Home

caution - Maersk Line

1. B D E F H J K L M N P R T 460 3 60 230 3 60 460 3 60 OR 10 4 SO R 380 3 50 on 190 3 50 380 3 50 POWER PLUG 01 2 cgi 12 4 SOM POWER PLUG CABLE A BLK CABLE CH ABLE WHT L1 A 1 RI BLK BLK T T oy 11 21 Lim Lim 1 4 BK BLK aA 12 ER WET W Y 12 2 52 WHT WHT BLU gt 121 22 L2 2 12 T2 2 5 2 RED RED gt WHT 1 BRND 13 23 L3 T3 T3
2. Controller Software Programming Port Mounting Screw Controller Test Points 6 14 Controller Section of the Control Box 6 18 3 Controller Programming Procedure To load new software into the module the programming card is inserted into the programming software port CAUTION The unit must be OFF whenever a program ming card is inserted or removed from the controller programming port 1 Turn unit OFF via start stop switch ST 3 If Insert software programming PCMCIA card contain ing the following example files into the program ming software port See Figure 6 14 menuDDMM this file allows the user to select a file program to upload into the controller cfYYMMDD mi3 multi configuration file Turn unit ON via start stop switch ST ruN COnFG is displayed follow procedure 6 18 3 1 If Set UP is displayed follow procedure 6 18 3 2 6 18 3 1 Programming Procedure for Software Versions Prior to 5328 and or Cards Without Updated Menu Option 0111 a Procedure for loading operational software 1 The display module will display the message ruN COnFG If a defective card is being used the display will blink the message bAd CArd Turn start stop switch OFF and remove the card Press the UP or DOWN arrow key until displa
3. 7 Communications interface Module Figure 6 21 Communications Interface Installation Units that have been factory provisioned for installation of acommunication interface module CIM have the re quired wiring installed If the unit is not factory provi sioned a provision wiring kit Carrier Transicold part T 340 6 24 number 76 00685 00 must be installed Installation in structions are packaged with the kit To install the mod ule do the following Installation requires wiring to the main unit circuit breaker CB1 Make sure the power to the unit is off and power plug disconnected before beginning installation is connected to the power system see wiring schematic Ensure that the unit power is off AND that the unit power plug is disconnected b Open control box see Figure 6 21 and remove low voltage shield Open high voltage shield c If using factory provisioned wiring remove the cir cuit breaker panel with circuit breaker from the control box Locate wires CB21 CIA3 CB22 CIA5 and CB23 CIA7 that have been tied back in the wire harness Remove the protective heat shrink from the ends of the wires d Refit the circuit breaker panel e Fitthe new CIM into the unit f Attach three wires CB21 CIA3 CB22 CIA5 and CB23 CIA7 to the CIM at connection CIA g Locate connectors CIA and CIB remove plugs if re quired and attach
4. 3 12 3 7 4 Logging Interval i 2 22 EIE Ue RI EE TE 3 12 3 7 5 Thermistor Format 04 3 12 3 7 6 Sampling Type 5 amp dCF06 3 14 3 7 7 Alarm Configuration ACFO7 dCF10 3 14 3 7 8 DataCORDER 2 4 3 14 3 7 9 Pre Trip Data Recording 3 14 3 7 10 DataCORDER Communications 3 14 94 11 USDA Gold Treatment eurer Ice ett CEY IRE 3 15 3 7 12 USDA Cold Treatment Procedure 3 15 3 7 19 DataCORDER Alarms ERE Roe E tne TR a Dre DR CUR TRU 3 16 3 714 ISO Trip Header 2227 Lepus up nete 3 16 OPERATION 2 2 Revier venu he weave Reha eR 4 1 4 1 INSPECTION Before Starting 4 1 42 CONNEGT POWER hee MIEL LR 4 1 4 2 1 Connection To 380 460 VAC
5. C gt 2 CONTROLLER EC I VP534 D Upper Air Exchange VPS NOTE VPS 2 MAY BE CONNECTED TO L1 OR T1 DEPENDING ON CONFIGURATION w N lt s lt 1 T T T Keves X1 2 lt 4 lt 53 52 57 4 E 2 C 5 2 A 2 1 VPS3 e 2 CONTROLLER Lower Air Exchange VPS Figure 7 3 SCHEMATIC AND WIRING DIAGRAM Vent Position Sensors VPS 7 3 T 340 O M 9 5 an a Do pir A A VEM pot to 0 ool mol mo mo l moou v vil x l 11 ii 9 I CRD gt 7 GRN a x gt gt RED 35 68 55 55 555665 n Ub uu Utt Has me 12 bbe LL i cla LERES MNT te m AC TI ee
6. 2 6 2 2 REFRIGERATION SYSTEM 2 7 2 9 ELECTRIGAL DATA ete pter iot tete oe reete eee t uns 2 8 24 SAFETY AND PROTECTIVE DEVICES 2 9 25 REFRIGERATION CIRCUIT 2 10 251 Standard Operation ds e Gee Gale Gale cate Tee 2 10 2 5 2 Economized Operation rest eg Ed 2 10 2 5 3 Liquid Injection Valve 2 10 2 5 4 Electronic Expansion Valve 2 10 MICROPROCESSOR 2 er wx e rex E exe me rx hx Reve E een x teas 3 1 31 TEMPERATURE CONTROL MICROPROCESSOR SYSTEM 3 1 3 1 1 Keypad Ce re ea ANA TRUE IT Metu I PREDA RIT 3 2 Display Module 3 2 oy xm rr ett Re Rees ge RR EM E Re 3 2 9 1 9 Controler 3 3 3 2 CONTROLLER SOFTWARE 3 3 3 2 1 Configuration Software 3 3 3 2 2 Operational Software Function Codes 3 3 33 CONTROLLER SEQUENCE AND MODES OF OPERATION 3
7. 6 21 Figure 6 18 Return Sensor Positioning 2 6 21 Figure 6 19 Evaporator Temperature Sensor Positioning 6 21 Figure 6 20 Electronic Partlow Temperature 6 23 Figure 6 21 Communications Interface Installation 6 24 Figure 7 1 LEGEND ER rr LUE RR iy Wee de Aa EU ae E ALS 7 1 Figure 7 2 SCHEMATIC DIAGRAM 7 2 Figure 7 3 SCHEMATIC AND WIRING DIAGRAM Vent Position Sensors VPS 7 3 Figure 7 4 UNIT SCHEMATIC DIAGRAM 7 4 T 340 vi LIST OF TABLES TABLE NUMBER Page Table 2 1 Safety and Protective Devices 2 9 Table 3 1 Keypad Function 21 0 3 2 Table 3 2 DataCORDER Configuration Variables 3 12 Table 3 3 DataCORDER Standard Configurations 3 14 Table 3 4 Controller Configuration Variables 3 17 Table 3 5 Controller Function Codes 3 19
8. 5 12 ELECTRONIC EXPANSION VALVE MALFUNCTION Incorrect software and or controller configuration Failed suction pressure transducer Suction service valve partially closed REMEDY CONDITION POSSIBLE CAUSE REFERENCE SECTION Filter drier partially plugged Low refrigerant charge S Excessive frost on evaporator coil High suction pressure with ow superheat Ensure power Improperly seated powerhead head is locked and in place Failed suction pressure transducer SPT iquid slugging in compressor ee 460 VAC power plug is not inserted into the receptacle 4 2 2 5 14 WATER COOLED CONDENSER OR WATER PRESSURE SWITCH High disch M naa Noncondensibles Water pressure switch malfunction Condenser fan starts and stops Water supply interruption T 340 5 4 REMEDY CONDITION POSSIBLE CAUSE REFERENCE SECTION 5 15 COMPRESSOR OPERATING IN REVERSE NOTE The compressor may start in reverse for up to 10 seconds to determine correct phase rotation if required for phase detection CAUTION Allowing the scroll compressor to operate in reverse for more than two minutes will result in internal compressor damage Turn the start stop switch OFF immediately Incorrect wiring of compressor Electrical Incorrect wiring of compressor contactor s Check Incorrect wiring of current sensor 5 16 ABNORMAL TEMPERATURES Discharge temperature sensor drifting high Failed economizer expansion val
9. Rx hehe p baee E ad ech then E E s 6 2 Figure 6 4 Refrigeration System Service Connections 1 6 3 Figure 6 5 CompressoriKit kenir mii eee ux ee ehe RG et e ect ORCI dca e 6 5 Figure 6 6 High Pressure Switch Testing 6 6 Figure 6 7 Water Cooled Condenser Cleaning Forced Circulation 6 8 Figure 6 8 Water Cooled Condenser Cleaning Gravity Circulation 6 9 Figure 6 9 Evaporator Fan Assembly 1 6 10 Figure 6 10 Electronic Expansion Valve 2 6 11 Figure 6 11 Economizer Expansion Valve 22 6 11 Figure 6 12 Hermetic Thermostatic Expansion Valve Brazing Procedure 6 12 Figure 6 13 Coil View of Economizer Solenoid Valve ESV and Liquid Injection Valve LIV 6 12 Figure 6 14 Controller Section of the Control 6 16 Figure 6 15 Sensor 1 1 4 2 2 6 20 Figure 6 16 Sensor and Cable Splice 6 20 Figure 6 17 Supply Sensor Positioning
10. 1 2 1 93 23 Evaporator et A Ee eed 1 2 1 3 24 Evaporator Fan Operation 1 2 13 25 Labels iore See abe 1 2 13 26 Plate cerno uda debes A Va eoi Gains v dude a 1 2 1 3 27 acct peed tee Peed tee 1 2 1 3 28 Condenser Grille 1 2 222 1 2 DESCRIPTION esate tad e ede Er pe 2 1 21 GENERAL DESCRIPTION pror Ee kG Gs eas dG RR ee enn 2 1 2 1 1 Refrigeration Unit Front Section 2 1 2 1 2 Fresh Air Makeup Vent Hasse ott tian E MR ae Ie ar ain TI WR epe 2 1 2 1 3 Evaporator Section ils sale pale ee RU Gale gee eG 2 2 2 1 4 Compressor Section che bd ee o ee ee LEES 2 3 2 1 5 Air Cooled Condenser Section 2 4 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page 2 1 6 Water Cooled Condenser Section 2 2 5 2 1 4 Control BOX Section iia mode rend gne an eed 2 6 2 1 8 Communications Interface 0
11. 4 3 4 7 4 CompletInSpectiOn be he C Qebkrb3ed brit i ONT 4 3 4 8 PRE TRIP BIAGNOSIS erre ener retenu Pese endete 4 3 49 OBSERVE UNIT OPERATION 4 4 4 9 1 Probe Check eds tive eben ieee nals des pine ost edd 4 4 TROUBLESHOOTING rey xn meg any 5 1 5 1 UNIT WILL NOT START OR STARTS THEN 5 1 iii T 340 TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page 5 2 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING 5 1 5 8 UNIT RUNS BUT HAS INSUFFICIENT COOLING 5 2 5 4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING 5 2 55 UNIT WILL NOT TERMINATE HEATING 5 2 56 UNIT WILL NOT DEFROST PROPERLY 5 2 5 7 UNIT WILL NOT DEFROST PROPERLY Continued 5 3 5 8 ABNORMAL PRESSURES COOLING 5 3 5 9 ABNORMAL NOISE OR VIBRATIONS 5 3 5 10 MICROPROCESSOR MALFUNCTION 5 3 5 11 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR F
12. 6 5 65 HIGH PRESSURE SWITCH 2 6 6 6 5 1 Replacing High Pressure 6 6 6 5 2 Checking High Pressure Switch 6 6 66 GONDENSER COIL es pct i we dre te aa geen ea ea ae ae a ee end 6 6 6 7 CONDENSER FAN AND MOTOR ASSEMBLY 6 7 6 8 WATER COOLED CONDENSER CLEANING 6 7 6 9 EIETERODRIEEB esos dae dee eatin cas aie daa e DEREN RE 6 9 6 10 EVAPORATOR COIL AND HEATER ASSEMBLY 6 9 6 10 1 Evaporator Coil Replacement 6 9 6 10 2 Evaporator Heater Replacement 6 9 6 11 EVAPORATOR FAN AND MOTOR ASSEMBLY 6 9 6 11 1 Replacing The Evaporator Fan 6 10 6 11 2 Disassemble The Evaporator Fan Assembly 6 10 6 11 3 Assemble The Evaporator Fan 6 10 6 12 ELECTRONIC EXPANSION VALVE 2 6 10 6 12 1 Replacing Expansion Valve and Screen 6 11
13. 4 1 4 2 2 Connection To 190 230 VAC 4 1 4 3 ADJUST FRESH AIR MAKEUP 4 1 4 3 1 Upper Fresh Air Makeup Vent 4r eee hale ERI REEF WES 4 2 4 3 2 Lower Fresh Air Makeup 4 2 4 3 8 Vent Position Sensor 4 2 44 CONNECT WATER COOLED CONDENSER 4 2 4 4 1 Water Cooled Condenser with Water Pressure Switch 4 2 4 4 2 Water Cooled Condenser with Condenser Fan Switch 4 2 4 5 CONNECT REMOTE MONITORING RECEPTACLE 4 3 4 6 STARTING AND STOPPING INSTRUCTIONS 4 3 4 6 15 Starting the eth a ao es Baie ee 4 3 4 6 2 Stopping the Uniti ee Pea a Rat See an UR re RI 4 3 47 START UP INSPECTION 4 3 471 Physical NSpection eerta erac wad ete adem edd wigan 4 38 4 7 2 Check Controller Function Codes 4 3 4 7 8 Start Temperature Recorder
14. iussu ot 1425 rpm 1725 rpm Bearing Lubrication Solenoi Valve Nominal Resistance Colle EN ine ve 250 7 7 ohms 5 24 VDC Maximum Current Draw Nominal Resistance DUV Coils 77 20C 14 8 ohms 5 12 VDC Maximum Current Draw 929 mA EEV Coil Feed to Ground 47 oh Nominal Resist Gray Wire bre ance Coil Feed to Coll Feed T 340 2 8 Section 2 3 ELECTRICAL DATA CONTINUED Orange wire Red wire Brown wire Input voltage Output voltage k Humidity Sensor 0 99 V 0 70 1 65 V 2 31 V 2 97 V 2 4 SAFETY AND PROTECTIVE DEVICES Unit components are protected from damage by safety and protective devices listed in Table 2 1 These de vices monitor the unit operating conditions and open a set of electrical contacts when an unsafe condition oc curs Open safety switch contacts on either or both of devices IP CP or HPS will shut down the compressor Open safety switch contacts on device IP CM will shut down the condenser fan motor The entire refrigeration unit will shut down if one of the following safety devices open a circuit breaker s b fuse F3A F3B 7 5A or c evaporator fan motor in ternal protector s IP Table 2 1 Safety and Protective Devices UNSAFE CONDITION DEVICE DEVICE SETTING Circuit Breaker CB 1 Circuit Breaker CB 2 50 amp Manual Reset Excessive current draw Circuit Breaker CB 2 70 amp Manual Reset
15. temperature that is more than 2 5C 4 5F above set point the system will be in the frozen pulldown mode It will transition to economized operation However pressure and current limit functions may restrict the valve if either exceeds the preset value 3 3 13 Frozen Mode Temperature Control When in the frozen mode the controller maintains the return air temperature at set point the RETURN indicator light will be illuminated on the display module and the default reading on the display window will be the return air probe reading When the return air temperature enters the in range temperature tolerance as selected at function code Cd30 the in range light will energize 3 3 14 Frozen Mode Conventional Frozen range cargos are not sensitive to minor temperature changes The method of temperature control employed in this range takes advantage of this to greatly improve the energy efficiency of the unit Temperature control in the frozen range is accomplished by cycling the compressor on and off as the load demand requires Once set point is reached the unit will transition to the frozen steady state mode economized operation When temperature drops to set point minus 0 2C and the compressor has run for at least five minutes the unit will transition to the frozen idle mode The compressor is turned off and the evaporator fans continue to run to circulate air throughout the container If temperature rises above set point 0
16. Excessive current draw in the control circuit Fuse F3A amp F3B Manual Reset Trips at 29 amps 460 VAC Trips at 62 5 amps 230 VAC Trips at 87 5 amps 230 VAC 7 5 amp rating Excessive current draw by the Excessive condenser fan motor winding temperature Internal Protector IP CM Automatic Reset Excessive compressor motor winding temperature Excessive evaporator fan motor s winding temperature Abnormal pressures tempera tures in the high refrigerant side denser Abnormally high discharge pressure Internal Protector IP CP Internal Protector s IP EM Fusible Plug Used on the Receiver Rupture Disc Used on the Water Cooled Con High Pressure Switch HPS 2 9 Automatic Reset Automatic Reset 99C 35 kg cm 210F 500 psig Opens at 25 kg cm 350 psig T 340 2 5 REFRIGERATION CIRCUIT 2 5 1 Standard Operation Starting at the compressor see Figure 2 7 upper schematic the suction gas is compressed to a higher pressure and temperature In the standard mode the economizer valve is closed Therefrigerant gas flows through the discharge line and continues into the air cooled condenser When operat ing with the air cooled condenser active air flowing across the coil fins and tubes cools the gas to saturation temperature By removing latent heat the gas con denses to a high pressure high temperature liquid and flows to the receiver which stores the additi
17. 2 Flat washer 5 8 3 Locknut 5 8 18 4 Impeller Fan 5 Screw 1 4 6 Flat washer 1 4 7 Mylar Protector 8 Evaporator Motor Figure 6 9 Evaporator Fan Assembly e 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 Connect the wiring con nector f Replace access panel making sure that panel does not leak Make sure that the TIR locking device is lockwired 6 12 ELECTRONIC EXPANSION VALVE The electronic expansion valve EEV is an automatic device which maintains required superheat of the refrig erant gas leaving the evaporator The valve functions are a automatic response of refrigerant flow to match the evaporator load and b prevention of liquid refriger ant entering the compressor Unless the valve is defec tive it seldom requires any maintenance See Figure 6 10 FLOW DIRECTION 1 Coil Boot 2 Coil 3 Electronic Expansion Valve Figure 6 10 Electronic Expansion Valve 6 12 1 Replacing Expansion Valve and Screen Pump down the unit Refer to Section 6 3 2 Remove coil Use a wet rag to keep valve cool whenever brazing Heat inlet and outlet connections to valve body and remove valve Clean all tube stubs so new valve fits on easily Install new valve and screen with cone of screen pointing into liquid line at inlet to the valve by revers ing steps a through c
18. 5 R E len 6 GRN 3 cs GRN Y CORE GRN YELD DVR PE pe Li UTI R COMMUNICATIONS TRANS AUTOS ha INTERFACE 7 m TR MODULE 3 CI 5 7 D ST Bis f LES 4071 05 CR 9 HR DHTL DHMR n9 oa Lim DHML DHBR L2 2 F38 ES DHBL DHTR pij RM L3 11 DL KB n aS 2f 22 al 2 E n 14 18 L3 H3 ART s EM GRD te KD3 KD2 21 22 Al A2 TC B HPS A TA i U ES 12 KA2 ECF2 d A2 Fri i 11 15 Lal 172 lt TP7 leg 13 EF ECH3 tlm 1 H2 gn V m Tal gt lt 2 1113 t GRO 1 Tra TN LIV 6 ECG 0 1 51 cm2 2 2 i ES 451 M d 2 2 TL RM RM B Cy A ES 21 22 A1 A2 1 2 i TE EF 14 19 29 26 2 24 2 KAS A2 HTT TOP TH HR ECD3 TEM 2 TI RM Ry RM 0 see Figure 7 3 for VPS EEV BLK ORG 1 KEYPAD 2 YEL GRY ai MK ER RED DISPLAY RECHARGEABLE 5 MODULE BATTERY PACK KG 7 2VDC x MB S Ue e ET EA 1 18 4 16 1 e OO 20 uc 1018 1511
19. 54 3 2 1 8 1 1 6 5 4 2 1 2 1 5 2 1 79101112 21 28 568 TR KH KE J MX ranr d F1 2 2807 CONTROLLER PROGRAMMING SLOT EC A 8 D E L M EC N P R 5 W x Y EC 1 1 1 2 a a a 2 2 H H h 3 h h 3 o m D a 3 4 8 53 u 21 v su e 5 8 E Dc 9 DUV A al 8 C T PR2 BEA DCS 14 20 22 T 340 Figure 7 2 SCHEMATIC DIAGRAM 7 2 lt a e SEE NOTE vPSI L3 2 2 VPS O 2 rii 2 QT lt lt 3 w N w w N KD 2 4 SEE NOTE 12 1 vPs2 i 3 T Mer y Qi 82 6 2
20. Table 3 5 Controller Function Codes Sheet 4 of 4 Variable rcm Temperature rcm Dehumidification Pa Cd48 rameter Selection Days Since Last Cd49 Successful Pre trip Automatic Cold Cd51 Treatment Parameter Selection Automatic Set point Cd53 Change Mode Parameter Selection Electronic Expan Cd55 Super T 340 Code Cd47 is used with optional economy mode The values are 0 5C 4 0C The default is 3 0C If the unit is not configured for economy mode will be dis played Code 48 is used both when dehumidification set point is set above 6596 RH and below 6496 RH When dehumidification set point is set above 6596 RH select goes to LO if it had been set to hi When dehumidification set point is set below 6496 RH select goes to Alt if it had been set to LO Code Cd49 will display the time period days since the last successful pre trip Code 51 initially displays countdown timer increments of 1 day 1 hour with the temperature default Pressing ENTER allows selection of within the current menu and proceeds to the next menu After five seconds of no activity the display re verts to normal system display but retains the parameters previously selected On Off or The default is Off trEAt C F in 0 1 degree increments The default is 0 0C DAy S 0 99 increments of 1 The default is 0 Probe probe positions example 12_4 The default
21. eration in the heat or defrost mode 3 Defrost Orange LED Energized when the unit is in the defrost mode 4 In Range Green LED Energized when the con trolled temperature probe is within specified tolerance of set point T 340 3 2 air probe This LED will flash if dehumidification or humidification is enabled Return Yellow LED Energized when the return air probe is used for control When this LED is illuminated the temperature displayed in the AIR TEMPERATURE display is the reading at the return air probe This LED will flash if dehumidification or humidification is enabled Alarm Red LED Energized when there is an active or an inactive shutdown alarm in the alarm queue COOL HEAT DEFROSTIN RANGEALARM SUPPLY RETURN SETPOINT Code AIR TEMPERATURE Data Figure 3 3 Display Module 3 1 3 Controller CAUTION Do remove wire harnesses from con troller modules unless you are grounded to the unit frame with a static safe wrist strap CAUTION Unplug all controller module wire harness connectors before performing arc welding on any part of the container CAUTION Do not attempt to use ML2i PC card in an ML3 equipped unit The PC cards are physi cally different and will result in damage to the controller NOTE Do not attempt to service the controller modules Breaking the seal will void the warranty The Micro L
22. mulation of ice on the evaporator coil Following a start up or after termination of a defrost the time will not begin counting down until the defrost temperature sen sor DTS reading falls below set point If the reading of DTS rises above set point any time during the timer count down the interval is reset and the count down begins over If DTS fails alarm code AL60 is activated and control switches Defrost Interval over to the the return temperature sensor The controller will act in the same man Hours or Automatic ner as with the DTS except the return temperature sensor reading will be used Defrost Interval Timer Value Configuration variable CnF23 If the software is configured to SAv save for this option 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 that will be used for all tem perature 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 NOTE This function code will display if Configuration Variable CnF34 is set to F If all of the control sensors are out of range alarm code AL26 o
23. Data is logged at exact intervals in accordance with the real time clock The clock is factory set at Greenwich Mean Time GMT 3 7 5 Thermistor Format dCF04 The user may configure the format in which the thermistor readings are recorded The short resolution is a 1 byte format and the long resolution is a 2 byte format The short requires less memory and records temperature with variable resolutions depending on temperature range The long records temperature in 0 01C 0 02F steps for the entire range Table 3 2 DataCORDER Configuration Variables dor acros LogsngimemaliMiutes 153080420 dCFO4 Shor dCF05 Thermistor Samping Type dCF06 Controlled Atmosphere Humidity Sampling Type Alarm Configuration USDA Sensor 1 Auto On Off A dCF07 Alarm Configuration USDA Sensor 2 9 Alarm Configuration USDA Sensor 3 A Auto On Off dCF10 Alarm Configuration Cargo Sensor Auto On Off T 340 3 12 WiewD ata Raw Data Report 1 File Reports Window la x ekila Sam m Raw Data Report for ABC1234567 May 31 2007 to Jun 04 2007 System Configuration at the Time of Interrogation Interrogated On May 05 2007 Extracted by DataLINE Rev 1 0 0 Controller Software 5327 Controller Serial 4 04163552 Bill of Lading 1 Origin Origin Date Destination Discharge Date Commen
24. During reinstallation make sure the EEV coil is snapped down fully and the coil retention tab is prop erly seated in one of the valve body dimples Also ensure that coil boot is properly fitted over valve body See Figure 6 10 Evacuate by placing vacuum pump on liquid line and suction service valve Open liquid line service valve and check refrigerant level Check superheat Refer to Section 2 2 i Check unit operation by running Pre trip Refer to Section 3 7 6 11 6 13 ECONOMIZER EXPANSION VALVE The economizer expansion valve can be found in Figure 2 4 Item 15 The economizer expansion valve is an automatic device that maintains constant super heat of the refrigerant gas leaving at the point of bulb at tachment regardless of suction pressure Unless the valve is defective it seldom requires main tenance other than periodic inspection to ensure that the thermal bulb is tightly secured to the suction line and wrapped with insulating compound 6 13 1 Valve Replacement a Removing an Expansion Valve NOTES The economizer expansion valve is a hermetic valve and does not have adjustable superheat See Figure 6 11 1 Inlet Outlet Figure 6 11 Economizer Expansion Valve 1 Pump down the unit per paragraph 6 3 2 Evacuate if unit is not equipped with service valves Refer to paragraph 6 4 4 2 Remove cushion clamps located on the inlet and out let lines 3 Remove insulation Presstite from
25. O position The condenser fan will be on when the switch is placed in the I position During the standard mode of operation the normally closed digital unloader valve DUV controls the system refrigerant flow and capacity by loading and unloading T 340 2 10 the compressor in frequent discrete time intervals If the system capacity has been decreased to the lowest al lowable capacity with the DUV the unit will enter a trim heat mode of operation during which the controller will pulse the evaporator heaters in sequence with the com pressor digital signal in order to absorb the excess capa city 2 5 2 Economized Operation In the economized mode see Figure 2 8 the frozen and pull down capacity of the unit is increased by sub cooling the liquid refrigerant entering the electronic ex pansion valve Overall efficiency is increased because the gas leaving the economizer enters the compressor at a higher pressure therefore requiring less energy to compress it to the required condensing conditions Liquid refrigerant for use in the economizer circuit is tak en from the main liquid line as it leaves the filter drier The flow is activated when the controller energizes the economizer solenoid valve ESV The liquid refrigerant flows through the economizer ex pansion valve and the economizer internal passages absorbing heat from the liquid refrigerant flowing to the electronic expansion valve The resultant medium temp
26. T 340 Safety 2 WARNING Always turn OFF the unit circuit breakers CB 1 amp CB 2 and disconnect main power supply before working on moving parts 44 WARNING Installation requires wiring to the main unit circuit breaker CB1 Make sure the power to the unit is off and power plug disconnected before beginning installation CAUTION Do not remove wire harnesses from con troller modules unless you are grounded to the unit frame with a static safe wrist strap CAUTION Unplug all controller module wire harness connectors before performing arc welding on any part of the container CAUTION Do not attempt to use an ML2i card in ML3 equipped unit The PC cards are physi cally different and will result in damage to the controller CAUTION Pre trip inspection should not be per formed with critical temperature cargoes in the container CAUTION When key is pressed economy de humidification and bulb mode will be deac tivated At the completion of Pre Trip activi ty economy dehumidification and bulb mode must be reactivated CAUTION When condenser water flow is below 11 8 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 CAUTION Pre trip inspection should not be per formed with critical temperature cargoes in the container CAUTI
27. sc cic A HE IB it 2 119 9 Mi i G paras 2 1 bo E 517 PHASE 1 L wcR FUSE 1 AT Cc IF EQUIPPED O PHASE 2 7 FUSE jou is 22 1 AT KEYWAY SIDE 22 5 CIF EQUIPPED GY 2 C PHASE 3 l mune FUSE 1 2 CIF EQUIPPED 7 l e 4 97 i 4 E I 3 2 1 1 5 2 l l Figure 7 4 UNIT SCHEMATIC DIAGRAM Sheet 2 of 2 7 5 T 340 Adjusting Fresh Air Makeup 4 1 Air Cooled Condenser Section 2 4 Alarm Configuration 3 14 Autotransformer 6 15 B Battery Replacement 6 18 C Capacity Trim Heat 3 6 Communications Interface Module 2 6 3 15 6 24 Compressor 6 4 Compressor Section 2 3 Condenser Coil 6 6 Condenser Fan 6 7 Condenser Pressure Control 3 10 Configuration Identification 1 1 Configuration Software 3 3 3 12 Connect Remote Monitoring Receptacle 4 3 Connect Water Cooled Condenser 4 2 Connecting Power 4 1 Control Box Section 2 6 Controller 3 3 6 15 Controller Alarms 3 10 3 23 Controller Configuration Codes 3 17 Controller Function Codes 3 19 Controller Sequence and Modes of Operation 3 4 Controller Software 3 3 D DataCORDER 3 11 3 14 4 3 DataCORDER Alarms
28. 20 volts for the humidity sensor Requirements Test P5 11 must pass before this test is run Pass Fail Criteria Passes if the voltage for the humidity sensor is between 0 66 volts and 4 volts Fails if voltage is outside of the 0 66 volt to 4 volt range 3 28 Table 3 7 Temperature Controller Pre Trip Test Codes Sheet 3 of 4 Discharge If alarm 64 is activated any time during the first 45 second period of Step 1 the Thermistor Test test fails Suction Alarm is activated if suction temperature is outside of the valid range of 60C P6 1_ Thermistor Test CODD 150C 302F any time during the first 45 second period of Step 1 the P6 2 Discharge Pressure If alarm 65 is activated any time during the first 45 second period of Step 1 the Sensor Test test fails ERU E If alarm 66 is activated the test fails Compressor current is tested before and 10 seconds after start up If current does not increase the test fails P6 7 is run at the end of P6 4 If this test fails P6 6 is skipped Compressor Current P6 4 Draw Test NOTE P6 6 through P6 10 tests are conducted by changing the status of each individual valve and comparing suction pressure change and or compressor current change with predetermined values The tests will cause the compressor and condenser fans to cycle on and off as needed to generate the pressure required for the individual pre trip sub tests The compressor will start in order to build discharge pressure f
29. 2C the unit will transition back to the frozen steady state mode 3 3 15 Frozen Mode Heat Lockout Temperature With configuration variable CnF26 Heat Lockout Temperature set to 10C the frozen mode of operation is active with set points at or below 10C 14F With the variable set to 5C the frozen mode is active at or below 5C 23F If the temperature drops 10C below set point the unit will transition to the frozen heating mode in which the evaporator fans are brought to high speed The unit will transition back to the frozen steady state mode when the temperature rises back to the transition point 3 3 16 Frozen Mode Economy In order to activate economy frozen mode operation a frozen set point temperature must be selected The economy mode is active when function code Cd34 is set to ON When economy mode frozen is active the system will perform normal frozen mode operations except that the entire refrigeration system excluding the controller will be turned off when the control temperature is less than or equal to the set point 2C 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 the unit will restart the refrigeration system and continue to cool until the previously mentioned off cycle temperature criteria are met If the control tempe
30. 6 13 ECONOMIZER EXPANSION VALVE 1 1 1 2 2 6 11 6 13 44 Valve Replacement x RUE Ee ue Eee 6 11 T 340 iv TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page 6 14 ECONOMIZER AND LIQUID INJECTION SOLENOID VALVES 6 12 6 15 DIGITAL UNLOADER VALVE 6 12 6 16 VALVE OVERRIDE CONTROLS a pex eet seen be Ge bangs cee alee 6 13 6 17 or eatin et ble E Rte Re 6 15 6 18 GONTROPEER tate donet recette 6 15 6 18 1 Handling Modules arer reres ee rege o ude iad eee GER 6 15 6 18 2 Controller Troubleshooting 4 6 15 6 18 3 Controller Programming Procedure 6 16 6 18 4 Removing and Installing a Module 6 18 6 18 5 Battery Replacement e ode e T 6 18 6 19 VENT POSITION SENSOR 6 18 6 20 TEMPERATURE SENSOR SERVICE 6 19 6 20 1 Sensor Checkout Procedure 6 19 6 20 2 Sensor Replacement
31. DataLINE This calibration procedure determines the probe offsets and stores them in the controller for use in generating the cold treatment report Refer to the Data Retrieval manual 62 02575 for more details Pre cool the container to the treatment temperature or below Install the DataCORDER module battery pack if not already installed Place the three probes The probes are placed into the pulp of the product at the locations defined in the following table as the product is loaded T 340 Place in pulp of the product located next to the return air intake Place in pulp of the product five feet from the end of the load for 40 foot con tainers or three feet from the end of the load for 20 foot containers This probe should be placed in a center carton at Sensor 2 one half the height of the load Place in pulp of product five feet from the end of the load for 40 foot containers or three feet from the end of the load for 20 foot containers This probe should be placed in a carton at a side wall at one half the height of the load Sensor 3 To initiate USDA recording connect the personal computer and perform the configuration as follows using either the DataView or DataLINE software 1 Enter ISO header information 2 Enter a trip comment if desired 3 Configure the DataCORDER for five probes s P1 P2 dcf02 5 4 Configure the logging interval for one hour 5 the sen
