ELECTRICAL ALARMS 0 cece heh mr enn nn 7 47 71 BAD FZOR F3 F SE se cocinas cec eee eg Ret es e ce d OR WU EHE CE AAA PIT ATI RR 7 47 172 BAD FA OR FO RU SE 45a SEC n e abi bets 7 47 78 GHECKSV1 CIRCUM riori eorr ei A AA E A ei eas 7 48 79 GHECIKCSVA CIRGULT cu trie e Ee tet Ces Ie pede hae Ar CERRO E Feu ed LEE e 7 48 81 CHECK FHR CIRCUIT irm e tita Rei ced ed Gale wells RU ce e e 7 49 82 CHECK REMOTE OUT RANGE LIGHT sssssse rr 7 49 83 CHECK REMOTE DEFROST LIGHT sssssssssee e eee 7 50 84 CHECK REMOTE ALARM LIGHT
265. icroprocessor 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 off the card LOADING INFO will be displayed during this time When finished the MessageCenter will show ALL INFO LOADED REMOVE CARD Remove the Configuration PC card When the PC card is removed the MessageCenter will show MICRO WILL RESET AND RESTART NOW NOTE Units with IntelliSet will NOT START UNTIL an IntelliSet is selected The MessageCenter will show PRESS 1 TO VIEW INTELLISETS will flash continuously until an IntelliSet is se lected Press the key to display the 1 IntelliSet En able IntelliSet at key must be configured ON See Section 5 2 1 OR press the SELECT key until PRESS 1 TO VIEW INTELLISETS is dis played Pressing the Up Arrow key will bring the first IntelliSet name into the Message Center The first IntelliSet will appear in the MessageCenter Press either the UP or Down Arrow keys to move through the IntelliSet List Move to the desired Intelli Set and press the key The desired IntelliSet is auto matically active 5 6 8 Microprocessor Final Checkout a b Start the unit and allow it to run for a few minutes While the unit is running scroll through the Data List of the microprocessor Verify that all the data that was recorded in Step b of Section 5 6 1 is now accurately
266. ied NEW SW TO 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 Micro Press 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 The PC card may be safely removed from the slot NO ACTIVE ALARMS There are no active alarms in the Micro Alarm list 6 3 62 10683 MessageCenter MESSAGES 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 NO INACTIVE ALARMS A Download PC card has been inserted into the PC card slot and there is no valid data in the data recorder to copy onto the PC card The PC card may safely be removed from the unit 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 micro requires IntelliSets to be written to the Configuration PC Card usin
267. if the Pretrip cycle was aborted by an alarm before it was completed 62 10683 3 6 3 4 CHANGING SETPOINT e e HEAT COOL DEFROST 200 SETPOINT MANUAL DEFROST PLATTERS OO e e START STOP CONTINUOUS 3345 F BOX TEMPERATURE 14 TO SCROLL THEN TO SAVE RET 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 TO SCROLL THEN TO SAVE 2 Press the key to save the new setpoint Setpoints of 22 F to 89 6 F 30 C to 32 C may be entered The microprocessor always retains the last entered setpoint in memory The setpoint may be changed up or down one tenth of a degree in 0 1 C or 0 1 F increments providing Decimal Displayed is configured in the configuration list Refer to the configuration table Section 5 2 1 NOTE The microprocessor Configurations allow a minimum and maximum setpoint to be entered so that only setpoints within that range may be selected MAX SETPOINT HAS BEEN REACHED or MIN SETPOINT HAS BEEN REACHED WILL APPEAR in the Message Center when either of these conditions are met You can not change the setpoint when viewing the Alarm List Data List or Functional Parameters or when unit is in Pretrip or is in Sleep mode Setpoint may be changed any other time the START RUN OFF switch is in the START RUN position or with the unit in P
268. igh Speed Delay When operating in low speed there is a delay when switching to high speed The default delay is one minute Refer to Contiguration Mode Section 5 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 5 2 62 10683 4 22 4 6 2 Unloader Control Priority UL1 8 UL2 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 ofthe unloaders in addition to the unloader control used by the temperature control described in section 4 4 9 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 other 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 energi
269. ign 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 8 11 The V belts must be kept in good condition with the proper tension to provide adequate air movement across the coils wa Figure 8 10 Belt Tension Gauge Part No 07 00253 8 7 2 Water Pump Alternator Crankshaft V Belt The water pump alternator crankshaft V belt is driven by a sheave on the engine crankshaft Frayed cracked or worn belts must be replaced Adjustment is achieved by altering the position of the front side idler alternator When replacing a V belt avoid excessive force when applying tension to the V belt to prevent damage to the water pump bearings Refer to Table 8 2 a Make sure negative battery terminal is disconnected and remove old belt b Place V belt on alternator sheave and then install al ternator with two bolts loosely in position Gearbox to Fan Shaft Belt Engine to Gearbox Belt c Check the center alignment of the engine drive alter nator and water pump sheaves to ensure proper alignment Pulley misalignment will create excess belt wear and shorten alternator bearing life Th
270. ilure Compressor valves defective 9 4 INDICATION ACTION TROUBLE POSSIBLE CAUSES REFERENCE SECTION b Heating High discharge pressure Solenoid valves SV1 and SV4 malfunction Condenser fan defective V belts broken or loose Non condensables in system Low discharge pressure Compressor valve s worn or broken Solenoid valve SV1 malfunction Low refrigerant charge Low suction pressure Refrigerant shortage Solenoid SV1 open 9 3 8 Abnormal Noise Compressor Loose mounting bolts Worn bearings Worn or broken valves Liquid slugging Insufficient oil Condenser or Loose or striking shroud evaporator fan Bearings defective Bent shaft Cluteh Gearbox 9 3 9 Control System Malfunction Will not control Sensor defective Relay s defective Microprocessor controller malfunction 9 3 10 No Evaporator Air Flow Or Restricted Air Flow Evaporator coil blocked Frost on coil Dirty coil No or partial evaporator V belt broken or loose air flow Clutch Gearbox defective Evaporator fan loose or defective Evaporator fan rotating backwards Evaporator air flow blocked in trailer box 9 3 11 Expansion Valve Malfunction Low suction pressure with Low refrigerant charge 8 10 8 12 high superheat External equalizer line plugged Clean Ice formation at valve seat 8 11 Wax oil or dirt plugging valve or orifice 8 18 Broken capillary 8 18 Power assembly failure or partial loss of element bulb charge Replace Superheat setting too
271. in Table 2 2 The model serial number plate is located inside the unit on the frame as shown in Figure 2 3 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 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 for use on insulated trailers or rail cars to maintain cargo Also disconnect the negative battery cable temperatures within very close limits Table 2 1 Model Chart Advance Model sa ee eee Engine Speed vance Moaels KG LB ompresso Low Ultra XTC NDL 98NN Ultra XTC Rail Edition NDL 93NR j 2 Ultra XTC with Tier 2 Engine NDL 93VN 0 1700 1350 Ultima XTC NDL 93PN eT Ie dpi a 05G 41cfm Ultima XTC Rail Edition NDX 93PR 2200 Ultima XTC with Tier 2 Engine NDL 93RN 21 1475 X2 2100A and R NDL93S V2203 DI 1700 X2 2500A and R NDL93U ESC 2200 Table 2 2 Additional Support Manuals Equipment Covered Type of Manual iosri Pars Ls emm Pars List 62 10646 Operator s Manual 52 1068 Easy To Run 5210295 Pars Usi 62 10863 Engine Tier 2 Parts List 62 11168 Engine Electronic Speed Control Parts List 62 10301 Engine V2203 DI Workshop 62 10865 Engine Tier 2 Workshop 62 11167 Engine Electronic Speed Control Workshop 62 10209 P
272. ined by the High Air Max Temp and the High Air Min Temp When both of these configurations Refer to Section 5 2 1 for configuration list are set for a value the unit will operate as described above When ProductShield High Air Max Temp is set for a value and High Air Min Temp is set for OFF ProudctShield High Air mode will only be allowed for temperatures above the High Air Max setting When ProductShield High Air Max Temp is set for OFF and High Air Min Temp is set for a value ProudctShield High Air mode will only be allowed for temperatures below the High Air Min setting e When both ProductShield High Air Max and Min Temps are set to OFF ProductShield High Air will not operate at any ambient air temperature Once the micro detects that the pre programmed criteria have been met the unit will switch from normal operation to High Air The unit will continue to operate at High Air for a minimum of 30 minutes After 30 minutes the unit will returnto normal operation if the ambient temperature falls inside the pre programmed temperature range by 3 6 F 2 C Ifthe 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 switc
273. ines 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 arora Open the LIQUID valve on drum and purge all oses b Start the unit Adjust the setpoint so that the unit will run in high speed cool mode c 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 20 d Check the appropriate sight glass to determine charge See Step g for determination of charge If undercharged proceed with step e 62 10683 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 Ibs 1 4 kg of refrigerant into the system at a time After metering 3 Ibs 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 approximately
274. ing 5 Defrost evaporator EXE a Initiate Manual Defrost Cycle Must terminate automatically Additional steps on the next page 7 97 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 53 BOX TEMP OUT OF RANGE 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 above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Check refrigerant level a Visually check refrigerant level in Must be at correct level receiver tank 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 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 A 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 62 10683
275. ip this section and proceed to hourmeter Setup a Refer to Section 3 18 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 5 6 4 above O 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 02 00 or higher NOTE ReeferManager 03 02 00 is REQUIRED in or der to view change and send new features to and from the microprocessor o In ReeferManager go to the Serial Operations Tab and then click on DataRecorder Microprocessor set up button Select the Sensors to be recorded and whether you wish averaged or snapshot recordings averaged is recommended for all temperature sensors snapshot is recommended for pressure voltage amperage amp RPM When the setup is correct press the Send button to send the new settings to the microprocessor 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 Q 2 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 Time i Leave the microprocessor powered up as you con
276. ircuit is shorted The Defrost Light output from the micro is negative so the circuit will not be shorted 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 12 Check defrost light wiring a Inspect harness amp control box See Notes 3 4 amp 9 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 12 for normal current values Section 5 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 13 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 circ
277. ires 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 normally vents small amounts of flammable hydrogen gas Do not smoke when checking the battery A battery explosion can cause serious physical harm and or blindness 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 4 amp 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 4X WARNING
278. is completely closed which ReeferManager program will delay the actual process for about 45 seconds Did you find and correct the J YE dal 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 NO y Software has finished e YES Is the card status LED on solid loading NO Y There is a problem loading Has the card status the software Turn unit 1S the card st tus PEOR E 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 9 Micro does ot recognize the card Try another Wait at least 5 minutes program card
279. is of the tube in tube type con nected in the main suction line and liquid line Within the heat exchanger the cold suction gas is used to cool the warm liquid refrigerant This results in greater system capacity and efficiency 2 13 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 Os and give off carbon dioxide COs This will eventually cause the atmosphere within a refrigerated compartment to have higher levels of COs and lower levels of Oz 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 build up of CO and the depletion of O by using fresh air exchange in addition to accurate temperature control AutoFresh Air Exchange provides the ability to
280. ischarge 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 Filter Engine Speed Control Unit Ambient Temperature Sensor AAT Water Temperature Sensor WTS On Back of Engine Figure 2 4 Front View Of Unit With Electronic Speed Control Electronic Speed Control 62 10683 1 Condenser Pressure Control Solenoid Valve SV1 Defrost Air Switch Filter Drier Receiver Sight Glass Receiver Liquid Line Solenoid Valve SV2 Battery Location Figure 2 5 Curbside Electronic Speed Control nO GSg ROI 2 5 Condenser Radiator Pressurized Coolant System Control Box See Figure 2 8 Serial Port Download Plug SLP Model Serial No Location IAN Figure 2 6 Roadside Electronic Speed Control 62 10683 ADN T Rd Vr SS Be Y Y a Evaporator Fan Expansion Valve Heat Exchanger Nozzle Cover Return Air Thermistor RAT AutoFresh Air Exchange See Sections Evaporator Coil 2 4 3 and 3 19 4 Figure 2 7 Evaporator Section Panels and Grille Removed Defrost Termination Thermostat DTT2 Supply
281. ist 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 in 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 section to the Active Alarm list section As additional alarms occur they will be placed first in the Active Alarm list An alarm can not be active and inactive at the same time Each alarm can only be present in either the Active or Inactive Alarm list at any given time As conditions changed 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 7 1 TIP When alarms are cleared from the Inactive Alarm list both active and inactive alarm lists are cleared If there is asafety shutdown UNIT SHUTDOWN SEE ALARM LIST will be shown Pressing the Alarm List key will bring any Active Alarms into the MessageCenter NOTE Thelnactive Alarm Listis also called the Techni cians List Only qualified refrigeration techni cians should access the inactive list It is not in te
282. it and replace filter drier b The recommended procedure for finding leaks in a system is to use an electronic leak detector Testing joints with soapsuds is satisfactory only for locating large leaks or pinpointing small leaks once a general area has been located c If the system is without refrigerant charge system with refrigerant to build up pressure between 30 to 50 PSIG 2 04 to 3 40 Bars Remove refrigerant drum and leak check all connections 44 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 d Remove refrigerant using a refrigerant recovery sys tem and repair any leaks Evacuate and dehydrate the unit Refer to Section 8 11 Charge unit with re frigerant Refer to Section 8 12 e Check for proper unit operation by running Pretrip Refer to Section 3 3 8 11 EVACUATION AND DEHYDRATION 8 11 1 General Moisture is the enemy of refrigerant systems The presence of moisture in a refrigeration system can have many undesirable effects The most common are copper plating acid sludge formation freezing up of metering devices TXV by free water and formation of acids resulting in metal corrosion 8 11 2 Preparation a Evacuate and dehydrate only after pre
283. it may run in Cool for up to nine seconds then Null for one second if the Control Temperature is away from setpoint As the Control Temperature comes closer to setpoint 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 band 2 CSMV Control The CSMV will automatically go to 30 when it enters Ultra Fresh 3 at 1 5 F 0 8 C above setpoint 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 of time For example high ambients and low setpoints may cause the CSMV to open higher than 30 4 4 6 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 setpoint is in the frozen setpoint range the unit will run low speed loaded cool WARNING NO TEMP CONTROL will be displayed In the perishable setpoint range the unit will shutdown See section 4 4 1 for definition of perishable amp frozen setpoints 4 4 7 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 setpoint as follows Mode HIGHSPEED 7 LOW SPEED COOL Control Temp is more than 3 6 F 2 0 C Contro
284. it will not be shorted to ground but is shorted either within the Out Of Range Light itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when In range 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 1 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 12 2 Check out of range light wiring a Inspect harness amp control box See Notes 3 4 amp 9 connector pins amp terminals See wiring No physical damage to harness schematic No damaged or corroded pins 3 Check out of range light current draw a Use Component Test mode See Refer to Section 2 12 for normal current values Section 5 2 5 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 13 7 49 62 10683 NOT 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 c
285. itch a Pump down the unit Refer to Section 8 9 1 Front O 8 29 seat both suction and discharge service valves to iso late compressor Slowly release compressor pressure through the ser vice valve gauge ports Disconnect wiring from defective switch and remove old switch The HPS is located at the side of the cen ter compressor cylinder head See Figure 8 20 Install new cutout switch after verifying switch set tings Refer to Section 8 19 2 Evacuate and dehydrate the compressor Draw down to 500 microns Refer to Section 8 11 Check unit operation by running Pretrip Refer to Sec tion 3 3 62 10683 8 19 2 Checking High Pressure Switch 44 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 8 26 Cylinder Valve and Gauge Pressure Regulator Nitrogen Cylinder Pressure Gauge O to 400 PSIG 0 to 27 2 Bars Bleed Off Valve 1 4 inch Connection BONN 5 6 Figure 8 26 Typical Setup for Testing High Pressure Switch Remove switch as outlined in Section 8 19 1 oO 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 Figur
286. itch contacts will be OPEN SWITCH ON whenever the door is OPEN CONTACTS OPEN DOOR OPEN SWITCH CLOSED The Remote switch will be used as a refrigerated compartment SWITCH ON CON door switch The switch contacts will be CLOSED TACTS CLOSE D whenever the door is OPEN SWITCH ON CONTACTS OPEN The Remote 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 CONTACTS CLOSE D The Re mote switch will be used as a remote control switch The switch contacts will be CLOSED whenever the switch is in the ON position REMOTE SWITCH 1 2 ALARM ONLY ALARM ONLY When Door switch indicates that Optional the door is open a warning alarm will be displayed in the MessageCenter UNIT SHUTDOWN When Door switch indicates UNIT SHUTDOWN that the door is open a warning alarm will be dis played in the MessageCenter and the unit will shut down LOW ENGINE SPEED When Door switch indi cates that the door is open the engine will be forced to low speed DATA RECORDER ONLY The data recorder will DATA RECORDER record every time the door is opened or closed ONLY There will be no alarms or messages displayed in the MessageCenter SET TIME The following will allow the Real Time Clock in the DataRecorder to be set The time set here can be read in the unit data list MONTH Select the correct month of the year Select the correct day of the month YEAR 1998
287. ith IntelliSet and ProductShield and the unit is running in the High Air Mode When unit is equipped with IntelliSet and ProductShield and the unit is running in Winter Mode PRODUCT SHIELD WINTER ON PRODUCT SHIELD ECONO ON RECOVER LEAK CHK EVAC MODE This message will be displayed when the unit is in Service mode and the CSMV is open to 100 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 is open May be connected to a trailer or rail car compartment door or a remote control switch Shows that the remote switch is open and that the unit is running in low speed Switch may be connected to a trailer or rail car compart ment door or a remote control switch REMOVE CARD BATTERY TOO LOW REMOTE SWITCH 1 2 OPEN REMOTE SWITCH 1 2 OPEN LOW SPEED 62 10683 MessageCenter MESSAGES Mesas 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 Micro Press to reload the same program SERVICE MODE Selection in Configuration and Technician Test Modes which is used when servicing the refrigeration system See Section 5 2 3 SETPOINT CHANGED The new setpoint has been entered saved into Mi
