Carrier 69NT40-489-100 Series Operation manual

T−305 Rev C
OPERATION AND SERVICE
for
EverFresh Controlled Atmosphere
69NT40-489-100 Series
Container Refrigeration Units
r
Container Refrigeration

OPERATION & SERVICE MANUAL
CONTAINER REFRIGERATION UNIT
EVERFRESH
CONTROLLED ATMOSPHERE
MODEL
69NT40-489-100 Series
©Carrier Corporation, 2018 DPrinted in U. S. A. January 2018

T-305Safety--1
SAFETY SUMMARY
CONTROLLED ATMOSPHERE (CA) SAFETY CONSIDERATIONS
Air contains nitrogen and oxygen, and only oxygen supports life. Oxygen is normally present at a concentration of
about 21% in the atmosphere. The balance is nitrogen, with traces of other gases.
Controlled atmosphere (CA) systems reduce the oxygen content in the container to 2 -- 5%. These levels will not
support life. The low-oxygen atmosphere is colorless, odorless and tasteless. Indications of a potentially hazardous
situation are generally absent.
One or two breaths in a low-oxygen atmosphere will cause unconsciousness within 10 seconds and death within a few
minutes.
Before entering containers which are equipped with CA systems, the oxygen content must be increased to normal
(21%) by ventilation.
Carrier Transicold containers using the CA option are equipped with:
1. Hazard labels on the front of the unit.
2. Hazard labels near the evaporator access panels. Hazard labels on the evaporator motor mounting bracket.
3. Hazard labels on rear doors of the container.
4. Door interlock system on rear doors of the container to prevent access of personnel when low-oxygen levels are
present.
In addition, a hazard label is provided with the poly sheet curtain, which is used to help stop gas leakage at the rear
doors of the container.
IMMEDIATE EFFECTS OF BREATHING OXYGEN DEFICIENT ATMOSPHERES
As blood passes through the lungs it gives up carbon dioxide and accepts oxygen through the thin walls of tiny air sacs.
-- Blood from the lungs takes less than 10 seconds to reach the brain.
-- Breathing oxygen deficient air flushes the blood of oxygen.
-- The brain is quickly depleted of oxygen resulting in swift unconsciousness.
-- Within 5 seconds of breathing oxygen-free gas, there is a rapid drop of oxygen in the blood. As the oxygen
concentration is progressively lowered the physiological effects are:
SGiddiness
SMental confusion
SLoss of judgement
SIncoordination
SWeakness
SNausea
SFainting
SDeath
-- Symptoms or warnings are generally absent.
HUMAN RESPONSE TO OXYGEN DEFICIENT ATMOSPHERES
OXYGEN CONTENT OF AIR SIGNS/SYMPTOMS OF PERSON AT REST
15% -- 19% Decreased ability to work strenuously. May impair coordination and may induce
early symptoms in persons with coronary, pulmonary or circulatory problems.
12% -- 14% Respiration deeper, increased pulse rate and impaired coordination, perception
and judgement.
10% -- 12% Further increase in rate and depth of respiration, further increase in pulse rate,
performance failure, giddiness, poor judgement, blue lips.
8% -- 10% Mental failure, nausea, vomiting, fainting, unconsciousness, ashen face, blue
face.
6% -- 8% 8 minutes, 100% fatal; 6 minutes, 50% fatal; 4-5 minutes, recovery with treat-
ment for all exposures.
4% Coma in 40 seconds, convulsions, respiration ceases, death.