32. Midnight Manual changes greater than 5 CMH 3 CFM remaining in the new position for at least 4 minutes NOTE The user has four minutes to make necessary adjustments to the vent setting This time calculation begins on the initial movement of the sensor The vent can be moved to any position within the four minutes On completion of the first four minutes the vent is required to remain stable for the next four minutes If vent position changes are detected during the four minute stability period an alarm will be generated This provides the user with the ability to change the vent setting without generating multiple events in the DataCORDER 4 4 CONNECT WATER COOLED CONDENSER The water cooled condenser is used when cooling wa ter is available and heating the surrounding air is objec tionable such as in a ship s hold If water cooled opera tion is desired connect in accordance with the following subparagraphs 4 4 4 Water Cooled Condenser with Water Pres sure Switch a Connect the water supply line to the inlet side of con denser and the discharge line to the outlet side of the condenser See Figure 2 5 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 To shift to air cooled condenser operation discon nect t
33. RE 3 7 3 3 17 Frozen Mode Cooling Sequence of Operation 3 8 33 18 D frost Interval 2 5 ee DR eoru meten e e nb m tee aa 3 9 3 3 19 Defrost Mode Sequence of Operation 3 9 3 4 PROTECTION MODES OF OPERATION 3 10 3 4 1 Evaporator Fan Operation 3 10 3 42 Fare ACION sek See de veces ecu aren tian Do cet and 3 10 3 4 3 Generator Protection iscing RUE ERR EE EG 3 10 3 4 4 Compressor High Temperature Low Pressure Protection 3 10 T 340 ii TABLE OF CONTENTS Continued PARAGRAPH NUMBER Page 3 4 5 Perishable Mode System Pressure 3 10 3 4 6 Condenser Fan Switch Override 3 10 3 5 CONTROLLER ALARMS 3 10 36 UNIT PRE TRIP DIAGNOSTICS 3 11 3 7 IData amp OBDER ALLEE ALL EL ei ro 3 11 3 2 1 eda kaki DI RI 3 11 3 7 2 DataCORDER Software 3 11 3 7 8 Sensor Configuration ACFO2
34. a Compressor Motor Weight With Oil 42 9 kg 95 Ib Assembly Approved Oil Uniqema Emkarate RL 32 3MAF Oil Charge 1774 ml 60 ounces 2 Verify at 18C b Electronic Expansion Valve OF container box 4 4 to 6 7C 8 to 12F Superheat Evaporator temperature Verify at 18C c Economizer Expansion OF container box 4 4 to 11 1C 8 to 20F Valve Superheat temperatur VERBERE 54 GF 3 C 130 eater Termination ermosta 38 4 C 100 7 we 25 1 0 kg cm 350 10 psig pado dace iui e 18 0 7 kg cm 250 10 psig Charge Requirements R 134a Unit Configuration Compressors are shipped with factory charge f Refrigerant Charge oe ioe 12 5 22 kg Receiver 11 5 Ibs Unit Weight model number plate _ Em 0 5 0 2 kg cm 7 3 psig Alae 1 6 0 4 kg cm 22 5 psig 2 7 T 340 2 3 ELECTRICAL DATA a Circuit Breaker CB 2 50 amp Trips at b el a Full Load Amps FLA 13 amps 460 VAC 380 VAC Single Phase 460 VAC Single Phase 50 Hz 60 Hz eee Motor Factory lubricated additional grease not required d Evaporator Coil Heaters 460 VACIS PHIGO Hz Full Load Amps High Speed ng 1 2 Full Load Amps Low Speed Nominal Horsepower e Evaporator Fan Nominal Horsepower 0 11 Motor s Low Speed n 2850 3450
35. backup Six Thermistor Inputs Interrogation Connections Power Supply battery pack The DataCORDER performs the following functions a Logs data at 15 30 60 or 120 minute intervals and stores two years of data based on one hour interval b Records and displays alarms on the display module c Records results of pre trip testing d Records DataCORDER and temperature control software generated data and events as follows Container ID Change Software Upgrades Alarm Activity Battery Low battery pack Data Retrieval Defrost Start and End Dehumidification Start and End Power Loss with and without battery pack Power Up with and without battery pack Remote Probe Temperatures in the Container USDA Cold treatment and Cargo probe recording Return Air Temperature Set Point Change Supply Air Temperature Real Time Clock Battery internal battery Replace ment Real Time Clock Modification Trip Start ISO Trip Header When entered via Interrogation program Economy Mode Start and End Auto 1 Auto 2 Auto 3 Pre Trip Start and End Bulb Mode Start Bulb Mode Changes Bulb Mode End USDA Trip Comment Humidification Start and End USDA Probe Calibration Fresh Air Vent Position 3 7 2 DataCORDER Software The DataCORDER Software is subdivided into the Operational Software Configuration Software and the Data Memory T 340 a Operational Software The Operational Software reads and interprets inputs for use by the Conf
36. code Cd35 to bulb After bulb has been selected and entered the user may utilize function codes Cd36 and Cd37 to make the desired changes This code is enabled only if in the dehumidification mode code Cd33 and bulb mode Cd35 has been set to bulb If these conditions are not met alt will be displayed indicating that the evaporator fans will alternate their speed and the Cd36 Evaporator Speed display cannot be changed If a dehumidification set point has been selected Select along with bulb mode alt may be selected for alternating speed Lo for low speed evaporator fan only or for high speed evaporator fan only If a setting other than alt has been selected and bulb mode is deactivated in any manner the 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 Defrost Termination temperature above which defrost will terminate It allows the user to change the Cd37 Temperature Setting setting within a range of 4C to 25 6C in 0 1C 0 2F increments This value is Bulb Mode changed using the UP DOWN ARROW keys followed by the ENTER key when the desired value is displayed If bulb mode is deactivated the DTS setting re turns to the default Display Only Functions Continued Code Cd38 will display the current secondary supply temperature sensor SRS Cd38 Secondary Supp
37. connected to a 190 230 VAC 3 phase power source 1 Make sure that the start stop switch ST on control panel and circuit breakers CB 1 in the control box and CB 2 on the transformer are in position 0 OFF Plug in and lock the 460 VAC power plug atthe receptacle on the transformer Plug the 230 VAC black cable into a de energized 190 230 VAC 3 phase power source Energize the power source Set circuit breakers CB 1 and CB 2 to position I ON Close and secure control box door 1 Dual Voltage Modular Autotransformer Circuit Breaker CB 2 230 Volt 460 VAC Power Receptacle Figure 4 1 Autotransformer 4 3 ADJUST FRESH AIR MAKEUP VENT The purpose of the fresh air makeup vent is to provide ventilation for commodities that require fresh air circula tion The vent must be closed when transporting frozen foods Air exchange depends on static pressure differential which will vary depending on the container and how the container is loaded Units may be equipped with a vent position sensor VPS The VPS determines the position of the fresh air vent and sends data to the controller display T 340 4 3 1 Upper Fresh Air Makeup Vent Two slots and a stop are designed into the Upper Fresh Air discfor air flow adjustments The first slot allows for a Oto 30 air flow the second slot allows for a 30 to 100 air flow To adjust the percentage of air flow loosen the wing nut and rotate the disc until th
38. day is aligned with the start arrow and hand tighten the chart nut Gently lower the stylus arm until the pen tip item 4 comes in contact with the chart Recorder Door Change Chart Button Recorder Box Pen Tip Stylus Arm N gt Calibration Button Located underneath Mounting Screws 10 24 x 7 16 inches long Hold Down Tab Chart Retaining Nut Figure 6 20 Electronic Partlow Temperature Recorder CAUTION Do not allow the recorder stylus to snap back down The stylus arm base is spring loaded and damage may occur to the chart or the stylus force may be altered DO NOT move the stylus arm up and down on the chart face This will result in damage to the stylus motor gear 6 21 3 Adjusting the Recorder Stylus Proper stylus force upon the chart paper is important Factory adjustment is 113 to 127 grams 4 to 4 5 oz To measure the force use a spring type gage and attach it under the stylus as close as possible to the pen tip item 4 Exert pull on the gage perpendicular to the chart sur face The measured force should be noted just as the pen tip leaves the surface NOTE The two coil springs near the base of the stylus are NOT involved in establishing chart contact force They serve only to hold the stylus in its re tracted position 6 23 Correct adjustment is
39. expansion valve bulb 4 Unstrapthe bulb located on the economizer line and remove the valve b Installing an Expansion Valve 1 Braze inlet connection to inlet line see Figure 6 12 2 Braze outlet connection to outlet line 3 The economizer valve should be wrapped in a soaked cloth for brazing See Figure 6 12 Braze inlet connection to inlet line 4 Braze outlet connection to outlet line 5 Reinstallthe cushion clamps on inlet and outlet lines 6 Check superheat see Section 2 2 T 340 Apply heat for 10 15 sec onds 1 Copper Tube 2 Bi metallic Tube 2 5 seconds Connection Apply heat for 3 Braze Rod Sil Phos 5 5 Silver 6 Phosphorus 4 Use of a wet cloth is not necessary due to rapid heat dissipation of the bi metallic connections Figure 6 12 Hermetic Thermostatic Expansion Valve Brazing Procedure 6 14 ECONOMIZER AND LIQUID INJECTION a o 1 SOLENOID VALVES Replacing the Coil NOTE The coil may be replaced without removing the refrigerant Slotted Screw Top Coil small O ring Solenoid Coil Enclosing Tube and Body Bottom Coil large O ring Brass Spacer ESV ONLY Figure 6 13 Coil View of Economizer Solenoid Valve ESV and Liquid Injection Valve LIV Be sure electrical power is removed from the unit Disconnect leads Remove top screw and o ring Lift off coil See Figure 6 13 T 340 6 12 2 Verify coil type voltage an
40. functions may restrict the valve if either exceeds the preset value 3 3 4 Perishable Set Point Temperature Conven tional Temperature Control Mode The unit is capable of maintaining supply air temperature to within 0 25C 0 5F of set point Supply air temperature is controlled by positioning of the electronic expansion valve EEV cycling of the compressor and cycling of the heaters Once set point is reached the unit will transition to the perishable steady state mode This results in unloaded operation If the controller has determined that cooling is not re quired or the controller logic determines suction pres sure is at the low pressure limit the unit will transition to the perishable idle mode The compressor is turned off and the evaporator fans continue to run to circulate air throughout the container If temperature rises above set point 0 2C the unit will transition back to the perishable steady state mode If the temperature drops to 0 5C 0 9F below set point the unit will transition to the perishable heating mode and the heaters will be energized The unit will transition back to the perishable idle mode when the temperature rises to 0 2C 0 4F below the set point and the heaters will de energize 3 3 5 Perishable Set Point Temperature my Mode The economy mode is an extension of the conventional mode The mode is activated when the setting of function code Cd34 is ON Economy mode
41. into the program ming software port See Figure 6 14 menuDDMM nil this file allows the user to select the file program to upload into the controller cfYYMMDD mi3 multi configuration file Turn unit ON using start stop switch ST The display module will display the message ruN COnFG If a defective card is being used the display will blink the message bAd CArd Turn start stop Switch OFF and remove the card Press the ENTER key on the keypad The display module will go blank briefly and then dis play 551 00 based on the operational software installed Press the UP or DOWN ARROW key to scroll through the list to obtain the proper model dash num ber If a defective card is being used the display will blink the message bAd CArd Turn start stop switch OFF and remove the card Press the ENTER key on the keypad When the software loading has successfully com pleted the display will show the message EEPrM donE If a problem occurs while loading the soft ware the display will blink the message Pro FAIL or bad 12V Turn start stop switch OFF and remove the card 10 Turn unit OFF using start stop switch ST 11 Remove the PCMCIA card from the programming software port and return the unit to normal operation by placing the start stop switch in the ON position 12 Confirm correct model configuration using the padto choose code 20 CD20 The model displayed s
42. is placed on the mat 6 18 2 Controller Troubleshooting A group of test points TP see Figure 6 14 are pro vided on the controller for troubleshooting electrical cir cuits see schematic diagram section 7 A description of the test points follows NOTE Use a digital voltmeter to measure AC voltage between TP s and ground TP9 except for TP8 TP1 This test point is not used in this application TP2 This test point enables the user to check if the high pres sure switch HPS is open or closed TP3 This test point enables the user to check if the water pressure switch WP contact is open or closed 4 This test point enables the user to check if the internal protector for the condenser fan motor IP CM is open or closed TP5 This test point enables the user to check if the internal protectors for the evaporator fan motors IP EM1 or IP EMO are open or closed TP6 This test point enables the user to check if the controller liquid injection valve relay TQ is open or closed TP7 This test point enables the user to check if the controller economizer solenoid valve relay TS is open or closed TP8 This test point is not used in this application TP 9 This test point is the chassis unit frame ground con nection TP 10 This test point enables the user to check if the heat ter mination thermostat HTT contact is open or closed T 340
43. is 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 There is no active display indicator that economy mode has been activated To check for economy mode perform a manual display of code Cd34 In order to achieve economy mode a perishable set point must be selected prior to activation When economy mode is active the evaporator fans will be controlled as follows At the start of each cooling or heating cycle the evaporator fans will run in high speed for three minutes They will then be switched to low speed any time the supply air temperature is within 0 25C 0 45F of the set point and the return air temperature is less than or equal to the supply air temperature 3C 5 4F The fans will continue to run in low speed for one hour At the end of the hour the evaporator fans will switch back to high speed and the cycle will be repeated If bulb mode is active the economy fan activity will be overridden 3 3 6 Perishable Set Point Temperature Control With configuration variable CnF26 Heat Lockout Temperature set to 10C the perishable mode of operation is active with set points above 10C 14F With the variable set to 5C the perishable mode is active above 5C 23F Refer to Table 3 4 When in the perishable mode the controller maintains the supply air temperatu
44. is terminated by a condition other than the humidity sensor e g an out ofrange or compressor shutdown condition the heat relay is de energized immediately Two timers are activated in the dehumidification mode to prevent rapid cycling and consequent contactor wear They are 1 Heater debounce timer three minutes 2 Out of range timer five minutes The heater debounce timer is started whenever the heater contactor status is changed The heat contactor remains energized or de energized for at least three minutes even if the set point criteria are satisfied The out of range timer is started to maintain heater operation during a temporary out of range condition If the supply air temperature remains outside of the user selected in range setting for more than five minutes the heaters will be de energized to allow the system to recover The out of range timer starts as soon as the temperature exceeds the in range tolerance value set by function code 3 3 11 Perishable Dehumidification Bulb Mode Bulb mode is an extension of the dehumidification mode which allows changes to the evaporator fan speed and or defrost termination set points Bulb mode is active when configuration code Cd35 is set to Bulb Once the bulb mode is activated the user may then change the dehumidification mode evaporator fan operation from the default speed alternates from low to high each hour to constant low or constant high speed Th
45. made by carefully bending the portion of the stylus arm between the bend near the pen and the first bend towards the stylus arm base If the force is too low the stylus trace will be light and difficult to read If the force is too great wrinkling or tearing of the paper chart may occur 6 21 4 Rezeroing the Recording Thermometer For Electronic Partlow Recorder CTD part number 12 00464 xx Where xx an odd number example 12 00464 03 NOTE Use chart CTD part number 09 00128 00 F part number 09 00128 01 C a Press the Calibration button item 7 Figure 6 20 on the bottom ofthe recorder The pen tip will drive ful ly down scale then move upscale to the chart ring at 29C 20F and stop If the tip of the pen item 4 is on the 29C 20F chart ring the recorder is in calibration proceed to step c If the tip of the pen is NOT onthe 29C 20F chart ring the operator must loosen the two screws on the bot tom of the stylus arm to adjust the pen tip manually to the 29C 20F chart ring Tighten the screws when adjustment is complete Press the calibration button and the pen will position itself to the correct temperature reading T 340 For Electronic Partlow Recorder part number 12 00464 xx Where xx an even number example 12 00464 08 NOTE Use chart CTD part number 09 00128 00 F part number 09 00128 01 C a Press the Calibration button item 7 Figure 6 20 on the bottom oft
46. n eek 6 19 6 20 3 Sensor Re Installation 6 20 6 21 ELECTRONIC PARTLOW TEMPERATURE RECORDER 6 22 6 22 MAINTENANCE OF PAINTED SURFACES 6 24 6 23 COMMUNICATIONS INTERFACE MODULE INSTALLATION 6 24 ELECTRICAL WIRING SCHEMATICS 7 1 7 1 INTRODUCTIONS 23203 ise Saat CA a ee EET ME Rr 7 1 M T 340 LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figure 2 1 Refrigeration Unit Front Section 2 1 Fig re 2 2 Evaporator Section ene eee end PER QUAERERE D EIS 2 2 Figure 2 3 Compressor Section 2 3 Figure 2 4 Air Cooled Condenser Section 2 4 Figure 2 5 Water Cooled Condenser Section 2 5 Figure 2 6 Control Box Section 2 6 Figure 2 7 Refrigeration Circuit Schematic Standard Operation 2 11 Figure 2 8 Refrigeration Circuit Schematic Economized Operation 2 12 Figure 3
47. pad display module current sensor module controller module and the communications interface module DU DU H 0 OES EF 15 14 13 Compressor Contactor CH Compressor Phase A Contactor PA Compressor Phase B Contactor PB Heater Contactor HR Display Module Communications Interface Module Controller DataCORDER Module Controller Key Pad Remote Monitoring Receptacle 2 1 8 Communications Interface Module The communications interface module is a slave mod ule that allows communication with a master central monitoring station The module will respond to commu nication and return information over the main power line Refer to the master system technical manual for further information 10 Controller Battery Pack Standard Location 11 Interrogator Connector Box Location 12 Control Transformer 13 High Speed Evaporator Fan Contactor EF 14 Low Speed Evaporator Fan Contactor ES 15 Condenser Fan Contactor CF 16 Circuit Breaker 460V 17 Current Sensor Module Figure 2 6 Control Box Section T 340 2 2 REFRIGERATION SYSTEM DATA Model Number ZMD26KVE TFD 272
48. repeat the test the UP ARROW to skip to the next test or the PRE TRIP key to terminate test ing The unit will wait indefinitely or until the user manually enters a command T 340 CAUTION When test Auto 2 runs to comple tion without being interrupted the unit will terminate pre trip and display Auto 2 end Theunit will suspend operation until the user depresses the ENTER key When an Auto 1 runs to completion without a failure the unit will exit the pre trip mode and return to normal control operation However dehumidification and bulb mode must be reactivated manually if required TO RUN AN INDIVIDUAL TEST Scroll through the selections by pressing the UP ARROW or DOWN ARROW keys to display an individual test code Pressing ENTER when the desired test code is displayed 1 Individually selected tests other than the LED Display test will perform the operations necessary to verify the operation of the component At the conclusion PASS or FAIL will be displayed This message will remain displayed for up to three minutes during which time a user may select another test If the three minute time period expires the unit will terminate pre trip and return to control mode operation While the tests are being executed the user may terminate the pre trip diagnostics by pressing and holding the PRE TRIP key The unit will then resume normal operation If the user decides to terminate a test but remai
49. set point Failure action D all machinery off is triggered if the unit has a frozen set point 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 50C to 70 58F to 158 This alarm triggers the failure action code set by Func tion Code Cd29 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 read ings 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 Alarm 28 is triggered if evaporator pressure is invalid This alarm triggers shut down of the compressor off for three minutes This alarm will be inactivated when suction pressure rises above 2 psia for three continuous minutes Alarm 29 is triggered if CO2 or O2 level is outside of the limit range and the vent position is at 10096 for longer than 90 minutes Alarm LED will be activated and user intervention is required The alarm is triggered off when atmospheric condi tions are within limit settings Alarm 50 is activated whenever the sensor is outside the valid range There is a four minute adjustment period where the user can change the vent position with out generating an alarm eve
50. set the controller set point to 25C 13F Partially block the condenser coil inlet air Increase the area blocked until the compressor discharge pressure is raised to approximately 12 8 bar 185 psig Onunits equipped with a receiver the level should be between the glasses On units equipped with a water cooled condenser the level should be at the center of the glass If the refrigerant level is not correct contin ue with the following paragraphs to add or remove re frigerant as required Adding Refrigerant to System Full Charge Evacuate unit and leave in deep vacuum Refer to paragraph 6 3 4 Place cylinder of R 134a on scale and connect charg ing line from cylinder to liquid line valve Purge charg ing line at liquid line valve and then note weight of cyl inder and refrigerant 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 refer to paragraph 2 2 has been added as indicated by scales T 340 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 Backseat manual liquid line valve to close off gauge port Close liquid valve on cylinder Start unit in cooling mode Run for approximately 10 minutes and check the refrigerant charge Adding Refrigerant to System Partial Ch
51. there is a fault Hecorder Supply with this sensor Temperature Out of Range NOTE The P5 Pre Trip test must be run to inactivate the alarm The return recorder sensor reading is outside of the range of 50C to 70C 58F to 158F or the probe check logic has determined there is a fault Recorder Return with this sensor Temperature Out of Range NOTE The P5 Pre Trip test must be run to inactivate the alarm dAL72 74 USDA Temperatures USDA probe temperature reading is outside of 50C to 70C 1 2 3 Out of Range 58F to 158F range dAL75 Cargo Probe 4 Out of The cargo probe temperature reading is outside of 50C to 70C Range 58F to 158F range dAL76 77 Future Expansion These alarms are for future expansion and are not in use at this time The network data point is outside of its specified range The DataCORD ER is configured by default to record the supply and return recorder sen sors The DataCORDER may be configured to record up to eight addition al network data points An alarm number AL78 to AL85 is assigned to each configured point When an alarm occurs the DataCORDER must be interrogated to identify the data point assigned When a humidity sensor is installed it is usually assigned to AL78 The real time clock RTC backup battery is too low to adequately main dAL86 RTC Battery Low tain the RTC reading An invalid date or time has been detected This situation may be corrected dAL87 RTC Failure
52. tubing and change the filter drier Evacuate unit to 500 microns Close the electronic vacuum gauge and vacuum pump valves Shut offthe vacuum pump Wait five minutes to see if vacuum holds This procedure checks for residual moisture and or leaks With a vacuum still in the unit the refrigerant charge may be drawn into the system from a refrigerant con tainer on weight scales Procedure Partial System If refrigerant charge has been removed from the low side only evacuate the low side by connecting the evacuation set up at the compressor suction valve and the liquid service valve but leave the service valves frontseated until evacuation is completed Once evacuation has been completed and the pump has been isolated fully backseat the service valves to isolate the service connections and then continue with checking and if required adding refrigerant in accordance with normal procedures 6 3 5 Refrigerant Charge 5 Checking Refrigerant Charge NOTE Use a refrigerant recovery system whenever removing refrigerant When working with refrig erants you must comply with all local govern ment environmental laws In the U S A referto EPA Section 608 Connect the gauge manifold to the compressor dis charge and suction service valves For units operat ing on a water cooled condenser change over to air cooled operation Bring the container temperature to approximately OC S2F or below Then
53. will auto repeat by starting P8 0 over Setup The defrost temperature sensor DTS reading 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 until the DTT is considered closed Once the DTT is considered closed the unit simulates defrost by running the heaters for up to two hours or until the DTT is considered open Pass Fail Criteria The test fails if the DTT is not considered closed after the 30 minutes of full cooling HTT opens when DTT is considered closed or if return air temperature rises above 49C 120F Setup If the container temperature is below 7 2C 45F the set point is changed to 7 2C and a 180 minute timer is started The control will then be placed in the equivalent of normal heating If the container temperature is above 7 2C at the start of the test then the test proceeds immediately to test 10 1 During this test the control temperature will be shown in the right display Pass Fail Criteria The test fails if the 180 minute timer expires before the con trol temperate reaches set point 0 3C 0 17F If the test fails it will not auto re peat There is no pass display for this test Once the control temperature reach es set point the test proceeds to test 10 1 Requirements Control temperature must be at least 7 2C 45F Setup The set point is changed to 17 8C OF The system will then attempt to pull down the cont
54. will energize and perform a software battery voltage check before DataCORDER logging If either test fails the real time clock battery power up will be disabled until the next AC power cycle Further DataCORDER temperature logging will be prohibited until that time An alarm will be generated when the battery voltage transitions from good to bad indicating that the battery pack needs recharging If the alarm condition persists for more than 24 hours on continuous AC power the battery pack needs replacement 3 7 9 Pre Trip Data Recording The DataCORDER will record the initiation of a pre trip test refer to paragraph 3 6 and the results of each of the tests included in pre trip The data is time stamped and may be extracted via the Data Retrieval program Refer to Table 3 9 for a description of the data stored in the DataCORDER for each corresponding Pre Trip test 3 7 10 DataCORDER Communications Data retrieval from the DataCORDER can be accomplished by using one of the following DataReader DataLINE DataView or a communications interface module NOTE A DataReader DataLINE DataView or a com munications interface module display of Com munication Failed is caused by faulty data transfer between the DataCORDER and the data retrieval device Common causes include 1 Badcable or connection between DataCORDER and data retrieval device 2 communication port s unavailable or misassigned 3 Chart Recorder Fuse FCR blow
55. 1 P4 0 and P4 1 will fail immediately if Controller alarm codes AL11 or AL12 are active at the start of testing Evaporator Fan Motors On Pass Fail Criteria Passes if change in current draw is within the range speci fied Fails if AL11 or AL12 activates during test for units operating with single fan only Setup The Low Speed Evaporator fan is turned off a current draw test is done Low Speed after 10 seconds Evaporator Fan Pass Fail Criteria Passes if change in current draw is within the range speci Motors Off fied Fails if AL11 or AL12 activates during test for units operating with single fan only Setup The high speed evaporator fan is turned on a current draw test is done High Speed after 60 seconds Evaporator Fan Pass Fail Criteria Passes if change in current draw is within the range speci Motors On fied Fails if AL11 or AL12 activates during test for units operating with single fan only High Speed Setup The high speed evaporator fan is turned off a current draw test is done g gt p after 10 seconds Pass Fail Criteria Passes if change in current draw is within the range speci fied Fails if AL11 or AL12 activates during test Evaporator Fan Motors Off Setup The High Speed Evaporator fans will be turned on for 10 seconds then Low Speed off for two seconds then the low speed evaporator fans are turned on A current P3 0 p draw test is done after 60 seconds 3 27 T 340 Table 3 7 Controller Pre Trip Te
56. 1 1 186 reos me D n irr pe PE Lc rs i 1 1 Tor Interrogator ii e RE een wh ve etc oe 1 1 1 3 8 Remote Monitoring teen I eet IDE ber ed 1 1 1 9 9 Communications ir mE RUE an eS RR UC ERR RE EY Ree D RAD e DET RR 1 1 1 9 10 COmpreSSOF c cnm ooo eua See dune Um dec ge te 1 1 1 9 11 Gondenser Coll oi E eL m eer tp 1 1 1 9 12 A totransformer loda ce CRM esq 1 2 1 3 13 Becorder pest eke E CURE Te ep TR 1 2 1 3 14 d eR RA ERA Ap re A e AREA 1 2 1 315 Thermometer Port eR EUER PERO EDU bes hee EE eg US 1 2 1 3216 Cooling e epo ee we x 1 2 1321 7 Back Panels im de een DIC ador d dd ee aei enden uo 1 2 1 3 18 460 Volt Cable x RACE EDU pete etr Mate Petite or E Mate ra cR TR 1 2 19 19 230 Vot Cable RR qtue 1 2 1 3 20 Cable Restraint nece oni Se TUE Dep Per tes adeeb eed E ES 1 2 1 3 21 Upper Air Fresh Air Make Up 1 2 1 3 22 Lower Air Fresh Air Make Up
