T 258

Model
69NT40-469
T-258 $6.00
OPERATION AND
SERVICE MANUAL
CONTAINER REFRIGERATION UNIT
MODEL
69NT40-469
Carrier Transicold Division, Carrier Corporation, P.O. Box 4805, Syracuse, N.Y. 13221
Carrier Corporation 1993 D Printed in U. S. A. 1093
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.4 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.5 Safety And Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.6 Fresh Air Makeup Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.7 Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.8 Refrigeration Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.9 Remote Monitoring Receptacle And Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.10 Suction Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.11 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.12 Humidistat (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.13 Voltage Switch And Power Transformer (Optional) . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.14 Water-Cooled Condenser And Water Pressure Switch (Optional) . . . . . . . . . . . . 1-13
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.4 Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.4.1 Cooling --- Controller Set Below ---10_C (+14_F) . . . . . . . . . . . . . . . . 2-1
2.4.2 Controller Set Above ---10_C (+14_F) . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4.3 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
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 Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Suction and Discharge Service Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3 Pumping the Unit Down or Removing the Refrigerant . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 Refrigerant Leak Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.5 Evacuation And Dehydration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.5.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.5.3 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.6 Adding Or Checking The Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.6.1 Checking The Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.6.2 Adding Refrigerant To System (Full Charge) . . . . . . . . . . . . . . . . . . . . 4-4
4.6.3 Adding Refrigerant To System (Partial Charge) . . . . . . . . . . . . . . . . . . 4-6
4.7 Replacing The Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.8 Compressor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.9 Compressor Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.10 Checking The Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.11 Checking Or Replacing Moisture-Liquid Indicator . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.12 Checking Or Replacing The Filter-Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.13 Checking Or Replacing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.13.1 Replacing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.13.2 Checking High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.14 Replacing The Evaporator Coil And Heater Assembly . . . . . . . . . . . . . . . . . . . . . 4-11
4.15 Replacing The Evaporator Fan And Motor Assembly . . . . . . . . . . . . . . . . . . . . . . 4-12
4.16 Servicing The Evaporator Coil Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.17 Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.18 Condenser Fan And Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.19 Recording Thermometer (Partlow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.20 Maintenance Of Painted Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.21 Servicing The Suction Modulation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.22 Controller Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.22.1 Controller Pre-Trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.22.2 Temperature Control Board Checkout Procedure With TCSM . . . . . 4-16
4.22.3 Replacing The Unit Main Control Board . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.22.4 Printed Circuit Board Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . 4-17
4.22.5 Temperature Set Station Checkout Procedure . . . . . . . . . . . . . . . . . . . 4-18
4.22.6 Temperature Controller Sensor Checkout Procedure . . . . . . . . . . . . . 4-18
4.22.7 Replacing Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.23 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.24 Evaporator Fan Motor Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.25 Humidistat (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.26 Checkout Procedure For Optional Power Transformer . . . . . . . . . . . . . . . . . . . . . 4-20
4.27 Servicing The Optional Water-Cooled Condenser . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
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 Receiver and Tubing Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-4 Control Box And Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1-5 Refrigeration Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1-6 Current Control Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-7 Controller Set Point Below ---10_C (+14_F) (Return Air Control) . . . . . . . . . . . 1-14
1-8 Controller Set Point Above ---10_C (+14_F) (Supply Air Control) . . . . . . . . . . . 1-14
2-1 Cooling --- Within 2_C (3.6_F) Of Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2-2 Heating --- Within 2_C (3.6_F) Of Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-3 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
4-1 Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-2 R-134a Manifold Gauge Set Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-4 Suction or Discharge Service Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-4 Vacuum Pump Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-5 Compressor --- Model 06DR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-6 Exploded View Of Valve Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-7 Bottom Plate Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-8 Gear Oil Pump And Bearing Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-9 Motor End Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-10 Crankshaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-11 Removing Equalizing Tube And Lock Screw Assembly . . . . . . . . . . . . . . . . . . . . . 4-8
4-12 Terminal Mounting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-13 Suction Valve And Positioning Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-14 Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-15 Typical Setup For Testing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4-16 Evaporator Fan Locating Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-17 Partlow Recording Thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4-18 Suction Modulation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4-19 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-20 Temperature Set Station And Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-21 Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-22 Sensor And Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-23 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-24 Humidistat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-25 Water-Cooled Condenser Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4-25 R-134a Compressor Pressure and Motor Current Curves Versus Ambient Temperature 4-27
5-1 Electrical Wiring Schematic (Model 69NT40-469-7) . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-2 Electrical Wiring Diagram (Model 69NT40-469-7) . . . . . . . . . . . . . . . . . . . . . . . . 5-4
iii
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-4 Current Limiting Switch Positions And Amperages . . . . . . . . . . . . . . . . . . . . . . . 1-10
2-1 Electrical Control Positions --- Above ---10_C (+14_F) . . . . . . . . . . . . . . . . . . . . 2-5

2-2 Electrical Control Positions --- Below ---10_C (+14_F) . . . . . . . . . . . . . . . . . . . . . 2-6
4-1 Partlow Bulb Temperature --- Resistance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

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-134a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
iv
SECTION 1
DESCRIPTION
1.1 INTRODUCTION These units are dual voltage units designed to

operate on 190/230 or 380/460 vac, 3 phase, 50-60 hertz
power. (Refer to Table 1-1 and section 1.13)
WARNING
WARNING
It has been determined that pressurized,
air-rich mixtures of refrigerants and air can Beware of unannounced starting of the
undergo combustion when exposed to an evaporator and condenser fans. Do not open
ignition source. condenser fan grille before turning power OFF
and disconnecting power plug.
This manual contains Operating Data, Electrical Operating control power is provided by a single
Data and Service Instructions for the refrigeration units phase transformer which steps down the AC power
listed in Table 1-1. Also, Table 1-1 charts most of the supply voltage to 24 vac, 1 phase control power.
significant differences between these models. The temperature controller is a solid state controller.
(Refer to section 1.11) Once the temperature controller
The unit, of lightweight aluminum frame is set at desired container temperature, the unit will
construction, is an all electric, one piece self-contained operate automatically to maintain the desired
cooling and heating refrigeration unit. The unit is temperature within very close limits. The control system
designed to fit in the front of a container and to serve as automatically selects cooling, holding or heating as
the container front wall. Fork lift pockets are provided necessary to maintain the desired temperature within the
for installation and removal of the unit. container.
The units are equipped with a Partlow temperature
The unit is complete with a charge of
recorder.
Refrigerant-134a, compressor lubricating oil, mode
indicating lights, temperature controller and is ready for Also, these units are equipped with a digital display
operation upon installation. (switchable for _C or _F). Refer to section 1.7.
Table 1-1. Model Chart
REFRIGER-
UNIT WEIGHT ANT
MODELS 134a
LB KG LB KG
69NT40-469-7 1265 574 11.5 5.2 --- --- X --- --- X
A --- Provision for water-cooled condenser. If water-cooled condenser is added, refrigerant charge will change.
B --- Provision for step-up power transformer.
X --- Designates item provided.
1-1
1.2 GENERAL DESCRIPTION
a. Compressor Section When the unit is operating with air-cooled condenser
NOTE operation, air is pulled in the bottom of the coil and
discharges horizontally out the front center of the unit.
Check the compressor Serial/Model Number
plate for CFM displacement, refer to Table 1-2. Some units are equipped with a water-cooled
condenser (condenser/receiver) and a water pressure
The compressor section includes the compressor switch. This switch is located on the water inlet line.
(with high pressure switch), power cable storage c. Evaporator Section
compartment, and an optional power transformer, The evaporator section contains the recorder bulb,
located to the left of the compressor. controller return temperature sensor (RTS),
This section also contains the suction modulation thermostatic expansion valve, evaporator fan motors and
valve, suction solenoid valve, quench expansion valve, fans (2), evaporator coil and heaters, drain pan and
moisture-liquid indicator, manual liquid line valve, heaters, defrost and heat termination switches,
filter-drier, pressure relief valves (high and low), humidistat (optional), heat exchanger, and the suction
discharge pressure regulator valve, and the receiver or solenoid thermostat (located above the fan deck).
the water-cooled condenser/receiver. The evaporator fans circulate air throughout the
The supply air temperature sensor (STS) is located at container by pulling air in the top of the refrigeration unit
the right of the compressor. and directing the air through the evaporator coil where it
is either heated or cooled, and then discharged out the
Table 1-2. Compressor Model Number bottom of the refrigeration unit into the container.
Significance Chart The evaporator coil heaters and the thermostatic
06DR2419CC1970 expansion valve are accessible by removing the front,
lower access panel. The defrost termination switch is
1st, 2nd & 3rd DIGIT located on the center bracket of the evaporator coil and
may be serviced by removing the rear, middle, panel or by
06D Hermetic Reciprocal removing the front, upper access panel and reaching
through the left hand evaporator fan venturi AFTER
4th DIGIT POWER IS TURNED OFF AND POWER PLUG
DISCONNECTED.
R Refrigeration Duty
d. Control Box
6th & 7th DIGIT VOLUME The control box and door include the indicator lights,
manual switches, temperature set station, circuit
41 41CFM
breaker(s), contactors, relays, transformers (current
limiting and control), the optional digital display and
b. Condenser Section fuses (6 amp for control and 3 amp for controller). (See
The condensing section consists of a condenser fan Figure 1-4) Also, located above the temperature set
motor, condenser fan, and an air-cooled condenser coil. station is the defrost interval.
1-2
22
1
21
3
20
19 4
18
5
17
16
6
15
14
13
12
11
10
9
8
7
1. Access Panel (Evaporator Fan Motor #1) 12. High Pressure Switch (HPS)
2. Access Panel (Heater and Thermostatic 13. Compressor Sight Glass
Expansion Valve Location) 14. Discharge Service Valve
3. Fork Lift Pockets 15. Unit Serial/Model No. Plate --- Location
4. Control Box 16. Power Cables and Plug
5. Voltage Selector Switch Cover 17. Power Transformer (Optional) --- Location
6. Receiver and Tubing Section 18. Condenser Fan Motor (CM)
7. Suction Service Valve 19. Make-Up Air Cover
8. Compressor Motor (CP) 20. Recording Thermometer
9. Start-Stop Switch (ST) 21. TIR Locking Devices
10. Manual Defrost Switch (MDS) 22. Access Panel (Evaporator Fan Motor #2)
11. Remote Monitoring Receptacle (RM)
Figure 1-1. Refrigeration Unit --- Front
1-3
4
5 7
6
3
2
1
10
11
12
13
1. Evaporator Fan Motor #1 (EM1) 8. Heater Termination Thermostat (HTT)

2. Humidistat (Optional) --- Location 9. Evaporator Coil
3. Return Temperature Sensor (RTS) 10. Thermostatic Expansion Valve
4. Partlow Thermister Sensor 11. Drain Pan Heater (DPH)
5. Evaporator Fan Motor #2 (EM2) 12. Evaporator Coil Heaters
6. Suction Solenoid Thermostat (SST) 13. Heat Exchanger
7. Defrost Termination Thermostat (DTT)
Figure 1-2. Refrigeration Unit --- Rear (Panels Removed)
1-4
5
9
10
12 11
1 Discharge Pressure Regulating Valve 8. Filter-Drier

2. Suction Modulation Valve (SMV) 9. Receiver
3. Pressure Relief Valve --- High Side 10. Receiver Sight Glasses
4. Suction Solenoid Valve (SSV) 11. Supply Temperature Sensor (STS)
5. Quench Expansion Valve 12. Pressure Relief Valve --- Low Side
6. Manual Liquid Line Valve
7. Moisture-Liquid Indicator
Figure 1-3. Receiver and Tubing Section
1-5
1 2 3 4 5 6 7 8 9 10 11 12 13
25 24 23 22 21 20 19 18 17 16 15 14
1. Power Supply and In-Range Board 14. Voltage Switch (VS)

2. Timing and Current Control Board 15. Circuit Breaker (CB2 --- 230v)
3. Temperature Control Board 16. Circuit Breaker (CB1 --- 460v)
4. Fuse Location (F1 --- 3 amp) 17. Control Fuse (F --- 6 amp)
5. Temperature Simulator Switch (TSS) 18. Control Transformer (TR)
6. Defrost Interval Selector (DIS) 19. Current Limiting Transformer (CLT)
7. Time Delay Override Switch (TDS) 20. Status Indicator
8. Set Temperature Display Switch (SDS) 21. Digital Display (DD)
9. Temperature Set Station (CSS) 22. Scale Selector Switch (SSS)
10. Condenser Fan Contactor (CF) 23. Relay (24 vac w/12 vdc coil)
11. Evaporator Fan Contactor (EF) (DR, IRS, TC, TU & TQ)
12. Heat Contactor (HF) 24. Terminal Block Connection (TB)
13. Compressor Contactor (C) 25. Controller (Mother) Board
Figure 1-4. Control Box and Controller
1-6
1.3 REFRIGERATION SYSTEM DATA 1.4 ELECTRICAL DATA
a. Compressor --- Motor Assembly
a. Circuit Breaker(s)
No. of Cylinders: 6
Model: 06DR CB-1 Trips at: 29 Amps
Weight (Dry): 118 kg (260 lb) CB-2 Trips at: 62.5 Amps
b. Approved Compressor Oil b. Compressor Motor
Castrol Icematic --- SW20 Full Load Amps (FLA): 17.6 Amps@ 460 vac
(with current limiting switch in position B)
c. Compressor Oil Charge
c. Condenser Fan Motor
3.6 liters (7.6 U.S. pints)
Bearing Lubrication: Factory lubricated, additional
d. Compressor Oil Sight Glass
grease not required.
Oil level should be between 1/8 to 1/4 Full Load Amps: 2.0/4.0 FLA
of the sight glass with the compressor in operation. Nominal Horsepower: 0.43/0.75 hp
Rotation: CCW when viewed from shaft end.
e. Defrost Timer Speed: 1425/1725
Initiates Defrost: Refer to paragraph 1.11.f. Voltage: 190/380/208/230/460 vac/1ph/50/60 hz
f. Defrost Termination Thermostat d. Drain Pan Heaters
Opens: 23.9 ( 3)_C = 75 ( 5)_F Number of Heaters: 1

Closes: 15.6 ( 3)_C = 60 ( 5)_F Rating: 750 watts +5 /---10 % at 460 Vac
Resistance (cold): 22.7 5% ohms nominal
g. Expansion Valve Superheat Type: Sheath
Setting at 0_C (32_F) container box temperature: e. Evaporator Coil Heaters
3.36 to 4.48_C (6 to 8_F)
Number of Heaters: 4
h. Heater Termination Thermostat Rating: 750 watts each at 230 +5 /---10 volts
Resistance (cold) @ 20_C (68_F)
Opens: 54 ( 3)_C = 130 ( 5)_F Ambient: 66.8 to 77.2 ohms
Closes: 38 ( 3)_C = 100 ( 5)_F Type: Sheath
i. High Pressure Switch
f. Evaporator Fan Motor(s)
Cutout: 25 ( 0.7) kg/cm@ = 350 ( 10) psig
Bearing Lubrication: Factory lubricated, additional
Cut-In: 18 ( 0.7) kg/cm@ = 250 ( 10) psig
grease not required.
j. Refrigeration Charge
Full Load Amps:
Refer to Table 1-1 High Speed: 2.0/2.3 Amps
Low Speed: 0.4/0.6 Amps
k. Pressure Relief Valves Single Speed Motor: 2.0/4.0
Low Side Valve: Nominal Horsepower:
Opens: 18.63 kg/cm@ (265 psig) High Speed: 0.58/1.0 hp
High Side Valve: Low Speed: 0.07/0.12 hp
Opens: 35 kg/cm@ (500 psig) Single Speed Motor: 0.58/1.0 hp
l. Refrigerant Operating Level (after 20 minutes Rotation:

operation with unit in cooling) Evaporator Fan Motor #1 (See Figure 1-2):
CW when viewed from shaft end
Refer to section 4.6 CCW when viewed from end opposite shaft end
m. Unit Weight Evaporator Fan Motor #2 (See Figure 1-2):
CCW when viewed from shaft end
Refer to Table 1-1 CW when viewed from end opposite shaft end.
n. Water Pressure Switch (Optional) Speed: 2850/3450 rpm
Cut-In: 0.5 0.2 kg/cm@ (7 3 psig) Voltage: 380/460 vac/1 ph/50/60 hz
Cutout: 1.6 0.4 kg/cm@ (22 5 psig)
g. Fuses
o. Suction Solenoid Thermostat
Control Circuit: 6 amp (F)
Closes at: ---12.2 1.7_C (10 3_F)
Opens at: ---6.7 3.3_C (20 6_F) Unit Control Board: 3 amp (F1)
1-7
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 29 amps

