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Carrier TRANSICOLD X Series Manual

Trailer and rail refrigeration units with advance microprocessor and tier 4i engine
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Summary of Contents for Carrier TRANSICOLD X Series

  • Page 2 OPERATION AND SERVICE MANUAL NOSEMOUNT TRAILER AND RAIL REFRIGERATION UNITS WITH ADVANCE MICROPROCESSOR AND TIER4i ENGINE...
  • Page 3 TABLE OF CONTENTS PARAGRAPH NUMBER Page SAFETY PRECAUTIONS ..............SAFETY PRECAUTIONS .
  • Page 4 TABLE OF CONTENTS (Continued) PARAGRAPH NUMBER Page OPERATION ................. 3- -1 STARTING UNIT -- AUTO .
  • Page 5 TABLE OF CONTENTS (Continued) PARAGRAPH NUMBER Page TEMPERATURE CONTROL ..............PERISHABLE AND FROZEN SETPOINT RANGES .
  • Page 6 TABLE OF CONTENTS (Continued) PARAGRAPH NUMBER Page TECHNICIAN INTERFACE ..............6- -1 PC MODE/DOWNLOAD PORT .
  • Page 7 TABLE OF CONTENTS (Continued) PARAGRAPH NUMBER Page 8.4 SHUTDOWN ALARMS ..............8- -7 LOW ENGINE OIL PRESSURE .
  • Page 8 TABLE OF CONTENTS (Continued) PARAGRAPH NUMBER Page 8.7 ELECTRICAL ALARMS ..............8- -45 BAD F2 OR F3 FUSE .

  • Page 9: Table Of Contents

    TABLE OF CONTENTS (Continued) PARAGRAPH NUMBER Page 8.9 PRETRIP ALARMS (Continued) ............8- -64 P162 CHECK AUTO FRESH AIR EXCHANGE SOLENOID (AFAS) CIRCUIT...
  • Page 10 TABLE OF CONTENTS (Continued) PARAGRAPH NUMBER Page SERVICE ..................9- -1 MAINTENANCE SCHEDULE .
  • Page 11 TABLE OF CONTENTS (Continued) PARAGRAPH NUMBER Page SERVICE (Continued) ............... . 9- -1 9.16 CHECKING COMPRESSOR OIL LEVEL .
  • Page 12 TABLE OF CONTENTS (Continued) PARAGRAPH NUMBER Page UNIT TROUBLESHOOTING ..............10- -1 10.1 DIESEL ENGINE .
  • Page 13 LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figure 2-1. Front View Of Unit ..............2--2 Figure 2-2.
  • Page 14 LIST OF ILLUSTRATIONS (Continued) FIGURE NUMBER Page Figure 9--24. Compressor ..............9--32 Figure 9--25.

  • Page 15: Section 1 Safety Precautions

    SAFETY PRECAUTIONS Engine Coolant 1.1 SAFETY PRECAUTIONS Your Carrier Transicold refrigeration unit has been designed with the safety of the operator in mind. During The engine is equipped with a pressurized cooling normal operation, all moving parts are fully enclosed to system.
  • Page 16 CDP. WARNING Never run unit with discharge service valve WARNING frontseated. Carrier Transicold does not recommend al- Never remove fill plug with pressure in lowing the compressor to pull less than 0 compressor. Bar/PSIG at any time.
  • Page 17 WARNING CAUTION When changing oil filters, the new filters Personal protection equipment must be should be primed (partially filled) with clean utilized when performing coil cleaning. oil if possible. If the filters are not primed, the engine may operate for a period with no oil supplied to the bearings.
  • Page 18 Unit uses R404A and POE oil. The use of in- An overcharge of oil will reduce system ca- ert gas brazing procedures is mandatory for pacity and possibly cause internal com- all Carrier Transicold refrigeration units; pressor damage. otherwise compressor failure will occur. For more information Refer to Technical...

  • Page 19: Safety Decals

    1.3 SAFETY DECALS 62-03958-00 Heat Warning ONLY USED ON UNITS WITH TWO-WAY COMMUNICATION CAPABILITIES 1--5 62-11336...
  • Page 20 62-11336 1--6...
  • Page 21 1--7 62-11336...

  • Page 22: Section 2 Unit Description

    SECTION 2 UNIT DESCRIPTION 2.1 INTRODUCTION This manual contains Operating Data, Electrical Data and Service Instructions for the refrigeration units listed in Table 2-1. WARNING Additional support manuals are listed in Table 2-2. The model/serial number plate is located inside the unit on the frame as shown in Figure 2-3.

  • Page 23: Figure 2-1. Front View Of Unit

    King Valve Lube Oil Fill and Dipstick Hot Gas Solenoid Valve (SV4) Lube Oil Filter Suction Modulation Valve (CSMV) Mechanical Fuel Pump High Pressure Cutout Switch (HPS), Compres-- Engine Oil Pressure Switch (ENOPS) sor Discharge Transducer (CDT) and Unloader Engine Speed Sensor (ENSSN) Solenoid Valve Fuel and Speed Actuator (FSA) and Alternator Discharge Service Valve...

  • Page 24: Figure 2-2. Curbside

    Condenser Pressure Control Condenser/Radiator Solenoid Valve (SV1) Pressurized Coolant System Defrost Air Switch Evaporator Filter-Drier Resonator Receiver Sight Glass Control Box -- See Figure 2-5 Receiver Serial Port / Download Plug (SLP) Liquid Line Solenoid Valve (SV2) Model/Serial No. Location Battery Location Figure 2-2.

  • Page 25: Figure 2-4. Evaporator Section -- Panels And Grille Removed

    CURBSIDE Evaporator Fan Defrost Termination Thermostat (DTT2) Expansion Valve Supply Air Thermistor (SAT) Heat Exchanger Nozzle Cover Return Air Thermistor (RAT) AutoFresht Air Exchange (See Sections Evaporator Coil 2.4.3 and 3.18.4 Figure 2-4. Evaporator Section - - Panels and Grille Removed 62-11336 2--4...

  • Page 26: Figure 2-5. Control Box

    Control Module (Microprocessor) Fuse (F8) 20 Amp (Optional Fuel Heater) Refer to Section 2.5.3 Fuse (F7) 5 Amp Fuse (F1) 7.5 Amp -- Located next to control AutoFresh Relay (AFAR) -- Location Only module Fuse (F5) 80 Amp Fuse (F10) 40 Amp -- Optional Auto Fresh Air Fuel Heater Relay (FHR) -- Location Only Exchange -- Location Only Starter Solenoid Relay (SSR)

  • Page 27: Condensing Section

    2.3 CONDENSING SECTION condensing section consists engine-compressor drive package, condenser fan, condenser/radiator coil, refrigerant controls, piping, wiring, defrost air switch, and associated components. The drive equipment includes the engine, clutch, air cleaner, muffler, coolant overflow bottle, and drive belts. Refrigeration components mounted in the condensing section include the compressor, defrost air switch, suc- tion modulation valve, filter drier, and receiver.

  • Page 28: Figure 2-7. Alternator And Regulator

    2.3.2 Alternator/Regulator The alternator converts mechanical and magnetic energy to alternating current (AC) and voltage, by the Electrical power for the control system and for charging rotation of an electromagnetic field (rotor) inside a three- the battery is provided by the 12 VDC alternator. phase stator assembly.

  • Page 29: Figure 2-8. Compressor Cylinder Head Unloaded

    2.3.3 Compressor The compressor assembly includes the refrigerant com- b. Unloaded Operation pressor, suction and discharge service valves, high Pressure from the discharge manifold (Figure 2-8, item pressure switch, and the suction pressure transducer. 15) passes through the strainer (9) and bleed orifice (8) The compressor withdraws refrigerant gas from the to the back of the piston bypass valve (7).

  • Page 30: Figure 2-9. Compressor Cylinder Head Loaded

    c. Loaded Operation closing the gas bypass from the discharge manifold to the suction manifold (10). Discharge pressure bleeds from the discharge manifold Cylinder discharge pressure will force open the (Figure 2-9, item 15) through the strainer (9) and (8) discharge piston check...

  • Page 31: Evaporator Section

    COMPONENTS (termination switch). The location of the thermostat is shown in Figure 2-4. The return air sensor is also shown The temperature controller is a Carrier Transicold in Figure 2-4. Advance Microprocessor controller (Refer to Section 2.4.1 Thermal Expansion Valve 2.5.3 and 3).
  • Page 32 DataRecorder date and time can be set from the 2.5.2 Special Features keypad The following special features are incorporated into the Auto Start-Stop Carrier Transicold Advance Microprocessor: A MessageCenter which clearly displays all Trip Start to record date/time of trip in information in dot matrix form. DataRecorder memory...

  • Page 33: Figure 2-10. Control Module

    FETs (Field Effect Transistors). CAUTION Under no circumstances should anyone attempt to repair the Logic or Display boards. Should a problem develop with either of these components, contact your nearest Carrier Transicold dealer for replacement. RUN RELAY (K2) SPEED RELAY (K1) LED29 F4 (7.5A)
  • Page 34 The PC card slot is also shown in Figure 2-10. This card 6.6.7) and install optional features. slot is used with all Carrier Transicold PC cards. The While these cards are constructed for a rugged controller automatically detects the presence and type of PC card inserted and responds accordingly.
  • Page 35 b. Display and Keypad DISPLAY MODE LIGHTS +34.5°F -20.0 DOOR MessageCenter -20.0 +34.5°F STATUS OK DEFAULT MESSAGE MAY BE REPLACED BY USER DEFINED MESSAGE DISPLAY and KEYPAD MODULE 62-11336 2--14...
  • Page 36 The Display and Keypad module is located for operator MessageCenter access at the lower roadside corner of the unit. The MessageCenter is used to show messages. Details The display board is mounted in the Keypad and Display of the messages are described in Section 7.1 module.
  • Page 37 Key Descriptions UP ARROW and DOWN ARROW Keys SELECT Key SELECT Press the SELECT key to scroll through the These keys allow you to change the menu selections. One of the five standard setpoints or other displayed data of the and one optional menu selections will system.

  • Page 38: Led Light Bar

    c. Light Bar The Light Bar is an external set of indicator lights that START-STOP, ALARM. can be seen in the mirror from the cab of a truck or on the ENGINE-AUTO-START light is only illuminated when front of a rail car. They are controlled by the unit operating Start-Stop.
  • Page 39 d. Door and Remote Switches Out of Range is determined by the Functional Parameter setting. Selections of 4°F (2°C), 5.5°F (3°C), The unit has provisions to install a Door switch (DS), and 7°F (4°C), and OFF are available. The OFF setting up to two remote switches (REMS1 and 2), and connect disables the Out of Range alarm.

  • Page 40: Table 2-3. Engine Data

    10W 30 or years/150,000 miles) on the label. 15W 40 Extended Service Interval (ESI) packages are standard on X series units. The ESI package reduces the frequency of scheduled service intervals. Oil Change Intervals - - Extended Service Interval MOBIL...

  • Page 41: Engine Screw Threads

    NOTE 2.10 REFRIGERATION SYSTEM DATA The maximum oil change interval is one year for Table 2-5. Refrigeration System Data CG oil or two years for Mobil Delvac 1 unless Defrost Air Switch 1.40 (¦ .07) inch (35 ¦ 1.8 units are equipped with Extended Service Inter- (DAS) Initiates Defrost: mm) WG val Packages.

  • Page 42: Safety Devices

    2.11 SAFETY DEVICES System components are protected from damage caused by unsafe operating conditions by automatic shut-down of the unit when such conditions occur. This is accomplished by the safety devices listed in Table 2-6. Table 2-6. Safety Devices Unit Shutdown Safety Devices Unsafe Conditions Safety Device Device Setting...

  • Page 43: Table 2-7. Component Resistance And Current Draw

    2.12 COMPONENT RESISTANCE AND CURRENT DRAW Table 2-7. Component Resistance and Current Draw Component Ohms Amps 7.8 ± 0.3 Ohms 0.10 to 2.0 Amps SV2 and 4 10.6 ± 0.3 Ohms 0.75 to 2.0 Amps AFAS (Auto Fresh Air Pull in -- 0.36 Ohms ± 10% Pull in -- 29 Amps Solenoid) Hold -- 14.4 Ohms ±...

  • Page 44: Figure 2-11. Refrigerant Circuit During Cooling

    2.13 REFRIGERANT CIRCUIT DURING COOLING (See Figure 2-11) When cooling, the unit operates as a vapor compression The refrigerant flows to the “Liquid/suction” heat refrigeration system. The main components of the exchanger. Here the liquid is further reduced in system are: the (1) reciprocating compressor, (2) temperature by giving off some of its heat to the suction air-cooled condenser, (3) expansion valve, and (4) gas.

  • Page 45: Figure 2-12. Refrigerant Circuit During Heating And Defrost

    2.14 REFRIGERANT CIRCUIT - - HEATING AND DEFROSTING (See Figure 2-12) When vapor refrigerant is compressed to a high pressure When additional heating capacity is required the microprocessor opens the Liquid Line Solenoid valve and temperature in a reciprocating compressor, the (SV2) to allow additional refrigerant to be metered into mechanical energy necessary to operate the compressor the hot gas cycle (through the expansion valve).
  • Page 46 SECTION 3 OPERATION 3.1 STARTING UNIT - - AUTO WARNING Under no circumstances should ether or any other starting aids be used to start engine. MODE LIGHTS DISPLAY -20.0 +34.5° F 1. Place the START/RUN-OFF switch Door MessageCenter to START/RUN position. 3--1 62-11336...
  • Page 47 STARTING UNIT - - AUTO (Continued) The suction modulation valve (CSMV) will go through a When first powered up, the microprocessor controller procedure to close itself. The microprocessor starts out will run a self test. All of the mode lights will light, all of the giving the CSMV the command to close completely.
  • Page 48 3.2 PRETRIP HEAT COOL DEFROST ALARM START-STOP CONTINUOUS PPPP SETPOINT BOX TEMPERATURE TEST #1 MANUAL SELECT ALARM LIST START- - STOP/ DEFROST CONTINUOUS 1. Press the SELECT key until the MessageCenter displays “PRESS THE = KEY TO START PRETRIP.” 2. Press the = key to start PRETRIP. 3.
  • Page 49 PRETRIP (Continued) NOTES Test 2 - - Amperage Check of Electrical Components NOTE 1: Pretrip may be initiated any time the unit is running, or when the unit is off but the Check the amperage (current) draw of the following START/RUN-OFF switch components:...
  • Page 50 PRETRIP (Continued) Test 4 - - Warm Up Test 10 - - Check Suction Modulation Valve (CSMV) This test is to ensure that the CSMV is opening and The engine is started automatically and the ambient air closing properly. If suction pressure doesn’t change as sensor is read.
  • Page 51 Test 16 - - Check For Other Alarms That May Be Present: Check for the following alarms: Alarm Alarm Description LOW FUEL LEVEL WARNING (for units with Low Fuel Level switch/no fuel level display in Data List) LOW FUEL LEVEL WARNING (for units with Low Fuel Level 0% to 100% Sensor / fuel level is dis- played in Data List) LOW ENGINE OIL LEVEL LOW COOLANT LEVEL...

