Carrier 40RM, Operation & Service Manual

Page 1: ...Truck Refrigeration 62 10630 Rev A EVAPORATOR CONDENSER TXV TXV BULB RECEIVER OPERATION SERVICE for INTEGRA 40 50S Truck Refrigeration Units MP ...

Page 2: ...SERVICE MANUAL OPERATION AND TRUCK REFRIGERATION UNIT Integra 40S Integra 50S ...

Page 3: ...dging an overload or using any sort of jumper wires Problems with the system should be diagnosed and any necessary repairs performed by qualified service personnel When performing any arc welding on the unit or container disconnect all wire harness connectors from the microprocessor Do not remove wire harness from the modules unless you are grounded to the unit frame with a static safe wrist strap...

Page 4: ...ing valve will need to be reset refer to paragraph 4 15 CAUTION If starting unit for the first time after installation or starting after adding removing of an optional fea ture or if Owners operating parameters have changed the Configuration will need to be reset refer to paragraph 2 9 CAUTION Under no circumstances should anyone attempt to service the microprocessor see section 4 17 Should a prob...

Page 5: ... Keypad 2 1 2 3 2 Additional Key Functions 2 2 2 3 3 Unit Operating Data LED Status 2 2 2 3 4 Digital Display 2 2 2 4 STARTING 2 3 2 5 STOPPING 2 3 2 6 SET POINT ADJUSTMENT 2 3 2 7 DEFROST CYCLE ADJUSTMENT 2 3 2 8 SEQUENCE OF OPERATION 2 4 2 8 1 Perishable Mode 2 4 2 8 2 Frozen Mode 2 4 2 9 CONFIGURATION 2 4 2 10 ALARM DISPLAY 2 6 2 10 1 Low Battery Voltage Alarm 2 6 2 10 2 Accessing Alarm Message...

Page 6: ...CUATION AND DEHYDRATION 4 3 4 9 1 General 4 3 4 9 2 Preparation 4 3 4 9 3 Evacuation and Dehydration Complete System 4 3 4 9 4 Evacuation and Dehydration Partial System 4 4 4 10 CHARGING THE REFRIGERATION SYSTEM 4 4 4 10 1 Checking The Refrigerant Charge 4 4 4 10 2 Installing A Complete Charge 4 4 4 10 3 Adding A Partial Charge 4 5 4 11 REPLACING THE COMPRESSOR 4 5 4 12 HIGH PRESSURE OR CONDENSER ...

Page 7: ...an motor brushes 4 6 Figure 4 5 Hot Gas or Condenser Pressure Control Solenoid 4 6 Figure 4 6 Compressor Pressure Regulating Valve 4 6 Figure 4 7 Thermostatic Expansion Valve Bulb And Thermocouple 4 7 Figure 5 1 Schematic Diagram Road Only 5 2 Figure 5 2 Schematic Diagram Three Phase Stand By Units 5 4 Figure 5 3 Schematic Diagram Single Phase Stand By Units 5 6 LIST OF TABLES TABLE NUMBER Page Ta...

Page 8: ...ee Figure 1 2 Figure 1 3 contains the condenser fan coil filter drier oil separator condenser pressure control valve hot gas valve and microprocessor On road standby units the condenser also houses the standby compressor control box and rectifier transformer assembly In addition single phase units are fitted with a start box which contains the capacitors and relay The evaporator assembly consists ...

Page 9: ...sembly RB 2 Condenser 3 Sight Glass 4 Filter Drier 5 Condenser Fan 6 Fan Guard 7 Transformer TR 8 Heat Sink 9 Condenser Fan Motor CFM 10 Oil Separator 11 Frame Assembly 12 Solenoid Coil 13 Condenser Pressure Control Valve HGS2 14 Hot Gas Valve HGS1 Figure 1 2 Condenser ...

Page 10: ... Standby Fuse FS 3 Road Fuse FR 4 Harness 5 1A Field Replaceable Fuse 12 00526 88 Starting with Controller S N 1997 6 Fused Disconnect FB Three Phase Only 7 Electronic Overload Relay KR 8 Standby Contactor MC 9 Primary Transformer Fuses F1 2 3 Three Phase Units F1 Single Phase Units Figure 1 3 Control Box ...

