Documente Academic
Documente Profesional
Documente Cultură
EVAPORATOR
TXV BULB
CONDENSER
TXV
RECEIVER
OPERATION AND
SERVICE MANUAL
FOR
TABLE OF CONTENTS
PARAGRAPH NUMBER
Page
SAFETY SUMMARY
Safety-1
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 CONDENSING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3.2 Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.3.3 Standby Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.3.4 Alternator/Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.3.5 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.3.6 Compressor Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.3.7 Condenser/Subcooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.3.8 Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.3.9 Compressor Pressure Regulating Valve (CPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.3.10 Hot Gas Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.3.11 Hot Gas Bypass Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.3.12 Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.3.13 Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4 EVAPORATOR SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4.1 Thermal Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4.2 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4.3 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4.4 Electric and Water Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.5 SYSTEM OPERATING CONTROLS AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.5.1 SWITCHES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.6 Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.6.1 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.6.2 Compressor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.7 REFRIGERATION SYSTEM DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.8 ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.9 TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.10 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.11 REFRIGERANT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.11.1 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.11.2 Heat and Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 MICROPROCESSOR CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.2 Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.1.3 Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 MICROPROCESSOR CONFIGURATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
62--10808
62--10808
ii
iii
4-1
4-1
4-1
4-1
4-1
4-2
4-2
4-2
4-3
4-3
62--10808
LIST OF ILLUSTRATIONS
FIGURE NUMBER
Page
Figure 1-1. Condensing Section -- Top View/Cab Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Figure 1-2. Unit Curbside View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Figure 1-3. Unit Roadside View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Figure 1-4. Cylinder Head -- Unloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Figure 1-5. Cylinder Head -- Loaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Figure 1-6. Hot Gas Valve -- Cooling Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Figure 1-7. Hot Gas Valve -- Heat and Defrost Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Figure 1-8. Water and Electric Heat Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Figure 1-9. Electrical Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Figure 1-10. Control Relay Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Figure 1-11. Refrigeration Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Figure 2-1. Cab Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-2. Auto Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Figure 3-1. Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Figure 3-2. Speed and Run Control Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-3. Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-4. Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Figure 3-5. 70 Amp Alternator (P/N 30--60050--04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Figure 3-6. V-Belt Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Figure 3-7 Belt Tension Gauge (Part No. 07-00203) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Figure 3-8. Vacuum Pump Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-9. Compressor -- Model 05K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Figure 3-10. Unloader Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
62--10808
iv
LIST OF TABLES
TABLE NUMBER
Page
Table 1-1. Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Table 1-2. Additional Support Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Table 1-3. Safety Devices -- Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Table 2-1. Function Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Table 2-2. Unit Data Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Table 2-3. Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Table 2-4. Manual Glow Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Table 3-1. Belt Tension (See Figure 3-5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Table 3-2. Connection Point Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Table 3-3. Configuration Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Table 3-4. Sensor Resistance -- Micro Units (ATS,CDT, RAS, SAS & WTS) . . . . . . . . . . . . . . . . . . . . . 3-17
Table 3-6. R-404A Temperature--Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
62--10808
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. A listing of the specific warnings and cautions
appearing elsewhere in the manual follows the general safety notices.
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 inspections,
and problem troubleshooting, you may be exposed to moving parts. Stay clear of all moving parts when the unit is in
operation and when the unit main power switch is in the START/RUN position.
FIRST AID
An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately.
OPERATING PRECAUTIONS
Always wear safety glasses. Wear hearing protection as required.
Keep hands, clothing and tools clear of the evaporator and condenser fans.
No work should be performed on the unit until all circuit breakers and the Emergency Switch are turned off, and battery
power supply is disconnected.
Always work in pairs. Never work on the equipment alone.
In case of severe vibration or unusual noise, stop the unit and investigate.
MAINTENANCE PRECAUTIONS
Beware of unannounced starting of the unit. This unit is equipped with Auto--Start in both the road and standby modes.
The unit may start at any time. When performing any check of the system make certain the Emergency Switch is in the
OFF position.
Be sure power is turned off before working on motors, controllers, solenoid valves and electrical control switches. Tag
circuit breaker and vehicle ignition to prevent accidental energizing of circuit.
Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems with
the system should be diagnosed, and any necessary repairs performed, by qualified service personnel.
When performing any arc welding on the unit or container, disconnect all wire harness connectors from the
microprocessor. Do not remove wire harness from the modules unless you are grounded to the unit frame with a static
safe wrist strap.
In case of electrical fire, open circuit switch and extinguish with CO2 (never use water).
AUTO-START
Your refrigeration unit is equipped with Auto-Start in both Start/Stop and Continuous Run modes. The unit may start at
any time. A buzzer will sound for 5 seconds before the unit is started. When performing any check of the refrigeration
unit (e.g., checking the belts, checking the oil), make certain that the Start-Run / Off switch is in the OFF (0) position.
ENGINE COOLANT
The engine is equipped with a pressurized cooling system. Under normal operating conditions, the coolant in the
engine and radiator is under high pressure and is very hot. Contact with hot coolant can cause severe burns. Do not
remove the cap from a hot radiator; if the cap must be removed, do so very slowly in order to release the pressure
without spray.
REFRIGERANTS
The refrigerant contained in your unit can cause frostbite, severe burns, or blindness when in direct contact with the
skin or eyes. For this reason, and because of legislation regarding the handling of refrigerants during system service,
we recommend that you contact your nearest Carrier Transicold authorized repair facility whenever your unit requires
refrigeration system service .
Safety-1
62--10808
BATTERY
This unit is equipped with a lead-acid type battery. The battery normally vents small amounts of flammable hydrogen
gas. Do not smoke when checking the battery. A battery explosion can cause serious physical harm and/or blindness.
SPECIFIC WARNING AND CAUTION 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 -- means an immediate hazard which WILL result in severe personal injury or death.
WARNING -- means to warn against hazards or unsafe conditions which COULD result in severe personal injury or
death.
CAUTION -- means to warn against potential hazard or unsafe practice which could result in minor personal injury,
product or property damage.
The statements listed below are specifically applicable to this refrigeration unit and appear elsewhere in this manual.
These recommended precautions must be understood and applied during operation and maintenance of the equipment covered herein.
WARNING
Beware of unannounced starting of the engine, standby motor, evaporator fan or condenser fan. The
unit may cycle the engine, standby motor or fans unexpectedly as control requirements dictate
WARNING
Under no circumstances should ether or any other starting aids be used to start engine.
WARNING
Beware of V-belts and belt driven components as the unit may start automatically. Before servicing
unit, make sure the Run-Stop switch is in the STOP position. Also disconnect the negative battery
cable.
WARNING
Do not use a nitrogen cylinder without a pressure regulator. Cylinder pressure is approximately 2350
psi (160 bar). Do not use oxygen in or near a refrigerant system as an explosion may occur.
WARNING
Do not attempt to connect or remove power plug before ensuring the unit is OFF (press OFF key on
Cab Command) and external power circuit breaker is open.
WARNING
Make sure the power plug is clean and dry before connecting to any power source.
WARNING
Testing of the generator presents hazards which can result in personal injury or death. Only persons
qualified to carry out electrical and mechanical servicing should undertake this work
WARNING
When flashing the generator, the jumpers should be connected to 12VDC for no longer than one second.
WARNING
Ensure power to the unit is OFF and power plug is disconnected or vehicle engine is OFF and negative battery cable is disconnected before replacing the compressor.