288. itions by automatic shut down of the unit when such conditions occur This is accomplished by the safety devices listed in Table 2 6 Table 2 6 Safety Devices Unit Shutdown Safety Devices Unsafe Conditions Safety Device Device Setting Low engine lubricating oil pressure Oil pressure safety switch EN Opens below 15 3 PSIG OPS microprocessor reset 2 1 1 2 Bars High engine cooling water temperature Engine coolant temp ENCT Refer to section 2 6 microprocessor reset Fuse F1 Opens at 7 1 2 amps Fuse F2 Opens at 10 amps Fuse F3 Opens at 7 1 2 amps Fuse F4 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 F6 valves and unloaders and light bar 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 Excessive current draw by fuel heater Fuse F8 Optional Opens at 20 amps Excessive current draw by light bar Fuse F9 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 7 HPS automatic reset Other Safety Devices Unsafe Conditions Safety Device Device Setting Low Engine Coolant Level Engine Coolant Level Switch Engine coolant level is more ENCLS
289. ized 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 a Check for alarms 80 P148 Alarm conditions must be corrected and the alarm cleared to continue 2 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 SV1 operation Unit must be running in Heat Cycle See Note 10 See Section 8 23 2 Checking SV1 a Set unit to operate in high speed heat After 3 minutes note discharge and suction pressures b De energize SV1 coil Compressor discharge pressure will drop Receiver tank pressure will raise slightly 4 Manually test refrigeration system a Run Quick Check Must pass all tests Correct any problems found before proceeding El LI EN 7 87 62 10683 NO
290. ized Carrier Transicold Dealers only 62 10683 7 44 NO Steps ALARM CAUSE CORRECTIVE ACTION 60 DATALOGGER TIME WRONG 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 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 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 Reset microprocessor a 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 3 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
291. just switch by turn ing adjusting screw clockwise to increase setting or counterclockwise to decrease setting Repeat checkout procedure until switch 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 62 10683 8 27 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 c
292. k 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 Remote Temperature sensor 3 REMSN3 a Verify that Remote Temperature Remote Temperature Sensor 3 is installed 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 a 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 8 29 for complete resistance chart resistance See Note 6 10 000 Ohms 77 F 25 C 3 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 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 7 66 NO Steps ALARM CAUSE CORRECTIVE ACTION 7 9 PRETRIP ALARMS P141 PRETRIP STOPPED BY USER TRIGGER ON Pretrip cycle was stopped before the Pretrip cy
293. l Components Engines with electronic speed control have no RPM sensor speed or fuel solenoids Engine speed is controlled by way of 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 Figure 8 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 8 6 6 Engine Air Filter a 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 following simple service steps are easily made while the engine is being serviced in the field 1 Check all connections for mechanical tightness Be sure filter outlet pipe is not fractured Incase of leakage and if adjustment does n
294. l de energize to stop the starter NOTE If the ambient air temperature is above 120 F 48 9 C when the engine starts the unit will operate in low speed 2 cylinder operation for the first 2 minutes before allowing high speed Heat or Cool operation or allowing either un loader to load If Defrost is started this override will be ignored and the unit will go to the correct speed for De frost 4 1 3 Initial Engine Operation If a unit is started when the Engine Coolant Temperature is 79 F 26 C or below after the engine starts the unit will immediately go to low speed 4 cylinder operation until the water temperature reaches 79 F 26 C The CSMV will control suction pressure to 78 PSIG 5 3 Bars Max during low speed 4 cylinder operation Refer to Chart Section 4 7 Once the water temperature is greater than 79 F 26 C the unit will run at high speed 4 cylinder operation 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 cylinder cool operation and the CSMV will control to a maximum suction pressure of 27 PSIG 1 8 Bars The unit will continue in high speed 6 cylinder cool until the controlling temperature is 3 2 F 1 8 C away from setpoint The microprocessor will then follow the ladder logic on Figure 4 2 62 10683 4 2 4 2 START STOP OPERATION Start Stop is provided to permit starting stopping restarting ofthe engine
295. l 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 and until the ambient air temperature drops below 110 F 43 3 C 4 11 62 10683 4 4 8 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 setpoint 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 Defrost Initiation Before a defrost cycle can be initiated DTT2 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 DTT2 and SAT alarms are active then the RAT Return Air Temperature sensor must be below 45 F 7 2 C Once
296. l shut down except during cranking If the unit has cycled off in Start Stop mode and battery voltage drops below the selected voltage in 12 2 to the Configuration List the selectable range is 12 0 to 12 8 vdc 12 2 volts is the factory setting see 13 4 VDC 4 2 2 2 below the unit is automatically started in order to charge battery This restart criteria will override the Minimum Off Time and restart temperatures The unit will operate until all conditions required for an off cycle are again met 17 VDC ar Unit will shut down e The compartment temperature is at setpoint After the Minimum Run Time expires the unit will go into an Off Cyclewhen the compartment temperature is within 0 5 F 0 3 C of setpoint for setpoints in the Perishable range or is less than 0 5 F 0 3 C above setpoint for setpoints in the Frozen range 4 2 2 Restart A restart will be initiated when any one of the following conditions occurs a Engine coolant temperature drops below 34 F 1 C However if the coolant sensor alarm is active theunit will re start if the ambient air temperature drops to 32 F 0 C after the unit has been in the OFF cycle for 60 minutes b Battery voltage falls below the configured value See Configuration list 5 2 1 The selectable range is between 12 0 to 12 8 VDC The factory setting is 12 2 VDC c Compartment Temperature has exceeded Off Time Override Temperature compartment temperature is more than the selec
297. larm 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 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 8 29 for complete resistance chart See Note 6 10 000 Ohms 77 F 25 C 2 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 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 7 55 62 10683 NOT 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
298. larm should not come on Install new sensor 7 59 62 10683 NOT 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 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 Coolant Temperature sensor ENCT a Inspect Engine Coolant Sensor amp No damage to sensor connector No damage moisture or corrosion in connector b Check Engine Coolant Sensor Refer to Section 8 29 for complete resistance chart resistance See 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 Check remote sensor switch connector a Locate and inspect 10 way connector Connector must have cap on for optional sensors and switches No co
299. le will need to be on a Configuration PC card in order to install the IntelliSet parameters into the replacement microprocessor 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 62 10683 5 20 5 6 1 Microprocessor Replacement a If possible power the microprocessor up either using a PC mode jumper or by turning the START RUN OFF switch to the Run position If the microprocessor 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 ReeferMa nager PC Program Then scroll through the Data List and make note of the following from the MessageCenter e ID Number Unit Serial Number e Unit Model Number Engine Protect Hours e Switch On Protect Hours Engine Sleep Hours e Switch On Sleep Hours e High Speed Hours e Clutch Hours Start Cycles Date and Time 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 cont
300. lear 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 UL1 a Check resistance of UL1 coil Refer to Section 2 12 b Check amp draw of coil Use Component Test mode Section 5 2 2 to test Refer to Section 2 12 for amp values View current draw in the Unit Data list Refer to Section 3 13 A ET a Inspect UL1 and wiring No damage or corrosion 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 4 LED must be ON c Check voltage to front unloader Must be 11 VDC or higher across the 2 wires Check UL 1 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 62 10683 7 68 NO 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 O 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 t
301. ll 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 compartment This only applies to Frozen Setpoints in Start Stop operation This offset is the number of degrees below setpoint that the unit will run before cycling off This will allow for a lower average 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 setpoint 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 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 3 25 62 10683 FUNCTIONAL PARAMETER SELECTIONS DESCRIPTION DISPLAY IN ENGLISH UNITS The display will show temperatures and pressures in either English METRIC UNITS and PSIG or Metric C and Bars RESET PM HOURMETERS Maintenance hourmeters that have expired will appear in this list ENGINE If there are no active maintenance hourmeters this me
302. lter 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 Must be clear and unobstructed lli E f La li il ES ES E ES ES 62 10683 7 28 NO 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 and 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 Check Model Number a Verify that the
303. lutch engages properly no slip or unusual noises Check for unusual noises alternator fan shaft water pump idler and gearbox bearings etc Review Functional Parameters Download recorder data If required nter Trip Start in Micro 62 10683 8 4 8 3 PRIMING FUEL SYSTEM 8 3 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 8 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 Re
304. ly 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 in doubt remove the snubber restrictor with a hammer sensors and small punch then restart pretrip BE m W a 62 10683 7 88 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 SV 2 Refer to Section 2 12 b Check amp draw of SV2 Use Component Test mode Section 5 2 2 to test Refer to Section 2 12 for amp valu
305. m 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 r ance or shorted con NO nections Did you find and correct the condition System OK Is there 12V or higher at the Speed Solenoid or FSA NO v YES Check the speed solenoid or FSA gt and linkage for binding Did you find and correct the condition NO y Review the test results with your supervisor If necessary go to the beginning of the table and test again Figure 9 9 Micro Diagnostic Tree Cond 5 Unit Will Not Run In Low Speed 62 10683 9 16 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 on 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 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 operat
306. m 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 he es below as necessary 1 Check for alarms te Check for shut down alarms Alarm conditions must be corrected and the alarm s cleared to continue 62 10683 7 20 NO 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 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 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 9 1 thru Figure 9 4 There must be no LED flashing alarm codes occurring to continue 2 Check fuel level in tank MCCAIN Era a O O I UU Check for alarms a Check for the following alarms Alarm conditions must be corrected and the alarm cleared
307. maller range calibration of the CSP is not required 8 21 2 Testing Compressor Suction Pressure Transducer a Verify that the wiring to the transducer is correct See wiring diagram Section 10 b Power up the transducer circuit Place unit into PC mode Refer to Section 5 1 or place unit in Manual Start mode c 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 B and C The reading should be as shown in table be low 4X 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 for non ESC engines or ENSSN for engines with electronic speed control If this circuit is shorted to ground due to one of the men tioned components being defective or a worn wire the MessageCenter will show Suction Pressure 29 9inHg 1 Bar Discharge Pressure 0 Bar PSIG Engine RPM 0 Table 8 4 Compressor Suction Pressure Transducer PSB vage rsiGare votage PSN 30 2 04 35 2 38 40 2 72 45 3 06 50 3 4 55 3 74 60 4 08 was 97 0 0 5 0 34 15 1 02 20 1 36 Ones qi e 1 70 4 76 75 5 1 80 5 44 85 5 78 90 6 12 95 6 46 100 6 8 1
308. mbient 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 14 for more on the defrost mode 4 4 9 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 3 for more information on compressor unloaders Unloaders will use the differences of Controlling Temperature and setpoint as follows Mode 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 more than 2 7 F 1 5 C Control Te
309. me 15 Seconds Glow Time in Seconds STOP Engine Coolant Temperature Short Default Less than 32 F 0 C Apr snl 33 F to 50 F 1 C to 10 C GLOW 51 F to 77 F 11 C to 25 C SECOND Greater than 78 F 26 C ae ATTEMPT The second start attempt has five seconds of glow time added to 15 Seconds the time shown in the table The third start attempt will have 10 STOP 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 MAXIMUM 10 Seconds Checked at 2 Seconds FIRST ATTEMPT A VARIABLE 0 to 55 SECONDS GLOW HOMING CSMV Auto Start Sequence 4 1 62 10683 4 1 2 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 is 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 activated NOTE While the starter is engaged if the engine speed is less than 50 RPM for more than 3 seconds the SSR wil
310. me 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 O to 100 sensor is installed the low fuel level WARNING alarm 1 will come on when the level reaches 1596 or less and the unit will shutdown alarm 19 when the level reaches 10 NO YES YES This hourmeter will be displayed during the startup messaging sequence and will be in hour meter menu BIS Res TOTAL ENGINE BR NO This hourmeter will not be displayed during the startup messaging sequence and will be shown with the other meters and counters lists NO YES YES This hourmeter will be displayed during the startup messaging sequence and will be in hour meter menu DISPLAY TOTAL SWITCH ON HR NO This hourmeter will not be displayed during the startup messaging sequence and will be shown with the other meters and counters lists DIESEL RESET VALUE OFF OFF The Engine Maintenance hourmeter is Refer i Section 2 6 for oil change 59 TO 30 000 HRS turned off intervals 50 30 000 hrs The value selected here will be the number of hours between engine service inter vals SWITCH ON RESET VALUE OFF OFF The Switch On Maintenance hourmeter is 50 TO 30 000 HRS turned off 50 30 000 hrs The value selected here will be the number of hours between Switch On service intervals 5 5 62 10683 CONFIGURATION SELECTIONS DESCRIPTION PM 1 5 PM
311. me 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 setpoint changed Defrost Cycle Started or Main Power On etc d User Area Data The user or service technician is able to enter a comment into the DataRecorder using the ReeferManager program 3 31 3 18 3 Sensor and Event Data Sensors The following sensors may be recorded either with an averaged reading or snapshot e Return Air Temperature e Supply Air Temperature e Ambient Air Temperature e Defrost Termination Temperature 2 e Compressor Discharge Temperature e Engine Coolant Temperature e Compressor Discharge Pressure e Compressor Suction Pressure Battery Voltage e Battery DC Current Engine RPM e Remote Sensors 1 thru 3 Time Intervals The following intervals are available for sensor recording e 2 Minutes e 5 Minutes e 10 Minutes e 15 Minutes e 30 Minutes e 1 Hour e 2 Hours e 4 Hours 62 10683 DATA RECORDING CONTINUED Optional Sensors and Events In addition to the above Sensors and Events the DataRecorder also has the capabilities to record the following e Remote Temperature Sensor 1 e Remote Temperature Sensor 2 e Remote Temperature Sensor 3 Remote Switch 1 Remote Switch 2 e Door Switch e Fuel Tank Level 3 18 4 Data Downloading
312. meters are entered the micro will add the correct hours together and calculate the Total Engine Hours and Total Switch On Hours When the end of the 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 g Now press the Down Arrow key until SET TIME ap pears Press the key then the Up Arrow key to enter that menu 62 10683 44 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 h When MONTH appears press the key then the Up Arrow key The MessageCenter will begin to flash in dicating that it is ready to accept changes Use the Up or Down Arrow keys to scroll through the number list until the correct number of the current month ap pears Press the
313. model number on the Enter the correct number in the data list Refer to Section unit data label matches the model 3 13 number shown in the micro unit data list Check for proper voltage to the Engine Speed Control Unit ENSCU pin 22 based on the model Check for proper voltage with unit running a Ultima XTC and 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 O 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 harness a Inspect harness 8 control box No physical damage to harness connector pins amp terminals See wiring No damaged or corroded pins or terminals schematic b Check resistance of speed solenoid Refer to Section 2 12 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 12 Use Component Test Mode Refer to Section 5 2 2 to test Refer to Section 2 12 for amp values View current draw in the Unit Data List Section 3 13 7 29 62 10683 NO
314. mount of refrigerant is added e 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 3 62 10683 8 22 8 13 REPLACING THE COMPRESSOR 44 CAUTION Service mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating Refer to Section 5 2 3 AX 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 19 3 for more information on two way communication NOTE The service replacement compressor is sold without shutoff valves but with valve pads The valve pads should be installed on the re moved compressor prior to return shipping Customer should retain the original capacity unloader valves for use on replacement com pressor Check oil level in service replacement compressor Refer to Section 8 14 If compressor is inoperative and unit s
315. mp Screen a Pump down the unit by closing the king valve Refer to Section 8 9 1 b Remove insulation Presstite from expansion valve bulb and then remove bulb from suction line O 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 o 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 8 25 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 Q Open king valve and then check refrigerant level See Section 8 12 1 Check unit operation by running Pretrip Refer to Sec tion 3 3 8 18 2 Checking Superheat NOTE Do not adjust expansion valve unless abso lutely necessary Due to the time involved in adjusting the superheat replace the valve rather than adjusting it 8 18 3To Measure Superheat NOTE The expansion valve and bulb location are shown in Figure 2 7 R
316. mp 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 4 4 10SV1 Operation The SV1 valve will be open de energized whenever the system is operating in the Cool Cycle The 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 4 5SV2 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 open pressure settings are based on the model
317. mpressor 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 Check MOP of expansion valve 4 Manually test refrigeration system See note a Run Quick Check Must pass all tests Correct any problems found before proceeding 62 10683 7 90 ANO 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 10 for MOP values OR RAT minus 40 F 22 C Calculate suction pressure using a Temperature Pressure chart See Table 8 8 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 8 8 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 wiri
318. ms c Verify coil type voltage and frequency of old and new coil This information appears on the coil housing d Place new coil over enclosing tube and retainer and connect wiring e Check unit operation by running Pretrip Refer to Sec tion 3 3 oO 62 10683 8 26 8 15 3 Replacing Valve Internal Parts See Figure 8 21 a Pump down the unit Refer to Section 8 9 1 Front seat both service valves to isolate the compressor o Remove coil retaining cap if equipped and coil c Remove enclosing tube collar item 2 Figure 8 21 using installation removal tool supplied with repair kit item 3 d Check plunger for restriction due to a Corroded or worn parts b Foreign material lodged in valve c 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 f Remove supplied installation removal tool Install coil and voltage plate g Evacuate and dehydrate the compressor Refer to Section 8 11 Start unit and check unloader operation Refer to Section 8 15 1 Check unit operation by running Pretrip Refer to Sec tion 3 3 44 CAUTION Service mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating Refer to Section 5 2 3 2 8 16 REPLACING OR SERVICING CHECK VALVE A check valve allows the hot gas to travel in one direction only The function of the
