Page 1 Trailer & Rail Refrigeration FUSIBLE CONDENSER PLUG RECEIVER BYPASS CHECK VALVE FIL TER-DRIER OPERATION & SERVICE MANUAL For The X4 7300 & X4 7500 Trailer and Rail Refrigeration Units 62-11637 Rev B...
Page 2 OPERATION & SERVICE MANUAL For The X4 7300 & X4 7500 Trailer and Rail Refrigeration Units © Carrier Corporation, 2014 Printed in U. S. A. September 2014...
Page 3: Table Of Contents
TABLE OF CONTENTS PARAGRAPH NUMBER Page SAFETY PRECAUTIONS ............. . . 1–1 SAFETY PRECAUTIONS .
Page 4 2.4.4 Evaporator Switches, Transducers and Sensors ....... . 2–10 a. Evaporator Outlet Pressure Transducer (EVOP) .
Page 5 3.12 ADVANCED USER ............3–15 3.13 UNIT DATA...
Page 6 4.11 PREPROGRAMMED SOFTWARE OVERRIDES ........4–14 4.11.1 Cargo Protect Mode .
Page 7 00022 LOW SUCTION SUPERHEAT ..........7–12 00027 HIGH SUCTION PRESSURE .
Page 8 P00141 PRETRIP STOPPED BY USER ..........7–49 P00143 CHECK CLUTCH CIRCUIT .
Page 9 00246 EEPROM WRITE FAILURE ..........7–74 00248 CONFIG MODE / HP2 ERROR .
Page 10 8.5.15 Water Pump/Alternator Belt ..........8–13 8.5.16 Crankcase Breather .
Page 11 UNIT TROUBLESHOOTING ............. 9–1 ENGINE .
Page 12 LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figure 2.1 Front View - Refrigeration System Components ........2–2 Figure 2.2 Front View - Engine, Control System &...
Page 13 Figure 8.16 Water Pump/Alternator Belt ........... . 8–14 Figure 8.17 Engine Crankcase Breather .
Page 14 LIST OF TABLES TABLE NUMBER Page Table 2–1 Model Chart ..............2–1 Table 2–2 Additional Support Manuals .
Page 15: Safety Precautions
SECTION 1 - SAFETY PRECAUTIONS PARAGRAPH NUMBER Page SAFETY PRECAUTIONS ............1–1 SPECIFIC WARNING, CAUTION, AND NOTICE STATEMENTS .
Page 16 (e.g., checking the belt, checking the oil, checking the electri- Your Carrier Transicold refrigeration unit has been cal connections), make certain that the START/RUN- designed with the safety of the operator in mind. During OFF switch is in the OFF position.
Page 17 SPECIFIC WARNING, CAUTION, AND NOTICE WARNING STATEMENTS To help identify the label hazards on the unit and Under no circumstances should ether or explain the level of awareness each one carries, an any other starting aids be used to start explanation is given with the appropriate conse- the engine.
Page 18 Should a problem develop capscrews all the way before breaking with these components, contact your seal. Entrapped pressure could result in injury. nearest Carrier Transicold dealer for replacement. WARNING Do not unscrew enclosing tube nut all the way before breaking seal. Entrapped Use Texaco Havoline extended life cool- pressure could result in injury.
Page 19 Unit uses R404A and POE oil. The use of inert gas brazing procedures is manda- when work is complete. If Technician tory for all Carrier Transicold refrigera- Mode is not canceled, Technician Mode tion units; otherwise compressor failure will be available for 60 minutes after the will occur.
Page 20 Unit uses R404A and POE oil. The use of inert gas brazing procedures is manda- tory for all Carrier Transicold refrigera- tion units; otherwise compressor failure will occur. For more information Refer to...
Page 21: Safety Decals
SAFETY DECALS 62-11637 1–6...
Page 22 62-03958 1–7 62-11637...
Page 23 62-11637 1–8...
Page 24 1–9 62-11637...
Page 25: Figure 2.4 Power Train
SECTION 2 - UNIT DESCRIPTION PARAGRAPH NUMBER Page INTRODUCTION ............. 2–1 GENERAL DESCRIPTION .
Page 26: Unit Description
WARNING mounts separately on the front outside corner of the compartment. APX control system equipped units may Temperature control is provided by the Carrier Transi- start automatically at any time the cold APX control system (Refer to Section 2.5).
Page 27: Figure 2.1 Front View - Refrigeration System Components
Figure 2.1 Front View - Refrigeration System Components MOUNT ATT AS SHOWN PARTITION 16,17 18,19 1. Condenser Coil & Subcooler 14. Compressor Suction Temperature Sensor (CST) 2. Ambient Air Temperature Sensor (AAT) 15. Discharge Service Valve & Strainer 3. Condenser Fan 16.
Page 28: Engine
Figure 2.2 Front View - Engine, Control System & AutoFresh Components 1. Coolant Bottle 19. Engine Oil Fill & Dipstick 20. Rack Position Sensor (RPS) 2. Clutch (CLH) 21. Engine Oil Drain 3. Fuel Filter/Heater (FH) or Fuel Head Assembly 4.
Page 29: Evaporator Outlet Pressure Transducer (Evop)
Figure 2.3 Evaporator Section - Grille Removed MOUNT DTT AS SHOWN TUBE SHEET 1. Evaporator Air Nozzle 9. Compressor Suction Modulation Valve (CSMV) 10. Defrost Termination Temperature Sensor (DTT) 2. Evaporator Fan 3. Supply Air Temperature Sensor (SAT) 11. Return Air Temperature Sensor (RAT) 12.
Page 30 Figure 2.2) transducer (MAP). These sensors are installed when consists of an engine-compressor drive (unidrive Carrier Transicold factory monitoring of the air system assembly), power train (which drives the fans), AutoF- is required. resh Air Exchange, condenser fan, condenser, radiator, heat exchanger, solenoid valves, defrost air switch, 2.3.3...
Page 31: Alternator
2.3.4 Alternator sensor and the suction and discharge pressure trans- ducers. The compressor draws refrigerant gas from the Electrical power for the control system and for charging evaporator and delivers it to the condenser at an the battery is provided by the 12 VDC alternator. increased temperature and pressure.
Page 32: Unloaded Operation
Figure 2.5 Compressor Cylinder Head Unloaded Valve Stem Solenoid Valve Gas Bypass Port Spring Guide Bypass Valve Spring Piston Bleed Orifice Cylinder Discharge Valve Strainer Discharge Manifold Suction Manifold Discharge Check Valve Assembly Valve Plate Cylinder Suction Valve b. Unloaded Operation When the pressure behind the piston has been reduced sufficiently, the valve spring will force the pis- Pressure from the discharge manifold...
Page 33: Loaded Operation
Figure 2.6 Compressor Cylinder Head Loaded Valve Stem Solenoid Gas Bypass Port Valve Spring Guide Bypass Valve Spring Piston Bleed Orifice Strainer Cylinder Discharge Valve Discharge Manifold Suction Manifold Discharge Check Valve Assembly Valve Plate Cylinder Suction Valve c. Loaded Operation b.
Page 34: Condenser Coil
2.3.9 Condenser Coil sensitive perishable products. When transporting these products, it may be desirable to maintain normal atmo- The condenser coil is a microchannel type and acts as spheric conditions (prevent the build up of CO and the a heat exchanger in which the compressed refrigerant depletion of O ) by using fresh air exchange, in addi- gas is lowered in temperature and condensed into a...
Page 35: System Operating Controls And Components
DataLink data recorder and The following additional special features are incorpo- used to determine the required position of the evapora- rated into the Carrier Transicold APX control system: tor expansion valve. • An easy to read LCD display MessageCenter which clearly displays all required information.
Page 36: Power Control Module
Figure 2.7 Power Control Module F6 (10 amp) located at the AutoFresh Exchange solenoid harness connector. 1. Fuse (F5=30 amp), Power Enable Relay 9. Battery Positive Connection (T1) 2. Fuse (F1=5 amp), Main Microprocessor/Buzzer 10. Battery Negative Connection (T2) Power 11.
Page 37: Engine Control Unit (Encu)
Figure 2.8 Display Module START/STOP - Status Bar Alarm LED ALARM Key = (Select) Key CONTINUOUS Key ALARM START/STOP START/STOP DIESEL CONTINUOUS DEFROST Key Arrow DEFROST Keys MENU MENU Key BOX TEMPERATURE F SETPOINT F STATUS OK LCD Display START/RUN USB Interface Port Soft Keys MessageCenter...
Page 38: Display Module Keys
k. Display Module Keys Figure 2.9 Light Bar ALARM Key ALARM The ALARM key allows viewing of the alarms stored in the system. UP ARROW and DOWN ARROW AMBER START‐STOP Keys These keys allow scrolling through the selections presented. GREEN EQUAL Key (ENTER) DEFROST The EQUAL key is used to confirm a...
Page 39: Remote Temperature Sensors
2.6.3 Remote Temperature Sensors When the ambient air sensor is reading 68°F (20°C) or lower, the control system will enable this circuit. The The unit is provisioned to connect one or two remote circuit is disabled when the ambient air sensor reading temperature sensor directly to the control system.
Page 40: Engine Data
ENGINE DATA Unit Specification Engine Model V2203L−DI−EB4−CTD−2 (Base Part Number 26−00132) Rated Power 24.7 hp (18.5 KW) @1800 rpm Displacement 135 in (2.2 liters) No. Cylinders NOTE: Refer to Table 2–1 for engine speed settings Weight 439 lbs (199 kg) Coolant Capacity 2.9 U.S.
Page 41: Refrigeration System Data
Opens, on pressure rise, at: 465 ± 10 psig (32 ± 0.7 bar) Closes, on pressure fall, at: 350 ± 10 psig (24 ± 0.7 bar) Unit Dry Weight, Less Battery X4 7300 = 1610 (730 KG) X4 7500 = 1620 pounds (735 KG) Battery 50 pounds (23 KG.) Fan Clutch Air Gap 0.011 to 0.085 inch (0.28 to 2.2 mm)
Page 42: Refrigeration Circuit During Cooling
2.12 REFRIGERATION CIRCUIT DURING COOL- The refrigerant then flows through the liquid line sole- noid valve (SV2) to the suction line heat exchanger. Here the liquid is further reduced in temperature by giv- When cooling, (See Figure 2.10) the unit operates as a ing off some of its heat to the suction gas.
Page 43: Figure 2.10 Refrigeration Circuit Cooling
Figure 2.10 Refrigeration Circuit Cooling CONDENSER FUSIBLE PLUG RECEIVER BYPASS CHECK SUBCOOLER VALVE EVXV EVOT EVOP CSMV LIQUID LINE SERVICE VALVE HEAT FILTER-DRIER EXCHANGER EVAPORATOR DRAIN PAN DISTRIBUTOR VIBRASORBER VIBRASORBER DISCHARGE CHECK VALVE COMPRESSOR 62-11637 2–18...
Page 44: Figure 2.11 Refrigeration Circuit - Heat And Defrost
2.13 REFRIGERANT CIRCUIT - HEATING AND The refrigerant is warmer than the air that is circulated DEFROSTING over the tubes by the evaporator fan. The evaporator tubes have aluminum fins to increase heat transfer; When vapor refrigerant is compressed to a high pres- therefore heat is transferred to the air circulated over sure and temperature in a reciprocating compressor, the evaporator.
Page 45 SECTION 3 - OPERATION PARAGRAPH NUMBER Page DISPLAY ..............3–1 DISPLAY SCREENS .
Page 46: Operation
SECTION 3 OPERATION DISPLAY WARNING APX control system equipped units may start automatically at any time the START/RUN - OFF switch (SROS) is in the START/RUN position. Also, the unit may be fitted with two way commu- nication equipment that will allow starting of the unit from a remote location even though the switch is in the OFF position.
Page 47: Display Screens
DISPLAY SCREENS LCD DISPLAY SCREENS START/STOP DIESEL BOX TEMPERATURE F SETPOINT F STATUS OK DEFAULT SCREEN START/STOP DIESEL Viewing Menu Soft Key Selections Press Menu Key to Scroll INTELLISET HOUR UNIT METERS DATA TYPICAL MENU SCREEN SAMPLE SCREEN (1 OF 3) DISPLAYED ITEM #1 DISPLAYED ITEM #2 DISPLAYED ITEM #3...