CAUTION
Under no circumstances should anyone attempt to repair the Logic or Display Boards. Should a
problem develop with these components, contact your nearest Carrier Transicold dealer for replacement.
CAUTION
Unit with R404A and POE oil, the use of inert gas brazing procedures is mandatory; otherwise compressor failure will occur. For more information see Technical Procedure 98-50553-00 Inert Gas Brazing
62--10808
Safety-2
CAUTION
Use only ethylene glycol anti-freeze (with inhibitors) in system as glycol by itself will damage the
cooling system.
Always add pre-mixed 50/50 anti-freeze and water to radiator/engine. Never exceed more than a 50%
concentration of anti-freeze. Use a low silicate anti-freeze.
CAUTION
Extreme care must be taken to ensure the manifold common connection remains immersed in oil at
all times. Otherwise air and moisture will be drawn into the compressor.
CAUTION
Observe proper polarity, reverse polarity will destroy the diodes. As a precaution, disconnect positive terminal when charging.
CAUTION
Do not damage or over tighten the enclosing tube assembly. Also make sure all parts are placed in
the enclosing tube in proper sequence to avoid premature coil burn-out.
CAUTION
Under no circumstances should a technician electrically probe the microprocessor at any point, other than the connector terminals where the harness attaches. Microprocessor components operate at
different voltage levels and at extremely low current levels. Improper use of voltmeters, jumper
wires, continuity testers, etc. could permanently damage the microprocessor.
CAUTION
Most electronic components are susceptible to damage caused by electrical static discharge (ESD).
In certain cases, the human body can have enough static electricity to cause resultant damage to the
components by touch. This is especially true of the integrated circuits found on the microprocessor.
CAUTION
Under no circumstances should anyone attempt to service the microprocessor . Should a problem
develop with the microprocessor, contact your nearest Carrier Transicold dealer for replacement.
CAUTION
Refrigerant R404A must be charged as a liquid. Refrigerant R404A is a blend. Charging as a vapor will
change the properties of the refrigerant.
Safety-3
62--10808
SECTION 1
DESCRIPTION
1.1 INTRODUCTION
Standby Operation
TDS units are equipped with an internal combustion
diesel engine and an electric standby motor. In Standby
Operation, the compressor and alternator are driven by
the electric standby motor.
WARNING
Beware of unannounced starting of the engine, standby motor, evaporator fan or condenser fan. The unit may cycle the engine,
standby motor or fans unexpectedly as
control requirements dictate
REFRIGERANT
R--404A
LB
KG
11
5.0
11
5.0
12
5.4
12
5.4
15
6.8
15
6.8
ENGINE
COMPRESSOR
CT3 44TV
CT3-44TV
05K 012
2 Cylinder
y
05K 024
4Cylinder
STANDBY
MOTOR
60 hz
-7.6 hp
-7.6 hp
-7.6 hp
Equipment Covered
Supra 644,744
Supra 844
Engine
Engine
1-1
Type of Manual
Parts List
Parts List
Operation and Service
Parts List
62--10808
10
11
12
16
14
15
13
ALARM/FAULT
UNIT DATA
SETPOINT
BOX TEMPERATURE
ENTER
FUNCTION
AUTO START/STOP
PRETRIP
I
ROAD
CITY
SPEED
MAN
DEFROST
BUZZER OFF
STANDBY
CAB COMMAND
1.
2.
3.
4.
5.
6.
7.
8.
Muffler
9. Compressor Pressure Regulating Valve (CPR)
Thermal Expansion Valve (Location)
10. Accumulator
Engine (Refer toTable 1-1)
11. Filter-Drier
Heat Exchanger (Location)
12. Hot Gas Bypass Solenoid (HGS2)
Compressor
13. Receiver
Alternator
14. Hot Gas Valve (Three-Way) (HGS1)
Electric Standby Motor
15. Condenser
Defrost Air Switch
16. Radiator Overflow Reservoir
Figure 1-1. Condensing Section -- Top View/Cab Command
62--10808
1-2
1. Fuel Filter
2. Serial/Model Number Plate
3. Speed & Run Solenoid
4. Air Cleaner
5. Oil Filter
Figure 1-2. Unit Curbside View
3. Evaporator
Figure 1-3. Unit Roadside View
1-3
62--10808
62--10808
4
5
6
11
10
8
12
13
14
15
1. Solenoid Valve
2. Valve Stem
3. Gas Bypass Port
4. Spring Guide
5. Spring
6. Piston
7. Piston Bypass Valve
8. Bleed Orifice
9. Strainer
10.Suction Manifold
1-4
4
5
6
11
10
8
9
12
13
14
15
1. Solenoid Valve
2. Valve Stem
3. Gas Bypass Port
4. Spring Guide
5. Spring
6. Piston
7. Piston Bypass Valve
8. Bleed Orifice
9. Strainer
10.Suction Manifold
To compressor
suction
Solenoid
de-energized
To evaporator
From
compressor
1.3.8 Accumulator
The accumulator is a refrigerant holding tank located in
the suction line between the evaporator and compressor. The purpose of the accumulator is to prevent entry
of any liquid refrigerant into the compressor.
Refrigerant vapor leaves the accumulator outlet pipe at a
point well above any liquid level thus preventing the entrance of liquid. The outlet pipe is equipped with an orifice
that controls oil return to the compressor and prevents
accumulation of oil within the tank.
