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Supra 422, 522, Supra Multi-Temp - Sunbelt Transport Refrigeration

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3. 12 lt 21 Not Use on Supra 422 18 M Seit 12 15 D be HEAT AND DEFROST CYCLE Drain Pan Heater 10 Receiver Inlet Check Valve 18 Compressor Pressure Expansion Valve Bulb 11 Bypass Check Valve Regulating Valve CPR Evaporator 12 Condenser 19 Low Pressure Switch LP External Equalizer Line 13 Hot Gas Valve Three Way Solid State Control ETO Only Expansion Valve 14 Discharge Service Valve 20 Accumulator Filter Drier 15 Suction Service Valve 21 Quench Valve Not Used on Receiver King Valve 16 Compressor Supra 422 Receiver 17 High Pressure Switch HP 22 Subcooler Receiver Sight Glass Figure 1 14 R 22 Refrigeration Circuit 1 23 rg Drain Pan Heater Expansion Valve Bulb Evaporator External Equalizer Line Expansion Valve Filter Drier Receiver King Valve Receiver
4. 1 20 1 14 1 Alternator 1 20 1 14 2 Integral Voltage Regulator Operation 12 volts d c 1 20 115 Refrigerant Circuit During Cooling 1 22 116 Refrigerant Circuit During Heat and Defrost 1 22 117 056 Compressor Unloader 1 25 1 17 1 Unloading in Temperature Mode 1 25 1 17 2 Suction Pressure Operation Diesel 1 25 1 17 3 Suction Pressure Operation Standby 1 26 1 17 4 Hot Gas Bypass 1 27 2 OPERATION UNITS WITH MICROPROCESSOR CONTROLLER 2 1 21 Inspection ted ete eR ice ue peste n tae ee add err RA pais ehe 2 1 22 Starting and Stopping Instructions Engine 2 1 221 Automatic SEALE us cere auc e IR Cau Cedo P ED eua 2 1 2 22 ManualStar ng eec TEETE CERES 2 2 2 3 Starting and Stopping Instructions Standby Motor Drive 2 2 24 Control Circuit Operation Engine 2 2 241 lIntrod ction ec 2 2 Section 2 2
5. 5 2 Alternator Automotive 5532 eer ee eese Ber pe ree tee aged dee 5 3 1 Unit Will Not 2 5 3 2 Unit Runs But Has Insufficient Cooling 5 33 Unit Operates Long or Continuously in Cooling 5 34 Unit Will Not Heat or Has Insufficient 5 3 5 Defrost Cycle Malfunction 2 5 3 07 Abnormal Pressures ie sti eee ee ed uds 5 3 0 L Cooling uid Ge wheal a d EE E 5 3 62 H eatIng 4 ate uei e EE eae sega 2 31 Abnormal NOISE 2i see e Pepe Aere d e ide a e doi 5 3 8 Control System Malfunction 5 3 9 Evaporator Air Flow or Restricted Air Flow 5 3 10 Expansion Valve Malfunction 5 3 11 Hot Gas Three Way Valve Malfunction 5 4 Standby Motor Malfunction 2 6 ELECTRICAL SCHEMATIC WIRING DE Introduction Sie LEER EE Een ace ged idee 4 1 4 7 4 8 4 9 4 10 4 11 4 11 4 12 4 12 4 12 4 12 4 13
6. HEAT AND DEFROST CYCLE 9 10 11 12 13 14 15 Receiver Sight Glass 16 Receiver Inlet Check Valve 17 Bypass Check Valve 18 Condenser Hot Gas Valve Three Way 19 Discharge Service Valve 20 Suction Service Valve 21 Figure 1 15 R 404A Refrigeration Circuit 1 24 Compressor High Pressure Switch HP Compressor Pressure Regulating Valve CPR Accumulator Heat Exchanger Subcooler 1 17 05G COMPRESSOR UNLOADER 1 17 1 Unloading in Temperature Mode The 05G compressor is equipped with an unloader electronically controlled by the microprocessor for capacity control The capacity controlled cylinders are easily identified by the solenoid which extends from the side of the cylinder head When the solenoid is energized the cylinders unload The unloaded cylinders operate with little or no pressure differential consuming very little power A de energized solenoid reloads the cylinders NOTE The unloader relayislocked in for a minimum of 2 minutes once it is energized due to suction pressure There are two modes of unloader operation temperature control and suction pressure control a Temperature Control Within 1 4 F 0 8 C of Set Point 1 Cool light CL or heat light HL illuminated depending on mode of operation 2 If in low speed cooling unloader relays UFR may energize to unload compressor banks Refer to Table 1 8 3 In low speed heating front unloader rela
7. Unit Roadside View gt au u cece eee eee Electrical Box Solid State Controller Electrical Box Microprocessor Controller Relay Module eines eren Cab Command aoan eai erede AE AUtO Start Sequehce 22229 her eae Hot Gas Valve Cooling Flow Hot Gas Valve Heat and Defrost Flow 65 Amp Alternator amp Regulator P N 30 00393 00 65 Amp Alternator and Regulator P N 30 00409 00 70 Amp Alternator and Regulator for Units Built In Europe ETO R 22 Refrigeration Circuit R 404A Refrigeration Circuit Compressor Cylinder Head Unloaded Hot Gas Bypass Compressor Cylinder Head Loaded Hot Gas Bypass Temperature Controller Operating Sequence Engine Drive Controller Set Point Above 129 109 Temperature Controller Operating Sequence Engine Drive Controller Set Point Below 12 C 10 F Temperature Controller Operating Sequence Standby Operation Controller Set Point Above 129 109 Temperature Controller Operating Sequence Standby Operation Controller Set Point Below 12 C 10 F Speed and Run
8. a 50 Tose 50 Supra 744 10819 12 54 Supra 744 0519 12 54 Surasa 35 88 Supra 944 08 32 Supra 944 TO 32 05K CT3 44TV 2 Cylinder 05K 4Cylinder 6 4 hp 7 6 hp E ee a 15 68 CT369TV 056 6 121 14 7 hp 1 Muffler 8 Defrost Air Switch 2 Engine Refer toTable 1 1 9 Filter Drier 3 Compressor Refer toTable 1 1 10 Receiver 4 Alternator 11 Hot Gas Valve Three Way 5 Electric Standby Motor 12 Condenser 6 Accumulator 13 Compressor Pressure Regulating Valve CPR 7 Quench Valve Not Used on Supra 422 14 Radiator Overflow Reservoir Figure 1 1 Condensing Section Top View Model 722 Shown 1 2 1 Air Cleaner 2 Speed amp Run Solenoid 3 Fuel Filter 4 Serial Model Plate Figure 1 2 Unit Curbside View 1 Electrical Box See Figure 1 4 or Figure 1 5 2 Temperature Controller Sensor 3 Evaporator Fan Motor Figure 1 3 Unit Roadside View 1 3 RI CSR 5 cS 6 7 8 1 Running Time Meter Standby RTMS 8 Start Run Stop Switch SRS 2 Running Time Meter RTM 9 Selector Switch SSW 3 Temperature Control Module TCM 10 Relay Fuse Board See Figure 1 6 4 CoolLight CL 11 Standby Motor Contactor MC 5 Heat Light HL 12 Motor Overload Relay MOL 6 Defrost Light DL 13 Defrost Timer 7 Glow Defrost Sw
9. lt A AY oa Figure 7 4 Multi Temp Refrigerant Circuit Cooling 7 3 B D E F 6 H I J K L 1 2 2 2 3 11 30A 1 1 To FLRO B Oi 62 Deko 394 G7A 4 2Ras D3 2RR 20R A GH cca 62 3 53 teer n2 227 5 25 J3 9 Hs 96 Gras a Ag zB 6 2DTT SBocR BS CCR DRB87 CCV 2 Sach a CCL EFMR386 2 eme QHO 2HR 2HR 281 NDS E 20R D4 c lt lt za g vod 20 2 1 auf mm SG D ES D 2 15 5 Om 5 R2 2 5 LY LA 1 11 T T 0 0 D RI R2 R3 Me 12 F13 14 GH Q FER 2HVR 2HVR 2HVR 13 SH SP16 14 SPK3 MPTI SP14 5 15 4 1 1 2 Cp3 TO TO 15 MCTI MCT2 DECAL NO REV 62 03943 00 TDS MULTI TEMP Figure 7 5 Electrical Schematic Wiring Diagram M
10. NA lorO O ior O Oo O lorO 11 29 21220 O O lorO 1 1 oft fiero O O o o O O NA O lorO a fna ifi O O O lorO lor O lor O lor O lor O lor O lor O FHR lor O lor O lor O lor O lor O lor O lor O O O O DPR O O O O O O O O O O O SECTION 3 OPERATION UNITS WITH SOLID STATE CONTROLLER 3 1 PRE TRIP INSPECTION a Before Starting Engine 1 Drain water and sediment from fuel tank sump Then fill tank with diesel fuel 2 Check radiator coolant level Add pre mixed 50 50 permanent antifreeze water as required USE ETHYLENE GLYCOL ONLY Refer to section 1 2 3 Check evaporator and condenser coil for cleanliness 4 Check engine lubrication and fuel filter oil lines and connections for leaks Tighten connections and or replace gaskets 5 Check engine oil level Refer to section 1 2 6 Check V belts for proper tension fraying or cracks Adjust belt or replace 7 Check battery terminals for cleanliness and tightness Clean and coat with a mineral type grease such as Vaseline 8 Check engine air cleaner for cleanliness and condition of air cleaner hose 9 Check defrost drain pan hoses Should be clear of debris 10 Check defrost air switch tubes and connections for breaks or air leaks b After Starting Refrigeration Unit
11. SOLENOID DE ENERGIZED TO COMPRESSOR CRANKCASE FROM COMPRESSOR TO CONDENSER Figure 1 9 HotGas Valve Cooling Flow c Heat and Defrost O peration See Figure 1 10 When the hot gas solenoid coil is energized discharge gas flows to the evaporator for heating or defrost When energized the solenoid plunger is lifted allowing discharge gasto fill the volume above the piston assembly D ischarge gas is also allowed to fill the volume below the piston assembly through the compressor discharge connection pressure on both sides of the piston assembly is now equal and the piston spring exerts a force on top of the piston assembly and shifts it downward The condenser port is now closed and the evaporator port is open In both the energized and de energized positions the bypass of discharge gas to the suction port is prevented SOLENOID ENERGIZED lt TO COMPRESSOR CRANKCASE TO EVAPORATOR FROM COMPRESSOR Figure 1 10 Hol Ges Vave Heat and Defrost ow 1 13 ACCUMULATOR The accumulator is a refrigerant holding tank located in the suction line between the evaporator and compressor The purpose of the accumulator is to prevent or minimize entry of any liquid refrigerant that may be entrained in the suction line into the compressor causing internal damage This is accomplished by the compressor drawing the refrigerant vapor through the outlet pipe of the accumulator which is equipped with
12. Multi Temp Refrigerant Circuit Electrical Schematic Wiring Diagram Multi Temp Page 1 2 1 3 1 3 1 4 1 4 1 5 1 9 1 17 1 19 1 20 1 20 1 21 1 21 1 23 1 24 1 27 1 27 3 3 4 2 4 3 4 4 4 4 4 6 4 8 4 9 4 10 4 10 4 11 4 12 4 12 4 13 4 13 4 14 4 14 4 15 6 2 6 4 7 1 7 2 7 3 7 3 7 4 SECTION 1 DESCRIPTION 1 1 INTRODUCTION WARNING Beware of unannounced starting of the fans and V belts caused by the thermostat and the start stop cycling of the unit This manual contains Operating Data Electrical D ata and Service Instructions for the truck refrigeration units listed in Table 1 1 Also Table 1 1 charts some significant differences between these models The Supra models are one piece units designed for truck applications The TDS models are equipped with an electric standby motor The TDB models have a standby motor shell installed without the motor winding to allow the same belt arrangement for both units The model serial number plate is located inside of the unit on the frame as shown in Figure 1 2 The standard control system is a microprocessor controller Refer to section 1 8 Once the controller remote Cab Command within the cab of the truck is set at the desired temperature the unit will operate automatically to maintain the desired temperature within very close limits The control system autom
13. OO 20A DPR oe rme S 2 een Om 9 SEE NOTE 7 6 x S e kes REE ae 8 CCS ce CCH Dee X 5 68 1901 14 0 AF105 FHTH FH OD s 25 FHR EE eee 9 2 wo m 5 5 7 ESSA ee 900 LIVE BUE CIRCUITS FOR DIESEL ELECTRIC ERE er 440V 460V 60 Hz 3PH D D 2 EFMR1 Y 415 440 SOHz 3PH ix BLOCK 1 ERI us 0 GLOW ie Go Le CK CRANK i 1 TO r8 Go 87 HCKZ FH 1 O G d ee 5 BLOCK 1b SES TO BTY DCS i SEE NOTE 7 7 SE 11 E DPS A 208V 230V 2 HCB3 220 50Hz 12 5 5 ALTERNATOR 3 PSR Des PH 13 To 2 TO DER 87 C3 11 69 46 302 ES n WIRING FOR ALTERNATOR WIRING FOR ALTERNATOR WITHOUT STANDBY MOTOR SEE NOTE amp 30 00393 7102526 qu cue ge nx Je ip cope CAE PS CM Figure 6 1 Electrical Schematic Wiring Diagram MICROPROCESSOR CONTROLLER Dwg 62 60017 Rev C Sheet 2 of 2 F LOCATION D 14 C 16 F 16 D 11 E 6 L 0 9 11 H 14 G 9 H 11 C 6 C 14 H 11 D 5 G 7 G 11 F 7 H 5 H 7 G 13 14 A 14 B 14 B 14 D 8 A 6 D 8 B 6 E 8 B 6 H 3 1 4 M 4 0 4 4 B 4 B 4 4 1 11 L14 0 14 M 10 0 6 M 14 N 14 J 5 N 7 N 14 M 8
14. 2 Minimum ON time 5 minutes The unit must run for the minimum run time before it can consider shutting off This minimum run time is to prevent short cycling and ensure adequate air flow through the load to allow the controller to accurately sense load temperature and bring the battery up to minimum voltage level It also prevents hot spots in a properly loaded box After the minimum run time is complete the microprocessor will look at the remaining conditions that must be satisfied to allow a shutdown These are A Battery condition Battery voltage must be above 13 4 volts measured at Y1 B The box temperature active probe must be satisfied Perishable Range Setpoints 0 3 C 0 5 F Frozen Range Setpoints 0 3 C 0 5 F If ALL of these conditions are not satisfied the motor will continue to run until they are This prevents rapid cycling of the electric drive motor 3 Minimum OFF time 5 minutes Once the motor has cycled off it will remain off for the minimum off time This prevents the motor from rapid cycling due to changes in air temperature Air temperature in the box can change rapidly but it takes time for the product temperature to change 4 Low battery voltage protection The microprocessor will restart the unit if the battery voltage drops below 11 0 volts to recharge the battery after the minimum off time delay NOTE When in Continuous Run perishable range
15. 2 1 2 2 STARTING AND STOPPING INSTRUCTIONS ENGINE DRIVE WARNING Under no circumstances should ether or any other starting aids be used to start engine NOTE Whenever starting the engine in order to reduce starter cranking and engine loads the microprocessor always starts and operates low speed unloaded cool for the first 15 seconds After first 15 seconds the microprocessor will allow the unit to operate normally providingthe coolant temperature is above 26 79 In order to prolong engine life the microprocessor will prevent operation in high speed until coolant temperature reaches this temperature 2 2 1 AUTOMATIC START a Starting Instructions 1 Place the Run Stop Switch in the RUN position 2 Place the On Off Switch Cab Command to ON position and press the Road Key T he microprocessor will perform a self test all display messages will appear in display window Then setpoint and box temperature will be displayed 3 The microprocessor will energize glow cycle length of time dependson engine temperature and start the engine 4 To change the setpoint press the Up Or Down Arrow Key and then the Enter Key 5 Pressing the Auto S S Continuous Key changes the operation of the unit between automatic start stop unit will automatically start and stop in response to changing boxtemperature or automatic start continuous run unit will operate continuously after starting b Stopping Instructi
16. The Code display isAL 22 This alarm is generated when the remote compartment 3 is out of range refer to section 1 8 5 The fault light FL is turned on No Power for Standby Alarm NO POWER will be displayed if unit is switch to standby and power plug is not plugged in 1 8 8 PRE TRIP The pretrip key is for checking unit operation and evaluating operation of all modes and indicating a failure when detected The following details the sequence a Unit operating and box temperature is below 4 4 C 40 F b Operator presses the pretrip key If the defrost thermostat DTT is closed the controller will display PPPP If DTT is open no response end of test c Controller displays PPPP Pre trip mode is started After 30 seconds high speed cool unit cycles to low speed loaded cool e After 30 seconds unit cycles to low speed unloaded cool f After 30 seconds unit cycles to low speed unloaded heat g After 30seconds unit cycles to low speed loaded heat h After 30 seconds unit cycles to high speed heat and displays coolant temperature i After 30 seconds unit cycles to high speed cool and displays defrost interval selected for 30 seconds then unit cycles to defrost if DTT is closed j After standard defrost cycle Pre trip terminated and unit returns to normal operation is 1 8 9 HEAT COOL MODE There are two control ranges Frozen and Perishable The Frozen range is active with s
17. 1 Check engine speed Refer to section 4 2 3 2 Listen for abnormal noises Refer to section 3 3 7 3 Check compressor oil level Refer to section 4 9 4 Observe any signs of lube or fuel oil leaks 5 Check radiator hoses for leaks 6 Check refrigerant level Refer to section 4 7 7 Feel filter drier Excessive temperature drop across drier indicates restriction Refer to section 4 13 3 2 STARTING AND STOPPING INSTRUCTIONS ENGINE DRIVE a Starting Instructions WARNING Under no circumstances should ether or any other starting aids be used to start engine NOTE When starting the engine it is necessary to continue to hold the glow defrost switch in the UP position until the engine develops sufficient oil pressure to close the oil pressure safety switch OP energizing and completing all circuits for unit operation 1 Hold Glow Defrost Switch in UP position for 30 seconds NOTE Below 17 8 C 0 F hold glow defrost switch for two minutes release switch for 30 seconds and again hold glow defrost switch for two minutes If engine does not start after 10 seconds cranking wait for 30 seconds before repeating starting procedure 2 With the Glow Defrost Switch held in the UP position push the Start Run Stop Switch to the START position 3 After engine has started release the START switch but continue to hold the glow defrost switch in the UP position until the oil pressure safety switch cl
18. 2m 2 teen BULTINUSA LE LL BUILTIN U S A 15 BUILTIN EURORE BUILT IN EUROPE CIRCUIT FOR DIESEL ELECTRIC A 208 230 60Hz 3PH CIRCUIT FOR DIESEL ELECTRIC TO HCB3 lt ce ON ZONE OPI 380V 460V 60Hz 3PH 16 TO EXC Y 380V 415V 440V 50Hz 3PH HCA3 gt CHT G nn WIRING FOR ALTERNATOR e 17 WIRING FOR ALTERNATOR e 38200302260 Ki H3 9 30 00363 00 E PLUG Ad PLUG c le F j Ik L N lo p Figure 6 2 Electrical Schematic Wiring Diagram SOLID STATE CONTROLLER Dwg No 62 60018 Rev A Sheet 2 of 2 SECTION 7 MULTI TEMP BI TEMP OPERATION AND SERVICE 7 1 INTRODUCTION 1 2 CARRIER D lt Ec TES EE mE 3 4 gt FRONT VIEW aC 1 Remote Evaporator 2 Main Unit Supra 722 3 Remote Control Box 4 Additional Heater Box Figure 7 1 Multi Temp Unit a System The remote control box includes indicating lights The Supra Multi Temp Bi Iemp multiple switches and relays compartment refrigeration system offers two c Microprocessor Controller compartment temperature control The Multi Temp allows the shipper to ship frozen and perishable commodities in the same load under separate refrigeration control The Supra Multi Temp unit is comprised of th
19. 9 Strainer 15 Discharge Manifold 10 Suction Manifold Figure 1 16 Compressor Cylinder Head Unloaded Hot Gas Bypass c Loaded Operation Discharge pressure bleeds from the discharge manifold Figure 1 17 item 15 through the strainer 9 and 8 bleed orifice to the solenoid valve stem 2 chamber and the back of the piston bypass valve 7 With the solenoid valve 1 de energized the solenoid valve stem will close the gas bypass port 3 Refrigerant pressure will overcome the bypass valve spring 5 tension and force the piston 6 forward closing the gas bypass from the discharge manifold to the suction manifold 10 Cylinder discharge pressure will force open the discharge piston check valve assembly 14 Refrigerant gas will pass into the compressor discharge manifold The loaded cylinder bank will continue to operate fully loaded until the solenoid valve control device is energized and the gas bypass port is opened 1 Solenoid Valve 11 Cylinder Discharge 2 Valve Stem Valve 3 Gas Bypass Port 12 Valve Plate 4 Spring Guide 13 Cylinder Suction 5 Spring Valve 6 Piston 14 Discharge Piston 7 Piston Bypass Valve Check Valve 8 Bleed Orifice Assembly 9 Strainer 15 Discharge Manifold 10 Suction Manifold Figure 1 17 Compressor Cylinder Head Loaded Hot Gas Bypass SECTION 2 OPERATION UNITS WITH MICROPROCESSOR CONTROLLER 2 1 PRE TRIP INSPECTION a Before Starting Engine 1 Drain water
20. A suction pressure transducer is used to signal the microprocessor when to load or unload the compressor a R 22Refrigeration System At ambient temperatures of 90 F 32 2 C or below When the system is operating and the suction pressure drops below 18 psig the front bank is loaded At ambient temperatures of 90 F 32 2 C or higher At ambient temperatures of 90 F or higher the unloading suction pressure settings relative to ambient temperatures are a straight line Refer to chart below R 22 REFRIGERATION SYSTEM STANDBY OPERATION SUCTION PRESSURES UNLOADING 80 90 100 110 120 130 AMBIENT TEMPERATURE F b R 404A Refrigeration System At ambient temperatures of 90 F 32 2 C or below When the system is operating and the suction pressure drops below 26 psig the front bank is loaded At ambient temperatures of 90 F 32 2 C or higher At ambient temperatures of 90 F or higher the unloading suction pressure settings relative to ambient temperatures are a straight line Refer to chart below R 404A REFRIGERATION SYSTEM STANDBY OPERATION SUCTION PRESSURES UNLOADING 35 30 SUCTION PRESSURE PSIG 25 80 90 100 110 120 130 AMBIENT TEMPERATURE 1 17 4 HotGas Bypass Unloader a Major Working Parts 1 Solenoid and valve system 2 Spring loaded piston type bypass control valve 3 Spring loaded discharge check valve b Unloaded Operation Pressure from the discharge manifold
21. Autostart Stop Continuous NOTE With software revision 3 08 or higher when configuration 1115 and setpoint is 32 to 42 F 0 to 5 5 the unit is locked into continuous run Start Stop Continuous key is disabled A key is provided to select between continuous run and auto start stop operating mode In the continuous run mode the diesel engine will not shut down except for safeties or if the engine stalls This function also apply to the operation of the electric motor b Auto Mode Indicator The Auto start stop indicator is lit and AR L light will be on to indicate the autostart stop mode has been selected c Auto Start Failure If the unit failsto start shuts down on a safety or fails to run for the minimum run time three consecutive times the Start Fail alarm is activated d Continuous Run Mode In continuous run mode the engine is started but not allowed to shut off except for safeties or if the engine stalls Auto Start Sequence When the starting conditions are met the start sequence will begin by energizing the run relay and after 5 seconds energize the glow plug relay GPR to supply power to the glow plugs and 5 seconds later the starter is energized On initial power up the control will delay 5 seconds before the starting sequence begins If the required glow time is zero the control will energize the starter after a 5 second delay A fter a period of time the starte
22. Figure 1 16 item 15 passes through the strainer 9 and bleed orifice 8 to the back of the piston bypass valve 7 U nless bled away this pressure would tend to close the piston 6 against the piston spring 5 pressure With the solenoid valve 1 energized the solenoid valve stem 2 will open the gas bypass port 3 Refrigerant pressure will be bled to the suction manifold 10 through the opened gas bypass port A reduction in pressure on the piston bypass valve will take place because the rate of bleed through the gas bypass port is greater than the rate of bleed through the bleed orifice 8 When the pressure behind the piston has been reduced sufficiently the valve spring will force the piston bypass valve back opening the gas bypass from the discharge manifold to the suction manifold Discharge pressure in the discharge manifold will dose the discharge piston check valve assembly 14 isolating the compressor discharge manifold from the individual cylinder bank manifold The unloaded cylinder bank will continue to operate fully unloaded until the solenoid valve control device is de energized and the gas bypass port is closed ne SS Ges BOC eeh 1 Solenoid Valve 11 Cylinder Discharge 2 Valve Stem Valve 3 Gas Bypass Port 12 Valve Plate 4 Spring Guide 13 Cylinder Suction 5 Spring Valve 6 Piston 14 Discharge Piston 7 Piston Bypass Valve Check Valve 8 Bleed Orifice Assembly
23. b Water Temperature Sensor WTS This sensor senses engine water temperature The microprocessor will stop the unit when this temperature exceeds 110 3 230 5 F Thesensor islocated near the thermostat housing in the cylinder head 1 10 SWITCHES AND CONTROLS SOLID STATE CONTROLLER 1 10 1 Introduction Components required for monitoring and controlling the diesel engine refrigeration system are located in the electrical box door T he water temperature sensor is located on top of the engine 1 10 2 Control Panel and Related Components a Indicating Lights 1 Cool Light When illuminated indicated unitin either high or low speed cooling mode 2 Defrost Light When illuminated indicates unit is in defrost mode high speed only When the unit isin defrost the heating light will also be illuminated 3 Heat Light When illuminated indicated unitin either high or low speed heating mode b Meter Running Time RTM RTM S These meters designates the total hours and provides an accurate readout of accumulated engine standby motor running time This data can be used to establish the proper periodic maintenance schedule Refer to Section 4 1 c Switches 1 Glow Defrost Switch The glow defrost switch momentary contact type when held in the UP position pre heat permits battery current to flow to the glow plugsin the engine to pre heat the combustion chamber The glow plugs are located under the fuel in