319. n 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 Ifthe discharge pressure rises to 340 psig 23 1 Bar UL1 will energize and unload for the remainder of the de frost cycle If the discharge pressure rises to 350 psig the SV1 valve will de energize open for 1 second to reduce the discharge pressure Ifthe discharge pressure remains at 350 psig 23 8 Bar the SV1 valve may de energize open again ad much as twice a minute 4 13 62 10683 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 Cycle Engine Clutch OPEN CLOSE CLOSE LOW de ener de en de ener de ener ENGAGE UNLOAD UNLOAD 100 Open gized ergize gize gize energized energized energized 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 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 Refer to SV2
320. n 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 3 5 Test 10 Check Suction Modulation Valve CSMV This test is to ensure that the CSMV is opening and closing properly If suction pressure doesn t change as expected with CSMV closed then CHECK SMV alarm will be displayed Test 11 SV1 Cool Pretrip Only With the unit running in two cylinder Low Speed Cool the
321. n step 4 nonconden sibles are present Remove refrigerant using a refrigerant recovery sys tem Refer to Section 8 9 Evacuate and dehydrate the system Refer to Sec tion 8 11 Charge the unit Refer to Section 8 12 62 10683 8 23 SERVICING SOLENOID VALVES b Replacing solenoid valve internal parts 8 23 1 Solenoid Valve SV2 SV4 AX WARNING A CAUTION UNITS EQUIPPED WITH STAR TRAK TWO WAY COMMUNICATION CAPABILITIES MAY Do not over tighten or damage the enclos HAVE THE ABILITY TO BE STARTED OR ing tube assembly Torque to 17 ft pounds TURNED OFF REMOTELY REGARDLESS OF 2 4 Mkg Also make sure all parts are THE SETTING OF THE START RUN OFF placed on the enclosing tube in proper se SWITCH quence to avoid premature coil burnout The unit is controlled locally and there can a Replacing the Coil be no two way communication when the NOTE mode switch on the Remote Monitoring The coil may be replaced without removing the Control Box is in MAINTENANCE MODE n i Therefore when performing any work on efrigerant o the unit down AS i the unit place the mode switch in MAINTE 1 Unplug from wiring harness remove coil retainer NANCE MODE After the unit is serviced re and coil assembly turn the mode switch to REMOTE ON Re 2 Verify coil type voltage and frequency This informa fer to Section 3 19 3 for more information tion appears on the coil housing on two way communication 3 Place new coil over enclosing
322. nactive 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 steps 4 5 and 10 Totest electrical circuits when unit is without a glow crank switch locate the 3 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 do this 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 wil 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 5 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 po
323. nal Parameters All must be set for selectable values Reset microprocessor a Turn Start Run Off switch off for 30 Microprocessor powers up OK seconds then turn back on b Check for valid Functional Parameters Valid number is present in Functional Parameters List Alarm is cleared c Valid Functional Parameter s can not Replace microprocessor be entered See Note 1 a Clear the inactive alarms All alarms cleared 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 selectable values b Install new configurations using Verify that the current version of ReeferManager is being ReeferManager via serial connection used check for the latest version information on the or Configuration PC Card Information Center web site c Verify that the mo
324. nance 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 8 1 ME See Note 1 Ja Clear the inactive alarms 62 10683 7 102 NO 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 1 Check unit maintenance records a Schedule unit into service facility for Must be done soon maintenance 2 Perform maintenance a Perform appropriate engine amp unit Follow instructions on proper maintenance form maintenance a 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 8 1 4 See Note 1 a Clear the inactive alarms All alarms cleared NE Nw Bs a p 7 108 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 7 11 MICROPROCESSOR ALARMS 232 SETPOINT ERROR TRIGGER ON There is an error in the Setpoint that is stored in the microprocesso
325. nd 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 ES a Check fuel level in the fuel tank Add fuel as needed to the fuel tank 2 Check fuel level sensor E ETC Medi fuel level sensor amp connector No physical damage to sensor pins ETC Medi terminals No damaged or corroded pins in plug Check fuel level sensor pd Place unit in Manual Start mode see Note 4 Use Component Test Mode to eae the Run Tin pee e NOT START UNIT Refer to Section 5 2 2 BH 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 3 Check fuel level sensor calibration a Check fuel level sensor calibration See Section 8 5 Check circuits with test substitute sensor E a Substitute known good sensor and clear alarm Start unit and run for 30 seconds b Check to see if alarm re occurs A
326. nd the alarm cleared to continue Check clutch a Check resistance of clutch coil Refer to Section 2 12 b Check amp draw of clutch coil Use Component Test mode Section 5 2 2 to test Refer to Section 2 12 for amp values View current draw in the Unit Data list Refer to Section 3 13 3 Check clutch amp circuit a Inspect 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 4 LED 29 must be ON d Check voltage to clutch Must be 11 5 VDC or higher 4 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 7 67 62 10683 NOT 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 Follow the steps below until a problem is found Once a repair or correction has been made c
327. nded for the use of drivers or operators 62 10683 Table 3 1 Shutdown Alarms SHUTDOWN ALARMS SHUTDOWN ALARM ONLY or may be configured as SHUTDOWN see configuration list Section 5 2 1 O XA i 12 13 15 16 17 18 19 20 Maximum Compressor Alarms Optional 27 28 29 30 3i 32 35 39 4 51 53 56 57 58 6i 72 122 125 204 232 233 237 238 242 243 246 248 249 Mirprcesor amp mr X O oO 1 lf Alarms 122 and 123 are both active and setpoint is in the perishable range 10 4 F 12 C and higher the unit will shut down Otherwise alarm only 62 10683 3 18 3 13 UNIT DATA e e e e e e HEAT COOL DEFROST START STOP CONTINUOUS 200 4I45 F SETPOINT BOX TEMPERATURE PRESS 1 TO VIEW DATA MANUAL ALARM LIST START STOP SELECT DEFROST CONTINUOU o AN 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 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 ltem will remain in the MessageCenter for 10 seconds then the default message STATUS OK 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 i
328. ne compressor oil pump that may be purchased is a Robinair part no 14388 This oil pump adapts to a one U S gallon 3 785 liters metal refrigeration oil container and pumps 2 1 2 ounces 0 0725 liters per stroke when connected to the oil fill item 3 Figure 8 20 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 8 20 Purge the oil hose at oil pump Add oil as necessary Refer to Section 2 9 b Closed System Method 44 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 connection 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 t
329. nformation on these test modes Configuration Mode e Component Test Mode e Service Mode d To change one ofthe configurations bring the Config uration to change into the MessageCenter and press y TO SCROLL THEN TO SAVE will show in the MessageCenter for 10 seconds Then the se lected Configuration will flash showing the current value Press the UP or DOWN ARROW key to scroll through the list of available selections for this Config uration e Once a new value is showing in the MessageCenter press the key to save the selection The MessageCenter will stop flashing The new value is now in memory Press the UP ARROW key to continue to scroll through the Configuration list CONFIGURATION SELECTIONS DESCRIPTION UNIT SERIAL NUMBER Wu dil NEN PON i GLOW TIME LONG SHORT UNIT MODEL FAMILY ULTRA XTC ULTIMA XTC Pick one of these models from the X VECTOR series model family UNIT MODEL NUMBER NDL93N ABO NDL93P ABO NDL93R ABO NDL93S ABO NDL93S ABA NDL93U ABA NDL93V ABO This list contains many selections Only those covered by this manual are shown here Pick one of these models from the X series model family Units models are grouped into families The correct family must be identified for the correct model num ber to be displayed in the next selection The correct model number must be selected for proper operation and control The model number selected here can be
330. ng 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 a PC mode jumper 22 50180 01 is available This looks very similar to the Configuration jumper refer to Section 5 2 but has a 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 terminals C and E If the START RUN OFF switch is put into 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 44 WARNING Do not place the START RUN OFF Switch in the START RUN position or the unit will start 5 2 MICROPROCESSOR CONFIGURATION AND TECHNICIAN TEST MODES REMOVE JUMPER MODE c Turn the START RUN OFF switch to 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 50
331. ng 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 a Inspect SV2 coil amp connector pins amp No damage to coil terminals No damaged or corroded pins b Check resistance of SV2 Refer to Section 2 12 c Check amp draw of SV2 Refer to Section 2 12 Use ammeter Check SV2 wiring a Inspect harness amp control box See Notes 3 4 amp 9 connector pins amp terminals See No physical damage to harness wiring schematic No damaged or corroded pins Check SV2 current draw a Use Component Test mode Refer to Refer to Section 2 12 for normal current values Section 5 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 13 62 10683 7 54 ANO Steps ALARM CAUSE CORRECTIVE ACTION 7 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 will be used for any calculations RESET CONDITION Auto Reset when Ambient Air Sensor is in range or A
332. ng 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 2 Check fan belts a Check upper fan belt tension amp Refer to Section 8 7 for belt tensions condition No Glazing no cracking no slipping b Check lower fan belt tension amp Refer to Section 8 7 for belt tensions condition No Glazing no cracking no slipping 3 Check evaporator air flow See note 10 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 Check for Check SV2 Circuit Alarm rd B 3 D a Check for alarm 97 or P192 Alarm conditions must be corrected and the alarm cleared T lu im Ne Eee xj 5 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 refrigerant charge a Check for undercharged system See Level must be above lower sight glass Section 8 12 1 Checking Refrigerant Charge 7 Manually defrost unit a Defrost unit and terminate Typical defrost cycle time is 5 20 minutes automatically Suction pressure
333. nician 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 62 10683 Test 16 Check For Other Alarms That May Be Present Check for the following alarms Alarm Description 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 2 LOW ENGINE OIL LEVEL 3 LOW COOLANT LEVEL 18 LOW REFRIGERANT PRESSURE 27 HIGH SUCTION PRESSURE 28 CHECK REFRIGERATION SYSTEM 34 ENGINE FAILED TO STOP 36 CHECK COOLANT TEMPERATURE 51 ALTERNATOR NOT CHARGING 54 DEFROST NOT COMPLETE 55 CHECK DEFROST AIR SWITCH 59 DATALOGGER NOT RECORDING DATALOGGER TIME WRONG 71 BADF2 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 or PRETRIP FAIL IN TEST
334. noid and install the clip to the linkage rod b Low Speed Adjustment 1 Hold the speed lever against the low speed stop and check the RPM Adjust the low speed stop screw if necessary 2 Check engine speed using microprocessor data list 3 Check for proper operation by running Pretrip Re fer to Section 3 3 c High Speed Adjustment 1 Loosen but do not remove the 4 speed solenoid 1 Engine Block mounting nuts 2 OilPan 2 Turnthe jacking nut allowing the solenoid to move 3 Full Flow Oil Filter along the slots until the desired high speed is 4 Engine Oil Connection reached Tighten the solenoid mounting bolts and 5 Oil Pressure Switch verify correct high and low speed RPM 3 Check for proper unit operation by running Pretrip Figure 8 5 Lube Oil Flow Diagram Refer to Section 3 3 62 10683 8 8 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 8 6 5 Electronic Speed Control ESC Units begin ning with below serial numbers and ALL X2 units Ultra XTC KAV90910396 Ultima XTC KAV90910334 Refer to Section 10 for schematic wiring diagram Refer to Section 9 for ESC diagnostic alarms and diagnostic trees Figure 8 7 Electronic Speed Contro
335. not used at this time 62 10683 MessageCenter The MessageCenter is used to show messages Details of the messages are described in Section 6 1 MessageCenter Switch Descriptions START RUN OFF Switch START RUN ay The START RUN OFF switch is a 12 VDC lt input to the microprocessor When placed in OFF the START RUN position this switch activates the Control module To stop the unit move the switch to the OFF position 4X 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 19 3 for more information on two way communication 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 CRANK GLOW IS q NV 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
336. nu 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 NO HOURMETERS TO RESET When any maintenance hourmeter has timed out and preventative PM 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 setpoint 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 4 F 2 C Of Range Shutdown after 45 minutes the unit will shut down This 5 F 3 C setting determines how far away from setpoint the temperature must TF 4C move before the timer is started 4 F may be used for very critical temperature products 7 F may be used for less critical products The alarm may be turned off by selecting the OFF setting AIR FLOW NORMAL The NORMAL selection allows the unit to cycle from High Speed to HIGH Low Speed depending on how close the compartment temperature is to setpoint Some products generate a considerable amount of heat heat of respiration during transportation This frequently occurs with produce The HIGH selection can be used for these loads since con tinuous high air flow may be required to keep the entire load at a constant temperature The engine will remain in High Speed wh
337. nual 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 obtain 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 vapori
338. nually 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 1 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 12 2 Check AFAR wiring a Inspect harness amp control box See Notes 3 4 amp 9 connector pins amp terminals See wiring No physical damage to harness schematic No damaged or corroded pins 3 Check AFAR current draw a Use Component Test mode Refer to Refer to Section 2 12 for normal current values Section 5 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 13 7 53 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 93 CHECK START UP BUZZER 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
339. 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 HEAT 4 15 62 10683 4 5 1 Temperature Range Lock 1 8 2 The unit can be locked into Start Stop or Continuous Run operation for various setpoints Two ranges are available for setpoint range lock selection Each Range can be independently set to lock it s setpoint temperatures into either Start Stop or Continuous Run Each Range has its own selectable minimum and maximum temperatures which define the span of the range If some setpoint temperatures are contained in both ranges due to range overlap Range 1 will always have priority over Range 2 For example refer to following figure if Continuous Run operation is ALWAYS required whenever the setpoint is between 28 F and 55 F 2 2 C and 12 8 C Range 1 will be set for Continuous Run with a Minimum Temperature of 28 F 2 2 C and a Maximum Temperature of 55 F 12 8 C Should Continuous Run operation ALWAYS also be required with setpoints between 22 F 30 C and 0 F 17 8 C then Range 2 will be set for Continuous Run with a Minimum Temperature of 22 F 30 C and a Maximum Temperature of O F 17 8 C Any setpoint outside of Range 1 or 2 will allow changes between Start Stop and Continuous Run 62 10683 4 16 Range Lock 1 amp 2 Range 2 is set for 0 to 22 F Range 1 is
340. nutes 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 Check and compare compressor Suction 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 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 heads amp inspect Must be in good condition condition of all reeds amp gaskets Check compressor pistons and connecting rods a Check compressor pistons and Must be in good condition connecting rods See Refrigeration System Troublesho
341. nutes 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 Alarm 130 Check RPM Sensor a 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 the ENSCU Refer to Electronic Speed Control Diagnostic tables Figure 9 1 thru Figure 9 4 Was engine shut off manually a Check for external cause Correct problem Check for Bad F2 or F3 Fuse Alarm a Check for alarm 71 Alarm conditions must be corrected and the alarm cleared to continue 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 d Check fuel system check valve from Check valve must hold fuel and not leak back filter to injection pump Check Fuel Solenoid non ESC engines or Fuel
342. of the table amp test again with your super visor If necessary go to the beginning of the table amp test again Figure 9 3 ESC Diagnostic Tree 2 Long 3 Short LED Code 9 9 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 supervisor If necessary go to the beginning of the table amp test again Review results of above
343. 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 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 detected Test 4 i
344. olenoid Use Component Test Mode Section 5 2 2 to test Refer to Section 2 12 for amp values View current draw in the Unit Data list Refer to Section 3 13 Check fuel and speed actuator FSA ESC engines only a Check resistance of FSA Refer to Section 2 12 With FSA unplugged ohm spec is 3 4 ohms 10 b Check amp draw between MPQC4 amp Use Component Test Mode Section 5 2 2 to test terminal 13 and 15 of the ENSCU Refer to Section 2 12 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 2 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
345. ollowing 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 b Check the Micro Status LED near the PC card slot on the microprocessor It should be blinking continuous ly at the rate of one second on and one second off This is the normal heartbeat rate of the micropro cessor 5 17 c Ifthe Micro Status LED is blinking at the rate of 5 sec onds on and 5 seconds off the microprocessor 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 d If the Micro Status LED is not on at all check voltage to QC1 amp QC2 Also check for voltage from the START RUN OFF switch between QC2 and 5MPA1 Voltage readings should be 12 0 to 13 0 vdc If voltage and grounds check OK the micropro cessor may be dead and require replacement 62 10683 5 5 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 O e L e e e HEAT COOL DEFROST START STOP CONTINUOUS 200 3245 F SETPOINT BOX TEMPERATURE PRESS 1 TO VIEW SETTINGS Pb MANUAL ua aLarM List sTarT stop _ SELECT DEFROST Sarees DOJLA j ZA dl p pad 1 Press the SELECT key until PRESS 1 TO VIEW SET
346. om 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 desired 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 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 5 19 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 Once the PM hourmeters are activated from the Configuration List they can only be RESET for a new interval from the Functional Parameter List The PM hourmeters may be set or reset using either a PC or the keypad Reset is accessible from the Functional Paramet
347. ompartment b Remove evaporator bulkhead and back panel then spray coil with a mild detergent solution such as Oakite 164 or any good commercial grade automatic dish washer detergent such as Electrosol or Cascade and let the solution stand for a few minutes and re 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 O 62 10683 8 40 8 28 CONDENSER COIL CLEANING Remove all foreign material from the condenser coil by reversing the normal air flow Air 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 8 29 CONTROLLER SENSOR CHECKOUT An accurate ohmmeter must be used to check resistance values shown in Table 8 6 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 8 6 At least one lead from th