Page 11: ...1 4 62 10630 START BOX LOCATION SINGLE PHASE ONLY 1 2 3 4 1 1 Start Capacitor 2 Resistor Start Capacitor Discharge 3 Run Capacitor 4 Start Relay Figure 1 4 Start Box Single Phase Only ...

Page 12: ...ng 5 Evaporator Coil Assembly 6 Compressor Pressure Regulating Valve CPR 7 Heat Exchanger 8 Defrost Termination Thermostat DTT 9 Low Pressure Switch LP 10 Quench Valve 11 Hot Gas Fitting 12 Standby Suction Line Fitting 13 Road Suction Line Fitting 14 Liquid Line Fitting 15 Liquid Line Check Valve Figure 1 5 Evaporator 3 Fans Integra 50S ...

Page 13: ...3 Quench Valve 4 Low Pressure Switch LP 5 Liquid Line Check Valve 6 Liquid Line Fitting 7 Standby Suction Line Fitting 8 Hot Gas Line Fitting 9 Road Suction Line Fitting 10 Orifice 11 Expansion Valve 12 Evaporator Coil Assembly 13 Compressor Pressure Regulating Valve CPR Figure 1 6 Evaporator 2 Fans Integra 40S ...

Page 14: ...t at 245 10 psig1 7 bar Cut in at 320 10 psig 22 bar e Standby High Pressure Switch HP3 Cutout at 430 10 psig 30 bar Cut in at 360 10 psig 25 bar f Refrigerant charge Refer to Table 1 1 g Compressor Pressure Regulating Valve CPR Setting 36 1 psig 2 5 bar h Thermostatic Expansion Valve Type 50S TES 2 Orifice n_4 MOP 75 psi 5 1 bar 40S TES 2 Orifice n_3 MOP 75 psi 5 1 bar Superheat setting 7 1_F 4_C...

Page 15: ...m components are protected from damage caused by unsafe operating conditions by automatically shutting down the unit when such conditions occur This is accomplished by the fuses listed in Table 1 2 and safety devices listed in Table 1 3 Table 1 2 Fuses Item Rating Road supply fuse FR 50 A Standby supply fuse FS a 50 A Main standby fuse FB X3 16 A Electric heat fuses F4 F5 F6 Future 6 3 A Transform...

Page 16: ...ge pressure Automatic reset of High pressure switch HP1 HP3 YES Timer 5 mn 6 Excessive current draw unit on standby Standby fuse NO See fuse Table 1 2 7 Excessive current draw unit on road Road fuse NO See fuse Table 1 2 8 Connection error on primary transformer Fuses NO See fuse Table 1 2 9 Excessive compressor motor winding temperature O L P overload protector YES Self protected opening 10 Clutc...

Page 17: ... regulates the flow rate of refrigerant towards the evaporator in orderto obtain maximum use of the evaporator heat transfer surface The evaporator tubes have aluminium fins to increase heat transfer therefore heat is removed from the air circulated through the evaporator This cold air is circulated throughout the truck to maintain the cargo at the desired temperature The transfer of heat from the...

Page 18: ...9 Manual Shut off Valve King Valve 10 Receiver 11 Condenser 12 Condenser Pressure Control Valve HGS2 13 Condenser Pressure Control Switch HP2 14 High Pressure Switch HP1 15 Relief Valve 16 Standby Discharge Check Valve 17 Standby High Pressure Switch HP3 18 Standby Compressor 19 Road Compressor 20 Quench Liquid Injection Thermostat BPT 21 Oil Separator 22 Road Discharge Check Valve 23 Low Pressure...

