Carrier Operation & Service 69nt20 - 284

Models
69NT20-284
69NT40-461
69NT40-464
T-252-05 $6.00
OPERATION AND
SERVICE MANUAL
CONTAINER REFRIGERATION UNIT
MODELS
69NT20-284
69NT40-461
69NT40-464
Carrier Transicold Division, Carrier Corporation, P.O. Box 4805, Syracuse, N.Y. 13221
Carrier Corporation 1993 D Printed in U. S. A. 0393
TABLE OF CONTENTS
Section Page
1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 Refrigeration System Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.4 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.5 Safety Override Thermostat (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.6 Voltage Switch And Power Transformer (Optional) . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.7 Humidistat (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.8 Fresh Air Makeup Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.9 Digital Temperature Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.10 Safety And Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.11 Refrigeration Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.12 Water-Cooled Condenser And Water Pressure Switch (Optional) . . . . . . . . . . . . 1-11
1.13 Remote Monitoring Receptacle And Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.14 Suction Solenoid Valve (Model 69NT40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.15 Frost Formation On Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.16 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Pre-Trip Inspection (Before Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Starting And Stopping Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 After Starting Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4 Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4.1 Cooling --- Controller Set Below ---10_C (+14_F) . . . . . . . . . . . . . . . . 2-2
2.4.2 Controller Set Above ---10_C (+14_F) . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4.3 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Unit Will Not Start Or Starts Then Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Unit Runs But Has Insufficient Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 Unit Operates Long Or Continuously In Cooling . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.4 Unit Will Not Heat Or Has Insufficient Heating . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.5 Unit Will Not Terminate Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.6 Unit Will Not Defrost Properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.7 Abnormal Pressures (Cooling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.8 Abnormal Noise Or Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.9 Temperature Controller Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.10 No Evaporator Air Flow Or Restricted Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.11 Expansion Valve Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.12 Water-Cooled Condenser Or Water Pressure Switch Malfunction . . . . . . . . . . . 3-4
3.13 Step-Up Power Transformer Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
i
TABLE OF CONTENTS (CONTINUED)
Section Page
4 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Removing The Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Refrigerant Leak Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Evacuation And Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.4 Adding Or Checking The Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4.1 Checking The Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4.2 Adding Refrigerant To System (Full Charge) . . . . . . . . . . . . . . . . . . . . 4-2
4.4.3 Adding Refrigerant To System (Partial Charge) . . . . . . . . . . . . . . . . . . 4-2
4.5 Replacing The Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.6 Compressor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.7 Compressor Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.8 Checking The Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.9 Checking Or Replacing Moisture-Liquid Indicator . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.10 Checking Or Replacing The Filter-Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.11 Checking Or Replacing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.11.1 Replacing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.11.2 Checking High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.12 Servicing Quench Solenoid Valve (QV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.13 Replacing The Evaporator Coil And Heater Assembly . . . . . . . . . . . . . . . . . . . . . 4-10
4.14 Replacing The Evaporator Fan And Motor Assembly . . . . . . . . . . . . . . . . . . . . . . 4-10
4.15 Servicing The Evaporator Coil Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.16 Checking Calibration Of The Defrost Air Switch . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.17 Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.18 Condenser Fan And Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.19 Recording Thermometer (Partlow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.20 Recording Thermometer (Saginomiya) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.21 Recording Thermometer (Fuji Kiki) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.22 Rust Prevention And Maintenance Of Painted Surfaces . . . . . . . . . . . . . . . . . . . . 4-14
4.23 Servicing The Water-Cooled Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.24 Checkout Procedure For Optional Power Transformer . . . . . . . . . . . . . . . . . . . . . 4-16
4.25 Servicing The Modulating Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.26 Controller Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.26.1 Controller Pre-Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.26.2 Temperature Control Board Checkout Procedure With TCSM . . . . . 4-18
4.26.3 Replacing The Unit Main Control Board . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.26.4 Printed Circuit Board Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . 4-19
4.26.5 Temperature Set Station Checkout Procedure . . . . . . . . . . . . . . . . . . . 4-19
4.26.6 Temperature Controller Sensor Checkout Procedure . . . . . . . . . . . . . 4-20
4.26.7 Replacing Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.27 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.28 Evaporator Fan Motor Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.29 Humidistat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
5 ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS . . . . . . . . . . . . . . . . . . 5-1

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
ii
LIST OF ILLUSTRATIONS
Figure Page
1-1 Refrigeration Unit --- Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-2 Refrigeration Unit --- Rear (Panels Removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-3 Water-Cooled Condenser/Receiver Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-4 Control Box And Controller (Units With Two-Speed Evaporator Motors) . . . . 1-6
1-5 Control Box And Controller (Units With One-Speed Evaporator Motors) . . . . 1-7
1-6 Refrigeration Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1-7 Frost Pattern On Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1-8 Current Control Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1-9 Controller Set Point Below ---10_C (+14_F) (Return Air Control) . . . . . . . . . . . 1-16
1-10 Controller Set Point Above ---10_C (+14_F) (Supply Air Control) . . . . . . . . . . . 1-16
2-1 Cooling --- Within 2_C (3.6_F) Of Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2-2 Heating --- Within 2_C (3.6_F) Of Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-3 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
4-1 Vacuum Pump Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2 Compressor --- Model 06DR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-3 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-4 Exploded View Of Valve Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-5 Bottom Plate Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-6 Vane Oil Pump And Bearing Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-7 Gear Oil Pump And Bearing Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-8 Motor End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-9 Crankshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-10 Removing Equalizing Tube And Lock Screw Assembly . . . . . . . . . . . . . . . . . . . . . 4-6
4-11 Terminal Mounting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-12 Suction Valve And Positioning Springs In Place . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-13 Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-14 Typical Setup For Testing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-15 Evaporator Fan Locating Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4-16 Defrost Air Switch Test Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4-17 Partlow Recording Thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-18 Saginomiya Recording Thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4-19 Fuji Kiki Recording Thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4-20 Water-Cooled Condenser Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4-21 Modulating Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-22 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-23 Temperature Set Station And Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-24 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-25 Sensor And Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-26 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4-27 Humidistat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
iii
LIST OF ILLUSTRATIONS (CONTINUED)
Figure Page
5-1 Electrical Wiring Schematic (Model 69NT20-284) . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2 Electrical Wiring Diagram (Model 69NT20-284) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-3 Electrical Wiring Schematic (Model 69NT40-464) . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-4 Electrical Wiring Diagram (Model 69NT40-464) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-5 Electrical Wiring Schematic (Model 69NT40-464-1) . . . . . . . . . . . . . . . . . . . . . . . 5-10
5-6 Electrical Wiring Diagram (Model 69NT40-464-1) . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-9 Electrical Wiring Schematic (Model 69NT40-464-8)
(Units with S/N 90105284 thru 90105383) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-10 Electrical Wiring Diagram (Model 69NT40-464-8)
(Units with S/N 90105284 thru 90105383) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5-11 Electrical Wiring Schematic (Model 69NT40-464-8) (Units starting with S/N 90105384) 5-22
5-12 Electrical Wiring Diagram (Model 69NT40-464-8) (Units starting with S/N 90105384) 5-24
5-15 Electrical Wiring Schematic (Model 69NT20-284-1 & -284-2) . . . . . . . . . . . . . . . 5-30
5-16 Electrical Wiring Diagram (Model 69NT20-284-1 & -284-2) . . . . . . . . . . . . . . . . 5-32
5-23 Electrical Wiring Schematic (Model 69NT40-464-7 & 69NT40-461-7, -8) . . . . . 5-46
5-24 Electrical Wiring Diagram (Model 69NT40-464-7 & 69NT40-461-7, -8) . . . . . . . 5-48
5-25 Electrical Wiring Schematic (Model 69NT40-464-9, -15) . . . . . . . . . . . . . . . . . . . 5-50
5-26 Electrical Wiring Diagram (Model 69NT40-464-9, -15) . . . . . . . . . . . . . . . . . . . . 5-52
5-27 Electrical Wiring Schematic (Model 69NT40-464-10) . . . . . . . . . . . . . . . . . . . . . . 5-54
5-28 Electrical Wiring Diagram (Model 69NT40-464-10) . . . . . . . . . . . . . . . . . . . . . . . 5-56
5-29 Electrical Wiring Schematic (Model 69NT40-464-12) . . . . . . . . . . . . . . . . . . . . . . 5-58
5-30 Electrical Wiring Diagram (Model 69NT40-464-12) . . . . . . . . . . . . . . . . . . . . . . . 5-60
LIST OF TABLES
Table Page
1-1 Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Compressor Model Number Significance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-3 Safety And Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-4 Current Limiting Switch Positions And Amperages . . . . . . . . . . . . . . . . . . . . . . . 1-13
2-1 Electrical Control Positions --- Above ---10_C (+14_F) . . . . . . . . . . . . . . . . . . . . 2-6

2-2 Electrical Control Positions --- Below ---10_C (+14_F) . . . . . . . . . . . . . . . . . . . . . 2-7
4-1 Partlow Bulb Temperature --- Resistance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-2 Selector Settings And Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-3 Recommended Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-4 Wear Limits For Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4-5 Compressor Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4-6 Sensor D.C. Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4-7 Temperature-Pressure Chart --- R-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
iv
SECTION 1
DESCRIPTION
1.1 INTRODUCTION Operating control power is provided by a single
phase transformer which steps down the AC power
This manual contains Operating Data, Electrical supply voltage to 24 vac, 1 phase control power.
Data and Service Instructions for the refrigeration units
listed in Table 1-1. Also Table 1-1 charts most of the The temperature controller is a solid state controller.
significant differences between these models. (Refer to section 1.16) Once the temperature controller
is set at desired container temperature, the unit will
The unit, of lightweight aluminum frame
operate automatically to maintain the desired
construction, is an all electric, one piece self-contained
temperature within very close limits. The control system
cooling and heating refrigeration unit. The unit is
automatically selects cooling, holding or heating as
designed to fit in the front of a container and to serve as
necessary to maintain the desired temperature within the
the container front wall. Fork lift pockets are provided
container.
for installation and removal of the unit.
The unit is complete with a charge of Refrigerant-12 The units are equipped with a Partlow dual Simpson
(These units can be converted to Refrigerant-22. The probe recorder or a Fuji Kiki or Saginomiya
electrical schematic has an R-22 option for CDV, CHT, battery-driven recorder.
UV and UVT, these parts can be added to convert the Also, these units are equipped with a digital
unit to R-22), compressor lubricating oil, mode indicating temperature display (switchable for _C or _F). Refer to
lights, temperature controller and is ready for operation section 1.9.
upon installation.
Some units are dual voltage units designed to WARNING
operate on 190/230 or 380/460 vac, 3 phase, 50-60 hertz Beware of unannounced starting of the
power. (Refer to Table 1-1 and section 1.6) Other units evaporator and condenser fans. Do not open
are designed to operate on 380/460 vac, 3 phase 50/60 condenser fan grille before turning power OFF
hertz power. and disconnecting power plug.
Table 1-1. Model Chart
REFRIGER-
UNIT WEIGHT ANT
MODELS 12
LB KG LB KG
69NT20-284 1330 620 9.0 4.1 X --- --- X X --- ---

69NT20-284-1 1170 531 9.0 4.1 --- --- --- --- --- --- ---
69NT20-284-2 1160 526 9.0 4.1 --- --- --- --- --- --- ---
69NT20-284-3 1285 583 12.3 5.6 --- X --- --- --- X ---
69NT40-461-7 1260 571 12.3 5.6 --- --- X --- --- X C
69NT40-461-8 1260 572 12.3 5.6 --- --- X --- --- X ---
69NT40-464 1200 545 8.8 4.0 --- A --- --- --- X ---
69NT40-464-1 1210 560 8.8 4.0 --- A --- --- X X ---
69NT40-464-2 1200 545 8.8 4.0 --- A --- --- --- X ---
69NT40-464-3 1470 667 12.0 4.4 X X --- X X --- ---
69NT40-464-4 1250 567 8.8 3.9 X --- --- X X --- ---
69NT40-464-5 1230 558 8.8 4.0 --- A --- --- --- X ---
69NT40-464-7 1260 572 12.3 5.58 --- --- X --- --- X C
69NT40-464-8 1200 545 8.8 4.0 --- A --- --- --- X ---
69NT40-464-9 1240 562 8.8 4.0 --- A --- --- --- X C
69NT40-464-10 1230 558 12.3 5.6 --- --- X --- --- --- ---
69NT40-464-12 1200 545 8.8 4.0 --- A --- --- --- --- ---
69NT40-464-15 1230 558 8.8 4.0 --- A --- --- --- X ---
A --- Provision for water-cooled condenser. If water-cooled condenser is added, refrigerant charge will change.
B --- Provision for step-up power transformer.
C --- Provision for heat exchanger.
X --- Designates item provided.
1-1
1.2 GENERAL DESCRIPTION
a. Compressor Section operation, air is pulled in the bottom of the coil and
NOTE discharges horizontally through the center of the unit.
Check the compressor Serial/Model Number Some units are equipped with an optional
plate for CFM displacement, refer to Table 1-2. water-cooled condenser (condenser/receiver) and a
water pressure switch. This switch is located on the water
The compressor section includes the compressor inlet line.
(with high pressure switch), power cable storage c. Evaporator Section
compartment, and an optional power transformer,
located to the left of the compressor. The evaporator section contains the recorder bulb,
controller return air sensor (RTS), thermostatic
This section also contains the modulating solenoid expansion valve, evaporator fan motors and fans (2),
valve, suction solenoid valve (69NT40), quench valve, evaporator coil and heaters, drain pan and heaters,
moisture-liquid indicator, manual liquid line valve, defrost and heat termination switches, humidistat
filter-drier, pressure relief valves, an optional receiver, (optional), safety override thermostat (optional), and the
and the optional water-cooled condenser/receiver. suction solenoid thermostat (located on the fan deck,
The supply air temperature sensor (STS) is located at model 69NT40 only).
the right of the compressor. The evaporator fans circulate air throughout the
container by pulling air in the top of the refrigeration unit
Table 1-2. Compressor Model Number and directing the air through the evaporator coil where it
Significance Chart is either heated or cooled, and then discharged out the
bottom of the refrigeration unit into the container.
06DR2379CC1970
The evaporator coil heaters and the thermostatic
1st, 2nd & 3rd DIGIT expansion valve are accessible by removing the front,
lower access panel. The safety override thermostat may
06D Hermetic Reciprocal
be serviced by removing the rear, middle, panel. The
defrost termination switch is located on the far side of the
4th DIGIT coil and may be serviced by removing the rear, middle,
R Reefer panel or by removing the front, upper access panel and
reaching through the left hand evaporator fan venturi
AFTER POWER IS TURNED OFF AND POWER
6th & 7th DIGIT VOLUME PLUG DISCONNECTED.
28 28CFM
d. Control Box
37 37CFM
The control box and door include the indicator lights,
41 41CFM manual switches, temperature selector, circuit
breaker(s), relays, transformers (current limiting and
b. Condenser Section control) and fuses (6 amp for control and 3 amp for
The condensing section consists of a condenser fan controller). (See Figure 1-4 or Figure 1-5) Also, located
motor, condenser fan, and an air-cooled condenser coil. above the temperature selector is the defrost interval
When the unit is operating with air-cooled condenser selector.
1-2
1 19
2
18
3
17
16
5
6
15
7
14
8
9 10 11 12 13
1. Access Panel (Evaporator Fan Motor #2) 11. High Pressure Switch
2. Access Panel (Heater Location) 12. Compressor
3. TIR Locking Devices 13. Remote Monitoring Receptacle (RM)
4. Recording Thermometer 14. Manual Defrost Switch
5. Make-Up Air Cover 15. Start-Stop Switch
6. Unit Serial/Model No. Plate --- Location 16. Condenser Fan and Motor
7. Power Cables and Plug 17. Fork Lift Pockets
8. Power Transformer --- Location 18. Thermostatic Expansion Valve --- Location
9. Discharge Service Valve 19. Access Panel (Evaporator Fan Motor #1)
10. Compressor Sight Glass
Figure 1-1. Refrigeration Unit --- Front
1-3
1 2 3 4 5 6 7 8
13 12 11 10 9
1. Evaporator Fan Motor #1 8. Return Air Temperature Sensor

2. Humidistat --- Location (Optional) 9. Evaporator Coil Heaters
3. Air Pressure Switch 10. Defrost Termination Thermostat
4. Suction Solenoid Thermostat --- Location 11. Heater Termination Thermostat
(69NT40) 12. Drain Pan Heater
5. Evaporator Coil 13. Safety Override Thermostat --- Location
6. Evaporator Fan Motor #2 (Optional)
7. Recording Thermometer Bulb
Figure 1-2. Refrigeration Unit --- Rear (Panels Removed)
1-4
14
13
12 11 10
7
9
1 2 3 4 5
SIDE VIEW
1. Suction Service Valve 8. Moisture-Liquid Indicator

2. Supply Air Temperature Sensor 9. Liquid Line and Charging Valve
3. Water-Cooled Condenser/Receiver 10. Suction Solenoid Valve (69NT40)
4. Sight Glass 11. Modulating Solenoid Valve
5. Water Pressure Switch --- Location 12. High Side Pressure Relief Valve
6. Filter-Drier 13. Low Side Pressure Relief Valve
7. Quench Valve (Solenoid) or 14. Receiver
Quench Valve (Thermostatic Expansion)
Figure 1-3. Water-Cooled Condenser/Receiver Section
1-5
1 2 3 4 5 6 7 8 9 10 11 12 13
14
15
16
4
6
0
26
17
27
25 24 23 22 21 20 19 18
UNITS WITH TWO-SPEED EVAPORATOR MOTORS
1. Power Supply and In-Range Board 15. Evaporator Fan Motor Relay --- Low Speed
2. Timing and Current Control Board 16. Voltage Switch
3. Temperature Control Board 17. Circuit Breaker (230v)
4. Fuse Location (3A) 18. Circuit Breaker (460v)
5. Temperature Simulator Switch 19. Control Fuse (6A)
6. Defrost Interval Selector 20. Control Transformer
7. Set Temperature Display Switch 21. Current Limiting Transformer --- Location
8. Time Delay Override Switch 22. Digital Temperature Display
9. Temperature Selector 23. Humidistat Control Switch (Optional)
10. Condenser Fan Motor Relay 24. Scale Selector Switch
11. Hour Meter (Optional) 25. Relay (24 vac w/12 vdc coil)
12. Heat Relay 26. Main Control Board
13. Compressor Contactor 27. Contol Relays (CR & KR) (Optional)
14. Evaporator Fan Motor Relay --- High Speed
Figure 1-4. Control Box and Controller (Units with Two-Speed Evaporator Motors)
1-6
1 2 3 4 5 6 7 8 9 10 11 12 13
14
23 15
22 21 20 19 18 17 16
UNITS WITH ONE-SPEED EVAPORATOR MOTORS
1. Power Supply and In-Range Board 13. Compressor Contactor