Manual Reset (460 vac)
1. Circuit Breaker (CB-2) --- 1. Trips at 62.5 amps
Manual Reset (230 vac)
2. Excessive current draw on control circuit 2. Fuse (F) 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. Abnormal pressures in the low 6. Pressure Relief Valve --- 6. Opens at 18.63 kg/cm@
refrigerant side Low Side (265 psig)
7. Abnormal pressures in the high 7. Pressure Relief Valve --- 7. Opens at 35 kg/cm@
refrigerant side High Side (500 psig)
8. Abnormally high discharge pressures 8. High
g Pressure Switch (HPS)( ) 8. Opens
p at 25 0.7 kg/cm@
g/
(350 10 psig)
i )
9. Solid state circuitry high voltage surge 9. Fuse (F1) 9. Opens at 3 amps
10. Excessive power transformer winding 10. Internal Protector (IP-Trans) --- 10. Opens at 178 5_C
temperature Automatic Reset (350 10_F)
Closes at 150 7_C
(300 12_F)
1.5 SAFETY AND PROTECTIVE DEVICES label. Tighten wing nuts and attach 3/8 tube to the
sampling tube.
System components are protected from damage by
safety and protective devices listed in Table 1-3. These
devices monitor the system operating conditions and If the internal atmosphere content has reached an
open a set of electrical contacts when an unsafe condition unacceptable level, the operator may adjust the cover
occurs. opening to meet the required air flow volume to ventilate
Open safety switch contacts of one or more of the the container.
following devices IP-CM, IP-CP, HPS, or IP-Trans (Auto)
will shut down the compressor. The condenser fan motor
will stop if contacts IP-CM, IP-CP, or IP-Trans (Auto)
open.
69NT40 FRESH AIR MAKEUP
The entire refrigeration system will shut down if one ZERO EXTERNAL STATIC 50HZ
of the following safety devices open: (a) Circuit T-BAR
Breaker(s) or; (b) Fuse (6A) or; (c) Evaporator Fan 240 1-!/2
Motor Internal Protector(s) --- (IP-EM).
210 T-BAR
1.6 FRESH AIR MAKEUP VENT 2-%/8
180 T-BAR
The purpose of the vent is to provide ventilation for 3
commodities that require fresh air circulation and must AIR 150
be closed when transporting frozen foods. FLOW
a. Full Open or Closed Positions (CMH) 120
Maximum air flow is achieved by loosening the wing 90

nuts and moving the cover to the maximum open position
(100% position). The closed position is 0% air flow 60
position.
30
The operator may also adjust the opening to increase
or decrease the air flow volume to meet the required air 0
flow. (See chart below.) 0
10 20 30 40 50 60 70 80 90 100
PERCENT OPEN
b. Air Sampling for Carbon Dioxide (CO2) Level For 60HZ operation multiply curves by 1.2
Loosen wing nuts and move cover until the arrow on
the cover is aligned with the atmosphere sampling port
1-8
1.7 DIGITAL DISPLAY
7
The digital display receives signals from the 9 8
controller and normally displays temperature at the
6
active controller probe (return temperature sensor RTS
or supply temperature sensor STS). 10
Depressing the set display switch (SDS, momentary
11 12
contact) will display the controller set point temperature
while depressed. 3
5
2 18 13
Display is selectable in Celsius or Fahrenheit. Placing 4
the scale selector switch in the down position causes the
temperature to be displayed in degrees Fahrenheit (_F).
Display will read in degrees Celsius (_C) with the switch
in the up position. 16
19 17
With perishable cargo (set points above ---10_C = 15 14
14_F) the digital display and recording thermometer may 1
not agree as the recorder bulb is sensing the return air
temperature and the digital display will indicate supply 1. Suction Service Valve
air temperature. 2. Discharge Service Valve
3. Pressure Regulator Valve
With a frozen load (set points below ---10_C = 14_F), 4. Pressure Relief Valve (Low Side)
the recording thermometer and the digital display both 5. Air-Cooled Condenser
indicate return air temperature and should be in close 6. Evaporator
agreement. 7. Expansion Valve
8. External Equalizer Line
1.8 REFRIGERATION CIRCUIT 9. Expansion Valve Bulb
10. Heat Exchanger
Starting at the compressor (see Figure 1-5), the 11. Pressure Relief Valve (High Side)
suction gas is compressed to a higher temperature and 12. Liquid Line Valve
pressure. 13. Moisture-Liquid Indicator
When operating with the air-cooled condenser, the 14. Filter-Drier
gas flows through the discharge service valve into the 15. Sight Glass
pressure regulator valve that is normally open, however, 16. Receiver or Water-cooled Condenser
if ambient conditions are low the pressure regulator valve 17. Suction Solenoid Valve
restricts the flow of refrigerant to maintain a discharge 18. Suction Modulation Valve
pressure of 5 kg/cm@ (70 psig). Refrigerant gas then 19. Quench Expansion Valve
moves into the air-cooled condenser. Air flowing across
the coil fins and tubes cools the gas to saturation
temperature. By removing latent heat, the gas condenses
to a hot liquid and then flows by a pressure relief valve Figure 1-5. Refrigeration Circuit
which opens if the refrigerant pressure is abnormally
high, to the receiver which stores the additional charge
necessary for low temperature operation. 1.9 REMOTE MONITORING RECEPTACLE
AND CIRCUIT
From the receiver or water-cooled condenser, the
liquid refrigerant continues through a liquid line shutoff When the remote monitor is connected to the
valve, filter-drier (which keeps refrigerant clean and dry), remote monitoring receptacle, Figure 1-1, the following
a moisture-liquid indicator, a heat exchanger (that remote circuits are energized.
increases subcooling of liquid refrigerant) to the
thermostatic expansion valve. As the liquid refrigerant
passes through the orifice of the expansion valve some of Circuit Function
it vaporizes into a gas (flash gas). Heat is absorbed from
the return air by the balance of the liquid causing it to Sockets B to A Energizes remote cool light
vaporize in the evaporator coil. The vapor then flows Sockets C to A Energizes remote defrost light
through the suction modulation valve to the compressor. Sockets D to A Energizes remote in-range light
The thermostatic expansion valve bulb on the suction
line near the evaporator coil outlet, controls the valve, Note
maintaining a relatively constant superheat at the coil
outlet regardless of load conditions except at abnormally The in-range light will be illuminated if the
high container temperatures such as during pulldown container return air temperature is within 2_C
(valve at maximum operating pressure condition). (3.6_F). Refer to paragraph 1.11.g.
1-9
1.10 SUCTION SOLENOID VALVE
The suction solenoid valve, shown in Figure 1-3 is B C

