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Carrier TRANSICOLD OptimaLINE 69NT40-701-001 Operation And Service Manual

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Container Refrigeration
OPERATIONS AND SERVICE
MANUAL
For
OptimaLINE
69NT40-701-001 to 099
69NT40-701-100 to 149
Container Refrigeration Units
T-383 Rev B

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Summary of Contents for Carrier TRANSICOLD OptimaLINE 69NT40-701-001

  • Page 1 Container Refrigeration OPERATIONS AND SERVICE MANUAL OptimaLINE 69NT40-701-001 to 099 69NT40-701-100 to 149 Container Refrigeration Units T-383 Rev B...
  • Page 3 OPERATIONS AND SERVICE MANUAL OptimaLINE 69NT40-701-001 to 099 69NT40-701-100 to 149 Container Refrigeration Units This manual and others may be viewed in Carrier’s ContainerLINK™ app. The QR code below provides a link to download the app, which can be installed on IOS or Android devices. ContainerLINK provides technicians with a suite of diagnostic and reference tools accessible from one location.
  • Page 5 Table of Contents PARAGRAPH NUMBER PAGE 1 SAFETY SUMMARY ..............1–1 GENERAL SAFETY NOTICES .

  • Page 6: Table Of Contents

    MAIN COMPONENT DESCRIPTIONS ..........3–8 3.3.1 Compressor...
  • Page 7 4.3.1 Start Up - Compressor Phase Sequence ........4–16 4.3.2 Perishable Mode Temperature Control...
  • Page 8 6 TROUBLESHOOTING ............. . . 6–1 UNIT WILL NOT START OR STARTS THEN STOPS .
  • Page 9 7.7.1 Evaporator Section Cleaning ..........7–23 7.7.2 Replacing the Evaporator Coil...
  • Page 10 List of Figures FIGURE NUMBER Page Figure 2.1 Unit Nameplate ............. . . 2–1 Figure 2.2 PED Label .
  • Page 11 Figure 4.3 Perishable Mode - Cooling and Heating Chart ........4–17 Figure 4.4 Frozen Mode - Cooling and Heating Chart .
  • Page 12 List of Tables TABLE NUMBER Page Table 3–1 Refrigeration System Data ............3–23 Table 3–2 Electrical Data .

  • Page 13: Section 1 Safety Summary

    Section 1 Safety Summary 1.1 General Safety Notices Installation and servicing of refrigeration equipment can be hazardous due to system pressures and electrical components. Only trained and qualified service personnel should install, repair, or service refrigeration equipment. When working on refrigeration equipment, observe all potential Danger, Warning and Caution hazards, including those shown below and on hazard labels attached to the unit.
  • Page 14 1.6 Specific Hazard 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 - an immediate hazard that WILL result in severe personal injury or death. WARNING - a hazards or unsafe condition that COULD result in severe personal injury or death.
  • Page 15 WARNING There are no serviceable parts on a pressure relief valve (PRV). Attempting to repair or alter the PRV is not permitted. If the PRV has released pressure, the entire PRV must be replaced. WARNING Do not use a nitrogen cylinder without a pressure regulator. WARNING Do not open the condenser fan grille before turning power OFF and disconnecting power plug.
  • Page 16 CAUTION Pre-trip inspection should not be performed with critical temperature cargoes in the container. CAUTION When a failure occurs during automatic Pre-Trip testing, the unit will suspend operation awaiting operator intervention. CAUTION To prevent trapping liquid refrigerant in the manifold gauge set, make sure set is brought to suction pressure before disconnecting.

  • Page 17: Configuration Identification

    Introduction 2.1 Introduction The Carrier Transicold OptimaLINE units, model numbers 69NT40-701-xxx, are of lightweight aluminum frame construction, designed to be bolted onto the front of a container and serve as the container’s front wall. Forklift pockets are provided for unit installation and removal.

  • Page 18: Feature Descriptions

    Units are equipped with an aluminum control box, and may be fitted with a lockable door. 2.4.2 Controller The controller is a Carrier Transicold Micro-Link 5 microprocessor. See Section 4.1 for more information. Controllers will be factory-equipped with the latest version of operational software, but will NOT be configured for a specific model number and will need to be configured at the time of installation or sale.

  • Page 19: Option Descriptions

    2.4.4 Pressure Readout The unit is fitted with evaporator, suction, and discharge pressure transducers. The transducer readings may be viewed on the controller display. 2.4.5 Compressor The unit is fitted with a R-513A-ready variable speed scroll compressor equipped with suction and discharge service connections.
  • Page 20 2.5.4 Back Panels Aluminum back panels may have access doors and/or hinge mounting. 2.5.5 460 Volt Cable Various power cable and plug designs are available for the main 460 volt supply. The plug options tailor the cables to each customer’s requirements. 2.5.6 Cable Restraint Various designs are available for storage of the power cables.

  • Page 21: Figure 3.1 Container Unit - Front Section

    Section 3 Description 3.1 Introduction The container unit, shown in Figure 3.1, is designed so that the majority of the components are accessible from the front. The unit model number, unit serial number and parts identification number can be found on the unit nameplate on the side wall next to the power cable storage area.

  • Page 22: Component Overviews

    3.2 Component Overviews The container unit components, as shown in Figure 3.2, are explained in this manual by dividing into four sections: 1. Compressor section 2. Condenser section 3. Evaporator section 4. Control box section Figure 3.2 Container Unit Sections T-383...
  • Page 23 3.2.1 Compressor Section The compressor is a variable speed scroll compressor that receives refrigerant vapor from the evaporator and compresses it to a high pressure, high temperature gas before directing it to the condenser. The compressor section includes a compressor, variable frequency drive (VFD), discharge service valves (discharge and suction), discharge pressure transducer (DPT), suction pressure transducer (SPT), evaporator pressure transducer (EPT), a high pressure switch (HPS), a discharge temperature sensor (CPDS) and connections to the compressor.

  • Page 24: Figure 3.3 Compressor And Condenser Sections

    Figure 3.3 Compressor and Condenser Sections Standard Unit Unit with Water-Cooled Condenser 1) Compressor 5) Receiver with Sight Glass and Moisture Indicator 2) Variable Frequency Drive (VFD) 6) Filter Drier 3) Condenser Coil, MCHE 7) Economizer 4) Condenser Fan and Motor 8) Water Cooled Condenser (Option) - - - - - T-383...

  • Page 25: Figure 3.4 Compressor And Condenser Sections

    Figure 3.4 Compressor and Condenser Sections Receiver Assembly 701-001 to 099 701-100 to 149 Models Models Economizer Assembly Compressor 1) Compressor Terminal Box 9) Receiver Sight Glass 2) Discharge Service Valve 10) Receiver Moisture Indicator 3) High Pressure Switch (HPS) 11) Fusible Plug (701-001 to 099 Models) 4) Discharge Temperature Sensor (CPDS) 12) Pressure Relief Valve (701-100 to 149 Models)

  • Page 26: Figure 3.5 Evaporator Section

    Figure 3.5 Evaporator Section 9, 10 1) Evaporator Fan and Motor (EM1, EM2) 6) Evaporator Coil 2) Return Temperature Sensor (RTS) / Return 7) Heaters (6) Recorder Sensor (RRS) 8) Defrost Drain 3) Humidity Sensor (HS)** 9) Heat Termination Thermostat (HTT)** 4) Electronic Expansion Valve (EEV) 10) Defrost Temperature Sensor (DTS)** 5) Evaporator Temperature Sensors (ETS1 / ETS2)

  • Page 27: Figure 3.6 Control Box Section

    Figure 3.6 Control Box Section 1) Controller 8) Condenser Fan Contactor Low Speed (CL) 2) Controller Battery Pack and Battery 9) Condenser Fan Contactor High Speed (CF) Note: located above controller (not shown) 10) Low Speed Evaporator Fan Contactor (ES) 3) Start/Stop Switch 11) High Speed Evaporator Fan Contactor (EF) 4) Compressor Contactor (CH)

  • Page 28: 3.3 Main Component Descriptions

    3.3 Main Component Descriptions 3.3.1 Compressor The compressor, shown in Figure 3.7, is a variable speed scroll compressor with a permanent magnet motor. The compressor receives refrigerant vapor from the evaporator and compresses it to a high pressure, high temperature gas before directing it to the condenser.

  • Page 29: Condenser Coil And Fan

    3.3.3 Condenser Coil and Fan From the compressor, the refrigerant flows to the air-cooled condenser, shown in Figure 3.9. The condenser fan blows the air across the coil fins and tubes to cool the gas to saturation temperature. By removing latent heat, the gas condenses to a high pressure / high temperature liquid and flows to the receiver.