To condenser
1-5
62--10808
Solenoid
energized
To evaporator
From
compressor
62--10808
1-6
Electric
Heat
Elements
4
1
HOT WATER HEAT COMPONENTS
1. Water Valve
2. Water Tube (HWH)
3. Hose (HWH)
4. Harness (HWH)
1-7
62--10808
4
5
1
1. Run-Stop Switch (RS)
5. Motor Overload Relay (MOL)
2. Manual Glow/Crank Switch (MGC)
6. Microprocessor Module
3. Relay/Fuse Board (See NO TAG &
7. Fuse (F1, 80 amp)
Figure 1-10)
4. Standby Motor Contactor (MC)
Note: See Figure 2-1 for Cab Command
Figure 1-9. Electrical Box
62--10808
1-8
CT3-44TV (D744)
Used on
SUPRA 644/744/844
Displacement
No. Cylinders
Horsepower
Weight
63 kg (139 lbs)
3.7 liters (3.9 U.S. quarts)
Coolant Capacity
Use 50/50 to 60/40 ethylene glycol/water mix, standard or extended life antifreeze
8.1 liters (8.5 U.S. quarts)
Oil Capacity
Operating
Speeds
High
Low
Injection Setting
Water Safety
Switch
Oil Pressure
Switch
Glow Plug
Lubrication System
Lube Oil Viscosity: (API Classification CD)
Outdoor Temperature
SAE
Fahrenheit
Centigrade
Below 32_
Below 0_C
10W or 10W30
32_ to 77_F
0_ to 25_C
20W
Over 77_F
Over +25_C
30W or 15W40
Refrigerant
R 404A
R-404A
1-9
62--10808
a. Defrost Timer
1-1/2, 3, 6, or 12 hours
CPR Setting
psig
281
321
291
CPR Setting
kg/cm@
1.970.07
2.250.07
2.040.07
7 to 10 amps
2250
rpm
12 vdc
b. Standby Motors
Bearing Lubrication: Factory lubricated additional grease not required
Rotation Speed: 1760 rpm@ 60hz/1500 rpm@ 50hz
Voltage
3ph, 60 hz
Connection Type
230
460
230
460
SUPRA
Power
HP
644/744
76
7.6
23
13
83
8.3
19.6
9.8
SUPRA 844
62--10808
1-10
c. Alternator: 70 amps
d. Standby Motor Overload
MODEL
644/744
844
SETTING
230V, 3 ph, 60 hz
460V, 3 ph, 60 hz
20 AMPS
14 AMPS
20 AMPS
12.5 AMPS
ft--lb
40
40
50
40
32
22
22
kg--m
5.5
5.5
7.0
5.5
4.5
3.0
3.0
13
7
7
22
40
7
18
40
1.8
1.0
1.0
3.0
5.5
1.0
2.5
5.5
Unsafe Conditions
Device Setting
Fuse (F1)
Opens at 80 amps
Fuse (F2)
Opens at 5 amps
Fuse (F3)
Opens at 25 amps
Fuse (F4)
Opens at 15 amps
Fuse (F5)
Fuse (F6)
Opens at 5 amps
Opens at 20 amps
Fuse (F11)
Opens at 5 amps
Compressor discharge
temperature sensor (CDT)
1-11
62--10808
62--10808
1-12
FILTER DRIER
EVAPORATOR
TXV
BULB
TXV
HOT GAS
BYPASS
SOLENOID
VALVE
(HGS2)
CHECK
VALVE
RECEIVER VALVE
RECEIVER
HEAT
EXCHANGER
INLET
CHECK
VALVE
HOT GAS
VALVE (HGS1)
SUBCOOLER
COMPRESSOR
PRESSURE
REGULATOR
VALVE
DISCHARGE
SERVICE
VALVE
SPT
HP
METERING
ORIFICE
CONDENSER
SUCTION
SERVICE
VALVE
ACCUMULATOR
COMPRESSOR
Discharge
Liquid
Suction
COOLING CYCLE
FILTER DRIER
EVAPORATOR
TXV
TXV
BULB
CHECK
VALVE
HOT GAS
BYPASS
SOLENOID
VALVE
RECEIVER VALVE
RECEIVER
INLET
CHECK
VALVE
HOT GAS
VALVE
HEAT
EXCHANGER
SUBCOOLER
COMPRESSOR
PRESSURE
REGULATOR
VALVE
DISCHARGE
SERVICE
VALVE
SPT
HP
METERING
ORIFICE
ACCUMULATOR
CONDENSER
SUCTION
SERVICE
VALVE
COMPRESSOR
Discharge
Liquid
Suction
62--10808
SECTION 2
OPERATION
keypad. The key pad and display serve to provide
user access and readouts of microprocessor information. The information is accessed by key pad
selections and viewed on the display.
The Carrier Transicold Microprocessor System incorporates the following features:
a. Control supply or return air temperature to tight limits
by providing refrigeration control, heat and defrost to
ensure conditioned air delivery to the load.
b. Default independent readouts of set point (at the left
of the display) and actual supply or return air temperature (at the right).
c. Digital readout of unit data points such as pressures,
temperatures and other microprocessor inputs.
d. Digital readout of selectable operating parameters
(Function Codes) and the ability to change those settings.
e. Digital display of Alarm Indications.
f. A self-test check on program memory and data
memory at start--up.
13
14
15
16
17
18
19
20
ALARM/FAULT
i
UNIT DATA
SETPOINT
BOX TEMPERATURE
FUNCTION
ENTER
AUTO START/STOP
PRETRIP
I
ROAD
11
1.
2.
3.
4.
5.
6.
10
CITY
SPEED
MAN
DEFROST
8
7.
8.
9.
10.
11.
12.
13.
BUZZER
OFF
STANDBY
14.
15
16.
17.
18.
19.
20.
Defrost Mode
Road Mode
Auto Start/Stop Mode
Stand-by Mode
City Speed Mode
Out-of-range
Fault Light
2-1
62--10808
CAUSE
Processor failure
Check chip installation or Replace
microprocessor.
Display board to logic board communication failure.
This can be caused by a defective
ribbon cable or ribbon cable not
plugged in properly.
2.1.3 Keypad
The keypad (Figure 2-1) has 12 keys which allow the
operator to initiate various functions, display operating
data and change operating parameters.
Arrow Keys
The up and down ARROW keys are used
to modify (increment or decrement) the
displayed data. If the unit is in the default
display these keys are pressed to change the setpoint
selection.
Enter Key
62--10808
2-2
Road Key
Stand-by Key
The STAND-BY key selects the electric
motor operating mode. The microprocessor retains the last entered setpoint in
memory even if the unit is shut down or a power failure
occures. NO POWER will be displayed, if unit is
switched to standby and power is not available.
2.2 MICROPROCESSOR CONFIGURATION
The microprocessor is configured in accordance with
the equipment supplied on an individual unit and the
requirements of the original purchase order. The configurations do not require change unless the unit has an
equipment change or a change is required by the owner.
Although the configurations may not be modified using
the key pad, operational differences will be noted
throughout the following descriptions and operating procedures.
CODE
FN0
DEFR
DATA
Defrost Interval
FN1 ON
FN1 OFF
FN2
OFF T
Minimum Off-time
FN3
ON T
On-time
FN4 a
REM
PROBE
FN4 b
SUP
PROBE
FN5
Degrees
F or C
Temperature Unit
_C or _F
FN6 ON
TIME
STRT
FN6 OFF
TEMP
STRT
Temperature Based
Restarting
FN7
NOTE
If configuration CNF11 is ON functional parameters are locked out and the ability to
change functional parameters from keypad is
disabled.
ENGLISH
FN8
2SET
Compartment 2 Setpoint
FN9
3SET
Compartment 3 Setpoint
FN10 ON
FN10
OFF
MAN OP
FN11
62--10808
62--10808
2-4
Out-of-Range Tolerance
NOTE
If configuration CNF9 is ON the unit will shut
down if an out of tolerance condition exists for
over 45 minutes. If configuration CNF9 is OFF
and an out of tolerance condition exists, the unit
will continue to operate.
The English display for Out-Of-Range Temperature Tolerance is T RANGE. The code display is FN11. The
choices are A, B or C. A = 3.6_F(2_C), B = 5.4_F(3_C)
and C = 7.2_F (4_C).
When the out-of-range temperature is configured ON,
the microprocessor indicates out-of-range when the
temperature has been within the tolerance band at least
once, and then goes outside the tolerance band for 45
minutes. Also, the unit will shut down.
When the out-of-range temperature is configured OFF,
the microprocessor indicates out-of-range when the
temperature has been within the tolerance band at least
once, and then goes outside the tolerance band for 15
minutes. Also, the unit will continue to operate.
For set points at or below +10_F (--12.2_C) frozen range
the unit is only considered out-of-range for temperatures above set point.
DATA
Suction Pressure
Engine Hours
Engine Temperature
Return Air Temperature
Supply Air Temperature
Remote Air Temperature
Ambient Temperature
Future Expansion
Discharge Temperature
Battery Voltage
Standby Hours
Future Expansion
Software Revision
Serial Number Low
Serial Number Upper
Compartment 2
CD16
2RA
Air Temperature
Compartment 3
CD17
3RA
Air Temperature
CD18
MHR1
Maintenance Hour Meter 1
CD19
MHR2
Maintenance Hour Meter 2
CD20
SON
Switch On Hour Meter
* Codes 5 & 6 are variable. SAS is displayed when
the SUP Probe Function is selected. REM is displayed when the REM Probe Function is selected.