Safety--2T-305
CONTROLLED ATMOSPHERE (CA) SAFE CONTAINER ENTRY
Entry into a CA equipped container must be performed by a (minimum) two person team. The operator will be the person
performing the required procedures and that person is to be supervised by someone who is familiar with the required
procedures. The person supervising entry must ensure that all venting procedures outlined in section 10.7 page 113 have
been performed and all waiting periods have expired. The following steps must be adhered to:
1. Both persons are to read and understand the preceding Safety Considerations and all hazard labels on the unit.
2. The supervising person is responsible for keeping all persons away from open doors and access panels until the
venting procedure is completed.
3. Avoid opening doors of a low-oxygen level container while at a loading platform. Never open doors if rain or refrig-
eration barriers are near the door. Low-oxygen content gas will exit the container and can asphyxiate nearby per-
sonnel who are working an adjacent container or are in the warehouse. Instead, follow the venting procedure before
backing up to the loading platform.
4. Avoid venting in a confined space.
5. A hazardous low-oxygen atmosphere exists within the evaporator section. Before opening the evaporator access
panel(s) the container must first be ventilated per section 10.5, page 114. Then the access panel(s) must be open
for 10 minutes before working inside the evaporator section.
6. The supervising person will declare it safe to enter the container. Prior to entry the supervisor or a second person
must be present. Every time the doors or panels are to be opened, the supervising person must ensure the venting
procedures are performed and the waiting times have expired prior to declaring the container safe to enter and
allowing any person to enter. Every time.
ALWAYS:
SLook for Danger, Warning and Caution hazard labels on containers. Use a flashlight if necessary!
SAssume there is a low-oxygen atmosphere present when the doors are closed.
SAssume low-oxygen content even if there was air yesterday.
SAssume low-oxygen content even if the CA start-stop switch (CAS) is OFF.
SAssume low-oxygen content even if no generator set is attached.
SAssume low-oxygen content even if the container has no load in it.
SAssume low-oxygen content even if the door is not locked.
SAssume low-oxygen content even if the container is in for maintenance.
SAssume low-oxygen content even if the container is to be washed out.
SUse your watch and write times down when ventilating a container.
SWarn others of the hazard. Tell them from a distance if necessary.
SAsk qualified personnel if you are not sure or forgot some of this training.
RESUSCITATION
Personnel working with or near hazardous atmosphere or materials shall be familiar with approved resuscitation
methods. If someone is injured and stops breathing, initiate resuscitation immediately. A delay could cost the victim’s
life.
RESCUE
-- All rescue personnel shall have adequate supplies of oxygen or air from self-contained breathing apparatuses or
fresh air lines
-- Only those who are properly trained in the use of self-contained breathing apparatus will attempt to rescue the
victim. All other personnel will stay clear of the area until the oxygen level stabilizes.
-- The victim shall be removed to the open air without delay and shall be kept warm. Oxygen shall be administered or
artificial respiration shall be applied by an approved method.
-- Resuscitation procedures shall be continued until the patient revives or until a doctor gives instructions.
FIRST AID
-- Persons suffering from lack of oxygen should be quickly moved to areas with normal atmosphere.
-- If the person is not breathing, assisted ventilation should be the first step.
-- Give supplemental oxygen with ventilation if oxygen is available.

T-305Safety--3
ENTERING CONTAINER IN AN EMERGENCY
In case of a power failure to the unit, there is no emergency provision to unlock the automatic door interlock system:
DANGER
WHEN OVERRIDING THE CA CONTROLLER, THE OPERATOR MUST BE AWARE OF THE IMMEDIATE
DANGER OF UNCONSCIOUSNESS AND DEATH. THE OPERATOR MUST READ AND UNDERSTAND ALL
WARNING LABELS AND SAFETY INSTRUCTIONS BEFORE PROCEEDING WITH THE EMERGENCY BY-
PASS PROCEDURE.
To enter the container in a true emergency situation, do the following:
1. Ensure at least two persons are present. One person is to act in a supervisory manner, and that person is charged
with the responsibility to ensure all procedures are performed correctly and all waiting times have expired before
allowing entry.
2. Open the fresh air makeup vent 100% (fully open). Avoid any direct breathing of venting gases from the air makeup
vent.
3. To enter the container, the interlock system must be removed. To remove the system, remove the center bolt from
the catch or remove the four screws holding the interlock system to the container door. Refer to Figure A.
WARNING
Low oxygen levels inside container. Ventilate container before entering. Stay away from doors while
venting.
4. Fully open container doors.
5. Pull back the curtain (poly sheet) to accelerate the time of a complete ambient air exchange.
6. Step away from the container rear doors. Do not close doors. Wait 30 minutes prior to entry or unloading of the
container. Wait 45 minutes before climbing on contents inside of the container.
7. If access to the container is necessary (i.e., life and death situations) prior to the safety venting procedures being
performed, then: only rescue personnel trained in safety procedures in removing victims from hazardous atmo-
spheres are to be allowed entry into the container at this point.
8. All other personnel are to stay well clear of the doors.
CONTAINER REAR DOOR VIEW
REMOVE OR CUT
AS REQUIRED
Figure A. Emergency Bypass for the Door Interlock System

