ultima ultra multi-temp ultra xl extra optima with standard micro prior ...

LIST OF ILLUSTRATIONS (CONT’D)FigurePage1-28 Optima ---R-22 Refrigerant Circuit --- Cooling .................................. 1-361-29 Phoenix Ultra --- R-22 Refrigerant Circuit --- Heating and Defrosting ............... 1-381-30 Optima --- R-22 Refrigerant Circuit --- Heating and Defrosting .................... 1-381-31 R-404A Refrigerant Circuit --- Heating and Defrosting .......................... 1-394-1 Priming Fuel Pump ......................................................... 4-34-2 Speed Control Solenoid ..................................................... 4-44- Air Filter .................................................................. 4-54-4 Engine Crankcase Breather .................................................. 4-64-5 Mechanical Fuel Pump ...................................................... 4-64-6 Electric Fuel Pump (Optional) ................................................ 4-64-7 Belt Tension Gauge ......................................................... 4-74-8 V-Belt Arrangement ........................................................ 4-84-9 Removing V-Belt from Engine Adapter Drive Sheave (NDA or NDX) .............. 4-94-10 Removing V-Belt from Clutch (NDM) ......................................... 4-94-11 Standby Clutch Assembly (NDM) ............................................. 4-104-12 Gearbox Clutch ............................................................ 4-114-13 Vacuum Pump Connection ................................................... 4-134-14 Compressor Drive Assembly .................................................. 4-144-15 Pressure Switches HP-1 and HP-2 ............................................. 4-144-16 Oil Level in Sight Glass ...................................................... 4-154-17 Compressor ................................................................ 4-164-18 Unloader Solenoid Valve .................................................... 4-174-19 Compressor Unloader Valve --- Suction Cutoff .................................. 4-184-20 Check Valve --- Serviceable Type .............................................. 4-184-21 Typical Setup for Testing High Pressure Switch .................................. 4-194-22 Solenoid Valves --- Alco ...................................................... 4-204-23 Solenoid Valves --- Sporlan ................................................... 4-204-24 Defrost Air Switch Test Setup ................................................ 4-224-25 Evaporator/Condenser Fan Shaft Assembly (All Models Except Ultima) ............ 4-234-26 Evaporator/Condenser Fan Shaft Assembly (Ultima) ............................. 4-244-27 Thermostatic Expansion Valve ................................................ 4-254-28 Thermostatic Expansion Valve Bulb and Thermocouple .......................... 4-264-29 Phase Sequence Module ..................................................... 4-274-30 ULTIMA, PHOENIX ULTRA & EXTRA --- Unidrive Torque Requirements ........ 4-304-31 OPTIMA --- Unidrive Torque Requirements .................................... 4-315-1 NDA-94A Electrical Schematic Wiring Diagram ---Prior to S/N DAF90209263 --- Dwg. No. 62-02457 Rev. C .......................... 5-25-2 NDA-94A & NDA-94B Electrical Schematic Wiring Diagram ---Starting with S/N DAF90209263 --- Dwg. No. 62-02589 Rev A ...................... 5-45-3 NDA-94 Electrical Schematic Wiring Diagram ---Starting with S/N EAE90310998 --- Dwg. No. 62-03935 ............................ 5-65-4 NDM-94A EURO Electrical Schematic Wiring Diagram ---Prior to S/N EAE90310998 --- Dwg. No. 62-02590 ............................... 5-85-5 NDM-94 (EURO) Electrical Schematic Wiring Diagram ---Starting with S/N EAE90310998--- Dwg. No. 62-03936 ............................ 5-105-6 NDM-94A Electrical Schematic Wiring Diagram ---Prior to S/N EAE90310998 --- Dwg. No. 62-02620 ) .............................. 5-125-7 NDM-94 Electrical Schematic Wiring Diagram ---Starting with S/N EAE90310998 --- Dwg. No. 62-03937 .......................... 5-14v 62-02461

LIST OF TABLES (CONT’D)TablePage6-1 Multi-Temp Model Chart ...................................................... 6-16-2 Safety Devices --- Remote Evaporator ........................................... 6-26-3 Generator Voltage Output ..................................................... 6-76-4 2 Compartment Reversible Multi-Temp Logic Control ............................. 6-96-5 3 Compartment Reversible Multi-Temp Logic Control ............................. 6-106-5 3 Compartment Reversible Multi-Temp Logic Control ............................. 6-11vii 62-02461

9SECTION 1DESCRIPTION1.1 INTRODUCTIONTable 1-1. Model ChartRefrigerantEngine SpeedModels ElectricR-22 R-404A Compressor EngineHigh Low StandbyLB KG LB KGULTIMANDX-93D --- --- 26 11.8 05G 41 cfm CT4-134-DI 2200 1475 ---PHOENIX ULTRANDA-93A 05G 41 cfm 1900 ---NDA-93A Euro --- --- 26 11.8 05G 37 cfm 1700 ---NDM-93A Euro05G 37 cfm 1700 380V 50hzNDA-94A 05G 41 cfm CT4-134-TV TV 1900 1350 ---NDA-94A Euro05G 37 cfm1700---26 11.8 --- ---NDM-94A05G 37 cfm 1900 230V 60hzNDM-94A Euro 05G 37 cfm 1700 380V 50hzPHOENIX ULTRA XLNDA-93D 05G 41 cfm 1900 ---NDM-93D --- --- 26 11.8Euro05G 37 cfm 1700 380V 50hzNDA-94D 05G 41 cfm CT4-134-DI 1900 1350 ---NDM-94D05G 37 cfm1900230V 60hz26 11.8 --- ---NDM-94D05G 37 cfm 1700 380V 50hzEuroEXTRANDA-93E ---NDM-93E --- --- 26 11.8 05G 37 cfm CT4-114-TV TV 1700 1350 230V 60hzNDM-93E Euro380V 50hzNDA-94E ---NDM-94E 26 11.8 --- --- 05G 37 cfm CT4-114-TV TV 1700 1350 230V 60hzNDM-94E Euro380V 50hzOPTIMANDA-93B --- --- 21 9.53---05K CT4-91-TVO TVO 2200 1650NDA-94B 21.5 9.75 --- ------This manual contains Operating Data, Electrical Dataand Service Instructions for the refrigeration units listedin Table 1-1.WARNINGBeware of V-belts and belt driven components asthe unit may start automatically. Beforeservicing unit, make sure the Run - Stop switch isin the STOP position. Also disconnect thenegative battery cable.a. Model NDAThe unit is a one piece, self-contained, fully charged,pre-wired, refrigeration/heating “nosemount” dieselpowered unit for use on insulated trailers to maintaincargo temperatures within very close limits. Themodel/serial number plate is located inside of the unit ontherearframeasshowninFigure1-4.The evaporator fits into a rectangular opening in theupper portion of the trailer front wall. When installed,the evaporator section is located inside the trailer; andthe condensing section is outside and on the front of thetrailer.The condensing unit consists of an engine---compressordrive package, condenser fan, condenser coil, radiatorcoil, control panel, relay module, refrigerant controls,piping, wiring, defrost air switch, and associatedcomponents.The evaporator assembly consists of an evaporator coil,evaporator fan, expansion valve, two defrost thermostats1-1 62-02461

1.1.1 HEAT/COOL MODE(termination switches). The location of the thermostatsare shown in Figure 1-9. The return air sensor is alsoshowninFigure1-9.Heating is accomplished by circulating hot gas directlyfrom the compressor to the evaporator coil. Four electricsolenoid valves control the refrigerant circuit to operatethe heating/cooling system.Automatic evaporator coil defrosting is initiated byeither sensing the air pressure drop across the coil with adifferential air switch or with the defrost timer in themicroprocessor.The control door and relay module include manualswitches, microprocessor, ammeter, fuses, andassociated wiring. Also, the unit is equipped with aremote light bar as standard equipment. It is mountedseparately on the front roadside corner of the trailer.The temperature controller is a microprocessor solidstate controller (Refer to section 1.10). Once thecontroller is set at the desired temperature, the unit willoperate automatically to maintain the desiredtemperature within very close limits. The control systemautomatically selects high and low speed cooling or highand low speed heating as necessary to maintain thedesired temperature within the trailer.The refrigeration compressor used (Refer to Table 1-1) isequipped with Varipowr as standard equipment.Varipowr is used as a compressor capacity control tounload the compressor during periods of reduced loads.This provides closer temperature control, reducespotential for top freezing and reduces power required tooperate the compressor; thus reducing fuel consumption.The engine (Refer to Table 1-1) gives excellent fueleconomy and has easy starting characteristics. Theengine is equipped with spin-on lube oil and fuel oil filtersforeasierfilterchanges.NOTEThroughout this manual, whenever the “left” or“right” hand side of the engine is referred to, it isthe side as viewed from the flywheel end of theengine.The diesel engine drives the compressor directly througha nylon drive gear and adapter. The adapter also includesa V-belt sheave which drives the clutch/gearbox. Thecondenser/evaporator fan shaft is driven with a V-beltfrom the clutch/gearbox. A separate V-belt from theclutch/gearbox drives the alternator.Electrical power for the control system and for chargingthe batteries is provided by the 12 vdc alternator.Also the auto start/stop feature is standard equipment.The auto start/stop operation provides automatic cyclingof the diesel engine, which in turn offers an energyefficient alternative to continuous operation of theengine with control of temperature by alternate coolingand heating of the supply air (evaporator outlet air).b. Model NDMThe model NDM is similar to the model NDA except thatit contains a standby electric motor, standby motorcontactor and a receptacle for a power plug.The diesel engine drives the compressor directly througha centrifugal clutch, except during standby operation.During standby operation, the centrifugal clutch isdisengaged from the compressor sheave. The compressoris then belt driven by the standby motor.Table 1-2. Electric Standby Motor Data50HZ 60HZHorsepower 12hp 15hpVoltage 380 230Full Load Amps 17.6 35.6Lock Rotor Amps 137 298RPM 2935 3550230V CIRCUIT380V CIRCUITc. ModelNDMwithPhaseSequenceModuleSome NDM have a Phase Sequence Module (SeeFigure 1-12 & Figure 4-29). This phase sequence sensingsystem provides a safe method of automatically providingcorrectly phased 3 phase power to the unit. This featureallows the user to connect the unit to any three phasepower source of correct voltage and frequency withoutregard to the phase sequence of the power source.This module contains two electrically identical sectionsof circuitry, each connected to a different pair of phases.Depending on the phase sequence occurring at themodule inputs (X1, X2, H4 and 46), relay PR-1 or PR-2will be energized as required to effect correct phasing ofpower to unit.d. Model NDXThe model NDX is similar to the model NDA except thatthe evaporator extends into the trailer. The condensercoil/subcooler and radiator are combined. The clutch ismoved from gearbox to fan shaft.62-024611-2

91123234564758961. Condenser Pressure ControlSolenoid Valve (SV-1)2. Defrost Air Switch3. Receiver4. Receiver Sight Glass5. Filter-Drier6. Liquid Line Solenoid Valve (SV-2)7. Discharge Check Valve8. Model/Serial No. Location9. Battery LocationFigure 1-1. Curbside --- Ultima1. Condenser/Radiator2. Radiator Fill Neck3. Engine Air Cleaner4. Radiator Overflow Reservoir5. DataLinkRecorder---SeeFigure1-226. Control Box Door --- See Figure 1-10Figure 1-2. Roadside --- Ultima1-3 62-02461

1.1.1 HEAT/COOL MODE12223214520196789 10 11 12 13 14 15 16 17 181. King Valve2. Hot Gas Solenoid Valve - Large (SV-3)3. Hot Gas Solenoid Valve - Small (SV-4)4. Discharge Service Valve5. High Pressure Cutout Switch (HP-1)and Head Pressure Control Switch (HP-2)6. Unloader Solenoid Valve7. Compressor --- 05G8. Compressor Sight Glass9. Suction Pressure Transducer (SPT)10. Suction Service Valve11. Fuel Filter12. By-pass Oil Filter13. Oil Drain14. Starter Motor15. Lube Oil Fill16. Lube Oil Filter17. Oil Pressure Switch18. Relay Module --- See Figure 1-1119. Injection Pump20. Fuel Bleed Valve21. Speed Control Solenoid22. Air Cleaner Service IndicatorFigure 1-3. Front View --- Ultima62-024611-4

91. Condenser Pressure ControlSolenoid Valve (SV-1)2. Defrost Air Switch3. Receiver4. Receiver Sight Glass5. Filter-Drier6. Liquid Line Solenoid Valve (SV-2)7. Quench Valve --- R-22 Only8. Battery9. Model/Serial No. LocationFigure 1-4. Curbside --- Phoenix Ultra1. Engine Air Cleaner2. Radiator Overflow Reservoir3. Radiator Fill Neck4. Radiator5. Control Box Door --- See Figure 1-10Figure 1-5. Roadside --- Phoenix Ultra1-5 62-02461

1.1.1 HEAT/COOL MODE1. King Valve2. Hot Gas Solenoid Valve - Large (SV-3)3. Hot Gas Solenoid Valve - Small (SV-4)4. DischargeLineCheckValve5. Discharge Service Valve6. Compressor Discharge TemperatureSensor (CDT)7. Unloader Solenoid Valve8. High Pressure Cutout Switch (HP-1)and Head Pressure Control Switch (HP-2)9. Compressor --- 05G10. Compressor Sight Glass11. Suction Service Valve12. Suction Pressure Transducer (SPT)13. Fuel FilterFigure 1-6. Front View --- Phoenix Ultra14. Starter Motor15. Oil Drain16. Lube Oil Fill17. Mechanical Fuel Pump18. Lube Oil Filter19. Oil Pressure Switch20. Relay Module --- See Figure 1-1121. Injection Pump22. Fuel Bleed Valve23. Speed Control Solenoid24. Alternator and Regulator25. Clutch/Gearbox26. Air Cleaner Service Indicator27. Ambient Temperature Sensor (ATS)62-024611-6

91. King Valve2. Hot Gas Solenoid Valve (SV-3)3. Hot Gas Solenoid Valve (SV-4)4. Bypass Oil Filter5. Fuel Filter6. DischargeLineCheckValve7. Unloader Solenoid Valve8. High Pressure Cutout Switch (HP-1)and Head Pressure Control Switch (HP-2)9. Compressor --- 05K10. Starter Motor11. Speed Control Solenoid12. Oil Dipstick13. Oil Pressure Switch14. Lube Oil Filter15. Oil Drain16. Relay Module --- See Figure 1-1117. Fuel Bleed Valve18. Lube Oil Fill19. Clutch/Gearbox20. Alternator and Regulator21. Air Cleaner Service Indicator22. Ambient Temperature Sensor (ATS)Figure 1-7. Front View --- Optima1-7 62-02461

1.1.1 HEAT/COOL MODE1 231. Standby Electric Box (See Figure 1-12)2. Standby Motor3. Power ReceptacleFigure 1-8. Front View --- NDM-9462-024611-8

9165341. Evaporator Fan2. Expansion Valve3. Heat Exchanger --- R404A Only24. Return Air Sensor5. Defrost Termination Thermostats6. Supply Air Sensor (If Used)Figure 1-9. Evaporator Section --- Panels and Grille Removed1231. Fault Light2. Standby Power Light (PL) --- Model NDM3. Run-Stop SwitchFigure 1-10. Control Box Door6544. Selector Switch (SSW) --- Model NDM5. Keypad Door6. Microprocessor Control Panel (See Figure 1-19)1-9 62-02461

1.1.1 HEAT/COOL MODE4 5 6GPRSSRFHRRRURRFRARRDERHR2ORHR4SRDRHR3HR171UFRDB1 DB2 DB3STARTING with S/N DAF902092634 5 6GPRSSRRRURRFRARRDERHR2ORFHR23SRUFRDR HR3 HR1DB1 DB2 DB37PRIOR to S/N DAF902092631. Ammeter2. Manual Glow/Crank Switch3. Buzzer4. Starter Solenoid Relay (SSR) andGlow Plug Relay (GPR)5. Fuses - F1 (80A), F3 (25A), F4 (15A), F5 (7.5A)F6, F9 (5A)6. Relays, Run (RR), Diesel Electric (DER), Speed (SR)Unloader Front (UFR), Unloader Rear (URR),Heat (HR1, HR2, HR3 & HR4), Defrost (DR),Fault (FR), Out-of-Range (OR), Auto Restart (ARR),Fuel Heater (FHR)7. Diode, Block (DB1, DB2 & DB3)Figure 1-11. Relay Module62-024611-10

943112 2200V/50hz230V/60hz380V/50hz4331165652PHASE REVERSAL 200V/50hz230V/60hz1. Motor Contactor (MC)2. Motor Overload (MOL)3. Transformer (TR)PHASE REVERSAL 380V/50hz4. Motor Contactor Relay (MCR)5. Overload (OL)6. Phase Reversal Circuit Board2Figure 1-12. Standby Electric Box1-11 62-02461

1.2 ENGINE DATA1.1.1 HEAT/COOL MODEEngine ModelsCT4-134TV CT4-134DI CT4-114TV CT4-91TVO(V2203TV) (V2203DI)(V1903)(V1505)Used on Ultra Ultra XL/Ultima Extra OptimaDisplacement 2.2 liters (134 in 3 ) 2.2 liters (134 in 3 ) 1.8 liters (113 in 3 ) 1.5 liters (91.4 in 3 )No. Cylinders 4 4 4 4Horsepower34 hp @1900 rpm 33 hp@1900 rpm 24 hp @1700 rpm 24.5 hp @ 2200 rpm25 hp @ 1350 rpm 35 hp@2200 rpm 20 hp @1350 rpm 20 hp @ 1650 rpmWeight 189.5 kg (417.8 lbs) 110 kg (242.5 lbs)Coolant Capacity7.6liters(2gallons)ThermostatStarts to open 157to 162_F (69to72_C) fully open185_F (85_C)Starts to open 177 to 182_F (81 to 83_C)fully open 203_F (95_C)Oil Capacity with Filter14 liters (15 quarts)13.2 liters(14 quarts)Injection Setting140 to 150 kg/cm 2 (1991 to 2133 psi)Fuel Winter: Diesel No. 1 Summer: Diesel No. 2Firing Order 1 --- 3 --- 4 --- 2 1 --- 3 --- 4 --- 2 1 --- 3 --- 4 --- 2 1 --- 3 --- 4 --- 2Glow Plug Amperage7.0 amps per plug at 10.5 vdc (nominal)Valve Clearance (Cold)(Intake and Exhaust)0.0071 to 0.0087 inch (0.18 to 0.22 mm)a. Lubrication SystemOil Pressure:40 to 60 psig (2.8 to 4.2 kg/cm@)(Engine in high speed)Oil Pressure Safety Switch Setting Closes:15 ( ¦ 3) psig (1.05 kg/cm@)Lube Oil Viscosity:Outdoor TemperatureFahrenheit CentigradeSAEBelow 32_ 0_C 10W or 15W4032_ to 77_F 0_ to 25_C 20W or 15W40Over 77_F Over +25_C 30W or 15W40Oil Change Intervals:First 400 hours, thereafter as listed below.CAUTIONThe maximum oil change interval is 1 year (foreither approved oil). The only approvedsynthetic lube oil is Mobil Delvac 1. The normaloil change intervals (listed below) should bereduced if the equipment is operated underextreme conditions such as in dirtyenvironments.ENGINEAPIClass CD(Hours)MOBILDELVAC 1(Hours)TV 1500 3000DI 2000 40001.3 COMPRESSOR DATACompressorModels05G05KNo. Cylinders 6 4No. Unloaders 2 1Weight 62 kg (137 lbs) 49 kg (108 lbs)Oil Charge 2.8 L (6.0 pints) 2.6 L (5.5 pts)APPROVED COMPRESSOR OILRefrigerant 05G 05KR-22Zerol 150(synthetic) Suniso 3GSP/N 07-00274R-404A Mobil Arctic EAL 681.4 REFRIGERATION SYSTEM DATAa. Defrost Air SwitchInitiates Defrost:1.40 (¦ .07) inch (35 ¦ 1.8 mm) WGb. Defrost Timer1-1/2, 3, 6, or 12 hoursc. Defrost ThermostatsOpens: 50 ¦ 5_F (10¦ 3_C)Closes: 40 ¦ 5_F (4.4 ¦ 3_C)d. Expansion Valve SuperheatSetting at 0_F (---17.8_C) box temperature:62-024611-12

MODELUltima, Phoenix Ultra,Ultra XL, ExtraOptimaSETTING8to10_F (4.4to5.6_C)5to8_F (2.8to4.5_C)e. Fusible Plug Setting208 to 220_F (97.8_ to 104.4_C)f. Head Pressure Control Switch (HP-2)Phoenix Ultra, Extra & Optima:Cutout: 350 ¦ 10 psig (24.6 ¦ 0.7 kg/cm@)Cut-in: 290 ¦ 10 psig (20.4 ¦ 0.7 kg/cm@)Ultima:Cutout: 300 ¦ 10 psig (21.1 ¦ 0.7 kg/cm@)Cut-in: 200 ¦ 10 psig (14.1 ¦ 0.7 kg/cm@)g. High Pressure Switch (HP-1)Prior to S/N EAD90304846:Cutout: 428 ¦ 10 psig (30 ¦ 0.7 kg/cm@)Cut-in: 320 ¦ 10 psig (22.5 ¦ 0.7 kg/cm@)Starting with S/N EAD90304846:Cutout: 465 ¦ 10 psig (32.7 ¦ 0.7 kg/cm@)Cut-in: 350 ¦ 10 psig (24.6 ¦ 0.7 kg/cm@)h. Refrigeration ChargeRefer to Table 1-1i. Gearbox OilMobil SHC 75---90W: 15ozj. Fanshaft OilMobil SHC 630: 3.2ozk. Unit Weights (Approximate)Ultima: 1665 lb. (755 kg)Phoenix Ultra: 1610 lb. (730 kg)Extra: 1610 lb. (730 kg)Optima: 1435 lb (651 kg)Low engine lubricating oilpressure91.5 SAFETY DEVICESSystem components are protected from damage causedby unsafe operating conditions by automatically shuttingdown the unit when such conditions occur. This isaccomplished by the safety devices listed in Table 1-3.The quench valve (R-22 Only) opens as required tomaintain a 265 to 285_F (129 to 141_C) dischargetemperature. Should this valve fail, the compressordischarge temperature sensor (CDT) will shut the unitdown if center compressor head discharge temperaturereaches 310_F (154_C)for3minutesor350_F (177_C) .If ambient temperature sensor (ATS) is at 120_F(49_C)or higher, the CDT limits are increased to 340_F (171_C)for 3 minutes.1.6 ENGINE SCREW THREADSAll threads used on the diesel engine are metric.1.7 ENGINE AIR SYSTEMThe air cleaner is put on the engine to prolong its life andperformance by preventing dirt and grit from getting intothe engine causing excessive wear on all operating parts.However, it is the responsibility of the operator to givethe air cleaner equipment regular and constant attentionin accordance with the instructions. (Refer to section4.3.4)Clean air is supplied to the engine through the air cleaner(See Figure 1-5). The air is necessary for completecombustion and scavenging of the exhaust gases. As theengine piston goes through the intake stroke, the pistondraws clean fresh air down into the cylinder for thecompression and power strokes. As the engine goesthrough its exhaust stroke, the upward movement of thepiston forces the hot exhaust gases out of the cylindersthrough the exhaust valves and the exhaust manifold. Ifthe air filter is allowed to become dirty, the operation ofthe engine would be impaired.Table 1-3. Safety DevicesUnsafe Conditions Safety Device Device SettingOil pressure safety switch (OP)(microprocessor reset)Water temperature sensor(microprocessor reset)Fuse (F1)Opens below 15 ¦ 3psig(2.1 ¦ 1.2 kg/cm@)Refer to section 1.11.3High engine cooling watertemperatureExcessive current draw by glow plug circuit,Opens at 80 ampscontrol circuit or starter solenoid (SS)Excessive current draw by control circuit Fuse (F3) Opens at 25 ampsExcessive current draw by speed control Fuse (F4)Opens at 15 ampssolenoid, front or rear unloaderExcessive current draw by SV3, auto restart or Fuse (F5)Opens at 7 1/2 ampsout-of-range lightsExcessive current draw by microprocessor Fuse (F9) Opens at 5 ampsExcessive compressorHigh pressure cutout switch Refer to section 1.4.g.discharge pressure(HP-1) automatic resetExcessive compressorRefer to section 1.5discharge temperatureCompressor dischargetemperature sensor (CDT)(microprocessor reset)Excessive current draw by standby motor Overload Protector (MOL) Opens at 21.5 amps1-13 62-02461

1.1.1 HEAT/COOL MODE1.8 LUBE OIL AND FUEL FLOW DIAGRAMS121131098475, 61. Fuel Tank7. Fuel Bleed Valve2. Fuel Supply Line 8. Injection Pump3. Fuel Pump9. Injector Nozzles4. Mechanical10. Fuel Leak-off LineLift Pump --- Ultra 11. Fuel Return Line5. Fuel Filter6. Fuel Warmer(Optional)Figure 1-13. Fuel System Diagram123 41. Engine Block2. Oil Pan3. Full Flow Oil Filter4. Bypass Oil Filter (Optional)5. Engine Oil Connection6. Oil Pressure SwitchFigure 1-14. Lube Oil Flow Diagram1.9 COMPRESSOR UNLOADERSThis section contains two compressor unloader systems:the first one is hot gas bypass and the second is suctioncutoff. They are easily distinguished from each other byobserving the bottom side of the compressor cylinderhead, it is either blank (hot gas bypass) or has a coverplate (suction cutoff). The unit operates the same withboth unloader systems.561.9.1 Unloading in Temperature ModeThe compressor is equipped with unloaders(electronically controlled by the microprocessor) forcapacity control.The capacity controlled cylinders are easily identified bythe solenoid which extends from the side of the cylinderhead. When the solenoid is energized the cylindersunload. The unloaded cylinders operate with little or nopressure differential, consuming very little power. Ade-energized solenoid reloads the cylinders.NOTES1. The unloader relay is locked in for aminimum of 2 minutes once it is energizeddue to suction pressure.2. There is a delay of 30 seconds betweende-energizing one unloader tode-energizing the other unloader.There are two modes of unloader operation,temperature control and suction pressure control.a. Temperature Control Within 1.4_F (0.8_C)of Set Point1. Cool light (CL) or heat light (HL) illuminated(depending on mode of operation).2. If in low speed cooling, unloader relays (UFR, orUFR & URR) may energize to unload compressorbanks. Refer to Table 1-43. Theheatmodeforcestherearunloader(UR)toaloaded condition (de-energized) for dieseloperation. In low speed heating, front unloader relay(UFR ) energizes to unload compressor bank.Table 1-4. Unloading in Temperature ModeSETPOINTBELOW10_F ( --- 12_C)SETPOINTABOVE10_F ( --- 12_C)ULTIMA, PHOENIX ULTRA or EXTRACool High Speed 6Cool High Speed 6Cool Low Speed 4Cool Low Speed 2Heat Low Speed 4Cool Low Speed 6 Heat Low Speed 6Cool Low Speed 4 Heat High Speed 6OPTIMACool High Speed 4Cool High Speed 4Cool Low Speed 2Heat Low Speed 2Heat Low Speed 4Cool Low Speed 2 Heat High Speed 462-024611-14