24. ATS B CDT CL DA DER DL DDS DPR DPS DR DTT EFM 1 2 3 EFMR 1 2 3 EHC DESCRIPTION ALTERNATOR AUTOSTART LIGHT LIGHT BAR AUTO RESTART RELAY AMBIENT TEMPERATURE SENSOR BUZZER BATTERY COMPRESSOR DISCHARGE TEMPERATURE SENSOR COOL LIGHT LIGHT BAR DEFROST AIR SWITCH DIESEL ELECTRIC RELAY DEFROST LIGHT LIGHT BAR DEFROST DAMPER SOLENOID DAMPER RELAY OPTION 922 DETECTOR POWER SUPPLY DEFROST RELAY DEFROST THERMOSTAT ELECTRIC FAN MOTOR ELECTRIC FAN MOTOR RELAY EVAPORATOR HEAT CONTACTOR EVAPORATOR HEAT RELAY FUSE MAXI FUSE 80A FUSE 25A FUSE 15A FUSE 7 5A FUSE 5A FUSE 20A FAULT LIGHT LIGHT BAR amp DOOR FUEL HEATER OPTION FUEL HEATER RELAY OPTION FUEL HEATER THERMOSTAT OPTION FAULT RELAY FUEL PUMP GLOW PLUG GLOW PLUG RELAY HOT GAS SOLENOID HEAT LIGHT LIGHT BAR HEAT LIGHT RELAY HIGH PRESSURE CUT OUT SWITCH HEAT RELAY INSULATING PLUG 1 INSULATING PLUG 2 MANUAL GLOW CRANK MICROPROCESSOR BOARD MOTOR CONTACTOR OVERLOAD PROTECTOR OIL PRESSURE SAFETY SWITCH NO OUT OF RANGE RELAY OUT OF RANGE LIGHT LIGHT BAR CAB COMMAND PLUG CONNECTOR MICROPROCESSOR CAB COMMAND PLUG CONNECTOR POWER LIGHT POWER SUPPLY RECEPTACLE RETURN AIR SENSOR RUN CONTROL RELAY RUN RELAY RUN SOLENOID RUN STOP SWITCH SUPPLY AIR SENSOR OPTIONAL STANDBY MOTOR SPEED CONTROL SOLENOID STARTER MOTOR SERIAL PORT SUCTION PRESSURE TRANSDUCER SPEED RELAY STARTER SOLENOID
25. N 6 E 14 E 11 K 13 G 9 E 10 F 10 H 2 L13 K 14 J 11 l 16 M 16 J 9 K 8 L 7 J 9 16 16 K 14 1 14 H 16 M 16 F 2 L14 K 11 L5 N 10 J 11 J 16 0 16 7 14 H 6 J 2 F 9 M 10 M 5 N 9 L14 1 2 7 F 6 K 14 SYMBOL ALT ALTR BTY B CL DA DL DDR DDS DR DR1 DTR DTT EFM1 EFM2 EFM3 EFMR1 EFMR2 EFMR3 F1 F2 F3 F4 F5 F6 F7 F8 F9 FP FH FHR FHT GDS GP GPR HGS HL HP HR IP2 LP MC MCP MOT OL OP OPS PSR RAS RS RR RTM RTMS SBM SBR SCS SDT SM SR SRS SS SSC SSW TCM WT DESCRIPTION ALTERNATOR ALTERNATOR RELAY BATTERY BUZZER EUROPE ONLY COOL LIGHT WHITE DEFROST AIR SWITCH DEFROST LIGHT AMBER DEFROST DAMPER RELAY DEFROST DAMPER SOLENOID DEFROST RELAY DEFROST RELAY 1 DEFROST TIMER RELAY OPTION DEFROST THERMOSTAT ELECTRIC FAN MOTOR 1 ELECTRIC FAN MOTOR 2 ELECTRIC FAN MOTOR 3 ELECTRIC FAN MOTOR RELAY 1 ELECTRIC FAN MOTOR RELAY 2 ELECTRIC FAN MOTOR RELAY 3 FUSE 80 AMPERE FUSE 20 AMPERE FUSE 20 AMPERE FUSE 25 AMPERE FUSE 20 AMPERE FUSE 20 AMPERE FUSE 20 AMPERE FUSE 10 AMPERE FUSE 15 AMPERE FUEL PUMP FUEL HEATER OPTION FUEL HEATER RELAY OPTION FUEL HEATER THERMOSTAT OPTION GLOW DEFROST SWITCH GLOW PLUG GLOW PLUG RELAY HOT GAS SOLENOID HEAT LIGHT AMBER HIGH PRESS CUT OUT SWITCH N C HEAT RELAY INSULATING PLUG 1 INSULATING PLUG 2 LOW PRESSURE SWITCH EUROPE ONLY MO
26. NOTE It must be emphasized that only the correct refrigerant cylinder be connected to pressurize the system Any other gas or vapor will contaminate the system which will require additional purging and evacuation of the high side discharge of the system c Remove refrigerant using a refrigerant recovery system and repair any leaks Evacuate and dehydrate the unit Refer to section 4 6 Charge unit with refrigerant Refer to section 4 7 4 6 EVACUATION AND DEHYDRATION 4 6 1 General Moisture is the deadly enemy of refrigerant systems The presence of moisture in a refrigeration system can have many undesirable effects The most common are copper plating acid sludge formation freezing up of metering devices by free water and formation of acids resulting in metal corrosion 4 6 2 Preparation a Evacuate and dehydrate only after pressure leak test Refer to section 4 5 b Essential tools to properly evacuate and dehydrate any system include a good vacuum pump 5 cfm 8m3H volume displacement P N 07 00176 01 and a good vacuum indicator such as a thermocouple vacuum gauge vacuum indicator Available through Robinair Manufacturing Montpelier Ohio Part Number 14010 NOTE It is not recommended using a compound gauge because of its inherent inaccuracy Keep ambient temperature above 15 6 C 60 F to speed evaporation of moisture If ambient temperature is lower than 15 6 C 60 F ice might f
27. RUN RELAY C2ND COMPARTMENT BOX MULTI TEMP 010 610 R1 RESISTANCE 2ND EVAPORATOR D10 610 R2 RESISTANCE 2ND EVAPORATOR E10 H10 R3 RESISTANCE 2ND EVAPORATOR H4 2T 2ND TIMER BOX MULTI TEMP R11 R15 SBM STAND BY MOTOR MAIN UNIT E14 SH SHUNT 5 OHM 25 WATT BOX MULTI TEMP NOTES CIRCUITS FOR DIESEL ELECTRIC 1 UNIT SHOWN IN OFF POSITION 2 WIRE IDENTIFICATION SYSTEM COLOR WHITE DC CONTROL CIRCUITS BLACK DC GROUNDS RED AC CIRCUITS GREEN AC GROUNDS 3 ADDRESS SYSTEM EXAMPLE HCD2 MPW2 INDICATES A WIRE BETWEEN PLUG HC PIN D2 amp MICROPROCESSOR MP amp PIN W2 4 VOLTAGE BELOW 12 VOLTS 208V 230V 60Hz 3e 220V 50Hz 5 ENGINE CT2 29 2 GLOW PLUGS ENGINE CT3 44 3 GLOW PLUGS SR Ss NO CONNECTIONS OF STANDBY PANEL DL MC AND DPS ON D 77 L t 1 JUNCTION BLOCK L2 T 402 407 07 NDICATES A SOLDERED SPLICE POINT LIGHT LINES INDICATE SYSTEM WIRES L3 T29 Cc 3 1 19 o NORMALLY CLOSED CONTACTS OL SBM NORMALLY OPEN CONTACTS NDICATES CONNECTION DPS PH SP16 A NDICATES INSULATING PLUG 1 HC2F MULTIPLE PLUG CONNECTION NUMBER COMPONENT CONNECTION NUMBER OR LETTER Ka 440
28. Replace Check Engine 4 2 6 4 2 3 4 2 5 Starter cranks engages Engine lube oil too heavy but dies after a few seconds Voltage drop in starter cable s 5 1 2 Engine Starts Then Stops Engine stops after Fuel supply restricted Check several rotations No fuel in tank Leak in fuel system Faulty fuel control operation Fuel filter restricted Injector nozzle s defective Injection pump defective Air cleaner or hose restricted Safety device open Open wiring circuit to run solenoid Fuel pump FP malfunction 5 1 3 Starter Motor Malfunction Starter motor will not crank or turns slowly Battery insufficiently charged Battery cable connections loose or oxidized Battery cables defective Starter brushes shorted out Starter brushes hang up or have no contact Starter solenoid damaged Run Stop or Start Run Stop switch defective Engine lube oil too heavy 5 1 Check Check Engine Replace Engine Manual Engine Manual Check Replace Engine Manual Engine Manual Engine Manual Replace 1 2 INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 5 1 3 Starter Motor Malfunction CONTINUED Starter motor turns Pinion or ring gear obstructed or worn Clean both but pinion does not engage remove burrs or replace apply grease Starter motor does not disen Run Stop or Start Run Stop switch defective Replace gage after switch was depressed Starter motor solenoid defective Engine Manual Pinion does not disengage
29. a slight positive pressure should be indicated on the pressure gauge 6 When opening up the refrigerant system certain parts may frost Allow the part to warm to ambient temperature before dismantling This avoids internal condensation which puts moisture in the system 7 Open backseat King valve and midseat suction service valve 8 Leak check connections with a leak detector Refer to section 4 5 9 Start the unit in cooling and check for noncondensibles 10 Check the refrigerant charge Refer to section 4 7 3 NOTE Store the refrigerant charge in an evacuated container if the system must be opened between the compressor discharge valve and receiver Whenever the system is opened it must be evacuated and dehydrated Refer to section 4 6 b Removing the Refrigerant Charge Connect a refrigerant recovery system to the unit to remove refrigerant charge Refer to instruction provided by the manufacture of the refrigerant recovery system 4 5 REFRIGERANT LEAK CHECKING If system was opened and repairs completed leak check the unit a The recommended procedure for finding leaks in a system is with a halide torch or electronic leak detector Testing joints with soapsuds is satisfactory only for locating large leaks b Ifsystem is without refrigerant charge system with refrigerant to build up pressure between 2 1 to 3 5 kg cm 30 to 50 psig Remove refrigerant cylinder and leak check all connections
30. an orifice This orifice controls the oil return to the compressor and prevents the accumulation of oil within the accumulator tank Positive Output B 12vdc Test Lamp Terminal D Ground Terminal Excitation Input Suppression Capacitor Regulator Brush Holder amp Brushes Nr c 1 14 CHARGING ALTERNATOR 1 14 1 Alternator Operation CAUTION Observe proper polarity when installing battery negative battery terminal must be grounded Reverse polarity will destroy the rectifier diodes in alternator As a precautionary measure disconnect positive battery terminal when charging battery in unit C onnecting charger in reverse will destroy the rectifier diodes in alternator The alternator converts mechanical and magnetic energy to alternating current A C and voltage by the rotation of an electromagnetic field rotor inside a three phase stator assembly The alternating current and voltage is changed to direct current and voltage by passing A C energy through a three phase full wave rectifier system Six silicon rectifier diodes are used See Figure 1 13 1 14 2 Integral Voltage Regulator Operation 12 volts d c The regulator is an all electronic transistorized device No mechanical contacts or relays are used to perform the voltage regulation of the alternator system The electronic circuitry should never require adjustment and the solid state active elements used have proved reliab
31. and forces it into the condenser tubes The condenser fan circulates surrounding air over the outside of the condenser tubes Heat transfer is thus established from the refrigerant gas inside the tubes to the condenser air flowing over the tubes The condenser tubes have fins designed to improve the transfer of heat This removal of heat causes the refrigerant to liquefy liquid refrigerant flows from the condenser and through a check valve to the receiver The receiver stores the additional charge necessary for low ambient operation and for heating and defrost modes The refrigerant leaves the receiver and flowsthrough a manual receiver shutoff valve king valve The refrigerant then flows through the subcooler The subcooler occupies a portion of the main condensing coil surface and gives off further heat to the passing air The refrigerant then flows through a filter drier where an absorbent keeps the refrigerant clean and dry In R 404A units the refrigerant flows to the Liquid suction heat exchanger Here the liquid is further reduced in temperature by giving off some of its heat to the suction gas The liquid then flows to an externally equalized thermostatic expansion valve TX V which reduces the pressure of the liquid and meters the flow of liquid refrigerant to the evaporator to obtain maximum use of the evaporator heat transfer surface The evaporator tubeshave aluminum fins to increase heat transfer therefore
32. b Replacing Solenoid Valve Internal Parts See Figure 7 3 The liquid line solenoid valve may be serviced by pumping the unit down Refer to section 4 4 a Remove and store the refrigerant charge in an evacuated container to service hot gas solenoid valve Refer to section 4 4 b 1 Remove coil retainer and coil assembly from valve Remove enclosing tube assembly and related items 2 Check for foreign material in valve body 3 Install new parts EVAPORATOR PRESSURE REGULATING VALVE REMOTE EVAPORATOR gt Is j X9 gi lt o A 4 Tighten enclosing tube assembly to a torque value of 200 inch pounds 2 3 mkg and leak check the valve Refer to section 4 5 5 6 Start unit and check refrigerant charge per section 4 7 f Install coil assembly and retainer 7 Check refrigeration cycles Refer to section 2 M4 3 i 4 d eT 8 1 Retainer 5 Gasket 2 Coil Assembly 6 Piston 3 Enclosing Tube 7 Body 4 Plunger Assembly 8 Bracket Adapter Figure 7 3 Solenoid Valves Alco 7 8 MULTI TEMP REFRIGERANT CIRCUIT The Multi Iemp refrigerant circuit is the same as Supra but with the addition of a remote evaporator The remote evaporator refrigerant flows through the electrically controlled liquid line solenoid valve LSV which starts or stops the flow of liquid refrigerant lt LIQUID SOLENOID VALVE LSV A gt
33. display OFF Do Not Turn Offi OUT RANGE will be displayed alternately with CNF6 the default display of the setpoint box o All Supra Units temperature With this CNF in the ON position All Supra Units once the box temperature has been CNF7 Out Of Range for 45 minutes the unit will shut 1 ON Do Not Turn down and the same alarms as described above 922 944 Only will be displayed CNF8 0 All Other Supra Units CNF3 amp o OFF Out of range alarm only Standard Function Lock allows the Function o M 1 Out of range alarm and unit shut down Key and the Start Stop Continuous Run Key to be locked so that no changes can be made Standby Diesel Backup is disabled CNF10 And All Units Prior to Rev 3 23 Modified Function Lock is the same as Enables Standby Diesel Backup Rev 3 23 Standard Function Lock except that with the and higher setpoint at or between 32 F and 42 F the unit will always operate in Continuous Run If o OFF Functions change normally the setpoint is outside this range either o B 2 Functions amp Start Stop locked Start Stop or Continuous Run can be selected OFF Supra Units 422 522 622 722 822 922 The maximum setpoint and function lock are CNF12 o Supra Units 644 744 844 944 controlled via a combination of CNF3 and CNF11 NUS OFF All Supra Units Do Not Turn On CNF11 OFF CNF3 OFF Maximum set All Supra Units poin
34. display will flash warning the operator that the displayed value has not been entered Press the ENTER key to enter the new selection into memory The display will revert to the original selection if no further action is taken for the next 5 seconds c Continue to scroll through the configuration list by pressing the FUNCTION key Change any other configurations as required d When finished turn the Run Stop switch to the Stop position then back to the Run position to start the unit SETTINGS CONFIGURATION DESCRIPTION DI Long glow cycle NOTES Short glow cycle These settings are optional and can be set to CNF2 844 ONLY customer specifications or left at default values Alll ON 622 644 722 744 Only other settings not marked with MUST be set as Max Set Point 86 F 30 c All functions Shown for proper unit operation CNF3 locked 1 CNF9 allows selection of how the unit will react Note 2 Max Set Point 90 F 32 2C Modified func under an Out Of Range condition tion lock Out Of Range condition is described as the box SF temperature having arrived at setpoint then Single Temp OFF OFF Heat Lockout On At 10 F 12 2 C drifting away from setpoint With this CNE in the Multitemp ON Heat Lockout Off OFF position once the box temperature has R 502 been Out Of Range for 15 minutes the ALARM CNF5 sli R 22 R 404A light will be turned on and the alarm
35. displayed with the description ENG or CD 2 The data is displayed with units designator H i e ENG 5040H OR CD2 5040H The display range is 0 to 99999 Engine Temperature The coolant temperature is displayed with the description WT or CD3 The data is displayed with the proper unit designator Degree C or Degree F i e WT 185F or CD 3185F Thedisplayrangeis 12 C to 130 10 F to 266 F Return Air Temperature The return air temperature is displayed with the description RAS or CD 4 The data is displayed with one decimal place and the proper unit designator Degree or DegreeF i e RAS 85 0F The displayrangeis 38 to 70 36 to 158 Coi SS ca CDs Co SS Software Revision A A 2R Compartment 2 Air Temperature Compartment 3 Air Temperature MHR1 Maintenance Hour Meter 1 CD1 MHR2 Maintenance Hour Meter 2 CD20 Switch On Hour Meter Codes 5 amp 6 are variable SAS is displayed when the SUP Probe Function is selected REM is dis played when the REM Probe Function is selected CD10 CD11 CD12 CD13 CD14 CD15 CD16 CODE ED CD3 CD4 CD5 CD6 CD8 CD9 CD10 CDM CD12 CD13 CD14 CD15 CD18 CD18 9 Supply Air Temperature The supply air temperature is displayed with the description SAS or CD5 The data is displayed with one decimal place and the proper unit designator D eg
36. function selection T hetwo choices are displayed as ENGLISH or CODES With this parameter set to CODES all display descriptions are set to their code display This parameter will not change due to this selection Refer to each section for the alternate display description M anual Glow Override The auto start glow time can be manually overridden through this function The messages is displayed as NORM GLOW or ADD GLOW If the ADD GLOW selection is entered the control will add 30 seconds of glow to the glow times listed in section 1 8 11 This feature must be selected before the 3 start attempts have been completed At higher ambients this override will only affect the second or third start attempt The add glow time is deselected when the engine starts or fails to start This parameter will not change due to the Code vs English selection Alarm Reset Alarms can be reset through this function The messages are displayed as ALARM RST or ALARM CLR If the ALARM RST is displayed then there is at least one alarm present Pressing enter key will clear all the alarms present Ifthe ALARM CLR isdisplayed then there are no alarms present See section 1 8 7 This parameter will not change due to the code vs English selection CODE ENGLISH REM Controlling Probe PROBE Return Air SUP Controlling Probe PROBE Supply Air Degrees Temperature Unit ForC Cor TIME STRT Maximum Off time 30 Min TEMP Temperature Base
37. has cooled down Refill system with water e Runengine to operating temperature Drain system again and fill with treated water anti freeze see Caution and refer to section 1 2 NEVER POUR COLD WATER INTO A HOT ENGINE however hot water can always be added to a cold engine 4 2 2 Changing Lube Oil and Lube Oil Filters After warming up the engine stop engine remove drain plug from oil reservoir and drain engine lube oil CAUTION When changing oil filters the new filters should be primed with clean oil if the filters are not primed the engine may operate for a period with no oil supplied to the bearings Replace filter s lightly oil gasket on filter before installing and add lube oil Refer to section 1 2 Warm up engine and check for leaks 4 2 3 Replacing the Speed and Run Control Solenoids a Run Solenoid see Figure 4 1 1 Remove spring item 7 from the engine run lever 2 Disconnect wiring to solenoid Remove clip item 5 from linkage rod item 8 Remove mounting hardware and solenoid 3 Attach linkage to new solenoid and install the clip to the linkage rod Install the replacement solenoid and mounting hardware loosely Connect the ground wire and spring 4 Energize the solenoid with a jumper wire connected to a battery Slide the solenoid far enough back on the bracket to set the engine run lever item 9 against the stop Tighten solenoid mounting hardware 5 De energize the solenoid If the e
38. in the written text the schematic in this manual has map coordinates added to the margins These locations have also been added to the legend The relay module which contains plug in interchangeable relays provides the controller with a means for switching the unit components to achieve a desired operating mode 3 4 2 Cooling There are two control ranges Frozen and Perishable The Frozen range is active with set points at or below 12 10 F and the Perishable range is active at set points above 12 C 10 F The controller automatically selects the mode necessary to maintain box temperature at set point If the unit is in high speed cool the controller will de energize the speed relay A set of normally closed contacts SR close to energize the speed control solenoid SCS The engine will be in high speed As the box temperature falls toward set point the controller will place the unit in low speed cool See Figure 3 1 Figure 3 2 Figure 3 3 or Figure 3 4 The speed relay SR energizes to open the circuit to the speed control solenoid SCS Engine speed decreases from high speed to low speed For set points above 12 10 F and with decreasing temperature the unit will shift to low speed heat Unit will remain in various stages of heating until the boxtemperature increases enough to place the unit in the low speed cool mode As the box temperature increases the unit will shift to high speed
39. is operating at low speed and the suction pressure drops below 21 psig the front bank is loaded At ambient temperatures of 90 F 32 2 C or higher At ambient temperatures of 90 F or higher the unloading suction pressure settings relative to ambient temperatures are a straight line Refer to following chart R 22 REFRIGERATION SYSTEM DIESEL OPERATION SUCTION PRESSURES UNLOADING 35 30 SUCTION 55 20 PSIG 80 90 100 110 120 130 AMBIENT TEMPERATURE UF FRONT UNLO R ENERGIZED b R 404A Refrigeration System At ambient temperatures of 90 32 2 C or below When the system is operating at high speed and the ae pressure drops below 33 psig the front bank is oaded When the system is operating at low speed and the pressure drops below 35 psig the front bank is oaded At ambient temperatures of 90 32 2 C or higher At ambient temperatures of 90 F or higher the unloading suction pressure settings relative to ambient temperatures are a straight line Refer to chart below R 404A REFRIGERATION SYSTEM DIESEL OPERATION SUCTION PRESSURES UNLOADING 40 35 SUCTION 30 PRESSURE PSIG 25 KR 15 Li d d AMBIENT TEMPERATURE CF UF FRONT UNLOADER ENERGIZED 1 17 3 Suction Pressure Operation Standby Motor The microprocessor will monitor suction pressure of the refrigeration system and control the unloader to maintain a maximum operating pressure
40. is pointing up or down 6 Purge the crankcase by cracking the suction valve for 1 or 2 seconds 7 Replace oil fill plug When inserting the oil fill plug the sealing O ring is slipped over the oil fill plug threads in such a manner that the O ring is not twisted Insert the oil plug in the oil fill opening and tighten the plug to a torque value of 4 to 11 ft Ib 0 55 to 1 5 mkg If the plug leaks do not attempt to stop the leak by over tightening the oil fill plug A leak may be caused by dirt under the O ring or on the seat a fractured O ring or a damaged seat on the oil fill plug or oil fill opening To stop leaks at the oil fill plug correct the mechanical damages and insert a new O ring 8 Fully backseat suction and discharge service valves Table 4 2 Oil Charge Vs Oil Level Increments York Compressor b Making a York Compressor Oil Dipstick 1 The oil dipstick can be formed as shown in Figure 4 7 from a g inch diameter by 8 5 16 long stick preferably nonferrous material which is not subject to corrosion 2 Place notches at the end of the dipstick in 1 8 inch increments This will help determine the oil depth FINGER RING 12 NOTCHES 1 g APART Refer to Table 4 1 Figure 4 7 York Compressor Oil Dipstick 4 11 CHECKING 05GCOMPRESSOR OIL LEVEL To Check the Oil Level in the 05G Compressor 1 Operate the unit in high speed cooling for at least 20 minutes a 2 Check the oil sigh
41. it is important to check that the configurations are compatible for the unit into which it will be installed This same board fits both trailer and truck model units All configuration fields should be viewed before starting the unit To reach the configuration fields 1 Turn the Run Stop switch to the Stop position 2 With the unit off locate the serial port plug located below the control panel Remove the protective plug to gain access to the wire terminals Place an insulated jumper wire between wires SPA and SPB at the serial port plug Change 01 08 4 16 CAUTION Do not allow jumper wire to touch any ground 3 Turn the Run Stop switch to the Run position The FAULT light will come on and the micro display will read TV or CNF1 DI Remove the jumper wire from the serial port and reinstall the protective plug The configuration screen will now remain available for 5 minute Scroll through the configuration list using the FUNCTION key and compare the settings with those shown on the table in the next column If any of the configurations need to be changed continue with step 4 below 4 change the configuration selection a Bring the configuration to be changed onto the display Press the ENTER key to allow change access to the displayed configuration b Press either the UP or DOWN keys to display available selections for that configuration Leave the correct selection on the screen The selection
42. motor overload alarm is displayed with the description SBY MOTOR or AL 14 This alarm is generated when the M OL input is sensed open with the Run Relay energized in electric mode Diesel Electric Relay energized Fuse Alarm The fuse alarm is displayed with the description FUSE BAD 15 This alarm is generated when the FU SE input is sensed low The fault light FL is turned Display Alarm When no communications exist between the main board and the display board for 8 seconds the display alarm description is DISPLAY or AL17 Maintenance H our M eter 1 Alarm The maintenance hour meter alarm 1 is displayed with the description SERVICE 18 This alarm 15 generated when the designated hour meter is greater than maintenance hour meter 1 Maintenance H our M eter 2 Alarm The maintenance hour meter alarm 2 is displayed with the description SERVICE 2 or AL19 This alarm 15 generated when the designated hour meter is greater than maintenance hour meter 2 Out of R ange Alarm The out of range alarm is displayed with the description OUT RANGE AL20 This alarm is generated when the main compartment is out of range refer to section 1 8 5 The fault light FL is turned on Remote Compartment 2 O ut of range Alarm The Code display is A L 21 This alarm is generated when the remote compartment 2 is out of range refer to section 1 8 5 The fault light FL is turned on Remote Compartment 3 O ut of range Alarm
