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Ultima 53, Phoenix ultra, and Extra, With advanced Micro service

1. HOT GAS 2 EXTERNAL EQUALIZER EXPANSION VALVE BYPASS LINE N EXPANSION 0 VALVE FUSIBLE PLUG wo BUB __ RECEIVER A A A EVAPORATOR Soa A BYPASS gt gt gt CHECK HEAT EXCHANGER VALVE lt LIQUID LINE SHUT OFF SOLENOID mE GAS VALVE SV2 NC um nues VALVE SERVICE Y SUBCOOLER DRIER VALVE HOT GAS 1 SOLENOID 0 SV3 NC gt Y Bl SOLENOID CONDENSER 5 2 NC PRESSURE CONTROL COMPRESSOR DISCHARGE ea NG CHECK VALVE gt NDENSER gt VIBRASORBER gt CONDENS Figure 7 13 R 404A Refrigerant Circuit Cooling EXTERNAL EQUALIZER EXPANSION VALVE gos EXPANSION n oa E VALVE BULB avens RECEIVER CHECK SUCTION LINE EVAPORATOR A VALVE V LIQUID LINE lt lt lt Y QUENCH VALVE HOT GAS LIQUID IM BYPASS SOLENOID VIBRASORBER HOT SHUT OFF VALVE SV2 NC _ MER UE LINE DISCHARGE VALVE FILTER BULB SERVICE HPS DRIER VALVE SUCTION
2. 5 5 HCS 9 3MP19 SP13 3MP 12 3MP23 SPK3 SPK3 SPK2 LHR SPK2 NOT GOLD MS L1 L2y 3 PCMCIA F p 3 5 22 3MP35 Y 11 3MP22 Evie 5 nem Spk CONTROL BOX 2 4 5 18 SPK3 1 ULTRA ULTRA XL EXTRA HR EV2A n X sac SP24 B EVIC 5 24 FET LEGEND C 5 12 FSH AJ 99 FSC CHS SPKE AUTO RESTART LIGHT FSE FET 8 HEAT LIGHT Evap 95 12 p Esra FET 9 5V4 CONTROL Po FET 10 5V1 CONTROL FET 12 FUEL HEATER RELAY S SPKE 14 FAULT LIGHT TO 2MP15 E6 FET 15 OUT OF RANGE LIGHT n FET 18 DEFROST LIGHT SP24 FET COOL LIGHT TO SPKS TO 1MP26 E4 BUZZER RELAY POWER csp FET 20 SV3 CONTROL SSR FET 21 5V2 CONTROL NOT GOLD 9 LHCE FET UNLOADER 2 CONTROL n GPR FET UNLOADER 1 CONTROL xi oHoHoHoeHe HC 14 FHR HCTE 30 87 ENG BLOCK GRD 20A
3. gt GRN RED r Q MH 9 FIELD B NEGATIVE o GRN OUTPUT YEL D EMULATION REGULATOR D Emulation Orange Not used on Advance 10 24 AC Terminal 10 24 Ground Screw 1 4 20 Positive Output Cable Figure 7 12 Alternator and Regulator P N 30 00409 02 gt 7 11 2 Integral Voltage Regulator Operation 12 volts dc The regulator is an all electronic transistorized device No mechanical contacts or relays are used to perform the voltage regulation of the alternator system The electronic circuitry should never require adjustment and the solid state active elements used have proved reliable enough to warrant a sealed unit The system is temperature compensated to permit the ideal charging rate at all temperatures The regulator is an electronic switching device It senses the system voltage level and switches the voltage applied to the field in order to maintain proper system voltage 62 10285 7 18 Section 7 Unit Description 7 12 Refrigerant Circuit During Cooling When cooling the unit operates as a vapor compression refrigeration system The main components of the system are the 1 reciprocating compressor 2 air cooled condenser 3 expansion valve and 4 direct expansion evaporator See Figure 7 13 or Figure 7 14 The compressor raises the pressure and the temperature of the refrigerant and forces it into the condenser tubes T
4. 8 42 8 31 Unidrive Torque Requirements 8 44 SSL Drive Gear 22 oca As a 8 44 Section 8 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 CAUTION Unit with R404A and POE oil the use of inert gas brazing procedures is mandatory otherwise compressor failure will occur For more information see Technical Procedure 98 50553 00 Inert Gas Brazing NOTE To avoid damage to the earth s ozone layer use a refrigerant recovery system whenever removing refrigerant When working with refrigerants you must comply with all local government environmental laws U S A EPA section 608 8 1 Maintenance Schedule UNIT ene a Daily Maintenance X 1 Pre Trip Inspection Check X 2 Check engine hours and hours to engine maintenance Check b Every 1500 Hour or Annual Maintenance Other hour intervals may apply See Section 7 2 Perform 1500 hour Preventive Maintenance Inspection Form 62 02522 01 Refer to Section 7 2 for oil change intervals Tighten engine compressor and unit mounting bolts Tighten all electrical connection in control box Calibrate defrost air switch Clean air cleaner check hose and connections Check water pum
5. 1 D CLHR RR SR SPK7 I 5 REMS2 05 5 05 05 HPS SPKS 9 2 20 2 2 WHT 1 SP24 9 B TA 2MP19 CRED 55 _ 5 coco 0 ENCLSC 0152 D GRN ENOPS 2 EA an PCMCIA TO HC9 102 2MP10 S C aen SPK4 2 ECXV GOLD 9 2MP34 GCS ULTIMA GOLD SPK4 2n E LOCATED IN ENGINE HARNESS CSP Gla ae rap 2MP12 TET z SMPAS AO ee aoa O S To LHCS f T0 2 25 7 2MP23 2MP35 x 321 CONTROL BOX B B GPR SSR 2 5 3MP33 3MP09 20 3MP32 9 55 Cect 3MP19 SFI3 12 eae 23 3MP11 1 EVIA 3MP22 2 2 F6B B1 LB G I 9 OUTPUT POWER y HCS SPK3 SPK3 SP
6. 8 10 8 0 3 Alternator V Belt 8 11 8 6 4 Driveshaft to Gearbox and Gearbox To Fan Shaft V Belt 8 11 8 7 Gearbox Clutch Ultra Ultra XL amp 8 13 8 8 Replacing Condenser Evaporator Fan Shaft or Bearing Ultra Ultra XL amp 8 14 8 9 Replacing Condenser Evaporator Fan Shaft or Fan Clutch Ultima ess iaae a E 8 16 8 10 Pumping Unit Down or Removing Refrigerant Charge 8 18 8 11 Refrigerant Leak 8 19 8 12 Evacuation and Dehydration 8 19 8 2 1 General te si et cane ERA eee eee VETE 8 19 8 12 2 8 19 8 12 3 Procedure for Evacuation and Dehydrating System 8 19 8 13 Adding Refrigerant to 8 21 8 13 1 Full Charge R 22 404 8 21 8 13 2 Partial Charge Using Vapor R 22 Only 8 21 8 13 3 Partial Charge Using Liquid R 22 or 404 8 21 8 14 Replacing the 8 23 8 15 Checking Compressor Oil 8 25 8 16 Compressor Unloader Valve 8 27 8 17 Servicing Check Valve Serviceable Type 8 28 8 18 Checking and Replacing 8 29
7. HEAT DEFROST ALARM START STOP CONTINUOUS 988 8 9898 SETPOINT BOX TEMPERATURE PRESS 1 TO VIEW SETTINGS FUNCTION CHANGE 2 1 Press the SELECT key until FUNCTION CHANGE is lit The Message Center will show PRESS 1 TO VIEW SETTINGS 2 Press the 1 UP ARROW key or the DOWN ARROW key until SET PM HOURMETERS is displayed Press ENTER key ft TO SCROLL THEN TO SELECT will show in the Message Center Press UP DOWN ARROW key until the Hourmeter you wish to reset is shown Press ENTER key to select Press 1 UP or DOWN ARROW keys until RESET is shown Press ENTER key to save Repeat steps 3 7 to Reset additional PM Hourmeters OND FW NOTE First the Hourmeters must be configured on Refer to Section 2 17 1 PM Preventative Maintenance Hourmeters are provided to track unit operation and to notify the user when periodic preventative maintenance is due Within the Advance Microprocessor there are seven 7 PM Hourmeters available for use Engine Switch On 5 programmable Hourmeters 2 41 62 10285 Section 2 Operation The programmable PM Hourmeters PM1 PMS which can be configured to count any of the following Engine Hours Switch On Hours Clutch Cycles e Start Cycles High Speed Hours The PM Hourmeters are activated and the reset interval is selected from the Configuration List To turn on t
8. 2 CLHR RR D 5 7 REMS2 lt 6MP6 DS SPK OHDS A 05 8 SPKS re 2 20 2 2 5 24 9 BTA 2 19 CSMV GOLD ENOPS TO ENCLSC J15 7 TO HC9 K10 ENRPM ex 2MP21 gt 2MP33 ECXV GOLD 2 9 321 2MP34 NTR X CCS CONTROL BO 2MP23 ULTIMA GOLD 2 5 2 11 EVXV GOLD 2MP22 2 12 5 Lj SPK1 EVOP HCS GOLD ee ODO 0 9 TO 2MP25 E7 SSR FHR PCMCIA LOCATED IN ENGINE HARNESS CECP 5 T0 12 GOLD P2 3MP33 B 3MPOS 3 GOLD CST 20 OUTPUT POWER 3MP32 C1 GOLD CEVOT GOLD CECT 3MP19 HCS 3MP12 1 A 3MP23 gj 5 11 pm EVIA 3MP22 DTT2 SPK3 SPK3 SPK2 PK2 NOT 5 2 GOLD T3 5 2 PCMCIA
9. SETPOINT BO TEMP ERATURE STA RT RUN D OFF 1 Hold GLOW CRANK switch in the GLOW position toggle towards trailer for Ultima toggle down for Ultra Ultra XL amp Extra 2 Place START RUN OFF switch to the START RUN position m 3 Continue to hold GLOW CRANK switch in the GLOW d position for up to 55 seconds based on the Ambient Temperature table below m 4 Then crank the engine by holding the GLOW CRANK switch in the Back side of Control Box CRANK position for up to 10 seconds to start the diesel engine WARNING Under no circumstances should ether or any other starting aids be used to start engine The diesel engine may be manually started using the GLOW CRANK switch and the START RUN OFF switch When the micro powers up MANUAL START MODE SELECTED will appear in the Message Center and the Alarm LED will blink for 5 seconds NOTE Manual Start will automatically put the unit in Continuous Run mode Placing the unit in Start Stop will automatically put it back into Auto Start operation Manual Start Mode will automatically be cancelled when the Start Run Off switch is turned off them back to Start Run Glow Time in Seconds Sh Long 33 F to 50 F 1 C to 10 C 51 F to 77 F 11 C to 25 C Greater than
10. TA J 2 RELAY TEMP SWITCH OPTIONAL T LIGHT BAR WITCH 3 DAN D CRANK SWITCH wo 20 LAY RENT PLUG 1 OVVYOIMV YO nA r HT LIGHT BAR 6 SSURE CUT OUT SWITCH N C 5 UMPER 3 HT BAR ROPROCESSOR BOARD ICROPROCESSOR QUICKCONNECT OUT OF RANGE LIGHT LIGHT BAR RETURN AIR TEMPERATURE REMOTE SWITCH REMOTE SENSOR RUN RELAY SUPPLY AIR TEMPERATURE SATELLITE COMMUNICATION SPEED CONTROL SOLENOID SERIAL PORT STARTER MOTOR SPLICE POINT I J C 1 J C C C H C 2 6 J2 L2 2 02 6 09 010 D11 D15 M14 J11 J16 0 15 17 3 B6 D8 D10 L11 L13 M14 M16 H1S B3 C0 C0 CO CO CO C ZU Z0 ZU 20 CO U A SPLICE PAC SPEED RELAY START RUN OFF SWI TCH STARTER SOLENOID STARTER SOLENOID CONTACTOR STARTER SOLENOID RELAY SOLENOID VALVE UNLOADER o lt OU000C0 22 22 DO 2 0 K16 3 2 10 9 62 10285 Index A Air Switch 7 14 8 40 Alarms amp Default Messages 2 20 Alternator 7 20 Alternator V Belt 8 11 Auto Start Sequence 4 1 Battery Voltage 4 4 Belt tension Gauge 8 10 C Changing Setpoint 2 4 Check Valve 8 28 Clutch Gearbox V Belt 8 12 Component Description and Location 3 1 Component Test Mode 2 37 Compressor 8 23 Compressor Data 7 13 Compressor Discharge Pressure Transducer
11. 9 7 SECTION 9 TROUBLESHOOTING CAUTION Under no circumstances should anyone attempt to service the Advance Microprocessor Should a problem develop with the Advance Microprocessor contact your nearest Carrier Transicold dealer for replacement INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 9 1 DIESEL ENGINE 9 1 1 Engine Will Not Start Starter motor will not Battery insufficiently charged Check crank or low cranking speed Battery terminal post dirty or defective Check Bad electrical connections at starter Check Starter motor malfunctions 9 1 3 Starter motor solenoid defective Engine Manual Open starting circuit 9 1 4 Incorrect grade of lubricating oil Starter motor cranks but engine fails to start Starter cranks engages but dies after a few seconds Unloaders not unloaded No fuel in tank Air in fuel system Water in fuel system Plugged fuel filter s Plugged fuel lines to injector s Fuel control operation erratic Glow plug s defective Fuel solenoid defective Fuel pump FP malfunction Engine lube oil too heavy Voltage drop in battery cable s 9 1 2 Engine Starts Then Stops Engine stops after several rotations Fuel supply restricted 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 Fuel solenoid defective Fuel pump FP malfunctio
12. USURIS RU EXTRA with Advance Microprocessor E SAEI WARNING Beware of V belts and belt driven components as the unit may start automatically Before servicing unit make sure the Start Run Stop switch is in the STOP position Also disconnect the negative battery cable The unit is a one piece self contained fully charged pre wired refrigeration heating nosemount diesel powered unit for use on insulated trailers to maintain cargo temperatures within very close limits The model serial number plate is located inside of the unit on the rear frame as shown in Figure 7 2 The evaporator fits into a rectangular opening in the upper portion of the trailer front wall When installed the evaporator section is located inside the trailer and the condensing section is outside and on the front of the trailer The condensing unit consists of an engine compressor drive package condenser fan condenser radiator coil Ultima or condenser coil radiator Ultra Ultra XL amp Extra control panel refrigerant controls piping wiring defrost air switch and associated components The evaporator assembly consists of an evaporator coil evaporator blower wheel expansion valve Return Air Temperature sensor RAT Supply Air Temperature sensor SAT and two Defrost Termination Temperature se
13. EVIB Teri 3MP34 SPK2 CONTROL BOX EV2B 3MP18 SPK3 L ULTRA ULTRA XL EXTRA EV2A 1 SP24 ae 5 24 FET LEGEND C SP12 1 FSH A FSC CHO SPK6 AUTO RESTART LIGHT FET 8 HEAT LIGHT EZ reper FET 5 4 CONTROL FET 10 5V1 CONTROL FET 12 FUEL HEATER RELAY SPkG 14 FAULT LIGHT 0 2MP15 E5 FET 15 OUT OF RANGE LIGHT A B FET DEFROST LIGHT 5 24 COOL LIGHT SP23 TO 2MPO4 E41 FET BUZZER RELAY POWER o FET 5V3 CONTROL SPKE A FET SV2 CONTROL NOT GOLD pace 3 55 FET UNLOADER 2 CONTROL FET UNLOADER 1 CONTROL SAT RAT AAT REMSN REMSN REMSN2 REMSN2 REMSN3 REMSN3 1921 30 87 ENG BLOCK GRD 20A Schematic 62 10499 00 Rev B 62 10285 10 4 ZONE SPLICE PACK INDICATES A SOLDERED SPLICE POINT PIN CONNECTION COMPONENT CONNECTION NUMBER OR LETTER NORMALLY C NORMALLY 0 INDICATES MULTIPLE LOSED CONTACTS PEN CONTACTS CONNECTION LUG CONNECTION NU SWITCH SYMBOL INDICATES MOMENTARY CONTACTS INDICATES A WIRE GROUND INDICATES A CHASSIS GROUND NO WIRE INDICATES A
14. Check voltage at microprocessor a Check voltage reading at Run Stop switch ON Manual Start Mode See Note 2 microprocessor input QC1 to QC2 Must be below 17 VDC b Check voltage reading on Must be within 5 VDC of reading obtained in 3a above microprocessor display 62 10285 5 10 Section 5 Alarm Troubleshooting ALARM CAUSE CORRECTIVE ACTION BATTERY VOLTAGE TOO LOW TRIGGER ON Voltage at the microprocessor is less than 10 VDC except when the engine starter is engaged UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset after 15 minutes when the voltage at the microprocessor is between 11 14 VDC or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for Alternator Not Charging Alarm a Check for alarm 51 Alarm conditions must be corrected and the alarm cleared to continue Check battery voltage a Inspect battery cable ends and posts Must be clean and tight b Test voltage at battery with unit off Must be above 11 VDC Test voltage at battery with unit Must be above 11 VDC running d Test specific gravity of b
15. Check SV 2 amp circuit a Inspect SV 2 and wiring No damage or corrosion Connector fits together tightly no moisture inside b Check operation of SV 2 FET 21 Run Stop switch in Run Manual Start Operation See Note 2 LED must be ON c Check voltage to SV 2 Must be 11 VDC or higher across the 2 wires Check SV 2 circuit wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Check SV 2 a Check resistance of SV 2 Refer to Section 7 8 b Check amp draw of SV2 Use Component Test Mode Section 2 17 3 to test Refer to Section 7 8 for amp values HIGH SUCTION PRESSURE TRIGGER ON This alarm is generated during Test 4 of Cool PreTrip Suction pressure is higher than normal UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for Check SV3 alarm a Check for alarm P183 Alarm conditions must be corrected and the alarm cleared to continue Check for Check SV4 alarm a Check for alarm P181
16. alarm list is available for you to look at any active or inactive alarms The Select key will only allow access to the Data List The and keys will allow you to scroll through the Alarm and Data Lists The following cycles are available in Diagnostic Mode Diagnostic Mode Menu Message Center COOL HIGH SPEED UNLOADED COOL REMAINING XX MINS HEAT HIGH SPEED UL1 UNLOADED HEAT REMAINING XX MINS DEFROST DEFROST CYCLE STARTED See notes 2 amp 3 below CANNOT START DEFROST CYCLE PULSED COOL LOW SPEED UNLOADED NULL COOL REMAINING XX MINS PULSED HEAT LOW SPEED UNLOADED NULL HEAT REMAINING XX MINS MAIN MENU To access Component Test Mode or Configuration Mode NOTES 1 In each of the Pulsed Modes each 10 second segment will consist of either cool or heat mode for 5 seconds then null for 5 seconds 2 The unit must be running before Defrost can be started All other modes will start the unit automatically To start Defrost first select another Test Mode After the unit has started and UNIT STARTING has cleared from the Message Center press to abort stop the cycle The unit will continue to run and the Message Center will go to the Diagnostic Mode Main Menu From the Main Menu use the 1 keys to select Defrost then press to start the Defrost cycle 3 The Defrost Mode is controlled by the Defrost Termination Temperature Sensors DTTs If both of the DTTs are above 40 F 4 4 C the unit will not st
17. Alarm 239 is cleared 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION HOUR METER ERROR TRIGGER ON There is an error in the number of hours in memory for one or more of the system Hour Meters UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset when valid hours are read for all Hour Meters or Alarm may be manually reset by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Hour Meters a Check Hour Meters must read valid values Reset Microprocessor a Turn Start Run Off switch off for 30 Microprocessor powers up OK seconds then turn back on b Checkfor valid Hour Meter readings in All hour meters show valid numbers Data List Alarm is cleared c Valid Hour Meter readings can not be Replace Microprocessor entered See Note 1 a Clear the inactive fault code Alarm 240 is cleared ALARM STATUS ERROR TRIGGER ON There is an error in an Alarm that is stored in the Microprocessor memory UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Alarm may be manually reset via Keypad or by turning the unit off then back on again NO
18. Section 6 Message Center and Alarms This section describes all the messages and alarms which can be displayed on the Messages Center Section 7 Unit Description This section describes the units listed in the Model Chart Table 7 1 Section 8 Service This section describes the service procedures for the unit Section 9 Troubleshooting This section provides information on the probable causes for unit troubleshooting Section 10 Electrical Schematic Wiring Diagrams This section contains Electrical Schematic Wiring Diagrams for the models covered in this book Section 1 Safety Precautions 1 1 Safety Precautions 1 1 17 Decals iuo teach Sade ev aah 1 2 Section 1 Safety Precautions 1 1 Safety Precautions Your Carrier Transicold refrigeration unit has been designed with the safety of the operator in mind During normal operation all moving parts are fully enclosed to help prevent injury During all pre trip inspections daily inspections and problem troubleshooting you may be exposed to moving parts please stay clear of all moving parts when the unit is in operation and when the unit main power switch is in the START RUN 1 position CAUTION Under no circumstances should anyone attempt to repair the Logic or Display Boards Should a problem develop with these component contact your nearest Carrier Transicold dealer for replacement CAUTION Under
19. Selectable Unit Model Number Changed Selectable Unit Mode Start Stop Continuous Run Selectable e Control Mode Heat Cool Defrost etc Selectable e Door Opened Closed Selectable Transducer Calibration Selectable The following Events will be recorded e Set Point Changed Fixed ES ee EK Fixed e Defrost Started essi ede n Fixed By Keypad By Air Switch By Timer e Functional Parameter Changes Fixed e Configuration Changes Fixed Data Recorder Setup Changes Fixed e Start Run Off Switch turned to Run Fixed e Start Run Off Switch turned to Off Fixed e Data Download Fixed e Software Upgrade Fixed e Real Time Clock Changes Fixed 3 4 4 Optional Sensors amp Events In addition to the above Sensors and Events the Advance DataLink Data Recorder also has the capabilities to record the following e Remote Temperature Sensor 1 e Remote Temperature Sensor 2 e Remote Temperature Sensor 3 e Remote Switch 1 e Remote Switch 2 Fuel Tank Level 62 10285 3 6 Section 3 System Description 3 4 5 Data Downloading The data within the Data Recorder can be downloaded by either the Data Manager Program using a PC and a Serial D
20. 3 B co qoj o Pod Fed Pd SIs w Qo BRIN 2 ng o 5 S gt S t 8 46 Tem _ spre s oar 729 spen 10 sf es pus 2502 1787 37 272 4 19 15 18 291 6 20 50 21 92 2150 2341 2296 of 2496 2448 Qo aio 4 Bo alz B DISINI 5 E IN A o gt 3 Section 8 Service Table 8 5 R 22 Pressure Temperature Chart Fag 0 8 69 4 16 8 1 8 6 3 1 9 8 7 3 1 4 04 3 16 3 29 3 42 3 49 3 57 3 65 10 3 72 2 81 2 2 2 2 2 2 2 1 1 12 10 2 4 1 1 1 ES v o BIO O O M KR a Mm a 45 a2 2 o ss 4 339 2 0 2 4 0 2 4 6 8 0 2 2 2 2 2 3 3 Temperature 631 7 07 7 6 816 126 8 8 74 135 7 9 36 145 10 0 154 7 10 67 164 9 11 37 175 4 12 09 186 5 12 86 197 9 13 64 09 9 14 47 22 3 15 33 35 2 16 22 48 7 17 15 62 6 18 11 77 0 19 10 91 8 20 12 07 1 21 17 23 6 22 31 41 3 23 53 59 4 24 78 77 9 26 06 96 6 27 34 415 6 28 65 434 6 29 96 60 5 63 3 66 1 417 4 36 4 56 4 76 5 17 5 61 6 07 0
21. Keypad or by turning the RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check wiring to DPT amp SPT a Verify that correct wires are connected to each transducer Plugs to transducers are the same The correct wire plug must be connected to the proper transducer Check system pressures a Check and compare compressor discharge amp suction pressures with those shown on the microprocessor controller Suction amp Discharge Pressures must have the same reading 5 psig on gauges amp on micro display Check for Check SV2 Circuit Alarm a Check for alarm 97 or P192 Alarm conditions must be corrected and the alarm cleared to continue Check for Check UL1 alarm a Check for alarm 85 or P144 Alarm conditions must be corrected and the alarm cleared to continue Check UL1 operation Unit must be runnin g See Note 7 a Energize UL1 coil b De energize UL1 coil Suction pressure must raise slightly Discharge pressure must drop slightly Suction pressure must drop slightly Discharge pressure must raise slightly Check for Check UL2
22. Recorded data can also be downloaded from the Microprocessor through the PC card slot Data downloading is automatic unless there is an error The Microprocessor will recognize that there is a DataShare Download PC Card present and automatically download copy all data from the Data Recorder to the PC Download Card Data must then be downloaded off the PC Download Card onto a computer drive before it can be viewed 62 10285 2 38 Section 2 Operation 2 19 Installing New Software TIP Whenever performing a major operation to a Microprocessor such as installing new operating software it is always a good idea to start the unit and give it a quick check over prior to performing the operation 2 19 1 Using the DataShare Program PC Card 1 3 Place the Micro in PC Mode See Section 2 16 or turn the SROS switch to the Run Position Insert a DataShare Program Card into the PC card slot on the front of the Microprocessor Be certain that the instruction label is facing the Caution label Do not force card into slot If the current software version is prior to 01 06 00 after a few seconds the Message Center will go blank If the engine is running it will shut down Then the green PC CARD STATUS LED and MICRO STATUS LED will flash together at the rate of 5 seconds 5 seconds off Both LEDs will blink 2 3 times then stop Blinking will resume within 10 seconds Both LEDs will continue to blink together
23. 5 83 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION MICRO SW REV ERROR TRIGGER ON There is an error in the Microprocessor Revision Number that is stored in the Microprocessor memory NOTE This alarm may be present after new software is programmed into the controller UNIT CONTROL Alarm Only RESET CONDITION Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Microprocessor Software Revision a Check Microprocessor Software Must be a valid number Revision Reset Microprocessor a Turn Start Run Off switch off for 30 Microprocessor powers up OK seconds then turn back on See Note 1 a Clear the inactive fault code Alarm 245 is cleared EEPROM WRITE FAILURE TRIGGER ON There is an error in the ability to write information to be stored in the memory UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through th
24. 62 10285 5 48 Section 5 Alarm Troubleshooting ALARM CAUSE CHK REMOTE TEMP SENSOR 2 the temperature as 52 6 F UNIT CONTROL Alarm only CORRECTIVE ACTION Remote Temperature Sensor 2 circuit is configured on and has failed open or shorted If shorted the data list will display 158 F 70 C If the circuit is open the data list will show 47 C RESET CONDITION Auto Reset when Remote Temperature Sensor 2 is in range or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found On should clear itself see reset condition above Operate the alarm occurs Continue with the steps below as necessary ce a repair or correction has been made the active alarm unit through the appropriate modes to see if any active 1 Check Remote Temperature Sensor 2 a Verify that Remote Temperature Sensor 2 has been installed and is correctly wired to the unit Remote Temperature Sensor 2 is installed Wires are connected to 10 pin connector at cavities G amp H If sensor is not present change micro configuration to OFF Check Remote Temperature Sensor 2 a Inspect Remote Temperature Sensor 2 amp connector b Check Remote Temperature Sensor 2 resistance See Note 4 No damage to sensor No damage moisture or corrosion in connector Refer to Section 8 30 for complete resistance chart 10 000 Ohms
25. 62 10499 03 Rev E UNITS WITH J 1 JUMPER 62 10285 10 8 ZONE SPLICE PACK SWITCH SYMBOL INDICATES MOMENTARY CONTACTS INDICATES A SOLDERED SPLICE POINT INDICATES A WIRE GROUND PIN CONNECTION COMPONENT CONNECTION NUMBER OR LETTER INDICATES A CHASSIS GROUND NO WIRE INDICATES A CONNECTION 06 NORMALLY CLOSED CONTACTS NORMALLY OPEN CONTACTS INDICATES CONNECTION MULTIPLE PLUG CONNECTION NUMBER N e NE SYMBOL DESCRIPTION AAT AMBIENT AIR TEMPERATURE ALT ALTERNATOR ARL RESTART LIGHT LIGHT BAR B R BTY RY CDP RESSOR DISCHARGE PRESSURE CDT 550 DISCHARGE TEMPERATURE CECT ESSOR ECONOMIZER TEMPERATURE GOLD R T CECP ESSOR ECONOMIZER PRESSURE GOLD CL LIGHT LIGHT BAR CLH H CLHR H RELAY CSP ESSOR SUCTION PRESSURE ESSOR SUCTION ODULATION VALVE GOLD ESSOR SUCTION TEMPERATURE GOLD T TRANSFORMER ST AIR SWITCH ST LIGHT LIGHT BAR SWITCH ST TERMINATION TEMPERATURE IZER EXPANSION VALVE GOLD NE COOLANT LEVEL SWITCH OLANT TEMPERATURE L LEVEL SWITCH L PRESSURE SWITCH N 0 00007Axoco090 1 120 ENGINE EVAPORATOR PLUG EVAPORATOR OUTLET PRESSURE GOLD EVAPORATOR OUTLET TEMPERATURE GOLD EVAPORATOR EXPANSION VALVE GOLD FUSE MP 7 5 AMPERE FUSE SR 10 AMPERE FUSE RR 7 5 AMPERED FUSE CLHR 7 5 PERE FUSE FUSE O AMPERE FUSE UL 15 AMPERE 5 AMPERE HR 20 AMPERE LB 3 AMPERE HEATER EATE
26. TO FLSC 1151 GRN DISPLAY 6 4 KEYPAD A C SPK lt gt REMS1 lt 5 BRN KS S 5 m CLHR SR 52 lt 1 R PCMCIA GDS 23 EB ie a YEL HPS A BLR SPK5 2MP20 2 2 WHT 1B 1A B 5 24 BLA 2 19 L CSMV GOLD ENOPS TO ENCLSC 151 D GRN 28 2A ORG A 2 TO HC9 K10 2MP10 C 233 2 9 2MP34 2 23 2MP35 2MP11 2 22 2MP 12 5MPA9 HC6 B3 S TO SMPAI E3 ET MPac9 9 HC8 e T0 2MP25 E7 WHT ECXV GOLD MP C B D E 321 Re CONTROL BOX C B D ULTIMA GOLD LOCATED IN ENGINE HARNESS EVXV GOLD GPR SSR FHR SP2 GOLD 5 21 SMPA8 gt TO 11 3MP33 LB G B 9 B 3 2 6 5 1 GOLD CST 3MP20 OUTPUT 3 5 POWER 3MP32 C1 9
27. TRIGGER ON Engine is turning more than 500 RPM for 20 seconds after unit shut down or cycled off or Oil Pressure Switch is closed longer than 20 seconds after unit shut down or cycle off UNIT CONTROL Alarm Only RESET CONDITION Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for engine running a Verify that engine is still running Engine should not be running Check for Bad Engine RPM Sensor alarm a Check for alarm 130 Alarm conditions must be corrected and the alarm cleared to continue Check engine oil pressure switch a Inspect switch amp connector pins amp No physical damage to switch terminals No damaged or corroded pins in plug b Check engine oil switch operation Contacts closed when oil pressure is above 15 psig Contacts open when oil pressure is below 12 psig Check engine oil switch harness a Inspect harness amp control box physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Check for shorted circuit in harness Run Stop switch ON Manual Start Mode See Note 2 and continuity through the harness
28. This will appear for 5 seconds then return to the last Functional Parameter shown Ifno further keys are pressed the default display will return in another 10 seconds 2 25 62 10285 FUNCTIONAL PARAMETER DEFROST TIMER SET FOR SELECTIONS 1 5HRS 3HRS 6HRS 12HRS Section 2 Operation DESCRIPTION The defrost timer will automatically put the unit into the defrost cycle at the interval selected If evaporator is below 40 F Shorter times are generally used for warm humid products like produce Longer times can be used for dry and frozen products SET S S PARAMETERS These may be displayed individually 8 parameters as PERISH and FROZEN or combined 4 parameters with no designation Time and Temperature values that control the Automatic Start Stop operation are set in this section PERISH FROZEN MIN RUN TIME 4MINS TO 60MINS in 1 minute increments This determines the minimum length of time the unit will run every time the unit starts in Perishable or Frozen or both Auto Start Stop Modes e PERISH FROZEN MIN OFF TIME 10MINS TO 90MINS 20MINS default in 1 minute increments This determines the minimum length of time the unit will remain off whenever the unit cycles off in Perishable or Frozen or both Auto Start Stop Modes e PERISH FROZEN OVERRIDE TEMP 3 5 F 2 C TO 18 F 10 C 11 F 6 C default in 0 5 degree increm
29. 988 8 9898 SETPOINT BOX TEMPERATURE NO INACTIVE ALARMS MANUAL ALARM LIST STAR STOR SELECT USJ LA 1 Press hold both the ALARM LIST key and the UP ARROW key for 6 seconds If there are no inactive alarms the display will say NO INACTIVE ALARMS for 5 seconds 2 If there are inactive alarms the display will be I and the alarm number and message 3 Press the ALARM LIST or UP or DOWN key to scroll through the list of alarms 4 When you reach the end of the alarm list LIST END TO CLEAR ALARMS is displayed for 5 seconds 5 To clear the active and inactive alarm list press the key while LIST END TO CLEAR ALARMS is being displayed ALL ALARMS CLEAR is displayed The Microprocessor can hold up to 16 alarms within the Active and Inactive Alarm Lists combined The list can be read via the Message Center or using the PC Service Tool There are 2 sections in the Alarm List an Active Alarm Section and Inactive Alarm Section Alarms in these sections are in the order in which the alarms activate and deactivate respectively On startup all alarms are marked as inactive in the entire list If an inactive alarm becomes active the alarm is moved from the Inactive Alarm List section to the Active Alarm List section As additional alarms occur they will be placed first in the Active Alarm List An alarm can not be active and inactive at the same time Each alarm can only be present in either the
30. CHECK LOW SPEED RPM TRIGGER ON in Test 7 With Speed Relay turned off speed solenoid de energized engine RPMs are _ NOT Between 1375 and 1600 for Ultima or Between 1275 and 1500 for Ultra or or Ultra X L or Extra TRIGGER ON in Test 9 15 seconds after the High Speed Test engine RPMs have NOT dropped from the high speed RPMs in Test 8 by Between 450 and 925 for Ultima or Between 350 and 725 for Ultra or Ultra X L or Between 150 and 525 for Extra UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check speed solenoid amp linkage a Check speed solenoid plunger b Check engine speed arm amp linkage Force Low Speed operation See note 7 Must move in and out freely Must move freely a Turn unit OFF wait 10 seconds then turn ON Set for Start Stop operation b Check operation of Speed Relay LED c Check voltage to speed solenoid Controller will call for Low Speed operation for the next 10 minutes LED 27 must be OFF Must be 0 VDC Check engine RPMs a Check actual engine RPM using hand held tachometer
31. ET SEAT ONTO SHAFT 19 TOP INTERNAL HEX HD COIL FILL CURB SIDE INTERNAL HEX HD LEVEL VIEW B B ORIENTATION OF ACCESS PORTS 15 VIEW A A uw A T 17 16 8E e o b z a Bx 1 Fi 2 11 4 2 T 14 12 MOUNTING SURFACE 10 VERTICAL FRAME MEMBER 13 8 1 Screw Hex Head 1 4 20 X 110 8 Special Washer 2 Lock Washer 1 4 9 Retainer Washer 3 Condenser Fan 10 Clutch 4 Adapter 11 Special Washer 5 Screw Hex Head 5 16 18 X 110 12 Screw Hex Head 3 8 16 X 1 5lg 6 Lock Washer 5 16 13 Lock Washer 3 8 7 Screw Hex Head 3 8 16 X 119 14 Special Washer 15 Plate 16 Pressure Relief Valve 17 Bearing Housing 18 Clip 19 Screw Hex Head 10 32 X 25lg Figure 8 13 Evaporator Condenser Fan Shaft Assembly Ultima 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 OFF position Also disconnect the negative battery cable a To Remove the Clutch See Figure 8 13 NOTE The air gap between the clutch contact surfaces is non adjustable The original air gap is set to 0 020 and can wear up to 0 040 before replacement is needed 1 Disconnect the
32. Engine Coolant Temperature The unit will not cycle off if the engine coolant temperature is less than 122 F 50 C If the unit can not cycle off it will operate as if in Continuous Run mode The engine coolant temperature will override the minimum off time and out of range condition to force engine restarting when the engine coolant temperature drops below 34 F 1 C Battery Voltage Provisions are made to sense when the battery charge is good A good battery is defined as having 13 4 Vdc at 75 F and the charging rate is below that selected in the Configuration List This condition is used to allow cycle off of the engine Battery Voltages Voltage Level 10 Vdc or Less Description Unit will shut down except during cranking If the unit has cycled off in Start Stop mode and battery voltage drops below 11 0 volts the unit is automatically started to charge battery Unit will operate until the battery voltage is high enough to allow unit to cycle off provided that all other conditions required for an off cycle are met When battery voltage is above minimum limits O K will appear in the Message Center right after the voltage in the Unit Data list 11 to 13 4 17 4 3 Continuous Run Operation In the Continuous Run mode the engine will not shut down except for safeties or if the engine stalls Continuous Run operation is normally used for fresh produce and other sensiti
33. NO All Functional Parameters in the function list can be changed using the keypad unless individually locked out by Service Tool 62 10285 2 30 Section 2 Operation CONFIGURATION DESCRIPTION SELECTIONS DESCRIPTION RPM ALARM SHUTDOWN YES NO YES If alarm 39 Check Engine RPM is active turn the alarm light on and shut the engine off NO If alarm 39 Check Engine RPM is active turn the alarm light on and allow the unit to continue to run LOW PRESSURE SHUTDOWN YES NO YES When low refrigerant pressure is sensed in the system alarm 18 is active turn the alarm light on and shut the unit down after the time delay in the following selection NO When low refrigerant pressure is sensed in the system alarm 18 is active turn the alarm light on and the unit will continue to run LP SHUTDOWN DELAY 120SECS After the Low Pressure signal is received how long shall 0 255 seconds the unit continue to run before it is shut down HIGH SUCT PRESS SHUTDOWN YES NO YES If the unit is running and the suction pressure rises to 98 psig or higher for 10 minutes alarm 27 is active the unit will shut down NO High suction pressure will not shut down the unit REFRIGERATION SYS YES NO YES When the unit is running and the discharge SHUTDOWN pressure is not at least 5 psig higher than the suction pressure alarm 28 is active shut the unit down NO When the unit is running do not shut the unit down if th
34. RESET CONDITION Auto Reset when Defrost light current amp draw is normal or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Defrost light a Inspect Defrost light amp socket No damage to solenoid No damaged or corroded pins b Check resistance of light bulb Refer to Section 7 8 Check Defrost light wiring a Inspect harness amp control box See Notes 2 amp 6 connector pins amp terminals See No physical damage to harness wiring schematic No damaged or corroded pins Check Defrost light current draw a Use Component Test Mode Refer to Refer to Section 7 8 for normal current values Section 2 17 3 to test actual current draw of the circuit CHECK REMOTE ALARM LIGHT TRIGGER ON Remote Alarm light Driver s Light Bar circuit is shorted The Alarm Light output from the Micro is negative so the circuit will not be shorted to ground but is shorted either within the Alarm Light itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when Alarm light current amp draw is normal or Alarm may be manually reset via Keypad or by turning the unit off then back o
35. TO VIEW SETTINGS FUNCTION CHANGE MANUAL ALARM LIST 5 SELECT anes 1 Press the SELECT key until FUNCTION CHANGE is lit The Message Center will show PRESS 1 TO VIEW SETTINGS 2 By pressing the 1 UP ARROW key you will move through the Function List beginning at the top or by pressing the DOWN ARROW key you will move through the Function List beginning at the bottom 3 To change one of the Functions bring the Function you wish to change into the Message Center and press ENTER key 1 TO SCROLL THEN TO SAVE will show in the Message Center Pressing either 1 UP DOWN ARROW key will begin to change the Function setting The Message Center will flash indicating that a change has been made that has not been entered into memory 4 Continue pressing 1 UP or DOWN ARROW key until the desired value is showing then press the ENTER key The Message Center will stop flashing The new value is now in memory If the key is not pressed within 10 seconds the Message Center will change to FUNCTION NOT CHANGED This will appear for 5 seconds then return to the last Functional Parameter shown If no further keys are pressed the default display will return in another 10 seconds 62 10285 2 24 Section 2 Operation Functional Change Parameters To view or change any of the Functional Parameters for the Microprocessor 1 Press the SELECT Key until Function Change is highlighted
36. Trailer Refrigeration Wei jaa 22000515535 Or e 09829999951 wo wem Bier pwa wes un OPERATION amp SERVICE for ULTIMA 53 PHOENIX ULTRA AND EXTRA with Advance Microprocessor Prior to S Ns Beginning with HAY 62 10285 Rev D TRANSICOLD OPERATION AND SERVICE MANUAL TRAILER REFRIGERATION UNIT Ultima 53 NDX 93M Phoenix Ultra NDA 93A 94A Phoenix Ultra XL NDA 93M 94M Extra NDA 93E 94E NDA 93N 94N with Advance Microprocessor Prior To S Ns Beginning With HAY How to use this manual Please take a few minutes to read this page It explains the content and structure of this manual This will make it easier for you to find the information that you need Section 1 Safety Precautions This section contains the Safety Precautions Safety Decals and Microprocessor cautions Read this section before working on the unit Section 2 Operation This section shows you how to configure and operate the Carrier Advance Microprocessor controller Section 3 System Description This section describes the components of the control system special control features and options Section 4 Engine and Temperature Control This section describes the engine and temperature control Section 5 Alarm Troubleshooting This section provides information on the probable causes of the alarm codes given by the microprocessor controller
37. amp DTT2 are 55 F 12 8 C or above software versions prior to 01 06 00 or DTT1is above 45 F 7 2 C and DTT2 is above 55 F 12 8 C software versions 01 06 00 and later Should the defrost cycle not complete within 45 minutes the defrost cycle will be terminated after 45 minutes and DEFROST NOT COMPLETE will be in the Message Center The Microprocessor will initiate another Defrost Cycle in 1 5 hours Pressing the manual defrost key will override this mode and start a defrost cycle If a shutdown alarm occurs defrost will be terminated In the event that one of the DTT sensors fails the unit will disregard that DTT sensor and use only the remaining DTT sensor to determine the 40 F 4 4 C requirement to begin a defrost cycle and the 45 F 7 2 C or 55 F 12 8 C temperature at which the defrost cycle will terminate Ifboth DTT sensors fail the unit may be put into defrost at any temperature and the defrost cycle will terminate at the end of 20 minutes 62 10285 2 10 Section 2 Operation 2 8 2 Automatic Defrost The defrost mode may be automatically initiated by either or two devices Defrost Timer Defrost Air Differential Switch a Defrost Initiation Timer The Defrost Timer is set in the Functional Parameter List Refer to Section 2 15 The Defrost Timer may be set for 1 5 3 0 6 0 or 12 0 hour intervals When the correct amount of time has elapsed a defrost cycle will be initiated providing
38. b Compare actual RPMs with those shown on display Refer to Section 7 2 Adjust engine linkage setting as needed Both readings within 50 RPM Check engine air intake system a Check air filter indicator b Inspect air intake system Flag must not be visible Hoses amp tubes in good condition No kinks or restrictions Check engine exhaust system 62 10285 a Inspect the exhaust system Must be clear and unobstructed 5 62 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK HIGH SPEED RPMs TRIGGER ON With Speed Relay turned on speed solenoid energized engine RPMs Between 2000 and 2300 for Ultima or Between 1700 and 2000 for Ultra or Ultra X L or Between 1500 and 1800 for Extra UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check speed solenoid linkage a Check speed solenoid plunger Must move in and out freely b Check engine speed arm amp linkage Must move freely Force High Speed operation See note 7 a Startunit setpoint morethan
39. 34 2 697 500 32 2 509 940 30 2 336 720 56 80 600 28 2 186 670 26 2 028 680 90 733801 24 1 891 780 22 1 765 060 20 1 647 700 96 63 880 18 1 538 950 98 61 040 16 1 498 120 14 1 344 580 12 1 257 770 400 600 10 1 177 150 4 967 830 60 152 990 66 131 310 68 124 870 NK Egi mE EEG IE ES 2 2 4 10 12 14 16 8 43 62 10285 Section 8 Service 8 31 Unidrive Torque Requirements See Figure 8 26 Extensive damage may occur if the proper hardware and procedures are not followed Periodic inspection of hardware and bolt torque is recommended to insure the integrity of the unidrive NOTE Thread locking sealant 5 16 flat washer and 5 16 lock washer must be used on bolts between the compressor mounting flange and the engine bellhousing The recommended sealant is Loctite screw lock no 262 The following figures show the torque value size and grade of the hardware to be used when reassembling the unidrive assembly 8 31 1 Drive Gear When installing a nylon drive gear always 1 Install with black dot facing steel gear 2 Use new bolts and locking tabs included in drive gear kit 3 Use Locktite or a similar thread locking compound on threads of drive gear bolts 4 DO NOT use never seize or any other lubricating compound on the nylon drive gear or compressor steel gear The gear must be assembled dry 5 Torque the 6 bolt nylon drive gear bolts to 3
40. 77 F 25 C Check Remote Temperature Sensor 2 wir ing a Inspect harness amp control box connector pins amp terminals See wiring schematic No physical damage to harness No damaged or corroded pins CHK REMOTE TEMP SENSOR 3 the temperature as 52 6 F UNIT CONTROL Alarm only Remote Temperature Sensor 3 circuit is configured on and has failed open or shorted If shorted the data list will display 158 F 70 C If the circuit is open the data list will show 47 C RESET CONDITION Auto Reset when Remote Temperature Sensor 3 is in range or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found On should clear itself see reset condition above Operate the alarm occurs Continue with the steps below as necessary ce a repair or correction has been made the active alarm unit through the appropriate modes to see if any active 1 Check Remote Temperature Sensor 3 a Verify that Remote Temperature Sensor 3 has been installed and is correctly wired to the unit Remote Temperature Sensor 3 is installed Wires are connected to 10 pin connector at cavities J amp K If sensor is not present change micro configuration to OFF Check Remote Temperature Sensor 3 a Inspect Remote Temperature Sensor 3 amp connector b Check Remote Temperature Sensor 3 resistance See
41. AY PLUG ama IGHT L RESSURE BAR ROCESSOR BOARD ROCESSOR QUICKCONNECT RANGE LIGHT LIGHT BAR AIR TEMPERATURE SWITCH SENSOR ELAY AIR TEMPERATURE LITE COMMUNICATION CONTROL SOLENOID L PORT R MOTOR LICE POINT IGHT BAR CUT OUT SWITCH N C C0 C0 CO C0 C0 CO 20 20 20 CU CO 2 02 B5 D9 D10 D11 D1I5 M14 J11 J16 0 M15 F17 B3 B6 08 010 L11 L13 M14 M16 15 B2 LICE PAC PEED RELAY START RUN OFF SW1TCH STARTER SOLENOID STARTER SOLENOID CONTACTOR STARTER SOLENOID RELAY SOLENOID VALVE UNLOADER U DD 2 0 1 3 c anoancepoonoo co co lt 2 10 7 62 10285 SPK3 L11 NOTES OUTPUT HEZA 1 UNIT SHOWN IN OFF POSITION POWER 5 80 WIRE IDENTIFICATION SYSTEM TO SP1tI1 2 F615A SPIEL SINA G COLOR WHITE DC CONTROL CIRCUITS A E HC3 BLACK GROUNDS 5 1 TO SP2 K10 SP1 ADDRESS SYSTEM EXAMPLE 9 2 25 DO INDICATES A WIRE BETWEEN PLUG HC C B n PIN 9 AND MICROPROCESSOR PLUG2 SA 8 PIN 25 1 5 3MP17 LOCATED IN ENGINE HARNESS SP1 10 CPR86 K9 3MPO3 15 27 HC6 TO SSR86 291 29 9 Fl 3mP13 Q 7 5A SYSTEM bs K POWER 6MP1 6 2
42. CONTINUOUS LOCKED appears in the Message Center when the key is pressed and the unit is in Continuous Run Mode See the configuration table Section 2 17 The unit will remain in low speed for 10 minutes after engine start up when the Continuous Run setpoint is below 10 4 12 C Ifthe unit fails to start after three start attempts the FAILED TO START AUTO alarm will be activated While running if the unit shuts down on a safety device three consecutive times without running a minimum of 15 minutes between shutdowns the FAILED TO RUN MINIMUM TIME Alarm will be activated The shutdown counter is cleared when the unit has run for 15 minutes Also any time the ambient temperature is below 35 F 1 7 C the unit will not operate in High Speed Cool Low Speed Cool High and Low Speed Heat cycles will operate at all ambient temperatures 2 7 62 10285 Section 2 Operation 2 7 Sleep Mode ON HEAT COOL DEFROST START STOP CONTINUOUS B 98889 SETPOINT BOX TEMPERATURE PRESS 1 TO VIEW SETTINGS FUNCTION CHANGE ES Lo 222 1 Press the SELECT key until FUNCTION CHANGE is lit Message Center will show PRESS 1 TO VIEW SETTINGS 2 By pressing the DOWN ARROW key you will move through the Function List to SLEEP MODE 3 Press ENTER key 4 Continue pressing 1 UP or DOWN ARROW key until YES is showing then press the ENTER key to select Sleep Mod
43. Control Box Door See Figure 7 7 Serial Port Downloader Plug SLP 7 6 Section 7 Unit Description 4 amp 5 2 Evaporator Fan 5 Supply Air Temperature Sensor SAT Expansion Valve 6 Defrost Termination Temp DTT1 Heat Exchanger R404A Only 7 Defrost Termination Temp DTT2 Return Air Temperature Sensor RAT Figure 7 5 Evaporator Section Panels and Grille Removed 7 7 62 10285 Section 7 Unit Description 2 Control Module Microprocessor Refer to Section 3 3 Serial Port Downloader Plug SLP Glow Plug Relay GPR Starter Solenoid Relay SSR Fuel Heater Relay FHR Fuse F8 Fuse F6 Fuse F7 Figure 7 6 Control Box Ultima 53 62 10285 7 8 Section 7 Unit Description 3 4 5 im 9 H Y 1 Control Module Microprocessor Refer to Section 3 3 Glow Crank Switch GCS Glow Plug Relay GPR Fuel Heater Relay FHR Starter Solenoid Relay SSR Figure 7 7 Control Box Ultra Extra 7 9 62 10285 Section 7 Unit Description 7 2 Engine Data 4 134 CT4 134DI CT
44. Epio ata a fh oes or one dus 7 12 7 3 Engine Screw 7 13 LA Engine Air Systemi yea eee 7 13 Lo JOOmpressor Data 25a tone ge eS aes 7 13 7 6 Refrigeration System Data 7 14 Safety DEVICES ERE ND RC NES 7 15 78 Data Ohms and Amps 7 16 7 9 Lube and Fuel Flow Diagrams 7 17 7 10 Compressor Unloaders 7 18 7 11 Battery Charging Alternator 7 20 7 11 1 Alternator Operation 7 20 7 11 2 Integral Voltage Regulator Operation 12 volts dc 7 20 7 12 Refrigerant Circuit During Cooling 7 21 7 13 Refrigerant Circuit During Heating and Defrosting 7 23 7 13 1 Heating and Defrost 7 23 7 13 2 Defrost with Greater Than 80 F 26 7 C Ambient 7 24 Section 7 Unit Description 7 1 Introduction Table 7 1 Model Chart 404 Compressor cu e 18 EN ULTIMA 53 with Advance Microprocessor 8 2200 3475 PHOENIX ULTRA with Advance Microprocessor NDA 25 a PHOENIX ULTRA XL with Advance Microprocessor 25
45. Locking Tab Nylon Drive Gear Drive Sheave Bolts V Belt Engine Adapter Drive Sheave Figure 8 15 Compressor Drive Assembly n Remove the complete High Pressure Switch assembly HPS See Figure 8 16 and install on new compressor after checking switch settings Remove Compressor Discharge Temperature Sensor CDT Compressor Discharge Pressure Transducer CDP and Compressor Suction Pressure Transducer CSP and install on new compressor Install compressor frame to new compressor if removed with defective compressor gt COMPRESSOR Ei EC cor EC Ou H HPS H H epp Figure 8 16 Pressure Switch and Sensor o Install compressor in unit by reversing step 4 12 b through n It is recommended using new locknuts when replacing compressor Torque bolts to a value of 46 ft lb 6 4 mkg Install new gaskets on service valves and tighten bolts uniformly Refer to Section 8 31 1 driver gear installation p Attach two lines with hand valves near vacuum pump to the suction and discharge service valves Leak test then dehydrate and evacuate compressor to 500 microns 29 90 Hg vacuum 75 9 cm Hg vacuum Turn off valves on both lines to pump q Fully backseat open both suction and discharge service valves Remove vacuum pump lines and install manifold gauges Start unit and check for
46. Refer to Section 7 8 for amp values 5 50 Section 5 Alarm Troubleshooting outside this range Steps ALARM CAUSE CORRECTIVE ACTION CHECK UL1 CIRCUIT TRIGGER ON Normal Amps for the UL1 Front Unloader Circuit is 0 75 to 2 0 Amps The circuit tests UNIT CONTROL Abort PreTrip amp display PRETRIP FAILED IN TEST 2 Alarm RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for Bad F4 or F6 Fuse alarm a Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue Check UL1 amp circuit a Inspect UL1 and wiring b Check operation of UL1 FET 23 c Check voltage to front unloader No damage or corrosion Connector fits together tightly no moisture inside Run Stop switch in Run Manual Start Operation See Note 2 LED must be ON Must be 11 VDC or higher across the 2 wires Check UL 1 circuit wiring a Inspect harness amp control box connector pins amp terminals See wiring schematic No physical damage to harness No damaged or corroded pins Check UL 1 a Check
47. Refer to Section 8 30 for complete resistance chart 10 000 Ohms 77 F 25 Check Return Air Sensor wiring a Inspect harness amp control box connector pins amp terminals See wiring schematic No physical damage to harness No damaged or corroded pins CHECK SUPPLY AIR SENSOR 47 C TRIGGER ON Supply Air Sensor circuit has failed open or shorted If shorted the data list will display 158 F 70 C If the circuit is open the data list will show the temperature as 52 6 F UNIT CONTROL Use Return Air Sensor 3 6 F 2 C If Return Air Sensor Alarm is on and setpoint is at or below 10 4 F 12 C unit will run in Low Speed Cool only If setpoint is above 10 4 12 C unit will shut down RESET CONDITION Auto Reset when Supply Air Sensor is in range or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Supply Air Sensor a InspectSupply Air Sensor amp connector b Check Supply Air Sensor resistance See Note 4 No damage to sensor No damage moisture or corrosion in connector Refer to Section 8 30 for complete resistance chart
48. SUBCOOLER HOT GAS SERVICE SV3 NC A HOT GAS gt SOLENOID gt E p SV4 NC j 1 DISCHARGE A CHECK VALVE A y CONDENSER DISCHARGE LINE VIBRASORBER CONDENSER PRESSURE CONTROL SOLENOID 5 1 NO 62 10285 7 20 Figure 7 14 R 22 Refrigerant Circuit Cooling Section 7 Unit Description 7 13 Refrigerant Circuit During Heating and Defrosting When vapor refrigerant is compressed to a high pressure and temperature in a reciprocating compressor the mechanical energy necessary to operate the compressor is transferred to the gas as it is being compressed This energy is referred to as the heat of compression and is used as the source of heat during the heating cycle See Figure 7 15 or Figure 7 16 7 13 1 Heating and Defrost NOTES 1 Solenoid valve SV 2 remains open during heating or defrosting to allow additional refrigerant to be metered into the hot gas cycle through the expansion valve providing additional heating capacity until de energized by the microprocessor 2 SV 3 will open under the following conditions The unit is operating in High Speed and Ambient Air Temperature AAT alarm is not active and SV4 has been open for at least 60 seconds and Ambient Air Temperature is less than 70 F 21 1 C and CDT minus AAT is more than 100 F 55 C 3 SV 3 will close under the following conditions Ambient Air Temperature AAT alarm becomes active or CDT min
49. The coil may be removed without pumping the unit down 1 Disconnect leads Remove retainer Lift off coil See Figure 8 19 2 Verify coil type voltage and frequency of old and new coil Thisinformation appears on the coil housing 3 Place new coil over enclosing tube retainer and connect wiring 1 6 2 1 S 2 Coil Assembly 2 5 3 Installation RemovalTool ee 4 Enclosing TubeCollar 5 5 Ring 6 Enclosing Tube 7 Plunger Spring 12 7 i 8 Plunger Assembly s T d 13 9 Gasket 9 c 10 Valve Body b 11 Gasket 12 Bolt 13 Gasket Bolt 14 Piston Ring Figure 8 19 Unloader Solenoid Valve c Replacing Solenoid Valve Internal Parts See Figure 8 19 1 Pump down the unit Frontseat both service valves to isolate the compressor 2 Remove coil retainer and coil 8 27 62 10285 Section 8 Service 3 Remove enclosing tube collar item 4 Figure 8 19 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 over tighten enclosing tube assembly Torque to a value of 100 inch pounds 1 15 mkg 6 Remove supplied installation removal tool Install coil voltage plate and retainer 7 Evacuate and dehydrate the compressor Refer to Section 8 14 p through 8 14 w 8 Start u
50. ZONE SPLICE PACK INDICATES A SOLDERED SPLICE POINT PIN CONNECT ION SWITCH SYMBOL INDICATES MOMENTARY CONTACTS INDICATES A WIRE GROUND INDICATES A CHASSIS GROUND NO WIRE COMPONENT CONNECTION NUMBER OR LETTER INDICATES A CONNECTION WIRE LUG ETC NORMALLY CLOSED CONTACTS NORMALLY OPEN CONTACTS INDICATES CONNECTION MULTIPLE PLUG CONNECTION NU N m ON IR TEMPERATURE R ART LIGHT LIGHT BAR R DISCHARGE PRESSURE R DISCHARGE TEMPERATURE R ECONOMIZER TEMPERATURE GOLD R ECONOMIZER PRESSURE GOLD T LIGHT BAR 0000Axoco90 LAY R SUCTION PRESSURE R SUCTION ODULATION VALVE SUCTION TEMPERATURE GOLD RANSF ORMER IR SWITCH HT LIGHT BAR GOLD ERMINATION TE R EXPANSION VALVE OLANT LEVEL SWITCH OLANT TEMPERATURE L LEVEL SWITCH L PRESSURE SWITCH PERATURE GOLD D 1 N 0 ENGINE EVAPORATOR EVAPORATOR EVAPORATOR R PLUG OUTLET PRESSURE GOLD OUTLET TEMPERATURE GOLD EVAPORATOR EXPANSION VALVE GOLD FUSE MP 7 5 AMPERE FUSE SR 10 AMPERE FUSE RR 7 5 AMPERE FUSE CLHR 7 5 AMPERE FUSE MAXI FUSE 80 AMPERE FUSE SV amp UL 15 AMPERE FUSE SROS 5 AMPERE FUSE FHR 20 AMPERE FUSE LB 3 AMPERE HEATER EATER R EATER T LIGHT L EVEL SWI D J ELAY EMP GHT CH SWITCH BAR COPTIONALD DARN RANK SWITCH
51. a b Check resistance of UL2 Check amp draw of UL2 Refer to Section 7 8 Use Component Test Mode Section 2 17 3 to test Refer to Section 7 8 for amp values CANNOT PUMP DOWN TRIGGER ON With SV1 SV2 SV3 amp SV4 in the closed position the compressor is not able to pull the low side of the refrigerant system down to 5psig UNIT CONTROL Abort PreTrip amp display PRETRIP FAILED IN TEST 11 12 or 13 Alarm RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Visually Inspect Unit a Is compressor turning with engine Compressor must turn with engine Check for Check SV3 alarm a Check for alarm P183 Condition must be corrected and alarm cleared to proceed Check for Check SV4 alarm a Check for alarm P181 Condition must be corrected and alarm cleared to proceed Manually test refrigeration system See note 7 a Run Quick Check Must pass all tests Correct any problems found before proceeding 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION
52. cartons create much more fiber dust during transport than new cartons The fiber dust and particles are drawn into the evaporator where they lodge between the evaporator fins If the coil is not cleaned on a regular basis sometimes as often as after each trip the accumulation can be great enough to restrict air flow cause coil icing repetitive defrosts and loss of unit capacity Due to the washing action of normal defrost the fiber dust and particles may not be visible on the face of the coil but may accumulate deep within 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 front of trailer 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 Make sure drain lines are clean c Run unit until defrost mode can be initiated to check for proper draining from drain pan 8 29 Condenser Coil C
53. compressor unloader decreases the capacity of the system by decreasing the number of cylinders pumping refrigerant Unloaders will use the differences of Controlling Temperature and setpoint as follows LOAD de energize UL1 and UL2 UNLOAD energize UL1 and UL2 COOL Control Temp is more than 2 7 F 1 5 C Control Temp is less than 2 3 F 1 3 C above set point above set point HEAT Control Temp is more than 2 7 F 1 5 C Control Temp is less than 2 3 F 1 3 C below set point below set point 62 10285 4 10 Section 4 Engine and Temperature Control SV2 Operation Heating and Defrost The HP2 switch used in other models of Carrier Transicold trailer refrigeration systems is not used with the Advanced Microprocessor In its place there is a discharge pressure transducer which tells the Microprocessor exactly what the compressor discharge pressure is at all times Because the operation of the HP2 switch is very important to unit operation we will continue to refer to the control of the SV2 valve in the Heat and Defrost cycles as by the HP2 The following HP2 control is accessed during the Heat and Defrost cycles If the Discharge Pressure is greater than HP2 CUT OUT then 5 2 is closed If the Discharge Pressure is less than HP2 CUT IN then SV2 is open HP2 Cut out and HP2 Cut in are based on the model number as follows as other model units use the Advance Microprocessor different values will be associated wit
54. 5 6 Piston Assembly ce 7 Body 6 4 8 Bracket Adapter a g n Figure 8 23 Solenoid Valves Alco 62 10285 8 36 Section 8 Service 8 24 2 Solenoid Valve Sporlan SV1 SV3 a Replacing the Coil NOTE The coil may be replaced without removing the refrigerant or pumping the unit down 1 2 3 Remove top locknut spacer cup and nameplate SV1 For SV3 remove screw and nameplate Disconnect wiring and remove coil Replace coil by reversing steps 1 and 2 b Replacing Internal Components See Figure 8 24 1 2 SD AT gt 10 11 Remove and store the refrigerant charge in an evacuated container Refer to Section 8 10 b Remove the top locknut spacer cup nameplate coil assembly and spacer SV1 For SV3 remove screw and nameplate Using a 12 point 1 3 8 inch box wrench loosen the enclosing tube locknut and bleed off remaining refrigerant Remove enclosing tube and locknut assembly The gasket is inside the enclosing tube Remove seat disc from inside of body and check for obstructions and foreign material Place the seat disc into the valve body with the smaller diameter end facing up For SV3 install stem and plunger item 11 Figure 8 24 Place the enclosing tube locknut over the enclosing tube Install spacer over enclosing tube making sure it is seated properly in the enclosing tube locknut Tighten enclosing tube locknut to a torque value of 20 ft lb 2 78 mkg Do not over tighten Inst
55. 6 F 1 5 2 7 F High Speed 6 Cylinder Cool 1 0 C 1 8 F 0 5 C 0 9 F 0 5 C 0 9 F UNIT OFF STOP 1 0 1 8 F UNIT OFF STOP 1 5 2 7 F 2 0 3 6 F Start Stop Temperature Control Operating Sequence Frozen Range 62 10285 4 8 Section 4 Engine and Temperature Control Pulldown Pull up Mode Pulldown or Pull up will be initiated in any of the following conditions at engine start setpoint change operational mode change ie start stop continuous operation e defrost termination e Ifthe system is running in Start Stop Run Mode the minimum run time has expired and other conditions for shutdown are met except that the box temperature has not reached setpoint e pretrip termination Pulldown or Pull up will end in the following conditions For CONTINUOUS RUN MODE The Active Probe Temperature is within RAT SAT of setpoint when the setpoint is below 60 F 15 6 C and both supply and um sensors are good OR The Active Probe Temperature is within the low speed operation range For START STOP RUN MODE The Active Probe Temperature is within the set point range which allows the unit to shut off Heat Cool Null Switching Operation When not in pulldown UltraFresh 2 controls the unit based on the following switch points Note that the switch points are based upon the Controlling Temperature rath
56. 8 32 Compressor Oil Level 8 25 Compressor Suction Pressure Transducer 8 34 Compressor Unloader 7 18 8 27 Condenser Coil 8 41 Continuous Run Operation 2 7 4 4 Control Module Description 3 3 Controller Sensor 8 42 Cool Mode Operation 4 10 Coolant Level Switch 8 6 D Data Recording 3 4 DataLink 3 4 DataShare Program PC Card 2 39 Default Mode 4 10 Defrost 4 16 Defrost Air Switch 7 14 8 40 Defrost Cycle 8 39 Dehydration 8 19 Diagnostic Mode 2 36 Display 3 9 Display amp KeyPad Description 3 8 Door Switches amp Remote Switches 3 14 Downloading Data with the PC card 2 38 Driver s Light Bar 3 12 E Engine Air Cleaner 8 8 Engine Air System 7 13 Engine Coolant Temperature 4 3 4 4 Engine Cooling System 8 6 Engine Crankcase Breather 8 9 Engine Data 7 12 Engine Oil 7 12 Engine Screw Threads 7 13 Evacuation 8 19 Evaporator Coil 8 41 Expansion Valve 7 14 8 29 F Fan Clutch 8 16 Fan Shaft 8 14 Fan Shaft V Belt 8 11 Fanshaft Oil 7 14 Filter Drier 8 29 Fuel Flow Diagram 7 17 Fuel Level Sensor 8 4 Fuel Level Switch 8 4 Fuel Pump 8 3 Functional Change Parameters 2 24 Fusible Plug 7 14 G Gearbox Clutch 8 13 Gearbox Oil 7 14 Glow Plugs 8 10 H Heat Mode Operation 4 9 Heat Cool Null Switching Operation 4 9 Heating Cycle 8 39 High Pressure Switch 7 14 8 31 Indicator LEDs 3 5 3 6 3 9 Installing New Software 2 39 Introduction 7 1 Introduction To Trou
57. 8 6 for belt tensions No Glazing no cracking no slipping Check evaporator air flow See note 7 a Check evap fan clutch b Check evaporator section return air bulkhead air chute cleanliness of evap coil Must be engaged Good Air Flow Return air not restricted Air chute in good condition No damage to blower wheel Evap coil clean Check for Check SV2 Circuit Alarm a Check for alarm 97 or P192 Alarm conditions must be corrected and the alarm cleared to continue Check system pressures a Check and compare compressor discharge amp suction pressures with those shown on the microprocessor controller Suction amp Discharge Pressures must have the same reading x 5 psig on gauges amp on micro display Check refrigerant charge a Check for undercharged system Level must be above lower sight glass Manually defrost unit a Defrost unit and terminate automatically Typical defrost cycle time is 5 20 minutes Suction pressure should rise gradually during cycle Check system pressures a Check and compare compressor discharge amp suction pressures with those shown on the microprocessor controller Suction amp Discharge Pressures must have the same reading x 5 psig on gauges amp on micro display Check Expansion Valve TXV a Visually inspect valve b Check MOP of valve c Check superheat of valve Bulb must be clamped tightly on the su
58. BTY To Main Power In 12 Output from Run Relay to SP3 12 Output unswitched to 5 2 SPK3 12 Output from SROS to 5 5 SPK7 or 12 Output from J1 jumper to SPK5 SPK7 12 Output from Clutch Relay to Clutch 12 Output to Starter Solenoid SS 12 Output to 2MP25 2 3 4 EN EE NEN g 7 Unused Teminals 10 12 18 18 amp 19 NOTE Terminal 11 used only with units with J 1 Jumper 10 3 62 10285 gt SPK3IL11 NOTES OUTPUT 1 UNIT SHOWN IN OFF POSITION TO 5 1 2 WIRE IDENTIFICATION SYSTEM 15 peau COLOR WHITE DC CONTROL CIRCUITS 4 AUN A a LHC3 BLACK GROUNDS 5 1 5 1 ADDRESS SYSTEM EXAMPLE 9 2 25 RX TX INDICATES A WIRE BETWEEN PLUG HC C B n PIN 9 AND MICROPROCESSOR PLUG2 F7 SA PIN 25 TO GPR86 SSR86 1 3MPO5 tJ103 L 5 17 LOCATED IN ENGINE HARNESS 3MPO3 3MP15 3MP27 29 9 1 3mP 13 0 7 5 2 5 1 DAS SYSTEM POWER 6MP 1 ENOLS 2 TO FLSC 115 DISPLAY A BEA KEYPAD 5 REMS1 lt 5
59. C or e Battery voltage falls below 11 0 Vdc e temperature is more than the selected Off Time Override Temperature Functional Parameter of 3 6 F to 18 F 2 C to 10 C from set point above setpoint in the frozen range or e After the Minimum Off Time expires and the box temperature is more than 3 6 F 2 C from set point e After the Maximum Off Time expires NOTE The unit will remain in low speed for 10 minutes after engine start up when In Start Stop Mode at any setpoint or in Continuous Run Mode and setpoint is below 10 4 F 12 C Start Stop Indicator The Start Stop LED indicator is lit and Engine Auto Start light on the light bar will be ON to indicate the Start Stop mode has been selected Failed To Start Auto Mode If the unit fails to start after three start attempts the Alarm A31 FAILED TO START AUTO MODE will appear in the Message Center and the Alarm LED on the Keypad and the Fault light on the light bar will flash on and off once a second Minimum RunTime The Minimum Run Time is selected in the Microprocessor Functional Parameter List The purpose of this is to force the unit to run long enough to completely circulate the air within the inside of the trailer and to insure that the product temperature is at set point This may be set for any value between 4 minutes and 60 minutes in 1 minute intervals The engine must run for the Minimum Run Time before cycling off The factory set
60. CONNECTION WIRE LUG ETC pa SY AAT ALT ARL B BTY CDP CDT CECT CECP CL CLH CLHR CSP CSI ON IR TEMPERATURE R LIGHT BAR N e ART LIGHT 9 R R R R E DISCHARGE DISCHARGE ECONOMIZE ECONOMIZE CLIGHT BA PRESSURE TEMPERATURE R TEMPERATURE GOLD PRESSURE GOLD R 0000Axoco90 LAY R SUCTION PRESSURE R SUCTION ODULATION VALVE SUCTION TEMPERATURE GOLD RANSFORMER IR SWITCH HT LIG V GOLD HT BAR ER R OL INATION TE EXPANSION VALVE ANT LEVEL SWITCH OLANT TEMPERATURE L LEVEL SWITCH L PRESSURE SWITCH PERATURE GOLD nommza N 0 2 ENGINE RP EVAPORATO EVAPORATO EVAPORATO PLUG OUTLET PRESSURE GOLD OUTLET TEMPERATURE GOLD EVAPORATOR EXPANSION VALVE GOLD FUSE MP 7 5 AMPERE FUSE SR 10 AMPERE FUSE RR 7 5 AMPERE FUSE CLHR 7 5 AMPERE FUSE MAXI FUSE 80 AMPERE FUSE SV amp UL 15 AMPERE FUSE SROS 5 AMPERE FUSE FHR 20 AMPERE FUSE LB AMPERE EATER EATER EATER LIGHT EVEL 5 R R R R E J ELAY EMP SWITCH BAR 2 GHT CH DARN R T L WIT D C RANK SWITCH AY PLUG URRENT IGHT LIGHT BAR RESSURE CUT OUT SWITCH BAR ROCESSOR BOARD ROCESSOR QUICKCONNECT RANGE LIGHT LIGHT BAR AIR TEMPERATURE SWITCH SENSOR Y AIR TEMPERATURE LITE COMMUNICATION
61. CONTROL Immediate Unit Shutdown amp Alarm RESET CONDITION Auto Reset after 15 minutes if the compressor discharge pressure falls below 350 CORRECTIVE ACTION PSIG or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check fan belts a Check upper fan belt tension amp condition b Check lower fan belt tension amp condition Refer to Section 8 6 for belt tensions No Glazing no cracking no slipping Refer to Section 8 6 for belt tensions No Glazing no cracking no slipping Check Wiring a Visually Inspect wiring to HPS SV3 SVA amp both Compressor Unloaders Wires must be connected properly amp securely to each component Check airflow through condenser coil a Inspect condenser radiator fins b Check airflow with unit running Fins must be straight 9096 or more of the coil surface must be undamaged No dead air spaces Condenser Radiator coil must be clean Even airflow through the entire coil No dead spots Check system pressures a Install Manifold Test Set and check and compare compressor discharge amp suction pressures
62. CONTROL SOLENOID RIAL PORT ARTER MOTOR LICE POINT C0 C0 CO CO C0 C0 20 20 20 CU CO 2 02 6 09 010 011 015 14 11 16 0 M15 F17 B3 B6 08 010 L11 L13 M14 M16 15 B2 2 0 1 3 c aneancoonoo co co lt NNMNDDDV 2 LICE PEED RELA START RUN STARTER SO STARTER SO STARTER SO SOLENOID V UNLOADER 10 5 Y OFF SWITCH LENOID LENOID CONTACTOR LENOID RELAY ALVE 62 10285 gt SPK3 L11 NOTES OUTPUT ACSA 2008 1 UNIT SHOWN IN OFF POSITION TO 5 1 F5 804 2 WIRE IDENTIFICATION SYSTEM 515 t8 COLOR WHITE DC CONTROL CIRCUITS b BLACK GROUNDS ADDRESS SYSTEM EXAMPLE HC9 2MP25 Os SATCOM G mo TX INDICATES A WIRE BETWEEN PLUG HC PIN 9 AND MICROPROCESSOR PLUG2 F7 5 PIN 25 SROS p GPR86 SSR86 3MP05 J 10 91 1 LOCATED IN ENGINE HARNESS Hee 3MP03 15 3MP27 29 F9 3A A 3MP13 7 SA MPQC2 DAS SYSTEM POWER 1 ENOLS 2 TO SP2 K10 SP1 GPR SSR FHR B TO FLSC 115 DISPLAY KEYPAD 0 REMS lt m
63. Check Expansion Valve TXV a Visually inspect valve Bulb must be clamped tightly on the suction line and insulated No physical damage to bulb capillary tube of valve body b Check MOP of valve Refer to Section 7 6 c Check superheat of valve Refer to Section 7 6 Check system for non condensables a Check refrigeration system for No non condensable gas es may be present non condensable gas es 62 10285 5 12 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION LOW REFRIGERANT PRESSURE TRIGGER ON A Suction Pressure is less than 3 0 psig 6 inches vacuum for more than 120 seconds when the RAT is above 10 F 23 3 C or If the Suction Pressure is less than 8 0 psig 16 inches vacuum for more than 120 seconds at any RAT temperature UNIT CONTROL Alarm Only or Unit Shutdown amp Alarm if configured RESET CONDITION Auto Reset after 15 minutes if Suction Pressure is more than 2 0 psig 4 inches vacuum or if RAT falls below 10 F 23 3 C or Alarm may be manually reset via Keypad or by turning the unit off then back on again Time may be configured from 0 255 seconds NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as
64. Condition must be corrected and alarm cleared to proceed Check system pressures a Check and compare compressor Suction amp Discharge Pressures must have the same discharge amp suction pressures with reading 5 psig on gauges amp on micro display those shown on the microprocessor controller Check MOP of expansion valve a Test MOP of Expansion valve Refer to Section 7 6 Manually test refrigeration system See note 7 a Run Quick Check Must pass all tests Correct any problems found before proceeding 62 10285 5 68 Section 5 Alarm Troubleshooting ALARM CAUSE LOW SUCTION PRESSURE normal UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via CORRECTIVE ACTION TRIGGER ON This alarm is generated during Test 4 of Cool PreTrip Suction pressure is lower than Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check fan belts a Check upper fan belt tension amp condition b Check lower fan belt tension amp condition Refer to Section 8 6 for belt tensions No Glazing no cracking no slipping Refer to Section
65. Configuration List as required Hour Meter is reset in the Functional Parameter list Follow maintenance interval recommendations in Section 8 1 See Note 1 a Clear the inactive fault code 5 75 Alarm 226 is cleared 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION SERVICE SOON PM 2 DUE TRIGGER ON The Maintenance Hour Meter 2 time has expired UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via Keypad 1 Check unit maintenance records a Schedule unit into service facility for Must be done soon maintenance Perform maintenance a Perform appropriate engine amp unit Follow instructions on proper maintenance form maintenance Reset Maintenance Hour Meter 2 a Check that Maintenance Hour Meter Reset Interval in Configuration List as required 2 interval is set for your requirements Hour Meter is reset in the Functional Parameter list Follow maintenance interval recommendations in Section 8 1 b Reset Maintenance Hour Meter 2 for the next service interval See Note 1 a Clear the inactive fault code Alarm 227 is cleared SERVICE SOON PM 3 DUE TRIGGER ON The Maintenance Hour Meter 3 time has expired UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via Keypad 1 Check unit maintenance records a S
66. Discharge Pressures must have the same discharge amp suction pressures with reading 5 psig on gauges amp on micro display those shown on the microprocessor controller Check SV3 operation Unit must be running in Heat Cycle See Note 7 a De energize SV3 coil After 60 seconds note discharge and suction pressures b Energize SV3 coil Hot gas hissing sound will begin immediately Suction pressure must raise slightly Discharge pressure must drop slightly Manually test refrigeration system a Run Quick Check Must pass all tests Correct any problems found before proceeding CHECK UL2 UNLOADER TRIGGER ON The pressure differential between discharge and suction pressures did not change as expected when the UL2 Rear Unloader was loaded de energized or unloaded energized UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for Check SV2 Circuit Alarm a Check for alarm 97 or P192 Alarm conditions must be corrected and the alarm cleared to continue Check for Check UL2 Unloader alarm a Check fo
67. INSTRUCTIONS Section 1 Safety Precautions SN A WARNING OF FAN BLADES A WARNING UNIT MAY START AN AUTOMATICALLY Ns 62 92509 00 REV AY TOP COOLANT INTO RECOVERY BOTTLE ONLY FILL EMPTY RADIATOR THROUGH FILLER NECK SLOWLY TO AVOID AIR ENTRAPMENT CAUTION REMOVE FILLER CAP SLOWLY SS 62 02142 00 REV_A IJ Section 2 Operation 2 1 Starting Unit 2 1 2 2 Manual Start Glow Crank 2 2 23 Stopping Lit ie riae a Cx A PERO ERR 2 3 24 Changing Selpolit Ier ode ics 2 4 2 5 Start Stop Operation 2 5 23 11 Chardins AMPS P eoe TEE SR 2 6 2 6 X Continuous Run 2 7 24 MOS veces donde cede d e obe a e baat aa 2 8 2 2 10 2 61 Manual Defrost 2 10 2 8 2 Automatic 2 11 290 Preti edes ku ee da sane o o oe era 2 13 2 10 ip Start ce seg tated 2 17 241 View Active Alarms 2 18 2 12 View Inactive 1 lt 2 19 2 13 Alarms amp Default Messages 2 20 DA
68. Meter is reset in the Functional Parameter list Follow maintenance interval recommendations in Section 8 1 See Note 1 a Clear the inactive fault code Alarm 229 is cleared SERVICE SOON PM 5 DUE TRIGGER ON The Maintenance Hour Meter 5 time has expired UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via Keypad 1 Check unit maintenance records a Schedule unit into service facility for maintenance Must be done soon Perform maintenance a Perform appropriate engine amp unit maintenance Follow instructions on proper maintenance form Reset Maintenance Hour Meter 5 a Check that Maintenance Hour Meter 5 interval is set for your requirements Reset Maintenance Hour Meter 5 for the next service interval Reset Interval in Configuration List as required Hour Meter is reset in the Functional Parameter list Follow maintenance interval recommendations in Section 8 1 See Note 1 a Clear the inactive fault code 5 77 Alarm 230 is cleared 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION 5 10 MICROPROCESSOR ALARMS SETPOINT ERROR TRIGGER ON There is an error in the Setpoint that is stored in the Microprocessor memory UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset when a valid Setpoint is entered or Alarm m
69. Mode See Note 2 and continuity through the harness Battery voltage reading 12 13 VDC between wires in plug Check engine oil pressure a Connect mechanical oil gauge Oil pressure must be greater than 15 psig 5 7 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION HIGH COOLANT TEMPERATURE TRIGGER ON For ambient temperatures below 120 F 48 9 C Engine coolant temperature is above 230 F 110 C or Ambient temperatures above 120 F 48 9 C engine coolant temp is over 241 F 116 C or Engine coolant temperature is between 230 F and 241 F 110 C and 116 C for more than 5 minutes UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset after 15 minutes if the engine coolant temp falls below 212 F 100 C or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check coolant level a Check coolant level in overflow bottle b Check coolant level in radiator Level must be in the Normal range Level must be at the top of the radiator fill tube Check for Bad Eng Coolant Sensor alarm a Check for ala
70. PULSED NULL BAND Cool Heat 2 Cylinder Low Speed 2 Cylinder Heat Low Speed 6 Cylinder Heat High Speed 6 Cylinder Heat Continuous Run Temperature Control Operating Sequence Perishable Range FALLING TEMPERATURE High Speed 6 Cylinder Cool Low Speed 6 Cylinder Cool Low Speed 2 Cylinder Cool PULSED NULL BAND Cool Heat 2 Cylinder Low Speed 2 Cylinder Heat 2 0 C 3 6 F 1 5 C 2 7 F 1 0 C 1 8 F 0 5 C 0 9 F 0 5 C 0 9 F 1 0 C 1 8 F 1 5 C 2 7 F 2 0 3 6 F RISING TEMPERATURE High Speed 6 Cylinder Cool Low Speed 6 Cylinder Cool Low Speed 2 Cylinder Cool PULSED NULL BAND Cool Heat 2 Cylinder Low Speed 2 Cylinder Heat Continuous Run Temperature Control Operating Sequence Frozen Range 4 7 62 10285 Section 4 Engine and Temperature Control FALLING RISING TEMPERATURE TEMPERATURE i High Speed 6 Cylinder Cool 2 0 C 3 6 F 6 Cylinder Cool 1 5 C 2 7 F Low Speed 5 6 Cylinder 1 0 C 1 8 F UNIT OFF STOP 0 5 C 0 9 F SET POINT 0 5 C 0 9 F UNIT OFF STOP 1 0 1 8 Low Speed 6 Cylinder Heat 1 5 2 7 F 2 0 C 3 6 F High Speed unger He 6 Cylinder Heat 6 Cylinder Heat Start Stop Temperature Control Operating Sequence Perishable Range RISING TEMPERATURE High Speed 6 Cylinder Cool FALLING TEMPERATURE 2 0 C 3
71. Section 8 Service 8 22 3 Replacing Compressor Suction Pressure Transducer a Pump down the unit at the King Valve until the suction pressure is approximately 5 psig Refer to Section 8 10 a b Disconnect wiring from defective transducer Slowly remove the transducer The pressure remaining in the suction line will be held in place by a Schrader valve located inside the fitting The CSP is located on the suction line just above the Suction Service Valve See Figure 7 1 c Install the new transducer in compressor Check for leaks d Open the King Valve and check operation e Install new suction transducer being careful to obtain the correct transducer for your unit R 22 CSPs have a green dot on the side R 404A CSPs have a blue dot on the side Refer to Section 8 22 2 f Evacuate and dehydrate the compressor Refer to Section 8 14 p through 8 14 w 8 23 Replacing Receiver Sight Glass Assembly a Store the refrigerant in an evacuated container Refer to Section 8 10 b b Unscrew the sight glass assembly Wrap threads with teflon tape or spread some sealing compound on pipe threads of new sight glass assembly and install Leak check receiver sight glass per Section 8 11 After leak checking unit evacuate and dehydrate as outlined in Section 8 12 Add refrigerant charge Refer to Section 8 13 Check for noncondensibles 8 35 62 10285 Section 8 Service 8 24 Servicing Solenoid Valves 8 24 1 Solenoid
72. TANK SIZE OFF OFF No Low Fuel Level Switch or to 100 30 GALLONS Sensor is installed in the tank OR 50 GALLONS A Low Fuel Level Switch or a 0 to 100 Sensor is 75 GALLONS installed in the tank but the unit will not shutdown due to a Low Fuel Level Alarm 100 GALLONS 120 GALLONS 30 120 GALLONS When a Low Fuel Level Switch is installed and the LOW FUEL LEVEL WARNING alarm 1 is on the unit will shutdown alarm 19 after a time delay see chart below 30 gal 30 min 50 gal 60 min 75 gal 90 min 100 gal 120 min 120 gal 150 min OR If 1 100 Sensor is installed the low fuel level WARNING alarm 1 will come on when the level reaches 15 or less and the unit will shutdown alarm 19 when the level reaches 10 DIESEL RESET VALUE OFF OFF The Engine Maintenance Hour Meter is turned off Refer to Section 7 2 for oil change intervals 1500 Factory 50 30 000 hrs The value selected here will be the setting number of hours between engine service intervals 50 TO 30 000 HRS SWITCH ON RESET VALUE OFF OFF The Switch On Maintenance Hour Meter is turned off 50 TO 30 000 HRS 50 30 000 hrs The value selected here will be the number of hours between Switch On service intervals OFF OFF The PM 1 5 Maintenance Hour Meter s is turned off ENGINE HOURS ENGINE HOURS PM Meter will count engine hours SWITCH ON until the next service interval H OURS SWITCH ON HOURS PM Meter will count S
73. TO VIEW SETTINGS will appear in the Message Center Press the 1 UP ARROW Key to scroll through the Function list beginning at the top Press the DOWN ARROW Key to scroll through the Function list beginning at the bottom TO SCROLL THEN TO SELECT will appear in the Message Center To read through the Function list continue to press either the 1 or key The Functional Parameters will appear in the Message Center in the order as shown below The list is circular meaning that once the end is reached it is repeated from the beginning If no key presses are made for 10 seconds the Message Center will return to the default message Status OK Check At Next Service Interval etc NOTE Any Function that is shown with a lock symbol can not be changed from the keypad 5 To change one of the Functions bring the Function you wish to change into the Message Center and press key ENTER 1 TO SCROLL THEN TO SAVE will show in the Message Center Pressing either 1 or UP or DOWN ARROW key will begin to change the Function setting The Message Center will flash indicating that a change has been made that has not been entered into memory Continue pressing or UP DOWN ARROW key until the desired value is showing then press the key ENTER The Message Center will stop flashing The new value is now in memory If the key is not pressed within 10 seconds the Message Center will change to FUNCTION NOT CHANGED
74. Temperature Control Maximum Operating Pressure MOP Override The Microprocessor monitors the suction pressure of the refrigeration system and controls the unloaders to maintain a Maximum Operating Pressure MOP A suction pressure transducer is used to provide this information to the Microprocessor This pressure is calculated based on suction pressure and ambient air temperature From this the Microprocessor will be able to determine the system load The system load will correspond to a maximum horse power discharge pressure and coolant temperature which the unit can operate with By overriding temperature control and unloading cylinder banks on the compressor these conditions can be maintained at the appropriate levels When the compressor is fully loaded it is operating on 6 cylinders When the front unloader UL1 is UNLOADED energized the unit operates on 4 cylinders When and the rear unloader UL2 are UNLOADED energized the unit operates on 2 cylinders The front unloader UL always UNLOADS before the rear unloader UL2 UNLOADS Suction Pressure Operation d R 404A Refrigeration System At ambient temperatures of 90 F 32 2 C or below When the system is operating in high speed and the suction pressure is greater than 63 psig both unloaders are unloaded As the suction pressure drops below 63 psig the UL2 unloader is loaded If the suction pressure drops below 32 psig the UL1 unloader is loaded When the system is operati
75. Too High Battery Voltage Too Low Temp Low Refrigerant Pressure Low Fuel Level Shutdown Not Used High Suction Pressure Check Refrigeration System Failed to Run Minimum Time Failed to Start Auto Failed to Start Manual Not Used Engine Failed To Stop Check Starter Circuit Check Coolant Temperature Check Low Speed RPM Check High Speed RPM Check Engine RPM Alarms List CAUSES DRIVER ALARMS Less than 1 8 or 15 of fuel remaining in fuel tank Engine oil level is sensed approx 7 qts low for more than 10 seconds Radiator is less than 2 3 full of coolant SHUTDOWN ALARMS Engine oil pressure is less than 12 psig when engine is running Coolant temperature is greater than 116 C when the ambient temperature exceeds 48 9 C greater than 110 C when the ambient temperature is less than 48 9 C or between 116 C and 110 C for 5 minutes temperature exceeds 48 9 C greater than 154 4 C for 3 minutes when the ambient temperature is less than 48 9 C or ever greater than 176 7 C Compressor suction pressure is less than 3 0 psig for more than seconds when RAT is above 10 F Compressor suction pressure is less than 8 0 psig for more than seconds Time may be configured from 0 to 255 seconds Low Fuel Level warning alarm active for amount of time based on tank size from configuration parameter Compressor suction pressure has been greater than 98 psig for longer than 10 minutes C
76. Ultra or Ultra X L or Between 1100 to 2000 for Extra for more than 5 minutes or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for engine stalled alarm a Check for alarm 41 When both alarms are present unit may have been run out of fuel Check speed solenoid amp linkage a Check speed solenoid plunger Must move in and out freely b Check engine speed arm amp linkage Must move freely Check fuel system a Check for Alarm 1 Fill tank as needed b Check fuel flow Unrestricted fuel flow through system Fuel not gelled c Check fuel system prime No air in fuel system Check engine air intake system a Check air filter indicator Flag must not be visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Force Low Speed operation See note 7 a Turn unit OFF wait 10 seconds then Controller will call for Low Speed operation for the next 10 turn ON Set for Start Stop operation minutes b Check operation of Speed Relay LED LED 27 must be OFF c Check voltage to speed solenoid Must be 0 VDC Check low speed engine
77. Valves Alco SV2 SV4 b The liquid line solenoid valve SV2 may be serviced by pumping the unit down Refer to Section CAUTION Do not damage or over tighten 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 Unplug from wiring harness remove coil retainer and coil assembly 2 Verify coil type voltage and frequency This information appears on the coil housing 3 Place new coil over enclosing tube retainer and connect wiring Replacing Solenoid Valve Internal Parts See Figure 8 23 8 10 a Remove and store the refrigerant charge in an evacuated container to service hot gas solenoid valve SV4 Refer to Section 8 10 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 4 Tighten enclosing tube assembly to a torque value of 200 inch pounds 2 3 mkg and leak check the valve Refer to Section 8 11 5 Install coil assembly and retainer 6 Start unit and check refrigerant charge per Section 8 13 f 7 Check refrigeration cycles B 3 1 Retainer 2 Coil Assembly 2 3 Enclosing Tube Assembly 4 Plunger Assembly 4 5
78. adjusting screw counter clockwise until the display indicates 100 DO NOT ADJUST ANY FURTHER S Red Wire to SPK5 12Vdc Input White Wire B to 1MP26 Micro Input Black Wire C to SP24 ground Figure 8 3 Fuel Sensor Wiring 62 10285 8 4 Section 8 Service 8 4 2 Testing the 0 100 Fuel Level Sensor a b Verify that the wiring to sensor is correct Check voltage at the Fuel Level Sensor with the SROS in the Run position Unit running or Unit off and Manual Start Mode selected Voltage between Red Wire positive and Black Wire negative should be 12 5 to 13 5 VDC Do not disconnect the Red or Black wires from the switch Disconnect the White Wire output from the sensor Voltage between Black Wire negative and White Wire output should be 0 VDC when the switch is dry and out of the fuel When the switch is immersed into fuel the voltage reading between Black Wire negative and White Wire output increase up to 5 VDC when fuel has reached the full mark 8 4 3 Testing the Fuel Level Switch a b Verify that the wiring to switch is correct See wiring schematic Check voltage at the Fuel Level Switch with the Run Relay energized Unit running Unit off Manual Start Mode selected and test must be completed within 5 minutes before the Failed To Start Manual Mode occurs or Component Test Mode will energize the Run Relay for 5 minutes without starting the unit Voltage bet
79. all energy saving features off Turn off any screen saver or any hard drive time out settings 1 10 Connect the computer to the Microprocessor using a Carrier Transicold Downloader Cable Once the cable is connected to the download port the Microprocessor will power up and show PC MODE Start the program by double clicking on the Microprogrammer icon on your computer desktop Click on the Load File button The Open box will appear on the screen Using the mouse select the file you want to load this will be a file by clicking once on it to highlight it Click the OK button Watch the lower left message area of the program Once the file is validated the Program Micro button will become active Turn the SROS switch to the Run position Wait for the Main Display and Message Center to power up Click on the Program Micro button The Message Center will go blank If the engine was running it will shut down The Micro Status LED will start blinking at the rate of 5 seconds on 5 seconds off The complete value on the screen will increment itself as the program is loaded The complete will stop several times during the loading process for up to 15 seconds This is normal DO NOTHING DURING THIS TIME BUT WAIT The time to load the program is dependent upon the speed of the computer This will generally take from 4 to 6 minutes Once the complete reaches 100 the shutdown box will appear Click the OK button The Micr
80. amp draw of SV2 Refer to Section 7 8 Check 5 2 wiring a Inspect harness amp control box See Notes 2 amp 6 connector pins amp terminals See No physical damage to harness wiring schematic No damaged or corroded pins Check SV2 current draw a Use Component Test Mode Refer to Refer to Section 7 8 for normal current values Section 2 17 3 to test actual current draw of the circuit 5 7 SENSOR ALARMS CHECK AMBIENT AIR SENSOR TRIGGER ON Ambient Air Sensor circuit has failed open or shorted If shorted the data list will display 158 F 70 C If the circuit is open the data list will show the temperature as 52 6 F 47 C UNIT CONTROL A default value of 122 F 50 C will be used for any calculations RESET CONDITION Auto Reset when Ambient Air Sensor is in range or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Ambient Air Sensor a Inspect Ambient Air Sensor amp No damage to sensor connector No damage moisture or corrosion in connector b Check Ambient Air Sensor resistance Refer to Section 8 30 for complete resistance chart See Not
81. 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 8 18 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 8 18 Purge the oil hose at oil pump Add oil as necessary Refer to Section 7 5 8 25 62 10285 Section 8 Service 2 Closed System Method When an oil pump is not available oil may be drawn into the compressor through the oil fill port 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 hose is immersed in the 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 the common connection of the gauge manifold to a vacuum pump Remove
82. be displayed in the Message Center and the unit will shutdown 62 10285 2 34 Section 2 Operation CONFIGURATION DESCRIPTION SELECTIONS DESCRIPTION SET TIME The following will allow the Real Time Clock in the Data Recorder to be set The time set here can be read in the unit data list MONTH YEAR HOURS MINUTES BACK TO CONFIGS Press to reum tothe Configuration Wain Mena 8 HR ADDITIONAL DATA YES NO YES When the SROS is turned OFF the data recorder will continue to record data for an additional 8 hours gt lt NO When the SROS is turned OFF the data recorder will stop recording data DISPLAYED DISPLAYED Set point will be shown with a decimal and NOT DISPLAYED temperatures may be selected to a tenth of a degree NOT DISPLAYED Set point will not be shown with a decimal All other temperatures will still be displayed with a decimal SATELLITE COMM QUALCOMM QUALCOMM The Microprocessor is set to send Optional OTHER Qualcomm communication messages This configuration is only visible OTHER The Microprocessor is set to send when more than 1 type of satellite communication messages other than Qualcomm communication option is installed in the Microprocessor 2 35 62 10285 Section 2 Operation 2 17 2 Diagnostic Mode NOTE To enter Diagnostic Mode Refer to Section 2 17 When Diagnostic Mode is selected the Main Display will show OFE DIAGNOSTIC MODE 1 TO SCROLL is the defaul
83. be manually reset by turning the unit off then back on again Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Microprocessor a Check Temperature Sensor Data Must be valid reading for RAT SAT AAT etc b Check for any Active Sensor Alarms Must all be cleared Check Microprocessor amp Unit Wiring a Check Wiring to Mlcro and at input Must not be miss wired to allow 12 VDC on any of the devices to the Micro sensor input circuits Reset Microprocessor a Turn Start Run Off switch off for 30 Microprocessor powers up OK seconds then turn back on b Alarm 249 remains active Replace microprocessor 62 10285 5 86 Section 6 Message Center and Alarms 6 1 Message Center What each Display Message Means 6 1 Section 6 Message Center and Alarms 6 1 Message Center What each Display Message Means The following table lists all of the messages which are not Alarms that can be displayed in the Message Center Display and a description of their use Refer to the Alarm list Page 6 7 for Alarm messages MESSAGE CENTER MESSAGES Message Description 14 TO SCROLL THEN TO LOCK This message is used when viewing Unit Data Use the 1 amp arrow keys to move through
84. be turned on RESET CONDITION Alarm may be manually reset via Keypad 1 Check unit maintenance records a Schedule unit into service facility for maintenance Must be done soon Perform maintenance a Perform appropriate engine amp unit maintenance Follow instructions on proper maintenance form Reset General Maintenance Hour Meter a Check that the General Maintenance Hour Meter interval is set for your requirements Reset General Maintenance Hour Meter for the next service interval Reset Interval in Configuration List as required Hour Meter is reset in the Functional Parameter list Follow maintenance interval recommendations in Section 8 1 See Note 1 b Clear the inactive fault code All faults cleared SERVICE SOON PM 1 DUE TRIGGER ON The Maintenance Hour Meter 1 time has expired UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via Keypad 1 Check unit maintenance records a Schedule unit into service facility for maintenance Must be done soon Perform maintenance a Perform appropriate engine amp unit maintenance Follow instructions on proper maintenance form Reset Maintenance Hour Meter 1 a Check that Maintenance Hour Meter 1 interval is set for your requirements Reset Maintenance Hour Meter 1 for the next service interval Reset Interval in
85. bracket from 05G compressor Disconnect wiring to unloader valve assemblies Compressor Discharge Temperature Sensor CDT Compressor Discharge Pressure Transducer CDP Compressor Suction Pressure Transducer CSP and the wiring to the high pressure cutout switch HPS Identify wiring and switches if necessary See Figure 8 16 Remove 10 bolts from the engine compressor spacer Disconnect ground strap from frame Remove Compressor Suction Pressure Transducer from compressor Attach sling or other device to the compressor Slide compressor enough to clear nylon drive gear Figure 8 15 and remove compressor from unit Drain oil from defective compressor before shipping The original unloader valves must be transferred to the replacement compressor The plug arrangement removed from the replacement is installed in the original compressor as a seal If piston is stuck it may be extracted by threading socket head cap screw into top of piston A small teflon seat ring at bottom of piston must be removed NOTE The service replacement compressor is sold without shutoff valves but with valve pads The valve pads should be installed on the removed compressor prior to shipping Customer should retain the original capacity unloader valves for use on replacement compressor Check oil level in service replacement compressor Refer to Section 8 15 8 23 62 10285 Section 8 Service Compressor Bolts Spacer Key Compressor Drive Gear
86. by pressing the key The timer may only be reset once during each test After the 5 minute timer expires the Message Center will return to the Component Test Mode Menu and display the last component tested To retest the same component and circuit again press To select another component to test 1 keys to select another component and press To go to Diagnostic Mode or Configuration Mode select Main Menu and press The only keys that operate during Diagnostic Test Mode are the Alarm and Select keys The alarm list is available for you to look at any active or inactive alarms The Select key will only allow access to the Current Draw item in the Data List When Component Test Mode is selected the Main Display will show The following components may be tested during the Component Test Mode Component Menu List Message Center FETLED Board LED Cool Light COOL LIGHT OFF IN X MINS 17 Heat Light HEAT LIGHT OFF IN X MINS 8 Defrost Light DEFROST LIGHT OFF IN X MINS Auto Restart Light ARL LIGHT OFF IN X MINS Out Of Range Light ORL LIGHT OFF IN X MINS Fault Light FAULT LIGHT OFF IN X MINS Unloader 1 front UL1 OFF IN X MINS Unloader 2 rear UL2 OFF IN X MINS SV1 OFF IN X MINS SV2 OFF IN X MINS SV3 SV3 OFF IN X MINS SV4 SV4 OFF IN X MINS Clutch Relay CLHR OFF IN X MINS Speed Relay SR OFF IN X MINS Run Relay RR OFF IN X MINS Buzzer BUZZER OFF IN X MINS Glow Plug Relay GPR OFF IN X MINS Main Menu
87. configured to do so will turn the engine off when the level reaches 10 The 12 00461 00 switch has a fixed point within the extended rod that reacts to a full or low fuel level There is no calibration required with this switch The 12 01147 00 sensor has the capability of sending the fuel level from 0 to 100 to the microprocessor The fuel tank level will be displayed in the Unit Data List This sensor may be calibrated if necessary 8 4 1 Calibrating the 0 100 Fuel Level Sensor NOTE Both the Empty and the Full level settings should be calibrated whenever a new sensor is installed into a fuel tank a Verify that the wiring is correct See Figure 8 3 for correct wiring b To adjust the Empty setting make certain that the fuel tank is empty and that the sensor is dry If the sensor has been in the fuel let it hang to dry for 2 hours before attempting to calibrate c Withthe sensor in the tank dry and the tank empty turn both the Full and Empty Adjustments to the full clockwise position d Place Start Run Off switch in Start Run position and place unit in Manual Start Mode e Pressthe Select Key to bring up the Unit Data List Scroll through the list until you reach Fuel Level 20 Press the key to lock the fuel level into the Message Center f Slowly turn the Empty screw counter clockwise until the display indicates 0 DO NOT ADJUST ANY FURTHER Fill the tank with fuel until full h Slowly turn the Full
88. continuity of the wire from the Must be less than 10 ohms harness plug pin C to the microprocessor plug 1MP26 Check fuel level sensor calibration a Check fuel level sensor calibration See section 8 4 1 for sensor calibration procedure Check circuits with test substitute sensor a Substitute known good sensor and clear alarm Start unit and run for 30 seconds Alarm should not come on Install new sensor b Check to see if alarm re occurs CHECK ENG COOLANT SENSOR TRIGGER ON Engine Coolant Sensor circuit has failed open or shorted If shorted the data list will display 266 F 130 C If the circuit is open the data list will show the temperature as 58 F 50 C UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when Engine Coolant Sensor is in range or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Engine Coolant Sensor a Inspect Engine Coolant Sensor amp No damage to sensor connector No damage moisture or corrosion in connector b Check Engine Coolant Sensor Refer to Section 8 30 for complete resistance chart resistance See N
89. control the unit Check to see if trailer side or rear door is open or if the device that Remote Switch 1 is connected to is set to trigger the alarm a Inspect trailer doors Trailer door s must be closed b Check devise at Remote Switch 1 Must have switch in position that allows unit to operate Check Wiring a Visually inspect wiring to switch Wiring must be connected b Visually inspect condition of switch Must not be damaged Check Remote Switch 1 a Check switch operation Contacts must Open amp Close as switch is opened and closed Check Configurations a Verify that Configuration is set for the Must be correct for type of Remote Switch being used type of switch being used ie when Door is open switch contacts are closed etc 62 10285 5 32 Section 5 Alarm Troubleshooting CHECK REMOTE SWITCH 2 more than 5 seconds Steps ALARM CAUSE CORRECTIVE ACTION TRIGGER ON Remote Switch 2 is set to trigger alarm contacts open or contacts closed depending on set up in configuration list for Remote Switch 2 for more than 5 seconds UNIT CONTROL Alarm Only or may be configured to shut unit down RESET CONDITION Alarm Only Auto Reset after Remote Switch 2 has been set to allow unit to run for Shutdown Auto Reset after 3 minutes minimum off time for Remote Switch shutdown condition and Remote Switch 2 has been set to allow unit to run for more than 5 second
90. defective or disconnected Check Will not initiate defrost manually Microprocessor defective Replace Loose terminal connections Tighten Both DTT1 amp DTT2 are above 40 F 4 4 C Cool Box Down Unit has been running less than 15 seconds Try again Initiates but does not defrost Low refrigerant charge 8 13 Solenoid valve malfunction 9 3 11 Clutch Gearbox defective Replace Frequent defrost Defrost air switch DAS out of adjustment 8 26 amp 8 27 Wet load Normal Does not terminate or Low refrigerant charge 8 13 cycles on defrost Defrost air switch DAS out of adjustment 8 26 amp 8 27 9 3 6 Abnormal Pressure 9 3 6 1 Cooling High discharge pressure Condenser coil dirty Condenser fan defective V belt broken or loose Discharge check valve restricted Noncondensibles or refrigerant overcharge Replace Solenoid valve SV 1 malfunction 8 25 Low discharge pressure SV3 or SV4 leaking by Compressor valves s worn or broken High suction pressure SV3 or SV4 leaking by Compressor valves s worn or broken Compressor gasket s defective 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 Solenoid valve SV 2 defective Clutch Failure Ultima Suction and discharge Compressor valves defective pressures tend to equalize when unit is operating
91. duce eer roe e wien 10 6 62 10499 03 Rev E UNITS WITH J 1 JUMPER Plugs Used With Schematic 62 10499 00 1 MP White zm CN 16 30 CIS M d 5 ____ 17 30 wis 749 N DTS2 MININ a iafafiafiufalfalo I lalalalalalala QIN jN 07 5 TS CDT TS RAS TS SAS RAS DPT SPT SAS gt o o o o m 3 olwv l ol o o m o Xella 5 9 gis 5 ae DTS1 Unused terminals 1 2 3 4 8 13 14 15 19 24 25 26 27 28 29 31 32 amp 33 gt ala 2 Black XN 1 24 13 2 25 14 3 26 15 4 27 J 6 29 4 a 30 19 me 20 9 32 21 10 33 22 1 34 23 12 35 18 81 1 lt gt 18 7 18 Unused terminals 1 2 3 4 6 8 9 10 11 12 13 14 15 19 20 21 22 23 24 26 27 30 32 33 34 amp 35 10 1 Componen t 8 15 27 5 17 29 Unused terminals 1 2 4 6 7 10 13 14 16 18 21 24 25 26 28 30 amp 31 62 10285 Plugs used with Schematic 62 10499 03 Rev am
92. feature for the CDP built into the microprocessor To calibrate the CDP it must be removed from the compressor and be exposed to 0 psig During the calibration process the microprocessor measures the difference between what the transducer is sending and what the microprocessor was expecting for a zero reading The difference between these two is called an offset This offset is then stored in the microprocessor s memory and is used in all future calculations for displaying compressor discharge pressure NOTE The Compressor Discharge Pressure on the microprocessor Data List will never read less than 0 psig even if it is exposed to a vacuum such as when evacuating the system Because of this just because the transducer reads 0 does not mean that it is accurately calibrated Every Discharge Transducer must be calibrated before being installed into a compressor a Power up the transducer circuit Place unit into PC Mode Refer to Section 2 16 or place unit in Manual Start Mode b Press the Select Key until Press to View Data appears in the Message Center c Press the 1 Up Arrow until Discharge Pressure is showing in the Message Center d Press and hold the Equal Key for 6 seconds The Message Center will blink 5 times When it quits blinking the display will either show 0 0 psig pressure or the message Calibration Unsuccessful e When Discharge Pressure 0 0 psig appears the offset has been saved into the m
93. for voltage at harness plug between pins for BLACK SP24 Voltage should be 12 volts negative and RED SPK5 positive wires d Check for voltage at harness plug between pins for BLACK SP24 Voltage should be greater than 0 VDC and less than 5 negative and WHITE 1 26 unless the probe is completely dry e Check continuity of the wire from the har Start Run Off Switch OFF prior to checking for continuity ness plug pin C to the microprocessor Must be less than 10 ohms plug 1MP26 Check fuel level sensor calibration a Check fuel level sensor calibration See Section 8 4 1 for sensor calibration procedure Check circuits with test substitute sensor c Substitute known good sensor and clear alarm Start unit and run for 30 seconds Alarm should not come on Install new sensor d Check to see if alarm re occurs 62 10285 5 4 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION LOW ENGINE OIL LEVEL TRIGGER ON Engine oil level is sensed approx 7 or more qts low for longer than 10 seconds UNIT CONTROL Alarm Only or may be configured to shut unit down RESET CONDITION Auto reset if engine oil level is above 4 qt Low for more than 10 seconds or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm s
94. functional parameters for this unit for more than 45 minutes UNIT CONTROL Alarm Only or Unit Shutdown amp Alarm if configured RESET CONDITION Auto Reset or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check trailer doors a Inspect all trailer doors Must be closed no air leakage Check for Low Refrigerant Pressure alarm a Check for alarm 18 Alarm conditions must be corrected and the alarm cleared to continue Check system pressures a Install Manifold Test Set and check Suction amp Discharge Pressures must be in the normal System pressures range Suction amp Discharge Pressures must have the same reading on gauges amp on micro display Check for Check Evaporator Airflow Alarm a Check for alarm 56 Must be corrected and cleared to continue Perform Pretrip Check a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding Defrost Evaporator a Initiate Manual Defrost Cycle Must terminate automatically Check refrigerant level a Visually check refrigerant level in Must be at correct level receiv
95. in Ib the 6 bolts which hold the boot and ring to the pod WARNING Do not start unit without installing the evaporator panels as unit damage or body harm may result 10 Start unit and check refrigeration cycle 8 17 62 10285 Section 8 Service 8 10 Pumping Unit Down or Removing Refrigerant Charge NOTE To avoid damage to the earth s ozone layer use a refrigerant recovery system whenever removing refrigerant When working with refrigerants you must comply with all local government environmental laws U S A EPA section 608 a Pumping the Unit Down To service the filter drier liquid line solenoid valve SV 2 expansion valve quench valve evaporator coil or heat exchanger 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 valve King Valve by turning clockwise Start unit and run in high speed cooling Place Run stop switch in the STOP position when unit reaches 1 psig 0 1 kg cm 4 Frontseat close by turning clockwise suction service valve and the refrigerant will be trapped between the compressor suction service valve and the King Valve 5 Before opening up any part of the system a slight positive pressure should be indicated on the pressure gauge 6 When opening up
96. input TEST 1 to 15 Pretrip is currently running this test and is complete TRAILER ID 2 XXXXXXXXXX Trailer identification TRIP START ENTERED The Trip start marker has been placed in the Data Recorder UNIT MODEL XXXXXXXXXX Unit model UNIT SERIAL XXXXXXXXXX Unit serial UNIT SHUTDOWN DOOR OPEN The unit has shut down because the trailer door is open UNIT SHUTDOWN SEE ALARM LIST The controller has detected a condition which caused it to shut down the unit Refer to message type SHUTDOWN ALARM in this table UNIT STARTING When Diagnostic Mode has been selected this message will appear just prior to the unit starting 6 5 62 10285 Section 6 Message Center and Alarms MESSAGE CENTER MESSAGES Message Description UNKNOWN CARD REMOVE CARD A non DataShare PC Card has been inserted into the PC Card slot The Micro can not recognize any data on the card The card may be safely removed from the Micro WARNING NO TEMP CONTROL When the unit is running in Sleep Mode it is doing so only to warm the engine up and charge the unit battery There is no temperature control and the unit may shut off before setpoint is reached 62 10285 6 6 Section 6 Message Center and Alarms ALARM Low Fuel Level Low Engine Oil Level Low Coolant Level Low Engine Oil Pressure High Coolant Temperature High Discharge Pressure Not Used Battery Voltage
97. line of the lower receiver sight glass If charge is inadequate add refrigerant charge with condenser coil still blocked Open suction valve of the manifold gauge set Add charge until level appears at center line of the lower receiver sight glass Close valve Backseat close discharge and suction service valves Close vapor valve on refrigerant drum noting weight Vent charging line and replace all caps Start unit and check for noncondensibles 8 13 3 Partial Charge Using Liquid R 22 or R 404A a Place drum of refrigerant on scale and note weight Backseat discharge and suction service valves and install a manifold gauge set Purge lines Connect a second manifold test set discharge gauge to the King Valve Purge line Connect a charging line between the center tap of the second gauge set and refrigerant drum Open the LIQUID valve on drum and purge charging line Start the unit Adjust the setpoint so that the unit will run in the cool mode 821 62 10285 Section 8 Service c Run the unit in cooling for ten minutes until the refrigeration system is warmed up and balanced and then partially block off air flow to condenser coil so discharge pressure will rise 10 psig 0 7 kg cm2 Refrigerant should appear at center line of the lower receiver sight glass If charge is inadequate continue with step d d Frontseat the King Valve and monitor the manifold gauge set When the King Valve pressure drops below the pressure i
98. made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check UL2 Rear Unloader Coil a Inspect UL2 Unloader coil amp terminals b Check resistance of coil c Check amp draw of coil No damage to solenoid No damaged or corroded pins Refer to Section 7 8 Refer to Section 7 8 Check UL2 coil wiring box See a Inspect harness amp control connector pins amp terminals wiring schematic See Notes 2 amp 6 No physical damage to harness No damaged or corroded pins Check UL2 current draw a Use Component Test Mode Refer to Section 2 17 3 to test actual current draw of the circuit 62 10285 Refer to Section 7 8 for normal current values 5 40 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK REMOTE HEAT LIGHT TRIGGER ON Remote Heat light Driver s Light Bar circuit is shorted The Heat Light output from the Micro is negative so the circuit will not be shorted to ground but is shorted either within the Heat Light itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when Heat light current amp draw is normal or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found O
99. may safely remove the PC Card from the slot XXznumber of empty download slots remaining on the card COPYING DATA PLEASE WAIT CURRENT DRAW 80 0A to 80 0A A DataShare DownLoad PC Card has been inserted into the PC Card slot and all data from the Data Recorder is being copied onto the PC Card DO NOT REMOVE THE CARD WHILE THIS MESSAGE IS BEING DISPLAYED Unit current amp draw DATA RECORDER FAILURE The controller has stopped recording unit data DEFROST CYCLE STARTED The unit has gone into defrost 62 10285 6 2 Section 6 Message Center and Alarms MESSAGE CENTER MESSAGES Message DEFROST TIMER SET FOR 1 5 HRS or 3HRS or 6 HRS 12 HRS Description This Functional Parameter allows the user to select the correct time interval between defrost cycles DIAGNOSTIC MODE Pressing while this message is being displayed allows the user to enter the Diagnostic Mode DISCHARGE PRESSURE 50 0PSIG to 500 0PSIG Compressor discharge pressure DISPLAY IN ENGLISH UNITS or METRIC UNITS Allows the user to display temperatures in either F or C and pressures in either psig or bars DISPLAY SOFTWARE REV XXXXXX Keypad Display board software revision number DOOR OPEN The trailer door is open DOOR SWITCH UNIT SHUTDOWN or DOOR SWITCH ALARM ONLY This Configuration allows the user to determine whether the door switch will display an alarm only when the trailer door