57. 1 Temperature Control System 3 1 Figure 3 2 Keypad erret no oe 3 2 Figure 3 3 Display Module 3 3 Figure 3 4 Control 2 4 4 3 3 Figure 3 5 Controller Operation Perishable Mode 3 5 Figure 3 6 Perishable Mode Cooling 000 cece ete eee 3 5 Figure 3 7 Perishable Mode Heating 1 1 14 4 4 3 6 Figure 3 8 Controller Operation Frozen 3 8 Fig re 3 9 Erozen Mode ERE einen ted 3 8 Figure 3 10 Defrost ore rne esr ewe x Y Recte wa Ain a Y Aet e Wu d a 3 10 Figure 3 11 Standard Configuration Download Report 3 13 Figure 3 12 Data Reader ise eee ee dede vec bee ps 3 15 Figure 4 1 Autotransformer 4 1 Figure 6 1 Manifold Gauge Set 6 1 Figure 6 2 R 134a Manifold Gauge Hose Set 6 1 Figure 6 3 Service Valve
58. 3 16 3 33 DataCORDER Communications 3 14 DataCORDER Function Codes 3 31 DataCORDER Pre Trip Codes 3 32 DataCORDER Software 3 11 DataReader 3 14 INDEX DataView 3 15 Defrost Interval 3 9 Defrost Mode Sequence of Operation 3 9 Digital Unloader Valve 6 12 Display Module 3 2 E Economized Operation Refrigeration Circuit 2 10 Economizer Expansion Valve 6 11 Electrical Data 2 8 Electronic Expansion Valve 2 10 6 10 Evacuation 6 3 Evaporator 2 2 6 9 Evaporator Fan 6 9 Evaporator Fan Operation 3 10 F Failure Action 3 10 Filter Drier 6 9 Fresh Air Makeup 2 1 Frozen Pulldown Mode 3 7 Frozen Mode Conventional 3 7 Frozen Mode Economy 3 7 Frozen Mode Cooling Sequence of Operation 3 8 Frozen Mode Temperature Control 3 7 G Generator Protection 3 10 H Heat Lockout 3 4 3 7 Heater 6 9 High Pressure Switch 6 6 High Temperature Low Pressure Protection 3 10 Inspection 4 1 ISO Trip Header 3 16 Index 1 T 340 INDEX Continued K Keypad 3 2 L Liquid Injection Valve Operation 2 10 Logging Interval 3 12 Lower Fresh Air Makeup Vent 4 2 Manifold Gauge Set 6 1 Microprocessor System 3 1 Modes of Operation 3 10 O Operational Software 3 3 3 12 Option Description 1 1 P Painted Surfaces 6 24 Perishable System Pressure Regulation 3 10 Perishable Mode Bulb 3 7 Perishable Mode Dehumidification 3 6 Perishable Mode Cooling Seq
59. 4 3 3 1 Start up Compressor Phase Sequence 3 4 3 3 2 Start up Compressor Bump Start 3 4 3 3 3 Perishable Set Point Temperature Perishable Pulldown 3 4 3 3 4 Perishable Set Point Temperature Conventional Temperature Control Mode 3 4 3 3 5 Perishable Set Point Temperature Economy Mode 3 4 3 3 6 Perishable Set Point Temperature Control 3 4 3 3 7 Perishable Mode Cooling Sequence of Operation 3 5 3 3 8 Perishable Mode Heating Sequence of Operation 3 6 3 3 9 Sequence of Operation Perishable Mode Capacity Trim Heat 3 6 3 3 10 Perishable Mode 0 00 cece e 3 6 3 3 11 Perishable Dehumidification Bulb Mode 3 7 3 3 12 Frozen PulldOWN ee 3 7 3 3 13 Frozen Mode Temperature Control 3 7 3 3 14 Frozen Mode Conventional 3 7 3 3 15 Frozen Mode Heat Lockout Temperature 3 7 3 3 16 Frozen Mode Economy Y RR E
60. 555 555555555555 5555 555555555555 5555 lt lt NTN M 55555 555555525552 SS eS SENSN 5555555 SORES SS XN 5552555 55 99 555555555 555555555555 555555 555555555555 5555 55 555 5552555 555555555555 55555 SS SATS SS 5559 74 WoO SSS PRT SS 555555 555555555 555 55 SSS Ie 555555555556 555555559555 SES 555555555 SS 5 SSS SSS SSS SSS SSE SSO 9997 NS gt 240 oS Evaporator Fan Motor 1 EM1 Return Recorder Sensor Temperature Sensor RRS RTS Humidity Sensor HS Evaporator Fan Motor 2 EM2 Evaporator Coil Evaporator Coil Heaters Underside of Coil Heater Termination Thermostat HTT Defrost Temperature Sensor DTS N gt 9 Electronic Expansion Valve EEV 10 Evaporator Temperature Sensors Location ETS1 amp ETS2 11 Interrogator Connector Rear ICR 12 USDA Probe Receptacle PR2 13 USDA Probe Receptacle PR1 14 USDA Probe Receptacle PR3 15 Cargo Probe Receptacle PR4 Figure 2 2 Evaporator Section T 340 2 1 4 Compressor Section pressure transducer EPT and the suction pressure transducer SPT The compressor section includes the compressor The supply temperature sensor supply recorder sensor digital unloader valve DUV high pressure switch and ambient sensor are located to the left of the com discharge pressure transducer DP
61. 6 is triggered if an evaporator pressure transducer is less than 0 2 volts or greater than 4 95 volts When alarm 66 is triggered on use the Suction port pressure to calculate superheat Alarm is triggered off when evaporator pressure sensor is back in range Humiditv Sensor Alarm 67 is triggered by a humidity sensor reading outside the valid range of 0 AL67 Failure y to 10026 relative humidity If alarm AL67 is triggered when the dehumidification mode is activated then the dehumidification mode will be deactivated AL68 Condenser Pressure Alarm 68 is triggered when the Condenser Pressure Sensor is out of range This Sensor Fault is a display alarm and has no associated failure action Alarm 69 is triggered when the primary evaporator temperature sensor ETS1 is out of range The controller switches to use of the secondary evaporator temper ature sensor ETS2 This is a display alarm and triggered off when ETS1 is back within range Evaporator Pressure AL66 Transducer Out of Range Primary Evaporator AL69 Temperature Sensor Out of Range NOTE If the controller is configured for four probes without a DataCORDER the DataCORDER alarms AL70 and AL71 will be processed as Controller alarms AL70 and AL71 Refer to Table 3 10 page 3 33 The controller performs self check routines If an internal failure occurs an ERR alarm will appear on the display This is an indication the controller needs to be replaced ERROR DESCRIPTIO
62. ALARMS Alarm display is an independent controller software function If an operating parameter is outside of expected range or a component does not return the correct signals back to the controller an alarm is generated A listing of the alarms is provided in Table 3 6 page 3 23 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 have time delays before and after to try to keep the compressor on line An example is alarm code LO low main voltage when a voltage drop of over 2596 occurs an indication is given on the display but the unit will continue to run When an Alarm Occurs a The red alarm light will illuminate for alarm code num bers 15 17 20 21 22 23 24 25 26 and 27 b If a detectable problem exists its alarm code will be alternately displayed with the set point on the left display c The user should scroll through the alarm list to determine what alarms exist or have existed Alarms must be diagnosed and corrected before Alarm List can be cleared To Display Alarm Codes a While in the Default Display mode press the ALARM LIST key This accesses the Alarm List Display Mode which displays any alarms archived in the alarm queue b The alarm queue s
63. ATAREADER DataCORDER SOFTWARE It ft N gos CONFIGURATION OPERATIONAL ALARMS STORAGE SOFTWARE SOFTWARE AL gt 68 MEMORY aE ne t t l Software CONFIGURATION FUNCTION TO TO VARIABLE CODE dc DISPLAY DISPLAY J DATABANK CARD dCF read only Scrollback Figure 3 1 Temperature Control System 3 1 T 340 3 1 4 Keypad NOTE The controlling probe in the perishable range The keypad Figure 3 2 is mounted on the right hand side of the control box The keypad consists of eleven will be the SUPPLY air probe and the controlling push button switches that act as the user s interface probe in the frozen range will be the RETURN with the controller Descriptions of the switch functions air probe are provided in Table 3 1 Table 3 1 Keypad Function FUNCTION Code 5 Pre Tri Displays the pre trip selection menu Discontinues pre trip in progress Displays alarm list and clears the Manual Displays selected defrost mode De Defrost pressing and holding the Defrost in Interval terval key for five b seconds will ini tiate defrost using the same logic as if the optional manual defrost switch was toggled on Enter Confirms a selection or saves a selection to the controller Change or scroll a selection upward Pre trip advance or test interruption Change or scroll a selection down ward P
64. Capability CnF32 set to 1EFO the alarm is triggered by opening of both internal protectors It will disable all control units until a motor protector resets Alarm 23 is triggered if low current draw is detected on phase B and IPCP HPS or IPEM is not tripped If the compressor should be running the controller will ini tiate a start up every five minutes and trigger off if current reappears If the evap orator fan motors only should be running the alarm will trigger off if current reap pears This alarm triggers failure action C evaporator fan only or D all machin ery off of Function Code Cd29 if the unit has a perishable set point Failure ac tion D all machinery off is triggered if the unit has a frozen set point Alarm 24 is triggered when compressor is not drawing any current It also triggers failure action C or D set by function Code 29 for perishable set point or D for frozen set point If the compressor should be running the controller will initiate a start up every five minutes and trigger off if current reappears This alarm will re main active until compressor draws current 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 re main active until the motor protector resets This alarm triggers failure action C evaporator fan only or D all machinery off of Function Code Cd29 if the unit has a perishable
65. Closed o will again be displayed and the user may continue to scroll through the various codes This code indicates the dash number of the model for which the Controller is con Cd20 Config Model figured i e if the unit is G9NT40 551 100 the display will show 51100 EM The status of the valve is displayed Open Closed Cd22 The status of the compressor is displayed Off On Cd23 Displays the current evaporator fan state high low or off Controlled re on Atmosphere State Not used in this application 3 19 T 340 A Table 3 5 Controller Function Codes Sheet 2 of 4 Compressor Run This code displays the time remaining until the unit goes into defrost in tenths of Cd25 Time Remaining an hour This value is based on the actual accumulated compressor running Until Defrost time Cd26 Defrost temperature sensor reading is displayed Configurable 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 There are two modes for defrost initiation user selected timed intervals or auto matic control The user selected values are OFF 3 6 9 12 24 hours or AUTO The factory default is AUTO Automatic defrost starts with an initial defrost at three hours then the interval to the next defrost is adjusted based on the accu
66. Container Refrigeration OPERATION AND SERVICE for 69NT40 561 001 to 199 Container Refrigeration Units T 340 TRANSICOLD OPERATION AND SERVICE MANUAL CONTAINER REFRIGERATION UNIT Models 69NT40 561 001 to 199 TABLE OF CONTENTS PARAGRAPH NUMBER Page GENERAL SAFETY NOTICES Safety 1 FIRST AID oi erinnern etie eem i ree e Safety 1 OPERATING PRECAUTIONS v cte ver te bering um reper rb nets ads Safety 1 MAINTENANCE PRECAUTIONS Safety 1 SPECIFIC WARNING AND CAUTION STATEMENTS Safety 1 INTRODUCTION ed desea dE 1 1 1 4 INTRODUCTION ida dec See nde ee 1 1 12 CONFIGURATION IDENTIFICATION 2 1 1 1 9 OPTION DESCRIPTION ee Ret bles RO Reate rA e AUR DR UL E Re RR S 1 1 1 31 Battery oce eee hoe Debe tore ope Ee 1 1 1 3 2 Dehumidification ci eR e E ex AL RICE EG denas 1 1 123292 Control BOX dades I EBD CI PEU EE UE 1 1 1 3 4 Temperature ico Shane doko She 1 1 1 3 5 Pressure Readout aie eee een
67. DO SIs 59 PNE eos 56 M25 js 15 ln 585 i RTS 1 GRN CGRNZYEL oe NY e 54 Epl Zaz EE AMBS b x X X Goot OEYUTO 2 lt e I FES 50 Ps st 8 4 62 6 52 26 KAS l D EE ESLI N ECH3 HRL2 ue ECY3 ESL2 T 2 N pU Ec Co ESL3 N 5 5 ecee gee cae wep ORS eei 2060 SG TI 5 81 Ecy2 OE DAGE TRX2 s 2 9 696 fa Gy fep bases X aA Ee 58556 EFL1 2 east 9 ER m 3 ge ES PAL2 e PAT2 EFL2 62 5 EFL3 S PALI 25 i 5 N S S NE N Pee PY TL Ma uis up 88 omar a ii eoe due ode EFA2 nN m 4 lt gt glg g 8 ond 3 1 KAS zh 2 zl eem 28888 a 2 Doo re DO M m E E CHL2 Re
68. EATING Controller improperly set Controller malfunction Heater termination thermostat remains closed along with the heat relay 5 6 UNIT WILL NOT DEFROST PROPERLY Defrost timer malfunction Cd27 Table 3 5 Loose terminal connections Tighten Will not initiate defrost Defective wiring automatically Defrost temperature sensor defective or heat termination thermostat open P RE SET Tighten m Unit fails to stop heating o 4 o T 340 5 2 REMEDY CONDITION POSSIBLE CAUSE REFERENCE SECTION 5 7 UNIT WILL NOT DEFROST PROPERLY Continued d Heater contactor or coil defective Replace nitiates but does not defros Heater s burned out 6 10 Frequent defrost Wet load Normal 5 8 ABNORMAL PRESSURES COOLING 67 T 69 Filter drier partially plugged Low refrigerant charge 6 Low suction pressure No evaporator air flow or restricted air flow 6 6 Excessive frost on evaporator coil 5 se eee ren sures tend to equalize when uni 5 operating 5 9 ABNORMAL NOISE OR VIBRATIONS Compressor start up after an extended shutdown Normal Brief chattering when manually shut down Compressor operating in reverse Compressor 5 Loose mounting bolts or worn resilient mounts Tighten Replace Condenser or Evaporator Fan 5 10 MICROPROCESSOR MALFUNCTION 5 3 340 5 11 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW
69. G INSTRUCTIONS AX WARNING Make sure that the unit circuit breaker s CB 1 amp CB 2 and the START STOP switch ST are in the O OFF position before connecting to any electrical power source 4 6 1 Starting the Unit a With power properly applied the fresh air vent posi tion set and if required the water cooled condenser connected refer to paragraphs 4 2 4 3 amp 4 4 place the START STOP switch to 4 ON NOTE The electronic phase detection system will check for proper compressor rotation within the first 30 seconds If rotation is not correct the compressor will be stopped and restarted in the opposite direction If the compressor is produc ing unusually loud and continuous noise after the first 30 seconds of operation stop the unit and investigate b The Controller Function Codes for the container ID 40 software version Cd18 and unit model num ber Cd20 will be displayed in sequence c Continue with Start Up Inspection paragraph 4 7 4 6 2 Stopping the Unit To stop the unit place the START STOP switch in posi tion 0 OFF 4 7 START UP INSPECTION 4 7 1 Physical Inspection a Check rotation of condenser and evaporator fans 4 7 2 Check Controller Function Codes Check and if required reset controller Function Codes Cd27 through Cd39 in accordance with desired oper ating parameters Refer to Table 3 5 4 7 3 Start Temperature Recorder Partlow Recorders a Open rec
70. ID this will cause spattering and excessive heat 1 Pump support 7 Vent WARNING 2 Tank 8 Close vent pipe valve 3 Suction when pump is running Wear rubber gloves and wash the solution 4 Pump 9 Condenser from the skin immediately if accidental con 5 Priming Connection 10 Remove water tact occurs Do not allow the solution to splash onto concrete Centrifugal pump regulating valve 50 gpm at 35 head 11 Return 6 Globe valves 12 Fine mesh screen 5 Fill the tubes with this solution by filling from the bot tom See Figure 6 7 Figure 6 7 Water Cooled Condenser Cleaning Forced Circulation 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 Oakite No 22 thru the tubes to neutralize Drain this NOTE It is important to provide a vent at the top for escaping gas Allow the Oakite No 32 solution to soak in the tube coils for several hours periodically pump circulating it with an acid proof pump An alternate method may be used whereby a pail see Figure 6 8 filled with the solution and attached to the coils by ahose can serve the same purpose by filling and draining The solution must contact the scale at every point for thorough de scaling Air solution 10 Flush the tubes thoroughly with fresh water NOTE If the condenser cooling water is not being used a
71. ING Make sure the power plugs are clean and dry before connecting to power receptacle WARNING Make sure that the unit circuit breaker s CB 1 amp CB 2 and the START STOP switch ST are in the O OFF position before connecting to any electrical power source AX WARNING Never use air for leak testing It has been determined that pressurized air rich mix tures of refrigerants and air can undergo combustion when exposed to an ignition source 44 WARNING Make sure power to the unit is OFF and power plug disconnected before replacing the compressor 44 WARNING Before disassembly of the compressor be sure to relieve the internal pressure very carefully by slightly loosening the cou plings to break the seal 44 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 WARNING Do not open the condenser fan grille before turning power OFF and disconnecting power plug 44 WARNING Do not open condenser fan grille before turning power OFF and disconnecting power plug 44 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 44 WARNING Wear rubber gloves and wash the solution from the skin immediately if accidental con tact occurs Do not allow the solution to splash onto concrete
72. LOW 5 4 5 12 ELECTRONIC EXPANSION VALVE 5 4 5 13 AUTOTRANSFORMER MALFUNCTION 5 4 5 14 WATER COOLED CONDENSER OR WATER PRESSURE SWITCH 5 4 5 15 COMPRESSOR OPERATING IN REVERSE 5 5 5 16 ABNORMAL TEMPERATURES 5 5 5 17 ABNORMAL CURRENTS talker ties 5 5 cld 4 e cm 6 1 6 1 SECTION LAYOUT REPE bree Keep E E Rove a 6 1 6 2 MANIFOLD GAUGE SET 1 21 24 4 4 6 1 6 3 REFRIGERATION SYSTEM SERVICE UNITS WITH STANDARD PIPING with Service Valves 6 2 6 3 1 Service Connections 6 2 6 3 2 Pumping Down the Unit 1 2 6 2 6 3 8 Refrigerant Leak Checking 6 3 6 3 4 Evacuation and Dehydration 2 7 6 3 6 3 5 Refrigerant Charge 4 6 4 6 4 COMPRESSOR gels ine wee ine TELE Er 6 4 6 4 4 Removal and Replacement of Compressor
73. N ERR 0 RAM failure Indicates that the controller working memory has failed ERR ee Memory Indicates a problem with the controller program ERR 2 Watchdog The controller program has entered a mode whereby time out the controller program has stopped executing ERR 3 N A ERR 4 N A ERR 5 A D failure Analog to Digital converter has internal ERR 6 IO Board failure Internal program update failure Microprocessor ERR 7 Controller failure Internal version firmware incompatible Faure ERR Internal DataCORDER memory failure ERR 9 Controller failure Internal controller memory failure In the event that a failure occurs and the display cannot be updated the status LED will indicate the appropriate ERR code using Morse code as shown below E ERRO ERR1 ERR2 ERR3 ERR4 ERR5 ERR6 ERR7 ERR8 ERRQ Entr Enter Set point StPt Press Arrow amp The controller is prompting the operator to enter a set point Enter Low Main Voltage LO Ed This message will be alternately displayed with the set point whenever the supply and NO alarm voltage is less than 7596 of its proper value stored T 340 3 26 Table 3 7 Controller Pre Trip Test Codes Sheet 1 of 4 TITLE DESCRIPTION NOTE Auto or Auto1 menu includes the PO P1 P2 P3 P4 P5 P6 and rSLts Auto2 menu in cludes PO P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 and rSLts Auto3 menu includes PO P1 P2
74. ON When Pre Trip key is pressed economy dehumidification and bulb mode will be deactivated At the completion of Pre Trip activity economy dehumidification and bulb mode must be reactivated CAUTION When a failure occurs during automatic testing the unit will suspend operation awaiting operator intervention CAUTION When test Auto 2 runs to comple tion without being interrupted the unit will terminate pre trip and display Auto 2 end Theunit will suspend operation until the user depresses the ENTER key CAUTION Allowing the scroll compressor to operate in reverse for more than two minutes will re sult in internal compressor damage Turn the start stop switch OFF immediately CAUTION To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suction pressure before disconnecting CAUTION The scroll compressor achieves low tion pressure very quickly Do not operate the compressor in a deep vacuum internal damage will result CAUTION The scroll compressor achieves low suc tion pressure very quickly Do not use the compressor to evacuate the system below 0 psig Never operate the compressor with the suction or discharge service valves closed frontseated Internal damage will result from operating the compressor in a deep vacuum Safety 3 CAUTION Take necessary steps place plywood over
75. ORDER Standard Configurations Standard GCro2 gt 2 thermistor inputs Supply amp return 5 sensors 2 thermistor inputs supply amp return dCFO2 5 3 USDA thermistor inputs 2 thermistor inputs Supply amp return 3 USDA thermistor inputs 1 humidity input 9 sensors dCF02 9 Not Applicable 2 thermistor inputs supply amp return 3 USDA thermistor inputs 1 cargo probe thermistor input 2 thermistor inputs supply amp return 3 USDA thermistor inputs 1 humidity input 1 cargo probe thermistor input 2 thermistor inputs supply amp return 3 USDA thermistor inputs ACR O2 94 1 humidity input 1 cargo probe thermistor input 3 C A inputs NOT APPLICABLE 3 7 6 Sampling Type 4 5 amp dCFO6 Three types of data sampling are available average snapshot and USDA When configured to average the average of readings taken every minute over the recording period is recorded When configured to snapshot the sensor reading at the log interval time is recorded When USDA is configured the supply and return temperature readings are averaged and the three USDA probe readings are snapshot 3 7 7 Alarm Configuration dCF07 dCF10 The USDA and cargo probe alarms may be configured to OFF ON or AUTO If a probe alarm is configured to OFF the alarm for this probe is always disabled If a probe alarm is configured to ON the associated alarm is always enabled If the probes are configured t
76. P3 P4 P5 P6 P7 and P8 All lights and display segments will be energized for five seconds at the start of Pre Trip Initiated 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 Setup Heater must start in the OFF condition and then be turned on A current 1 0 Heaters Turned On draw test is done after 15 seconds Pass Fail Criteria Passes if current draw change is within the range specified Setup Heater must start in the ON condition and then be turned off A current m reae Turned Off draw test is done after 10 seconds Pass Fail Criteria Passes if current draw change is within the range specified Requirements Water pressure switch or condenser fan switch input must be closed 2 0 Fan On Setup Condenser fan is turned ON a current draw test is done after 15 seconds Pass Fail Criteria Passes if current draw change is within the range specified Setup Condenser fan is turned OFF a current draw test is done after Condenser Fan Off 10 seconds Pass Fail Criteria Passes if current draw change 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 Low Speed NOTE FANS If the unit is configured for single evaporator fan operation Pre Trip tests P3 0 P3
77. PBT3 eua a 94945 S CHLI N mor o TE a 8 Bog wd gt lt lt MS 4 amp Cay z5 EM 50 558 3 39 esse JJ LESI HHHH i 5 JIJR m O u o o w 5 FRAG m 5 m 9 Nx oc n lt T RED TAN 1 l 4 I C822 PAL2 ORN amp BLK 4 PATS nee BLK RED Exo BLU lox m E CB21 PAL1 599 l Figure 7 4 UNIT SCHEMATIC DIAGRAM Sheet 1 of 2 7 4 T 340 DISPLAY MODULE BATTERY 393 1393 gt lt 14 g G amp 2e493 l gt gt ENIJ inoa 3 9 Se 5 EH23 o L zuo3 o gt L i93 IOS IE m RUE y VENTUM P l l l B l KEYPAD COMMUNICATIONS CONTROLLER 1 INTERFACE MODULE l MAINS POWER 795 FUSE 2 EQUIPPED HTT mm Mas I ee 2 Praa ESV 9 I 5 e
78. SSOR SYSTEM The temperature control Micro Link 3 microprocessor system see Figure 3 1 consists of a keypad display module the control module controller interconnecting wiring The controller houses the temperature control software and the DataCORDER software Thetemperature control software functions to operate the unit components as required to provide the desired cargo temperature and humidity The DataCORDER software functions to record unit operating parameters cargo temperature parameters for future retrieval Coverage of the temperature control software begins with paragraph 3 2 Coverage of the DataCORDER software is provided in paragraph 3 7 The keypad and display module serve to provide user access and readouts for both of the controller functions temperature control and DataCORDER The functions are accessed by keypad selections and viewed on the display module The components are designed to permit ease of installation and removal e o CONTROL MODULE tL TEMPERATURE CONTROL SOFTWARE CONFIGURATION FUNCTION TO DISPLAY CONFIGURATION OPERATIONAL ALARMS PRE TRIP SOFTWARE SOFTWARE AL 70 DISPLAY MODULE fo e e INTERROGATION CONNECTOR A P ala U D
79. SURE PRESSURE LIQUID LINE TRANSDUCER TRANSDUCER SERVICE lt _ VALVE SUCTION RECEIVER SERVICE VALVE STANDARD OPERATION WITH WATER COOLED CONDENSER EVAPORATOR COMPRESSOR ammi ETS1 1 gt ETS2 ELECTRONIC EXPANSION VALVE CONDENSER DIGITAL UNLOADER VALVE LIQUID INJECTION VALVE DISCHARGE TEMPERATURE ECONOMIZER SENSOR SOLENOID VALVE T DISCHARGE SERVICE ECONOMIZER VALVE TXV EVAPORATOR DISCHARGE ks PRESSURE DRIER TRANSDUCER ECONOMIZER TRANSDUCER SUCTION MOISTURE PRESSURE INDICATOR SIGHT TRANSDUCER LIQUID LINE lt GLASS SUCTION SERVICE SERVICE VALVE VALVE WATER COOLED CONDENSER mm COMPRESSOR DISCHARGE LIQUID SUCTION Figure 2 7 Refrigeration Circuit Schematic Standard Operation T 340 2 11 T3 ECONOMIZER SOLENOID VALVE ECONOMIZER TXV LIQUID LINE LIQUID INJECTION ECONOMIZER SERVICE VALVE RECEIVER ELECTRONIC EXPANSION VALVE COMPRESSOR LIQUID ECONOMIZER PRESSURE T 340 Figure 2 8 Refrigeration Circuit Schematic Economized Operation SECTION 3 MICROPROCESSOR 3 1 TEMPERATURE CONTROL MICROPROCE
80. SYMBOL DESCRIPTION HR HS HTT HEATER CONTACTOR P 4 M 13 HUMIDITY SENSOR OPTIONAL F 21 HEAT TERMINATION THERMOSTAT G 13 INTERROGATOR CONNECTOR FRONT T 21 INTERROGATOR CONNECTOR REAR T 22 INTERNAL PROTECTOR E 12 H 10 H 12 IN RANGE LIGHT L 14 LIQUID INJECTION SOLENOID VALVE K 10 UNIT PHASE CONTACTOR L 1 6 UNIT PHASE CONTACTOR L 3 M 7 USDA PROBE RECEPTACLE E 21 L 22 M 22 REMOTE MONITORING RECEPTACLE OPTION L 6 M 6 L 11 M 11 L 14 M 14 RETURN RECORDER SENSOR C 21 RETURN TEMPERATURE SENSOR B 21 SUCTION PRESSURE TRANSDUCER G 21 SUPPLY RECORDER SENSOR K 21 START STOP SWITCH G 4 G 5 SUPPLY TEMPERATURE SENSOR A 21 CONTROLLER RELAY COOLING H 7 TRANSFRESH COMMUNICATIONS CONNECTOR OPTION D 5 CONTROLLER RELAY COMPRESSOR PHASE SEQUENCING K 6 K 7 CONTROLLER RELAY HIGH SPEED EVAPORATOR FANS K 12 CONTROLLER RELAY HEATING K 13 IN RANGE RELAY F 14 CONTROLLER RELAY COOL LIGHT K 11 CONTROLLER RELAY CONDENSER FAN K 10 TEST POINT F 8 F 9 F 10 H 7 J 10 J 12 M 15 CONTROLLER RELAY LIQUID INJECTION E 9 TRANSFORMER M 3 AUTO TRANSFORMER 230 460 OPTION D 2 TRANSFRESH REAR CONNECTOR OPTION E 5 CONTROLLER RELAY ECONOMIZER SOLENOID VALVE E 9 CONTROLLER RELAY LOW SPEED EVAPORATOR FANS J 11 WETTING CURRENT RESISTOR OPTION H 10 WATER PRESSURE SWITCH OPTION D 10 Figure 7 1 LEGEND 7 1 T 340
81. T evaporator pressor 1 Compressor 9 Digital Unloader Valve DUV 2 Discharge Temperature Sensor CPDS 10 Evaporator Pressure Transducer EPT Location 11 Discharge Service Valve 3 Discharge Connection 12 High Pressure Switch HPS 4 Suction Connection Location 13 Suction Pressure Transducer SPT 5 Compressor Terminal Box 14 Suction Service Valve 6 Oil Drain Location 15 Supply Temperature Supply Recorder Sensor 7 Economizer Connection Assembly STS SRS 8 Discharge Pressure Transducer DPT Figure 2 3 Compressor Section 2 3 T 340 2 1 5 Air Cooled Condenser Section valve economizer solenoid valve ESV and sight The air cooled condenser section Figure 2 4 consists glass moisture indicator of the condenser fan condenser coil receiver liquid The condenser fan pulls air through the bottom of the line service valve filter drier fusible plug economizer coil and discharges it horizontally through the con liquid injection valve LIV economizer expansion denser fan grille 1 Grille and Venturi Assembly 9 Filter Drier 2 Condenser Fan 10 Economizer 3 Key 11 Liquid Injection Valve LIV 4 Condenser Fan Motor 12 Economizer Solenoid V
82. Table 3 6 Controller Alarm Indications 3 23 Table 3 7 Controller Pre Trip Test Codes 3 27 Table 3 8 DataCORDER Function Code Assignments 3 31 Table 3 9 DataCORDER Pre Trip Result Records 3 32 Table 3 10 DataCORDER Alarm Indications 3 33 Table 6 1 Valve Override Control Displays 6 14 Table 6 2 Sensor Temperature Resistance Chart 6 19 Table 6 3 Recommended Bolt Torque Values 4 6 24 Table 6 4 R 134a Temperature Pressure Chart 6 25 vii T 340 SAFETY SUMMARY GENERAL SAFETY NOTICES The following general safety notices supplement specif ic warnings and cautions appearing elsewhere in this manual They are recommended precautions that must be understood and applied during operation and mainte nance of the equipment covered herein The general safety notices are presented in the following three sec tions labeled First Aid Operating Precautions and Maintenance Precautions A listing of the specific warn ings and cautions appearing elsewhere in the manual follows the general s
83. able If the timer is not operating follow the above proce dureto display the timer Use an ARROW key to scroll to desired time interval and press ENTER to start the timer The above described sequence may be repeated during the timer cycle to change to another override T 340 Table 6 1 Valve Override Control Displays Left Display Controller Communications Codes Setting Codes Right Display Right Display Cd 41 SELCt CAP AUtO Capacity Mode Normal Control UnLd Economizer Closed ECOn Economizer Open PCnt Setting DUV Capacity Modulation EEV Setting Electronic Expansion Valve Normal Machinery Control CLOSE Closed 0 LIV AUto Liquid Valve Setting Normal Control CLOSE Closed OPEn Open 0 00 0 minutes O Seconds Override Timer In 30 second increments to 5 00 5 minutes 0 seconds T 340 6 14 6 17 AUTOTRANSFORMER 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 4 1 and locked in place Make sure that circuit breakers CB 1 and CB 2 are in the ON position If the circuit breakers do not hold check voltage supply There is no internal protector for this transformer design therefore no checking of the internal protec tor is required Using a voltmeter and with the primary supply circuit ON check the primary input voltage 460 VAC N
84. able and set the display module aside NOTE The battery wires must face toward the right Remove the old battery from the bracket and clean bracket surface Remove the protective backing from the new battery and assemble to the bracket Secure battery by inserting the wire tie from the back of the bracket around the battery and back through the bracket Reconnect the ribbon cable to display and re install the display Route the battery wires from the battery along the dis play harness and connect the red battery wire and one end of the red jumper to KA14 the other end of the red jumper wire to KA11 and the black wire to KA13 h Replace wire ties that were removed 6 19 VENT POSITION SENSOR SERVICE The fresh air vent position sensor alarm AL50 will oc cur if the sensor reading is not stable for four minutes or if the sensor is outside of its valid range shorted or open This can occur if the vent is loose or the panel is defective To confirm a defective panel assure that the wing nut is secure and then power cycle the unit If the alarm immediately reappears as active the panel should be replaced The alarm should immediately go inactive check the 4 minute stability requirement If the alarm reoccurs af ter the four minutes and the panel was known to have been stable then the sensor should be replaced In order to replace the VPS the panel must be removed and replaced with another upper f
