Page 3 - GENERAL SAFETY NOTICES; elsewhere in the manual follows the general safety notices.; FIRST AID
S A FE TY S U MMA R Y Safety-1 T-268-07 SAFETY SUMMARY GENERAL SAFETY NOTICES The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautions that must be understood and applied during operation and maintenance o...
Page 4 - SPECIFIC WARNING AND CAUTION STATEMENTS; product or property damage.
Safety-2 T-268-07 SPECIFIC WARNING AND CAUTION STATEMENTS To help identify the label hazards on the Unit and explain the level of awareness each one carries, an explanation is given with the appropriate consequences:DANGER -- means an immediate hazard which WILL result in severe personal injury or d...
Page 6 - ii; Section
ii T-268-07 TABLE OF CONTENTS (CONTINUED) Section Page 3.3.1 Brief Description 3-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.2 DataCORDER Configuration 3-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.3 DataCORDER Function ...
Page 7 - iii
TABL E O F C ONT E NT S iii T-268-07 TABLE OF CONTENTS (CONTINUED) Section Page SERVICE 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 MANIFOLD GAUGE SET 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 8 - iv; LIST OF ILLUSTRATIONS
iv T-268-07 TABLE OF CONTENTS (CONTINUED) Section Page 6.26 THERMOSTATIC EXPANSION VALVE 6-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27 CONTROLLER/DATACORDER 6-28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.27.1 Controller/DataCORDER Progr...
Page 9 - Figure
TABL E O F C ONT E NT S v T-268-07 LIST OF ILLUSTRATIONS (CONTINUED) Figure Page Figure 6-1 Manifold Gauge Set 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Figure 6-2 R-134a Manifold Gauge Set Connection 6-3 . . . . . . . . . . . . . . . . . . . . . . ....
Page 10 - LIST OF TABLES; Table
vi T-268-07 LIST OF TABLES Table Page Table 1-1 Model Chart 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 2-1 Safety and Protective Devices 2-19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table 3-1 Controlle...
Page 11 - This manual contains Operating Data, Electrical Data; NOTE; Beginning with early 1995 production, in; WARNING
SECT IO N 1 1-1 T-268-07 SECTION 1 INTRODUCTION 1.1 INTRODUCTION WARNING It has been determined that pressurized,air-rich mixtures of refrigerants and air can undergo combustion when exposed to anignition source. This manual contains Operating Data, Electrical Data and Service Instructions for the r...
Page 20 - Unit Serial Number, Model Number and Parts
SECT IO N 2 2-1 T-268-07 SECTION 2 DESCRIPTION 2.1 GENERAL DESCRIPTIONa. Refrigeration Unit -- Front Section The front section of the refrigeration unit shows accessto most parts of the unit (i.e., compressor, condenser, receiver, etc.), which will be discussed in more detail ofthe following section...
Page 21 - b. Evaporator Section; The evaporator fans circulate air throughout the
2-2 T-268-07 b. Evaporator Section The evaporator section contains the optionalmechanical temperature recording bulb, return recordersensor (RRS), return temperature sensor (RTS), thermostatic expansion valve, dual-speed evaporatorfan motors and fans (2), evaporator coil and heaters,drain pan and he...
Page 22 - Mechanical Recording Thermometer Bulb
SECT IO N 2 2-3 T-268-07 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1. Evaporator Fan Motor #1 (EM1) 2. Humidity Sensor (HS) -- Optional 3. Return Recorder Sensor (RRS) 4. Return Temperature Sensor (RTS) 5. Mechanical Recording Thermometer Bulb 6. Mechanical Recording Thermometer Bulb -- Used o...
Page 23 - c. Compressor Section; Power Cables and Plug
2-4 T-268-07 c. Compressor Section The compressor section includes the compressor, powercable storage compartment, and an optional transformer (refer to Table 1-1 and Figure 2-9), which is located to the left of the compressor. This section also contains the optional discharge/suction pressure trans...
Page 24 - front of the condenser fan grille.; Grille and Venturi Assembly
SECT IO N 2 2-5 T-268-07 d. Condenser Section The condensing section consists of a condenser fanmotor, a condenser fan and an air-cooled condenser coil. When the unit is operating, air is pulled in the bottom ofthe coil and discharged horizontally out through the front of the condenser fan grille. 1...
Page 25 - discharge pressure regulator valve.; Discharge Pressure Regulator Valve
2-6 T-268-07 e. Receiver Section The receiver section consists of quench expansionvalve, manual liquid line valve, filter-drier, receiverwith sight glass/moisture-liquid indicator, condenser pressure transducer (CPT), fusible plug, suctionmodulation valve, suction solenoid valve, and discharge press...