2. Timing and Current Control Board 14. Voltage Switch
3. Temperature Control Board 15. Circuit Breaker (230v)
4. Fuse Location (3A) 16. Circuit Breaker (460v)
5. Temperature Simulator Switch 17. Control Fuse (6A)
6. Defrost Interval Selector 18. Control Transformer --- Location
7. Time Delay Override Switch 19. Current Limiting Transformer
8. Set Temperature Display Switch 20. Digital Temperature Display
9. Temperature Selector 21. Scale Selector Switch
10. Condenser Fan Motor Relay 22. Relay (24 vac w/12 vdc coil)
11. Evaporator Fan Motor Relay 23. Main Control Board
12. Heat Relay
Figure 1-5. Control Box and Controller (Units with One-Speed Evaporator Motors)
1-7
1.3 REFRIGERATION SYSTEM DATA p. Suction Solenoid Thermostat (69NT40)
a. Compressor --- Motor Assembly Closes at: ---12.2 1.7_C (10 3_F)
No. of Cylinders: 6 Opens at: ---6.7 3.3_C (20 6_F)
Model: 06DR 1.4 ELECTRICAL DATA
Weight (Dry): 132 kg (290 lb)
a. Circuit Breaker(s)
b. Approved Compressor Oil
CB-1 Trips at: 24.2 Amps
Petroleum Specialties Inc. --- Cryol 150
CB-2 Trips at: 50.0 Amps
Witco --- Suniso 3GS
Texaco --- Capella WF32 b. Compressor Motor
c. Compressor Oil Charge Full Load Amps (FLA) (Model 69NT40): 17.6 Amps
@ 460 vac (with current limiting switch in position B)
4.0 liters (8.5 U.S. Pints)
c. Condenser Fan Motor
d. Compressor Oil Sight Glass
Bearing Lubrication: Factory lubricated, additional
Oil level should be between 1/4 to 1/2 grease not required.
of the sight glass with the compressor in operation. Full Load Amps: 2.0/4.0 FLA
e. Defrost Air Pressure Swich Nominal Horsepower: 0.43/0.75 hp
Rotation: CCW when viewed from shaft end.
Initiates at: 20.3 1.8 mm WG Speed: 1425/1725
(0.80 .07 inch) Voltage: 190/380/208/230/460 vac/1ph/50/60 hz
f. Defrost Timer d. Drain Pan Heaters
Initiates Defrost: Refer to paragraph 1.16.m. Number of Heaters: 1
g. Defrost Termination Thermostat Rating: 750 watts +5 /---10 % at 460 Vac
Resistance (cold): 22.7 5% ohms nominal
Opens: 23.9 ( 3)_C = 75 ( 5)_F Type: Sheath
Closes: 15.6 ( 3)_C = 60 ( 5)_F
e. Evaporator Coil Heaters
h. Expansion Valve Superheat
Number of Heaters: 4
Setting at 0_C (32_F) container box temperature: 4.4 Rating: 750 watts each at 230 +5 /---10 volts
to 5.5_C (8 to 10_F) Resistance(cold)@20_C(68_F)Ambient:66.8 to
i. Heater Termination Thermostat 77.2 ohms
Type: Sheath
Opens: 54 ( 3)_C = 130 ( 5)_F
Closes: 38 ( 3)_C = 100 ( 5)_F f. Evaporator Fan Motor(s)
j. High Pressure Switch Bearing Lubrication: Factory lubricated, additional
grease not required.
28 or 37 CFM Compressor:
Cutout: 21 ( 0.7) kg/cm@ = 295 ( 10) psig Full Load Amps:
Cut-In: 13 ( 0.7) kg/cm@ = 190 ( 10) psig High Speed: 2.0/2.3 Amps
41 CFM Compressor: Low Speed: 0.4/0.6 Amps
Cutout: 25 ( 0.7) kg/cm@ = 350 ( 10) psig Single Speed Motor: 2.01/4.0
Cut-In: 18 ( 0.7) kg/cm@ = 250 ( 10) psig Nominal Horsepower:
k. Refrigeration Charge High Speed: 0.58/1.0 hp
Low Speed: 0.07/0.12 hp
Refer to Table 1-1 Single Speed Motor: 0.58/1.0 hp
l. Refrigerant Pressure Relief Valves Rotation:
Low Side Valve: Evaporator Fan Motor #1 (See Figure 1-2): CW when
Opens: 18.63 kg/cm@ (265 psig) viewed from shaft end/CCW when viewed from end
opposite shaft end.
High Side Valve: Evaporator Fan Motor #2 (See Figure 1-2): CCW
Opens: 34.10 kg/cm@ (485 psig) when viewed from shaft end/CW when viewed from end
m. Refrigerant Operating Level (after 20 minutes opposite shaft end.
operation with unit in cooling) Speed: 2850/3450 rpm
Refer to section 4.4
Voltage: 380/460 vac/1 ph/50/60 hz
n. Unit Weight
g. Fuses
Refer to Table 1-1 Control Circuit:
o. Water Pressure Switch Amps: 6 amp
Cut-In: 0.5 0.2 kg/cm@ (7 3 psig) Unit Control Board:
Cutout: 1.6 0.4 kg/cm@ (22 5 psig) Amps: 3 amp
1-8
1.5 SAFETY OVERRIDE THERMOSTAT The humidistat (Figure 1-2) is factory set at 70%
(OPTIONAL) relative humidity (R.H.) and is designed to operate when
transporting a chill load (controller set above ---10_C
This thermostat is fixed at ---3.9_C (25_F) to provide (14_F) and is locked out when the controller is set below
a low temperature limit on the evaporator supply air ---10_C (TU contacts T35 to T37 are open).
(discharge air) when transporting perishable
commodities. a. The humidistat will be in operation if:
When the temperature controller is set below ---10_C 1. Supply air is in-range (in-range light illuminated).
(14_F), the safety override thermostat is bypassed as
relay TU is de-energized and contacts T36 to T35 are 2. Humidistat control switch in the ON position.
closed, refer to section 5. 3. Controller is set above ---10_C (14_F).
For thermostat location see Figure 1-2.
4. Container relative humidity reaches the 70%
1.6 VOLTAGE SWITCH AND POWER R.H. setting of humidistat.
TRANSFORMER (OPTIONAL)
The above energizes the humidistat circuit as relay
WARNING IRS contacts T24 to T23, TU relay contacts T35 to T37,
Do not attempt to remove power plug(s) before HCS contacts 1-2, and HC contacts 1-3 close to energize
turning OFF start-stop switch (ST), unit circuit the heaters and heat light.
breaker(S) and external power source. Make sure
b. For testing purposes:
the power plugs are clean and dry before
connecting to any power receptacle. WARNING
Beware of rotating evaporator fan when
a. Step-Up Power Transformer
conducting following test.
The transformer is located under the condenser coil
(left-hand side of unit) and the purpose of this 1. Remove the front evaporator fan motor #1
transformer is to provide 380 vac/3 ph/50 hz power when access panel (see Figure 1-1). The humidistat is located
the 190/230 vac power cable (black) is connected to a 190 behind this panel.
vac power supply or to provide 460 vac/3 ph/60 hz when
the 190/230 vac power cable (black) is connected to a 230 2. Move the controller set pointer within 2_C
vac power supply. (3.6_F) of container supply air temperature.
WARNING 3. Move the humidistat control switch to ON
Do not attempt to remove power plug before position (position 1).
turning OFF voltage switch (VS), start-stop
4. Turn the humidistat control knob until heaters
switch (ST), unit circuit breakers (CB-1 And are energized (heat light ON) and then reset control to
CB-2), and external power source. 70% R.H. Replace access panel and lockwire.
b. To Place Unit on 190/230 vac Power Supply 1.8 FRESH AIR MAKEUP VENT
1. Make sure voltage switch (VS) is in the OFF
position. Make sure start-stop switch (ST, on control The purpose of the vent is to provide ventilation for
panel) and circuit breakers CB-2 is in position O commodities that require fresh air circulation and must
(OFF). (See Figure 1-4 or Figure 1-5) be closed when transporting frozen foods.
2. Connect 190/230 vac power cable plug (black 69NT40 FRESH AIR MAKEUP
cable). Place voltage switch (VS) in the 230 v position. ZERO EXTERNAL STATIC 50HZ
Place circuit breaker (CB-2) in position 1. Close and T-BAR
secure control box door and then place the start-stop 240 1-!/2
switch (ST) in position 1.
210 T-BAR
c. To Place Unit on 380/460 vac Power Supply 2-%/8
180 T-BAR
1. Make sure voltage switch (VS) is in the OFF 3
position. Make sure start-stop switch (ST, on control
panel) and circuit breaker (CB-1) is in position O. AIR 150
FLOW
(OFF). (CMH) 120
2. Connect 380/460 vac power cable plug (yellow
cable). Place voltage switch (VS) in the 460 v position. 90
Place circuit breaker (CB-1) in position 1. Close and
60
secure control box door and then place the start-stop
switch (ST) in position 1. 30
1.7 HUMIDISTAT (OPTIONAL)
0
NOTE 0
10 20 30 40 50 60 70 80 90 100
The supply air must be in-range or humidistat PERCENT OPEN
For 60HZ operation multiply curves by 1.2
circuit will not energize.
1-9
Table 1-3. Safety and Protective Devices
UNSAFE CONDITIONS SAFETY DEVICES DEVICE SETTING
1. Excessive current draw 1. Circuit Breaker (CB-1) --- 1. Trips at 24.2 amps
Manual Reset (460 vac)
1. Circuit Breaker (CB-2) --- 1. Trips at 50 amps
Manual Reset (230 vac)
2. Excessive current draw on control circuit 2. Fuse 2. Opens at 6 amps
3. Excessive condenser fan motor 3. Internal Protection (IP-CM) --- 3. N/A
winding temperature Automatic Reset
4. Excessive compressor motor winding 4. Internal Protector (IP-CP) --- 4. N/A
temperature Automatic Reset
5. Excessive evaporator fan motor(s) 5. Internal Protector(s) (IP-EM) --- 5. N/A
winding temperature Automatic Reset
6. Abnormally low refrigerant temperature 6. Low Side Pressure 6. Opens at 18.63 kg/cm@
Relief Valve (265 psig)
7. Abnormally high refrigerant temperature 7. High Side Pressure 7. Opens at 34.10 kg/cm@
Relief Valve (485 psig)
8. Abnormally high discharge pressure 8. High Pressure Switch --- 28 or 8. Opens at 21 0.7 kg/cm@
37 CFM (295 10 psig)
8. High Pressure Switch --- 41 CFM 8. Opens at 25 0.7 kg/cm@
(350 10 psig)
9. Solid state circuitry high voltage surge 9. Fuse (F1) 9. Opens at 3 amps
10. Excessive power transformer winding 10. Over Temperature Sensor --- 10. Opens at 178 5_C
temperature Automatic Reset (350 10_F)
Closes at 150 7_C
(300 12_F)
11. Return air temperature below ---3.9_C 11. Safety override temperature 11. Opens to stop the unit
(25_F) Set points above ---10_C = 14_F
a. Full Open or Closed Positions Display will read in degrees centigrade (_C) with the
switch in the up position.
Maximum air flow is achieved by loosening the wing
nuts and moving the cover to the maximum open position
With perishable cargo (set points above ---10_C =
(100% position). The closed position is 0% air flow
14_F) the digital temperature display and recording
position.
thermometer may not agree as the recorder bulb is
The operator may also adjust the opening to increase sensing the return air temperature and the digital
or decrease the air flow volume to meet the required air temperature display will indicate supply air temperature.
flow.
b. Air Sampling for Carbon Dioxide (CO2) Level With a frozen load (set points below ---10_C = 14_F),
the recording thermometer and the digital temperature
Loosen wing nuts and move cover until the arrow on both indicate return air temperature and should be in
the cover is aligned with the atmosphere sampling port close agreement.
label. Tighten wing nuts and attach 3/8 tube to the
sampling tube. 1.10 SAFETY AND PROTECTIVE DEVICES
If the internal atmosphere content has reached an
unacceptable level, the operator may adjust the cover System components are protected from damage by
opening to meet the required air flow volume to ventilate safety and protective devices listed in Table 1-3. These
the container. devices monitor the system operating conditions and
1.9 DIGITAL TEMPERATURE DISPLAY open a set of electrical contacts when an unsafe condition
occurs.
The digital temperature display receives signals from
the controller and normally displays temperature at the Open safety switch contacts of one or more of the
active controller probe (return air temperature sensor following devices IP-CM, IP-CP, HPS, or IP-Trans (Auto)
RTS or supply air temperature sensor STS). will shut down the compressor. The condenser fan motor
will stop if contacts IP-CM, IP-CP, or IP-Trans (Auto)
Depressing the set display switch (SDS, momentary open.
contact) will display the controller set point temperature
while depressed.
The entire refrigeration system will shut down if one
Display is selectable in celsius or fahrenheit. Placing of the following safety devices open: (a) Circuit
the scale selector switch in the down position causes the Breaker(s) or; (b) Fuse (6A) or; (c) Evaporator Fan
temperature to be displayed in degrees fahrenheit (_F). Motor Internal Protector(s) --- (IP-EM).
1-10
1.11 REFRIGERATION CIRCUIT The liquid refrigerant continues through a liquid line
Starting at the compressor (see Figure 1-6), the shutoff valve, filter-drier (which keeps refrigerant clean
suction gas is compressed to a higher temperature and and dry), a moisture-liquid indicator and then to the
pressure. thermostatic expansion valve. As the liquid refrigerant
passes through the orifice of the expansion valve some of
it vaporizes into a gas (flash gas). Heat is absorbed from
15 the evaporator air by the balance of the liquid causing it
to vaporize in the evaporator coil. The vapor then flows
3 16 13 through the suction line to the compressor.
The thermostatic expansion valve bulb on the suction
14 line near the evaporator coil outlet, controls the valve,
maintaining a relatively constant superheat at the coil
12 outlet regardless of load conditions except at abnormally
8 high container temperatures such as during pulldown
2 17 10
9 (valve at maximum operating pressure condition).
1.12 WATER-COOLED CONDENSER AND
11 WATER PRESSURE SWITCH
(OPTIONAL)
4
18 The water-cooled condenser is used when heating
19 5 6 7 the surrounding air is objectionable such as in a ships
1 hold and cooling water is available.
The water-cooled condenser is of the shell and coil
1. Suction Service Valve type with circulating water through the cupro-nickel coil.
2. Discharge Service Valve The refrigerant vapor is admitted to the shell side and is
3. Air-Cooled Condenser condensed on the outer surface of the coil.
4. Water-Cooled Condenser or Receiver
5. Sight Glass For operation of the refrigeration unit with the water-cooled
6. Water Outlet condenser, do the following:
7. Water Inlet a. Connect water supply line to inlet side of
8. Pressure Relief Valve (High Side) condenser and discharge line to outlet side of condenser.
9. Pressure Relief Valve (Low Side)
10. Liquid Line Valve b. Maintain a flow rate of 11 to 26 litres (3 to 7 U.S.
11. Filter-Drier gallons) per minute. The water pressure switch will open
12. Moisture-Liquid Indicator to de-energize the condenser fan relay. The condenser
13. Expansion Valve fan motor will stop and will remain stopped until the
14. External Equalizer Line water pressure switch closes.
15. Expansion Valve Bulb The refrigeration unit operating with the
16. Evaporator water-cooled condenser will perform as outlined in
17. Suction Solenoid Valve (69NT40) section 2.4 except that the condenser fan motor is
18. Modulating Solenoid Valve stopped in all modes.
19. Quench Valve (Solenoid or Thermostatic)
To shift to air-cooled condenser operation, do the following:
Figure 1-6. Refrigeration Circuit
Disconnect the water supply and the discharge line to
When operating with the air-cooled condenser, the the water-cooled condenser. The refrigeration unit will
gas flows through the discharge service valve into the shift to air-cooled condenser operation when the water
air-cooled condenser. Air flowing across the coil fins and pressure switch closes. (Refer to paragraph 1.3.o.)
tubes cools the gas to saturation temperature. By
removing latent heat, the gas condenses to a hot liquid
and then flows to the water-cooled condenser/receiver
which stores the additional charge necessary for low
temperature operation.
When operating with the water-cooled condenser, the
hot gas flows through the air-cooled condenser and into
the water-cooled condenser. The heat flows from the hot
gas into the condenser coolant thus cooling the
compressed gas and changing the state of refrigerant
from a gas to a liquid.
From the condenser/receiver, the liquid refrigerant
flows by a pressure relief valve which opens if the
refrigerant pressure is abnormally high.
1-11
1.13 REMOTE MONITORING RECEPTACLE suction line down stream of the suction modulation valve.
AND CIRCUIT Because of low compressor suction pressures created by
the suction modulation valve, the liquid fed by the
When the remote monitor is connected to the quench valve flashes to a low temperature gas and,
remote monitoring receptacle, Figure 1-1, the following therefore, the compressor may form frost or ice on the
remote circuits are energized. end bell and top of the motor cavity adjacent to the
suction gas path of flow. This is not harmful to the
Circuit Function compressor, as the restrictor in the quench valve line
prevents excessive liquid from flowing into the
Sockets B to A Energizes remote cool light compressor.
Sockets C to A Energizes remote defrost light
Sockets D to A Energizes remote in-range light
Note
The in-range light will be illuminated if the
container return air temperature is within 2_C
(3.6_F). Refer to paragraph 1.16.n.
1.14 SUCTION SOLENOID VALVE

