Carrier Transicold 69nt40-561-199 Operation manual

T−340 Rev D

OPERATION AND SERVICE

for

69NT40-561-001 to 199

Container Refrigeration Units

Container Refrigeration

OPERATION AND SERVICE MANUAL

CONTAINER REFRIGERATION UNIT

Models

69NT40−561−001 to 199

©Carrier Corporation, 2012 Printed in U. S. A. May 2012

iT-340

TABLE OF CONTENTS

PARAGRAPH NUMBER Page

INTRODUCTION 1−1..............................................................................

1.1 INTRODUCTION 1−1.....................................................................

1.2 CONFIGURATION IDENTIFICATION 1−1...................................................

1.3 FEATURE DESCRIPTIONS 1−1............................................................

1.3.1 Control Box 1−1......................................................................

1.3.2 Temperature Readout 1−1..............................................................

1.3.3 Pressure Readout 1−1.................................................................

1.3.4 Compressor 1−1......................................................................

1.3.5 Condenser Coil 1−1...................................................................

1.3.6 Evaporator 1−1.......................................................................

1.3.7 Evaporator Fan Operation 1−1..........................................................

1.3.8 Plate Set 1−1.........................................................................

1.4 OPTION DESCRIPTIONS 1−1.............................................................

1.4.1 Battery 1−1...........................................................................

1.4.2 Dehumidification 1−1..................................................................

1.4.3 USDA 1−1...........................................................................

1.4.4 Interrogator 1−1.......................................................................

1.4.5 Remote Monitoring 1−1................................................................

1.4.6 Quest −CCPC 1−2....................................................................

1.4.7 Communications Interface Module 1−2...................................................

1.4.8 Autotransformer 1−2...................................................................

1.4.9 Temperature Recorder 1−2.............................................................

1.4.10 Gutters 1−2..........................................................................

1.4.11 Handles 1−2..........................................................................

1.4.12 Thermometer Port 1−2.................................................................

1.4.13 Water Cooling 1−2....................................................................

1.4.14 Back Panels 1−2......................................................................

1.4.15 460 Volt Cable 1−2....................................................................

1.4.16 230 Volt Cable 1−2....................................................................

1.4.17 Cable Restraint 1−2...................................................................

1.4.18 Upper Air (Fresh Air Make Up) 1−2......................................................

1.4.19 Lower Air (Fresh Air Make Up) 1−2......................................................

1.4.20 Labels 1−2...........................................................................

1.4.21 Controller 1−2........................................................................

1.4.22 Condenser Grille 1−2..................................................................

1.4.23 Emergency Bypass 1−2................................................................

1.4.24 eAutoFresh 1−2.......................................................................

T-340

TABLE OF CONTENTS (Continued)

PARAGRAPH NUMBER Page

DESCRIPTION 2−1...............................................................................

2.1 GENERAL DESCRIPTION 2−1.............................................................

2.1.1 Refrigeration Unit −Front Section 2−1...................................................

2.1.2 Fresh Air Makeup Vent 2−1.............................................................

2.1.3 Evaporator Section 2−2................................................................

2.1.4 Compressor Section 2−3...............................................................

2.1.5 Air−Cooled Condenser Section 2−4......................................................

2.1.6 Water−Cooled Condenser Section 2−5...................................................

2.1.7 Control Box Section 2−6...............................................................

2.1.8 Communications Interface Module 2−6...................................................

2.2 REFRIGERATION SYSTEM DATA 2−7......................................................

2.3 ELECTRICAL DATA 2−8...................................................................

2.4 SAFETY AND PROTECTIVE DEVICES 2−9.................................................

2.5 REFRIGERATION CIRCUIT 2−10...........................................................

2.5.1 Standard Operation 2−10................................................................

2.5.2 Economized Operation 2−10.............................................................

2.5.3 Electronic Expansion Valve 2−10.........................................................

MICROPROCESSOR 3−1..........................................................................

