Carrier 69NT40-511-1 Operating And Service Manual Download

Page: 6 / 138

T-268-07

TABLE OF CONTENTS (CONTINUED)

Section

Page

3.3.1

Brief Description

3-24

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.2

DataCORDER Configuration

3-25

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.3

DataCORDER Function Codes

3-26

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.4

DataCORDER Alarms

3-27

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.5

Access to DataCORDER Functions

3-29

. . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.6

USDA/ Message Trip Comment

3-31

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.7

USDA Recording

3-31

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.8

Pre-Trip Data Recording

3-31

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.9

DataCORDER Communications

3-31

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.10 DataCORDER Scrollback

3-32

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4

USDA COLD TREATMENT PROCEDURE

3-32

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION

4-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1

PRE-TRIP INSPECTION (Before Starting)

4-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2

STARTING AND STOPPING INSTRUCTIONS

4-2

. . . . . . . . . . . . . . . . . . . . . . . . .

4.3

AFTER STARTING INSPECTION

4-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4

UNIT OPERATION

4-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.1

Crankcase Heater

4-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.2

Probe Check Initiation

4-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.3

Cooling -- Controller Set BELOW --10

C (+14

F), or

--5

C (+23

F) optionally

4-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.4

Controller Set ABOVE --10

C (+14

F), or --5

C (+23

F) optionally

4-3

4.4.5

Heating (See Figure 4-4.)

4-10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.6

Defrost

4-12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.7

Arctic

4-12

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING

5-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1

UNIT WILL NOT START OR STARTS THEN STOPS

5-1

. . . . . . . . . . . . . . . . . . . .

5.2

UNIT RUNS BUT HAS INSUFFICIENT COOLING

5-1

. . . . . . . . . . . . . . . . . . . . . .

5.3

UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING

5-1

. . . . . . . . . . . .

5.4

UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING

5-2

. . . . . . . . . . . . . .

5.5

UNIT WILL NOT TERMINATE HEATING

5-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6

UNIT WILL NOT DEFROST PROPERLY

5-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7

ABNORMAL PRESSURES (COOLING)

5-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8

ABNORMAL NOISE OR VIBRATIONS

5-3

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.9

TEMPERATURE CONTROLLER MALFUNCTION

5-3

. . . . . . . . . . . . . . . . . . . . . .

5.10

NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW

5-3

. . . . . . . . . . . .

5.11

THERMOSTATIC EXPANSION VALVE MALFUNCTION

5-4

. . . . . . . . . . . . . . . . .

5.12

POWER AUTOTRANSFORMER MALFUNCTION

5-4

. . . . . . . . . . . . . . . . . . . . . .

5.13

WATER-COOLED CONDENSER OR WATER PRESSURE SWITCH

5-4

. . . . . .

Summary of Contents for 69NT40-511-1

Page 1: ...and 69NT40 521 T 268 Rev G Container Refrigeration Unit DUE TO THE LARGE NUMBER OF SCHEMATIC DIAGRAMS CONTAINED IN THIS BOOK THE BOOK IS PRESENTED AS TWO FILES REFER TO FILE T268 DIAGRAMS FOR THE CHAPTER 7 ELECTRICAL DIAGRAMS AND SCHEMATICS ...

Page 2: ...ivision Carrier Corporation P O Box 4805 Syracuse N Y 13221 OPERATION AND SERVICE MANUAL E Carrier Corporation 1999 S Printed in U S A 0499 CONTAINER REFRIGERATION UNIT MODELS 69NT40 511 1 to 69NT40 511 199 and 69NT40 521 ...

Page 3: ... and power supply is disconnected Always work in pairs Never work on the equipment alone In case of severe vibration or unusual noise stop the unit and investigate MAINTENANCE PRECAUTIONS Beware of unannounced starting of the evaporator and condenser fans Do not open the condenser fan grille or evaporator access panels before turning power off and disconnecting and securing the power plug Besurepo...

Page 4: ...ant coming in contact with the eyes Should refrigerant come in contact with the eyes wash eyes for a minimum of 15 minutes with potable water only THE USE OF MINERAL OIL OR REFRIGERANT OILS IS NOT RECOMMENDED WARNING Be sure to avoid refrigerant coming in contact with the skin Should refrigerant come in contact with the skin it should be treated as if the skin had been frostbitten or frozen WARNIN...

Page 5: ...CONDENSER Optional 2 16 2 9 1 Water Cooled Condenser with Water Pressure Switch WP 2 16 2 9 2 Water Cooled Condenser with Condenser Fan Switch CFS 2 16 2 10 SUCTION SOLENOID VALVE 2 18 2 11 REMOTE MONITORING OPTIONAL 2 18 2 12 SAFETY AND PROTECTIVE DEVICES 2 19 MICROPROCESSOR 3 1 3 1 MICRO LINK 2i CONTROLLER MODULE 3 1 3 1 1 Brief Description 3 1 3 1 2 Controller Programming Memory Cards 3 2 3 1 3...

Page 6: ...tiation 4 2 4 4 3 Cooling Controller Set BELOW 10_C 14_F or 5_C 23_F optionally 4 3 4 4 4 Controller Set ABOVE 10_C 14_F or 5_C 23_F optionally 4 3 4 4 5 Heating See Figure 4 4 4 10 4 4 6 Defrost 4 12 4 4 7 Arctic 4 12 TROUBLESHOOTING 5 1 5 1 UNIT WILL NOT START OR STARTS THEN STOPS 5 1 5 2 UNIT RUNS BUT HAS INSUFFICIENT COOLING 5 1 5 3 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING 5 1 5 4 UNIT WI...

Page 7: ... DRIER 6 15 6 12 HIGH PRESSURE SWITCH 6 15 6 12 1 Replacing High Pressure Switch 6 15 6 12 2 Checking High Pressure Switch 6 15 6 13 EVAPORATOR COIL AND HEATER ASSEMBLY 6 16 6 14 EVAPORATOR COIL HEATERS 6 16 6 15 EVAPORATOR FAN AND MOTOR ASSEMBLY 6 16 6 16 EVAPORATOR FAN MOTOR CAPACITORS 6 17 6 17 CONDENSER COIL 6 18 6 18 CONDENSER FAN AND MOTOR ASSEMBLY 6 18 6 19 PARTLOW RECORDING THERMOMETER 6 1...

Page 8: ...ith a Two Speed Compressor Optional 2 9 Figure 2 9 Power Autotransformer Optional 2 12 Figure 2 10 Refrigeration Circuit with Receiver 2 15 Figure 2 11 Refrigeration Circuit with Water Cooled Condenser Optional 2 17 Figure 3 1 Micro Link 2i Controller DataCORDER Module 3 1 Figure 3 1 Key Pad 3 4 Figure 3 2 Display Module 3 5 Figure 3 3 Standard Configuration Report Sample 3 34 Figure 3 4 Controlle...

Page 9: ...ing High Pressure Switch 6 15 Figure 6 18 Evaporator Fan Assembly 6 17 Figure 6 19 Partlow Recording Thermometer 6 20 Figure 6 20 Saginomiya Recording Thermometer 6 21 Figure 6 21 Supply Sensor Positioning 6 22 Figure 6 22 Sensor RRS RTS SRS or STS 6 23 Figure 6 23 Sensor and Cable Assembly RRS RTS SRS or STS 6 23 Figure 6 24 Return Sensor Positioning 6 24 Figure 6 25 Sensor AMBS or DTS 6 24 Figur...

