30S

62-10050

$6.00

OPERATION AND SERVICE MANUAL

TRUCK REFRIGERATION UNITS

30S

Carrier Transicold Division, Carrier Corporation, P Box 4805, Syracuse, N.Y. 13221 U. S. A. .O. Carrier Transicold E.T.O. Boite Postale Nr. 16 Franqueville --- Saint--- Pierre 76520 Boos, FRANCE Carrier Corporation 1998 D Printed in U. S. A. 0798

TABLE OF CONTENTS
SECTION 1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Reference Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigeration System Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.2 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.3 Set-point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.4 Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.5 Functional Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.6 Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.7 Checking The Eprom Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.8 Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 Compressor Pressure Regulating Valve (CPR) on 30s R404A Only . . . . . . . . . . . . 1.9 Hot Gas Solenoid (Two-way) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 Condenser Closing Solenoid (Two-way) (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 Refrigerant Circuit During Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 Refrigerant Circuit During Heat And Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Control and Starting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.1 On Road . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.2 On Standby (Road/Standby Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-1 2-1 2-1 1-1 1-1 1-5 1-5 1-6 1-6 1-7 1-8 1-8 1-8 1-9 1-9 1-9 1-10 1-10 1-11 1-11 1-11 1-11 1-11 1-13

SECTION 3 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Unit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1 Unit Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.2 Description of Maintenance Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Belt Maintenance and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 Belt Tension Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.2 Standby Motor-compressor V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Removing The Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Refrigerant Leak Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 Evacuation and Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i 3-1 3-1 3-1 3-1 3-2 3-2 3-2 3-2 3-3 3-3 3-3 3-3

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3.5.3 Evacuation and Dehydration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 Charging The Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.1 Installing a Complete Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.2 Adding a Partial Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.3 Checking The Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 Replacing The Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 Checking and Replacing Filter--drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 Checking and Replacing High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . 3.9.1 Replacing High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.2 Checking High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10 Checking and Replacing Evaporator Fan Motor Brushes and Commutator . . . . . . 3.11 Evaporator Coil--cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12 Condenser Coil--cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 Hot Gas (Two-way) Solenoid and Condenser Closing Solenoid (Two-way) . . . . . . 3.13.1 Replacing Solenoid Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13.2 Replacing Solenoid Valve Internal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14 Adjusting The Compressor Pressure Regulating Valve (CPR) (Only On R404a) . 3.15 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16 Microprocessor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17 Controller Sensor Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Refrigeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 Unit Will Not Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2 Unit Runs But Has Insufficient Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3 Unit Operates Long or Continuously in Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.4 Unit Will Not Heat or Heating Insufficient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.5 Defrost Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.6 Abnormal Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.7 Abnormal Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.8 Cab Command Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.9 No Evaporator Air Flow or Restricted Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.10 Expansion Valve Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.11 Malfunction Hot Gas (Two-way) Solenoid / Expansion Closure Valve . . . . . . . 4.2 Standby Motor Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 ELECTRICAL SCHEMATIC WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-1 4-1 4-1 4-1 4-1 4-1 4-1 4-1 4-2 4-2 4-2 4-2 4-3 4-3 4-3 3-3 3-4 3-4 3-5 3-5 3-5 3-5 3-5 3-5 3-5 3-6 3-6 3-6 3-6 3-6 3-7 3-7 3-7 3-8 3-8

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LIST OF FIGURES
Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 1-5 Figure 1-6 Figure 1-7 Figure 1-8 Figure 2-1 Top View of 30S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear View Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single-phase Road/Standby Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three-phase Road/Standby Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Microprocessor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heating Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat operating sequence - Standby or road operation Set-point higher than -12_C (+10_F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Layout of V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt Tension Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Pump Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Typical setup for Testing High Pressure Switch 1 and HP2 . . . . . . . . . . . . . . Fan Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hot gas (two-way) solenoid or Condenser closing solenoid (Two-Way) . . Compressor Pressure Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostatic Expansion Valve Bulb and Thermocouple . . . . . . . . . . . . . . . . Superheat Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Wiring Diagram -- Drawing No. 62-60331 . . . . . . . . . . . . . . . . . . . . Electrical Wiring Diagram -- Drawing No. 62-60333 . . . . . . . . . . . . . . . . . . . . Electrical Wiring Diagram -- Drawing No. 62-60327 . . . . . . . . . . . . . . . . . . . . Electrical Wiring Diagram -- Drawing No. 62-60328 . . . . . . . . . . . . . . . . . . . . Single--Phase Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three--Phase Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-2 1-3 1-4 1-8 1-9 1-13 1-14

2-2 3-2 3-2 3-4 3-5 3-6 3-6 3-7 3-8 3-8 5-2 5-3 5-4 5-5 5-6 5-6

Figure 3-1 Figure 3-2 Figure 3-3 Figure 3-4 Figure 3-5 Figure 3-6 Figure 3-7 Figure 3-8 Figure 3-9 Figure 5-1 Figure 5-2 Figure 5-3 Figure 5-4 Figure 5-5 Figure 5-6

LIST OF TABLES
Table 1-1 Table 1-2 Table 2-1 Table 3-1 Table 3-2 Table 3-3 Table 3-4 Table 3-5 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Devices - Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . Management of Condenser, Evaporator Fans and Heat, Defrost Valves . . Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor Resistance (RAS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R-404A Temperature--Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R-134a Temperature-Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-7 2-3 3-1 3-2 3-8 3-9 3-10

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SECTION 1 DESCRIPTION
1.1 INTRODUCTION WARNING Beware of unannounced starting of the fans and V-belts caused by the thermostat and the start/stop cycling of the unit. This manual contains Operating Data, Electrical Data and Service Instructions for the truck refrigeration units listed in Table 1-1. Also Table 1-1 charts some significant differences between these models. The 30S models are multi-piece units designed for truck applications. Two type of drive are available: Road operation (30S only) : - driven by the engine of the vehicle when in operation over-the-road. Road/Standby Version : - driven by the engine of the vehicle when in operation over-the-road and by connecting the unit to the an alternate AC power source. The model/serial nameplate is located inside of the unit on the frame (Figure 1-1). The standard control system is a microprocessor controller (See section 1.7). Once the controller (remote Cab Command within the cab of the truck) is set to the desired temperature, the unit will operate automatically to maintain the desired temperature within very close limits. The control system automatically selects cooling or heating cycles as necessary to maintain the desired temperature. The evaporator assembly consists of an evaporator coil, an expansion valve, one defrost thermostat (termination switch) and an electrical evaporator fan motor, one starting valve and one injection valve on 30S with R404A -- injection valve optional on R134a.

Table 1- - Description -1 Model 30S Refrigerant R134a LB 4 KG 1.8 Road compressor* TM 16 Standby compressor TM 16 Standby Motor 1ph/3ph, 50hz 1.5 kW 1ph/3ph, 60hz 1.5 kW

Model 30S

Refrigerant R404A LB 4 KG 1.8

Road compressor TM 15

Standby compressor TM 15

Standby motor 1ph/3ph, 50hz 1.5 kW 1ph/3ph, 60hz Not available

* In certain cases, road compressors TM 15 and TM 16 cannot be installed in the engine compartments. The SD5H09 compressor can be used in these cases, although performance will be impaired (please see your CARRIER representative for further details).

1-1

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10

2
1. 2. 3. 4. 5. 6. Frame Condenser Compressor (see table 1-1) Standby motor Control box Filter-drier

7. Receiver 8. Nameplate 9. Platform suspended on shock mount 10. Oil separator 11. Transformer

Figure 1-1 - Top View of 30S 1 2 3

4
1. 2. 3. 4. Pressure regulator (CPR) (R404A only) Quench valve (option on R134a) (standard on R404A) Expansion valve Evaporator coil

Figure 1-2 - Rear View Evaporator

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6 5

10
1. 2. 3. 4. 5. 6. Standby clutch fuse Standby fuse Discharge resistor Main + auxiliary contactor Starter relay Filter capacitor

11

12

7. Overload relay 8. Diode 9. Diode bridge 10. Permanent capacitor 11. Starter capacitor 12. Heat sink (diode bridge)

Figure 1-3 - Single-phase Road/Standby Control Box

1-3

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9
1. 2. 3. 4. 5. Standby clutch fuse Standby fuse Discharge resistor Main + auxiliary contactor Filter capacitor 6. 7. 8. 9. Overload relay Diode Diode bridge Heat sink (diode bridge)

Figure 1-4 - Three-phase Road/Standby Control Box

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7 2

8 3

1. 2. 3. 4. 5. 6. 7. 8.