Page 27 - g. Control Box with a Single-Speed Compressor; current; some models; Figure 2-7. Control Box on Units with a Single-Speed Compressor
2-8 T-268-07 g. Control Box with a Single-Speed Compressor The control box includes the manual switches, circuitbreaker(s), contactors, transformer, fuses, key pad,display module, current sensor module, Controller/DataCORDER module (See Figure 2-7), anoptional remote monitoring unit (CI), and an opt...
Page 28 - h. Control Box with a Two-Speed Compressor; display
SECT IO N 2 2-9 T-268-07 h. Control Box with a Two-Speed Compressor (Optional) The control box includes the manual switches, circuitbreaker(s), contactors, transformer, fuses, key pad, display module, current sensor module, Controller/DataCORDER module (See Figure 2-8), and an optional remote monito...
Page 31 - Output voltage readings verses relative humidity (RH) percentage:; The modular transformer (if equipped) is located under; b. To Operate Unit on 190/230 vac Power Supply; Dual Voltage Modular Transformer
2-12 T-268-07 Orange wire Power Red wire Output Brown wire Ground Input voltage 5 vdc i. Humidity Sensor Output voltage 0 to 3.3 vdc i. Humidity Sensor (HS) -- Optional Output voltage readings verses relative humidity (RH) percentage: ( ) p 30% 0.99 V 50% 1.65 V 70% 2.31 V 90% 2.97 V 2.4 POWER AUTOT...
Page 32 - UPPER FRESH AIR MAKEUP VENT; a. Full Open or Closed Positions; a. Full Open or Closed Positions
SECT IO N 2 2-13 T-268-07 2.5 UPPER FRESH AIR MAKEUP VENT The purpose of the fresh air makeup vent is to provideventilation for commodities that require fresh aircirculation. The vent must be closed when transporting frozen foods or controlled atmosphere loads.Air exchange depends on static pressure...
Page 34 - Figure 2-10. Refrigeration Circuit with Receiver
SECT IO N 2 2-15 T-268-07 19 18 17 1 2 3 4 5 6 7 8 9 11 12 14 15 16 10 13 1. Suction Service Valve 2. Discharge Service Valve 3. Discharge Pressure Regulator Valve 4. Air-Cooled Condenser 5. Evaporator 6. Thermostatic Expansion Valve 7. External Equalizer Line 8. Thermostatic Expansion Valve Bulb 9....
Page 35 - To shift to air-cooled condenser operation, do the
2-16 T-268-07 2.8 REFRIGERATION CIRCUIT WITH THE WATER-COOLED CONDENSER (Optional) Starting at the compressor, the suction gas iscompressed to a higher temperature and pressure.When operating with the water-cooled condenser, thegas flows through the discharge service valve into thepressure regulator...
Page 37 - SUCTION SOLENOID VALVE; F) above set point, and ends as soon as the control; b. Suction Solenoid Override; at least one of the sensors is repaired.; When the remote monitor plug is connected to the; CIRCUIT; Sockets B to A Energizes remote cool light
2-18 T-268-07 2.10 SUCTION SOLENOID VALVE The suction solenoid valve, shown in Figure 2-5, is controlled by the Controller relay (TS). a. Operation If set point is below --10 _ C (+14 _ F), or --5 _ C (+23 _ F) optionally, and the suction solenoid valve override is notactivated, Controller relay (TS...
Page 38 - SAFETY AND PROTECTIVE DEVICES; Unit components are protected from damage by safety; UNSAFE CONDITION
SECT IO N 2 2-19 T-268-07 2.12 SAFETY AND PROTECTIVE DEVICES Unit components are protected from damage by safety and protective devices listed in Table 2-1 . These devices monitor the unit operating conditions and opena set of electrical contacts when an unsafe conditionoccurs.Open safety switch con...
Page 39 - Control Circuit Power Connection; Brief Description
SECT IO N 3 3-1 T-268-07 SECTION 3 MICROPROCESSOR 3.1 MICRO-LINK 2i CONTROLLER MODULE 1 2 2 6 7 8 3 4 2 2 2 5 1. Micro-Link 2i Controller/DataCORDER Module 2. Connectors 3. Test Points 4. Fuses 5. Control Circuit Power Connection (Location: In back of connector) 6. Battery Pack (Optional) 7. Softwar...
