Carrier 69NT40-511-300 Operation manual

Container Refrigeration
T--285 Rev G
OPERATION AND SERVICE
for
69NT40--511--300 to 399
(excluding --310, --344 & --359)
Container Refrigeration Units

OPERATION AND SERVICE MANUAL
CONTAINER REFRIGERATION UNIT
69NT40--511--300 to 399
(excluding --310, --344 & --359)

T-285Safety-1
SAFETY SUMMARY
GENERAL SAFETY NOTICES
The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this
manual. They arerecommendedprecautions thatmustbeunderstoodandappliedduringoperationandmaintenance
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 workshouldbe performed onthe 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 poweris 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.
Donotbypassanyelectricalsafetydevices,e.g.bridginganoverload,orusinganysortofjumperwires.Problemswith
the system should be diagnosed, and any necessary repairs performed, by qualified service personnel.
Whenperformingany arcwelding on theunit or container,disconnectallwireharnessconnectorsfromthe modulesin
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 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.
SPECIFIC 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 theevaporatorand condenserfans. The unit may cycle the fans
and compressor unexpectedly as control requirements dictate.
WARNING
Donotattemptto removepowerplug(s)beforeturningOFFstart-stopswitch(ST),unit circuitbreak-
er(s) and external power source.
WARNING
Make sure the power plugs are clean and dry before connecting to any power receptacle.

Safety-2T-285
SPECIFIC WARNING AND CAUTION STATEMENTS -- Continued
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 determined that pressurized, mixtures of refrigerant 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 compressor 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
Donotuseanitrogen cylinderwithoutapressure regulator. Do not use oxygen in or near a refrigera-
tion 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
Wearrubberglovesandwashthesolutionfromtheskinimmediatelyifaccidental contact 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.
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 removewire harnessesfrom controllerunless you aregroundedtotheunitframewithastatic
safe wrist strap.
CAUTION
Unplug all controllerwire harnessconnectors beforeperforming arcwelding onanypartof thecon-
tainer.

T-285Safety-3
SPECIFIC WARNING AND CAUTION STATEMENTS -- Continued
CAUTION
Pre-trip inspection should not be performed with critical temperature cargoes in the container.
CAUTION
When Pre-Trip key is pressed, dehumidification and bulb mode will be deactivated. At the comple-
tion of Pre-Trip activity, dehumidification and bulb mode must be reactivated.
CAUTION
Whencondenserwaterflowisbelow11lpm(3gpm)orwhenwater-cooledoperationisnotinuse,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 operator
intervention.
CAUTION
When Pre--Trip test Auto 2runs to completion withoutbeing interrupted, the unit will terminatepre-
tripanddisplay“Auto2”“end.”The unitwill suspendoperation until the userdepresses the ENTER
key!
CAUTION
The unit will remain in the full cooling mode as long as the emergency bypass switch is in the BY-
PASS position. If the cargo may be damaged by low temperatures, the operator must monitor con-
tainertemperatureand manuallycycleoperationasrequiredtomaintaintemperaturewithinrequired
limits.
CAUTION
The unit will remain in the DEFROST mode as long as the emergency defrost switch is in the DE-
FROST position. To prevent cargo damage, the operator must monitor container temperature 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 stator in the field is not recommended. The rotor and sta-
tor are a matched pair and should not be separated.
CAUTION
The copper tube which connects to the oil suction strainer extends out the bottom with the bottom
plate removed. Take precautions to avoid bending or breaking it while changing crankcase posi-
tions.
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) -- Mobil ST32 compressor 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.

Safety-4T-285
SPECIFIC WARNING AND CAUTION STATEMENTS -- Continued
CAUTION
Take necessary steps (place plywood over coil or use sling on motor) to prevent motor from falling
into condenser coil.
CAUTION
If the thermostatic expansion valve is found to be in need of replacement, then the power head and
cage assembly areto replaced as a pair. They area 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 programming card is inserted or removed fromthe controller pro-
gramming 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.
CAUTION
Do not allow the recorder stylus to snap back down. The stylus arm base is spring loaded, and
damage may occur to the chart, or the stylus force may be altered.
CAUTION
Theinsidemechanismoftherecorder,particularlytheinsideoftheelementhousingshouldneverbe
oiled, however, control mechanisms should be sprayed periodically (every 60 days) with corrosion
inhibiting CRC 3-36a or 6-66 or LPS no. 2.
CAUTION
Recorderelementcapillarytubingmaybebent,butneversharper than 1/2” radius; extra careshould
be taken when bending adjacent to welds. The bulb should never be bent, as this will affect
calibration.