Page 48: Starting
START/RUN position. • Check the battery voltage. A booster battery may be needed. 2. The system will display the Carrier Transicold logo, display the default screen, present lan- • Check for blown fuse(s). guage selection and the hour meter readings (if •...
Page 49 • The above settings are examples of possible settings. Factory IntelliSets are available from your authorized Carrier Transicold Truck/Trailer dealer. • An IntelliSet may be pre-programmed as “IntelliSleep” which allows Sleep Mode to be entered by simply changing to that IntelliSet.
Page 50: Pretrip
PRETRIP Pretrip is a set of tests run by the control system to check unit operation. It is recommended that a Pretrip is run prior to loading the refrigerated compartment. It will indicate a failure if one is detected. A Pretrip can be started at any box temperature. If Pretrip is started while the unit is in a Start-Stop off cycle the unit will start during the course of the test.
Page 51 PRETRIP STATUS Pretrip Type: Cool - Ambient 75 F Test 2 of 10 - Current Test Current Draw - 2 Amps UNIT TEST STOP DATA RESULTS PRETRIP 5. During Pretrip Test 1, verify that the buzzer is energized, the amber light on the light bar is illuminated (if equipped) and the AutoFresh air port opens and closes (if equipped).
Page 52 In the Heat Pretrip Mode, the unit will operate in four cylinder Low Speed Heat. The System will check for a rise in compressor discharge pressure, fan clutch operation and SV1 operation. Appropriate alarms will be displayed if any problem is detected. Test 4 in Heat Pretrip may last up to 12 minutes depending on ambient and compartment temperature and unit condition.
Page 53: Changing Setpoint
CHANGING SETPOINT ALARM START/STOP IntelliSets (2 of 7) START/STOP DIESEL COOL START/STOP DIESEL COOL PRETRIP MENU CONTINUOUS IntelliSet Off Start Pretrip Viewing Menu Soft Key DEFROST Banana Active View Results of Last Pretrip Selections Flowers Press Menu Key to Scroll Lettuce MENU Cheese...
Page 54: Start-Stop Operation
START-STOP OPERATION 1 & 3 ALARM START/STOP IntelliSets (2 of 7) DIESEL START/STOP START/STOP DIESEL COOL COOL PRETRIP MENU CONTINUOUS IntelliSet Off Start Pretrip Viewing Menu Soft Key DEFROST Banana Active View Results of Last Pretrip Selections Flowers Press Menu Key to Scroll Lettuce MENU Cheese...
Page 55: Continuous Operation
CONTINUOUS OPERATION 1 & 3 ALARM START/STOP IntelliSets (2 of 7) CONTINUOUS DIESEL START/STOP DIESEL COOL COOL START/STOP DIESEL COOL PRETRIP MENU CONTINUOUS IntelliSet Off Start Pretrip Viewing Menu Soft Key DEFROST Banana Active View Results of Last Pretrip Selections Flowers Press Menu Key to Scroll Lettuce...
Page 56: Control System Information
3.9.1 Control System Information The control system information that may be recorded is as follows: • DataLink data recorder time clock date / time • Controller (main microprocessor) Serial Number • Setpoint • Controller (main microprocessor) Software Rev • DataLink data recorder settings •...
Page 57 ALARM START/STOP START/STOP START/STOP DIESEL DIESEL COOL COOL CONTINUOUS Viewing Menu Soft Key DEFROST Viewing Menu Soft Key Selections Selections Press Menu Key to Scroll Press Menu Key to Scroll MENU INTELLISET PRETRIP HOUR UNIT LANGUAGE DATA EXIT METERS DATA RECORDER 1.
Page 58: 3.10 Manual Defrost
3.10 MANUAL DEFROST ALARM START/STOP START/STOP DIESEL DEFROST START/STOP DIESEL COOL CONTINUOUS Viewing Menu Soft Key DEFROST Selections DEFROST Press Menu Key to Scroll MENU SETPOINT F INTELLISET PRETRIP HOUR UNIT METERS DATA DEFROST CYCLE STARTED 1. With the system powered up (START/RUN-OFF switch in the START/RUN position) press the MANUAL DEFROST key.
Page 59: 3.11 Language Selection
3.11 LANGUAGE SELECTION ALARM START/STOP START/STOP START/STOP DIESEL DIESEL COOL COOL CONTINUOUS Viewing Menu Soft Key DEFROST Viewing Menu Soft Key Selections Selections Press Menu Key to Scroll Press Menu Key to Scroll MENU INTELLISET PRETRIP HOUR UNIT LANGUAGE DATA EXIT METERS DATA...
Page 60: 3.12 Advanced User
3.12 ADVANCED USER ALARM START/STOP IntelliSets (2 of 7) START/STOP DIESEL COOL START/STOP DIESEL COOL PRETRIP MENU CONTINUOUS IntelliSet Off Start Pretrip Viewing Menu Soft Key DEFROST Banana Active View Results of Last Pretrip Selections Flowers Press Menu Key to Scroll Lettuce MENU Cheese...
Page 61: 3.13 Unit Data
3.13 UNIT DATA ALARM START/STOP START/STOP DIESEL COOL CONTINUOUS Viewing Menu Soft Key DEFROST Selections Press Menu Key to Scroll MENU INTELLISET PRETRIP HOUR UNIT METERS DATA 1. With the system powered up (START/RUN-OFF switch in the START/RUN position) or in PC Mode, press the MENU key until UNIT DATA is displayed.
Page 62: Table 3-1 Unit Data
Table 3–1 Unit Data DATA DEFINITION ENGINE This is only displayed when the optional sensor is installed and config- FUEL LEVEL ured YES. Displays % of fuel in tank. BATTERY Battery voltage AMP DRAW Battery charging or discharging amps ENGINE COOLANT TEMP Engine coolant temperature ENGINE SPEED Engine revolutions per minute...
Page 63: 3.14 View Active Alarms
3.14 VIEW ACTIVE ALARMS ALARM START/STOP ACTIVE ALARMS (2 of 5) CONTINUOUS A13 High Discharge Pressure DEFROST A97 Check SV2 Circuit A86 Check UL2 Circuit MENU CLEAR BACK ALARMS 1. With the system powered up (START/RUN-OFF switch in the START/RUN position) or in PC Mode press the ALARM key.
Page 64: 3.15 View Hour Meters
3.15 VIEW HOUR METERS ALARM START/STOP START/STOP DIESEL COOL CONTINUOUS Viewing Menu Soft Key DEFROST Selections Press Menu Key to Scroll MENU INTELLISET PRETRIP HOUR UNIT METERS DATA 1. With the system powered up (START/RUN-OFF switch in the START/RUN position) or in PC Mode, press the MENU key until HOUR METERS is displayed.
Page 65: Table 3-2 Functional Parameters
FUNCTIONAL PARAMETERS (1 OF 5) FUNCTION DESCRIPTION (1 OF 3) FUNCTION DESCRIPTION (1 OF 3) ECONOMY SETTINGS FUNCTION 1 SELECTION FUNCTION 1 SELECTION TEMPERATURE SETTINGS FUNCTION 2 SELECTION FUNCTION 2 SELECTION START-STOP SETTINGS FUNCTION 3 SELECTION FUNCTION 3 SELECTION SAMPLE SCREEN A OVERRIDES SAMPLE SCREEN B SAMPLE SCREEN C...
Page 66 Table 3–2 Functional Parameters FUNCTION PARAMETER DESCRIPTION SELECTIONS TEMP CONTROL RETURN AIR The evaporator has both a Return Air Sensor and a Supply Air Sensor. SUPPLY AIR RETURN AIR = With this setting the unit will operate so that the return air (air entering the evaporator) will be controlled to setpoint.
Page 67 Table 3–2 Functional Parameters FUNCTION PARAMETER DESCRIPTION SELECTIONS RESTART 5 to 18°F (0.28 to Following the Minimum Off Time, should a compartment tem- TEMPERATURE 10°C) (in 0.5° incre- perature drift this far above or below setpoint in the Perishable ments) Range or above setpoint in the Frozen Range, the unit will re- start.
Page 68: 3.17 Sleep Mode
3.17 SLEEP MODE Sleep Mode is generally used in cold ambients when the unit will be off for an extended period of time with no product inside the refrigerated compartment. Many times units are difficult to start due to a discharged battery, thickened engine oil, etc.
Page 69 In ambients above 32°F (0°C), the unit will run as above, and will monitor battery voltage and charging amps only (according to the Configuration setting). In ambients below 32°F (0°C), the unit will run for 20 minutes minimum run time, then restart every 60 minutes (maximum off time).
Page 70: 3.18 Stopping Unit
Carrier Transicold has worked with approved communication providers with recommended installation locations, and wiring connections to Carrier units. Instructions for installing this equipment is supplied by each individual pro- vider, and not by Carrier Transicold. Communications electrical harnesses are available from Carrier Transicold Performance Parts Group (PPG).
Page 71: 3.20 Remote Panel
3.20 REMOTE PANEL The unit may be fitted with an optional remote control panel. The remote panel, which is very similar to the main control panel, displays compartment setpoints, compartment temperatures and operating modes (heat, cool or defrost). The setpoint may be modified and the unit may be started and stopped using the remote panel. This compact remote panel can be mounted to suit the individual operator’s preferences −...
Page 72 Turning the Unit ON/OFF Using the Remote Panel: NOTES The unit can be shutdown using either the remote panel or the SROS switch on the Main Panel. The remote panel cannot operate if the SROS switch is in the OFF position. In order to prevent a constant drain on the battery, the remote panel illuminates when the SROS switch is turned on, but the remote panel will turn off after 30 minutes of inactivity.
Page 73 SECTION 4 - ENGINE AND TEMPERATURE CONTROL PARAGRAPH NUMBER Page 4.14.1 INTRODUCTION ............. 4–1 SEQUENCE OF OPERATION - ELECTRICAL .
Page 74: Introduction
SECTION 4 ENGINE AND TEMPERATURE CONTROL NOTES 1. If the unit is in an alarm condition, the control system alarm response may override the operation described herein. If an alarm is displayed in the MessageCenter, refer to the specific alarm description in Section 9 “Unit Control”...
Page 75: Figure 4.1 Auto Start Sequence
The engine start sequence consists of periods of time the cranking period. The engine is considered to be with the engine preheater (EPH − power from 3MM−14 running, and the start sequence will be stopped, when engine speed is greater than 1000 rpm and the engine through PCM −27 to EPHT) and starter (SM −...
Page 76: Modes Of Operation
MODES OF OPERATION 4.4.2 Cooling In the Cool Mode, the control system will operate the Once the engine is started, the system will operate in unit controls as follows: Start-Stop or Continuous Operation energizing and de- energizing the following components: Engine •...
Page 77: Cool Pulsed Mode
As the system operates in the Heat Mode with SV2 Note: For CSMV/EVXV control, see following step d. closed, discharge pressure tends to decrease. As the c. Heat Pulsed Mode system operates in the Heat Mode with SV2 open dis- charge pressure tends to increase.
Page 78: Temperature Control
TEMPERATURE CONTROL • When SEPARATE is chosen the control action will be different, depending on whether the set- 4.5.1 Temperature Determination point is in the Perishable Range or in the Frozen Range (refer to Section 4.5.2). The control system monitors the temperature readings from the supply and return temperature sensors to •...
Page 79: Re-Start Parameters
2. The engine coolant temperature has warmed If battery voltage is at or below the VOLTAGE FOR START-STOP RESTART Configuration value the Each time the unit is started it must continue to run until engine will be started. The value may be set from 12.0 the coolant temperature rises to 95°F (35°C) to ensure to 12.8 volts.
Page 80: Figure 4.2 Start-Stop Default Operating Sequence
Figure 4.2 Start-Stop Default Operating Sequence FALLING REFRIGERATED COMPARTMENT TEMPERATURE Pull Down SWITCH POINT +3.6 F (+2.0 C ) +0.5 F (+0.3 C ) Start-Stop Setpoint Setpoint Off Cycle -0.5 F (+0.3 C ) -3.6 F (-2.0 C ) Pull-Up RISING REFRIGERATED COMPARTMENT...
