Page 1 of 125

Models

69NT40-511-200

to

69NT40-511-299

T-294 Rev A

Container

Refrigeration

Unit

Page 2 of 125

Carrier Transicold Division, Carrier Corporation, P.O. Box 4805, Syracuse, N.Y. 13221

OPERATION AND

SERVICE MANUAL

E Carrier Corporation 2000 S Printed in U. S. A. 0200

CONTAINER REFRIGERATION UNIT

MODELS

69NT40-511-200

to

69NT40-511-299

Page 3 of 125

Safety-1 T-294-01

SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this

manual. They are recommended precautions that must be understood and applied during operation and maintenance

of the equipment covered herein. The general safety notices are presented in the following three sections labeled: First

Aid, Operating Precautions and Maintenance Precautions. A listing of the specific warnings and cautions appearing

elsewhere in the manual follows the general safety notices.

FIRST AID

An injury, no matter how slight, should never go unattended. Always obtain first aid ormedical attentionimmediately.

OPERATING PRECAUTIONS

Always wear safety glasses.

Keep hands, clothing and tools clear of the evaporator and condenser fans.

No work should be performed on the unit until all circuit breakers, start-stop switches are turned off, 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, disconnecting and securing the power plug.

Be sure power is turned off before working on motors, controllers, solenoid valves and electrical control switches. Tag

circuit breaker and power supply to prevent accidental energizing of circuit.

Do not bypass any electrical safety devices, e.g. bridging 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 modules in

both control boxes. Do not remove wire harness from the modules unless you are grounded to the unit frame with a

static safe wrist strap.

In case of electrical fire, open circuit switch and extinguish with CO2 (never use water).

Page 4 of 125

T-294-01 Safety-2

SPECIFIC WARNING AND CAUTION STATEMENTS

To help identify the label hazards on the Unit and explain the level of awareness each one carries, an explanation is

given with the appropriate consequences:

DANGER -- means an immediate hazard which WILL result in severe personal injury or death.

WARNING -- means to warn against hazards or unsafe conditions which COULD result in severe personal injury or

death.

CAUTION -- means to warn against potential hazard or unsafe practice which could result in minor personal injury,

product or property damage.

The statements listed below are applicable to the refrigeration unit and appear elsewhere in this manual. These rec- ommended precautions must be understood and applied during operation and maintenance of the equipment covered

herein.

WARNING

When servicing the unit, use caution when handling R-134a. The refrigerant when in contact with

high temperatures (about 1000_F) will decompose into highly corrosive and toxic compounds.

WARNING

Be sure to avoid refrigerant 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.

WARNING

Be sure ventilation in the workspace is adequate to keep the concentration of refrigerant below

1000 parts per million. If necessary, use portable blowers.

WARNING

Beware of rotating fan blades and unannounced starting of fans.

WARNING

Do not use a nitrogen cylinder without a pressure regulator. 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.

WARNING

Never fill a refrigerant cylinder beyond its rated capacity. Cylinder may rupture due to excessive

pressure when exposed to high temperatures.

WARNING

When starting the unit, be sure that all manual refrigerant valves in the discharge line are open.

Severe damage could occur from extremely high refrigerant pressures.

WARNING

When brazing (soldering) refrigeration system, residual oil can cause a fire and potential injury.

Refer to proper procedure before starting repair.

Page 5 of 125

i T-294-01

TABLE OF CONTENTS

Section Page

SAFETY SUMMARY ...................................................... Safety-1

GENERAL SAFETY NOTICES Safety-1 ..............................................

FIRST AID ............................................................... Safety-1

OPERATING PRECAUTIONS Safety-1 ..............................................

MAINTENANCE PRECAUTIONS Safety-1 ...........................................

SPECIFIC WARNING AND CAUTION STATEMENTS Safety-2 .........................

INTRODUCTION 1-1 ..........................................................

1.1 BRIEF UNIT DESCRIPTION 1-1 .........................................

DESCRIPTION ........................................................... 2-1

2.1 GENERAL DESCRIPTION 2-1 ...........................................

2.2 REFRIGERATION SYSTEM DATA 2-8 ....................................

2.3 ELECTRICAL DATA 2-9 ................................................

2.4 POWER AUTOTRANSFORMER (TRANS) 2-10 .............................

2.5 REFRIGERATION CIRCUIT WITH THE WATER-COOLED CONDENSER 2-11 .

2.6 WATER-COOLED CONDENSER 2-11 .....................................

2.6.1 Water--Cooled Condenser with Water Pressure Switch (WP) 2-11 .....

2.6.2 Water-Cooled Condenser with Condenser Fan Switch (CFS) -- Optional 2-11

2.7 UPPER FRESH AIR MAKEUP VENT 2-13 .................................

2.8 LOWER FRESH AIR MAKEUP VENT (Optional) 2-13 ........................

2.9 REMOTE MONITORING (RM) -- Optional 2-14 ..............................

2.10 SAFETY AND PROTECTIVE DEVICES 2-14 ...............................

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 General Layout of the Controller Section 3-4 ..............................

3.1.4 Controller Function Codes 3-6 ...........................................

3.1.5 Controller Alarms 3-10 ...................................................

3.1.6 Condenser Pressure Control (CPC) 3-14 ...................................

3.1.7 Controller Temperature Control 3-14 ...............................

3.1.7.1 Perishable (Chill) Range Above --10_C (+14_F), or

--5_C (+23_F) Optionally. 3-14 ...........................

3.1.7.2 Frozen Range Below --10_C (+14_F), or

--5_C (+23_F) Optionally 3-17 ............................

Page 8 of 125

T-294-01 iv

TABLE OF CONTENTS (CONTINUED)

Section Page

6.16 EVAPORATOR FAN AND MOTOR ASSEMBLY 6-16 ........................

6.17 EVAPORATOR FAN MOTOR CAPACITORS 6-17 ...........................

6.18 CONDENSER COIL 6-18 ................................................

6.19 CONDENSER FAN AND MOTOR ASSEMBLY 6-18 .........................

6.20 MAINTENANCE OF PAINTED SURFACES 6-19 ............................

6.21 POWER AUTOTRANSFORMER (TRANS) -- Optional 6-19 ...................

6.22 TRANSFORMER BRIDGING UNIT (TBU) 6-19 .............................

6.23 SENSOR CHECKOUT PROCEDURE (AMBS, DTS, RRS, RTS, SRS & STS) 6-19

6.23.1 Checking Sensor (RRS, RTS, SRS or STS) 6-19 ....................

6.23.2 Replacing Sensor (STS and SRS) 6-20 ............................

6.23.3 Replacing Sensor (RRS and RTS) 6-21 ............................

6.23.4 Checking Sensor (AMBS or DTS) 6-21 .............................

6.23.5 Replacing Sensor (AMBS or DTS) 6-21 ............................

6.24 STEPPER MOTOR SUCTION MODULATION VALVE (SMV) 6-22 .............

6.25 HERMETIC THERMOSTATIC EXPANSION VALVE 6-24 .....................

6.26 POWER FACTOR CORRECTOR CAPACITORS (PFC) 6-27 ..................

6.27 CONTROLLER/DATACORDER 6-27 ......................................

6.27.1 Controller/DataCORDER Programming Procedure 6-28 ..............

6.27.2 Controller Trouble-Shooting 6-29 ..................................

6.28 WATER-COOLED CONDENSER 6-30 .....................................

ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS 7-1 ........................

7.1 INTRODUCTION 7-1 ...................................................

INDEX ................................................................... INDEX-1

LIST OF ILLUSTRATIONS

Figure Page

Figure 2-1 Refrigeration Unit -- Front Section 2-1 ................................

Figure 2-2 Evaporator Section 2-3 .............................................

Figure 2-3 Compressor Section 2-4 ............................................

Figure 2-4 Condenser Section 2-5 .............................................

Figure 2-5 Water-Cooled Condenser Section 2-6 ................................

Figure 2-6 Control Box Section 2-7 ............................................

Figure 2-7 Power Autotransformer 2-10 .........................................

Figure 2-8 Refrigeration Circuit with Water-Cooled Condenser 2-12 .................

Page 10 of 125

T-294-01 vi

LIST OF ILLUSTRATIONS (CONTINUED)

Figure Page

Figure 6-26 Stepper Motor Suction Modulation Valve (SMV) 6-22 ....................

Figure 6-27 Jumper Assembly 6-24 ..............................................

Figure 6-28 Hermetic Thermostatic Expansion Valve Bulb 6-25 ......................

Figure 6-29 Hermetic Thermostatic Expansion Valve 6-25 ..........................

Figure 6-30 Hermetic Thermostatic Expansion Valve Brazing Procedure 6-26 .........

Figure 6-31 Controller side of the Control Box 6-28 ................................

Figure 6-32 Water-Cooled Condenser Cleaning -- Forced Circulation 6-31 ............

Figure 6-33 Water-Cooled Condenser Cleaning -- Gravity Circulation 6-31 ............

Figure 6-34 R-134a Compressor Pressure Versus Ambient Temperature 6-36 .........

Figure 7-1 Electrical Schematic 7-2 ............................................

Figure 7-2 Electrical Wiring Diagram 7-4 .......................................

LIST OF TABLES

Table Page

Table 1-1 Model Chart 1-2 ...................................................