3.1 TEMPERATURE CONTROL MICROPROCESSOR SYSTEM 3−1..............................

3.1.1 Keypad 3−2..........................................................................

3.1.2 Display Module 3−2...................................................................

3.1.3 Controller 3−3........................................................................

3.2 CONTROLLER SOFTWARE 3−3...........................................................

3.2.1 Configuration Software (CnF Variables) 3−3..............................................

3.2.2 Operational Software (Cd Function Codes) 3−4...........................................

3.3 MODES OF OPERATION 3−4.............................................................

3.3.1 Start up - Compressor Phase Sequence 3−4..............................................

3.3.2 Start up - Compressor Bump Start 3−4...................................................

3.3.3 Perishable Mode Temperature Control 3−4...............................................

3.3.4 Perishable Pulldown 3−4...............................................................

3.3.5 Perishable Steady State 3−4............................................................

3.3.6 Perishable Idle, Air Circulation 3−4......................................................

3.3.7 Perishable Heating 3−4................................................................

3.3.8 Perishable Dehumidification 3−5........................................................

3.3.9 Perishable Dehumidification - Bulb Mode 3−6.............................................

3.3.10 Perishable Economy 3−6...............................................................

3.3.11 Perishable Mode Cooling - Sequence of Operation 3−6.....................................

3.3.12 Perishable Mode Heating - Sequence of Operation 3−7....................................

3.3.13 Perishable Mode - Trim Heat 3−7........................................................

3.3.14 Frozen Mode - Temperature Control 3−7.................................................

3.3.15 Frozen Steady State 3−7...............................................................

3.3.16 Frozen Idle Mode 3−7.................................................................

3.3.17 Frozen “Heat” Mode 3−8...............................................................

iii T-340

TABLE OF CONTENTS (Continued)

PARAGRAPH NUMBER Page

3.3.18 Frozen Economy Mode 3−8............................................................

3.3.19 Frozen Mode Cooling - Sequence of Operation 3−8........................................

3.3.20 Defrost 3−9..........................................................................

3.3.21 Automatic Defrost 3−9.................................................................

3.3.22 Defrost Initiation 3−9..................................................................

3.3.23 Defrost Interval 3−10...................................................................

3.3.24 Defrost Related Settings 3−10...........................................................

3.4 PROTECTION MODES OF OPERATION 3−11................................................

3.4.1 Evaporator Fan Operation 3−11..........................................................

3.4.2 Failure Action 3−11.....................................................................

3.4.3 Generator Protection 3−11..............................................................

3.4.4 Compressor High Temperature, Low Pressure Protection 3−11...............................

3.4.5 Perishable Mode - System Pressure Regulation 3−11.......................................

3.4.6 Condenser Fan Override 3−11...........................................................

3.5 QUEST −CCPC 3−12......................................................................

3.6 CONTROLLER ALARMS 3−12..............................................................

3.7 PRE−TRIP DIAGNOSTICS 3−12............................................................

3.8 DataCORDER 3−13........................................................................

3.8.1 Description 3−13.......................................................................

3.8.2 DataCORDER Software 3−13............................................................

3.8.3 Sensor Configuration (dCF02) 3−14......................................................

3.8.4 Logging Interval (dCF03) 3−14...........................................................

3.8.5 Thermistor Format (dCF04) 3−14.........................................................

3.8.6 Sampling Type (dCF05 & dCF06) 3−16...................................................

3.8.7 Alarm Configuration (dCF07 - dCF10) 3−16................................................

3.8.8 DataCORDER Power Up 3−16...........................................................

3.8.9 Pre-trip Data Recording 3−16............................................................

3.8.10 DataCORDER Communications 3−16.....................................................

3.8.11 USDA Cold Treatment 3−17.............................................................

3.8.12 USDA Cold Treatment Procedure 3−17...................................................

3.8.13 DataCORDER Alarms 3−18.............................................................

3.8.14 ISO Trip Header 3−18..................................................................

3.9 CONTROLLER CONFIGURATION VARIABLES 3−19..........................................

3.10 CONTROLLER FUNCTION CODES 3−20....................................................

3.11 CONTROLLER ALARM INDICATIONS 3−29..................................................

3.12 CONTROLLER PRE−TRIP TEST CODES 3−37...............................................

OPERATION 4−1.................................................................................

4.1 INSPECTION (Before Loading) 4−1.........................................................

4.2 CONNECT POWER 4−1..................................................................

4.2.1 Connection To 380/460 VAC Power 4−1..................................................

4.2.2 Connection To 190/230 VAC Power 4−1..................................................

4.3 ADJUST FRESH AIR MAKEUP VENT 4−1...................................................

4.3.1 Upper Fresh Air Makeup Vent 4−2.......................................................

4.3.2 Lower Fresh Air Makeup Vent 4−2.......................................................

4.3.3 Vent Position Sensor 4−3..............................................................

T-340

TABLE OF CONTENTS (Continued)

PARAGRAPH NUMBER Page

4.4 eAutoFresh OPERATION 4−3..............................................................

4.4.1 eAutoFresh Pre−Trip Inspection 4−3.....................................................

4.4.2 eAutoFresh Start−Up Procedure 4−3....................................................

