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Carrier TRANSICOLD 40X Operation And Service Manual

Direct drive truck refrigeration units
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Operation and Service Manual
40X and 50X
Starting with Serial Number PC723318
Direct Drive Truck Refrigeration Units
62-12158 Rev A

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  • Page 1 Operation and Service Manual 40X and 50X Starting with Serial Number PC723318 Direct Drive Truck Refrigeration Units 62-12158 Rev A...
  • Page 3 Operation and Service Manual 40X and 50X Starting with Serial Number PC723318 Direct Drive Truck Refrigeration Units ©Carrier Corporation, 2020 Printed in U. S. A. August 2020...
  • Page 4 Manual Revision History - 62-12158 Date Reason for Release 06/2020 Initial release 08/2020 Section 1 - Added notice blocks for refrigerant, added decals and labels; Table 2-1 and 2.5.1 – Added reference to R452a; Section 5 – added warnings and caution statements regarding R-452a;...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Page 1. Safety Precautions… .......................... 1-1 1.1 First Aid ............................. 1-1 1.2 Operating Precautions ....................... 1-1 1.3 Maintenance Procedures ......................1-1 1.4 Refrigerants ..........................1-1 1.5 Specific Warning, Caution, and Notice Statements ..............1-2 1.6 Safety Decals ..........................1-2 2.
  • Page 6 3.2 Start-Up ............................. 3-3 3.2.1 Inspection ........................3-3 3.2.2 Starting ..........................3-3 3.2.3 Start-up Process Prior to Software I.90 ................3-4 3.2.4 Start-up Process Beginning with SoftwareI.90 ..............3-4 3.3 Setpoint Adjustment ......................... 3-5 3.4 Defrost ............................3-5 3.4.1 Manual Defrost ........................ 3-5 3.4.2.
  • Page 7 5.9 Checking and Replacing Condenser Fan Motor Brushes ............5-14 5.10 HGS1, HGS2, Liquid Solenoid Valve, and BPV ..............5-15 5.10.1 Replacing Solenoid Coil ....................5-15 5.10.2 Replacing Valve Internal Parts ..................5-15 5.11 Adjusting the Compressor Pressure Regulating Valve (CPR) ..........5-16 5.12 Thermostatic Expansion Valve ....................

  • Page 9: Safety Precautions

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

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

    Specific Warning, Caution, and Notice Statements To help identify the label hazards on the unit and explain the level of awareness each one carries, an explanation is given with the appropriate consequences: DANGER: Warns against an immediate hazard which WILL result in severe personal injury or death. WARNING: Warns against hazards or unsafe conditions which COULD result in severe personal injury or death.
  • Page 11 Do not use a nitrogen cylinder without a pressure regulator. (See Figure 4-6) Cylinder pressure is approximately 2350 psi (160 bar). Do not use oxygen in or near a refrigerant system as an explosion may occur. Under no circumstances should anyone attempt to repair the microprocessor module or Cab Command! Should a problem develop with these components, contact your nearest Carrier Transicold dealer for replacement.
  • Page 12 Unit uses R-404a / R-452a and POE oil. The use of inert gas brazing procedures is mandatory for all Carrier Transicold refrigeration units; otherwise compressor failure will occur. For more information, refer to technical procedure 98-50553-00 Inert Gas Brazing.

  • Page 13: Safety Decals

    Safety Decals Figure 1.1 Safety Label 62-61655-00 Figure 1.2 Refrigerant Label 62-03797-01 Figure 1.3 Refrigerant Label 62-60063-02 THIS UNIT IS CHARGED WITH 452 A WARNING SPECIAL CARE IS REQUIRED WHEN RECLAIMING R 452A PRIOR TO BRAZING WORK. REFER TO SERVICE PROCEDURE Figure 1.4 Safety Equipment Label 62-61398 1 - 5 62-12158...
  • Page 14 Figure 1.5 Sticker No Modifications 62-61774-00 Figure 1.6 R-404A Refrigerant with POE Oil Decal 62-04160-00 1 - 6 62-12158...
  • Page 15 Figure 1.7 R-404a Refrigerant Decal 62-04160-01 Figure 1.8 R-452a Refrigerant with POE Oil Decal 62-04160-02 Figure 1.9 R-452a Refrigerant Decal 62-04160-03 1 - 7 62-12158...
  • Page 16 1 - 8 62-12158...