  • Page 52: Changing Setpoint

    3.3 CHANGING SETPOINT HEAT COOL DEFROST ALARM START-STOP CONTINUOUS -20.0 +34.5° F SETPOINT BOX TEMPERATURE ↑↓ TO SCROLL, THEN = TO SAVE MANUAL SELECT ALARM LIST START- - STOP/ DEFROST CONTINUOUS 1. With the setpoint displayed, press the UP ARROW or DOWN ARROW key to change the setpoint to the desired value.

  • Page 53: Start-Stop Operation

    3.4 START-STOP OPERATION START-STOP LIGHT HEAT COOL DEFROST ALARM START-STOP CONTINUOUS -20.0 +34.5° F SETPOINT BOX TEMPERATURE START/STOP MODE SELECTED MANUAL SELECT ALARM LIST START-STOP/ DEFROST CONTINUOUS 1. Press the START-STOP/CONTINUOUS key until the START-STOP Light on the controller illuminates. 2.

  • Page 54: Continuous Run Operation

    3.5 CONTINUOUS RUN OPERATION CONTINUOUS RUN LIGHT HEAT COOL DEFROST ALARM START-STOP CONTINUOUS +34.5° F -20.0 SETPOINT BOX TEMPERATURE CONTINUOUS RUN MODE SELECTED MANUAL SELECT ALARM LIST START- - STOP/ DEFROST CONTINUOUS 1. Press the START-STOP/CONTINUOUS key until the CONTINUOUS RUN 2.
  • Page 55 3.6 SLEEP MODE ON HEAT COOL DEFROST ALARM START-STOP CONTINUOUS SETPOINT BOX TEMPERATURE SLEEP MODE SETTINGS MANUAL SELECT ALARM LIST START- - STOP/ DEFROST CONTINUOUS 1. Press the SELECT key until the MessageCenter displays “PRESS ↑↓ TO VIEW SETTINGS”. 2. By pressing the UP or DOWN ARROW key, you will move through the Function List until “SLEEP MODE SETTINGS”...
  • Page 56 3.7 SLEEP MODE OFF WARNING UNITS EQUIPPED WITH STAR-TRAK TWO WAY COMMUNICATION CAPABILITIES HAVE THE ABILITY TO BE STARTED OR TURNED OFF REMOTELY REGARDLESS OF THE SETTING OF THE START/RUN-- OFF SWITCH. The unit is controlled locally and there can be no two-way communication when the Mode switch on the Remote Monitoring Control Box is in MAINTENANCE MODE.
  • Page 57 SLEEP MODE ON (Continued) No further menu selections are available when NO is There is NO TEMPERATURE CONTROL in Sleep selected from the mode and it should never be used for hauling perishable “SLEEP MODE: YES OF NO” menu. The following sub or frozen products.
  • Page 58 3.8 DEFROST 3.8.1 Manual Defrost DEFROST LIGHT HEAT COOL DEFROST ALARM START-STOP CONTINUOUS +34.5 SETPOINT BOX TEMPERATURE DEFROST CYCLE STARTED MANUAL SELECT ALARM LIST START- - STOP/ DEFROST CONTINUOUS 1. Press the MANUAL DEFROST key. The DEFROST light will come on and the Messa- geCenter will display “DEFROST CYCLE STARTED”...
  • Page 59 3.9 TRIP START HEAT COOL DEFROST ALARM START-STOP CONTINUOUS +34.5° F -20.0 SETPOINT BOX TEMPERATURE TRIP START ENTERED MANUAL SELECT ALARM LIST START- - STOP/ DEFROST CONTINUOUS 1. To mark the start of a trip in the data recorder, press the SELECT key until The MessageCenter displays “PRESS = TO ENTER TRIP START.”...

  • Page 60: View Active Alarms

    3.10 VIEW ACTIVE ALARMS ALARM LIGHT HEAT COOL DEFROST ALARM START-STOP CONTINUOUS +34.5° F -20.0 SETPOINT BOX TEMPERATURE NO ACTIVE ALARMS MANUAL SELECT ALARM LIST START- - STOP/ DEFROST CONTINUOUS 1. Press the ALARM LIST key. If there are no active alarms, the display will say “NO ACTIVE ALARMS”...
  • Page 61 3.11 VIEW INACTIVE ALARMS HEAT COOL DEFROST ALARM START-STOP CONTINUOUS +34.5° F -20.0 SETPOINT BOX TEMPERATURE NO INACTIVE ALARMS MANUAL SELECT ALARM LIST START-STOP/ DEFROST CONTINUOUS 1. Press and hold both the ALARM LIST key and the UP ARROW key for six seconds.

  • Page 62: Table 3-1. Shutdown Alarms

    Table 3-1. Shutdown Alarms SHUTDOWN ALARMS SHUTDOWN ALARM ONLY or may be configured as SHUTDOWN (see configuration list Section 6.2.1) Low Oil Level Low Engine Oil Pressure High Coolant Temperature High Discharge Pressure Battery Voltage Too High Battery Voltage Too Low High Comp Discharge Temp Low Refrigerant Pressure Low Fuel Shutdown...
  • Page 63 3.12 UNIT DATA HEAT COOL DEFROST ALARM START-STOP CONTINUOUS +34.5° F -20.0 SETPOINT BOX TEMPERATURE PRESS ↑ ↓ TO VIEW DATA MANUAL SELECT ALARM LIST START-STOP/ DEFROST CONTINUOUS 1. Press the SELECT key until the MessageCenter displays “PRESS ↑↓ TO VIEW DATA.” 2.

  • Page 64: Table 3-2. Unit Data

    Table 3-2. UNIT DATA * Also appear in Configurations + May or may not be displayed depending on functional parameter settings SUCTION PRESSURE Compressor suction pressure DISCHARGE PRESSURE Compressor discharge pressure ENGINE COOLANT TEMP Engine coolant temperature RETURN AIR TEMP Return (air entering evaporator) air temperature SUPPLY AIR TEMP Supply (air leaving evaporator) air temperature...
  • Page 65 Table 3-2. UNIT DATA * Also appear in Configurations + May or may not be displayed depending on functional parameter settings PRODUCTSHIELD SETUP: Indicates that unit has IntelliSet installed and displays ProductShield settings. PRODUCTSHIELD Indicates if ProductShield Econo is OFF OR Go To Start-Stop OR Go ECONO: To Continuous Run ECONO MIN TEMP...
  • Page 66 3.13 VIEW HOURMETERS HEAT COOL DEFROST ALARM START-STOP CONTINUOUS +34.5° F -20.0 SETPOINT BOX TEMPERATURE TOTAL ENGINE HOURS: 0 HRS MANUAL SELECT ALARM LIST START- - STOP/ DEFROST CONTINUOUS 1. Press the SELECT key until the MessageCenter displays “PRESS ↑↓ TO VIEW HOURMETERS.” 2.
  • Page 67 3.14 FUNCTIONAL CHANGE (PARAMETERS) HEAT COOL DEFROST ALARM START-STOP CONTINUOUS +34.5° F -20.0 SETPOINT BOX TEMPERATURE PRESS ↑ ↓ TO VIEW SETTINGS MANUAL SELECT ALARM LIST START- - STOP/ DEFROST CONTINUOUS 1. Press the SELECT key until the MessageCenter displays “PRESS ↑↓...

  • Page 68: Table 3-3. Functional Parameters

    Table 3-3. Functional Parameters FUNCTIONAL DESCRIPTION SELECTIONS PARAMETER DEFROST TIMER 1.5HRS The defrost timer will automatically put the unit into the defrost cycle at SET FOR 3HRS the interval selected. If evaporator is below 40°F (4.4°C). 6HRS Shorter times are generally used for warm, humid products like pro- 12HRS duce.
  • Page 69 FUNCTIONAL DESCRIPTION SELECTIONS PARAMETER DISPLAY IN ENGLISH UNITS The display will show temperatures and pressures in either English (°F and PSIG) or Metric (°C and Bars) METRIC UNITS Maintenance hourmeters that have expired will appear in this list. *RESET PM HOURMETERS S ENGINE If there are no active maintenance hourmeters, this menu item will not appear in the Functional Parameters.
  • Page 70 OFF or --START-STOP 1 to 255 minutes (10 min) UNLOADER The recommended setting for this is Std. This setting should not be changed unless discussed with a Carrier Transicold Factory Service PRESSURE CONTROL Engineer or Field Service Engineer. SLEEP MODE SETTINGS...
  • Page 71 FUNCTIONAL DESCRIPTION SELECTIONS PARAMETER S RUN PRETRIP NO -- The unit will wake up at the designated time and control to set- point. AT WAKE YES -- The unit will wake up at the designated time, automatically run Pretrip and then control to setpoint. The Pretrip Pass/Fail message will remain in the MessageCenter until the message is manually cleared.

  • Page 72: Language Selection

    3.15 LANGUAGE SELECTION HEAT COOL DEFROST ALARM START-STOP CONTINUOUS +34.5° F -20.0 SETPOINT BOX TEMPERATURE ESPAÑOL MANUAL SELECT ALARM LIST START- - STOP/ DEFROST CONTINUOUS 1. Press and hold the SELECT key for six seconds until MessageCenter displays current language (ENGLISH, ESPAÑOL, FRANÇAIS or PORTUGUÊS 2.
  • Page 73 3.16 STOPPING UNIT -20.0 +34.5° F 1. To stop the unit, place the START/RUN - OFF switch in the OFF position. The diesel engine will stop and the microprocessor NOTE controller will display “MICRO WILL STOP IN XX The CSMV will close to 0% when START/- SECONDS”.

  • Page 74: Data Recording

    3.17 DATA RECORDING The Advance microprocessor contains a built-in 3.17.3 Sensor and Event Data DataRecorder with 512K of memory. The recorded data can be downloaded from the DataRecorder using either Sensors ReeferManager, a PC software program, or a Download PC card. The following sensors may be recorded either with an The DataRecorder reads the same input information as averaged reading, or snapshot.
  • Page 75 DATA RECORDING (CONTINUED) Optional Sensors and Events 3.17.5 DataRecorder Power-Up In addition to the above Sensors and Events, the The DataRecorder records data the entire time the DataRecorder also has the capabilities to record the START/RUN-OFF switch is in the Run position. A following: configuration exists which allows the user to select Remote Temperature Sensor 1...
  • Page 76 3.18 OPTIONS 3.18.1 IntelliSet HEAT COOL DEFROST ALARM START-STOP CONTINUOUS 34.0 +34.5° F SETPOINT BOX TEMPERATURE APPLES ACTIVE MANUAL SELECT ALARM LIST START- - STOP/ DEFROST CONTINUOUS DURING START UP Observe the MessageCenter during the power up process. If the unit is equipped with IntelliSet, the name of the active or modified IntelliSet will be displayed for approximately 10 seconds before the engine starts.
  • Page 77 a. Changing IntelliSets HEAT COOL DEFROST ALARM START-STOP CONTINUOUS -20.0 +34.5° F SETPOINT BOX TEMPERATURE PRESS ↑ ↓ TO VIEW INTELLISETS MANUAL SELECT ALARM LIST START- - STOP/ DEFROST CONTINUOUS 1. PRESS = Key to display current IntelliSet. (Enable IntelliSet at = Key must configured ON.
  • Page 78 REMOTE ON. supplied by each individual provider, and not by Carrier Transicold. Communications electrical harnesses and serial port splitters are available from Carrier Transicold Performance Parts Group (PPG). Communication Providers will connect into the wiring harness at the SATCOM port, and possibly at the J1 connector.

  • Page 79: Figure 3--1. Autofresh Air Exchange

    3.18.4 AutoFresh Air Exchange ITEMS 6, 7 AND 8 ARE NOT ACTUALLY To activate AutoFresh operation, the AutoFresh Air SHOWN . ONLY LOCATIONS ARE INDICATED. Exchange configuration needs to be set (See Section 6.2.1). A second configuration, AutoFresh Air Delay, can be used to delay the start of AutoFresh operation by up to 48 hours after engine start-up.

  • Page 80: Figure 3--2. Autofresh In Closed Position

    AIR OPENINGS POINT DOWN TO PREVENT RAIN WATER ENTRY. Figure 3- -2. AutoFresh in Closed Position Figure 3- -3. AutoFresh in Open Position 3--35 62-11336...

  • Page 81: Auto Start Sequence

    SECTION 4 ENGINE 4.1 AUTO START SEQUENCE Once the starting conditions are met, the start sequence will begin by energizing the run relay (RR), and after 5 seconds energizing the glow plug relay (GPR) for up to 30 seconds in order to supply power to the air intake heater. (See Figure 4--1.) The buzzer will sound for 5 seconds, and then the starting sequence will begin.
  • Page 82 4.1.2 Engine Running The engine is considered to be running when: a.Engine RPM are greater than 1000, and b.The engine oil pressure switch contacts are closed within 15 seconds of the engine starting. OR if the RPM sensor is not reading correctly, and the engine is being started for the second or third attempt, the engine is considered to be running when: a.For ambient temperatures at or above 32°F (0°C) the engine oil pressure switch contacts are closed.