100. necessary 1 Check fan belts a Check upper fan belt tension amp condition b Check lower fan belt tension amp condition Refer to Section 8 6 for belt tensions No Glazing no cracking no slipping Refer to Section 8 6 for belt tensions No Glazing no cracking no slipping Check system pressures a Install Manifold Test Set and check and compare compressor discharge amp suction pressures with those shown on the microprocessor controller Suction pressure must be above 3 psig Suction amp Discharge Pressures must have the same reading on gauges amp on micro display Perform Pretrip Check a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding Manually defrost unit a Defrost unit and terminate automatically Typical defrost cycle time is 5 20 minutes Suction pressure should rise gradually during cycle Check evaporator air flow a Check evap fan clutch b Check evaporator section return air bulkhead air chute cleanliness of evap coil Must be engaged Good Air Flow Return air not restricted Air chute in good condition No damage to blower wheel Evap coil clean Check refrigerant charge a Check for undercharged system Level must be above lower sight glass Check Expansion Valve TXV a Visually inspect valve b Check MOP of valve c Check superheat of valve B
101. noncondensibles Check refrigerant level Check compressor oil level Refer to Section 8 15 Add oil if necessary Check compressor unloader operation Refer to Section 8 16 Check refrigerant cycles Refer to Section 2 9 62 10285 8 24 Section 8 Service 8 15 Checking Compressor Oil Level a To Check The Oil Level In The Compressor 1 Operate the unit in high speed fully loaded cool for at least 15 minutes Unplug wires to the unloaders if necessary to insure 6 cylinder operation NOTE Check the oil sight glass on the compressor to ensure that no foaming of the oil is present after 15 minutes of operation If the oil is foaming excessively check the refrigerant system for flood back of liquid refrigerant Correct this situation before performing step 2 2 After 15 minutes initiate a defrost cycle This will allow any residual oil to be returned to the compressor NOTE Operate the unit in defrost for 3 5 minutes only Do not allow the unit to terminate defrost automatically The sudden reduction of crankcase pressure at defrost termination could cause a temporary increase oil circulation and gave a false oil level reading 3 After3 5 minutes of defrost operation turn the unit off and wait 5 15 seconds Observe the compressor oil level in the sightglass See Figure 8 17 Oil level should be between the Minimum and Maximum marks Maximum Minimum Figure 8 17 Oil Level in Sight Glass
102. oO 75 0 81 4 88 1 91 5 102 5 110 2 118 3 1 12 16 18 20 22 24 5 Q o a gt el la XN m N 29 31 33 36 10 38 104 40 108 42 112 44 47 49 12 12 12 13 13 14 14 14 15 15 62 64 67 71 8 47 62 10285 Section 9 Troubleshooting 9 1 DIESEL ENGINE 9 1 1 Engine Will Not Start 9 1 9 1 2 Engine Starts Then Stops 9 1 9 1 3 Starter Motor Malfunction 9 2 9 1 4 Malfunction In the Engine Starting Circuit 9 2 9 2 ALTERNATOR 12 Volt DC 9 3 9 3 REFRIGERATION 9 3 1 Wit Will Not Cool et sene HERO HON A 9 4 9 3 2 Unit Runs But Has Insufficient Cooling 9 4 9 3 3 Unit Operates Long or Continuously in Cooling 9 4 9 3 4 Unit Will Not Heat or Has Insufficient Heating 9 4 9 3 5 Defrost Cycle Malfunction 9 5 9 3 6 Abnormal Pressure 95 01 COOBBD cL epe t SEA UU 9 5 9 0 2 Heatlig v eit ores RE EET pea TS 9 6 9 3 7 Abnormal NOISE oec eaae Ue noe ele i e 9 6 9 3 8 Control System Malfunction 9 6 9 3 9 No Evaporator Air Flow or Restricted Air Flow 9 6 9 3 10 Expansion Valve 9 7 9 3 11 Solenoid Valve Malfunction
103. recorded data can be downloaded from the DataLink Data Recorder using either DataManager a PC software program or a DataShare PCMCIA PC card The Advance Data Recorder reads the same input information as the Microprocessor Functional Parameter Configurations and Unit Data at all times The Data Recorder records events as they occur such as Set Point changes and Defrost Initiation and Termination and can record any or all temperature and pressure sensors in averaged or snapshot format The details are provided below 3 4 4 Microprocessor Information The Microprocessor Information that is available within a downloaded data file is as follows Recorder Configurations Logging Interval Event Logging Sensor Logging Real Time Clock Date Time e Compartment setpoints e Truck Trailer ID Unit Serial Number Unit Model Number e Current System Mode e Functional Parameters Controller Configurations 3 4 2 Data Recording The DataLink Data Recorder data comes from four general categories of information 1 Microprocessor Information as described in section 3 4 1 2 Sensor Data e This information is recorded at pre determined intervals as a snapshot of the sensor at the time of the recording or an averaged reading of the sensor readings since the last recording The user can determine which sensor s will be recorded at what interval and whether snapshot or averaged readings are preferred Snapshot readings of sens
104. reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Functional Parameters a Check Functional Parameters All must be set for selectable values Reset Microprocessor a Turn Start Run Off switch off for 30 Microprocessor powers up OK seconds then turn back on b Checkfor valid Functional Parameters Valid number is present in Functional Parameters List Alarm is cleared c Valid Functional Parameter s can not Replace Microprocessor be entered See Note 1 a Clear the inactive fault code Alarm 237 is cleared 62 10285 5 80 Section 5 Alarm Troubleshooting CONFIGURATIONS 1 ERROR UNIT CONTROL Unit Shutdown amp Alarm Steps ALARM CAUSE CORRECTIVE ACTION TRIGGER ON There is an error in Configuration Group 1 that is stored in the Microprocessor memory RESET CONDITION Auto Reset when valid Configuration s are entered or Alarm may be manually reset by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Configurations a Check Configurations All must be set for selectabl
105. senses a shorted circuit Out Range Light 83 Check Remote The Defrost FET senses a shorted circuit Defrost Light Check Remote Alarm The Fault output FET senses a shorted circuit Light Check UL1 Unloader The Front Unloader FET senses a shorted circuit 86 Check UL2 Unloader The Rear Unloader FET senses a shorted circuit Check Remote Heat The Remote Heat Light FET senses a shorted circuit Light Check Remote Cool The Remote Cool Light FET senses a shorted circuit Light E Check Remote Auto The Remote Autostart Light FET senses a shorted circuit Light Check Start up Buzzer output is active and the Buzzer FETsenses a shorted circuit Buzzer 62 10285 6 8 Section 6 Message Center and Alarms ALARM LL Check SV2 Circuit The SV2 Output FET senses a short in the circuit to the SV2 valve when the SV2 circuit is active SENSOR ALARMS 121 Check Ambient Air Ambient air sensor is reading lt 47 C or gt 70 C Sensor Check Return Air Return air sensor is reading 47 C or 70 C Sensor Check Supply Air Supply air sensor is reading 47 C or 70 C Sensor CHK Defrost Term 1 Defrost termination temperature sensor is reading 47 C or gt 70 C Sensor Check Disch Temp Compressor discharge temperature sensor is reading lt 40 C or gt 200 C Sensor Not Used Not Used Not Used Check Eng Coolant Coolant Temperatu
106. shorted either within the SV1 coil itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when unit calls for Heat or Defrost and the SV1 coil current amp draw is normal or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check SV1 coil a Inspect SV1 coil amp connector pins amp No damage to solenoid terminals No damaged or corroded pins b Check resistance of solenoid Refer to Section 7 8 c Check amp draw of coil Refer to Section 7 8 Check SV1 wiring a Inspect harness amp control box See Notes 2 amp 6 connector pins amp terminals See No physical damage to harness wiring schematic No damaged or corroded pins Check SV1 current draw a Use Component Test Mode Refer to Refer to Section 7 8 for normal current values Section 2 17 3 to test actual current draw of the circuit CHECK SV4 CIRCUIT TRIGGER ON In either the Heat or Defrost cycles the SV4 coil circuit is shorted The SV4 output from the Micro is negative so the circuit will not be shorted to ground but is shorted either within the SV4 coil itself or to a positive wire
107. the Data list Press the key to lock a Data item in the Message Center 14 TO SCROLL THEN TO SAVE Press the up or down arrow keys to scroll through menu selections available in this mode When you reach the desired selection press the key to store new value in Microprocessor s memory 14 TO SCROLL THEN TO SELECT Press the up or down arrow keys to scroll through menu selections available in this mode When you reach the desired selection press the key to select it TO INSTALL INSTALLS LEFT XX An Options DataShare PC Card has been inserted into the PC Card slot Press to install the option into the Micro The number of installs remaining on the PC Card will be shown ACTIVE ALARM LIST CLEARED The list of active alarms in the Micro alarm has been erased This does not remove alarms from the data recorder AIR FLOW NORMAL or HIGH This selectable Functional Parameter allows the user to determine whether the unit will operate with normal high and low engine speeds or if the engine will continuously operate in High Speed and provide high air flow to the refrigerated product ALL ALARMS CLEARED The list of active and inactive alarms in the Micro alarm lists have been erased This does not remove alarms from the data recorder ALL INFO LOADED REMOVE CARD All data has been loaded into the Micro from the PC Card The card may be safely removed from the Micro ALTERNATOR CHECK SHUTDOWN YES This Micro configuration allows the user
108. the PC Card for another attempt REMOVE JUMPER The Configuration Technician Test Mode has been entered Remove the jumper wire before continuing RETURN AIR TEMP 52 6 F to 158 0 F 47 0 C to 70 0 C 62 10285 Return air temperature 6 4 Section 6 Message Center and Alarms MESSAGE CENTER MESSAGES Message SAME PROGRAM TO LOAD 1 TO CANCEL Description A DataShare Program PC Card has been inserted into the PC Card slot and the program on the PC Card is the same as the program currently in the Micro Press to reload the same program S S MINIMUM OFF TIME 10MINS or 20MINS 30MINS or 45MINS 90 5 This Functional Parameter allows the user to determine what the minimum off time between start stop run cycles will be S S PARAMETERS SEPARATE S S PARAMETERS TOGETHER This Configuration allows the user to determine whether the same Start Stop parameters will be used for setpoints in both the Perishable Range and the Frozen Range or if each range will be handled separately SET PM HOUR METERS Pressing when this Functional Parameter message is shown allows the user access to the PM hour meter settings SET S S PARAMETERS Pressing when this Functional Parameter message is shown allows the user access to the Start Stop Minimum Run and Off times and the restart override temperatures SETPOINT CHANGED The new setpoint has been entered saved in
109. the discharge hose from the gauge manifold connect one end to the compressor oil fill port and immerse the other endin an open container of refrigeration oil Start the vacuum pump and pull the compressor into 10 15 vacuum Stop the pump Watch the oil level in the sightglass As it reaches the minimum mark stop the flow of oil from the container Refer to Section 7 5 Break any remaining vacuum raise to 0 psig with refrigerant remaining in the system crack open the suction service valve or from a fresh drum of refrigerant Replace the oil port plug and evacuate the compressor crankcase Open both service valves before starting the unit High Pressure Switch Connection Suction Service Valve Oil Fill Plug Bottom Plate Oil Drain Plug Oil Level Sight Glass Oil Pump Unloader Solenoid Discharge Thermistor Connection Discharge Service Valve OOONDARWN Figure 8 18 Compressor 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 7 5 through the suction service valve flange cavity or by removing the oil fill plug See Figure 8 18 d To remove oil from the compressor 1 Close suction service valve frontseat and pump unit down to 1 to 2 psig 0 07 to 0 1 kg cm Frontseat discharge service va
110. time is the beginning of a new trip 2 17 62 10285 Section 2 Operation 2 11 View Active Alarms ALARM LIGHT HEAT DEFROST SETPOINT BOX TEMPERATURE NO ACTIVE ALARMS will say ACTIVE ALARMS for 5 seconds 1 Press the ALARM LIST key If there are no active alarms the display 2 If there are active alarms the display will be A active and the alarm number and message The last Alarm that occurred will be the first Alarm displayed and so on 3 Press the ALARM LIST or UP ARROW key to scroll through the list of alarms 4 When you reach the end of the alarm list LIST END TO CLEAR ALARMS is displayed for 5 seconds 5 To deactivate the active alarm list press the key while LIST END TO CLEAR ALARMS is being displayed ACTIVE ALARMS LIST CLEAR is displayed This will move all Alarms to the Inactive Alarm list Unit problems detected by the controller are stored in the Alarm List in the controller Stored alarms may be viewed on the 30 character display For a complete list of Alarms and their meaning refer to the Message Center display description in Section 6 1 Refer to Section 5 1 for troubleshooting information To deactivate active alarms turn the controller OFF and then back ON using the START RUN OFF switch 62 10285 2 18 Section 2 Operation 2 12 View Inactive Alarms HEAT COOL DEFROST START STOP CONTINUOUS
111. to 13 5 VDC Do not disconnect the Red or Black wires from the switch Disconnect the Blue Wire output from the unit wiring Voltage between Black Wire negative and Blue Wire output should be 12 VDC when the switch is immersed in coolant When the switch is removed from the coolant residual coolant will evaporate quickly from the end of the switch Once the coolant has evaporated approximately 30 seconds the voltage reading between Black Wire negative and Blue Wire output should be 0 VDC NOTE Perform this test using 50 50 ethelene glycol and water mixture only This test will not perform correctly if only water is used 62 10285 8 6 Section 8 Service 8 5 3 Testing the RPM Sensor a Verify that the wiring to sensor is correct See wiring schematic section b Check voltage at the RPM Sensor connector with the Run Relay energized Unit running Unit off Manual Start Mode selected and test must be completed within 5 minutes before the Failed To Start Manual Mode occurs or Component Test Mode will energize the Run Relay for 5 minutes without starting the unit Voltage between ENRPMA 2MP31 and ENRPMC 2MP7 should be 5 0 VDC d Check continuity between ENRPMB and 2MP18 e Ifthe above tests check OK read Warning below If the RPM display is still not correct replace the RPM sensor WARNING The 5 0 VDC terminal B is common between the Compressor Discharge Pressure Transducer the Compressor Suctio
112. to determine whether the or NO unit will continue to operate or shut down when an alternator problem is detected See Configuration List for recommended settings for your model AMBIENT AIR TEMP 52 6 F to 158 0 F Ambient air entering condenser temperature 47 0 C to 70 0 C ARL LIGHT OFF IN XMINS The Auto Restart Light circuit to the Driver s Light Bar has been energized in Component Test Mode The ARL circuit will continue to be energized for the number of minutes shown BACK TO CONFIGS Pressing the key with this message showing will return the user to the main Micro Configuration list BACK TO FUNC PARAMS Pressing the key with this message showing will return the user to the main Functional Parameter list BAD PC CARD OR CARD SLOT The Micro has detected a problem with either the PC Card or the PC Card slot BATTERY 0 0V to 28 0V Unit battery voltage BUZZER OFF IN XMINS The Buzzer circuit has been energized in Component Test Mode The Buzzer circuit will continue to be energized for the number of minutes shown CALIBRATION UNSUCCESSFUL Transducer calibration was unsuccessful CANNOT ENTER TRIP START Cannot enter trip start A problem has been detected within the Data Recorder CANNOT START DEFROST CYCLE Cannot start defrost cycle Refer to Defrost Sections 2 8 4 7 7 13 and 8 26 CANNOT START PRETRIP Cannot start pretrip Refer to Pre Trip Section 2 9 6 1 62 102
113. to operate the compressor thus reducing fuel consumption The engine Refer to Table 7 1 gives excellent fuel economy and has easy starting characteristics The engine is equipped with spin on lube oil and fuel oil filters for easier filter changes NOTE Throughout this manual whenever the left or right hand side of the engine is referred to it is the side as viewed from the flywheel end of the engine The diesel engine drives the compressor directly through a nylon drive gear and adapter The adapter also includes a V belt sheave which drives the clutch gearbox The condenser evaporator fan shaft is driven with a V belt from the clutch gearbox A separate V belt from the clutch gearbox drives the alternator Electrical power for the control system and for charging the batteries is provided by the 12 alternator Also the auto start stop feature is standard equipment The auto start stop operation provides automatic cycling of the diesel engine which in turn offers an energy efficient alternative to continuous operation of the engine with control of temperature by alternate cooling and heating of the supply air evaporator outlet air 62 10285 7 2 Section 7 Unit Description 10 11 12 13 14 15 16 17 18 19 20 1 King Valve 13 By pass Oil Filter 2 Hot Gas Solenoid Valve Large SV 3 14 Engine RPM Sensor ENRPM 3 Hot Gas Solenoid Valve Small SV 4 15 Starter Motor 4 Discharge Service Valve 16 Oil Drai
114. 0 ft lbs 62 10285 8 44 i lt 4 He pP at s M12 x 1 25 x 25 mm lg HH 3 Req d 65 ft lbs 8 99 mkg SOL Section 8 Service M8 x 1 25 x 20 mm 19 3 8 24 x 1 00 Ig Grade 8 28 ft Ibs 3 87 mkg 4 Req d 28 ft Ibs 3 87 mkg 5 16 18 x 3 4 Ig Grade 8 4 25 ft lbs 3 46 mkg 9 3 8 16 x 1 3 4 19 Grade 5 6 Req d 30 ft lbs 4 15 8 45 90 ft lbs 12 45 mkg a EH A 3 8 16 x 1 lg Grade 5 10 Req d 28 ft lbs 3 87 mkg Figure 8 26 Unidrive Torque Requirements 62 10285 62 10285 Section 8 Service Table 8 4 R 404A Temperature Pressure Chart Tem EE B Kg cm 1 72 112 1 22 87245 8 249 9 273 1 289 S ao 01757
115. 10 away Controller will call for High Speed operation from setpoint and set for Continuous Run with Setpoint above 11 F Check operation of Speed Relay LED 27 must be ON Check voltage to speed solenoid Must be 12 14 VDC Check resistance of speed solenoid Refer to Section 7 8 Check amp draw of speed solenoid Refer to Section 7 8 Inspect harness amp control box No physical damage to harness connector pins amp terminals See damaged or corroded pins or terminals wiring schematic Check engine RPMs a Check actual engine RPM using hand Refer to Section 7 2 held tachometer Adjust engine linkage setting as needed b Compare actual RPMs with those Both readings within 50 RPM shown on display Check engine air intake system a Check air filter indicator Flag must not be visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Check engine exhaust system a Inspect the exhaust system Must be clear and unobstructed 5 63 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK UL1 UNLOADER TRIGGER ON The pressure differential between suction and discharge pressures did not change as expected when the UL1 Front Unloader was loaded de energized or unloaded energized UNIT CONTROL If alarm A191 is already on then Abort PreTrip amp display PRETRIP FAILED IN TEST 6 Alarm
116. 10 000 Ohms 77 F 25 Check Supply Air Sensor wiring a Inspect harness amp control box connector pins amp terminals See wiring schematic 62 10285 physical damage to harness No damaged or corroded pins 5 44 Section 5 Alarm Troubleshooting ALARM CAUSE CORRECTIVE ACTION CHK DEFROST TERM 1 SENSOR e TRIGGER ON Defrost Termination Temperature Sensor circuit has failed open or shorted If shorted the data list will display 158 F 70 C If the circuit is open the data list will show the temperature as 52 6 F 47 C UNIT CONTROL Alarm Only UNLESS Check Defrost Termination Sensor 2 alarm is also active Then defrost cycle time will be 20 minutes RESET CONDITION Auto Reset when Defrost Termination Temperature Sensor is in range or Alarm maybe manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Defrost Termination Temperature Sensor 1 a Inspect Defrost Termination No damage to sensor Temperature Sensor 1 amp connector damage moisture or corrosion in connector b Check Defrost Termination Refer to Section 8 30 for complete resistance chart Temperat
117. 12 3 psig 1 0 0 2 kg cm2 will automatically stop the engine upon loss of oil pressure There is a 15 second delay after the engine starts to allow the oil pressure to build up before the microprocessor looks at the input from this switch c Engine Coolant Temp Sensor ENCT This sensor senses engine coolant temperature The microprocessor will stop the unit when this temperature exceeds 230 F 110 C If ambient air temperature sensor AAT is at 120 F 49 C or higher the ENCT limits are increased to 230 to 240 F for 5 minutes or immediately over 240 F 116 C The sensor is located near the thermostat housing in the cylinder head d Engine RPM Sensor ENRPM The engine RPM sensor is used as an input to the microprocessor to monitor engine speed It is located on the bell housing between the engine and compressor 7 3 Engine Screw Threads All threads used on the diesel engine are metric 7 4 Engine Air System The air cleaner is put on the engine to prolong its life and performance by preventing dirt and grit from getting into the engine causing excessive wear on all operating parts However it is the responsibility of the operator to give the air cleaner equipment regular and constant attention in accordance with the instructions Refer to section 8 5 6 Clean air is supplied to the engine through the air cleaner The air is necessary for complete combustion and scavenging of the exhaust gases As the engine piston goe
118. 2 Seconds Engine Running The engine is considered to be running when VARIABLE ATTEMPT 1 Engine RPM s are greater than 1000 and 0 to 55 SECONDS i i GLOW 2 Oil pressure is ok Auto Start Sequence 4 1 62 10285 Section 4 Engine and Temperature Control 4 2 Start Stop Operation Start Stop is provided to permit starting stopping restarting of the engine driven compressor as required This feature allows full automatic control of the 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 certain conditions are met The Start Stop Continuous key is provided to select between Continuous Run and Start Stop operating modes NOTE The Microprocessor may be locked so that the unit will always operate in Start Stop whenever the setpoint is within a specific range Refer to Section 4 4 Range Lock for additional information System shut off is allowed only if the box temperature is within close range of setpoint the battery condition signal is good the battery charging amps are less than the setting selected in the Configuration List the engine has run for the minimum run time and engine coolant temperature is above 122 F 50 A restart will be initiated when one of the following conditions occurs Engine coolant temperature drops below 34 F 1
119. 4 114TV Engine Models V2203TV 220301 V1903 134 in 2 2 liters 134 in 2 2 liters 114 in 1 9 liters No Cylinders 34 hp 91900 rpm 33 hp 1900 rpm 24 hp 21700 rpm Tile OS p OW 25 hp 1350 rpm 35 2200 rpm 20 hp 91350 rpm NOTE See Table 7 1 for actual engine RPM settings for various models Weight 417 8 1 5 189 5 kg Coolant Capacity 2 gallons 7 6 liters Starts to open 157 to 5 Thermostat 162 F 69 to 72 C fully Starts to 83 open 185 F 85 Valve Clearance Cold Intake and Exhaust 0 0071 to 0 0087 inch 0 18 to 0 22 mm Engine compression must be above 400 psig a Lubrication System Oil Pressure 40 to 60 psig 2 8 to 4 2 kg cm2 Engine in high speed Oil Pressure Safety Switch Setting Closes 12 3 psig 1 05 kg cm2 Lube Oil Viscosity oF 20 10 0 10 20 30 40 50 60 70 80 90 100 30W 10W 30 15W 40 10W 30 or 15W 40 OW 20 or 5W 30 Oil Change Intervals See chart below CAUTION The maximum oil change interval is 1 year for either approved oil The only approved synthetic lube oil is Mobil Delvac 1 The normal oil change intervals listed below should be reduced if the equipment is operated under extreme conditions such as in dirty environments API MOBIL Class DELVAC 1 Hours Hours 1500 3000 2000 4000 62 10285 7 10 Section 7 Unit Description b Engine Oil Pressure Safety Switch ENOPS This switch set to open below
120. 5 5 WARNING STATUS ALARMS ALTERNATOR NOT CHARGING TRIGGER ON Unit is running either engine or standby and the current flow is more than 1 0 Amps discharge between the alternator to the battery for 3 continuous minutes UNIT CONTROL Alarm Only or Unit Shutdown amp Alarm if configured RESET CONDITION Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Microprocessor Current Sensor a Check Micro Current Value Run Stop switch ON Manual Start Mode all electrical circuits off See Note 3 Must be 0 0 5 Amps with no load Check alternator belt a Check alternator belt tension amp condition Refer to Section 8 6 for belt tensions No Glazing no cracking no slipping Check alternator wiring a Checkoutput amp ground wire unit OFF Check exciter wire if used Check AUX D terminal Inspect harness amp control box connector pins amp terminals See wiring schematic e Check output wire unit running f Check ground wire unit running Negative lead on Ground terminal Positive lead on Output terminal same as battery voltage Run Stop switch ON Man
121. 78 F 26 C 62 10285 2 2 Section 2 Operation 2 3 Stopping Unit 5 O COOL DEFROST START STOP CON TINUOU BB OINT TEMPERATURE TE J STA RUN 2 1 To stop the unit place the START RUN OFF switch to OFF position The diesel engine will stop and the Microprocessor controller will turn off The Microprocessor Main Display Message Center and all indicator LEDs will also turn off NOTE Due to internal processing within the Microprocessor turning the Start Run Off switch OFF then back to RUN will result in a 10 to 15 second delay between the display going off and coming back on again 2 3 62 10285 Section 2 Operation 2 4 Changing Setpoint HEAT COOL DEFROST ALARM START STOP CONTINUOUS 995 8 BOB SETPOINT BOX TEMPERATURE 1 TO SCROLL THEN TO SAVE MANUAL sak H AN 1 With the setpoint displayed press the UP ARROW DOWN ARROW key to change the setpoint to the desired value The display will flash to indica
122. 8 19 Thermostatic Expansion Valve 8 29 Section 8 Service 8 20 Checking and Replacing High Pressure Cutout Switch HPS 8 31 8 20 1 Replacing High Pressure 8 31 8 20 2 Checking High Pressure Switch 8 31 8 21 Compressor Discharge Pressure Transducer CDP 8 32 8 21 1 Calibrating Compressor Discharge Pressure Transducer 8 32 8 21 2 Testing Compressor Discharge Pressure Transducer 8 32 8 21 3 Replacing Compressor Discharge Pressure Transducer 8 33 8 22 Compressor Suction Pressure Transducer CSP 8 34 8 22 1 Calibrating Compressor Suction Pressure Transducer 8 34 8 22 2 Testing Compressor Suction Pressure Transducer 8 34 8 22 3 Replacing Compressor Suction Pressure Transducer 8 35 8 22 Replacing Receiver Sight Glass Assembly 8 35 824 Servicing Solenoid 8 36 8 24 1 Solenoid Valves Alco 5 2 5 8 36 8 24 2 Solenoid Valve Sporlan SV1 SV3 8 37 8 25 Solenoid Valve SV 1 Checkout Procedure 8 38 8 26 Checking Defrost or Heating Cycle 8 39 8 27 Checking Calibration of Defrost Air Switch 8 40 8 28 Evaporator Coil Cleaning 8 41 8 29 Condenser Coil Cleaning 8 41 8 30 Controller Sensor
123. 85 Section 6 Message Center and Alarms MESSAGE CENTER MESSAGES Message CARD FULL REMOVE CARD Description The PC Downloader Card is full of downloaded files There is no additional room to download the Micro You may safely remove the PC Card from the slot CARD LOCKED REMOVE CARD The lock switch on the PC Card is in the Locked position To use the PC Card move the switch to the Unlocked position CARD REMOVED DATA NOT COPIED The PC Card was removed before all data was copied onto the card CARD REMOVED REINSERT CARD The PC Card was removed from the card slot before the operation was completed Reinsert the PC Card into the card slot to perform the operation CHECK AT NEXT SERVICE INTERVAL The unit needs to be checked at next service interval One or more of the following have occurred Preventative maintenance is due or There is currently an active non shutdown alarm in the alarm list CHECK COOLANT LEVEL The engine coolant level is not full CHECK DOOR Door switch indicates that trailer door is not closed CHECK DEFROST AIR SWITCH Check defrost air switch Refer to Sections 4 7 and 8 26 CHECK ENGINE OIL LEVEL The oil level in the diesel engine is low CHECK FUEL LEVEL The level in the fuel tank is very close to empty CLHR OFF IN XMINS COMPONENT TEST MODE The Clutch Relay circuit has been energized in Component Test Mode The Clut
124. 9 5 62 10285 SECTION 9 TROUBLESHOOTING INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 9 3 6 2 Heating High discharge pressure Solenoid valves SV 1 SV 3 and SV 4 malfunction Condenser fan defective V belts broken or loose Non condensibles in system Low discharge pressure Compressor valve s worn or broken Solenoid valve SV 1 malfunction Low refrigerant charge Low suction pressure Refrigerant shortage Solenoid SV 1 open 9 3 7 Abnormal Noise Compressor Loose mounting bolts Worn bearings Worn or broken valves Liquid slugging Insufficient oil Condenser or Loose or striking shroud evaporator fan Bearings defective Bent shaft GlutchiGearbox Tighten 8 14 8 14 9 3 10 8 15 Check 8 9 8 9 9 3 8 Control System Malfunction Will not control Sensor defective Relay s defective Microprocessor controller malfunction 9 3 9 No Evaporator Air Flow or Restricted Air Flow Evaporator coil blocked Frost on coil Dirty coil No or partial evaporator V belt broken or loose air flow Clutch Gearbox defective Evaporator fan loose or defective Evaporator fan rotating backwards Evaporator air flow blocked in trailer box 62 10285 9 6 8 6 Replace 8 9 8 6 Check SECTION 9 TROUBLESHOOTING INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION 9 3 10 Expansion Valve Malfunction Low suction pressure with Low refrigerant charge 8 11 8 13 high superheat External equalizer line plugged Clean Ice for
125. A Upit DACA PL 2 22 2 15 Functional Change Parameters 2 24 2 16 freee Va i o Ue 2 28 2 17 Microprocessor Configuration and Technician Test Modes Remove Jumper Mode 2 29 2 17 1 Configuration Mode 2 30 2 17 2 Diagnostic Mode 2 36 2 17 3 Component Test Mode 2 37 2 18 Downloading Data with the PC 2 38 2 19 Installing New Software iicet Rene mets 2 39 2 19 1 Using the DataShare Program PC Card 2 39 2 19 2 Using Microprogrammer 2 40 2 19 3 Troubleshooting Software Loading Problems 2 40 2 200 Setting PM Preventative Maintenance Hourmeters 2 41 2 21 Recommended Transport Temperatures 2 43 Section 2 Operation 2 1 Starting Unit Auto MODE LIGHTS DISPLAY 3 O HEAT COOL DEFROST ALARM STARTSTOP CON TINUOU B TEMP ERATURE START RUN 79 N ae MESSAG
126. Active or Inactive Alarm List at any given time As conditions changed alarms may be moved from the Active Alarm List to the inactive alarm list and back Alarms are also recorded in the DataLink Data Recorder They are recorded at the time they occur become active and the time they become inactive TIP When alarms are cleared from the Inactive Alarm List both active and inactive alarm lists are cleared 2 19 62 10285 Section 2 Operation 2 13 Alarms amp Default Messages Unit problems detected by the controller are stored in the Alarm List in the Microprocessor controller Stored alarms may be viewed in the Message Center STATUS OK will be shown in the Message Center most of the time DATA RECORDER FAILURE will be shown if there is a problem with the DataLink data recorder If a problem begins to develop one of the following messages may be shown LOW FUEL LEVEL WARNING means that the fuel level in the fuel tank needs to be checked and fuel added CHECK ENGINE OIL LEVEL means that the engine oil level needs to be checked and oil added LOW COOLANT LEVEL means that the engine coolant level needs to be checked and coolant anti freeze added SLEEP MODE OFF ON TO WAKE will appear when the unit is in Sleep Mode and the engine has cycled off See page 2 8 for more information on Sleep Mode WARNING NO TEMP CONTROL will be displayed when the unit is in Sleep Mode and the unit has temporarily woke up and is ru
127. Battery voltage reading 12 13 VDC between wires in plug Check fuel solenoid amp circuit Check Run Relay LED LED 28 must be OFF Check voltage at harness to fuel Must be 0 VDC solenoid Check fuel solenoid plunger Must be free to move 5 19 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK STARTER CIRCUIT TRIGGER ON Engine speed failed to reach 50 RPMs during 2 start attempts UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check starter relay circuit a Check operation of starter solenoid relay b Check relay socket amp terminals Check voltage to Starter Solenoid Relay Inspect wiring to starter solenoid amp starter motor e Check voltage to starter solenoid f Check voltage to starter motor Run Stop switch ON Manual Start Mode See Note 2 Relay contacts closed when crank switch is ON No signs of discoloration from overheating No corrosion Negative lead on 85 Positive lead on 86 12 VDC Negative lead on Gnd Positive lead on 87 amp 30 12 VDC No physical dama
128. Center and Alarms ALARM Check Ambient Air Sensor Check Defrost Term 1 Sensor Check Disch Temp Sensor Not Used Not Used Not Used Check UL2 Circuit Can Not Pump Down Not Used Check Low Speed RPM Check High Speed RPM Not Used Not Used Check UL1 Not Used Not Used Check SV4 Valve Check SV1 Valve Check SV3 Valve Not Used Check UL2 Check SV2 Circuit Not Used High Suction Pressure Low Suction Pressure High Discharge Pressure Not Used Low Discharge Pressure Not Used Check UL1 Cylinders Check UL2 Cylinders High Side Leak Chk Discharge Check Valve Alarms List Engine RPM is outside limits when engine is running in low speed mode See Alarm Troubleshooting Section for RPM values for each model Engine RPM is outside limits when engine is running in high speed mode See Alarm Troubleshooting Section for RPM values for each model The difference between the compressor suction and discharge pressure did not change as expected when the front unloader was loaded or unloaded The compressor suction pressure did not increase enough when SV4 was opened during pretrip The compressor discharge pressure pressure did not increase enough when SV1 was closed during pretrip The suction pressure did not increase enough when SV3 was opened during pretrip The difference between the compressor suction and discharge pressure did not change as expected when the rear unloader was loaded or unloade
129. Check Ambient Air Sensor resistance 10 000 Ohms 77 F 25 See manual for complete See Note 4 table of temperatures and resistance values Check Ambient Air Sensor wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic 5 59 62 10285 Section 5 Alarm Troubleshooting ALARM CAUSE CORRECTIVE ACTION CHK DEFROST TERM 1 SENSOR TRIGGER ON Defrost Termination Temperature Sensor 1 is not within the maximum range of 53 F to 158 F 47 C to 70 C UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Defrost Termination Temperature Sensor 1 a Inspect Defrost Termination No damage to sensor Temperature Sensor 1 amp connector moisture damage or corrosion in connector b Check Defrost Termination 10 000 Ohms 77 F 25 C See manual for complete Temperature Sensor 1 resistance table of temperatures and resistance values See Note 4 Check Defrost Termination Temperature Sensor 1 wiring a Inspe
130. Check for valid Configurations in Data Valid number is present List Alarm is cleared c Valid Configurations can not be Microprocessor entered d Alarm 247 remains active Replace Microprocessor CONFIG MODE HP2 ERROR TRIGGER ON Microprocessor internal operational program error UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset only when valid info is available for the Microprocessor are entered Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Microprocessor a Check Setpoint setting Must be between 22 to 89 6 F 30 C to 32 C b Enter new Setpoint Must be between 22 F to 89 6 F 30 C to 32 c Check Functional Parameters All settings must be valid Reset Microprocessor a Turn Start Run Off switch off for 30 Microprocessor powers up OK seconds then turn back on b Alarm 248 remains active Replace microprocessor 5 85 62 10285 Section 5 Alarm Troubleshooting ALARM CAUSE CORRECTIVE ACTION MICROPROCESSOR ERROR TRIGGER ON Microprocessor Input Conversion Error UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset when input conversions are valid or Alarm may
131. Crank switch in the Crank position until the engine starts 62 10285 5 2 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION 5 2 DRIVER ALARMS LOW FUEL LEVEL for units with Low Fuel Level Switch no fuel level display in Data List TRIGGER ON Fuel level is less than 1 8 of a tank for more than 30 seconds UNIT CONTROL Alarm only RESET CONDITION Auto reset when fuel level is above 1 4 tank for more than 30 seconds Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for low fuel level a Check fuel level in the fuel tank Add fuel as needed to the fuel tank Check fuel level switch a Inspect fuel level switch amp connector No physical damage to switch pins amp terminals No damaged or corroded pins in plug b Check fuel level switch operation Place unit in PC Mode or in Manual Start Mode see Note 2 DO NOT START UNIT c Check for voltage at harness plug between pins A and B Voltage should be 12 volts at harness plug between pins A and B Check continuity of the wire from the harness plug pin to the Start Run Off Switch OFF prior to checking
132. Defrost Air Differential Switch The Defrost Air Differential Switch measures the difference in air pressure entering the evaporator against the pressure of the air leaving the evaporator A build up of ice will cause the difference to increase Once the pressure difference increases to the setting of the switch the contacts will go closed and initiate a defrost cycle providing that at least one of the DTTs is reading a temperature at or below 40 F 4 4 C The Defrost Air Differential Switch requires periodic testing and calibration Refer to Section 8 27 In the case where the switch is out of adjustment it will either not put the unit into defrost as soon as needed or it will attempt to put the unit into defrost prematurely In the first case the defrost timer will help correct any icing problem 2 11 62 10285 Section 2 Operation If the Defrost Air Switch calls for a defrost cycle within 8 minutes of the previous defrost cycle termination in two consecutive defrost cycles Alarm 55 Check Defrost Air Switch alarm will become active In this case the Defrost Initiation Timer will be set for 1 5 hours and the Defrost Air Switch signal will not be used to start a defrost cycle during this time TIP The Manual Defrost Key can be used at any time to start a Defrost Cycle TIP Ice is not the only thing that will cause the air differential to increase across the evaporator coil Shrink wrap paper plastic bags and other such i
133. E CENTER DOOR Place the START RUN OFF switch to START RUN position The microprocessor controller will run a self test All of the mode lights will light all of the segments on the display will be turned on all of the Liquid Crystal Display LCDs in the Message Center will be turned on and all of the selectable option lights will light to verify their operation The display will then show the setpoint temperature in the left four characters and the box temperature of the trailer in the right four characters The last character after the degree symbol shows the temperature units as Celsius or F Fahrenheit The Message Center will show STATUS OK unless there is an alarm s stored in the controller If there is an alarm s stored in the controller INACTIVE ALARMS IN MEMORY will be displayed on the Message Center and the Alarm LED will flash for 5 seconds then turn off CHECK NEXT SERVICE INTERVAL will then be displayed if there are any active non shutdown alarms present WARNING Under no circumstances should ether or any other starting aids be used to start engine The glow plugs will energize as required the buzzer will sound and the diesel engine will start 2 1 62 10285 Section 2 Operation 2 2 Manual Start Glow amp Crank O O COOL DEFROST ALARM START STOP CON TINUOU 398 8
134. ETRIP will stay displayed until a key is pressed or until the SROS switch is turned Off Once Pretrip is started the control panel keys are disabled until Pretrip is completed TIP If NOT START PRETRIP is displayed in the message center check the alarm list for active shutdown alarms or if the unit is in Sleep Mode or PC Mode 2 13 62 10285 Section 2 Operation Pretrip NOTE 1 Pretrip may be initiated any time the unit is running or when the unit is off but the Start Run Off switch is in the Run position Pretrip will not start if there is an active shutdown alarm or if the unit is in Sleep Mode or PC Mode NOTE 2 Pretrip will run until completed unless an alarm occurs that causes Pretrip to be aborted Only alarms that will result in other erroneous alarms will allow Pretrip to be aborted TIP Pretrip may be stopped by the user by either turning the unit off then back on again or by pressing and holding the Key for 5 seconds PRETRIP STOPPED BY USER will appear in the Message Center If unit is running the micro will shut it down by de energizing the fuel solenoid Once the unit is not running Pretrip will begin TIP It is always a good idea to clear all alarms from both Alarm Lists before starting Pretrip This practice allows the technician to know that any alarms present following Pretrip had to occur during Pretrip and are not old alarms that had simply never been cleared out befor
135. Heat Mode and Cool Mode there is a delay before the engine is switched into high speed The specifics are detailed below Pulldown or pull up there are no delays There is a 10 minute delay when switching from Low Speed Cool to High Speed Cool The delay timer begins when the unit first goes into Low Speed Cool e There is a 1 minute delay when switching from Low Speed Heat to High Speed Heat This timer begins when the unit first goes into Low Speed Heat 62 10285 4 12 Section 4 Engine and Temperature Control 4 6 2 Unloader Control Priority UL1 amp UL2 There is a delay of 10 seconds between LOADING de energizing compressor cylinders under all operating conditions Unloader Overrides in priority order If an override only applies or takes effect for one unloader continue down the priority list for the other unloader 1 MOP Override Maximum Operating Pressure Control see section MOP Override 2 Ifthe unit is operating in Defrost or if the Temp Control calls for 6 cylinder HEAT the MOP Override can only UNLOAD the UL1 The UL2 must remain LOADED 3 Defrost see defrost control Refer to Section 4 7 4 Frozen Setpoint Ifthe setpoint is in the frozen range below 10 4 F and the Control Temperature is below setpoint unload both unloaders 5 In the Cool Mode when the ambient temperature is below 35 F 1 7 C UL 1 will be Unloaded 6 Ifthe setpoint is in the frozen range below 10 4 F and
136. IQUID SHUT OFF VIBRASORBER SOLENOID ls HOT GAS VALVE VALVE 5 2 NC LINE gil DISCHARGE Y A FILTER SUCTION AE HPS SERVICE ces n SUBCOOLER DRIER VALVE HOT GAS 1 a lek SOLENOID T SV3 NC gt OL Y da c CONDENSER PRESSURE NC CONTROL SOLENOID DISCHARGE SV1 NO compressor A CONDENSER gt VIBRASORBER Figure 7 15 R 404A Refrigerant Circuit Heating and Defrosting 62 10285 7 22 Section 7 Unit Description EXTERNAL EQUALIZER EXPANSION A EXPANSION i VALVEBULB RECEIVER SUCTION LINE EVAPORATOR A VALVE V LIQUID LINE lt lt QUENCH VALVE gt GAs BYPASS SOLENOID VIBRASORBER HOT SHUT OFF VALVE SV2 NC GAS VALVE QUENCH LINE VALVE DISCHARGE m FILTE SERVICE HPS gt DRIER BULB VALVE B CHON Y SUBCOOLER HOT GAS ANE SOLENOID S
137. K2 SPK2 NOT GOLD PCMCIA CLHR TT LETT SPK2 3MP34 SPK2 CONTROL BOX EV2B SPK3 1 ULTRA ULTRA EXTRA EV2A X e 5 24 EVIC MPQCS SP24 ioHoH9H9eHe FET LEGEND V1 C D lt 5212 447 ESH AI 3 FSC CH9 5 6 AUTO RESTART LIGHT 280 ESPB TO SM FET HEAT LIGHT SR SAT RAT P 127 FET 9 5 4 CONTROL FET SV1 CONTROL FET FUEL HEATER RELAY o FET FAULT LIGHT TO 2MP15 E6 FET 15 OUT OF RANGE LIGHT FET 16 DEFROST LIGHT See FET 17 COOL LIGHT TO SPKS TO 1MP26 E4 FET BUZZER RELAY POWER c FET 20 5V3 CONTROL 5 FET 21 5 2 CONTROL GOLD AAT REMSN1 lt REMSN1 lt REMSN2 lt REMSN2 lt REMSN3 lt REMSN3 lt LHCE FET UNLOADER 2 CONTROL 86 UNLOADER 1 CONTROL GPR 14 301187 AEP PPR Lee Le T 25 FHR HC18 A 30 87 ENG BLOCK GRD 20 62 10499 03 Rev NDA UNITS STARTING WITH S N GAX90527303 NDX UNITS STARTING WITH S N GAT90515415 62 10285 10 6
138. NIT SHUTDOWN Message Center DATA RECORDER UNIT SHUTDOWN When Door Switch indicates that ONLY the door is open a warning alarm will be displayed in the Message Center and the unit will shutdown DATA RECORDER ONLY The data recorder will record every time the door is opened or closed There will be no alarms or messages displayed in the Message Center REMS 1 2 NOT INSTALLED NOT INSTALLED This remote switch is not installed this unit Optional DOOR OPEN 5 SWITCH OPEN DOOR OPEN SWITCH OPEN The Remote Switch will be used as a trailer door switch The switch contacts will DOOR OPEN be OPEN whenever the door is OPEN SWITCH CLOSED DOOR OPEN SWITCH CLOSED The Remote Switch SWITCH ON will be used as a trailer door switch The switch contacts CONTACTS will be CLOSED whenever the door is OPEN OPEN SWITCH ON CONTACTS OPEN The Remote Switch SWITCH ON will be used as a remote control switch The switch CONTACTS contacts will be OPEN whenever the switch is in the ON CLOSE D position SWITCH ON CONTACTS CLOSE D The Remote Switch will be used as a remote control switch The switch contacts will be CLOSED whenever the switch is in the ON position REMS 1 2 ALARM ONLY ALARM ONLY When Remote Switch 1 2 indicates Optional DOOR OPEN or SWITCH ON a warning alarm will be UNIT SHUTDOWN displayed in the Message Center UNIT SHUTDOWN When Remote Switch 1 2 indicates DOOR OPEN or SWITCH ON a warning alarm will
139. Note 4 No damage to sensor No damage moisture or corrosion in connector Refer to Section 8 30 for complete resistance chart 10 000 Ohms 77 F 25 C Check Remote Temperature Sensor 3 wir ing a Inspect harness amp control box connector pins amp terminals See wiring schematic 5 No physical damage to harness No damaged or corroded pins 49 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION 5 8 PRETRIP ALARMS PRETRIP STOPPED BY USER UNIT CONTROL Alarm Only TRIGGER ON Pretrip cycle was stopped before the Pretrip cycle ended automatically RESET CONDITION Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for any Pretrip alarms a Scroll the alarm list for any Active Pretrip alarms Alarm conditions must be corrected and the alarm cleared to continue Rerun Pretrip check if desired a Place into Pretrip mode b Allow to terminate automatically Unit running in Pretrip mode Pretrip cycle operates normally CHECK CLUTCH CIRCUIT TRIGGER ON Normal Amps for the Clutch Circuit is 2 0 to 5 5 Amps
140. Only RESET CONDITION Auto Reset when Fuel Heater Relay current amp draw is normal or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Fuel Heater Relay a Inspect Fuel Heater Relay amp socket No damage to solenoid No damaged or corroded pins b Check resistance of relay coil Refer to Section 7 8 Check Fuel Heater Relay wiring a Inspect harness amp control box See Notes 2 amp 6 connector pins amp terminals See No physical damage to harness wiring schematic No damaged or corroded pins Check Fuel Heater Relay current draw a Use Component Test Mode Refer to Refer to Section 7 8 for normal current values Section 2 17 3 to test actual current draw of the circuit 5 37 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHK REMOTE OUT RANGE LIGHT TRIGGER ON Out of Range light Driver s Light Bar circuit is shorted The Out Of Range Light output from the Micro is negative so the circuit will not be shorted to ground but is shorted either within the Out Of Range Light itself or to a positive wire UNIT CONTROL Alarm O
141. Overrides 4 12 Start Stop Operation 4 2 Start Stop Operation 2 5 Starting Unit 2 1 Stopping Unit 2 3 SV 1 Checkout Procedure 8 38 SV2 Operation Heating and Defrost 4 11 SV3 Operation Heating and Defrost 4 11 Switch Descriptions 3 10 T Temperature Control 4 6 Temperature Range Lock 1 amp 2 4 4 Thermostatic Expansion Valve 7 14 8 29 Trip Start 2 17 Troubleshooting 5 1 9 1 U UltraFresh 2 Temperature Control 4 6 Unidrive torque Requirements 8 44 Unit Data 2 22 Unit Weight 7 14 Unloader 7 18 8 27 Unloader Control Operation 4 10 Unloader Control Priority 4 13 V V Belts 8 10 Variable Glow Time 4 1 View Active Alarms 2 18 View Inactive Alarms 2 19 W Water Pump V Belt 8 10 Index 2 TRANSICOLD North America Central America Carrier Transicold and Mexico 700 Olympic Drive Ejercito Nacional No 418 Athens GA 30601 USA Piso 9 Torre Yumal Tel 1 706 357 7223 Col Chapultepec Morales Fax 1 706 355 5435 11570 Mexico D F Tel 5255 9126 0300 Fax 5255 9126 0373 A member of the United Technologies Corporation family Stock symbol UTX 2006 Carrier Corporation Printed in U S A 0606 Carrier A United Technologies Company Carrier Transicold Division Carrier Corporation Truck Trailer Products Group P O Box 4805 Syracuse N Y 13221 0 5 www carrier transicold com
142. R ON There is an error in the Trailer ID Number that is stored in the Microprocessor memory UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset only when a valid Trailer ID Number is entered NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Trailer ID Number a Check Trailer ID Number Must be between 0 to 10 digits Reset Microprocessor a Turn Start Run Off switch off for 30 Microprocessor powers up OK seconds then turn back on b Check for valid Trailer ID Number in Valid number is present Data List Alarm is cleared c Valid Trailer ID Number can not be Replace Microprocessor entered See Note 1 a Clear the inactive fault code Alarm 236 is cleared FUNCTIONAL PARAMETERS ERROR TRIGGER ON There is an error in one or more of the Functional Parameters that are stored in the Microprocessor memory UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset when valid Functional Parameters are entered or Alarm may be manually reset by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see
143. RIGGER ON No data is being recorded by the data recorder reset via Keypad NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Clear Alarm a Clear Active Alarm s b Check for Active Alarm reoccurrence Alarms Clear If Inactive download all data amp retain If Active go to next step Microprocessor defective a Download previous data using DataShare Download PC Card or DataManager Program Replace Microprocessor amp set Configurations Functional Parameters Maintenance Hour Meters and Data Recorder Setup 5 33 Data retrieval OK New Microprocessor in place 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION DATALOGGER TIME WRONG TRIGGER ON The real time clock in the Data Recorder does not contain a valid date UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when the Data Recorder Real Time Clock is reset or Alarm may be manually reset by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Conti
144. RPMs a Check actual engine RPM using hand Refer to Section 7 2 held tachometer Adjust engine linkage setting as needed b Compare actual RPMs with those Both readings within 50 RPM shown on display 62 10285 5 24 Section 5 Alarm Troubleshooting ALARM CAUSE Force High Speed operation See note 7 CORRECTIVE ACTION a Startunit setpoint more than 10 away from setpoint and set for Continuous Run operation b Check operation of Speed Relay c Check voltage to speed solenoid Controller will call for High Speed operation LED 27 must be ON Must be 12 14 VDC Check high speed engine RPMs a Check actual engine RPM using hand held tachometer b Compare actual RPMs with those shown on display Refer to Section 7 2 Adjust engine linkage setting as needed Both readings within 50 RPM CHECK GLOW PLUGS UNIT CONTROL Alarm Only TRIGGER ON Glow Plug amperage is less than 30 Amps or greater than 43 Amps after 13 seconds of glow time NOTE Coolant Temperature is below 32 F 0 C and the glow time is configured SHORT In auto start this can only occur when the Engine RESET CONDITION Auto Reset if glow plug amperage is between 30 to 43 amps for at least 13 seconds during the glow cycle or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or co
145. Start unit setpoint more than 10 Unit running in Heat Cycle above boxtemperature and setabove 11 F See note 7 c Check operation of SV 3 FET 20 LED must be ON d Check voltage to SV 3 Must be 11 VDC or higher across the 2 wires Check SV 3 circuit wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Check SV 3 a Check resistance of SV 3 Refer to Section 7 8 b Check amp draw of SV 3 Use Component Test Mode Section 2 17 3 to test Refer to Section 7 8 for amp values 62 10285 5 54 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK SV4 CIRCUIT TRIGGER ON Normal Amps for the SV 4 Circuit is 0 75 to 2 0 Amps The circuit tests outside this range UNIT CONTROL Abort PreTrip amp display PRETRIP FAILED IN TEST 2 Alarm RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for Bad F4 or F6 Fuse alarm a Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to
146. TE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Alarms a Check Alarms All must read valid values Reset Microprocessor a Turn Start Run Off switch off for 30 Microprocessor powers up OK seconds then turn back on b Check for valid Alarms in Alarms List All Alarms show valid data Alarm is cleared c Alarms can not be cleared Replace Microprocessor See Note 1 a Clear the inactive fault code Alarm 241 is cleared 62 10285 5 82 Section 5 Alarm Troubleshooting ALARM CAUSE CORRECTIVE ACTION DIS PRESS CALIBRATE ERROR TRIGGER ON There is an error in the Discharge Pressure Sensor Calibration value stored in memory UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset when the Discharge Pressure Sensor is calibrated successfully or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Discharge Pressure Reading a Check Discharge Pres
147. The circuit tests outside this range UNIT CONTROL Abort PreTrip amp display PRETRIP FAILED IN TEST 2 Alarm RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for Bad F4 or F6 Fuse alarm a Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue Check clutch amp circuit a Inspect clutch and wiring b Inspect clutch relay amp socket c Check operation of Clutch Relay d Check voltage to clutch No damage or corrosion Connector fits together tightly no moisture inside No signs of discoloration from overheating No corrosion Run Stop switch in Run Manual Start Operation See Note 2 LED 29 must be ON Must be 11 5 VDC or higher Check clutch circuit wiring a Inspect harness amp control box connector pins amp terminals See wiring schematic No physical damage to harness No damaged or corroded pins Check clutch a Check resistance of clutch coil b Check amp draw of clutch coil 62 10285 Refer to Section 7 8 Use Component Test Mode Section 2 17 3 to test