Safety--4T-305
PRECAUTIONS FOR HANDLING COMPRESSED GAS
Chemical safety goggles or a full face shield shall be used while handling cylinders of compressed gas.
If the unit is being supplied with nitrogen or carbon dioxide, all nonessential persons shall be prohibited from being in or
entering the container space while this procedure is taking place.
Emergency self-contained breathing apparatuses shall be located within the immediate area to permit safe
evacuation in the event of an accident. A high concentration of nitrogen gas will dilute the air (oxygen) in the space.
Breathing this diluted, contaminated air can result in rapid (5 to 10 seconds) loss of consciousness. Therefore, it is
necessary to stop breathing until the self-contained breathing apparatus has been put on and is supplying air.
Emergency rescue procedures shall be established to ensure all personnel can be safely removed from potentially
hazardous exposures.
HAZARDOUS ATMOSPHERE INSIDE.
LOW OXYGEN INSIDE CONTAINER CAN
CAUSE DEATH.
DANGER
Performing service on, or entering a CA
equipped unit can be extremely dangerous.
Refer to the Safety section of this manual
before servicing or entering the container.
DANGER
HAZARDOUS ATMOSPHERE INSIDE OF
THE CONTAINER. LOW OXYGEN LEVEL IN-
SIDE CONTAINER CAN CAUSE DEATH.
THE CONTAINER MUST BE VENTED PRIOR
TO ENTERING.
1. On keypad press VENT and then press
ENTER.
2. Fully open fresh air port, and then press
ENTER on keypad. Avoid direct
breathing of venting gases.
3. Allow refrigeration unit to run. Door
lock will open.
4. Open both rear doors and pull curtain
back. Step away from rear doors.
Continue refrigeration operation for ten
minutes prior to entry or unloading. Do
not close doors. (Wait 45 minutes
before climbing on contents inside
container.)
DANGER
LOW OXYGEN LEVELS INSIDE CONTAIN-
ER. VENTILATE CONTAINER BEFORE EN-
TERING. STAY AWAY FROM DOORS WHILE
VENTING.
DANGER
HAZARDOUS ATMOSPHERE INSIDE. VEN-
TILATE CONTAINER BEFORE ACCESS.
DANGER
WHEN OVERRIDING THE CA CONTROLLER,
THE OPERATOR MUST BE AWARE OF THE
IMMEDIATE DANGER OF UNCONSCIOUS-
NESS AND DEATH. THE OPERATOR MUST
READ AND UNDERSTAND ALL WARNING
LABELS AND SAFETY INSTRUCTIONS BE-
FORE PROCEEDING WITH THE EMERGEN-
CY BYPASS PROCEDURE.
WARNING
When servicing the unit, use caution when
handling R-134a. The refrigerant when in
contact with high temperatures (about
1000_F) will decompose into highly corro-
sive and toxic compounds.
WARNING
Be sure ventilation in the workspace is ade-
quate to keep the concentration of refriger-
ant below 1000 parts per million. If neces-
sary, use portable blowers.
WARNING
Beware of rotating fan blades and unan-
nounced starting of fans.
WARNING
Do not use a nitrogen cylinder without a
pressure regulator. Never mix refrigerants
with air for leak testing. It has been deter-
mined that pressurized, air-rich mixtures of
refrigerants and air can undergo combus-
tion when exposed to an ignition source.

T-305Safety--5
WARNING
Never fill a refrigerant cylinder beyond its
rated capacity. Cylinder may rupture due to
excessive pressure when exposed to high
temperatures.
WARNING
When starting the unit, be sure that all
manual refrigerant valves in the discharge
line are open. Severe damage could occur
from extremely high refrigerant pressures.

Safety--6T-305
GENERAL SAFETY NOTICES
The following general safety notices supplement the specific danger, warning and caution hazard labels 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.
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.
Keep hands, clothing and tools clear of the evaporator and condenser fans.
No work should be performed on the unit until all circuit breakers, start-stop switches are turned off, and 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 evaporator and condenser fans. Do not open the condenser fan grille or
evaporator access panels before turning power off, disconnecting and securing the power plug.
Be sure power is turned off before working on motors, controllers, solenoid valves and electrical control switches. Tag
circuit breaker and power supply 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 modules in
both control boxes. 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).
UNIT LABEL IDENTIFICATION
To help identify the hazard labels 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, or
damage to product or property.