  • Page 30: Receiver

    3.3.5 Receiver The receiver receives high pressure / high temperature liquid refrigerant from the condenser and stores it for when it is needed during low temperature operation. The receiver contains a sight glass and a moisture indicator. R-513A-ready units (models 701-001 to 099) have a receiver, Figure 3.11, with a fusible plug.

  • Page 31: Filter Drier

    3.3.6 Filter Drier Refrigerant flows from the receiver through the filter drier, shown in Figure 3.13, which removes particulates and small amounts of water from the refrigerant to keep it clean and dry. Figure 3.13 Filter Drier 3.3.7 Economizer The economizer, shown in Figure 3.14, is only active when the unit enables economized mode and the controller energizes the economizer expansion valve (ECV), see...

  • Page 32: Evaporator Coil And Fans

    3.3.8 Evaporator Coil and Fans Refrigerant enters the evaporator coil, shown in Figure 3.15, as a low pressure, low temperature saturated mixture and exits as a vapor. As the refrigerant enters the coil, two dual speed evaporator fans blow air on the coil. Heat is absorbed from the air by the balance of the liquid, causing it to vaporize in the coil.

  • Page 33: 3.3.10 Heat Termination Thermostat

    3.3.10 Heat Termination Thermostat The heat termination thermostat (HTT), shown in Figure 3.17, is a safety device attached to an evaporator coil circuit that opens the heating circuit if overheating occurs. Figure 3.17 Heat Termination Thermostat (HTT) 3.3.11 Evaporator Access Panels and Air Makeup Vent Most evaporator components are accessible by removing the upper back rear panel, inside the container unit.

  • Page 34: 3.4 Service Valves Descriptions

    3.4 Service Valves Descriptions 3.4.1 Compressor Service Valves The discharge service valve and suction service valve, shown in Figure 3.19, allow connecting of the manifold gauge set to perform refrigerant service. The service valves are provided with a double seat and an access valve which enables servicing of the compressor and refrigerant lines.

  • Page 35: 3.5 Refrigerant Valves Descriptions

    3.5 Refrigerant Valves Descriptions 3.5.1 Electronic Expansion Valve The electronic expansion valve (EEV), shown in Figure 3.21, drops the pressure of the liquid refrigerant to suction pressure. As this happens, some of the liquid vaporizes to a gas (flash gas), removing heat from the remaining liquid.

  • Page 36: 3.6 Refrigerant Probes Description

    3.6 Refrigerant Probes Description 3.6.1 Compressor Discharge Temperature Sensor The compressor discharge temperature sensor (CPDS), shown in Figure 3.23, measures the temperature of the refrigerant as it is discharged from the compressor. NOTE: The CPDS reading can be viewed on the unit display at function code Cd11. Figure 3.23 Compressor Discharge Temperature Sensor (CPDS) 3.6.2 High Pressure Switch...

  • Page 37: Discharge Pressure Transducer

    3.6.3 Discharge Pressure Transducer The discharge pressure transducer (DPT), shown in Figure 3.25, monitors refrigerant pressure on the discharge side of the compressor. The DPT is located behind the receiver. NOTE: The DPT reading can be viewed on the unit display at function code Cd14. Figure 3.25 Discharge Pressure Transducer (DPT) 3.6.4 Economizer Pressure Transducer...

  • Page 38: Economizer Temperature Sensor

    3.6.5 Economizer Temperature Sensor The economizer temperature sensor (ECT), shown in Figure 3.27, monitors refrigerant temperature between the economizer and the compressor. It is located near the economizer connection to the compressor. NOTE: The ECP reading can be viewed on the unit display at function code Cd84. Figure 3.27 Economizer Temperature Sensor (ECT) 3.6.6 Evaporator Temperature Sensor...

  • Page 39: Evaporator / Suction Pressure Transducer

    3.6.7 Evaporator / Suction Pressure Transducer The evaporator pressure transducer (EPT) and suction pressure transducer (SPT), shown in Figure 3.29, monitors refrigerant on the suction side of the compressor. NOTE: The EPT and SPT readings can be viewed on the unit display at function code Cd12. Figure 3.29 Evaporator Pressure Transducers - EPT (bottom) and SPT (top) 3.7 Air Stream Sensors Descriptions 3.7.1...

  • Page 40: Return Temperature Sensors

    3.7.2 Return Temperature Sensors The return temperature sensor (RTS) and return recorder sensor (RRS) are shown in Figure 3.31. The RTS monitors the return air temperature at the top of the container unit above the evaporator fans. The controller maintains the return air temperature at setpoint during frozen mode according to the RTS. The RRS is for recording temperature and also to backup the RTS in case of failure.

  • Page 41: Defrost Temperature Sensor

    3.7.4 Defrost Temperature Sensor The defrost temperature sensor (DTS), shown in Figure 3.33, determines the initiation of Defrost mode. When the DTS senses a temperature less than 10°C (50°F), the defrost options become active and the timer is engaged for the initiation of the defrost cycle.

  • Page 42: Usda Probes And Cargo Probe

    3.7.6 USDA Probes and Cargo Probe If equipped, the unit has the capability of recording three USDA probes (USDA 1-3) and one cargo probe. The 3- pin receptacles for plugging in the probes are located in the evaporator section. The probe leads are plugged into the desired receptacle, shown in Figure 3.35.

  • Page 43: 3.9 Refrigeration System Data

    3.9 Refrigeration System Data WARNING EXPLOSION HAZARD: Failure to follow this WARNING can result in death, serious personal injury and / or property damage. Never use air or gas mixtures containing oxygen (O2) for leak testing or operating the product. Charge only with refrigerants R-134a or R-513A as specified for the unit model number.

  • Page 44: Safety And Protective Devices

    Table 3–2 Electrical Data (Continued) Evaporator Coil Heaters Number of Heaters Rating 750 watts +5/-10% each @ 230 VAC Resistance (cold) 66.8 to 77.2 ohms @ 20°C (68°F) Type Sheath Evaporator Fan Motor(s) Nominal Supply 380 VAC, 3 Phase, 460 VAC, 3 Phase, 50 Hz +/- 1.25 Hz 60 +/- 1.25 Hz Full Load Amps (H / L)

  • Page 45: Table 3-3 Safety And Protective Devices

    Table 3–3 Safety and Protective Devices Unsafe Condition Device Device Setting Excessive current draw Circuit Breaker (CB-1, 25 amp) - Manual Reset Trips at 29 amps (460 VAC) Excessive current draw in the Fuse (F3 / F4) 7.5 amp rating control circuit Excessive current draw by the Fuse (F1 / F2)

  • Page 46: Figure 3.36 Refrigeration Circuit Diagram, 701-001 To 099 Models

    Figure 3.36 Refrigeration Circuit Diagram, 701-001 to 099 Models Note: Objects outlined by dashed lines (- - -) indicate an optional water cooled condenser installed. 1) Compressor 16) Filter Drier 2) Discharge Service Valve 17) Economizer 3) High Pressure Switch (HPS) 18) Economizer Expansion Valve (ECV) 4) Discharge Temperature Sensor (CPDS) 19) Economizer Pressure Transducer (ECP)

  • Page 47: Figure 3.37 Refrigeration Circuit Diagram, 701-100 To 149 Models

    Figure 3.37 Refrigeration Circuit Diagram, 701-100 to 149 Models Note: Objects outlined by dashed lines (- - -) indicate an optional water cooled condenser installed. 1) Compressor 16) Filter Drier 2) Discharge Service Valve 17) Economizer 3) High Pressure Switch (HPS) 18) Economizer Expansion Valve (ECV) 4) Discharge Temperature Sensor (CPDS) 19) Economizer Pressure Transducer (ECP)

  • Page 49: Temperature Control Microprocessor System

    Section 4 Microprocessor 4.1 Temperature Control Microprocessor System The temperature control Micro-Link 5 microprocessor system consists of a controller (control module), display module, keypad and interconnecting wiring. 4.1.1 Controller The controller, see Figure 4.1, is fitted with power connectors, a micro USB port and short range wireless connectivity.

  • Page 50: Figure 4.2 Display Module And Keypad

    4.1.2 Display Module and Keypad The display module and keypad, as shown in Figure 4.2, are mounted on the control box door and serve to provide user access and readouts for both of the controller functions: temperature control and DataCORDER. The functions are accessed by keypad selections and viewed on the display module.

  • Page 51: Controller Software

    Table 4–2 Keypad Function Function CODE Access function codes. SELECT Display Pre-Trip selection menu. TRIP Discontinue a Pre-Trip in progress. ALARM Display alarm list and clear alarm queue. LIST MANUAL Display selected defrost mode. DEFROST / Press and hold this key for five seconds to initiate defrost using same logic as if the optional manual defrost switch was toggled on.