4.4.3 eAutoFresh Modes of Operation 4−3.....................................................

4.5 CONNECT WATER-COOLED CONDENSER 4−4.............................................

4.5.1 Water-Cooled Condenser with Water Pressure Switch 4−4..................................

4.5.2 Water−Cooled Condenser with Condenser Fan Switch 4−5.................................

4.6 CONNECT REMOTE MONITORING RECEPTACLE 4−5......................................

4.7 STARTING AND STOPPING INSTRUCTIONS 4−5...........................................

4.7.1 Starting the Unit 4−5...................................................................

4.7.2 Stopping the Unit 4−5..................................................................

4.8 START−UP INSPECTION 4−5.............................................................

4.8.1 Physical Inspection 4−5................................................................

4.8.2 Check Controller Function Codes 4−5....................................................

4.8.3 Start Temperature Recorder 4−5........................................................

4.8.4 Complete Inspection 4−5...............................................................

4.9 PRE−TRIP DIAGNOSIS 4−6...............................................................

4.10 PROBE DIAGNOSTICS 4−7...............................................................

4.11 EMERGENCY BYPASS OPERATION 4−8...................................................

TROUBLESHOOTING 5−1.........................................................................

5.1 UNIT WILL NOT START OR STARTS THEN STOPS 5−1......................................

5.2 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING 5−1..............................

5.3 UNIT RUNS BUT HAS INSUFFICIENT COOLING 5−2........................................

5.4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING 5−2................................

5.5 UNIT WILL NOT TERMINATE HEATING 5−2................................................

5.6 UNIT WILL NOT DEFROST PROPERLY 5−2................................................

5.7 ABNORMAL PRESSURES 5−3............................................................

5.8 ABNORMAL NOISE OR VIBRATIONS 5−3..................................................

5.9 MICROPROCESSOR MALFUNCTION 5−3..................................................

5.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW 5−4..............................

5.11 EAUTOFRESH NOT OPERATING 5−4......................................................

5.12 ELECTRONIC EXPANSION VALVE MALFUNCTION 5−4......................................

5.13 AUTOTRANSFORMER MALFUNCTION 5−5................................................

5.14 WATER−COOLED CONDENSER OR WATER PRESSURE SWITCH 5−5.......................

5.15 COMPRESSOR OPERATING IN REVERSE 5−5.............................................

5.16 ABNORMAL TEMPERATURES 5−5........................................................

5.17 ABNORMAL CURRENTS 5−5..............................................................

SERVICE 6−1....................................................................................

6.1 SECTION LAYOUT 6−1...................................................................

6.2 MANIFOLD GAUGE SET 6−1..............................................................

6.3 SERVICE CONNECTIONS 6−2............................................................

6.4 PUMP DOWN THE UNIT 6−2..............................................................

vT-340

TABLE OF CONTENTS (Continued)