Connector Battery Fuse (F1) C_ or F_ Temperature Selector Microprocessor Road Relay 12 Volt dc Road Connection 12 Volt dc Standby Connection Standby Relay

Figure 1-5. Microprocessor Module

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1.2 COMPRESSOR REFERENCE DATA Model Displacement No. Cylinders Weight Oil Charge Approved Oil 1.3 REFRIGERATION SYSTEM DATA a. Defrost Timer Automatic triggering or at preset intervals : 0, auto, 1 h, 2 h, 3 h, 4 h, 5 h, 6 h b. Defrost Thermostat Opens at : 9 3C (48 5F) Closes at : 3 3C (37 5F) c. HP R134a Pressure Switch (HP1) Cutout at : 24.5 bars (355 psig 10 PSI) Cut-in at : 20 bars (290 psig 10 PSI) HP R404A Pressure Switch (HP1) Cutout at : 32 bars (465 psig 10 PSI) Cut-in at : 25 bars (360 psig 10 PSI) R134a High Pressure Cutout Switch (HP2) Cutout at : 9 bars (130 psig 10 PSI) Cut-in at : 12 bars (175 psig 10 PSI) R404A High Pressure Cutout Switch (HP2) Cutout at : 17 bars (245 psig 10 PSI) Cut-in at : 22 bars (320 psig 10 PSI) SD 5H09 87 cm3 (5.82 in3) 5 5.3 kg 11.68 lbs 200 cm3 6.75 oz. TM 15 147 cm3 (8.99 in3) 6 6.7 kg 14.77 lbs 250 cm3 road 150 cm3 standby TM 16 162 cm3 (9.9 in3) 6 7 kg 15.5 lbs 250 cm3 road 150 cm3 standby York 209 SC 142 cm3 (8.69 in3) 2 6.6 kg 14.5 lbs 355 cm3 12 oz.

Mobil Arctic EAL68 d. Refrigerant charge R134a or R404A See Table 1-1. e. Compressor Pressure Regulating Valve (CPR) R404A only Model 30S 1.8 CPR Settings kg/cm2 psi 261

f. Thermostatic Expansion Valve Superheat Setting for a box temperature of - 17.8C (0F) 4C (7 1F) g. R134a Low Pressure switch Cutout at : -- 0.45 bar (-- 6.5 psig 3 PSI) Cut-in at : + 0.45 bar (+ 6.5 psig 3 PSI) R404A low pressure switch Cutout at : -- 0.2 bar (-- 2.9 psig 3 PSI) Cut-in at : 1 bar (14.5 psig 3 PSI) h. Quench valve Opens at : 127C (260F) Closed at : 105C (221F)

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1.4 ELECTRICAL DATA a. Evaporator Fan Motors Bearing Lubrication: Factory lubricated. Horsepower: 0.14 kW (1/5 hp) Operating Amps: 5 to 7 amps Speed: 2500 rpm (rated) Voltage: 12 vdc b. Standby Motors Bearing Lubrication: Factory additional grease not required.

lubricated

Speed: 1760 rpm - 60 Hz / 1500 rpm - 50 Hz. c. Standby Motor Ratings Operating Voltage 115/1/60 208/1/60 230/1/60 230/3/60 Type of Connection kW 1.5 1.5 1.5 1.5 HP 2 2 2 2 Max Amps 18.3 9.2 8.5 5.9 LRA 132.5 70 60 40 Unit CB Setting 25 11 11 7 Speed 1745 1690 1715 1700

1.5 TORQUE VALUES Assembly Standby compressor platform Standby motor platform Standby compressor platform Standby motor pulley Evaporator fan motor Evaporator fan Condenser - frame Condenser fan blade Mounting Bolts kg-m 5.5 5.5 5.5 4.5 1.8 1.0 1.0 2.5 6 to 8 ft-lb 40 40 40 32 13 7 7 18 44 to 60

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1.6 SAFETY DEVICES System components are protected from damage caused by unsafe operating conditions by automatically shutting down the unit when such conditions occur. This is accomplished by the safety devices listed in Table 1--2. Table 1- Safety Devices - Microprocessor Controller -2. Unsafe Conditions 1. Excessive drop in pressure Safety Device Automatic reset of Low Pressure switch Automatic restart with Device Setting fault cleared YES Cutout : --6.5 psig / - 0.45 bar (R134a) -2.9 psig / 0.2 bar (R404A) YES NO YES/NO NO YES Self-protected opening Self-protected opening See electrical wiring diagram

2. Excessive current draw on Electronic relay all microprocessor outputs 3. Excessive current draw control circuit 4. Excessive current draw Standby motor 5. Excessive current draw evaporator and condenser fan motors 6. Excessive compressor discharge pressure 7. Excessive current draw standby clutch 8. Excessive current draw unit on standby 9. Excessive current draw unit on road 10. Connection error on primary transformer 11. Excessive temperature on standby motor bearing 12. Clutch malfunction - Road (excessive current draw) 13. Clutch malfunction - Road (insufficient current draw) Fuse on electronic board Overload relay except 115/1/60 115/1/60 = Overload switch Electronic relay

Self-protected opening

Automatic reset of High Pressure switch (HP) Fuse F3 Fuse F2 Fuse F1 Fuse F4 PT0 Electronic relay Electronic relay NO NO NO NO YES YES YES

Cutout : 355 psig / 24.5 bar (R134a) 464 psig / 32 bar (R404A) Opens at 5 A (12 V) Opens at 30 A (12 V) Opens at 30 A (12 V) Opens at 4 A Self-protected opening Self-protected opening Opens 311_ F Detection of min. threshold at 750 mA Display on Cab Command until one of the 2 power supplies has been disconnected YES Cutout/cut-in at 10 V

14. Double power supply (road Microprocessor + standby) 15. Low battery voltage Microprocessor

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1.7 CAB COMMAND From his seat, the driver can carry out all the control operations: shut-down, automatic start-up in road or standby mode, adjusting the set-point, defrost. The driver can display the box temperature, and see whether the set-point is being maintained by checking the green indicator. The indicator lights up red in the event of a malfunction. When the battery voltage is too low, a fail-safe system shuts down the unit. Unit restart is automatic and time-delayed if the voltage rises to the normal level (see Figure 1-6.) Cab command

The Carrier Transicold microprocessor controls the following functions: a. Maintains the box temperature at set-point by regulating through cooling, heat, off mode and automatic defrost cycles. b. Permanently displays the return air temperature and on request the set-point temperature. c. Digital display and selection of data. For further details on digital message display, see section 1.7.6. 1.7.2 KEYPAD The keypad comprises six keys enabling the operator to activate various functions, display operating data and to modify operating parameters. Display Readout Standby operation led Road operation led Unit operating data led Green = cycling (left-hand side) Red = malfunction (right-hand side) Keys Manual defrost control key

Figure 1-6. Cab command 1.7.1 INTRODUCTION The microprocessor controller card is located in the control box. The controller comprises the microprocessor, the program memory and the input/output circuits required to interface with the unit. The cab command is mounted remote in the cab. The command comprises the green and red LED readouts, the keypad and keypad interface (see Figure 1-6). WARNING The controller card and cab command must never be repaired by the driver! (see section 3.16). In the event of a malfunction with any of their components please contact your nearest Carrier Transicold distributor so that they can be replaced.