Table 2-1 Safety and Protective Devices 2-14 ...................................

Table 3-1 Controller Configuration Variables 3-3 ................................

Table 3-2 Key Pad Function 3-4 ..............................................

Table 3-3 Controller Function Code Assignments 3-6 ...........................

Table 3-4 Controller Alarm Indications 3-11 .....................................

Table 3-5 Pre-Trip Test Codes 3-19 ............................................

Table 3-6 DataCORDER Function Code Assignments 3-25 .......................

Table 3-7 DataCORDER Alarm Indications 3-27 .................................

Table 3-8 DataCORDER Alarm Configurations 3-28 ..............................

Table 3-9 DataCorder Standard Configuration 3-29 ..............................

Table 3-10 DataCORDER Pre-Trip Data 3-32 ....................................

Table 4-1 Electrical Control Positions -- BELOW --10_C (+14_F), or

--5_C (+23_F) optionally 4-10 .........................................

Table 4-2 Electrical Control Positions -- ABOVE --10_C (+14_F), or

--5_C (+23_F) optionally 4-11 .........................................

Table 6-1 Tools Required 6-32 ................................................

Table 6-2 AMBS, DTS, RRS, RTS, SRS and STS Temperature-Resistance Chart 6-32

Table 6-3 Recommended Bolt Torque Values 6-32 ...............................

Table 6-4 Wear Limits For Compressors 6-33 ...................................

Table 6-5 Compressor Torque Values 6-34 ......................................

Table 6-6 Temperature-Pressure Chart -- R-134a 6-35 ............................

Page 11 of 125

1-1 T-294-01

SECTION 1

INTRODUCTION

1.1 BRIEF UNIT DESCRIPTION

WARNING

It has been determined that pressurized,

air-rich mixtures of refrigerants and air can

undergo combustion when exposed to an

ignition source.

This manual contains Operating Data, Electrical Data

and Service Instructions for the refrigeration unit listed

in Table 1-1.

NOTE

Beginning with early 1995 production, in

addition to a model number, Carrier Transicold

began using a parts identification (PID) number

in the format NT0000. In the parts manual, the

PID number is shown in boldface to point out

parts variations within models. The PID

number must be included when ordering and

inquiring about your unit.

The unit, of lightweight aluminum frame construction,

is an all electric, one piece, self-contained cooling and

heating refrigeration unit (see Figure 2-1). The unit is

designed to fit in the front of a container and to serve as

the container front wall. Forklift pockets are provided

for installation and removal of the unit.

The unit is complete with a charge of R-134a,

compressor lubricating oil (approved POE SW20

compressor oil for R-134a only), mode indicating

lights, and temperature controller, and is ready for

operation upon installation.

Some units are dual voltage units designed to operate on

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 2-7 and section

2.4).

Operating control power is provided by a control

transformer which steps down the AC supply power

source to 18 and 24 volts AC, single phase control

power.

The temperature Controller/DataCORDER

(Micro-Link 2i) is a microprocessor-based controller

and an integrated electronic data logging device. Refer

to sections 3.1 and 3.3. Once the temperature controller

is set at a desired container temperature, the unit will

operate automatically to maintain the desired

temperature within very close limits. The control

system automatically selects cooling, holding or

heating as necessary to maintain the desired

temperature within the container.

WARNING

Beware of unannounced starting of the

evaporator and condenser fans. Do not open

the condenser fan grille before turning

power OFF and disconnecting power plug.

Some units may have a TransFRESH controlled

atmosphere system added. Contact TransFRESH

Corporation, P.O. Box 1788, Salinas, CA 93902 for

information on their system.

Page 12 of 125

T-294-01 1-2

Table 1-1. Model Chart

MODEL PID A Cold

tment

sformer

r-Cooled

enser

Condenser

Coil

Discharge

Option

idification

nsFresh

nications

e Module

re Recorder

Factor

or (PFC)

Option

etic Unit

e

MODEL PID

Control Box

Schematic & Diagra

USDA

Treatm

Trans

Water- Conde

3 Row

4 Row

Suction &

D

Pressure

O

Dehumid

Trans

Communi

Interface

Temperature

Power Fa

Corrector

Arctic

O

Hermet

Composite

g

69NT40 511 201

NT0448 P X X -- X -- P -- X -- X -- X -- 77-01698-38

69NT40-511-201

NT0569 P X X X -- -- P -- X -- X -- X X 77-01698-60

69NT40-511-201 NT0602 P X X X -- -- P X X -- X -- X X 77-01698-60

A = Factory Installed Pressure Gauges

B = Factory Installed Pressure Transducers

P = Provision

X = Features that apply to model

-- = Features that are not applicable to model

Page 13 of 125

2-1 T-294-01

SECTION 2

DESCRIPTION

2.1 GENERAL DESCRIPTION

a. Refrigeration Unit -- Front Section

The front section of the refrigeration unit shows access

to most parts of the unit (i.e., compressor, condenser,

receiver, etc.), which will be discussed in more detail of

the following sections in 2.1. The upper access panels

allow front entry into the evaporator section, and the

center access panel allows access to the evaporator coil

heaters. The unit model number, serial number and

parts identification number will be found on the front of

the unit to the left of the compressor.

1

2

3

4

5

6

7

1. Access Panel (For Evap. Fan Motor #1)

2. Access Panel (For Heater)

3. Fork Lift Pockets

4. Unit Serial Number, Model Number and

Parts Identification Number (PID) Plate

5. Interrogator Connector (IC)

6. Lower Fresh Air Makeup Vent or Blank Plate --

Optional

7. Upper Fresh Air Makeup Vent and

Access Panel (For Evap. Fan Motor #2)

Figure 2-1. Refrigeration Unit -- Front Section

Page 14 of 125

T-294-01 2-2

b. Evaporator Section

The evaporator section (see Figure 2-2) contains the

return temperature sensor (RTS), hermetic thermostatic

expansion valve, dual-speed evaporator fan motors

(EM1 and EM2) and fans (2), evaporator coil and heater

(HR), drain pan heater (DPH), defrost heaters (DHBL,

DHBR, DHTK and DHTR), defrost termination sensor

(DTS), heat termination thermostat (HTT), interrogator

and USDA receptacles, and heat exchanger.

The evaporator fans circulate air throughout the

container by pulling air in the top of the refrigeration

unit, directing the air through the evaporator coil 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 is located on the coil center tube sheet and may

be serviced by removing the upper rear panel, or by

removing the left front upper access panel,

disconnecting the evaporator fan connector and

reaching through the access panel opening.

WARNING

Before servicing unit, make sure the unit

circuit breakers (CB-1, and an optional

CB-2 -- if equipped), and the start-stop

switch (ST) are in the OFF position. Also

disconnect power plug and cable.

Page 15 of 125

2-3 T-294-01

12

1

2

3

5

7

8

9

13

10

11

6

(RTS)

(RRS)

14

15

16

17

18

4

1. Evaporator Fan Motor #1 (EM1)

2. Humidity Sensor (HS) -- Optional

3. Return Temperature Sensor (RTS)

4. Return Recorder Sensor (RRS) -- Optional

5. Evaporator Fan Motor #2 (EM2)

6. Power Factor Corrector (PFC)

7. Defrost Termination Sensor (DTS)

8. Heat Termination Thermostat (HTT)

9. Evaporator Coil

10. Evaporator Coil Heaters

11. Hermetic Thermostatic Expansion Valve

12. Drain Pan Heater (DPH)

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

Figure 2-2. Evaporator Section

Page 16 of 125

T-294-01 2-4

c. Compressor Section

The compressor section includes the compressor (with

high pressure switch), power cable storage

compartment, and autotransformer (TRANS), which is

located to the left of the compressor.

This section also contains the stepper motor suction

modulation valve (SMV), quench expansion valve,

stepper motor drive (SD), and the discharge pressure

regulator valve.

The supply temperature sensor (STS), and ambient

sensor (AMBS) are located at the right side of the

compressor, and the suction line process tube.

1

2

3

4

5

6

7

11

10

14

9

13

15

12

16

8

1. Power Autotransformer (TRANS)

2. Power Cables and Plug

3. Compressor Sight Glass View Port

4. Compressor Guard

5. Supply Temperature Sensor (STS)

6. Ambient Sensor (AMBS)

7. Discharge Pressure Regulator Valve

8. Suction Line Process Tube

9. Quench Expansion Valve

10. Stepper Motor Suction Modulation Valve (SMV)

11. Stepper Motor Drive (SD)

12. Suction Flange

13. Compressor Sight Glass

14. Compressor Motor (CP)

15. Discharge Flange

16. High Pressure Switch (HPS)

Figure 2-3. Compressor Section

Page 17 of 125

2-5 T-294-01

d. Condenser Section

The condensing section consists of a condenser fan

motor (CM), a condenser fan and an air-cooled

condenser coil. When 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 Mounting Bracket

Figure 2-4. Condenser Section

Page 18 of 125

T-294-01 2-6

e. Water-Cooled Condenser Section

The water-cooled condenser section consists of

water-cooled condenser, sight glass, and rupture disc,

condenser pressure transducer (CPT), filter-drier, water

hook-up couplings, water pressure switch (WP), and the

liquid line process tube

8 7

1 23 4

9 6 5

1. Water-Cooled Condenser

2. Rupture Disc

3. Condenser Pressure Transducer (CPT)

4. Filter-Drier

5. Moisture Liquid Indicator/Sight Glass

6. Coupling (Water In)

7. Self Draining Coupling (Water Out)

8. Liquid Line Process Tube

9. Water Pressure Switch (WP)

Figure 2-5. Water-Cooled Condenser Section

Page 19 of 125

2-7 T-294-01

f. Control Box Section

The control box (see Figure 2-6) includes the manual

switches (ST and MDS), circuit breaker (CB-1),

contactors (CF, CH, EF, ES and HR), hour meter (HM),

transformer (TR), fuses (F), key pad (KP), display

module, current sensor module (CS),

Controller/DataCORDER module, and an optional

remote monitoring unit (CI).

