Carrier Neos 100S Operation & Service Manual
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Carrier Neos 100S Operation & Service Manual

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Truck Refrigeration
OPERATION & SERVICE MANUAL
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Neos™ 100S
Truck Refrigeration Units
62-11848 Rev B

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  • Page 1 Truck Refrigeration OPERATION & SERVICE MANUAL For The Neos™ 100S Truck Refrigeration Units 62-11848 Rev B...
  • Page 3 OPERATION & SERVICE MANUAL For The Neos™ 100S Truck Refrigeration Units © 2017 Carrier Corporation Printed in USA September 2017 ●...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS PARAGRAPH NUMBER PAGE SAFETY SUMMARY ..............1-1 GENERAL SAFETY NOTICES .
  • Page 6 STOPPING THE UNIT ............SETPOINT ADJUSTMENT .
  • Page 7 5.12 THERMOSTATIC EXPANSION VALVE ......... . 5-9 5.12.1 Replacing expansion valve .
  • Page 9 LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figure 2.1 Main Unit Components ............2–3 Figure 2.2 Evaporator .
  • Page 10 LIST OF TABLES TABLE NUMBER Page Table 2–1 Model Chart ..............2–2 Table 2–2 Additional Support Manuals .

  • Page 11: Safety Summary

    Your Carrier Transicold refrigeration unit has been designed with the safety of the operator in mind. During normal operation, all moving parts are fully enclosed to help prevent injury. During all pre-trip inspections, daily inspec- tions, and problem troubleshooting, you may be exposed to moving parts.

  • Page 12: Refrigerants

    Before servicing this refrigeration unit, make sure the main power switch is in the OFF position. Ensure this refrigeration unit is disconnected from the local electrical network. Implement Carrier Logout/ Tag-out procedure (CTE mandatory Fatality Prevention Review: LO/TO and Electricity). Before working in the electrical control box, it is required to control the absence of tension.

  • Page 13: Specific Warning And Caution Statements

    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.
  • Page 14 CAUTION If starting a unit for the first time after installation, or starting after adding/removing an optional feature, or if Owner’s operating parameters have changed, the Configuration will need to be reset. CAUTION Compressor failure will occur if inert gas brazing procedures are not used on units with R-134a and POE oil.

  • Page 15: Description

    The Neos 100S unit is a simple design for operation in smaller delivery vehicles. The unit (Figure 2.1) is manufac- tured as a split system type enabling it to adapt to any vehicle and any configuration. The Neos 100S has the fol- lowing components: a. Evaporator b.

  • Page 16: Table 2-1 Model Chart

    Table 2–1 Model Chart Model No. Description R134A Compressor Condenser Weight Evap. Weight Neos 100S Road Only 2.2 lbs / 1 kg SD 5H09 105.8 lb (48 kg) 33 lb (15 Kg) Table 2–2 Additional Support Manuals Manual Number Equipment Covered...

  • Page 17: Figure 2.1 Main Unit Components

    Figure 2.1 Main Unit Components 1. Condenser Fan 6. Compressor 2. Nameplate 7. Condenser Coil 3. Cab Command 8. Filter Drier / Receiver 4. Electric Motor 9. Hot Gas Valve (HGS1) 5. Control Box 10. Main Heat Valve (HGS2) - - - - - 62-11848...

  • Page 18: Figure 2.2 Evaporator

    Figure 2.2 Evaporator 1. Evaporator coil 6. Compressor Pressure Regulating Valve (CPR) 2. Defrost Termination Thermostat (DTT) 7. LP Manifold Fitting (CPR adjustment) 3. Low Pressure Switch (LP) 8. Expansion Valve (TXV) 4. Defrost Element 9. LP Manifold Fitting (TXV adjustment) 5.

  • Page 19: Figure 2.3 Control Box

    Figure 2.3 Control Box 1. RR - run relay (DC motor) 4. Microprocessor board 2. RSSP - Relay shunt switch pressure 5. FMC - Fuse for MC protection 3. RPM - Micro board relay - - - - - Figure 2.4 Microprocessor Board 1.