348. ompressor 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 in doubt remove the snubber restrictor with a hammer sensors and small punch then restart pretrip 62 10683 7 84 ANO Steps ALARM CAUSE CORRECTIVE ACTION P180 CHECK SUCTION MODULATION 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 ee 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 Porn below as necessary inn Check connector to the suction modulation valve Connector fits together tightly No moisture inside 2 Check operation of suction modulation valve lee 7 85 62 10683 NOT 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 RESET CONDITION Auto Reset if Pretrip mode is started again or Alarm may be manually reset via keypad or b
349. ompressor within its operating envelope 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 The process of fully closing the CSMV on startup is known as homing the CSMV When homing is complete the MessageCenter will display SETTING SMV XX The XX will count up to a predetermined percentage depending on ambient temperature and refrigerated compartment temperature The unit will then go through its normal start procedure 2 1 8 inch Nut Figure 8 30 Compressor Suction Modulation Valve CSMV 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 micro Looking at the 4 pin connector on the CSMV coil the wiring is as follows Table 8 5 CSMV Connections Connector Wire Color Winding Pin Pole A BLACK m 1A 1B B 2A 8 wE 0 oen 2A Each winding has a resistance of about 75 Q There is no common connection point between the two windings The reason this coil design is bipolar is that the microprocessor causes the valve to open by energizing the windings in a particular sequence and by reversing the polarity of the current through the windings in a specific sequence Energizing the windings with the correct polarity in the correct sequen
350. on between the card and the other device may not be performed correctly Retention of programmed data for extended periods 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 close by 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 Replacement Components Division b Display and Keypad MODE LIGHTS DISPLAY O 0 0 O O CON TINUOUS HEAT COOL DEFROST ALARM STAR T STOP 200 324 5 F SETPOINT BOX TEMPERATURE HEDERNE n ERES
351. on 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 Lie AAS f 8 i Solenoid Valve Valve Stem Gas Bypass Port Spring Guide Spring Piston Piston Bypass Valve Bleed Orifice OSON 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 4 4 9 for more information on Loaded Operation X e A CA CZA A N 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 5 Filter Drier The drier is a cylinder shell containing a drying agent and screen It is installed in the liquid line and functions to keep the system clean and remove moisture from the refrigerant 62 10683 2 3 6 Receiver Liquid refrigerant from the condenser drains into the receiver The receiver serves as a liquid reservoir when there are surges d
352. ons Oil pressure safety switch ENOPS defective Run relay RR defective Engine coolant temp ENCT defective Fuel solenoid defective Start Run Off switch defective Limited charging system operating time Battery condition Alternator belt loose broken Loose dirty corroded terminals or broken leads Excessively worn open or defective brushes Open blocking diode Regulator faulty Open isolation diode Open rotor field coil Alternator belt loose Loose dirty corroded terminals or broken leads Excessively worn sticky or intermittent brushes Faulty regulator Grounded or shorted turns in rotor Open grounded or shorted turns in stator Check Tighten Replace Replace Replace Engine Manual Replace Check Check 8 7 Check Repair Check Check Check Check Replace 8 7 Check Repair Check Check Check Replace Excessive charging rate Regulator leads loose dirty corroded terminals or as evidenced by battery wires broken Clean Repair requiring too frequent refilling or Defective regulator Check amp reading shows constant high amp charge Noisy alternator 62 10683 Defective or badly worn V belt Worn bearing s Misaligned belt or pulley Loose pulley 9 2 8 7 Replace 8 7 Tighten INDICATION ACTION TROUBLE POSSIBLE CAUSES REFERENCE SECTION 9 3 REFRIGERATION 9 3 1 Unit Will Not Cool Compressor malfunction Compressor drive defective 8 13 Compressor defective 8 13 Refriger
353. ontroller 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 Woublosheolfng reente SEGNOR ve 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 controller OFF and then back ON using the START RUN OFF switch 62 10683 3 16 3 12 VIEW INACTIVE ALARMS e HEAT O COOL 200 SETPOINT e DEFROST e e 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 say NO INACTIVE ALARMS for five seconds ALARM LIST id SELECT CONTINUOU i 2 If there are inactive alarms the display will be I and the alarm number and 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 within the Active and Inactive Alarm Lists combined The l
354. or 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 Check remote temperature sensor 2 a Inspect Remote Temperature Sensor 2 No damage to sensor amp connector No damage moisture or corrosion in connector b Check Remote Temperature Sensor 2 Refer to Section 8 29 for complete resistance chart resistance See Note 6 10 000 Ohms 77 F 25 C 3 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 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 7 65 62 10683 NOT 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 bac
355. 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 SK SRI UL1 FRONT UNLOADER UL2 REAR UNLOADER SUCTION ABOVE THE LINE UNLOADED PRESSURE BELOW THE LINE LOADED 80 00 90 00 100 00 110 00 120 00 130 00 F AMBIENT TEMPERATURE 4 25 62 10683 SECTION 5 TECHNICIAN INTERFACE 5 1 PC 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 22 01737 04 20 Long to the download port with the START RUN OFF switch inthe 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 7iwdvance 62 10683 Some of the things that you may want to use PC mode for are e Changing setpoint for the next load Changi
356. orque Requirements Non ESC Engine 0 c cee cee eee eens 8 44 Figure 8 34 Unidrive Torque Requirements Electronic Speed Control Engine 000 8 45 Figure 9 1 ESC Diagnostic Tree 1 Long 1 Short LED Code ooocccccccccc 9 7 Figure 9 2 ESC Diagnostic Tree 2 Long 1 Short LED Code ooccccccccccc esee 9 8 Figure 9 3 ESC Diagnostic Tree 2 Long 3 Short LED Code 0 cece eee 9 9 Figure 9 4 ESC Diagnostic Tree 2 Long 7 Short LED Code ooocccccccccc eee 9 10 Figure 9 5 Micro Diagnostic Tree Cond 1 Start Run Off Switch On Unit Does Not Operate 9 12 Figure 9 6 Micro Diagnostic Tree Cond 2 Start Run Off Switch On Unit Operates But Not Properly 9 13 Figure 9 7 Micro Diagnostic Tree Cond 3 Start Run Off Switch Off Unit Fails To Stop 9 14 Figure 9 8 Micro Diagnostic Tree Cond 4 Unit Will Not Run In High Speed 9 15 Figure 9 9 Micro Diagnostic Tree Cond 5 Unit Will Not Run In Low Speed 9 16 Figure 9 10 Micro Diagnostic Tree Cond 6 Data Recorder Data Download Problems When Using ReeferManager and a Download Cable Data File Analysis Problems Using Reports 9 17 Figure 9 11 Microprocessor Diagnostic Tree PC Card Problems 000 cece eee eee eee 9 18 Figure 9 12 Micro Diagnostic Tree Cond 8 Programming Problems With PC Cards 9 19 Figure 9 13 Micro Diagnos
357. orque the retaining bolt to 25 30 ft lb 3 5 to 4 1 Mkg 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 050inches 0 38and12 7mm If itis not remove entire clutch If gap is less than 0 050 12 7mm remove one of the fan shaft hub shims Ifthegapismorethan0 050 12 7mm add enough shims to reduce gap to approximately 0 020 0 51mm Shims CTD P N 50 00232 30 are 0 010 0 25mm each Reinstall clutch assembly g Installcushionclamponcoilharnessapproximate ly 3 from coil to prevent harness from rubbing on rotor h 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 i Reinstallthe upper drive belt and adjustidler to at tain a belt tension of 70 80 ft Ib 9 7 to 11 1 Mkg 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 Re connect negative battery cable 8 17 m Check unit for proper clutch operation 4 amp WARNING Do not start unit without installing the evapo rator panels as unit damage or body harm may result n Check for proper
358. orrection 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 Compressor Discharge Temperature 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 9 77 F 25 C See section 2 12 for Sensor resistance See Note 4 complete table of temperatures and resistance values Check compressor discharge temp 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 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 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
359. ot 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 12 ae Check cool light wiring E a Inspect harness amp control box See Notes 3 4 amp 9 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 12 for normal current values Section 5 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 13 62 10683 7 52 NO Steps ALARM CAUSE CORRECTIVE ACTION 89 CHECK REMOTE AUTO LIGHT TRIGGER ON 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 bu
360. ot correct the trouble replace necessary parts or gaskets Swelled or distorted gaskets must always be re placed 3 The air filter indicator is connected to the engine air intake manifold and its function is to indicate when the air filter requires replacing When a plugged air filter decreases intake manifold pressure to 20 500 mm Hg the indicator moves to the red line The air filter should be replaced and the indicator reset by pressing the reset button Air Filter Service Indicator 4 Service Procedure Stop the engine remove air filter Install new air filter 62 10683 8 6 7 Engine Crankcase Breather The engine uses a closed type breather with the breather line attached to the cylinder head cover See Figure 8 9 The breather assembly should be cleaned once a year or at every 2000 hours maintenance interval whichever comes first See Table 8 1 1 Screw 2 Breather Cover 3 Breather Valve 4 Breather Tube Figure 8 9 DI Engine Crankcase Breather 8 6 8 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 nominal 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 M value for the glow plug is 14 to 18 ft Ib 1 9 to 2 5 9 Checking for a Defective Glow Plug a The entire circuit may be tested using Component Test
361. ote 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 8 29 for complete resistance chart resistance See Note 6 10 000 Ohms 77 F 25 C 3 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 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 7 64 NO 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 1 Check Remote Temperature sens
362. oth Wires must be connected properly amp securely to each Compressor Unloaders component Check airflow through condenser coil See note 10 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 Pressures must be suction pressures with those shown on in the normal range for ambient amp box temperature the microprocessor controller conditions Check for refrigerant overcharge a Check refrigerant level in the receiver Level must be between upper amp lower sight glasses tank E Check discharge check valve a 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 Manually test refrigeration system See note 10 a Run Quick Check Must pass all tests Correct any problems found before proceeding Check system for non condensable a Check refrigeration system for No non condensable gas es may be present non condensable gas es b See Refrigeration Troubleshooting Section 9 3 7 High Discharge Pressu
363. oting Section 9 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 9 3 Refrigeration System Not Heating 7 19 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 7 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 shutdown 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 alar
364. ound but is shorted either within the Fuel Heater Relay coil itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset 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 12 Check fuel heater relay wiring a Inspect harness amp control box See Notes 3 4 amp 9 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 12 for normal current values Section 5 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 13 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 circu
365. ow 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 see Section 4 5 2 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 15 for additional information 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 run time has expired and the refrigerated compartment temperature is not yet down to setpoint the engine will be forced to high speed operation H
366. ower head should be set to 10096 Open when 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 specialtool P N 07 00375 00 to manual ly open the valve to 10096 before it is installed Torque the 2 1 8 nut to 35 to 40 ft lbs 4 8 to 5 5 Mkg Reconnect the CSMV connector to the engine har ness 44 CAUTION Service mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating Evacuate the low side of the refrigeration system Refer to Section 8 11 Open the king valve run the unit for approximately 10 minutes and initiate a pretrip 8 25 CHECKING DEFROST OR HEATING CYCLE NOTE DTT2 must be 40 F 4 4 C or lower before any checks can be made 8 25 1 Hot Gas Solenoid Valve SV1 8 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 Pressthe MANUAL DE FROST key to initiate defrost DTT2 must be at or below 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
367. ownload the light will blink once per second and will blink every 1 5 seconds when the download is complete A red PC Card Fault LED blinks 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 2 16 2 5 4 Handling of PC Cards PC cards can be used to upgrade software Section 5 4 2 download recorder data Section 5 6 1 set configurations and functional parameters Section 5 6 7 and install optional features While these cards are constructed for a rugged environment they are not intended to be stored in a 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 When a PC card is connected to an Advance controller or computer at temperatures outside this range data transmissi
368. ox 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 19 2 for more information on two way communication 62 10683 3 9 DEFROST 3 9 1 Manual Defrost DEFROST LIGHT e HEAT e COOL 1245 SETPOINT DEFROST Pb E e e START STOP CONTINUOUS OF BOX TEMPERATURE DEFROST CYCLE STARTED MANUAL i aLARMLIST ISTART STOP SELECT DEFROST soak vi SUAN 1 Press the MANUAL DEFR ST 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 DTT2 must be below 40 F 4 4 C OR SAT must be below 45 F 7 2 C in order to initiate Manual Defrost If both the SAT and DTT2 alarms are active then RAT is used for defrost initiation and it must be below 45 F 7 2 C When Defrost mode CANNOT be manually initiated CANNOT START DEFROST CYCLE is displayed in the MessageCenter This will occur when e DTT2 is above 40 F 4 4 C and SAT is above 45 F 7 2 C OR The engine has not run a minimum of15 seconds after starting OR The unit is in PC mode OR The unit is in Pretrip OR There is an active shutdown Alarm Check for any of the above conditions then run the unit to lower the DTT2 temperature to below 40 F 4 4 C or t
369. p cycle and verify that no further active alarms occur Also both Alarm lists should be cleared so that 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 between 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 4X 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 AX WARNING UNITS EQUIPPED WITH STAR TRAK TWO WAY COMMUNICATION CAPABILITIES MAY HAVE THE ABILITY TO BE STARTED OR TURNED OFF REMOTELY REGARDLESS OF T
370. p tests 11 12 and 18 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 Check fan belts a Check upper fan belt tension 4 Refer to Section 8 7 for belt tensions condition No Glazing no cracking no slipping b Check lower fan belt tension amp Refer to Section 8 7 for belt tensions condition No Glazing no cracking no slipping Check Wiring a Visually Inspect wiring to HPS SV4 amp Wires must be connected properly amp securely to each both Compressor Unloaders component 1 E E Check airflow through condenser coil a Inspect condenser 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 a I 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 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 gl
371. p the transducer circuit Place unit into PC mode Refer to Section 5 1 or place unit in Manual Start mode Check Voltage to transducer connector Voltage reading between A negative and B positive should be 5 0 VDC Check wire resistance between C output to micro processor and 1MP5 o e Place 5 0 VDC on transducer terminal B and 5 0 microprocessor Test voltage between B and C The VDC on transducer terminal A Disconnect C from the reading should be as shown in table below 2 2 2 3 3 3 3 Bars PSIG 0 0 0 68 10 1 36 20 2 04 30 2 72 40 3 4 50 4 08 60 4 76 70 0 5 44 80 1 17 0 250 25 T 0 6 12 90 1 18 7 275 MA 6 8 100 20 41 300 29 10 21 150 23 81 350 0 11 91 175 1 25 52 375 1 13 61 200 2 27 22 400 cip 1 15 31 225 2 30 62 450 C AR 5 1 6 2 0 7 1 3 0 8 1 7 9 9 0 T 1 1 3 5 y 9 2 3 5 7 4 1 WARNING The 5 0 VDC terminal B is common between the Compressor Discharge Pressure Transducer 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 men tioned components being defective or a worn wire the MessageCenter will show Suction Pressure 29 9inHg 1 Bar Discharge Pressure 0 Bar PSIG Engine RPM 0 8 20 3 Replacing Compressor Discharge Pressure Transducer a Pump down the compressor
372. pins wiring schematic 7 69 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION P148 CHECK SV1 CIRCUIT TRIGGER ON Normal Amps for the SV1 Circuit is 0 75 to 2 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 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 bad F4 or F6 fuse alarm a Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue 2 Check SV1 a Check resistance of SV1 Refer to Section 2 12 b Check amp draw of SV1 Use Component Test mode Section 5 2 2 to test Refer to Section 2 12 for amp values View current draw in the Unit Data list Refer to Section 3 13 3 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 10 c Check operation of SV1 FET 10 LED must be ON d Check voltage to SV1 Must be 11 VDC o
373. placed without removing the refrigerant or pumping the unit down 1 Remove top locknut spacer cup and nameplate 2 Disconnect wiring and remove coil 3 Replace coil by reversing steps 1 and 2 b Replacing Internal Components See Figure 8 29 44 CAUTION Service mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating AX WARNING UNITS EQUIPPED WITH STAR TRAK TWO WAY COMMUNICATION CAPABILITIES MAY HAVE THE ABILITY TO BE STARTED OR TURNED OFF REMOTELY EVEN IF THE START RUN OFF SWITCH IS IN THE OFF POSITION 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 19 3 for more information on two way communication Remove and store the refrigerant charge in an eva cuated container Refer to Section 8 9 2 Remove the top locknut spacer cup nameplate coil assembly and spacer 3 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 Remove seat disc from inside of body and check for obstructions and foreign material Plac
374. placement Components Group RCG 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 35 3 19 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 4 amp 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 62 10683 Sele Huon eek Alr Exchange ITEMS 6 7 AND 8 ARE NOT ACTUALLY To activate AutoFresh opera
375. 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 engine starts 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 7 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 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 ES a Check fuel level in the fuel tank Add fuel as needed to the fuel tank Check fuel level
376. position Does the engine continue to run There a problem with the StarTrak system Repair as necessary YE YES y S Replace Start Run Off switch Did you find and correct the condition M 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 v Y 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 v Verify the Run Relay de energizes when the Start Run Off switch is in the OFF position Replace Run z Relay Did Unplug fuel solenoid or fuel you find and T actuator Does eden x the condition Is the relay YES defective Check wiring for fuel NO l 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 operation 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 mechanic
377. pressor Slide compressor enough to clear nylon drive gear as shown in Figure 8 18 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 fromthe replacementis 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 ring at bottom of pis ton must be removed o Remove the complete High Pressure switch assem bly HPS See Figure 8 17 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 ure Switch and Sensor p 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 Mkg Install new gaskets on service valves and tighten bolts uniformly Refer to Section 8 30 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