Page 19: ...Manual Shut off Valve King Valve 10 Receiver 11 Condenser 12 Condenser Pressure Control Valve HGS2 13 Condenser Pressure Control Switch HP2 14 High Pressure Switch HP1 15 Relief Valve 16 Standby Discharge Check Valve 17 Standby High Pressure Switch HP3 18 Standby Compressor 19 Road Compressor 20 Quench Liquid Injection Thermostat BPT 21 Oil Separator 22 Road Discharge Check Valve 23 Low Pressure S...

Page 20: ... plug is clean and dry before connecting to any power source a Check that the external power source corresponds to the characteristics of the unit see paragraph 1 4 step c Make sure external power source circuit breaker is open b Make sure unit is OFF by pressing the OFF button on the Cab Command c Plug the power cord into unit receptacle 2 3 CAB COMMAND The Cab Command is mounted remote in the ca...

Page 21: ...vill between defrosts min as calculated by the microprocessor Press to display the elapsed time min since the last defrost Press to return to box temperature 2 3 3 Unit Operating Data LED Status After an alarm AXX has been present for 15 minutes the red unit operating data LED flashes at 3 Hz The LED will continue to flash at 0 5 Hz when the temperature goes back within the Set point range differe...

Page 22: ...rns to display of the box tempe rature 2 7 DEFROST CYCLE ADJUSTMENT Defrost is an independent cycle overriding cooling and heating functions to melt frost and ice from the evaporator when necessary Defrost may be initiated by the microprocessor or manually by the operator once the defrost termination thermostat has closed at approximately 38 F 3 3 C In defrost mode the microprocessor displays dF o...

Page 23: ...ve SV4 energized open The condenser fan and con denser pressure control valve will operate under the control of the condenser pressure switch HP2 If the heat option is installed those heaters will also be en ergized 1_C 1 8_F or 2_C 3 6_F or 3_C 5 4_F SET POINT 1_C 18_F or 2_C 3 6_F or 3_C 5 4_F setting COOL UNIT STOPPED HEAT Figure 2 2 Operating Sequence Perishable Mode 2 8 2 Frozen Mode The unit...

Page 24: ...osing valve 2 Et 40S with condenser closing valve 3 Et Press the SET key to validate OPTIONAL ROAD HEATING KIT hrOF option road heating kit not installed hrOn option road heating kit installed Press the and keys to change hrOF or hrOn Press the SET key to validate OPTIONAL STANDBY HEAT KIT hSOF standby heating kit not installed hSOn standby heating kit installed Press the and keys to change hrOF o...

Page 25: ...ng Alarm Messages Current alarms will be displayed with an A preceding the alarm number while past alarms will be displayed with a P preceding the alarm number To access the alarm messages Press SET for 5 seconds enables access to alarm messages In the event of more than one alarm press the and keys to list them 2 10 3 Clearing Alarm Messages The alarm list provides information on current alarms a...

Page 26: ...fault electric heat Future Control fault multi temp liquid line valve Future Low pressure switch LPS open Standby Compressor contactor MC open circuit Condenser fan motor CFM open circuit Hot water solenoid valve HWV open circuit Hot gas valve HGS1 open circuit Quench valve BPV open circuit Condenser Pressure Control Valve HGS2 open circuit Evaporator drain line heater DWR open circuit Relay fault...

Page 27: ...ponents functioning normally A01 Low Pressure Switch LPS O R d Unit undercharged 4 10 1 Open Road Liquid line filter drier restricted 4 5 TXV strainer plugged with foreign material ice 4 6 TXV malfunction 4 16 Verify operation of evaporator fans Failed switch 4 12 2 A02 High Pressure Switch HP1 O Unit overcharged 4 10 1 g Open Verify operation of condenser fan Noncondensibles in system 4 7 1 Disch...

Page 28: ...ce High load on rectification system Correct A18 Electrical Heating Relay F t Relay shorted Replace g y Future Wiring shorted Correct A19 Multi Temp Liquid Solenoid Valve high amps draw Valve coil shorted Replace Valve high amps draw Future Wiring shorted Correct A20 Low Pressure Switch LPS O St db Unit undercharged 4 10 1 Open Standby Liquid line filter drier restricted 4 5 TXV strainer plugged w...