PARAGRAPH NUMBER Page

6.5 REFRIGERANT LEAK CHECKING 6−3.....................................................

6.6 EVACUATION AND DEHYDRATION 6−3....................................................

6.6.1 General 6−3..........................................................................

6.6.2 Preparation 6−3.......................................................................

6.6.3 Complete System 6−3.................................................................

6.6.4 Partial System 6−4....................................................................

6.7 REFRIGERANT CHARGE 6−4.............................................................

6.7.1 Checking the Refrigerant Charge 6−4....................................................

6.7.2 Adding Refrigerant to System (Full Charge) 6−4...........................................

6.7.3 Adding Refrigerant to System (Partial Charge) 6−4........................................

6.8 COMPRESSOR 6−5......................................................................

6.8.1 Removal and Replacement of Compressor 6−5...........................................

6.9 HIGH PRESSURE SWITCH 6−6...........................................................

6.9.1 Checking High Pressure Switch 6−6.....................................................

6.9.2 Replacing High Pressure Switch 6−6.....................................................

6.10 CONDENSER COIL 6−7..................................................................

6.11 CONDENSER FAN AND MOTOR ASSEMBLY 6−7...........................................

6.12 WATER−COOLED CONDENSER CLEANING 6−7............................................

6.13 FILTER DRIER 6−9.......................................................................

6.14 EVAPORATOR COIL & HEATER ASSEMBLY 6−9............................................

6.14.1 Evaporator Coil Replacement 6−9.......................................................

6.14.2 Evaporator Heater Replacement 6−10....................................................

6.15 EVAPORATOR FAN AND MOTOR ASSEMBLY 6−10..........................................

6.15.1 Replacing the Evaporator Fan Assembly 6−10.............................................

6.15.2 Disassemble the Evaporator Fan Assembly 6−10...........................................

6.15.3 Assemble the Evaporator Fan Assembly 6−11.............................................

6.16 EVAPORATOR SECTION CLEANING 6−11...................................................

6.17 ELECTRONIC EXPANSION VALVE 6−12.....................................................

6.17.1 Replacing Electronic Expansion Valve and Screen 6−12.....................................

6.18 ECONOMIZER SOLENOID VALVE 6−13.....................................................

6.19 ECONOMIZER EXPANSION VALVE 6−13....................................................

6.19.1 Economizer Expansion Replacement 6−13................................................

6.20 DIGITAL UNLOADER VALVE 6−14..........................................................

6.21 VALVE OVERRIDE CONTROLS 6−15........................................................

6.22 AUTOTRANSFORMER 6−16...............................................................

6.23 CONTROLLER 6−16.......................................................................

6.23.1 Handling Modules 6−16.................................................................

6.23.2 Controller Troubleshooting 6−16..........................................................

6.23.3 Controller Programming Procedure 6−17..................................................

6.23.4 Removing and Installing a Controller 6−19.................................................

6.23.5 Battery Replacement 6−19..............................................................

T-340

TABLE OF CONTENTS (Continued)

PARAGRAPH NUMBER Page

6.24 TEMPERATURE SENSOR SERVICE 6−19...................................................

6.24.1 Sensor Checkout Procedure 6−19........................................................

6.24.2 Sensor Replacement 6−22..............................................................

6.24.3 Sensor Re-Installation 6−22.............................................................

6.25 VENT POSITION SENSOR (VPS) 6−24......................................................

6.26 eAutoFresh SERVICE 6−25.................................................................

6.26.1 Servicing the eAutoFresh Air Filter 6−25...................................................

6.26.2 Checking eAutoFresh Drive System 6−25.................................................

6.26.3 Checking the Controller 6−26............................................................

6.26.4 Servicing the eAutoFresh Drive System 6−26..............................................

6.27 ELECTRONIC PARTLOW TEMPERATURE RECORDER 6−28..................................

6.28 MAINTENANCE OF PAINTED SURFACES 6−29..............................................

6.29 COMMUNICATIONS INTERFACE MODULE INSTALLATION 6−29..............................

ELECTRICAL WIRING SCHEMATICS 7−1...........................................................

7.1 INTRODUCTION 7−1.....................................................................

LIST OF ILLUSTRATIONS

FIGURE NUMBER Page

Figure 2−1 Refrigeration Unit −Front Section 2−1....................................................

Figure 2−2 Evaporator Section 2−2.................................................................

Figure 2−3 Compressor Section 2−3................................................................

Figure 2−4 Air−Cooled Condenser Section 2−4.......................................................

Figure 2−5 Water−Cooled Condenser Section 2−5....................................................

Figure 2−6 Control Box Section 2−6................................................................

Figure 2−7 Refrigeration Circuit Schematic −Standard Operation 2−11...................................

Figure 2−8 Refrigeration Circuit Schematic −Economized Operation 2−12................................

Figure 3−1 Temperature Control System 3−1.........................................................

Figure 3−2 Keypad 3−2...........................................................................

Figure 3−3 Display Module 3−3....................................................................

Figure 3−4 Control Module 3−3.....................................................................

Figure 3−5 Controller Operation - Perishable Mode 3−5...............................................

Figure 3−6 Perishable Mode Cooling 3−6............................................................

Figure 3−7 Perishable Mode Heating 3−7............................................................

Figure 3−8 Controller Operation - Frozen Mode 3−8...................................................

Figure 3−9 Frozen Mode 3−9......................................................................

Figure 3−10 Defrost 3−10..........................................................................

Figure 3−11 Standard Configuration Download Report 3−15.............................................

Figure 3−12 DataReader 3−17......................................................................

Figure 3−13 Alarm Troubleshooting Sequence 3−28....................................................

Figure 4−1 Autotransformer 4−1....................................................................

Figure 4−2 Upper Fresh Air Make Up Flow Chart 4−2.................................................

vii T-340

LIST OF ILLUSTRATIONS (Continued)

FIGURE NUMBER Page

Figure 4−3 Diagram of Emergency Bypass Connections 4−8...........................................

Figure 6−1 Manifold Gauge Set 6−1................................................................

Figure 6−2 R-134a Manifold Gauge/Hose Set 6−1....................................................

Figure 6−3 Service Valve 6−2......................................................................

Figure 6−4 Refrigeration System Service Connections 6−3.............................................

Figure 6−5 Compressor Kit 6−5....................................................................