43. of paint or glycerol on the adjusting screw so that vibration will not change switch setting 4 16 CHECKING AND REPLACING EVAPORA TOR FAN MOTOR BRUSHES amp COMMUTATOR The fan motor commutator and brushes should be checked periodically for cleanliness and wear to maintain proper operation of the the fan motors 1 Brush Cap 2 Brush Figure 4 13 Fan Motor Brushes To check brushes proceed as follows a With unit off and battery disconnected remove brush cap item 1 2 per motor See Figure 4 13 b Remove brushes item 2 2 per motor and check the length of the brush If the length is less than 1 4 inch the brushes should be replaced after checking commutator c Blow out the brush holder with low pressure air to remove any carbon dust in the holder This dust could prevent a good contact between the brushes and commutator d Remove the back cover of the motor and inspect the commutator If the commutator is heavily grooved polish it using fine sandpaper do not use emery cloth Wipe out any accumulation of greasy material using a clean rag dampened with solvent R eassemble the motor install new brushes and replace cap 4 17 EVAPORATOR COIL CLEANING The use of recycled cardboard cartons is increasing across the country The recycled cardboard cartons create much more fiber dust during transport than new cartons The fiber dust and particles are drawn into the evaporator where they lodge between the evap
44. the Defrost Air Switch 4 16 Checking and Replacing Evaporator Fan Motor Brushes amp Commutator 4 17 Evaporator Coil Cleaning 4 18 Condenser Coil 419 Hot Gas Three way 4 19 1 Replacing Solenoid Coil 4 19 2 Replacing Solenoid Valve Internal Parts 4 20 Adjusting the Compressor Pressure Regulating Valve 4 201 Thermostatic Expansion Valve 4 22 sent tesa toda oe Leda EH eu x eie UR 4 23 Configuration of Microprocessor 4 24 Controller Sensor Checkout nee 4 25 Suction Pressure Transducer Re ERE DU ER S 4 26 Servicing Defrost Damper Solenoid DDS Optional 5 TROUBLESHOOTING 5 1 EEN 5 1 Engine Will Not Start NENNEN ER ap qa NEE Ne 5 1 2 Engine Starts Then Stops 5 1 3 Starter Motor Malfunction 5 1 4 Malfunction in the Engine Starting
45. the compressor Refer to section 4 8 4 14 2 Checking High Pressure Switch WARNING Do not use a nitrogen cylinder without a pressure regulator Cylinder pressure is approximately 165 kg cm 2350 psi Do not use oxygen in or near a refrigerant system as an explosion may occur See Figure 4 11 Cylinder Valve and Gauge Pressure Regulator Nitrogen Cylinder Pressure Gauge 0 to 400 psig 0 to 28 kg cm Bleed Off Valve 1 4 inch Connection Figure 4 11 Typical Setup for Testing High Pressure Switch a Remove switch as outlined in section 4 14 1 b Connect ohmmeter or continuity light across switch terminals Ohmmeter will indicate resistance and continuity light will be lighted if switch closed after relieving pressure c Connect switch to a cylinder of dry nitrogen See Figure 4 11 d Set nitrogen pressure regulator higher than cutout point on switch being tested Pressure switch cutout and cut in points are shown in sections 1 3 e f Open cylinder valve Slowly close bleed off valve and increase pressure until the switch opens If light is used light will go out and if an ohmmeter is used the meter will indicate open Open pressure on gauge Slowly open Close valve on cylinder and open bleed off valve 4 12 bleed off valve to decrease pressure until switch closes light will light or ohmmeter will move 4 15 CHECKING CALIBRATION OF THE DEFROST AIR SWITCH Ohmmeter or Continuity Devic
46. the run relay and flash SP on the left hand display until a valid setpoint is entered The setpoint may be changed up or down in whole numbers until the desired setpoint is displayed T he display will flash to indicate that the setpoint reading being displayed is a non entered value E ach time the up down arrow keyis pressed the 5 second display timer will be reset Depressingthe enter key will cause the new displayed setpoint value to become active If the display isflashing and the new value is not entered after 5 seconds of no keypad activity the display will revert back to the active setpoint 1 8 4 DIGITAL DISPLAY The digital display has 9 digits T he default display is setpoint on the left and controlled air temperature on the right The readout is keypad selectable for D egrees C or Degrees F See Figure 1 7 The display also has symbol indicators for the following modes Cool Heat Defrost Out of range City Speed Autostart Stop Stand by and Road diesel operation Oneach power up the unit will displaya D isplay Test for 5 seconds then display the default reading 1 8 5 FUNCTIONAL PARAMETERS NOTE If configuration CNF11 is ON functional parameters are lockout The ability to change functional parametersfrom keypad are disabled The functional parameters will control selected operating features of the unit These parameters can be displayed by pressing the function change key All functional parameter
47. 0 1 o 71 9 9 o od 0 0 o 0 1 1 o o o o High SpeedHeaing 0 o 1 0 9 9 9 o STANDBY MOTOR OPERATION 3 6 SECTION 4 SERVICE WARNING Beware of V belts and belt driven components as the unit may start automatically Before servicing unit make sure the Run Stop switch is in the STOP position Also disconnect the negative battery cable NOTE To avoid damage to the earth s ozone layer use a refrigerant recovery system whenever removing refrigerant 4 1 MAINTENANCE SCHEDULE UNIT REFERENCE ON OFF OPERATION SECTION a Daily Inspection Perform daily inspection 4 1 Check wire harness for chafing and loose terminals Replace Tighten Check unit mounting bolts for tightness 1 6 Check standby motor bearings for end play None Change engine lube oil and filter Perform daily inspection Tighten all electrical connections Check defrost air switch calibration Check that evaporator drain lines are clear Replace fuel filter Remove and inspect evaporator fan motor brushes Check engine speeds d Oil Change Intervals Without With MODEL Bypass Oil Filter Bypass Oil Filter Supra 422 522 500 Hours 600 Hours Supra 622 722 822 750 Hours 1000 Hours Supra 922 944 1000 Hours 1250 Hours 4 2 SERVICING ENGINE RELATED COMPONENTS 4 2 1 Cooling System The condenser and radiator asse
48. 1 2 2 3 3 3 Table 4 6 Sensor Resistance Solid State Units RAS amp SAS RAS amp SAS Resistance In Ohms s 58 50 54 7529 4390 0 4 0 20 0 0 70 2 9 T 501 9 TT 495 514 568 625 686 750 817 887 61 SEH ERI m iw 8s 3o 199 iw 4 o 4 25 SUCTION PRESSURE TRANSDUCER Before installing a new suction pressure transducer it must be calibrated The calibration will not be performed if the run relay is energized This prevents the operator from calibrating the unit with the sensor in the system T he reading of the sensor must be at atmospheric pressure 0 psig or 14 7 psi f the sensor readingis greater than 20 psig 34 7 psi or lessthan 6 7 psig 8 psi itcan not be calibrated nce the micro is calibrated the display will readout the actual value a Turn power off and remove starter solenoid wire then let unit fail to start This will de energize run relay b Connect wiring to new suction pressure transducer B efore installing suction pressuretransducer into unit display the suction pressure via the unit status display While the suction pressure is being displayed pressE nter Key for 3 seconds the display should read 0 If display reads 0 install suction pressure transducer into unit 4 26 SERVICING DEFROST DAMPER SOLENOID DDS OPTIONAL a Replacing Solenoid 1 Disconnect wiring to soleno
49. 10 The data is displayed with one decimal place and then the capital letter V for volts i e BATT 12 2V or CD 10 12 2V The voltage reading is displayed with a plus sign if the battery status is good Standby H ours The number of electric motor hours are displayed with the description SBY or CD 11 The data is displayed hoursand units designator H i e SBY 5040H or CD 11 5040H The display range is 0 to 99999 Mod V Future Expansion This unit data is not used at this time The Code display is CD 12 Software Revision The Eprom software revision number is displayed with the description REV or CD 13ontheleftand E prom software revision number on the right side Pressing the enter keyfor 3 seconds will display R EV U 2ontheleftand the board mounted software revision number on the right side Serial Number Low The low serial number of the unit is displayed with the description SERL or CD 14 The data isthe lower 3 digits of the serial number burned in to the E prom i e SERL 504 or CD 14 504 Serial Number U pper The upper serial number of the unit is displayed with the description SERU or CD 15 The data isthe upper 3 digits of the serial number burned in to the E prom i e SERH 001 or CD 15 001 Compartment 2 Air Temperature The air temperature for the second compartment will be displayed with the abbreviated description 2RA on the left hand side The code displayisCD 16 The data will be dis
50. 17 For set points above 12 10 F and with decreasing temperature the unit will shift to low speed heat Unit will remain in various stages of heating until the box temperature increases enough to place the unit in the low speed cool mode As the box temperature increases the unit will shift to high speed cool mode speed relay energizes 2 4 3 Heating Refer to section 1 16 for description on heating cycle The unit will only heat when the controller is set above 12 C 10 F as the heat relays electronically locked out with set points at or below 12 C 10 F The controller automatically selects the mode necessary to maintain box temperature at set point The heating modes are follows with descending temperatures a Low Speed Heating b High Speed Heating The controller will shift the unit into low speed unloaded heat when the box temperature falls below set point The microprocessor pulls terminal X1 low to complete the ground paths for the heat relay HR1 When the unloader front relay UFR energizes a set of N O contacts UFR close to energize the compressor front unloader UF Compressor will be in 4 cylinder heating Ifmore heating capacity is required the unit will shift to high speed heating The microprocessor energizes the and speed relay SR coils Terminals X1 and 3 will be pulled low SR contacts close to energize the speed control solenoid SCS The engin
51. 18 1 8 Unloading in Temperature 1 25 2 1 Manual Glow Time ith ate dagen re a e EET 2 2 2 2 Relay Operation Microprocessor Controller 2 5 3 1 Manual Glow KEE 3 1 3 2 Relay Operation Solid State Controller 3 6 4 1 Belt Tension rece rm RUE Ree Dee in a beet 4 4 4 2 Oil Charge vs Oil Level Increments York Compressor 4 9 4 3 Connection Point Voltage 4 15 4 4 Microprocessor Configuration 2 4 16A 4 5 Sensor Resistance Micro Units ATS CDT RAS SAS amp WTS 4 17 4 6 Sensor Resistance Solid State Units RAS amp SAS 4 17 4 7 R 404A Temperature Pressure Chart 4 18 4 8 R 22 Pressure Temperature Chart 4 19 7 1 Safety Devices Remote 7 1 iv Change 01 08 Figure 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 1 10 1 11 1 12 1 13 1 14 1 15 1 16 1 17 3 1 3 2 3 3 3 4 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 4 11 4 12 4 13 4 14 4 15 4 16 4 17 6 2 7 1 7 2 7 3 7 4 7 5 LIST OF ILLUSTRATIONS Condensing Section Top View Unit Curbside View terret e ea me ete pe
52. 4 13 4 13 4 13 4 13 4 14 4 14 4 14 4 15 4 16 4 17 4 17 4 18 5 1 5 1 5 1 5 1 5 1 5 2 5 2 5 3 5 3 5 3 5 3 5 4 5 4 5 4 5 5 5 5 5 5 5 5 5 6 5 6 5 6 6 1 6 1 TABLE OF CONTENTS CONT D Section Page 7 MULTI TEMP BI TEMP OPERATION AND SERVICE 7 1 7 1 ZIntroductiom eoo Ca am E e hua ee EE 7 1 1 2 blectrical dia de etn 7 1 73 gt Satety Devices sep one een e dr EE A PERPE PU eere 7 1 7 4 Remote Compartment Operation 7 2 1 5 Microprocessor Controller 4 e e Eu Wate 7 2 7 6 Servicing Remote Evaporator 7 2 77 Servicing Liquid Solenoid Valve 18 7 3 7 8 Multi Temp Refrigerant Circuit 7 3 LIST OF TABLES Table Page 1 1 Model Chart bbe be E ied AAG ad Bae akg aka 1 1 1 2 Safety Devices Microprocessor Controller 1 8 1 3 Safety Devices Solid State Controller 1 8 1 4 Function COd6es ee tale adhe cde Pd eb each duds 1 11 1 5 Unit Data Codes e p EE 1 13 1 6 Alarm Display 39 nihit t v ad te EA Pare REL OF Pd E 1 14 1 7 Battery Voltages ese De RE au E ACRES AUR RET ACER pt 1
53. 5 3 1 3 2 3 3 3 4 3 5 4 1 4 2 4 3 4 4 4 5 4 6 4 7 TABLE OF CONTENTS CONT D OPERATION UNITS WITH MICROPROCESSOR CONTROLLER CONT D DAZ Le estes eee bee deen Mone 2 43 Heating e ee 24A Defrost aeus Ser err eR ew ed e ew Obs eee Geena W Control Circuit Operation Standby Motor 251 Electric Standby Features 2 5 2 Standby Cool uum k eis II RIT a RES 253 Standby OFE u u Ue de sese gts 2 5 4 Standby Defrost itor RE e e ee eee e p aA ee OPERATION UNITS WITH SOLID STATE CONTROLLER Pre Irip Inspection s l d ines E pied aus re e oad e Starting and Stopping Instructions Engine Starting and Stopping Instructions Standby Motor Drive Control Circuit Operation Engine S L Hitroduction ic coe obs de haqa qaa qon 3 4 2 CQoolng oe de EE EA e E E e AE E Se S43 Heating ee tree e P eR THIS Ee A EE Ge zs Eee e IE TUNER INE TEUER Hes Control Circuit Operation Standby Motor 351 Standby COOL ee E DOE See aee eds 3 9 2 Standby us a sama bg e alate LE
54. 9 16 9 35 46 92 73 89 04 21 54 18 8 72 3 7 2 7 3 6 3 1 8 1 3 6 5 1 7 5 35 30 25 220 18 16 Sp 12 10 2 2 10 12 14 20 22 6 24 4 26 28 30 0 31 1 22 1 32 1 43 1 54 1 65 1 77 1 88 2 01 2 13 2 26 2 40 2 54 2 68 2 83 2 99 3 14 3 31 3 47 3 65 3 83 4 01 4 20 4 39 4 59 4 79 4 18 Temperature Fees Psig Bar 7721701 125 5101 500 74017417855 61 590 742161790 626 614 al 7 925 650 638 al 8 962 676 663 999 702 689 956 87 DU 11 40 16 18 21 24 27 29 32 35 38 41 43 52 54 57 63 2 2 2 2 2 2 2 7 96 8 69 9 47 10 30 11 18 12 10 13 07 14 10 15 18 16 33 17 53 18 78 0 11 1 50 2 95 4 48 6 07 7 74 9 48 31 30 90 TEMPERATURE _F Cc 40 40 36 38 32 36 28 33 26 32 24 31 22 30 20 29 18 28 16 27 14 26 12 24 10 23 8 22 6 21 4 20 2 19 0 18 2 17 4 16 6 14 8 13 10 12 12 11 14 10 16 9 18 8 20 7 22 6 24 4 26 3 28 2 30 1 32 0 Psig Table 4 8 R 22 Pressure Temperature Chart PRESSURE Kg cm Bar 4 19 TEMPERATURE F Psig 60 5 63 3 66 1 69 75 0 81 4 88 1 91 5 102 5 110 2 118 3 126 8 135 7 145 154 7 164 9 175 4 186 5 197 9 209 9 222 3 235 2 248 7 262 6 277 0 291 8 307 1 323 6 341 3 359 4 377 9 396 6 415 6 434 6
55. Belts a allow for easy removal installation and adjustment of the V belts it is recommended that the muffler be disconnected from the muffler bracket and moved b Except for Supra 422 remove alternator V belt Refer to Section 4 3 2 c Remove the standby motor compressor V belt Refer to Section 4 3 4 d Loosen belt idler bolt 24mm Move idler to remove V belts e Replace V belts Position the idler to the correct belt tension Tighten the idler retaining bolt 4 4 PUMPING THE UNIT DOWN OR REMOVING THE REFRIGERANT CHARGE NOTE To avoid damage to earth s ozone layer use refrigerant recovery system whenever removing refrigerant a Pumping the Unit Down To service the filter drier expansion valve quench valve CPR valve or evaporator coil pump most of refrigerant into condenser coil and receiver as follows 1 Backseat suction and discharge service valve turn counterclockwise to close off gauge connection and attach manifold gauges to valves 2 Open valves two turns clockwise Purge gauge line 3 Close the receiver outlet king valve by turning clockwise Start unit and run in high speed cooling Place Run stop switch in the STOP position when unit reaches 0 1 kg cm 1 psig 4 Frontseat close suction service valve and the refrigerant will be trapped between the compressor suction service valve and the manual shutoff King valve 5 Before opening up any part of the system
56. Control Solenoids Electric Fuel PUMP REPE Dex PEE d a V Belt Arrangement Belt Tension Vacuum Pump Connection Compressor Model 05K York Compressor Dipstick Oil Level in Sight Glass 05 Compressor OSG etes ee eee eevee Unloader Solenoid Valve Typical Setup for Testing High Pressure Switch Defrost Air Switch Test Setup Fan Motor Brushes Hot Gas Three Way Valve Compressor Pressure Regulating Valve Thermostatic Expansion Valve Thermostatic Expansion Valve Bulb and Thermocouple Electrical Schematic Wiring Diagram Microprocessor Controller Dwg 62 60017 Electrical Schematic Wiring Diagram Solid State Controller Dwg 62 60018 Multi Temp temet Remote Control BOX 25455 40 vet eal Sae Ee a val ea ete ad a P tele Bod aa e stats Solenoid Valves
57. Defective starter Engine Manual after engine is running 5 1 4 Malfunction In the Engine Starting Circuit No power to starter Battery defective Check motor solenoid SS Loose electrical connections Tighten Run solenoid Battery defective Check does not energize or does Loose electrical connections Tighten not remain energized Oil pressure safety switch OP defective Replace Run relay RR defective Replace Water temperature safety switch open 1 2 Water temperature sensor WTS defective Replace Run solenoid defective 4 2 3 Run Stop or Start Run Stop switch defective Replace 5 2 ALTERNATOR AUTOMOTIVE TYPE Alternator fails to charge Limited charging system operating time Check Battery condition Check Alternator belt loose broken 4 3 Loose dirty corroded terminals or broken leads Check Repair Excessively worn open or defective brushes Check Open blocking diode Check Regulator faulty Check Open isolation diode Check Open rotor field coil Replace Low or unsteady charging rate Alternator belt loose 4 3 Loose dirty corroded terminals or broken leads Check Repair Excessively worn sticky or intermittent brushes Check Faulty regulator Check Grounded or shorted turns in rotor Check Open grounded or shorted turns in stator Replace Excessive charging rate Regulator leads loose dirty corroded terminals or as evidenced by battery wires broken Clean Repair requiring too frequent refilling or Defective regulator Check charg
58. EREN 353 Standby Detrost rH ees Hund SERVICE FE C E e ERE RUE TA PONE ee EC ee Maintenance Schedule etx d D t Rei t eet et t ee eas Servicing Engine Related Components AZI Cooling System uqa etr e eor eL e dp 4 22 Changing Lube Oil and Lube Oil 4 23 Replacing the Speed and Run Control Solenoids 42 4 Air CIeanet deis Aen Desert e eU doter Seier AA Zeie 42 5 Servicing Pump e et RS 4 26 Servicing Glow Plugs Servicing and Adjusting V Belts 431 Belt Tension Gauge 43 2 Alternator V Belt a a tr veneta nets Deo Ald deus 433 Water Pump Belt Tensioner 4 3 4 Standby Motor Compressor V Belt 4 3 5 Engine Compressor V Belts Pumping The Unit Down or Removing the Refrigerant Charge Refrigerant Leak Checking Evacuation and Dehydration 4 61 gt General precise cute a usa ae See ee aether 46 2 Pr paratiOn yy yi aap Ph be eee he E E 4 63 Procedure for
59. Engine Supra 522 to 822 With Evaporator Motors 1 Engine to Compressor V belt 2 Alternator V belt 3 Standby Motor to Compressor V belt Figure 4 3 V Belt Arrangement Figure 4 4 Belt Tension Gauge Part No 07 00203 4 3 2 Alternator V Belt a Make sure negative battery terminal is disconnected b For Supra 422 place V belt on alternator sheave and standby motor pulley For Supra 522 to 822 place V belt on alternator sheave and driving pulley c Pivot alternator to place tension on belt using hand force only Do not use pry bar or excessive force as it may cause bearing failure For correct belt tension see Table 4 1 Tighten pivot and adjustment bolts 4 3 3 Water Pump Belt Tensioner Water pump belt is driven by the diesel engine crankshaft pulley The automatic belt tensioner ensures the correct tension To change the water pump belt proceed as follows a To compress the tensioner spring place a threaded bolt or rod into hole and turn clockwise This will draw the spring up and slacken V belt for easy removal b After replacing V belt remove the bolt to release the spring to return the idler to it s correct tension 4 3 4 Standby Motor Compressor V Belt a Remove alternator V belt Refer to Section 4 3 2 b Loosen the V belt idler securing bolt 22mm c Replace V belt and alternator V belt Position the idler to correct belt tension Tighten the idler retaining bolt 4 3 5 Engine Compressor V
60. Evacuation and Dehydrating System Charging the Refrigeration System 471 Installing a Complete Charge 4 7 2 Adding a Partial Charge R 22 Only 4 7 3 Checking the Refrigerant Page 2 1 2 2 2 3 2 3 2 4 2 4 2 4 2 4 2 4 3 1 3 1 3 1 3 1 3 2 3 2 3 2 3 2 3 2 3 4 3 4 3 4 3 4 4 1 4 1 4 2 4 2 4 2 4 2 4 3 4 3 4 4 4 4 4 4 4 5 4 5 4 5 4 5 4 5 4 5 4 6 4 6 4 6 4 6 4 7 4 7 4 7 4 7 TABLE OF CONTENTS CONT D Section 4 SERVICE CONT D 4 8 Replacing the 4 9 Checking 05K Compressor Oil 410 Checking EF 210 York Compressoroil Level 411 Checking 05G Compressor Oil Level 4 12 Compressor Unloader Valve 4 13 Checking and Replacing Filter drier 4 14 Checking and Replacing High Pressure Cutout Switch 4 14 1 Replacing High Pressure Switch 4 14 2 Checking High Pressure Switch 4 15 Checking Calibration of
61. GROUNDS 3 ADDRESS SYSTEM EXAMPLE HCL1 FHR85 INDICATES A WIRE BETWEEN PLUG HC PIN L1 AND TERMINAL 85 OF RELAY FHR 4 VOLTAGE BELOW 12 VOLTS 5 ENGINE CT2 29 2 GLOW PLUG ENGINE CT3 44 3 GLOW PLUG 6 WITHOUT STANDBY MOTOR XNO CONNECTION OF SWITCH SSW XNO CONNECTION STANDBY PANEL MC OL XNO CONNECTION HOURMETER XNO CONNECTION RELAY SBR XNO CONNECTION OPS XSHUNT BETWEEN THE TERMINAL 4 OF THE SWITCH SRS AND THE TERMINAL 5 OF THE SWITCH GDS XSHUNT BETWEEN THE TERMINAL 3 OF THE C8 CONNECTOR AND THE TERMINAL 6 OF THE C8 CONNECTOR 0812 DIODE IS IN DIODE BLOCK 1 DB1 IT S THE DIODE D2 SAME AS DIODE BLOCK 2 AND 3 SWITCH SYMBOL INDICATES MOMENTARY CONTACTS COMPONENT CONNECTION NUMBER OR LETTER LIGHT LINES INDICATES WIRES IN THE SYSTEM NORMALLY CLOSED CONTACTS NORMALLY OPEN CONTACTS HCF2 MULTIPLE PLUG CONNECTION NUMBER INDICATES A WIRE GROUND INDICATES A CHASSIS GROUND NO WIRE Ep olx INDICATES STANDARD OPTIONS INDICATES A CONNECTION WIRE LUG ETC INSULATING PLUG bai PIN CONNECTION C8 6 INDICATES C8 CONNECTOR EX C8 6 TERMINAL 6 OF C8 CONNECTOR Figure 6 2 Electrical Schematic Wiring Diagram SOLID STATE CONTROLLERDwg No 62 60018 Rev C Sheet 1 of 2 9
62. LTS WARNING Beware of V belts and belt driven components as the unit may start automatically 4 3 1 Belt Tension Gauge It is recommended using a belt tension gauge tester P N 07 00203 shown in Figure 4 4 whenever V belts are adjusted or replaced A belt tension gauge provides an accurate and easy method of adjusting belts to their proper tension Properly adjusted belts give long lasting and efficient service Too much tension shortens belt and bearing life and too little tension causes slippage and excessive belt wear It is also important to keep belts and sheaves free of any foreign material which may cause the belts to slip The belt tension gauge can be used to adjust all belts The readings which we specify for Carrier Transicold units are applicable only for our belts and application as the tension is dependent on the size of the belt and distance between sheaves When using this gauge it should be placed as close as possible to the midpoint between two sheaves See Figure 4 3 The V belts must be kept in good condition with the proper tension to provide adequate air movement across the coils When installing a new V belt the tension should be somewhat higher than specified and readjusted after allowing the unit to run for some time Table 4 1 Belt Tension See Figure 4 4 BELTS CT3 44TV engine D722 Water 30 to 40 Standby Engine Supra 422 With Evaporator Motors Standby Motor
63. ON LIGHT LINES INDICATES WIRES IN THE SYSTEM NORMALLY CLOSED CONTACTS NORMALLY OPEN CONTACTS 9 INDICATES CONNECTION HCF2 MULTIPLE PLUG CONNECTION NUMBER 15 DIODE IS IN DIODE BLOCK1 081 WITH CATHODE ON PIN 5 ANODE IS ON PIN 9 OF DIODE BLOCK 1 FOR ALL DIODES SAME AS DIODE BLOC 2 AND 3 SWITCH SYMBOL INDICATES MOMENTARY CONTACTS COMPONENT CONNECTION NUMBER OR LETTER INDICATES A WIRE GROUND INDICATES A CHASSIS GROUND NO WIRE x INDICATES STANDARD OPTIONS INDICATES A CONNECTION WIRE LUG ETC INSULATING PLUG Figure 6 1 Electrical Schematic Wiring Diagram MICROPROCESSOR CONTROLLER Dwg 62 60017 Rev Sheet 1 of 2 9 F2
64. PRESSURE Kg cm 4 25 4 45 4 65 4 85 5 27 5 72 6 19 6 43 7 21 7 15 8 32 8 91 9 54 10 19 10 88 11 59 12 33 13 11 13 91 14 76 15 63 16 54 17 49 18 46 19 48 20 52 21 59 22 75 24 0 25 27 26 57 27 88 29 22 30 56 Bar 4 17 4 36 4 56 4 76 5 17 5 61 6 07 6 31 7 07 7 6 8 16 8 74 9 36 10 0 10 67 11 37 12 09 12 86 13 64 14 47 15 33 16 22 17 15 18 11 19 10 20 12 21 17 22 31 23 53 24 78 26 06 27 34 28 65 29 96 SECTION 5 TROUBLESHOOTING CAUTION Under no circumstances should anyone attempt to service the microprocessor see section 4 22 Should a problem develop with the microprocessor contact your nearest Carrier Transicold dealer for replacement INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 5 1 DIESEL ENGINE 5 1 1 Engine Will Not Start Starter motor will not crank or low cranking speed Starter motor cranks but engine fails to start Battery insufficiently charged Battery terminal post dirty or defective Bad electrical connections at starter Starter motor malfunctions Starter motor solenoid defective Open starting circuit Incorrect grade of lubricating oil No fuel in tank Air in fuel system Water in fuel system Plugged fuel filters Plugged fuel lines to injector s Fuel control operation erratic Glow plug s defective Run solenoid defective Fuel pump FP malfunction Check Check Check 5 1 3 Engine Manual 5 1 4 1 2 Check Check Drain Sump
65. STARTER SOLENOID CONTACTOR STARTER SOLENOID RELAY UNLOADER FRONT RELAY UNLOADER FRONT WATER TEMPERATURE SENSOR LOCATION MID FRAME LIGHT BAR CONTROL BOX CONDENSER CONTROL BOX COMPRESSOR LIGHT BAR FRAME CONTROL BOX LIGHT BAR EVAPORATOR CONTROL BOX CONTROL BOX CONTROL BOX EVAPORATOR EVAPORATOR CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX LIGHT BAR ENGINE CONTROL BOX ENGINE CONTROL BOX FUEL TANK ENGINE CONTROL BOX FRAME LIGHT BAR CONTROL BOX COMPRESSOR CONTROL BOX CONTROL BOX FRAME CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX ENGINE CONTROL BOX LIGHT BAR CONTROL BOX CONTROL BOX LIGHT BAR EVAPORATOR CONTROL BOX CONTROL BOX ENGINE CONTROL BOX EVAPORATOR FRAME ENGINE ENGINE CONTROL BOX COMPRESSOR CONTROL BOX STARTER STARTER CONTROL BOX CONTROL BOX COMPRESSOR ENGINE NOTES 1 UNIT SHOWN OFF POSITION 2 WIRE IDENTIFICATION SYSTEM COLOR WHITE DC CONTROL CIRCUITS BLACK DC GROUNDS RED AC CIRCUITS GREEN AC GROUNDS 3 ADDRESS SYSTEM EXAMPLE HCD2 MPW2 INDICATES A WIRE BETWEEN PLUG HC PIN D2 AND MICROPROCESSOR MP AND PIN W2 4 VOLTAGE BELOW 12 VOLTS 5 ENGINE CT2 29 2 GLOW PLUG ENGINE CT3 44 3 GLOW PLUG NO CONNECTION OF STANDBY PANEL OC AND DPS 7 SUPRA 422 2 ELECTRIC FANS ONLY 8 ATS UFR UF AND THE 3 WIRE FOR RS ONLY FOR SUPRA 922 INDICATES A SOLDERED SPLICE POINT ai PIN CONNECTI