T-305Safety--7
SPECIFIC DANGER, WARNING AND CAUTION STATEMENTS
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
evaporator and condenser fans. The unit
may cycle the fans and compressor unex-
pectedly as control requirements dictate.
WARNING
Do not attempt to remove power plug(s) be-
fore turning OFF start-stop switch (ST), unit
circuit breaker(s) and external power
source.
WARNING
Make sure the power plugs are clean and
dry before connecting to any power recep-
tacle.
WARNING
Make sure that the unit circuit breaker(s)
(CB-1 & CB-2) and the START-STOP switch
(ST) are in the “O” (OFF) position before
connecting to any electrical power source.
WARNING
Never use air for leak testing. It has been de-
termined that pressurized, mixtures of re-
frigerant and air can undergo combustion
when exposed to an ignition source.
WARNING
Make sure power to the unit is OFF and
power plug disconnected before replacing
the compressor.
WARNING
Before disassembly of any external com-
pressor component make sure to relieve
possible internal pressure by loosening the
bolts and tapping the component with a
soft hammer to break the seal.
WARNING
Do not use a nitrogen cylinder without a
pressure regulator. Do not use oxygen in or
near a refrigeration system as an explosion
may occur.
WARNING
Do not open the condenser fan grille before
turning power OFF and disconnecting
power plug.
WARNING
Oakite No. 32 is an acid. Be sure that the
acid is slowly added to the water. DO NOT
PUT WATER INTO THE ACID -- this will
cause spattering and excessive heat.
WARNING
Wear rubber gloves and wash the solution
from the skin immediately if accidental con-
tact occurs. Do not allow the solution to
splash onto concrete.
WARNING
Always turn OFF the unit circuit breakers
(CB-1 & CB-2) and disconnect main power
supply before working on moving parts.

Safety--8T-305
SPECIFIC WARNING AND CAUTION STATEMENTS -- Continued
WARNING
Make sure power to the unit is OFF and
power plug disconnected before removing
capacitor(s).
WARNING
With power OFF discharge the capacitor
before disconnecting the circuit wiring.
WARNING
The unit power plug must be disconnected
to remove power from circuit breaker CB1
CAUTION
Do not remove wire harnesses from controller
unless you are grounded to the unit frame with a
static safe wrist strap.
CAUTION
Unplug all controller wire harness connectors
before performing arc welding on any part of the
container.
CAUTION
Pre-trip inspection should not be performed
with critical temperature cargoes in the contain-
er.
CAUTION
When Pre-Trip key is pressed, dehumidification
and bulb mode will be deactivated. At the
completion of Pre-Trip activity, dehumidification
and bulb mode must be reactivated.
CAUTION
When condenser water flow is below 11 lpm (3
gpm) or when water-cooled operation is not in
use, the CFS switch MUST be set to position ”1”
or the unit will not operate properly.
CAUTION
When a failure occurs during automatic testing
the unit will suspend operation awaiting opera-
tor intervention.
CAUTION
When Pre--Trip test Auto 2 runs to completion
without being interrupted, the unit will terminate
pre-trip and display “Auto 2” “end.” The unit will
suspend operation until the user depresses the
ENTER key!
CAUTION
The unit will remain in the full cooling mode as
long as the emergency bypass switch is in the
BYPASS position. If the cargo may be dam-
aged by low temperatures, the operator must
monitor container temperature and manually
cycle operation as required to maintain temper-
ature within required limits.
CAUTION
The unit will remain in the DEFROST mode as
long as the emergency defrost switch is in the
DEFROST position. To prevent cargo damage,
the operator must monitor container tempera-
ture and manually cycle operation as required
to maintain temperature within required limits.
CAUTION
To prevent trapping liquid refrigerant in the
manifold gauge set be sure set is brought to
suction pressure before disconnecting.
CAUTION
Removing the compressor motor press-fit sta-
tor in the field is not recommended. The rotor
and stator are a matched pair and should not be
separated.