148. To access Component Test Mode or Configuration Mode These are for the Driver s Light Bar only The FET LED will illuminate however the corresponding indicator LED on the Display will not illuminate 2 37 62 10285 Section 2 Operation 2 18 Downloading Data with the PC Card MICROPROCESSOR MUST BE POWERED UP TO DOWNLOAD DATA 1 Insert a DataShare Download Card into the PC H card slot on the front of the Microprocessor Be certain that the instruction label is facing the Caution label Do not force card into slot 2 The Message Center will show COPYING DATA PLEASE WAIT While the data is being copied the green PC CARD STATUS LED will flash 3 When the copy is complete COPY COMPLETE REMOVE CARD X X is the number of empty spaces remaining on the card will show in the Message Center The PC Card Status LED will be solid You may then remove the PC card Do not remove the card until prompted to do so 4 When the card is removed the Message Center will return to the default message 5 If any other messages appear refer to section 6 1 MESSAGE CENTER for an explanation of the error message If there is an error the PC CARD FAULT LED will be on until the card is removed START STOP CONTINUOUS BOX TEMPERATURE COPYING DATA PLEASE WAIT MANUAL nes ALARM LIST S STO PAY
149. UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when unit calls for Heat or Defrost and the SV4 coil current amp draw is normal or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check SVA coil a Inspect SV4 coil amp connector pins amp No damage to solenoid terminals No damaged or corroded pins b Check resistance of solenoid Refer to Section 7 8 c Check amp draw of coil Refer to Section 7 8 Check SVA wiring a Inspect harness amp control box See Notes 2 amp 6 connector pins amp terminals See wiring No physical damage to harness schematic No damaged or corroded pins Check SV4 current draw a Use Component Test Mode Refer to Refer to Section 7 8 for normal current values Section 2 17 3 to test actual current draw of the circuit 62 10285 5 36 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK SV3 CIRCUIT TRIGGER ON In either the Heat or Defrost cycles the SV3 coil circuit is shorted The SV3 output from the Micro is negative so the circuit will not be shorted to ground but is s
150. Ultra Ultra XL and Extra units The Switch is mounted horizontal on Ultima s and vertical on all other models ofA GLOW CRANK Switch GCS lt gt 27 NOTE The GLOW CRANK Switch will energize the glow and crank circuits only when the Start Run Off switch is in the Run position and after the Microprocessor has gone through the self test GLOW CRANK switch when held in the GLOW position tells the Microprocessor to energize the glow plug relay which powers the glow plugs in the engine to preheat the combustion chamber The CRANK position of the switch tells the Microprocessor to engage the engine starter If the switch is held in the CRANK position the starter will engage after a short delay of up to 1 second for a maximum 10 seconds If the GLOW CRANK switch is held in the GLOW position before the Start Run Off switch is placed in the Start Run position when the Start Run Off switch is turned on the unit start mode is changed to MANUAL START and the unit operation mode is set to CONTINUOUS RUN When the engine is running this switch is disabled Key Descriptions MANUAL DEFROST 7 0 ALARM LIST UP ARROW and DOWN ARROW Keys These keys allow you to change the set points or other displayed data of the system Also allows you to scroll through the Unit Data List Function Parameters List Alarm List etc EQUAL Key ENTER The EQUAL key is used for many things including entering a setpo
151. Unloader Circuit is 0 75 to 2 0 Amps The circuit tests outside this range UNIT CONTROL Abort PreTrip amp display PRETRIP FAILED IN TEST 3 Alarm RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check wiring to DPT amp SPT a Verify that correct wires are connected to each transducer Plugs to transducers are the same The correct wire plug must be connected to the proper transducer Check for Bad F4 or F6 Fuse alarm a Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue Check UL2 amp circuit a b Inspect UL2 and wiring Check operation of UL2 FET 22 Check voltage to UL2 No damage or corrosion Connector fits together tightly no moisture inside Run Stop switch in Run Manual Start Operation See Note 2 LED must be ON Must be 11 VDC or higher across the 2 wires Check UL2 circuit wiring a Inspect harness amp control box connector pins amp terminals See wiring schematic No physical damage to harness No damaged or corroded pins Check UL2
152. Unloader alarm a Check for alarm P191 Alarm conditions must be corrected and the alarm cleared to continue Check SV1 for being closed 62 10285 Check voltage to SV1 coil b Check pressure differential between compressor discharge port and Must be 0 VDC Must be less than 25 psig receiver king valve 5 64 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK SV4 VALVE TRIGGER ON Suction pressure did not rise within range amp discharge pressure did not drop within range when SV4 was energized opened UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for SV4 Alarm a Check for alarms 79 P150 Alarm conditions must be corrected and the alarm cleared to continue Check system pressures a Check and compare compressor discharge amp suction pressures with those shown on the microprocessor controller Suction amp Discharge Pressures must have the same reading 5 psig on gauges amp on micro display Check SV4 operation Unit must be
153. V3 NC j A HOT GAS gt SOLENOID p SV4 NC DISCHARGE CHECK VALVE f A DISCHARGE LINE VIBRASORBER E CONDENSER PRESSURE CONTROL Figure 7 16 R 22 Refrigerant Circuit Heating and Defrosting 7 23 SOLENOID SV1 NO 62 10285 Section 8 Service 8 1 Maintenance Schedule bee ed a 8 1 8 2 Priming Fuel System 8 2 5 9 spserviciny Fuel P MP aod 8 3 8 4 Fuel Level Switch and Fuel Level Sensor 8 4 8 4 1 Calibrating the 0 100 Fuel Level Sensor 8 4 8 4 2 Testing the 0 100 Fuel Level Sensor 8 5 8 4 3 Testing the Fuel Level Switch 8 5 85 Engine Service and Components 8 6 5o T Cooling System 8 6 8 5 2 Testing the Coolant Level Switch 8 6 8 5 3 Testing the RPM Sensor 8 7 8 3 4 Lube Pers bea teener 8 7 8 5 5 Servicing the Speed Control Solenoid and Linkage 8 7 8 5 6 Engine Air Cleaner 8 8 8 5 7 Engine Crankcase Breather 8 9 8 5 8 Servicing Glow 8 10 8 6 Servicing and Adjusting V belts 8 10 8 6 1 Belt Tension Gauge 8 10 8 6 2 Water Pump
154. Write Failure Configurations 3 Error CONFIG MODE HP2 Error Microprocessor Error 2 21 SHUTDOWN ALARMS Alarms may be cleared from the display by turning the Start Run Off switch off waiting afew seconds then turning it back on again or by viewing all the alarms in the Active Alarm list At the end of the list are the instructions LIST END TO CLEAR ALARMS Pressing the enter key while this message is in the Message Center will clear all active alarms In the event that the alarm re occurs it will reappear in the Message Center The unit may need to go in for repairs if an alarm reappears multiple times 62 10285 2 14 Unit Data Section 2 Operation HEAT COOL DEFROST START STOP CONTINUOUS B 98889 SETPOINT BOX TEMPERATURE PRESS 1 TO VIEW DATA MANUAL DEFROST EAM Se 1 Press the SELECT key until DATA is lit The Message Center will show PRESS 1 TO VIEW DATA 2 By pressing the 1 UP ARROW key you will move through the Data List beginning at the top and moving toward the bottom or by pressing the DOWN ARROW key you will move through the Data List beginning at the bottom and moving toward the top 3 To lock a Data List item in the Message Center press the ENTER key The Data item will flash on and off to indicate it is locked 4 Pressing 1 UP or DOWN key will unlock that item and move to the next data item Pressing the ENTER k
155. a functional parameter setting stored in the microprocessor Error memory 205 IN N N NIN 238 Configurations 1 Error There is an error in a configurations 1 stored in the microprocessor memory 39 Configurations 2 Error There is an error in a configurations 2 stored in the microprocessor memory Hour Meter Error There is an error in the number of hours in microprocessor memory PO A EB N 41 Alarm Status Error There is an error an Alarm that is stored in microprocessor memory 242 DIS Press Calibrate There is an error in the discharge pressure sensor calibration that is stored in Error memory 243 Suct Evap Calibrate There is an error in the suction evaporator pressure sensor calibration that is stored Error in memory Micro SW Rev Error There is an error the microprocessor revision number that is stored memory EEPROM Write There is an error in the ability to write information to be stored in memory Failure 247 Configurations 3 Error There is an error in a configurations 3 stored in the microprocessor memory 48 Config mode HP2 There is an error a configurations HP2 stored in the microprocessor memory Error 249 Microprocessor Error Microprocessor input conversion error N A A 6 11 62 10285 Section 7 Unit Description lt ier sac et 7 1 T
156. all coil assembly nameplate and top locknut or screw Dehydrate and evacuate the system Refer to section 8 12 Charge unit with refrigerant per sections 8 13 Start unit and check operation Locknut Screw Spacer Cup Nameplate Coil Spacer Enclosing Tube Locknut Enclosing Tube Gasket Seat Disc Body Stem and Plunger h h Figure 8 24 Solenoid Valves Sporlan 8 37 62 10285 Section 8 Service 8 25 Solenoid Valve SV 1 Checkout Procedure To obtain proper heating and defrost the normally open N O SV 1 solenoid valve must energize and close tightly during the heat and defrost cycles If the valve does not close tightly due to physical damage foreign material or wear refrigerant leakage through the valve can reduce heating capacity a During normal heat or defrost cycles the following conditions will be observed when the valve is Operating properly 1 Receiver refrigerant level will drop quickly at the initiation of heating or defrost mode 2 Suction pressure will rise slowly to 90 100 psig 6 3 to 7 0 kg cm 3 Discharge pressure will drop quickly but begin to rise to a minimum of 250 psig 17 5 kg cm2 within 15 to 20 minutes b Ifsuction and discharge pressures remain low and the receiver level does not drop the valve may be inoperative and can be checked by the following method 1 Verify the solenoid coil has proper voltage and is ene
157. and remove old belt Place V belt on alternator sheave and then install alternator with two bolts loosely in position Check the center alignment of the Gearbox Clutch Ultra Ultra XL amp Extra or Gearbox Ultima drive pulley and alternator pulley to ensure proper alignment Pulley misalignment will create excess belt wear and shorten alternator bearing life The center line of the alternator sheave and the drive sheave must be in line Pivot alternator to place tension on belt using hand force only Do not use pry bar or excessive force as it may cause bearing failure For correct belt tension see Table 8 1 Tighten pivot and adjustment bolts Reinstall negative battery cable 1 1 2 1 E 5 OC Evaporator Condenser Fan V Belt Idler Pulley Alternator V Belt Drive V Belt ROD Figure 8 9 V Belt Arrangement 8 6 4 Driveshaft to Gearbox and Gearbox To Fan Shaft V Belt a Gearbox to Fan Shaft V Belt To Replace V belt 1 5 Disconnect negative battery cable and remove V belt guard 2 Loosen idler pulley 3 4 Using a belt tension gauge Figure 8 8 on the belt rotate idler pulley so that the gauge reads Remove old belt and replace with new belt See Figure 8 9 the correct tension Refer to Table 8 1 Tighten idler carriage bolt and bolts NOTE B
158. ant temp ENCT defective Fuel solenoid defective Run Stop switch defective 62 10285 9 2 Check Tighten Replace Replace Replace Engine Manual Replace SECTION 9 TROUBLESHOOTING 9 2 ALTERNATOR 12 Volt DC INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION Alternator fails to charge Low or unsteady charging rate Excessive charging rate as evidenced by battery requiring too frequent refilling or amp reading shows constant high amp charge Noisy alternator Limited charging system operating time Battery condition Alternator belt loose broken Loose dirty corroded terminals or broken leads Excessively worn open or defective brushes Open blocking diode Regulator faulty Open isolation diode Open rotor field coil Alternator belt loose Loose dirty corroded terminals or broken leads Excessively worn sticky or intermittent brushes Faulty regulator Grounded or shorted turns in rotor Open grounded or shorted turns in stator Regulator leads loose dirty corroded terminals or wires broken Defective regulator Defective or badly worn V belt Worn bearing s Misaligned belt or pulley Loose pulley 9 3 Check Check 8 6 Check Repair Check Check Check Check Replace 8 6 Check Repair Check Check Check Replace Clean Repair Check 8 6 Replace 8 6 Tighten 62 10285 SECTION 9 TROUBLESHOOTING INDICATION REFERENCE 9 3 REFRIGERATION 2 3 1 Unit Will Not Cool Co
159. ant to the evaporator to obtain maximum use of the evaporator heat transfer surface The refrigerant pressure drop caused by the expansion valve is accompanied by a drop in temperature thus the low pressure low temperature fluid that flows into the evaporator tubes is colder than the air that is circulated over the evaporator tubes by the evaporator fan The evaporator tubes have aluminum fins to increase heat transfer therefore heat is removed from the air circulated over the evaporator This cold air is circulated throughout the trailer 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 404A units this low temperature low pressure vapor passes through the Liquid Line Suction Line heat exchanger where it absorbs more heat from the high pressure high temperature liquid and then returns to the compressor 7 19 62 10285 Section 7 Unit Description
160. art the Defrost Cycle Only one of the DTTs must be below 40 F 4 4 C to allow the Defrost Cycle to start After the Defrost Cycle is started it will terminate automatically when Both DTTs rise to 55 F 12 8 C software versions prior to 01 06 00 or DTT1 is above 45 F 7 2 C and DTT2 is above 55 F 12 8 C software versions 01 06 00 and later 62 10285 2 36 Section 2 Operation 2 17 3 Component Test Mode NOTE To enter Component Test Mode Refer to Section 2 17 Component Test Mode allows the Technician to energize individual circuits for 5 minutes at a time The engine is not allowed to start when the Micro is in Component Test Mode From the Main Menu select Component Test Mode and press 1 TOSCROLL THEN TO SELECT are your instructions to use the up amp down arrow keys to scroll through the list select the component you wish to test then press For example if the Cool Light is selected the Cool Light on the Driver s Light Bar will come on and COOL LIGHT OFF IN 5 MINUTES will appear in the Message Center The minutes will count down to 0 at which time the Cool Light circuit will be de energized and the Message Center will display the last component tested The test may be stopped at any time by turning the Start Run Off Switch SROS to the Off position or by pressing and holding the key for 6 seconds Should you need more than 5 minutes the timer may be reset to 5 minutes anytime during the test
161. as failed open or shorted If shorted the data list will display 158 F 70 C If the circuit is open the data list will show the temperature as 52 6 F 47 C UNIT CONTROL Alarm Only UNLESS Check Defrost Termination Sensor 1 alarm is also active Then defrost cycle time will be 20 minutes RESET CONDITION Auto Reset when Defrost Termination Temperature Sensor 2 is in range or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Defrost Termination Temperature Sensor 2 a Inspect Defrost Termination No damage to sensor Temperature Sensor 2 amp connector No damage moisture or corrosion in connector b Check Defrost Termination Refer to Section 8 30 for complete resistance chart Temperature Sensor 2 resistance 10 000 Ohms 9 77 F 25 C See Note 4 Check Defrost Termination Temperature Sensor 2 wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic CHK REMOTE TEMP SENSOR 1 TRIGGER ON Remote Temperature Sensor 1 circuit is configured on and has failed open or shorted If shorted the data lis
162. ater than 80 F 26 7 C the following stages are performed for defrost Refer to Table 7 3 The first stage Pump Down runs for a minimum of thirty seconds and then checks the suction pressure When the suction pressure is less than 10 PSIG it will continue to stage 2 The total time in stage one cannot be greater than 330 seconds If 330 seconds is reached stage two Defrost Begins will automatically be entered regardless of suction pressure Stage 2 is defrost Stage 3 Defrost Termination is the termination of defrost When defrost is terminated SV4 will remain energized for 15 seconds Table 7 3 Stages for Defrost with Greater Than 80 F 26 7 C Ambient smGE svi 5 svs sva UR UF SPEED OPEN OPEN De energ De energized CLOSED De energ Energ Energized HOT GA EXTERNAL EQUALIZER EXPANSION VALVE BYPASS LINE pa EXPANSION A VALVE FUSIBLE Ho BULB A _ RECEIVER EVAPORATOR J BYPASS M gt A CHECK Y HEAT EXCHANGER VALVE 1 LIQUID LINE L
163. ator coil by reversing the normal air flow Air is pulled in through the front and discharges over the engine 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 Drain coolant completely by removing lower radiator hose and radiator cap Install hose and fill system with clean water to which an akaline based radiator cleaner is added use a good brand name heavy duty radiator flush and follow the manufacturer s directions Run engine 6 to 12 hours and drain system while warm Rinse system three times after it has cooled down Refill system with water Run engine to operating temperature Drain system again and fill with 50 50 water anti freeze mixture see Caution Note and refer to Section 7 2 NEVER POUR COLD WATER INTO HOT ENGINE however hot water can always be added to a cold engine 8 5 2 Testing the Coolant Level Switch a b Verify that the wiring to switch is correct See wiring schematic Check voltage at the Coolant Level Switch with the Run Relay energized Unit running Unit off Manual Start Mode selected and test must be completed within 5 minutes before the Failed To Start Manual Mode occurs or Component Test Mode will energize the Run Relay for 5 minutes without starting the unit Voltage between Red Wire positive and Black Wire negative should be 12 5
164. attery Check for battery specifications e Perform load test on battery Follow Check for battery specifications battery manufacturer s procedure Check voltage at microprocessor a Check voltage reading at Run Stop switch ON Manual Start Mode See Note 2 microprocessor input MPQC1 to Must be above 11 VDC MPQC2 Check voltage reading on Must be within 5 VDC of reading obtained in 3a above microprocessor display 5 11 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION HIGH COMP DISCHARGE TEMP TRIGGER ON Ambient temp below 120 F 48 9 C discharge temp was between 310 F 349 F 154 4 C 176 7 C for 3 minutes or Ambient temp above 120 F 48 9 C Discharge temp was between 340 F 349 F 171 1 C 176 7 C for 3 minutes or Discharge temp ever reaches 350 F 176 7 C UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset after 15 minutes with Ambient temp below 120 F 48 9 C the discharge temp falls below 300 F 148 8 C or Auto Reset after 15 minutes with Ambient temp above 120 F 48 9 C the discharge temp falls below 330 F 165 4 C or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appro
165. ature pulley has been located to the shaft c Remove the shaft key 7 and shims 5 3 Remove rotor pulley assembly 3 a Remove bearing retainer nut 4 using removal tool 07 00303 01 b Slide rotor pulley assembly 3 from gearbox housing 4 Remove the field coil assembly 1 a Remove field coil assembly retaining ring 2 b Remove field coil assembly 1 from gearbox b Clutch Installation 1 Install field coil assembly 1 a Place field coil assembly 1 on pilot diameter of gearbox Align slot in field coil assembly with locator pin in gearbox housing b Install field coil retaining ring 2 IMPORTANT The retaining ring s beveled or tapered edge must face away from the gearbox to obtain proper retention force 2 Install rotor pulley assembly 3 8 13 62 10285 3 Section 8 Service a Slide rotor pulley onto gearbox housing DO NOT POUND on rotor assembly rock back and forth gently with hand pressure until unit slides on b Install bearing retainer nut 4 Tighten nut to 65 Ib ft Rotor should spin free without noise Install armature pulley assembly 6 a Slide armature assembly 6 onto gearbox shaft Measure air gap between armature face and rotor face using Air Gap Tool 07 00360 01 or a wire type feeler gauge Three access holes are provided in the pulley face b Iftheairgapislessthan 0 020 in remove armature assembly and add shim s 5 to shaft as shown in Figure 8 11 Use only new shim
166. ature will not and REMOVE JUMPER will appear in the Message Center for 10 seconds Remove the jumper at this time 1 TO SCROLL THEN TO SELECT will appear in the Message Center for 10 seconds or until either the 1 keys are pressed 4 The first selection is Configuration Mode then Diagnostic Mode and finally Component Test Mode 5 Press the ARROW Key to scroll through the Main Menu beginning at the top Press the ARROW Key to scroll through the Main Menu beginning at the bottom 6 Select the Mode you wish to access and press the key 7 For Configuration Mode Refer to Section 2 17 1 For Diagnostic Mode Refer to Section 2 17 2 For Component Test Mode Refer to Section 2 17 3 2 29 62 10285 Section 2 Operation 2 17 1 Configuration Mode NOTE To enter Configuration Mode Refer to Section 2 17 1 1 TO SCROLL THEN TO SELECT will appear in the Message Center 2 Press the ARROW Key to scroll through the Configuration list beginning at the top Press the ARROW Key to scroll through the Configuration list beginning at the bottom 3 To read through the Configuration list continue to press either the 1 or The list is circular meaning that once the end is reached it is repeated from the beginning 4 change one of the Configurations bring the Configuration to change into the Message Center and press 1 TO SCROLL THEN TO SAVE will show in the Message Center for 10 seconds Then the selec
167. aximum Temperature of 0 F Any setpoint outside of Range 1 or 2 will allow changes between Start Stop and Continuous Run 62 10285 4 4 Section 4 Engine and Temperature Control Range Lock 1 amp 2 ee ea This Range is set for 28 F to 55 F a s 222 10 0 10 20 30 40 50 60 70 80 In the same example as above Range 1 or Range 2 can be changed to lock the unit operation into Start Stop The primary time that it is important to determine which range is to be Range 1 and which is to be Range 2 is when the ranges overlap each other In example 2 see Figure below the ranges will be set to lock all setpoints into Start Stop except for a small range between 32 F and 42 F where the unit will always operate in Continuous Run Range 1 Minimum Temperature will be set for 32 and Maximum Temperature of 42 F Range 2 will be set for a Minimum Temperature of 22 F and a Maximum Temperature of 89 6 Whenever Range 1 amp Range 2 overlap Range 1 always has the priority Range 1 is 32 F to 42 F Set for Continuous r J 22 10 0 10 20 30 40 50 60 70 80 4 5 62 10285 Section 4 Engine and Temperature Control 4 5 Temperature Control Perishable or Frozen There are two control ranges Frozen and Perishable The Frozen range is active with set points at or below 10 4 F 12 C and the Perishable ran
168. ay be manually reset by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Setpoint a Check Setpoint setting Must be between 22 F to 89 6 F 30 C to 32 C b Enter new Setpoint Must be between 22 F to 89 6 F 30 C to 32 Reset Microprocessor a Turn the Start Run Off switch off for The microprocessor powers up OK and the latest setpoint 30 seconds then turn back on appears in the display b Valid Setpoint can not be entered Replace Microprocessor See Note 1 a Clear the inactive fault code Alarm 232 is cleared MODEL ERROR TRIGGER ON There is an error in the Model Number that is stored in the Microprocessor memory UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset only when a valid Model number is entered NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Model Number a Check Model Number in Must be a valid Model Numbe
169. ay be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for low fuel level warning alarm a Check for alarm 1 Add fuel as needed to the fuel tank 62 10285 5 14 Section 5 Alarm Troubleshooting ALARM CAUSE CORRECTIVE ACTION HIGH SUCTION PRESSURE TRIGGER ON Suction pressure has been greater than 98 psig for more than 10 minutes UNIT CONTROL Alarm Only or Unit Shutdown amp Alarm if configured RESET CONDITION Auto reset when suction pressure is less than 75 psig for 5 minutes or alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check system pressures a Check and compare compressor Suction amp Discharge Pressures must have the same discharge amp suction pressures with reading x 5 psig on gauges amp on micro display those shown on the micro
170. b Visually inspect condition of switch Must not be damaged Check Door Switch a Check switch operation Contacts must Open amp Close as door is opened and closed Check Configurations a Verify that Configuration is set for the Must be correct for type of door switch type of switch being used ie when Door is open switch contacts are closed etc 62 10285 5 34 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION 5 6 ELECTRICAL ALARMS BAD F2 OR F3 FUSE TRIGGER ON One or more of the following fuse circuits have been open for more than 2 seconds F2 F3 UNIT CONTROL Alarm Only RESET CONDITION Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check unit operation a Did unit shut down Yes Check No Check F2 Check fuses a Locate blown fuse s Will have open circuit b Verify fuse size Refer to Section 7 7 Must be correct rating for circuit see wiring diagram Inspect fuse amp fuse holder Terminals tight No signs of overheating melting or discoloration Check circuit a Check amperage draw on Speed Refer to Section 7 8 Relay circu
171. be locked out using Service Tool When Keypad access is locked out a padlock symbol will appear in the Message Center Available selections from the Functional Parameter List for the PM Hourmeters are OFF This selection will suspend the operation of the PM Hourmeter The Hourmeter will continue to count hours but the alarm will not be generated RESUME This selection will resume the operation of a PM Hourmeter that has been turned off If the Hourmeter is currently running then this selection will have no effect on the Hour Meter RESET This selection is only available when the accumulated hours are within 5 or more ofthe reset value for that Hourmeter For example the Engine PM Hourmeter Reset Interval is 1000 hrs Reset will be allowed anytime after 950 hours have expired TIP Units originally came from the factory with the Engine PM Hourmeter on and the reset value set for 400 Hrs For these units at the first PM the reset value in the Configuration List should be changed to the recommended interval for each particular engine or to the user s requirements Current units come with the Engine PM Hourmeter set for 1500 Hrs 62 10285 2 42 Section 2 Operation In the event that the Engine PM Hourmeter is reset to 400 hours from the Functional Parameter List before the reset value in the Configuration List has been changed the following procedure may be From the Configuration List select the PM Hourmeter and change the reset in
172. bleshooting Guide 5 1 K Key Descriptions 3 10 L Lube Oil Diagram 7 17 Lube Oil Filter 8 7 Lubrication System 7 12 INDEX Index 1 Index M Maintenance Schedule 8 1 Manual Defrost 2 10 Manual Start Glow amp Crank 2 2 Maximum Off Time 4 3 Maximum Operating Pressure MOP Override 4 14 Message Center 3 9 Message Center What each Display Message Means 6 1 Microprocessor Configurations 2 10 2 11 2 29 2 30 Microprogrammer 2 40 Minimum Off Time 4 3 Minimum On Time 4 2 Out Of Range Alarm 3 15 Output Overrides 4 12 PC Communication Mode 3 13 PC Mode 2 28 Perishable Frozen 4 6 Pretrip 2 13 Priming Fuel System 8 2 Pulldown Pull up Mode 4 9 Pulsed Null Mode Operation 4 10 Pumping Unit Down 8 18 R Receiver Sight Glass 8 35 Recommended Transport Temperatures 2 43 Recording 3 4 Refrigerant Charge 8 18 8 21 Refrigerant Circuit Heating amp Defrosting 7 23 Refrigerant Circuit Cooling 7 21 Refrigeration Charge 7 14 Refrigeration System Data 7 14 Remote Switches 3 14 RPM Sensor 8 7 Safety Decals 1 2 Safety Precautions 1 1 Safety Devices 7 15 Selected Option Lights 3 11 Sensor 8 42 Serial Port 3 13 Setting PM Preventative Maintenance Hourmeters 2 41 Sleep Mode 2 8 3 14 Solenoid Valves 8 36 Special Features 3 2 Speed Control Solenoid 8 7 Speed Control Solenoid SCS Operation 4 10 Speed Control Solenoid SCS
173. both RAT and SAT sensor alarms are active the unit will run in low speed cool 7 Auto Start Unloader Override Function Ifthe system is running in Start Stop Run Mode the minimum run time has expired and the box temperature is not at set point both unloaders will be LOADED de energized 8 Ifthe set point is in the perishable range and the Control Temperature is within the low engine speed range UNLOAD the ULI 9 UltraFresh 2 Unloader Override Function Perishable Setpoint UNLOAD both and UL2 if the following conditions are satisfied The system is in the Cool Mode AND The Supply Air Sensor is good AND The main compartment setpoint is in the perishable range above 10 AND e Supply Air Temperature is less than 5 4 F 3 C below setpoint The system is in Cool Mode AND The Supply Air Sensor is defective but the Return Air Sensor is good AND The main compartment setpoint is in the perishable range above 10 4 AND The Ambient Air Temperature is less than 90 F 32 2 C AND The Return Air Temperature is less than 9 F 5 C above the setpoint If the Supply Air Sensor is good then UNLOAD the UL1 and UL2 until the Supply Air Temperature is greater than the setpoint OR If the Supply Air sensor is not good UNLOAD both UL2 and UL until the Return Air Temperature is more than 14 4 F 8 C above the setpoint or the ambient exceeds 90 F 32 2 C 4 13 62 10285 Section 4 Engine and
174. cated box temperature to obtain high speed cooling Press the MANUAL DEFROST key to initiate defrost or DTT2 must be at or below 40 F 4 4 C The hot gas solenoid valve SV4 will energize and the hot gas line will be hot to touch on both sides of the valve The condenser pressure control solenoid SV1 closes and suction pressure will rise approximately 10 to 15 psig 0 70 to 1 05 kg cm after 5 minutes on unit operation Refer to Section 8 25 if unit does not heat properly SV 3 will open under the following conditions The unit is operating in High Speed and Ambient Air Temperature AAT alarm is not active and SV4 has been open for at least 60 seconds and Ambient Air Temperature is less than 70 F 21 1 C and CDT minus AAT is more than 131 F 55 C SV 3 will close under the following conditions Ambient Air Temperature AAT alarm becomes active or CDT minus AAT becomes less than 82 F 27 8 C or Ambient Air Temperature rises to 80 F 26 7 C Unit should remain in defrost until located in the blower housing reaches 45 F 7 2 C and DTT2 located on the center tube sheet below the evaporator reaches 55 F 12 8 C At this point the defrost cycle will terminate and the unit will resume automatic operation b Defrost Air Switch DAS 1 To check the Defrost Air Switch run unit in high speed cooling and jump across the air switch terminals This will start the defrost cycle as it sim
175. ce of buzzer Refer to Section 7 8 Check buzzer wiring a Inspect harness amp control box See Notes 2 amp 6 connector pins amp terminals See No physical damage to harness wiring schematic No damaged or corroded pins Check Buzzer current draw a Use Component Test Mode Refer to Refer to Section 7 8 for normal current values Section 2 17 3 to test actual current draw of the circuit 62 10285 5 42 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK SV2 CIRCUIT TRIGGER ON SV2 coil circuit is shorted The SV2 output from the Micro is negative so the circuit will not be shorted to ground but is shorted either within the SV2 coil itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when unit calls for Heat or Defrost and the SV2 coil current amp draw is normal or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check SV coil a Inspect SV2 coil amp connector pins amp No damage to solenoid terminals No damaged or corroded pins b Check resistance of SV2 Refer to Section 7 8 c Check
176. ch Relay circuit will continue to be energized for the number of minutes shown Pressing while this message is being displayed will allow user access to Component Test Mode COMPONENT TEST MODE MENU SELECTIONS The selections following this message will be the components available for energizing during Component Test Mode COMP DISCHARGE TEMP 40 0 F to 392 0 F 40 0 C to 200 0 C Compressor discharge temperature CONFIG ERROR REMOVE CARD CONFIGURATION MODE There was an error configuring the Micro with the DataShare Configuration PC Card Remove the PC Card from the slot Press to enter Configuration Mode CONFIGURATION NOT CHANGED New configuration selection was not Entered saved CONTINUOUS LOCKED The current Set Point is within a range that has been locked into the Continuous Run mode Start Stop can not be selected CONTINUOUS RUN MODE SELECTED CONTROL SERIAL XXXXXXXXXX Continuous run mode is selected Microprocessor serial COPY COMPLETE REMOVE CARD XX A DataShare DownLoad PC Card has been inserted into the PC Card slot and all data from the Data Recorder has been copied onto the PC Card You may safely remove PC Card from the slot XX number of empty download slots remaining on the card COPY ERROR REMOVE CARD XX A DataShare DownLoad PC Card has been inserted into the PC Card slot and an error occurred while the data was being copied onto the PC Card You
177. charge amp suction pressures with reading x 5 psig on gauges amp on micro display those shown on the microprocessor controller Check SV1 operation Unit must be running in Heat Cycle See Note 7 a Set unit to operate in high speed heat After 3 minutes note discharge and suction pressures b De energize SV1 coil Compressor discharge pressure will drop Receiver tank pressure will raise slightly Manually test refrigeration system a Run Quick Check Must pass all tests Correct any problems found before proceeding 62 10285 5 66 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK SV3 VALVE TRIGGER ON Suction pressure did not rise within range amp discharge pressure did not drop within range when SV3 was energized opened UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for SV3 Alarm a Check for alarms 80 P149 Alarm conditions must be corrected and the alarm cleared to continue Check system pressures a Check and compare compressor Suction amp
178. chedule unit into service facility for Must be done soon maintenance Perform maintenance a Perform appropriate engine amp unit Follow instructions on proper maintenance form maintenance Reset Maintenance Hour Meter 3 a Check that Maintenance Hour Meter Reset Interval in Configuration List as required 3 interval is set for your requirements Hour Meter is reset in the Functional Parameter list Follow maintenance interval recommendations in Section 8 1 b Reset Maintenance Hour Meter 8 for the next service interval See Note 1 a Clear the inactive fault code Alarm 228 is cleared 62 10285 5 76 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION SERVICE SOON PM 4 DUE TRIGGER ON The Maintenance Hour Meter 4 time has expired UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via Keypad 1 Check unit maintenance records a Schedule unit into service facility for maintenance Must be done soon Perform maintenance a Perform appropriate engine amp unit maintenance Follow instructions on proper maintenance form Reset Maintenance Hour Meter 4 a Check that Maintenance Hour Meter 4 interval is set for your requirements b Reset Maintenance Hour Meter 4 for the next service interval Reset Interval in Configuration List as required Hour
179. condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Defrost air switch a Inspect switch amp connector pins amp terminals b Check switch setting and resistance of switch contacts No damaged or corroded pins Refer to Section 7 6 Contacts closed with pressure applied to high side Contacts open with no pressure applied Check switch wiring a Inspect harness amp control box connector pins amp terminals See wiring schematic See Note 5 No physical damage to harness No damaged or corroded pins Check air switch hoses a Inspect air hoses to switch No kinks or other obstructions No holes Connected to correct nipple Check evaporator pressure drop a Check pressure with Magnehelic Gauge reading Refer to Section 7 6 Check Evap Fan Clutch a Check Evap Fan Clutch operation in defrost Must disengage fan Check Condition of Trailer amp Load 62 10285 a Check condition of trailer doors amp seals b Check condition of product If it is warm and moist frequent defrost cycles can be expected Doors must be closed and door seals must seal and prevent outside air from leaking in 5 30 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK AIRFLOW TRIGGER ON In the Cool mode the Supply Air temperature
180. continue Check SV 4 amp circuit a Inspect SV 4 and wiring No physical damage to harness No damaged or corroded pins b Start unit setpoint more than 10 F Unit running in Heat Cycle above boxtemperature and set above 11 F See note 7 c Check operation of SV 4 FET 9 LED must be ON d Check voltage to SV 4 Must be 11 VDC or higher across the 2 wires Check SV 4 circuit wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Check SV 4 a Check resistance of SV 4 Refer to Section 7 8 b Check amp draw of SV 4 Use Component Test Mode Section 2 17 3 to test Refer to Section 7 8 for amp values 5 55 62 10285 Section 5 Alarm Troubleshooting ALARM CAUSE CHECK GLOW PLUG CIRCUIT CORRECTIVE ACTION TRIGGER ON Normal Amps for the Glow Plugs Circuit is 23 to 35 Amps after 15 seconds The circuit tests outside this UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again range NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check
181. correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check speed solenoid amp linkage a Check speed solenoid plunger Must move in and out freely b Check engine speed arm amp linkage Must move freely Force Low Speed operation See note 7 a Turn unit OFF wait 10 seconds then Controller will call for Low Speed operation for the next 10 turn ON Set for Start Stop operation minutes b Check operation of Speed Relay LED LED 27 must be OFF c Check voltage to speed solenoid Must be 0 VDC Check engine RPMs a Check actual engine RPM using hand Refer to Section 7 2 held tachometer Adjust engine linkage setting as needed b Compare actual RPMs with those Both readings within 50 RPM shown on display Check engine air intake system a Check air filter indicator Flag must not be visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Check engine exhaust system a Inspect the exhaust system Must be clear and unobstructed 62 10285 5 22 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK HIGH SPEED RPMs TRIGGER ON Controller is set for high engine speed operation and RPMs are Less than 2000 or greater than 2400 for Ultima or Less t
182. ct harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic CHECK DISCH TEMP SENSOR TRIGGER ON Compressor Discharge Temp Sensor is not within the maximum range of 40 F to 392 F 40 C to 200 C UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Compressor Discharge Temp Sensor a Inspect Compressor Discharge Temp No damage to sensor Sensor amp connector No damage or corrosion in connector b Check Compressor Discharge Temp 100 000 Ohms 9 77 F 25 See manual for complete Sensor resistance See Note 4 table of temperatures and resistance values Check Compressor Discharge Temp Sensor wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic 62 10285 5 60 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK UL2 CIRCUIT TRIGGER ON Normal Amps for the 012 Rear
183. cted properly amp securely to each component Check airflow through condenser coil See note 7 a Inspect condenser radiator fins b Check airflow with unit running Fins must be straight 9096 or more of the coil surface must be undamaged No dead air spaces Condenser Radiator coil must be clean Even airflow through the entire coil No dead spots Check system pressures a Install Manifold Test Set and check and compare compressor discharge amp suction pressures with those shown on the microprocessor controller Suction amp Discharge Pressures must have the same reading on gauges amp on micro display Pressures must be in the normal range for ambient amp box temperature conditions Check for refrigerant overcharge a Check refrigerant level in the receiver tank Level must be between upper amp lower sight glasses Check discharge check valve a Check that discharge check valve opens fully b Check discharge check valve screen Must open fully with unit running Must be clean of any debris Manually test refrigeration system See note 7 a Run Quick Check Must pass all tests Correct any problems found before proceeding Check system for non condensable a Check refrigeration system for non condensable gas es No non condensable gas es may be present Check Compressor 62 10285 a Remove all Compressor heads and inspec
184. ction line and insulated Refer to Section 7 6 Refer to Section 7 6 Check for damage to the suction line a Visually inspect suction line for any kinks restrictions or other damage No damage to line Check for restricted compressor suction screen a Visually inspect compressor suction inlet screen for material Must be clean and unobstructed 62 10285 Section 5 Alarm Troubleshooting ALARM CAUSE HIGH DISCHARGE PRESSURE higher than normal UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via CORRECTIVE ACTION TRIGGER ON This alarm is generated during Test 4 of Cool PreTrip Discharge pressure is Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check fan belts a Check upper fan belt tension amp condition b Check lower fan belt tension amp condition Refer to Section 8 6 for belt tensions No Glazing no cracking no slipping Refer to Section 8 6 for belt tensions No Glazing no cracking no slipping Check Wiring a Visually Inspect wiring to SV3 SV4 amp both Compressor Unloaders Wires must be conne
185. d Discharge pressure in the discharge manifold will close the discharge piston check valve assembly 14 isolating the compressor discharge manifold from the individual cylinder bank manifold The unloaded cylinder bank will continue to operate fully unloaded until the solenoid valve control device is de energized and the gas bypass port is closed 1 Solenoid Valve 9 Strainer 2 Valve Stem 10 Suction Manifold 3 Gas Bypass Port 11 Cylinder Discharge Valve 4 Spring Guide 12 Valve Plate 5 Spring 13 Cylinder Suction Valve 6 Piston 14 Discharge Piston Check Valve Assembly 7 Piston Bypass Valve 15 Discharge Manifold 8 Bleed Orifice Figure 7 10 Compressor Cylinder Head Unloaded 62 10285 7 16 Section 7 Unit Description c Loaded Operation Discharge pressure bleeds from the discharge manifold Figure 7 11 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 cont
186. d during pretrip The SV2 circuit is reading lt 0 75 Amps or gt 2 0 Amps Compressor suction pressure is too high during test 4 of pretrip Compressor suction pressure is too low during test 4 of pretrip Compressor discharge pressure is too high during test 4 of pretrip Compressor discharge pressure is too low during test 4 of pretrip Value out of range in pretrip test Value out of range in pretrip test Value out of range in pretrip test Value out of range in pretrip test Low Suction Pressure Compressor suction pressure is less than 3 0 psig for more than 60 seconds 62 10285 6 10 Section 6 Message Center and Alarms Alarms List ALARM CAUSES Chk Defrost Term 2 Defrost Termination Sensor 2 is reading lt 53 F or gt 158 F ensor MAINTENANCE ALARMS 223 Engine Maintenance The engine maintenance hour meter has expired 2244 NotUsed SSS Due 225 General Maintenance The general maintenance hour meter has expired Due 226 Service Soon The programmable preventative maintenance PM 1 thru 5 Due 30 Maintenance Hour Hour meter is greater than user programmed Meter s1 S SOSCSCS 32 235 Control Serial Error There is an error in the microprocessor controller serial number stored in the microprocessor memory 36 Trailer ID Error There is an error in the trailer identification number stored in the microprocessor memory 237 Function Parameter There is an error in
187. ds b Check to see if alarm re occurs 62 10285 Alarm should not come on Install new sensor 5 6 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION 5 3 SHUTDOWN ALARMS LOW ENGINE OIL PRESSURE TRIGGER ON Engine oil pressure is below 12 psig while the engine is running UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the active alarm s See Note 1 Operate the unit through the appropriate modes to see if any active active alarm occurs Continue with the steps below as necessary 1 Check for Low Engine Oil Level alarm a Check for alarm 2 Alarm conditions must be corrected and the alarm cleared to continue Check engine oil pressure switch a Inspect switch amp connector pins amp No physical damage to switch terminals No damaged or corroded pins in plug b Check engine oil switch operation Contacts closed when oil pressure is above 15 psig Contacts open when oil pressure is below 12 psig Check engine oil switch harness a Inspect harness amp control box physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Check for shorted circuit in harness Run Stop switch ON Manual Start
188. due in xxxx hours NO ACTION TAKEN REMOVE CARD A DataShare Program PC Card has been inserted into the PC Card slot and no key presses have been made to install the program into the Micro The PC Card may be safely removed from the slot NO ACTIVE ALARMS There are no active alarms in the Micro Alarm List NO DATA ON CARD REMOVE CARD A DataShare Program PC Card has been inserted into the PC Card slot and no valid data is present on the PC Card The PC Card may safely be removed from the unit NO DATA TO COPY REMOVE CARD A DataShare Download PC Card has been inserted into the PC Card slot and there is no valid data in the Data Recorder to copy onto the PC Card The PC Card may safely be removed from the unit NO INACTIVE ALARMS There are no inactive alarms in the Alarm List NO INSTALLS LEFT REMOVE CARD A DataShare Option PC Card has been inserted into the PC Card slot and all install options have been used The PC Card may safely be removed from the unit OLDER PROGRAM TO LOAD 1 TO CANCEL A DataShare Program PC Card has been inserted into the PC Card slot and the program on the PC Card is an older version than what is already loaded in the Micro Press to load the older program OUT OF RANGE ALARM 4 F or 5 5 F or 7 F or OFF if ENGLISH UNITS selected or 2 C or 3 C or 4 C or OFF if METRIC UNITS selected 4 F or 5 5 F or 7 F Tells the user how far the temperature must m
189. e NOTE The operator MUST be present and validate this test by watching the micro display during Test 1 Display Test The micro will turn on all segments of the LCD and LED display Test 1 Display Test The Microprocessor activates the LCD LED display Thistestwilllast5 seconds All segments ofthe display all LEDs on the Microprocessor will be on during this test Any segments that are not visible any LEDsthat do not come on indicate a defective display test During the next5 seconds all the lights in the Driver s Light Bar will be turned on and the buzzer will sound Test 1 is the only portion of the Pretrip cycle that must be monitored by the technician or driver Any lights that do not illuminate or if the buzzer does not sound should be repaired at the conclusion of the Pretrip cycle Pretrip will continue regardless of the outcome of this test A faulty display light bar or buzzer will not affect the operation of the unit but will affect what is displayed during unit operation Test 2 Amperage check of electrical components Check the amperage current draw of the following components Battery DC Current all components turned off SV1 Evaporator Condenser Fan clutch SV2 UL1 Front Unloader e SV3 UL2 Rear Unloader e 5 4 Speed Solenoid Glow Plugs Fuel Solenoid Most components will be energized for 4 seconds at which time the amperage reading is taken There is a 2 second rest period between each co
190. e Sleep Mode OFF saman 1 To take the unit out of Sleep Mode place the START RUN OFF switch to OFF position then back ON 62 10285 2 8 Section 2 Operation Sleep Mode is used generally in cold ambients when the trailer may be parked and the unit OFF for an extended period of time 1 day to several weeks with no product in the trailer Many times units are very difficult to start due to battery being discharged engine oil being very thick etc after that time in cold ambients In Sleep Mode the unit will Wake Up periodically and run to keep the battery charged and the engine warm There is NO temperature control in Sleep Mode and it should never be used for hauling perishable or frozen products While the unit is running in Sleep Mode WARNING NO TEMP will be displayed in the Message Center No setpoint or box temperature will be shown as the unit is not running to control the box temperature The unit will operate for a minimum run time of 4 minutes and until the battery is fully charged and the engine coolant temperature is 122 F 50 C or above NOTE In the event that the Engine Coolant Temperature sensor fails Sleep Mode will operate Ambients above 32 F 0 C unit will run as above monitor battery voltage and charging amps according to the configuration setting only Ambients below 32 F 0 C unit will run for 20 minutes minimum run time then restart every 60 minutes maxim
191. e displayed This test may last up to 3 minutes 2 15 62 10285 Section 2 Operation Test 11 Check SV4 NOTE The Cool and Heat Pretrip modes will merge together at this step With the unit running in 2 cylinder Low Speed Heat SV4 is tested for opening and closing If the valve does not operate correctly the CHECK SV4 VALVE alarm will be displayed This test may last up to 8 minutes Also if the unit cannot pump down the CANNOT PUMP DOWN alarm is displayed Test 12 Check SV3 With the unit running in 2 cylinder Low Speed Heat SV3 is tested for opening and closing Ifthe valve does not operate correctly the CHECK SV3 VALVE alarm will be displayed This test may last up to 8 minutes Also if the unit cannot pump down the CANNOT PUMP DOWN alarm is displayed Test 13 Low Side Pump Down With the unit running in 2 cylinder Low Speed SV2 SV3 SV4 will all be closed to pump the low side of the unit down If a problem is detected the alarm CANNOT PUMP DOWN LOW SIDE will be displayed Test 13 may last up to 8 minutes Test 14 High to Low Side Leakage The unit will shut down and check for pressure equalization between the high and low sides If any leakage is detected the HIGH SIDE LEAK alarm will be displayed This test will last 1 minute Test 15 Check Discharge Check Valve With the unit off the discharge check valve is checked for leakage If any leakage is detected the CHECK DISCHARGE CHECK VALVE alarm w
192. e 4 10 000 Ohms 77 F 25 Check Ambient Air Sensor wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic 5 43 62 10285 Section 5 Alarm Troubleshooting CHECK RETURN AIR SENSOR 47 C Steps ALARM CAUSE CORRECTIVE ACTION TRIGGER ON Return Air Sensor circuit has failed open or shorted If shorted the data list will display 158 F 70 C If the circuit is open the data list will show the temperature as 52 6 F UNIT CONTROL Use Supply Air Sensor 3 6 F 2 C If Supply Air Sensor Alarm is on and setpoint is at or below 10 4 F 12 C unit will run in Low Speed Cool only If setpoint is above 10 4 F 12 C unit will shut down RESET CONDITION Auto Reset when Return Air Sensor is in range or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the alarm occurs Continue with the steps below as necessary unit through the appropriate modes to see if any active 1 Check Return Air Sensor a Inspect Return Air Sensor amp connector b Check Return Air Sensor resistance See Note 4 No damage to sensor No damage moisture or corrosion in connector
193. e above condition exists CURRENT FOR S S SHUTOFF 6 5A This is the maximum charging amps permitted for 1A TO 10A start stop off cycle in 5A increments ALTERNATOR CHECK YES NO YES When the alternator is not charging alarm 51 is SHUTDOWN active turn the alarm light on and shut the unit down NO When the alternator is not charging alarm 51 is active turn the alarm light on and the unit will continue to run ENGINE OIL LEVEL SWITCH YES NO YES This unit has a low engine oil level switch installed NO This unit does not have a low engine oil level switch installed ENGINE OIL LEVEL SHUTDOWN YES NO YES When low engine oil level is sensed alarm 2 is active turn the alarm light on and shut the unit down NO When a low engine oil level is sensed alarm 2 is active turn the alarm light on and the unit will continue to run LOW COOLANT LEVEL YES NO YES A Low Coolant Level Sensor is installed in the coolant system NO There is no Low Coolant Level Sensor installed in the coolant system FUEL TANK NO DEVICE NO DEVICE There is no Low Fuel Level Sensor installed in the fuel tank SWITCH INSTALLED SWITCH INSTALLED A Low Fuel Level Switch is installed in the fuel tank 0 to 100 SENSOR A Low Fuel Level Sensor is installed in the fuel tank The fuel level may be read in the unit data list 2 31 62 10285 Section 2 Operation CONFIGURATION DESCRIPTION SELECTIONS DESCRIPTION FUEL
194. e alarms turn the microprocessor OFF and then back ON using the START RUN OFF switch If there is a safety shutdown UNIT SHUTDOWN SEE ALARM LIST will be shown Pressing the Alarm List Key will bring any Active Alarms into the Message Center The following are the Shutdown Alarms that may appear 62 10285 2 20 Section 2 Operation Low Engine Oil Level Low Engine Oil Pressure High Coolant Temperature High Discharge Pressure Battery Voltage too High Battery Voltage too Low High Comp Discharge Temp Low Refrigerant Pressure Low Fuel Shutdown High Suction Pressure Check Refrigeration System Failed to run Minimum Time Failed to Start Auto Mode Failed to Start Manual Check Starter Circuit Check Engine RPM Engine Stalled Alternator not Charging Box Temp Out of Range Check Evaporator Airflow Check Remote Switch 1 Check Remote Switch 2 Door Open Bad F2 or F3 Fuse Bad F4 or F6 Fuse Check Return Air Sensor Check Supply Air Sensor Low Suction Pressure Setpoint Error Model Error Unit Serial Error Control Serial Error Trailer Id Error Function Parameter Error Configurations 1 Error Configurations 2 Error Hour Meter Error Alarm Status Error DIS PRESS Calibrate Error SUCT EVAP Calibrate Error MICRO SW REV Error EEPROM
195. e appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Microprocessor a Check Setpoint setting Must be between 22 F to 89 6 F 30 C to 32 C b Enter new Setpoint Must be between 22 F to 89 6 F 30 C to 32 Reset Microprocessor a Turn Start Run Off switch off for 30 Microprocessor powers up OK seconds then turn back on b Alarm 246 remains active Replace microprocessor See Note 1 a Clear the inactive fault code Alarm 246 is cleared 62 10285 5 84 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CONFIGURATIONS 3 ERROR TRIGGER ON There is an error in Configuration Group 3 that is stored in the Microprocessor memory UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset when valid Configuration s are entered or Alarm may be manually reset by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Configurations a Check Configurations All must be set for selectable values Reset Microprocessor a Turn Start Run Off switch off for 30 Microprocessor powers up OK seconds then turn back on b