controlled by the suction solenoid thermostat (located on A D
the evaporator fan motor deck as shown in Figure 1-2). SW1 E
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
CURRENT LIMIT SWITCH
capacity.
Figure 1-6. Current Control Printed Circuit Board
The thermostat opens with increasing return air
temperature at ---7 3_C (20 6_F) to de-energize the NOTES
valve. 1. If the current limiting switch is set too low,
unit pulldown capacity may be reduced due to
1.11 CONTROLLER limitation of compressor amperage as
determined by the timing and current control
board.
a. General Description (See Figure 1-4)
2. Table 1-4 shows the approximate total unit
The Carrier Transicold controller is a modular amps for each position of the current limit
assembly of electronic circuits that combines a number of control.
refrigeration system control functions in a single unit. Table 1-4. Current Limiting Switch Positions and
Amperages
The functions are: (1) temperature control; (2)
current control; (3) temperature control function time Switch Position A B C D E
delays; (4) selectable time interval defrost; and, (5) 460 vac Operation 15A 17A 19A 21A 23A
out-of-range indication time delay.
230 vac Operation 30A 34A 38A 42A 46A
The controller consists of a programmed main circuit c. Temperature Control (Capacity Control)
board, three plug-in control circuit boards, five or six
The temperature control portion of the controller
plug-in relays, and remote located components which
consists of a temperature set point potentiometer (CSS),
are: (1) temperature set point potentiometer; (2) two
return air (RTS) and supply air (STS) temperature
temperature sensing probes; (3) two switches for
sensors (two thermistor probes), solid state circuitry
checking calibration; and, (4) current limiting
(temperature control, timing and current control, power
transformer.
supply and IRS printed circuit boards), and associated
control relays. Each temperature sensor is located in its
The controller has high precision components in
respective air stream.
critical circuits which result in the elimination of
calibration adjustments. As long as component Operation at any desired temperature within the set
replacements are made using factory specified parts, point range (---25_C to +25_C or ---15_F to +80_F) is
calibration will be maintained. achieved by turning the set point potentiometer knob to
position the pointer at the desired temperature.
b. Current Control (Capacity Override) A change in sensed air temperature (supply or return
air depending on set point) causes a corresponding
The current control function of the controller limits change in electrical resistance of the thermistor sensor.
the maximum unit current draw to prevent possible This change is processed by the electronic circuitry of the
overloading of limited power sources such as an controller which actuates control relays and the
engine-generator set when operating with high container refrigerant suction modulation valve in accordance with
temperatures and high ambient temperatures. Refer to the controller operating diagrams as shown in Figure 1-7
Table 1-4. and Figure 1-8.
The current control function, when required, will Units with Two-speed Evaporator Motors:
override the normal modulated capacity control function For set points above ---10_C (14_F) relay TU will be
(described in paragraph 1.11.c.) to reduce cooling energized along with contactor EF. The two-speed
capacity sufficiently to prevent total unit current from evaporator motors will be in high speed.
exceeding a preset value. This is accomplished by Units with Optional Humidistat:
circuitry on the timing and current control circuit board
in response to the current sensed in one phase of the Also, for set points above ---10_C (14_F), the
compressor power line by current limiting transformer controller will maintain supply air at the set temperature
(CLT). The current limit on the timing and current by the following modes of operation:
control board is factory set in switch position B (see 1. Conventional, Humidity Control Switch (HCS)
Figure 1-6). in position O --- cooling by refrigeration with suction
1-10
modulation and the compressor cycling at light loads. Also, for set points below ---10_C (14_F), the
Electric resistance heating. controller will maintain return air at the set temperature
by refrigeration. Electric resistance heating is
2. Conventional plus Dehumidification, Humidity electronically locked out in this temperature range. Units
Control Switch in position 1 --- cooling by refrigeration with two-speed evaporator fan motors will have the
with suction modulation and compressor cycling at low evaporator fan motors in low speed as relay TU will be
humidities, suction modulation and simultaneous de-energized. (Contactor ES energized.)
electric resistance heating at high humidities.
Electric resistance heating is locked out for set points
1. Operation in the Conventional Mode below ---10_C (14_F) by controller relay TH being locked
Operation in the Conventional Mode (HCS in out to prevent energizing the circuit.
position O, that is if the optional humidistat is Cargo temperatures will necessarily vary somewhat
installed) with the set point setting below the air from controlled air temperatures. A simple numerical
temperature at the supply air probe but above ---10_C difference between product temperature and controlled
(14_F) the unit starts in cooling with controller relay TU air temperature cannot be stated because of the complex
(used only with two-speed evaporator fan motors) relationship of air flow variations within the container
energized. Compressor and condenser fan contactors are and temperature gradients of air and product. However,
energized through relay TC contacts T9 and T31 (now during cooling, it can be stated that with supply air
closed). control, a minimum product temperature will be
effectively maintained and with return air control, a
As the sensed temperature continues to fall, the
maximum product temperature will be effectively
modulating valve current will remain at minimum (under
maintained.
0.2 amp) until the sensed temperature drops to 0.25_C
(0.45_F) above set point. 2. Operation in the Dehumidification Mode
With any further drop in sensed temperature, Operation in the Dehumidification Mode (HCS in
modulated (continuously variable) capacity reduction position 1, that is if the humidistat is installed). With
occurs to match cooling requirements that are less than the set point setting below the air temperature at the
the maximum capacity of the unit. This permits exact supply air probe (but above ---10_C (14_F) starts with
balancing of unit capacity with a wide range of cooling controller relay TU (used only with two-speed
loads while maintaining continuous compressor evaporator fan motors) energized. The compressor and
operation and holding the temperature very close to set condenser fan contactors are energized through normally
point. This variable cooling capacity is achieved by a closed TC relay contacts. The evaporator fan motors are
suction modulation valve which provides a variable as previously described.
restriction in the compressor suction line. This valve Cooling capacity reduction by modulation is the
varies the flow rate of the refrigerant pumped by the same as described for the conventional operating mode
compressor. 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 d.) (N.O.) relay HC contacts. Also, the in-range and heat
In cold ambients when container heating is required, lights are illuminated at this time.
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 delay on energization similar to that open the modulating valve to match the new total heat
associated with compressor cycling. The heat relay load while still holding the supply air temperature very
(contactor HR) is energized through the closed contacts close to set point.
(N.C.) of relay TC by controller relay TH energizing and
closing the TH contacts (N.O.). Heat relay (contactor) Opening the modulating valve reduces the
HR energizes the defrost and drain pan heaters. temperature of the evaporator coil surface which
increases the rate water is condensed from the air passing
For set points below ---10_C (14_F), return air through the coil. Removing water from the air reduces
temperature is sensed and the range of capacity the relative humidity until the HC setting is reached and
reduction is more limited than for higher set points. controller HC contacts open to de-energize heating.
When cooling requirements are less than the minimum
Humidity controller HC will continue to cycle
continuous operating capacity of the unit, the unit reverts
heating to maintain relative humidity below HC setting.
to on-off compressor cycling to match the load. When
cooling, compressor and condenser fan contactors are With set points below ---10_C (14_F), operation is
energized through the normally open (N.O.) contacts of the same as previously described for conventional mode
relay TC. --- heating and dehumidification are locked out.
1-11
d. Time Delays temperature at the sensing probe goes beyond the
TC relay operation is affected by a time delay in-range temperature limits. A normal operating unit will
function of the Timing and Current Control Board; its return from defrost to an in-range condition before
purpose is to prevent short cycling of the compressor. expiration of the 90 minute delay and no interruption of
in-range indication will occur. Indication of the
To prevent short cycling of the compressor, a six instantaneous temperature condition (in or
minute compressor off time must be satisfied. When the out-of-range) can be obtained by pressing the time delay
timer completes its six minute cycle, the compressor will overrride switch (TDS).
start if the sensed temperature is greater than 0.25_C
h. Function and Calibration Check
(0.45_F) above setpoint.
The controller has precision resistors that simulate
Additional transient override time delays affect the sensing probe temperatures to permit readily checking
operation of TC and TH relays. These delays are all controller functions and calibration without using
overridden by pressing the time delay override switch temperature baths or other temperature measuring
(TDS). instruments.
e. Lockout Functions Sensing probe temperature is simulated by holding
Heating function lockout for set points below ---10_C the temperature simulator switch (TSS) in the desired
(14_F) is achieved by relay TH being prevented from position, 0_C (32_F) or ---17.8_C (0_F).
energizing. When checking controller functions and calibration,
f. Selectable Time Interval Defrost it is also necessary to hold the time delay override switch
(TDS) depressed to obtain immediate controller
A selectable interval defrost initiation timer is responses. Depressing switch TDS does the following:
included in the timing and current control board. The
time interval between defrost initiations (90 second test, 1. Cancels 90 minute in-range delay (paragraph g.).
3 hours, 6 hours, 12 hours, or 24 hours) is set with the 2. Cancels 6 minute compressor recycle delay
defrost interval selector switch (DIS). (paragraph d.).
The controller initiates defrost (providing the 3. Cancels relay TH ON nuisance cycling
evaporator coil temperature is below 13_C = 55_F delays.(Paragraphs c. and d.).
required to close the defrost termination thermostat 4. Resets defrost interval timing to zero (paragraph g.).
contacts) by:
1.12 HUMIDISTAT (OPTIONAL)
1. Energizing defrost relay (DR) energizes the defrost NOTE
light and stops the evaporator fan motors by
de-energizing the evaporator fan motor contactor. The supply air must be in-range or humidistat
circuit will not energize.
2. De-energizing cooling relay (TC) and energizing and The humidistat (Figure 1-2) is designed to operate
heating relay (TH). This stops the compressor and when transporting a chill load (controller set above ---10_C
condenser fan motor and energizes the defrost and drain (14_F) and is locked out when the controller is set below
pan heaters. ---10_C (TU contacts T35 to T37 are open).
Defrosting is terminated by the defrost termination a. The humidistat will be in operation if:
thermostat (DTT), which opens when the evaporator coil 1. Supply air is in-range (in-range light illuminated).
temperature rises to 24_C (75_F) after all frost has been
melted from the coil. 2. Humidistat control switch in the ON position.
Also, defrost may be manually initiated at any time 3. Controller is set above ---10_C (14_F).
by actuating the manual defrost switch (MDS) if DTT is 4. Container relative humidity reaches setpoint of
closed. the users desired R.H. setting on the humidistat.
NOTE The above energizes the humidistat circuit as relay
Defrost interval timing restarts at time zero IRS contacts T24 to T23, TU relay contacts T35 to T37,
whenever the time delay override switch (TDS) HCS contacts 1-2, and HC contacts 1-3 close to energize
is depressed or control circuit power is restored the heaters and heat light.
after an interruption such as occurs when b. For testing purposes:
stopping or starting unit (ST switch) and when WARNING
DTT opens. Beware of rotating evaporator fan when
conducting following test.
g. Out-of-Range Indication Time Delay
1. Remove the front evaporator fan motor #1
During defrost, the temperature at the sensing probe access panel (see Figure 1-1). The humidistat is located
rises above the upper in-range limit which would result in behind this panel.
an out-of-range indication if the temporary condition
were not overridden. Circuitry on the timing and current 2. Move the controller set pointer within 2_C
control board works in conjunction with the temperature (3.6_F) of container supply air temperature.
control circuitry to delay de-energization of the in-range 3. Move the humidistat control switch to ON
relay (IRS) until approximately 90 minutes after the position (position 1).
1-12
4. Turn the humidistat control knob until heaters For operation of the refrigeration unit with the water-cooled
are energized (heat light ON) and then reset control to condenser, do the following:
the users desired R.H. value. Replace access panel and a. Connect water supply line to inlet side of
lockwire. condenser and discharge line to outlet side of condenser.
1.13 VOLTAGE SWITCH AND POWER
TRANSFORMER (OPTIONAL) b. Maintain a flow rate of 11 to 26 liters (3 to 7 U.S.
WARNING gallons) per minute. The water pressure switch will open
Do not attempt to remove power plug(s) before to de-energize the condenser fan relay. The condenser
turning OFF start-stop switch (ST), unit circuit fan motor will stop and will remain stopped until the
breaker(S) and external power source. Make sure water pressure switch closes.
the power plugs are clean and dry before The refrigeration unit operating with the
connecting to any power receptacle. water-cooled condenser will perform as outlined in
a. Step-Up Power Transformer section 2.4 except that the condenser fan motor is
The transformer is located under the condenser coil stopped in all modes.
(left-hand side of unit) and the purpose of this To shift to air-cooled condenser operation, do the following:
transformer is to provide 380 vac/3 ph/50 hz power when
the 190/230 vac power cable (black) is connected to a 190 Disconnect the water supply and the discharge line to
the water-cooled condenser. The refrigeration unit will
vac power supply or to provide 460 vac/3 ph/60 hz when
shift to air-cooled condenser operation when the water
the 190/230 vac power cable (black) is connected to a 230
vac power supply. pressure switch closes. (Refer to paragraph 1.3.n.)
WARNING
Do not attempt to remove power plug before
turning OFF voltage switch (VS), start-stop
switch (ST), unit circuit breakers (CB-1 And
CB-2), and external power source.
b. To Place Unit on 190/230 vac Power Supply
1. Make sure voltage switch (VS) is in the OFF
position. Make sure start-stop switch (ST, on control
panel) and circuit breakers CB-2 is in position O
(OFF). (See Figure 1-4)
2. Connect 190/230 vac power cable plug (black
cable). Place voltage switch (VS) in the 230 v position.
Place circuit breaker (CB-2) in position 1. Close and
secure control box door and then place the start-stop
switch (ST) in position 1.
c. To Place Unit on 380/460 vac Power Supply
1. Make sure voltage switch (VS) is in the OFF
position. Make sure start-stop switch (ST, on control
panel) and circuit breaker (CB-1) is in position O
(OFF).
2. Connect 380/460 vac power cable plug (yellow
cable). Place voltage switch (VS) in the 460 v position.
Place circuit breaker (CB-1) in position 1. Close and
secure control box door and then place the start-stop
switch (ST) in position 1.
1.14 WATER-COOLED CONDENSER AND
WATER PRESSURE SWITCH
(OPTIONAL)
The water-cooled condenser is used when heating
the surrounding air is objectionable such as in a ships
hold and cooling water is available.
The water-cooled condenser is of the shell and coil
type with circulating water through the cupro-nickel coil.
The refrigerant vapor is admitted to the shell side and is
condensed on the outer surface of the coil.
1-13
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 1-7. 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 1-8. Controller Set Point Above --- 10_C (14_F) --- Supply Air Control
NOTE
Switching functions are affected by time delays. (Refer to paragraph 1.11.d.)
1-14
SECTION 2
OPERATION
2.1 PRE-TRIP INSPECTION (Before Starting) 2.2 STARTING AND STOPPING INSTRUCTIONS
CAUTION
WARNING Make sure that the unit circuit breaker(S) (CB)
Beware of unannounced starting of the and the start-stop switch are in the OFF position
evaporator and condenser fan. before connecting to any electrical power source.
i. Starting the Unit
a. If container is empty, check inside for the following:
1. Refer to Pre-Trip Inspection, section 2.1.
1. Check channels or T bars on floor for 2. Make sure unit circuit breaker(s) and start-stop
cleanliness. Channels must be free of debris for proper switch are in position O (OFF position).
air circulation.
3. Check power source for proper voltage. Connect
2. Check container panels, insulation and door unit power plug and turn main power ON.
seals for damage. Effect permanent or temporary 4. Turn refrigeration unit circuit breaker(s), and
repairs. the start-stop switch ON (position 1).
3. Visually check evaporator fan motor mounting 5. To adjust the temperature set point, depress
bolts for proper securement. SDS switch and turn temperature selector knob while
4. Check for dirt or grease on evaporator fan or fan looking at the digital temperature display. This
deck and clean if necessary. procedure allows temperature settings within a tenth of a
degree centigrade.
5. Check evaporator coil for cleanliness or 6. Refer to section 2.3 after unit is running.
obstructions. Wash with fresh water. (Refer to section 4.14)
j. Stopping the Unit
6. Check defrost drain pans and drain lines for
obstructions and clear if necessary. Wash with fresh Turn the start-stop switch to position O (OFF).
water. 2.3 AFTER STARTING INSPECTION
7. Check panels on refrigeration unit for loose a. Check rotation of condenser and evaporator fans.
bolts and condition of panels. Make sure T.I.R. devices b. Check compressor oil level.
are in place on access panels. c. Check operation --- determine if unit responds
b. Check condenser coil for cleanliness. Wash with properly to setting of controller, cycling from heat to cool,
fresh water. (Refer to section 4.17) at controller setting.
d. Feel filter-drier. Excessive temperature drop across
c. Check position of fresh air makeup vent cover.
drier indicates restriction.
Operator must determine if fresh air makeup vent cover
is to be opened or closed. 2.4 UNIT OPERATION
d. Open Partlow recording thermometer (if so 2.4.1 Cooling --- Controller Set Below --- 10_C (14_F)
equipped) door and do the following:
On decreasing return air temperature the unit will be
1. Manually wind clock on recording thermometer in cooling with the condenser fan motor and evaporator
(key is located in a clip.) KEY MUST STAY WITH THE fan motors energized. With set points below ---10_C
THERMOMETER. (14_F), units with two-speed evaporator fan motors will
be in low speed as relay TU will be de-energized
2. Lift stylus (pen) by pulling the marking tip
(contactor ES energizes).
outward until the stylus arm snaps into its retracted
position. If the container return air is within 2_C (3.6_F) of set
point, the in-range relay contacts (IRS) are closed and
3. Install new chart on recording thermometer the in-range light (IRL) is illuminated.
making sure chart is under the four corner tabs. Lower
When the return air temperature decreases to
the stylus until stylus has made contact with chart. Then
0.25_C (0.5_F) below set point, a timing function
close and secure door.
commences which delays de-energizing of relay TC and
e. Open the control box door. Check for loose electrical resulting in de-energizing the compressor and condenser
connections or hardware. fan motor. Also, the cool light is de-energized. The
evaporator fan motors continue to run to circulate air
f. Check color of moisture-liquid indicator. throughout the container.
g. Check oil level in compressor sight glass. When the return air temperature increases to 0.25_C
h. Check suction modulation valve coil resistance. (0.5_F) above set point, and providing a sufficient off
(Refer to section 4.21) period has elapsed, relay TC energizes to restart the
compressor. Also, at this time, the condenser fan motor
i. Start refrigeration unit. (Refer to section 2.3) starts and the cool light is illuminated.
2-1
NOTES When the air temperature decreases to 2_C (3.6_F)
1. When the return air temperature decreases to above set point relay IRS energizes and the in-range light is
---12.2_C (10_F), the suction solenoid thermostat illuminated.
closes to energize the suction solenoid valve. The If the air temperature continues to fall, modulating
valve opens to increase the refrigerant flow rate cooling starts at approximately 0.25_C (0.45_F) above set
and cooling capacity. point. The modulating valve will have a variable current up
2. In the frozen range the suction modulation is to 1.45 amps at full modulation.
limited to approximately 0.4 amp or valve is 25 When the supply air temperature decreases to 0.25_C
percent closed. (0.5_F) below set point, a timing function commences
3. Setting the controller below ---10_C (14_F) on which delays de-energizing of relay TC resulting in
units with two-speed motors will place the motors de-energizing the compressor and condenser fan motor.
in low speed (contactor ES energizes). Also, the cool light is de-energized.
The evaporator fan motors continue to run to circulate
2.4.2 Controller Set Above ---10_C (14_F) air throughout the container. The in-range light remains
illuminated as long as the return air is within 2_C (3.6_F) of
a. Cooling (See Figure 2-1)
set point.
With decreasing supply air temperature and if the If the unit is in the holding mode (neither heating or
supply air is more than 2_C (3.6_F) above set point, the unit cooling) and the supply air temperature increases to 0.25_C
will be cooling with the condenser fan motor, compressor (0.5_F) above set point, and providing a sufficient off time
motor and evaporator fan motors energized. The has elapsed, relay TC energizes to restart the compressor.
two-speed evaporator fan motors will be in high speed as Also, at this time, the condenser fan motor starts and the
relay TU is energized (contactor ES de-energizes and cool light is illuminated.
contactor EF energizes). When the supply air temperature increases 2_C (3.6_F)
Also, at this time, the cool light is illuminated. The above set point, relay IRS and the in-range light is off. The
in-range light is de-energized. cool light remains energized.
TO CONTROL TRANSFORMER
= Energized Circuit = De-energized Circuit
Figure 2-1. Cooling --- Within 2_C (3.6_F) of Set Point
2-2
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.
2-3
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 1.11.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 1.11.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
2-4
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
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
TU (Utility) Energized with controller settings above - 10_C (14_F)
(Two-Speed Motors)
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 1.12)
N/A - Not Applicable
2-5
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
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
TU (Utility) Energized with controller settings below - 10_C (14_F)
(Two-Speed Motors)
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
2-6
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 4.15
Condenser fan motor internal protector open 4.18
Compressor internal protector open 4.7
High pressure switch open 4.13
Compressor hums, Low line voltage Check

but does not start Single phasing Check
Shorted or grounded motor windings 4.7
Compressor seized 4.7
Voltage Switch (VS) not wired properly Check
3.2 UNIT RUNS BUT HAS INSUFFICIENT COOLING

Compressor Compressor valves defective 4.7
Refrigeration System Abnormal pressures 3.7

Temperature controller malfunction 3.9
Evaporator fan or motor defective 4.15
Suction modulation valve malfunction 4.21
Suction solenoid valve malfunction 1.10
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 4.4/4.6

Evaporator coil covered with ice 3.6
Evaporator coil plugged with debris 4.14
Evaporator fan(s) rotating backwards 4.15/4.24
Defective evaporator fan motor/capacitor 4.15/4.24
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 4.27
Compressor worn 4.7
Current limit switch set to wrong value 1.11.b
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 4.15
Heat relay defective Check
Heater termination switch open 4.14
Unit will not heat or Heater(s) defective 4.16

has insufficient heat Heater contactor or coil defective Replace
Evaporator fan motor(s) defective or rotating backwards 4.15/4.24
Evaporator fan motor contactor defective Replace
Defective wiring Replace
Loose terminal connections Tighten
Low line voltage 1.13
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 4.14
3.6 UNIT WILL NOT DEFROST PROPERLY

Will not initiate Defrost timer malfunction 1.11.f
defrost automatically Loose terminal connections Tighten
Defective wiring Replace
Defrost termination or heat termination switch open 4.14
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 Defective timing and current control board Replace
(DR) drops out Low line voltage 1.13
Initiates but does not defrost Heater contactor or coil defective Replace
Heater(s) burned out 4.16
Frequent defrost Wet load Normal
3-2
TROUBLE SECTION
3.7 ABNORMAL PRESSURES (COOLING)

High discharge pressure Condenser coil dirty 4.17 or 4.27
Condenser fan rotating backwards 4.18
Condenser fan inoperative 4.18
Refrigerant overcharge or noncondensibles 4.6
Pressure regulator valve Replace
Low suction pressure Suction service valve partially closed Open

Filter-drier partially plugged 4.12
Low refrigerant charge 4.4/4.6
Expansion valve defective 4.23
No evaporator air flow or restricted air flow 3.10
Excessive frost on evaporator coil 3.6
Evaporator fan(s) rotating backwards 4.15/4.24
Suction and discharge pressures Heat exchanger defective Replace
tend to equalize when unit Compressor valves defective 4.8
is operating
3.8 ABNORMAL NOISE OR VIBRATIONS

Compressor Loose mounting bolts Tighten
Worn bearings 4.7
Worn or broken valves 4.7
Liquid slugging 3.11
Insufficient oil 4.10
Condenser or Bent, loose or striking venturi Check

Evaporator Fan Worn motor bearings 4.15/4.18
Bent motor shaft 4.15/4.18
3.9 TEMPERATURE CONTROLLER MALFUNCTION

Will not control or relay(s) Controller relay(s) defective 4.22
do not actuate at Defective Sensor 4.22.6
proper temperature Defective wiring 4.22
Controller malfunction 4.22
Compressor does not start

or stop at specified temperature Time delay period not elapsed 1.11.d
3.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW

Evaporator coil blocked Frost on coil 3.6
Dirty coil 4.14
No or partial Evaporator fan motor internal protector open 4.15

evaporator air flow Evaporator fan motor(s) defective 4.15/4.24
Evaporator fan(s) loose or defective 4.15
3-3
TROUBLE SECTION
3.11 EXPANSION VALVE MALFUNCTION

Low suction pressure Low refrigerant charge 4.4/4.6
with high superheat External equalizer line plugged Open
Wax, oil or dirt plugging valve or orifice 4.23
Ice formation at valve seat 4.4/4.5
Superheat too high 4.23.c
Power assembly failure 4.23
Loss of element/bulb charge 4.23
Broken capillary 4.23
Foreign material in valve 4.23
High suction pressure Superheat setting too low 4.23.c

with low superheat External equalizer line plugged Open
Ice holding valve open 4.4/4.5
Foreign material in valve 4.23
Liquid slugging in compressor Pin and seat of expansion valve eroded or

held open by foreign material 4.23
Fluctuating suction pressure Improper bulb location or installation 4.23

Low superheat setting 4.23.c
3.12 WATER-COOLED CONDENSER OR WATER PRESSURE SWITCH MALFUNCTION

