Carrier Manual t 340

T340 Rev D

OPERATION AND SERVICEfor

69NT40-561-001 to 199Container Refrigeration Units

Container Refrigeration

OPERATION AND SERVICE MANUALCONTAINER REFRIGERATION UNIT

Models 69NT40561001 to 199

Carrier Corporation, 2012 Printed in U. S. A. May 2012

i T-340

TABLE OF CONTENTS

PARAGRAPH NUMBER Page

INTRODUCTION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 INTRODUCTION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 CONFIGURATION IDENTIFICATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3 FEATURE DESCRIPTIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.1 Control Box 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.2 Temperature Readout 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.3 Pressure Readout 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.4 Compressor 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.5 Condenser Coil 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.6 Evaporator 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.7 Evaporator Fan Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.8 Plate Set 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 OPTION DESCRIPTIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.1 Battery 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.2 Dehumidification 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.3 USDA 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.4 Interrogator 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.5 Remote Monitoring 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.6 Quest CCPC 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.7 Communications Interface Module 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.8 Autotransformer 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.9 Temperature Recorder 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.10 Gutters 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.11 Handles 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.12 Thermometer Port 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.13 Water Cooling 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.14 Back Panels 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.15 460 Volt Cable 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.16 230 Volt Cable 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.17 Cable Restraint 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.18 Upper Air (Fresh Air Make Up) 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.19 Lower Air (Fresh Air Make Up) 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.20 Labels 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.21 Controller 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.22 Condenser Grille 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.23 Emergency Bypass 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.4.24 eAutoFresh 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iiT-340

TABLE OF CONTENTS (Continued)


DESCRIPTION 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 GENERAL DESCRIPTION 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 Refrigeration Unit Front Section 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.2 Fresh Air Makeup Vent 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.3 Evaporator Section 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.4 Compressor Section 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.5 AirCooled Condenser Section 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.6 WaterCooled Condenser Section 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.7 Control Box Section 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1.8 Communications Interface Module 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 REFRIGERATION SYSTEM DATA 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3 ELECTRICAL DATA 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4 SAFETY AND PROTECTIVE DEVICES 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5 REFRIGERATION CIRCUIT 210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.1 Standard Operation 210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.2 Economized Operation 210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.3 Electronic Expansion Valve 210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MICROPROCESSOR 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 TEMPERATURE CONTROL MICROPROCESSOR SYSTEM 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1 Keypad 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.2 Display Module 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.3 Controller 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 CONTROLLER SOFTWARE 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.1 Configuration Software (CnF Variables) 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.2 Operational Software (Cd Function Codes) 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 MODES OF OPERATION 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.1 Start up - Compressor Phase Sequence 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.2 Start up - Compressor Bump Start 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.3 Perishable Mode Temperature Control 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.4 Perishable Pulldown 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.5 Perishable Steady State 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.6 Perishable Idle, Air Circulation 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.7 Perishable Heating 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.8 Perishable Dehumidification 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.9 Perishable Dehumidification - Bulb Mode 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.10 Perishable Economy 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.11 Perishable Mode Cooling - Sequence of Operation 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.12 Perishable Mode Heating - Sequence of Operation 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.13 Perishable Mode - Trim Heat 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.14 Frozen Mode - Temperature Control 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.15 Frozen Steady State 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.16 Frozen Idle Mode 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.17 Frozen Heat Mode 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii T-340



3.3.18 Frozen Economy Mode 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.19 Frozen Mode Cooling - Sequence of Operation 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.20 Defrost 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.21 Automatic Defrost 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.22 Defrost Initiation 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.23 Defrost Interval 310. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.24 Defrost Related Settings 310. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 PROTECTION MODES OF OPERATION 311. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4.1 Evaporator Fan Operation 311. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4.2 Failure Action 311. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4.3 Generator Protection 311. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4.4 Compressor High Temperature, Low Pressure Protection 311. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4.5 Perishable Mode - System Pressure Regulation 311. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4.6 Condenser Fan Override 311. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 QUEST CCPC 312. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6 CONTROLLER ALARMS 312. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.7 PRETRIP DIAGNOSTICS 312. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8 DataCORDER 313. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.1 Description 313. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.2 DataCORDER Software 313. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.3 Sensor Configuration (dCF02) 314. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.4 Logging Interval (dCF03) 314. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.5 Thermistor Format (dCF04) 314. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.6 Sampling Type (dCF05 & dCF06) 316. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.7 Alarm Configuration (dCF07 - dCF10) 316. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.8 DataCORDER Power Up 316. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.9 Pre-trip Data Recording 316. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.10 DataCORDER Communications 316. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.11 USDA Cold Treatment 317. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.12 USDA Cold Treatment Procedure 317. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.13 DataCORDER Alarms 318. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.14 ISO Trip Header 318. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 CONTROLLER CONFIGURATION VARIABLES 319. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10 CONTROLLER FUNCTION CODES 320. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11 CONTROLLER ALARM INDICATIONS 329. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12 CONTROLLER PRETRIP TEST CODES 337. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 INSPECTION (Before Loading) 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 CONNECT POWER 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 Connection To 380/460 VAC Power 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2.2 Connection To 190/230 VAC Power 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 ADJUST FRESH AIR MAKEUP VENT 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.1 Upper Fresh Air Makeup Vent 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.2 Lower Fresh Air Makeup Vent 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3.3 Vent Position Sensor 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4.4 eAutoFresh OPERATION 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.1 eAutoFresh PreTrip Inspection 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.2 eAutoFresh StartUp Procedure 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.3 eAutoFresh Modes of Operation 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 CONNECT WATER-COOLED CONDENSER 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.1 Water-Cooled Condenser with Water Pressure Switch 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.2 WaterCooled Condenser with Condenser Fan Switch 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 CONNECT REMOTE MONITORING RECEPTACLE 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7 STARTING AND STOPPING INSTRUCTIONS 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.1 Starting the Unit 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.7.2 Stopping the Unit 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8 STARTUP INSPECTION 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8.1 Physical Inspection 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8.2 Check Controller Function Codes 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8.3 Start Temperature Recorder 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8.4 Complete Inspection 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.9 PRETRIP DIAGNOSIS 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.10 PROBE DIAGNOSTICS 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.11 EMERGENCY BYPASS OPERATION 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 UNIT WILL NOT START OR STARTS THEN STOPS 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 UNIT RUNS BUT HAS INSUFFICIENT COOLING 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 UNIT WILL NOT TERMINATE HEATING 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 UNIT WILL NOT DEFROST PROPERLY 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 ABNORMAL PRESSURES 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8 ABNORMAL NOISE OR VIBRATIONS 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9 MICROPROCESSOR MALFUNCTION 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.11 EAUTOFRESH NOT OPERATING 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.12 ELECTRONIC EXPANSION VALVE MALFUNCTION 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.13 AUTOTRANSFORMER MALFUNCTION 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.14 WATERCOOLED CONDENSER OR WATER PRESSURE SWITCH 55. . . . . . . . . . . . . . . . . . . . . . .