Unit start-up key Unit shut-down key in standby or road mode. On road operation, the unit can be shut down with the ignition key. Unit data and function modification The SET key, together with the + and keys, enables display and modification of unit operating data. The display changes parameter each time the SET key is pressed. Decrement key for selected data

Increment key for selected data

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1.7.3 SET-POINT Modification of the set-point temperature Display of the set-point temperature. Decrements the set-point. Increments the set-point. Validates set-point temperature. Returns to

Return to normal operation of unit After 5 seconds without pressing any key Exit box temperature display menu 1.7.4 DIGITAL DISPLAY The digital display comprises three alphanumeric characters. The default value displayed is the set-point. The microprocessor enables selection of the display in degrees Celsius or Fahrenheit (see photo Road control box). The display also includes settings for defrost operation (dF). 1.7.5 FUNCTIONAL PARAMETERS Modification of defrost parameters

display of the box temperature. It is possible to increase or decrease the set-point by whole numbers until the requisite set-point is displayed. If display stays highlighted, this indicates the set-point displayed has not been validated. The new setting for the set-point is validated by pressing the SET key. Locking the set-point Unit start-up. Access to menu. or or flash The indicators light up depending on whether you are in STANDBY or ROAD mode. Displays maximum set-point 32 to --17F(0 to -27C). Modification of maximum set-point. Validates set-point. Display of thermostat differential temperature. Modification of thermostat differential After accessing the Set-point lock function: Modification of setting if necessary. (3 possibilities : 1/2/3C) Validates modified setting. Evaporator fan on/off at set point After accessing the Thermostat differential setting function: Select ON or OFF. Validate selection. Exit box temperature display menu 62-10050

Display of defrost interval previously selected. Modification of defrost interval. 0: complete deletion of defrost. 0.5 to 0.9: decreases time interval between 2 auto defrost cycles in relation to calculated time (coefficient 1). AUT: automatic defrost optimized by the microprocessor according to the type of cargo transported (variable intervals). 1.1 to 1.5: increases the time interval between 2 automatic defrost cycles in relation to calculated time (coefficient 1). 1 H, 2 H,... 6 H: Forced interval between each defrost expressed in

hours.

Validates modified setting. Returns to display of box temperature.

1-10

1.7.6 ALARM DISPLAY Access to malfunction codes Malfunction management Press SET for 5 seconds: enables access to malfunction codes. Malfunction Codes Description Red LED flashes No malfunction. Unit in operation. Low pressure switch High pressure safety switch Electric motor overload protection on start-up Road operation clutch Standby clutch and contactor Condenser fan control Evaporator fan 1 control Heating option command Defrost valve control Quench valve control Heating valve control High temperature alarm Low temperature alarm Defrost alarm > 45 minutes Setpoint is out of controller temperature range of --20.2_F to 86_F.

These malfunction messages are displayed instead of the temperature. GREEN LIGHT STATUS Green Led flashing 0.5 Hz Green Led flashing 3 Hz Steady green Led SET POINT Steady green Led Green Led flashing 3 Hz Green Led flashing 0.5 Hz Set-point differencial 1, 2, 3C Set-point differencial +4C

Set-point + 4C

A00 A01 A02 A03 A04 A05 A06 A07 A08 A09 A10 A11 A12 A13 A14 A15

Set-point + diffe--rential Hysteresis 1, 2, 3

The red alarm LED flashes at 3 Hz after 15 of high or low alarm. The red LED goes out when the temperature is within the Set-point range differential (steady green LED). Except on versions older than 3.00 (steady red). In the case of defrost, the time of 15 is extended to 60. 1.7.7 CHECKING THE EPROM VERSION Start-up unit. First check for any eventual malfunction codes. Display on-screen the version no. (e.g.: 2.02).

In cases of several simultaneous malfunctions, use the keys to list them.

Display of program version Return to box temperature Evaporator temperature probe Low battery voltage alarm < 10V Twin power supply (Diesel and Standby) Setpoint is lower than programmed minimum setpoint, but within controller range of --20.2_F to 86_F. Programming error on part of operator Revised 3/00 1-11 62-10050

ERR

1.7.8 DEFROST CYCLE Defrost is an independent cycle overriding cooling and heating functions, because it enables the evaporator to be defrosted when necessary. In defrost mode, the microprocessor displays dF on the cab command, which no longer displays the set-point. DEFROST Defrost is fully automatic but can be manually controlled if authorized by the defrost thermostat. The defrost cycles are fully managed by the integrated microprocessor. During the defrost phase, the evaporator fan shuts down. The condenser fan is controlled by the microprocessor. The end of the cycle is controlled by a Klixon thermostat. During the defrost phase, the readout of the cab command indicates dF. a. Defrost Defrost mode is activated by the microprocessor automatically or manually by the operator. The cycle stops when the defrost termination thermostat (DTT) is activated. The defrost interval timer is reset to zero when the defrost cycle is terminated, for whatever reason. b. Defrost termination safety If the defrost cycle does not terminate after 45 minutes, the cycle terminates automatically and displays alarm code A14. c. Modifying defrost parameters Shut-down unit.+ + Display parameters Modify parameters Validate modified setting.

d. Minimum shut-down only on standby The minimum shut-down for the standby motor is 5 minutes. After this minimum shut-down period, the unit restarts when the temperature goes out of the cycling range by 1. 2 or 3C ( 1.8. 3.6 or 5.4F). e. Battery voltage The battery voltage is detected. The correct voltage is 13.4 V at 24C (75F). If the battery voltage drops below 10 V, the unit shuts down and the cab command displays the message bAt.

1.8 COMPRESSOR PRESSURE VALVE (CPR) ON R404A ONLY

REGULATING

This CPR valve is installed on the suction line of the compressor to regulate the amount of suction pressure entering the compressor. The CPR valve is set to limit the maximum suction pressure. For CPR settings refer to section 1.3. The suction pressure is controlled to avoid overloading the electric motor or engine during high box temperature operation. To adjust the CPR valve, refer to section 4.17

1.9 HOT GAS SOLENOID (TWO-WAY) The hot gas solenoid is normally closed (NC) and is only powered in defrost or heat modes. If HP2 is closed, the condenser fan is ON. If HP2 is opened, the condenser fan is OFF.

1.10 CONDENSER CLOSING (TWO-WAY) (OPTION)

SOLENOID

The condenser closing solenoid is normally open (NO). It is powered if the pressure switch for fan cycling is closed. 1.11 REFRIGERANT CIRCUIT DURING COOLING (SEE FIGURE 1-7) When cooling, the unit operates as a vapor compression refrigeration system. The main components of the system are the reciprocating compressor, air-cooled condenser, thermostatic expansion valve, direct expansion evaporator, and hot gas solenoid (two-way). The compressor raises the pressure and temperature of the refrigerant and forces it into the condenser tubes. The condenser fan circulates surrounding air over the outside of the condenser tubes. Heat transfer is thus established from the refrigerant gas (inside the tubes) to the condenser air (flowing over the tubes). The

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condenser tubes have fins designed to improve the transfer of heat. This removal of heat causes the refrigerant to liquefy; liquid refrigerant flows from the condenser to the receiver. The receiver stores the additional charge necessary for low ambient operation and for heating and defrost modes. The refrigerant leaves the receiver and flows through a manual receiver shut-off valve (king valve). The refrigerant then flows through a check valve (optional). The refrigerant then flows through the filter-drier, where an absorbent keeps it dry and clean. The refrigerant then flows though a sight glass with moisture indication through the subcooler. The subcooler occupies a portion of the main condensing coil surface and gives off further heat to the passing air and then towards a thermostatic expansion valve (with external pressure equalizer) which regulates

the flow rate of refrigerant towards the evaporator in order to obtain maximum use of the evaporator heat transfer surface. The evaporator tubes have aluminium fins to increase heat transfer; therefore heat is removed from the air circulated through the evaporator. This cold air is circulated throughout the truck to maintain the cargo at the desired temperature. The transfer of heat from the air to the low temperature liquid refrigerant causes the liquid to vaporize. The steam at low temperature and pressure enters the accumulator and is then drawn out by the compressor. Only on the R404A. The refrigerant then enters the compressor pressure regulating valve (CPR) which regulates refrigerant pressure entering the compressor, where the cycle starts over. The quench valve opens as required to maintain a maximum discharge temperature of 127C (260F).

