Carrier Transicold 69NT40-541 Series Operation manual

ÓÓ
ÓÓ
Container Refrigeration
T-318 Rev B
OPERATION AND SERVICE
for
69NT40-541-300 to 499
Container Refrigeration Units


OPERATION AND SERVICE MANUAL
CONTAINER REFRIGERATION UNIT
Models
69NT40-541-300 to 499
©Carrier Corporation, 2012 Printed in U. S. A. July 2012

iT-318
TABLE OF CONTENTS
PARAGRAPH NUMBER Page
GENERAL SAFETY NOTICES Safety−1..........................................................
FIRST AID Safety−1...........................................................................
OPERATING PRECAUTIONS Safety−1.........................................................
MAINTENANCE PRECAUTIONS Safety−1.......................................................
SPECIFIC WARNING AND CAUTION STATEMENTS Safety−1........................................
INTRODUCTION 1−1..............................................................................
1.1 INTRODUCTION 1−1.....................................................................
1.2 CONFIGURATION IDENTIFICATION 1−1...................................................
1.3 FEATURE DESCRIPTIONS 1−1............................................................
1.3.1 Control Box 1−1......................................................................
1.3.2 Temperature Readout 1−1..............................................................
1.3.3 Pressure Readout 1−1.................................................................
1.3.4 Compressor 1−1......................................................................
1.3.5 Condenser Coil 1−1...................................................................
1.3.6 Evaporator 1−1.......................................................................
1.3.7 Evaporator Fan Operation 1−1..........................................................
1.3.8 Plate Set 1−1.........................................................................
1.4 OPTION DESCRIPTIONS 1−1.............................................................
1.4.1 Battery 1−1...........................................................................
1.4.2 Dehumidification 1−1..................................................................
1.4.3 USDA 1−1...........................................................................
1.4.4 Interrogator 1−1.......................................................................
1.4.5 Remote Monitoring 1−2................................................................
1.4.6 Quest −CCPC 1−2....................................................................
1.4.7 Communications Interface Module 1−2...................................................
1.4.8 Autotransformer 1−2...................................................................
1.4.9 Temperature Recorder 1−2.............................................................
1.4.10 Gutters 1−2..........................................................................
1.4.11 Handles 1−2..........................................................................
1.4.12 Thermometer Port 1−2.................................................................
1.4.13 Water Cooling 1−2....................................................................
1.4.14 Back Panels 1−2......................................................................
1.4.15 460 Volt Cable 1−2...................................................................
1.4.16 230 Volt Cable 1−2....................................................................
1.4.17 Cable Restraint 1−2...................................................................
1.4.18 Upper Air (Fresh Air Make Up) 1−2......................................................
1.4.19 Lower Air (Fresh Air Make Up) 1−2......................................................
1.4.20 Labels 1−2...........................................................................
1.4.21 Controller 1−3........................................................................
1.4.23 Condenser Grille 1−3..................................................................
1.4.25 eAutoFresh 1−3.......................................................................
1.4.26 Arctic Mode 1−3......................................................................
1.4.27 Power Correction 1−3..................................................................

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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 Keypad 3−2..........................................................................
3.1.2 Display Module 3−2...................................................................
3.1.3 Controller 3−3........................................................................
3.2 CONTROLLER SOFTWARE 3−3...........................................................
3.2.1 Configuration Software (CnF Variables) 3−3..............................................
3.2.2 Operational Software (Cd Function Codes) 3−4...........................................
3.3 MODES OF OPERATION 3−4................................................................
3.3.1 Perishable Mode Temperature Control 3−4...............................................
3.3.2 Perishable Pulldown 3−4...............................................................
3.3.3 Perishable Steady State 3−4............................................................
3.3.4 Perishable Idle, Air Circulation 3−4......................................................
3.3.5 Perishable Heating 3−4................................................................
3.3.6 Perishable Mode Dehumidification 3−5...................................................
3.3.7 Perishable, Dehumidification −Bulb Mode 3−6............................................
3.3.8 Perishable Economy 3−6...............................................................
3.3.9 Perishable Mode Cooling −Sequence of Operation 3−6....................................
3.3.10 Perishable Mode Heating −Sequence of Operation 3−7....................................
3.3.11 Frozen Mode - Temperature Control 3−7.................................................
3.3.12 Frozen Steady State 3−7...............................................................
3.3.13 Frozen Idle Mode 3−8.................................................................
3.3.14 Frozen “Heat” Mode 3−8...............................................................
3.3.15 Frozen Economy Mode 3−8............................................................
3.3.16 Frozen Mode Cooling −Sequence of Operation 3−9.......................................
3.3.17 Defrost 3−9..........................................................................
3.3.18 Automatic Defrost 3−9.................................................................
3.3.19 Defrost Initiation 3−10..................................................................
3.3.20 Defrost Interval 3−11...................................................................
3.3.21 Defrost Related Settings 3−11...........................................................

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3.4 PROTECTION MODES OF OPERATION 3−11................................................
3.4.1 Evaporator Fan Operation 3−11..........................................................
3.4.2 Failure Action 3−11.....................................................................
3.4.3 Generator Protection 3−11..............................................................
3.4.4 Condenser Pressure Control 3−11........................................................
3.4.5 Arctic Mode 3−12......................................................................
3.5 QUEST −CCPC 3−12......................................................................
3.6 CONTROLLER ALARMS 3−12..............................................................
3.7 PRE−TRIP DIAGNOSTICS 3−12............................................................
3.8 DataCORDER 3−13........................................................................
3.8.1 Description 3−13.......................................................................
3.8.2 DataCORDER Software 3−13............................................................
3.8.3 Sensor Configuration (dCF02) 3−14......................................................
3.8.4 Logging Interval (dCF03) 3−14...........................................................
3.8.5 Thermistor Format (dCF04) 3−14.........................................................
3.8.6 Sampling Type (dCF05 & dCF06) 3−16...................................................
3.8.7 Alarm Configuration (dCF07 −dCF10) 3−16...............................................
3.8.8 DataCORDER Power-Up 3−16...........................................................
3.8.9 Pre-trip Data Recording 3−16............................................................
3.8.10 DataCORDER Communications 3−16.....................................................
3.8.11 USDA Cold Treatment 3−17.............................................................
3.8.12 USDA Cold Treatment Procedure 3−17...................................................
3.8.13 DataCORDER Alarms 3−18.............................................................
3.8.14 ISO Trip Header 3−18..................................................................
3.9 CONTROLLER CONFIGURATION VARIABLES 3−19..........................................
3.10 CONTROLLER FUNCTION CODES 3−20....................................................
3.11 CONTROLLER ALARM INDICATIONS 3−30..................................................
3.12 CONTROLLER PRE−TRIP TEST CODES 3−36...............................................
OPERATION 4−1.................................................................................
4.1 INSPECTION (Before Loading) 4−1.........................................................
4.2 CONNECT POWER 4−1..................................................................
4.2.1 Connection To 380/460 VAC Power 4−1..................................................
4.2.2 Connection to 190/230VAC Power 4−1...................................................
4.3 ADJUST FRESH AIR MAKEUP VENT 4−1...................................................
4.3.1 Upper Fresh Air Makeup Vent 4−2.......................................................
4.3.2 Lower Fresh Air Makeup Vent 4−2.......................................................
4.3.3 Vent Position Sensor 4−3..............................................................
4.4 eAutoFresh OPERATION 4−3..............................................................
4.4.1 eAutoFresh Pre−Trip Inspection 4−3.....................................................
4.4.2 eAutoFresh Start−Up Procedure 4−3....................................................
4.4.3 eAutoFresh Modes of Operation 4−3.....................................................
4.5 CONNECT WATER−COOLED CONDENSER 4−4............................................
4.5.1 Water-Cooled Condenser with Water Pressure Switch 4−4..................................
4.5.2 Water-Cooled Condenser with Condenser Fan Switch 4−5..................................

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TABLE OF CONTENTS (Continued)
PARAGRAPH NUMBER Page
4.6 CONNECT REMOTE MONITORING RECEPTACLE 4−5......................................
4.7 STARTING AND STOPPING INSTRUCTIONS 4−5...........................................
4.7.1 Starting the Unit 4−5...................................................................
4.7.2 Stopping the Unit 4−5..................................................................
4.8 START−UP INSPECTION 4−5.............................................................
4.8.1 Physical Inspection 4−5................................................................
4.8.2 Check Controller Function Codes 4−5....................................................
4.8.3 Start Temperature Recorder 4−5........................................................
4.8.4 Complete Inspection 4−5...............................................................
4.9 PRE−TRIP DIAGNOSIS 4−6...............................................................
4.10 PROBE DIAGNOSTICS 4−7...............................................................
4.11 EMERGENCY BYPASS OPERATION 4−8...................................................
4.11.1 Emergency Bypass Operation 4−8......................................................
4.11.2 Emergency Defrost Operation 4−8.......................................................
4.12 ARCTIC MODE 4−8......................................................................
4.12.1 Crankcase Heater 4−8.................................................................
TROUBLESHOOTING 5−1.........................................................................
5.1 UNIT WILL NOT START OR STARTS THEN STOPS 5−1......................................
5.2 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING 5−1..............................
5.3 UNIT RUNS BUT HAS INSUFFICIENT COOLING 5−2........................................
5.4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING 5−2................................
5.5 UNIT WILL NOT TERMINATE HEATING 5−2................................................
5.6 UNIT WILL NOT DEFROST PROPERLY 5−2................................................
5.7 ABNORMAL PRESSURES (COOLING) 5−3.................................................
5.8 ABNORMAL NOISE OR VIBRATIONS 5−3..................................................
5.9 MICROPROCESSOR MALFUNCTION 5−3..................................................
5.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW 5−3..............................
5.11 EAUTOFRESH NOT OPERATING 5−4......................................................
5.12 THERMOSTATIC EXPANSION VALVE MALFUNCTION 5−4...................................
5.13 AUTOTRANSFORMER MALFUNCTION 5−4................................................
5.14 WATER−COOLED CONDENSER OR WATER PRESSURE SWITCH 5−4.......................
SERVICE 6−1....................................................................................
6.1 SECTION LAYOUT 6−1...................................................................
6.2 MANIFOLD GAUGE SET 6−1..............................................................
6.3 SERVICE VALVES 6−2....................................................................
6.4 PUMP 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 Complete System 6−3.................................................................
6.6.4 Procedure - Partial System 6−4.........................................................