High discharge pressure Dirty coil 4.27
Noncondensibles 4.27
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 4.26
Step-up transformer defective 4.26
Power source not turned ON Check
3-4
SECTION 4
SERVICE
4.1 MANIFOLD GAUGE SET NOTE
The manifold gauge set can be used to determine If a manifold gauge set is new or was exposed to the
system operating pressure, add a refrigerant charge, atmosphere. Due to repair, it will need to be
equalize or evacuate the system. evacuated to remove contaminants and air as
follows:
The manifold gauge in Figure 4-1 shows hand valves, a. Midseat both hand valves.
gauges and refrigerant openings. When the low pressure
hand valve is frontseated (turned all the way in), the low b. Connect the utility hose (yellow) to a vacuum
(evaporator) pressure can be checked. When the high pump.
pressure hand valve is frontseated, high (condensing) c. Evacuate to 10 inches of vacuum.
pressure can be checked. When both valves are open
(turning counter clockwise), high pressure vapor will flow d. Charge with R-134a to a slightly positive
into the low side. When the low pressure valve is open, pressure of 0.1 kg/cm@ (1.0 psig).
the system can be charged. Oil can also be added to the e. The gauge set is now ready for use.
system.
2. Connect the high side field service coupling
(backseated) to the discharge service valve port (or the
Only a R-134a manifold gauge set with self-sealing manual liquid line valve port, whichever is applicable).
hoses as shown in Figure 4-2 (CTD P/N 07-00294-00,
which includes items 1 through 6) can be used when 3. Turn the high side field service coupling (red
working on the models covered within this manual. knob) clockwise, which will open the high side of the
system to the gauge set.
4. Connect the low side field service coupling to the
Low Pressure Gauge High Pressure Gauge suction service valve port.
5. Turn the low side field service coupling (blue
knob), which will open the low side of the system to the
gauge set.
6. To read system pressures; slightly midseat the
discharge and suction service valves, and frontseat both
manifold gauge set hand valves.
CAUTION
To prevent trapping liquid refrigerant in the service
A C B valve after charging, while the compressor is ON
and before disconnecting the manifold gauge set,
Opened perform the following steps:
(Backseated Hand Valve )
a. Backseat applicable discharge or manual liquid
Closed line valve.
(Frontseated Hand Valve) b. Midseat manifold gauge set hand valves.
c. Allow the gauge set to pull down to suction pressure.
A. Connection to Low Side of System b. Removing the Manifold Gauge Set

B. Connection to High Side of System
C. Connection to Either: 1. While the compressor is still ON, backseat the
Refrigerant Cylinder or discharge service valve.
Oil Container 2. Midseat both hand valves on the manifold gauge
set and allow the pressure in the manifold gauge set to be
drawn down to suction pressure. This enables the liquid
Figure 4-1. Manifold Gauge Set that condensed in the high side hose to be returned to the
system.
a. Connecting the Manifold Gauge Set (See Figure 4-2) 3. Backseat the suction service valve. Backseat
both field service couplings, and remove the couplings
from the service ports.
1. Remove service valve stem caps and check both
service valves to make sure they are backseated (counter 4. Install both service valve stem caps and service
clockwise). Remove service port caps. port caps (finger-tight only).
4-1
8
8
1
To Suction Service Port To Discharge Service or

2 2 Manual Liquid Line Ports
2
Blue Hose Red Hose
3 3 3
4 4
Red Knob
Blue Knob Yellow Hose

6
2 5
1. Manifold Gauge Set 5. High Side Field Service 8. Low Side Service Port
2. Hose Fitting (0.500-16 Acme) Coupling (SAE J639 Male)
3. Refrigeration or Evacuation 6. Low Side Field Service
Hoses (SAE J2196/R-134a) Coupling
4 Hose Fitting w/O-ring 7. High Side Service Port
(M14 x 1.5) (SAE J639 Male)
Figure 4-2. R-134a Manifold Gauge Set Connection
4-2
4.2 SUCTION AND DISCHARGE SERVICE VALVES 3. Frontseat (close) the suction service valve and
The suction and discharge service valves used on the the refrigerant will be trapped between the compressor
compressor are equipped with mating flanges for suction service valve and the liquid line valve.
connection to flanges on the compressor. These valves 4. Before opening up any part of the system, a
are provided with a double seat and a gauge connection, slight positive pressure should be indicated on the
which enable servicing of the compressor and refrigerant pressure gauge. If a vacuum is indicated, emit refrigerant
lines. by cracking the liquid line valve momentarily to build up a
slight positive pressure.
Turning the valve stem clockwise (all the way forward)
will frontseat the valve to close off the suction or 5. When opening up the refrigerant system, certain
discharge line and opens the gauge connection to the parts may frost. Allow the part to warm to ambient
compressor. See Figure 4-3. Turning the valve stem temperature before dismantling. This avoids internal
counterclockwise (all the way out) will backseat the valve condensation which puts moisture in the system.
to open the suction or discharge line to the compressor 6. After repairs have been made, be sure to
and close off the gauge connection. perform a refrigerant leak check (section 4.4), and
evacuate and dehydrate the system (section 4.5).
With the valve stem midway between frontseated and
backseated positions, suction or discharge line is open to 7. Check refrigerant charge (Refer to section 4.6).
both the compressor and the gauge connection. 4.4 REFRIGERANT LEAK CHECKING
For example, when connecting a manifold gauge to WARNING
measure suction or discharge pressure, the valve stem is Never mix refrigerants with air for leak testing.
fully backseated. Then, to measure suction or discharge It has been determined that pressurized,
pressure, crack open the valves 1/4 to 1/2 turn. air-rich mixtures of refrigerants and air can
undergo combustion when exposed to an
Gauge Connection ignition source.
To Suction or Valve Cap a. The recommended procedure for finding leaks in a
Discharge Line system is with a R-134a electronic leak detector. Testing
joints with soapsuds is satisfactory only for locating large
leaks.
b. If the system is without refrigerant, charge the system
with refrigerant to build up pressure between 2.1 to 3.5
Valve Stem kg/cm@ (30 to 50 psig). Remove refrigerant drum and leak
Compressor
check all connections.
Valve Valve NOTE
Frontseated Backseated It must be emphasized that only the correct
(clockwise) (counterclockwise) refrigerant drum be connected to pressurize the
system. Any other gas or vapor will contaminate
Figure 4-3. Suction or Discharge Service Valve the system which will require additional purging
and evacuation of the system.
4.3 PUMPING THE UNIT DOWN OR
REMOVING THE REFRIGERANT c. Remove refrigerant using a refrigerant recovery
system and repair any leaks.
NOTE
d. Evacuate and dehydrate the unit. (Refer to section 4.5)
To avoid damage to the earths ozone layer,
use a refrigerant recovery system whenever e. Charge unit per section 4.6.
removing refrigerant. 4.5 EVACUATION AND DEHYDRATION
a. Pumping the Unit Down 4.5.1 General
To service the filter-drier, moisture-liquid indicator, Moisture is the deadly enemy of refrigeration
expansion valve, suction modulation valve, suction solenoid systems. The presence of moisture in a refrigeration
valve or evaporator coil, pump most of the refrigerant into system can have many undesirable effects. The most
the condenser coil and receiver as follows: common are copper plating, acid sludge formation,
freezing-up of metering devices by free water, and
1. Backseat the suction and discharge valves (turn formation of acids, resulting in metal corrosion.
counterclockwise) to close off gauge connections and
attach manifold gauges to valves. Refer to section 4.1.a. 4.5.2 Preparation
a. Evacuate and dehydrate only after pressure leak test.
2. Allow the compressor to run 10 to 15 minutes
before frontseating the liquid line valve. Then close (Refer to section 4.4)
(front seat) liquid line valve by turning clockwise. Start b. Essential tools to properly evacuate and dehydrate
the unit and run in a cooling mode. Place start-stop switch any system include a vacuum pump (8 m3H = 5 cfm
in the OFF position when the unit reaches a positive volume displacement, P/N 07-00176-01) and electronic
pressure of 0.1 kg/cm@ (1.0 psig). vacuum gauge.
4-3
c. If possible, keep the ambient temperature above 4.6 ADDING OR CHECKING THE
15.6_C (60_F) to speed evaporation of moisture. If REFRIGERANT CHARGE
ambient temperature is lower than 15.6_C (60_F) ice 4.6.1 Checking the Refrigerant Charge
might form before moisture removal is complete. Heat
lamps or alternate sources of heat may be used to raise NOTES
the system temperature. 1. Set the controller set point to ---25_C (---13_F) to
ensure that the suction modulation valve is fully
d. Replace the filter-drier with a section of copper open when checking operation of unit.
tubing with the appropriate fittings. This idea will help
speed up the evacuation procedure. 2. The refrigerant level should only be checked when
the unit is running with the suction modulation
4.5.3 Procedure valve fully open. The container temperature
should be approximately 1.7_C (35_F) or
a. Remove all refrigerant using a refrigerant recovery ---17.8_C (0_F).
system.
a. Connect the gauge manifold to the compressor
b. The recommended method to evacuate and discharge and suction service valves.
dehydrate the system is to connect three evacuation b. Units equipped with the receiver; partially block the
hoses (Do not use standard service hoses, as they are not condenser coil inlet air starting from the front of the
suited for evacuation purposes.) as shown in Figure 4-4 condenser coil. Increase the area blocked until the
to the vacuum pump and refrigeration unit. Also, as compressor discharge pressure is raised to approximately
shown, connect a evacuation manifold, with evacuation 12 kg/cm@ (175 psig). Refrigerant level on the receiver will
hoses only, to the vacuum pump, electronic vacuum normally be between the sight glasses. If not, refer to
gauge, and refrigerant recovery system. section 4.6.3.
c. With the unit service valves closed (back seated) and c. Units equipped with the water-cooled condenser;
the vacuum pump and electronic vacuum gauge valves check charge only on air-cooled operation. Refrigerant
open, start the pump and draw a deep vacuum. Shut off level in the water-cooled operation will be normally
the pump and check to see if the vacuum holds. This above sight glass. Partially block the condenser coil inlet
operation is to test the evacuation setup for leaks, repair air starting from the front of the condenser coil. Increase
if necessary. the area blocked until the compressor discharge pressure
is raised to approximately 12 kg/cm@ (175 psig).
d. Midseat the refrigerant system service valves. Refrigerant should appear at center line of sight glass on
the water-cooled condenser. If not, refer to section 4.6.3.
e. Then open the vacuum pump and electronic vacuum
gauge valves, if they are not already open. Start the vacuum 4.6.2 Adding Refrigerant to System (Full Charge)
pump. Evacuate unit until the electronic vacuum gauge a. Evacuate unit and leave in deep vacuum. (Refer to
indicates 2000 microns. Close the electronic vacuum gauge section 4.5)
and vacuum pump valves. Shut off the vacuum pump. Wait
a few minutes to be sure the vacuum holds. b. Place drum of R-134a on scale and connect charging
line from drum to liquid line valve. Purge charging line at
f. Break the vacuum with clean dry refrigerant gas. Use liquid line valve and then note weight of drum and
refrigerant that the unit calls for. Raise system pressure refrigerant.
to approximately 2 psig by monitoring it with the c. Open liquid valve on drum. Open liquid line valve
compound gauge. half-way and allow the liquid refrigerant to flow into the
g. Remove refrigerant using a refrigerant recovery unit until the correct weight of refrigerant has been
system. added as indicated by scales. Correct charge is noted in
Table 1-1.
h. Repeat steps e through g one time. NOTE
i. Remove the copper tubing and change the It may be necessary to finish charging unit
filter-drier. Evacuate unit to 500 microns. Close the through suction service valve in gas form, due to
electronic vacuum gauge and vacuum pump valves. Shut pressure rise in high side of the system. (Refer to
off the vacuum pump. Wait five minutes to see if vacuum section 4.6.3)
holds. This checks for residual moisture and/or leaks. d. Backseat liquid line valve (to close off gauge port).
Close liquid valve on drum. Crack connection on
j. With a vacuum still in the unit, the refrigerant charge
charging line at liquid line valve to vent charging line.
may be drawn into the system from a refrigerant
container on weight scales. The correct amount of e. Start unit in cooling mode. Run approximately ten
refrigerant may be added by observing the scales. (Refer minutes and check the refrigerant charge. (Refer to
to section 4.6) section 4.6.1)
4-4
12
11 10 8
4 4
1 3
6 4
2 5
1. Refrigerant Recovery Unit 5. Vacuum Pump 9. Suction Service Valve
2. Refrigerant Cylinder 6. Electronic Vacuum Gauge 10. Compressor
3. Evacuation Manifold (R-134a) 7. Manual Liquid Line Valve 11. Discharge Service Valve
4 Hand Valve 8. Condenser Coil 12. Evaporator Coil
Figure 4-4. Vacuum Pump Connections
4-5
4.6.3 Adding Refrigerant to System NOTES
(Partial Charge) 1. Check the compressor Serial/Model Number
plate for CFM displacement, refer to Table 1-2.
a. Examine the unit refrigerant system for any evidence
of leaks. Repair as necessary. (Refer to section 4.4) 2. The compressor should not operate in a
vacuum greater than 50.80 cm Hg vacuum (20
b. Maintain the conditions outlined in section 4.6.1. inches Hg vacuum).
3. The service replacement compressor is sold
c. Fully backseat (to close off gauge port) the suction without shutoff valves (but with valve pads), and
service valve (see Figure 1-3) and remove the service port without terminal box and cover. Customer should
cap. retain the original terminal box, cover, and high
d. Connect charging line between suction service valve pressure switch for use on replacement
port and drum of Refrigerant-12. Open VAPOR valve on compressor.
drum. Purge charging line. 4. Check oil level in service replacement
compressor. (Refer to paragraph 1.3.b. and
e. Partially frontseat (turn clockwise) the suction service section 4.10)
valve and slowly add charge until the refrigerant appears at
5. A compressor terminal wiring kit must be
the proper level (refer to section 4.6.1).
ordered as a separate item when ordering
4.7 REPLACING THE COMPRESSOR replacement compressor. Appropriate installation
(See Figure 4-5) instructions are included with kit.
6. Refer to Table 4-4 and Table 4-5 for applicable
WARNING
compressor wear limits and torque values.
Make sure power to the unit is OFF and power
plug disconnected before replacing the 7. Refer to Figure 4-26 for charts on compressor
compressor. pressure-temperature and motor current curves.
a. Remove protective guard from lower section of the

1 2 3 unit.
b. If compressor is inoperative and unit still has
14 refrigerant pressure, remove refrigerant
(refer to section 4.3).
13 c. Disconnect wiring in the compressor junction box after
identifying same. Disconnect wiring from compressor
12
4 terminals and remove compressor junction box.
d. Remove bolts from service valve flanges.
e. Remove compressor plate mounting bolts.
f. Remove compressor and mounting plate. The
11 5 compressor weighs approximately 118 kg (260 pounds).
10 g. Remove high pressure switch (HPS) from compressor
and check operation of switch (section 4.13).
7 6 h. Remove compressor mounting bolts from mounting
9 8 plate and install mounting plate on replacement
1. Discharge Valve Flange compressor.
2. High Pressure Switch Connection i. Install replacement terminal block kit (following
3. Low Pressure Connection instructions included with kit).
4. Suction Valve Flange
5. Motor End Cover j. Install high pressure switch on compressor.
6. Serial/Model No. Plate k. Install compressor and mounting plate in unit.
7. Sight Glass
l. Install junction box to compressor and connect all
8. Bottom Plate
wiring per wiring diagram (refer to section 5) and then
9. Oil Drain Plug
install junction box cover.
10. Bearing Head
11. Oil Pump m. Install new gaskets on service valves.
12. Oil Fill Plug (Refer to paragraph 4.10.c) n. Install mounting bolts in service valves and torque to a
13. Cylinder Head value of 2.77 to 4.15 mkg (20-30 ft/lb).
14. Valve Plate
o. Change filter-drier. (Refer to section 4.12)
p. Attach two lines (with hand valves near vacuum pump)
Figure 4-5. Compressor --- Model 06DR to the suction and discharge service valves. Dehydrate and
4-6
evacuate compressor to 500 microns (75.9 cm HG vacuum b. Remove cylinder head capscrews. If the cylinder head
= 29.90 inches Hg vacuum). Turn off valves on both lines to is stuck, tap the center of the cylinder head with a wooden
pump. or lead mallet. DO NOT STRIKE THE SIDE OF THE
CYLINDER HEAD! Be careful not to drop the head or
q. Fully backseat (open) both suction and discharge
damage the gasket sealing surface. (See Figure 4-5 and
service valves.
Figure 4-6) Remove cylinder head gasket.
r. Remove vacuum pump lines. c. Free the valve plate from the cylinder deck by using the
s. Start unit and check refrigerant charge. (Refer to discharge valve hold down capscrews as jack screws through
section 4.6 ) the tapped holes of the valve plate after the valve stops and
valves have been removed. Remove valve plate gasket. (See
t. Check moisture-liquid indicator for wetness. Change Figure 4-6)
filter-drier if necessary. (Refer to sections 4.11 and 4.12)
d. Turn the compressor over on its side and remove the
u. Check compressor oil level per section 4.10. Add oil if bottom plate. Match mark each connecting rod cap and
necessary. connecting rod for correct assembly. Remove the capscrews
4.8 COMPRESSOR DISASSEMBLY and connecting rod caps (see Figure 4-7). Push the piston
rods up as far as they will go without having the piston rings
NOTE extend above the cylinders.
Removing the press fit stator in the field is not e. If necessary, remove the oil return check valve. Inspect
recommended. The rotor and stator are a matched it for check valve operation (flow in one direction only).
pair and should not be separated. Replace assembly if its check valve operation is impaired.
(See Figure 4-7)
When disassembling compressor, matchmark parts so
they may be replaced in their same relative positions. (See
Figure 4-5 for an illustration of the compressor.) Refer to
Table 4-4 and Table 4-5 for applicable compressor wear
limits and torque values. 2
a. Place the compressor in a position where it will be 3

convenient to drain the oil. Remove the oil plug on oil pump
inlet passage (see Figure 4-8 for location) to vent the 1
crankcase. Loosen the drain plug (see Figure 4-5) in bottom
plate and allow the oil to drain out slowly. Remove the plug 5
slowly to relieve any crankcase pressure. A plug in the
bottom center of the crankcase may also be removed for
draining the motor end more quickly. (Some units do not 4
have this plug.)
1 2 3 4 5 7
1. Oil Pressure Relief Valve
2. Oil Return Check Valve
3. Oil Suction Tube
4. Capscrew
5. Connecting Rod and Cap Assembly
Jack here Figure 4-7. Bottom Plate Removed

