Carrier 40RM Operation manual

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

SERVICE MANUAL
OPERATION AND
TRUCK REFRIGERATION UNIT
Integra 40S
Integra 50S

62--10630Safety-1
SAFETY SUMMARY
GENERAL SAFETY NOTICES
The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this
manual. They arerecommendedprecautionsthatmust beunderstoodandappliedduringoperationandmaintenance
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.
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.
Noworkshouldbeperformedonthe unituntilallcircuit breakersandtheEmergency Switchareturnedoff,andbattery
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
Bewareofunannouncedstartingofthe unit.Thisunitisequippedwith Auto--Startinboththeroadandstandbymodes.
Theunit maystartatanytime.WhenperforminganycheckofthesystemmakecertaintheEmergencySwitchisinthe
OFF position.
Be sure poweris turnedoff before working on motors, controllers, solenoid valves and electricalcontrol switches. Tag
circuit breaker and vehicle ignition to prevent accidental energizing of circuit.
Donotbypassanyelectricalsafetydevices,e.g.bridginganoverload,orusinganysortofjumperwires.Problemswith
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.Donot removewireharnessfromthemodulesunlessyouaregroundedtotheunit framewithastatic
safe wrist strap.
In case of electrical fire, open circuit switch and extinguish with CO2(never use water).
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 applicable to the 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 unit. The unitmay cycle the fans and operating compressor
unexpectedly as control requirements dictate.
WARNING
Do not attempt to connect or remove powerplug beforeensuring theunit isOFF (pressOFF keyon
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
Beware of unannounced starting of the unit. The unitmay cycle the fans and operating compressor
unexpectedly as control requirements dictate. To ensure unit will not start, place the EMERGENCY

Safety-2
62--10630
SWITCH (see Figure 1-1) in the OFF position. To ensure unit is without power, remove power plug
and remove battery negative cable.
WARNING
Ensurepowerto the unit isOFF and powerplug is disconnected orvehicle engineis OFF andnega-
tive battery cable is disconnected before replacing the compressor.
WARNING
Do not use a nitrogen cylinder without a pressure regulator. (See Figure 4-3.) Cylinder pressure is
approximately 2350 psi (160 bar). Do not use oxygen in or near a refrigerant system as an explosion
may occur.
CAUTION
If starting unit for the first time after installation the compressor pressure regulating valve will need
to be reset (refer to paragraph 4.15)
CAUTION
If starting unit for the first timeafter installation or starting afteradding/removing ofan optionalfea-
tureorifOwnersoperatingparametershavechangedtheConfigurationwillneedtobereset (referto
paragraph 2.9)
CAUTION
Under no circumstances should anyone attempt to service the microprocessor (see section 4.17).
Should a problem develop with the microprocessor, contact your nearest Carrier Transicold dealer
for replacement.
CAUTION
Refrigerant R404Amustbechargedasaliquid. RefrigerantR404Aisablend.Chargingasavaporwill
change the properties of the refrigerant.
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.