CODE
CD1
CD2
CD3
CD4
*CD5
*CD6
CD7
CD8
CD9
CD10
CD11
CD12
CD13
CD14
CD15
ENGLISH
SUCT
ENG
WT
RAS
SAS
REM
ATS
EVP
CDT
BATT
SBY
MOD V
REV
SERL
SERU
2-5
62--10808
Ambient Temperature
The English display for Ambient Air Temperature is
ATS, the code display is CD7. The English units are
designated by an F following the reading (i.e, ATS
85.0F or CD7 85.0F) while the metric are designated by
a C (i.e, ATS 29.4C or CD7 29.4C). The display range
is--36_F to 158_F (--38_C to 70_C).
EVP -- Future Expansion
This unit data is not used at this time. The English display is EVP. The code display is CD8.
Compressor Discharge Temperature
The English display for Compressor Discharge Temperature is CDT, the code display is CD9. The English
units are designated by an F following the reading (i.e,
CDT 185.0F or CD9 185.0F) while the metric are designated by a C (i.e, CDT 85.0C or CD9 85.0C). The
display range is --40_F to 392_F (--40_C to 200_C).
Battery Voltage
62--10808
2-6
DEFR FAIL
AL7
ALT AUX
AL8
STARTER
AL9
RA
SENSOR
AL10
SA
SENSOR
AL11
WT
SENSOR
AL12
HIGH CDT
AL13
CD
SENSOR
AL15
FUSE BAD
AL16
SYSTEM CK
AL17
DISPLAY
Display
AL18
SERVICE 1
AL19
SERVICE 2
AL20
RAS OUT
Defrost Override
Fuse Open
Check Refrigeration System
AL23
NO POWER
2-7
62--10808
62--10808
2-8
2-9
62--10808
2-10
Ambient Temperature
Glow Time in
S
Seconds
d
55
40
25
10
2-11
62--10808
Power flows from RSS through fuse F2 to the Run Control Relay (RCR). RCR is grounded by the microprocessor through the Door Switch Relay (DSR) and cab
command to energize RCR. The RCR contacts close to
provide power to the control relays. Power to the Run
Relay (RR) is dependent on the High Pressure Switch
(HP1) being closed. If the high pressure switch is open,
power will not be applied to microprocessor terminal M1
and operation will not be allowed.
Energizing RR closes a set of contacts to supply power
through the motor Overload (OL) to the Motor Contactor
(MC1). Energizing MC1 closes its contacts to start the
Standby Motor (SBM).
On Supra 844 units, power is also supplied from the
DER contacts to energize the Standby Unloader Front
Relay (SUFR). Energizing SUFR opens a set of normally closed contacts in the power line to the unloader
preventing unloaded operation.
Once the motor starts the alternator begins to produce
power. The microprocessor senses the power at terminal L3 and it will complete the Defrost Transistor (DT)
circuit to energize the Electric Fan Motor Relays (EFMR
1 through 3). The relays close contacts to energize the
Electric (Evaporator) Fan Motors (EFM1 through 3).
The microprocessor continues to monitor inputs to determine required modes of operation. The inputs include
the Suction Pressure Transducer (SPT), Return Air
Sensor(RAS), Supply Air Sensor (SAS), and the Compressor Discharge Transducer (CDT) .
As required, the microprocessor will take the following
actions:
On call for heat, the Heat Relay (HR) is energized to
close a set of contacts and energize the hot gas bypass
solenoid valve (HGS2) and the hot gas valve (HGS1)
placing the unit in the heat mode. In the heat mode the
microprocessor also energizes the Evaporator Heat
Relay (EHR). Energizing EHR closes a set of contacts
to energize the Evaporator heat Contactor (EHC) which
closes its contacts to energize the Evaporator Heaters.
On call for defrost, the microprocessor energizes the hot
gas bypass solenoid valve (HGS2) and the hot gas
valve (HGS1) in the same manner as in heat. Also, DT is
de--energized, stopping the evaporator fan motors.
62--10808
2-12
THIRD
ATTEMPT
15 Seconds
STOP
REPEAT FIRST
+ 5 Seconds
GLOW
SECOND
ATTEMPT
15 Seconds
STOP
MAXIMUM
10 Seconds
Checked at CRANK
2 Seconds*
VARIABLE
0 to 85 SECONDS
GLOW
FIRST
ATTEMPT
GLOW
2-13
62--10808
SECTION 3
SERVICE
WARNING
Beware of V-belts and belt driven components as the unit may start automatically. Before
servicing unit, make sure the Run-Stop switch is in the STOP position. Also disconnect the
negative battery cable.
CAUTION
Unit with R404A and POE oil, the use of inert gas brazing procedures is mandatory; otherwise
compressor failure will occur. For more information see Technical Procedure 98-50553-00 Inert Gas Brazing
NOTE
To avoid damage to the earths ozone layer, use a refrigerant recovery system whenever removing
refrigerant. When working with refrigerants you must comply with all local government environmental
laws, U.S.A. EPA section 608.
3.1 MAINTENANCE SCHEDULE
UNIT
OPERATION
REFERENCE
SECTION
a. Daily Maintenance
Pre-Trip Inspection -- before starting
Pre-Trip Inspection -- after starting
Check Engine Hours
2.1.a
2.1.b
Check
Engine
Check
Check
Check
Check
Check
3.3
Check
Check
3.2.2
Check
Check
1.1
1. Check antifreeze
2. Clean radiator/condenser fin surface
3. Check hoses and connections
4. Check water pump
5. Check water temperature sensor functions
3-1
-----3.2.5
3.2.5
-----Check
Check/Replace
Check
3.2.1
3.2.1
Check/Replace
Check
Check
62--10808
Charging
System
Check
Check
4.2.4
4.2.4
1. Check battery
2. Clean battery connections and cable ends
3. Check battery hold down clamps
4. Check starter operation
5. Check glow plug operation
Check/Replace
Check/Replace
Check
Check
4.26
4.2.7
4.2.7
4.2.7
1. Check air switch & calibrate =1.0 +/-- .07_ W.C. (644/744)
.7+/--.07_ W.C. (844)
2. Check & clean evaporator
3. Check compressor oil level
4. Check refrigerant level
5. Check operating refrigerant pressure
6. Check all sensor calibrations
7. Check defrost drains
8. Check auto start/stop operation (if applicable)
9. Check quench valve operation
10. Check manual defrost operation
11. Check CPR setting: 644 = 24+/-- 1 PSIG
744 = 32+/-- 1 PSIG
844 = 29+/-- 1 PSIG
Refrigeration
System
4.15
4.17
4.9
4.7.3
1.7
Check
Check
2.1.2/2.15
Check
2.7.6
4.2.7
Fuel System
Cooling System
Without
Bypass Oil Filter
With
Bypass Oil Filter
Petroleum
750 Hours
1000 Hours
Synthetic**
1500 Hours
2000 Hours
* Maximum oil drain interval is one year (12 months).
** Mobil Delvac1 is the only approved synthetic oil. Maximum oil drain interval is two (2) years. Oil filter change
required once a year (every 12 months).