85. active in order to clear the alarm list To clear the alarm list 1 Press the ALT MODE amp ALARM LIST keys 2 Press the UP DOWN ARROW key until CLEAr is displayed 3 Press the ENTER key The alarm list will clear and will be displayed 4 Press the ALARM LIST key AL will show on the left display and on the right display when there are no alarms in the list 5 Upon clearing of the alarm queue the alarm light will be turned off 3 7 14 ISO Trip Header DataLINE provides the user with an interface to view modify current settings of the ISO trip header through the ISO Trip Header screen The ISO Trip Header screen is displayed when the user clicks on the ISO Trip Header button in the Trip Functions Group Box on the System Tools screen F9 function Provides the user with a shortcut for manually triggering the refresh operation Before sending modified parameter values the user must ensure that a successful connection is established with the controller If the connection is established with the DataCORDER the current contents of the ISO Trip Header from the DataCORDER will be displayed in each field If the connection is not established with the DataCORDER all fields on the screen will be displayed as Xs If at any time during the display of the ISO Trip Header screen the connection is not established or is lost the user is alerted to the status of the connection After modifying t
86. afety notices FIRST AID An injury no matter how slight should never go unat tended Always obtain first aid or medical attention im mediately 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 openthe condenser fan grille or evaporator access panels before turning power off dis connecting and securing the power plug Be sure power is turned off before working on motors controllers solenoid valves and electrical control switches Tag circuit breaker and power supply to pre vent accidental energizing of circuit Do not bypass any electrical safety devices e g bridg ing an overload or using any sort of jumper wires Prob lems with the system should be diagnosed and any necessary repairs performed by qualified service per sonnel When performing any arc welding on the unit or contain er disconnect all wire harness connectors from the modules in both control boxes Do not remove wire har ness from the modules unless you are grounded to the unit frame with a sta
87. alues of the network data points as configured Data point 1 dC6 13 Points 1 8 Code 6 is generally the humidity sensor and its value is obtained from the controller once every minute dC14 ie Current reading of the cargo probe 4 dC15 19 Future Expansion 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 pro gram 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 An approximation of the number of logging days remaining until the Data dC28 Minimum Days Left CORDER starts to overwrite the existing data dC29 Days Stored Number of days of data that are currently stored in the DataCORDER 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 auto matically be generated on the next AC power up Press and hold ENTER key for five seconds to initiate a Trip Start Shows the current status of the optional battery pack dC31 Battery Test PASS Battery pack is fully charged FAIL Batte
88. alve ESV 5 Condenser Coil 13 Economizer Expansion Valve 6 Condenser Coil Cover 14 Service Access Valve 7 Receiver 15 Sight Glass Moisture Indicator 8 Sight Glass 16 Fusible Plug Figure 2 4 Air Cooled Condenser Section T 340 2 4 2 1 6 Water Cooled Condenser Section pansion valve economizer solenoid valve ESV and The water cooled condenser section Figure 2 5 con sists of a water cooled condenser sight glass rupture disc filter drier water couplings water pressure switch The water cooled condenser replaces the standard unit economizer liquid injection valve LIV economizer ex receiver moisture liquid indicator 1 Water Cooled Condenser 8 Economizer Expansion Valve 2 Rupture Disc 9 Coupling Water In 3 Moisture Liquid Indicator 10 Liquid Line Service Valve Connection 4 Filter Drier 11 Self Draining Coupling Water Out 5 Economizer 12 Water Pressure Switch WP 6 Liquid Injection Valve LIV 13 Sight Glass 7 Economizer Solenoid Valve ESV Figure 2 5 Water Cooled Condenser Section 2 5 T 340 2 1 7 Control Box Section The control box Figure 2 6 includes the manual op eration switches circuit breaker CB 1 compressor fan and heater contactors control power transformer fuses key
89. and a two digit dash number 1 3 27 Controller Two different controllers are available 1 Remanufactured Controller is the equivalent of a new OEM controller and is supplied with a 12 month warranty 2 Repaired Controller has had previous faults repaired and upgraded with the latest software Note Repaired controllers are NOT to be used for warranty repairs only full OEM Remanufactured controllers are to be used Controllers will be factory equipped with the latest version of operational software but will NOT be configured for a specific model number and will need to be configured at the time of installation or sale 1 3 28 Condenser Grille Two styles of condenser grilles are available direct bolted grilles and hinged grilles SECTION 2 DESCRIPTION 2 1 GENERAL DESCRIPTION 2 1 2 Fresh Air Makeup Vent 2 1 1 Refrigeration Unit Front Section The function of the upper or lower makeup air vent is to provide ventilation for commodities that require fresh air circulation The unit is designed so that the majority of the compo nents are accessible from the front see Figure 2 1 Theunit model number serial number and parts identifi cation number can be found on the serial plate to the left of the economizer 1 Access Panel Evap Fan 1 11 Autotransformer Location 2 Fork Lift Pockets 12 TransFRESH Communications Connector 3 Co
90. arge Examine the unit refrigerant system for any evidence of leaks Repair as necessary Refer to paragraph 6 3 3 Maintain the conditions outlined in paragraph 6 3 5 Fully backseat the suction service valve and remove the service port cap Connect charging line between suction service valve port and cylinder of refrigerant R 134a Open VAPOR valve Partially frontseat turn clockwise the suction service valve and slowly add charge until the refrigerant appears atthe proper level Be careful notto frontseat the suction valve fully ifthe compressor is operated in vacuum internal damage may result 6 4 COMPRESSOR Make sure power to the unit is OFF and power plug disconnected before replacing the compressor Before disassembly of the compressor be sure to relieve the internal pressure very carefully by slightly loosening the cou plings to break the seal CAUTION The scroll compressor achieves low suc tion pressure very quickly Do not use the compressor to evacuate the system below 0 psig Never operate the compressor with the suction or discharge service valves closed frontseated Internal damage will result from operating the compressor in a deep vacuum 6 4 1 Removal and Replacement of Compressor a Turn the unit ON and run it in full cool mode for 10 minutes NOTE If the compressor is not operational front seat the suction and discharge service valves and go to step f belo
91. ation code CnF31 is configured for standard the criteria used for comparison between the primary and secondary control probes is 1C 1 8F for perishable set points or 2 3 6F for frozen set points If 25 or more of 30 readings taken within a 30 minute period are outside of the limit then a defrost is initi ated and a probe check is performed In this configuration a probe check will be run as a part of every normal time initiated defrost b Probe Diagnostic Logic Special If the probe check option is configured for special the above criteria are applicable A defrost with probe check will be initiated if 25 of 30 readings or 10 consecutive readings are outside of the limits In this configuration a probe check will not be run as part of a normal defrost but only as part of a defrost initiated due to a diagnostic reading outside of the limits The 30 minute timer will be reset at each of the following conditions 1 At every power up 2 At the end of every defrost 3 After every diagnostic check that does not fall out side of the limits as outlined above c Probe Check A defrost cycle probe check is accomplished by energizing just the evaporator motors for eight minutes at the end of the normal defrost The probes will be compared to a set of predetermined limits at the end of the eight minute period The defrost indicator will remain on throughout this period Any probe s determined to be outside t
92. ay be obtained in the Container Identification Matrix located in the Container Products Group Information Center available to authorized Carrier Transicold Service Centers 1 3 OPTION DESCRIPTION Various options may be factory or field equipped to the base unit These options are listed in the tables and described in the following subparagraphs 1 3 1 Battery The refrigeration controller may be fitted with standard replaceable batteries or a rechargeable battery pack Rechargeable battery packs may be fitted in the standard or in a secure location 1 1 1 3 2 Dehumidification The unit may be fitted with a humidity sensor This sensor allows setting of a humidity set point in the controller In dehumidification mode the controller will operate to reduce internal container moisture level 1 3 3 Control Box Units are equipped with either an aluminum or composite material box and may be fitted with a lockable door 1 3 4 Temperature Readout The unit is fitted with suction and discharge temperature sensors The sensor readings may be viewed on the controller display 1 3 5 Pressure Readout The unit is fitted with evaporator and discharge transducers The transducer readings may be viewed on the controller display 1 3 6 USDA The unit may be supplied with fittings for additional temperature probes which allow recording of USDA Cold Treatment data by the integral DataCORDER function of the Micro Link refrigeration co
93. bubbles are constantly moving through the sight glass the unit may have a low refrigerant charge or the filter drier could be partially plugged a To Check Filter Drier 1 Test for a restricted or plugged filter drier by feeling the liquid line inlet and outlet connections of the drier cartridge If the outlet side feels cooler than the inlet side then the filter drier should be changed Check the moisture liquid indicator if the indicator shows a high level of moisture the filter drier should be replaced b To Replace Filter Drier 1 Pump down the unit refer to paragraph 6 3 2 Eva cuate if unit is not equipped with service valves Then replace filter drier Evacuate the paragraph 6 3 4 After unit is in operation inspect for moisture in sys tem and check charge low side in accordance with 6 10 EVAPORATOR COIL AND HEATER ASSEMBLY The evaporator section including the coil should be cleaned regularly The preferred cleaning fluid is fresh water or steam Another recommended cleaner is Oakite 202 or similar following manufacturer s instruc tions The two drain pan hoses are routed behind the con denser fan motor and compressor The drain pan line s must be open to ensure adequate drainage 6 10 1 Evaporator Coil Replacement a Pump unit down Refer to paragraph 6 3 2 Evacua te if unit is not equipped with service valves Refer to paragraph 6 3 4 With power OFF and power plug removed
94. by changing the real time clock RTC to a valid value using the DataView A write of critical DataCORDER information to the EEPROM has failed An error has been detected in the process of writing daily data to the non dAL89 Flash Memory Error volatile FLASH memory dAL90 Future Expansion This alarm is for future expansion and is not in use at this time dAL91 Alarm List Full The DataCORDER alarm queue is determined to be full eight alarms Network Data Point dAL78 85 8 Out of Range 3 33 T 340 SECTION 4 OPERATION 4 1 INSPECTION Before Starting 44 WARNING Beware of unannounced starting of the evaporator and condenser fans The unit may cycle the fans and compressor unex pectedly as control requirements dictate If container is empty check inside for the following 1 Check channels or T bar floor for cleanliness Channels must be free of debris for proper air cir culation Check container panels insulation and door seals for damage Effect permanent or temporary repairs Visually check evaporator fan motor mounting bolts for proper securement refer to paragraph 6 11 Check for dirt or grease on evaporator fans or fan deck and clean if necessary Check evaporator coil for cleanliness or obstruc tions Wash with fresh water Check defrost drain pans and drain lines for obstruc tions and clear if necessary Wash with fresh water Check panels on refri
95. ch after verifying Switch settings d Evacuate dehydrate and recharge e Start unit verify refrigeration charge and oil level 6 5 2 Checking High Pressure Switch 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 NOTE The high pressure switch is non adjustable a Remove switch as outlined in paragraph 6 5 1 b Connect ohmmeter or continuity light across switch terminals Ohm meter will indicate no resistance or continuity light will be illuminated if the switch closed after relieving compressor pressure c Connect hose to a cylinder of dry nitrogen See Figure 6 6 T 340 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 Figure 6 6 High Pressure Switch Testing Set nitrogen pressure regulator at 26 4 kg cm 375 psig with bleed off valve closed Close valve on cylinder and open bleed off valve 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 circuit Slowly open bleed off valve to decrease the pressure The switch should close at 18 kg cm 250 psig 6 6 CONDENSER COIL The condenser consist
96. coil or use sling on motor to prevent motor from falling into condenser coil CAUTION Do not remove wire harnesses from module unless you are grounded to the unit frame with a static safe wrist strap CAUTION Unplug all module connectors before per forming arc welding on any part of the con D 2 24 CAUTION The unit must be OFF whenever a program ming card is inserted or removed from the controller programming port 24 CAUTION Use care when cutting wire ties to avoid nicking or cutting wires CAUTION Do not allow moisture to enter wire splice area as this may affect the sensor resis tance CAUTION Do not allow the recorder stylus to snap back down The stylus arm base is spring loaded and damage may occur to the chart or the stylus force may be altered DO NOT move the stylus arm up and down on the chart face This will result in damage to the stylus motor gear T 340 SECTION 1 INTRODUCTION 1 1 INTRODUCTION The Carrier Transicold model 69NT40 561 001 to 199 series units are of lightweight aluminum frame construction designed to fit in the front of a container and serve as the container s front wall They are one piece self contained all electric units which include cooling and heating systems to provide precise temperature control The units are supplied with a complete charge of refrigerant R 134a and compressor lubricating oil and are ready for operat
97. coil that needs to be reinstalled into the solenoid valve coil When removing the coil it may fall out when lif ted from the valve body Take care that the spacer is not lost the valve will not function cor rectly without it Remove clamps holding the DUV to the discharge line Loosen the nuts attaching the DUV to the top of the compressor and the service valve Remove the valve assembly Examine compressor and service valves Ensure that the o rings are not stuck in the glands of the valves Discard the o rings on the o ring face seal connec tions Replacing the Coil Install new DUV and tubing assembly lubricate the gland shoulder area and o rings with refrigerant oil Hand tighten the o ring nuts Re install and tighten the brackets that secure the valve body to the discharge line Torque o ring face seal connections to 18 to 20 ft Ibs Install the coil onto the valve body and tighten the at tachment bolt NOTES Confirm that the small spacer tube is inserted into the coil prior to attaching it to the valve body The valve will not function correctly without it Leak check and evacuate low side or unit as applic able Refer to paragraph 6 3 4 Open service valves 6 13 6 16 VALVE OVERRIDE CONTROLS Controller function code Cd41 is a configurable code that allows timed operation of the automatic valves for troubleshooting Test sequences are provided in Table 6 1 Capaci
98. d the controller will activate the heat relay to begin dehumidification 1 The humidity sensor reading is above the set point 2 The unit is in the perishable steady state mode and supply air temperature is less than 0 25C above set point The heater debounce timer three minutes has timed out 4 Heater termination thermostat HTT is closed If the above conditions are true the evaporator fans will switch from high to low speed operation 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 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 Power is applied to the defrost heaters in the dehumidification mode This added heat load causes the controller to open the ESV to match the increased heat load while still holding the supply air temperature very close to the set point Opening the ESV reduces the temperature of the evaporator coil surface which increases the rate at 3 which water is condensed from the passing air Removing water from the air reduces the relative humidity When the relative humidity sensed is 296 below the set point the controller de energizes the heat relay The controller will continue to cycle heating to maintain relative humidity below the selected set point If the mode
99. d frequency of old and new b 1 coil This information appears on the coil housing Replacing Valve To replace the economizer or liquid injection valves pump down the unit Refer to paragraph 6 3 2 Eva cuate if unit is not equipped with service valves Re fer to paragraph 6 4 4 To replace the oil return valve remove the refrigerant charge Be sure electrical power is removed from the unit Disconnect leads Remove and discard the old coil and mounting hardware See Figure 6 13 Clean the valve stem with mild cleaner if necessary 4 Installthe brass spacer onthe valve stem if replacing the ESV ONLY If replacing the LIV discard brass spacer Lubricate both o rings with silicone provided in the kit 6 Install bottom coil o ring on the valve stem 7 Install the solenoid coil on the valve stem 8 Place the top coil o ring on the coil mounting screw and secure the coil to the valve using a torque wrench Torque the screw to 25 Connect coil wires using butt splices and heat shrink tubing 6 15 DIGITAL UNLOADER VALVE a Removing the Coil 1 Pump down the compressor refer to paragraph 6 3 2 and frontseat both suction and discharge valves In the event the DUV is stuck open and com pressor cannot pump down remove charge Loosen bolt on top of the DUV and remove coil assembly NOTES There is a loose steel spacer tube between the top of the valve and the 12 VDC
100. e YELLOW Refrigeration and or Evacuation Hose SAE J2196 R 134a Hose Fitting with O ring M14 x 1 5 High Side Field Service Coupling Red Knob BLUE Refrigeration and or Evacuation Hose SAE J2196 R 134a Low Side Field Service Coupling Blue Knob Figure 6 2 R 134a Manifold Gauge Hose Set Evacuate to 10 inches of vacuum and then charge with R 134a to a slightly positive pressure of 0 1 kg cm 1 0 psig Front seat both manifold gauge set valves and dis connect from cylinder The gauge set is now ready for use NO Ao 340 6 3 REFRIGERATION SYSTEM SERVICE UNITS WITH STANDARD PIPING with Service Valves 6 3 1 Service Connections The compressor suction compressor discharge and the liquid line service valves see Figure 6 3 are pro vided with a double seat and an access valve which enable servicing of the compressor and refrigerant lines Turning the valve stem clockwise all the way for ward will frontseat the valve to close the line connec tion and open a path to the access valve Turning the stem counterclockwise all the way out will backseat the valve to open the line connection and close off the path to the access valve With the valve stem midway between frontseat and backseat both of the service valve connections are open to the access valve path For example the valve stem is first fully backseated when connecting a manifold gauge to measure pres sure Then th
101. e however that capacity is also reduced The five values for 460 VAC operation are 15 17 19 21 or 23 amperes The factory default setting is 21 amperes Relative humidity set point is available only on units configured for dehumidifica tion 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 Cd33 Current Limit Cd32 Amperes Perishable Mode and will display The value can be set to OFF TEST or a range of 65 to Dehumidification 95 relative humidity in increments of 1 If bulb mode is active code Cd35 Control 96 RH and Lo speed evaporator motors are selected code Cd36 then set point 5 ranges from 60 to 9596 When TEST is selected or test set point is entered the heat LED should illuminate indicating that dehumidification mode is activated After a period of five minutes in the TEST mode has elapsed the previously selected mode is reinstated Cd34 Economy Mode On Economy mode is a user selectable mode of operation provided for power saving Off purposes Bulb mode is a user selectable mode of operation that is an extension of dehu midification control Cd33 If dehumidification is set to Off code Cd35 will dis Bulb Mode play 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 change
102. e access valves Install both service valve stem caps and service port caps finger tight only 6 3 2 Pumping Down the Unit To service the filter drier economizer expansion valves economizer solenoid valve liquid injection valve digital unloader valve or evaporator coil pump the refrigerant into the high side as follows CAUTION The scroll compressor achieves low suc tion pressure very quickly Do not operate the compressor in a deep vacuum internal damage will result 4 a Attach manifold gauge set to the compressor suction and discharge service valves Refer to paragraph 6 2 b Start the unit and run in the frozen mode controller set below 10C 14F for 10 to 15 minutes Check function code Cd21 refer to paragraph 3 2 2 The economizer solenoid valve should be open If not continue to run until the valve opens Frontseat the liquid line service valve Place start stop switch in the OFF position when the suction reaches a positive pressure of 0 1 bar 1 4 psig Frontseat the suction and discharge service valves The refrigerant will be trapped between the compres sor discharge service valves and the liquid line valve f 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 When opening up the refrigerant
103. e desired percentage of air flow matches with the arrow Tighten the wing nut To clear the gap between the slots loosen the wing nut until the disc clears the stop 4 3 2 Lower Fresh Air Makeup Vent Full Open or Closed Positions Maximum air flow is achieved by loosening the wing nuts and moving the cover to the maximum open position 10096 position The closed position is 0 air flow position The operator may also adjust the opening to increase or decrease the air flow volume to meet the required air flow b Reduced Flow for Lower Fresh Air Makeup NOTE In order to prevent inaccurate display readings on units equipped with a Vent Position Sensor VPS ensure that the rack and pinion drive of the VPS is not disrupted when adjusting the air makeup vent NOTE Do not loosen the hex nut beyond its stop Do ing so may cause inaccurate display readings and errors in DataCORDER reports Similar to the Upper Fresh Air Makeup vent two slots and a stop are designed into the Lower Fresh Air slide for air flow adjustments The first slot allows for a 0 to 2596 air flow the second slot allows for a 25 to 10096 air flow To adjust the percentage of air flow loosen the hex nut and rotate the disc until the desired percentage of air flow matches with the arrow Tighten the hex nut To clear the gap between the slots loosen the hex nut until the disc clears the stop On some models the air slide is supplied with two adjustable air co
104. e valve is opened 1 4 to 1 2 turn to mea sure the pressure SA 5222 SS CES jm a ADR ARES NSSSSSSSSNS SS WY 1 Line Connection 5 Compressor Or Filter 2 Access Valve Drier Inlet Connection 3 Stem Cap 6 Valve Frontseated 4 Valve stem 7 Backseated Figure 6 3 Service Valve To connect the manifold gauge hose set for reading pressures do the following 1 Remove service valve stem cap and check to make sure it is backseated Remove access valve cap See Figure 6 3 Connect the field service coupling see Figure 6 2 to the access valve Turnthe field service coupling knob clockwise which will open the system to the gauge set To read system pressures slightly midseat the ser vice valve Repeat the procedure to connect the other side of the gauge set T 340 CAUTION To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suction pressure before disconnecting Removing the Manifold Gauge Set 1 While the compressor is still ON backseat the high side service valve Midseat both hand valves on the manifold gauge set and allow the pressure in the manifold gauge set to be drawn down to low side pressure This returns any liquid that may be in the high side hose to the system Backseat the low side service valve Backseat both field service couplings and frontseat both manifold hand valves Remove the couplings from th
105. ed slide the cap and grommet assembly onto the replacement sensor 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 crimp ing tool T 340 j Solder spliced wires with a 6096 tin and 4096 lead Rosincore solder k Slide heat shrink tubing over splice so that ends of tubing cover both ends of crimp as shown in Figure 6 16 Heattubingto shrink over splice Make sure all seams are sealed tightly against the wiring to prevent mois ture seepage CAUTION Do not allow moisture to enter wire splice area as this may affect the sensor resis tance m Position sensor in unit as shown in Figure 6 16 and re check sensor resistance n Reinstall sensor refer to paragraph 6 20 3 NOTE The P5 Pre Trip test must be run to inactivate probe alarms refer to paragraph 4 8 6 20 3 Sensor Re Installation Sensors STS and SRS To properly position a supply sensor the sensor must be fully inserted into the probe holder See Figure 6 17 Do not allow heat shrink covering to contact the probe hold er For proper placement of the sensor be sure to posi tion the enlarged positioning section of the sensor against the the side of the mounting clamp This posi tioning will give the sensor the optimum amount of expo sure to the supply air stream and will allow the controller to operate correctly Sensors RRS and RTS Reinstall
106. efore the replaced compressor was removed Otherwise evacuate the complete unit and charge it with R 134a refrigerant see Sec tions 6 3 4 and 6 3 5 t Open the compressor terminal cover and connect the compressor power cable following the steps be low Liberally coat the orange gasket surfaces with the Krytox lubricant Install the orange gasket part onto the compressor fusite with the grooved or threaded side out Ensure that the gasket is seated onto the fusite base Coatthe inside ofthe power plug female connector pins with the Krytox lubricant and insert the plug onto the compressor terminal connections Make sure the orange gasket has bottomed out onto the T 340 fusite and it fits securely onto the terminal pins while fully inserted into the orange plug Connect the green ground wire to the grounding tab located inside the terminal box ofthe compressor us ing the self tapping grounding screw Close the compressor terminal box using the terminal cover re moved in step 20 above Backseat all service valves connect the power to the unit and run it for at least 20 minutes z Perform a leak check of the system 6 5 HIGH PRESSURE SWITCH 6 5 1 Replacing High Pressure Switch a Remove the refrigerant charge b Disconnect wiring from defective switch The high pressure switch is located on the discharge connec tion or line and is removed by turning counterclock wise c Install a new high pressure swit
107. emperature with time The electronic recorder will automatically record the return air supply air or both based on the setting of temperature controller configuration code CnF37 refer to Table 3 4 The recorder reads and records data from the controller in present time under normal operating conditions Ifthe power has been OFF for more than thirty days the recorder will NOT re synchronize the chart will not advance to present time the pen tip will move to the currently recorded temperature and the recorder will resume normal temperature recording If using the Electronic Partlow Recorder CTD part number 12 00464 xx Where xx an even number example 12 00464 08 The recorder will STOP when the power is OFF and the pen tip will remain at the last recorded temperature on the chart When power is applied and the power off period is less than thirty days the recorder will retrieve the logged data from the DataCORDER for the power off period and record it onto the chart Thereafter the recorder will resume normal temperature recording If the optional DataCORDER battery pack is being used and the charge is too low to enable recording during the power off period of less than thirty days the pen tip will move to below the inner chart ring for the period when NO data was recorded by the DataCORDER Ifthe power has been OFF for more than thirty days the recorder will NOT re synchronize the chart will not advance to present time
108. erature pressure gas enters the compressor at the economizer port fitting Whenthe air temperature falls to 2 5 C 4 5 F above set point the DUV unloads the compressor s scroll and be gins to reduce the capacity ofthe unit Percentage ofthe unit capacity is accessed through code select 01 Cd01 For example if 01 displays 70 it indicates that the compressor is operating unloaded with the DUV engaged 30 of the time 2 5 3 Liquid Injection Valve The normally closed liquid injection valve LIV will open and close to cool the compressor and prevent it from overheating 2 5 4 Electronic Expansion Valve The microprocessor controls the superheat leaving the evaporator via the electronic expansion valve EEV based on inputs from the evaporator temperature sensor ETS and the evaporator pressure transducer EPT The microprocessor transmits electronic pulses to the EEV stepper motor which opens or closes the valve orifice to maintain the superheat setpoint STANDARD OPERATION WITH RECEIVER EVAPORATOR E Lemma ETS2 ELECTRONIC EXPANSION VALVE CONDENSER DIGITAL UNLOADER VALVE Q LIQUID INJECTION w ee VALVE DISCHARGE TEMPERATURE ECONOMIZER SENSOR SOLENOID Ex VALVE DISCHARGE i SERVICE ECONOMIZER VALVE DA H i SIGHT 5 A GLASS mE EVAPORATOR DRIER PRESSURE TRANSDUCER i ECONOMIZER MOISTURE DISCHARGE SUCTION INDICATOR Q PRES