i62--10630
TABLE OF CONTENTS
PARAGRAPH NUMBER Page
GENERAL SAFETY NOTICES Safety-1............................................................
FIRST AID Safety-1.............................................................................
OPERATING PRECAUTIONS Safety-1............................................................
MAINTENANCE PRECAUTIONS Safety-1..........................................................
SPECIFIC WARNING AND CAUTION STATEMENTS Safety-1........................................
DESCRIPTION 1-1...............................................................................
1.1 INTRODUCTION 1-1.....................................................................
1.2 COMPRESSOR REFERENCE DATA 1-7....................................................
1.3 REFRIGERATION SYSTEM DATA 1-7......................................................
1.4 ELECTRICAL DATA 1-7...................................................................
1.5 TORQUE VALUES 1-8....................................................................
1.6 SAFETY DEVICES 1-8...................................................................
1.7 REFRIGERANT CIRCUIT DURING COOLING 1-10...........................................
1.8 REFRIGERANT CIRCUIT DURING HEAT AND DEFROST 1-10................................
OPERATION 2-1.................................................................................
2.1 INSPECTION 2-1........................................................................
2.2 CONNECT POWER 2-1..................................................................
2.3 CAB COMMAND 2-1.....................................................................
2.3.1 Keypad 2-1..........................................................................
2.3.2 Additional Key Functions 2-2...........................................................
2.3.3 Unit Operating Data LED Status 2-2.....................................................
2.3.4 Digital Display 2-2....................................................................
2.4 STARTING 2-3..........................................................................
2.5 STOPPING 2-3..........................................................................
2.6 SET-POINT ADJUSTMENT 2-3............................................................
2.7 DEFROST CYCLE ADJUSTMENT 2-3......................................................
2.8 SEQUENCE OF OPERATION 2-4..........................................................
2.8.1 Perishable Mode 2-4..................................................................
2.8.2 Frozen Mode 2-4.....................................................................
2.9 CONFIGURATION 2-4....................................................................
2.10 ALARM DISPLAY 2-6.....................................................................
2.10.1 Low Battery Voltage Alarm 2-6.........................................................
2.10.2 Accessing Alarm Messages 2-6........................................................
2.10.3 Clearing Alarm Messages 2-6..........................................................
TROUBLESHOOTING 3-1.........................................................................
3.1 INTRODUCTION 3-1.....................................................................
3.2 REFRIGERATION 3-3....................................................................
3.2.1 Unit Will Not Cool 3-3.................................................................
3.2.2 Unit Runs But Has Insufficient Cooling 3-3...............................................
3.2.3 Unit Operates Long or Continuously in Cooling 3-3.......................................
3.2.4 Unit Will Not Heat or Heating Insufficient 3-3.............................................
3.2.5 Defrost Malfunction 3-3...............................................................
3.2.6 Abnormal Pressure 3-4...............................................................
3.2.6.1 Cooling 3-4....................................................................

ii
62--10630
TABLE OF CONTENTS
PARAGRAPH NUMBER Page
3.2.6.2 Heating 3-4...................................................................
3.2.7 Abnormal Noise 3-4..................................................................
3.2.8 Cab Command Malfunction 3-4........................................................
3.2.9 No Evaporator Air Flow or Restricted Air Flow 3-4........................................
3.2.10 Expansion Valve 3-5...................................................................
3.2.11 Malfunction Hot Gas Solenoid or Condenser Pressure Regulating Valve 3-5...................
3.2.12 Standby Compressor Malfunction 3-5....................................................
SERVICE 4-1....................................................................................
4.1 PREVENTATIVE MAINTENANCE 4-1......................................................
4.2 BELT MAINTENANCE AND ADJUSTMENT 4-1..............................................
4.3 EVAPORATOR COIL CLEANING 4-2.......................................................
4.4 CONDENSER COIL CLEANING 4-2........................................................
4.5 CHECKING AND REPLACING FILTER-DRIER 4-2...........................................
4.6 CHECKING THE TXV ORIFICE STRAINER 4-2.............................................
4.7 REMOVING THE REFRIGERANT CHARGE 4-2.............................................
4.7.1 Removing Complete Charge 4-2........................................................
4.7.2 Pumping The Unit Down 4-2...........................................................
4.8 REFRIGERANT LEAK CHECKING 4-3.....................................................
4.9 EVACUATION AND DEHYDRATION 4-3....................................................
4.9.1 General 4-3..........................................................................
4.9.2 Preparation 4-3.......................................................................
4.9.3 Evacuation and Dehydration -- Complete System. 4-3.....................................
4.9.4 Evacuation and Dehydration -- Partial System. 4-4........................................
4.10 CHARGING THE REFRIGERATION SYSTEM 4-4...........................................
4.10.1 Checking The Refrigerant Charge 4-4...................................................
4.10.2 Installing A Complete Charge 4-4.......................................................
4.10.3 Adding A Partial Charge 4-5............................................................
4.11 REPLACING THE COMPRESSOR 4-5.....................................................
4.12 HIGH PRESSURE OR CONDENSER PRESSURE SWITCH 4-5...............................
4.12.1 Removing Switch 4-5..................................................................
4.12.2 Checking Pressure Switch 4-5..........................................................
4.13 CHECKING AND REPLACING CONDENSER FAN MOTOR BRUSHES 4-6.....................
4.14 HOT GAS AND CONDENSER PRESSURE CONTROL SOLENOID VALVES 4-6.................
4.14.1 Replacing Solenoid Coil 4-6...........................................................
4.14.2 Replacing Valve Internal Parts 4-6.......................................................
4.15 ADJUSTING THE COMPRESSOR PRESSURE REGULATING VALVE (CPR) 4-7................
4.16 THERMOSTATIC EXPANSION VALVE 4-7..................................................
4.16.1 Replacing expansion valve 4-7.........................................................
4.16.2 Measuring superheat 4-7..............................................................
4.17 MICROPROCESSOR 4-7.................................................................
SCHEMATIC DIAGRAMS 5-1......................................................................
5.1 INTRODUCTION 5-1.....................................................................