62--10808
3-2
Change 09/06
a. Remove all foreign material from the radiator/condenser coil by reversing the normal air flow. (Air is
pulled in through the front and discharges over the
standby motor.) Compressed air or water may be
used as a cleaning agent. It may be necessary to use
warm water mixed with any good commercial dishwasher detergent. Rinse coil with fresh water if a detergent is used.
b. Drain coolant by removing lower radiator hose and radiator cap.
c. Install hose and fill system with clean, untreated water to which three to five percent of an akalined based
radiator cleaner should be added (six ounces -- dry
151 grams to one gallon = 3.78 liters) of water.
Water
Temperature
Sensor
(microprocessor)
Thermostat
Coolant outlet
(hot side)
Pressure cap
Overflow Tank
Coolant pump
Coolant inlet
(cold side)
Figure 3-1. Coolant System
3-3
62--10808
1
10
10
6
1.
2.
3.
4.
5.
6.
Run Solenoid
Spring (Run Control)
Engine Run Lever
Linkage Rod (Run)
Clip
Speed Solenoid
7. Spring
(Speed Control)
8. Linkage Rod
(Speed )
9. Engine Speed Lever
10. Boot
Return tube
Injection pump
Bleed port
Fuel filter
Fuel pump
Injectors
Supply line
Return line
Figure 3-3. Fuel System
62--10808
3-4
The alternator and regulator are housed in a single assembly. A diagram for alternator troubleshooting or replacement is provided below. See Figure 3-5.
2
WARNING
Beware of V-belts and belt driven components as the unit may start automatically.
3.3.1 Belt Tension Gauge
It is recommended that a belt tension gauge (Carrier
P/N 07-00203, see Figure 3-7) is used whenever Vbelts are adjusted or replaced. The belt tension gauge
provides an accurate and easy method of adjusting belts
to their proper tension. Properly adjusted belts give long
lasting and efficient service. Too much tension shortens
belt and bearing life, and too little tension causes slippage
and excessive belt wear. It is also important to keep belts
and sheaves free of any foreign material which may cause
the belts to slip.
The belt tension gauge can be used to adjust all belts.
The readings which we specify for Carrier Transicold
units are applicable only for our belts and application, as
the tension is dependent on the size of the belt and
distance between sheaves. When using this gauge, it
should be placed as close as possible to the midpoint
between two sheaves. (See Figure 3-6)
1. Cover
2.Gasket
3. Filter
4.Fuel Figure
Pump 3-4. Electric Fuel Pump
3.2.6 Servicing Glow Plugs
When servicing, the glow plug is to be fitted carefully into
the cylinder head to prevent damage to glow plug.
Torque value for the glow plug is 0.8 to 1.5 mkg (6 to 11
ft-lb).
Checking for a Defective Glow Plug
a. One method is to place an ammeter (or clip-on ammeter) in series with each glow plug and energize the
plugs. Each plug (if good) should show amperage
draw.
2
3
L
B --
4
1.
2.
3.
4.
Positive Output
Terminal
Regulator
12vdc Test Lamp
Terminal
Ground Terminal
B+
Figure 3-5. 70 Amp Alternator (P/N 30--60050--04)
3-5
62--10808
Standby
Motor
Engine
Supra 844
Standby
Motor
Engine
62--10808
New Install
Running
Tension
Tension
(ft./lbs)
(ft./lbs)
30 to 40
110 to 120
80 to 90
110 to 120
110 to120
80 to 90
80 to 90
3-6
NOTE
To avoid damage to the earths ozone layer, use
a refrigerant recovery system whenever removing refrigerant.
NOTE
Store the refrigerant charge in an evacuated
container if the system must be opened between the compressor discharge valve and receiver.
NOTE
Whenever the system is opened, it must be evacuated and dehydrated. (Refer to section 3.6)
NOTE
Use of a compound gauge is not recommended
because of its inherent inaccuracy.
c. Keep the ambient temperature above 60_F (15.6_C)
to speed evaporation of moisture. If ambient temperature is lower than 60_F (15.6_C), ice might form before moisture removal is complete. Heat lamps or alternate sources of heat may be used to raise system
temperature.
3-7
62--10808
f. Break the vacuum with clean dry refrigerant. Use refrigerant that the unit calls for. Raise system pressure
to approximately 2 psig.
g. Remove refrigerant using a refrigerant recovery system.
h. Repeat steps e through g one time.
i. Evacuate unit to 500 microns. Close off vacuum
pump valve and stop pump. Wait five minutes to see if
vacuum holds. This checks for residual moisture and/
or leaks.
j. With a vacuum still in the unit, the refrigerant charge
may be drawn into the system from a refrigerant container on weight scales. The correct amount of refrigerant may be added by observing the scales. (Refer
to section 3.7)
11
10
4
3
1
2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
CAUTION
Refrigerant R404A must be charged as a liquid. Refrigerant R404A is a blend. Charging
as a vapor will change the properties of the
refrigerant.
62--10808
NOTE
It is possible that all liquid may not be pulled into
the receiver, as outlined in step d. In this case,
vapor charge remaining refrigerant through the
suction service valve.
e. When refrigerant cylinder weight (scale) indicates
that the correct charge has been added, close liquid
line valve on cylinder and backseat the king valve.
3-8
CAUTION
Extreme care must be taken to ensure the
manifold common connection remains immersed in oil at all times. Otherwise air and
moisture will be drawn into the compressor.
NOTE
It is important to check the compressor oil level
of the new compressor and fill if necessary.
6. Check compressor oil level. (Refer to section 3.9)
Add oil if necessary.
3-9
62--10808
2. Remove wiring from the unloader coil. Place electrical tape over wire terminals.
3. Set controller upscale (cooler to warmer). This mechanically simulates falling temperature. Approximately 2_F (1.1_C) below box temperature the unloader coil will energize. Note suction pressure, a
rise of approximately 3 psig (0.2 kg/cm@) will be
noted on the suction pressure gauge.
4. Reconnect wiring on the unloader.
5. Reverse the above procedure to check out compressor loading. Suction pressure will drop with this test.
NOTE
If either unloader coil energizes and the suction
pressure does not change, the unloader assembly must be checked.
b. Solenoid Coil Replacement
NOTE
The coil may be removed without pumping the
unit down.
1
5
5
4
1.
2.
3.
4.
5.
6.
4 CYLINDER
2 CYLINDER
Suction Service Valve
Discharge Service Valve
Oil Level Sight Glass
Oil Drain Plug
Oil Fill Plug
Unloader Assembly
Figure 3-9. Compressor -- Model 05K
62--10808
3-10
d. Install new cutout switch after verifying switch settings. (Refer to section 3.12.2)
e. Evacuate and dehydrate the compressor. (Refer to
section 3.8)
3.12.2 Checking High Pressure Switch
1
2
3
10
4
5
6
7
8
9
WARNING
Do not use a nitrogen cylinder without a
pressure regulator. Cylinder pressure is
approximately 2350 psi (165 kg/cm@). Do not
use oxygen in or near a refrigerant system
as an explosion may occur. (See
Figure 3-11)
12
13
11
14
1. Retainer
2. Coil Assembly
3. Installation/Removal
Tool
4. Enclosing Tube
Collar
5. O Ring
6. Enclosing Tube
7.
8.
9.
10.
11.
12.
13.
14.
Plunger Spring
Plunger Assembly
Gasket
Valve Body
Gasket
Bolt
Gasket, Bolt
Piston Ring
1. Cylinder Valve
and Gauge
2. Pressure Regulator
3. Nitrogen Cylinder
4. Pressure Gauge
(0 to 400 psig =
0 to 28 kg/cm@)
5. Bleed-Off Valve
6. 1/4 inch Connection
3-11
62--10808
2
5
3
1
1.