109. ext check the secondary output voltage 230 VAC The transformer is defective if output voltage is not avail able 6 18 CONTROLLER 6 18 1 Handling Modules CAUTION Do not remove wire harnesses from module unless you are grounded to the unit frame with a static safe wrist strap CAUTION Unplug all module connectors before per forming arc welding on any part of the con tainer The guidelines and cautions provided herein should be followed when handling the modules These precau tions and procedures should be implemented when replacing a module when doing any arc welding on the unit or when service to the refrigeration unit requires handling and removal of a module a Obtain a grounding wrist strap Carrier Transicold part number 07 00304 00 and a static dissipation mat Carrier Transicold part number 07 00277 00 The wrist strap when properly grounded will dissi pate any potential buildup on the body The dissipa tion mat will provide a static free work surface on which to place and or service the modules o Disconnect and secure power to the unit Place strap on wrist and attach the ground end to exposed unpainted metal area on the refrigeration unit frame bolts screws etc 6 15 d Carefully remove the module Do not touch any of the electrical connections if possible Place the module on the static mat e The strap should be worn during any service work on a module even when it
110. ey is pressed economy de humidification and bulb mode will be deac tivated At the completion of Pre Trip activi ty economy dehumidification and bulb mode must be reactivated Testing may be initiated by use of the keypad or via communication but when initiated by communication the controller will execute the entire battery of tests auto mode At the end of a pre trip test the message P rSLts pretest results will be displayed Pressing the ENTER key will allow the user to see the results for all subtests The results will be displayed as PASS or FAIL for all the tests run to completion A detailed description ofthe pre trip tests and test codes is provided in Table 3 7 page 3 27 detailed operating instructions are provided in paragraph 4 8 3 7 DataCORDER 3 7 1 Description The Carrier Transicold DataCORDER software is integrated into the controller and serves to eliminate the temperature recorder paper chart The DataCORDER functions may be accessed by keypad selections and viewed on the display module The unit is also fitted with interrogation connections see Figure 3 1 which may be used with the Carrier Transicold Data Reader to down load data A personal computer with Carrier Transicold DataLINE software may also be used to download data and configure settings The DataCORDER consists of Configuration Software Operational Software Data Storage Memory Real Time Clock with internal battery
111. f operation descriptions for the various modes of operation are provided in paragraph 3 3 LEGEND SYMBOL DESCRIPTION AMBS C CB1 CB2 CF CH CI CL CM CP CR CS AMBIENT SENSOR C 21 CONTROLLER J 19 CIRCUIT BREAKER 460 VOLT F 1 OPTIONAL CIRCUIT BREAKER DVM OPTION C 1 TERMINAL BLOCK WHEN CB2 NOT PRESENT CONDENSER FAN CONTACTOR M 11 P 6 COMPRESSOR CONTACTOR M 7 P 1 COMMUNICATIONS INTERFACE MODULE OPTION 3 COOL LIGHT OPTION M 11 CONDENSER FAN MOTOR H 10 T 6 COMPRESSOR MOTOR T 1 DISCHARGE TEMPERATURE SENSOR B 21 CHART TEMPERATURE RECORDER OPTIONAL A 15 CURRENT SENSOR J 2 DEFROST HEATER BOTTOM LEFT R 5 DEFROST HEATER BOTTOM RIGHT T 4 DEFROST HEATER MIDDLE LEFT R 4 DEFROST HEATER MIDDLE RIGHT T 4 DEFROST HEATER TOP LEFT R 4 DEFROST HEATER TOP RIGHT T 5 DEFROST LIGHT OPTION L 6 DISCHARGE PRESSURE TRANSDUCER J 21 DEFROST TEMPERATURE SENSOR C 21 DIGITAL UNLOADER VALVE E 22 DUAL VOLTAGE MODULE OPTIONAL D 1 DUAL VOLTAGE RECEPTACLE OPTIONAL F 1 ELECTRONIC EXPANSION VALVE N 15 EVAPORATOR FAN CONTACTOR HIGH SPEED M 12 N 8 EVAPORATOR FAN MOTOR D 12 F 12 T 7 T 10 EVAPORATOR PRESSURE TRANSDUCER R 14 EVAPORATOR FAN CONTACTOR LOW SPEED M 11 P 7 EVAPORATOR TEMPERATURE SENSOR SUCTION D 16 D 21 ECONOMIZER SOLENOID VALVE K 9 FUSE C 6 D 6 D 18 E 18 FULL LOAD AMPS HIGH PRESSURE SWITCH G 7
112. geration unit for loose bolts and condition of panels Make sure TIR devices are in place on access panels b Check condenser coil for cleanliness Wash with fresh water c Opencontrol box door Check for loose electrical con nections or hardware d Check color of moisture liquid indicator 4 2 CONNECT POWER WARNING Do not attempt to remove power plug s be fore turning OFF start stop switch ST unit circuit breaker s and external power source 4 WARNING Make sure the power plugs are clean dry before connecting to power receptacle 4 2 1 Connection To 380 460 VAC Power 1 Make sure start stop switch ST on control panel and circuit breaker CB 1 in the control box are in position 0 OFF 2 Plug the 460 VAC yellow cable into a de energized 380 460 VAC 3 phase power source Energize the power source Place circuit breaker CB 1 in position ON Close and secure control box door 4 2 2 Connection To 190 230 VAC Power An autotransformer Figure 4 1 is required to allow op eration on nominal 230 volt power It is fitted with a 230 VAC cable and a receptacle to accept the standard 460 VAC power plug The 230 volt cable is black in color while the 460 volt cable is yellow The transformer may also be equipped with a circuit breaker CB 2 The transformer is a step up transformer that will provide 380 460 VAC 3 phase 50 60 Hz power to the unit when the 230 VAC power cable is
113. he date and time will not be committed until start up procedures are completed on the next power up Procedure for setting the container ID NOTE The characters will be preset to the container ID already on the controller If none exist the de fault will be AAAA0000000 Oo Pressthe UP or DOWN arrow key until display reads Set ID Press the ENTER key on the keypad Thevalues will be entered from rightto left Press the UP or DOWN ARROW key to increase or decrease the values The ENTER key will enter the information for the current field and move to the next value the CODE SELECT key will allow modification of the previous value T 340 When the last value is entered press the ENTER key to enter the information to the controller the CODE SELECT key will allow modification of the previous value 6 18 4 Removing and Installing a Module a Removal 1 Disconnect all front wire harness connectors and move wiring out of way The lower controller mounting is slotted loosen the top mounting screw see Figure 6 14 and lift up and out Disconnect the back connectors and remove mod ule When removing the replacement module from its packaging note how it is packaged When returning the old module for service place it in the packaging in the same manner as the replacement The pack aging has been designed to protect the module from both physical and electrostatic discharge damage during storage and t
114. he display will show the message EEPrM donE If a problem occurs while loading the soft ware the display will blink the message Pro FAIL or bad 12V Turn start stop switch OFF and remove the card 12 Turn unit OFF using start stop switch ST 18 Remove the PCMCIA card from the programming software port and return the unit to normal operation by placing the start stop switch in the ON position 14 Confirm correct model configuration using the key pad to choose code 20 CD20 The model displayed should match the unit serial number plate Procedure for setting the date and time Pressthe UP or DOWN arrow key until display reads Set TIM Press the ENTER key on the keypad The first value to be modified is the date in YYYY MM DD format The values will be entered from right to left Press the UP or DOWN ARROW key to in crease or decrease the values The ENTER key will enter the information for the current field and moveto the next value the CODE SELECT key will allow modification of the previous value Press the ENTER key on the keypad The next value to be modified is the time in HH MM format The values will be entered from right to left Press the UP or DOWN ARROW key to increase or decrease the values The ENTER key will enter the information for the current field and move to the next value the CODE SELECT key will allow modification of the previous value Press the ENTER key on the keypad T
115. he limits will cause the appropriate alarm code s to be displayed to identify which probe s needs to be replaced The P5 Pre Trip test must be run to inactivate alarms T 340 SECTION 5 TROUBLESHOOTING REMEDY CONDITION POSSIBLE CAUSE REFERENCE SECTION 5 1 UNIT WILL NOT START OR STARTS THEN STOPS TE M D oak Compressor hums but does not 5 2 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING Cantal Hot load ntainer TSRS Defective box insulation or air leak Repair Shortage of refrigerant Evaporator coil covered with ice Evaporator coil plugged with debris Evaporator fan s rotating backwards 6 10 6 11 Air bypass around evaporator coil Controller set too low Refri ti t Compressor service valves or liquid line shutoff valve Open valves system partially closed completely Dirty condenser Compressor worn 5 1 T 340 5 3 UNIT RUNS BUT HAS INSUFFICIENT COOLING EN Refrigeration system Compressor service valves or liquid line shutoff valve Open valves partially closed completely Frost on coil 5 11 Digital unloader valve stuck open Replace Electronic expansion valve Replace 5 4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING Start Stop switch OFF or defective Check No operation of any Kind No control power REMEDY CONDITION POSSIBLE CAUSE REFERENCE SECTION ne cient heat Loose terminal connections Low line voltage 5 5 UNIT WILL NOT TERMINATE H
116. he recorder The pen tip will drive ful ly down scale then move upscale to the chart ring at OC 32F and stop b If the tip of the pen item 4 is on the OC 32F chart ring the recorder is in calibration proceed to step c If the tip of the pen is NOT on the OC 32F chart ring the operator must loosen the two screws on the bottom ofthe stylus arm to adjust the pen tip manually to the OC 32F chart ring Tighten the screws when adjustment is complete o Press the calibration button and the pen will position itself to the correct temperature reading 6 22 MAINTENANCE OF PAINTED SURFACES The refrigeration unit is protected by a special paint system against the corrosive atmosphere in which it normally operates However should the paint system be damaged the base metal can corrode In order to protect the refrigeration unit from the highly corrosive sea atmosphere or if the protective paint system is scratched or damaged clean area to bare metal using a wire brush emery paper or equivalent cleaning method Immediately following cleaning apply two part epoxy paint to the area and allow to dry After the first coat dries apply a second coat 6 23 COMMUNICATIONS INTERFACE MODULE INSTALLATION
117. he remaining codes may be user configured The value of the user configurable codes can be assigned in accordance with user desired mode of operation A list of the function codes is provided in Table 3 5 To access the function codes perform the following a Press the CODE SELECT key then press an arrow key until the left window displays the desired code number b The right window will display the value of this item for five seconds before returning to the normal display mode Ifalonger time is desired press the ENTER key to ex tend the time to five minutes 3 8 CONTROLLER SEQUENCE AND MODES OF OPERATION General operation sequences for cooling heating and defrost are provided in the following subparagraphs Schematic representation of controller action is provided in Figure 3 5 The operational software responds to various inputs These inputs come from the temperature and pressure sensors the temperature set point the settings of the configuration variables and the function code assignments The action taken by the operational software will change if any one of the inputs change Overall interaction of the inputs is described as a mode of operation The modes of operation include perishable chill mode and frozen mode Descriptions of the controller interaction and modes of operation are provided in the following sub paragraphs 3 3 1 Start up Compressor Phase Sequence The controller logic will check fo
118. he values and ensuring a successful connection has been made with the DataCORDER click on the Send button to send the modified parameter values The maximum allowed length of the ISO Trip Header is 128 characters If the user tries to refresh the screen or close the utility without sending the changes made on the screen to the DataCORDER the user is alerted with a message Table 3 4 Controller Configuration Variables Sheet 1 of 2 CONFIGURATION NUMBER TITLE DEFAULT OPTION i am CnF08 Single Phase 3 Phase Evaporator Fan Motor 3Ph Single ingle Suction Temperature Display Option Expanded Current Limit Range 3 17 T 340 Table 3 4 Controller Configuration Variables Sheet 2 of 2 CONFIGURATION NUMBER TITLE DEFAULT OPTION Timed Defrost Disable _ o Water Cool O1 Retum Logo _ ors Boost Grout Condenser Motor type o Ope tap CnF59 Electronic Expansion Valve 0 1 EC 2 KE 3 NA CnF60 Compressor Cycle Perishable Cooling o jOoutin Note Configuration numbers not listed are not used in this application These items may appear when loading configura tion software to the controller but changes will not be recognized by the controller programming T 340 3 18 Table 3 5 Controller Function Codes Sheet 1 of 4 DESCRIPTION Note If the function is not applicable the disp
119. he water supply and the discharge line to the water cooled condenser The refrigeration unit will shift to air cooled condenser operation when the wa ter pressure switch closes 4 4 2 Water Cooled Condenser with Condenser Fan Switch Connect the water supply line to the inlet side of con denser and the discharge line to the outlet side of the condenser See Figure 2 5 Maintain a flow rate of 11 to 26 Ipm 3 to 7 gpm c Set the condenser fan switch to position O This will de energize the condenser fan relay The condenser fan motor will stop and remain stopped until the CFS switch is set to position I a 5 CAUTION When condenser water flow is below 11 lpm 8 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 d To shift to air cooled condenser operation stop the unit set the CFS switch to position I and restart the unit Disconnect the water lines to the water cooled condenser 4 5 CONNECT REMOTE MONITORING RECEPTACLE If remote monitoring is required connect remote moni tor plug at unit receptacle When the remote monitor plug is connected to the remote monitoring receptacle the following remote circuits are energized 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 4 6 STARTING AND STOPPIN
120. hen the compressor is running these conditions are present only when the compressor is energized in the direction opposite of that indicated by electronic phase sequence detection If the system is unable to determine the proper rela tionship alarm 14 will remain active Additional information on phase detection may be displayed at Function Code Cd41 If the right most digit of Code Cd41 is 3 or 4 this indicates incorrect motor or sensor wiring If the right most digit is 5 this indicates a failed current sensor assembly Alarm 16 is triggered if compressor current draw is 15 over calculated maxi AL16 Current mum for 10 minutes out of the last hour The alarm is display only and will trigger 9 off when the compressor operates for one hour without over current Alarm 17 is triggered if a compressor start in both directions fails to generate suf ficient pressure differential The controller will attempt restart every 20 minutes AL17 Phase Sequence Failure Electronic Phase Sequence and deactivate the alarm if successful This alarm triggers failure action C evap Failure Pressure orator fan only or D all machinery off of Function Code Cd29 if the unit has a perishable set point Failure action D all machinery off is triggered if the unit has a frozen set point Alarm 18 is triggered if discharge pressure is 10 over calculated maximum for AL18 Discharge Pressure 10 minutes within the last hour The alarm is display o
121. hould match the unit serial number plate 6 18 3 2 Programming Procedure for Software Versions 5328 and Later AND With Updated Menu Option menu0111 ml The updated menu option allows the operational soft ware to be loaded and time and container identification to be set a Procedure for loading operational software 1 The display module will display the message Set UP 2 Press the UP or DOWN arrow key until display reads LOAd 53XX for Scroll odd numbers 3 Press the ENTER key on the keypad The display will alternate to between PrESS EntR and rEV XXXX Press the ENTER key on the keypad The display will show the message Pro SoFt This message will last for up to one minute The display module will go blank briefly then read Pro donE when the software loading has loaded If a problem occurs while loading the software the dis play will blink the message Pro FAIL or bad 12V Turn start stop switch OFF and remove the card Turn unit OFF via start stop switch ST Remove the PCMCIA card from the programming software port and return the unit to normal operation by placing the start stop switch in the ON position 10 Turn power on and wait 15 seconds The status LED will flash quickly and there will be no display The controller is loading the new software into memory This takes about 15 seconds When complete the controller will reset and power up normally Wait for default disp
122. icate a good sensor If a sensor is defective the resistance read ing will usually be much higher or lower than the resis tance values given Table 6 2 Sensor Temperature Resistance Chart 002 Temperature Resistance C Ohms RTS RRS STS SRS 0 32650 226500 20 68 12490 12490 30 800 8060 60 140 2490 24900 6 20 2 Sensor Replacement a Turn unit power OFF and disconnect power supply b Cut cable 5 cm 2 inches from shoulder of defective sensor and discard the defective probe only Slide the cap and grommet off a bulb type sensor and save for reuse Do not cut the grommet Cut one wire of existing cable 40 mm 1 1 2 inches shorter than the other wire Cut one replacement sensor wire opposite color back 40 mm 1 1 2 inches See Figure 6 15 Strip back insulation on all wiring 6 3 mm 1 4 inch T 340 Mounting Stud Type Bulb Type 3 6 3mm 1 4 in 1 Sensor 2 40mm 1 1 2 in Figure 6 15 Sensor Types 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 fit tings as shown in Figure 6 16 2 1 Cable 2 Sensor Typical 3 Large Heat Shrink Tubing 1 4 Heat Shrink Tubing 2 Figure 6 16 Sensor and Cable Splice g Slide large heat shrink tubing over both splices and shrink h If requir
123. ice cycle The minimum defrost interval under the automatic setting is three hours while the maximum is 24 In frozen mode the amount of wall clock time necessary to accumulate a given amount of defrost interval time will exceed the defrost interval time by a factor of two to three depending on the compressor duty cycle Defrost interval time is not accumulated in any mode until the defrost termination sensor reads less than 10C 50F If defrost does not terminate correctly and temperature reaches set point of the heat termination thermostat HTT the thermostat will open to de energize the heaters If termination does not occur within two hours the controller will terminate defrost An alarm will be activated to inform of a possible DTS failure If probe check controller function code CnF31 is configured to SPECIAL the unit will proceed to the next operation snap freeze or terminate defrost If the code is configured to STANDARD the unit will perform a probe check The purpose of the probe check is to detect malfunctions in the sensed temperature If probe check fails the system will run for eight minutes to validate At the end of eight minutes probe alarms will be set or cleared based on the conditions seen When the return air falls to 7C 45F the controller ensures that the defrost temperature sensor DTS reading has dropped to 10C or below If it has not aDTS failure alarm is given and the defrost mode is operated by the
124. ice 8 Manifold Gauge Set Connection 9 Refrigerant Cylinder 10 Reclaimer Figure 6 4 Refrigeration System Service Connec tions Procedure Complete System NOTE Refer to Partial System procedure for informa tion pertaining to partial system evacuation and dehydration Remove all refrigerant using a refrigerant recovery system The recommended method to evacuate and dehy drate the system is to connect evacuation hoses at the compressor suction and liquid line service valve see Figure 6 4 Be sure the service hoses are suited for evacuation purposes Test the evacuation setup for leaks by backseating the unit service valves and drawing a deep vacuum with the vacuum pump and gauge valves open Shut off the pump and check to see if the vacuum holds Repair leaks if necessary Midseat the refrigerant system service valves Open the vacuum pump and electronic vacuum gauge valves if they are not already open Start the vacuum pump Evacuate unit until the electronic vac uum gauge indicates 2000 microns Close the elec tronic vacuum gauge and vacuum pump valves Shut off the vacuum pump Wait a few minutes to be sure the vacuum holds f Break the vacuum with clean dry refrigerant 134a gas Raise system pressure to roughly 0 14 bar 2 psig monitoring it with the compound gauge Remove refrigerant using a refrigerant recovery sys tem 340 Repeat steps e and f one time Remove the copper
125. iguration Software The inputs are labeled Function Codes Controller functions see Table 3 8 page 3 31 which the operator may access to examine the current input data or stored data To access these codes do the following 1 Press the ALT MODE and CODE SELECT keys 2 Press an arrow key until the left window displays the desired code number The right window will display the value of this item for five seconds before returning to the normal display mode 3 If a longer display time is desired press the ENTER key to extend the display time to five minutes b Configuration Software The configuration software controls the recording and alarm functions of the DataCORDER Reprogramming to the factory installed configuration is achieved via a configuration card Changes to the unit DataCORDER configuration may be made made using the DataView DataLINE interrogation software A listing of the configuration variables is provided in Table 3 2 Descriptions of DataCORDER operation for each variable setting are provided in the following paragraphs 3 7 8 Sensor Configuration dCF02 Two modes of operation may be configured the Standard Mode and the Generic Mode a Standard Mode In the standard mode the user may configure the DataCORDER to record data using one of seven standard configurations The seven standard configuration variables with their descriptions are listed in Table 3 3 The inputs of the six thermistors supp
126. iled heater s d Remove hold down clamp securing heater s to coil e Lift the bent end of the heater with the opposite end down and away from coil Move heater to the side enough to clear the heater end support and remove 6 11 EVAPORATOR FAN AND MOTOR ASSEMBLY The evaporator fans circulate air throughout the con tainer by pulling air in the top ofthe unit The air is forced through the evaporator coil where it is either heated or cooled and then discharged out the bottom of the refrig eration unit into the container The fan motor bearings are factory lubricated and do not require additional grease T 340 6 11 1 Replacing The Evaporator Fan Assembly Always turn OFF the unit circuit breakers CB 1 and CB 2 and disconnect main power supply before working on moving parts a Remove upper access panel see Figure 2 2 by removing mounting bolts and TIR locking device Reach inside of unit and remove the Ty Rap securing the wire harness loop Disconnect the connector by twisting to unlock and pulling to separate Loosen four 1 4 20 clamp bolts that are located on the underside of the fan deck at the sides of the of the fan assembly Slide the loosened clamps back from the fan assembly Oo Slide the fan assembly out from the unit and place on a sturdy work surface 6 11 2 Disassemble The Evaporator Fan Assembly a Attach a spanner wrench to the two 1 4 20 holes located in the fan hub Loosen the 5 8 18 shaft nu
127. iled explanation of the DataLINE interrogation software The DataLINE manual may be found on the internet at www container d Communications Interface Module The communications interface module is a slave module which allows communication with a master central monitoring station The module will respond to communication and return information over the main power line With a communications interface module installed all functions and selectable features that are accessible at the unit may be performed at the master station Retrieval of all DataCORDER reports may also be performed Refer to the master system technical manual for further information 3 15 3 7 11 USDA Cold Treatment 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 2C 36F or below for specific periods results in the mortality of the various stages of this group of insects In response to the demand to replace fumigation with this environmentally sound process Carrier has integrated Cold Treatment capability into its microprocessor system These units have the ability to maintain supply air temperature within one quarter degree Celsius of set point and record minute changes in product temperature within the DataCORDER memory thus meeting USDA criteria Information on USDA is provided in the f
128. ined above 1 66C for five minutes continuously while the compressor is running Manual Defrost Alarm 05 is triggered if the controller detects continuous Manual Defrost Switch ALOS Switch Failure action for five minutes or more The alarm will only trigger off when the unit is power cycled Alarm 06 is triggered if the controller detects continuous keypad button activity ALOG SS ON amens for five minutes or more The alarm will only trigger off when the unit is power cycled Alarm 07 is triggered if the VPS is reading greater than 0 CMH based on the Fresh Air Vent Open function code display value and a frozen set point is active ALO7 with Frozen Set If AL 50 is active AL 07 will not be generated Point The alarm will go inactive if the VPS reading transitions to 0 CMH the set point transitions to the perishable range or an 50 is active High Compressor Alarm 08 is triggered when the controller detects that the discharge pressure to 08 Patio suction pressure ratio is too high The alarm triggers shut down of the com pressor which will restart in normal staging logic after three minutes Alarm 14 is triggered if the electronic phase detection system is unable to deter mine the correct phase relationship AL 14 is also triggered if electronic phase sequence detection was successful and conclusive but unit is miswired The AL14 miswiring causes increased suction pressure and decreased discharge pressure w
129. ink 3 controller is a dual module microprocessor as shown in Figure 3 4 It is fitted with test points harness connectors and a software card programming port 3 2 CONTROLLER SOFTWARE The controller software is a custom designed program that is subdivided into configuration software and operational software The controller software performs the following functions a Control supply or return air temperature to required limits provide modulated refrigeration operation economized operation unloaded operation electric heat control and defrost Defrost is performed to clear buildup of frost and ice and ensure proper air flow across the coil b Provide default independent readouts of set point and supply or return air temperatures c Provide ability to read and if applicable modify the configuration software variables operating software Function Codes and Alarm Code indications 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 pressure limiting and current limiting settings e Provide battery powered ability to access or change selected codes and set point without AC power connected f Provide the ability to reprogram the software through the use of a memory card 3 2 1 Configuration Software Variables The configuration software is a variable listing of the compo
130. ion upon installation Forklift pockets are provided for unit installation and removal The base unit operates on nominal 380 460 volt 3 phase 50 60 hertz Hz power An optional autotransformer may be fitted to allow operation on nominal 190 230 3 phase 50 60 Hz power Power for the control system is provided by a transformer which steps the supply power down to 18 and 24 volts single phase The controler is a Carrier Transicold Micro Link 3 microprocessor controller will operate automatically to select cooling holding or heating as required to maintain the desired set point temperature within very close limits The unit may also be equipped with an electronic temperature recorder The controller has a keypad and display for viewing or changing operating parameters The display is also equipped with lights to indicate various modes of operation 1 2 CONFIGURATION IDENTIFICATION Unit identification information is provided on a plate located near the economizer heat exchanger on the back wall of the condenser section The plate provides the unit model number the unit serial number and the unit parts identification number PID The model number identifies the overall unit configuration while the PID provides information on specific optional equipment factory provisioned to allow for field installation of optional equipment and differences in detailed parts Configuration identification for the models covered herein m
131. ipped with an autotransformer require an additional power cable for connection to the 230 volt source Various power cable and plug designs are available The plug options tailor the cables to each customer s requirements T 340 1 2 1 3 20 Cable Restraint Various designs are available for storage of the power cables These options are variations of the compressor section cable guard 1 3 21 Upper Air Fresh Air Make Up The unit may be fitted with an upper fresh air makeup assembly The fresh air makeup assembly is available with a vent positioning sensor VPS and may also be fitted with screens 1 3 22 Lower Air Fresh Air Make Up The unit may be fitted with a lower fresh air makeup assembly The fresh air makeup assembly is available with a vent positioning sensor VPS and may also be fitted with screens 1 3 23 Evaporator Evaporator section is equipped with an electronic expansion valve EEV 1 3 24 Evaporator Fan Operation Units are equipped with three phase evaporator fan motors Opening of an evaporator fan internal protector will shut down the unit 1 3 25 Labels Safety Instruction and Function Code listing labels differ depending on the options installed Labels available with additional languages are listed in the parts list 1 3 26 Plate Set Each unit is equipped with a tethered set of wiring schematics and wiring diagram plates The plate sets are ordered using a seven digit base part number
132. is SPnEW C F in 0 1 degree increments The default is 10 0 Code C453 initially displays countdown timer increments of 1 day 1 hour with the temperature default Pressing ENTER allows selection of within the current menu and proceeds to the next menu After five seconds of no activity the display re verts to normal system display but retains the parameters previously selected 5 or Off The default is Off NSC z 1 2 SP 0 F in 0 1 degree increments The default is 10 0C DAY 0 0 99 increments of 1 The default is 1 SP 1 F in 0 1 degree increments The default is 10 0C DAY 1 0 99 increments of 1 The default is 1 SP 2 2C F in 0 1 degree increments The default is 10 0C Reading for evaporator superheat is shown on the right display Press ENTER at Cd54 to show reading for EEV position in 96 on left display Code Cd55 will display the discharge superheat values in C F as calculated by the discharge temperature minus the discharge saturation temperature as calcu lated from discharge pressure will be displayed if the selection is not valid 3 22 Table 3 6 Controller Alarm Indications Sheet 1 of 4 TITLE DESCRIPTION Alarm 03 is triggered if superheat operates below 1 66C 3F for five minutes 103 Loss of Superheat continuously while the compressor is running and the EEV is at 096 open The Control alarm will trigger off when superheat has rema
