Carrier TRANSICOLD Integra 35X Operation And Service Manual
  1. Manuals
  2. Brands
  3. Carrier TRANSICOLD Manuals
  4. Refrigerator
  5. Integra 35X
  6. Operation and service manual

Carrier TRANSICOLD Integra 35X Operation And Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Operation and Service Manual
Integra 35X
Beginning with S/N PC710307
TruckRefrigeration Units
62-12023 Rev E

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Integra 35X and is the answer not in the manual?

Questions and answers

Related Manuals for Carrier TRANSICOLD Integra 35X

Summary of Contents for Carrier TRANSICOLD Integra 35X

  • Page 1 Operation and Service Manual Integra 35X Beginning with S/N PC710307 TruckRefrigeration Units 62-12023 Rev E...
  • Page 3 Operation and Service Integra 35X Beginning with S/N PC710307 Truck Refrigeration Units Printed in USA May 2020 © 2020 Carrier Corporation ●...
  • Page 4 Manual Revision History - 62-12023 Date Reason for Release 09/29/2017 New product – new manual 05/23/2018 Updated unit description; wiring harness 10/12/2018 Page 2-7 section 2.6.2; Page 2-11, 2-12, 2-13 Add CPR back into line (dlr) 10/24/2018 Updated path of flow drawings (pages 2-11, 2-12, 2-13); removed reference to alarms A46 and A47 in several sections (dlr) 4/28/2020...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS PARAGRAPH NUMBER PAGE SAFETY SUMMARY ..............1-1 GENERAL SAFETY NOTICES .
  • Page 6 START-UP ..............3.2.1 Inspection .
  • Page 7 HIGH, CONDENSER, AND LOW PRESSURE CONTROL SWITCH (HP1, HP2, LP) ..5-9 5.9.1 Removing Switches ..........5-9 5.9.2 Checking Switches .

  • Page 9: 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 10: Specific Warning, Caution, And Notice Statements

    Specific Warning, Caution, and Notice 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 DANGER − warns against an immediate hazard which WILL result in severe personal injury or death. WARNING WARNING −...
  • Page 11 Under no circumstances should anyone attempt to repair the microprocessor module or either Cab Command module! Should a problem develop with these components, contact your near- est Carrier Transicold dealer for replacement. CAUTION If starting unit for the first time after installation the compressor pressure regulating valve will...

  • Page 13: Unit Description

    Do not attempt to connect or remove power plug before ensuring the unit is OFF (press OFF key on Cab Command) and external power circuit breaker is open. This manual contains operating data, electrical data, and service instructions for the Carrier Transicold 35X truck refrigeration units listed in Table 2–1.

  • Page 14: Condensing Section

    Figure 2.1 Main Unit Components Condensing Section 2.2) contains the condenser fan and coil, receiver/drier, oil separator, The condenser section (see Figure condenser pressure control valve, condenser pressure control switch, hot gas valve, high pressure switch and microprocessor. On road/standby units the condenser also houses the standby compressor, control box and rectifier/transformer assembly.
  • Page 15 Figure 2.2 Condensing Section Road Only 1, 2, 3 Road / Standby 1, 2, 3 1. Receiver 7. Hot Gas Valve (HGS1) and Coil 2. Filter Drier 8. Oil Separator 3. Sight Glass 9. Condenser Coil 4. Frame Assembly 10. Condenser Pressure Control Valve (HGS2) & Coil 5.
  • Page 16 Figure 2.3 Evaporator 7, 8 1. Evaporator Coil Assembly 8. Thermostatic Expansion Valve (TXV) 2. Evaporator Fan Motor and Blowers (EFM) 9. Compressor Pressure Regulating Valve (CPR) 3. Heat Exchanger 10. Hot Gas Fitting 4. Defrost Termination Thermostat (DTT) 11. Road Suction Line Fitting 5.

  • Page 17: Condenser Pressure Control Valve (Hgs2)

    2.3.3 Condenser Pressure Control Valve (HGS2) The condenser pressure control valve (or condenser closing valve) is a normally open valve that is powered when the condenser pressure control switch (HP2) is closed. With the solenoid coil de-energized, the valve is in the cool mode and the compressor discharge gas is delivered to the condenser.