  • Page 83: Table 4-2 Battery Voltages

    4.2 START-STOP OPERATION Start-Stop is provided to permit starting/stopping/restarting of the engine–driven compressor as required. This feature allows full automatic control of the engine starting and stopping by monitoring refrigerated compartment temperature, battery charging amps, and engine coolant temperature. The main function of automatic engine cycling is to turn off the refrigeration system near setpoint to provide a fuel efficient temperature control system and to initiate a restart sequence after certain conditions are met.
  • Page 84 4.2.2 Restart A restart will be initiated when any one of the following conditions occurs: a. Engine coolant temperature drops below 34_F (1_C): However, if the coolant sensor alarm is active, the unit will re- start if the ambient air temperature drops to 32°F (0°C) after the unit has been in the OFF cycle for 60 minutes. b.
  • Page 85 4.2.5 Start- -Stop Parameters The selectable Start-Stop parameters in the Functional Parameter list can be applied to Start-Stop operation so that: a.The same settings apply to any setpoint, or b.The settings can be specified to be different, depending on whether the setpoint is above +10.4°F (-12°C) (in the per- ishable range), or +10.4°F (-12°C) or below (in the frozen range).

  • Page 86: Output Overrides

    4.4 OUTPUT OVERRIDES 4.4.1 Speed Control Overrides Speed Control Overrides in priority order: a. High Ambient: If ambient temperature is 120°F (48.9°C) or above during the engine starting sequence, the unit will run in low speed for the first 2 minutes or operation. This applies to Heat and Cool modes only - - not Defrost. b.

  • Page 87: Temperature Control

    SECTION 5 TEMPERATURE CONTROL 5.1 PERISHABLE AND FROZEN SETPOINT RANGES There are two ranges defined for setpoint. a. Setpoints above +10.4°F (-12°C) are considered Perishable. b. Setpoints of +10.4°F (-12°C) or below are considered Frozen. Perishable Frozen When the compartment tempera- When the compartment tempera- ture is near setpoint, the unit will ture is near setpoint, the unit will...
  • Page 88 5.2.2 Pulldown or Pull-up will end in the following conditions: a. For Continuous Run Mode -- Pulldown or Pull--up will end: SAT - RAT • When the RAT and SAT are equally spaced above and below setpoint, ( ) equals setpoint for setpoints below 65°F (18.4_C), and both supply and return air sensors are good.

  • Page 89: Figure 5--1. Continuous Run Temperature Control Operating Sequence -- Perishable Range

    Note: The following temperature control operating sequence diagrams are after pulldown and do not show overrides. RISING BOX TEMPERATURE High Speed 6 Cylinder Cool +3.6_F ( +2.0_C ) +3.2_F (+1.8_C ) Low Speed 6 Cylinder Cool +2.7_F (+1.5_C ) +2.3_F (+1.3_C ) Low Speed 2 Cylinder Cool +1.5_F (+0.8_C )

  • Page 90: Figure 5--3. Start-Stop -- Temperature Control Operating Sequence -- Perishable Range

    RISING BOX TEMPERATURE High Speed 6 Cylinder Cool +3.6_F ( +2.0_C ) ** +3.2_F (+1.8_C ) Low Speed 6 Cylinder Cool +2.7_F (+1.5_C ) +2.3_F (+1.3_C ) Low Speed 2 Cylinder Cool * +0.5_F (+0.3_C ) Setpoint Setpoint Start/Stop Off Cycle -0.5_F (-0.3_C) Low Speed 2 Cylinder Heat...
  • Page 91 5.5 ULTRAFRESH 3 TEMPERATURE CONTROL UltraFresh 3 is an advanced method of temperature control for both Perishable or Frozen ranges. It produces a reduced capacity state by: throttling down the CSMV and pulsing the SV4 valve (SV4 Pulse Mode), or mixing heating and cooling modes (Pulsed Null Mode).
  • Page 92 • Heat Pulsed Mode Engine Clutch CSMV Speed Output Refer to SV2 Opera- CLOSED OPEN ENGAGE UNLOAD UNLOAD Refer to CSMV Control tion Section 5.13 Pulsed Null Mode operation will modify the length of each Mode in 10 second cycles. That is, if the unit is in the Cool Null Pulse band, the unit may run in Cool for up to nine seconds, then Null for one second, if the Control Temperature is away from setpoint.

  • Page 93: Table 5-1 Freshprotect

    FreshProtect places a flexible limit on how far below setpoint the SAT can drop while the unit is operating in Cool Mode. Table 5-1 below shows the functional parameter settings and the corresponding ranges below setpoint that the Supply Air Temperature can go, when the RAT is 10°F (5.6°C) or less above setpoint. Whenever the RAT is more than 10°F (5.6°C) above setpoint, it is possible for the SAT to be lower than the shown range since the air temperature within the cargo area is a considerable distance from its desired point and additional cooling capacity is required.
  • Page 94 5.10 DEFROST Defrost is an independent cycle overriding cooling and heating functions in order to de-ice the evaporator as required. When the unit is in Defrost, the DEFROST LED will be on, the MessageCenter will display DEFROST CYCLE STARTED for the first 5 seconds, then the default message will be displayed for the rest of the Defrost Cycle. The compartment temperature section of the Main Display will show “dF”.
  • Page 95 5.10.3 Normal Defrost Termination Defrost Termination: Defrost will be terminated once any of the following conditions are met: a.When the defrost termination temperature (DTT2) and Supply Air Temperature (SAT) are both above 55_F (12.8_C) and the sensors are working properly. If either the DTT2 or the SAT sensor alarm is active, defrost will ter- minate when the remaining ’good’...
  • Page 96 5.10.5 High Ambient Defrost Operation (Ambient Air Temperature is greater than 80 ° F (26.7 ° C) The High Ambient Defrost Cycle has three separate modes: a. Pump Down Mode -- The Pump Down Mode pumps the low side of the refrigeration system down to a lower suction pressure, and reduces the engine load normally seen at the beginning of a Defrost Cycle.
  • Page 97 5.12 SV1 OPERATION The SV1 valve will be open (de--energized) whenever the system is operating in the Cool Cycle. The SV1 valve will be primarily closed (energized) during Heat and Defrost Cycles. When the system is operating in the Defrost Cycle, and the Discharge Pressure reaches 350 PSIG (23.8 Bars) , SV1 opens (de--energizes) for 1 second then closes (energizes) again to control the Discharge Pressure to less than 350 psig.
  • Page 98 5.14 TEMPERATURE RANGE LOCK 1 & 2 The unit can be locked into Start-Stop or Continuous Run operation for various setpoints. Two ranges are available for setpoint range lock selection. Each Range can be independently set to lock it’s setpoint temperatures into either Start-Stop or Continuous Run.
  • Page 99 Range Lock 1 & 2 Range 2 is set for 0° to -22°F Range 1 is set for (-17.8° to -30°C) +28° to +55°F (-2.2° to +12.8°C) Range 1 Range 2 -23.3 -17.8 -12.2 -6.7 - -1.1 10.0 15.6 21.1 26.7 °C °F...
  • Page 100 5.15 PRODUCTSHIELD NOTE ProductShield does not operate within Sleep Mode. ProductShield is a group of configuration settings within the microprocessor that are available in all Advance Micropro- cessors that have the IntelliSet option installed. The ProductShield Modes work together with the various IntelliSets to allow improved operating efficiency while providing customized product protection for up to 31 different commodities.
  • Page 101 ProductShield Econo: Go To Start/Stop Examples The following examples apply in situations where all other Start/Stop conditions have been met. If the Minimum is set to 30°F (-1.1°C) and the Maximum is set to 40°F (4.4°C) and the ambient air temperature falls between these temperatures, the unit operation can change to Econo Start/Stop.
  • Page 102 The operator can also optionally pre--program a maximum evaporator coil temperature differential (delta--t) between the return air and supply air sensors as an additional criteria for switching to high air. When the delta--T setting is used, the unit must bring the delta--t above this setting before going to High Air Mode. The delta--T setting is used to prevent ProductShield High Air from operating when the heat load on the refrigeration unit is low.
  • Page 103 5.16 OUTPUT OVERRIDES 5.16.1 Unloader Control Priority (UL1 & UL2) The compressor unloaders will operate in either a de--energized (loaded) or energized (unloaded) position, depending on current operating conditions. The list below shows the conditions that will control the operation of the unloaders in addition to the unloader control used by the temperature control described in section 5.11.

  • Page 104: Table 5-2 Suction Mop

    5.17 MAXIMUM SUCTION OPERATING PRESSURE (COOL ONLY) In Cool Mode, the CSMV is used to control Suction Pressure to these MAXIMUM operating limits determined by the compressor speed and number of loaded cylinders, as shown in the following table. Pressures may be lower depending on ambient and control temperatures, etc.

  • Page 105: Figure 5--5. Refrigeration System Suction Pressures For Loading And Unloading

    5.18.1 Suction Pressure Operation Directions For Reading the Chart Below a. At ambient temperatures of 90_F (32.2_C) or below: When the system is operating in high speed and the suction pressure is greater than 63 PSIG (4.3 Bars), both unloaders are unloaded. As the suction pressure drops below 63 PSIG (4.3 Bars), the UL2 unloader is loaded. If the suction pressure drops below 32 PSIG (2.2 Bars), the UL1 unloader is loaded.
  • Page 106 SECTION 6 TECHNICIAN INTERFACE 6.1 PC MODE/DOWNLOAD PORT PC mode allows the user to access and download data All functions available from the keypad may be viewed using a computer when the unit is not running and or changed using the ReeferManager and a personal without starting the eight-hour DataRecorder timer.
  • Page 107 Some of the things that you may want to use PC mode • Demonstrating the operation of the for are: microprocessor without the engine running. • Changing setpoint for the next load • Use any of the PC cards (Download, Program, Configuration or Option) •...
  • Page 108 e. Turn the START/RUN-OFF switch to the START/- Menu beginning at the top. RUN position. The ALARM LED will come on, the set- Press the DOWN ARROW key to scroll through the point will appear, but the refrigerated compartment Main Menu beginning at the bottom. temperature will not and “REMOVE JUMPER”...
  • Page 109 CONFIGURATION SELECTIONS DESCRIPTION OUT OF RANGE SHUTDOWN: YES / NO YES = When the compartment temperature has been out-of-range for 30 minutes, the alarm light will come on, and the unit will shut down. NO = When the compartment temperature has been out-of-range for 15 minutes, the alarm light will come on and the unit will continue to run.
  • Page 110 CONFIGURATION SELECTIONS DESCRIPTION LOW COOLANT LEVEL YES / NO YES = A Low Coolant Level sensor is installed in the coolant system. NO = There is no Low Coolant Level sensor installed in the coolant system. FUEL TANK NO DEVICE NO DEVICE = There is no Low Fuel Level sensor installed in the fuel tank.
  • Page 111 CONFIGURATION SELECTIONS DESCRIPTION OFF = The PM 1-5 Maintenance hourmeter(s) is • PM (1-5) turned off. ENGINE HOURS = PM meter will count engine ENGINE HOURS hours until the next service interval. SWITCH ON SWITCH ON HOURS = PM meter will count Switch HOURS On Hours until the next service interval.
  • Page 112 CONFIGURATION SELECTIONS DESCRIPTION PRODUCTSHIELD ECONO OFF or OFF = There is no lower limit for this parameter. -20°F to +119.0°F Refer to Section 5.15 for more information on this MIN TEMP (-28.9°C to setting. +48.4°C ) Select the lowest ambient temperature desired to (in 0.5°...
  • Page 113 CONFIGURATION SELECTIONS DESCRIPTION -22°F TO +89.6°F Select the lowest temperature desired for either (-30°C to +32°C) Range 1 and/or Range 2. •RANGE (1-2) MINIMUM TEMP (in 0.1° incre- ments) 〈-22°F TO +89.6°F Select the highest temperature desired for either (-30°C to +32°C) Range 1 and/or Range 2.
  • Page 114 CONFIGURATION SELECTIONS DESCRIPTION ALARM ONLY ALARM ONLY = When Door switch indicates that the door is open, a warning alarm will be displayed in the MessageCenter. UNIT SHUTDOWN UNIT SHUTDOWN = When Door switch indicates that the door is open, a warning alarm will be dis- played in the MessageCenter and the unit will shut- down.
  • Page 115 CONFIGURATION SELECTIONS DESCRIPTION LIGHT BAR 8 / 2 Indicates the type of light bar installed. 8 HR ADDITIONAL DATA: YES / NO YES = When the START/RUN-OFF switch is turned OFF, the data recorder will continue to record sensor data for an additional 8 hours. NO = When the START/RUN-OFF switch is turned OFF, the data recorder will stop recording all data.
  • Page 116 6.2.2 Component Test Mode NOTE pressing and holding the = key for six seconds. Should you need more than five minutes, the timer may be reset To enter Component Test mode refer to Section to five minutes anytime during the test by pressing the = 6.2.
  • Page 117 6.2.3 Service Mode Scroll through the Main Menu then press the = key CAUTION when SERVICE MODE appears MessageCenter. Service mode MUST be used whenever re- ENTERING SERVICE MODE will appear in the moving refrigerant charge, refrigerant leak MessageCenter, and OFF will be displayed checking or evacuating.
  • Page 118 6.3 DOWNLOADING DATA WITH THE PC CARD 1. Place the Micro in PC mode (Refer to Section 6.1), or place the START/RUN-OFF switch in the START/RUN position. 2. Insert a Download PC card into the PC card slot on the front of the microprocessor.

