Carrier VECTOR 6500 Operation & Service Manual Download

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Trailer & Rail Refrigeration

EVAPORATOR

CONDENSER EVXV

RECEIVER

62--11389 Rev A Change 09/11

OPERATION & SERVICE

MANUAL

for

VECTOR 6500

Single--Temp Trailer and Rail

Refrigeration Units

With Advance

Microprocessor

Summary of Contents for VECTOR 6500

Page 1: ...ler Rail Refrigeration EVAPORATOR CONDENSER EVXV RECEIVER 62 11389 Rev A Change 09 11 OPERATION SERVICE MANUAL for VECTOR 6500 Single Temp Trailer and Rail Refrigeration Units With Advancet Microproce...

Page 2: ...OPERATION SERVICE MANUAL for VECTOR 6500 Single Temp Trailer and Rail Refrigeration Units With Advance Microprocessor...

Page 3: ...pressor Switches Transducers and Sensors 2 9 a Compressor Discharge Pressure Transducer CDP 2 9 b Compressor Suction Pressure Transducer CSP 2 9 c Compressor Discharge Temperature Sensor CDT 2 9 d Com...

Page 4: ...2 7 4 Remote Control Panel 2 16 2 8 ENGINE DATA 2 16 2 9 COMPRESSOR DATA 2 17 2 10 REFRIGERATION SYSTEM DATA 2 17 2 11 ELECTRICAL DATA 2 17 2 12 COMPONENT RESISTANCE CURRENT DRAW DATA 2 18 2 13 SAFETY...

Page 5: ...eed 4 2 4 3 TEMPERATURE CONTROL 4 2 4 3 1 Temperature Determination 4 2 4 3 2 Perishable And Frozen Set Point Ranges 4 3 4 3 3 Pull Down Pull Up 4 3 4 3 4 Defrost 4 3 4 3 5 Overrides 4 3 4 4 START STO...

Page 6: ...verride 4 16 MICROPROCESSOR INTERFACE 5 1 5 1 INTERFACE METHODS 5 1 5 2 TECHNICIAN INTERFACE 5 1 5 2 1 Configuration Mode 5 2 5 2 2 Component Test Mode 5 2 5 2 3 Service Mode 5 3 5 3 PC MODE 5 3 5 4 P...

Page 7: ...MAXIMUM COMPRESSOR ALARMS 7 15 21 TECHNICIAN RESET REQUIRED 7 15 22 LOW SUCTION SUPERHEAT 7 16 23 A C CURRENT OVER LIMIT 7 18 27 HIGH SUCTION PRESSURE 7 20 28 CHECK REFRIGERATION SYSTEM 7 21 7 5 START...

Page 8: ...TCON2 RELAY COIL 7 57 93 CHECK START UP BUZZER 7 58 94 CHECK COMP CONTACTOR 1 7 58 95 CHECK CDCON RELAY COIL 7 59 96 CHECK GENCONR RELAY COIL 7 60 98 CHECK HIGH TEMP THERMOSTAT 7 61 99 CHECK STANDBY C...

Page 9: ...0 P164 CHECK UL2 CIRCUIT 7 80 P174 CHECK LOW SPEED RPM 7 81 P175 CHECK HIGH SPEED RPM 7 82 P177 CHECK EVAP SUPERHEAT 7 84 P178 CHECK UL1 7 85 P180 CHECK SUCTION MOD VALVE 7 86 P186 CHECK EVAP OUTLET T...

Page 10: ...r Latch Maintenance And Replacement 8 6 a Door Latch Maintenance 8 6 b Cable Replacement 8 6 8 4 4 Display Keypad Assembly 8 6 a Disassembly 8 6 b Reassembly 8 7 8 5 ENGINE AND ENGINE RELATED SYSTEMS...

Page 11: ...ide 8 20 c Evacuation of the Compressor 8 20 8 7 COMPRESSOR AND UNLOADER SERVICE 8 20 8 7 1 Repair or Replacement Determination 8 20 8 7 2 Removal and Replacement of Compressor 8 21 8 7 3 Cylinder Hea...

Page 12: ...8 41 UNIT TROUBLESHOOTING 9 1 9 1 ENGINE 9 1 9 1 1 Engine Will Not Start 9 1 9 1 2 Engine Starts Then Stops 9 2 9 1 3 Engine Will Not Shut Off 9 2 9 1 4 Starter Motor Malfunction 9 2 9 1 5 Malfunction...

Page 13: ...0 1 10 2 HARNESS PLUG WIRING FOR UNITS WITH A MAIN POWER SWITCH LABELED START RUN OFF 10 6 10 3 CONTROL BOX INTERIOR SPLICE POINTS FOR UNITS WITH A MAIN POWER SWITCH LABELED ENGINE OFF STANDBY 10 11 1...

Page 14: ...ode set to YES 4 7 Figure 4 4 Range Lock Settings Non Overlapping 4 10 Figure 4 5 Range Lock Settings Overlapping 4 11 Figure 4 6 Evaporator Pressure Chart 4 15 Figure 5 1 Technicians Interface Connec...

Page 15: ...an Assembly 8 36 Figure 8 38 Generator Assembly 8 40 Figure 8 39 Bolt Hole Pattern For Bell Housing and Crankshaft 8 40 Figure 9 1 ENSCU Diagnostic Tree 1 Long 1 Short LED Code 9 9 Figure 9 2 ENSCU Di...

Page 16: ...me 4 2 Table 5 1 Component Test 5 3 Table 5 2 Microprocessor Configurations 5 12 Table 8 1 Maintenance Schedule 8 2 Table 8 2 Pre Trip Inspection 8 4 Table 8 3 CSMV Connections 8 28 Table 8 4 EVXV Con...

Page 17: ...1 1 62 11389 SECTION 1 SAFETY PRECAUTIONS PARAGRAPH NUMBER Page 1 1 SAFETY PRECAUTIONS 1 1 1 2 SPECIFIC WARNING AND CAUTION STATEMENTS 1 2 1 3 SAFETY DECALS 1 6...

Page 18: ...k of the refrigeration unit e g checking the belt checking the oil make certain that the Main Power Switch is in the OFF position Engine Coolant The engine is equipped with a pressurized cooling syste...

Page 19: ...enever practical disconnect the high voltage source lockout tagout the receptacle and disconnect the negative battery connec tion NEVER dis assemble the generator HIGH MAGNETIC FIELD INSIDE This field...

Page 20: ...this type should not be flashed Operation with external voltage source or momentary shorting of leads will damage the generator and may cause in jury CAUTION Under no circumstances should anyone at te...

Page 21: ...t gas brazing procedures is mandatory for all Carrier Transicold refrigeration units otherwise compressor failure will occur For more information Refer to Technical Procedure 98 50553 00 Inert Gas Bra...

Page 22: ...r CAUTION Do not bend the copper tubing on the con denser coil when installing the new con denser Bend the unit tubing if tubes do not align correctly CAUTION Before connecting a megohmmeter place the...

Page 23: ...THE RECEIVER KING VALVE LIQUID LINE SERVICE VALVE AND DISCHARGE SERVICE VALVES MUST BE OPENED BEFORE STARTING ENGINE 62 03953 01 NOTE This tag is attached to the liquid line ser vice valve and discha...

Page 24: ...MABLE MATERIALS SUCH AS BIRD NESTS LEAVES TREE LIMBS OR MAINTENANCE MATERIALS SUCH AS SHOP RAGS DO NOT OPERATE WITHOUT INSPECTION FIRES AND SERIOUS INJURIES MAY RESULT SAFETY INSTRUCTIONS INSPECT UNIT...

Page 25: ...1 8 62 11389...

Page 26: ...1 9 62 11389 THIS UNIT CHARGED WITH R 404A CAUTION COMPRESSOR MUST BE CHARGED WITH P O E OIL ONLY CTD P N 07 00317 00 MOBIL ARCTIC P N EAL63 CTD P N 62 03797 11...

Page 27: ...Modulation Valve CSMV 2 10 2 4 5 Evaporator Switches Transducers and Sensors 2 10 2 5 SYSTEM OPERATING CONTROLS AND COMPONENTS 2 11 2 5 1 Multiple Languages 2 11 2 5 2 Automatic Start Stop 2 11 2 5 3...

Page 28: ...power plug or by the A C generator which is driven by the engine The generator provides nominal 480V 3 60Hz power when the engine is in high speed and nominal 350V 3 45Hz power in low speed The contr...

Page 29: ...Serial Number Nameplate 4 Power Supply Receptacle PSR Under Unit 5 Compressor Sight Glass 6 Compressor C 7 Front Unloader Valve UL1 8 Compressor Suction Temperature Sensor CST 9 Compressor Suction Mo...

Page 30: ...Valve 5 Compressor Suction Service Valve 6 Compressor Discharge Service Valve 7 Compressor Discharge Temperature Sensor CDT 8 Compressor Discharge Pressure Transducer CDP 9 High Pressure Switch HP1 10...