Page 81: Figure 4.3 Continuous Default Operating Sequence
Table 4–2 Continuous Operation Modes SETPOINT ALLOWED OPERATION 32°F (0.0°C) and above UltraFresh with FreshProtect (if Configured*) Below 32°F (0.0°C) & Above 10.4°F (-12°C) UltraFresh (FreshProtect Not Applicable) Less than 10.4°F (-12°C) Cooling (only) with UltraFreeze * Refer to Section 4.10.1 for information on FreshProtect.
Page 82: Defrost
The first parameter is the AUTOFRESH AIR Functional NOTE Parameter. It may be set to CLOSED, OPEN or CFM The unit will operate in high speed in the CONTROL. When set to CLOSED, AutoFresh Air is not Defrost Mode except during pump down in operational.
Page 83: High Ambient Defrost Operation
4.9.5 High Ambient Defrost Operation • When suction pressure has risen 10 PSIG (0.7 bar) above start point or after 15 seconds, the High ambient defrost is used if the ambient air tem- control system will place the unit in low speed, perature is greater than 80°F (26.7°C).
Page 84: Figure 4.4 Range Lock Settings - Non Overlapping
Figure 4.4 Range Lock Settings - Non Overlapping Range Lock 1 & 2 Range 1 is set for Range 2 is set for 28 to 55 F 0 to -22 F (-2.2 to +12.8 C) (-17.8 to -30 C) Range 2 Range 1 -23.3 -17.8...
Page 85: Productshield
The primary time that it is important to determine which NOTE range is to be Range 1 and which is to be Range 2 is In ProductShield Econo: Go to Start/Stop, when the ranges overlap each other. the delta-t must be lower than the value In example 2 (see Figure 4.5), the ranges have been...
Page 86 ProductShield Econo - Go to Continuous Opera- Operation in High Air is controlled by four Configura- tion. tions; PRODUCTSHIELD HIGH AIR, HIGH AIR MINI- M U M T E M P E R AT U R E , H I G H A I R M A X I M U M When the unit is set for Start/Stop, ProductShield TEMPERATURE and HIGH AIR DELTA-T.
Page 87: Air Flow
Once the control system detects that the ambient tem- stant temperature. The engine will remain in high perature has dropped below the pre-programmed tem- speed when HIGH is selected, unless a low speed perature, the unit will switch into ProductShield Winter override (refer to Section 4.11.2) is active.
Page 88: Unloader Control Overrides
6. RAT & SAT Alarms. 1. High Ambient. When the A122 - “CHECK RETURN AIR SENSOR” If the ambient temperature is above 120°F (48.9°C) and A123 - “CHECK SUPPLY AIR SENSOR” alarms when the engine starts UL1 and UL2 will both be are both active at the same time the control system will unloaded for the first 2 minutes of unit operation.
Page 89: Csmv Control Overrides
8. Start/Stop Override. 2. Engine RPM. If the system is running in a Start/Stop run cycle, and When the engine throttle position has been more than the minimum run time has expired and the compart- 90% for three seconds the control system will monitor ment temperature is not at setpoint, both unloaders will actual engine RPM verses desired engine RPM (if the be loaded to increase the unit capacity so that set point...
Page 90: Figure 5.3 Inactive Alarms
SECTION 5 - CONTROL SYSTEM INTERFACE PARAGRAPH NUMBER Page INTERFACE METHODS ............5–1 TECHNICIAN MODE .
Page 91: Figure 5.1 Technician Mode
SECTION 5 CONTROL SYSTEM INTERFACE INTERFACE METHODS There are four methods for interfacing with the APX control system: 1. Driver/Advanced User Interface - Driver & Advanced User Interface activities such as start, stop, Pretrip, reading alarms, reading data and changing Functional Parameters may all be performed using the display mounted keys (refer to Section 2.
Page 92: Figure 5.2 Technician Hour Meters
3. Press the ▲ or ▼ key to scroll through the list of menu items. Press the “=” key to enter the settings or test modes. Technician Mode should be canceled when work is complete. If Technician Mode is not can- celed, Technician Mode will be available for 60 minutes after the last key press without requir- ing a code, even after placing the SROS in the OFF and then back in the RUN/STOP position.
Page 93: Inactive Alarms
3. The hour meter screen will display with a 15 second timeout. Press the Arrow keys to scroll through the available selections. With the desired sub-menu highlighted, Press the “=” key to view the data. STANDARD HOUR METERS OTHER METERS & COUNTERS Engine Protect Hours Engine Hours 1060 Hours...
Page 94: Figure 5.4 Setting Configurations
1. Enter the Technician Mode, as described in Figure 5.1, then press the ALARM key. 2. Press the INACTIVE ALARMS soft key. 3. If there are inactive alarms, the alarm number will be displayed preceded by the letter “I” (inactive alarm) or “P”...
Page 95 4. Data entry screens are displayed for the UNIT MODEL #, TRAILER ID #, UNIT SERIAL #, SET DATE & TIME and SET NEW HOURS (in a replacement main microprocessor) Configurations. To change a data entry screen press the “=” key with the configuration highlighted. SET # SET DATE AND TIME UNIT IDENTIFICATION (2 OF 4)
Page 96 5.2.4 Component Test Mode Component Test Mode allows the technician to energize individual circuits for 5 minutes at a time. The engine is not allowed to start when the System is in Component Test Mode. Instructions for entering the Component Test Mode are provided in Figure 5.5.
Page 97: Service Mode
5.2.5 Service Mode CAUTION Service Mode MUST be used whenever removing refrigerant charge, refrigerant leak checking or evacuating. NOTE If the START/RUN - OFF switch is toggled to the OFF position, the System will exit Service Mode. To enter Service Mode: a.
Page 98: Figure 5.6 Creating A Data Transfer Usb Memory Device
Figure 5.6 Creating a Data Transfer USB Memory Device 1. Using a standard computer file creation program, create a folder on the device labeled CARRIER. The file name must be in all uppercase letters. 2. Open the CARRIER folder and create three sub-folders labeled DATAEXT, CONFIG and PROGRAM. The file names must be in uppercase letters.
Page 99 1. With the START/RUN - OFF switch in the OFF position, remove protective cover from the USB interface port and insert a Data Transfer USB. NOTES: (1) A PC–USB service cable (Carrier Transicold part num- ber22-04253–20) may also be used. (2) If configured to do so, the System will prompt for entry of the data protect PIN code (refer to “PROTECT DATA WITH PIN”,...
Page 100: Figure 5.8 Downloading Data Files
5.3.3 Downloading Data Files Instructions for downloading data from the DataLink data recorder to a Data Transfer USB memory device are pro- vided in Figure 5.8. Figure 5.8 Downloading Data Files ALARM START/STOP START/STOP DIESEL COOL CONTINUOUS DEFROST MENU BOX TEMPERATURE F SETPOINT F READING USB START/RUN...
Page 101: Figure 5.9 Installing Software
Whenever installing new software, it is always a good idea to start the unit and give it a quick check over prior to performing the operation. All units should have the software upgraded to the latest ver- sion, provided for Carrier Transicold dealers on the TransCentral web site. Figure 5.9 Installing Software...
Page 102: Figure 5.10 Transferring Configuration Files
6. Once the “=” key is pressed, the operator message panel will display “UNIT AND MICRO WILL STOP NOW” and the unit will stop. The System will begin downloading software from the USB memory device and the operator message panel will display “SOFTWARE INSTALL IN PROGRESS”. The percent downloaded will display as the software is copied and then the operator message panel will display “SOFTWARE INSTALL COMPLETE - MICRO WILL RESTART NOW - REMOVE USB.
Page 103: Tru-Tech & Tru-View
INSTALL SETTINGS MENU (1 OF 3) CTD IntelliSet_2008_0219 ACME TRUCKING ACME EXPRESS BACK EXIT 6. With the desired file highlighted, press the “=” key to start the installation. Press any other key to exit and return to the USB soft keys. INSTALL SETTINGS MENU INSTALL SETTINGS MENU INSTALL SETTINGS IN PROCESS...
Page 104: Figure 5.11 Tru-Tech/Tru-View Connection
##.##.01 SOFTW ARE ON USB: ##.##.02 PRESS = TO LOAD, OTHER TO EXIT When field diagnosis of a Carrier Transicold refrigeration unit determines that an APX main microprocessor is not performing properly and must be replaced the replace- ment microprocessor must be setup for this unit and customer by entering the required Configurations, Func- tional Parameters and DataLink data recorder settings.
Page 105: Pre-Replacement Steps
keys. If the main microprocessor is setup using the dis- 2. Release the tabs on and remove the two 35 pin play mounted keys and this feature is needed, it may connectors and 8 pin connector from the front of be loaded at a later date.
Page 106: Configurations Via Display Mounted Keys
7. Now, press the DOWN ARROW key until “SET 2. After the unit specific and time sensitive configu- ration settings are complete use the UP or DATE & TIME” appears. Refer to Section 5.2.3 DOWN ARROW keys until “CONFIGS COM- for instructions on entering the date and time.
Page 107: Table 5-1 Configuration Settings
5.5.7 System Final Checkout 1. Start the unit and allow it to run for a few minutes. 2. While the unit is running, scroll through the Data List. Verify that all the data is now accurately displayed. 3. Initiate a Pretrip test. Allow the unit to complete the Pretrip and check for any alarms. Make any necessary repairs before returning the unit into service.
Page 108 Table 5–1 Configuration Settings Configuration Selections Description SETPOINT(S) & RANGE LOCK DECIMAL DISPLAYED DISPLAYED = setpoint will be shown with a decimal and temperatures may be selected to a tenth of a de- gree. NOT DISPLAYED NOT DISPLAYED = setpoint will not be shown with a decimal.
Page 109 Table 5–1 Configuration Settings Configuration Selections Description S/S PARAMETERS TOGETHER TOGETHER = When the Minimum Run Time, Mini- mum Off Time, Restart Temperature, Maximum Off SEPARATE Time, and Override Temperatures are set in the Functional Parameter List, the same values will be used for both Frozen and Perishable setpoints.
Page 110 Table 5–1 Configuration Settings Configuration Selections Description PRODUCTSHIELD: HIGH OFF = The unit will operate normally in high and low speeds. ON = The unit will operate in high speed when the ambient air temperature is outside a user defined range.
Page 111 Table 5–1 Configuration Settings Configuration Selections Description ENGINE SETTINGS GLOW TIME SHORT Indicates to the main microprocessor which engine LONG is in the system. INTAKE HEATER LONG = Glow Plug equipped and longer glow times are used (TV engines). SHORT= Glow Plug equipped and shorter glow times are used (DI engines).
Page 112 Table 5–1 Configuration Settings Configuration Selections Description THROTTLE POSI- 80 - 125 IF THIS CONFIGURATION IS AVAILABLE, USE TION 120 default FACTORY DEFAULT ONLY, DO NOT OPERATE WITH A DIFFERENT SETTING. ALARM SETTINGS OUT OF RANGE SHUT- YES / NO YES = When the refrigerated compartment tempera- DOWN ture has been out-of-range for 45 minutes, the alarm...
Page 113 Table 5–1 Configuration Settings Configuration Selections Description ALTERNATOR CHECK YES / NO YES = When the A00051 - “ALTERNATOR NOT SHUTDOWN CHARGING” alarm is activated the alarm light will il- luminate and the unit will shut down. NO = When the A00051 - “ALTERNATOR NOT CHARGING”...
Page 114 Table 5–1 Configuration Settings Configuration Selections Description SWITCH ON RESET VAL- When the switch on maintenance hour meter is re- set, the value selected here will be added to the 50 to 30,000 hours in 50 hour present meter reading to indicate to the micropro- increments cessor when the next service interval alarm will be activated.