  • Page 119: Installing New Software

    6.4 INSTALLING NEW SOFTWARE NOTE All units should have the Controller software upgraded to 04.09.00 or above. It is no longer possible to load any versions of 03 software into that microprocessor. Newer versions can be loaded as they are released. 6.4.1 Software Version Numbers The first two digits of the software revision number (e.g.
  • Page 120 6.4.2 Using The Program PC Card Whenever performing a major operation to a microprocessor, such as installing new operating software, it is always a good idea to start the unit and give it a quick check over prior to performing the operation. NOTE Once the unit shuts down to begin the software install process, the Suction Modulation Valve closing process begins.
  • Page 121 6.4.3 Using ReeferManager a. Connect the computer to the microprocessor using a Download Cable. Once the cable is connected to the download port, the microprocessor will power up and CAUTION show “PC MODE.” b. Start the program by double clicking on the Micropro- It is important that communications be- grammer icon on your computer desktop.
  • Page 122 6.4.4 Troubleshooting Software Loading c. If the Micro Status LED is blinking at the rate of .5 sec- Problems onds on and .5 seconds off, the microprocessor is still in Program mode, and the software is not fully loaded after loading software program,...
  • Page 123 6.5 RE-SETTING PM (PREVENTATIVE MAINTENANCE) HOURMETERS PM hourmeters may be reset for the next maintenance interval from the Functional Parameter list using the keypad. HEAT COOL DEFROST ALARM START-STOP CONTINUOUS -20.0 +34.5° F SETPOINT BOX TEMPERATURE PRESS ↑ ↓ TO VIEW SETTINGS MANUAL SELECT ALARM LIST...
  • Page 124 SETTING PM (PREVENTATIVE MAINTENANCE) in 1,000 cycle increments anywhere from 1,000 to HOURMETERS (Continued) 90,000 cycles. Selecting OFF instead of an interval will also disable the PM hourmeter. The programmable PM hourmeters (PM1 – PM5) that can Once the PM hourmeters are activated from the be configured to count any of the following: Configuration List, they can only be RESET for a new •...

  • Page 125: Table 6-1. Connection Point Voltage

    When field diagnosis of a Carrier Transicold Trailer or where the harness attaches. Microproces- Rail refrigeration unit determines that an Advance sor components operate at different volt-...
  • Page 126 6.6.1 Microprocessor Replacement • Date and Time d. Remove PC jumper or turn START/RUN-OFF a. If possible, power the microprocessor up, either using switch to Off. a PC mode jumper, or by turning the START/RUN-- OFF switch to the Run position. If the microprocessor e.
  • Page 127 6.6.2 Microprocessor Setup f. The first hourmeter is Engine Protect Hours. Press the = key to select this meter. The cursor will be blink- NOTE ing on the ten-thousands place. Press the Up or Before starting the unit, the microprocessor Down Arrow key to select the correct value, then must be configured for the correct unit model press the = key.
  • Page 128 6.6.4 Functional Parameters via Keypad CAUTION Refer to Section 3.14 for the list of available Microprocessor Functional Parameters Be certain that the clock you are using is ac- directions on how to access them. curate, and is showing the correct time. 6.6.5 Data /Recorder Via ReeferManager PC Pro- Also, some customers are located in differ- gram...
  • Page 129 6.6.6 Engine And Switch-on Hourmeters Via Reef- 6.6.7 Configuration/IntelliSet PC Card erManager PC Program a. Place the START/RUN-OFF switch in the OFF posi- a. Start the ReeferManager program. Go to the Serial tion to power down the microprocessor and to take it Operations Tab.
  • Page 130 6.6.9 Replacing Keypad, Window or Door Keypad Installation Should damage to the keypad of the microprocessor oc- CAUTION cur, it is possible to replace only the keypad. Do not overtorque screws. All replacement keypads are packaged with replace- ment gaskets. a.

  • Page 131: Figure 6--1. Display Module Assembly

    DETENT SPRINGS DETENTS DISPLAY WINDOW KEYPAD DOOR DISPLAY BEZEL WINDOW GASKET DISPLAY BOARD WINDOW GASKET NOTE: GASKET IS NOTCHED KEYPAD BOARD FOR CLEARANCE AROUND DETENTS. MOUNTING BRACKET/CONTROL BOX GASKET Figure 6- -1. Display Module Assembly 62-11336 6--26...
  • Page 132 SECTION 7 MessageCenter 7.1 MessageCenter MESSAGES The following table lists all of the messages that do not appear in other lists in this manual and a description of their meaning. Refer to Section 8 for a list of alarm messages. Refer to Section 3.12 for a list of Unit Data messages. Refer to Section 3.14 for a list of Functional Parameter messages.
  • Page 133 MessageCenter MESSAGES Message Description CARD REMOVED, DATA NOT COPIED The PC card was removed before all data recorder data was cop- ied onto the card. CARD REMOVED, REINSERT CARD The PC card was removed from the card slot before the operation was completed.
  • Page 134 MessageCenter MESSAGES Message Description DATA RECORDER FAILURE The controller has stopped recording unit data. DEFROST CYCLE STARTED The unit has gone into defrost. DOOR OPEN The trailer or rail compartment door is open. DOOR OPEN -- LOW SPEED The trailer or rail compartment door is open forcing the unit to run in low speed.
  • Page 135 MessageCenter MESSAGES Message Description NO ACTIVE ALARMS There are no active alarms in the Micro Alarm list. NO DATA ON CARD, REMOVE CARD A Program or Configuration PC card has been inserted into the PC card slot, and no valid data is present on the PC card. The PC card may safely be removed from the unit.
  • Page 136 MessageCenter MESSAGES Message Description REMOVE CARD -- BATTERY TOO LOW If a PC card is inserted when battery is below 7.0 volts this mes- sage will be displayed until card is removed. REMOVE JUMPER The Configuration / Technician Test mode has been entered. Re- move the jumper wire before continuing.

  • Page 137: Section 8 Alarm Troubleshooting

    SECTION 8 ALARM TROUBLESHOOTING 8.1 INTRODUCTION TO ALARM TROUBLE- If the message “CHK WIRES FROM MICRO TO SHOOTING GUIDE KEYPAD.” appears in the MessageCenter, there is a communication error between the Keypad and the microprocessor. With no communication, there will not The Alarm Troubleshooting Guide should be used be an associated alarm.
  • Page 138 8.2 NOTES Note 1 Active alarms will always be in the Alarm list. Note 4 Many checks will be made with the They will have an “A” in front of the alarm microprocessor powered up, but with no number. Active alarms may be inactivated by outputs to the unit components.
  • Page 139 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION 8.3 DRIVER/OPERATOR ALARMS LOW FUEL LEVEL WARNING (for units with Low Fuel Level 0% to 100% Sensor / fuel level is displayed in Data list) • TRIGGER ON: Fuel level is 15% or less for more than 30 seconds. •...
  • Page 140 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION LOW FUEL LEVEL WARNING (for units with Low Fuel Level switch/no fuel level display in Data list • TRIGGER ON: Fuel level is less than 1/8 of a tank for more than 30 seconds. •...
  • Page 141 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION LOW ENGINE OIL LEVEL • TRIGGER–ON: Engine oil level is sensed approx. 7 or more qts. (6.62 or more liters) low for longer than 30 seconds. • UNIT CONTROL: Alarm Only, or may be configured to shut unit down on some models. •...
  • Page 142 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION LOW COOLANT LEVEL • TRIGGER ON: Engine coolant level is 1 or more quarts (.95 or more liters) low for more than 30 seconds. • UNIT CONTROL: Alarm only • RESET CONDITION: Auto reset if engine coolant level is at the full mark for more than 30 seconds. Alarm may be manually reset via keypad or by turning the unit off, then back on again.

  • Page 143: Alarm / Cause

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION 8.4 SHUTDOWN ALARMS LOW ENGINE OIL PRESSURE • TRIGGER–ON: Engine oil pressure is below 12 PSIG (0.82 Bar) for longer than five seconds while the engine is running. • UNIT CONTROL: Unit Shutdown & Alarm. •...
  • Page 144 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION HIGH COOLANT TEMPERATURE • TRIGGER–ON: For ambient temperatures below 120°F (48.9°C) Engine coolant temperature is above 230°F (110°C), or Ambient temperatures above 120°F (48.9°C), engine coolant temp is over 241°F (116°C), or Engine coolant temperature is between 230°F and 241°F (110°C and 116°C) for more than five minutes.
  • Page 145 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION HIGH DISCHARGE PRESSURE • TRIGGER–ON: Compressor discharge pressure is over 465 PSIG (31.6 Bars) • UNIT CONTROL: Immediate Unit Shutdown & Alarm • RESET CONDITION: Auto Reset after 15 minutes if the compressor discharge pressure falls below 350 PSIG (23.8 Bars), or Alarm may be manually reset via keypad or by turning the unit off, then back on again.
  • Page 146 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION HIGH DISCHARGE PRESSURE (Continued) Check HPS switch harness a. Inspect harness & control No physical damage to harness. connector pins & terminals (See wiring No damaged or corroded pins schematic) b. Check for shorted circuit in harness, START/RUN-OFF switch in START/RUN position, Manual and continuity through the harness Start mode (See Note 3)

  • Page 147: Battery Voltage Too Low

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION BATTERY VOLTAGE TOO HIGH • TRIGGER–ON: Voltage at the microprocessor is greater than 17 VDC. • UNIT CONTROL: Unit Shutdown & Alarm • RESET CONDITION: Auto Reset after 15 minutes when the voltage at the microprocessor is between 11 -- 14 VDC, or Alarm may be manually reset via keypad or by turning the unit off, then back on again.
  • Page 148 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION HIGH COMP DISCHARGE TEMP • TRIGGER–ON: Ambient temp below 120°F (48.9°C) discharge temp was between 310°F -- 349°F (154.4°C -- 176.7°C) for three minutes, or Ambient temp above 120°F (48.9°C) Discharge temp was between 340°F -- 349°F (171.1°C -- 176.7°C) for three minutes, or Discharge temp ever reaches 350°F (176.7°C) •...
  • Page 149 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION HIGH COMP DISCHARGE TEMP (Continued) Check Expansion Valve (TXV) a. Visually inspect valve Bulb must be clamped tightly on the suction line and insulated. No physical damage to bulb, capillary tube of valve body. b.

  • Page 150: Low Refrigerant Pressure

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION LOW REFRIGERANT PRESSURE • TRIGGER–ON (A): Suction Pressure is less than -6 inHg (-0.2 Bar) for more than 120* seconds, when the RAT is above -10°F (-23.3°C), or If the Suction Pressure is less than -16 inHg (-0.41 Bar) for more than 120*seconds at any RAT temperature, •...
  • Page 151 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION LOW FUEL SHUTDOWN (for units with Low Fuel Level 0% to 100% Sensor / fuel level is displayed in Data list) • TRIGGER ON: Fuel level is 10% or less for more than 1 minute. •...
  • Page 152 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION MAXIMUM COMPRESSOR ALARMS • TRIGGER ON: One of the following alarms: 13 -- High Discharge Pressure 17 -- High Compressor Discharge Temperature 18 -- Low Refrigerant Pressure 27 -- High Suction Pressure 28 -- Check Refrigerant System 29 -- Check Heat Cycle 56 -- Check Evaporator Airflow has occurred three times during the last two hours of actual unit operation (off cycle time is...
  • Page 153 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION HIGH SUCTION PRESSURE • TRIGGER ON: Suction pressure has been greater than 98 PSIG (6.7 Bars) for more than 10 minutes • UNIT CONTROL: Alarm Only or Unit Shutdown & Alarm (if configured) •...
  • Page 154 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK REFRIGERATION SYSTEM • TRIGGER ON: Discharge pressure is not at least 5 PSIG (0.34 Bar) higher than Suction pressure for more than 10 minutes • UNIT CONTROL: Alarm Only or Unit Shutdown & Alarm (if configured) •...
  • Page 155 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION 8.5 START UP ENGINE ALARMS FAILED TO RUN MINIMUM TIME • TRIGGER–ON: Engine has shut down on an alarm 3 times without having run for at least 15 minutes between each shutdown (not including Door or Remote switch shut downs). •...
  • Page 156 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION FAILED TO START - - AUTO MODE • TRIGGER–ON: Engine has tried to start three times unsuccessfully in the auto start mode. • UNIT CONTROL: Unit Shutdown & Alarm • RESET CONDITION: Alarm may be manually reset via keypad or by turning the unit off, then back on again. NOTE: Follow the steps below until a problem is found.
  • Page 157 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION FAILED TO START - - MANUAL • TRIGGER–ON: The unit was placed in Manual Start mode, and the engine was not manually started within five minutes. or, The user has tried to start the engine three times unsuccessfully in the Manual Start mode. •...
  • Page 158 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION FAILED TO START - - MANUAL (Continued) Check engine air–intake system a. Check air filter indicator Flag must not be visible. b. Inspect air intake system Hoses & tubes in good condition. No kinks or restrictions Check for correct engine oil a.
  • Page 159 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION ENGINE FAILED TO STOP • TRIGGER–ON: Engine is turning more than 500 RPM (or the micro input shows that the engine is turning more than 500 RPM) for 20 seconds after unit was turned off, shut down on an alarm or cycled off in a Start/Stop Off Cycle, or Oil Pressure Switch contacts are closed longer than 20 seconds after unit was turned off, shut down on an alarm, or cycled off in a Start/Stop Off Cycle.
  • Page 160 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK STARTER CIRCUIT • TRIGGER–ON: Engine speed failed to reach 50 RPM during 2 start attempts. • UNIT CONTROL: Unit Shutdown & Alarm • RESET CONDITION: Alarm may be manually reset via keypad or by turning the unit off, then back on again. NOTE: Follow the steps below until a problem is found.
  • Page 161 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK STARTER CIRCUIT (Continued) Check battery voltage a. Inspect battery cable ends and posts Must be clean and tight No corrosion b. Test voltage at battery with unit off. Must be above 11 VDC c.
  • Page 162 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK LOW SPEED RPM • TRIGGER–ON: Controller is set for low engine speed operation, and RPM being read by the microprocessor are not correct. The correct RPM for low speed are different for different models as shown below: Less than 1325 or greater than 1625 for Ultima XTC and X2 2500A/R;...
  • Page 163 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK HIGH SPEED RPM • TRIGGER–ON: Controller is set for high engine speed operation, and RPM being read by the microprocessor are not correct. The correct RPM for low speed are different for different models as shown below: Less than 2000, or greater than 2400 for Ultima XTC and X2 2500A/R;...
  • Page 164 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK HIGH SPEED RPM (Continued) Check engine RPM a. Check actual engine RPM using hand Refer to Section 2.6 held tachometer Adjust engine linkage setting as needed. b. Compare actual RPM with those Both readings within ±...
  • Page 165 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK ENGINE RPM • TRIGGER–ON: Engine RPM have been: Less than 1200 or greater than 2500 for Ultima XTC and X2 2500A/R; or Less than 1100 or greater than 2000 for Ultra XTC and X2 2100A/R for more than five minutes •...
  • Page 166 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK ENGINE RPM (Continued) Check low speed engine RPM a. Check actual engine RPM using hand Refer to Section 2.6 held tachometer Adjust engine linkage setting as needed. b. Compare actual RPM with those Both readings within ±...
  • Page 167 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK GLOW PLUGS (This alarm applies to Intake Air Heater) • TRIGGER–ON: Intake air heater amperage is less than 25 Amps, or greater than 55 Amps after 14 seconds of glow time (NOTE: In auto start, this can only occur when the Engine Coolant Temperature is below 50°F (11°C).
  • Page 168 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION ENGINE STALLED • TRIGGER–ON: The engine is running, RPM sensor is good, and engine speed is less than 10 RPM; or The engine is running, RPM sensor alarm is ON, and the Oil Pressure switch contacts are open. •...
  • Page 169 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION ENGINE STALLED (Continued) Check Engine Speed Sensor (ENSSN) a. Inspect harness & control No physical damage to harness. connector pins & terminals (See wiring No damaged or corroded pins schematic) Check engine air–intake system a.

