Carrier 40 Operation & Service Manual
  1. Manuals
  2. Brands
  3. Carrier Manuals
  4. Refrigerator
  5. 40RM
  6. Operation & service manual
Carrier 40 Operation & Service Manual

Carrier 40 Operation & Service Manual

Truck refrigeration
Hide thumbs Also See for 40:
Table of Contents

Advertisement

Quick Links

Truck Refrigeration
MP
EVAPORATOR
TXV BULB
TXV
CONDENSER
RECEIVER
OPERATION & SERVICE
for
INTEGRA 40/50S
Truck Refrigeration Units
62--10630 Rev A

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 40 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Carrier 40

Summary of Contents for Carrier 40

  • Page 1 Truck Refrigeration EVAPORATOR TXV BULB CONDENSER RECEIVER OPERATION & SERVICE INTEGRA 40/50S Truck Refrigeration Units 62--10630 Rev A...
  • Page 2 OPERATION AND SERVICE MANUAL TRUCK REFRIGERATION UNIT Integra 40S Integra 50S...

  • Page 3: First Aid

    SAFETY SUMMARY GENERAL SAFETY NOTICES The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance of the equipment covered herein. The general safety notices are presented in the following three sections labeled: First Aid, Operating Precautions and Maintenance Precautions.
  • Page 4 SWITCH (see Figure 1-1) in the OFF position. To ensure unit is without power, remove power plug and remove battery negative cable. WARNING Ensure power to the unit is OFF and power plug is disconnected or vehicle engine is OFF and nega- tive battery cable is disconnected before replacing the compressor.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS PARAGRAPH NUMBER Page GENERAL SAFETY NOTICES ............Safety-1 FIRST AID .
  • Page 6 TABLE OF CONTENTS PARAGRAPH NUMBER Page 3.2.6.2 Heating ..............3.2.7 Abnormal Noise .
  • Page 7 Figure 1-5 Evaporator 3 Fans (Integra 50S) ........... .

  • Page 8: Description

    06VM306 (3 & 1 phase) 64 lb (29kg) 192 lb 192 lb 320 lb 320 lb 06VM307 (3 phase) (87 kg) (145 kg) TM 16 86 lb (39 kg) 06VM306 (1 phase) NAMEPLATE EMERGENCY SWITCH CAB COMMAND Figure 1-1 Integra 50S 62-10630...

  • Page 9: Figure 1-2 Condenser

    Rectifier Bridge Assembly (RB) Condenser Fan Motor (CFM) Condenser Oil Separator Sight Glass Frame Assembly Filter--Drier Solenoid Coil Condenser Fan Condenser Pressure Control Valve (HGS2) Fan Guard Hot Gas Valve (HGS1) Transformer (TR) Heat Sink Figure 1-2 Condenser 62-10630...

  • Page 10: Figure 1-3 Control Box

    LOGIC BOARD THREE PHASE UNITS SINGLE PHASE UNITS Microprocessor Fused Disconnect (FB) -- Three Phase Only Standby Fuse (FS) Electronic Overload Relay (KR) Road Fuse (FR) Standby Contactor (MC) Harness Primary Transformer Fuses 1A Field Replaceable Fuse (12--00526--88) (F1,2,3 Three Phase Units -- F1 Single Phase Units) (Starting with Controller S/N 1997) Figure 1-3 Control Box 62-10630...

  • Page 11: Figure 1-4 Start Box (Single Phase Only)

    START BOX LOCATION (SINGLE PHASE ONLY) Start Capacitor Run Capacitor Resistor, Start Capacitor Discharge Start Relay Figure 1-4 Start Box (Single Phase Only) 62-10630...

  • Page 12: Figure 1-5 Evaporator 3 Fans (Integra 50S)

    Water Drain Hose Fitting Standby Suction Line Fitting Evaporator Coil Assembly Road Suction Line Fitting Compressor Pressure Regulating Valve (CPR) Liquid Line Fitting Heat Exchanger Liquid Line Check Valve Defrost Termination Thermostat (DTT) Figure 1-5 Evaporator 3 Fans (Integra 50S) 62-10630...

  • Page 13: Figure 1-6 Evaporator 2 Fans (Integra 40S)

    Road Suction Line Fitting Quench Valve Orifice Low Pressure Switch (LP) Expansion Valve Liquid Line Check Valve Evaporator Coil Assembly Liquid Line Fitting Compressor Pressure Regulating Valve (CPR) Standby Suction Line Fitting Figure 1-6 Evaporator 2 Fans (Integra 40S) 62-10630...