CAUTION
The copper tube which connects to the oil suction
6 strainer extends out the bottom with the bottom
1. Cylinder Head Gasket plate removed. Take precautions to avoid bending
2. Discharge Valve Screw and Lockwasher or breaking it while changing crankcase positions.
3. Discharge Valve Stop f. Remove eight capscrews and remove oil pump bearing
4. Discharge Valve head assembly, gasket and thrust washer. (See Figure 4-8)
5. Valve Plate
6. Valve Plate Assembly If it was determined that the oil pump was not
7. Valve Plate Gasket operating properly, the entire oil pump and bearing head
assembly must be replaced. Replacement parts for the
Figure 4-6. Exploded View of Valve Plate Assembly pump are not available.
4-7
and remove the equalizer tube. (See Figure 4-11) The
1 slinger at the end of the shaft draws vapor from the
crankcase. It may discharge through a tee or a single
equalizer tube.
j. If the piston rings extend beyond the cylinder tops, the
pistons can be pulled through the bottom plate opening
after the piston rings are compressed. A piston 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.
2
6
5
3 7
4
1. Oil Pump & Bearing Head 8
2. Thrust Washer (Gear Pump Only) 9 4
3. Oil Pickup Tube 3
4. Oil Inlet Port 2
Figure 4-8. Gear Oil Pump and Bearing Head 10 1
g. Be very careful not to damage the motor windings

when removing the motor end cover as the cover fits over 1. Capscrew 6. Connecting Rod
the winding coils. Remove all capscrews except one in the 2. Cap 7. Compression Ring
top of the cover. Then, while holding the cover in place, 3. Crankshaft 8. Piston
remove the remaining capscrew. Do not allow the cover to 4, Thrust Washer 9. Pin
drop from its own weight. To prevent striking the winding, 5. Rotor Drive Key 10. Retainer
move the cover off horizontally and in line with the motor
axis. Figure 4-10. Crankshaft Assembly
h. Remove the refrigerant suction strainer and if it is k. Since the stator is not replaced in the field, the terminal
removed with ease it may be cleaned with solvent and plate assembly need not be disturbed unless a leak exists or
replaced. (See Figure 4-9) If the strainer is broken, a terminal part requires replacing.
corroded or clogged with dirt that is not easily removed,
replace the strainer. Install new gaskets upon reassembly. Disassemble and assemble the terminal plate as shown
in Figure 4-12.
7 6 5 4 3 2 1
1
2
3
1. Equalizer Tube and Lockscrew Assembly

2. Lockwasher
1. Valve Capscrew
3. Counterweight --- Motor End
2. Suction Service Valve
3. Valve Gasket Figure 4-11. Removing Equalizing Tube and Lock Screw
4. Motor End Cover Assembly
5. Motor End Cover Gasket
6. Suction Strainer The terminal mounting plate assembly as originally
7. Strainer Screws and Washers installed is assembled so as to leave a small space between
the outer terminal bushing and the surface of the mounting
Figure 4-9. Motor End Cover plate. This is to provide further crush of the terminal
bushing in case a leak should occur. To stop leak, tighten the
i. Block the compressor crankshaft so that it cannot turn. terminal bushing nut only enough to stop the escape of gas.
Use a screw driver to bend back the tabs on the lockwasher Do not tighten until terminal bushing is flush with the
4-8
mounting plate. The tightening torque used at the factory is 1
0.21 to 0.23 mkg (18 to 20 inch pounds) maximum to
prevent damage to the plastic parts.
2
3
12
11 6
8
6
10 4
9 2
7
5
3
1
1. Suction Valve Positioning Spring
NOTE: Parts shown are for one terminal. 2. Suction Valve
1. Terminal Bushing Nut 3. Valve Plate Dowel Pin
2. Lock Washer Figure 4-13. Suction Valve and Positioning Springs
3. Terminal Washer
4. Outer Terminal Bushing b. Compression Rings
5. O-Ring The compression ring is chamfered on the inside
6. Terminal Bushing Washers (Grey) circumference. This ring is installed with the chamfer
7. Terminal Bushing Washers (Red) towards the top. Stagger the ring end gaps so they are not
8. Inner Terminal Bushing aligned.
9. Terminal Mounting Plate
The gap between the ends of the piston rings can be
10. Cover Gasket
checked with a feeler gauge by inserting the ring into the
11. Inner Terminal Block
piston bore about one inch below the top of the bore.
12. Terminal Screw
Square the ring in the bore by pushing it slightly with a
piston. The maximum and minimum allowable ring gaps are
0.33 and 0.127 mm (0.013 and 0.005 inch)
Figure 4-12. Terminal Mounting Assembly
4.9 COMPRESSOR REASSEMBLY
Compression Ring
To clean compressor parts, use a suitable solvent with
proper precautions. Coat all moving parts with compressor Figure 4-14. Piston Rings
oil before assembly. Refer to Table 4-5, for applicable
compressor torque values. C. Installing the Components
1. Install the crankshaft through the pump end of the
a. Suction and Discharge Valves compressor. Do not damage main bearings. Push pistons
from the inside of the crankcase through the cylinders being
If the valve seats look damaged or worn, replace valve careful not to break the rings. Place chamfered side of
plate assembly. Always use new valves because it is difficult connecting rod against radius of crankpins. Install matching
to reinstall used discharge valves so that they will seat as connecting rod caps through bottom cover plate.
before removal. Any valve wear will cause leakage for this 2. The oil screen (located in the bottom of the
reason. crankcase), is connected to the inlet of the oil pump.
Whenever the compressor crankcase is opened, inspect the
Suction valves are positioned by dowel pins (see screen for holes or an accumulation of dirt. The screen can
Figure 4-13) and will assume their original position when be cleaned with a suitable solvent.
reinstalled. No two valves are likely to wear exactly the 3. Install the pump end thrust washer on the two
same. Never interchange used valves. dowel pins located on the bearing head.
CAUTION
Do not omit the suction valve positioning springs. (See
Figure 4-13) Place the springs so that the ends bear against Ensure that the thrust washer does not fall off the
the cylinder deck (middle bowed away from cylinder deck). dowel pins while installing the oil pump.
Use new gaskets when reinstalling valve plates and cylinder 4. Install the bearing head assembly with a new
heads. gasket on the compressor crankshaft. Carefully push the oil
4-9
pump on by hand ensuring that the thrust washer remains SLOWLY crack the suction gauge manifold valve and oil
on the dowel pins, the tang on the end of the drive segment will flow through the suction service valve into the
engages the slot in the crankshaft, and the oil inlet port on compressor. Add oil as necessary.
the pump is aligned with the oil pickup tube in the Run unit for 20 minutes, in cooling, and check the oil
crankcase. The pump should mount flush with the level.
crankcase.
c. Adding Oil to Service Replacement Compressor
5. Align the gasket and install the eight capscrews in
the mounting flange. NOTES
6. Install rotor with key. Screw on equalizer tube and 1. The correct oil charge is 3.6 liters (7.6 U.S. pints).
lock screw assembly with lock washer and bend over tabs of
lock washer. Assemble suction strainer to motor and cover 2. Service replacement compressors are shipped
and bolt cover to crankcase. Assemble valve plates and without oil.
gaskets. Assemble cylinder heads and gaskets. Feel if the
shaft will turn by hand. 3. When at first adding oil to the compressor, add
only 3 liters (6.3 pints) to the compressor. Run the
7. Install oil suction screen and bottom plate. unit for 20 minutes, in cooling, and check the oil
4.10 CHECKING THE COMPRESSOR level in the compressor sight glass. Add oil as
OIL LEVEL necessary. This procedure is suggested due to the
oil that has migrated with refrigerant to other parts
CAUTION of the system.
Use only Carrier Transicold approved Polyol Ester
Oil (POE) --- Castrol-Icematic SW20 compressor If compressor is without oil:
oil with R-134a. Buy in small quantities (one Add oil, (paragraphs 1.3.b and 4.10.b) through the
quart). When using this hygroscopic oil, suction service valve flange cavity or by removing the oil fill
immediately reseal. Do not leave container of oil plug (see Figure 4-5). Some compressors have the oil plug
open or contamination will occur. located on the crankcase, at the right or left side of the oil
a. To Check the Oil Level in the Compressor: pump.
1. Operate the unit in cooling for at least 20 minutes. d. To Remove Oil From an 06DR Compressor:
2. Check the front oil sight glass on the compressor to 1. If the oil level recorded in step a.3 is above 1/4 of
ensure that no foaming of the oil is present after 20 minutes the sight glass, oil must be removed from the compressor.
of operation. If the oil is foaming excessively after 20 2. Close (frontseat) suction service valve and pump
minutes of operation, check the refrigerant system for unit down to 0.2 to 0.3 kg/cm@ (2 to 4 psig). Frontseat
flood-back of liquid refrigerant. Correct this situation discharge service valve and slowly bleed remaining
before performing step a.3. refrigerant.
3. Turn unit off and the correct oil level should be 3. Remove the oil drain plug on the bottom plate of
between 1/8 and 1/4 of the sight glass. If the level is above the compressor and drain the proper amount of oil from the
1/4, oil must be removed from the compressor. To remove compressor to obtain the 1/2 sight glass maximum level.
oil from the compressor, follow step d. If the level is below Replace the plug securely back into the compressor. DO
the bottom of the sight glass, add oil to the compressor NOT FORGET TO OPEN SUCTION AND DISCHARGE
following step b. below. SERVICE VALVES.
b. Adding Oil with Compressor in System 4. Repeat Step a. to ensure proper oil level.
Where an oil pump is not available, oil may be drawn 4.11 CHECKING OR REPLACING MOISTURE-
into the compressor through the suction service valve. LIQUID INDICATOR
CAUTION When the refrigeration system is operating, the
Extreme care must be taken to ensure the moisture-liquid indicator provides an indication of
manifold common connection remains immersed moisture in the system.
in oil at all times. Otherwise air and moisture will The indicator element is highly sensitive to moisture
be drawn into the compressor. and will gradually change color in direct relation to an
increase or decrease in the moisture content of the system.
Connect the suction connection of the gauge manifold The safe, caution, and unsafe system operating conditions
to the compressor suction service valve port, and immerse are then easily determined by matching the element color
the common connection of the gauge manifold in an open with the colors displayed on the reference label.
container of refrigeration oil. Crack the suction service
valve and gauge valve to vent a small amount of refrigerant To change indicator or lens:
through the common connection and the oil to purge the a. Pump down the unit per section 4.3 and install new
lines of air. Close the gauge manifold valve. indicator or lens. Replace the filter-drier per section 4.12.
With the unit running, frontseat the suction service b. Evacuate the unit per section 4.5 and add refrigerant
valve and pull a vacuum in the compressor crankcase. charge per section 4.6.
4-10
c. Start unit and after twelve hours re-check indicator. If 4.13.2 Checking High Pressure Switch
indicator does not indicate a safe condition, pump unit WARNING
down and change filter-drier. (Refer to section 4.11)
Do not use a nitrogen cylinder without a pressure
regulator because cylinder pressure is
4.12 CHECKING OR REPLACING THE approximately 165 kg/cm@ (2350 psi). Do not use
FILTER-DRIER oxygen in or near a refrigeration system as an
explosion may occur.
If the sight glass appears to be flashing or bubbles are NOTE
constantly moving through the sight glass, the unit may The high pressure switch (HPS) is non-adjustable.
have a low refrigerant charge, or the filter-drier could be 4
1
partially plugged.
To Check Filter-Drier: 5 8
2
6 7
a. One test for a restricted or plugged filter-drier is by
feeling the liquid line inlet and outlet connections of the
drier cartridge. If the outlet side feels cooler than the inlet
3
side, then the filter-drier should be changed.
b. Another test is that the moisture-liquid indicator shows

moisture in the system (refer to section 4.11).
1. Cylinder Valve and 5. Bleed-Off Valve
To Replace Filter-Drier: Gauge 6. 1/4 inch Connection
2. Pressure Regulator 7. High or Low
a. Remove the refrigerant (refer to section 4.3). 3. Nitrogen Cylinder Pressure Switch
4. Pressure Gauge 8. Ohmmeter
(0 to 36 kg/cm@ =
b. Remove filter-drier clamp, then replace drier. 0 to 500 psig)
Figure 4-15. Typical Setup for Testing High Pressure
c. Evacuate the unit per section 4.5. Switch
a. Remove switch as outlined in paragraph 4.13.1.
d. Charge unit with refrigerant per section 4.6.
b. Connect ohmmeter or continuity light across switch
terminals. Ohm meter will indicate resistance and
e. After unit is in operation, inspect for moisture in continuity light will be illuminated if switch closed after
system. (Refer to section 4.11) removing compressor pressure.
c. Connect capillary to a cylinder of dry nitrogen. (See
4.13 CHECKING OR REPLACING HIGH Figure 4-15)
PRESSURE SWITCH d. Set nitrogen pressure regulator at 21kg/cm@ (300 psig)
with bleed-off valve closed.
4.13.1 Replacing High Pressure Switch e. Close valve on cylinder and open bleed-off valve.
f. Open cylinder valve. Slowly close bleed-off valve to
a. Remove the refrigerant (refer to section 4.3). Frontseat increase pressure on switch. The switch will open at a static
both suction and discharge service valves to isolate pressure up to 25 kg/cm@ (350 psig). If light is used, light will
compressor. go out and if ohmmeter is used, the meter will indicate
open.
g. Slowly open bleed-off valve to decrease the pressure.
b. Disconnect wiring from defective switch. The high The switch will close at 18 kg/cm@ (250 psig).
pressure switch is located on the center head and is
4.14 REPLACING THE EVAPORATOR COIL
removed by turning counterclockwise. (See Figure 1-1) AND HEATER ASSEMBLY
The evaporator section, including the coil, should be
c. Install new cutout switch after verifying switch settings. cleaned with fresh water or steam, preferably. Another
(Refer to section 4.13.2) recommendation is to use Oakite 202 or similar cleaner
following manufacturers instructions.
d. Evacuate and dehydrate the compressor per paragraph The two drain pan hoses connected to the drain pan,
4.5.1.o through 4.5.1.u. are routed behind the condenser fan motor and
4-11
compressor. The drain pan line(s) must be open to ensure power, momentarily, to check fan rotation. (Refer to
adequate drainage. paragraph 1.4.f) If fan spins backwards, refer to section 4.24
for two-speed motors.
To Replace the Evaporator Coil:
a. Recover the refrigerant charge or pump the unit down Replace access panel, making sure panel does not leak.
per section 4.3. Make sure T.I.R. locking device is lockwired.
b. With power OFF and power plug removed, remove the