5.15 COMPRESSOR OPERATING IN REVERSE 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.16 ABNORMAL TEMPERATURES 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.17 ABNORMAL CURRENTS 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 SECTION LAYOUT 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 MANIFOLD GAUGE SET 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 SERVICE CONNECTIONS 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 PUMP DOWN THE UNIT 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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6.5 REFRIGERANT LEAK CHECKING 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6 EVACUATION AND DEHYDRATION 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6.1 General 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6.2 Preparation 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6.3 Complete System 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6.4 Partial System 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7 REFRIGERANT CHARGE 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.7.1 Checking the Refrigerant Charge 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.7.2 Adding Refrigerant to System (Full Charge) 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.7.3 Adding Refrigerant to System (Partial Charge) 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8 COMPRESSOR 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8.1 Removal and Replacement of Compressor 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9 HIGH PRESSURE SWITCH 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.9.1 Checking High Pressure Switch 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.9.2 Replacing High Pressure Switch 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.10 CONDENSER COIL 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.11 CONDENSER FAN AND MOTOR ASSEMBLY 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.12 WATERCOOLED CONDENSER CLEANING 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.13 FILTER DRIER 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14 EVAPORATOR COIL & HEATER ASSEMBLY 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.14.1 Evaporator Coil Replacement 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14.2 Evaporator Heater Replacement 610. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.15 EVAPORATOR FAN AND MOTOR ASSEMBLY 610. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.15.1 Replacing the Evaporator Fan Assembly 610. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.15.2 Disassemble the Evaporator Fan Assembly 610. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.15.3 Assemble the Evaporator Fan Assembly 611. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.16 EVAPORATOR SECTION CLEANING 611. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.17 ELECTRONIC EXPANSION VALVE 612. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.17.1 Replacing Electronic Expansion Valve and Screen 612. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.18 ECONOMIZER SOLENOID VALVE 613. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.19 ECONOMIZER EXPANSION VALVE 613. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.19.1 Economizer Expansion Replacement 613. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.20 DIGITAL UNLOADER VALVE 614. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.21 VALVE OVERRIDE CONTROLS 615. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.22 AUTOTRANSFORMER 616. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.23 CONTROLLER 616. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.23.1 Handling Modules 616. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.23.2 Controller Troubleshooting 616. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.23.3 Controller Programming Procedure 617. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.23.4 Removing and Installing a Controller 619. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.23.5 Battery Replacement 619. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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6.24 TEMPERATURE SENSOR SERVICE 619. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24.1 Sensor Checkout Procedure 619. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24.2 Sensor Replacement 622. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.24.3 Sensor Re-Installation 622. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.25 VENT POSITION SENSOR (VPS) 624. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.26 eAutoFresh SERVICE 625. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.26.1 Servicing the eAutoFresh Air Filter 625. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.26.2 Checking eAutoFresh Drive System 625. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.26.3 Checking the Controller 626. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.26.4 Servicing the eAutoFresh Drive System 626. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.27 ELECTRONIC PARTLOW TEMPERATURE RECORDER 628. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.28 MAINTENANCE OF PAINTED SURFACES 629. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.29 COMMUNICATIONS INTERFACE MODULE INSTALLATION 629. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL WIRING SCHEMATICS 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1 INTRODUCTION 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIST OF ILLUSTRATIONS

FIGURE NUMBER Page

Figure 21 Refrigeration Unit Front Section 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 22 Evaporator Section 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 23 Compressor Section 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 24 AirCooled Condenser Section 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 25 WaterCooled Condenser Section 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 26 Control Box Section 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 27 Refrigeration Circuit Schematic Standard Operation 211. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 28 Refrigeration Circuit Schematic Economized Operation 212. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 31 Temperature Control System 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 32 Keypad 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 33 Display Module 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 34 Control Module 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 35 Controller Operation - Perishable Mode 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 36 Perishable Mode Cooling 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 37 Perishable Mode Heating 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 38 Controller Operation - Frozen Mode 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 39 Frozen Mode 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 310 Defrost 310. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 311 Standard Configuration Download Report 315. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 312 DataReader 317. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 313 Alarm Troubleshooting Sequence 328. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 41 Autotransformer 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 42 Upper Fresh Air Make Up Flow Chart 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vii T-340

LIST OF ILLUSTRATIONS (Continued)

FIGURE NUMBER Page

Figure 43 Diagram of Emergency Bypass Connections 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 61 Manifold Gauge Set 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 62 R-134a Manifold Gauge/Hose Set 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 63 Service Valve 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 64 Refrigeration System Service Connections 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 65 Compressor Kit 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 66 High Pressure Switch Testing 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 67 Water-Cooled Condenser Cleaning, Forced Circulation 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 68 Water-Cooled Condenser Cleaning - Gravity Circulation 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 69 5+1 Heater Arrangement Omega Heater 610. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 610 Evaporator Fan Assembly 611. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 611 Electronic Expansion Valve 612. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 612 Coil View of Economizer Solenoid Valve (ESV) 613. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 613 Economizer Expansion Valve 613. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 614 View of Digital Unloader Valve (DUV) Assembly 614. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 615 Autotransformer 616. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 616 Controller Section of the Control Box 617. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 617 Sensor Types 622. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 618 Sensor and Cable Splice 622. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 619 Supply Sensor Positioning 623. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 620 Return Sensor Positioning 623. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 621 Evaporator Temperature Sensor Positioning 623. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 622 Compressor Discharge Temperature Sensor 624. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 623 Stepper Components 625. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 624 Jumper Assembly 626. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 625 Motor Cup Replacement 627. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 626 Electronic Partlow Temperature Recorder 628. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 627 Communications Interface Installation 629. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 71 LEGEND Standard Unit Configuration 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 72 SCHEMATIC DIAGRAM Standard Unit Configuration 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 73 LEGEND Configuration Includes Available Options

(Except Vent Positioning System, eAutoFresh, Emergency Bypass Options) 74. . . . . . . . . . . . . .

Figure 74 SCHEMATIC DIAGRAM Configuration Includes Available Options(Except Vent Positioning System, eAutoFresh, Emergency Bypass Options) 75. . . . . . . . . . . . . .

Figure 75 LEGEND Configuration Includes eAutoFresh and Emergency Bypass Options 76. . . . . . . . . . . .Figure 76 SCHEMATIC DIAGRAM Configuration Includes eAutoFresh and Emergency Bypass Options 77Figure 77 SCHEMATIC AND WIRING DIAGRAM Upper Vent Position Sensor (VPS) Option 78. . . . . . . . .Figure 78 SCHEMATIC AND WIRING DIAGRAM Lower Vent Position Sensor (VPS) Option 79. . . . . . . . .