(Model 69NT40)
The suction solenoid valve, shown in Figure 1-3 is Figure A
controlled by the suction solenoid thermostat (located on Controller Set Above -- 10_C (14_F)
the evaporator fan motor deck as shown in Figure 1-2).
In operation, if the return air temperature decreases
to ---12.2_C (10_F), the suction solenoid thermostat
(SST) closes to energize the suction solenoid valve, which
opens to increase the refrigerant flow rate and cooling
capacity.
The thermostat opens with increasing return air
temperature at ---7 3_C (20 6_F) to de-energize the
valve.
1.15 FROST FORMATION ON COMPRESSORS
Figure B
Note Controller Set Below -- 10_C (14_F)
Some models have a thermostatic expansion Figure 1-7. Frost Pattern on Compressors
quench valve, so frost formation on the
compressor is not applicable. To see which With the controller set below ---10_C (14_F) the
models use a solenoid quench valve refer to allowable compressor frost pattern limit is shown in
section 5. Figure 1-7B. The frost line will not normally extend
beyond the suction service valve as the quench valve
Frost may, in normal operation, form on the should not energize when operating with the controller
compressor suction service valve and end bell. This is set point below ---10_C (14_F).
caused by normal quench valve operation in conjunction
with the suction modulation valve. Figure 1-7A shows the If excessive frost is noticed on the compressor and
allowable frost limit pattern for units operating with the the suction modulation system is operating normally,
controller set point above ---10_C (14_F). This frost then the thermal expansion valve superheat setting
pattern is described below. should be checked. Flooding by a thermal expansion
valve may cause oil to foam excessively. Normal quench
The temperature controller varies the amount of valve operation will not foam the oil significantly after
current through the suction modulation valve coil which operation has stabilized.
in turn increases or decreases the amount of restriction in
the suction line, so that the net cooling capacity of the Adhesive-backed labels depicting allowable frost
unit will match the cooling required to maintain the load patterns on compressors are available from Carrier
at set point. Transicold Replacement Component Group.
When the suction modulation valve is approximately 1.16 CONTROLLER
50% closed (approximately 0.6 amps output to the h. General Description (See Figure 1-4 or Figure 1-5)
suction modulation valve coil from the temperature
controller), the temperature controller will energize the The Carrier Transicold controller is a modular
quench solenoid valve. When the quench valve is opened, assembly of solid state electronic circuits that combines a
a small amount of liquid refrigerant is metered through number of refrigeration system control functions in a
an orifice (which acts as an expansion device) into the single unit.
1-12
The functions are: (1) temperature control; (2) NOTES
current control; (3) temperature control function time 1. If the current limiting switch is set too low,
delays; (4) selectable time interval defrost; and, (5) unit pulldown capacity may be reduced due to
out-of-range indication time delay. limitation of compressor amperage as
determined by the timing and current control
The controller consists of a programmed main circuit board.
board, three plug-in control circuit boards, five or six
plug-in relays, and remote located components which 2. Table 1-4 shows the approximate total unit
are: (1) temperature set point potentiometer; (2) two amps for each position of the current limit
temperature sensing probes; (3) two switches for control.
checking calibration; and, (4) current limiting
transformer. j. Temperature Control (Capacity Control)
The temperature control portion of the controller
The controller has high precision components in consists of a temperature set point potentiometer (CSS),
critical circuits which result in the elimination of return air (RTS) and supply air (STS) temperature
calibration adjustments. As long as component sensors (two thermistor probes), solid state circuitry
replacements are made using factory specified parts, (temperature control, timing and current control, power
calibration will be maintained. supply and IRS printed circuit boards), and associated
control relays. Each temperature sensor is located in its
i. Model 69NT40 Current Control respective air stream.
(Capacity Override) Operation at any desired temperature within the set
point range (---25_C to +25_C or ---15_F to +80_F) is
The current control function of the controller limits achieved by turning the set point potentiometer knob to
the maximum unit current draw to prevent possible position the pointer at the desired temperature.
overloading of limited power sources such as an
engine-generator set when operating with high container A change in sensed air temperature (supply or return
temperatures and high ambient temperatures. Refer to air depending on set point) causes a corresponding
Table 1-4. change in electrical resistance of the thermistor sensor.
This change is processed by the electronic circuitry of the
The current control function, when required, will controller which actuates control relays and the
override the normal modulated capacity control function refrigerant suction modulating valve in accordance with
(described in paragraph 1.16.j.) to reduce cooling the controller operating diagrams as shown in NO TAG
capacity sufficiently to prevent total unit current from and NO TAG.
exceeding a preset value. This is accomplished by For set points above ---10_C (14_F) relay TU will be
circuitry on the timing and current control circuit board energized along with contactor EF. The two-speed
in response to the current sensed in one phase of the evaporator motors will be in high speed.
compressor power line by current limiting transformer
(CLT). The current limit on the timing and current Also, for set points above ---10_C (14_F), the
control board is factory set in switch position B (see controller will maintain supply air at the set temperature
Figure 1-8). by the following modes of operation:
1. Conventional, Humidity Control Switch (HCS)
in position O --- cooling by refrigeration with suction
modulation and the compressor cycling at light loads.
B
Electric resistance heating.
C
A D
2. Conventional plus Dehumidification, Humidity
SW1 E Control Switch in position 1 --- cooling by refrigeration
with suction modulation and compressor cycling at low
humidities, suction modulation and simultaneous
electric resistance heating at high humidities.
1. Operation in the Conventional Mode
CURRENT LIMIT SWITCH
Operation in the Conventional Mode (HCS in
position O) with the set point setting below the air
Figure 1-8. Current Control Printed Circuit Board temperature at the supply air probe but above ---10_C
(14_F) the unit starts in cooling with controller relays TU
and TQ energized. Compressor and condenser fan
contactors are energized through relay TC contacts T9
Table 1-4. Current Limiting Switch Positions and
Amperages and T3 (now closed) and relay TQ contacts T7 to T6 (now
closed).
Switch Position A B C D E As the sensed temperature continues to fall, the
modulating valve current will remain at minimum (under
460 vac Operation 15A 17A 19A 21A 23A 0.2 amp) until the sensed temperature drops to 0.25_C
230 vac Operation 30A 34A 38A 42A 46A (0.45_F) above set point.
1-13
With any further drop in sensed temperature, relationship of air flow variations within the container
modulated (continuously variable) capacity reduction and temperature gradients of air and product. However,
occurs to match cooling requirements that are less than during cooling, it can be stated that with supply air
the maximum capacity of the unit. This permits exact control, a minimum product temperature will be
balancing of unit capacity with a wide range of cooling effectively maintained and with return air control, a
loads while maintaining continuous compressor maximum product temperature will be effectively
operation and holding the temperature very close to set maintained.
point. This variable cooling capacity is achieved by a 2. Operation in the Dehumidification Mode
modulating solenoid valve which provides a variable
restriction in the compressor suction line. This valve Operation in the Dehumidification Mode (HCS in
varies the flow rate of the refrigerant pumped by the position 1). With the set point setting below the air
compressor. temperature at the supply air probe (but above ---10_C
(14_F) starts with controller relays TU and TQ
For low cooling capacity operation requiring higher energized. The compressor and condenser fan contactors
than 0.62 amp modulating valve current, the two-way are energized through normally closed TC relay contacts.
quench solenoid valve is energized (opened) which The evaporator fan motors are as previously described.
allows a small, metered flow of liquid refrigerant to enter
Cooling capacity reduction by modulation is the
the suction line and provide supplemental compressor
same as described for the conventional operating mode
motor cooling.
when the return air relative humidity is below the setting
For very small cooling requirements that are less on the humidity controller (HC) and as long as an
than the minimum refrigeration capacity of the unit (fully out-of-range temperature condition exists, regardless of
closed modulating valve), the controller will cycle return air relative humidity.
compressor on and off to match the load. For relative humidities higher than the HC setting, if
De-energization of relay TC to stop the compressor is the supply air temperature drops to 2_C (3.6_F) above
delayed to prevent nuisance cycling from brief low set point, in-range relay (IRS) energizes and, in turn,
temperature swings. Once off, the compressor will not energizes heat relay (contactor) HR thorough closed
restart for 5 to 6 minutes. (Refer to paragraph k.) (N.O.) relay HC contacts. Also, the in-range and heat
lights are illuminated at this time.
In cold ambients when container heating is required,
the sensed temperature will drop to 1.0_C (1.8_F) below This applies power to the defrost and drain pan
set point and the controller will cycle electric resistance heaters. This added head load causes the controller to
heating with a transient masking delay on energization open the modulating valve to match the new total heat
similar to that associated with compressor cycling. The load while still holding the supply air temperature very
heat relay (contactor HR) is energized through the closed close to set point.
contacts (N.C.) of relay TC by controller relay TH Opening the modulating valve reduces the
energizing and closing the TH contacts (N.O.). Heat temperature of the evaporator coil surface which
relay (contactor) HR energizes the defrost and drain pan increases the rate water is condensed from the air passing
heaters. through the coil. Removing water from the air reduces
For set points below ---10_C (14_F), return air the relative humidity until the HC setting is reached and
temperature is sensed and the range of capacity controller HC contacts open to de-energize heating.
reduction is more limited than for higher set points. Humidity controller HC will continue to cycle
When cooling requirements are less than the minimum heating to maintain relative humidity below HC setting.
continuous operating capacity of the unit, the unit reverts
to on-off compressor cycling to match the load. When With set points below ---10_C (14_F), operation is
cooling, compressor and condenser fan contactors are the same as previously described for conventional mode
energized through the normally open (N.O.) contacts of --- heating and dehumidification are locked out.
relay TC. k. Time Delays
Also, for set points below ---10_C (14_F), the TC relay operation is affected by a time delay
controller will maintain return air at the set temperature function of the Timing and Current Control Board; its
by refrigeration. Electric resistance heating is purpose is to prevent short cycling of the compressor.
electronically locked out in this temperature range. Units To prevent short cycling of the compressor, a six
with two-speed evaporator fan motors will have the minute compressor off time must be satisfied. When the
evaporator fan motors in low speed as relay TU will be timer completes its six minute cycle, the following
de-energized. (Contactor ES energized.) temperature requirements must be met to allow the
compressor to start.
Electric resistance heating is locked out for set points
below ---10_C (14_F) by controller relay TH being locked 1. .25_C ( .45_F) from setpoint, setpoints
out to prevent energizing the circuit. above ---10_C (14_F).
Cargo temperatures will necessarily vary somewhat 2. .50_C ( .9_F) from setpoint, setpoints below
---10_C (14_F).
from controlled air temperatures. A simple numerical
difference between product temperature and controlled Until these temperature requirements are met, the
air temperature cannot be stated because of the complex timer will continue to cycle.
1-14
Additional transient override time delays affect the temperature baths or other temperature measuring
operation of TC and TH relays. These delays are all instruments.
overridden by pressing the time delay override switch Sensing probe temperature is simulated by holding
(TDS). the temperature simulator switch (TSS) in the desired
l. Lockout Functions position, 0_C (32_F) or ---17.8_C (0_F).
Heating function lockout for set points below ---10_C
When checking controller functions and calibration,
(14_F) is achieved by relay TH being prevented from
energizing. it is also necessary to hold the time delay override switch
(TDS) depressed to obtain immediate controller
m. Selectable Time Interval Defrost responses. Depressing switch TDS does the following:
A selectable interval defrost initiation timer is
included in the timing and current control board. The 1. Cancels 90 minute in-range delay (paragraph n.).
time interval between defrost initiations (90 second test, 2. Cancels 6 minute compressor recycle delay
3 hours, 6 hours, 12 hours, or 24 hours) is set with the (paragraph k.).
defrost interval selector switch (DIS).
3. Cancels relays TC OFF and TH ON nuisance
The controller initiates defrost (providing the cycling delays.(Paragraphs j. and k.).
evaporator coil temperature is below 13_C = 55_F
required to close the defrost termination thermostat 4. Resets defrost interval timing to zero (paragraph n.).
contacts) by:
1. Energizing defrost relay (DR) energizes the defrost
light and stops the evaporator fan motors by
de-energizing the evaporator fan motor contactor.
2. De-energizing cooling relay (TC) and energizing and
heating relay (TH). This stops the compressor and
condenser fan motor and energizes the defrost and drain
pan heaters.
Defrosting is terminated by the defrost termination
thermostat (DTT), which opens when the evaporator coil
temperature rises to 24_C (75_F) after all frost has been
melted from the coil.
Also, defrost may be manually initiated at any time
by actuating the manual defrost switch (MDS).
NOTE
Defrost interval timing restarts at time zero
whenever the time delay override switch (TDS)
is depressed or control circuit power is restored
after an interruption such as occurs when
stopping or starting unit (ST switch).
n. Out-of-Range Indication Time Delay
During defrost, the temperature at the sensing probe
rises above the upper in-range limit which would result in
an out-of-range indication if the temporary condition
were not overridden. Circuitry on the timing and current
control board works in conjunction with the temperature
control circuitry to delay de-energization of the in-range
relay (IRS) until approximately 90 minutes after the
temperature at the sensing probe goes beyond the
in-range temperature limits. A normal operating unit will
return from defrost to an in-range condition before
expiration of the 90 minute delay and no interruption of
in-range indication will occur. Indication of the
instantaneous temperature condition (in or
out-of-range) can be obtained by pressing the time delay
overrride switch (TDS).
o. Function and Calibration Check
The controller has precision resistors that simulate
sensing probe temperatures to permit readily checking
controller functions and calibration without using
1-15
FALLING RISING
IRS TEMPERATURE TEMPERATURE IRS
Energizes 2_C (3.6_F) De-energizes
1.5_C (2.7_F)
1_C (1.8_F)
In-Range
0.5_C (0.9_F) TC
In-Range 0.25_C Energizes
(See Note)
TC SET POINT
De-energizes
(See Note)
---0.25_C
---0.5_C (---0.9_F)
---1_C (---1.8_F)
---1.5_C (---2.7_F)
IRS IRS
De-energizes ---2_C (---3.6_F) Energizes
Figure 1-9. Controller Set Point Below --- 10_C (14_F) --- Return Air Control
FALLING RISING
TEMPERATURE TEMPERATURE
IRS IRS
Energizes 2_C (3.6_F) De-energizes
(See Note)
In-Range 1.5_C (2.7_F) In-Range
1_C (1.8_F)
0.5_C (0.9_F)
TC
0.25_C Energizes
(See Note)
SET POINT AIR
CIRCULATION
TC ---0.25_C ONLY
De-energizes
(See Note) AIR ---0.5_C ( ---0.9_F) TH De-energizes
CIRCULATION
ONLY
TH Energizes
(See Note)
---1_C ( ---1.8_F)
---1.5_C ( ---2.7_F)
IRS IRS
De-energizes ---2_C ( ---3.6_F) Energizes
(See Note)
Figure 1-10. Controller Set Point Above --- 10_C (14_F) --- Supply Air Control
NOTE
Switching functions are affected by time delays. (Refer to paragraph 1.17.k.)
1-16
SECTION 2
OPERATION
2.1 PRE-TRIP INSPECTION (Before Starting) counterclockwise until stylus lifter locks in position and
stylus has made contact with chart. Then secure door.
WARNING
f. Open Fuji Kiki recording thermometer (if so
Beware of unannounced starting of the equipped) door and do the following:
evaporator and condenser fan.
1. Check Chart drive battery condition. (Refer to
a. If container is empty, check inside for the following: section 4.21)
1. Check channels or T bars on floor for
2. Lift stylus (pen) by pushing in the stylus lifter
cleanliness. Channels must be free of debris for proper
and rotating the lifter clockwise (raising stylus at same
air circulation.
time) until lifter locks in position.
2. Check container panels, insulation and door
seals for damage. Effect permanent or temporary 3. Install new chart on recording thermometer
repairs. making sure chart is under the four corner tabs. Release
stylus lifter by pushing down and rotating lifter
3. Visually check evaporator fan motor mounting counterclockwise until stylus lifter locks in position and
bolts for proper securement. stylus has made contact with chart. Then secure door.
4. Check for dirt or grease on evaporator fan or fan
deck and clean if necessary. g. Open the control/contactor box door. Check for
loose electrical connections or hardware.
5. Check evaporator coil for cleanliness or
obstructions. Wash with fresh water. (Refer to section 4.13) h. Check color of moisture-liquid indicator.
6. Check defrost drain pans and drain lines for i. Check oil level in compressor sight glass.
obstructions and clear if necessary. Wash with fresh
water. j. Check quench valve operation.
7. Check panels on refrigeration unit for loose k. Check modulation valve coil resistance. (Refer to
bolts and condition of panels. Make sure T.I.R. devices section 4.25)
are in place on access panels.
l. Start refrigeration unit. (Refer to section 2.3)
b. Check condenser coil for cleanliness. Wash with
fresh water. (Refer to section 4.17) 2.2 STARTING AND STOPPING INSTRUCTIONS
c. Check position of fresh air makeup vent cover.
Operator must determine if fresh air makeup vent cover CAUTION
is to be opened or closed.
d. Open Partlow recording thermometer (if so Make sure that the unit circuit breaker(S) (CB)
equipped) door and do the following: and the start-stop switch are in the OFF position
before connecting to any electrical power source.
1. Manually wind clock on recording thermometer
(key is located in a clip.) KEY MUST STAY WITH THE
THERMOMETER. p. Starting the Unit
2. Lift stylus (pen) by pushing down the stylus lifter 1. Refer to Pre-Trip Inspection, section 2.1.
time) until lifter locks in position. 2. Make sure unit circuit breaker(s) and start-stop
switch are in position O (OFF position).
3. Install new chart on recording thermometer
making sure chart is under the four corner tabs. Release 3. Check power source for proper voltage. Connect
stylus lifter by pushing down and rotating lifter unit power plug and turn main power ON.
counterclockwise until stylus lifter locks in position and 4. Turn refrigeration unit circuit breaker(s), and
stylus has made contact with chart. Then secure door. the start-stop switch ON (position 1).
e. Open Saginomiya recording thermometer (if so
equipped) door and do the following: 5. To adjust the temperature set points, depress
SDS switch and turn temperature selector knob while
1. Check Chart drive battery condition. (Refer to looking at the digital temperature display. This
section 4.20) procedure allows temperature settings within a tenth of a
2. Lift stylus (pen) by pushing in the stylus lifter degree centigrade.
time) until lifter locks in position. 6. Refer to section 2.3 after unit is running.
3. Install new chart on recording thermometer q. Stopping the Unit
making sure chart is under the four corner tabs. Release
stylus lifter by pushing down and rotating lifter Turn the start-stop switch to position O (OFF).
2-1
2.3 AFTER STARTING INSPECTION period has elapsed, relay TC energizes to restart the
compressor. Also, at this time, the condenser fan motor
a. Check rotation of condenser and evaporator fans.
starts and the cool light is illuminated.
b. Check compressor oil level.
c. Check operation --- determine if unit responds 2.4.2 Controller Set Above --- 10_C (14_F)
properly to setting of controller, cycling from heat to cool, a. Cooling (See Figure 2-1)
at controller setting.
d. Feel filter-drier. Excessive temperature drop across With decreasing supply air temperature and if the
drier indicates restriction. supply air is more than 2_C (3.6_F) above set point, the
2.4 UNIT OPERATION unit will be cooling with the condenser fan motor,
compressor motor and evaporator fan motors energized.
2.4.1 Cooling --- Controller Set Below --- 10_C (14_F) The evaporator fan motors will be in high speed as relay
TU is energized (contactor ES de-energizes and
On decreasing return air temperature the unit will be contactor EF energizes).
in cooling with the condenser fan motor and evaporator
fan motors energized. With set points below ---10_C Also, at this time, the cool light is illuminated. The
(14_F), the evaporator fan motors will be in low speed as in-range light is de-energized.
relay TU is de-energized (contactor ES energizes). When the air temperature decreases to 2_C (3.6_F)
If the container return air is within 2_C (3.6_F) of set above set point relay IRS energizes and the in-range light
point, the in-range relay contacts (IRS) are closed and is illuminated.
the in-range light (IRL) is illuminated. If the air temperature continues to fall, modulating
When the return air temperature decreases to cooling starts at approximately 0.25_C (0.45_F) above set
0.25_C (0.5_F) below set point, a timing function point. The modulating valve will have a variable current
commences which delays de-energizing of relay TC and up to 1.45 amps at full modulation.
resulting in de-energizing the compressor and condenser At this time, it is possible for the quench valve to
fan motor. Also, the cool light is de-energized. The energize before the compressor shuts off as the valve
evaporator fan motors continue to run to circulate air energizes with a minimum amp draw of 0.6. The quench
throughout the container. valve will de-energize if the amp draw falls below 0.55
amp.
NOTES
1. When the return air temperature decreases NOTE
to ---12.2_C (10_F) on the Model 69NT40 units,
the suction solenoid thermostat closes to Some Models have a thermostatic expansion
energize the suction solenoid valve. The valve quench valve (refer to section 5).
opens to increase the refrigerant flow rate and
cooling capacity. When the supply air temperature decreases to 0.25_C
(0.5_F) below set point, a timing function commences
2. In the frozen range the suction modulation which delays de-energizing of relay TC resulting in
is limited to approximately 0.4 amp or valve is 25 de-energizing the compressor and condenser fan motor.
percent closed. Also, the cool light is de-energized.
The evaporator fan motors continue to run to circulate
3. The quench valve will not be energized at air throughout the container. The in-range light remains
this time as the suction modulation valve current illuminated as long as the return air is within 2_C (3.6_F) of
will not reach 0.6 amp (necessary to energize set point.
quench valve).
If the unit is in the holding mode (neither heating or
4. Some models have a thermostatic expansion cooling) and the supply air temperature increases to 0.25_C
quench valve (refer to section 5). (0.5_F) above set point, and providing a sufficient off time
has elapsed, relay TC energizes to restart the compressor.
5. Setting the controller below ---10_C (14_F) Also, at this time, the condenser fan motor starts and the
on units with two-speed motors will place the cool light is illuminated.
motors in low speed (contactor ES energizes).
When the supply air temperature increases 2_C (3.6_F)
When the return air temperature increases to 0.25_C above set point, relay IRS and the in-range light is off. The
(0.5_F) above set point, and providing a sufficient off cool light remains energized.
2-2
TO CONTROL TRANSFORMER
= Energized Circuit = De-energized Circuit
Figure 2-1. Cooling --- Within 2_C (3.6_F) of Set Point
2-3
Figure 2-2. Heating --- Within 2_C (3.6_F) of Set Point
b. Heating (See Figure 2-2) When the temperature rises to 0.5_C (0.9_F) below
The unit will only heat when the controller is set set point, TH opens (heating off) and the system again
above ---10_C (14_F) as relay TH is electronically locked enters the holding zone. The compressor and condenser
out to prevent heating when the controller is set below fan motor are not running as contactors C and CF remain
---10_C (14_F). de-energized. The evaporator fans continue to run in
If the supply air temperature decreases 1.0_C high speed to circulate air throughout the container.
(1.8_F) below controller set point TH closes and the A safety heater termination thermostat (HTT)
system enters the heating mode which is designed to raise attached to an evaporator coil support, set to open at
the container air temperature. When TH closes, power 54.5_C (130_F) will open the heating circuit if
flows through the TC contacts T9 and T8, TH contacts, overheating occurs.
the heat termination thermostat to energize the heat
relay (HR). This in turn energizes the heaters and heat
light. The evaporator fans continue to run in high speed
to circulate air throughout the container.
As the supply air decreases to 2_C (3.6_F) below set
point, relay IRS and the in-range light de-energize (after
90 minutes time delay) and will remain de-energized until
the supply air increases to 2_C (3.6_F) below set point.
2-4
2.4.3 Defrost (See Figure 2-3) TC (T9 to T31) opens to de-energize the compressor
contactor, cool light, and the condenser fan motor
Refer to paragraph 1.16.f for description of the
contactor.
defrost interval selector and automatic defrost initiation.
When the defrost mode is initiated, the controller The in-range light remains illuminated during
relay contacts (TH, T11 to T10) close to supply power to defrost. (Refer to paragraph 1.16.g)
the heat relay and in turn energizes the defrost heaters. When the coil temperature reaches 24_C (75_F)
Also, at the same time, the defrost relay contacts defrost termination thermostat opens to interrupt the
(T19 to T20) close to illuminate the defrost light. defrost cycle and the unit returns to its normal function.
Energizing the defrost relay also opens the normally The 54.5_C (130_F) heat termination thermostat
closed contacts (T19 to T18) to stop the evaporator fan will open the circuit if the defrost mode does not
motors. terminate at 24_C (75_F).
Figure 2-3. Defrost
2-5
Table 2-1. Electrical Control Positions --- Above --- 10_C (14_F)
CONTROL CIRCUIT COOLING HOLDING * Dehumidifica- HEATING DEFROST

ZONE tion
Compressor Contactor Energized De-energized Energized De-energized De-energized
(C)
Condenser Fan Motor Energized De-energized Energized De-energized De-energized
Contactor (CF)
One Speed Evaporator Energized Energized Energized Energized De-energized
Motor Relay (EF)
Two Speed Evaporator Energized at set points above - 10_C (14_F) De-energized
Motor Relay (EF)
Two Speed Evaporator De-energized at set points above - 10_C (14_F)
Motor Relay (ES)
Defrost Relay (DR) De-energized De-energized De-energized De-energized Energized
Heater Relay (HR) De-energized De-energized Energized Energized Energized
Quench Solenoid (QV) Refer to para- De-energized Refer to para- De-energized De-energized
graph 1.16.c graph 1.16.c
CONTROLLER RELAYS
DR (Defrost) OFF OFF OFF OFF ON
IRS (In-Range) Closed - If supply air is within 2_C (3.6_F) of set point
TC (Cooling) ON OFF ON OFF OFF
TH (Heating) OFF OFF ON ON ON
TQ (Quench) Refer to N/A N/A N/A N/A
TU (Utility) paragraph 1.16.c
(Two-Speed Motors) Energized with controller settings above - 10_C (14_F)
INDICATING LIGHTS
Cool ON OFF ON OFF OFF
Defrost OFF OFF OFF OFF ON
In-Range On - If supply air is within 2_C (3.5_F) of set point
Heat OFF OFF ON ON ON
POWER CIRCUIT
Compressor Energized De-energized Energized De-energized De-energized
Condenser Fan Motor Energized De-energized Energized De-energized De-energized
Heaters De-energized De-energized Energized Energized Energized
Evaporator Fan Motors Energized Energized Energized Energized De-energized
* Unit with optional Humidistat (Refer to section 1.7)
N/A - Not Applicable
2-6
Table 2-2. Electrical Control Positions --- Below --- 10_C (14_F)
CONTROL CIRCUIT COOLING HOLDING **Dehumidifica- HEATING DEFROST