iii 62--10630
LIST OF ILLUSTRATIONS
FIGURE NUMBER Page
Figure 1-1 Integra 50S 1-1......................................................................
Figure 1-2 Condenser 1-2.......................................................................
Figure 1-3 Control Box 1-3......................................................................
Figure 1-4 Start Box (Single Phase Only) 1-4......................................................
Figure 1-5 Evaporator 3 Fans (Integra 50S) 1-5....................................................
Figure 1-6 Evaporator 2 Fans (Integra 40S) 1-6....................................................
Figure 1-7 Cooling Cycle 1-11....................................................................
Figure 1-8 Heat/Defrost Cycle 1-12................................................................
Figure 2-1 Cab Command 2-1...................................................................
Figure 2-2 Operating Sequence -- Perishable Mode 2-4.............................................
Figure 2-3 Configuration Button 2-4..............................................................
Figure 4-1. Belt Tension Gauge 4-2...............................................................
Figure 4-2. Vacuum Pump Connection 4-4.........................................................
Figure 4-3. Typical Setup For Testing Pressure Switches HP1, HP2 and HP3 4-5.......................
Figure 4-4. Fan motor brushes 4-6................................................................
Figure 4-5. Hot Gas or Condenser Pressure Control Solenoid 4-6.....................................
Figure 4-6. Compressor Pressure Regulating Valve 4-6..............................................
Figure 4-7 Thermostatic Expansion Valve Bulb And Thermocouple 4-7................................
Figure 5-1 Schematic Diagram -- Road Only 5-2....................................................
Figure 5-2 Schematic Diagram -- Three Phase Stand By Units 5-4....................................
Figure 5-3 Schematic Diagram -- Single Phase Stand By Units 5-6....................................
LIST OF TABLES
TABLE NUMBER Page
Table 1-1 Model Chart 1-1.......................................................................
Table 1-2 Fuses 1-8............................................................................
Table 1-3 Safety Devices -- Microprocessor controller 1-9............................................
Table 2-1 Error Messages 2-6....................................................................
Table 2-2 Alarm Messages 2-6...................................................................
Table 3-1 Alarm Indications 3-1..................................................................
Table 3-1 Alarm Indications -- Continued 3-2.......................................................
Table 3-2 Mechanical Indications 3-3..............................................................
Table 4-1 Preventive Maintenance schedule 4-1....................................................
Table 4-2 Service Category Descriptions 4-1.......................................................
Table 4-3 R-404A Temperature--Pressure Chart 4-8................................................

1-1 62-10630
SECTION 1
DESCRIPTION
1.1 INTRODUCTION
WARNING
Beware of unannounced starting of the
unit. Theunitmaycyclethefansandoperat-
ingcompressor unexpectedlyas control re-
quirements dictate.
This manual contains Operating Data, Electrical Data
and Service Instructions for the Carrier Transicold
Model 40S and 50S truck refrigeration units listed in
Table 1-1.
The unit (Figure 1-1) is of the split system type with the
condenser mounted outside the truck body, evaporator
mounted in the body, and a CAB COMMAND control
center mounted in the drivers compartment. Two types
of compressor drive are available:
D
DD
DRoad operation
the compressor is driven by the engine of thevehicle
when in operation over-the-road.
D
DD
DRoad/Standby version
With the standby option a second compressor is
mounted in the condenser section. This compressor
is driven by 230 volt, single or three phase power.
The model/serial nameplate is located inside of the unit
on the frame as shown in Figure 1-1.
The condenser section (see Figure 1-2 & Figure 1-3)
contains the condenser fan & coil, filter--drier, oil
separator, condenser pressure control valve, hot gas
valve and microprocessor. On road/standby units the
condenser also houses the standby compressor,
control box and rectifier/transformer assembly. In
addition, single phase units are fitted with a start box
which contains the capacitors and relay.
The evaporator assembly consists of the evaporator
fans (3 each = 50S, see Figure 1-5; 2 each = 40S, see
Figure 1-6), evaporator coil, expansion valve, defrost
termination thermostat, compressor pressure
regulating valve, heat exchanger, low pressure switch
and quench valve.
Thecontrolsystemisamicroprocessorcontroller.Once
the controller is set at the desired temperature, the
systemautomaticallyselectscoolingandheatingcycles
as necessary to maintain the desired temperature with
in very close limits.
Table 1-1 Model Chart
R-404A
R
o
a
d
Condenser Weight
Model LB KG
R
oa
d
Compressor Standby Compressor Road Road and
Standby Evaporator Weight
40S 62.7 TM 16 06VM306 (3 & 1 phase)
1
9
2
l
b
3
2
0
l
b
64 lb (29kg)
50S 6.5 2.9 TM 16 06VM307 (3 phase)
06VM306 (1 phase)
192 lb
(87 kg) 320 lb (145 kg) 86 lb (39 kg)
NAMEPLATE
CAB COMMAND
EMERGENCY
SWITCH
Figure 1-1 Integra 50S