2.
3.
4.
NOTE
The magnehelic gauge may be used in any
position, but must be re-zeroed if position of
gauge is changed from vertical to horizontal or
vice versa. USE ONLY IN POSITION FOR
WHICH IT IS CALIBRATED.
b. With air switch in vertical position, connect high pressure side of magnehelic gauge to high side connection of air switch. (See Figure 3-12)
c. Install tee in pressure line to high side connection. Tee
should be approximately half-way between gauge
and air switch or an improper reading may result.
d. Attach an ohmmeter to the air switch electrical contacts to check switch action.
NOTE
Use a hand aspirator (P/N 07-00177-01), since
blowing into tube by mouth may cause an incorrect reading.
e. With the gauge reading at zero, apply air pressure
very slowly to the air switch. An ohmmeter will indicate continuity when switch actuates.
f. Refer to section 1.3 for switch settings. If switch fails
to actuate at correct gauge reading, adjust switch by
turning adjusting screw clockwise to increase setting
or counterclockwise to decrease setting.
g. Repeat checkout procedure until switch actuates at
correct gauge reading.
h. After switch is adjusted, place a small amount of paint
or glycerol on the adjusting screw so that vibration will
not change switch setting.
62--10808
1. Brush Cap
2. Brush
1. Cap
2. Jam Nut
3. Setting Screw
CAUTION
Do not damage or over tighten the enclosing tube assembly. Also make sure all parts
are placed on the enclosing tube in proper
sequence to avoid premature coil burnout.
1
2
3
6
1. Snap cap
2. Voltage plate
3. Coil assembly
4. Enclosing tube
5. Plunger assembly
6. Valve body assembly
3-13
62--10808
3
5
2
1
1. Suction Line
2. TXV Bulb Clamp
3. Nut and Bolt
4. TXV Bulb
5. Thermocouple
1
2
1.Orifice
2.Strainer
3.20
MICROPROCESSOR CONTROLLER
NOTE
The erasable, programmable, read only
memory (EPROM) chip (component U3 on the
microprocessor logic board) has a label on it
listing the revision level of the software.
CAUTION
Under no circumstances should a
technician electrically probe the processor
at any point, other than the connector
terminals where the harness attaches.
Microprocessor components operate at
different voltage levels and at extremely low
current levels. Improper use of voltmeters,
jumper wires, continuity testers, etc. could
permanently damage the processor.
62--10808
3-14
CAUTION
Most
electronic
components
are
susceptible to damage caused by electrical
static discharge (ESD). In certain cases, the
human body can have enough static
electricity to cause resultant damage to the
components by touch. This is especially
true of the integrated circuits found on the
truck/trailer microprocessor.
b.
Hour Meters
The hour meter can be set to any value via the serial
port, if the meter has less then 5 hours on it. This allows
a replacement microprocessor to be set to the same
hours as the microprocessor it is replacing.
3-15
62--10808
SETTINGS
TV
644/744
ON
844
OFF
OFF*
CONFIGURATION
DI
TV
OFF
CNF2
ON
CNF1
CNF3
Note 2
OFF
CNF4
OFF
CNF5
ON
CNF6
OFF
CNF7
ON
CNF8
OFF*
CNF9
Note 1
OFF*
CNF10
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF*
CNF11
Note 2
OFF
CNF12
OFF
CNF13
OFF
CNF14
OFF
CNF15
OFF*
CNF16
OFF
CNF17
ON*
CNF18
OFF
CNF19
OFF*
CNF20
Note 3
OFF
CNF21
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
CNF22
CNF23
CNF24
CNF25
CNF26
CNF27
CNF28
CNF29
CNF30
CNF31
CNF32
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
DESCRIPTION
Long glow cycle
Short glow cycle
844 Only
644/744 Only
Max Set Point +86F (30c) (All functions
locked)
Max Set Point +90F (32.2C)Modified function lock)
Heat Lockout On At 10F (--12.2C)
Heat Lockout Off
644/744/844
Do Not Turn On!
Do Not Turn Off!
Supra Units 644/744/844
Supra Units 644/744/844
Do Not Turn On!
Do Not Turn Off!
Supra Units 644/744/844
Out--of--range alarm only
Out--of--range alarm and unit shut down
Standby Diesel Backup is disabled.
And All Units Prior to Rev. 3.23
Enables Standby Diesel Backup. Rev. 3.23
and higher
Functions change normally
Functions & Start Stop locked
Supra Units 644/744/844
Do Not Turn On!
Supra Units 644/744/844
Do Not Turn On!
Supra Units 644/744/844
Do Not Turn On!
Supra Units 644/744/844
Do Not Turn On!
Alt Aux alarm only
Alt Aux alarm shuts unit down
Supra Units 644/744/844
Do Not Turn On!
SYSTEM CK alarm Off
SYSTEM CK alarm On
OFF All Units
Do Not Turn On!
Display Units Unlocked
Display Units Locked (Not applicable with
Revisions lower Than 3.23)
Supra Units 644/744/844
Do Not Turn On!
For future use. Do not turn on.
For future use. Do not turn on.
For future use. Do not turn on.
For future use. Do not turn on.
For future use. Do not turn on.
For future use. Do not turn on.
For future use. Do not turn on.
For future use. Do not turn on.
For future use. Do not turn on.
For future use. Do not turn on.
For future use. Do not turn on.
NOTES
* These settings are optional and can be set to
customer specifications, or left at default values. All
other settings
g (not
(
marked with *)) MUST be set as
shown for
f proper unit operation.
1.
2
2.
3.
Maximum set
point 86_F. No
p
f
function
ti lock
l k
Maximum set
point 86_F.
86 F.
Standard func
ti lock
tion
l k
Maximum set
point 90_F.
90 F. No
function lock
Maximum set
point 90_F
Modified func
tion lock
62--10808
3-16
An accurate ohmmeter must be used to check resistance values shown in Table 3-4 .
Due to variations and inaccuracies in ohmmeters, thermometers or other test equipment, a reading within 2%
of the chart value would indicate a good sensor. If a
sensor is bad, the resistance reading will usually be
much higher or lower than the resistance values given in
Table 3-4.
At least one lead from the sensor (RAS, terminals D1
and E1 or SAS, terminals D2 and E2) must be disconnected from the unit electrical system before any reading is taken. Not doing so will result in a false reading.
Two preferred methods of determining the actual test
temperature at the sensor, is an ice bath at 32_F (0_C)
or a calibrated temperature tester.