ZONE tion
Compressor Contactor Energized De-energized ** ** De-energized
(C)
Condenser Fan Motor Energized De-energized ** ** De-energized
Contactor (CF)
One Speed Evaporator Energized Energized ** ** De-energized
Motor Relay (EF)
Two Speed Evaporator De-energized at set points below - 10_C (14_F)
Motor Relay (EF)
Two Speed Evaporator Energized at set points below - 10_C (14_F) De-energized
Motor Relay (ES)
Defrost Relay (DR) De-energized De-energized ** ** Energized
Heater Relay (HR) De-energized De-energized ** ** Energized
Quench Solenoid (QV) Refer to De-energized ** ** De-energized
paragraph 1.16.c
CONTROLLER RELAYS
DR (Defrost) OFF OFF ** ** ON
IRS (In-Range) Closed - If supply air is within 2_C (3.6_F) of set point
TC (Cooling) ON OFF ** ** OFF
TH (Heating) OFF OFF ** ** ON
TQ (Quench) Refer to N/A ** ** N/A
TU (Utility) paragraph 1.16.c
(Two-Speed Motors) Energized with controller settings below - 10_C (14_F)
INDICATING LIGHTS
Cool ON OFF ** ** OFF
Defrost OFF OFF ** ** ON
In-Range On - If supply air is within 2_C (3.5_F) of set point
Heat OFF OFF ** ** ON
POWER CIRCUIT
Compressor Energized De-energized ** ** De-energized
Condenser Fan Motor Energized De-energized ** ** De-energized
Heaters De-energized De-energized ** ** Energized
Evaporator Fan Motors Energized Energized ** ** De-energized
** Dehumidification and heating modes do not operate at set points below - 10_C (14_F)
N/A - Not Applicable
2-7
SECTION 3
TROUBLESHOOTING
INDICATION/ POSSIBLE CAUSES REFERENCE

TROUBLE SECTION
3.1 UNIT WILL NOT START OR STARTS THEN STOPS

No power to unit External power source OFF Turn on
Start-Stop switch OFF or defective Check
Circuit breaker tripped or OFF Check
Loss of control power Circuit breaker OFF or defective Check

Control transformer defective (TR) Replace
Fuse blown (3A or 6A) Check
Start-Stop switch OFF or defective Check
Evaporator fan motor internal protector open 4.14
Condenser fan motor internal protector open 4.18
Compressor internal protector open 4.5
High pressure switch open 4.11
Compressor hums, Low line voltage Check

but does not start Single phasing Check
Shorted or grounded motor windings 4.5
Compressor seized 4.5
3.2 UNIT RUNS BUT HAS INSUFFICIENT COOLING
Compressor Compressor valves defective 4.5
Refrigeration System Abnormal pressures 3.7

Temperature controller malfunction 3.9
Evaporator fan or motor defective 4.14
Modulating solenoid valve malfunction 4.25
Suction solenoid valve malfunction 1.14
3.3 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING
Container Hot load Normal
Defective box insulation or air leak Repair
Refrigeration System Shortage of refrigerant 4.2/4.4

Evaporator coil covered with ice 3.6
Evaporator coil plugged with debris 4.13
Evaporator fan(s) rotating backwards 4.14/4.28
Defective evaporator fan motor/capacitor 4.14/4.28
Air bypass around evaporator coil Check
Controller set too low Reset
Compressor service valves or liquid Open valves
line shutoff valve partially closed completely
Dirty condenser 4.17 or 4.23
Compressor worn 4.5
3-1
TROUBLE SECTION
3.4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING

No power to unit Start-Stop switch OFF or defective Check
Circuit breaker OFF or defective Check
External power source OFF Turn on
No control power Circuit breaker or fuse defective Replace

Transformer defective (TR) Replace
Condenser fan internal motor protector open 4.18
Evaporator fan internal motor protector open 4.14
Heat relay defective Check
Heater termination switch open 4.13
Unit will not heat or Heater(s) defective 4.15

has insufficient heat Heater contactor or coil defective Replace
Evaporator fan motor(s) defective or rotating backwards 4.14/4.28
Evaporator fan motor contactor defective Replace
Defective wiring Replace
Loose terminal connections Tighten
Low line voltage 1.5
3.5 UNIT WILL NOT TERMINATE HEATING
Unit fails to stop heating Temperature controller improperly set Reset
Heater termination switch remains
closed along with the heat relay 4.13
3.6 UNIT WILL NOT DEFROST PROPERLY
Will not initiate Defrost timer malfunction 1.16.f
defrost automatically Loose terminal connections Tighten
Defective wiring Replace
Defrost termination or heat termination switch open 4.13
Heater contactor or coil defective Replace
Will not initiate Manual defrost switch defective Replace

defrost manually Defrost termination switch open 2.4.3
Initiates but defrost relay

(DR) drops out Low line voltage 1.6
Initiates but does not defrost Heater contactor or coil defective Replace
Heater(s) burned out 4.15
Frequent defrost Wet load Normal
3-2
TROUBLE SECTION
3.7 ABNORMAL PRESSURES (COOLING)

High discharge pressure Condenser coil dirty 4.17 or 4.23
Condenser fan rotating backwards 4.18
Condenser fan inoperative 4.18
Refrigerant overcharge or noncondensibles 4.4
Quench solenoid valve malfunction 4.12
Low suction pressure Suction service valve partially closed Open

Filter-drier partially plugged 4.10
Low refrigerant charge 4.2/4.4
Expansion valve defective 4.27
No evaporator air flow or restricted air flow 3.10
Excessive frost on evaporator coil 3.6
Evaporator fan(s) rotating backwards 4.14/4.28
3.8 ABNORMAL NOISE OR VIBRATIONS
Compressor Loose mounting bolts Tighten
Worn bearings 4.5
Worn or broken valves 4.5
Liquid slugging 3.11
Insufficient oil 4.8
Condenser or Bent, loose or striking venturi Check

Evaporator Fan Worn motor bearings 4.14/4.18
Bent motor shaft 4.14/4.18
3.9 TEMPERATURE CONTROLLER MALFUNCTION
Will not control or relay(s) Controller relay(s) defective 4.26
do not actuate at Defective Sensor 4.26.6
proper temperature Defective wiring 4.26
Controller malfunction 4.26
Compressor does not start

or stop at specified temperature Time delay period not elapsed 1.16.d
3.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW
Evaporator coil blocked Frost on coil 3.6
Dirty coil 4.13
No or partial Evaporator fan motor internal protector open 4.14

evaporator air flow Evaporator fan motor(s) defective 4.14/4.28
Evaporator fan(s) loose or defective 4.14
3-3
TROUBLE SECTION
3.11 EXPANSION VALVE MALFUNCTION

Low suction pressure Low refrigerant charge 4.2/4.4
with high superheat External equalizer line plugged Open
Wax, oil or dirt plugging valve or orifice 4.27
Ice formation at valve seat 4.2/4.3
Superheat too high 4.27.c
Power assembly failure 4.27
Loss of element/bulb charge 4.27
Broken capillary 4.27
Foreign material in valve 4.27
High suction pressure Superheat setting too low 4.27.c

with low superheat External equalizer line plugged Open
Ice holding valve open 4.2/4.3
Foreign material in valve 4.27
Liquid slugging in compressor Pin and seat of expansion valve eroded or

held open by foreign material 4.27
Fluctuating suction pressure Improper bulb location or installation 4.27

Low superheat setting 4.27.c
3.12 WATER-COOLED CONDENSER OR WATER PRESSURE SWITCH MALFUNCTION
High discharge pressure Dirty coil 4.23
Noncondensibles 4.23
Condenser fan Water pressure switch malfunction Check

starts and stops Water supply interruption Check
3.13 STEP-UP POWER TRANSFORMER MALFUNCTION
Unit will not start Circuit breaker (CB2) tripped Check
Step-up transformer internal protector open 4.24
Step-up transformer defective 4.24
Power source not turned ON Check
3-4
SECTION 4
SERVICE
4.1 REMOVING THE REFRIGERANT d. Replace the filter-drier with a section of copper
tubing with the appropiate fittings. This idea will help
NOTE
speed up the evacuation procedure.
To avoid damage to the earths ozone layer,
use a refrigerant recovery system whenever 4.3.3 Procedure
removing refrigerant.
To Service any High and Low Side Refrigeration Component:
Store the refrigerant charge in an evacuated
container. Attach hose (line) to liquid line valve to 12
remove liquid refrigerant.
4.2 REFRIGERANT LEAK CHECKING
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 11 10 8 7
locating large leaks.
b. If system is without refrigerant, charge system with
refrigerant to build up pressure between 2.1 to 3.5 kg/cm@
(30 to 50 psig). Remove refrigerant drum and leak check
all connections.
NOTE
9
It must be emphasized that only the correct
refrigerant drum be connected to pressurize the 4 4
system. Any other gas or vapor will contaminate
the system which will require additional purging 3
and evacuation of the high side (discharge) of
the system.
c. Remove refrigerant using a refrigerant recovery 1

4
system and repair any leaks. 6
d. Evacuate and dehydrate the unit. (Refer to section 4.3)
e. Charge unit per section 4.4.
4.3 EVACUATION AND DEHYDRATION 1. Refrigerant Recovery Unit 5
2 2. Refrigerant Cylinder
4.3.1 General 3. Evacuation Manifold
Moisture is the deadly enemy of refrigeration 4 Valve
systems. The presence of moisture in a refrigeration 5. Vacuum Pump
system can have many undesirable effects. The most 6. Electronic Vacuum Gauge
common are copper plating, acid sludge formation, 7. Liquid Line Valve
freezing-up of metering devices by free water, and 8. Condenser Coil
formation of acids, resulting in metal corrosion. 9. Suction Service Valve
10. Compressor
4.3.2 Preparation 11. Discharge Service Valve
a. Evacuate and dehydrate only after pressure leak test. 12. Evaporator Coil
(Refer to section 4.2) Figure 4-1. Vacuum Pump Connections
b. Essential tools to properly evacuate and dehydrate a. Remove all refrigerant using a refrigerant recovery
any system include a vacuum pump (8 m@H = 5 cfm system.
volume displacement, P/N 07-00176-01) and electronic
b. The recommended method to evacuate and
vacuum gauge.
dehydrate the system is to connect three evacuation
c. Keep the ambient temperature above 15.6_C (60_F) hoses (Do not use standard service hoses, as they are not
to speed evaporation of moisture. If ambient suited for evacuation purposes.) as shown in Figure 4-1
temperature is lower than 15.6_C (60_F) ice might form to the vacuum pump and refrigeration unit. Also, as
before moisture removal is complete. Heat lamps or shown, connect a evacuation manifold, with evacuation
alternate sources of heat may be used to raise the system hoses only, to the vacuum pump, electronic vacuum
temperature. gauge, and refrigerant recovery system.
4-1
c. With the unit service valves closed (back seated) and Units equipped with air-cooled condenser only,
the vacuum pump and electronic vacuum gauge valves partially block the condenser coil inlet air starting from
open, start the pump and draw a deep vacuum. Shut off the front of the condenser coil. Increase the area blocked
the pump and check to see if the vacuum holds. This until the compressor discharge pressure increases to
operation is to test the evacuation setup for leaks, repair approximately 13 kg/cm@ (190 psig) with the container
if necessary. temperature about 2_C (35_F) or 11 kg/cm@ (160 psig)
with the container temperature about ---18_C (0_F).
d. Midseat the refrigerant system service valves. Allow the system to stabilize for 5 minutes of continuous
e. Then open the vacuum pump and electronic vacuum operation maintaining the head pressure at the proper
gauge valves, if they are not already open. Start the level. Proceed to step c.
vacuum pump. Evacuate unit until the electronic vacuum c. For units with air-cooled condenser only, check the
gauge indicates 2000 microns. Close the electronic liquid line sight glass. If the sight glass appears clear with
vacuum gauge and vacuum pump valves. Shut off the no bubbles visible or only occasional intermittent
vacuum pump. Wait a few minutes to be sure the vacuum bubbles, then the unit has an adequate charge. If the sight
holds. glass appears to be flashing or bubbles are constantly
f. Break the vacuum with clean dry refrigerant gas. Use moving through the sight glass, then the unit may have a
refrigerant that the unit calls for. Raise system pressure low refrigerant charge, or the filter-drier could be
to approximately 2 psig by monitoring it with the partially plugged (refer to section 4.10). If it is
compound gauge. determined that the filter-drier is not restricted, then it
will be necessary to add some refrigerant to the system.
g. Remove refrigerant using a refrigerant recovery Refer to section 4.4.3.
system. 4.4.2 Adding Refrigerant to System (Full Charge)
h. Repeat steps e through g one time. a. Evacuate unit and leave in deep vacuum. (Refer to
i. Remove the copper tubing and change the section 4.3)
filter-drier. Evacuate unit to 500 microns. Close the b. Place drum of R-12 on scale and connect charging
electronic vacuum gauge and vacuum pump valves. Shut line from drum to liquid line valve. Purge charging line at
off the vacuum pump. Wait five minutes to see if vacuum liquid line valve and then note weight of drum and
holds. This checks for residual moisture and/or leaks. refrigerant.
j. With a vacuum still in the unit, the refrigerant charge c. Open liquid valve on drum. Open liquid line valve
may be drawn into the system from a refrigerant half-way and allow the liquid refrigerant to flow into the
container on weight scales. The correct amount of unit until the correct weight of refrigerant has been
refrigerant may be added by observing the scales. (Refer added as indicated by scales. Correct charge is noted in
to section 4.4) Table 1-1.
4.4 ADDING OR CHECKING THE NOTE
REFRIGERANT CHARGE It may be necessary to finish charging unit
4.4.1 Checking the Refrigerant Charge through suction service valve in gas form, due to
pressure rise in high side of the system. (Refer to
NOTE section 4.4.3)
1. Set the controller set point to ---25_C d. Backseat liquid line valve (to close off gauge port).
(---13_F) to ensure that the modulating solenoid Close liquid valve on drum. Crack connection on
valve is fully open when checking operation of charging line at liquid line valve to vent charging line.
unit.
e. Start unit in cooling mode. Run approximately ten
minutes and check the refrigerant charge. (Refer to
2. The refrigerant level should only be checked paragraph 4.4.1.b)
when the unit is running with the modulating
solenoid valve fully open. The container 4.4.3 Adding refrigerant to System
temperature should be approximately 1.7_C (Partial Charge)
(35_F) or ---17.8_C (0_F). a. Examine the unit refrigerant system for any evidence
of leaks. Repair as necessary. (Refer to section 4.2)
a. Connect the gauge manifold to the compressor b. Maintain the conditions outlined in section 4.4.1.
discharge and suction service valves.
c. Fully backseat (to close off gauge port) the suction
b. Units equipped with the optional water-cooled service valve (see Figure 1-3) and remove the 1/4 inch
condenser, check charge only on air-cooled operation. flare cap.
Refrigerant level on water-cooled operation will be
normally above sight glass. Partially block the condenser d. Connect charging line between suction service valve
coil inlet air starting from the front of the condenser coil. port and drum of Refrigerant-12. Open VAPOR valve on
Increase the area blocked until the compressor discharge drum. Purge charging line.
pressure is raised to approximately 12 kg/cm@ (175 psig). e. Partially frontseat (turn clockwise) the suction
Refrigerant should appear at center line of sight glass on service valve and slowly add charge until the refrigerant
the water-cooled condenser. If not, refer to section 4.4.3. appears at the proper level (refer to section 4.4.1).
4-2
4.5 REPLACING THE COMPRESSOR NOTES
(See Figure 4-2) 1. Check the compressor Serial/Model Number
WARNING plate for CFM displacement, refer to Table 1-2.
Make sure power to the unit is OFF and power 2. The service replacement compressor is sold
plug disconnected before replacing the without shutoff valves (but with valve pads), and
compressor. without terminal box and cover. Customer
should retain the original terminal box, cover,
1 2 3 and high pressure switch for use on replacement
compressor.
3. Check oil level in service replacement
14 compressor. If none, add 4.0 liters (8.5 U.S. pints).
13 (Refer to paragraph 1.3.b. and section 4.8)
12 4. A terminal block kit must be ordered as a
4 separate item when ordering replacement
compressor. Appropriate installation
instructions are included with kit.
11 5. Refer to Table 4-4 and Table 4-5 for

applicable compressor wear limits and torque
5 values.
10
a. Remove protective guard from lower section of the
7 6 unit.
9 8
b. If compressor is inoperative and unit still has
1. Discharge Valve Flange refrigerant pressure, remove refrigerant
2. High Pressure Switch Connection (refer to section 4.1).
3. Low Pressure Connection c. Disconnect wiring in the compressor junction box after
4. Suction Valve Flange identifying same. Disconnect wiring from compressor
5. Motor End Cover terminals and remove compressor junction box.
6. Serial/Model No. Plate
7. Sight Glass d. Remove bolts from service valve flanges.
8. Bottom Plate e. Remove compressor plate mounting bolts.
9. Oil Drain Plug
10. Bearing Head f. Remove compressor and mounting plate. The
11. Oil Pump (See Figure 4-3) compressor weighs approximately 118 kg (260 pounds).
12. Oil Fill Plug (Refer to paragraph 4.8.c) g. Remove high pressure switch (HPS) from compressor
13. Cylinder Head and check operation of switch (section 4.11.2).
14. Valve Plate
Figure 4-2. Compressor --- Model 06DR h. Remove compressor mounting bolts from mounting
plate and install mounting plate on replacement
compressor.
i. Install replacement terminal block kit (following
instructions included with kit).
j. Install high pressure switch on compressor.
k. Install compressor and mounting plate in unit.
l. Install junction box to compressor and connect all
wiring per wiring diagram (refer to section 5) and then
install junction box cover.
VANE PUMP GEAR PUMP
m. Install new gaskets on service valves.
Figure 4-3. Oil Pump n. Install mounting bolts in service valves and torque to
a value of 2.77 to 4.15 mkg (20-30 ft/lb).
There are two types of oil pumps; vane and gear. o. Change filter-drier. (Refer to section 4.10)
Force-feed lubrication of the compressor is accomplished
p. Attach two lines (with hand valves near vacuum
by a oil pump driven directly from the compressor
pump) to the suction and discharge service valves.
crankshaft. Refrigeration oil is drawn from the
compressor crankcase through the oil filter screen and Dehydrate and evacuate compressor to 500 microns (75.9
cm HG vacuum = 29.90 inches Hg vacuum). Turn off
pick up tube to the oil pump located in the bearing head
valves on both lines to pump.
assembly. The crankshaft is drilled to enable the pump to
supply oil to the main bearings, connecting rod bearings, q. Fully backseat (open) both suction and discharge
and the shaft seal. service valves.
4-3
r. Remove vacuum pump lines. d. Turn the compressor over on its side and remove the
bottom plate. Remove the capscrews and connecting rod
s. Start unit and check refrigerant charge. (Refer to caps (see Figure 4-5). Match mark each connecting rod
paragraph 4.4.1.b) cap and connecting rod for correct assembly. Push the
t. Check moisture-liquid indicator for wetness. Change piston rods up as far as they will go without having the
filter-drier if necessary. (Refer to sections 4.9 and 4.10) piston rings extend above the cylinders.
u. Check compressor oil level per paragraph 4.8.a. Add e. If necessary, remove the oil return check valve. Inspect
oil if necessary. (Refer to paragraph 4.8.b) it for check valve operation (flow in one direction only).
Replace assembly if its check valve operation is impaired.
4.6 COMPRESSOR DISASSEMBLY (See Figure 4-5)
NOTE
Removing the press fit stator in the field is not
recommended. The rotor and stator are a
matched pair and should not be separated. 2
3
When disassembling compressor, matchmark parts
so they may be replaced in their same relative positions. 1
(See Figure 4-2 for an illustration of the compressor.)
Refer to Table 4-4 and Table 4-5 for applicable
compressor wear limits and torque values. 5
a. Place the compressor in a position where it will be

