Carrier Refrigerator 69NT40 511 1 User Manual

Container

Refrigeration

Unit

Models

69NT40-511-1

69NT40-511-199

and

69NT40-521

DUE TO THE LARGE NUMBER OF SCHEMATIC

DIAGRAMS CONTAINED IN THIS BOOK, THE

BOOK IS PRESENTED AS TWO FILES.

REFER TO FILE T268--DIAGRAMS FOR THE

CHAPTER 7 ELECTRICAL DIAGRAMS AND

SCHEMATICS

T-268 Rev G

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SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this

manual. They are recommended precautions that must be understood and applied during operation and maintenance

of the equipment covered herein. The general safety notices are presented in thefollowing threesections labeled: First

Aid, Operating Precautions and Maintenance Precautions. A listing of the specific warnings and cautions appearing

elsewhere in the manual follows the general safety notices.

FIRST AID

An injury, no matterhowslight, should nevergo unattended. Always obtain first aid ormedical attentionimmediately.

OPERATING PRECAUTIONS

Always wear safety glasses.

Keep hands, clothing and tools clear of the evaporator and condenser fans.

No work should be performed on the unit until all circuit breakers and start-stop switches are turned off, and power

supply is disconnected.

Always work in pairs. Never work on the equipment alone.

In case of severe vibration or unusual noise, stop the unit and investigate.

MAINTENANCE PRECAUTIONS

Beware of unannounced starting of the evaporator and condenser fans. Do not open the condenser fan grille or

evaporator access panels before turning power off, and disconnecting and securing the power plug.

Besurepoweris turned offbeforeworking on motors, controllers, solenoid valves and electrical control switches. Tag

circuit breaker and power supply to prevent accidental energizing of circuit.

Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems

with the system should be diagnosed, and any necessary repairs performed, by qualified service personnel.

When performing any arcwelding on theunit orcontainer, disconnect all wire harness connectors from the modules in

the control box. Do not remove wire harness from the modules unless you are grounded to the unit frame with a

static-safe wrist strap.

In case of electrical fire, open circuit switch and extinguish with CO₂(never use water).

Safety-1

T-268-07

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SPECIFIC WARNING AND CAUTION STATEMENTS

To help identify the label hazards on the Unit and explain the level of awareness each one carries, an explanation is

given with the appropriate consequences:

DANGER -- means an immediate hazard which WILL result in severe personal injury or death.

WARNING -- means to warn against hazards or unsafe conditions which COULD result in severe personal injury or

death.

CAUTION -- means to warn against potential hazard or unsafepracticewhich COULD result in minor personal injury,

product or property damage.

The statements listed below are applicable to the refrigeration unit and appear elsewhere in this manual. These rec-

ommended precautions must be understood and applied during operation and maintenance of the equipment covered

herein.

WARNING

When servicing the unit, use caution when handling R-134a. The refrigerant when in contact with

high temperatures (about 1000_F) will decompose into highly corrosive and toxic compounds.

WARNING

Be sure to avoid refrigerant coming in contact with the eyes. Should refrigerant come in contact

with the eyes, wash eyes for a minimum of 15 minutes with potable water only. THE USE OF

MINERAL OIL OR REFRIGERANT OILS IS NOT RECOMMENDED.

WARNING

Be sure to avoid refrigerant coming in contact with the skin. Should refrigerant come in contact

with the skin, it should be treated as if the skin had been frostbitten or frozen.

WARNING

Be sure ventilation in the workspace is adequate to keep the concentration of refrigerant below

1000 parts per million. If necessary, use portable blowers.

WARNING

Beware of rotating fan blades and unannounced starting of fans.

WARNING

Do not use a nitrogen cylinder without a pressure regulator. Never mix refrigerants with air for

leak testing. It has been determined that pressurized, air-rich mixtures of refrigerants and air can

undergo combustion when exposed to an ignition source.

WARNING

Never fill a refrigerant cylinder beyond its rated capacity. Cylinder may rupture due to excessive

pressure when exposed to high temperatures.

WARNING

When starting the unit, be sure that all manual refrigerant valves in the discharge line are open.

Severe damage could occur from extremely high refrigerant pressures.

T-268-07

Safety-2

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TABLE OF CONTENTS

Section

Page

SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety-1

GENERAL SAFETY NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety-1

FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety-1

OPERATING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety-1

MAINTENANCE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety-1

SPECIFIC WARNING AND CAUTION STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . Safety-2

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

2-1

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.8

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REFRIGERATION SYSTEM DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POWER AUTOTRANSFORMER (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UPPER FRESH AIR MAKEUP VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LOWER FRESH AIR MAKEUP VENT (Optional) . . . . . . . . . . . . . . . . . . . . . . . .

REFRIGERATION CIRCUIT WITH RECEIVER . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

2-10

2-11

2-12

2-13

2-14

REFRIGERATION CIRCUIT WITH THE

WATER-COOLED CONDENSER (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-16

2.9

WATER-COOLED CONDENSER (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.1

2.9.2

Water--Cooled Condenser with Water Pressure Switch (WP) . . . . .

Water-Cooled Condenser with Condenser Fan Switch (CFS) . . . . .

2.10 SUCTION SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.11 REMOTE MONITORING (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.12 SAFETY AND PROTECTIVE DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MICROPROCESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-18

2-19

3-1

3.1

MICRO-LINK 2i CONTROLLER MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

3.1.1

3.1.2

3.1.3

3.1.4

3.1.5

3.1.6

3.1.7

Brief Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Programming (Memory) Cards . . . . . . . . . . . . . . . . . . . . . .

General Layout of the Controller Section . . . . . . . . . . . . . . . . . . . . . . .

Controller Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Condenser Pressure Control (CPC) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Controller Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

3-2

3-4

3-6

3-10

3-14

3.1.7.1 Perishable (Chill) Range Above --10_C (+14_F),

or --5_C (+23_F) Optionally. . . . . . . . . . . . . . . . . . . . . . . . . .

3-14

3.1.7.2 Frozen Range Below --10_C (+14_F),

or --5_C (+23_F) Optionally . . . . . . . . . . . . . . . . . . . . . . . . .

3-17

3-18

3-19

3-24

3.2

3.3

PRE-TRIP DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1

3.2.2

Pre-Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre-Trip Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTEGRATED DataCorder (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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TABLE OF CONTENTS (CONTINUED)

Section

3.3.1

Page

Brief Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DataCORDER Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DataCORDER Function Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DataCORDER Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Access to DataCORDER Functions . . . . . . . . . . . . . . . . . . . . . . . . . . .

USDA/ Message Trip Comment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

USDA Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre-Trip Data Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DataCORDER Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-24

3-25

3-26

3-27

3-29

3-31

3-32

3.3.2

3.3.3

3.3.4

3.3.5

3.3.6

3.3.7

3.3.8

3.3.9

3.3.10 DataCORDER Scrollback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

USDA COLD TREATMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4

3-32

4-1

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1

4.2

4.3

4.4

PRE-TRIP INSPECTION (Before Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING AND STOPPING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . .

AFTER STARTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

4-2

4.4.1

4.4.2

4.4.3

Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Probe Check Initiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling -- Controller Set BELOW --10_C (+14_F), or

-- 5 _C (+23_F) optionally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3

4.4.4

4.4.5

4.4.6

4.4.7

Controller Set ABOVE --10_C (+14_F), or --5_C (+23_F) optionally

Heating (See Figure 4-4.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Arctic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10

4-12

5-1

5-2

5-3

5-4

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1

5.2

5.3

5.4

5.5

5.6

5.7

5.8

5.9

UNIT WILL NOT START OR STARTS THEN STOPS . . . . . . . . . . . . . . . . . . . .

UNIT RUNS BUT HAS INSUFFICIENT COOLING . . . . . . . . . . . . . . . . . . . . . .

UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING . . . . . . . . . . . .

UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING . . . . . . . . . . . . . .

UNIT WILL NOT TERMINATE HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT WILL NOT DEFROST PROPERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ABNORMAL PRESSURES (COOLING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ABNORMAL NOISE OR VIBRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TEMPERATURE CONTROLLER MALFUNCTION . . . . . . . . . . . . . . . . . . . . . .

5.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW . . . . . . . . . . . .

5.11 THERMOSTATIC EXPANSION VALVE MALFUNCTION . . . . . . . . . . . . . . . . .

5.12 POWER AUTOTRANSFORMER MALFUNCTION . . . . . . . . . . . . . . . . . . . . . .

5.13 WATER-COOLED CONDENSER OR WATER PRESSURE SWITCH . . . . . .

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TABLE OF CONTENTS (CONTINUED)

Section

Page

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

6.1

6.2

6.3

6.4

6.5

MANIFOLD GAUGE SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SUCTION AND DISCHARGE SERVICE VALVES . . . . . . . . . . . . . . . . . . . . . . .

PUMPING THE UNIT DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REFRIGERANT LEAK CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EVACUATION AND DEHYDRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4

6-5

6.5.1

6.5.2

6.5.3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5

6.6

6.7

REFRIGERANT CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5

6.6.1

6.6.2

6.6.3

Checking the Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adding Refrigerant to System (Full Charge) . . . . . . . . . . . . . . . . . . . .

Adding Refrigerant to System (Partial Charge) . . . . . . . . . . . . . . . . . .

6-5

6-8

COMPRESSOR -- MODEL 06DR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7.1 Removal and Replacement of Compressor . . . . . . . . . . . . . . . . . . . . .

6-8

6-9

6.8

6.9

COMPRESSOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-9

6-13

6-14

6-15

6-16

6-17

6-18

6-20

6-21

6.10 COMPRESSOR OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11 FILTER-DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.12 HIGH PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.12.1 Replacing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.12.2 Checking High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.13 EVAPORATOR COIL AND HEATER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .

6.14 EVAPORATOR COIL HEATERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.15 EVAPORATOR FAN AND MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . .

6.16 EVAPORATOR FAN MOTOR CAPACITORS . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.17 CONDENSER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.18 CONDENSER FAN AND MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .

6.19 PARTLOW RECORDING THERMOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.20 SAGINOMIYA RECORDING THERMOMETER . . . . . . . . . . . . . . . . . . . . . . . . .

6.21 MAINTENANCE OF PAINTED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.22 POWER AUTOTRANSFORMER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . .

6.23 SENSOR CHECKOUT PROCEDURE (AMBS, DTS, RRS, RTS, SRS & STS) 6-21

6.23.1 Checking Sensor (RRS, RTS, SRS or STS) . . . . . . . . . . . . . . . . . . . .

6.23.2 Replacing Sensor (STS and SRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.23.3 Replacing Sensor (RRS and RTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.23.4 Checking Sensor (AMBS or DTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.23.5Replacing Sensor (AMBS or DTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24 SUCTION SOLENOID VALVE (SSV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.25 SUCTION MODULATION VALVE (SMV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-21

6-22

6-23

6-24

6-25

iii

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TABLE OF CONTENTS (CONTINUED)

Section

Page

6.26 THERMOSTATIC EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.27 CONTROLLER/DATACORDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.27.1 Controller/DataCORDER Programming Procedure . . . . . . . . . . . . . .

6.27.2 Controller Trouble-Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-26

6-28

6-29

6.28 WATER-COOLED CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . .

6-30

7-1

7.1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

LIST OF ILLUSTRATIONS

Figure

Page

Figure 2-1 Refrigeration Unit -- Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-2 Refrigeration Unit -- Rear (Panels Removed) . . . . . . . . . . . . . . . . . . . . . .

Figure 2-3 Compressor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-4 Condenser Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-5 Units with Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-6 Units with Water-Cooled Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-7 Control Box on Units with a Single-Speed Compressor . . . . . . . . . . . . .

Figure 2-8 Control Box on Units with a Two-Speed Compressor (Optional) . . . . . .

Figure 2-9 Power Autotransformer (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-10 Refrigeration Circuit with Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 2-11 Refrigeration Circuit with Water-Cooled Condenser (Optional) . . . . . . .

2-1

2-3

2-4

2-5

2-6

2-7

2-8

2-9

2-12

2-15

2-17

Figure 3-1 Micro-Link 2i Controller/DataCORDER Module . . . . . . . . . . . . . . . . . . . . .

Figure 3-1 Key Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3-2 Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3-3 Standard Configuration Report Sample . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

3-4

3-5

3-34

Figure 3-4 Controller Set Point BELOW --10_C (+14_F), or

-- 5 _C (+23_F) optionally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-35

Figure 3-5 Controller Set Point ABOVE --10_C (+14_F), or

-- 5 _C (+23_F) optionally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 3-6 Two-Speed Compressor Speed Change Logic -- Perishable Range Only 3-36

Figure 3-7 Two-Speed Compressor Speed Change Logic -- Frozen Range Only .

3-37

Figure 4-1 Cooling in High Speed with Two-Speed Compressor . . . . . . . . . . . . . . .

Figure 4-2 Cooling in Low Speed with Two-Speed Compressor . . . . . . . . . . . . . . . .

Figure 4-3 Cooling with Single-Speed Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-4 Heating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 4-5 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5

4-7

4-9

4-11

4-13

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LIST OF ILLUSTRATIONS (CONTINUED)

Figure

Page

Figure 6-1 Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-2 R-134a Manifold Gauge Set Connection . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-3 Suction or Discharge Service Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-4 Vacuum Pump Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-5 Compressor -- Model 06DR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-6 Exploded View of Valve Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-7 Bottom Plate Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-8 Oil Pump and Bearing Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-9 Low Profile Gear Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-10 Motor End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-11 Crankshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-12 Removing Equalizing Tube and Lock Screw Assembly . . . . . . . . . . . . . .

Figure 6-13 Terminal Mounting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-14 Suction Valve & Positioning Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-15 Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-16 Compressor Oil Pump End View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-17 Typical Setup for Testing High Pressure Switch . . . . . . . . . . . . . . . . . . . .

Figure 6-18 Evaporator Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-19 Partlow Recording Thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-20 Saginomiya Recording Thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-21 Supply Sensor Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-22 Sensor (RRS, RTS, SRS or STS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-23 Sensor and Cable Assembly (RRS, RTS, SRS or STS) . . . . . . . . . . . . .

Figure 6-24 Return Sensor Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-25 Sensor (AMBS or DTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-26 Sensor and Wire Assembly (AMBS or DTS) . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-27 Suction Solenoid Valve (SSV) -- Alco . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-28 Suction Modulation Valve (SMV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-29 Thermostatic Expansion Valve -- Alco . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-30 Thermostatic Expansion Valve Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-31 Controller side of the Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 6-32 Water-Cooled Condenser Cleaning -- Forced Circulation . . . . . . . . . . . .

Figure 6-33 Water-Cooled Condenser Cleaning -- Gravity Circulation . . . . . . . . . . . .

6-1

6-3

6-4

6-7

6-9

6-10

6-11

6-12

6-13

6-14

6-15

6-17

6-20

6-21

6-22

6-23

6-24

6-25

6-26

6-27

6-28

6-31

6-32

Figure 6-34 R-134a Compressor Pressure and Motor Current Curves Versus

Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-37

Figures 7-1/7-68 Electrical Schematic -- See Model Chart . . . . . . . . . . . . . . . . . . . . . 7-2/7-137

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LIST OF TABLES

Table

Page

Table 1-1 Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2

Table 2-1 Safety and Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-19

Table 3-1 Controller Configuration Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-2 Key Pad Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-3 Controller Function Code Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-4 Controller Alarm Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-5 Pre-Trip Test Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-6 DataCORDER Function Code Assignments . . . . . . . . . . . . . . . . . . . . . . .

Table 3-7 DataCORDER Alarm Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-8 DataCORDER Alarm Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-9 DataCorder Standard Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 3-10 DataCORDER Pre-Trip Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3

3-4

3-6

3-11

3-19

3-26

3-28

3-29

3-30

3-33

Table 4-1 Electrical Control Positions -- BELOW --10_C (+14_F), or

-- 5 _C (+23_F) optionally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-14

4-15

Table 4-2 Electrical Control Positions -- ABOVE --10_C (+14_F), or

-- 5 _C (+23_F) optionally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-1 AMBS, DTS, RRS, RTS, SRS and STS Temperature-Resistance Chart 6-32

Table 6-2 Partlow Bulb Temperature-Resistance Chart . . . . . . . . . . . . . . . . . . . . . . .

Table 6-3 Recommended Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-4 Wear Limits For Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-5 Compressor Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 6-6 Temperature-Pressure Chart -- R-134a . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-32

6-33

6-34

6-35

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SECTION 1

INTRODUCTION

1.1 INTRODUCTION

WARNING

The temperature Controller/DataCORDER (Micro-Link

2i) is a microprocessor-based controller and a integrated

electronic data logging device. Refer to sections 3.1 and

3.3. Once the temperature controller is set at a desired

container temperature, the unit will operate automatically

to maintain the desired temperature within very close

limits. The control system automatically selects cooling,

holding or heating as necessary to maintain the desired

temperature within the container.

It has been determined that pressurized,

air-rich mixtures of refrigerants and air can

undergo combustion when exposed to an

ignition source.

This manual contains Operating Data, Electrical Data

and Service Instructions for the refrigeration units listed

in Table 1-1. Also, Table 1-1 charts some significant

differences between these models.

WARNING

NOTE

Beware of unannounced starting of the

evaporator and condenser fans. Do not open

the condenser fan grille before turning

power OFF and disconnecting power plug.

Beginning with early 1995 production, in

addition to a model number, Carrier Transicold

began using aparts identification (PID)number

in the format NT0000. In the parts manual, the

PID number is shown in boldface to point out

parts variations within models. The PID

number must be included when ordering and

inquiring about your unit.

Some units are equipped with a mechanical temperature

recorder.

Some units may have a TransFRESH controlled

atmosphere system added. Contact TransFRESH

Corporation, P.O. Box 1788, Salinas, CA 93902 for

information on their system.

The unit, of lightweight aluminum frame construction,

is an all electric, one piece, self-contained cooling and

heating refrigeration unit. The unit is designed to fit in

thefront ofacontainerand to serveas thecontainerfront

wall. Forklift pockets are provided for installation and

removal of the unit.

The unit is complete with a charge of R-134a,

compressor lubricating oil (approved POE SW20

compressor oil for R-134a only), mode indicating

lights, and temperature controller, and is ready for

operation upon installation.

Some units are equipped with a two-speed compressor

that is used to enhance power saving.

Someunits aredual voltageunits designed to operateon

190/230 or 380/460 volts AC, 3-phase, 50-60 hertz

power (refer to section 2.4). Other units are designed to

operate on 380/460 volts AC, 3-phase 50/60 hertz

power only. An external autotransformer is required for

190/230 vac operation (refer to Figure 2-9 and section

2.4).

Operating control power is provided by a control

transformer which steps down the AC supply power

source to 18 and 24 volts AC, single phase control

power.

1-1

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Table 1-1. Model Chart

Electrical Wiring

Schematics and

Diagrams

MODEL

PID

NT0001

---

69NT40-511-1

69NT40-511-2

NT0062

NT0002

NT0017

NT0007

NT0037

NT0011

NT0038

---

Figure 7-1 &

Figure 7-2

69NT40-511-3

69NT40-511-4

Figure 7-3 &

Figure 7-4

69NT40-511-5

Figure 7-9 &

Figure 7-10

NT0099

---

69NT40-511-6

69NT40-511-7

NT0013

NT0014

NT0005

NT0037

---

Figure 7-3 &

Figure 7-4

69NT40-511-8

69NT40-511-9

Figure 7-9 &

Figure 7-10

NT0094

---

NT0064

NT0089

---

Figure 7-3 &

Figure 7-4

Figure 7-9 &

Figure 7-10

NT0152

---

NT0024

NT0027

NT0040

NT0041

NT0104

---

Figure 7-3 &

Figure 7-4

69NT40-511-10

Figure 7-9 &

Figure 7-10

NT0112

---

NT0173

NT0209

NT0008

NT0076

NT0082

NT0015

NT0022

NT0018

NT0029

NT0044

NT0028

NT0054

NT0070

NT0083

---

Figure 7-19 &

Figure 7-20

69NT40-511-11

69NT40-511-12

Figure 7-3 &

Figure 7-4

69NT40-511-13

69NT40-511-14

Figure 7-5 &

Figure 7-6

69NT40-511-15

Figure 7-3 &

Figure 7-4

69NT40-511-16

69NT40-511-17

Figure 7-1 &

Figure 7-2

NT0043

---

T-268-07

1-2

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Electrical Wiring

Schematics and

Diagrams

MODEL

PID

69NT40-511-18

69NT40-511-19

69NT40-511-21

NT0035

NT0037

NT0055

NT0046

NT0121

NT0139

---

Figure 7-3 &

Figure 7-4

Figure 7-9 &

Figure 7-10

69NT40-511-22

Figure 7-41 &

Figure 7-42

NT0252

---

NT0050

NT0069

NT0051

NT0053

---

69NT40-511-23

Figure 7-3 &

Figure 7-4

69NT40-511-24

69NT40-511-25

Figure 7-1 &

Figure 7-2

Figure 7-21 &

Figure 7-22

NT0047

NT0175

---

69NT40-511-26

69NT40-511-27

69NT40-511-28

NT0056

NT0057

---

Figure 7-3 &

Figure 7-4

Figure 7-9 &

Figure 7-10

Figure 7-3 &

Figure 7-4

Figure 7-19 &

Figure 7-20

Figure 7-57 &

Figure 7-58

NT0132

NT0059

NT0219

NT0343

NT0060

---

69NT40-511-29

Figure 7-7 &

Figure 7-8

69NT40-511-30

69NT40-511-31

NT0061

NT0067

---

Figure 7-3 &

Figure 7-4

69NT40-511-32

Figure 7-9 &

Figure 7-10

Figure 7-3 &

Figure 7-4

Figure 7-41 &

Figure 7-42

NT0097

NT0068

NT0239

---

69NT40-511-33

69NT40-511-34

69NT40-511-35

NT0065

NT0071

---

Figure 7-3 &

Figure 7-4

Figure 7-5 &

Figure 7-6

Figure 7-3 &

Figure 7-4

69NT40-511-36

69NT40-511-37

NT0072

NT0073

---

1-3

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Electrical Wiring

Schematics and

Diagrams

MODEL

PID

NT0074

NT0135

---

Figure 7-11 &

Figure 7-12

Figure 7-31 &

Figure 7-32

NT0208

---

NT0246

NT0253

NT0267

---

69NT40-511-38

69NT40-511-39

Figure 7-47 &

Figure 7-48

Figure 7-63 &

Figure 7-64

NT0307

---

NT0078

NT0084

---

Figure 7-3 &

Figure 7-4

Figure 7-9 &

Figure 7-10

NT0095

---

NT0079

NT0085

---

Figure 7-3 &

Figure 7-4

69NT40-511-40

69NT40-511-41

Figure 7-9 &

Figure 7-10

Figure 7-3 &

Figure 7-4

Figure 7-65 &

Figure 7-66

NT0096

NT0080

NT0090

---

69NT40-511-42

69NT40-511-43

NT0088

NT0081

NT0091

NT0102

NT0137

---

Figure 7-3 &

Figure 7-4

Figure 7-9 &

Figure 7-10

Figure 7-19 &

Figure 7-20

NT0185

---

69NT40-511-44

NT0213

NT0244

NT0266

---

Figure 7-41 &

Figure 7-42

Figure 7-3 &

Figure 7-4

69NT40-511-45

69NT40-511-46

NT0092

---

NT0110

NT0098

NT0124

---

Figure 7-9 &

Figure 7-10

Figure 7-23 &

Figure 7-24

Figure 7-19 &

Figure 7-20

Figure 7-3 &

Figure 7-4

69NT40-511-47

69NT40-511-48

NT0146

NT0186

NT0101

---

T-268-07

1-4

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Electrical Wiring

Schematics and

Diagrams

MODEL

PID

NT0103

NT0134

NT0184

NT0216

NT0268

NT0282

NT0283

NT0303

NT0308

NT0341

NT0345

NT0106

NT0178

---

Figure 7-9 &

Figure 7-10

Figure 7-19 &

Figure 7-20

69NT40-511-49

Figure 7-41 &

Figure 7-42

Figure 7-57 &

Figure 7-58

Figure 7-9 &

Figure 7-10

69NT40-511-50

69NT40-511-51

Figure 7-13 &

Figure 7-14

Figure 7-45 &

Figure 7-46

Figure 7-67 &

Figure 7-68

Figure 7-9 &

Figure 7-10

Figure 7-3 &

Figure 7-4

Figure 7-9 &

Figure 7-10

Figure 7-19 &

Figure 7-20

Figure 7-41 &

Figure 7-42

NT0107

NT0207

NT0417

NT0109

NT0111

NT0133

NT0162

NT0225

---

69NT40-511-52

69NT40-511-53

69NT40-511-54

NT0113

NT0118

NT0136

---

Figure 7-9 &

Figure 7-10

Figure 7-41 &

Figure 7-42

Figure 7-9 &

Figure 7-10

Figure 7-19 &

Figure 7-20

Figure 7-41 &

Figure 7-42

NT0215

NT0120

NT0188

NT0242

NT0156

---

69NT40-511-55

69NT40-511-56

69NT40-511-57

Figure 7-9 &

Figure 7-10

1-5

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Electrical Wiring

Schematics and

Diagrams

MODEL

PID

NT0105

NT0122

NT0138

NT0141

NT0160

NT0161

NT0189

NT0240

NT0269

NT0309

NT0340

NT0386

NT0418

NT0428

---

Figure 7-9 &

Figure 7-10

Figure 7-19 &

Figure 7-20

69NT40-511-58

Figure 7-41 &

Figure 7-42

Figure 7-57 &

Figure 7-58

---

Figure 7-9 &

Figure 7-10

NT0167

---

NT0174

NT0211

---

Figure 7-19 &

Figure 7-20

69NT40-511-59

69NT40-511-60

Figure 7-41 &

Figure 7-42

Figure 7-57 &

Figure 7-58

NT0272

NT0312

---

NT0125

NT0153

NT0126

NT0154

---

Figure 7-9 &

Figure 7-10

69NT40-511-61

69NT40-511-62

Figure 7-17 &

Figure 7-18

Figure 7-9 &

Figure 7-10

Figure 7-19 &

Figure 7-20

NT0127

NT0140

NT0192

---

69NT40-511-63

69NT40-511-64

69NT40-511-65

NT0131

NT0119

NT0129

NT0147

NT0143

---

Figure 7-9 &

Figure 7-10

69NT40-511-66

69NT40-511-67

69NT40-511-69

Figure 7-19 &

Figure 7-20

NT0177

---

NT0241

NT0271

NT0311

NT0353

---

Figure 7-41 &

Figure 7-42

69NT40-511-70

Figure 7-57 &

Figure 7-58

T-268-07

1-6

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Electrical Wiring

Schematics and

Diagrams

MODEL

PID

Figure 7-19 &

Figure 7-20

Figure 7-41 &

Figure 7-42

Figure 7-25 &

Figure 7-26

Figure 7-33 &

Figure 7-34

NT0166

NT0235

NT0157

NT0200

---

69NT40-511-71

69NT40-511-72

69NT40-511-73

NT0158

NT0159

NT0223

NT0163

---

Figure 7-9 &

Figure 7-10

69NT40-511-74

69NT40-511-75

69NT40-511-76

Figure 7-19 &

Figure 7-20

Figure 7-15 &

Figure 7-16

NT0169

---

69NT40-511-77

69NT40-511-78

NT0176

NT0182

---

Figure 7-9 &

Figure 7-10

Figure 7-39 &

Figure 7-40

69NT40-511-79

69NT40-511-80

NT0190

---

NT0165

NT0151

---

Figure 7-9 &

Figure 7-10

Figure 7-19 &

Figure 7-20

Figure 7-9 &

Figure 7-10

NT0168

NT0180

---

69NT40-511-81

NT0236

NT0258

---

Figure 7-41 &

Figure 7-42

Figure 7-31 &

Figure 7-32

Figure 7-27 &

Figure 7-28

Figure 7-35 &

Figure 7-36

Figure 7-43 &

Figure 7-44

Figure 7-19 &

Figure 7-20

Figure 7-41 &

Figure 7-42

Figure 7-57 &

Figure 7-58

NT0187

NT0198

NT0199

NT0210

NT0191

NT0201

NT0334

---

69NT40-511-82

69NT40-511-83

69NT40-511-84

NT0183

NT0226

NT0280

---

Figure 7-31 &

Figure 7-32

69NT40-511-85

Figure 7-55 &

Figure 7-56

NT0317

---

69NT40-511-87

69NT40-511-89

NT0214

NT0212

NT0243

---

Figure 7-41 &

Figure 7-42

1-7

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Electrical Wiring

Schematics and

Diagrams

MODEL

PID

Figure 7-19 &

Figure 7-20

Figure 7-37 &

Figure 7-38

69NT40-511-90

69NT40-511-91

NT0222

NT0202

---

NT0238

NT0278

---

Figure 7-51 &

Figure 7-52

Figure 7-61 &

Figure 7-62

Figure 7-41 &

Figure 7-42

NT0318

NT0218

---

69NT40-511-92

69NT40-511-93

NT0197

NT0204

NT0262

NT0265

---

Figure 7-29 &

Figure 7-30

69NT40-511-94

Figure 7-19 &

Figure 7-20

NT0220

---

NT0322

NT0344

NT0365

NT0224

NT0228

NT0285

---

69NT40-511-95

Figure 7-57 &

Figure 7-58

69NT40-511-96

69NT40-511-97

Figure 7-41 &

Figure 7-42

Figure 7-57 &

Figure 7-58

NT0322

---

69NT40-511-98

69NT40-511-99

69NT40-511-100

NT0297

NT0245

NT0247

NT0250

NT0298

---

Figure 7-41 &

Figure 7-42

69NT40-511-101

Figure 7-57 &

Figure 7-58

NT0333

---

NT0251

NT0254

NT0259

NT0260

---

69NT40-511-102

Figure 7-41 &

Figure 7-42

69NT40-511-103

69NT40-511-104

Figure 7-53 &

Figure 7-54

Figure 7-41 &

Figure 7-42

69NT40-511-105

NT0274

NT0263

---

69NT40-511-106

NT0414

NT0415

---

Figure 7-57 &

Figure 7-58

T-268-07

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Electrical Wiring

Schematics and

Diagrams

MODEL

PID

NT0275

NT0277

NT0315

NT0354

NT0381

NT0385

NT0264

NT0284

NT0288

NT0296

NT0347

NT0349

NT0286

NT0295

---

Figure 7-49 &

Figure 7-50

69NT40-511-107

Figure 7-59 &

Figure 7-60

69NT40-511-108

69NT40-511-109

---

Figure 7-41 &

Figure 7-42

69NT40-511-110

69NT40-511-111

---

Figure 7-41 &

Figure 7-42

Figure 7-57 &

Figure 7-58

Figure 7-41 &

Figure 7-42

Figure 7-57 &

Figure 7-58

NT0429

NT0289

NT0325

---

69NT40-511-112

69NT40-511-113

NT0294

NT0290

NTO326

NT0335

NT0336

NT0358

NT0299

NT0300

NT0302

NT0348

NT0387

NT0388

NT0389

NT0410

---

Figure 7-41 &

Figure 7-42

69NT40-511-114

Figure 7-57 &

Figure 7-58

69NT40-511-115

Figure 7-41 &

Figure 7-42

69NT40-511-116

69NT40-511-117

69NT40-511-118

Figure 7-57 &

Figure 7-58

69NT40-511-119

69NT40-511-120

Figure 7-9 &

Figure 7-10

69NT40-521-10

NT0108

---

A -- Factory Installed Pressure Gauges

B -- Factory Installed Pressure Transducers.

P -- Provision.

X -- Features that apply to model.

1-9

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SECTION 2

DESCRIPTION

2.1 GENERAL DESCRIPTION

allow front entry into the evaporator section, and the

center access panel allows access to the thermostatic

expansion valve and evaporator coil heaters. The unit

model number, serial number and parts identification

numberwill befound on thefront oftheunit to theleftof

the compressor.

a. Refrigeration Unit -- Front Section

The front section of the refrigeration unit shows access

to most parts of the unit (i.e., compressor, condenser,

receiver, etc.), which will be discussed in more detail of

the following sections in 2.1. The upper access panels

6. Interrogator Connector (Also see Figure 2-7)

7. Mechanical Recording Thermometer -- Optional --

(Partlow or Saginomiya)

8. Lower Fresh Air Makeup Vent or Blank Plate --

Optional

1. Access Panel (For Evap. Fan Motor #1)

2. Access Panel (For Heater & Thermostatic

Expansion Valve)

3. Fork Lift Pockets

4. Unit Serial Number, Model Number and Parts

Identification Number (PID) Plate

5. TransFRESH Communications Connector (TCC)

-- Optional

9. Upper Fresh Air Makeup Vent and Access Panel

(For Evap. Fan Motor #2)

10. Return Air Thermometer Port -- Optional

Figure 2-1. Refrigeration Unit -- Front

2-1

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b. Evaporator Section

When transporting perishable (chilled) commodities,

the fan motors will normally be in high speed above

-- 1 0 _C (+14_F), or --5_C (+23_F) optionally.

The evaporator section contains the optional

mechanical temperature recording bulb, return recorder

sensor (RRS), return temperature sensor (RTS),

thermostatic expansion valve, dual-speed evaporator

fan motors and fans (2), evaporator coil and heaters,

drain pan and heater, defrost termination sensor, heat

termination thermostat, and heat exchanger. See

Figure 2-2 and Figure 2-5 for sensor locations.

The evaporator coil heaters are accessible by removing

the front lower access panel. The defrost termination

sensor (DTS) is located on the coil center tube sheet and

may be serviced by removing the upper rear panel, orby

removing the left front upper access panel,

disconnecting the evaporator fan connector and

reaching through the access panel opening.

WARNING

The evaporator fans circulate air throughout the

container by pulling air in the top of the refrigeration

unit, directing the air through the evaporator coil where

it is either heated or cooled, and discharging the air

through the bottom of the refrigeration unit into the

container.

Before servicing unit, make sure the unit

circuit breakers (CB-1 & CB-2) and the

start-stop switch (ST) are in the OFF

position. Also disconnect power plug and

cable.

T-268-07

2-2

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1. Evaporator Fan Motor #1 (EM1)

2. Humidity Sensor (HS) -- Optional

3. Return Recorder Sensor (RRS)

10. Evaporator Coil

11. Drain Pan Heater (DPH)

12. Thermostatic Expansion Valve

4. Return Temperature Sensor (RTS)

13. Heat Exchanger

5. Mechanical Recording Thermometer Bulb

6. Mechanical Recording Thermometer Bulb --

Used on PID NT0073

7. Evaporator Fan Motor #2 (EM2)

8. Defrost Termination Sensor (DTS)

9. Heater Termination Thermostat (HTT)

14. Interrogator Receptacle (IC) -- Optional

15. USDA Probe Receptacle (PR2) -- Optional

16. USDA Probe Receptacle (PR1) -- Optional

17. USDA Probe Receptacle (PR3) -- Optional

18. Cargo Probe Receptacle (PR4) -- Optional

19. Evaporator Coil Heaters

Figure 2-2. Refrigeration Unit -- Rear (Panels Removed)

2-3

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c. Compressor Section

the left of the compressor.

This section also

Thecompressorsection includes thecompressor, power

cable storagecompartment, and an optional transformer

(refer to Table 1-1 and Figure 2-9), which is located to

contains

the

optional

discharge/suction pressure transducers.

1. Power Autotransformer -- Optional

2. Power Cables and Plug

3. Compressor Sight Glass View Port

4. Compressor Guard

5. Suction/Discharge Pressure Gauges -- Optional

6. Suction Service Valve

7. Compressor Crankcase Heater (CCH) -- Optional

8. Compressor Motor (CP)

9. Discharge Service Valve

10. Discharge Pressure Transducer (DPT) -- Optional

11. Suction Pressure Transducer (SPT) -- Optional

Figure 2-3. Compressor Section

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d. Condenser Section

When the unit is operating, air is pulled in the bottom of

the coil and discharged horizontally out through the

front of the condenser fan grille.

The condensing section consists of a condenser fan

motor, acondenserfan and an air-cooled condensercoil.

1. Grille and Venturi Assembly

2. Retaining Screw

3. Condenser Fan

4. Key

5. Condenser Fan Motor (CM)

6. Condenser Coil Cover

7. Condenser Coil

8. Condenser Motor Mount Bracket

Figure 2-4. Condenser Section

2-5

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e. Receiver Section

discharge pressure regulator valve.

The receiver section consists of quench expansion

valve, manual liquid line valve, filter-drier, receiver

with sight glass/moisture-liquid indicator, condenser

pressure transducer (CPT), fusible plug, suction

modulation valve, suction solenoid valve, and

The supply temperature sensor (STS), supply recorder

sensor (SRS) and ambient sensor (AMBS) are located at

the right side of the compressor.

1. Discharge Pressure Regulator Valve

2. Suction Modulation Valve (SMV)

3. Schrader Valve

4. Supply Air Thermometer Port -- Optional

5. Suction Solenoid Valve (SSV)

6. Quench Expansion Valve

7. Electro-Coated Modular Receiver

8. Sight Glass

Located on back side of Receiver)

11. Sight Glass/Moisture Indicator

12. Filter-Drier

13. Manual Liquid Line Valve

14. Ambient Sensor (AMBS)

15. Supply Temperature Sensor (STS)

16. Supply Recorder Sensor (SRS)

17. High Pressure Switch (HPS)

18. Thermistor Sensor (CPDS)

19. Thermistor Sensor (CPSS)

9. Fusible Plug

10. Condenser Pressure Transducer (CPT) --

Figure 2-5. Units with Receiver

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f. Water-Cooled Condenser Section (Optional)

discharge pressure regulator valve, water hook-up

couplings and water pressure switch.