  • Page 170: Alternator Not Charging

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION 8.6 WARNING / STATUS ALARMS ALTERNATOR NOT CHARGING • TRIGGER–ON: Unit is running (either engine or standby) and the current flow is more than -1.0 Amps (discharge) between the alternator to the battery for three continuous minutes. •...
  • Page 171 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION BOX TEMP OUT-OF-RANGE • TRIGGER–ON: UNIT CONTROL: Alarm Only: • The box temperature has been in range -- within ±2.7°F (±1.5°C) of setpoint for perishable and frozen -- at least once since the unit was started (Sleep Model and Component Test Modes excluded), and is now further away from setpoint than the limit set in the functional parameters -- 4°, 5.5°, or 7°F (2.°, 3°, or 4°C) for this unit, for more than 30 minutes OR...
  • Page 172 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION BOX TEMP OUT-OF-RANGE (Continued) NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (see reset condition above). Operate the unit through the appropriate modes to see if any active alarm occurs.
  • Page 173 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION DEFROST NOT COMPLETE • TRIGGER–ON: Defrost cycle did not terminate automatically. [DTT2 and SAT did not reach termination temperature of 55°F (12.8°C) within 45 minutes]. • UNIT CONTROL: Alarm Only. While this alarm is active, the Defrost Timer will be temporarily set to initiate a defrost cycle 90 minutes (1.5 hours) of unit running time after the alarm comes on.
  • Page 174 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK DEFROST AIR SWITCH • TRIGGER–ON: The defrost air switch has called for a defrost cycle within eight minutes of a defrost termination for two consecutive defrost cycles. (The air switch contact must be closed continuously for 15 seconds before the defrost cycle is started.) •...
  • Page 175 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK EVAPORATOR AIRFLOW • TRIGGER–ON: 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 Supply Air temperature is 5°F (2.8°C) or more warmer than Return Air Temperature for five minutes.
  • Page 176 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK REMOTE SWITCH 1 • TRIGGER–ON:Remote Switch 1 is set to trigger alarm (contacts open or contacts closed depending on set up in configuration list for Remote Switch 1) for more than five seconds. NOTE: SThis alarm is disabled for Shutdown when the ’Unit Operation’...
  • Page 177 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK REMOTE SWITCH 2 • TRIGGER–ON: Remote Switch 2 is set to trigger alarm (contacts open or contacts closed depending on set up in configuration list for Remote Switch 2) for more than five seconds. NOTE: SThis alarm is disabled for Shutdown when the ’Unit Operation’...
  • Page 178 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION DATALOGGER NOT RECORDING • TRIGGER–ON: No data is being recorded by the data recorder. • UNIT CONTROL: Alarm Only • RESET CONDITION: Alarm may be manually reset via keypad. NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s).
  • Page 179 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION DATALOGGER TIME WRONG • TRIGGER–ON: The real time clock in the Data Recorder does not contain a valid date. • UNIT CONTROL: Alarm Only • RESET CONDITION: Auto Reset when the Data Recorder Real Time Clock is reset, or Alarm may be manually reset by turning the unit off, then back on again.
  • Page 180 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION DOOR OPEN • TRIGGER–ON: Trailer or rail car compartment door has been open for more than five seconds. NOTE: SThis alarm is disabled for Shutdown when the ’Unit Operation’ configuration is set for Rail and the unit is operating in Sleep Mode.
  • Page 181 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION 8.7 ELECTRICAL ALARMS BAD F2 OR F3 FUSE • TRIGGER–ON: One or more of the following fuse circuits have been open for more than 2 seconds: F2 (Speed Relay output circuit), or F3 (Run relay output circuit) •...
  • Page 182 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK SV1 CIRCUIT • TRIGGER–ON: In either the Heat, Null, or Defrost cycles, the SV1 coil circuit is shorted. (The SV1 output from the micro is negative, so the circuit will not be shorted to ground, but is shorted either within the SV1 coil itself, or to a positive wire.) •...
  • Page 183 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK FHR CIRCUIT • TRIGGER–ON: Fuel Heater Relay circuit is shorted. (The Fuel Heater Relay output from the micro is negative, so the circuit will not be shorted to ground, but is shorted either within the Fuel Heater Relay coil itself, or to a positive wire.
  • Page 184 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK REMOTE DEFROST LIGHT • TRIGGER–ON: The micro Light Bar configuration is set for an 8--LIGHT BAR, and the Defrost light circuit (to the Light Bar) circuit is shorted. (The Defrost Light output from the micro is negative, so the circuit will not be shorted to ground, but is shorted either within the Defrost Light itself, or to a positive wire.
  • Page 185 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK UL1 CIRCUIT • TRIGGER–ON: UL1 (Front) Unloader Coil circuit is shorted. (The UL1 output from the micro is negative, so the circuit will not be shorted to ground, but is shorted either within the UL1 itself, or to a positive wire. •...
  • Page 186 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK REMOTE HEAT LIGHT • TRIGGER–ON: The micro Light Bar configuration is set for an 8--LIGHT BAR, and the Remote Heat light circuit (to the Light Bar) circuit is shorted. (The Heat Light output from the micro is negative, so the circuit will not be shorted to ground, but is shorted either within the Heat Light itself, or to a positive wire.
  • Page 187 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK REMOTE AUTO LIGHT • TRIGGER–ON: Remote Auto light circuit (to the Light Bar) circuit is shorted. (The Auto Light output from the micro is negative, so the circuit will not be shorted to ground, but is shorted either within the Auto Light itself, or to a positive wire.
  • Page 188 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK START UP BUZZER • TRIGGER–ON: The Buzzer circuit is shorted. (The Buzzer output from the micro 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 189: Sensor Alarms

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION 8.8 SENSOR ALARMS CHECK AMBIENT AIR SENSOR • TRIGGER–ON: Ambient Air Sensor circuit has failed open or shorted. If shorted, the data list will display 158°F (70°C). If the circuit is open, the data list will show the temperature as -52.6°F (-47°C) •...
  • Page 190 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK RETURN AIR SENSOR • TRIGGER–ON: Return Air Sensor circuit has failed open or shorted. If shorted, the data list will display 158°F (70°C). If the circuit is open, the data list will show the temperature as -52.6°F (-47°C) •...
  • Page 191 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK SUPPLY AIR SENSOR • TRIGGER–ON: Supply Air Sensor circuit has failed open or shorted. If shorted, the data list will display 158°F (70°C). If the circuit is open, the data list will show the temperature as -52.6°F (-47°C) •...
  • Page 192 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK COMP DISCH SENSOR • TRIGGER–ON: Compressor Discharge Sensor circuit has failed open or shorted. If shorted, the data list will display 392°F (200°C). If the circuit is open, the data list will show the temperature as -40°F (-40°C) •...
  • Page 193 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK FUEL SENSOR CIRCUIT • TRIGGER–ON: The Low Fuel Shutdown is configured as a 0% to 100% sensor, and the fuel level reading (in the data list) is less than 2% for 30 seconds. •...
  • Page 194 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK ENG COOLANT SENSOR • TRIGGER–ON: Engine Coolant Sensor circuit has failed open or shorted. If shorted, the data list will display 266°F (130°C). If the circuit is open, the data list will show the temperature as -58°F (-50°C) •...
  • Page 195 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK ENGINE RPM SENSOR • TRIGGER–ON: With the unit in Auto Start: The ambient temperature is above 32°F (0°C), and this is the 2nd or 3rd start attempt, and the Engine Oil Pressure switch is closed (oil pressure good), and engine RPM are sensed at less than 1000 RPM; or The ambient is below 32°F (0°C) and the DC amp draw is more than 2 amps , and this is the 2nd or 3rd start attempt, and engine RPM are sensed at less than 1000 RPM;...
  • Page 196 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK DEFROST TERM 2 SENSOR • TRIGGER–ON: Defrost Termination Temperature Sensor 2 circuit has failed open or shorted. If shorted, the data list will display 158°F (70°C). If the circuit is open, the data list will show the temperature as -52.6°F (-47°C) •...
  • Page 197 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK REMOTE TEMP SENSOR 1 • TRIGGER–ON: Remote Temperature Sensor 1 circuit is configured on, and has failed open or shorted. If shorted, the data list will display 158°F (70°C). If the circuit is open, the data list will show the temperature as -52.6°F (-47°C) •...
  • Page 198 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK REMOTE TEMP SENSOR 2 • TRIGGER–ON: Remote Temperature Sensor 2 circuit is configured on, and has failed open or shorted. If shorted, the data list will display 158°F (70°C). If the circuit is open, the data list will show the temperature as -52.6°F (-47°C) •...
  • Page 199 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION CHECK REMOTE TEMP SENSOR 3 • TRIGGER–ON: Remote Temperature Sensor 3 circuit is configured on, and has failed open or shorted. If shorted, the data list will display 158°F (70°C). If the circuit is open, the data list will show the temperature as -52.6°F (-47°C) •...

  • Page 200: Pretrip Alarms (Continued)

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION 8.9 PRETRIP ALARMS P141 PRETRIP STOPPED BY USER • TRIGGER–ON: Pretrip cycle was stopped before the Pretrip cycle ended automatically • UNIT CONTROL: Alarm Only • RESET CONDITION: Alarm may be manually reset via keypad or by turning the unit off, then back on again. NOTE: Follow the steps below until a problem is found.
  • Page 201 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P144 CHECK UL1 CIRCUIT • TRIGGER–ON: Normal Amps for the UL1 (Front) Unloader Circuit is 0.75 to 2.0 Amps. The circuit tests outside this range. • UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST 2” will be displayed in MessageCenter.
  • Page 202 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P145 CHECK SPEED SOL CIRCUIT • TRIGGER–ON: Normal Amps for the Speed Circuit is 0 to 1.0 Amps. The circuit tests outside this range. • UNIT CONTROL: Alarm Only • RESET CONDITION: Auto Reset if Pretrip mode is started again, or Alarm may be manually reset via keypad or by turning the unit off, then back on again.
  • Page 203 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P148 CHECK SV1 CIRCUIT • TRIGGER–ON: Normal Amps for the SV1 Circuit is 0.75 to 2.5 Amps. The circuit tests outside this range. • UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST 2” will be displayed in MessageCenter.
  • Page 204 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P150 CHECK SV4 CIRCUIT • TRIGGER–ON: Normal Amps for the SV4 Circuit is 0.75 to 2.0 Amps. The circuit tests outside this range. • UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST 2” will be displayed in MessageCenter.
  • Page 205 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P151 CHECK GLOW PLUG CIRCUIT (This applies to the Intake Air Heater) • TRIGGER–ON: Normal Amps for the Intake Air Heater Circuit is 23 to 70 Amps after 15 seconds. The circuit tests outside this range. •...
  • Page 206 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P152 CHECK FUEL SOLENOID CIRC • TRIGGER–ON: Normal Amps for the Fuel Solenoid Hold Circuit is 0.2 to 4.5 Amps (including possible electric fuel pump). The circuit tests outside this range. • UNIT CONTROL: Alarm Only •...
  • Page 207 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P153 CHECK RETURN AIR SENSOR • TRIGGER–ON: Return Air Sensor is not within the maximum range of --53°F to +158°F (--47°C to +70°C) • UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST 3” will be displayed in MessageCenter.
  • Page 208 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P154 CHECK SUPPLY AIR SENSOR • TRIGGER–ON: Supply Air Sensor is not within the maximum range of --53°F to +158°F (--47°C to +70°C) • UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST 3” will be displayed in MessageCenter.
  • Page 209 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P155 CHECK COOLANT TEMP SENSOR • TRIGGER–ON: Engine Coolant Temp Sensor is not within the maximum range of --58°F to +266°F (--50°C to +130°C) • UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST 3” will be displayed in MessageCenter.
  • Page 210 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P157 CHECK BATTERY CURRENT • TRIGGER–ON: With all circuits off, current flow of more than +1.5 or --2 Amps is detected in the electrical circuits. NOTE: If this alarm occurs, Pretrip Test #2 will not be performed. You will need to run Pretrip again.
  • Page 211 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P158 CHECK AMBIENT AIR SENSOR • TRIGGER–ON: Ambient Air Sensor is not within the maximum range of --53°F to +158°F (--47°C to +70°C) • UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST 3” will be displayed in MessageCenter.
  • Page 212 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P160 CHECK DISCH TEMP SENSOR • TRIGGER–ON: Compressor Discharge Temp Sensor is not within the maximum range of --40°F to +392°F (--40°C to +200°C ) • UNIT CONTROL: Alarm Only • RESET CONDITION: Auto Reset if Pretrip mode is started again, or Alarm may be manually reset via Keypad or by turning the unit off, then back on again.