2

16 10 15 13 11 14 12

1 3 45 6 7

9 8

1. Compressor Contactor (CH)

2. Hour Meter (HM)

3. Heater Contactor (HR)

4. Display Module

5. Remote Monitoring Unit (CI) -- Optional

6. Controller/DataCORDER Module

7. Key Pad

8. Start-Stop Switch (ST)

9. Manual Defrost Switch (MDS)

10. Controller/DataCORDER Battery Pack -- Optional

11. Control Transformer (TR)

12. Evaporator Fan Contactor (EF) High Speed

13. Evaporator Fan Contactor (ES) Low Speed

14. Condenser Fan Contactor (CF)

15. Circuit Breaker (CB-1) -- 460V

16. Current Sensor Module (CS)

Figure 2-6. Control Box Section

Page 20 of 125

T-294-01 2-8

2.2 REFRIGERATION SYSTEM DATA

Number of Cylinders 6

Model 06DR

CFM 41

a Compressor/Motor Assembly Weight (Dry) 118 kg (260 lb) a. Compressor/Motor Assembly

(CP) Approved Oil Castrol Icematic -- SW20 )

Oil Charge 3.6 liters (7.6 U.S. pints)

Oil Sight Glass

The oil level range, with the compressor off,

should be between the bottom and one-eighth

level of the capacity of the sight glass.

b. Expansion Valve Superheat

Verify at --18 _C

(0_F) container box

temperature

4.48 to 6.67 _C (8 to 12 _F)

c. Heater Termination Thermostat c. Heater Termination Thermostat Opens 54 (¦ 3) _C = 130 (¦ 5) _F

(HTT) Closes 38 (¦ 4) _C = 100 (¦ 7) _F

d High Pressure Switch (HPS) Cutout 25 (¦ 1.0) kg/cm@ = 350 (¦ 10) psig d. High Pressure Switch (HPS) Cut-In 18 (¦ 0.7) kg/cm@ = 250 (¦ 10) psig

Charge Requirements -- R-134a

e. Refrigerant Charge

Unit Configuration 2* row

condenser

3* row

condenser

4* row

e. Refrigerant Charge condenser

Water-Cooled

Condenser

4.5 kg

(9.0 lbs)

4.88 kg

(10.75 lbs)

5.22 kg

(11.5 lbs)

* Refer to Table 1-1.

NOTE

When replacing components (f.) in section 2.2, refer to the installation instructions included with the

ordered new part for additional information.

Bursts at 35 ¦ 5% kg/cm@ = (500 ¦ 5% psig)

f. Rupture Disc

Torque

(P/N 14-00215-03) 1.4 to 2 mkg (10 to 15 ft-lbs) f. Rupture Disc

Torque

(P/N 14-00215-04) 6.2 to 6.9 mkg (45 to 50 ft-lbs)

g. Condenser Pressure

Condenser Fan Starts

The condenser fan will start if the condenser

pressure is greater than 14.06 kg/cm@ (200

psig) OR the condenser fan is OFF for more

g than 60 seconds. . Condenser Pressure

Transducer (CPT)

Condenser Fan Stops

The condenser fan will stop if the condenser

pressure is less than 9.14 kg/cm@ (130 psig)

AND the condenser fan remains ON for at least

30 seconds.

h. Unit Weight Refer to unit model number plate, see Figure 2-1 for location of plate.

i Water Pressure Switch (WP) Cut-In 0.5 ¦ 0.2 kg/cm@ (7 ¦ 3 psig) i. Water Pressure Switch (WP) Cutout 1.6 ¦ 0.4 kg/cm@ (22 ¦ 5 psig)

Page 22 of 125

T-294-01 2-10

Orange wire Power

Red wire Output

Brown wire Ground

Input voltage 5 vdc

i. Humidit i. Humidity Sensor Output voltage 0 to 3.3 vdc

(HS) -- Optional ( ) p Output voltage readings verses relative humidity (RH) percentage:

30% 0.99 V

50% 1.65 V

70% 2.31 V

90% 2.97 V

2.4 POWER AUTOTRANSFORMER (TRANS)

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.

a. Step-Up Power Autotransformer

The modular transformer (if equipped) is located under

the condenser coil on the left-hand side of the unit (see

Figure 2-7).

The modular transformer (item 1, Figure 2-7) provides

380/460 vac, 3-phase, 50/60 hertz power to the unit

when the 230 vac (black) power cable is connected to a

190/230 vac, 3-phase power source. The module, in

addition to the transformer, includes a 230 vac cable and

a receptacle to accept the unit 460 vac power plug. The

modular transformer may be equipped with an optional

circuit breaker (CB-2).

WARNING

Do not attempt to unplug the power cable

connected to the autotransformer before

performing 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 into the

receptacle on the modular transformer and circuit

breaker (CB-1, in the control box) is in position “1”

(ON).

2. Plug the 230 vac (black) cable into a de-energized

190/230 vac, 3-phase power source. Energize the

power source. Set circuit breaker (CB-2 if

equipped) to position “1” (ON). Close and secure

control box door and place the start-stop switch

(ST) in position “1” (ON) to start the unit.

c. To Operate Unit on 380/460 vac Power Supply

1. Make sure start-stop switch (ST, on control panel)

and circuit breaker (CB-1, in the control box) are in

position “0” (OFF).

2. Plug the 460 vac (yellow) cable into a de-energized

380/460 vac, 3-phase power source. Energize the

power source. Place circuit breaker (CB-1) in

position “1” (ON). Close and secure control box

door and then place the start-stop switch (ST) in

position “1” (ON) to start the unit.

1

2

3

4

1. Dual Voltage Modular Transformer

2. Circuit Breaker (CB-2) 230V (Optional)

3. Transformer Bridging Unit (TBU)

4. 460 vac Power Receptacle

Figure 2-7. Power Autotransformer

Page 23 of 125

2-11 T-294-01

2.5 REFRIGERATION CIRCUIT WITH THE

WATER-COOLED CONDENSER

Starting at the compressor, the suction gas is

compressed to a higher temperature and pressure.

When operating with the water-cooled condenser, the

gas flows through the discharge line into the pressure

regulator valve that is normally open. The pressure

regulator valve may restrict the flow of refrigerant to

maintain a minimum discharge pressure of 5 kg/cm2 (70

psig).

Refrigerant gas then moves through the air-cooled coil

to the water-cooled condenser. As the refrigerant flows

across the water chilled coiled tube bundle, it is cooled

to saturation temperature and exits the condenser as a

high pressure/saturated liquid.

From the water-cooled condenser, the liquid refrigerant

continues through the filter-drier (which keeps

refrigerant clean and dry), and a heat exchanger that

increases subcooling of liquid refrigerant to the

thermostatic expansion valve. As the liquid refrigerant

passes through the orifice of the hermetic expansion

valve, some of it vaporizes into a gas (flash gas). Heat is

absorbed from the return air by the balance of the liquid,

causing it to vaporize in the evaporator coil. The vapor

then flows through the stepper motor suction

modulation valve to the compressor.

The hermetic thermostatic expansion valve bulb (on the

suction line near the evaporator coil outlet) controls the

expansion valve, maintaining a constant superheat at

the coil outlet regardless of load conditions.

2.6 WATER-COOLED CONDENSER

The water-cooled condenser is used when cooling water

is available and heating the surrounding air is

objectionable, such as in a ship’s hold.

The water-cooled condenser is of the shell and coil type,

with water circulating through the cupro-nickel coil.

The refrigerant vapor is admitted to the shell side and is

condensed on the outer surface of the coil.

2.6.1 Water--Cooled Condenser with Water

Pressure Switch (WP)

For operation of the refrigeration unit with the

water-cooled condenser, perform the following:

a. Connect the water supply line to the inlet side of

condenser and the discharge line to the outlet side of

the condenser.

b. Maintain a flow rate of 11 to 26 liters per minute (3

to 7 gallons per minute). The water pressure switch

will open to de-energize the condenser fan relay,

unless overridden by the out-of-range lockout

feature (if so equipped). The condenser fan motor

will stop and will remain stopped until the water

pressure switch closes, or it is overridden by the

out-of-range lockout feature (if so equipped).

The refrigeration unit operating with the water-cooled

condenser will perform as outlined in section 4.4 except

that the condenser fan motor may be stopped in all

modes.

To shift to air-cooled condenser operation, perform the

following:

Disconnect the water supply and the discharge line to

the water-cooled condenser. The refrigeration unit will

shift to air-cooled condenser operation when the water

pressure switch closes. (Refer to section 2.2.)

