Carrier NEOS 100S User Manual Download

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Truck Refrigeration

OPERATION & SERVICE MANUAL

For The

Neos™ 100S

Truck Refrigeration Units

62-11848 Rev B

Summary of Contents for NEOS 100S

Page 1: ...Truck Refrigeration OPERATION SERVICE MANUAL For The Neos 100S Truck Refrigeration Units 62 11848 Rev B ...

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Page 3: ...OPERATION SERVICE MANUAL For The Neos 100S Truck Refrigeration Units 2017 Carrier Corporation Printed in USA September 2017 ...

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Page 5: ... 2 7 2 3 7 High Pressure Switch HP1 2 7 2 3 8 Condenser Pressure Control Switch HP2 2 7 2 4 EVAPORATOR SECTION 2 7 2 4 1 Thermostatic Expansion Valve TXV 2 7 2 4 2 Compressor Pressure Regulating Valve CPR 2 7 2 4 3 Evaporator Coil 2 7 2 4 4 Low Pressure Switch LP 2 7 2 5 SYSTEM OPERATING CONTROLS AND COMPONENTS 2 8 2 6 UNIT SPECIFICATIONS 2 8 2 6 1 Compressor Data 2 8 2 6 2 Refrigeration System Da...

Page 6: ...necting Manifold Gauge Hose Set 5 3 5 2 3 Removing the Manifold Gauge Set 5 3 5 3 REMOVING THE REFRIGERANT CHARGE 5 4 5 3 1 Removing Complete Charge 5 4 5 4 REFRIGERANT LEAK CHECKING 5 5 5 5 EVACUATION AND DEHYDRATION 5 5 5 5 1 General 5 5 5 5 2 Preparation 5 5 5 5 3 Procedure For Evacuation And Dehydrating System 5 5 5 6 CHARGING THE REFRIGERATION SYSTEM 5 6 5 6 1 Checking The Refrigerant Charge ...

Page 7: ...l Not Cool 6 2 6 2 2 Unit Runs But Has Insufficient Cooling 6 2 6 2 3 Unit Operates Long or Continuously in Cooling 6 3 6 2 4 Unit Will Not Heat or Heating Insufficient 6 3 6 2 5 Defrost Malfunction 6 3 6 2 6 Abnormal Pressure 6 3 6 2 7 Abnormal Noise 6 4 6 2 8 Cab Command Malfunction 6 4 6 2 9 No Evaporator Air Flow or Restricted Air Flow 6 4 6 2 10 Expansion Valve 6 5 6 2 11 Malfunction Hot Gas ...

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Page 9: ...ht Status 3 3 Figure 4 1 Operating Sequence Perishable Mode 4 1 Figure 4 2 Operating Sequence Frozen Mode 4 2 Figure 5 1 Manifold Gauge Set R 134a 5 3 Figure 5 2 Vacuum Pump Connection 5 4 Figure 5 3 Procedure for Adding a Complete Charge 5 6 Figure 5 4 Typical Switch Setup for Testing Pressure Switches HP 1 and HP2 5 8 Figure 5 5 Hot Gas Valve Condenser Pressure Control Valve Quench Valve Hot Gas...

Page 10: ...2 2 Table 2 2 Additional Support Manuals 2 2 Table 3 1 Malfunctions 3 6 Table 5 1 Maintenance Schedule 5 1 Table 5 2 Service Category Descriptions 5 2 Table 5 3 R 134a Temperature Pressure Chart 5 12 Table 6 1 Alarm Indications 6 1 Table 6 2 Mechanical Indications 6 2 ...

Page 11: ...t With Skin Immediately rinse your skin thoroughly with water Cooling Oil Avoid prolonged or repeated contact with the skin Wash carefully after handling 1 3 OPERATING PRECAUTIONS Always wear safety glasses Hearing protection is recommended while unit is running Always keep your hands hair clothing and tools clear of the evaporator and condenser fans No work should be performed on the unit until t...

Page 12: ...in or eyes can cause severe burns Keep any flame any lighted object or any source of sparks away from the battery elements Always use Personal Protective Equipment when handling and charging battery safety clothes safety gloves and safety glasses Respect polarity when connecting a battery 1 5 REFRIGERANTS The refrigerant contained in your unit can cause frostbite severe burns or blindness when in ...