Page 10: ...28 Table 3 8 DataCORDER Alarm Configurations 3 29 Table 3 9 DataCorder Standard Configuration 3 30 Table 3 10 DataCORDER Pre Trip Data 3 33 Table 4 1 Electrical Control Positions BELOW 10_C 14_F or 5_C 23_F optionally 4 14 Table 4 2 Electrical Control Positions ABOVE 10_C 14_F or 5_C 23_F optionally 4 15 Table 6 1 AMBS DTS RRS RTS SRS and STS Temperature Resistance Chart 6 32 Table 6 2 Partlow Bul...

Page 11: ... installation Some units are equipped with a two speed compressor that is used to enhance power saving Someunits aredual voltageunits designed to operateon 190 230 or 380 460 volts AC 3 phase 50 60 hertz power refer to section 2 4 Other units are designed to operate on 380 460 volts AC 3 phase 50 60 hertz power only An external autotransformer is required for 190 230 vac operation refer to Figure ...

Page 12: ... 7 3 Figure 7 4 69NT40 511 8 NT0037 P X P X P X g 69NT40 511 8 NT0094 P X P X P X Figure 7 9 Figure 7 10 NT0064 P P P X P X Figure 7 3 69NT40 511 9 NT0089 P P P X P X Figure 7 3 Figure 7 4 69NT40 511 9 NT0152 P P P X P X Figure 7 9 Figure 7 10 NT0024 P X P X P X X NT0027 P X P X P X X Fi 7 3 NT0040 P X P X P X X Figure 7 3 Figure 7 4 NT0041 P X P X P X X Figure 7 4 69NT40 511 10 NT0104 P X P X P X...

Page 13: ...9NT40 511 23 NT0050 P X P X P P X 69NT40 511 23 NT0069 P X P X P P X Figure 7 3 69NT40 511 24 NT0051 P P P X P P P Figure 7 3 Figure 7 4 69NT40 511 25 NT0053 P P P X P X g 69NT40 511 26 NT0047 P P X P X P P P P Figure 7 1 Figure 7 2 69NT40 511 26 NT0175 P P X P X P P P P Figure 7 21 Figure 7 22 69NT40 511 27 NT0056 X X P X P P X Figure 7 3 NT0057 P P P X P X X Figure 7 3 Figure 7 4 69NT40 511 28 N...

Page 14: ...X X Figure 7 3 69NT40 511 39 NT0084 X P X X X X X Figure 7 3 Figure 7 4 69NT40 511 39 NT0095 X P X X X X X Figure 7 9 Figure 7 10 NT0079 X P P X X X X Figure 7 3 69NT40 511 40 NT0085 X P P X X X X Figure 7 3 Figure 7 4 69NT40 511 40 NT0096 X P P X X X X Figure 7 9 Figure 7 10 69NT40 511 41 NT0080 P P P X P P Figure 7 3 Figure 7 4 69NT40 511 41 NT0090 P P P X P P Figure 7 65 Figure 7 66 69NT40 511 ...

Page 15: ... P P X P P X Figure 7 41 Figure 7 42 NT0303 P P P X P X g NT0308 P P P X P P X Fi 7 57 NT0341 P P P X P P X Figure 7 57 Figure 7 58 NT0345 P P P X P P X Figure 7 58 69NT40 511 50 NT0106 X X P X X X X Figure 7 9 69NT40 511 50 NT0178 X X P X X X X Figure 7 9 Figure 7 10 NT0107 X X P X A P X Figure 7 13 Figure 7 14 69NT40 511 51 NT0207 X X P X A P X Figure 7 45 Figure 7 46 NT0417 X P P X P P Figure 7...

Page 16: ...P X P X P P Fi 7 57 NT0386 P X P X P X P X Figure 7 57 Figure 7 58 NT0418 P X P X P P X Figure 7 58 NT0428 P X P X P P X NT0167 P P P X P P X Figure 7 9 Figure 7 10 NT0174 P P P X P P X Figure 7 19 69NT40 511 59 NT0211 P P P X P P X Figure 7 19 Figure 7 20 69NT40 511 59 NT0272 P P P X P P X Figure 7 41 Figure 7 42 NT0312 P P P X P P X Figure 7 57 Figure 7 58 69NT40 511 60 NT0125 X X P X A P X 69NT...

Page 17: ...T40 511 75 NT0163 X P P X A X P X Figure 7 19 Figure 7 20 69NT40 511 76 NT0169 P X X P X B P P X Figure 7 15 Figure 7 16 69NT40 511 77 NT0176 P X P X B P P X Figure 7 9 69NT40 511 78 NT0182 P X P X X P X Figure 7 9 Figure 7 10 69NT40 511 79 NT0190 X P X B P X Figure 7 39 Figure 7 40 69NT40 511 80 NT0165 P P P X P P P Figure 7 9 NT0151 P X P X P P X Figure 7 9 Figure 7 10 NT0168 P X P X P P X Figur...

Page 18: ...NT0204 X P X X X X Figure 7 29 69NT40 511 94 NT0262 X P X X X Figure 7 29 Figure 7 30 69NT40 511 94 NT0265 X P X X X g NT0220 P P P X P P P Figure 7 19 Figure 7 20 69NT40 511 95 NT0322 P P P X P P X Fi 7 57 69NT40 511 95 NT0344 P P P X P P X Figure 7 57 Figure 7 58 NT0365 P P P X P X P Figure 7 58 69NT40 511 96 NT0224 P X P X B P X Fi 7 41 69NT40 511 97 NT0228 P P P X P P X Figure 7 41 Figure 7 42...

Page 19: ...7 42 NT0288 X X P X X X P X 69NT40 511 110 NT0296 X X P X X X P X 69NT40 511 110 NT0347 X P P X X X P X Figure 7 41 NT0349 X X P X X X P X Figure 7 41 Figure 7 42 NT0286 X X X X X X P X g 69NT40 511 111 NT0295 X X X X X X P X 69NT40 511 111 NT0429 X P X X X P X Figure 7 57 Figure 7 58 69NT40 511 112 NT0289 P P P X P X Figure 7 41 Figure 7 42 69NT40 511 112 NT0325 P P P X P X Figure 7 57 Figure 7 5...

Page 20: ...del number serial number and parts identification numberwill befound on thefront oftheunit to theleftof the compressor 1 2 3 4 5 6 7 8 9 10 1 Access Panel For Evap Fan Motor 1 2 Access Panel For Heater Thermostatic Expansion Valve 3 Fork Lift Pockets 4 Unit Serial Number Model Number and Parts Identification Number PID Plate 5 TransFRESH Communications Connector TCC Optional 6 Interrogator Connect...

Page 21: ...il where it is either heated or cooled and discharging the air through the bottom of the refrigeration unit into the container When transporting perishable chilled commodities the fan motors will normally be in high speed above 10_C 14_F or 5_C 23_F optionally The evaporator coil heaters are accessible by removing the front lower access panel The defrost termination sensor DTS is located on the co...

Page 22: ...d on PID NT0073 7 Evaporator Fan Motor 2 EM2 8 Defrost Termination Sensor DTS 9 Heater Termination Thermostat HTT 10 Evaporator Coil 11 Drain Pan Heater DPH 12 Thermostatic Expansion Valve 13 Heat Exchanger 14 Interrogator Receptacle IC Optional 15 USDA Probe Receptacle PR2 Optional 16 USDA Probe Receptacle PR1 Optional 17 USDA Probe Receptacle PR3 Optional 18 Cargo Probe Receptacle PR4 Optional 1...

Page 23: ...al discharge suction pressure transducers 1 2 3 4 9 6 7 8 10 11 5 1 Power Autotransformer Optional 2 Power Cables and Plug 3 Compressor Sight Glass View Port 4 Compressor Guard 5 Suction Discharge Pressure Gauges Optional 6 Suction Service Valve 7 Compressor Crankcase Heater CCH Optional 8 Compressor Motor CP 9 Discharge Service Valve 10 Discharge Pressure Transducer DPT Optional 11 Suction Pressu...