convenient to drain the oil. Remove the oil plug on oil 4
pump inlet passage (see Figure 4-6 for location) to vent
the crankcase. Loosen the drain plug (see Figure 4-2) in
bottom plate and allow the oil to drain out slowly.
Remove the plug slowly to relieve any crankcase 1. Oil Pressure Relief Valve
pressure. A plug in the bottom center of the crankcase 2. Oil Return Check Valve
may also be removed for draining the motor end more 3. Oil Suction Tube
quickly. (Some units do not have this plug.) 4. Capscrew
5. Connecting Rod and Cap Assembly
1 2 3 4 5 7 Figure 4-5. Bottom Plate Removed
CAUTION
The copper tube which connects to the oil suction
strainer extends out the bottom with the bottom
plate removed. Take precautions to avoid
bending or breaking it while changing crankcase
positions.
f. There are two types of oil pumps; vane and gear. See
Figure 4-3 to identify which oil pump is used, then follow
6 the correct procedure below.
1. Cylinder Head Gasket Vane Oil Pump:
2. Discharge Valve Screw and Lockwasher 1. Remove the oil pump cover capscrews (See
3. Discharge Valve Stop Figure 4-2). This will free the oil feed guide retaining spring
4. Discharge Valve cover gasket, and the oil feed guide. (See Figure 4-6) Hold
5. Valve Plate piston to prevent shaft from turning if necessary.
6. Valve Plate Assembly 2. Remove the oil pump drive segment screws and
7. Valve Plate Gasket lockwashers before the bearing head is removed. (See
Figure 4-4. Exploded View of Valve Plate Assembly Figure 4-6) Unscrew the bearing head capscrews, remove
the bearing head, and then remove the bearing head
b. Remove cylinder head capscrews. If the cylinder gasket.
head is stuck, tap the cylinder head with a wooden or lead 3. With the pump-end bearing head removed from the
mallet. Be careful not to drop the head or damage the compressor, remove the plunger retaining rings with snap
gasket sealing surface. (See Figure 4-2 and Figure 4-4) ring pliers. As each retaining ring is removed, the spring
Remove cylinder head gasket. guide, vane spring and pump vane may be removed from
c. Free the valve plate from the cylinder deck by using the vane cylinder in the bearing head. (See Figure 4-6)
the discharge valve hold down capscrews as jack screws 4. Push the pump rotor out of the bearing head by
through the tapped holes of the valve plate after the valve forcing against the rotor with a thumb. Force from the
stops and valves have been removed. Remove valve plate bearing side and remove from the opposite side. The
gasket. (See Figure 4-4) pump rotor retaining ring will come out with the rotor.
4-4
5. A new bearing head complete with oil pump should
be obtained from Carrier Transicold as a replacement to 1
eliminate oil pump trouble. However, if the cause of
pump failure can be determined in the field, replacement
parts may be ordered from Carrier Transicold to repair
the pump.
15
14
13 11 9 2
5 10
12 8 3
1 4
2
1. Oil Pump & Bearing Head
3 2. Thrust Washer (Gear Pump Only)
4 3. Oil Pickup Tube
4. Oil Inlet Port
7
Figure 4-7. Gear Oil Pump and Bearing Head
6
g. Be very careful not to damage the motor windings
11 5 when removing the motor end cover as the cover fits over
the winding coils. Remove all capscrews except one in the
16 top of the cover. Then, while holding the cover in place,
remove the remaining capscrew. Do not allow the cover
TOP to drop from its own weight. To prevent striking the
12 winding, move the cover off horizontally and in line with
the motor axis.
h. Remove the refrigerant suction strainer and if it is
removed with ease it may be cleaned with solvent and
replaced. (See Figure 4-8) If the strainer is broken,
corroded or clogged with dirt that is not easily removed,
replace the strainer. Install new gaskets upon reassembly.
3
7 6 5 4 3 2 1
4
1. Oil Pump Cover 9. Retaining Ring
2. Cover Gasket 10. Spring Guide
3. Capscrews and 11. Bearing Head
Lockwashers 12. Pump Rotor
4. Oil Pump Drive 13. Oil Feed Guide
5. Rotor Retaining Ring 14. Retainer Spring
6. Pump Vane Cylinder 15. Capscrews and
7. Pump Vane Washers
8. Vane Spring 16. Oil Inlet Passage
Figure 4-6. Vane Oil Pump and Bearing Head 1. Valve Capscrew
2. Suction Service Valve
3. Valve Gasket
4. Motor End Cover
Gear Oil Pump: 5. Motor End Cover Gasket
6. Suction Strainer
1. Remove eight capscrews and remove oil pump
7. Strainer Screws and Washers
bearing head assembly, gasket and thrust washer. (See
Figure 4-7) Figure 4-8. Motor End Cover
2. If it was determined that the oil pump was not i. Block the compressor crankshaft so that it cannot
operating properly, the entire oil pump and bearing head turn. Use a screw driver to bend back the tabs on the
assembly must be replaced. Replacement parts for the lockwasher and remove the equalizer tube. (See
pump are not available. Figure 4-10) The slinger at the end of the shaft draws
4-5
vapor from the crankcase. It may discharge through a tee terminal bushing in case a leak should occur. To stop leak,
or a single equalizer tube. tighten the terminal bushing nut only enough to stop the
escape of gas. Do not tighten until terminal bushing is
j. If the piston rings extend beyond the cylinder tops,
flush with the mounting plate. The tightening torque
the pistons can be pulled through the bottom plate
used at the factory is 0.21 to 0.23 mkg (18 to 20 inch
opening after the piston rings are compressed. A piston
pounds) maximum to prevent damage to the plastic parts.
ring squeezer made from sheet metal which almost
encircles the periphery of the rings, will facilitate
removal. Each piston pin is locked in place by lock rings
which are snapped into grooves in the piston wall.
12
6
5 11
7 6
8
6
8 10 4
9 4 9 2
3 7
2 5
3
10 1 1
NOTE: Parts shown are for one terminal.
1. Capscrew 6. Connecting Rod 1. Terminal Bushing Nut
2. Cap 7. Compression Ring 2. Lock Washer
3. Crankshaft 8. Piston 3. Terminal Washer
4, Thrust Washer 9. Pin 4. Outer Terminal Bushing
5. Rotor Drive Key 10. Retainer 5. O-Ring
6. Terminal Bushing Washers (Grey)
Figure 4-9. Crankshaft Assembly 7. Terminal Bushing Washers (Red)
8. Inner Terminal Bushing
k. Since the stator is not replaced in the field, the 9. Terminal Mounting Plate
terminal plate assembly need not be disturbed unless a 10. Cover Gasket
leak exists or a terminal part requires replacing. 11. Inner Terminal Block
12. Terminal Screw
Disassemble and assemble the terminal plate as
shown in Figure 4-11. Figure 4-11. Terminal Mounting Assembly
4.7 COMPRESSOR REASSEMBLY
To clean compressor parts, use a suitable solvent with
proper precautions. Coat all moving parts with
1 compressor oil before assembly. Refer to Table 4-5, for
applicable compressor torque values.
2
a. Suction and Discharge Valves
3
If the valve seats look damaged or worn, replace
valve plate assembly. Always use new valves because it is
difficult to reinstall used discharge valves so that they will
seat as before removal. Any valve wear will cause leakage
for this reason.
1. Equalizer Tube and Lockscrew Assembly
2. Lockwasher Suction valves are positioned by dowel pins (see
3. Counterweight --- Motor End Figure 4-12) and will assume their original position when
reinstalled. No two valves are likely to wear exactly the
Figure 4-10. Removing Equalizing Tube and Lock same. Never interchange used valves.
Screw Assembly
Do not omit the suction valve positioning springs.
The terminal mounting plate assembly as originally (See Figure 4-12) Place the springs so that the ends bear
installed is assembled so as to leave a small space between against the cylinder deck (middle bowed away from
the outer terminal bushing and the surface of the cylinder deck). Use new gaskets when reinstalling valve
mounting plate. This is to provide further crush of the plates and cylinder heads.
4-6
the screen for holes or an accumulation of dirt. The
1
screen can be cleaned with a suitable solvent.
There are two types of oil pumps; vane and gear. See
2 Figure 4-3 to identify which oil pump is used, then follow
the correct procedure below.
3
Vane Oil Pump (See Figure 4-6):
a. Install the bearing head assembly with a new gasket
on the compressor crankshaft. Carefully push oil pump
on by hand ensuring that the bearing head mounts flush
to the crankcase body. The top of the bearing head is
marked on the mounting flange.
b. Align the gasket and install the eight capscrews in the
mounting flange.
c. Install the drive segment with the two capscrews and
lock washer.
1. Suction Valve Positioning Spring d. Insert the oil feed guide with the large diameter in.
2. Suction Valve Insert the guide retaining spring so that it fits over the
3. Valve Plate Dowel Pin smaller diameter of the feed guide. The pump cover can
now be installed.
Figure 4-12. Suction Valve and Positioning Springs
e. Place the pump cover, with a new gasket, over the
b. Compression Rings guide retaining spring and compress the spring to enable
installation of the cover capscrews.
1. Depending on date of manufacture, the
compressor may be equipped with double or single ring Gear Oil Pump (See Figure 4-7):
pistons. This variation may also exist with replacement a. Install the pump end thrust washer on the two dowel
piston assemblies. If double ring pistons and ring sets are pins located on the bearing head.
to be installed, both compression rings must be installed.
Also, double ring and single ring pistons may be installed CAUTION
in the compressor. Ensure that the thrust washer does not fall off
2. The compression ring is chamfered on the inside the dowel pins while installing the oil pump.
circumference. This ring is installed with the chamfer b. Install the bearing head assembly with a new gasket
towards the top. If using a double ring piston, stagger the on the compressor crankshaft. Carefully push the oil
ring end gaps so they are not aligned. pump on by hand ensuring that the thrust washer remains
The gap between the ends of the piston rings can on the dowel pins, the tang on the end of the drive
be checked with a feeler gauge by inserting the ring into segment engages the slot in the crankshaft, and the oil
the piston bore about one inch below the top of the bore. inlet port on the pump is aligned with the oil pickup tube
Square the ring in the bore by pushing it slightly with a in the crankcase. The pump should mount flush with the
piston. The maximum and minimum allowable ring gaps crankcase.
are 0.33 and 0.127 mm (0.013 and 0.005 inch) c. Align the gasket and install the eight capscrews in the
mounting flange.
3. Install rotor with key. Screw on equalizer tube
and lock screw assembly with lock washer and bend over
tabs of lock washer. Assemble suction strainer to motor
and cover and bolt cover to crankcase. Assemble valve
Compression Ring plates and gaskets. Assemble cylinder heads and gaskets.
Feel if the shaft will turn by hand.
Figure 4-13. Piston Rings
4. Install oil suction screen and bottom plate.
C. Installing the Components 4.8 CHECKING THE COMPRESSOR
OIL LEVEL
1. Install the crankshaft through the pump end of
the compressor. Do not damage main bearings. Push a. To Check the Oil Level in the Compressor:
pistons from the inside of the crankcase through the 1. Operate the unit in six cylinder cooling for at
cylinders being careful not to break the rings. Place least 20 minutes.
chamfered side of connecting rod against radius of
2. Check the front oil sight glass on the compressor
crankpins. Install matching connecting rod caps through
to ensure that no foaming of the oil is present after 20
bottom cover plate.
minutes of operation. If the oil is foaming excessively
2. The oil screen (located in the bottom of the after 20 minutes of operation, check the refrigerant
crankcase), is connected to the inlet of the oil pump. system for flood-back of liquid refrigerant. Correct this
Whenever the compressor crankcase is opened, inspect situation before performing step a.3.
4-7
3. Turn unit off and the correct oil level should be fill plug (see Figure 4-2). Some compressors have the oil
between 1/4 and 1/2 of the sight glass. If the level is above plug located on the crankcase, at the right or left side of
1/2, oil must be removed from the compressor. To remove the oil pump.
oil from the compressor, follow step d. If the level is below d. To Remove Oil From an 06DR Compressor:
1/8, add oil to the compressor following step b. below.
1. If the oil level recorded in step a.3 is above 1/2 of
b. Adding Oil with Compressor in System the sight glass, oil must be removed from the compressor.
Two methods for adding oil are the oil pump method 2. Close (frontseat) suction service valve and pump
and closed system method. unit down to 0.2 to 0.3 kg/cm@ (2 to 4 psig). Frontseat
1. Oil Pump Method: discharge service valve and slowly bleed remaining
refrigerant.
One compressor oil pump that may be purchased is a
Robinair, part no. 14388. This oil pump adapts to a 3.785 3. Remove the oil drain plug on the bottom plate of
liters (one U.S. gallon) metal refrigeration oil container the compressor and drain the proper amount of oil from
and pumps 0.0725 liters (3 and 1/2 ounces) per stroke the compressor to obtain the 1/2 sight glass maximum
when connected to the suction service valve port. Also level. Replace the plug securely back into the compressor.
there is no need to remove pump from can after each use. DO NOT FORGET TO OPEN SUCTION AND
DISCHARGE SERVICE VALVES.
When the compressor is in operation, the pump
check valve prevents the loss of refrigerant, while 4. Repeat Step a. to ensure proper oil level.
allowing servicemen to develop sufficient pressure to 4.9 CHECKING OR REPLACING MOISTURE-
overcome the operating suction pressure to add oil as LIQUID INDICATOR
necessary. When the refrigeration system is operating, the
Backseat suction service valve and connect oil moisture-liquid indicator provides an indication of
charging hose to port. Crack the service valve and purge moisture in the system.
the oil hose at oil pump. Add oil as necessary. The indicator element is highly sensitive to moisture
2. Closed System Method: and will gradually change color in direct relation to an
increase or decrease in the moisture content of the
In an emergency where an oil pump is not available, system. The safe, caution, and unsafe system operating
oil may be drawn into the compressor through the suction conditions are then easily determined by matching the
service valve. element color with the colors displayed on the reference
CAUTION label.
Extreme care must be taken to ensure the To change indicator or lens:
manifold common connection remains a. Pump down the unit per section 4.1 and install new
immersed in oil at all times. Otherwise air and indicator or lens.
moisture will be drawn into the compressor.
b. Evacuate the unit per section 4.3 and add refrigerant
Connect the suction connection of the gauge charge per section 4.4.
manifold to the compressor suction service valve port, c. Start unit and after twelve hours re-check indicator.
and immerse the common connection of the gauge If indicator does not indicate a safe condition, pump unit
manifold in an open container of refrigeration oil. Crack down and change filter-drier. (Refer to section 4.10)
the suction service valve and gauge valve to vent a small
4.10 CHECKING OR REPLACING THE
amount of refrigerant through the common connection FILTER-DRIER
and the oil to purge the lines of air. Close the gauge
manifold valve. If the sight glass appears to be flashing or bubbles are
constantly moving through the sight glass, the unit may
With the unit running, frontseat the suction service have a low refrigerant charge, or the filter-drier could be
valve and pull a vacuum in the compressor crankcase. partially plugged.
SLOWLY crack the suction gauge manifold valve and oil
will flow through the suction service valve into the To Check Filter-Drier:
compressor. Add oil as necessary. a. One test for a restricted or plugged filter-drier is by
Run unit for 20 minutes, in cooling, and check oil level. feeling the liquid line inlet and outlet connections of the
drier cartridge. If the outlet side feels cooler than the
c. Adding Oil to Service Replacement Compressor inlet side, then the filter-drier should be changed.
NOTE b. Another test is that the moisture-liquid indicator
The correct oil charge is 4.0 liters pints (8.5 U.S.). shows moisture in the system (refer to section 4.9).
To Replace Filter-Drier:
Service replacement compressors may or may not be
shipped with oil. a. Remove the refrigerant (refer to section 4.1).
If compressor is without oil: b. Remove filter-drier clamp, then replace drier.
Add oil, (paragraphs 1.3.b and 4.8.b) through the c. Evacuate the unit per section 4.3.
suction service valve flange cavity or by removing the oil d. Charge unit with refrigerant per section 4.4.1.
4-8
e. After unit is in operation, inspect for moisture in d. Set nitrogen pressure regulator at 21kg/cm@ (300
system. (Refer to section 4.9) psig) with bleed-off valve closed.
4.11 CHECKING OR REPLACING HIGH e. Close valve on cylinder and open bleed-off valve.
PRESSURE SWITCH
f. Open cylinder valve. Slowly close bleed-off valve to
4.11.1 Replacing High Pressure Switch increase pressure on switch. The switch will open at a
a. Remove the refrigerant (refer to section 4.1). static pressure up to 21 kg/cm@ (295 psig). If light is used,
Frontseat both suction and discharge service valves to light will go out and if ohmmeter is used, the meter will
isolate compressor. indicate open.
b. Disconnect wiring from defective switch. The high g. Slowly open bleed-off valve to decrease the pressure.
pressure switch is located on the center head and is The switch will close at 13 kg/cm@ (190 psig).
removed by turning counterclockwise. (See Figure 1-1) 4.12 SERVICING QUENCH SOLENOID VALVE (QV)
c. Install new cutout switch after verifying switch NOTE
settings. (Refer to section 4.11.2)
Some models have a thermostatic expansion
d. Evacuate and dehydrate the compressor per quench valve (refer to section 5), so servicing
paragraph 4.5.1.o through 4.5.1.u. quench valve is NOT APPLICABLE.
4.11.2 Checking High Pressure Switch
a. Checkout Procedure
WARNING It is important to verify (for 0_C = 32_F simulated
Do not use a nitrogen cylinder without a temperature only) that quench function occurs before
pressure regulator because cylinder pressure is full modulation valve (SMV) closure occurs and
approximately 165 kg/cm@ (2350 psi). Do not use compressor subsequently shuts off.
oxygen in or near a refrigeration system as an One of two ways of checking the above is by feeling
explosion may occur. for a large drop in temperature of the quench line (1/4
inch tube from solenoid valve QV) when the TQ light
NOTE emitting diode (LED) energizes (on the controller main
The high pressure switch (HPS) is board). A slight increase in suction pressure will be
non-adjustable. noticed when the quench function occurs.
1 4 The other method of checking operation of the valve is:
1. Place the Start-Stop switch in the OFF position
and cut a 2.54 cm (one inch) slit in the insulation of the 1/4
5 8
2 inch quench line approximately 10 cm (4 inches) past the
6 7 outlet of the quench valve. (See Figure 1-3)
2. Using a calibrated Simpson meter, firmly secure
the thermistor bulb against the copper tube and insulate
opening with tape or Presstite.
3
3. Set controller setting knob at ---3_C (26.6_F)
and start the unit. Move the temperature simulator
switch in the controller to 0_C (32_F) setting and hold in
this position.
4. Depress the time delay override switch and hold
1. Cylinder Valve and 5. Bleed-Off Valve in this position during test.
Gauge 6. 1/4 inch Connection
2. Pressure Regulator 7. High or Low 5. Slowly turn the control setting knob, from ---3_C
3. Nitrogen Cylinder Pressure Switch (26.6_F) towards 0_C (32_F), until the TQ light emitting
4. Pressure Gauge 8. Ohmmeter diode (LED) lights. At this time the quench solenoid should
(0 to 36 kg/cm@ = open and a temperature drop of approximately ---9.4 to
0 to 500 psig) ---6.7_C (15 to 20_F) will be noted on Simpson meter after
one minute.
Figure 4-14. Typical Setup for Testing High Pressure
Switch 6. Refer to paragraphs 4.12.b and 4.23 if the
temperature does not drop rapidly.
a. Remove switch as outlined in paragraph 4.11.1. b. Replacing Solenoid Valve Coil
b. Connect ohmmeter or continuity light across switch The coil may be removed without removing the
terminals. Ohm meter will indicate resistance and refrigerant.
continuity light will be illuminated if switch closed after
Remove screw, lockwasher and coil. Disconnect
removing compressor pressure.
leads and remove coil. Verify new coil type, voltage and
c. Connect capillary to a cylinder of dry nitrogen. (See frequency. (This information appears on the coil
Figure 4-14) housing.) Place new coil on valve stem and secure same.
4-9
4.13 REPLACING THE EVAPORATOR COIL b. Remove the two lower mounting bolts that secure the
AND HEATER ASSEMBLY motor-fan assembly to the unit. Loosen the two upper
bolts as the motor mount upper holes are slotted.
The evaporator section, including the coil, should be
cleaned with fresh water or steam, preferably. Another c. Remove motor, fan, and wiring from unit. Place fan
recommendation is to use Oakite 202 or similar cleaner motor and fan on a support. Remove the wiring and fan.
following manufacturers instructions. d. Lubricate fan motor shaft with a graphite-oil
The two drain pan hoses connected to the drain pan, solution (Never-Seez). Apply thread sealer (Loctite H,
are routed behind the condenser fan motor and brown in color) to the two fan set screws. Install fan on
compressor. The drain pan line(s) must be open to ensure motor. The evaporator fan locating dimension is shown
adequate drainage. in Figure 4-15.
e. Connect wiring per applicable wiring diagram
To Replace the Evaporator Coil: (refer to section 5) and install motor and fan assembly
a. Store the refrigerant charge in an evacuated in unit. Apply power, momentarily, to check fan
container by attaching a line to the liquid line valve. (See rotation. (Refer to paragraph 1.4.f) If fan spins
Figure 1-3 and refer to section 4.1) backwards, refer to section 4.28 for two-speed motors.
b. With power OFF and power plug removed, remove Replace access panel, making sure panel does not
the screws securing the panel covering the evaporator leak. Make sure T.I.R. locking device is lockwired.
section (upper panel).
c. Disconnect the defrost heater wiring.
d. Disconnect the klixon from the coil. The defrost
termination thermostat (DTT) is located on the middle
coil support as shown in Figure 1-2.
e. Remove middle coil support. 4 1/4 INCHES
(10.79 CM)
f. Remove the mounting hardware from the coil.
g. Unsolder the two coil connections, one at the Figure 4-15. Evaporator Fan Locating Dimension
distributor and the other at the coil header.
4.15 SERVICING THE EVAPORATOR COIL
NOTE HEATERS
It may be necessary to raise the fan deck to break WARNING
the solder connections (to raise coil). Before servicing unit, make sure the unit circuit
breaker (CB1) and the start-stop switch are in
h. After defective coil is removed from unit, remove the OFF position. Also disconnect power plug
defrost heaters and install on replacement coil. and cable.
i. Install coil assembly by reversing above steps. a. Remove the lower access panel (Figure 1-1) by
j. Leak check connections per section 4.2. Evacuate removing the T.I.R. locking device lockwire and
the unit per section 4.3 and add refrigerant charge per mounting screws.
section 4.4.2. b. Determine which heater(s) need replacing by checking
4.14 REPLACING THE EVAPORATOR FAN resistance on each heater as shown in paragraph 1.4.e.
AND MOTOR ASSEMBLY c. Remove hold-down clamp securing heaters to coil.
The evaporator fans circulate air throughout the d. Lift the U portion of the heater (with opposite end
container by pulling air in the top of the unit. The air is down and away from coil). Move heater left (or right)
discharged through the evaporator coil where it is either enough to clear the heater end support.
heated or cooled and then discharged out the bottom of 4.16 CHECKING CALIBRATION OF THE
the refrigeration unit into the container. (Refer to DEFROST AIR SWITCH
paragraph 1.4.f) The fan motor bearings are factory
lubricated and do not require additional grease. a. Make sure magnehelic gauge is in proper calibration.
NOTE
WARNING
The magnehelic gauge may be used in any
Always turn OFF the unit circuit breaker (CB1) position, but must be re-zeroed if position of
and disconnect main power supply before gauge is changed from vertical to horizontal or
working on moving parts. vice versa. USE ONLY IN POSITION FOR
WHICH IT IS CALIBRATED.
a. Remove upper access panel (See Figure 1-1) by
removing mounting bolts and T.I.R. locking device. b. With air switch in vertical position, connect high
Reach inside of unit and remove Ty-Rap securing wire pressure side of magnehelic gauge to high side
harness loop. connection of air switch. (See Figure 4-16)
4-10
c. Install tee in pressure line to high side connection. c. Unsolder discharge line and remove the line to the
Tee should be approximately half-way between gauge and water-cooled condenser (if so equipped).
air switch or an improper reading may result. d. Remove coil mounting hardware and then remove
d. Attach an ohmmeter to the air switch electrical the coil.
contacts to check switch action. e. Install replacement coil. Solder connections.
NOTE f. Leak check the coil per section 4.2. Evacuate the unit
Use a hand aspirator (P/N 07-00177-01), since per section 4.3 and then, charge the unit with refrigerant
blowing into tube by mouth may cause an per section 4.4.1.
incorrect reading. 4.18 CONDENSER FAN AND MOTOR
e. With the gauge reading at zero, apply air pressure ASSEMBLY
very slowly to the air switch. An ohmmeter will indicate WARNING
continuity when switch actuates.
Do not open condenser fan grille before turning
f. Refer to paragraph 1.3.e for switch settings. If switch power OFF and disconnecting power plug.
fails to actuate at correct gauge reading, adjust switch by
turning adjusting screw clockwise to increase setting or NOTE
counterclockwise to decrease setting. The replacement motor should be degreased
and sprayed with a coat of Tectyl before
g. Repeat checkout procedure until switch actuates at
installing in unit.
correct gauge reading.
h. After switch is adjusted, place a small amount of The condenser fan rotates counterclockwise (viewed
paint or glycerol on the adjusting screw so that vibration from front of unit) and pulls air through the the
will not change switch setting. condenser coil and discharges horizontally through the
front of the unit.
a. Open condenser fan screen guard.
2
b. Loosen square head set screws (2) on fan. (Thread
5 sealer has been applied to set screws at installation.)
Then disconnect wiring from motor junction box.
CAUTION
Take necessary steps (place plywood over coil or
6 3 use sling on motor) to prevent motor from falling
4 into condenser coil.
1
c. Remove motor mounting hardware and replace the
motor. It is recommended that new locknuts be used
when replacing motor. Connect wiring per wiring
1. Ohmmeter or Continuity Device diagram (refer to section 5).
2. Adjustment Screw (0.050 socket head size)
3. Low Side Connection d. Install fan loosely on motor shaft (hub side in). Install
4. Pressure Line or Aspirator Bulb (P/N 07-00177-01) venturi. Apply Loctite H to fan set screws. Adjust fan
5. Magnehelic Gauge (P/N 07-00177) within venturi so that the outer edge of the fan projects
6. High Side Connection 7.9 mm (5/16 inches) out from edge of venturi. Spin fan
by hand to check clearance.
Figure 4-16. Defrost Air Switch Test Set-Up e. Close and secure condenser fan screen guard.
4.17 CONDENSER COIL f. Apply power to unit and check fan rotation. If fan
The condenser consists of a series of parallel copper motor rotates backwards, reverse wires 5 and 8.
tubes expanded into copper or aluminum fins. The 4.19 RECORDING THERMOMETER (PARTLOW)
condenser coil must be cleaned with fresh water or steam
so the air flow is not restricted. Fan rotation is CAUTION
counterclockwise when viewed from shaft end of motor. The inside mechanism of the control,
particularly the inside of the element housing
WARNING
should never be oiled, however, control
Do not open condenser fan grille before turning mechanisms should be sprayed periodically
power OFF and disconnecting power plug. (every 60 days) with corrosion-inhibiting CRC
3-36a or 6-66 or LPS no. 2.
To Replace the Condenser Coil:
a. Instruments for Checking Bulb Temperature
a. Store the refrigerant charge in an evacuated
The recording thermometer may be equipped with
container by attaching a line to the liquid line valve. (See
one or two Simpson accessories (#344 units), each
Figure 1-3 and refer to section 4.1)
consisting of a thermistor probe and receptacle
b. Remove the condenser coil guard. (mounted to instrument case) Single probe is attached to
4-11
the element (bulb) capillary which senses the container this instrument, be certain that the recommended length
return air temperature. If using two probes, the other of the check probe is immersed so that it accurately will
probe is attached to the supply air temperature sensor. reflect temperature. Bear in mind that this measurement
checks the test probe at 0_C (32_F) only; it is possible for
In the event of a failure with the #344 test lead, other
this type of instrument to be inaccurate at other
instruments for checking bulb temperatures are:
temperatures. Rezero check thermometer, if necessary,
1. Simpson Meter, CTC P/N 07-00013 or Robinair by manufacturers instructions.
Thermistor Temperature Tester, Model 12860. c. Checking the Recording Thermometer Bulb
A resistance thermometer and a RCA lead with a Temperature
phono-plug at each end may be used to compare bulb Checking temperature is accomplished by
temperature and stylus indicated temperature on chart by comparing the instruments indicated temperature
inserting one end of the lead into receptacle provided on (stylus) with the known temperature existing at the
the controller and other end in the meter. Always check element sensing bulb. To properly check the temperature
resistance thermometer before using, refer to paragraph b. of the recorder, the element sensing bulb should be
2. Ohmmeter stabilized at a temperature of 0_C (32_F). This is
accomplished by using one of the two following methods,
a. Place one probe of ohmmeter in the middle of whichever is more convenient.
the receptacle provided on the chart platen and ground
other probe to unit. 1. Unit Running:
b. Note reading of meter and using Table 4-1, Place set point at 0_C (32_F). After unit has pulled
convert resistance to temperature. down to this temperature, allow compressor to cycle
ON-OFF 3 to 5 times to be certain temperature has
stabilized at 0_C (32_F) as verified by the resistance
thermometer. If the temperature indicated by the
thermometer differs from 0_C (32_F) by more than
0.6_C (1_F) when compressor cycles off, rezeroing must
be performed.
2. Unit Off:
2 Place the recording thermometer element (sensing
bulb) in 0_C (32_F) ice-water bath. Ice-water bath is
5 prepared by filling an insulated container (of sufficient
size to completely immerse bulb) with ice cubes or
chipped ice, then filling voids between ice with water, and
agitating until mixture reaches 0_C (32_F) as shown by a
laboratory thermometer.
1
When the temperature at the element sensing bulb
has stabilized at 0_C (32_F), as indicated by stable stylus
indication, compare temperature indicated by stylus with
temperature shown by a laboratory thermometer. If the
two readings do not agree, the recording thermometer
should be rezeroed. (Refer to paragraph d)
3
d. Rezeroing the Recording Thermometer
4
1. Be certain that element bulb temperature has
stabilized at 0_C (32_F). Note the amount of
temperature difference between the test meter or
thermometer reading and the stylus indicated
temperature.
1. Wind-up Key 4. Pinion Shaft
If the difference noted between the known element
2. Stylus 5. Stylus Lifter
temperature and indicated temperature is within
3. Set Screw
acceptable limits (0.3 of 0_C = 1/2_ of 32_F), do not
Figure 4-17. Partlow Recording Thermometer attempt to rezero. If more than 0.3_C (1/2_F) in
variation, carefully note the number of degrees.
b. Checking Resistance Thermometer 2. If recording thermometer is found to require
Calibrate the resistance thermometer by completely rezeroing:
filling a thermos container full of ice cubes or chips and a. Loosen set screw, item 3, Figure 4-17 and zero
filling the voids between the ice with plain water. Stir the thermometer by turning pinion shaft, item 4.
solution until the mixture registers 0 to 0.3_C (32 to Lengthening pinion shaft (counterclockwise) raises
32.5_F), as indicated by a laboratory thermometer. stylus indicated temperature reading: shortening shaft
Immerse the resistance thermometer in the 0_C (32_F) (clockwise) lowers stylus reading. Then retighten set
solution and check its accuracy at this temperature. With screw.
4-12
b. Reset control at 0_C (32_F), start refrigeration b. Calibration
unit and repeat accuracy check. After temperature 1. Install new chart on platen.
stabilization, recording thermometer should be within
0.3_C (1/2_F) limits. 2. Place recorder bulb in ice bath (0 0.2_C = 32
0.35_F). (Remove rear upper panel to remove bulb.)
e. Replacing Recording Thermometer Element Leave bulb immersed in ice bath for 10 minutes.
(Bulb and Capillary)
3. After 10 minutes, rotate the chart by hand and
The element is mercury-filled and the check the stylus indicated temperature. Do not touch
temperature-pressure of the element controls the stylus stylus during the checkout procedure.
which moves across the chart in response to temperature 4. If adjustment is required, loosen setscrew
changes as sensed by the bulb located in the evaporator (cross-recessed head). Using a 7 mm wrench, rotate the
supply air. adjustment screw clockwise to set the stylus 1 to 2_C (1.8
The element flange contains three O-rings. Care to 3.6_F) higher than desired temperature.
should be taken to install the new element flange without 5. Rotate the adjustment screw counterclockwise
damaging the O-rings. It is possible for a mercury leak to to set the stylus about 0.5_C (0.9_F) higher than set
develop at the flange if O-ring damage occurs. temperature. Rotate the chart by hand. The indicated
The stylus will continue to fall (container temperature should be 0_C (32_F).
temperature will actually be higher) if a leak develops in NOTES
the flange, capillary or bulb. 1. One full turn with the adjustment screw
To replace the recording thermometer element: changes the indicated temperature by
approximately 5_C (9_F).
1. Turn unit OFF and disconnect power source. 2. Overtightening of setscrew may change set
2. Remove middle back panel. Remove bulb clamps temperature.
securing bulb to unit. 3. Calibration should only be done when bulb
temperature is decreasing.
3. Remove two flange screws from recording 4. DO NOT move stylus by hand.
thermometer and feed capillary and element through the
unit.
4. Push replacement bulb end and capillary through the
unit. 4 5
5. Fill slots with silastic (RTV432, Dow Corning).
6. Attach bulb clamps tightly to bulb.
7. Connect element flange to recorder making sure hub 3 6
of flange faces out to fit into the hole in instrument case
(recording thermometer).
8. Rezero the recorder. (Refer to paragraphs 4.19.a. 2 7
through 4.19.d)
9. Install inlet air grille and lower panel. Start unit and 1
check recorder calibration. 8
CAUTION
Capillary tubing may be bent, but never sharper
than 1/2 inch radius: extra care should be taken
when bending adjacent to welds. The sensing 9
bulb should never be bent, as this will affect
calibration. 1. Voltage Indicator
2. Indicator Test Switch
4.20 RECORDING THERMOMETER 3. Battery (C size, Alkaline)
(SAGINOMIYA)
4. Sensor Assembly
NOTE 5. Stylus
6. Stylus Lifter
Do not overtighten chart nut after replacing 7. Setscrew(Adjustment)
chart. 8. Bulb and Mechanism
9. Bushing and Nut
a. Battery
Figure 4-18. Saginomiya Recording Thermometer
1. Open door and remove chart nut and platen.
c. Replacing Sensor Probe
2. Push voltage indicator test switch, item 2,
Figure 4-18. Replace battery if voltage indicator points to 1. Remove box from unit.
the red or white zone. 2. Remove nut and bushing, item 9, Figure 4-18.
4-13
3. Install replacement probe and bushing. Seal with 4. Release calibration button. Push calibration
silicone before securing to case. button, and hold in. After approximately 20 seconds
recorder should read ---20_C (---4_F).
4. Install box into unit.
5. If adjustment is required, rotate span
4.21 RECORDING THERMOMETER
(FUJI KIKI) adjustment to read ---20_C (---4_F).
1 2 3 4 5 6. Release calibration button. Push calibration
button, and hold in. After approximately 20 seconds
11 recorder should read 20_C (68_F).
7. If adjustment is required, rotate zero adjustment
to read 20_C (68_F).
8. Release calibration button.
9. Push calibration button and release. Recorder
will read actual box temperature.
10 10. Repeat above steps to check calibration.
4.22 RUST PREVENTION AND
MAINTENANCE OF PAINTED SURFACES
9 a. Rust Prevention --- Components
6
To prevent corrosion, external parts such as
8 compressor, cable clamps, fasteners, and evaporator fan
motor, should be sprayed with clear urethane (CRC
Chemicals, Part No. 2-53) every six months. The inside of
7 the control panel should be sprayed (CRC Chemicals,
Part No. 3-36) at similar time periods.
b. Maintenance of Painted Surfaces
The refrigeration unit is protected by a special paint
system against the corrosive atmosphere in which it
normally operates. However, should the paint system be
1. Setscrew (Adjustment) damaged, the base metal can corrode. In order to protect
2. Calibration Button the refrigeration unit from the highly corrosive sea
3. Sensor (Supply) Recording LED atmosphere or if the protective paint system is scratched
4. Sensor (Return) Recording LED or damaged, clean area to bare metal using a wire brush,
5. Sensor Alarm LED emery paper or equivalent cleaning method.
6. Chart Nut Immediately following cleaning, spray or brush on zinc
7. Battery (C size, Alkaline) rich primer. After the primer has dried, spray or brush on
--- Located behind plate finish coat of paint to match original unit color.
8. Stylus 4.23 SERVICING THE WATER-COOLED
9. Stylus Lifter CONDENSER
10. Voltage Indicator
11. Indicator Test Button NOTE
When Oakite compound No. 32 is being used for
Figure 4-19. Fuji Kiki Recording Thermometer the first time, the local Oakite Technical Service
representative should be called in for his
NOTE suggestions in planning the procedure. He will
show you how to do the work with a minimum
Do not overtighten chart nut after replacing chart. dismantling of equipment: how to estimate the
time and amount of compound required; how to
a. Battery prepare the solution; how to control and
1. Push voltage indicator test button, item 11, conclude the de-scaling operation by rinsing and
Figure 4-19. Replace battery if voltage indicator points to neutralizing equipment before putting it back
the red or silver zone. into service. His knowledge of metals, types of
scale, water conditions and de-scaling
b. Calibration techniques will be invaluable to you.
1. Install new chart on platen.
The water-cooled condenser is of the shell and coil
2. Push calibration button (item 2), and hold in. After type with circulating water through the cupro-nickel coil.
approximately 20 seconds recorder should read 0_C The refrigerant vapor is admitted to the shell side and is
(32_F). condensed on the outer surface of the coil.
3. If adjustment is required, rotate zero adjustment Rust, scale and slime on the water-cooling surfaces
to read 0_C (32_F). inside of the coil interfere with the transfer of heat,
4-14
reduce system capacity, cause higher head pressures and circulate through the tubes until all slime and mud has
increase the load on the system. been removed.
By checking the leaving water temperature and the c. After cleaning, flush tubes thoroughly with clean
actual condensing temperature, it can be determined if fresh water.
the condenser coil is becoming dirty. A larger than WARNING
normal difference between leaving condensing water Oakite No. 32 is an acid --- therefore be sure that
temperature and actual condensing temperature, the acid is slowly added to the water. DO NOT
coupled with a small difference in temperature of PUT WATER INTO THE ACID! --- this will cause
entering and leaving condensing water, is an indication of spattering and excessive heat.
a dirty condensing coil. Wear rubber gloves and wash the solution from
To find the approximate condensing temperature, with the skin immediately if accidental contact occurs.
the unit running in the cooling mode, install a gauge 0 to Do not allow the solution to splash onto concrete.
36.2 kg/cm@ (0 to 500 psig) on the compressor discharge d. Prepare a 15% by volume solution for de-scaling,
service valve. by diluting Oakite compound No. 32 with water. This is
For example: if the discharge pressure is 11.4 kg/cm@ accomplished by slowly adding 0.47 liter (one U.S. pint)
(147 psig), and referring to Table 4-7, R-12 of the acid (Oakite No. 32) to 2.8 liters (3 U.S. quarts) of
temperature-pressure chart, the 11.4 kg/cm@ (147 psig) water.
converts to 46_C (115_F). Centrifugal pump Gas Close vent pipe
30 GPM at 35 head vent
If the water-cooled condenser is dirty, it may be valve when pump
Priming is running.
cleaned and de-scaled by the following procedure: Globe
connection
a. Turn unit off and disconnect main power. Pump valves
b. Disconnect water pressure switch tubing by Suction