Liquid line Low pressure line

1. 2. 3. 4. 5. 6. 7. Thermostatic expansion valve Defrost element Liquid sight glass with humidity indicator Hot gas valve (normally closed) Control pressure switch (HP2) Evaporator Standby compressor 8. 9. 10. 11. 12. 13. 14. 15.

Hot gas line Discharge gas line

Filter-drier Road compressor High pressure switch (HP1) Condenser Receiver Discharge check valve section Low pressure switch Injection klixon

Oil return line Cooling Cycle

16. Oil separator 17. Condenser closing valve (option) (normally open) 18. CPR (only on R404A) 19. Check valve (option) 20. Quench valve Option with R134a Standard with R404A

Figure 1-7. Cooling Cycle

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1.12 REFRIGERANT CIRCUIT DURING HEAT AND DEFROST (SEE FIGURE 1-8) When refrigerant vapor 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 that is being compressed. This energy is refereed to as the heat of compression and is used as the source of heat during the heating cycle. Case 1: With condenser closing solenoid option. When the microprocessor activates heating or defrost, the hot gas (two-way) solenoid energizes, and (if HP2 is open) the condenser closing solenoid energizes, closing the port to the condenser and opening a port

which allows heated refrigerant vapor to flow directly to the evaporator coil. Case 2: Without condenser closing solenoid option. When the microprocessor activates heating or defrost, the hot gas solenoid (two-way) energizes, opening a port which allows heated refrigerant vapor to flow directly to the evaporator coil as well as through the condenser. The main difference between heating and defrosting is that, when in heating mode all the evaporator fans continue to run, blowing the air around the heated coils to heat the product. When defrosting, the evaporator fans stop, allowing the heated vapor to defrost any ice build-up there may be.

Liquid line Low pressure line

1. 2. 3. 4. 5. 6. 7. Thermostatic expansion valve Defrost element Liquid sight glass with humidity indicator Hot gas valve (normally closed) Control pressure switch (HP2) Evaporator Standby compressor 8. 9. 10. 11. 12. 13. 14. 15.

Hot gas line Discharge gas line

Filter-drier Road compressor High pressure switch (HP1) Condenser Receiver Discharge check valve section Low pressure switch Klixon injection

Oil return line Heating Cycle

16. Oil separator 17. Condenser closing valve (option) (normally open) 18. CPR (only on R404A) 19. Check valve (option) 20. Quench valve Option with R134a Standard with R404A

Figure 1-8. Heating Cycle

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SECTION 2 OPERATION
2.1 CONTROL AND STARTING UP 2.1.1 ON ROAD Check the belt tension of the compressor drive belts. Start-up and control of box temperature Start the vehicle engine. Press the ON key to start the unit (start-up is time-delayed for 40 seconds). The digital display of the cab command displays the box temperature. Check the temperature set-point is correct by pressing the SET key; the set-point temperature is highlighted on the digital display. Enter a new set-point if necessary (see temperature set-point adjustment). In the event of difficulty on start-up, check that: The control box fuses have not blown. The temperature selected by the cab command has not been affected. Unit shut-down Press the OFF key. Start-up and box temperature control Press the ON key. The digital display of the cab command displays the box temperature. Check the temperature set-point is correct by pressing the SET key; the set-point temperature is highlighted on the digital display. Enter a new set-point if necessary (see temperature set-point adjustment). Unit shut-down Press the key OFF. If you have difficulty in starting up, check: The set-point temperature selected on the cab command has not been reached. The control box fuses have not blown Cooling There are two control ranges, Frozen and Perishable. The frozen range is active with set points at or below -12C (+10F) and the Perishable range is active at set points above -12C (+10F). The controller automatically selects the mode necessary to maintain box temperature at set point. Heating See section 1.12 for a description of the heating cycle. The unit will only heat when the controller is set above -12C (+10F) as the heat relays are electronically locked out with set points at or below -12 (+10F) The microprocessor automatically selects the mode necessary to maintain box temperature at set point. In pulldown the heating modes are as follows (Figure 2.1 and 2.2):

2.1.2 ON STANDBY (ROAD/STANDBY VERSION) VERY IMPORTANT The unit must be shut-down to connect or disconnect the standby supply cable. Before start-up, check: On the power network: Check that the type of current corresponds to the characteristics of the unit (see section 1.8). On the unit : Connect the unit to the power network.

2-1

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INCREASE IN TEMPERATURE

COOL

or +3C (+ 5.4F) or +2C (+ 3.6F) +1C (+1.8F)

UNIT STOPPED

SETPOINT -1_C (-1.8_F) or - 2C (- 3.6F)

HEAT

or - 3C (- 5.4F)

DECREASE IN TEMPERATURE
Figure 2- Thermostat operating sequence - Standby or road operation -1. Set-point higher than -12_C (+10_F)

INCREASE IN TEMPERATURE

COOL

or +3C (+ 5.4F) or +2C (+ 3.6F) +1C (+1.8F) SETPOINT

UNIT STOPPED

DECREASE IN TEMPERATURE
NOTE: The thermostat inhibits heat mode when it is set to a temperature lower than -12C (+ 10F). Figure 2- Thermostat operating sequence - Standby or road operation -2. Set-point lower than -12C (+ 10F) 62-10050 2-2

Defrost See sections 1.11 or 1.12 for a description of heat and defrost cycles. Minimum OFF time (5 minutes): Once the motor has cycled off, it will remain off for the minimum off time. This prevents the motor from rapid cycling due to changes in air temperature. Air temperature in the box change rapidly, but it takes time for the product temperature to change. NOTE When in Continuous Run, perishable range, the unit cycle between cool and heat to maintain box temperature at setpoint. In frozen range the unit will run in cool only. Continuous Run is normally used for perishable products that require constant air flow. Defrost on standby Defrost on standby operates the same way as the defrost on road operation (see section 1.12). Table 2- Management of condenser, evaporator fans and heat, defrost valves -1. (from version 3.01)
EFM evaporator fan ON Cool OFF OFF ON CFM condenser fan OFF ON 3 mn minimum OFF OFF OFF ON
IF HGS2 = OFF + 1mn

Heat standby
OFF OFF OFF OFF ON ON OFF OFF

HGS2 heat valve OFF OFF OFF OFF ON OFF 1 mn mini ON OFF 1 mn mini

HGS1 defrost valve OFF OFF OFF OFF ON ON ON ON

HP2 Pressure switch OPEN CLOSED OPEN CLOSED OPEN CLOSED OPEN CLOSED

Klixon defrost XX XX XX XX XX XX CLOSED CLOSED

Cycling Heating if set-point = or > -12C Defrost

ON if forced by config.

ON ON OFF OFF

OFF ON
IF HGS2 = OFF + 1mn

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SECTION 3 SERVICE
WARNING Beware of V-belt and belt-driven components as the unit may start automatically. Before servicing unit, make sure the Run-Stop (ON/OFF) switch is in the OFF position. Also disconnect the negative battery cable. NOTE To avoid damage to the earths ozone layer, use a refrigerant recovery system whenever removing refrigerant. 3.1 UNIT MAINTENANCE 3.1.1 Unit maintenance schedules Regular servicing is required in order to optimize the service life and reliability of your unit. Service operations are to be carried out according to the following schedule. Table 3-1 Maintenance Schedules
Kilometers Miles Service A Service B Service C Service D 5 000 3 000
J

IMPORTANT Before servicing unit, check that: that the unit (cab command) is OFF. that it is impossible for the unit to automatically start up during maintenance. 3.1.2 Description of maintenance operations Maintenance operations Service A Check the tension of the compressor belt(s). Check that the vehicle engine runs correctly at low speed and that the compressor kit is correctly tightened Check the tightness of bolts and screws and that the unit is correctly fastened onto the box. Service B Clean the condenser and the evaporator. Replace the Road and Standby compressor belt(s). Replace the filter-drier. Check the compressor oil level. Check the operation of the cab command. Check the defrost - Cut-in, - Fan shut-down, - Cut-out, - Defrost water drain. Service C Check the bearings of the belt tension pulleys and bearing of the mechanics kit. Change the spring if there is one. Check the operation of the evaporator and condenser fans. Change the motor brushes. Change the compressor oil. Only use Ester oil (POE) approved by CARRIER. See the technical information sheets for the recommended quantities and types of oil. Service D Change the removable relays and fuses in the control box.