  • Page 17: Description

    This manual contains Operating Data, Electrical Data 2.2.1 Condenser Coil and Service Instructions for the Carrier Transicold Model 40X and 50X truck refrigeration units listed The condenser is of the tube and fin type and acts in Table 2-1. heat...
  • Page 18 Nameplate Emergency Switch Condenser Cab Command Two Drain Hose Water Fittings Evaporator (40X Shown) Figure 2-1 Main Unit Components 62-12158...
  • Page 19 Standby Compressor Condenser Fan Receiver 10. Fan Guard Filter Drier 11. Transformer (TR) 12. Frame Assembly Sight Glass 13. Rectifier Bridge Assembly (RB) Condenser Coil 14. Heat Sink Hot Gas Valve (HGS1) And Coil 15. Condenser Fan Motor (CFM) Condenser Pressure Control Valve (HGS2) And Coil 16.

  • Page 20: Logic Board

    Logic Board Three-Phase Units Single-Phase Units Microprocessor Fused Disconnect (FB) -- Three Phase Only Electronic Overload Relay (KR) Standby Fuse (FS) Standby Contactor (MC) Road Fuse (FR) Primary Transformer Fuses Harness 1A Field Replaceable Fuse (12--00526--88) (F1,2,3 Three Phase Units -- F1 Single Phase (Starting with Controller S/N 1997) Units) Figure 2-3 Control Box (Prior to S/N PC003091)
  • Page 21 Start Box Location (Prior to S/N PC003091) (Single Phase only) NOTE: Beginning with S/N PC003091 the components in this box will be incorporated in the new box displayed in Figure 2-5. Start Capacitor Run Capacitor Resistor, Start Capacitor Start Relay Discharge Figure 2-4 Start Box (Single Phase Only) (Prior to S/N PC003091) 62-12158...
  • Page 22 Logic Board Single-Phase Units Microprocessor Standby Contactor (MC) Primary Transformer Fuses Standby Fuse (FS) Run Capacitor Road Fuse (FR) Start Relay Harness 1A Field Replaceable Fuse (12--00526--88) Start Capacitor (Starting with Controller S/N 1997) Resistor, Start Contactor Discharge) Electronic Overload Relay (KR) Figure 2-5 Single Phase Control Box (Beginning With S/N PC003091) 62-12158...
  • Page 23 Evaporator Fan Motor and Blowers (EFM) Low Pressure Switch (LP) Orifice High Ambient Pressure Switch (HP4) (50X Only) Thermostatic Expansion Valve Hot Gas Fitting Evaporator Coil Assembly Road Suction Line Fitting Compressor Pressure Regulating Valve Standby Suction Line Fitting (CPR) Liquid Line Fitting Defrost Termination Thermostat (DTT) Liquid Line Check Valve (Prior to SN:...

  • Page 24: Condenser Pressure Control Valve (Hgs2)

    (three each for the rejected to surrounding air. With 50X; two each for the 40X), the evaporator solenoid coil energized, the valve is in the heat coil, thermostatic expansion valve, defrost mode and the compressor...

  • Page 25: Evaporator Coil

    2.3.5 Evaporator Coil The evaporator is of the tube and fin type. The operation of the compressor maintains a reduced pressure within the coil. this reduced pressure, liquid refrigerant evaporates temperature sufficiently low enough to absorb heat from the air. Air movement over the evaporator is provided by an electric fan.

  • Page 26: Unit Specifications

    Refrigerant Charge Refer to Table 2-1 Compressor Pressure Regulating 40X: Setting; 36 +/- 1 psig (2.3 bar) Adjust on road Valve (CPR) operation only; 50X: Setting; 38 +/- 1psig(2.6bar) TES 2/ Orifice n_4/ MOP 75 psig (5.1 bar): Super heat: 13°...