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TABLE OF CONTENTS (Continued)
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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 Checking High Pressure Switch 6−10.....................................................
6.9.2 Replacing 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 6−11............................................
6.13 FILTER−DRIER 6−13......................................................................
6.14 THERMOSTATIC EXPANSION VALVE 6−13..................................................
6.14.1 Checking Superheat 6−13...............................................................
6.14.2 TXV Replacement 6−13.................................................................
6.15 EVAPORATOR COIL & HEATER ASSEMBLY 6−14............................................
6.15.1 Evaporator Coil Replacement 6−14.......................................................
6.15.2 Evaporator Heater Replacement 6−15....................................................
6.16 EVAPORATOR FAN AND MOTOR ASSEMBLY 6−15..........................................
6.16.1 Replacing the Evaporator Fan Assembly 6−15.............................................
6.16.2 Disassemble the Evaporator Fan Assembly 6−15...........................................
6.16.3 Assemble the Evaporator Fan Assembly 6−15.............................................
6.17 EVAPORATOR FAN MOTOR CAPACITOR 6−16..............................................
6.17.1 When To Check For A Defective Capacitor 6−16...........................................
6.17.2 Removing the Capacitor 6−16............................................................
6.17.3 Checking the Capacitor 6−16............................................................
6.18 EVAPORATOR SECTION CLEANING 6−16...................................................
6.19 SUCTION MODULATION VALVE 6−17.......................................................
6.19.1 Pre-check Procedure 6−17..............................................................
6.20 VALVE OVERRIDE CONTROLS 6−18........................................................
6.20.1 Checking the Stepper Valve 6−18........................................................
6.20.2 Checking the Controller 6−19............................................................
6.20.3 SMV Emergency Repair Procedure 6−19..................................................
6.21 DPRV Check Procedure 6−19...............................................................
6.22 AUTOTRANSFORMER 6−19...............................................................

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6.23 CONTROLLER 6−20.......................................................................
6.23.1 Handling Controller 6−20................................................................
6.23.2 Controller Troubleshooting 6−20..........................................................
6.23.3 Controller Programming Procedure 6−21..................................................
6.23.4 Removing and Installing the Controller 6−21...............................................
6.23.5 Battery Replacement 6−22..............................................................
6.24 TEMPERATURE SENSOR SERVICE 6−22...................................................
6.24.1 Sensor Checkout Procedure 6−22........................................................
6.24.2 Sensor Replacement 6−22..............................................................
6.24.3 Sensor Re-Installation 6−24.............................................................
6.25 VENT POSITION SENSOR (VPS) 6−24......................................................
6.26 eAutoFresh SERVICE 6−25.................................................................
6.26.1 Servicing the eAutoFresh Air Filter 6−25...................................................
6.26.2 Checking eAutoFresh Drive System 6−25.................................................
6.26.3 Servicing the eAutoFresh Drive System 6−26..............................................
6.27 ELECTRONIC PARTLOW TEMPERATURE RECORDER 6−28..................................
6.27.1 Replacing the Recorder 6−28............................................................
6.27.2 Changing the Chart 6−28................................................................
6.27.3 Adjusting the Recorder Stylus 6−30.......................................................
6.27.4 Rezeroing the Recording Thermometer 6−30..............................................
6.27.5 Rezeroing the Recording Thermometer 6−30..............................................
6.28 MAINTENANCE OF PAINTED SURFACES 6−30..............................................
6.29 COMPOSITE CONTROL BOX REPAIRS 6−30................................................
6.30 COMMUNICATIONS INTERFACE MODULE INSTALLATION 6−34..............................
6.31 POWER FACTOR CORRECTOR CAPACITORS (PFC) 6−34....................................
ELECTRICAL WIRING SCHEMATIC 7−1............................................................
7.1 INTRODUCTION 7−1.....................................................................