Condenser
loosening the two flare nuts. Install 1/4 inch flare cap on Tank
water-cooled condenser inlet tube (replaces tubing flare
nut). De-scale tubing if necessary. Remove water
1. What You Will Need: regulating valve
Return
a. Oakite composition No. 22, available as a
powder in 68 kg (150 lb) and 136 kg (300 lb). Pump Fine mesh
b. Oakite composition No. 32, available as a liquid support screen
in cases, each containing 3.785 liters (4 U.S. gallon)
bottles and also in carboys of 52.6 kg (116 lbs) net. A --- Forced Circulation
c. Clean fresh water.

Fill condenser with
d. Acid proof pump and containers, or bottles with cleaning solution. Do
rubber hose. not add solution more
2. What You Will Do --- (Summary): rapidly than vent can ex-
haust gases caused by
a. Drain water from condenser tubing circuit. Clean chemical action.
water tubes with Oakite No. 22 to remove mud and slime. 1 Pipe
b. Flush. 5 Approximate
c. De-scale water tubes with Oakite No. 32 to
remove scale. Vent
d. Flush. pipe
e. Neutralize.
f. Flush. 3 to 4
g. Put unit back in service under normal load and
check head (discharge) pressure. Condenser
3. Detailed Procedure:
a. Drain and flush the water circuit of the
condenser coil. If scale on the tube inner surfaces is B --- Gravity Circulation
accompanied by slime, a thorough cleaning is necessary
before de-scaling process can be accomplished. Figure 4-20. Water-Cooled Condenser Cleaning
b. To remove slime or mud, use Oakite e. Fill the tubes with this solution by filling from the
composition No. 22, mixed 170 grams (6 ounces) per liter bottom. See Figure 4-20A. Important: be sure to provide
(one U.S. gallon) of water. Warm this solution and a vent at the top for escaping gas.
4-15
f. Allow the Oakite No. 32 solution to soak in the 3. Check for continuity across the internal
tube coils for several hours, periodically pump-circulating it protector (IP). If (IP) is open and will not reset, connect
with an acid-proof pump. wires 3 and 4 (18 gauge) to terminal board. Check to see
if unit will start.
An alternate method may be used, whereby a bottle
(see Figure 4-20B) filled with the solution and attached to d. If the internal protector and circuit breakers (CB1
the coils by a hose can serve the same purpose, by raising and CB2) are good, check the transformer. Use a
and lowering of the bottle. The solution must contact the voltmeter and with the primary supply circuit ON check
scale at every point for thorough de-scaling, therefore the primary (input) voltage (230 vac). Next, check the
ensure that no air pockets exist, by regularly opening the secondary (output) voltage (460 vac) at the voltage
vent to release gas. Keep flames away from the vent gases. selector switch. The transformer is defective if voltage is
not available.
g. The time required for de-scaling will vary,
depending upon the extent of the deposits. One way to 4.25 SERVICING THE MODULATING
determine when de-scaling has been completed is to SOLENOID VALVE
titrate the solution periodically, using titrating CAUTION
equipment provided free by the Oakite Technical Service
It is important to verify (for 0_C = 32_F
representative. As scale is being dissolved, titrate simulated temperature only) that the quench
readings will indicate that the Oakite No. 32 solution is function occurs before full modulating valve
losing strength. When the reading remains constant for a closure occurs and compressor shuts off. (Refer
reasonable time, this is an indication that scale has been to section 4.12)
dissolved. a. Valve Checkout Procedure
h. When de-scaling is complete, drain the solution Modulation for 0_C (32_F) simulated temperature
and flush thoroughly with fresh water. can be verified in several ways. Without use of test
i. Next circulate a 56.7 grams (2 ounce) per liter equipment, listen for a change in compressor sound. Feel
(one U.S. gallon) solution of Oakite No. 22 through the for a drop in condensing air temperature as the suction
tubes to neutralize. Drain this solution. modulating valve closes. If a gauge manifold is connected
to unit, pressures will drop as modulating valve closes.
j. Flush the tubes thoroughly with fresh water.
The preferred method of monitoring controller
NOTE output to the modulating valve is by reading the DC
If the condenser cooling water is not being used voltage between terminals 12 and 14 on the main circuit
as drinking water or is not re-circulated in a board (temperature controller). Readings under 0.2 vdc
closed or tower system, neutralizing is not correspond with valve wide open. Full closure of valve
necessary. corresponds with 1.1 and 1.3 vdc.
NOTE
k. Put the unit back in service and operate under
Above voltages are numerically equal to valve
normal load. Check the head pressure. If normal, a
currents (0.2 vdc = 0.2 amp DC).
thorough de-scaling has been achieved.
4. What You Can Do For Further Help: When cooling a chill load and with unit in operation,
turn set pointer downscale to ---17.8_C (0_F) and note
Contact the Engineering and Service Department of suction pressure. (Pressure should increase after
the OAKITE PRODUCTS CO., 19 Rector Street, New approximately one minute.) Slowly raise set point and
York, NY 10006 U.S.A. for the name and address of the just before compressor shuts off, a significant drop in
service representative in your area. suction pressure should be noted. If no pressure change is
4.24 CHECKOUT PROCEDURE FOR noticed, valve or controller malfunctioned.
OPTIONAL POWER TRANSFORMER
b. To Replace Valve
If the unit does not start when connected to a 190/230 1. Store the refrigerant in an evacuated container.
vac power supply, check the following:
2. Remove two bolts from suction service valve.
a. Make sure circuit breaker (CB2) is in the ON
position. If CB2 does not hold in, check voltage supply. 3. Melt solder at modulating valve connection and
rotate valve and tubing enough to clear compressor.
b. Check to see if the transformer internal protector Remove valve and tubing. Replace defective modulating
(IP-AUTO-TRANS) is closed. Allow a reasonable length solenoid valve being careful to wrap body of replacement
of time for transformer to cool down. The transformer valve with a wet cloth while brazing. The coil need not be
includes two (2) internal protectors. Only one is wired removed.
into the system as the second protector is a spare.
4. Install new suction service valve gasket and
c. To Check for Continuity Across the Internal Protector install bolts in suction service valve. Torque to a value of
(IP-AUTO-TRANS): 2.77 to 4.15 mkg (20 to 30 ft/lb).
1. Turn power OFF and disconnect power source. 5. Solder all connections and leak check same.
2. Disconnect white wires 1 and 2 from terminal 6. Dehydrate and evacuate the unit per section 4.3
board. and then add refrigerant charge per section 4.4.2.
4-16
ground short is present, inspect the length of wiring for
1 damaged or exposed wires. Replace where necessary.
2 3. Setting the digital ohmmeter for low range,
check coils resistance. If coils resistance is below 5 ohms
3 it is recommended to be replaced. New coils have an
approximate resistance of 7.6 ohms at 25_ C (77_ F). The
chart below gives the resistance of a new coil at various
4 ambient temperatures.
5 Ambient Temperature Cold Coil
10_ F 6.45 ohms