  • Page 20: Figure 2.5 Standby Module

    Figure 2.5 Standby Module 1. Phase cable (standby plug) 6. - Battery (from battery) 2. Neutral cable (standby plug) 7. - Battery (from the unit) 3. Ground cable (standby plug) 8. + Battery (from battery) 4. Ignition key OUT (to the unit) 9.

  • Page 21: Hot Gas Solenoid Valve (Hgs1)

    If the receiver king valve is not equipped with a service access port, install a charging connection (Car- rier Transicold P/N 40-60059-02) and (2) clamps (Carrier Transicold P/N 34-60019-02) in the liquid line before continuing with leak checking or charging instructions. (Refer to Figure 5.2.)

  • Page 22: System Operating Controls And Components

    CAUTION Under no circumstances should anyone attempt to repair the microprocessor module or Cab Command! Should a problem develop with these components, contact your nearest Carrier Transicold dealer for replacement. Figure 2.6 Cab Command UNIT SPECIFICATIONS 2.6.1...

  • Page 23: Electrical Data

    e. Compressor Pressure Regulating Valve (CPR) (At end of defrost) 10.3 psig f. Thermostatic Expansion Valve (TXV) Superheat setting at commissioning: 14.4°F at box temperature of 32°F (0°C); 7.2°F at box temperature of -4°F (-20°C). g. Low Pressure switch (LP) Cutout at: -6.5 psig ±...

  • Page 24: Safety Devices

    SAFETY DEVICES System components are protected from damage caused by unsafe operating conditions by automatically shutting down the unit when such conditions occur. This is accomplished by the following fuses and safety devices. Automatic re- Unsafe Conditions Safety Device start with fault Device setting cleared Cutout: -5.7 inHG ±...

  • Page 25: Refrigeration Circuit

    REFRIGERATION CIRCUIT 2.8.1 Cooling (See Figure 2.7) When cooling, the unit operates as a vapor compression refrigeration system. The main components of the system are the compressor, air-cooled condenser, thermostatic expansion valve, direct expansion evaporator, and hot gas solenoid (two-way). The compressor raises the pressure and temperature of the refrigerant and forces it into the condenser tubes.

  • Page 26: Figure 2.7 Refrigeration Circuit - Cooling Cycle

    Figure 2.7 Refrigeration Circuit - Cooling Cycle EVAP. FILTER DRIER DRAIN HEATER CONDENSER KING VALVE RECEIVER HOT GAS SOLENOID SERVICE VALVE (HGS1) FITTING COND. PRESS. (IF FITTED) CONTROL VALVE (HGS2) SUCTION ACCESS VALVE DISCHARGE ACCESS VALVE HIGH PRESSURE VAPOR COMPRESSOR HIGH PRESSURE LIQUID LIQUID INJECTION LINE LOW PRESSURE VAPOR...

  • Page 27: Figure 2.8 Refrigeration Circuit - Heating And Defrost Cycle

    Figure 2.8 Refrigeration Circuit - Heating and Defrost Cycle EVAP. FILTER DRIER DRAIN HEATER CONDENSER KING VALVE RECEIVER HOT GAS SOLENOID SERVICE VALVE (HGS1) FITTING COND. PRESS. (IF FITTED) CONTROL VALVE (HGS2) SUCTION ACCESS VALVE DISCHARGE ACCESS VALVE HIGH PRESSURE VAPOR COMPRESSOR LIQUID INJECTION LINE LOW PRESSURE VAPOR...

  • Page 29: Operation

    The unit can be completely shut down manually by pressing the OFF key on the Cab Command. STANDBY MODE The Neos 100S is powered by a standby module reducing the 230 VAC into 12 Vdc. The power network connec- tion is detected by the standby module which automatically starts up the unit in standby mode.

  • Page 30: Microprocessor Module

    3.2.2 Microprocessor Module The microprocessor controls the following functions: a. Maintains the box temperature at setpoint by regulating the cooling, heating, off mode and automatic defrost cycles. b. Permanently displays the return air temperature and, on request, the setpoint temperature. c.