30 000 18 000
J J

60 000 36 000
J J J

90 000 54 000
J J

120 000 72 000

J J J J

150 000 90 000

J J

180 000 108 000

J J J

210 000 126 000

J J

Refrigerant : type R134a or R404A. Road compressor oil type: The road compressors are supplied with CARRIER POLYESTER (POE) oil. The presence of a sticker indicates that the oil-change has been correctly carried out in our CARRIER TRANSICOLD plant. Oils of PAG type are strictly incompatible with the operation of our units, never use an oil other than that approved by CARRIER.

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3.2 BELT MAINTENANCE AND ADJUSTMENT

Beware of components automatically.

WARNING V-belt and as the unit

belt-driven may start

3.2.1 Belt tension gauge It is recommended to use a belt tension gauge (tester) code 07-00203, as shown in Figure 3-2, whenever V-belts are adjusted or replaced. A belt tension gauge provides an accurate and easy method of adjusting belts to their proper tension. Properly adjusted belts give long lasting and efficient service. Too much tension shortens belt and bearing life, and too little tension causes slippage and excessive belt wear. It is also important to keep belts and sheaves free of any foreign material which may cause the belts to slip. The Belt Tension gauge can be used to adjust all belts. The readings which we specify for Carrier Transicold units are applicable only for our belts and application, as the tension is dependent on the size of the belt and distance between sheaves. When using this gauge, it should be placed as close as possible to the midpoint between two sheaves. (See Figure 3-2). When installing a new V-belt the tension should be somewhat higher than specified and readjusted after allowing the unit to run for some time.
Standby motor Compressor

Figure 3-2 Belt Tension Gauge (Code 07-00203) 3.2.2 Standby motor-Compressor V-belt a. Loosen the retaining bolts of the standby motor support plate. b. Replace the V-belt. Position the motor to correct belt tension. Tighten the motor retaining bolts. 3.3 REMOVING THE REFRIGERANT CHARGE NOTE To avoid damage to the earths ozone layer, use a refrigerant recovery system whenever removing refrigerant. a. Pumping the Unit Down To service the filter-drier, expansion valve, quench valve, CPR valve or evaporator coil, pump most of refrigerant into condenser coil and receiver as follows: 1. Open valves two turns (clockwise). Purge gauge line. 2. Close the receiver outlet (king) valve by turning clockwise. Start unit 3. The refrigerant will be trapped between the compressor discharge valve and the receiver service valve.

1. Standby Motor-Compressor V-belt

4. Before opening up any part of the system, a slight positive pressure should be indicated on the pressure gauge. 5. When opening up the refrigerant system, certain parts may frost. Allow the part to warm to ambient temperature before dismantling. This avoids internal condensation. 6. Open the receiver service valve. 7. Leak check connections with a leak detector (see section 3.4). 8. Start the unit in cooling mode and check for non-condensable. 9. Check the refrigerant charge (see section 3.6.3). 3-2

Figure 3-1 Layout of V-belts

Table 3-2 Belt tension (see Figure 3-1) BELTS Standby motor - compressor 62-10050 Tension (daN) 20

NOTE Store the refrigerant charge in an evacuated container if the system must be opened between the compressor discharge valve and receiver. Once the system is OPEN, it must be evacuated and dehydrated (see section 3.5.3). b. Removing the Refrigerant Charge Connect a refrigerant system to the unit to remove refrigerant charge. Refer to instruction provided by the manufacture of the refrigerant recovery system. 3.4 REFRIGERANT LEAK CHECKING Once the recovery system is OPEN and repairs completed, leak check the unit by proceeding as follows: a. The recommended procedure for finding leaks in a system is with a halide torch or electronic leak detector. Testing joints with soapsuds is satisfactory only for locating large leaks. b. If system is without refrigerant, charge system with refrigerant to build up pressure between 2.1 to 3.5 kg/cm2 (30 to 50 psig). Remove refrigerant cylinder and leak check all connections. NOTE Important: only the correct refrigerant cylinder be connected to pressurize the system. Any other gas or vapor will contaminate the system which will require additional purging and evacuation of the high side (discharge) of the system.

3.5.2 Preparation a. Evacuate and dehydrate only after pressure leak test. (Refer to section(see section 3.4). b. Essential tools to properly evacuate and dehydrate any system include a good vacuum pump (5cfm = 8m3H volume displacement, code 07-00176-01) and a good vacuum indicator such as a thermocouple vacuum gauge (vacuum indicator). NOTE Use of a compound gauge is not recommended because of its inherent inaccuracy. c. Keep the ambient temperature above 15.6C (60F) to speed evaporation of moisture. if ambient temperature is lower than 15.6C (60F), ice might form before moisture removal is complete. Heat lamps or alternate sources of heat may be used to raise system temperature. 3.5.3 Evacuation and dehydration procedure a. Remove refrigerant using a refrigerant recovery system. b. The recommended method to evacuate and dehydrate the system is to connect three evacuation hoses to the vacuum pump and refrigeration unit as shown in Figure 3-3 (do not us standard service hoses as they are not suited for evacuation purposes). Also, as shown, connect an evacuation manifold with special evacuation hoses to the vacuum pump, to the electronic vacuum gauge and to the refrigerant recovery system. c. 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. e. Open the vacuum pump and electronic vacuum gauge valves, if they are not already open. Start the vacuum pump. Evacuate unit until the electronic vacuum gauge indicates 2000 microns. Close the electronic vacuum gauge and vacuum pump valves. Shut off the vacuum pump. Wait a few minutes to be sure the vacuum holds. f. Break the vacuum with clean dry refrigerant. Use refrigerant that the unit calls for. Raise system pressure to approximately 2 psig. g. Remove refrigerant using a refrigerant recovery system. h. Repeat steps e to g. i. Evacuate unit to 500 microns. Close off vacuum pump valve and stop pump. Wait five minutes to see if vacuum holds. This checks for residual moisture and/or leaks. j. With a vacuum still in the unit, the refrigerant charge may be drawn into the system from a refrigerant container on weight scales. The correct amount of refrigerant may be added by observing the scales (see section 3.6) 3-3 62-10050

NOTE Important: only the correct refrigerant cylinder be connected to pressurize the system. Any other gas or vapor will contaminate the system which will require additional purging and evacuation of the high side (discharge) of the system. c. Remove refrigerant using a refrigerant recovery system and repair any leaks. Evacuate and dehydrate the unit. (Refer to section 3.5) Charge unit with refrigerant. (Refer to section 3.6) 3.5 EVACUATION AND DEHYDRATION 3.5.1 General Moisture is the deadly enemy of refrigerant systems. The presence of moisture in a refrigeration system can have many undesirable effects. The most common are copper plating, acid sludge formation, freezing-up of metering devices by free water, and formation of acids, resulting in metal corrosion.

1. 2. 3. 4. 5.

Refrigerant Recovery Unit Refrigerant Cylinder Evacuation Manifold Valve Vacuum Pump

6. 7. 8. 9. 10.

Electronic Vacuum Gauge Evaporator Receiver Service Valve Condenser Sight glass

Figure 3-3. Vacuum Pump Connection 3.6 CHARGING THE REFRIGERATION SYSTEM 3.6.1 Installing a complete charge a. Dry the refrigeration circuit and create a high vacuum (see section 3.5). b. Place refrigerant cylinder on scale and connect charging line from cylinder to receiver outlet (king) valve. Purge charging line at outlet (king) valve. Purge charging line at outlet valve. c. Note weight of refrigerant cylinder. d. Open liquid valve on refrigerant cylinder. Open king valve half way and allow the liquid refrigerant to flow into the unit until the correct weight of refrigerant has been added as indicated by scales. (Correct charge will be 62-10050 3-4 e. When refrigerant cylinder weight (scale) indicates that the correct charge has been added, close liquid line valve on cylinder and open the service valve on the receiver. NOTE It is possible that all liquid may not be pulled into the receiver, as outlined in step d above. In this case, vapor charge remaining refrigerant through the suction service valve (see section 3.6.2). found in section 1.2).