Page 31: ...Speed Actuator FSA 8 Control Box Refer to Figure 2 5 9 Engine Speed Sensor ENSSN 10 Engine Oil Pressure Switch ENOPS 11 Display 12 Switch Board 13 Keypad Door 14 Serial Download Port SLP 15 Lube Oil...

Page 32: ...Evaporator Fan Motor Wiring 5 Supply Air Temperature Sensor 1SAT 6 Electronic Expansion Valve EVXV 7 Evaporator Outlet Pressure Transducer EVOP 8 Evaporator Outlet Temperature Sensor EVOT On suction...

Page 33: ...elay GENCONR 16 Compressor Contactor Relay CCONR 17 Main Fuse F5 18 Air Heater Relay IAHR or GPR 19 Starter Solenoid Relay SSR 20 Buzzer B 21 Fuse F19 22 Display 23 Microprocessor MP 24 Fuse Standby C...

Page 34: ...component Fuel supply to the injectors and engine speed is controlled by varying rod position in accordance with the signal from the ENSCU The FSA is located on the front of the injection pump c Engin...

Page 35: ...oid valve 1 energized the solenoid valve stem 2 will open the gas bypass port 3 Discharge pressure will be bled to the suction manifold 10 through the opened gas bypass port A reduction in pressure on...

Page 36: ...ssor discharge manifold The loaded cylinder bank will continue to operate fully loaded until the solenoid valve is energized and the gas bypass port is opened 2 3 7 Compressor Switches Transducers and...

Page 37: ...pro cessor 2 4 1 Evaporator Coil The evaporator is a tube in fin type The operation of the compressor maintains a reduced pressure within the coil At this reduced pressure the liquid refrigerant evapo...

Page 38: ...are and Configuration set up FET Field Effect Transistor indicating LEDs that are illuminated when a circuit is energized Automatic Engine Starting Functional Parameter locks Alarms are stored in micr...

Page 39: ...A red PC Card Fault LED blinks if there is a problem transferring data from the PC card that has been plugged into the PC card slot The red LED will continue to blink until the PC card is removed The...

Page 40: ...Heat Indicator Amber Illuminated when the unit is in Heat Mode Cool Indicator Green Illuminated when the unit is in Cool Mode Defrost Indicator Amber Illuminated when the unit is in Defrost Mode Alarm...

Page 41: ...Functional Parameter clearing alarms and locking the data menu MANUAL DEFROST Key The MANUAL DEFROST key may be used to initiate a defrost cycle when the required conditions are met ALARM LIST Key Th...

Page 42: ...oprocessor Two types of switches may be used 1 A switch with contacts that are open when the switch is activated 2 A switch with contacts that are closed when the switch is activated Four Configuratio...

Page 43: ...Refer to Table 2 1 for engine speed settings Weight 440 lbs 199 6 kg Coolant Capacity 2 U S gallons 7 6 liters 50 50 mix ethylene glycol antifreeze with inhibitors never to exceed 60 40 CAUTION Use o...

Page 44: ...0 7 bar Unit Dry Weight Less Battery 2045 pounds 928 KG Battery 50 pounds 23 KG 2 11 ELECTRICAL DATA Compressor Motor Full Load Amps FLA 17 5 amps 460 VAC Locked Rotor Amps 99 0 amps 460 VAC Winding R...

Page 45: ...voltage 14 8 VDC 77 F 25 C OGF Module Trips On High Current 40 Amps Maximum Trips on Ground Fault 150mA Battery Voltage 12 volt nominal 90 amp hour capacity Cold cranking amps 425 DIN 500 IEC 725 BCI...

Page 46: ...e F5 Opens at 80 amps Excessive current draw by control circuit Fuse F6 Opens at 15 amps Excessive current draw by battery charger in put 20 amp charger Fuse F7 F8 Opens at 3 amps single charger OR op...

Page 47: ...flows to an electronic expansion valve which reduces the pressure of the liquid and meters the flow of liquid refrigerant to the evaporator to obtain maxi mum use of the evaporator heat transfer surf...

Page 48: ...FILTER DRIER HEAT EXCHANGER SUBCOOLER LIQUID LINE SERVICE VALVE CDP COMPRESSOR CSMV CST SUCTION SERVICE VALVE DISCHARGE SERVICE VALVE CDT HP1 CSP EVOP EVOT EVAPORATOR DISCHARGE LINE LIQUID LINE SUCTIO...

Page 49: ...3 13 3 10 TRIP START 3 14 3 11 VIEW ACTIVE ALARMS 3 15 3 12 VIEW INACTIVE ALARMS 3 16 3 13 UNIT DATA 3 17 3 14 VIEW HOUR METERS 3 20 3 15 FUNCTIONAL PARAMETERS 3 21 3 16 LANGUAGE SELECTION 3 25 3 17 I...

Page 50: ...t the neg ative battery connection NEVER dis assemble the generator HIGH MAGNETIC FIELD INSIDE This field can interfere with cardiac implants such as pacemakers and defibrillators WARNING Under no cir...

Page 51: ...ch as pacemakers and defibrillators WARNING Ensure the power plug is clean and dry before connecting to any electrical outlet receptacle WARNING Do not connect power plug to any electrical outlet with...

Page 52: ...s with a Main Power switch labeled START RUN OFF 34 5 F 20 0 NOTE The unit is equipped with automatic phase re versal which ensures that the electric motors will run in the correct direction For safe...

Page 53: ...l be displayed and the Alarm LED will flash for 5 seconds then turn off Refer to Section 3 12 for information on viewing in active alarms If the IntelliSet option has been installed the name of the cu...

Page 54: ...trip can be started at any box temperat ure If Pretrip is started while the unit is in a Start Stop off cycle the unit will start during the course of the test If the unit is running when Pretrip is s...

Page 55: ...display all LEDs on the microproces sor both lights of the Light Bar will be on during this test This portion of the Pretrip requires that the operator de termines PASS or FAIL A defective display is...

Page 56: ...ange Test 10 Condenser Fan Motors Amperage Check The condenser fan motor contactor will be energized and checked for proper current draw An alarm will be activated if the condenser fan motors are not...

Page 57: ...HED or MIN SET POINT HAS BEEN REACHED will display in the MessageCenter when either of these condi tions is reached Set point may be changed any time the Main Power switch is not in the OFF position o...

Page 58: ...uous key is pressed to select between Continu ous Run and Start Stop Operation The corresponding LED will be iluminated The microprocessor may be configured with Start Stop operation tied to the set p...

Page 59: ...he microprocessor may be configured with Start Stop operation tied to the set point ranges for frozen and per ishable loads The START STOP CONTINUOUS key is locked out if START STOP LOCKED displays in...

Page 60: ...gs Entering using Functional Parameter settings TO EXIT SLEEP MODE Place the Main Power switch in the OFF position then back to the desired position Sleep Mode is generally used in cold ambients when...

Page 61: ...d setting While the unit is running in Sleep Mode SLEEP WARNING NO TEMP CONTROL will flash in the MessageCenter and the main display set point and compartment temperat ures will be off If the unit is...

Page 62: ...LE for five seconds dF When defrost mode cannot be manually initiated CAN NOT START DEFROST CYCLE is displayed in the MessageCenter This will occur when DTT is above 40 F 4 C Defrost may be entered an...

Page 63: ...y Otherwise CANNOT EN TER TRIP START will flash and then the display will revert back to the normal display 1 To mark the start of a trip in the DataLink data recorder press the SELECT key until the M...

Page 64: ...S LIST CLEAR is displayed This will move all Alarms to the Inactive Alarm list 2 If there are active alarms the alarm number will be displayed with the letter A in front and the alarm message followin...

Page 65: ...order in which the alarms activate and inactivate respectively On startup all alarms are marked as inactive in the en tire list If an inactive alarm becomes active the alarm is moved from the Inactiv...

Page 66: ...tem will remain in the MessageCenter for ten seconds then the de fault message STATUS OK or other customer specified message will display 4 To lock an item in the MessageCenter for continuous viewing...

Page 67: ...O if the engine will start automatically MANUAL if the engine must be started manually INSTALLED OPTIONS This is only displayed when one or more options is configured ON Lists installed options Press...

Page 68: ...when Range Lock 1 is configured ON Displays Range Lock 1 setting OFF Temperature Range 1 Lock is turned off CONTINUOUS When the set point is set between Range 1 Minimum Maximum Temperatures the unit i...

Page 69: ...e MessageCenter for continuous viewing press the key The Data item will flash continuously to indicate it is locked 7 Pressing any key on the keypad will unlock the item Pressing the UP or DOWN ARROW...

Page 70: ...The MessageCenter will flash indicating that a change to the displayed parameter selection has not been entered into memory 4 Continue pressing UP or DOWN ARROW key until the desired Parameter selecti...

Page 71: ...art Stop Operation MIN OFF TIME 10MINS TO 90MINS 20MINS in 1 minute incre ments This determines the minimum length of time the unit will remain off whenever the unit cycles off in Auto Start Stop Oper...

Page 72: ...in Continuous Operation control for maximum temperat ure protection YES When in Continuous Operation control for maximum fuel eco nomy RESET PM HOUR METERS This Functional Parameter allows resetting o...