. Perishable Cooling Unloader ControlDieselDuring perishable cooling the unloaders are energizedwhen the temperature approaches setpoint. If a supplyprobeispresenttheunloadersareenergizedwhenthesupply temperature decreases 5.4_F (3_C) belowsetpoint. It will stay unloaded until the supplytemperature rises above setpoint. If a supply probe is notpresent the unloaders are energized when the returntemperature decreases more than 9_F (5_C) abovesetpoint. It will stay unloaded until the returntemperature rises more than 14.4_F (8_C) abovesetpoint. With software revision 2.10 or higher the returnprobe logic is disabled for ambient temperature higherthan 90_F (32.2_C).StandbyDuring perishable cooling the unloaders are energizedwhen the control temperature reaches less than 2_F(1.1_C) above setpoint. The unloaders stay energizeduntil the control temperature reaches 2.5_F (1.4_C)above setpoint.c. Perishable Heating Unloader ControlDieselDuring perishable heating the front unloader isenergized when the control temperature increases to0.9_F (0.5_C) below setpoint. The unloader will stayenergized until the control temperature decreases to1.5_F (0.8_C) below setpoint.Note: These switch points may vary slightly dependingonthe amount of overshoot around setpoint.StandbyDuring perishable heating the unloaders are energizedwhen the control temperature increases to 1.5_F (0.8_C)below setpoint. The unloaders will stay energized until thecontrol temperature decreases to 2_F (1.1_C) belowsetpoint.Note: During standby operation the unit may energizeboth the front and rear unloaders in heat(2 cylinders).d. Frozen Unloader ControlDieselFor units with UltraFreeze refer to section 1.13.For units without UltraFreeze during frozen mode,heating is not allowed. The front unloader is energizedwhen the control temperature decreases to 1.5_F (0.8_C)above setpoint. The unloader will stay energized untilthecontrol temperature reaches 2_F (1.1_C) above setpoint.Note: During frozen mode only the front cylinder can beunloaded.StandbyFor units with UltraFreeze refer to section 1.13.For units without UltraFreeze during frozen mode,heating is not allowed. The front unloader is energizedwhen the control temperature decreases to 2_F (1.1_C)above setpoint. The unloader will stay energized until thecontrol temperature reaches 2.5_F (1.4_C) abovesetpoint.1.9.2 Suction Pressure Operation - Diesel EngineThe microprocessor will monitor suction pressure of therefrigeration system and control the unloaders tomaintain a maximum operating pressure. A suction9pressure transducer is used to signal the microprocessorwhen to load or unload the compressor.When the compressor is fully loaded it is operating on 6cylinders. When the front unloader UL1 is unloaded(energized), the unit operates on 4 cylinders. When UL1and the rear unloader UL2 are unloaded (energized), theunit operates on 2 cylinders. The front unloader, UL1,always unloades before the rear unloader, UL2.During the diesel heating and defrosting cycles, the rearunloader is locked out (loaded), forcing the compressorto always operate with at least four cylinders loaded.a. R-22 Refrigeration SystemAt ambient temperatures of 90_F (32.2_C) or belowWhen the system is operating in high speed and thesuction pressure is greater than 53 psig, both unloadersare unloaded. As the suction pressure drops below 52psig, the UL2 unloader is loaded. If the suction pressuredrops below 26 psig, the UL1 unloader is loaded.When the system is operating in low speed and the suctionpressure is greater than 56 psig, both unloaders areunloaded. As the suction pressure drops below 55 psig,the UL2 unloader is loaded. If the suction pressure dropsbelow 21 psig, the UL1 unloader is loaded.At ambient temperatures of 90_F (32.2_C) or higherAt ambient temperatures of 90_F or higher the unloadingsuction pressure settings relative to ambienttemperatures are a straight line.(Refer to chart below)SUCTIONPRESSURE(PSIG)R-22 DIESEL OPERATIONSUCTION PRESSURE UNLOADING60LOW SPEED (UL2)55504540353025HIGHSPEED(UL2)HIGH SPEED (UL1)20LOW15 SPEED10(UL1)80 90 100 110 120 130AMBIENT TEMPERATURE (_F)UL1 = FRONT UNLOADER, UL2 = REAR UNLOADERABOVE THE LINE = UNLOADED, BELOW THE LINE = LOADEDb. R-404A Refrigeration SystemAt ambient temperatures of 90_F (32.2_C) or belowWhen the system is operating in high speed and thesuction pressure is greater than 64 psig, both unloadersare unloaded. As the suction pressure drops below 64psig, the UL2 unloader is loaded. If the suction pressuredrops below 33 psig, the UL1 unloader is loaded.1-15 62-02461

1.1.1 HEAT/COOL MODEWhen the system is operating in low speed and the suctionpressure is greater than 65 psig, both unloaders areunloaded. As the suction pressure drops below 64 psig,the UL2 unloader is loaded. If the suction pressure dropsbelow 35 psig the UL1 unloader is loaded.At ambient temperatures of 90_F (32.2_C) or higherAt ambient temperatures of 90_F or higher the unloadingsuction pressure settings relative to ambienttemperatures are a straight line.(Refer to chart below)SUCTIONPRESSURE(PSIG)R-404A DIESEL OPERATIONSUCTION PRESSURES UNLOADING7065605550454035302520HIGHSPEED(UL2)LOW SPEED (UL1)HIGHSPEED(UL1)LOW SPEED (UL2)1580 90 100 110 120 130AMBIENT TEMPERATURE (_F)UL1 = FRONT UNLOADER, UL2 = REAR UNLOADERABOVE THE LINE = UNLOADED, BELOW THE LINE = LOADED1.9.3 Suction Pressure Operation - StandbyThe microprocessor will monitor suction pressure of therefrigeration system and control the unloaders tomaintain a maximum operating pressure. A suctionpressure transducer is used to signal the microprocessorwhen to load or unload the compressor.When the compressor is fully loaded it is operating on 6cylinders. When the front unloader UL1 is unloaded(energized), the unit operates on 4 cylinders. When UL1and the rear unloader UL2 are unloaded (energized), theunit operates on 2 cylinders. The front unloader, UL1,always unloades before the rear unloader, UL2.During the heating and defrosting cycles, the lowestpressure unloader is not locked out (loaded). This willallow the compressor to fully unload in standby.a. R-22 Refrigeration SystemAt ambient temperatures of 90_F (32.2_C) or belowWhen the system is operating and the suction pressure isgreater than 29 psig, both unloaders are unloaded. As thesuction pressure drops below 28 psig, the UL2 unloader isloaded. If the suction pressure drops below 10 psig, thethe UL1 unloader is loaded.At ambient temperatures of 90_F (32.2_C) or higherAt ambient temperatures of 90_F or higher the unloadingsuction pressure settings relative to ambienttemperatures are a straight line.(Refer to chart below)SUCTIONPRESSURE(PSIG)R-22 STANDBY OPERATIONSUCTION PRESSURES UNLOADING35302520151050REAR UNLOADERFRONT UNLOADER--- 580 90 100 110 120 130AMBIENT TEMPERATURE (_F)ABOVE THE LINE = UNLOADED, BELOW THE LINE = LOADEDb. R-404A Refrigeration SystemAt ambient temperatures of 90_F (32.2_C) or belowWhen the system is operating and the suction pressure isgreater than 57 psig, both unloaders are unloaded. As thesuction pressure drops below 56 psig, the UL2 unloader isloaded. If the suction pressure drops below 26 psig, thethe UL1 unloader is loaded.At ambient temperatures of 90_F (32.2_C) or higherAt ambient temperatures of 90_F or higher the unloadingsuction pressure settings relative to ambienttemperatures are a straight line.(Refer to chart below)SUCTIONPRESSURE(PSIG)R-404A STANDBY OPERATIONSUCTION PRESSURES UNLOADING60REAR UNLOADER5550454035302520FRONT UNLOADER1580 90 100 110 120 130AMBIENT TEMPERATURE (_F)ABOVE THE LINE = UNLOADED, BELOW THE LINE = LOADED62-024611-16

1.9.4 Hot Gas Bypass Unloadera. Major Working Parts1. Solenoid and valve system2. Spring loaded piston type bypass control valve3. Spring loaded discharge check valveb. Unloaded OperationPressure from the discharge manifold (Figure 1-15, item15) passes through the strainer (9) and bleed orifice (8) tothe back of the piston bypass valve (7). Unless bled away,this pressure would tend to close the piston (6) againstthe piston spring (5) pressure.With the solenoid valve (1) energized the solenoid valvestem (2) will open the gas bypass port (3).Refrigerant pressure will be bled to the suction manifold(10) through the opened gas bypass port . A reduction inpressure on the piston bypass valve will take placebecause the rate of bleed through the gas bypass port isgreater than the rate of bleed through the bleed orifice (8).When the pressure behind the piston has been reducedsufficiently, the valve spring will force the piston bypassvalve back, opening the gas bypass from the dischargemanifold to the suction manifold.Discharge pressure in the discharge manifold will closethe discharge piston check valve assembly (14) isolatingthe compressor discharge manifold from the individualcylinder bank manifold.The unloaded cylinder bank will continue to operate fullyunloaded until the solenoid valve control device isde-energized andthegasbypassportisclosed.45 7 112 3 618914151012139c. Loaded OperationDischarge pressure bleeds from the discharge manifold(Figure 1-16, item 15) through the strainer (9) and (8)bleed orifice to the solenoid valve stem (2) chamber andthe back of the piston bypass valve (7).With the solenoid valve (1) de-energized the solenoidvalve stem will close the gas bypass port (3).Refrigerant pressure will overcome the bypass valvespring (5) tension and force the piston (6) forward closingthe gas bypass from the discharge manifold to the suctionmanifold (10).Cylinder discharge pressure will force open the dischargepiston check valve assembly (14). Refrigerant gas willpass into the compressor discharge manifold.The loaded cylinder bank will continue to operate fullyloaded until the solenoid valve control device isenergized and the gas bypass port is opened.45 7 112 3 6114151. Solenoid Valve2. Valve Stem3.GasBypassPort4. Spring Guide5. Spring6. Piston7. Piston Bypass Valve8. Bleed Orifice9. Strainer10. Suction Manifold9810121311. Cylinder DischargeValve12. Valve Plate13. Cylinder SuctionValve14. Discharge PistonCheck ValveAssembly15. Discharge ManifoldFigure 1-16. Compressor Cylinder Head LoadedHot Gas Bypass1. Solenoid Valve2. Valve Stem3.GasBypassPort4. Spring Guide5. Spring6. Piston7. Piston Bypass Valve8. Bleed Orifice9. Strainer10. Suction Manifold11. Cylinder DischargeValve12. Valve Plate13. Cylinder SuctionValve14. Discharge PistonCheck ValveAssembly15. Discharge ManifoldFigure 1-15. Compressor Cylinder Head UnloadedHot Gas Bypass1-17 62-02461

1.1.1 HEAT/COOL MODE1.9.5 Suction Cutoff Unloadera. Major Working Parts1. Solenoid and valve system2. Unloader piston assembly3. Spring and cover plateb. Unloaded OperationWhen the unloader valve solenoid energizes, the capacitycontrol valve port opens (item 3, Figure 1-17). Thisallows the discharge gas behind the unloader pistonassembly (item 4) to vent back to the suction side. Theunloader valve spring (item 7) at this point, can move theunloader valve body to the left, blocking the unloadersuction port. The cylinder bank is now isolated from thecompressor suction manifold to unload these twocylinders. No refrigerant is allowed into the cylinders andno compression takes place.c. Loaded OperationWhen the unloader valve solenoid de-energizes, thecapacity control valve port closes (item 3, Figure 1-18).This allows discharge pressure to build-up behind theunloader piston assembly. The high pressure willcompress the unloader valve spring, opening theunloader suction port. Suction gas can now be drawn intothe cylinders, running the bank fully loaded.2 3 4 5 6 7 812 3 4 5 6 7 8116151413SUCTION PRESSURE1. Solenoid Valve2. Coil3. Capacity ControlValve (Closed)4. Unloader Piston5. Unloader Head6. Body7. Spring8. Cover Plate12DISCHARGE PRESSURE11109. Suction Manifold10. Suction Valve11. Piston12. Discharge Valve13. Discharge Manifold14. Valve Plate15. Strainer16. Bleed OrificeFigure 1-18. Compressor Cylinder Head (Loaded)Suction Cutoff9161514131211109SUCTION PRESSUREDISCHARGE PRESSURE1. Solenoid Valve2. Coil3. Capacity ControlValve (Open)4. Unloader Piston5. Unloader Head6. Body7. Spring8. Cover Plate9. Suction Manifold10. Suction Valve11. Piston12. Discharge Valve13. Discharge Manifold14. Valve Plate15. Strainer16. Bleed OrificeFigure 1-17. Compressor Cylinder Head (Unloaded)Suction Cutoff62-024611-18

91.10 MICROPROCESSOR CONTROLLERCOOL HEAT DEFROST START/STOP IN-RANGE HI AIR-20 34.5° FSETPOINTBOX TEMPERATUREFUNCTIONCHANGEENTERUNITDATAPRETRIPCHECKAUTO S/SCONTINUOUSMANUALDEFROSTFigure 1-19. Microprocessor Control Panel1.10.1INTRODUCTIONThe microprocessor controller is housed in the controlpanel on the lower roadside corner of the unit. Thiscontroller consists of 2 control boards and a relay module:1. The Processor Board includes the microprocessor,program memory, and necessary input/outputcircuitry to interface with the unit.2. The Display Board is mounted in the same controlbox as the processor board. The display boardincludes the LCD display, keypad and keypadinterface.3. The Relay Module contains replaceable relays, diodeblocks and fuses along with the wiring harness.The microprocessor is totally self-contained and does notcontain any serviceable components.CAUTIONUnder no circumstances should anyone attemptto repair the Logic or Display Boards! (seesection 4.29) Should a problem develop withthese component, contact your nearest CarrierTransicold dealer for replacement.The Carrier Transicold microprocessor controllerincorporates the following features:a. Control supply or return air temperature to tightlimits by providing refrigeration control, heat anddefrost to ensure conditioned air delivery to the load.b. Dual independent readouts of set point and supplyor return air temperatures.c. Digital readout and ability to select data. Refer toTable 1-5 for Function Code and Table 1-6 for UnitData.d. For alarm digital display identification refer toTable 1-7.e. A pre-trip checkout of refrigeration unit operation.Refer to section 1.10.8f. A self-test check on program memory and datamemory. The self-test is executed each time thesystem is switched from “Stop” to “Start.” Errors, ifany, shall be indicated on the display as a ERR.X,where X is a number corresponding to the number ofthe test. The unit shall display this error for 5 secondsand then reset the micro.ERRORERR.1ERR.2ERR.3ERR.4 orDisplayCAUSEProcessor failureCheck chip installation or Replacemicroprocessor.Display board to logic boardcommunication failure.This can be caused by a defectiveribbon cable or ribbon cable notplugged in properly.g. A communication link to transmit unit operationaldata to a remote computer. Refer to section 1.10.121.10.2KEYPADThe keypad has 8 keys which will allow the operator toinitiate various functions, display operating data andchange operating parameters.Arrow KeysThe keypad has UP and DOWN Arrow keys which areused to modify (increment or decrement) the setpointselection or modify the displayed data.1-19 62-02461

1.1.1 HEAT/COOL MODEEnter KeyThe ENTER key is used to accept a change in unitparameters or a change in setpoint.Manual Defrost KeyThe MANUAL DEFROST key is used to initiate adefrost cycle, given that the proper conditions are met(Refer section 1.10.10).Pretrip Check KeyThe PRETRIP CHECK key is used to initiate a pretripcycle, given that the proper conditions are met (Refer tosection 1.10.8).Auto Start/Stop Continuous KeyNOTEWith software revision 3.08 or 3.12 whenconfiguration CNF11 is “ON” and setpoint is 32to 42_ F (0 to 5.5_C) the unit is locked intocontinuous run. Start/Stop Continuous key isdisabled.The START/STOP CONTINUOUS key is used tochange the operating mode from “auto start/continuousrun” to “auto start/stop.” Each push of the key willalternate the operating modes. The operating status willbe stored in memory and will be retained through poweroutages. The digital display will indicate when stop/startis enabled (Also See Section 1.10.11).To start the unit in manual start mode, the START/STOPCONTINUOUS selection must be in continuous runmode.Function Change KeyThe FUNCTION CHANGE key is used to display theoperating parameters. Each time this key is pressed thedisplay will advance to the next parameter. This key, inconjunction with the UP/DOWN Arrow and ENTERkeys, will allow the user to change the parameters (SeeSection 1.10.5).Unit Data KeyThe UNIT DATA key is used to display the unit operatingdata. This key, in conjunction with the UP/DOWN Arrowkeys, will allow the user to display the unit’s operatingdata values (i.e, coolant temperature, battery voltage,etc.) (See Section 1.10.6).1.10.3SETPOINTSetpoints of --- 22_Fto+86_F ( --- 30_Cto+30_C) may beentered via keypad. The controller always retains the lastentered setpoint in memory. If no setpoint is in memory(i.e., on initialstartup), the controller will lock out the runrelay and flash “SP” on the left hand display until a validsetpoint is entered.The setpoint may be changed up or down in wholenumbers until the desired setpoint is displayed. Thedisplay will flash to indicate that the setpoint readingbeing displayed is a non-entered value. Each time theUP/DOWN Arrow key is pressed, the 5 second displaytimer will be reset.Depressing the ENTER key will cause the new displayedsetpoint value to become active. If the display is flashingand the new value is not entered, after 5 seconds of nokeyboard activity, the display will revert back to theactive setpoint.1.10.4DIGITAL DISPLAYThe digital display has 9 digits. The default display issetpoint on the left and controlled air temperature on theright. The readout is keypad selectable for Degrees C orDegrees F.Also digital displays are provided to indicate thefollowing modes: COOL, HEAT, DEFROST,IN-RANGE, HI AIR, START/STOP.On each power-up, the unit will display a Display Test for5 seconds then display the default reading.1.10.5FUNCTIONAL PARAMETERSNOTEIf configuration CNF11 is “ON” functionalparameters are lockout. The ability to changefunctional parameters from keypad are disabled.The functional parameters will control selectedoperating features of the unit. These parameters can bedisplayed by pressing the FUNCTION CHANGE key.All functional parameters are retained in memory. Thefollowing sections describe the list of functions which canbe modified via the keypad. A description of the functionwill be displayed on the left side with the correspondingdata on the right side. The function parameter list can bescrolled through by pressing the FUNCTION CHANGEkeyorbyusingtheUP/DOWNArrowkeys.WitheachFUNCTION CHANGE key push, the list will beadvanced one. If the function key is pressed and held forone second, the list will be advanced one item at a time.This list will be circular, meaning once the end of the list isreached the list will go to the first entry. While thefunctional parameter is displayed, the data can bechanged by pressing ENTER then pressing either the UPor DOWN Arrow keys. If the value is changed, thedisplayed data will then flash to indicate that the valuehas not been entered. If the new value is not entered in 5seconds, the display will revert back to the last enteredvalue. If the ENTER key is pressed, the display will stopflashing to indicate that the value has been entered. Thenew value will continue to be display for 5 seconds beforereverting back to the default display. Each time a key ispressed, the 5 second delay will be reset. To select adifferent functional parameter the FUNCTIONCHANGE key must be pressed first.Code Vs English MessagesThe description messages of the functional parameters,unit status and alarms can be displayed in English orCodes through this function selection. The two choiceswill be displayed as, ENGLISH or CODES. With thisparameter set to CODES, all display descriptions will beset to their code display. This parameter will not changedue to this selection. Refer to each section for thealternate display description.62-024611-20

Manual Glow OverrideThe auto start glow time can be manually overriddenthrough this function. The messages is displayed asNORM GLOW or ADD GLOW. If the ADD GLOWselection is entered, the control will add 30 seconds ofglow to the glow times listed in section 1.10.11. Thisfeature must be selected before the 3 start attempts havebeen completed. At higher ambients, this override willonly affect the second or third start attempt. The addglow time is deselected when the engine starts or fails tostart. This parameter will not change due to the Code vsEnglish selection.Alarm ResetAlarms can be reset through this function. The messagesare displayed as ALARM RST or ALARM CLR. If theALARM RST is displayed then there is at least one alarmpresent. Pressing the ENTER key will clear all the alarmspresent. If the ALARM CLR is displayed then there areno alarms present. See section 1.10.7. This parameter willnot change due to the code vs English selection.Table 1-5. Function CodesCODE ENGLISH DATAFN0 DEFR Defrost IntervalFN1 ON HIGH High Air FlowAIRFN1 OFF NORM Norm Air FlowAIRFN2 OFF T Off-timeFN3 ON T On-timeFN4 AREM Controlling Probe ---PROBE Return AirFN4 BSUP Controlling Probe ---PROBE Supply AirFN5Degrees Temperature UnitForC _C or_FFN6 ONTIME Maximum Off-time 30STRT Min.FN6 OFFTEMP Temperature BasedSTRT RestartingFN7 MOP STD Future ExpansionFN8 2SET Compartment 2 SetpointFN9 3SET Compartment 3 SetpointFN10 ON AUTO OP Auto Start OperationFN10 MAN OP Manual Start OperationOFFFN11 T RANGE Out-of-Range ToleranceCode vs English = Code or English display formatManual Glow Override = Normal or Add 30secAlarm Reset = Alarm Reset or No AlarmsDefrost IntervalThe defrost interval is displayed with the descriptionDEFR or FN0. The data for the interval will be displayedwith one decimal place and then the capital letter H forhours (i.e., DEFR 12.0H). The defrost intervals are 1.5,3,6or12hours.9AirflowThe status of the speed control solenoid override isdisplayed as HIGH AIR or NORM AIR. The codedisplay is FN1. The high air setting is “ON” and theNORM AIR setting is “OFF.” If the display shows HIGHAIR, the unit is locked into high speed for setpointsabove 10_F.Off-TimeThe off-time selection for the auto start mode isdisplayed with the description OFF T or FN2. Theoff-times are 10, 20, 30, 45 or 90 minutes. The data for theoff-time will be displayed with two digits and then thecapital letter M for minutes (i.e. OFF T 20M).On-TimeThe on-time selection for the auto start mode is displayedwith the description ON T or FN3. With software revisionless than 3.11 the on-times are 4 or 7 minutes. Withsoftware revision 3.11 or higher the on-time is 4 minutes.The data for the on-time will be displayed with two digitsand then the capital letter M for minutes (i.e. ON T 4M).Controlling ProbeThe number of controlling probes is displayed with thefollowing abbreviations: REM PROBE for a single probe(return air) control; SUP PROBE for a dual probecontrol (return and supply air). The code display is FN4.The 1-probe setting is “A” and the 2-probe setting is “B.”Standard Units SelectThe standard unit select will control how all parametersare displayed. The two choices are DEGREES F andDEGREES C. This parameter also will control units thatdata is displayed in psig or bars (i.e, Degrees F or DegreesC). The code display is FN5. The selections are “F” or“C.”Maximum Off TimeThe description for the maximum off time is TEMPSTRT OR TIME STRT. The code display is FN6 and theselections are “ON” or “OFF.” “ON” corresponds toTIME STRT. With the unit in time start, the control willforce the engine to restart 30 minutes after shutoff.MOP STD --- Future ExpansionThis function is not used at this time. The display is FN7.Compartment 2 SetpointSetpoints of --- 22_F ( --- 30_C) to +86_F(+30_C) may beentered through this function for the secondcompartment. The setpoint function will be displayedwith the abbreviated description 2SET. The code displayis FN8. The setpoint may be changed up or down in wholenumbers until the desired setpoint is displayed. Thedisplay will flash to indicate that the setpoint readingbeing displayed is a non-entered value. Each time the UPkey or the DOWN key is pressed, the 5 second displaytimer will be reset. Depressing the ENTER key will causethe new displayed setpoint value to become active. If thedisplay is flashing and the new value is not entered, after 5seconds of no keyboard activity, the display will revertback to the active setpoint. The update rate is once every0.5 seconds if the UP or DOWN keys are held down.1-21 62-02461

9Supply Air TemperatureThe supply air temperature is displayed with thedescription SAS or CD5. The data is displayed with onedecimal place and the proper unit designator, Degree Cor Degree F (i.e. SAS 85.0F). The display range is ---36_Fto 158_F ( --- 38_C to 70_C). This unit data will bedisplayed only if the SUP PROBE is selected in thecontrolling probe functional parameter.Remote Air TemperatureThe remote air temperature is displayed with thedescription REM or CD6. The data is displayed with onedecimal place and the proper unit designator, Degree Cor Degree F (i.e. REM 85.0F). The display range is--- 36_F to 158_F ( --- 38_Cto70_C). This unit data will bedisplayed only if the REM PROBE is selected in thecontrolling probe functional parameter.Ambient TemperatureThe ambient temperature is displayed with thedescription ATS or CD7. The data is displayed with onedecimal place and the proper unit designator, Degree Cor Degree F, (i.e. ATS 85.0F) . The display range is ---36_Fto 158_F ( --- 38_Cto70_C). If there is no sensor, then thedisplay will read --- --- --- for the data.Evp --- Future ExpansionThis unit data is not used at this time. The Code display isCD8.Compressor Discharge TemperatureThe compressor discharge temperature is displayed withthe description CDT or CD9. The data is displayed withthe proper unit designator, Degree C or Degree F, (i.e.CDT 85F) . The display range is ---40_F to 392_F ( --- 40_Cto 200_C). If there is no sensor, then the display will read--- --- --- for the data.Battery VoltageThe battery voltage is displayed with the descriptionBATT or CD10. The data is displayed with one decimalplace and then the capital letter V for volts (i.e, BATT12.2V or CD10 12.2V). The voltage reading is displayedwith a “+” plus sign if the battery status is high enough toallow unit shut down in “Auto Start/Stop”.Standby HoursThe number of electric motor hours are displayed withthe description SBY or CD11. The data is displayed inhours and units designator H (i.e, SBY 5040H or CD115040H). The display range is 0 to 99999.Mod V --- Future ExpansionThis unit data is not used at this time. The Code display isCD12.Software RevisionThe Eprom software revision number is displayed withthe description REV or CD13 on the left and Epromsoftware revision number on the right side. Pressing theENTER key for 3 seconds will display REV U2 on the leftand the board mounted software revision number on theright side.Serial Number LowThe low serial number of the unit is displayed with thedescription SERL or CD14. The data is the lower 3 digitsof the serial number burned in to the Eprom. (i.e, SERL504 or CD14 504).Serial Number UpperThe upper serial number of the unit is displayed with thedescription SERU or CD15. The data is the upper 3 digitsof the serial number burned in to the Eprom. (i.e, SERH001 or CD15 001).Compartment 2 Air TemperatureThe air temperature for the second compartment will bedisplayed with the abbreviated description 2RA on theleft-hand side. The code display is CD16. The data will bedisplayed with one decimal place and the proper unitdesignator, Degree C or Degree F (i.e. 2RA85.0F).Compartment 3 Air TemperatureThe air temperature for the second compartment will bedisplayed with the abbreviated description 3RA on theleft-hand side. The code display is CD17. The data will bedisplayed with one decimal place and the proper unitdesignator, Degree C or Degree F (i.e. 3RA85.0F).Maintenance Hour Meter 1The maintenance hour meter 1 setting is displayed withthe description MHR1 or CD18. The maintenance hourmeter is compared to one of the hour meters (diesel,standby, or switch on) determined by its mode. If the hourmeter is greater than the maintenance hour meter analarm will be generated.Maintenance Hour Meter 2The maintenance hour meter 2 setting is displayed withthe description MHR2 on the left side or CD19. Themaintenance hour meter is compared to one of the hourmeters (diesel, standby, or switch on) determined by itsmode. If the hour meter is greater than the maintenancehour meter an alarm will be generated.Switch On Hour MeterThenumberofswitchonhoursisdisplayedwiththedescription SON or CD20 (i.e. SON 2347H or CD202347H). The display range is 0 to 99999.1-23 62-02461