196. e in when installed in the unit b With air switch in vertical position connect high pressure side of magnehelic gauge to high side connection of air switch See Figure 8 25 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 The switch contacts should close and the ohmmeter needle move rapidly to 0 Any hesitation in the ohmmeter indicates a possible problem with the switch and it should be replaced f Refer to Section 7 6 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 Repeat checkout procedure until switch actuates at correct gauge reading qs h After switch is adjusted place a small amount of paint or fingernail polish on the adjusting screw so that vibration will not change switch setting 62 10285 8 40 Section 8 Service 8 28 Evaporator Coil Cleaning The use of recycled cardboard cartons is increasing across the country The recycled cardboard
197. e is running for 15 seconds Charging wot Use Box Temp Out Of _ If not configured for shutdown control probe defined by user as either return or Range supply air temperature goes out of tolerance band configured by user for 15 minutes If configured for shutdown control probe must be out of range for 45 minutes Defrost Not Complete Either defrost termination temperature sensor is less than 55 F after 45 minutes 55 Check Defrost Air Air switch did not open when unit exits defrost mode or air switch is calling for Switch another defrost cycle 2 consecutive times in less than 8 minutes following the previous defrost cycle 56 Check In the Cool mode the Supply Air temperature is 5 F warmer than Return Air Airflow Temperature for 5 minutes Inthe Heat mode the Suction pressure has been higher than or to 100 psig for more than 60 seconds for R404A 80 psig for R22 Check Remote Switch 1 Remote Switch may be connected to a trailer door or some other devise Check Check Remote Switch 2 Remote Switch may be connected to a trailer door or some other devise Check 59 Datalogger Not No data is being recorded by the Data recorder Recording Datalogger Time The internal clock is not operating correctly Wrong ELECTRICAL ALARMS 7 owe ee 77 CheckSV3 Circuit The SVS FET senses a short inthe circuit to the SVG valve inthe heat cycle 8 82 Chk Remote The Out of Range FET
198. e slot XX indicates number of option installations remaining on card INSTALLING OPTION PLEASE WAIT A DataShare Option PC Card has been inserted into the PC Card slot and the option is being installed in the Micro DO NOT REMOVE THE CARD WHILE THIS MESSAGE IS BEING DISPLAYED INSTALL STOPPED REINSERT CARD LIST END TO CLEAR ALARMS A DataShare Option PC Card has been inserted into the PC Card slot and the install process has been stopped been stopped by the PC Card not being fully inserted in the slot or by being removed Remove and reinsert PC Card to continue You have reached the end of the alarm list Pressing the key will clear the alarm list LOADING INFO MANUAL START MODE SELECTED A DataShare Configuration PC Card has been inserted into the PC Card slot and information from the Config card is being loaded into the Micro DO NOT REMOVE THE CARD WHILE THIS MESSAGE IS BEING DISPLAYED The user has selected manual start mode The Diesel engine must be started using the manual GLOW CRANK switch 6 3 62 10285 Section 6 Message Center and Alarms MESSAGE CENTER MESSAGES Message NEW PROGRAM TO LOAD TO 1 CANCEL Description A DataShare Program PC Card has been inserted into the PC Card slot and the program on the PC Card is a newer version than what is already loaded in the Micro Press to load the program NEXT ENGINE MAINT OHR to 99999HR Next engine maintenance is
199. e values Reset Microprocessor a Turn Start Run Off switch off for 30 seconds then turn back on b Check for valid Configurations in Data List c Valid Configurations can not be entered Microprocessor powers up OK Valid number is present Alarm is cleared Replace Microprocessor See Note 1 a Clear the inactive fault code Alarm 238 is cleared CONFIGURATIONS 2 ERROR TRIGGER ON There is an error in Configuration Group 2 that is stored in the Microprocessor memory UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset when valid Configuration s are entered or Alarm may be manually reset by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Configurations a Check Configurations All must be set for selectable values Reset Microprocessor a Turn Start Run Off switch off for 30 seconds then turn back on b Check for valid Configurations in Data List c Valid Configurations can not be entered Microprocessor powers up OK Valid number is present Alarm is cleared Replace Microprocessor See Note 1 a Clear the inactive fault code
200. eaner will impair its operation therefore a service schedule must be set up and followed Remember that the air cleaner cleans the air but the air cleaner requires cleaning The following simple service steps are easily made while the engine is being serviced in the field The simple inspection steps are as follows 1 Check all connections for mechanical tightness Be sure cleaner outlet pipe is not fractured 2 Incase of leakage and if adjustment does not correct the trouble replace necessary parts or gaskets Swelled or distorted gaskets must always be replaced b Air Cleaner Service Indicator The air cleaner indicator is connected to the engine air intake manifold and its function is to indicate when the air cleaner requires replacing In operation When a plugged air cleaner decreases intake manifold pressure to 20 500 mm WG the indicator moves to the red line The air cleaner should be replaced and the indicator reset by pressing the reset button c Service Procedure 1 Stop the engine remove air cleaner Install new air cleaner 62 10285 8 8 Section 8 Service 8 5 7 Engine Crankcase Breather The engine uses a closed type breather with the breather line attached to the cylinder head cover See Figure 8 6 or Figure 8 7 The breather assembly should be cleaned once a year or at every 3000 hours maintenance interval whichever comes first Screw Breather Cover Breather Valve Breather Tube gt Cyl
201. ecked by reading the Battery Voltage in the Data List If O K appears after the voltage reading both battery volts and engine coolant temperature are sufficient to allow the unit to cycle off If O K does not appear then one or both of these conditions have not been met and the unit is not ready to cycle off Also any time the ambient temperature is below 35 F 1 7 C the unit will not operate in High Speed Cool Low Speed Cool High and Low Speed Heat cycles will operate at all ambient temperatures 2 5 1 Charging Amps Beginning with software revision 01 06 00 a Configuration has been added that allows the Microprocessor to monitor battery charging amperage in addition to battery voltage The battery charging rate as seen in the Data List must be below the selected amp setting to allow the unit to cycle off The Configuration may be set from 1 0 to 10 0 Amps in 0 5 amp increments A weak or defective battery may show a suitable voltage charge while the alternator is putting a high charging rate into it then not be sufficiently charged to restart the engine at the end of a Start Stop Off Cycle The factory setting for this configuration is 6 5 amps This is a general setting that may need to be adjusted for the general operating environment of the unit Units operated in colder ambient temperatures may want to decrease this setting to force a higher charge in the battery prior to Start Stop Off Cycle Units operated in warme
202. ed as indicated by scales Correct charge will be found in Section 7 1 NOTE Itis possible that all liquid may not be pulled into the receiver as outlined in step d In this case frontseat the receiver outlet valve King Valve and start the unit The liquid will be pulled into the system Unit must be operating in the cooling mode f When drum weight scale indicates that the correct charge has been added close liquid line valve on drum and backseat the King Valve Start unit in cooling mode Run approximately ten minutes until the refrigeration system is warmed up and balanced Partially block off air flow to condenser coil so discharge pressure rises to 230 psig 16 kg cm Refrigerant should appear at center line of lower receiver sight glass 8 13 2 Partial Charge Using Vapor R 22 Only CAUTION Do not vapor charge R 404A Only liquid charging through the liquid line King Valve is acceptable a e b Place drum of refrigerant on scale and note weight Backseat discharge and suction service valves and install a manifold gauge set Purge lines Connect charging line between center port of manifold gauge set and drum Open VAPOR valve on drum and purge charging line Run the unit in cooling for ten minutes until the refrigeration system is warmed up and balanced and then partially block off air flow to condenser coil so discharge pressure will rise 10 psig 0 7 kg cm2 Refrigerant should appear at center
203. ee reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check coolant temperature a Check temperature of coolant or upper Must be above 32 F 0 C radiator hose Check Engine Coolant Sensor a Check resistance of Engine Coolant Refer to Section 7 8 for complete resistance chart Sensor See Note 4 10k Ohms 77 F 25 C b Inspect harness amp control box physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic 5 21 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK LOW SPEED RPMs TRIGGER ON Controller is set for low engine speed operation and RPMs Less than 1325 or greater than 1625 for Ultima or Less than 1200 or greater than 1500 for Ultra Ultra X L and Extra for more than 60 seconds 120 seconds when the Microprocessor calls for a change from high speed to low speed or when the unit first starts UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if controller is set for low engine speed operation and RPMs come Between 1375 to 1575 for Ultima or Between 1250 to 1400 for Ultra Ultra X L and Extra for 60 seconds or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or
204. eed Heat The micro will check for arise in compressor discharge pressure fan clutch operation and SV1 operation Appropriate alarms will be displayed if any problem is detected Test 4 in Heat Pretrip may last up to 12 minutes depending on ambient box temperature and unit condition For very low box temperature the unit may operate in 6 cylinder low speed heat Test 5 UL2 Rear Unloader With the unit still running the same as it was in Test 4 the operation of the rear Unloader is tested If the Rear Unloader fails to load or unload the CHECK UL2 alarm will be displayed Test 5 will last about 20 seconds Test 6 UL1 Front Unloader With the unit still running the same as it was in Test 5 the operation of the Front Unloader is tested If the Unloader fails to load or unload the CHECK 1 alarm will be displayed Test 6 willlast about 20 seconds Test 7 8 amp 9 Engine High and Low Speeds The engine will go from Low Speed to High Speed then back to Low Speed during these tests Engine RPMs will be checked If the engine is not operating within the operating range either the CHECK LOW SPEED RPM or CHECK HIGH SPEED RPM alarm will be displayed Tests 7 8 amp 9 willlast about 30 seconds Test 10 SV1 Cool Pretrip Only With the unit running in 2 cylinder Low Speed Cool the operation of SV1 will be tested for opening and closing If the valve does not operate correctly the CHECK SV1 VALVE alarm will b
205. efrigeration system of your unit can cause frostbite severe burns or blindness when in direct contact with the skin or eyes For this reason and because of legislation regarding the handling of refrigerants during system service we recommend that whenever your unit requires service of the refrigeration system you contact your nearest Carrier Transicold authorized repair facility for service BATTERY This unit is equipped with a lead acid type battery The battery normally vents small amounts of flammable hydrogen gas Do not smoke when checking the battery A battery explosion can cause serious physical harm and or blindness 1 1 62 10285 Section 1 Safety Precautions 1 2 Safety Decals ADANGER CA WARNING d 9 KEEP CLEAR OF ROTATING BELTS AND PULLEYS UNIT MAY CS ROTATION 7 R T AUTOMATICALLY NL 62 02146 00 REV A P Y 62 03958 00 Heat Warning 62 10285 1 2 Section 1 Safety Precautions d S WARNING DISCONNECT BATTERIES BEFORE DOING ANY ELECTRICAL WELDING ON UNIT OR TRAILER x THIS UNIT HAS A NEGATIVE GROUND SYSTEM IMMEDIATE FAILURE OF ELECTRICAL SYSTEM 62 02139 00 REV_A DO NOT REVERSE POLARITY REVERSED POLARITY WILL CAUSE CAUTION 1 3 62 10285 62 10285 RADIATOR COOLANT
206. efrost cycle begins The Microprocessor holds in memory the last entered Defrost Timer interval 2 Defrost Air Switch A Defrost Air Switch DAS measures the air restriction through the evaporator coil As ice forms and builds up the air flow is restricted Once enough ice builds up the switch contacts will close and initiate a defrost cycle 3 Manual Defrost The Defrost cycle may be started at any time by pushing the MANUAL DEFROST key Refer to Section 2 8 TIP Refer to Section 7 13 for more on the defrost mode When Defrost is Terminated Defrost will be terminated once any of the following conditions are met e When the defrost termination temperatures is above 45 F 7 2 C DTT2 is above 55 F 12 8 C and both sensors are working properly If a sensor is bad then it is ignored If both sensors are bad then defrost will terminate in 20 minutes A sensor is bad when its alarm is active e Defrost Terminated By Time Alarm The unit is allowed to stay in defrost for maximum time of 45 minutes NOTE If the Defrost Air Switch DAS contacts are still closed at defrost termination the following will occur The Defrost Air Switch DAS is ignored for defrost initiation until the unit has completed another defrost cycle in which the DAS contacts were open at termination The manual defrost switch can always start a new Defrost cycle A55 CHECK DEFROST AIR SWITCH Alarm is activated A Defrost Ove
207. elect 1 of 4 different selections on the controller The four menu selections are PRETRIP Used to initiate a pretrip DATA Displays Unit Data See Section 2 14 FUNCTION CHANGE Displays unit Functional Parameter settings See Functional Change Parameters Section 2 15 TRIP START This menu selection is only used with theData Recorder It is used to record a Trip Start event which is logged in the Data Recorder This records the time and date of the beginning of the trip Data can then be downloaded and reviewed by trip making data review much easier 3 11 62 10285 Section 3 System Description 3 6 Driver s Light Bar The Driver s Light Bar is an external set of indicator lights which can be seen in the mirror from the cab They are controlled by the Microprocessor These lights correspond to the Microprocessor LEDs HEAT COOL DEFROST START STOP and ALARM The ENGINE AUTO START light is only illuminated when the unit is operating in Start Stop The OUT OF RANGE light is illuminated when the Out of Range Alarm is active 62 10285 3 12 Section 3 System Description 3 7 Serial Port SLP PC Communication Mode PC Mode is entered into when a PC Cable P N 22 01737 00 or a PC Mode Jumper P N 22 50180 01 is connected to the Serial Port or the Serial Port terminals C amp E is jumped using an insulated jumper wire and the Start Run Off Switch SROS is in the OFF position If the unit is started the Microp
208. en Cylinder Pressure Gauge 0 to 400 psig 0 to 28 kg cm2 Bleed Off Valve 1 4 inch Connection gt oo Figure 8 22 Typical Setup for Testing High Pressure Switch Remove switch as outlined in Section 8 20 1 Connect ohmmeter or continuity light across switch terminals Ohmmeter will indicate resistance and continuity light will be lighted if switch closed after relieving pressure Connect switch to a cylinder of dry nitrogen See Figure 8 22 Set nitrogen pressure regulator higher than cutout point on switch being tested Pressure switch cutout and cut in points are shown in Sections 7 6 Close valve on cylinder and open bleed off valve Open cylinder valve Slowly close bleed off valve and increase pressure until the switch opens If light is used light will go out and if an ohmmeter is used the meter will indicate open Open pressure on gauge Slowly open bleed off valve to decrease pressure until switch closes light will light or ohmmeter will move 8 31 62 10285 Section 8 Service 8 21 Compressor Discharge Pressure Transducer CDP 8 21 1 Calibrating Compressor Discharge Pressure Transducer The Compressor Discharge Pressure Transducer CDP has a range of 0 psig to 500 psig With this large of a pressure range some transducers will not read exactly the same as the next To allow for variations in transducers and still display an accurate pressure reading in the Data List there is a calibration
209. ents This selects the override temperature for the Perishable or Frozen or both Auto Start Stop Off Cycle During the Minimum Off Time should the box temperature drift this far above or below setpoint in the Perishable Range or above setpoint in the Frozen Range the unit will override the Minimum Off Time and restart PERISH FROZEN MAX OFF TIME OFF 10 5 TO 255MINS in 1 minute increments OFF There is no maximum off time When a minute value is selected this is the longest amount of time the unit will remain off during a Perishable or Frozen or both Auto Start Stop Off Cycle When this time expires the unit will restart and run for the Minimum Run Time regardless of any temperature change inside the box FROZEN SHUT DOWN OFFSET 0 0 C TO 3 5 F 2 C This only applies to Frozen Setpoints in Start Stop operation This offset is the number of degrees below setpoint that the unit will run before cycling off This will allow for a lower average box temperature when considering temperature rises during off cycles TEMP CONTROL RETURN AIR SUPPLY AIR The unit has both a Return Air Sensor and a Supply Air Sensor This selection determines which sensor temperature will be used for Set Point selections above 10 4 F 12 C to determine when Set Point is reached Return Air is generally selected for most products Products that are sensitive to small temperature changes may
210. er tank 62 10285 5 28 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION DEFROST NOT COMPLETE TRIGGER ON Defrost cycle did not terminate automatically Defrost Termination Temperature 1 or 2 did not reach termination temperatures within 45 minutes UNIT CONTROL Alarm Only While this alarm is active the Defrost Timer will be set to initiate a defrost cycle 90 minutes 1 5 hours after the alarm comes on RESET CONDITION Auto Reset when defrost cycle is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Evap Fan Clutch a Check Evap Fan Clutch operation in Must disengage fan defrost Check refrigerant level a Visually check refrigerant level in Must be at correct level receiver tank Check for Low Refrigerant Pressure alarm a Check for alarm 18 Alarm conditions must be corrected and the alarm cleared to continue Check for Chk Defrost Term 1 or 2 Sensor Alarm a Check for Alarm s 124 and or 132 Alarm conditions must be corrected and the alarm cleared to continue Check accuracy of DTT1 amp DTT2 temperature readi
211. er than the Active Probe There are three possible modes for UltraFresh 2 control These are heat cool and null To enter COOL the control temperature must be greater than or equal to 1 8 1 C above setpoint To exit cool and enter PULSED NULL the control temperature must be less than 1 5 F 0 8 C above setpoint To exit PULSED NULL and enter HEAT the control temperature must be more than or equal to 1 8 F 1 C below setpoint and to exit heat and enter PULSED NULL the control temperature must be less than 1 5 F 0 8 C below setpoint See the temperature control operating sequence diagrams Heat Mode Operation In the Heat Mode the Microprocessor will operate the unit controls as follows Clutch Output SV2 SV3 SCS Refer to SV2 Refer to SV3 Refer to SCS Operation Operation Operation UL1 UL2 Refer to UL1 Refer to UL2 Operation Operation ENGAGE 4 9 62 10285 Section 4 Engine and Temperature Control Cool Mode Operation In the Cool Mode the Microprocessor will operate the unit controls as follows Clutch Output SCS Refer to SCS Operation UL1 UL2 Refer to UL1 Refer to UL2 ENGAGE Operation Operation Pulsed Null Mode Operation Pulsed Null Mode will combine the Heat and Cool operation described above with the following Null Mode operation SV1 2 SV3 4 SCS Clutch UL1 UL2 Output OPEN OPEN CLOSE OPEN LOW ENGAGE UNLOAD UNLOAD Pulsed Null Mode operation will modi
212. erature Control 4 1 Auto Start Sequence 4 1 4 2 Statt Stop Operation 4 2 43 Continuous Run 4 4 44 Temperature Range Lock 1 amp 2 4 4 4 5 Temperature 1 4 6 Output s aea u ao Gx oe OC dea yc 4 12 4 6 1 Speed Control Solenoid SCS Overrides 4 12 4 6 2 Unloader Control Priority UL1 amp UL2 4 13 4 7 DEOS zd es AT bm evar 4 16 Section 4 Engine and Temperature Control 4 1 Auto Start Sequence When the starting conditions are met the start sequence will begin by energizing the run and clutch relays along with the SV 2 and both unloaders After 5 seconds the glow plug relay GPR will energize to supply power to the glow plugs and the buzzer will sound for 5 seconds before the starter is energized On initial power up there will be 5 second delay before the starting sequence begins If the required glow time is zero warm engine short glow time the Microprocessor will energize the starter after a 5 second delay The engine will crank for a maximum of 10 seconds or until the engine is running The glow relay will also be de energized at the same time the starter disengages If the engine does not start a 15 second rest period will elapse before the next start attempt The run rela
213. es out of range regardless if the box temperature was ever within setpoint range or not Out of Range is determined by the Functional Parameter setting Selections of 4 F 2 C 5 5 F 3 C 7 F 4 C and OFF are available The OFF setting disables the Out of Range Alarm All other settings allow the user to determine how far away from setpoint the box temperature may move before turning on the Alarm Once the box temperature has moved the away from set point by the selected amount the Out of Range timer begins If the alarm is configured for Alarm Only after 15 minutes the alarm will be activated If the alarm is configured for Alarm amp Shutdown after 45 minutes the alarm will be activated and the unit will shutdown In Sleep Mode Pretrip Diagnostic Test Mode Component Test Mode or if the unit has a Door Switch and the door has been opened the Out of Range Alarm is not in use After exiting any of these modes or closing the trailer door the box temperature must again come In Range of the set point before the Out of Range Alarm can be activated In Defrost and in Start Stop Off Cycle the 15 or 45 minute timer does not count Once the unit leaves these modes and goes into a temperature control mode heat cool or null the timer will be reset for the full time allowing the unit either 15 or 45 minutes to bring the box temperature into range before activating the Out of Range Alarm 3 15 62 10285 Section 4 Engine and Temp
214. ey will unlock the item 62 10285 2 22 Unit Data Section 2 Operation Press the SELECT Key until the Data light comes on and Press 1 to View Data appears in the Message Center Pressing either 1 UP or DOWN ARROW key will bring up the instructions 1 to Scroll Then To Lock By pressing the 1 UP ARROW key you will move through the Data List beginning at the top and moving toward the bottom or by pressing the DOWN ARROW key you will move through the Data List beginning at the bottom and moving toward the top Ifno keys are pressed for 10 seconds the Message Center will return to the default display which is usually STATUS OK To lock a Data List item on the screen press the ENTER key The Message Center will flash the Data List item that is being displayed and will keep it visible until any key on the Keypad is pressed UNIT DATA DATA DEFINITION SUCTION PRESSURE Compressor suction pressure DISCHARGE PRESSURE ENGINE COOLANT TEMP RETURN AIR TEMP Compressor discharge pressure Engine coolant temperature Return air entering evaporator air temperature SUPPLY AIR TEMP AMBIENT AIR TEMP Supply air leaving evaporator air temperature Ambient air entering condenser air temperature DEFROST TERM TEMP 1 DEFROST TERM TEMP 2 Defrost termination temperature 1 Located in the blower housing near SAT Defrost termination temperature 2 Located on t
215. ff then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Manually test refrigeration system See note 7 a Run Quick Check b Check and compare compressor suction pressure with pressure shown on the microprocessor controller Must pass all tests Correct any problems found before proceeding Suction Pressure must have the same reading on gauge amp on micro display Check compressor rear head reed valves amp gaskets a Remove compressor rear head amp inspect condition of all reeds amp gaskets Must be in good condition HIGH SIDE LEAK refrigeration system UNIT CONTROL Alarm Only TRIGGER ON Refrigerant is leaking past one of the components in the High Pressure Side of the RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Manually test refrigeration system See note 7 a Run Quick Chec
216. for continuity microprocessor plug 2MP04 Must be less than 10 ohms Check circuits with test substitute switch a Substitute known good sensor and clear alarm Start unit and run for 30 seconds Alarm should not on Install new switch 5 5 3 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION LOW FUEL LEVEL for units with Low Fuel Level 0 to 100 Sensor fuel level is displayed in Data List TRIGGER ON Fuel level is 15 or less for more than 30 seconds UNIT CONTROL Alarm only RESET CONDITION Auto reset when the fuel level is above 1796 for more than 30 seconds or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for low fuel level a Check fuel level in the fuel tank Add fuel as needed to the fuel tank Check fuel level sensor a Inspect fuel level sensor amp connector No physical damage to switch pins amp terminals No damaged or corroded pins in plug b Check fuel level sensor operation Place unit in PC Mode or in Manual Start Mode see Note 2 DO NOT START UNIT c Check
217. frost Cycle Clutch SV1 SV2 SV3 SV4 scs Output UL1 UL2 OPEN CLOSE CLOSE CLOSE LOW ENGAGE UNLOAD UNLOAD The unit will remain in the Pump Down Mode until the following conditions are met e minimum of 30 seconds and the suction pressure is less than 10 psig for R404A units or 5 psig for R22 units OR e A maximum of 5 minutes regardless of suction pressure High Ambient Defrost Mode Following the Pump Down Mode the Defrost Cycle will begin The unit controls will be opened closed as follows Clutch SV2 Output UL1 See SV2 DISENGAGE UNLOAD Operation High Ambient Defrost Termination Once both of the Defrost Termination Temperature Sensors reach 55 F the defrost cycle will terminate The following sequence will be used to complete a High Ambient Defrost Termination Place the engine in Low Speed Open de energize SV1 and Open energize SV2 Unload energize both UL1 and UL2 The unit will remain in this mode for five seconds Then engage energize the Clutch The unit will remain in this mode for 10 seconds Then close de energize SV4 The unit will remain in this mode for 5 seconds e At this point the Microprocessor will return to normal temperature control The data recorder will record a Defrost Termination Event 62 10285 4 18 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 5 10 Section 5 Troubleshooting Introduction To Troubleshooting Guide 5 1 Driver Alarm
218. fy the length of each Mode in 10 second cycles That is if the unitis in the Cool Null Pulse band the unit may run in Cool for up to 9 seconds then Null for 1 second if the Control Temperature is away from set point As the Control Temperature comes closer to set point the length of Cool time will decrease and the amount of Null time will increase However the combination of the two will always equal 10 seconds The same is true for the Heat Null band Default Mode When both the return air sensor alarm and the supply air sensor alarm are active the unit will enter Default Mode for temperature control In the frozen setpoint range the unit will run low speed loaded cool WARNING NO TEMP CONTROL will be displayed In the perishable setpoint range the unit will shutdown Speed Control Solenoid SCS Operation The engine will operate the compressor at two different speeds low and high Speed Control will use the differences of Controlling Temperature and setpoint as follows LOW SPEED COOL Control Temp is more than 3 5 F 2 0 C Control Temp is less than 3 F 1 8 C above setpoint above set point HEAT Control Temp is more than 3 5 F 2 0 C Control Temp is less than 3 F 1 8 C below setpoint below set point Unloader Control Operation To LOAD or de energize a compressor unloader increases the capacity of the system by increasing the number of cylinders pumping refrigerant in the compressor To UNLOAD or energize a
219. ge is active at set points above 10 4 F 12 C When in Frozen range unit will default to low speed fully loaded if both the return and supply probes are bad WARNING NO TEMP CONTROL will be displayed When in Perishable range the unit will shut down if both the return and supply probes are bad UNIT SHUTDOWN SEE ALARM LIST will be displayed Temperature control is achieved by controlling engine speed compressor UL1 and UL2 unloaders and solenoid valves SV 1 SV 2 SV 3 SV 4 UltraFresh 2 Temperature Control UltraFresh 2 is an advanced method of temperature control for both Perishable or Frozen range It can produce a reduced capacity state between the Heat and Cool Modes This reduced capacity state is known as Pulsed Null which is not a constant operating mode but only operates for a few seconds at a time During Pulsed Null the heat and cool valves are opened simultaneously to reduce either the heating or cooling capacity In the Pulsed Null temperature band see the following charts the unit will pulse between Cool and Null or Heat and Null in 10 second increments The capacity in the Pulsed Null band is varied by adjusting the pulse rate UltraFresh 2 uses both the supply and return air sensors to control box temperature The sensor that is selected under the Functional Parameters for the temperature control is known as the Selected Probe This is the probe that will be used to determine whe
220. ge to wiring or battery cable end No damaged or corroded terminals Must be above 11 5 VDC Must be above 10 VDC while cranking Check starter a Inspect starter and wiring b Check resistance of solenoid c Check resistance of starter motor d Test amperage draw of starter No damage or corrosion Wiring and battery cable must be clean and tight Refer to Section 7 8 Refer to Section 7 8 Refer to Section 7 8 Check battery voltage a Inspect battery cable ends and posts b Test voltage at battery with unit off C Test specific gravity of battery d Perform load test on battery Follow battery manufacturer s procedure Must be clean and tight No corrosion Must be above 11 VDC Check Check Check for correct engine oil 62 10285 Check for correct viscosity for conditions Refer to Section 7 2 Must be correct for ambient conditions 5 20 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK COOLANT TEMPERATURE TRIGGER ON Coolant temperature is below 32 F 0 C after the engine has been running for 5 minutes UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when Coolant temp raises above 36 F 2 2 C or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself s
221. glow plug circuit a b d e Inspect glow plug relay amp socket Check operation of Glow Plug Relay Check voltage to glow plugs Check Glow Plug circuit Amps Check amp draw of each glow plug No signs of discoloration from overheating No corrosion Run Stop switch in Run Manual Start Operation See Note 2 Glow Crank switch in Glow position LED 30 must be ON Must be 11 VDC or higher Use Component Test Mode Section 2 17 3 to test Refer to Section 7 8 for amp values Refer to Section 7 8 for amp values Check glow plug circuit wiring 62 10285 Inspect harness amp control box connector pins amp terminals See wiring schematic No physical damage to harness No damaged or corroded pins 5 56 Section 5 Alarm Troubleshooting ALARM CAUSE CHECK FUEL SOLENOID CIRC CORRECTIVE ACTION TRIGGER ON Normal Amps for the Fuel Solenoid Hold Circuit is 0 4 to 3 5 Amps including possible electric fuel pump The circuit tests outside this range UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps be
222. h the cut in and cut out of the HP2 Model No HP2 CUT IN HP2 CUT OUT NDX93MNOAA Ultima R404a 190 psig 250 psig All Other Models R22 amp 404a 200 psig 300 psig SV3 Operation Heating and Defrost The SV3 valve will be opened during Heat or Defrost mode in the following circumstances e IfSV4 has been open for at least 60 seconds AND The engine is operating in High Speed AND The Compressor Discharge Temperature Sensor Alarm is not active AND The Ambient Temperature Sensor Alarm is not active AND The Compressor Discharge Temp Ambient Temp more than 100 F 55 5 C AND The Ambient Air Temp less than 70 F 21 1 C The SV3 valve will be closed during Heat or Defrost in the following circumstances Ifthe Compressor Discharge Temperature Sensor Alarm is active OR The Ambient Temperature Sensor Alarm is active OR The Compressor Discharge Temp Ambient Temp is less than 50 F 27 8 C OR e The Ambient Air Temp is more than 80 F 26 7 C NOTE Ifthe SV3 valve opens during the Heat or Defrost Cycle then the Ambient Air Temperature rises above 80 the SV3 valve will be closed for the remainder of that cycle 4 11 62 10285 Section 4 Engine and Temperature Control 4 6 Output Overrides 4 6 1 Speed Control Solenoid SCS Overrides Speed Control Solenoid Overrides in priority order 1 Low Speed Engine Coolant Warm up e If engine Coolant Temperature Sensor Alarm is not active the engi
223. h the drier Tighten drier outlet side fitting c Leak test drier connections d Check refrigerant level 8 19 Thermostatic Expansion Valve The Thermal Expansion Valve TXV is an automatic device which maintains constant superheat of the refrigerant gas leaving the evaporator regardless of suction pressure The valve functions are a automatic response of refrigerant flow to match the evaporator load and b prevention of liquid refrigerant entering the compressor Unless the valve is defective it seldom requires any maintenance a Replacing Expansion Valve amp Screen 1 2 d 8 9 Pump down the unit by closing the King Valve Refer to Section 8 10 a Remove insulation Presstite from expansion valve bulb and then remove bulb from suction line Remove Presstite from the expansion valve power head Unscrew power head if only the element is being changed and replace by reversing steps 1 through 3 Use a wet rag to keep TXV cool whenever brazing or unbrazing Unbraze inlet outlet and equalizer connection to valve body Clean all tube stubs so new valve fits on easily Install new valve and screen with cone of screen pointing into liquid line at inlet to the valve by reversing steps 1 through 4 The thermal bulb is located below the center of the suction line See Figure 8 21 This area must be clean to ensure positive bulb contact Firmly tighten the straps around the thermal bulb and suction line and insulate bot
224. h with Presstite Evacuate by placing vacuum pump on suction service valve Open King Valve and then check refrigerant level Check superheat Refer to Section 7 6 b Checking Superheat NOTE Itis not recommended adjusting expansion valves unless absolutely necessary Due to the time involved in adjusting the superheat replace the valve rather than adjusting it c To Measure Superheat NOTE The expansion valve and bulb location are shown in Figure 7 5 8 29 62 10285 Section 8 Service Remove evaporator panel from rear of unit and then pull loose the Presstite insulation from one end of the expansion valve bulb 2 Loosen one TX bulb clamp and make sure area under clamp above bulb is clean Place thermocouple above parallel TXV bulb and then secure loosened clamp making sure both bulbs are firmly secured to suction line as shown in Figure 8 21 Use Presstite insulation to completely cover both bulbs Suction Line TXV Bulb Clamp Nut and Bolt Clamp Thermocouple TXV Bulb gt Figure 8 21 Thermostatic Expansion Valve Bulb and Thermocouple NOTE When conducting this test the suction pressure must be 6 psig 0 4 kg cm2 below expansion valve maximum operating pressure MOP Refer to Section 7 6 For example R 22 units use an expansion valve with a 55 MOP The recommended test pressure should be below 49 psig 3 44 kg cm 6 7 8 9 Connect an accurate gauge to the 1 4 port on the
225. han 1700 or greater than 2100 for Ultra or Ultra X L or Less than 1500 or greater than 1900 for Extra for more than 60 seconds 120 seconds when the Microprocessor calls for a change from low speed to high speed UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if controller is set for high engine speed operation and RPMs come Between 2050 to 2350 for Ultima or Between 1750 to 2050 for Ultra or Ultra X L or Between 1550 to 1850 for Extra for 60 seconds or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check speed solenoid linkage a Check speed solenoid plunger Must move in and out freely b Check engine speed arm amp linkage Must move freely Check speed circuit a Inspect harness amp control box physical damage to harness connector pins amp terminals See damaged or corroded pins or terminals wiring schematic b Check resistance of speed solenoid Refer to Section 7 8 Check amp draw of speed solenoid Refer to Section 7 8 Force High Speed operation See note 7 a Start unit setpoint more than 10 F Controller will call for High Speed operation away from setpoint and set f
226. hat appears is the last alarm that was recorded The check items in the troubleshooting guide are listed in order of their likeliness of occurrence and ease of testing We recommend that you follow the order in which they are presented however there may be times when situations or experience directs you to use a different order For example if the trailer is loaded you may want to perform all the condensing unit checks first even though some evaporator section checks may be listed before them As you go through the troubleshooting steps you will find the cause of the problem When you find and correct the problem it is not necessary to continue through the remainder of the steps Some active alarms will clear inactivate themselves automatically once the cause has been corrected You then only need to go to the inactive list to clear all alarms before verifying the remainder of the unit operation Alarms that do not inactivate themselves automatically must be cleared manually See Note 1 When you are finished making repairs run the unit through a Pretrip cycle and verify that no further active alarms occur Also both alarm lists should be cleared so that there are no old alarms in memory when the unit leaves your repair facility If the message CHECK MICROPROCESSOR appears in the Message Center there is a communication error between the Keypad and the Microprocessor With no communication there will not be an associated alarm Shou
227. he Engine PM Hourmeter select the desired maintenance interval in hours and enter as the DIESEL RESET VALUE in the Configuration List Selecting OFF will completely turn the Engine PM Hourmeter off The reset value selected here will be the value used when the PM Hourmeter is reset from the Functional Parameter List To turn on the Switch On PM Hourmeter select the desired maintenance interval in hours and enter as the SWITCH ON RESET VALUE in the Configuration List Selecting OFF will completely turn the Switch On PM Hourmeter off To turn on any of the Programmable PM Hourmeters they must first be programmed to count one of the available parameters from the list above For example PM 1 may be programmed to count Clutch Cycles Selecting OFF will completely disable the PM Hourmeter Once a selection is made then a reset interval may be selected For hours the PM Hourmeter may be set in 50 hour increments anywhere from 50 to 30 000 hours For cycles the PM Hourmeter may be set in 1 000 cycle increments anywhere from 1 000 to 90 000 cycles Selecting OFF instead of an interval will also disable the PM Hourmeter Once the PM Hourmeters are activated from the Configuration List they can be turned OFF once off the operation can be RESUMED or it can be RESET for a new interval all from the Functional Parameter List The PM Hourmeters may be set or reset using either a PC or the Keypad Keypad access to the PM Hourmeters may
228. he Normal Defrost Operation will be used When the Ambient Air temperature is above 80 E the High Ambient Defrost Operation will be used Normal Defrost Operation SV1 2 SV3 4 SCS Clutch Output UL1 UL2 CLOSE See SV2 See SV3 open HIGH DISENGAGE LOAD LOAD Operation Operation Normal Defrost Termination Once DTT1 is above 45 F 7 2 C and DTT2 is above 55 F 12 8 C the defrost cycle will terminate The following sequence will be used to perform a Normal Defrost Termination Place the engine in Low Speed Open de energize SV1 and Open energize SV2 The unit will remain in this mode for two seconds Then close de energize SV3 and SV4 The unit will remain in this mode for three seconds Then the Clutch will be engaged energized There will be a minimum of 2 seconds before the engine can return to High Speed Atthis point the Microprocessor will return to normal temperature control The data recorder will record a Defrost Termination Event 4 17 62 10285 Section 4 Engine and Temperature Control High Ambient Defrost Operation The High Ambient Defrost Cycle has 3 separate modes within it The first is the Pump Down Mode followed by the Defrost Mode then the Defrost Termination Mode Each of these is described below Pump Down Mode The Pump Down Mode pumps the low side of the refrigeration system down to a lower suction pressure and reduces the engine load normally seen at the beginning of a De
229. he center evaporator tube sheet COMP DISCHARGE TEMP BATTERY CURRENT DRAW Compressor discharge temperature Battery voltage Battery charging or discharging amps 15 used in place of ammeter ENGINE RPM Engine revolutions per minute FUEL LEVEL of fuel in tank This is only shown when 0 100 sensor is configured ON START MODE AUTO if the engine will start automatically MANUAL if the engine must be started manually SOFTWARE REVISION DISPLAY SOFTWARE REV Revision of the software that is operating the Microprocessor Revision of the software that is operating the Keypad ENGINE HOURS SWITCH ON HOURS HOURS TO ENGINE MAINT CONTROL SERIAL Serial Number of the Microprocessor TRAILER ID Trailer ID as entered by the user UNIT SERIAL Unit serial number UNIT MODEL Unit model number selected through configurations Total engine operating time Total hours that the Start Run Off switch has been in the Start Run position Number of engine hours until the next programmed engine maintenance HOURS TO UNIT MAINT TIME LEFT TO PM 1 5 RANGE 1 LOCK Number of switch on hours until the next programmed general unit maintenance Number of hours until the next programmed PM maintenance OFF Temperature Range 1 Lock is turned off CONTINUOUS When the Set Point is set between Range 1 Minimum amp Maximum Temperatures the unit is set to operate only in C
230. he condenser fan circulates surrounding air over the outside of the condenser tubes The tubes have fins designed to improve the transfer of heat from the refrigerant gas to the air This removal of heat causes the refrigerant to liquefy thus liquid refrigerant leaves the condenser and flows through the solenoid valve SV 1 normally open and to the receiver The receiver stores the additional charge necessary for low ambient operation and for the heating and defrost modes The receiver is equipped with a fusible plug which melts if the refrigerant temperature is abnormally high and releases the refrigerant charge The refrigerant leaves the receiver and flows through the manual 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 and the electrically controlled liquid line solenoid valve SV 2 which starts or stops the flow of liquid refrigerant In R 404A units the refrigerant flows to the Liquid Line Suction Line 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 TXV which reduces the pressure of the liquid and meters the flow of liquid refriger
231. he key is pressed and the unit is in Continuous Run Mode See the configuration table Section 2 17 The unit will remain in low speed for 10 minutes after engine start up If the unit fails to start after three start attempts the FAILED TO 5 AUTO MODE alarm will be activated While running if the unit shuts down on a safety or fails to run for the minimum run time three consecutive times the FAILED TO RUN MINIMUM TIME Alarm will be activated The shutdown counter is cleared when the unit has run for 15 minutes or when the unit cycles off normally The Microprocessor monitors box temperature battery voltage and engine coolant temperature during the off cycle Once setpoint is reached the controller will shut off the diesel engine to conserve fuel Microprocessor will not shut off the engine if the battery voltage is not sufficient to restart it if the battery charge is greater than the amp setting selected in the Configuration List Refer to Section 2 17 or if the engine coolant temperature is below 122 F 50 The controller will restart the engine if the box temperature has moved away from set point by 3 6 F to 18 F 2 C to 10 depending on the unit Functional Parameter settings if the battery voltage drops below 11 Vdc or if the engine coolant temperature drops below 34 F 1 C 2 5 62 10285 Section 2 Operation TIP The status of the unit battery and engine coolant temperature can be readily ch
232. heel Remove venturi ring item 13 Figure 8 12 by removing 4 screws 10 Remove 4 screws from the bearing housing item 9 Figure 8 12 11 Remove the shaft and bearing housing 12 Install bearing housing assembly into unit by reversing steps 1 through 9 with a new gasket item 8 or using caulk Torque taper bushing bolt to 10 11 ft Ibs 13 Locate the fan and key so that 1 3 of the condenser fan extends beyond the leaving edge of the fan shroud Secure fan and hub to shaft 62 10285 8 14 Section 8 Service 14 Install evaporator fan venturi ring Then install tapered hub and blower wheel loosely Adjust blower wheel and tighten 15 Install evaporator panels WARNING Do not start unit without installing the evaporator panels as unit damage or body harm may result 16 Start unit and check refrigeration cycle Early Units 1 Condenser Fan 6 Key 10 Shaft 2 Adapter Condenser Fan 7 Flange Condenser Fan 11 Bushing 3 Sheave 8 Gasket Prior to S N 12 Blower Wheel 4 V Belt DAF90213555 13 Venturi Ring 5 Split Tapered Bushing 9 Bearing Housing Figure 8 12 Evaporator Condenser Fan Shaft Assembly All Models Except Ultima 8 15 62 10285 Section 8 Service 8 9 Replacing Condenser Evaporator Fan Shaft or Fan Clutch Ultima 18 NOTE WHILE INSTALLING CLUTCH ONTO SHAFT CARE MUST BE TAKEN TO INSURE SPRING CLIP 15 MOVED ASIDE TO ALLOW CLUTCH TO FULLY
233. hen release This is before the setpoint and box temp values are show The Message Center will show Manual Start Mode Selected however no electrical circuits will be energized Current draw in this state is 0 0 5 Amps Sensors and sensor circuits may be tested at the 1MP plug Remove plug from Microprocessor and using the MP1 Plug Map and an ohmmeter test resistance of circuits See chart of resistances for different sensors When checking the Defrost Air Switch RPM Sensor Engine Oil Level Switch Fuel Level Sensor Door Switch or HP1 unplug 2MP atthe Microprocessor Using the MP2 Plug Map and wiring diagram check for voltage at the appropriate terminal When checking the light bar SV amp Unloader circuits unplug at the microprocessor Using the MP3 Plug Map and wiring diagram check for voltage at terminal of the circuit you are testing Should be battery voltage Some tests can only be conducted with the unit operating The unit may be started automatically by placing the Start Run Off switch in the Start Run position To start the unit manually press and hold the Glow Crank switch in the Glow position Turn the Start Run Off Switch to Run Continue to hold the Glow Crank switch until the setpoint and box temperature are shown in the display then release it after glowing the engine for the appropriate time required for the ambient temperature The Message Center will show Manual Start Mode Selected Hold the Glow
234. hms 9 77 F 25 See manual for complete table of temperatures and resistance values Check Engine Coolant Sensor wiring a Inspect harness amp control box connector pins amp terminals See wiring schematic No physical damage to harness No damaged or corroded pins CHECK BATTERY VOLTS UNIT CONTROL Alarm Only TRIGGER ON Battery voltage is less than 11 VDC or greater than 17 VDC RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for Battery Voltage Too High alarm a Check for alarm 15 Alarm conditions must be corrected and the alarm cleared to continue Check for Battery Voltage Too Low alarm a Check for alarm A16 62 10285 Alarm conditions must be corrected and the alarm cleared to continue 5 58 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK BATTERY CURRENT TRIGGER ON With all circuits off current flow of more than 1 amp is detected in the electrical circuits NOTE If this alarm occurs Pretrip Test 42 will not be performed You will need to run Pretr
235. horted either within the SV3 coil itself or to a positive wire UNIT CONTROL Alarm Only e RESET CONDITION Auto Reset when unit calls for Heat or Defrost and the SV3 coil current amp draw is normal or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check SV3 coil a Inspect SV3 coil amp connector pins amp No damage to solenoid terminals No damaged or corroded pins b Check resistance of solenoid Refer to Section 7 8 c Check amp draw of coil Refer to Section 7 8 Check SV3 wiring a Inspect harness amp control box See Notes 2 amp 6 connector pins amp terminals See No physical damage to harness wiring schematic No damaged or corroded pins Check SV3 current draw a Use Component Test Mode Refer to Refer to Section 7 8 for normal current values Section 2 17 3 to test actual current draw of the circuit CHECK FHR CIRCUIT TRIGGER ON Fuel Heater Relay circuit is shorted The Fuel Heater Relay output from the Micro is negative so the circuit will not be shorted to ground but is shorted either within the Fuel Heater Relay coil itself or to a positive wire UNIT CONTROL Alarm
236. hould clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check engine oil level a Check engine oil dipstick Add engine oil as needed to fill Check engine oil level switch a Inspect engine oil level switch No physical damage to switch connector pins amp terminals No damaged or corroded pins in plug b Check engine oil level switch Contacts open when level is more than 7 qts low operation Contacts closed when level is less than 4 qts low Check engine oil level switch harness a Inspect harness amp control box physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Check for shorted circuit in harness Place unit in PC Mode or in Manual Start Mode see Note and continuity through the harness 2 DO NOT START UNIT Battery voltage reading 12 13 VDC between wires in plug 5 5 62 10285 Section 5 Alarm Troubleshooting LOW COOLANT LEVEL TRIGGER ON Engine coolant level is UNIT CONTROL Alarm only Steps ALARM CAUSE CORRECTIVE ACTION 1 or more quarts low for more than 30 seconds RESET CONDITION Auto reset if engine coolant level is at the full mark for more than 30 seconds Alarm may be manually reset via keypad or by turning the unit off then back on again NOTE Follow the steps below unti
237. ia Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Return Air Sensor a b Inspect Return Air Sensor amp connector Check Return Air Sensor resistance See Note 4 No physical damage to harness No moisture damaged or corroded pins 10 000 Ohms 77 F 25 C See manual for complete table of temperatures and resistance values Check Return Air Sensor wiring a Inspect harness amp control box connector pins amp terminals See wiring schematic 5 57 No physical damage to harness No damaged or corroded pins 62 10285 Section 5 Alarm Troubleshooting ALARM CAUSE CHECK SUPPLY AIR SENSOR Keypad or by turning the CORRECTIVE ACTION TRIGGER ON Supply Air Sensor is not within the maximum range of 53 F to 158 F 47 C to 70 C UNIT CONTROL Abort PreTrip amp display PRETRIP FAILED IN TEST 3 Alarm RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appro
238. ia Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Was engine shut off manually a Check for external cause Correct problem Check for Bad F2 or F3 Fuse Alarm a Check for alarm 71 Alarm conditions must be corrected and the alarm cleared to continue Check fuel system a Check for Alarm 1 Fill tank as needed b Check fuel flow Unrestricted fuel flow through system Fuel not gelled c Check fuel system prime No air in fuel system Check engine air intake system a Check air filter indicator Flag must not be visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Check engine exhaust system a Inspect the exhaust system Must be clear and unobstructed Check engine a Check Injection pump timing Timing must be correct b Check engine valve adjustment Rocker arm clearance must be correct c Check engine compression Compression must be above 400 psig Check refrigeration system a Check discharge amp suction pressures Must be within normal operating range for conditions 62 10285 5 26 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION
239. icroprocessor memory and the calibration is complete f If the calibration was unsuccessful either there is more than 0 psig on the transducer or the transducer is further away from 0 than an offset will allow The transducer must be replaced 8 21 2 Testing Compressor Discharge Pressure Transducer a Verify that the wiring to the transducer is correct See wiring diagram b Power up the transducer circuit Place unit into PC Mode Refer to Section 2 16 or place unit in Manual Start Mode c Check Voltage to transducer connector Voltage reading between A negative and B positive should be 5 0 VDC d Check wire resistance between output to microprocessor and 1 5 62 10285 8 32 Section 8 Service e Place 5 0 VDC on transducer terminal B and 5 0 VDC on transducer terminal A Disconnect C from the Microprocessor Test voltage between B and C The reading should be as shown in table below Compressor Discharge Pressure Transducer Voltage Psig Voltage Psig 80 1 1 2 90 1 2 100 1 3 3 125 1 5 150 1 7 175 1 9 3 200 2 1 225 2 3 4 25 AEA of es m ss 37 41 WARNING The 5 0 VDC terminal is common between the Compressor Discharge Pressure Transducer the Compressor Suction Pressure Transducer and the RPM sensor If this circuit is shorted to ground due to one of the mentioned components being defective or a worn wire the Message Center will show Suc
240. igerant drum and leak check all connections NOTE It must be emphasized that only the correct refrigerant drum 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 d Remove refrigerant using a refrigerant recovery system and repair any leaks Evacuate and dehydrate the unit Refer to Section 8 12 Charge unit with refrigerant Refer to Section 8 13 8 12 Evacuation and Dehydration 8 12 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 TXV by free water and formation of acids resulting in metal corrosion 8 12 2 Preparation a b Evacuate and dehydrate only after pressure leak test Refer to Section 8 11 Essential tools to properly evacuate and dehydrate any system include a good vacuum pump 5 cfm 8m3H volume displacement P N 07 00176 11 and a good vacuum indicator such as 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 the ambient temperature above 60 F 15 6 C to speed evaporation of moisture If ambient tempe