Page 115 Table 5–1 Configuration Settings Configuration Selections Description • DOOR SWITCH ALARM ONLY ALARM ONLY = When Door switch indicates that the door is open, a warning alarm will be displayed in UNIT SHUTDOWN the MessageCenter. LOW ENGINE SPEED UNIT SHUTDOWN = When Door switch indicates DATA RECORDER ONLY that the door is open, a warning alarm will be dis- played in the MessageCenter, and the unit will shut-...
Page 116 Table 5–1 Configuration Settings Configuration Selections Description • REMOTE SWITCH 1 ALARM ONLY ALARM ONLY = When the switch is activated, a warning alarm will be displayed in the Message- UNIT SHUTDOWN Center. LOW ENGINE SPEED UNIT SHUTDOWN = When the switch is activated, DATA RECORDER ONLY a warning alarm will be displayed in the Message- Center, and the unit will shutdown.
Page 117 Table 5–1 Configuration Settings Configuration Selections Description SET DATE AND TIME Indicates to the main microprocessor the current date and time. Refer to Section 5.2.3 for instructions on entering the date and time. NOTE Date and Time may also be configured under “Unit Identification”. SATELLITE COMM OTHER OTHER = The microprocessor is set for communica-...
Page 118 Table 5–1 Configuration Settings Configuration Selections Description AUTO FRESH AIR SETTINGS AUTOFRESH AIR NOT INSTALLED NOT INSTALLED = AutoFresh Air Exchange is not installed STANDARD STANDARD = AutoFresh Air Exchange is installed • AUTOFRESH AIR DELAY SETPOINT SETPOINT - Once the compartment temperature has reached setpoint 1.5°F (0.8°C), the Auto- Fresh 0-48 HOURS IN 1 HOUR IN- Air Exchange will start to operate based on the se-...
Page 119 SECTION 6 - MESSAGECENTER PARAGRAPH NUMBER Page MESSAGECENTER MESSAGES ..........6–1 62-11637...
Page 120: Table 6-1 Messagecenter Messages
SECTION 6 MESSAGECENTER MESSAGES MESSAGECENTER MESSAGES The following table lists all of the messages which do not appear in other lists in this manual and a description of their meaning. Refer to Section 9 for a list of Alarm messages. Refer to Section 3.13 for a list of Unit Data mes- sages.
Page 121 Table 6–1 MessageCenter Messages Message Description DOOR OPEN A refrigerated compartment door is open. DOOR OPEN − LOW SPEED A refrigerated compartment door is open forcing the unit to run in low speed. ENTERING SERVICE MODE The initial message for Service Mode. ERROR: ENG HRS >...
Page 122 Table 6–1 MessageCenter Messages Message Description PRETRIP PASS All of the Pretrip tests were ok. PRETRIP STOPPED BY USER Pretrip has been stopped by user. PRODUCTSHIELD: ECONO ON The unit is operating in ProductShield Econo which overrides normal unit Start−Stop or Continuous Run operation. Refer to Section 4.10.3.
Page 123 Table 6–1 MessageCenter Messages Message Description TECHNICIAN RESET REQUIRED AL00011 (Low Engine Oil Pressure) or AL00012 (High Coolant Tempera- (AL00021) ture) has been activated three times in the last two hours and the unit has been locked out. Refer to Section 7 for further information.
Page 124 SECTION 7 - ALARM TROUBLESHOOTING PARAGRAPH NUMBER Page INTRODUCTION ............. 7–1 NOTES .
Page 125 00085 CHECK UL1 CIRCUIT ........... . 7–37 00086 CHECK UL2 CIRCUIT .
Page 126 P00201 CHECK UL2 CYLINDERS ..........7–64 P00202 HIGH SIDE LEAK .
Page 127: Section 7 - Alarm Troubleshooting
SECTION 7 ALARM TROUBLESHOOTING cause of the problem will be obvious once a visual WARNING inspection is performed. For those cases where the cause of the problem is not obvious, this troubleshoot- ing guide will be of assistance. APX control system equipped units may start automatically at any time the Troubleshooting should begin with the first alarm that START/ RUN-OFF switch is in the START/...
Page 128: Notes
NOTES NOTE Note 3: Sensors may be tested by taking a NOTE resistance measurement, at the sensor side Note 1: The active alarm list may be cleared of the harness connector, at the sensor loca- when in the Driver Mode or Advanced User tion.
Page 129: Alarms
ALARMS 00001 LOW FUEL LEVEL WARNING NOTE This is an optional alarm which will only occur when a fuel level sensor is present & configured “YES”. • ACTIVATION: The ENCU circuit is energized (3MM−9) and fuel level is 15% or less for more than 30 seconds. •...
Page 130: 00011 Low Engine Oil Pressure
00011 LOW ENGINE OIL PRESSURE NOTE This alarm may be activated if too high a viscosity oil is used in cold ambient. • ACTIVATION: The ENCU circuit is energized (3MM−9) and engine oil pressure is below 12 psig (0.82 bar) for longer than 5 seconds while the engine is running.
Page 131: 00012 High Coolant Temperature
00012 HIGH COOLANT TEMPERATURE • ACTIVATION: Condition 1: Ambient temperature is below 120°F (48.9°C) and engine coolant temperature is above 230°F (110°C). Condition 2: Ambient temperature is above 120°F (48.9°C) and, engine coolant temp is above 241°F (116°C). Condition 3: Ambient temperature is below 120°F (48.9°C) and the engine coolant temperature has remained between 230 and 241°F (110 and 116°C) for more than 5 minutes.
Page 132 00012 HIGH COOLANT TEMPERATURE - CONTINUED 6. Check Engine Cooling System a. Compare actual engine temperature to the Unit Data reading. Temperature must be within ± 20°F (± 11.1°C). b. Test operation of thermostat. Must operate correctly. c. Check water pump operation. Verify no seepage at weep hole, bearings tight and quiet, and Impel- ler firmly attached to shaft.
Page 133: 00013 High Discharge Pressure
00013 HIGH DISCHARGE PRESSURE • ACTIVATION: Compressor discharge pressure switch (HPS) contacts are open. HPS contacts open when the discharge pressure rises to 465 psig (32 bar). • UNIT CONTROL: Shutdown and alarm. • RESET CONDITION: Auto reset after 15 minutes if the compressor discharge pressure falls below 350 psig (24 bar), or alarm may be manually reset using the display mounted keys or by turning the unit off, then back on again.
Page 134: 00015 Battery Voltage Too High
00015 BATTERY VOLTAGE TOO HIGH • ACTIVATION: Voltage at the main microprocessor is greater than 17 VDC. • UNIT CONTROL: Shutdown and alarm. • RESET CONDITION: Auto reset after 15 minutes when the voltage at the main microprocessor is between 11 and 14 VDC, or alarm may be manually reset using the display mounted keys or by turning the unit off, then back on again.
Page 135: 00017 High Comp Discharge Temp
00017 HIGH COMP DISCHARGE TEMP • ACTIVATION: Discharge sensor alarm not active AND: The ambient temperature is below 120°F (48.9°C) and discharge temperature is greater than 309°F (154.4°C) for 3 minutes, or the ambient temperature is above 120°F (48.9°C) and discharge tempera- ture is greater than 340°F (171.1°C) for 3 minutes, or the discharge temperature exceeded 350°F (176.7°C).
Page 136: 00018 Low Refrigerant Pressure
00018 LOW REFRIGERANT PRESSURE • ACTIVATION: The compressor is operating with the suction pressure less than -3 psig (-0.20 bar) for more than the LP SHUTDOWN DELAY Configuration (up to 5 minutes) with RAT above -10°F (-23.3°C) or less than -8 psig (-0.53 bar) with RAT at any temperature. •...
Page 137: 00019 Low Fuel Shutdown
00019 LOW FUEL SHUTDOWN NOTE This is an optional alarm. This alarm will not occur if the Fuel Level Sensor Configuration is NO. • ACTIVATION: The fuel level is 10% or less for more than 30 seconds AND Alarm 000126 - “Check Fuel Sensor Circuit”...
Page 138: 00021 Technician Reset Required
00021 TECHNICIAN RESET REQUIRED • ACTIVATION: The High Engine Temp Shutdown Configuration and/or Engine Oil Pressure Shutdown Con- figuration is/are set to YES, and either Alarm 00011 - Low Engine Oil Pressure, or Alarm 00012 - High Coolant Temperature has become active and shut the unit down three times within the past 2 hours. •...
Page 139: 00027 High Suction Pressure
00027 HIGH SUCTION PRESSURE • ACTIVATION: The refrigeration system is running and the suction pressure has been greater than 98 psig (6.7 bar) for more than 10 minutes. • UNIT CONTROL: Alarm only or (if configured for shutdown) engine and unit shutdown and alarm. •...
Page 140: 00028 Check Refrigeration System
00028 CHECK REFRIGERATION SYSTEM • ACTIVATION: Condition 1: When system has been operating in Pulldown for more than five minutes and the delta-t (SAT - RAT) is between -3.0°F (-1.7°C) and +5°F (+2.8°C). Condition 2: Discharge pressure is not at least 5 psig (0.34 bar) higher than suction pressure for more than 10 minutes.
Page 141: Check Heat Cycle
00029 CHECK HEAT CYCLE • ACTIVATION: The unit has been operating in the heat cycle for more than 5 minutes, and the SAT is more than 5.5°F (3°C) colder than the RAT constantly for more than 60 seconds. (Unit is actually cooling the air going through the evaporator).
Page 142: 00031 Failed To Start - Auto Mode
00031 FAILED TO START - AUTO MODE • ACTIVATION: Engine has tried to start three times unsuccessfully. • UNIT CONTROL: Shutdown and alarm. • RESET CONDITION: Alarm may be manually reset using the display mounted keys or by turning the unit off, then back on again.
Page 143: 00034 Engine Failed To Stop
00034 ENGINE FAILED TO STOP • ACTIVATION: Engine is turning more than 500 RPM for 20 seconds after unit shutdown or cycled off. • UNIT CONTROL: Shutdown and alarm. • RESET CONDITION: Alarm may be manually reset via keypad or by turning the unit off, then back on again.
Page 144: 00035 Check Starter Circuit
00035 CHECK STARTER CIRCUIT • ACTIVATION: Engine speed fails to reach 50 rpm during 2 start attempts. • UNIT CONTROL: Shutdown and alarm. • RESET CONDITION: Alarm may be manually reset using the display mounted keys or by turning the unit off, then back on again.
Page 145: 00036 Check Coolant Temperature
00036 CHECK COOLANT TEMPERATURE • ACTIVATION: Coolant temperature is below 32°F (0°C) after the engine has been running for 5 minutes. • UNIT CONTROL: Shutdown and alarm. • RESET CONDITION: Auto reset when coolant temperature is higher than 36°F (2.2°C) or alarm may be manually reset using the display mounted keys or by turning the unit off, then back on again.
Page 146: 00038 Check High Speed Rpm
00038 CHECK HIGH SPEED RPM • ACTIVATION: The control system is calling for high speed operation, and engine speed is less than 1650 rpm, or greater than 1950 rpm for more than 60 seconds (120 seconds when the control system calls for a change from low to high speed, or when unit first starts).
Page 147: Check Engine Rpm
00039 CHECK ENGINE RPM • ACTIVATION: Alarm 00130 (Check Engine Speed Sensor) is not active and engine speed is less than 1200 rpm or greater than 1950 rpm for 5 minutes. • UNIT CONTROL: Alarm only or (if configured for shutdown) shutdown and alarm. •...
Page 148: 00040 Check Engine Preheat Circuit
00040 CHECK ENGINE PREHEAT CIRCUIT • ACTIVATION: Engine preheater amperage is less than 70 Amps with heater activated. NOTE This alarm can only occur when the preheat time is greater than 14 seconds. Refer to Table 4–1 preheat times. • UNIT CONTROL: Alarm Only •...
Page 149: Engine Stalled
00041 ENGINE STALLED • ACTIVATION: The control system is calling for the engine to run, Engine speed sensor is good, and engine speed is less than 10 rpm; or the A00130 (Check Engine Speed Sensor) alarm is ON, and the Oil Pressure switch contacts are open.
Page 150 00041 ENGINE STALLED - CONTINUED 5. Check Engine Speed Sensor (ENSSN) Inspect harness, connector pins & terminals. (See wiring schematic Section 10.) Verify no physical damage to harness, and no damage, moisture, or corrosion in connectors. 6. Check Engine Air-Intake System a.