133. is is done by toggling function code Cd36 from its default of alt to Lo or Hi as desired If low speed evaporator fan operation is selected this gives the user the additional capability of selecting dehumidification set points from 60 to 9596 instead of the normal 65 to 9596 In addition if bulb mode is active function code Cd37 may be set to override the previous defrost termination thermostat settings Refer to paragraph NO TAG The temperature at which the defrost termination thermostat will be considered open may be changed in 0 1C 0 2F increments to any value between 25 6C 78F and 4C 39 2F The temperature at which the defrost termination thermostat is considered closed for interval timer start or demand defrost is 10C for open values from 25 6C 78F down to a 10C setting For open values lower than 10C the closed values will decrease to the same value as the open setting Bulb mode is terminated when 1 Bulb mode code Cd35 is set to Nor 2 Dehumidification code Cd33 is set to Off 3 The user changes the set point to one that is in the frozen range When bulb mode is disabled by any of the above the evaporator fan operation for dehumidification reverts to alt and the DTS termination setting resets to the value determined by controller configuration variable CnF41 3 3 12 Frozen Pulldown Schematic representation of controller action is provided in Figure 3 8 When cooling from
134. it breaker for the 230 volt power If the unit is equipped with an autotransformer and communications module the autotransformer will be fitted with a transformer bridge unit TBU to assist in communications 1 3 13 Temperature Recorder The units may be fitted with an electronic temperature recording device manufactured by the Partlow Corporation 1 3 14 Handles The unit may be equipped with handles to facilitate access to stacked containers These fixed handles are located on either side of the unit 1 3 15 Thermometer Port The unit may be fitted with ports in the front of the frame for insertion of a thermometer to measure supply and or return air temperature If fitted the port s will require a cap and chain 1 3 16 Water Cooling The refrigeration system may be fitted with a water cooled condenser The condenser is constructed using copper nickel tube for sea water applications The water cooled condenser is in series with the air cooled condenser and replaces the standard unit receiver When operating on the water cooled condenser the condenser fan is deactivated by either a water pressure Switch or condenser fan switch 1 3 17 Back Panels Aluminum back panels may have access doors and or hinge mounting 1 3 18 460 Volt Cable Various power cable and plug designs are available for the main 460 volt supply The plug options tailor the cables to each customer s requirements 1 3 19 230 Volt Cable Units equ
135. lay setpoint on the left and con trol temperature on the right 12 Confirm software is correct using keypad code se lect 18 to view Cd18 XXXX 13 Turn power off Operational software is loaded b Procedure for loading configuration software 1 Turn unit OFF using start stop switch ST 2 Insert software programming PCMCIA card contain ing the following example files into the program ming software port See Figure 6 14 this file allows the user to select the file program to upload into the controller cfYYMMDD mi3 multi configuration file Turn unit ON using start stop switch ST Pressthe UP or DOWN arrow key until display reads Set UP Press the ENTER key on the keypad Pressthe UP or DOWN arrow key until display reads XXXX the message ruN COnFG If a defective card is being used the display will blink the message bAd eid Turn start stop switch OFF and remove the card 1 Press the ENTER key on the keypad The display module will go blank briefly and then dis play 551 00 based on the operational software installed Press the UP or DOWN ARROW key to scroll through the list to obtain the proper model dash num ber If a defective card is being used the display will blink the message bAd CArd Turn start stop Switch OFF and remove the card 10 Press the ENTER key on the keypad 11 When the software loading has successfully com pleted t
136. lay will read Display Only Functions Diaital Unloader Displays the DUV percent closed The right display reads 100 when the valve is Cd01 Wane Opening fully closed The valve will usually be at 10 on start up of the unit except in very high ambient temperatures Compressor Motor The current sensor measures current draw in lines L1 amp L2 by all of the high volt CURE age components It also measures current draw in compressor motor leg The compressor leg T3 current is displayed 4 Line Current The current sensor measures current on two legs The third unmeasured leg is Phase calculated based on a current algorithm The current measured is used for control and diagnostic purposes For control processing the highest of the Phase A and Cd05 Line Current B current values is used for current limiting purposes For diagnostic processing PhaseB the current draws are used to monitor component energization Whenever a heat er or a motor is turned ON or OFF the current draw increase reduction for that CdO6 Line Current activity is measured The current draw is then tested to determine if it falls within Phase the expected range of values for the component Failure of this test will result in a pre trip failure or a control alarm indication 07 Main Power Voltage The main supply voltage is displayed Main Power The value of the main power frequency is displayed in Hertz The frequency dis F
137. low the defrost termination thermostat setting Defrost will terminate when the defrost temperature sensor reading rises above the defrost termination thermostat setting When a request for defrost is made with the defrost interval timer or by demand defrost the defrost temperature setting must be below 10 When the defrost mode is initiated the controller closes the EEV opens contacts TC TN and TE or TV to de energize the compressor condenser fan and evaporator fans The COOL light is also de energized The controller then closes contacts TH to supply power to the heaters The defrost light is illuminated When the defrost temperature sensor reading rises to the defrost termination thermostat setting the de icing operation is terminated defrost command T 340 ENERGIZED DE ENERGIZED 24 VOLT POWER NOTE The EEV and DUV are independently operated by the microprocessor For full diagrams and legend see Section 7 Figure 3 10 Defrost 3 4 PROTECTION MODES OF OPERATION 3 4 1 Evaporator Fan Operation Opening of an evaporator fan internal protector will shut down the unit 3 4 2 Failure Action Function code Cd29 may be operator set to select action the controller will take upon system failure The factory default is full system shutdown Refer to Table 3 5 3 4 3 Generator Protectio
138. lting from heater AL61 Heaters Failure activation or deactivation Each phase of the power source is checked for proper be reset by a proper amp draw of the heater Compressor Circuit Failure mum 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 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 mini AL62 lected 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 current decreases below the activation level Discharge Tempera Alarm 64 is triggered if the discharge temperature sensed is outside the range of AL64 ture Gu 60 76F to 175C 347F or if the sensor is out of range This is a display alarm and has no associated failure action AL65 Discharge Pressure Alarm 65 is triggered if a compressor discharge transducer is out of range This Transducer Failure is a display alarm and has no associated failure action 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 se AL63 Current Over Limit 3 25 T 340 Table 3 6 Controller Alarm Indications Sheet 4 of 4 Alarm 6
139. ly return USDA 1 2 3 and cargo probe and the humidity sensor input will be generated by the DataCORDER See Figure 3 11 NOTE The DataCORDER software uses the supply and return recorder sensors SRS RRS The temperature control software uses the supply and return temperature sensors STS RTS b Generic Mode The generic recording mode allows user selection of the network data points to be recorded The user may select up to a total of eight data points for recording A list of the data points available for recording follows Changing the configuration to generic and selecting which data points to record may be done using the Carrier Transicold Data Retrieval Program Control mode Control temperature Frequency Humidity Phase current Phase B current Phase C current Main voltage Evaporator expansion valve percentage Discrete outputs Bit mapped require special handling if used 11 Discrete inputs Bit mapped require special handling if used 12 Ambient sensor 13 Evaporator temperature sensor 14 Compressor discharge sensor 15 Return temperature sensor RTS 16 Supply temperature sensor STS 17 Defrost temperature sensor 18 Discharge pressure transducer 19 Suction pressure transducer 20 Condenser pressure transducer 21 Vent position sensor VPS h o 3 7 4 Logging Interval 4 The user may select four different time intervals between data recordings
140. ly and return probes If the controller is programmed with the Demand Defrost option and the option is set to IN the unit will enter defrost if it has been in operation for more than 2 5 hours without reaching set point The system is actively in a compressor suction pressure or high pressure ratio protection mode and reduced the average system capacity below a predetermined threshold value Defrost may be initiated any time the defrost temperature sensor reading falls below the controller defrost termination thermostat set point Defrost will terminate when the defrost temperature sensor reading rises above the defrost termination thermostat set point The defrost termination thermostat is not a physical component It is a controller setting that acts as a thermostat closing allowing defrost when the defrost temperature sensor reading is below the set point and opening terminating or preventing defrost when the sensor temperature reading is above set point When the unit is operating in bulb mode refer to paragraph NO TAG special settings may be applicable If the controller is programmed with the Lower DTT setting option the defrost termination thermostat set point may be configured to the default of 25 6C 78F or lowered to 18C 64F When a request for defrost is made through the manual defrost switch communications or probe check the unit will enter defrost if the defrost temperature thermostat reading is at or be
141. ly reading for units configured for four probes If the unit is configured with a Data Temperature Sensor CORDER Cd38 will display If the DataCORDER suffers a failure AL55 Cd38 will display the supply recorder sensor reading Code Cd39 will display the current secondary return temperature sensor RRS Cd39 Secondary Return reading for units configured for four probes If the unit is configured with a Data Temperature Sensor CORDER Cd39 will display If the DataCORDER suffers a failure AL55 Cd39 will display the return recorder sensor reading Container Identifica 940 is configured at commissioning to read valid container identification Cd40 tion Number number The reading will not display alpha characters only the numeric portion of the number will display SERVICE FUNCTION This code is used for troubleshooting and allows manual Cd41 Valve Override positioning of the economizer and oil return valves Refer to paragraph 6 16 for operating instructions Fresh Air Vent Unless AL50 is active or CnF47 is OFF the fresh air flow CMH CFM is Cd45 Position Sensor displayed This function code will automatically activate for 30 seconds and displayed when a vent position change occurs This code displays the airflow units to be displayed for Cd 45 Options are CF Cd46 Airflow Display Units Cw or bOth dependant on the setting of Cd28 or pressing of the C F key 3 21 T 340
142. mended that new locknuts be used when replacing motor Connect the wiring connector f 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 to fan set screws Adjust fan within venturi so that the outer edge of the fan is within 2 0 0 07 mm 0 08 0 03 from the outside of the orifice open ing Spin fan by hand to check clearance g Close and secure condenser fan screen guard 6 8 WATER COOLED CONDENSER CLEANING 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 con densed 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 nor mal difference between leaving condensing water tem perature and actual condensing temperature coupled with a small difference in temperature of entering and leaving condensing water is an indication of a dirty con densing coil To find the approximate condensing temperature with the unit running in the cooling mode install a ga
143. n Configuration identification for the models covered herein may be obtained on the Container Products Group Information Center by authorized Carrier Trans icold Service Centers a DataReader The Carrier Transicold Data Reader see Figure 3 12 is a simple to operate handheld device designed to ex tract data from the DataCORDER and upload it to a PC The Data Reader has the ability to store multiple data files Refer to Data Retrieval manual 62 02575 for a more detailed explanation of the DataReader TRANSICOLD DataReader N 1 OFF 5 ENTER 2 ON 6 Escape 3 UP Arrow 7 DOWN Arrow 4 RIGHT Arrow 8 LEFT Arrow Figure 3 12 Data Reader b DataBANK Card The DataBANK card is a PCMCIA card that interfaces with the controller through the programming slot and can download the data at a much faster rate when compared to the PC or DataReader Files downloaded to DataBANK card files are accessible through an Omni PC Card Drive The files can then be viewed using the DataLINE software c DataLINE The DataLINE software for a personal computer is supplied on both floppy disks and CD This software allows interrogation configuration variable assignment screen view of the data hard copy report generation cold treatment probe calibration and file management Refer to Data Retrieval manual 62 10629 for a more deta
144. n Function codes Cd31 Stagger Start Offset Time and Cd32 Current Limit may be operator set to control start up sequence of multiple units and operating current draw The factory default allows on demand starting no delay of units and normal current draw Refer to Table 3 5 3 4 4 Compressor High Temperature Low Pres sure Protection The controller monitors compressor discharge pressure and temperature and suction pressure If discharge pressure or temperature rises above the allowed limit or suction pressure falls below the allowed limit the compressor will be cycled off on a three minute timer Condenser and evaporator fans continue to operate during the compressor off cycle 1 If compressor dome temperature exceeds 136C 276 8F continuously for five seconds high dome temperature the liquid injection solenoid valve will open When compressor dome temperature then decreases to 121C 249 8F or below the liquid injection solenoid valve will close 2 If suction superheat exceeds a 55C range during unloaded capacity mode operation suction quench the liquid injection solenoid valve will open When suction superheat decreases below 20C range or if unit leaves unloaded capacity mode the liquid injection solenoid valve will close T 340 3 10 3 If conditions occur that would require the liquid injection valve to open valve will close when dome temperature goes below 136C and suction superheat is less than 20C ra
145. n tainer temperature is above 15 6C at the start of the test then the test proceeds immediately to test P8 1 and the left display will change to P8 1 Pass Fail Criteria The test fails if the 180 minute timer expires before the con trol temperature reaches set point The display will read P8 0 FAIL Requirements Control temperature must be at least 15 6C 60F Setup The set point is changed to OC 32F and 180 minute timer is started The left display will read P8 1 the right display will show the supply air temper ature The unit will then start to pull down the temperature to the OC set point 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 This test is skipped if the DataCORDER is not configured or not available Setup A 15 minute timer is started The unit will be required to minimize control temperature error supply temperature minus set point until the timer expires The control temperature will be sampled at least once each minute starting at the beginning of P8 2 Pass Fail Criteria If the average recorded temperature is within 1 0C 1 8F of set point the test passes If the average temperature is outside of the toler ance range or if the DataCORDER supply temperature probe is invalid the test fails and and the control probe temperature will be recorded as 50 0C P8 2
146. n at the test selection menu the user may press the UP ARROW key When this is done all test outputs will be de energized and the test selection menu will be displayed Throughout the duration of any pre trip test except the P 7 high pressure switch tests the current and pressure limiting processes are active The current limiting process only is active for P 7 d Pre Trip Test Results At the end of the pre trip test selection menu the mes sage rSLts pre trip results will be displayed Pressing the ENTER key will allow the user to see the results for all subtests i e 1 0 1 1 etc The results will be displayed as PASS or FAIL for all the tests run to completion since power up If a test has not been run since power up will be displayed Once all pre test activity is completed dehumidification and bulb mode must be reactivated manually if required 4 9 OBSERVE UNIT OPERATION 4 9 1 Probe Check If the DataCORDER is off or in alarm the controller will revert to a four probe configuration which includes the DataCORDER supply and return air probes as the sec ondary controller probes The controller continuously performs probe diagnosis testing that compares the four probes If the probe diagnosis result indicates a probe problem exists the controller will perform a probe check to identify the probe s in error a Probe Diagnostic Logic Standard If the probe check option controller configur
147. nents available for use by the operational software This software is factory installed in accordance with the equipment fitted and options listed on the original purchase order Changes to the configuration software are required only when a new controller has been installed or a physical change has been made to the unit such as the addition or removal of an option A configuration variable list is provided in Table 3 4 Change to the factory installed configuration software is achieved via a configuration card or by communications 3 2 2 Operational Software Function Codes The operational software is the actual operation programming of the controller which activates or deactivates components in accordance with current unit operating conditions and operator selected modes of operation lt CONTROLLER gd o With ink 3 5 DataCORDER xr rf 1 Mounting Screw 2 Micro Link Control DataCORDER Module 3 Connectors 4 Test Points Fuses Control Circuit Power Connection Software Programming Port Battery Pack Standard Location Figure 3 4 Control Module OND T 340 The programming is divided into function codes Some of the codes are read only while t
148. nge 3 4 5 Perishable Mode System Pressure Regula tion In perishable mode system pressures may need to be regulated at ambient temperatures of 20C 68F and below Once below this ambient temperature the condenser fan may cycle on and off based on limits imposed for discharge pressure For extremely cold ambient temperatures 18C OF heater cycling may occur within normal system operation based on discharge pressure limits 3 4 6 Condenser Fan Switch Override When configuration variable CnF15 Discharge Temperature Sensor is set to and CnF48 Condenser Fan Switch Override is set to On the condenser fan switch override logic is activated If condenser cooling water pressure is sufficient to open the water pressure switch de energizing the condenser fan when water flow or temperature conditions are not maintaining discharge temperature the logic will energize the condenser fan as follows 1 If the discharge temperature switch reading is valid and discharge temperature is greater than 115C 240F the condenser fan is energized When discharge temperature falls to 90 5C 195F the condenser fan is de energized If the system is running on condenser fan override and the high pressure switch opens twice within a seven minute period the condenser fan is ener gized and will remain energized until the system is power cycled Alarm 58 Compressor High Pressure Safety will be triggered 3 5 CONTROLLER
149. nly and will trigger off when 9 the compressor operates for one hour without overpressure Alarm 19 is triggered if discharge temperature exceeds 135 275F for AL19 Discharge Tempera 10 minutes within the last hour The alarm is display only and will trigger off when g the compressor operates for one hour without over temperature Control Circuit Fuse Alarm 20 is triggered by control power fuse F3A F3B opening and will cause AL20 Open 24 VAC the software shutdown of all control units This alarm will remain active until the fuse is replaced 3 23 T 340 Micro Circuit Fuse Open 18 VAC Evaporator Fan Motor Safety Loss of Phase B Compressor Motor Safety Condenser Fan Mo tor Safety All Supply and Re turn temperature Control Sensors Failure A D Accuracy Fail ure Low Suction Pres sure AutoFresh Failure Fresh Air Position Sensor VPS Alarm List Failure Alarm List Full Table 3 6 Controller Alarm Indications Sheet 2 of 4 Alarm 21 is triggered by one of the fuses F1 F2 being opened on 18 VAC power supply to the controller Temperature control will be maintained by cycling the compressor Alarm 22 responds to the evaporator motor internal protectors On units with Nor mal Evaporator Fan Operation CnF32 set to 2EFO the alarm is triggered by opening of either internal protector It will disable all control units until the motor protector resets On units with Single Evaporator Fan
150. nsor bacc Fail Skip Suction Pressure Sensor Test Pass Fail Skip Compressor Current Draw Pass Fail Skip 66 Economizer Valve Test Pass Fail Skip Digital Unloader Valve Test Pass Fail Skip Pass Fail Skip Result AMBS or CPT if equipped 7 0 High Pressure Switch Closed Input values that component opens Pass Fail Skip Result STS DPT or CPT if equipped 7 1 High Pressure Switch Open Input values that component closes Perishable Mode Heat Test Pass Fail Skip Result STS time it takes to heat to 16C 60F perishable Mode Pulldown pass Fail Skip Result STS time it takes to pull down to 32F Perishable Mode Maintain Pass Fail Skip Result Averaged DataCORDER supply temperature Test SRS over last recording interval Pass Fail Skip Result DTS reading at end of test line voltage line Defrost Test frequency time in defrost 10 0 Frozen Mode Heat Test Pass Fail Skip Result STS time unit is in heat 10 1 Frozen Mode Pulldown Test Pass Fail Skip Result STS time to pull down unit to 17 8C OF Pass Fail Skip Result Averaged DataCORDER return temperature 10 2 Frozen Mode Maintain Test RRS over last recording interval 8 1 2 8 T 340 3 32 Table 3 10 DataCORDER Alarm Indications To Access Press ALT MODE key Code No TITLE DESCRIPTION The supply recorder sensor reading is outside of the range of 50C to 70C 58F to 158F or the probe check logic has determined
151. nt The sensor requires four minutes of no movement to confirm stability If the vent position changes at any point beyond the four minute adjustment period the sensor will generate an alarm event The alarm is triggered off when the unit power cycles and the sensor is within valid range 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 involv ing 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 re set 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 24 Table 3 6 Controller Alarm Indications Sheet 3 of 4 Alarm 53 is caused by the battery pack charge being too low to provide sufficient power for battery backed recording If this alarm occurs on start up allow a unit fitted with rechargeable batteries to operate for
152. ntrol Box 13 Interrogator Connector Front left 4 Compressor 14 Temperature Recorder 5 Economizer 15 Lower Fresh Air Makeup Vent Location 6 Filter Drier Blank Cover Shown 7 Receiver or Water Cooled Condenser 16 TIR Transports Internationaux Routiers 8 Unit Serial Number Model Number and Sealing Provisions Typical All Panels Parts Identification Number PID Plate 17 Upper Fresh Air Makeup Vent 9 Power Cables and Plug Location 18 Access Panel Evap Fan 2 10 Condenser Fan Figure 2 1 Refrigeration Unit Front Section 2 1 T 340 2 1 3 Evaporator Section The evaporator section Figure 2 2 contains the return temperature sensor humidity sensor electronic expan sion valve dual speed evaporator fans EM1 and EM2 evaporator coil and heaters defrost temperature sen Sor heat termination thermostat and evaporator tem perature sensors ETS1 and ETS2 The evaporator fans circulate air through the container by pulling it in the top of the unit directing it through the evaporator coil where it is heated or cooled and dis charging it at the bottom Most evaporator components are accessible by remov ing the upper rear panel as shown in the illustration or by removing the front access panels SS 555 S 55 555555595555 SSS SSN SSS S 55 55555555555 55525555 SSS WSS 555525555 551 SS 55 5559 55555555555 555555555
153. ntrol discs The fresh air makeup can be adjusted for 15 35 50 or 75 cubic meters per hour CMH The air flow has been established at 60 Hz power and 2 1 2 inch T bar and with 15 mm 0 6 inch external static above free blow Loosen the hex nut adjust each disc to the required air flow then tighten hex nut NOTE The main air slide is in the fully closed position during reduced air flow operation when equipped with air control discs c Air Sampling for Carbon Dioxide 2 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 in hose to the sampling port If the internal atmosphere content has reached an unacceptable level the operator may adjust the disc opening to meet the required air flow volume to ventilate the container T 340 4 3 3 Vent Position Sensor The VPS allows the user to determine the position of the fresh air vent via Function Code 45 This function code is accessible via the Code Select key The vent position will display for 30 seconds whenever motion corresponding to 5 CMH 3 CFM or greater is detected It will scroll in intervals of 5 CMH 3 CFM Scrolling to Function Code 45 will display the Fresh Air Vent Position The position of the vent will be recorded in the DataCORDER whenever the unit is running under AC power and any of the following Trip start On every power cycle
154. ntroller 1 3 7 Interrogator Units that use the DataCORDER function are fitted with interrogator receptacles for connection of equipment to download the recorded data Two receptacles may be fitted one is accessible from the front of the container and the other is mounted inside the container with the USDA receptacles 1 3 8 Remote Monitoring The unit may be fitted with a remote monitoring receptacle This item allows connection of remote indicators for COOL DEFROST and IN RANGE Unless otherwise indicated the receptacle is mounted at the control box location 1 3 9 Communications The unit may be fitted with a communications interface module The communications interface module is a slave module which allows communication with a master central monitoring station The module will respond to communication and return information over the main power line Refer to the ship master system technical manual for further information 1 3 10 Compressor The unit is fitted with a scroll compressor that is equipped with suction and discharge service connections 1 3 11 Condenser Coil The unit is fitted with a four row coil using 7mm tubing T 340 1 3 12 Autotransformer An autotransformer may be provided to allow operation on 190 230 3 phase 50 60 Hz power The autotransformer raises the supply voltage to the nominal 380 460 volt power required by the base unit The autotransformer may also be fitted with an individual circu
155. o AUTO they act as a group This function is designed to assist users who keep their DataCORDER configured for USDA recording but do not install the probes for every trip If all the probes are disconnected no alarms are activated As soon as one of the probes is installed all of the alarms are enabled and the remaining probes that are not installed will give active alarm indications 3 7 8 DataCORDER Power Up The DataCORDER may be powered up in any one of four ways 1 Normal AC power The DataCORDER is powered up when the unit is turned on via the stop start switch 2 Controller DC battery pack power battery pack is installed the DataCORDER will power up for T 340 communication when an interrogation cable is plugged into an interrogation receptacle 3 External DC battery pack power A 12 volt battery pack may also be plugged into the back of the interrogation cable which is then plugged into an interrogation port No controller battery pack is required with this method 4 Real Time Clock demand If the DataCORDER is equipped with a charged battery pack and AC power is not present the DataCORDER will power up when the real time clock indicates that a data recording should take place When the DataCORDER is finished recording it will power down During DataCORDER power up while using battery pack power the controller will perform a hardware voltage check on the battery If the hardware check passes the controller
156. o low side of system OahWONM Figure 6 1 Manifold Gauge Set When the suction pressure hand valve is frontseated turned all the way in the suction low pressure can be checked When the discharge pressure hand valve is frontseated the discharge high pressure can be checked When both valves are open all the way out high pressure vapor will flow into the low side When the suction pressure valve is open and the discharge pres sure valve shut the system can be charged Oil can also be added to the system A R 134a manifold gauge hose set with self sealing ho ses see Figure 6 2 is required for service of the mod els covered within this manual The manifold gauge hose set is available from Carrier Transicold Carrier Transicold part number 07 00294 00 which includes items 1 through 6 Figure 6 2 To perform service using the manifold gage hose set do the following a Preparing Manifold Gauge Hose Set For Use If the manifold gauge hose set is new or was exposed to the atmosphere it will need to be eva cuated to remove contaminants and air as follows 1 Back seat turn counterclockwise both field service couplings see Figure 6 2 and midseat both hand valves Connect the yellow hose to a vacuum pump and re frigerant 134a cylinder To Low Side Access Valve To High Side Access Valve Manifold Gauge Set RED Refrigeration and or Evacuation Hose SAE J2196 R 134a Hose Fitting 0 5 16 Acm
157. o open the economizer solenoid valve ESV and place the unit in economized operation NOTE The EEV and DUV are independently ted by the microprocessor For full diagrams b When the air temperature decreases to a Opera predetermined tolerance above set point the 81 legend see Section 7 in range light is illuminated Figure 3 6 Perishable Mode Cooling 3 5 T 340 As the air temperature continues to fall modulated cooling starts approximately 2 5C 4 5F above set point See Figure 3 5 When modulated cool starts the EEV control will transition from a full cool superheat set point to a lower modulated cool superheat set point Once modulation starts the EEV controls evaporator superheat based on the system duty cycle where instantaneous superheat will vary When the return air has fallen to within 1 9C 3 4F of set point temperature and the average capacity ofthe system has fallen below 7096 the unit will open contacts TS and close the ESV The controller monitors the supply air Once the supply air falls below set point the controller periodically records the supply air temperature set point and time A calculation is then performed to determine temperature drift from set point over time If the calculation determines cooling is no longer required contacts TC and TN are opened to de energize compressor motor and condenser fan motor In addition the controller will close the EEV Peri
158. ollowed by a compressor pump down sequence At the conclusion of the compressor pump down sequence the compressor will shut down and the valve test will start Economizer Passes if suction pressure increases a minimum of 4 psi when the valve opens Valve Test for 15 seconds Digital Unloader Passes if pressure and current changes are within 3 seconds of DUV switch sig P6 7 Value Ti Test nal and either the pressure change or the current draw change is above 5 psi or above 1 5A respectively Injection Passes if increase in suction pressure reaches above 4 psi when the valve opens for 15 seconds Electronic Pass Fail Criteria The test records the suction pressure during the open valve P6 10 Valve position and passes if the suction pressure increase is above 3 psi when the valve opens for 10 seconds NOTE P7 0 amp P8 are included with Auto2 amp Auto 3 only P9 0 through P10 are included with Auto2 only NOTE This test is skipped ifthe sensed ambient temperature is less than 7C 45F the return air temperature is less than 17 8C OF the water pressure Switch is open or the condenser fan switch is open Setup With the unit running the condenser fan is turned off and a 900 second 15 minute timer is started The right display shows the value of the initial sensor configured and valid out of the discharge pressure CPC pressure dis charge temperature 7 0 Pass Fail Criteria The tes
159. ollowing subparagraphs a USDA Recording A special type of recording is used for USDA cold treatment purposes Cold treatment recording requires three remote temperature probes be placed at prescribed locations in 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 or five receptacles are provided The four 3 pin receptacles are for the probes The 5 pin receptacle is the rear connection for the Interrogator The probe receptacles are sized to accept plugs with tricam coupling locking devices A label on the back panel of the unit shows which receptacle is used for each probe The standard DataCORDER report displays the supply and return air temperatures The cold treatment report displays USDA 1 2 3 and the supply and return air temperatures Cold treatment recording is backed up by a battery so recording can continue if AC power is lost b USDA Message Trip Comment A special feature incorporated in DataLINE DataView allows the user to enter a USDA or other message in the header of a data report The maximum message length is 78 characters Only one message will be recorded per day 3 7 12 USDA Cold Treatment Procedure The following is a summary of the steps required to initiate a USDA Cold Treatment a Calibrate the three USDA probes by ice bathing the probes and performing the calibration function with the DataReader DataView or
160. onal charge necessary for low temperature operation When operating with the water cooled condenser active see Figure 2 7 lower schematic the refrigerant gas passes through the air cooled condenser and enters the water cooled condenser shell The water flowing inside the tubing cools the gas to saturation temperature in the same manner as the air passing over the air cooled con denser The refrigerant condenses on the outside of the tubes and exits as a high temperature liquid The water cooled condenser also acts as a receiver storing ex cess refrigerant The liquid refrigerant continues through the liquid line the filter drier which keeps refrigerant clean and dry andthe economizer which is not active during standard operation to the electronic expansion valve As the liq uid refrigerant passes through the variable orifice of the expansion valve some of it vaporizes into a gas flash gas Heat is absorbed from the return air by the balance ofthe liquid causing itto vaporize in the evaporator coil The vapor then flows through the suction tube back to the compressor On systems fitted with a water pressure switch the con denser fan will be off when there is sufficient pressure to open the switch If water pressure drops below the switch cut out setting the condenser fan will automatic ally start When operating a system fitted with a con denser fan switch the condenser fan will be off when the switch is placed in the
161. order door and check battery of electronic recorder Be sure key is returned to storage clip of mechanical recorder b Lift stylus pen by pulling the marking tip outward un til the stylus arm snaps into it s retracted position c Install new chart making sure chart is under the four corner tabs Lower the stylus until it has made contact with the chart Close and secure door DataCORDER a Check and if required setthe DataCORDER Config uration in accordance with desired recording parame ter Refer to paragraph 3 7 3 b Enter a Trip Start To enter a Trip Start do the fol lowing 1 Depress the ALT MODE key When the left display shows dC depress the ENTER key Scroll to Code dC30 Depress and hold the ENTER key for five seconds The Trip Start event will be entered in the Data CORDER 4 7 4 Complete Inspection Allow unit to run for five minutes to stabilize conditions and perform a pre trip diagnosis in accordance with the following paragraph 4 8 PRE TRIP DIAGNOSIS CAUTION Pre trip inspection should not formed with critical temperature cargoes in the container CAUTION When Pre Trip key is pressed economy dehumidification and bulb mode will be deactivated At the completion of Pre Trip activity economy dehumidification and bulb mode must be reactivated Pre Trip diagnosis provides automatic testing of the unit components using internal measurements and compari
162. ox 4805 Syracuse N Y 13221 U SA www carrier transicold com A member of the United Technologies Corporation family Stock symbol UTX TRANSICOLD 2008 Carrier Corporation Printed in U S A 02 08
163. ped with full oil charge of 60 oz Cut and discard the wire ties used to hold the base plate to the compressor Placethe new SST washers on each side ofthe resi lient mounts and the new Mylar washer on the bot tom of it as shown in Figure 6 5 Install the four base mounting screws loosely Place the new Teflon seals at the compressor suc tion and discharge ports as well as the O rings atthe unloader and economizer line connection ports Hand tighten all four connections Torque the four base mounting screws to 6 2 45 ft Ibs 1 Compressor 6 Resilient Mount 2 O Ring Unloader 7 Mylar Washers Connection 8 Wire Ties 3 O Ring Economizer 9 Power Cable Gasket Connection 10 Ground Connection 4 Teflon Seal for Valve Screw Connection 11 Power Cable 5 SST Washers Lubricant Krytox Not Shown Figure 6 5 Compressor Kit q Torque the compressor ports connections to Service Valve Connection Torque Value Suction and Discharge 108 5 to 135 5 Nm Rotalocks 80 to 100 ft Ibs Unloader connection 24 5 to 27 Nm 18 to 20 ft lbs Economized connection 32 5 to 35 Nm 24 to 26 ft Ibs r Connect butt splice and heat shrink the new com pressor dome temperature sensor with the old sensor wires removed in step 9 Wire tie any loose wiring as appropriate Evacuate the compressor to 1000 microns if the unit was pumped down b
164. putting it back into service The representative s knowledge of metals types of scale water conditions and de scaling techniques will be highly useful Summary of Procedure 1 Drain water from condenser tubing circuit 2 Clean water tubes with Oakite No 22 to remove mud and slime Flush De scale water tubes with Oakite No 32 to remove scale Flush Neutralize Flush Put unit back in service under normal load and check head discharge pressure Detailed Procedure 1 Drain and flush the water circuit of the condenser coil If scale on the tube inner surfaces is accompa nied by slime a thorough cleaning is necessary before de scaling process can be accomplished 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 circu A 340 late through the tubes until all slime and mud has been removed 3 After cleaning flush tubes thoroughly with fresh clean water 4 Preparea 1596 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 e acid Oakite No 32 to 2 8 liters 3 U S quarts of water constant for a reasonable time this is an indication that scale has been dissolved Oakite No 32 is an acid Be sure that the acid is slowly added to the water DO NOT PUT WATER INTO THE AC
165. r proper phase sequencing and compressor rotation If sequencing is allowing the compressor and three phase evaporator fan motor to rotate in the wrong direction the controller will energize or de energize relay TCP as required see Figure 7 2 Relay TCP will switch its contacts energizing or de energizing relays PA and PB Relay PA is wired to energize the circuits s on L1 L2 and L3 Relay PB is wired to energize the circuit s on L3 L2 and L1 thus providing reverse rotation 3 3 2 Start up Compressor Bump Start The controller logic will initiate a compressor bump start procedure to clear refrigerant from the compressor If the unit has been without power for four hours or if suction and discharge pressures have equalized the compressor will perform three compressor bump starts The EEV will close Relays TS TQ TN TE TV will be de energized opened The result of this action will close the ESV LIV and shut all fans off The compressor will start for 1 second then pause for five seconds This sequence will be repeated two additional times After the final bump start the unit will pre position the EEV to correct starting position pause and startup 3 3 3 Perishable Set Point Temperature Perish able Pulldown When cooling from a temperature that is more than 2 5C 4 5F above set point the system will be in the perishable pulldown mode It will be in economized operation However pressure and current limit T 340
166. r there is a probe circuit calibration failure alarm code 127 the unit will enter the shutdown state defined by this setting The user selects one of four possible actions as follows Failure Action A Full Cooling Compressor is on economized operation Mode B Partial Cooling Compressor is on standard operation C Evaporator Fan Only Evaporator fans on high speed not applicable with frozen set points D Full System Shutdown Factory Default Shut down every component in the unit 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 In Range Tolerance 1 0 5C 0 9F 2 1 0C 1 8F 3 1 5C 2 7F 4 2 0C 3 6F Factory Default The stagger start offset time is the amount of time that the unit will delay at start Stagger Start Offset up thus allowing multiple units to stagger their control initiation when all units are Time Seconds powered up together The eight possible offset values are 0 Factory Default 3 6 9 12 15 18 or 21 seconds T 340 3 20 Table 3 5 Controller Function Codes Sheet 3 of 4 The current limit is the maximum current draw allowed on any phase at any time Limiting the unit s current reduces the load on the main power supply When de sirable the limit can be lowered Not
167. ra Alarm 57 is triggered by an ambient temperature reading outside the valid range ture Sensor Failure from 50 to 70C 58F to 158F Compressor High Alarm 58 is triggered when the compressor high discharge pressure safety switch AL58 eiiis SE remains open for at least one minute This alarm will remain active until the pres y sure switch resets at which time the compressor will restart Heater Termination Alarm 59 is triggered when the heat termination thermostat switch is opened ex AL59 Thermostat HTT cept when defrost sensor alarm is active This alarm will remain active until the heat termination thermostat closes Alarm 60 is an indication of a probable failure of the defrost temperature sensor DTS It is triggered by the opening of the heat termination thermostat HTT or the failure of the DTS to go above set point within two hours of defrost initiation 160 Defrost Temperature After one half hour with a frozen range set point or one half hour of continuous Sensor Failure compressor run time if the return air falls below 7C 45F the controller checks to ensure the DTS reading has dropped to 10C or below If not a DTS failure alarm is given and the defrost mode is operated using the return temperature sensor The defrost mode will be terminated after one hour by the controller amperage This alarm is a display alarm with no resulting failure action and will Alarm 61 is triggered by detection of improper amperage resu
168. ransit b Installation Install the module by reversing the removal steps Torque values for mounting screws item 2 see Figure 6 14 are 0 23 mkg 20 inch pounds Torque value for the connectors is 0 12 mkg 10 inch pounds 6 18 5 Battery Replacement Standard Battery Location Standard Cells a Turn unit power OFF and disconnect power supply b Slide bracket out and remove old batteries See Figure 3 4 Item 8 c Install new batteries and slide bracket into control box slot CAUTION Use care when cutting wire ties to avoid nicking or cutting wires 2 Standard Battery Location Rechargeable Cells a Turn unit power OFF and disconnect power supply b Disconnect battery wire connector from control box Slide out and remove old battery and bracket See Figure 3 4 Item 8 Slide new battery pack and bracket into the control box slot Reconnect battery wire connector to control box and replace wire ties that were removed Secure Battery Option Rechargeable Cells Only a Turn unit power OFF and disconnect power supply b Open control box door and remove both the high volt age shield and clear plastic rain shield if installed c Disconnect the battery wires from the KA plug posi tions 14 13 11 d Using Driver Bit Carrier Transicold part number 07 00418 00 remove the 4 screws securing the dis d e T 340 6 18 play module to the control box Disconnect the ribbon c
169. rature is less than the set point 0 2C the unit will turn off the evaporator fans and restart another 60 minute off cycle T 340 FALLING RISING TEMPERATURE TEMPERATURE ECONOMIZED COOLING 0 2 C SET POINT SET POINT 0 2C AIR CIRCULATION NOTE TEMPERATURES INDICATIONS ARE ABOVE OR BELOW SET POINT Figure 3 8 Controller Operation Frozen Mode 3 3 17 Frozen Mode Cooling Sequence of Operation a When the supply air temperature is above set point and decreasing the unit will transition to economized cooling with the condenser fan motor CF compressor motor CH economizer solenoid valve ESV low speed evaporator fan motors ES energized and the COOL light illuminated See Figure 3 9 When the air temperature decreases to a predetermined tolerance above set point the in range light is illuminated c When the return air temperature decreases to 0 2C 0 4F below set point contacts TC TS and TN are opened to de energize the compressor economizer solenoid valve and condenser fan motor The cool light is also de energized The EEV will close d The evaporator fan motors continue to run in low speed to circulate air throughout the container The in range light remains illuminated as long as the return air is within tolerance of set point e If return air temperature drops to 10C 18F or more below set point the evaporator fans increase to high speed NOTE The EEV and DUV are independen
170. re at set point the SUPPLY indicator light will be illuminated on the display module and the default reading on the display window will be the supply temperature sensor reading When the supply air temperature enters the in range temperature tolerance as selected at function code Cd30 the in range light will energize FALLING RISING TEMPERATURE TEMPERATURE CONOMIZED COOLING MODULATED COOLING SEE NOTE 2 MODULATED COOLING STANDARD SET POINT SET POINT AIR 0 5 0 9 F HEATING NOTE 1 TEMPERATURES INDICATIONS ARE ABOVE OR BELOW SET POINT NOTE 2 ECONOMIZED MODULATED COOLING OCCURS IF RETURN TEMPERATURE SENSOR IS GREATER THAN SET POINT PLUS 1 9 C AND IF CAPACITY MODULATION IS GREATER THAN 70 IF CONDITIONS ARE NOT MET STANDARD MODULATED COOLING OCCURS Figure 3 5 Controller Operation Perishable Mode 3 3 7 Perishable Mode Cooling Sequence of Operation ENERGIZED DE ENERGIZED NOTE Inthe Conventional Perishable Mode of Opera tion the evaporator motors run in high speed In the Economy Perishable Mode the fan speed is varied a With supply air temperature above set point and decreasing the unit will cool with the condenser fan motor CF compressor motor CH evaporator fan motors EF energized and the COOL light illuminated See Figure 3 6 Also if current or pressure limiting is not active the controller will close contacts TS t
171. re trip repeat backward Return Displays non controlling probe tem Supply perature momentary display Displays alternate English Metric scale momentary display When set to F pressure is displayed in psig and Celsius Vacuum in hg P appears after the value to indicate psig and i appears Fahrenheit for inches of mercury When set to C pressure readings are in bars 0 appears after the value to indicate bars P OUR 5 Initiate battery backup mode to allow Fe DEIN ION ey set point and function code selection 3 Alarm List 8 Return Supply ower it AC power is not connected 4 Manual Defrost 9 Celsius Fahrenheit This Kev pressed to Swich ihe Interval 10 Battery Power functions from the temperature soft 5 ENTER 11 Alt Mode ware to the DataCORDER Software ALT The remaining keys function the Figure 3 2 Keypad same as described above except the readings or changes are made to the 3 1 2 Display Module DataCORDER programming The display module Figure 3 3 consists of two 5 digit 5 Supply Yellow LED Energized when the supply air displays and seven indicator lights The indicator lights probe is used for control When this LED is include illuminated the temperature displayed in the AIR TEMPERATURE display is the reading at the supply 1 Cool White LED Energized when the refrigerant compressor is energized 2 Heat Orange LED Energized to indicate heater op
172. remove the screws securing the panel covering the evapora tor section upper panel Disconnect the defrost heater wiring Remove the mounting hardware from the coil e Unsolder the two coil connections one at the distribu tor and the other at the coil header f Disconnect the defrost temperature sensor see Figure 2 2 from the coil Remove middle coil support After defective coil is removed from unit remove defrost heaters and install on replacement coil i Install coil assembly by reversing above steps j Leak check connections Evacuate and add refriger ant charge 6 10 2 Evaporator Heater Replacement The heaters are wired directly back to the contactor and ifa heater failure occurs during atrip the heater set con taining that heater may be disconnected at the contac tor The next pre trip will detect that a heater set has been disconnected and indicate that the failed heater should be replaced To replace a heater do the following a Before servicing unit make sure the unit circuit break ers CB 1 and CB 2 and the start stop switch ST areinthe OFF position and thatthe power plug is dis connected Remove the upper back panel Determine which heater s need replacing by check ing resistance of each heater set Refer to paragraph 2 3 for heater resistance values Once the set con taining the failed heater is determined cut the splice connection and retest to determine the actual fa
173. requency played will be halved if either fuse F1 or F2 is bad alarm code AL21 Cd09 The ambient sensor reading is displayed Cd10 iiM Evaporator temperature sensor reading is shown on the right display 11 Compressor Dis Compressor discharge temperature sensor reading using compressor dome tem charge Temperature perature is displayed 12 Compressor Suction Reading for primary transducer EPT is shown on the right display Press Pressure ENTER at Cd12 to show reading for secondary transducer SPT on left display Q Compressor Dis C ohare Pressure Compressor discharges pressure transducer reading is displayed Digital Unloader Cd15 Valve Compressor Motor Records total hours of compressor run time Total hours are recorded in incre Hour Meter ments of 10 hours i e 3000 hours is displayed as 300 Cd18 Software Revision The software revision number is displayed This code checks the Controller DataCORDER battery pack While the test is run ning btest will flash on the right display followed by the result PASS will be displayed for battery voltages greater than 7 0 volts FAIL will be displayed for Cd19 Battery Check 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 A The status of the valve is displayed Open
174. resh air panel equipped with VPS Upon installation a new vent position sensor assembly requires calibration as follows 1 Rotate the vent to the 0 CMH CFM position 2 Code select 45 will automatically display Press the Enter key and hold for five seconds After the enter key has been pressed the display will read CAL for calibration Press the ALT MODE key and hold for five seconds After the calibration has been completed Code 45 will display CMH CFM Lower Vent Position Sensor Calibration 3 4 5 Calibration of the Lower VPS is only required when the air makeup slide motor or sensor has been repaired or serviced The VPS is calibrated using the keypad 1 Remove the two nuts that secure the air makeup panel slide to the unit Rotate the gear clockwise until it stops Rotate the gear 1 4 turn counterclockwise Carefully reposition the slide onto the air makeup panel given that the gear is engaged with the rail and has not moved Position slide panel to the fully closed position 2 3 Code select Cd45 will automatically be shown on the left display Depress the ENTER key and hold for five seconds CAL for calibration is displayed Depress the ALT MODE key on the keypad and hold for five seconds 9 When calibration has been completed Cd45 causes 0 CMH CFM to be shown on the right display 10 Secure the air makeup panel slide to the unit with the two nuts s
175. return temperature sensor RTS If controller function code CnF33 is configured to snap freeze the controller will sequence to this operation The snap freeze consists of running the compressor without the evaporator fans in operation for a period of 4 minutes at 100 capacity When the snap freeze is completed defrost is formally terminated 3 3 19 Defrost Mode Sequence of Operation a The defrost cycle may consist of up to three distinct operations The first is de icing of the coil the second is a probe check cycle and the third is snap freeze Defrost may be initiated by any one of the following methods 1 The manual defrost function also manual defrost switch function if equipped is initiated by the user through the use of the keypad or manual defrost switch The manual defrost function is ended by use of the DTS NOTE The Manual Defrost Interval key can be used to initiate a manual defrost Manual Defrost Interval key operation Depressing and holding the Defrost Interval key for five seconds will initiate defrost If the defrost interval key is released in less than five seconds defrost interval code 27 shall be displayed The user sends communications The defrost interval timer controller function code Cd27 reaches the defrost interval set by the user The controller probe diagnostic logic determines that aprobe check is necessary based on the temperature values currently reported by the supp
176. rol temperature to set point using normal frozen mode cooling During this test the control temperate will be shown on the right display Pass Fail Criteria If the control temperature does not reach set point 0 3C 0 17F before the 180 minute timer expires the test fails and will auto repeat by starting P10 0 over Requirements Test P10 1 must pass for this test to execute This test is skipped if the DataCORDER is not configured or not available Setup A 15 minute timer is started The unit will be required to minimize return probe temperature error Supply temperature minus set point until the timer ex pires The return probe temperature will be sampled at least once each minute starting at the beginning of P10 2 Pass Fail Criteria If the average recorded temperature is within 1 6C 2 9 of set point the test passes If the average temperature is outside of the tolerance range or if the DataCORDER return temperature probe is invalid the test fails and the control probe temperature will be recorded as 50 0C P10 2 will auto repeat by starting P10 0 over 3 30 Table 3 8 DataCORDER Function Code Assignments NOTE Inapplicable Functions Display To Access Press ALT MODE key or TITLE DESCRIPTION dC1 opone M Current reading of the supply recorder sensor dC2 1 Current reading of the return recorder sensor USDA 1 2 3 Temper 9 3 5 atures Current readings of the three USDA probes Network Data Current v
177. ry pack voltage is low dC32 Current time on the real time clock RTC in the DataCORDER dC33 Date Month Day Current date month and day on the RTC in the DataCORDER Temperature Sen dC20 24 Sors 1 5 Calibration dC26 27 S N Left 4 Right 4 Date of last Trip start dC34 Current year on the RTC in the DataCORDER dC35 Cargo Probe 4 Current calibration value for the Cargo Probe This value is an input via the Calibration interrogation program 3 31 T 340 Table 3 9 DataCORDER Pre Trip Result Records Test No TITLE DATA 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 2 0 Condenser Fan On Change in currents for Phase A B and C Pass Fail Skip Result Change in currents for Phase A B and C Low Speed Evaporator Fan bass Fail Skip Result Change in currents for Phase A B and High Speed Evaporator Fan pass Fail Skip Result Change in currents for Phase B and C 4 1 High Speed Evaporator Fan pass Fail Skip Result Change in currents for Phase A and C Supply Return Probe Test Pass Fail Skip Result STS RTS SRS and RRS Secondary Supply Probe SRS Test Pass Fail Skip Secondary Return Probe uum RRS Test Pass Fail Skip 6 0 Discharge Thermistor Test Pass Fail Skip Suction Thermistor Test Pass Fail Skip Discharge Pressure Se
178. s d Evacuate and dehydrate the unit Refer to paragraph 6 3 4 e Charge unit per paragraph 6 3 5 6 3 4 Evacuation and Dehydration General Moisture is detrimental to refrigeration systems The presence of moisture in a refrigeration system can have many undesirable effects The most common are cop per plating acid sludge formation freezing up of metering devices by free water and formation of acids resulting in metal corrosion Preparation a Evacuate and dehydrate only after pressure leak test b Essential tools to properly evacuate and dehydrate any system include a vacuum pump 8 m3 hr 5 cfm volume displacement and an electronic vacuum gauge The pump is available from Carrier Trans icold part number 07 00176 11 If possible keep the ambient temperature above 15 6C 60F to speed evaporation of moisture If the ambient temperature is lower than 15 6C 60F ice might form before moisture removal is complete Heat lamps or alternate sources of heat may be used to raise the system temperature Additional time may be saved during a complete sys tem pump down by replacing the filter drier with a sec tion of copper tubing and the appropriate fittings Installation of a new drier may be performed during the charging procedure Suction Service Connection 1 Liquid Service Connection 2 Receiver or Water 6 Vacuum Pump Cooled Condenser 7 Electronic Vacuum 3 Compressor Gauge 4 Discharge Serv
179. s drinking water or is not re circulated in a closed or tower system neutralizing is not nec pockets in the solution should be avoided by regu essary larly opening the vent to release gas Keep flames away from the vent gases 11 Put the unit back in service and operate under nor mal load Check the head pressure If normal a thor ough de scaling has been achieved What You Can Do For Further Help Contact the Engineering and Service Department of the OAKITE PRODUCTS CO 675 Central Avenue New Providence NJ 07974 U S A or visit www oakite com for the name and address of the service representative in your area 7 The time required for de scaling will vary depending upon the extent of the deposits One way to deter mine when de scaling has been completed is to titrate the solution periodically using titrating equip ment 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 T 340 6 8 3 to 4 1 Fill condenser with cleaning solution Do not add solution more rapidly than vent can exhaust gases caused by chemical action 2 Approximately 5 3 Condenser 4 Vent pipe 5 1 pipe Figure 6 8 Water Cooled Condenser Cleaning Gravity Circulation 6 9 FILTER DRIER units equipped with water cooled condenser if the sight glass appears to be flashing or
180. s of a series of parallel copper tubes expanded into copper fins The condenser coil must be cleaned with fresh water or steam so the air flow is not restricted To replace the coil do the following Do not open the condenser fan grille before turning power OFF and disconnecting power plug Using a refrigerant reclaim system remove the refrig erant charge Remove the condenser coil guard Unsolder discharge line and remove the line to the receiver or water cooled condenser Remove coil mounting hardware and remove the coil Install replacement coil and solder connections f Leak check the coil connections per paragraph para graph 6 3 3 Evacuate the unit then charge the unit with refrigerant oa 6 7 CONDENSER FAN AND MOTOR ASSEMBLY Do not open condenser fan grille before turning power OFF and disconnecting power plug The condenser fan rotates counter clockwise viewed from front of unit pulls air through the the condenser coil and discharges horizontally through the front of the unit To replace motor assembly Open condenser fan screen guard b Loosen two square head set screws on fan Thread sealer has been applied to set screws at installation Disconnect wiring connector CAUTION Take necessary steps place plywood over coil or use sling on motor to prevent motor from falling into condenser coil Remove motor mounting hardware and replace the motor It is recom