screws securing the panel covering the evaporator 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 4 1/4 INCHES
support as shown in Figure 1-2. (10.79 CM)
e. Remove middle coil support.
f. Remove the mounting hardware from the coil. Figure 4-16. Evaporator Fan Locating Dimension
g. Unsolder the two coil connections, one at the 4.16 SERVICING THE EVAPORATOR COIL
distributor and the other at the coil header. HEATERS
NOTE
WARNING
It may be necessary to raise the fan deck to break
the solder connections (to raise coil). Before servicing unit, make sure the unit circuit
breaker (CB1) and the start-stop switch are in the
h. After defective coil is removed from unit, remove OFF position. Also disconnect power plug and
defrost heaters and install on replacement coil. 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 4.4. Evacuate the removing the T.I.R. locking device lockwire and mounting
unit per section 4.5 and add refrigerant charge per section screws.
4.6. b. Determine which heater(s) need replacing by checking
4.15 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)
forced through the evaporator coil where it is either heated enough to clear the heater end support.
or cooled and then discharged out the bottom of the
refrigeration unit into the container. (Refer to paragraph 4.17 CONDENSER COIL
1.4.f) The fan motor bearings are factory lubricated and do
not require additional grease. The condenser consists of a series of parallel copper
tubes expanded into copper fins. The condenser coil must
WARNING be cleaned with fresh water or steam so the air flow is not
Always turn OFF the unit circuit breaker (CB1) restricted. Fan rotation is counterclockwise when viewed
and disconnect main power supply before working from shaft end of motor.
on moving parts. WARNING
a. Remove upper access panel (See Figure 1-1) by Do not open condenser fan grille before turning
removing mounting bolts and T.I.R. locking device. Reach power OFF and disconnecting power plug.
inside of unit and remove Ty-Rap securing wire harness
loop. To Replace the Condenser Coil:
b. Remove the two lower mounting bolts that secure the a. Recover the refrigerant charge per section 4.3.
motor-fan assembly to the unit. Loosen the two upper bolts b. Remove the condenser coil guard.
as the motor mount upper holes are slotted.
c. Unsolder discharge line and remove the line to the
c. Remove motor, fan, and wiring from unit. Place fan water-cooled condenser (if so equipped).
motor and fan on a support. Remove the wiring and fan.
d. Remove coil mounting hardware and then remove the
d. Lubricate fan motor shaft with a graphite-oil solution coil.
(Never-Seez). Apply thread sealer (Loctite H, brown in
color) to the two fan set screws. Install fan on motor. The e. Install replacement coil. Solder connections.
evaporator fan locating dimension is shown in Figure 4-16.
f. Leak check the coil per section 4.4. Evacuate the unit
e. Connect wiring per applicable wiring diagram (refer to per section 4.5 and then, charge the unit with refrigerant per
section 5) and install motor and fan assembly in unit. Apply section 4.6.
4-12
4.18 CONDENSER FAN AND MOTOR A resistance thermometer and a RCA lead with a
ASSEMBLY phono-plug at each end may be used to compare bulb
temperature and stylus indicated temperature on chart by
WARNING inserting one end of the lead into receptacle provided on
Do not open condenser fan grille before turning the controller and other end in the meter. Always check
power OFF and disconnecting power plug. resistance thermometer before using, refer to paragraph b.
NOTE 2. Ohmmeter
The replacement motor should be degreased and a. Place one probe of ohmmeter in the middle of the
sprayed with a coat of Tectyl before installing in receptacle provided on the chart platen and ground other
unit. probe to unit.
The condenser fan rotates counterclockwise (viewed b. Note reading of meter and using Table 4-1, convert
from front of unit) and pulls air through the the condenser resistance to temperature.
coil and discharges horizontally out the front of the unit.
a. Open condenser fan screen guard.
b. Loosen square head set screws (2) on fan. (Thread
sealer has been applied to set screws at installation.) Then
disconnect wiring from motor junction box.
CAUTION
2
Take necessary steps (place plywood over coil or
use sling on motor) to prevent motor from falling 5
into condenser coil.
c. Remove motor mounting hardware and replace the
motor. It is recommended that new locknuts be used when
replacing motor. Connect wiring per wiring diagram (refer
1
to section 5).
d. Install fan loosely on motor shaft (hub side in). Install
venturi. Apply Loctite H to fan set screws. Adjust fan
within venturi so that the outer edge of the fan projects 7.9
mm (5/16 inches) out from edge of venturi. Spin fan by
hand to check clearance. 3
e. Close and secure condenser fan screen guard. 4
f. Apply power to unit and check fan rotation. If fan
motor rotates backwards, reverse wires 5 and 8.
4.19 RECORDING THERMOMETER (PARTLOW)
CAUTION 1. Wind-up Key 4. Pinion Shaft
The inside mechanism of the control, particularly 2. Stylus 5. Stylus Lifter
the inside of the element housing should never be 3. Set Screw
oiled, however, control mechanisms should be
Figure 4-17. Partlow Recording Thermometer
sprayed periodically (every 60 days) with
corrosion-inhibiting CRC 3-36a or 6-66 or LPS no. b. Checking Resistance Thermometer
2.
Calibrate the resistance thermometer by completely
a. Instruments for Checking Bulb Temperature filling a thermos container full of ice cubes or chips and
The recording thermometer may be equipped with one filling the voids between the ice with plain water. Stir the
or two Simpson accessories (#344 units), each consisting of solution until the mixture registers 0.0 to 0.3_C (32 to
a thermistor probe and receptacle (mounted to instrument 32.5_F), as indicated by a laboratory thermometer.
case) Single probe is attached to the element (bulb) Immerse the resistance thermometer in the 0_C (32_F)
capillary which senses the container return air temperature. solution and check its accuracy at this temperature. With
If using two probes, the other probe is attached to the this instrument, be certain that the recommended length of
supply air temperature sensor. the check probe is immersed so that it accurately will reflect
temperature. Bear in mind that this measurement checks
In the event of a failure with the #344 test lead, other
the test probe at 0_C (32_F) only; it is possible for this type
instruments for checking bulb temperatures are:
of instrument to be inaccurate at other temperatures.
1. Simpson Meter, CTC P/N 07-00013 or Robinair Rezero check thermometer, if necessary, by manufacturers
Thermistor Temperature Tester, Model 12860. instructions.
4-13
c. Checking the Recording Thermometer Bulb which moves across the chart in response to temperature
Temperature changes as sensed by the bulb located in the evaporator
supply air.
Checking temperature is accomplished by comparing
the instruments indicated temperature (stylus) with the The element flange contains three O-rings. Care
known temperature existing at the element sensing bulb. To should be taken to install the new element flange without
properly check the temperature of the recorder, the damaging the O-rings. It is possible for a mercury leak to
element sensing bulb should be stabilized at a temperature develop at the flange if O-ring damage occurs.
of 0_C (32_F). This is accomplished by using one of the two The stylus will continue to fall (container temperature
following methods, whichever is more convenient. will actually be higher) if a leak develops in the flange,
1. Unit Running: capillary or bulb.
Place set point at 0_C (32_F). After unit has pulled To replace the recording thermometer element:
down to this temperature, allow compressor to cycle 1. Turn unit OFF and disconnect power source.
ON-OFF 3 to 5 times to be certain temperature has
stabilized at 0_C (32_F) as verified by the resistance 2. Remove middle back panel. Remove bulb clamps
thermometer. If the temperature indicated by the securing bulb to unit.
thermometer differs from 0_C (32_F) by more than 0.6_C 3. Remove two flange screws from recording
(1_F) when compressor cycles off, rezeroing must be thermometer and feed capillary and element through the
performed. unit.
2. Unit Off: 4. Push replacement bulb end and capillary through the
Place the recording thermometer element (sensing unit.
bulb) in 0_C (32_F) ice-water bath. Ice-water bath is 5. Fill slots with silastic (RTV432, Dow Corning).
prepared by filling an insulated container (of sufficient size
to completely immerse bulb) with ice cubes or chipped ice, 6. Attach bulb clamps tightly to bulb.
then filling voids between ice with water, and agitating until 7. Connect element flange to recorder making sure hub of
mixture reaches 0_C (32_F) as shown by a laboratory flange faces out to fit into the hole in instrument case
thermometer. (recording thermometer).
When the temperature at the element sensing bulb has 8. Rezero the recorder. (Refer to paragraph 4.19.d)
stabilized at 0_C (32_F), as indicated by stable stylus 9. Install inlet air grille and lower panel. Start unit and
indication, compare temperature indicated by stylus with check recorder calibration.
temperature shown by a laboratory thermometer. If the two
readings do not agree, the recording thermometer should CAUTION
be rezeroed. (Refer to paragraph d) Capillary tubing may be bent, but never sharper
d. Rezeroing the Recording Thermometer than 1/2 inch radius: extra care should be taken
when bending adjacent to welds. The sensing bulb
1. Be certain that element bulb temperature has should never be bent, as this will affect calibration.
stabilized at 0_C (32_F). Note the amount of temperature
difference between the test meter or thermometer reading 4.20 MAINTENANCE OF PAINTED SURFACES
and the stylus indicated temperature. The refrigeration unit is protected by a special paint
If the difference noted between the known element system against the corrosive atmosphere in which it
temperature and indicated temperature is within normally operates. However, should the paint system be
acceptable limits (0.3 of 0_C = 1/2_ of 32_F), do not damaged, the base metal can corrode. In order to protect
attempt to rezero. If more than 0.3_C (1/2_F) in variation, the refrigeration unit from the highly corrosive sea
carefully note the number of degrees. atmosphere or if the protective paint system is scratched or
damaged, clean area to bare metal using a wire brush,
2. If recording thermometer is found to require emery paper or equivalent cleaning method. Immediately
rezeroing: following cleaning, spray or brush on zinc rich primer. After
a. Loosen set screw, item 3, Figure 4-17 and zero the primer has dried, spray or brush on finish coat of paint
thermometer by turning pinion shaft, item 4. Lengthening to match original unit color.
pinion shaft (counterclockwise) raises stylus indicated 4.21 SERVICING THE SUCTION MODULATION
temperature reading: shortening shaft (clockwise) lowers VALVE
stylus reading. Then retighten set screw.
a. Valve Checkout Procedure
b. Reset control at 0_C (32_F), start refrigeration
Modulation for 0_C (32_F) simulated temperature can
unit and repeat accuracy check. After temperature
stabilization, recording thermometer should be within be verified in several ways. Without use of test equipment,
0.3_C (1/2_F) limits. listen for a change in compressor sound. Feel for a drop in
condensing air temperature as the suction modulation valve
e. Replacing Recording Thermometer Element closes. If a gauge manifold is connected to unit, pressures
(Bulb and Capillary) will drop as modulating valve closes.
The element is mercury-filled and the The preferred method of monitoring controller output
temperature-pressure of the element controls the stylus to the modulating valve is by reading the DC voltage
4-14
between terminals 12 and 14 on the main circuit board
(temperature controller). Readings under 0.2 vdc Ambient Temperature Cold Coil
correspond with valve wide open. Full closure of valve
corresponds with 1.1 and 1.3 vdc.
10_ F 6.45 ohms
NOTE
40_ F 6.90 ohms
Above voltages are numerically equal to valve 70_ F 7.40 ohms
currents (0.2 vdc = 0.2 amp DC). 100_ F 7.90 ohms
When cooling a chill load and with unit in operation, NOTE
turn set pointer downscale to ---17.8_C (0_F) and note
suction pressure. (Pressure should increase after A cold coil is a coil which had not been operating
approximately one minute.) Slowly raise set point and just and is assumed to be at ambient temperature. Hot
before compressor shuts off, a significant drop in suction coil temperatures, taken after the unit has been
pressure should be noted. If no pressure change is noticed, operating in deep modulation for a long period of
valve or controller malfunctioned. time, may give higher resistance readings.
b. To Replace Valve 4. Reconnect the modulation valve coil wires to their