  • Page 18: Evaporator Coil

    Under no circumstances should anyone attempt to repair the microprocessor module or either Cab Command module! Should a problem develop with these components, contact your near- est Carrier Transicold dealer for replacement. Figure 2.4 Cab Command - Road Only Units Figure 2.5 Cab Command Two - Standby Units...

  • Page 19: Unit Specifications

    Unit Specifications 2.6.1 Compressor Reference Data Model Series 150 Displacement 8.91 in (147 cc) No. Cylinders Weight 9.68 lbs (4.4 kg) Oil Charge 6oz (180 ml) - Road and Standby Additional Oil Charge 4.23 oz (123 ml) NOTE: Additional oil is only to be charged at installation Approved oil POE - Mobil Arctic EAL 68 (Carrier Part Number 46-60002-02) 2.6.2...

  • Page 20: Torques Values Safety Devices

    c. Standby Motor Ratings Voltage Contactor Data - MRA* 115/1/60Hz 23.2A 230/1/60Hz 11.7A 230/3/60Hz 8.9A * MRA = Maximum Rotor Amps c. Road Compressor Clutch (CLHR) Coil Amp Draw = 3.75A; Resistance = 3.2 Ω d. Hot Gas Solenoid Valve (HGS1) Coil Amp Draw = 1330 mAmp;...
  • Page 21 Table 2–3 Safety Devices Unsafe Conditions Safety Device Automatic re- Device setting start with fault cleared 1 Excessive drop in pressure Automatic reset of low pres- Cutout: -2.9 psig (-0.2 Bar) sure switch Timer 5 min 2 Excessive current draw on all Electronic relay Self-protected opening microprocessor outputs (evapo-...

  • Page 22: Refrigerant Circuit

    Refrigerant Circuit 2.8.1 Refrigerant Circuit During Cooling When cooling (See Figure 2.9), the unit operates as a vapor compression refrigeration system. The main compo- nents of the system are as follows: • Reciprocating compressor • Air-cooled condenser • Thermostatic expansion valve •...
  • Page 23 Figure 2.6 Refrigeration Circuit Cooling Cycle - Road DISCHARGE LIQUID SUCTION LINE TXV EQUALIZER LINE 1. Road Compressor 12. Condenser Coil 2. Quench Thermostat (BPT) 13. Receiver/Drier with sightglass 3. Discharge Charging Port 14. Manual Shut-off Valve (King Valve) 4. Oil Separator 15.
  • Page 24 Figure 2.7 Refrigeration Circuit Heat and Defrost Cycle (HGS2 Open) - Road DISCHARGE DISCHARGE LIQUID LIQUID SUCTION LINE SUCTION LINE TXV EQUALIZER LINE TXV EQUALIZER LINE 1. Road Compressor 12. Condenser Coil 2. Quench Thermostat (BPT) 13. Receiver/Drier w/ sightglass 3.
  • Page 25 Figure 2.8 Refrigeration Circuit Heat and Defrost Cycle (HGS2 Closed) - Road DISCHARGE LIQUID SUCTION LINE TXV EQUALIZER LINE 1. Road Compressor 12. Condenser Coil 2. Quench Thermostat (BPT) 13. Receiver/Drier w/ sightglass 3. Discharge Charging Port 14. Manual Shut-off Valve (King Valve) 4.
  • Page 26 Figure 2.9 Refrigeration Circuit Cooling Cycle - Road and Standby 1. Road Compressor 13. Condenser Pressure Control Valve (HGS2) 2. Quench Thermostat (BPT) 14. Condenser Coil 3. Discharge Charging Port 15. Receiver/Drier w/ sightglass 4. Oil Separator 16. Manual Shut-off Valve (King Valve) 5.
  • Page 27 - - - - - Figure 2.10 Refrigeration Circuit Heating and Defrost Cycle (HGS2 Open) - Road and Standby 1. Road Compressor 13. Condenser Pressure Control Valve (HGS2) 2. Quench Thermostat (BPT) 14. Condenser Coil 3. Discharge Charging Port 15. Receiver/Drier w/ sightglass 4.
  • Page 28 - - - - - Figure 2.11 Refrigeration Circuit Heating and Defrost Cycle (HGS2 Closed) - Road and Standby 1. Road Compressor 13. Condenser Pressure Control Valve (HGS2) 2. Quench Thermostat (BPT) 14. Condenser Coil 3. Discharge Charging Port 15. Receiver/Drier w/ sightglass 4.