1-262-10630
1
14
13
12
1110987
6
5
43
2
1. Rectifier Bridge Assembly (RB)
2. Condenser
3. Sight Glass
4. Filter--Drier
5. Condenser Fan
6. Fan Guard
7. Transformer (TR)
8. Heat Sink
9. Condenser Fan Motor (CFM)
10. Oil Separator
11. Frame Assembly
12. Solenoid Coil
13. Condenser Pressure Control Valve (HGS2)
14. Hot Gas Valve (HGS1)
Figure 1-2 Condenser

1-3 62-10630
9
7
8
SINGLE PHASE UNITSTHREE PHASE UNITS
9
67
8
1
2
34
5
LOGIC BOARD
1. Microprocessor
2. Standby Fuse (FS)
3. Road Fuse (FR)
4. Harness
5 1A Field Replaceable Fuse (12--00526--88)
(Starting with Controller S/N 1997)
6. Fused Disconnect (FB) -- Three Phase Only
7. Electronic Overload Relay (KR)
8. Standby Contactor (MC)
9. Primary Transformer Fuses
(F1,2,3 Three Phase Units -- F1 Single Phase Units)
Figure 1-3 Control Box

1-462-10630
START BOX LOCATION
(SINGLE PHASE ONLY)
1
2
3
4
1
1. Start Capacitor
2. Resistor, Start Capacitor Discharge 3. Run Capacitor 4. Start Relay
Figure 1-4 Start Box (Single Phase Only)

1-5 62-10630
1
15
14 13 12 11
10
9
8
7
6
5
4
32
1. Evaporator Fan Motor & Blowers (EFM)
2. Orifice
3. Expansion Valve
4. Water Drain Hose Fitting
5. Evaporator Coil Assembly
6. Compressor Pressure Regulating Valve (CPR)
7. Heat Exchanger
8. Defrost Termination Thermostat (DTT)
9. Low Pressure Switch (LP)
10. Quench Valve
11. Hot Gas Fitting
12. Standby Suction Line Fitting
13. Road Suction Line Fitting
14. Liquid Line Fitting
15. Liquid Line Check Valve
Figure 1-5 Evaporator 3 Fans (Integra 50S)

1-662-10630
67 8
9
11
13
12
10
5
1
2
3
4
1. Evaporator Fan Motor & Blowers
2. Defrost Termination Thermostat (DTT)
3. Quench Valve
4. Low Pressure Switch (LP)
5. Liquid Line Check Valve
6. Liquid Line Fitting
7. Standby Suction Line Fitting
8. Hot Gas Line Fitting
9. Road Suction Line Fitting
10. Orifice
11. Expansion Valve
12. Evaporator Coil Assembly
13. Compressor Pressure Regulating Valve (CPR)
Figure 1-6 Evaporator 2 Fans (Integra 40S)