1.1.1 HEAT/COOL MODE1.10.7ALARM DISPLAYThe fault light (FL) is turned on only for alarms thatspecify it. The default display will be overridden if a alarmis generated. When an alarm is generated, the display willalternate the default display (setpoint/air temperature)and the active alarm(s). Each item will be displayed for 3to 10 seconds, and will continue to scroll through the list.See section 1.10.5 for the procedure on resetting alarms.Table 1-7. Alarm DisplayCODE ENGLISH ALARM DESCRIPTIONAL0 ENG OIL Low Oil PressureAL1 ENG HOTHigh CoolantTemperatureAL2 HI PRESS High PressureAL3 STARTFAIL Auto Start FailureAL4 LOW BATT Low Battery VoltageAL5 HI BATT High Battery VoltageAL6 DEFRFAIL Defrost OverrideAL7 ALT AUX Alternator AuxiliaryAL8 STARTER Starter MotorAL9 RA SENSOR Return Air SensorAL10 SA SENSOR Supply Air SensorAL11WT SEN-SORAL12 HIGH CDTAL13 CD SENSORAL14SBY MO-TORCoolant TemperatureSensorHigh DischargeTemperatureDischarge TemperatureSensorMotor OverloadAL15 FUSE BAD FuseAL17 DISPLAY DisplayAL18 SERVICE 1 Maintenance Hour Meter 1AL19 SERVICE 2 Maintenance Hour Meter 2AL20OUTRANGEMain CompartmentOut-of-rangeAL21 2RA OUT Remote Compartment 2Out-of-rangeAL22 3RA OUT Remote Compartment 3Out-of-rangeAL23 CLUTCH Clutch Failure =FAULTLIGHTONLow Oil Pressure AlarmThe low oil pressure alarm is displayed with thedescription ENG OIL or AL0. This alarm is generated ifthe control senses low oil pressure under the properconditions. The fault light (FL) is turned on. Engine willshut down.High Coolant Temperature AlarmThe high coolant temperature alarm is displayed with thedescription ENG HOT or AL1. This alarm is generated ifthe control senses a high coolant temperature 230 to240_F (110 to 116_C) for 5 minutes or immediately ifover 240_F (116_C). The fault light (FL) is turned on andengine will shut down.High Pressure AlarmThe high pressure alarm is displayed with the descriptionHI PRESS or AL2. This alarm is generated if the highpressure switch opens. The fault light (FL) is turned onand engine will shut down.Start Failure AlarmThe start failure alarm is displayed with the descriptionSTARTFAIL or AL3. This alarm is generated if theengine fails to start. The fault light (FL) is turned on.If function MAN OP (manual start mode) is selected thestart failure alarm will be generated if the engine fails tostart in 5 minutes.Low Battery Voltage AlarmThe low battery voltage alarm is displayed with thedescription LOW BATT or AL4. This alarm is generatedif the battery voltage falls below 10 vdc. The fault light(FL) is turned on and engine will shut down.High Battery Voltage AlarmThe high battery voltage alarm is displayed with thedescription HI BATT or AL5. This alarm is generated ifthe battery voltage is above 17 vdc. The fault light (FL) isturned on and engine will shut down.Defrost Override AlarmThe defrost override alarm is displayed with thedescription DEFR FAIL or AL6. This alarm is generatedif the unit is in a defrost override mode (See Section1.10.10).Alternator Auxiliary AlarmThe alternator auxiliary alarm is displayed with thedescription ALT AUX or AL7. This alarm is generated ifthe alternator auxiliary signal is not present with theengine running. (See Section 1.10.11) The fault light (FL)is turned on.Starter Motor AlarmThe starter motor alarm is displayed with the descriptionSTARTER or AL8. This alarm is generated if the startermotor input signal is not present with starter solenoidenergized. The fault light (FL) is turned on.ReturnAirSensorAlarmThe return air sensor alarm is displayed with thedescription RA SENSOR or AL9. This alarm isgenerated if the return air sensor is open or shorted. Thefault light (FL) is turned on if the unit shuts down becausethere is no controlling probe.Supply Air Sensor AlarmThe supply air sensor alarm is displayed with thedescription SA SENSOR or AL10. This alarm isgenerated if the supply air sensor is open or shorted. Thisalarm will be disabled if the REM PROBE is selected inthe controlling probe functional parameter.62-024611-24

Coolant Temperature Sensor AlarmThe coolant temperature sensor alarm is displayed withthe description WT SENSOR or AL11. This alarm isgenerated if the coolant temperature sensor is open orshorted.Compressor Discharge Temperature AlarmThe compressor discharge temperature alarm isdisplayed with the description HIGH CDT or AL12. Thisalarm is generated and unit shuts down if thetemperature is sensed above 310_ Ffor3minutes.Ifthedischarge temperature exceeds 350_ F, the 3 minutetimer will be overridden and the unit shut downimmediately. If ambient temperature sensor (ATS) is at120_F (49_C) or higher, the CDT limits are increased to340_F (171_C) for 3 minutes. The fault light (FL) isturned on.Compressor Discharge Temperature Sensor AlarmThe compressor discharge temperature sensor alarm isdisplayed with the description CD SENSOR or AL13.This alarm is generated if the sensor is open or shorted.Standby Motor Overload AlarmThe standby motor overload alarm is displayed with thedescription SBY MOTOR or AL14. This alarm isgenerated when the MOL input is sensed open with theRun Relay energized in electric mode (Diesel/ElectricRelay energized).Fuse AlarmThe fuse alarm is displayed with the description FUSEBAD or AL15. This alarm is generated when the FUSEinput is sensed low. The fault light (FL) is turned on. Theengine will shut down.Display AlarmWhen no communications exist between the main boardand the display board for 8 seconds, the display alarmdescription is DISPLAY or AL17Maintenance Hour Meter 1 AlarmThe maintenance hour meter alarm 1 is displayed withthe description SERVICE 1 or AL18. This alarm isgenerated when the designated hour meter is greaterthan maintenance hour meter 1.Maintenance Hour Meter 2 AlarmThe maintenance hour meter alarm 2 is displayed withthe description SERVICE 2 or AL19. This alarm isgenerated when the designated hour meter is greaterthan maintenance hour meter 2.Out-of-Range AlarmThe out-of-range alarm is displayed with the descriptionOUT RANGE or AL20. This alarm is generated whenthe main compartment is out-of-range refer to section1.10.5. The fault light (FL) is turned on.Remote Compartment 2 Out-of-range AlarmThe Code display is AL21. This alarm is generated whenthe remote compartment 2 is out-of-range refer tosection 1.10.5. The fault light (FL) is turned on.Remote Compartment 3 Out-of-range AlarmThe Code display is AL22. This alarm is generated whenthe remote compartment 3 is out-of-range refer tosection 1.10.5. The fault light (FL) is turned on.9Clutch AlarmThe clutch alarm is displayed with the descriptionCLUTCH or AL23. This alarm is generated if the clutchfails.1.10.8PRE-TRIPThe PRETRIP key is for checking unit operation andevaluating operation of all modes and indicating a failurewhen detected. The following details the sequence :a. Unit operating and box temperature is below 40_F(4.4_C).b. Operator presses the PRETRIP key. If the defrostthermostat (DTT) is closed, the controller will display“PPPP.” If DTT is open, no response --- end of test.c. Controller displays “PPPP” Pre-trip mode is started.d. After 30 seconds in high speed cool, unit cycles to lowspeed loaded cool.e. After 30 seconds, unit cycles to low speed unloadedcool.f. After 30 seconds, unit cycles to low speed unloadedheat.g. After 30 seconds, unit cycles to low speed loadedheat.h. After 30 seconds, unit cycles to high speed heat anddisplays coolant temperature.i. After 30 seconds, unit cycles to high speed cool anddisplays defrost interval selected for 30 seconds, thenunit cycles to defrost if DTT is closed.j. After standard defrost cycle, Pre-trip is terminatedand unit returns to normal operation.1.10.9HEAT/COOL MODEThere are two control ranges, Frozen and Perishable. TheFrozen range is active with set points at or below +10_F( --- 12_C) and the Perishable range is active at set pointsabove +10_F ( --- 12_C).The system is configured for cooling mode for enginestart and during the oil pressure delay.Hot gas heating is applied by energizing the HR1 andHR2 relays which will energize the hot gas solenoids.These relays will also control the remote heat and coollights.For units with UltraFreeze refer to section 1.13.For units without UltraFreeze heating is locked out ofoperation at setpoint temperatures less than +10_F( --- 12_C) except during defrost.Default ModeFor units with UltraFreeze refer to section 1.13.When in frozen range (setpoint at or below +10_F), unitshall default to low speed loaded if a loss of control (badsensor) is detected. Since electric driven units have nolow speed, the default in the frozen range shall be highspeed cooling unloaded. When in perishable range(setpoint above +10_F), the unit shall shut down. Theproper alarm indication shall be displayed when thismode is active.1-25 62-02461

1.1.1 HEAT/COOL MODE1.10.10 DEFROST CYCLEDefrost is an independent cycle overriding cooling andheating functions to de-ice the evaporator as required.The controller displays “DF” during defrost mode on theright hand temperature display. The left hand display willcontinue to display the setpoint.a. Defrost Timer InitiationA defrost timer initiation is a keyboard selection (Referto Section 1.10.5). The defrost timer is reset to zerowhenever a defrost cycle is initiated. The controller holdsin memory the last entered defrost interval.b. Defrost Air Switch InitiationAn external defrost signal (DA) may be supplied as a setof normally open switch contacts closing to initiate thedefrost cycle.c. Manual Defrost InitiationThe defrost cycle may be initiated by pushing theMANUAL DEFROST key.d. Defrost FunctionThe defrost mode is initiated upon expiration of thedefrost timing interval with the presence of a signal fromthe defrost termination thermostat (DTT). It may also beinitiated by the presence of a momentary manual defrostsignal. Defrost may also be initiated by an externaldefrost signal from a device such as an air switch. Thedefrost mode terminates when the defrost terminationthermostat (DTT) opens indicating the defrost cycle iscomplete. The defrost timer runs only when the DTT isclosed. The defrost interval timer resets to zero whendefrost is initiated by any means. The timer does notaccumulate time during defrost mode, during standby offcycles or auto-start off cycles.A defrost output is energized during defrost mode tode-energize the clutch to prevent hot air circulation to theload.In addition, the heating outputs (SR, HR1 & HR2) areenabled to apply high-speed heat for hot gas heating.The compressor operates at maximum capacity on dieseland diesel/electric units during defrost. The suctionpressure signal can force the unloaders to be unloaded.e. Fail safe Defrost TerminationShould the defrost cycle not complete within 45 minutesor if the external defrost signal does not clear at defrosttermination, the defrost cycle is terminated. The internaltimer is reset for 1.5 hours and the external defrost signalis ignored for defrost initiation. The manual defrostswitch will override this mode and start a new 45 minutecycle. When defrost override is active, the appropriatealarm will be indicated. If the run relay is de-energizedduring defrost, defrost will be terminated.f. Defrost Termination at Low SpeedThe defrost terminates with HR1 and speed relayde-energizing. HR2 will turn off 2 seconds later. Thedefrost output will de-energize 5 seconds after HR1 toengage the clutch. If the temperature control requireshigh speed, it will energize 2 seconds after defrost relay isde-energized.1.10.11 AUTO START/STOP OPERATIONAutomatic start/stop is provided to permitstarting/restarting of the diesel-driven compressor asrequired. This feature fully enables automatic control ofthe diesel engine starting and stopping. The mainfunction of automatic engine cycling is to turn off therefrigeration system near setpoint to provide a fuelefficient temperature control system and to initiate arestart sequence after conditions are met. Systemshut-off is allowed only if the battery condition signal isgood. The engine coolant temperature shall override theminimum off time and out-of-range condition to forceengine restarting when the engine coolant temperaturedrops below 34_ F(1_C). A restart will also be initiated ifthe battery voltage falls below 11.0 Vdc. A restart will alsobe initiated if box temperature is more than 11_F (6_C)from set point.NOTEWith software 3.11 or higher the unit will remainin low speed for 10 minutes after engine start-upwhen: Auto Start/Stop is at any setpoint orContinuous Run setpoint is below 10_F( --- 12_C).a. Start/Stop --- ContinuousNOTEWith software 3.08 or 3.12 when configurationCNF11 is “ON” and setpoint is 32 to 42_ F(0to5.5_C) the unit is locked into continuous run.Start/Stop Continuous key is disabled.A key is provided to select between continuous run andauto start/stop operating mode. In the continuous runmode, the diesel engine will not shut down except forsafeties or if the engine stalls. This function also apply tothe operation of the electric motor.b. Auto Mode IndicatorThe “Auto Start/Stop” indicator is lit and ARL light willbe on to indicate the start/stop mode has been selected.c. Auto Start FailureIf the unit fails to start, shuts down on a safety, or fails torun for the minimum run time, three consecutive times,the “Auto Start/Failure” is activated.d. Continuous Run ModeIn continuous run mode, the engine is started but notallowed to shut off except for safeties or if the enginestalls.e. Auto Start SequenceWhen the starting conditions are met, the start sequencewill begin by energizing the run relay, and after 5 secondsenergize the glow plug relay (GPR) to supply power to theglow plugs, unit with buzzer will sound for 5 seconds thanthe starter is energized. On initial power-up, the controlwill delay 5 seconds before the starting sequence begins.If the required glow time is zero, the control will energizethe starter after a 5 second delay. After a period of time ,the starter solenoid (SS) is energized to crank the engine.The engine will crank for 10 seconds or until engineoperation is sensed by the alternator signal. The glowrelay will be de- energized after the auxiliary input issensed on. A 15 second null cycle will elapse beforesubsequent start attempts. The run relay will remainenergized until the next starting sequence.62-024611-26

Before the next starting sequence, the oil pressure ischecked to determine if the engine is running and thealternator auxiliary has failed. For the second and thirdstart attempts the glow time is increased by 5 secondsover the glow time of the first attempt listed below. Thecontrol allows three consecutive start attempts beforethe starting is locked out and the start failure alarm isactivated.REPEAT “A”+ 5 SecondsGLOW15 SecondsSTOPREPEAT “A”+ 5 SecondsGLOW15 SecondsSTOPMAXIMUM10 SecondsChecked at2 SecondsCRANKVARIABLE0to30SECONDSGLOWGLOWTHIRDATTEMPTSECONDATTEMPTFIRSTATTEMPT “A”Figure 1-20. Auto Start Sequencef. Variable Glow TimeTheglowtimeforthefirststartattemptwillvaryinduration based on engine coolant temperature and theengine as follows:9Engine Coolant Temperature Glow TimeGlow Time in Sec-Ambient TemperatureondsTV DILess than 32_F (0_C) 15 5533_F to50_F (1_C to10_C) 10 4051_F to77_F (11_C to25_C) 5 25Greater than 78_F (26_C) 0 10The second and third start attempts have a glow time thatis 5 seconds greater than the table amount. The glow timecan be manually overridden through the functionparameters. If the coolant temperature sensor isdefective the control assume a temperature of less than32_F (0_C) for the glow timing.g. Minimum On TimeThe engine is allowed to turn off only after a minimum of4 or 7 minutes of run time with software revision less than3.11. With software revision 3.11 or higher the on-time is4minutes.After the minimum on-time, the unit will go to fullyloaded for setpoints greater than 10_F ( --- 12_C) and highspeed loaded for setpoints of 10_F ( --- 12_C) or less.The unit will not cycle off if the engine coolanttemperature is less than 122_F (50_C) or the battery isnot good. If the unit can not cycle off, it will operatenormally in continuous mode. If all temperature probesfail and the setpoint is 10_F ( --- 12_C) or less, the unit willnot shut down.The unit will shut down when the box temperature iswithin ¦0.5_F(¦0.3_C) of setpoint for setpoints in thePerishable range or +0.5_F (+0.3)abovesetpointforsetpoints in the Frozen range.h. Minimum Off-TimeKeypad provision is provided to select the minimumoff-time of 10, 20, 30, 45 or 90 minutes.After the minimum off-time, the unit will restart fortemperatures beyond ¦3.6_F (¦2.0_C) of setpoint forthe Perishable range or above +3.6_F (+2.0_C) ofsetpoint for the Frozen range.The minimum off-time is overridden if the temperatureis more than ¦11_F (¦6_C) from setpoint.i. Battery VoltageProvisions are made to sense when the battery is good. Agood battery is defined as having 13.4v at 75_F. Thiscondition is used to allow shut- off of the diesel engine.1-27 62-02461

1.1.1 HEAT/COOL MODEIf the battery voltage falls below 10v during glow cycle, thestarter will not engage and the start sequence willcontinue, this is considered a failed start. The startsequence will be repeated until the unit starts or threeconsecutive start attempts have failed.MessageDisplayLOWBATTAL4HI BATTAL5Table 1-8. Battery VoltagesVoltageDescriptionLevel10or Less11 to13.417ormoreUnit will shut down exceptduring cranking.If the unit has cycled off in autostart/stop mode and batteryvoltage drops below 11.0 volts,the unit is automatically startedto charge battery. Unit willoperate until a battery voltage of13.4 volts is obtained at whichlevelunitwillstopiftemperatures are satisfied.Unit will shut down.j. Oil Pressure SignalWhen the oil pressure switch is closed it shows that theengine is running and prevents engagement of the startermotor when operating in the auto mode.k. Maximum Off-TimeProvision for a keypad selectable feature is providedwhich will cause the engine to be started 30 minutes afterthe engine has stopped regardless of the boxtemperature.1.10.12 Remote Monitoring - DataTrak (Optional)The microprocessor controller is equipped with a RS232communication port. This port can be used tocommunicate unit operating data to a mobile satellitetransmitter. This information will then be relayed back tothe office via a modem to a computer.There are presently three (3) protocols supported. Theprotocol for the QualComm transmitter, the protocol forthe HUGHES transmitter, and Carrier CommunicationProtocol. The microprocessor will power up and transmita HUGHES protocol packet and continue to transmit apacket every hour. The microprocessor will transmit inthe Carrier, QualComm protocol if a data packet isrequested.1.11 SWITCHES AND CONTROLS1.11.1 IntroductionComponents required for monitoring and controlling thediesel engine --- refrigeration system are located in thecontrol box door and relay module. The watertemperature sensor is located on top of the engine.1.11.2 Control Box Door and Relay Module(See Figure 1-10 and Figure 1-11)a. Gauges1. Ammeter Gauge (A)The d-cammeter indicates the rate of charge or dischargeof the battery charging system (including batteries),battery charging alternator and the voltage regulator.b. Switches1. Run-Stop Switch (RS)When placed in the RUN position, this switch providespower to the microprocessor. The microprocessorperforms a self-test (all segments of display areilluminated). Then Set Point and Box Temperature aredisplayed.To stop the unit or remove power from themicroprocessor, move the run-stop switch to the STOPposition.2. Manual Glow/Crank Switch (MGC)The manual glow/crank switch when held in the GLOWposition, energizes (approximately 7.5 amps per plug at12 vdc) the glow plugs in the engine to pre-heat thecombustion chamber. The CRANK position of the switchis used to manually engage the engine starter.3. Selector Switch (SSW) ---Model NDMThis switch is used to select mode of operation, eitherengine drive or standby electric motor drive. When thisswitch is placed in standby position, the electric motorwill not start until the oil pressure safety switch (OP)opens.1.11.3 Location of Engine Safety Devicesa. Oil Pressure Safety Switch (OP)This switch, set to open below 15 ¦ 3 psig (1.0 ¦ 0.2kg/cm@), will automatically stop the engine upon loss ofoil pressure. See Figure 1-6 for location.b. Water Temperature Sensor (WTS)This sensor senses engine water temperature. Themicroprocessor will stop the unit when this temperatureexceeds 230_F (110_C). If ambient temperature sensor(ATS) is at 120_F (49_C) or higher, the WTS limits areincreased to 230 to 240_F for 5 minutes or immediatelyover 240_F (116_C). The sensor is located near thethermostat housing in the cylinder head.1.12 ULTRAFRESH 2 TEMPERATURE CONTROLUltraFresh 2 temperature control algorithm is a methodof producing a reduced capacity state between heat andcool modes. This is done by combining a null pulse witheither heat or cool. The capacity in this band can vary byadjusting the duty cycle of the null portion of operation.During this null operation heat and cool valves areopened simultaneously to reduce heating or coolingcapacity.UltraFresh 2 temperature control uses both supply andreturn air sensors to achieve control. If both probes arepresent and neither is defective or out of range theselected probe is the active probe. The controlling probe62-024611-28

9will switch depending on if the unit has pulled down tosetpoint yet. During pulldown the controllingtemperature is from the active probe. When not inpulldown mode the controlling temperature is supply airplus an integrator error which is based on the selectedcontrolling (active) probe Again the 60_F exceptionoccurs. When not in pulldown mode and the setpoint is>= 60_F the active probe is used for control andintegration .There are three possible modes for UltraFresh 2 control.These are heat, cool and null. To enter COOL the controltemperature must be greater than or equal to 1_Cabovesetpoint. To exit cool and enter NULL the controltemperature must be less than 0.8_C abovesetpoint.Toexit NULL and enter HEAT the control temperaturemust be more than or equal to 1_C below setpoint and toexit heat and enter NULL the control temperature mustbe less than 0.8_ below setpoint. (See Figure 1-21).Null mode operates with a pulse, which combines coolingor heating with a null valve combination over a 10 secondperiod. The null valve portion of the period is defined asHR1, HR3, and HR4 de-energized and HR2 energized.The calculated pulse percentage determines the type ofpulse needed and the percentage of the 10 second periodto pulse. At the end of each period the type of pulse andpercentage is updated.When in the null mode: The HEAT and COOL LCD’s onthe microprocessor display will blank out. The heat andcool lights (on light bar) will flash back and forth every 10seconds or less.UltraFresh 2 only operates when: Setpoint is in theperishable range above10_F ( --- 12_C) and the unit is setfor continuous run operation.If ambient is 10_F ( --- 12_C) andthe supply air probe is present/valid, and supplytemperature is setpoint, (afterhaving been unloaded), allow the normal temperaturecontrol algorithm to control the unloaders. If the supplyair probe is not present/not valid, then use the return airtemperature and energize the unloader solenoids at(setpoint --- 5_C), allowing a 3_C bandabovesetpointbefore de-energizing the unloaders.There is a delay of 10 seconds between de-energizing oneunloader to de-energizing the other unloader under alloperating conditions excluding engine starting.1.13 ULTRA FREEZE TEMPERATURE CONTROLWITH SOFTWARE 3.11 OR HIGHERFor frozen setpoints, a modified Ultra Fresh 2temperature control is used to keep the unit from overcooling. Ultra Freeze operates the same as Ultra Fresh 2except as noted in this section. Ultra Freeze control willbe used anytime a frozen setpoint is selected in bothdiesel and standby units, in both continuous andstart/stop operation. When in standard multi-temptemperature control Ultra Freeze is used to control themaincompartmentifithasafrozensetpointselected.Ultra Freeze operates independently of the setting ofCNF-15.IfUltraFreezeisactivetheUltraFresh2unloadercooling logic is not invoked.a. Ultra Freeze OffsetIn continuous run a ---3_F offset is added which will forcethe unit to control to 3_F below setpoint. When the unitdemands high speed cool and the high speed is delayedthe unit will be allowed to run 6 cylinder low speed cool.b. Ultra Freeze Start/StopIn start/stop operation the unit’s control will not have the3_F offset and will control to setpoint by cycling the uniton and off according to the standard frozen modestart/stop startup and shutdown logic. The exception tothis is when a low battery voltage or low engine coolanttemperature defeats the normal shutdown logic, then theUltra Freeze logic will control to the 3_F below setpointoffset.c. Ultra Freeze Main Compartment Heat ModeThe main compartment is limited to 2 cylinder low speedheat. If either or both of the remote compartments areenabled and the main compartment goes to heat mode theremotes are immediately forced to null mode, no heat orcool.d. Ultra Freeze Main Compartment / RemotesControlWhen the main compartment is either heating or coolingThe remote compartments can override both the speedand unloaders. If a remote goes to cooling the unloaderswill be de-energized. If the remote then requests highspeed the unit will go to high speed with no delays. If aremote goes to heat mode the unloaders will becontrolled by the main compartment, (unless anotherremote is cooling), however the unit will go to high speed.1-29 62-02461

1.1.1 HEAT/COOL MODEFALLINGTEMPERATUREHIGH SPEEDLOADED COOLLOW SPEEDLOADED COOLLOW SPEEDUNLOADED COOL+2.0_C (+3.6_F)+1.5_C (+2.7_F)+1.0_C (+1.8_F)RISINGTEMPERATUREHIGH SPEEDLOADED COOLLOW SPEEDLOADED COOLLOW SPEEDUNLOADED COOLPULSEDNULL BANDLOW SPEEDUNLOADED HEATLOW SPEEDLOADED HEATHIGH SPEEDLOADED HEAT+0.5_C (+0.9_F)SET POINT--- 0.5_C ( --- 0.9_F)--- 1.0_C ( --- 1.8_F)--- 1.5_C ( --- 2.7_F)--- 2.0_C ( --- 3.6_F)PULSEDNULL BANDLOW SPEEDUNLOADED HEATLOW SPEEDLOADED HEATHIGH SPEEDLOADED HEATFigure 1-21 . UltraFresh 2 Temperature Control Operating Sequence62-024611-30

1.14 DATALINK MODULE (OPTIONAL)1.14.1Brief DescriptionWARNINGDo not attempt to service the DataLink module,breaking the warranty seal will void thewarranty.CAUTIONRemove DataLink module and unplug all wireharness connectors before performing any arcwelding on any part of the unit.Donotremovewireharness frommoduleunlessyou are grounded to the unit frame with a staticsafe wrist strap.Carrier Transicold has developed a recorder “DataLink”it is a self-contained module which consists of:--- Microprocessor--- Program memory--- Data memory--- Internally battery backed real time clock--- 5 thermistor inputs--- Fuel Level inputs--- Door open/closed switch--- Four status LED’s--- Software ports--- Electronic backup power packThis recorder eliminates the mechanical recorder andpaper chart, and replaces it with a custom-designedmodule (see Figure 1-22) that interfaces with thecontroller module and the Datalink Toolbox PC basedsoftware program.a. Operate as a stand alone device or as part of anetwork.b. Log data at 2, 15, 30, 60 or 120 minute intervals.c. Log DataLink alarms.d. Can be custom configured to record up to 13different sensors.1 2 39e. Record DataLink/Network generated events asfollows:--- Main Setpoint Change--- Defrost Initiation--- Defrost Termination--- Pre-Trip Initiation--- Pre-Trip Termination--- Alarm Activity--- Controller Software Upgrade--- Controller Replacement--- Trailer ID Change--- Trip Start--- Trip Comment--- Unit Start/Stop--- Controller Configuration Change--- Function Parameter Change--- Controller System Mode Change (diesel/elect)--- Control Mode Change--- In-Range Indicator--- RTC Battery Replaced (Internal Battery)--- Remote 1 Setpoint Change--- Remote 2 Setpoint Change--- DataLink Alarm Activity--- Power off--- Power on--- Data Retrieval--- RTC Modification--- DataLink Software Upgrade--- Network Failure--- Network Recovery--- Door Opened/Closed--- Fuel Level Low/Normalf. Download files contain the following information:--- Description Header--- DataLink Header--- Memory Configuration--- Current Values--- Alarm Table--- Time and Date--- Selected Event Data--- Recorded Sensor Values41. DataLink Module2. Backup Power Pack3. Software Port4 64. Connector5. Status LED’s6. FuseFigure 1-22. DataLink Module541-31 62-02461

1.1.1 HEAT/COOL MODE1.14.2DataLink Flash (Programming) CardsThe programming cards are used for loading softwareinto the DataLink. This is the same concept as using afloppy diskette to load software into a personalcomputer.Operational Software:This is the software that makes the DataLink module dowhat it does. Wake the unit up at a specified time, requestinformation from other modules in the unit, takereadings from probes, etc.1.14.3Functionsa. Memory Card OperationsThe DataLink will support the download of code via amemory card using the software port. See Figure 1-22.b. DataLink Power-UpThe DataLink may power up in any of 3 ways; normal DCpower, by the RTC (Real Time Clock) because a logginginterval has expired, or by plugging the computer cableinto the downloader port.If the DataLink has woken up because the logginginterval is up, the DataLink will log the appropriate dataand power-off when it is through. It will continue to logdata for the next hour (2 minute interval setting) or 8hour (all other setting). The data line will wake up onstandby power, during a start/stop off cycle, electricstandby off cycle, or following a unit safety shut down orturning unit switch off.c. DataLink DiagnosticsThe DataLink start up diagnostics processing will occureach time there is a power up or after a hardware reset.This processing will test the DataLink hardware forproper operation. If any critical test fails, then the faultLEDwillflashthetestcodethreetimestoindicatewhattest failed. If any of these test fails, the module must bereplaced.CODETEST1 Memory Test 12 Memory Test 23 Timer Test 14 Timer Test 25 Timer Test 36 Converter Test 1d. Trip Start ProcessingFor the user to initiate a Trip Start: press the PRETRIPCHECK key on the control panel or use the DataLinkTool Box program to initiate Trip Start.e. Data Recording ModeDataLink can have up to 5 thermistor, 1 fuel level sensorand 1 door open/closed switch.1.14.4Status LED’sThe DataLink contains four status LEDs. These are asfollows:--- Battery Status (Yellow)--- Communication (Green)--- Fault/Alarm (Red)--- Status/Power/Executing Code (Yellow)Batt --- Battery Status LED:The Battery status LED flashes once every 2 secondswhen the battery voltage is greater than or equal to 6.0V.It will be on solid when the battery voltage is less than6.0V but greater than or equal to 1.0V. It will be off whenthe battery voltage is less than 1.0V.Comm --- Communication LED:The Communication LED will normally be off. A couple ofblinks every minute shows DataLink is communicatingwith micro.Fail --- Fault/Alarm LED:The Fault/Alarm LED indicates if a hardware fault or alarmhas occurred in the DataLink. If a hardware fault occurs,the LED will flash the fault code three times, then theprocessor will reset. The fault codes and their code numbersare defined below. Fault codes will only be displayed onpower up. If the DataLink powers up properly, then thisLED will indicate an alarm condition that has beendetected. The alarm LED should turn on when the alarm isdetected, and off when the alarm goes away.If an alarm occurs, then the LED will be on solid until thealarm goes away.Theoutofrangevaluesareasfollows:Thermistor Inputs:Low limit = ---58.0_F ( --- 50_C)High limit = 158_F (70_C)Stat --- Status/Power LED:The Status/Power LED indicates if the DataLink ispowered up. The LED will be off when power is off or theDataLink is in a sleep mode running off the battery. TheLED will pulse at a once every 2 second rate.1.14.5Message Trip CommentDataLink has the capability to allow the user to entercomments directly into DataLink. The comments have amaximum length of 78 characters. Only one comment canbe recorded per day. In the event that multiple commentsare entered, then only the last will be saved.62-024611-32