6 40_ F 6.90 ohms
70_ F 7.40 ohms
100_ F 7.90 ohms
NOTE
7 A cold coil is a coil which had not been operating
and is assumed to be at ambient temperature.
8 Hot coil temperatures, taken after the unit has
been operating in deep modulation for a long
period of time, may give higher resistance
9 readings.
10 4. Reconnect the modulation valve coil wires to

11 their correct terminal locations.
d. Replacing the Coil
Remove coil nut and remove coil after disconnecting
wiring. When replacing nut, torque to a value of 0.41 mkg
(3 ft-lb).
4.26 CONTROLLER CHECKOUT PROCEDURE
1. Coil Nut 7. Piston NOTE
2. Coil Nut O-ring 8. Top Return Spring
3. Coil Housing 9. Valve Body If the unit is equipped with a Digital Display or a
4. Solenoid Coil 10. Bottom Return service accessory Digital Display is available,
Sleeve Spring this should be used for reading set point settings.
5. Solenoid Coil 11. Filter
4.26.1 Controller Pre-Trip
6. Enclosing Tube
Assembly a. Equipment Required
1. Volt-ohmmeter (capable of accurately reading 0
Figure 4-21. Modulating Solenoid Valve
to 2 vdc).
NOTE 2. Simpson temperature meter, sensor and lead
and gauge-manifold.
When repairing modulating valve with the
enclosing tube kit (CTD P/N 14-50021-01) be b. Preparation
sure not to remove items 7, 8 & 10. (See 1. Set volt-ohmmeter to read DC volts of
Figure 4-21) Proper alignment of these items is approximately 0 to 2 vdc.
achieved only at the factory.
2. Connect volt-ohmmeter common lead to terminal
c. Coil Checkout Procedure 12 (DC common) of unit control board. (Refer to section 5)
WARNING 3. Connect volt-ohmmeter positive lead to
terminal 14 of unit control board.
Make sure power to unit is OFF and power plug
disconnected before replacing the coil. 4. Connect Simpson sensor to 1/4 inch copper line
leaving quench valve by attaching sensor securely to
1. Disconnect the modulation valve coil wires from copper line and insulating same.
their terminal locations (T14 & T15) on the units main 5. Install gauge-manifold on compressor suction
control board (refer to section 5). service valve 1/4 inch port.
2. Using a reliable digital ohmmeter, test each 6. Set temperature selector below container
leads resistance to ground. If the resistance indicates a temperature and run unit 6 to 10 minutes in full cooling.
4-17
7. Set temperature selector to ---6_C (21_F). 4.26.2 Temperature Control Board Checkout
Procedure with TCSM
8. Position temperature simulator switch (TSS) to
0_C (32_F) position. (See Figure 1-4 or Figure 1-5) Hold a. Equipment Required
time delay override switch (TDS) in depressed position. 1. Multi-Test Meter (volt-ohmmeter)
c. Checking Suction Modulation Valve 2. Clamp-on Ammeter
and Quench Valve Operation 3. Gauge-Manifold
1. Note reading on volt-ohmmeter. It should be less 4. Temperature Control Simulator Module
than 0.3 vdc and quench valve LED should not be (P/N 07-00226).
illuminated. NOTE
2. Note temperature reading on Simpson meter. All references to the TCSM board toggle
switches (TC, TH, TQ, TU, DR and in-range)
3. Slowly raise temperature selector setting. As the positions will be either; left (away from the
temperature selector setting is raised, the reading on the board) or right (toward the board).
volt-ohmmeter will vary, increasing as temperature
setting is moved upscale. When the temperature selector b. Procedure
is moved below 0_C (32_F), the voltage will remain stable 1. Turn unit OFF and disconnect power supply.
momentarily and then slowly decrease. Also, when the
2. Open the control box door.
temperature setting is lowered the voltage will decrease.
3. Remove the temperature control board and
4. When suction modulation valve current reaches insert temperature control simulator module (TCSM).
0.6 vdc on volt-ohmmeter, the quench valve light emitting See Figure 4-22, item 3, for location of temperature
diode (LED) will energize and the temperature (Simpson control board.
meter reading) of the tube leaving the quench valve will
decrease showing that the quench valve opened when the 4. Place switches on the simulator in the air
signal was sent from the control board through relay TQ. circulation only position. Simulator (TCSM) switches TC,
TH, TQ and DR will be to the left. Switches TU and
5. When the reading on the volt-ohmmeter falls in-range will be to the left also. (Placing the in-range
below 0.5 vdc, the quench valve will de-energize and the switch to the left takes the humidistat control out of the
quench valve will close. system). The valve current will be in the OFF position.
d. In-Range Relay (IRS) Operation 5. Connect gauge-manifold to the suction and
discharge service valves.
Continue to raise the temperature selector setting until
the selector reaches ---2 0.5_C (29 1_F) where the 6. Turn unit power ON. The evaporator fan motors
in-range relay and light emitting diode (LED) will energize. are running in high speed at this time. Check to see if the
24 vac warning light is illuminated. This light is located on
e. Cooling --- Full Modulation the test board, near the return air sensor signal (TP6) test
point. (R.A. Sensor Signal). If the 24 vac light is
1. Continue to raise temperature selector setting to illuminated, stop the unit immediately and remove power
0.5 0.5_C (33 1_F). The suction modulation valve supply from unit. Check all wiring to the unit control
current will be 0.9 to 1.2 vdc. board.
2. Note that the compressor suction pressure gauge 7. Set multi-meter to 30 vdc and plug one test lead
reading drops between 0 psig and 50.8 cm (20 inches) Hg in the TP4 jack (DC com) on the simulator board.
vacuum. 8. Plug other test lead in the TP1 jack (12vdc) on
3. The quench valve LED will be illuminated and a the simulator board. Voltage should be 12.8 0.8 vdc on
substantial temperature drop will be seen on the Simpson the multi-meter. If no voltage appears here, check power
meter when compared to that noted at the start of supply.
checkout procedure. 9. Repeat step 8 for the TP2 jack 9vdc. Voltage
should be 9 1.4 vdc. If 12 vdc appears here, recheck
f. Checking Heating ON and Cooling OFF
wiring. This can happen after replacing a component on
1. Continue to raise temperature selector setting the unit.
to 1.0 0.5_C (34 1_F). The compressor and 10. Place IRS switch to the right. LED and IRS
condenser fan will cycle off and the cool (TC) LED will energize.
de-energize.
11. Turn simulator IRS OFF (left). LED and IRS
The heat relay will energize and the TH LED will be relay de-energize.
illuminated. 12. With the evaporator fan motors running, turn
TH switch ON (right). TH LED and relay energize.
2. Continue to raise the temperature selector
setting to 2 0.5_C (36 1_F). The in-range light and 13. Using clamp-on ammeter, read the amps of the
the IRS LED will de-energize. The heat relay will remain four (4) heater power leads. (Heater wiring connected to
on and the TH LED will be illuminated. the heat relay terminals 21, 22 and 23.) Amperage
4-18
reading should be 2.6 to 3.2 on four defrost heater leads e. Spray the connector terminals on the board with
marked DH. If amps vary more than two (2A) from leg to contact lubricant P/N 07-50003 before the board is
leg, turn power OFF and check wiring and/or heaters. inserted back in the unit.
The drain pan heater draws 1.3 to 1.6 amps on lead CAUTION
marked DPH. See applicable wiring schematic. Do not use aromatic hydro carbons, chlorinated
14. Place simulator switch TH to the left. Heaters solvents, or freon T.F. degreaser for cleaning.
and TH LED are de-energized. They will react with the plastic materials used in
the manufacture of the printed circuit board.
15. Place simulator switch TC to the right. Relay TC 1 2 3 4
and TC LED energize. The compressor and condenser
fan motor start.
16. Place simulator TQ switch to the right. TQ LED
energizes. Determine that the quench line is getting
5
colder. Refer to section 4.12.
6
17. Place TQ switch to the left.
CAUTION 7
In the next test, do not run unit more than five 8
minutes at full modulation without turning
quench (TQ) switch ON (right). 9
18. Turn simulator board modulation switch to 50% 10
modulation point and notice suction pressure drop. Turn 11
modulation switch to FULL modulation position and
note suction pressure drop. As modulation increases, the 12
modulation LED on the simulator board will grow
increasingly brighter. If modulating valve malfunctions, 16 13
refer to section 4.25.
15
19. Place switch TC to the left. TC LED 14
de-energizes, compressor, and condenser fan motor stop. 1. Power Supply and In-Range Board
2. Timing and Current Control Board
20. Place TU switch to the left. TU LED energizes, 3. Temperature Control Board
and the evaporator fan motors switch to low speed 4. Fuse, 3 Amp
operation. 5. Utility Relay (TU)
21. Turn power OFF and disconnect power source 6. Light Emitting Diode (TU --- LED)
and then remove simulator board and install regular 7. Quench Relay (TQ)
temperature board. 8. Light Emitting Diode (TQ --- LED)
9. Cooling Relay (TC)
4.26.3 Replacing the Unit Main Control Board 10. Light Emitting Diode (TC --- LED)
a. Turn OFF unit power and then open the controller 11. Heating Relay (HR)
door. 12. Light Emitting Diode (HR --- LED)
13. Defrost Relay (DR)
b. Disconnect wiring from defective control board. 14. Light Emitting Diode (DR --- LED)
Then remove screws securing board to unit. Remove 15. In-Range Relay
complete assembly. 16. Light Emitting Diode (IRS --- LED)
c. Install relays, fuses, three boards, and connect wiring Figure 4-22. Unit Control Board
to proper terminals on the replacement control board. 4.26.5 Temperature Set Station Checkout Procedure
4.26.4 Printed Circuit Board Cleaning Procedure
NOTE
a. Turn power OFF and remove the printed circuit The temperature set station (CSS) is sometimes
board from the unit. referred to as the temperature selector
b. Clean the surface of the printed circuit board with potentiometer.
dry air at low pressure, less than 2.4 Kg/cm@ (20 psig).
If a problem with the selector is suspected all three
c. If grease is encountered, spray the printed circuit wires must be checked. The selector should be checked
board with anhydrous alcohol. If this is not available, use for resistance using a reliable ohmmeter at the
a mixture of distilled water and liquid dishwashing soap, temperature selector connection as shown in Table 4-2.
then rinse the printed circuit board with distilled water.
Remove grime using clean dry air at low pressure. a. With multi-test meter set on ohms (1K).
d. The printed circuit board can be coated with b. Place one probe on selector connection pin 1 and
humiseal P/N 07-50001 to protect the components from other probe on pin 2 (see Figure 4-23). Ohms will be 324
corrosion. Be sure not to spray the terminals of the molex to 334.
connectors as the humiseal is a non-conductor. c. Complete checkout procedure by using Table 4-2.
4-19
be taken not to burn the heat shrink tubing or wire
insulation). Make sure all seams are sealed tightly against
ORANGE
4 the wiring to prevent moisture seepage.
3 LOCATING
k. Slide large heat shrink tubing over both splices and
2 shrink tubing and heat as in step j.
RED PIN
1 l. Secure sensor to unit and check sensor resistance as
BROWN detailed in section 4.26.6.
SENSOR 41mm (1 5/8 inch)