correct terminal locations.
1. Recover the refrigerant charge or pump the unit
down per section 4.3. d. Replacing the Coil
Remove coil nut and remove coil after disconnecting
2. Remove two bolts from suction service valve.
wiring. When replacing nut, torque to a value of 0.41 mkg (3
3. Melt solder at the y-connection to the right of the ft-lb).
modulating valve and rotate valve and tubing enough to
1
clear compressor. Remove valve and tubing. Replace
defective suction modulation valve being careful to wrap 2
body of replacement valve with a wet cloth while brazing.
The coil need not be removed. 3
4. Install new suction service valve gasket and install
bolts in suction service valve. Torque to a value of 2.77 to 4
4.15 mkg (20 to 30 ft/lb).
5. Solder all connections and leak check same. 5
6. Dehydrate and evacuate the unit per section 4.5
and then add refrigerant charge per section 4.6. 6
NOTE
When repairing the suction modulation valve with
the enclosing tube kit (CTD P/N 14-50021-01) be
sure not to remove items 7, 8 & 10. (See
Figure 4-18) Proper alignment of these items is 7
achieved only at the factory.
8
c. Coil Checkout Procedure
WARNING
9
Make sure power to unit is OFF and power plug
disconnected before replacing the coil. 10
11
1. Disconnect the modulation valve coil wires from
their terminal locations (T14 & T15) on the units main
control board (refer to section 5).
2. Using a reliable digital ohmmeter, test each leads
resistance to ground. If the resistance indicates a ground 1. Coil Nut 7. Piston
short is present, inspect the length of wiring for damaged or 2. Coil Nut O-ring 8. Top Return Spring
exposed wires. Replace where necessary. 3. Coil Housing 9. Valve Body
3. Setting the digital ohmmeter for low range, check 4. Solenoid Coil 10. Bottom Return
coils resistance. If coils resistance is below 5 ohms it is Sleeve Spring
recommended to be replaced. New coils have an 5. Solenoid Coil 11. Filter
approximate resistance of 7.6 ohms at 25_ C (77_ F). The 6. Enclosing Tube
chart below gives the resistance of a new coil at various Assembly
ambient temperatures. Figure 4-18. Suction Modulation Valve
4-15
4.22 CONTROLLER CHECKOUT PROCEDURE d. In-Range Relay (IRS) Operation
Continue to raise the temperature selector setting until
the selector reaches ---2 0.5_C (29 1_F) where the
NOTE in-range relay and light emitting diode (LED) will energize.
e. Cooling --- Full Modulation
If the unit is equipped with a Digital Display or a
1. Continue to raise temperature selector setting to
service accessory Digital Display is available, this 0.5 0.5_C (33 1_F). The suction modulation valve
should be used for reading set point settings. current will be 0.9 to 1.2 vdc.
2. Note that the compressor suction pressure gauge
reading drops between 0 psig and 50.8 cm (20 inches) Hg
4.22.1 Controller Pre-Trip vacuum.
f. Checking Heating ON and Cooling OFF
1. Continue to raise temperature selector setting to
a. Equipment Required 1.0 0.5_C (34 1_F). The compressor and condenser
fan will cycle off and the cool (TC) LED will de-energize.
1. Digital volt-ohmmeter (capable of accurately The heat relay will energize and the TH LED will be
reading 0 to 2 vdc). illuminated.
2. Continue to raise the temperature selector setting
2. Manifold gauge set. to 2 0.5_C (36 1_F). The in-range light and the IRS
LED will de-energize. The heat relay will remain on and the
TH LED will be illuminated.
b. Preparation
4.22.2 Temperature Control Board Checkout
Procedure with TCSM
1. Set volt-ohmmeter to read DC volts of
a. Equipment Required
approximately 0 to 2 vdc.
1. Multi-Test Meter (volt-ohmmeter)
2. Clamp-on Ammeter
2. Connect volt-ohmmeter common lead to terminal
12 (DC common) of unit control board. (Refer to section 5) 3. Gauge-Manifold
4. Temperature Control Simulator Module
3. Connect volt-ohmmeter positive lead to terminal (P/N 07-00226).
14 of unit control board. NOTE
All references to the TCSM board toggle switches
(TC, TH, TQ, TU, DR and in-range) positions will
5. Install the manifold gauge set on compressor be either; left (away from the board) or right
suction service port. (toward the board). TQ switch is not used in units
with a quench expansion valve.
6. Set temperature selector below container b. Procedure
temperature and run unit 6 to 10 minutes in full cooling. 1. Turn unit OFF and disconnect power supply.
2. Open the control box door.
7. Set temperature selector to ---6_C (21_F).
3. Remove the temperature control board and insert
temperature control simulator module (TCSM). See
8. Position temperature simulator switch (TSS) to Figure 4-19, item 3, for location of temperature control
0_C (32_F) position. (See Figure 1-4) Hold time delay board.
override switch (TDS) in depressed position. 4. Place switches on the simulator in the air
circulation only position. Simulator (TCSM) switches TC,
c. Checking Suction Modulation Valve TH and DR will be to the left. Switches TU and in-range
will be to the left also. (Placing the in-range switch to the left
takes the humidistat control out of the system). The valve
Slowly raise temperature selector setting. As the current will be in the OFF position.
temperature selector setting is raised, the reading on the 5. Connect gauge-manifold to the suction and
volt-ohmmeter will vary, increasing as temperature setting discharge service valves.
is moved upscale. When the temperature selector is moved 6. Turn unit power ON. The evaporator fan motors
below 0_C (32_F), the voltage will remain stable are running in high speed at this time. Check to see if the 24
momentarily and then slowly decrease. Also, when the vac warning light is illuminated. This light is located on the
temperature setting is lowered the voltage will decrease. test board, near the return air sensor signal (TP6) test point.
4-16
(R.A. Sensor Signal). If the 24 vac light is illuminated, stop 13. Using clamp-on ammeter, read the amps of the
the unit immediately and remove power supply from unit. four (4) heater power leads. (Heater wiring connected to
Check all wiring to the unit control board. the heat relay terminals 21, 22 and 23.) Amperage reading
1 2 3 4 should be 2.6 to 3.2 on four defrost heater leads marked
DH. If amps vary more than two (2A) from leg to leg, turn
power OFF and check wiring and/or heaters.
The drain pan heater draws 1.3 to 1.6 amps on lead
marked DPH. See applicable wiring schematic.
5
6 14. Place simulator switch TH to the left. Heaters and
TH LED are de-energized.
7 15. Place simulator switch TC to the right. Relay TC
8 and TC LED energize. The compressor and condenser fan
motor start.
9 18. Turn simulator board modulation switch to 50%
10 modulation point and notice suction pressure drop. Turn
modulation switch to FULL modulation position and note
11 suction pressure drop. As modulation increases, the
modulation LED on the simulator board will grow
12 increasingly brighter, do not leave the switch in this position
16 for longer than 30 seconds. If modulating valve
13 malfunctions, refer to section 4.21.
15
14 19. Place switch TC to the left. TC LED de-energizes,
1. Power Supply and In-Range Board compressor, and condenser fan motor stop.
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)
6. Light Emitting Diode (TU --- LED) 21. Turn power OFF and disconnect power source and
7. Quench Relay (TQ) then remove simulator board and install regular
8. Light Emitting Diode (TQ --- LED) temperature board.
9. Cooling Relay (TC) 4.22.3 Replacing the Unit Main Control Board
10. Light Emitting Diode (TC --- LED)
11. Heating Relay (HR) a. Turn OFF unit power and then open the controller
12. Light Emitting Diode (HR --- LED) door.
13. Defrost Relay (DR)
b. Disconnect wiring from defective control board. Then
14. Light Emitting Diode (DR --- LED) remove screws securing board to unit. Remove complete
15. In-Range Relay assembly.
16. Light Emitting Diode (IRS --- LED)
c. Install relays, fuses, three boards, and connect wiring to
Figure 4-19. Unit Control Board proper terminals on the replacement control board.
4.22.4 Printed Circuit Board Cleaning Procedure
7. Set multi-meter to 30 vdc and plug one test lead in
the TP4 jack (DC com) on the simulator board. a. Turn power OFF and remove the printed circuit board
from the unit.
8. Plug other test lead in the TP1 jack (12vdc) on the
simulator board. Voltage should be 12.8 0.8 vdc on the b. Clean the surface of the printed circuit board with dry
multi-meter. If no voltage appears here, check power air at low pressure, less than 2.4 Kg/cm@ (20 psig).
supply. c. If grease is encountered, spray the printed circuit board
9. Repeat step 8 for the TP2 jack 9vdc. Voltage with anhydrous alcohol. If this is not available, use a mixture
should be 9 1.4 vdc. If 12 vdc appears here, recheck of distilled water and liquid dishwashing soap, then rinse
wiring. This can happen after replacing a component on the the printed circuit board with distilled water. Remove grime
unit. using clean dry air at low pressure.
10. Place IRS switch to the right. LED and IRS d. The printed circuit board can be coated with humiseal
energize. P/N 07-50001 to protect the components from corrosion. Be
sure not to spray the terminals of the molex connectors as
11. Turn simulator IRS OFF (left). LED and IRS relay the humiseal is a non-conductor.
de-energize.
e. Spray the connector terminals on the board with
12. With the evaporator fan motors running, turn TH contact lubricant P/N 07-50003 before the board is inserted
switch ON (right). TH LED and relay energize. back in the unit.
4-17
CAUTION d. Cut one replacement sensor wire (opposite color) back
41 mm (1-5/8 inch).
Do not use aromatic hydro carbons, chlorinated
solvents, or freon T.F. degreaser for cleaning. They e. Strip back insulation on all wiring 6.35mm (1/4 inch).
will react with the plastic materials used in the CAUTION
manufacture of the printed circuit board.
Do not allow moisture to enter wire splice area as
4.22.5 Temperature Set Station Checkout Procedure this may affect the sensor resistance.
NOTE f. Slide a large piece of heat shrink tubing over cable and
The temperature set station (CSS) is sometimes the two small pieces of heat shrink tubing over the wires
referred to as the temperature selector before adding crimp fittings as shown in Figure 4-22.
potentiometer. g. Slip crimp fittings over dressed wires (keep wire colors
together). Make sure wires are pushed into crimp fittings as
If a problem with the selector is suspected all three far as possible and crimp with crimping tool.
wires must be checked. The selector should be checked for
resistance using a reliable ohmmeter at the temperature h. Solder spliced wires with a 60% tin and 40% lead
selector connection as shown in Table 4-2. Rosincore solder.
a. With multi-test meter set on ohms (1K). i. Slide heat shrink tubing over splice so that both ends of
tubing cover both ends of crimp as shown in Figure 4-22.
b. Place one probe on selector connection pin 1 and other
j. Heat tubing, preferably with a flameless heat gun. If
probe on pin 2 (see Figure 4-20). Ohms will be 324 to 334
not available, a propane torch will work (caution should be
with the selector set at ---25_C (---15_F).
taken not to burn the heat shrink tubing or wire insulation).
c. Complete checkout procedure by using Table 4-2. Make sure all seams are sealed tightly against the wiring to
prevent moisture seepage.
k. Slide large heat shrink tubing over both splices and
ORANGE
4 shrink tubing and heat as in step j.
3 LOCATING l. Secure sensor to unit and check sensor resistance as
RED 2 PIN detailed in section 4.22.6.
1
BROWN SENSOR 41mm (1 5/8 inch)
Figure 4-20. Temperature Set Station and Plug
4.22.6 Temperature Controller Sensor Checkout SHOULDER 6.35mm (1/4 inch)

Procedure
Due to variations and inaccuracies in thermometers or Figure 4-21. Sensor
other test equipment, a reading close to the chart value
would indicate a good sensor. If a sensor is bad, the SENSOR
resistance reading will usually be much higher or lower than
the resistance values given in Table 4-6.
a. Turn unit OFF and disconnect power supply.
b. Remove temperature control board, item 3,
Figure 4-19 and insert temperature control simulator board
(CTD P/N 07-00226).
HEAT SHRINK TUBING (2)
c. Apply power to unit. CABLE
d. Place one probe on TP4 jack (DC Com) and other LARGE HEAT SHRINK TUBING (1)
probe on the sensor test point (either TP5 or TP6). The two
sensor test points on the board are marked S.A. sensor Figure 4-22. Sensor and Cable Assembly
signal and R.A. sensor signal. Readings are shown in
Table 4-6. 4.23 THERMOSTATIC EXPANSION VALVE
4.22.7 Replacing Temperature Sensor The thermal expansion valve is an automatic device
which maintains constant superheat of the refrigerant gas
a. Turn unit power OFF and disconnect power supply. leaving the evaporator regardless of suction pressure. The
b. Cut cable 2 inches from shoulder of defective sensor valve functions are: (a) automatic response of refrigerant
and discard defective probe. flow to match the evaporator load and (b) prevention of
liquid refrigerant entering the compressor. Unless the valve
c. Cut one wire of existing cable 41 mm (1-5/8 inch) is defective, it seldom requires any maintenance other than
shorter than the other wire. (See Figure 4-21) some minor periodic maintenance as follows:
4-18
1. Make sure that the excess capillary tube is 4. Run unit until unit has stabilized. Set controller
secured to the power head assembly and wrapped with 5.5_C (10_F) below container temperature.
Presstite.
2. Make sure that the thermal bulb is tightly
secured to the suction line and wrapped with Presstite. NOTE
a. Removing Expansion Valve
1. Recover the refrigerant charge or pump the unit Suction pressure must be 0.5 kg/cm@ (6 psig) below
down per section 4.3. valve M.O.P. (maximum operating pressure).
2. Remove insulation (Presstite) from expansion Example: if valve rated at 55 MOP, suction
valve bulb and power assembly and then remove thermal pressure must be below this MOP. Recommended
bulb from the suction line. pressure is below 3.44 kg/cm@ (49 psig).
3. Loosen flare nut and disconnect equalizing line
from expansion valve.
5. From the temperature/pressure chart (Table 4-7),
4. Remove capscrews and lift off power assembly and
remove cage assembly. Check for foreign material in valve determine the saturation temperature corresponding to the
body. evaporator outlet pressure.
5. The thermal bulb is located below the center of the
suction line (4 oclock position). This area must be clean to 6. Note the temperature of the suction gas at the
ensure positive bulb contact.
expansion valve bulb.
b. Installing Expansion Valve
1. Replace all gaskets, make sure to lightly coat with
refrigerant oil. Insert cage and power assembly and bolts. 7. Subtract the saturation temperature determined
Tighten bolts equally. Fasten equalizer flare nut to in Step 6 from the average temperature measured in Step 5.
expansion valve. The difference is the superheat of the suction gas.
2. Leak check the unit per section 4.4. Evacuate and
dehydrate unit per section 4.5 and add refrigerant charge
per section 4.6.
3. Clean suction line with sandpaper before installing
bulb to ensure proper heat transfer. Strap thermal bulb to
suction line, making sure bulb is firmly against suction line. 1 4
The bulb is located in the 4 oclock position on the suction
line.
4. Check superheat. (See Table 4-7) Superheat
setting is 3.36 to 4.48_C (6 to 8_F) at 0_C (32_F) container 2 5
temperature.
c. Checking Superheat
NOTE
It is not recommended adjusting internal 3
adjustable valves unless absolutely necessary. This
valve has been factory adjusted and set with 6
Locktite thats applied to the internal adjusting
nut. 7
If a replacement valve has the wrong superheat setting,
1. Power Assembly
the valve may be adjusted if you do not have another 2. Body Flange Gaskets
replacement valve on hand. Due to the time involved in 3. Seat Gasket
adjusting the superheat, replace the valve rather than
4. Bulb
adjusting it. 5. Cage Assembly
To Measure Superheat: 6. Body Flange
1. Open access panel to expose the expansion valve 7. Body Flange Screws
and service port (see Figure 1-1).
2. Attach a temperature tester sensor near the
expansion valve bulb and insulate. Make sure the suction
line is clean and firm contact is made with tester.
3. Connect an accurate gauge to the service port. Figure 4-23. Thermostatic Expansion Valve
4-19
4.24 EVAPORATOR FAN MOTOR analyzer is its ability to locate capacitors that have failed to
CAPACITORS hold their microfarad ratings or ones that are breaking
down internally during operation. It is also useful in
The two-speed evaporator fan motors are of the identifying capacitors when their microfarad rating marks
permanent-split capacitor type. The motor is equipped with have become unreadable.
one capacitor (used in high speed circuit) and another
capacitor is used for the low speed circuit. 4.25 HUMIDISTAT (OPTIONAL)
a. When to check for a defective capacitor a. Maintenance
1. Fan motor will not change speed. For example: Soiled sensing elements can be cleaned by dipping the
controller settings above ---10_C (14_F) should cause the stem in soapy fresh water or fresh water with washing
motor to run in high speed. powder (maximum 80_C = 176_F).
Controller settings below ---10_C (14_F) should cause When drying, the stem must remain tensioned, i.e., the
the motor to run in low speed. set point knob is set to its lowest possible R.H. value.
Drying time is approximately 24 hours. If necessary,
2. Motor running in wrong direction (after checking
recalibrate the humidistat.
for correct wiring application).
b. Setting
b. Removing the capacitor
1. The upper switching point of switch A is set by the
WARNING set point knob E (see Figure 4-24).
Make sure power to unit is OFF and power plug
2. In case of deviations of the measured humidity
disconnected before removing capacitor(S).
from the set point, a recalibration by means of the nut S is
1. The capacitor located on the motor and above the recommended:
evaporator fan deck may be removed by two methods:
3. If the actual value is higher than the set point, turn
a. If container is empty, open upper, rear, panel of nut S clockwise.
unit and capacitor may be serviced after disconnecting 4. If the actual value is lower than the set point,
power plug. turn nut S counterclockwise.
b. If container is full, turn unit power OFF and
disconnect power plug. Remove the evaporator fan motor Set Point 20% 40% 60% 70% 80%
access panel. (See Figure 1-1) Remove two lower capscrews 1/6 turn --- 15% 15% 11% 8% 5%
securing motor assembly to bracket and then remove
Ty-Raps from wire harness. Loosen two upper capscrews on
fan motor assembly. Remove or set aside motor to reach E
capacitors.
WARNING
With power OFF discharge the capacitor and
disconnect the circuit wiring.
c. Checking the capacitor
Three methods for checking capacitors are: A
(1) Direct replacement, (2) volt-ohmmeter, and (3) S
capacitor analyzer.
1. Direct replacement:
Replace capacitor with one of the same value.
Figure 4-24. Humidistat
2. Volt-ohmmeter:
Set meter on RX 10,000 ohms. Connect ohmmeter 4.26 CHECKOUT PROCEDURE FOR
OPTIONAL POWER TRANSFORMER
leads across the capacitor terminals and observe the meter
needle. If the capacitor is good, the needle will make a rapid If the unit does not start when connected to a 190/230
swing toward zero resistance and then gradually swing back vac power supply, check the following:
toward a very high resistance reading.
a. Make sure circuit breaker (CB2) is in the ON position.
If the capacitor has failed open, the ohmmeter needle If CB2 does not hold in, check voltage supply.
will not move when the meter probes touch the terminals. If
b. Check to see if the transformer internal protector
the capacitor is shorted, the needle will swing to zero
(IP-AUTO-TRANS) is closed. Allow a reasonable length of
resistance position and stay there.
time for transformer to cool down. The transformer
3. Capacitor analyzer: includes two (2) internal protectors. Only one is wired into
The function of the analyzer is to read the microfarad the system as the second protector is a spare.
value of a capacitor and to detect insulation breakdown c. To Check for Continuity Across the Internal Protector
under load conditions. The important advantages of a (IP-AUTO-TRANS):
4-20
1. Turn power OFF and disconnect power source. condenser inlet tube (replaces tubing flare nut). De-scale
tubing if necessary.
2. Disconnect white wires 1 and 2 from terminal
board. 1. What You Will Need:
3. Check for continuity across the internal protector a. Oakite composition No. 22, available as a powder
(IP). If (IP) is open and will not reset, connect wires 3 and 4 in 68 kg (150 lb) and 136 kg (300 lb).
(18 gauge) to terminal board. Check to see if unit will start. b. Oakite composition No. 32, available as a liquid in
d. If the internal protector and circuit breakers (CB1 and cases, each containing 3.785 liters (4 U.S. gallon) bottles
CB2) are good, check the transformer. Use a voltmeter and and also in carboys of 52.6 kg (116 lbs) net.
with the primary supply circuit ON check the primary c. Clean fresh water.
(input) voltage (230 vac). Next, check the secondary
(output) voltage (460 vac) at the voltage selector switch. d. Acid proof pump and containers, or bottles with
The transformer is defective if voltage is not available. rubber hose.
2. What You Will Do --- (Summary):
4.27 SERVICING THE OPTIONAL
WATER-COOLED CONDENSER a. Drain water from condenser tubing circuit. Clean
water tubes with Oakite No. 22 to remove mud and slime.
NOTE
b. Flush.
When Oakite compound No. 32 is being used for
the first time, the local Oakite Technical Service c. De-scale water tubes with Oakite No. 32 to remove
representative should be called in for his scale.
suggestions in planning the procedure. He will d. Flush.
show you how to do the work with a minimum
dismantling of equipment: how to estimate the e. Neutralize.
time and amount of compound required; how to f. Flush.
prepare the solution; how to control and conclude
g. Put unit back in service under normal load and
the de-scaling operation by rinsing and
check head (discharge) pressure.
neutralizing equipment before putting it back into
service. His knowledge of metals, types of scale, 3. Detailed Procedure:
water conditions and de-scaling techniques will be a. Drain and flush the water circuit of the condenser
invaluable to you. coil. If scale on the tube inner surfaces is accompanied by
slime, a thorough cleaning is necessary before de-scaling
The water-cooled condenser is of the shell and coil type process can be accomplished.
with circulating water through the cupro-nickel coil. The
refrigerant vapor is admitted to the shell side and is b.To remove slime or mud, use Oakite composition No.
condensed on the outer surface of the coil. 22, mixed 170 grams (6 ounces) per liter (one U.S. gallon) of
water. Warm this solution and circulate through the tubes
Rust, scale and slime on the water-cooling surfaces until all slime and mud has been removed.
inside of the coil interfere with the transfer of heat, reduce
system capacity, cause higher head pressures and increase c. After cleaning, flush tubes thoroughly with clean
the load on the system. fresh water.
WARNING
By checking the leaving water temperature and the
Oakite No. 32 is an acid --- therefore be sure that
actual condensing temperature, it can be determined if the
the acid is slowly added to the water. DO NOT
condenser coil is becoming dirty. A larger than normal
PUT WATER INTO THE ACID! --- this will cause
difference between leaving condensing water temperature
spattering and excessive heat.
and actual condensing temperature, coupled with a small
Wear rubber gloves and wash the solution from
difference in temperature of entering and leaving
the skin immediately if accidental contact occurs.
condensing water, is an indication of a dirty condensing coil.
Do not allow the solution to splash onto concrete.
To find the approximate condensing temperature, with d. Prepare a 15% by volume solution for de-scaling,
the unit running in the cooling mode, install a gauge 0 to by diluting Oakite compound No. 32 with water. This is
36.2 kg/cm@ (0 to 500 psig) on the compressor discharge accomplished by slowly adding 0.47 liter (one U.S. pint) of
service valve. the acid (Oakite No. 32) to 2.8 liters (3 U.S. quarts) of
For example: if the discharge pressure is 11.4 kg/cm@ water.
(147 psig), and referring to Table 4-7, R-12
temperature-pressure chart, the 11.4 kg/cm@ (147 psig) e. Fill the tubes with this solution by filling from the
converts to 46_C (115_F). bottom. See Figure 4-25A. Important: be sure to provide a
vent at the top for escaping gas.
If the water-cooled condenser is dirty, it may be
cleaned and de-scaled by the following procedure: f. Allow the Oakite No. 32 solution to soak in the
tube coils for several hours, periodically pump-circulating it
a. Turn unit off and disconnect main power. with an acid-proof pump.
b. Disconnect water pressure switch tubing by loosening An alternate method may be used, whereby a bottle
the two flare nuts. Install 1/4 inch flare cap on water-cooled (see Figure 4-25B) filled with the solution and attached to
4-21
the coils by a hose can serve the same purpose, by raising Centrifugal pump Gas Close vent pipe
and lowering of the bottle. The solution must contact the 30 GPM at 35 head vent valve when pump
scale at every point for thorough de-scaling, therefore Priming
Globe is running.
ensure that no air pockets exist, by regularly opening the connection
vent to release gas. Keep flames away from the vent gases. Pump valves
Suction
g. The time required for de-scaling will vary, Condenser
depending upon the extent of the deposits. One way to Tank
determine when de-scaling has been completed is to titrate
the solution periodically, using titrating equipment Remove water
provided free by the Oakite Technical Service regulating valve
representative. As scale is being dissolved, titrate readings Return
will indicate that the Oakite No. 32 solution is losing
strength. When the reading remains constant for a Pump Fine mesh
reasonable time, this is an indication that scale has been support screen
dissolved.
A --- Forced Circulation
h. When de-scaling is complete, drain the solution
and flush thoroughly with fresh water.
Fill condenser with
i. Next circulate a 56.7 grams (2 ounce) per liter (one cleaning solution. Do
U.S. gallon) solution of Oakite No. 22 through the tubes to not add solution more
neutralize. Drain this solution. rapidly than vent can ex-
haust gases caused by
j. Flush the tubes thoroughly with fresh water. chemical action.
1 Pipe
NOTE 5 Approximate
If the condenser cooling water is not being used as
drinking water or is not re-circulated in a closed or Vent
tower system, neutralizing is not necessary. pipe
k. Put the unit back in service and operate under 3 to 4