181. se tests may fail incorrectly 2 All alarms must be rectified and cleared before starting tests 3 Pre trip may be initiated communications The operation is the same as for the keypad initiation described below except that should a test fail the pre trip mode will automatically terminate When initiated via communications a test may not be interrupted with an arrow key but the pre trip mode can be terminated with the PRE TRIP key a Press the PRE TRIP key This accesses a test selection menu b TO RUN AN AUTOMATIC TEST Scroll through the selections by pressing the UP ARROW or DOWN ARROW keys to display AUTO AUTO 1 AUTO 2 AUTO 3 as desired then press the ENTER key 1 The unit will execute the series of tests without any need for direct user interface These tests vary in length depending on the component under test 2 While tests are running will appear on the left display the s indicate the test number and sub test The right display will show a countdown time in minutes and seconds indicating the amount of time remaining in the test When a failure occurs during automatic testing the unit will suspend operation awaiting operator intervention When an automatic test fails it will be repeated once A repeated test failure will cause FAIL to be shown onthe right display with the corresponding test num ber to the left The user may then press the DOWN ARROW to
182. shable heat mode is locked disabled for five minutes The cool light is also de energized e The evaporator fan motors continue to run to circulate air throughout the container The in range light remains illuminated as long as the supply air is within tolerance of set point f Ifthe return air temperature increases to 1 0C 1 8F above set point and three minutes have elapsed contacts TC and TN close to restart the compressor and condenser fan motors in standard mode non economized operation The cool light is also illuminated g If the average system capacity has risen to 10096 during modulated cooling and three minutes has elapsed relay TS will energize and open the ESV placing the unit in economized mode h If the supply air increases more than 2 5C 4 5F above set point temperature the microprocessor will transition the evaporator superheat control from modulation back to full cool control 3 3 8 Perishable Mode Heating Sequence of Operation a If the air temperature decreases 0 5C 0 9F below set point the system enters the heating mode See Figure 3 5 The controller closes contacts TH see Figure 3 7 to allow power flow through the heat termination thermostat HTT to energize the heaters HR The HEAT light is also illuminated The evaporator fans continue to run to circulate air throughout the container When the temperature rises to 0 2C 0 4F below set point contacts TH open to de energize the hea
183. son logic The program will provide a PASS or FAIL display to indicate test results The testing begins with access to a pre trip selection menu The user may have the option of selecting one of two automatic tests These tests will automatically perform a series of individual pre trip tests The user may also scroll down to select any ofthe individual tests When only the short sequence is configured it will appear as in the display Otherwise AUtO1 will indicate the short sequence and AUtO 2 will indicate the long sequence The test short sequence will run tests PO through P6 The long test sequence will run tests PO through P10 2 3 4 T 340 A detailed description of the pre trip test codes is listed in Table 3 7 page 3 23 If no selection is made the pre trip menu selection process will terminate automatically However dehumidification and bulb mode must be reactivated manually if required Scrolling down to the rSLts code and pressing ENTER will allow the user to scroll through the results of the last pre trip testing run If no pre testing has been run or an individual test has not been run since the unit was powered up will be displayed To start a pre trip test do the following NOTE 1 Prior to starting tests verify that unit voltage Function Code 07 is within tolerance and unit amperage draw Function Codes Cd04 Cd05 Cd06 are within expected limits Otherwi
184. sor configuration to USDA 6 Configure for two byte memory storage format dcfO4 LONG 7 Perform a trip start 3 7 13 DataCORDER Alarms The alarm display is an independent DataCORDER function If an operating parameter is outside of the expected range or a component does not return the correct values to the DataCORDER an alarm is generated The DataCORDER contains a buffer of up to eight alarms A listing of the DataCORDER alarms is provided in Table 3 10 page 3 33 Refer to paragraph 3 7 7 for configuration information To display alarm codes a While in the Default Display mode press the ALT MODE amp ALARM LIST keys This accesses the DataCORDER Alarm List Display Mode which displays any alarms stored in the alarm queue b To scroll to the end of the alarm list press the UP ARROW Depressing the DOWN ARROW key will scroll the list backward The left display will show where is the alarms number in the queue The right display will show if the alarm is active where is the alarm number IA will show if the alarm is inactive 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 Oo 340 e If no alarms are active the alarm queue may be cleared The exception to this rule is the DataCORDER alarm queue Full alarm AL91 which does not have to be in
185. st Codes Sheet 2 of 4 Supply Return Probe Supply Probe Test Return Probe Test Evaporator Fan Direction Test Primary vs Secondary P5 7 Evaporator Temperature Sensor Test Primary vs Secondary Suction P5 9 Evaporator Pressure Transducer Test Humidity Sensor P5 10 Controller Configura tion Verification Test Humidity Sensor P5 11 Installation Verifica tion Test Humidity Sensor PS 12 Range Check Test T 340 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 Requirements For units equipped with secondary supply probe only Pass Fail Criteria The temperature difference between primary STS and second ary SRS probe supply is compared NOTE 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 RTS and sec ondary RRS probe return is compared NOTES 1 If this test fails 5 2 and FAIL
186. system certain parts may frost Allow the part to warm to ambient temperature before dismantling This avoids internal condensation which puts moisture in the system After repairs have been made be sure to perform a refrigerant leak check refer to paragraph 6 3 3 and evacuate and dehydrate the low side refer to paragraph 6 3 4 Check refrigerant charge refer to paragraph 6 3 5 g 2 6 3 3 Refrigerant Leak Checking Never use air for leak testing It has been determined that pressurized air rich mix tures of refrigerants and air can undergo combustion when exposed to an ignition source 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 Ifthe system is without refrigerant charge the system with refrigerant 134a to build up pressure between 2 1 to 3 5 bar 30 5 to 50 8 psig To ensure complete pressurization of the system refrigerant should be charged at the compressor suction valve and the liq uid line service valve Remove refrigerant cylinder and leak check all connections NOTE Only refrigerant 134a should be used to pres surize the system Any other gas or vapor will contaminate the system which will require additional purging and evacuation of the sys tem c If required remove refrigerant using a refrigerant recovery system and repair any leaks Check for leak
187. t DataLINE Tool Probe Calibration Readings USDA1 0 0 USDA2 0 0 USDA3 0 0 Temperature Units Centigrade May 31 2007 Setpoint 1 66 Container 9 Sensors Logged at 15 Minute Interval Sensor Format Resolution 2 Fi Help 234567 ML2i ABC1234567 T 09 05 2001 A Start s View ata Raw Dat 7 Microsoft Word 1 43PM Ta ViewD ata Graph Report 5 File Reports Toggle window xl f ana i 4 NU a n o mmm 140 IL NEUE ANOA LL IHE 1006 20 1006 60 unr 002 pg unr Fi Help 234567 ML2i ABC1234567 04163552 08 22 2000 09 05 2001 A Start s ViewD ata Graph Microsoft Word Documenti 1 41 PM Figure 3 11 Standard Configuration Download Report 3 13 T 340 6 sensors dCF02 54 7 sensors dCF02 64 Table 3 3 DataC
188. t by holding the spanner wrench stationary and turning the 5 8 18 nut counter clockwise see Figure 6 9 Remove the spanner wrench Use a universal wheel puller and remove the fan from the shaft Remove the washers and key Remove the four 1 4 20 x 3 4 long bolts that are located under the fan that support the motor and sta tor housing Remove the motor and plastic spacer 6 11 3 Assemble The Evaporator Fan Assembly Oo Assemble the motor and plastic spacer onto the stator NOTE When removing the black nylon evaporator fan blade care must be taken to assure that the blade is not damaged In the past it was a com mon practice to insert a screwdriver between the fan blades to keep it from turning This prac tice can no longer be used as the blade is made up of a material that will be damaged It is rec ommended that an impact wrench be used when removing the blade Do not use the im pact wrench when reinstalling as galling of the stainless steel shaft can occur b Apply Loctite to the 1 4 20 x 3 4 long bolts and torque to 0 81 mkg 70 inch pounds c Place one 5 8 flat washer on the shoulder of the fan motor shaft Insert the key inthe keyway and lubricate T 340 6 10 the fan motor shaft and threads with a graphite oil solution such as Never seez d Install the fan onto the motor shaft Place one 5 8 flat washer with a 5 8 18 locknut onto the motor shaft and torque to 40 foot pounds 1 Stator
189. t fails immediately if High Pressure all three sensors are not configured or are invalid Switch Open the ambient temperature or return air temperature sensors are invalid at the start of the test The test fails if the high pressure switch if open at the start of the test the high pressure switch fails to open within 15 minutes a valid discharge temperature exceeds 137 78 C 280 F a valid discharge pressure or valid condensing pressure exceeds 390 psig The test passes if the high pressure switch opens within the 15 minute time limit and before any of the valid and configured sensors exceed their limits Requirements Test P7 0 must pass for this test to execute Setup The con High Pressure denser fan is started and a 60 second timer is started Switch Closed Pass Fail Criteria Passes the test if the high pressure switch HPS closes within the 60 second time limit otherwise it fails 3 29 T 340 Table 3 7 Temperature Controller Pre Trip Test Codes Sheet 4 of 4 Perishable Mode Heat Test Perishable Mode Pulldown Test Perishable Mode Maintain Tempera ture Test Defrost Test Frozen Mode Heat Test Frozen Mode Pull down Test Frozen Mode Maintain Temperature Test Setup If the container temperature is below 15 6C 60F the set point is changed to 15 6C and 180 minute timer is started The left display will read P8 0 The control will then heat the container until 15 6C is reached If the co
190. take threads 6 20 TEMPERATURE SENSOR SERVICE Procedures for service of the return recorder return temperature supply recorder supply temperature am bient defrost temperature evaporator temperature and compressor discharge temperature sensors are provided in the following sub paragraphs 6 20 1 Sensor Checkout Procedure To check a sensor reading do the following a Remove the sensor and place in a OC 32F ice water bath The ice water bath is prepared by filling an insu lated container of sufficient size to completely immerse bulb with ice cubes or chipped ice then fill ing voids between ice with water and agitating until mixture reaches OC 32F measured on a laboratory thermometer Start unit and check sensor reading on the control panel The reading should be OC 32F If the reading is correct reinstall sensor if itis not continue with the following Turn unit OFF and disconnect power supply d Referto paragraph 6 18 and remove controller to gain access to the sensor plugs Using the plug connector marked EC that is con nected to the back of the controller locate the sensor wires RRS RTS SRS STS AMBS DTS or CPDS as required Follow those wires to the connector and using the pins of the plug measure the resistance Values are provided in Table 6 2 Due to the variations and inaccuracies in ohmmeters thermometers or other test equipment a reading within 296 of the chart value would ind
191. ters The HEAT light is also de energized The evaporator fans continue to run to circulate air throughout the container Oo The safety heater termination thermostat HTT is attached to an evaporator coil circuit and will open the heating circuit if overheating occurs T 340 ENERGIZED DE ENERGIZED NOTE The EEV and DUV are independently operated by the microprocessor For full diagrams and legend see Section 7 Figure 3 7 Perishable Mode Heating 3 3 9 Sequence of Operation Perishable Mode Capacity Trim Heat a If the system capacity has been decreased to the lowest allowable capacity and conditions exist that warrant maximum temperature stability the controller will pulse the HR relay to energize the evaporator heaters in sequence with the compressor digital signal Trim heat is enabled only if 12 77C set point 15 55C 54 99F set point 59 99F and 6 67C ambient temperature 1 66 C 19 99F ambient temperature lt 34 99F 3 3 10 Perishable Mode Dehumidification The dehumidification mode is provided to reduce the humidity levels inside the container The mode is activated when a humidity value is set at function code Cd33 The display module SUPPLY LED 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 satisfie
192. the pen tip will move to the currently recorded temperature and the recorder will resume normal temperature recording 6 21 1 Replacing the Recorder a Turn power to the unit OFF b Open the recorder door item 1 see Figure 6 20 T 340 6 22 Locate the connector below the recorder and squeeze the ears together to disconnect the plug item 10 d Remove the four mounting screws item 2 and remove the recorder e Install the new recorder by reversing the above steps 6 21 2 Changing the Chart NOTE To prevent recorder corrosion it is important to assure the door is securely closed at all times after completing the chart change Lift the stylus item 5 Figure 6 20 by grasping the arm near the base and pull the arm away from the chart until it snaps into its retracted position Remove the chart retaining nut item 10 remove the used chart and record current date on the old chart Press the Change Chart button item 2 NOTE Failure to press the change chart button when changing a chart with the power OFF may result in the chart advancing when power is applied Install a new chart make sure the chart center hole is placed over the center hub and the chart edges are behind the four hold down tabs item 9 Mark the current date container number and other required information on the new chart and install under hold down tabs Replace the chart nut loosely rotate the chart until the correct
193. the return sensor as shown in Figure 6 18 For proper placement of the return sensor be sure to posi tion the enlarged positioning section of the sensor against the the side of the mounting clamp See Figure 6 18 Sensor DTS The DTS sensor must have insulating material placed completely over the sensor to ensure the coil metal tem perature is sensed Sensors ETS1 and ETS2 The ETS1 and ETS2 sensors are located in tube hold ers under insulation as illustrated in Figure 6 19 When sensors are removed and reinstalled they must be placed in tube holders and insulating material must completely cover the sensor to ensure the correct tem perature is sensed soot 1 PN Soh 7 2 SHES S SLE zii 2 7 A 1 Supply Air Stream 8 Gasket Mounting Plate 2 Insulation 9 Gasketed Support Plate 3 Back Panel 10 Gasketed Cover 4 Supply Sensor 11 TIR Bolts 5 Mounting Clamp 12 STS Probe 6 Sensor Wires 13 SRS Probe 7 Loop Figure 6 17 Supply Sensor Positioning 1 Wire Tie 4 Insulation 1 Mounting Clamp 2 ETS1 5 ETS2 2 Return Sensor 3 ETS Tube Holders Figure 6 19 Evaporator Temperature Figure 6 18 Return Sensor Positioning Sensor Positioning 6 21 T 340 6 21 ELECTRONIC PARTLOW TEMPERATURE RECORDER The microprocessor based temperature recorder is designed to interface with the DataCORDER to log t
194. tic safe wrist strap In case of electrical fire open circuit switch and extin guish with CO never use water 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 that WILL re sult in severe personal injury or death Safety 1 WARNING means to warn against hazards or unsafe conditions that COULD result in severe personal injury or death CAUTION means to warn against potential hazard or unsafe practice that could result in minor personal injury product or property damage The statements listed below are applicable to the refrig eration unit and appear elsewhere in this manual These recommended precautions must be understood and ap plied during operation and maintenance of the equip ment covered herein DANGER Never use air for leak testing It has been de termined that pressurized mixtures of re frigerant and air can undergo combustion when exposed to an ignition source WARNING Beware of unannounced starting of the evaporator and condenser fans The unit may cycle the fans and compressor unex pectedly as control requirements dictate WARNING Do not attempt to remove power plug s be fore turning OFF start stop switch ST unit circuit breaker s and external power o c WARN
195. tly f OAP 222 operated by the microprocessor For full diagrams elapsed the EEV opens and contacts TC TS and TN and legend see Section 7 close to restart the compressor open the ESV and restart the condenser fan motor The cool light is illuminated Figure 3 9 Frozen Mode ENERGIZED DE ENERGIZED T 340 3 8 3 3 18 Defrost Interval Controller function code Cd27 sets two modes for defrost initiation either user selected timed intervals or automatic control The user selected values are 3 6 9 12 24 hours or AUTO Some units may be configured to allow defrost to be disabled altogether In this case a user selected value of OFF will be available Thefactory default for defrost is AUTO Refer to Table 3 5 In perishable mode perishable pulldown mode or frozen pulldown mode automatic defrost starts with an initial defrost set to three hours and then adjusts the interval to the next defrost based on the accumulation of ice on the evaporator coil In this way defrosts are scheduled to occur only when necessary Once set point has been reached in frozen operation the automatic selection will set the time interval to 12 hours for the first two defrosts once the return probe is reading below the frozen set point and then adjust to 24 hours thereafter All defrost interval times reflect the number of compressor runtime hours since the last defrost de
196. to the module h Replace the low voltage shield Table 6 3 Recommended Bolt Torque Values 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 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 Table 6 4 R 134a Temperature Pressure Chart Vacuum c 36 2r 20 _ psig bar 22 2 9 0 20 0 46 7471736 593 059 78 178 174 m s 799 172 147 6 25 Temperature Pressure c bar L8 o 1 192 50 8 16 358 404 7o 79 zr 5978 596 E 125 740 292 1680 1611 1580 7180 2629 1849 1848 1813 718 6 1996 1976 1937 2 2 T 340 7 1 SECTION 7 ELECTRICAL WIRING SCHEMATICS INTRODUCTION This section contains the Electrical Schematics and Wiring Diagrams The diagrams are presented as follows Figure 7 1 Figure 7 2 Figure 7 3 Figure 7 4 provides the legend for use with all figures provides the basic schematic diagram for units covered in this manual provides the schematic and wiring diagrams for Upper and Lower Vent Positioning Sensor VPS basic wiring diagram for units covered in this manual Sequence o
197. tores up to 16 alarms in the sequence in which they occurred The user may scroll through the list by depressing an ARROW key c The left display will show AL where is the alarm number sequentially in the queue d The right display will show the actual alarm code AA will display for an active alarm where is the alarm code Or will display for an inactive alarm See Table 3 6 page 3 23 e END is displayed to indicate the end of the alarm list if any alarms are active f CLEAr is displayed if all alarms are inactive The alarm queue may then be cleared by pressing the ENTER key The alarm list will clear and will be displayed Note AL26 is active when all of the sensors are not responding Check the connector at the back of the controller if it is loose or unplugged recon nect it then run a pre trip test P5 to clear AL26 3 6 UNIT PRE TRIP DIAGNOSTICS Pre Trip Diagnostics is an independent controller function that suspends normal refrigeration controller activities and provide preprogrammed test routines The test routines include Auto Mode testing which automatically preforms a pre programmed sequenced of tests or Manual Mode testing which allows the operator to select and run any of the individual tests CAUTION Pre trip inspection should not be per formed with critical temperature cargoes in the container CAUTION When k
198. ty mode CAP allows alignment of the economizer solenoid valve in the standard and economized operating configurations DUV Capacity Modulation 96 Setting PCnt and Electronic Expansion Valve EEV allows opening of the digital unloader valve and electronic expansion valve respectively to various percentages The Liquid Valve Setting LIV allows the LIV to be automatically controlled or manually opened and closed The Override Timer selection is also provided to enter a time period of up to five minutes during which the override s are active If the timer is active valve override selections will take place immediately If the timer is not active changes will not take place for a few seconds after the timer is started When the timer times out override function is automatically terminated and the valves return to normal machinery control To oper ate the override do the following a Press the CODE SELECT key then press an AR ROW key until Cd41 is displayed in the left window The right window will display a controller communica tions code Pressthe ENTER key The left display will show atest name alternating with the test setting or time remain ing Use an ARROW key to scroll to the desired test Press the ENTER key and SELCt will appear in the left display Use an ARROW key to scroll to the desired setting and then press the ENTER key Selections available for each of the tests are provided in the following t
199. uence of Operation 3 5 Perishable Mode Heating Sequence of Operation 3 6 Perishable Set Point Temperature Conventional Temperature Control Mode 3 4 Perishable Set Point Temperature Economy Mode 3 4 Perishable Set Point Temperature Perishable Pull down 3 4 Perishable Set Point Temperature Control 3 4 Pre Trip Data Recording 3 14 Pre Trip Diagnosis 3 11 4 3 Pre Trip Test Codes 3 27 Probe Check 4 4 Pumping Down 6 2 T 340 R Refrigerant Charge 6 4 Refrigeration Circuit 2 10 Refrigeration System Data 2 7 Refrigeration System Units with Service Valves 6 2 Refrigeration Unit Front Section 2 1 S Safety and Protective Devices 2 9 Sampling Type 3 14 Sensor Configuration 3 12 Solenoid Valves 6 12 Standard Operation Refrigeration Circuit 2 10 Start up Compressor Bump Start 3 4 Start up Compressor Phase Sequence 3 4 Start Up Inspection 4 3 Starting Instructions 4 3 Stopping Instructions 4 3 T Temperature Recorder 4 3 6 22 Temperature Sensor 6 18 6 19 Thermistor Format 3 12 Torque Values 6 24 Troubleshooting 5 1 U Upper Fresh Air Makeup Vent 4 2 USDA 3 15 V Valve Override Controls 6 13 Valve Replacement 6 11 Vent Position Sensor 4 2 W Water Cooled Condenser 2 5 6 7 Wiring Schematic 7 1 Index 2 Carrier A United Technologies Company Carrier Transicold Division Carrier Corporation Container Products Group P O B
200. uge 0 to 36 2 kg cm 0 to 500 psig on the compressor dis charge service valve Example Discharge pressure is 10 3 kg cm 146 4 psig Referring to Table 6 4 R 134a pressure temperature chart the 10 3 kg cm 146 4 psig value converts to 43C 110F 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 b Disconnect water pressure switch tubing by loosen ing 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 What You Will Need 1 Oakite Composition No 22 available as a powder in 68 kg 150 Ib and 136 kg 300 Ib containers 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 Ibs net Fresh clean water Acid proof pump and containers or bottles with rubber hose 2 NOTE When Oakite Compound No 32 is used for the first time the local Oakite Technical Service representative should be called in for suggestions in planning the procedure The representative will advise the reader on 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
201. up to 24 hours to charge re chargeable batteries sufficiently to deactivate the alarm Alarm 54 is activated by an invalid supply temperature sensor STS reading that is sensed outside the range of 50 to 70C 58F to 158F or if the probe check logic has determined there is a fault with this sensor If alarm 54 is activated and AL54 AL53 Battery Pack Failure Primary Supply Tem the primary supply is the control sensor the secondary supply sensor SRS will perature Sensor be used for control if the unit is so equipped If the unit does not have a second Failure STS ary supply temperature sensor and AL54 is activated the primary return sensor reading minus 2C will be used for control NOTE The P5 Pre Trip test must be run to inactivate the alarm 155 1 O Failure activates to indicate I O functions have failed and require replace Alarm 56 is activated by an invalid primary return temperature sensor RTS reading that is outside the range of 50 to 70C 58F to 158F If alarm 56 is activated and the primary return is the control sensor the secondary return sen AL56 Primary Return Tem Sor RRS will be used for control if the unit is so equipped If the unit is not perature Sensor equipped with a secondary return temperature sensor or it fails the primary sup Failure RTS ply sensor will be used for control NOTE The P5 Pre Trip test must be run to inactivate the alarm AL57 Ambient Tempe
202. ve economizer coil or economizer solenoid valve Replace High discharge temperature Plugged economizer expansion valve economizer coil or Replace economizer solenoid valve Liquid injection valve failure Loose or insufficiently clamped sensor 5 17 ABNORMAL CURRENTS Unit reads abnormal currents Current sensor wiring Check 5 5 T 340 SECTION 6 SERVICE NOTE Use a refrigerant recovery system whenever removing refrigerant When working with refrigerants you must comply with all local government environmental laws In the U S A refer to EPA section 608 Never use air for leaktesting It has been de termined that pressurized mixtures of re frigerant and air can undergo combustion when exposed to an ignition source SECTION LAYOUT Service procedures are provided herein beginning with refrigeration system service then refrigeration system component service electrical system service tempera ture recorder service and general service Refer to the Table of Contents to locate specific topics 6 1 6 2 MANIFOLD GAUGE SET The manifold gauge set see Figure 6 1 is used to determine system operating pressure add refrigerant charge and to equalize or evacuate the system Opened Backseated Hand Valve Suction Pressure Gauge Discharge Pressure Gauge Closed Frontseated Hand Valve Connection to high side of system Connection to either a Refrigerant cylinder OR b Oil Container Connection t
203. w Frontseat the manual liquid line valve and allow the unit to pull down to 0 1 kg cm 1 psig c Turn the unit start stop switch ST and unit circuit breaker CB 1 OFF and disconnect power to the unit d Frontseat the discharge and suction service valves e Remove all remaining refrigerant from the com pressor using a refrigerant recovery system f Remove the compressor terminal cover disconnect the ground wire and pull the cable plug from the com pressor terminals Install the terminal cover back after removing the power cable NOTE Inspect the power cable plug terminals to en sure they are not deformed or have any signs of heat or arcing If any damage is noted replace the power cable Remove the Rotalock fittings from the suction and discharge service connections and uncouple the unloader and economizer lines from the com pressor Cut the dome temperature sensor wires The re placement compressor comes with a dome temper ature sensor already assembled i Remove and save the compressor base mounting bolts Discard the 4 top resilient mounts and wash ers j Remove slide out the old compressor from the unit k Inspect compressor base plate for wear Replace if necessary l Wire tie the compressor base plate to the com pressor and slide the new compressor into the unit Refer to Figure 6 5 NOTE DO NOT add any oil to the replacement com pressor Replacement compressor is ship
204. 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 The results of Pre Trip tests 5 0 5 1 and 5 2 will be used to activate or clear control probe alarms Requirements Test P5 0 must pass before this test is run Setup While the evaporator is running on high speed the temperature differen tial between primary supply STS and primary return RTS probes is measured with and without heaters energized Pass Fail Criteria Passes if differential of primary supply temperature is 0 25 degree C higher than primary return temperature Pass Fail Criteria Passes if secondary evaporator temperature sensor ETS2 is within 0 5 degree C of the primary evaporator temperature sensor ETS1 Pass Fail Criteria Passes if secondary transducer SPT is within 1 5 psi of the primary transducer Requirements Test P5 9 must pass before this test is run Test is skipped if controller is not configured for the humidity sensor and the voltage is less than 0 20 volts Pass Fail Criteria Passes if controller configuration has the humidity sensor in stalled Fails if controller is not configured for humidity sensor and the voltage is greater than 0 20 volts Requirements Test P5 10 must pass before this test is run Pass Fail Criteria Passes if voltage is greater than 0 20 volts for the humidity sensor Fails if voltage is less than 0
205. y reads LOAd 53XX for Scroll odd numbers Press the ENTER key on the keypad T 340 The display will alternate to between PrESS EntR and rEV XXXX Press the ENTER key on the keypad The display will show the message Pro SoFt This message will last for up to one minute The display module will go blank briefly then read Pro donE when the software loading has loaded If a problem occurs while loading the software the dis play will blink the message Pro FAIL or bad 12V Turn start stop switch OFF and remove the card Turn unit OFF via start stop switch ST 9 Remove the PCMCIA card from the programming software port and return the unit to normal operation by placing the start stop switch in the ON position 10 Turn power and wait 15 seconds status LED 1 will flash quickly and there will be no display The controller is loading the new software into memory This takes about 15 seconds When complete the controller will reset and power up normally Wait for default display zc Pt on the left and con trol temperature on the right 12 Confirm software is correct using keypad code se XXXX lect 18 to view Cd18 13 Turn power off Operational software is loaded b Procedure for loading configuration software 1 2 Turn unit OFF using start stop switch ST Insert software programming PCMCIA card contain ing the following example files

caution - Maersk Line

Contents

Download Pdf Manuals

Related Search

Related Contents