66. Seat Gasket 4 Bulb Figure 4 16 Thermostatic Expansion Valve 5 Cage Assembly 6 Body Flange 7 Body Flange Screws b Checking Superheat NOTE It is not recommended adjusting expansion valves unless absolutely necessary D ue to the time involved in adjusting the superheat replace the valve rather than adjusting it Measure Superheat NOTE The expansion valve and bulb location are shown in Figure 1 2 1 Remove Presstite from expansion valve bulb and suction line 2 LoosenoneT XV bulb clamp and make sure area under clamp above T X V bulb is clean 3 Place thermocouple above parallel bulb and then secure loosened clamp making sure both bulbs are firmly secured to suction line as shown in Figure 4 17 4 N 1 1 s 1 Suction Line end view 2 TXV Bulb Clamp 3 Nut and Bolt clamp 4 Thermocouple 5 TXV Bulb Figure 4 17 Thermostatic Expansion Valve Bulb and Thermocouple NOTE When conducting this test the suction pressure must be 0 4 kg cm 6 psig below expansion valve maximum operating pressure M O P For example R 22 units use an expansion valve with a 55 MOP The recommended test pressure should be below 3 44 kg cm 49 psig 4 Connect an accurate gauge to the 1 4 port on the suction service valve 5 Run unit until stabilized Set controller 5 5_C 10 below box temperature 6 From the temperature pressure chart determine the saturation temperatur
67. TOR CONTACTOR MOTOR CONTACTOR PILOT RELAY MOTOR OVERLOAD TIMER OVERLOAD PROTECTOR OIL PRESS SAFETY SWITCH N O OIL PRESS SAFETY SWITCH S BY NC POWER SUPPLY RECEPTACLE RETURN AIR SENSOR RUN SOLENOID RUN RELAY RUNNING TIME METER RUNNING TIME METER STAND BY STAND BY MOTOR STAND BY RELAY SPEED CONTROL SOLENOID SOLID STATE DEFROST TIME OPTION STARTER MOTOR SPEED RELAY START RUN STOP SWITCH STARTER SOLENOID STARTER SOLENOID CONTACTOR SELECTOR SWITCH TEMPERATURE CONTROL MODULE WATER TEMPERATURE SENSOR LOCATION MID FRAME CONTROL BOX CONTROL BOX CONTROL PANEL FRAME CONTROL PANEL CONTROL BOX EVAPORATOR CONTROL BOX CONTROL BOX CONTROL BOX EVAPORATOR EVAPORATOR EVAPORATOR EVAPORATOR CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX FUEL TANK ENGINE CONTROL BOX ENGINE CONTROL PANEL ENGINE CONTROL BOX FRAME CONTROL PANEL COMPRESSOR MOTHER BOARD CONTROL BOX FRAME FRAME CONTROL BOX CONTROL BOX CONTROL BOX CONTROL BOX ENGINE ENGINE EVAPORATOR ENGINE CONTROL BOX CONTROL PANEL CONTROL PANEL FRAME CONTROL BOX ENGINE CONTROL BOX ENGINE CONTROL BOX CONTROL PANEL STARTER STARTER CONTROL PANEL CONTROL PANEL ENGINE NOTES 1 UNIT SHOWN OFF POSITION 2 WIRE IDENTIFICATION SYSTEM COLOR WHITE DC CONTROL CIRCUITS BLACK DC GROUNDS RED AC CIRCUITS GREEN AC
68. TRANSICOLD Truck Refrigeration Unit Supra 422 522 622 722 822 922 644 744 844 944 amp Supra Multi Temp 62 02536 03 Change 01 08 OPERATION AND SERVICE TRANSICOLD OPERATION AND SERVICE MANUAL TRUCK REFRIGERATION UNITS Supra 422 522 622 722 822 922 644 744 844 944 amp Supra Multi Temp A TECHNOLOGIES Carrier Trans sicold D n Carrier Corporation Box 4805 Syracuse N Y 13221 U S A TRANSICOLD Carrier Transicold EI Boite Postale Nr ECH anqueville Saint Pierre 76520 Boos FRANCE Carrier Corporation 1996 e Printed in U S A 1196 TABLE OF CONTENTS Section Page 1 DESCRIPTION iN be vede ehe ER LENA DERE RT ede e eae 1 1 Ll ntroducti n ote eee REIHE RU ee tek orbe EPI ta 1 1 12 Engine Data tol te Reb Stead Re gite cite gat ens ee a 1 5 13 Compressor Reference Data 1 6 14 Refrigeration System Data 1 6 1 57 sBl ctrical Data 9 eed RR ue e qe e dei 1 7 1 6 Torque Values 1 7 Ki Safety Devices is ceo see 1 8 1 8 Microprocessor Controller 1 9 LSL 1 9 182 Keypad s be eei ds deer oe a eU 1 10 12833 Set
69. V 460V 60Hz 3e 380V 415V 440V 50Hz 3e ND T CATES CONTACTS rep NDICATES A WIRE GROUND 10 8 14 Hh NDICATES A CHASSIS GROUND NO WIRE p INDICATES STANDARD OPTIONS L1 T CH Lou NDICATES CONNECTION WIRE LUG ETC O D B 2 12 O Y CONNECT FOR MAIN e 13 QJ 3 2HR2 d EVAPORATOR SPLIT MC1 OL SBM BLOCK 2 pps To DPS PH SP16 HCL2 3 TO DR87 EE PLUG Figure 7 5 Electrical Schematic Wiring Diagram Multi Temp Sheet 2 of 2 7 5
70. and sediment from fuel tank sump Then fill tank with diesel fuel 2 Check radiator coolant level Add pre mixed 50 50 permanent antifreeze water as required USE ETHYLENE GLYCOL ONLY Refer to section 1 2 3 Check evaporator and condenser coil for cleanliness 4 Check engine lubrication and fuel filter oil lines and connections for leaks Tighten connections and or replace gaskets 5 Check engine oil level Refer to section 1 2 6 Check V belts for proper tension fraying or cracks Adjust belt or replace 7 Check battery terminals for cleanliness and tightness Clean and coat with a mineral type grease such as Vaseline 8 Check engine air cleaner for cleanliness and condition of air cleaner hose 9 Check defrost drain pan hoses Should be clear of debris 10 Check defrost air switch tubes and connections for breaks or air leaks b After Starting Refrigeration Unit 1 Check water temperature Should be 65 to 82 150 to 180 2 Check engine speed Refer to section 4 2 3 Listen for abnormal noises Refer to section Check compressor oil level Refer to section 5 Observe any signs of lube or fuel oil leaks 6 Check radiator hoses for leaks 7 Check refrigerant level Refer to section 4 7 Feel filter drier Excessive temperature drop across drier indicates restriction Refer to section 4 13 9 Start microprocessor Pre trip Inspection R efer to Section 1 8 8 D
71. arge pressure rises to 14 8 kg cm 210 psig The unit is correctly charged when the lower receiver sight glass is full and no refrigerant is in the upper receiver sight glass 4 8 REPLACING THE COMPRESSOR a Removing If compressor is inoperative and unit still has refrigerant pressure frontseat suction and discharge service valves to trap most of the refrigerant in the unit If compressor runs pump down the unit Refer to section 4 4 a 1 Slowly release compressor pressure to a recovery system 2 Remove bolts from suction and discharge service valve flanges 3 Disconnect wiring to compressor discharge temperature sensor CDT suction pressure transducer and the wiring to the high pressure switch HP 4 Release idler pulleys and remove belts 5 Remove the four bolts holding the compressor to the power tray Remove the compressor from chassis 6 Remove the pulley from the compressor 7 Drain oil from defective compressor before shipping b Installing 1 To install the compressor reverse the procedure outlined when removing the compressor Refer to section 1 6 for torque values NOTE The service replacement compressor is sold without shutoff valves but with valve pads Customer should retain the original capacity control valves for use on replacement compressor Check oil level service replacement compressor Refer to sections 1 3 and 4 9 2 Attach two lines with hand valves near vac
72. at 5 amps microprocessor 5 Excessive current draw by Fuse F3 Opens at 25 amps control circuit 6 Excessive current draw by speed Fuse F4 Opens at 15 amps control solenoid 7 Excessive current draw by auto Fuse F5 Opens at 7 1 2 amps restart or out of range lights 8 Excessive current draw by Fuse F7 F8 F9 Opens at 20 amps evaporator fan motors 9 Excessive compressor High pressure cutout switch HP Refer to Section 1 4 d discharge pressure automatic reset 10 Excessive compressor Compressor discharge Shuts unit down above discharge temperature temperature sensor CDT 154 C 310 F for 3 minutes or 177 C 350 F Table 1 3 Safety Devices Solid State Controller Unsafe Conditions Safety Device Device Setting 1 Low engine lubricating oil Oil pressure safety switch OP Opens below 1 0 2 kg pressure automatic reset 15 3 psig 2 High engine cooling water Water temperature switch Opens above 1101 temperature 230 5 3 Excessive current draw by glow plug Fuse F1 Opens at 80 amps circuit control circuit or starter solenoid SS 4 Excessive current draw by Fuse F2 Opens at 20 amps Solid State controller 5 Excessive current draw by Fuse F3 Opens at 20 amps control circuit 6 Excessive current draw by Fuse F5 F6 F7 Opens at 20 amps evaporator fan motors 7 Excessive current draw by Fuse F8 Opens at 10 amps evaporator fan clutch 8 Excessive current draw by Fuse F9 Opens at 15 amps
73. atically selects high and low speed cooling or high and low speed heating as necessary to maintain the desired temperature Themicroprocessor controller hasan auto start stop feature The auto start stop operation provides automatic cycling of the diesel engine or standby motor which in turn offers an energy efficient alternative to continuous operation of the engine or standby motor with control of temperature by alternate cooling and heating of the supply air evaporator outlet air The Supra models also have an optional Solid State temperature controller R efer to section 1 10 A remote standby receptacle is standard with all TD S standby units The evaporator assembly consists of an evaporator coil expansion valve two defrost thermostats termination switches and electrical evaporator fan motors Supra 922 944 also has a defrost damper and a damper solenoid Table 1 1 Model Chart RAO is KG Supra 422 70810 8 36 Supra 422 70540 8 36 229 ae PT Supra 622 10816 ii 50 Supra 622 T0516 11 50 Supra 722 T0819 i2 54 Supra 722 TD 19 iz 54 swa fi es Standby Motor Compressor EF 210 r 05 ie CT3 44TV 05K 4Cylinder 6 4 hp 7 6 hp Sup 38 amp 15 ee E EE Supa
74. charge Refer to section 1 3 through the suction service valve flange cavity or by removing the oil fill plug See Figure 4 6 d Toremove oil from the compressor 1 Close suction service valve frontseat and pump unit down to 2 to 4 psig 0 1 to 0 3 kg cm2 Frontseat discharge service valve and slowly bleed remaining refrigerant 2 Remove the oil drain plug from the compressor and drain the proper amount of oil Replace the plug securely back into the compressor 3 Open service valves and run unit to check oil level repeat as required to ensure proper oil level 4 12 COMPRESSOR UNLOADER VALVE The compressor unloader located on the compressor cylinder head is controlled by relay UFR and the temperature controller Refer to section 1 17 a Checkout Procedure 1 Connect manifold gauges to the compressor suction and discharge service valves and start unit in cooling with the trailer temperature at least 5 F 2 8 C above set point and the compressor will be fully loaded unloader coil de energized Note suction pressure 2 Remove wiring from the front unloader coil Place electrical tape over wire terminals 3 Set controller upscale cooler to warmer This mechanically simulates falling temperature Approximately 2 F 1 1 C below box temperature the unloader coils will energize but only the rear unloader valve will unload Note suction pressure a rise of approximately 3 psig 0 2 kg cm2 will be noted on the
75. cool mode speed relay energizes 3 4 3 Heating Refer to section 1 16for description on heating cycle The unit will only heat when the controller is set above 12 C 10 F as the heat relays are electronically locked out with set points at or below 12 C 10 F The controller automatically selects the mode necessary to maintain box temperature at set point The heating modes are as follows with descending temperatures a Low Speed Heating b High Speed Heating The heat light will also be illuminated The controller will shift the unit into low speed heat when the box temperature falls below set point See Figure 3 1 or Figure 3 3 If more heating capacity is required the unit will shift to high speed heating 3 4 4 Defrost Refer to section 1 16 for the heat and defrost cycle NOTE The unit will be in high speed in the defrost mode The defrost mode may be initiated by three different ways if the evaporator coil is below 1 7 C 35 F Refer to Section 1 4 Method one to initiate defrost is to place the Glow Defrost Switch in the DEFROST position Method two is that defrost may be initiated automatically at preset intervals by the defrost timer The third means of defrost initiation is by the defrost air switch DA The switch is an air pressure differential switch which measures air pressure differential across the evaporator coil and initiates the defrost cycle when the air pressure differential increas
76. d STRT Restarting MOP STD Future Expansion 2SET Compartment 2 Setpoint 3S Compartment 3 Setpoint AUTO OP Auto Start Operation FN10 OFF MAN Manual Start Operation FN11 RANGE Out of Range Tolerance Code vs English Code or English display format Manual Glow Override Normal or Add 30sec Alarm RST Alarm Reset Required Alarm CLR No Alarm Active Defrost Interval defrost interval is displayed with the description DEER FNO data for the interval is displayed with one decimal place and then the capital letter H for hours e DEER 12 0 The defrost intervals are 1 1 3 12 hours Airflow The status of the speed control solenoid override is displayed asCITY SPD or HIGH SPD The code display isFN1 Thecity speed setting is ON and the high speed settingis OFF If the display showsCITY SPD theunit is locked into low speed Minimum Off Time The off time selection for the auto start mode is displayed with the description OFF T or FN2 The off times are 10 20 30 45 or 90 minutes he data for the off time is displayed with two digits and then the capital letter M for minutes i e OFF T 20M FN4A FN4 B FN5 FN6 ON FN6 OFF FN7 FN8 FN9 FN10 ON On Time The on time selection for the auto start mode is displayed with the description ON T or FN3 With software revision less than 3 10 the on times are 4 or 7 minutes With software revision 3 10 or
77. d and back flushed At least once a year or at regular engine service periods remove the entire air cleaner and perform the following a Remove oil cup Check and clean center tube DO NOT USE GASOLINE b Pump solvent through the air outlet with sufficient force and volume to produce a hard even stream out the bottom of the body assembly Reverse flush until all foreign material is removed 4 2 5 Servicing Fuel Pump a To Check or Replace Filter 1 Remove 3 screws from cover item 1 Figure 4 2 2 Remove cover gasket and filter 3 Wash filter in cleaning solvent and blow out with air pressure Clean cover 4 Install reverse above steps 3 Filter 4 Fuel Pump 1 Cover 2 Gasket Figure 4 2 Electric Fuel Pump 4 2 6 Servicing Glow Plugs The glow plugs when energized draw a nominal 7 0 amps at 10 5 When servicing glow plug is to be fitted carefully into the cylinder head to prevent damage to glow plug Torque value for the glow plug is 0 8 to 1 5 mkg 6 to 11 ft lb Checking for a Defective Glow Plug a One method is to place an ammeter or clip on ammeter in series with each glow plug and energize the plugs Each plug if good should show amperage draw b second method is to disconnect the wire connection to the plug and test the resistance from the plug to a ground on the engine block The reading should be 0 7 to 1 2 ohms if the plug is good 4 3 SERVICING AND ADJUSTING V BE
78. d is used it is imperative that should a problem develop with the microprocessor it be replaced immediately The test board is intended to be a trouble shooting tool only When using the test board to troubleshoot the unit should be started in low speed unloaded cool in the same way as the processor would start the unit Good judgment should also be used when cycling any unit with the test board Rapid cycling should be avoided When welding is required on the unit frame or on the front area of trailer ALL wiring to microprocessor MUST be disconnected When welding is performed on other areas of the trailer the welder ground connection MUST be in close proximity to the area being welded It is also a good practice to remove both battery cables before welding on either the unit frame or the truck to prevent possible damage to other components such as the alternator and voltage regulator a Hour Meter The hour meter can be set to any value via the serial port if the meter has less then 5 hours on it This allows a replacement microprocessor to be set to the same hours as the microprocessor it is replacing The microprocessor has 2 programmable registers which are set via the serial port These registers are compared to one of the hour meters diesel standby or switch on If the hour meter is greater than the register then the proper alarm is set 4 23 CONFIGURATION of MICROPROCESSOR When replacing a microprocessor
79. down arrow keys which are used to modify increment or decrement the displayed data If the unitis in the default display then these keys will modify the setpoint selection gt gt o A o Enter Key The enter key is used to accept a change unit parameters or a change in setpoint M anual Defrost K ey ng The manual defrost key is used to initiate a defrost cycle given that the proper condi tions are met Refer to section 1 8 10 Pretrip Check Key The pretrip check key is used to initiate pretrip cycle given that the proper condi tions are met Refer to section 1 8 8 gt Start Stop Continuous K ey The autostart stop continuous key is used to change the operating mode from auto start continuous run to auto start stop Each push of the key will alternate the operating modes The operating status will be stored in memory and is retained through power outages The digital display will indicate when stop start is enabled Refer to Section 1 8 11 To start the unit in manual start mode the autostart stop continuous selection must bein continuous run mode NOTE With software revision 3 08 or higher when configuration 1115 and setpoint is 32 1042 0 to 5 5 C the unit is locked into continuous run Start Stop Continuous key is disabled Function C hange Key The function change key is used to display the operating parameters Each time this key
80. e Adjustment Screw 0 050 socket head size Low Side Connection Pressure Line or Aspirator Bulb P N 07 00177 01 Magnehelic Gauge P N 07 00177 High Side Connection Figure 4 12 Defrost Air Switch Test Setup Make sure magnehelic gauge is in proper calibration NOTE The magnehelic gauge may be used in any position but must be re zeroed if position of gauge is changed from vertical to horizontal or vice versa USE ONLY IN POSITION FOR WHICH IT IS CALIBRATED b With air switch in vertical position connect high pressure side of magnehelic gauge to high side connection of air switch See Figure 4 12 c Install tee in pressure line to high side connection Tee should be approximately half way between gauge and air switch or an improper reading may result d Attach an ohmmeter to the air switch electrical contacts to check switch action NOTE Use a hand aspirator P N 07 00177 01 since blowing into tube by mouth may cause an incorrect reading e With the gauge reading at zero apply air pressure very slowly to the air switch An ohmmeter will indicate continuity when switch actuates f Referto section 1 3 for switch settings If switch fails to actuate at correct gauge reading adjust switch by turning adjusting screw clockwise to increase setting or counterclockwise to decrease setting g Repeat checkout procedure until switch actuates at correct gauge reading h After switch is adjusted place a small amount
81. e Compressor valves s worn or broken Hot Gas three way valve malfunction High suction pressure Compressor valves s worn or broken Compressor gasket s defective Hot Gas three way valve malfunction Low suction pressure Suction service valve partially closed King valve partially closed Filter drier partially plugged Low refrigerant charge Expansion valve malfunction No evaporator air flow or restricted air flow Excessive frost on coil Suction and discharge Compressor valves defective pressures tend to equalize Hot Gas three way valve malfunction when unit is operating INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 5 3 6 2 Heating High discharge pressure Low discharge pressure Low suction pressure 5 3 7 Abnormal Noise Compressor Condenser or evaporator fan Overcharged system Condenser fan defective V belts broken or loose Noncondensibles in system Compressor valve s worn or broken Hot Gas three way valve malfunction Low refrigerant charge Refrigerant shortage Compressor pressure regulating valve malfunction Suction service valve partially closed Loose mounting bolts Tighten Worn bearings 4 8 Worn or broken valves 4 8 Liquid slugging 5 3 10 Insufficient oil 4 9 Loose or striking shroud Bearings defective Bent shaft 5 3 8 Control System Malfunction Will not control Sensor defective 4 24 Relay s defective Check Microprocessor controller malfunction 4 22 Solid State controller mal
82. e basic Supra diesel nosemount unit with one remote evaporators for a rear compartment b Remote Evaporator and Remote Control Box The rear compartment of the Multi Temp system is equipped with a separate evaporator and remote mounted control box The remote evaporator is ceiling mounted and includes evaporator coi drain pan evaporator fan and motor 12v dc defrost termination thermostat liquid line solenoid and expansion valve The Supra nosemount unit microprocessor controller controls all compartments Refer to sections 7 5 and 1 8 7 2 ELECTRICAL DATA a Remote Evaporator Fan Motors Volts 12 vdc Horsepower 15kw 1 5 hp Speed 2250 rpm Operating Amps 71010 7 3 SAFETY DEVICES Safety Devices for protection of the Remote Evaporator are listed in Table 7 1 Table 7 1 Safety Devices Remote Evaporator Unsafe Conditions 1 Excessive current draw by 2 compartment 2 Excessive current draw by Heater Fuses F12 F13 F14 Fuse F11 Opens at 30 amps Opens at 10 amps 3 Defrost heater over temperature High Temperature Klixon Opens at 120 5 F 7 4 REMOTE COMPARTMENT OPERATION To start remote evaporator place the remote compartment switch in the RUN position See Figure 7 2 b Set desired temperature using nosemount unit microprocessor controller Refer to section 1 8 The function lights for each compartment are the remote control box d Turn remote compartment
83. e corresponding to the evaporator outlet pressure 7 Note the temperature of the suction gas at the expansion valve bulb Subtract the saturation temperature determined in Step 6fromthe average temperature measured in Step 7 The difference is the superheat of the suction gas 4 22 MICROPROCESSOR NOTE The erasable programmable read only memory EPROM chip component U3 on the microprocessor logic board has a window on it which is covered with a label listing the revision level of the software he window isused to erase the chip s memory with the use of ultraviolet light the label prevents light from entering the chip and erasing the memory Under NO circumstances should this label be removed CAUTION Under no circumstances should a technician electrically probe the processor at any point other than the connector terminals where the harness attaches Microprocessor components operate at different voltage levels and at extremely low current levels Improper use of voltmeters jumper wires continuity testers etc could permanently damage the processor As mentioned above some microprocessor inputs operate at voltage levels other than the conventional 12 vdc Connector points and the associated approximate voltage levels are listed below for reference only U nder no circumstances should 12 vdc be applied at these connection points Grounded wrist cuffs are available at most radio computer and electronic supply store
84. e indicator shows constant charge with engine idling Noisy alternator Defective or badly worn V belt 4 3 Worn bearing s Replace Misaligned belt or pulley 4 3 Loose pulley Tighten 5 2 INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 53 REFRIGERATION 5 3 1 Unit Will Not Cool Compressor malfunction Compressor drive defective 4 8 Compressor defective 4 8 Refrigeration system Defrost cycle did not terminate Abnormal pressure Hot Gas three way valve malfunction 5 3 2 Unit Runs But Has Insufficient Cooling Compressor Compressor valves defective 4 8 Unloader malfunction 4 12 Refrigeration system Abnormal pressure Expansion valve malfunction No or restricted evaporator airflow Unloader malfunction Engine does not Speed control linkage develop full rpm Engine malfunction 5 3 3 Unit Operates Long or Continuously in Cooling Container Hot Load Allow time to pull down Defective box insulation or air leak Correct Refrigeration system Abnormal pressure Temperature controller malfunction 5 3 4 Unit Will Not Heat or Has Insufficient Heating Refrigeration Abnormal pressure Temperature controller malfunction Hot Gas three way valve malfunction Compressor Compressor drive defective Compressor defective Engine does not develop Speed control linkage full rpm Engine malfunction INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 5 3 5 Defrost Cycle Malfunction Will not initiate defrost Defrost air s