Figure 79 UNIT WIRING DIAGRAM Standard Unit Configuration with 3Phase Condenser Fan Motors 710Figure 710 UNIT WIRING DIAGRAM Configuration Includes Single Phase Condenser Fan Motor

& Optional Heater Arrangement 712. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Figure 711 UNIT WIRING DIAGRAM Configuration Includes eAutoFresh & Emergency Bypass Options 714Figure 711 UNIT WIRING DIAGRAM Configuration Includes eAutoFresh & Emergency Bypass Options 715

viiiT-340

LIST OF TABLES

TABLE NUMBER Page

Table 21 Safety and Protective Devices 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 31 Keypad Function 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 32 DataCORDER Configuration Variables 314. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 33 DataCORDER Standard Configurations 316. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 34 Controller Configuration Variables 319. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 35 Controller Function Codes 320. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 36 Controller Alarm Indications 329. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 37 Controller Pre-trip Test Codes 337. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 38 DataCORDER Function Code Assignments 343. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 39 DataCORDER Pre-trip Result Records 344. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 310 DataCORDER Alarm Indications 345. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 61 Valve Override Control Displays 615. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 62 Sensor Resistance 620. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 63 Sensor Resistance (CPDS) 621. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 64 R-134a Temperature - Pressure Chart 630. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 65 Recommended Bolt Torque Values 631. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T340 Safety1

SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement specif-ic warnings and cautions appearing elsewhere in thismanual. They are recommended precautions that mustbe understood and applied during operation and mainte-nance of the equipment covered herein. The generalsafety notices are presented in the following three sec-tions labeled: First Aid, Operating Precautions andMaintenance Precautions. A listing of the specific warn-ings and cautions appearing elsewhere in the manualfollows the general safety notices.

FIRST AID

An injury, no matter how slight, should never go unat-tended. Always obtain first aid or medical attention im-mediately.

OPERATING PRECAUTIONS

Always wear safety glasses.

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

No work should be performed on the unit until all circuitbreakers and start-stop switches are turned off, andpower supply is disconnected.

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

MAINTENANCE PRECAUTIONS

Beware of unannounced starting of the evaporator andcondenser fans. Do not open the condenser fan grille orevaporator access panels before turning power off, dis-connecting and securing the power plug.

Be sure power is turned off before working on motors,controllers, solenoid valves and electrical controlswitches. Tag circuit breaker and power supply to pre-vent accidental energizing of circuit.

Do not bypass any electrical safety devices, e.g. bridg-ing an overload, or using any sort of jumper wires. Prob-lems with the system should be diagnosed, and anynecessary repairs performed by qualified service per-sonnel.

When performing any arc welding on the unit or contain-er, disconnect all wire harness connectors from themodules in control boxes. Do not remove wire harnessfrom the modules unless you are grounded to the unitframe with a static safe wrist strap.

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

SPECIFIC WARNING AND CAUTION STATEMENTS

To help identify the label hazards on the unit and explainthe level of awareness each one carries, an explanationis given with the appropriate consequences:

DANGER - means an immediate hazard that WILL re-sult in severe personal injury or death.

WARNING - means to warn against hazards or unsafeconditions that COULD result in severe personal injuryor death.

CAUTION - means to warn against potential hazard orunsafe practice that could result in minor personal injury,product or property damage.

The statements listed below are applicable to the refrig-eration unit and appear elsewhere in this manual. Theserecommended precautions must be understood and ap-plied during operation and maintenance of the equip-ment covered herein.

WARNINGEXPLOSION HAZARD: Failure to follow thisWARNING can result in death, seriouspersonal injury and / or property damage.Never use air or gas mixtures containingoxygen (O2) for leak testing or operating theproduct.Charge Only With R134a: Refrigerant mustconform to AHRI Standard 700specification.

WARNING

Beware of unannounced starting of theevaporator and condenser fans. The unitmay cycle the fans and compressor unex-pectedly as control requirements dictate.

WARNING

Do not attempt to remove power plug(s) be-fore turning OFF start-stop switch (ST), unitcircuit breaker(s) and external powersource.

WARNINGMake sure the power plugs are clean anddry before connecting to power receptacle.

WARNINGMake sure that the unit circuit breaker(s)(CB-1 & CB-2) and the START-STOP switch(ST) are in the O (OFF) position beforeconnecting to any electrical power source.

Safety2T340

WARNING

Make sure power to the unit is OFF andpower plug disconnected before replacingthe compressor.

WARNING

Before disassembly of the compressor, besure to relieve the internal pressure verycarefully by slightly loosening the cou-plings to break the seal.

WARNING

Do not use a nitrogen cylinder without apressure regulator.

WARNINGDo not open the condenser fan grille beforeturning power OFF and disconnectingpower plug.

WARNINGOakite No. 32 is an acid. Be sure that theacid is slowly added to the water. DO NOTPUT WATER INTO THE ACID - this will causespattering and excessive heat.

WARNING

Wear rubber gloves and wash the solutionfrom the skin immediately if accidental con-tact occurs. Do not allow the solution tosplash onto concrete.

WARNING

Always turn OFF the unit circuit breakers(CB-1 & CB-2) and disconnect main powersupply before working on moving parts.

WARNING

Installation requires wiring to the main unitcircuit breaker, CB1. Make sure the power tothe unit is off and power plug disconnectedbefore beginning installation.

CAUTION

Charge watercooled condenser or receiv-er according to nameplate specifications toensure optimal unit performance.

CAUTION

Do not remove wire harnesses from con-troller modules unless you are grounded tothe unit frame with a static safe wrist strap.

CAUTION

Unplug all controller module wire harnessconnectors before performing arc weldingon any part of the container.

CAUTION

Do not attempt to use an ML2i PC card in anML3 equipped unit. The PC cards are physi-cally different and will result in damage tothe controller.

CAUTION

Pre-trip inspection should not be per-formed with critical temperature cargoes inthe container.

CAUTION

When Pre-Trip key is pressed, economy, de-humidification and bulb mode will be deac-tivated. At the completion of Pre-Trip activi-ty, economy, dehumidification and bulbmode must be reactivated.

CAUTION

When condenser water flow is below 11 lpm(3 gpm) or when water-cooled operation isnot in use, the CFS switch MUST be set toposition 1 or the unit will not operateproperly.

T340 Safety3

CAUTION

When a failure occurs during automatictesting, the unit will suspend operationawaiting operator intervention.

CAUTION

When Pre-Trip test Auto 2 runs to comple-tion without being interrupted, the unit willterminate pre-trip and display Auto 2end. The unit will suspend operation untilthe user depresses the ENTER key!

CAUTION

The unit will remain in the full cooling modeas long as the EB switch is in the On posi-tion and the Mode Switch is in the Full Coolposition. If the cargo can be damaged bylow temperatures, the operator must monit-or container temperature and manuallycycle operation as required to maintaintemperature within required limits.

CAUTION

Allowing the scroll compressor to operatein reverse for more than two minutes will re-sult in internal compressor damage. Turnthe start-stop switch OFF immediately.

CAUTION

To prevent trapping liquid refrigerant in themanifold gauge set be sure set is brought tosuction pressure before disconnecting.

CAUTION

The scroll compressor achieves lowsuction pressure very quickly. Do not usethe compressor to evacuate the systembelow 0 psig. Never operate thecompressor with the suction or dischargeservice valves closed (frontseated). Internaldamage will result from operating thecompressor in a deep vacuum.