The water-cooled condenser section consists of

water-cooled condenser, sight glass, moisture-liquid

indicator, quench expansion valve, rupture disc,

condenser pressure transducer (CPT), filter-drier,

suction modulation valve, suction solenoid valve,

The supply temperature sensor (STS), supply recorder

sensor (SRS) and ambient sensor (AMBS) are located at

the right side of the compressor.

1. Discharge Pressure Regulator Valve

2. Suction Modulation Valve (SMV)

3. Schrader Valve

11. Supply Air Thermometer Port -- Optional

12. Coupling (Water In)

13. Self Draining Coupling (Water Out)

14. Water Pressure Switch (WPS)

15. Sight Glass

4. Rupture Disc

5. Condenser Pressure Transducer (CPT)

6. Suction Solenoid Valve (SSV)

7. Quench Expansion Valve

8. Filter-Drier

9. Manual Liquid Line Valve

10. Moisture-Liquid Indicator

16. Water-Cooled Condenser

17. Supply Recorder Sensor (SRS) -- Optional

18. Supply Temperature Sensor (STS)

19. Ambient Sensor (AMBS)

Figure 2-6. Units with Water-Cooled Condenser

2-7

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g. Control Box with a Single-Speed Compressor

Controller/DataCORDER module (See Figure 2-7), an

optional remote monitoring unit (CI), and an optional

emergency bypass cooling switch (EB), emergency

defrost switch (ED) and emergency defrost fuse (FED).

The control box includes the manual switches, circuit

breaker(s), contactors, transformer, fuses, key pad,

display

module,

current

sensor

module,

18 17

1. Compressor Contactor (CH)

2. Hour Meter (HM) -- Optional

3. Heat Contactor (HR)

4. Display Module

5. Remote Monitoring Unit (RMU) -- Optional

6. Controller/DataCORDER Module

13. Manual Defrost Switch (MDS)

14. Condenser Fan Switch (CFS) -- Optional

15. Controller/DataCORDER Battery Pack -- Optional

16. Interrogator Connector -- Optional location for

some models

17. Control Transformer (TR)

7. Emergency Bypass Cooling Switch (EB)--Optional

8. Emergency Defrost Fuse (FED) -- Optional

9. Emergency Defrost Switch (ED) -- Optional

10. Key Pad

18. Evaporator Fan Contactor (EF) High Speed

19. Evaporator Fan Contactor (ES) Low Speed

20. Condenser Fan Contactor (CF)

21. Circuit Breaker (CB-1) -- 460V

11. Start-Stop Switch (ST)

22. Current Sensor Module (CS)

12. Remote Monitoring Receptacle (RM) -- Optional

Figure 2-7. Control Box on Units with a Single-Speed Compressor

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h. Control Box with a Two-Speed Compressor

(Optional)

display

module,

current

sensor

module,

Controller/DataCORDER module (See Figure 2-8),

and an optional remote monitoring unit (CI).

The control box includes the manual switches, circuit

breaker(s), contactors, transformer, fuses, key pad,

CAUTION: DO NOT MANUALLY

ENGAGE CONTACTORS

1. Compressor Contactor (CH) High Speed

2. Compressor Contactor (CL) Low Speed

3. Compressor Contactor (SC) Shorting

4. Heat Contactor (HR)

10. Manual Defrost Switch (MDS)

11. Remote Monitoring Receptacle (RM) -- Optional

12. Controller/DataCORDER Battery Pack -- Optional

13. Control Transformer (TR)

14. Evaporator Fan Contactor (EF) High Speed

15. Evaporator Fan Contactor (ES) Low Speed

16. Condenser Fan Contactor (CF)

5. Display Module

6. Remote Monitoring Unit (RMU) -- Optional

7. Controller/DataCORDER Module

8. Key Pad

17. Circuit Breaker (CB-1) -- 460V

9. Start-Stop Switch (ST)

18. Current Sensor Module (CS)

Figure 2-8. Control Box on Units with a Two-Speed Compressor (Optional)

2-9

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2.2 REFRIGERATION SYSTEM DATA

i. Compressor/Motor Assembly

Number of Cylinders

Model

CFM

06DR

118 kg (260 lb) - Single-Speed

129.39 kg (285.25 lb) - Two-Speed

Castrol Icematic -- SW20

3.6 liters (7.6 U.S. pints)

Weight (Dry)

Approved Oil

Oil Charge

The oil level range, with the compressor off,

should be between the bottom and one-eighth

level of the capacity of the sight glass.

Oil Sight Glass

Verify at --18 _C

(0 _F) container box

temperature

j. Expansion Valve Superheat

4.48 to 6.67 _C (8 to 12 _F)

Opens

Closes

Cutout

Cut-In

54 (¦ 3) _C = 130 (¦ 5) _F

38 (¦ 4) _C = 100 (¦ 7) _F

25 (¦ 1.0) kg/cm@ = 350 (¦ 10) psig

18 (¦ 0.7) kg/cm@ = 250 (¦ 10) psig

Charge Requirements -- R-134a

k. Heater Termination Thermostat

l. High Pressure Switch

Unit Configuration

2* row condenser

4* row condenser

5.22 kg (11.5 lbs)

4.88 kg (10.75 lbs)

m. Refrigerant Charge

Water-Cooled

Condenser

Receiver

4.5 kg (9.0 lbs)

3.74 kg (8.25 lbs)

* Refer to Table 1-1.

NOTE

When replacing the components (n.), (o.) and (p.) in section 2.2, refer to the installation instructions

included with the ordered new part for additional information.

Melting point

Torque

o. Sight Glass/Moisture Indicator Torque

99 _C = (210 _F)

n. Fusible Plug

6.2 to 6.9 mkg (45 to 50 ft-lbs)

8.9 to 9.7 mkg (65 to 70 ft-lbs)

35 5% kg/cm@ = (500 5% psig)

Bursts at

Torque

(P/N 14-00215-03)

Torque

(P/N 14-00215-04)

1.4 to 2 mkg (10 to 15 ft-lbs)

6.2 to 6.9 mkg (45 to 50 ft-lbs)

p. Rupture Disc

The condenser fan will start if the condenser

pressure is greater than 14.06 kg/cm@ (200

psig) OR the condenser fan is OFF for more

than 60 seconds.

The condenser fan will stop if the condenser

pressure is less than 9.14 kg/cm@ (130 psig)

AND the condenser fan remains ON for at least

30 seconds.

Condenser Fan Starts

Condenser Fan Stops

q. Condenser Pressure

Transducer (CPT)

r. Unit Weight

Refer to unit model number plate, see Figure 2-1 for location of plate.

Cut-In

Cutout

0.5 ¦ 0.2 kg/cm@ (7 ¦ 3 psig)

1.6 ¦ 0.4 kg/cm@ (22 ¦ 5 psig)

s. Water Pressure Switch

(Optional)

T-268-07

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2.3 ELECTRICAL DATA

a. Circuit Breaker

CB-1 Trips at

CB-2 (50 amp) Trips at

CB-2 (70 amp) Trips at

29 amps

62.5 amps

87.5 amps

b. Compressor

Motor

17.6 amps @ 460 vac

(with current limiting set at 21 amps)

Full Load Amps (FLA)

380 vac, 3 Phase, 50 hz

1.3 amps

0.43 hp

1425 rpm

360 -- 460 vac ¦ 1.25 hz

460 vac, 3 Phase, 60 hz

1.6 amps

0.75 hp

1725 rpm

400 -- 500 vac ¦ 1.5 hz

Full Load Amps

Horsepower

Rotations Per Minute

Voltage and Frequency

Bearing Lubrication

Rotation

c. Condenser Fan

Motor

Factory lubricated, additional grease not required.

Counter-clockwise when viewed from shaft end.

Number of Heaters

Rating

Resistance (cold)

Type

750 watts +5 /--10 % @ 460 vac

285 ¦ 7.5% ohms nominal

Sheath

d. Drain Pan Heaters

Number of Heaters

Rating

Resistance (cold)

Ambient

750 watts +5/--10% each @ 230 vac

66.8 to 77.2 ohms

@ 20 _C (68 _F)

Sheath

e. Evaporator Coil

Heaters

Type

380 vac, 3 Phase, 50 hz

460 vac, 3 Phase, 60 hz

Full Load Amps -- High

Speed

1.6 amps

2.0 amps

Full Load Amps -- Low

Speed

Nominal Horsepower --

High Speed

0.8 amps

0.70 hp

1.0 amps

0.84 hp

Nominal Horsepower --

Low Speed

Rotations Per Minute --

High Speed

0.09 hp

0.11 hp

f. Evaporator Fan

Motor(s)

2850 rpm

3450 rpm

Rotations Per Minute --

Low Speed

1425 rpm

1750 rpm

Voltage and Frequency

Voltage and Frequency --

using modular transformer

360 -- 460 vac ¦ 1.25 hz

180 -- 230 vac ¦ 1.25 hz

400 -- 500 vac ¦ 1.5 hz

200 -- 250 vac ¦ 1.5 hz

Bearing Lubrication

Rotation

Control Circuit

Factory lubricated, additional grease not required

Clockwise when viewed from shaft end.

15 amps (F3)

g. Fuses

Controller/DataCORDER

5 amps (F1 & F2)

h. Compressor Crankcase Heater (CCH) --

Optional

180 watts @ 460 vac

2-11

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Orange wire

Red wire

Power

Output

Brown wire

Input voltage

Output voltage

Ground

5 vdc

0 to 3.3 vdc

i. Humidity Sensor

(HS) -- Optional

Output voltage readings verses relative humidity (RH) percentage:

30%

50%

70%

90%

0.99 V

1.65 V

2.31 V

2.97 V

2.4 POWER AUTOTRANSFORMER (Optional)

2. Plug the 230 vac (black) cable into a de-energized

190/230 vac, 3-phase power source. Energize the

power source. Set circuit breaker (CB-2 if

equipped) to position “1” (ON). Close and secure

control box door and place the start-stop switch

(ST) in position “1” (ON) to start the unit.

WARNING

Do not attempt to remove power plug(s)

before turning OFF start-stop switch (ST),

unit circuit breaker(s) and external power

source.

c. To Operate Unit on 380/460 vac Power Supply

Make sure the power plugs are clean and dry

before connecting to any power receptacle.

1. Make sure start-stop switch (ST, on control panel)

and circuit breaker (CB-1, in the control box) are in

position “0” (OFF).

a. Step-Up Power Autotransformer

The modular transformer (if equipped) is located under

the condenser coil on the left-hand side of the unit (see

Figure 2-9).

2. Plug the 460 vac (yellow) cable into a de-energized

380/460 vac, 3-phase power source. Energize the

power source. Place circuit breaker (CB-1) in

position “1” (ON). Close and secure control box

door and then place the start-stop switch (ST) in

position “1” (ON) to start the unit.

The modular transformer (item 1, Figure 2-9) provides

380/460 vac, 3-phase, 50/60 hertz power to the unit

when the 230 vac (black) power cable is connected to a

190/230 vac, 3-phase power source. The module, in

addition to thetransformer, includes a 230 vac cableand

a receptacle to accept the unit 460 vac power plug. The

modular transformer may be equipped with an optional

circuit breaker (CB-2).

WARNING

Do not attempt to unplug the power cable

connected to the autotransformer before

performing the following operations: Move

the start-stop switch (ST), the unit circuit

breaker(s), CB-1 and CB-2 (if equipped)

and any external power source to their OFF

positions.

b. To Operate Unit on 190/230 vac Power Supply

1. Make sure that the start-stop switch (ST, on control

panel) and circuit breaker (CB-2 if equipped, on the

modular transformer) are in position “0” (OFF).

Make sure the 460 vac power plug is locked into the

receptacle on the modular transformer and circuit

breaker (CB-1, in the control box) is in position “1”

(ON).

1. Dual Voltage Modular Transformer

2. Circuit Breaker (CB-2) 230V (Optional)

3. 460 vac Power Receptacle

Figure 2-9. Power Autotransformer (Optional)

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2.5 UPPER FRESH AIR MAKEUP VENT

arrow on the disc with the percentage of desired air flow

marked on the supplied label (see Figure 2-1).

The purpose of the fresh air makeup vent is to provide

ventilation for commodities that require fresh air

circulation. The vent must be closed when transporting

frozen foods or controlled atmosphere loads.

2.6 LOWER FRESH AIR MAKEUP VENT

(Optional)

Air exchange depends on static pressure differential,

which will vary depending on the container and howthe

container is loaded. The chart below gives air exchange

values for an empty container. Higher values can be

expected for a fully loaded container.

The purpose of the lower fresh air makeup vent is to

provide ventilation for commodities that require fresh

air circulation. The vent must be closed when

transporting frozen foods.

ZERO EXTERNAL STATIC PRESSURE, 50HZ POWER

Air exchange depends on static pressure differential,

which will vary depending on the container and howthe

container is loaded. The chart across gives air exchange

values for an empty container. Higher values can be

expected for a fully loaded container.

AIR

FLOW

(CMH)

225

T-BAR

2-3/8 ”

200

a. Full Open or Closed Positions

175

150

125

100

The air slide is supplied with two adjustable air control

discs. The fresh air makeup can be adjusted for 15, 35,

50 and 75 cubicmeters perhour(CFM). Theairflowhas

been established at 60 Hz power, and a 2 1/2 inch T bar,

with 15 mm (0.6 inch) H₂O external static above free

blow.

Maximum air flow is achieved by loosening the hex

nuts and rotating each disc to the maximum open

position (100% open). The closed position is 0% air

flow.

10 20 30 40 50 60 70 80 90 100

PERCENT OPEN

The operator may also adjust the openings to increaseor

decrease the air flow volume to meet the required air

For 60HZ operation multiply air flow values from curve by 1.2

flow.

NOTE

a. Full Open or Closed Positions

Maximum air flow is achieved by loosening the wing

nut and rotating the disc to the maximum open position

(100% open). The closed position is 0% air flow.

The main air slide is in the fully closed position

during reduced air flow operation.

Two slots and a stop are designed into the disc for air

flow adjustments. The first slot allows for a 0 to 30% air

flow, and the second slot allows for a 30 to 100% air

flow. To increase the percentage of air flow, the wing

nut must be loosened, and the disc rotated until the

desired percentage of air flow matches withthe arrowon

the disc. Tighten the wing nut. To clear the gap between

the slots, loosen the wing nut until the disc clears the

stop, and rotate the disc for the second slot.

a. Air Sampling for Carbon Dioxide (CO₂) Level

Loosen hex nuts and move the cover until the arrow on

the cover is aligned with the “atmosphere sampling

port” label. Tighten the hex nuts and attach a 3/8 hose to

the sampling port.

If the internal atmosphere content has reached an

unacceptable level, the operator may adjust the disc

opening to meet the required air flow volume to

ventilate the container.

The operator may also increase or decrease the air flow

volume to meet the required air flow by aligning the

2-13

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2.7 REFRIGERATION CIRCUIT WITH RECEIVER

superheat at thecoil outlet regardless ofload conditions,

except at abnormally high container temperatures such

as during pulldown (valve at maximum operating

pressure condition).

Starting at the compressor, the suction gas is

compressed to a higher temperature and pressure.

When operating with the air-cooled condenser, the gas

flows through the discharge service valve into the

pressure regulator valve that is normally open. The

pressure regulator valve restricts the flow of refrigerant

to maintain a minimum discharge pressure of 5 kg/cm@

(70 psig). Refrigerant gas then movesinto theair-cooled

condenser. Air flowing across the coil fins and tubes

cools the gas to saturation temperature. By removing

latent heat, the gas condenses to a high pressure/high

temperature liquid and flows to the receiver which

stores the additional charge necessary for low

temperature operation.

NOTE

pressure control system has been

incorporated by means of a condenser pressure

transducer (CPT) and condenser pressure

control (CPC) logic to maintain discharge

pressures above 130 psig in low ambients.

Regardless of pressure, CPC will be disabled at

every compressor start-up, 15 seconds before

the compressor is energized and 30 seconds

after. An exception, for two-speed compressor

units, is the low speed to high speed switching

sequence, where CPC will be disabled while

SMV is at 0% during the entire switching

sequence for a total of 47 seconds.

From the receiver, the liquid refrigerant continues

through the manual liquid line valve, the filter-drier

(which keeps refrigerant clean and dry), and a heat

exchanger that increases subcooling of liquid

refrigerant to the thermostatic expansion valve. As the

liquid refrigerant passes through the orifice of the

expansion valve, some of it vaporizes into a gas (flash

gas). Heat is absorbed from the return air by the balance

of the liquid, causing it to vaporize in the evaporator

coil. The vapor then flows through the suction

modulation valve (and suction solenoid valve under

some conditions) to the compressor.

a. At ambients below 27_C (80_F), the condenser

fan will cycle on/off depending on condenser

pressure and on/off times.

1. The condenser fan will start if the condenser

pressure is greater than 200 psig OR the condenser

fan is OFF for more than 60 seconds.

2. The condenser fan will stop if the condenser

pressure is less than 130 psig AND the condenser

fan remains ON for at least 30 seconds.

The thermostatic expansion valve bulb on the suction

line near the evaporator coil outlet controls the

thermostatic expansion valve, maintaining a constant

b. At ambients above 27_C (80_F), condenser

pressure control (CPC) is disabled and the

condenser fan runs continuously.

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1. Suction Service Valve

2. Discharge Service Valve

3. Discharge Pressure Regulator Valve

4. Air-Cooled Condenser

5. Evaporator

6. Thermostatic Expansion Valve

7. External Equalizer Line

8. Thermostatic Expansion Valve Bulb

9. Heat Exchanger

11. Sightglass

12. Condenser Pressure Transducer (CPT)

(Located on the back-side of the receiver)

13. Sight Glass/Moisture Indicator

14. Electro-Coated Modular Receiver

15. Manual Liquid Line Valve

16. Filter-Drier

17. Quench Expansion Valve

18. Suction Solenoid Valve

10. Fusible Plug (Located on back of receiver)

19. Suction Modulation Valve

Figure 2-10. Refrigeration Circuit with Receiver

2-15

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2.8 REFRIGERATION CIRCUIT WITH THE

WATER-COOLED CONDENSER (Optional)

b. Maintain a flow rate of 11 to 26 liters per minute (3

to 7 gallons per minute). The water pressure switch

will open to de-energize the condenser fan relay.

The condenser fan motor will stop and will remain

stopped until the water pressure switch closes.

Starting at the compressor, the suction gas is

compressed to a higher temperature and pressure.

When operating with the water-cooled condenser, the

gas flows through the discharge service valve into the

pressure regulator valve that is normally open. The

pressure regulator valve may restrict the flow of

refrigerant to maintain a minimum discharge pressure

of 5 kg/cm@ (70 psig).

Refrigerant gas then moves through the air-cooled coil

to the water-cooled condenser. As the refrigerant flows

across the water chilled coiled tube bundle, it is cooled

to saturation temperature and exits the condenser as a

high pressure/saturated liquid.

The refrigeration unit operating with the water-cooled

condenser will perform as outlined in section 4.4 except

that the condenser fan motor is stopped in all modes.

To shift to air-cooled condenser operation, do the

following:

Disconnect the water supply and the discharge line to

the water-cooled condenser. The refrigeration unit will

shift to air-cooled condenser operation when the water

pressure switch closes. (Refer to section 2.2.)

From the water-cooled condenser, the liquid refrigerant

continues through the manual liquid line valve, the

filter-drier (which keeps refrigerant clean and dry), a

moisture-liquid indicator, and a heat exchanger that

increases subcooling of liquid refrigerant to the

thermostatic expansion valve. As the liquid refrigerant

passes through the orifice of the expansion valve, some

of it vaporizes into a gas (flash gas). Heat is absorbed

from thereturn airby thebalanceoftheliquid, causing it

to vaporize in the evaporator coil. The vapor then flows

through the suction modulation valve (and suction

solenoid valve under some conditions) to the

compressor.

2.9.2 Water-Cooled Condenser with Condenser

Fan Switch (CFS)

For operation of the refrigeration unit with the

water-cooled condenser with (CFS), do the following:

a. Connect the water supply line to the inlet side of

condenserand thedischargelineto theoutlet sideof

the condenser.

b. Maintain a flow rate of 11 to 26 lpm (3 to 7 gpm).

c. Set CFS switch to position ”O” when water is

supplied to the water-cooled condenser. This will

de-energize the condenser fan relay. The condenser

fan motor will stop and will remain stopped until

the CFS switch is set to position ”1.”

The thermostatic expansion valve bulb (on the suction

line near the evaporator coil outlet) controls the

thermostatic expansion valve, maintaining a constant

superheat at the coil outlet regardless of load conditions

except at abnormally high container temperatures such

as during pulldown (valve at maximum operating

pressure condition).

The refrigeration unit operating with the water-cooled

condenser and the CFS switch in position ”O,” will

perform as outlined in section 4.4 except that the

condenser fan motor is stopped in all modes.

2.9 WATER-COOLED CONDENSER (Optional)

The water-cooled condenseris used when cooling water

is available and heating the surrounding air is

objectionable, such as in a ship’s hold.

WARNING

The water-cooled condenseris ofthe shell and coil type,

with water circulating through the cupro-nickel coil.

The refrigerant vapor is admitted to the shell side and is

condensed on the outer surface of the coil.

When water flow is below 11 lpm (3 gpm) or

when water-cooled operation is not in use,

the CFS switch MUST be set to position ”1”

or the unit will not operate properly.

2.9.1 Water--Cooled Condenser with Water

Pressure Switch (WP)

To shift to air-cooled condenser operation, do the

following:

For operation of the refrigeration unit with the

water-cooled condenser, do the following:

Turn the unit OFF and set the CFS switch to position

”1.” Disconnect the water supply and the discharge line

to the water-cooled condenser. The unit should now

perform as outlined in section 4.4.

a. Connect the water supply line to the inlet side of

condenserand thedischargelineto theoutlet sideof

the condenser.

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1. Suction Service Valve

2. Discharge Service Valve

3. Discharge Pressure Regulator Valve

4. Air-Cooled Condenser

5. Evaporator

6. Thermostatic Expansion Valve

7. External Equalizer Line

8. Thermostatic Expansion Valve Bulb

9. Heat Exchanger

11. Manual Liquid Line Valve

12. Moisture-Liquid Indicator

13. Condenser Pressure Transducer (CPT)

14. Filter-Drier

15. Sight Glass

16. Water-Cooled Condenser

17. Suction Solenoid Valve

18. Suction Modulation Valve

19. Quench Expansion Valve

10. Rupture Disc

Figure 2-11. Refrigeration Circuit with Water-Cooled Condenser (Optional)

2-17

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2.10 SUCTION SOLENOID VALVE

2.11 REMOTE MONITORING (Optional)

The suction solenoid valve, shown in Figure 2-5, is

controlled by the Controller relay (TS).

a. Operation

NOTE

The in-range light will be illuminated if the

container control air temperature is within the

tolerance selected. Refer to section 3.1.4

(Code 30).

If set point is below --10_C (+14_F), or --5_C (+23_F)

optionally, and the suction solenoid valve override is not

activated, Controller relay (TS) closes to energize the

suction solenoid valve (SSV). Once opened, the

refrigerant flow rate and unit cooling capacity is

increased.

When the remote monitor plug is connected to the

remote monitoring receptacle, the following remote

circuits are energized:

If set point is above --10_C (+14_F), or --5_C (+23_F)

optionally, the suction solenoid valve opens during the

temperaturepulldown period unless the current limiting

suction solenoid overrides or compressor reliability

enhancement logic restricts its use. A pulldown period

begins when the control temperature is more than 5_C

(+9_F) above set point, and ends as soon as the control

temperature equals set point.

CIRCUIT

FUNCTION

Sockets B to A Energizes remote cool light

Sockets C to A Energizes remote defrost light

Sockets D to A Energizes remote in-range light

For both conditions above, at the instant when the SSV

opens, the SMV will drop to 20% open, then gradually

increase to 100% open. Unless the current limiting

suction solenoid overrides or compressor reliability

enhancement logic (CREL) restricts its use.

b. Suction Solenoid Override

The suction solenoid override function restricts the

opening of the suction solenoid valve (SSV) under

certain high ambient and/or box temperature conditions

to prevent compressor overload under these high

capacity conditions. If the primary return sensor (RTS)

fails (alarm code AL56), the suction solenoid valve will

not open unless the ambient temperature is less than

10_C (50_F). If the ambient sensor fails (AL57), the

suction solenoid valve will not be allowed to open until

the return air temperature is less than 1.67_C (35_F). If

both the ambient and return air (RTS) sensors fail, the

suction solenoid valve will not be allowed to open until

at least one of the sensors is repaired.

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2.12 SAFETY AND PROTECTIVE DEVICES

IP-CP or HPS will shut down the compressor.

Open safety switch contacts on device IP-CM will shut

down the condenser fan motor.

Unit components are protected from damage by safety

and protective devices listed in Table 2-1. These

devices monitor the unit operating conditions and open

a set of electrical contacts when an unsafe condition

occurs.

The entire refrigeration unit will shut down if one of the

following safety devices open: (a) Circuit Breaker(s);

(b)Fuse(F3/15A); or(c) EvaporatorFan MotorInternal

Protector(s) -- (IP-EM).

Open safety switch contacts on either or both of devices

Table 2-1. Safety and Protective Devices

SAFETY DEVICE

UNSAFE CONDITION

DEVICE SETTING

Circuit Breaker (CB-1) -- Manual Reset

Trips at 29 amps (460 vac)

Circuit Breaker (CB-2, 50 amp) --Manual

Reset

Excessive current draw

Trips at 62.5 amps (230 vac)

Circuit Breaker (CB-2, 70 amp) --Manual

Reset

Trips at 87.5 amps (230 vac)

Excessive current draw on the

control circuit

Fuse (F3)

15 amp rating

5 amp rating

N/A

Excessive current draw by the

Controller/DataCORDER

Fuse (F1 & F2)

Excessive condenser fan

motor winding temperature

Internal Protector (IP-CM) -- Automatic

Reset

Excessive compressor motor Internal Protector (IP-CP) -- Automatic

N/A

winding temperature

Reset

Excessive evaporator fan

Internal Protector(s) (IP-EM) -- Automatic

N/A

motor(s) winding temperature Reset

Fusible Plug -- Used on the Receiver

93 _C = (200 _F)

35 kg/cm@ = (500 psig)

Abnormal

pressures/temperatures in the

high refrigerant side

Rupture Disc -- Used on the Water-Cooled

Condenser

Abnormally high discharge

pressure

High Pressure Switch (HPS)

Opens at 25 kg/cm@ (350 psig)

2-19

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SECTION 3

MICROPROCESSOR

3.1 MICRO-LINK 2i CONTROLLER MODULE

1. Micro-Link 2i Controller/DataCORDER Module

5. Control Circuit Power Connection

(Location: In back of connector)

6. Battery Pack (Optional)

7. Software Programming Port

8. Mounting Screw

2. Connectors

3. Test Points

4. Fuses

Figure 3-1. Micro-Link 2i Controller/DataCORDER Module

3.1.1 Brief Description

NOTE

The

Carrier

Transicold

Micro-Link

custom-designed

Controller/DataCORDER is

microprocessor-based module which incorporates

embedded software to:

Some units are equipped with an optional

emergency bypass switch (EB), which permits

a. Control supply or return air temperature to

extremely tight limits by providing modulated

refrigeration control, electric heat control and

defrost to ensure continuous conditioned air

delivery to the load.

manually overriding

malfunctioning

Controller by locking the unit into acontinuous

full cooling mode (see Figure 2-7).

WARNING

b. Provide dual independent readouts of set point and

supply or return air temperatures.

Do not attempt to service the

c. Provide digital readout and ability to select data.

Refer to Table 3-3 for Controller Function Codes.

For Controller alarm digital display identification

refer to Table 3-4.

Controller/DataCORDER

module.

Breaking the warranty seal will void the

warranty.

CAUTION

d. Provide a pre-trip step-by-step checkout of

refrigeration unit performance including: proper

component operation, electronic and refrigeration

control operation, heater operation, probe

calibration and current limiting. Refer to section

3.2.

Remove the Controller/DataCORDER

module and unplug all wire harness

connectors before performing any arc

welding on any part of the container.

Do not remove wire harnesses from module

unless you are grounded to the unit frame

with a static safe wrist strap.

e. Provide the ability to select or change Codes 27 to

37 and set point without AC power being hooked

up. Refer to section 3.1.4.

3-1

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f. Provide reprogrammability and configuration

through a memory card. The memory card

automatically downloads new software to the

Controller when inserted, and controls output to the

display for status information.

Operational Software:

This software operates the Controller module, which

turns fans on and off, turns the compressor on and off,

etc.

Configuration Software:

g. Provide electronic data storage.

This software tells the Operational Software what

physical components are built into the container unit.

Refer to Table 3-1.

NOTE

For the benefit of the reader the remaining parts

of section 3.1 will devote themselves to the

temperature controller portion of the module.

For the integrated DataCORDER refer to

section 3.3.

Programming cards with eitherOperational Softwareor

Configuration Software are available through CTD

Replacement Components Group.

The use of a configuration program card in the field

should only occur under unusual circumstances. Some

of these circumstances may include:

3.1.2 Controller Programming (Memory) Cards

The programming cards are used for loading software

into the Controller. This is the same concept as using a

floppy diskette to load software into a personal

computer.

a. A Controller module that has an older version of

Operational Software, when the need exists to

upgrade to a newer version of the software.

b. A physical component in the container unit is

changed to a different component, resulting in a

new configuration for the unit.

The software that can be loaded into the Controller

module comes in one of two forms: “Operational

Software” or “Configuration Software.”

c. A Controller module was damaged in such a way

that the integrity or existence of software within the

module is questionable.

Procedure for loading software:

Refer to section 6.27.1.

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Table 3-1. Controller Configuration Variables

CONFIGURATION

NUMBER

TITLE

Bypass Valve Enable

DEFAULT

OPTION

Out

Evaporator Fan Speed

Number of Sensor Probes

Dehumidification Mode

Probe Calibration

Condenser Fan Speed Select

Unit Selection, 20FT/ 40FT/45FT

Single Phase/Three Phase Motor

Refrigerant Selection

dS (Dual)

FoUR

noCal

Off (Single)

40ft

SS (Single)

dUAL

Off

CAL

On (Variable)

20ft,45

3Ph

r12, r22, bLEnd

In (Dual)

OFF

In (Solenoid)

Out

Off (No)

In (Yes)

1Ph

r134a

Out (Single)

noOFF

Out (TXV)

Out

Compressor Speed

Defrost “Off” Selection

TXV/Solenoid Quench Valve

Unloader

Condenser Pressure Control (CPC)

Discharge Temperature Sensor

DataCORDER Option

Discharge Pressure Sensor

Heater

Controlled Atmosphere

Pressure Sensor (Suction)

Auto-Transformer

Economy Mode Option

Defrost Interval Timer Save Option

Advanced Pre-Trip Enhanced Test

Pre-Trip Test Points/Results Recording

Heat Lockout

Suction Temperature Display

Bulb Mode

Arctic Mode

Compressor Size

Probe Check Logic

Single Evaporator Fan Option

Snap Freeze Option

Degree Celsius Lockout Option

Humidification Mode

Modulation Valve Type

Electronic Partlow

Quench Bypass Valve

Current Limit Range

Demand Defrost

Out

On (Yes)

Out (No)

Old (Low Watt)

Out (No)

Std

Off

noSAV

Off

rSLts

Set to --10_C

Out

Nor

Out

41 CFM

Std

2EF0

Off

bOth

Off

rEtur

Out

nEW (High Watt)

In (Yes)

Std, Full

SAV

data

Set to--5_C

bulb

37 CFM

SPEC

1EF0

SnAP

2, 3

SuPPL, bOth

Out

3-3

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3.1.3 General Layout of the Controller Section

Table 3-2. Key Pad Function

FUNCTION

The Micro-Link 2i Controller/DataCORDER consists

of a key pad, display module and Controller module.

Connectors are used to attach the wiring of the unit to

the Controller module. The Controller module is

designed to permit ease of installation and removal.

KEY

Change set point upward. Change

codes upward. Scan alarm list upward.

Change user selectable features

upward. Pre-trip advance forward.

Arrow Up

Pre-trip test interruption. DataCORDER

Function and Alarm Codes are scrolled

upward after the ALT. MODE key is

depressed.

All control functions are accessed by key pad selections

and viewed on the display module which are designed

for optimum user friendliness and convenience.

The key pad (see Figure 3-1) is mounted on the

right-hand side of the control box. The key pad consists

of eleven push-energized membrane switches that act as

the user’s interface with the Controller and the optional

DataCORDER. Refer to Table 3-2.

Change set point downward. Change

codes downward. Scan alarm list

downward. Change user selectable

features downward. Pre-trip repeat

backward. DataCORDER Function and

Alarm Codes are scrolled downward

after the ALT. MODE key is depressed.

Arrow Down

Return/Sup Displays

non-controlling

probe

ply

temperature (momentary display).

Displays alternate temperature scale

(momentary display).

CODE

SELECT

PRE

TRIP

_C/_F

Displays alarm list and clearing of the

alarm queue (when followed by Enter

key) for the Controller, and also for the

DataCORDER after the ALT. MODE

key is depressed.

Alarm List

ALARM

LIST

DEFROST

INTERVAL

Access function codes (see arrow up

and arrow down) for the Controller,

and also for the DataCORDER after

the ALT. MODE key is depressed.

Code Select

Defrost

Interval

Displays selected defrost interval.

ENTER

Displays a pre-trip selection menu.

Discontinues pre-trip in progress.

Pre–Trip

If the unit is equipped with the optional

battery pack, initiate the battery

backup mode to allow set point and

function code selection if no mains

power is present.

Battery

Power

Entering

set point change.

RETURN

SUPPLY

Extending to 30 seconds the time a

chosen data function code is

displayed. Entering the value of a user

selectable mode. Clearing the alarm

list and initiating pre-trip. Also used for

various DataCORDER functions after

the ALT. MODE key is depressed.

Enter

BATTERY

POWER

ALT.

MODE

Allows access to DataCORDER

function

codes,

alarm codes,

ALT. Mode

DataCORDER configuration and

scrollback.

Figure 3-1. Key Pad

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The display module (see Figure 3-2) is mounted at a 20

degree downward tilt to aid in visibility. The display

module consists of:

COOL

HEAT

DEFROST IN RANGE ALARM

SUPPLY RETURN

a. Two 25mm (1 inch) high, five digit LCD displays

which are easily viewed in direct sunlight and

backlighted for superior low-light visibility.

SETPOINT/Code

AIR TEMPERATURE/Data

b. Seven Indicators:

Cool -- White Lamp: Energized when the

refrigerant compressor is energized.

Heat -- Orange LED: Energized when the

heaters are on, and the unit is in the heat or

defrost mode.

Figure 3-2. Display Module

NOTE

Defrost -- Orange LED: Energized when the

heaters are on, and the unit is in the defrost

mode.

The default display mode will show the set

point temperature (on the left display) and

controlling probe temperature (on the right

display). The controlling probe in the

perishable range will be the SUPPLY air probe

and the controlling probe in the frozen range

will be the RETURN air probe.

In-Range -- Green LED: Energized when the

controlling temperature probe is in range.

(Supply air probe will be used for control in

the perishable ranges and the return air probe is

used for control in the frozen ranges.)

Alarm -- Red LED: Energized when there is

an active or an inactive shutdown alarm

(AL20 to AL27) in the alarm queue.

Supply -- Yellow LED: Energized when

supply temperature and set point are

displayed. Flashes if dehumidification or

humidification is enabled on units so

equipped.

Return -- Yellow LED: Energized when return

temperature and set point are displayed.

3-5

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3.1.4 Controller Function Codes

(see Table 3-3). For the display only function codes, the

right window will display the value of this item for five

seconds before returning to the normal display mode. If

a longer time is desired, pressing the ENTER key will

extend the time to 30 seconds after the last pressing of

the ENTER key. Function codes are explained in

Table 3-3.

There are thirty-nine functions which the operator may

access to examine the operating status of the unit. To

access these functions, perform the following steps:

Press the CODE SELECT key, then press an arrow key

until the left window displays the desired code number

Table 3-3. Controller Function Code Assignments

CODE

TITLE

DESCRIPTION

Inapplicable Functions Display ----------

Display Only Functions

The suction modulation valve (SMV) is a normally open valve which restricts flow

of refrigerant to the compressor when energized by a pulse width modulated

(PWM) output. The amount of valve closure is proportional to the applied current

over the range of 0.2 to 1.3 A. The valve is completely open (right display reads

100%) below 0.2 amps and is completely closed (right display reads 0%) at 1.3

amps.

Modulation Valve

Opening (%)

Cd01

Quench Valve

(Open--Closed)

Cd02

Cd03

Shows state of the solenoid quench valve, if so equipped (open or closed).

The suction solenoid valve (SSV) provides maximum refrigerant flow to the

refrigeration unit. This valve will always be open for set points at or below --10_C

(+14_F), or --5_C (+23_F) optionally, and during temperature pulldown periods

unless suction solenoid override or current limiting restricts its use.

Suction Solenoid

Valve

(Open--Closed)

Unit current is monitored by two current sensors. The current measured is used

for control and diagnostic purposes.For control processing, the highest of the

Phase A and B current values is used for current limiting purposes. The third

unmeasured leg is calculated based on a current algorithm. For diagnostic

processing, the current draws are used to determine control unit operations.

Whenever a heater or a motor is turned ON or OFF, the current draw

increase/reduction for that activity is measured. The current draw is then tested to

determine if it falls within the expected range of values for the unit. Failure of this

test will result in a pre-trip failure or a control alarm indication.

Line Current, Phase

Cd04

Cd05

Cd06

Cd07 Main Power Voltage The main supply voltage is displayed.

The value of the main power frequency is displayed in Hertz. The frequency

Mains Power

Frequency

displayed will be halved if either fuse F1 or F2 is bad and alarm code AL21 is

active.