85. e the gauge manifold valve With the unit running frontseat the suction service valve and pull a vacuum in the compressor crankcase SLOWLY crack the suction gauge manifold valve and oil will flow through the suction service valve into the compressor Add oil as necessary c Adding Oil to Service Replacement Compressor Service replacement compressors may or may not be shipped with oil If compressor is without oil Add correct oil charge Refer to section 1 3 by removing the oil fill plug See Figure 4 6 d To remove oil from the compressor 1 Close suction service valve frontseat and pump unit down to 0 1 to 0 3 kg cm 2 to 4 psig Frontseat discharge service valve and slowly bleed remaining refrigerant 2 Remove the oil drain plug from compressor and drain the proper amount of oil from the compressor Replace the plug securely back into the compressor 3 Open service valves and run unit to check oil level repeat as required to ensure proper oil level 2 4 CYLINDER 2 CYLINDER Suction Service Valve Discharge Service Valve Oil Level Sight Glass Oil Drain Plug Oil Fill Plug Figure 4 6 Compressor Model 05K 4 10 CHECKING EF 210 YORK COMPRESSOR OIL LEVEL a Checking EF 210 York Compressor Oil Level 1 Run unit for 20 minutes to stabilize box temperature at a maximum temperature of 35 F 1 7 C It is very important t
86. e will be in high speed The microprocessor will break the ground path to de energize the front unloader relay which in turn de energizes the compressor unloader compressor shifts from 4 cylinder to 6 cylinder operation 2 4 4 Defrost Refer to sections 1 8 10 and 1 16 for the heat and defrost cycle NOTE The unit will be in high speed in the defrost mode The defrost mode may be initiated by three different ways if the evaporator coil is below 1 7 C 35 F Refer to section 1 4 Method one to initiate defrost is by pressing the Manual Defrost Key Method two is that defrost may be initiated automatically at preset intervals by the defrost timer in the microprocessor Refer to section 1 8 2 The manual defrost key and defrost timer are part of the microprocessor and are not shown on the schematic The third means of defrost initiation is by the defrost air switch DA The switch is an air pressure differential switch which measures air pressure differential across the evaporator coil and initiates the defrost cycle when the air pressure differential increases enough to close the DA contacts such as would happen when excessive frost builds up on the evaporator coil surface When the defrost air switch contacts close there is a 12 potential to terminal K1 on the microprocessor The microprocessor looks for voltage at terminal K2 Voltage at K2 indicates that at least one defrost termination thermostat is cl
87. ection of the schematic is controlled by a low voltage 12VDC Motor Contactor MC in the control circuitry 1 Perishable range setpoints above 10 F 12 C Standby Cool Standby OFF Standby Heat During Standby operation there are three operating modes for the TCM in the perishable range The electric motor is limited to one operating speed When the box temperature is significantly above setpoint the unit will be in the COOL mode of operation TCM calling for high speed cool When the box temperature falls to 0 75 C 1 4 F above setpoint the unit will cycle OFF TCM calling for low speed cool When the box temperature gets to 0 75 C 1 4 F below setpoint the unit will switch to the HEAT mode TCM calling for high speed heat NOTE When the TCM energizes low speed the standby relay will also energize This will cycle the unit off 2 Frozen Range Setpoints Below 12 10 F Standby Cool Standby Off When in the frozen range of operation the unit will operate in COOL OFF The HEAT output from the TCM is locked out Therefore it is possible for the box temperature to fall below setpoint in the frozen range 3 5 1 Standby Cool This schematic shows the unit in the standby cool mode of operation With the Start Run Stop switch SRS in the RUN position and the Selector Switch SSW in the STANDBY position the following electrical circuits will be energized Looking at the SRS potent
88. ed for 5 seconds and then the display will revert back to the default display if no further action istaken T he following sections describe the list of data which can be displayed via the keypad The description of the data is displayed on the left side with the actual data on the right side T he unit data list can be scrolled through by pressing the unit data key With each successive key push the list is advanced one If the unit data up or down arrow key is held for one second the list will change at a rate of one item every 0 5 seconds This list will circular meaning once the end of the listis reached the list will go to the first entry Each time the unit data key or the up down arrow key is pressed the display time will be reset to 5 seconds If the enter key is pressed the display time will be set to 30 seconds The position in the unit data list will remain at the last selected value except if power is removed If the display were to time out and revert to the default display the operator would only have to press the unit data key to display the same data again Suction Pressure The suction pressure is displayed with the description SU or CD 1 The data is displayed with the proper unit designator P psig or B Bars i e SUCT 25P The display is in inches of mercury for readings below 0 psig The display range is 0 7 Barsto 29 4 Bars 20 to 420 psig Engine Hours The number of diesel engine hours are
89. ed in valve c Bent or dented enclosing tube Valve shifts but refrigerant Foreign material lodged under seat continues to flow Defective seat 5 4 Standby Motor Malfunction Standby motor fails to start Motor contactor MC defective Motor Overload OL open Improper power supply Oil pressure switch OPS open Selector switch SSW defective Standby motor starts then stops Motor Overload OL open High amperage draw Replace Replace 4 21 Check 4 19 4 19 4 19 Replace Replace Replace motor SECTION 6 ELECTRICAL SCHEMATIC WIRING DIAGRAM 6 1 INTRODUCTION This section contains Electrical Schematic Wiring Diagram covering the Models listed in Table 1 1 The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein WARNING Beware of unannounced starting of the fans and V belts caused by the thermostat and the start stop cycling of the unit WARNING Under no circumstances should ether or any other starting aids be used to start engine CAUTION Under no circumstances should anyone attempt to repair the Logic or Display Boards see section 4 22 Should a problem develop with these components contact your nearest Carrier Transicold dealer for replacement CAUTION Observe proper polarity when installing battery negative batter
90. efault display setpoint air temperature and the active alarm s E ach item will be displayed for 3 to 10 seconds and will continue to scroll through the list See section 1 8 5 for the procedure on resetting alarms Low Oil Pressure Alarm The low oil pressure alarm is displayed with the description ENG OIL or ALO This alarm is generated if the control senses low oil pressure under the proper conditions The fault light FL is turned on Engine will shut down High Coolant Temperature Alarm The high coolant temperature alarm is displayed with the description ENG HOT AL1 This alarm is generated if the control senses high coolant temperature over 110 230 The fault light FL is turned on and the engine will shut down High Pressure Alarm The high pressure alarm is displayed with the description HI PRESS or AL2 This alarm is generated if the high pressure switch opens The fault light FL is turned on and the engine will shut down Start Failure Alarm The start failure alarm is displayed with the description START FAIL or AL3 Thisalarmisgenerated if the engine fails to start The fault light FL is turned on If function M AN OP manual start mode is selected the start failure alarm will be generated if the engine fails to start in 5 minutes L ow Battery Voltage Alarm The low battery voltage alarm is displayed with the description LOW BATT orAL4 Thisalarm is generated if the battery voltage fall
91. enoid energized The fault light FL is turned on 8 9 AL21 Return Air Sensor Alarm The return air sensor alarm is displayed with the description RA SENSOR or 19 This alarm is generated if the return air sensor is open or shorted The fault light FL isturned on if the unit shuts down because there is no controlling probe Supply Air Sensor Alarm The supply air sensor alarm is displayed with the description SA SENSOR or AL10 This alarm is generated if the supply air sensor is open or shorted T his alarm will be disabled if the REM PROBE is selected in the controlling probe functional parameter Coolant Temperature Sensor Alarm The coolant temperature sensor alarm is displayed with the description WT SENSOR orAL11 Thisalarmis generated if the coolant temperature sensor is open or shorted Compressor Discharge Temperature Alarm The compressor discharge temperature alarm is displayed with the description HIGH CDT orAL12 This alarm is generated if the temperature is sensed above 155 310 for 3 minutes If the discharge temperature exceeds 177 350 the 3 minute timer is overridden and the unit shut down immediately T he fault light FL is turned on Compressor Discharge Temperature Sensor Alarm The compressor discharge temperature sensor alarm is displayed with the description CD SENSOR orAL 13 This alarm is generated if the sensor is open or shorted Standby M otor Overload Alarm The standby
92. ervice valve CAUTION Extreme care must be taken to ensure the manifold common connection remains immersed in oil at all times Otherwise air and moisture will be drawn into the compressor Connect the suction connection of the gauge manifold to the compressor suction service valve port and immerse the common connection of the gauge manifold in an open container of refrigeration oil Crack the suction service valve and gauge valve to vent a small 4 10 amount of refrigerant through the common connection and the oil to purge the lines of air Close the gauge manifold valve With the unit running frontseat the suction service valve and pull a vacuum in the compressor crankcase SLOWLY crack the suction gauge manifold valve and oil will flow through the suction service valve into the compressor Add oil as necessary Refer to section 1 3 UD UU UL UD High Pressure Switch Connection Suction Pressure Transducer Connection Suction Service Valve Oil Fill Plug Bottom Plate Oil Drain Plug Oil Level Sight Glass Oil Pump Unloader Solenoid Discharge Thermistor Connection Discharge Service Valve Figure 4 9 Compressor 05G Adding Oil to Service Replacement Compressor O O O O O Q N sch Service replacement compressors may or may not be shipped with oil If compressor is without oil Add correct oil
93. es enough to close the DA contacts such as would happen when excessive frost builds up on the evaporator coil surface In defrost the controller will shift the unit into high speed heat The defrost and heat light will also be illuminated Also N C defrost relay contacts open to stop the evaporator fans The unit will remain in defrost until one defrost termination thermostat opens to remove voltage from the defrost relay FALLING TEMPERATURE RISING TEMPERATURE HIGH SPEED COOL HIGH SPEED COOL 1 5 C 2 7 LOW SPEED COOL 0 75 C 1 4 F LOW SPEED COOL LOW SPEED HEAT 0 75 1 4 F LOW SPEED HEAT 1 5 2 7 F HIGH SPEED MEAT HIGH SPEED HEAT Figure 3 1 Temperature Controller Operating Sequence Engine Drive Controller Set Point Above 12 10 F FALLING TEMPERATURE RISING TEMPERATUR HIGH SPEED COOL HIGH SPEED COOL 1 5 C 2 7 0 75 C 1 4 F SET POINT LOW SPEED COOL LOW SPEED COOL 0 75 C 1 4 F 1 5 C 2 7 F NOTE The controller prevents heating when set below 10 F 12 C Figure 3 2 Temperature Controller Operating Sequence Engine Drive Controller Set Point Below 12 C 10 F 3 3 3 5 CONTROL CIRCUIT OPERATION STANDBY MOTOR DRIVE The control circuitry for standby operation is the same as for the engine operation 12 volts DC is supplied from the battery and the alternator to power the control circuit The high voltage s
94. et points at or below 12 10 and the Perishable range is active at set points above 12 C 10 The system is configured for cooling mode for engine start and during the oil pressure delay Hot gas heating is applied by energizing the HR1 relay which will energize the hot gas solenoid The relay will also control the remote heat and cool lights Heating is locked out of operation at setpoint temperatures at or below 12 C 10 except during defrost Default M ode W hen in frozen range setpoint at or below 10 F unit shall default to low speed if a loss of control bad sensor is detected Since electric driven units have no low speed the default in the frozen range shall be high speed cooling When in perishable range setpoint gt 10 the unit shall shut down The proper alarm indication shall be displayed when this mode is active 1 8 10 DEFROST CYCLE Defrost is an independent cycle overriding cooling and heating functions to de ice the evaporator as required The controller displays DF during defrost mode on the right hand temperature display The left hand display will continue to display the setpoint a Defrost Timer Initiation A defrost timer initiation is a keypad selection Refer to Section 1 8 5 The defrost timer 15 reset to zero whenever a defrost cycle is initiated The controller holds in memory the last entered defrost interval b Defrost Air Switch Initiation Anexternal def
95. et screw 10 32 x 1 2 lg cone point and remove fan Remove fan motor hardware and fan wiring if required 3 Replace fan motor and fan blade before tightening fan setscrew align fan with 1 3 of the fan blades extending beyond the leaving edge of the housing Replace fan guard and front panel test fan operation b Fan Motor Brushes and Commutator Fan motor brushes should be inspected every 1500 operating hours Brushes should be replaced when brush is approximately 1 4 or less in length Blow out brush holder with low pressure air to remove any carbon dust in holder Before installing brushes remove back cover of motor and inspect commutator If commutator is heavily grooved polish it using 220 grit sandpaper do not use emery cloth Wipe out any accumulation of dust using a clean rag with solvent Reassemble motor and reinstall brushes 7 7 SERVICING LIQUID SOLENOID VALVE LSV CAUTION Do not damage or overtighten the enclosing tube assembly Torque to 200 inch pounds 2 3 mkg Also make sure all parts are placed on the enclosing tube in proper sequence to avoid premature coil burnout Replacing the Coil NOTE The coil may be replaced without removing the refrigerant or pumping the unit down 1 Disconnect leads remove coil retainer and coil assembly 2 Verify coil type voltage and frequency This information appears on the coil housing 9 Place new coil over enclosing tube retainer and connect wiring
96. fuel pump or run solenoid 9 Excessive compressor High pressure cutout switch HP Refer to Section 1 4 d discharge pressure automatic reset 1 8 1 8 MIC e Ee aa eae ae SET FUNCTION NE D os oe lt 1 BOX TEMPERATURE ENTER 11 10 9 8 7 6 5 1 Unit Data Key 7 Manual Defrost Key 14 Defrost Mode 2 Auto Start Stop 8 City Speed Key 15 Road Mode Continuous Key 9 Road Key 16 Autostart Stop Mode 3 Pretrip Key 10 Function Key 17 Stand by Mode 4 Stand by Key 11 ON OFF Key 18 City Speed Mode 5 Buzzer Off Key 12 Cool Mode 19 Out of range 6 Enter Key 13 Heat Mode 20 Fault Light Figure 1 7 Cab Command 1 8 1 INTRODUCTION The microprocessor controller is housed in the control box This controller consists of 2 control boards and a relay module 1 The Procesor Board includes the microprocessor program memory and necessary input output circuitry to interface with the unit 2 The Relay Module contains replaceable relays diodes and fuses along with the wiring harness The Cab Command is remote mounted in the truck The Cab Command includes the LCD display keypad and keypad interface See Figure 1 7 CAUTION Under no circumstances should anyone attempt to repair the Logic or Display Boards see section 4 22 Should a problem develop with these components contact your nearest Carrier Transicold dealer for replacement The Carrier Transicold microprocessor controlle
97. function Replace 5 3 9 No Evaporator Air Flow or Restricted Air Flow Evaporator coil blocked No or partial evaporator air flow Frost on coil Dirty coil Fan motor s malfunction V belt broken or loose 4 3 Clutch defective Replace Evaporator fan loose or defective Evaporator fan rotating backwards Evaporator air flow blocked in trailer box Fan motor s malfunction INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 5 3 10 Expansion Valve Malfunction Low suction pressure with Low refrigerant charge high superheat External equalizer line plugged Ice formation at valve seat Wax oil or dirt plugging valve or orifice Broken capillary Power assembly failure or partial Loss of element bulb charge Superheat setting too high Low superheat and liquid Superheat setting too low slugging in compressor External equalizer line plugged Ice holding valve open Foreign material in valve Pin and seat of expansion valve eroded or held open by foreign material Fluctuating suction Improper bulb location or installation pressure Low superheat setting High superheat Broken capillary 5 3 11 Hot Gas Three Way Valve Malfunction Valve does not function properly No power to valve Improper wiring or loose connections Coil defective Valve improperly assembled Coil or coil sleeve improperly assembled Temperature controller malfunction Movement of plunger restricted due to a Corroded or worn parts b Foreign material lodg
98. gerant using a refrigerant recovery system h Repeatsteps e through g one time i Evacuate unit to 500 microns Close off vacuum pump valve and stop pump Wait five minutes to see if vacuum holds This checks for residual moisture and or leaks j With a vacuum still in the unit the refrigerant charge may be drawn into the system from a refrigerant container on weight scales The correct amount of refrigerant may be added by observing the scales Refer to section 4 7 w Refrigerant Recovery Unit Refrigerant Cylinder Evacuation Manifold Valve Vacuum Pump Electronic Vacuum Gauge Evaporator Coil Receiver Outlet King Valve Condenser Coil Suction Service Valve Discharge Service Valve 1 2 3 4 5 6 T 8 9 0 1 Figure 4 5 Vacuum Pump Connection 4 7 CHARGING THE REFRIGERATION SYSTEM 4 7 1 Installing a Complete Charge a Dehydrate unit and leave in deep vacuum Refer to section 4 6 b Place refrigerant cylinder on scale and connect charging line from cylinder to receiver outlet king valve Purge charging line at outlet valve c Note weight of refrigerant cylinder d Open liquid valve on refrigerant cylinder Open king valve half way and allow the liquid refrigerant to flow into the unit until the correct weight of ref
99. heat is removed from the air circulated through the evaporator This cold air is circulated throughout the truck to maintain the cargo at the desired temperature The transfer of heat from the air to the low temperature liquid refrigerant causes the liquid to vaporize In R 22 units this low temperature low pressure vapor passes into the accumulator tank R 404A units this low temperature low pressure vapor passes through the suction line liquid line heat exchanger where it absorbs more heat from the high pressure high temperature liquid and then returns to the accumulator The compressor draws this vapor out of the accumulator through a pick up tube which is equipped with a metering orifice This orifice prevents the accumulation of oil in the accumulator tank The metering orifice is calibrated to control the rate of oil flowing back to the compressor The vapor refrigerant then enters the compressor pressure regulating valve CPR which regulates refrigerant pressure entering the compressor where the cycle starts over The quench valve not used on Supra 422 or R 404A units opens as required to maintain 132 270 maximum discharge temperature 1 16 REFRIGERANT CIRCUIT DURING HEAT AND DEFROST See Figure 1 14 When refrigerant vapor is compressed to a high pressure and temperature a reciprocating compressor the mechanical energy necessary to operate the compressor is transferred to the gas as it
100. higher the on times are 1 or 4 minutes The data for the on time is displayed with two digits and then the capital letter M for minutes i e 4 Controlling Probe The number of controlling probes is displayed with the following abbreviations REM PROBE for a single probe return air control SU P PROBE for a dual probe control return and supply air The code display is FN 4 The 1 probe setting is A and the 2 probe setting is B Standard Units Select The standard unit select will control how all parameters are displayed The two choices are DEGREES F and DEGREES C This parameter also will control units that data is displayed in psig or bars i e Degrees F or Degrees The code display is F N5 The selections are or C M aximum Off Time The description for the maximum off time is TEM P STRT OR TIME STRT The code display 15 N6 and the selections are ON or OFF ON corresponds to TIME STRT With the unit in time start the control will force the engine to restart 30 minutes after shutoff MOP STD Future Expansion This function is not used at this time The display is FN7 Compartment 2 Setpoint Setpoints may be entered through this function for the second compartment The setpoint function will be displayed with the abbreviated description 2SET The codedisplayisFN8 Thesetpoint may be changed refer to section 1 8 3 Compartment 3 Setpoint Setpoints may be entered through this func
101. ial will be present at terminal SRS 4 to SSW 5 through to SSW 6 From SSW 6 voltage will be available to the positive terminal of the Motor Overload Timer MOT Also voltage will flow through diode D2 to terminals 2 and 11 of the Temperature Control Module TCM At the same time voltage will flow from SSW 6 through the N C Standby Relay SBR contacts N C Oil Pressure Safety switch OPS and the Overload Protector OL to MOT 95 energizing MOT With MOT energized voltage will flow from MOT S to the Motor Contactor Pilot Relay MCP terminal MPC 86 and through diode D14 to the RR terminal RR 86 energizing both MCP and RR When RR energizes the N O RR contacts close supplying voltage to the N C MCP contacts energized open and through the N O MCP contacts energized closed to the Run Time Meter Standby RTMS and to the Motor Contactor MC terminal MC 86 Looking back to the N O RR contacts energized closed voltage is available through diode D12 to energize the Alternator Relay RALT through the N C Heat Relay HR contacts energizing the Cool Light CL and through the N C Defrost Relay DR contacts to the N C RALT contacts energized open Also through diode D1 to the Temperature Control Module TCM Solid State Defrost Timer SDT Defrost Timer Relay DTR terminal DTR 86 N O DTR contacts and the N O Defrost Air Switch DA Voltage will also be ava
102. id Remove clip from linkage rod Remove mounting hardware from defective solenoid and replace 2 Attach linkage to new solenoid and install the clip to the linkage rod 3 Energize the damper solenoid to close shutter blade 4 f the damper does not close tightly eyebolt adjustment not adequate tighten eyebolt against the blade Slide the solenoid boot so you can see the snap ring Loosen the four bolts mounting the solenoid M ove the solenoid until the blade is just touching one of the rubber bumpers and the plunger is just touching the snap ring 5 Tighten solenoid mounting bolts solenoid boot and energize solenoid b Replacing Bearings Bushings or Damper Blade 1 Remove damper return spring from damper 2 Remove clip from eyebolt end of linkage rod 3 Remove mounting hardware from bearing flange assembly Remove blade and bearings Replace parts as necessary replace Table 4 7 R 404A Temperature Pressure Chart Fo Bar 401 451 032 03i 771170591 049 sa 076 0681 REESEN 192 135 132 207 146 143 223 157 154 239 168 165 256 180 177 273 192 1861 77911 205 201 309 247 213 73281 231 226 348 245 240 368 259 254 73821 273 268 239 283 74331 304 299 456 321 314 480 337 331 504 354 347 523 372 365 75551 3 90 383 sei 408 4 01 653 428 420 76371 448 439 665 468 459 69 5 489 479 0 4
103. ilable at the N O Defrost Relay DR contacts With MC energized the N O MC contacts close supplying high voltage to the Standby Motor SBM When SBM is turning fast enough to cause the Alternator ALT to charge the system the RALT will de energize closing the N C RALT contacts This will energize the Evaporator Fan Motor Relays EMFR1 EMFR2 and EMFR3 closing the N O EFMR contacts energizing the Evaporator Fan Motors EFM1 EFM2 and EFM3 3 5 2 Standby OFF When the unit is running on Standby the TCM will cycle the unit off when the box temperature falls to 1 4 0 75 C above set point and the TCM attempts to select low speed To do this the TCM will supply voltage from TCM 8 to energize the Standby Relay SBR When SBR is energized the N C SBR contacts will open breaking the voltage path to MOT 95 With no voltage at MOT 95 the MOT will de energize MOT S At this time MCP and RR will de energize When MCP is de energized the N O MCP contacts will open causing MC to de energize This will open the N O MC contacts shutting down the Standby Motor With RR de energized the N O RR contacts will open This de energizes the refrigeration control circuitry The TCM will remain energized from terminal SSW 6 through diode D2 allowing the TCM to monitor box temperature even during the OFF cycle NOTE The Standby mode of operation has a min