Page 40 - Procedure for loading software:
3-2 T-268-07 f. Provide reprogrammability and configuration through a memory card. The memory card automatically downloads new software to theController when inserted, and controls output to thedisplay for status information. g. Provide electronic data storage. NOTE For the benefit of the reader the...
Page 42 - Enter
3-4 T-268-07 3.1.3 General Layout of the Controller Section The Micro-Link 2i Controller/DataCORDER consistsof a key pad, display module and Controller module.Connectors are used to attach the wiring of the unit to the Controller module. The Controller module isdesigned to permit ease of installatio...
Page 45 - CODE
SECT IO N 3 3-7 T-268-07 CODE # DESCRIPTION TITLE Inapplicable Functions Display -- -- -- -- -- Cd13 Condenser Pressure (CPC) Condenser pressure is displayed using a pressure transducer. Pressure is displayed in units of psig when code 28 is set to _ F and units of bars when function code Cd28 is se...
Page 46 - these functions to meet the operational needs of the container.; Defrost Interval Timer Value Option:; This function code will display “
3-8 T-268-07 CODE # DESCRIPTION TITLE Inapplicable Functions Display -- -- -- -- -- Display Only Functions NOTE Function codes Cd27 through Cd37 are user-selectable functions. The operator can change the value of these functions to meet the operational needs of the container. Cd27 Defrost Interval (...
Page 48 - Secondary Return; Controller Alarms; The alarm philosophy balances the protection of the
3-10 T-268-07 CODE # DESCRIPTION TITLE Inapplicable Functions Display -- -- -- -- -- Cd39 Secondary Return Air Temperature (Optional) This code is only applicable to units without a DataCORDER, that are configured to have four probes. If this is true, it will then display the current secondary retur...
Page 50 - Check for recharging or replacing battery pack.
3-12 T-268-07 CODE # DESCRIPTION TITLE AL53 NiCad Battery Pack Failure Alarm 53 is caused by the nicad battery pack being too low of a charge for battery-backed recording. NOTE Check for recharging or replacing battery pack. AL54 Primary Supply Air Sensor Failure (STS) Alarm 54 is activated by an in...
Page 51 - ERROR
SECT IO N 3 3-13 T-268-07 CODE # DESCRIPTION TITLE AL63 Current Over Limit Alarm 63 is triggered by the current limiting system. If the compressor is ON and current limiting procedures cannot maintain a current level below the user selected limit, the current limit alarm is activated.This alarm is a...
Page 52 - Controller Temperature Control; at or; NOTES; a. Operation in the conventional mode without; If the unit starts when ambient is below --10; above
3-14 T-268-07 3.1.6 Condenser Pressure Control (CPC) A pressure control system has been incorporated bymeans of a condenser pressure transducer (CPT) andcondenser pressure control (CPC) logic to maintaindischarge pressures above 130 psig in lowtemperatures.In order for the CPC logic to be enabled, t...
Page 53 - b. Operation in the dehumidification mode
SECT IO N 3 3-15 T-268-07 modulation valve (SMV) and suction solenoid valve(SSV) with the compressor energized.When pulling down from a control temperature that ismore than 5 _ C (9 _ F) above set point, both valves will be open to reduce the pulldown time unless suctionsolenoid override or current ...
Page 55 - below; a. Operation in the conventional mode; at or below; CAUTION
SECT IO N 3 3-17 T-268-07 3.1.7.2 Frozen Range Below --10 _ C (+14 _ F), or --5 _ C (+23 _ F) Optionally For set points below --10 _ C (+14 _ F), or --5 _ C (+23 _ F) optionally, the Controller maintains RETURN air at theset point temperature using the following modes ofoperation: a. Operation in th...
Page 56 - PRE-TRIP SELECTION MENU; rSLts; the right display will show applicable data.; a. Manual Test Operation
3-18 T-268-07 the VENT mode is selected on the CA Controller. Theuser must scroll through the selection by pressing the UP ARROW or DOWN ARROW keys, then pressingthe ENTER key when the selection is made. While thetests are being executed, the user can terminate thepre-trip mode by holding the PRE-TR...
Page 57 - c. Auto Test Operation From Serial; Pre-trip may also be initiated via communications. The
SECT IO N 3 3-19 T-268-07 c. Auto Test Operation From Serial Communications Pre-trip may also be initiated via communications. The operation is the same as for the Auto Test modedescribed above except that should a test fail, thepre-trip mode will automatically terminate. Wheninitiated via communica...