  • Page 213: P162 Check Auto Fresh Air Exchange Solenoid (Afas) Circuit

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P162 CHECK AUTO FRESH AIR EXCHANGE SOLENOID (AFAS) CIRCUIT • TRIGGER–ON: Normal Amps for the AFAX Circuit is 0.4 to 2.5 Amps. The circuit tests outside this range. • UNIT CONTROL: Alarm Only. •...

  • Page 214: P164 Check Ul2 Circuit

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P164 CHECK UL2 CIRCUIT • TRIGGER–ON: Normal Amps for the UL2 (Rear) Unloader Circuit is 0.75 to 2.0 Amps. The circuit tests outside this range. • UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST 3” will be displayed in MessageCenter.

  • Page 215: P165 Cannot Pump Down

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P165 CANNOT PUMP DOWN • TRIGGER–ON: 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). •...

  • Page 216: P174 Check Low Speed Rpm

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P174 CHECK LOW SPEED RPM • TRIGGER–ON in Test #7: With Speed Relay turned off, engine RPM are Between 1375 and 1600 for Ultima XTC and X2 2500A/R; or Between 1275 and 1500 for Ultra XTC and X2 2100A/R •...

  • Page 217: P175 Check High Speed Rpm

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P175 CHECK HIGH SPEED RPM • TRIGGER–ON: With Speed Relay turned on (voltage at the Engine Speed Control Unit for high speed operation, engine RPM are NOT Between 2000 and 2300 for Ultima XTC/X2 2500A/R; or Between 1700 and 2000 for Ultra XTC/X2 2100A/R •...
  • Page 218 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P175 CHECK HIGH SPEED RPM (Continued) NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.

  • Page 219: P178 Check Ul1

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P178 CHECK UL1 • TRIGGER–ON: The pressure differential between suction and discharge pressures did not change as expected when the UL1 (Front) Unloader was loaded (de-energized) or unloaded (energized) • UNIT CONTROL: If alarm A191 is already on, then Pretrip will be aborted & display will read “PRETRIP FAILED IN TEST 6”.

  • Page 220: P180 Check Suction Modulation Valve

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P180 CHECK SUCTION MODULATION VALVE • TRIGGER–ON: Suction pressure did not drop as expected during Test 10 in Pretrip, when the CSMV was changing position. • UNIT CONTROL: Alarm only. • RESET CONDITION: Auto Reset if Pretrip mode is started again, or Alarm may be manually reset via keypad or by turning the unit off, then back on again.

  • Page 221: P181 Check Sv4 Valve

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P181 CHECK SV4 VALVE • TRIGGER–ON: 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 mode is started again, or Alarm may be manually reset via keypad or by turning the unit off, then back on again.

  • Page 222: P182 Check Sv1 Valve

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P182 CHECK SV1 VALVE • TRIGGER–ON: Discharge pressure did not decrease when SV1 was de--energized (opened) as expected in Heat Pretrip Mode, or discharge pressure did not increase as expected when SV1 was energized (closed) in Cool Pretrip Mode.

  • Page 223: P191 Check Ul2

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P191 CHECK UL2 • TRIGGER–ON: The pressure differential between discharge and suction pressures did not change as expected when the UL2 (Rear) Unloader was loaded (de-energized) or unloaded (energized) • UNIT CONTROL: Alarm Only •...

  • Page 224: P192 Check Sv2 Circuit

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P192 CHECK SV2 CIRCUIT • TRIGGER–ON: Normal Amps for the SV2 Circuit is 0.75 to 2.0 Amps. The circuit tests outside this range. • UNIT CONTROL: Pretrip will abort and “PRETRIP FAILED IN TEST 2” will be displayed in MessageCenter.

  • Page 225: P194 High Suction Pressure

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P194 HIGH SUCTION PRESSURE • TRIGGER–ON: This alarm is generated during Test 4 of Cool Pretrip. Suction pressure is higher than normal. (Maximum suction pressure should be approximate MOP of TXV or a little bit higher during this test.

  • Page 226: P195 Low Suction Pressure

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P195 LOW SUCTION PRESSURE • TRIGGER–ON: This alarm is generated during Test 4 of Cool Pretrip. Suction pressure is lower than normal, using the lesser value of the two following calculations. Minimum suction pressure should be 15 PSIG (1Bar) less than TXV MOP (see section 2.10 for MOP values);...
  • Page 227 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P195 LOW SUCTION PRESSURE (Continued) NOTE: Follow the steps below until a problem is found. Once a repair or correction has been made, clear the alarm(s). (See Note 1) Operate the unit through the appropriate modes to see if any active alarm occurs. Continue with the steps below as necessary.

  • Page 228: P196 High Discharge Pressure

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P196 HIGH DISCHARGE PRESSURE • TRIGGER–ON: This alarm is generated during Test 4 of Cool Pretrip. Discharge pressure is higher than normal. (“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 F (16.6 C) to it, then looking at a pressure temperature chart- -see Table 9- -8- - for the corresponding...

  • Page 229: P198 Low Discharge Pressure

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P198 LOW DISCHARGE PRESSURE • TRIGGER–ON: In the Heat Pretrip mode, the Compressor Discharge Pressure did not rise to normal. (The minimum “Normal” discharge pressure for systems operating in the Heat Pretrip Mode can be estimated by taking the temperature of the air entering the condenser coil (Ambient Air Temperature AAT) and looking at a pressure temperature chart- -see table Table 9- -8- -for the corresponding pressure, then adding 80 psig (5.5bars) to it.)

  • Page 230: P200 Check Ul1 Cylinders

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P200 CHECK UL1 CYLINDERS • TRIGGER–ON: A problem has been detected inside the front cylinder head of the compressor with a suction reed, discharge reed, head gasket or valve plate gasket. • UNIT CONTROL: Alarm Only •...

  • Page 231: P201 Check Ul2 Cylinders

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P201 CHECK UL2 CYLINDERS • TRIGGER–ON: A problem has been detected inside the rear cylinder head of the compressor with a suction reed, discharge reed, head gasket or valve plate gasket. • UNIT CONTROL: Alarm Only •...

  • Page 232: P203 Chk Discharge Check Valve

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P203 CHK DISCHARGE CHECK VALVE • TRIGGER–ON: Refrigerant is leaking backwards through the Discharge Check Valve • UNIT CONTROL: Alarm Only • RESET CONDITION: Auto Reset if Pretrip mode is started again, or Alarm may be manually reset via keypad or by turning the unit off, then back on again.

  • Page 233: P204 Low Suction Pressure

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P204 LOW SUCTION PRESSURE • TRIGGER–ON: 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. •...

  • Page 234: P205 Chk Defrost Term 2 Sensor

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION P205 CHK DEFROST TERM 2 SENSOR • TRIGGER–ON: Defrost Termination Temperature Sensor 2 is not within the maximum range of --53°F to +158°F (--47°C to +70°C) • UNIT CONTROL: Alarm and defrost cycle will terminate as described in section 5.10. •...

  • Page 235: 8.10 Maintenance Alarms

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION 8.10 MAINTENANCE ALARMS ENGINE MAINTENANCE DUE • TRIGGER–ON: The Engine Maintenance Hour Meter time has expired. • UNIT CONTROL: Alarm Only. Alarm Light will NOT be turned on. • RESET CONDITION: Alarm may be manually reset via keypad. Check unit maintenance records a.

  • Page 236: Service Soon -- Pm #1 Due

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION SERVICE SOON - - PM #1 DUE • TRIGGER–ON: The Maintenance Hour Meter #1 time has expired. • UNIT CONTROL: Alarm Only. Alarm Light will NOT be turned on. • RESET CONDITION: Alarm may be manually reset via keypad. Check unit maintenance records a.

  • Page 237: Service Soon -- Pm #4 Due

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION SERVICE SOON - - PM #3 DUE • TRIGGER–ON: The Maintenance Hour Meter #3 time has expired. • UNIT CONTROL: Alarm Only. Alarm Light will NOT be turned on. • RESET CONDITION: Alarm may be manually reset via keypad. Check unit maintenance records a.
  • Page 238 Alarm Steps ALARM / CAUSE CORRECTIVE ACTION SERVICE SOON - - PM #5 DUE • TRIGGER–ON: The Maintenance Hour Meter #5 time has expired. • UNIT CONTROL: Alarm Only. Alarm Light will NOT be turned on. • RESET CONDITION: Alarm may be manually reset via keypad. Check unit maintenance records a.

  • Page 239: 8.11 Microprocessor Alarms

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION 8.11 MICROPROCESSOR ALARMS SETPOINT ERROR • TRIGGER–ON: There is an error in the Setpoint that is stored in the microprocessor memory, or in the memory sector of the microprocessor that the Setpoint is stored in. •...

  • Page 240: Functional Parameters Error

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION FUNCTIONAL PARAMETERS ERROR • TRIGGER–ON: There is an error in one or more of the Functional Parameters that are stored in the microprocessor memory, , or in the memory sector of the microprocessor that the Functional Parameters are stored in.

  • Page 241: Dis Press Calibrate Error

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION DIS PRESS CALIBRATE ERROR • TRIGGER–ON: There is an error in the Discharge Pressure Sensor Calibration value stored inthe microprocessor memory or in the memory sector of the microprocessor that the calibration value is stored •...

  • Page 242: Eeprom Write Failure

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION EEPROM WRITE FAILURE • TRIGGER-ON: There is an error in the ability to write information to be stored in the memory • UNIT CONTROL: Unit Shutdown & Alarm • RESET CONDITION: Alarm may be manually reset via keypad or by turning the unit off, then back on again.

  • Page 243: Microprocessor Error

    Alarm Steps ALARM / CAUSE CORRECTIVE ACTION MICROPROCESSOR ERROR • TRIGGER–ON: Microprocessor Input Conversion Error • UNIT CONTROL: Unit Shutdown & Alarm • RESET CONDITION: Auto Reset when input conversions are valid, or Alarm may be manually reset by turning the unit off, then back on again. Follow the steps below until a problem is found.

  • Page 244: Section 9 Service

    Beware of V-belts and belt driven compo- ert gas brazing procedures is mandatory for nents as the unit may start automatically. all Carrier Transicold refrigeration units; Before servicing unit, make sure the otherwise compressor failure will occur. START/RUN-OFF switch is in the OFF posi- For more information, refer to Technical tion or the unit is in Maintenance mode.

  • Page 245: Table 9--1. Maintenance Schedule

    Table 9- -1. Maintenance Schedule ACTION/- SYSTEM OPERATION REFERENCE SECTION a. Daily Maintenance Pre-Trip Inspection - before starting Check Engine Hours Check Check Engine Oil Level Check b. Every Service Interval or Annually Unit 1. Check unit mounting bolts Check 2.
  • Page 246 ACTION/- SYSTEM OPERATION REFERENCE SECTION b. Every Service Interval or Annually (Continued) 1. Check air switch & calibrate 4.15 Refrigera- tion 2. Check & clean evaporator coil and defrost drain hoses 9.29 System 3. Check operating refrigerant pressure Check 4. Check all sensor calibrations Check 5.

  • Page 247: Pretrip Inspection

    9.2 PRETRIP INSPECTION WARNING Inspect battery cables for signs of wear, abrasion or damage at every Pre- -Trip inspection and replace if necessary. Also check battery cable routing to ensure that clamps are secure and that cables are not pinched or chafing against any components. The following pretrip inspection should be performed before every trip and at regular maintenance intervals.

  • Page 248: Figure 9--1. Grille Insert Removal And Door Latch Maintenance

    9.3 GRILLE INSERT REMOVAL (See Figure 9- -1) b. Remove the 2 bolts on top of the grille insert. Removal of insert will ease in condenser coil cleaning. c. Swing insert down and lift out of locating holes. (Refer to Section 9.30). a.

  • Page 249: Figure 9--2. Surround Removal

    9.4 SURROUND REMOVAL a. Turn the SROS to the “OFF” position and disconnect c. Remove the bolts that secure the surround to the unit. the starter. b. Open both side and front doors. d. Reverse above steps to install new surround. SURROUND MOUNTING BOLTS IF DECAL IS NOT REMOVABLE TYPE, REPLACE WITH NEWER...

  • Page 250: Figure 9--3. Side Door Latch Lower Cable Removal

    9.5 DOOR LATCH MAINTENANCE AND 9.5.2 Side Door Latch Cable Replacement REPLACEMENT a. Remove circular clip that secures the cable to the Proper maintenance is important for smooth operation paddle assembly. of the latch assembly and the latch pins that are moun- ted on the unit’s frame (See Figure 9--1).

  • Page 251: Priming Fuel System

    9.6 PRIMING FUEL SYSTEM 9.6.1 Mechanical Fuel Pump c. Continue to pump S-L-O-W-L-Y (up/down once per second) approximately 100 more strokes to fill the The mechanical fuel lift pump is mounted on the engine filter and bleed the air out of the lines. next to the injection pump.

  • Page 252: Figure 9--5. Mechanical Fuel Pump

    9.7 SERVICING FUEL PUMP The fuel filter may become plugged or restricted with for- 9.8 ENGINE SERVICE & COMPONENTS eign particles or wax as a result of using the wrong grade 9.8.1 Cooling System of fuel or untreated fuel in cold weather. This will cause the engine to lose capacity.

  • Page 253: Figure 9--6. Fuel Level Sensor Wiring

    9.8.2 FUEL LEVEL SENSOR 9.8.3 Lube Oil Filters To check the engine oil level: An optional fuel level sensor (p/n 12-00548-07 or new Run the unit to bring the engine sensor 12-00548-06) supplies an input signal to the up to operating temperature, microprocessor as to the % of fuel remaining in the fuel shut the unit off, and unscrew tank.

  • Page 254: Figure 9--7. Fuel System Diagram

    Lube Oil And Fuel Flow Diagrams 1. Engine Block 2. Oil Pan 3. Full Flow Oil Filter 4. Engine Oil Connection 5. Oil Pressure Switch Figure 9- -8. Lube Oil Flow Diagram 1. Fuel Tank 7. Fuel Bleed Valve 2. Fuel Supply Line 8.

  • Page 255: Figure 9--9. Electronic Speed Control Components

    9.8.4 Electronic Speed Control (ESC) The ENSSN provides the RPM signal to the ENSCU for speed control. Refer to Section 10 for schematic wiring diagram. Refer to Section 10 for ESC diagnostic alarms and diagnostic trees. 9.8.5 Engine Air Cleaner a.