CAUTION

Take necessary steps (place plywood overcoil or use sling on motor) to prevent motorfrom falling into condenser coil.

CAUTION

Do not remove wire harnesses from moduleunless you are grounded to the unit framewith a static safe wrist strap.

CAUTIONUnplug all module connectors before per-forming arc welding on any part of the con-tainer.

CAUTIONThe unit must be OFF whenever a program-ming card is inserted or removed from thecontroller programming port.

CAUTION

Use care when cutting wire ties to avoidnicking or cutting wires.

CAUTIONDo not allow moisture to enter wire splicearea as this may affect sensor resistance.

11 T340

SECTION 1

INTRODUCTION

1.1 INTRODUCTION

The Carrier Transicold model 69NT40561001 to 199series units are of lightweight aluminum frameconstruction, designed to fit in the front of a containerand serve as the containers front wall.

They are one piece, selfcontained, all electric units,which include cooling and heating systems to provideprecise temperature control.

The units are supplied with a complete charge ofrefrigerant R134a and compressor lubricating oil, andare ready for operation upon installation. Forkliftpockets are provided for unit installation and removal.

The base unit operates on nominal 380/460 volt,3phase, 50/60 hertz (Hz) power. An optionalautotransformer may be fitted to allow operation onnominal 190/230, 3phase, 50/60 Hz power. Controlsystem power is provided by a transformer which stepsthe supply power down to 18 and 24 volts, single phase.

The controller is a Carrier Transicold MicroLink 3microprocessor. The controller operates automaticallyto select cooling, holding or heating as required tomaintain the desired set point temperature within veryclose limits. The unit may also be equipped with anelectronic temperature recorder.

The controller has a keypad and display for viewing orchanging operating parameters. The display is alsoequipped with lights to indicate various modes ofoperation.

1.2 CONFIGURATION IDENTIFICATION

Unit identification information is provided on a platelocated to the left of the receiver or watercooledcondenser, on the back wall of the condenser section.The plate provides the unit model number, the unit serialnumber and the unit parts identification number (PID).The model number identifies the overall unitconfiguration, while the PID number providesinformation on specific optional equipment, factoryprovisioned to allow for field installation of optionalequipment and differences in detailed parts.

1.3 FEATURE DESCRIPTIONS

1.3.1 Control Box

Units are equipped with either an aluminum orcomposite material box, and may be fitted with alockable door.

1.3.2 Temperature Readout

The unit is fitted with suction and discharge temperaturesensors. The sensor readings may be viewed on thecontroller display.

1.3.3 Pressure Readout

The unit is fitted with evaporator and dischargetransducers. The transducer readings may be viewedon the controller display.

1.3.4 Compressor

The unit is fitted with a scroll compressor equipped withsuction and discharge service connections.

1.3.5 Condenser Coil

The unit is fitted with a fourrow condenser coil using7mm tubing.

1.3.6 Evaporator

Evaporator section is equipped with an electronicexpansion valve (EEV).

1.3.7 Evaporator Fan Operation

Units are equipped with threephase evaporator fanmotors. Opening of an evaporator fan internal protectorwill shut down the unit.

1.3.8 Plate Set

Each unit is equipped with a tethered set of wiringschematics and wiring diagram plates. The plate setsare ordered using a sevendigit base part number and atwodigit dash number.

1.4 OPTION DESCRIPTIONS

Various options may be factory or field equipped to thebase unit. These options are described in the followingsubparagraphs.1.4.1 Battery

The refrigeration controller may be fitted with standardreplaceable batteries or a rechargeable battery pack.Rechargeable battery packs may be fitted in thestandard location or in a secure location.

1.4.2 Dehumidification

The unit may be fitted with a humidity sensor. Thissensor allows setting of a humidity set point in thecontroller. In dehumidification mode, the controller willoperate to reduce internal container moisture level.

1.4.3 USDA

The unit may be supplied with fittings for additionaltemperature probes, which allow recording of USDACold Treatment data by the integral DataCORDERfunction of the MicroLink refrigeration controller.1.4.4 Interrogator

Units that use the DataCORDER function are fitted withinterrogator receptacles for connection of equipment todownload the recorded data. Two receptacles may befitted; one is accessible from the front of the containerand the other is mounted inside the container (with theUSDA receptacles).

1.4.5 Remote Monitoring

The unit may be fitted with a remote monitoringreceptacle. This item allows connection of remoteindicators for COOL, DEFROST and IN RANGE.Unless otherwise indicated, the receptacle is mountedat the control box location.

12T340

1.4.6 Quest CCPC

CompressorCycle Perishable Cooling (CCPC) is amethod of temperature control used duringsteadystate perishable cooling that cycles thecompressor on and off according to supply / return airtemperature conditions.

1.4.7 Communications Interface Module

The unit may be fitted with a communications interfacemodule. The communications interface module is aslave module, which allows communication with amaster central monitoring station. The module willrespond to communication and return information overthe main power line. Refer to the ship master systemtechnical manual for further information.

1.4.8 Autotransformer

An autotransformer may be provided to allow operationon 190/230, 3phase, 50/60 Hz power. Theautotransformer raises the supply voltage to thenominal 380/460 volt power required by the base unit.The autotransformer may also be fitted with anindividual circuit breaker for the 230 volt power.

If the unit is equipped with an autotransformer andcommunications module, the autotransformer will befitted with a transformer bridge unit (TBU) to assist incommunications.

1.4.9 Temperature Recorder

The unit may be fitted with an electronic temperaturerecording device.

1.4.10 Gutters

Rain gutters may be fitted over the control box andrecorder section to divert rain away form the controls.The different gutters include standard length boltedgutters, extended length gutters, and riveted gutters.

1.4.11 Handles

The unit may be equipped with handles to facilitateaccess to stacked containers. These fixed handles arelocated on either side of the unit.

1.4.12 Thermometer Port

The unit may be fitted with ports in the front of the framefor insertion of a thermometer to measure supply and/orreturn air temperature. If fitted, the port(s) will require acap and chain.

1.4.13 Water Cooling

The refrigeration system may be fitted with awatercooled condenser. The condenser is constructedusing coppernickel tube for sea water applications.The watercooled condenser is in series with the aircooled condenser and replaces the standard unitreceiver. When operating on the watercooledcondenser, the condenser fan is deactivated by a waterpressure switch or condenser fan switch.

1.4.14 Back Panels

Aluminum back panels may have access doors and/orhinge mounting.

1.4.15 460 Volt Cable

Various power cable and plug designs are available forthe main 460 volt supply. The plug options tailor thecables to each customers requirements.

1.4.16 230 Volt Cable

Units equipped with an autotransformer require anadditional power cable for connection to the 230 voltsource. Various power cable and plug designs areavailable. The plug options tailor the cables to eachcustomers requirements.

1.4.17 Cable Restraint

Various designs are available for storage of the powercables. These options are variations of the compressorsection cable guard.