241. ill be displayed Test 15 will last 40 seconds Pretrip Termination When the Pretrip cycle is completed the unit will return to normal temperature control operation PRETRIP PASS will be shown in the display until the operator presses any key In the event that the Pretrip test triggered an alarm s the display will show either PRETRIP FAIL amp COMPLETE if the entire Pretrip cycle was completed or PRETRIP FAIL IN TEST if the Pretrip cycle was aborted by an alarm before it was completed 62 10285 2 16 Section 2 Operation 2 10 Trip Start HEAT COOL DEFROST START STOP CONTINUOUS 988 8 98898 SETPOINT BOX TEMPERATURE RIP START ENTERED A vw swiss Mmi 1 To mark the start of a trip in the data recorder press the SELECT key until TRIP START is PRESS TO ENTER TRIP START will be displayed 2 Press the key 3 If trip start is acknowledged by the data recorder TRIP START ENTERED will be displayed for 5 seconds and then the display will revert back to the normal display Otherwise CANNOT ENTER TRIP START will flash and then the display will revert back to the normal display Trip Start places a time stamp in the data recorder memory to allow easy review of the data from the last trip and to allow downloading data from a specific trip A trip begins at a Trip Start and ends at the next Trip Start Trip Start tells the data recorder that the present date and
242. inder Head Cover Breather Cover Breather Element Plate Breather Oil Shield Bolt Breather Assembly O Ring ONOARWON gt Figure 8 7 TV Engine Crankcase Breather 8 9 62 10285 Section 8 Service 8 5 8 Servicing Glow Plugs The total circuit amp draw for the glow plug circuit is checked during a Pretrip cycle The glow plugs when energized draw a nominal 6 to 7 amps each at 10 5 vdc When servicing the glow plug is to be fitted carefully into the cylinder head to prevent damage to glow plug Torque value for the glow plug is 14 to 18 ft Ib 1 9 to 2 5 mkg Checking for a Defective Glow Plug a The entire circuit may be tested using Component Test Mode Refer to Section 2 17 3 b To test individual glow plugs disconnect all glow plugs from each other and place an ammeter or clip on ammeter in series with each glow plug and energize the plugs Each plug if good should show 6 to 9 amps draw at 12 Asecond 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 8 6 Servicing and Adjusting V belts WARNING Beware of V belts and belt driven components as the unit may start automatically 8 6 1 Belt Tension Gauge It is recommended using a belt tension gauge tester P N 07 00253 shown in Figure 8 8 whenever V belts are adjusted or replaced A belt tension gauge provides a
243. inder head of the compressor UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check refrigerant charge a Check for undercharged system Level must be above lower sight glass Manually test refrigeration system See note 7 a Run Quick Check Must pass all tests Correct any problems found before proceeding b Check and compare compressor Suction Pressure must have the same reading on gauge amp suction pressure with pressure shown on micro display on the microprocessor controller Check compressor front head reed valves amp gaskets a Remove compressor front head amp Must be in good condition inspect condition of all reeds amp gaskets 5 7 62 10285 Section 5 Alarm Troubleshooting CHECK REAR CYLINDERS UNIT CONTROL Alarm Only Steps ALARM CAUSE CORRECTIVE ACTION TRIGGER ON A problem has been detected inside the rear cylinder head of the compressor RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit o
244. int changing a Functional Parameter clearing alarms and locking the data menu among other things MANUAL DEFROST Key The MANUAL DEFROST key is used to initiate a defrost cycle given that the proper conditions are met ALARM LIST Key The ALARM LIST key allows you to view the alarms stored in the Microprocessor The alarm list is displayed in the Message Center Pressing the ALARM LIST key once displays the active alarm list Each successive press cycles through the list to the end To view the inactive alarm list see Section 2 62 10285 3 10 Section 3 System Description mum START STOP CONTINUOUS Key CONTINUOUS This key allows you to change from Start Stop operation to Continuous Run operation In Start Stop operation when the controller is in Cycle mode the unit will not be running During Off Cycle mode the Microprocessor monitors box temperature battery voltage and engine coolant temperature and will restart the unit when needed SELECT Key MB Press the SELECT key to scroll through the menu selections When the SELECT key is pressed one of the four menu selections PRETRIP DATA FUNCTION CHANGE or TRIP START will light Repeated presses of the SELECT key will sequence the menu through the four selections The menu will wrap around from TRIP START to PRETRIP Press the SELECT key until the desired menu selection is lit Selected Menu Lights Pressing the SELECT key allows you to s
245. inue with the steps below as necessary 1 Check for alarms a Check for shut down alarms Alarm conditions must be corrected and the alarm s cleared to continue 62 10285 5 16 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION FAILED TO START AUTO MODE TRIGGER ON Engine has tried to start 3 times unsuccessfully in the auto start mode UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check fuel level in tank a Check fuel gauge on tank Fill tank as needed Check for alarms a Check for the following alarms Alarm conditions must be corrected and the alarm cleared 71 Check for Bad F2 or Fuse alarm to continue 40 Check Glow Plugs alarm 35 Check Starter Circuit alarm Check Fuel Solenoid a Check Run Relay LED Must be ON b Check voltage to fuel solenoid Run Stop switch ON Manual Start Mode See Note 2 12 VDC between FSC C ground amp FSH A hold With Manual Crank Switch in crank position 12 VDC between FSC C ground amp FSP B pick Inspect solenoid amp connector pins amp No damage to solenoid te
246. inue to operate fully loaded until the solenoid valve control device is energized and the gas bypass port is opened mn m 9 aw pom 4 14 T 1 6 15 1 Solenoid Valve 9 Strainer 2 Valve Stem 10 Suction Manifold 3 Gas Bypass Port 11 Cylinder Discharge Valve 4 Spring Guide 12 Valve Plate 5 Spring 13 Cylinder Suction Valve 6 Piston 14 Discharge Piston Check Valve Assembly 7 Piston Bypass Valve 15 Discharge Manifold 8 Bleed Orifice Figure 7 11 Compressor Cylinder Head Loaded 7 17 62 10285 Section 7 Unit Description 7 11 Battery Charging Alternator 7 11 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 Connecting 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 POS OUTPUT
247. ip again UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check battery current draw a Note amp draw on display See Note Must show 0 2 amps 3 Check individual circuits a Isolate individual circuits and test amp Must be in range Refer to Section 7 8 draw CHECK AMBIENT AIR SENSOR TRIGGER ON Ambient Air Sensor is not within the maximum range of 53 F to 158 F 47 C to 70 UNIT CONTROL Abort PreTrip amp display PRETRIP FAILED IN TEST 3 Alarm RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Ambient Air Sensor a Inspect Ambient Air Sensor amp No damage to sensor connector No moisture damage or corrosion in connector b
248. is 5 F 2 8 C or more warmer than Return Air Temperature for 5 minutes or In the Heat mode the Suction pressure has been higher than 100 psig for R404a or 80 psig for R22 for more than 60 seconds NOTE For this alarm the unit must be running This alarm will not occur in either the Defrost or Pretrip cycles UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check fan belts a Check upper fan belt tension amp condition b Check lower fan belt tension amp condition Refer to Section 8 6 for belt tensions No Glazing no cracking no slipping Refer to Section 8 6 for belt tensions No Glazing no cracking no slipping Check evaporator air flow a Check evap fan clutch b Check evaporator section return air bulkhead air chute cleanliness of evap coil Must be engaged Good Air Flow Return air not restricted Air chute in good condition No damage to blower wheel Evap coil clean Check system pressures a Install Manifold Test Set and check and compare compressor discharge amp suction pressures with those shown on the
249. is opened or display and alarm and shut the unit down DOOR SWITCH YES or NO This configuration allows the user to program the Microprocessor that a door switch has been installed ENGINE COOLANT TEMP 58 0 F to 266 0 F 50 0 C to 130 0 C Engine coolant temperature ENGINE HOURS OHR to 99999HR Total number of hours that the engine has run ENGINE OIL LEVEL SHUTDOWN YES or NO ENGINE OIL LEVEL SWITCH YES or NO This Configuration allows the user to determine whether the engine oil level switch will turn on an alarm only or if it will shut the engine down when the engine oil level is approx 7 quarts low This allows the user to configure the Micro whether an engine oil level switch is being used in this particular unit or not ENGINE RPM 0 to 3000 Engine RPM speed FUNCTION NOT CHANGED The key was not pressed in the allotted amount of time to select the new Functional Parameter setting The new setting was not stored and the old setting will be used GLOW TIME SHORT or LONG INACTIVE ALARMS IN MEMORY This configuration allows the user to determine how long the glow plugs will stay on in automatic mode There are inactive alarms in the Micro alarm list which have not yet been cleared out INSTALLED REMOVE CARD XX A DataShare Option PC Card has been inserted into the PC Card slot and the option has been installed in the Micro The PC Card may safely be removed from th
250. isplay is flashing will stop the flashing and perform the requested function TIP You may press and hold the UP ARROW or DOWN ARROW key to quickly change the setpoint The longer the key is held the faster the setting will change 62 10285 2 4 Section 2 Operation 2 5 Start Stop Operation HEAT COOL DEFROST ALARM START STOP CONTINUOUS BURG 9898 SETPOINT BOX TEMPERATURE START STOP MODE SELECTED ALARM LIST STARTSTOP SELECT A 2 1 Press the START STOP CONTINUOUS until the START STOP Light on the controller illuminates 2 Verify that START STOP MODE SELECTED is displayed on the Message Center and that the START STOP light is illuminated The unit is now in Start Stop operation Automatic start stop gives the Microprocessor automatic control of starting and stopping the diesel engine as required The main function of automatic start stop is to turn off the refrigeration system near the setpoint to provide a fuel efficient temperature control system and then restart the engine when needed Start Stop operation is normally used for frozen loads Start Stop and Continuous operation may be tied to the setpoint ranges for frozen and perishable loads The START STOP CONTINUOUS key is locked out if START STOP LOCKED appears in the Message Center when the key is pressed and the unit is in Start Stop Mode or CONTINUOUS LOCKED appears in the Message Center when t
251. it b Check amperage draw on Run Relay Refer to Section 7 8 circuit BAD F4 OR F6 FUSE TRIGGER ON One or more of the following fuse circuits have been open for more than 2 seconds F4 F6 UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset when the fuse is replaced and the unit is powered up or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check fuse a Locate blown fuse Will have open circuit b Verify fuse size Refer to Section 7 7 Must be correct rating for circuit see wiring diagram Inspect fuse amp fuse holder Terminals tight No signs of overheating melting or discoloration Check circuit a Check amperage draw on clutch Refer to Section 7 8 circuit b Check amperage draw on F6 circuit Refer to Section 7 8 See wiring schematic 5 35 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK SVI CIRCUIT TRIGGER ON In either the Heat or Defrost cycles the SV1 coil circuit is shorted The SV1 output from the Micro is negative so the circuit will not be shorted to ground but is
252. k b Check and compare compressor suction pressure with pressure shown on the microprocessor controller Must pass all tests Correct any problems found before proceeding Suction Pressure must have the same reading on gauge amp on micro display CHK DISCHARGE CHECK VALVE UNIT CONTROL Alarm Only TRIGGER ON Refrigerant is leaking backwards through the Discharge Check Valve RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Discharge Check Valve a Test Discharge Check Valve for leakage Must not leak Manually test refrigeration system See note 7 a Run Quick Check b Check and compare compressor suction pressure with pressure shown on the microprocessor controller 62 10285 Must pass all tests Correct any problems found before proceeding Suction Pressure must have the same reading on gauge amp on micro display 5 72 Section 5 Alarm Troubleshooting ALARM CAUSE LOW SUCTION PRESSURE CORRECTIVE ACTION TRIGGER ON Suction Pressure is less than 5 0 psig 10 inches vacuum f
253. l Pump optional 9 Injector Nozzles Mechanical 10 Fuel Leak off Line Lift Pump 11 Fuel Return Line Fuel Filter Fuel Warmer Optional Figure 7 8 Fuel System Diagram _ 6 Engine Block Oil Pan Full Flow Oil Filter Bypass Oil Filter Optional Engine Oil Connection Oil Pressure Switch Figure 7 9 Lube Oil Flow Diagram 7 15 62 10285 Section 7 Unit Description 7 10 Compressor Unloaders Major Working Parts a 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 Figure 7 10 item 15 passes through the strainer 9 and bleed orifice 8 to the back of the piston bypass valve 7 Unless bled away this pressure would tend to close the piston 6 against the piston spring 5 pressure With the solenoid valve 1 energized the solenoid valve 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 manifol
254. l a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the alarm occurs Continue with the steps below as necessary unit through the appropriate modes to see if any active 1 Check for low coolant level a Check engine coolant level in the coolant bottle Add coolant as needed to the coolant reservoir and to the fill tube on the radiator b Check coolant hoses for leaks or breaks Repair all leaks and breaks as necessary Add coolant as needed to the coolant reservoir and to the fill tube on the radiator Check engine coolant level switch a Inspect engine coolant level switch amp connector pins amp terminals b Check harness wiring to plug c Check engine coolant level switch operation Check for voltage at harness plug between pins A and B Check continuity of the wire from the harness plug pin to the microprocessor plug 2MP15 No physical damage to switch No damaged or corroded pins in plug Verify wires are in correct plug orifice Place unit in PC Mode or in Manual Start Mode see Note 2 DO NOT START UNIT Voltage should be 12 volts at harness plug between pins A and B Start Run Off Switch OFF prior to checking for continuity Must be less than 10 ohms Check circuits with test substitute switch a Substitute known good sensor and clear alarm Start unit and run for 30 secon
255. larms that have been cleared inactivated are moved to the Inactive Alarm List This list is reached by first pressing and holding the Alarm List key then the Key and holding both of them for 4 seconds Alarms in this list will begin with I Inactive followed by the alarm number Clearing alarms from the Inactive Alarm list will also clear alarms from the Active Alarm List Go to the end of the Inactive Alarm List LIST END TO CLEAR ALARMS will show in the Message Center Press to clear all alarms from both lists To test electrical circuits place the unit in Manual Start Operation To do this first turn the unit off Press and hold the Glow Crank switch in the Glow position Turn the Start Run Off Switch to Run Continue to hold the Glow Crank switch until the setpoint and box temperature are shown in the display then release it The Message Center will show Manual Start Mode Selected and the Run Relay will be energized See Unit non running amps below for current draw in this state Many checks will be made with the microprocessor powered up but with no outputs to the unit components The unit may be put into PC Mode to do this For additional information see PC Mode section 3 7 An alternative method to power up the microprocessor with no load hold the Glow Crank switch in the glow position and move the Start Run Off switch to Run Continue to hold the Glow Crank switch for 2 seconds after the self test begins t
256. lay Unit Data and Functional Parameters Programmable Maintenance Hour Meters PM Hour Meters are resettable from the Keypad Bright LED Alarm Light Bright LED Mode Lights Fully Automated Pretrip Automated Micro Self test DataLink Data Recorder DataLink Data Recorder date amp time can be set from the Keypad Auto Start Stop Trip Start to record date time of trip in Data Recorder memory PC card functionality for Downloading data upgrade programming and Configuration set up FETs Field Effect Transistors for switching components on amp off and checking circuit current Automatic or Manual Engine Starting Functional Parameter locks Alarms are stored in Microprocessor memory for future reference New Menu system to simplify keyboard and enhance functionality 62 10285 3 2 Section 3 System Description 3 3 Control Module Description pU d CLUTCH RELAY RUN RELAY K2 ROS TESA F3 7 5A GROUND STRAP SPEED RELAY K1 CARD FAULT LED RED F2 10A CONNECTOR 1 WN V DC CURRENT PC SENSOR CARD SLOT if A CONNECTOR 2 lt CONNECTOR 6 CARD STATUS LED Be CONNECTOR 5 o CONNECTOR 4 MICRO STATUS LED p not used in Ultima Ultra GREEN T Ultra XL or Extra 3 T QC1 D 2 1 7 5 n i 72 FET LED S N lt p d Control Module 4 The figure above shows the Control Module The Control Module has 3 relays and 4 fuses
257. ld this occur check the wire connections behind the Keypad Assembly at the Keypad itself remove the rear cover from it to check and at connector 6 on the Microprocessor When working on the refrigeration system an accurately calibrated manifold test set should always be installed It is also a good idea to connect an additional high pressure gauge to the king valve In high or low ambients it may be necessary to cool or warm the box temperature before performing specific tests providing that the trailer is not loaded with perishable product WARNING Whenever working around the engine drive train belts pulleys or fans always remove either a battery cable from the battery or the starter solenoid wire 5 1 62 10285 Note 1 Note 2 Note 3 Note 4 Note 5 Note 6 Note 7 Section 5 Alarm Troubleshooting NOTES Active alarms will always be in the Alarm List They will have an in front of the alarm number Active alarms may be inactivated by going to the end of the Active Alarm list LIST END TO CLEAR ALARMS will appear in the Message Center Pressing will clear or inactivate the alarms This moves the alarm to the Inactive Alarm list ifthe condition that caused the alarm has been corrected When Shutdown Alarms are cleared the unit will attemptto restart ifthe micro is set for auto start When non Shutdown Alarms are cleared there will be no noticeable change in the unit s operation Active a
258. leaning Remove all foreign material from the condenser coil by reversing the normal air flow Air is pulled in through the front and discharges over the engine Compressed air or water may be used as a cleaning agent It may be necessary to use warm water mixed with any good commercial dishwasher detergent Rinse coil with fresh water if a detergent is used 8 41 62 10285 Section 8 Service 8 30 Controller Sensor Checkout An accurate ohmmeter must be used to check resistance values shown in Table 8 2 Due to variations and inaccuracies in ohmmeters thermometers or other test equipment a reading within 2 of the chart value would indicate a good sensor If a sensor is bad the resistance reading will usually be much higher or lower than the resistance values given in Table 8 2 At least one lead from the sensor must be disconnected from the unit electrical system before any reading is taken Not doing so will result in a false reading Two preferred methods of determining the actual test temperature at the sensor is an ice bath at 32 F 0 C or a calibrated temperature tester Onms Ohms Ohms Ohms 80 92 se 8 057 eof 7 994 36 6 984 38 60 e 110 500 EX 7 6 10390 o e5400 e 153 6 70720 65460 13 130 ee 12490 62 10285 8 42 Section 8 Service Ohms F Ohms F Ohms Ohms 40 3 960 000 3 3 121 020 36 2 900 710 80 92 990
259. low as necessary 1 Check for Bad F2 Fuse alarm a Check for alarm 71 Alarm conditions must be corrected and the alarm cleared to continue Check fuel solenoid amp circuit a Inspect fuel solenoid and wiring b Check operation of Run Relay Check voltage to fuel solenoid No physical damage to harness No damaged or corroded pins Run Stop switch in Run Manual Start Operation See Note 2 LED 28 must be ON Run Stop switch ON Manual Start Mode See Note 2 12 VDC between FSCC ground amp FSHA hold With Manual Crank Switch in crank position 12 VDC between FSCC ground amp FSPB pick Check fuel solenoid circuit wiring a Inspect harness amp control box connector pins amp terminals See wiring schematic No physical damage to harness No damaged or corroded pins Check fuel solenoid a Check resistance of fuel solenoid b Check amp draw of fuel solenoid Check operation of solenoid Refer to Section 7 8 Use Component Test Mode Section 2 17 3 to test Refer to Section 7 8 for amp values Plunger must move in when energized CHECK RETURN AIR SENSOR TRIGGER ON Return Air Sensor is not within the maximum range of 53 F to 158 F 47 C to 70 C UNIT CONTROL Abort PreTrip amp display PRETRIP FAILED IN TEST 3 Alarm RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset v
260. lve and slowly bleed remaining refrigerant 2 Slowly 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 62 10285 8 26 Section 8 Service 8 16 Compressor Unloader Valve The compressor unloaders located on the compressor cylinder heads are controlled by the Advance Microprocessor Refer to Section 7 10 a Checkout Procedure 1 Connect manifold gauges to the compressor suction and discharge service valves and start unit in cooling with the set point within 1 F 2 F 0 6 C 1 1 C of the trailer temperature 2 Unplug both unloader coils The compressor should be operating with all 6 cylinders Note suction pressure 3 Plug UL1 front unloader in Note discharge and suction pressures the suction pressure should rise approximately 3 psig 0 2 kg cm2 and the discharge should drop approximately 5 15 psig 0 35 to 1 05 kg cm 4 Unplug UL1 and note pressures Suction pressure should drop and discharge pressure should rise by the same amounts they changed in step 3 above 5 Repeatsteps3 amp 4 for UL2 rear unloader At the end ofthe test plug both unloaders back in NOTE If either unloader coil energizes and the suction and discharge pressures do not change the unloader assembly must be checked b Solenoid Coil Replacement NOTE
261. m pressures a Check and compare compressor Suction amp Discharge Pressures must have the same discharge amp suction pressures with reading 5 psig on gauges amp on micro display those shown on the microprocessor controller Check compressor drive coupling a Verify that compressor coupling is Compressor crankshaft must be turning intact and that the compressor crankshaft is turning Perform Pretrip Check a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding Check compressor reed valves amp gaskets a Remove compressor heads amp inspect Must be in good condition condition of all reeds amp gaskets Check compressor pistons and connecting rods a Check compressor pistons and Must be in good condition connecting rods 5 4 START UP ENGINE ALARMS FAILED TO RUN MINIMUM TIME TRIGGER ON Engine has shut down on an alarm 3 times without having run for at least 15 minutes between each shutdown not including Door or Remote Switch shut downs UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Cont
262. matic Check Fuel Solenoid a Check Run Relay LED LED 28 must be ON b Check voltage to fuel solenoid Run Stop switch ON Manual Start Mode See Note 2 More than 11 VDC positive and good ground Inspect solenoid amp connector pins amp No damage to solenoid or wires terminals No damaged or corroded pins Wires plugged in d Check resistance of solenoid Refer to Section 7 8 e Check operation of solenoid Plunger must move in when energized Check fuel solenoid harness a Inspect harness amp control physical damage to harness connector pins amp terminals See No damaged or corroded pins Wiring Schematic 62 10285 5 18 Section 5 Alarm Troubleshooting ALARM CAUSE CORRECTIVE ACTION Check fuel system a Check fuel system prime No air in fuel system b Check fuel flow Unrestricted fuel flow through system Check engine air intake system a Check air filter indicator Flag must not be visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Check for correct engine oil a Check for correct oil viscosity weight Refer to Section 7 2 for conditions Must be correct for ambient conditions Check engine exhaust system a Inspect the exhaust system Must be clear and unobstructed Check engine a Check engine compression Compression must be above 400 psig ENGINE FAILED TO STOP
263. mation at valve seat 8 12 Wax oil or dirt plugging valve or orifice 8 19 Broken capillary 8 19 Power assembly failure or partial Loss of element bulb charge Replace Superheat setting too high 8 19 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 8 19 pressure Low superheat setting 8 19 High superheat Broken capillary 9 3 11 Solenoid Valve Malfunction Solenoid valve does not No power to valve function properly Improper wiring or loose connections Coil defective Valve improperly assembled Coil or coil sleeve improperly assembled Movement of plunger restricted due to a Corroded or worn parts b Foreign material lodged in valve c Bent or dented enclosing tub Solenoid valve closes but Foreign material lodged under seat Clean refrigerant continues to flow Defective seat Replace 9 7 62 10285 Section 10 Electrical Diagrams Plugs Used With Schematic 62 10499 00 10 1 Plugs used with Schematic 62 10499 03 Rev amp 10 2 HCO PIG ou duck dee ey EENE 10 3 Schematic 62 10499 00 10 4 62 10499 03 Rev C NDA UNITS STARTING WITH S N GAX90527303 And NDX UNITS STARTING WITH S N 15415 iius
264. microprocessor controller Suction amp Discharge Pressures must have the same reading on gauges amp on micro display Perform Pretrip Check a Run Pretrip amp check for alarms 5 31 Any active alarms must be corrected and cleared before proceeding 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK REMOTE SWITCH 1 e TRIGGER ON Remote Switch 1 is set to trigger alarm contacts open or contacts closed depending on set up in configuration list for Remote Switch 1 for more than 5 seconds UNIT CONTROL Alarm Only or may be configured to shut unit down e RESET CONDITION Alarm Only Auto Reset after Remote Switch 1 has been set to allow unit to run for more than 5 seconds Shutdown Auto Reset after 3 minutes minimum off time for Remote Switch shutdown condition and Remote Switch 1 has been set to allow unit to run for more than 5 seconds Shut down may be disarmed in the Functional Parameter List NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Determine what Remote Switch 1 is controlled by a Remote Switch 1 may be connected to Find and locate Remote Switch 1 a Trailer Door or some other devise and used to remotely
265. mponent The glow plugs will be energized for 15 seconds at which time the amperage reading is taken Test 2 will last approximately 2 minutes If a problem is detected with any of the listed components the corresponding alarm will be displayed 62 10285 2 14 Section 2 Operation Test 3 Temperature amp Pressure Sensor Check Check the condition of the following sensors Return Air Sensor Ambient Air Sensor Supply Air Sensor Defrost Termination Sensor 1 Engine Coolant Sensor Defrost Termination Sensor 2 Battery Voltage Sensor Compressor Discharge Sensor Test 3 will last approximately 5 seconds If a problem is detected with any of the listed components the corresponding alarm will be displayed Test 4 Warm Up The engine is started automatically and the ambient air sensor is read The Pretrip Mode divides at this point as the engine and compressor are allowed to run and be warmed up If the ambient temperature is above 32 E the unit will operate in the Cool Pretrip Mode If the ambient temperature is at or below 32 the unit will operate in the Heat Pretrip Mode In the Cool Pretrip mode the unit will operate in 2 cylinder Low Speed Cool The compressor suction and discharge pressures will be tested Appropriate alarms will be displayed if any problem is detected Test 4 in Cool Pretrip will last approximately 60 seconds In the Heat Pretrip mode the unit will operate in 4 cylinder Low Sp
266. mpressor malfunction Compressor drive defective Compressor defective Refrigeration system Defrost cycle did not terminate Abnormal pressure Solenoid valve malfunction Clutch Failure Ultima 9 3 2 Unit Runs But Has Insufficient Cooling Compressor Compressor valves defective 8 14 Unloader malfunction 8 16 Refrigeration system Abnormal pressure Unloader malfunction Expansion valve malfunction No or restricted evaporator airflow Clutch Failure Ultima Engine does not Speed control linkage develop full rpm Engine malfunction 9 3 3 Unit Operates Long or Continuously in Cooling Trailer Hot Load Allow time to pull down Defective box insulation or air leak Correct Refrigeration system Abnormal pressure Temperature controller malfunction 9 3 4 Unit Will Not Heat or Has Insufficient Heating Refrigeration Abnormal pressure Temperature controller malfunction Solenoid valve malfunction 1 4 check valve bypass defective Clutch Failure Ultima Compressor Compressor drive defective Compressor defective Engine does not develop Speed control linkage full rpm Engine malfunction 62 10285 9 4 SECTION 9 TROUBLESHOOTING INDICATION REFERENCE 9 3 5 Defrost Cycle Malfunction Will not initiate defrost Defrost air switch DAS out of calibration 8 27 automatically Both DTT1 amp DTT2 are above 40 F 4 4 C Cool Box Down Defrost air switch DAS defective 8 26 amp 8 27 Loose terminal connections Tighten Air sensing tubes
267. n 9 1 Drain Sump Replace Check Engine Manual 8 5 8 Engine Manual 8 2 Check Check Check Engine Replace Engine Manual Engine Manual 8 5 6 7 7 Engine Manual 8 2 62 10285 SECTION 9 TROUBLESHOOTING 9 1 3 Starter Motor Malfunction INDICATION REFERENCE TROUBLE POSSIBLE CAUSES SECTION Starter motor will not crank or turns slowly Battery insufficiently charged Check Battery cable connections loose or oxidized Check Battery cables defective Starter brushes shorted out Starter brushes hang up or have no contact Starter solenoid damaged Glow Crank switch defective Engine lube oil too heavy Starter motor turns Pinion or ring gear obstructed or worn but pinion does not engage Starter motor does not disengage Glow Crank switch defective after switch was depressed Starter motor solenoid defective Engine is already running Replace Engine Manual Engine Manual Engine Manual Replace 7 2 Clean both remove burrs or replace apply grease Replace Engine Manual Check Pinion does not disengage Defective starter Engine Manual after engine is released 9 1 4 Malfunction In the Engine Starting Circuit No power to starter Battery defective Check motor solenoid SS Loose electrical connections Tighten Fuel solenoid Battery defective does not energize or does Loose electrical connections not remain energized Oil pressure safety switch ENOPS defective Run relay RR defective Engine cool
268. n 5 High Pressure Cutout Switch HPS 17 Lube Oil Fill 6 Compressor Discharge Pressure Transducer CDP 18 Engine Oil Level Switch ENOLS 7 Unloader Solenoid Valve 19 Lube Oil Filter 8 Compressor 05G 20 Engine Oil Pressure Switch ENOPS 9 Compressor Oil Sight Glass 21 Injection Pump 10 Compressor Suction Pressure Transducer CSP 22 Fuel Bleed Valve 11 Suction Service Valve 23 Speed Control Solenoid SCS 12 Fuel Filter 24 Ambient Air Temperature Sensor AAT Figure 7 1 Front View Ultima 53 Shown 7 3 62 10285 Section 7 Unit Description Condenser Pressure Control Solenoid Valve SV 1 Defrost Air Switch Receiver Receiver Sight Glass Filter Drier Liquid Line Solenoid Valve SV 2 Discharge Check Valve Model Serial No Location Battery Location Figure 7 2 Curbside Ultima 53 Shown 62 10285 7 4 Section 7 Unit Description Radiator Fill Neck 6 Radiator Overflow Reservoir Condenser Radiator 7 Control Box Door See Figure 7 6 Engine Air Cleaner 8 Serial Port Downloader Plug SLP Coolant Level Switch ENCLS Air Cleaner Service Indicator Figure 7 3 Roadside Ultima 53 7 5 62 10285 62 10285 Section 7 Unit Description Radiator Fill Neck Condenser Engine Air Cleaner Air Cleaner Service Indicator Coolant Level Switch ENCLS Figure 7 4 Roadside Phoenix Ultra Radiator Overflow Reservoir Radiator
269. n 7 1 e Check engine speed With the engine stopped place a mark on the crankshaft sheave white paint for example Speed may be verified in the microprocessor Data List by locking in the RPM in the display or using a Strobette model 964 strobe tachometer Carrier Transicold P N 07 00206 f Hold the speed lever against the high speed stop and check the RPM s LE Low Emission DI engines are delivered with a tamper resistant high speed adjustment screw on the engine High speed adjustments are made using the slotted holes in the solenoid mounting bracket and 86 03027 00 speed solenoid adjusting bracket with solenoid adjusting bolt and lockout on the bracket If high speed adjustment is required 1 Loosen but do not remove the 4 speed solenoid mounting nuts 2 Adjust low speed as normal using the low speed adjusting screw on the engine speed lever plate This screw is not seal wired 3 Turn the jacking nut allowing the solenoid to move along the slots until the desired high speed is reached Tighten the solenoid mounting bolts and verify correct high and low speed RPM 8 5 6 Engine Air Cleaner a Inspection The dry type air cleaner should be inspected regularly for leaks A damaged air cleaner or hose can seriously affect the performance and life of the engine The air cleaner is designed to effectively remove contaminants from the air stream entering the engine An excessive accumulation of these contaminants in the air cl
270. n Pressure Transducer and the RPM sensor If this circuit is shorted to ground due to one of the mentioned components being defective or a worn wire the Message Center will show Suction Pressure 14 7 psig Discharge Pressure 0 psig Engine RPM 0 8 5 4 Lube Oil Filters After warming up the engine stop engine place shallow drain pan under filter and remove filter Lightly oil gasket on new filter before installing Tighten per the filter manufacturer s directions CAUTION When changing oil filters the new filters should be primed partially filled with clean oil if the filters are not primed the engine may operate for a period with no oil supplied to the bearings Replace filter s and add lube oil Refer to Section 7 2 Warm up engine and check for leaks 8 5 5 Servicing the Speed Control Solenoid and Linkage Solenoid Bolt Solenoid Bracket Linkage Speed Clip A EN 2 E Figure 8 5 Speed Control Solenoid a Disconnect wiring to solenoid Disconnect linkage arm item 4 Figure 8 5 from solenoid Remove mounting hardware from solenoid and then remove solenoid b Install replacement solenoid and mounting hardware Do not tighten at this time c Attach linkage to solenoid and install the clip to the linkage rod 8 7 62 10285 Section 8 Service d Hold the speed lever against the low speed stop and check the RPM s Adjust the low speed stop screw if necessary See Sectio
271. n 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 8 9 The V belts must be kept in good condition with the proper tension to provide adequate air movement across the coils Table 8 1 Belt Tension See Figure 8 8 BELTS Water pump to Crankshaft 35 to 40 Figure 8 8 Belt Tension Gauge Part No 07 00253 8 6 2 Water Pump V Belt The water pump V belt is driven by a sheave on the engine crankshaft Frayed cracked or worn belts must be replaced Adjustment is achieved by altering the position of the front side idler When replacing V belt avoid excessive force when applying tension to the V belt to prevent damage to the water pump bearings Refer to Table 8 1 62 10285 8 10 Section 8 Service 8 6 3 Alternator V Belt Make sure negative battery terminal is disconnected
272. n again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Alarm light a Inspect Remote Alarm light amp socket No damage to solenoid No damaged or corroded pins b Check resistance of light bulb Refer to Section 7 8 Check Alarm light wiring a Inspect harness amp control box See Notes 2 amp 6 connector pins amp terminals See No physical damage to harness wiring schematic No damaged or corroded pins Check Alarm light current draw a Use Component Test Mode Refer to Refer to Section 7 8 for normal current values Section 2 17 3 to test actual current draw of the circuit 5 39 62 10285 Section 5 Alarm Troubleshooting CHECK UL1 UNLOADER a positive wire UNIT CONTROL Alarm Only Steps ALARM CAUSE CORRECTIVE ACTION TRIGGER ON UL1 Front Unloader Coil circuit is shorted The UL1 output from the Micro is negative so the circuit will not be shorted to ground but is shorted either within the UL1 itself or to RESET CONDITION Auto Reset when the UL1 Coil current amp draw is normal or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE F
273. n the refrigerant drum open the manifold gauge set discharge valve and allow liquid refrigerant to flow into the system e Carefully weigh the refrigerant into the system Never allow more than 5 lbs of refrigerant into the system at a time since with the unit in this charging state it is not possible to accurately determine when the system will be full f After metering 5 lbs of refrigerant into the system close the valve of the manifold gauge set connected to the King Valve Open the King Valve partially block the air flow to the condenser coil and allow the system to balance out approximately 4 5 minutes Refrigerant should appear at center line of the lower receiver sight glass If charge is inadequate repeat steps d thru f until system is full 62 10285 8 22 Section 8 Service 8 14 Replacing the Compressor 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 8 10 a If compressor does not operate frontseat both suction and discharge service valves and remove refrigerant charge from compressor Refer to Section 8 10 b a moan Disconnect negative battery cable Remove the two rear compressor bracket mounting bolts compressor shockmount end Block up engine Remove bolts from suction and discharge service valve flanges Remove oil filter and
274. n the temperature is at set point The Active Probe is the sensor actually used by the Microprocessor to perform the temperature control It is the same as the Selected Probe unless that sensor is not installed or is defective or if supply is the selected probe in Frozen Range SELECTED PROBE ACTIVE PROBE Return Air Sensor Return Air Sensor only Supply Air Sensor Supply Air Sensor Perishable Range Return Air Sensor Frozen Range The Controlling Temperature is a calculated temperature value based upon both the Supply and Return Air temperatures and Set Point Most of the time the Controlling Temperature will be very close to or the same as the Active Probe temperature In the case of a bad probe the remaining probe will be used for temperature control NOTE The following temperature control operating sequence diagrams are after pulldown and do not show overrides 62 10285 4 6 Section 4 Engine and Temperature Control FALLING TEMPERATURE High Speed 6 Cylinder Cool Low Speed 4 Cylinder Cool Low Speed 2 Cylinder Cool PULSED NULL BAND Cool Heat 2 Cylinder Low Speed 2 Cylinder Heat Low Speed 6 Cylinder Heat High Speed 6 Cylinder Heat 2 0 C 3 6 F 1 5 2 7 F 1 0 C 1 8 F 0 5 C 0 9 F 0 5 C 0 9 F 1 0 C 1 8 F 1 5 2 7 F 2 0 3 6 F RISING TEMPERATURE 6 Cylinder Cool Low Speed Low Speed 2 Cylinder Cool
275. nce a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Heat light a Inspect Heat light amp socket No damage to solenoid No damaged or corroded pins b Check resistance of light bulb Refer to Section 7 8 Check Heat light wiring a Inspect harness amp control Notes 2 amp 6 connector pins amp terminals See No physical damage to harness wiring schematic No damaged or corroded pins Check Heat light current draw a Use Component Test Mode Refer to Refer to Section 7 8 for normal current values Section 2 17 3 to test actual current draw of the circuit CHECK REMOTE COOL LIGHT TRIGGER ON Remote Cool light Driver s Light Bar circuit is shorted The Cool Light output from the Micro is negative so the circuit will not be shorted to ground but is shorted either within the Cool Light itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when Cool light current amp draw is normal or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the app
276. ncluded in kit Remove key from key way if damaged Install clutch on fan shaft assembly by reversing steps 1 7 Add a thin coating of anti seize compound to new clutch bore Do not get anti seize compound on clutch contact surfaces Be sure to align anti rotation tang of rotor field assembly 12 o clock position between the two backer plate supports while sliding it into position and also pull the tension clip item 18 out of the way about 1 to fully seat this clutch half Orient retainer washer 9 so that bent tab is inserted into key way then bend two tabs over the bolt Clutch bolts torque is 25 to 30 ft Ibs To Remove the Fanshaft Bearing Assembly See Figure 8 13 1 2 3 4 First complete clutch removal refer to steps above Remove washer item 11 from shaft behind clutch Remove evaporator panels Remove two screws securing split tapered bushing to blower wheel items 12 and 13 Figure 8 13 Place the two screws in the threaded holes of the fan hub and use screws as jacking bolts to remove bushing from blower wheel Remove venturi ring item 13 Figure 8 13 by removing 4 screws Remove clamp from rubber boot on the back of the fan shaft housing and remove the 6 bolts and ring securing the boot to the pod Remove 4 screws from the bearing housing item 17 Remove the shaft and bearing housing Install bearing housing assembly into the unit by reversing steps 1 through 8 Torque 45 to 50
277. ne will run in low speed until the coolant is above 79 F 26 2 Defrost see Defrost Control Refer to Section 4 7 3 10 Minute Startup low speed operation e For the first 10 minutes of operation the unit will run in low speed except for perishable continuous run mode 4 High Air Flow For Perishable Set Points the AIR FLOW Functional Parameter will force the unit to operate in continuous High Speed operation when AIR FLOW HIGH is selected When AIR FLOW NORMAL is selected the unit will cycle normally between high and low speeds 5 Low Ambient Cool When the Ambient Temperature falls below 35 F 1 7 C and the microprocessor calls for Cool the engine will only operate in Low Speed If the ambient Temperature rises above 40 F 4 4 C High Speed will again be allowed for Cool Mode 6 Default Mode Ifthe setpoint is in the frozen range below 10 4 F and both RAT and SAT sensor alarms are active the unit will run in low speed cool 7 Start Stop Frozen Range e In Start Stop Mode with the setpoint in the frozen range below 10 4 F minimum run time has expired and the box temperature is not yet down to set point the engine will be forced to high speed operation 8 Frozen Setpoint Ifthe setpoint is in the frozen range below 10 4 F and the control temperature is below setpoint the unit will run in low speed 9 High Speed Delay When operating in low speed the Microprocessor switches between
278. negative battery cable 2 Remove top 8 bolts 4 along top edge and 2 down each side that hold fan shroud to condenser frame Remove top frame cross member 6 bolts 3 Pry top of shroud away from frame and hold it open by inserting any object about 3 50 deep between frame and shroud on each side short pieces of 2 X 4 s works well 4 Loosen the fan belt idler and remove belt 62 10285 8 16 10 11 1 N Section 8 Service Remove the 3 bolts item 5 which secure the condenser fan and hub assembly items 3 4 to the clutch and carefully remove condenser fan assembly from unit Bend the lock tabs of the retaining washer item 9 away from the clutch mounting bolt item 7 Using an 1 4 Allen wrench or rod slide it through the notch on either side of the backer plate item 15 until it touches the washer behind the clutch Slowly rotate the fan shaft while applying a slight pressure to the rod until the rod slips into one of the anti rotation holes in the washer With the rod in place remove the bolt and washers items 7 8 amp 9 which secure the clutch onto the shaft Remove the clutch pulley armature from the shaft be careful not to get the anti seize compound on the clutch engagement surfaces if clutch is to be reused Unplug the wire connector to the clutch rotor field assembly and remove from the shaft Remove the spacer washer which was behind coil Discard this washer and use new improved washer i
279. ng a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Check speed solenoid a Check resistance of speed solenoid Refer to Section 7 8 b Check amp draw of speed solenoid Use Component Test Mode Section 2 17 3 to test Refer to Section 7 8 for amp values 62 10285 5 52 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK SV1 CIRCUIT TRIGGER ON Normal Amps for the SV 1 Circuit is 0 75 to 2 5 Amps The circuit tests outside this range UNIT CONTROL Abort PreTrip amp display PRETRIP FAILED IN TEST 2 Alarm RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for Bad F4 or F6 Fuse alarm a Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue Check SV 1 amp circuit a Inspect SV 1 and wiring No physical damage to harness No damaged or corroded pins b Start unit setpoint more than 10 Unit running in Heat Cycle above box temperature and set abo
280. ng in low speed and the suction pressure is greater than 65 psig both unloaders are unloaded As the suction pressure drops below 64 psig the UL2 unloader is loaded If the suction pressure drops below 35 psig the UL1 unloader 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 follow a descending straight line Refer to following chart R 404A REFRIGERATION SYSTEM SUCTION PRESSURES UNLOADING 70 65 LOW SPEED U 60 55 50 UL1 FRONT UNLOADER UL2 REAR UNLOADER SUCTION ABOVE THE LINE UNLOADED PRESSURE BELOW THE LINE LOADED PSIG 80 90 100 110 120 130 AMBIENT TEMPERATURE F 62 10285 4 14 Section 4 Engine and Temperature Control e R 22 Refrigeration System At ambient temperatures of 90 F 32 2 C or below When the system is operating in high speed and the suction pressure is greater than 53 psig both unloader banks are unloaded As the suction pressure drops below 52 psig the UL2 unloader is loaded If the suction pressure drops below 26 psig the UL1 unloader is loaded When the system is operating in ow speed and the suction pressure is greater than 56 psig both unloader banks are unloaded As the suction pressure drops below 55 psig the UL2 unloader is loaded If the suction pressure drops below 21 psig the UL1
281. ngs a Check Defrost Termination Refer to Section 7 8 for complete resistance chart Temperature Sensor 1 amp 2 n a resistance See Note 4 10K Ohms 77 F 25 Check DTT1 amp DTT2 for proper mounting a Inspect DTT1 amp DTT2 Should be screwed tightly in place Flat area of DTT should be against metal surface Perform Pretrip Check a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding 5 29 62 10285 Section 5 Alarm Troubleshooting CORRECTIVE ACTION ALARM CAUSE CHECK DEFROST AIR SWITCH TRIGGER ON The defrost air switch has called for a defrost cycle within 8 minutes of a defrost termination for 2 consecutive defrost cycles UNIT CONTROL Alarm ON While this alarm is active the defrost air switch will NOT be used to initiate a defrost cycle however the Defrost Timer will initiate a defrost cycle 90 minutes after the alarm comes on and the manual defrost switch will remain operative RESET CONDITION Auto Reset when defrost cycle terminates correctly and the air switch does not call for a defrost cycle within the 8 minutes following defrost termination or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset
282. nit and check unloader operation Refer to Section 8 16 a 8 17 Servicing Check Valve Serviceable Type A check valve allows the hot gas to travel in one direction only The function of the Hot Gas Bypass Check Valve is to raise the receiver pressure when the ambient temperature is low so that refrigerant can flow from the receiver to the evaporator when the unit is in heating or defrost The function of the Discharge Line Check Valve is to prevent any liquid refrigerant from migrating into the compressor during the unit off cycle Cap Spring Gasket Stem Seat Body DAON 5 Figure 8 20 Check Valve Serviceable a To replace check valve store the refrigerant into an evacuated container Refer to Section 8 10 b Replace necessary parts Evacuate and dehydrate unit Refer to Section 8 12 d Add refrigerant charge Refer to Section 8 13 62 10285 8 28 Section 8 Service 8 18 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 8 10 Remove bracket then replace drier Tighten inlet side fitting b Slowly open King Valve and purge air throug
283. nit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary Operator failed to crank engine a Manually start unit Engine starts and runs Check fuel level in tank a Check fuel gauge on tank Fill tank as needed Check for Check Glow Plugs alarm a Check for alarm 40 Alarm conditions must be corrected and the alarm cleared to continue Check glow crank switch a Check the glow crank switch No damaged or corroded pins No physical damage b Check voltage to glow crank switch Run Stop switch ON Manual Start Mode See Note 2 Voltmeter lead on Battery post Position Terminals VDC Voltmeter lead on switch terminals ge 1 11 V min With wires connected to switch 2 amp 3 0 V min Glow 1 amp 3 10 1 2 V min 2 0 V min Disconnect wire to Starter Solenoid before checking Crank 1 amp 2 11 1 2V min 3 0 V min c Check voltage to glow plugs Glow Plug switch ON Manual Start Mode More than 11 VDC d Check voltage to starter solenoid Crank switch ON Manual Start More than 11 VDC Check glow crank switch harness a Inspect harness amp control box No physical damage to harness connector pins amp terminals No damaged or corroded pins wiring sche
284. nits the Control Module is located in the control box below the radiator inside the lower roadside door The Control Module contains replaceable relays and fuses which are externally accessible LEDs are located next to the 3 relays plugged into the control module to indicate relay operation Additional LEDs indicate operation of the FETs Field Effect Transistors The Display amp Keypad Module is located for driver access at the lower roadside corner of the unit The Control Module includes the logic board program memory FETs PC Card slot and necessary input output circuitry to interface with the unit The Display Board is mounted in the Keypad amp Display Module The display board includes the LCD display keypad and keypad interface The logic board is located within the Control Module and does not contain any serviceable components CAUTION Under no circumstances should anyone attempt to repair the Logic or Display Boards Should a problem develop with either of these components contact your nearest Carrier Transicold dealer for replacement a ww E Li 22 Advance E Display amp Keypad Location 3 1 62 10285 Section 3 System Description 3 2 Special Features The Carrier Transicold Advance Microprocessor controller incorporates the following features Message Center Unit Operation amp Alarms are displayed in English not in codes UltraFresh 2 UltraFreeze Large LCD Disp
285. nly e RESET CONDITION Auto Reset when In range light current amp draw is normal or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Out of Range light a Inspect Out of Range light amp socket No damage to solenoid No damaged or corroded pins b Check resistance of light bulb Refer to Section 7 8 Check Out of Range light wiring a Inspect harness amp control box See Notes 2 amp 6 connector pins amp terminals See No physical damage to harness wiring schematic No damaged or corroded pins Check Out of Range light current draw a Use Component Test Mode See Refer to Section 7 8 for normal current values section 2 16 3 to test actual current draw of the circuit 62 10285 5 38 Section 5 Alarm Troubleshooting ALARM CAUSE CORRECTIVE ACTION CHECK REMOTE DEFROST LIGHT TRIGGER ON Defrost light Driver s Light Bar circuit is shorted The Defrost Light output from the Micro is negative so the circuit will not be shorted to ground but is shorted either within the Defrost Light itself or to a positive wire UNIT CONTROL Alarm Only
286. nnected to the high engine speed hour meter which counts only high speed engine hours The reset interval will be 50 HIGH SPEED 30 000 hrs HOURS 50 30000 HRS in 50 hr increments RANGE 1 2 LOCK OFF OFF If both Range 1 amp Range 2 Locks are off Start Stop or Continuous Run may be selected If either Range 1 or Range 2 is not OFF the unit will CONTINUOUS operate in the selected mode whenever the set point is within that range START STOP The unit will always operate in Start Stop whenever the set point is between the minimum amp maximum temperatures for that range see below CONTINUOUS The unit will always operate in Continuous Run whenever the set point is between the minimum amp maximum temperatures for that range see below e RANGE 1 2 MINIMUM TEMP 22 F TO 89 6 F Select the lowest temperature desired for either Range 1 30 C to 32 C and or Range 2 in 0 1 F or C increments RANGE 1 2 MAXIMUM TEMP 22 F TO 89 6 F Select the highest temperature desired for either Range 1 30 C to 32 C and or Range 2 in 0 1 F or C increments MIN SETPOINT 22 F TO 89 6 F Select the lowest temperature that will ever be used as 30 C to 32 C setpoint Setpoint can not be set lower than this value in 0 1 F or C increments MAX SETPOINT 22 F TO 89 6 F Select the highest temperature that will ever be used as 30 C to 32 setpoint Setpoint can not be set higher than thi
287. nning See page 2 8 for more information on Sleep Mode This will also be displayed when the unit is running in Default Mode See Section 4 5 CHECK DOOR will be displayed if the trailer door is opened and your trailer has an optional door switch to notify you when the door is opened or not closed tightly UNIT SHUTDOWN DOOR OPEN will be displayed if the trailer door is opened and your trailer has an optional door switch to shut the unit down when the door is opened or not closed tightly CHECK REMOTE SWITCH 1 2 will be displayed if an optional remote control switch is installed as a warning devise for example a second door switch or remote toggle OFF ON switch and the switch is in the OFF position UNIT SHUTDOWN REMOTE SWITCH 1 2 will be displayed if an optional remote control switch is installed and configured to shut the unit down when it is turned OFF for example a second door switch and the door is opened whenever the door is opened or not tightly closed CHECK AT NEXT SERVICE INTERVAL is shown when there is an active non shutdown alarm present the alarm condition is present but is not serious enough to stop the unit These alarms may be viewed by pressing the Alarm List Key The message will clear itself when the condition is corrected PM DUE is shown when any of the maintenance hour meters has expired indicating that the unit should be brought into a shop for scheduled maintenance TIP To deactivate activ