1-7 62-10630
1.2 COMPRESSOR REFERENCE DATA
Model TM 16 06VM306 06VM307
Displacement 163 cc 113 cc 130 cc
No. Cylinders 6 2 2
Weight 7kg 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
a. Defrost Timer
Automatic triggering or at present intervals :
0, auto, 1h, 2h, 3h, 4h, 5h, 6h
b. Defrost Termination Thermostat
Opens at: 48_¦5_F(9_¦3_C)
Closes at: 37_¦5_F(3_¦3_C)
c. High Pressure Switch (HP1)
Cutout at : 465 ¦10 psig (32 bar)
Cut-in at : 360 ¦10 psig (25 bar)
d. Condenser Pressure Switch (HP2)
Cutout at : 245 ¦10 psig1 (7 bar)
Cut-in at : 320 ¦10 psig (22 bar)
e. Standby High Pressure Switch (HP3)
Cutout at : 430 ¦10 psig (30 bar)
Cut-in at : 360 ¦10 psig (25 bar)
f. Refrigerant charge
RefertoTable1-1.
g. Compressor Pressure Regulating Valve (CPR)
Setting; 36 ¦1psig(2.5bar)
h. Thermostatic Expansion Valve
Type: 50S = TES 2/ Orifice n_4/ MOP 75 psi (5.1 bar)
40S = TES 2/ Orifice n_3/ MOP 75 psi (5.1 bar)
Superheat setting = 7 ¦1_F(4_C)at0_F(-20_C) box
temperature.
i. Low Pressure Switch (LP)
Cutout at : -2.9 psig ¦3 psi (-0.2 bar)
Cut-in at : 14.5 psig ¦3 psi (1 bar)
j. Quench Valve (BPV)
Opens at: 260_F (127_C)
Closes at: 212_F (105_C)
1.4 ELECTRICAL DATA
a. Evaporator Fan Motors
Bearing Lubrication Factory Lubricated
Horse Power 0.1 kw
Operating Amps 7to9amps
Speed 2100 rpm (rated)
b. Standby Compressor Speed
-- 1740 rpm -- 60 hz

1-862-10630
c. Compressor Motor Ratings
C
o
n
t
a
c
t
o
r
d
a
t
a
C
on
t
ac
t
or
d
a
t
a
UNIT Voltage Frequency Phase kW HP MRA* LRA*
230 400 230 400
50S 230 / 400 60 Hz 31.491 211.8 9.8 45.1 26
5
0
S
208 / 230 60 Hz 11.491 215.6 -- 78.7 --
4
0
S
230 / 400 60 Hz 31.491 211.8 9.8 45.1 26
4
0
S
208 / 230 60 Hz 11.491 215.6 -- 78.7 --
* MRA = Maximum Rotor Amps LRA = Locked Rotor Amps
1.5 TORQUE VALUES
Assembly Ft--Lbs N.m Size
Standby compressor 4.1 5.5 M10
Evaporator Fan Motor -- Bracket 2.2 3M4
Condenser -- frame 7.4 10 M6
Condenser Fan -- Blade 3.7 5M6
Mounting bolts 84.1 114 M12
1.6 SAFETY DEVICES
System components are protected from damage caused by unsafe operating conditions by automatically shutting
down the unit when such conditions occur. This is accomplished by the fuses listed in Table 1-2 and safety devices
listedinTable1-3.
Table 1-2 Fuses
Item Rating
Road supply fuse (FR) 50 A
Standby supply fuse (FS) (a) 50 A
Main standby fuse (FB -- X3) 16 A
Electric heat fuses (F4/F5/F6) [Future] 6.3 A
Transformer primary fuses (F1/F2/F3) 3.15 A
Main road fuse (FR1) (b) 60 A
Field Replaceable Fuse (c)
(Starting with Controller S/N 1997) 1A
(a) On road / standby unit only
(b) This fuse is located close to the vehicle battery (12 v).
(c) This fuse is located on the logic board inside the microprocessor and protects the
microprocessor against reverse polarity on the power supply. (See Figure 1-3).

1-9 62-10630
Table 1-3 Safety Devices -- Microprocessor controller
Unsafe Conditions Safety Device Automatic
restart
with fault
cleared Device setting
1 Excessive drop in pressure Automatic reset of low
pressure switch YES Cutout : --2.9 psig (-0.2 bar) Timer 5 mn
2Excessive current draw on all mi-
croprocessor outputs (evaporator
and condenser fan)
Electronic relay YES Self-protected opening
3Excessive current draw control
circuit Fuse on electronic board NO Self-protected opening
4Excessive current draw motor
compressor Overload relay YES See electrical wiring diagram
5 Excessive compressor discharge
pressure Automatic reset of High pressure switch (HP1,
HP3) YES Timer 5 mn
6 Excessive current draw unit on
standby Standby fuse NO SeefuseTable1-2
7 Excessive current draw unit on
road Road fuse NO SeefuseTable1-2
8Connection error on primary
transformer Fuses NO SeefuseTable1-2
9Excessive compressor motor
winding temperature O.L.P. (overload protector) YES Self-protected opening
10 Clutch malfunction - road (exces-
sive current draw) Electronic relay YES Self-protected opening
11 Clutch malfunction - road (insuffi-
cient current draw) Electronic relay YES Detection of min. threshold at 750 mA
12 Double power supply (road +
standby) Microprocessor YES Display on Cab Command until one of the 2 power sup-
plies have been discon-
nected.
13 Low battery voltage Microprocessor YES Cutout/cut-in at 10 V