Page 58 - If this test fails, “P5-2” and “FAIL” will be displayed. If both Probe; Component
3-20 T-268-07 CODE # DESCRIPTION TITLE P4-1 High Speed Evaporator Fan Motors Off Setup: The high speed Evaporator Fan is turned off, a current draw test is done after 10 seconds. Pass/Fail Criteria: Passes if change in current draw is within the range specified. Fails if AL11 or AL12 activates durin...
Page 60 - Note, this test is skipped if the unit does NOT have:; The sensed ambient temperature is less than 7; OR; The high pressure switch (HPS) fails to open within 15 minutes.
3-22 T-268-07 CODE # DESCRIPTION TITLE NOTE Starting with test P7-0 through test P10, these tests are only included with the “Auto2” (Optional) selection menu. (Refer to section 3.2.1.) Setup: When the unit is running, the condenser fan is de-energized, and a 15 minute timer is started. The right di...
Page 63 - DataCORDER Configuration; ITEM
SECT IO N 3 3-25 T-268-07 S Real Time Clock (RTC) Modification S Pre-Trip result & data S Trip Start S ISO Trip Header (Must be entered first via Interrogation program) S Economy Mode Start S Economy Mode End S “Auto 2” Pre-Trip Start S “Auto 2” Pre-Trip End S Bulb Mode Start S Bulb Mode changes...
Page 65 - DataCORDER Alarms
SECT IO N 3 3-27 T-268-07 3.3.4 DataCORDER Alarms To Display Alarm Codes:While in Set Point Selection or Default Display mode,press the ALT. MODE & ALARM LIST keys. Thisaccesses the Alarm List Display Mode, which displaysany alarms stored in the Alarm Queue. The user mayscroll to the end of the ...
Page 67 - Real Time Clock (RTC) because a logging interval
SECT IO N 3 3-29 T-268-07 The DataCORDER alarms for the USDA and cargoprobes are configurable using the interrogation program or via a configuration card. There are four configurationvariables for the DataCORDER, which are listed inTable 3-8 with their descriptions and selection values. Table 3-8. D...
Page 69 - “dALnn” where nn = the alarm; USDA/ Message Trip Comment; The optional interrogation software for a portable
SECT IO N 3 3-31 T-268-07 Left Display: “dALnn” where nn = the alarm history entry 01-08 Right Display: “xA nn” where x = “I” (inactive) or “A” (active) Or: “-- -- -- -- --” if no alarms are currently in the alarm history list h. Alarm ProcessingThe DataCORDER contains an eight alarm history queue w...
Page 70 - USDA COLD TREATMENT PROCEDURE
3-32 T-268-07 Start, Power Outages, and Temperature Out-of-Rangeconditions. 3.3.10 DataCORDER Scrollback The DataCORDER will display probe values for the sixDataCORDER probes up to 99 hours back from thecurrent hour. The probe values may be displayed by depressing the ALT. MODE key and then depressi...
Page 71 - TITLE
SECT IO N 3 3-33 T-268-07 Table 3-10. DataCORDER Pre-Trip Data TEST # TITLE DATA NOTE “Auto” or “Auto1” menu includes the following: P, P1, P2, P3, P4, P5, P6 and rSLts. “Auto2’ (Optional) menu includes the following: P, P1, P2, P3, P4, P5, P6,P7, P8, P9, P10 and rSLts. (Refer to section 3.2.1.) 1-0...
Page 72 - Figure 3-3. Standard Configuration Report Sample
3-34 T-268-07 CONTAINER ABCDXXXXXXX ON 08Jul 94 FROM 15Apr94 TO 17Apr94 (DEGREES C) PAGE: 1 HEADER INFORMATION DataCorder SN: XXXXXXXX ALARMS REPORT ALARM NUM FIRST ACTIVE LAST ACTIVE CONTROLLER ALARMS: 60 17Apr94 03:28 17Apr94 16:13 DATACORDER ALARMS No Alarms Reported USDA SUMMARY LEGEND DATE: 15A...
Page 73 - AIR CIRCULATION ONLY
SECT IO N 3 3-35 T-268-07 AIR CIRCULATION ONLY SET POINT FALLING TEMPERATURE RISING TEMPERATURE --1.5 _ C (2.7 _ F) --1 _ C (1.8 _ F) --0.5 _ C (0.9 _ F) --0.20 _ C +.20 _ C +1.5 _ C (2.7 _ F) +1 _ C (1.8 _ F) +0.5 _ C (0.9 _ F) COOLING AIR CIRCULATION ONLY COOLING NOTE For In-range Tolerance, Refer...