2.6.2 Water-Cooled Condenser with Condenser

Fan Switch (CFS) -- Optional

For operation of the refrigeration unit with the

water-cooled condenser with (CFS), perform the

following:

a. Connect the water supply line to the inlet side of

condenser and the discharge line to the outlet side of

the condenser.

b. Maintain a flow rate of 11 to 26 lpm (3 to 7 gpm).

c. Set CFS switch to position ”O” when water is

supplied to the water-cooled condenser. This will

de-energize the condenser fan relay. The condenser

fan motor will stop and will remain stopped until

the CFS switch is set to position ”1.”

The refrigeration unit operating with the water-cooled

condenser and the CFS switch in position ”O,” will

perform as outlined in section 4.4 except that the

condenser fan motor is stopped in all modes.

WARNING

When water flow is below 11 lpm (3 gpm) or

when water-cooled operation is not in use,

the CFS switch MUST be set to position ”1”

or the unit will not operate properly.

To shift to air-cooled condenser operation, perform the

following:

Turn the unit OFF and set the CFS switch to position

”1.” Disconnect the water supply and the discharge line

to the water-cooled condenser. The unit should now

perform as outlined in section 4.4.

Page 24 of 125

T-294-01 2-12

15

14

9

2

3

4

5

6

7

8

12

13

11 1

10

1. High Pressure Switch

2. Discharge Pressure Regulator Valve

3. Air-Cooled Condenser

4. Evaporator

5. Hermetic Thermostatic Expansion Valve

6. External Equalizer Line

7. Hermetic Thermostatic Expansion Valve Bulb

8. Heat Exchanger

9. Rupture Disc

10. Moisture-Liquid Indicator

11. Condenser Pressure Transducer (CPT)

12. Filter-Drier

13. Water-Cooled Condenser

14. Stepper Motor Suction Modulation Valve (SMV)

15. Quench Expansion Valve

Figure 2-8. Refrigeration Circuit with Water-Cooled Condenser

Page 25 of 125

2-13 T-294-01

2.7 UPPER FRESH AIR MAKEUP VENT

The purpose of the upper 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 differential,

which will vary depending on the container and how the

container is loaded. The chart below gives air exchange

values for an empty container. Higher values can be

expected for a fully loaded container.

0

25

50

75

100

125

150

175

200

225

0 10 20 30 40 50 60 70 80 90 100

AIR

FLOW

(CMH)

2-3/8 ”

PERCENT OPEN

T-BAR

ZERO EXTERNAL STATIC PRESSURE,

50HZ POWER

For 60HZ operation multiply air flow values from curve by 1.2

a. Full Open or Closed Positions

Maximum air flow is achieved by loosening the wing

nut and rotating the disc to the maximum open position

(100% open). The closed position is 0% air flow.

Two slots and a stop are designed into the disc for air

flow adjustments. The first slot allows for a 0 to 30% air

flow, and the second slot allows for a 30 to 100% air

flow. To increase the percentage of air flow, the wing

nut must be loosened, and the disc rotated until the

desired percentage of air flow matches withthe arrow on

the disc. Tighten the wing nut. To clear the gap between

the slots, loosen the wing nut until the disc clears the

stop, and rotate the disc for the second slot.

The operator may also increase or decrease the air flow

volume to meet the required 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).

2.8 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 differential,

which will vary depending on the container and how the

container is loaded. The chart across gives air exchange

values for an empty container. Higher values can be

expected for a fully loaded container.

a. Full Open or Closed Positions

The air slide is supplied with two adjustable air control

discs. The fresh air makeup can be adjusted for 15, 35,

50 and 75 cubic meters per hour (CFM). The air flow has

been established at 60 Hz power, and a 2 1/2 inch T bar,

with 15 mm (0.6 inch) H2O external static above free

blow.

Maximum air flow is achieved by loosening the hex

nuts and rotating each disc to the maximum open

position (100% open). The closed position is 0% air

flow.

The operator may also adjust the openings to increase or

decrease the air flow volume to meet the required air

flow.

NOTE

The main air slide is in the fully closed position

during reduced air flow operation.

a. Air Sampling for Carbon Dioxide (CO2) Level

Loosen hex nuts and move the cover until the arrow on

the cover is aligned with the “atmosphere sampling

port” label. Tighten the hex nuts and attach a 3/8 hose to

the sampling port.

If the internal atmosphere content has reached an

unacceptable level, the operator may adjust the disc

opening to meet the required air flow volume to

ventilate the container.

Page 26 of 125

T-294-01 2-14

2.9 REMOTE MONITORING (RM) -- Optional

NOTE

The in-range light will be illuminated if the

container control air temperature is within the

tolerance selected. Refer to section 3.1.4 (Code

30).

When the remote monitor plug is connected to the

remote monitoring receptacle, the following remote

circuits are energized:

CIRCUIT FUNCTION

Sockets B to A Energizes remote cool light

Sockets C to A Energizes remote defrost light

Sockets D to A Energizes remote in-range light

2.10 SAFETY AND PROTECTIVE DEVICES

Unit components are protected from damage by safety

and protective devices listed in Table 2-1. These

devices monitor the unit operating conditions and open

a set of electrical contacts when an unsafe condition

occurs.

Open safety switch contacts on either or both of devices

IP-CP or HPS will shut down the compressor.

Open safety switch contacts on device IP-CM will shut

down the condenser fan motor.

The entire refrigeration unit will shut down if one of the

following safety devices open: (a) Circuit Breaker(s);

(b) Fuse (F3/10A); or (c) Evaporator Fan Motor Internal

Protector(s) -- (IP-EM).

Table 2-1. Safety and Protective Devices

UNSAFE CONDITION SAFETY DEVICE DEVICE SETTING

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) 10 amp rating

Excessive current draw by the

Controller/DataCORDER Fuse (F1 & F2) 5 amp rating

Excessive condenser fan

motor winding temperature Internal Protector (IP-CM) -- Automatic Reset N/A

Excessive compressor motor

winding temperature Internal Protector (IP-CP) -- Automatic Reset N/A

Excessive evaporator fan

motor(s) winding temperature Internal Protector(s) (IP-EM) -- Automatic Reset N/A

Abnormal

pressures/temperatures in the

high refrigerant side

Rupture Disc -- Used on the Water-Cooled

Condenser

35 kg/cm@ = (500 psig)

Abnormally high discharge

pressure High Pressure Switch (HPS) Opens at 25 kg/cm@

(350 psig)

Page 27 of 125

3-1 T-294-01

SECTION 3

MICROPROCESSOR

3.1 MICRO-LINK 2i CONTROLLER MODULE

1 2 33 3 3 3 4 5 67 8

1. Mounting Screw

2. Micro-Link 2i

Controller/DataCORDER Module

3. Connectors

4. Test Points (TP)

5. Fuses (F)

6. Control Circuit Power Connection

(Location: In back of connector)

7. Battery Pack (Optional)

8. Software Programming Port

Figure 3-1. Micro-Link 2i Controller/DataCORDER Module

3.1.1 Brief Description

WARNING

Do not attempt to service the

Controller/DataCORDER module.

Breaking the warranty seal will void the

warranty.

CAUTION

Remove the Controller/DataCORDER

module and unplug all wire harness

connectors before performing any arc

welding on any part of the container.

Do not remove 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 to ensure continuous conditioned air

delivery to the load.

b. Provide dual independent readouts of set point and

supply or return air temperatures.

c. Provide digital readout and ability to select data.

Refer to Table 3-3 for Controller Function Codes.

For Controller alarm digital display identification

refer to Table 3-4.

d. Provide a pre-trip step-by-step checkout of

refrigeration unit performance including: proper

component operation, electronic and refrigeration

control operation, heater operation, probe

calibration, pressure limiting and current limiting.

Refer to section 3.2.

e. Provide the ability to select or change Codes 27 to

37 and set point without AC power being hooked

up. Refer to section 3.1.4.

f. Provide reprogrammability and configuration

through a memory card. The memory card

automatically downloads new software to the

Controller when inserted, and controls output to the

display for status information.

g. Provide electronic data storage.

NOTE

For the benefit of the reader the remaining parts

of section 3.1 will devote themselves to the

temperature controller portion of the module.

For the integrated DataCORDER refer to

section 3.3.

Page 28 of 125

T-294-01 3-2

3.1.2 Controller Programming (Memory) Cards

The programming cards are used for loading software

into the Controller. This is the same concept as using a

floppy diskette to load software into a personal

computer.

The software that can be loaded into the Controller

module comes in one of two forms: “Operational

Software” or “Configuration Software.”

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 either Operational Software or

Configuration Software are available through CTD

Replacement Components Group.

The use of a configuration program card in the field

should only occur under unusual circumstances. Some

of these circumstances may include:

a. A Controller module that has an older version of

Operational Software, when the need exists to

upgrade to a newer version of the software.

b. A physical component in the container unit is

changed to a different component, resulting in a

new configuration for the unit.

c. A Controller module was damaged in such a way

that the integrity or existence of software within the

module is questionable.

Page 30 of 125

T-294-01 3-4

3.1.3 General Layout of the Controller Section

The Micro-Link 2i Controller/DataCORDER consists

of a key pad, display module and Controller module.