Page 151: 00051 Alternator Not Charging
00051 ALTERNATOR NOT CHARGING • ACTIVATION: Unit is running and the current flow is less than -1.0 amps (discharge) between the alterna- tor and the battery for 3 continuous minutes. • UNIT CONTROL: Alarm only, or if Alternator Check Shutdown Configuration is set to “YES” shutdown & alarm.
Page 152: 00053 Box Temp Out-Of-Range
00053 BOX TEMP OUT-OF-RANGE • ACTIVATION: Condition One: If the unit is running in Pulldown and the SAT is not greater than 1°F (0.56°C) below the RAT or if the unit is running in Pull-Up and the SAT is not above the RAT, the configured action (Alarm only after 30 minutes or Alarm and Shutdown after 45 minutes) will be activated.
Page 153 00053 BOX TEMP OUT-OF-RANGE - CONTINUED CORRECTIVE ACTIONS: 1. Check Compartment Doors Inspect all compartment doors. Must be closed, and not allowing any air leakage. 2. Defrost Evaporator Initiate manual defrost cycle. Must terminate automatically. Verify that all ice cleared from evaporator coil.
Page 154: 00054 Defrost Not Complete
00054 DEFROST NOT COMPLETE • ACTIVATION: Defrost cycle did not terminate automatically. (DTT and SAT did not reach termination tem- perature of 55°F/12.8°C within 45 minutes or the SAT rose to 120°F/48.9°C during the cycle.) • UNIT CONTROL: Alarm Only. While this alarm is active, the defrost timer will be temporarily set to initiate a defrost cycle 1.5 hours of unit running time after the alarm comes on.
Page 155: 00055 Check Defrost Air Switch
00055 CHECK DEFROST AIR SWITCH • ACTIVATION: The defrost air switch has called for a defrost cycle within 8 minutes of a defrost termination for 2 consecutive defrost cycles. (The air switch contacts were closed continuously for 15 seconds before the defrost cycle was started.) •...
Page 156: 00056 Check Evaporator Air Flow
00056 CHECK EVAPORATOR AIR FLOW • ACTIVATION: In the Heat Mode, the Suction pressure has been higher than 100 PSIG (6.8 bar) for more than 60 seconds OR In the Cool Mode, the SAT is 5°f (2.8°c) or more warmer than RAT for 3.5 minutes. After the first occur- rence of this alarm, the MessageCenter will display “NO TEMP CONTROL - SEE ALARM LIST”.
Page 157: 00057 Check Remote Switch 1 (Rems1)
00057 CHECK REMOTE SWITCH 1 (REMS1) • ACTIVATION: REMS1 is set to trigger an alarm if the switch is activated (opened or closed, depending on switch type) for more than five seconds. • UNIT CONTROL: May be configured as alarm only, alarm and force low engine speed, or alarm and shut- down.
Page 158: 00059 Datalogger (Datalink Data Recorder) Not Recording
Replace and setup main microprocessor. Refer to Section 5.5. NOTE Specific Configurations may be found on the TransCentral Website (Authorized Carrier Transicold Dealers only). 00060 DATALOGGER (DataLink data recorder) TIME WRONG • ACTIVATION: The real time clock in the DataLink data recorder does not contain a valid date.
Page 159: 00061 Door Open (Ds1)
00061 DOOR OPEN (DS1) • ACTIVATION: DS1 is set to trigger an alarm if the switch is activated (opened or closed, depending on switch type) for more than five seconds. • UNIT CONTROL: May be configured as alarm only, alarm and force low engine speed, or alarm and shut- down.
Page 160: 00067 Sensor 1 Input Voltage Low
00067 SENSOR 1 INPUT VOLTAGE LOW • This alarm may be activated with earlier software versions. Follow procedure for Alarm 22101 SENSOR INPUT VOLTAGE LOW INP1. 00072 CHECK ENCU POWER CIRCUIT • This alarm may be activated with earlier software revisions, follow procedure for alarm 05012 CHECK ENCU POWER CIRCUIT.
Page 161: Check Sv4 Circuit
00079 CHECK SV4 CIRCUIT • ACTIVATION: A problem has been detected in the SV4 coil circuit. If this alarm is activated while the unit is operating in heat or defrost, the circuit is detected shorted. If this alarm is activated while the unit is operat- ing in cool, the circuit is detected open.
Page 162: Check Fhr Circuit
00081 CHECK FHR CIRCUIT • ACTIVATION: A problem has been detected in the fuel heater relay coil circuit. If this alarm occurs while the fuel heater circuit is operating, the circuit is detected shorted. If this alarm occurs while the fuel heater circuit is not operating, the circuit is detected open.
Page 163: 00085 Check Ul1 Circuit
00085 CHECK UL1 CIRCUIT • ACTIVATION: A problem has been detected in the front unloader (UL1) coil circuit. If this alarm is activated while the control system is calling for UL1 to be energized, the circuit is detected shorted. If this alarm occurs at any other time, the circuit is detected open.
Page 164: 00086 Check Ul2 Circuit
00086 CHECK UL2 CIRCUIT • ACTIVATION: A problem has been detected in the front unloader (UL2) coil circuit. If this alarm is activated while the control system is calling for UL2 to be energized, the circuit is detected shorted. If this alarm occurs at any other time, the circuit is detected open.
Page 165: 00090 Chk Afa Solenoid Circuit
00090 CHK AFA SOLENOID CIRCUIT • ACTIVATION: A problem has been detected in the AutoFresh Air Exchange relay coil circuit. If this alarm is activated while the control system is calling for AFAR to be energized, the circuit is detected shorted. If this alarm occurs at any other time, the circuit is detected open.
Page 166: 00093 Check Startup Buzzer
00093 CHECK STARTUP BUZZER • ACTIVATION: The Buzzer (B) circuit is shorted or open. (The Buzzer output from the microprocessor [PCM-23 to 3MM15] is negative, so the circuit will not be shorted to ground, but is shorted either within the Buzzer itself, or to a positive wire.) •...
Page 167: 00097 Check Sv2 Circuit
00097 CHECK SV2 CIRCUIT • ACTIVATION: A problem has been detected in the SV2 coil circuit . If this alarm is activated while the con- trol system is calling for SV2 to be energized, the circuit is detected shorted. If this alarm is activated at any other time, the circuit is detected open.
Page 168: 00123 Check Supply Air Sensor
00122 CHECK RETURN AIR SENSOR • ACTIVATION: Return Air Temperature Sensor (RAT) is not within the range of -53 to +158°F (-47 to +70° C). • UNIT CONTROL: If Alarm 00123 is not active: Alarm and switch to supply air control. If Alarm 00123 is active: Alarm and the System will enter Cargo Protect Mode.
Page 169: 00125 Check Comp Discharge Sensor
00125 CHECK COMP DISCHARGE SENSOR • ACTIVATION: Compressor Discharge Temperature Sensor (CDT) is not within the range of -40° to +392°F (-40° to +200°C). • UNIT CONTROL: Alarm Only. • RESET CONDITION: Auto reset when sensor is in range or, alarm may be manually reset using the dis- play mounted keys or by turning the unit off, then back on again.
Page 170: 00129 Check Eng Coolant Sensor
00127 CHECK SUCTION TEMP SENSOR • ACTIVATION: Compressor Suction Temperature Sensor (CST) is not within the range of −53 to +158°F (−47 to +70° C.) • UNIT CONTROL: Alarm only. • RESET CONDITION: Auto reset or alarm may be manually reset using the display mounted keys or by turning the unit off, then back on again.
Page 171: 00130 Check Engine Rpm Sensor
00130 CHECK ENGINE RPM SENSOR • ACTIVATION: If ambient temperature is above 32°F (0°C), and this is the second or third start attempt, and the engine oil pressure switch is closed (oil pressure good), and engine speed is sensed at less than 1000; OR, if ambient is below 32°F (0°C) and the DC amp draw is more than 2 amps, and this is the second or third start attempt, and engine speed is sensed at less than 1000.
Page 172: 00131 Check Evap Temp Sensor
00131 CHECK EVAP TEMP SENSOR • ACTIVATION: Evaporator Outlet Temperature Sensor (EVOT) is not within the range of −53 to +158°F (−47 to +70°C) • UNIT CONTROL: Alarm only and superheat for EVXV will be calculated using SAT or DTT if alarm 00123 (Check Supply Air Sensor) is active.
Page 173: 00132 Check Defrost Term 2 Sensor
00132 CHECK DEFROST TERM 2 SENSOR NOTE The APX control system uses one Defrost Termination Sensor (DTT) and that sensor will activate this “CHECK DEFROST TERM 2 SENSOR” alarm. • ACTIVATION: Defrost Termination Temperature Sensor (DTT) is not within the range of -58 to +266°F (-50 to +130°C).
Page 174: 00133 Check Remote Temp Sensor 1
00133 CHECK REMOTE TEMP SENSOR 1 00134 CHECK REMOTE TEMP SENSOR 2 • ACTIVATION: Remote Temperature Sensor (REMSN1 or REMSN2) is not within the range of -53 to +158°F (-47 to +70°C.) • UNIT CONTROL: Alarm only. • RESET CONDITION: Auto Reset when sensor is in range or, alarm may be manually reset via keypad or by turning the unit off, then back on again.
Page 175: P00141 Pretrip Stopped By User
P00141 PRETRIP STOPPED BY USER • ACTIVATION: Pretrip cycle was stopped by user before the Pretrip cycle ended automatically. • UNIT CONTROL: Alarm Only. • RESET CONDITION: Alarm may be manually reset using the display mounted keys or by turning the unit off, then back on again.
Page 176: P00144 Check Ul1 Circuit
P00144 CHECK UL1 CIRCUIT • ACTIVATION: The circuit current draw is outside the normal range. • UNIT CONTROL: Pretrip will fail in test 2 and display “PRETRIP FAIL AND COMPLETED”. • RESET CONDITION: Auto reset if Pretrip is started again, or alarm may be manually reset using the dis- play mounted keys or by turning the unit off, then back on again.
Page 177: P00152 Check Fuel Solenoid Circuit
P00152 CHECK FUEL SOLENOID CIRCUIT • ACTIVATION: The circuit current draw is outside the normal range. • UNIT CONTROL: Pretrip will fail in test 2 and display “PRETRIP FAIL AND COMPLETED”. • RESET CONDITION: Auto reset if Pretrip is started again or alarm may be manually reset using the dis- play mounted keys or by turning the unit off then back on again.
Page 178: P00155 Check Coolant Temp Sensor
P00155 CHECK COOLANT TEMP SENSOR • ACTIVATION: Engine Coolant Temperature Sensor (ENCT) is not within the range of -58 to +266°F (-50 to +130°C). • UNIT CONTROL: Pretrip will fail and display “PRETRIP FAIL AND COMPLETED”. • RESET CONDITION: Auto reset if Pretrip is started again, or alarm may be manually reset using the dis- play mounted keys or by turning the unit off, then back on again.
Page 179: P00158 Check Ambient Air Sensor
P00158 CHECK AMBIENT AIR SENSOR • ACTIVATION: Ambient Air Temperature Sensor (AAT) is not within the range of -53 to +158°F (-47 to +70°C). • UNIT CONTROL: Pretrip will fail and display “PRETRIP FAIL AND COMPLETED”. • RESET CONDITION: Auto reset if Pretrip is started again, or alarm may be manually reset using the dis- play mounted keys or by turning the unit off, then back on again.
Page 180: P00162 Check Afa Solenoid Circuit
P00162 CHECK AFA SOLENOID CIRCUIT • ACTIVATION: The (AFAR) circuit current draw is outside the normal range. • UNIT CONTROL: Pretrip will fail and display “PRETRIP FAIL AND COMPLETED”. • RESET CONDITION: Auto reset if Pretrip is started again, or alarm may be manually reset using the dis- play mounted keys or by turning the unit off, then back on again.