3.6.2 Adding a partial charge a. Place refrigerant cylinder on scale and note weight Backseat suction service valve and connect charging line between suction valve port and refrigerant cylinder. b. Run the unit in high speed cool and open suction service valve. c. If necessary partially block the condenser coil to raise the head pressure to 12 bars = 174 psig (R134a) or 22 bars = 319 psig (R404A). NOTE * When charging the refrigeration system with R134a, install a vapor charge. * When charging the refrigeration system with R404A, install a liquid charge. d. Open suction service valve. Close VAPOR valve on refrigerant cylinder, noting weight. e. Start unit and check for non-condensable. 3.6.3 Checking the refrigerant charge a. Start unit in cooling mode. Run approximately ten minutes. Partially block off air flow to condenser coil so discharge pressure rise to 12 bars = 174 psig (R134a) or 22 bars = 319 psig (R404A). The charge is correct if there are no bubbles at the coolant light level (10). 3.7 REPLACING THE COMPRESSOR a. Evacuate the unit. Repeat the steps in section 3.3. b. Installation 1. To install the compressor, reverse the procedure outlined when removing the compressor. Refer to section 1.5 for torque values.

Replacing the filter-drier a. Pump unit down according to section 3.3. Remove the drier mounting clip, then replace the filter-drier. 3.9 CHECKING AND REPLACING PRESSURE CUTOUT SWITCH a. Remove defective switch. b. Install the new switch. 3.9.2 Checking high pressure cutout switch WARNING Do not use a nitrogen cylinder without a pressure regulator. Cylinder pressure is approximately 165 kg/cm2 (2350 psi). Do not use oxygen in or near a refrigerant system as an explosion may occur. (See Figure 3-4). HIGH

3.9.1 Replacing high pressure cutout switch

1. Cylinder Valve and Gauge 2. Pressure Regulator 3. Nitrogen Cylinder 4. Pressure Gauge (0 to 400 psig = 0 to 28 bars) 5. Bleed-Off Valve 6. inch Connection

Figure 3-4. Typical setup for Testing High Pressure Switch 1 and HP2 a. Remove switch as outlined in section 3.9.1. b. Connect ohmmeter or continuity light across switch terminals. Ohmmeter will indicate resistance and continuity light will be lighted if switch is closed (HP1) or open (HP2) after relieving pressure. c. Connect switch to a cylinder of dry nitrogen (see Figure 3-4). d. Set nitrogen pressure regulator higher than cut-out point on switch being tested. Pressure switch cut-in points are shown in sections 1.3. e. Close valve on cylinder and open bleed-off valve. f. Open cylinder valve. Slowly close bleed-off valve and increase pressure until the switch opens. If light is used, light will go out and if an ohmmeter is used, the meter will indicate open. Open pressure on gauge. Slowly open bleed-off valve (to decrease pressure) until switch closes (light will light or ohmmeter will move). 3-5 62-10050

NOTE The replacement compressor is sold without flanges. Pump down the unit, see section 3.5 then charge system, see section 3.6. 3.8 CHECKING AND REPLACING FILTER-DRIER Checking filter-drier Check for any obstruction of the filter-drier by feeling the inlet and outlet connections of the liquid line on the filter cartridge. If the temperature of the discharge connection seems lower than that of the suction connection, replace the filter-drier.

3.10 CHECKING AND REPLACING EVAPORATOR FAN MOTOR BRUSHES AND COMMUTATOR The fan motor commutator and brushes should be checked periodically for cleanliness and wear to maintain proper operation of the fan motors.

detergent and let the solution stand for a few minutes. 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. b. Run unit until defrost mode be initiated to check for proper draining from drain pan. 3.12 CONDENSER COIL-CLEANING Remove all foreign material from the condenser coil by reversing the normal air flow. (Air is pulled in through the front and discharges out the top grille.) 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. 3.13 HOT GAS (TWO-WAY) SOLENOID AND CONDENSER CLOSING SOLENOID (TWO-WAY) 3.13.1Replacing solenoid coil It is not necessary to pump the unit down to replace the coil (see Figure 3-6). a. Remove coil snap cap, voltage plate and coil assembly. Disconnect leads and remove coil junction box if necessary. b. Verify coil type, voltage and frequency. This information appears on the coil voltage plate and the coil housing. c. Place new coil over enclosing tube and then install voltage plate and snap cap. CAUTION Do not damage or over tighten the enclosing tube assembly. Also make sure all parts are placed on the enclosing tube in proper sequence to avoid premature coil burn-out. 1 2 3 4
1. Snap Cap 2. Voltage Plate 3. Coil Assembly 4. Enclosing Tube 5. Plunger Assembly 6. Valve Body Assembly

2 1
1. Brush Cap 2. Brush

Figure 3-5. Fan Motor Brushes To check brushes proceed as follows: a. With unit off and battery disconnected, remove brush cap (item 1; 2 per motor). See Figure 3-5. b. Remove brushes (item 2; 2 per motor) and check the length of the brush. If the length is less than 1/4 inch (6 mm) the brushes should be replaced (after checking collector). c. Blow out the brush holder with low pressure air to remove any carbon dust in the holder. This dust could prevent a good contact between the brushes and collector. d. Remove the back cover of the motor and inspect the collector. If the collector is heavily grooved, polish it using fine sandpaper; do not use emery cloth. Wipe out any accumulation of greasy material using a clean rag dampened with solvent. Reassemble the motor; install new brushes and replace cap. 3.11 EVAPORATOR COIL-CLEANING The use of recycled cardboard cartons is increasing. The recycled cardboard cartons create much more fiber dust during transport than new cartons. The fiber dust and particles are drawn into the evaporator where they lodge between the evaporator fins. If the coil is not cleaned on a regular basis, sometimes a 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 an the evaporator coil on a regular basis, not only to remove cardboard dust, but to remove any grease 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. Spray coil with a mild detergent solution such as any good commercial-grade automatic dish washer 62-10050 3-6

6 Figure 3-6. Hot gas (two-way) solenoid or Condenser closing solenoid (Two-Way)

3.13.2 Replacing solenoid valve internal parts If the hot gas solenoid is to be replaced, or if a service operation is scheduled on the internal components of the valve, the refrigerant must be evacuated. a. Remove and store the refrigerant charge in an evacuated container (see section 3.3). b. Remove coil snap cap, voltage cover and coil assembly. Remove the valve body head. c. Check for foreign material in valve body. d. Check for damaged plunger and O-ring. If O-ring is to be replaced, always put refrigerant oil on O-rings before installing. e. Tighten enclosing tube. If the valve has been removed from the circuit, check for eventual leaks. f. Install coil assembly, voltage cover and snap cap. g. Evacuate and dehydrate the circuit. h. Install a complete refrigerant charge. i. Start unit and check operation.

e. When the setting has been adjusted, tighten the jam nut securely against the setting screw (item 3). This will prevent any movement of the setting screw due to vibrations in the unit. Replace the cap. 3.15 THERMOSTATIC EXPANSION VALVE The thermal expansion valve is an automatic device which maintains constant superheat of the refrigerant gas leaving the evaporator regardless of suction pressure. The valve functions are: (a) automatic response of refrigerant flow to match the evaporator load and (b) prevention of liquid refrigerant entering the compressor. Unless the valve is defective, it requires no maintenance. a. Replacing expansion valve 1. Pump down the unit by closing the receiver service valve (see section 3.3.a). 2. Remove insulation from expansion valve bulb and then remove bulb from suction line. 3. Loosen flare nut and disconnect equalizer line from expansion valve. 4. The thermal bulb is located below the center of the suction line (See Figure 3-8). This area must be clean to ensure positive bulb contact. Strap thermal bulb to suction line and insulate both. 5. Braze the equalizer tubes to expansion valve. 6. Evacuate by placing vacuum pump on suction service valve. 7. Open receiver service valve and then check refrigerant level (see section 3.6.3). 8. Check superheat (see section 1.3). b. Measuring Superheat