1.4.18 Upper Air (Fresh Air Make Up)

The unit may be fitted with an upper fresh air makeupassembly. The fresh air makeup assembly is availablewith a vent positioning sensor (VPS) and may also befitted with screens.

1.4.19 Lower Air (Fresh Air Make Up)

The unit may be fitted with a lower fresh air makeupassembly. The fresh air makeup assembly is availablewith a vent positioning sensor (VPS) and may also befitted with screens.

1.4.20 Labels

Safety Instruction and Function Code listing labelsdiffer, depending on the options installed. Labelsavailable with additional languages are listed in the partslist.

1.4.21 Controller

Two replacement controllers are available:

1. Remanufactured Controller is the equivalent of anew OEM controller and is supplied with a 12monthwarranty.

2. Repaired Controller has had previous faults re-paired and upgraded with the latest software.

Note: Repaired controllers are NOT to be used forwarranty repairs; only full OEM Remanufacturedcontrollers are to be used.

Controllers will be factoryequipped with the latestversion of operational software, but will NOT beconfigured for a specific model number and will need tobe configured at the time of installation or sale.

1.4.22 Condenser Grille

Two styles of condenser grilles are available: directbolted grilles and hinged grilles.

1.4.23 Emergency Bypass

The optional Emergency Bypass switch (EB) functionsto bypass the controller in the event of controller failure.

1.4.24 eAutoFresh

The optional eAutoFresh venting system moderates theatmospheric level inside the container unit in responseto cargo respiration.

T-34021

SECTION 2

DESCRIPTION2.1 GENERAL DESCRIPTION

2.1.1 Refrigeration Unit Front SectionThe unit is designed so that the majority of the compo-nents are accessible from the front (see Figure 21).The unit model number, serial number and parts identifi-cation number can be found on the serial plate to the leftof the receiver or watercooled condenser on the backwall of the condenser section.

2.1.2 Fresh Air Makeup VentThe function of the upper or lower makeup air vent is toprovide ventilation for commodities that require fresh aircirculation. A manually operated venting system is loc-ated in the upper left access panel.The optional eAutoFresh vent system is to moderate theatmospheric level in the container in response to cargorespiration. When transporting frozen cargo loads thevent will be closed. The upper left access panel containsthe vent slide and motor assembly. It may be removed toallow entry into the evaporator section where the CO2sensor and drive pack are located.

1

2

9

3

14

5

15

17

10

19

13

16

11

12

67

18

8

4

1. Access Panel (Evap. Fan #1)2. Fork Lift Pockets3. Control Box4. Compressor5. Ambient Sensor (AMBS)6. Economizer 7. Filter Drier 8. Receiver or Water Cooled Condenser9. Unit Serial Number, Model Number and

Parts Identification Number (PID) Plate10. Power Cables and Plug (Location)11. Condenser Fan

12. Autotransformer (Location)13. TransFRESH Communications Connector14. Interrogator Connector (Front left)15. Temperature Recorder16. Lower Fresh Air Makeup Vent Location

(Blank Cover Shown)17. TIR (Transports Internationaux Routiers)

Sealing Provisions Typical All Panels18. Upper Fresh Air Makeup Vent or eAutoFresh

(Automatic Vent) panel19. Access Panel (Evap. Fan #2)

Figure 21 Refrigeration Unit Front Section

22T-340

2.1.3 Evaporator SectionThe evaporator section (Figure 22) contains the returntemperature sensor, humidity sensor, electronic expan-sion valve, dual speed evaporator fans (EM1 and EM2),evaporator coil and heaters, defrost temperature sen-sor, heat termination thermostat and evaporator tem-perature sensors (ETS1 and ETS2).The evaporator fans circulate air through the containerby pulling it in the top of the unit, directing it through theevaporator coil, where it is heated or cooled, anddischarging it at the bottom.

If the unit is equipped with eAutoFresh, system compon-ents are mounted in addition to the standard refrigera-tion unit components. The stepper motor component isinstalled in the vent; the air filter, CO2 sensor, steppermotor drive and CO2 sensing lines are installed on therib of the upper grill.

Most evaporator components are accessible by remov-ing the upper rear panel (as shown in the illustration) orby removing the evaporator fan access panels (seeFigure 21, Items 1 and 19).

21

12

34

5

6

7

8

9

10

17

18

1920

11

13

15

16

14

12

1. Evaporator Fan Motor #1 (EM1)2. Return Recorder Sensor/Temperature Sensor

(RRS/RTS)3. Humidity Sensor (HS)4. Evaporator Fan Motor #2 (EM2)5. Evaporator Coil6. Evaporator Coil Heaters (Underside of Coil)7. Heater Termination Thermostat (HTT)8. Defrost Temperature Sensor (DTS)9. Electronic Expansion Valve (EEV)

10. Evaporator Temperature Sensors (Location) (ETS1 and ETS2)

11. Air Filter12. CO2 Sensor Sensing Line13. CO2 Sensor (COS)14. CO2 Sensor Outlet Line15. Stepper Motor Drive (SD)16. Stepper Motor (AF)17. Interrogator Connector (Rear) (ICR)18. USDA Probe Receptacle PR219. USDA Probe Receptacle PR120. USDA Probe Receptacle PR321. Cargo Probe Receptacle PR4

Figure 22 Evaporator Section

T-34023

2.1.4 Compressor Section

The compressor section includes the compressor,digital unloader valve (DUV), high pressure switch,discharge pressure transducer (DPT), evaporator

pressure transducer (EPT) and the suction pressuretransducer (SPT).

The supply temperature sensor, supply recorder sensorand ambient sensor are located to the left of the com-pressor.

1

16

813

9

5

6

11

3

7

4

10

15

12

2

14

1. Compressor2. Compressor Discharge Temperature Sensor

(CPDS) (Location)3. Discharge Connection4. Suction Connection (Location)5. Compressor Terminal Box6. Oil Drain (Location)7. Economizer Connection

8. Discharge Pressure Transducer (DPT)

9. Suction Pressure Transducer (SPT)10. Digital Unloader Valve (DUV)11. Evaporator Pressure Transducer (EPT)12. Discharge Service Valve13. High Pressure Switch (HPS)14. Warning Label15. Suction Service Valve16. Supply Temperature/Supply Recorder Sensor

Assembly (STS/SRS)

Figure 23 Compressor Section

24T-340

2.1.5 AirCooled Condenser SectionThe aircooled condenser section (Figure 24)consists of the condenser fan, condenser coil, receiver,liquid line service valve, filter drier, fusible plug,economizer, economizer expansion valve, economizer

solenoid valve (ESV), and sight glass/moistureindicator.

The condenser fan pulls air through the bottom of thecoil and discharges it horizontally through the con-denser fan grille.