Page 24: ...the unit is operating air is pulled in the bottom of the coil and discharged horizontally out through the front of the condenser fan grille 1 2 3 4 5 6 7 8 2 1 Grille and Venturi Assembly 2 Retaining Screw 3 Condenser Fan 4 Key 5 Condenser Fan Motor CM 6 Condenser Coil Cover 7 Condenser Coil 8 Condenser Motor Mount Bracket Figure 2 4 Condenser Section ...

Page 25: ...ressor 17 1 2 10 5 6 13 14 11 12 9 8 7 15 16 3 4 18 19 1 Discharge Pressure Regulator Valve 2 Suction Modulation Valve SMV 3 Schrader Valve 4 Supply Air Thermometer Port Optional 5 Suction Solenoid Valve SSV 6 Quench Expansion Valve 7 Electro Coated Modular Receiver 8 Sight Glass 9 Fusible Plug 10 Condenser Pressure Transducer CPT Located on back side of Receiver 11 Sight Glass Moisture Indicator ...

Page 26: ... AMBS are located at the right side of the compressor 17 1 2 10 5 6 13 14 11 12 9 8 7 15 16 3 4 18 19 1 Discharge Pressure Regulator Valve 2 Suction Modulation Valve SMV 3 Schrader Valve 4 Rupture Disc 5 Condenser Pressure Transducer CPT 6 Suction Solenoid Valve SSV 7 Quench Expansion Valve 8 Filter Drier 9 Manual Liquid Line Valve 10 Moisture Liquid Indicator 11 Supply Air Thermometer Port Option...

Page 27: ... Display Module 5 Remote Monitoring Unit RMU Optional 6 Controller DataCORDER Module 7 Emergency Bypass Cooling Switch EB Optional 8 Emergency Defrost Fuse FED Optional 9 Emergency Defrost Switch ED Optional 10 Key Pad 11 Start Stop Switch ST 12 Remote Monitoring Receptacle RM Optional 13 Manual Defrost Switch MDS 14 Condenser Fan Switch CFS Optional 15 Controller DataCORDER Battery Pack Optional ...

Page 28: ...CH High Speed 2 Compressor Contactor CL Low Speed 3 Compressor Contactor SC Shorting 4 Heat Contactor HR 5 Display Module 6 Remote Monitoring Unit RMU Optional 7 Controller DataCORDER Module 8 Key Pad 9 Start Stop Switch ST 10 Manual Defrost Switch MDS 11 Remote Monitoring Receptacle RM Optional 12 Controller DataCORDER Battery Pack Optional 13 Control Transformer TR 14 Evaporator Fan Contactor EF...

Page 29: ...r 3 74 kg 8 25 lbs 4 88 kg 10 75 lbs Refer to Table 1 1 NOTE When replacing the components n o and p in section 2 2 refer to the installation instructions included with the ordered new part for additional information n Fusible Plug Melting point 99 _C 210 _F n Fusible Plug Torque 6 2 to 6 9 mkg 45 to 50 ft lbs o Sight Glass Moisture Indicator Torque 8 9 to 9 7 mkg 65 to 70 ft lbs Bursts at 35 5 kg...

Page 30: ...al Type Sheath Number of Heaters 4 E t C il Rating 750 watts 5 10 each 230 vac e Evaporator Coil Heaters Resistance cold 66 8 to 77 2 ohms Heaters Ambient 20 _C 68 _F Type Sheath 380 vac 3 Phase 50 hz 460 vac 3 Phase 60 hz Full Load Amps High Speed 1 6 amps 2 0 amps Full Load Amps Low Speed 0 8 amps 1 0 amps Nominal Horsepower High Speed 0 70 hp 0 84 hp f Evaporator Fan Nominal Horsepower Low Spee...

Page 31: ...rming the following operations Move the start stop switch ST the unit circuit breaker s CB 1 and CB 2 if equipped and any external power source to their OFF positions b To Operate Unit on 190 230 vac Power Supply 1 Make sure that the start stop switch ST on control panel and circuit breaker CB 2 if equipped on the modular transformer are in position 0 OFF Make sure the 460 vac power plug is locked...

Page 32: ...ired air flow by aligning the arrow on the disc with the percentage of desired air flow marked on the supplied label see Figure 2 1 2 6 LOWER FRESH AIR MAKEUP VENT Optional The purpose of the lower fresh air makeup vent is to provide ventilation for commodities that require fresh air circulation The vent must be closed when transporting frozen foods Air exchange depends on static pressure differen...

Page 33: ...ion modulation valve and suction solenoid valve under some conditions to the compressor The thermostatic expansion valve bulb on the suction line near the evaporator coil outlet controls the thermostatic expansion valve maintaining a constant superheat at thecoil outlet regardless ofload conditions except at abnormally high container temperatures such as during pulldown valve at maximum operating ...

Page 34: ...alizer Line 8 Thermostatic Expansion Valve Bulb 9 Heat Exchanger 10 Fusible Plug Located on back of receiver 11 Sightglass 12 Condenser Pressure Transducer CPT Located on the back side of the receiver 13 Sight Glass Moisture Indicator 14 Electro Coated Modular Receiver 15 Manual Liquid Line Valve 16 Filter Drier 17 Quench Expansion Valve 18 Suction Solenoid Valve 19 Suction Modulation Valve Figure...

Page 35: ...itted to the shell side and is condensed on the outer surface of the coil 2 9 1 Water Cooled Condenser with Water Pressure Switch WP For operation of the refrigeration unit with the water cooled condenser do the following a Connect the water supply line to the inlet side of condenserand thedischargelineto theoutlet sideof the condenser b Maintain a flow rate of 11 to 26 liters per minute 3 to 7 ga...

Page 36: ...Expansion Valve 7 External Equalizer Line 8 Thermostatic Expansion Valve Bulb 9 Heat Exchanger 10 Rupture Disc 11 Manual Liquid Line Valve 12 Moisture Liquid Indicator 13 Condenser Pressure Transducer CPT 14 Filter Drier 15 Sight Glass 16 Water Cooled Condenser 17 Suction Solenoid Valve 18 Suction Modulation Valve 19 Quench Expansion Valve Figure 2 11 Refrigeration Circuit with Water Cooled Conden...

Page 37: ...ty enhancement logic CREL restricts its use b Suction Solenoid Override The suction solenoid override function restricts the opening of the suction solenoid valve SSV under certain high ambient and or box temperature conditions to prevent compressor overload under these high capacity conditions If the primary return sensor RTS fails alarm code AL56 the suction solenoid valve will not open unless t...

Page 38: ...TTING Circuit Breaker CB 1 Manual Reset Trips at 29 amps 460 vac Excessive current draw Circuit Breaker CB 2 50 amp Manual Reset Trips at 62 5 amps 230 vac Circuit Breaker CB 2 70 amp Manual Reset Trips at 87 5 amps 230 vac Excessive current draw on the control circuit Fuse F3 15 amp rating Excessive current draw by the Controller DataCORDER Fuse F1 F2 5 amp rating Excessive condenser fan motor wi...

Page 39: ...move wire harnesses from module unless you are grounded to the unit frame with a static safe wrist strap The Carrier Transicold Micro Link 2i Controller DataCORDER is a custom designed microprocessor based module which incorporates embedded software to a Control supply or return air temperature to extremely tight limits by providing modulated refrigeration control electric heat control and defrost...

Page 40: ...e Procedure for loading software Refer to section 6 27 1 Operational Software This software operates the Controller module which turns fans on and off turns the compressor on and off etc Configuration Software This software tells the Operational Software what physical components are built into the container unit Refer to Table 3 1 Programming cards with eitherOperational Softwareor Configuration S...