  • Page 31: Figure 3.2 Green Light Status

    Unit Operating LEDs Green Light Status Under normal operation, the green LED will indicate the temperature control status as follows: Figure 3.2 Green Light Status Steady green COOLING NULL Green LED is BAND SETPOINT Green LED HEATING flashing 1 Hz Red Light Status When an alarm has been detected, the red unit indicating light flashes at 1 Hz.

  • Page 32: Starting-Up The Unit

    STARTING-UP THE UNIT 3.3.1 Inspection Before starting the truck engine check the following: a. Check condenser coil for cleanliness. b. Check condition of refrigerant hoses. c. Check condition and tension of compressor belt(s). d. Check condition of condenser fan blades and motor. e.

  • Page 33: Setpoint Adjustment

    SETPOINT ADJUSTMENT 1. Press the SET key to display the setpoint temperature. 2. Press the - key to decrease the setpoint. 3. Press the + key to increase the setpoint. 4. Press the SET key to validate the setpoint temperature and return to the display of box temperature.

  • Page 34: Accessing Alarm Messages

    3.8.1 Accessing Alarm Messages 1. Press the SET key for 5 seconds. This enables access to the alarm messages. 2. In the event of more than one alarm, press the + or - keys to display them. 3. To scroll through the alarm list, use the + key. 3.8.2 Clearing Passive Alarms and the Maintenance Interval Message SE 1.

  • Page 35: 3.10 Product Loading

    3.10 PRODUCT LOADING Before Loading • Pre-cool the inside of the insulated body by lowering the temperature for about 15 minutes. • Evacuate the humidity existing inside the box by carrying out a manual defrost. This can only take place when enabled by the defrost thermostat (box temperature lower than 37°F (3°C) during pull down and 46°F (10°C) during heating.

  • Page 36: 3.11 Recommended Transport Temperatures

    Below are some general recommendations on product transport temperatures and operating modes for the unit. These are included for reference only. The shipper or receiver may require different set points than those listed. More detailed information can be obtained from a Carrier Transicold dealer. Set Point Range Product °F...
  • Page 37 The defrost interval parameter is displayed next. This setting determines the time between defrosts in hours. The defrost interval can be selected by scrolling through available options (0, 1, 1.5, 2, 2.5, 3, 4, 5, 6 hours) using the + or - keys. Selection MUST be validated by pressing the SET key. d.

  • Page 39: Figure 4.1 Operating Sequence - Perishable Mode

    SECTION 4 CONTROL LOGIC AND TEMPERATURE CONTROL SEQUENCE OF OPERATION General operation sequences for cooling, null, and heating are provided in the following paragraphs. The micropro- cessor automatically selects the mode necessary to maintain box temperature at setpoint. 4.1.1 Perishable Mode The unit operates in the perishable mode with set points above 10°F (-12°C).

  • Page 40: Frozen Mode

    4.1.2 Frozen Mode The unit operates in frozen mode if the set point is below 10°F (-12°C). In this case, the unit switches to two modes of operation, as shown in Figure 4.2. Figure 4.2 Operating Sequence - Frozen Mode Differential between setpoint Differential between setpoint and box T°...

  • Page 41: Service

    WARNING Use proper Lockout/Tagout procedures before inspecting or servicing this unit. WARNING All maintenance services must be done by a technician trained on Carrier products respecting all safety and quality standards of Carrier. NOTE To avoid damage to the earth’s ozone layer, use a refrigerant recovery system whenever removing refrigerant.

  • Page 42: Table 5-2 Service Category Descriptions

    Carrier. On request, Carrier can analyze your compressor oil. To do this, a small drum is sent with a label attached. On the label, indicate: the type of compressor, the lapse time or mileage since the last oil change, the type of Carrier equipment, and the date of initial operation.

  • Page 43: Installing Manifold Gauge Set

    Figure 5.1 Manifold Gauge Set (R-134a) A manifold gauge/hose set with self-sealing hoses is required for service of models covered within this manual. The manifold gauge/hose set is available from Carrier Transicold. (Carrier Transicold P/N 07-00294-00, which Low Pressure High Pressure...