288. 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 AUTO START Your refrigeration unit is equipped with Auto Start in both Start Stop and Continuous Run modes The unit may start at any time a buzzer will sound for 5 seconds before the unit is started When performing any check of the refrigeration unit e g checking the belts checking the oil make certain that the Start Run Off switch is in the OFF 0 position ENGINE COOLANT The engine is equipped with a pressurized cooling system Under normal operating conditions the coolant in the engine and radiator is under high pressure and is very hot Contact with hot coolant can cause severe burns Do not remove the cap from a hot radiator if the cap must be removed do so very slowly in order to release the pressure without spray REFRIGERANTS The refrigerant contained in the r
289. nsors DTT1 amp DTT2 The location of the RAT SAT and both DTT s are shown in Figure 7 5 Heating is accomplished by circulating hot gas directly from the compressor to the evaporator coil Four electric solenoid valves control the refrigerant circuit to operate the heating cooling system Automatic evaporator coil defrosting is initiated by either sensing the air pressure drop across the coil with a differential air switch or with the defrost timer in the Advance Microprocessor The control door include manual switches keypad and associated wiring Also available is an optional Driver s Light Bar It is generally mounted separately on the front roadside corner of the trailer The temperature controller is the Advance Microprocessor solid state controller Once the Advance Microprocessor is set at the desired temperature the unit will operate automatically to maintain the 7 1 62 10285 Section 7 Unit Description desired temperature within very close limits The control system automatically selects high and low speed cooling or high and low speed heating as necessary to maintain the desired temperature within the trailer The refrigeration compressor used Refer to Table 7 1 is equipped with Varipowr as standard equipment Varipowr is used as a compressor capacity control to unload the compressor during periods of reduced loads This provides closer temperature control reduces potential for top freezing and reduces power required
290. ntil the conditions described above are met then shut off go to sleep While the unit is cycled off in Sleep Mode SLEEP MODE OFF ON TO WAKE will be displayed in the Message Center Sleep Mode may be exited by either turning the Start Run Stop switch to the OFF position then back to the ON position or by accessing the Functional Parameter list and selecting SLEEP MODE OFF While in Sleep Mode Unit Data and Alarm Lists may be viewed and Functional Parameters may be viewed and changed as necessary Data may be downloaded from the DataLink Data Recorder However Start Stop Continuous Run selections and set point can not be changed and Manual Defrost can not be initiated 62 10285 3 14 Section 3 System Description 3 10 Out Of Range Alarm The Out Of Range Alarm is intended to notify the driver when the box temperature is moving away from Set Point The Out Of Range Alarm may be configured as an Alarm Only or as an Alarm and Unit Shutdown Refer to Section 2 17 1 Configuration Mode Generally before the Out of Range Alarm can be triggered the box temperature must have first been In Range In Range is defined as the box temperature having been within 2 7 F 1 5 C of setpoint in the Perishable Range or within 2 7 F 1 5 C of setpoint in the Frozen Range If the unit shuts down due to a shutdown alarm the Out Of Range Alarm will come on after the timer expires 15 or 45 minutes and when the box temperature go
291. nue with the steps below as necessary 1 Check Real Time Clock a Check Real Time Clock in the Data Must show correct date and time Change as needed List or using DataManager Configuration List Reset Microprocessor a Turn main switch off for 30 seconds Microprocessor powers up OK then turn on b Check for valid Real Time Clock Valid date and time in memory reading in Data List Alarm is cleared automatically c Real Time Clock can not be Replace Microprocessor changed DOOR OPEN TRIGGER ON Trailer Door has been open for more than 5 seconds UNIT CONTROL Alarm Only or may be configured to shut unit down e RESET CONDITION Alarm Only Auto Reset after the door has been closed for more than 5 seconds Shutdown Auto Reset after 3 minutes minimum off time for door open condition and the door has been closed for more than 5 seconds Shut down may be disarmed in the Functional Parameter List NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check to see if trailer side or rear door is open a Inspect trailer doors Trailer door s must be closed Check Wiring a Visually inspect wiring to door switch Wiring must be connected
292. o a value of 28 ft lb 3 87 mkg Place V belt on the Gearbox sheave and adjust belt tension as indicated in Table 8 1 Install V belt guard DO NOT START UNIT UNTIL V BELT GUARD IS INSTALLED WARNING Keep hands and arms away from unit when operating without belt guard in place Never release a unit for service without the belt guard securely tightened in place 7 Reconnect negative battery cable Start unit and run for 10 minutes to allow for belt stretch 8 Turn unit off and recheck belt tension Install belt guard ATTACHING SCREWS FLYWHEEL FLYWHEEL SLIDE ADAPTER Figure A Figure B Figure 8 10 Removing V Belt from Engine Adapter Drive Sheave 62 10285 8 12 Section 8 Service 8 7 Gearbox Clutch Ultra Ultra XL amp Extra 5 Beveled Edge Shims NA X 22 SS 4 4 SIDES Pg 4 Clutch Assembly Cross Section View Coil Assembly Retaining Ring 7 Rotor Pulley Assembly Retainer Nut w Shims Pulley Assembly Key Washer 9 Nut Figure 8 11 Gearbox Clutch Clutch Removal 1 Disconnect electrical input 2 Remove armature pulley assembly Figure 8 11 6 a Remove shaft nut 9 and washer 8 b Using a standard 2 or 3 jaw gear puller pull the armature 6 off the shaft Apply the puller jaws to the pulley hub not the rim of the pulley NOTE The arm
293. of this much smaller range calibration of the CSP is not required A general rule is that 2 inches of vacuum equals 1 psig 8 22 2 Testing Compressor Suction Pressure Transducer a Verify that the wiring to the transducer is correct See wiring diagram b Power up the transducer circuit Place unit into PC Mode Refer to Section 2 16 or place unit in Manual Start Mode c Check Voltage to transducer Voltage reading between A negative and B positive should be 5 0 VDC d Check wire resistance between C output to microprocessor and 1MP6 e Place 45 0 VDC on transducer terminal B and Ground on transducer terminal A Test voltage between B and C The reading should be as shown in table below ria Veiage reis Psia 91 277 EIR AEZ 8 0 2 8 9 Es m WARNING The 5 0 VDC terminal is common between the Compressor Discharge Pressure Transducer the Compressor Suction Pressure Transducer and the RPM sensor If this circuit is shorted to ground due to one of the mentioned components being defective or a worn wire the Message Center will show Suction Pressure 14 7 psig Discharge Pressure 0 psig Engine RPM 0 3 6 4 1 TIP A reading of 14 7 will occur if there is an open circuit between the transducer and the microprocessor 62 10285 8 34
294. ollow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check UL1 Front Unloader Coil a Inspect UL1 Unloader coil amp terminals b Check resistance of coil c Check amp draw of coil No damage to solenoid No damaged or corroded pins Refer to Section 7 8 Refer to Section 7 8 Check UL1 Unloader coil wiring box See a Inspect harness amp control connector pins amp terminals wiring schematic See Notes 2 amp 6 No physical damage to harness No damaged or corroded pins Check UL1 current draw a Use Component Test Mode Refer to Section 2 17 3 to test actual current draw of the circuit Refer to Section 7 8 for normal current values CHECK UL2 UNLOADER a positive wire UNIT CONTROL Alarm Only TRIGGER ON UL2 Rear Unloader Coil circuit is shorted The UL2 output from the Micro is negative so the circuit will not be shorted to ground but is shorted either within the UL2 itself or to RESET CONDITION Auto Reset when the UL2 Coil current amp draw is normal or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been
295. ompressor discharge pressure is not at least 5 psig higher than the suction pressure for 10 minutes START UP ENGINE ALARMS Engine failed to run for at least 15 minutes following a shutdown alarm 3 consecutive times Engine fails to start on 3 consecutive attempts in automatic start mode Engine fails to start on 3 consecutive attempts in manual start mode Engine RPM is greater than 500 RPMs or engine oil pressure switch is closed longer than 5 seconds after attempting to stop engine Engine failed to reach 50 RPM on 2 consecutive attempts Coolant temperature is less than 32 F 0 C after engine has been running for 5 minutes Engine RPM is outside limits when engine is running in low speed mode See Alarm Troubleshooting Section for RPM values for each model Engine RPM is outside limits when engine is running in high speed mode See Alarm Troubleshooting Section for RPM values for each model Engine RPM is completely outside limits for 5 minutes See Alarm Troubleshooting Section for RPM values for each model Check Glow Plug When glow plugs are energized glow plug current is lt 30 Amps or gt 43 Amps after being energized for 13 seconds 6 7 62 10285 Section 6 Message Center and Alarms Alarms List ALARM CAUSES 41 Engine Stalled Engine RPM 10 or engine oil pressure is less than 8 psig when engine RPM sensor is not operating WARNING STATUS ALARMS 51 Alternator Not Battery is not charging after engin
296. ontinuous Run START STOP When the Set Point is set between Range 1 Minimum amp Maximum Temperatures the unit is set to operate only in Start Stop RANGE 1 MINIMUM TEMP RANGE 1 MAXIMUM TEMP This is the lower limit for Range 1 This is the upper limit for Range 1 RANGE 2 LOCK RANGE 2 MINIMUM TEMP OFF Temperature Range 2 Lock is turned off CONTINUOUS When the Set Point is set between Range 2 Minimum amp Maximum Temperatures the unit is set to operate only in Continuous Run START STOP When the Set Point is set between Range 2 Minimum amp Maximum Temperatures the unit is set to operate only in Start Stop This is the lower limit for Range 2 RANGE 2 MAXIMUM TEMP This is the upper limit for Range 2 TEMPERATURE This is the temperature at remote Temperature Sensor 1 2 and 3 These sensors are SENSOR 1 3 optional and may not be applicable to your unit Up to 3 remote sensors may be listed DATALOGGER This is the current Date and Time that the Data Recorder is using This may be different than your actual time depending on the Time Zone and Daylight Savings Time selections made by the owner of the unit These may or may not be displayed depending on the Functional Change Parameters settings 2 23 62 10285 Section 2 Operation 2 15 Functional Change Parameters HEAT COOL DEFROST START STOP CONTINUOUS 988 8 9898 SETPOINT BOX TEMPERATURE PRESS 1
297. oprocessor will power up and the unit will start Allow the engine to start completely the first time after loading software DO NOT TURN THE SROS SWITCH OFF DURING THE INITIAL START FOLLOWING A SOFTWARE UPGRADE 2 19 3 Troubleshooting Software Loading Problems If after loading the software program the microprocessor does not power up or the engine does not start use the following to isolate the problem 1 Did the unit perform properly prior to loading the software If not the problem most likely is not a result of the software loading process Check the Micro Status LED near the PC Card slot on the Microprocessor It should be blinking continuously at the rate of 1 second on and 1 second off This is the normal heartbeat rate of the Microprocessor If the Micro Status LED is blinking at the rate of 5 seconds on and 5 seconds off the Microprocessor is still in Program Mode and the software is not fully loaded into memory Load the software again being careful to follow each step completely in sequence If the Micro Status LED is not on at all check voltage to QC1 amp QC2 Also check for voltage from the SROS at SMPA1 If voltage and grounds check OK the Microprocessor may be dead and require replacement 62 10285 2 40 Section 2 Operation 2 20 Setting PM Preventative Maintenance Hourmeters TIP PM Hourmeters may be reset for the next maintenance interval from the Functional Parameter List using the Keypad
298. or Continuous Run with Setpoint above 11 F b Check operation of Speed Relay LED 27 must be ON c Check voltage to speed solenoid Must be 12 14 VDC Check engine RPMs a Check actual engine RPM using hand Refer to Section 7 2 held tachometer Adjust engine linkage setting as needed b Compare actual RPMs with those Both readings within 50 RPM shown on display Check engine air intake system a Check air filter indicator Flag must not be visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Check engine exhaust system a Inspect the exhaust system Must be clear and unobstructed 5 23 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK ENGINE RPM TRIGGER ON Engine RPMs have been Less than 1200 or greater than 2500 for Ultima or Less than 1100 or greater than 2200 for Ultra or Ultra X L or Less than 1100 or greater than 2000 for Extra for more than 5 minutes UNIT CONTROL Alarm Only or Unit Shutdown amp Alarm if configured RESET CONDITION Auto Reset if unit is set for Alarm Only when engine RPMs are between 1200 to 2500 for more than 5 minutes or Alarm may be manually reset via Keypad or by turning the unit off then back on again RESET CONDITION Auto Reset if unit is set for Alarm Only when engine RPMs are Between 1200 to 2500 for Ultima or Between 1100 to 2200 for
299. or temperature temperature sensor CDT Alarm 17 in Section 5 microprocessor reset Other Safety Devices Unsafe Conditions Safety Device Device Setting Low Engine Coolant Level Engine Coolant Level Switch Engine coolant level is more ENCLS than 1 quart low Low Engine Oil Level Low Engine Oil Level Switch Engine oil level is more than 7 May be configured for alarm only or alarm ENOLS quarts low and shutdown Low Fuel Level Low Fuel Level Switch or See Trigger On criteria for May be configured for alarm only or alarm Low Fuel Level Sensor alarms 1 and 19 in Section 5 and shutdown Trailer Door Open Door Switch or Remote Switch See Trigger On criteria for May be configured for alarm only or alarm Alarms 57 58 and 61 in and shutdown Section 5 Box Temperature Out Of Range Microprocessor See Trigger On criteria for May be configured for alarm only or alarm Alarm 53 in Section 5 and shutdown o o o 5 Q 7 13 62 10285 Section 7 Unit Description 7 8 Data Ohms and Amps Component ohms amps Fuel solenoid 11 1 Ohms to 13 4 Ohms 0 25 to 2 0 Amps Red Black wires White Black wires Can not be accurately measured 30 0 to 40 0 Amps with Coil Commander in circuit StarerAmps 20 na 62 10285 7 14 own Section 7 Unit Description 7 9 Lube Oil and Fuel Flow Diagrams 5 6 Fuel Tank 7 Fuel Bleed Valve Fuel Supply Line 8 Injection Pump Electric Fue
300. or more than 30 seconds or less than 8 psig 16 inches vacuum for more than 5 seconds at any time during PreTrip UNIT CONTROL Abort PreTrip amp display PRETRIP FAILED IN TEST Alarm RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check fan belts a Check upper fan belt tension amp condition b Check lower fan belt tension amp condition Refer to Section 8 6 for belt tensions No Glazing no cracking no slipping Refer to Section 8 6 for belt tensions No Glazing no cracking no slipping Check system pressures a Install Manifold Test Set and check and compare compressor discharge amp suction pressures with those shown on the microprocessor controller Suction pressure must be above 3 psig Suction amp Discharge Pressures must have the same reading on gauges amp on micro display Manually defrost unit a Defrost unit and terminate automatically Typical defrost cycle time is 5 20 minutes Suction pressure should rise gradually during cycle Check evaporator air flow a Check evap fan clutch b Check e
301. or will recognize switches with contacts that are either open when the door is open or that are closed when the door is open Additionally the Configuration List gives you the ability to determine whether the switch will enable the alarm only to enable the alarm and also shut the unit down or to have no alarm and only record door openings amp closing in the data recorder If the Door Switch or Remote Switches are configured to shut the unit down there is an Override Door Switch and Remote Switch Shutdown selection in the Functional Parameter List When this is turned OFF the Door Switch or Remote Switch Alarm s will come on as needed however the unit will not shut down 3 9 Sleep Mode If Sleep Mode is selected when the unit is not running Start Stop Off Cycle any remaining Minimum Off Time will be ignored and the engine will start It will run for 4 minutes minimum until the Engine Coolant Temperature is above 122 F 50 C and the battery is fully charged O K appears in the Data List voltage line and charging amps are less than amps set in the Configuration List While the unit is running in Sleep Mode WARNING NO TEMP CONTROL will flash in the Message Center and the Main Display set point and box temperature will be turned off This is because box temperature does not have to be at set point to allow the unit to cycle off go to sleep If the unit is already running when Sleep Mode is selected it will continue to run u
302. ors are also taken at the time of a shutdown alarm 3 Event Occurrences e This information is any additional data that is recorded on a when it occurs basis In general Events are recorded by the recorder as they occur An Event is defined as something that happens i e Set Point changed Defrost Cycle Started or Main Power On etc 4 User Area Data The User or service technician is able to enter a Comment into the DataLink Data Recorder using the Data Manager Program 62 10285 3 4 Section 3 System Description 3 4 3 Sensor amp Event Data Sensors The following sensors may be recorded either with an averaged reading or snapshot Return Air Temperature Supply Air Temperature Ambient Air Temperature Defrost Termination Temperature 1 Defrost Termination Temperature 2 Compressor Discharge Temperature Engine Coolant Temperature Compressor Discharge Pressure Compressor Suction Pressure Battery Voltage Battery DC Current Engine RPMs Time Intervals The following intervals are available for sensor recording 2 Minutes 5 Minutes 10 Minutes 15 Minutes 30 Minutes 1 Hour 2 Hours 4 Hours 3 5 62 10285 Section 3 System Description Events The following Events may be recorded 6 Start cessat eet A bete So cta Selectable Pretrp End 24222 Selectable e Trailer ID change Selectable e Unit Serial Number Changed
303. ote 4 10 000 Ohms 9 77 F 25 C Check Engine Coolant Sensor wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic 62 10285 5 46 Section 5 Alarm Troubleshooting ALARM CAUSE CORRECTIVE ACTION CHECK ENGINE RPM SENSOR TRIGGER ON With the unit in Auto Start The ambient temperature is above 32 F 0 C and this is the 2nd or 3rd start attempt and the Engine Oil Pressure switch is closed oil pressure good and engine RPMs are sensed at less than 1000 RPM or The ambient is below 32 F 0 C and the DC amp draw is more than 2 amps and this is the 2nd or 3rd start attempt and engine RPMs are sensed at less than 1000 RPM or With the unit in Manual Start The ambient temperature is above 32 F 0 C and this is the 2nd or 3rd start attempt and the Engine Oil Pressure switch is closed oil pressure good engine RPMs are sensed at less than 50 RPM or The ambient is below 32 F 0 the DC amp draw is more than 2 amps and this is the 2nd or 3rd start attempt and engine RPMs are sensed at less than 50 RPM UNIT CONTROL Alarm Only Engine will be considered running RESET CONDITION With the unit in Auto Start Auto Reset in Auto Start when engine RPMs are greater than 1 000 or With the unit in Manual Start Auto Reset in Auto Start when engine RPMs are greater than 1 000 or
304. oth belts must be checked and retensioned if necessary after a brief run in period see step 6 8 11 62 10285 Section 8 Service WARNING Keep hands and arms away from unit when operating without belt guard in place Never release a unit for service without the belt guard securely tightened in place 6 Reconnect negative battery cable and operate unit in high speed for 5 10 minutes Repeat steps 4 and 5 7 Replace belt guard b Driveshaft to Gearbox V Belt 1 Disconnect negative battery cable and remove V belt guard and then loosen idler bolt 2 Match mark adapter to engine flywheel See Figure 8 10A for ease of assembly 3 Remove six bolts 5 16 18 x 1 lg securing adapter drive sheave to engine flywheel Figure 8 10A Insert 2 of the six bolts 5 16 18 x 1 lg into the threaded holes jacking holes provided on engine adapter Jack adapter from engine flywheel Remove the 2 screws from adapter Insert a pry bar between engine flywheel and adapter Figure 8 10A and slide the adapter sheave toward the compressor enough to change the V belt as shown in Figure 8 10B Replace V belt Pry the adapter back toward the engine flywheel or use 5 16 18 x 2 1 2 lg bolts 3 in every other hole of adapter and take up evenly on the bolts until the 5 16 18 x 1 lg bolts will start in the engine flywheel Apply thread sealer Loctite 262 to the bolts used to secure adapter to flywheel Take up on all bolts evenly and then torque t
305. ove away from setpoint before an out of range alarm is generated PM DUE Preventative Maintenance is now due on the unit PM HOUR METER NOT CHANGED The last change for the PM hour meter was not received by the micro PRESS 1 TO VIEW DATA PRESS 1 TO VIEW SETTINGS Press the up or down arrow key to scroll through the Data List Press the up or down arrow key to scroll through the Functional Parameters settings PRESS TO MARK TRIP START Press the key to mark the start of the trip in the Data Recorder PRESS TO START PRETRIP Press the key to begin pretrip tests PRETRIP FAIL Some of the pretrip tests did not pass PRETRIP FAIL amp NOT COMPLETED Some of the pretrip tests did not pass and the pretrip was not completed PRETRIP PASS All of the pretrip tests were ok PRETRIP STOPPED BY USER Pretrip testing was stopped by the operator PRETRIP TEST 1 15 Each test number and a description of the test will be displayed as itis being performed during a Pretrip Test PROGRAM COMPLETED A DataShare Program PC Card has been inserted into the PC Card slot and the entire program has been loaded into the Micro The PC Card may safely be removed from the slot PROGRAM NOT LOADED REMOVE CARD A DataShare Program PC Card has been inserted into the PC Card slot and there was an error installing the program The PC Card may safely be removed from the slot Reinsert
306. ownload Cable connected to the Download Port Refer to Section 3 7 or with a DataShare PC Download Card Refer to Section 2 18 3 4 6 Data Recorder Power Up The Data Recorder records data the entire time the Start Run Off switch is in the Run position Software versions prior to 01 06 00 continue data recording for 8 hours after the Start Run Off switch is turned to the Off position Software versions starting with 01 06 00 have a configuration added to allow the user to select the additional 8 hours of data to be recorded or to stop recording at the same time the Start Run Off Switch SROS is turned to the Off position 3 7 62 10285 Section 3 System Description 3 5 Display amp KeyPad Description MODE LIGHTS DISPLAY COOL DEFROST ALARM STAR rs Top ON TINUOUS 888 8 cj TPOINT BOX TEMPERATURE START RUN MESSAGE CENTER DOOR e HEAT COOL DEFROST ALARM START STOP SETPOINT BOX TEMPERATURE STATUS OK e CONTINUOUS S A BE Display amp Keypad Module 62 10285 3 8 Section 3 System Description The Keypad amp Display Module provides the user
307. p E N Component Terminal REMSN1 REMSN2 CDP CSP ENCT CDT DTT2 K 22 gt gt oy amp Ni l NID oy BR BY PO PIR gt REMSN1 SP23 REMSN2 SP23 REMSN3 CDP CSP DTT1 SP11 DTT2 SP11 T SAT SP12 RAT SP12 FLS CSP SPK4 REMSN3 DTT1 SAT Unused terminals 1 2 19 24 25 26 27 28 2 amp 32 h e x oi Go 5 lt 227828 eo Sue 41S 1611215155156 Re KS a wiojojo clala N ags Sje N oil To 13 31 62 10285 Component REMS Unused terminals 1 2 4 5 8 9 10 11 12 14 19 20 21 22 23 24 26 27 30 32 33 34 amp 35 10 2 SATCOM UL1 Front Terminal r D 18 31 ME A FHR HC 17 UL2 Rear SLP B Unused terminals 1 2 4 6 7 10 14 16 21 24 25 26 28 30 amp 31 m D C C C 17 www v A O NOI NISIN Ojojoo O1 Po T LP L LP x lt lt lt Component 12 Input from SPK3 to Fuel Heater Relay Coil 12vdc Output from Speed Relay to Speed Solenoid SCS 12vdc Input unswitched Power from Battery
308. p terminals See No damaged or corroded pins wiring schematic 5 45 62 10285 Section 5 Alarm Troubleshooting ALARM CAUSE CORRECTIVE ACTION CHECK FUEL SENSOR CIRCUIT TRIGGER ON The Low Fuel Shutdown is configured as a 0 to 100 sensor and the fuel level reading in the data list is less than 296 for 30 seconds UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when fuel level is sensed above 4 for 30 seconds or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for low fuel level a Check fuel level in the fuel tank Add fuel as needed to the fuel tank Check fuel level sensor a Inspect fuel level sensor amp connector No physical damage to switch pins amp terminals No damaged or corroded pins in plug b Check fuel level sensor operation Place unit in Manual Start Mode see Note 2 DO NOT START UNIT c Check for voltage at harness plug Voltage should be 12 volts at harness plug between pins between pins for BLACK SP24 for BLACK SP24 and RED SPK5 wires ang SED SEIS Wires Start Run Off Switch OFF prior to checking for continuity d Check
309. p bearing end play Check alternator brushes Clean evaporator and condenser coils Check fuel pump FP filter Replace fuel filter s Reset Engine Maintenance Hour Meter in Function Change List c Every 3000 Hour Maintenance X X X X X X X X X Complete a 1500 Hour Maintenance Clean crankcase breather Replace all V belts 8 6 Check starter condition Engine Manual Check and adjust injector nozzles Engine Manual d Every 6000 Hour or 2 Years Maintenance Check and adjust injector nozzles Engine Manual Check engine compression Engine Manual Adjust engine valves Engine Manual Drain and flush cooling system 8 5 1 8 1 62 10285 Section 8 Service 8 2 Priming Fuel System a Mechanical Fuel Pump The mechanical fuel lift pump is mounted on the engine next to the injection pump Refer to Section 8 3 This pump has a manual plunger for bleeding fuel when the fuel tank has been run dry Since the unit employs a closed fuel circuit it is recommended to use the following steps 1 4 5 Turn the top of the manual plunger counter clockwise to unlock it See Figure 7 1 Then slowly up down once per second pump the manual plunger up and down until a positive pressure resistance is felt which will indicate fuel flow about 100 strokes This will bleed the air out of the fuel lines and the fuel filter Turn bleed valve Red counter clockwise until fully opened See Figu
310. priate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for Bad Compressor Discharge Temperature Sensor a Check for alarm 125 Alarm conditions must be corrected and the alarm cleared to continue Check refrigerant charge a Check for undercharged system Level must be above lower sight glass Check airflow through condenser coil a Inspect condenser radiator fins Fins must be straight 90 or more of the coil surface must be undamaged No dead air spaces Condenser Radiator coil must be clean b Check airflow with unit running Even airflow through the entire coil No dead spots Check system pressures a Install Manifold Test Set and check Suction amp Discharge Pressures must have the same and compare compressor discharge amp reading on gauges amp on micro display suction pressures with those shown on the microprocessor controller Check mounting of DTTs a Visually inspect the mounting and Must be mounted tightly to the evap section with the long orientation of DTT1 and DTT2 flat surface of the DTT in contact with the metal surface Perform Pretrip Check a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding Check compressor reed valves amp gaskets a Remove compressor heads amp inspect Must be in good condition condition of all reeds amp gaskets
311. priate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Supply Air Sensor a Inspect Supply Air Sensor amp connector b Check Supply Air Sensor resistance See Note 4 No physical damage to harness No moisture damaged or corroded pins 10 000 Ohms 77 F 25 C See manual for complete table of temperatures and resistance values Check Supply Air Sensor wiring a Inspect harness amp control box connector pins amp terminals See wiring schematic No physical damage to harness No damaged or corroded pins CHECK COOLANT TEMP SENSOR 50 C to 130 C TRIGGER ON Engine Coolant Temp Sensor is not within the maximum range of 58 F to 266 F UNIT CONTROL Abort PreTrip amp display PRETRIP FAILED IN TEST 3 Alarm RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Engine Coolant Sensor a Inspect Engine Coolant Sensor amp connector b Check Engine Coolant resistance See Note 4 Sensor No damage to sensor No moisture damage or corrosion in connector 10 000 O
312. processor controller Check compressor drive coupling a Verify that compressor coupling is Compressor crankshaft must be turning intact and that the compressor crankshaft is turning Perform Pretrip Check a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding Check compressor reed valves amp gaskets a Remove compressor heads amp inspect Must be in good condition condition of all reeds amp gaskets Check compressor pistons and connecting rods a Check compressor pistons Must be in good condition connecting rods 5 15 62 10285 Section 5 Alarm Troubleshooting ALARM CAUSE CORRECTIVE ACTION CHECK REFRIGERATION SYSTEM TRIGGER ON Discharge pressure is not at least 5 psig higher than Suction pressure for more than 10 minutes UNIT CONTROL Alarm Only or Unit Shutdown amp Alarm if configured RESET CONDITION Auto reset when discharge pressure is more than 20 psig above the suction pressure for 5 minutes or alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check syste
313. r Raise system pressure to approximately 2 psig Remove refrigerant using a refrigerant recovery system 95 h Repeat steps through one time 1 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 8 13 Refrigerant Recovery Unit Refrigerant Cylinder Evacuation Manifold Valve Vacuum Pump Vacuum King Valve Receiver Condenser 10 Evaporator 11 Discharge Valve 12 Suction Valve 13 Compressor 4 m 5 Figure 8 14 Vacuum Pump Connection 62 10285 8 20 Section 8 Service 8 13 Adding Refrigerant to System 8 13 1 Full Charge R 22 or R 404A a b Dehydrate unit and leave in deep vacuum Refer to Section 8 12 Place drum of refrigerant on scale and connect charging line from drum to King Valve Purge charging line at outlet valve Note weight of drum and refrigerant Open liquid valve on drum Open King Valve half way and allow the liquid refrigerant to flow into the unit until the correct weight of refrigerant has been add
314. r alarm 85 or P144 Alarm conditions must be corrected and the alarm cleared to continue Check system pressures a Check and compare compressor Suction amp Discharge Pressures must have the same discharge amp suction pressures with reading 5 psig on gauges amp on micro display those shown on the microprocessor controller Check UL2 operation Unit must be running See Note 7 a Energize UL2 coil Suction pressure must raise slightly Discharge pressure must drop slightly b De energize UL2 coil Suction pressure must drop slightly Discharge pressure must raise slightly 5 67 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK SV2 CIRCUIT TRIGGER ON Normal Amps for the SV 2 Circuit is 0 75 to 2 0 Amps The circuit tests outside this range UNIT CONTROL Abort PreTrip amp display PRETRIP FAILED IN TEST 2 Alarm RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for Bad F4 or F6 Fuse alarm a Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue
315. r ambient temperatures may use a higher setting As a battery ages it is normal for it to require longer re charging periods If the running time is gradually increasing in Start Stop operation due to the battery requiring a longer charging period this run time may be shortened by raising the amp setting This may be seen by reviewing downloaded data and looking at the amp reading during prolonged engine Start Stop On Cycles 62 10285 2 6 Section 2 Operation 2 6 Continuous Run Operation CONTINUOUS RUN LIGHT HEAT COOL DEFROST ALARM START STOP CONTINUOUS 988 8 8080 SETPOINT BOX TEMPERATURE CONTINUOUS RUN MODE SELECTED MANUAL ALARM LIST START STOR SELECT A Q 1 Press the START STOP CONTINUOUS key until the CONTINUOUS RUN Light on the controller illuminates 2 Verify that CONTINUOUS RUN MODE SELECTED is displayed on the Message Center and that the CONTINUOUS RUN light is illuminated The unit is now in Continuous Run operation In the continuous run mode the diesel engine will not shut down except for safeties or if the engine stalls Continuous Run operation is normally used for perishable loads Start Stop and Continuous operation may be tied to the setpoint ranges for frozen and perishable loads The START STOP CONTINUOUS key is locked out if START STOP LOCKED appears in the Message Center when the key is pressed and the unit is in Start Stop Mode or
316. r from Configuration List Microprocessor b Enter correct Model Number From Configuration List select correct Model Number Reset Microprocessor a Turn Start Run Off switch off for 30 Microprocessor powers up OK seconds then turn back on b Check for valid Model number in Data Valid number is present List Alarm is cleared c Valid model number can not be Replace Microprocessor entered Clear the fault code a See Note 1 Alarm 233 is cleared b Clear the inactive fault code All faults cleared 62 10285 5 78 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION UNIT SERIAL ERROR TRIGGER ON There is an error in the Unit Serial Number that is stored in the Microprocessor memory UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset only when a valid Unit Serial Number is entered NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Unit Serial Number a Check Unit Serial Number May be up to 11 characters long no spaces or punctuation marks b Enter correct Serial Number Serial Number may be entered using either DataManager or Service Tool computer program Reset Microproce
317. rature is lower than 60 F 15 6 C ice might form before moisture removal is complete Heat lamps or alternate sources of heat may be used to raise system temperature 8 12 3 Procedure for Evacuation and Dehydrating System a b Remove refrigerant using a refrigerant recovery system 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 8 14 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 With the unit service valves closed back seated and the vacuum pump and electronic vacuum gauge valves open start the pump and draw a deep vacuum Shut off the pump and check to see if the vacuum holds This operation is to test the evacuation setup for leaks repair if necessary 8 19 62 10285 Section 8 Service d Midseat the refrigerant system service valves Then open the vacuum pump and electronic vacuum gauge valves if they are not already open Start the vacuum pump Evacuate unit until the electronic vacuum gauge indicates 2000 microns Close the electronic vacuum gauge and vacuum pump valves Shut off the vacuum pump Wait a few minutes to be sure the vacuum holds f Break the vacuum with clean dry refrigerant Use refrigerant that the unit calls fo
318. re 7 1 Continue slowly pumping the manual plunger until the fuel system is completely full about another 150 strokes This will bleed any remaining air out of the fuel filter and out of the injection pump Depress and turn the top of the manual plunger clockwise to lock in place Start engine When engine is running properly turn bleed valve clockwise until fully closed b Electrical Fuel Pump If the unit is equipped with an optional electrical fuel pump it will be mounted on the fuel tank mounting bracket Refer to Section 8 3 It is recommended to use the following steps to bleed out the fuel system 1 2 Open bleed valve located on top of the injection pump See Figure 7 1 Place unit in Manual Start Mode Hold Glow Crank Switch in the Glow position then turn the Start Run Stop Switch to the Run position Continue holding the Glow Crank switch until the Main Display lights up This will turn on the electric fuel pump Allow the electric pump to operate for 2 3 minutes Start engine When engine is running properly turn bleed valve clockwise until fully closed 62 10285 8 2 Section 8 Service 8 3 Servicing Fuel Pump a Mechanical Pump See Figure 8 1 Due to foreign particles in the fuel and wax as a result of using the wrong grade of fuel or untreated fuel in cold weather the fuel filter may become plugged or restricted and the engine will loose capacity The filter must be cleaned ona regular schedule s
319. re sensor is reading lt 50 C or gt 130 C Sensor Check Engine RPM In automatic start mode diesel engine rpm is above 100 RPMs and in manual start ensor mode diesel engine RPMs are above 50 RPMs Not Used CHK Defrost Term Defrost termination temperature sensor is reading 47 C or gt 70 Sensor 2 130 11 C2 PRETRIP ALARMS 141 Pretrip By Pretrip cycle was stopped by user ser Not Used Check Clutch Circuit Clutch circuit is reading lt 2 0 Amps or gt 5 0 Amps Check UL1 Circuit Front Unloader circuit is reading lt 0 75 Amps gt 2 0 Amps Check Speed Sol Circ Speed Solenoid circuit is reading lt 3 0 Amps or gt 9 0 Amps Not Used Check SV1 Circuit SV1 circuit is reading 0 75 Amps 52 5 Amps Check SV3 Circuit SV3 circuit is reading 0 75 Amps or gt 2 5 Amps Check SV4 Circuit SV4 circuit is reading 0 75 Amps or gt 2 0 Amps 152 Check Fuel Solenad Fuel Solenoid circuit is reading lt 0 4 Amps or gt 3 5 Amps n uc uc Check Battery Volts Battery voltage is reading 11 VDC or gt 17VDC Check Battery Battery current is reading lt 1 Amp or 1 Amp when all circuits are off Current 6 9 62 10285 A A BR RR O O1 A Gy D A A Section 6 Message
320. resistance of UL1 coil b Check amp draw of coil Refer to Section 7 8 Use Component Test Mode Section 2 17 3 to test Refer to Section 7 8 for amp values 5 51 62 10285 Section 5 Alarm Troubleshooting ALARM CAUSE CORRECTIVE ACTION CHECK SPEED SOLENOID CIRC TRIGGER ON Normal Amps for the Speed Solenoid Circuit is 3 0 to 9 0 Amps The circuit tests outside this range UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for Bad F2 or F3 Fuse alarm a Check for alarm 71 Alarm conditions must be corrected and the alarm cleared to continue Check speed solenoid amp circuit a Inspect speed solenoid and wiring No physical damage to harness No damaged or corroded pins b Start unit setpoint more than 10 away Controller will call for High Speed operation from setpoint and set for Continuous Run with Setpoint above 11 F See note 7 c Check operation of Speed Relay LED LED 27must be ON d Check voltage to speed solenoid Must be 11 VDC or higher across the 2 wires Check speed solenoid circuit wiri
321. rgized in heating and defrosting 2 Connect a discharge pressure gauge to the compressor discharge service valve and connect a gauge to the liquid line valve King Valve leaving the receiver tank 3 With the trailer temperature at 35 F 1 7 C or lower operate the unit in high speed cool and remove or disconnect the GND wire leading to the SV 1 coil 4 With a separate 12 vdc negative voltage energize SV 1 with the unit in high speed cooling and observe the discharge and receiver pressures If the valve is closing properly compressor discharge pressure will begin to rise and the receiver pressure will remain the same or begin to drop slowly If the valve is not seating properly both discharge and receiver pressure will rise slowly or remain the same Operate the unit until discharge pressure reaches 200 psig 14 kg cm2 and disconnect jumper wire to SV 1 valve Discharge and receiver pressure should be within 5 to 15 psig 0 4 to 1 0 2 of each other 62 10285 8 38 Section 8 Service 8 26 Checking Defrost or Heating Cycle NOTE DTT1 or DTT2 must be 40 F 4 4 C or lower before any checks can be made a Hot Gas Solenoid Valve SV 1 SV 3 amp SV 4 Heating and Defrosting 1 Connect a discharge pressure gauge to the King Valve and another gauge to the compressor discharge service valve Connect a gauge to the compressor suction service valve Start unit with controller set at least 10 F 5 5 C below indi
322. rm 129 Alarm conditions must be corrected and the alarm cleared to continue Check freeze point of coolant a Use Coolant tester to check concentration of anti freeze mixture Must be between 40 to 6096 Ethylene Glycol to water mixture Check airflow through radiator condenser coil a Inspect condenser amp radiator fins Fins must be straight 9096 or more of the coil surface must be undamaged No dead air spaces Condenser Radiator coil must be clean Check condenser amp water pump belts a Check upper fan belt tension amp condition Check lower fan belt tension amp condition c Check water pump belt tension amp condition Refer to Section 8 6 for belt tensions No Glazing no cracking no slipping Refer to Section 8 6 for belt tensions No Glazing no cracking no slipping Refer to Section 8 6 for belt tensions No Glazing no cracking no slipping Check engine cooling system 62 10285 Compare actual engine temperature to the microprocessor reading Test operation of engine coolant thermostat Check water pump operation Temperature must be within 20 F 11 1 C Refer to Section 7 2 for coolant thermostat specifications Must not leak impeller attached tightly to shaft 5 8 Section 5 Alarm Troubleshooting ALARM CAUSE HIGH DISCHARGE PRESSURE TRIGGER ON Compressor discharge pressure is over 465 PSIG UNIT
323. rminals No damaged or corroded pins Inspect harness amp control box physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic e Check resistance of solenoid Refer to Section 7 8 f Check operation of solenoid Plunger must move in when energized Check fuel system a Check fuel system prime No air in fuel system b Check fuel flow Unrestricted fuel flow through system Check engine air intake system a Check air filter indicator Flag must not be visible b Inspect air intake system Hoses amp tubes in good condition No kinks or restrictions Check for correct engine oil a Check for correct oil viscosity weight Refer to Section 7 2 for conditions Must be correct for ambient conditions Check engine exhaust system a Inspect the exhaust system Must be clear and unobstructed Check engine a Check engine compression Refer to Section 7 2 5 17 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION FAILED TO START MANUAL TRIGGER ON The unit was placed in Manual Start Mode and the engine was not manually started within 5 minutes or The user has tried to start the engine 3 times unsuccessfully in the Manual Start Mode UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Reset by changing to Auto Start Mode or Alarm may be manually reset via Keypad or by turning the u
324. rocessor will go to normal operation If the unit is shut down with the PC Cable or jumper still in place the engine will shut down and the Microprocessor will remain powered up All functions available from the Keypad may be viewed or changed using the Advance Service Tool Program and a Personal Computer PC connected to the Serial Port Using the PC will provide additional programming and configuring capabilities that will not be available through the Keypad NOTE The unit also has a3 wire Packard Connector similar to the Serial Port used on other models This connector is used with remote communication options and DOES NOT allow PC access to the Microprocessor or DataLink Data Recorder The Data Recorder may also be configured and downloaded through the Serial Port using the Data Manager Program 3 13 62 10285 Section 3 System Description 3 8 Door Switches amp Remote Switches The unit has provisions to install a Trailer Door Switch DS and up to 2 remote switches REMS1 amp 2 and connect them to the Microprocessor so that when the door is opened or a remote switch is turned on off either an alarm is displayed or the unit may be programmed to shut down Either event may also be recorded by the DataLink Data Recorder Because different door switches are available there are provisions within the Configuration List to configure the Microprocessor to correctly read the type of switch that is installed The Microprocess
325. ropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Cool light a Inspect Cool light amp socket No damage to solenoid No damaged or corroded pins b Check resistance of light bulb Refer to Section 7 8 Check Cool light wiring a Inspect harness amp control box See Notes 2 amp 6 connector pins amp terminals See No physical damage to harness wiring schematic No damaged or corroded pins Check Cool light current draw a Use Component Test Mode Refer to Refer to Section 7 8 for normal current values Section 2 17 3 to test actual current draw of the circuit 5 41 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK REMOTE AUTO LIGHT TRIGGER ON Remote Auto light Driver s Light Bar circuit is shorted The Auto Light output from the Micro is negative so the circuit will not be shorted to ground but is shorted either within the Auto Light itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when Auto light current amp draw is normal or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occ
326. rrection has been made the active alarm should clear itself see reset condition above Operate the alarm occurs Continue with the steps below as necessary unit through the appropriate modes to see if any active 1 Check glow plug circuit a Inspect glow plug relay amp socket b Check operation of Glow Plug Relay c Check Non Running Amps d Check Glow Plug circuit amperage e Check voltage to glow plugs No signs of discoloration from overheating No corrosion Run Stop switch in Run Manual Start Operation See Note 2 Glow Crank switch in Glow position LED 30 must be ON View Current Draw in Data List Refer to Section 7 8 Current Draw Non Running Amps Glow Plug Amps Must be 11 VDC or higher Check glow plug circuit wiring box See a Inspect harness amp control connector pins amp terminals wiring schematic No physical damage to harness No damaged or corroded pins Check Glow Plugs a Check amp draw of each glow plug 5 25 Refer to Section 7 8 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION ENGINE STALLED TRIGGER ON The engine is running RPM sensor is good and engine speed is less than 10 RPM or The engine is running RPM sensor alarm is ON and the Oil Pressure switch contacts are open UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Restart after 15 minutes or Alarm may be manually reset v
327. rride timer is activated which will initiate another defrost cycle in 1 5 hours regardless of the standard Defrost Timer setting 62 10285 4 16 Section 4 Engine and Temperature Control Defrost Timer Operation There are two timers which the Main Compartment Defrost Controller must maintain as described below 1 Defrost Cycle Timer This is the amount of time that the system is actually defrosting This timer starts when a Defrost Cycle is initiated It is used to terminate Defrost after a maximum time of 45 minutes a The purpose for maintaining a Defrost Cycle Timer is to monitor the total time of the Defrost cycle If the Defrost cycle does not complete within 45 minutes the following will occur The Defrost cycle will be terminated Defrost Override timer is activated which will initiate another defrost cycle in 1 5 hours regardless of the standard Defrost Timer setting A54 DEFROST NOT COMPLETE Alarm is activated 2 Defrost Interval Timer This is the amount of time between defrost cycles However this timer does not accumulate time during the following periods When the unit is running in the Defrost Cycle e During engine Off cycles or compressor Off cycles Defrost Control Operation The Defrost Control will control the following Solenoid valves SV1 SV4 e Speed Control Solenoid SCS e Front and Rear Unloaders UL1 and UL2 Clutch If the Ambient Air temperature is below 80 F 26 7 C then t
328. running in Heat Cycle See Note 7 a Set unit to run in high speed cool b Energize SV4 coil c De energize SV4 coil After 60 seconds note suction and discharge pressures Hot gas hissing sound will begin immediately Suction pressure must rise slightly Discharge pressure must drop slightly Hot gas hissing sound will stop immediately Suction pressure must drop slightly Discharge pressure must rise slightly Manually test refrigeration system a Run Quick Check Must pass all tests Correct any problems found before proceeding 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK SV1 VALVE TRIGGER ON Discharge pressure did not increase as expected with SV1 energized closed UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for SV1 Alarm a Check for alarms 80 P148 Alarm conditions must be corrected and the alarm cleared to continue Check system pressures a Check and compare compressor Suction amp Discharge Pressures must have the same dis
329. s Repeat steps a and b until an average air gap of 0 020 to 0 025 in is obtained Install a new key 7 in shaft Apply Loctite 609 to shaft and pulley hub bore Slide armature pulley onto gearbox shaft Install washer 8 and lock nut 9 NOTE two types of locking nuts may be used Standard nylon locknut uses flat washer and requires 65 70 ft Ibs torque e Upset thread type with integral washer DOES NOT use a separate washer and requires 55 60 ft Ibs torque DO NOT over tighten this type 8 8 Replacing Condenser Evaporator Fan Shaft or Bearing Ultra Ultra XL amp Extra 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 OFF position Also disconnect the negative battery cable a To Remove the Fan Shaft 1 eec c uns 9 Disconnect negative battery cable Remove 4 screws securing condenser fan item 1 Figure 8 12 to adapter Remove V Belt Refer to Section 8 6 4 Remove 3 screws securing adapter item 2 Remove 3 screws securing sheave item 3 Remove tapered bushing item 5 and flange item 7 on early units Remove evaporator panels Remove two screws securing split tapered bushing to blower wheel items 12 and 13 Figure 8 12 Place the two screws in the threaded holes of the taper bushing and use screws as jacking bolts to remove bushing from blower w
330. s 77 F 25 C See manual for complete Temperature Sensor 2 resistance table of temperatures and resistance values See Note 4 Check Defrost Termination Temperature Sensor 2 wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic 5 9 MAINTENANCE ALARMS ENGINE MAINTENANCE DUE TRIGGER ON The Engine Maintenance Hour Meter time has expired UNIT CONTROL Alarm Only Alarm Light will NOT be turned on RESET CONDITION Alarm may be manually reset via Keypad 1 Check unit maintenance records a Schedule unit into service facility for Must be done soon maintenance Perform maintenance a Perform appropriate engine amp unit Follow instructions on proper maintenance form maintenance Reset Engine Maintenance Hour Meter a Check that the Engine Maintenance Reset Interval in Configuration List as required Hour Meter interval is set for your requirements Hour Meter is reset in the Functional Parameter list Follow maintenance interval recommendations in Section 8 1 Reset Engine Maintenance Hour Meter for the next service interval 62 10285 5 74 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION GENERAL MAINTENANCE DUE TRIGGER ON The General Maintenance Hour Meter time has expired UNIT CONTROL Alarm Only Alarm Light will NOT
331. s Shut down may be disarmed in the Functional Parameter List NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Determine what Remote Switch 2 is controlled by a Remote Switch 2 may be connected to a Trailer Door or some other devise and used to remotely control the unit Find and locate Remote Switch 2 Check to see if trailer side or rear door is is set to trigger the alarm open or if the device that Remote Switch 2 is connected to a Inspect trailer doors b Check devise at Remote Switch 2 Trailer door s must be closed Must have switch in position that allows unit to operate Check Wiring a Visually inspect wiring to switch b Visually inspect condition of switch Wiring must be connected Must not be damaged Check Remote Switch 2 a Check switch operation Contacts must Open amp Close as switch is opened and closed Check Configurations a Verify that Configuration is set for the type of switch being used ie when Door is open switch contacts are closed etc Must be correct for type of Remote Switch being used DATALOGGER NOT RECORDING UNIT CONTROL Alarm Only RESET CONDITION Alarm may be manually T
332. s how far away from Set Point the temperature must move before the timer is started 4 may be used for very critical temperature products 7 may be used for less critical products The alarm may be turned off by selecting the OFF setting AIR FLOW NORMAL HIGH The Normal selection allows the unitto cycle from High Speed to Low Speed depending on how close the box temperature is to Set Point Some products generate a considerable amount of heat heat of respiration during transportation This frequently occurs with produce The High selection can be used for these loads since continuous high air flow may be required to keep the entire load at a constanttemperature The engine will remain in High Speed when High is selected NOTE HIGH AIR FLOW does not work with setpoints below 10 4 UNLOADER PRESSURE CONTROL The recommended setting for this is Std This setting should not be changed unless discussed with a Carrier Transicold Factory Service Engineer or Field Service Engineer SLEEP MODE NO is the normal operating selection YES selects Sleep Mode In this mode the unit will operate only as needed to keep the engine warm and the battery charged There is NO TEMPERATURE CONTROL in Sleep Mode OVERRIDE DOOR SHUTDOWN NO allows the door switch to shut the unit down whenever the trailer door is opened and the door switch is configured for shutdown YES allows you to over ride the trailer door sh
333. s through the intake stroke the piston draws clean fresh air down into the cylinder for the compression and power strokes As the engine goes through its exhaust stroke the upward movement of the piston forces the hot exhaust gases out of the cylinders through the exhaust valves and the exhaust manifold If the air filter is allowed to become dirty the operation of the engine would be impaired 7 5 Compressor Data 988 058 7 11 62 10285 Section 7 Unit Description 7 6 Refrigeration System Data Defrost Air Switch DAS Initiates Defrost 1 40 07 inch 85 1 8 WG Expansion Valve Superheat Setting 8 to 10 F 4 4 to 5 6 C Setting at O F 17 8 C box temperature Expansion Valve MOP Ultra Ultra XL amp Extra R22 55 MOP R404A 45 MOP Ultima R404A 55 Fusible Plug Setting 208 to 220 F 97 8 to 104 4 C High Pressure Switch HPS Cutout 465 10 psig 32 7 0 7 kg cm2 Cut in 350 10 psig 24 6 0 7 kg cm2 Unit Weights Approximate Ultima 53 1665 Ib 755 kg Phoenix Ultra 1610 Ib 730 kg Extra 1610 Ib 730 kg 62 10285 7 12 Section 7 Unit Description 7 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 7 2 The Compressor Discharge Tempera
334. s us ot peek x hie te beati eot e a adt 5 3 Shutdown Alarms 5 7 Start Up Engine Alarms 5 16 Warning Status Alarms 5 27 Electrical Alanis uuo oo ata LI 5 35 Sensor eos eek RN S RARE ow EE 5 43 Pretrip Alarms e Ca stead 5 50 Maintenance 1 8 5 74 Microprocessor Alarms 5 78 Section 5 Alarm Troubleshooting 5 1 Introduction To Alarm Troubleshooting Guide The Alarm Troubleshooting Guide should be used whenever an alarm occurs Alarms will appear in the Message Center and will begin with the alarm number Alarms are listed in the Troubleshooting Guide by alarm number When an alarm occurs look through both alarm lists see Note 1 and make note of all alarms Before beginning to actually troubleshoot a unit visually inspect the unit and in particular the area of the unit that is causing problem In many cases the cause of the problem will be obvious once a visual inspection is performed For those cases where the cause of the problem is not so obvious this troubleshooting guide will be of assistance Usually you should begin troubleshooting with the first alarm that appears in the active alarm list Other alarms in the list may have contributed to the occurrence of the first alarm The first alarm t