Figure 6−6 High Pressure Switch Testing 6−6........................................................

Figure 6−7 Water-Cooled Condenser Cleaning, Forced Circulation 6−8.................................

Figure 6−8 Water-Cooled Condenser Cleaning - Gravity Circulation 6−9.................................

Figure 6−9 5+1 Heater Arrangement −Omega Heater 6−10.............................................

Figure 6−10 Evaporator Fan Assembly 6−11..........................................................

Figure 6−11 Electronic Expansion Valve 6−12.........................................................

Figure 6−12 Coil View of Economizer Solenoid Valve (ESV) 6−13........................................

Figure 6−13 Economizer Expansion Valve 6−13.......................................................

Figure 6−14 View of Digital Unloader Valve (DUV) Assembly 6−14.......................................

Figure 6−15 Autotransformer 6−16...................................................................

Figure 6−16 Controller Section of the Control Box 6−17.................................................

Figure 6−17 Sensor Types 6−22.....................................................................

Figure 6−18 Sensor and Cable Splice 6−22...........................................................

Figure 6−19 Supply Sensor Positioning 6−23..........................................................

Figure 6−20 Return Sensor Positioning 6−23..........................................................

Figure 6−21 Evaporator Temperature Sensor Positioning 6−23..........................................

Figure 6−22 Compressor Discharge Temperature Sensor 6−24..........................................

Figure 6−23 Stepper Components 6−25..............................................................

Figure 6−24 Jumper Assembly 6−26.................................................................

Figure 6−25 Motor Cup Replacement 6−27...........................................................

Figure 6−26 Electronic Partlow Temperature Recorder 6−28.............................................

Figure 6−27 Communications Interface Installation 6−29................................................

Figure 7−1 LEGEND −Standard Unit Configuration 7−2...............................................

Figure 7−2 SCHEMATIC DIAGRAM −Standard Unit Configuration 7−3..................................

Figure 7−3 LEGEND −Configuration Includes Available Options

(Except Vent Positioning System, eAutoFresh, Emergency Bypass Options) 7−4..............

Figure 7−4 SCHEMATIC DIAGRAM −Configuration Includes Available Options

(Except Vent Positioning System, eAutoFresh, Emergency Bypass Options) 7−5..............

Figure 7−5 LEGEND −Configuration Includes eAutoFresh and Emergency Bypass Options 7−6............

Figure 7−6 SCHEMATIC DIAGRAM −Configuration Includes eAutoFresh and Emergency Bypass Options 7−7

Figure 7−7 SCHEMATIC AND WIRING DIAGRAM −Upper Vent Position Sensor (VPS) Option 7−8.........

Figure 7−8 SCHEMATIC AND WIRING DIAGRAM −Lower Vent Position Sensor (VPS) Option 7−9.........

Figure 7−9 UNIT WIRING DIAGRAM −Standard Unit Configuration with 3−Phase Condenser Fan Motors 7−10

Figure 7−10 UNIT WIRING DIAGRAM −Configuration Includes Single Phase Condenser Fan Motor

& Optional Heater Arrangement 7−12.....................................................

Figure 7−11 UNIT WIRING DIAGRAM −Configuration Includes eAutoFresh & Emergency Bypass Options 7−14

Figure 7−11 UNIT WIRING DIAGRAM −Configuration Includes eAutoFresh & Emergency Bypass Options 7−15

viii

T-340

LIST OF TABLES

TABLE NUMBER Page

Table 2−1 Safety and Protective Devices 2−9.........................................................

Table 3−1 Keypad Function 3−2.....................................................................

Table 3−2 DataCORDER Configuration Variables 3−14..................................................

Table 3−3 DataCORDER Standard Configurations 3−16.................................................

Table 3−4 Controller Configuration Variables 3−19......................................................

Table 3−5 Controller Function Codes 3−20.............................................................

Table 3−6 Controller Alarm Indications 3−29...........................................................

Table 3−7 Controller Pre-trip Test Codes 3−37..........................................................

Table 3−8 DataCORDER Function Code Assignments 3−43..............................................

Table 3−9 DataCORDER Pre-trip Result Records 3−44..................................................

Table 3−10 DataCORDER Alarm Indications 3−45......................................................

Table 6−1 Valve Override Control Displays 6−15........................................................

Table 6−2 Sensor Resistance 6−20...................................................................

Table 6−3 Sensor Resistance (CPDS) 6−21............................................................

Table 6−4 R-134a Temperature - Pressure Chart 6−30..................................................

Table 6−5 Recommended Bolt Torque Values 6−31.....................................................

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