1.14.6DataLink Communicationsa. DataLink Retrieval --- InterrogationData retrieval from the DataLink can be accomplishedwith a IBM compatible computer with appropriate cableand software.The Toolbox software for a computer is supplied on a 3.5inch floppy disk. This software allows downloading,screen view of the data, and printing.9Door SwitchFuel Level SensorSpare Voltage SensorFigure 1-23. DataLink Electrical Schematic1-33 62-02461

1.1.1 HEAT/COOL MODE1.15 BATTERY CHARGING ALTERNATOR1.15.1Alternator OperationCAUTIONObserve proper polarity when installing battery,negative battery terminal must be grounded.Reverse polarity will destroy the rectifier diodesin alternator. As a precautionary measure,disconnect positive battery terminal whencharging battery in unit. Connecting charger inreverse will destroy the rectifier diodes inalternator.The alternator converts mechanical and magnetic energyto alternating current (A.C.) and voltage, by the rotationof an electromagnetic field (rotor) inside a three phasestator assembly. The alternating current and voltage ischanged to direct current and voltage, by passing A.C.energy through a three phase, full-wave rectifier system.Six silicon rectifier diodes are used.Yellow2Red4Yellow12Black31236341. Positive Output(B+)2. 12vdc Terminal (D+)3. Ground Terminal4. Excitation Input5. Suppression Capacitor6. Regulator, Brush Holder & BrushesFigure 1-24. Alternator and RegulatorP/N 30-00393-0051. D+ Emulation (Orange)2. #10-24 AC Terminal3. #10-24 Ground Screw4. 1/4-20 Positive Output CableFigure 1-25. Alternator and RegulatorP/N 30-00409-021.15.2Integral Voltage Regulator Operation(12 volts dc)The regulator is an all-electronic, transistorized device.No mechanical contacts or relays are used to perform thevoltage regulation of the alternator system. Theelectronic circuitry should never require adjustment andthesolidstateactiveelementsusedhaveprovedreliableenough to warrant a sealed unit. The system istemperature compensated to permit the ideal chargingrate at all temperatures.The regulator is an electronic switching device. It sensesthe system voltage level and switches the voltage appliedto the field in order to maintain proper system voltage.62-024611-34

1.16 REFRIGERANT CIRCUIT DURINGCOOLING (See Figures 1-20, 1-21 or 1-22)When cooling, the unit operates as a vapor compressionrefrigeration system. The main components of the systemare the (1) reciprocating compressor, (2) air-cooledcondenser, (3) expansion valve, and (4) direct expansionevaporator.The compressor raises the pressure and the temperatureof the refrigerant and forces it into the condenser tubes.The condenser fan circulates surrounding air over theoutside of the condenser tubes. The tubes have finsdesigned to improve the transfer of heat from therefrigerant gas to the air. This removal of heat causes therefrigerant to liquefy; thus liquid refrigerant leaves thecondenser and flows through the solenoid valve SV-1(normally open) and to the receiver.The receiver stores the additional charge necessary forlow ambient operation and for the heating and defrostmodes. The receiver is equipped with a fusible plug whichmelts if the refrigerant temperature is abnormally highand releases the refrigerant charge.The refrigerant leaves the receiver and flows through themanual receiver shutoff valve (King valve). Therefrigerant then flows through the subcooler. Thesubcooler occupies a portion of the main condensing coilsurface and gives off further heat to the passing air.The refrigerant then flows through a filter-drier where anabsorbent keeps the refrigerant clean and dry; and theelectrically controlled liquid line solenoid valve (SV-2)which starts or stops the flow of liquid refrigerant.In R-404A units the refrigerant flows to the“Liquid/suction” heat exchanger. Here the liquid is9further reduced in temperature by giving off some of itsheat to the suction gas.The liquid then flows to an externally equalizedthermostatic expansion valve which reduces the pressureof the liquid and meters the flow of liquid refrigerant tothe evaporator to obtain maximum use of the evaporatorheat transfer surface.The refrigerant pressure drop caused by the expansionvalve is accompanied by a drop in temperature; thus, thelow pressure, low temperature fluid that flows into theevaporator tubes is colder than the air that is circulatedover the evaporator tubes by the evaporator fan. Theevaporator tubes have aluminum fins to increase heattransfer; therefore heat is removed from the aircirculated over the evaporator. This cold air is circulatedthroughout the trailer to maintain the cargo at thedesired temperature.The transfer of heat from the air to the low temperatureliquid refrigerant causes the liquid to vaporize. In R-22units this low temperature, low pressure vapor returns tothe compressor.In R-404A units this low temperature, low pressure vaporpasses through the “suction line/liquid line” heatexchanger where it absorbs more heat from the highpressure/high temperature liquid and then returns to thecompressor.The quench valve (R-22 Only) opens as required tomaintain a 265 to 285_F (129 to 141_C) maximumdischarge temperature.NOTEOn Optima the quench valve is before SV2 andon Phoenix Ultra it is after SV2.EXTERNAL EQUALIZEREXPANSIONVALVEBULBEXPANSION VALVEHOT GASBYPASS LINEFUSIBLEPLUGRECEIVERHEAT EXCHANGEREVAPORATORBYPASSCHECKVALVEDISCHARGESERVICEVALVEVIBRASORBERHP-2 HP-1LIQUID LINESUCTIONSERVICEVALVEHOT GASSOLENOID(SV3), NCHOT GASLINESHUT-OFFVALVESUBCOOLERLIQUIDSOLENOIDVALVE (SV2), NCFILTERDRIERCOMPRESSORHOT GASSOLENOID(SV4), NCDISCHARGECHECK VALVECONDENSERPRESSURECONTROLSOLENOID(SV1), NOVIBRASORBERCONDENSERFigure 1-26. R-404A Refrigerant Circuit --- Cooling1-35 62-02461

1.17 REFRIGERANT CIRCUIT DURINGHEATING AND DEFROSTING(See Figures 1-23, 1-24 or 1-25)For units with UltraFreeze refer to section 1.13.For units without UltraFreeze the unit will only heat whenthe controller is set above +10_F ( --- 12.2_C) as the heatrelays are electronically locked out with set points below+10_F ( --- 12.2_C).When vapor refrigerant is compressed to a high pressureand temperature in a reciprocating compressor, themechanical energy necessary to operate the compressor istransferredtothegasasitisbeingcompressed.Thisenergyis referred to as the “heat of compression” and is used as thesource of heat during the heating cycle.The quench valve (R-22 Only) opens as required tomaintain a 265 to 285_F (129 to 141_C) maximumdischarge temperature.1.17.1Heating and DefrostNOTES1.Solenoid valve (SV-2) remains open duringheating or defrosting to allow additionalrefrigerant to be metered into the hot gas cycle(through the expansion valve) providingadditional heating capacity until de-energizedby head pressure control switch HP-2.2. SV-3 on Ultima’s, will not open when theambient temperature exceeds 80_F (26.7_C).3.SV-3 will open after a 60 second delay, if theengine is in high speed and the differencebetween ambient and discharge temperaturesexceeds 100_F (55.5_C). If the differencebetween ambient and discharge temperaturesgoes below 50_F (27.8_C) SV-3 will close.When the controller calls for heating, hot gas solenoidvalve (SV-4) opens and the condenser pressure controlsolenoid valve (SV-1) closes. The condenser coil then fillswith refrigerant, and hot gas from the compressor entersthe evaporator. Also the liquid line solenoid valve (SV-2)will remain energized (valve open) as the head pressurecontrol switch (HP-2) will remain closed until thecompressor discharge pressure increases to cut-outsetting (refer to section 1.4).9Switch HP-2 opens to de-energize the liquid line solenoidvalve (SV-2) and the valve closes to stop the flow ofrefrigerant to the expansion valve.When the compressor discharge pressure falls to cut-insetting (refer to section 1.4), pressure switch (HP-2) closesand in turn energizes the normally closed liquid solenoidvalve (SV-2) which opens, allowing refrigerant from thereceiver to enter the evaporator through the expansionvalve.When in engine operation and the discharge pressureexceeds pressure settings detailed in section 1.4, pressurecutout switch (HP-1) opens to de-energize the run relaycoil (RR). When the RR coil is de-energized, the RRcontacts open stopping the engine. The function of thehot gas bypass line is to raise the receiver pressure whenthe ambient temperature is low (below 0_F = ---17.8_C)so that refrigerant flows from the receiver to theevaporator when needed.1.17.2Defrost with Greater Than 100_F (37.8_C)Ambienta. Diesel Engine OperationUnits utilizing the new wiring harness & HR4 relay willinitiate a pump down cycle during defrost above 100_Fambient temperature.(See Figure 1-11)Units with older wiring harness, will not have HR4 and nopump down cycle.If the ambient is greater than 100_F (37.8_C) thefollowing stages are performed for defrost (Refer toTable 1-9). The first stage (Pump Down) runs for aminimum of thirty seconds and then checks the suctionpressure. When the suction pressure is less than 10 PSIG,it will continue to stage 2. The total time in stage onecannot be greater than 330 seconds. If 330 seconds isreached stage two (Defrost Begins) will automatically beentered regardless of suction pressure. Stage 2 is defrost.Stage 3 (Defrost Termination) is the termination ofdefrost. When defrost is terminated SV4 will remainenergized for 15 seconds.b. Electric Standby Motor OperationOn electric standby motor operation HR4 relay is used toinitiate a pump down cycle in heat or defrost.Table 1-9. Stages for Defrost with Greater Than 100 _F (37.8_C) AmbientSTAGESV1 SV2 SV3 SV4(HR1) (HR4) (HR3) (HR2)UR UF SPEED1OPEN CLOSED CLOSED CLOSED(De-energ) (Energ) (De-energ) (De-energ)Energ Energ De-energ2HP2CLOSEDCLOSED OPENControl(Energ)(De-energ) (Energ)(Energ)De-energ Energ Energ3OPEN OPEN CLOSED OPEN(De-energ) (De-energ) (De-energ) (Energ)De-energ Energ De-energDe-energ = De-energizedEnerg = EnergizedCLH(DR)Energ(De-energ)De-energ(Energ)Energ(De-energ)1-37 62-02461

1.1.1 HEAT/COOL MODEEXTERNAL EQUALIZEREXPANSION VALVEEXPANSIONVALVE BULBSUCTION LINEEVAPORATORFUSIBLEPLUGBYPASSCHECKVALVERECEIVERLIQUID LINEQUENCHVALVEBULBVIBRASORBERDISCHARGESERVICE HP-2 HP-1VALVEQUENCH VALVESUCTIONSERVICEVALVEHOT GASSOLENOID(SV3), NCHOT GASSOLENOID(SV4), NCHOTGASLINESHUT-OFFVALVEHOT GASBYPASSLINESUBCOOLERLIQUIDSOLENOIDVALVE (SV2), NCFILTERDRIERCOMPRESSORDISCHARGE LINEDISCHARGECHECK VALVEVIBRASORBERCONDENSERFigure 1-29. Phoenix Ultra --- R-22 Refrigerant Circuit --- Heating and DefrostingCONDENSERPRESSURECONTROLSOLENOID(SV1), NOEXTERNAL EQUALIZEREXPANSION VALVEEXPANSIONVALVE BULBSUCTION LINEQUENCH VALVEEVAPORATORFUSIBLEPLUGBYPASSCHECKVALVERECEIVERQUENCHVALVEBULBSUCTIONSERVICEVALVEVIBRASORBERHP-2 HP-1DISCHARGESERVICEVALVEHOT GASSOLENOID(SV3), NCHOTGASLINEHOT GASSOLENOID(SV4), NCSHUT-OFFVALVESUBCOOLERLIQUIDSOLENOIDVALVE (SV2), NCFILTERDRIERCOMPRESSORDISCHARGECHECK VALVECONDENSERDISCHARGE LINEVIBRASORBERFigure 1-30. Optima --- R-22 Refrigerant Circuit --- Heating and DefrostingCONDENSERPRESSURECONTROLSOLENOID(SV1), NO62-024611-38

9EXTERNAL EQUALIZEREXPANSIONVALVEBULBEXPANSION VALVEHOT GASBYPASS LINEFUSIBLEPLUGRECEIVERHEAT EXCHANGEREVAPORATORBYPASSCHECKVALVEDISCHARGESERVICEVALVEVIBRASORBERHP-2 HP-1LIQUID LINESUCTIONSERVICEVALVEHOT GASSOLENOID(SV3), NCHOT GASLINESHUT-OFFVALVESUBCOOLERLIQUIDSOLENOIDVALVE (SV2), NCFILTERDRIERCOMPRESSORHOT GASSOLENOID(SV4), NCDISCHARGECHECK VALVECONDENSERPRESSURECONTROLSOLENOID(SV1), NOVIBRASORBERCONDENSERFigure 1-31. R-404A Refrigerant Circuit --- Heating and Defrosting1-39 62-02461

SECTION 2OPERATION2.1 PRE-TRIP INSPECTIONa. Before Starting Engine1. Drain water and sediment from fuel tank sump. Thenfill tank with diesel fuel. (Refer to section 1.2)2. Check radiator coolant level. (Add pre-mixed 50/50permanent antifreeze-water as required.) USEETHYLENE GLYCOL ONLY. (Refer to section1.2)3. Check evaporator and condenser coil for cleanliness.4. Check engine lubrication and fuel filter, oil lines, andconnections for leaks. (Tighten connections and/orreplace gaskets.)5. Check engine oil level. (Refer to section 1.2)6. Check V-belts for proper tension, fraying or cracks.Adjust belt or replace.7. Check battery terminals for cleanliness andtightness. Clean and coat with a mineral type grease(such as Vaseline).8. Check condenser/evaporator fan shaft bearing forexcessive play.9. Check engine air cleaner for cleanliness andcondition of air cleaner hose.10. Check oil level in compressor sight glass.11. Check defrost drain pan hoses. (Should be clear ofdebris.)12. Check defrost air switch tubes and connections forbreaks or air leaks.b. After Starting Refrigeration Unit1. Check water temperature. (Should be 160 to 180_F=71to82_C.)2. Check ammeter. (Should indicate +2 to +10 ampsafter start-up.)3. Check engine speed. (Refer to section 4.3.3)4. Listen for abnormal noises. (Refer to section 3.3.7)5. Check compressor oil level. (Refer to section 4.13)6. Observe any signs of lube or fuel oil leaks.7. Check radiator hoses for leaks.8. Check refrigerant level. (Refer to section 4.10.f)9. Feel filter-drier. Excessive temperature drop acrossdrier indicates restriction. (Refer to section 4.16)10. Check clutch/gearbox for excessive noise. On Ultimaclutch is on fanshaft.11. Start microprocessor Pre-trip Inspection. (Refer toSection 1.10.8 )2.2 STARTING AND STOPPING INSTRUCTIONS- ENGINE DRIVEWARNINGUndernocircumstancesshouldetheroranyother starting aids be used to start engine.NOTES1. Whenever starting the engine, in order to reducestarter cranking and engine loads, themicroprocessor always starts and operates in lowspeed, unloaded cool for the first 15 seconds.After first 15 seconds the microprocessor willallow the unit to operate normally, providing thecoolant temperature is above 79_F (26_C). Inorder to prolong engine life, the microprocessorwill prevent operation in high speed untilcoolant temperature reaches this temperature.2. With software 3.11 or higher the unit will remainin low speed for 10 minutes after engine start-upwhen: Auto Start/Stop is at any setpoint orContinuous Run setpoint is below 10_F( --- 12_C).2.2.1 AUTOMATIC STARTa. Starting Instructions1. Place the RUN-STOP switch in the RUN position.The microprocessor will perform a self-test (alldisplay messages will appear in display window).Then setpoint and box temperature will be displayed.2. The microprocessor will energize glow cycle (lengthof time depends on engine temperature). Units withbuzzer will sound for 5 seconds before starting theengine.3. To change the setpoint press the UP or DOWN arrowkey and ENTER key.4. Pressing the AUTO S/S---CONTINUOUS keychanges the operation of the unit between automaticstart/stop (unit will automatically start and stop inresponse to changing box temperature) or automaticstart continuous run (unit will operate continuouslyafter starting).b. Stopping InstructionsPlace RUN-STOP switch in the STOP position to stopunit.2.2.2 MANUAL STARTINGa. Starting Instructions (Manual Starting)1. To start the unit manually, place Run/Stop Switch toRUN position.2. Press the AUTO S/S---CONTINUOUS key (ifnecessary) to erase START/STOP from the display.2-1 62-02461

3. Press the FUNCTION CHANGE key until AUTOOP or MAN OP appears on the display.a. If AUTO OP appears:(1) Press the ENTER key.(2) Press the UP or DOWN arrow key to makeMAN OP appear on the display.(3) Press the ENTER key. The unit is in MANUALSTART mode.b. If MAN OP appears: the unit is in MANUALSTART mode.4. Use the Manual Glow/Crank switch to start the unitrefer to Table 2-1.NOTEOnce the unit is programmed for Man OP, theAUTO S/S --- CONTINUOUS key can be usedto toggle between Auto Start/Stop andContinuous RunTable 2-1. Manual Glow TimeGlow Time inAmbient Temperature Seconds ForTV DILess than 32_F (0_C) 15 5533_F to50_F (1_C to10_C) 10 4051_F to77_F (11_C to25_C) 5 25Greater than 78_F (26_C) 0 10b. Stopping InstructionsPlace RUN-STOP switch in the STOP position to stopunit.2.3 STARTING AND STOPPING INSTRUCTIONS -STANDBY MOTORWARNINGMake sure the power plugs are clean and dry beforeconnecting to any power receptacle.Beware of unannounced starting of fans andV-belts caused by thermostatic cycling of unitduring standby operation.a. Starting Instructions1. Place the Run/Stop Switch in the STOP (0) position.2. Plug in the power plug.3. Place the Engine/Standby Switch in the STANDBYposition.4. Place the Run/Stop Switch in the RUN (I) position.Units with buzzer will sound for 5 seconds beforestarting.5. Check for proper motor rotation. Condenser airmust be drawn into unit. To reverse rotation, stopunit, disconnect power cord and change polarity ofplug.b. Stopping InstructionsWARNINGWhen changing from standby operation, firstturn the unit OFF, turn OFF main power andremove power plug.1. Place the Run/Stop Switch in the STOP (0) position.2.4 CONTROL CIRCUIT OPERATION -ENGINE DRIVE2.4.1 IntroductionNOTEThe schematic in this manual has mapcoordinates added to the margins. For example,to locate the ammeter (A) on the schematic, itwould follow the component designation by thedesignation (I2). This would indicate that it isclosest to lines I and 2 on the schematic. Theselocations have been added to the legend.The controller boards shown on the electrical schematic(Figure 5-1) that interface with unit components are theanalog interface or processor board on the left and therelay module on the right.Connections to these boards are made through 3multiple-pin plug connectors HC, HC2, & MP. Theaddress system (example HCD2-MPW2) indicates a wirebetween plug HC, pin D2 and microprocessor MP & pinW2.The processor board connections are mainly inputs andoutputs for control switches, temperature sensors, safety,and auto start functions that control the operation of theunit. The processor board also controls the operation ofthe relay board through plug connections.The relay module, which contains plug-ininterchangeable relays provides the microprocessor witha means for switching the unit components to achieve adesired operating mode.2.4.2 CoolingThere are two control ranges, Frozen and Perishable. TheFrozen range is active with set points at or below +10_F( --- 12_C) and the Perishable range is active at set pointsabove +10_F ( --- 12_C).The controller automatically selects the mode(s)necessary to maintain box temperature at set point. ThemodesareshowninTable2-2.For units with UltraFresh 2 refer to section 1.12.If the unit is in high speed loaded cool, themicroprocessorwillpullterminalN3lowtoenergizethespeed relay. A set of normally open contacts (SR) close toenergize the speed control solenoid (SCS). The enginewill be in high speed.When the unit is running in high speed loaded cool andwith the evaporator coil temperature below 40_F (4.4_C)to close at least one defrost termination thermostat, apre-trip may be initiated by depressing the PRETRIP62-024612-2

key. The operator now may verify the pre-trip sequence.(Refer to Section 1.10.8)As the trailer temperature falls toward set point, themicroprocessor will place the unit in low speed loadedcool. The temperature at which this occurs is not fixed butdepends upon the rate at which the trailer temperature isapproaching set point.The speed relay (SR) de-energizes to open the circuit tothe speed control solenoid (SCS). Engine speeddecreases from high speed to low speed.As the trailer temperature falls closer to set point, thecontroller will shift the operation from low speed loadedcool to low speed unloaded cool to further reduce coolingcapacity. To do this, the microprocessor will pullterminals X2 or X2 & X3 low, completing the groundpath for the unloader relays (UFR & URR). The coilsenergizes to close the UFR & URR contacts. One or bothunloaders (UF and UR) may energize to unload thecompressor (Refer to Section 1.9).For setpoints above 10_F ( --- 12_C) and with decreasingtemperature, the unit will shift to low speed unloadedheat.For units with UltraFreeze refer to section 1.13.For units without UltraFreeze setpoints below 10_F( --- 12_C) heating is locked out. Therefore, it is possiblefor the box temperature to fall below setpoint in thefrozen range.Unit will remain in various stages of heating until the boxtemperature increases enough to place the unit in the lowspeed unloaded cool mode. As the box temperatureincreases, the unit will shift to low speed loaded cool , andthen to high speed cool mode (speed relay energizes).2.4.3 HeatingNOTES1. SV-3 will open after a 60 second delay, if theengine is in high speed and the differencebetween ambient and discharge temperaturesexceeds 100_F (55.5_C). If the differencebetween ambient and discharge temperaturesgoes below 50_F (27.8_C) SV-3 will close.2. SV-3 on Ultima’s, will not open when the ambienttemperature exceeds 80_F (26.7_C).3. Whenever the unit shifts to heat or defrost, HR1and HR2 energize simultaneously. Whenswitching from heat (or defrost) to cool, HR1de-energizes 2 seconds before HR2. This allowstime for SV-1 to open and clear the condenser ofliquid before SV4 closes. This will eliminate anyhigh pressure buildup which could occur. Duringthis time, only on the remote light bar, the heatand cool lights will be on together. The heat andcool display on the control panel changeimmediately.Refer to section 1.17 for description on heating cycle.For units with UltraFreeze refer to section 1.13.The unit will only heat when the controller is set above+10_F ( --- 12_C) as the heat relays are electronicallylocked out with set points at or below +10_F ( --- 12_C).The controller automatically selects the mode(s)necessary to maintain box temperature at set point. Theheating modes are as follows with descendingtemperatures:(a) Low Speed Unloaded Heating, (b) Low SpeedLoaded Heating, (c) High Speed Loaded HeatingThe controller will shift the unit into low speed unloadedheat when the trailer temperature falls below set point(compressor in four cylinder heating). Themicroprocessor pulls terminals N1, X1 and X2 low tocomplete the ground paths for the heat relays (HR1 andHR2) and unloader front relay (UFR). When theserelays energize, several things happen. This opens the(N.C.) contacts to the cool light and solenoid valve(SV2). SV2 now operates in conjunction with the headpressure control switch (HP2). (Refer to section 1.17)Also, HR1 closes a set of normally open contacts toenergize solenoid valve SV1 to close the condenser outletline.When the unloader front relay (UFR) energizes, a set ofN.O. contacts (UFR) close to energize the compressorfront unloader (UF). Compressor will be in four cylinderheating.Energizing HR2 closes two sets of N.O. contacts.Solenoid SV4 energizes and opens to allow hotrefrigerant vapor to enter the evaporator (section 1.17).The other set of HR2 contacts supply power to the heatlight on light bar.If more heating capacity is required, the unit will shift tolow speed loaded heating. The microprocessor will breakthe ground path to de-energize the front unloader relay,which in turn, de-energizes the compressor unloaders(compressor shifts from four cylinder to six cylinderoperation).NOTEHigh speed heat is locked out for 5 minutesafter switching from cool to heat.When maximum heating capacity is required, the unitwill shift to high speed loaded heat. The microprocessorenergizes the HR1, HR2, and speed relay (SR) coils.Terminals N1, X1 and N3 will be pulled low. The onlychange from the low speed loaded heat mode is that thespeed relay is now energized. SR contacts close toenergize the speed control solenoid (SCS). The enginewill be in high speed.2.4.4 DefrostRefer to sections 1.10.10 and 1.17 for the heat and defrostcycle.NOTEThe unit will be in high speed in the defrostmode.2-3 62-02461

Thedefrostmodemaybeinitiatedbythreedifferentways if the evaporator coil is below 35_F (1.7_C). (Referto section 1.4)Method one to initiate defrost is by pressing theMANUAL DEFROST key.Method two is that defrost may be initiated automaticallyat preset intervals by the defrost timer in themicroprocessor. (Refer to section 1.10.2). The manualdefrost key and defrost timer are part of themicroprocessor and are not shown on the schematic.The third means of defrost initiation is by the defrost airswitch (DA). The switch is an air pressure differentialswitch which measures air pressure differential across theevaporator coil and initiates the defrost cycle when theair pressure differential increases enough to close the DAcontacts, such as would happen when excessive frostbuilds up on the evaporator coil surface.When the defrost air switch contacts close, there is a 12vdc potential to terminal K1 on the microprocessor. Themicroprocessor looks for voltage at terminal K2. Voltageat K2 indicates that at least one defrost terminationthermostat is closed. The unit will shift to the defrostmode if voltage is present at K2.If both defrost thermostats (klixons) are open (no voltageat K2), defrost cannot be initiated by any means.In defrost the microprocessor pulls terminals N1, X1, andN3 low to shift the unit into high speed heat. Theprocessor also pulls terminal W2 low to energize thedefrost relay coil. This closes the N.O. defrost relaycontacts to energize the defrost light on the remote lightbar. The defrost and heat display will also be illuminated.Also N.C. defrost relay contacts open to de-energize theclutch (CLH) to stop the evaporator and condenser fans.On Ultima the clutch stop only the evaporator fans.The unit will remain in defrost until both defrosttermination thermostats open to remove voltage fromthe defrost relay. If the thermostats fail to open in 45minutes, the microprocessor will terminate defrost andshift between normal control and defrost at 1 1/2 hourintervals. This will also occur if the defrost air switch isstuck closed.If the problem corrects itself, (thermostats opens forexample), the unit will automatically resume its normalfunctions).The defrost termination starts with HR1 and speed relayde-energizing. HR2 will turn off 2 seconds later. Thedefrost output will de-energize 5 seconds after HR1. Ifthe temperature control requires high speed, it willenergize 2 seconds after defrost relay is de-energized.2.5 CONTROL CIRCUIT OPERATION -STANDBY MOTOR DRIVENOTETo make it easier to locate the schematiccomponents referred to in the written text, theschematic in this manual has map coordinatesadded to the margins. These locations have alsobeen added to the legend.The relay module, which contains plug-ininterchangeable relays provides the controller with ameans for switching the unit components to achieve adesired operating mode.With software 3.11 or higher and units with UltraFresh 2refer to section 1.12.2.5.1 Electric Standby Features1. Two Operating Modes2. Minimum “ON” Time (5 Minutes)3. Minimum “OFF” Time (5 Minutes)4. Low Battery Protection1. Two operating modes: Electric Standby can operate inthe Start/Stop mode or the Continuous Run mode.During Start/Stop operation, (Perishable Range) the unitwill operate in 3 modes: A) “Cool” cycle B) “Off” cycleC) “Heat” cycleDuring Start/Stop operation, (Frozen Range) the unitwill operate in 2 modes: A) “Cool” cycle B) “Off” cycleIn the Start/Stop mode, when the box temperature getsclose to setpoint, the controller will cycle the StandbyMotor(SBM) off to conserve energy. The microprocessorautomatically locks out heating for entered setpointsbelow ---12.2_C (10_F). Therefore, it is possible for thebox temperature to fall below setpoint in the frozenrange.2. Minimum “ON” time (5 minutes): The unit must runfor the minimum run-time before it can consider shuttingoff. This minimum run time is to prevent short cycling andensure adequate air flow through the load to allow thecontroller to accurately sense load temperature and bringthe battery up to minimum voltage level. It also prevents“hot spots” in a properly loaded box.After the minimum run time is complete, themicroprocessor will look at the remaining conditions thatmust be satisfied to allow a shutdown. These are:A) Battery condition --- Battery voltage must be above13.4 volts. (measured at Y1)B) The box temperature (active probe) must be satisfied:Perishable Range Setpoints +/ --- 0.3_C (0.5_F)Frozen Range Setpoints + 0.3_C (0.5_F)If ALL of these conditions are not satisfied, the motorwill continue to run until they are. This prevents rapidcycling of the electric drive motor.3) Minimum “OFF” time (5 minutes): Once the motorhas cycled off, it will remain off for the minimum “off62-024612-4

time”. This prevents the motor from rapid cycling due tochanges in air temperature. Air temperature in the boxcan change rapidly, but it takes time for the producttemperature to change.4) Low battery voltage protection: The microprocessorwill restart the unit if the battery voltage drops below 11.0volts to recharge the battery after the minimum off-timedelay.NOTEWhen in Continuous Run, perishable range, theunit will cycle between cool and heat to maintainbox temperature at setpoint. In frozen range theunit will run in cool only. Continuous Run isnormally used for perishable products thatrequire constant air flow.2.5.2 Standby CoolWhen in standby cool, Start/Stop, the microprocessor willenergize the following circuits:First the microprocessor will energize (ARR), this willclose a set of N.O. (ARR) contacts, energizing the AutoRestart Light (ARL) on the light bar, indicating to theoperator that the unit is in the START/STOP mode andmay start at any time. After a 5 second delay the DieselElectric Relay (DER) will be energized, this will open theN.C. (DER) contacts to prevent the Fuel Heater Relay(FHR), Fuel Pump (FP) and the Fuel Solenoid (FS) frombeing energized during standby operation. At the sametime the N.O. (DER) contacts will close. This willenergize the Power Light (PL) on the light bar indicatingto the operator that the unit is in the standby mode ofoperation, and also energize the Motor Contactor (MC).With the motor contactor energized, the N.O. (MC)contacts will close, supplying voltage to energize thestandby motor.At the same time, (RR) will be energized, closing theN.O. (RR) contacts supplying voltage to the refrigerationcontrol circuitry.2.5.3 Standby OFFIn the start/stop mode,after the standby motor has run atleast five minutes and the controller is ready to switchfrom cool to heat (box temperature near setpoint), themicroprocessor will de-energize the (RR) causing thestandby motor to cycle off.When the unit is “OFF,” the microprocessor keeps(ARR) energized. The unit will remain off for at least 5minutes before restarting. If after 5 minutes, the batteryvoltage drops below 11.0 volts or the box temperaturedrifts out-of-range, +/--- 2.0_C (3.6_F) from setpoint forperishable range and +2.0_C (3.6_F) above setpoint forfrozen range, the standby motor will restart.2.5.4 Standby DefrostStandby defrost operates the same as engine drivedefrost refer to section 2.4.4.2-5 62-02461

ModeTable 2-2. Relay OperationDEPerishable FrozenGPR RR SSR SRRUFR URR UFR URR 5 HR1 HR2 HR3 HR4 DR OR ARR FROff O O O O O O O O O O O O O O O O OGlow O I I O O I I I I O O O O O IorO IorO IorOStart O I I I O I I I I O O O O O IorO IorO IorOHigh Speed Cooling O O I O I IorO 1 IorO 1 IorO 1 O 1 O O O O O IorO IorO IorOLow Speed Cooling O O I O O I IorO 1 IorO 1 O 1 O O O O O IorO IorO IorOOff Cycle O O O O O O O O O O O O O O IorO IorO IorOLow Speed Heating O O I O O IorO 1 O 4 N/A N/A I I IorO 2 I O IorO IorO IorOHigh Speed Heating O O I O I O 1 O 4 N/A N/A I I I 3 I O IorO IorO IorODefrost O O I O I O 1 O 4 O 1 O 4 I I I 3 I I IorO IorO IorOHigh Ambient DefrostStage 1O O I O O I I I I O O O I O IorO IorO IorOUltraFresh 2 O O I O O O 1 O 1 N/A N/A O/I O/I O O/I O O O IorOUltraFreeze O O I O O N/A N/A O O O/I O/I O O/I O O IorO IorOSTANDBY MOTOR OPERATIONCooling I O I O O O 1 O 1 O 1 O 1 O O O O O IorO O OCoolingUnloadedI O I O O I I I I O O O O O IorO O OOff Cycle O O O O O O O O O O O O O O IorO O OHeating I O I O O O 1 O 4 N/A N/A I I I 3 I O IorO O OHeatingUnloadedI O I O O I O4 N/A N/A I I IorO 2 I O IorO O ODefrost I O I O O O 1 O 4 O 1 O 4 I I I 3 I I IorO O OHigh Ambient DefrostStage 1I O I O O I I I I O O O I O IorO O OUltraFresh 2 I O I O O O 1 O 1 N/A N/A O/I O/I O O/I O O O IorOUltraFreeze I O I O O N/A N/A O O O/I O/I O O/I O O IorO IorOI = Output is ONO = Output is OFF1 Sequence shown is thermostat control selection. This may be overridden by suction pressure.2 Output will only energize in high speed heat, but will remain energized if unit goes to low speed heat.3 Certain conditions must be met before output is energized.4 Suction pressure will not override this unloader in heat.5 No (URR) rear unloader on model NDA-93/94B Optima.2-6 62-02461

SECTION 3TROUBLESHOOTINGCAUTIONUnder no circumstances should anyone attempt to service the microprocessor!(see section 4.29) Should aproblem develop with the microprocessor, contact your nearest Carrier Transicold dealer for replacement.INDICATION/TROUBLE3.1 DIESEL ENGINE3.1.1 Engine Will Not StartStarter motor will notcrank or low cranking speedPOSSIBLE CAUSESBattery insufficiently chargedBattery terminal post dirty or defectiveBad electrical connections at starterStarter motor malfunctionsStarter motor solenoid defectiveOpen starting circuitIncorrect grade of lubricating oilREFERENCESECTIONCheckCheckCheck3.1.3Engine Manual3.1.41.2Starter motor cranksbut engine fails to startNo fuel in tankAir in fuel systemWater in fuel systemPlugged fuel filtersPlugged fuel lines to injector (s)Fuel control operation erraticGlow plug(s) defectiveFuel solenoid defectiveFuel pump (FP) malfunctionCheck4.2Drain Sump ReplaceCheckEngine Manual4.3.7Engine Manual4.2Starter cranks, engages,but dies after a few secondsEngine lube oil too heavyVoltage drop in starter cable(s)1.2Check3.1.2 Engine Starts Then StopsEngine stops afterseveral rotationsFuel supply restrictedNo fuel in tankLeak in fuel systemFaulty fuel control operationFuel filter restrictedInjector nozzle(s) defectiveInjection pump defectiveAir cleaner or hose restrictedSafety device openFuel solenoid defectiveFuel pump (FP) malfunctionCheckCheckCheckEngineReplaceEngine ManualEngine Manual4.3.41.5Engine Manual4.23.1.3 Starter Motor MalfunctionStarter motor will notcrank or turns slowlyBattery insufficiently chargedBattery cable connections loose or oxidizedBattery cables defectiveStarter brushes shorted outStarter brushes hang up or have no contactStarter solenoid damagedRun-Stop switch defectiveEngine lube oil too heavyCheckCheckReplaceEngine ManualEngine ManualEngine ManualReplace1.23-1 62-02461

INDICATION/TROUBLEPOSSIBLE CAUSESREFERENCESECTION3.1.3Starter Motor Malfunction (CONTINUED)Starter motor turnsPinion or ring gear obstructed or wornbut pinion does not engageClean both,remove burrs,or replace;apply greaseStarter motor does not disengageafter switch was depressedRun-Stop switch defectiveStarter motor solenoid defectiveReplaceEngine ManualPinion does not disengageafter engine is runningDefective starterEngine Manual3.1.4Malfunction In the Engine Starting CircuitNo power to startermotor solenoid (SS)Battery defectiveLoose electrical connectionsCheckTightenFuel solenoiddoes not energize or doesnot remain energizedBattery defectiveLoose electrical connectionsOil pressure safety switch (OP) defectiveRun relay (RR) defectiveWater temperature sensor (WTS) defectiveFuel solenoid defectiveRun-Stop switch defectiveCheckTightenReplaceReplaceReplaceEngine ManualReplace3.2 ALTERNATOR (AUTOMOTIVE TYPE)Alternator fails to charge Limited charging system operating timeBattery conditionAlternator belt loose/brokenLoose, dirty, corroded terminals, or broken leadsExcessively worn, open or defective brushesOpen blocking diodeRegulator faultyOpen isolation diodeOpen rotor (field coil)CheckCheck4.4Check/RepairCheckCheckCheckCheckReplaceLow or unsteady charging rateAlternator belt looseLoose, dirty, corroded terminals, or broken leadsExcessively worn, sticky or intermittent brushesFaulty regulatorGrounded or shorted turns in rotorOpen, grounded or shorted turns in stator4.4Check/RepairCheckCheckCheckReplaceExcessive charging rate(as evidenced by batteryrequiring too frequent refilling) orcharge indicator shows constant“charge with engine idling”Noisy alternatorRegulator leads loose, dirty, corroded terminals, orwires brokenDefective regulatorDefective or badly worn V-beltWorn bearing(s)Misaligned belt or pulleyLoose pulleyClean/RepairCheck4.4Replace4.4Tighten62-024613-2

INDICATION/TROUBLEPOSSIBLE CAUSESREFERENCESECTION3.3 REFRIGERATION3.3.1Unit Will Not CoolDiesel engine Malfunction(s) 3.1Compressor malfunctionCompressor drive defectiveCompressor defective4.124.12Refrigeration systemDefrost cycle did not terminateAbnormal pressureSolenoid valve malfunctionClutch Failure (Ultima)3.3.53.3.63.3.114.243.3.2Unit Runs But Has Insufficient CoolingCompressorCompressor valves defectiveUnloader malfunctionRefrigeration systemAbnormal pressureUnloader malfunctionExpansion valve malfunctionNo or restricted evaporator airflowClutch Failure (Ultima)Engine does notdevelop full rpmSpeed control linkageEngine malfunction4.124.143.3.64.143.3.103.3.94.244.3.33.13.3.3Unit Operates Long or Continuously in CoolingTrailerHot LoadDefective box insulation or air leakAllow time topull downCorrectRefrigeration systemAbnormal pressureTemperature controller malfunction3.3.63.3.8Compressor Defective 4.123.3.4Unit Will Not Heat or Has Insufficient HeatingRefrigerationHead pressure control switch (HP-2) defectiveAbnormal pressureTemperature controller malfunctionSolenoid valve malfunction1/4” check valve (bypass) defectiveClutch Failure (Ultima)CompressorCompressor drive defectiveCompressor defective4.173.3.63.3.83.3.114.154.244.124.12Engine does not developfull rpmSpeed control linkageEngine malfunction4.3.33.13-3 62-02461

INDICATION/TROUBLE3.3.5Defrost Cycle MalfunctionWill not initiate defrostautomaticallyWill not initiate defrost manuallyInitiates but does not defrostFrequent defrostDoes not terminate orcycles on defrostPOSSIBLE CAUSESDefrost air switch (DA) out of calibrationDefrost thermostats (DTT) open or defectiveDefrost air switch (DA) defectiveLoose terminal connectionsAir sensing tubes defective or disconnectedMicroprocessor defectiveLoose terminal connectionsDefrost thermostats (DTT) open or defectiveGlow/Crank switch defectiveSolenoid valve malfunctionDefrost relay (DR) defectiveClutch/Gearbox defectiveDefrost air switch (DA) out of adjustmentWet loadDefrost thermostats (DTT) shorted closedHead pressure control switch (HP-2) defectiveLow refrigerant chargeDefrost air switch (DA) out of adjustmentREFERENCESECTION4.224.214.21 & 4.22TightenCheckReplaceTightenReplaceReplace3.3.11ReplaceReplace4.21 & 4.22Normal4.214.174.114.21 & 4.223.3.6Abnormal Pressure3.3.6.1CoolingHigh discharge pressureQuench valve malfunctionCondenser coil dirtyCondenser fan defectiveV-belt broken or looseDischarge check valve restrictedNoncondensibles or refrigerant overchargeSolenoid valve (SV-1) malfunctionReplace4.264.234.44.15Replace4.20Low discharge pressure Compressor valves(s) worn or broken 4.12High suction pressureCompressor valves(s) worn or brokenCompressor gasket(s) defective4.124.12Low suction pressureSuction and dischargepressures tend to equalizewhen unit is operatingSuction service valve partially closedKing valve partially closedFilter-drier partially pluggedLow refrigerant chargeExpansion valve malfunctionNo evaporator air flow or restricted air flowExcessive frost on coilSolenoid valve (SV-2) defectiveClutch Failure (Ultima)OpenOpen4.164.113.3.103.3.94.214.194.24Compressor valves defective 4.1262-024613-4

INDICATION/TROUBLE3.3.6.2HeatingHigh discharge pressureLow discharge pressurePOSSIBLE CAUSESSolenoid valves (SV-1, SV-3 and SV-4) malfunctionCondenser fan defectiveV-belts broken or looseNoncondensibles in systemHead pressure control switch (HP-2) defective (closed)Compressorvalve(s)wornorbrokenHead pressure control switch (HP-2) defective(open)Solenoid valve (SV-1) malfunctionLow refrigerant chargeREFERENCESECTION3.3.114.234.4Check4.174.124.173.3.114.11Low suction pressureRefrigerant shortageSolenoid (SV-1) openDefective HP-24.113.3.114.173.3.7Abnormal NoiseCompressorLoose mounting boltsWorn bearingsWorn or broken valvesLiquid sluggingInsufficient oilTighten4.124.123.3.104.13Condenser orevaporator fanLoose or striking shroudBearings defectiveBent shaftCheck4.234.23Clutch/Gearbox Defective ReplaceV-belts Cracked or worn 4.43.3.8Control System MalfunctionWill not controlSensor defectiveRelay(s) defectiveMicroprocessor controller malfunction4.31Check4.293.3.9No Evaporator Air Flow or Restricted Air FlowEvaporator coil blockedFrost on coilDirty coil4.214.25No or partial evaporatorair flowV-belt broken or looseClutch/Gearbox defectiveEvaporator fan loose or defectiveEvaporator fan rotating backwardsEvaporator air flow blocked in trailer (box)4.4Replace4.234.4Check3-5 62-02461

INDICATION/TROUBLEPOSSIBLE CAUSESREFERENCESECTION3.3.10 Expansion Valve MalfunctionLow suction pressure with Low refrigerant chargehigh superheatExternal equalizer line pluggedIce formation at valve seatWax, oil or dirt plugging valve or orificeBroken capillaryPowerassemblyfailureorpartialLoss of element/bulb chargeSuperheat setting too high4.8/4.11Clean4.94.274.27ReplaceReplace4.27Low superheat and liquidslugging in compressorSuperheat setting too lowExternal equalizer line pluggedIceholdingvalveopenForeign material in valvePin and seat of expansion valve eroded orheld open by foreign material4.27Open4.9Clean4.27Fluctuating suctionpressureImproper bulb location or installationLow superheat setting4.274.27High superheat Broken capillary 4.273.3.11 Solenoid Valve MalfunctionSolenoid valve does notfunction properlySolenoid valve closes butrefrigerant continues to flowNo power to valveImproper wiring or loose connectionsCoil defectiveValve improperly assembledCoil or coil sleeve improperly assembledMovement of plunger restricted due to:a. Corroded or worn partsb. Foreign material lodged in valvec. Bent or dented enclosing tubForeign material lodged under seatDefective seatCheckCheck4.194.194.194.194.194.19CleanReplace3.4 Standby Motor MalfunctionStandby motor fails to startStandby motor starts, then stopsMotor contactor (MC) defectiveInternal Motor Overload (MOL) openImproper power supplyOil pressure switch (OPS) openSelector switch (SSW) defectivePhase sequence defectiveInternal Motor Overload (MOL) openHigh amperage drawReplaceReplace motorCheckCheckReplace4.28CheckCheckFans rotating backwards Motor incorrectly wired Check62-024613-6

SECTION 4SERVICEWARNINGBeware ofV-belts and belt driven components as the unit may start automatically. Before servicingunit,make sure the Run-Stop switch is in the STOP position. Also disconnect the negative battery cable.CAUTIONUnit uses R404A and POE oil. The use of inert gas brazing procedures is mandatory for all CarrierTransicold refrigeration units; otherwise compressor failure will occur. For more information Refer toTechnical Procedure 98-50553-00 Inert Gas Brazing.NOTETo avoid damage to the earth’s ozone layer, use a refrigerant recovery system whenever removingrefrigerant. When working with refrigerants you must comply with all local government environmentallaws, U.S.A. EPA section 608.4.1 MAINTENANCE SCHEDULEFor the most reliable operation and for maximum life,your unit requires regular maintenance. This includes oiland filter changes, fuel and air filter replacement, coolantreplacement and pretrip inspections. Maintenanceshould be performed according to the following schedule:SYSTEMOPERATIONa. Daily MaintenancePre-Trip Inspection --- before startingPre-Trip Inspection --- after startingCheck Engine Hoursb. Every 2000 Hour Maintenance (Normal Operating Conditions)Unit 1. Check unit mounting bolts2. Check engine and compressor mount bolts3. Check door latches & hinges4. Check muffler and exhaust pipes5. Check gauges, switches and electrical connections6. Check all belt tensions7. Check controL box8. Check gearbox and fanshaft for oil leaks9. Check fanshaft and gearbox bearings10. Check clutch air gap and adjust as required.Engine 1. Check oil/filter change interval (refer to section f.of this table)2. Check for oil leaks3. Check low oil pressure safety4. Clean crankcase breatherFuel System 1. Drain fuel tank sump2. Clean fuel pump strainer3. Change fuel filter(s)4. Check fuel heater (optional)5. Check for fuel leaks6. Check fuel lines for chafing2.12.1Check4.44.3.21.54.3.5--- --- ---4.3.64.3.6--- --- ---REFERENCESECTIONCheck/Replace4-1 62-02461

. Every 2000 Hour Maintenance --- Normal Operating Conditions (Continued)Cooling SystemExhaust SystemAir IntakeSystemStarting SystemChargingSystemRefrigerationSystem1. Check antifreeze using a refractometer (CTD P/N 07---00435---00)2. Clean radiator/condenser fin surface3. Check hoses and connections4. Check water pump5. Check water temperature sensor functions1. Check mounting hardware2. Check muffler and exhaust pipes1. Check and reset air filter indicator (optional)2. Check air cleaner --- clean or replace as required 4.3.41. Check battery2. Clean battery connections and cable ends3. Check battery hold down clamps4. Check starter operation5. Check glow plug operation4.3.14.3.1 and 4.26Check/Replace1.2Check/ReplaceCheck/Replace4.3.71. Check alternator mounting bolts2. Check alternator brushes3. Check alternator output 1.151. Check air switch & calibrate2. Check & clean evaporator3. Check compressor oil level4. Check refrigerant level5. Check operating refrigerant pressure6. Check all sensor calibrations7. Check defrost drains8. Check manual defrost operation9. Check Compressor drive couplingc. Every 3000 Hour Maintenance (Normal Operating Conditions)Perform complete 2000 hour Preventive Maintenance and the following:4.154.254.134.8CheckEngine 1. Check oil/filter change interval (refer to section f.of this table) Engine Service Guided. Every 6000 Hour Maintenance (Normal Operating Conditions)Cooling System1.Drainandflushcoolingsystem(12,000 hours with Extended LifeCoolant)Engine Service Guidee. Every 10,000 Hour MaintenancePerform complete 2000 and 3000 hour Preventive Maintenance and the following:Engine 1. Check oil/filter change interval (refer to section f.of this table) Engine Service GuideFuel System 2. Clean and adjust injector nozzles. Engine Service Guidef. Oil Change IntervalsOil Type Without Bypass Filter With Bypass Filter With ESI Oil FiltersPetroleum2000 hoursSynthetic* 3000 hours 4000 hours2000 hours* Mobil Delvac1 is the only approved synthetic oil. Maximum oil drain interval is two (2) years.These maintenance schedules are based on the use of approved oils and regular Pretrip inspections of the unit. Failureto follow the recommended maintenance schedule may affect the life and reliability of the refrigeration unit.62-024614-2

4.2 PRIMING FUEL SYSTEM4.2.1 Mechanical Fuel PumpThe mechanical fuel lift pump is mounted on the enginenext to the injection pump. This pump has a manualplunger for priming the fuel system when the fuel tankhas been run dry. (See Figure 4-1).To prime the fuel system, use the following steps:1. Turnthebleedvalve(Red)counter-clockwiseuntilfully opened.2. Turn the top of the manual fuel pump plungercounter-clockwise to unlock it. S --- L --- O --- W --- L --- Y(up/down once per second) pump the manualplunger until positive pressure (resistance) is felt.This may take up to 200 strokes. This will indicatefuel flow.3. Continue to pump S --- L --- O --- W --- L --- Y (up/downonce per second) approximately 100 more strokes tofill the filter and bleed the air out of the lines.4. Start engine. It may be necessary to continue topump until the engine starts.5. Depress and turn the top of the manual plungerclockwise to lock in place.6. When engine is running smoothly, turn bleed valveclockwise until fully closed.RedFuel BleedValveManualFuel PumpPlungerFigure 4-1. Priming Fuel Pump4.2.2 Electric Fuel PumpIf the unit is equipped with an optional electric fuel 3. Allow the electric pump to operate for 2---3 minutes.pump, it will be mounted on the fuel tank mountingbracket.(Refer to Section 4.3.6) Use the following steps4. Start engine.to bleed out the fuel system:5. When engine is running properly, turn bleed valveclockwise until fully closed.1. Open bleed valve located on top of the injection pump.(See section Figures 1 --- 3 and 1 --- 6 for location on allunits.)2. Place unit in Manual Start Mode. (Hold Glow/CrankSwitch in the Glow position, then place the Start/Run---OffSwitchintheStart/Runposition.Continueholding the Glow/Crank switch until the Main Displaylights up.) This will turn on the electric fuel pump.4-3 62-02461

4.3 ENGINE SERVICE AND COMPONENTS4.3.1 Cooling SystemAir flows through the condenser/radiator on Ultima. Onall other models the air flows through the radiator byusing the engine fan.The radiator, externally and internally, must be clean foradequate cooling. The water pump V-belt must beadjusted periodically to provide maximum air flow.(Refer to section 4.4.2)Do the following to service the cooling system:CAUTIONUse only ethylene glycol anti-freeze (withinhibitors) in system as glycol by itself willdamage the cooling system.Always add pre-mixed 50/50 anti-freeze andwater to radiator/engine. Never exceed morethan a 50% concentration of anti-freeze. Use alow silicate anti-freeze meeting GMspecifications GM 6038M or equal.a. Remove all foreign material from the radiator coil byreversing the normal air flow. (Air is pulled inthrough the front and discharges over the engine.)Compressed air or water may be used as a cleaningagent. It may be necessary to use warm water mixedwith any good commercial dishwasher detergent.Rinse coil with fresh water if a detergent is used.b. Drain coolant completely by removing lower radiatorhose and radiator cap.c. Install hose and fill system with clean, untreatedwater to which three to five percent of an akalinebased radiator cleaner should be added (six ounces ---dry 151 grams to one gallon = 3.78 liters) of water.d. Run engine 6 to 12 hours and drain system whilewarm. Rinse system three times after it has cooleddown. Refill system with water.e. Run engine to operating temperature. Drain systemagain and fill with treated water/anti-freeze. (seeCaution Note and refer to section 1.2) NEVERPOUR COLD WATER INTO A HOT ENGINE,however hot water can always be added to a coldengine.4.3.2 Lube Oil FiltersAfter warming up the engine, stop engine, remove drainplug from oil reservoir and drain engine lube oil. Lightlyoil gasket on filter before installing.CAUTIONWhen changing oil filters, the new filters shouldbe primed with clean oil. if the filters are notprimed, the engine may operate for a period withno oil supplied to the bearings.Replace filter(s) and add lube oil. (Refer to section 1.2)Warm up engine and check for leaks.4.3.3 Servicing the Speed Control Solenoid andLinkage211. Solenoid2. Bolt3. Solenoid Bracket3544. Linkage (Speed)5. ClipFigure 4-2. Speed Control Solenoida. Disconnect wiring to solenoid. Disconnect linkagearm (item 6, Figure 4-2) from solenoid. Removemounting hardware from solenoid and then removesolenoid.b. Install replacement solenoid and mountinghardware. Do not tighten at this time.c. Attach linkage to solenoid and install the clip to thelinkage rod.d. Hold the speed lever against the low speed stop andcheck the RPM (Refer to Table 1-1). Adjust the lowspeed stop screw if necessary.e. Check engine speed. With the engine stopped, placea mark on the crankshaft sheave (white paint forexample). Speed may be verified by astrobe-tachometer, Carrier Transicold P/N 07-00206.f. Hold the speed lever against the high speed stop andcheck the RPM (Refer to Table 1-1). Adjust the highspeed stop screw if necessary.g. Energize the speed solenoid. Push the solenoid sothat the speed arm rests against the high speed stopscrew and tighten solenoid mounting bolts. Connectwiring to solenoid.LE (Low Emission) DI engines are delivered with atamper resistant high-speed adjustment screw on theengine. High-speed adjustments are made using theslotted holes in the solenoid mounting bracket and86-03027-00 speed solenoid adjusting bracket withsolenoid adjusting bolt and lockout (on the bracket).62-024614-4

4.3.4 Engine Air Cleanera. InspectionThe dry type or oil bath air cleaner should be inspectedregularly for leaks. A damaged air cleaner or hose canseriously affect the performance and life of the engine.The air cleaner is designed to effectively removecontaminants from the air stream entering the engine.An excessive accumulation of these contaminants in theair cleaner will impair its operation, therefore, a serviceschedule must be set up and followed. Remember that theair cleaner cleans the air, but the air cleaner requirescleaning. The following simple service steps are easilymade while the engine is being serviced in the field.The simple inspection steps are as follows:1. Check all connections for mechanical tightness. Besure cleaner outlet pipe is not fractured.2. In case of leakage and if adjustment does not correctthe trouble, replace necessary parts or gaskets.Swelled or distorted gaskets must always be replaced.b. Air Cleaner Service IndicatorThe air cleaner indicator is connected to the engine airintake manifold and its function is to indicate when theair cleaner requires replacing. In operation: When aplugged air cleaner decreases intake manifold pressureto 20” (500 mm) WG, the indicator moves to the red line.The air cleaner should be replaced and the indicator resetby pressing the reset button.c. Service Procedure (Dry Type)1. Stop the engine, remove air cleaner. Install new aircleaner.d. Service Procedure (Oil Type)12CAUTIONAlways cover the engine inlet tube while the aircleaner is being serviced.1. Oil CupsWhen to Service:Remove the oil cup at regular intervals. Initially inspectdaily or as often as conditions require. Never allow morethan 1/2 inch (12.7 mm) of dirt deposit in either cup.More than 1/2 inch accumulation could result in oil anddirt to carry over into the engine causing acceleratedengine wear. Heavily contaminated oil will not allow theair cleaner to function properly.How to Service:Stoptheengineandremovetheoilcupfromtheaircleaner. Dump the oil from the oil cups. Remove theinner cup from the oil cup and clean both cups of sludge.Reassemble and fill both oil cups to the indicated levelwith SAE #10 oil for temperatures below freezing orSAE #30 for temperatures above freezing. It is generallya recommended practice to use the same oil as requiredin the engine crankcase. (Refer to section 1.2)CAUTIONDo not underfill or overfill the cups. Overfillingof cups means loss of capacity and underfillingmeans lack of efficiency.2. Body AssemblyWhen to Service:The lower portion of the fixed element should beinspected each time the oil cup is inspected or serviced. Ifthere is any sign of contaminant buildup or plugging, thebody assembly should be removed and back flushed. Atleast one a year or at regular engine service periodsremove the entire air cleaner and perform the following:(a) Remove oil cup. Check and clean centertube. DO NOT USE GASOLINE.(b) Pump solvent through the air outlet withsufficient force and volume to produce a hard, evenstream out the bottom of the body assembly. Reverseflush until all foreign material is removed.3451. Air Inlet Hood2. Air Cleaner Body3. ClampFigure 4-3 Air Filter4. Inner Cup(Oil bath)5. Oil or Dust Cup4-5 62-02461