iT-285
TABLE OF CONTENTS
PARAGRAPH NUMBER Page
GENERAL SAFETY NOTICES Safety-1.......................................................
FIRST AID Safety-1........................................................................
OPERATING PRECAUTIONS Safety-1.......................................................
MAINTENANCE PRECAUTIONS Safety-1.....................................................
UNIT LABEL IDENTIFICATION Safety-1......................................................
SPECIFIC WARNING AND CAUTION STATEMENTS Safety-1...................................
INTRODUCTION 1-1..............................................................................
1.1 INTRODUCTION 1-1.....................................................................
1.2 CONFIGURATION IDENTIFICATION 1-1...................................................
1.3 OPTION DESCRIPTION 1-1..............................................................
1.3.1 Battery 1-1...........................................................................
1.3.2 Dehumidification 1-1..................................................................
1.3.3 Control Box 1-1......................................................................
1.3.4 Temperature Readout 1-1..............................................................
1.3.5 Pressure Readout 1-1.................................................................
1.3.6 USDA 1-1...........................................................................
1.3.7 Interrogator 1-1.......................................................................
1.3.8 Remote Monitoring 1-1................................................................
1.3.9 Communications. 1-1..................................................................
1.3.10 Compressor 1-1......................................................................
1.3.11 Condenser Coil 1-2...................................................................
1.3.12 Autotransformer 1-2...................................................................
1.3.13 Temperature Recorder 1-2.............................................................
1.3.14 Gutters 1-2..........................................................................
1.3.15 Handles 1-2..........................................................................
1.3.16 Thermometer Port 1-2.................................................................
1.3.17 Water Cooling 1-2....................................................................
1.3.18 Back Panels 1-2......................................................................
1.3.19 460 Volt Cable 1-2...................................................................
1.3.20 230 Volt Cable 1-2....................................................................
1.3.21 Cable Restraint 1-2...................................................................
1.3.22 Upper Air (Fresh Air Make Up) 1-2......................................................
1.3.23 Lower Air (Fresh Air Make Up) 1-2......................................................
1.3.24 Controlled Atmosphere 1-2.............................................................
1.3.25 Arctic Mode 1-2......................................................................
1.3.26 Humidification 1-2....................................................................
1.3.27 Power Correction 1-2..................................................................
1.3.28 Evaporator 1-2.......................................................................
1.3.29 Evaporator Fan Operation 1-3..........................................................
1.3.30 Labels 1-3...........................................................................
1.3.31 Plate Set 1-3.........................................................................
1.3.32 Controller 1-3........................................................................
1.3.33 Condenser Grille 1-3..................................................................
1.3.34 Emergency Bypass 1-3................................................................

ii
T-285
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...........................................................
MICROPROCESSOR 3-1..........................................................................
3.1 TEMPERATURE CONTROL MICROPROCESSOR SYSTEM 3-1..............................
3.1.1 Key Pad 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 (Configuration Variables) 3-3......................................
3.2.2 Operational Software (Function Codes) 3-3..............................................
3.3 MODES OF OPERATION 3-3.............................................................
3.3.1 Temperature Control -- Perishable Mode 3-4..............................................
3.3.2 Evaporator Fan Operation 3-4..........................................................
3.3.3 Defrost Interval 3-4...................................................................
3.3.4 Failure Action 3-4.....................................................................
3.3.5 Generator Protection 3-4..............................................................
3.3.6 Condenser Pressure Control 3-4........................................................
3.3.7 Arctic Mode 3-4......................................................................
3.3.8 Perishable Mode -- Conventional 3-4....................................................
3.3.9 Perishable Mode -- Economy 3-5.......................................................
3.3.10 Perishable Mode -- Dehumidification 3-5.................................................
3.3.11 Perishable, Dehumidification -- Bulb Mode 3-5............................................
3.3.12 Temperature Control -- Frozen Mode 3-5.................................................
3.3.13 Frozen Mode -- Conventional 3-6.......................................................
3.3.14 Frozen Mode -- Economy 3-6...........................................................
3.4 CONTROLLER ALARMS 3-6..............................................................
3.5. UNIT PRE-TRIP DIAGNOSTICS 3-7.......................................................
3.6 DataCORDER 3-7........................................................................
3.6.1 Description 3-7.......................................................................
3.6.2 DataCORDER Software 3-7............................................................
3.6.3 Sensor Configuration (dCF02) 3-8......................................................
3.6.4 Logging Interval (dCF03) 3-10...........................................................