  • Page 27: Electrical Data

    2.5.3 Electrical Data a. Fan Motors Evaporator Fan Motor (EFM) Condenser Fan Motor (CFM) Bearing Lubrication Factory Lubricated Bearing Lubrication Factory Lubricated Horse Power 100w Operating Amps 8.4 amps Operating Amps 7.5 amps Speed 2100 rpm (rated) Speed 2350/2600 rpm b.

  • Page 28: Safety Devices

    2.7 Safety Devices System components are protected from damage caused by unsafe operating conditions by automatically shutting down the unit when such conditions occur. This is accomplished by the fuses and safety devices listed in the following table. Table 2-3 Safety Devices Automatic restart Unsafe Conditions...

  • Page 29: Refrigerant Circuit

    2.8 Refrigerant Circuit The transfer of heat from the air to the low temperature liquid refrigerant causes the liquid to 2.8.1 Refrigerant Circuit During Cooling vaporize. The vapor temperature enters When cooling (see Figure 1-8), the unit operates as the compressor pressure regulating valve (CPR), a vapor compression refrigeration system.
  • Page 30 Discharge Liquid Hot Gas Line Suction Line TXV EQUALIZER LINE Road Compressor 17 Condenser Coil Quench Thermostat (BPT) 18 Receiver Discharge Charging Port 19 Manual Shut-off Valve (King Valve) Oil Separator 20 Sight Glass Road Discharge Check Valve 21 Filter Drier Standby Discharge Service Valve 22 Subcooler Standby Compressor...
  • Page 31 Discharge Liquid Hot Gas Line Suction Line TXV EQUALIZER LINE Road Compressor 17 Condenser Coil Quench Thermostat (BPT) 18 Receiver Discharge Charging Port 19 Manual Shut-off Valve (King Valve) Oil Separator 20 Sight Glass Road Discharge Check Valve 21 Filter Drier Standby Discharge Service Valve 22 Subcooler Standby Compressor...
  • Page 32 Discharge Liquid Hot Gas Line Suction Line TXV EQUALIZER LINE Road Compressor 17 Condenser Coil Quench Thermostat (BPT) 18 Receiver Discharge Charging Port 19 Manual Shut-off Valve (King Valve) Oil Separator 20 Sight Glass Road Discharge Check Valve 21 Filter Drier Standby Suction Service Valve 22 Subcooler Standby Compressor...

  • Page 33: Operation

    Section 3 Operation Unit may start automatically at any time even if the switch is in the OFF position. Use proper lockout/tagout procedures before inspection/servicing. All unit inspection/servicing by prop- erly trained personnel only. 3.1 Control System The driver can display the box temperature, and see whether the setpoint is being maintained by checking 3.1.1 Introduction the green indicator.
  • Page 34 Unit operating LEDs 3.1.3.2. Keypad Green Light Status The keypad consists of six keys that enable the Under normal operation, the green LED will indicate operator activate various functions, display operating data and modify operating parameters. the temperature control status as follows: Quick Manual defrost control key Setpoint +5°C...

  • Page 35: Start-Up

    Additional Key Functions 1. Check condenser coil for cleanliness. To access additional key functions, press and 2. Check condition of refrigerant hoses. hold the SET five seconds. 3. Check condition and tension of compressor microprocessor will provide a set of additional belt(s).

  • Page 36: Start-Up Process Prior To Software I.90

    Connect Power for Standby Start- -up on Road with cool setpoint and box temp <- -5°F (- -20.6°C): If the unit is to be operated in the standby mode, connect power as follows: a. 0 time: ON key pushed b. 40 seconds: CLHR / fans ON (unit in cool) Start- -up on Standby with cool setpoint and box temp <- -5°F (- -20.6°C): Do not attempt to connect or remove power...

  • Page 37: Setpoint Adjustment

    Start- -up on Road with cool setpoint and box temp <- -5°F (- -20.6°C): Increase the setpoint a. 0 time: ON key pushed b. 20 seconds: CLHR / fans ON (unit in cool) Validates setpoint temperature. Returns to display of the box tempe- Start- -up on Standby with cool setpoint and box rature.