4.3.5 Engine Crankcase BreatherThe engine uses a closed type breather with the breatherline attached to the cylinder head cover. (See Figure 4-4)The breather assembly should be cleaned once a year orat every 3000 hours maintenance interval (whichevercomes first).37182411. Cylinder Head Cover2. Breather Cover3. Breather Element4. Plate234565. Breather Oil Shield6. Bolt7. Breather Assembly8. O-RingFigure 4-4. Engine Crankcase Breather11. Nut2. Banjo3. Filter4. Copper RingsFigure 4-5. Mechanical Fuel Pumpb. Electric Pump (See Figure 4-6)To Check or Replace Filter1. Remove 3 screws from cover (item 1, Figure 4-6).2. Remove cover, gasket and filter.3. Wash filter in cleaning solvent and blow out with airpressure. Clean cover.4. To Install reverse above steps.4.3.6 Servicing Fuel Pumpa. Mechanical Pump (See Figure 4-5)Due to foreign particles in the fuel and wax as a result ofusing the wrong grade of fuel or untreated fuel in coldweather. The fuel filter may become plugged orrestricted, and the engine will loose capacity. The filtermust be cleaned on a regular schedule such as unitpre-trip or when the oil and fuel filters are changed(Refer to section 4.1).3211. Turn nut counter-clockwise to loosen and remove(item 1, Figure 4-5).2. Remove banjo fitting (item 2) and let it hang loose,making sure to keep copper rings (item 4) forreplacement.3. Turn filter (item 3) counter-clockwise and remove.Check and clean.4. To install reverse steps 1 through 3.1. Cover2. Gasket3. FilterFigure 4-6. Electric Fuel Pump (Optional)62-024614-6

4.3.7 Servicing Glow PlugsThe glow plugs, when energized, draw a nominal 7.0 ampsat 10.5 vdc. When servicing, the glow plug is to be fittedcarefully into the cylinder head to prevent damage toglow plug. Torque value for the glow plug is 14 to 18 ft-lb(1.9 to 2.5 mkg).Checking for a Defective Glow Pluga. One method is to place an ammeter (or clip-onammeter) in series with each glow plug and energizethe plugs. Each plug (if good) should show 7 to 10amps draw.b. A second method is to disconnect the wireconnection to the plug and test the resistance fromthe plug to a ground on the engine block. The readingshould be 0.7 to 1.2 ohms if the plug is good.4.4 SERVICING AND ADJUSTING V-BELTSWARNINGBeware of V-belts and belt driven components asthe unit may start automatically.4.4.1 Belt Tension GaugeIt is recommended using a belt tension gauge (tester) P/N07-00253, shown in Figure 4-7 whenever V-belts areadjusted or replaced.A belt tension gauge provides an accurate and easymethod of adjusting belts to their proper tension.Properly adjusted belts give long lasting and efficientservice. Too much tension SHORTENS belt and bearinglife, and too little tension causes slippage and excessivebelt wear. It is also important to keep belts and sheavesfree of any foreign material which may cause the belts toslip.The belt tension gauge can be used to adjust all belts. Thereadings which we specify for Carrier Transicold units areapplicable only for our belts and application, as thetension is dependent on the size of the belt and distancebetween sheaves. When using this gauge, it should beplaced as close as possible to the midpoint between twosheaves. (See Figure 4-8)The V-belts must be kept in good condition with theproper tension to provide adequate air movement acrossthe coils. Pre---tension new belt to tension indicated inchart below. Check and re---tension belt to final tensionafter 15 minute break---in.Table 4-1. Belt Tension (See Figure 4-7)BELTSPre TensionTensionWater pump to Crankshaft 35/40 35/40Clutch/Gearbox to Fan shaft 140/150 70/80Clutch/Gearbox to Compressor 140/150 70/80Clutch/Gearbox to Alternator 60/70 40/50Standby Motor to Clutch 140/150 70/80Figure 4-7 Belt Tension Gauge(Part No. 07-00253)4.4.2 Water Pump V-BeltThe water pump V-belt is driven by a sheave on theengine crankshaft. Frayed, cracked or worn belts must bereplaced. Adjustment is achieved by altering the positionof the front side idler.When replacing V-belt, avoid excessive force whenapplying tension to the V-belt to prevent damage to thewater pump bearings. (Refer to Table 4-1)4.4.3 Alternator V-Belta. Make sure negative battery terminal is disconnectedand remove old belt.b. Place V-belt on alternator sheave and then installalternator with two bolts loosely in position.c. Check the center alignment of the Clutch/Gearboxdriving pulley and alternator pulley, to ensure properdrive. Pulley misalignment will create excess beltwear and limit alternator bearing life. The center lineof the alternator sheave, and the driving sheave mustbe in line.d. Pivot alternator to place tension on belt using handforce only. Do not use pry bar or excessive force as itmay cause bearing failure. For correct belt tension seetable 4-1. Tighten pivot and adjustment bolts.NOTEBelt must be checked and retensioned, ifnecessary, after a brief run-in period.4-7 62-02461

421. Evaporator/Condenser Fan V-Belt2. Idler Pulley3. Alternator V-Belt4. Drive V-BeltFigure 4-8. V-Belt Arrangement4.4.4 Driveshaft to Clutch/Gearbox andClutch/Gearbox To Evaporator/CondenserFansa. Clutch/Gearbox to Fan Shaft V-BeltTo Replace V-belt:1. Disconnect negative battery cable and remove V-beltguard.2. Loosen idler pulley.3. Remove old belt and replace with new belt. (SeeFigure 4-8)4. Using a belt tension gauge (Figure 4-7) on the belt,rotate idler pulley so that the gauge reads the correcttension (Refer to Table 4-1).5. Tighten idler, carriage bolt, and bolts.NOTEBoth belts must be checked and retensioned, ifnecessary, after a brief run-in period. (see step 6)132b. Driveshaft to Clutch/Gearbox V-Belt1. Disconnect negative battery cable and remove V-beltguard and then loosen idler bolt.2. Match mark adapter to engine flywheel (SeeFigure 4-9A) for ease of assembly.3. Remove six bolts (5/16-18 x 1 lg) securing adapterdrivesheavetoengineflywheel,Figure4-9A.4. Insert 2 of the six bolts (5/16-18 x 1 lg) into thethreaded holes (jacking holes) provided on engineadapter. Jack adapter from engine flywheel. Removethe 2 screws from adapter. Insert a pry bar betweenengine flywheel and adapter, Figure 4-9A and slidethe adapter-sheave toward the compressor enoughto change the V-belt as shown in Figure 4-9B.Replace V-belt.5. Pry the adapter back toward the engine flywheel oruse 5/16-18 x 2-1/2 lg bolts (3) in every other hole ofadapter and take up evenly on the bolts until the5/16-18 x 1 lg bolts will start in the engine flywheel.Apply thread sealer (Loctite #262) to the bolts usedto secure adapter to flywheel. Take up on all boltsevenly and then torque to a value of 28 ft-lb (3.87mkg).6. Place V-belt on the Clutch/Gearbox sheave andadjust belt tension as indicated in Table 4-1. InstallV-belt guard. DO NOT START UNIT UNTILV-BELT GUARD IS INSTALLED.7. Start unit and run for 10 minutes to allow for beltstretch.8. Turn unit off and recheck belt tension.6. Operate unit in high speed for 5 to 10 minutes.Repeat steps 4 and 5.7. Replace belt guard.62-024614-8

BOLTSFigure ABOLTSFigure AFigure BFigure 4-9. Removing V-Belt from Engine AdapterDrive Sheave (NDA or NDX)4.4.5 Standby Motor V-belts (NDM)NOTEThe standby motor V-belts are a matched set.Always replace both belt.Figure BFigure 4-10. Removing V-Belt from Clutch (NDM)a. Remove V-belt guard.b. Remove 6 bolts on rear face of clutch flange (SeeFigure 4-10).c. Slide clutch flange forward inside clutch sheave.d. Remove and replace V-belt through opening.e. Adjust belt tension as indicated in Table 4-1. InstallV-belt guard. DO NOT START UNIT UNTILV-BELT GUARD IS INSTALLED.f. Start unit and run for 10 minutes to allow for beltstretch.g. Turn unit off and recheck belt tension.4-9 62-02461

4.5 SERVICING STANDBY CLUTCH (NDM)The clutch must be inspected if the clutch slips or grabs.The clutch automatically engages (clutch engagement550 ¦50 rpm) during starting cycle of the engine as theengine accelerates to low speed. The clutch does notengage during standby motor operation.a. Unplug unit from external electrical outlet anddisconnect battery.b. Remove the two rear compressor bracket mountingbolts (compressor shockmount end).c. Block up engine.d. Remove clutch V-belts as outlined in section 4.4.5.e. Pump down the unit.f. Remove suction and discharge service valve.g. Attach sling or other device to the compressor.h. Slide compressor enough to remove clutch.i. Remove (6) 5/16-18 capscrews from rotor assembly(Item 2, Figure 4-11).j. Using 3 of the capscrews as jacking screws, removethe center section of the clutch housing. This willexpose the snap ring holding the housing to the drivehub. Remove snap ring and housing.k. After replacing necessary parts, reassembly byreversing above steps. Install snap ring, painted sidemust face away from bearing.l. Startunitandcheckoperation.1715148234561213101191. Rotor Plate2. Friction Shoe3. Delta Bridge4. Spring, Leaf5. Screw6. Washer7. Coupling, Adapter8. Housing Assembly9. Housing10. Screw11. Washer12. Ball Bearing Assembly13. Snap Ring14. Retaining Plate15. Snap Ring, ExternalFigure 4-11. Standby Clutch Assembly (NDM)62-024614-10

4.6 GEARBOX CLUTCH1. Coil Assembly2. Retaining Ring3. Rotor/Pulley Assembly4. Retainer Nut5. Shims6. Pulley Assembly7. Key8. Washer9. NutFigure 4-12. Gearbox Clutcha. Clutch Removal2. Install rotor/pulley assembly (3)1. Disconnect electrical input.a. Slide rotor/pulley onto gearbox housing. DONOT POUND on rotor assembly; rock back and2. Remove armature/pulley assembly (Figure 4-12, 6)forth gently with hand pressure until unit slidesa. Remove shaft nut (9) and washer (8).on.b. Using a standard 2 --- or 3 --- jaw gear puller, pullthe armature (6) off the shaft. Apply the pullerjaws to the pulley hub, not the rim of the pulley.NOTE: The armature pulley has been loctited tothe shaft.c. Remove the shaft key (7) and shims (5).3. Remove rotor/pulley assembly (3)a. Remove bearing retainer nut (4) using removaltool CTD P/N 07---00303---01.b. Slide rotor/pulley assembly (3) from gearboxhousing.4. Remove the field coil assembly (1)a. Remove field coil assembly retaining ring (2).b. Remove field coil assembly (1) from gearbox.b. Clutch Installation1. Install field coil assembly (1)a. Place field coil assembly (1) on pilot diameter ofgearbox. Align slot in field coil assembly withlocator pin in gearbox housing.b. Install field coil retaining ring (2).IMPORTANT: The retaining ring’s beveled ortaperededgemustfaceawayfromthegearboxtoobtain proper retention force.b. Install bearing retainer nut (4). Tighten nut to 65lb-ft. Rotor should spin free without noise.3. Install armature/pulley assembly (6)a. Slide armature assembly (6) onto gearbox shaft.Measure air gap between armature face androtor face using a wire type feeler gauge. Threeaccess holes are provided in the pulley face.b. Iftheairgapislessthan0.050in.,removearmature assembly and add shim(s) (5) to shaftas shown in Figure 4-12. Use only new shims.c. Repeat steps a. and b. until an average air gap of0.025 to 0.035 in. is obtained.d. Install a new key (7) in shaft.e. Apply Loctite #609 to shaft and pulley hub bore.Slide armature/pulley onto gearbox shaft.f. Install washer (8) and lock nut (9). NOTE: twotypes of locking nuts may be used ---• Standard nylon locknut uses flat washer andrequires 65-70 ft/lbs. torque.• Upset thread type with integral washer DOES NOTuse a separate washer and requires 55-60 ft/lbs.torque - DO NOT over-tighten this type.4-11 62-02461

4.7 PUMPING THE UNIT DOWN ORREMOVING THE REFRIGERANT CHARGENOTETo avoid damage to the earth’s ozone layer, use arefrigerant recovery system whenever removingrefrigerant. When working with refrigerants youmust comply with all local governmentenvironmental laws, U.S.A. EPA section 608.a. Pumping the Unit DownTo service the filter-drier, liquid line solenoid valve(SV-2), expansion valve, quench valve or evaporator coil,pump most of refrigerant into condenser coil andreceiver as follows:1. Backseat suction and discharge service valve (turncounterclockwise) to close off gauge connection andattach manifold gauges to valves.2. Open valves two turns (clockwise). Purge gauge line.3. Close the receiver outlet (king) valve by turningclockwise. Start unit and run in high speed cooling.Place Run-stop switch in the STOP position whenunit reaches 1 psig (0.1 kg/cm@).4. Frontseat (close) suction service valve and therefrigerant will be trapped between the compressorsuction service valve and the manual shutoff (King)valve.5. Before opening up any part of the system, a slightpositive pressure should be indicated on the pressuregauge.6. When opening up the refrigerant system, certainparts may frost. Allow the part to warm to ambienttemperature before dismantling. This avoidsinternal condensation which puts moisture in thesystem.7. Open (backseat) King valve and midseat suctionservice valve.8. Leak check connections with a leak detector. (Referto section 4.8)9. Evacuate and dehydrate the low side. (Refer tosection 4.9).10. Start the unit in cooling and check fornoncondensibles.11. Check the refrigerant charge. (Refer to section4.10.f)NOTEStore the refrigerant charge in an evacuatedcontainer if the system must be opened betweenthecompressordischargevalveandreceiver.Whenever the system is opened, it must beevacuated and dehydrated. (Refer to section4.9)b. Removing the Refrigerant ChargeConnect a refrigerant recovery system to the unit toremove refrigerant charge. Refer to instruction providedby the manufacture of the refrigerant recovery system.4.8 REFRIGERANT LEAK CHECKINGa. If system was opened and repairs completed, leakcheck the unit.b. The recommended procedure for finding leaks in asystem is with an electronic leak detector. Testingjoints with soapsuds is satisfactory only for locatinglarge leaks.c. If system is without refrigerant, charge system withrefrigerant to build up pressure between 30 to 50 psig(2.1 to 3.5 kg/cm@). Remove refrigerant drum andleak check all connections.NOTEConnect the refrigerant drum intended for yoursystem. Any other gas or vapor will contaminatethe system which will require additional purgingand evacuation of the high side (discharge) ofthe system.d. Remove refrigerant using a refrigerant recoverysystem and repair any leaks. Evacuate and dehydratethe unit. (Refer to section 4.9) Charge unit withrefrigerant. (Refer to section 4.10)4.9 EVACUATION AND DEHYDRATION4.9.1 GeneralMoisture is the deadly enemy of refrigerant systems. Thepresence of moisture in a refrigeration system can havemany undesirable effects. The most common are copperplating, acid sludge formation, “freezing-up” of meteringdevices by free water, and formation of acids, resulting inmetal corrosion.4.9.2 Preparationa. Evacuate and dehydrate only after pressure leak test.(Refer to section 4.8)b. Essential tools to properly evacuate and dehydrateany system include a good vacuum pump (5 cfm =8m#H volume displacement, P/N 07-00176-01) and agood vacuum indicator such as a thermocouplevacuum gauge (vacuum indicator). (Availablethrough Robinair Manufacturing, Montpelier, Ohio,Part Number 14010.)NOTEIt is not recommended using a compound gaugebecause of its inherent inaccuracy.c. Keep the ambient temperature above 60_F (15.6_C)to speed evaporation of moisture. If ambienttemperature is lower than 60_F (15.6_C), ice mightform before moisture removal is complete. Heatlamps or alternate sources of heat may be used toraise system temperature.4.9.3 Procedure for Evacuation andDehydrating Systema. Remove refrigerant using a refrigerant recoverysystem.b. The recommended method to evacuate anddehydrate the system is to connect three evacuationhoses (Do not use standard service hoses, as they are62-024614-12

not suited for evacuation purposes.) as shown inFigure 4-13 to the vacuum pump and refrigerationunit. Also, as shown, connect a evacuation manifold,with evacuation hoses only, to the vacuum pump,electronic vacuum gauge, and refrigerant recoverysystem.c. With the unit service valves closed (back seated) andthe vacuum pump and electronic vacuum gaugevalves open, start the pump and draw a deep vacuum.Shut off the pump and check to see if the vacuumholds. This operation is to test the evacuation setupfor leaks, repair if necessary.d. Midseat the refrigerant system service valves.1113210431121. Refrigerant RecoveryUnit2. Refrigerant Cylinder3. Evacuation Manifold4. Valve5. Vacuum Pump6. Vacuum Gauge7. King Valve4684758. Receiver9. Condenser10. Evaporator11. Discharge Valve12. Suction Valve13. CompressorFigure 4-13. Vacuum Pump Connectione. Then open the vacuum pump and electronic vacuumgauge valves, if they are not already open. Start thevacuum pump. Evacuate unit until the electronicvacuum gauge indicates 2000 microns. Close theelectronic vacuum gauge and vacuum pump valves.9Shut off the vacuum pump. Wait a few minutes to besure the vacuum holds.f. Break the vacuum with clean dry refrigerant. Userefrigerant that the unit calls for. Raise systempressure to approximately 2 psig.g. Remove refrigerant using a refrigerant recoverysystem.h. Repeat steps e through g one time.i. Evacuate unit to 500 microns. Close off vacuumpump valve and stop pump. Wait five minutes to seeif vacuum holds. This checks for residual moistureand/or leaks.j. With a vacuum still in the unit, the refrigerant chargemay be drawn into the system from a refrigerantcontainer on weight scales. The correct amount ofrefrigerant may be added by observing the scales.(Refer to section 4.10)4.10 ADDING REFRIGERANT TO SYSTEM(FULL CHARGE)a. Dehydrate unit and leave in deep vacuum. (Refer tosection 4.9)b. Place drum of refrigerant on scale and connectcharging line from drum to king valve. Purgecharging line at outlet valve.c. Note weight of drum and refrigerant.d. Open liquid valve on drum. Open king valve half wayand allow the liquid refrigerant to flow into the unituntil the correct weight of refrigerant has been addedas indicated by scales. Correct charge will be found insection 1.3.NOTEIt is possible that all liquid may not be pulled intothe receiver, as outlined in step d. In this case,frontseat the receiver outlet valve (king valve)and the liquid will be pulled into the system. Unitmust be operating in the cooling mode.e. When drum weight (scale) indicates that the correctcharge has been added, close liquid line valve ondrum and backseat the king valve.f. Start unit in cooling mode. Run approximately tenminutes. Partially block off air flow to condenser coilso discharge pressure rises to 230 psig (16 kg/cm@).Refrigerant should appear at center line of lower receiversight glass. If charge is inadequate, add refrigerant charge(per section 4.11).4.11 ADDING REFRIGERANT TO SYSTEM(PARTIAL CHARGE) - R-22 ONLYCAUTIONDo not vapor charge R-404A. Only liquidcharging through the liquid line king valve isacceptable.a. Place drum of refrigerant on scale and note weight.Backseat suction service valve and connect chargingline between suction valve port and drum. OpenVAPOR valve on drum and purge charging line.4-13 62-02461

. Run the unit in cooling for ten minutes and thenpartially block off air flow to condenser coil sodischarge pressure will rise 10 psig (0.7 kg/cm@).Refrigerant should appear at center line of the lowerreceiver sight glass . If charge is inadequate, addrefrigerant charge with condenser coil still blocked.c. Open suction service valve three turns. Add chargeuntil level appears at center line of the lower receiversight glass.d. Backseat (close) suction service valve. Close vaporvalve on refrigerant drum, noting weight. Ventcharging line and replace all caps.e. Start unit and check for noncondensibles.2NOTESThe service replacement compressor is soldwithout shutoff valves (but with valve pads).Customer should retain the original capacitycontrol valves for use on replacementcompressor. Check oil level in servicereplacement compressor. (Refer to sections 1.3,and 4.13)3467104.12 REPLACING THE COMPRESSORIf compressor is inoperative and unit still has refrigerantpressure, remove the refrigerant. (Refer to section4.7.b.).If compressor runs, pump down the unit. (Refer tosection 4.7.a)a. Disconnect negative battery cable.b. Remove bolts from suction and discharge servicevalve flanges.c. Disconnect wiring to unloader valve assemblies,compressor discharge temperature sensor (CDT),suction pressure transducer and the wiring to thehigh pressure cutout switches (HP-1 and HP-2).Identify wiring and switches if necessary. (SeeFigure 4-15)d. Remove the two rear compressor bracket mountingbolts (compressor shockmount end).e. Block up engine.f. Remove oil filter and bracket from 05G compressor.g. Remove 10 bolts from the engine-compressor spacer.h. Disconnect ground strap from frame.i. Disconnect suction pressure transducer fromcompressor .j. Attach sling or other device to the compressor.k. Slide compressor enough to clear nylon drive gear(or clutch housing on model NDM), Figure 4-14, andremove compressor from unit.l. Drain oil from defective compressor before shipping.m. The original unloader valves must be transferred tothe replacement compressor. The plug arrangementremoved from the replacement is installed in theoriginal compressor as a seal. If piston is stuck, it maybe extracted by threading socket head cap screw intotop of piston. A small teflon seat ring at bottom ofpiston must be removed.1. Compressor2. Bolts3. Spacer4. Key5. Compressor DriveGear15896. Locking Tab7. Nylon Drive Gear8. DriveSheaveBolts9. V-Belt10. Engine AdapterDrive SheaveFigure 4-14. Compressor Drive Assemblyn. Remove the complete high pressure switch assembly(HP-1 and HP-2) (See Figure 4-15) and install onnew compressor after checking switch settings.Remove compressor discharge temperature sensor(CDT) and suction pressure transducer and installon new compressor. Install compressor frame to newcompressor (if removed with defective compressor).HP-1HP-2Figure 4-15. Pressure Switches HP-1 and HP-2o. Install compressor in unit by reversing step 4.12.cthrough n. It is recommended using new locknutswhen replacing compressor. Torque bolts to a valueof 46 ft/lb (6.4 mkg). Install new gaskets on servicevalves and tighten bolts uniformly. Refer to section4.33.1 driver gear installation.p. Attach two lines (with hand valves near vacuumpump) to the suction and discharge service valves.Dehydrate and evacuate compressor to 500 microns(29.90” Hg vacuum = 75.9 cm Hg vacuum). Turn offvalves on both lines to pump.q. Fully backseat (open) both suction and dischargeservice valves.62-024614-14

4311d. To remove oil from the compressor:1. Close suction service valve (frontseat) and pump unitdown to 2 to 4 psig (0.1 to 0.3 kg/cm@). Frontseatdischarge service valve and slowly bleed remainingrefrigerant.2. Remove the oil drain plug from the compressor anddrain the proper amount of oil. Replace the plugsecurely back into the compressor.3. Open service valves and run unit to check oil level,repeat as required to ensure proper oil level.87611109605K05G1 21. High Pressure Switch Connection2. Suction Pressure Transducer Connection3. Suction Service Valve4. OilFillPlug5. Bottom Plate6. Oil Drain Plug7. Oil Level Sight Glass8. Oil Pump9. Unloader Solenoid10. Discharge Thermistor Connection11. Discharge Service ValveFigure 4-17. Compressorc. Adding Oil to Service ReplacementCompressorService replacement compressors may or may not beshipped with oil.If compressor is without oil:Add correct oil charge (Refer to section 1.3) through thesuction service valve flange cavity or by removing the oilfill plug (See Figure 4-17)73454.14 COMPRESSOR UNLOADER VALVEThe compressor unloaders (located on the compressorcylinder heads) are controlled by relays UFR,URR andthe temperature controller. (Refer to section 1.9)This section contains two compressor unloader systems:hot gas bypass and suction cutoff. They are easilydistinguished from each other by observing the bottomside of the compressor cylinder head, it is either blank(hot gas bypass) or has a cover plate (suction cutoff). Theunit operates the same with ether unloader systems.a. Checkout Procedure1. Connect manifold gauges to the compressor suctionand discharge service valves and start unit in coolingwith the trailer temperature at least 5_F (2.8_C)above set point and the compressor will be fullyloaded (both unloader coils are de-energized). Notesuction pressure.2. Remove wiring from the front unloader coil. Placeelectrical tape over wire terminals.3. Set controller upscale (cooler to warmer). Thismechanically simulates falling temperature.Approximately 2_F (1.1_C) below box temperaturethe unloader coils will energize, but only the rearunloader valve will unload. Note suction pressure, arise of approximately 3 psig (0.2 kg/cm@)willbenotedon the suction pressure gauge.4. Reconnect wiring on the front unloader. The frontunloader will retract and an additional 3 psig (0.2kg/cm@) rise on the suction gauge will be noted.Compressor is now fully unloaded and only the topbank is loaded (two cylinders).5. Reverse the above procedure to check outcompressor loading. Suction pressure will drop withthis test.NOTEIf either unloader coil energizes and the suctionpressure does not change, the unloader assemblymust be checked.62-024614-16

. Solenoid Coil ReplacementNOTEThe coil may be removed without pumping theunit down.1. Disconnect leads. Remove retainer. Lift off coil.(See Figure 4-18)2. Verify coil type, voltage and frequency of old and newcoil. This information appears on the coil housing.3. Place new coil over enclosing tube, retainer andconnect wiring.1101132456789SUCTION CUTOFF1. Retainer2. Coil Assembly3. Installation/RemovalTool4. Enclosing TubeCollar5. “O” Ring6. Enclosing Tube7. Plunger Spring121314HOT GAS BYPASS8. Plunger Assembly9. Gasket10. Valve Body11. Gasket12. Bolt13. Gasket, Bolt14. Piston RingFigure 4-18. Unloader Solenoid Valvec. Replacing Solenoid Valve Internal Parts(See Figure 4-18)1. Pump down the unit. Frontseat both service valves toisolate the compressor.2. Remove coil retainer, and coil.3. Remove enclosing tube collar (item 4, Figure 4-18)using installation/removal tool supplied with repairkit (item 3).4. Check plunger for restriction due to: (a) Corrodedor worn parts; (b) Foreign material lodged in valve;(c)Bentordentedenclosingtube.5. Install new parts. Do not overtighten enclosing tubeassembly. Torque to a value of 100 inch pounds (1.15mkg).6. Remove supplied installation/removal tool. Installcoil, voltage plate, and retainer.7. Evacuate and dehydrate the compressor. (Refer tosection 4.12.p through 4.12.w.)8. Start unit and check unloader operation (Refer tosection 4.14.a).d. Replacing the Suction Cutoff UnloaderWARNINGMake sure power to unit is OFF and negativebattery cable is disconnected before servicingthe compressor unloader.1. Close off suction and discharge service valve to trapmost of the refrigerant in the unit (this will preventmoisture from entering the system and save most ofthe refrigerant charge).2. Slowly release compressor pressure through theservicevalvegaugeports.3. Remove cylinder head and unloader fromcompressor. Have on hand valve plate gasket,cylinder head gasket, suction and discharge servicevalve gaskets.4. Proceed to step 11 if not rebuilding unloader at thistime.CAUTIONCare must be exercised when handling valvebody and enclosing tube as a dent in theenclosing tube could mean failure to unload thecompressor.5. Remove valve body and enclosing tube assembly andgasket. (Items 1, 2, and 3, Figure 4-19).6. Remove cover and gasket (items 9,10 & 11) frombottom of cylinder head. Then remove spring andvalve body (items 7 and 8).7. From the top of the cylinder head, push piston (item6) out of piston cavity.8. On the replacement piston, place ring seal in positionon piston by positioning in place (using two thumbs).Make sure seal is firmly in place.9. From bottom of cylinder head, insert seal and pistonin cylinder head. Using piston driver, push pistoninto cylinder head cavity.10. Re-assemble rest of unloader.11. Install new valve plate gasket and cylinder headgasket before installing cylinder head.12. After installing cylinder head, torque bolts to a valueof 35 to 40 ft/lb (4.84 to 5.53 mkg).13. Place unloader coil and snap cap on unloader valveenclosing tube.4-17 62-02461