Page 181: P00165 Cannot Pump Down
P00165 CANNOT PUMP DOWN • ACTIVATION: With SV1, SV2, & SV4 in the closed position, the compressor is not able to pull the low side of the refrigerant system down to 10 PSIG (0.68 bar). • UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST 12, 13 or 14” will be displayed in Mes- sageCenter.
Page 182: P00175 Check High Speed Rpm
P00175 CHECK HIGH SPEED RPM • ACTIVATION: In Test #8 with the CAN calling for high speed, engine speed is NOT between: 1650 and 1950 rpm. • UNIT CONTROL: Pretrip will fail and display “PRETRIP FAIL AND COMPLETED”. • RESET CONDITION: Auto reset if Pretrip is started again, or Alarm may be manually reset using the dis- play mounted keys or by turning the unit off, then back on again.
Page 183: P00178 Check Ul1
P00178 CHECK UL1 • ACTIVATION: The pressure differential between suction and discharge pressures did not change as expected when the Front Unloader (UL1) was de-energized / loaded (discharge pressure should rise and suction pressure should drop) or when it was energized / unloaded (discharge pressure should drop and suc- tion pressure should rise.
Page 184: P00180 Check Suction Mod Valve
P00180 CHECK SUCTION MOD VALVE • ACTIVATION: With the unit running in Pretrip Test #10, after the microprocessor attempts to close CSMV, the suction pressure fails to drop below 4in. Hg (-0.14 bar). • UNIT CONTROL: Pretrip will fail and display “PRETRIP FAIL IN TEST 10”. •...
Page 185: P00181 Check Sv4 Valve
P00181 CHECK SV4 VALVE • ACTIVATION: Suction pressure did not rise within range & discharge pressure did not drop within range when SV4 was energized (opened). • UNIT CONTROL: Alarm only. • RESET CONDITION: Auto reset if Pretrip is started again or alarm may be manually reset using the dis- play mounted keys or by turning the unit off then back on again.
Page 186: P00191 Check Ul2
P00191 CHECK UL2 • ACTIVATION: The pressure differential between suction and discharge pressures did not change as expected when the Rear Unloader (UL2) was de-energized / loaded (discharge pressure should rise and suction pressure should drop) or when it was energized / unloaded (discharge pressure should drop and suction pressure should rise.
Page 187: P00194 High Suction Pressure
P00194 HIGH SUCTION PRESSURE • ACTIVATION: This alarm is generated during Test 4 of Cool Pretrip. Suction pressure is higher than normal. • UNIT CONTROL: Alarm Only • RESET CONDITION: Auto reset if Pretrip is started again, or Alarm may be manually reset using the dis- play mounted keys or by turning the unit off, then back on again.
Page 188: P00196 High Discharge Pressure
P00196 HIGH DISCHARGE PRESSURE • ACTIVATION: This alarm is generated during Test 4 of Cool Pretrip. Discharge pressure is higher than nor- mal. (“Normal” discharge pressure for systems operating in the Cool Mode can be estimated by taking the temperature of the air entering the condenser coil (Ambient Air Temperature AAT) and adding 30 F (16.6 C) to it, then looking at a pressure temperature chart-see Table 8–5 for the corresponding pressure.)
Page 189: P00198 Low Discharge Pressure
P00198 LOW DISCHARGE PRESSURE • ACTIVATION: In Pretrip heat, the compressor discharge pressure did not rise to normal. (“Normal” dis- charge pressure for systems operating in Pretrip heat can be estimated by adding 80 psig (5.5 bars) toe the saturation temperature of the air entering the condenser (ATS reading). •...
Page 190: P00200 Check Ul1 Cylinders
P00200 CHECK UL1 CYLINDERS • ACTIVATION: A problem has been detected inside the front cylinder head of the compressor with a cylin- der suction valve, cylinder discharge valve, head gasket or valve plate gasket. • UNIT CONTROL: Alarm Only • RESET CONDITION: Auto reset if Pretrip is started again, or Alarm may be manually reset using the dis- play mounted keys or by turning the unit off, then back on again.
Page 191: P00202 High Side Leak
P00202 HIGH SIDE LEAK • ACTIVATION: Refrigerant pressure is leaking past one of the components in the high pressure side of the refrigeration system into the low pressure side. • UNIT CONTROL: Alarm Only • RESET CONDITION: Auto reset if Pretrip is started again, or Alarm may be manually reset using the dis- play mounted keys or by turning the unit off, then back on again.
Page 192: P00204 Low Suction Pressure
P00204 LOW SUCTION PRESSURE • ACTIVATION: Suction Pressure is less than -10inHg (-0.34 bar) for more than 30 continuous seconds, or less than -16inHg (-0.54 bar) for more than 5 seconds at any time during Pretrip. • UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST X” will be displayed in MessageCenter indicating in which test the suction pressure was too low.
Page 193: P00205 Chk Defrost Term 2 Sensor
P00205 CHK DEFROST TERM 2 SENSOR NOTE The APX control system uses one Defrost Termination Sensor (DTT) and that sensor will trigger this “CHK DEFROST TERM 2 SENSOR” alarm. • ACTIVATION: Defrost Termination Temperature Sensor is not within the maximum range of -53°F to +158°F (-47°C to +70°C).
Page 194: 00225 General Maintenance Due
00225 GENERAL MAINTENANCE DUE • ACTIVATION: The General Maintenance Hour Meter time has expired. • UNIT CONTROL: Alarm Only. Alarm Light will NOT be turned on. • RESET CONDITION: Alarm may be manually reset using the display mounted keys. CORRECTIVE ACTIONS: 1.
Page 195: 00227 Service Soon-Pm #2 Due
00227 SERVICE SOON-PM #2 DUE • ACTIVATION: The Maintenance Hour Meter #2 time has expired. • UNIT CONTROL: Alarm Only. Alarm Light will NOT be turned on. • RESET CONDITION: Alarm may be manually reset using the display mounted keys. CORRECTIVE ACTIONS: 1.
Page 196: 00229 Service Soon-Pm #4 Due
00229 SERVICE SOON-PM #4 DUE • ACTIVATION: The Maintenance Hour Meter #4 time has expired. • UNIT CONTROL: Alarm Only. Alarm Light will NOT be turned on. • RESET CONDITION: Alarm may be manually reset via keypad. CORRECTIVE ACTIONS: 1. Check Unit Maintenance Records Schedule unit into service facility for maintenance.
Page 197: Setpoint Error
Enter correct Model Number. Check Model Number on Nameplate. Select the correct model num- ber in the “MODEL NUMBER” Configuration. If correct model number is not found, Install (or have Carrier Transicold dealer install) latest software revision. 2. Reset Microprocessor a.
Page 198: 00237 Function Parameters Error
00237 FUNCTION PARAMETERS ERROR • ACTIVATION: There is an error in one or more of the Functional Parameters that are stored in the main microprocessor memory. • UNIT CONTROL: Incorrect Functional Parameter(s) will be automatically set for default value. • RESET CONDITION: Auto reset when valid Functional Parameters are entered, or alarm may be manually reset by turning the unit off, then back on again.
Page 199: 00238 Configurations Error
00238 CONFIGURATIONS ERROR • ACTIVATION: There is an error in the Configuration settings that are stored in the main microprocessor memory. • UNIT CONTROL: Incorrect Configuration(s) will be automatically set for default value. • RESET CONDITION: Auto reset when valid Configuration(s) are entered, or alarm may be manually reset by turning the unit off, then back on again NOTE: Follow the steps below until a problem is found.
Page 200: 00245 Cannot Save Setting
1. Check Microprocessor Software Revision Check microprocessor software Unit should have the software upgraded to the latest version, pro- vided for Carrier Transicold dealers on the TransCentral site. 2. Reset Microprocessor a. Place the START/RUN-OFF switch in the OFF position. Disconnect positive battery cable, remove F7 fuse or unplug 1MM connector, wait 20 seconds and reinstall.
Page 201: 00248 Config Mode / Hp2 Error
00248 CONFIG MODE / HP2 ERROR • ACTIVATION: EEPROM Configuration is out of range. • UNIT CONTROL: Shutdown and alarm. • RESET CONDITION: Auto reset only when valid info is entered. NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s).
Page 202: 00254 Loss Of Communication With Display Module
(refer to reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary. CORRECTIVE ACTIONS: 1. Software Reload software. Unit should have the software upgraded to the latest version, provided for Carrier Transicold dealers on the TransCentral site. 62-11637 7–76...
Page 203: 03001 Engine Load Calibration
03001 ENGINE LOAD CALIBRATION • ACTIVATION: Activate alarm if: Condition 1 = At engine start if the engine throttle sensor (Rack Position Sensor) value is less than 90%. Condition 2 = After start if the sensor value does not drop below 90% within 5 seconds. Condition 3 = At engine shutoff if the sensor value does not drop below 10% within 5 seconds.
Page 204: 05012 Check Encu Power Circuit
05012 CHECK ENCU POWER CIRCUIT NOTE When operation of the engine is required the main microprocessor will provide a signal from terminal 3MM−9. This signal has been referred to as the “run relay”, based on pre−APX control systems that had an actual relay in place. Whenever the term “run relay” is used in APX control system discussion, it is referring to the engine run output from 3MM−9 to the ENCU at terminal ENCU−44.
Page 205: 05013 Check Clutch Circuit
05013 CHECK CLUTCH CIRCUIT • ACTIVATION: A problem has been detected in the clutch coil (CLH) circuit. If this alarm is activated while the control system is calling for CLH to be energized, the circuit is detected shorted. If this alarm occurs at any other time, the circuit is detected open.
Page 206: 05014 Check Starter Solenoid Circuit
05014 CHECK STARTER SOLENOID CIRCUIT • ACTIVATION: A problem has been detected in the starter solenoid coil (SS) circuit. If this alarm is activated while the control system is calling for SS to be energized, the circuit is detected shorted. If this alarm occurs at any other time, the circuit is detected open.
Page 207: Check Glow Plug Relay
05017 CHECK GLOW PLUG RELAY • ACTIVATION: A problem has been detected in the engine preheat enable circuit (EPHT). If this alarm is activated when the circuit is energized, the circuit is detected shorted. If this alarm is activated at any other time, the circuit is detected open.
Page 208: 20100 No Comm From Micro To Display
20100 NO COMM FROM MICRO TO DISPLAY NOTE This alarm will be available in the inactive alarm list and download only. It is an indication that an inter- mittent failure is occurring, causing a break in the circuit sufficient to activate the alarm. •...
Page 209: 21100 No Comm From Any Board To Main Micro
21100 NO COMM FROM ANY BOARD TO MAIN MICRO NOTE This alarm will be available in the inactive alarm list and download only. It is an indication that an inter- mittent problem has occurred and a careful diagnosis is required. •...
Page 210: 22101 Sensor Input Voltage Low Inp1
22101 SENSOR INPUT VOLTAGE LOW INP1 NOTE This alarm is an indication that there is a short in the transducer or DC current transformer wiring and the voltage supply in the main microprocessor is overloaded. • ACTIVATION: Voltage from main microprocessor to the components is less than 4.5 VDC •...
Page 211: 22102 Sensor Input Voltage High Inp1
22102 SENSOR INPUT VOLTAGE HIGH INP1 NOTE This alarm is an indication that there is a short in the DC current transformer wiring from another (nom- inal 12 VDC) circuit into the transducer or CT sensor circuit. • ACTIVATION: Voltage from main microprocessor to the sensors is greater than 5.5 VDC •...
Page 212: 25100 No Comm From Micro To Stp1
25100 NO COMM FROM MICRO TO STP1 • ACTIVATION: Main microprocessor cannot communicate with stepper valve module over the CAN bus. • UNIT CONTROL: Shut down and alarm. The stepper valve module status LED may be on steady green (not pulsing) or red. •...
Page 213: 26100 No Comm From Micro To Encu
26100 NO COMM FROM MICRO TO ENCU • ACTIVATION: Main microprocessor cannot communicate with the engine control unit over the CAN bus. • UNIT CONTROL: Shutdown and alarm. • RESET CONDITION: Auto reset when CAN communication is restored, alarm reset or alarm may be man- ually reset by turning the unit off, then back on again.