Connectors are used to attach the wiring of the unit to

the Controller module. The Controller module is

designed to permit ease of installation and removal.

All control functions are accessed by key pad selections

and viewed on the display module which are designed

for optimum user friendliness and convenience.

The key pad (see Figure 3-2) is mounted on the

right-hand side of the control box. The key pad consists

of eleven push-energized membrane switches that act as

the user’s interface with the Controller and the optional

DataCORDER. Refer to Table 3-2.

ENTER

BATTERY

POWER

DEFROST

INTERVAL

CODE

SELECT

PRE

TRIP

ALARM

LIST

ALT.

MODE

RETURN

SUPPLY

_C

_F

Figure 3-2. Key Pad

Table 3-2. Key Pad Function

KEY FUNCTION

Arrow Up

Change set point upward. Change

codes upward. Scan alarm list upward.

Change user selectable features

upward. Pre-trip advance forward.

Pre-trip test interruption. DataCORDER

Function and Alarm Codes are scrolled

upward after the ALT. MODE key is

depressed.

Arrow Down

Change set point downward. 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/

Supply

Displays non-controlling probe

temperature (momentary display).

_C/_F Displays alternate temperature scale

(momentary display).

Alarm List

Displays alarm list and clearing of the

alarm queue (when followed by Enter

key) for the Controller, and also for the

DataCORDER after the ALT. MODE

key is depressed.

Code Select

Access function codes (see arrow up

and arrow down) for the Controller,

and also for the DataCORDER after

the ALT. MODE key is depressed.

Defrost

Interval

Displays selected defrost interval.

Pre–Trip Displays a pre-trip selection menu.

Discontinues pre-trip in progress.

Battery

Power

If the unit is equipped with the optional

battery pack, initiate the battery

backup mode to allow set point and

function code selection if no mains

power is present.

Enter

Entering a set point change.

Extending to 30 seconds the time a

chosen data function code is

displayed. Entering the value of a user

selectable mode. Clearing the alarm

list and initiating pre-trip. Also used for

various DataCORDER functions after

the ALT. MODE key is depressed.

ALT. Mode

Allows access to DataCORDER

function codes, alarm codes,

DataCORDER configuration and

scrollback.

Page 32 of 125

T-294-01 3-6

3.1.4 Controller Function Codes

There are thirty-nine functions which the operator may

access to examine the operating status of the unit. To

access these functions, perform the following steps:

Press the CODE SELECT key, then press an arrow key

until the left window displays the desired code number

(see Table 3-3). For the display only function codes, the

right window will display the value of this item for five

seconds before returning to the normal display mode. If

a longer time is desired, pressing the ENTER key will

extend the time to 30 seconds after the last pressing of

the ENTER key. Function codes are explained in

Table 3-3.

Table 3-3. Controller Function Code Assignments

Code

No. TITLE DESCRIPTION

Inapplicable Functions Display -- -- -- -- --

Display Only Functions

Cd01 Modulation Valve

Opening (%)

The valve is completely open (right display reads 100%) and is completely closed

(right display reads 0%). The stepper motor SMV, on start up of the unit, usually

will be at a 21% open position, except for very high ambients.

Cd02 Quench Valve

(Open--Closed) Shows state of the solenoid quench valve, if so equipped (open or closed).

Cd03 Not Applicable This code is not in use starting with model number 69NT40-511-200 and UP.

Cd04

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 current draws are used to determine control unit operations.

Whenever a heater or a motor is turned ON or OFF, the current draw

increase/reduction for that activity is measured. The current draw is then tested to

determine if it falls within the expected range of values for the unit. Failure of this

test will result in a pre-trip failure or a control alarm indication.

Cd07 Main Power Voltage The main supply voltage is displayed.

Cd08 Mains Power

Frequency

The value of the main power frequency is displayed in Hertz. The frequency

displayed will be halved if either fuse F1 or F2 is bad and alarm code AL21 is

active.

Cd09 Ambient

Temperature The ambient sensor (AMBS) measures the temperature outside the container.

Cd10

Compressor Suction

Temperature

(Optional)

Compressor suction temperature is measured just prior to the compressor suction

line, and is a display-only temperature.

Cd11

Compressor

Discharge

Temperature

(Optional)

The compressor discharge temperature is measured near the compressor

discharge line and is display only.

Cd12 Compressor Suction

Pressure (Optional)

Compressor suction pressure is displayed using a pressure transducer. Pressure

is displayed in units of psig when code 28 is set to _F and units of bars when

code 28 is set to _C. “P” appears after the value to indicate psig, “b” appears

after the value to indicate bars and “i” appears after the value for inches of

mercury.

Cd13 Condenser Pressure

(CPC)

Condenser pressure is displayed using a pressure transducer. Pressure is

displayed in units of psig when code 28 is set to _F and units of bars when

function code Cd28 is set to _C. “P” is displayed after the value to indicate psig,

“b” appears after the value to indicate bars and “i” appears after the value for

inches of mercury.

Page 36 of 125

T-294-01 3-10

Code

No. TITLE DESCRIPTION

Inapplicable Functions Display -- -- -- -- --

Cd39

Secondary Return

Air Temperature

(Optional)

This code is only applicable to units without a DataCORDER, that are configured

to have four probes. If this is true, it will then display the current secondary return

air temperature.If the unit is configured with a DataCORDER, the Controller

function code Cd39 will display “-- -- -- -- --,” and the display values for RRS will

appear on the DataCORDER function code dC2.

3.1.5 Controller Alarms

The alarm philosophy balances the protection of the

refrigeration unit and that of the refrigerated cargo. The

action taken when an error is detected always considers

the survival of the cargo. Rechecks are made to confirm

that an error actually exists.

Some alarms requiring compressor shutdown have time

delays before and after to try to keep the compressor on

line. An example (see Table 3-4) is a low mains voltage,

when the voltage drops over 25%, an indication is given

on the display, but the unit will continue to run.

An alarm is indicated by flashing an alarm code on the

display panel, and for some alarms, by the alarm light

illuminating.

When an Alarm Occurs:

S The red alarm light will illuminate for “20

series” alarms only.

S If a detectable problem is found to exist, its

alarm code will be alternately displayed with

the set point on the left display.

S The user should scroll through the alarm list

to determine what alarms 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 through the list by depressing the UP

ARROW key. Depressing the DOWN ARROW key

allows the user to scroll backward through the list.

The left display will show “AL#,” where # is the alarm

number sequentially in the queue.

The right display will show:

S “AAXX” for an active alarm, where “XX” is

the alarm code. See Table 3-4, Controller

Alarm Indications.

S “IAXX” for an inactive alarm.

“END” is displayed to indicate the end of the alarm list

if any alarms are active. “CLEAr” is displayed if all

alarms are inactive.

S The alarm queue may only be cleared if no

alarms are active, other than alarm code

AL51, and “CLEAr” is displayed.

To Clear the Alarm List:

If all above conditions have been satisfied, e.g. no

alarms are active other than AL51, the alarm queue may

be cleared.

S Press the ENTER key. The alarm list will

clear and “-- -- -- -- --” will be displayed.

Page 43 of 125

3-17 T-294-01

3.1.7.2 Frozen Range Below --10_C (+14_F), or

--5_C (+23_F) Optionally

For set points below --10_C (+14_F), or --5_C (+23_F)

optionally, the Controller maintains RETURN air at the

set point temperature using the following modes of

operation:

a. Operation in the conventional mode

(Code 33 OFF)

The return air probe is used for control and is so

indicated by the LED on the display board.

The Frozen temperature range is not sensitive to minor

temperature changes. The method of temperature

control employed in this range takes advantage of this

fact to greatly improve the energy efficiency of the unit.

Temperature control in the Frozen range at or below

--10_C (+14_F), or --5_C (+23_F) optionally, is

accomplished by cycling the compressor on and off as

the load demand requires.

If the return air temperature in the container drops 0.2_C

(0.4_F) below the set point temperature, the compressor

is cycled off. When the temperature is greater than

0.2_C (0.4_F) above the set point and the three minute

time delay has been met, the compressor will restart.

The unit will always operate at full capacity, and the

stepper motor suction modulation valve (SMV) will

open to 100%, or as allowed by current and pressure

limiting.

NOTE

On start up of the unit, SMV will reset to a

known open position. This is accomplished by

assuming the valve was fully open, driving it

fully closed, resetting the percentage open to

zero, then opening to a known 21% staging

position. This makes the unit ready to start and

normal operation will begin.

To prevent on/off cycling of the compressor from

occurring, a three minute compressor off time must be

satisfied before the compressor will restart. Under a

condition of rapidly changing return air temperature,

the time delay may allow the return air temperature to

rise slightly more than 0.2_C (0.4_F) above the set

point temperature before the compressor can restart.

b. Operation in the economy mode (Code 34 OFF)

The economy mode is deactivated by setting function

code Cd34 to the “OFF” status. Economy mode has no

active display indicator to show that it is enabled, so a

manual display of function code Cd34 must be

performed to enable the user to see its current status. A

second way to deactivate economy mode is to change

the set point. Once economy mode is deactivated, the

system will return to normal control mode operations.