3.14 ADJUSTING THE COMPRESSOR PRESSURE REGULATING VALVE (CPR) (ONLY ON R404A) The CPR valve is factory pre-set and should not need adjustment. If it is necessary to adjust the valve for any reason, proceed with the following outline: When adjusting the CPR valve, the unit must be running in the high speed heat or defrost. This will ensure a suction pressure above the proper CPR setting. 1 2 3

NOTE The expansion valve and bulb location are shown in Figure 1.4. 1. Remove insulation from expansion valve bulb and suction line. 2. Loosen one TXV bulb clamp and make sure area under clamp (above TXV bulb) is clean. 3. 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 3-8. 4. Connect an accurate gauge to the port on the suction service valve. 5. Run unit until stabilized at -17.8C = 0F (box temperature). 6. From the temperature/pressure chart, determine the saturation temperature corresponding to the evaporator outlet pressure. 3-7 62-10050

1. Cap

2. Jam Nut

3. Setting Screw

Figure 3-7. Compressor Pressure Regulating Valve To adjust the CPR valve, proceed as follows: a. Install a low-pressure gauge. b. Remove cap (item 1) from CPR valve. c. With an 8 mm Allen wrench, loosen the jam nut (Figure 3-7, item 2). d. Using the 8 mm Allen wrench, adjust the setting screw. To raise the suction pressure turn the setting screw (item 3) clockwise; to lower the suction pressure, turn the setting screw counterclockwise. Refer to section 1.3 for CPR valve setting.

3.16 MICROPROCESSOR Although there is less danger of electrical static discharge ESD damage in the outdoor environment, where the processor is likely to be handled, proper board handling techniques should always be stressed. Boards should always be handled by their edges, in much the same way one would handle a photograph. This not only precludes the possibility of ESD damage, but also lowers the possibility of physical damage to the electronic components. Although the microprocessor boards are fairly rugged when assembled, they are more fragile when separated and should always be handled carefully. When welding is required on the unit frame, or on the front area of the trailer, ALL wiring to the microprocessor MUST be disconnected. When welding is performed on other areas of the trailer, the welder ground connection MUST be in close proximity to the area being welded. It is also a good practice to remove both battery cables before wedding on either the unit frame or the truck to prevent possible damage to other components such as the alternator and voltage regulator. 3.17 CONTROLLER SENSOR CHECKOUT An accurate ohmmeter must be used to check resistance values shown in Table 3-3. 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 3-3. At least one lead from the sensor (RAS) 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 0_C (32_F) or a calibrated temperature tester. Table 3-3. Sensor Resistance (RAS) Temperature RAS Resistance In Ohms _F _C --67 --55 490 --58 --50 515 --40 --40 567 --22 --30 624 --4 --20 684 14 --10 747 32 0 816 50 10 886 68 20 961 77 25 1000 86 30 1040 104 40 1122 122 50 1209 3-8

1. Suction Line (end view) 2. TXV Bulb Clamp 3. Nut and Bolt (clamp) 4. Thermocouple 5. TXV Bulb

Figure 3-8. Thermostatic Expansion Valve Bulb and Thermocouple 7. Note the temperature of the suction gas at the expansion valve bulb. 8. Subtract the saturation temperature determined in Step 7 from the average temperature measured in Step 6. The difference is the superheat of the suction gas. (see section 1.3.f) c. Adjusting Superheat The thermostatic expansion valve used in this application is externally adjustable. The valve is preset at the factory and should not be adjusted unnecessarily. If necessary to adjust the superheat, proceed as follows: 1. Remove the seal cap to gain access to the superheat adjusting stem (see Figure 3-9). 2. Turn the adjusting stem clockwise to compress the valve spring which will decrease refrigerant flow through the valve, increasing superheat. Turn the adjusting stem counterclockwise to decompress the valve spring which will increase refrigerant flow through the valve, decreasing superheat. 3. When the unit has stabilized operation for at least 20 minutes, recheck superheat setting. 4. If superheat setting is correct, replace stem cap, remove gauge and thermocouple. Insulate bulb and suction line.

Decrease flow

Increase flow

Figure 3-9. Superheat Adjustment 62-10050

Table 3-4. R-404A Temperature-Pressure Chart Temperature _F _C --40 --40 --35 --37 --30 --34 --25 --32 --20 --29 --18 --28 --16 --27 --14 --26 --12 --24 --10 --23 --8 --22 --6 --21 --4 --20 --2 --19 0 --18 2 --17 4 --16 6 --14 8 --13 10 --12 12 --11 14 --10 16 --9 18 --8 20 --7 22 --6 24 --4 26 --3 28 --2 30 --1 Psig 4.5 7.1 9.9 12.9 16.3 17.7 19.2 20.7 22.3 23.9 25.6 27.3 29.1 30.9 32.8 34.8 36.8 38.9 41.1 43.3 45.6 48.0 50.4 52.9 55.5 58.1 60.9 63.7 66.5 69.5 Pressure Kg/cm2 0.32 0.50 0.70 0.91 1.15 1.24 1.35 1.46 1.57 1.68 1.80 1.92 2.05 2.17 2.31 2.45 2.59 2.73 2.89 3.04 3.21 3.37 3.54 3.72 3.90 4.08 4.28 4.48 4.68 4.89 Bar 0.31 0.49 0.68 0.89 1.12 1.22 1.32 1.43 1.54 1.65 1.77 1.88 2.01 2.13 2.26 2.40 2.54 2.68 2.83 2.99 3.14 3.31 3.47 3.65 3.83 4.01 4.20 4.39 4.59 4.79 Temperature _F _C 32 0 34 1 36 2 38 3 40 4 42 6 44 7 46 8 48 9 50 10 55 13 60 16 65 18 70 21 75 24 80 27 85 29 90 32 95 35 100 38 105 41 110 43 115 46 120 49 125 52 130 54 135 57 140 60 145 63 150 66 Psig 72.5 75.6 78.8 82.1 85.5 89.0 92.5 96.2 99.9 103.7 115.4 126.1 137.4 149.4 162.1 175.5 189.6 204.5 220.2 236.8 254.2 272.4 291.6 311.8 332.9 355.0 378.1 402.3 427.6 454.0 Pressure Kg/cm2 5.10 5.32 5.54 5.77 6.01 6.26 6.50 6.76 7.02 7.29 8.11 8.87 9.66 10.50 11.40 12.34 13.33 14.38 15.48 16.65 17.87 19.15 20.50 21.92 23.41 24.96 26.58 28.28 30.06 31.92 Bar 5.00 5.21 5.43 5.66 5.90 6.14 6.38 6.63 6.89 7.15 7.96 8.69 9.47 10.30 11.18 12.10 13.07 14.10 15.18 16.33 17.53 18.78 20.11 21.50 22.95 24.48 26.07 27.74 29.48 31.30

3-9

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Table 3-5. R-134a Temperature-Pressure Chart BOLD FIGURES = Inches Mercury Vacuum (cm Hg VAC) LIGHT FIGURES = psig (kg/cm2) PRESSURE TEMPERATURE 2 Psig Kg/cm Bar _F _C Psig 14.6 37.08 -.49 30 --1 26.1 12.3 31.25 -.42 32 0 27.8 9.7 24.64 -.33 34 1 29.6 6.7 17.00 -.23 36 2 31.3 3.5 8.89 -.12 38 3 33.2 2.1 5.33 -.07 40 4 35.1 0.6 1.52 -.02 45 7 40.1 0.4 .03 .03 50 10 45.5 1.2 .08 .08 55 13 51.2 2.0 .14 .14 60 16 57.4 2.9 .20 .20 65 18 64.1 3.7 .26 .26 70 21 71.1 4.6 .32 .32 75 24 78.7 5.6 .39 .39 80 27 86.7 6.5 .46 .45 85 29 95.3 7.6 .53 .52 90 32 104.3 8.6 .60 .59 95 35 114.0 9.7 .68 .67 100 38 124.2 10.8 .76 .74 105 41 135.0 12.0 .84 .83 110 43 146.4 13.2 .93 .91 115 46 158.4 14.5 1.02 1.00 120 49 171.2 15.8 1.11 1.09 125 52 184.6 17.1 1.20 1.18 130 54 198.7 18.5 1.30 1.28 135 57 213.6 19.9 1.40 1.37 140 60 229.2 21.4 1.50 1.48 145 63 245.6 22.9 1.61 1.58 150 66 262.9 24.5 1.72 1.69 155 68 281.1