Page 74 - STEP; NOTE B; Low Speed Soft Start is; NOTE A; During
3-36 T-268-07 Compressor Starting Sequence Is Ambient Temperature Less Than 60 ˚ F ? High Speed Start Has Compressor Run For 20 Minutes ? Has Set Point Been Reached ? Is The Operating Capacity * Below Low Speed Capacity ? Low Speed Soft Start (See Note B) Run 20 Minutes Is Supply 3 ˚ F Above Set Poi...
Page 77 - STARTING AND STOPPING INSTRUCTIONS; Units equipped with the integrated DataCORDER:; AFTER STARTING INSPECTION
4-2 T-268-07 4.2 STARTING AND STOPPING INSTRUCTIONS CAUTION Make sure that the unit circuit breaker(s)(CB-1 & CB-2) and the start-stop switch (ST) are in the OFF position beforeconnecting to any electrical power source. a. Starting the Unit NOTE The evaporator fans will always start in high spee...
Page 80 - CONTROL TRANSFORMER; = 18 Volt Energized Circuit
SECT IO N 4 4-5 T-268-07 CONTROL TRANSFORMER = 18 Volt Energized Circuit = 24 Volt Energized Circuit = De-energized Circuit Figure 4-1. Cooling in High Speed with Two-Speed Compressor
Page 82 - = 24 Volt Energized Circuit
SECT IO N 4 4-7 T-268-07 = 18 Volt Energized Circuit CONTROL TRANSFORMER = 24 Volt Energized Circuit = De-energized Circuit Figure 4-2. Cooling in Low Speed with Two-Speed Compressor
Page 87 - Defrost; configured for and operating in bulb mode]; Arctic
4-12 T-268-07 4.4.6 Defrost Refer to section 3.1.4 (Code 27) for description of thedefrost interval selector and automatic defrostinitiation. The defrost cycle (see Figure 4-5) consists of twodistinct sub-cycles. The first sub-cycle is the de-icecycle, the second is a probe check cycle. Defrost may ...
Page 88 - C, the system will run
SECT IO N 4 4-13 T-268-07 If Pre-Trip is initiated during the 30 minute time period,Pre-Trip will be allowed to run normally. Once Pre-Tripis over, the controller will revert to its normal controlmode logic.If ambient is warmer than --10.0 _ C, the system will run its normal startup logic.Arctic mod...
Page 89 - Holding Zone
4-14 T-268-07 Table 4-1. Electrical Control Positions -- BELOW --10 _ C (+14 _ F), or --5 _ C (+23 _ F) optionally CONTROL CIRCUIT COOLING Holding Zone **Dehumidification HEATING DEFROST Single-Speed Compressor: Compressor Contactor (C) Energized De-energized ** ** De-energized 1 Two-Speed Compresso...
Page 90 - * Unit with optional Humidity sensor
SECT IO N 4 4-15 T-268-07 Table 4-2. Electrical Control Positions -- ABOVE --10 _ C (+14 _ F), or --5 _ C (+23 _ F) optionally CONTROL CIRCUIT COOLING Holding Zone * Dehumidification HEATING DEFROST Single-Speed Compressor: Compressor Contactor (C) Energized De-energized ** ** De-energized 1 Two-Spe...
Page 95 - MANIFOLD GAUGE SET; A. Connection to Low Side of System; a. Connecting the Manifold Gauge Set
SECT IO N 6 6-1 T-268-07 SECTION 6 SERVICE NOTE To avoid damage to the earth’s ozone layer, use a refrigerant recovery system whenever removing refrigerant.When working with refrigerants you must comply with all local government environmental laws. In theU.S.A., refer to EPA section 608. 6.1 MANIFOL...
Page 96 - b. Removing the Manifold Gauge Set
6-2 T-268-07 CAUTION To prevent trapping liquid refrigerant in theservice valve after charging, perform the following steps while the compressor is ONand before disconnecting the manifoldgauge set: S Backseat applicable discharge or manualliquid line valve. S Midseat manifold gauge set hand valves. ...
Page 102 - Adding Refrigerant to System (Full Charge); Adding Refrigerant to System (Partial
6-8 T-268-07 6.6.2 Adding Refrigerant to System (Full Charge) a. Evacuate unit and leave in deep vacuum. (Refer to section 6.5.) b. Place cylinder of R-134a on scale and connect charging line from cylinder to liquid line valve.Purge charging line at liquid line valve and thennote weight of cylinder ...