In order to achieve economy mode frozen operation, a

frozen set point temperature must be selected PRIOR to

activating economy mode. When economy mode frozen

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 temperature is less than or equal to the set point --

2_C, (i.e., the set point is set at --11_C and the operator

subtracts --2_C, the result will equal --13_C). After an

off-cycle period of 60 minutes, the unit will turn on high

speed evaporator fans for three minutes, and then check

the control temperature. If the control temperature is

greater than or equal to the set point + 0.2_C., the unit

will restart the refrigeration system and continue to cool

until the previously mentioned off-cycle temperature

criteria are met. If the control temperature is less than

the set point + 0.2_C, the unit will turn off the

evaporator fans and restart another 60 minute off-cycle.

c. Operation in the bulb mode (Code 35 OFF)

The unit will not run in bulb mode if a frozen range set

point is selected. As described in section 3.1.7.1.d., if a

frozen set point is selected, dehumidification is

deactivated and the temperature above which DTS must

go during defrost resets to 25.6_C (78_F).

3.2 PRE-TRIP DIAGNOSTICS

CAUTION

Pre-trip inspection should not be performed

with critical temperature cargoes in the

container.

NOTE

When Pre-Trip is initiated, dehumidification

and bulb mode will be deactivated. At the

completion of Pre-Trip, dehumidification and

bulb mode must be turned back on again.

Pre-trip Diagnostics is an independent mode which will

suspend the normal Control Mode activities when

initiated by the user. With pre-trip diagnostics, either all

the pre-trip tests can be executed in a defined sequence

(Auto Mode), or one of the pre-trip tests can be selected

to be executed (Manual Mode), based on the sequence

of key selections made.

Page 46 of 125

T-294-01 3-20

Code

No. TITLE DESCRIPTION

P3-0

Low Speed

Evaporator Fan

Motors On

Setup: The high speed evaporator fans will be turned on for 10 seconds, then off

for two seconds, then the low speed evaporator fans are turned on. A current

draw test is done after 60 seconds.

Pass/Fail Criteria: Passes if change in current draw is within the range

specified. Fails if AL11 or AL12 activates during test.

P3-1

Low Speed

Evaporator Fan

Motors Off

Setup: The low speed Evaporator Fan is turned off, a current draw test is done

after 10 seconds.

Pass/Fail Criteria: Passes if change in current draw is within the range

specified. Fails if AL11 or AL12 activates during test.

P4-0

High Speed

Evaporator Fan

Motors On

Setup: The high speed Evaporator Fan is turned on, a current draw test is done

after 60 seconds.

Pass/Fail Criteria: Passes if change in current draw is within the range

specified. Fails if AL11 or AL12 activates during test.

P4-1

High Speed

Evaporator Fan

Motors Off

Setup: The high speed Evaporator Fan is turned off, a current draw test is done

after 10 seconds.

Pass/Fail Criteria: Passes if change in current draw is within the range

specified. Fails if AL11 or AL12 activates during test.

P5-0 Supply/Return Probe

Test

Setup: The High Speed Evaporator Fan is turned on and run for eight minutes,

with all other outputs de-energized.

Pass/Fail Criteria: A temperature comparison is made between the return and

supply probes.

NOTE

If this test fails, “P5-0” and “FAIL” will be displayed. If both Probe tests

(this test and the PRIMARY/ SECONDARY) pass, the display will read

“P5” “PASS.”

P5-1 Supply Probe Test

Requirements: For units equipped with secondary supply probe only.

Pass/Fail Criteria: The temperature difference between primary and secondary

probe (supply) is compared.

NOTE

If this test fails, “P5-1” and FAIL will be displayed. If both Probe tests (this

and the SUPPLY/ RETURN TEST) pass, because of the multiple tests, the

display will read ’P 5’ ’PASS’.

P5-2 Return Probe Test

Requirements: For units equipped with secondary return probe only.

Pass/Fail Criteria: The temperature difference between primary and secondary

probe (return) 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.

P6-0 Compressor On

Setup: A current draw test is performed before the compressor is started. The

compressor is started. SMV is opened to 30%, and another current draw test is

performed. If it is the first compressor start, the compressor reliability

enhancement logic (CREL) is executed, running a current draw test on the

additional output of the following state:

Component Normal Logic

(10 seconds) CREL (3 minutes)

SMV 30% 100% (for 3 minutes) then 30%

P-6 Not Applicable This test is not in use starting with model number 69NT40-511-200 and UP.

Page 49 of 125

3-23 T-294-01

Code

No. TITLE DESCRIPTION

P10-1 Frozen Mode (Pull

Down) Test

Setup: When the container temperature is greater than or equal to the 45_F. set

point which was set in the frozen mode heat test, the left display will read “P101”

and the right display will show the return air temperature. The set point will then

be changed to --17.7_C (0_F). The unit will then have a maximum of three hours

to pull the container temperature down to the 0_F set point.

Pass/Fail Criteria: If this occurs within the three hour time limit, the test passes.

If pulldown is not completed within the three hour time limit, the test fails.

P10-2

Frozen Mode

Maintain

Temperature Test

Setup: After the unit has successfully completed the frozen pulldown test, the

left display will read “P102” and the right display will show the return air

temperature. The unit will then be required to maintain the 0_F temperature

within + or -- 0.5_C (0.9_F) of set point until a DataCORDER recording is

executed. The recorder return probe temperature running total (and its

associated readings counter) will be zeroed out for the remainder of the

recording period at the start of this test, so that the actual value recorded in the

DataCORDER will be an average of only this test’s results. Once the recording

interval is complete, the average recorder return temperature will be recorded in

the DataCORDER, as well as stored in memory for use in applying the test

pass/fail criteria.

Pass/Fail Criteria: If the recorded temperature is within +/-- 0.5_C of 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 section has been separated to explain

the DataCORDER side of the module. The

DataCORDER consists of:

S Microprocessor

S Program memory

S Data memory

S Internally battery backed real time clock

S Six thermistor inputs

S Two communication ports

S Power supply (optional battery pack).

This recorder eliminates the mechanical recorder and

paper chart, and replaces it with a custom-designed

module (see Figure 3-1) that interfaces with the

Interrogator and operates in the following ways:

a. Logs data at 15, 30, 60 or 120 minute intervals.

b. Records and displays alarms through the digital

display module. (Refer to Table 3-7.)

c. Stores at least two years’ worth of data based on

typical one hour intervals.

d. Records DataCORDER/Network generated data

and events as follows:

S Container ID Change

S S/W Upgrade

S Controller configuration change

S Alarm Activity

S Battery Low (Battery Pack)

S Data Retrieval

S Defrost Start

S Defrost End

S Dehumidification Start

S Dehumidification End

S Power Loss (w/wo battery backup)

S Power Up (w/wo battery backup)

S “Auto 1” Pre-Trip Start

S “Auto 1” Pre-Trip End

S Remote Probe Temperatures in the Container

(USDA Cold treatment and Cargo probe

recording)

S Return Air Temperature

S Set Point Change

S Supply Air Temperature

S Real Time Clock (RTC) Battery (Internal

Battery) Replaced

Page 51 of 125

3-25 T-294-01

Table 3-6. DataCORDER Function Code Assignments

NOTE

Inapplicable Functions Display “--- --- --- --- ---”

To Access: Press ALT. MODE key

Code

No. TITLE DESCRIPTION

dC1 Recorder Supply

Temperature Current recorder supply air temperature.

dC2 Recorder Return

Temperature Current recorder return air temperature.

dC3-5 USDA 1,2,3

Temperatures Current temperatures of the three USDA probes.

dC6-13 Network Sensors

1-8

Current values of the network sensors (as configured). Network sensor 1 (Code

6) is generally the humidity sensor and its value is obtained from the Controller

once every minute.

dC14 Cargo Probe 4

Temperature Current temperature of the cargo probe #4.

dC15-19 Future Expansion These codes are for future expansion, and are not in use at this time.

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 first four characters. Function code dC27 contains the last

four characters. (This serial number is the same as the Controller serial

number.)

dC28 Minimum Days Left An approximation of the number of logging days remaining until the

DataCORDER starts to overwrite the existing data.

dC29 Days Stored Number of days of data that are currently stored in the DataCORDER.

dC30 Date of last Trip start

The date when a Trip Start was initiated by the user. In addition, if the system

goes without power for seven continuous days or longer, a trip start will

automatically be generated on the next AC power up.

dC31 Battery Test

Shows the current status of the optional battery pack.

PASS: Battery pack is fully charged.

FAIL: Battery pack voltage is low.

dC32 Time: Hour, Minute Current time on the real time clock (RTC) in the DataCORDER.

dC33 Date: Month, Day Current date (month and day) on the RTC in the DataCORDER.

dC34 Date: Year Current year on the RTC in the DataCORDER.

dC35 Cargo Probe 4

Calibration

Current calibration value for the Cargo Probe. This value is an input via the

interrogation program.

Page 53 of 125

3-27 T-294-01

Table 3-7. DataCORDER Alarm Indications

To Access: Press ALT. MODE key

Code

No. TITLE DESCRIPTION

AL70

Recorder Supply

Temperature Out of

Range

The recorder supply air temperature is sensed outside of the range of

--50_C to 70_C (--58_F to +158_F) or if the probe check logic has

determined there is a fault with this sensor.