  • Page 52: Operational Software (Cd Function Codes)

    4.2.2 Operational Software (Cd Function Codes) The operational software is the actual operation programming of the controller which activates or deactivates components in accordance with current unit operating conditions and selected modes of operation. The programming is divided into function codes. Some of the codes are read only, while the remaining codes may be user configured.

  • Page 53: Table 4-3 Controller Function Codes (Cd) - Summary

    Table 4–3 Controller Function Codes (Cd) - Summary Code Description Configurable Cd01 Compressor Capacity Percentage Cd03 Compressor Current / Percentage / Power Cd04 Line Current, Phase A Cd05 Line Current, Phase B Cd06 Line Current, Phase C Cd07 Mains Supply Voltage Cd08 Mains Supply Frequency Cd09...
  • Page 54 Code Description Configurable Cd65 TripWise Cd66 Power (kW) Cd67 Energy (kW-hr) Cd70 Temperature Setpoint Lock Cd71 EverFRESH Mode Cd72 Air Compressor Hours Since Last Service Cd73 Air Compressor Total Operational Hours Cd74 Controller Diagnostic Cd75 Pharma Mode Cd76 CO2 Injection Mode Cd77 Baudrate Selection Cd78...
  • Page 55 Cd10 Evaporator Refrigerant Temperature (ETS) Cd10 displays the Evaporator Temperature Sensor (ETS) reading. Cd11 Compressor Discharge Temperature (CPDS) Cd11 displays the Compressor Discharge Temperature Sensor (CPDS) reading, using compressor dome temperature. Cd12 Evaporator / Compressor Suction Port Pressure (SPT) Cd12 displays the Evaporator Pressure Transducer (EPT) pressure reading in the left display; Press the ENTER key to show the reading for Compressor Suction Transducer (SPT) suction port pressure in the right display.
  • Page 56 Cd23 Evaporator Fan State Cd23 displays the current state of the evaporator fan as OFF, LOW or HIGH. Cd25 Time Remaining Until Defrost Cd25 displays the time remaining until the unit goes into defrost (in tenths of an hour). This value is based on the actual accumulated compressor running time.
  • Page 57 Cd32 System Current Limit (Amperes) Cd32 displays the current limit, which is the maximum current draw allowed on any phase at any time. Limiting the unit’s current reduces the load on the main power supply. When desirable, the limit can be lowered. Note, however, that capacity is also reduced.
  • Page 58 Cd48 Dehumidification / Bulb Mode Cd48 will initially display current Dehumidification Mode; “bUlb” (bulb cargo mode), “dEhUM” (normal dehumidification), or “OFF”. Press the ENTER key to take the interface down into a hierarchy of parameter selection menus (mode, setpoint, evaporator speed, DTT setting). Press the ENTER key in any parameter selection menu to commit selection of the currently displayed parameter and cause the interface to descend into the next parameter selection menu.
  • Page 59 Turn On ACT: 1. With “ACt” displayed, select “On” and press the ENTER key to enable ACT Mode. See Section 5.9.3 detail procedure to set ACT values using Cd51. While ACT is On: • The left display will flash “COLd” and the right display will flash “trEAt”, and this will alternate between the unit setpoint and control temperature at 5 second intervals.
  • Page 60 Cd54 Suction Port Superheat / Electronic Expansion Valve Status Cd54 displays the reading for evaporator superheat (suction temperature minus suction saturation temperature as calculated from suction pressure) in the right display. Press the ENTER key to show the reading for Electronic Expansion Valve (EEV) position (%) in the left display. Cd55 Discharge Superheat Cd55 displays discharge superheat (discharge temperature minus discharge saturation temperature as calculated from discharge pressure) values in C / F as calculated by the discharge temperature minus the...
  • Page 61 Perishable FuelWise Mode is an extension of Perishable Mode. When active, the system will perform Perishable Pulldown operation. The compressor will be turned off when the controlled temperature is less than or equal to the setpoint. During the compressor off-cycle period, the evaporator fans are switched to low speed. When the heater is turned on, or when the compressor is turned on to provide cooling, the evaporator fans are switched to high speed.
  • Page 62 Cd70 Temperature Setpoint Lock Cd70 enables or disables the Temperature Setpoint Lock feature. When set to “On”, this will prevent setpoint change from the keypad. The default setting is “OFF”. An event will be recorded in the DataCorder each time an action is taken at Cd70.
  • Page 63 Cd74 Controller Diagnostic Cd74 is for running a Controller Self Diagnostic test. After selecting CD74, press the ENTER key while “tESt” is displayed to run the test. While the test is running, “tESt” will flash on the display. Once the test is complete, the Test Result will be displayed.

  • Page 64: Modes Of Operation

    Cd78 EverFRESH Air Compressor State Cd78 displays the state of the EverFRESH Air Compressor as On or OFF. If a unit does not have the EverFRESH option, dashes “-----” will be displayed. This code has no sub menu. Cd79 EverFRESH Water Drain Valve (WDV) State Cd79 displays the state of the EverFRESH Water Drain Valve (WDV) as On or OFF.

  • Page 65: Figure 4.3 Perishable Mode - Cooling And Heating Chart

    Figure 4.3 Perishable Mode - Cooling and Heating Chart Perishable Pulldown ° +2.0 Perishable Cooling ° +0.25 Setpoint Setpoint ° ° -0.25 -0.25 ° -0.50 Perishable Heating Temperature Temperature Decreasing Increasing 4.3.2.1 Perishable Dehumidification Perishable Dehumidification is provided to control the return air humidity levels inside the container to below a set value.

  • Page 66: Frozen Mode Temperature Control

    4.3.2.7 Pharma Mode Pharma Mode option (ML3 only for now) allows cargoes to be maintained at temperature setpoints of either 5°C (41°F) or 20°C (68°F), while maintaining lower humidity levels. Pharma Mode is active when a unit is equipped with a humidity sensor, code Cd75 is set to ON and a temperature setpoint has been chosen at Cd75.

  • Page 67: Defrost Operation

    • Snap Freeze allows the system to cool for a period of time after de-icing, with the evaporator fans turned off and is only carried out if configured by model number. Snap-Freeze allows for the removal of latent de-icing heat from the evaporator coils, and freezes any remaining moisture that might otherwise be blown into the container.

  • Page 68: 4.4 Controller Alarms

    4.4 Controller Alarms Alarm display is an independent controller software function. If an operating parameter is outside of expected range or a component does not return the correct signals back to the controller, an alarm is generated. The alarm philosophy balances the protection of the refrigeration unit and that of the refrigerated cargo. The action taken when an error is detected always considers the survival of the cargo.