Page 29: ...Abnormal pressure Expansion valve malfunction No or restricted evaporator airflow 3 2 6 3 2 10 3 2 9 3 2 3 Unit Operates Long or Continuously in Cooling Box Hot Load Defective box insulation or air leak Insufficient pull down time Correct Refrigeration system Abnormal pressure Temperature controller malfunction 3 2 6 3 2 8 Compressor Defective 4 11 3 2 4 Unit Will Not Heat or Heating Insufficient ...

Page 30: ...e Overcharged system Condenser fan or HP2 pressure switch defective Noncondensibles in system Condenser motor fan defective 4 10 1 4 12 4 7 1 4 13 Low discharge pressure Compressor defective Hot gas valve malfunction 4 11 4 14 Low suction pressure Low refrigerant charge Compressor pressure regulating valve misadjusted CPR Condenser Pressure Regulating valve fault HGS2 4 10 1 4 15 4 14 3 2 7 Abnorm...

Page 31: ... from sensing bulb Low superheat setting 4 16 Replace 4 16 2 High superheat Expansion valve setting 4 16 2 3 2 11 Malfunction Hot Gas Solenoid or Condenser Pressure Regulating Valve Valve does not function properly No power to valve Improper wiring or loose connections Valve improperly assembled Coil or coil sleeve improperly assembled Movement of plunger restricted due to a Corroded or worn parts...

Page 32: ...graph 4 6 5 Check standby compressor oil level Level should be from 1 4 to 1 2 sight glass Service B Cont d 6 Check standby compressor oil level Level should be from 1 4 to 1 2 sight glass 7 Check the operation of cab com mand 8 Check the defrost DCut in DFan shut down DCut out DDefrost water drain 9 Check the water tightness of the emergency switch cap Service C 1 Check the bearings of the belt t...

Page 33: ...filter drier by feeling the inlet and outlet connections of the liquid line on the filter cartridge If the temperature of the outlet connection seems lower than the temperature of the inlet connection replace the filter drier Replacing the filter drier Pump the unit down refer to paragraph 4 7 2 Remove the drier mounting clip then replace the filter drier Following drier replacement evacuate and r...

Page 34: ...Transicold For the pump order part number 07 00176 11 and for the indicator order part number 07 00414 00 NOTE Use of a compound gauge is not recommended because of its inherent inaccuracy c If possible keep the ambient temperature above 60 F 15 6 C to speed evaporation of moisture if ambient temperature is lower than 60 F 15 6 C ice might form before moisture removal is complete Heat lamps or alt...

Page 35: ...and the pump has been isolated fully backseat the service valves to isolate the service connections and then continue with checking and if required adding refrigerant in accordance with normal procedures 4 10 CHARGING THE REFRIGERATION SYSTEM 4 10 1 Checking The Refrigerant Charge Start unit in cooling mode Run approximately ten minutes Partially block off air flow to condenser coil increase the a...

Page 36: ... 1 Removing Switch a A schreader valve is located under each switch to al low removal and installation without removing the re frigerant charge b Remove switch and test in accordance with para graph 4 12 2 c Replace or reinstall switch 4 12 2 Checking Pressure Switch WARNING Do not use a nitrogen cylinder without a pressure regulator See Figure 4 3 Cylin der pressure is approximately 2350 psi 160 ...

Page 37: ...n replace the coil see Figure 4 5 a Remove coil snap cap voltage plate and coil assem bly Disconnect leads and remove coil junction box if necessary b Verify coil type voltage and frequency This informa tion appears on the coil voltage plate and the coil housing c Place new coil over enclosing tube and then install voltage plate and snap cap 1 2 3 4 5 6 7 1 Snap cap 2 Voltage plate 3 Coil assembly...

Page 38: ...er to paragraph 1 3 4 16 2 Measuring superheat a Remove insulation from expansion valve bulb and suction line See Figure 4 7 b Loosen one TXV bulb clamp and make sure area un der clamp above TXV bulb is clean c Place thermocouple above parallel to the TXV bulb and then secure loosened clamp making sure both bulbs are firmly secured to suction line as shown in Figure 4 7 d Connect an accurate gauge...