Temperature
3-17
_F
_C
--20
--10
0
10
20
30
32
40
50
60
70
77
80
90
100
110
120
194
212
266
302
325
350
--28.9
--23.3
--17.8
--12.2
-- 6.7
-- 1.1
0
4.4
10.0
15.6
21.1
25
26.7
32.2
37.8
43.3
48.9
90
100
130
150
163
177
CDT
Resistance
In Ohms
1,653,000
1,178,000
855,000
624,000
463,000
345,000
327,000
262,000
199,000
153,000
119,000
100,000
93,000
73,000
58,000
47,000
38,000
9,150
6,800
3,010
1,860
1,358
1,202
62--10808
62--10808
Psig
4.5
7.1
9.9
12.9
16.3
17.7
19.2
20.7
22.3
23.9
25.6
27.3
29.1
30.9
32.8
34.8
36.8
38.9
41.1
43.3
45.6
48.0
50.4
52.9
55.5
58.1
60.9
63.7
66.5
69.5
Pressure
Kg/cm@
0.32
0.50
0.70
0.91
1.15
1.24
1.35
1.46
1.57
1.68
1.80
1.92
2.05
2.17
2.31
2.45
2.59
2.73
2.89
3.04
3.21
3.37
3.54
3.72
3.90
4.08
4.28
4.48
4.68
4.89
Bar
0.31
0.49
0.68
0.89
1.12
1.22
1.32
1.43
1.54
1.65
1.77
1.88
2.01
2.13
2.26
2.40
2.54
2.68
2.83
2.99
3.14
3.31
3.47
3.65
3.83
4.01
4.20
4.39
4.59
4.79
3-18
Temperature
_F
_C
32
0
34
1
36
2
38
3
40
4
42
6
44
7
46
8
48
9
50
10
55
13
60
16
65
18
70
21
75
24
80
27
85
29
90
32
95
35
100
38
105
41
110
43
115
46
120
49
125
52
130
54
135
57
140
60
145
63
150
66
Pressure
Psig Kg/cm@ Bar
72.5
5.10
5.00
75.6
5.32
5.21
78.8
5.54
5.43
82.1
5.77
5.66
85.5
6.01
5.90
89.0
6.26
6.14
92.5
6.50
6.38
96.2
6.76
6.63
99.9
7.02
6.89
103.7
7.29
7.15
115.4
8.11
7.96
126.1
8.87
8.69
137.4
9.66
9.47
149.4 10.50 10.30
162.1
11.40 11.18
175.5 12.34 12.10
189.6 13.33 13.07
204.5 14.38 14.10
220.2 15.48 15.18
236.8 16.65 16.33
254.2 17.87 17.53
272.4 19.15 18.78
291.6 20.50 20.11
311.8 21.92 21.50
332.9 23.41 22.95
355.0 24.96 24.48
378.1 26.58 26.07
402.3 28.28 27.74
427.6 30.06 29.48
454.0 31.92 31.30
SECTION 4
TROUBLESHOOTING
CAUTION
DO NOT attempt to service the microprocessor!
Should a problem develop with the microprocessor, contact your nearest Carrier Transicold
dealer for replacement.
INDICATION/
TROUBLE
4.1 DIESEL ENGINE
4.1.1 Engine Will Not Start
Starter motor will not
crank or low cranking speed
POSSIBLE CAUSES
4-1
REFERENCE
SECTION
Check
Check
Check
4.1.3
Engine Manual
4.1.4
1.6
Check
Check
Drain Sump
Replace
Check
Engine Manual
3.2.6
3.2.3
3.2.5
1.6
Check
Check
Fill Tank
Repair
Engine Manual
3.2.5
Engine Manual
Engine Manual
3.2.4
1.10
3.2.3
3.2.5
Check
Check
Replace
Engine Manual
Engine Manual
Engine Manual
3.2.3
1.6
62--10808
INDICATION/
POSSIBLE CAUSES
TROUBLE
4.1.3 Starter Motor Malfunction (CONTINUED)
Starter motor turns
Pinion or ring gear obstructed or worn
but pinion does not engage
REFERENCE
SECTION
3.2.3
Engine Manual
Engine Manual
62--10808
4-2
Clean both,
remove burrs,
or replace;
apply grease
Check
Tighten
Check
Tighten
Replace
Replace
1.6
Replace
3.2.3
Replace
Check
Check
3.3
Check/Repair
Check
Check
Check
Check
Replace
3.3
Check/Repair
Check
Check
Check
Replace
Clean/Repair
Check
3.3
Replace
3.3
Tighten
INDICATION/
TROUBLE
4.3 REFRIGERATION
4.3.1 Unit Will Not Cool
Diesel engine
Compressor malfunction
Refrigeration system
POSSIBLE CAUSES
Malfunction(s)
Compressor drive defective
Compressor defective
Defrost cycle did not terminate
Abnormal pressure
Hot Gas (three-way) valve malfunction
4-3
REFERENCE
SECTION
4.1
3.8
3.8
4.3.5
4.3.6
4.3.11
3.8
3.10
4.3.6
4.3.10
4.3.9
3.10
3.2.3
4.1
Allow time to
pull down
Correct
4.3.6
4.3.8
3.8
4.3.6
4.3.8
4.3.11
3.8
3.8
3.2.3
4.1
62--10808
INDICATION/
POSSIBLE CAUSES
TROUBLE
4.3.5 Defrost Cycle Malfunction
Will not initiate defrost
Defrost air switch (DA) out of calibration
automatically
Defrost thermostats (DTT) open or defective
Defrost air switch (DA) defective
Loose terminal connections
Air sensing tubes defective or disconnected
Defrost timer defective
Will not initiate defrost manually
Microprocessor defective
Loose terminal connections
Defrost thermostats (DTT) open or defective
Glow/Defrost switch defective
Initiates but does not defrost
Frequent defrost
Does not terminate or
cycles on defrost
4.3.6 Abnormal Pressure
4.3.6.1 Cooling
High discharge pressure
62--10808
REFERENCE
SECTION
3.13
Replace
3.13
Tighten
Check
Check/Replace
Replace
Tighten
Replace
Replace
4.3.11
Replace
Replace
3.13
Normal
Replace
Check/Replace
Replace
3.13
Replace
3.16
Check
3.3
Replace
Replace
3.8
3.17
3.8
3.8
3.17
Open
Open
3.11
3.7
4.3.10
4.3.9
Check
3.8
3.17
4-4
INDICATION/
TROUBLE
4.3.6.2 Heating
High discharge pressure
Condenser or
evaporator fan
V-belts
POSSIBLE CAUSES
REFERENCE
SECTION
Overcharged system
Condenser fan defective
V-belts broken or loose
Noncondensibles in system
3.7.2
Check
3.3
Check
3.8
3.17
3.7
3.7
3.18
Open
Tighten
3.8
3.8
4.3.10
3.9
Check
Check
Check
3.3
3.22
Check
3.20
Replace
Check
3.15
3.14
3.3
Replace
Check
3.3
Check
3.14
4-5
62--10808
INDICATION/
TROUBLE
POSSIBLE CAUSES
62--10808
4-6
REFERENCE
SECTION
3.5/3.7
Clean
3.6
3.19
3.19
Replace
Replace
3.19
3.19
Open
3.6
Clean
3.19
3.19
3.19
3.19
Check
Check
3.17
3.17
3.17
Replace
3.17
3.17
3.17
Replace
Replace motor
1.8
Check
Replace
1.8
Check
SECTION 5
ELECTRICAL SCHEMATIC WIRING DIAGRAM
5.1 INTRODUCTION
This section contains Electrical Schematic Wiring Diagram covering the Models listed in Table 1-1. 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.
WARNING
Beware of unannounced starting of the fans and V-belts caused by the thermostat and the start/stop
cycling of the unit.
WARNING
Under no circumstances should ether or any other starting aids be used to start engine.
CAUTION
Under no circumstances should anyone attempt to repair the Logic or Display Boards! Should a
problem develop with these components, contact your nearest Carrier Transicold dealer for
replacement.
CAUTION
Observe proper polarity when installing battery, negative battery terminal must be grounded.
Reverse polarity will destroy the rectifier diodes in alternator. As a precautionary measure,
disconnect positive battery terminal when charging battery in unit. Connecting charger in reverse
will destroy the rectifier diodes in alternator.