  • Page 69: Alarm Code Descriptions

    4.4.2 Alarm Code Descriptions A summary of alarms is provided in Table 4–4, and completed descriptions below the table. Table 4–4 Alarm Indications - Summary Code Description AL003 Evaporator Superheat Control Failure AL012 Variable Frequency Drive (VFD) Control Instruction Timeout AL013 Variable Frequency Drive (VFD) Communication Failure AL015...
  • Page 70 Table 4–4 Alarm Indications - Summary Code Description AL265 Discharge Pressure Transducer (DPT) Fault AL266 Evaporator Pressure Transducer (EPT) Fault AL267 Humidity Sensor (HS) Fault AL269 Evaporator Temperature Sensors (ETS1 / ETS2) Fault AL270 Supply Recorder Sensor (SRS) Fault AL271 Return Recorder Sensor (RRS) Fault AL272 USDA1 Temperature Out of Range...
  • Page 71 Component: Evaporator Fans Troubleshooting: Confirm that the fans are operating properly. Replace fan(s) if defective. See Evaporator Fan Motor Assembly, Section 7.7. AL012 Variable Frequency Drive (VFD) Control Instruction Timeout Cause: Communication timeout between the VFD and the controller after attempted VFD restart. Component: Variable Frequency Drive (VFD) Troubleshooting:...
  • Page 72 Troubleshooting: Confirm accurate SPT pressure readings. Hook up the Manifold Gauge Set to check pressures. See Manifold Gauge Set, Section 7.1.1. Replace the SPT if defective. Component: Monitor the unit. The alarm is display only; the alarm may clear itself during operation. Troubleshooting: If the alarm remains active or repeats, replace the compressor at next available opportunity.
  • Page 73 AL022 Evaporator Fan Internal Protector Open Cause: The evaporator motor internal protector (IP) is open. Component: Evaporator motor Troubleshooting: Shut down the unit and disconnect power. Check the harness between CA22 and CA12. If open circuit, check the evaporator motor IP at plug connection pins 4 & 6. Replace defective evaporator fan motor. See Evaporator Fan Motor Service, Section 7.7.
  • Page 74 AL065 Discharge Pressure Transducer (DPT) Failure Cause: The Compressor Discharge Pressure Transducer (DPT) is out of range. Component: Discharge Pressure Transducer (DPT) Troubleshooting: Confirm accurate DPT pressure readings. See Refrigerant Service, Section 7.1. Replace the DPT if defective. AL066 All Low Pressure Sensor Failure (EPT and SPT) Cause: Both Suction Pressure Transducer (SPT) and Evaporator Pressure Transducer (EPT) values are outside of their operating range and the compressor has been on for at least 60 continuous seconds of controller clock time...
  • Page 75 AL092 Variable Frequency Drive (VFD) Internal Failure Cause: An internal fault occurred in the Variable Frequency Drive (VFD). Component: Variable Frequency Drive (VFD) Troubleshooting: Power cycle the unit. If the alarm cannot be reset, replace the VFD. AL093 Variable Frequency Drive (VFD) Fan Failure Cause: The Variable Frequency Drive (VFD) temperature exceeded the trip level with a fan error detected.
  • Page 76 Troubleshooting: Check to see why the compressor is over-shooting setpoint temperature. Run a Pre-Trip test P6 to test the compressor and related components. AL202 Economizer Superheat Control Fault Cause: Low Economizer or Discharge Superheat while the Economizer Expansion Valve (ECV) is 0% open Component: Economizer Expansion Valve (ECV) Troubleshooting:...
  • Page 77 AL208 Compressor Pressure Ratio High Cause: The controller detects that discharge pressure to suction pressure ratio is too high. The controller will attempt to correct the situation by restarting the compressor. Component: Discharge Pressure Transducer (DPT) Troubleshooting: Confirm accurate DPT pressure readings. See Refrigerant Service, Section 7.1.
  • Page 78 Component: Non-condensables in the refrigeration system Troubleshooting: With the unit off, allow the system to stabilize to ambient temperature. Check system pressure against the Pressure / Temperature chart. Correct as required. See Refrigerant Service, Section 7.1. Component: Refrigerant Troubleshooting: Check refrigerant level. Correct as required. See Refrigerant Service, Section 7.1.
  • Page 79 AL251 Data Storage Fault (Non-Volatile Memory Fault) Cause: Controller memory failure Component: Controller Troubleshooting: 1. Press the ENTER key when “CLEAr” is displayed to attempt to clear the alarm. If the action is successful (all alarms are inactive), alarm 251 will reset. 2.
  • Page 80 AL256 Return Temperature Sensor (RTS) Fault Cause: The Return Temperature Sensor (RTS) reading is invalid. Component: Return Temperature Sensor (RTS) Troubleshooting: Perform a pre-trip P5. If P5 passes, no further action is required. If P5 fails, replace the defective sensor as determined by P5.
  • Page 81 AL261 Improper Heater Current Fault Cause: The current draw during heat or defrost mode is improper. Component: Heater(s) Troubleshooting: While in heat or defrost mode, check for proper current draw at the heater contactors. Reference the Electrical Data table in Section 3.10.
  • Page 82 AL266 Evaporator Pressure Transducer (EPT) Fault Cause: The Evaporator Pressure Transducer (EPT) is out of range. Component: Evaporator Pressure Transducer (EPT) Troubleshooting: Confirm accurate EPT pressure readings. See Refrigerant Service, Section 7.1. Performing a pre-trip P5-9 test will also check the transducers. Replace the EPT if defective. If the alarm persists, it may indicate a failing compressor.
  • Page 83 AL272 USDA1 Temperature Out of Range Cause: The USDA Temp 1 Sensor is out of range. Component: Sensor Troubleshooting: Validate sensor values. See the Sensor Checkout Procedure, Section 7.11.2. Replace the sensor if defective. If not, verify harness wiring and controller connections. AL273 USDA2 Temperature Out of Range Cause: The USDA Temp 2 Sensor is out of range.
  • Page 84 AL289 DataCorder Storage Fault Cause: The DataCORDER is unable to store data. Component: DataCORDER Troubleshooting: Power cycle the unit and verify that the alarm goes inactive. If the alarm stays active, replace the controller. See Controller Service, Section 7.9. AL293 Variable Frequency Drive (VFD) Fan Fault Cause: A fan error was detected while the VFD temperature is not exceeding trip level.
  • Page 85 AL910 Carbon Dioxide Sensor (CO2) Fault Cause: Triggered anytime the CO2 sensor reading is outside normal operation range, after an initial signal detected. Action: EverFRESH Air Compressor (EAC) 100% duty cycle and open the EverFRESH Air Valve (EA). Will prevent low O2 and cargo loss.
  • Page 86 Component: Water Drain Valve (WDV) Troubleshooting: A closed or plugged WDV or filter housing could prevent any air from entering the container. P20-3 tests valve operation. Potential failure results: • MPT pressure fails to change when the valve is energized. Check for signs of blockage by removing the WDV housing and particulate filter housings.
  • Page 87 AL977 Membrane Pressure Transducer (MPT) Fault Cause: When the EverFRESH Air Compressor (EAC) is running and pressure is not between -5 psig and 200 psig or the EAC has been OFF for five minutes and pressure is not within the range of -5 psig and 5 psig. Component: Membrane Pressure Transducer (MPT) Troubleshooting:...
  • Page 88 AL980 EverFRESH Air Valve (EA) Fault Cause: When the system energizes the EverFRESH Air Valve (EA) solenoid and membrane pressure does not drop 40 psi, the alarm is triggered. The alarm triggers OFF when membrane pressure transducer (MPT) pressure drop is more than 40 psi when EA is opened.
  • Page 89 AL983 CO2 Injection Pressure Transducer (IPT) Fault Cause: If unit is configured with the CO2 injection option, this alarm is triggered when Cd76 is set to “On” to enable CO2 injection and volts are not in the range of 0.5 to 4.95 VDC. Component: CO2 Injection Pressure Transducer (IPT) Troubleshooting:...

  • Page 90: Pre-Trip Inspection

    4.5 Pre-Trip Inspection Pre-Trip Inspection is an independent controller function that suspends the normal refrigeration control mode activities and provides pre-programmed test routines of unit operations. The test routines can be run in Auto Mode, which automatically performs a sequence of pre-programmed tests, or Manual Mode, which allows individual tests to be selected with the keypad.

  • Page 91: Pre-Trip Test Codes

    4.5.4 Pre-Trip Test Codes A summary of alarms is provided in Table 4–5, and completed descriptions below the table. Table 4–5 Pre-Trip Codes Summary Code Description Auto 1 Auto 2 Auto 3 P0-0 RMU Detection P1-0 Heaters On P1-1 Heaters Off P2-0 Low Speed Condenser Fan On P2-1...
  • Page 92 Configuration Display, Indicator Lamps, LEDs and Displays Container identifier code, Cd18 Software Revision Number, Cd20 Container Unit Model Number, & configuration database identifier CFMMYYDD are displayed in sequence. Next the unit will indicate the presence or non- presence of an RMU according to whether any RMU inquiry messages have been received since the unit was booted.
  • Page 93 P3-0 Low Speed Evaporator Fan Motors On The low speed evaporator fans start in the off condition and current draw is measured. The low speed evaporator fan contactor is energized and the current draw is measured for 4 seconds. The change in current draw is then recorded.
  • Page 94 P5-9 Primary vs. Secondary Evaporator Pressure Transducer This is a Pass / Fail test of the primary evaporator pressure transducer and secondary evaporator pressure transducer. The test passes if pressure difference between the two pressure transducers is within tolerance as noted below: •...

  • Page 95: Perishable Mode

    P6-7 Evaporator Expansion Valve (EEV) The variable frequency drive (VFD) holds the compressor speed steady while the EEV is closed. Test passes if the pressure variation meets the criteria. P6-8 Economizer Expansion Valve (ECV) After suction pressure is reduced, the compressor is shut off and the valves are closed. When the economizer expansion valve (ECV) opens, the pressure variation is checked.
  • Page 96 Defrost Termination Thermostat (DTT) For the P9 tests, the defrost termination thermostat (DTT) in this control is not a physical device, with actual metallic contacts. It is a software function that acts similar to a thermostat. Using various temperature inputs, the DTT function determines whether a thermostat mounted on the evaporator coil would have OPEN or CLOSED contacts.

  • Page 97: 4.6 Controller Communications

    4.6 Controller Communications The ML5 controller allows the following methods for connectivity, as shown in Figure 4.5: • Micro USB port allows USB connection to PC for advanced functions • Wireless connection (short-range) capability for remote access via the ContainerLINK™ app •...