Page 73: ...The purpose of this setting is to temporarily override the Configuration setting in situations where switching to engine power is not desired OVERRIDE REMOTE SWITCH 1 SHUTDOWN REMS1 AND OVERRIDE REMOT...

Page 74: ...ndicates the de sired language Press the key The new language will now be active If the key is not pressed within 10 seconds the MessageCenter will change to FUNCTION NOT CHANGED This will flash for 5...

Page 75: ...C with a defrost every 3 hours while a load of cheese may require the same operation with set points ranging from 35 F to 42 F 1 7 C to 5 6 C and a load of ice cream requires Start Stop op eration at...

Page 76: ...move through the IntelliSet List The current In telliSet will have either ACTIVE or MODIFIED to the right of the name 3 To use a different IntelliSet bring the desired IntelliSet into the MessageCent...

Page 77: ...the UP ARROW key is pressed the IntelliSet List will scroll up beginning at the bottom When the DOWN ARROW key is pressed the IntelliSet List will scroll down beginning at the top The current IntelliS...

Page 78: ...mpressor will stop and the micro processor will display MICRO WILL STOP IN SECONDS At the end of the countdown time the Mi croprocessor Main Display MessageCenter and all in dicator LEDs will then tur...

Page 79: ...r averaged readings are preferred Snapshot readings of sensors are also taken at the time of a shut down alarm All of the sensors and transducers that may be read un der Unit Data refer to Table 3 1 m...

Page 80: ...y scrolling through the Unit Data refer to Section 3 13 DataTrak will be listed under the Installed Options head ing if it is installed Once DataTrak is installed the Advance Micropro cessor must be p...

Page 81: ...CONFIGURATION 2 ENGINE LIGHT WILL NOT ILLUMINATE IN THIS APPLICATION P1 DISPLAYED WHEN SETTING PRE SET SETPOINTS 3 The unit may be fitted with an optional remote control panel The panel displays comp...

Page 82: ...gize after two hours If the panel is equipped with a RESET button press the button to re energize the panel If the panel is not equipped with a RESET button the panel may be re energized by placing th...

Page 83: ...ith Remote Control Panel The control panel allows the user to pre set 5 different temperatures NOTE Once preset set points have been chosen only those 5 designated set points can be used 1 Place the u...

Page 84: ...nel 2 Press Carrier logo and the lock light will illuminate 3 Press UP ARROW for 10 sec onds P1 will be displayed 4 Set temperature to lowest pre set set point and OFF will be displayed 1 Place the un...

Page 85: ...art Stop Configuration 4 3 4 4 2 Stop Parameters 4 4 4 4 3 Re Start Parameters 4 5 4 5 CONTINUOUS OPERATION 4 5 4 5 1 Introduction 4 5 4 5 2 Continuous Operation 4 5 4 6 DEFROST 4 8 4 6 1 Defrost Init...

Page 86: ...position the generator contactor relay GENCONR is energized Energizing GENCONR reverses its contacts to allow the engine and generator to operate while power from the power plug is locked out Once the...

Page 87: ...vated If the unit fails to start after three start attempts the A31 FAILED TO START AUTO alarm will be activated If the unit is equipped with a fuel heater the microprocessor will monitor ambient temp...

Page 88: ...uous Operation perishable and the High Speed Pulldown Configuration is ON when the tem perature is equal to or less than 0 36 F 0 2 C above set point 4 3 4 Defrost Refer to Section 4 6 for a descripti...

Page 89: ...an be readily checked by reading the Battery Voltage in the Data List If OK appears after the voltage reading bat tery voltage is sufficient to allow the unit to cycle off If in Engine Operation and a...

Page 90: ...Frozen Range restart is allowed when the compartment temperature is greater than the FROZEN RESTART value above set point The MINUMUM OFF TIME parameter value may be set from 10 to 90 minutes in 1 min...

Page 91: ...0 5 C Set point 0 4_F 0 2_C 1 6 F 0 9 C 3 2 F 1 8 C 3 6 F 2 0 C Pulldown High Speed 6 Cylinder COOL Low Speed 6 Cylinder COOL Set point Low Speed HEAT HTCON1 1 1 F 0 6 C NULL 0 5 F 0 3 C 0 4 F 0 2 C...

Page 92: ...lts are above set point results are below set point Switch points are the same for Perishable Range and Frozen Range except in Frozen Range heating is not allowed Enter cool at Start Stop Override Fun...

Page 93: ...ed when the heaters are de energized a Normal Defrost Mode Normal Defrost Mode will be entered if RAT is less than 39 2 F 4 0 C and SAT is less than 45 0 F 7 2 C Defrost will be accomplished by shutti...

Page 94: ...ERISHABLE SENSITIVE PRODUCT Functional Parameter is set to OFF the supply air temperature will be the coldest temperature of 32 F 0 C OR the calculated value of Set Point minus the configured Supply A...

Page 95: ...mperature of 28 F 2 2 C and a Maximum Temperature of 55 F 12 8 C Should Continuous Operation ALWAYS also be required with set points between 22 and 0 F 30 and 17 8 C then Range 2 will be set for Conti...

Page 96: ...l Parameter setting whichever time is lon ger AND The ambient temperature falls within the pre pro grammed temperature range AND The unit is not already running in ProductShield Win ter See Section c...

Page 97: ...above 90 F 32 2 C the unit operation can change to Econo Continuous Operation Example 4 If both the Minimum and Maximum are set to OFF ProductShield Econo Go To Continuous can not operate as there is...

Page 98: ...ting in Cargo Protect Mode 4 8 2 Compressor Minimum Operating Time Each time the compressor is started it must operate for a minimum of 3 minutes before it can be de energized If during the 3 minutes...

Page 99: ...if one of the required conditions for shutdown is no longer met during this time for example the battery voltage drops below the configured value or the charging amps increase above the configured va...

Page 100: ...C UL2 will be energized when the suction pressure rises to approximately 75 psig 5 bar UL2 can load as soon as the pressure is 5 psig 0 3 bar less than the value in the chart 9 High Discharge Pressur...

Page 101: ...the return air temperature rises to 95 F 35 C regardless of the temperature of the DTT the unit will go into low speed and all electric heaters will be de energized The unit will remain in defrost wi...

Page 102: ...4 3 Configuration PC Card 5 6 5 4 4 Option PC Card 5 6 5 4 5 Download PC Card 5 6 5 5 REEFERMANAGER REPORTS 5 6 5 5 1 Introduction 5 6 5 6 MICROPROCESSOR DISPLAY DIAGNOSTICS 5 8 5 7 MICROPROCESSOR RE...

Page 103: ...ted jumper see Figure 5 1 NOTE For units equipped with a switch labeled ENGINE OFF STANDBY DOES The DOES may be placed in either the ENGINE or STANDBY position to enter the technician in terface mode...

Page 104: ...nter the Technician Interface Component Test Mode as described in Section 5 2 b To read through the Component Test list press either the UP or DOWN ARROW keys The list is circular meaning that once th...

Page 105: ...opens the CSMV and EXV to 100 open c Once the valves are open RECOVER LEAK CHK EVAC MODE is displayed in the MessageCenter d Refrigerant recovery leak checking or evacuation may be performed on the un...

Page 106: ...ronment they are not intended to be stored in a techni cian s toolbox back pocket or on the dashboard of a vehicle The label on each card clearly states that the card is to be handled with care not to...

Page 107: ...rd using ReeferManager refer to manual 62 10889 Software may be downloaded by a Carrier Transicold dealer from the TransCentral site TIP Whenever performing a major operation to a microprocessor such...

Page 108: ...be purchased with five or ten clicks Each click allows downloading to an individual microprocessor To transfer data from the card to the microprocessor insert the card in accordance with the instruct...

Page 109: ...erest Synchronize multiple graphical and numerical win dows to better understand historical operation PC Setup enables the user to select how to display various parameters for use in the graph and tex...

Page 110: ...croprocessor has failed and must be replaced 6MP1 6MP4 Figure 5 5 Connector 6MP Connections e With the negative meter lead on QC2 without remov ing the spade connector test voltage at the micro proces...

Page 111: ...ts or use of PC cards refer to Section 9 6 Before the unit can be started using the replacement microprocessor certain unit specific and time sensitive data must be known That information includes Uni...

Page 112: ...ugh the number list until the correct number of the current month appears Press the key to enter that number for the month h Press the UP ARROW key to go to Day i Using the same key presses as in step...

Page 113: ...ferManager version 03 08 00 or higher NOTE ReeferManager 03 08 00 is REQUIRED in or der to view change and send new features to and from the microprocessor c In ReeferManager go to the Serial Operatio...

Page 114: ...ther than the TRAILER ID default Refer to the UNIT OPERATION Configuration later in this table SET NEW HOURS This Configuration will display when a replacement microprocessor is installed It allows en...

Page 115: ...tivated the alarm light will illumin ate and the unit will shutdown NO When the A27 HIGH SUCTION PRES SURE alarm is activated the alarm light will illumin ate and the unit will continue to run REFRIGE...