  • Page 29: Operation

    Under no circumstances should anyone attempt to service the microprocessor components or either Cab Command module. Should a problem develop with the control system, contact your nearest Carrier Transicold dealer for replacement components. The control system consists of the microprocessor (Figure 2.2), Cab Command/Cab Command Two...

  • Page 30: Road Only - Cab Command

    3.1.4 Road Only - Cab Command Figure 3.1 Cab Command - Road Only Units a. Display The digital display consists of three alphanumeric characters and three LEDs. The default value displayed is the box temperature. The microprocessor enables selection of the display in degrees Celsius or Fahrenheit. The dis- play also includes sentines for defrost operation (dF).

  • Page 31: Road/Standby - Cab Command Two

    c. Keypad The keypad consists of six keys that enable the operator to activate various functions, display operating data and modify operating parameters. Manual defrost control key Unit start-up key Unit shut-down key The unit can also be shut down with the ignition key. Unit data and function modification keys The SET key, together with the + and - keys, enables display and modification of unit operating data.
  • Page 32 During start up the brightness of the display may be adjusted: Press the Unit start-up key to turn on the unit. Press the - key during the first five seconds to decrease the display brightness. Press the + key during the first five seconds to increase the display brightness. b.
  • Page 33 c. Keypad The keypad consists of six keys that enable the operator to activate various functions, display operating data and modify operating parameters. Manual defrost control key Unit start-up key Unit shut-down key in standby or road mode In road operation, the unit can also be shut down with the ignition key. Unit Data and Function Modification Keys The SET key, together with the + and - keys, enables display and modification of unit operating data.

  • Page 34: Start-Up

    Start-Up 3.2.1 Inspection Before starting the truck engine or connecting standby power check the following: • Check condenser coil for cleanliness. • Check condition of refrigerant hoses. • Check condition and tension of compressor belt(s). • Check condition of condenser fan blade, motor and brushes. •...

  • Page 35: Start-Up Process

    If the unit is to be operated in the standby mode, connect power as follows: 1. Check that the external power source corresponds to the characteristics of the unit (see Section 2.6.3). The external power source circuit breaker must be open. 2.

  • Page 36: Minimum Shut-Down Time On Standby

    3.2.6 Minimum Shut-Down Time on Standby The minimum shut-down for the standby compressor is five minutes after reaching setpoint. After this minimum shut-down period, the unit restarts when the temperature goes out of the cycling range by ± 1.8. 3.6 or 5.4°F (± 1, 2 or 3°C). Setpoint Adjustment 3.3.1 Road Only and Road/Standby Units - Cab Command and Cab Command Two...

  • Page 37: Low Battery Voltage Alarms

    3.5.2 Low Battery Voltage Alarms There is a 40 second time delay during start-up. After this delay if the battery voltage drops below 10.5V ±0.5V, the microprocessor will react 20 seconds later and the unit will go out of temperature control mode. The microproces- sor will check the voltage after another 20 seconds.

  • Page 38: Clearing Past Alarm Messages

    Table 3–1 Alarm Messages (Continued) Road Only Standby Alarm Codes Description Relay fault, electric heat (option) EPROM Failure Low battery voltage Functional parameters have not been set or have been lost. Press and hold the SET key to clear the alarm. Refer to Section 2.7.1 to set parameters.

  • Page 39: Road/Standby Units - Cab Command Two

    • The defrost duration parameter is displayed. This setting determines the length of time in minutes the unit will remain in defrost once defrost is initiated. The defrost duration can be selected by scrolling through available options (10, 20, 25, 30 or 45 minutes) using the (+) or (-) keys. Selection MUST be validated by pressing the SET key.