  • Page 98: Wireless Connection

    4.6.2 Wireless Connection The ML5 controller offers short range wireless connectivity through wireless 802.11 b/g/n. Wireless connectivity may only operate when ambient temperatures are above -20°C (-4°F). Connectivity will be intermittent below this temperature. A mobile device can wirelessly connect to the ML5 controller using Carrier’s ContainerLINK™ app, which provides container technicians with access to a suite of tools and resources from one location.

  • Page 99: Figure 4.7 Containerlink - View Real Time Data

    ContainerLINK will also display real time data from the unit in the app when a connection is established. The following components and details can be monitored, see Figure 4.7: • System status including: control mode, operating mode, box temperature, and alarms. •...
  • Page 100 2. On the display, look up the six character wireless password. The password changes every four hours. a. Press the ALT MODE key. b. Use the Arrow keys to display "nEt", then press ENTER. c. Use the Arrow keys to display "PASSW EntR", then press ENTER. d.
  • Page 101 2. Depending on the mobile device, all available networks (along with Container IDs) within range may appear. Choose a Container ID to connect to. See Section 4.6.2.1 for obtaining Container ID. On some mobile devices, this screen is bypassed and the Login screen appears directly. 3.
  • Page 102 4. If a prompt asks to Join the network, select Join. After clicking Connect, a message will appear “Connected to the WIFI Successfully”. Click OK to begin using the connected features of ContainerLINK™. 4.6.2.3 Connecting a Laptop with ContainerLINK to a Unit This procedure explains how to enter wifi settings for a particular container unit into the ContainerLINK app to establish a connection to the unit.
  • Page 103 2. Choose the container unit to connect from the Select SSID box. After selecting, the ID is filled into the Container ID box on the right. Type in the password and click Connect. See Section 4.6.2.1 for container ID and password information. Container ID Password COOL...

  • Page 104: Optional Interrrogator Ports Connection

    4.7.1 DataCORDER Description Carrier Transicold DataCORDER software is integrated into the controller and serves to eliminate the temperature recorder and paper chart. DataCORDER functions are accessed by keypad selections and viewed on the display. The DataCORDER consists of the following components: •...
  • Page 105 The Generic Mode allows user selection of up to eight network data points to be recorded. Changing the configuration to generic and selecting which data points to record may be done using the Carrier Transicold Data Retrieval Program. A list of the data points available for recording follows.

  • Page 106: Datacorder Operational Software

    Table 4–7 DataCORDER Sensor Configurations Standard Config Description 2 sensors (dCF02=2) 2 thermistor inputs (supply & return) 5 sensors (dCF02=5) 2 thermistor inputs (supply & return) 3 USDA thermistor inputs 6 sensors (dCF02=6) 2 thermistor inputs (supply & return) 3 USDA thermistor inputs 1 humidity input 6 sensors (dCF02=54) 2 thermistor inputs (supply &...
  • Page 107 Descriptions of DataCORDER function codes are provided in the following paragraphs. dC1 - Recorder Supply Temperature Current reading of the Supply Recorder Sensor (SRS). dC2 - Recorder Return Temperature Current reading of the Return Recorder Sensor (RRS). dC3 - USDA 1 Temperatures Current readings of the USDA #1 probe.

  • Page 108: Datacorder Power Up

    4.7.4 DataCORDER Power Up The DataCORDER may be powered up in any one of the following methods: 1. Normal AC power: The DataCORDER is powered up when the unit is turned on via the Stop-Start switch. 2. Controller DC battery pack power: If a battery pack is installed, the DataCORDER will power up for communication when the user presses the battery key.

  • Page 109: Operation

    Section 5 Operation 5.1 Inspecting the Unit WARNING Beware of unannounced starting of the evaporator and condenser fans. The unit may cycle the fans and compress or unexpectedly as control requirements dictate. 1. Check inside the unit for the following conditions: •...

  • Page 110: 5.3 Starting And Stopping Instructions

    5.3 Starting and Stopping Instructions WARNING Make sure that the unit circuit breaker(s) (CB-1 & optional CB-2) and the Start-Stop switch (ST) are in the “O” (OFF) position before connecting to any electrical power source. NOTE: The electronic phase detection system will check for proper compressor rotation within the first 30 seconds.

  • Page 111: Upper Fresh Air Makeup Vent

    5.5.1 Upper Fresh Air Makeup Vent Two slots and a stop are designed into the Upper Fresh Air disc for air flow adjustments. The first slot allows for a 0 to 30% air flow; the second slot allows for a 30 to 100% air flow. To adjust the percentage of air flow, loosen the wing nut and rotate the disc until the desired percentage of air flow matches with the arrow.

  • Page 112: Displaying Pre-Trip Test Results From The Keypad

    3. To Run an Automatic Test: Scroll through the selections by pressing the Arrow keys to display AUtO1, AUtO2 or AUtO3 as desired, then press the ENTER key. • The unit will execute the series of tests without any additional need for user interaction. These tests vary in length, depending on the component under test.

  • Page 113: Probe Disagreement

    In Perishable Mode, both pairs of supply and return probes are monitored for probe disagreement. Probe disagreement is considered a difference of 0.5°C (0.9°F) or greater between the supply air sensors and / or a difference of 2.0°C (3.6°F) between the return air sensors. Probe disagreement found in either pair can trigger a defrost probe check. In Frozen Mode, only the controlling probes are considered.
  • Page 114 NOTE: The expiration interval is the total maximum days allowed between the running of each test. For example, if days are set to 30 and the low speed evaporator fan test has not run within those 30 days, the TripWise expired message will be displayed. If the TripWise expired message is displayed, it is recommended to Pre-Trip the unit following customer specific guidelines prior to the next trip.

  • Page 115: Automatic Setpoint Change (Asc) Mode

    8. The display will show “SPnEW | ##.#°C” with the right display flashing the setpoint for when cold treatment process has completed. Use the Arrow keys to select the setpoint and press ENTER to confirm. COOL HEAT DEFROST IN RANGE ALARM SUPPLY RETURN...

  • Page 116: Pharma Mode

    13. The Cd53 menu is returned to the top level and the display will show “Cd 53 | 0 0“. Upon exiting Cd53 and then returning, the display will now show “Cd 53 | # #“, where the right display is the countdown timer of days and hours remaining.
  • Page 117 4. The CO2 setpoint is displayed. “CO2SP” appears in the left display with the setpoint value blinking in the right display. Use the Arrow keys to change the setpoint and press ENTER to confirm. Or, just press ENTER to keep the originally displayed value. 5.

  • Page 119: Figure 6.1 Unit Troubleshooting Sequence

    Section 6 Troubleshooting Figure 6.1 Unit Troubleshooting Sequence Start Troubleshooting Section 5.2 Connecting Check Power Unit does Power Procedure. self test? Supply Section 5.2 Connecting Check Power Evaporator Power Procedure. Supply fans start? Install Latest Section 7.10 Controller Correct Software software Software Loading Procedure.

  • Page 120: Table 6-1 Troubleshooting Symptoms

    Table 6–1 Troubleshooting Symptoms Condition Possible Cause Remedy / Reference Unit will not Start or Starts then Stops External power source OFF Turn on No power to unit Start-Stop switch (ST) OFF or defective Check Circuit breaker tripped or OFF Check Circuit breaker OFF or defective Check...
  • Page 121 Table 6–1 Troubleshooting Symptoms (Continued) Condition Possible Cause Remedy / Reference Unit Runs but has Insufficient Cooling Abnormal pressures Section 6.7 Abnormal temperatures Section 6.13 Abnormal currents Section 6.14 Controller malfunction Section 6.9 Refrigeration system Evaporator fan or motor defective Section 7.7 Compressor service valves or liquid line shutoff valve par- Open valves complete-...

  • Page 122: Figure 3.7 Compressor

    Table 6–1 Troubleshooting Symptoms (Continued) Condition Possible Cause Remedy / Reference Manual defrost switch defective Replace Will not initiate defrost Keypad defective Replace manually Defrost Temperature Sensor (DTS) open Replace Initiates but relay (DR) drops Line voltage is low Section 3.10 Heater contactor or coil defective Replace Initiates but does not defrost...
  • Page 123 Table 6–1 Troubleshooting Symptoms (Continued) Condition Possible Cause Remedy / Reference Microprocessor Malfunction Software and/or controller configuration incorrect Check Sensor defective Section 7.11 Will not control Wiring defective Check Refrigerant charge low 6.10 No Evaporator Air Flow or Restricted Air Flow Coil has frost build-up Section 6.6 Evaporator coil blocked...
  • Page 124 Table 6–1 Troubleshooting Symptoms (Continued) Condition Possible Cause Remedy / Reference 6.13 Abnormal Temperatures Condenser coil dirty Section 7.3 Condenser fan rotating backwards Section 7.3 Condenser fan inoperative Section 7.3 Refrigerant overcharge or non-condensibles Discharge service valve partially closed Open Electronic Expansion Valve (EEV) control malfunction Replace High discharge temperature...