Page 214 SECTION 8 - SERVICE PARAGRAPH NUMBER Page SECTION LAYOUT ............8–1 SCHEDULED MAINTENANCE .
Page 215: Scheduled Maintenance
RUN position. Also, the unit may be fitted inert gas brazing procedures is manda- with two way communication equipment tory for all Carrier Transicold refrigera- that will allow starting of the unit from a tion units; otherwise compressor failure remote location even though the switch will occur.
Page 216: Table 8-1 Maintenance Schedule
Cooling System 1. Check coolant change interval (refer to Section e. of this Section 8.5.14 table). If replacement is not required, check antifreeze con- centration using a refractometer (Carrier Transicold P/N 07- 00435-00) Section 8.5.14 2. Clean condenser/radiator surfaces Check 3.
Page 217 Table 8–1 Maintenance Schedule System Operation Reference Section Unit 1. Check unit mounting bolts Check 2. Check engine and compressor mounting bolts Check 3. Check door latches & hinges Section 8.4.4 4. Check all belt tensions, adjust as necessary Check 5.
Page 218: Figure 8.1 Automatic Fresh Air Exchange
EXTERNAL SURFACE SERVICE b. Solenoid 1. Ensure the unit will not start automatically by dis- Procedures for servicing or maintaining the automatic abling any two way communication and placing fresh air exchange, grille, surround, doors, door latches the STOP/RUN-OFF switch in the OFF position. and display module are provided in the following sub- paragraphs.
Page 219: Figure 8.3 Surround Removal
2. Remove the 3 grille insert mounting bolts on 8.4.4 Door Latch Maintenance and Replace- each side of the grille insert, See Figure 8.2. ment a. Door Latch Maintenance 3. Remove the 2 grille insert mounting bolts on top of the grille insert. Proper maintenance is important for smooth operation of the latch assemblies and the latch pins that are 4.
Page 220: Figure 8.5 Fuel System Diagram
ENGINE AND ENGINE RELATED SYSTEMS 8.5.1 Fuel System SERVICE The fuel system consists of the fuel tank, mechanical fuel pump, fuel filter, fuel injection pump, the injectors Procedures for servicing the engine, fuel system, and interconnecting tubing. The fuel system may also engine cooling system and air cleaner are provided in be equipped with an optional electric pump and/or the following sub-paragraphs.
Page 221: Figure 8.6 Fuel Bleed Components
Figure 8.6 Fuel Bleed Components Running the engine for an extended period of time with the manual plunger up can cause a priming pump failure 6. Depress and turn the top of the manual plunger clockwise to lock in place. 7.
Page 222: Figure 8.8 Electric Fuel Pump
NOTE ing the STOP/RUN-OFF switch in the OFF posi- If required, use a lock collar wrench (Carrier tion. Transicold P/N 07–00423–00) to loosen the 2. Place a shallow pan under filter (item 7, Figure collar or vent cap.
Page 223: Figure 8.10 Fuel Level Sensor
6. Install new filter element, cover seal and vent To Check the Fuel Level Sensor, do the following: cap seal. Install filter with spring at top and hand 1. Ensure unit will not start automatically by dis- tighten collar. abling any two way communication and placing the STOP/RUN-OFF switch in the OFF position.
Page 224: Figure 8.11 Engine Oil Level
7. With the fuel tank empty the output reading 8.5.9 Engine Oil And Oil Filter should be approximately 0.25 VDC. a. To Check The Engine Oil Level: 8. With the fuel tank full, the output reading should 1. Warm up the engine and then stop it by placing be approximately 4.75 VDC.
Page 225: Figure 8.13 Engine Preheater
c. To Change Engine Oil Filter: 7. Start unit and check for leaks. Reset air cleaner service indicator. 1. If not continuing from preceding step b., warm up the engine and then stop it by placing the 8.5.11 Engine Preheater STOP/ RUN-OFF switch in the OFF position.
Page 226: Figure 8.14 Engine Control System Components
Figure 8.14 Engine Control System Components 8.5.13 Rack Position Sensor (RPS) Calibration The Rack Position Sensor calibration procedure is a 1, 2 software function that can only be initiated in Techni- cian Mode. This calibration procedure should be per- formed after replacing the Engine, the ECU, or the Rack Position Sensor.
Page 227 1. Ensure the unit will not start automatically by dis- b. Radiator Replacement abling any two way communication and placing 1. Ensure the unit will not start automatically by dis- the STOP/RUN-OFF switch in the OFF position. abling any two way communication and placing 2.
Page 228: Figure 8.15 Radiator Assembly
Do not use pry bar or excessive 2. Gasket (Typical) force as it may cause bearing failure. Check belt 3. Radiator tension, using belt tension tool Carrier Transi- 4. Radiator Mounting Bracket cold part number 07-00203-00 or 07-00253-00, 5. Radiator Mounting Bracket Bolts in accordance with the following chart.
Page 229: Figure 8.17 Engine Crankcase Breather
8.5.16 Crankcase Breather POWER TRAIN SERVICE The engine uses a closed type breather with the breather line attached to the cylinder head cover. (See WARNING Figure 8.17). The breather assembly should be cleaned once a year Beware of moving belt and belt driven or at every oil change interval (whichever comes first).
Page 230 8. Pivot idler to place tension on belt and set belt 3. Loosen the lower idler pivot bolt and slide tension, using belt tension tool Carrier Transi- adjustment bolt to release belt tension. cold part number 07-00203-00 or 07-00253-00, in accordance with the following chart.
Page 231: Figure 8.19 Upper Power Train
Figure 8.19 Upper Power Train 1. Condenser Fan 15. Armature Retaining Bolts & Washers 2. Clutch 16. Key (Round End) 3. Fanshaft 17. Armature 4. Upper Belt 18. Rotor Retaining Nut 5. Upper Idler 19. Rotor 6. Gear Box 20. Rotor Spacer 7.
Page 232: Figure 8.20 Surround
(8) to 5. Remove the upper frame support. pivot idler, set belt tension. Use belt tension tool Carrier Transicold part number 07-00203-00 or 6. Pull the unattached surround towards the front 07-00253-00, in accordance with the following of the unit to gain access to the upper frame chart.
Page 233 4. Remove the two bolts (13) from the split taper bushing (12), insert them into the threaded 4. Using a spanner socket (Carrier Transicold part holes and tighten evenly to push fan away from number 07-00303-02) remove the rotor retaining the bushing.
Page 234 8.6.6 Fanshaft 8.6.7 Gearbox To remove and reinstall the fanshaft (Item 3, Figure To remove and reinstall the gearbox (right angle drive) 8.19) do the following: (Item 6, Figure 8.19) do the following: 1. Ensure the unit will not start automatically by 1.
Page 235: Figure 8.22 Refrigerant System Service Equipment
REFRIGERANT SYSTEM SERVICE 8.7.2 Servicing the Refrigerant Charge Servicing of the refrigerant charge includes: checking of refrigerant system equipment, servicing the refriger- the charge level, checking for noncondensibles, remov- ant charge, leak checking and evacuation. Procedures ing the charge, pumping down the low side, pumping for refrigerant system service are provided in the fol- down the compressor, adjusting the charge level and lowing sub paragraphs.
Page 236 c. Removing Charge d. Pumping Down The Low Side To remove the refrigerant charge, proceed as follows: Components on the low side of the refrigeration system (the filter drier, EVXV, evaporator coil, CSMV, heat 1. If the system is in operating condition, it will be exchanger, suction line etc.) may be serviced or quicker to remove the charge by continuing with replaced without having to completely remove the...
Page 237 e. Pumping Down The Compressor 3. If charge is to be added: place cylinder of refrig- erant on a scale and connect a charging line The compressor or any of the components attached to and gauge from cylinder to liquid line service it (unloaders, high pressure switch, discharge and suc- valve.
Page 238 8.7.3 Leak Checking WARNING WARNING Only a refrigerant cylinder containing R404A should be connected to this refrig- Never use air or gases containing oxygen eration unit in order to pressurize the for leak testing or operating refrigerant system. However, dry nitrogen may be compressors.
Page 239 c. Leak Checking With Low Side Pumped Down 6. The recommended procedure for finding leaks from a system is with an electronic leak detector. The low side of the system must be leak checked once Checking joints with soapsuds is satisfactory it is closed and all repairs complete.
Page 240 (5 cfm/8mH vol- 9. Break the vacuum with dry nitrogen through the ume displacement, Carrier Transicold part num- discharge service valve. Raise system pressure ber 07-00176-11) and a good vacuum indicator to approximately 2 psig (0.1 bar). Ensure that...
Page 241 11. Open the vacuum pump valve and start the Charge Mode. If this occurs, switch it back to the pump. Evacuate unit to 500 microns. Close the “RECOVER/LEAK CHK/EVAC MODE” (Refer to vacuum pump valve and shut off the pump. Wait Section 5.2.5.
Page 242: Compressor And Unloader Service
COMPRESSOR AND UNLOADER SERVICE 5. Loosen the suction and discharge service valve mounting bolts. Tap the valve bodies to break 8.8.1 Repair or Replacement Determination the seal and then remove bolts. Certain operating conditions or refrigeration system 6. Disconnect all low voltage connectors (UL1, components may be misdiagnosed and subsequently UL2, CDT, CDP &...
Page 243: Figure 8.23 Compressor
Figure 8.23 Compressor Refer to Section 8.8.6 for reassembly. Torque 26 to 30 ft/lbs (35.3 to 40.7 Nm) Torque 30 ft/lbs (40.7 Nm) then, bend locking tabs against flat of bolt head Torque 26 to 30 ft/lbs (35.3 to 40.7 Nm) Torque 90 to 120 ft/lbs (122 to 163 Nm) 1.
Page 244: Figure 8.24 Cylinder Head & Valve Plate
Figure 8.24 Cylinder Head & Valve Plate Typical Arrangement - Center Head Shown 1. Capscrew 7. Discharge Valve 2. Cylinder Head 8. Valve Plate 3. Cylinder Head Gasket 9. Valve Plate Gasket 4. Capscrew 10. Suction Valve 5. Lockwasher 11. Suction Valve Spring 6.
Page 245: Figure 8.25 Checking Suction Valve
Figure 8.25 Checking Suction Valve Figure 8.26 Oil Pump & Bearing Head Assembly 1. Oil Pump & Bearing 3. Oil Pickup Tube 14. Install capscrews, cylinder head and new cylin- Head 4. Oil Inlet Port der head gasket (with flat side toward valve 2.
Page 246: Figure 8.28 Oil Level In Sight Glass
Robinair, part no. 14388. This oil pump adapts to a one U.S. gallon (3.785 liters) metal refrigeration oil con- For this reason, Carrier Transicold re−manufactured tainer and pumps 2-1/2 ounces (0.0725 liters) per compressors now contain a reduced oil charge to com-...
Page 247: Figure 8.29 Unloader Coil
3. Break any remaining vacuum (raise to 0 psig/ b. Unloader Coil Replacement bar) with refrigerant remaining in the system NOTE (crack open the suction service valve), or from a fresh cylinder of refrigerant. Evacuate the com- The coil may be removed while the compres- pressor crankcase to 500 microns.
Page 248: Refrigerant System Component Service
A garden hose with spray nozzle is usually unloader valve body (with flat side toward the sufficient. Make sure drain lines are clean. head) and, using unloader ring pliers, (Carrier Transicold P/N 07-00223-00) compress the 4. Re-install check valves and run unit until Defrost...
Page 249 Torque con- inert gas brazing procedures is manda- denser/radiator assembly mounting bolts (11) 95 tory for all Carrier Transicold refrigera- to 119 inch/lbs (10.7 to 13.4 Nm). Braze con- tion units; otherwise compressor failure denser coil refrigerant connections.
Page 250: Figure 8.30 Condenser/Radiator Assembly
Figure 8.30 Condenser/Radiator Assembly 1. Condenser/Radiator Assembly 7. Condenser Coil Mounting Brackets 2. Ambient Air Temperature Sensor (ATT) 8. Radiator 3. Front Condenser Frame 9. Rear Condenser Frame 4. Gasket (Typical) 10. Rear Condenser Frame Mounting Bolts 5. Radiator Mounting Brackets 11.