104. imum off time of 5 minutes to prevent rapid on off cycling of the standby motor This is controlled by MOT When the voltage has been removed from MOT S a 5 minute off time delay timer will start If MOT 95 receives voltage during the 5 minute off time delay MOT S will remain energized until the timer times out 3 5 3 Standby Defrost Standby defrost operates the same as engine drive defrost refer to section 3 4 4 FALLING TEMPERATURE RISING TEMPERATURE COOLING ON COOLING ON 1 5 C 2 7 F 0 75 C 1 4 F SET POINT 0 75 C 1 4 F UNIT OFF UNIT OFF 1 5 C 2 7 F HEATING ON HEATING ON Figure 3 3 Temperature Controller Operating Sequence Standby Operation Controller Set Point Above 12 C 10 F FALLING TEMPERATURE RISING TEMPERATUR COOLING ON COOLING ON 1 5 C 2 7 F 0 75 C 1 4 F SET POINT UNIT OFF UNIT OFF 0 75 1 4 F 1 5 C 2 7 F NOTE The controller prevents heating when set below 10 F 12 C Figure 3 4 Temperature Controller Operating Sequence Standby Operation Controller Set Point Below 12 10 F 3 5 E 2 3 D o S o I Be Q gt tc qi U Output is ON Output is OFF s 1 eso High Speed cooing o o o o o tow Speed o o
105. increase to high speed If engine speed is not correct engine lever against stop stop engine and move the solenoid forward slightly Repeat procedure if adjustments need to be made 7 When operating correctly tighten solenoid mounting hardware and reconnect the positive wire 8 If adjustment is not achieved by doing step 6 stop engine and remove linkage from solenoid Remove boot item 10 from solenoid and pull solenoid shaft out far enough to loosen jam nut on solenoid shaft Energize solenoid for maximum force pull and then turn shaft clockwise to shorten 9 De energize solenoid tighten shaft jam nut and replace boot Connect linkage and repeat steps 5 and 6 4 2 4 Engine Air Cleaner a Inspection The oil type air cleaner hose and connections should be inspected for leaks A damaged air cleaner or hose can seriously affect the performance and life of the engine If housing has been dented or damaged check all connections immediately When inspecting air cleaner housing and hoses check the connections for mechanical tightness and look for fractures in the inlet and outlet hoses When leakage occurs and adjustment does not correct the problem replace necessary parts or gaskets Swelled or distorted gaskets must always be replaced b Service Procedure Dry Type 1 Stop engine remove air filter Install new air filter c Service Procedure Oil Type The air cleaner is designed to effectively remove contamina
106. is being compressed This energy is referred to as the heat of compression and is used as the source of heat duringthe heating cycle When the controller calls for heating or defrost the hot gas valve three way solenoid energizes closing the port to the condenser and opening a port which allows heated refrigerant vapor to flow directly to the evaporator coil The main difference between heating and defrosting is that when in heating all the evaporator fans continue to run blowing the air over the heated coils to heat the product When defrosting the evaporator fans stop allowing the heated vapor to defrost any ice build up there maybe The function of the bypass line from the hot gas valve to the receiver is to allow discharge pressure into the receiver Under pressure the liquid refrigerant will flow from the receiver through the expansion valve to the evaporator This will force all the refrigerant out of the receiver and into the evaporator to be used for heating The quench valve not used on Supra 422 or R 404A units opens as required to maintain a 132 270 maximum discharge temperature d A lt i Y 1 21 13 gt Not Use on Supra 422 18 A
107. is pressed the display will advance to the next parameter This key in conjunction with the up down arrow and enter keys will allow the user to change the parameters Refer to Section 1 8 5 d 1 10 Unit Data Key The unit data key is used to display the unit operating data This key in conjunction with the up down arrow keys will allow the user to display the unit s operating data values i e coolant temperature battery voltage etc R efer to Section 1 8 6 City Speed Key The city speed key enables the city speed low speed Each push of the key toggles the operating mode The operating status will be stored in memory The display will indicate when city speed is activated Pii Buzzer Off Key The buzzer off key will turn off the cab 19 command buzzer The buzzer is turned when the fault light is energized and off when the fault light is de energized The road key selects the diesel engine operating mode The operating status will be stored in memory Stand by Key The stand by key selects the electric motor operating mode The operating status will be stored in memory NO POWER will be displayed if unit isswitch to standby and power plugis not plugged in 1 8 3 SETPOINT Setpoints of 30 30 22 F to 86 may be entered via keypad The controller always retains the last entered setpoint in memory If no setpointisin memory i e on initial startup the controller shall lock out
108. itch GDS 14 Fuse F1 80 amp Figure 1 4 Electrical Box Solid State Controller C 6 1 1 Run Stop Switch RS 5 Motor Overload Relay MOL 2 Manual Glow Crank Switch MGC 6 Microprocessor Module 3 Relay Fuse Board See Figure 1 6 7 Fuse F1 80 amp 4 Standby Motor Contactor MC Note See Figure 1 7 for Cab Command Figure 1 5 Electrical Box Microprocessor Controller 1 4 F F3 F4 F5 FO F FB F9 LELEII HO Littl 1 ED DDD n LN AMO opp SOLID STATE iai MICROPROCESSOR RELAYS uses 2 Diode Block DB1 DB2 amp DB3 3 Relays See Figure 6 1 or Figure 6 2 F3 F4 F5 F6 F7 F8 F9 F10 Figure 1 6 Relay Module 1 2 ENGINE DATA Pedum erem SUPRA 2098 SUPRA 9221944 2250 rpm SUPRA 822 2300 rpm Mic ss Closes at 1 05 0 2kg cm2 15 3 psig Operating Speeds a Lubrication System Lube Oil Viscosity API Classification CD Outdoor Temperature Centigrade Below 32_ 10W or 10W30 32 to 77 0 to25 C Over 77 F Over 25 30W or 15W40 1 5 1 3 COMPRESSOR REFERENCE DATA 056 EFzi Displacement mE E EE No Cylinders Weight Oil Charge 62 kg 137 lbs 3 8 L 8 0 pts No Unloaders 1 0 O APPROVED COMPRESSOR OIL d Se GE R 404A Mobil Arctic EAL 68 P N 07 Castrol SW 68C Icematic SW 68C 1 4 REFRIGERATION SYSTEM DATA a Defro
109. jectors When starting engine it is necessary to continue to hold the glow defrost switch in the UP position until the engine has developed sufficient oil pressure to close the oil pressure safety switch OP The glow defrost switch momentary contact when held inthe DOWN position is provided so that the system may be placed in the defrost mode manually by the operator When this switch is closed the unit will defrost in the same manner as when on automatic defrost R efer to Section 3 4 4 2 Start Run Stop Switch This switch is a three position switch which are STA RT momentary contact RUN and STOP With the switch in the START position power is supplied to the starter motor Releasing this switch after engine start up will automatically place the switch in the RUN position The switch must be moved manually to the STOP position 3 Selector Switch SSW This switch is used to select mode of operation either engine drive or standby electric motor drive Also when this switch isplaced in standby position the electric motor will not start until the oil pressure safety switch OPS closes d Defrost Timer Solid State Optional The solid state defrost timer is an optional method of defrost initiation The timer will automatically initiate defrost mode at a preset time interval of 1 1 2 3 or 6 hours The defrost intervals are selected by placing the jumper shunt in the appropriate interval position The interva
110. l are the oil pump method and closed system method 1 Oil Pump Method One compressor oil pump that may be purchased is a Robinair part no 14388 This oil pump adapts to a one U S gallon 3 785 liters metal refrigeration oil container and pumps 2 1 2 ounces 0 0725 liters per stroke when connected to the suction service valve port Also there is no need to remove pump from can after each use When the compressor is in operation the pump check valve prevents the loss of refrigerant while allowing servicemen to develop sufficient pressure to overcome the operating suction pressure to add oil as necessary Backseat suction service valve and connect oil charging hose to port Crack the service valve and purge the oil hose at oil pump Add oil as necessary 2 Closed System Method In an emergency where an oil pump is not available oil may be drawn into the compressor through the suction service valve CAUTION Extreme care must be taken to ensure the manifold common connection remains immersed in oil at all times Otherwise air and moisture will be drawn into the compressor Connect the suction connection of the gauge manifold to the compressor suction service valve port and immerse the common connection of the gauge manifold in an open container of refrigeration oil Crack the suction service valve and gauge valve to vent a small amount of refrigerant through the common connection and the oil to purge the lines of air Clos
111. l time designations are labeled on the side of the defrost timer A second jumper shunt located on the timer is used to determine defrost termination T he two designationsfor termination are the 1 and 20 minute positions The 1 position will allow termination bythe defrost thermostats DT The 20 minute position will automatically terminate defrost after 20 minutes has elapsed It is recommended applications were a 7 day approximately deep frozen conditions apply the defrost termination shunt should be placed in the 20 minute position This will prevent potential ice buildup over time NOTE The evaporator coil temperature must be below 2 8 37 before defrost can be initiated Test points are provided on the defrost timer By placing a jumper across the test points designated TEST on the side of the timer will accelerate the timer to initiate defrost within a seconds Also located on the defrost timer is an LED that will blink on and off at approximately 3 second intervals which indicatesthe timer isfunctioning and a 1 amp fuse for timer protection e Motor Overload MOL The function of the motor overload isto protect the standby motor against high amperage draw The overload providesan adjustable knob to set the maximum amperage overload draw In this application the setting should be 12 5 amps 1 19 The motor overload is also equipped with a reset button This button hasthree positions automatic re
112. le enough to warrant a sealed unit The system is temperature compensated to permit the ideal charging rate at all temperatures The regulator is an electronic switching device It senses the voltage appearing at the auxiliary terminal of the alternator and supplies the necessary field current for maintaining the system voltage at the output terminal The output current is determined by the load DF ReguLator D Figure 1 11 65 Amp Alternator and Regulator P N 30 00393 00 1 20 POS OUTPUT SE RED 9 FIELD NEGATIVE YEL o OT RN OUTPUT TEL o BLK G D EMULATION REGULATOR D Emulation Orange 10 24 AC Terminal 10 24 Ground Screw 1 4 20 Positive Output Cable Figure 1 12 65 Amp Alternator and Regulator P N 30 00409 02 Positive Output B Regulator 12vdc Test Lamp Terminal L Ground Terminal UNE 1 15 REFRIGERANT CIRCUIT DURING COOLING See Figure 1 14 When cooling the unit operates as vapor compression refrigeration system The main components of the system are the reciprocating compressor air cooled condenser thermostatic expansion valve direct expansion evaporator and hot gas valve three way The compressor raises the pressure and temperature of the refrigerant
113. lunger and O ring If O ringis to be replaced always put refrigerant oil on O rings before installing Tighten enclosing tube assembly If the valve has not been removed from the unit leak check the valve f Install coil assembly voltage cover and cap g Evacuate and dehydrate the unit h Install a complete refrigerant charge i Start unit and check operation 4 20 ADJUSTING THE COMPRESSOR PRESSURE REGULATING VALVE CPR valve is factory pre set and should not need adjustment If it is necessary to adjust the valve for any reason proceed with the following outline When adjusting the CPR valve the unit must be runningin the high speed heat or defrost This will ensure a suction pressure above the proper CPR setting 1 Cap 2 Jam Nut 3 Setting Screw Figure 4 15 Compressor Pressure Regulating Valve To adjust the CPR valve proceed as follows a Install a manifold gauge set b Remove cap item 1 from CPR valve c With an 8 mm Allen wrench loosen the jam nut Figure 4 15 item 2 d Using the 8 mm Allen wrench adjust the setting screw To raise the suction pressure turn the setting screw item 3 clockwise to lower the suction pressure turn the setting screw counterclockwise Refer to section 1 4 for CPR valve setting e When the setting has been adjusted tighten the jam nut securely against the setting screw item 3 This will prevent any movement of the setting screw due to vibra
114. mbly is designed with the radiator located above the condenser coil The condenser fans draw the air through the condenser and radiator coil To provide maximum air flow the condenser fan belt should be checked periodically and adjusted if necessary to prevent slippage The condenser and radiator can be cleaned at the same time The radiator must be cleaned internally as well as externally to maintain adequate cooling CAUTION Use only ethylene glycol anti freeze with inhibitors in system as glycol by itself will damage the cooling system Always add pre mixed 50 50 anti freeze and water to radiator engine Never exceed more than a 50 concentration of anti freeze Use a low silicate anti freeze a Remove all foreign material from the radiator condenser coil by reversing the normal air flow Airis pulled in through the front and discharges over the standby motor Compressed air or water may be used as a cleaning agent It may be necessary to use warm water mixed with any good commercial dishwasher detergent Rinse coil with fresh water if a detergent is used b Drain coolant by removing lower radiator hose and radiator cap c Install hose and fill system with clean untreated water to which three to five percent of an akalined based radiator cleaner should be added six ounces dry 151 grams to one gallon 3 78 liters of water d Run engine 6 to 12 hours and drain system while warm Rinse system three times after it
115. n and press the Standby Key The microprocessor will perform a self test all display messages will appear in display window Then setpoint and box temperature will be displayed NO POWER will be displayed if unit is switch to standby and power plug not plugged in 2 4 CONTROL CIRCUIT OPERATION ENGINE DRIVE 2 4 1 Introduction NOTE To make it easier to locate the schematic components referred to in the written text the schematic in this manual has map coordinates added to the margins These locations have also been added to the legend The controller boards shown on the electrical schematic Figure 5 1 that interface with unit components are the analog interface or processor board on the left and the relay module on the right Connections to these boards are made through 3 multiple pin plug connectors HC HC2 amp MP The address system example HCD2 MPW2 indicates a wire between plug HC pin D2 and microprocessor MP amp pin W2 The processor board connections are mainly inputs and outputs for control switches temperature sensors safety and auto start functions that control the operation of the unit The processor board also controls the operation of the relay board through plug connections The relay module which contains plug in interchangeable relays provides the microprocessor with a means for switching the unit components to achieve a desired operating mode 2 4 2 Cooling There are two control range
116. ngine does not shut off repeat step 4 and adjust the solenoid forward slightly When operating correctly tighten solenoid mounting hardware and reconnect the positive wire 6 Run Solenoid 7 Spring Run Control 8 Linkage Rod Run 9 Engine Run Lever 10 Boot 1 Speed Solenoid 2 Spring Speed Control Engine Speed Lever Linkage Rod Speed Clip Figure 4 1 Speed and Run Control Solenoids oR b Speed Control Solenoid see Figure 4 1 1 Remove spring item 2 from the engine speed lever item 3 2 Disconnect wiring to solenoid Disconnect linkage rod item 4 from solenoid Remove mounting hardware and solenoid 3 Attach linkage to new solenoid and install the clip item 5 to the linkage rod Install the replacement solenoid and mounting hardware loosely Connect the ground wire and spring 4 Energize the solenoid with a jumper wire connected to a battery Slide the solenoid far enough back on the bracket to set the engine speed lever against the stop Tighten solenoid mounting hardware 5 With the engine stopped place a mark on the crankshaft sheave white paint for example Check engine speed Speed may be verified by a Strobette model 964 strobe tachometer Carrier Transicold P N 07 00206 6 Disconnect the jumper wire and start the engine The engine is in low speed Refer to section 1 2 for engine speed Reconnect the jumper wire to energize the solenoid The engine should
117. nsor is defective the control assume a temperature of less than 32 for the glow timing 9 Minimum On Time The engine is allowed to turn off only after a minimum of 4 or 7 minutes of run time After the minimum on time the unit will go to fully loaded for setpoints greater than 12 10 and high speed loaded for setpoints of 12 C 10 or less The unit will not cycle off if the engine coolant temperature is less than 50 C 122 F or the battery is less than 13 4 volts If the unit can not cycle off it will operate normally in continuous mode If all temperature probes fail and the setpointis 12 C 10 F or less the unit will not shut down Theunit will shut down when the box temperature is within 0 3 C 0 5 of setpoint for setpoints in the Perishable range or 0 3C 0 5 above setpoint for setpoints in the Frozen range h Minimum Off Time K eypad provision is provided to select the minimum off time of 10 20 30 45 or 90 minutes After the minimum off time the unit will restart for temperatures beyond 2 0 3 6 of setpoint for the Perishable range or above 2 0 3 6 of setpoint for the Frozen range The minimum off time is overridden if the temperature is more than 6 11 from setpoint i Battery Voltage Provisions are made to sense when the battery is good A good battery is defined as having 13 4v at 24C _ 75_F This condition is used to allow sh
118. nts from the air stream entering the engine An excessive accumulation of these contaminants in the air cleaner will impair operation therefore a service schedule must be set up and followed 1 Oil Cups When to Service Remove the oil cup at regular intervals Initially inspect daily or as often as conditions require Never allow more than 12 7 mm 1 2 inch of dirt deposit in either cup More than 12 7 mm 1 2 inch accumulation could cause oil and dirt to enter the engine causing accelerated engine wear Heavily contaminated oil will not allow the air cleaner to function properly CAUTION Always cover the engine inlet tube while the air cleaner is being serviced How to Service Stop the engine and remove the oil cup from the air cleaner Dump the oil from the oil cups Remove the inner cup from the oil cup and clean Reassemble and fill both oil cups to the indicated level with SAE 10 oil for temperatures below freezing or SAE 30 for temperatures above freezing It is generally a recommended practice to use the same oil as required in the engine crankcase CAUTION Do not under fill or over fill the cups over filling of cups means loss of capacity and under filling means lack of efficiency 2 Body Assembly When to Service The lower portion of the fixed element should be inspected each time the oil cup is inspected or serviced If there is any sign of contaminant build up or plugging the body assembly should be remove
119. o check the compressor oil level after the system has been in operation and the desired box temperature is obtained because an amount of oil will be absorbed by the refrigerant and entrained in the system 2 Slowly close the suction service valve on the compressor until the suction pressure is 0 psig Stop the compressor and frontseat the suction and discharge service valves CAUTION It is very important that the suction service valve be closed slowly when pumping down the system because an abnormal amount of oil may leave the compressor due to the sudden pressure reduction on the refrigerant saturated oil in the compressor crankcase 3 Slowly loosen one of the compressor oil fill plugs to release remaining compressor pressure The residual refrigerant in the crankcase will generate a slight continuing pressure and outflow of refrigerant vapor during the period when the compressor is exposed to the atmosphere preventing the entrance of serious amounts of either air or moisture 4 Remove the oil fill plug and determine the oil level by using a dipstick CTD P N 17 32127 and Table 4 2 A dipstick may be made see Figure 4 7 The compressor oil charge after the system is stabilized should be maintained between 6 ounces 0 17 liter minimum and 10 ounces 0 29 liter maximum for best results 5 When the compressor is mounted in the vertical position the oil level may be checked from either oil fill hole when the crankshaft
120. oil voltage plate and retainer 7 Evacuate and dehydrate the compressor Refer to section 4 8 p through 4 8 w 8 Start unit and check unloader operation Refer to section 4 12 a 1 Retainer 8 Plunger Assembly 2 Coil Assembly 9 Gasket 3 Installation Removal 10 Valve Body Tool 11 Gasket 4 Enclosing Tube 12 Bolt Collar 13 Gasket Bolt 5 O Ring 14 Piston Ring 6 Enclosing Tube 7 Plunger Spring Figure 4 10 Unloader Solenoid Valve 4 13 CHECKING AND REPLACING FILTER DRIER To Check Filter Drier Check for a restricted or plugged filter drier by feeling the liquid line inlet and outlet connections of the drier cartridge If the outlet side feels cooler than the inlet side then the filter drier should be changed To Replace Filter Drier a Pump down the unit per section 4 4 Remove bracket then replace drier b Check refrigerant level Refer to section 4 7 3 4 14 CHECKING AND REPLACING HIGH PRESSURE CUTOUT SWITCH 4 14 1 Replacing High Pressure Switch a Pump down the unit Refer to section 4 4 a Frontseat both suction and discharge service valves to isolate compressor b Slowly release compressor pressure through the service valve gauge ports c Disconnect wiring from defective switch The high pressure switch is located near the top of the compressor See Figure 4 6 d Install new cutout switch after verifying switch settings Refer to section 4 14 2 e Evacuate and dehydrate
121. omputer There are presently three 3 protocols supported The protocol for the QualComm transmitter the protocol for the HUGHES transmitter and Carrier Communication Protocol The microprocessor will power up and transmit a HU GHES protocol packet and continue to transmit a packet every hour The microprocessor will transmit in the Carrier QualComm protocol if a data packet is requested 1 9 SWITCHES AND CONTROLS MICROPROCESSOR CONTROLLER 1 9 1 Introduction Components required for monitoring and controlling the diesel engine refrigeration system are located in the electrical box door T he water temperature sensor is located on top of the engine 1 9 2 Electrical Box Door See Figure 1 5 1 Run Stop Switch R S When placed in the RUN position this switch provides power to the microprocessor 1 18 To stop the unit or remove power from the microprocessor move the run stop switch to the STOP position 2 Manual Glow Crank Switch M GC The manual glow crank switch when held in the GLOW position energizes approximately 7 5 amps per plugat 12 vdc the glow plugsinthe engineto pre heatthe combustion chamber The CRANK position of the switch is used to manually engage the engine starter 1 9 3 Location of Engine Safety Devices a Oil Pressure Safety Switch OP Thisswitch set to open below 1 0 0 2 kg cm 15 3 psig will automatically stop the engine upon loss of oil pressure See Figure 1 1 for location
122. ons Place the On Off Switch Cab Command to OFF position or place Run Stop Switch in the STOP position to stop unit 2 2 2 MANUAL STARTING a Starting Instructions Manual Starting 1 Tostart the unit manually place Run Stop Switch to RUN position and the On Off Switch Cab Command to ON position 2 Press the Auto S S Continuous Key if necessary to erase AUTOSTART STOP Symbol from the display 3 Press the Function Change Key until AUTO OP or MAN OP appears on the display a If AUTO OP appears 1 Press the Enter Key 2 Press the Up Or Down Arrow Key to make MAN OP appear on the display 3 Press the Enter Key The unit is in MANUAL START mode b If MAN OP appears the unit is in MANUAL START mode 4 Use the Manual Glow Crank Switch to start the unit refer to Table 2 1 NOTE Once the unit is programmed for Man OP the Auto S S Continuous Key can be used to toggle between Auto Start Stop and Manual Start Continuous Run Table 2 1 Manual Glow Time Ambient Temperature S in Less than 0 C 32 F 1 C to 10 C 33 F to 50 F 0775 11 C to 25 51 F to 77 F Greater than 26 C 78 F b Stopping Instructions Place the On Off Switch Cab Command to OFF position or place Run Stop Switch in the STOP position to stop unit 2 3 STARTING AND STOPPING INSTRUCTIONS STANDBY MOTOR DRIVE 1 Plug in the power plug 2 Place the On Off Switch Cab Command to ON positio