5

6

1

243

7

8 9 10

11

12

14

15

16

13

1. Grille and Venturi Assembly2. Condenser Fan3. Key4. Condenser Fan Motor5. Condenser Coil6. Condenser Coil Cover7. Receiver8. Sight Glass

9. Filter Drier10. Economizer11. Economizer Solenoid Valve (ESV)12. Economizer Expansion Valve13. Warning Label14. Service Access Valve15. Liquid Level/Moisture Indicator16. Fusible Plug

Figure 24 AirCooled Condenser Section

T-34025

2.1.6 WaterCooled Condenser SectionThe watercooled condenser section (Figure 25)consists of a watercooled condenser, sight glass,rupture disc, filter drier, water couplings, water pressureswitch, economizer, economizer expansion valve,

economizer solenoid valve (ESV), and moisture/liquidindicator.

The watercooled condenser replaces the standard unitreceiver.

1

2 3 4

6

7

5

10 9 81112

1. WaterCooled Condenser2. Rupture Disc3. Moisture/Liquid Indicator4. Filter Drier5. Economizer6. Economizer Solenoid Valve (ESV)

7. Economizer Expansion Valve 8. Coupling (Water In) 9. Liquid Line Service Valve/Connection10. Self Draining Coupling (Water Out) 11. Water Pressure Switch (WP)12. Sight Glass

Figure 25 WaterCooled Condenser Section

26T-340

2.1.7 Control Box Section

The control box (Figure 26) includes: the manualoperation switches, circuit breaker (CB1),compressor, fan and heater contactors, control powertransformer, fuses, key pad, display module, currentsensor module, controller module and thecommunications interface module.

2.1.8 Communications Interface Module

The communications interface module is a slavemodule which allows communication between therefrigeration unit and a ship system master centralmonitoring station. The module will respond tocommunication, and return information over the shipsmain power line. Refer to the master system technicalmanual for further information.

1718 13

32

15 14

1 5 6 7

9

12

8

11

4

16

10

1. Compressor Contactor CH2. Compressor Phase A Contactor PA3. Compressor Phase B Contactor PB4. Heater Contactor HR 5. Display Module6. Communications Interface Module7. Controller/DataCORDER Module (Controller)8. Key Pad9. Remote Monitoring Receptacle

10. StartStop Switch, ST11. Controller Battery Pack (Standard Location)12. Interrogator Connector (Box Location)13. Control Transformer14. High Speed Evaporator Fan Contactor EF15. Low Speed Evaporator Fan Contactor ES16. Condenser Fan Contactor CF17. Circuit Breaker 460V18. Current Sensor Module

Figure 26 Control Box Section

T-34027

2.2 REFRIGERATION SYSTEM DATA

a. Compressor/Motor Assembly

Model Number ZMD26KVETFD272Weight (With Oil) 42.9 kg (95 lb)Approved Oil Uniqema Emkarate RL323MAFOil Charge 1774 ml (60 ounces)

b. Electronic Expansion Valve Superheat (Evaporator)

Verify at 18C(0F) container boxtemperature

4.4 to 6.7C (8 to 12F)

c. Economizer ExpansionValve Superheat

Verify at 18C(0F) container boxtemperature

4.4 to 11.1C (8 to 20F)

d. Heater Termination ThermostatOpens 54 (+/ 3) C = 130 (+/ 5) FCloses 38 (+/ 4) C = 100 (+/ 7) F

e. High Pressure SwitchCutOut 25 (+/ 1.0) kg/cm2 = 350 (+/ 10) psigCutIn 18 (+/ 0.7) kg/cm2 = 250 (+/ 10) psig

WARNINGEXPLOSION HAZARD: Failure to follow this WARNING can result in death, serious personal injuryand / or property damage.Never use air or gas mixtures containing oxygen (O2) for leak testing or operating the product.Charge Only With R134a: Refrigerant must conform to AHRI Standard 700 specification.

f. Refrigerant R134a Conforming to AHRI standard 700specifications.

CAUTIONCharge watercooled condenser or receiver according to nameplatespecifications to ensure optimal unit performance.

g. Refrigerant Charge

WaterCooledCondenser

5.44 kg(12 lbs)

Receiver 4.99 kg(11 lbs)

h. Fusible PlugMelting point 99C = (210F)Torque 6.2 to 6.9 mkg (45 to 50 ftlbs)

i. Rupture DiscBursts at 35 +/ 5% kg/cm2 = (500 +/ 5% psig)Torque 6.2 to 6.9 mkg (45 to 50 ftlbs)

j. Unit Weight Refer to unit model number plate.

k. Water Pressure SwitchCutIn 0.5 +/ 0.2 kg/cm2 (7 +/ 3 psig)Cutout 1.6 +/ 0.4 kg/cm2 (22 +/ 5 psig)

28T-340

2.3 ELECTRICAL DATA

a. Circuit Breaker

CB1 (25 amp) Trips at 29 ampsCB2 (50 amp) Trips at 62.5 ampsCB2 (70 amp) Trips at 87.5 amps

b. CompressorMotor Full Load Amps (FLA) 13 amps @ 460 VAC

c. Condenser FanMotor

380 VAC, Single Phase,50 Hz

460 VAC, Single Phase,60 Hz

Full Load Amps 1.3 amps 1.6 ampsHorsepower 0.43 hp 0.75 hpRotations Per Minute 1425 rpm 1725 rpmVoltage and Frequency 360 460 VAC +/ 2.5 Hz 400 500 VAC +/ 2.5 HzBearing Lubrication Factory lubricated, additional grease not required.Rotation Counterclockwise when viewed from shaft end.

d. Evaporator CoilHeaters

Number of Heaters 6Rating 750 watts +5/10% each @ 230 VACResistance (cold) 66.8 to 77.2 ohms @ 20C (68F)Type Sheath

e. Evaporator FanMotor(s) 380 VAC/3 PH/50 Hz 460 VAC/3 PH/60 Hz

f. Evaporator FanMotor(s)

Full Load AmpsHigh Speed 1.0 1.2

Full Load AmpsLow Speed 0.6 0.6

Nominal HorsepowerHigh Speed 0.49 0.84

Nominal HorsepowerLow Speed 0.06 0.11

Rotations Per MinuteHigh Speed 2850 rpm 3450 rpm

Rotations Per MinuteLow Speed 1425 rpm 1725 rpm

Voltage and Frequency 360 460 VAC +/ 1.25 Hz 400 500 VAC +/ 1.5 HzBearing Lubrication Factory lubricated, additional grease not requiredRotation CW when viewed from shaft end

g. Fuses

Control Circuit 7.5 amps (F3A,F3B)Controller/DataCORDER 5 amps (F1 & F2)Emergency Bypass 10 amps (FEB)

h. Vent PositioningSensor

Electrical Output 0.5 VDC to 4.5 VDC over 90 degree rangeSupply Voltage 5 VDC +/ 10%Supply Current 5 mA (typical)

i. Solenoid ValveCoils (ESV)24 VDC

Nominal Resistance @77F (25C) 7.7 ohms +/ 5%

Maximum Current Draw 0.7 amps

j. DUV Coils12 VDC

Nominal Resistance @77F (20C) 14.8 ohms +/ 5%

Maximum Current Draw 929 mA

k. EEV NominalResistance

Coil Feed to Ground(Gray Wire) 47 ohms

Coil Feed to Coil Feed 95 ohms

T-34029

Section 2.3 ELECTRICAL DATACONTINUED

l. Humidity Sensor

Orange wire PowerRed wire OutputBrown wire GroundInput voltage 5 VDCOutput voltage 0 to 3.3 VDC

Output voltage readings verses relative humidity (RH) percentage:30% 0.99 V50% 1.65 V70% 2.31 V90% 2.97 V

2.4 SAFETY AND PROTECTIVE DEVICESUnit components are protected from damage by safetyand protective devices listed in Table 21. These de-vices monitor the unit operating conditions and open aset of electrical contacts when an unsafe condition oc-curs.