  • Page 125: Section 7 Service

    The manifold gauge set with self-sealing hoses and couplers is required for service of the models covered within this manual. The set is available from Carrier Transicold, part number 07-00294-00 or 07-00294-05 (metric). Hoses are refrigeration and/or evacuation hoses (SAE J2196/R-134a).

  • Page 126: Figure 7.2 Manifold Gauge Set Layout

    The gauge set layout with hoses and couplings is shown in Figure 7.2. The gauge set connects to the service connections on the refrigeration unit using the blue and red hoses. Service connections are described in Section 7.1.3. The yellow hose is a utility connection that can be connected to a a refrigerant cylinder or vacuum pump. Once connected, the following procedures can be performed: •...

  • Page 127: Service Connections

    7.1.2 Evacuating the Manifold Gauge Set If a manifold gauge set is new or was exposed to the atmosphere, it will need to be evacuated to remove contaminants and air. This is done while the gauge set blue and red hoses are not connected to the service connections.

  • Page 128: Connecting The Manifold Gauge Set

    7.1.4 Connecting the Manifold Gauge Set Connection of the manifold gauge set is dependent on the procedure performed or components serviced. For reading system pressures, performing a manual pump down, or checking refrigerant charge, the manifold gauge set connects to the suction service valve (blue hose) and discharge service valve (red hose): •...

  • Page 129: Figure 7.5 Connection For Adding A Partial Charge

    Figure 7.5 Connection for Adding a Partial Charge 1) Manifold Gauge Set 4) Compressor 2) Discharge Service Valve 5) Refrigerant Cylinder 3) Suction Service Valve - - - - - Figure 7.6 Connection for Adding a Full Charge (Liquid) 1) Manifold Gauge Set 4) Compressor 2) Liquid Line Service Valve 5) Refrigerant Cylinder...

  • Page 130: Figure 7.7 Connection For Evacuation And Dehydration

    Figure 7.7 Connection for Evacuation and Dehydration 1) Manifold Gauge Set 5) Compressor 2) Liquid Line Service Valve 6) Vacuum Gauge 3) Discharge Service Valve 7) Refrigerant Recovery System 4) Suction Service Valve 8) Vacuum Pump - - - - - 7.1.4.1 Connect the Manifold Gauge Set to Access Valves 1.

  • Page 131: Checking The Refrigerant Charge

    7.1.5 Reading System Pressures 1. Connect the manifold gauge set to the suction service valve and discharge service valve. Section 7.1.4.1 for procedure to connect to valves. See Figure 7.4 for connection diagram. 2. Make sure both hand valves on the manifold gauge set are fully closed. 3.

  • Page 132: Refrigerant Leak Checking

    7.1.6.3 Adding Refrigerant to System - Partial Charge 1. Examine the refrigerant system for any evidence of leaks, and repair as necessary. See Section 7.1.7. 2. Maintain the conditions outlined in the beginning of this section. See Section 7.1.6.1. 3. Fully backseat the suction service valve and remove the service port cap. 4.
  • Page 133 7.1.8.2 Evacuating and Dehydrating - Complete System 1. Remove all refrigerant using the refrigerant recovery system. First recover liquid refrigerant from the receiver. Then, finish the recovery procedure in vapor mode. Connect a manifold gauge set to a refrigerant recovery system (blue hose), electronic micron gauge (red hose) and a vacuum pump (yellow hose).

  • Page 134: Replacing The Compressor

    7.2 Compressor WARNING Make sure the start/stop switch is OFF, unit circuit breaker (CB-1) is OFF and the power plug disconnected before servicing unit components or moving parts. Follow local lockout / tagout procedures for working on equipment. WARNING The compressor can run at hot surface temperatures. A compressor shield is in place to prevent contact with the compressor.

  • Page 135: Figure 7.8 Compressor Base Mounting Hardware

    11. Wire tie the power cable to the compressor. 12. Slide the new compressor into the unit. NOTE: DO NOT add any oil to the replacement compressor, as it is shipped with a full oil charge. 13. Reusing the hardware from the old compressor, place the washers on each side of the bushing, and the new Mylar washer on the bottom of it as shown in Figure 7.8.

  • Page 136: Figure 7.9 Variable Frequency Drive (Vfd)

    7.2.2 Replacing the Variable Frequency Drive (VFD) The compressor variable speed synchronous motor is driven by a variable frequency drive (VFD), shown in Figure 7.9. NOTE: When a VFD fails, it can not be bypassed and therefore the compressor will not run. Figure 7.9 Variable Frequency Drive (VFD) CAUTION Electrical Hazard.
  • Page 137 3. Open the VFD service cover to gain access to the wiring. 4. Release both sets of wires (compressor power cable and line power cable) from the VFD terminals. Make a note of the exact wire position as the same connections must be done on the replacement VFD. 5.
  • Page 138 2. Remove the bracket / guard below the control box for better access to the VFD. Save the mounting hardware. Note: the compressor guard may also need to be removed to gain proper access. 3. Open the VFD service cover to gain access to the fan assembly. 4.
  • Page 139 5. Remove (pull out) the red and black fan wires from the terminal. This is done by inserting a small flathead screwdriver in the terminal hole above the wire to be removed, followed by a gentle lifting the screwdriver until the terminal jaws open and the wire is free to be pulled out.
  • Page 140 7. Pull the lower end of the fan assembly radially out. Use a screwdriver to pull out the fan assembly if needed. 8. The replacement fan (part # 10-00560-31) comes with new wire grommet installed. Assemble the replacement VFD fan by reversing the order of the above steps: a) Secure the fan by tightening the torx bolt.

  • Page 141: Figure 7.10 High Pressure Switch Testing With Nitrogen

    Figure 7.10 High Pressure Switch Testing with Nitrogen 1) Cylinder Valve 5) Pressure Gauge (0 to 36 kg/cm2 = 0 to 400 psig) 2) Cylinder Gauge 6) Bleed-Off Valve 3) Pressure Regulator 7) 1/4 inch Connection 4) Nitrogen Cylinder - - - - - 7.2.5 Replacing the High Pressure Switch 1.
  • Page 142 7.3.2 Removing the Condenser Coil 1. Using a refrigerant reclaim system remove the refrigerant charge. 2. Turn the unit start-stop switch (ST) and unit circuit breaker (CB-1) off and disconnect power to the unit. 3. Remove the condenser fan grille. Retain all bolts and washers for reuse. 4.

  • Page 143: Figure 7.11 Condenser Fan Position

    8. Secure the receiver assembly to the side support bracket. 9. Pressure / leak test the coil and filter drier connections. See Section 7.1.7. 10. Evacuate the entire unit. See Section 7.1.8. 11. Slide the top and bottom drain lines back into place through the side support bracket. 12.

  • Page 144: Water-Cooled Condenser Cleaning

    5. Note the number of shims on each side of the motor. The same configuration is required to refit the new motor. 6. Remove the fan motor mounting hardware and remove the motor. 7. Loosely mount the new motor using new lock nuts. 8.

  • Page 145: Filter Drier

    7.4.2 Cleaning Procedure Detailed 1. Drain and flush the water circuit of the condenser coil. If scale on the tube inner surfaces is accompanied by slime, a thorough cleaning is necessary before de-scaling process can be accomplished. 2. To remove slime or mud, use Aluminum Cleaner® 164. Mix 170 grams (6 ounces) per 3.785 liters (1 U.S. gallon) of water.

  • Page 146: Pressure Relief Valve

    Figure 7.12 Filter Drier 7.5.1 Checking the Filter Drier 1. Test for a restricted or plugged filter drier by feeling the liquid line inlet and outlet connections. If the outlet side feels cooler than the inlet side, then the filter drier should be changed. 2.

  • Page 147: Evaporator Section Cleaning

    HD) for the unit. This will assist in helping to remove the corrosive fumigation chemicals and dislodging of the corrosive elements. This cleaner is available from the Carrier Transicold Performance Parts Group (PPG) and can be ordered through any of the PPG locations; Part Number NU4371-88.

  • Page 148: Cleaning Procedure

    7.7.1.2 Cleaning Procedure 1. Remove the upper evaporator access panel inside of the unit. 2. Spray the surface with water before applying the cleaning solution. This helps the cleaner work better. 3. Liberally apply the prepared cleaner solution (5 parts water and 1 part cleaner). 4.
  • Page 149 All of the checks performed during this procedure should be carried out using a 500v Meg-ohm tester. 1. Connect the ground wire from the insulation tester to a fixed ground point, preferably the ground plate in the control box. 2. At the load side of the heater contactor, check the insulation resistance to ground. If readings are >...
  • Page 150 a) With the heater pair identified, remove the upper back panel inside the container. b) Identify the center point connection for the heater pair (black wiring from heaters) either against the unit back wall or in the wiring loom. c) Cut the splice to separate the two heaters. d) Carry out a Megger check on the two heaters in the same way as for units with heater panel.