T-305Safety--9
SPECIFIC WARNING AND CAUTION STATEMENTS -- Continued
CAUTION
The copper tube which connects to the oil suc-
tion strainer extends out the bottom with the
bottom plate removed. Take precautions to
avoid bending or breaking it while changing
crankcase positions.
CAUTION
Ensure that thrust washer does not fall off dowel
pins while installing oil pump.
CAUTION
The set screw on the crankshaft must be
removed for this type of oil pump.
CAUTION
Use only Carrier Transicold approved Polyol
Ester Oil (POE) -- Castrol-Icematic SW20 com-
pressor oil with R-134a. Buy in quantities of one
quart or smaller. When using this hygroscopic
oil, immediately reseal. Do not leave container
of oil open or contamination will occur.
CAUTION
Take necessary steps (place plywood over coil
or use sling on motor) to prevent motor from fal-
ling into condenser coil.
CAUTION
If the thermostatic expansion valve is found to
be in need of replacement, then the power head
and cage assembly are to replaced as a pair.
They are a matched pair and replacing one
without the other will affect the superheat
setting.
CAUTION
DO NOT disassemble piston from NEW suction
modulating valve powerhead assembly. Doing
so may result in damage to piston.
CAUTION
The unit must be OFF whenever a program-
ming card is inserted or removed from the con-
troller programming port.
CAUTION
All 69NT40-511-3XX units must use software
revision 5108 or higher to enable stepper motor.
Optional features may require higher software
revision levels to enable functionality.
CAUTION
Do not allow moisture to enter wire splice area
as this may affect the sensor resistance.

Safety--10T-305

iT-305
FOREWORD
The Model 69NT40--489--100 Series (100 through 199) units are basic Carrier Transicold ThinLine container
refrigeration units which are equipped with the Carrier Transicold EverFresh controlled atmosphere system. The
EverFresh system provides continuous, precise management of the gases surrounding the cargo. Coverage of the
equipment is provided in this manual as follows:
PART ONE
PART ONE of this manual contains Operating Data, Electrical Data and Service Instructions for the refrigeration unit.
Part One is divided into six sections. These sections are: One, Introduction; Two, Description; Three, Microprocessor;
Four, Operation; Five, Troubleshooting and Six, Service.
PART TWO
PART TWO of this manual covers the Controlled Atmosphere system. The units are equipped with a separate
controller module and support equipment dedicated to the Controlled Atmosphere system. PART TWO is also divided
into sections in the same manner as Part One, that is Seven, Introduction; Eight, Description; Nine, Microprocessor;
Ten, Operation; Eleven, Troubleshooting and Twelve, Service.
PART THREE
PART THREE of this manual contains the Electrical Schematics for both the refrigeration unit and the Controlled
Atmosphere system. PART THREE has been divided into two sections; Thirteen contains the schematics for the
refrigeration controls, and Fourteen contains the schematics for the Controlled Atmosphere system.
ABOUT REFERENCES IN THIS MANUAL
When references are made in the manual, the reference will include a page number unless the referenced item is on
the same page. For example, when reading the following reference text: (Refer to section 3.2), the reader will not
need to turn to another page to find section 3.2. The other example is: (Refer to section 4.2, page45), this would
indicate the reader must turn to page 45 to find the referenced item.