Page 103 - Discharge Valve Flange; Removal and Replacement of Compressor; Turn off valves on both hoses to pump.; COMPRESSOR DISASSEMBLY
SECT IO N 6 6-9 T-268-07 1 2 3 4 5 6 7 8 10 11 12 13 14 15 9 1. Discharge Valve Flange 2. High Side Pressure Connection 3. Low Side Pressure Connection 4. Suction Valve Flange (Refer to note #7) 5. Motor End Cover 6. Serial/Model No. Plate 7. Crankcase Heater (Optional) 8. Bottom Plate 9. Sight Glas...
Page 104 - b. Remove cylinder head capscrews. If the cylinder; Jack here; c. Remove valve stops and valves. After they have
6-10 T-268-07 Table 6-4 and Table 6-5 for compressor wear limits andbolt torque values.a. Place the compressor in a position where it will be convenient to drain the oil. Remove the oil plug onthe oil pump inlet passage (see Figure 6-8 forlocation) to vent the crankcase. Loosen the drainplug (see Fi...
Page 105 - Set screw must be removed.; Reversing Assembly
SECT IO N 6 6-11 T-268-07 2 1 3 4 5 Set screw must be removed. 1. Oil Pump & Bearing Head 2. Thrust Washer 3. Oil Pickup Tube 4. Oil Inlet Port 5. Oil Pump Inlet Figure 6-8. Oil Pump and Bearing Head If it was determined that the oil pump is not operatingproperly, the entire oil pump and bearing...
Page 106 - k. Since the stator cannot be replaced in the field, the; Figure 6-12. Removing Equalizing Tube and Lock
6-12 T-268-07 opening after the piston rings are compressed. Apiston ring compresser will facilitate removal. Each piston pin is locked in place by lock rings which aresnapped into grooves in the piston wall. 1 2 3 4 5 6 7 8 9 10 1. Capscrew 2. Cap 3. Crankshaft 4. Thrust Washer 5. Rotor Drive Key 6...
Page 107 - COMPRESSOR REASSEMBLY; Suction Valve Positioning Spring; a. Suction and Discharge Valves
SECT IO N 6 6-13 T-268-07 6.9 COMPRESSOR REASSEMBLY To clean compressor parts, use a suitable solvent with proper precautions. Coat all moving parts with theproper compressor oil before assembly. Refer toTable 6-5 for applicable compressor torque values. 1 2 3 1. Suction Valve 2. Suction Valve Posit...
Page 108 - If compressor is without oil:
6-14 T-268-07 Figure 6-16. Compressor Oil Pump End View 5. Align the gasket and install the eight capscrews in the mounting flange. Refer to Table 6-5 forapplicable torque values. 6. Install rotor with key. Screw on equalizer tube and lock screw assembly with lock washer and bend over tabs of lock w...
Page 109 - d. To Remove Oil From an 06DR Compressor:; and Gauge; High Pressure Switch
SECT IO N 6 6-15 T-268-07 suction service valve flange cavity or by removing theoil fill plug. (See Figure 6-5.) Some compressors have the oil plug located on the crankcase, at the right or leftside of the oil pump. d. To Remove Oil From an 06DR Compressor: 1. If the oil level recorded in step a.3 i...
Page 110 - manufacturer’s instructions.; EVAPORATOR COIL HEATERS; EVAPORATOR FAN AND MOTOR ASSEMBLY; To Replace the Evaporator Fan Assembly:; To disassemble the Evaporator Fan Assembly:
6-16 T-268-07 f. Open cylinder valve. Slowly close bleed-off valve to increase pressure on switch. The switch should open at a static pressure up to 25 kg/cm @ (350 psig). If a light is used, light will go out. If an ohmmeter isused, the meter will indicate open circuits. g. Slowly open bleed-off va...
Page 111 - To assemble the Evaporator Fan Assembly:; EVAPORATOR FAN MOTOR CAPACITORS; b. Removing the capacitor; If container is empty
SECT IO N 6 6-17 T-268-07 by holding the spanner wrench stationary andturning the 5/8-18 nut counter-clockwise (see Figure 6-18). 1 2 3 4 5 6 5 7 8 9 1. Stator 2. Flat washer, 1/4 3. Bolt, 1/4-20 x 3/4 4. Locknut, 5/8-18 5. Flat washer, 5/8 6. Impeller Fan 7. Key 8. Mylar Protector 9. Evaporator Mot...
Page 112 - c. Checking the capacitor; Capacitor analyzer; CONDENSER FAN AND MOTOR ASSEMBLY
6-18 T-268-07 WARNING With power OFF discharge the capacitor and disconnect the circuit wiring. c. Checking the capacitor If the capacitor is suspected of malfunction, you maychoose to simply replace it. Direct replacement requiresa capacitor of the same value. Two methods forchecking capacitor func...