Figure 4-23. Temperature Set Station and Plug
4.26.6 Temperature Controller Sensor Checkout
Procedure
Due to variations and inaccuracies in thermometers SHOULDER 6.35mm (1/4 inch)
or other test equipment, a reading close to the chart value
would indicate a good sensor. If a sensor is bad, the Figure 4-24. Sensor
resistance reading will usually be much higher or lower
than the resistance values given in Table 4-6. SENSOR
a. Turn unit OFF and disconnect power supply.
b. Remove temperature control board, item 3,
Figure 4-22 and insert temperature control simulator
board (CTD P/N 07-00226).
c. Apply power to unit.
d. Place one probe on TP4 jack (DC Com) and other HEAT SHRINK TUBING (2)
CABLE
probe on the sensor test point (either TP5 or TP6). The
two sensor test points on the board are marked S.A. LARGE HEAT SHRINK TUBING (1)
sensor signal and R.A. sensor signal. Readings are shown
in Table 4-6. Figure 4-25. Sensor and Cable Assembly
4.26.7 Replacing Temperature Sensor 4.27 THERMOSTATIC EXPANSION VALVE
a. Turn unit power OFF and disconnect power supply. The thermal expansion valve is an automatic device
which maintains constant superheat of the refrigerant gas
b. Cut cable 2 inches from shoulder of defective sensor
leaving the evaporator regardless of suction pressure.
and discard defective probe.
The valve functions are: (a) automatic response of
c. Cut one wire of existing cable 41 mm (1-5/8 inch) refrigerant flow to match the evaporator load and (b)
shorter than the other wire. (See Figure 4-24) prevention of liquid refrigerant entering the compressor.
Unless the valve is defective, it seldom requires any
d. Cut one replacement sensor wire (opposite color)
maintenance.
back 41 mm (1-5/8 inch).
a. Removing Expansion Valve
e. Strip back insulation on all wiring 6.35mm (1/4 inch).
1. Store the refrigerant in an evacuated container
CAUTION by attaching a hose to the liquid line valve.
Do not allow moisture to enter wire splice area as 2. Remove insulation (Presstite) from expansion
this may affect the sensor resistance. valve bulb and power assembly and then remove thermal
bulb from the suction line.
f. Slide a large piece of heat shrink tubing over cable
3. Loosen flare nut and disconnect equalizing line
and the two small pieces of heat shrink tubing over the
from expansion valve.
wires before adding crimp fittings as shown in
Figure 4-25. 4. Remove capscrews and lift off power assembly
and remove cage assembly. Check for foreign material in
g. Slip crimp fittings over dressed wires (keep wire valve body.
colors together). Make sure wires are pushed into crimp
fittings as far as possible and crimp with crimping tool. 5. The thermal bulb is located below the center of
the suction line (4 oclock position). This area must be
h. Solder spliced wires with a 60% tin and 40% lead clean to ensure positive bulb contact. Strap thermal bulb
Rosincore solder. to suction line and insulate both with Presstite.
i. Slide heat shrink tubing over splice so that both ends b. Installing Expansion Valve
of tubing cover both ends of crimp as shown in
1. Replace all gaskets, make sure to lightly coat
Figure 4-25.
with refrigerant oil. Insert cage and power assembly and
j. Heat tubing, preferably with a flameless heat gun. If bolts. Tighten bolts equally. Fasten equalizer flare nut to
not available, a propane torch will work (caution should expansion valve.
4-20
2. Leak check the unit per section 4.2. Evacuate NOTE
and dehydrate unit per section 4.3 and add refrigerant Suction pressure must be 0.5 kg/cm@ (6 psig) below
charge per section 4.4.2. valve M.O.P. (maximum operating pressure).
3. Clean suction line with sandpaper before Example: if valve rated at 55 MOP, suction
installing bulb to ensure proper heat transfer. Strap pressure must be below this MOP. Recommended
thermal bulb to suction line, making sure bulb is firmly pressure is below 3.44 kg/cm@ (49 psig).
against suction line. The bulb is located in the 4 oclock 5. From the temperature/pressure chart (Table 4-7),
position on the suction line. determine the saturation temperature corresponding to the
4. Check superheat. (See Table 4-7) Superheat evaporator outlet pressure.
setting is 4.4 to 5.5_C (8 to 10_F) at 0_C (32_F) container 6. Note the temperature of the suction gas at the
temperature. expansion valve bulb.
c. Checking Superheat 7. Subtract the saturation temperature determined
in Step 6 from the average temperature measured in Step 5.
NOTE The difference is the superheat of the suction gas.
It is not recommended adjusting internal d. Adjusting Superheat
adjustable valves unless absolutely necessary.
1. Remove the refrigerant and then remove the two
bolts holding the valve body together.
If a replacement valve has the wrong superheat
setting, the valve may be adjusted if you do not have 2. Remove the cage assembly and rotate the
another replacement valve on hand. Due to the time adjusting nut to increase or decrease the superheat.
involved in adjusting the superheat, replace the valve Turning the nut to compress the valve spring will increase
rather than adjusting it. the superheat and decrease refrigerant flow through the
valve. Decompressing the spring will decrease the
superheat and increase the refrigerant flow through the
valve (one complete turn will change the setting
1 4 approximately 1.7_C (3_F).
3. Reassemble the valve and then start the unit.
4. When the unit has stabilized operation for at
least 20 minutes, recheck superheat setting.
2 5 5. If superheat setting is correct, remove gauge and
thermocouple. Secure panel in position.
4.28 EVAPORATOR FAN MOTOR
CAPACITORS
3
The two-speed evaporator fan motors are of the
6 permanent-split capacitor type. The motor is equipped
with one capacitor (used in high speed circuit) and
7 another capacitor is used for the low speed circuit.
a. When to check for a defective capacitor
1. Power Assembly
2. Body Flange Gaskets 1. Fan motor will not change speed. For example:
3. Seat Gasket controller settings above ---10_C (14_F) cause the motor
4. Bulb to run in high speed.
5. Cage Assembly Controller settings below ---10_C (14_F) cause the
6. Body Flange motor to run in low speed.
7. Body Flange Screws
2. Motor running in wrong direction (after
Figure 4-26. Thermostatic Expansion Valve checking for correct wiring application).
b. Removing the capacitor
To Measure Superheat:
WARNING
1. Open access panel to expose the expansion valve Make sure power to unit is OFF and power plug
and 1/4 inch port. (See Figure 1-1) The 1/4 inch port is disconnected before removing capacitor(S).
equipped with a Schrader fitting.
1. The capacitor located on the motor and above
2. Attach a temperature tester sensor near the the evaporator fan deck may be removed by two methods:
expansion valve bulb and insulate. Make sure the suction
line is clean and firm contact is made with tester. a. If container is empty, open upper, rear, panel of
unit and capacitor may be serviced after disconnecting
3. Connect an accurate gauge to the 1/4 inch port. power plug.
4. Run unit until unit has stabilized. Set controller b. If container is full, turn unit power OFF and
5.5_C (10_F) below container temperature. disconnect power plug. Remove the #2 evaporator fan
4-21
motor access panel. (See Figure 1-1) Remove two lower When drying, the stem must remain tensioned, i.e.,
capscrews securing motor assembly to bracket and then the set point knob is set to approximately 0% R.H.
remove Ty-Raps from wire harness. Loosen two upper Drying time approximately 24 hours. If necessary,
capscrews on fan motor assembly. Remove or set aside recalibrate the humidistat.
motor to reach capacitors. With power OFF discharge
the capacitor and disconnect the circuit wiring.
E
c. Checking the capacitor
Three methods for checking capacitors are:
(1) Direct replacement, (2) volt-ohmmeter, and (3)
capacitor analyzer.
1. Direct replacement:
A
Replace capacitor with one of the same value.
S
2. Volt-ohmmeter:
Set meter on RX 10,000 ohms. Connect ohmmeter
leads across the capacitor terminals and observe the meter
needle. If the capacitor is good, the needle will make a rapid
swing toward zero resistance and then gradually swing back Figure 4-27. Humidistat
toward a very high resistance reading.
If the capacitor has failed open, the ohmmeter needle
will not move when the meter probes touch the terminals. If Table 4-1. Partlow Bulb Temperature ---
the capacitor is shorted, the needle will swing to zero Resistance Chart
resistance position and stay there.
3. Capacitor analyzer: TEMPERATURE RESISTANCE
The function of the analyzer is to read the microfarad F C (OHMS)
value of a capacitor and to detect insulation breakdown ---10 ---23.3 12561.00
under load conditions. The important advantages of a ---5 ---20.6 10579.70
analyzer is its ability to locate capacitors that have failed
to hold their microfarad ratings or ones that are breaking 0 ---17.8 8944.17
down internally during operation. It is also useful in 5 ---15.0 7588.89
identifying capacitors when their microfarad rating 15 ---9.4 5520.32
marks have become unreadable.
20 ---6.7 4731.71
4.29 HUMIDISTAT
25 ---3.9 4068.68
a. Setting 30 ---1.1 3509.36
1. The upper switching point of switch (A) is set by 32 0 3310.57
the set point knob (E). 35 1.7 3035.99
2. In case of deviations of the measured humidity 40 4.4 2634.10
from the set point, a recalibration by means of the nut (S)
45 7.2 2291.85
is recommended:
50 10.0 1999.52
3. If the actual value is higher than the set point,
turn nut (S) clockwise. 55 12.8 1749.11
4. If the actual value is lower than the set point, 60 15.6 1534.00
turn nut (S) counterclockwise. 65 18.3 1348.72
75 23.9 1050.14
Set Point 20% 40% 60% 70% 80% 80 26.7 929.87
1/6 turn --- 15% 15% 11% 8% 5% 85 29.4 825.21
90 32.2 733.93
b. Maintenance
95 35.0 654.12
Soiled sensing elements can be cleaned by dipping
the stem in soapy fresh water or fresh water with washing 100 37.8 584.19
powder (maximum 80_C = 176_F). 105 40.6 522.79
4-22
Table 4-2. Selector Settings and Resistance Table 4-3. Recommended Bolt Torque Values
BOLT DIA. THREADS TORQUE MKG
SELECTOR SELECTOR RESISTANCE
SETTINGS CONNECTIONS IN FREE SPINNING
F C (PINS) OHMS #4 40 5.2 in-lbs 0.05
#6 32 9.6 in-lbs 0.11
---15 ---25 CSS 1 to CSS 2 324 to 334 #8 32 20 in-lbs 0.23
---15 ---25 CSS 2 to CSS 3 1648 to 1656 #10 24 23 in-lbs 0.26
1/4 20 75 in-lbs 0.86
---15 ---25 CSS 1 to CSS 3 1980 to 1988 5/16 18 11 ft-lbs 1.52
32 0 CSS 1 to CSS 2 980 to 988 3/8 16 20 ft-lbs 2.76
7/16 14 31 ft-lbs 4.28
5/8 11 92 ft-lbs 12.72
77 25 CSS 2 to CSS 3 347 to 355
77 25 CSS 1 to CSS 3 1980 to 1988 NONFREE SPINNING (LOCKNUTS ETC.)
1/4 20 82.5 in-lbs 0.95
5/16 18 145.2 in-lbs 1.67
3/8 16 22.0 ft-lbs 3.04
7/16 14 34.1 ft-lbs 4.71
1/2 13 47.3 ft-lbs 6.54
9/16 12 62.7 ft-lbs 8.67
5/8 11 101.2 ft-lbs 13.99
3/4 10 136.4 ft-lbs 18.86
4-23
Table 4-4. Wear Limits For Compressors
MAXIMUM WEAR
FACTORY MAXIMUM FACTORY MINIMUM BEFORE REPAIR
PART NAME
INCHES MM INCHES MM INCHES MM
MAIN BEARING
Main Bearing Diameter 1.6268 41.3207 .0020 0.0508
Main Bearing Journal Diameter 1.6233 41.2318 .0020 0.0508
PUMP END
Main Bearing Diameter 1.3760 34.9504 .0020 0.0508
Main Bearing Journal Diameter 1.3735 34.8869 .0020 0.0508
CONNECTING ROD 1.3768 34.9707 .0020 0.0508
Piston Pin Bearing 0.6878 17.4701 .0010 0.0254
CRANKPIN DIAMETER 1.3735 34.8869 .0025 0.0635
Throw (28 CFM) 0.7354 18.6792 0.7334 18.6284
Throw (37 CFM) 0.9698 24.6329 0.9678 24.5821
Throw (41 CFM) 1.072 27.2288 1.070 27.1780
THRUST WASHER
(Thickness) (28 & 37 CFM) 0.145 3.6830 0.1440 03.6576 .0250 0.6350
THRUST WASHER
(Thickness) (41 CFM) 0.154 3.9116 0.1520 03.8608 .0250 0.6350
CYLINDERS
Bore 2.0010 50.8254 .0020 0.0508
Piston (Diameter) 1.9860 50.4444 .0020 0.0508
Piston Pin (Diameter) 0.6873 17.4574 .0010 0.0254
Piston Ring Gap 0.013 00.3302 0.0050 00.1270 .0250 0.6350
Piston Ring Side Clearance
(28 & 37 CFM) 0.001 00.0254 0.0000 00.0000 .0020 0.0508
Piston Ring Side Clearance
(41 CFM) 0.002 00.0508 0.0010 00.0254 .0020 0.0508
4-24
Table 4-5. Compressor Torque Values
TORQUE RANGE
SIZE
USAGE
DIAMETER THREADS
FT LB
FT-LB MKG
(INCHES) PER INCH
1/16 27 (pipe) 8 --- 12 1.11 --- 1.66 Pipe Plug --- Crankshaft
1/8 20 (pipe) 6 --- 10 0.83 --- 1.38 Oil Return Check Valve --- Crankcase
1/4 20 (pipe) 20 --- 25 2.77 --- 3.46 Pipe Plug --- Gauge Connection
1/4 20 10 --- 12 1.38 --- 1.66 Connecting Rod Capscrew
12 --- 15 1.66 --- 2.07 Baffle Plate --- Crankcase
12 --- 16 1.66 --- 2.21 Side Shield
1/4 28
6 --- 10 0.83 --- 1.38 Oil Pump Drive Segment
12 --- 16 1.66 --- 2.21 Unloader Valve
Cover Plate --- Plate End
16 --- 20 2.21 --- 2.77 Bearing Head
5/16 18 Terminal Block Cap Screws
Suction Valve
20 --- 30 2 77 --- 4
2.77 4.15
15
Discharge Valve
Pump End Bearing Head
3/8 16 40 --- 50 5.53 --- 6.92 Bottom Plate --- Crankcase Compressor Foot
Cylinder Head
7/16 14 55 --- 60 7.61 --- 8.30 Motor End Cover --- Crankcase
5/8 11 25 --- 30 3.46 --- 4.15 Crankshaft
5/8 18 60 --- 75 8.30 --- 10.37 Oil Bypass Plug --- Crankcase
#10 32 4 --- 6 0.55 --- 0.83 Oil Pump Drive Segment
1-1/2 18 NEF 35 --- 45 4.84 --- 6.22 Oil Level Sight Glass
NEF --- National Extra Fine
Table 4-6. Sensor D.C. Voltages
TEMPERATURE D.C. TEMPERATURE D.C. TEMPERATURE D.C.

F C VOLTS F C VOLTS F C VOLTS
---20 ---28.9 1.57 14 ---10.0 3.45 48 8.9 5.32
---18 ---27.8 1.68 16 ---8.9 3.56 50 10.0 5.45
---16 ---26.7 1.78 18 ---7.8 3.68 52 11.1 5.55
---14 ---25.6 1.90 20 ---6.7 3.79 54 12.2 5.67
---12 ---24.4 2.00 22 ---5.5 3.90 56 13.3 5.78
---10 ---23.3 2.10 24 ---4.4 4.00 58 14.4 5.88
---8 ---22.2 2.22 26 ---3.3 4.10 60 15.6 5.98
---6 ---21.1 2.32 28 ---2.2 4.22 62 16.7 6.10
---4 ---20.0 2.44 30 ---1.1 4.32 64 17.8 6.20
---2 ---18.9 2.55 32 0 4.45 66 18.9 6.32
0 ---17.8 2.70 34 1.1 4.55 68 20.0 6.42
2 ---16.7 2.80 36 2.2 4.68 70 21.1 6.55
4 ---15.6 2.90 38 3.3 4.78 72 22.2 6.65
6 ---14.4 3.00 40 4.4 4.88 74 23.3 6.77
8 ---13.3 3.10 42 5.5 5.00 76 24.4 6.88
10 ---12.2 3.23 44 6.7 5.10 78 25.6 6.98
12 ---11.1 3.33 46 7.8 5.22
4-25
Table 4-7. Temperature-Pressure Chart --- R-12
BOLD FIGURES = Inches Mercury Vacuum (cm Hg Vac)
LIGHT FIGURES = psig (kg/cm@)
TEMPERATURE PRESSURE TEMPERATURE PRESSURE

F C Psig Kg/cm2 Bar F C Psig Kg/cm2 Bar
---40 ---40 11.0 27.90 -- .37 28 ---2 26.9 1.89 1.85
---35 ---37 8.4 21.30 -- .28 30 ---1 28.5 2.00 1.97
---30 ---34 5.5 14.00 -- .19 32 0 30.1 2.12 2.08
---28 ---33 4.3 10.90 -- .15 34 1 31.7 2.23 2.19
---26 ---32 3.0 7.60 -- .10 36 2 33.4 2.35 2.30
---24 ---31 1.6 4.10 -- .05 38 3 35.2 2.47 2.43
---22 ---30 0.3 0.80 -- .01 40 4 37.0 2.60 2.55
---20 ---29 0.5 .04 .03 45 7 41.7 2.93 2.88
---18 ---28 1.3 .09 .09 50 10 46.7 3.28 3.22
---16 ---27 2.1 .15 .14 55 13 52.0 3.66 3.59
---14 ---26 2.8 .20 .19 60 16 57.7 4.06 3.98
---12 ---24 3.7 .26 .26 65 18 63.8 4.49 4.40
---10 ---23 4.5 .32 .31 70 21 70.2 4.94 4.84
---8 ---22 5.4 .38 .37 75 24 77.0 5.41 5.31
---6 ---21 6.3 .44 .43 80 27 84.2 5.92 5.81
---4 ---20 7.2 .51 .50 85 29 91.8 6.45 6.33
---2 ---19 8.2 .58 .57 90 32 99.8 7.02 6.88
0 ---18 9.2 .65 .63 95 35 108.2 7.61 7.42
2 ---17 10.2 .72 .70 100 38 117.2 8.24 8.08
4 ---16 11.2 .79 .77 105 41 126.6 8.90 8.73
6 ---14 12.3 .86 .85 110 43 136.4 9.59 9.40
8 ---13 13.5 .95 .93 115 46 146.8 10.32 10.12
10 ---12 14.6 1.03 1.01 120 49 157.6 11.08 10.87
12 ---11 15.8 1.11 1.09 125 52 169.1 11.89 11.66
14 ---10 17.1 1.20 1.18 130 54 181.0 12.73 12.48
16 ---9 18.4 1.29 1.27 135 57 193.5 13.60 13.34
18 ---8 19.7 1.39 1.36 140 60 206.6 14.53 14.24
20 ---7 21.0 1.48 1.45 145 63 220.3 15.49 15.19
22 ---6 22.4 1.57 1.54 150 66 234.6 16.49 16.18
24 ---4 23.9 1.68 1.65 155 68 249.5 17.54 17.20
26 ---3 25.4 1.79 1.75 160 71 265.1 18.64 18.28
4-26
SECTION 5
ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS
5.1 INTRODUCTION
This section contains Electrical Wiring Schematics and 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 recommeded precautions that must be understood and applied during operation and maintenance of the equipment
covered herein.
WARNING
Beware of unannounced starting of the evaporator and condenser fans. Do not open condenser fan grille before
turning power OFF and disconnecting power plug.
WARNING
Do not attempt to remove power plug(s) before turning OFF start-stop switch (ST), unit circuit breaker(s) and
external power source.
Make sure the power plugs are clean and dry before connecting to any power receptacle.
WARNING
Do not use a nitrogen cylinder without a pressure regulator because cylinder pressure is approximately 165
kg/cm@ (2350 psi). Do not use oxygen in or near a refrigeration system as an explosion may occur.
WARNING
Make sure power to unit is OFF and power plug disconnected before removing capacitor(S).
CAUTION
Make sure that the unit circuit breaker(s) (CB) and the start-stop switch are in the OFF position before
connecting to any electrical power source.
5-1
Figure 5-1. Electrical Wiring Schematic --- Model 69NT20-284
(Sheet 1 of 2)
5-2
(Sheet 2 of 2)
5-3
Figure 5-2. Electrical Wiring Diagram --- Model 69NT20-284
(Sheet 1 of 2)
5-4
(Sheet 2 of 2)
5-5
(Sheet 1 of 2)
5-6
(Sheet 2 of 2)
5-7
(Sheet 1 of 2)
5-8
(Sheet 2 of 2)
5-9
Figure 5-5. Electrical Wiring Schematic --- Model 69NT40-464-1
(Sheet 1 of 2)
5-10
(Sheet 2 of 2)
5-11
Figure 5-6. Electrical Wiring Diagram --- Model 69NT40-464-1
(Sheet 1 of 2)
5-12
(Sheet 2 of 2)
5-13
(Sheet 1 of 2)
5-14
(Sheet 2 of 2)
5-15
(Sheet 1 of 2)
5-16
(Sheet 2 of 2)
5-17
Figure 5-9. Electrical Wiring Schematic --- Model 69NT40-464-8 (Units with S/N 90105284 thru 90105383)
(Sheet 1 of 2)
5-18
Figure 5-9. Electrical Wiring Schematic --- Model 69NT40-464-8 (Units with S/N 90105284 thru 90105383)
(Sheet 2 of 2)
5-19
Figure 5-10. Electrical Wiring Diagram --- Model 69NT40-464-8 (Units with S/N 90105284 thru 90105383)
(Sheet 1 of 2)
5-20
Figure 5-10. Electrical Wiring Diagram --- Model 69NT40-464-8 (Units with S/N 90105284 thru 90105383)
(Sheet 2 of 2)
5-21
Figure 5-11. Electrical Wiring Schematic --- Model 69NT40-464-8 (Units starting with S/N 90105384)
(Sheet 1 of 2)
5-22
Figure 5-11. Electrical Wiring Schematic --- Model 69NT40-464-8 (Units starting with S/N 90105384)
(Sheet 2 of 2)
5-23
Figure 5-12. Electrical Wiring Diagram --- Model 69NT40-464-8 (Units starting with S/N 90105384)
(Sheet 1 of 2)
5-24
Figure 5-12. Electrical Wiring Diagram --- Model 69NT40-464-8 (Units starting with S/N 90105384)
(Sheet 2 of 2)
5-25
(Sheet 1 of 2)
5-26
(Sheet 2 of 2)
5-27
(Sheet 1 of 2)
5-28
(Sheet 2 of 2)
5-29
Figure 5-15. Electrical Wiring Schematic --- Model 69NT20-284-1 & -284-2
(Sheet 1 of 2)
5-30
Figure 5-15. Electrical Wiring Schematic --- Model 69NT20-284-1 & -284-2
(Sheet 2 of 2)
5-31
Figure 5-16. Electrical Wiring Diagram --- Model 69NT20-284-1 & -284-2
(Sheet 1 of 2)
5-32
Figure 5-16. Electrical Wiring Diagram --- Model 69NT20-284-1 & -284-2
(Sheet 2 of 2)
5-33
(Sheet 1 of 2)
5-34
(Sheet 2 of 2)
5-35
(Sheet 1 of 2)
5-36
(Sheet 2 of 2)
5-37
(Sheet 1 of 2)
5-38
(Sheet 2 of 2)
5-39
(Sheet 1 of 2)
5-40
(Sheet 2 of 2)
5-41
(Sheet 1 of 2)
5-42
(Sheet 2 of 2)
5-43
(Sheet 1 of 2)
5-44
(Sheet 2 of 2)
5-45
Figure 5-23. Electrical Wiring Schematic --- Model 69NT40-464-7 & 69NT40-461-7, -8
(Sheet 1 of 2)
5-46
Figure 5-23. Electrical Wiring Schematic --- Model 69NT40-464-7 & 69NT40-461-7, -8
(Sheet 2 of 2)
5-47
Figure 5-24. Electrical Wiring Diagram --- Model 69NT40-464-7 & 69NT40-461-7, -8
(Sheet 1 of 2)
5-48
Figure 5-24. Electrical Wiring Diagram --- Model 69NT40-464-7 & 69NT40-461-7, -8
(Sheet 2 of 2)
5-49
Figure 5-25. Electrical Wiring Schematic --- Model 69NT40-464-9, -15
(Sheet 1 of 2)
5-50
(Sheet 2 of 2)
5-51
(Sheet 1 of 2)
5-52
(Sheet 2 of 2)
5-53
(Sheet 1 of 2)
5-54
(Sheet 2 of 2)
5-55
(Sheet 1 of 2)
5-56
(Sheet 2 of 2)
5-57
(Sheet 1 of 2)
5-58
(Sheet 2 of 2)
5-59
(Sheet 1 of 2)
5-60
(Sheet 2 of 2)
5-61

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Models

5 ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS . . . . . . . . . . . . . . . . . . 5-1

1-1 Refrigeration Unit --- Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2-1 Cooling --- Within 2_C (3.6_F) Of Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

4-1 Vacuum Pump Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

2-1 Electrical Control Positions --- Above ---10_C (+14_F) . . . . . . . . . . . . . . . . . . . . 2-6

4-1 Partlow Bulb Temperature --- Resistance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

69NT20-284 1330 620 9.0 4.1 X --- --- X X --- ---

Figure 1-1. Refrigeration Unit --- Front

1. Evaporator Fan Motor #1 8. Return Air Temperature Sensor

Figure 1-2. Refrigeration Unit --- Rear (Panels Removed)

1. Suction Service Valve 8. Moisture-Liquid Indicator

Figure 1-3. Water-Cooled Condenser/Receiver Section

UNITS WITH TWO-SPEED EVAPORATOR MOTORS

UNITS WITH ONE-SPEED EVAPORATOR MOTORS

1. Power Supply and In-Range Board 13. Compressor Contactor

1.14 SUCTION SOLENOID VALVE

In-Range 1.5_C (2.7_F) In-Range

= Energized Circuit = De-energized Circuit

Figure 2-1. Cooling --- Within 2_C (3.6_F) of Set Point

= Energized Circuit = De-energized Circuit

Figure 2-2. Heating --- Within 2_C (3.6_F) of Set Point

= Energized Circuit = De-energized Circuit

Figure 2-3. Defrost

CONTROL CIRCUIT COOLING HOLDING * Dehumidifica- HEATING DEFROST

CONTROL CIRCUIT COOLING HOLDING **Dehumidifica- HEATING DEFROST

INDICATION/ POSSIBLE CAUSES REFERENCE

3.1 UNIT WILL NOT START OR STARTS THEN STOPS

Loss of control power Circuit breaker OFF or defective Check

Compressor hums, Low line voltage Check

Refrigeration System Abnormal pressures 3.7

Refrigeration System Shortage of refrigerant 4.2/4.4

3.4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING

No control power Circuit breaker or fuse defective Replace

Heater termination switch open 4.13

Unit will not heat or Heater(s) defective 4.15

Will not initiate Manual defrost switch defective Replace

Initiates but defrost relay

Frequent defrost Wet load Normal

3.7 ABNORMAL PRESSURES (COOLING)

Low suction pressure Suction service valve partially closed Open

Condenser or Bent, loose or striking venturi Check

Compressor does not start

No or partial Evaporator fan motor internal protector open 4.14

3.11 EXPANSION VALVE MALFUNCTION

High suction pressure Superheat setting too low 4.27.c

Liquid slugging in compressor Pin and seat of expansion valve eroded or

Fluctuating suction pressure Improper bulb location or installation 4.27

Condenser fan Water pressure switch malfunction Check

c. Remove refrigerant using a refrigerant recovery 1

11 5. Refer to Table 4-4 and Table 4-5 for

a. Place the compressor in a position where it will be

If compressor is without oil: b. Remove filter-drier clamp, then replace drier.

b. Disconnect water pressure switch tubing by Suction

c. Clean fresh water.

5 Ambient Temperature Cold Coil

10_ F 6.45 ohms

10 4. Reconnect the modulation valve coil wires to

SENSOR 41mm (1 5/8 inch)