ii
T-305
TABLE OF CONTENTS
PARAGRAPH NUMBER Page
SAFETY SUMMARY Safety--1.........................................................
CONTROLLED ATMOSPHERE (CA) SAFETY CONSIDERATIONS Safety--1.........................
IMMEDIATE EFFECTS OF BREATHING OXYGEN DEFICIENT ATMOSPHERES Safety--1............
HUMAN RESPONSE TO OXYGEN DEFICIENT ATMOSPHERES Safety--1..........................
CONTROLLED ATMOSPHERE (CA) SAFE CONTAINER ENTRY Safety--2..........................
ALWAYS: Safety--2............................................................................
RESUSCITATION Safety--2....................................................................
RESCUE Safety--2............................................................................
FIRST AID Safety--2..........................................................................
ENTERING CONTAINER IN AN EMERGENCY Safety--3..........................................
PRECAUTIONS FOR HANDLING COMPRESSED GAS Safety--4..................................
GENERAL SAFETY NOTICES Safety--6.........................................................
FIRST AID Safety--6..........................................................................
OPERATING PRECAUTIONS Safety--6.........................................................
MAINTENANCE PRECAUTIONS Safety--6.......................................................
UNIT LABEL IDENTIFICATION Safety--6........................................................
SPECIFIC DANGER, WARNING AND CAUTION STATEMENTS Safety--7...........................
PART ONE -- REFRIGERATION UNIT 1...............................................
INTRODUCTION 1..............................................................................
1.1 INTRODUCTION 1.....................................................................
1.2 CONFIGURATION IDENTIFICATION 1...................................................
1.3 OPTION DESCRIPTION 1..............................................................
DESCRIPTION 5...............................................................................
2.1 GENERAL DESCRIPTION 5.............................................................
2.1.1 Refrigeration Unit -- Front Section 5...................................................
2.1.2 Upper Fresh Air Makeup Vent 5.......................................................
2.1.3 Evaporator Section 6................................................................
2.1.4 Compressor Section 7...............................................................
2.1.5 Air Cooled Condenser Section 8......................................................
2.1.6 Water-Cooled Condenser Section 9...................................................
2.1.7 Control Box Section 10...............................................................
2.1.8 Communications Interface Module 10...................................................
2.2 REFRIGERATION SYSTEM DATA 11......................................................
2.3 ELECTRICAL DATA 12...................................................................
2.4 SAFETY AND PROTECTIVE DEVICES 13.................................................
2.5 REFRIGERATION CIRCUIT 14...........................................................
MICROPROCESSOR 17..........................................................................
3.1 TEMPERATURE CONTROL MICROPROCESSOR SYSTEM 17..............................
3.1.1 Key Pad 18.........................................................................
3.1.2 Display Module 18...................................................................
3.1.3 Controller 19........................................................................

iii T-305
TABLE OF CONTENTS -- Continued
PARAGRAPH NUMBER Page
3.2 REFRIGERATION CONTROLLER SOFTWARE 19..........................................
3.2.1 Configuration Software (Configuration Variables) 19......................................
3.2.2 Operational Software (Function Codes) 19..............................................
3.3 MODES OF OPERATION 20.............................................................
3.3.1 Temperature Control -- Perishable Mode 20..............................................
3.3.2 Evaporator Fan Operation 20..........................................................
3.3.3 Defrost Interval 20...................................................................
3.3.4 Failure Action 20.....................................................................
3.3.5 Generator Protection 20..............................................................
3.3.6 Condenser Pressure Control 20........................................................
3.3.7 Arctic Mode 20......................................................................
3.3.8 Perishable Mode -- Conventional 20....................................................
3.3.9 Perishable Mode -- Economy 21.......................................................
3.3.10 Perishable Mode -- Dehumidification 21.................................................
3.3.11 Perishable, Dehumidification -- Bulb Mode 21............................................
3.3.12 Temperature Control -- Frozen Mode 22.................................................
3.3.13 Frozen Mode -- Conventional 22.......................................................
3.3.14 Frozen Mode -- Economy 22...........................................................
3.4 CONTROLLER ALARMS 22..............................................................
3.5. UNIT PRE-TRIP DIAGNOSTICS 22.......................................................
3.6 DataCORDER 23........................................................................
3.6.1 Description 23.......................................................................
3.6.2 DataCORDER Software 23............................................................
3.6.3 Sensor Configuration (dCF02) 24......................................................
3.6.4 Logging Interval (dCF03) 27...........................................................
3.6.5 Thermistor Format (dCF04) 27.........................................................
3.6.6 Sampling Type (dCF05 & dCF06) 27...................................................
3.6.7 Alarm Configuration (dCF07 -- dCF10) 27...............................................
3.6.8 DataCORDER Power-Up 27...........................................................
3.6.9 Pre-Trip Data Recording 27...........................................................
3.6.10 DataCORDER Communications 27.....................................................
3.6.11 USDA Cold Treatment 28.............................................................
3.6.12 USDA Cold Treatment Procedure 28...................................................
3.6.13 DataCORDER Alarms 29.............................................................
OPERATION 45.................................................................................
4.1 INSPECTION (Before Starting) 45.........................................................
4.2 CONNECT POWER 45..................................................................
4.2.1 Connection To 380/460 vac Power 45...................................................
4.2.2 Connection to190/230 vac Power 45....................................................
4.3 ADJUST FRESH AIR MAKEUP VENT 45...................................................
4.3.1 Upper Fresh Air Makeup Vent 45.......................................................
4.4 CONNECT WATER-COOLED CONDENSER 46.............................................
4.4.1 Water--Cooled Condenser with Water Pressure Switch 46.................................
4.4.2 Water-Cooled Condenser with Condenser Fan Switch 46..................................