Page 113 - c. Checking the Recording Thermometer Bulb
SECT IO N 6 6-19 T-268-07 (mounted to instrument case). A single probe is attachedto the element (bulb) capillary which senses the container return air temperature. If using two probes,one probe will be attached to the supply air temperaturesensor. In the event of a failure with the #344 test lead, ...
Page 114 - To replace the recording thermometer element:; SAGINOMIYA RECORDING THERMOMETER
6-20 T-268-07 raises stylus indicated temperature reading;shortening shaft (clockwise) lowers stylus reading. Then retighten set screw. (b) Reset control at 0 _ C (32 _ F), start the refrigeration unit and repeat accuracy check.After temperature stabilization, recordingthermometer should be within 0...
Page 115 - c. Replacing Sensor Probe; Indicator Test Switch; Figure 6-20. Saginomiya Recording Thermometer; MAINTENANCE OF PAINTED SURFACES
SECT IO N 6 6-21 T-268-07 4. If adjustment is required, loosen setscrew (cross-recessed head). Using a 7 mm wrench, rotate the adjustment screw clockwise to set the stylus 1 to2 _ C (1.8 to 3.6 _ F) higher than desired temperature. 5. Rotate the adjustment screw counterclockwise to set the stylus ab...
Page 116 - Do not cut the grommet.
6-22 T-268-07 completely immerse bulb) with ice cubes orchipped ice, then filling voids between ice with water and agitating until mixture reaches 0 _ C (32 _ F) measured on a laboratory thermometer. b. Start unit and check air temperature/data readout on the control panel. The reading should be 0 _...
Page 117 - Sensor
SECT IO N 6 6-23 T-268-07 Sensor 41 mm (1-5/8 inches) 6.35 mm (1/4 inch) Figure 6-22. Sensor (RRS, RTS, SRS or STS) f. Strip back insulation on all wiring 6.35 mm (1/4 inch). g. Slide a large piece of heat shrink tubing over the cable, and place the two small pieces of heat shrinktubing, one over ea...
Page 119 - a. Replacing the Coil; Enclosing Tube Collar; a. Coil Checkout Procedure
SECT IO N 6 6-25 T-268-07 6.24 SUCTION SOLENOID VALVE (SSV) a. Replacing the Coil NOTE The coil may be replaced without removing therefrigerant. 1. Disconnect leads by unplugging the connector. Remove snap cap or locknut. Lift off coil. (SeeFigure 6-27) 2. Verify coil type, voltage and frequency of ...
Page 120 - Solenoid Coil Sleeve; b. Replacing the Coil
6-26 T-268-07 Ambient Temperature Cold Coil 10 _ F 6.45 ohms 40 _ F 6.90 ohms 70 _ F 7.40 ohms 100 _ F 7.90 ohms 4. Plug in the connector for the modulation valve. NOTE A cold coil is a coil which has not beenoperating and is assumed to be at ambienttemperature. Hot coils, taken after the unit hasbe...
Page 121 - Body Flange Gaskets; b. Installing Expansion Valve; Figure 6-30. Thermostatic Expansion Valve Bulb; To Measure Superheat:
SECT IO N 6 6-27 T-268-07 6 2 5 3 7 1 4 1. Power Assembly 2. Body Flange Gaskets 3. Seat Gasket 4. Bulb 5. Cage Assembly 6. Body Flange 7. Body Flange Screws Figure 6-29. Thermostatic Expansion Valve -- Alco 5. The thermal bulb is located below the center of the suction line (4 o’clock position). Th...
Page 122 - b. Removing and Installing the; Make sure that; Programming Port; Figure 6-31. Controller side of the Control Box
6-28 T-268-07 NOTE Suction pressure must be 0.5 kg/cm @ (6 psig) below valve maximum operating pressure (M.O.P.). Example: if valve rated at 55 MOP,suction pressure must be below this MOP.Recommended pressure is below 3.44 kg/cm @ (49 psig). 6.27 CONTROLLER/DATACORDER a. Handling of Controller/DataC...
Page 123 - Programming; Procedure for loading Operational Software:
SECT IO N 6 6-29 T-268-07 NOTE This packaging has been designed to protect theController/DataCORDER module from bothphysical and electrostatic discharge damage during storage and transit. Installation: Install the module by reversing the steps in section6.27.b.Torque values for mounting screws (item...