34124.15 SERVICING THE CHECK VALVE -SERVICEABLE TYPEThe check valve allows the hot gas to travel in onedirection only.The function of the condenser coil bypass is to raise thereceiver pressure when the ambient temperature is low sothat refrigerant can flow from the receiver to theevaporator when the unit is in heating or defrost.5432156256CAP4BOLT78910111. Valve Body andEnclosing Tube2. Bolt and Gaskets3. Gasket4. Strainer5. Cylinder Head6. Piston and Ring Seal7. Valve Body8. Spring9. Cover Gasket10. Cover11. BoltsFigure 4-19. Compressor Unloader Valve ---Suction Cutoff14. Attach two lines (with hand valves near vacuumpump) to the suction and discharge service valves.Dehydrate and evacuate compressor to 500 microns(75.9 cm = 29.90 inches Hg vacuum). Turn off valveson both lines to pump.15. Fully backseat (open) both suction and dischargeservice valves.16. Remove vacuum pump lines.17. Start unit and check refrigerant charge. (Refer tosection 4.10.f)18. Check system for wetness. Change filter-drier ifnecessary. (Refer to section 4.16)19. Check compressor oil level per section 4.13.a. Addoil if necessary. (Refer to section 4.13.b.)1. Cap4. Brass/Teflon Seat2. Copper Washer 5. Body3. Spring6. CoverFigure 4-20. Check Valve --- Serviceable Typea. To replace check valve, store the refrigerant into anevacuated container. (Refer to section 4.7)b. Replace necessary parts.c. Evacuate and dehydrate unit. (Refer to section 4.9)d. Add refrigerant charge. (Refer to section 4.10)4.16 CHECKING AND REPLACINGFILTER-DRIERTo Check Filter-DrierCheck for a restricted or plugged filter-drier by feelingthe liquid line inlet and outlet connections of the driercartridge. If the outlet side feels cooler than the inletside, then the filter-drier should be changed.To Replace Filter-Driera. Pump down the unit per section 4.7. Removebracket, then replace drier.b. Check refrigerant level. (Refer to section 4.11.b)62-024614-18

4.17 CHECKING AND REPLACING HIGHPRESSURE CUTOUT SWITCHES4.17.1Replacing High Pressure Switcha. Pump down the unit. (Refer to section 4.7.a)Frontseat both suction and discharge service valvesto isolate compressor.b. Slowly release compressor pressure through theservicevalvegaugeports.c. Disconnect wiring from defective switch. The highpressure switches are located on the top cylinderhead.(SeeFigure4-17)d. Install new cutout switch after verifying switchsettings. (Refer to section 4.17.2)e. Evacuate and dehydrate the compressor. (Refer tosection 4.12.p through 4.12.w)4.17.2Checking High Pressure Switch(HP-1 or HP-2)WARNINGDo not use a nitrogen cylinder without apressure regulator. Cylinder pressure isapproximately 2350 psi (165 kg/cm@). Do not useoxygen in or near a refrigerant system as anexplosion may occur. (See Figure 4-21)1234561. Cylinder Valveand Gauge2. Pressure Regulator3. Nitrogen Cylinder4. Pressure Gauge(0 to 400 psig =0to28kg/cm@)5. Bleed-Off Valve6. 1/4 inch ConnectionFigure 4-21. Typical Setup for Testing HighPressure Switcha. Remove switch as outlined in section 4.17.1.b. Connect ohmmeter or continuity light across switchterminals. Ohmmeter will indicate resistance andcontinuity light will be lighted if switch closed afterrelieving pressure.c. Connect switch to a cylinder of dry nitrogen. (SeeFigure 4-21)d. Set nitrogen pressure regulator higher than cutoutpoint on switch being tested. Pressure switch cutoutandcut-inpointsareshowninsections1.3.e. Close valve on cylinder and open bleed-off valve.f. Open cylinder valve. Slowly close bleed-off valve andincrease pressure until the switch opens. If light isused, light will go out and if an ohmmeter is used, themeter will indicate open. Open pressure on gauge.Slowly open bleed-off valve (to decrease pressure)until switch closes (light will light or ohmmeter willmove).4.18 REPLACING RECEIVER SIGHT GLASSASSEMBLYNOTEThere are two types of receiver sight glasses.One is the floating ball type (P/N 14-00111), andthe second is the prism type (P/N 14-50023-00);both are interchangeable.a. Store the refrigerant in an evacuated container.(Refer to section 4.7.b)b. Unscrew the sight glass assembly. Spread somesealing compound on pipe threads of new sight glassassembly and install.c. Leak check receiver sight glass per section 4.8.d. After leak checking unit, evacuate and dehydrate asoutlined in section 4.9.e. Add refrigerant charge. (Refer to section 4.10)f. Check for noncondensibles.4.19 SERVICING SOLENOID VALVES4.19.1Solenoid Valves - AlcoSV2/SV4 on Ultima, Ultra & ExtraSV2/SV3/SV4 on OptimaCAUTIONDo not damage or overtighten the enclosing tubeassembly. Torque to 200-inch pounds (2.3 mkg).Also make sure all parts are placed on theenclosing tube in proper sequence to avoidpremature coil burnout.a. Replacing the CoilNOTEThe coil may be replaced without removing therefrigerant or pumping the unit down.1. Disconnect leads, remove coil retainer and coilassembly.2. Verify coil type, voltage and frequency. Thisinformation appears on the coil housing.3. Place new coil over enclosing tube, retainer andconnect wiring.4-19 62-02461

. Replacing Solenoid Valve Internal Parts(See Figure 4-22)The liquid line solenoid valve (SV2) may be serviced bypumping the unit down. (Refer to section 4.7.a)Remove and store the refrigerant charge in an evacuatedcontainer to service hot gas solenoid valve. (Refer tosection 4.7.b)1. Remove coil retainer and coil assembly from valve.Remove enclosing tube assembly and related items.2. Check for foreign material in valve body.3. Install new parts.4. Tighten enclosing tube assembly to a torque value of200 inch pounds (2.3 mkg) and leak check the valve.(Refer to section 4.8)5. Install coil assembly and retainer.6. Start unit and check refrigerant charge per section4.10.f.7. Check refrigeration cycles.(Refer to section 2)213b. Replacing Internal Components(See Figure 4-23)1. Remove and store the refrigerant charge in anevacuated container. (Refer to section 4.7.b)2. Remove the top locknut, spacer cup, nameplate, coilassembly and spacer (SV1). For SV3, remove screwand nameplate.3. Using a 12 point, 1-3/8 inch box wrench, loosen theenclosing tube locknut and bleed off remainingrefrigerant.4. Remove enclosing tube and locknut assembly. Thegasket is inside the enclosing tube.5. Remove seat disc from inside of body and check forobstructions and foreign material.6. Place the seat disc into the valve body with thesmallerdiameterendfacingup.7. For SV3 install stem and plunger (item 11,Figure 4-23)8. Place the enclosing tube locknut over the enclosingtube. Install spacer over enclosing tube making sureit is seated properly in the enclosing tube locknut.Tighten enclosing tube locknut to a torque value of20 ft-lb (2.78 mkg). Do not overtighten.1231346574564678781. Retainer2. Coil Assembly3. Enclosing TubeAssembly4. Plunger Assembly5. Gasket6. Piston Assembly7. Body8. Bracket AdapterFigure 4-22. Solenoid Valves --- Alco4.19.2Solenoid Valve - SporlanSV1/SV3 on Ultima, Ultra & ExtraSV1 on Optimaa. Replacing the CoilNOTEThe coil may be replaced without removing therefrigerant or pumping the unit down.1. Remove top locknut, spacer cup and nameplate(SV1). For SV3, remove screw and nameplate.2. Disconnect wiring and remove coil.3. Replace coil by reversing steps 1 and 2.8910SV-11. Locknut/Screw2. Spacer Cup3. Nameplate4. Coil5. Spacer6. Enclosing TubeLocknut11910SV-37. Enclosing Tube8. Gasket9. Seat Disc10. Body11. Stem andPlungerFigure 4-23. Solenoid Valves --- Sporlan9. Install coil assembly, nameplate and top locknut orscrew.62-024614-20

10. Dehydrate and evacuate the system. (Refer tosection 4.9) Charge unit with refrigerant per sections4.10 and 4.11.11. Start unit and check operation. (Refer to section 2)4.20 SOLENOID VALVE SV-1 CHECKOUTPROCEDURETo obtain proper heating and defrost, the normally open(N.O.) SV-1 solenoid valve must energize and closetightly during the heat and defrost cycles. If the valve doesnot close tightly due to physical damage, foreign materialor wear, refrigerant leakage through the valve can reduceheating capacity.a. During normal heat or defrost cycles the followingconditions will be observed when the valve isoperating properly:(1) Receiver refrigerant level will drop quicklyat the initiation of heating or defrost mode.(2) Suction pressure will rise slowly to 90---100psig (6.3 to 7.0 kg/cm@).(3) Discharge pressure will drop quickly, butbegin to rise to a minimum of 250 psig (17.5 kg/cm@)within 15 to 20 minutes.b. If suction and discharge pressures remain low andthe receiver level does not drop, the valve may beinoperative and can be checked by the followingmethod.(1) Verify the solenoid coil has proper voltageand is energized in heating and defrosting.(2) Connect a discharge pressure gauge to thecompressor discharge service valve and connect a gaugeto the liquid line valve (king valve) leaving the receivertank.(3) With the trailer temperature at 35_F(1.7_C) or lower, operate the unit in high speed cool andremove or disconnect the “hot” wire leading to the SV-1coil.(4) With a separate 12 vdc positive voltage,energize SV-1 with the unit in high speed cooling andobserve the discharge and receiver pressures. If the valveis closing properly, compressor discharge pressure willbegin to rise and the receiver pressure will remain thesame or begin to drop slowly. If the valve is not seatingproperly, both discharge and receiver pressure will riseslowly or remain the same.Operate the unit until discharge pressure reaches 200psig (14 kg/cm@) and disconnect jumper wire to SV-1valve. Discharge and receiver pressure should be within 5to 15 psig (0.4 to 1.0 kg/cm@) ofeachother.4.21 CHECKING DEFROST OR HEATINGCYCLENOTEThe evaporator temperature must be 35_F(1.7_C) (approximately 40_F = 4.4_C boxtemperature) or lower, before any checks can bemade.a. Hot Gas Solenoid Valve (SV-1,SV-3 & SV-4)Heating and Defrosting1. Connect a discharge pressure gauge to the King valveand another gauge to the compressor dischargeservice valve. Connect a gauge to the compressorsuction service valve.2. Start unit with controller set at least 10_F = 5.5_Cbelow indicated box temperature to obtain highspeed cooling. Press the MANUAL DEFROST keyto initiate defrost. (Box temperature must be below40_F = 4.4_C.) The hot gas solenoid valve (SV4) willenergize and the hot gas line will be hot to touch oneither side of the valve. The condenser pressurecontrol solenoid (SV1) closes and suction pressurewill rise approximately 10 to 15 psig (0.70 to 1.05kg/cm@) after 5 minutes on unit operation. Refer tosection 4.20 if unit does not heat properly.3. SV-3 will open after a 60 second delay, if the engine isin high speed and the difference between ambientand discharge temperatures exceeds 100_F(55.6_C).If the difference between ambient anddischarge temperatures goes below 50_F (27.8_C)SV-3 will close. The unit will remain in defrost untilcoil temperature increases to 50_F(10_C) where thedefrost thermostats open and the unit resumesautomatic operation.b. Defrost Air Switch (DA)1. To check air switch, run unit in high speed coolingand jump across the air switch terminals. This willstart the defrost cycle as it simulates the action of thedefrost air switch. Bypassing the switch in thismanner operates all components involved in defrost.2. Unit should remain in defrost until evaporator coiltemperature reaches 50_F (10_C). At this point thetwo defrost thermostats should open to terminatethe defrost cycle. Replace the defrost thermostats ifunit fails to terminate defrost.3. If the above test indicates satisfactory operation, testdefrost air switch (DA) settings using a DwyerMagnehelic gauge (P/N 07-00177) or similarinstrument. (Refer to section 4.22)c. Solid State Defrost TimerRefer to section 1.10.10 for description.4-21 62-02461

4.22 CHECKING CALIBRATION OF THEDEFROST AIR SWITCH52641. OhmmeterorContinuityDevice2. Adjustment Screw (0.050 socket head size)3. Low Side Connection4. Pressure Line or Aspirator Bulb(P/N 07-00177-01)5. Magnehelic Gauge (P/N 07-00177)6. High Side ConnectionFigure 4-24. Defrost Air Switch Test Setup31a. Make sure magnehelic gauge is in proper calibration.NOTEThe magnehelic gauge may be used in anyposition, but must be re-zeroed if position ofgauge is changed from vertical to horizontal orvice versa. USE ONLY IN POSITION FORWHICH IT IS CALIBRATED.b. With air switch in vertical position, connect highpressure side of magnehelic gauge to high sideconnection of air switch. (See Figure 4-24)c. Install tee in pressure line to high side connection.Tee should be approximately half-way betweengaugeandairswitchoranimproperreadingmayresult.d. Attach an ohmmeter to the air switch electricalcontacts to check switch action.NOTEUse a hand aspirator (P/N 07-00177-01), sinceblowing into tube by mouth may cause anincorrect reading.e. With the gauge reading at zero, apply air pressurevery slowly to the air switch. An ohmmeter willindicate continuity when switch actuates.f. Refer to section 1.3 for switch settings. If switch failsto actuate at correct gauge reading, adjust switch byturning adjusting screw clockwise to increase settingor counterclockwise to decrease setting.g. Repeat checkout procedure until switch actuates atcorrect gauge reading.h. After switch is adjusted, place a small amount ofpaint or glycerine on the adjusting screw so thatvibration will not change switch setting.62-024614-22

4.23 REPLACING THE CONDENSER/ EVAPORATOR FAN SHAFT OR BEARING (ALL MODELS EXCEPTULTIMA)75103Early Units984352161312111. Condenser Fan2. Adapter Condenser Fan3. Sheave4. V-Belt5. Split Tapered Bushing6. Key7. Flange Condenser Fan8. Gasket (Prior to S/NDAF90213555)9. Bearing Housing10. Shaft11. Bushing12. Blower Wheel13. Venturi RingFigure 4-25. Evaporator/Condenser Fan Shaft Assembly (All Models Except Ultima)WARNINGBeware of unannounced starting of theevaporator and condenser fan.a. To Remove the Fan Shaft1. Disconnect negative battery cable.2. Remove 4 screws securing condenser fan (item 1,Figure 4-25) to adapter.3. Remove V-Belt. (Refer to section 4.4.4.)4. Remove 3 screws securing adapter (item 2).5. Remove 3 screws securing sheave (item 3).6. Remove tapered bushing (item 5) and flange (item7) on early units.7. Remove evaporator panels.8. Remove two screws securing split tapered bushing, toblower wheel (items 12 and 13, Figure 4-25). Placethe two screws in the threaded holes of the fan huband use screws as jacking bolts to remove bushingfrom blower wheel.9. Remove venturi ring (item 13, Figure 4-25) byremoving 4 screws.10. Remove 4 screws from the bearing housing (item 9,Figure 4-25).11. Remove the shaft and bearing housing.12. Install bearing housing assembly into unit byreversing steps 1 through 9 with a new gasket (item8)or using caulk.13. Locate the fan and key so that 1/3 of the condenserfan extends beyond the leaving edge of the fanshroud. Secure fan and hub to shaft.14. Install evaporator fan venturi ring. Then installtapered hub and blower wheel loosely. Adjust blowerwheel and tighten.15. Install evaporator panels.WARNINGDo not start unit without installing theevaporator panels as unit damage or body harmmay result.16. Start unit and check refrigeration cycle.4-23 62-02461

4.24 REPLACING THE CONDENSER/EVAPORATOR FAN SHAFT ASSEMBLY OR FAN CLUTCH (ULTIMA)183569A1517VIEW A- A1619ABVIEW B- B12411B781012132141. Screw Hex Head 1/4-20 X 1lg2. Lock Washer 1/43. Condenser Fan4. Adapter5. Screw Hex Head 5/16-18 X 1lg6. Lock Washer 5/167. Screw Hex Head 3/8-16 X 1lg8. Special Washer9. Retainer Washer10. Clutch11. Special Washer12. Screw Hex Head 3/8-16 X 1.5lg13. Lock Washer 3/8Figure 4-26. Evaporator/Condenser Fan Shaft Assembly (Ultima)14. Special Washer15. Plate16. Pressure Relief Valve17. Bearing Housing18. Clip19. Screw Hex Head #10-32 X .25lgWARNINGBeware of V-belts and belt drivencomponents as the unit may startautomatically. Before servicing unit,make sure the Run-Stop switch is in theSTOP position. Also disconnect thenegative battery cable.a. To Remove the Clutch (See Figure 4-26)NOTEThe air gap between the clutch contact surfacesis non-adjustable. The original air gap is set to0.020” and can wear up to 0.040” beforereplacement is needed.1. Disconnect the negative battery cable.2. Remove top 8 bolts (4 along top edge and 2 downeach side) that hold fan shroud to condenser frame.Remove top frame cross member (6 bolts).3. Loosen the fan belt idler and remove belt.4. Pry top of shroud away from frame and hold it open byinserting any object about 3.50” deep between frameandshroudoneachside(shortpiecesof2X4’sworkswell).5. Remove the 4 screws securing the condenser fan(item 3, Figure 4-26) to the adapter (item 4) or skipthis operation to remove the fan/adapter as oneassembly.6. Remove the 3 screws securing the adapter (/ fan).7. Using an Allen wrench or 1/4” rod, slide it throughthe notch on either side of the backer plate (item 15)until it touches the washer behind the clutch. Slowlyrotate the fan shaft while applying a slight pressure tothe rod until the rod slips into one of theanti-rotation holes in the washer. With the rod inplace, remove the bolt and washers (items 7, 8 & 9)which secure the clutch onto the shaft.8. Remove the clutch pulley/armature from the shaft(be careful not to get the anti-seize compound on theclutch engagement surfaces if clutch is to be reused).9. Unplug the wire connector to the clutch rotor/fieldassembly and remove from the shaft.62-024614-24

10. Install clutch on fan shaft assembly by reversing steps1-7. Add a thin coating of anti-seize compound tonew clutch bore. Do not get anti-seize compound onclutch contact surfaces. Be sure to align anti-rotationtang of rotor/field assembly (12 o’clock position)between the two backer plate supports while slidingitinto position and also pull the tension clip (item 18)out of the way (about 1”) to fully seat this clutch half.Orient retainer washer (9) so that bent tab is insertedinto key way, then bend two tabs over the bolt. Clutchbolts torque is 25 to 30 ft/lbs.b. To Remove the Fan shaft/bearing Assembly(See Figure 4-26)1. First complete clutch removal refer to steps above.2. Remove washer (item 11) from shaft (behind clutch).3. Remove evaporator panels.4. Remove two screws securing split tapered bushing, toblower wheel (items 12 and 13, Figure 4-25). Placethe two screws in the threaded holes of the fan huband use screws as jacking bolts to remove bushingfrom blower wheel.5. Remove venturi ring (item 13, Figure 4-25) byremoving 4 screws.6. Remove clamp from rubber boot on the back of thefan shaft housing and remove the 6 bolts and ringsecuring the boot to the pod.7. Remove 4 screws from the bearing housing (item 17).8. Remove the shaft and bearing housing.9. Install bearing housing assembly into the unit byreversing steps 1 through 8. Torque 45 to 50 in/lb the 6bolts which hold the boot and ring to the pod.WARNINGDo not start unit without installing the evaporatorpanels as unit damage or body harm may result.10. Start unit and check refrigeration cycle.4.25 EVAPORATOR COIL CLEANINGThe use of recycled cardboard cartons is increasing acrossthe country. The recycled cardboard cartons create muchmore fiber dust during transport than “new” cartons. Thefiber dust and particles are drawn into the evaporatorwhere they lodge between the evaporator fins. If the coilis not cleaned on a regular basis, sometimes as often asafter each trip, the accumulation can be great enough torestrict air flow, cause coil icing, repetitive defrosts andloss of unit capacity. Due to the “washing” action ofnormal defrost the fiber dust and particles may not bevisible on the face of the coil but may accumulate deepwithin.It is recommended to clean the evaporator coil on aregular basis, not only to remove cardboard dust, but toremove any grease or oil film which sometimes coats thefins and prevents water from draining into the drain pan.Cardboard fiber particles after being wetted and driedseveral times can be very hard to remove. Therefore,several washings may be necessary.a. Remove rubber check valves (Kazoo) from drainlines (front of trailer).b. Spray coil with a mild detergent solution such asOakite 164 or any good commercial grade automaticdish washer detergent such as Electrosol or Cascadeand let the solution stand for a few minutes andreverse flush (opposite normal air flow) with cleanwater at mild pressure. A garden hose with spraynozzle is usually sufficient. Make sure drain lines areclean.c. Run unit until defrost mode can be initiated to checkfor proper draining from drain pan. (Refer to section2)4.26 CONDENSER COIL CLEANINGRemove all foreign material from the condenser coil byreversing the normal air flow. (Air is pulled in through thefront and discharges over the engine.) Compressed air orwater may be used as a cleaning agent. It may be necessaryto use warm water mixed with any good commercialdishwasher detergent. Rinse coil with fresh water if adetergent is used.4.27 THERMOSTATIC EXPANSION VALVEThe thermal expansion valve is an automatic devicewhich maintains constant superheat of the refrigerant gasleaving the evaporator regardless of suction pressure.The valve functions are: (a) automatic response ofrefrigerant flow to match the evaporator load and (b)prevention of liquid refrigerant entering the compressor.Unless the valve is defective, it seldom requires anymaintenance.a. Replacing Expansion Valve (All ModelsExcept Ultima)2 51. Power Assembly2. Body Flange Gaskets3. Seat Gasket4. Bulb136745. Cage Assembly6. Body Flange7. Body Flange ScrewsFigure 4-27. Thermostatic Expansion Valve1. Pump down the unit by closing the King valve. (Referto section 4.7.a)4-25 62-02461

2. Remove insulation (Presstite) from expansion valvebulb and then remove bulb from suction line.3. Loosen flare nut and disconnect equalizer line fromexpansion valve.4. Remove flange screws and lift off power assembly.Thenremovethecageassembly.Checkforforeignmaterial in valve body.5. The thermal bulb is located below the center of thesuction line (See Figure 4-28). This area must beclean to ensure positive bulb contact. Apply thermalmastic and strap thermal bulb to suction line andinsulate both with Presstite.6. Install new gaskets and insert cage assembly andinstall power assembly.7. Fasten equalizer tube to expansion valve.8. Evacuate by placing vacuum pump on suction servicevalve.9. Open King valve and then check refrigerant level.(Refer to section 4.11.b)10. Check superheat. (Refer to section 1.3.h)b. Replacing Expansion Valve & Screen (Ultima)1. Pump down the unit by closing the King valve. (Referto section 4.7.a)2. Remove insulation (Presstite) from expansion valvebulb and then remove bulb from suction line.3. Remove Presstite from the expansion valve powerhead. Unscrew power head if only the element isbeing changed and replace by reversing steps 1through 3.4. Use a wet rag to keep TXV cool whenever brazing orunbrazing. Unbraze inlet, outlet and equalizerconnection to valve body. Clean all tube stubs so newvalve fits on easily.5. Install new valve and screen, with cone of screenpointing into liquid line at inlet to the valve byreversing steps 1 through 4.6. The thermal bulb is located below the center of thesuction line (See Figure 4-28). This area must beclean to ensure positive bulb contact. Apply thermalmastic and strap thermal bulb to suction line andinsulate both with Presstite.7. Evacuate by placing vacuum pump on suction servicevalve.8. Open King valve and then check refrigerant level.(Refer to section 4.11.b)9. Check superheat. (Refer to section 1.3.h)c. Checking SuperheatNOTEIt is not recommended adjusting expansionvalves unless absolutely necessary.Due to the time involved in adjusting the superheat,replace the valve rather than adjusting it.d. To Measure SuperheatNOTEThe expansion valve and bulb location are shownin Figure 1-9.1. Remove evaporator panel from rear of unit and thenremove Presstite from expansion valve bulb andsuction line.2. Loosen one TX bulb clamp and make sure areaunder clamp (above TXV bulb) is clean.3. Place thermocouple above (parallel) TXV bulb andthen secure loosened clamp making sure both bulbsare firmly secured to suction line as shown inFigure 4-28.3211. Suction Line (end view)2. TXV Bulb Clamp3. Nut and Bolt (clamp)4. Thermocouple5. TXV BulbFigure 4-28. Thermostatic Expansion Valve Bulband ThermocoupleNOTEWhen conducting this test the suction pressuremust be 6 psig (0.4 kg/cm@) below expansionvalve maximum operating pressure (MOP). Forexample: R-22 units use an expansion valve witha 55 MOP. The recommended test pressureshould be below 49 psig(3.44 kg/cm@).4. Connect an accurate gauge to the 1/4” port on thesuction service valve.5. Run unit until stabilized. Set controller 10_F (5.5_C)below box temperature.6. From the temperature/pressure chart, determine thesaturation temperature corresponding to theevaporator outlet pressure.7. Note the temperature of the suction gas at theexpansion valve bulb.Subtract the saturation temperature determined in Step6 from the average temperature measured in Step 7. Thedifference is the superheat of the suction gas.4.28 SERVICING PHASE SEQUENCE -OPTIONALWARNINGHigh voltage in electrical box, disconnect powerbefore servicing unit.Oneofthephaserelays(PR-1orPR-2)mustpull-inwhenpower is applied to the unit.4562-024614-26

To check Phase Sequence Module:a. Verify that three phase power exists on supply sideand that the same voltage is present betweenterminals H4 and 46 on the phase sequence module.(See Figure 4-29)b. Verify that 17 to 26 vac exists between terminals 4and X2 on module.c. If 17 to 26 vac does not exists between eitherterminals 5 and X2 or 6 and X2 on the module,module is defective and should be replaced.Figure 4-29. Phase Sequence Module4.29 MICROPROCESSOR CONTROLLERNOTEThe erasable, programmable, read only memory(EEPROM) chip (component U3 on themicroprocessor logic board) has a window on itwhich is covered with a label listing the revisionlevel of the software. The window is used to erasethe chip’s memory with the use of ultravioletlight. the label prevents light from entering thechip and erasing the memory. Under NOcircumstances should this label be removed.CAUTIONUnder no circumstances should a technicianelectrically probe the processor at any point,other than the connector terminals where theharness attaches. Microprocessor componentsoperate at different voltage levels and atextremely low current levels. Improper use ofvoltmeters, jumper wires, continuity testers, etc.could permanently damage the processor.As mentioned above, some microprocessor inputsoperate at voltage levels other than the conventional 12vdc. Connector points and the associated approximatevoltage levels are listed below for reference only. Underno circumstances should 12 vdc be applied at theseconnection points.Grounded wrist cuffs are available at most radio,computer and electronic supply stores. It isrecommended that these be worn whenever handling amicroprocessor.Table 4-2. Connection Point VoltageConnection PointCDT, RAS, SAS, WTSMPF1Approximate Voltage2.5 vdc (Variable)5.0 vdcCAUTIONMost electronic components are susceptible todamage caused by electrical static discharge(ESD). In certain cases, the human body canhave enough static electricity to cause resultantdamage to the components by touch. This isespecially true of the integrated circuits foundon the truck/trailer microprocessor.Although there is less danger of electrical static dischargeESD damage in the outdoor environment, where theprocessor is likely to be handled, proper board handlingtechniques should always be stressed. Boards shouldalways be handled by their edges, in much the same wayone would handle a photograph. This not only precludesthe possibility of ESD damage, but also lowers thepossibility of physical damage to the electroniccomponents. Although the microprocessor boards arefairly rugged when assembled, they are more fragile whenseparated and should always be handled carefully.During emergency situations, the test board may be usedto keep a unit running and prevent a critical load fromspoiling. Since the microprocessor is totally disconnectedfrom the unit, it cannot monitor the engine’s safetyswitches for oil pressure and coolant temperature. Sincethe engine is running unprotected when the test board isused, it is imperative that should a problem develop withthe microprocessor, it be replaced immediately. The testboard is intended to be a trouble-shooting tool only.When using the test board to troubleshoot, the unitshould be started in low speed, unloaded cool in the sameway as the processor would start the unit. Good judgmentshould also be used when cycling any unit with the testboard. Rapid cycling should be avoided.When welding is required on the unit frame, or on thefront area of the trailer, ALL wiring to themicroprocessor MUST be disconnected. When weldingis performed on other areas of the trailer, the welderground connection MUST be in close proximity to thearea being welded. It is also a good practice to removeboth battery cables before welding on either the unitframe or the trailer to prevent possible damage to othercomponents such as the alternator and voltage regulator.a. Replacing Key BoardShould damage to the Key Board of the microprocessoroccur, it is possible to replace only the Key Board.All replacement key boards are packaged withreplacement O-Ring. The recommended torque forsecuring nuts or bolts is 15 inch-lbs.b. Hour MetersThe hour meter can be set to any value via the serial port,if the meter has less then 5 hours on it. This allows areplacement microprocessor to be set to the same hoursas the microprocessor it is replacing.4-27 62-02461