  • Page 151: Figure 7.14 Access Panel Torque Pattern

    3. Place one 5/8 flat washer on the shoulder of the fan motor shaft. Insert the key in the keyway and lubricate the fan motor shaft and threads with a graphite-oil solution (such as Never-seez). 4. Install the fan onto the motor shaft. Place one 5/8 flat washer with a 5/8-18 locknut onto the motor shaft and torque to 40 foot-pounds.

  • Page 152: Figure 7.16 Economizer Expansion Valve (Ecv)

    The Economizer Expansion Valve (ECV), as shown in Figure 7.16, maintains superheat of the refrigerant gas leaving at the point of bulb attachment, regardless of suction pressure. Figure 7.16 Economizer Expansion Valve (ECV) The Electronic Expansion Valve (EEV, as shown in Figure 7.17, maintains superheat of the refrigerant gas leaving the evaporator.

  • Page 153: Handling Modules

    1. Obtain a grounding wrist strap (Carrier Transicold P/N 07-00304-00) and a static dissipation mat (Carrier Transicold P/N 07-00277-00). The wrist strap, when properly grounded, will dissipate any potential static buildup on the body.

  • Page 154: Installation

    4. Using a Driver Bit, Carrier Transicold part number 07-00418-00, loosen the left hand screw on the battery pack cover then remove the second screw on the outer edge of the battery pack cover.

  • Page 155: Ac Line Filter

    7.9.4 AC Line Filter There is an AC Line Filter installed between the Control Transformer and the PW Connector on the ML5 controller. This filter reduces Electromagnetic Voltage Transients induced / coupled on to the 36 VAC Control Transformer secondary of the Transformer. When the AC Line filter fails, 18 VAC will not be provided to the controller and the system will not power up.
  • Page 156 4. With the power filter removed, check for a capacitance reading of 0.54 uF +/-10% across pins 1 and 3. And then across pins 2-4. 5. Each individual pin can also be verified between the ground pin #5 and 1, 2, 3, 4. Testing each individual pin to the ground pin should read a capacitance of 0.011 uF +/-10%.
  • Page 157 6. Final check on the power filter is to verify the discharge resistor on the power filter output. Check resistance between pins 2 and 4 on the load side of the power filter for 330k +/- 10%. Ώ 7. Reinstall the power filter. Install the right side of the power filter to the bracket with ground leads.Then, install the mounting screw on the right side of the power filter.
  • Page 158 7.9.4.2 Filter Emergency Bypass Procedure 1. Connect the following with a 7.5 Amp automotive type fuse and cover the connections with electrical tape: • PF1-TRX4 to ST5-PF2 • PF3-TRX3 to STS2-PF4 7.10 Controller Programming Procedures Notes Regarding USB Devices: • The USB must have an ML5 software file or ML5 configuration file on the root level.

  • Page 159: Setting The Date And Time

    7. Press the ENTER key to load the software to the controller. The display will flash “LoAd SoFt”. 8. When “CAn PULL” and “USb noW” appears on the displayed, remove the USB drive from the port. 9. The display will flash “Pro SoFt”, then display “rE StArt” and “StArt UP” after that. 10.

  • Page 160: Temperature Sensor Service

    7.10.5 Setting the Container ID This procedure explains how to set the Container ID, which can be found in Function Code Cd40. The characters will be preset to the container ID of the box that the refrigeration unit was originally commissioned in. If no ID has been loaded, Cd40 will show dashes as the ID will be invalid.

  • Page 161: Figure 7.18 Controller Harness Tool

    a) Crush or chip the ice to completely fill the container. Finer ice particles will produce a more accurate mixture. b) Add enough pre-cooled distilled water to fill the container. c) Stir the mixture for a minimum of 2 minutes to ensure water is completely cooled and mixture is good. d) The mixture should generally contain about 85% ice with distilled water occupying the rest of the space.
  • Page 162 3. Locate the proper wires to be ohmed by referring to the system schematic. 4. Check against the temperature resistance chart provided in Table 9–1 Table 9–2. 7.11.4 Supply and Return Sensor Calibration - GDP European Commission GDP (Good Distribution Practices) guidelines, used worldwide, call for the equipment that controls or monitor environments where medicinal products are stored or transported be calibrated in accordance with pharmaceutical shipper specifications, typically every six months or annually.
  • Page 163 GDP Calibration, Removing Supply Sensors (STS / SRS) from Unit: 1. Locate the supply sensors cover assembly on the suction side of the compressor. Remove the two fasteners securing the cover of the sensors. Remove the cover and rotate the supply air sensors, STS / SRS, in a clockwise direction and remove the sensors from the sensor housing.
  • Page 164 3. Loosen the fastener on the sensor bracket. 4. Cut all the wire ties that are securing the sensors to the harness and remove sensor. GDP Calibration, Perform Calibration: WARNING Before powering on the unit, it is important to ensure that all dismantling work is done and tools are away and service personnel are not working on the unit at the time of power on.

  • Page 165: Usda Cold Treatment

    6. Place the ice bath in a location near sensors. For Return Sensors, place the ice bath on an elevated platform or ladder of appropriate height. 7. Once temperature stability is ensured, submerge the sensors in the ice water slurry. Make certain that the sensors do not contact the container sides or bottom, or each other.

  • Page 166: Replacing A Sensor

    USDA Cold Treatment Procedure: The following is a summary of the steps required to initiate a USDA Cold Treatment. 1. From the ContainerLINK application, navigate to the Container > System Configuration screen. Then, select the DataCorder Configuration tab. 2. Verify that the DataCORDER is configured as follows and then close all screens when finished: •...

  • Page 167: Figure 7.19 Sensor Types

    Figure 7.19 Sensor Types 40 mm (1 1/2 in) 2 or 3 wires as required 6.3 mm (1/4 in) 40 mm (1 1/2 in) 2 or 3 wires as required 6.3 mm (1/4 in) 1. Turn unit power off (“0”) at the Start-Stop switch (ST). Disconnect the power supply. 2.

  • Page 168: Figure 7.21 Supply Sensor (Sts / Srs)

    13. Position sensor in unit as shown in Figure 7.20 and re-check sensor resistance. • Supply Sensor (STS / SRS) Positioning, see Figure 7.21 • Return Sensor (RTS / RRS) Positioning, see Figure 7.22 • Evaporator Temperature Sensor (ETS1 / ETS2) Positioning, see Figure 7.23 14.

  • Page 169: Figure 7.22 Return Sensor (Rrs / Rts)

    7.11.8 Installing a Return Sensor (RTS / RRS) Reinstall the Return Temperature or Return Recorder sensor (RTS / RRS), as shown in Figure 7.22. For proper placement of the return sensor, be sure to position the enlarged positioning section of the sensor against the side of the mounting clamp.

  • Page 170: Figure 7.24 Compressor Discharge Temperature Sensor (Cpds)

    Figure 7.24 Compressor Discharge Temperature Sensor (CPDS) CPDS 1. Ensure the unit is disconnected from the power source. 2. Verify that the Start-Stop switch (ST) is in the “0” position. 3. Remove the existing sensor. 4. Clean all silicone sealer and dielectric compound from the sensor well. Make sure that the well is clean and dry.
  • Page 171 7.12.2 Checking the Humidity Sensor This procedure is to be performed in an effort to ease the troubleshooting of the humidity sensor. When performing this procedure and while working on the unit, always follow the proper lockout / tagout procedures. Items Required: •...

  • Page 172: Vent Position Sensor (Vps)

    7.12.3 Vent Position Sensor (VPS) The optional vent position sensor (VPS) determines fresh air vent position in near real-time via function code Cd45. The fresh air vent position sensor alarm (AL250) will occur if the sensor reading is not stable for four minutes or if the sensor is outside of its valid range (shorted or open).