CAUTION
Under no circumstances should a technician electrically probe the processor at any point, other than
the connector terminals where the harness attaches. Microprocessor components operate at
different voltage levels and at extremely low current levels. Improper use of voltmeters, jumper
wires, continuity testers, etc. could permanently damage the processor.
CAUTION
Most electronic components are susceptible to damage caused by electrical static discharge (ESD).
In certain cases, the human body can have enough static electricity to cause resultant damage to the
components by touch. This is especially true of the integrated circuits found on the truck/trailer
microprocessor.
5-1
62--10808
62--10808
5-2
LOCATION
SYMBOL
DESCRIPTION
LOCATION
F1
G1
D1
T10
O10
A8
G5
O2/03/K9
O11
T11
K3
O1O (SHEET 3)
N10 (SHEET 3)
G4
O5
S12/S13
O11/O12P5/Q5/R5
T4
K9/O4
I2
N2
N7
N9
K3/N10
N11
N11/N12/N13
P5
P7
L7 (SHEET 3)
T1/ N7(SHEET 3)
M7 (SHEET 3)
T3
T7
K6/O7
S7
S7
H6
K10/O1
H8
D6
D7/D11/F4 (SHEET 3)
F8/F11(SHEET 3)
B2
F3
H3
B11 (SHEET 3)
A7
K2/L3
K6/O2
T3
H2
A7
G7/G11 (SHEET 3)
S9
B1
B3
A5
K10/O9
B2
K7
T4/T10
K7O10
T10
A6
ALT
B
BTY
CC
CCR
CDT
DA
DER
DDR
DDS
DPS
DS
DSR
DTT
DT
EFM 1,2,3
EFMR 1,2,3
EHC
EHR
F1
F3
F4
F5
F2,F6
F7
F8,F9, F10
F11
F12
FH
FHR
FHTH
FP
GP
GPR
HGS1
HGS2
HP1
HR1
MGC
MP
MC
OL
OP
P1
P2
PSR
RAS
RCR
RR
RS
RSS
SAS
SBM
SCS
SM
SP
SPT
SR
SS
SSR
SUFR
UFR
UF
WTS
ALTERNATOR
BUZZER
BATTERY
COMPRESSOR CLUTCH
COMPRESSOR CLUTCH RELAY
COMPRESSOR DISCHARGE TEMPERATURE SENSOR
DEFROST AIR SWITCH
DIESEL ELECTRIC RELAY
DERFROST DAMPER RELAY
DEFROST DAMPER SOLENOID
DETECTOR POWER SUPPLY
DOOR SWITCH
DOOR SWITCH RELAY
DEFROST THERMOSTAT
DEFROST TRANSISTOR
ELECTRIC FAN MOTOR
ELECTRIC FAN MOTOR RELAY
EVAPORATOR HEAT CONTACTOR
EVAPORATOR HEAT RELAY
FUSE (MAXI FUSE 80A)
FUSE 15A
FUSE 3/5A
FUSE 10A
FUSE 5A
FUSE 15A
FUSE 20A
FUSE 5A
FUSE 25A
FUEL HEATER (OPTION)
FUEL HEATER RELAY (OPTION)
FUEL HEATER THERMOSTAT (OPTION)
FUEL PUMP
GLOW PLUG
GLOW PLUG RELAY
HOT GAS SOLENOID
HOT GAS BYPASS SOLENOID
HIGH PRESSURE CUT-OUT SWITCH
HEAT RELAY
MANUAL GLOW/CRANK
MICROPROCESSOR BOARD
MOTOR CONTACTOR
OVERLOAD PROTECTOR
OIL PRESSURE SAFETY SWITCH (NO)
CAB COMMAND PLUG CONNECTOR
MICROPROCESSOR-CAB COMMAND PLUG CONNECTOR
POWER SUPPLY RECEPTACLE
RETURN AIR SENSOR
RUN CONTROL RELAY
RUN RELAY
RUN SOLENOID
RUN STOP SWITCH
SUPPLY AIR SENSOR (OPTIONAL)
STANDBY MOTOR
SPEED CONTROL SOLENOID
STARTER MOTOR
SERIAL PORT
SUCTION PRESSURE TRANSDUCER
SPEED RELAY
STARTER SOLENOID
STARTER SOLENOID RELAY
STANDBY UNLOADER FRONT RELAY
UNLOADER FRONT RELAY
UNLOADER FRONT
WATER TEMPERATURE SENSOR
MID FRAME
CONTROL BOX
CONTROL BOX
CONTROL BOX
COMPRESSOR
FRAME
CONTROL BOX
CONTROL BOX
EVAPORATOR
CONTROL BOX
CONTROL BOX
CONTROL BOX
EVAPORATOR
CONTROL BOX
EVAPORATOR
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
LIGHT BAR
ENGINE
CONTROL BOX
ENGINE
FUEL TANK
ENGINE
CONTROL BOX
FRAME
FRAME
COMPRESSOR
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
CONTROL BOX
ENGINE
CONTROL BOX
CONTROL BOX
EVAPORATOR
CONTROL BOX
CONTROL BOX
ENGINE
CONTROL BOX
EVAPORATOR
FRAME
ENGINE
ENGINE
CONTROL BOX
COMPRESSOR
CONTROL BOX
STARTER
CONTROL BOX
CONTROL BOX
CONTROL BOX
COMPRESSOR
ENGINE
Figure 5-1. Electrical Schematic Wiring Diagram - MICROPROCESSOR CONTROLLER Based On Dwg. No. 62-60925 Rev C (Sheet 1 of 3)
844 ONLY
844 ONLY
5-3
844 ONLY
844 ONLY
844 ONLY
844 ONLY
844 ONLY
62--10808
Figure 5-1. Electrical Schematic Wiring Diagram - Based On Dwg. No. 62-60925 Rev C Sheet 2 of 3
5-4
62--10808
Figure 5-1. Electrical Schematic Wiring Diagram - MICROPROCESSOR CONTROLLER Based On Dwg. No. 62-60925 Rev C Sheet 3 of 3
INDEX
Accumulator , 1-5
Alternator: , 1-11
Condenser/Subcooler, 1-5
Controller, 3-14
Controller Sensor Checkout , 3-17
Index-1
62--10808
INDEX
Keypad, 2-2
F
Fail safe Defrost Termination, 2-10
Filter Drier, 1-6
Fuel Heater , 2-9
Fuel Pump , 3-5
Functional Parameters, 2-3
Fuse Alarm, 2-8
G
Glow Plugs, 3-5
62--10808
Index-2
INDEX
P
Pre--trip, 2-8
Pre--trip Inspection, 2-10
Pre--trip Inspection -- Starting , 2-10
Pre--trip Inspection -- Before Starting , 2-10
Pumping The Unit Down, 3-7
Receiver, 1-6
Refrigeration, 4-3
Superheat , 3-14
S
Safety Devices, 1-11
Setpoint, 2-3
Software Revision, 2-6
Index-3
62--10808
North America
Carrier Transicold
700 Olympic Drive
Athens, GA 30601 USA
Tel: 1--706--357--7223
Fax: 1--706--355--5435
Central America
and Mexico
Ejercito Nacional No. 418
Piso 9, Torre Yumal
Col. Chapultepec Morales
11570 Mexico, D.F.
Tel: (5255) 9126.0300
Fax: (5255) 9126.0373