Page 13: ...unit The unit may cycle the fans and compressor unex pectedly as control requirements dictate Press the OFF key on the Cab Command WARNING Beware of V belt and belt driven components as the unit may start automatically WARNING Ensure power to the unit is OFF the vehicle engine is OFF and the negative battery cable is connected before replacing the compressor WARNING Slowly open the plug on the suc...

Page 14: ...n the enclosing tube assembly Place all parts in the enclosing tube in proper sequence in order to avoid premature coil burn out CAUTION Observe proper polarity when installing battery Negative battery terminal must be grounded CAUTION Under no circumstances should a technician electrically probe the processor at any point other than the connector terminals where the harness attaches Microprocesso...

Page 15: ...some other information If a problem occurs please refer to the information on this plate and make a note of the model and serial number before calling for assistance This information will be needed when you contact a technician so that he may prop erly assist you 2 1 2 Noise Level Sticker This sticker indicates the noise level in Lwa sound power level 2 2 GENERAL DESCRIPTION The Neos 100S unit is ...

Page 16: ...A Compressor Condenser Weight Evap Weight Neos 100S Road Only 2 2 lbs 1 kg SD 5H09 105 8 lb 48 kg 33 lb 15 Kg Table 2 2 Additional Support Manuals Manual Number Equipment Covered Type of Manual 62 11850 Neos 100S Operator s Manual 62 11852 Neos 100S Part s List ...

Page 17: ...e 2 1 Main Unit Components 1 Condenser Fan 2 Nameplate 3 Cab Command 4 Electric Motor 5 Control Box 6 Compressor 7 Condenser Coil 8 Filter Drier Receiver 9 Hot Gas Valve HGS1 10 Main Heat Valve HGS2 10 5 6 7 8 4 9 1 2 3 ...

Page 18: ...coil 2 Defrost Termination Thermostat DTT 3 Low Pressure Switch LP 4 Defrost Element 5 Frame 6 Compressor Pressure Regulating Valve CPR 7 LP Manifold Fitting CPR adjustment 8 Expansion Valve TXV 9 LP Manifold Fitting TXV adjustment 1 2 3 4 5 6 9 8 7 ...

Page 19: ...M Micro board relay 4 Microprocessor board 5 FMC Fuse for MC protection Figure 2 4 Microprocessor Board 1 Microprocessor fuse 25A 2 12 Vdc 3 Micro sticker 4 CN2 connector 5 Ground 6 Cab Command connector 7 CN4 connector RAT 8 EEPROM 9 T selection bridge 10 CN3 connector 1 2 3 4 5 1 2 3 4 5 6 7 8 9 10 ...

Page 20: ...ble standby plug 2 Neutral cable standby plug 3 Ground cable standby plug 4 Ignition key OUT to the unit 5 Ignition key IN from the vehicle 6 Battery from battery 7 Battery from the unit 8 Battery from battery 9 Battery from the unit 1 2 3 4 5 6 7 8 9 ...

Page 21: ...rises above a predetermined setting For HP1 settings see Section 2 6 2 2 3 8 Condenser Pressure Control Switch HP2 Condenser pressure control switch HP2 is a normally open switch which closes to signal the microprocessor to activate the condenser fan HP2 also cycles the condenser pressure control valve HGS2 in addition to the con denser fan in order to maintain discharge pressure for heating capac...

Page 22: ... repair the microprocessor module or Cab Command Should a problem develop with these components contact your nearest Carrier Transicold dealer for replacement Figure 2 6 Cab Command 2 6 UNIT SPECIFICATIONS 2 6 1 Compressor Data 2 6 2 Refrigeration System Data a Defrost Timer Automatic triggering or at preset intervals 0 Disabled auto 1h 2h 3h 4h 5h 6h b High Pressure Switch HP1 Cutout at 355 psig ...

Page 23: ...ance 7 3Ω Electrical System Requirements In order to ensure proper unit and vehicle operation the vehicle should have an electrical system capable of producing an additional 90 amps of current above the full load current required for the rest of the vehicle including all accessories e Standby Module Input Voltage 230 VAC 1 phase 50 60hz Amp Draw 10 Amp AC Output Voltage 13 7 VDC Output Current 90 ...