335. s value in 0 1 F or C increments 2 33 62 10285 Section 2 Operation CONFIGURATION DESCRIPTION SELECTIONS DESCRIPTION S S PARAMETERS TOGETHER TOGETHER When the Minimum Run Time Minimum Off Time Maximum Off Time and Override Temperatures SEPARATE are set in the Functional Parameter List the same values will be used for both Frozen and Perishable setpoints SEPARATE When the Minimum Run Time Minimum Off Time Maximum Off Time and Override Temperatures are set in the Functional Parameter List different values may be entered for Perishable and Frozen setpoints REMOTE TEMP SENSOR 1 3 ON OFF ON A remote sensor has been added to the unit and Optional connected into the hire harness at Remote Temp Sensor 1 3 plug This enables Remote Temp Sensor 1 3 to be read through the Data List OFF There is no Remote Sensor 1 3 in this unit DOOR SWITCH NOT SWITCH NOT INSTALLED There is no door switch in Optional INSTALLED this trailer OPEN SWITCH DOOR OPEN SWITCH OPEN A Door Switch has been OPEN installed on one of the trailer doors The switch contacts will be OPEN whenever the door is OPEN OPEN SWITCH CLOSED DOOR OPEN SWITCH CLOSED A Door Switch has been installed on one of the trailer doors The switch contacts will be CLOSED whenever the door is OPEN DOOR SWITCH ALARM ONLY ALARM ONLY When Door Switch indicates that the Optional door is open a warning alarm will be displayed in the U
336. splayed with either a decimal or comma See Configurations Section 2 17 1 Indicator LEDs The display has six LED s across the top to indicate operation status These indicators are Cool Indicator Green Turned on when the unit is in Cool Mode Heat Indicator Amber Turned on when the unit is in Heat Mode Defrost Indicator Amber Turned on when the unit is in Defrost Mode e Start Stop Indicator Green Turned on when the Start Stop Mode has been selected Continuous Indicator Green Turned on when the Continuous Mode has been selected Alarm Indicator Red Off or Flashes at a rate of 0 5 seconds NOTE When the unit is in Null mode the Mode indicators Cool Heat and Defrost are all off NOTE There is an opening between the Alarm and Start Stop LEDs that is not used at this time Message Center The Message Center is used to show messages Details of the messages are described in Section 6 1 MESSAGE CENTER 3 9 62 10285 Switch Section 3 System Description Descriptions START RUN START RUN OFF Switch SROS The Start Run Off switch is a 12VDC input to the Microprocessor When placed in the RUN position this switch activates the Control Module To stop the unit move the switch to the OFF position The GLOW CRANK switch is located on the back side of the control box near the bottom on Ultima units and on the left side of the control box behind the front unit door on
337. ssor a Turn Start Run Off switch off for 30 Microprocessor powers up OK seconds then turn back on b Check for valid Model number in Data Valid number is present List Alarm is cleared c Valid Unit Serial Number can not be Replace Microprocessor entered See Note 1 a Clear the inactive fault code Alarm 234 is cleared CONTROL SERIAL ERROR TRIGGER ON There is an error in the Microprocessor Serial Number that is stored in the Microprocessor UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset only when valid Microprocessor Serial Number is read NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Microprocessor Serial Number a Check Microprocessor Serial Number Will be a 10 character number this can not be entered or changed Reset Microprocessor a Turn Start Run Off switch off for 30 Microprocessor powers up OK seconds then turn back on Alarm is reset b Alarm 235 remains active Replace microprocessor See Note 1 a Clear the inactive fault code Alarm 235 is cleared 5 79 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION TRAILER ID ERROR TRIGGE
338. suction service valve Run unit until stabilized Set controller 10 F 5 5 C below box temperature From the temperature pressure chart determine the saturation temperature corresponding to the evaporator outlet pressure Note the temperature of the suction gas at the expansion valve bulb Subtract the saturation temperature determined in Step 6 from the average temperature measured in Step 7 The difference is the superheat of the suction gas 62 10285 8 30 Section 8 Service 8 20 Checking and Replacing High Pressure Cutout Switch HPS 8 20 1 Replacing High Pressure Switch a b Pump down the unit Refer to Section 8 10 Frontseat both suction and discharge service valves to isolate compressor Slowly release compressor pressure through the service valve gauge ports Disconnect wiring from defective switch and remove old switch The HPS is located at the side of the center compressor cylinder head See Figure 8 18 Install new cutout switch after verifying switch settings Refer to Section 8 20 2 Evacuate and dehydrate the compressor Refer to Section 8 14 p through 8 14 w 8 20 2 Checking High Pressure Switch WARNING Do not use a nitrogen cylinder without a pressure regulator Cylinder pressure is approximately 2350 psi 165 kg cm2 Do not use oxygen in or near a refrigerant system as an explosion may occur See Figure 8 22 1 Cylinder Valve and Gauge Pressure Regulator Nitrog
339. sulated Serial Downloader Port Jumper P N 22 50180 01 One big advantage of using PC Mode is that it allows the technician or service writer to read various data from the Microprocessor without starting the 8 hour data recorder timer and without having to start the units Some of the things that you may want to use PC Mode for are Changing setpoint for the next load Changing any of the functional parameters for the next load Reading Engine hour meters Reading Maintenance hour meters Resetting Maintenance hour meters Viewing the Active and Inactive alarm lists Entering a Trip Start Keeping the Microprocessor powered up after turning the SROS to the OFF position Demonstrating the operation of the Microprocessor 62 10285 2 28 Section 2 Operation 2 17 Microprocessor Configuration and Technician Test Modes Remove Jumper Mode 1 Turn the Start Run Off switch to the Stop position 2 With the unit off locate the serial downloader port Refer to Section 3 7 Remove the protective plug to gain access to the wire terminals Plug in Serial Jumper P N 22 50180 00 or connect an insulated jumper wire between plug terminals A and B Insulated Jumper Serial Downloader Port Jumper P N 22 50180 00 Caution Do Not Allow Jumper Wire To Touch Any Ground 3 Turn the Start Run Off switch to the Run position The ALARM LED will come on the setpoint will appear but the Box Temper
340. sure Reading Must read valid data Calibrate Discharge Pressure Sensor a Calibrate Discharge Pressure Sensor Calibration successful b Discharge Pressure Sensor can not Replace Microprocessor be successfully calibrated See Note 1 a Clear the inactive fault code Alarm 242 is cleared SUCT EVAP CALIBRATE ERROR TRIGGER ON There is an error in the Suction Evaporator Pressure Sensor Calibration value stored in the Microprocessor memory UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset when the Suction Evaporator Pressure Sensor is calibrated successfully or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Suction Evaporator Pressure Reading a Check Suction Evaporator Pressure Must read valid data Reading Calibrate Suction Evaporator Pressure Sensor a Calibrate Suction Evaporator Calibration successful Pressure Sensor b Suction Evaporator Pressure Sensor Replace Microprocessor can not be successfully calibrated See Note 1 a Clear the inactive fault code Alarm 243 is cleared
341. t message This will appear when you within the Diagnostic Mode Menu and have not selected a Mode and after a Mode has timed out by the timer Diagnostic Mode allows the Technician to place the unit into one of the primary refrigeration system operating modes and lock that mode in for 15 minutes with no regard to set point or controlling box temperature All unit safety circuits are operational during Diagnostic Mode and will shut the unit down if a fault should occur Once a Mode is selected UNIT STARTING will appear in the Message Center This will remain in the Message Center until 15 seconds after the engine starts Then the Diagnostic Mode and time remaining will be displayed for example COOL REMAINING 15 MINS Once the unit is running the minute timer will decrement every minute until the time runs out The timer may be reset to 15 minutes once during the test by pressing the key once During the final minute the buzzer will be on to alert the Technician that the test is about to end Once the test ends the unit will shut off To stop the test press and hold the key for 6 seconds The unit will go to low speed cool default mode DIAGNOSTIC MODE 1 SCROLL will appear in the Message Center and allow you to select another mode When a test is aborted the unit will continue to run and allow you to start another test The only keys that operate during Diagnostic Test Mode are the Alarm Select 1 and keys
342. t valve plates unloaders reed valves amp gaskets Must be in good condition No broken or missing parts 5 70 Section 5 Alarm Troubleshooting ALARM CAUSE CORRECTIVE ACTION LOW DISCHARGE PRESSURE TRIGGER ON In the Heat PreTrip mode the Compressor Discharge Pressure did not rise to normal UNIT CONTROL Abort PreTrip amp display PRETRIP FAILED IN TEST 4 Alarm RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for Ambient Sensor Alarm a Check for alarm s 121 and P158 Alarm conditions must be corrected and the alarm cleared to continue b Check Ambient Sensor calibration Must be within 10 F of actual temperature Manually test refrigeration system See note 7 a Run Quick Check Must pass all tests Correct any problems found before proceeding b Check and compare compressor Suction Pressure must have the same reading on gauge amp suction pressure with pressure shown on micro display on the microprocessor controller CHECK FRONT CYLINDERS TRIGGER ON A problem has been detected inside the front cyl
343. t will display 158 F 70 C If the circuit is open the data list will show the temperature as 52 6 F 47 C UNIT CONTROL Alarm only RESET CONDITION Auto Reset when Remote Temperature Sensor 1 is in range or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Remote Temperature Sensor 1 a Verify that Remote Temperature Remote Temperature Sensor 1 is installed Sensor 1 has been installed and is Wires are connected to 10 pin connector at cavities E amp F correctly wired to the unit If sensor is not present change micro configuration to OFF Check Remote Temperature Sensor 1 a Inspect Remote Temperature Sensor No damage to sensor 1 amp connector No damage moisture or corrosion in connector b Check Remote Temperature Sensor 1 Refer to Section 8 30 for complete resistance chart resistance See Note 4 10 000 Ohms 77 F 25 Check Remote Temperature Sensor 1 wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic
344. te that the setpoint reading being displayed is a non entered value The Message Center will show 14 TO SCROLL THEN TO SAVE The setpoint display will flash for 5 seconds or until the ENTER key is pressed 2 Press the key ENTER to save the new setpoint Setpoints of 22 to 89 6 F 30 C to 32 C may be entered The Microprocessor always retains the last entered setpoint in memory The setpoint may be changed up or down one tenth of a degree in 0 1 F or 0 1 C increments providing Decimal Displayed is configured in the configuration list See the configuration table Section 2 17 NOTE The Microprocessor Configurations allow a Minimum and Maximum Setpoint to be entered so that only Setpoints within that range may be selected You not change the setpoint when viewing the Alarm List Data List or Functional Parameters or when unit is in Pretrip or is in Sleep Mode Setpoint may be changed any other time the SROS is in the Run position or with the unit in PC Mode Pressing the key ENTER will cause the new displayed setpoint value to become active and SET POINT CHANGED is displayed If the display is flashing and the new value is not entered after 5 seconds of no keyboard activity the entire display and Driver s Light Bar will flash for 15 seconds with SET POINT NOT CHANGED displayed and then revert back to the active setpoint All other keys are active at this time and if pushed while the d
345. ted Configuration will flash showing the current value Press the or ARROW Key to scroll through the list of available selections for this Configuration 5 Once anew value is showing the Message Center press the Key to save the selection The Message Center will stop flashing The new value is now in memory 6 Press the ARROW Key to continue to scroll through the Configuration list CONFIGURATION DESCRIPTION SELECTIONS DESCRIPTION UNIT MODEL NUMBER NDX93MNOAA The correct model number must be selected for proper NDA93ANOAA operation and control NDA94ANOAA NDA93MNOAA NDA94MNOAA NDA93ENOCA NDA93NNOCA NDA94ENOCA NDA94NNOCA NDX93GNODB NDP33LN6FBR3 TRAILER ID The trailer ID may be entered This may be up to 10 characters long Numbers Letters and a space are available by scrolling through the available list GLOW TIME LONG SHORT LONG Longer glow times may be used for units in colder ambient conditions SHORT Shorter glow times are used as the factory setting for all engines NOTE See Section 4 1 for glow time table OUT OF RANGE SHUTDOWN YES NO YES When the box temperature has been out of range for 45 minutes the alarm light will come on and the unit will shut down NO When the box temperature has been out of range for 15 minutes the alarm light will come on and the unit will continue to run PARAMETERS LOCKOUT YES NO YES Functional Parameters in the function list are locked in place
346. tems when caught in the return air stream and pulled up against the evaporator coil or the return air grill can also cause the Defrost Air Switch contacts to close When looking at a unit for a Defrost Air Switch problem be sure to also inspect the condition and cleanliness of the evaporator coil and the return air area 62 10285 2 12 Section 2 Operation 2 9 Pretrip HEAT COOL DEFROST ALARM START STOP CONTINUOUS 998 8 BOB SETPOINT BOX TEMPERATURE TEST 1 ALARM LIST Sparsron SELECT 1 Press the SELECT key until PRETRIP is illuminated 2 Press the key to start PRETRIP 3 Verify that during TEST 1 the complete display is turned on that the buzzer comes on and that all lights on the Drivers Light Bar come on 4 The remainder of Pretrip will take 7 to 15 minutes and will run itself automatically The PRETRIP mode is for checking unit operation and evaluating operation of all modes and indicating a failure when detected TIP A Pretrip can be started with any box temperature The Message Center displays the current test and the complete of the test When the Pretrip tests are complete the Message Center will display PASS If PRETRIP FAIL IN TEST X or PRETRIP FAILED amp COMPLETE is displayed the ALARM light will flash Press the ALARM LIST key to review the alarms set by the Pretrip tests PRETRIP PASS or PR
347. terval to OFF Press to enter 1 2 3 Now select the desired new interval 4 Press to enter 3 Turn the Start Run Off switch off then back to Run Check the Data List The correct number of hours should be showing as HOURS TO ENGINE MAINT 2 21 Recommended Transport Temperatures Below are some general recommendations on product transport temperatures and operating modes for the unit These are included for reference only and should not be considered preemptive of the set point required by the shipper or receiver More detailed information can be obtained from your Carrier Transicold dealer Set Point Range Product Operating Bananas 55 to 60 13 to 16 Continuous Fresh fruits and vegetables 33 to 38 Oto3 Continuous Fresh meats and seafood 28 to 32 2100 Auto Start Stop or Continuous Dairy Products 33 to 38 Oto3 Auto Start Stop or Continuous Ice 15 to 20 10 to 7 Auto Start Stop2 Frozen fruits and vegetables 0 18 Auto Start Stop Frozen meats and seafood 10 to 0 23to 18 Auto Start Stop2 Ice Cream 20 29 Auto Start Stop2 During delivery cycles that include frequent stops and door openings it is recommended that the unit always be operated in the continuous run mode to help insure product quality If it is possible the unit should be turned off during the time the trailer doors are open to help conserve the product temperature Varia
348. that are user accessible There are three 7 5 amp fuses and one 10 amp fuse The PC card slot is also shown above This card slot is used with all Carrier Transicold DataShare PC Cards The controller automatically detects the presence and type of DataShare PC Card inserted and responds accordingly The different types of DataShare PC Cards are Download Card for downloading unit data e Options PC Card for installing optional software programs e Configuration PC Card for setting the Microprocessor Functions Configurations and Data Recorder configurations and e Program PC Card for upgrading the Microprocessor software There are three LEDs associated with the function of the PC card slot These are The green Micro Status LED which will blink steadily every 1 second indicating that the Microprocessor is operating The green PC Card Status LED which comes on when there is a PC card inserted in the slot This LED will blink when data is being transferred to or from the PC Card and will be on steady when the operation is complete and the PC Card may be removed e The red PC Card Fault LED comes on if there is a problem transferring data from the PC card that has been plugged into the PC card slot The red LED will stay on until the PC card is removed 3 3 62 10285 Section 3 System Description 3 4 DataLink Data Recording The Advance Microprocessor contains a built in DataLink Data Recorder with 512K of memory The
349. that at least one of the DTTs is at a temperature at or below 40 F 4 4 C If the DTTs are both above this temperature the unit will not go into a defrost cycle the timer will reset to zero and will begin counting toward the next interval The Defrost Timer increments counts time only when the engine is running Units running in Start Stop will not increment the timer during off cycles For this reason the defrost timer can not attempt to initiate a defrost cycle during an off cycle However it is possible that the unit will go into a defrost cycle very shortly after restarting if the timer expires then When a Defrost Cycle is initiated by the defrost timer the timer is reset to zero and will not begin counting until the defrost cycle has terminated When the SROS is turned off the defrost timer will be reset to zero b Defrost Maximum Time Timer The Defrost Maximum Time Timer monitors the length of the defrost cycle Once the unit has been in a defrost cycle for 45 minutes this timer will terminate the defrost cycle and allow the unit to heat or cool as needed to maintain temperature control When the Defrost Maximum Time Timer is used to terminate the defrost cycle Alarm 54 Defrost Not Complete will be active and the Defrost Initiation Timer will be temporarily reset to 1 5 hours This temporary setting will not be shown in the Functional Parameters list Only the saved defrost interval will be displayed there c
350. 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 After making necessary repairs leak test and evacuate the low side of the refrigeration system Refer to Section 8 12 8 Open backseat King valve and midseat suction service valve 9 Start the unit in cooling and check for noncondensibles 10 Check the refrigerant charge Refer to Section 8 13 f 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 8 12 b Removing the Refrigerant Charge Connect a refrigerant recovery system to the unit to remove refrigerant charge Refer to instructions provided by the manufacture of the refrigerant recovery system 62 10285 8 18 Section 8 Service 8 11 Refrigerant Leak Checking a b If system was opened and repairs completed leak check the unit The recommended procedure for finding leaks in a system is with an electronic leak detector or halide torch Testing joints with soapsuds is satisfactory only for locating large leaks or pinpointing small leaks once a general area has been located Ifsystem is without refrigerant charge system with refrigerant to build up pressure between 30 to 50 psig 2 1 to 3 5 kg cm2 Remove refr
351. ting is 4 minutes 62 10285 4 2 Section 4 Engine and Temperature Control Off Cycle Temperature After the Minimum Run Time expires the unit will shut down when the box temperature is within 0 5 F 0 3 C of setpoint for setpoints in the Perishable range or is less than 0 5 F 0 3 C above setpoint for setpoints in the Frozen range Minimum Off Time The Minimum Off Time allows the unit to remain off for extended periods of time maximizing fuel economy The Minimum Off Time is selected in the Microprocessor Functional Parameter List Settings may be for 10 minutes to 90 minutes in 1 minute intervals The factory setting is 20 minutes Restart Temperature After the Minimum Off Time the unit will restart when the box temperature goes beyond 3 6 F 2 0 C of setpoint for the Perishable range or above 3 6 F 2 0 C of setpoint for the Frozen range Off Time Override Temperature During the Minimum Off Time the Microprocessor continually monitors the Box Temperature If the temperature should go beyond the Off Time Override Temperature the unit will restart regardless of how much Off Time remains The Off Time Override Temperature is selected in the Microprocessor Functional Parameter List This can be set for 3 5 F to 18 F 2 C to 10 C in 5 increments Maximum Off Time Insome ambient conditions there are times when the unit may be off for very long periods of time To insure that the product temperature is al
352. tion Pressure 14 7 psig Discharge Pressure 0 psig Engine RPM 0 2 3 3 4 2 5 2 7 2 9 1 3 7 4 1 8 21 3 Replacing Compressor Discharge Pressure Transducer a Pump down the compressor Refer to Section 8 10 a Frontseat both suction and discharge service valves to isolate compressor b Equalize compressor discharge and suction pressures through the service valve gauge set Slowly purge off the high side pressure to 0 psig c Disconnect wiring from defective transducer and remove The CDP is located at the side of the center compressor cylinder head See Figure 8 18 WARNING The Compressor Discharge Pressure Transducer does not have a Schrader valve in the connecting fitting Any discharge pressure remaining in the compressor will be released when removing the CDP d Calibrate new discharge transducer before installing in compressor Refer to Section 8 21 1 e Install new discharge transducer being careful to obtain the correct transducer for your unit R 22 CDPs have a white dot on the side R 404A CDPs have a red dot on the side See Figure 8 16 f Evacuate and dehydrate the compressor Refer to Section 8 14 p through 8 14 w 8 33 62 10285 Section 8 Service 8 22 Compressor Suction Pressure Transducer CSP 8 22 1 Calibrating Compressor Suction Pressure Transducer The Compressor Suction Pressure Transducer CSP has a range of 14 7 psig 29 92 mercury to 100 psig Because
353. tions may be necessary for very high or very low ambient temperatures 2 43 62 10285 Section 3 System Description 3 1 Component Description and 3 1 3 2 33 Control Module Description 3 3 3 4 DataLink Data Recording 3 4 3 4 1 Microprocessor 3 4 3452 Data Recording 1554452 95 iad 3 4 3 4 3 Sensor amp Event 1 3 5 3 4 4 Optional Sensors amp 3 6 3 4 5 Data 3 7 3 4 6 Data Recorder 3 7 3 5 Display amp KeyPad Description 3 8 3 0 Driver sight Bar oco zd vn dae DOR ee ona 3 12 3 7 Serial Port SLP PC Communication Mode 3 13 38 Door Switches amp Remote Switches 3 14 3 9 Sleep Mode euo edere o hatte Fact e xata er E uox 3 14 3 10 Of Range Alarm 3 15 Section 3 System Description 3 1 Component Description and Location The Advance Microprocessor controller consists of two modules the Control Module and Display amp Keypad Module In Ultima units the Control Module is housed in the control box on the lower roadside right corner of the unit just inside the lower roadside door In Ultra u
354. to Micro memory the new setpoint will be used SETPOINT NOT CHANGED SLEEP MODE OFF ON TO WAKE The new setpoint has NOT been entered NOT saved into Micro memory the old setpoint will be used The unit has been placed in Sleep Mode Turn the Start Run Off Switch OFF then back ON to wake the Micro up SLEEP MODE YES or NO This Functional Parameter allows the user to place the unit in the Sleep Mode SOFTWARE REVISION XXXXXX Micro operating program software revision number STANDBY HOURS OHR to 99999HR START MODE AUTO or MANUAL The number of hours the Standby Motor has actually operated This Data Message tells the user if the unit is in Auto Start or Manual Start Mode START STOP LOCKED START STOP MODE SELECTED This Set Point has been locked into the Start Stop mode Continuous Run can not be selected The current Set Point is within a range that has been locked into the Start Stop Mode Continuous Run can not be selected STATUS OK The unit is working just great SUCTION PRESSURE 10 0 PSIG to 100 0 PSIG Compressor suction pressure SUPPLY AIR TEMP 52 6 F to 158 0 F 47 0 to 70 0 C Supply air temperature SWITCH ON HOURS OHR to 99999HR Hours the unit Start Run Off switch has been in the ON position TEMP CONTROL RETURN AIR or SUPPLY AIR This Functional Parameter allows the user to select which air sensor is used for the control temperature
355. ture sensor CDT will shut the unit down if center compressor head discharge temperature reaches 310 F 154 C for 3 minutes or 350 F 177 C If ambient temperature sensor AAT is at 120 F 49 C or higher the CDT limits are increased to 340 F 171 C for 3 minutes Table 7 2 Safety Devices Unit Shutdown Safety Devices Unsafe Conditions Safety Device Device Setting Low engine lubricating oil pressure Oil pressure safety switch Opens below 12 psig ENOPS microprocessor reset 2 1 1 2 kg cm High engine cooling water temperature Engine coolant temp ENCT Refer to section 7 2 microprocessor reset Excessive current draw by microprocessor Fuse F1 Opens at 7 1 2 amps Excessive current draw by speed control Fuse F2 Opens at 10 amps Excessive current draw by fuel pump Fuse Opens at 7 1 2 amps Excessive current draw by evap fan clutch Fuse F4 Opens at 7 1 2 amps Excessive current draw by glow plug circuit Fuse F5 Opens at 80 amps control circuit or starter solenoid SS Excessive current draw by buzzer light bar Fuse F6 Opens at 15 amps and front or rear unloader Excessive current draw by glow amp crank Fuse F7 Opens at 5 amps Excessive current draw by fuel heater Fuse F8 Opens at 20 amps Excessive compressor discharge pressure High pressure cutout switch Refer to section 7 6 HPS automatic reset Excessive compressor discharge Compressor discharge See Trigger On criteria f
356. ual Start Mode See Note 2 Must have 11 or more VDC with switch ON Must have less than 3 VDC with unit OFF No physical damage to harness No damaged or corroded pins Must have 13 or more VDC when tested against battery post Must have 13 or move VDC when tested against battery post Check for add on equipment drawing too much current a Check amperage of added on components amp accessories All add on components amp accessories must draw less than 20 Amps Perform Pretrip Check a Run Pretrip amp check for alarms 5 27 Any active alarms must be corrected and cleared before proceeding 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION BOX TEMP OUT OF RANGE TRIGGER ON UNIT CONTROL Alarm Only The box temperature has been in range within 2 7 F of setpoint for perishable and within 2 7 for frozen at least once since the unit was started Sleep Mode Diagnostic and Component Test Modes excluded and is now further away from setpoint than the limit set in the functional parameters 4 5 OR 7 F for this unit for more than 15 minutes Shut Down amp Alarm The box temperature has been in range within 2 7 F of setpoint for perishable and within 2 7 for frozen at least once since the unit was started Sleep Mode Diagnostic and Component Test Modes excluded and is now further away from setpoint than the limit set in the
357. uch as unit pre trip or when the oil and fuel filters are changed Refer to Section 8 1 1 Turn nut counter clockwise to loosen and remove item 1 Figure 8 1 2 Remove banjo fitting item 2 and let it hang loose making sure to keep copper rings item 4 for replacement 3 Turn filter item 3 counter clockwise and remove Check and clean 4 To install reverse steps 1 through 3 1 Nut 2 Banjo 3 Filter 4 Copper Rings Figure 8 1 Mechanical Fuel Pump b Electrical Pump See Figure 8 2 To Check or Replace Filter 1 Remove 3 screws from cover item 1 Figure 8 2 2 Remove cover gasket and filter 3 Wash filter in cleaning solvent and blow out with air pressure Clean cover 4 To Install reverse above steps 1 Cover 2 Gasket 3 Filter Figure 8 2 Electric Fuel Pump Optional 8 3 62 10285 Section 8 Service 8 4 Fuel Level Switch and Fuel Level Sensor An optional fuel level switch or fuel level sensor is available for Advance Microprocessor units Earlier units used a fuel level switch p n 12 00461 00 which have the ability to turn on the Check Fuel Level Alarm Current units use a fuel level sensor p n 12 01147 00 which supplies an input signal to the microprocessor as to the of fuel remaining in the fuel tank The microprocessor then determines based on the input signal to turn on the Check Fuel Level Alarm when the level reaches 15 and if
358. ulates the action of the defrost air switch Bypassing the switch in this manner operates all components involved in defrost NOTE If both DTT1 amp DTT2 are above 40 F 4 4 C the Message Center will show Can Not Start Defrost Cycle 2 3 Unit should remain in defrost until DTT1 located in the blower housing reaches 45 F 7 2 C and DTT2 located on the center tube sheet below the evaporator reaches 55 F 12 8 C At this point the defrost cycle will terminate and the unit will resume automatic operation If the above test indicates satisfactory operation test Defrost Air Switch DAS settings using a Dwyer Magnehelic gauge P N 07 00177 or similar instrument Refer to Section 8 27 c Solid State Defrost Timer Refer to Section 4 7 for description 8 39 62 10285 Section 8 Service 8 27 Checking Calibration of Defrost Air Switch Ohmmeter or Continuity Device Adjustment Screw 0 050 socket head size Low Side Connection Pressure Line or Aspirator Bulb P N 07 00177 01 Magnehelic Gauge P N 07 00177 00 High Side Connection DARN Figure 8 25 Defrost Air Switch Test Setup a Make sure magnehelic gauge is in proper calibration NOTE The Magnehelic Gauge may be used in any position but must be re zeroed if position of gauge is changed from vertical to horizontal or vice versa USE ONLY IN POSITION FOR WHICH IT IS CALIBRATED The Defrost Air Switch MUST be in the same orientation as it will b
359. ulb must be clamped tightly on the suction line and insulated Refer to Section 7 6 Refer to Section 7 6 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION LOW FUEL LEVEL for units with Low Fuel Level Switch no fuel level display in Data List TRIGGER ON Alarm 1 LOW FUEL LEVEL has been on past the allowed run time See chart below UNIT CONTROL Unit shutdown and Alarm e RESET CONDITION Auto reset when fuel level is above 4 tank for more than 30 seconds or Alarm may be manually reset via Keypad or by turning the unit off then back on again 30 gal Fuel tank 30 Minutes 50 gal Fuel tank 60 Minutes 75 gal Fuel tank 90 Minutes 100 gal Fuel tank 120 Minutes 120 gal Fuel tank 150 Minutes NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for low fuel level warning alarm a Check for alarm 1 Add fuel as needed to the fuel tank LOW FUEL LEVEL for units with Low Fuel Level 0 to 100 Sensor fuel level is displayed in Data List TRIGGER ON Fuel level is 10 or less for more than 1 minute UNIT CONTROL Unit shutdown and Alarm RESET CONDITION Auto reset when fuel level is above 1296 for more than 1 minute or alarm m
360. um off time Battery voltage and amperage will be monitored normally While the unit is cycled off in Sleep Mode SLEEP MODE OFF ON TO WAKE will be shown in the Message Center To exit Sleep Mode you can use the instructions for changing Functional Parameters as shown in section 2 15 and select Sleep Mode NO or simply turn the Start Run Off switch to the Off position then back to the Start Run position 2 9 62 10285 Section 2 Operation 2 8 DEFROST 2 8 1 Manual Defrost DEFROST LIGHT HEAT COOL DEFROST ALARM START STOP CONTINUOUS 998 8 BOB SETPOINT BOX TEMPERATURE DEFROST CYCLE STARTED P4 E ALARM LIST START STOR SELECT H O 1 Press the MANUAL DEFROST key The DEFROST light will come on and the Message Center will display DEFROST CYCLE STARTED for 5 seconds or flash CANNOT START DEFROST CYCLE for 5 seconds The defrost mode may be manually initiated If CANNOT START DEFROST CYCLE is displayed the coil temperature is above 40 F 4 4 C the unit is in a Start Stop Off Cycle or the engine has not run 15 seconds after starting Run the unit to lower temperature below 40 F 4 4 C and then restart defrost Only one DTT needs to be below 40 F 4 4 C to allow Defrost to start Defrost can not be started with the unit in Sleep Mode or in PC Mode or if there is an active Shut Down Alarm The defrost mode terminates when Both
361. unloader 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 follow a descending straight line Refer to chart below R 22 REFRIGERATION SYSTEM SUCTION PRESSURES UNLOADING SPEED UL2 SPEED UL2 UL1 FRONT UNLOADER UL2 REAR UNLOADER SUCTION ABOVE THE LINE UNLOADED PRESSURE HIGH SPEED UL1 BELOW THE LINE LOADED PSIG 80 90 100 110 120 130 AMBIENT TEMPERATURE F 4 15 62 10285 Section 4 Engine and Temperature Control 4 7 Defrost Defrost is an independent cycle overriding cooling and heating functions to de ice the evaporator as required When the unit is in Defrost the DEFROST LED will be on the Message Center will display DEFROST CYCLE STARTED for 5 seconds The center of the Main Display will show dF The set point will continue to be displayed on the left side Box Temperature will not be displayed during Defrost NOTE The unit will operate in high speed in the defrost mode When Defrost is Initiated The Defrost Mode may be initiated in three different ways once either DTT1 or DTT2 is below 40 F 4 4 C 1 Defrost Timer The Microprocessor contains an internal Defrost Timer Functional Parameter which can be set using the keyboard Refer to Section 2 15 Functional Change The Defrost Timer is restarted whenever a d
362. ure Sensor 1 resistance 10 000 Ohms 77 F 25 See Note 4 Check Defrost Termination Temperature Sensor 1 wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic CHECK COMP DISCH SENSOR TRIGGER ON Compressor Discharge Sensor circuit has failed open or shorted If shorted the data list will display 392 F 200 C If the circuit is open the data list will show the temperature as 40 F 40 C UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when Compressor Discharge Sensor is in range or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Compressor Discharge Sensor a Inspect Compressor Discharge No damage to sensor Sensor amp connector No damage moisture or corrosion in connector b Check Compressor Discharge Sensor Refer to Section 8 30 for complete resistance chart resistance See Note 4 100 000 Ohms 77 F 25 Check Compressor Discharge Sensor wiring a Inspect harness amp control box No physical damage to harness connector pins am
363. urs Continue with the steps below as necessary 1 Check Auto light a Inspect Auto light amp socket No damage to solenoid No damaged or corroded pins b Check resistance of light bulb Refer to Section 7 8 Check Auto light wiring a Inspect harness amp control box See Notes 2 amp 6 connector pins amp terminals See No physical damage to harness wiring schematic No damaged or corroded pins Check Auto light current draw a Use Component Test Mode Refer to Refer to Section 7 8 for normal current values Section 2 17 3 to test actual current draw of the circuit CHECK START UP BUZZER TRIGGER ON The Buzzer circuit is shorted The Buzzer output from the Micro is negative so the circuit will not be shorted to ground but is shorted either within the Buzzer itself or to a positive wire UNIT CONTROL Alarm Only RESET CONDITION Auto Reset when Buzzer amp draw is normal or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Buzzer a Inspect Buzzer amp wire connections No damage to solenoid No damaged or corroded pins b Check resistan
364. us AAT becomes less than 50 F 10 or Ambient Air Temperature rises to 80 F 26 7 C When the controller calls for heating hot gas solenoid valve SV 4 opens and the condenser pressure control solenoid valve SV 1 closes The condenser coil then fills with refrigerant and hot gas from the compressor enters the evaporator Also the liquid line solenoid valve SV 2 will remain energized valve open until the compressor discharge pressure increases to cut out setting in the microprocessor The microprocessor de energizes the liquid line solenoid valve SV 2 and the valve closes to stop the flow of refrigerant to the expansion valve When the compressor discharge pressure falls to cut in setting the normally closed liquid solenoid valve SV 2 energizes and opens allowing refrigerant from the receiver to enter the evaporator through the expansion valve When in engine operation and the discharge pressure exceeds pressure settings detailed in section 7 6 pressure cutout switch HPS opens to de energize the run relay coil RR When the RR coil is de energized the RR contacts open stopping the engine The function of the hot gas bypass line is to raise the receiver pressure when the ambient temperature is low below 0 F 17 8 C so that refrigerant flows from the receiver to the evaporator when needed 7 21 62 10285 Section 7 Unit Description 7 13 2 Defrost with Greater Than 80 F 26 7 C Ambient If the ambient is gre
365. use the Supply Air setting Supply Air limits the temperature of the air leaving the evaporator to the Set Point setting DISPLAY IN ENGLISH UNITS METRIC UNITS The display will show temperatures amp pressures in either English F amp psig or Metric C amp Bars SET PM HOURM ETERS Maintenance Hour Meters that are enabled will appear in this list ENGINE SWITCH ON PM 1 Thru 5 ON OFF RESUME RESET 62 10285 When the Hour Meter has timed out and preventative maintenance has been performed selecting RESET and pressing will de activate the alarm and reset the Hour Meter for the next service interval When the Hour Meter is between intervals OFF or RESUME will be the only selections Pressing the key while OFF is displayed will suspend operation of that Hour Meter and prevent any maintenance alarms from showing Hour Meters that have been turned off can be activated by selecting RESUME Pressing will resume the Hour Meter including all the hours that had been logged while it had been turned off 2 26 FUNCTIONAL PARAMETER OUT OF RANGE ALARM SELECTIONS English Metric OFF OFF 4 F 2 5 5 F 3 C TF 4C Section 2 Operation DESCRIPTION Once the unit is at Set Point then drifted away for more than 15 minutes an Out Of Range Alarm will come on Or if configured for Out Of Range Shutdown after 45 minutes the unit will shut down This setting determine
366. utdown switch and allow the unit to continue to run even with the trailer door open OVERRIDE REMS 1 2 SHUTDOWN NO allows remote switch 1 and or 2 to shutthe unit down whenever door is open or the switch is turned OFF YES allows you to over ride remote switch 1 and or 2 and allow the unit to continue to run even with the remote switch in the OFF position or the door is open LANGUAGE IDIOMAS ENGLISH ESPANOL ENGLISH All information displayed in the Message Center will be shown in English ESPANOL All information displayed in the Message Center will be shown in Spanish Selections in BOLD are the factory settings This Functional Parameter may not appear in the list for your unit depending on how the Microprocessor has been configured 2 27 62 10285 Section 2 Operation 2 16 PC Mode PC Mode was created for the ability to download data using a computer without having to have the unit run Connecting a download cable to the download port with the SROS in the OFF position allows the Advance Microprocessor to power up and communicate with the computer To better utilize PC Mode PC Mode Jumper 22 50180 01 is available With the unit off locate the serial downloader port Refer to Section 3 7 Remove the protective plug to gain access to the wire terminals Plug in Serial Jumper P N 22 50180 01 or connect an insulated jumper wire between plug terminals C and E In
367. vaporator section return air bulkhead air chute cleanliness of evap coil Must be engaged Good Air Flow Return air not restricted Air chute in good condition No damage to blower wheel Evap coil clean Check refrigerant charge a Check for undercharged system Level must be above lower sight glass Check Expansion Valve TXV a Visually inspect valve b Check MOP of valve c Check superheat of valve 5 73 Bulb must be clamped tightly on the suction line and insulated Refer to Section 7 6 Refer to Section 7 6 62 10285 Section 5 Alarm Troubleshooting ALARM CAUSE CORRECTIVE ACTION CHK DEFROST TERM 2 SENSOR TRIGGER ON Defrost Termination Temperature Sensor 2 is not within the maximum range of 53 F to 158 F 47 C to 70 C UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Defrost Termination Temperature Sensor 2 a Inspect Defrost Termination No damage to sensor Temperature Sensor 2 amp connector No damage or corrosion in connector b Check Defrost Termination 10 000 Ohm
368. ve 11 F See note 7 Check operation of SV 1 FET 10 LED must be ON Check voltage SV 1 Must be 11 VDC or higher across the 2 wires Check SV 1 circuit wiring a Inspect harness amp control box No physical damage to harness connector pins amp terminals See No damaged or corroded pins wiring schematic Check SV 1 a Check resistance of SV 1 Refer to Section 7 8 b Check amp draw of SV 1 Use Component Test Mode Section 2 17 3 to test Refer to Section 7 8 for amp values 5 53 62 10285 Section 5 Alarm Troubleshooting Steps ALARM CAUSE CORRECTIVE ACTION CHECK SV3 CIRCUIT TRIGGER ON Normal Amps for the SV 3 Circuit is 0 75 to 27 Amps The circuit tests outside this range UNIT CONTROL Alarm Only RESET CONDITION Auto Reset if Pre Trip mode is started again or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check for Bad F4 or F6 Fuse alarm a Check for alarm 72 Alarm conditions must be corrected and the alarm cleared to continue Check 5 3 amp circuit a Inspect SV 3 and wiring No physical damage to harness No damaged or corroded pins b
369. ve Must open fully with unit running opens fully b Check discharge check valve screen Must be clean of any debris Check system for non condensable a Check refrigeration system for No non condensable gas es may be present non condensable gas es Check Compressor a Remove all Compressor heads and Must be in good condition inspect valve plates unloaders reed No broken or missing parts valves amp gaskets BATTERY VOLTAGE TOO HIGH e TRIGGER ON Voltage at the microprocessor is greater than 17 VDC UNIT CONTROL Unit Shutdown amp Alarm RESET CONDITION Auto Reset after 15 minutes when the voltage at the microprocessor is between 11 14 VDC or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check battery voltage a Test voltage at battery with unit off Must be below 17 VDC b Test voltage at battery with unit Must be below 17 VDC running Check alternator voltage a Test voltage at alternator output Must be below 17 VDC terminal with unit off b Test voltage at alternator output Must be below 17 VDC terminal with unit running
370. ve product loads The Start Stop Continuous key is provided to switch between Continuous Run and Start Stop operating modes Unit will shut down NOTE The Microprocessor may be locked so that the unit will always operate in Start Stop or in Continuous Run whenever the setpoint is within a specific range Refer to Section 4 4 Range Lock for additional information The unit will remain in low speed for 10 minutes after engine start up when setpoint is below 10 4 F 122 4 4 Temperature Range Lock 1 amp 2 The unit can be locked into Start Stop or Continuous Run operation for various setpoints Two ranges are available for setpoint range lock selection Each Range can be independently set to lock it s setpoint temperatures into either Start Stop or Continuous Run Each Range has it s own selectable minimum and maximum temperatures which define the span of the range If some setpoint temperatures are contained in both ranges due to range overlap Range 1 will always have priority over Range 2 For example see following figure if Continuous Run operation is ALWAYS required whenever the setpoint is between 28 F and 55 Range 1 will be set for Continuous Run with a Minimum Temperature of 28 F and a Maximum Temperature of 55 Should Continuous Run operation ALWAYS also be required with setpoints between 22 F and 0 F then Range 2 will be set for Continuous Run with a Minimum Temperature of 22 F and a M
371. ways protected the Maximum Off Time may be used to force the unit to restart Maximum Off Time is selected in the Microprocessor Functional Parameter List This may be set for or 10 minutes to 255 minutes in 1 minute intervals When the Maximum Off Time expires the unit will restart regardless of any change in box temperature Perishable amp Frozen Selections The Functional Parameter List has selections available to set different values for Perishable and Frozen setpoints in Start Stop or for the same values to be used for both The Configuration List allows the user to select having these Start Stop Parameters either TOGETHER or SEPARATE The following may be set either for both Frozen and Perishable or separately for each depending on how it is Configured PERISH MIN RUN TIME FROZEN MIN RUN TIME PERISH MIN OFF TIME FROZEN MIN OFF TIME PERISH OVERRIDE TEMP FROZEN OVERRIDE TEMP PERISH MAX OFF TIME FROZEN MAX OFF TIME FROZEN SHUTDOWN OFFSET only applies to Frozen Start Stop operation The available selections are 0 F to 3 6 F 0 C to 2 C The factory setting is 0 F C which effectively turns this feature off This feature is first available with software version 01 07 00 When different Perishable and Frozen values are entered through Functional Parameters and then the Configuration is changed to TOGETHER the values that had been entered for Perishable will be used 4 3 62 10285 Section 4 Engine and Temperature Control
372. ween Red Wire positive and Black Wire negative should be 12 5 to 13 5 VDC Do not disconnect the Red or Black wires from the switch Disconnect the Blue Wire output from the unit wiring Voltage between Black Wire negative and Blue Wire output should be 12 VDC when the switch is immersed in fuel When the switch is removed from the fuel residual fuel will evaporate quickly from the end of the switch Once the fuel has evaporated the voltage reading between Black Wire negative and Blue Wire output should be 0 VDC Red FLSA SP3 12VDC Blue FLSC 2MP04 Output Black FLSB SPK6 Gnd Figure 8 4 Fuel Level Switch Wiring 8 5 62 10285 Section 8 Service 8 5 Engine Service and Components 8 5 1 Cooling System Air flows through the radiator Ultra Ultra XL amp Extra units or condenser radiator Ultima The radiator externally and internally must be clean for adequate cooling The water pump V belt must be adjusted periodically to provide maximum air flow Refer to Section 8 6 2 Do the following to service the cooling system 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 60 concentration of anti freeze Use a low silicate anti freeze meeting GM specifications GM 6038M or equal a Remove all foreign material from the radiator or condenser radi
373. when Oil Pressure Switch contacts OPEN or Alarm may be manually reset via Keypad or by turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Engine RPM Sensor a Inspect Engine RPM Sensor amp No damage to sensor connector No damage moisture or corrosion in connector b Compare actual engine RPMs with Must be 20 RPMs those shown onthe display using hand held tachometer Check Engine RPM Sensor wiring a Inspect harness amp control box See Note 5 connector pins amp terminals See No physical damage to harness wiring schematic No damaged or corroded pins Check RPM wiring Place unit in PC Mode or in Manual Start Mode see Note 2 DO NOT START UNIT Check voltage reading between plug terminals A amp B With lead on A and lead on C reading should be 5 VDC gt 2 volts Check circuits with test sensor a Substitute known good sensor and Must be within 20 RPMs or reading on tachometer check Data reading 5 47 62 10285 Section 5 Alarm Troubleshooting ALARM CAUSE CORRECTIVE ACTION CHK DEFROST TERM 2 SENSOR TRIGGER ON Defrost Termination Temperature Sensor 2 circuit h
374. while the program is being loaded this will take about 90 seconds The CARD STATUS LED will come on solid when the programming is complete Remove card at this time If the current software version is 01 06 00 or later the Message Center will show one of 3 different messages Same SW to Load 1 To Cancel Old SW to Load 1 To Cancel New SW to Load To Cancel 5 Press to load the program The Message Center will go blank If the engine is running it will shut down Then the green PC CARD STATUS LED and MICRO STATUS LED will flash together at the rate of 5 seconds 5 seconds off Both LEDs will blink 2 3 times then stop Blinking will resume within 10 seconds Both LEDs will continue to blink together while the program is being loaded this will take about 90 seconds The CARD STATUS LED will come on solid when the programming is complete Remove card at this time 6 When the card is removed the Micro will power up as it was prior to inserting the card PC Mode or unit running Allow the Micro to completely power up Main Display and Message Center displaying appropriate messages once after installing the new software before turning the power off or removing the PC Mode jumper 2 39 62 10285 Section 2 Operation 2 19 2 Using Microprogrammer CAUTION It is important that communications between the Micro and the computer are not disturbed during the software loading process If using a laptop computer turn
375. witch On Hours until the next service interval CLUTCH CYCLES CLUTCH CYCLES PM Meter will count how many START CYCLES times the fan clutch cycled on off until the next service HIGH SPEED interval HOURS START CYCLES PM Meter will count how many times the engine has started until the next service interval HIGH SPEED HOURS PM Meter will count how many hours the unit operated in high speed until the next service interval 62 10285 2 32 Section 2 Operation CONFIGURATION DESCRIPTION SELECTIONS DESCRIPTION PM 1 5 RESET INTERVAL OFF OFF PM 1 5 is not being used ENGINE HOURS ENGINE HOURS PM 1 5 is connected to the engine 50 TO 30 000 HRS hour meter The reset interval will be 50 30 000 hrs in 50 hr increments SWITCH ON HOURS PM 1 5 is connected to the SWITCH ON switch on hour meter The reset interval will be 60 HOURS 30 000 hrs 50 TO 30 000 HRS CLUTCH CYCLES PM 1 5 is connected to the clutch in 50 hr increments cycle meter This meter counts every time the fan clutch engages The reset interval will be 1 000 to 90 000 CLUTCH CYCLES cycles 1 000 TO 90 000 CYCLES 1 000 START CYCLES PM 1 5 is connected to the clutch cycle increments cycle meter This meter counts every time the engine starter engages The reset interval will be 1 000 to START CYCLES 90900 cycles 1 000 TO 90 000 CYCLES in 1 000 cycle increments HIGH SPEED HOURS PM 1 5 is co
376. with a panel to view and control the functions of the refrigeration unit The module consists of a switch keypad Message Center and Main Display You select the set points and other system information using the keypad The figure above shows the Display amp Keypad Module Display The Main Display has 9 characters 7 seven segment characters and 2 nine segment characters 2 decimal points 2 commas and a degree symbol The display is used to provide the user a setpoint and box temperature either in degrees Celsius or Fahrenheit The comma symbols are used as the decimal indicators in Europe When Metric Units is selected in the Functional Parameters the two comma icons are used to indicate decimal points When English Units is selected in the Functional Parameters the decimal points are used Temperature display is right justified with unused digits blank A negative sign will be displayed for all setpoint and box temperatures below Zero A positive sign will be displayed for all setpoint and box temperatures above Zero but less than 100 degrees 0 0 degrees will not have a sign in front of it The resolution for box temperature in both Celsius and Fahrenheit is one tenth 0 1F or 0 1C degrees Beginning with software version 01 06 00 the user has the option of whether to have the set point displayed with a decimal or comma Only the setpoint is affected by this selection other temperatures and pressures will continue to be di
377. with those shown on the microprocessor controller Suction amp Discharge Pressures must have the same reading on gauges amp on micro display Pressures must be in the normal range for ambient amp box temperature conditions Perform Pretrip Check a Run Pretrip amp check for alarms Any active alarms must be corrected and cleared before proceeding Check for refrigerant overcharge a Check refrigerant level in the receiver tank Level must be between upper amp lower sight glasses Check HPS switch a Inspect switch amp connector pins amp terminals b Check switch operation Refer to Section 7 6 for pressure settings No physical damage to switch No damaged or corroded pins in plug Contacts open when compressor discharge pressure is above cut out point 10 psig Contacts closed when compressor discharge pressure is below cut in point 10 psig Check HPS switch harness box See a Inspect harness 8 control connector pins amp terminals wiring schematic Check for shorted circuit in harness and continuity through the harness No physical damage to harness No damaged or corroded pins Run Stop switch ON Manual Start Mode See Note 2 Battery voltage reading 12 13 VDC between wires in plug 5 9 62 10285 Section 5 Alarm Troubleshooting ALARM CAUSE CORRECTIVE ACTION Check discharge check valve a Check that discharge check val
378. y clutch relay both unloaders and SV 2 will remain energized until the next starting sequence Before beginning another starting sequence the oil pressure is checked to determine if the engine is running or the RPM sensor has failed For the second and third start attempts the glow time is increased by 5 seconds over the glow time of the first attempt listed below The Microprocessor allows three start attempts before the starting is locked out and the Failed To Start Auto Mode alarm is activated NOTE If the Engine Coolant Sensor Alarm is Active the glow time for temperatures less than 32 F will be used REPEAT A Variable Glow Time LL MN The glow time for the first start attempt will vary in THIRD duration based on engine coolant temperature and how ATTEMPT the microprocessor is configured Short or Long as follows da ae Glow Time EndimeCaolantiTempberatur Glow Time in Seconds gine Coolant Temperature Shot Long REPEAT A Less than 32 F 0 C 15 55 ee 33 F to 50 F 1 C to 10 C 10 40 SECOND 51 F to 77 F 11 C to 25 C 5 25 ATTEMPT Greater than 78 F 26 C 0 10 18 eT The second start attempt has 5 seconds of glow time added to the time shown in the table The third start attempt will have 10 seconds added If the coolant temperature sensor is defective the Microprocessor assumes temperature of econds er vine n Checked less than 32 F 0 C for the glow timing

Ultima 53, Phoenix ultra, and Extra, With advanced Micro service

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