  • Page 44: Removing The Refrigerant Charge

    NOTE To avoid damage to the earth’s ozone layer, use a refrigerant recovery system whenever removing refrigerant. Connect a refrigerant recovery system (Carrier P/N Diablo - 115V (115V) or 240-V (240V)) to the unit to remove refrigerant charge. (See Figure 5.2.) Refer to instructions provided by the manufacturer of the refrigerant recovery...

  • Page 45: Refrigerant Leak Checking

    (discharge) of the system. a. The recommended procedure for finding leaks in a system is with an electronic leak detector. (Carrier P/N 07- 00295-00). Testing joints with soap suds is only satisfactory for locating large leaks.

  • Page 46: Charging The Refrigeration System

    Install a new filter-drier. Evacuate the unit to 500 microns. Close off the vacuum pump valve and stop the pump. Wait five minutes to see if the vacuum holds. This checks for residual moisture and/or leaks. With a vacuum still in the unit, the refrigerant charge may be drawn into the system from a refrigerant con- tainer on a scale.

  • Page 47: Installing A Partial Charge

    5.6.3 Installing a Partial Charge There are no partial charges of the Neos 100S unit. If leak is suspected, for instance, all remaining charge should be removed and a complete charge must be performed and then weighted in after repair.

  • Page 48: Hot Gas Solenoid Valve (Hgs1), Condenser Pressure Control Valve (Hgs2) And Quench Valve

    b. Connect ohmmeter across switch terminals. Ohmmeter will indicate resistance if switch is closed (HP1) or open (HP2) after relieving pressure. c. Connect switch to a cylinder of dry nitrogen. Refer to Figure 5.4. d. Set the nitrogen pressure regulator higher than the switch - over point on switch being tested. Pressure switch settings points are provided in Section 2.6.2.

  • Page 49: Replacing Valve Internal Parts

    5.10.2 Replacing Valve Internal Parts a. Remove the refrigerant charge. Refer to Section 5.3. b. Remove the coil snap cap, voltage cover and coil assembly. Remove the enclosing tube. c. Check for foreign material in the valve body. d. Check for a damaged plunger and o-ring. If the o-ring is to be replaced, always put refrigerant oil on o-rings before installing.

  • Page 50: Replacing Expansion Valve

    5.12.1 Replacing expansion valve a. Remove the refrigerant charge. Refer to Section 5.3. b. Remove insulation from the expansion valve bulb and then remove the bulb from the suction line. c. Loosen flare nut and disconnect equalizer line from expansion valve. d.

  • Page 51: 5.14 Microprocessor

    WARNING Under no circumstances should anyone attempt to repair the microprocessor module or Cab Command! Should a problem develop with these components, contact your nearest Carrier Transicold dealer for replacement. Although there is less danger of electrical static discharge (ESD) damage in the outdoor environment, where the processor is likely to be handled, proper board handling techniques should be stressed.

  • Page 52: Table 5-3 R-134A Temperature Pressure Chart

    Table 5–3 R-134a Temperature Pressure Chart Temperature Pressure °F °C Psig 14.5 (in Hg) 1.00 (in Hg) 12.3 (in Hg) 0.85 (in Hg) 9.7 (in Hg) 0.67 (in Hg) 6.9 (in Hg) 0.48 (in Hg) 3.6 (in Hg) 0.25 (in Hg) 2.3 (in Hg) 0.16 (in Hg) 0.8 (in Hg)
  • Page 53 Table 5–3 R-134a Temperature Pressure Chart Temperature Pressure °F °C Psig 27.8 1.92 29.5 2.04 31.3 2.16 33.2 2.29 35.1 2.42 37.0 2.55 39.1 2.70 41.1 2.84 43.3 2.99 45.5 3.14 51.2 3.53 57.5 3.97 64.1 4.42 71.2 4.91 78.7 5.43 86.8 5.99...

  • Page 55: Troubleshooting

    SECTION 6 TROUBLESHOOTING WARNING Beware of unannounced starting of the unit. The unit may cycle the fans and operating com- pressor unexpectedly as control requirements dictate. Press OFF key on the Cab Command and turn vehicle engine off. CAUTION Under no circumstances should anyone attempt to service the microprocessor module and Cab Command.