  • Page 38: Configuration Button

    Configuration Button Figure 3-3 Configuration Button Configuration Available Configuration / Description Ut.°C (Celsius degree Ut.°F (Fahrenheit Temperature Unit display) degree display) PS.24 (Unit voltage Unit Voltage PS.12 (Unit voltage 12V) 24V) Number of Evap Fans FAn.1 (One Fan) FAn.2 (Two Fans) FAn.3 (Three Fans) SPd.= (Second speed SPd.=...

  • Page 39: Modification Of Parameters

    NOTE 3.6.3 Defrost Parameters If no key is activated after validating a configu- ration, the system reverts to box temperature Shut-down unit. display and the configuration procedure is aborted. Only validated changes are recorded. Display parameters. 3.6 Modification of Parameters The procedure to adjust the unit functional parameters Modify parameters.

  • Page 40: Alarm Display

    3.7 Alarm Display In the event of a malfunction the unit will be shut down and the Cab Command will immediately display an error message. Section 3.7.2 accessing alarm messages. The message will remain displayed until the malfunction is corrected. If standby power is connected and the malfunction is such that standby operation can be allowed, the unit will start in the standby mode.
  • Page 41 3.7.3 Clearing Past Alarm Messages The alarm list provides information on current alarms and past alarms which may be helpful in trouble shooting unit problems. Once all the alarm information has been noted and service is complete, the alarm list may be cleared. To clear the past alarm messages: P ress and the - - keys at the same time...

  • Page 42: Stopping The Unit

    3.8 Stopping the Unit Press the OFF key or turn off the ignition key. Unit start-up Press the +, then -- then DEFROST THEN keys. All keys should be held mo- mentarily after pressing in the correct sequence. Modify parameters. (See 1), 3) and 4) below) 3-10 62-12158...

  • Page 43: Temperature Control

    Section 4 Temperature Control 4.1 Sequence of Operation General operation sequences cooling, null, and heating provided +5.4°F ( + 3 °C ) following paragraphs. microprocessor automatically selects mode necessary to COOL maintain box temperature at setpoint. +3.6°F ( + 2 °C ) 4.1.1 Perishable Mode +1.8°F ( + 1 °C) The unit operates in the perishable mode with...

  • Page 44: Defrost Cycle

    4.2 Defrost Cycle During defrost, the evaporator fans shut down and operation of the condenser fan is controlled by the Defrost is an independent cycle overriding cooling microprocessor. The end of the cycle is controlled by and heating functions melt frost the opening of the defrost termination thermostat from the evaporator when necessary.

  • Page 45: Service

    SECTION 5 Service WARNING Unit may start automatically at any time even if the switch is in the OFF position. Use proper lockout/tagout procedures before inspection/servicing. All unit inspection/servicing by prop- erly trained personnel only. WARNING Beware of V-belts and belt driven components as the unit may start automatically. Before ser- vicing unit, the RUN/ STOP Switch must be in the STOP position.

  • Page 46: Preventative Maintenance

    5.1 Preventative Maintenance Table 5-4 Service Category Descriptions Regular servicing is required in order to optimize Service A 1. Check the tension of the alternator the life reliability your unit. belt(s). recommended scheduled maintenance intervals and 2. Check that the vehicle engine runs categories are provided Table...

  • Page 47: Installing Manifold Gauge Set

    The manifold gauge/hose set is available from Carrier Transicold. (Carrier e. Front seat both manifold gauge set hand valves and Transicold P/N 07-00314-00,...

  • Page 48: Removing The Manifold Gauge Set

    5.2.3 Removing the Manifold Gauge Set 5.3 Removing Refrigerant Charge 1. While the compressor is still ON, backseat the high side service valve. When working with refrigerant use safety 2. Midseat both hand valves on the manifold gauge glasses and gloves to avoid burns. Hoses set and allow the pressure in the manifold gauge and copper tubing can be hot when unit is set to be drawn down to low side pressure.