Page 41: ... 16 DataCORDER Option On Yes Off No 17 Discharge Pressure Sensor Out No In Yes 18 Heater Old Low Watt nEW High Watt 19 Controlled Atmosphere Out No In Yes 20 Pressure Sensor Suction Out No In Yes 21 Auto Transformer Std 22 Economy Mode Option Off Std Full 23 Defrost Interval Timer Save Option noSAV SAV 24 Advanced Pre Trip Enhanced Test Off On 25 Pre Trip Test Points Results Recording rSLts data 2...

Page 42: ...wnward Change codes downward Scan alarm list downward Change user selectable features downward Pre trip repeat backward DataCORDER Function and Alarm Codes are scrolled downward after the ALT MODE key is depressed Return Sup ply Displays non controlling probe temperature momentary display _C _F Displays alternate temperature scale momentary display Alarm List Displays alarm list and clearing of th...

Page 43: ...will be used for control in the perishable ranges and the return air probe is used for control in the frozen ranges S Alarm Red LED Energized when there is an active or an inactive shutdown alarm AL20 to AL27 in the alarm queue S Supply Yellow LED Energized when supply temperature and set point are displayed Flashes if dehumidification or humidification is enabled on units so equipped S Return Yel...

Page 44: ...Cd05 Cd06 Line Current Phase A Line Current Phase B Line Current Phase C Unit current is monitored by two current sensors The current measured is used for control and diagnostic purposes For control processing the highest of the Phase A and B current values is used for current limiting purposes The third unmeasured leg is calculated based on a current algorithm For diagnostic processing the curren...

Page 45: ...he Controller DataCORDER battery pack While the test is running btest will flash on the right display followed by the result PASS will be displayed for battery voltages greater than 7 0 volts and for alkaline batteries with voltages greater than 7 5 volts FAIL will be displayed for battery voltages between 4 5 and 7 0 volts and will be displayed for battery voltages less than 4 5 volts After the r...

Page 46: ...ired defrost interval and possibly delaying a needed defrost cycle NOTE The defrost interval timer counts only during compressor run time Cd28 Temperature Units _C or _F This code determines the temperature units _C or _F which will be used for all temperature displays The user selects _C or _F by selecting function code Cd28 and pushing the ENTER key The factory default value is Celsius units NOT...

Page 47: ...ge code Cd35 to bulb After bulb has been selected and entered the user may then utilize function codes Cd36 and Cd37 to make the desired changes Cd36 Evaporator Speed Select Cd35 must be in Bulb This code is enabled only if a dehumidification set point has been selected using function code Cd33 and bulb has been selected using function code Cd35 If these conditions are not met alt will be displaye...

Page 48: ...arms exist or have existed Alarms must be diagnosed and corrected before the Alarm List can be cleared To Display Alarm Codes While in Set Point Selection or Default Display mode press the ALARM LIST key This accesses the Alarm List Display Mode which displays any alarms archived in the Alarm Queue The alarm list stores up to 16 alarms in the sequence in which they occurred The user may scroll thr...

Page 49: ...o refer to code Cd29 AL25 Condenser Fan Motor Safety Alarm 25 is triggered by the opening of the condenser motor internal protector and will disable all control units except for the evaporator fans This alarm will remain active until the motor protector resets This alarm is deactivated if the unit is operating on water cooled condensing AL26 All Supply and Return Air Control Sensors Failure Alarm ...

Page 50: ... the valid range from 50_C 58_F to 70_C 158_F AL58 Compressor High Pressure Safety HPS Alarm 58 is triggered when the compressor high discharge pressure safety switch HPS remains open for at least one minute This alarm will remain active until the pressure switch resets at which time the compressor will restart AL59 Heat Termination Thermostat HTT Safety Alarm 59 is triggered by the opening of the...

Page 51: ...8 Condenser Pressure Transducer Failure CPT Alarm 68 is triggered by a condenser pressure transducer reading outside the valid range of 73 20 cm Hg 30 in Hg to 32 34 Kg cm2 460 psig This is a display alarm and has no associated failure action AL69 Suction Temperature Sensor Failure CPSS Alarm 69 is triggered by a suction temperature sensor reading outside the valid range of 60_C 76_F to 150_C 302_...

Page 52: ...ptionally See Figure 3 4 and Figure 3 5 The Controller configuration variable for Heat Lockout refer to Table 3 1 can be changed for set points of either 10_C 14_F or 5_C 23_F optionally NOTES S When upward set point changes are made at ambients below 27_C 80_F the compressor is immediately cycled OFF The compressor three minute time delay will be overridden so that as soon as the control temperat...

Page 53: ... and valid AL67 2 The pulldown mode is NOT active ie The SSV valve is closed and the control temperature is less than 5_C above set point 3 The control probe i e Supply 1 temperature is less than set point plus 0 25_C 4 Temperature control set point is greater than 10_C 14_F or 5_C 23_F optionally in the perishable range and the compressor is running 5 The heater debounce timer three minutes has t...

Page 54: ...5_C 0 45_F of the set point and the return air temperatureis less than or equal to the supply air temperature 3_C 5 4_F When the fans switch to low speed they will run in low speed for one hour At the end of the hour the evaporator fans will switch back to high speed The evaporator fans will again run in high speed for three minutes and the above mentioned cycle will be repeated just as it was fro...

Page 55: ...nomy mode frozen operation a frozen set point temperature must be selected PRIOR to activating economy mode When economy modefrozen is active the system will perform normal frozen mode operations except that the entire refrigeration system excluding the Controller will be turned off when the control temperatureis less than orequal to theset point 2_C i e the set point is set at 11_C and the operat...

Page 56: ...est may be interrupted by pressing the UP ARROW key This will return the user to the test selection mode described above and all machinery outputs will be de energized While certain tests from Auto 1 are running PX X will appear on the left display where the X s indicate the test number and sub test The right display will show a countdown time in minutes and seconds indicating how much time there ...

Page 57: ...w test is done after 10 seconds Pass Fail Criteria Passes if change in current draw is within the range specified P2 0 Condenser Fan On Requirements Water pressure switch WP input must be closed Setup Condenser fan is turned ON a current draw test is done after 15 seconds Pass Fail Criteria Passes if change in current draw test is within the range specified P2 1 Condenser Fan Off Setup Condenser f...

Page 58: ...eturn is compared NOTES S If this test fails P5 2 and FAIL will be displayed If both Probe tests this test and the SUPPLY RETURN pass because of the multiple tests the display will read P 5 PASS S The results of Pre Trip tests 5 0 5 1 and 5 2 will be used to activate or clear control probe alarms Single Speed C T Setup The compressor is started If it is the first compressor start the compressor re...

Page 59: ...Test Setup The compressor suction temperature is measured with the Quench valve closed The Quench valve is energized and the suction temperature drop is checked Pass Fail Criteria Passes if suction temperature is within the valid range P6 4 Suction Modulation Valve Closed Setup The heaters are energized The suction modulation valve is set to 100 and run for one minute At the end of the one minute ...

Page 60: ...s are sensed to be invalid S Compressor discharge sensor CPDS S Discharge pressure transducer DPT S Condenser pressure transducer CPT OR if any one of the following inputs are sensed to be invalid S Return temperature sensor RTS S Ambient sensor AMBS In addition the test will fail if S The high pressure switch HPS fails to open within 15 minutes S The discharge temperature exceeds 138_C 280_F S Th...

Page 61: ...R recording the test passes If the average temperature is outside of the tolerance range at the DataCORDER recording the test fails P9 0 Defrost Test Setup The defrost temperature sensor DTS temperature will be displayed on the left display The right display will show the supply air temperature The unit will run FULL COOL for 30 minutes maximum while the DTS sensor temperature is above 10_C Once t...