Page 24: ...ard NO Self protected opening 4 Excessive current draw Motor Compressor Fuse YES See electrical wiring diagram 5 Excessive current draw Evaporator and Condenser fan motors Electronic relay YES Self protected opening 6 Excessive Compressor discharge pressure Automatic reset of High pressure switch HP1 YES Timer 5 min 7 Excessive current draw unit in road operation Road Supply Fuse FMP NO Opens at 2...

Page 25: ...erature The transfer of heat from the air to the low temperature liquid refrigerant causes the liquid to vaporize The vapor at low temperature and pressure enters the heat exchanger then enters the compressor pressure regulating valve CPR which regulates refrigerant pressure entering the compressor where the cycle starts over The discharge pressure is regulated with HP2 2 8 2 Heat And Defrost See ...

Page 26: ...EIVER TXV EVAP DRAIN PAN HEATER HP1 SUCTION ACCESS VALVE DISCHARGE ACCESS VALVE HIGH PRESSURE VAPOR HIGH PRESSURE LIQUID LIQUID INJECTION LINE LOW PRESSURE VAPOR LOW PRESSURE LIQUID KING VALVE CPR FILTER DRIER SERVICE FITTING IF FITTED HOT GAS SOLENOID VALVE HGS1 COND PRESS CONTROL VALVE HGS2 ...

Page 27: ...LP COMPRESSOR CONDENSER RECEIVER FILTER DRIER TXV EVAP DRAIN PAN HEATER HP1 SUCTION ACCESS VALVE DISCHARGE ACCESS VALVE HIGH PRESSURE VAPOR LIQUID INJECTION LINE LOW PRESSURE VAPOR KING VALVE CPR SERVICE FITTING HOT GAS SOLENOID VALVE HGS1 COND PRESS CONTROL VALVE HGS2 IF FITTED ...

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Page 29: ...ation currently applicable on the site of use and with the unit specifications as described in the table below The unit connection cable must be fitted with a ground connection The cable must be connected to earth ground On the 230 V supply the unit should be connected to a Ground Fault Protection Device Operations on the 230 V supply for the unit must only be carried out by authorized personnel T...

Page 30: ...s possible to program the microprocessor to obtain continu ous ventilation by the evaporator while at setpoint The driver can display the box temperature and see whether the setpoint is being maintained by checking the green indicator The indicator lights up red in the event of a malfunction When the battery voltage is too low a fail safe system shuts down the unit Unit restart is automatic and ti...

Page 31: ...The keypad consists of six keys that enable the operator to activate various functions display operating data and modify operating parameters Manual defrost control key Unit start up key Unit shut down key The unit can also be shut down with the ignition key The SET key together with the and keys enables display and modification of unit operating data The display scrolls through pa rameters each t...

Page 32: ...ter installation the compressor pressure regulating valve will need to be reset refer to Section 5 11 CAUTION If starting unit for the first time after installation or starting after adding removing an optional feature or if Owners operating parameters have changed the Configuration will need to be reset refer to Section 3 12 1 Start the vehicle engine or connect the standby plug 2 Press the ON ke...

Page 33: ...SET key to validate the setpoint temperature and return to the display of box temperature NOTE If no key is pressed within 5 seconds of adjusting settings the system reverts to displaying the box temperature Only validated changes are recorded 3 8 ALARM DISPLAY In the event of a malfunction the unit will shut down and the Cab Command will display an error message or alarm message The message will ...

Page 34: ... not risen after this 10 minute period the unit will remain out of temperature control mode another 2 minutes and the microprocessor will check the battery voltage every 2 minutes The unit will return to temperature control mode in its current configuration when battery voltage rises to 10 5V 0 5V 3 9 CHECKING THE SOFTWARE VERSION AND HOURMETER 1 Start up the unit 2 Press the SET key for 5 seconds...

Page 35: ...tilization we recommend to place the vehicle in the shade CAUTION Never allow your unit to sit more than a month without running Proper air circulation in the insulated box refers to air that can move around and through the load This is a critical element in maintaining product quality during transport If air cannot circulate completely around the load hot spots or top freeze can occur The use of ...