Cd08

Cd09

Cd10

Ambient

Temperature

Compressor Suction

Temperature

(Optional)

The ambient sensor (AMBS) measures the temperature outside the container.

For location of the sensor, see Figure 2-5.

Compressor suction temperature is measured just prior to the compressor suction

service valve, and is a display-only temperature.

Compressor

Discharge

Temperature

(Optional)

The compressor discharge temperature is measured near the compressor

discharge valve and is display only.

Cd11

Cd12

Compressor suction pressure is displayed using a pressure transducer. Pressure

is displayed in units of psig when code 28 is set to _F and units of bars when

Compressor Suction

Pressure (Optional) code 28 is set to _C. “P” appears after the value to indicate psig, “b” appears after

the value to indicate bars and “i” appears after the value for inches of mercury.

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CODE

TITLE

DESCRIPTION

Inapplicable Functions Display ----------

Condenser pressure is displayed using a pressure transducer. Pressure is

displayed in units of psig when code 28 is set to _F and units of bars when

function code Cd28 is set to _C. “P” is displayed after the value to indicate psig,

“b” appears after the value to indicate bars and “i” appears after the value for

inches of mercury.

Condenser Pressure

(CPC)

Cd13

Cd14

Compressor discharge pressure is displayed using a pressure transducer.

Pressure is displayed in units of psig when function code Cd28 is set to _F and

Compressor

Discharge Pressure units of bars when Cd28 is set to _C. “P” is displayed after the value to indicate

(Optional)

psig, “b” appears after the value to indicate bars and “i” appears after the value

for inches of mercury.

Unloader Valve

(On--Off)

Compressor Motor

Hour Meter

Relative Humidity

(%) (Optional)

Cd15

Cd16

Cd17

The status of the unloader valve (if present) is displayed (on or off).

Records total hours of compressor run time. Total hours are recorded in

increments of 10 hours (i.e., 3000 hours displayed as 300).

This code is only applicable to units with a humidity sensor (HS). This code

displays, as a percent value, the relative humidity at that time.

Cd18 Software Revision # The software revision number is displayed.

This code checks the Controller/DataCORDER battery pack. While the test is

running, “btest” will flash on the right display, followed by the result. “PASS” will

be displayed for battery voltages greater than 7.0 volts and for alkaline batteries

with voltages greater than 7.5 volts, “FAIL” will be displayed for battery voltages

between 4.5 and 7.0 volts, and “------” will be displayed for battery voltages less

than 4.5 volts. After the result is displayed for four seconds, “btest” will again be

displayed, and the user may continue to scroll through the various codes.

Cd19 Battery Check

This code indicates the dash number of the model for which the Controller is

configured (i.e., if the unit is a 69NT40-511-105, the display will show 11105).

Cd20 Config/Model #

Cd21 Future Expansion

This code is for future expansion, and is not in use at this time.

Compressor Speed

(High--Low--Off)

Cd22

The status of the compressor is displayed (high, low or off).

Evaporator Fan

Speed

Cd23

Cd24

Cd25

Cd26

Displays the current evaporator fan state (high, low or off).

(High--Low--Off)

Controlled

Atmosphere State

(On--Off) (Optional)

This code shows the state of Controlled Atmosphere (enabled or disabled), if

equipped.

Compressor Run

Time Remaining

Until Defrost

This code displays the time remaining until the unit goes into defrost (in tenths of

an hour). This value is based on the actual accumulated compressor running

time.

The defrost termination sensor (DTS) is located immediately above the

evaporator coil. It is used by the Controller for defrost initiation and termination.

(See Figure 2-2.)

Defrost Termination

Sensor Temperature

3-7

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CODE

TITLE

DESCRIPTION

Inapplicable Functions Display ----------

Display Only Functions

NOTE

Function codes Cd27 through Cd37 are user-selectable functions. The operator can change the value of

these functions to meet the operational needs of the container.

The defrost interval is the time interval between defrost cycles. Five selectable

values are available: 3, 6, 9, 12 or 24 hours. The factory default value is 12 hours.

The time interval of the first defrost will not begin counting down until defrost

termination sensor (DTS) is below 10_C (50_F). The time interval to the next

defrost cycle is entered into the Controller at the time DTS is below 10_C (50_F)

or at power-up. (See code Cd37 for deviations.) If DTS reaches 25.6_C (78_F) at

any time during the timer count down, the interval is reset and the countdown

begins over. If DTS has failed (i.e., alarm code AL60 is active) and the primary

return sensor temperature is less than 10_C, the interval timer countdown begins.

The interval timer is reset if the return sensor temperature rises above 25.6_C.

(See section 4.4.6.)

Defrost Interval

(Hours)

Cd27

Defrost Interval Timer Value Option: If the software is configured to “ON” for this

option, then the value of the defrost interval timer will be saved at power down

and restored at power up. This option prevents short power interruptions from

resetting an almost expired defrost interval, and possibly delaying a needed

defrost cycle.

NOTE

The defrost interval timer counts only during compressor run time.

This code determines the temperature units (_C or _F) which will be used for all

temperature displays. The user selects _C or _F by selecting function code Cd28

and pushing the ENTER key. The factory default value is Celsius units.

Temperature Units

(_C or _F)

Cd28

Cd29

NOTE

This function code will display “--- --- --- --- --- “ if the Controller configuration

variable option 34 is set to _F (refer to Table 3-1).

If all of the control sensors are out of range (alarm code AL26) or there is an

alarm code AL27 failure, the unit will enter the shutdown state defined by the

failure action. The user selects one of four possible actions as designated by a

selection code:

Failure Action

(Mode)

A -- Full Cooling (SMV 100%)

B -- Partial Cooling (SMV 50% open)

C -- Evaporator Fan Only

D -- Full System Shutdown -- Factory Default

The in-range tolerance will determine the band of temperatures around the set

point which will be designated as in-range. If the control temperature is in-range,

the in-range light will be illuminated. There are four possible values:

1. ¦ 0.5_C (¦ 0.9_F)

Cd30 In-Range Tolerance

2. ¦ 1.0_C (¦ 1.8_F)

3. ¦ 1.5_C (¦ 2.7_F)

4. ¦ 2.0_C (¦ 3.6_F) -- Factory Default

The stagger start offset time is the amount of time that the unit will delay at

start-up, thus allowing multiple units to stagger their control initiation when all

units are powered up together. The eight possible offset values are:

0 (Factory Default), 3, 6, 9, 12, 15, 18 or 21 seconds

Stagger Start Offset

Cd31

Time (Seconds)

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CODE

TITLE

DESCRIPTION

Inapplicable Functions Display ----------

The current limit is the maximum current demand allowed on any phase at any

time. Limiting the unit’s current (amperage) reduces the load on the main power

and lowers the compressor discharge pressure. When desirable, the limit can be

lowered. Note, however, that capacity is also reduced. The five values for 460vac

operation are:

Current Limit

(Amperes)

Cd32

Cd33

15, 17, 19, 21 (Factory Default), 23

This code is only applicable to units with a humidity sensor (HS).Relative humidity

set point is available only on units configured for dehumidification. When the

mode is activated, the control probe LED flashes on and off every second to alert

the user. If not configured, the mode is permanently deactivated and Cd33 will

display “----------.” When set point is available, it can be set to “OFF.” “TEST,” or 65

to 95% relative humidity in increments of 1%. If bulb mode is active (code Cd35)

and “Lo” speed evaporator motors are selected (code Cd36) then set point

ranges from 60 to 95%. When “TEST” is selected or test set point is entered, the

heaters should be turned on, indicating that dehumidification mode is activated.

After a period of five minutes has elapsed in this mode, the previously selected

mode is reinstated.

Dehumidification

Control (% RH)

(Optional)

Economy mode is a user selectable mode of operation provided for power saving

purposes. Refer to sections 3.1.7.1 and 3.1.7.2 for a more detailed description of

economy mode.

Economy Mode

Cd34

Cd35

(On--Off) (Optional)

Bulb mode is a user selectable mode of operation that is an extension of normal

dehumidification. If dehumidification is set to “Off,” code Cd35 will display “Nor”

and the user will be unable to change it. After a dehumidification set point has

been selected and entered for code Cd33, the user may then change code Cd35

to “bulb.” After bulb has been selected and entered, the user may then utilize

function codes Cd36 and Cd37 to make the desired changes.

Bulb Mode

(Normal--Bulb)

(Optional)

This code is enabled only if a dehumidification set point has been selected using

function code Cd33 and “bulb” has been selected using function code Cd35. If

these conditions are not met, “alt” will be displayed indicating that the evaporator

fans will alternate their speed whenever a dehumidification set point is selected.

This display cannot be changed by the user. If a dehumidification set point has

been selected along with bulb mode then “alt” may be selected for alternating

speed, “Lo” for low speed evaporator fan only, or “Hi” for high speed evaporator

fan only. If a setting other than “alt” has been selected and bulb mode is

deactivated in any manner, then selection reverts back to “alt.”

This code, as with function code Cd36, is used in conjunction with bulb mode and

dehumidification. If bulb mode is active, this code allows the user to change the

temperature above which the defrost termination sensor (DTS) temperature must

go to terminate defrost. It allows the user to change the setting from 4_C to

25.6_C in 0.1_C (0.2_F) increments. This value is changed using the UP/DOWN

ARROW keys, followed by the ENTER key when the desired value is displayed. If

bulb mode is deactivated in any manner, the DTS setting above which defrost

terminates defaults to the normal 25.6_C (78_F) setting.

Evaporator Speed

Select

(Cd35 must be in

“Bulb”)

Cd36

Cd37

Defrost Temperature

Sensor Setting

(Optional)

NOTE

In the unlikely event that AL55 activates, Function Codes Cd38 and Cd39 will display SRS and RRS,

respectively.

This code is only applicable to units without a DataCORDER that are configured

to have four probes. If this is true, it will then display the current secondary supply

air temperature.If the unit is configured with a DataCORDER, the Controller

function code Cd38 will display “----------.” and the display values for SRS will

appear on the DataCORDER function code dC1.

Secondary Supply

Air Temperature

(Optional)

Cd38

3-9

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CODE

TITLE

DESCRIPTION

Inapplicable Functions Display ----------

This code is only applicable to units without a DataCORDER, that are configured

to have four probes. If this is true, it will then display the current secondary return

air temperature.If the unit is configured with a DataCORDER, the Controller

function code Cd39 will display “----------,” and the display values for RRS will

appear on the DataCORDER function code dC2.

Secondary Return

Air Temperature

(Optional)

Cd39

3.1.5 Controller Alarms

To Display Alarm Codes:

While in Set Point Selection or Default Display mode,

press the ALARM LIST key. This accesses the Alarm

List Display Mode, which displays any alarms archived

in the Alarm Queue. The alarm list stores up to 16

alarms in the sequence in which they occurred. The user

may scroll through the list by depressing the UP

ARROW key. Depressing the DOWN ARROW key

allows the user to scroll backward through the list.

The alarm philosophy balances the protection of the

refrigeration unit and that of the refrigerated cargo. The

action taken when an error is detected always considers

the survival of the cargo. Rechecks are made to confirm

that an error actually exists.

Some alarms requiring compressor shutdown havetime

delays before and after to try to keep the compressor on

line. An example is a low mains voltage, when the

voltage drops over 25%, an indication is given on the

display, but the unit will continue to run.

The left display will show “AL#,” where # is the alarm

number sequentially in the queue.

The right display will show:

An alarm (See Table 3-4) is indicated by flashing an

alarm codeon thedisplay panel, and forsomealarms, by

the alarm light illuminating.

“AAXX” for an active alarm, where “XX” is

the alarm code. See Table 3-4, Controller

Alarm Indications.

When an Alarm Occurs:

“IAXX” for an inactive alarm.

The red alarm light will illuminate for “20

series” alarms only.

“END” is displayed to indicate the end of the alarm list

if any alarms are active. “CLEAr” is displayed if all

alarms are inactive.

If a detectable problem is found to exist, its

alarm code will be alternately displayed with

the set point on the left display.

The alarm queue may only be cleared if no

alarms are active, other than alarm code

AL51, and “CLEAr” is displayed.

The user should scroll through the alarm list

to determine what alarms exist or have

existed. Alarms must be diagnosed and

corrected before the Alarm List can be

cleared.

To Clear the Alarm List:

If all above conditions have been satisfied, e.g. no

alarms are active other than AL51, the alarm queue may

be cleared.

Press the ENTER key. The alarm list will

c l e a r a n d “ -- -- -- -- -- ” w i l l b e d i s p l a y e d .

NOTE

If the unit is configured for single evaporator

fan operation (refer to Table 3-1), and

troubleshooting alarms AL11 and AL12, be

aware that the presence of 24 vac on the

evaporator fan motor internal protector safety

sense lines (MC6 and KB10) will indicate a

failure condition. This differs from most other

circumstances, whereby the absence of 24 vac

usually means an alarm condition is present.

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Table 3-4. Controller Alarm Indications

CODE

TITLE

DESCRIPTION

MODEL 69NT40-511-72

Alarm 11 is triggered by the opening of the internal protector for evaporator fan

motor #1. This alarm will disable the probe check portion of defrost and the probe

diagnostic logic.

Evaporator Fan

Motor 1 Safety

AL11

AL12

Alarm 12 is triggered by the opening of the internal protector for evaporator fan

motor #2. This alarm will disable the probe check portion of defrost and the probe

diagnostic logic.

Evaporator Fan

Motor 2 Safety

ALL MODELS

Control Circuit Fuse Alarm 20 is triggered by fuse (F3) opening and will cause the software shutdown

AL20

AL21

Open (24 vac)

of all control units. This alarm will remain active until the 15 amp fuse is replaced.

Alarm 21 is triggered by one of the fuses (F1/F2) being opened on 18 volts AC

power supply to the Controller. The suction modulation valve (SMV) will be

opened and current limiting is halted. The compressor will cycle. Temperature

control will be maintained by cycling the compressor.

Micro Circuit Fuse

Open (18 vac)

Alarm 22 is triggered by the opening of the evaporator motor internal protector.

This alarm will disable all control units until the motor protector resets. Also, refer

to code Cd29.If the unit is configured for single evaporator fan operation, alarm

AL22 will also activate if alarms AL11 and AL12 are active simultaneously.

Evaporator Fan

Motor Safety

AL22

KA2--KB10 Jumper

Disconnected

Alarm 23 is triggered by a missing jumper wire. The alarm will stay active until the

jumper wire is reconnected.

Alarm 24 is triggered by the opening of the compressor motor internal protector.

This alarm will disable all control units except for the evaporator fans and will

remain active until the motor protector resets. Also, refer to code Cd29.

AL23

AL24

Compressor Motor

Safety

Alarm 25 is triggered by the opening of the condenser motor internal protector

and will disable all control units except for the evaporator fans. This alarm will

remain active until the motor protector resets. This alarm is deactivated if the unit

is operating on water cooled condensing.

Alarm 26 is triggered if the Controller determines that all of the control sensors

are out-of-range. This can occur for box temperatures outside the range of --50_C

to +70_C (--58_F to +158_F). This alarm triggers the failure action code set by

Function Code Cd29.

Condenser Fan

Motor Safety

AL25

AL26

All Supply and

Return Air Control

Sensors Failure

The Controller has a built-in Analog to Digital (A-D) converter, used to convert

analog readings (i.e. temperature sensors, current sensors, etc.) to digital

readings. The Controller continuously performs calibration tests on the A-D

converter. If the A-D converter fails to calibrate for 30 consecutive seconds, this

alarm is activated.This alarm will be inactivated as soon as the A-D converter

calibrates.

Probe Circuit

Calibration Failure

AL27

During start-up diagnostics, the EEPROM is examined to determine validity of its

contents. This is done by testing the set point and the alarm list. If the contents

are invalid, Alarm 51 is activated.During control processing, any operation

involving alarm list activity that results in an error will cause Alarm 51 to be

activated.Alarm 51 is a “display only” alarm and is not written into the alarm list.

Pressing the ENTER key when “CLEAr” is displayed will result in an attempt to

clear the alarm list. If that action is successful (all alarms are inactive), Alarm 51

will be reset.

AL51 Alarm List Failure

AL52 Alarm List Full

Alarm 52 is activated whenever the alarm list is determined to be full; at start-up

or after recording an alarm in the list. Alarm 52 is displayed, but is not recorded in

the alarm list. This alarm can be reset by clearing the alarm list. This can be done

only if all alarms written in the list are inactive.

3-11

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CODE

TITLE

DESCRIPTION

Alarm 53 is caused by the nicad battery pack being too low of a charge for

battery-backed recording.

NiCad Battery Pack

Failure

AL53

NOTE

Check for recharging or replacing battery pack.

Alarm 54 is activated by an invalid primary supply sensor reading that is sensed

outside the range of --50 to +70_C (--58_F to +158_F) or if the probe check logic

has determined there is a fault with this sensor. If Alarm 54 is activated and the

primary supply is the control sensor, the secondary supply sensor will be used for

control if the unit is so equipped. If the unit does not have a secondary supply

probe, and AL54 is activated, the (primary return sensor, minus 2_C) will be used

for control.

Primary Supply Air

Sensor Failure

(STS)

AL54

NOTE

The P5 Pre-Trip test must be run to inactivate the alarm (refer to section 3.2.1).

This alarm has been activated to indicate the DataCORDER has been disabled

due to internal failure. To clear this alarm, simply reconfigure the unit to its OEM

model number by using the multi-configuration card.

DataCORDER

Failure

AL55

AL56

Alarm 56 is activated by an invalid primary return sensor reading that is outside

the range of --50 to +70_C (--58_F to +158_F). If Alarm 56 is activated and the

primary return is the control sensor, the secondary return sensor will be used for

control if the unit is so equipped. If the unit is not equipped with a secondary

return sensor or it fails, the primary supply sensor will be used for control.

Primary Return Air

Sensor Failure

(RTS)

NOTE

The P5 Pre-Trip test must be run to inactivate the alarm (refer to section 3.2.1).

Ambient

Alarm 57 is triggered by an ambient temperature reading outside the valid range

Temperature Sensor

Failure (AMBS)

AL57

AL58

AL59

from --50_C (--58_F) to +70_C (+158_F).

Compressor High

Pressure Safety

(HPS)

Alarm 58 is triggered when the compressor high discharge pressure safety switch

(HPS) remains open for at least one minute. This alarm will remain active until the

pressure switch resets, at which time the compressor will restart.

Heat Termination

Thermostat (HTT)

Safety

Alarm 59 is triggered by the opening of the heat termination thermostat (HTT) and

will result in the disabling of the heater. This alarm will remain active until the

thermostat resets.

Alarm 60 is an indication of a probable failure of the defrost termination sensor

(DTS). It is triggered by the opening of the heat termination thermostat (HTT) or

the failure of the DTS to go above 25.6_C (78_F) within two hours of defrost

initiation. After one-half hour with a frozen range set point, or one-half hour of

continuous compressor run time, if the return air falls below 7_C (45_F), the

Controller checks to ensure defrost termination sensor (DTS) has dropped to

10_C or below. If not, a DTS failure alarm is given and the defrost mode is

operated off of return temperature sensor (RTS). The defrost mode will be

terminated after one hour by the Controller.

Defrost Termination

Sensor Failure

(DTS)

AL60

Alarm 61 is the heater alarm caused by detection of improper amperage resulting

from heater activation (deactivation). Each phase of the power source is checked

for proper amperage.This alarm is a display alarm with no resulting failure action,

and will be reset by a proper amp draw of the heater.

AL61 Heaters Failure

Alarm 62 is triggered by improper current draw increase (or decrease) resulting

from compressor turn on (or off). The compressor is expected to draw a minimum

of 2 amps; failure to do so will activate the alarm.This is a display alarm with no

associated failure action and will be reset by a proper amp draw of the

compressor.

Compressor Circuit

Failure

AL62

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CODE

TITLE

DESCRIPTION

Alarm 63 is triggered by the current limiting system. If the compressor is ON and

current limiting procedures cannot maintain a current level below the user

selected limit, the current limit alarm is activated.This alarm is a display alarm and

is inactivated by power cycling the unit, changing the current limit via the code

select Cd32, or if the suction modulation valve (SMV) is allowed to open to 100%

and the suction solenoid valve is allowed to open.

AL63 Current Over Limit

Alarm 64 is triggered if the discharge temperature is sensed greater than 135_C

(275_F) for three continuous minutes, if it exceeds 149_C (300_F), or if the

sensor is out of range. This is a display alarm and has no associated failure

action.

Discharge

Temperature Over

Limit (CPDT)

AL64

Discharge Pressure Alarm 65 is triggered by a compressor discharge transducer reading outside the

Transducer Failure

(DPT)

valid range of 73.20 cm Hg (30 in Hg) to 32.34 Kg/cm²(460 psig). This is a

display alarm and has no associated failure action.

AL65

AL66

AL67

AL68

AL69

Suction Pressure

Transducer Failure

(SPT)

Alarm 66 is triggered by a suction pressure transducer reading outside the valid

range of 73.20 cm Hg (30 in Hg) to 32.34 Kg/cm²(460 psig). This is a display

alarm and has no associated failure action.

Alarm 67 is triggered by a humidity sensor reading outside the valid range of 0%

to 100% relative humidity. If alarm AL67 is active and the dehumidification mode

was previously activated, then the dehumidification mode will be deactivated.

Humidity Sensor

Failure

Condenser Pressure Alarm 68 is triggered by a condenser pressure transducer reading outside the

Transducer Failure

(CPT)

valid range of 73.20 cm Hg (30 in Hg) to 32.34 Kg/cm²(460 psig). This is a

display alarm and has no associated failure action.

Suction Temperature Alarm 69 is triggered by a suction temperature sensor reading outside the valid

Sensor Failure

(CPSS)

range of --60_C (--76_F) to 150_C (302_F). This is a display alarm and has no

associated failure action.

NOTE

If the Controller is configured for four probes without a DataCORDER, the DataCORDER alarms AL70

and AL71 (See Table 3-7) will be processed as Controller alarms AL70 and AL71.

The Controller performs self-check routines. if an internal failure occurs, an ERR

#0--5 will appear on the display. This is an indication the Controller needs to be

replaced.

ERROR

DESCRIPTION

Indicates that the Controller working memory has

failed.

#0 -- RAM failure

#1 -- Program Memory

failure

Indicates a problem with the Controller program.

Internal

Microprocessor

Failure

ERR

The Controller program has entered a mode whereby

the Controller program has stopped executing.

#2 -- Watchdog time--out

#3 -- On board timer

failure

The on board timers are no longer operational. Timed

items such as; defrost, etc. may not work.

#4 -- Internal counter

failure

Internal multi-purpose counters have failed. These

counters are used for timers and other items.

The Controller’s Analog to Digital (A-D) converter has

failed.

#5 -- A-D failure

Enter Setpoint

(Press Arrow &

Enter)

Entr

StPt

The Controller is prompting the operator to enter a set point.

Low Mains Voltage

(Function Codes

Cd27--38 disabled

and NO alarm

stored.)

This message will be alternately displayed with the set point whenever the mains

voltage is less than 75% of its proper voltage.

3-13

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3.1.6 Condenser Pressure Control (CPC)

The Controller configuration variable for “Heat

Lockout” (refer to Table 3-1) can be changed for set

points of either --10_C (+14_F), or --5_C (+23_F)

optionally.

A pressure control system has been incorporated by

means of a condenser pressure transducer (CPT) and

condenser pressure control (CPC) logic to maintain

discharge pressures above 130 psig in low

temperatures.

NOTES

When upward set point changes are made at

ambients below 27_C (80_F), the compressor

is immediately cycled OFF. The compressor

three minute time delay will be overridden, so

that as soon as the control temperature is at

least 0.2_C (0.4_F) above set point the

compressor will turn ON.

In order for the CPC logic to be enabled, the following

conditions must be met:

CPC configuration variable set to “In”

CPT sensor is valid (alarm code AL68

inactive)

AMBS sensor is valid

(alarm code AL57 inactive)

When the compressor starts for the first time

after power is applied manually, the SMV

will open to 100% and the unit will run for

three minutes to boil off dissolved refrigerant

from the compressor oil.

AMBS is less than or equal to 26.6_C

(79.9_F)

Voltage/Frequency ratio is less than or equal

to 8.38

3.1.7.1 Perishable (Chill) Range Above --10_C

(+14_F), or --5_C (+23_F) Optionally.

When condenser pressure control (CPC) is enabled (all

of the above conditions are met), either pressures or

timers may dictate a change of state from OFF to ON, or

ON to OFF. If the condenser fan is OFF, it will be

energized if saturation condensing pressure is greater

than 200 psig OR if the condenser fan has been OFF for

a maximum of sixty seconds depending on the ambient

temperature. If the condenser fan is ON, it will

de-energizeonly ifthesaturation condensing pressureis

less than 130 psig and the condenser fan has been

running for a minimum of thirty seconds depending on

the ambient temperature. As the ambient temperature

increases, the amount of time that the condenser fan is

energized will correspondingly increase.

For set points above -- 1 0 _C (+14_F), or --5_C (+23_F)

optionally, the Controller maintains SUPPLY air at the

set temperature by the following modes of operation:

a. Operation in the conventional mode without

dehumidification (Code 33 OFF)

1. At ambients below 27_C (80_F), the condenser fan

will cycle on/off depending on condenser pressure and

on/off times.

If thecondenser pressureis greaterthan 200 psig OR the

condenser fan has been OFF at least 60 seconds, the

condenser fan will start.

If the condenser pressure is less than 130 psig AND the

condenser fan remains ON for at least 30 seconds, the

condenser fan will stop.

If any one of the following conditions occur the CPC

logic will be disabled:

2. At ambients above 27_C (80_F), condenser

pressure control (CPC) is disabled and the condenser

fan runs continuously.

CPT sensor is invalid

(alarm code AL68 activates)

AMBS sensor is invalid

(alarm code AL57 activates)

If the unit starts when ambient is below --10_C

(+14_F) and condenser pressure is below 200 psig,

the condenser fan will not start until pressure

reaches 200 psig.

AMBS is greater than 29.5_C (85.1_F)

Voltage/Frequency ratio is greater than 8.42

The supply probe is used for control and is so indicated

by the “SUPPLY” LED on the display module. The

Perishable temperature range demands high accuracy.

The unit is capable of maintaining supply air

temperature to within ¦0.25_C (¦0.5_F) of the set

point temperature setting. In Perishable range above

-- 1 0 _C (+14_F), or --5_C (+23_F)optionally, control is

maintained by controlling the positions of the suction

3.1.7 Controller Temperature Control

There are two control ranges, Frozen and Perishable

(chill). The Frozen range is active with set points at or

below --10_C (+14_F), or --5_C (+23_F) optionally,

and the Perishable range is active at set points above

-- 1 0 _C (+14_F), or --5_C (+23_F) optionally. See

Figure 3-4 and Figure 3-5.

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modulation valve (SMV) and suction solenoid valve

(SSV) with the compressor energized.

3. The control probe (i.e.; Supply 1) temperature is

less than set point, plus 0.25_C.

4. Temperature control set point is greater than -- 1 0 _C

(+14_F), or --5_C (+23_F) optionally, in the

perishable range, and the compressor is running.

When pulling down from a control temperature that is

more than 5_C (9_F) above set point, both valves will

be open to reduce the pulldown time unless suction

solenoid override or current limiting is activated. See

section 2.10 for explanation of suction solenoid

override. The current limit function will restrict the

valves if the current is above the selected value. When

the controlling probe temperature reaches set point, the

suction solenoid valve will close.

5. The heater debounce timer (three minutes) has

timed out.

6. Heater termination thermostat (HTT) is closed.

7. The Controlled Atmosphere (CA) option VENT or

Pre-Trip mode is not initiated.

When the controlling probe temperature enters the

in-range temperature tolerance as selected at function

code Cd30, the in-range light will energize.

8. Humidity sensor alarm is not active (AL67).

9. High pressure switch (HPS) is not open.

If the above conditions remain true for at least one hour

the evaporator fans will switch from high to low speed

operation (on units so equipped). The evaporator fan

speed will switch every hour thereafter as long as all

conditions are met (see Bulb Mode section for different

evaporator fan speed options). If any condition except

for item (1.) becomes false OR if the relative humidity

sensed is 2% below the dehumidification set point, the

high speed evaporator fans will be energized.

The Controller logic is designed so the suction

modulation valve will begin to close as the set point is

reached. The modulation valve will close to restrict

refrigerant flow until the capacity of the unit and the

load are balanced, unless the compressor reliability

enhancement logic on the first compressor start

prevents closure.

If the temperature drops below the set point, the

compressor will remain running for a few minutes. This

is to accommodate any initial undershoot which might

occur. After this time, and at 0.2_C (0.4_F) or greater

below the set point, the compressor will be turned OFF.

Thedehumidification modeapplies powerto thedefrost

and drain pan heaters. This added heat load causes the

Controller to open the modulating valve to match the

new total heat load while still holding the supply air

temperature very close to the set point.

The heaters will be energized if the temperature drops to

0.5_C (0.9_F) below the set point. The heaters will

de-energize when the temperature rises to 0.2_C

(0.4_F) below the set point. The compressor will not

restart until the temperature rises to 0.2_C (0.4_F)

above the set point and a three minute time delay since

the last compressor turn off has been satisfied.

Opening the modulating valve reduces the temperature

of the evaporator coil surface, which increases the rate at

which water is condensed from the air passing through

the coil. Removing water from the air reduces the

relative humidity. When the relative humidity sensed is

2% below the set point (function code Cd33), the

Controller de-energizes the heat relay. The Controller

will continue to cycle heating to maintain relative

humidity below the selected set point.

b. Operation in the dehumidification mode

(Code 33 value selected) -- Optional

The dehumidification mode is activated by selecting

Code 33, choosing a desired relative humidity value,

and pressing the ENTER key. The control probe LED

(supply 1) will flash ON and OFF every second to

indicate that the dehumidification mode is active. Once

the Mode is active and the following conditions are

satisfied, the Controller will activate the heat relay to

begin dehumidification.

Two timers are provided in the Dehumidification mode

to prevent rapid mode switching and consequent

contactor wear. They are:

Heater debounce timer (three minutes).

Out-of-range timer (five minutes).

The heater debounce timer is activated whenever the

heat contactor status is changed. The heat contactor

remains energized (or de-energized) for at least three

minutes even if theset point criteria aresatisfied. This is

to prevent rapid cycling of the heat contactor when the

humidity set point is satisfied. If the mode is terminated

by a condition other than the humidity sensor, e.g., an

1. The humidity sensor reading is above the set point

and valid (AL67).

2. The pulldown mode is NOT active. (ie., The SSV

valve is closed, and the control temperature is less

than 5_C above set point.)

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out-of-range or compressor shutdown condition, the

heat relay is de-energized immediately.

minutes and the above mentioned cycle will be

repeated, just as it was from the start of the cooling or

heating cycle. If theunit is not equipped with dual speed

evaporator fans, then economy mode perishable will

perform exactly the same as the normal control mode.

The out-of-range timer is provided to allow the heaters

to remain energized during a temporary out-of-range

condition. If the control probe temperature remains

outside of the user selected in-range setting for more

than five minutes, the heaters will be de-energized to

allow the system to recover. The out-of-range timer

starts as soon as the temperature exceeds the in-range

tolerance value set by function code Cd30.

d. Operation in bulb mode (Code 35 set to bulb and

Code 33 selected)

Bulb mode is an extension of the dehumidification

mode. Dehumidification must be enabled by selecting a

value (percentage of relative humidity) at function code

Cd33 before bulb mode function code Cd35 can be

initiated.

Cooling capacity reduction by modulation is the same

as described for the conventional operating mode when

any of the above first four conditions (1. thru 4.) are

invalid.

With set points below --10_C (+14_F), or --5_C

(+23_F) optionally, heating and dehumidification are

locked out.

To initiate bulb mode, use the ARROW keys to scroll to

function code Cd35 and change from “Nor” to “bulb.”

Once the bulb mode is activated, the user may then

change from the normal evaporator fan operation where

the fan speed alternates every hour between low or high

speed operation. This is done by toggling function code

Cd36 from its default of “alt” to “Lo” or “Hi”

respectively. If low speed evaporator fan operation is

selected, this gives the user the additional capability of

selecting dehumidification set points from 60 to 95%

(instead of the normal 65 to 95%).

c. Operation in the economy mode

(Code 34 set to ON)

The economy mode selection determines the status of

the economy mode of operation. There are two values:

“ON” and “OFF.” A code which represents the status of

this function is recorded in the DataCorder memory

whenever the value is changed.

Economy mode is a user selectable mode of operation

provided for power saving purposes. Economy mode

could be utilized in the transportation of temperature

tolerant cargo or non-respiration items which do not

require high airflow for removing respiration heat.

In addition, if bulb mode is active, the user is given the

option to change the defrost termination sensor (DTS)

temperature, in which defrost is terminated from the

normal 25.6_C (78_F) temperature setting to 4_C

(39.2_F) in 0.1_C (0.2_F) increments. The temperature

set point that the DTS temperature must go below

before the defrost interval timer begins counting down

also changes from 0_C to 10_C as the desired DTS

termination temperature is raised.

The economy mode is activated by selecting function

codeCd34 to the“ON” status. There is no activedisplay

indicator that economy mode has been activated, and a

manual display of Cd34 is a way to be sure if the

economy mode is or is not active.

In orderto achieveeconomy modeperishableoperation,

a perishable set point must be selected PRIOR to

activating economy mode. When economy mode

perishable is active, the evaporator fans will be

controlled as follows: At the start of each cooling or

heating cycle, thehigh speed evaporator fans will berun

for three minutes. After that initial three minutes, the

evaporator fans will be switched to low speed any time

the supply air temperature is within ¦ 0.25_C (0.45_F)

of the set point and the return air temperatureis less than

or equal to the supply air temperature + 3_C (5.4_F).

When the fans switch to low speed, they will run in low

speed for one hour. At the end of the hour, the

evaporator fans will switch back to high speed. The

evaporator fans will again run in high speed for three

Bulb mode is terminated when:

Code Cd35 is set to “Nor.”

Code Cd33 for dehumidification is set to

“Off.”

The user changes the set point to one

that is in the frozen range.

When bulb mode is disabled by any of the abovemeans,

the evaporator fan operation for dehumidification

reverts to “alt” and the DTS termination setting resets to

the normal 25.6_C (78_F).

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3.1.7.2 Frozen Range Below --10_C (+14_F), or

-- 5 _C (+23_F) Optionally

excluding the Controller, will be turned off when the

control temperatureis less than orequal to theset point --

2_C, (i.e., the set point is set at --11_C and the operator

subtracts --2_C, the result will equal --13_C). After an

off-cycle period of 60 minutes, the unit will turn on high

speed evaporator fans for three minutes, and then check

the control temperature. If the control temperature is

greater than or equal to the set point + 0.2_C., the unit

will restart the refrigeration system and continue to cool

until the previously mentioned off-cycle temperature

criteria are met. If the control temperature is less than

the set point + 0.2_C, the unit will turn off the

evaporator fans and restart another 60 minute off-cycle.

For set points below -- 1 0 _C (+14_F), or --5_C (+23_F)

optionally, the Controller maintains RETURN air at the

set point temperature using the following modes of

operation:

a. Operation in the conventional mode

(Code 33 OFF)

The return air probe is used for control and is so

indicated by the LED on the display board.

The Frozen temperature range is not sensitive to minor

temperature changes. The method of temperature

control employed in this range takes advantage of this

fact to greatly improve the energy efficiency of the unit.

Temperature control in the Frozen range at or below

-- 1 0 _C (+14_F), or --5_C (+23_F) optionally, is

accomplished by cycling the compressor on and off as

the load demand requires.

c. Operation in the bulb mode (Code 35 OFF)

The unit will not run in bulb mode if a frozen range set

point is selected. As described in section 3.1.7.1.d., if a

frozen set point is selected, dehumidification is

deactivated and the temperature abovewhich DTS must

go during defrost resets to 25.6_C (78_F).

Ifthereturn airtemperaturein thecontainerdrops0.2_C

(0.4_F)belowtheset point temperature, thecompressor

is cycled off. When the temperature is greater than

0.2_C (0.4_F) above the set point and the three minute

time delay has been met, the compressor will restart.

The unit will always operate at full capacity, with both

the suction modulation (SMV) and suction solenoid

(SSV) valves fully open unless suction solenoid

override or current limiting is activated. See section

2.10 for explanation of suction solenoid override.

3.2 PRE-TRIP DIAGNOSTICS

CAUTION

Pre-trip inspection should not be performed

with critical temperature cargoes in the

container.

NOTE

When Pre-Trip is initiated, dehumidification

and bulb mode will be deactivated. At the

completion of Pre-Trip, dehumidification and

bulb mode must be turned back on again.

To prevent on/off cycling of the compressor from

occurring, a three minute compressor off time must be

satisfied before the compressor will restart. Under a

condition of rapidly changing return air temperature,

the time delay may allow the return air temperature to

rise slightly more than 0.2_C (0.4_F) above the set

point temperature before the compressor can restart.

Pre-trip Diagnostics is an independent mode which will

suspend the normal Control Mode activities when

initiated by the user. With pre-trip diagnostics, eitherall

the pre-trip tests can be executed in a defined sequence

(Auto Mode), or one of the pre-trip tests can be selected

to be executed (Manual Mode), based on the sequence

of key selections made.

b. Operation in the economy mode (Code 34 OFF)

The economy mode is deactivated by setting function

code Cd34 to the “OFF” status. Economy mode has no

active display indicator to show that it is enabled, so a

manual display of function code Cd34 must be

performed to enable the user to see its current status. A

second way to deactivate economy mode is to change

the set point. Once economy mode is deactivated, the

system will return to normal control mode operations.

a. Starting and Terminating Pre-Trip

NOTE

Prior to starting tests, verify that Controller

function codes Cd04, Cd05, Cd06 and Cd07are

operational. Otherwise, tests may fail

incorrectly. All alarms must be rectified and

cleared.