  • Page 14: Compressor Reference Data

    1.2 COMPRESSOR REFERENCE DATA Model TM 16 06VM306 06VM307 Displacement 163 cc 113 cc 130 cc No. Cylinders Weight 7 kg 37 kg 47 kg Oil Charge 250 ml 1200 ml 1200 ml Approved oil POE -- Mobil Arctic EAL 68 (Carrier Part Number 46-60002-02) 1.3 REFRIGERATION SYSTEM DATA e.

  • Page 15: Torque Values

    c. Compressor Motor Ratings Contactor data Contactor data Voltage Frequency Phase MRA* LRA* UNIT 230 / 400 60 Hz 1.491 11.8 45.1 208 / 230 60 Hz 1.491 15.6 78.7 230 / 400 60 Hz 1.491 11.8 45.1 208 / 230 60 Hz 1.491 15.6...

  • Page 16: Safety Devices

    Table 1-3 Safety Devices - - Microprocessor controller Automatic restart Unsafe Conditions Safety Device Device setting with fault cleared Excessive drop in pressure Automatic reset of low Cutout : --2.9 psig (-0.2 bar) pressure switch Timer 5 mn Excessive current draw on all mi- Electronic relay Self-protected opening croprocessor outputs (evaporator...

  • Page 17: Refrigerant Circuit During Cooling

    1.7 REFRIGERANT CIRCUIT DURING COOLING The evaporator tubes have aluminium fins to increase heat transfer; therefore heat is removed from the air When cooling (See Figure 1-7), the unit operates as a circulated through the evaporator. This cold air is vapor compression refrigeration system.

  • Page 18: Figure 1-7 Cooling Cycle

    21 22 DISCHARGE LIQUID SUCTION NORMALLY NORMALLY OPEN CLOSED Quench (Liquid Injection) Valve (BPV) Relief Valve Thermostatic Expansion Valve Standby Discharge Check Valve Heat Exchanger Standby High Pressure Switch (HP3) Hot Gas Solenoid Valve (HGS1) Standby Compressor Liquid Line Check Valve Road Compressor Sight Glass Quench (Liquid Injection) Thermostat (BPT)

  • Page 19: Figure 1-8 Heat/Defrost Cycle

    21 22 DISCHARGE LIQUID SUCTION NORMALLY NORMALLY OPEN CLOSED Quench (Liquid Injection) Valve (BPV) Relief Valve Thermostatic Expansion Valve Standby Discharge Check Valve Heat Exchanger Standby High Pressure Switch (HP3) Hot Gas Solenoid Valve (HGS1) Standby Compressor Liquid Line Check Valve Road Compressor Sight Glass Quench (Liquid Injection) Thermostat (BPT)

  • Page 20: Operation

    SECTION 2 OPERATION WARNING Beware of unannounced starting of the unit. The unit may cycle the fans and operating compressor unexpectedly as control requirements dictate. 2.1 INSPECTION 2.3 CAB COMMAND The Cab Command is mounted remote in the cab. The Before starting the truck engine or connecting standby Command consists of the green and red LED readouts, power check the following...

  • Page 21: Additional Key Functions

    Keys Press to display the elapsed time (min) since the last defrost Manual defrost control key Press to return to box temperature Unit start-up key 2.3.3 Unit Operating Data LED Status After an alarm (AXX) has been present for 15 minutes, Unit shut-down key in standby or road the red unit operating data LED flashes at 3 Hz.

  • Page 22: Starting

    During start up, the evaporator motor speed in- Modify parameters. creases continuously from 0 to 2100 rpm over a 30 seconds time period. Also, the hot gas valve Validate modified settings. is energized for 40 seconds seconds. Return to display of box tempera- ture. 2.5 STOPPING NOTE...

  • Page 23: Sequence Of Operation

    2.8 SEQUENCE OF OPERATION General operation sequences for cooling, null, and heating are provided in the following subparagraphs. +1_C (+1.8_F) COOL 2.8.1 Perishable Mode or +2_C (+3.6_F) The unit operates in the perishable mode with set points or +3_C (+5.4_F) above 10°F (--12°C) a.
  • Page 24 UNIT VOLTAGE OPTIONAL ROAD HEATING KIT PS12 : unit voltage 12 V hrOF : option road heating kit not installed PS24 : unit voltage 24 V hrOn : option road heating kit installed Press the + and -- keys to change PS12 or PS24.

  • Page 25: Alarm Display

    2.10 ALARM DISPLAY 2.10.2 Accessing Alarm Messages Current alarms will be displayed with an “A” preceding In the event of a malfunction the unit will be shut down the alarm number while past alarms will be displayed and the Cab Command will display an error message or with a “P”...
  • Page 26 Table 2-2 Alarm Messages - - Continued Compressor contactor (MC) open circuit Defrost cycle > 45 minutes Condenser fan motor (CFM) open circuit Setpoint adjusted out of the range Hot water solenoid valve (HWV) open --29°C/+30°C circuit Evaporator drain line heater (DWR) mal- Hot gas valve (HGS1) open circuit function Quench valve (BPV) open circuit...