Page 36: ...e display to Fahrenheit the selection jumper must be removed and discarded See Figure 2 4 NOTE The board contains another set of pins similar to the Degrees C Degrees F selection jumper marked as J1 This jumper is not used for unit operation but it is used during the microprocessor controller manufacturing process DO NOT CONNECT THE J1 PINS TOGETHER 2 The following steps must be performed with the...

Page 37: ... through available options 20 F 28 9 C 4 F 20 C 32 F 0 C using the or keys Factory setting is 20 F Selection MUST be validated by pressing the SET key The null mode differential temperature is displayed next This setting determines the temperature difference between box temperature and setpoint that controls compressor cycling The differential can be selected by scrolling through available options...

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Page 39: ...point the unit will then enter the null mode If the continuous air flow parameter is set to ON the evaporator fans will continue to operate with all other components OFF If the continuous air flow parameter is OFF the evaporator fans and all other components will be OFF A five min ute delay is required before restart is allowed c If temperature increases during the null mode the unit will restart ...

Page 40: ...icroprocessor displays dF on the cab command and setpoint is no longer displayed During defrost the evaporator fans shut down and operation of the condenser fan is controlled by the microproces sor For a description of the refrigeration circuit during heat and defrost see Section 2 8 2 4 3 MINIMUM OFF TIME Once the unit has cycled off it will remain off for the minimum off time of five minutes Thi...

Page 41: ...em whenever removing refrigerant When working with refrigerants you must comply with all local government environmental laws U S A EPA section 608 5 1 MAINTENANCE SCHEDULE A comprehensive maintenance program is required in order to optimize the life and reliability of your unit The rec ommended scheduled maintenance intervals and categories are provided in Table 5 1 A service message will appear o...

Page 42: ...ery clamps Check and adjust all belts Replace if needed Clean up the condenser and evaporator coil Check for refrigerant leaks on road and standby circuit Check harness and refrigerant hoses aspect Check functions parameters and configuration table according to customer application Check the defrost operation check settings according to customer application refrigerant control valves fans stop and...

Page 43: ...ess valve See Figure 5 1 b Turn the field service coupling knob clockwise which will open the system to the gauge set c Read system pressures d Repeat the procedure to connect the other side of the gauge set to the discharge access valve Figure 5 1 Manifold Gauge Set R 134a 1 Manifold Gauge Set 2 Hose Fitting 0 5 16 Acme 3 Refrigeration and or Evacuation Hose SAE J2196 R 134a 4 Hose Fitting w O ri...

Page 44: ...move refrigerant charge See Figure 5 2 Refer to instructions provided by the manufacturer of the refrigerant recovery system 5 3 1 Removing Complete Charge Connect a refrigerant recovery system to the suction and discharge access valves to remove refrigerant charge Refer to instructions provided by the manufacturer of the refrigerant recovery system Figure 5 2 Vacuum Pump Connection 1 Refrigerant ...

Page 45: ...n of moisture If ambient tempera ture is lower than 60 F 15 6 C ice might form before moisture removal is complete Heat lamps or alter nate sources of heat may be used to raise system temperature d Additional time may be saved during a complete system evacuation by replacing the filter drier with a sec tion of copper tubing and the appropriate fittings Installation of a new filter drier may be per...

Page 46: ...ctly charged when there are no bubbles in the sight glass 5 6 2 Installing A Complete Charge NOTE The ambient air entering the condenser air temperature should be above 40 F 4 4 C a Evacuate the refrigeration circuit leave in a deep vacuum Refer to Section 5 5 for more information b Place refrigerant R 134a cylinder on a scale Connect the discharge gauge field coupler of the manifold test set to t...

Page 47: ...non condensables are present f Remove refrigerant using a refrigerant recovery system Refer to Section 5 3 g Evacuate and dehydrate the system Refer to Section 5 5 h Charge the unit Refer to Section 5 6 5 8 CHECKING AND REPLACING FILTER DRIER 5 8 1 Checking Filter Drier Check for any obstruction of the filter drier by feeling the inlet and outlet connections of the liquid line on the filter cartri...

Page 48: ...T GAS SOLENOID VALVE HGS1 CONDENSER PRESSURE CONTROL VALVE HGS2 AND QUENCH VALVE 5 10 1 Replacing the Solenoid Coil It is not necessary to remove the refrigerant charge to replace the coil Refer to Figure 5 5 a Remove the coil snap cap voltage plate and coil assembly Disconnect the leads and remove the coil junction box if necessary b Verify the coil type voltage and frequency This information app...