1-1062-10630
1.7 REFRIGERANT CIRCUIT DURING COOLING
When cooling (See Figure 1-7), the unit operates as a
vapor compression refrigeration system. The main
components of the system are the reciprocating
compressor, air-cooled condenser, thermostatic
expansion valve and direct expansion evaporator.
Thecompressorraisesthepressureandtemperatureof
therefrigerantand forcesit throughthedischargecheck
valve and condenser pressure control valve into the
condenser tubes. The discharge check valves prevent
reverse flow through the non operating compressor.
When operating on the road compressor, the flow also
passes through the oil separator where oil is removed
and returned to the compressors.
The condenser fan circulates surrounding air over the
outside of the condenser tubes. Heat transfer is thus
establishedfromtherefrigerantgas(insidethetubes)to
the condenser air (flowing over the tubes). The
condenser tubes have fins designed to improve the
transfer of heat. This removal of heat causes the
refrigerant to liquefy; liquid refrigerant flows from the
condenser to the receiver.
The receiver stores any excess charge due to surges in
load on the system and stores refrigerant during low
side service.
The refrigerant then flows through the subcooler,
filter-drier, sight glass, liquid line check valve (option for
40S)and liquid/gasheat exchanger tothethermostatic
expansion valve.
The subcooler and heat exchanger remove additional
heat form the liquid to provide improvement in system
efficiency. The filter--drier contains an absorbent and
filter screen that keeps the refrigerant dry and clean.
The sight glass is fitted with an indicator that changes
color to indicate moisture content of the refrigerant. The
checkvalveservestoprevent reverseflowofrefrigerant
during the heating/defrost cycle.
The liquid than enters the thermostatic expansion valve
(with external pressure equalizer) which regulates the
flowrateofrefrigeranttowardstheevaporatorinorderto
obtain maximum use of the evaporator heat transfer
surface.
The evaporator tubes have aluminium fins to increase
heat transfer; therefore heat is removed from the air
circulated through the evaporator. This cold air is
circulated throughout the truck to maintain the cargo at
the desired temperature.
The transfer of heat from the air to the low temperature
liquid refrigerant causes the liquid to vaporize. The
vapor at low temperature and pressure passes back
throughtheheatexchangerthenentersthecompressor
pressure regulating valve (CPR) which regulates
refrigerant pressureenteringthecompressortoprevent
overloading of the vehicle engine. From this point, the
cycle starts over.
The quench valve (BPV) opens as required to maintain
a maximum discharge temperature of 127_C (260°F).
1.8 REFRIGERANT CIRCUIT DURING HEAT AND
DEFROST
When refrigerant vapor is compressed to a high
pressure and temperature in a compressor, the
mechanical energy necessary to operate the
compressor is transferred to the gas as it is being
compressed. This energy is referred to as the ”heat of
compression ” and is used as the source of heat during
the heating or defrost cycle (See Figure 1-8).
The main difference between heating and defrosting is
that,wheninheatingmodetheevaporatorfanscontinue
to run circulating the air throughout the truck to heat the
product. When defrosting, the evaporator fans stop,
allowing the heated vapor todefrost any ice build-up on
the coil.
When heating or defrost is required, the hot gas
solenoid valve is energized (opened) to allow heated
refrigerant vapor to flow directly to the evaporator coil.
The system is fitted with a condenser pressure control
valve (see Figure 1-8). The valvecloses when pressure
is above the setting of the condenser pressure control
switch to prevent additionalpressure risein thesystem.
When pressure is below the setting of the condenser
pressure control switch, the valve is opened to
pressurize the receiver and force additional refrigerant
into the system and increase heating capacity.