378. product protection for extreme ambient temperatures Unit will return to START STOP when ambient comes back inside range CONFIGURATION SELECTIONS DESCRIPTION PRODUCTSHIELD ECONO MIN TEMP OFF or 20 F to 119 0 F 28 9 C to 48 4 C in 0 5 incre ments Default 119 0 F 48 4 C PRODUCTSHIELD ECONO MAX TEMP OFF or 20 F to 119 0 F 28 9 C to 48 4 C in 0 5 incre ments Default 119 0 F 48 4 C PRODUCTSHIELD ECONO DELTA T OFF 3 6 F to 27 0 F 2 C to 15 C in 0 5 increments OFF There is no lower limit for this parameter Refer to Section 4 5 2 for more information on this setting Select the lowest ambient temperature desired to activate ProductShield Econo If ProductShield Econo is Go To Cont this parame ter s upper limit is ProductShield Econo Max Temp minus 10 F 5 5 C If ProductShield Econo is Go To Cont default is OFF otherwise 119 0 F 48 4 C OFF There is no upper limit for this parameter Select the highest ambient temperature desired to activate ProductShield Econo If ProductShield Econo Install is Go To Cont this parameter s upper limit is ProductShield Econo Min Temp plus 10 F 5 5 C If ProductShield Econo Install is Go To Cont de fault is OFF otherwise 119 0 F 48 4 C OFF Delta T is not used in determining when the unit will go into Econo Go To Start Stop mode Select the desired delta T value for acti
379. que bolts to 28 to 30 ft Ib 3 9 to 4 1 Mkg making sure the plug for the vent is pointing up NOTE To aid in fan shaft alignment install two 3 8 16 X 1 1 2 studs bolts with heads cut off into the fan shaft mounting hub Once the first two fan shaft mounting bolts are loosely installed re move the studs and install bolts e Apply pipe thread sealant to barb fitting and install into vent hole Slide hose vent onto barb fitting f Apply caulk to the fan shaft seal and place on the fan shaft Place fan shaft seal ring clamp on seal and tighten 3 Bolts See Clutch Installation Step 8 18 to 22 ft lbs 2 5 to 3 0 Mkg Clutch Coil Figure 8 14 Fanshaft Assembly 62 10683 8 8 4 Blower Wheel Installation a Make sure key is properly placed in keyway Slide blower wheel and bushing onto shaft b Loosely attach blower wheel to bushing and slide as sembly forward until blower wheel touches pod This will set approximate clearance between blower wheel and pod c Loosely attach the nozzle cover to pod with retaining bolts Install SAT with at least 1 2 of sensor in the nozzle Reattach DTT2 Nozzle Cover Bolts Bushing Nozzle Cover Gasket Nozzle Cover Ring Clamp Blower Wheel Blower Wheel d Slowly and evenly torque blower wheel bushing bolts to 10 to 11 ft lbs 1 4 to 1 5 Mkg e Position nozzle cover so that blower wheel is cen tered in cover opening Torque nozzle cover
380. quirements 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 8 1 See Note 1 a Clear the inactive alarms All alarms cleared 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 1 Check unit maintenance records a Schedule unit into service facility for Must be done soon maintenance 2 Perform maintenance a Perform appropriate engine amp unit Follow instructions on proper maintenance form maintenance 3 Reset general maintenance hour meter a 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 8 1 4 See Note 1 a Clear the inactive alarms All alarms cleared 62 10683 7 100 ANO 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 record
381. r Maintenance with extended life coolant Cooling 1 Drain and flush cooling system 6 000 hours with Conventional amp selion 8631 System Coolant ection 8 6 f Oil And Filter Change Intervals Oil amp Filter Change Interval us API Class CG engine oil ing Mobil Delvac 1 engine oil a eee 0 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 inspections ofthe unit Failure to follow the recommended maintenance schedule may affect the life and reliability of the refrigeration unit 8 3 62 10683 8 2 PRETRIP INSPECTION The following pretrip inspection should be performed before every trip and at regular maintenance intervals BEFORE STARTING ENGINE PRETRIP Drain water from bottom of fuel tank Drain water from water separator on fuel List any Pretrip Alarms filter if applicable AFTER OPERATING UNIT FOR 15 MINUTES OR MORE Check radiator coolant level heck refrigerant level Check condenser coil for cleanliness heck compressor oil level Check engine oil level heck auto start stop operation Check condition and tension of belts Initiate defrost and allow to terminate Check all fan and idler bearings heck engine speeds OPERATE IN jean COOL AND From Microprocessor Unit Data List IMMEDIATELY AFTER STARTING Check oil lines and filters for leaks Ensure c
382. r adequate cooling The water pump V belt must Serial Number Cut Offs be adjusted periodically to provide maximum air flow Refer to Section 8 7 2 Ultra XTC KAV90910396 44 CAUTION Use only ethylene glycol anti freeze with inhibitors in system as glycol by itself will damage the cooling system Always add pre mixed 50 50 anti freeze and water to 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 Do the following to service the cooling system a 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 Drain coolant completely by removing lower radiator hose and radiator cap 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 Run engine and drain while warm Rinse system three times after it has cooled down Refill system with water
383. r corroded pins in plug 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 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 C 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 7 7 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 7 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
384. r higher across the 2 wires 4 Check SV1 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 62 10683 7 70 NO 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 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 bad F4 or F6 fuse alarm a Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue 2 Check SV4 a Check resistance of SV4 Refer to Section 2 12 b Check amp draw of SV4 Use Component Test mode Section 5 2 2 to test Refer to Section 2 12 for amp values View current draw in the Unit Data list Refer to Section 3 13 3 Check SV4 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 He
385. r 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 4 Glow Crank switch in Glow position OR use Component Test Mode to energize the Glow Plug Relay Refer to Section 5 2 2 LED 30 must be ON c Check Non Running Amps View Current Draw in Data list Refer to Section 2 12 Nu l T 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 glow plugs Must be 11 VDC or higher Check glow plug 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 Check Glow Plugs a Check amp draw of each glow plug Refer to Section 2 12 7 33 62 10683 NOT 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 mi
386. r 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 setpoint L3 fa Check Setpoint setting Must be between 30 C to 32 C 22 F to 89 6 F b Enter new Setpoint Mustbe between 30 C to 32 C 22 F to 89 6 F A seconds and then turn back on appears in the display B Vaid Setpoint can not be entered Replace microprocessor 3 3 See Note 1 __ 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 been made the active alarm should clear itself see reset condition above Operate the unit through the appropria
387. r of installs remain ing on the PC card will be shown ACTIVE This message will appear in the MessageCenter along with the current Intelligent 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 Micro Alarm has been erased This does not remove alarms from the data recorder ALL ALARMS CLEARED The list of active and inactive alarms in the Micro Alarm lists have been erased This does not remove alarms from the data record er ALL INFO LOADED REMOVE CARD All data has been loaded into the Micro from the PC card The card may be safely removed from the Micro 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 Micro 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 Micro 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 CALIBRATION UNSUCCESSFUL Attempt to calibrate discharge transducer failed C
388. r up there will be a 5 second delay before the starting sequence begins If the 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 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 1 1 Variable Glow Time REPEAT A 10 Seconds The glow time for the first start attempt will vary in duration based GLOW on engine coolant temperature and how the microprocessor is THIRD configured Short or Long as follows ATTEMPT Table 4 1 Glow Ti
389. range Not Used on Advance 10 24 AC Terminal 10 24 Ground Screw 1 4 20 Positive Output Cable Figure 2 11 Alternator and Regulator 62 10683 2 3 3 Compressor The compressor assembly includes the refrigerant com pressor suction and discharge service valves high pressure switch and the suction pressure transducer The compressor withdraws refrigerant gas from the evaporator and delivers it to the condenser at an in creased pressure The pressure is such that refrigerant heat can be absorbed by the surrounding air at ordinary temperatures 2 3 4 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 controlto unload the compressor during periods of reduced loads This provides closer temperature control reduces potential for top freezing and reduces power required to operate the compressor thus reducing fuel consumption a Major Working Parts e Solenoid and valve system e Spring loaded piston type bypass control valve e Spring loaded discharge check valve b Unloaded Operation Pressure from the discharge manifold Figure 2 12 item 15 passes through the strainer 9 and bleed orifice 8 to the back of the piston bypass valve 7 Unless bled away this pressure would tend to close the piston 6 against the piston spring 5 pressure With the solenoid valve 1 energized the solenoid valve st
390. rate 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 controller 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 a predetermined setting in 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 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 10 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 O F so that refrigerant flows from the receiver to the evaporator when needed EXTERNAL
391. re Check Compressor a Remove all Compressor heads and Must be in good condition inspect valve plates unloaders reed No broken or missing parts valves 8 gaskets 7 93 62 10683 NOT 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 8 8 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 steps below as necessary Check for ambient sensor alarm a 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 of actual temperature Check sy
392. re 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 3 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 system is operating in the Cool Mode 4 21 62 10683 4 6 OUTPUT OVERRIDES 4 6 1 Speed Control Solenoid SCS Overrides Speed Control Solenoid Overrides in priority order a High Ambient If ambient temperature is 120 F 48 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 If UL
393. re longer recharging periods If the running time is gradually increasing in Start Stop operation due to the battery requiring 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 4 3 CONTINUOUS RUN OPERATION In the Continuous Run mode the engine will not shut down except for shut down alarms or if the engine stalls Continuous Run operation is normally used for fresh produce and other sensitive product loads The Start Stop Continuous key is pressed to switch between Continuous Run and Start Stop operating modes NOTE The microprocessor may be locked so that the unit will always operate in Start Stop or in Continuous Run whenever the setpoint is within a specific range Refer to Section 4 5 1 Range Lock and Section 4 5 2 ProductShield Econo for additional information NOTE The unit will remain in low speed until water temperature reads 79 F 26 C in Continuous Run Mode Low Speed Startup can be changed from OFF to 255 minutes Refer to Functional Parameters in Section 3 15 4 5 62 10683 4 4 TEMPERATURE CONTROL 4 4 1 Perishable and Frozen Setpoint Ranges There are two ranges defined for setpoint a Setpoints above 10 4 F 12 C are considered Perishable b Setpoints of 10 4 F 12 C or below are considered Frozen gt Perishable ron Temperature Control
394. re turning on the alarm Once the refrigerated compartment temperature has moved the away from setpoint by the selected amount the Out of Range timer begins Ifthe alarm is configured for Alarm Only after 30 minutes the alarm will be activated If the alarm is configured for Alarm Shutdown after 45 minutes the alarm will be activated and the unit will shutdown In Sleep mode Pretrip Diagnostic Test mode Component Test mode or if the unit has a Door switch and the door has been opened the Out of Range alarm is not in use After exiting any of these modes or closing the trailer or rail car door the refrigerated compartment temperature must again come In Range of the setpoint before the Out of Range alarm can be activated In Defrost and in Start Stop Off Cycle the 15 or 45 minute timer does not count Once the unit leaves these modes and goes into a temperature control mode heat cool or null the timer will be reset for the full time allowing the unit either 15 or 45 minutes to bring the refrigerated compartment temperature into range before activating the Out of Range alarm If the unit is not heating or cooling correctly the Out of Range alarm may come on when The unit is in cool and RAT plus SAT divided by 2 is more than setpoint and delta T is not at least 10 F 0 56 C for 30 minutes The unit is in heat and RAT plus SAT divided by 2 is less than setpoint and delta T is 0 or less for 30 minutes 62 10683 2
395. ressor 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 4 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 4 Cylinders 2 Cylinders Ultima XTC and X2 2500 25 PSIG 40 PSIG 76 PSIG 19 PSIG 30 PSIG 70 PSIG dich pena 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 15 Bars 5 2 Bars 1 4 Bars 24Bars 4 1 Bars Low Speed Ultra XTC a X2 2100 31 PSIG 50 PSIG 76 PSIG 20 PSIG 40 PSIG 70 PSIG NM 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 4 8 MAXIMUM OPERATING PRESSURE MOP OVERRIDE HEAT AND DEFROST ONLY The microprocessor monitors the suction pressure of the refrigeration system and controls 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
396. rns clockwise Purge gauge lines Frontseat the receiver manual shut off valve king valve by turning clockwise Start unit and run in high speed cooling Place START RUN OFF switch in the OFF position when compressor suction pressure ap proaches 1 PSIG 0 07 Bar 44 CAUTION Do not allow suction pressure to go below 0 Psig Bar If the compressor does not pump down to 1 PSIG 0 07 Bar there may be a problem with the compressor reed valves or other internal compo nents See Section 8 13 Frontseat close by turning clockwise suction ser vice valve and the refrigerant will be trapped between the compressor suction service valve and the manual shut off valve king valve Check the manifold gauge pressure prior to opening the refrigeration system If the pressure rises the dis charge check valve may be leaking refrigerant back into the system Check and replace if necessary See Section 8 16 Before opening up any part of the system a slight positive pressure should be indicated on the pressure gauge When opening up the refrigerant system certain parts may frost Allow the part to warm to ambient temperature before dismantling This avoids internal condensation which puts moisture in the system After making necessary repairs leak test and evacu ate the low side of the refrigeration system Refer to Sections 8 10 and 8 11 Backseat manual shut off valve king valve and mid sea
397. roblem 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 7 56 NO Steps ALARM CAUSE CORRECTIVE ACTION 123 CHECK SUPPLY AIR SENSOR e 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 4 4 8 RESET CONDITION Auto Reset when Supply 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 1 Check Supply Air Temperature sensor SAT a Inspect Supply Air Sensor amp connector No damage to sensor No damage moisture or corrosion in connector
398. rol 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 j 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 k o Oo e Q gt o 2 T OA 5 6 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 used 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
399. roughly clean off oil compound with contact or brake cleaner if this occurs 62 10683 44 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 44 CAUTION Do not vapor charge R404a systems Only liquid charging through the receiver outlet King valve is acceptable 44 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 44 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 air and moisture will be drawn into the com pressor 62 10683 1 4 1 3 SAFETY DECALS e A DANGER uw KEEP CLEAR OF ROTATING BELTS o AND PULLEYS A 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
400. rrosion 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 7 60 NO 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 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 Wi
401. rt 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 Remove fan shaft from unit 8 8 3 Fanshaft Installation a Install two keys into the shaft keyways NOTE If itis necessary to drive the keys into place be sureto support the shaft while tapping the keys b Position the fan shaft so that the housing is in the nor mal mounting position with the shaft horizontal and the vent hole facing directly up Remove both pipe plugs 1 8 NPT from fan shaft 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 fan shaft housing and tighten Reinstall pipe plug on hub to prevent oil spillage Retaining Bolt LEFT HAND THREAD See Clutch Installation Step 6 25 to 30 ft lbs 3 5 to 4 1 Mkg Condenser Fan Hub Adapter Clutch Rotor Clutch Armature 10 to 11 ft Ibs 1 4 to 1 5 Mkg Spanner Nut 80 to 85 ft lbs 11 1 to 11 5 Mkg d Install the fan shaft into the unit with the four fan shaft mounting bolts and tor
402. ry restart value selected in the configurations See 5 2 1 Sleep mode is used generally 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 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 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 IntelliSet 31 IntelliSleep See Section 3 19 1 AX 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 B
403. s a Schedule unit into service facility for Must be done soon maintenance Perform maintenance a Perform appropriate engine amp unit Follow instructions on proper maintenance form maintenance Reset maintenance hour meter 1 3 a 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 8 1 Pp See Note 1 Pp a 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 a Schedule unit into service facility for Must be done soon maintenance 2 Perform maintenance EN Perform appropriate engine amp unit Follow instructions on proper maintenance form maintenance 3 Reset maintenance hour meter 2 Em 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 8 1 a See Note 1 Ja Clear the ina
404. s may be present non condensable gas es 62 10683 7 14 ANO Steps ALARM CAUSE CORRECTIVE ACTION 18 LOW REFRIGERANT PRESSURE TRIGGER ON A 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 5 2 1 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 fan belts a Check upper fan belt tension 4 Refer to Section 8 7 for belt tensions condition No Glazing no cracking no slipping b Check lower fan belt tension amp Refer to Section 8 7 for belt tensions condition No Glazing no cracking no slipping Check system pressures 3 Check refrigerant charge a Install Manifold Test Set and check and Suction pressure must be above
405. s 8 37 8 24 2 Replacing The CSMV Power Head issussssssssssese 8 38 8 25 CHECKING DEFROST OR HEATING CYCLE ssssssssssee een 8 39 8 25 1 Hot Gas Solenoid Valve SV1 amp SV4 Heating and Defrosting 0coooooccccooo 8 39 8 25 2 Defrost Air Switch DAS oooocoococcccocor hh 8 39 8 25 3 Electronic Defrost Timer 0 cc esse 8 39 62 10683 viii TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page 8 26 CHECKING CALIBRATION OF DEFROST AIR SWITCH sssssssee eene 8 39 8 27 EVAPORATOR COIL CLEANING ssssssssee eese n mn 8 40 8 28 CONDENSER COIL CLEANING sssssssssee ees nmn 8 40 8 29 CONTROLLER SENSOR CHECKOUT sssssssses eese hn 8 40 8 30 UNIDRIVE TORQUE REQUIREMENTS ssssssesesess e hn 8 43 8 30 1 Drive Gear pup A A EET A GPG ete Sh 8 43 UNIT TROUBLESHOOTING araka aan aaa a ky lut a Ex etu axes i eat 9 1 9 1 DIESEEENGINE 5 obe R6 DE RUE Rue x gae te uoi vate nie 9 1 9 1 1 Engine Will Not Start 2 0 0 ee mr 9 1 9 1 2 Engine Starts Then Stops 0 00 Ma E A ees nnn 9 1 9 1 3 Starter Motor Malfunction sssssssssssese e hh 9 1 9 1 4 Malfunction In The Engine Starting Circuit oooooccccccccccconcrrnn 9 2 9 27 ALTERNATOR sid eoo Ss toes ttes cC we oo s eo a oh e sa DE oat e 9 2 9 3 REFRIGERATION iri xev E aa da IASTES I RU REO PEH PIT 9 3 9 9 1 Unit WII NOE COOL sitas aei rara ete ite deseo Ile eee halk i EN