Page 116: ...MP SENSOR WITH TEMP SENSOR NO TEMP SENSOR Use this setting when the battery charger does not have the temperature sensor wire WITH TEMP SENSOR Use this setting when the battery charger does have the t...

Page 117: ...ration USE FACTORY DEFAULT SETTING ONLY DO NOT OPERATE UNIT WITH DIFFERENT SETTING STANDBY MAX GEN AMPS 25A 10 TO 35 in 0 5A increments Indicates to the microprocessor the maximum al lowable amperage...

Page 118: ...ding to indicate to the micropro cessor when the next service interval alarm will be activated If the value entered is 0 the alarm fea ture is turned off SWITCH ON RESET VALUE 0FF 50 TO 30 000 hours i...

Page 119: ...hat meter will not count a specif ic instance such as hours of operation or number of cycles for a particular component The meter is connected to the real time clock and will activate the alarm after...

Page 120: ...start stop will be allowed PRODUCTSHIELD HIGH AIR OFF OFF The unit will operate normally in high and low speeds ON ON The unit will operate in high speed when the ambient air temperature is outside a...

Page 121: ...ure desired for this range MIN SET POINT 225F TO 89 6 F 305C to 32 C in 0 1 F or C in crements Indicates to the microprocessor the desired minim um allowable set point MAX SET POINT 22 F TO 89 65F 30...

Page 122: ...n the engine will be forced to low speed If this setting is chosen the following run low speed below setting will also be available NOTE The DataLink data recorder will record every time the door is o...

Page 123: ...et to this value the remote panel SYSTEM ON OFF key will be enabled The switch panel mounted Main Power Switch must be toggled out of the OFF position and the remote panel SYSTEM ON OFF key must be pr...

Page 124: ...lcomm T2 Trailer Tracs 2 or any other supplier QUALCOMM The microprocessor is set for com munication from Qualcomm Trailer Tracs UNIT OPERATION STANDARD RAIL STANDARD The microprocessor is set to cont...

Page 125: ...Stop Opera tion in accordance with the formula Set Point this value coldest allowable supply air temperat ure For example Fahrenheit if the set point is 35 F and the Config uration value is set at 10...

Page 126: ...1 6 62 11389 SECTION 6 MESSAGECENTER PARAGRAPH NUMBER Page 6 1 MESSAGECENTER MESSAGES 6 1...

Page 127: ...does not remove alarms from the DataLink data recorder ALL ALARMS CLEARED The list of active and inactive alarms in the microprocessor alarm lists have been erased This does not remove alarms from th...

Page 128: ...is being displayed will allow user access to Component Test Mode CONFIG ERROR REMOVE CARD There was an error configuring the microprocessor with the Config uration PC Card Remove the PC Card from the...

Page 129: ...lled in the microprocessor The PC Card may safely be removed from the slot XX indicates the number of option installations remaining on card INSTALLING OPTION PLEASE WAIT An Option PC Card has been in...

Page 130: ...have been used The PC Card may safely be re moved from the unit OLD INTELLISETS USE REEFERMAN The IntelliSets that are on the Configuration PC Card were written with too old of a PC Program like Serv...

Page 131: ...d compart ment door or a remote control switch REMOVE JUMPER The Configuration Technician Test Mode has been entered Re move the jumper wire before continuing SAME SW TO LOAD TO CANCEL A Program PC Ca...

Page 132: ...more than 10 sec onds UNIT SHUTDOWN DOOR OPEN The unit has shutdown because the refrigerated compartment door is open UNIT SHUTDOWN SEE ALARM LIST An active shutdown alarm has shut the unit down UNIT...

Page 133: ...Page 7 1 INTRODUCTION 7 1 7 2 NOTES 7 2 7 3 DRIVER OPERATOR ALARMS 7 3 7 4 SHUTDOWN ALARMS 7 4 7 5 START UP ENGINE ALARMS 7 22 7 6 WARNING STATUS ALARMS 7 36 7 7 ELECTRICAL ALARMS 7 46 7 8 SENSOR ALA...

Page 134: ...is the last alarm that was recorded Other alarms in the list may have contributed to the occurrence of the first alarm The check items in the troubleshooting guide are listed in order of their likeli...

Page 135: ...s equipped with a Main Power switch labeled START RUN OFF SROS place the switch labeled STANDBY ENGINE DES in the STANDBY position and then place the SROS in the START RUN position Note 3 Sensors may...

Page 136: ...Only or may be configured to shut unit down RESET CONDITION Auto reset if engine oil level is above 4 qt 3 79 liters low for more than 30 seconds or alarm may be manually reset via keypad or by turnin...

Page 137: ...ne oil dipstick Add engine oil as needed 2 Check Engine Oil Pressure Switch Wiring a Inspect switch connector pins terminals No physical damage to switch No damage or corrosion in connector b Check sw...

Page 138: ...if the cap must be removed do so very slowly in order to release the pressure without spray Level must be in the normal range b Inspect connecting tube between overflow bottle and radiator Connections...

Page 139: ...croprocessor output and wiring connections to sensor 8 Check Engine Cooling System a Compare actual engine tempera ture to the microprocessor reading Temperature must be within 20 F 11 1 C b Test oper...

Page 140: ...d compartment temperature conditions If discharge pressure is in normal range proceed to step 4 NOTE Microprocessor suction CSP and evaporator EVOP pressure readings have a maximum value of 100 psig 7...

Page 141: ...VAC 2 Check Power Source Voltage If Used When Alarm Occurred Check voltage at PSCON L1 L2 L1 L3 L2 L3 Must be nominal 460 VAC 3 Check Voltage Output From Contactors a Check voltage at GENCON T1 T2 T1...

Page 142: ...rm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Battery Voltage a T...

Page 143: ...below as necessary 1 Check For Alarm 51 Check for Alternator Not Charging Alarm Note The A51 name is car ried over from unit models with alter nators For the Vector Model Alarm 51 indicates that the...

Page 144: ...the alarm cleared to continue 2 Check Refrigerant Charge Check for undercharged system Refer to Section 8 6 2 3 Check Airflow Through Condenser Coil a Inspect condenser radiator Ninety percent or mor...

Page 145: ...ugh the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Refrigerant Charge Check for undercharged system Refer to Section 8 6 2 2 Check System Pr...

Page 146: ...blies Evap coil clean Evap fan rotation ok b Check airflow with unit running Even airflow through the entire coil No dead spots 8 Visually Inspect Unit Visually inspect unit for damage to the liquid l...

Page 147: ...elf see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check For Low Fuel Level Warning Alarm Check...

Page 148: ...Reset Alarm Reset all alarms from the inactive alarm list All alarms must be cleared to start unit 21 TECHNICIAN RESET REQUIRED TRIGGER ON The High Engine Temp Shutdown Configuration and or Engine Oil...

Page 149: ...CSP and evaporator EVOP pressure readings have a maximum value of 100 psig 7 5 bar The actual suction pressure must be lower than 100 psig in order to perform this test 2 Check Refrigerant Charge Chec...

Page 150: ...icroprocessor output and wiring connections to sensor h Verify accuracy of EVOT using in frared or other accurate temperat ure testing tool EVOT reading must be within 3 F 1 7 C of test temperature to...

Page 151: ...tive alarm occurs Continue with the steps below as necessary 1 Perform Pretrip Clear Active Alarm list then run Pre trip check for any new alarms Any active alarms must be corrected and cleared be for...

Page 152: ...1 3HTCON2 if applicable 5 Check Generator Voltage If Used When Alarm Occurred Check voltage at GENCON L1 L2 L1 L3 L2 L3 Must be within voltage limits shown in Section 2 11 6 Check Power Source Voltage...

Page 153: ...d gauge set and check and compare compressor discharge suction pressures with those shown on the microprocessor dis play Suction pressure must be above 3 psig 0 2 bar Suction Discharge Pressures must...

Page 154: ...ith the steps below as necessary 1 Verify Compressor Is Running Check compressor amp draw on all three legs Readings must be in the range as shown in Section 2 11 2 Check System Pressures Install mani...

Page 155: ...th PSCON still energized RESET CONDITION Alarm may be manually reset via keypad or by turning the unit off then back on again If the Unit Operation configuration is set to Rail Mode this alarm will re...

Page 156: ...uel gauge on tank Fill tank as needed 3 Check For Alarms Check for the following alarms 71 Check for Bad F2 or F3 Fuse alarm 40 Check Glow Plug alarm 35 Check Starter Circuit alarm Alarm conditions mu...

Page 157: ...rgize the intake air heater relay LED 30 must be illuminated Amperage must be correct refer to Section 2 8 for correct electrical values 7 Check Engine Air intake System a Check air cleaner indicator...

Page 158: ...t be running 2 Check For Bad Engine RPM Sensor Alarm Check for Alarm 130 Alarm conditions must be corrected and the alarm cleared to continue 3 Check Engine Oil Pressure Switch a Inspect switch connec...

Page 159: ...Negative lead on Gnd Positive lead on 87 30 12 VDC d Inspect wiring to starter solenoid and starter motor See wiring schematic Section 10 No physical damage to wiring or battery cable end No damage o...

Page 160: ...ce a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessar...