Page 49: ...as follows a Install a gauge on the suction line b Remove cap from CPR valve c With an 8 mm Allen wrench loosen the jam nut d Using the 8mm Allen wrench adjust the set screw To raise the suction pressure turn the set screw clock wise to lower the suction pressure turn counterclockwise Refer to Section 2 6 2 for CPR valve setting e When the setting has been adjusted tighten the jam nut securely aga...

Page 50: ... sure both bulbs are firmly secured to the suction line as shown in Figure 5 7 d Connect an accurate gauge to the port on the suction service valve e Run the unit until stabilized at 4 F 20 C box temperature f From the temperature pressure chart Table 5 3 determine the saturation temperature corresponding to the evaporator outlet pressure g Note the temperature of the suction gas at the expansion ...

Page 51: ...UST be in close proximity to the area being welded It is also a good practice to remove both battery cables before welding on either the unit frame or the truck to prevent possible damage to other components such as the alternator and voltage regulator 5 15 EVAPORATOR COIL CLEANING The use of recycled cardboard cartons is increasing The recycled cardboard cartons create much more fiber dust during...

Page 52: ... 0 25 in Hg 18 28 2 3 in Hg 0 16 in Hg 16 27 0 8 in Hg 0 06 in Hg 14 26 0 03 in Hg 0 02 in Hg 12 24 1 1 0 08 10 23 1 9 0 13 8 22 2 8 0 19 6 21 3 6 0 25 4 20 4 5 0 31 2 19 5 5 0 38 0 18 6 5 0 45 2 17 7 5 0 52 4 16 8 5 0 59 6 14 9 6 0 66 8 13 10 8 0 75 10 12 12 0 0 83 12 11 13 1 0 90 14 10 14 4 1 00 16 9 15 7 1 08 18 8 17 1 1 18 20 7 18 5 1 28 22 6 19 9 1 37 24 4 21 4 1 48 26 3 22 9 1 58 28 2 24 5 1...

Page 53: ...65 18 64 1 4 42 70 21 71 2 4 91 75 24 78 7 5 43 80 27 86 8 5 99 85 29 95 4 6 58 90 32 104 4 7 20 95 35 114 1 7 87 100 38 124 3 8 58 105 41 135 1 9 32 110 43 146 5 10 11 115 46 158 6 10 94 120 49 171 3 11 82 125 52 184 8 12 74 130 54 198 9 13 72 135 57 213 8 14 74 140 60 229 4 15 83 145 63 245 8 16 95 150 66 263 0 18 15 Table 5 3 R 134a Temperature Pressure Chart Temperature Pressure F C Psig Bar ...

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Page 55: ...ct headings in Table 6 2 Table 6 1 Alarm Indications ALARM Description CORRECTIVE ACTION Reference Section A00 No Malfunction All components functioning normally A01 A02 A03 Alternating Alarm Low Pressure Switch Open or Unit undercharged 5 6 1 Liquid line filter drier restricted 5 8 1 TXV strainer plugged with foreign material ice 5 12 TXV malfunction 5 12 Verify operation of evaporator fans Faile...

Page 56: ...point value entered 3 5 EE Evaporator Temperature Sen sor Failure Return air sensor is defective Replace bAt Low Battery Voltage Vehicle battery voltage low Correct Check alternator system SE Maintenance needed Perform unit basic maintenance Table 6 2 Mechanical Indications INDICATION TROUBLE POSSIBLE CAUSES REFERENCE SECTION 6 2 REFRIGERATION 6 2 1 Unit Will Not Cool Compressor malfunction Compre...

Page 57: ... defrost will not initiate Microprocessor defective Replace Defrost thermostat DTT open or defective Replace Defrost cycle initiates but does not defrost Hot gas solenoid malfunction 5 10 Condenser Pressure Control valve malfunction 5 10 Frequent defrost Wet load Defrost settings set too low 3 6 Does not terminate or cycles on defrost Defrost thermostats DTT shorted closed Replace 6 2 6 Abnormal P...