Page 62: ...f set point from test start to DataCORDER recording the test passes If temperature is outside of the tolerance range at the DataCORDER recording the test fails 3 3 INTEGRATED DATACORDER OPTIONAL 3 3 1 Brief Description Carrier Transicold has developed a recorder which we have termed the DataCORDER and is integrated into a module with the Controller For reader simplicity and understanding this sect...

Page 63: ...ctions see section 3 1 2 Changes to the factory default configuration must be made with the Interrogation device Configuration Tells the operational software what physical components are built into the container unit how many sensors to record what recording interval should be used etc ITEM SETTING FACTORY DEFAULT Sensor Logging Network Average or Snapshot Average Sensor Logging Thermistor Average...

Page 64: ...me dC20 24 Temperature Sensors 1 5 Calibration Current calibration offset values for each of the five probes supply return USDA 1 2 and 3 These values are entered via the interrogation program dC25 Future Expansion This code is for future expansion and is not in use at this time dC26 27 S N Left 4 Right 4 The DataCORDER serial number consists of eight characters Function code dC26 contains the fir...

Page 65: ...m number See Table 3 7 DataCORDER Alarm Indications S IAXX if the alarm is inactive END is displayed to indicate the end of the alarm list if any alarms are active CLEAr is displayed if all the alarms in the list are inactive S The exception to this rule is the DataCORDER Alarm Queue Full AL91 alarm which does not have to be inactive in order to clear the alarm list To Clear the Alarm List If no a...

Page 66: ...side of its specified range See NOTE below NOTE While the DataCORDER is normally setup to record only supply and return recorder sensors the DataCORDER has the capability to record the data of eight additional sensors Any sensor installed on the unit may be recorded and are identifiable as Network Sensors AL 78 to AL85 Which alarm AL78 to AL 85 is associated with the physical sensor depends on how...

Page 67: ...on and scrollback b DataCORDER Power Up TheDataCORDER may bepowered up in several ways 1 Normal AC power The DataCORDER is powered up when the unit is turned on via the stop start switch ST 2 Normal DC power If a rechargeable battery pack is installed fully charged the user may plug the interrogation cable into the front interrogation receptacle and the DataCORDER will power up for communications ...

Page 68: ...e user to configure the DataCORDER to monitor data using one of seven standard configurations The seven standard configuration variables with their descriptions are listed in Table 3 9 The six thermistor inputs supply return USDA 1 2 3 and cargo probe and the humidity sensor will be DataCorder inputs The three inputs will be read over a network from the Controlled Atmosphere module In addition if ...

Page 69: ... two wire thermistor probe A label on the back panel of the unit shows which receptacle is used for each probe The USDA 1 2 and 3 probes and possibly the optional Cargo probe are installed in their receptacles The DataCORDER records up to six probe temperatures supply return USDA 1 2 3 and an optional cargo probe 4 at the logging interval The standard DataCORDER report displays the supply and retu...

Page 70: ... in product temperature within the DataCORDER memory thus meeting USDA criteria refer to section 3 3 7 The following is a summary of the steps required to initiate a USDA Cold Treatment a Pre cool the container to the treatment temperature or below b Pre cool to treatment temperature c Install the DataCORDER module battery pack if not already installed d Calibrate the three USDA probes by ice bath...

Page 71: ...r On High Speed Pass Fail Skip Result Change in currents for Phase A B and C 6 1 Compressor On Low Speed Pass Fail Skip Result Change in currents for Phase A B and C 6 2 Suction Modulation Valve Open Pass Fail Skip Result STS RTS Is current limit in effect Y N 6 4 Suction Modulation Valve Closed Pass Fail Skip Result STS RTS Delta T1 Delta T2 Is current limit in effect Y N 6 5 Suction Solenoid Val...

Page 72: ...16 13 DATACORDER ALARMS No Alarms Reported USDA SUMMARY LEGEND DATE 15Apr94 23 49 Trip Start SP Setpoint Change PS PE Pretrip Start End NEW SN Controller Rep dal Datacorder Alm NEW SW Software Upgrade DS Defrost Start DHS DHE Dehumid Start End NEW ID Container ID OFF Power Loss COMM NetWork Off DE Defrost End AL Alarm Activity TS Trip Start BATT Power Loss Setp SupAir RetAir Figure 3 3 Standard Co...

Page 73: ...re 3 4 Controller Set Point BELOW 10_C 14_F or 5_C 23_F optionally SET POINT FALLING TEMPERATURE RISING TEMPERATURE 1 5_C 2 7_F 1_C 1 8_F 0 5_C 0 9_F 0 20_C 20_C 1 5_C 2 7_F 1_C 1 8_F 0 5_C 0 9_F HEATING HEATING MODULATING COOLING AIR CIRCULATION ONLY AIR CIRCULATION ONLY MODULATING COOLING NOTE For In range Tolerance Refer to section 3 1 4 Code 30 For Two Speed compressor operation refer to Figur...

Page 74: ...r box temperature YES Continue In Low Speed NO Does High Pressure Switch HPS Trip NO YES NO J Was Ambient Greater Than 60 F During Start Is Supply Voltage Greater Than Required Voltage Is Supply Voltage Greater Than Required Voltage Required voltage is a function of operating capacity and supply frequency NO YES L YES NO NO NOTE B Low Speed Soft Start is performed by closing the SMV to 0 opening f...

Page 75: ...Soft Start is performed by closing the SMV to 0 opening for ten seconds during the start up of the compressor The SMV opening is then gradually increased to thedesired value at the rate of a 3 opening per second NO Has Set Point Been Reached Compressor Cycles OFF NOTE A During compressor operation if at anytime the High Pressure Switch HPS trips the logic will switch to Low Speed Soft Start Figure...

Page 76: ...r is to be opened or closed d Open Partlow recording thermometer door if so equipped and do the following 1 Manually wind clock on key wound recording thermometer key is located in a clip KEY MUST STAY WITH THE THERMOMETER Check battery on battery powered recording thermometer 2 Lift stylus pen by pulling the marking tip outward until the stylus arm snaps into it s retracted position 3 Install new...

Page 77: ...he compressor contactor CH 4 4 2 Probe Check Initiation Whenevertheunit is in normal control mode that is not in pre trip defrost or shutdown modes and there are NO active probe alarms and alarm codes AL11 and AL12 are inactive for units so equipped the following probe diagnostic functions are performed by the controller The following is based on current ML2i operational software logic version 510...

Page 78: ...The function of the probe check is to determine what probe s is in error S The P5 Pre Trip test must be run to inactivate alarms refer to section 3 2 1 4 4 3 Cooling Controller Set BELOW 10_C 14_F or 5_C 23_F optionally NOTES S The suction solenoid valve SSV will be open to increase the refrigerant flow rate and cooling capacity unless SSV override is activated S The suction modulation valve SMV i...

Page 79: ... to 0 2_C below set point and the running sum is less than 250 degrees C seconds relays TN and TC de energize shutting off the condenser fan and compressor motors Also the cool light is de energized The evaporator fan motors continue to run to circulate air throughout the container The in range light remains illuminated as long as thesupply airis within atolerance of set point and the 15 minute ov...

Page 80: ...SECTION 4 4 5 T 268 07 CONTROL TRANSFORMER 18 Volt Energized Circuit 24 Volt Energized Circuit De energized Circuit Figure 4 1 Cooling in High Speed with Two Speed Compressor ...

Page 81: ...o 1 30 amps at full modulation During this cooling mode a running sum of the temperature differential supply air temperature set point is kept When the supply air falls below set point the differential is negative The longer supply air remains below set point the greater the negative differential in the running sum When the supply air temperature decreases to 0 2_C below set point and the running ...

Page 82: ...SECTION 4 4 7 T 268 07 18 Volt Energized Circuit CONTROL TRANSFORMER 24 Volt Energized Circuit De energized Circuit Figure 4 2 Cooling in Low Speed with Two Speed Compressor ...