Page 161: ...Check ENSCU 16 0 VDC between ENSCU 16 and ENSCU 19 GND 3 Check Fuel Speed Actuator FSA Check fuel speed actuator Plunger must move in and out freely Refer to Engine Manual 4 Force Low Speed operation...

Page 162: ...2 1 2 Check for proper voltage to the Engine Speed Control Unit ENSCU pin 16 Check for proper voltage with unit running a Check ENSCU 16 12 VDC between ENSCU 16 and ENSCU19 b Check circuit from ENSCU...

Page 163: ...eter Refer to Table 2 1 b Compare actual RPM with those shown on display Both readings within 50 RPM 7 Check Engine Air Intake System a Check air cleaner indicator Flag must not be visible b Inspect a...

Page 164: ...model number on the nameplate matches the model number shown in the microprocessor Unit Data Enter the correct number in Configurations Refer to Section 5 2 1 2 Check For Flash Code On Engine Speed C...

Page 165: ...compartment temperature and a temperature greater than 20 F 5 6 C If the unit does not immediately go into High Speed set the AIRFLOW Functional Parameter to HIGH The microprocessor will call for Hig...

Page 166: ...umber on the nameplate matches the model number shown in the microprocessor Unit Data Enter the correct number in Configurations Refer to Section 5 2 1 2 Check Glow Configuration Verify that the Glow...

Page 167: ...U Check for flash codes on the ENSCU Refer to ENSCU LED Fault Chart Section 9 5 must be no LED alarm codes occurring to continue 3 Was Engine Shut Off Manually Check for external cause Correct problem...

Page 168: ...With the unit operating check all 3 high voltage circuits for amperage Must be no more than 26 Amps 9 Check engine air intake system a Check air cleaner indicator Flag must not be visible b Inspect a...

Page 169: ...ection of the arrow on the sensor away from the F 5 fuse for units with a Main Power switch labeled Engine Off Standby toward the F 5 fuse for units with a Main Power switch labeled Start Run Off 3 Ch...

Page 170: ...erated compartment temperature has been in range or not UNIT CONTROL Engine and standby Operation If the microprocessor is not configured for shutdown alarm only If the microprocessor is configured fo...

Page 171: ...cleared to continue 5 Check Refrigerant Level Visually check refrigerant level in receiver Must be at correct level Refer to Section 8 6 2 6 Check System Pressures Install manifold gauge set and chec...

Page 172: ...Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Perform Pretrip Check Clear Active Alarm list then run Pretrip check for a...

Page 173: ...rection has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as n...

Page 174: ...t be de activated 3 Check REMS1 Remote Switch 1 Configuration Verify that Configuration is set for the type of switch being used i e when switch is activated switch contacts are closed etc Configurati...

Page 175: ...be closed and switch must be de activated 3 Check REMS2 Remote Switch 2 Configuration Verify that Configuration is set for the type of switch being used i e when switch is activated switch contacts ar...

Page 176: ...odes to see if any active alarm occurs Continue with the steps below as necessary 1 Clear Alarm a Clear Active Alarm s Alarms Clear b Check for Active Alarm re occurrence If Inactive download all data...

Page 177: ...tinue with the steps below as necessary 1 Check Real Time Clock Check Real Time Clock in the Data List or using ReeferManager Must show correct date and time Change as needed Configuration List 2 Rese...

Page 178: ...be de activated 3 Check DOOR SWITCH Configuration Verify that Configuration is set for the type of switch being used i e when switch is activated switch contacts are closed etc Configuration must agre...

Page 179: ...Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alar...

Page 180: ...ck on If the unit is running in Engine Backup when the A C power has been restored for 5 continuous minutes and the above conditions have been met the engine will stop and the unit will restart in Sta...

Page 181: ...cleared itself b If no power 0VDC Continue with step 3 3 Check IPC circuit a Use Component Test Mode to ener gize CCON circuit Refer to Section 5 2 2 FET 2 will be on b Check IPC harness to microproce...

Page 182: ...DC Alarm should have cleared itself b If no power 0VDC Continue with step 2 below 3 Check IPC circuit a Check MPQC9 There should be 12 VDC from MPQC9 to Ground b Use Component Test Mode to ener gize C...

Page 183: ...motor If closed then an intermittent IP circuit is suspect Check phase to phase and phase to ground for short or open circuits Refer to Section 2 11 for correct electrical values If motor tests good...

Page 184: ...2 Check For 12 VDC At 4MP3 a If 12VDC Alarm should have cleared itself b If no power 0VDC Continue with step 2 below 3 Check IPC Circuit a Use Component Test Mode to ener gize Evaporator Motor Contact...

Page 185: ...motor If closed then an intermittent IP circuit is suspect Check phase to phase and phase to ground for short or open circuits Refer to Section 2 11 for correct electrical values If motor tests good...

Page 186: ...turning the unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Op...

Page 187: ...the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Front Unloader UL1 Coil a Inspect Front Unloader UL1 coil connector No damage to coil No dama...

Page 188: ...he unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Rear Unloader UL2 Coil a Inspect Rear Unloader UL2 coil connector No damage t...

Page 189: ...ECK 1HTCON1 RELAY COIL TRIGGER ON Heater Contactor 1 1HTCON1 circuit is shorted The contactor output from the microprocessor 4MP13 is negative so the circuit will not be shorted to ground but is short...

Page 190: ...erate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check 1HTCON2 a Inspect heater contactor coil and terminals No damage to coi...

Page 191: ...Section 2 12 for correct electrical values View current draw in Data List 94 CHECK COMP CONTACTOR 1 TRIGGER ON Compressor motor contactor relay CCONR circuit is shorted The relay output from the micr...

Page 192: ...ove Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check CDCON a Inspect condenser fan contactor coil and terminals No da...

Page 193: ...the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check GENCONR a Inspect generator contactor relay coil and terminals No damage to...

Page 194: ...Evaporator Area For High Temperature Check Evaporator temperature using a test thermometer EVHTS opens when the temperature of the evaporator becomes very high Refer to Section 2 10 For example if th...

Page 195: ...been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1...

Page 196: ...ith the steps below as necessary 1 Check Overload Ground Fault Detector OGF LED Check status LED LED is On Ground Fault is detected Start with Step 3 below LED is Off Circuit Overload is detected Star...

Page 197: ...ould clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check 1EVCON a Inspect evapora...

Page 198: ...the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Sensor a Inspect sensor connector No damage to sensor No damage moisture or...

Page 199: ...unit off then back on again NOTE Follow the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the u...

Page 200: ...been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1...

Page 201: ...Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with...

Page 202: ...isture or corrosion in connectors b Power up the microprocessor see Note 2 page 7 2 Disconnect sensor from harness Check for 2 5 VDC at harness plug between pins Voltage should be 2 5 VDC volts at har...

Page 203: ...age should be 2 5 VDC volts at harness plug be tween pins This verifies microprocessor output and wiring connections to sensor 128 LOW UNBALANCED A C AMPS TRIGGER ON The compressor is on and AC Curren...

Page 204: ...appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Sensor a Inspect sensor connector No damage to sensor No damage moisture or corrosion in connect...

Page 205: ...above Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Alarm List Check for Alarm 41 When alarms 41 and 130 occur at...

Page 206: ...ugh the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Sensor a Inspect sensor connector No damage to sensor No damage moisture or corrosion in...

Page 207: ...e or corrosion in connector b Check Remote Temp Sensor resistance See Note 3 page 7 2 10 000 Ohms 77 F 25 C See Table 8 5 for complete table of temperatures and resistance values 2 Check Wiring a Insp...

Page 208: ...y 1 Check For Any Pretrip Alarms Scroll the alarm list for any Active Pretrip alarms Alarm conditions must be corrected and the alarm cleared to continue 2 Rerun Pretrip Check If Desired a Clear Activ...

Page 209: ...pin 16 and MPQC3 on the microprocessor Use Component Test mode to energize the Speed Relay Section 5 2 2 Refer to Section 2 12 for amp values View current draw in the Unit Data Refer to Section 3 13...

Page 210: ...Follow the steps below until a problem is found Once a repair or correction has been made clear the alarm s See Note 1 Operate the unit through the appropriate modes to see if any active alarm occurs...

Page 211: ...EMP SENSOR TRIGGER ON Engine Coolant Temperature Sensor ENCT is not within the range of 58 to 266 F 50 to 130 C UNIT CONTROL Engine and Standby Operation Pretrip will fail and display PRETRIP FAIL AND...

Page 212: ...Disconnect F5 wire and remove from inside DC current sensor see Figure 2 9 page 2 12 Reconnect at F5 and power the microprocessor by toggling the Main Power switch out of the OFF position Without wir...

Page 213: ...may be manually reset via keypad or by turning the unit off then back on again Check Sensor refer to procedure for alarm 125 P161 CHECK SUCTION TEMP SENSOR CST TRIGGER ON Suction Temp Sensor CST is n...

Page 214: ...ber shown in the microprocessor Un it Data Enter the correct number in Configurations Refer to Section 5 2 1 2 Check the fuel speed actuator Check FSA plunger Must move in and out freely 3 Verify low...