iv
T-305
TABLE OF CONTENTS -- Continued
PARAGRAPH NUMBER Page
4.5 CONNECT REMOTE MONITORING RECEPTACLE 46......................................
4.6 STARTING AND STOPPING INSTRUCTIONS 46...........................................
4.6.1 Starting the Unit 46...................................................................
4.6.2 Stopping the Unit 46..................................................................
4.7 START--UP INSPECTION 46.............................................................
4.7.1 Physical Inspection 46................................................................
4.7.2 Check Controller Function Codes 46....................................................
4.7.3 Complete Inspection 47...............................................................
4.8 PRE-TRIP DIAGNOSIS 47...............................................................
4.9 OBSERVE UNIT OPERATION 48.........................................................
4.9.1 Crankcase Heater 48.................................................................
4.9.2 Probe Check 48.....................................................................
4.10 SEQUENCE OF OPERATION 48...........................................................
4.10.1 Sequence Of operation -- Perishable Mode -- Cooling 50...................................
4.10.2 Sequence Of Operation -- Perishable Mode -- Heating 50..................................
4.10.3 Sequence Of Operation -- Frozen Mode -- Cooling 50.....................................
4.10.4 Sequence Of Operation -- Defrost Mode 51..............................................
4.11 EMERGENCY OPERATION 52...........................................................
4.11.1 Emergency Bypass Operation 52......................................................
4.11.2 Emergency Defrost Operation. 52......................................................
TROUBLESHOOTING 53.........................................................................
5.1 UNIT WILL NOT START OR STARTS THEN STOPS 53......................................
5.2 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING 53..............................
5.3 UNIT RUNS BUT HAS INSUFFICIENT COOLING 54........................................
5.4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING 54................................
5.5 UNIT WILL NOT TERMINATE HEATING 54................................................
5.6 UNIT WILL NOT DEFROST PROPERLY 54................................................
5.7 ABNORMAL PRESSURES (COOLING) 55.................................................
5.8 ABNORMAL NOISE OR VIBRATIONS 55..................................................
5.9 REFRIGERATION CONTROLLER MALFUNCTION 55.......................................
5.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW 56..............................
5.11 THERMOSTATIC EXPANSION VALVE MALFUNCTION 56...................................
5.12 AUTOTRANSFORMER MALFUNCTION 56................................................
5.13 WATER-COOLED CONDENSER OR WATER PRESSURE SWITCH 56........................
SERVICE 57....................................................................................
6.1 SECTION LAYOUT 57...................................................................
6.2 SERVICE VALVES 57....................................................................
6.3. MANIFOLD GAGE SET 57...............................................................
6.4 PUMPING THE UNIT DOWN 59..........................................................
6.5 REFRIGERANT LEAK CHECKING 59.....................................................

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TABLE OF CONTENTS -- Continued
PARAGRAPH NUMBER Page
6.6 EVACUATION AND DEHYDRATION 59....................................................
6.6.1 General 59..........................................................................
6.6.2 Preparation 59.......................................................................
6.6.3 Procedure - Complete system 59.......................................................
6.6.4 Procedure - Partial System 60.........................................................
6.7 REFRIGERANT CHARGE 60.............................................................
6.7.1 Checking the Refrigerant Charge 60....................................................
6.7.2 Adding Refrigerant to System (Full Charge) 60...........................................
6.7.3 Adding Refrigerant to System (Partial Charge) 60........................................
6.8 COMPRESSOR 61......................................................................
6.8.1 Removal and Replacement of Compressor 61...........................................
6.8.2 Compressor Disassembly 62..........................................................
6.8.3 Compressor Reassembly 64...........................................................
6.8.4 Preparation 64.......................................................................
86.8.5 Installing the Components 65..........................................................
6.8.6 Compressor Oil Level 65..............................................................
6.9 HIGH PRESSURE SWITCH 66...........................................................
6.9.1 Replacing High Pressure Switch 66.....................................................
6.9.2 Checking High Pressure Switch 66.....................................................
6.10 CONDENSER COIL 66..................................................................
6.11 CONDENSER FAN AND MOTOR ASSEMBLY 66...........................................
6.12 WATER COOLED CONDENSER CLEANING 67............................................
6.13 FILTER-DRIER 68.......................................................................
6.14 THERMOSTATIC EXPANSION VALVE 68..................................................
6.14.1 Checking Superheat. 69..............................................................
6.14.2 Hermetic Valve Replacement 69.......................................................
6.15 EVAPORATOR COIL AND HEATER
ASSEMBLY 70................................................................................
6.15.1 Evaporator Coil Replacement 70.......................................................
6.15.2 Evaporator Heater Replacement 70....................................................
6.16 EVAPORATOR FAN AND MOTOR ASSEMBLY 70..........................................
6.17 EVAPORATOR FAN MOTOR CAPACITORS 71.............................................
6.17.1 When To Check For A Defective Capacitor 71...........................................
6.17.2 Removing The Capacitor 71...........................................................
6.17.3 Checking The Capacitor 71............................................................
6.18 SUCTION MODULATION VALVE 71.......................................................
6.18.1 Precheck Procedure 71...............................................................
6.18.2 Checking The Stepper valve 72........................................................
6.18.3 Checking The Drive Module 72........................................................
6.18.4 Checking The Controller 72...........................................................
6.18.5 Emergency Repair Procedures: 73.....................................................
6.19 DISCHARGE PRESSURE REGULATOR VALVE Check Procedure 73..........................
6.20 AUTOTRANSFORMER 74...............................................................