In order to achieve economy mode frozen operation, a

frozen set point temperature must be selected PRIOR to

activating economy mode. When economy modefrozen

is active, the system will perform normal frozen mode

operations except that the entire refrigeration system,

A Pre-trip selection menu is displayed by pressing the

PRE-TRIP key. This accesses a test selection menu. If

no selection is made, the pre-tripmenu selectionprocess

will terminate automatically. Pre-Trip will terminate if

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the VENT mode is selected on the CA Controller. The

user must scroll through the selection by pressing the

UP ARROW or DOWN ARROW keys, then pressing

the ENTER key when the selection is made. While the

tests are being executed, the user can terminate the

pre-trip mode by holding the PRE-TRIP key. The unit

will then resumenormal operation. If theuser decides to

terminateatest but remain at thetest selection menu, the

user may press the UP ARROW key. When this is done

all machinery outputs will be de-energized and the test

selection menu will be displayed.

Any test may be interrupted by pressing the UP

ARROW key. This will return the user to the test

selection mode described above, and all machinery

outputs will be de-energized.

While certain tests from “Auto 1” are running, “PX-X”

will appear on the left display, where the X’s indicate

the test number and sub-test. The right display will

show a countdown time in minutes and seconds,

indicating how much time there is left remaining in the

test.

For “Auto 2,” the left display will show “PX-X,” while

the right display will show applicable data.

The pre-trip diagnostics may also be initiated via

communication, but when initiated will always attempt

to execute the entire battery of tests (auto mode).

a. Manual Test Operation

Individually selected tests, other than the LED/Display

test, will perform the operations necessary to verify the

operation of the component under test. At the

conclusion of the selected test, PASS or FAIL will be

displayed. Upon failure, the Supply and Return LED’s

will flash on alternately. This message will remain

displayed for up to three minutes, during which time a

user may select another test. If the three minute time

period expires, theunit will terminatepre-trip andreturn

to control mode operation. Following any individually

selected test, all outputs will be de-energized.

b. Current Limiting During Pre-Trip

Throughout the duration of any pre-trip mode, the

Current Limit processing is active.

c. Test Codes

A detailed description of the pre-trip test codes is listed

in Table 3-5.

3.2.1

Pre-Trip

In this mode, the unit will automatically test unit

components using internal measurements and

comparison logic, and will provide a “PASS” or

“FAIL” display to indicate the results of each test.

b. Auto Test Operation From Keypad

If “Auto,” “Auto 1” or “Auto 2”test is initiated, then the

unit will execute a series of consecutive tests, each

related to an identifiable unit component, without any

need for direct user interface. These tests vary in length,

depending on the component under test.

If the user depresses the PRE-TRIP key, the unit gives

access to a pre-trip selection menu. The contents of the

menu are as follows:

When an automatic test fails, it will be repeated once

automatically. A repeated test failurewill cause“FAIL”

to be shown on theright display, with thecorresponding

test number to the left. The user may then press the

DOWN ARROW to repeat the test or the UP ARROW

to skip to the next test. Theunit will wait indefinitelyfor

user input. Holding the PRE-TRIP key will terminate

the pre-trip mode operation.

PRE-TRIP SELECTION MENU

Auto or Auto 1

Auto 2 (Optional)

P, P1, P2, P3, P4, P5,

P6, rSLts

P, P1, P2, P3, P4, P5,

P6, P7, P8, P9, P10,

rSLts

If the pre-trip was last executed manually after power

up, the last menu selection will appear on the left

display. If pre-trip was not executed since power up,

then theright display will show“Auto”or“Auto 1.”The

user may scroll through the test selection menu using

the arrow keys.

When “Auto” or “Auto 1” is allowed to run to

completion without being interrupted, the unit will exit

the pre-trip mode, and return to normal control

operation.

A given test is selected by pressing ENTER while it is

displayed. The entire battery of tests may be run by

pressing ENTER while “Auto 1” or “Auto 2” is

displayed.

CAUTION

When “Auto 2” is allowed to run to

completion without being interrupted, the

unit will terminate pre-trip and display

“Auto 2” “end.” The unit WILL REMAIN

SUSPENDED in this mode until the user

depresses the ENTER key!

During this selection mode, failure to press either an

arrow key or ENTER for five seconds will return the

unit to its default display, and normal operating mode.

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c. Auto Test Operation From Serial

Communications

d. Pre-Trip Test Results

Pre-trip may also be initiated via communications. The

operation is the same as for the Auto Test mode

described above except that should a test fail, the

pre-trip mode will automatically terminate. When

initiated via communications, a test may not be

interrupted with an arrow key, but the pre-trip mode can

be terminated with the PRE-TRIP key.

At the end of the pre-trip test selection menu, the

message “P,” “rSLts” will be displayed. Pressing the

ENTER key will allow the user to see the results for all

subtests (i.e., 1-0, 1-1, etc). Theresults will bedisplayed

as “PASS” or “FAIL” for all the tests run to completion

sincepowerup. Ifatest has not been run since powerup,

“----------” will be displayed.

3.2.2

Pre-Trip Mode

Table 3-5. Pre-Trip Test Codes

DESCRIPTION

CODE

TITLE

NOTE

“Auto” or “Auto1” menu includes the following: P, P1, P2, P3, P4, P5, P6 and rSLts. “Auto2’ (Optional)

menu includes the following: P, P1, P2, P3, P4, P5, P6,P7, P8, P9, P10 and rSLts. (Refer to section 3.2.1.)

All lights and display segments will be energized for five seconds at the start of

the pre-trip. Since the unit cannot recognize lights and display failures, there are

no test codes or results associated with this phase of pre-trip.

Pre-Trip Initiated

Setup: Heater must start in the OFF condition, and then be turned on. A current

draw test is done after 15 seconds.

Pass/Fail Criteria: Passes if change in current draw is within the range

specified.

Setup: Heater must start in the ON condition, and then be turned off. A current

draw test is done after 10 seconds.

Pass/Fail Criteria: Passes if change in current draw is within the range

specified.

P1-0 Heaters Turned On

P1-1 Heaters Turned Off

Requirements: Water pressure switch (WP) input must be closed.

Setup: Condenser fan is turned ON, a current draw test is done after 15

seconds.

P2-0 Condenser Fan On

P2-1 Condenser Fan Off

Pass/Fail Criteria: Passes if change in current draw test is within the range

specified.

Setup: Condenser fan is turned OFF, a current draw test is done after 10

seconds.

Pass/Fail Criteria: Passes if change in current draw test is within the range

specified.

Requirements: The unit must be equipped with a low speed evaporator fan, as

determined by the Evaporator Fan speed select configuration variable.

NOTE: If the unit is configured for single evaporator fan operation, Pre-Trip tests

P3-0, P3-1, P4-0 and P4-1 will fail immediately if Controller alarm codes AL11 or

AL12 are active at the start of testing.

Low Speed

Evaporator Fans

Setup: The high speed evaporator fans will be turned on for 10 seconds, then off

for two seconds, then the low speed evaporator fans are turned on. A current

draw test is done after 60 seconds.

Pass/Fail Criteria: Passes if change in current draw is within the range

specified. Fails if AL11 or AL12 activates during test.

Low Speed

Evaporator Fan

Motors On

P3-0

Setup: The low speed Evaporator Fan is turned off, a current draw test is done

after 10 seconds.

Pass/Fail Criteria: Passes if change in current draw is within the range

specified. Fails if AL11 or AL12 activates during test.

Setup: The high speed Evaporator Fan is turned on, a current draw test is done

after 60 seconds.

Pass/Fail Criteria: Passes if change in current draw is within the range

specified. Fails if AL11 or AL12 activates during test.

Low Speed

Evaporator Fan

Motors Off

P3-1

P4-0

High Speed

Evaporator Fan

Motors On

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CODE

TITLE

DESCRIPTION

Setup: The high speed Evaporator Fan is turned off, a current draw test is done

after 10 seconds.

Pass/Fail Criteria: Passes if change in current draw is within the range

specified. Fails if AL11 or AL12 activates during test.

High Speed

Evaporator Fan

Motors Off

P4-1

Setup: The High Speed Evaporator Fan is turned on and run for eight minutes,

with all other outputs de-energized.

Pass/Fail Criteria: A temperature comparison is made between the return and

supply probes.

NOTE: If this test fails, “P5-0” and “FAIL” will be displayed. If both Probe tests

(this test and the PRIMARY/ SECONDARY) pass, the display will read “P5”

“PASS.”

Supply/Return Probe

Test

P5-0

Requirements: For units equipped with secondary supply probe only.

Pass/Fail Criteria: The temperature difference between primary and secondary

probe (supply) is compared.

NOTE

P5-1 Supply Probe Test

If this test fails, “P5-1” and FAIL will be displayed. If both Probe tests (this

and the SUPPLY/ RETURN TEST) pass, because of the multiple tests, the

display will read ’P 5’ ’PASS’.

Requirements: For units equipped with secondary return probe only.

Pass/Fail Criteria: The temperature difference between primary and secondary

probe (return) is compared.

NOTES

If this test fails, “P5-2” and “FAIL” will be displayed. If both Probe

tests (this test and the SUPPLY/ RETURN) pass, because of the

multiple tests, the display will read “P 5,” “PASS.”

P5-2 Return Probe Test

The results of Pre-Trip tests 5-0, 5-1 and 5-2 will be used to activate or

clear control probe alarms.

Setup: The compressor is started. If it is the first compressor start, the

compressor reliability enhancement logic (CREL) is executed, running a current

draw test with the additional outputs (if installed) in the following states:

Single Speed

Compressor Test

Normal Logic

(10 seconds)

Closed

P6-0

Component

CREL (3 minutes)

(For single speed

units)

SSV

SMV

Open

70%

100% (for 3 minutes) then 70%

Setup: Prior to this testing the ambient temperature is checked. If the ambient

temperature is less than 60_F, the high speed compressor test will run first. If the

ambient temperature is greater than 60_F, or if the ambient temperature is

invalid, the low speed compressor test will run first. Once the first compressor

test has been completed, the switch over to the other compressor test will follow.

Upon entry to this test section, the high speed evaporator fan should already be

running, if not, it is started. After the evaporator fan has run for five seconds, the

high speed condenser fan is started. After the condenser fan has run for five

seconds, the compressor test is run.

Dual Speed

Compressor Tests

P-6

(For dual speed

units)

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CODE

TITLE

DESCRIPTION

Setup: The compressor is started. If it is the first compressor start, the

compressor reliability enhancement logic (CREL) is executed, running a current

draw test with the additional outputs (if installed) in the following states:

High Speed

Normal Logic

Component

CREL (3 minutes)

Compressor Tests

(For dual speed

units)

(10 seconds)

Closed

P6-H

SSV

SMV

Open

20%

100% (for 3 minutes) then 20%

Pass/Fail Criteria: Passes if the change in current draw is within the valid

range.

Setup: The compressor is started. When ambient temperature is greater than

60_F, a two minute CREL is executed. If the ambient temperature is less than

60_F, a three minute CREL is executed. Then a current draw test is done for 10

seconds with the additional outputs (if installed) in the following states:

Low Speed

Normal Logic

(10 seconds)

CREL (2

minutes)

Closed

CREL (3

minutes)

Closed

Component

SSV

Compressor Tests

(For dual speed

units)

P6-L

P6-2

Closed

100% (for 3

minutes) then 20%

SMV

20%

Pass/Fail Criteria: Passes if the change in current draw is within the valid

range.

Setup: The suction modulation valve (SMV) is opened to 100% unless restricted

by current limit function, and the unit is run for two minutes.

Pass/Fail Criteria: The supply and return probe temperature reading difference

is compared to a predetermined value.

Suction Modulation

Valve (Open)

Setup: The compressor suction temperature is measured with the Quench valve

closed. The Quench valve is energized and the suction temperature drop is

checked.

P6-3 Quench Valve Test

Pass/Fail Criteria: Passes if suction temperature is within the valid range.

Setup: The heaters are energized. The suction modulation valve is set to 100%,

and run for one minute. At the end of the one minute run, the supply temperature

is subtracted from the return temperature and the result is saved (reading 1).The

SMV is dropped to 60% and run for one minute. At the end of this one minute

run, the supply temperature is again subtracted from the return temperature and

the result is saved (reading 2).

Suction Modulation

P6-4

Valve (Closed)

Pass/Fail Criteria: If the difference between reading 1 & 2 is within a

predetermined range, the test passes. If current limiting occurs, the test passes.

Requirements: The unit must be equipped with a suction solenoid valve (SSV).

Current limiting may close SSV. If this happens, the test will automatically pass.

Setup: The SSV is opened, the suction modulation valve (SMV) is closed. The

quench valve (if configured) will operate according to normal operating rules. If

the return temperature probe is lower than --5.0_C, the test is run for two

minutes, otherwise for one minute. Condenser Pressure Control (CPC) logic is

used for this test if the controller is configured for it.

Suction Solenoid

Valve

P6-5

Pass/Fail Criteria: If the SSV is closed due to current limiting, the test passes. If

supply and return probes are invalid, the test fails. If the test is within a

predetermined range, the test passes. The SSV is closed following this test.

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CODE

TITLE

DESCRIPTION

NOTE

Starting with test P7-0 through test P10, these tests are only included with the “Auto2” (Optional) selection

menu. (Refer to section 3.2.1.)

Setup: When the unit is running, the condenser fan is de-energized, and a 15

minute timer is started. The right display shows discharge pressure if equipped

with the discharge pressure transducer (DPT), or condenser pressure if

equipped with a condenser pressure transducer (CPT), or discharge pressure if

equipped with either a discharge pressure transducer (DPT) or a condenser

pressure transducer (CPT).

Pass/Fail Criteria: The test fails if high pressure switch fails to open in 900

seconds.

Note, this test is skipped if the unit does NOT have:

A compressor discharge sensor (CPDS).

A discharge pressure transducer (DPT).

Condenser pressure transducer (CPT).

In addition, this test is skipped if:

The sensed ambient temperature is less than 7_C (45_F).

The return air temperature is less than --17.8_C (0_F).

The water pressure switch (WP) is open, indicating that the unit is

operating with a water-cooled condenser.

High Pressure

Switch Closed

P7-0

Pass/Fail Criteria: Under conditions of the above Note, the test immediately

fails if the following inputs are sensed to be invalid:

Compressor discharge sensor (CPDS).

Discharge pressure transducer (DPT).

Condenser pressure transducer (CPT).

OR if any one of the following inputs are sensed to be invalid:

Return temperature sensor (RTS).

Ambient sensor (AMBS).

In addition, the test will fail if:

The high pressure switch (HPS) fails to open within 15 minutes.

The discharge temperature exceeds 138_C (280_F).

The discharge temperature is less than or equal to ambient temperature

plus 5_C (9_F).

The condenser pressure transducer (CPT) or discharge pressure

transducer (DPT) pressure exceeds 27.42 kg/cm₂(390 psig).

Requirements: Test P7-0 must pass for this test to execute. Setup: The

condenser fan is started and a 60 second timer is started.

Pass/Fail Criteria: Passes the test if the high pressure switch (HPS) closes

within the 60 second time limit, otherwise, it fails.

Setup: If the container temperature is below 60_F, the set point is changed to

60_F, and a 60 minute timer is started. The left display will read “P8-0.” The

control will then heat the container until 60_F is reached. If the container

temperature is above 60_F at the start of the test, then the test proceeds

immediately to test P8-1 and the left display will change to “P8-1.”

High Pressure

Switch Open

P7-1

P8-0

Perishable Mode

Heat Test

Pass/Fail Criteria: The test fails if the 180 minute timer expires before the

control temperature reaches set point. The display will read “P8--0,” “FAIL.”

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CODE

TITLE

DESCRIPTION

Requirements: Control temperature must be at least 60_F.

Setup: The set point is changed to 32_F, and a 180 minute timer is started. The

left display will read “P8-1,” the right display will show the supply air temperature.

The unit will then start to pull down the container temperature to the 32_F set

point.

Perishable Mode

Pull Down Test

P8-1

Pass/Fail Criteria: The test passes if the container temperature reaches set

point before the 180 minute timer expires.

Requirements: Test P8-1 must pass for this test to execute.

Setup: The left display will read “P8-2,” and the right display will show the supply

air temperature. A 60 minute timer is started. The unit will be required to

maintain the 32_F temperature to within + or -- 0.5_C (0.9_F) of set point until a

DataCORDER recording is executed. The recorder supply probe temperature

running total (and its associated readings counter) will be zeroed out for the

remainder of the recording period at the start of this test, so that the actual value

recorded in the DataCORDER will be an average of only this test’s results. Once

a recording interval is complete, the average recorder supply temperature will be

recorded in the DataCORDER, as well as stored in memory for use in applying

the test pass/fail criteria.

Perishable Mode

Maintain

Temperature Test

P8-2

Pass/Fail Criteria: If the recorded temperature is within +/-- 0.5_C. of set point

from test start to DataCORDER recording, the test passes. If the average

temperature is outside of the tolerance range at the DataCORDER recording, the

test fails.

Setup: The defrost temperature sensor (DTS) temperature will be displayed on

the left display. The right display will show the supply air temperature. The unit

will run FULL COOL for 30 minutes maximum while the DTS sensor temperature

is above 10_C. Once the DTS is below 10_C, the unit simulates defrost by

running the heaters for up to two hours, or until the DTS senses the temperature

above 25.6_C.

Pass/Fail Criteria: The test passes if DTS is sensed above 25.6_C before a two

hour timer times out. The test fails if DTS does not go below 10_C after 30

minutes of full cooling, and/or the heater termination thermostat (HTT) is open

when the DTS is below 10_C. The test also fails if the HTT opens anytime during

the defrost cycle and/or the return air temperature exceeds 120_F anytime

during the heat cycle.

P9-0 Defrost Test

Setup: After completion of the DTS test, the set point will be set to 7_C (45_F).

The left display will read “P100,” and if the container temperature is below 45_F,

will continue this display until the container temperature is raised to set point.

The left display will change to “P101” and execute the frozen pull down test

when the container temperature reaches set point, or if the container

temperature initially was greater than or equal to set point. The maximum time

allowed in heat mode is one hour.

Frozen Mode

P10-0

(Setup) Test

Pass/Fail Criteria: If this time limit is exceeded, the test fails. There will be no

pass indication for this test. However, if the test fails the display will read “P100,”

“FAIL.”

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CODE

TITLE

DESCRIPTION

Setup: When the container temperature is greater than or equal to the 45_F. set

point which was set in the frozen mode heat test, the left display will read “P101”

and the right display will show the return air temperature. The set point will then

be changed to --17.7_C (0_F). The unit will then have a maximum of three hours

to pull the container temperature down to the 0_F set point.

Frozen Mode (Pull

Down) Test

P10-1

Pass/Fail Criteria: If this occurs within the three hour time limit, the test passes.

If pulldown is not completed within the three hour time limit, the test fails.

Setup: After the unit has successfully completed the frozen pulldown test, the

left display will read “P102” and the right display will show the return air

temperature. The unit will then be required to maintain the 0_F temperature

within + or -- 0.5_C (0.9_F) of set point until a DataCORDER recording is

executed. The recorder return probe temperature running total (and its

associated readings counter) will be zeroed out for the remainder of the

recording period at the start of this test, so that the actual value recorded in the

DataCORDER will be an average of only this test’s results. Once the recording

interval is complete, the average recorder return temperature will be recorded in

the DataCORDER, as well as stored in memory for use in applying the test

pass/fail criteria.

Frozen Mode

Maintain

Temperature Test

P10-2

Pass/Fail Criteria: If the recorded temperature is within +/-- 0.5_C of set point

from test start to DataCORDER recording, the test passes. If temperature is

outside of the tolerance range at the DataCORDER recording, the test fails.

3.3 INTEGRATED DATACORDER (OPTIONAL)

d. Records DataCORDER/Network generated data

and events as follows:

3.3.1 Brief Description

Container ID Change

S/W Upgrade

Carrier Transicold has developed a recorder, which we

have termed the “DataCORDER,” and is integrated into

a module with the Controller. For reader simplicity and

understanding this section has been separated to explain

the DataCORDER side of the module. The

DataCORDER consists of:

Controller configuration change

Alarm Activity

Battery Low (Battery Pack)

Data Retrieval

Microprocessor

Defrost Start

Program memory

Defrost End

Data memory

Dehumidification Start

Dehumidification End

Power Loss (w/wo battery backup)

Power Up (w/wo battery backup)

“Auto 1” Pre-Trip Start

“Auto 1” Pre-Trip End

Internally battery backed real time clock

Six thermistor inputs

Two communication ports

Power supply (optional battery pack).

This recorder eliminates the mechanical recorder and

paper chart, and replaces it with a custom-designed

module (see Figure 3-1) that interfaces with the

Interrogator and operates in the following ways:

Remote Probe Temperatures in the Container

(USDA Cold treatment and Cargo probe

recording)

Return Air Temperature

Set Point Change

a. Logs data at 15, 30, 60 or 120 minute intervals.

b. Records and displays alarms through the digital

display module. (Refer to Table 3-7.)

Supply Air Temperature

c. Stores at least two years’ worth of data based on

typical one hour intervals.

Real Time Clock (RTC) Battery (Internal

Battery) Replaced

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Real Time Clock (RTC) Modification

Pre-Trip result & data

Trip Start

FACTORY

DEFAULT

ITEM

SETTING

Sensor Logging

(Network)

Average or

Snapshot

Average,

Snapshot or

USDA

1 or 2 byte

Refer to section

3.3.5.f.

Average

ISO Trip Header (Must be entered first via

Interrogation program)

Sensor Logging

(Thermistor)

Average

Economy Mode Start

Economy Mode End

“Auto 2” Pre-Trip Start

“Auto 2” Pre-Trip End

Bulb Mode Start

Sensor Format

Sensor

Configuration

1 byte

2 sensors

15, 30, 60 or

120 minutes

Logging Interval

60 minutes

Bulb Mode changes

Bulb Mode End

Configuration cards are available thru CTD

Replacement Components Group.

USDA Trip Comment

CTD Controlled Atmosphere Information

Humidification Start

Humidification End

USDA Probe Calibration

The use of a programming card in the field should only

occur under unusual circumstances, such as a physical

component in thecontainer unit is changed to adifferent

component, resulting in a new configuration for the

unit.

3.3.2

DataCORDER Configuration

NOTE

The DataCORDER software is integrated with

the Controller software.

Configuration to factory installed default configuration

is achieved via a common configuration card used for

controller functions, see section 3.1.2.

Changes to the factory default configuration must be

made with the Interrogation device.

Configuration:

Tells the operational software what physical

components are built into the container unit, how many

sensors to record, what recording interval should be

used, etc..

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3.3.3 DataCORDER Function Codes

until the left window displays the desired code number

(seeTable 3-6). Theright windowwill display thevalue

of this item for five seconds before returning to the

normal display mode. If a longer time is desired,

pressing the ENTER key will extend the time to 30

seconds after the last pressing of the ENTER key.

There are 35 functions which the operator may access to

examine the operating status of the unit. To access these

functions, perform the following: Press the ALT.

MODE & CODE SELECT keys, press an arrow key

Table 3-6. DataCORDER Function Code Assignments

NOTE: Inapplicable Functions Display “----------”

To Access: Press ALT. MODE key

CODE #

TITLE

DESCRIPTION

Recorder Supply

Temperature

dC1

Current recorder supply air temperature.

Recorder Return

Temperature

dC2

Current recorder return air temperature.

USDA 1,2,3

Temperatures

dC3-5

Current temperatures of the three USDA probes.

Current values of the network sensors (as configured). Network sensor 1 (Code

6) is generally the humidity sensor and its value is obtained from the Controller

once every minute.

Network Sensors

1-8

dC6-13

dC14

Cargo Probe 4

Temperature

Current temperature of the cargo probe #4.

dC15-19 Future Expansion

Temperature

These codes are for future expansion, and are not in use at this time.

Current calibration offset values for each of the five probes: supply, return,

USDA #1, #2, and #3. These values are entered via the interrogation program.

Sensors 1-5

Calibration

dC20-24

dC25

Future Expansion

This code is for future expansion, and is not in use at this time..

The DataCORDER serial number consists of eight characters. Function code

dC26 contains the first four characters. Function code dC27 contains the last

four characters. (This serial number is the same as the Controller serial

number.)

dC26,27 S/N, Left 4, Right 4

An approximation of the number of logging days remaining until the

DataCORDER starts to overwrite the existing data.

Number of days of data that are currently stored in the DataCORDER.

dC28

dC29

Minimum Days Left

Days Stored

The date when a Trip Start was initiated by the user. In addition, if the system

goes without power for seven continuous days or longer, a trip start will

automatically be generated on the next AC power up.

dC30

dC31

Date of last Trip start

Battery Test

Shows the current status of the optional battery pack.

PASS -- Battery pack is fully charged.

FAIL -- Battery pack voltage is low.

dC32

dC33

dC34

Time: Hour, Minute

Date: Month, Day

Date: Year

Current time on the real time clock (RTC) in the DataCORDER.

Current date (month and day) on the RTC in the DataCORDER.

Current year on the RTC in the DataCORDER.

Cargo Probe 4

Calibration

Current calibration value for the Cargo Probe. This value is an input via the

interrogation program.

dC35

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3.3.4 DataCORDER Alarms

The exception to this rule is the

DataCORDER Alarm Queue Full AL91

alarm, which does not have to be inactive in

order to clear the alarm list.

To Display Alarm Codes:

While in Set Point Selection or Default Display mode,

press the ALT. MODE & ALARM LIST keys. This

accesses the Alarm List Display Mode, which displays

any alarms stored in the Alarm Queue. The user may

scroll to the end of the alarm list by pressing the UP

ARROW key after the ALARM LIST key is depressed.

Depressing the DOWN ARROW key allows the user to

scroll backward in the alarm list.

To Clear the Alarm List:

If no alarms are active, the Alarm Queue may be

cleared.

Press the ALT. MODE & ALARM LIST

keys.

The left display will show “AL#” where # is the alarms

number in the queue.

Press the UP/DOWN ARROW key until

“CLEAr” is displayed.

The right display will show:

Press the ENTER key. The alarm list will

c l e a r a n d “ -- -- -- -- -- ” w i l l b e d i s p l a y e d .

“AAXX,” if the alarm is active, where XX is

the alarm number. See Table 3-7,

DataCORDER Alarm Indications.

Press the ALARM LIST key. “AL” will show

o n t h e l e f t d i s p l a y a n d “ -- -- -- -- -- ” o n t h e r i g h t

display when there are no alarms in the list.

“IAXX,” if the alarm is inactive

“END” is displayed to indicate the end of the alarm list

if any alarms are active. “CLEAr” is displayed if all the

alarms in the list are inactive.

Upon clearing of the Alarm Queue, the Alarm

light will be turned off.

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Table 3-7. DataCORDER Alarm Indications

To Access: Press ALT. MODE key

CODE #

TITLE

DESCRIPTION

The recorder supply air temperature is sensed outside of the range of

-- 5 0 _C to 70_C (--58_F to +158_F) or if the probe check logic has

determined there is a fault with this sensor.

Recorder Supply

Temperature Out of

Range

AL70

NOTE

The P5 Pre-Trip test must be run to inactivate the alarm (refer to section

3.2.1).

The recorder return air temperature is sensed outside of the range of

-- 5 0 _C to 70_C (--58_F to +158_F) or if the probe check logic has

determined there is a fault with this sensor.

Recorder Return

Temperature Out of

Range

AL71

NOTE

The P5 Pre-Trip test must be run to inactivate the alarm (refer to section

3.2.1).

USDA Temperatures 1,

2, 3 Out of Range

Cargo Probe 4 Out of

Range

AL72-74

AL75

The USDA probe temperature reading is sensed outside of range.

The cargo probe temperature reading is sensed outside of range.

These alarms are for future expansion, and are not in use at this time.

The network sensor is outside of its specified range. See NOTE below.

NOTE

AL76, 77 Future Expansion

Network Sensors 1 -- 8

Out of Range

AL78-85

While the DataCORDER is normally setup to record only supply and return recorder sensors, the

DataCORDER has the capability to record the data of eight additional sensors. Any sensor installed on the

unit may be recorded, and are identifiable as Network Sensors AL 78 to AL85. Which alarm (AL78 to AL

85) is associated with the physical sensor, depends on how the DataCORDER was configured. To identify

which sensor is at fault, the unit must be interrogated to locate the sensor being recorded. Generally, the

humidity sensor is AL78, as it is the only network sensor recorded.

The Real Time Clock (RTC) backup battery is too low to adequately

maintain the RTC reading.

AL86

RTC Battery Low

An invalid date or time has been detected. This situation may be corrected

by changing the Real Time Clock (RTC) to a valid value using the

DataView.

AL87

RTC Failure

DataCORDER

AL88

AL89

A write of critical DataCORDER information to the EEPROM has failed.

EEPROM Failure

An error has been detected in the process of writing daily data to the

non-volatile FLASH memory.

Flash Memory Error

AL90

AL91

Future Expansion

Alarm List Full

This alarm is for future expansion, and is not in use at this time.

The DataCORDER alarm queue is determined to be full (eight alarms).

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The DataCORDER alarms for the USDA and cargo

probes areconfigurable using the interrogation program

or via a configuration card. There are four configuration

variables for the DataCORDER, which are listed in

Table 3-8 with their descriptions and selection values.

The DataCORDER may be powered up in several ways:

1. Normal AC power: The DataCORDER is powered

up when the unit is turned on via the stop-start switch

(ST).

2. Normal DC power: If a rechargeable battery pack is

installed (fully charged), the user may plug the

interrogation cable into the front interrogation

receptacle and the DataCORDER will power up for

communications.

Table 3-8. DataCORDER Alarm

Configurations

Configuration

Variable

Selection

Values

Description

dCF07

dCF08

dCF09

dCF10

USDA (PR1)

USDA (PR2)

USDA (PR3)

Auto,On,Off

On every DataCORDER wake-up, while using

battery-pack power, the Controller will first perform a

hardware voltage check on the battery. If the hardware

check passes, the Controller will energize the

appropriate circuitry and perform a software battery

voltage check before DataCORDER logging. If either

the hardware or software battery test fails, the real time

clock (RTC) battery-backed wake-up will be disabled

until the next AC power cycle. Further DataCORDER

temperature logging will be prohibited until that time.

Cargo Probe (PR4) Auto,On,Off

The default configuration for the four probes is “Auto.”

If the alarms are configured as “Auto,” and all the

probes are missing (i.e., appear open-circuited to the

DataCORDER), no alarms are activated. As soon as one

of the probes is installed (plugged into the receptacle),

then all of the alarms are enabled and the remaining

probes that are not installed will give active alarm

indications. This function is designed to assist those

users who wish to keep their DataCORDER configured

for USDA recording, and do not wish to install the

probes for every trip.

A 12 volt VCR battery pack may also be plugged into

the back of the interrogation cable, which is then

plugged into either interrogation port. No rechargeable

battery pack is required with this method. The user may

now interrogate the DataCORDER.

3. Real Time Clock (RTC) because a logging interval

has expired: If the DataCORDER is equipped with a

charged battery pack and AC power is not present, the

DataCORDER will power up when the RTC indicates

that a data recording should take place. When the

DataCORDER is finished recording, it will power

down.

If a probe alarm is configured to be “On,” then the

associated alarm is always enabled. As long as the probe

remains in-circuit (plugged in), the alarm will not be

activated. Probes with this configuration have alarms

that act likethealarms forthe supply and return recorder

sensors. It is presumed that normal operation includes

the probe in question.

c. DataCORDER Battery Pack Test

Ifaprobealarm is configured to be “Off,”then thealarm

for this probe is always disabled. It is not possible to

activate the respective alarm for this probe no matter

what the circumstance.

If the DataCORDER has the optional battery pack, then

the battery voltage will be tested once every five

minutes. An alarm will be generated when the battery

voltage transitions from good to bad indicating that the

battery pack needs recharging. If the alarm condition

persists for more than 24 hours on continuous AC

power, the battery pack probably needs replacement.

3.3.5

Access to DataCORDER Functions

To access the DataCORDER functions codes, alarm

codes, configuration and scrollback, the user must first

press the ALT. MODE key, then press the applicable

key for functions (CODE SELECT) or alarms

(ALARM LIST).

d. Trip Start Processing

To initiate Trip Start:

Press the ALT. MODE key

a. Keypad/Display Interface

Select function code dC30

The DataCORDER uses the Controller display and

keypad. The DataCORDER contains four types of

display parameters. They are: functions codes, alarm

codes, configuration and scrollback.

Depress the ENTER key for five seconds

Trip Start will flash for five seconds, turn solid, then the

datewill appearto indicatethat a Trip Start is registered.

Trip Start may also be initiated via communications

using the interrogation program.

b. DataCORDER Power-Up

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e. Display vs. Configuration Codes

Standard Mode:

TheDataCORDER contains two types ofdisplay codes;

Display and Configuration. Display codes will display

parameter values, but will not let them be modified.

Configuration codes can be modified via the

interrogator or with the insertion of the common

configuration software card.

The standard recording mode allows the user to

configure the DataCORDER to monitor data using one

of seven standard configurations. The seven standard

configuration variables, with their descriptions, are

listed in Table 3-9.

The six thermistor inputs (supply, return, USDA #1, #2,

#3 and cargo probe) and the humidity sensor will be

DataCorder inputs. The three inputs will be read over a

network from the Controlled Atmosphere module.

f. Data Recording Mode

The DataCORDER recording mode is labeled as

Standard. To see an example ofa report using astandard

configuration, see Figure 3-3.

In addition, if NO Controller alarms are active, the most

recent active DataCORDER alarm will be displayed on

the Display Module alternately with set point.

Generic Mode:

The generic recording mode is used for special data

recordings. The user may select up to eight different

sensor readings. The sensors available for this type of

recording are listed below. Changing the configuration

to generic and selecting which sensors to record may be

done via the Interrogation program.

Table 3-9. DataCorder Standard Configuration

Standard

Configura-

tion

Description

2 sensors

(dCF02 = 2)

Configurable Generic Recording Options:

2 thermistor inputs(supply & return)

Control mode

5 sensors

2 thermistor inputs(supply & return)

3 USDA thermistor inputs

2 thermistor inputs(supply & return)

3 USDA thermistor inputs

1 humidity input

2 thermistor inputs(supply & return)

3 USDA thermistor inputs

* 3 Controlled Atmosphere inputs

1 humidity input

(dCF02 = 5)

Control temperature

Frequency

6 sensors

(dCF02 = 6)

Humidity (Standard configuration: 6 or 64)

Phase A current

9 sensors

(dCF02 = 9)

Phase B current

2 thermistor inputs(supply & return)

3 USDA thermistor inputs

1 cargo probe (thermistor input)

Phase C current

6 sensors

(dCF02 = 54)

Mains voltage

2 thermistor inputs(supply & return)

3 USDA thermistor inputs

1 humidity input

Suction modulation valve (SMV) percentage

7 sensors

(dCF02 = 64)

Discrete outputs (Bit mapped -- require

special handling if used)

1 cargo probe (thermistor input)

2 thermistor inputs(supply & return)

3 USDA thermistor inputs

* 3 Controlled Atmosphere inputs

1 humidity input

1 cargo probe (thermistor input)

Discrete inputs (Bit mapped -- require special

handling if used)

10 sensors

(dCF02 = 94)

Ambient sensor (AMBS)

Compressor suction sensor (CPSS)

Compressor discharge sensor (CPDS)

Return temperature sensor (RTS)

Supply temperature sensor (STS)

Defrost termination sensor (DTS)

Discharge pressure transducer (DPT)

Suction pressure transducer (SPT)

Condenser pressure transducer (CPT)

* Not Available on models 69NT40-511 or

69NT40-521.

g. DataCORDER Alarm History List

The DataCORDER contains a buffer of up to eight

alarms. The list may be displayed by pressing the

ALARM LIST key. The alarm history keypad and

display processing will be the same as the Controller

module. The format of an alarm history display entry is

as follows:

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#3 probes (and possibly the optional Cargo probe) are

installed in their receptacles.

“dALnn” where nn = the alarm

history entry 01-08

Left Display:

Right

“xA nn” where x = “I” (inactive) or “A”

(active)

“----------” if no alarms are currently in

the alarm history list

The DataCORDER records up to six probe

temperatures (supply, return, USDA #1, #2, #3 and an

optional cargo probe #4), at the logging interval.

Display:

Or:

The standard DataCORDER report displays the supply

and return air temperatures. The cold treatment report

displays USDA #1, #2, #3 and the supply and return air

temperatures. Cold treatment recording is backed up by

a battery so recording can continue if AC power is lost.

h. Alarm Processing

The DataCORDER contains an eight alarm history

queue which will contain the first eight alarms detected

by the DataCORDER. The alarms and their

corresponding alarm codes are specified in Table 3-7.

The alarm queue will be located in the Battery Backed

RAM (BRAM). The queue will also have a

corresponding status which will indicate whether each

alarm is currently active or inactive. If multiple

consecutive occurrences of an alarm are generated, only

the first will be stored. The queue may be cleared by

using the keypad. (If more than eight alarms occur

before the queue is cleared, later alarms will be

ignored.) In addition, AL91 alarm code will appear if

the DataCORDER queue is full.

When the Relative Humidity Set Point mode is

activated or de-activated (ie., Controller function code

Cd33), this status is stored in the DataCORDER

memory and reported at the next recording, as are like

events such as economy mode and bulb mode.

3.3.8 Pre-Trip Data Recording

The unit is equipped with the ability to record pass/fail

information along with unit data resulting from the

initiation of pre-trip (see section 3.2.2). The data is

time-stamped and may be extracted via interrogation

using CTD’s interrogation program. See Table 3-10 for

a description of the data stored in the DataCORDER for

each corresponding Pre-Trip test.