  • Page 256: Figure 9--12. Intake Air Heater

    9.8.7 Servicing Intake Air Heater 9.9 SERVICING AND ADJUSTING V-BELTS The total circuit amp draw for the air heater circuit is checked during a Pretrip cycle. The air heater, when energized, draws 38 to 46 amps. The intake air heater resistance factory spec is 0.3Ω. To WARNING troubleshoot the heater: 1.

  • Page 257: Figure 9--13. Di-- Belt Tension Gauge

    The belt tension gauge can be used to adjust all belts. The readings, which we specify for Carrier Transicold units are applicable only for our belts and application, as the tension is dependent on the size of the belt and Figure 9- -13.

  • Page 258: Figure 9--14. Gauge Placement

    9.9.2 Water Pump/Alternator/Crankshaft V-Belt The water pump/alternator/crankshaft V-belt is driven c. Check the center alignment of the engine drive, alter- by a sheave on the engine crankshaft. Frayed, cracked nator and water pump sheaves to ensure proper or worn belts must be replaced. Adjustment is achieved alignment.

  • Page 259: Figure 9--15 V-Belt Arrangement

    Gearbox to fanshaft Belt Note: 1 - - Loosen the pivot bolt 2 - - Using 1/2” ratchet, rotate idler until appropriate tension is obtained. 3 - - Torque pivot bolt to correct tension Upper Belt Idler Use 1/2” ratchet here (Gearbox to Fanshaft) Torque to 80 ft-lbs (108 Nm) Pivot Bolt...
  • Page 260 9.9.3 Gearbox To Fanshaft And Engine To Gearbox V-Belts a. Gearbox to fanshaft V-Belt (Upper Belt) NOTE Both belts must be checked and re--tensioned WARNING after a brief run-in period. (See step 7.) Beware of V-belts and belt driven compo- 7.

  • Page 261: Figure 9--16. Upper Belt Replacement

    Slide belt between fan blade and clutch assembly. Figure 9- -16. Upper Belt Replacement b. Engine To Gearbox V-Belt (Lower Belt) 5. Pry the adapter back toward the engine flywheel or use 5/16-18 x 2-1/2 lg bolts (3) in every other hole of 1.
  • Page 262 9.10 FANSHAFT ASSEMBLY - - SEE FIGURE 9- -18 For Plastic Fan: WARNING c.Remove the retaining bolts that secure the Curbside of fan shroud and remove fan shroud from unit. Beware of V-belts and belt driven compo- d. Remove the 3 bolts that thread through the back of nents as the unit may start automatically.
  • Page 263 9.10.2 Blower Wheel And Fanshaft Removal 9.10.3 Fanshaft Installation a. Install key (included) into the shaft keyway. a. Remove bulkhead and air chute (if so equipped). Re- move evaporator back panel. NOTE b. Remove the bolts that secure DTT2 and SAT to the If it is necessary to drive the key into place, be nozzle cover.

  • Page 264: Figure 9--18. Standard Condenser Fan And Clutch

    Apply thin layer of anti-seize compound to smooth fanshaft hub surface behind threads Fanshaft Hub, Clutch air-gap is set with shims that mount here over fanshaft pin Torque 3 Bolts 18 to 22 ft--- Condenser Fan lbs.(24 to 30 Nm) Clutch Adapter Rotor...

  • Page 265: Figure 9--18. Plastic Condenser Fan And Clutch

    Fanshaft Hub, Clutch air-gap is set with shims that position over fanshaft pin Condenser Fan mounting bolts Torque 3 Bolts 18 to 22 ft--lbs.(24 to Apply thin layer of anti-seize 30 Nm) compound to smooth fan- shaft hub surface behind threads Clutch Condenser Fan...

  • Page 266: Figure 9--19. Blower Wheel And Nozzle Cover Assembly

    9.10.4 Blower Wheel Installation a. Make sure key is properly placed in keyway. Slide d. Slowly and evenly torque blower wheel bushing bolts blower wheel and bushing onto shaft. to 10 to 11 ft-lbs (14 to 15 Nm) e. Position nozzle cover so that blower wheel is cen- b.
  • Page 267 9.10.5 Clutch Installation NOTE g. Install cushion clamp on coil harness approximate- ly 3” from coil to prevent harness from rubbing on The orientation of the clutch coil MUST be on rotor. the bottom. Secure the harness to the lower h.
  • Page 268 9.11 PUMPING UNIT DOWN OR REMOVING RE- 9.11.1 Pumping Down The Unit FRIGERANT CHARGE In order to service the components downstream of the NOTE king valve (and back to the compressor), the unit can be pumped down in the standard manner: To avoid damage to the earth’s ozone layer, use a a.

  • Page 269: Refrigerant Leak Checking

    9.11.2 Removing The Refrigerant Charge CAUTION Connect a refrigerant recovery system to the unit to remove refrigerant charge. Refer to instructions provided by the manufacture of the refrigerant recovery Only a refrigerant drum containing R404a system. should be connected to this refrigeration unit in order to pressurize the system.

  • Page 270: Figure 9--20. Vacuum Pump Connection

    9.13.3 Procedure For Evacuation And Dehydrating d. Midseat the refrigerant system service valves. System e. Open the vacuum pump and electronic vacuum gauge valves, if they are not already open. Start the vacuum pump. Evacuate unit until the electronic vac- NOTE uum gauge indicates 2000 microns.
  • Page 271 9.14 ADDING REFRIGERANT TO SYSTEM 9.14.2 Adding A Partial Charge CAUTION CAUTION Do not vapor charge R-404A. Only liquid Do not vapor charge R-404A. Only liquid charging through the receiver outlet (king) charging through the receiver (king) valve valve is acceptable. is acceptable.

  • Page 272: Replacing The Compressor

    9.14.3 Adding Full Charge WARNING UNITS EQUIPPED WITH STAR-TRAK TWO CAUTION WAY COMMUNICATION CAPABILITIES HAVE THE ABILITY TO BE STARTED OR TURNED OFF REMOTELY REGARDLESS OF THE Do not vapor charge R-404A. Only liquid SETTING OF THE START/RUN-OFF SWITCH. charging through the receiver outlet (king) valve is acceptable.

  • Page 273: Figure 9--21. Pressure Switch And Sensor

    COMPRESSOR Figure 9- -21. Pressure Switch and Sensor h. Remove fuel filter bracket (if necessary) and any oth- t. Remove the complete High Pressure switch / Com- er interfering components from the compressor bell pressor Transducer assembly (See Figure 9--21) and housing.

  • Page 274: Figure 9--22. Compressor Drive Assembly

    Refer to Section For this reason, Carrier Transicold re--manufactured 6.2.3. compressors now contain a reduced oil charge to compensate for oil remaining in the system. A level...

  • Page 275: Figure 9--23. Oil Level In Sight Glass

    When an oil pump is not available, oil may be drawn into the compressor through the oil fill port or through the suction service valve. 1.Connect the suction connection of the gauge manifold to the compressor suction service valve port, and the common connection of the gauge manifold to a vacu- um pump.

  • Page 276: Figure 9--25. Unloader Coil

    9.16.3 Adding Oil To Service Replacement Com- 9.17.2 Unloader Coil Replacement pressor NOTE Service replacement compressors may or may not be The coil may be removed without pumping the shipped with oil. unit down. If compressor is without oil: a. Disconnect leads. Remove retainer, if equipped. Lift Add correct oil charge (Refer to Section 2.9) through the off coil.

  • Page 277: Figure 9--26. Discharge Check Valve (Non-Serviceable)

    NOTE h. Start unit and check unloader operation (Refer to Place magnetic discharge check valve tool Section 9.17.1.). (Carrier Transicold P/N 07-00457-00) on top i. Check unit operation by running Pretrip (Refer to Sec- ofdischargecheckvalve(Figure 9--26)topull tion 3.2). the plunger from the body seat.

  • Page 278: Thermostatic Expansion Valve

    9.19 CHECKING AND REPLACING FILTER-DRIER The thermostatic expansion valve (TXV) is an automatic device which maintains constant superheat 9.19.1 To Check Filter-Drier of the refrigerant gas leaving the evaporator regardless Check for a restricted or plugged filter-drier by feeling of suction pressure. The valve functions are: (a) the liquid line inlet and outlet connections of the drier automatic response of refrigerant flow to match the cartridge.

  • Page 279: Figure 9--28. Thermostatic Expansion Valve Bulb And Thermocouple

    9.20.2 Checking Superheat 9.21 CHECKING AND REPLACING HIGH PRES- SURE CUTOUT SWITCH (HPS) NOTE 9.21.1 Replacing High Pressure Switch Superheat cannot be adjusted on the braze--in a. Pump down the unit. (Refer to Section 9.11.1) Front- TXV. I superheat is out of adjustment, the valve seat both suction and discharge service valves to iso- must be replaced.

  • Page 280: Table 9--3. Compressor Discharge Pressure Transducer

    a. Remove switch as outlined in Section 9.21.1. NOTE The Compressor Discharge Pressure on the b. Connect ohmmeter or continuity light across switch microprocessor Data list will never read less terminals. Ohmmeter will indicate resistance and than 0 Bar/PSIG, even if it is exposed to a vacu- continuity light will be lit if switch closes after relieving um (such as when evacuating the system.) pressure.
  • Page 281 WARNING The +5.0 VDC (terminal B) is common between the Compressor Discharge Pressure Transducer, the Compressor Suction Pressure Transducer, and the ENSSN. If this circuit is shorted to ground (due to one of the mentioned components being defective, or a worn wire) the MessageCenter will show: SSuction Pressure: -14.7 PSIG (-1 Bar) SDischarge Pressure: 0 PSIG/Bar SEngine RPM: 0.

  • Page 282: Table 9--4. Compressor Suction Pressure Transducer

    9.23 COMPRESSOR SUCTION PRESSURE d. Check wire continuity C (output to microprocessor) TRANSDUCER (CSP) and 1MP6. (CTD P/N 12-00352-03 - BLUE) e. Place +5.0 VDC on transducer terminal B and -5.0 VDC on transducer terminal A. Test voltage between 9.23.1 Calibrating Compressor Suction Pressure B and C.
  • Page 283 9.23.3 Replacing Compressor Suction Pressure 9.24 REPLACING RECEIVER SIGHT GLASS AS- Transducer SEMBLY OR FUSIBLE PLUG CAUTION WARNING Service mode MUST be used whenever re- UNITS EQUIPPED WITH STAR-TRAK TWO moving refrigerant charge, refrigerant leak WAY COMMUNICATION CAPABILITIES HAVE checking or evacuating. THE ABILITY TO BE STARTED OR TURNED OFF REMOTELY REGARDLESS OF THE a.
  • Page 284 9.25 SERVICING SOLENOID VALVES b. Replacing solenoid valve internal parts 9.25.1 Solenoid Valve - - SV2/SV4 CAUTION Do not over tighten or damage the enclos- ing tube assembly. Torque to 17-ft pounds (24 Nm). Also make sure all parts are placed on the enclosing tube in proper sequence to avoid premature coil burnout.

  • Page 285: Figure 9--31 Sv-2/Sv-4 Marking

    b. Replacing Internal Components (See Figure 9--32) CAUTION Service mode MUST be used whenever re- DIMPLES moving refrigerant charge, refrigerant leak checking or evacuating. WARNING UNITS EQUIPPED WITH STAR-TRAK TWO WAY COMMUNICATION CAPABILITIES HAVE THE ABILITY TO BE STARTED OR TURNED OFF REMOTELY EVEN IF THE START/RUN-- OFF SWITCH IS IN THE OFF POSITION.
  • Page 286 If suction and discharge pressures remain low and the receiver level does not drop, the valve may be inoperative and can be checked by the follow- ing method. a. Verify the solenoid coil has proper voltage and is en- ergized in heating and defrosting. b.

  • Page 287: Figure 9--33. Compressor Suction Modulation Valve (Csmv)

    BLACK WHITE WARNING GREEN Carrier Transicold does not recommend al- lowing the compressor to pull less than 0 Bar/PSIG at any time. Each winding has a resistance of about 75 Ω. c. Once the unit has reached suction pressure of 0 Bar/-...
  • Page 288 d. Wait about two minutes after the engine stops to en- i. Place the START/RUN-OFF switch in the START/- sure the valve is fully shut and then energize SV2 with RUN position. DO NOT ALLOW THE UNIT TO 12 VDC manually. START.

  • Page 289: Figure 9--35. Defrost Air Switch Test Setup

    9.27 CHECKING DEFROST OR HEATING CYCLE 9.28.2 Checking Calibration Of Defrost Air Switch 9.27.1 Defrost Operation a. Connect a discharge pressure gauge to the receiver outlet (king valve) and another gauge to the compres- sor discharge service valve. Connect a gauge to the compressor suction service valve.

  • Page 290: Condenser Coil Cleaning

    9.29 EVAPORATOR COIL CLEANING 9.30 CONDENSER COIL CLEANING WARNING WARNING Personal protection equipment must be Personal protection equipment must be utilized when performing coil cleaning. utilized when performing coil cleaning. The use of recycled cardboard cartons is increasing across the country. The recycled cardboard cartons Remove all foreign material from the condenser coil by create much more fiber dust during transport than new reversing the normal air flow.

  • Page 291: Table 9--6. Sensor Resistance (Enct, Rat, Sat, Att, Dtt2)

    9.31 CONTROLLER SENSOR CHECKOUT much higher or lower than the resistance values given in Table 9--6. An accurate ohmmeter must be used to check At least one lead from the sensor must be disconnected resistance values shown in Table 9--6. from the unit electrical system before any reading is Due to variations and inaccuracies in ohmmeters, taken.

  • Page 292: Table 9--7. Sensor Resistance (Cdt)

    Table 9- -7. Sensor Resistance (CDT) Ohms Ohms Ohms Ohms Ohms °F °C °F °C °F °C °F °C °F °C 3,360,000 -7.8 189,690 24.4 102,460 56.7 28,160 126.7 3,290 -38.9 3,121,020 -6.7 461,170 25.6 97,600 57.8 27,040 132.2 2,850 -37.8 2,900,710 -5.6...
  • Page 293 9.32 UNIDRIVE TORQUE REQUIREMENTS See Figure 9--36 for torque value, size and grade of the (FIGURE 9- -36) hardware to be used when reassembling the unidrive assembly. 9.32.1 Drive Gear (See Figure 9- -22.) Extensive damage may occur if the proper hardware When installing a nylon drive gear always: and procedures are not followed.