123. or water may be used as a cleaning agent It may be necessary to use warm water mixed with any good commercial dishwasher detergent Rinse coil with fresh water if a detergent is used 4 19 HOT GAS Three Way VALVE 4 19 1 Replacing Solenoid Coil It is not necessary to pump the unit down to replace the coil see Figure 4 14 a Remove coil snap cap voltage plate and coil assembly Disconnect leads and remove coil junction box if necessary b Verify coil type voltage and frequency This information appears on the coil voltage plate and the coil housing c Place new coil over enclosing tube and then install voltage plate and snap cap CAUTION Donotdamageor over tighten the enclosingtube assembly Also make sureall parts are placed on the enclosing tube in proper sequence to avoid premature coil burnout nl Snap Cap Voltage Plate Coil Assembly Enclosing Tube Plunger Assembly OOo OY 1 Q N P Body Head 6 Gasket dy Valve Body 7 Assembly Figure 4 14 Hot Gas Three Way Valve 4 19 2 Replacing Solenoid Valve Internal Parts If the hot gas valve is to be replaced or the internal parts serviced the refrigerant charge must be removed a Remove and store the refrigerant charge in an evacuated container refer to section 4 4 b Remove coil snap cap voltage cover and coil assembly Remove the valve body head c Check for foreign material in valve body d Check for damaged p
124. orator fins If the coil is not cleaned on a regular basis sometimes as often as after each trip the accumulation can be great enough to restrict air flow cause coil icing repetitive defrosts and loss of unit capacity Due to the washing action of normal defrost the fiber dust and particles may not be visible on the face of the coil but may accumulate deep within It is recommended to clean the evaporator coil on a regular basis not only to remove cardboard dust but to remove any grease or oil film which sometimes coats the fins and prevents water from draining into the drain pan Cardboard fiber particles after being wetted and dried several times can be very hard to remove Therefore several washings may be necessary a Remove rubber check valves Kazoo from drain lines b Spray coil with a mild detergent solution such as Oakite 164 or any good commercial grade automatic dish washer detergent such as Electrosol or Cascade and let the solution stand for a few minutes and reverse flush opposite normal air flow with clean water at mild pressure A garden hose with spray nozzle is usually sufficient M ake sure drain lines are clean c Rununituntil defrost mode can beinitiated to check for proper draining from drain pan 4 18 CONDENSER COIL CLEANING Remove all foreign material from the condenser coil by reversing the normal air flow Airis pulled in through the front and discharges over the engine Compressed air
125. orm before moisture removal is complete Heat lamps or alternate sources of heat may be used to raise system temperature 4 6 3 Procedure for Evacuation and Dehydrating System a Remove refrigerant using a refrigerant recovery system b The recommended method to evacuate and dehydrate the system is to connect three evacuation hoses Do not use standard service hoses as they are not suited for evacuation purposes as shown in Figure 4 5 to the vacuum pump and refrigeration unit Also as shown connect a evacuation manifold with evacuation hoses only to the vacuum pump electronic vacuum gauge and refrigerant recovery system c Withthe unit service valves closed back seated and the vacuum pump and electronic vacuum gauge valves open start the pump and draw a deep vacuum Shut off the pump and check to see if the vacuum holds This operation is to test the evacuation setup for leaks repair if necessary d Midseat the refrigerant system service valves e Thenopen the vacuum pump and electronic vacuum gauge valves if they are not already open Start the vac uum pump Evacuate unit until the electronic vacuum gauge indicates 2000 microns Close the electronic vac uum 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 Use refrigerant that the unit calls for Raise system pressure to approximately 2 psig g Remove refri
126. osed The unit will shift to the defrost mode if voltage is present at K2 If both defrost thermostats klixons are open no voltage at K2 defrost cannot be initiated by any means In defrost the microprocessor pulls terminals X1 and N3 low to shift the unit into high speed heat The processor also pulls terminal W2 low to energize the defrost relay coil This closes the N O defrost relay contacts to energize the defrost light on the remote light bar The defrost and heat display will also be illuminated Also N C defrost relay contacts open to to stop the evaporator fans On Supra 922 944 the microprocessor pulls terminal W3 low to energize damper relay DPR This closes N O damper relay contacts to energize close defrost damper solenoid DDS The unit will remain in defrost until both defrost termination thermostats open to remove voltage from the defrost relay If the thermostats fail to open in 45 minutes the microprocessor will terminate defrost and shift between normal control and defrost at 1 1 2 hour intervals This will also occur if the defrost air switch is stuck closed If the problem corrects itself thermostats opens for example the unit will automatically resume its normal functions The defrost termination starts with HR1 and speed relay de energizing The defrost output will de energize 5 seconds after HR1 If the temperature control requires high speed it will energize 2 seconds after defrost relay i
127. oses when engine develops sufficient oil pressure The glow plug switch will automatically be in the OFF position when released 4 Set the temperature controller for desired cargo temperature 5 Complete pre trip inspection Refer to Section 3 1 b Table 3 1 Manual Glow Time Ambient Temperature Se Less than 0 C 32 F 1 C to 10 C 33 F to 50 F x F 11 C to 25 C 51 F to 77 F Greater than 26 C 78 F b Stopping Instructions Place Start Run Stop switch in the STOP position 3 3 STARTING AND STOPPING INSTRUCTIONS STANDBY MOTOR DRIVE WARNING Beware of unannounced starting of fans and V belts caused by thermostatic cycling of unit during standby operation a Starting Instructions 1 Place the Start Run Stop Switch in the STOP position 2 Place the Engine Standby Switch in the STANDBY position 3 Plugin the power plug 4 Place the Start Run Stop Switch Switch in the RUN position 5 Check for proper motor rotation Condenser air must be drawn into unit To reverse rotation stop unit disconnect power cord and change polarity of plug b Stopping Instructions WARNING When changing from standby operation first turn the unit OFE turn OFF main power and remove power plug 1 Place the Start Run Stop Switch in the STOP position 3 4 CONTROL CIRCUIT OPERATION ENGINE DRIVE 3 4 1 Introduction NOTE To make it easier to locate the schematic components referred to
128. played with one decimal place and the proper unit designator Degree C or Degree i e 2RA 85 0F Compartment 3 Air Temperature The air temperature for the second compartment will be displayed with the abbreviated description 3RA on the left hand side The code displayisCD 17 The data will be displayed with one decimal place and the proper unit designator Degree C or Degree i e 85 0 M aintenance H our M eter 1 The maintenance hour meter 1 setting is displayed with the description M HR 1 or CD18 The maintenance hour meter is compared to one of the hour meters diesel standby or switch on determined byits mode the hour meter is greater than the maintenance hour meter an alarm will be generated Maintenance H our M eter 2 The maintenance hour meter 2 setting is displayed with the description M HR 2on the left side or 19 The maintenance hour meter is compared to one of the hour meters diesel standby or switch on determined by its mode If the hour meter is greater than the maintenance hour meter an alarm will be generated Switch On H our M eter The number of switch on hoursis displayed with the description SON or CD20 i e SON 2347H or CD20 2347H The display range is 0 to 99999 1 8 7 ALARM DISPLAY The fault light FL isturned on only for alarms that specify it The default display will be overridden if a alarm 15 generated W hen an alarm is generated the display will alternate the d
129. point serere Or ERE n ed e e eire e M 1 10 1 8 4 Digital Display eR ss ERE eene Pd ab 1 10 1 8 5 Functional Parameters 1 11 186 22er oe et ere ee 1 12 187 Alarm Display uy ies eu eee BG are eee es 1 14 18 8 Prep Za asa aaa sad Sess SE 1 15 18 9 Heat Cool Mod s der re oO Me oe Rid oO Pad e Rio es 1 15 1 8 10 Defrost eere EEN erm ER eer rede 1 16 1 8 11 Auto Start Stop Operation 1 16 1 8 12 Remote Monitoring Microlink Optional 1 18 19 Switches and Controls Microprocessor Controller 1 18 191 Introduction icon rr RET PORT Re Re 1 18 19 2 El ctrica Box Doot SEENEN f re 1 18 1 9 3 Location of Engine Safety Devices 1 18 1 10 Switches and Controls Solid State Controller 1 18 107 Introduction e ARRA i RS 1 18 1 10 2 Control Panel and Related Components 1 18 111 Compressor Pressure Regulating Valve 1 19 112 Hot Gas Valve Three Way 1 19 1 13 E EE 1 20 114 Battery Charging Alternator
130. r incorporates the following features a Control supply or return air temperature to tight limits by providing refrigeration control heat and defrost to ensure conditioned air delivery to the load 1 9 b Dual independent readouts of set point and supply or return air temperatures c Digital readout and ability to select data Refer to Table 1 4 for Function Codes and Table 1 5 for U nit D ata d For alarm digital display identification Refer to Table 1 6 e A pre trip checkout of refrigeration unit operation Refer to section 1 8 8 f A self test check on program memory and data memory self test is executed each time the system is switched from Stop to Start Errors if any shall be indicated the displayasa ERR X where X isa number corresponding to the number of the test The unit shall display this error for 5 seconds and then reset the micro ERROR CAUSE ERR 1 Processor failure ERR 2 Check chip installation or Replace ERR 3 microprocessor Display board to logic board communication failure This can be caused by a defective ribbon cable or ribbon cable not plugged in properly ERR 4 or Display A communication link to transmit unit operational data to a remote computer Refer to section 1 8 12 e 1 8 2 KEYPAD The keypad has 12 keys which will allow the operator to initiate various functions display operating data and change operating parameters The keypad has up and
131. r at defrost termination the defrost cycle is terminated The internal timer is reset for 1 5 hours and the external defrost signal is ignored for defrost initiation The 1 16 manual defrost switch will override this mode and start a new 45 minute cycle W hen defrost override is active the appropriate alarm will be indicated If the run relay is de energized during defrost defrost is terminated f Defrost Termination at L ow Speed The defrost terminates with HR1 and speed relay de energizing The defrost output will de energize 5 seconds after HR 1 If the temperature control requires high speed it will energize 2 seconds after defrost relay 15 de energized 1 8 11 AUTO START STOP OPERATION Automatic start stop is provided to permit starting restarting of the diesel driven compressor as required T his feature fully enables automatic control of the diesel engine starting and stopping The main function of automatic engine cycling is to turn off the refrigeration system near setpoint to provide a fuel efficient temperature control system and to initiate a restart sequence after conditions are met System shut off is allowed only if the battery condition signal is good The engine coolant temperature shall override the minimum off time and out of range condition to force engine restarting when the engine coolant temperature drops below 1 34 restart will also be initiated if the battery voltage falls below 11 0 V de a
132. r solenoid SS is energized to crank the engine The engine will crank for 10 seconds or until engine operation is sensed by the alternator signal The glow relay is de energized after the auxiliary input is sensed 15 second null cycle will elapse before subsequent start attempts The run relay will remain energized until the next starting sequence Before the next starting sequence the oil pressure alternator auxiliary output is checked to insure that the engine is not running For the second and third start attempts the glow time is increased by 5 seconds over the glow time of the first attempt listed below The control allows three consecutive start attempts before the startingis locked out and the start failure alarm is activated REPEAT A 5 Seconds GLOW THIRD AT 15 Seconds TEMPT STOP REPEAT A 5 Seconds GLOW SECOND AT 159 STOP MAXIMU 10 Seconds Checked at CRAN 2 Seconds FIRST VARIABLE ATTEMPT 0 to 30 SE CONDS GLO Figure 1 8 Auto Start Sequence f Variable Glow Time The glow time for the first start attempt will vary in duration based on engine coolant temperature and the engine as follows Temperature Seconds The second and third start attempts have a glow time that is 5 seconds greater than the table amount T he glow time can be manually overridden through the function parameters If the coolant temperature se
133. ree C or D egreeF i e SAS 85 0F The display range is 38 to 70 C 36 F to 158 F This unit data will be displayed only if the SUP PROBE is selected in the controlling probe functional parameter Remote Air Temperature The remote air temperature is displayed with the description REM or CD6 The data is displayed with one decimal place and the proper unit designator D egree C or Degree F i e REM 85 0F The display range is 38 Cto70 C 36 to 158 Thisunit data will be displayed only if the REM PROBE is selected in the controlling probe functional parameter Ambient Temperature The ambient temperature is displayed with the description ATS or CD 7 The data is displayed with one decimal place and the proper unit designator D egree C or Degree F i e ATS 85 0F The display range is 38 Cto70 36 Fto158 F Ifthesensorisabsent then the display will read for the data Evp Future Expansion This unit data is not used at this time The Code display is CD 7 Compressor Discharge Temperature The compressor discharge temperature is displayed with the description CDT or CD9 The data is displayed with the proper unit designator D egree C or Degree F i e CDT 85F The display range 15 40 C to 200 C 40 to 392 If the sensor is absent then the display will read for the data Battery Voltage The battery voltage is displayed with the description or CD
134. rigerant has been added as indicated by scales Correct charge will be found in section 1 3 NOTE It is possible that all liquid may not be pulled into the receiver as outlined in step d In this case vapor charge remaining refrigerant through the suction service valve Refer to section 4 7 2 e When refrigerant cylinder weight scale indicates that the correct charge has been added close liquid line valve on cylinder and backseat the king valve 4 7 2 Adding a Partial Charge R 22 Only CAUTION Do not vapor charge R 404A Only liquid charging through the liquid line king valve is acceptable a Place refrigerant cylinder on scale and note weight Backseat suction service valve and connect charging line between suction valve port and refrigerant cylinder Open VAPOR valve on cylinder and purge charging line b Run the unit in high speed cool and open suction service valve three turns Ifnecessary partially block the condenser coil to raise the head pressure to 14 8 kg cm 210 psig The unit is correctly charged when the lower receiver sight glass is full and no refrigerant is in the upper receiver sight glass d Backseat close suction service valve Close vapor valve on refrigerant cylinder noting weight e Start unit and check for noncondensibles 4 7 3 Checking the Refrigerant Charge a Start unit in cooling mode Run approximately ten minutes Partially block off air flow to condenser coil so disch
135. rost signal DA may be supplied asa set of normally open switch contacts closingto initiate the defrost cycle c Manual Defrost Initiation The defrost cycle may be initiated by pushing the manual defrost key DTT must be closed d Defrost Function The defrost mode is initiated upon expiration of the defrost timing interval with the presence of a signal from the defrost termination thermostat D TT It may also be initiated by the presence of amomentary manual defrost signal Defrost may also be initiated by an external defrost signal from a device such as an air switch The defrost mode terminates when the defrost termination thermostat DTT opens indicating the defrost cycle is complete The defrost timer runs only when the DTT is closed The defrost interval timer resets to zero when defrost is initiated by any means The timer does not accumulate time during defrost mode during standby off cycles or auto start off cycles A defrost output is energized during defrost mode to de energize the evaporator fan motors or energize the damper solenoid to prevent hot air circulation to the load In addition the heating outputs SR amp HR1 are enabled to apply high speed heat for hot gas heating The compressor operates at maximum capacity on diesel and diesel electric units during defrost Fail safe Defrost Termination Should the defrost cycle not complete within 45 minutes or if the external defrost signal does not clea
136. s Frozen and Perishable The Frozen range is active with set points at or below 12 C 10 F and the Perishable range is active at set points above 12 C 10 F The controller automatically selects the mode necessary to maintain box temperature at set point If the unit is in high speed cool the microprocessor will pull terminal N3 low to energize the speed relay A set of normally open contacts SR close to energize the speed control solenoid SCS The engine will be in high speed When the unit is running in high speed cool and with the evaporator coil temperature below 4 4 C 40 F to close at least one defrost termination thermostat a pre trip may be initiated by depressing the Pretrip Key The operator now may verify the pre trip sequence Refer to Section 1 8 8 As the box temperature falls toward set point the microprocessor will place the unit in low speed cool The temperature at which this occurs is not fixed but depends upon the operating conditions The speed relay SR de energizes to open the circuit to the speed control solenoid SCS Engine speed decreases from high speed to low speed Supra 922 944 has an unloader when the unit goes to low speed it will also unload To do this the microprocessor will pull terminals X2 low completing the ground path for the unloader relay UFR The coil energizes to close the UFR contacts and unloader UF energize to unload the compressor Refer to Section 1
137. s It is recommended that these be worn whenever handling a microprocessor Table 4 3 Connection Point Voltage Connection Point Approximate Voltage RAS SAS WTS 2 5 vdc Variable CAUTION M ost electronic components are susceptible to damage caused by electrical static discharge ESD In certain cases the human body can have enough static electricity to cause resultant damage to the components by touch This is especially true of the integrated circuits found on the truck trailer microprocessor Although there is less danger of electrical static discharge ESD damage in the outdoor environment where the processor is likely to be handled proper board handling techniques should always be stressed Boards should always be handled by their edges in much the same way one would handle photograph T his not only precludes the possibility of ESD damage but also lowers the possibility of physical damage to the electronic components Although the microprocessor boards are fairly rugged when assembled they are more fragile when separated and should always be handled carefully D uring emergency situations the test board may be used to keep a unit running and prevent a critical load from spoiling Since the microprocessor is totally disconnected from the unit it cannot monitor the engine s safety switches for oil pressure and coolant temperature Since the engine is running unprotected when the test boar
138. s de energized NOTE The microprocessor chip 2 06 or higher will lock out evaporator fans for 1 minute at the termination of defrost 2 5 CONTROL CIRCUIT OPERATION STANDBY MOTOR DRIVE NOTE To make it easier to locate the schematic components referred to in the written text the schematic in this manual has map coordinates added to the margins These locations have also been added to the legend The relay module which contains plug in interchangeable relays provides the controller with a means for switching the unit components to achieve a desired operating mode 2 5 1 Electric Standby Features 1 Two Operating Modes 2 Minimum ON Time 5 Minutes 3 Minimum OFF Time 5 Minutes 4 Low Battery Protection 1 Two operating modes Electric Standby can operate in the Start Stop mode or the Continuous Run mode During Start Stop operation Perishable Range the unit will operate in 3 modes A Cool cycle Off cycle C Heat cycle During Start Stop operation Frozen Range the unit will operate in 2 modes A Cool cycle B Off cycle In the Start Stop mode when the box temperature gets close to setpoint the controller will cycle the Standby Motor SBM off to conserve energy The microprocessor automatically locks out heating for entered setpoints at or below 12 2 C 10 F Therefore it is possible for the box temperature to fall below setpoint in the frozen range
139. s are retained in memory The following sections describe the list of functions which can be modified the keypad A description of the function is displayed on the left side with the corresponding data on the right side The function parameter list can be scrolled through by pressing the function changekey or by using the up down arrow keys With each function change key push the list is advanced one If the function key is pressed and held for one second the list will advanced one item at a time This list will circular meaning once the end of the list is reached the list will go to the first entry While the functional parameter is displayed the data can be changed by pressing enter then pressing either the up or down arrow keys If the value is changed the displayed data will then flash to indicate that the value has not been entered If the new value is not entered in 5 seconds the display will revert back to the last entered value If the enter key is pressed the display will stop flashingto indicate that the value has been entered The new value will continue to be display for 5 seconds before reverting back to the default display Each time a key is pressed the 5 second delay will reset To select a different functional parameter the function change key must be pressed first Code Vs English M essages The description messages of the functional parameters unit status and alarms can be displayed in English or Codesthrough this
140. s below 10 vdc The fault light FL is turned on 1 14 X TARTER Starter Motor RA SENSOR Return Air Sensor SA SENSOR Supply Air Sensor T L Coolant Temperature R D ALO AL1 AL2 AL3 AL4 AL5 AL6 AL7 AL8 19 AL10 AL11 D ALT AU Alternator Auxiliary S AL12 v High Discharge Discharge Temperature AL13 AL14 AL15 AL17 AL1 AL1 AL20 OUT Main Compartment RANGE Out of range Remote Compartment 2 ZBRQUT Out of range Y Remote Compartment 3 AL22 3RA OUT Out of range NO POWER No Power for Standby FAULT LIGHT ON High Battery Voltage Alarm The high battery voltage alarm is displayed with the description BATT or AL5 This alarm is generated if the battery voltage is above 17 vdc The fault light FL is turned on and the engine will shut down Defrost Override Alarm The defrost override alarm is displayed with the description DEER FAIL or AL6 This alarm is generated if the unit isin a defrost override mode See Section 1 8 10 Alternator Auxiliary Alarm The alternator auxiliary alarm is displayed with the description ALT AUX orAL 7 This alarm is generated if the alternator auxiliary signal is not present with the engine running See Section 1 8 11 The fault light FL is turned on Starter M otor Alarm The starter motor alarm is displayed with the description STARTER orAL8 Thisalarm is generated if the starter motor input signal is not present with starter sol
141. set manual and test In this application the button should remain in the automatic reset position 1 11 COMPRESSOR PRESSURE REGULATING VALVE CPR This adjustable regulating valve is installed on the suction line of the compressor to regulate the amount of suction pressure enteringthe compressor T he CPR valve is adjusted to maintain a maximum suction pressure for CPR settings refer to section 1 4 The suction pressure is controlled to avoid overloadingthe electric motor or engine during high box temperature operation To adjust the CPR valve refer to section 4 20 1 12 HOT GAS VALVE Three Way a Description Operation of the hot gas three way valve is governed by the position of the plunger in the hot gas solenoid The valve is pilot operated and therefore depends on the refrigerant gas to shift the piston assembly b Cooling Operation See Figure 1 9 With the solenoid coil de energized the valveisinthe cool operating mode and the refrigerant gasis diverted to the condenser The volume directly above the piston assembly is open to suction pressure through the external pilot connection and the volume underneath the piston assembly is open to discharge pressure through the compressor discharge connection This difference in pressure across the piston assembly results in the piston assembly being shifted upward shutting the heat and defrost port opening the condenser port and allowing refrigerant to flow to the condenser