Page 83: ...approximately 2 5_C 4 5_F above set point Themodulating valvewill havea variablecurrent up to 1 30 amps at full modulation During this cooling mode a running sum of the temperature differential supply air temperature set point is kept When the supply air falls below set point the differential is negative The longer supply air remains below set point the greater the negative differential in the run...

Page 84: ...SECTION 4 4 9 T 268 07 18 Volt Energized Circuit CONTROL TRANSFORMER 24 Volt Energized Circuit De energized Circuit Figure 4 3 Cooling with Single Speed Compressor ...

Page 85: ...ght The evaporator fans continue to run to circulate air throughout the container As the supply air decreases to the in range tolerance below set point relay TI and the in range light de energize after a 15 minute time delay and will remain de energized until the supply air increases to a tolerance below set point Refer to section 3 1 4 Code 30 When the temperature rises to 0 2_C 0 4_F below set p...

Page 86: ...SECTION 4 4 11 T 268 07 CONTROL TRANSFORMER 18 Volt Energized Circuit 24 Volt Energized Circuit De energized Circuit Figure 4 4 Heating Mode ...

Page 87: ... controller will perform a probe check cycle The purposeoftheprobecheck cycleis to perform aperiodic check of the controller sensors to detect malfunctions or drift in the sensed temperature that is too small to be detected by the normal sensor out of range tests The system will run for eight minutes in this condition At the end of the eight minutes the primary supply primary return and DataCORDER...

Page 88: ...over the controller will revert to its normal control mode logic If ambient is warmer than 10 0_C the system will run its normal startup logic Arctic mode is configurable by using the configuration variable 29 refer to Table 3 1 CONTROL TRANSFORMER 18 Volt Energized Circuit 24 Volt Energized Circuit De energized Circuit Figure 4 5 Defrost ...

Page 89: ... a 2 De energized 2 Low Speed Evaporator Contactor ES Energized Energized Refer to section 3 1 7 a 2 Refer to section 3 1 7 a 2 De energized Defrost Relay TF De energized De energized Energized Heater Relay HR De energized De energized Energized INDICATING LIGHTS Cool ON OFF OFF Defrost OFF OFF ON In Range On If In Range Refer to paragraph 3 1 4 Code 30 Heat OFF OFF ON POWER CIRCUIT Compressor Ene...

Page 90: ... section 3 1 7 a 2 Refer to section 3 1 7 a 2 De energized 2 Low Speed Evaporator Contactor ES De energized De energized Refer to section 3 1 7 a 2 Refer to section 3 1 7 a 2 De energized Defrost Relay TF De energized De energized De energized De energized Energized Heater Relay HR De energized De energized Energized Energized Energized INDICATING LIGHTS Cool ON OFF ON OFF OFF Defrost OFF OFF OFF ...

Page 91: ...o speed compressor only Check Check 6 7 6 7 Check Compressor will occasionally de energize for 15 seconds Compressor speed change On units with two speed compressor Normal 5 2 UNIT RUNS BUT HAS INSUFFICIENT COOLING Compressor Compressor valves defective 6 7 Refrigeration System Abnormal pressures Temperature controller malfunction Evaporator fan or motor defective Suction modulation valve malfunct...

Page 92: ...ose terminal connections Low line voltage 6 14 Replace 6 15 6 16 Replace 5 9 Replace Tighten 2 4 5 5 UNIT WILL NOT TERMINATE HEATING Unit fails to stop heating Temperature controller improperly set Temperature controller malfunction Heater termination switch remains closed along with the heat relay Reset 5 9 6 13 5 6 UNIT WILL NOT DEFROST PROPERLY Will not initiate defrost automatically Defrost ti...

Page 93: ...6 4 6 6 6 26 5 10 5 6 6 14 6 16 Replace 6 25 Suction and discharge pressures tend to equalize when unit is operating Heat exchanger defective Compressor valves defective Compressor cycling stopped Replace 6 8 Check 5 8 ABNORMAL NOISE OR VIBRATIONS Compressor Loose mounting bolts Worn bearings Worn or broken valves Liquid slugging Insufficient oil Tighten 6 7 6 7 5 11 6 10 Condenser or Evaporator F...

Page 94: ...ne plugged Ice holding valve open Foreign material in valve 6 26 c Open 6 4 6 5 6 26 Liquid slugging in compressor Pin and seat of expansion valve eroded or held open by foreign material 6 26 Fluctuating suction pressure Improper bulb location or installation Low superheat setting 6 26 6 26 c 5 12 POWER AUTOTRANSFORMER MALFUNCTION Unit will not start Circuit breaker CB 1 or CB 2 tripped Power tran...

Page 95: ...e High Pressure Gauge A B C A Connection to Low Side of System B Connection to High Side of System C Connection to Either Refrigerant Cylinder or Oil Container Figure 6 1 Manifold Gauge Set a Connecting the Manifold Gauge Set See Figure 6 2 1 Remove service valve stem caps and check both service valves to make sure they are backseated turned counter clockwiseall theway out Remove service port caps...

Page 96: ...n pressure b Removing the Manifold Gauge Set 1 While the compressor is still ON backseat the discharge service valve 2 Midseat both hand valves on themanifold gaugeset and allow the pressure in the manifold gauge set to bedrawn down to suction pressure This enables the liquid that condensed in the high side hose to be returned to the system 3 Backseat the suction service valve Backseat both field ...

Page 97: ...ose Red Knob Blue Knob 8 1 Manifold Gauge Set 2 Hose Fitting 0 500 16 Acme 3 Refrigeration or Evacuation Hoses SAE J2196 R 134a 4 Hose Fitting w O ring M14 x 1 5 5 High Side Field Service Coupling 6 Low Side Field Service Coupling 7 High Side Service Port SAE J639 Male 8 Low Side Service Port SAE J639 Male Figure 6 2 R 134a Manifold Gauge Set Connection ...

Page 98: ...e liquid line valve Then close front seat the liquid line valve by turning clockwise Start the unit and run in a cooling mode Placestart stop switch in theOFFposition whenthe unit reaches a positive pressure of 0 1 kg cm 1 0 psig c Frontseat close the suction service valve The refrigerant will be trapped between the compressor suction service valve and the liquid line valve d Before opening up any...

Page 99: ...ff the pump and check to see if the vacuum holds This operation is to test the evacuation setup for leaks Repair if necessary d Midseat the refrigerant system service valves e Open the vacuum pump and electronic vacuum gauge valves if they are not already open Start the vacuum pump Evacuate unit until the electronic vacuum gauge indicates 2000 microns Close the electronic vacuum gauge and vacuum p...

Page 100: ...oundaries refer to section 6 6 3 c For Units equipped with water cooled condenser check charge only on air cooled operation Refrigerant level in the water cooled operation will be normally above sight glass Partially block the condenser coil inlet air starting from the front of the condenser coil Increase the area blocked until the compressor discharge pressure is raised to approximately 12 kg cm ...

Page 101: ...ry Unit 2 Refrigerant Cylinder 3 Evacuation Manifold R 134a 4 Hand Valve 5 Vacuum Pump 6 Electronic Vacuum Gauge 7 Manual Liquid Line Valve 8 Condenser Coil 9 Suction Service Valve 10 Compressor 11 Discharge Service Valve 12 Evaporator Coil Figure 6 4 Vacuum Pump Connections ...

Page 102: ... d Connect charging line between suction service valve port and cylinder of refrigerant R 134a Open VAPOR valve e Partially frontseat turn clockwise the suction service valve and slowly add charge until the refrigerant appears at the proper level refer to section 6 6 1 6 7 COMPRESSOR MODEL 06DR WARNING Make sure power to the unit is OFF and power plug disconnected before replacing the compressor N...