1-11 62-10630
DISCHARGE
LIQUID
SUCTION
NORMALLY
OPEN NORMALLY CLOSED
26
1
2
3
4
56 7
8
9
10
11
12
13
14
15
16
17
18
19
20
21 22
23
24
25
1 Quench (Liquid Injection) Valve (BPV)
2 Thermostatic Expansion Valve
3 Heat Exchanger
4 Hot Gas Solenoid Valve (HGS1)
5 Liquid Line Check Valve
6 Sight Glass
7 Filter--Drier
8 Subcooler
9 Manual Shut-off Valve (King Valve)
10 Receiver
11 Condenser
12 Condenser Pressure Control Valve (HGS2)
13 Condenser Pressure Control Switch (HP2)
14 High Pressure Switch (HP1)
15 Relief Valve
16 Standby Discharge Check Valve
17 Standby High Pressure Switch (HP3)
18 Standby Compressor
19 Road Compressor
20 Quench (Liquid Injection) Thermostat (BPT)
21 Oil Separator
22 Road Discharge Check Valve
23 Low Pressure Switch (LPS)
24 Compressor Pressure Regulating Valve (CPR)
25 Drain Pan Hot Gas Line
26 Evaporator
Figure 1-7 Cooling Cycle

1-1262-10630
DISCHARGE
LIQUID
SUCTION
NORMALLY
OPEN NORMALLY CLOSED
26
1
2
3
4
56 7
8
9
10
11
12
13
14
15
16
17
18
19
20
21 22
23
24
25
1 Quench (Liquid Injection) Valve (BPV)
2 Thermostatic Expansion Valve
3 Heat Exchanger
4 Hot Gas Solenoid Valve (HGS1)
5 Liquid Line Check Valve
6 Sight Glass
7 Filter--Drier
8 Subcooler
9 Manual Shut-off Valve (King Valve)
10 Receiver
11 Condenser
12 Condenser Pressure Control Valve (HGS2)
13 Condenser Pressure Control Switch (HP2)
14 High Pressure Switch (HP1)
15 Relief Valve
16 Standby Discharge Check Valve
17 Standby High Pressure Switch (HP3)
18 Standby Compressor
19 Road Compressor
20 Quench (Liquid Injection) Thermostat (BPT)
21 Oil Separator
22 Road Discharge Check Valve
23 Low Pressure Switch (LPS)
24 Compressor Pressure Regulating Valve (CPR)
25 Drain Pan Hot Gas Line
26 Evaporator
Figure 1-8 Heat/Defrost Cycle

2-1 62-10630
SECTION 2
OPERATION
WARNING
Beware of unannounced starting of the unit. The unitmay cycle the fans and operating compressor
unexpectedly as control requirements dictate.
2.1 INSPECTION
Before starting the truck engine or connecting standby
power check the following
a. Check condenser coil for cleanliness
b. Check condition of refrigerant hoses
c. Check condition and tension of compressor belt(s)
d. Check condition of condenser fan blade, motor and
brushes
e. Check truck battery fluid level
f. Check truckbattery andterminalconnections -- clean
and tighten as necessary
g. Check defrost water drains from evaporator
h. Check evaporator coil for cleanliness
i. Check condition of evaporator fan blades, motor and
brushes
j. Check oil level in standby compressor sight glass
2.2 CONNECT POWER
If the unit is to be operated in the stand by mode,
connect power as follows:
WARNING
Do not attempt to connect orremovepower
plug before ensuring the unitis 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
a. Check that the external power source corresponds to
thecharacteristicsof theunit(seeparagraph1.4step
c.). Make sure external power source circuit breaker
is open.
b. Makesureunit isOFF by pressing theOFF buttonon
the Cab Command.
c. Plug the power cord into unit receptacle.
2.3 CAB COMMAND
The Cab Command is mounted remote in the cab. The
Command consists of the green and red LED readouts,
the keypad and keypad interface (see Figure 2-1).
Figure 2-1 Cab Command
From his seat, the operator can carry out all the control
operations :
Dautomatic start-up in road or standby mode,
Dshut-down,
Dadjusting the set-point,
Ddefrost.
Observing the Cab Command, the operator can
determine the the box temperature and determine if the
set-point is being maintained by checking the LED
indicator. The indicator lights up green if the box
temperature is within set point and red in the event of a
malfunction.
2.3.1 Keypad
Thekeypadconsistsof sixkeys enablingtheoperatorto
activatevariousfunctions,displayoperatingdataandto
modify operating parameters.
Display
Readout
Standby operation LED
Road operation LED
Unit operating data LED
DGreen : cycling (left-hand side)
DRed : malfunction (right-hand side)