Page 215: ...5 page 7 2 a Set Functional Parameter LOW SPEED START to zero and adjust set point at least 10 F 5 6 C above or below refrigerated com partment temperature then start the unit Set Functional Parameter...

Page 216: ...EED RPM Continued 6 Check engine air intake system a Check air cleaner indicator Flag must not be visible b Inspect air intake system Hoses tubes in good condition No kinks or restrictions 7 Check eng...

Page 217: ...charge suction pressures with those shown on the microprocessor display Suction and Evaporator Outlet pressures must be above 3 psig 0 2 bar Suction Evaporator Outlet Discharge Pressures must have the...

Page 218: ...ns to transducers are the same The Discharge Transducer should have a RED mark ing dot on it The Suction Transducer should have a BLUE mark ing dot on it 2 Check for Check UL1 Alarm Check for alarm 85...

Page 219: ...rier Transicold dealer install latest revision 2 Check wiring to DPT SPT a Verify that correct wires are con nected to each transducer Plugs to transducers are the same The correct wire plug must be c...

Page 220: ...repair or correction has been made clear the alarm s See Note 1 page 7 2 Operate the unit through the appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 D...

Page 221: ...Elements a Check heater elements with the unit Off No visual physical damage Remove and replace if damaged b Check heater element resistance Check from T terminals on 1HTCON1 contactor See section 2 1...

Page 222: ...steps below as necessary 1 Determine Which Test This Alarm Occurred In a Review active alarm list Make a note of all alarms b Clear active alarm list c Restart and monitor Pretrip Stop Pretrip during...

Page 223: ...ction2 11for L1 L2 L1 L3 and L2 L3 Must be within range shown in Section 2 11 for T1 T2 T1 T3 and T2 T3 7 Check Heater Elements a Check heater elements with the unit Off No visual physical damage Remo...

Page 224: ...appropriate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Determine Which Test This Alarm Occurred In a Review active alarm list Make a note of all alarms b Clea...

Page 225: ...T1 T2 T1 T3 and T2 T3 6 Check Evaporator Fan Motor a With the unit off visually check fan motor and blower wheel No visual physical damage No blockage to blower wheels Blower wheels spin freely Remov...

Page 226: ...ring for the motors must be separated and each motor tested in dividually b Check fuses for condenser fan mo tors F26 F27 and F28 must not be blown c Check voltage at CDCON contacts Must be within ran...

Page 227: ...h transducer Plugs to transducers are the same The correct wire plug must be connected to the proper transducer b Verify that correct transducer is be ing used in each position Mechanical connections...

Page 228: ...s P207 CHECK COMPRESSOR CONTACT CIRC TRIGGER ON Normal draw for the CCONR and CCON relay coils is 0 0 to 1 0 Amps 12 VDC The circuit tests outside this range UNIT CONTROL Engine and Standby Operation...

Page 229: ...s Continue with the steps below as necessary 1 Check GENCONR a Inspect GENCONR and GENCON contactor coils and wire connec tions No damage to coil No damage moisture or corrosion in connections b Check...

Page 230: ...NDBY MODE THIS PRETRIP ALARM WILL GENERATE MANY OTHER PRETRIP ALARMS THEREFORE IT SHOULD BE ADDRESSED FIRST 1 Check PSCONR a Inspect PSCONR PSCON and PSCON2 contactor coils and wire connections No dam...

Page 231: ...tenance Hour Meter for the next service interval Hour Meter reset is a Functional Parameter Follow maintenance interval recommendations in Section 8 2 224 STANDBY MAINTENANCE DUE TRIGGER ON The Standb...

Page 232: ...e Hour Meter for the next service interval Hour Meter reset is a Functional Parameter Follow maintenance interval recommendations in Section 8 2 226 SERVICE SOON PM 1 DUE TRIGGER ON The Maintenance Ho...

Page 233: ...r the next service interval Hour Meter reset is a Functional Parameter Follow maintenance interval recommendations in Section 8 2 228 SERVICE SOON PM 3 DUE TRIGGER ON The Maintenance Hour Meter 3 time...

Page 234: ...r the next service interval Hour Meter reset is a Functional Parameter Follow maintenance interval recommendations in Section 8 2 230 SERVICE SOON PM 5 DUE TRIGGER ON The Maintenance Hour Meter 5 time...

Page 235: ...active Download and replace microprocessor Refer to Section 5 7 233 MODEL ERROR TRIGGER ON There is an error in the Model Number that is stored in the microprocessor memory UNIT CONTROL Unit Shutdown...

Page 236: ...riate modes to see if any active alarm occurs Continue with the steps below as necessary 1 Check Functional Parameters Check Functional Parameters All must be set for selectable values 2 Check Softwar...

Page 237: ...er ver sions of ReeferManager may contain configurations that were not present in older versions of micropro cessor software 3 Reconfigure Microprocessor Send settings to microprocessor Using the late...

Page 238: ...low the steps below until a problem is found Once a repair or correction has been made the active alarm should clear itself see reset condition above Operate the unit through the appropriate modes to...

Page 239: ...gauge set and check and compare compressor suction evaporator pressures with those shown on the microprocessor display Suction and Evaporator Outlet Pressures must have the same reading on gauges on...

Page 240: ...arm 245 remains active Unit will operate but changes to the settings will not be retained in the microprocessor memory Download and replace microprocessor Refer to Section 5 7 246 EEPROM WRITE FAILURE...

Page 241: ...and 89 6 F 30 and 32 C c Check Functional Parameters All settings must be valid 2 Check Software Revision a Check microprocessor software revision Upgrade to the latest revision of software The latest...

Page 242: ...inue with the steps below as necessary 1 Check Software Revision Check microprocessor software revi sion Upgrade to the latest revision of software 2 Check Microprocessor a Check Temperature Sensor Da...

Page 243: ...igerant Charge 8 15 8 6 3 Leak Checking 8 17 8 6 4 Evacuation And Dehydration 8 19 8 7 COMPRESSOR AND UNLOADER SERVICE 8 20 8 7 1 Repair or Replacement Determination 8 20 8 7 2 Removal and Replacement...

Page 244: ...for all Carrier Transicold refrigeration units otherwise compressor failure will occur For more information Refer to Technical Procedure 98 50553 00 Inert Gas Brazing 8 1 SECTION LAYOUT Service proce...

Page 245: ...tration using a refractometer Carrier Transicold part number 07 00435 00 2 Clean condenser radiator surfaces 3 Check water pump 4 Check water temperature sensor 8 5 12 8 5 12 Check Check Exhaust Syste...

Page 246: ...refer to Section 8 9 1 Check Check 2 11 2 11 2 11 2 11 c Every Second Service Interval or 2 years Cooling System Drain and flush cooling system 8 5 12 d Every 10 000 Hour Maintenance Perform complete...

Page 247: ...heck battery cables and terminals j j Check evaporator coil for cleanliness j j Check bulkheads and return air screens j j Check all defrost water drains j j Place in continuous run and start unit j j...

Page 248: ...the grille surround doors door latches and display keypad assembly are provided in the following sub paragraphs 8 4 1 Grille Insert Removal To remove the grille insert do the following NOTE If difficu...

Page 249: ...ower cable is inserted through the upper cable eyelet The lower cable is to be removed to gain access to the upper cable 3 Reverse above steps to install new cable 1 4 3 2 1 Paddle Assembly Typical Fr...

Page 250: ...Install the display board and reconnect wiring between the keypad display assembly and har ness 3 Reconnect negative battery cable and standby plug as required and run Pretrip to check unit operation...

Page 251: ...ump the manual plunger until positive pressure re sistance is felt This may take up to 200 strokes This will indicate fuel flow c Continue to pump S L O W L Y up down once per second approximately 100...

Page 252: ...l Pump 8 5 5 Fuel Filter To replace filter a Ensure the unit will not start automatically by dis abling any two way communication and placing the Main Power switch in the OFF position Disconnect the h...

Page 253: ...eading should be approximately 4 75 VDC i Start unit and check for leaks 8 5 7 Fuel Heater The optional fuel heater item 6 Figure 8 5 applies heat to fuel in the fuel filter Heating the fuel dissolves...

Page 254: ...up the engine and then stop it by placing the Main Power switch in the OFF position Ensure the unit will not start automatically by disabling any two way commu nication Disconnect the high voltage so...

Page 255: ...cation and placing the Main Power switch in the OFF position Disconnect the high voltage source and lockout tagout the re ceptacle 2 Remove the inlet hose 3 Disconnect the lead 4 Remove the flange int...

Page 256: ...ing radiator cap and then the lower radiator hose CAUTION NEVER POUR COLD WATER INTO A HOT ENGINE however hot water can always be added to a cold engine 4 Install hose and fill system with clean untre...

Page 257: ...osed type breather with the breather line attached to the cylinder head cover See Figure 8 17 The breather assembly should be cleaned once a year or at every 2000 hours maintenance interval whichever...

Page 258: ...per sight glass is not full 5 If the system appears to be overcharged or under charged adjust charge Refer to following step f b Checking For Noncondensibles To check for noncondensibles proceed as fo...