iii T-285
TABLE OF CONTENTS -- Continued
PARAGRAPH NUMBER Page
3.6.5 Thermistor Format (dCF04) 3-10.........................................................
3.6.6 Sampling Type (dCF05 & dCF06) 3-10...................................................
3.6.7 Alarm Configuration (dCF07 -- dCF10) 3-10...............................................
3.6.8 DataCORDER Power-Up 3-10...........................................................
3.6.9 Pre-Trip Data Recording 3-10...........................................................
3.6.10 DataCORDER Communications 3-10.....................................................
3.6.11 USDA Cold Treatment 3-11.............................................................
3.6.12 USDA Cold Treatment Procedure 3-11...................................................
3.6.13 DataCORDER Alarms 3-11.............................................................
OPERATION 4-1.................................................................................
4.1 INSPECTION (Before Starting) 4-1.........................................................
4.2 CONNECT POWER 4-1..................................................................
4.2.1 Connection To 380/460 vac Power 4-1...................................................
4.2.2 Connection to190/230 vac Power 4-1....................................................
4.3 ADJUST FRESH AIR MAKEUP VENT 4-1...................................................
4.3.1 Upper Fresh Air Makeup Vent 4-1.......................................................
4.3.1 Fresh Air Vent Position Sensor (VPS) 4-2...............................................
4.3.2 Lower Fresh Air Makeup Vent 4-2.......................................................
4.4 CONNECT WATER-COOLED CONDENSER 4-2.............................................
4.4.1 Water--Cooled Condenser with Water Pressure Switch 4-2.................................
4.4.2 Water-Cooled Condenser with Condenser Fan Switch 4-2..................................
4.5 CONNECT REMOTE MONITORING RECEPTACLE 4-3......................................
4.6 STARTING AND STOPPING INSTRUCTIONS 4-3...........................................
4.6.1 Starting the Unit 4-3...................................................................
4.6.2 Stopping the Unit 4-3..................................................................
4.7 START--UP INSPECTION 4-3.............................................................
4.7.1 Physical Inspection 4-3................................................................
4.7.2 Check Controller Function Codes 4-3....................................................
4.7.3 Start Temperature Recorder 4-3........................................................
4.7.4 Complete Inspection 4-3...............................................................
4.8 PRE-TRIP DIAGNOSIS 4-3...............................................................
4.9 OBSERVE UNIT OPERATION 4-4.........................................................
4.9.1 Crankcase Heater 4-4.................................................................
4.9.2 Probe Check 4-5.....................................................................
4.10 SEQUENCE OF OPERATION 4-5...........................................................
4.10.1 Sequence Of operation -- Perishable Mode Cooling 4-6....................................
4.10.2 Sequence Of Operation -- Perishable Mode Heating 4-7...................................
4.10.3 Sequence Of operation -- Frozen Mode Cooling 4-7........................................
4.10.4 Sequence Of Operation -- Defrost 4-7...................................................
4.11 EMERGENCY OPERATION 4-9...........................................................
4.11.1 Emergency Bypass Operation. 4-9......................................................
4.11.2 Emergency Defrost Operation. 4-9......................................................

iv
T-285
TABLE OF CONTENTS -- Continued
PARAGRAPH NUMBER Page
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 (COOLING) 5-3.................................................
5.8 ABNORMAL NOISE OR VIBRATIONS 5-3..................................................
5.9 CONTROLLER MALFUNCTION 5-3........................................................
5.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW 5-4..............................
5.11 THERMOSTATIC EXPANSION VALVE MALFUNCTION 5-4...................................
5.12 AUTOTRANSFORMER MALFUNCTION 5-4................................................
5.13 WATER-COOLED CONDENSER OR WATER PRESSURE SWITCH 5-4........................
SERVICE 6-1....................................................................................
6.1 SECTION LAYOUT 6-1...................................................................
6.2 SERVICE VALVES 6-1....................................................................
6.3. MANIFOLD GAUGE SET 6-1..............................................................
6.4 PUMPING THE UNIT DOWN 6-2..........................................................
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 Procedure - Complete system 6-3.......................................................
6.6.4 Procedure - 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...........................................
6.8.2 Compressor Disassembly 6-6..........................................................
6.8.3 Compressor Reassembly 6-8...........................................................
6.8.4 Preparation 6-8.......................................................................
6.8.5 Installing the Components 6-9..........................................................
6.8.6 Compressor Oil Level 6-9..............................................................
6.9 HIGH PRESSURE SWITCH 6-10...........................................................
6.9.1 Replacing High Pressure Switch 6-10.....................................................
6.9.2 Checking High Pressure Switch 6-10.....................................................
6.10 CONDENSER COIL 6-10..................................................................
6.11 CONDENSER FAN AND MOTOR ASSEMBLY 6-10...........................................
6.12 WATER COOLED CONDENSER CLEANING 6-10............................................
6.13 FILTER-DRIER 6-12.......................................................................
6.14 THERMOSTATIC EXPANSION VALVE 6-12..................................................