The out of range value is as follows:

Low limit = --50.0 degC

Thermistor Inputs:

High limit = 70.0 degC

3.3.9 DataCORDER Communications

a. DataCORDER Retrieval -- Interrogation

3.3.6 USDA/ Message Trip Comment

Aspecial caseevent is supported forallowing theuserto

enter comments for a (USDA or any message) trip

recording. The comments will be received from the

interrogator and have a maximum length of 78

characters. Only one comment will be recorded per day.

In theevent that multiplecomments occur, then only the

last is saved.

Data retrieval from the DataCORDER can be

accomplished with three devices: a CTD DataReader

and DataView software, a stand-alone DOS-base

portable computer with appropriate cable and

DataView software, or a Remote Monitoring Unit

(RMU).

NOTE

The RMU designation is used in the industry.

Be aware that CTD uses the designation CI

(Communications Interface Module) on its

schematics.

3.3.7 USDA Recording

A special type of recording is provided for USDA cold

treatment purposes. Cold treatment recording requires

three remote temperature probes to be placed at various

locations of the cargo. Provision is made to connect

these probes to the DataCORDER via receptacles

located at the rear left-hand side of the unit. Four (five,

on some units) receptacles are provided. Four

(three-pin) receptacles are for the probes and one (five

pin) receptacle is provided for the Interrogator. All

receptacles are sized to accept a Deutsch HD16-5-16S

size plug with a tricam coupling locking device. The

DataCORDER inputs are designed to accept a two wire

thermistor probe.

The optional interrogation software for a portable

computer is supplied on a 3.5 and 5.25 inch floppy disk.

This software allows interrogation, screen view of the

data, hard copy report generation, cold treatment probe

calibration, cold treatment initialization and file

management.

NOTE

Refer to Interrogation manual 62-02575 for a

more detailed explanation of the interrogation

software.

A label on the back panel of the unit shows which

receptacle is used for each probe. The USDA #1, #2 and

A short report on that interrogation can be displayed on

the computer to identify key information such as Trip

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Start, Power Outages, and Temperature Out-of-Range

conditions.

b. Pre-cool to treatment temperature.

c. Install the DataCORDER module battery pack (if

not already installed).

3.3.10 DataCORDER Scrollback

d. Calibrate the three USDA probes by ice bathing the

probes and performing the calibration function with the

hand held DataReader or a DOS-based portable

computer. This calibration procedure determines the

probe offsets and stores them in the Controllerfor usein

generating the cold treatment report. Refer to the

Interrogation manual 62-02575 for more details.

The DataCORDER will display probe values for the six

DataCORDER probes up to 99 hours back from the

current hour. The probe values may be displayed by

depressing the ALT. MODE key and then depressing

the UP or DOWN ARROW keys until “dCdSP” is

shown in the left display window and then depressing

the ENTER key. The sensor to display can then be

chosen by depressing the UP or DOWN ARROW key

until the desired sensor (S for supply, r for return, P1,

P2, P3 and C4 for USDA and Cargo probes) is shown in

theleft display windowand then depressing theENTER

key. A temperaturevalue will appear in the right display

window and 1 (with sensor designation) will appear in

the left display window to signify the temperature

displayed is the most recent reading. Each press of the

DOWN ARROW key displays the temperature one

hour earlier. Use the ENTER key to alternate between

sensors and times/temperatures. Use the ARROW keys

for scrolling. The display will return to normal if 15

seconds lapse without a key being pressed.

e. Place the three probes required for a USDA cold

treatment procedure. The probes are placed into the pulp

or the fruit at the locations defined below as the product

is loaded.

Place in pulp of the product located next

Sensor 1

to the return air intake.

Place in pulp of the product five feet

from the end of the load for 40 foot

containers, and three feet from the end

Sensor 2

of the load for 20 foot containers. This

probe should be placed in a center

carton at one-half the height of the load.

Place in pulp of product five feet from

the end of the load for 40 foot containers

and three feet from the end of the load

for 20 foot containers. This probe should

Sensor 3

3.4 USDA COLD TREATMENT PROCEDURE

be placed in a carton at a side wall at

one-half the height of the load.

Sustained cold temperature has been employed as an

effective postharvest method for the control of

Mediterranean and certain other tropical fruit flies.

Exposing infested fruit to temperatures of 2.2 degrees

Celsius (36_F) or below for specific periods results in

the mortality of the various stages of this group of

notoriously injurious insects.

f. To initiate USDA Recording begin the cold

treatment recording, connect the Interrogator and

perform the configuration as follows:

Trip Start

Trip Comment

In response to the demand to replace fumigation with

this environmentally sound process, Carrier has

integrated this Cold Treatment capability into its

DataCORDER. These units have the ability to maintain

supply air temperature within one-quarter degree

Celsius of setpoint and record minute changes in

product temperature within the DataCORDER

memory, thus meeting USDA criteria (refer to section

3.3.7).

Configure for five probes

One hour logging interval

USDA temperature log in

Two byte memory storage format

Probe calibration

g. Retrieval of trip data from the DataCORDER

memory can be accomplished with a DataReader and

DataView software or DataView software and a

DOS-based portable computer. Contact a Carrier

Transicold Service Parts representative for details.

The following is a summary of the steps required to

initiate a USDA Cold Treatment.

a. Pre-cool the container to the treatment temperature

or below.

T-268-07

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Table 3-10. DataCORDER Pre-Trip Data

DATA

TEST #

TITLE

NOTE

“Auto” or “Auto1” menu includes the following: P, P1, P2, P3, P4, P5, P6 and rSLts. “Auto2’ (Optional)

menu includes the following: P, P1, P2, P3, P4, P5, P6,P7, P8, P9, P10 and rSLts. (Refer to section 3.2.1.)

1-0

1-1

2-0

Heater On

Heater Off

Condenser Fan On

Pass/Fail/Skip Result, Change in current for Phase A, B and C

Pass/Fail/Skip Result, Change in currents for Phase A, B and C

Pass/Fail/Skip Result, Water pressure switch (WPS) -- Open/Closed,

Change in currents for Phase A, B and C

2-1

3-0

Condenser Fan Off

Low Speed Evaporator Fan

Pass/Fail/Skip Result, Change in currents for Phase A, B and C

3-1

4-0

4-1

Low Speed Evaporator Fan

High Speed Evaporator Fan

Supply/Return Probe Test

Secondary Supply Probe Test Pass/Fail/Skip Result

Secondary Return Probe Test Pass/Fail/Skip Result

Compressor On -- High Speed Pass/Fail/Skip Result, Change in currents for Phase A, B and C

Compressor On -- Low Speed Pass/Fail/Skip Result, Change in currents for Phase A, B and C

Suction Modulation Valve

Open

Pass/Fail/Skip Result, Change in currents for Phase A, B and C

Pass/Fail/Skip Result, STS, RTS, SRS and RRS

5-0

5-1

5-2

6-0

6-1

6-2

Pass/Fail/Skip Result, STS, RTS, Is current limit in effect? (Y,N)?

6-4

Suction Modulation Valve

Closed

Pass/Fail/Skip Result, STS, RTS, Delta T1, Delta T2,

Is current limit in effect? (Y,N)?

6-5

7-0

Suction Solenoid Valve Open Pass/Fail/Skip Result, STS, RTS, Is current limit in effect? (Y,N)?

Pass/Fail/Skip Result, AMBS, DPT or CPT (if equipped)

High Pressure Switch Closed

Input values that component opens?

Pass/Fail/Skip Result, STS, DPT or CPT (if equipped)

Input values that component closes?

7-1

High Pressure Switch Open

8-0

8-1

Perishable Heat

Perishable Pull Down

Pass/Fail/Skip Result, STS, time it takes to heat to 16_C (60_F)?

Pass/Fail/Skip Result, STS, time it takes to pull down to 0_C (32_F)?

Pass/Fail/Skip Result, Averaged DataCORDER supply temperature

(SRS) over last recording interval.

Pass/Fail/Skip Result, DTS temperature at end of test, line voltage,

line frequency, time in defrost.

8-2

9-0

Perishable Maintain

Defrost Test

10-0

10-1

Frozen Mode Set-up

Frozen Mode Pull Down

Pass/Fail/Skip Result, STS, time unit is in heat.

Pass/Fail/Skip Result, STS, time to pull down unit to --17.8_C (0_F).

Pass/Fail/Skip Result, Averaged DataCORDER return temperature

(RRS) over last recording interval.

10-2

Frozen Mode Maintain

3-33

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CONTAINER ABCDXXXXXXX ON 08Jul 94 FROM 15Apr94 TO 17Apr94 (DEGREES C)

HEADER INFORMATION

PAGE: 1

DataCorder SN: XXXXXXXX

ALARMS REPORT

LAST ACTIVE

ALARM NUM

FIRST ACTIVE

CONTROLLER ALARMS:

17Apr94 03:28

17Apr94 16:13

DATACORDER ALARMS

No Alarms Reported

USDA SUMMARY

DATE: 15Apr94 23:49 Trip Start

LEGEND

Setpoint Change

Pretrip Start/End

Controller Rep.

Datacorder Alm

Software Upgrade

Defrost Start

PS, PE

NEW SN

dal

DHS, DHE Dehumid Start/End

NEW ID

OFF

Container ID

Power Loss

NetWork Off

Defrost End

Alarm Activity

Trip Start

NEW SW

COMM

BATT

Power Loss

Setp

SupAir

RetAir

Figure 3-3. Standard Configuration Report Sample

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FALLING

TEMPERATURE

RISING

TEMPERATURE

+1.5_C (2.7_F)

+1_C (1.8_F)

+0.5_C (0.9_F)

COOLING

+.20_C

SET POINT

--0.20_C

-- 0 . 5 _C (0.9_F)

AIR

CIRCULATION

ONLY

AIR

CIRCULATION

ONLY

-- 1 _C (1.8_F)

-- 1 . 5 _C (2.7_F)

NOTE

For In-range Tolerance, Refer to section 3.1.4 Code 30.

Figure 3-4. Controller Set Point BELOW --10_C (+14_F), or --5_C (+23_F) optionally

FALLING

TEMPERATURE

RISING

TEMPERATURE

+1.5_C (2.7_F)

+1_C (1.8_F)

+0.5_C (0.9_F)

MODULATING

COOLING *

MODULATING

COOLING *

+.20_C

SET POINT

--0.20_C

-- 0 . 5 _C (0.9_F)

AIR CIRCULATION ONLY

-- 1 _C (1.8_F)

HEATING

-- 1 . 5 _C (2.7_F)

NOTE

For In-range Tolerance, Refer to section 3.1.4 Code 30.

* For Two-Speed compressor operation refer to Figure 3-6.

Figure 3-5. Controller Set Point ABOVE --10_C (+14_F), or --5_C (+23_F) optionally

3-35

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STEP

Operating capacity is the required capacity to maintain

container box temperature.

Compressor

Starting Sequence

** Required voltage is a function of operating capacity and

supply frequency.

Is Ambient

Temperature Less

Than 60 ˚F ?

Low Speed

Run For 2

Minutes

Soft Start

(See Note A & B)

YES

High Speed Start

Was Ambient Greater

Than 60 ˚F During Start ?

YES

Is Supply Voltage

Greater Than

Required Voltage ** ?

Does High Pressure

Switch (HPS) Trip ?

YES

Are High Speed Switch

Over Conditions Satisfied ?

(Refer To Steps “J & L”)

Has Compressor Run

For 20 Minutes ?

YES

Continue In

Low Speed

Has Set Point

Been Reached ?

YES

Is The Operating Capacity *

Below Low Speed Capacity ?

YES

NOTE A

Is Supply Voltage

Greater Than

Required Voltage ** ?

YES

During

compressor

operation, if at anytime the

High Pressure Switch (HPS)

trips, the logic will switch to

Low Speed Soft Start.

Low Speed

Soft Start (See Note B)

Run 20 Minutes

NOTE B

Low Speed Soft Start is

performed by closing the

SMV to 0% opening for ten

seconds during the start-up

of the compressor. The SMV

opening is then gradually

increased to the desired value

at the rate of a 3% opening

per second.

Continue In

Low Speed

Is Supply 3 ˚F Above Set Point

Or Is Operating Capacity *

Greater Than Low Speed Capacity ?

YES

Figure 3-6. Two-Speed Compressor Speed Change Logic -- Perishable Range Only

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STEP

Compressor

Starting Sequence

YES

Is Ambient

Temperature Less

Than 60 ˚F ?

Low Speed

Has Set Point

Been Reached ?

Soft Start

(See Note A & B)

YES

Run For 2

Minutes

High Speed Start

YES

Has Set Point

Been Reached ?

Compressor Cycles OFF

Continue In

High Speed

NOTE A

During

compressor

operation, if at anytime the

High Pressure Switch (HPS)

trips, the logic will switch to

Low Speed Soft Start.

NOTE B

Low Speed Soft Start is

performed by closing the

SMV to 0% opening for ten

seconds during the start-up

of the compressor. The SMV

opening is then gradually

increased to the desired value

at the rate of a 3% opening

per second.

Figure 3-7. Two-Speed Compressor Speed Change Logic -- Frozen Range Only

3-37

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SECTION 4

OPERATION

4.1 PRE-TRIP INSPECTION (Before Starting)

d. Open Partlow recording thermometer door (if so

equipped) and do the following:

WARNING

1. Manually wind clock on key wound recording

thermometer (key is located in a clip.) KEY MUST

STAY WITH THE THERMOMETER. Check

battery on battery powered recording thermometer.

Beware of unannounced starting of the

evaporator and condenser fans.

a. If container is empty, check inside for the

following:

2. Lift stylus (pen) by pulling the marking tip outward

until the stylus arm snaps into it’s retracted

position.

1. Check channels or “T” bars on floor for cleanliness.

Channels must be free of debris for proper air

circulation.

3. Install new chart on recording thermometer making

sure chart is under the four corner tabs. Lower the

stylus until stylus has made contact with the chart.

Then close and secure door.

2. Check container panels, insulation and door seals

for damage. Effect permanent or temporary repairs.

3. Visually check evaporator fan assembly clamp

bolts for proper securement (refer to section 6.15).

e. Open Saginomiya recording thermometer door (if so

equipped) and do the following:

4. Check for dirt or grease on evaporator fan or fan

deck and clean if necessary.

1. Check Chart drive battery condition.

(Refer to section 6.20.)

5. Check evaporator coil for cleanliness or

obstructions. Wash with fresh water.

(Refer to section 6.13.)

2. Lift stylus (pen) by pushing in the stylus lifter and

rotating the lifter clockwise (raising stylus at same

time) until lifter locks in position.

6. Check defrost drain pans and drain lines for

obstructions and clear if necessary. Wash with fresh

water.

3. Install new chart on recording thermometer making

sure chart is under the four corner tabs. Release stylus

lifter by pushing down and rotating lifter

counterclockwise until stylus lifter locks in position

and stylus has made contact with chart. Then close

door.

7. Check panels on refrigeration unit for loose bolts

and condition of panels. Make sure T.I.R. devices

are in place on access panels.

f. Open control box door. Check for loose electrical

connections or hardware.

b. Check condenser coil for cleanliness. Wash with

fresh water. (Refer to section 6.17.)

g. Check color of moisture-liquid indicator.

h. Check oil level in compressor sight glass.

i. Start refrigeration unit. (Refer to section 4.3.)

c. Check position of fresh air makeup vent cover.

Operator must determine if fresh air makeup vent

cover is to be opened or closed.

4-1

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4.2 STARTING AND STOPPING INSTRUCTIONS

4.4 UNIT OPERATION

4.4.1 Crankcase Heater

CAUTION

When the crankcase heater is installed, it will be

operational whenever the compressor is off and there is

power to the unit. The heater is connected to a set of

normally closed auxiliary contacts on the compressor

contactor (CH).

Make sure that the unit circuit breaker(s)

(CB-1 & CB-2) and the start-stop switch

(ST) are in the OFF position before

connecting to any electrical power source.

4.4.2

Probe Check Initiation

a. Starting the Unit

Whenevertheunit is in normal control mode, that is, not

in pre-trip, defrost or shutdown modes and there are NO

active probe alarms, and alarm codes AL11 and AL12

are inactive (for units so equipped), the following probe

diagnostic functions are performed by the controller.

NOTE

The evaporator fans will always start in high

speed regardless of set point and will switch to

low speed after approximately 20 to 30 seconds

if the set point is below --10_C (+14_F), or

-- 5 _C (+23_F) optionally.

The following is based on current ML2i operational

software logic, version 5103. Older versions of

software will have differences.

a. Probe Diagnostic Logic

If the unit is configured for standard (Std) “ProbeCheck

Logic,” the criteria used for comparison between the

primary and secondary control probes is:

1. Refer to Pre-Trip Inspection, section 4.1.

2. Check power source for proper voltage. Connect

unit power plug and turn main power ON.

1_C (1.8_F) for perishable set points, above

-- 1 0 _C (+14_F), or --5_C (+23_F) optionally.

3. Turn refrigeration unit circuit breaker(s), and the

start-stop switch to ON (position “1”).

2_C (3.6_F) for frozen set points, below

above range.

If 25 or more of 30 readings taken within a 30

minute period are out-of-range per the above

criteria, then a defrost* is initiated and a

probe check is performed.

4. Units equipped with the integrated DataCORDER:

Trip start is initiated by depressing the ALT.

MODE key and selecting Code dc30, then

depressing the ENTER key for five seconds.

b. Special

If the unit is configured for special (SPEC) “Probe

Check Logic,” the above criteria is identical except for

the diagnostic readings which are:

5. Refer to section 4.3 after unit is running.

If 25 or more of 30 readings taken within a

30 minute period OR any 10 consecutive

readings at any time are out-of-range per the

above criteria, then a defrost* is initiated and

a probe check is performed.

b. Stopping the Unit

Turn the start-stop switch to position “0” (OFF

position).

The only time defrost will not be initiated is if the

defrost termination sensor (DTS) is greater than

25.56_C (78_F).

4.3 AFTER STARTING INSPECTION

The 30 minute timer will be reset for each of the

following conditions:

a. Check rotation of condenser and evaporator fans.

b. Check compressor oil level. (Refer to section 6.10.)

At every power up.

At the end of every defrost.

c. Run unit at least five minutes to stabilize. Start

controller Pre-Trip diagnostics.

After every diagnostic check that does not fall

outside of the limits as described under

“standard or special” as outlined above.

(Refer to section 3.2.)

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4.4.3

Cooling -- Controller Set BELOW --10_C

(+14_F), or --5_C (+23_F) optionally

If AL55 is active, meaning that the DataCORDER (DC)

functionality is no longer active (DC configuration

variable off), the Controller will act as a four probe

configured system during probe checks. The only

differences will be that the Controller Function Codes

Cd38 and Cd39 will become enabled thus allowing

access to the secondary probe readings since the DC

functions, codes and alarms have become deactivated.

Controller alarms AL70 and AL71 will replace DC

alarms AL70 and AL71 respectively for the secondary

probes.

NOTES

The suction solenoid valve (SSV) will be

open to increase the refrigerant flow rate and

cooling capacity unless SSV override is

activated.

The suction modulation valve (SMV) is

100% open.

The evaporator motors run in low speed.

The compressor runs in high speed.

If the unit is configured for standard (Std) “ProbeCheck

Logic,” a probe check will be run as a part of every

normal defrost.

Refer to Figure 3-7 for a description of the

dual speed compressor change logic.

When the return air temperature decreases to 0.2_C

(0.4_F) below set point, relays TD and TN de-energize.

This results in de-energizing the compressor and

condenser fan motor. Also, the cool light is

de-energized. The evaporator fan motors continue to

run to circulate air throughout the container.

If the unit is configured for special (SPEC) “Probe

Check Logic,” a probe check will not be run as a part of

a normal defrost, but only as a part of a defrost initiated

due to a diagnostic reading outside of the limits as

outlined above under “special.”

c. Probe Check

When the return air temperature increases to 0.2_C

(0.4_F) above set point, and providing a sufficient

off-time period has elapsed, relays TD and TN energize

to restart the compressor and condenser fan motor. Also

at this time, the cool light is illuminated.

During a defrost cycle that includes a probe check, after

the heaters turn off, the evaporator motors will be

energized for an additional eight minutes after which all

the primary/secondary probes will be compared to a set

of predetermined limits.

4.4.4 Controller Set ABOVE --10_C (+14_F), or

-- 5 _C (+23_F) optionally

The defrost indicator will remain on throughout this

period.

NOTE

Evaporator fan motors will run in high speed.

(Contactor EF energized.)

Any probe(s) determined to be outside the limits will

cause the appropriate alarm code(s) to be displayed to

identify which probe(s) needs to be replaced.

a. Cooling in High Speed with Two-Speed

Compressor (See Figure 4-1.)

NOTE

The limits used during a probe check are tighter than

those used for thediagnostic criteria to ensureaccurate

detection of a faulty probe(s).

pressure control system has been

incorporated by means of a condenser pressure

transducer (CPT) and condenser pressure

control (CPC) logic to maintain discharge

pressures above 130 psig in low ambients.

NOTES

Be aware that probe check and probe

diagnostics are two separate functions. The

function of the diagnostic logic is to alert the

microprocessor of a discrepancy with the

control probe(s). The function of the probe

check is to determine what probe(s) is in

error.

The condenser fan will cycle off if the

condenser pressure is below 130 psig. If the

condenser pressure rises above 200 psig, the

condenser fan will cycle on.

With supply air temperature decreasing, and if the

supply air is above set point, the unit will be cooling

with the condenser fan motor, compressor motor and

evaporator fan motors energized. Also, at this time, the

cool light is illuminated.

The P5 Pre-Trip test must be run to inactivate

alarms (refer to section 3.2.1).

4-3

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When the air temperature decreases to a predetermined

tolerance above set point, relay TI energizes and the

in-range light is illuminated.

shutting off the condenser fan and compressor motors.

Also, the cool light is de-energized.

The evaporator fan motors continue to run to circulate

air throughout the container. The in-range light remains

illuminated as long as thesupply airis within atolerance

of set point, and the 15 minute override is met.

(Refer to section 3.1.4, Code 30.)

If the air temperature continues to fall, modulating

cooling starts at approximately 2.5_C (4.5_F) above set

point. Themodulating valvewill havea variablecurrent

up to 1.30 amps at full modulation.

If the unit is in the holding mode (neither heating nor

cooling) and the supply air temperature increases to

0.2_C (0.4_F) above set point, and providing a six

minute off time has elapsed, relay TC energizes to

restart the compressor. Also, at this time, the condenser

fan motor starts and the cool light is illuminated.

During this cooling mode, a running sum of the

temperature differential (supply air temperature minus

the set point)is kept. When thesupply airfalls belowset

point, the differential is negative. The longer supply air

remains below set point, the greater the differential in

the running sum.

During this mode the dual speed compressor can be

either running in high or low speed depending on the

box load. Refer to Figure 3-6 for a description of the

speed change logic.

When the supply air temperature decreases to 0.2_C

below set point and the running sum is less than --250

degrees C-seconds, relays TN and TC de-energize

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CONTROL TRANSFORMER

= 18 Volt Energized Circuit

= 24 Volt Energized Circuit

= De-energized Circuit

Figure 4-1. Cooling in High Speed with Two-Speed Compressor

4-5

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b. Cooling in Low Speed with Two-Speed

Compressor (See Figure 4-2.)

point. Themodulating valvewill havea variablecurrent

up to 1.30 amps at full modulation.

NOTE

During this cooling mode, a running sum of the

temperature differential (supply air temperature -- set

point) is kept. When the supply air falls below set point,

the differential is negative. The longer supply air

remains below set point, the greater the negative

differential in the running sum.

Evaporator fan motors will run in high speed.

(Contactor EF energized)

NOTE

pressure control system has been

incorporated by means of a condenser pressure

transducer (CPT) and condenser pressure

control (CPC) logic to maintain discharge

pressures above 130 psig in low ambients.

When the supply air temperature decreases to 0.2_C

below set point and the running sum is less than --250

degrees C-seconds, relays TN and TC de-energize

shutting off the condenser fan and compressor motors.

Also, the cool light is de-energized.

The condenser fan will cycle off if the

condenser pressure is below 130 psig. If the

condenser pressure goes above 200 psig, the

condenser fan will cycle on.

The evaporator fan motors continue to run to circulate

air throughout the container. The in-range light remains

illuminated as long as thesupply airis within atolerance

of set point, and the 15 minute override is met.

With supply air temperature decreasing, and if the

supply air is above set point, the unit will be cooling

with the condenser fan motor, compressor motor and

evaporator fan motors energized. Also, at this time, the

cool light is illuminated.

If the unit is in the holding mode (neither heating nor

cooling) and the supply air temperature increases to

0.2_C (0.4_F) above set point, and providing a six

minute off time has elapsed, relay TC energizes to

restart the compressor. Also, at this time, the condenser

fan motor starts and the cool light is illuminated.

When the air temperature decreases to a predetermined

tolerance above set point, relay TI energizes and the

in-range light is illuminated.

During this mode the two-speed compressor can be

either running in high or low speed depending on the

box load, ambient temperature, time since power-on,

AC line voltage and the position of the SSV.

(Refer to section 3.1.4, Code 30.)

If the air temperature continues to fall, modulating

cooling starts at approximately 2.5_C (4.5_F) above set

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CONTROL TRANSFORMER

= 18 Volt Energized Circuit

= 24 Volt Energized Circuit

= De-energized Circuit

Figure 4-2. Cooling in Low Speed with Two-Speed Compressor

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c. Cooling with Single-Speed Compressor

(See Figure 4-3.)

If the air temperature continues to fall, modulating

cooling starts at approximately 2.5_C (4.5_F) above set

point. Themodulating valvewill havea variablecurrent

up to 1.30 amps at full modulation.

NOTE

Evaporator fan motors will run in high speed.

(Contactor EF energized)

During this cooling mode, a running sum of the

temperature differential (supply air temperature -- set

point) is kept. When the supply air falls below set point,

the differential is negative. The longer supply air

remains below set point, the greater the negative

differential in the running sum.

NOTE

pressure control system has been

incorporated by means of a condenser pressure

transducer (CPT) and condenser pressure

control (CPC) logic to maintain discharge

pressures above 130 psig in low ambients.

When the supply air temperature decreases to 0.2_C

below set point and the running sum is less than --250

degrees C-seconds, relays TN and TC de-energize

shutting off the condenser fan and compressor motors.

Also, the cool light is de-energized.

The condenser fan will cycle off if the

condenser pressure is below 130 psig. If the

condenser pressure goes above 200 psig, the

condenser fan will cycle on.

The evaporator fan motors continue to run to circulate

air throughout the container. The in-range light remains

illuminated as long as thesupply airis within atolerance

of set point, and the 15 minute override is met.

With supply air temperature decreasing, and if the

supply air is above set point, the unit will be cooling

with the condenser fan motor, compressor motor and

evaporator fan motors energized. Also, at this time, the

cool light is illuminated.

If the unit is in the holding mode (neither heating nor

cooling) and the supply air temperature increases to

0.2_C (0.4_F) above set point, and providing a six

minute off time has elapsed, relay TC energizes to

restart the compressor. Also, at this time, the condenser

fan motor starts and the cool light is illuminated.

When the air temperature decreases to a predetermined

tolerance above set point, relay TI energizes and the

in-range light is illuminated. (Refer to section 3.1.4,

Code 30.)

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CONTROL TRANSFORMER

= 18 Volt Energized Circuit

= 24 Volt Energized Circuit

= De-energized Circuit

Figure 4-3. Cooling with Single-Speed Compressor

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4.4.5 Heating (See Figure 4-4.)

As the supply air decreases to the in-range tolerance

below set point, relay TI and the in-range light

de-energize (after a 15 minute time delay) and will

remain de-energized until the supply air increases to a

tolerance below set point. (Refer to section 3.1.4, Code

30.)

The unit will heat only when the controller set point is

above --10_C (+14_F), or --5_C (+23_F) optionally, as

relay TH is electronically locked out to prevent heating

when the controller set point is below -- 1 0 _C (+14_F),

or --5_C (+23_F) optionally.

When the temperature rises to 0.2_C (0.4_F) below set

point, TH opens (heating off) and the system again

enters the holding zone. The compressor and condenser

fan motor are not running as contactors CH and CF

remain de-energized. The evaporator fans continue to

run to circulate air throughout the container.

If the air temperature decreases 0.5_C (0.9_F) below

controller set point, TH closes and the system enters the

heating modewhich is designed to raisethecontainerair

temperature. When TH closes, power flows through TH

contacts and the heat termination thermostat to energize

the heat contactor (HR). This in turn energizes the

heaters and heat light. The evaporator fans continue to

run to circulate air throughout the container.

A safety heater termination thermostat (HTT) attached

to an evaporator coil support, set to open at 54.5_C

(130_F), will open the heating circuit if overheating

occurs.

T-268-07

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CONTROL TRANSFORMER

= 18 Volt Energized Circuit

= 24 Volt Energized Circuit

Figure 4-4. Heating Mode

= De-energized Circuit

4-11

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4.4.6 Defrost

Upon completion of the de-ice phase of defrost, the

controller will perform a probe check cycle. The

purposeoftheprobecheck cycleis to perform aperiodic

check of the controller sensors to detect malfunctions or

drift in the sensed temperature that is too small to be

detected by the normal sensor out of range tests. The

system will run for eight minutes in this condition. At

the end of the eight minutes, the primary supply,

primary return and DataCORDER sensor temperatures

will be compared. The controller probe alarms will be

set or cleared based on the conditions seen.

Refer to section 3.1.4 (Code 27) for description of the

defrost interval selector and automatic defrost

initiation.

The defrost cycle (see Figure 4-5) consists of two

distinct sub-cycles. The first sub-cycle is the de-ice

cycle, the second is a probe check cycle.

Defrost may take place any timethe DTS allows, and no

shutdown alarms are active. With these conditions

satisfied, defrost is initiated when one of the following

conditions becomes true:

The54.5_C (130_F)heat termination thermostat (HTT)

will open the circuit if the defrost mode does not

terminate at 25.6_C (78_F). If termination does not

occur within 2.0 hours, the controller will terminate

defrost. An alarm will be given of a possible DTS

failure.

a. The manual defrost switch (MDS) is closed by the

user. Refer to Figure 2-7 or Figure 2-8 for location.

The MDS is ignored during Pre-Trip.

b. The defrost interval timer reaches or exceeds the

defrost interval selected and set by the user.

When the return air falls to 7_C (45_F), the controller

checks to ensure the defrost termination sensor (DTS)

has dropped to 10_C or below. If it has not, a DTS

failure alarm is given and the defrost mode is operated

by the return temperature sensor (RTS).

c. During Pre-Trip (auto, not manual) defrost can

occur during the advanced Pre-Trip tests P-8 and

P-10. Defrost is forced during advanced Pre-Trip

test P-9.

Snap Freeze Option:

d. When the probe diagnostic logic determines that a

probe check is necessary based on the temperature

values currently reported by the supply and return

probes.

NOTE

Controller configuration variable 33 must be

set to SnAP to activate this option, refer to

Table 3-1.

e. When bulb mode is active, and the defrost

termination sensor(DTS)is between 0_C and 10_C

(32_F and 50_F).

If the probe check portion of defrost is required

(depending on the configuration of probe check), snap

freeze will run after the probe check cycle. Otherwise,

snap freeze will run immediately following the de-ice

portion of defrost.

When the defrost mode is initiated, the controller relay

contacts (TH) close to supply power to the heat

contactor (HR) and in turn, energize the defrost heaters.

The defrost light is illuminated.

The snap freeze cycle consists of running the

compressor without the evaporator fans running for a

period offourminutes with both suction solenoid(SSV)

and suction modulation (SMV) valves fully open.

Relay TC and TD open to de-energize the compressor

contactor and cool light. Also relay TN opens to

de-energize the condenser fan contactor (CF).

If current limiting activates (see section 3.1.4, Cd32)

during snap freeze, the state of the SSV and SMV valves

may change. When the snap freeze cycle is completed,

defrost is formally terminated.

Relay TE and TV open to stop the evaporator fan

motors.

The in-range light remains illuminated during defrost.

4.4.7 Arctic

When the coil tube sheet temperature reaches 25.6_C

(78_F), [4_C and 25.6_C (39.2_F and 78_F) if

configured for and operating in bulb mode], the defrost

termination sensor (DTS) causes the controller to end

the defrost cycle and the unit returns to its normal

function. Under certain circumstances, defrost may also

be forced to terminate through special communication

commands.

With arctic mode enabled, if the ambient is colder than

--10.0_C there is a 30 minute time delay at startup for

any of the components in the system, except for the

controller and the compressor crankcase heater (CCH),

which should be active at this point. In arctic mode, the

CCH is energized for 30 minutes to warm the oil in the

compressor, and boil off any liquid refrigerant that may

be present in the crankcase.

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If Pre-Trip is initiated during the 30 minute time period,

Pre-Trip will be allowed to run normally. OncePre-Trip

is over, the controller will revert to its normal control

mode logic.

its normal startup logic.

Arctic mode is configurable by using the configuration

variable #29, refer to Table 3-1.

If ambient is warmer than --10.0_C, the system will run

CONTROL TRANSFORMER

= 18 Volt Energized Circuit

= 24 Volt Energized Circuit

= De-energized Circuit

Figure 4-5. Defrost

4-13

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Table 4-1. Electrical Control Positions -- BELOW --10_C (+14_F), or --5_C (+23_F) optionally

**Dehumidification

CONTROL CIRCUIT

COOLING

HEATING

DEFROST

Holding Zone

Single-Speed Compressor:

Compressor Contactor

(C)

De-energized

Energized

De-energized

Two-Speed Compressor:

Compressor Contactor

(CH)

De-energized

Energized

De-energized

Compressor Contactor

(CS)

De-energized

Compressor Contactor

(CL)

De-energized

Energized

Condenser Fan

Contactor (CF)

De-energized

Refer to

section

High Speed Evaporator

Contactor (EF)

Refer to section

3.1.7.a.2

De-energized

Energized

De-energized

Energized

3.1.7.a.2

Refer to

section

3.1.7.a.2

Low Speed Evaporator

Contactor (ES)

Refer to section

3.1.7.a.2

De-energized

Defrost Relay (TF)

Heater Relay (HR)

INDICATING LIGHTS

Cool

De-energized

Energized

OFF

Defrost

OFF

In-Range

On -- If In-Range (Refer to paragraph 3.1.4, Code 30)

Heat

OFF

POWER CIRCUIT

Compressor

Energized

De-energized

Energized

De-energized

Energized

Condenser Fan Motor

Heaters

De-energized

Energized

Evaporator Fan Motors

De-energized

** Dehumidification and heating modes do not operate at set points below --10_C (14_F), or --5_C (23_F)optionally

¹-- May be energized in defrost if snap freeze portion of defrost is run.

²-- May be energized in defrost if probe check portion of defrost is run.

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Table 4-2. Electrical Control Positions -- ABOVE --10_C (+14_F), or --5_C (+23_F) optionally

* Dehumidification

CONTROL CIRCUIT

COOLING

HEATING

DEFROST

Holding Zone

Single-Speed Compressor:

Compressor Contactor

(C)

De-energized

Energized

De-energized

Two-Speed Compressor in high speed mode:

Compressor Contactor

Energized

De-energized

(CH)

Compressor Contactor

Energized

De-energized

(CS)

Compressor Contactor

De-energized

(CL)

De-energized

Two-Speed Compressor in low speed mode:

Compressor Contactor

De-energized

(CH)

De-energized

Compressor Contactor

De-energized

(CS)

De-energized

Compressor Contactor

Energized

De-energized

(CL)

Condenser Fan

Energized

De-energized De-energized

Contactor (CF)

Refer to

High Speed Evaporator

Energized

Refer to section

3.1.7.a.2

De-energized

section

Energized

Contactor (EF)

3.1.7.a.2

Refer to

Low Speed Evaporator

De-energized

Refer to section

3.1.7.a.2

section

De-energized

Contactor (ES)

3.1.7.a.2

Defrost Relay (TF)

Heater Relay (HR)

INDICATING LIGHTS

Cool

De-energized

Energized

De-energized

Energized

OFF

Defrost

OFF

In-Range

On -- If In-Range (Refer to paragraph 3.1.4, Code 30)

Heat

OFF

POWER CIRCUIT

Compressor

Energized

De-energized

Energized

De-energized De-energized

Condenser Fan Motor

Heaters

De-energized

Energized

Evaporator Fan Motors

De-energized

Unit with optional Humidity sensor

** Dehumidification and heating modes do not operate at set points below --10_C (14_F), or --5_C (23_F)optionally

¹-- May be energized in defrost if snap freeze portion of defrost is run.

²-- May be energized in defrost if probe check portion of defrost is run.