406. s Bena E UY Lie Sata ea ue 7 104 237 FUNCTIONAL PARAMETERS ERROR 0 0000 cece eese hn 7 105 238 CONFIGURATIONS 1 ERROR sssssssssese een mnn 7 105 242 DIS PRESS CALIBRATE ERROR sssssesesess ees n mn 7 106 243 SUCT EVAP CALIBRATE ERROR ssssssessesess eer n 7 106 246 EEPROM WRITE FAILURE 0 00 coa REIR IS ERIGI ERROROITURLUDCPeERLBUEU IS ERU 7 107 248 CONF MODE HPZ ERROR eu i eke wk he a EP lal RR EM eee p 7 107 249 MICROPROCESSOR ERROR 000 cece ete teen eee 7 108 cizi4 e cam UE 8 1 8 1 MAINTENANCE SCHEDULE sssssessseese ern 8 1 8 2 PRETRIP INSPECTION cin gue Ep Eee x pd peg uc iat 8 4 8 3 PRIMING F EL SYSTEM 02 nk xung Dev Emme ER ene eh we A a 8 5 8 3 1 Mechanical Fuel Pump i eiszkRe eR OE ER e LUERTIA CLER Rd 8 5 8 4 SERVICING FUEL PUMP oaair houaa rao a rte Mee breit recep redet rM 8 6 841 Mechanical PUMP zenna er reos ke UU exec res koe ee e UU E ce 8 6 8 5 FUELEEEVEE SENSOR c meer A TC edge dtes 8 6 8 6 ENGINE SERVICE AND COMPONENTS sssssssssee es hn 8 7 8 6 1 Cooling System tere p A ues E NER PLA Oe Rr nen UR 8 7 8 6 2 Testing The RPM Sensor 00 cece rr 8 7 9 6 3 Lube OM PINGS uo cri Rd HG RENE QENER lb ir ERI UUCLHEER D enu 8 7 8 6 4 Servicing The Speed Control Solenoid And Linkage Non ESC engines only 8 8 8 6 5 Electronic Speed Control Units beginning with below serial numbers and ALL X2 units 8 9
407. s 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 7 63 62 10683 NOT Steps ALARM CAUSE CORRECTIVE ACTION 133 CHECK REMOTE TEMP SENSOR 1 TRIGGER ON Remote Temperature Sensor 1 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 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 1 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 a Inspect Rem
408. s in alternator As a precau tionary measure disconnect positive bat tery terminal when charging battery in unit Connecting charger in reverse will destroy the rectifier diodes in alternator The alternator converts mechanical and magnetic energy to alternating current AC and voltage by the rotation of an electromagnetic field rotor inside a three phase stator assembly The alternating current and voltage is changed to direct current and voltage by passing 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 system voltage b Integral Voltage Regulator Operation 12 VDC The regulator is an all electronic transistorized device No mechanical contacts or relays are used to perform the voltage regulation of the alternator system The electronic circuitry should never require adjustment and the solid state active elements used have proved reliable enough to warrant a sealed unit The system is temperature compensated to permit the ideal charging rate at all temperatures POS OUTPUT RONA GRN Pr O NEGATIVE GRN OUTPUT O D EMULATION REGULATOR D Emulation O
409. s locked 5 Pressing UP or DOWN key will unlock that item and move to the next T5 data item Pressing the key will unlock the item and after 10 seconds the default message will be displayed 3 19 62 10683 Table 3 2 UNIT DATA Also appear in Configurations May or may not be displayed depending on functional parameter settings Return air entering evaporator air temperature Supply air leaving evaporator air temperature Ambient air entering condenser air temperature BU termination temperature Located on the center evaporator tube FUEL LEVEL 96 of fuel in tank This is only shown when 096 10096 sensor is config ured ON SUCTION MOD VALVE 96 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 SOFTWARE REVISION Revision of the software that is operating the microprocessor ID as entered by the user Trailer Car or Asset ID 4 HOURS TO ENGINE Number of engine hours until the next programmed engine maintenance MAINT 62 10683 3 20 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
410. s 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 26 FUNCTIONAL 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 Service 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 two sub menu selections will be available if YES available YES selects Sleep Mode In this mode the unit will operate only as needed to keep the engine warm and the battery charged There is NO TEMPERATURE CONTROL in Sleep Mode is selected The following Sleep Mode parameters were added in Software Version 04 07 00 WAKE UP TIME NO NO the unit will remain in Sleep Mode until it is taken out manually YES T
411. se Both readings within 50 RPM shown on display mM E 4 62 10683 7 82 P175 CHECK HIGH SPEED RPM 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 the steps below as necessary Check engine air intake system NE a Check air filter indicator Flag must not be visible c Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions 6 Check engine exhaust system Must be clear and unobstructed a Inspect the exhaust system 7 83 62 10683 NOT 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
412. sensor 0 fuel level Check fuel level sensor 0 E d fuel level sensor amp connector No physical damage to switch E d amp terminals No damaged or corroded pins in plug wires d Check for E WT at harness plug Voltage should be greater than 0 VDC and less than 5 between pins for BLACK SP24 VDC unless the probe is completely dry negative and WHITE E WT MP26 e Check E Ww opn G 0 Te ji ine wie TOM the Place Start Run Off Switch in OFF position prior to checking harness E Ww opn G 0 Te the for continuity Must be less than 10 ohms microprocessor m IMP Check fuel level sensor calibration a Check fuel level sensor calibration See Section 8 5 1 Check circuits with test substitute sensor a Substitute known good sensor and clear alarm Start unit and run for 30 seconds Alarm should not come on Install new sensor b Check to see if alarm re occurs wm b Check fuel level sensor operation Place START RUN OFF switch in START RUN position c Check for voltage at harness plug Voltage should be approximately12VDC between pins for BLACK SP24 negative and RED SPKS positive 62 10683 7 4 NO 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
413. should rise gradually during cycle 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 Additional steps on the next page 7 91 62 10683 NOT 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 the steps below as necessary 9 Manually test refrigeration system See note 10 a Run Quick Check Must pass all tests Correct any problems found before proceeding b See Refrigeration Troubleshooting Section 9 3 7 Low Suction Pressure a a Visually inspect valve Bulb must be clamped tightly on the suction line and insulated an Pm kinks restrictions or other damage a Visually inspect compressor suction Must be clean and unobstructed inlet screen for material Check expansion valve TXV a Visually inspect valve Bulb must be clamped tightly on the suction line and insulated b CheckMOPofvave RefertoSecion2410 O O e Verify that correct TXVis nuni Musthavecomectvave dChecks
414. signation e PERISH FROZEN MIN RUN TIME e PERISH FROZEN MIN OFF TIME e PERISH FROZEN OVERRIDE TEMP e PERISH FROZEN MAX OFF TIME FROZEN SHUT DOWN OFFSET TEMP CONTROL in one minute increments in one minute increments 3 6 F 2 C TO 18 F 10 C 11 F 6 C in 0 5 F or C increments in one minute increments 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 This determines the minimum length of time the unit will run every time the unit starts in Auto Start Stop modes This determines the 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 setpoint 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 wi
415. sition Manual Start mode See Note 4 More than 11 VDC positive and good ground c Inspect solenoid amp connector pins 4 No damage to solenoid or wires terminals No damaged or corroded pins Wires plugged in d Inspect harness control box No physical damage to harness connector pins amp anar See wiring No damaged or corroded pins schematic See Wiring schema Section 10 fe Check resistance of solenoid cc AN to Section 2 12 Check operation of solenoid Hp ae fuel solenoid harness 2 Inspect harness amp control box No physical damage to harness connector pins amp terminals See Wiring No damaged or corroded pins Schematic Section 10 10 Check fuel system Ea a Check fuel system prime No air in fuel system E 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 11 Check engine air intake system Em 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 12 Check for correct engine oil a Check for correct oil viscosity weight Refer to Section 2 6 for conditions Must be correct for ambient conditions NES engine exhaust system fa Inspect the exhaust system Must be clear and unobstructed DEEN Check engine Ja Check engine compression Compression must be above 400 PSIG 27 22 Bar
416. sition 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 no 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 8 29 for chart of resistances for different sensors When checking the Defrost Air Switch RPM Sensor non Electronic Speed Control ESC 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 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 Note 10 Some tests can only be conducted with the unit operating The unit may be started automatically by
417. six and SAT sensor alarms are active Unit will shut down cylinder cool 4 4 2 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 6 1 Pulldown or Pull up will be initiated in any of the following conditions 1 At engine start 2 Setpoint change 3 Operational mode change such as Start Stop Continuous Operation 4 Defrost termination 5 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 setpoint 6 Pretrip termination Pulldown or Pull up will end in the following conditions 1 For Continuous Run Mode Whenthe RAT and SAT are equally spaced above and below setpoint SAT Zu equals setpoint for setpoints below 60 F 15 6 C and both supply and return air sensors are good NOTE Temperature control is achieved by controlling engine speed compressor UL1 and UL2 unloaders and sole noid valves SV1 SV2 SV4 and the CSMV 62 10683 4 6 2 For START STOP Mode The selected Control Probe Temperature is within 0 5F 0 3C of setpoint NOTE When the system leaves Pulldown Cool or Pull up Heat modes it will enter UltraFresh 3 temperature con trol mode see Section 4 4 5 when the setpoint is between 10 4 F and 65 F 12 C to 18 4 C For set points at or below 10 4 F
418. sor defrost air switch suc tion modulation valve filter drier and receiver 2 3 1 Engine The diesel engine 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 The engine refer to Section 2 6 gives excellent fuel economy and has easy starting characteristics It is equipped with spin on lube oil and fuel oil filters for easier filter changes Engine Transducers and Sensors a Engine RPM Sensor ENRPM Non ESC engines only Provides micro 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 b Engine Oil Pressure Switch ENOPS This normally open switch allows the engine to operate when oil pressure is above 15 3 PSIG 1 02 0 2 Bars The switch will open and automatically stop the engine 5 seconds after pressure drops below 12 3 3 PSIG 0 84 Bar 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 c Engine Oil Level Switch ENOLS Optional ENOLS sets off alarm when oil level is low Located on the oil pan next to the oil fill d Engine Coolant
419. spect harness amp control box No physical damage to harness connector pins amp terminals 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 4 for units with GCS only For units without a GCS use Component Test Mode to energize the Run Relay Refer to Section 5 2 2 Battery voltage reading 12 13 VDC between wires in plug to Oil Pressure Switch when disconnected from the Switch 5A Check Fuel and Speed Actuator FSA amp circuit a Check Run 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 88 a Check Run Relay LED solenoid non ESC engines sj c Check fuel solenoid plunger Must be free to move 7 25 62 10683 NOT 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 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 occ
420. ss if the unit is cooling at a higher capacity or not NOTE If the unit is set for Continuous Run and ProductShield Econo is configured for GO TO CONTINUOUS the unit will remain in Continuous Run Oncethe micro detects that the above criteria have been met the unit will switch from Continuous Run to a Start Stop Off Cycle for the minimum run time as set in the Functional Parameter list During the Minimum Run Time the Restart Override Temperature can cause the unit to restart to protect the load temperature After the minimum run time has expired the unit will return to Continuous Run once the Return Air temperature is more than 3 6 F x2 C away from setpoint If the unit shuts down in Auto Start Stop it will remain shut down according to the pre programmed start stop parameters 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 time is longer The original activation conditions must then be met in order for the unit to return to ProductShield Econo Go to Start Stop While the unit is running the FreshProtect settings as selected in the Functional Parameter list will be effective When ProductShield Econo Max Temp is set for OFF and ProductShield Econo Min Temp is set for a temperature the ambient air temperature will be considered to be inside the range whenever the ambient air temperature is higher than the Min
421. ss of Air chute in good condition evap coil No damage to blower wheel Evap coil clean 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 i Check refrigerant charge a Check for undercharged system Level must be above lower sight glass 5 Perform pretrip check Any active alarms must be corrected and cleared before Check SV4 a Check SVA for leakage when closed Must not leak not leak 7 41 62 10683 NOT 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 Shut 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 fi
422. ssageCenter 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 Visually inspect unit a Is compressor turning with engine Compressor must turn with engine 2 Check system pressure 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 3 Manually test refrigeration system See note 10 a See Refrigeration Troubleshooting Must pass all tests PUn 9 3 System Will Not Pump Correct any problems found before proceeding own b Run Quick Check Correct any problems found before proceeding 62 10683 7 80 NO 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 speed
423. sssee ee n m 3 9 Qu SLEEP MODE ON costa pet te eee cir eee ie A EE Ee eet e 3 10 3 8 SLEEP MODE OFF 5a ecg ais ak ani 3 11 3 9 zBEEROST sida fein Os Ad ei acide nere ode od Gece ee aa t ds 3 14 3 10 TRIPS TART ri ai A A gere mors Mohs Bante phan Mackin ala ES 3 15 3 14 VIEW ACTIVE ALARMS re ae kee ices a Receta ble we 3 16 3 12 VIEW INACTIVE ALARMS imac Ram User eb une oe dee e epu EE a 3 17 3 19 UNIT DAT Art 2 Er zi Eb ESL epe er hd cs dulce or es 3 19 3 14 VIEW HOURMETERS 5 hiv tia EE A a aaa RP PUASTu T E ae 3 23 3 15 FUNCTIONAL CHANGE PARAMETERS 0occcccccccccc en 3 24 3 16 LANGUAGE SELECTION sssssesesess eer mh 3 29 3217 S TOPPING UNLF 5 5 tete scene ia 3 30 3 18 DATA RECORDING pes eR A et Be bct a 3 31 3 18 1 Microprocessor Information 0060 ccc ee mne 3 31 3 18 2 Data RECOMING ixi ad ERE RARO RERUFe A EERUIA d mbes red ui Ere Pd 3 31 3 19 9 Serisor and Event Data er ii Wades eo ee i Eee deir o aee c etus 3 31 3 18 4 Data Downloading arie r earan eE anA e hr 3 32 3 18 5 DataRecorder Power Up as coc cede eis HER eee ep Repub eme pe DE E OE P RE Re Edd 3 32 3 19 OPTIONS ec ED Fe ete eret tw eed 3 33 3 19 1 IntelliSet coi ea Ratatat Shit yeaa eda Vd REI ia tia 3 33 3 19 2 DataTrak for Advance Microprocessors oooocccccccccc enn 3 35 3 19 3 Two Way Remote Communication ssssssssssessee ees nn 3 35 3 19 4 AutoFresh Air Exchange ese vesc ERIS ideas 3 36 ENGINE AND TEMPERATURE
424. ssssssssess esee 8 28 8 18 2 Checking Superheat sssssussssssssssess les hh 8 28 8 18 3 To Measure Superheat oooocccocccc hee 8 29 8 19 CHECKING AND REPLACING HIGH PRESSURE CUTOUT SWITCH HPS 8 29 8 19 1 Replacing High Pressure Switch 0 er 8 29 8 19 2 Checking High Pressure Switch ooococoocccccccoccn en 8 30 8 20 COMPRESSOR DISCHARGE PRESSURE TRANSDUCER CDP ssuusssssess 8 30 8 20 1 Calibrating Compressor Discharge Pressure Transducer 000 e eee e eens 8 30 8 20 2 Testing Compressor Discharge Pressure Transducer oooooccccccccccc esee 8 30 8 20 3 Replacing Compressor Discharge Pressure Transducer 0 0c eee eee 8 31 8 21 COMPRESSOR SUCTION PRESSURE TRANSDUCER CSP 000 cee eee eee 8 32 8 21 1 Calibrating Compressor Suction Pressure Transducer 0 0 cece eee cence eee 8 32 8 21 2 Testing Compressor Suction Pressure Transducer 0 0 cece eee eese 8 32 8 21 3 Replacing Compressor Suction Pressure Transducer 00 cece eee ees 8 33 8 22 REPLACING RECEIVER SIGHT GLASS ASSEMBLY OR FUSIBLE PLUG 8 33 8 23 SERVICING SOLENOID VALVES niran aa eaa tenet eee eee 8 34 8 23 1 Solenoid Valve SV2 SV4 oo eens 8 34 8 23 2 Solenoid Valve SV1 00 ete he hn 8 35 8 24 COMPRESSOR SUCTION MODULATION VALVE CSMV 0 00 cee eee eee 8 37 8 24 1 CSMV Diagnostics crues ke RA Ea de Lea UR Rea TR C eae am DR cn
425. ssure leak test Refer to Section 8 10 b Essential tools to properly evacuate and dehydrate any system include a good vacuum pump 5 cfm 8m3H volume displacement P N 07 00176 11 anda good vacuum indicator such as athermocouple vacu um gauge vacuum indicator 07 00414 00 NOTE The use of a manifold gauge is not recom mended because of its inherent inaccuracy c Keep the ambient temperature above 60 F 15 6 C to speed evaporation of moisture If ambient temper ature is lower than 60 F 15 6 C ice might form be fore moisture removal is complete Heat lamps or al ternate sources of heat may be used to raise system temperature 8 11 3 Procedure For Evacuation And Dehydrating System NOTE Standard service hoses are not suitable for evacuation purposes a Remove refrigerant using a refrigerant recovery sys tem b The recommended method to evacuate and dehy drate the system is to connect three evacuation hoses as shown in Figure 8 16 to the vacuum pump and refrigeration unit Also as shown connect an evacuation manifold with evacuation hoses only to the vacuum pump electronic vacuum gauge and refrigerant recovery system c With the unit service valves closed back seated and the vacuum pump and electronic vacuum gauge valves open start the pump and draw a deep vac uum Shut off the pump and check to see if the vac uum holds This operation is to test the evacuation setup for leaks repair if nec
426. st be clean and tight b Cheek resistance of solenoid RefertoSedonzia Te Check resistance of starter motor Referto Section 2 12 SSS d Test amperage draw of starter 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 Check d Perform load test on battery Follow Check battery manufacturer s procedure 6 Check for correct engine oil a Check for correct viscosity for Refer to Section 2 6 conditions Must be correct for ambient conditions c Check SPK20 for voltage Must be 12 VDC 62 10683 7 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 Ma Check coolant temperature Ap radiator hose Check Engine Coolant Sensor a Check resistance of Engine Coolant
427. st read valid data Calibrate discharge pressure sensor a Calibrate Discharge Pressure Sensor Calibration successful 5 MR NNNM successfully calibrated s a Clear the inactive alarms 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 evaporator pressure sensor a Calibrate Suction vaporator Calibration successful Pressure Sensor b Suction Evaporator Pressure Sensor Replace microprocessor can not be successfully calibrated See Note 1 _ a Clear the inactive alarms All alarms cleared 62 10683 7 106 NO Steps ALARM CAUSE CORRECTIVE ACTION
428. st recent version of Check for the latest version of Advance Microprocessor microprocessor software is installed in software on the Information Center web site the controller PERA Install the latest version if necessary Reset microprocessor a 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 not be Replace microprocessor entered See Note 1 EE a Clear the inactive alarm All alarms cleared 7 105 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 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 discharge pressure reading __ a Check Discharge Pressure Reading Mu
429. stall J1 jumper This will eliminate StarTrak from the system START HERE Is unit equipped with StarTrak NO Is Micro Status NO nana ee 2 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 y the top of this shit Micro Status LED Micro Status LED is blinking N is blinking at 1 at 1 2 second ON amp 1 2 A second ON 4 1 second OFF ES second OFF i MAL M Inspect and repair poor Check the Glow Crank switch batten star connections at the micro and wiring for shorting Is the y 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 E th Y tori it IIA A nsure the operator is waiting Replace NO long enough by turning the Load current version Switch and y Start Run Off switch ON and of software from http ener Check voltage waiting 2minutes for the display www transcentral p between QC1 amp QC2 to come on Did you find and carrier com Did the Men SOHO Voltage should read correct the condition current version of bob Te 11 volts or higher software load correctly you find and Is voltage within range NO correct the problem
430. stem 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 Check SV1 operation See Section 8 23 2 Checking SV1 a Check the operation of the SV1 valve Must perform correctly test Por ies proceduie Correct any problems found before proceeding 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 a Remove compressor heads amp inspect Must be in good condition condition of all reeds amp gaskets 62 10683 7 94 NO 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 Once a repair or correction has been ma