  • Page 27: Troubleshooting

    SECTION 3 TROUBLESHOOTING WARNING Beware of unannounced starting of the unit. The unit may cycle the fans and operating compressor unexpectedly as control requirements dictate. To ensure unit will not start, place the EMERGENCY SWITCH (see Figure 1-1) in the OFF position. To ensure unit is without power, remove power plug and remove battery negative cable.
  • Page 28 Table 3-1 Alarm Indications - - Continued Reference ALARM Description CORRECTIVE ACTION Paragraph Hot Gas Valve (HGS1) Current draw of coil high or low (approx 1.6 amp) ---- hi h high amp draw Replace coil 4.14.1 Quench Valve (BPV) Current draw of coil high or low (approx 1.2 amp) ---- hi h high amp draw...

  • Page 29: Refrigeration

    Table 3-1 Alarm Indications - - Continued Reference ALARM Description CORRECTIVE ACTION Paragraph Return Air Sensor Return air sensor defective Replace Low Battery Voltage Vehicle battery voltage low Correct Low Battery Voltage Check alternator system ---- ------ Using Road & Standby opera- If operating on road, disconnect standby power sup- ---- ------...

  • Page 30: Abnormal Pressure

    Table 3-2 Mechanical Indications - - Continued REFERENCE INDICATION/TROUBLE POSSIBLE CAUSES SECTION 3.2.6 Abnormal Pressure 3.2.6.1 Cooling High discharge pressure Condenser coil dirty Noncondensibles or refrigerant overcharge 4.10.1 Condenser fan/motor defective 4.13 Low discharge pressure Compressor defective 4.11 Hot gas solenoid malfunction 4.14 Low refrigerant charge 4.10.1...

  • Page 31: Expansion Valve

    Table 3-2 Mechanical Indications - - Continued REFERENCE INDICATION/TROUBLE POSSIBLE CAUSES SECTION 3.2.10 Expansion Valve Low suction pressure with high Low refrigerant charge 4.10.1 superheat External equalizer line plugged Repair Ice wax, oil or dirt plugging valve strainer Broken capillary Repair Superheat setting too high 4.16.2...

  • Page 32: Table 4-1 Preventive Maintenance Schedule

    SECTION 4 SERVICE WARNING Beware of unannounced starting of the unit. The unit may cycle the fans and operating compressor unexpectedly as control requirements dictate. To ensure unit will not start, place the EMERGENCY SWITCH (see Figure 1-1) in the OFF position. To ensure unit is without power, remove power plug and remove battery negative cable.

  • Page 33: Figure 4-1. Belt Tension Gauge

    4.5 CHECKING AND REPLACING FILTER-DRIER Checking filter-drier Check for any obstruction of the filter-drier by feeling the inlet and outlet connections of the liquid line on the filter cartridge. If the temperature of the outlet connection seems lower than the temperature of the inlet connection, replace the filter-drier.

  • Page 34: Refrigerant Leak Checking

    f. After repairs have been made, be sure to perform a the pump, order part number 07--00176--11 and for refrigerant leak check (refer to paragraph 4.8), and the indicator order part number 07--00414--00. evacuate and dehydrate the low side (refer to para- graph 4.9.4).

  • Page 35: Figure 4-2. Vacuum Pump Connection

    Refrigerant Recovery Unit Valve Refrigerant Cylinder Vacuum Pump Evacuation Manifold Electronic Vacuum Gauge Figure 4-2. Vacuum Pump Connection g. Remove refrigerant using a refrigerant recovery sys- 4.10 CHARGING THE REFRIGERATION SYSTEM tem. 4.10.1 Checking The Refrigerant Charge h. Repeat steps e. to g. Start unit in cooling mode.

  • Page 36: Figure 4-3. Typical Setup For Testing Pressure Switches Hp1, Hp2 And Hp3

    4.10.3 Adding A Partial Charge 4.12.2 Checking Pressure Switch a. Place refrigerant cylinder on scale and note weight. WARNING b. Connect charging line from the cylinder to the receiv- Do not use a nitrogen cylinder without a er valve. Purge the line at the cylinder valve. pressure regulator.

  • Page 37: Figure 4-4. Fan Motor Brushes

    4.13 CHECKING AND REPLACING CONDENSER FAN MOTOR BRUSHES To maintain proper operation of the fan motors, the fan motor brushes should be checked periodically for cleanliness and wear . 1. Snap cap 5. Plunger assembly 2. Voltage plate 6. Valve body assembly 3.