142. st Timer 1 1 2 3 6 or 12 hours b Defrost Air Switch Setting Initiates at 16 51 1 7 mm wg 0 65 07 inch c Defrost Thermostat Opensat 8 3C 47 5 F Closesat 3 3 C 37 5 F d High Pressure Cutout Switch HP R 22 Cutout at 30 0 7 kg cm 428 10 psig Cut in at 2251 0 7 kg cm 320 10 psig R 404A Cutout at 32 7 0 7 kg cm 465 10 psig Cut in at 24 6 0 7 350 10 psig e Refrigerant Charge Refer to Table 1 1 f Compressor Pressure Regulating Valve psig Change 03 05 1 6 400 cc 24 4 in3 49 kg 108 105 2 6 L 5 5 pts g Thermostatic Expansion Valve Superheat 200 cc 12 2 in3 169 cc 10 3 in3 38 kg 84 lbs 1 9 L 4 0 pints 6 8 kg 15 105 0 36 L 0 76 pints Setting at 17 8 0 box temperature 7_ 13 Low Pressure Switch LPS Solid State Control ETO Only Opensat 38 15 hg vacuum Quench Valve Used on Supra 422 or R 404A Opens at 121 C 250 Compressor Discharge Temperature Sensor U nit shut down at 154 C 310 F for 3 minutes or 177 C 350 F 15 ELECTRICAL DATA 1 6 TORQUE VALUES a Evaporator Fan M otors Assembly kg m ft lb Bearing Lubrication Factory lubricated PowerTraytoFrame 55 40 additional grease not required Standby Motor to Power Tray 55 40 15kw 1 5hp 7tol0amps 2250 rpm Compressor to Power Tray 55 40 b Standby Motors Stand by Mo
143. suction pressure gauge 4 Reconnect wiring on the front unloader The front unloader will retract and an additional 3 psig 0 2 kg cm2 rise on the suction gauge will be noted Compressor is now fully unloaded and only the top bank is loaded two cylinders 5 Reverse the above procedure to check out compressor loading Suction pressure will drop with this test NOTE If either unloader coil energizes and the suction pressure does not change the unloader assembly must be checked b Solenoid Coil Replacement NOTE The coil may be removed without pumping the unit down 1 Disconnectleads Remove retainer Lift off coil See Figure 4 10 2 Verify coiltype voltage and frequency of old and new coil This information appears on the coil housing 3 Place new coil over enclosing tube retainer and connect wiring c Replacing Solenoid Valve Internal Parts See Figure 4 10 1 Pump down the unit Frontseat both service valves to isolate the compressor 2 Remove coil retainer and coil 3 Remove enclosing tube collar item 4 Figure 4 10 using installation removal tool supplied with repair kit item 3 4 Check plunger for restriction due to a Corroded or worn parts b Foreign material lodged in valve c Bent or dented enclosing tube 5 Install new parts Do not overtighten enclosing tube assembly Torque to a value of 100 inch pounds 1 15 mkg 6 Remove supplied installation removal tool Install c
144. switch to STOP when remote evaporator is not required NOTE For starting instructions on the nosemount unit refer to section 2 2 Gre MICROPROCESSOR CONTROL SYSTEM DEFROST MEAT LM 1 Cool Heat Defrost Power Light 2 Compartment RUN STOP Switch Figure 7 2 Remote Control Box 7 5 MICROPROCESSOR CONTROLLER NOTE The Supra nosemount unit microprocessor controller controls all compartments Refer to section 1 8 The Supra microprocessor controller controls up to two compartments The 2 compartment is enabled by the compartment ON OFF switch located on the remote control box When the compartment is enabled the controller will maintain temperature based on setpoints entered via the keypad function parameter selections Two temperature thermistor sensors are used to monitor the return air of each evaporator Temperature control is achieved by switching between 4 modes high speed cool low speed cool null and high speed heat When heating is required the microprocessor will energize 2HR and the speed relay at 1 8 F 1 C below setpoint The remote heat relays will be de energized when the temperature rises above 0 9 F 0 5 C below setpoint When the heat relay is de energized the compartment will stay in null mode until the temperature rises greater than 1 8 F 1 C above setpoint At this point the controller will energize 2CR If
145. t 86 F No OFF All Supra Units CNF11 OFF set Do Not Turn On point 86 F EN Alt Aux alarm only Standard func Alt Aux alarm shuts unit down tion lock OFF All Supra Units CNF11 Maximum set Do Not Turn On point 90 F No TEE OFF SYSTEM CK alarm Off function lock ON SYSTEM CK alarm On I CNF11 ON CNF3 ON Maximum set All Supra Units i point 90 F Do Not Turn On Modified func CNF20 Display Units Unlocked tion lock E Display Units Locked Not applicable with Revisions lower 52 CNF20 allows the Fahrenheit Celsius function me eae dr to be locked In order to change the units setting om me eae dr CNF20 must be OFF The units setting can then EAM GE CNF20 ON the units setting cannot be OFF 23 OFF Forfutureuse Donotturnon changed from the functional parameters list Orr OFF For uture use Donottum on Orr CNE OFF For ture use Donottum on OFF CNF26 OFF For ture use Donottumon CNF27 OFF For ture use Donottumon Orr OFF For uture use Donottum on OFF For tuture use Donottumon Orr Jee OFF For uture use Donottum on Orr enest_ OFF For uture use Donottum on OFF CNF32 Forfutureuse Donott
146. t glass on the compressor to ensure that no foaming of the oil is present after 20 minutes of operation If the oil is foaming excessively after 20 minutes of operation check the refrigerant system for flood back of liquid refrigerant Correct this situation before performing step 3 3 Check the level of the oil in the sight glass with the compressor operating See Figure 4 8 Maximum Minimum Figure 4 8 Oil Level in Sight Glass 05G b Adding Oil with Compressor in System Two methods for adding oil are the oil pump method and closed system method 1 Oil Pump Method One compressor oil pump that may be purchased is a Robinair part no 14388 This oil pump adapts to a one U S gallon 3 785 liters metal refrigeration oil container and pumps 2 1 2 ounces 0 0725 liters per stroke when connected to the oil fill item4 Figure 4 6 Also there is no need to remove pump from can after each use When the compressor is in operation the pump check valve prevents the loss of refrigerant while allowing servicemen to develop sufficient pressure to overcome the operating suction pressure to add oil as necessary Backseat suction service valve and connect oil charging hose to oil fill item4 Figure 4 6 Purge the oil hose at oil pump Add oil as necessary Refer to section 1 3 2 Closed System Method In an emergency where an oil pump is not available oil may be drawn into the compressor through the suction s
147. the temperature continues to rise the speed relay will be energized at 2 5 C above setpoint If the temperature falls below 3 6 F 2 C above setpoint the speed relay is de energized and if it falls below 0 5 C above setpoint the remote cool relays are de energized There are overriding factors which would prevent the remote compartment from cooling or heating If the main compartment is in heat or defrost then no cool or heat will be allowed in the remote compartment In addition if the unit is being forced to run in low speed remote heat will be locked out Defrost in the remote compartment will be activated independently from the controller When a remote compartment is in defrost the controller will energize the speed solenoid Start Stop mode is also available for Multi compartment units A remote compartment can override shutdown after the minimum run time if the temperature is not within 1 8 F 1 C of setpoint A remote compartment will cause the unit to restart after the minimum off time if temperature is more than 3 6 F 2 C from setpoint The minimum off time can be overridden if the remote temperature is more than 6 C from setpoint 7 6 SERVICING REMOTE EVAPORATOR WARNING Before servicing the remote evaporator remove negative battery cable and tag nosemount start run stop switch to prevent starting a Fan Motor or Blade Replacement 1 Remove front panel 2 Remove fan guard loosen fan hub s
148. the unit will cycle between cool and heat to maintain box temperature at setpoint In frozen range the unit will run in cool only Continuous Run is normally used for perishable products that require constant air flow 2 5 2 Standby Cool When standby cool Start Stop microprocessor will energize the following circuits the First the microprocessor will energize ARR this will close a set of N O ARR contacts energizing the Auto Restart Light ARL on the light bar indicating to the operator that the unit is in the START STOP mode and may start at any time After a 5 second delay the Diesel Electric Relay DER will be energized this will open the N C DER contacts to prevent the Fuel Heater Relay FHR Fuel Pump FP and the Fuel Solenoid FS from being energized during standby operation At the same time the N O DER contacts will close This will energize the Power Light PL on the light bar indicating to the operator that the unit is in the standby mode of operation and also energize the Motor Contactor MC With the motor contactor energized the N O MC contacts will close supplying voltage to energize the standby motor At the same time RR will be energized closing the N O RR contacts supplying voltage to the refrigeration control circuitry 2 5 3 Standby OFF In the start stop mode after the standby motor has run at least five minutes and the controller is ready to switch from cool to heat bo
149. tion for the third compartment The setpoint function will be displayed with the abbreviated description 3SET The code displayisF N 9 T he setpoint may be changed refer to section 1 8 3 Auto M anual Start Operation The selection for starting the unit are displayed AUTO OP code FN 10 ON for auto start operation or MAN OP codeFN10OFF for manual start operation To start the unit in manual start mode the START STOP CONTINUOUS selection must be in continuous run mode Out of Range Tolerance The out of range temperature tolerance selection is displayed with the description T RANGE or codeFN11 The selection are A and C 2 3 6 F B 3 C 54 C 4 C 7 2 When the out of range temperature is configured ON the controller indicates out of range when the temperature has been within the tolerance band at least once and then goes outside the tolerance band for 45 minutes Also the unit will shut down When the out of range temperature is configured OFF the controller indicates out of range when the temperature has been within the tolerance band at least once and then goes outside the tolerance band for 15 minutes Also the unit will continue to operate For set points at or below 12 2 C 10_F frozen range the unit is only considered out of range for temperatures above set point 1 8 6 UNIT DATA The unit data key can be used to display the unit operating data values T he data values are display
150. tions in the unit Replace the cap 4 14 4 21 THERMOSTATIC EXPANSION VALVE The thermal expansion valve is an automatic device which maintains constant superheat of the refrigerant gas leaving the evaporator regardless of suction pressure The valve functions are a automatic response of refrigerant flow to match the evaporator load and b prevention of liquid refrigerant entering the compressor U nless the valve is defective it seldom requires any maintenance a Replacing Expansion Valve 1 Pump down the unit by closing the K ing valve Refer to section 4 4 a 2 Remove insulation Presstite from expansion valve bulb and then remove bulb from suction line 3 Loosen flare nut and disconnect equalizer line from expansion valve 4 Remove flange screws and lift off power assembly Then remove the cage assembly Check for foreign material in valve body 5 Thethermal bulb is located below the center of the suction line See Figure 4 17 This area must be clean to ensure positive bulb contact Strap thermal bulb to suction line and insulate both with Presstite 6 Install new gaskets and insert cage assembly and install power assembly 7 Fasten equalizer tube to expansion valve 8 Evacuate by placing vacuum pump on suction service valve 9 Open King valve and then check refrigerant level Refer to section 4 7 3 10 Check superheat Refer to section 1 4 1 Power Assembly 2 Body Flange Gaskets 3
151. tor Pulley Bearing Lubrication Factory lubricated Engine Pulley additional grease not required Rotation Speed 1760 rpm 60hz 1500rpm 50hz STANDBY MOTOR Engine Suppor ss 4 s 40 SUPRA 422 522 Voltage Type of Connection N N LA e LA CO e i SS SUPRA 622 722 822 644 744 844 N N LA e Bl Wil N Ns e p jojojo LA CO SUPRA 922 944 c Alternator 65 amps North amp South America 70 amps Europe d Standby M otor Overload STANDBY MOTOR OVERLOAD MODEL SETTING Supra 422 d Supra 722 822 Supra 922 944 522 622 1 7 1 7 SAFETY DEVICES System components are protected from damage caused by unsafe operating conditions by automatically shutting down the unit when such conditions occur This is accomplished by the safety devices listed in Table 1 2 or Table 1 3 Table 1 2 Safety Devices Microprocessor Controller Unsafe Conditions Safety Device Device Setting 1 Low engine lubricating oil Oil pressure safety switch OP Opens below 1 0 2 kg pressure automatic reset cm 15 3 psig 2 High engine cooling water Water temperature sensor Opens above 1101 temperature microprocessor 230 5 3 Excessive current draw by glow Fuse F1 Opens at 80 amps plug circuit control circuit or start er solenoid SS 4 Excessive current draw by Fuse F2 Opens
152. ture decreases to 1 5 F 0 8 C below setpoint Note These switch points may vary slightly depending on the amount of overshoot around setpoint Standby D uring perishable heating the unloader is energized when the control temperature increasesto 1 5 F 0 8 C below setpoint The unloader will stay energized until the control temperature decreases to 2 F 1 1 C below setpoint d Frozen Unloader Control Diesel During frozen mode heating is not allowed The front unloader is energized when the control temperature decreasesto 1 5 F 0 8 C above setpoint The unloader will stay energized until the control temperature reaches 2 F 1 1 C above setpoint Standby During frozen mode heating is not allowed The front unloader is energized when the control temperature decreases to 2 F 1 1 C above setpoint The unloader will stay energized until the control temperature reaches 2 5 F 1 4 C above setpoint 1 17 2 Suction Pressure Operation Diesel Engine The microprocessor will monitor suction pressure of the refrigeration system R 22 or R 404A and control the unloader to maintain a maximum operating pressure A suction pressure transducer is used to signal the microprocessor when to load or unload the compressor a R 22Refrigeration System At ambient temperatures of 90 F 32 2 C or below When the system is operating at high speed and the suction pressure drops below 26 psig the front bank is loaded When the system
153. ulti Temp Sheet 1 of 2 7 4 R 5 T U W X ZONE SYMBOL DESCRIPTION LOCATION 14 1 CAPACITOR BOX HEATER G14 Cp2 CAPACITOR BOX HEATER H14 Cp3 CAPACITOR BOX HEATER J2 2cL COOL LIGHT C2ND COMPARTMENT BOX MULTI TEMP B6 H2 2CR COOL RELAY C2ND COMPARTMENT BOX MULTI TEMP 16 2DL DEFROST LIGHT 2ND COMPARTMENT BOX MULTI TEMP G8 H5 J4 20 DEFROST RELAY COMPARTMENT BOX MULTI TEMP HS 2011 2ND DEFROST THERMISTAT 2ND EVAPORATOR G2 2EFM ELECTRIC MOTORC2ND COMP 2ND EVAPORATOR 21 2ND TIMER BOX MULTI TEMP 12 FLR FLASH RELAY BOX MULTI TEMP F11 FUSE 30 AMP 2ND COMPARTMENT BOX HEATER G12 F12 FUSE HEATER BOX MULTI TEMP 612 F13 FUSE HEATER BOX HEATER H12 14 FUSE HEATER BOX HEATER 1g 15 FUSE BOX HEATER 69 2HL HEAT LIGHT 2ND COMPARTMENT BOX MULTI TEMP 17 2HR1 2ND HEAT RESISTANCE 1 2ND EVAPORATOR VIS 2HR2 2ND HEAT RESISTANCE 2 1ST EVAPORATOR 7 6 7 2HR HEAT RELAY OND COMPARTMENT BOX MULTI TEMP 18 2HT1 2ND HEATER THERMISTAT 1 BOX HEATER F13 613 2HVR 2ND HIGH VOLTAGE RELAY ADD HEATER BOX H13 110 J3 1 1 INSULATING PLUG 1 CONTROL BOX J2 2LSV LIQUID SOLENOID VALVEC2ND COMP 2ND EVAPORATOR 011 015 MC MOTOR CONTACTOR CONTROL BOX 4 MP MICROPROCESSOR BOARD CONTROL BOX 011 015 OL OVERLOAD PROTECTOR CONTROL BOX cg 2PL 2ND POWER LIGHT BOX MULTI TEMP 11 15 PSR POWER SUPPLY RECEPTACLE MAIN UNIT B4 2RAS 2ND RETURN AIR SENSOR 2ND EVAPORATOR B 14 2RR
154. umon Table 4 4 Microprocessor Configuration 4 16A Change 01 08 4 24 CONTROLLER SENSOR CHECKOUT An accurate ohmmeter must be used to check resistance values shown in Table 4 5 or Table 4 6 Due to variations and inaccuracies in ohmmeters thermometers or other test equipment a reading within 2 of the chart value would indicate a good sensor If a sensor is bad the resistance reading will usually be much higher or lower than the resistance values given in Table 4 5 or Table 4 6 Atleast one lead from the sensor RAS terminals D 1 and 1 or SAS terminals D2 and E2 must be disconnected from the unit electrical system before any reading is taken Not doing so will result in a false reading Two preferred methods of determining the actual test temperature the sensor isan ice bath at0_C 32 or a calibrated temperature tester Table 4 5 Sensor Resistance Micro Units ATS CDT RAS SAS amp WTS SSES WTS Resistance In Ohms ee el 44 26 200 25 1000 90 100 130 150 163 CDT Resistance In Ohms 1 653 000 1 178 000 855 000 624 000 463 000 345 000 327 000 262 000 199 000 153 000 119 000 100 000 93 000 73 000 58 000 47 000 38 000 9 150 6 800 3 010 1 860 1 358 1 202 p prx m C 9 3 3 7 8 2 2 6 7 1 1 0 0 5 6 1 1 25 6 7 2 2 7 8 3 3 8 9 100 130 150 163 177 10 10 20 30 32 50 70 77 00 10 20 94 12 66 02 25 50 1 1 1
155. ut off of the diesel engine If the battery voltage falls below 10v during glow cycle the starter will not engage and the start sequence will continue this is considered a failed start The start sequence is repeated until the unit starts or three consecutive start attempts have failed Table 1 7 Battery Voltages Message Voltage Display Level LOW BATT 10 AL4 or Less Description Unit will shut down ex cept during cranking If the unit has cycled off in auto start stop mode and battery voltage drops below 11 0 volts the unit is automatically started to charge battery U nit will operate until a battery voltage of 13 4 volts is obtained at which level unit will stop if tempera tures are satisfied Unit will shut down AL5 j Oil Pressure Signal When the oil pressure switch is closed it shows that the engine is running and prevents engagement of the starter motor when operating in the auto mode k Maximum Off Time Provision for a keypad selectable feature is provided which will cause the engine to be started 30 minutes after the engine has stopped regardless of the box temperature I 17 or more 1 8 12 Remote Monitoring Microlink Optional The microprocessor controller is equipped with a RS232 communication port T his port can be used to communicate unit operating data to a mobile satellite transmitter T hisinformation will then berelayed back to the office via a modem to a c
156. uum pump to the suction and discharge service valves Dehydrate and evacuate compressor to 500 microns 29 90 Hg vacuum 75 9 cm Hg vacuum Turn off valves on both lines to pump 3 Fullybackseat open both suction and discharge service valves 4 Remove vacuum pump lines and install manifold gauges 5 Check refrigerant level Refer to section 4 7 3 NOTE It is important to check the compressor oil level of the new compressor and fill if necessary 6 Check compressor oil level Refer to section 4 9 Add oil if necessary 7 Check refrigerant cycles 4 9 CHECKING 05K COMPRESSOR OIL LEVEL a To Check Oil Level in 05K Compressor 1 Operate the unit in high speed cooling for at least 20 minutes 2 Check the oil sight glass on the compressor to ensure that no foaming of the oil is present after 20 minutes of operation If the oil is foaming excessively after 20 minutes of operation check the refrigerant system for flood back of liquid refrigerant Correct this situation before performing step 3 3 Check the level of the oil in the front sight glass with the compressor operating The correct level should be between bottom and 1 4 of the sight glass If the levelis above 1 4 oil must be removed from the compressor To remove oil from the compressor follow step d If the level is below sight glass add oil to the compressor following step b b Adding Oil with Compressor in System Two methods for adding oi
157. witch DA out of calibration 4 15 automatically Defrost thermostats DTT open or defective Replace Defrost air switch DA defective 4 15 Loose terminal connections Tighten Air sensing tubes defective or disconnected Check Defrost timer defective 1 10 2 Replace Defrost Damper relay DPR defective Replace Will not initiate defrost manually Microprocessor defective Replace Loose terminal connections Tighten Defrost thermostats DTT open or defective Replace Glow Defrost switch defective Replace Defrost Damper relay DPR defective Replace Initiates but does not defrost Hot Gas three way valve malfunction 5 3 11 Defrost relay DR defective Replace Evaporator Clutch defective Replace Defrost damper solenoid DDS or linkage defective 4 26 Damper open or defective 4 26 Frequent defrost Defrost air switch DA out of adjustment 4 15 Wet load Normal Damper blade does not close Defrost damper solenoid DDS defective 4 26 Damper defective 4 26 Does not terminate or Defrost thermostats DTT shorted closed Replace cycles on defrost Defrost timer defective 1 10 2 Replace Glow Defrost switch defective Replace Defrost air switch DA out of adjustment 4 15 5 3 6 Abnormal Pressure 5 3 6 1 Cooling High discharge pressure Quench valve malfunction Replace Condenser coil dirty Condenser fan defective V belt broken or loose Discharge check valve restricted Replace Noncondensibles or refrigerant overcharge Replace Low discharge pressur
158. x temperature near setpoint the microprocessor will de energize the RR causing the standby motor to cycle off When the unit is OFF the microprocessor keeps ARR energized The unit will remain off for at least 5 minutes before restarting If after 5 minutes the battery voltage drops below 11 0 volts or the box temperature drifts out of range 2 0 C 3 6 F from setpoint for perishable range and 2 0 C 3 6 F above setpoint for frozen range the standby motor will restart 2 5 4 Standby Defrost Standby defrost operates the same as engine drive defrost refer to section 2 4 4 ec Mode Off Glow Start High Speed Cooling Low Speed Cooling Off Cycle Low Speed Heating High Speed Heating Defrost DER O O O O O O O O GPR OjJOjJO O Oj O O STANDBY MOTOR OPERATION Cooling Cooling Unloaded Off Cycle Heating Heating Unloaded Defrost Output is ON O Output is OFF Sequence shown is thermostat control selection This may be overridden by suction pressure O O O O Table 2 2 Relay Operation Microprocessor Controller RCR o SSR O O O O o A 1 O oe o 6 o O O o O O llorO O O O Wero II og O O 100 Oo O O O O 100 1 NA O O lorO
159. y UFR energizes to unload compressor bank Table 1 8 Unloading in Temperature Mode SETPOINT BELOW 10 12 SETPOINT ABOVE 10 12 Supra 922 944 Cool High Speed Cool Low Speed Cool Low Speed b Perishable Cooling Unloader Control Diesel D uring perishable cooling the unloader is energized when the temperature approaches setpoint If a supply probe is present the unloader is energized when the supply temperature decreases 5 4 F 3 C below setpoint It will stay unloaded until the supply temperature rises above setpoint If a supply probe isnot present the unloader is energized when the return temperature decreases more than 9 F 5 C above setpoint It will stay unloaded until the return temperature rises more than 14 4 F 8 C above setpoint The return probe logic is disabled for ambient temperature higher than 90 F 32 2 C eat Low Speed Heat Low Speed Heat High Speed Cool High Speed Cool Low Speed 6 4 Standby D uring perishable cooling the unloader is energized when the control temperature reaches less than 2_F 11 above setpoint The unloader stay energized until the control temperature reaches 2 5 F 1 4 C above setpoint Perishable Heating Unloader Control Diesel During perishable heating the front unloader is energized when the control temperature increases to 0 9 F 0 5 C below setpoint The unloader will stay energized until the control tempera
160. y terminal must be grounded Reverse polarity will destroy the rectifier diodes in alternator As a precautionary measure disconnect positive battery terminal when charging battery in unit Connecting charger in reverse will destroy the rectifier diodes in alternator CAUTION Under no circumstances should a technician electrically probe the processor at any point other than the connector terminals where the harness attaches Microprocessor components operate at different voltage levels and at extremely low current levels Improper use of voltmeters jumper wires continuity testers etc could permanently damage the processor CAUTION Most electronic components are susceptible to damage caused by electrical static discharge ESD In certain cases the human body can have enough static electricity to cause resultant damage to the components by touch This is especially true of the integrated circuits found on the truck trailer microprocessor 9 P 2 R 11 12 0 5 a LOY o e o o ud b e p IZOQOIIPIOOIIOUZZAXUI ANNAO ONA A No oo DN gt n o A 9 O UID o B a cm Ad g N zc IRI N 2210220 i 1 AoW YO oar ML d g m n jk N OO SYMBOL ALT ARL ARR

Supra 422, 522, Supra Multi-Temp - Sunbelt Transport Refrigeration

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