431. sure proper oil level 8 25 62 10683 8 15 COMPRESSOR UNLOADER VALVE The compressor unloaders located on the compressor cylinder heads are controlled by the Advance Microprocessor Refer to Section 2 3 4 8 15 1 Checkout Procedure a Connect manifold gauges to the compressor suction and discharge service valves and start unit in cooling with the setpoint within 1 to 2 F 0 6 to1 1 C of the refrigerated compartment temperature Unplug both unloader coils The compressor should be operating with all six cylinders Note suction pres sure c Plug UL1 front unloader in Note discharge and suc tion pressures the suction pressure should rise approximately 3 PSIG 0 2 Bar and the discharge Bae drop approximately 5 15 PSIG 0 35 to 1 05 Bars d Unplug UL1 and note pressures Suction pressure should drop and discharge pressure should rise by the same amounts they changed in step b above e Repeat steps c amp d for UL2 rear unloader At the end of the test plug both unloaders back in oO NOTE If either unloader coil energizes and the suction and discharge pressures do not change the un loader assembly must be checked 8 15 2 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 8 21 Check unloader coil resistance with an ohm meter Correct resistance should be between 7 5 and 10 5 oh
432. t is available for you to look at 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 FET LED Board LED Cool Light Heat Light Defrost Light COOL LIGHT OFF IN X MINS poaz E HEAT LIGHT OFF IN X MINS in 8 DEFROST LIGHT OFF IN X MINS Unioader 1 roni Unioader 2 rear svi sv2 Clutch Relay QHROFFINXMNS O Speed Relay SROFFINXMNS RunRehy AROFFINX MINS o 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 Sva SV4 OFF IN X MINS EINER a NOTE Electronic speed control modules can not be tested through the microprocessor Refer to Section 9 4 1 for Troubleshooting guide for units with Electronic Speed Control Engines 5 11 62 10683 5 2 3 Service Mode 44 CAUTION Service mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating NOTE Unit START RUN OFF switch MUST be in START RUN position to keep unit in Service mode If the switch is turned OFF
433. t 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 12 Check auto light wiring a Inspect harness amp control box See Notes 3 4 amp 9 connector pins amp terminals See wiring No physical damage to harness schematic No damaged or corroded pins Check auto light current draw a Use Component Test mode Refer to Refer to Section 2 12 for normal current values Section 5 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 13 90 AUTOFRESH AIR EXCHANGE RELAY TRIGGER ON AutoFresh Air Exchange circuit to the relay coil is shorted The 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 ma
434. t is shorted either within the UL1 itself or to a positive wire UNIT CONTROL 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 Check UL1 Front unloader coil a Inspect UL1 Unloader coil amp terminals No damage to coil No damaged or corroded pins b Check resistance of coil Refer to Section 2 12 __ Check amp draw of coil Refer to Section 2 12 Use ammeter 2 Check UL1 unloader coil wiring a Inspect harness amp control box See Notes 3 4 amp 9 connector pins amp terminals See wiring No physical damage to harness schematic No damaged or corroded pins 3 Check UL1 current draw a Use Component Test mode Refer to Refer to Section 2 12 for normal current values Section 5 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 13 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 to ground but is shorted either within the UL2 itself or to a
435. t suction service valve Start the unit in cooling and check for nonconden sibles Check the refrigerant charge Refer to Section 8 12 1 NOTE Store the refrigerant charge in an evacuated container if the system must be opened be tween the compressor discharge valve and re ceiver Whenever the system is opened it must be evacuated and dehydrated Refer to Section 8 11 62 10683 8 18 8 9 2 Removing The Refrigerant Charge Connect a refrigerant recovery system to the unit to remove refrigerant charge Refer to instructions provided by the manufacture of the refrigerant recovery system 44 CAUTION Service mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating Refer to Section 5 2 3 8 10 REFRIGERANT LEAK CHECKING 4X 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 19 3 for more information on two way communication a If the system was opened and repairs completed leak check the un
436. tallation processes will not begin until the CSMV is completely closed which will delay the actual process for about 45 seconds 44 CAUTION The display and MessageCenter may behave differently during the 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 Micro in PC mode Refer to Section 5 1 or place the START RUN OFF switch in the START RUN position E 2 Insert a Program PC card into the PC card slot CAUTION 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 t To Cancel Old SW to Load 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 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 t
437. te modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check model number a Check Model Number in Must be a valid Model Number from Configuration List microprocessor b Enter correct Model Number From Configuration List select correct Model Number 2 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 Replace microprocessor entered 3 See Note 1 a Clear the inactive alarms All alarms cleared 62 10683 7 104 NO 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 the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check functional parameters a Check Functio
438. ted Off Time Override Temperature Functional Parameter of 3 6 F to 18 F 2 C to 10 C from setpoint above setpoint in the frozen range The factory setting is 11 0 F 6 1 C 4 3 62 10683 d The Minimum Off Time Has Expired The Minimum Off Time has expired and the compartment temperature has moved away from setpoint by more than 3 6 F 2 C The Minimum Off Time allows the unit to remain off for ex tended periods of time maximizing fuel economy The Minimum Off Time is selected in the microprocessor Func tional Parameter list Referto Section 3 15 Settings may be for 10 minutes to 90 minutes in one minute intervals The factory setting is 20 minutes During the Minimum Off Time the microprocessor continually monitors the compartment temperature If the tem perature should go beyond the Off Time Override Temperature the unit will restart regardless of how much Off Time remains The Off Time Override Temperature is selected in the microprocessor Functional Parameter list Refer to Section 3 15 This can be set for 3 6 F to 18 F 2 C to 10 C in 0 5 increments After the Minimum Off Time the unit will restart when the compartment temperature goes beyond 3 6 F 2 0 C of setpoint for the Perish able range or above 3 6 F 2 0 C of setpoint for the Frozen range e 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 en
439. tem whenever remov ing refrigerant When working with refrigerants you must comply with all local government envi ronmental laws U S A EPA section 608 8 1 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 62 10683 Table 8 1 Maintenance Schedule ACTION 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 radia
440. ter NULL Band while in either Continuous Run or Start Stop the control temperature must be less than 1 5 F 0 8 C above setpoint 4 To exit NULL Band and enter HEAT the control temperature must be more than or equal to 1 8 F 1 C below set point 5 To exit heat and enter NULL Band the control temperature must be less than 1 5 F 0 8 C below setpoint b Null Band Operation Null Band consists of 1 Pulsed Null Mode Operation Reduced capacity is produced between the Heat and Cool Modes by a mode known as Pulsed Null This mode is nota constant operating mode but only operates for 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 Band 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 Band is varied by adjusting the pulse rate Cool Pulsed Mode Engine Clutch OPEN OPEN CLOSED ENGAGE UNLOAD UNLOAD Refer to CSMV Control Null Pulsed Mode Engine Clutch OPEN OPEN OPEN ENGAGE UNLOAD UNLOAD Refer to CSMV Control 62 10683 4 10 Heat Pulsed Mode Engine Clutch Refer to SV2 CLOSED eae OPEN LOW ENGAGE UNLOAD UNLOAD Refer to CSMV Control Section 4 5 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 un
441. th 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 steps below as necessary Check for engine stalled alarm 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 3 Check Engine Speed Sensor ENSSN ESC engines Only a Inspect circuit from ENSCU terminal 3 No damage to unit to micro connection 2MP18 amp No damage moisture or corrosion in connector connector b Compare actual engine RPM with Must be 20 RPM those shown on the display using hand Must be a steady reading held tac
442. 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 setpoint 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 18 1 Microprocessor Information The microprocessor Information that is available to be recorded is as follows e DataRecorder Setup Sensor Being Recorded Logging Intervals Events and Sensors e DataRecorder Time Clock Date Time e Setpoints And all setpoint changes e D Number e Unit Serial Number e Unit Model Number e Current System Mode e Functional Parameters e Controller Configurations 3 18 2 Data Recording The DataRecorder data comes from four general categories of information a Microprocessor Information as described in Section 3 18 1 above b Sensor Data This information is recorded at predetermined intervals as a 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 interval and whether snapshot or averaged readings are preferred Snapshot readings of sensors are also taken at the ti
443. the temperatures are below these values defrost may be initiated by any of three 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 15 Functional Change The Defrost Timer may be setfor 1 5 3 0 6 0 or 12 0 hour intervals When the unit has run for the selectedamount of time a defrost cycle will be initiated 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 increments counts time only when the engine and compressor are running and the DTT2 is be low 40 F 4 4 C or the SAT is below 45 F 7 2 C When the START RUN OFF switch is turned off 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 then 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
444. the unit exits Service mode and closes CSMV to 0 open and de energizes UL1 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 19 3 for more information on two way communication 62 10683 Scroll through the Main Menu then press the key when SERVICE MODE appears in the MessageCenter ENTERING SERVICE MODE will appear in the MessageCenter and OFF will be displayed instead of the setpoint and compartment temperature Once the CSMV is 100 open RECOVER LEAK CHK EVAC MODE 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 8 When the refrigeration system is evacuated the system pressure will go into a deep vacuum Once this occurs the MessageCenter will change to EVAC CHARGE MODE The position of the CSMV and UL1 does not change in this mode Following the evacuation as refrigerant pressure is introduced into the s
445. tic Tree Cond 9 Programming Problems With MicroProgrammer 9 20 LIST OF TABLES TABLE NUMBER Page Table 2 1 Model Chart 0 0 cece cc nnn ren 2 1 Table 2 2 Additional Support Manuals 0 00 cece es hn 2 1 Tabl 2 3 Ename Data er eor A E AA A E E aaa T cipe MR 2 22 Table 2 4 Compressor Data cantes Ev I ead eee ei es ee ep eee US 2 23 Table 2 5 Refrigeration System Data 0 cette hen 2 23 Table 2 6 Safety Devices xcceteresru ick iudice kr a a 2 24 Table 2 7 Component Resistance and Current Draw 0 00 eects 2 25 Table 3 1 Shutdown Alarms ooococccococcnc eh rn 3 18 Table 3 2 Unit Data ius rt het trt mr ARR er Re eae eer ee NE 3 20 Table 3 3 Functional Parameters o co res crana reii a re eee eee meh 3 25 Table 4 1 Glow Time c ira Mees PEN eed Bee ret eee ate Feb ue ep E 20s 4 1 Table 4 2 Battery Voltages vus ette OU tego e Re ge dee Re t ate ec ee Oden abet dee 4 3 Table 433 EreshlProtect uoces secte ade de die e regt 4 21 Table 4 4 Suction MOP iiis Ru eR Vane HENS Gi FA ec EU Ree he ec ATE 4 24 Table 8 1 Maintenance Schedule oooooccccccccccc ehe 8 2 Table 8 2 Belt Tension See Figure 8 11 2 cece nn 8 10 Table 8 2 Compressor Discharge Pressure Transducer 00 ee cece esses 8 31 Table 8 3 Compressor Discharge Pressure Transducer 2000 e cece teen eee 8 31 Table 8 4 Compressor Suction Pressure Transducer 1 2 0 0
446. till 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 8 11 If compressor does not operate frontseat both suction and discharge service valves and remove refrigerant charge from compressor Refer to Section 8 9 2 a Disconnect negative battery cable b Remove the two rear compressor bracket mounting bolts compressor shockmount end c Block up engine d Back out suction and discharge service bolt valve flange by two complete revolutions and leave threads engaged e Break seal between service valves and compressor and remove bolts from valve flanges f Remove fuel filter bracket if necessary from the compressor bell housing g Disconnect wiring to unloader valve assemblies Compressor Discharge Temperature Sensor CDT Compressor Discharge Pressure Transducer CDP Compressor Suction Pressure Transducer CSP and the wiring to the high pressure cutout switch HPS Identify wiring and switches if necessary See Figure 8 17 h Remove 10 bolts from the engine compressor bell housing PA COMPRES EC 6 0 sor O F Figure 8 17 Press i Disconnect ground strap from frame Remove Suction Pressure Transducer from suction line j k Attach sling or other device to the com
447. tin ue with the next section 5 6 6 Engine And Switch on Hourmeters Via Reef a b e erManager PC Program Start the ReeferManager program Go to the Serial Operations Tab Click on DataRecorder Microprocessor Setup but ton In the upper left menu bar click on MicroprocessorTools gt Set New Micro Hours At this screen enter the hours that were recorded in step b of Section 5 6 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 reaches 25 hours no further changes are allowed Your computer may now be disconnected and turned off or you can continue setting up the configurations 5 23 5 6 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 turning the START RUN OFF switch to the START RUN posi tion OK to place in Manual Start Operation if de sired or by inserting a PC mode jumper into the download port Insert your Configuration PC card into the PC card slot in the m
448. tinuous 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 setpoint is between the minimum amp maximum temperatures for that range see below CONTINUOUS The unit will always operate in Continuous Run whenever the setpoint is between the minimum amp maximum temperatures for that range see below 62 10683 CONFIGURATION SELECTIONS DESCRIPTION 22 F TO 89 6 F Select the lowest temperature desired for either RANGE 1 2 MINIMUM TEMP RANGE 1 2 MAXIMUM TEMP MIN SETPOINT MAX SETPOINT AUTO FRESH AIR EXCHANGE AUTO FRESH AIR DELAY S S PARAMETERS REMOTE TEMP SENSOR 1 3 Optional NOTE Sensor s on DataRecorder must also be set DOOR SWITCH Optional NOTE Sensor s on DataRecorder must also be set 62 10683 30 C to 32 C in 0 1 incre ments MES 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 22 F TO 89 6 F 30 C to 32 C in 0 1 incre ments NOT INSTALLED STANDARD SETPOINT 0 48 HOURS IN 1 HOUR INCREMENTS TOGETHER SEPARATE ON OFF SWITCH NOT INSTALLED OPEN SWITCH OPEN OPEN SWITCH CLOSED 5 8 Range 1 and or Range 2 Select the highest temperature desired for either Range 1 an
449. tion the AutoFresh Air SHOWN ONLY LOCATIONS ARE INDICATED Exchange configuration needs to be set See Section 5 2 1 A second configuration AutoFresh Air Delay 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 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
450. tion can change to Econo Continuous Run or High Air 3 If the Minimum is set to OFF and the Maximum is set to 90 F 32 2 C and the ambient air temperature falls above 90 F 32 2 C the unit operation can change to Econo Continuous Run or High Air 4 If both the Min and the Maxare setto OFF ProductShield Econo Go To Cont and ProductShield High air can not operate as there is no range for the ambient to fall outside of ProductShield Delta T Examples Settings can be used for ProductShield Econo Go to Start Stop and Product Shield High Air When OFF is selected delta T is not used as criteria for entering into one of the ProductShield modes When a value is selected for delta T the delta T will be used in addition to the ambient temperature range in determining when to allow the unit to go into a ProductShield mode In ProductShield Econo Go to Start Stop the delta T must be lower than the value selected in order to enter the mode 2 In ProductShield High Air the delta T must be higher than the value selected in order to enter the mode 3 Delta T settings are not used with ProductShield Econo Go to Continuous Run Oo 62 10683 4 20 4 5 4 FreshProtect Supply Air Control FreshProtect operates between setpoints 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 setpoint and criteria
451. tion 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 5 2 2 to beginning of the table verify operation Did you find and correct amp test again the condition NO Y NO Y Use this manual to check for correct operation Did you find and correct the condition NO y Download data recorder amp review unit operation Did you find and correct the condition NO y 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 i 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 9 6 Micro Diagnostic Tree Cond 2 Start Run Off Switch On Unit Operates But Not Properly 9 13 62 10683 START HERE Is the unit equipped with StarTrak Turn the Start Run Off switch to the OFF
452. tire load stays within safe temperature ranges the Maximum Off Time may be used to force the unit to restart Maximum Off Time is selected in the microprocessor Functional Parameter list This may be set for OFF or 10 minutes to 255 minutes in one minute intervals When the Maximum Off Time ex pires the unit will restart regardless of any change in compartment temperature The factory setting is OFF NOTE The unit may remain in low speed for 10 minutes Factory Setting after engine start up when in Start Stop Mode High speed delay can be set from Off to 255 minutes in one minute increments Refer to Functional Parameters Section 3 15 TIP While the unit is running the status of the unit battery and engine coolant temperature can be readily checked by reading the Battery Voltage in the Data List If O K appears after the voltage reading battery voltage battery charging amps and engine coolant temperature are sufficient to allow the unit to cycle off If O K does not appear then one or more of these conditions have not been met and the unit is not ready to cycle off 4 2 3 Start Stop Indicator To indicate that the unit is in the Start Stop mode the Start Stop LED indicator and Engine Auto Start lights on the light bar will be illuminated 4 2 4 Failed To Start Auto Mode If the unit fails to start after three start attempts the Alarm A31 FAILED TO START AUTO MODE will appear in the MessageCenter and the Alarm
453. to properly install the 04 05 00 or 04 06 00 software Earlier versions of MicroProgrammer should be discarded MicroProgrammer ONLY RUNS ON Windows 95 98 It will NOT RUN on Windows 2000 or XP Computer Preparation t is important to set up the PC that will be used with MicroPro grammer 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 62 10683 a Oo e Q 2 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 Micropro grammer 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 wantto load this will be a bex file by clicking once on it to highlight it 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 Turn the START RUN OFF switch to the START RUN position Wait for the Main Display and Messa geCenter to power up Click on th
454. to provide a fuel efficient temperature control system and then restart the engine when needed Refer to Section 4 2 for more detailed information on Start Stop mode Start Stop and Continuous operation may be tied to the setpoint 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 5 2 62 10683 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 3 6 CONTINUOUS RUN OPERATION e HEAT e COOL 200 SETPOINT e DEFROST e ALARM CONTINUOUS RUN LIGHT START STOP CONTINUOUS 4I45 F BOX TEMPERATURE CONTINUOUS RUN MODE SELECTED PESIMA MANUAL DEFROST 75 1 Press the START STOP CONTINUOUS key until the CONTINUOUS RUN Light on the controller illuminates
455. top Examples requires thatthe ambient temperature go INSIDE the range in order for ProductShield mode to be activated The following examples apply in situations where all other Start Stop conditions have been met 1 If the Minimum is set to 30 F 1 1 C and the Maximum is set to 40 F 4 4 C and the ambient air temperature falls between these temperatures the unit operation can change to Econo Start Stop 2 If the Minimum is set to 30 F 1 1 C and the Maximum is set to OFF and the ambient air temperature is above 30 F 1 1 C the unit operation can change to Econo Start Stop 3 Ifthe Minimum is set to OFF and the Maximum is set to 40 F 4 4 C and the ambient air temperature falls below 40 F 1 7 C the unit operation can change to Econo Start Stop 4 If both the Min and the Max are set to OFF unit operation can change to Econo Start Stop at any ambient temper ature b ProductShield Econo Go To Continuous Run and ProductShield High Air Examples Both require that the ambient temperature go OUTSIDE the range in order for ProduceShield mode to be activated 1 Ifthe Minimum is set to O F 17 8 C and the Maximum 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 or High Air 2 If the Minimum is set to O F 17 8 C and the Maximum is set to OFF and the ambient air temperature falls be low O F 17 8 C the unit opera