4-15

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SECTION 5

TROUBLESHOOTING

REMEDY/

REFERENCE

SECTION

CONDITION

POSSIBLE CAUSE

5.1 UNIT WILL NOT START OR STARTS THEN STOPS

External power source OFF

Turn on

Check

6.22

Start-Stop switch OFF or defective

Circuit breaker tripped or OFF

No power to unit

Modular transformer not connected

Circuit breaker OFF or defective

Control transformer (TR) defective

Fuse (F3) blown

Check

Replace

Check

Loss of control power Loss of

control power in respective branch

of control circuit only

Start-Stop switch OFF or defective

Evaporator fan motor internal protector open

Condenser fan motor internal protector open

Compressor internal protector open

High pressure switch open

6.15

6.18

6.7

Loss of control power in respective

branch of control circuit only

5.7

Heat termination thermostat (HTT) open

Replace

Low line voltage

Check

6.7

Single phasing

Shorted or grounded motor windings

Compressor seized

Contactor (SC) shorting (in high speed mode of two-speed Check

compressor only)

Compressor hums, but does not

start

6.7

Compressor will occasionally

de-energize for 15 seconds

Compressor speed change (On units with two-speed

compressor)

Normal

5.2 UNIT RUNS BUT HAS INSUFFICIENT COOLING

Compressor

Compressor valves defective

6.7

Abnormal pressures

5.7

Temperature controller malfunction

Evaporator fan or motor defective

Suction modulation valve malfunction

Suction solenoid valve malfunction

Condenser Pressure Transducer (CPT) defective

Shortage of refrigerant

5.9

6.15

6.25

2.10/6.24

Check

6.6

Refrigeration System

5.3 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING

Hot load

Container

Normal

Repair

Defective box insulation or air leak

Shortage of refrigerant

6.4/6.6

5.6

Evaporator coil covered with ice

Evaporator coil plugged with debris

Evaporator fan(s) rotating backwards

Defective evaporator fan motor/capacitor

Air bypass around evaporator coil

6.13

6.15/6.16

Check

Reset

Refrigeration System

Controller set too low

Compressor service valves or liquid line shutoff valve

partially closed

Dirty condenser

Compressor worn

Current limit (Code 32) set to wrong value

Suction modulation valve (SMV) malfunction

Open valves

completely

6.17

6.7

3.1.4

6.25

5-1

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REMEDY/

REFERENCE

SECTION

CONDITION

POSSIBLE CAUSE

5.4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING

Start-Stop switch OFF or defective

Circuit breaker OFF or defective

External power source OFF

Check

Turn on

No power to unit

Circuit breaker or fuse defective

Transformer defective (TR)

Replace

6.15

Check

6.13

Evaporator fan internal motor protector open

Heat relay defective

No control power

Heater termination switch open

Heater(s) defective

6.14

Heater contactor or coil defective

Evaporator fan motor(s) defective or rotating backwards

Evaporator fan motor contactor defective

Temperature controller malfunction

Defective wiring

Replace

6.15/6.16

Replace

5.9

Unit will not heat or has insufficient

heat

Replace

Tighten

2.4

Loose terminal connections

Low line voltage

5.5 UNIT WILL NOT TERMINATE HEATING

Temperature controller improperly set

Reset

5.9

6.13

Temperature controller malfunction

Heater termination switch remains closed along with the

heat relay

Unit fails to stop heating

5.6 UNIT WILL NOT DEFROST PROPERLY

Defrost timer malfunction

3.1.4

Loose terminal connections

Defective wiring

Tighten

Replace

Will not initiate defrost automatically

Defrost termination sensor defective or heat termination

switch open

Heater contactor or coil defective

Replace

Manual defrost switch defective

Defrost termination sensor open

Low line voltage

Heater contactor or coil defective

Heater(s) burned out

Wet load

Replace

4.4.6

2.4

Replace

6.14

Normal

Will not initiate defrost manually

Initiates but relay (DR) drops out

Initiates but does not defrost

Frequent defrost

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REMEDY/

REFERENCE

SECTION

CONDITION

POSSIBLE CAUSE

5.7 ABNORMAL PRESSURES (COOLING)

Condenser coil dirty

6.17

Condenser fan rotating backwards

Condenser fan inoperative

6.18

6.6

Replace

Open

Normal

6.25

Refrigerant overcharge or noncondensibles

Discharge pressure regulator valve defective

Discharge service valve partially closed

Perishable set point

High discharge pressure

Low suction pressure

Suction modulation valve (SMV) malfunction

Suction service valve partially closed

Filter-drier partially plugged

Open

6.11

Low refrigerant charge

6.4/6.6

6.26

Expansion valve defective

No evaporator air flow or restricted air flow

Excessive frost on evaporator coil

Evaporator fan(s) rotating backwards

Discharge pressure regulator valve defective

Suction modulation valve (SMV) malfunction

5.10

5.6

6.14/6.16

Replace

6.25

Suction and discharge pressures

tend to equalize when unit is

operating

Heat exchanger defective

Compressor valves defective

Compressor cycling/stopped

Replace

6.8

Check

5.8 ABNORMAL NOISE OR VIBRATIONS

Loose mounting bolts

Tighten

6.7

Worn bearings

Worn or broken valves

Liquid slugging Insufficient oil

6.7

Compressor

5.11

6.10

Bent, loose or striking venturi

Worn motor bearings

Bent motor shaft

Check

6.15/6.18

Condenser or Evaporator Fan

5.9 TEMPERATURE CONTROLLER MALFUNCTION

Defective Sensor

6.23

Defective wiring

Check

Replace

6.25

Will not control

Fuse (F1, F2) blown

Suction modulation valve (SMV) circuit malfunction

5.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW

Frost on coil

Evaporator coil blocked

5.6

6.13

Dirty coil

Evaporator fan motor internal protector open

6.15

Evaporator fan motor(s) defective

Evaporator fan(s) loose or defective

Evaporator fan contactor defective

6.15/6.16

6.15

No or partial evaporator air flow

Replace

5-3

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REMEDY/

REFERENCE

SECTION

CONDITION

POSSIBLE CAUSE

5.11 THERMOSTATIC EXPANSION VALVE MALFUNCTION

Low refrigerant charge

6.4/6.6

Open

6.26

External equalizer line plugged

Wax, oil or dirt plugging valve or orifice Ice formation at

valve seat

Low suction pressure with high

superheat

Superheat too high

Power assembly failure

Loss of element/bulb charge

Broken capillary

6.4/6.6

6.26.c

6.26

Foreign material in valve

6.26

Superheat setting too low

External equalizer line plugged Ice holding valve open

Foreign material in valve

6.26.c

High suction pressure with low

superheat

Open

6.4/6.5 6.26

Pin and seat of expansion valve eroded or held open by

foreign material

Improper bulb location or installation

Low superheat setting

6.26

Liquid slugging in compressor

Fluctuating suction pressure

6.26

6.26.c

5.12 POWER AUTOTRANSFORMER MALFUNCTION

Circuit breaker (CB-1 or CB-2) tripped

Check

6.22

Check

2.4

Power transformer defective

Unit will not start

Power source not turned ON

460 VAC power plug is not inserted into the receptacle

5.13 WATER-COOLED CONDENSER OR WATER PRESSURE SWITCH

Dirty coil

High discharge pressure

6.28

Noncondensibles

Water pressure switch malfunction

Water supply interruption

Check

Condenser fan starts and stops

T-268-07

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SECTION 6

SERVICE

NOTE

To avoid damageto theearth’s ozonelayer, usea refrigerant recovery system whenever removing refrigerant.

When working with refrigerants you must comply with all local government environmental laws. In the

U.S.A., refer to EPA section 608.

6.1 MANIFOLD GAUGE SET

a. Connecting the Manifold Gauge Set

(See Figure 6-2)

Themanifold gaugeset can be used to determinesystem

operating pressure, add a refrigerant charge, and to

equalize or evacuate the system.

1. Remove service valve stem caps and check both

service valves to make sure they are backseated

(turned counter-clockwiseall theway out). Remove

service port caps.

Figure 6-1 shows hand valves, gauges and refrigerant

openings. When the low pressure hand valve is

frontseated (turned all the way in), the low (evaporator)

pressure can be checked. When the high pressure hand

valve is frontseated, high (condensing) pressure can be

checked. When both valves are open (turned

counter-clockwise all the way out), high pressure vapor

will flow into thelow side. When thelow pressurevalve

is open, the system can be charged. Oil can also be

added to the system.

2. Connect the high side field service coupling

(backseated) to the discharge service valve port (or

the manual liquid line valve port, whichever is

applicable).

3. Turn the high side field service coupling (red knob)

clockwise, which will open the high side of the

system to the gauge set.

4. Connect the low side field service coupling to the

suction service valve port.

Only a R-134a manifold gauge set with self-sealing

hoses, as shown in Figure 6-2 (CTD P/N 07-00294-00,

which includes items 1 through 6) can be used when

working on the models covered within this manual.

5. Turn the low side field servicecoupling (blueknob)

clockwise, which will open the low side of the

system to the gauge set.

Low Pressure Gauge

High Pressure Gauge

6. To read system pressures: slightly midseat the

discharge and suction service valves, and frontseat

both manifold gauge set hand valves.

NOTE

Ifamanifold gaugeset is new orwas exposed to

the atmosphere due to repair, it will need to be

evacuated to remove contaminants and air as

follows:

Opened

Midseat both hand valves.

(Backseated Hand Valve )

Closed

(Frontseated Hand Valve)

Connect the utility hose (yellow) to a vacuum

pump.

A. Connection to Low Side of System

B. Connection to High Side of System

C. Connection to Either:

Refrigerant Cylinder or

Evacuate to 10 inches of vacuum.

Charge with R-134a to a slightly positive

pressure of 0.1 kg/cm@ (1.0 psig). The gauge

set is now ready for use.

Oil Container

Figure 6-1. Manifold Gauge Set

6-1

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b. Removing the Manifold Gauge Set

CAUTION

1. While the compressor is still ON, backseat the

discharge service valve.

To prevent trapping liquid refrigerant in the

service valve after charging, perform the

following steps while the compressor is ON

and before disconnecting the manifold

gauge set:

2. Midseat both hand valves on themanifold gaugeset

and allow the pressure in the manifold gauge set to

bedrawn down to suction pressure. This enables the

liquid that condensed in the high side hose to be

returned to the system.

Backseat applicable discharge or manual

liquid line valve.

3. Backseat the suction service valve. Backseat both

field service couplings, and remove the couplings

from the service ports.

Midseat manifold gauge set hand valves.

Allow the gauge set to pull down to suction

pressure.

4. Install both service valve stem caps and serviceport

caps (finger-tight only).

T-268-07

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To Discharge Service or

Manual Liquid Line

Ports

To Suction Service

Port

Blue Hose

Red Hose

Red Knob

Blue Knob

Yellow Hose

1. Manifold Gauge Set

Coupling

6. Low Side Field Service

Coupling

7. High Side Service Port

(SAE J639 Male)

8. Low Side Service Port

(SAE J639 Male)

2. Hose Fitting (0.500-16 Acme)

3. Refrigeration or Evacuation

Hoses (SAE J2196/R-134a)

Hose Fitting w/O-ring

(M14 x 1.5)

5. High Side Field Service

Figure 6-2. R-134a Manifold Gauge Set Connection

6-3

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6.2 SUCTION AND DISCHARGE SERVICE

VALVES

clockwise. Start the unit and run in a cooling mode.

Placestart-stop switch in theOFFposition whenthe

unit reaches a positive pressure of 0.1 kg/cm@ (1.0

psig).

The suction and discharge service valves used on the

compressor are equipped with mating flanges for

connection to flanges on the compressor. These valves

are provided with a double seat and a gauge connection

which enable servicing of the compressor and

refrigerant lines.

c. Frontseat (close) the suction service valve. The

refrigerant will be trapped between the compressor

suction service valve and the liquid line valve.

d. Before opening up any part of the system, a slight

positive pressure should be indicated on the

pressure gauge. If a vacuum is indicated, emit

refrigerant by cracking the liquid line valve

momentarily to build up a slight positive pressure.

Turning the valve stem clockwise (all the way forward)

will frontseat the valve to close off the suction or

discharge line and open the gauge connection to the

compressor. See Figure 6-3. Turning the valve stem

counterclockwise (all the way out) will backseat the

valve to open the suction or discharge line to the

compressor and close off the gauge connection.

e. 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.

With the valve stem midway between frontseated and

backseated positions, the suction or discharge line is

open to both the compressor and the gauge connection.

f. After repairs have been made, be sure to perform a

refrigerant leak check (section 6.4), and evacuate

and dehydrate the system (section 6.5).

For example, when connecting a manifold gauge to

measure suction or discharge pressure, the valve stem is

fully backseated. Then, to measure suction or discharge

pressure, crack open the valves 1/4 to 1/2 turn.

g. Check refrigerant charge (refer to section 6.6).

6.4 REFRIGERANT LEAK CHECKING

Gauge Connection

To Suction or

Discharge Line

WARNING

Valve Cap

Never mix refrigerants with air for leak

testing. It has been determined that

pressurized,

air-rich

mixtures

refrigerants and air can undergo

combustion when exposed to an ignition

source.

Valve Stem

Compressor

Valve

Backseated

(counterclockwise)

Frontseated

(clockwise)

a. The recommended procedure for finding leaks in a

system is with a R-134a electronic leak detector.

Testing joints with soapsuds is satisfactory only for

locating large leaks.

Figure 6-3. Suction or Discharge Service Valve

6.3 PUMPING THE UNIT DOWN

b. If the system is without refrigerant, charge the

system with refrigerant to build up pressure

between 2.1 to 3.5 kg/cm@ (30 to 50 psig). Remove

refrigerant cylinder and leak-check all connections.

To service the filter-drier, moisture-liquid indicator,

expansion valve, suction modulation valve, suction

solenoid valve or evaporator coil, pump most of the

refrigerant into the condenser coil and receiver as

follows:

NOTE

It must be emphasized that only the correct

refrigerant cylinder be connected to pressurize

the system. Any other gas or vapor will

contaminate the system, which will require

additional purging and evacuation of the

system.

a. Backseat the suction and discharge valves (turn

counterclockwise) to close off gauge connections

and attach manifold gauges to valves.

Refer to section 6.1.a.

b. Allow the compressor to run 10 to 15 minutes

before frontseating the liquid line valve. Then close

(front seat) the liquid line valve by turning

c. Remove refrigerant using a refrigerant recovery

system and repair any leaks.

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d. Evacuate and dehydrate the unit. (Refer to section

6.5.)

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

vacuum gauge indicates 2000 microns. Close the

electronic vacuum gauge and vacuum pump valves.

Shut off the vacuum pump. Wait a few minutes to

be sure the vacuum holds.

e. Charge unit per section 6.6.

6.5 EVACUATION AND DEHYDRATION

6.5.1 General

Moisture is the deadly enemy of refrigeration systems.

The presence of moisture in a refrigeration system can

have many undesirable effects. The most common are

copper plating, acid sludge formation, “freezing-up” of

metering devices by free water, and formation of acids,

resulting in metal corrosion.

f. Break the vacuum with clean dry refrigerant gas.

Use refrigerant specified for the unit. Raise system

pressure to approximately 2 psig, monitoring it

with the compound gauge.

g. Remove refrigerant using a refrigerant recovery

system.

6.5.2 Preparation

h. Repeat steps (e) through (g) one time.

a. Evacuate and dehydrate only after pressure leak

test. (Refer to section 6.4.)

i. Remove the copper tubing and change the

filter-drier. Evacuate unit to 500 microns. Close the

electronic vacuum gauge and vacuum pump valves.

Shut off the vacuum pump. Wait fiveminutes to see

if vacuum holds. This procedurechecks forresidual

moisture and/or leaks.

b. Essential tools to properly evacuate and dehydrate

any system include a vacuum pump (8 m³/hr = 5

cfm volume displacement, P/N 07-00176-01) and

electronic vacuum gauge.

c. If possible, keep the ambient temperature above

15.6_C (60_F) to speed evaporation of moisture. If

the ambient temperature is lower than 15.6_C

(60_F), ice might form before moisture removal is

complete. Heat lamps or alternate sources of heat

may be used to raise the system temperature.

j. With a vacuum still in the unit, the refrigerant

charge may be drawn into the system from a

refrigerant container on weight scales. The correct

amount of refrigerant may be added by observing

the scales. (Refer to section 6.6)

6.6 REFRIGERANT CHARGE

d. Replace the filter-drier with a section of copper

tubing with theappropriate fittings. This action will

help speed the evacuation procedure.

6.6.1 Checking the Refrigerant Charge

NOTE

6.5.3 Procedure

To avoid damage to the earth’s ozone layer, use

a refrigerant recovery system whenever

removing refrigerant. When working with

refrigerants you must comply with all local

government environmental laws. In theU.S.A.,

refer to EPA section 608.

a. Remove all refrigerant using a refrigerant recovery

system.

b. The recommended method to evacuate and

dehydrate the system is to connect three evacuation

hoses, as shown in Figure 6-4, to the vacuum pump

and refrigeration unit. DO NOT use standard

service hoses, as they are not suited for evacuation

purposes. Also as shown, connect a evacuation

manifold, with evacuation hoses only, to the

vacuum pump, electronic vacuum gauge, and

refrigerant recovery system.

NOTES

Set the controller set point to --25_C (--13_F)

to ensure that the suction modulation valve is

fully open when checking operation of unit.

The refrigerant level should only be checked

when the unit is running with the suction

modulation valve fully open. The container

temperature should be approximately 1.7_C

(35_F) or --17.8_C (0_F).

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

vacuum. Shut off the pump and check to see if the

vacuum holds. This operation is to test the

evacuation setup for leaks. Repair if necessary.

a. Connect the gauge manifold to the compressor

discharge and suction service valves.

6-5

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b. For Units equipped with receiver: partially block

thecondensercoil inlet air, starting from thefront of

the condenser coil. Increase the area blocked until

the compressor discharge pressure is raised to

approximately 12 kg/cm@ (175 psig). Refrigerant

level on the receiver will normally be between the

sight glasses. If the refrigerant level is not between

these boundaries, refer to section 6.6.3.

check charge only on air-cooled operation.

Refrigerant level in the water-cooled operation will

be normally above sight glass. Partially block the

condenser coil inlet air starting from the front of the

condenser coil. Increase the area blocked until the

compressor discharge pressure is raised to

approximately 12 kg/cm@ (175 psig). Refrigerant

should appear at center line of sight glass on the

water-cooled condenser. If the refrigerant level is

not between theseboundaries, referto section 6.6.3.

c. For Units equipped with water-cooled condenser:

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1. Refrigerant Recovery Unit

2. Refrigerant Cylinder

3. Evacuation Manifold (R-134a)

7. Manual Liquid Line Valve

8. Condenser Coil

9. Suction Service Valve

10. Compressor

Hand Valve

5. Vacuum Pump

6. Electronic Vacuum Gauge

11. Discharge Service Valve

12. Evaporator Coil

Figure 6-4. Vacuum Pump Connections

6-7

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6.6.2 Adding Refrigerant to System (Full Charge)

6.7 COMPRESSOR -- MODEL 06DR

a. Evacuate unit and leave in deep vacuum. (Refer to

section 6.5.)

WARNING

b. Place cylinder of R-134a on scale and connect

charging line from cylinder to liquid line valve.

Purge charging line at liquid line valve and then

note weight of cylinder and refrigerant.

Make sure power to the unit is OFF and

power plug disconnected before replacing

the compressor.

NOTES

c. Open liquid valve on cylinder. Open liquid line

valve half-way and allow the liquid refrigerant to

flow into the unit until the correct weight of

refrigerant has been added as indicated by scales.

Correct charge is noted in Table 6-6.

The compressor should not operate in a

vacuum greater than 500 mm Hg (20 inches

Hg).

NOTE

The service replacement compressor is sold

without shutoff valves (but with valve pads),

and without terminal box and cover.

Customer should retain the original terminal

box, cover, and high pressure switch for use

on replacement compressor.

It may be necessary to finish charging unit

through suction service valve in gas form, due

to pressure rise in high side of the system.

(Refer to section 6.6.3)

d. Backseat manual liquid line valve (to close off

gauge port). Close liquid valve on cylinder.

Check oil level in service replacement

compressor. (Refer to sections 2.2 and 6.10.)

e. Start unit in cooling mode. Run approximately 10

minutes and check the refrigerant charge. (Refer to

section 6.6.1.)

A compressor terminal wiring kit must be

ordered as a separate item when ordering

replacement compressor. Appropriate

6.6.3 Adding Refrigerant to System (Partial

Charge)

installation instructions are included with kit.

a. Examine the unit refrigerant system for any

evidence of leaks. Repair as necessary. (Refer to

section 6.4.)

Refer to Table 6-4 and Table 6-5 for

applicable compressor wear limits and torque

values.

b. Maintain the conditions outlined in section 6.6.1.

Refer to Figure 6-34 for charts on compressor

pressure-temperature and motor current

curves.

c. Fully backseat (to close off gauge port) the suction

service valve (see Figure 2-5) and remove the

service port cap.

d. Connect charging line between suction service

valve port and cylinder of refrigerant R-134a. Open

VAPOR valve.

When servicing the compressor, you must

first identify whether it is a single- or

two-speed compressor. This can be

determined by the bolt pattern of the suction

service valve flange. Single-speed has a two

bolt configuration and the two-speed has a

four bolt configuration.

e. Partially frontseat (turn clockwise) the suction

service valve and slowly add charge until the

refrigerant appears at the proper level (refer to

section 6.6.1).

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h. Remove compressor mounting bolts from

mounting plate and install mounting plate on

replacement compressor.

i. Install replacement compressor terminal wiring kit,

following instructions included with kit.

j. Install high pressure switch on compressor.

k. Install compressor and mounting plate in unit.

l. Connect junction box(es) to compressor and

connect all wiring per wiring diagram. Install

junction box cover(s).

m. Install new gaskets on service valves.

n. Install mounting bolts in service valves and torque

to a value of 2.77 to 4.15 mkg (20-30 ft/lb).

1. Discharge Valve Flange

o. Install a new filter-drier. (Refer to section 6.11)

2. High Side Pressure Connection

3. Low Side Pressure Connection

4. Suction Valve Flange (Refer to note #7)

5. Motor End Cover

6. Serial/Model No. Plate

7. Crankcase Heater (Optional)

8. Bottom Plate

p. Attach two hoses (with hand valves near vacuum

pump) to the suction and discharge service valves.

Dehydrate and evacuate compressorto 500 microns

(75.9 cm Hg vacuum = 29.90 inches Hg vacuum).

Turn off valves on both hoses to pump.

q. Fully backseat (open) both suction and discharge

service valves.

9. Sight Glass

10. Oil Drain Plug

11. Bearing Head

12. Oil Pump

13. Oil Fill Plug (Refer to section 6.10)

14. Cylinder Head

r. Remove vacuum pump lines.

s. Start unit and check refrigerant charge. (Refer to

section 6.6.1.)

15. Valve Plate

t. Check moisture-liquid indicator for wetness.

Change filter-drier if necessary. (Refer to section

6.11)

Figure 6-5. Compressor -- Model 06DR

u. Check compressor oil level per section 6.10. Add

oil if necessary.

6.7.1 Removal and Replacement of Compressor

a. Remove the protective guard from lower section of

the unit.

6.8 COMPRESSOR DISASSEMBLY

WARNING

b. Remove all refrigerant using a refrigerant recovery

system. (Refer to section 6.3)

Before disassembly of the compressor make

sure to relieve the internal pressure very

carefully by slightly loosening the bolts on

both service valve flanges/blank valve pads,

then lightly tap the center of the valve

flanges/pads with a lead hammer to break

the seal.

c. Locate the compressor junction box, see

Figure 6-5. Remove wiring. Disconnect wiring

from compressor terminals and remove compressor

junction box.

d. Remove bolts from service valve flanges.

e. Remove compressor plate mounting bolts.

CAUTION

Removing the press-fit stator in the field is

not recommended. The rotor and stator are

a matched pair and should not be separated.

f. Remove compressor and mounting plate. Refer to

section 2.2 for weight of compressor.

g. Remove high pressure switch (HPS) from

compressor and check operation of switch (refer to

section 6.12.2).

When disassembling compressor, matchmark parts so

they may be replaced in their same relative positions.

(See Figure 6-5 compressor illustration.) Refer to

6-9

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Table 6-4 and Table 6-5 for compressor wear limits and

bolt torque values.

a. Place the compressor in a position where it will be

convenient to drain the oil. Remove the oil plug on

the oil pump inlet passage (see Figure 6-8 for

location) to vent the crankcase. Loosen the drain

plug (see Figure 6-5) in bottom plate and allow the

oil to drain out slowly. Remove the plug slowly to

relieve any crankcase pressure. Some units have a

plug in the bottom center of the crankcase which

may be removed for draining the motor end more

quickly.

1. Oil Pressure Relief Valve

2. Oil Return Check Valve

3. Oil Suction Tube

4. Capscrew

5. Connecting Rod and Cap Assembly

b. Remove cylinder head capscrews. If the cylinder

head is stuck, tap the center of the cylinder head

with a wooden or lead mallet. DO NOT STRIKE

THE SIDE OF THE CYLINDER HEAD! Be

careful not to drop the head or damage the gasket

sealing surface. (See Figure 6-5 and Figure 6-6.)

Remove cylinder head gasket.

Figure 6-7. Bottom Plate Removed

c. Remove valve stops and valves. After they have

been removed, freethevalve platefrom thecylinder

deck by using the outside discharge valve

hold-down capscrew as a jack screw through the

tapped hole of the valve plate. Remove the valve

plate gasket, see Figure 6-6, item 7.

d. Turn the compressor on its side and remove the

bottom plate and the oil suction screen hold down

plate. Match mark each connecting rod cap and

connecting rod for correct reassembly. Remove the

bolts and connecting rod caps (see Figure 6-7).

Push thepiston rods up as faras they will go without

having the piston rings extend above the cylinders.

Jack here

1. Cylinder Head Gasket

CAUTION

2. Discharge Valve Screw and Lockwasher

3. Discharge Valve Stop

4. Discharge Valve

The copper tube which connects to the oil

suction strainer extends out the bottom with

the bottom plate removed. Take precautions

to avoid bending or breaking it while

changing crankcase positions.

5. Valve Plate

6. Valve Plate Assembly

7. Valve Plate Gasket

Figure 6-6. Exploded View of Valve Plate

e. If necessary, remove the oil return check valve.

Inspect it for check valve operation (flow in one

direction only). Replace the assembly with a new

unit if check valve operation is impaired. (See

Figure 6-7.)

f. To remove the oil pump. Remove eight capscrews,

oil pump bearing head assembly, gasket and thrust

washer. (See Figure 6-8.)

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Set screw must be removed.

1. Capscrews

2. Cover

3. Reversing Assembly

4. Pinion

5. Gear

6. Drive

1. Oil Pump & Bearing Head

2. Thrust Washer

3. Oil Pickup Tube

4. Oil Inlet Port

5. Oil Pump Inlet

7. O-Ring

8. Oil Pump & Bearing

9. Set Screw

10. Relief Valve

11. Pin

Figure 6-8. Oil Pump and Bearing Head

If it was determined that the oil pump is not operating

properly, theentire oil pump and bearing head assembly

must be replaced. Replacement parts for the pump are

not available. However, in the event the pump requires

inspection or cleaning, disassemble and reassemble by

referring to Figure 6-9. Clean all parts and coat all

moving parts with compressor oil before proceeding

with reassembly.

Figure 6-9. Low Profile Gear Oil Pump

g. Be very careful not to damage the motor windings

when removing the motor end cover, as the cover

fits over the winding coils. Remove all capscrews

except one in the top of the cover. Then, while

holding the cover in place, remove the remaining

capscrew. Do not allow the cover to drop from its

own weight. To prevent striking the winding,

remove the cover horizontally and in line with the

motor axis.

1. Valve Capscrew

2. Suction Service Valve

(Used on single-speed compressor)

3. Valve Gasket

(Used on single-speed compressor)

4. Suction Service Valve

(Used on two-speed compressor)

5. Valve Gasket

(Used on two-speed compressor)

6. Motor End Cover

h. Remove the refrigerant suction strainer. If it is

removed with ease it may be cleaned with solvent

and replaced. (See Figure 6-10.) If the strainer is

broken, corroded or clogged with dirt that is not

easily removed, replace the strainer. Install new

gaskets upon reassembly.

7. Motor End Cover Gasket

8. Suction Strainer

9. Strainer Screws and Washers

i. Block the compressor crankshaft so that it cannot

turn. Use a screwdriver to bend back the tabs on the

lockwasher and remove the equalizer tube. (See

Figure 6-12.) The slinger at the end of the shaft

draws vapor from the crankcase. It may discharge

through a tee or a single equalizer tube.

Figure 6-10. Motor End Cover

j. If the piston rings extend beyond the cylinder tops,

the pistons can be pulled through the bottom plate

6-11

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opening after the piston rings are compressed. A

piston ring compresser will facilitate removal. Each

piston pin is locked in place by lock rings which are

snapped into grooves in the piston wall.

Disassemble and assemble the terminal plate as shown

in Figure 6-13.

The terminal mounting plate assembly, as originally

installed, is assembled so as to leave a small space

between the outer terminal bushing and the surface of

the mounting plate. This is to provide further crush of

theterminal bushing in casealeak should occur. To stop

a leak, tighten the terminal bushing nut only enough to

stop the escape of gas. Do not tighten until the terminal

bushing is flush with themounting plate. Thetightening

torque used at the factory is 0.21 to 0.23 mkg (18 to 20

inch pounds)maximum to prevent damageto theplastic

parts.

1. Capscrew

2. Cap

3. Crankshaft

4. Thrust Washer

5. Rotor Drive Key

6. Connecting Rod

7. Compression Ring

8. Piston

9. Pin

10. Retainer

Figure 6-11. Crankshaft Assembly

NOTE: Parts shown are for one terminal.

1. Terminal Bushing Nut

2. Lock Washer

3. Terminal Washer

4. Outer Terminal Bushing

5. O-Ring

k. Since the stator cannot be replaced in the field, the

terminal plate assembly need not be disturbed

unless a leak exists or a terminal part requires

replacing.

6. Terminal Bushing Washers (Grey)

7. Terminal Bushing Washers (Red)

8. Inner Terminal Bushing

9. Terminal Mounting Plate

10. Cover Gasket

11. Inner Terminal Block

12. Terminal Screw

Figure 6-13. Terminal Mounting Assembly

1. Equalizer Tube and Lockscrew Assembly

2. Lockwasher

3. Counterweight -- Motor End

Figure 6-12. Removing Equalizing Tube and Lock

Screw Assembly

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6.9 COMPRESSOR REASSEMBLY

The gap between the ends of the piston rings can be

checked with afeelergaugeby inserting thering into the

piston bore approximately one inch below the top of the

bore. Square the ring in the bore by pushing it slightly

with a piston. The maximum and minimum allowable

ring gaps are 0.33 and 0.127 mm (0.013 and 0.005 inch)

respectively.

To clean compressor parts, use a suitable solvent with

proper precautions. Coat all moving parts with the

proper compressor oil before assembly. Refer to

Table 6-5 for applicable compressor torque values.

Figure 6-15. Piston Rings

c. Installing the Components

1. Push pistons from the inside of the crankcase

through the cylinders, being careful not to break the

rings. Place chamfered side of connecting rod

against radius of crankpins. Install the crankshaft

through the pump end of the compressor. Do not

damagemain bearings. Install matching connecting

rod caps through bottom cover plate.

1. Suction Valve

2. Suction Valve Positioning Spring

3. Valve Plate Dowel Pin

2. The oil screen (located in the bottom of the

crankcase), is connected to the inlet of the oil pump.

Whenever the compressor crankcase is opened,

inspect the screen for holes or an accumulation of

dirt. The screen can be cleaned with a suitable

solvent.

Figure 6-14. Suction Valve & Positioning Springs

a. Suction and Discharge Valves

If the valve seats look damaged or worn, replace valve

plate assembly. Always use new valves because it is

difficult to reinstall used discharge valves so that they

will seat as before removal. Any valve wear will cause

leakage for this reason.

CAUTION

The set screw on the crankshaft must be

removed for the oil pump installation (see

Figure 6-8).

Suction valves are positioned by dowel pins (see

Figure 6-14) and will assume their original position

when reinstalled. No two valves are likely to wear in

exactly the same way. Never interchange used valves.

3. Install thepump end thrust washer on the two dowel

pins located on the bearing head. (See Figure 6-8)

CAUTION

Ensure that thrust washer does not fall off

dowel pins while installing oil pump.

Do not omit the suction valve positioning springs. (See

Figure 6-14.) Place the springs so that the ends bear

against the cylinder deck (middle bowed away from

cylinderdeck). Usenewgaskets when reinstalling valve

plates and cylinder heads.

4. Install the bearing head assembly with a new gasket

on the compressor crankshaft. Carefully push oil

pump on by hand, ensuring that the thrust washer

remains on the dowel pins. The tang on the end of

the drive engages the slot in the crankshaft, and the

oil inlet port on the pump is aligned with the oil

pickup tube in the crankcase. The pump should

mount flush with the crankcase and should be

oriented as shown in Figure 6-16.

b. Compression Rings

The compression ring is chamfered on the inside

circumference. This ring is installed with the chamfer

toward the top. Stagger the ring end gaps so they are not

aligned.

6-13

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compressor. To remove oil from the compressor,

follow step d in this section. If the level is below the

bottom of the sight glass, add oil to the compressor

following step b below.

b. Adding Oil with Compressor in System

In an emergency where an oil pump is not available, oil

may be drawn into the compressor through the suction

service valve.

CAUTION

Extreme care must be taken to ensure the

manifold common connection remains

immersed in oil at all times. Otherwise air

and moisture will be drawn into the

compressor.

Figure 6-16. Compressor Oil Pump End View

5. Align the gasket and install the eight capscrews in

the mounting flange. Refer to Table 6-5 for

applicable torque values.

Connect the suction connection of the gauge manifold

to the compressor suction service valve port, and

immerse the common connection of the gaugemanifold

in an open container of refrigeration oil. Crack the

suction service valve and gauge valve to vent a small

amount of refrigerant through the common connection

and the oil to purge the lines of air. Close the gauge

manifold valve.

6. Install rotor with key. Screw on equalizer tube and

lock screw assembly with lock washer and bend

over tabs of lock washer. Assemble suction strainer

to motor and cover and bolt cover to crankcase.

Assemble valve plates and gaskets. Assemble

cylinder heads and gaskets. Turn the shaft by hand

to see that it moves freely.

7. Install the oil suction screen, the oil suction screen

hold down plate and the bottom plate.

With the unit running, frontseat the suction service

valveand induceavacuum inthecompressorcrankcase.

SLOWLY crack the suction gauge manifold valve and

oil will flow through the suction service valve into the

compressor. Add oil as necessary.

6.10 COMPRESSOR OIL LEVEL

CAUTION

Use only Carrier Transicold approved

Polyol Ester Oil (POE) -- Castrol-Icematic

SW20 compressor oil with R-134a. Buy in

quantities of one quart or smaller. When

using this hygroscopic oil, immediately

reseal. Do not leave container of oil open or

contamination will occur.

Run unit for 20 minutes in cooling mode. Check oil

level at the compressor sight glass.

c. Adding Oil to Service Replacement

Compressor

NOTES

The correct oil charge is 3.6 liters (7.6 U.S.

pints).

a. To Check the Oil Level in the Compressor:

Service replacement compressors are shipped

without oil.

1. Operate the unit in cooling mode for at least 20

minutes.

When first adding oil to the compressor, add

only three liters (6.3 pints) to the compressor.

Run the unit for 20 minutes in cooling mode.

Check the oil level in the compressor sight

glass. Add oil as necessary. This procedure is

designed to compensate for excess oil that

may have migrated with refrigerant to other

parts of the system during unit operation.

2. Check the front oil sight glass on the compressor to

ensure that no foaming of the oil is present after 20

minutes of operation. If the oil is foaming

excessively after 20 minutes ofoperation, check the

refrigerant system for flood-back of liquid

refrigerant. Correct this situation before performing

step 6.10.a.3.

3. Turn unit off to check the oil level. The correct oil

level range should be between the bottom to

one-eighth level of the sight glass. If the level is

above one-eighth, oil must be removed from the

If compressor is without oil:

If oil is present in the compressor, ensure that it is the

correct oil. Add oil (sections 2.2 and 6.10) through the

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6.12 HIGH PRESSURE SWITCH

suction service valve flange cavity or by removing the

oil fill plug. (See Figure 6-5.) Some compressors have

the oil plug located on the crankcase, at the right or left

side of the oil pump.

6.12.1 Replacing High Pressure Switch

a. Turn unit start-stop switch OFF. Frontseat both

suction and discharge service valves to isolate

compressor. Remove the refrigerant from the

compressor.

d. To Remove Oil From an 06DR Compressor:

1. If the oil level recorded in step a.3 is above

one-eighth level of the capacity of the sight glass,

oil must be removed from the compressor.

b. Disconnect wiring from defective switch. The high

pressure switch is located on the center head and is

removed by turning counterclockwise. (See

Figure 2-1.)

2. Close (frontseat) suction service valve and pump

unit down to 1.2 to 1.3 kg/cm@ (2 to 4 psig).

Frontseat discharge service valve and slowly bleed

remaining refrigerant.

c. Install a new high pressure switch after verifying

switch settings. (Refer to section 6.12.2.)

d. Evacuate and dehydrate the compressor per

section 6.5.1.

3. Remove theoil drain plug on the bottom plate ofthe

compressor and drain the proper amount of oil from

the compressor to obtain the correct level

(maximum is one-eight level of the sight glass).

Replacetheplug securely back into thecompressor.

DO NOT FORGET TO OPEN SUCTION AND

DISCHARGE SERVICE VALVES.

6.12.2 Checking High Pressure Switch

WARNING

Do not use a nitrogen cylinder without a

pressure regulator. Do not use oxygen in or

near a refrigeration system as an explosion

may occur.

4. Repeat step (a) to ensure proper oil level.

NOTE

6.11 FILTER-DRIER

The high pressure switch (HPS) is

non-adjustable.

On units equipped with a water-cooled condenser, if the

sight glass appears to be flashing or bubbles are

constantly moving through the sight glass when the

suction modulation valve is fully open, the unit may

have a low refrigerant charge or the filter-drier could be

partially plugged.

a. Remove switch as outlined in section 6.12.1.

b. Connect ohmmeterorcontinuity light across switch

terminals. Ohm meter will indicate no resistance or

continuity light will be illuminated if the switch

closed after relieving compressor pressure.