  • Page 173: Maintenance Of Painted Surfaces

    Signal Range Condition Recommended Action 21 to 16°C Cargo Sensor Fault 1. Verify wiring to interrogator port #4 inside container. 2. Check IR sensor window on cargo sensor for obstruction. 3. Replace cargo sensor. 14 to 9°C Cargo present, battery low No immediate action, replace battery before next trip 7°...
  • Page 175 Section 8 Electrical Schematic and Wiring Diagrams This chapter contains sets of electrical schematics and wiring diagrams for the technician to reference when troubleshooting the unit. Each set contains four pages. The Schematic Legend is the first page of each set. It lists the components that are contained in the second page Schematic, along with a coordinate location.
  • Page 176 Electrical Schematic and Wiring Diagrams Legend - Unit Models 701-001 to 099 T-383...
  • Page 177 Electrical Schematic and Wiring Diagrams Schematic Diagram - Unit Models 701-001 to 099 T-383...
  • Page 178 Electrical Schematic and Wiring Diagrams Wiring Diagram (Sheet 1) - Unit Models 701-001 to 099 T-383...
  • Page 179 Electrical Schematic and Wiring Diagrams Wiring Diagram (Sheet 2) - Unit Models 701-001 to 099 T-383...
  • Page 180 Electrical Schematic and Wiring Diagrams Legend - Unit Models 701-100 to 149 T-383...
  • Page 181 Electrical Schematic and Wiring Diagrams Schematic Diagram - Unit Models 701-100 to 149 T-383...
  • Page 182 Electrical Schematic and Wiring Diagrams Wiring Diagram (Sheet 1) - Unit Models 701-100 to 149 T-383...
  • Page 183 Electrical Schematic and Wiring Diagrams Wiring Diagram (Sheet 2) - Unit Models 701-100 to 149 T-383...

  • Page 185: Sensor Resistance Tables

    Section 9 Appendix 9.1 Sensor Resistance Tables Table 9–1 Sensor Resistance - AMBS, DTS, ETS, RRS, RTS, SRS, STS °C °F OHMS °C °F OHMS 336,500 42.8 24,173 -38.2 314,773 44.6 23,017 -36.4 294,600 46.4 21,922 -34.6 275,836 48.2 20,886 -32.8 258,336 19,900...

  • Page 186: Table 9-2 Sensor Resistance - Cpds

    Table 9–2 Sensor Resistance - CPDS °C °F OHMS °C °F OHMS 849,822 64.4 136,705 -36.4 834,450 68.0 124,876 -32.8 819,079 71.6 114,101 -29.2 803,707 75.2 104,352 -25.6 788,336 100,000 -22.0 772,964 78.8 95,585 -18.4 757,593 82.4 87,619 -14.8 742,221 83.0 80,447 -11.2...

  • Page 187: Table 9-4 R-134A Refrigerant Pressure Temperature Chart

    9.2 Refrigerant Pressure Temperature Charts Table 9–4 R-134a Refrigerant Pressure Temperature Chart Note: Underline figures are inches of mercury vacuum °F °C PSIG °C °F -40.0 14.8 -40.0 -0.49 -38.9 13.9 -38.2 -0.46 -37.8 13.0 -36.4 -0.43 -36.7 12.0 -34.6 -0.40 -35.6 10.9...
  • Page 188 Table 9–4 R-134a Refrigerant Pressure Temperature Chart Note: Underline figures are inches of mercury vacuum °F °C PSIG °C °F 18.9 65.4 55.4 3.58 20.0 68.2 57.2 3.73 21.1 71.1 59.0 3.88 22.2 74.1 60.8 4.04 23.3 77.1 62.6 4.21 24.4 80.2 64.4...

  • Page 189: Table 9-5 R-513A Refrigerant Pressure Temperature Chart

    Table 9–5 R-513A Refrigerant Pressure Temperature Chart Note: Underline figures are inches of mercury vacuum °F °C PSIG °C °F -40.0 -40.0 -0.32 -38.9 -38.2 -0.28 -37.8 -36.4 -0.25 -36.7 -34.6 -0.21 -35.6 -32.8 -0.17 -34.4 -31.0 -0.13 -33.3 -29.2 -0.09 -32.2 -27.4...
  • Page 190 Table 9–5 R-513A Refrigerant Pressure Temperature Chart Note: Underline figures are inches of mercury vacuum °F °C PSIG °C °F 18.9 78.7 55.4 4.39 20.0 81.8 57.2 4.56 21.1 85.0 59.0 4.73 22.2 88.2 60.8 4.91 23.3 91.6 62.6 5.09 24.4 95.0 64.4...

  • Page 191: Table 9-6 Recommended Bolt Torque Values (Dry, Non-Lubricated For 18-8 Stainless Steel)

    9.3 Bolt Torque Values Table 9–6 Recommended Bolt Torque Values (Dry, Non-Lubricated for 18-8 Stainless Steel) Bolt Diameter Threads In-Lbs Ft-Lbs Free Spinning 5/16 14.9 27.1 7/16 58.3 9/16 77.3 1104 124.7 1488 168.1 Non Free Spinning (Locknuts etc.) 82.5 5/16 145.2 12.1...

  • Page 193: Eu Declaration Of Conformity

    Serial Number: Manufacturing Date: __________-__________ ___________ We, manufacturer: Carrier Transicold Pte Ltd 251 Jalan Ahmad Ibrahim Singapore 629146 Declare, under our sole responsibility, that the OptimaLINE Container Unit: Model: 69NT40-701 is in conformity with the provisions of the following European Directives: •...

  • Page 194: Machinery Directive

    Serial Number: Manufacturing Date: __________-__________ ___________ We, manufacturer: Carrier Transicold Pte Ltd 251 Jalan Ahmad Ibrahim Singapore 629146 Declare, under our sole responsibility, that the OptimaLINE Container Unit: Model: 69NT40-701-100 to 199 is in conformity with the provisions of the following European Directives: •...

  • Page 195: Wireless Certification

    Section 11 Wireless Certification Product name: Micro-Link 5 Controller Model name: ML5 Manufacturer: UTEC for Carrier Transicold Pte. Ltd Made in China CMIIT ID: XXXXXXXXXX IC: 703A-MICROLINK5 FCC ID: KC Number: Anatel Number: 2AK6N-MICROLINK5 R-C-Ctd-ML5 04787-19-12327 CCAJ19LP5180T0 R 018-190082 TA-2019/684 This device complies with Part 15 of the FCC Rules.
  • Page 196 China RoHS per SJ/T 11364-2014 产品中有害物质的名称及含量 有害物质 铅 汞 镉 六价铬 多溴联苯 多溴二苯醚 部件名称 (Pb) (Hg) (Cd) (Cr (VI)) (PBB) (PBDE) 金属板部件 塑料部件 盘管组件 加热部件 马达，压缩机与风扇组件 温度控制微处理器系统 断路器与接触器 变压器 传感器 通讯组件 阀组件 电缆线/电源 电池 标签与绝缘材料 玻璃部件 本表格依据 SJ/T 11364 的规定编制。 O：表示该有害物质在该部件所有均质材料中的含量均在...
  • Page 197 Index Numerics Ambient Temperature Sensor (AMBS) Description 3– 460 Volt Cable 2–4 Automatic Cold Treatment (ACT) Mode 5–6 Automatic Setpoint Change (ASC) Mode 5–7 Air Stream Sensors Descriptions 3–19 AL003 4–22 Back Panels 2–4 AL012 4–23 Battery 2–3 7–30 AL013 4–23 AL015 4–23 AL017 4–23 Cable Restraint 2–4...
  • Page 198 Cd65 4–13 dC04 4–59 Cd66 4–13 dC05 4–59 Cd67 4–13 dC14 4–59 Cd70 4–14 dC22 4–59 Cd71 4–14 dC23 4–59 Cd72 4–14 dC24 4–59 Cd73 4–14 dC28 4–59 Cd74 4–15 dC29 4–59 Cd75 4–15 dC30 4–59 Cd76 4–15 dC31 4–59 Cd77 4–15 dC32 4–59 Cd78 4–16...
  • Page 199 Evaporator Fan Operation 2–3 Evaporator Fans Location 3–3 Manifold Gauge Set 7–1 Evaporator Pressure Transducer (EPT) Description 3– Manifold Gauge Set Evacuate 7–3 Manifold Gauge Set Remove 7–6 Evaporator Section Description 3–3 Manifold Gauge Set, Connect 7–4 Evaporator Temperature Sensor (ETS1/2) Description Micro-Link 5 Microprocessor 4–1 3–18 Microprocessor 4–1...
  • Page 200 Pressure Readout 2–3 Pre-Trip Diagnosis 5–3 Upper Air 2–4 Probe Check 4–19 Upper Fresh Air Makeup Vent 2–4 5–3 Probe Diagnostics 5–4 USDA 2–3 Push Button Switches 4–2 USDA and Cargo Probes 3–22 USDA Cold Treatment 7–41 USDA Probes Description 3–22 Receiver Description 3–10 USDA Probes Location 3–3 Receiver Location 3–3...
  • Page 202 Carrier Transicold Division, Carrier Corporation P.O. Box 4805 Syracuse, NY 13221 USA www.carrier.com/container-refrigeration/...

This manual is also suitable for:

Optimaline 69nt40-701-099Optimaline 69nt40-701-100Optimaline 69nt40-701-149

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