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TABLE OF CONTENTS -- Continued
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6.21 REFRIGERATION CONTROLLER 74......................................................
6.21.1 Handling Controller 74................................................................
6.21.2 Controller Trouble-Shooting 74.........................................................
6.21.3 Controller Programming Procedure 75..................................................
6.21.4 Removing and Installing the Controller 75...............................................
6.21.5 Battery Replacement 75..............................................................
6.22 TEMPERATURE SENSOR SERVICE 75...................................................
6.22.1 Sensor Checkout Procedure 75........................................................
6.22.2 Sensor Replacement 76..............................................................
6.22.3 Sensor Re-Installation 77.............................................................
6.23 MAINTENANCE OF PAINTED SURFACES 77..............................................
6.24 COMPOSITE CONTROL BOX REPAIRS 77................................................
6.24.1 Introduction 77......................................................................
6.24.2 Cracks 78...........................................................................
6.24.3 Chips And Holes 78..................................................................
6.24.4 Inserts 78...........................................................................
6.24.5 Door Hinge Inserts 78................................................................
6.25 COMMUNICATIONS INTERFACE MODULE INSTALLATION 81..............................
6.26 POWER FACTOR CORRECTOR CAPACITORS (PFC) 81....................................
PART TWO -- CONTROLLED ATMOSPHERE SYSTEM 87...............................
INTRODUCTION 87..............................................................................
7.1 INTRODUCTION 87.....................................................................
DESCRIPTION 89...............................................................................
8.1 GENERAL DESCRIPTION 89...............................................................
8.1.1 CA Equipment Location -- front Section 89...............................................
8.1.2 Calibration, Gas Charge and Pressurization/Gage Ports 89................................
8.1.3 CA Components in the Refrigeration Evaporator Section 90...............................
8.1.4 Control Box 92......................................................................
8.1.5 CA Components in the Refrigeration Condenser Section 93................................
8.1.6 Container Rear Door Section 94.......................................................
8.2 CONTROLLED ATMOSPHERE SYSTEM DATA 95............................................
8.3 ELECTRICAL DATA 95.....................................................................
8.4 CONTROLLED ATMOSPHERE (CA) FLOW CIRCUIT 96.......................................
8.5 FRESH AIR MAKEUP VENT 98.............................................................
8.6 SAFETY AND PROTECTIVE DEVICES 98....................................................
MICROPROCESSOR 99..........................................................................
9.1 CONTROLLED ATMOSPHERE CONTROLLER MODULE 99...................................
9.1.1 Brief Description 99..................................................................
9.1.2 CA Controller Programming (Memory) Card 100...........................................
9.1.3 General Layout of the CA Controller Section 100..........................................
9.1.4 CA Controller Function and Data Codes 102..............................................
9.1.5 Configuration Software (Configuration Variables) 104......................................
9.1.6 CA Controller Alarms 104..............................................................
9.1.7 Controller CA Control 106..............................................................