Carrier 69NT40--541--200 TO 299 Operation manual

T--317 Rev A
OPERATION AND SERVICE
for
69NT40--541--200 TO 299
Container Refrigeration Units
Container Refrigeration
r

OPERATION AND SERVICE MANUAL
CONTAINER REFRIGERATION UNIT
Models
69NT40--541--200 to 299

T-317Safety-1
SAFETY SUMMARY
GENERAL SAFETY NOTICES
The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this
manual. They are recommended precautions that must be understood and applied during operation and maintenance
of the equipment covered herein. The general safety notices are presented in the following three sections labeled:
First Aid, Operating Precautions and Maintenance Precautions. A listing of the specific warnings and cautions
appearing elsewhere in the manual follows the general safety notices.
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 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 the
evaporator and condenser fans. The unit
may cycle the fans and compressor unex-
pectedly as control requirements dictate.
WARNING
Make sure the power plugs are clean and
dry before connecting to any power recep-
tacle.
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.

Safety-2T-317
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 or gases containing oxygen
for leak testing or operating refrigerant
compressors. Pressurized mixtures of air
or gases containing oxygen can lead to ex-
plosion.
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.
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 con-
troller unless you are grounded to the unit
frame with a static safe wrist strap.
CAUTION
Unplug all controller wire harness connec-
tors before performing arc welding on any
part of the container.
CAUTION
Pre-trip inspection should not be per-
formed with critical temperature cargoes in
the container.

T-317Safety-3
SPECIFIC WARNING AND CAUTION STATEMENTS -- Continued
CAUTION
When Pre-Trip key is pressed, dehumidifi-
cation and bulb mode will be deactivated.
At the completion of Pre-Trip activity, dehu-
midification and bulb mode must be reacti-
vated.
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 operator intervention.
CAUTION
When Pre--Trip test Auto 2 runs to comple-
tion 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
damaged by low temperatures, the operator
must monitor container temperature and
manually cycle operation as required to
maintain temperature within required lim-
its.
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 con-
tainer temperature and manually cycle op-
eration 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 stator 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 pre-
cautions 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) -- Mobil ST32 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 contamina-
tion will occur.
CAUTION
Take necessary steps (place plywood over
coil or use sling on motor) to prevent motor
from falling into condenser coil.

Safety-4T-317
SPECIFIC WARNING AND CAUTION STATEMENTS -- Continued
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 suc-
tion modulating valve powerhead assem-
bly. Doing so may result in damage to pis-
ton.
CAUTION
The unit must be OFF whenever a program-
ming card is inserted or removed from the
controller programming port.
CAUTION
Do not allow moisture to enter wire splice
area as this may affect the sensor resis-
tance.
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,
orthestylusforcemaybealtered.
CAUTION
The inside mechanism of the recorder,
particularly the inside of the element
housing should never be 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
Recorder element capillary tubing may be
bent, but never sharper than 1/2” radius;
extra care should be taken when bending
adjacent to welds. The bulb should never
be bent, as this will affect calibration.

iT-317
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 Arctic Mode 1-2......................................................................
1.3.25 Power Correction 1-2..................................................................
1.3.26 Evaporator 1-2.......................................................................
1.3.27 Labels 1-2...........................................................................
1.3.28 Plate Set 1-2.........................................................................
1.3.29 Controller 1-2........................................................................
1.3.30 Condenser Grille 1-2..................................................................

ii
T-317
TABLE OF CONTENTS -- Continued
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 3-4.............................................................
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 3-5....................................................
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 3-6.................................................
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.......................................................

iii T-317
TABLE OF CONTENTS -- Continued
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...........................................................
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 3-12...................................................
3.6.13 DataCORDER Alarms 3-12.............................................................
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 4-2.......................................................
4.3.2 Lower Fresh Air Makeup Vent 4-2.......................................................
4.3.3 Fresh Air Position Sensor 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 4-3..................................
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...................................................

iv
T-317
TABLE OF CONTENTS -- Continued
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 REPAIRING THE REFRIGERATION SYSTEM 6-1...........................................
6.2 PIERCING VALVES 6-1...................................................................
6.3 MANIFOLD GAUGE SET 6-1..............................................................
6.4 REFRIGERANT RECOVERY 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.......................................................
6.7 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........................................
6.7.4 Emergency Shipboard Refrigerant Charging Procedure 6-4.................................
6.8 COMPRESSOR 6-6......................................................................
6.8.1 Removal and Replacement of Compressor 6-6...........................................
6.8.2 Compressor Disassembly 6-7..........................................................
6.8.3 Compressor Reassembly 6-9...........................................................
6.8.4 Preparation 6-9.......................................................................
6.8.5 Installing the Components 6-9..........................................................
6.8.6 Compressor Oil Level 6-10..............................................................
6.9 HIGH PRESSURE SWITCH 6-11...........................................................
6.9.1 Replacing High Pressure Switch 6-11.....................................................
6.9.2 Checking High Pressure Switch 6-11.....................................................
6.10 CONDENSER COIL 6-11..................................................................
6.11 CONDENSER FAN AND MOTOR ASSEMBLY 6-11...........................................
6.12 WATER COOLED CONDENSER CLEANING 6-12............................................
6.13 FILTER-DRIER 6-13.......................................................................