To Check Filter-Drier:

c. Connect hose to a cylinder of dry nitrogen. (See

Figure 6-17.)

a. Test forarestricted orpluggedfilter-drierbyfeeling

the liquid line inlet and outlet connections of the

driercartridge. Iftheoutlet side feels cooler than the

inlet side, then the filter-drier should be changed.

1. Cylinder Valve

and Gauge

2. Pressure Regulator

3. Nitrogen Cylinder

4. Pressure Gauge

(0 to 36 kg/cm@ =

0 to 400 psig)

5. Bleed-Off Valve

6. 1/4 inch Connection

b. A second test for moisture in the filter-drier is that

the moisture-liquid indicator shows moisture in the

system.

To Replace Filter-Drier:

a. Pump unit down to 0 psi and replace filter-drier.

(Refer to section 6.3.)

Figure 6-17. Typical Setup for Testing

High Pressure Switch

b. Evacuate the unit per section 6.5 and open the

manual liquid line valve.

d. Set nitrogen pressure regulator at 26.4 kg/cm@ (375

psig) with bleed-off valve closed.

c. After unit is in operation, inspect for moisture in

system.

e. Close valve on cylinder and open bleed-off valve.

6-15

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6.14 EVAPORATOR COIL HEATERS

f. Open cylinder valve. Slowly close bleed-off valve

to increase pressure on switch. The switch should

open at a static pressure up to 25 kg/cm@ (350 psig).

If a light is used, light will go out. If an ohmmeter is

used, the meter will indicate open circuits.

WARNING

Before servicing unit, make sure the unit

circuit breakers (CB-1 & CB-2) and the

start-stop switch (ST) are in the OFF

position, and that the power plug and cable

are disconnected.

g. Slowly open bleed-off valve to decrease the

pressure. The switch will close at 18 kg/cm@ (250

psig).

a. Remove the lower access panel (Figure 2-1) by

removing the T.I.R. locking device lockwire and

mounting screws.

6.13 EVAPORATOR COIL AND HEATER

ASSEMBLY

b. Determine which heater(s) need replacing by

checking resistance on each heater as shown in

section 1.4.e.

The evaporator section, including the coil, should be

cleaned regularly. The preferred cleaning fluid is fresh

water or steam. Another possible cleaner is Oakite 202

or similar, following manufacturer’s instructions.

c. Remove hold-down clamp securing heaters to coil.

d. Lift the “U” or “W” portion of the heater (with the

opposite end down and away from coil). Move

heater left (or right) enough to clear the heater end

support.

The two drain pan hoses connected to the drain pan are

routed behind the condenser fan motor and compressor.

The drain pan line(s) must be open to ensure adequate

drainage.

6.15 EVAPORATOR FAN AND MOTOR ASSEMBLY

The evaporator fans circulate air throughout the

container by pulling air in through the top of the unit.

The air is forced through the evaporator coil where it is

either heated or cooled and then discharged out the

bottom of the refrigeration unit into the container.

(Refer to section 2.3.) The fan motor bearings are

factory lubricated and do not require additional grease.

To Replace the Evaporator Coil:

a. Pump unit down. (See Figure 2-5, refer to section

6.3.)

b. With power OFF and power plug removed, remove

the screws securing the panel covering the

evaporator section (upper panel).

To Replace the Evaporator Fan Assembly:

WARNING

c. Disconnect the defrost heater wiring.

Always turn OFF the unit circuit breakers

(CB-1 & CB-2) and disconnect main power

supply before working on moving parts.

d. Disconnect the sensor from the coil. The defrost

termination sensor (DTS) is located on the middle

coil support as shown in Figure 2-2.

a. Remove upper access panel (see Figure 2-1) by

removing mounting bolts and T.I.R. locking

device. Reach inside of unit and remove the Ty-Rap

securing the wire harness loop. Then unplug the

connector by twisting to unlock and pulling to

separate.

e. Remove middle coil support.

f. Remove the mounting hardware from the coil.

g. Unsolder the two coil connections, one at the

distributor and the other at the coil header.

b. Loosen four 1/4-20 clamp bolts that are located on

theundersideofthefan deck at thesides oftheofthe

fan assembly. Slide the loosened clamps back from

the fan assembly.

h. After defective coil is removed from unit, remove

defrost heaters and install on replacement coil.

c. Slide the fan assembly out from the unit and place

on a sturdy work surface.

i. Install coil assembly by reversing above steps.

To disassemble the Evaporator Fan Assembly:

j. Leak check connections per section 6.4. Evacuate

the unit per section 6.5 and add refrigerant charge

per section 6.6.2.

1. Attach a spanner wrench to the two 1/4-20 holes

located in the fan hub. Loosen the 5/8-18 shaft nut

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by holding the spanner wrench stationary and

turning the 5/8-18 nut counter-clockwise (see

Figure 6-18).

lubricate the fan motor shaft and threads with a

graphite-oil solution (such as Never-seez).

4. Install the fan onto the motor shaft. Place one 5/8

flat washer with a 5/8-18 locknut onto the motor

shaft and torque to 40 foot-pounds.

d. Install the evaporator fan assembly in reverse order

of removal. Torque the four 1/4-20 clamp bolts to

0.81 mkg (70 inch-pounds) Apply power

momentarily to check for proper fan rotation (refer

to section 2.3). If fan spins backward, then motor

wiring or motor is defective.

e. Replace access panel making sure that panel does

not leak. Make sure that the T.I.R. locking device is

lockwired.

6.16 EVAPORATOR FAN MOTOR CAPACITORS

The evaporator fan motors are of the permanent-split

capacitor type. The motor is equipped with one

capacitor (used in the high speed circuit) and another

capacitor used for the low speed circuit.

a. When to check for a defective capacitor

1. Fan motor will not change speed. For example:

controller settings above --10_C (+14_F), or --5_C

(+23_F) optionally, should cause the motor to run in

high speed.

1. Stator

NOTE

2. Flat washer, 1/4

3. Bolt, 1/4-20 x 3/4

4. Locknut, 5/8-18

5. Flat washer, 5/8

6. Impeller Fan

7. Key

8. Mylar Protector

9. Evaporator Motor

The evaporator fan motors will always start in

high speed.

Controller settings below --10_C (+14_F), or --5_C

(+23_F) optionally, should cause the motor to run in

low speed.

2. Motor running in wrong direction (after checking

for correct wiring application).

Figure 6-18. Evaporator Fan Assembly

b. Removing the capacitor

2. Remove the spanner wrench. Use a universal wheel

puller and remove the fan from the shaft. Remove

the washers and key.

WARNING

Make sure power to the unit is OFF and

power plug disconnected before removing

capacitor(s).

3. Remove the four 1/4-20 x 3/4 long bolts that are

located under the fan that support the motor and

stator housing. Remove the motor and plastic

spacer.

1. The capacitor located on the motor and above the

evaporator fan deck may be removed by two methods:

To assemble the Evaporator Fan Assembly:

(a) If container is empty, open upper rear panel of

the unit. The capacitor may be serviced after

disconnecting power plug.

1. Assemble the motor and plastic spacer onto the

stator.

(b) If container is full, turn the unit power OFF and

disconnect power plug. Remove the evaporator

fan motor access panel. (See Figure 2-1). For

removal oftheevaporatorfan assembly, referto

section 6.15.

2. Apply loctite to the 1/4-20 x 3/4 long bolts and

torque to 0.81 mkg (70 inch-pounds).

3. Place one 5/8 flat washer on the shoulder of the fan

motor shaft. Insert the key in the keyway and

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WARNING

e. Install replacement coil and solder connections.

f. Leak-check the coil per section 6.4. Evacuate the

unit per section 6.5, then charge the unit with

refrigerant per section 6.6.1.

With power OFF discharge the capacitor

and disconnect the circuit wiring.

c. Checking the capacitor

6.18 CONDENSER FAN AND MOTOR ASSEMBLY

If the capacitor is suspected of malfunction, you may

choose to simply replace it. Direct replacement requires

a capacitor of the same value. Two methods for

checking capacitor function are:

WARNING

Do not open condenser fan grille before

turning power OFF and disconnecting

power plug.

1. Volt-ohmmeter set on RX 10,000 ohms. Connect

ohmmeter leads across the capacitor terminals and

observe the meter needle. If the capacitor is good, the

needle will make a rapid swing toward zero resistance

and then gradually swing back toward a very high

resistance reading.

The condenser fan rotates counter-clockwise (viewed

from front of unit), pulls air through the the condenser

coil, and discharges horizontally through thefront ofthe

unit. To replace motor assembly:

a. Open condenser fan screen guard.

If the capacitor has failed open, the ohmmeter needle

will not move when the meter probes touch the

terminals. If the capacitor is shorted, the needle will

swing to zero resistance position and stay there.

b. Loosen two square head set screws on fan. (Thread

sealer has been applied to set screws at installation.)

Disconnect wiring from motor junction box.

CAUTION

2. Capacitor analyzer

Take necessary steps (place plywood over

coil or use sling on motor) to prevent motor

from falling into condenser coil.

The function of the analyzer is to read the microfarad

value of a capacitor and to detect insulation breakdown

under load conditions. The important advantages of a

analyzer are its ability to locate capacitors that have

failed to hold their microfarad ratings, or those that are

breaking down internally during operation. It is also

useful in identifying capacitors when their microfarad

rating marks have become unreadable.

c. Remove motor mounting hardware and replace the

motor. It is recommended that newlocknuts beused

when replacing motor. Connect wiring per wiring

diagram.

d. Install fan loosely on motor shaft (hub side in). DO

NOT USE FORCE. If necessary, tap the hub only,

not the hub nuts or bolts. Install venturi. Apply

“Loctite H” to fan set screws. Adjust fan within

venturi so that the outer edge of the fan projects 3.2

to 6.4 mm (3/16” ¦1/16”) back from edge of the

venturi. Spin fan by hand to check clearance.

6.17 CONDENSER COIL

The condenser consists of a series of parallel copper

tubes expanded into copper fins. The condenser coil

must becleaned with fresh water orsteam so the airflow

is not restricted. Fan rotation is counterclockwise when

viewed from shaft end of motor.

e. Close and secure condenser fan screen guard.

WARNING

f. Apply power to unit and check fan rotation. If fan

motor rotates backward, reverse wire numbers 5

and 8.

Do not open the condenser fan grille before

turning power OFF and disconnecting

power plug.

6.19 PARTLOW RECORDING THERMOMETER

To Replace Condenser Coil:

NOTE

a. Remove the refrigerant charge per section 6.3.

b. Remove the condenser coil guard.

The Controller/DataCORDER return air probe

is located adjacent to the Partlow bulb, and can

be used to calibrate the chart recorder.

c. Unsolder discharge line and remove the line to the

receiver or water-cooled condenser (if so

equipped).

a. Instruments for Checking Bulb Temperature

Therecording thermometermay be optionally equipped

with one or two Simpson accessories (#344 units), each

consisting of a thermistor probe and receptacle

d. Remove coil mounting hardware and remove the

coil.

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c. Checking the Recording Thermometer Bulb

Temperature

(mounted to instrument case). Asingleprobeis attached

to the element (bulb) capillary which senses the

container return air temperature. If using two probes,

one probe will be attached to the supply air temperature

sensor.

Checking temperature is accomplished by comparing

the instrument’s indicated temperature (stylus) with the

known temperature existing at the element sensing

bulb. To properly check the temperature of therecorder,

the element sensing bulb should be stabilized at a

temperature of 0_C (32_F). This is accomplished by

using one of the two following methods, whichever is

more convenient.

In the event of a failure with the #344 test lead, other

instruments for checking bulb temperatures are:

Simpson Meter, CTC P/N 07-00013 or Robinair

Thermistor Temperature Tester, Model 12860:

Unit Running:

A resistance thermometer with RCA lead and a

phono-plug at each end may beused to comparethebulb

temperature and the stylus indicated temperature on the

chart by inserting one end of the lead into the receptacle

provided on the controller and the other end in the

meter. Always check resistance thermometer before

using. (Refer to 6.19.b.)

Place set point at 0_C (32_F). After unit has pulled

down to this temperature, allow the compressor to cycle

ON-OFF three to five times to be certain temperature

has stabilized at 0_C (32_F)as verified by theresistance

thermometer. If the temperature indicated by the

thermometer differs from 0_C (32_F) by more than

0.6_C (1_F) when compressor cycles off, rezeroing

must be performed.

Ohmmeter:

Unit Off:

1. Place one probe of ohmmeter in the middle of the

receptacle provided on the chart platen (Figure 6-19).

Ground other probe to unit.

Place the recording thermometer element (sensingbulb)

in 0_C (32_F) ice-water bath. Ice-water bath is prepared

by filling an insulated container (of sufficient size to

completely immersebulb)with icecubesorchippedice,

filling voids between ice with water, and agitating until

mixture reaches 0_C (32_F) as shown by a laboratory

thermometer.

2. Note reading of meter and using Table 6-2, convert

resistance to temperature.

CAUTION

When the temperature at the element sensing bulb has

stabilized at 0_C (32_F), as shown by stable stylus

indication, compare the temperature indicated by stylus

with temperatureshown by alaboratory thermometer. If

the two readings do not agree, the recording

thermometer should be rezeroed. (Refer to paragraph d.)

The inside mechanism of the control,

particularly the inside of the element

housing should never be oiled, however,

control mechanisms should be sprayed

periodically (every 60 days) with corrosion

inhibiting CRC 3-36a or 6-66 or LPS no. 2.

d. Rezeroing the Recording Thermometer

1. Be certain that the element bulb temperature has

stabilized at 0_C (32_F). Note the amount of

temperature difference between the test meter or

thermometer reading and the stylus indicated

temperature.

b. Checking Resistance Thermometer (Optional)

Calibrate the resistance thermometer by completely

filling a thermos container full of ice cubes or chips and

filling the voids between the ice with plain water. Stir

the solution until the mixture registers 0 to 0.3_C (32 to

32.5_F), as indicated by a laboratory thermometer.

Immerse the resistance thermometer in the 0_C (32_F)

solution to check its accuracy at this temperature. It is

important that the recommended length of the check

probe is immersed so that it will accurately reflect

temperature. This measurement checks the test probe at

0_C (32_F) only. It is possible for the resistance

thermometer to be inaccurate at other temperatures.

Rezero check thermometer if necessary following

manufacturer’s instructions.

If the difference noted between the known element

temperature and indicated temperature is within

acceptable limits (0.3 of 0_C = 1/2_ of 32_F), do not

attempt to rezero. If more than 0.3_C (1/2_F) in

variation, carefully note the number of degrees.

2. If recording thermometer is found to require

rezeroing:

(a) Loosen set screw (item 3, Figure 6-19) and zero

thermometer by turning pinion shaft (item 4).

Lengthening pinion shaft (counterclockwise)

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raises stylus indicated temperature reading;

shortening shaft (clockwise) lowers stylus

reading. Then retighten set screw.

The stylus will continue to fall (container temperature

will actually be higher) if a leak develops in the flange,

capillary or bulb.

To replace the recording thermometer element:

(b) Reset control at 0_C (32_F), start the

refrigeration unit and repeat accuracy check.

After temperature stabilization, recording

thermometer should be within 0.3_C (1/2_F)

limits.

1. Turn unit OFF and disconnect power source.

2. Remove upper back panel. Remove bulb clamps

securing bulb to unit.

3. Remove two flange screws from recording

thermometer and feed capillary and element

through the unit.

4. Push replacement bulb end and capillary through

the unit.

5. Fill slots with silastic (RTV432, Dow Corning).

6. Attach bulb clamps tightly to bulb.

7. Connect element flange to recorder making sure

hub of flange faces out to fit into the hole in

instrument case (recording thermometer).

8. Rezero the recorder. (Refer to sections 6.19.a.

through 6.19.d.)

9. Install inlet air grille and upper panel. Start unit and

check recorder calibration.

CAUTION

Capillary tubing may be bent, but never

sharper than 1/2” radius; extra care should

be taken when bending adjacent to welds.

The sensing bulb should never be bent, as

this will affect calibration.

6.20 SAGINOMIYA RECORDING THERMOMETER

1. Wind-up Key

2. Stylus

3. Set Screw

4. Pinion Shaft

5. Stylus Lifter

6. Bulb

NOTE

Do not overtighten chart nut after replacing

chart.

a. Battery

1. Open door and remove chart nut and platen.

Figure 6-19. Partlow Recording Thermometer

2. Push voltage indicator test switch (item 2,

Figure 6-20). Replace battery if voltage indicator

points to the red or white zone.

e. Replacing Recording Thermometer Element

(Bulb and Capillary)

b. Calibration

The

element

mercury-filled

and

the

1. Install new chart on platen.

temperature-pressure of the element controls the stylus,

which moves across thechart in response to temperature

changes as sensed by the bulb located in the evaporator

supply air.

2. Place recorder bulb in ice bath (0 ¦ 0.2_C = 32 ¦

0.35_F). (Remove rear upper panel to remove

bulb.) Leave bulb immersed in ice bath for 10

minutes.

The element flange contains three O-rings. Care should

be taken to install the new element flange without

damaging the O-rings. It is possible for a mercury leak

to develop at the flange if O-ring damage occurs.

3. After 10 minutes, rotate the chart by hand and check

the stylus indicated temperature. Do not touch

stylus during the checkout procedure.

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4. If adjustment is required, loosen setscrew

(cross-recessed head). Using a 7 mm wrench, rotate

the adjustment screwclockwise to set thestylus 1 to

2_C (1.8 to 3.6_F) higher than desired temperature.

Calibration should only be done when bulb

temperature is decreasing.

DO NOT move stylus by hand.

6.21 MAINTENANCE OF PAINTED SURFACES

5. Rotate the adjustment screw counterclockwise to

set the stylus about 0.5_C (0.9_F) higher than set

temperature. Rotate the chart by hand. The

indicated temperature should be 0_C (32_F).

The refrigeration unit is protected by a special paint

system against the corrosive atmosphere in which it

normally operates. However, should thepaint system be

damaged, the base metal can corrode. In order to protect

the refrigeration unit from the highly corrosive sea

atmosphere, or if the protective paint system is

scratched or damaged, clean area to bare metal using a

wire brush, emery paper or equivalent cleaning method.

Immediately following cleaning, spray or brush on

zinc-rich primer. After the primer has dried, spray or

brush on finish coat ofpaint to match original unit color.

c. Replacing Sensor Probe

1. Remove box from unit.

2. Remove nut and bushing (item 9, Figure 6-20).

6.22 POWER AUTOTRANSFORMER (OPTIONAL)

If the unit does not start, check the following:

a. Make sure the 460 vac (yellow) power cable is

plugged into the receptacle (item 3, Figure 2-9) and

locked in place.

b. Make sure that circuit breakers CB-1 and CB-2 are

in the “ON” position. If the circuit breakers do not

hold in, check voltage supply.

c. There is no internal protector for this particular

transformer design, therefore, no checking of the

internal protector is required.

d. Using a voltmeter, and with the primary supply

circuit ON, check the primary (input) voltage (460

vac). Next, check the secondary (output) voltage

(230 vac). The transformer is defective if voltage is

not available.

1. Voltage Indicator

2. Indicator Test Switch

3. Battery (“C” size, Alkaline)

4. Sensor Assembly

5. Stylus

6. Stylus Lifter

6.23 SENSOR CHECKOUT PROCEDURE (AMBS,

DTS, RRS, RTS, SRS & STS)

7. Setscrew (Adjustment)

8. Bulb and Mechanism

9. Bushing and Nut

An accurate ohmmeter must be used to check the

resistance values shown in Table 6-1.

Figure 6-20. Saginomiya Recording Thermometer

Due to the 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 defective, the resistance reading will usually

bemuch higherorlowerthan theresistancevaluesgiven

in Table 6-1.

3. Install replacement probe and bushing. Seal with

silicone before securing to case.

4. Install box into unit.

NOTES

One full turn with the adjustment screw

changes the indicated temperature by

approximately 5_C (9_F).

6.23.1 Checking Sensor (RRS, RTS, SRS or STS)

a. Place the sensor (sensing bulb) in a 0_C (32_F)

ice-water bath. The ice-water bath is prepared by

filling an insulated container (of sufficient size to

Overtightening of setscrew may change set

temperature.

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completely immerse bulb) with ice cubes or

chipped ice, then filling voids between ice with

water and agitating until mixture reaches 0_C

(32_F) measured on a laboratory thermometer.

Cap and Grommet

Assembly

Evaporator

Back Panel

b. Start unit and check air temperature/data readout on

the control panel. The reading should be 0_C

(32_F); ifit is not, continueon to thefollowingstep.

Sensor

Wires

Probe

Holder

c. Turn unit OFF and disconnect power supply.

Supply

Air

Stream

d. Refer to section 6.27 for removal of the Controller

module.

Unit Frame

RTS or STS:

Using the plug connector marked “EC” that is

connected to the Controller module. Locate the wires

marked RTS or STS, depending on which sensor needs

to be replaced. Follow that wire to the connector and

using the pins of the plug, measure the ohms resistance.

Readings are shown in Table 6-1.

Supply Sensor

6 mm

(1/4 inch)

OLD STYLE PROBE HOLDER

Sensor

RRS or SRS:

Wires

Cap and Grommet

Assembly

Using the plug connector marked “EC” that is

connected to the Controller module. Locate the wires

marked RRS or SRS, depending on which sensor needs

to be replaced. Follow that wire to the connector and

using the pins of the plug, measure the ohms resistance.

Readings are shown in Table 6-1.

Evaporator

Back Panel

Probe

Holder

6.23.2 Replacing Sensor (STS and SRS)

Supply

Air

To properly position a unit supply sensor, the sensor

must be fully inserted into the probe holder. This

positioning will give the sensor the optimum amount of

exposure to the supply air stream, and will allow the

Controller to operate correctly. Insufficient probe

insertion into the probe holder will result in poor

temperature control due to the lack of air flow over the

sensor.

Stream

Supply Sensor

6 mm

(1/4 inch)

It is also necessary to ensure that the probe tip does not

contact theevaporatorback panel. Thedesign minimum

clearance of 6 mm (1/4 inch) should be maintained (see

Figure 6-21).

NEW STYLE PROBE HOLDER

Figure 6-21. Supply Sensor Positioning

a. Turn unit power OFF and disconnect powersupply.

b. Remove and save any cover (if present) over wiring

and probe holder.

c. Cut cable5 cm (2 inches)fromshoulderofdefective

sensor and discard the defective probe only. Save

cap and grommet assembly for reuse on the

replacement probe. Do not cut the grommet.

d. Cut one wire of existing cable 41 mm (1-5/8 inches)

shorter than the other wire.

e. Cut one replacement sensor wire (opposite color)

back 41 mm (1-5/8 inches). (See Figure 6-22.)

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n. Position sensor in unit per Figure 6-21 and check

sensor resistance as detailed in section 6.23.1.

41 mm (1-5/8 inches)

Sensor

o. Reinstall the cover (if present) that was removed in

step (b.) over wiring and probe holder.

NOTE

6.35 mm (1/4 inch)

The P5 Pre-Trip test must be run to inactivate

the alarm (refer to section 3.2.1).

Figure 6-22. Sensor (RRS, RTS, SRS or STS)

f. Strip back insulation on all wiring 6.35 mm (1/4

inch).

6.23.3 Replacing Sensor (RRS and RTS)

a. Turn unit power OFF and disconnect powersupply.

g. Slide a large piece of heat shrink tubing over the

cable, and place the two small pieces of heat shrink

tubing, one over each wire, before adding crimp

fittings as shown in Figure 6-23.

b. Cut cable5 cm (6 inches)fromshoulderofdefective

sensor and discard the defective probe only.

c. Cut one wire of existing cable 41 mm (1-5/8 inches)

shorter than the other wire.

h. Slide the cap and grommet assembly, which was

saved in step (c.), onto the replacement sensor.

d. Cut one replacement sensor wire (opposite color)

back 41 mm (1-5/8 inches). (See Figure 6-22.)

i. Slip crimp fittings over dressed wires (keeping wire

colors together). Make sure wires are pushed into

crimp fittings as far as possible and crimp with

crimping tool.

e. Strip back insulation on all wires 6.35 mm (1/4

inch).

f. Slide a large piece of heat shrink tubing over the

unit cable, and place the two small pieces of heat

shrink tubing, one over each wire, before adding

crimp fittings as shown in Figure 6-23.

j. Solder spliced wires with a 60% tin and 40% lead

Rosincore solder.

k. Slide heat shrink tubing over splice so that both

ends of tubing cover both ends of crimp as shown in

Figure 6-23.

g. Slip crimp fittings over dressed wires (keeping wire

colors together). Make sure wires are pushed into

crimp fittings as far as possible and crimp with

crimping tool.

Sensor

h. Solder spliced wires with a 60% tin and 40% lead

Rosincore solder.

i. Slide heat shrink tubing over splice so that both

ends of tubing cover both ends of crimp as shown in

Figure 6-23.

Cable

Heat Shrink

Tubing (2)

Large Heat Shrink

Tubing (1)

j. Heat tubing, preferably with a flameless heat gun. If

not available, a propane torch will work (caution

should betaken not to burn theheat shrinktubingor

wire insulation). Make sure all seams are sealed

tightly against the wiring to prevent moisture

seepage.

Figure 6-23. Sensor and Cable Assembly (RRS,

RTS, SRS or STS)

l. Heat tubing, preferably with a flameless heat gun. If

not available, a propane torch will work (caution

should betaken not to burn theheat shrinktubingor

wire insulation). Make sure all seams are sealed

tightly against the wiring to prevent moisture

seepage.

k. Slide large heat shrink tubing over both splices and

shrink tubing and heat as in step (j).

CAUTION

Do not allow moisture to enter wire splice

area as this may affect the sensor resistance.

m. Slide large heat shrink tubing over both splices and

shrink tubing and heat as in step (l.).

l. Check sensor resistance as detailed in section

6.23.1.

CAUTION

Do not allow moisture to enter wire splice

area as this may affect the sensor resistance.

m. Reinstall the return sensor as shown in Figure 6-24.

For proper placement of the return sensor, be sure to

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position the enlarged positioning section of the

sensor against the the side of the mounting clamp.

Sensor

25.4 mm (1.0 inch)

6.35mm (1/4 inch)

NOTE

The P5 Pre-Trip test must be run to inactivate

the alarm (refer to section 3.2.1).

Mounting Stud

Evaporator Grille

Figure 6-25. Sensor (AMBS or DTS)

f. Slide two small pieces of heat shrink tubing over

each wire before adding crimp fittings as shown in

Figure 6-26.

Return Sensor

g. Slip crimp fittings over dressed wires. Make sure

wires are pushed into crimp fittings as far as

possible and crimp with crimping tool.

h. Solder spliced wires with a 60% tin and 40% lead

Rosincore solder.

i. Slide heat shrink tubing over splice so that both

ends of tubing cover both ends of crimp as shown in

Figure 6-26.

Enlarged Positioning

(Plastic) Section

Mounting Clamp

Sensor

Crimp Fitting

Figure 6-24. Return Sensor Positioning

6.23.4 Checking Sensor (AMBS or DTS)

a. Turn unit OFF and disconnect power supply.

b. Refer to section 6.27 for removal of the Controller

module.

Heat Shrink

Crimp Fitting

Tubing (2)

AMBS or DTS:

Using the plug connector marked “EC” that is

connected to the Controller module. Locate the wires

marked AMBS or DTS, depending on which sensor

needs to be replaced. Follow that wire to the connector

and using the pins of the plug, measure the ohms

resistance. Readings are shown in Table 6-1.

Figure 6-26. Sensor and Wire Assembly

(AMBS or DTS)

j. Heat tubing, preferably with a flameless heat gun. If

not available, a propane torch will work (caution

should betaken not to burn theheat shrinktubingor

wire insulation). Make sure all seams are sealed

tightly against the wiring to prevent moisture

seepage.

6.23.5

Replacing Sensor (AMBS or DTS)

a. Turn unit power OFF and disconnect powersupply.

CAUTION

b. Cut wires to 25.4 cm (10 inches) from the back of

the mounting stud of the defective sensor and

discard.

Do not allow moisture to enter wire splice

area as this may affect the sensor resistance.

k. Secure sensor to unit and check sensor resistance as

detailed in section 6.23.4.

c. Cut one of the two wires from step b 25.4 mm (1.0

inch) shorter than the other wire.

NOTE

d. Cut one replacement sensor wire back 25.4 mm (1.0

inch). (See Figure 6-25.)

The DTS sensor must have “Presstite”

insulating material placed completely over the

sensor to insure proper function of the sensor.

e. Strip back insulation on all wiring 6.35mm (1/4

inch).

T-268-07

6-24

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6.24 SUCTION SOLENOID VALVE (SSV)

2. Remove snap cap and coil.

3. Remove enclosing tube collar (item 4, Figure 6-27)

using installation/removal tool supplied with repair

kit (item 3).

a. Replacing the Coil

NOTE

The coil may be replaced without removing the

refrigerant.

4. Check plunger for restriction due to: (a) corroded or

worn parts; (b) foreign material lodged in valve; (c)

bent or dented enclosing tube.

1. Disconnect leads by unplugging the connector.

Remove snap cap or locknut. Lift off coil. (See

Figure 6-27)

5. Remove top plate, diaphragm spring, diaphragm

and body gaskets.

2. Verify coil type, voltage and frequency of old and

new coil. This information appears on the coil

housing.

6. Install new parts, assemble in reverse order of

disassembly.

7. Torque the four capscrews to 40 inch-pounds.

b. Replacing Valve Internal Parts -- Alco

(See Figure 6-27)

8. Do not overtighten enclosing tube assembly.

Torque to a value of 1.15 mkg (100 inch pounds).

9. Remove supplied installation/removal tool. Install

coil, and snap cap.

10. Dehydrate and evacuate the system. (Refer to

section 6.5) Charge unit with refrigerant per section

6.6.1.

11. Plug in the connector. Start unit and check

operation.

6.25 SUCTION MODULATION VALVE (SMV)

NOTE

When repairing suction modulation valve with

the enclosing tube kit (CTD P/N 14-50021-01)

be sure not to remove items 7, 8 & 10. (See

Figure 6-28) Proper alignment of these items is

achieved only at the factory.

a. Coil Checkout Procedure

WARNING

1. Snap Cap

2. Coil

3. Installation/Removal Tool

4. Enclosing Tube Collar

5. O-Ring

6. Enclosing Tube

7. Spring

8. Plunger

Make sure power to the unit is OFF and

power plug disconnected before replacing

the coil.

1. Disconnect the suction modulation valve coil wires

by unplugging the connector (Refer to section 5).

2. Using a reliable digital ohmmeter, test each lead’s

resistance to ground. If the resistance indicates a

ground short is present, inspect the length of wiring

for damaged or exposed wires. Replace where

necessary.

9. Gasket

10. Top Plate

11. Capscrews

12. Spring

13. Gasket

14. Diaphragm

15. O-Ring

3. Setting the digital ohmmeter for low range, check

coil’s resistance. If coil’s resistance is below five

ohms, replacement is recommended. New coils

have an approximate resistance of 7.6 ohms at 25_

C (77_ F). The chart below gives the resistance of a

new coil at various ambient temperatures.

16. Body

Figure 6-27. Suction Solenoid Valve (SSV) -- Alco

1. Pump down the unit. (Refer to section 6.3.)

6-25

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b. Replacing the Coil

Ambient Temperature

Cold Coil

6.45 ohms

6.90 ohms

7.40 ohms

7.90 ohms

10_ F

40_ F

70_ F

100_ F

Remove locking nut and remove coil after

disconnecting wiring. When replacing nut, torque to a

value of 0.41 mkg (3 ft-lb).

c. To Replace Valve

1. Pump down the unit per section 6.3.

2. Remove two bolts from suction service valve.

4. Plug in the connector for the modulation valve.

NOTE

A cold coil is a coil which has not been

operating and is assumed to be at ambient

temperature. Hot coils, taken after the unit has

been operating in deep modulation for a long

period of time, may give higher resistance

readings.

3. Melt solder at modulating valve connection and

rotate valve and tubing enough to clear compressor.

Remove valve and tubing. Replace defective

suction modulation valve, being careful to wrap

body of replacement valve with a wet cloth while

brazing (inert gas brazing procedures MUST be

used only). The coil need not be removed.

4. Install new suction service valve gasket and install

bolts in suction service valve. Torque to a value of

2.77 to 4.15 mkg (20 to 30 ft/lb).

5. Solder all connections and leak check same.

6. Dehydrate and evacuate the unit per section 6.5.

Add refrigerant charge per section 6.6.

6.26 THERMOSTATIC EXPANSION VALVE

The thermal expansion valve is an automatic device

which maintains constant superheat of the refrigerant

gas leaving the evaporator, regardless of suction

pressure. The valve functions are: (a) automatic

response of refrigerant flow to match the evaporator

load and (b) prevention of liquid refrigerant entering the

compressor. Unless the valve is defective, it seldom

requires any maintenance other than minor periodic

maintenance as follows:

1. Make sure that the excess capillary tube is secured

to the power head assembly and wrapped with

“Presstite.”

2. Make sure that the thermal bulb is tightly secured to

the suction line and wrapped with “Presstite.”

1. Coil Nut

2. Coil Nut O-ring

3. Coil Housing

4. Solenoid Coil Sleeve

5. Solenoid Coil

6. Enclosing Tube Assy.

7. Piston

8. Top Return Spring

9. Valve Body

a. Removing Expansion Valve (See Figure 6-29)

1. Pump down the unit per section 6.3.

2. Remove insulation (Presstite) from expansion

valve bulb and power assembly and then remove

thermal bulb from the suction line.

3. Loosen flare nut and disconnect equalizing line

from expansion valve.

10. Bottom Return Spring

11. Filter

12. Schrader Valve

4. Remove capscrews and lift off power assembly and

remove cage assembly. Check for foreign material

in valve body.

Figure 6-28. Suction Modulation Valve (SMV)

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1. Suction Line

2. TXV Bulb Clamp

3. Nut and Bolt

4. TXV Bulb

Figure 6-30. Thermostatic Expansion Valve Bulb

c. Checking Superheat

NOTE

1. Power Assembly

2. Body Flange Gaskets

3. Seat Gasket

4. Bulb

5. Cage Assembly

Adjusting internal adjustable valves is not

recommended. This valve has been factory

adjusted and set with “Locktite” that is applied

to the internal adjusting nut.

6. Body Flange

7. Body Flange Screws

Due to the time involved in adjusting the superheat,

replace the valve (power head & cage assembly) rather

than adjusting it. Refer to section 6.26.b.

Figure 6-29. Thermostatic Expansion Valve -- Alco

5. The thermal bulb is located below the center of the

suction line (4 o’clock position). This area must be

clean to ensure positive bulb contact.

To Measure Superheat:

NOTE

b. Installing Expansion Valve

Proper superheat measurement should be

completed at --18_C (0_F) container box

temperature where possible.

CAUTION

If the thermostatic expansion valve is found

to be in need of replacement, then the power

head and cage assembly are to replaced as a

pair. They are a matched pair and replacing

one without the other will affect the

superheat setting.

1. Open access panel to expose the expansion valve

(see Figure 2-1).

2. Attach a temperature tester sensor near the

expansion valve bulb and insulate. Make sure the

suction line is clean and that firm contact is made

with the sensor.

1. Replace all gaskets, making sure to lightly coat with

oil. Insert cage and power assembly and bolts.

Tighten bolts equally. Fasten equalizer flare nut to

expansion valve.

3. Connect an accurate gauge to the service port

directly upstream of the suction modulation valve.

4. Run unit until unit has stabilized. Set controller

5.5_C (10_F) below container temperature.

2. Leak check the unit per section 6.4. Evacuate and

dehydrate unit per section 6.5. Add refrigerant

charge per section 6.6.2.

5. From the temperature/pressure chart (Table 6-6),

determine

the

saturation

temperature

corresponding to the evaporator outlet pressure at

the suction modulation valve.

3. Clean suction line with sandpaper before installing

bulb to ensure proper heat transfer. Strap thermal

bulb to suction line, making sure bulb is placed

firmly into the indentation of the suction line. See

Figure 6-30 for bulb placement.

6. Note the temperature of the suction gas at the

expansion valve bulb.

7. Subtract the saturation temperature determined in

step (5.) from the average temperature measured in

step (6.). The difference is the superheat of the

suction gas.

4. Check superheat. (Refer to section 2.2 and

Table 6-6.) Container box temperature should be at

-- 1 8 _C (0_F).

6-27

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NOTE

6. Upon completion of your service work, put the

wrist strap back on, and re-install the module into

the refrigeration unit.

Suction pressure must be 0.5 kg/cm@ (6 psig)

below valve maximum operating pressure

(M.O.P.). Example: if valve rated at 55 MOP,

suction pressure must be below this MOP.

Recommended pressure is below 3.44 kg/cm@

(49 psig).

b. Removing and Installing the

Controller/DataCORDER Module

Removal:

1. Disconnect all front wire harness connectors (MA,

MB, MC, KA & KB) and move wiring out of way.

6.27 CONTROLLER/DATACORDER

a. Handling of Controller/DataCORDER

2. Loosen one mounting screw (see Figure 6-31, item

1)and pull out thetop ofthemodule(item2). Liftup

and out.

These guidelines should be followed when handling the

Controller/DataCORDER module. These steps should

be implemented when replacing the module, when

doing any arc welding on the unit, or when service to the

refrigeration unit requires handling and removal of the

Controller.

3. Turning the module around will give access to the

two back connectors (EC) which can be

disconnected. Remove module.

4. RemovethenewController/DataCORDERmodule

from its packaging and install it in the refrigeration

unit. Place the old module into the same packaging

that accompanied the new module. Make sure that

you packageit in theexact mannerthat youreceived

it.

CAUTION

Remove Controller/DataCORDER module

and unplug all connectors before

performing any arc welding on any part of

the container.

Do not remove wire harnesses from modules

unless you are grounded to the unit frame

with a static safe wrist strap.