  • Page 40: Microprocessor Configuration - Road / Standby Only (Cab Command Two)

    • The return air temperature will be displayed after the above sequence. Adjusting Defrost Parameters: 1. Press the Unit shut-down key to turn off the unit. 2. Hold both DEFROST and ON keys momentarily in order to display parameters. 3. Use the + and - keys to modify parameters as needed. 4.
  • Page 41 Ut°C: Celsius degree display Ut°F: Fahrenheit degree display Temperature Unit 1. Press the + or - keys to change Ut°C or Ut°F. 2. Press the SET key to validate and go to the next configuration PS12: unit voltage 12 V PS24: unit voltage 24 V Unit Voltage 1.

  • Page 42: Stopping The Unit

    EUOF: Adjusting Standby set-point identical to road set-point EUOn: Set-point locked at -31°F (-35°C) in standby mode Hybrid Unit (option) 1. Press the + or - keys to change EUOFF or EUOn. 2. Press the SET key to validate and go to the next configuration. SPOF: setpoint lock option is not active SPON: setpoint lock option is active Setpoint Lock (option)

  • Page 43: Temperature Control

    SECTION 4 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 Cooling Mode a. With return air temperature above setpoint and decreasing, the unit will be cooling with the compressor and evaporator fans operating.

  • Page 44: Frozen Mode

    4.1.3 Frozen Mode The unit operates in the frozen mode with setpoints at or below 10°F (-12°C).Operation in the frozen mode is the same as in the perishable mode except no heating takes place. Figure 4.2 Operating Sequence - Frozen Mode +5.4°F (+3°C) COOL or +3.6°F (+2°C)

  • Page 45: Service

    SECTION 5 Service WARNING Beware of unannounced starting of the unit. The unit may cycle the fans and one of the operat- ing compressors unexpectedly as control requirements dictate. To ensure unit is without power, remove power plug and remove battery negative cable. Maintenance Regular servicing is required in order to optimize the life and reliability of your unit.

  • Page 46: Installing R-404A Manifold Gauge Set

    Installing R-404A Manifold Gauge Set A manifold gauge/hose set is required for service of models covered within this manual. The manifold gauge/hose set is available from Carrier Transicold. (Carrier Transicold P/N 07-00314-00, which includes items 1 through 4, Figure 5.1). To perform service using the manifold gauge/hose set, do the following:...

  • Page 47: Preparing Manifold Gauge/Hose Set For Use

    Figure 5.1 Manifold Gauge Set (R-404A) Low Pressure Gauge High Pressure Gauge Closed (Frontseated) Opened (Backseated) Hand Valve Hand Valve To High Side To Low Side Access Valve Access Valve BLUE YELLOW (Blue Knob) (Red Knob) 1. Manifold Gauge Set 4.

  • Page 48: Pumping Down Or Removing The Refrigerant Charge

    CAUTION To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suc- tion pressure before disconnecting. 3. Backseat the low side service valve. Frontseat both manifold set hand valves. Remove the refrigeration hoses from the access valves. 4.

  • Page 49: Pumping The Unit Down If Standby Is Available

    Removing the Refrigerant Charge Connect a refrigerant recovery system [Carrier P/N MVS-115-F-L-CT (115V) or MVS-240-F-L-CT (240V)] to the unit to remove refrigerant charge. Refer to instructions provided by the manufacturer of the refrigerant recovery system. 5.3.1 Pumping the Unit Down If Standby Is Available To service the moisture liquid indicator, liquid line check valve, expansion valve, quench valve, evaporator coil, compressor pressure regulating valve, or suction bypass valve, pump the refrigerant into the high side as fol-lows: 1.

  • Page 50: Preparation

    5.5.2 Preparation 1. Evacuate and dehydrate only after pressure leak test (refer to Section 5.4). 2. Essential tools to properly evacuate and dehydrate any system include a good vacuum pump (5 cfm = H volume displacement, P/N07-00176-01) and a good vacuum indicator such as a thermocouple vac- uum gauge (vacuum indicator).

  • Page 51: Charging The Refrigeration System

    Figure 5.2 Vacuum Pump Connection 1. Refrigerant Recovery Unit 5. Refrigerant Cylinder 2. Suction Valve (Low Side) 6. Electronic Vacuum Gauge 3. Manifold Gauge Set 7. Vacuum Pump Valve 4. Discharge Valve (High Side) 8. Vacuum Pump - - - - - 7.