Page 259: ...der to raise the pressure above 0 9 Connect a refrigerant recovery device and a clean re frigerant recovery cylinder to the suction and dis charge service valves and remove any remaining re frigerant...

Page 260: ...the system is without charge when the low side has been pumped down and when only the compressor is to be leak checked Procedures for each condition are provided in the following subsections a Leak C...

Page 261: ...quid line service valve is acceptable 3 Ensure that the microprocessor MessageCenter dis plays RECOVER LEAK CHK EVAC MODE during the pressurizing and leak checking procedures Re fer to Section 5 2 3 I...

Page 262: ...ly evacuate any system include a good vacuum pump 5 cfm 8m H volume displacement Carrier Transicold part number 07 00176 11 and a good vacuum indicator such as a thermocouple vacuum gauge micrometer C...

Page 263: ...shut off the pump Wait a few minutes to be sure the vacuum holds below 2000 microns 10 If vacuum holds below 2000 microns continue to step 12 If vacuum rises above 2000 microns contin ue to step 11 1...

Page 264: ...ped pressure could result in injury c Loosen the suction and discharge service valve mounting bolts Tap the valve bodies to break the seal and then remove bolts d Locate the compressor junction box it...

Page 265: ...q Leak check and evacuate the compressor Refer to Section 8 6 3 and Section 8 6 4 8 7 3 Cylinder Head and Valve Plate Service a Pumpdown the compressor Refer to Section 8 6 2 b Ensure the unit will no...

Page 266: ...valve plates Torque the capscrews to 12 to 16 ft lbs 16 3 to 21 7 Nm i Turn the valve plate over j Install the suction valve spring on the dowel pins with the spring ends bearing away from the cylind...

Page 267: ...the oil sight glass to ensure that no foaming of the oil is present after 20 minutes of operation If the oil is foaming excessively after 20 minutes of opera tion check the refrigerant system for floo...

Page 268: ...the compressor suc tion and discharge service valves and start unit in cooling with compartment temperatures at least 5_F 2 8_C below set point The compressor will be fully loaded both unloader coils...

Page 269: ...ng the valve body and gasket Insert mounting bolts align with gasket holes and mounting holes in head Start bolts by hand and then toque mounting bolts 12 to16 ft lbs 1 3 to 1 8 Nm 7 Leak check and ev...

Page 270: ...ins aren t bent during this procedure b Condenser Coil Replacement Note If the condenser coil Item 3 Figure 8 25 re quires replacement the entire condenser radi ator assembly 1 must be removed from th...

Page 271: ...to 15 to 25 ft lbs 20 to 34 Nm Torque the fusible plug to 4 to 8 ft lbs 5 to 11 Nm d Leak check evacuate and charge the system Refer to Sections 8 6 3 8 6 4 8 6 2 8 8 5 Compressor Suction Modulation...

Page 272: ...ve motor assembly is to be replaced d Replacing the Drive and Motor Assembly 1 Pump down the low side Refer to section 8 6 2 2 Remove valve piston and motor assembly and re place with a new assembly a...

Page 273: ...otor may be tested using a stepper motor drive tester or ohmmeter 1 To test with a stepper motor drive tester Carrier Transicold part number 07 00375 00 connect the 5 pin test cable to the valve conne...

Page 274: ...Close valve on cylinder and open bleed off valve 6 Open cylinder valve Slowly close bleed off valve and increase pressure until the switch opens If light is used light will go out and if an ohmmeter i...

Page 275: ...action NOTE Use a hand aspirator Carrier Transicold part number 07 00177 01 since blowing into tube by mouth may cause an incorrect reading h With the gauge reading at zero apply air pressure very sl...

Page 276: ...tactor 2 PSCON2 6 Generator contactor GENCON 7 Heater contactor 2 1HTCON2 8 Compressor contactor CCON Figure 8 33 High Voltage Contactors 8 9 2 Phase Reversal Module PRM One principle of three phase m...

Page 277: ...oss of power at 2MP26 activates the A100 OVERLOAD GROUND FAULT alarm and illuminates the OGF mounted fault LED b OGF Checkout Procedure 1 Check the FAULT LED on the module If the LED is illuminated th...

Page 278: ...eaters 8 9 6 Evaporator Blower Motor NOTE The blower motor bearings are factory sealed and do not require additional grease a Ensure the unit will not start automatically by dis abling any two way com...

Page 279: ...the lower right hand leg of the welded support See Figure 8 37 c Remove the condenser fan assembly mounting bolts and slide the assembly out of unit If required the di vider may be removed by removin...

Page 280: ...ckout tagout the receptacle and disconnect the negative battery connec tion NEVER dis assemble the generator HIGH MAGNETIC FIELD INSIDE This field can interfere with cardiac implants such as pacemaker...

Page 281: ...move the nuts 2 from the exhaust connection 3 4 3 Disconnect ground wire 4 Cut the generator cables Leave the same length as new generator wires 8 5 6 6 7 5 Unbolt snubber Unplug the ENSCU 6 Remove th...

Page 282: ...ed as one piece with the shim in place DO NOT attempt to remove the rotor from the stator NOTE Do not remove and use the shim from a replace ment generator the replacement generator shim must remain i...

Page 283: ...e sure the generator leads Item 11 Figure 8 38 exit the stator winding on the side away from the engine 8 The mounting holes on the generator rotor Item 10 have two holes offset to match the ones in t...

Page 284: ...d with two washers 19 Torque the stator mounting screws to 33 37 foot pounds 44 8Nm to 50 1 Nm NOTE Mark each stator screw after it is torqued to ensure that all the screws are torqued 20 Assemble the...

Page 285: ...7 6 099 165 73 9 1 537 16 26 7 144 200 42 5 5 24 700 100 37 8 5 828 170 76 7 1 402 14 25 6 134 800 44 6 6 23 390 102 38 9 5 571 175 79 4 1 281 12 24 4 126 100 46 7 7 22 160 104 40 0 5 327 180 82 2 1 1...

Page 286: ...20 1 480 23 3 10 1 177 150 16 6 62 145 340 56 7 134 28 160 165 5 330 1 310 22 2 8 1 102 240 17 7 64 138 120 57 8 136 27 040 171 1 340 1 160 21 1 6 1 032 600 18 9 66 131 310 58 9 138 25 970 176 7 350 1...

Page 287: ...5 6 13 55 8 0 115 4 21 6 1 88 27 3 16 60 8 7 126 1 20 4 2 0 29 1 18 65 9 5 137 4 19 2 2 1 30 9 21 70 10 3 149 4 18 0 2 3 32 8 24 75 11 2 162 1 17 2 2 4 34 8 27 80 12 1 175 5 16 4 2 5 36 8 29 85 13 1 1...

Page 288: ...9 4 9 4 REFRIGERATION TEMPERATURE CONTROL 9 4 9 4 1 Unit Will Not Cool 9 4 9 4 3 Unit Operates Long Or Continuously In Cooling 9 4 9 4 4 Unit Will Not Terminate Cooling 9 5 9 4 6 Unit Will Not Termina...

Page 289: ...ery insufficiently charged 9 2 Battery terminal post dirty or defective Check Bad electrical connections at starter Check Starter motor malfunctions 9 1 4 Starter motor solenoid defective Engine Manua...

Page 290: ...t Off Engine will not shut off ESC operation defective 9 5 9 1 4 Starter Motor Malfunction Starter motor will not crank or turns slowly Battery insufficiently charged 9 2 Battery cable connections loo...

Page 291: ...ective thermostat Engine Manual Defective water pump belt Engine Manual Excessive crankcase pressure Plugged crankcase breather 8 5 14 9 2 BATTERY CHARGER Indication Trouble Possible Causes Action Ref...

Page 292: ...ction 9 4 1 Unit Will Not Cool Compressor malfunction Compressor contactor or relay defective Check Compressor defective 8 7 1 Refrigeration system A defrost cycle did not terminate Check DTT 8 9 10 A...

Page 293: ...roprocessor malfunction 9 6 Temperature sensor malfunction 8 9 10 9 4 7 Defrost Cycle Malfunction Will not initiate defrost automatically Defrost timer has not expired Check Reset Defrost air switch D...

Page 294: ...tion valve malfunction 8 8 5 Liquid or suction line service valve partially closed Open High suction pressure Compressor valves s worn or broken 8 7 1 Compressor gasket s defective 8 7 1 Heater contac...

Page 295: ...10 EVOP defective 8 8 8 Coil not seated properly on valve Check EVXV inlet screen plugged Check and Re place Loose connector Check and Tighten 9 4 12 Compressor Suction Modulation Valve CSMV Malfunct...

Page 296: ...1 2 No signal from ENSSN for 2 seconds after RPM is greater than 1 000 RPM for 10 seconds OR for 5 seconds while engine cranking no voltage at ENSCU pin 18 Two Long One Short Figure 9 2 3 Fuel speed a...

Page 297: ...PM Table 2 1 Lock screws in place and rewire Did you find and correct the condition Using jumper wire check for 5 VDC at ENSCU terminal 10 Do you have 5 VDC at terminal 10 Remove new ENSCU and re inst...