NOTE

The P5 Pre-Trip test must be run to inactivate the alarm (refer to section

3.2.1).

AL71

Recorder Return

Temperature Out of

Range

The recorder return air temperature is sensed outside of the range of

--50_C to 70_C (--58_F to +158_F) or if the probe check logic has

determined there is a fault with this sensor.

NOTE

The P5 Pre-Trip test must be run to inactivate the alarm (refer to section

3.2.1).

AL72-74 USDA Temperatures 1,

2, 3 Out of Range The USDA probe temperature reading is sensed outside of range.

AL75 Cargo Probe 4 Out of

Range The cargo probe temperature reading is sensed outside of range.

AL76, 77 Future Expansion These alarms are for future expansion, and are not in use at this time.

AL78-85 Network Sensors 1 -- 8

Out of Range The network sensor is outside 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 the DataCORDER was configured. To identify

which sensor is at fault, the unit must be interrogated to locate the sensor being recorded. Generally, the

humidity sensor is AL78, as it is the only network sensor recorded.

AL86 RTC Battery Low The Real Time Clock (RTC) backup battery is too low to adequately

maintain the RTC reading.

AL87 RTC Failure

An invalid date or time has been detected. This situation may be corrected

by changing the Real Time Clock (RTC) to a valid value using the

DataView.

AL88 DataCORDER

EEPROM Failure A write of critical DataCORDER information to the EEPROM has failed.

AL89 Flash Memory Error An error has been detected in the process of writing daily data to the

non-volatile FLASH memory.

AL90 Future Expansion This alarm is for future expansion, and is not in use at this time.

AL91 Alarm List Full The DataCORDER alarm queue is determined to be full (eight alarms).

Page 54 of 125

T-294-01 3-28

The DataCORDER alarms for the USDA and cargo

probes are configurable using the interrogation program

or via a configuration card. There are four configuration

variables for the DataCORDER, which are listed in

Table 3-8 with their descriptions and selection values.

Table 3-8. DataCORDER Alarm Configurations

Configuration

Variable Description Selection

Values

dCF07 USDA (PR1) Auto,On,Off

dCF08 USDA (PR2) Auto,On,Off

dCF09 USDA (PR3) Auto,On,Off

dCF10 Cargo Probe (PR4) Auto,On,Off

The default configuration for the four probes is “Auto.”

If the alarms are configured as “Auto,” and all the

probes are missing (i.e., appear open-circuited to the

DataCORDER), no alarms are activated. As soon as one

of the probes is installed (plugged into the receptacle),

then all of the alarms are enabled and the remaining

probes that are not installed will give active alarm

indications. This function is designed to assist those

users who wish to keep their DataCORDER configured

for USDA recording, and do not wish to install the

probes for every trip.

If a probe alarm is configured to be “On,” then the

associated alarm is always enabled. As long as the probe

remains in-circuit (plugged in), the alarm will not be

activated. Probes with this configuration have alarms

that act like the alarms for the supply and return recorder

sensors. It is presumed that normal operation includes

the probe in question.

If a probe alarm is configured to be “Off,” then the alarm

for this probe is always disabled. It is not possible to

activate the respective alarm for this probe no matter

what the circumstance.

3.3.5 Access to DataCORDER Functions

To access the DataCORDER functions codes, alarm

codes, configuration and scrollback, the user must first

press the ALT. MODE key, then press the applicable

key for functions (CODE SELECT) or alarms

(ALARM LIST).

a. Keypad/Display Interface

The DataCORDER uses the Controller display and

keypad. The DataCORDER contains four types of

display parameters. They are: functions codes, alarm

codes, configuration and scrollback.

b. DataCORDER Power-Up

The DataCORDER may be powered 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.

On every DataCORDER wake-up, while using

battery-pack power, the Controller will first perform a

hardware voltage check on the battery. If the hardware

check passes, the Controller will energize the

appropriate circuitry and perform a software battery

voltage check before DataCORDER logging. If either

the hardware or software battery test fails, the real time

clock (RTC) battery-backed wake-up will be disabled

until the next AC power cycle. Further DataCORDER

temperature logging will be prohibited until that time.

A 12 volt VCR battery pack may also be plugged into

the back of the interrogation cable, which is then

plugged into either interrogation port. No rechargeable

battery pack is required with this method. The user may

now interrogate the DataCORDER.

3. Real Time Clock (RTC) because a logging interval

has expired: If the DataCORDER is equipped with a

charged battery pack and AC power is not present, the

DataCORDER will power up when the RTC indicates

that a data recording should take place. When the

DataCORDER is finished recording, it will power

down.

c. DataCORDER Battery Pack Test

If the DataCORDER has the optional battery pack, then

the battery voltage will be tested once every five

minutes. An alarm will be generated when the battery

voltage transitions from good to bad indicating that the

battery pack needs recharging. If the alarm condition

persists for more than 24 hours on continuous AC

power, the battery pack probably needs replacement.

d. Trip Start Processing

To initiate Trip Start:

S Press the ALT. MODE key

S Select function code dC30

S Depress the ENTER key for five seconds

Trip Start will flash for five seconds, turn solid, then the

date will appear to indicate that a Trip Start is registered.

Page 57 of 125

3-31 T-294-01

Start, Power Outages, and Temperature Out-of-Range

conditions.

3.3.10 DataCORDER Scrollback

The DataCORDER will display probe values for the six

DataCORDER probes up to 99 hours back from the

current hour. The probe values may be displayed by

depressing the ALT. MODE key and then depressing

the UP or DOWN ARROW keys until “dCdSP” is

shown in the left display window and then depressing

the ENTER key. The sensor to display can then be

chosen by depressing the UP or DOWN ARROW key

until the desired sensor (S for supply, r for return, P1,

P2, P3 and C4 for USDA and Cargo probes) is shown in

the left display window and then depressing the ENTER

key. A temperature value will appear in the right display

window and 1 (with sensor designation) will appear in

the left display window to signify the temperature

displayed is the most recent reading. Each press of the

DOWN ARROW key displays the temperature one

hour earlier. Use the ENTER key to alternate between

sensors and times/temperatures. Use the ARROW keys

for scrolling. The display will return to normal if 15

seconds lapse without a key being pressed.

3.4 USDA COLD TREATMENT PROCEDURE

Sustained cold temperature has been employed as an

effective postharvest method for the control of

Mediterranean and certain other tropical fruit flies.

Exposing infested fruit to temperatures of 2.2 degrees

Celsius (36_F) or below for specific periods results in

the mortality of the various stages of this group of

notoriously injurious insects.

In response to the demand to replace fumigation with

this environmentally sound process, Carrier has

integrated this Cold Treatment capability into its

DataCORDER. These units have the ability to maintain

supply air temperature within one-quarter degree

Celsius of setpoint and record minute changes 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 bathing the

probes and performing the calibration function with the

hand held DataReader or a DOS-based portable

computer. This calibration procedure determines the

probe offsets and stores them in the Controller for use in

generating the cold treatment report. Refer to the

Interrogation manual 62-02575 for more details.

e. Place the three probes required for a USDA cold

treatment procedure. The probes are placed into the pulp

or the fruit at the locations defined below as the product

is loaded.

Sensor 1 Place in pulp of the product located next

to the return air intake.

Sensor 2

Place in pulp of the product five feet

from the end of the load for 40 foot

containers, and three feet from the end

of the load for 20 foot containers. This

probe should be placed in a center

carton at one-half the height of the load.

Sensor 3

Place in pulp of product five feet from

the end of the load for 40 foot containers

and three feet from the end of the load

for 20 foot containers. This probe should

be placed in a carton at a side wall at

one-half the height of the load.

f. To initiate USDA Recording begin the cold

treatment recording, connect the Interrogator and

perform the configuration as follows:

S Trip Start

S Trip Comment

S Configure for five probes

S One hour logging interval

S USDA temperature log in

S Two byte memory storage format

S Probe calibration

g. Retrieval of trip data from the DataCORDER

memory can be accomplished with a DataReader and

DataView software or DataView software and a

DOS-based portable computer. Contact a Carrier

Transicold Service Parts representative for details.

Page 60 of 125

T-294-01 3-34

AIR

CIRCULATION

ONLY

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

+1.5_C (2.7_F)

+1_C (1.8_F)

+0.5_C (0.9_F)

COOLING

AIR

CIRCULATION

ONLY

COOLING

NOTE

+0.20_C

For In-range Tolerance, Refer to section 3.1.4 Code 30..

Figure 3-5. 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 and

possible modulated cooling

MODULATING

COOLING

NOTE

For In-range Tolerance, Refer to section 3.1.4 Code 30..

Figure 3-6. Controller Set Point ABOVE --10_C (+14_F), or --5_C (+23_F) optionally

Page 61 of 125

4-1 T-294-01

SECTION 4

OPERATION

4.1 PRE-TRIP INSPECTION (Before Starting)

WARNING

Beware of unannounced starting of the

evaporator and condenser fans.

a. If container is empty, check inside for the

following:

1. Check channels or “T” bars on floor for cleanliness.

Channels must be free of debris for proper air

circulation.

2. Check container panels, insulation and door seals

for damage. Effect permanent or temporary repairs.

3. Visually check evaporator fan assembly clamp

bolts for proper securement (refer to section 6.16).