  • Page 38: Figure 4-7 Thermostatic Expansion Valve Bulb And Thermocouple

    4.15 ADJUSTING THE COMPRESSOR PRESSURE c. Place thermocouple above (parallel to) the TXV bulb REGULATING VALVE (CPR) and then secure loosened clamp making sure both bulbs are firmly secured to suction line as shown in When adjusting the compressor pressure regulating Figure 4-7.

  • Page 39: Table 4-3 R-404A Temperature--Pressure Chart

    Table 4-3. R-404A Temperature- -Pressure Chart Temperature Pressure Temperature Pressure _ _ _ _ C Psig Kg/cm Psig 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...

  • Page 40: Schematic Diagrams

    SECTION 5 SCHEMATIC DIAGRAMS WARNING Beware of unannounced starting of the unit. The unit may cycle the fans and operating compressor unexpectedly as control requirements dictate. To ensure unit will not start, place the EMERGENCY SWITCH (see Figure 1-1) in the OFF position. To ensure unit is without power, remove power plug and remove battery negative cable.
  • Page 41 BASED ON DRAWING 62--60873, REVISION C MODIFIED FOR SERVICE MANUAL Figure 5-1. Schematic Diagram - - Road Only (Page 1 of 2) 62-10630...

  • Page 42: Figure 5-1 Schematic Diagram -- Road Only

    Micro Fuse Figure 5-1. Schematic Diagram - - Road OnlY (Page 2 of 2) 62-10630...
  • Page 43 BASED ON DRAWING 62--60856, REVISION E MODIFIED FOR SERVICE MANUAL Figure 5-2. Schematic Diagram - - Three Phase Stand By Units (Page 1 of 2) 62-10630...

  • Page 44: Figure 5-2 Schematic Diagram -- Three Phase Stand By Units

    Figure 5-2. Schematic Diagram - - Three Phase Stand By Units (Page 2 of 2) 62-10630...
  • Page 45 ALARM RELAY (OPTION) QUENCH (LIQUID INJECTION) THERMOSTAT QUENCH (LIQUID INJECTION) VALVE CAPACITOR CIRCUIT BREAKER CAB COMMAND CONDENSER FAN MOTOR COMPRESSOR CLUTCH (ROAD) RUN CAPACITOR START CAPACITOR DOOR SWITCH (OPTION) DEFROST TERMINATION THERMOSTAT EVAPORATOR DRAIN LINE HEATER EMERGENCY SWITCH EVAPORATOR FAN MOTOR FUSE, TRANSFORMER FUSE, IGNITION FUSE, ROAD (DC)

  • Page 46: Figure 5-3 Schematic Diagram -- Single Phase Stand By Units

    Figure 5-3. Schematic Diagram - - Single Phase Stand By Units (Page 2 of 2) 62-10630...
  • Page 47 INDEX HIGH PRESSURE SWITCH , 4-5 Abnormal Noise, 3-4 HOT GAS SOLENOID, 4-6 Abnormal Pressure, 3-4 Accessing Alarm Messages, 2-6 ALARM DISPLAY, 2-6 Alarm Indications, 3-1 INSPECTION, 2-1 Insufficient Cooling, 3-3 INTRODUCTION, 3-1, 5-1 BELT ADJUSTMENT, 4-1 Key Functions, 2-2 Keypad, 2-1 CAB COMMAND, 2-1 Cab Command Malfunction, 3-4...
  • Page 48 INDEX Temperature--Pressure Chart , 4-8 SCHEMATIC DIAGRAMS, 5-1 THERMOSTATIC EXPANSION VALVE, 4-7 SEQUENCE OF OPERATION, 2-4 TROUBLESHOOTING, 3-1 TXV ORIFICE STRAINER, 4-2 SERVICE, 4-1 SET--POINT, 2-3 Standby Compressor Malfunction, 3-5 Unit Operates Long or Continuously in Cooling, 3-3 STARTING, 2-3 Unit Will Not Cool, 3-3 STOPPING, 2-3 Unit Will Not Heat or Heating Insufficient, 3-3...
  • Page 49 Central America North America and Mexico Carrier Transicold Ejercito Nacional No. 418 700 Olympic Drive Carrier Transicold Division, Piso 9, Torre Yumal Athens, GA 30601 USA Carrier Corporation Col. Chapultepec Morales Tel: 1- -706- -357- -7223 Truck/Trailer Products Group 11570 Mexico, D.F. Fax: 1- -706- -355- -5435 P.O.

This manual is also suitable for:

Integra 50sIntegra 40

Table of Contents

Save PDF