  • Page 56: Refrigeration

    Table 6–1 Alarm Indications Reference ALARM Description CORRECTIVE ACTION Section Verify motor rotates freely / no obstructions Evaporator Fan Motor (EFM) high amp draw Replace motor Current draw of coil high or low (approx. 1.33 Defrost Valve (HGV) high amp amp) draw Replace coil...

  • Page 57: Unit Operates Long Or Continuously In Cooling

    Table 6–2 Mechanical Indications REFERENCE INDICATION / TROUBLE POSSIBLE CAUSES SECTION 6.2.3 Unit Operates Long or Continuously in Cooling Hot Load Insufficient pull down time Defective box insulation or air leak Correct Abnormal pressure 6.2.6 Refrigeration system Temperature controller malfunction 6.2.8 Compressor Defective...

  • Page 58: Abnormal Noise

    Table 6–2 Mechanical Indications REFERENCE INDICATION / TROUBLE POSSIBLE CAUSES SECTION Filter-drier partially plugged Low refrigerant charge 5.6.1 Low suction pressure Expansion valve malfunction 6.2.10 No evaporator air flow or restricted air flow 6.2.9 Excessive frost on coil Check Suction and discharge Compressor defective Replace pressures tend to equalize...

  • Page 59: Expansion Valve

    Table 6–2 Mechanical Indications REFERENCE INDICATION / TROUBLE POSSIBLE CAUSES SECTION 6.2.10 Expansion Valve Low refrigerant charge 5.6.1 External equalizer line plugged Repair Low suction pressure with high superheat Broken capillary Repair Superheat setting too high 5.12.2 Superheat setting too low 5.12.2 Low superheat and liquids External equalizer line plugged...

  • Page 61: Wiring Diagrams

    SECTION 7 WIRING DIAGRAMS INTRODUCTION This section contains Electrical Schematic Wiring Diagram covering the Models listed in Table 1-1. The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein.
  • Page 62 SWITCH TO IGNITION FIGN1 (S. KEY) CN3-1 C2F-2 C2M-2 DETAIL 1 CHART 1 CHART1 FIGN1 FRPM +BAT=12VDC 7.5A 125A CHART1 +BAT FRPM SEE CHART1 C2F-1 C2M-1 CHART2 MCPTO SEE CHART1 130°C DECAL NO. 62-61620-00 NEOS 100S SERIES ROAD CIRCUITS 62-11848...
  • Page 63 SWITCH RIGN CN3-1 C2F-2 C2M-2 IGNO IGNI DETAIL 1 FIGN2 CHART1 FIGN1 FRPM FIGN2 CHART1 +BAT=12VDC 7.5A 125A +BAT +12V SEE CHART1 C2F-1 C2M-1 CHART2 MCPTO 130°C CHART1 DECAL NO. FRPM 62-61620-50 SEE CHART1 NEOS 100S SERIES ROAD-STBY CIRCUITS 62-11848...

  • Page 65: Index

    INDEX Abnormal Noise 6–4 Filter Drier 2–1 Abnormal Pressure, Cooling 6–3 First Aid 1–1 Abnormal Pressure, Heating 6–4 Frozen Mode 4–2 Accessing Alarm Messages 3–6 Functional Settings 3–8 Adding a Partial Charge 5–7 Adjusting the Compressor Pressure Regulating Valve (CPR) 5–9 General Description 2–1...
  • Page 66 Operating Precautions 1–1 Safety Devices 2–10 Sequence of Operation 4–1 Setpoint Adjustment 3–5 Standby Mode 3–1 Perishable Mode 4–1 Starting the Unit 3–4 Preparing Manifold Gauge/Hose Set For Use 5–3 Start-Up 3–4 Product Loading 3–7 Start-Up Inspection 3–4 Stopping the Unit 3–4 System Operating Controls and Components 2–8 Quench Valve...
  • Page 68 State of California to cause cancer, birth defects, and other reproductive harm. North America Central America and Mexico Carrier Transicold Ejercito Nacional 253−A Piso 5 700 Olympic Drive Colonia Anahuac Athens, GA 30601 USA 11320 Mexico, D.F.

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