normal load. Check the head pressure. If normal, a
thorough de-scaling has been achieved. Condenser
4. What You Can Do For Further Help:
Contact the Engineering and Service Department of

the OAKITE PRODUCTS CO., 19 Rector Street, New B --- Gravity Circulation
York, NY 10006 U.S.A. for the name and address of the
service representative in your area. Figure 4-25. Water-Cooled Condenser Cleaning
4-22
Table 4-1. Partlow Bulb Temperature --- Table 4-3. Recommended Bolt Torque Values
Resistance Chart
TEMPERATURE RESISTANCE BOLT DIA. THREADS TORQUE MKG
F C (OHMS) FREE SPINNING
---10 ---23.3 12561.00 #4 40 5.2 in-lbs 0.05
#6 32 9.6 in-lbs 0.11
---5 ---20.6 10579.70 #8 32 20 in-lbs 0.23
0 ---17.8 8944.17 #10 24 23 in-lbs 0.26
1/4 20 75 in-lbs 0.86
5 ---15.0 7588.89 5/16 18 11 ft-lbs 1.52
15 ---9.4 5520.32 3/8 16 20 ft-lbs 2.76
7/16 14 31 ft-lbs 4.28
20 ---6.7 4731.71 1/2 13 43 ft-lbs 5.94
25 ---3.9 4068.68 9/16 12 57 ft-lbs 7.88
5/8 11 92 ft-lbs 12.72
30 ---1.1 3509.36 3/4 10 124 ft-lbs 17.14
32 0 3310.57
35 1.7 3035.99 NONFREE SPINNING (LOCKNUTS ETC.)
40 4.4 2634.10 1/4 20 82.5 in-lbs 0.95
5/16 18 145.2 in-lbs 1.67
45 7.2 2291.85 3/8 16 22.0 ft-lbs 3.04
50 10.0 1999.52 7/16 14 34.1 ft-lbs 4.71
55 12.8 1749.11 1/2 13 47.3 ft-lbs 6.54
9/16 12 62.7 ft-lbs 8.67
60 15.6 1534.00 5/8 11 101.2 ft-lbs 13.99
65 18.3 1348.72 3/4 10 136.4 ft-lbs 18.86
75 23.9 1050.14
80 26.7 929.87
85 29.4 825.21
90 32.2 733.93
95 35.0 654.12
100 37.8 584.19
105 40.6 522.79
Table 4-2. Selector Settings and Resistance

SELECTOR SELECTOR RESISTANCE
SETTINGS CONNECTIONS IN
F C (PINS) OHMS
---15 ---25 CSS 1 to CSS 2 324 to 334
---15 ---25 CSS 2 to CSS 3 1648 to 1656
---15 ---25 CSS 1 to CSS 3 1980 to 1988
32 0 CSS 1 to CSS 2 980 to 988
32 0 CSS 2 to CSS 3 1000 to 1008
32 0 CSS 1 to CSS 3 1980 to 1988
77 25 CSS 1 to CSS 2 1633 to 1641
77 25 CSS 2 to CSS 3 347 to 355
77 25 CSS 1 to CSS 3 1980 to 1988
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-134a
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 14.6 37.08 -- .49 30 ---1 26.1 1.84 1.80
---35 ---37 12.3 31.25 -- .42 32 0 27.8 1.95 1.92
---30 ---34 9.7 24.64 -- .33 34 1 29.6 2.08 2.04
---25 ---32 6.7 17.00 -- .23 36 2 31.3 2.20 2.16
---20 ---29 3.5 8.89 -- .12 38 3 33.2 2.33 2.29
---18 ---28 2.1 5.33 -- .07 40 4 35.1 2.47 2.42
---16 ---27 0.6 1.52 -- .02 45 7 40.1 2.82 2.76
---14 ---26 0.4 .03 .03 50 10 45.5 3.30 3.14
---12 ---24 1.2 .08 .08 55 13 51.2 3.60 3.53
---10 ---23 2.0 .14 .14 60 16 57.4 4.04 3.96
---8 ---22 2.9 .20 .20 65 18 64.1 4.51 4.42
---6 ---21 3.7 .26 .26 70 21 71.1 5.00 4.90
---4 ---20 4.6 .32 .32 75 24 78.7 5.53 5.43
---2 ---19 5.6 .39 .39 80 27 86.7 6.10 5.98
---0 ---18 6.5 .46 .45 85 29 95.3 6.70 6.57
2 ---17 7.6 .53 .52 90 32 104.3 7.33 7.19
4 ---16 8.6 .60 .59 95 35 114.0 8.01 7.86
6 ---14 9.7 .68 .67 100 38 124.2 8.73 8.56
8 ---13 10.8 .76 .74 105 41 135.0 9.49 9.31
10 ---12 12.0 .84 .83 110 43 146.4 10.29 10.09
12 ---11 13.2 .93 .91 115 46 158.4 11.14 10.92
14 ---10 14.5 1.02 1.00 120 49 171.2 12.04 11.80
16 ---9 15.8 1.11 1.09 125 52 184.6 12.98 12.73
18 ---8 17.1 1.20 1.18 130 54 198.7 13.97 13.70
20 ---7 18.5 1.30 1.28 135 57 213.6 15.02 14.73
22 ---6 19.9 1.40 1.37 140 60 229.2 16.11 15.80
24 ---4 21.4 1.50 1.48 145 63 245.6 17.27 16.93
26 ---3 22.9 1.61 1.58 150 66 262.9 18.48 18.13
28 ---2 24.5 1.72 1.69 155 68 281.1 19.76 19.37
4-26
Note: Curves to be used as troubleshooting guide only for model series 69NT40-469 with fresh air makeup vent
closed, unit powered on 460vac/60hz and SMV 100% open.
(Bar) psig (Bar) psig
(22.0) 320 (22.0) 320
(20.7) 300 (20.7) 300
(19.3) 280 (19.3) 280
(17.9) 260 (17.9) 260
35_F (1.7_C) Box
(16.6) 240 (16.6) 240
SSV closed
(15.2) 220 (15.2) 220
(13.8) 200 (13.8) 200
(12.4) 180 (12.4) 180
(11.0) 160 (11.0) 160
(9.7) 140 (9.7) 140 0_F ( -- 17.8_C) Box
(8.3) 120 (8.3) 120 SSV open
(6.9) 100 (6.9) 100
(5.5) 80 (5.5) 80
60 70 80 90 100 110 120 _F 60 70 80 90 100 110 120 _F
(15.6) (21.1) (26.7) (32.2) (37.8) (43.3) (48.9) (_C) (15.6) (21.1) (26.7) (32.2) (37.8) (43.3) (48.9) (_C)
Ambient Air Temperature Ambient Air Temperature
4-27
(Bar)
Compressor Discharge Pressure Versus Ambient Air Temperature at Stable Box Temperature
psig
14 17
(.97)
(.83) 12 16
(.69)
35_F (1.7_C) Box
10 15
SSV closed
(.55) 8 35_F (1.7_C) Box 14
SSV closed
(.41) 6
13
(.28) 4
12
(.14) 2
11
(0) 0 0_F ( -- 17.8_C) Box 0_F ( -- 17.8_C) Box
SSV open 10 SSV open
(--- .14) --- 2
9
(--- .28) --- 4
(--- .41) --- 6 8
60 70 80 90 100 110 120 _F 60 70 80 90 100 110 120 _F
(15.6) (21.1) (26.7) (32.2) (37.8) (43.3) (48.9) (_C) (15.6) (21.1) (26.7) (32.2) (37.8) (43.3) (48.9) (_C)
Ambient Air Temperature Ambient Air Temperature
Compressor Suction Pressure Versus Ambient Air Temperature at Stable Box Compressor---Motor Current Versus Ambient Air Temperature
Temperature At Stable Box Temperature
Figure 4-26. R-134a Compressor Pressure and Motor Current Curves Versus Ambient Temperature
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).
WARNING
Do not open condenser fan grille before turning power OFF and disconnecting power plug.
WARNING
Always turn OFF the unit circuit breaker (CB1) and disconnect main power supply before working on moving parts.
WARNING
Never mix refrigerants with air for leak testing. It has been determined that pressurized, air-rich mixtures of
refrigerants and air can undergo combustion when exposed to an ignition source.
CAUTION
Use only Carrier Transicold approved Polyol Ester Oil (POE) --- Castrol-Icematic SW20 compressor oil with R-134a.
Buy in small quantities (one quart). When using this hygroscopic oil, immediately reseal. Do not leave container of
oil open or contamination will occur.
CAUTION
To prevent trapping liquid refrigerant in the service valve after charging, while the compressor is ON and before
disconnecting the manifold gauge set, perform the following steps:
a. Backseat applicable discharge or manual liquid line valve.

b. Midseat manifold gauge set hand valves.
c. Allow the gauge set to pull down to suction pressure.
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 69NT40-469-7
(Sheet 1 of 2)
5-2
Figure 5-1. Electrical Wiring Schematic --- Model 69NT40-469-7
(Sheet 2 of 2)
5-3
Figure 5-2. Electrical Wiring Diagram --- Model 69NT40-469-7
(Sheet 1 of 2)
5-4
Figure 5-2. Electrical Wiring Diagram --- Model 69NT40-469-7
(Sheet 2 of 2)
5-5

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Model

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

4-1 Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5-1 Electrical Wiring Schematic (Model 69NT40-469-7) . . . . . . . . . . . . . . . . . . . . . . . 5-2

2-1 Electrical Control Positions --- Above ---10_C (+14_F) . . . . . . . . . . . . . . . . . . . . 2-5

4-1 Partlow Bulb Temperature --- Resistance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

1.1 INTRODUCTION These units are dual voltage units designed to

Table 1-1. Model Chart

69NT40-469-7 1265 574 11.5 5.2 --- --- X --- --- X

Figure 1-1. Refrigeration Unit --- Front

1. Evaporator Fan Motor #1 (EM1) 8. Heater Termination Thermostat (HTT)

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

1 Discharge Pressure Regulating Valve 8. Filter-Drier

Figure 1-3. Receiver and Tubing Section

1. Power Supply and In-Range Board 14. Voltage Switch (VS)

Figure 1-4. Control Box and Controller

f. Defrost Termination Thermostat d. Drain Pan Heaters

Opens: 23.9 ( 3)_C = 75 ( 5)_F Number of Heaters: 1

l. Refrigerant Operating Level (after 20 minutes Rotation:

UNSAFE CONDITIONS SAFETY DEVICES DEVICE SETTING

1. Excessive current draw 1. Circuit Breaker (CB-1) --- 1. Trips at 29 amps

Maximum air flow is achieved by loosening the wing 90

The suction solenoid valve, shown in Figure 1-3 is B C

In operation, if the return air temperature decreases

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

3.2 UNIT RUNS BUT HAS INSUFFICIENT COOLING

Refrigeration System Abnormal pressures 3.7

3.3 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING

Refrigeration System Shortage of refrigerant 4.4/4.6

3.4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING

No control power Circuit breaker or fuse defective Replace

Heater termination switch open 4.14

Unit will not heat or Heater(s) defective 4.16

3.5 UNIT WILL NOT TERMINATE HEATING

3.6 UNIT WILL NOT DEFROST PROPERLY

Will not initiate Manual defrost switch defective Replace

Frequent defrost Wet load Normal

3.7 ABNORMAL PRESSURES (COOLING)

Low suction pressure Suction service valve partially closed Open

3.8 ABNORMAL NOISE OR VIBRATIONS

Condenser or Bent, loose or striking venturi Check

3.9 TEMPERATURE CONTROLLER MALFUNCTION

Compressor does not start

3.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW