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Table Of Contents - Carrier VECTOR 6500 Operation & Service Manual

Single-temp trailer and rail refrigeration units with advancet microprocessor

Table Of Contents

Table of Contents

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Table of Contents

Table Of Contents3

List Of Illustrations14

List Of Tables16

Safety Precautions17

Paragraph Number Page17

Figure 1−1 Lockout/Tagout18

Specifica Warnings And Caution Statements19

Safety Decals23

Safety Instructions24

Unit Description27

General Description28

Table 2-1 Model Chart28

Table 2-2 Additional Support Manuals28

Figure 2−1 Front View - Refrigeration System Components29

Figure 2−2 Road Side/Rear Compressor View - Refrigeration System Components30

Figure 2−3 Front View - Engine Components31

Figure 2−4 Evaporator Section - Grille Removed32

Figure 2−5 Control Box33

Condensiong Section34

Engine Air System34

Figure 2−6 Engine Speed Control Unit34

Unloaded Operation35

Figure 2−7 Compressor Cylinder Head Unloaded35

Compressor Switches, Transducers Andsensors36

Loaded Operation36

Compressor Discharge Pressure Transducer (Cdp)36

Compressor Suction Pressuret Ransducer (Csp)36

Figure 2−8 Compressor Cylinder Head Loaded36

Evaporator Section37

Condenser Coil37

Ambient Air Temperature Sensor (Aat)37

Electronic Expansion Valve (Evxv)37

System Operating Controls And Components38

Multiple Languages38

Automatic Start-Stop38

Special Features38

Figure 2−9 Control Module39

Indicator Lights40

Figure 2−10 Display And Keypad Assembly40

Electronic Modules42

Overload Ground Fault Module (Ogf)42

Phase Reversal Module (Prm)42

Figure 2−11 Ogf Module42

Figure 2−12 Prm Module42

Figure 2−13 Light Bar42

Remote Temperature Sensors43

Remote Control Panel43

Compressor Data44

Refrigeration System Data44

Electrical Data44

Component Resistance & Current Draw Data45

Safety Devices46

Refrigerant Circuit During Cooling47

Refrigerant Circuit - Heating And Defrosting47

Figure 2−14 Refrigerant Circuit48

Starting - Engine Operation50

Starting - Standby Operation51

Starting Units With A Main Power Switch Labeled Engine/Off/Standby51

Starting Units With A Main Power Switch Labeled Start/Run-Off52

Sound And 12Vdc Electrical Component Amperage Check55

Refrigeration System Equalization Check55

Changing Set Point57

Start-Stop Operation58

Continuous Operation59

Manual Defrost62

View Active Alarms64

View Inactive Alarms65

Table 3-1 Unit Data66

View Hour Meters69

Functional Parameters70

Table 3-2 Functional Parameters71

Language Selection74

Changing Intellisets - With The = Key Enabled76

Changing Intellisets - Without The = Key Enabled77

Stopping Unit78

Datalink Data Recorder79

Microprocessor Information79

Data Recording79

Data Downloading79

Starting Unit With Remote Control Panel82

Changing Set Point With Remote Control Panel82

Lock / Unlock The Remote Control Panel83

Pre-Setting Set Point With Remote Control Panel83

Removing Pre-Set Set Points With Remote Control Panel84

Engine/Standby/Temperature Control85

Engine/Standby Operation86

Standby Start-Up86

Engine Start-Up86

Figure 4−1 Auto Start Sequence86

Temperature Control87

Transition To High Speed87

Temperature Determination87

Table 4−1 Intake Air Heat Time87

Pull Down/Pull-Up88

Start-Stop Configuration88

Perishable And Frozen Set Point Ranges88

Stop Parameters89

Re-Start Parameters90

Figure 4−2 Continuous Operation Switch Points With Eco Mode Set To91

Figure 4−3 Continuous Operation Switch Points With Eco Mode Set To Yes92

Defrost Initiation And Start93

Defrost Modes93

User Selected Override Operation94

Supply Air Limit Control94

Temperature Range Lock 1 & 295

Figure 4−4 Range Lock Settings - Non Overlapping95

Productshield96

Figure 4−5 Range Lock Settings - Overlapping96

Programmed Software Overrides98

Cargo Protect Mode98

Compressor Minimum Operating Time98

Engine Speed Overrides98

Unloader Control Overrides99

Figure 4−6 Evaporator Pressure Chart100

Defrost Safety Override101

Microprocessor Interface102

Interface Methods103

Technical Interface103

Figure 5−1 Technicians Interface Connection103

Configuration Mode104

Component Test Mode104

Service Mode105

Table 5−1 Component Test105

Handling Pc Cards106

Figure 5−2 Pc Mode Connection106

Program Pc Card107

Figure 5−3 Pc Card Interaction107

Reefermanager & Reports108

Configuration Pc Card108

Option Pc Card108

Download Pc Card108

Connecting Computer And Microprocessor109

Figure 5−4 Reefermanager & Reports Connection109

Microprocessor Display Diagnostics110

Microprocessor Replacement & Setup110

Figure 5−5 Connector 6Mp Connections110

Figure 5−6 Display Test Points110

Pre-Replacement Steps111

Microprocessor Replacement111

Microprocessor Setup112

Configurations Via Keypad113

Functional Parameters Via Keypad113

Datalink Data Recorder Via Reefermanager113

Microprocessor Final Checkout113

Table 5−2 Microprocessor Configurations114

Messagecenter126

Messagecenter Messages127

Alarm Troubleshooting133

Driver/Operator Alarms136

Shutdown Alarms137

Start Up / Engine Alarms155

Wiring 10−1159

Warning / Status Alarms169

Electrical Alarms179

Sensor Alarms198

Pretrip Alarms208

Maintenance Alarms231

Microprocessor Alarms235

Section Layout244

Scheduled Maintenance244

Pre Trip Inspection244

Table 8−1 Maintenance Schedule245

Table 8−2 Pre Trip Inspection247

External Surface Service248

Surround Removal248

Figure 8−1 Grille Insert Removal And Door Latch Maintenance248

Door Latch Maintenance And Replacement249

Display & Keypad Assembly249

Door Latch Maintenance249

Cable Replacement249

Figure 8−2 Surround Removal249

Figure 8−3 Door Latch Cable Removal249

Engine And Engine Related Systems Service250

Figure 8−4 Display And Keypad Assembly250

Priming The Fuel System251

Mechanical Fuel Pump Screen251

Figure 8−5 Fuel System Diagram251

Figure 8−6 Fuel Bleed Components251

Electric Fuel Pump Screen252

Fuel Level Sensor (Fls)252

Figure 8−7 Mechanical Fuel Pump252

Figure 8−8 Electric Fuel Pump252

Engine Oil And Oil Filter253

Figure 8−9 Fuel Level Sensor253

To Change Engine Oil254

To Change Engine Oil Filter254

Figure 8−10 Engine Oil Level254

Figure 8−11 Engine Oil Flow Diagram254

Figure 8−12 Oil Drain Tool254

Speed Control System255

Troubleshooting The Intake Air Heater (Iah)255

Replacing The Intake Air Heater255

Figure 8−13 Intake Air Heater255

Figure 8−14 Electronic Speed Control Components255

Cooling System256

Cleaning And Flushing256

Radiator Replacement256

Figure 8−15 Condenser And Radiator Assemblies256

Refrigerant System Service257

Refrigerant System Service Connections257

Figure 8−16 Water Pump V-Belt257

Figure 8−17 Engine Crankcase Breather257

Servicing The Refrigerant Charge258

Checking Charge Level258

Checking For Noncondensibles258

Removing Charge258

Figure 8−18 Refrigerant System Service Equipment258

Pumping Down The Low Side259

Pumping Down The Compressor259

Adjusting The Charge Level259

Leak Checking260

Adding A Complete Charge260

Leak Checking A Charged System260

Leak Checking A System Without Charge260

Leak Checking With Low Side Pumped Down261

Leak Checking Compressor261

Evacuation And Dehydration262

Evacuation Of The Complete System262

Compressor And Unloader Service263

Repair Or Replacement Determination263

Evacuation Of The Low Side263

Evacuation Of The Compressor263

Removal And Replacement Of Compressor264

Figure 8−19 Compressor - Model 06D264

Cylinder Head And Valve Plate Service265

Figure 8−20 Cylinder Head & Valve Plate265

Figure 8−21 Checking Suction Valve266

Figure 8−22 Oil Pump And Bearing Head Assembly266

Compressor Oil Level267

Checking Compressor Oil Level267

Adding Oil With Compressor In System267

Removing Oil From The Compressor268

Unloader Checkout Procedure268

Unloader Coil Replacement268

Figure 8−24 Unloader Coil268

Refrigerant System Component Service269

Evaporator Coil269

Replacing Unloader Valve Internal Parts269

Unloader Valve Replacement269

Condenser Coil Replacement270

Figure 8−25 Condenser/Radiator Assembly270

Filter-Drier271

Replacing Receiver Sight Glass Or Fusible Plug271

Figure 8−26 Suction Modulation Valve (Csmv)271

Table 8−3 Csmv Connections271

Electronic Expansion Valve272

Diagnostics - Stepper Motor272

Diagnostics - Valve272

Emergency Repair Procedures272

Figure 8−27 Csmv Coil272

Diagnostics - Microprocessor Or Wiring273

Figure 8−28 Electronic Expansion Valve273

Figure 8−29 Electronic Expansion Valve273

Table 8−4 Evxv Connections273

Pressure Transducers274

Defrost Air Switch274

Figure 8−30 Typical Setup For Testing High Pressure Switch274

Electrical System Component Service275

Megohmmeter Test Procedure275

Figure 8−31 Defrost Air Switch Test Setup275

Figure 8−32 Megohmmeter Connection To Ground Plate276

Figure 8−33 High Voltage Contactors276

Overload Ground Fault (Ogf)277

Evaporator Heaters277

Ogf Checkout Procedure277

Figure 8−34 Light Bar Connections277

Figure 8−35 Overload Ground Fault Connections277

Evaporator Blower & Motor278

Figure 8−36 Evaporator Blower Assembly278

Condenser Fan Assemblies279

Figure 8−37 Condenser Fan Assembly279

Battery Charger (Btyc)280

Generator (Gen)280

Preventive Maintenance And Operating Precautions280

Generator Removal281

Generator Assembly Procedure283

Figure 8−38 Generator Assembly283

Figure 8−39 Bolt Hole Pattern For Bell Housing And Crankshaft283

Sensor Checkout284

Table 8−5 Sensor Resistance285

Table 8−6 Sensor Resistance (Cdt)286

Table 8−7 Temperature Pressure Chart287

Unit Troubleshooting288

Engine Will Not Start289

Engine Starts Then Stops290

Engine Will Not Shut Off290

Starter Motor Malfunction290

Malfunction In The Engine Starting Circuit290

Battery Charger291

Miscellaneous Engine Troubleshooting291

Refrigerant/Temperature Control292

Unit Will Not Cool292

Unit Runs But Has Insufficient Cooling292

Unit Will Not Terminate Cooling293

Unit Will Not Heat Or Has Insufficient Heating293

Unit Will Not Terminate Heating293

Defrost Cycle Malfunction293

Abnormal Pressure294

Abnormal Noise294

No Evaporator Air Flow Or Restricted Air Flow294

Evaporator Expansion Valve (Evxv) Malfunction295

Compressor Suction Modulation Valve (Csmv) Malfunction295

Speed Control System Diagnostics296

Table 9−1 Enscu Led Fault Chart296

Figure 9−1 Enscu Diagnostic Tree - 1 Long, 1 Short Led Code297

Figure 9−2 Enscu Diagnostic Tree - 2 Long, 1 Short Led Code298

Figure 9−3 Enscu Diagnostic Tree - 2 Long, 3 Short Led Code299

Figure 9−4 Enscu Diagnostic Tree - 2 Long, 7 Short Led Code300

Table 9−2 Microprocessor Diagnostics301

Figure 9−5 Micro Diagnostic Tree - Condition 1 - Main Power Switch On - Unit Does Not Operate302

Micro Diagnostic Tree - Condition 2 - Main Power Switch On - Unit Operates But Not Properly303

Figure 9−7 Micro Diagnostic Tree - Condition 3 - Main Power Switch Off - Unit Fails To Stop304

Figure 9−8 Micro Diagnostic Tree - Condition 4 - Unit Will Not Run In High Speed305

Figure 9−9 Micro Diagnostic Tree - Condition 5 - Unit Will Not Run In Low Speed306

Micro Diagnostic Tree - Condition 6 - Datalink Data Recorder Data Download Problemswhen Using Reefermanager And A Download Cable. Data File Analysis P307

Figure 9−10 Micro Diagnostic Tree - Condition 6 - Datalink Data Recorder Data Download307

Figure 9−11 Microprocessor Diagnostic Tree - Condition 7 - Pc Card Problems308

Figure 9−12 Micro Diagnostic Tree - Condition 8 - Programming Problems With Pc Cards309

10.1 Harness Plug Wiring For Units With A Main Power Switch Labeled310

Engine/Off/Standby310

Harness Plug Wiring For Units With A Main Power Switch Labeled Start/Run-Off310

10.3 Control Box Interior Splice Points For Units With A Main Power Switch310

Labeled Engine/Off/Standby310

Control Box Interior Splice Points For Units With A Main Power Switch Labeled Start/Run-Off310

Harness Plug Wiring For Units With A Main Power Switch Labeled Engine/Off/Standby311

Control Box Interior Splice Points For Units With A Main Power Switch Labeled Engine/Off/Standby321

Display Test Pointsd323

Wiring Schematics323

Schematic Diagram324

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Troubleshooting