Page 58: ...r Pressure Regulating valve mis adjusted 5 11 Condenser Pressure Regulating valve fault 5 10 6 2 7 Abnormal Noise Compressor Loose mounting bolts Tighten Worn bearings Replace Worn or broken valves Replace Liquid slugging 6 2 10 Insufficient oil Check Condenser or evaporator fan Loose shroud Check Bearings defective Check Fan loose on shaft Check Bent shaft 6 2 8 Cab Command Malfunction Cab Comman...

Page 59: ...sing from sensing bulb Replace Low superheat setting 5 12 2 High superheat Expansion valve setting 5 12 2 6 2 11 Malfunction Hot Gas Solenoid Condenser Pressure Regulating Valve or Quench Valve Valve does not function properly No power to valve Check Improper wiring or loose connections Check Valve improperly assembled 5 10 Coil or coil sleeve improperly assembled Movement of plunger restricted du...

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Page 61: ...these components contact your nearest Car rier Transicold dealer for replacement CAUTION Observe proper polarity when installing battery negative battery terminal must be grounded CAUTION Under no circumstances should a technician electrically probe the processor at any point other than the connector terminals where the harness attaches Microprocessor components operate at different voltage levels...

Page 62: ...TS NEOS 100S SERIES 62 61620 00 REV DECAL NO ROAD 12VDC DC CIRCUITS COLOR USE FOR WHITE GREEN RED BLACK DC CONTROLS CIRCUITS DC GROUNDS DC BATTERY PLUS DC BATTERY MINUS CHART1 FIGN1 FMC FMP FRPM FR1 BAT 12VDC 2A 80A 25A 7 5A 125A CHART2 MCPTO 130 C A B CFM 62 61620 ART1 REV HGV1 MHV CLHC RAS HP2 A B V DATA BAT 0V CN3 1 CN2 8 CN2 7 CN2 2 CN2 5 CN2 9 CN2 1 CN2 4 CN2 12 CN2 11 CN2 10 CN3 9 CN3 6 CN3 ...

Page 63: ...O ROAD 12VDC 230 1 50 HZ 230 1 60 HZ DC CIRCUITS COLOR USE FOR WHITE GREEN RED BLACK DC CONTROLS CIRCUITS DC GROUNDS DC BATTERY PLUS DC BATTERY MINUS CHART1 FIGN1 FIGN2 FMC FMP FRPM FR1 BAT 12VDC 2A 80A 25A 7 5A 125A CHART2 MCPTO 130 C A B CFM 62 61620 ART2 REV MHV CLHC RAS V DATA BAT 0V CN3 1 CN2 8 CN2 7 CN2 2 CN2 5 CN2 9 CN2 1 CN2 4 CN2 12 CN2 11 CN2 10 CN3 9 CN3 6 CN3 2 CN4 2 CN4 3 CN3 8 CN3 5 ...

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Page 65: ...ost Cycle 4 2 Defrost Malfunction 6 3 Diagnostic Tool 5 10 E Electrical Data 2 9 Evacuation and Dehydration 5 5 General 5 5 Preparation 5 5 Procedure 5 5 Evaporator Coil 2 7 Evaporator Coil Cleaning 5 11 Evaporator Section 2 7 Expansion Valve 6 5 F Filter Drier 2 1 First Aid 1 1 Frozen Mode 4 2 Functional Settings 3 8 G General Description 2 1 General Safety Notices 1 1 H Heat And Defrost 2 11 HGS...

Page 66: ... 5 10 Replacing Filter Drier 5 7 Replacing the Solenoid Coil 5 8 Replacing Valve Internal Parts 5 9 Restricted Air Flow 6 4 S Safety Devices 2 10 Sequence of Operation 4 1 Setpoint Adjustment 3 5 Standby Mode 3 1 Starting the Unit 3 4 Start Up 3 4 Start Up Inspection 3 4 Stopping the Unit 3 4 System Operating Controls and Components 2 8 T Thermostatic Expansion Valve TXV 2 7 Thermostatic Expansion...

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Page 68: ...ca Carrier Transicold 700 Olympic Drive Athens GA 30601 USA Tel 1 706 357 7223 Fax 1 706 355 5435 Central America and Mexico Ejercito Nacional 253 A Piso 5 Colonia Anahuac 11320 Mexico D F Tel 55315010 Fax 55315010 ext 1005 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive h...

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