Open safety switch contacts on either or both of devicesIPCP or HPS will shut down the compressor.

Open safety switch contacts on device IPCM will shutdown the condenser fan motor.

The entire refrigeration unit will shut down if one of thefollowing safety devices open: (a) circuit breaker(s); (b)fuse (F3A/F3B, 7.5A); or (c) evaporator fan motor in-ternal protector(s) (IP).

Table 21 Safety and Protective Devices

UNSAFE CONDITION DEVICE DEVICE SETTING

Circuit Breaker (CB1, 25 amp) Manual Reset Trips at 29 amps (460 VAC)

Excessive current draw Circuit Breaker (CB2, 50 amp) Manual Reset Trips at 62.5 amps (230 VAC)

Circuit Breaker (CB2, 70 amp) Manual Reset Trips at 87.5 amps (230 VAC)

Excessive current draw in thecontrol circuit Fuse (F3A & F3B) 7.5 amp rating

Excessive current draw by thecontroller Fuse (F1 & F2) 5 amp rating

Excessive current draw by theEmergency Bypass module Fuse (FEB) 10 amp rating

Excessive condenser fan motor winding temperature Internal Protector (IPCM) Automatic Reset N/A

Excessive compressor motorwinding temperature Internal Protector (IPCP) Automatic Reset N/A

Excessive evaporator fan motor(s) winding temperature Internal Protector(s) (IPEM) Automatic Reset N/A

Abnormal pressures/tempera-tures in the high refrigerantside

Fusible Plug Used on the Receiver

Rupture Disc Used on the WaterCooled Con-denser

99C = (210F)

35 kg/cm2 = (500 psig)

Abnormally high dischargepressure High Pressure Switch (HPS)

Opens at 25 kg/cm2(350 psig)

210T-340

2.5 REFRIGERATION CIRCUIT2.5.1 Standard Operation

Starting at the compressor, (see Figure 27, upperschematic) the suction gas is compressed to a higherpressure and temperature.

The refrigerant gas flows through the discharge line andcontinues into the aircooled condenser. When operat-ing with the aircooled condenser active, air flowingacross the coil fins and tubes cools the gas to saturationtemperature. By removing latent heat, the gas con-denses to a high pressure/high temperature liquid andflows to the receiver, which stores the additional chargenecessary for low temperature operation.

When operating with the watercooled condenser ac-tive (see Figure 27, lower schematic), the refrigerantgas passes through the aircooled condenser and en-ters the watercooled condenser shell. The water flow-ing inside the tubing cools the gas to saturation temper-ature in the same manner as the air passing over theaircooled condenser. The refrigerant condenses onthe outside of the tubes and exits as a high temperatureliquid. The watercooled condenser also acts as a re-ceiver, storing refrigerant for low temperature operation.

The liquid refrigerant continues through the liquid line,the filter drier (which keeps refrigerant clean and dry)and the economizer (not active during standard opera-tion) to the electronic expansion valve.

As the liquid refrigerant passes through the variableorifice of the expansion valve, the pressure drops tosuction pressure. In this process some of the liquidvaporizes to a gas (flash gas), removing heat from theremaining liquid. The liquid exits as a low pressure, lowtemperature, saturated mix. Heat is then absorbed fromthe return air by the balance of the liquid, causing it tovaporize in the evaporator coil. The vapor then flowsthrough the suction tube back to the compressor.

On systems fitted with a water pressure switch, the con-denser fan will be off when there is sufficient pressure toopen the switch. If water pressure drops below theswitch cut out setting, the condenser fan will automatic-ally start.

During the standard mode of operation, the normallyclosed digital unloader valve (DUV) controls the systemrefrigerant flow and capacity by loading and unloadingthe compressor in frequent discrete time intervals. If thesystem capacity has been decreased to the lowest al-lowable capacity with the DUV, the unit will enter a trimheat mode of operation, during which the controller willpulse the evaporator heaters in sequence with the com-pressor digital signal in order to absorb the excess capa-city.

2.5.2 Economized Operation

In the economized mode, (see Figure 28) the frozenand pull down capacity of the unit is increased by sub-cooling the liquid refrigerant entering the electronic ex-pansion valve. Overall efficiency is increased becausethe gas leaving the economizer enters the compressorat a higher pressure, therefore requiring less energy tocompress it to the required condensing conditions.

Liquid refrigerant for use in the economizer circuit is tak-en from the main liquid line as it leaves the filter drier.The flow is activated when the controller energizes theeconomizer solenoid valve (ESV).

The liquid refrigerant flows through the ESV to the ex-pansion valve internal passages, absorbing heat fromthe liquid refrigerant flowing to the electronic expansionvalve. The resultant medium temperature/pressuregas enters the compressor at the economizer port fit-ting.

When the control air temperature falls to 2.0C (3.6F)above set point, the DUV unloads the compressorsscroll and begins to reduce the capacity of the unit. Per-centage of the unit capacity is accessed through codeselect 01 (Cd01). For example, if Cd01 displays 70, it in-dicates that the compressor is operating unloaded withthe DUV engaged 30% of the time.

2.5.3 Electronic Expansion Valve

The microprocessor controls the superheat leaving theevaporator via the electronic expansion valve (EEV),based on inputs from the evaporator pressure trans-ducer (EPT). The microprocessor transmits electronicpulses to the EEV stepper motor, which opens or closesthe valve orifice to maintain the superheat set point.