4. Check for dirt or grease on evaporator fan or fan

deck and clean if necessary.

5. Check evaporator coil for cleanliness or

obstructions. Wash with fresh water.

(Refer to section 6.14.)

6. Check defrost drain pans and drain lines for

obstructions and clear if necessary. Wash with fresh

water.

7. Check panels on refrigeration unit for loose bolts

and condition of panels. Make sure T.I.R. devices

are in place on access panels.

b. Check condenser coil for cleanliness. Wash with

fresh water. (Refer to section 6.18.)

c. Check position of fresh air makeup vent cover.

Operator must determine if fresh air makeup vent

cover is to be opened or closed.

d. Open control box door. Check for loose electrical

connections or hardware.

e. Check color of moisture-liquid indicator.

f. Check oil level in compressor sight glass.

g. Start refrigeration unit. (Refer to section 4.3.)

4.2 STARTING AND STOPPING INSTRUCTIONS

CAUTION

Make sure that the unit circuit breaker(s)

(CB-1 & CB-2) and the start-stop switch

(ST) are in the OFF position before

connecting to any electrical power source.

a. Starting the Unit

NOTE

The evaporator fans will always start in high

speed regardless of set point and will switch to

low speed after approximately 20 to 30 seconds

if the set point is below --10_C (+14_F), or

--5_C (+23_F) optionally.

1. Refer to Pre-Trip Inspection, section 4.1.

2. Check power source for proper voltage. Connect

unit power plug and turn main power ON.

3. Turn refrigeration unit circuit breaker(s), and the

start-stop switch to ON (position “1”).

4. Units equipped with the integrated DataCORDER:

Trip start is initiated by depressing the ALT.

MODE key and selecting Code dc30, then

depressing the ENTER key for five seconds.

5. Refer to section 4.3 after unit is running.

b. Stopping the Unit

Turn the start-stop switch (ST) to position “0” (OFF

position).

4.3 AFTER STARTING INSPECTION

a. Check rotation of condenser and evaporator fans.

b. Check compressor oil level. (Refer to section 6.11.)

c. Run unit at least five minutes to stabilize. Start

controller Pre-Trip diagnostics.

(Refer to section 3.2.)

Page 63 of 125

4-3 T-294-01

Page is left intentionally blank.

Page 64 of 125

T-294-01 4-4

4.4.3 Cooling -- Controller Set BELOW --10_C

(+14_F), or --5_C (+23_F) optionally

NOTES

S The stepper motor suction modulation valve

(SMV) may be up to 100% open depending

on the current and pressure limiting controls.

S The evaporator motors run in low speed.

S The compressor runs in high speed.

When the return air temperature decreases to 0.2_C

(0.4_F) below set point, relays TD and TN de-energize.

This results in de-energizing the compressor and

condenser fan motor. Also, the cool light is

de-energized. The evaporator fan motors continue to

run to circulate air throughout the container.

When the return air temperature increases to 0.2_C

(0.4_F) above set point, and providing a sufficient

off-time period has elapsed, relays TD and TN energize

to restart the compressor and condenser fan motor. Also

at this time, the cool light is illuminated.

4.4.4 Controller Set ABOVE --10_C (+14_F), or

--5_C (+23_F) optionally

a. Cooling Mode (See Figure 4-1.)

NOTES

S Evaporator fan motors will run in high speed.

(Contactor EF energized)

S A pressure control system has been

incorporated by means of a condenser

pressure transducer (CPT) and condenser

pressure control (CPC) logic to maintain

discharge pressures above 130 psig in low

ambients.

S The condenser fan will cycle off if the

condenser pressure is below 130 psig. If the

condenser pressure goes above 200 psig, the

condenser fan will cycle on.

With supply air temperature decreasing, and if the

supply air is above set point, the unit will be cooling

with the condenser fan motor, compressor motor and

evaporator fan motors energized. Also, at this time, the

cool light is illuminated.

When the air temperature decreases to a predetermined

tolerance above set point, relay TI energizes and the

in-range light is illuminated. (Refer to section 3.1.4,

Code 30.)

If the air temperature continues to fall, modulating

cooling starts at approximately 2.5_C (4.5_F) above set

point.

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 or

more below set point and the running sum is greater than

or equal to --250 degrees Celsius seconds, relays TN and

TC de-energize shutting off the condenser fan and

compressor motors. Also, the cool light is de-energized.

NOTE

For example: If the temperature in the container

box falls 1_C below set point for 250 seconds,

or any combination of temperature and time

that equals 250 degrees Celsius seconds, the

unit will shut off. (Formula: X_C times TIME

in seconds. Where X is the amount of degrees in

Celsius, i.e., 1_C times 250 seconds = 250

degrees Celsius seconds.)

The evaporator fan motors continue to run to circulate

air throughout the container. The in-range light remains

illuminated as long as the supply air is within atolerance

of set point, and the 15 minute override is met.

If the unit is in the holding mode (neither heating nor

cooling) and the supply air temperature increases to

0.2_C (0.4_F) above set point, and providing a six

minute off time has elapsed, relay TC energizes to

restart the compressor. Also, at this time, the condenser

fan motor starts and the cool light is illuminated.

Page 65 of 125

4-5 T-294-01

= 18 Volt Energized Circuit

CONTROL TRANSFORMER

= 24 Volt Energized Circuit = De-energized Circuit

Figure 4-1. Cooling Mode

Page 66 of 125

T-294-01 4-6

4.4.5 Heating Mode

The unit will heat only when the controller set point is

above --10_C (+14_F), or --5_C (+23_F) optionally, as

relay TH is electronically locked out to prevent heating

when the controller set point is below --10_C (+14_F),

or --5_C (+23_F) optionally.

If the air temperature decreases 0.5_C (0.9_F) below

controller set point, TH closes (see Figure 4-2) and the

system enters the heating mode which is designed to

raise the container air temperature. When TH closes,

power flows through TH contacts and the heat

termination thermostat to energize the heater contactor

(HR). This in turn energizes the heaters and heat light.

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

point, TH opens (heating off) and the system again

enters the holding zone. The compressor and condenser

fan motor are not running as contactors CH and CF

remain de-energized. The evaporator fans continue to

run to circulate air throughout the container.

A safety heat termination thermostat (HTT) attached to

an evaporator coil support, set to open at 54.5_C

(130_F), will open the heating circuit if overheating

occurs.

Page 67 of 125

4-7 T-294-01

= 18 Volt Energized Circuit

CONTROL TRANSFORMER

= 24 Volt Energized Circuit = De-energized Circuit

Figure 4-2. Heating Mode

Page 76 of 125

6-1 T-294-01

SECTION 6

SERVICE

NOTE

To avoid damage to the earth’s ozone layer, use a refrigerant recovery system whenever removing refrigerant.

When working with refrigerants you must comply with all local government environmental laws. In the

U.S.A., refer to EPA section 608.

6.1 REPAIRING THE REFRIGERATION SYSTEM

The unit is designed as a hermetic system, which

reduces the number of potential leak-points for

refrigerant. Therefore the suction service, discharge

service and manual liquid line valves have been

eliminated in comparison to the standard container unit.

In conjunction, the sight glass on the water-cooled

condenser, and the filter-drier quick--connect nuts have

also been removed. These areas have either been

completely eliminated, or have been replaced with

brazed joints.

To perform maintenance on the system, two process

tubes have been provided, which are the liquid line and

suction line process tubes, see Figure 6-4 for locations.

Refer to Table 6-4 for a list of the tools required to

perform the tasks in sections 6.2, 6.3 and 6.4.

6.2 PIERCING VALVES

To gain access to the hermetic system, it is

recommended to use the Robinair P/N 40288 piercing

valve on the units process tubes.

a. Preparation

1. Tubing should be straight and round.

2. Carefully clean the process tubing where the

piercing valve will be attached, do NOT scratch the

tubing.

3. Make sure there are no dents in the tubing.

4. Apply a little clean refrigerant oil to the tubing

where the piercing valve will be placed.

b. Installing

1. Make sure the gasket (item 2, refer to Figure 6-1) is

in place, and the piercing needle (item 3) is backed

all the way out by turning the hand valve (item 1)

counter-clockwise.

2. Remove the nut (item 5) and u-shaped block (item

4) from the base of the piercing valve.

3. Straddle the process tube with the hand valve

portion of the piercing valve.

4. Install the u-shaped block and nut onto the base of

the piercing valve that was removed in step 2.

5. Tighten the valve to the process tube by turning the

nut enough to seal the gasket and to secure the valve

to the process tube.

6. Do NOT overtighten. Overtightened valves can

actually cause a leak.

7. Install the manifold gauge hose (refer to section 6.3)

to the one-quarter inch connector (item 6) using a

low or high side R-134a connector (item 13 or 14,

Table 6-4), and a low or high side swivel elbow

(item 11 or 12).

8. Turn the hand valve clockwise to pierce the tubing

and access the refrigeration system.

1

2

3

4

5

6

1. Hand Valve

2. Gasket

3. Piercing Needle

4. U-Shaped Block

5. Nut

6. One-Quarter Inch S.A.E. Connector

Figure 6-1. Piercing Valve

c. Removal

1. Reverse the steps in section 6.2.b.