  • Page 294: Direct Drive

    M8 x 1.25 x 20 mm lg (6 Required) 28 ft-lbs (38 Nm) 3/8-16 x 1-3/4 lg Grade 5 (6 Required) 30 ft-lbs (41 Nm) 3/8-24 x 1.00 lg Grade 8 28 ft-lbs (38 Nm) DIRECT DRIVE 90 ft-lbs (122 Nm) M12 x 1.25 x 25 mm lg (3 Required) 65 ft-lbs (88 Nm) 3/8-16 x 1 lg Grade 5 (12 Required)

  • Page 295: Table 9--8. R-404A Temperature-Pressure Chart

    Table 9- -8. R-404A Temperature-Pressure Chart Temperature Pressure Temperature Pressure Bars PSIG Bars PSIG 0.31 5.00 72.5 0.49 5.21 75.6 0.68 5.43 78.8 0.89 12.9 5.66 82.1 1.12 16.3 5.90 85.5 1.22 17.7 6.14 89.0 6.38 92.5 1.32 19.2 6.63 96.2 1.43 20.7...

  • Page 296: Unit Troubleshooting

    UNIT TROUBLESHOOTING CAUTION Under no circumstances should anyone attempt to service the Advance Microprocessor. See Sec- tion 10.5 for microprocessor troubleshooting. Should a problem develop with the Advance Micro- processor, contact your nearest Carrier Transicold dealer for replacement. INDICATION/ ACTION/ TROUBLE...
  • Page 297 INDICATION/ ACTION/- TROUBLE POSSIBLE CAUSES REFERENCE SECTION Starter motor turns Pinion or ring gear obstructed or worn Clean both, but pinion does not engage remove burrs, or replace Starter motor does not disengage Starter motor solenoid defective Engine Manual after switch was depressed Engine is already running Check Pinion does not disengage...
  • Page 298 INDICATION/ ACTION/- TROUBLE POSSIBLE CAUSES REFERENCE SECTION 10.3 REFRIGERATION 10.3.1Unit Will Not Cool Diesel engine Malfunction(s) 10.1 Compressor malfunction Compressor drive defective 9.15 Compressor defective 9.15 Refrigeration system Defrost cycle did not terminate 10.3.6 Abnormal pressure 10.3.7 Solenoid valve malfunction 10.3.12 Clutch Failure 9.10.5...
  • Page 299 INDICATION/ ACTION/- TROUBLE POSSIBLE CAUSES REFERENCE SECTION 10.3.6Defrost Cycle Malfunction Will not initiate defrost Defrost air switch (DAS) out of calibration 9.28.2 automatically DTT2 is above 40_F (4.4_C) Cool Box Down Defrost air switch (DAS) defective 9.27 & 9.28.2 Loose terminal connections Tighten Air sensing tubes defective or disconnected Check...
  • Page 300 INDICATION/ ACTION/- TROUBLE POSSIBLE CAUSES REFERENCE SECTION b. Heating High discharge pressure Solenoid valves (SV1 and SV4) malfunction 10.3.12 Condenser fan defective 9.10 V-belts broken or loose Non-condensables in system Check Low discharge pressure Compressor valve(s) worn or broken 9.15 Solenoid valve (SV1) malfunction 10.3.12 Low refrigerant charge...

  • Page 301: Table 10-1. Enscu Led Fault Chart (See Following Pages For Troubleshooting Trees)

    INDICATION/ ACTION/- TROUBLE POSSIBLE CAUSES REFERENCE SECTION Low superheat and liquid Superheat setting too low 9.20 slugging in compressor External equalizer line plugged Open Ice holding valve open 9.13 Foreign material in valve Clean Pin and seat of expansion valve eroded or held open by foreign material 9.20 Fluctuating suction...

  • Page 302: Figure 10--1. Esc Diagnostic Tree -- 1 Long, 1 Short Led Code

    START HERE Start unit. Using strobe light 07-00177-01 or equivalent, NOTE : Ensure the run relay is check engine RPM. energized during test . With ENSSN Is RPM equal to or over 2,530? unplugged during testing , unit will stall & go through start sequence again .

  • Page 303: Figure 10--2. Esc Diagnostic Tree -- 2 Long, 1 Short Led Code

    START HERE Verify unit starts, go into high speed and stall after running for a few seconds? Using jumper wire, verify there is at least 11 VDC at ENSCU terminal 25? Check for high resistance or an Verify there is at least 11 open in the VDC going into the ENSSN ground...

  • Page 304: Figure 10--3. Esc Diagnostic Tree -- 2 Long, 3 Short Led Code

    START HERE Go to Advance Micro Does the engine starter diagnostic table engage & turn the engine Figure 10- - 6 over? Verify the proper voltage Check for high resistance Using jumper wire, are the going into FSA terminal or an open on the FSA ground proper voltages present 1.

  • Page 305: Figure 10--4. Esc Diagnostic Tree -- 2 Long, 7 Short Led Code

    START HERE With the Start/Run-Off switch ON and the ENSCU wire 13 removed from the connector (connector Check voltage output at plugged in), check voltage Replace ENSCU. Did you at ENSCU terminal 13. Is alternator. Is voltage 26 find and correct the condition? VDC or higher? voltage 26 VDC or higher? NOTE: With connector...
  • Page 306 10.5 Advance Microprocessor Troubleshooting Guide The purpose of the following procedure is to provide a logical and straightforward guide to be used when troubleshooting operational or other problems occurring with the microprocessor. Often users and technicians have mistakenly worked to correct a problem that has ended up being normal operation. The microprocessor has several different conditions contributing to operating parameters.

  • Page 307: Figure 10--5. Micro Diagnostic Tree -- Cond. 1 -- Start/Run-Off Switch On -- Unit Does Not Operate

    Disconnect StarTrak from unit START HERE and install J1 jumper. This will Is unit equipped eliminate StarTrak from the system. with StarTrak? Is Micro Status LED blinking? Check the F1 fuse. Check Micro Status Is the fuse blown? LED blink rate. Replace the fuse.

  • Page 308: Figure 10--6. Micro Diagnostic Tree -- Cond. 2 -- Start/Run-Off Switch On -- Unit Operates But Not Properly

    START HERE Wrong Chart. The unit starts & runs. See Condition 1. Micro may not be configured properly. Verify correct model number is selected in the micro via unit data. Did you find and correct the condition? Unit may be running on old software. Upgrade software to current version.

  • Page 309: Figure 10--7. Micro Diagnostic Tree -- Cond. 3 -- Start/Run-Off Switch Off -- Unit Fails To Stop

    There a problem Turn the Start/Run with the - - Off switch to the START HERE StarTrak OFF position. Is the unit system. Does the engine equipped with Repair as continue to run? StarTrak? necessary. Replace Start/Run -Off switch. Did Check for defective you find and Disconnect StarTrak...

  • Page 310: Figure 10--8. Micro Diagnostic Tree -- Cond. 4 -- Unit Will Not Run In High Speed

    Unit may be running old soft ware. Upgrade software from START HERE Check the Speed Solenoid http://www.transcentral.carrier.com. or FSA and linkage for correct operation. Did you find and correct Did you find and correct the condition? the condition? Check System discharge pressure at compressor. Is discharge pressure 435PSI or higher? Check system suction pressure at compressor.

  • Page 311: Figure 10--9. Micro Diagnostic Tree -- Cond. 5 -- Unit Will Not Run In Low Speed

    START HERE Is the unit operating in defrost? Unit may be running old software. Upgrade software from http: //www.transcentral.carrier.com. Did you find and correct the condition? Check functional parameter settings for air flow. Does the setting show high? Does the unit have IntelliSet options? Is ProductShield High Air configured on? What is the version of software in the micro?

  • Page 312: Figure 10--10. Micro Diagnostic Tree -- Cond. 6 -- Data Recorder Data Download Problems

    START HERE What does the ReeferManager program “NOT CONNECTED” “CONNECTION OK” display on the bottom of the screen of your PC? Are the dates for the There is no data on the download serial screen? connection. System Data Recorder date & time may Is the micro be set wrong.

  • Page 313: Figure 10--11. Microprocessor Diagnostic Tree -- Pc Card Problems

    Usint either a PC card or computer with a START HERE download cable hooked into the serial Make sure the Start/Run-Off port/download plug, load current version of switch is ON or the micro is the software into micro. Insert PC card in PC Mode.

  • Page 314: Figure 10--12. Micro Diagnostic Tree -- Cond. 8 -- Programming Problems With Pc Cards

    START HERE Are you trying to load any version of Does the MessageCenter say software that is older than 04.00.00? “OLD SOFTWARE: CANNOT LOAD”? Insert the PC Card into the PC Card slot on the front of the micro. Be certain that the instructions label on the download card is Once 04.00 is installed into the micro, it is no facing the “Caution”...

  • Page 315: Figure 10--13. Micro Diagnostic Tree -- Cond. 9 -- Programming Problems With Microprogrammer

    START HERE Does the MessageCenter say Once 04.00 is installed into the micro, it Are you trying to load any version of “OLD SOFTWARE: CANNOT s no longer possible to load any version software that is older than 04.00.00? LOAD”? of 03 or previous software.
  • Page 316 10.6 Compressor Troubleshooting Guide The purpose of the following procedure is to provide a logical and systematic method of determining whether 05G compressor repair or replacement is required. A. Checkout Procedure For Determining If Compressor Repair Or Replacement Is Required Certain operating conditions or refrigeration system components may be misdiagnosed and subsequently lead to the determination that the compressor is bad.
  • Page 317 B. Compressor Inspection Procedure NOTE Only conduct this procedure after running Pretrip. The system must be OFF during the following procedure. 1. Refrigerant Recovery a. Close (frontseat) the suction and discharge service valves. b. Reclaim the refrigerant by using an approved refrigerant recovery machine, and reduce the compressor pressure to zero psig.
  • Page 318 4. Replacement of the compressor. a. Refer to Section 9.15 for compressor replacement procedures. b. Drain and measure the compressor oil, and put it in a plastic bottle. Follow Carrier Transicold instructions for re- turning the oil with the compressor.

  • Page 319: Figure 10--14. Compressor Diagnostics

    START HERE Gone through the system diagnostics. No system or other component defect dis- covered. The system is OFF. Recover refrigerant. Start the compressor inspection with front cylinder head. Remove the cylinder head. Inspect the parts of the head and the valve plate. Next (center or rear) Inspect pistons.
  • Page 320 C. Procedure After Compressor Repair Or Replacement 1. Run Pretrip to ensure all refrigeration components function properly. 2. In addition, to ensure the repair of the original compressor or the reliability of the replacement compressor, check the following: a. Verify proper air switch setting using 07--00177 magnehelic gauge or equal. b.
  • Page 321 SECTION 11 WIRING Plugs used with Schematic 62- -11300 Rev - - 1 MP - - Natural 2 MP - - Black 3 MP - - Grey Component Terminal Component Terminal Component Terminal REMSN1 REMS1 SATCOM (C) REMSN2 SLP (C) CDP (C) CSMV--D CSP (C)

  • Page 322: Voltage Tests

    Plugs used with Schematic 62- -11300 Rev - - (Cont) 5 MP Component Terminal SSR86 BUZZER AFAR ADVANCE MICRO DISPLAY HARNESS CONNECTIONS (6MP) Test Point Color Description TP14 Pin 1 Black +12 Vdc for Display backlighting and indicator LED s TP13 Pin 2 White...
  • Page 323 HC Plug Component Terminal +12vdc Input from SPK3 to Fuel Heater Relay Coil +12vdc Output from (MPQC3) to ENSCU--16 +12vdc Output from transformer to starter motor (SM) +12vdc Input unswitched Power from Battery (BTY+) To Main Power In (MPQCI) +12vdc Output from (MPQC4) to SPK20 +12vdc Output unswitched to –...
  • Page 325 Index Advance Microprocessor Troubleshooting Data Ohms And Amps, 2--22 Guide, 10--11 Data Recording, 3--29 Air Switch, 2--20, 9--46 Defrost, 5--8 Alternator / Regulator, 9--13 Defrost Air Switch, 2--20, 9--46 Alternator Operation , 2--7 Ambient Air Temperature Sensor, 2--10 Defrost Cycle, 9--46 Auto Fresh Air Exchange (AFAX), 3--34 Defrost Initiation, 5--8 Auto Start Sequence, 4--1...
  • Page 326 Index Failed To Start -- Auto Mode, 4--4 Maintenance Schedule, 9--1 Fan Clutch Air Gap, 2--20 Manual Defrost, 3--13 Fan Shaft V--Belt, 9--17 Max Operating Pressureoverride (Heat And Defrost Only), 5--18 Fanshaft, 9--19 MessageCenter, 2--15 Fanshaft Oil, 2--20 MessageCenter , 7--1 Filter--Drier, 9--35 Microprocessor Replacement, 6--20 FreshProtect, 5--6...
  • Page 327 Index Safety Decals, 1--5 UltraFresh 3 Temperature Control , 5--5, 5--6 Safety Devices, 2--21 Safety Precautions, 1--1 Unidrive torque Requirements, 9--50 Service Mode, 6--12 Unit Data, 3--18 Servicing Air Intake Heater, 9--13 Unit Weight, 2--20 Servicing Fuel Pump, 9--9 Servicing Solenoid Valves , 9--41 Unloader, 2--8, 9--33 Sleep Mode On, 3--10, 3--11 Unloader Control Operation, 5--10...
  • Page 328 Central America North America and Mexico Carrier Transicold Ejercito Nacional No. 418 700 Olympic Drive Carrier Transicold Division, Piso 9, Torre Yumal Athens, GA 30601 USA Carrier Corporation Col. Chapultepec Morales Tel: 1- -706- -357- -7223 Truck/Trailer Products Group 11570 Mexico, D.F.