T-340211

STANDARD OPERATION WITH WATERCOOLED CONDENSER

CONDENSER

DISCHARGE LIQUID SUCTION

COMBOETS1 AND 2

EVAPORATOR

DISCHARGE SERVICE VALVE

SUCTIONSERVICEVALVE

FILTERDRIER

LIQUID LINESERVICEVALVE

ECONOMIZERSOLENOIDVALVE

ECONOMIZERTXV

ELECTRONICEXPANSIONVALVE

DIGITALUNLOADERVALVE

ECONOMIZER

RECEIVER

COMPRESSOR

SIGHTGLASS

LIQUID LEVEL/MOISTUREINDICATOR

STANDARD OPERATION WITH RECEIVER

CONDENSER

ETS1 AND 2EVAPORATOR

DISCHARGE SERVICE VALVE

SUCTIONSERVICEVALVE

FILTERDRIER



ECONOMIZERTXV


DIGITALUNLOADERVALVE

ECONOMIZER

WATERCOOLEDCONDENSER

COMPRESSOR

SIGHTGLASS

MOISTUREINDICATOR

DISCHARGEPRESSURETRANSDUCER

DISCHARGEPRESSURETRANSDUCER

DISCHARGE TEMPERATURE SENSOR

DISCHARGE TEMPERATURE SENSOR

EVAPORATORPRESSURETRANSDUCER

SUCTIONPRESSURETRANSDUCER

ECON.TXV

SENSINGBULB

EVAPORATORPRESSURETRANSDUCER

SUCTIONPRESSURETRANSDUCER

Figure 27 Refrigeration Circuit Schematic Standard Operation

212T-340

LIQUID



ECONOMIZERTXV


ECONOMIZER

RECEIVER

COMPRESSOR

ECONOMIZER PRESSURE

ECON.TXV

SENSINGBULB

Figure 28 Refrigeration Circuit Schematic Economized Operation

31 T-340

SECTION 3MICROPROCESSOR

3.1 TEMPERATURE CONTROLMICROPROCESSOR SYSTEM

The temperature control Micro-Link 3 microprocessorsystem (see Figure 31) consists of a keypad, displaymodule, the control module (controller) andinterconnecting wiring. The controller houses thetemperature control software and the DataCORDERsoftware. The temperature control software functions tooperate the unit components as required to provide thedesired cargo temperature and humidity.

The DataCORDER software functions to record unitoperating parameters and cargo temperatureparameters for future retrieval. Coverage of thetemperature control software begins with paragraph 3.2.Coverage of the DataCORDER software is provided inparagraph 3.8.The keypad and display module serve to provide useraccess and readouts for both of the controller functions,temperature control and DataCORDER. The functionsare accessed by keypad selections and viewed on thedisplay module. The components are designed topermit ease of installation and removal.

TODISPLAY

CONTROL MODULEDISPLAY MODULE

KEYPAD

CONFIGURATIONSOFTWARE

CONFIGURATIONVARIABLE

(CnF##)

TEMPERATURE CONTROL SOFTWARE

ALARMS(AL68)

DATASTORAGEMEMORY

OPERATIONALSOFTWARE

FUNCTION

CODE (dC)

TO DISPLAY

(Scrollback)

Operation/Config.PCMCIA CARD

Data BankPCMCIA CARD

Figure 31 Temperature Control System

32T-340

3.1.1 Keypad

The Keypad (Figure 32) is mounted on the right-handside of the control box. The keypad consists of elevenpush button switches that act as the users interfacewith the controller. Descriptions of the switch functionsare provided in Table 31.

ENTER

BATTERYPOWER

MANUALDEFROST/INTERVAL

CODESELECT

PRETRIP

ALARMLIST

ALT.MODE

RETURNSUPPLY

C

F

Figure 32 Keypad

3.1.2 Display Module

The display module (Figure 33) consists of two 5-digitdisplays and seven indicator lights. The indicator lightsinclude:

1. COOL - White or Blue LED: Energized when the re-frigerant compressor is energized.

2. HEAT - Orange LED: Energized to indicate heateroperation in heat mode, defrost mode, ordehumidification.

3. DEFROST - Orange LED: Energized when the unitis in defrost mode.

4. IN RANGE - Green LED: Energized when the con-trolled temperature probe is within the specified toler-ance of set point.

Table 31 Keypad Function

KEY FUNCTION

CODE SELECT Accesses function codes.

PRE TRIP Displays Pre-trip selection menu.Discontinues Pre-trip in progress.

ALARM LIST Displays alarm list and clears thealarm queue.

MANUALDEFROST /INTERVAL

Displays selected defrost mode.Depress and hold the MANUALDEFROST / INTERVAL key forfive (5) seconds to initiate defrostusing the same logic as if the op-tional manual defrost switch wastoggled on.

ENTER Confirms a selection or saves aselection to the controller.

Arrow Up Change or scroll a selection up.Pre-trip advance or test interrupt.

Arrow Down Change or scroll selection down-ward. Pre-trip repeat backward.

RETURN /SUPPLY

Display non-controlling probe tem-perature (momentary display).

Celsius /

Fahrenheit

Display alternate English/Metricscale (momentary display). Whenset to F, pressure is displayed inpsig and vacuum in /hg. P ap-pears after the value to indicatepsig and i appears for inches ofmercury. When set to C, pressurereadings are in bars. b appearsafter the value to indicate bars.

BATTERYPOWER

Initiate battery backup mode to al-low set point & function code se-lection if AC power is not con-nected.

ALT MODE

This key is pressed to switch thefunctions from temperature soft-ware to the DataCORDER soft-ware. The remaining keys functionthe same as described above ex-cept the readings or changes aremade to the DataCORDER pro-gramming.

NOTEThe controlling probe in perishable range is theSUPPLY air probe and the controlling probe infrozen range is the RETURN air probe.

5. SUPPLY - Yellow LED: Energized when the supplyair probe is used for control. When this LED is illu-minated, the temperature displayed in the AIR TEM-PERATURE display is the reading at the supply airprobe. This LED will flash if dehumidification or hu-midification is enabled.

6. RETURN - Yellow LED: Energized when the returnair probe is used for control. When this LED is illu-minated, the temperature displayed in the AIR TEM-PERATURE display is the reading at the return airprobe.

7. ALARM - Red LED: Energized when an active or aninactive shutdown alarm in the alarm queue.

33 T-340

COOL HEAT DEFROST IN RANGE ALARM SUPPLY RETURN

SETPOINT/Code AIR TEMPERATURE/Data

Figure 33 Display Module3.1.3 Controller

CAUTION

Do not remove wire harnesses from con-troller modules unless you are grounded tothe unit frame with a static safe wrist strap.

CAUTION

Unplug all controller module wire harnessconnectors before performing arc weldingon any part of the container.

CAUTIONDo not attempt to use an ML2i PC card in anML3 equipped unit. The PC cards are physi-cally different and will result in damage tothe controller.

NOTE

Do not attempt to service the controller mod-ules. Breaking the seal will void the warranty.

The Micro-Link 3 controller is a dual module micropro-cessor as shown in Figure 34. It is fitted with testpoints, harness connectors and a software card pro-gramming port.

3.2 CONTROLLER SOFTWARE

The controller software is a custom designed programthat is subdivided into configuration software and opera-tional software. The controller software performs the fol-lowing functions:

a. Control supply or return air temperature to requiredlimits, provide modulated refrigeration operation,economized operation, unloaded operation, electricheat control, and defrost. Defrost is performed toclear buildup of frost and ice to ensure proper air flowacross the coil.

b. Provide default independent readouts of set point andsupply or return air temperatures.

c. Provide ability to read and (if applicable) modify theconfiguration software variables, operating softwareFunction Codes and Alarm Code indications.

d. Provide a Pre-trip step-by-step checkout of refrigera-tion unit performance including: proper componentoperation, electronic and refrigeration control opera-tion, heater operation, probe calibration, pressurelimiting and current limiting settings.

e. Provide battery-powered ability

Documents

Carrier Manual t 340