Page 251: Figure 8.31 Condenser Pressure Control Solenoid Valve (Sv1)
8.9.5 Condenser Pressure Control Solenoid 2. Connect a discharge pressure gauge at the dis- charge service valve and connect a gauge to Valve (SV1) the liquid line service valve. Figure 8.31 Condenser Pressure Control Solenoid 3. With the refrigerated compartment temperature Valve (SV1) at 35°F (1.7°C) or lower, operate the unit in high speed cool and disconnect the coil.
Page 252: Figure 8.32 Sv-2 And
4. Using a 12 point, 1-3/8 inch box wrench, loosen a. Replacing the Coil the enclosing tube locknut and bleed off any NOTE remaining pressure. The coil may be replaced without removing 5. Remove enclosing tube lock nut, enclosing tube the refrigerant or pumping the unit down.
Page 253: Compressor Suction Modulation Valve (Csmv)
The valve stepper motor may be tested using a stepper the B1/B2 connectors may be used to perform the motor drive tester or ohmmeter. CSMV testing. 1. To test with a stepper motor drive tester (Carrier 8.9.8 Compressor Suction Modulation Valve Transicold part number 07-00375-00), connect...
Page 254: Figure 8.36 Evaporator Expansion Valve
c. Diagnostics Valve 6. Leak check, evacuate & dehydrate, and charge system as required. Refer to Section 8.7.2, NOTE 8.7.3 & 8.7.4. If the valve failed pretest and passed the 7. Start the unit. preceding diagnostic testing, this is an indi- cation that the valve mechanism is damaged 8.
Page 255: Figure 8.37 Evaporator Expansion Valve
Within one minute the suction pressure 1. To test with a stepper motor drive tester (Carrier should begin to fall. Transicold part number 07−00375−00SV), con- nect the 5 pin test cable to the valve connector 3.
Page 256: Figure 8.38 Check Valves
8.7.2. Unit uses R404A and POE oil. The use of inert gas brazing procedures is manda- tory for all Carrier Transicold refrigera- tion units; otherwise compressor failure will occur. For more information Refer to Technical Procedure 98-50553-00 Inert Gas Brazing.
Page 257: Figure 8.40 Defrost Air Switch Test Setup
305 to 315 psig (20.75 to 21.43 bar). Comparisons in this pressure range are not con- 3. Low Side Connection clusive. 4. Pressure Line or Aspirator Bulb (Carrier Transi- cold part number 07-00177-01) 3. The compressor suction pressure and evapora- 5. Magnehelic Gauge (Carrier Transicold part...
Page 258: Figure 8.41 Power Control Module
8.40) 7. Attach an ohmmeter to the air switch electrical contacts to check switch action. NOTE Use a hand aspirator (Carrier Transicold P/N 1. Mounting Fasteners 07-00177-01), since blowing into tube by 2. 35 Pin Connector mouth may cause an incorrect reading.
Page 259 5. Unlock tab on 35pin connector (2) & remove 5. Make sure the latest software has been loaded connector. to ensure all modules are compatible, refer to Section 5.3.4 6. Remove the four fasteners (1) mounting Power Control module to unit frame & remove module from unit 7.
Page 260: Figure 8.42 Alternator
Figure 8.42 Alternator 4. Start unit and run Pretrip to check operation. c. Alternator Replacement In the event the alternator is replaced, install the pulley on the alternator shaft with the “shoulder” side toward the alternator. Torque left hand thread pulley nut 50 to 60 ft/lbs (68 to 88 Nm) while holding shaft using a six point Torx T50 wrench.
Page 261: Table 8-3 Sensor Resistance
Table 8–3 Sensor Resistance Sensors AAT, RAT, SAT, ENCT, DTT, CST, EVTO, REMSN 1, 2 °F °C Ohms °F °C Ohms °F °C Ohms °F °C Ohms 336,500 -7.8 49,060 24.4 10,250 56.7 2,809 -38.9 312,600 -6.7 46,230 25.6 9,760 57.8 2,697 -37.8...
Page 262: Table 8-4 Sensor Resistance (Cdt)
Table 8–4 Sensor Resistance (CDT) °C °F Ohms °C °F Ohms °C °F Ohms °C °F Ohms 3,360,000 325,860 40.0 53,330 101.7 6,510 -38.9 3,121,020 307,970 41.1 51,010 104.4 6,000 -37.8 2,900,710 291,180 42.2 48,800 107.2 5,540 -36.7 2,697,500 275,410 43.3 46,710 110.0...
Page 263: Table 8-5 Temperature Pressure Chart
Table 8–5 Temperature Pressure Chart Temperature Pressure Temperature Pressure °C °F PSIG °C °F PSIG 72.5 75.6 78.8 12.9 82.1 16.3 85.5 17.7 89.0 19.2 92.5 20.7 96.2 22.3 99.9 23.9 103.7 25.6 115.4 1.88 27.3 126.1 29.1 137.4 30.9 10.3 149.4 32.8...
Page 264 SECTION 9 - UNIT TROUBLESHOOTING PARAGRAPH NUMBER Page ENGINE ..............9–1 9.1.1 Engine Will Not Start...
Page 265 SECTION 9 UNIT TROUBLESHOOTING Should a problem develop with these components, contact your nearest Carrier Transicold dealer for replacement. NOTE Run a Pretrip and check all active alarms before continuing with troubleshooting. ENGINE Indication/Trouble Possible Causes Action / Reference 9.1.1...
Page 266 Indication/Trouble Possible Causes Action / Reference 9.1.2 Engine Starts Then Stops Fuel supply restricted Check No fuel in tank Check Leak in fuel system Check Faulty fuel control operation Engine Manual Plugged fuel filter 8.5.5 Plugged inlet screen to mechanical pump 8.5.3 Plugged inlet screen to electric pump 8.5.4...
Page 267 Indication/Trouble Possible Causes Action / Reference 9.1.6 Miscellaneous Engine Troubleshooting Air cleaner or hose restricted 8.5.10 Air in fuel system 8.5.2 Air vent restricted in fuel tank cap Clean Restricted fuel lines Engine Manual Loss of power Defective fuel injection pump Engine Manual Defective injector(s) or incorrect type Engine Manual...
Page 268 Excessive charging rate (evi- Regulator faulty 8.10.5 denced by need for frequent filling or constant high charging amper- age) Alternator belt loose/broken/misaligned 8.5.15 Alternator noisy Loose pulley 8.10.5 Worn bearings 8.10.5 REFRIGERATION / TEMPERATURE CONTROL Indication/Trouble Possible Causes Action / Reference 9.3.1 Unit Will Not Cool Compressor drive defective...
Page 269 Indication/Trouble Possible Causes Action / Reference 9.3.5 Unit Will Not Terminate Cooling Temperature sensor malfunction 8.10.7 Unit fails to stop cooling Incorrect temperature scale, check whether microproces- Check sor is set for °C or °F 9.3.6 Unit Will Not Heat Or Has Insufficient Heating Abnormal pressure 9.3.9 Main microprocessor malfunction...
Page 270 Indication/Trouble Possible Causes Action / Reference 9.3.9 Abnormal Pressure Cooling Condenser coil dirty 8.9.2 Condenser fan/upper belt defective 8.6.3 High discharge pressure Discharge check valve restricted 8.9.10 Refrigerant overcharge or noncondensibles 8.7.2 Discharge service valve partially closed Open SV4 leaking 8.9.6 Compressor valve(s) worn or broken 8.8.1...
Page 271 Indication/Trouble Possible Causes Action / Reference 9.3.11 Abnormal Noise Loose mounting bolts Tighten Worn bearings 8.8.1 Compressor Worn or broken valves 8.8.1 Liquid slugging 9.3.13 Insufficient oil 8.8.5 Condenser fan 8.6.3 Condenser or evaporator fan Evaporator fan 8.6.5 Fan shaft 8.6.6 Alternator/Water pump belt Alternator belt loose/broken...
Page 272 SECTION 10 - WIRING PARAGRAPH NUMBER Page 10.1 HARNESS CONNECTOR WIRING ..........10–1 10.2 SPLICE POINTS...
Page 273 SECTION 10 WIRING 10.1 HARNESS CONNECTOR WIRING NOTE All illustrations provided in this Section are looking at the connector connection end (with the wires in the back). BLACK WHITE Component Terminal PCM 19 Component Terminal SP 1 SP 8 3 (14) 1SVM 1 SATPWR B SP 4...
Page 274 BLACK GRAY Component Terminal Component Terminal AAT A SV1 A (+) AAT B SV2 A (+) RAT A SV4 A (+) RAT B UL1 A (+) SAT A LB H SAT B UL2 A (+) EVOT A ENCU 44 CDT A FP + CSP 3 CLH A (+)
Page 275 2SVM BLUE 1SVM BLACK Component Terminal Component Terminal CSMV A 1MM 3 CSMV B DM 2 CSMV C DM 1 CSMV D DM 6 EVXV E SP 1 EVXV A 1MM 8 EVXV B SP 4 EVXV C DM 10 EVXV D Unused terminals: None PCM 18...
Page 276 ENCU BLACK Component Terminal 1SVM 3 1SVM 2 SATCOM B 1SVM 4 J1 A SATCOM C 1SVM 8 SATCOM A Component Terminal Unused terminals: 4,5,9,11,13,14 ENCT B ENSSN 2 ENCT A RPS 3 ENOPS A ENOPS B ENCU GND A ENSSN 1 SP 6 SP 1...
Page 277 10.2 SPLICE POINTS Splice Point No. Component 1MM 2 SP 1 1SVM 5 (CAN high) ENCU 23 SATPWR A UL1 (negative) UL2 (negative) SP 2 (Ground) FP (negative) GND1 RING1* LB G AFAS B (negative) CLH B (negative) Harness Connector Shown GND1 RING1* UNITS WITH DS CONNECTOR SV1 B (negative)
Page 279 INDEX Display 3–1 Display Module 8–5 Advanced User 3–15 Display Module (DM) 8–45 Air Cleaner 8–11 Display Module Keys 2–13 Air Flow 4–14 Display Screens 3–2 Alternator 2–6 8–45 Door Latch Maintenance and Replacement 8–5 Ambient Air Temperature Sensor (AAT) 2–9 Downloading Data Files 5–10 AutoFresh Air Exchange 2–9 4–8...
Page 280 Power Train Service 8–15 Preprogrammed Software Overrides 4–14 Heat Exchanger 2–9 Pre-Replacement Steps 5–15 Heating 4–3 Pressure Transducers 8–43 High Ambient Defrost Operation 4–10 Pre-Trip Inspection 8–2 High Ambient Defrost Termination Sequence 4–10 Priming the Fuel System 8–7 High Pressure Switch 8–42 ProductShield 4–12 Pull Down/Pull-Up 4–3 Inactive Alarms 5–3...
Page 281 Troubleshooting, Unit Runs But Insufficient Cooling 9–4 Troubleshooting, Unit Will Not Cool 9–4 Technician Hour Meters 5–2 Troubleshooting, Unit Will Not Heat 9–5 Technician Mode 5–1 Troubleshooting, Unit Will Not Stop Heating 9–5 Temperature Control 4–5 Troubleshooting, Unit Will Not Terminate Cooling 9–5 Temperature Determination 4–5 TRU-Tech 5–13 Temperature Range Lock 1 &...
Page 282 Athens, GA 30601 USA Colonia Anahuac Tel: 1-706-357-7223 11320 Mexico, D.F. Fax: 1-706-355-5435 Tel: 55315010 Fax: 55315010 ext. 1005 Carrier Transicold Division, Carrier Corporation A member of the United Technologies Corporation. P.O. Box 4805 Stock symbol UTX. Syracuse, NY 13221 USA www.carrier.transicold.com...

This manual is also suitable for:

X4 7500

Carrier X4 7300 Operation & Service Manual

Operation & Service Manual X4 7300 & X4 7500

List of Illustrations

Section 3 - Operation

Section 4 - Engine and Temperature Control

Section 5 - Control System Interface

Section 7 - Alarm Troubleshooting

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Summary of Contents for Carrier X4 7300