456. top 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 9 1 ESC Diagnostic Tree 1 Long 1 Short LED Code 9 7 62 10683 START HERE Verify unit starts go into 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 Check for high resistance or an open between NO ENSCU terminal i v pisi Using jumper wire ch
457. tor If there is a problem with the connector and there are no remote sensors or switches in the unit the connector may others terminated and insulated with heat shrink P156 CHECK BATTERY VOLTS 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 62 10683 7 76 ANO 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 42 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
458. tor condenser fin surface System 2 Check antifreeze concentration 3 Check water pump 4 Check water temperature sensor functions 2 6 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 8 6 6 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 operation Check Charging 1 Check alternator brushes and replace if necessary Check System 2 Check alternator output 2 12 62 10683 8 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 8 6 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 Hou
459. ts 3 in every other hole of adapter and take up evenly on the bolts until the 5 16 18 x 1 lg bolts engage engine flywheel Apply thread sealer Loctite 262 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 lb 3 87 Mkg Place V belt on the gearbox sheave and adjust belt tension as indicated in Table 8 2 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 8 13 Removing V Belt from Engine Adapter Drive Sheave 62 10683 8 8 FANSHAFT ASSEMBLY SEE FIGURE 8 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 4X 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
460. uctShield Temperature Ranges o ccccccccccconccc enn 4 20 4 5 4 FreshProtectt Supply Air Control 0 0 0 0 cece e n 4 21 4 6 OUTPUT OVERRIDES tn edie Det iE RH Le Hee ees 4 22 4 6 1 Speed Control Solenoid SCS Overrides 0 0 cece esses 4 22 4 6 2 Unloader Control Priority UL1 amp UL2 oooccccccccccoccrcn III 4 23 4 7 MAXIMUM SUCTION OPERATING PRESSURE COOL ONLY ssssssssesess 4 24 4 8 MAXIMUM OPERATING PRESSURE MOP OVERRIDE HEAT AND DEFROST ONLY 4 24 4 8 1 Suction Pressure Operation 00 ccc hn 4 25 TECHNICIAN INTERFACE 2 1 9 6 a RI 5 1 5 1 PCMODE DOWNLOAD PORT ssssssesse ehh hs 5 1 5 2 MICROPROCESSOR CONFIGURATION AND TECHNICIAN TEST MODES 5 2 5 2 1 Configuration Mode oooococcococcnc ehh 5 3 5 2 2 Component Test Mode o occccccccccccr eens 5 11 5 2 3 Service MOJO A A LEA er RE DIEA PM punt 5 12 5 8 DOWNLOADING DATA WITH THE PC CARD sssssssesee ee rh 5 13 5 4 INSTALLING NEW SOFTWARE rerne e teen hh 5 14 5 4 1 Software Version Numbers 0 000s cece tenet eee eens 5 14 5 4 2 Using The Program PC Card 0 cece eens 5 15 5 4 8 Using MicroProgrammer oocooococonco eet hmm nnn 5 16 5 4 4 Troubleshooting Software Loading Problems 0 00 cece cece eene 5 17 5 5 RE SETTING PM PREVENTATIVE MAINTENANCE HOURMETERS 5 18 5 6 ADVANCE MICROPROCESSOR REPLACEMENT 8 CONFIGURATION SETUP
461. ue to load changes in the system as a 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 bulls eye sight glasses for the observation of liquid level and a pressure relief valve 2 3 7 Transducers and Sensors a Compressor Suction Pressure Transducer CSP Provides micro with suction pressure information to be displayed recorded in the DataRecorder and used to control the refrigeration system lt cannot be calibrated It is located near the oil pump on the compressor b Compressor Discharge Pressure Transducer CDP Provides micro with discharge pressure information to be displayed recorded in 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 micro with 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 higher the CDT limits are increased to 340 F 171 C for three minutes d Compressor Suction Modulation Valve CSMV The CSM
462. uit will not be shorted to ground but is shorted either within the Alarm Light itself 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 12 LT Check alarm light wiring E a Inspect harness amp control box See Notes 3 4 amp 9 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 12 for normal current values Section 5 2 2 to test actual current View current draw in the Unit Data list Refer to Section draw of the circuit 3 13 62 10683 7 50 NO 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 bu
463. unit isn t running The engine is not allowed to start when the Micro is in Component Test mode From the Main Menu select Component Test mode and press Use the UP or Down arrow keys to scroll through the list when y TO SCROLL THEN TO SELECT appears in the MessageCenter Press to select the component you wish to test For example if the Cool Light is selected the Cool Light on the Light Bar will come on and COOL LIGHT OFF IN 5 MINUTES will appear in the MessageCenter The minutes will count down to O at which time the Cool Light circuit will be de energized and the MessageCenter will display the last component tested The test may be stopped at any time by turning the START RUN OFF switch to the Off position or by pressing and holding the key for six seconds Should you need more than five minutes the timer may be reset tofive minutes anytime during the test by pressing the key The timer 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 To select another component to test press the UP or DOWN Arrow keys to select another component and press to select To go to Service mode or Configuration mode select Main Menu and press The only keys that operate during Component Test mode are the ALARM and SELECT keys The alarm lis
464. unit operation by running Pretrip Refer to Section 3 3 8 9 PUMPING UNIT DOWN OR REMOVING RE FRIGERANT CHARGE NOTE To avoid damage to the earth s ozone layer use a refrigerant recovery system whenever removing refrigerant When working with refrigerants you must comply with all local government environ mental laws U S A EPA section 608 44 CAUTION Service mode MUST be used whenever re moving refrigerant charge refrigerant leak checking or evacuating Refer to Section 5 2 3 4 amp 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 19 3 for more information on two way communication 62 10683 8 9 1 Pumping Down The Unit In order to service the components downstream of the king valve and back to the compressor the unit can be pumped down in the standard manner a pou 2 x Backseat suction and discharge service valves turn counterclockwise to close off gauge connection and attach manifold gauges to valves Open valves two tu
465. uperheatofvave RefertoSecion2t0 UC5d mer kinks restrictions or other damage a Visually inspect compressor suction Must be clean and unobstructed inlet screen for material 62 10683 7 92 NO 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 8 8 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 Check fan belts a Check upper fan belt tension amp Refer to Section 8 7 for belt tensions condition No Glazing no cracking no slipping b Check lower fan belt tension amp Refer to Section 8 7 for belt tensions condition No Glazing no cracking no slipping Check wiring a Visually Inspect wiring to SV4 amp b
466. ure with 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 seat the King Valve until the suction pressure reaches 5 psig 3 Correct any problems before proceeding bar then shut the engine off 62 10683 7 96 NO Steps ALARM CAUSE CORRECTIVE ACTION P203 CHK DISCHARGE CHECK VALVE TRIGGER ON Refrigerant is leaking backwards through the Discharge Check Valve e 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 See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue alarm s with e below as necessary 1 Check discharge check valve 2 Test Discharge Check Valve for Must not leak leakage 2 Manually test refrigeration system See note 10 Must Ee ee all tests NE Run pL Check pU any Ee ee found before proceeding M Check and compare compressor Suction Pressure must have the same reading on gauge amp suction pressure with pressure shown on micro display on the
467. urs Continue with the steps below as necessary Check if unit has electronic speed control flash code a Check for flash codes on the Engine Refer to Electronic Speed Control Diagnostic tables Speed Control Unit ENSCU Figure 9 1 thru Figure 9 4 PE b Check for voltage at ENSCU terminal Must be above 11 5 VDC 13 IET c Check for ground at ENSCU terminal No damage or high resistance 19 Check starter relay circuit a Check operation of starter solenoid START RUN OFF switch in START RUN position Manual relay Start mode See Note 4 Relay contacts closed when crank switch is ON b Check relay socket amp terminals No signs of discoloration from overheating No 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 i Al f Check voltage to starter motor Must be above 10 VDC while cranking Check Fuel and Speed Actuator FSA amp circuit a Check Run Relay LED LED 28 must be ON E b Check for 12 VDC on the Run Relay Must be 0 VDC circuit d Check ENSCU terminals 13 amp 15 for Must be 12 VDC voltage e Check FSA plunger a Inspect starter and wiring No damage or corrosion Wiring and battery cable mu
468. urs Continue with the steps below as necessary Check Compressor Discharge Temperature sensor CDT a 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 8 29 for complete resistance chart resistance See Note 6 100 000 Ohms 77 F 25 C Check compressor discharge 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 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 7 58 ANO Steps ALARM CAUSE CORRECTIVE ACTION 126 CHECK FUEL SENSOR CIRCUIT TRIGGER ON The Low Fuel Shutdown is configured as a 0 to 100 sensor and the fuel level reading in the data list is less than 2 for 30 seconds UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when fuel level is sensed above 4 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 fou
469. us 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 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 Section 7 2 When you are finished making repairs run the unit through a pretri
470. us Run START STOP When the setpoint is set between Range 1 Minimum and Maximum Temperatures the unit is set to operate only in Start Stop 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 When the setpoint is set between Range 2 Minimum and Maximum Temperatures the unit is set to operate only in Continu ous Run START STOP When the setpoint is set between Range 2 Minimum and Maximum Temperatures the unit is set to operate only in Start Stop RANGE 2 MIN TEMP This is the lower limit for Range 2 RANGE 2 MAX TEMP This is the upper limit for Range 2 T T T 3 21 62 10683 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 This 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 62 10683 3 22 3 14 VIEW HOURMETERS e e e e e e HEAT COOL DEFROST START STOP CONTINUOUS 200 345 F SETPOINT BOX TEMPERATURE
471. ust be O VDC for all units running 4 Check engine RPM a Check actual engine RPM using hand Refer to Section 2 6 held tachometer Adjust engine linkage setting as needed b Compare actual RPM with those Both readings within 50 RPM shown on display 5 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 engine exhaust system a Inspect the exhaust system Must be clear and unobstructed 7 81 62 10683 NOT 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 the steps below as necessary 1 Check speed solenoid amp linkage on non Electronic Speed Controlled ESC engines or thefuel and speed actuator on ESCengines a Check speed
472. vation of ProductShield Econo PRODUCTSHIELD HIGH AIR OFF OFF ProductShield High Air is OFF ON ON ProductShield High air is ON PRODUCTSHIELD HIGH AIR MIN TEMP OFF or 20 F to 119 0 F 28 9 C to 48 4 C in 0 5 F or C in crements Default 119 0 F 48 4 C OFF or 20 F to 119 0 F 28 9 C to 48 4 C in 0 5 incre ments Default 119 0 F 48 4 C OFF 3 6 F to 27 0 F 2 C to 15 C in 0 5 increments OFF 20 F to 32 0 F 28 9 C to 0 C in 0 5 C or F incre ments OFF START STOP CONTINUOUS PRODUCTSHIELD HIGH AIR MAX TEMP PRODUCTSHIELD HIGH AIR DELTA T PRODUCTSHIELD WINTER xx RANGE 1 2 LOCK 5 7 OFF There is no lower limit for this parameter Refer to Section 4 5 2 for more information on this setting Select the lowest ambient temperature desired to activate ProductShield High Air OFF There is no lower limit for this parameter Refer to Section 4 5 2 for more information on this setting Select the highest ambient temperature desired to activate ProductShield High Air OFF Delta T is not used in determining when the unit will go into Econo Go To Start Stop mode Select the desired delta T value for activation of ProductShield High Air 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 Con
473. ve 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 Determine what Remote Switch 1 is controlled by a Remote Switch 1 may be connected to Find and locate Remote Switch 1 a trailer or rail compartment door or some other device and used to remotely control the unit Check to see if trailer or rail compartment side or rear door is open or if the device that Remote Switch 1 is connected to is set to trigger the alarm a Inspect trailer or rail compartment Trailer or rail car compartment door s must be closed doors 3 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 Nu E EN MMC T La a 62 10683 7 42 ANO 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 con
474. vice versa This allows maximum product protection while providing for fuel savings depending on ambient conditions When the unit is set for Continuous Run ProductShield Econo allows the unit to run in Start Stop when e ProductShield Econo configuration is set to GO TO S S See Section 5 2 1 AND e The unit has run in Continuous Run for a minimum of either15 minutes or the Minimum Run Time as selected in the Functional Parameter list whichever time is longer AND e The ambient temperature falls within a pre programmed temperature range AND e The unit is not already running in ProductShield Winter mode See Section c below The operator can also optionally pre program a maximum evaporator coil temperature differential delta t between the return air and supply air sensors as an additional criteria for switching to Start Stop if the Econo Delta T configuration is NOT OFF The unit must bring the delta t below this setting before going to Start Stop if this option is chosen By setting this value for a relatively low temperature 4 to 6 F 2 2 to 3 3 C once the delta T reaches this level the indications are that the product is probably cooled close to setpoint as the unit is producing a low delta T which is an indication that not much heat is being removed in order to maintain the Return Air Temperature By setting this value for a higher value 8 15F or by leaving the setting OFF the unit will be able to cycle into an Off Cycle regardle
475. w 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 UL2 a Check resistance of UL2 Refer to Section 2 12 b Check amp draw of UL2 Use Component Test mode Section 5 2 2 to test Refer to Section 2 12 for amp values View current draw in the Unit Data list Refer to Section 3 13 Check UL2 amp circuit a Inspect UL2 and wiring No damage or corrosion Connector fits together tightly no moisture inside b Check operation of UL2 FET 22 START RUN OFF switch in START RUN Manual Start Operation See Note 4 LED must be ON c Check voltage to UL2 Must be 11 VDC or higher across the 2 wires Check UL2 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 7 79 62 10683 NOT 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 Me
476. will begin to rise to a minimum of 250 PSIG 17 0 Bars within 15 to 20 minutes 62 10683 8 36 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 follow ing method a Verify the solenoid coil has proper voltage and is en ergized in heating and defrosting b 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 c 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 d 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 andthe receiver pressure will re main 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 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 other 8 24 COMPRESSOR SUCTION MODULATION VALVE CSMV The purpose of the CSMV is to control suction pressure maintain the c
477. y ten minutes until the refrigeration system is warmed up and the refrigerated compartment temperature is less than 45 F 7 2C b 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 Be ginning 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 b 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 If the system appears to be overcharged Remove re frigerant through the king valve to correct refrigerant level d Ifthe refrigerant system appears to be undercharged Add refrigerant through the king valve 8 12 2 Partial Charge 44 CAUTION Do not vapor charge R 404A 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 a Place drum of refrigerant on scale and note weight Backseat discharge and suction service valves and install a manifold gauge set Purge l
478. y 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 SV4 alarm a Check for alarms 79 P150 Alarm conditions must be corrected and the alarm cleared to continue 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 SV4 operation Unit must be running in Heat Cycle See Note 10 See Section 8 23 1 Checking SV4 a Set unit to run in high speed cool After 60 seconds note suction and discharge pressures b Energize SV4 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 Discharge pressure must rise slightly Manually test refrigeration system a Run Quick Check Must pass all tests Correct any problems found before proceeding 62 10683 7 86 NO Steps ALARM CAUSE CORRECTIVE ACTION P182 CHECK SV1 VALVE TRIGGER ON Discharge pressure did not decrease when SV1 was de energ
479. y voltage reading 12 13 VDC between wires in plug Check oil level switch a Drain oil level to approximately 2 8 to 3 4 quarts 3 8 liters low Remove switch b Visually and physically inspect upper Must be securely fastened to center rod and lower float stops 62 10683 7 6 ANO 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 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 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 Check Engine Coolant Level switch a Inspect engine coolant level switch amp No physical damage to switch connector pins amp terminals No damaged o
480. yboard and enhance functionality 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 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 44 CAUTION Under no circumstances should anyone attempt to repair the Logic or Display boards Should a problem develop with either ofthese components contact your nearest Carrier Transicold dealer for replacement QC5 CLUTCH RELAY K3 GROUND STRAP PC CARD FAULT LED RED 1MP WHITE PC CARD SLO 2MP BLACK PC CARD STATUS LED GREEN MICRO STATUS LED EN GRE S 3MP GREY RUN RELAY K2 QC4 LED28 F3 7 5A SPEED RELAY K1 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 C
481. ystem once both the suction and discharge pressure both rise above 5 PSIG 0 34 Bar the microprocessor will close the CSMV to 0 and de energize UL1 When the CSMV is 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 turned Off then On 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 reenter making sure that RECOVER LEAK CHK EVAC MODE is displayed in the MessageCenter before performing any of these services To exit Service mode at any time press and hold the key for three seconds EXITING SERVICE mode will then appear in the MessageCenter When exiting Service mode the microprocessor closes the CSMV to 096 and de energizes UL1 5 3 DOWNLOADING DATA WITH THE PC CARD 1 Place the Micro in PC mode Refer to Section 5 1 or place the START RUN OFF switch in the START RUN position 2 Insert a Download PC card into the PC card slot on the front of the microprocessor Be certain that the instruction label is facing the Caution label Do not force card into slot Hold the Download PC card at the end opposite the plug end Do not squeeze the card in the middle while inserting 3 The Message
482. ze 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 ce Neate lt EVAPORATOR Be NN Ly A BYPASS RECEIVER CHECK A VALVE HEAT EXCHANGER LIQUID LINE VIBRASORBER COMPRESSOR DISCHARGE CHECK VALVE LIQUID LINE SERVICE VALVE z FILTER N C DRYER SUBCOOLER pay a gt VIBRASORBER CONDENSER Figure 2 15 Refrigerant Circuit During Cooling 62 10683 2 14 REFRIGERANT CIRCUIT HEATING AND DEFROSTING See Figure 2 16 When vapor refrigerant is compressed to a high pressure and temperature in a reciprocating compressor the mechanical energy necessary to ope
483. zed and de energized based on Compressor Suction Pressure CSP Refer to MOP Override Section 4 8 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 increase 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 o

Carrier – Ops And Service For X Series Trailer & Rail Refrigeration

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Carrier &ndash; Ops And Service For X Series Trailer &amp; Rail Refrigeration

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Carrier – Ops And Service For X Series Trailer & Rail Refrigeration