  • Page 49: Removing Complete Charge

    5.3.3 Removing Complete Charge 5.5.2 Preparation a. Evacuate and dehydrate only after pressure leak test. Connect a refrigerant recovery system to the unit to (Refer to Section 5.4). remove refrigerant charge. Refer to instructions b. Essential tools to properly evacuate and dehydrate provided by the manufacturer of the refrigerant recovery system.

  • Page 50: Evacuation And Dehydration - Partial System

    Refrigerant Recovery Unit Electronic Vacuum Gauge Suction Valve (Low Side) Vacuum Pump Valve Manifold Gauge Set Vacuum Pump Discharge Valve (High Side) Refrigerant Cylinder Figure 5-2 Vacuum Pump Connection g. Remove refrigerant using a refrigerant recovery b. If refrigerant charge has been removed from the low system.
  • Page 51 5.6.2 Installing a Complete Charge (See d. Open liquid valve on refrigerant cylinder. Open king Figure 5-3) valve half way and allow the liquid refrigerant to flow into the unit until the correct weight of NOTE refrigerant has been added indicated scales.

  • Page 52: Adding A Partial Charge

    5.6.3 Adding a Partial Charge (R-404a only) Start the unit with the road compressor turning at 2400 rpm. Check the sight glass to determine charge. See Sec- Refrigerant R-404a R-452a must tion 5.6.1. If undercharged, proceed with step d. charged liquid.
  • Page 53 5.6.4 Refrigerant Recovery Prior to Unbrazing Operation for R-452a Units WARNING R-452a refrigerant is an A1 non-flammable refrigerant blend which includes some mildly flammable constituents. As such, please follow all proper service and maintenance procedures. Ensure that proper evacuation procedure is strictly followed before performing any “hot work,”...
  • Page 54 5.6.4.1 Unit Connection Figure 6.12 Unit Connection Connect the manifold gauge set to the unit (refer to Figure 6.10 Figure 6.12) • Hose A to low-pressure compressor service valve • Hose B to vacuum pump • Hose C to high-pressure receiver tank king valve •...
  • Page 55 5.6.4.2 Evaporator Connection Figure 6.13 Evaporator Connection 1. Connect the manifold gauge (II) to the evaporator. Refer to Figure 6.13. • Hose A to the evaporator connection port. • Hose B to the vacuum pump 2. Start the vacuum pump. 3.
  • Page 56 5.6.4.3 Recovery System Installation Figure 6.14 Recovery System 1. Connect recovery machine to hose (B).Refer to Figure 6.14. 2. Place the R-452a recovery bottle onto the scale and note the weight. 3. Check the admissible charge indicated in the R-452a recovery bottle information. 4.
  • Page 57 10. Disconnect the recovery machine and dispose of R-452a recovery bottle according to local regulation. End of recovery procedure 11. Purge with Nitrogen. For more information about nitrogen instruction, refer to Carrier Transicold document #98-60068-00 (Brazing Instructions). The refrigerant circuit is ready for unbrazing operation. Perform unbrazing operation under nitrogen.

  • Page 58: Checking And Replacing The Filter Drier

    Checking and Replacing the Filter Drier 5.9 Checking and Replacing Condenser Fan Motor Brushes 5.7.1 Checking Filter Drier To maintain proper operation of the fan motors, the fan motor brushes should be checked periodically Check for any obstruction of the filter drier by feeling for cleanliness and wear .

  • Page 59: Replacing Solenoid Coil

    5.10.2 Replacing Valve Internal Parts 5.10 Hot Gas Solenoid Valve (HGS1), Condenser Pressure Control Valve (HGS2), Liquid a. Remove the refrigerant charge for high side compo- Solenoid Valve, and Quench Valve (BPV) nents or pump down to receiver if servicing low side components.

  • Page 60: Adjusting The Compressor Pressure Regulating Valve (Cpr)

    5.11 Adjusting the Compressor Pressure c. Loosen inlet nut, and unbraze equalizer line and outlet Regulating Valve (CPR) line from expansion valve. d. The thermal bulb is located below the center of the When adjusting the compressor pressure regulating suction line. This area must be clean to ensure positive valve (CPR) (see Figure 5-8), the unit must be bulb contact.