  • Page 52: Checking The Refrigerant Charge

    5.6.1 Checking the Refrigerant Charge Start unit in cooling mode. Run approximately ten minutes. Partially block off air flow to condenser coil increase the area blocked until compressor discharge pressure is raised to approximately 325 psig (22 Bars). The charge is correct if there are no bubbles at the liquid line sight glass. 5.6.2 Installing a Complete Charge NOTE...

  • Page 53: Checking For Non-Condensables

    - - - - - Checking for Non-Condensables To check for non-condensables, proceed as follows: 1. Stabilize system to equalize pressure between the suction and discharge side of the system. 2. Check temperature at the condenser and receiver. 3. Check pressure at the king valve access port or the liquid line charging port. 4.

  • Page 54: Hot Gas, Condenser, And Low Pressure Control Switch (Hgs1, Hgs2, Bpv)

    5. Open cylinder valve. While observing indicator (light or meter), slowly close bleed-off valve and increase pressure until the switch opens or closes. Slowly open bleed-off valve (to decrease pressure) until switch reverts to normal position. 6. If switch does not activate within tolerances provided, replace switch. Test new switch before installation. Figure 5.4 Typical Setup For Testing Pressure Switches HP1, HP2 and LP 1.Cylinder valve and gauge 4.

  • Page 55: Replacing Valve Internal Parts

    1. Remove coil snap cap, voltage plate and coil assembly. Disconnect leads and remove coil junction box if necessary. 2. Verify coil type, voltage and frequency. This information appears on the coil voltage plate and the coil housing. 3. Place new coil over enclosing tube and then install voltage plate and snap cap. 5.10.2 Replacing Valve Internal Parts 1.

  • Page 56: 5.12 Thermostatic Expansion Valve

    5.12 Thermostatic Expansion Valve MOP expansion valve characteristics: • In order to avoid compressor overcharge, an MOP expansion valve (with limited flow) is used. • Operating: the expansion valve will not open more than the MOP setpoint. Any temperature increase at the bulb should not open the expansion valve further.

  • Page 57: Checking The Txv Orifice Strainer

    7. Note the temperature of the suction gas at the expansion valve bulb. 8. Subtract the saturation temperature determined in Step 6 from the average temperature measured in Step 7. The difference is the superheat of the suction gas. Refer to Section 2.6.2 for superheat setting.

  • Page 58: 5.16 Evaporator Coil Cleaning

    5.16 Evaporator Coil Cleaning The use of recycled cardboard cartons is increasing. The recycled cardboard cartons create much more fiber dust during transport than “new” cartons. The fiber dust and particles are drawn into the evaporator where they lodge between the evaporator fins. If the coil is not cleaned on a regular basis, sometimes as often as after each trip, the accumulation can be great enough to restrict air flow, cause coil icing, repetitive defrosts and loss of unit capacity.
  • Page 59 Table 5–6 R-404A Temperature-Pressure Chart (Continued) Temperature Pressure °F Psig Kg/cm ° 45.6 3.21 3.14 48.0 3.37 3.31 50.4 3.54 3.47 52.9 3.72 3.65 55.5 3.90 3.83 58.1 4.08 4.01 60.9 4.28 4.20 63.7 4.48 4.39 66.5 4.68 4.59 69.5 4.89 4.79 72.5...
  • Page 60 Table 5–6 R-404A Temperature-Pressure Chart (Continued) Temperature Pressure °F Psig Kg/cm ° 402.3 28.28 27.74 427.6 30.06 29.48 454.0 31.92 31.30 Table 5–7 Sensor Resistance (RAS) Standby Only Temperature Resistance In Ohms °F ° -28.9 165,300 -23.3 117,800 -17.8 85,500 -12.2 62,400 -6.7...