TEMPERATURE _F _C --40 --40 --35 --37 --30 --34 --25 --32 --20 --29 --18 --28 --16 --27 --14 --26 --12 --24 --10 --23 --8 --22 --6 --21 --4 --20 --2 --19 --0 --18 2 --17 4 --16 6 --14 8 --13 10 --12 12 --11 14 --10 16 --9 18 --8 20 --7 22 --6 24 --4 26 --3 28 --2

PRESSURE Kg/cm2 1.84 1.95 2.08 2.20 2.33 2.47 2.82 3.30 3.60 4.04 4.51 5.00 5.53 6.10 6.70 7.33 8.01 8.73 9.49 10.29 11.14 12.04 12.98 13.97 15.02 16.11 17.27 18.48 19.76

Bar 1.80 1.92 2.04 2.16 2.29 2.42 2.76 3.14 3.53 3.96 4.42 4.90 5.43 5.98 6.57 7.19 7.86 8.56 9.31 10.09 10.92 11.80 12.73 13.70 14.73 15.80 16.93 18.13 19.37

62-10050

3-10

SECTION 4 TROUBLESHOOTING
CAUTION Under no circumstances should anyone attempt to service the microprocessor (see section 3.16). Should a problem develop with the microprocessor, contact your nearest Carrier Transicold dealer for replacement. INDICATION/TROUBLE 4.1 REFRIGERATION 4.1.1 UNIT WILL NOT COOL Compressor malfunction Refrigeration system Compressor drive defective Compressor defective Defrost cycle has not terminated Abnormal pressure Hot gas (two-way) solenoid malfunction 3.2.1 3.7 1.7.8 3.3 3.13 POSSIBLE CAUSES REFERENCE SECTION

4.1.2 UNIT RUNS BUT HAS INSUFFICIENT COOLING Compressor Refrigeration system Compressor valves defective Abnormal pressure Expansion valve malfunction No or restricted evaporator airflow 3.6.3 3.15 3.10

4.1.3 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING Box Hot Load Defective box insulation or air leak Refrigeration system Compressor Abnormal pressure Temperature controller malfunction Defective Insufficient pull down time Correct 3.6.3

4.1.4 UNIT WILL NOT HEAT OR HEATING INSUFFICIENT Refrigeration Abnormal pressure Temperature controller malfunction Hot gas (two-way) solenoid malfunction Compressor drive defective Compressor defective 3.6.3 3.13 3.2.1 3.7

Compressor

4.1.5 DEFROST MALFUNCTION Automatic defrost will not initiate Defrost thermostats (DTT) open or defective Hot gas valve Electronic card malfunction Microprocessor defective Defrost thermostats (DTT) open or defective Hot gas (two-way) solenoid malfunction Wet load Defrost settings set to low. Defrost thermostats (DTT) shorted closed Replace Check operation Check defrost parameters Replace Replace 3.13 Check defrost parameters Replace

Manual defrost will not initiate Defrost cycle initiates but does not defrost Frequent defrost Does not terminate or cycles on defrost

4-1

62-10050

INDICATION/TROUBLE

POSSIBLE CAUSES

REFERENCE SECTION

4.1.6 ABNORMAL PRESSURE 4.1.6.1 Cooling High discharge pressure Low discharge pressure High suction pressure Low suction pressure Condenser coil dirty Non-condensibles or refrigerant overcharge Compressor valves(s) worn or broken Hot gas (two-way) solenoid malfunction Compressor valves(s) worn or broken Hot gas (two-way) solenoid malfunction Suction service 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 Compressor valves defective Hot gas (two-way) solenoid malfunction Open Check

Check

Suction and discharge pressures tend to equalize when unit is operating 4.1.6.2 Heating High discharge pressure

Overcharged system Condenser fan of HP2 pressure switch defective Non-condensibles in system Condenser fan defective Compressor valve(s) worn or broken Hot Gas -two-way valve malfunction Refrigerant shortage Compressor pressure regulating valve malfunction

Check Check

Low discharge pressure Low suction pressure

4.1.7 Abnormal Noise Compressor Loose mounting bolts Worn bearings Worn or broken valves Liquid slugging Insufficient oil Loose shroud Bearings defective Bent shaft Check Check Check

Condenser or evaporator fan

4.1.8 Cab Command Malfunction Cab Command non-operational Sensor defective Microprocessor malfunction Microprocessor/Cab command cable

Change

4.1.9 No Evaporator Air Flow or Restricted Air Flow Evaporator coil blocked No or partial evaporator air flow Frost on coil or dirty Fan motor(s) malfunction Evaporator fan loose or defective Evaporator fan rotating backwards Evaporator air flow blocked in trailer (box) Fan motor(s) malfunction 4-2 Check Check Check

62-10050

INDICATION/TROUBLE

POSSIBLE CAUSES

REFERENCE SECTION

4.1.10Expansion valve malfunction Low suction pressure with high superheat Low refrigerant charge External equalizer line plugged Ice formation at valve seat Wax, oil or dirt plugging valve or orifice Broken capillary Power assembly failure or partial Loss of element/bulb charge Superheat setting too high

Clean Replace Replace

Low superheat and liquids lugging Superheat setting too low in compressor External equalizer line plugged Pin and seat of expansion valve eroded or held open by foreign material Fluctuating suction pressure High superheat Improper bulb location or installation Low superheat setting Expansion valve setting

Open

Adjust

4.1.11 Malfunction Hot gas (two-way) solenoid / expansion closure valve Valve does not function properly No power to valve Improper wiring or loose connections 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 tube Foreign material lodged under seat Defective seat Check Check

Valve shifts but refrigerant continues to flow

4.2 STANDBY MOTOR MALFUNCTION Standby motor fails to start Motor contactor defective Motor Overload open Improper power supply Malfunction displayed on Cab Command 5-minute timer on standby Motor Overload open High amperage draw Replace Check/ replace motor Check Check

Standby motor starts, then stops

4-3

62-10050

SECTION 5 ELECTRICAL SCHEMATIC WIRING DIAGRAMS

5.1 INTRODUCTION This section contains Electrical Schematic Wiring Diagrams covering the Models listed in Table 1-1. The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein. WARNING Beware of unannounced starting of the fans and V-belts caused by the thermostat and the start/stop cycling of the unit. CAUTION Under no circumstances should anyone attempt to repair the microprocessor! (see section 3.16) Should a problem develop with these components, contact your nearest Carrier Transicold dealer for replacement. CAUTION Under no circumstances should a technician electrically probe the processor at any point, other than the connector terminals where the harness attaches. Microprocessor components operate at different voltage levels and at extremely low current levels. Improper use of voltmeters, jumper wires, continuity testers, etc. could permanently damage the processor. CAUTION Most electronic components are susceptible to damage caused by electrical static discharge (ESD). In certain case, 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.

5-1

62-10050

U1 Z1 PTO = 0 Ohms

U2 (Mean) = 2.2 Ohms Z2 (Auxiliary) = 4.7 Ohms

Figure 5- Single-5. -Phase Connector

U1 V1 W1 PTO = 0 Ohms

U2 = 6.6 Ohms V2 = 6.6Ohms W2 = 6.6Ohms

Figure 5- Three-6. -Phase Connector 5--2