Page 298: ...the condition Using jumper wire check for 5 VDC at ENSCU terminal 10 Do you have 5 VDC at terminal 10 Replace ENSCU Did you find and correct the condition Remove new ENSCU and re install old ENSCU ba...

Page 299: ...correct the condition Check for open or high resistance on circuit between FSA and ENSCU Did you find and correct the condition Replace the FSA Did you find and correct the condition Remove the FSA fr...

Page 300: ...CU back into unit ENSCU is not the fault Review results of above tests with your supervisor If necessary go to the beginning of the tree test again Starting at terminal 13 at the ENSCU check circuit f...

Page 301: ...oprocessor then verify unit operation PRIOR TO writing hours Trailer ID Unit Serial Number etc into the new microprocessor Once the technician is sat isfied that a new microprocessor is required the h...

Page 302: ...for high resistance or an open Did you find and correct the condition Is the system operat ing OK now Inspect and repair he 3 wiring harnesses for the micro and display the cable from the micro to th...

Page 303: ...condition Review the results of above tests with your supervisor If necessary go to the begin ning of the tree test again Verify Functional Parameters and Configura tions are installed correct Did you...

Page 304: ...s the relay defective Replace Run Relay Did you find and correct the condition Check wiring to Run Relay for an open or short Did you find and correct the condition Fuel speed actuator is defective or...

Page 305: ...sting with your supervisor before changing microprocessor Is the F2 fuse blown Check the F2 circuit for excess amp draw or short to ground Did you find and correct the condition Is there voltage at QC...

Page 306: ...temperature equal to or colder than setpoint Is selected probe temperat ure greater than 3 6F from setpoint Is speed relay LED27 illuminated on the micro Did you find and correct the condition Is the...

Page 307: ...time Operate the system in order to verify the repair Verify PC power saving features are OFF I E screen saver monitor time out hard disc time out auto power down sleep mode Did you find and correct...

Page 308: ...on 6 1 for a list of MessageCenter error messages Find your specific error mes sage and follow the di rections in the descrip tion column Repair as needed Operate the system in order to verify the rep...

Page 309: ...ut 45 seconds Did you find and correct the condition Can the card be read by the ReeferManager program Micro display will show ENGINE AND MICRO WILL STOP NOW and engine will stop Did you find and corr...

Page 310: ...ARNESS PLUG WIRING FOR UNITS WITH A MAIN POWER SWITCH LABELED START RUN OFF 10 6 10 3 CONTROL BOX INTERIOR SPLICE POINTS FOR UNITS WITH A MAIN POWER SWITCH LABELED ENGINE OFF STANDBY 10 11 10 4 CONTRO...

Page 311: ...SP1 14 3 REMSN2 REMSN G SP1 14 4 REMSN3 REMSN K SP1 14 33 1MP NATURAL Continued Component Terminal CSP 1 SP16 15 29 30 OGF OV HC 1 SP16 15 CDP 1 16 5 30 EVOP 1 DP16 P 17 6 30 ENCT 18 7 CST SP14 19 10...

Page 312: ...19 32 EVXV D DP16 M 22 11 12 23 35 EVXV A DP16 J 23 11 12 22 35 HC19 SP61 26 ENOLS 28 SP15 29 CSMV B 32 8 19 20 EVXV C DP16 L 35 11 12 22 23 Unused terminals 1 2 4 5 7 9 10 14 15 21 24 25 27 30 31 33...

Page 313: ...F BROWN SP54 8 CT BLACK 9 CT BLUE OGF BLUE SP53 10 1HTCON1 A1 13 1HTCON2 A1 14 1EVCON A1 15 FHR 2 16 Unused terminals 11 12 5 MP 1 6 7 12 Component Terminal SP52 1 SP56 2 PRM OUT 4 PSCONR 2 7 BUZZER 8...

Page 314: ...1DTT B 1SAT C 1SAT D EVOT E EVOT F 1RAT G 1RAT H EVXV A J EVXV B K EVXV C L EVXV D M EVXV E N EVOP 1 P EVOP 2 R EVOP 3 S Unused terminals None ENSCU 20 26 7 1 8 14 13 19 Component Terminal 2MP 18 3 FS...

Page 315: ...Y Continued HC Plug 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Component Terminal OGF OV 1MP15 1 MPQC 3 ENSCU 16 2 MPQC 1 BTY 3 MPQC4 SP3 4 SP52 J1 A 7 SSR 87 SS 8 SP60 CCON IPC 11 IAHR 87 IAH 14...

Page 316: ...N G SP1 14 33 REMSN3 REMSN K SP1 14 33 1MP NATURAL Continued Component Terminal CSP A SP16 15 29 30 OGF OV HC 1 SP16 15 CDP A 16 5 30 EVOP A DP16 P 17 6 30 ENCT 18 7 CST SP14 19 10 EVOT DP16 F SP14 19...

Page 317: ...19 32 EVXV D DP16 M 22 11 12 23 35 EVXV A DP16 J 23 11 12 22 35 HC19 SP61 26 SP15 29 CSMV B 32 8 19 20 EVXV C DP16 L 35 11 12 22 23 Unused terminals 1 2 4 5 7 9 10 14 15 21 24 25 27 28 30 31 33 34 3...

Page 318: ...GF SP54 8 CT2 3 4 BLACK 9 CT3 OGF SP53 10 1HTCON1 A1 13 1HTCON2 A1 14 1EVCON A1 15 FHR 2 16 Unused terminals 11 12 5 MP 1 6 7 12 Component Terminal MPQCC9 SP52 1 SP56 DES B PRM 12V 2 PRM OUT 4 PSCONR...

Page 319: ...1DTT B 1SAT C 1SAT D EVOT E EVOT F 1RAT G 1RAT H EVXV A J EVXV B K EVXV C L EVXV D M EVXV E N EVOP A P EVOP B R EVOP C S Unused terminals None ENSCU 20 26 7 1 8 14 13 19 Component Terminal 2MP 18 3 FS...

Page 320: ...HC Plug Control Box Side 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Component Terminal OGF OV 1MP15 1 MPQC 3 ENSCU 16 2 MPQC 1 BTY 3 MPQC4 SP3 4 SP52 OC B 7 SSR 87 SS 8 SP60 IP C 11 F5 B BTY 12...

Page 321: ...P 1 OGF 12V SSR 86 HC 18 MPQC 9 MPQC 8 SP59 HC 7 SP62 53 CT BLUE 4MP 10 OGF BLUE 54 CT BROWN 4MP 8 OGF BROWN 55 4MP 4 1HTCON1 A2 1HTCON2 A2 SP63 56 5MP 2 PRM 12V DOES 6 Splice Point No Component 57 FH...

Page 322: ...OGF 12V SSR 86 HC 18 MPQC 9 MPQC 8 SP59 DES A HC 7 SP62 53 CT BLUE 4MP 10 OGF BLUE 54 CT BROWN 4MP 8 OGF BROWN 55 4MP 4 1HTCON1 A2 1HTCON2 A2 SP63 Splice Point No Component 56 5MP 2 PRM 12V DES B 57...

Page 323: ...d indicator LEDs TP12 Pin 4 Green 5 Vdc for Display processor and LCD TP11 Pin 5 Brown Display ground TP10 Pin 6 Orange TX the serial communications from the control to the display TP9 Pin 7 Blue RX t...

Page 324: ...BASED ON 62 11580 ART2 S2 REVD VECTOR 6500 With Main Power Switch labeled ENGINE OFF STANDBY...

Page 325: ...USE HEATERS 12 AMP QUICK BLOW P2 F26 27 28 FUSE EVAP COND FANS 12 AMP L14 FLS FUEL LEVEL SENSOR OPTION L15 FP FUEL PUMP OPTION O2 FSA FUEL SOLENOID ACTUATOR R12 P10 D1 GENCON GENERATOR CONTACTOR J7 S1...

Page 326: ...Oil Level 8 24 Compressor Oil Pump And Bearing Head 8 23 Compressor Removal and Replacement 8 21 Compressor Repair or Replacement Determination 8 20 Compressor Valve Plate 8 22 Configuration Mode 5 2...

Page 327: ...8 18 Leak Checking System Without Charge 8 17 Leak Checking With Low Side Pumped Down 8 18 Light Bar 2 15 8 34 lockout tagout 1 1 M Main Display 2 13 Megohmmeter Test Procedure 8 32 MessageCenter 2 1...

Page 328: ...ssor Suction Temperature 2 10 Sensor Defrost Termination Temperature 2 10 Sensor Engine Coolant Temperature 2 7 Sensor Engine Oil Level 2 7 Sensor Engine Speed 2 7 Sensor Evaporator Outlet Temperature...

Page 329: ...t Pressure 2 10 Transducers Service 8 31 Trip Start 3 14 U Unit Data 3 17 Unloader Checkout procedure 8 25 Unloader Coil Replacement 8 25 Unloader Replacing Internal Parts 8 26 Unloader Valve Replacem...

Page 330: ...A www carrier transicold com North America 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 No 418 Piso 9 To...

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