  • Page 61: Troubleshooting

    CAUTION Under no circumstances should anyone attempt to service the microprocessor (see Section 5.15) or either Cab Command module. Should a problem develop with the microprocessor, contact your nearest Carrier Transicold dealer for replacement. Introduction Table 6–1 Alarm Indications Alarm...
  • Page 62 Table 6–1 Alarm Indications (Continued) Road Compressor Replace Clutch (CLHR) not Current draw of road clutch coil either high or low functioning properly Current draw of contactor coil high or low (0.2 amps - 3 phase; 0.5 amps - 1 phase) Standby Contactor (MC) high amp draw Verify plunger moves freely...
  • Page 63 Table 6–1 Alarm Indications (Continued) Contactor coil open circuit Replace Compressor Contactor (MC) Open Circuit Wiring to coil open Check Condenser fan motor defective Section 5.16 Condenser Fan Motor (CFM) Open Circuit Wiring to motor open Check Hot Water Solenoid Valve coil shorted Replace Valve (HWV) Open...

  • Page 64: Refrigeration

    Table 6–2 Mechanical Indications Indication/Trouble Possible Causes Reference Refrigeration 6.2.1 Unit Will Not Cool Compressor not functioning prop- Compressor drive (clutch) defective Replace erly Compressor defective Refrigeration system Defrost cycle has not terminated Section 6.2.5 Abnormal pressure Section 6.2.6 Hot gas solenoid not functioning properly (HGS1) Section 5.10 6.2.2 Unit Runs But Has Insufficient Cooling...

  • Page 65: Abnormal Pressure

    Table 6–2 Mechanical Indications (Continued) 6.2.6 Abnormal Pressure Cooling High discharge pressure Condenser coil dirty Section 5.17 Noncondensibles or refrigerant overcharge Section 5.6.1 Condenser fan/motor defective Section 5.16 Low discharge pressure Compressor defective Replace Hot gas solenoid not functioning properly Section 5.10 Low refrigerant charge Section 5.6.1...

  • Page 66: Expansion Valve

    Table 6–2 Mechanical Indications (Continued) No Evaporator Air Flow or Restricted Air Flow Evaporator coil blocked Heavy frost on coil Check Coil dirty Section 5.16 No or partial evaporator air flow Evaporator fan loose or defective Check Evaporator fan rotating backwards Check Evaporator air flow blocked in box Check...

  • Page 67: Schematic Diagrams

    Under no circumstances should anyone attempt to service the microprocessor (see Section 5.15) or either Cab Command Module. Should a problem develop with the microprocessor, con- tact your nearest Carrier Transicold dealer for replacement. Introduction Schematic diagrams for the unit models listed in Table 2–1...
  • Page 69 wiring schematics...
  • Page 71 wiring schematics...
  • Page 73 wiring schematics...
  • Page 75 wiring schematics...

  • Page 77: Index

    INDEX Accessing Alarm Messages 3-8 First Aid Alarm Display Frozen Mode Cab Command, Road Only 3-2 General Description Display 3-2 General Safety Notices 1-1 Introduction 3-1 Keypad 3-3 Unit operating LEDs 3-2 Heating Mode Caution Statements High Pressure Switch (HP1) 2-5 Charging the Refrigeration System 5-7 Hot Gas Solenoid Valve (HGS1) 2-2 Checking the Charge 5-8...
  • Page 78 Refrigerant Leak Checking 5-5 Measuring Superheat 5-13 Refrigerants Replacing 5-13 Refrigeration System Data 2-7 Torques Values Safety Devices 2-8 Removing the Manifold Gauge Set 5-3 Troubleshooting Alarm Indications 6-1 Replacing Valve Internal Parts 5-12 Troubleshooting Evaporator Air Flow Problems 6-6 Expansion Valve 6-6 Malfunction Hot Gas Solenoid 6-6 Malfunction Standby Compressor 6-6...
  • Page 80 Central America and Mexico Carrier Transicold Carrier Transicold 700 Olympic Drive Ejercito Nacional 253-A Piso 5 Athens, GA 30601 USA Colonia Anahuac 11320 Mexico D.F. ©2020 Carrier Corporation. Printed in USA 05/20. Carrier, Carrier Transicold is a registered trademark of Carrier Corporation.

This manual is also suitable for:

Pc710307

Table of Contents

Save PDF