Page 39: ... 16 126 1 8 87 8 69 4 20 29 1 2 05 2 01 65 18 137 4 9 66 9 47 2 19 30 9 2 17 2 13 70 21 149 4 10 50 10 30 0 18 32 8 2 31 2 26 75 24 162 1 11 40 11 18 2 17 34 8 2 45 2 40 80 27 175 5 12 34 12 10 4 16 36 8 2 59 2 54 85 29 189 6 13 33 13 07 6 14 38 9 2 73 2 68 90 32 204 5 14 38 14 10 8 13 41 1 2 89 2 83 95 35 220 2 15 48 15 18 10 12 43 3 3 04 2 99 100 38 236 8 16 65 16 33 12 11 45 6 3 21 3 14 105 41 ...

Page 40: ...ting compressor unexpectedly as control requirements dictate To ensure unit will not start place the EMERGENCY SWITCH see Figure 1 1 in the OFF position To ensure unit is without power remove power plug and remove battery negative cable 5 1 INTRODUCTION Schematic diagrams for the unit models listed in Table 1 1 are provided herein ...

Page 41: ...5 2 62 10630 BASED ON DRAWING 62 60873 REVISION C MODIFIED FOR SERVICE MANUAL Figure 5 1 Schematic Diagram Road Only Page 1 of 2 ...

Page 42: ...5 3 62 10630 Micro Fuse 1A Figure 5 1 Schematic Diagram Road OnlY Page 2 of 2 ...

Page 43: ...5 4 62 10630 BASED ON DRAWING 62 60856 REVISION E MODIFIED FOR SERVICE MANUAL Figure 5 2 Schematic Diagram Three Phase Stand By Units Page 1 of 2 ...

Page 44: ...5 5 62 10630 Micro Fuse 1A Figure 5 2 Schematic Diagram Three Phase Stand By Units Page 2 of 2 ...

Page 45: ...USE ROAD DC FUSE STANDBY DC HIGH PRESSURE SWITCH CONDENSER PRESSURE CONTROL SWITCH HIGH PRESSURE SWITCH STANDBY HOT GAS SOLENOID VALVE CONDENSER PRESSURE CONTROL VALVE HOT WATER VALVE HOT WATER PUMP VEHICLE IGNITION KEY ELECTRONIC OVERLOAD RELAY LOW PRESSURE SWITCH COMPRESSOR MOTOR CONTACTOR MICROPROCESSOR THERMAL OVERLOAD POWER SUPPLY RECEPTACLE COMPRESSOR MOTOR THERMAL SENSOR RETURN AIR SENSOR R...

Page 46: ...5 7 62 10630 Micro Fuse 1A Figure 5 3 Schematic Diagram Single Phase Stand By Units Page 2 of 2 ...

Page 47: ...T POWER 2 1 D DEFROST CYCLE 2 3 Defrost Malfunction 3 3 Digital Display 2 2 E EVACUATION AND DEHYDRATION 4 3 EVAPORATOR COIL CLEANING 4 2 Expansion Valve 3 5 F FILTER DRIER 4 2 Frozen Mode 2 4 H HIGH PRESSURE SWITCH 4 5 HOT GAS SOLENOID 4 6 I INSPECTION 2 1 Insufficient Cooling 3 3 INTRODUCTION 3 1 5 1 K Key Functions 2 2 Keypad 2 1 L LED Status 2 2 Low Battery Alarm 2 6 M MICROPROCESSOR 4 7 N No ...

Page 48: ...2 3 Standby Compressor Malfunction 3 5 STARTING 2 3 STOPPING 2 3 T Temperature Pressure Chart 4 8 THERMOSTATIC EXPANSION VALVE 4 7 TROUBLESHOOTING 3 1 TXV ORIFICE STRAINER 4 2 U Unit Operates Long or Continuously in Cooling 3 3 Unit Will Not Cool 3 3 Unit Will Not Heat or Heating Insufficient 3 3 ...

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