1. Obtain a grounding wrist strap and a static

dissipation mat. The wrist strap, when properly

grounded, will dissipate any potential buildup on

the body. The dissipation mat will provide a

static-free work surface on which to place and/or

service the Controller/DataCORDER module.

NOTE

Use a dissipation mat, order CTD P/N

07-00277-00.

2. Disconnect and secure power to the unit.

3. Place strap on wrist and attach the ground or clip

end of the wrist strap to any exposed unpainted

metal area on the refrigeration unit frame (bolts,

screws, etc.).

4. Carefully remove the Controller/DataCORDER.

Do not touch any of the electrical components if

possible. Place the module on the static mat.

1. Mounting Screw

2. Controller/DataCORDER Module

3. Test Points

4. Controller/DataCORDER Software

Programming Port

5. If you are servicing the refrigeration unit, you are

free to remove the ground strap from your wrist and

complete your work.

Figure 6-31. Controller side of the Control Box

T-268-07

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NOTE

(2.) If a problem occurs while loading the software:

the Display will blink the message “Pro FAIL”

or “bad 12V.” (Turn start-stop switch OFF and

remove the card.)

This packaging has been designed to protect the

Controller/DataCORDER module from both

physical and electrostatic discharge damage

during storage and transit.

h. Turn unit OFF, via start-stop switch (ST).

i. Remove the programming card from the

programming/software port.

Installation:

Install the module by reversing the steps in section

6.27.b.

j. Turn unit ON, via start-stop switch (ST).

Procedure for loading Configuration Software:

a. Turn unit OFF using start-stop switch (ST).

Torque values for mounting screws (item 1,

Figure 6-31) are 0.23 mkg (20 inch-pounds), and 0.12

mkg (10 inch-pounds) for all connectors (MA, MB,

MC, KA & KB).

b. Insert the programming card, for Configuration

Software, into the programming/software port.

(See Figure 6-31.)

6.27.1 Controller/DataCORDER

Procedure

Programming

c. Turn unit ON using start-stop switch (ST).

d. The Display module will read:

To load new software into the module, the

programming card is inserted into the

programming/software port.

(1.) If the correct card is being used, the digital

display will show “nt40” on the left LCD

display and “511XXX” on the right LCD

display. “XXX” will indicate the dash number

for a given unit model number, use the UP or

DOWN ARROW key to scroll through the list

to obtain the proper model dash number (i.e.,

For the unit 69NT40-511-105, the left display

will show “nt40,” press the UP or DOWN

ARROW key until the right display shows

“511105.”)

WARNING

The unit must be OFF whenever a

programming card is inserted or removed

from the programming/software port.

The metal door on the programming card

must be facing to the left when inserting.

Procedure for loading Operational Software:

a. Turn unit OFF, via start-stop switch (ST).

(2.) If a defective card is being used, the Display

will blink the message “bAd CArd.” (Turn

start-stop switch OFF and remove the card.)

b. Insert the programming card for Operational

Software into the programming/software port. (See

Figure 6-31)

e. Press the ENTER key on the keypad.

f. The Display module will read:

c. Turn unit ON, via start-stop switch (ST).

d. The Display module will read:

(1.) When the software loading has successfully

completed, the Display will show the message

“EEPrM donE.”

(1.) If the correct card is being used the digital

display will alternate back and forth between

the messages “rEV XXXX” and “Press EntR.”

(2.) If a problem occurs while loading the software,

the Display will blink the message “Pro FAIL”

or “bad 12V.” Turn start-stop switch OFF and

remove the card.

(2.) If a defective card is being used: the Display

will blink the message “bAd CArd.” (Turn

start-stop switch OFF and remove the card.)

g. Turn unit OFF using start-stop switch (ST).

e. Press the ENTER key on the keypad.

h. Remove the programming card from the

programming/software port.

f. The Display will show the message “Pro SoFt.”

This message will last for up to one minute.

i. Turn unit ON using start-stop switch (ST).

g. The Display module will read:

6.27.2 Controller Trouble-Shooting

(1.) When the software loading has successfully

completed: the Display will show the message

“Pro donE.”

Agroup oftest points (tp)areprovided on theController

(see Figure 6-31, item 3) for trouble-shooting electrical

6-29

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circuits (refer to section 5). A description of the test

points follows:

Example: Discharge pressure is 10.3 kg/cm@ (146.4

psig). Referring to Table 6-6 (R-134a

pressure-temperature chart), the 10.3 kg/cm@ (146.4

NOTE

psig) value converts to 43_C (110_F).

Use a digital voltmeter to measure ac voltage

between TP’s and ground (TP9), except for

TP8.

If the water-cooled condenser is dirty, it may be cleaned

and de-scaled by the following procedure:

a. Turn unit off and disconnect main power.

TP2

b. Disconnect water pressure switch tubing by

loosening the two flare nuts. Install one-quarter

inch flare cap on water-cooled condenser inlet tube

(replaces tubing flare nut). De-scale tubing if

necessary.

This test point enables the user to check if the internal

protector for the compressor motor (IP-CP) is open or

closed (and the Auto Transformer-IP if so equipped).

TP3

What You Will Need:

This test point enables the user to check if the optional

water pressure switch (WP) contact is open or closed.

1. Oakite composition No. 22, available as a powder

in 68 kg (150 lb) and 136 kg (300 lb).

TP7

2. Oakite composition No. 32, available as a liquid in

cases, each containing 3.785 liters (4 U.S. gallon)

bottles and also in carboys of 52.6 kg (116 lbs) net.

This test point enables the userto check if theController

relay (TS) contact is open or closed.

TP8

3. Fresh clean water.

This test point enables the user to check the suction

modulation valve (SMV) current (amps), it is

represented by twice the dc volts between TP8 and TP9.

4. Acid proof pump and containers or bottles with

rubber hose.

NOTE

TP9

When Oakite compound No. 32 is being used

for the first time, the local Oakite Technical

Service representative should be called in for

their suggestions in planning the procedure.

They will show you how to do the work with a

minimum dismantling of equipment: how to

estimate the time and amount of compound

required; how to prepare the solution; how to

control and conclude the de-scaling operation

by rinsing and neutralizing equipment before

putting it back into service. Their knowledge of

metals, types of scale, water conditions and

de-scaling techniques will be highly useful to

you.

This test point is the chassis (unit frame) ground

connection.

6.28 WATER-COOLED CONDENSER

The water-cooled condenser is of the shell and coil type

with water circulating through the cupro-nickel coil.

The refrigerant vapor is admitted to the shell side and is

condensed on the outer surface of the coil.

Rust, scale and slime on the water-cooling surfaces

inside of the coil interfere with the transfer of heat,

reduce system capacity, cause higher head pressures

and increase the load on the system.

By checking the leaving water temperature and the

actual condensing temperature, it can be determined if

the condenser coil is becoming dirty. A larger than

normal difference between leaving condensing water

temperature and actual condensing temperature,

coupled with a small difference in temperature of

entering and leaving condensing water, is an indication

of a dirty condensing coil.

Summary of Procedure:

1. Drain water from condenser tubing circuit. Clean

water tubes with Oakite No. 22 to remove mud and

slime.

2. Flush.

3. De-scale water tubes with Oakite No. 32 to remove

scale.

To find the approximate condensing temperature, with

the unit running in thecooling mode, install agauge 0 to

36.2 kg/cm@ (0 to 500 psig) on the compressor

discharge service valve.

4. Flush.

5. Neutralize.

6. Flush.

T-268-07

6-30

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7. Put unit back in service under normal load and

check head (discharge) pressure.

Centrifugal pump

Gas

vent

Close vent pipe

valve when pump

is running.

30 GPM at 35’ head

Detailed Procedure:

Priming

connection

Pump

Globe

valves

1. Drain and flush the water circuit of the condenser

coil. If scale on the tube inner surfaces is

accompanied by slime, a thorough cleaning is

necessary before de-scaling process can be

accomplished.

Suction

Tank

Condenser

Remove water

regulating valve

2. To remove slime or mud, use Oakite composition

No. 22. Mixed 170 grams (6 ounces)per 3.785 liters

(1 U.S. gallon) of water. Warm this solution and

circulate through the tubes until all slime and mud

has been removed.

Return

Fine mesh

screen

Pump

support

3. After cleaning, flush tubes thoroughly with fresh

clean water.

Figure 6-32. Water-Cooled Condenser Cleaning --

Forced Circulation

6. Allow the Oakite No. 32 solution to soak in thetube

4. Prepare a 15% by volume solution for de-scaling,

by diluting Oakite compound No. 32 with water.

This is accomplished by slowly adding 0.47 liter (1

U.S. pint) of the acid (Oakite No. 32) to 2.8 liters (3

U.S. quarts) of water.

coils

for

several

hours,

periodically

pump-circulating it with an acid-proof pump.

An alternate method may be used whereby a bottle (see

Figure 6-33) filled with the solution and attached to the

coils by a hose can serve the same purpose by raising

and lowering ofthebottle. Thesolution must contactthe

scale at every point for thorough de-scaling. Airpockets

in the solution should be avoided by regularly opening

the vent to release gas. Keep flames away from the vent

gases.

WARNING

Oakite No. 32 is an acid --be sure that the

acid is slowly added to the water. DO NOT

PUT WATER INTO THE ACID! -- this will

cause spattering and excessive heat.

7. The time required for de-scaling will vary,

depending upon the extent of the deposits. One way

to determinewhen de-scaling has been completed is

to titrate the solution periodically, using titrating

equipment provided free by the Oakite Technical

Service representative. As scale is being dissolved,

titrate readings will indicate that the Oakite No. 32

solution is losing strength. When the reading

remains constant for a reasonable time, this is an

indication that scale has been dissolved.

Wear rubber gloves and wash the solution

from the skin immediately if accidental

contact occurs. Do not allow the solution to

splash onto concrete.

5. Fill the tubes with this solution by filling from the

bottom. See Figure 6-32. Important: be sure to

provide a vent at the top for escaping gas.

8. When de-scaling is complete, drain the solution and

flush thoroughly with water.

9. Following the water flush, circulate a 56.7 gram (2

ounce) per 3.785 liter (1 U.S. gallon) solution of

OakiteNo. 22 thru thetubes to neutralize. Drain this

solution.

10. Flush the tubes thoroughly with fresh water.

6-31

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NOTE

Table 6-2. Partlow Bulb Temperature-Resistance

Chart

If the condenser cooling water is not being used

as drinking water or is not re-circulated in a

closed or tower system, neutralizing is not

necessary.

TEMPERATURE

_F _C

RESISTANCE

(OHMS)

12561.00

10579.70

8944.17

7588.89

5520.32

4731.71

4068.68

3509.36

3310.57

3035.99

2634.10

2291.85

1999.52

1749.11

1534.00

1348.72

1050.14

929.87

-- 1 0

-- 5

--23.3

--20.6

--17.8

--15.0

-- 9 . 4

-- 6 . 7

-- 3 . 9

-- 1 . 1

11. Put the unit back in service and operate under

normal load. Check the head pressure. If normal, a

thorough de-scaling has been achieved.

What You Can Do For Further Help:

100

105

Contact the Engineering and Service Department of the

OAKITE PRODUCTS CO., 19 Rector Street, New

York, NY 10006 U.S.A. for the name and address of the

service representative in your area.

Fill condenser with

cleaning solution. Do

not add solution more

rapidly than vent can

exhaust gases caused

by chemical action.

1.7

4.4

7.2

10.0

12.8

15.6

18.3

23.9

26.7

29.4

32.2

35.0

37.8

40.6

1” Pipe

5’ Approximate

Vent

pipe

825.21

733.93

654.12

584.19

3’ to 4’

Condenser

522.79

Figure 6-33. Water-Cooled Condenser Cleaning --

Gravity Circulation

Table 6-1. AMBS, DTS, RRS, RTS, SRS and STS

Temperature-Resistance Chart

Temperature

Centigrade

Temperature

Fahrenheit

Resistance

(Ohms)

RRS, RTS, SRS and STS:

32,650 91

10,000 50

AMBS and DTS

32,650 +1720

-- 1620

10,000 + 450

-- 430

T-268-07

6-32

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Table 6-3. Recommended Bolt Torque Values

BOLT DIA. THREADS

TORQUE

MKG

FREE SPINNING

5.2 in-lbs

9.6 in-lbs

20 in-lbs

23 in-lbs

75 in-lbs

11 ft-lbs

20 ft-lbs

31 ft-lbs

43 ft-lbs

57 ft-lbs

92 ft-lbs

124 ft-lbs

0.05

0.11

0.23

0.26

0.86

1.52

2.76

4.28

5.94

7.88

12.72

17.14

#10

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

NONFREE SPINNING (LOCKNUTS ETC.)

1/4

5/16

3/8

82.5 in-lbs

145.2 in-lbs

22.0 ft-lbs

34.1 ft-lbs

47.3 ft-lbs

62.7 ft-lbs

101.2 ft-lbs

136.4 ft-lbs

0.95

1.67

3.04

7/16

1/2

4.71

6.54

9/16

5/8

3/4

8.67

13.99

18.86

Table 6-4. Wear Limits For Compressors

FACTORY MAXIMUM FACTORY MINIMUM

MAXIMUM WEAR

BEFORE REPAIR

PART NAME

INCHES

1.6233

1.3735

INCHES

MAIN BEARING

Main Bearing Diameter

Main Bearing Journal Diameter

PUMP END

Main Bearing Diameter

Main Bearing Journal Diameter

CONNECTING ROD

Piston Pin Bearing

CRANKPIN DIAMETER

Throw

1.6268

41.3207

.0020

0.0508

41.2318

34.8869

1.3760

1.3768

34.9504

34.9707

.0020

.0010

.0025

0.0508

0.0254

0.0635

0.6878

1.3735

1.070

17.4701

34.8869

27.1780

03.8608

1.072

0.154

27.2288

3.9116

THRUST WASHER (Thickness)

CYLINDERS

0.1520

.0250

0.6350

Bore

Piston (Diameter)

Piston Pin (Diameter)

Piston Ring Gap

Piston Ring Side Clearance

2.0010

50.8254

.0020

.0010

.0250

.0020

0.0508

0.0254

0.6350

0.0508

1.9860

0.6873

0.0050

0.0010

50.4444

17.4574

00.1270

00.0254

0.013

0.002

00.3302

00.0508

6-33

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Table 6-5. Compressor Torque Values

TORQUE RANGE

SIZE

USAGE

DIAMETER THREADS

(INCHES) PER INCH

FT-LB

MKG

1/16

1/8

1/4

27 (pipe)

20 (pipe)

8 -- 12

6 -- 10

1.11 -- 1.66

0.83 -- 1.38

2.77 -- 3.46

1.38 -- 1.66

1.66 -- 2.07

1.66 -- 2.21

0.83 -- 1.38

1.66 -- 2.21

Pipe Plug -- Crankshaft

Oil Return Check Valve -- Crankcase

Pipe Plug -- Gauge Connection

Connecting Rod Capscrew

Baffle Plate -- Crankcase

Side Shield

20 -- 25

10 -- 12

12 -- 15

12 -- 16

6 -- 10

1/4

Oil Pump Drive Segment

Unloader Valve

12 -- 16

Cover Plate -- Plate End

Bearing Head

Terminal Block Cap Screws

Suction Valve

16 -- 20

20 -- 30

40 -- 50

2.21 -- 2.77

2.77 -- 4.15

5.53 -- 6.92

5/16

3/8

Discharge Valve

Pump End Bearing Head

Bottom Plate -- Crankcase Compressor Foot

Cylinder Head

7/16

5/8

#10

1-1/2

55 -- 60

25 -- 30

60 -- 75

4 -- 6

7.61 -- 8.30

3.46 -- 4.15

8.30 -- 10.37

0.55 -- 0.83

4.84 -- 6.22

Motor End Cover -- Crankcase

Crankshaft

Oil Bypass Plug -- Crankcase

Oil Pump Drive Segment

Oil Level Sight Glass

18 NEF

35 -- 45

NEF -- National Extra Fine

T-268-07

6-34

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Table 6-6. Temperature-Pressure Chart -- R-134a

BOLD FIGURES = Inches Mercury Vacuum (cm Hg VAC)

LIGHT FIGURES = psig (kg/cm@)

TEMPERATURE

PRESSURE

Kg/cm²

37.08

31.25

24.64

17.00

8.89

5.33

1.52

.03

TEMPERATURE

PRESSURE

Kg/cm²

1.84

-- 4 0

-- 3 5

-- 3 0

-- 2 5

-- 2 0

-- 1 8

-- 1 6

-- 1 4

-- 1 2

-- 1 0

-- 8

-- 6

-- 4

-- 2

-- 0

-- 4 0

-- 3 7

-- 3 4

-- 3 2

-- 2 9

-- 2 8

-- 2 7

--26

--24

--23

--22

--21

--20

--19

--18

--17

--16

--14

--13

--12

--11

--10

--9

Psig

14.6

12.3

9.7

6.7

3.5

2.1

0.6

0.4

1.2

2.0

2.9

3.7

4.6

5.6

6.5

7.6

8.6

Bar

-- . 4 9

--.42

--.33

--.23

--.12

--.07

--.02

.03

.08

.14

.20

.26

.32

.39

.45

.52

.59

.67

.74

.83

-- 1

Psig

26.1

27.8

29.6

31.3

33.2

35.1

40.1

45.5

51.2

57.4

64.1

71.1

78.7

86.7

95.3

104.3

114.0

124.2

135.0

146.4

158.4

171.2

184.6

198.7

213.6

229.2

245.6

262.9

281.1

Bar

1.80

1.92

2.04

2.16

2.29

2.42

2.76

3.14

3.53

3.96

4.42

4.90

5.43

5.98

6.57

7.19

1.95

2.08

2.20

2.33

2.47

2.82

3.30

3.60

4.04

4.51

5.00

5.53

6.10

6.70

7.33

8.01

.08

.14

.20

.26

.32

.39

.46

.53

.60

.68

.76

.84

7.86

8.56

9.31

9.7

100

105

110

115

120

125

130

135

140

145

150

155

8.73

9.49

10.8

12.0

13.2

14.5

15.8

17.1

18.5

19.9

21.4

22.9

24.5

10.29

11.14

12.04

12.98

13.97

15.02

16.11

17.27

18.48

19.76

10.09

10.92

11.80

12.73

13.70

14.73

15.80

16.93

18.13

19.37

.93

.91

1.02

1.11

1.20

1.30

1.40

1.50

1.61

1.72

1.00

1.09

1.18

1.28

1.37

1.48

1.58

1.69

--8

--7

--6

--4

--3

-- 2

6-35

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Note: Curves to be used as troubleshooting guide only for model series 69NT40-511 with

fresh air makeup vent closed, unit powered on 460 VAC/60hz and SMV 100% open.

(Bar) psig

(22.0)

(20.7)

(19.3)

320

300

280

(17.9) 260

35_F (1.7_C) Box

(16.6)

(15.2)

240

220

200

180

160

(13.8)

(12.4)

(11.0)

(9.7) 140

(8.3)

(6.9)

(5.5)

120

100

(_C)

(15.6)

(21.1)

(26.7)

(32.2)

100

(37.8)

110

(43.3)

120

Ambient Air Temperature

(Bar) psig

(22.0)

(20.7)

(19.3)

320

300

280

(17.9) 260

(16.6)

(15.2)

240

220

200

180

160

(13.8)

(12.4)

(11.0)

(9.7) 140

0_F (--17.8_C) Box

(8.3)

(6.9)

(5.5)

120

100

(15.6)

(21.1)

(26.7)

(32.2)

100

(37.8)

110

(43.3)

120

(48.9) (_C)

Ambient Air Temperature

Compressor Discharge Pressure Versus Ambient Air Temperature at Stable Box Temperature

T-268-07

6-36

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(Bar)

(.97)

(.83)

psig

(.69) 10

(.55)

(.41)

35_F (1.7_C) Box

(.28)

(.14)

(0)

(--.14)

(--.28)

(--.41)

0_F (--17.8_C) Box

-- 2

-- 4

-- 6

120

(48.9) (_C)

(15.6)

(21.1)

100

(37.8)

110

(43.3)

(26.7)

(32.2)

Ambient Air Temperature

Compressor Suction Pressure Versus Ambient Air Temperature at Stable Box Temperature

35_F (1.7_C) Box

0_F (--17.8_C) Box

100

110

120 _F

(_C)

(48.9)

(15.6)

(21.1)

(26.7)

(32.2)

(37.8)

(43.3)

Ambient Air Temperature

Compressor--Motor Current Versus Ambient Air Temperature At Stable Box Temperature

Figure 6-34. R-134a Compressor Pressure and Motor Current Curves Versus Ambient Temperature

6-37

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SECTION 7

ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS

7.1

INTRODUCTION

PLEASE REFER TO FILE

T--268 DIAGRAMS

FOR SCHEMATICS AND DIAGRAMS

7-1

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INDEX

Compressor

Disassembly, 6-9

Full Load Amps, 2-11

Oil Level, 6-14

Access Panel, 2-1

Reassembly, 6-13

Removal/Replacement, 6-9

Specifications, 2-10

Air Makeup Vent

Lower Fresh, 2-13

Upper Fresh, 2-13

Compressor Contactor, 2-8, 2-9, 4-2, 4-10, 4-14, 4-15

Compressor Contactor Shorting, 2-9, 4-14, 4-15, 5-1

Compressor Crankcase Heater, 2-4, 2-11, 4-2, 6-9

Compressor Motor, 2-4

Air--Cooled Condenser, 2-15, 2-17

Alarms

Controller, 3-11

DataCORDER, 3-28

DataCORDER Configurations, 3-29

Condenser

Air--Cooled, 2-15, 2-17

Coil, 5-3, 6-18

Fan and Motor Assembly, 5-3, 6-18

Specifications, 2-11

Water--Cooled, 2-17

Ambient Sensor, 2-6, 2-7

Arctic, 4-12

Condenser Fan Contactor, 2-8, 2-9, 4-10, 4-12, 4-14,

4-15

Condenser Fan Motor, 2-5

Condenser Fan Relay, 4-3, 4-4, 4-6, 4-8, 4-12

Condenser Fan Switch, 2-8, 2-16

Battery Pack, Controller/DataCORDER, 2-8, 2-9, 3-1

Bulb

Condenser Pressure Control, 2-14, 3-3, 3-7, 3-14,

4-3, 4-6, 4-8

Expansion Valve, 2-14, 2-15, 2-16, 2-17, 5-4, 6-27

Mechanical Recording Thermometer, 2-3, 6-18

Mode, 3-9, 3-16, 3-17, 3-25, 4-12

Partlow, 6-18, 6-20

Condenser Pressure Transducer, 2-6, 2-7, 2-10, 2-14,

2-15, 2-17, 3-14, 3-30, 4-3, 4-6, 4-8, 5-1

Connector, Interrogator, 2-8

Saginomiya, 6-20, 6-21

Sensor, 6-22

Temperature--Resistance Chart, Partlow, 6-32

Contactor

Compressor, 2-8, 2-9, 4-2, 4-10, 4-14, 4-15

Compressor Shorting, 2-9, 4-14, 4-15, 5-1

Condenser Fan, 2-8, 2-9, 4-10, 4-12, 4-14, 4-15

Evaporator Fan, 2-8, 2-9, 4-3, 4-6, 4-8, 4-14, 4-15,

5-2, 5-3

Heat, 2-8, 2-9, 3-15, 4-10, 4-12, 5-2

Control Circuit Power Connection, 3-1

Control Transformer, 2-8, 2-9

Cargo Probe Receptacle, 2-3

Chart

Model, 1-2

Partlow Bulb, 6-32

R--134a Temperature--Pressure, 6-35

Sensor, 6-32

Controller

Alarms, 3-10

Configuration Variables, 3-3

Display Module, 2-8, 2-9, 3-5

Function Codes, 3-6

Installing, 6-28

Key Pad, 3-4

Module, 3-1

Programming Cards, 3-2

Programming Procedure, 6-29

Removing, 6-28

Circuit

Refrigeration with Receiver, 2-15

Refrigeration with Water--Cooled Condenser, 2-17

Circuit Breaker, 2-8, 2-9, 2-11, 2-12, 2-19, 5-1, 5-2,

5-4

Serial Number, 3-26

Temperature Control, 3-14

Test Points, 6-28, 6-29

Trouble--Shooting, 6-29

Codes

Controller Alarm, 3-11

Controller Function, 3-6

DataCORDER Alarm, 3-28

DataCORDER Function, 3-26

Pre--Trip, 3-19

Controller/DataCORDER Battery Pack, 2-8, 2-9, 3-1

Controller/DataCORDER Module, 2-8

Index-1

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INDEX

Cooling Relay, 4-4, 4-6, 4-8, 4-12

Current Sensor Module, 2-8, 2-9

Emergency Bypass Switch, 2-8, 3-1

Emergency Defrost Fuse, 2-8

Emergency Defrost Switch, 2-8

Evacuation, 6-5

Evaporator, 2-15, 2-17

Coil, 5-1, 5-3, 6-16

Data

Electrical, 2-11

Refrigeration System, 2-10

Contactor, Fan, 2-8, 2-9, 4-3, 4-6, 4-8, 4-14, 4-15,

5-2, 5-3

Fan and Motor Assembly, 5-3, 6-16

Fan Motor Capacitors, 6-17

Heaters, 6-16

DataCORDER, 3-24

Access to Functions, 3-29

Alarms, 3-27

Communications, 3-31

Configuration, 3-25

Function Codes, 3-26

Pre--Trip Data Recording, 3-31

Scrollback, 3-32

Serial Number, 3-26

USDA Cold Treatment, 3-32

USDA Recording, 3-31

USDA/Message, 3-31

Evaporator Coil, 2-3

Evaporator Coil Heater, Specifications, 2-11

Evaporator Coil Heaters, 2-3

Evaporator Fan Contactor, 2-8, 2-9, 4-3, 4-6, 4-8,

4-14, 4-15, 5-2, 5-3

Evaporator Fan Motor, 2-1, 2-3

Specifications, 2-11

Exchanger, Heat, 2-3, 2-15, 2-17

Defrost, 4-12

Expansion Valve, 2-10, 5-3, 5-4, 6-26

Defrost Relay, 4-14, 4-15, 5-2

Defrost Termination Sensor, 2-3, 3-7, 3-16, 3-23, 5-2

Alarm, 3-12

Dehydration, 6-5

Filter--Drier, 2-7, 2-15, 2-17, 5-3, 6-15

Disc, Rupture, 2-7, 2-17

Fork Lift Pockets, 2-1

Discharge Pressure Regulator Valve, 2-6, 2-7, 2-15,

2-17

Fuse, Emergency Defrost, 2-8

Discharge Pressure Transducer, 2-4

Discharge Service Valve, 2-4, 2-15, 2-17

Display Module, 2-8, 2-9, 3-5

Fuses, 2-11, 2-19, 3-1, 5-1, 5-2, 5-3

Specifications, 2-11

Fusible Plug, 2-6, 2-10, 2-14, 2-15, 2-19

Drain Pan Heaters, 2-3, 2-11

Specifications, 2-11

Gauge

High Pressure, 6-1

Low Pressure, 6-1

Manifold, 6-1

Economy Mode, 3-16, 3-17

Manifold Connections, 6-3

Electrical Data, 2-11

Electrical Schematic, 7-1

Gauges, Suction/Discharge Pressure, 2-4

Glass, Sight, 2-6, 2-17

Electro--Coated Modular Receiver, 2-6, 2-15

T-268-07

Index-2

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INDEX

Key Pad, 3-4

Heat Contactor, 2-8, 2-9, 3-15, 4-10, 4-12, 5-2

Heat Exchanger, 2-3, 2-15, 2-17, 5-3

Heat Relay, 3-15, 4-10, 4-12, 4-14, 4-15, 5-2

Heater, 2-1

Low Speed Compressor Relay, 4-3, 4-12

Low Speed Evaporator Fans Relay, 4-12

Lower Fresh Air Makeup Vent, 2-13

Alarm, 3-12

Compressor Crankcase, 2-4, 2-11, 6-9

Configuration Variable, 3-3

Drain Pan, 2-11

Evaporator Coil, 2-11, 6-16

Heater Termination Thermostat, 2-3, 2-10, 3-23, 4-10,

4-12, 5-1, 5-2

Alarm, 3-12

Manual Defrost Switch, 2-8

Manual Liquid Line Valve, 2-6, 2-7, 2-15, 2-17

Manual Start, 4-2

Heaters, Evaporator Coil, 2-3

Heating, 4-10

Manual Stop, 4-2

High Pressure Switch, 2-6, 2-10, 2-19, 3-12, 3-22,

5-1, 6-15

Mechanical Recording Thermometer Bulb, 2-3

Meter, Hour, 2-8

High Speed Evaporator Fans Relay, 4-12

Hour Meter, 2-8

Micro--link 2i, 3-1, 6-28

Models, 1-2

Humidity Sensor, 2-3, 3-7, 3-9, 3-13, 3-15

Specifications, 2-12

Modes of Operation

Arctic, 4-12

Cooling, 4-3

Defrost, 4-12

Frozen Range, 3-17

Heating, 4-10

Perishable Range, 3-14

Indicator

Moisture--Liquid, 2-7, 2-17

Sight Glass/Moisture, 2-6

Moisture Indicator, Sight Glass/, 2-6, 2-10, 2-15

Moisture--Liquid Indicator, 2-7, 2-17

Inrange Relay, 4-4, 4-6, 4-8, 4-10

Motor

Internal Protector

Compressor, 2-4

Condenser Fan, 2-5

Evaporator Fan, 2-1, 2-3

Compressor Motor, 2-19, 5-1, 6-30

Condenser Fan Motor, 2-19, 5-1

Evaporator Fan Motor, 2-19, 5-1, 5-2, 5-3

Power Autotransformer, 6-21

Interrogator Connector, 2-1, 2-8

Interrogator Receptacle, 2-3

Override, Suction Solenoid, 2-18

Index-3

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INDEX

Receiver, Electro--Coated Modular, 2-6, 2-15

Pad, Key, 2-8

Receptacle

Cargo Probe, 2-3

Interrogator, 2-3

Remote Monitoring, 2-8, 2-9

USDA Probe, 2-3

Parts Identification Number (PID), 1-1, 1-2, 2-1

PID, (Parts Identification Number), 1-1, 1-2, 2-1

Plug, Fusible, 2-6, 2-15

Recording Thermometer

Bulb, 2-3

Partlow, 2-1, 4-1, 6-18

Saginomiya, 2-1, 4-1, 6-20

Port

Software Programming, 3-1, 6-28

Supply Air Thermometer, 2-6, 2-7

Refrigerant

Charge, 2-10, 5-4

Full Charge, 6-8

Leak Checking, 6-4

Partial Charge, 6-8

Power Autotransformer, 2-4, 2-12, 5-1, 5-4, 6-21

Pre--Trip

Refrigeration

Auto Test, 3-18

Current Limiting, 3-17

Inspection, 4-1

Manual Test, 3-18

Selection Menu, 3-18

Starting, 3-17

Charge, 2-10

Checking Charge, 6-5

Dehydration, 6-5

Evacuation, 6-5

Full Charge, 6-8

Leak Checking, 6-4

Partial Charge, 6-8

System Data, 2-10

Test Codes, 3-19

Refrigeration Circuit

Receiver, 2-14

Water--Cooled Condenser, 2-16

Probe Check Initiation, 4-2

Probe Holder, Supply, 6-22

Relay

Condenser Fan, 4-3, 4-4, 4-6, 4-8, 4-12

Cooling, 4-4, 4-6, 4-8, 4-12

Defrost, 4-14, 4-15, 5-2

Heat, 3-15, 4-10, 4-12, 4-14, 4-15, 5-2

High Speed Evaporator Fans, 4-12

Inrange, 4-4, 4-6, 4-8, 4-10

Pump

Down, 6-4

Oil, 6-11, 6-14

Vacuum, 6-5

Vacuum Connections, 6-7

Low Speed Compressor, 4-3, 4-12

Low Speed Evaporator Fans, 4-12

Suction Solenoid Valve, 2-18, 6-30

Remote Monitoring, 2-18

Remote Monitoring Receptacle, 2-8, 2-9

Return Recorder Sensor, 2-3

Return Temperature Sensor, 2-3

Rupture Disc, 2-7, 2-10, 2-17, 2-19

Quench Expansion Valve, 2-6, 2-7, 2-15, 2-17, 3-6,

3-21

T-268-07

Index-4

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INDEX

Starting Instructions, 4-2

Stopping Instructions, 4-2

Safety and Protective Devices, 2-19

Suction Modulation Valve, 2-6, 2-7, 2-15, 2-17, 3-6,

3-14, 3-17, 3-21

Safety Summary

General, Safety-1

Warning and Cautions, Safety-2

Suction Pressure Transducer, 2-4

Suction Service Valve, 2-4, 2-15, 2-17

Suction Solenoid Override, 2-18

Sample, Standard Configuration Report, 3-34

Schematic, Electrical Wiring and Diagrams, 7-1

Schrader Valve, 2-6, 2-7

Suction Solenoid Valve, 2-6, 2-7, 2-15, 2-17, 3-6,

3-15, 3-17, 3-21

Sensor

Suction Solenoid Valve Relay, 2-18, 6-30

Suction/Discharge Pressure Gauges, 2-4

Supply Air Thermometer Port, 2-6, 2-7

Supply Recorder Sensor, 2-6, 2-7

Ambient, 2-6, 2-7, 3-6, 3-12, 3-14, 3-30, 6-24

Bulb, 6-22

Chart, 6-32

Checking, 6-21, 6-24

Current, 2-8, 2-9

Supply Temperature Sensor, 2-6, 2-7

Defrost Termination, 2-3, 3-7, 3-9, 3-12, 3-16, 3-23,

5-2, 6-16, 6-24

Switch

Defrost termination, 4-12

Discharge Temperature, 3-13, 3-22

Humidity, 2-3, 2-12, 3-7, 3-9, 3-13, 3-15

Network, 3-26, 3-28

Condenser Fan, 2-8, 2-16

Emergency Bypass, 2-8, 3-1

Emergency Defrost, 2-8

High Pressure, 2-6, 2-10, 2-19, 3-12, 3-22, 5-1,

6-15

Positioning

Manual Defrost, 2-8, 2-9, 5-2

Start--Stop, 2-8, 2-9, 4-2, 5-1, 5-2

Water Pressure, 2-7, 2-10, 2-16, 5-4

Return, 6-24

Supply, 6-22

Replacing, 6-24

Return, 6-23

Supply, 6-22

Return Recorder, 2-3, 6-22

Return Temperature, 2-3, 2-18, 3-11, 3-12, 3-26,

3-30, 4-12, 6-22

Suction Temperature, 3-13

Supply Recorder, 2-6, 2-7, 6-22

Supply Temperature, 2-6, 2-7, 3-11, 3-12, 3-26,

3-30, 6-22

Thermister (CPDS), 2-6

Thermister (CPSS), 2-6

USDA Cold Treatment, 3-32

Test Points, Controller, 3-1, 6-28, 6-29

Thermister Sensor (CPDS), 2-6

Thermister Sensor (CPSS), 2-6

Thermostat, Heater Termination, 2-3, 2-10, 3-23,

4-10, 4-12, 5-1, 5-2

Alarm, 3-12

Thermostatic Expansion Valve, 2-3, 2-15, 2-17

Thermostatic Expansion Valve Bulb, 2-15, 2-17

Serial Number

Controller, 3-26

DataCORDER, 3-26

Unit, 2-1

Transducer

Condenser Pressure, 2-6, 2-7, 2-10, 2-14, 2-15,

2-17, 3-13, 3-14, 3-30, 4-3, 4-6, 4-8, 5-1

Discharge Pressure, 2-4, 3-7, 3-13, 3-22, 3-30

Suction Pressure, 2-4, 3-6, 3-13, 3-30

Sight Glass, 2-6, 2-17

Sight Glass/Moisture Indicator, 2-6, 2-10, 2-15

Sightglass, 2-15

Transformer, 5-1, 5-2

Control, 2-8, 2-9

Power, Auto, 5-1, 5-4

Power Auto, 2-4, 2-12

Snap Freeze, 4-12

Software Programming Port, 3-1, 6-28

Start--Stop Switch, 2-8

Troubleshooting, 5-1

Index-5

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INDEX

Vacuum Pump, 6-5, 6-7

Connections, 6-7

Valve

Unit, Remote Monitoring, 2-8

Unit Operation, 4-2

Bulb, Expansion, 2-14, 2-16, 5-4, 6-27

Discharge Pressure Regulator, 2-6, 2-7, 2-15, 2-17,

5-3

Unit Serial Number, 2-1

Upper Fresh Air Makeup Vent, 2-13

USDA, 2-3, 3-31, 3-32

Discharge Service, 2-4, 2-15, 2-17

Expansion, 2-3, 2-10, 2-15, 2-17, 5-3, 5-4, 6-26

Manual Liquid Line, 2-6, 2-7, 2-15, 2-17

Quench Expansion, 2-6, 2-7, 2-15, 2-17, 3-6, 3-21

Schrader, 2-6, 2-7

USDA Probe Receptacle, 2-3

Suction and Discharge, 5-3, 6-4

Suction Modulation, 2-6, 2-7, 2-15, 2-17, 3-6, 3-14,

3-17, 3-21, 4-3, 4-6, 4-8, 4-12, 5-1, 6-25

Suction Service, 2-4, 2-15, 2-17

Suction Solenoid, 2-6, 2-7, 2-15, 2-17, 2-18, 3-6,

3-15, 3-17, 3-21, 4-3, 4-12, 5-1, 6-25

Water Pressure Switch, 2-7, 2-10, 2-16

Water--Cooled Condenser, 2-16, 2-17, 5-4, 6-30

Wiring Diagram, 7-1

T-268-07

Index-6

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