Page 103: ...r k Install compressor and mounting plate in unit l Connect junction box es to compressor and connect all wiring per wiring diagram Install junction box cover s m Install new gaskets on service valves n Install mounting bolts in service valves and torque to a value of 2 77 to 4 15 mkg 20 30 ft lb o Install a new filter drier Refer to section 6 11 p Attach two hoses with hand valves near vacuum pum...

Page 104: ...l Pressure Relief Valve 2 Oil Return Check Valve 3 Oil Suction Tube 4 Capscrew 5 Connecting Rod and Cap Assembly Figure 6 7 Bottom Plate Removed c Remove valve stops and valves After they have been removed freethevalve platefrom thecylinder deck by using the outside discharge valve hold down capscrew as a jack screw through the tapped hole of the valve plate Remove the valve plate gasket see Figur...

Page 105: ...frigerant suction strainer If it is removed with ease it may be cleaned with solvent and replaced See Figure 6 10 If the strainer is broken corroded or clogged with dirt that is not easily removed replace the strainer Install new gaskets upon reassembly i Block the compressor crankshaft so that it cannot turn Use a screwdriver to bend back the tabs on the lockwasher and remove the equalizer tube S...

Page 106: ...e as shown in Figure 6 13 The terminal mounting plate assembly as originally installed is assembled so as to leave a small space between the outer terminal bushing and the surface of the mounting plate This is to provide further crush of theterminal bushing in casealeak should occur To stop a leak tighten the terminal bushing nut only enough to stop the escape of gas Do not tighten until the termi...

Page 107: ...to the piston bore approximately one inch below the top of the bore 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 respectively Figure 6 15 Piston Rings c Installing the Components 1 Push pistons from the inside of the crankcase through the cylinders being careful not to break the rings Place c...

Page 108: ...is below the bottom of the sight glass add oil to the compressor following step b below b Adding Oil with Compressor in System In an emergency where an oil pump is not available oil may be drawn into the compressor through the suction service valve CAUTION Extreme care must be taken to ensure the manifold common connection remains immersed in oil at all times Otherwise air and moisture will be dra...

Page 109: ...ture liquid indicator shows moisture in the system To Replace Filter Drier a Pump unit down to 0 psi and replace filter drier Refer to section 6 3 b Evacuate the unit per section 6 5 and open the manual liquid line valve c After unit is in operation inspect for moisture in system 6 12 HIGH PRESSURE SWITCH 6 12 1 Replacing High Pressure Switch a Turn unit start stop switch OFF Frontseat both suctio...

Page 110: ... COIL HEATERS WARNING Before servicing unit make sure the unit circuit breakers CB 1 CB 2 and the start stop switch ST are in the OFF position and that the power plug and cable are disconnected a Remove the lower access panel Figure 2 1 by removing the T I R locking device lockwire and mounting screws b Determine which heater s need replacing by checking resistance on each heater as shown in secti...

Page 111: ...mentarily to check for proper fan rotation refer to section 2 3 If fan spins backward then motor wiring or motor is defective e Replace access panel making sure that panel does not leak Make sure that the T I R locking device is lockwired 6 16 EVAPORATOR FAN MOTOR CAPACITORS The evaporator fan motors are of the permanent split capacitor type The motor is equipped with one capacitor used in the hig...

Page 112: ...emove the line to the receiver or water cooled condenser if so equipped d Remove coil mounting hardware and remove the coil e Install replacement coil and solder connections f Leak check the coil per section 6 4 Evacuate the unit per section 6 5 then charge the unit with refrigerant per section 6 6 1 6 18 CONDENSER FAN AND MOTOR ASSEMBLY WARNING Do not open condenser fan grille before turning powe...

Page 113: ...manufacturer s instructions c Checking the Recording Thermometer Bulb Temperature Checking temperature is accomplished by comparing the instrument s indicated temperature stylus with the known temperature existing at the element sensing bulb To properly check the temperature of therecorder the element sensing bulb should be stabilized at a temperature of 0_C 32_F This is accomplished by using one ...

Page 114: ...anel Remove bulb clamps securing bulb to unit 3 Remove two flange screws from recording thermometer and feed capillary and element through the unit 4 Push replacement bulb end and capillary through the unit 5 Fill slots with silastic RTV432 Dow Corning 6 Attach bulb clamps tightly to bulb 7 Connect element flange to recorder making sure hub of flange faces out to fit into the hole in instrument ca...

Page 115: ...ve sea atmosphere or if the protective paint system is scratched or damaged clean area to bare metal using a wire brush emery paper or equivalent cleaning method Immediately following cleaning spray or brush on zinc rich primer After the primer has dried spray or brush on finish coat ofpaint to match original unit color 6 22 POWER AUTOTRANSFORMER OPTIONAL If the unit does not start check the follo...

Page 116: ...sor the sensor must be fully inserted into the probe holder This positioning will give the sensor the optimum amount of exposure to the supply air stream and will allow the Controller to operate correctly Insufficient probe insertion into the probe holder will result in poor temperature control due to the lack of air flow over the sensor It is also necessary to ensure that the probe tip does not c...

Page 117: ...hat was removed in step b over wiring and probe holder NOTE The P5 Pre Trip test must be run to inactivate the alarm refer to section 3 2 1 6 23 3 Replacing Sensor RRS and RTS a Turn unit power OFF and disconnect powersupply b Cut cable5 cm 6 inches fromshoulderofdefective sensor and discard the defective probe only c Cut one wire of existing cable 41 mm 1 5 8 inches shorter than the other wire d ...

Page 118: ...4 mm 1 0 inch See Figure 6 25 e Strip back insulation on all wiring 6 35mm 1 4 inch Sensor 25 4 mm 1 0 inch 6 35mm 1 4 inch Mounting Stud Figure 6 25 Sensor AMBS or DTS f Slide two small pieces of heat shrink tubing over each wire before adding crimp fittings as shown in Figure 6 26 g Slip crimp fittings over dressed wires Make sure wires are pushed into crimp fittings as far as possible and crimp...

Page 119: ... Torque the four capscrews to 40 inch pounds 8 Do not overtighten enclosing tube assembly Torque to a value of 1 15 mkg 100 inch pounds 9 Remove supplied installation removal tool Install coil and snap cap 10 Dehydrate and evacuate the system Refer to section 6 5 Charge unit with refrigerant per section 6 6 1 11 Plug in the connector Start unit and check operation 6 25 SUCTION MODULATION VALVE SMV...

Page 120: ...be used only The coil need not be removed 4 Install new suction service valve gasket and install bolts in suction service valve Torque to a value of 2 77 to 4 15 mkg 20 to 30 ft lb 5 Solder all connections and leak check same 6 Dehydrate and evacuate the unit per section 6 5 Add refrigerant charge per section 6 6 6 26 THERMOSTATIC EXPANSION VALVE The thermal expansion valve is an automatic device ...

Page 121: ...ture should be at 18_C 0_F 1 2 3 4 1 Suction Line 2 TXV Bulb Clamp 3 Nut and Bolt 4 TXV Bulb Figure 6 30 Thermostatic Expansion Valve Bulb c Checking Superheat NOTE Adjusting internal adjustable valves is not recommended This valve has been factory adjusted and set with Locktite that is applied to the internal adjusting nut Due to the time involved in adjusting the superheat replace the valve powe...

Page 122: ... secure power to the unit 3 Place strap on wrist and attach the ground or clip end of the wrist strap to any exposed unpainted metal area on the refrigeration unit frame bolts screws etc 4 Carefully remove the Controller DataCORDER Do not touch any of the electrical components if possible Place the module on the static mat 5 If you are servicing the refrigeration unit you are free to remove the gr...