Page 124 - Summary of Procedure:
6-30 T-268-07 circuits (refer to section 5). A description of the testpoints follows: NOTE Use a digital voltmeter to measure ac voltagebetween TP’s and ground (TP9), except forTP8. TP2 This test point enables the user to check if the internalprotector for the compressor motor (IP-CP) is open orclos...
Page 125 - Forced Circulation; Keep flames away from the vent
SECT IO N 6 6-31 T-268-07 7. Put unit back in service under normal load and check head (discharge) pressure. Detailed Procedure: 1. Drain and flush the water circuit of the condenser coil. If scale on the tube inner surfaces isaccompanied by slime, a thorough cleaning isnecessary before de-scaling p...
Page 126 - Put the unit back in service and operate under
6-32 T-268-07 NOTE If the condenser cooling water is not being usedas drinking water or is not re-circulated in aclosed or tower system, neutralizing is not necessary. 11. Put the unit back in service and operate under normal load. Check the head pressure. If normal, a thorough de-scaling has been a...
Page 131 - Ambient Air Temperature
SECT IO N 6 6-37 T-268-07 -- 6 -- 4 -- 2 0 2 4 6 8 10 12 14 60 70 80 90 100 110 120 Ambient Air Temperature psig _ F (Bar) (.97)(.83) (.69) (.55) (.41) (.28) (.14) (0) (-- .14) (-- .28) (-- .41) 0 _ _ _ _ F (--17.8 _ _ _ _ C) Box (48.9) (43.3) (37.8) (32.2) (26.7) (21.1) (15.6) ( _ _ _ _ C) 35 _ _ _...
Page 132 - INTRODUCTION; PLEASE REFER TO FILE
SEC TION 7 7-1 T-268-07 SECTION 7 ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS 7.1 INTRODUCTION PLEASE REFER TO FILE T--268 DIAGRAMS FOR SCHEMATICS AND DIAGRAMS
Page 133 - INDEX
INDEX INDEX Index-1 T-268-07 A Access Panel, 2-1 Air Makeup Vent Lower Fresh, 2-13 Upper Fresh, 2-13 Air--Cooled Condenser, 2-15, 2-17 Alarms Controller, 3-11DataCORDER, 3-28 DataCORDER Configurations, 3-29 Ambient Sensor, 2-6, 2-7 Arctic, 4-12 B Battery Pack, Controller/DataCORDER, 2-8, 2-9, 3-1 Bu...
Page 134 - Data
INDEX Index-2 T-268-07 Cooling Relay, 4-4, 4-6, 4-8, 4-12Current Sensor Module, 2-8, 2-9 D Data Electrical, 2-11 Refrigeration System, 2-10 DataCORDER, 3-24 Access to Functions, 3-29 Alarms, 3-27 Communications, 3-31 Configuration, 3-25 Function Codes, 3-26 Pre--Trip Data Recording, 3-31 Scrollback,...
Page 135 - Indicator
INDEX INDEX Index-3 T-268-07 H Heat Contactor, 2-8, 2-9, 3-15, 4-10, 4-12, 5-2Heat Exchanger, 2-3, 2-15, 2-17, 5-3Heat Relay, 3-15, 4-10, 4-12, 4-14, 4-15, 5-2Heater, 2-1 Alarm, 3-12 Compressor Crankcase, 2-4, 2-11, 6-9 Configuration Variable, 3-3 Drain Pan, 2-11 Evaporator Coil, 2-11, 6-16 Heater T...
Page 137 - Positioning
INDEX INDEX Index-5 T-268-07 S Safety and Protective Devices, 2-19Safety Summary General, Safety-1 Warning and Cautions, Safety-2 Sample, Standard Configuration Report, 3-34Schematic, Electrical Wiring and Diagrams, 7-1Schrader Valve, 2-6, 2-7Sensor Ambient, 2-6, 2-7, 3-6, 3-12, 3-14, 3-30, 6-24 Bul...
Page 138 - Valve
INDEX Index-6 T-268-07 U Unit, Remote Monitoring, 2-8Unit Operation, 4-2Unit Serial Number, 2-1Upper Fresh Air Makeup Vent, 2-13USDA, 2-3, 3-31, 3-32USDA Probe Receptacle, 2-3 V Vacuum Pump, 6-5, 6-7 Connections, 6-7 Valve Bulb, Expansion, 2-14, 2-16, 5-4, 6-27 Discharge Pressure Regulator, 2-6, 2-7...
Carrier 58CTA09010016
User Manual