  • Page 61: Checking The Txv Orifice Strainer

    5.12.3 Checking The TXV Orifice Strainer 5.15 Evaporator Coil Cleaning Pump the unit down (refer to Section 5.3.2). Remove recycled cardboard cartons the bottom connection on the TXV. Remove the increasing. recycled cardboard cartons strainer and check obstruction damage. create much more fiber dust during transport than Clean replace strainer assembly and tighten new cartons.
  • Page 62 Table 5-5. R-404a Temperature- -Pressure Chart Temperature Pressure Temperature Pressure Psig °F °C Kg/cm Psig °F °C Kg/cm --40 --40 0.32 0.31 72.5 5.10 5.00 --35 --37 0.50 0.49 75.6 5.32 5.21 --30 --34 0.70 0.68 78.8 5.54 5.43 --25 --32 12.9 0.91...
  • Page 63 Figure 5.6 R-452a Temperature/Pressure Chart Temperature Liquid Vapor Temperature Liquid Vapor °F °C psig psig °F °C psig psig -29.2 10.4 0.72 0.45 144.6 9.97 128.6 8.87 -25.6 12.7 0.87 0.58 71.6 153.5 10.59 136.9 9.44 15.1 1.04 10.6 0.73 75.2 162.8 11.23...

  • Page 65: Troubleshooting

    All unit inspection/servicing by prop- erly trained personnel only. Under no circumstances should anyone attempt to service the microprocessor (see section 5.14). Should a problem develop with the microprocessor, contact your nearest Carrier Transicold dealer for replacement. 6.1 Introduction Under normal circumstances, unit problems will be indicated by an active or inactive alarm in the alarm list.
  • Page 66 Table 6-1 Alarm Indications - Continued Reference ALARM Description Corrective Actions Paragraph Current draw of coil high or low (approximately 1.6 Hot Gas Valve (HGS1) amp) high amp draw Replace coil 5.10.1 Current draw of coil high or low (approximately 1.2 Quench Valve (BPV) amp) high amp draw...

  • Page 67: Refrigeration

    Reference ALARM Description Corrective Actions Paragraph Verify configuration on for 50X only Table 3-2 SBPV short circuit Valve coil shorted Correct (Integra 50X only) Check Check wiring to coil Verify configuration on for 50X only Table 3-2 SBPV open circuit Valve coil shorted Correct (Integra 50X only)

  • Page 68: No Evaporator Air Flow Or Restricted Air Flow

    Table 6-2 Mechanical Indications - Continued Reference Possible Causes Indication / Trouble Section 6.2.6 Abnormal Pressure 6.2.6.1 Cooling Condenser coil dirty 5.16 Noncondensibles or refrigerant overcharge 5.6.1 High discharge pressure Condenser fan/motor defective Compressor defective Replace Hot gas solenoid malfunction 5.10 Low discharge pressure 5.6.1...

  • Page 69: Expansion Valve

    Table 6-2 Mechanical Indications - Continued Reference Possible Causes Indication / Trouble Section 6.3.1 Expansion Valve 5.6.1 Low refrigerant charge External equalizer line plugged Repair Ice wax, oil or dirt plugging valve strainer 5.12.3 Low suction pressure with high Broken capillary Repair superheat Superheat setting too high...
  • Page 70 62-12158...

  • Page 71: Schematic Drawings

    All unit inspection/servicing by prop- erly trained personnel only. Under no circumstances should anyone attempt to service the microprocessor (see section 5.14). Should a problem develop with the microprocessor, contact your nearest Carrier Transicold dealer for replacement. 7.1 Introduction Schematic diagrams for the unit models listed in Table 1-1 are provided herein.
  • Page 80 Central America and Mexico Carrier Transicold Carrier Transicold 700 Olympic Drive Ejercito Nacional 253-A Piso 5 Athens, GA 30601 USA Colonia Anahuac 11320 Mexico D.F. ©2020 Carrier Corporation. Printed in USA Carrier, Carrier Transicold is a registered trademark of Carrier Corporation.

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