Page 123: ...E 2 If a problem occurs while loading the software the Display will blink the message Pro FAIL or bad 12V Turn start stop switch OFF and remove the card h Turn unit OFF via start stop switch ST i Remove the programming card from the programming software port j Turn unit ON via start stop switch ST Procedure for loading Configuration Software a Turn unit OFF using start stop switch ST b Insert the ...

Page 124: ...oximate condensing temperature with the unit running in thecooling mode install agauge 0 to 36 2 kg cm 0 to 500 psig on the compressor discharge service valve Example Discharge pressure is 10 3 kg cm 146 4 psig Referring to Table 6 6 R 134a pressure temperature chart the 10 3 kg cm 146 4 psig value converts to 43_C 110_F If the water cooled condenser is dirty it may be cleaned and de scaled by the...

Page 125: ...ort Tank Fine mesh screen Return Remove water regulating valve Condenser Globe valves Gas vent Close vent pipe valve when pump is running Priming connection Figure 6 32 Water Cooled Condenser Cleaning Forced Circulation 6 Allow the Oakite No 32 solution to soak in thetube coils for several hours periodically pump circulating it with an acid proof pump An alternate method may be used whereby a bott...

Page 126: ...sed by chemical action Condenser Vent pipe 1 Pipe 5 Approximate 3 to 4 Figure 6 33 Water Cooled Condenser Cleaning Gravity Circulation Table 6 1 AMBS DTS RRS RTS SRS and STS Temperature Resistance Chart Temperature Centigrade Temperature Fahrenheit Resistance Ohms RRS RTS SRS and STS 0 32 32 650 91 25 77 10 000 50 AMBS and DTS 0 32 32 650 1720 1620 25 77 10 000 450 430 Table 6 2 Partlow Bulb Tempe...

Page 127: ...ACTORY MINIMUM MAXIMUM WEAR PART NAME FACTORY MAXIMUM FACTORY MINIMUM MAXIMUM WEAR 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...

Page 128: ...hield 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 16 20 2 21 2 77 Terminal Block Cap Screws 5 16 18 20 30 2 77 4 15 Suction Valve 20 30 2 77 4 15 Discharge Valve Pump End Bearing Head 3 8 16 40 50 5 53 6 92 Bottom Plate Crankcase Compressor Foot 3 8 16 40 50 5 53 6 92 Cylinder Head 7 16 14 55 60 7 61 8 30 Mo...

Page 129: ...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 0...

Page 130: ...guide only for model series 69NT40 511 with fresh air makeup vent closed unit powered on 460 VAC 60hz and SMV 100 open Compressor Discharge Pressure Versus Ambient Air Temperature at Stable Box Temperature 80 100 120 140 160 180 200 220 240 260 280 300 320 60 70 80 90 100 110 120 Ambient Air Temperature psig 48 9 43 3 37 8 32 2 26 7 21 1 15 6 Bar 0_ _ _ _F 17 8_ _ _ _C Box 5 5 6 9 8 3 9 7 11 0 12 ...

Page 131: ...F 1 7_ _ _ _C Box Compressor Suction Pressure Versus Ambient Air Temperature at Stable Box Temperature 8 9 10 11 12 13 14 15 16 17 60 70 80 90 100 110 120 Ambient Air Temperature Compressor Motor Current Versus Ambient Air Temperature At Stable Box Temperature 35_F 1 7_C Box 0_F 17 8_C Box _F 48 9 43 3 37 8 32 2 26 7 21 1 15 6 _C Figure 6 34 R 134a Compressor Pressure and Motor Current Curves Vers...

Page 132: ...SECTION 7 7 1 T 268 07 SECTION 7 ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS 7 1 INTRODUCTION PLEASE REFER TO FILE T 268 DIAGRAMS FOR SCHEMATICS AND DIAGRAMS ...

Page 133: ... 4 2 4 10 4 14 4 15 Compressor Contactor Shorting 2 9 4 14 4 15 5 1 Compressor Crankcase Heater 2 4 2 11 4 2 6 9 Compressor Motor 2 4 Condenser Air Cooled 2 15 2 17 Coil 5 3 6 18 Fan and Motor Assembly 5 3 6 18 Specifications 2 11 Water Cooled 2 17 Condenser Fan Contactor 2 8 2 9 4 10 4 12 4 14 4 15 Condenser Fan Motor 2 5 Condenser Fan Relay 4 3 4 4 4 6 4 8 4 12 Condenser Fan Switch 2 8 2 16 Cond...

Page 134: ...7 Electrical Data 2 11 Electrical Schematic 7 1 Electro Coated Modular Receiver 2 6 2 15 Emergency Bypass Switch 2 8 3 1 Emergency Defrost Fuse 2 8 Emergency Defrost Switch 2 8 Evacuation 6 5 Evaporator 2 15 2 17 Coil 5 1 5 3 6 16 Contactor Fan 2 8 2 9 4 3 4 6 4 8 4 14 4 15 5 2 5 3 Fan and Motor Assembly 5 3 6 16 Fan Motor Capacitors 6 17 Heaters 6 16 Evaporator Coil 2 3 Evaporator Coil Heater Spe...

Page 135: ...ay 4 4 4 6 4 8 4 10 Internal Protector Compressor Motor 2 19 5 1 6 30 Condenser Fan Motor 2 19 5 1 Evaporator Fan Motor 2 19 5 1 5 2 5 3 Power Autotransformer 6 21 Interrogator Connector 2 1 2 8 Interrogator Receptacle 2 3 K Key Pad 3 4 L Low Speed Compressor Relay 4 3 4 12 Low Speed Evaporator Fans Relay 4 12 Lower Fresh Air Makeup Vent 2 13 M Manual Defrost Switch 2 8 Manual Liquid Line Valve 2 ...

Page 136: ... 2 3 Remote Monitoring 2 8 2 9 USDA Probe 2 3 Recording Thermometer Bulb 2 3 Partlow 2 1 4 1 6 18 Saginomiya 2 1 4 1 6 20 Refrigerant Charge 2 10 5 4 Full Charge 6 8 Leak Checking 6 4 Partial Charge 6 8 Refrigeration Charge 2 10 Checking Charge 6 5 Dehydration 6 5 Evacuation 6 5 Full Charge 6 8 Leak Checking 6 4 Partial Charge 6 8 System Data 2 10 Refrigeration Circuit Receiver 2 14 Water Cooled C...

Page 137: ...g Port 3 1 6 28 Start Stop Switch 2 8 Starting Instructions 4 2 Stopping Instructions 4 2 Suction Modulation Valve 2 6 2 7 2 15 2 17 3 6 3 14 3 17 3 21 Suction Pressure Transducer 2 4 Suction Service Valve 2 4 2 15 2 17 Suction Solenoid Override 2 18 Suction Solenoid Valve 2 6 2 7 2 15 2 17 3 6 3 15 3 17 3 21 Suction Solenoid Valve Relay 2 18 6 30 Suction Discharge Pressure Gauges 2 4 Supply Air T...

Page 138: ...17 5 3 Discharge Service 2 4 2 15 2 17 Expansion 2 3 2 10 2 15 2 17 5 3 5 4 6 26 Manual Liquid Line 2 6 2 7 2 15 2 17 Quench Expansion 2 6 2 7 2 15 2 17 3 6 3 21 Schrader 2 6 2 7 Suction and Discharge 5 3 6 4 Suction Modulation 2 6 2 7 2 15 2 17 3 6 3 14 3 17 3 21 4 3 4 6 4 8 4 12 5 1 6 25 Suction Service 2 4 2 15 2 17 Suction Solenoid 2 6 2 7 2 15 2 17 2 18 3 6 3 15 3 17 3 21 4 3 4 12 5 1 6 25 W ...

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Carrier 69NT40-511-1, Operating And Service Manual

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