The microprocessor has 2 programmable registers whichare set via the serial port. These registers are compared toone of the hour meters (diesel, standby, or switch on). Ifthe hour meter is greater than the register then theproper alarm is set.4.30 CONFIGURATION of MICROPROCESSORWhen replacing a microprocessor it is important to checkthat the configurations are compatible for the unit intowhich it will be installed. (This same board fits bothtrailer and truck model units.) All configuration fieldsshould be viewed before starting the unit.a. To reach the configuration fields:1. Turn the Run/Stop switch to the Stop position.2. With the unit off, locate the serial port plug locatedbelow the control panel. Remove the protective plugto gain access to the wire terminals. Place aninsulated jumper wire between wires SPA and SPB atthe serial port plug.CAUTIONDo not allow jumper wire to touch any ground.3. Turn the Run/Stop switch to the Run position. TheFAULT light will come on, and the micro display willread “CNF1 TV” or “CNF1 DI”. Remove the jumperwire from the serial port and reinstall the protectiveplug. The configuration screen will now remainavailable for 5 minute. Scroll through theconfiguration list using the FUNCTION key andcompare the settings with those shown on the table inthe next column. If any of the configurations need tobe changed continue with step (4) below.b. To change the configuration selection:1. Bring the configuration to be changed onto thedisplay. Press the ENTER key to allow change accessto the displayed configuration.2.. Press either the UP or DOWN keys to displayavailable selections for that configuration. Leave thecorrect selection on the screen. The selection displaywill flash warning the operator that the displayedvalue has not been entered. Press the ENTER key toenter the new selection into memory. (The displaywill revert to the original selection if no furtheraction is taken for the next 5 seconds.)3. Continue to scroll through the configuration list bypressing the FUNCTION key. Change any otherconfigurations as required.4. When finished turn the Run/Stop switch to the Stopposition, then back to the Run position to start theunit.ConfigurationCNF1DITVCNF2OFFONCNF3OFFONCNF4CNF5CNF6CNF7CNF8CNF9OFFONOFFONOFFONOFFONOFFONOFFONDescriptionDI Engine Glow TimeTV Engine Glow TimeCDT not usedCDT used86_ Setpoint90_ SetpointHeat lockout on +10_FHeat lockout off (Truck units)MOP Disabled (R-502)MOP Enabled (R-22/R-404A)Trailer unitTruck unitHigh speed start (Truck unit)Low speed start (Trailer unit)Belt driven fansElectric fan motorsOut-of-range alarmOut-of-range alarm and unit shut downOFF MOP Software Values (Must be Off)CNF10 ON MOP EEPROM Values (Do not turnon)CNF11OFF Functions normalON Functions lockedCNF12OFF MOP R-22ON MOP R-404ACNF13OFF Cool/Heat/DefrostON Heat Only (Solara)CNF14OFF Not ActiveON Reversible Multi-Temp ActiveCNF15OFF Not ActiveON UltraFresh 2 ActiveCNF16OFF Alt aux alarm onlyON Altauxalarmshutunitdown62-024614-28

4.31 CONTROLLER SENSOR CHECKOUTAn accurate ohmmeter must be used to check resistancevaluesshowninTable4-3.Due to variations and inaccuracies in ohmmeters,thermometers or other test equipment, a reading within2% of the chart value would indicate a good sensor. If asensor is bad, the resistance reading will usually be muchhigher or lower than the resistance values given inTable 4-3.At least one lead from the sensor (RAS, terminals D1 andE1 or SAS, terminals D2 and E2) must be disconnectedfrom the unit electrical system before any reading istaken. Not doing so will result in a false reading. Twopreferred methods of determining the actual testtemperature at the sensor, is an ice bath at 32_F(0_C) ora calibrated temperature tester.Table 4-3. Sensor Resistance(ATS,CDT,RAS,SAS,&WTS)Temperature ATS, RAS, SAS & CDT_F _CWTS ResistanceResistanceIn Ohms In Ohms--- 20 ---28.9 165,300 1,653,000--- 10 ---23.3 117,800 1,178,0000 ---17.8 85,500 855,00010 ---12.2 62,400 624,00020 --- 6.7 46,300 463,00030 --- 1.1 34,500 345,00032 0 32,700 327,00040 4.4 26,200 262,00050 10.0 19,900 199,00060 15.6 15,300 153,00070 21.1 11,900 119,00077 25 10,000 100,00080 26.7 9,300 93,00090 32.2 7,300 73,000100 37.8 5,800 58,000110 43.3 4,700 47,000120 48.9 3,800 38,000194 90 915 9,150212 100 680 6,800266 130 301 3,010302 150 186 1,8604.32 SUCTION PRESSURE TRANSDUCERBefore installing a new suction pressure transducer itmust be calibrated.The calibration will not be performed if the run relay isenergized. This prevents the operator from calibratingthe unit with the sensor in the system. The reading of thesensor must be at atmospheric pressure (0 psig or 14.7psi). If the sensor reading is greater than 20 psig (34.7 psi)or less than ---6.7 psig (8 psi) it can not be calibrated. Oncethe micro is calibrated, the display will readout the actualvalue.1. Turn power off and remove starter solenoid wire,then let unit fail to start. This will de-energize runrelay.2. Connect wiring to new suction pressure transducer.Before installing suction pressure transducer intocompressor, display the suction pressure via the unitstatus display. While the suction pressure is beingdisplayed press ENTER key for 3 seconds, thedisplay should read “0”. If display reads “0” installsuction pressure transducer into compressor.Table 4-4. Suction Pressure Transducer VoltagePsig Voltage Psig Voltage Psig Voltage20” 0.369 30 0.761 70 1.15510” 0.417 35 0.810 75 1.2040 0.466 40 0.860 80 1.2535 0.515 45 0.909 85 1.30310 0.564 50 0.958 90 1.35215 0.614 55 1.007 95 1.40120 0.663 60 1.056 100 1.45025 0.712 65 1.1064.33 UNIDRIVE TORQUE REQUIREMENTS(See Figure 4-30 or Figure 4-31)Extensive damage may occur if the proper hardware andprocedures are not followed. Periodic inspection ofhardware and bolt torque is recommended to insure theintegrity of the unidrive.NOTEThread locking sealant, 5/16 flat washer and 5/16lock washer must be used on bolts between thecompressor mounting flange and the enginebellhousing. The recommended sealant isLoctite screw lock no. 262.The following figures show the torque value, size andgrade of the hardware to be used when reassembling theunidrive assembly.4.33.1Drive GearWhen installing a nylon drive gear always:1. Install with black dot facing steel gear.2. Use new bolts and locking tabs included in drive gearkit.3. Use Locktite or a similar thread locking compoundon threads of drive gear bolts.4. DO NOT use never-seize or any other lubricatingcompound on the nylon drive gear or compressorsteel gear. The gear must be assembled dry.5. Torque the (4 bolt) nylon drive gear bolts to 25 ft-lbs.Torque the (6 bolt) nylon drive gear bolts to 30 ft-lbs.4-29 62-02461

M8 x 1.25 x 20 mm lg(4 Req’d) 28 ft-lbs (3.87 mkg)5/16-18 x 3/4 lg Grade 8(4 Req’d) 25 ft-lbs (3.46 mkg)or3/8-16 x 1-3/4 lg Grade 5(6 Req’d) 30 ft-lbs (4.15 mkg)3/8-24 x 1.00 lg Grade 828 ft-lbs (3.87 mkg)DIRECT DRIVE3/8-24 x 1.00 lg Grade 828 ft-lbs (3.87 mkg)Install snap ring with color coded sideaway from bearing90 ft-lbs (12.45 mkg)M8 x 1.25 x 20 mm lg(6 Req’d) 28 ft-lbs (3.87 mkg)STANDBY CLUTCH (NDM)3/8-16 x 1 lg Grade 5 (10 Req’d)28 ft-lbs (3.87 mkg)M12 x 1.25 x 25 mm lg(3 Req’d) 65 ft-lbs (8.99 mkg)Figure 4-30. ULTIMA, PHOENIX ULTRA & EXTRA --- Unidrive Torque Requirements62-024614-30

M8 x 20 mm lg(6 Req’d) 18 ft-lbs (2.49 mkg)90 ft-lbs (12.45 mkg)5/16-18 x 1-1/4 lg Grade 821 ft-lbs (2.9 mkg)5/16-18 x 1-1/4 lg Grade 8(4 Req’d) 25 ft-lbs (3.46 mkg)Figure 4-31. OPTIMA --- Unidrive Torque Requirements4-31 62-02461

Table 4-5. R-22 Pressure --- Temperature ChartTEMPERATURE PRESSURE TEMPERATURE PRESSURE_F _C Psig Kg/cm@ Bar _F _C Psig Kg/cm@ Bar---40 ---40 .6 .04 .04 34 1 60.5 4.25 4.17---36 ---38 2.3 .16 .16 36 2 63.3 4.45 4.36---32 ---36 4.1 .29 .28 38 3 66.1 4.65 4.56---28 ---33 6.0 .42 .41 40 4 69 4.85 4.76---26 ---32 7.0 .49 .48 44 7 75.0 5.27 5.17---24 ---31 8.1 .57 .56 48 9 81.4 5.72 5.61---22 ---30 9.2 .65 .63 52 11 88.1 6.19 6.07---20 ---29 10.3 .72 .71 54 12 91.5 6.43 6.31---18 ---28 11.5 .81 .79 60 16 102.5 7.21 7.07---16 ---27 12.7 .89 .88 64 18 110.2 7.75 7.6---14 ---26 14.0 .98 .97 68 20 118.3 8.32 8.16---12 ---24 15.2 1.07 1.05 72 22 126.8 8.91 8.74---10 ---23 16.6 1.17 1.14 76 24 135.7 9.54 9.36--- 8 ---22 18.0 1.27 1.24 80 27 145 10.19 10.0--- 6 ---21 19.4 1.36 1.34 84 29 154.7 10.88 10.67--- 4 ---20 21.0 1.48 1.45 88 31 164.9 11.59 11.37--- 2 ---19 22.5 1.58 1.55 92 33 175.4 12.33 12.090 ---18 24.1 1.69 1.66 96 36 186.5 13.11 12.862 ---17 25.7 1.81 1.77 100 38 197.9 13.91 13.644 ---16 27.4 1.93 1.89 104 40 209.9 14.76 14.476 ---14 29.2 2.05 2.01 108 42 222.3 15.63 15.338 ---13 31.0 2.18 2.14 112 44 235.2 16.54 16.2210 ---12 32.9 2.31 2.27 116 47 248.7 17.49 17.1512 ---11 34.9 2.45 2.41 120 49 262.6 18.46 18.1114 ---10 36.9 2.59 2.54 124 51 277.0 19.48 19.1016 --- 9 39.0 2.74 2.69 128 53 291.8 20.52 20.1218 --- 8 41.1 2.89 2.83 132 56 307.1 21.59 21.1720 --- 7 43.3 3.04 2.99 136 58 323.6 22.75 22.3122 --- 6 45.5 3.2 3.14 140 60 341.3 24.0 23.5324 --- 4 47.9 3.37 3.3 144 62 359.4 25.27 24.7826 --- 3 50.2 3.53 3.46 148 64 377.9 26.57 26.0628 --- 2 52.7 3.71 3.63 152 67 396.6 27.88 27.3430 --- 1 55.2 3.88 3.81 156 69 415.6 29.22 28.6532 0 57.8 4.06 3.99 160 71 434.6 30.56 29.9662-024614-32

Table 4-6. R-404A Temperature---Pressure ChartTemperaturePressureTemperaturePressure_F _C Psig Kg/cm@ Bar _F _C Psig Kg/cm@ Bar--- 40 --- 40 4.5 0.32 0.31 32 0 72.5 5.10 5.00--- 35 --- 37 7.1 0.50 0.49 34 1 75.6 5.32 5.21--- 30 --- 34 9.9 0.70 0.68 36 2 78.8 5.54 5.43--- 25 --- 32 12.9 0.91 0.89 38 3 82.1 5.77 5.66--- 20 --- 29 16.3 1.15 1.12 40 4 85.5 6.01 5.90--- 18 --- 28 17.7 1.24 1.22 42 6 89.0 6.26 6.14--- 16 --- 27 19.2 1.35 1.32 44 7 92.5 6.50 6.38--- 14 --- 26 20.7 1.46 1.43 46 8 96.2 6.76 6.63--- 12 --- 24 22.3 1.57 1.54 48 9 99.9 7.02 6.89--- 10 --- 23 23.9 1.68 1.65 50 10 103.7 7.29 7.15--- 8 --- 22 25.6 1.80 1.77 55 13 115.4 8.11 7.96--- 6 --- 21 27.3 1.92 1.88 60 16 126.1 8.87 8.69--- 4 --- 20 29.1 2.05 2.01 65 18 137.4 9.66 9.47--- 2 --- 19 30.9 2.17 2.13 70 21 149.4 10.50 10.300 --- 18 32.8 2.31 2.26 75 24 162.1 11.40 11.182 --- 17 34.8 2.45 2.40 80 27 175.5 12.34 12.104 --- 16 36.8 2.59 2.54 85 29 189.6 13.33 13.076 --- 14 38.9 2.73 2.68 90 32 204.5 14.38 14.108 --- 13 41.1 2.89 2.83 95 35 220.2 15.48 15.1810 --- 12 43.3 3.04 2.99 100 38 236.8 16.65 16.3312 --- 11 45.6 3.21 3.14 105 41 254.2 17.87 17.5314 --- 10 48.0 3.37 3.31 110 43 272.4 19.15 18.7816 --- 9 50.4 3.54 3.47 115 46 291.6 20.50 20.1118 --- 8 52.9 3.72 3.65 120 49 311.8 21.92 21.5020 --- 7 55.5 3.90 3.83 125 52 332.9 23.41 22.9522 --- 6 58.1 4.08 4.01 130 54 355.0 24.96 24.4824 --- 4 60.9 4.28 4.20 135 57 378.1 26.58 26.0726 --- 3 63.7 4.48 4.39 140 60 402.3 28.28 27.7428 --- 2 66.5 4.68 4.59 145 63 427.6 30.06 29.4830 --- 1 69.5 4.89 4.79 150 66 454.0 31.92 31.304-33 62-02461

SECTION 5ELECTRICAL SCHEMATIC WIRING DIAGRAM5.1 INTRODUCTIONThis section contains Electrical Schematic Wiring Diagram covering the Models listed in Table 1-1. The followingsupplement the specific warnings and cautions appearing elsewhere in this manual. They are recommended precautionsthat must be understood and applied during operation and maintenance of the equipment covered herein.WARNINGHigh voltage in electrical box, disconnect power before servicing unit.WARNINGBeware of V-belts and belt driven components as the unit may start automatically. Before servicing unit, makesure the Run-Stop switch is in the STOP position. Also disconnect the negative battery cable.WARNINGBeware of unannounced starting of the evaporator and condenser fan.WARNINGMake sure power to unit is OFF and negative battery cable is disconnected before servicing the compressor unloader.CAUTIONUnder no circumstances should anyone attempt to repair the logic or display boards! Should a problem developwith these components, contact your nearest Carrier Transicold dealer for replacement.CAUTIONUnder no circumstances should a technician electrically probe the processor at any point, other than theconnector terminals where the harness attaches. Microprocessor components operate at different voltage levelsand at extremely low current levels. Improper use of voltmeters, jumper wires, continuity testers, etc. couldpermanently damage the processor.CAUTIONObserve proper polarity when installing battery, negative battery terminal must be grounded. Reverse polaritywill destroy the rectifier diodes in alternator. As a precautionary measure, disconnect positive battery terminalwhen charging battery in unit. Connecting charger in reverse will destroy the rectifier diodes in alternator.5-1 62-02461

Figure 5-1. NDA-94A Electrical Schematic Wiring Diagram --- Prior to S/N DAF90209263 --- Dwg. No. 62-02457 Rev. C (Sheet 1 of 2)62---024615-2

Figure 5-1. NDA-94A Electrical Schematic Wiring Diagram --- Prior to S/N DAF90209263 --- Dwg. No. 62-02457 Rev. C (Sheet 2 of 2)5-362---02461

Figure 5-2. NDA-94A & NDA-94B Electrical Schematic Wiring Diagram --- Starting with S/N DAF90209263 --- Dwg. No. 62-02589 Rev A (Sheet 1 of 2)62---024615-4

NDA-94AONLYFigure 5-2. NDA-94A & NDA-94B Electrical Schematic Wiring Diagram --- Starting with S/N DAF90209263 --- Dwg. No. 62-02589 Rev A (Sheet 2 of 2)5-562---02461

Figure 5-3. NDA-94 Electrical Schematic Wiring Diagram --- Starting with S/N EAE90310998 --- Dwg. No. 62-03935 (Sheet 1 of 2)62---024615-6

Figure 5-3. NDA-94 Electrical Schematic Wiring Diagram --- Starting with S/N EAE90310998 --- Dwg. No. 62-03935 (Sheet 2 of 2)5-762---02461

Figure 5-4. NDM-94A EURO Electrical Schematic Wiring Diagram --- Prior to S/N EAE90310998 --- Dwg. No. 62-02590 (Sheet 1 of 2)62---024615-8

Figure 5-4. NDM-94A EURO Electrical Schematic Wiring Diagram --- Prior to S/N EAE90310998 --- Dwg. No. 62-02590 (Sheet 2 of 2)5-962---02461

Figure 5-5. NDM-94 (EURO) Electrical Schematic Wiring Diagram Starting with S/N EAE90310998--- Dwg. No. 62-03936 (Sheet 1 of 2)62---024615-10

Figure 5-5. NDM-94 (EURO) Electrical Schematic Wiring Diagram --- Starting with S/N EAE90310998 --- Dwg. No. 62-03936 (Sheet 2 of 2)5-1162---02461

Figure 5-6. NDM-94A Electrical Schematic Wiring Diagram --- Prior to S/N EAE90310998 --- Dwg. No. 62-02620 (Sheet 1 of 2)62---024615-12

Figure 5-6. NDM-94A Electrical Schematic Wiring Diagram --- Prior to S/N EAE90310998 ---Dwg. No. 62-02620 (Sheet 2 of 2)5-1362---02461

Figure 5-7. NDM-94 Electrical Schematic Wiring Diagram ---Starting with S/N EAE90310998 --- Dwg. No. 62-03937 (Sheet 1 of 2)62---024615-14

Figure 5-7. NDM-94 Electrical Schematic Wiring Diagram ---Starting with S/N EAE90310998 --- Dwg. No. 62-03937 (Sheet 2 of 2)5-1562---02461

Figure 5-8. NDM-94A --- 230v Phase Reversal Electrical Schematic Wiring Diagram --- Prior to S/N EAE90310998 --- Dwg. No. 62-02621 (Sheet 1 of 2)62---024615-16

Figure 5-8. NDM-94A --- 230v Phase Reversal Electrical Schematic Wiring Diagram --- Prior to S/N EAE90310998 --- Dwg. No. 62-02621 (Sheet 2 of 2)5-1762---02461

Figure 5-9. NDM-94 230v Phase Reversal Electrical Schematic Wiring Diagram --- Starting with S/N EAE90310998 --- Dwg. No. 62-03939 (Sheet 1 of 2)62---024615-18

Figure 5-9. NDM-94 230v Phase Reversal Electrical Schematic Wiring Diagram--- Starting with S/N EAE90310998 --- Dwg. No. 62-03939 (Sheet 2 of 2)5-1962---02461

Figure 5-10. NDM-94A --- 380v Phase Reversal Electrical Schematic Wiring Diagram --- Prior to S/N EAE90310998 --- Dwg. No. 62-02573 (Sheet 1 of 2)62---024615-20

Figure 5-10. NDM-94A --- 380v Phase Reversal Electrical Schematic Wiring Diagram --- Prior to S/N EAE90310998 --- Dwg. No. 62-02573 (Sheet 2 of 2)5-2162---02461

Figure 5-11. NDM-94 380v Phase Reversal Electrical Schematic Wiring Diagram --- Starting with S/N EAE90310998 --- Dwg. No. 62-03938 (Sheet 1 of 2)62---024615-22

Figure 5-11. NDM-94 380v Phase Reversal Electrical Schematic Wiring Diagram --- Starting with S/N EAE90310998 --- Dwg. No. 62-03938 (Sheet 2 of 2)5-2362---02461

Figure 5-12. NDA, NDM and NDX Electrical Schematic --- Units with Buzzer --- Dwg. No. 62-04001 Rev. A (Sheet 1 of 4)62---024615-24

Figure 5-12. NDA, NDM and NDX Electrical Schematic --- Units with Buzzer --- Dwg. No. 62-04001 Rev. A (Sheet 2 of 4)5-2562---02461

Figure 5-13. NDA, NDM and NDX Electrical Schematic --- Units with Buzzer --- Dwg. No. 62-04001 Rev. A (Sheet 3 of 4)62---024615-26

Figure 5-14. NDA, NDM and NDX Electrical Schematic --- Units with Buzzer --- Dwg. No. 62-04001 Rev. A (Sheet 4 of 4)5-2762---02461

SECTION 6MULTI-TEMP OPERATION AND SERVICE6.1 INTRODUCTION2 311. HighVoltageControlBox---SeeFigure6-22. Generator 5kw3. Alternator 105 ampsFigure 6-1. Unit Front Viewa. SystemThe Phoenix Ultra Multi-Temp, multiple compartmentrefrigeration system offers the versatility of two or threecompartment temperature control. The Multi-Tempallows the shipper to ship frozen and perishablecommodities in the same load under separaterefrigeration control. The Genesis TM1000 (ReversibleMulti-Temp) allows any compartment to be anytemperature.Table 6-1. Multi-Temp Model ChartModelsDescriptionNDA-94_____M2 2Compartment(OldStyle)NDA-94_____M3 3Compartment(OldStyle)NDA-94_____U2 2 Compartment (New Style)NDA-94_____U3 3 Compartment (New Style)NDA-94_____R2 Reversible 2 CompartmentNDA-94_____R3 Reversible 3 CompartmentThe Phoenix Ultra Multi-Temp unit is comprised of thebasic Phoenix Ultra diesel nosemount unit with one ortwo remote evaporators for rear compartments.The unit also is equipped with a 5-kilowatt, single phase,240 v-ac generator in the nosemount to power the electricheaters in the rear evaporators.Also mounted to the left of the generator is a high voltagebox. In the high voltage box are two 30 amp fuses and highvoltage relay(s).The Phoenix Ultra Multi-Temp unit has a 105 ampalternator.b. Remote Evaporator and Remote Control BoxThe rear compartments of the Multi-Temp system isequipped with a separate evaporator and remotemounted control box.Theremoteevaporatorscanbewallorceilingmountedand includes evaporator coil and heaters, drain pan,evaporator fan and motor (12v-dc), defrost terminationthermostat, liquid line solenoid, expansion valve, airswitch and evaporator pressure regulator.The remote control box includes indicating lights,switches and relays.c. Microprocessor ControllerThe Phoenix Ultra nosemount unit microprocessorcontroller controls all compartments (Refer to sections6.7 and 1.10).6-1 62-02461

6.2 REFRIGERATION SYSTEM DATAa. Defrost Air Switch (Remote Evaporator)Initiates Defrost:0.50 inch WG6.3 ELECTRICAL DATAa. Generator (5kw)WattageVolts5000 Watts240 v-acPhaseSpeed13600 rpm at 60 hzRotation either directionb. Alternator105 ampsc. Remote Evaporator Fan MotorsVolts 12 v-dcHorsepower 1/8 hpSpeedRotation3000 rpmClockwise when viewed from shaft endAmps 12 to 14 nominal eachd. Remote Evaporator Defrost Heaters1. Two CompartmentsNumberVoltage2240 v-ac/1 ph/60hzWattage 2500 watts each2. Three CompartmentsNumber 2VoltageWattage240 v-ac/1 ph/60hz1250 watts each6.4 SAFETY DEVICESSafety Devices for protection of the Remote Evaporatorare listed in Table 6-2Table 6-2. Safety Devices -- Remote EvaporatorUnsafe Conditions Safety Device Device Setting1. Excessive current draw by2compartmentFuse (F7)Opens at 30 amps2. Excessive current draw by3compartmentFuse (F8)Opens at 30 amps3. Excessive current draw by5 KW generatorFuses (F10, F11)Opens at 30 amps4. Defrostheaterovertemperature High Temperature Klixon Opens at 120 ¦ 5_F211. Fuse, 30 amps2. High Voltage RelayFigure 6-2. High Voltage Control Box62-024616-2

6.5 MULTI-TEMP REFRIGERANT CIRCUITThe Multi-Temp refrigerant circuit is the same as thePhoenix Ultra but with the addition of a remoteevaporator(s).The remote evaporator(s) refrigerant flows through theelectrically controlled liquid line solenoid valve (LSV)which starts or stops the flow of liquid refrigerant.The remote evaporator(s) is fitted with an evaporatorpressure regulating valve. This valve will automaticallythrottle flow fromthe evaporator in order to maintain thepreset minimum evaporator pressure. Refer to Section6.10EVAPORATOR PRES-SUREREGULATING VALVEREMOTE EVAPORATOREXPANSIONVALVELIQUIDSOLE-NOIDVALVE(LSV)EXTERNAL EQUALIZEREXPANSION VALVEEXPANSIONVALVE BULBSUCTION LINEEVAPORATORFUSIBLEPLUGBYPASSCHECKVALVERECEIVERLIQUID LINEQUENCHVALVEBULBDISCHARGESERVICEVALVEVIBRASORBERHP-2 HP-1QUENCH VALVESUCTIONSERVICEVALVEHOT GASSOLE-NOID(SV3), HOTNCGASHOTGASLINESHUT-OFFVALVEHOT GASBYPASSLINESUBCOOLERLIQUIDSOLENOIDVALVE (SV2),NCFILTERDRIERCOMPRESSORDISCHARGE LINESOLE-NOID(SV4), NCDISCHARGECHECKVALVEVIBRASORBERCONDENSERFigure 6-3. Multi-Temp Refrigerant Circuit -- CoolingCONDENS-ERPRESSURECONTROLSOLENOID(SV1), NO6-3 62-02461

6.6 REMOTE COMPARTMENT OPERATIONa. To start remote evaporator, place the remotecompartment switch in the ON position (SeeFigure 6-4 or Figure 6-5).b. Set desired temperature using nosemount unitmicroprocessor controller (Refer to section 1.10).c. The manual defrost switch and function lights foreach compartment are on the remote control box.d. Turn remote compartment switch OFF when remoteevaporator is not required.NOTEFor starting instructions on the nosemount unitrefer to section 2.2.12376HR DB1 DB2CRBCRADRDROEFR1EFR2RREFR3412354756891. Cool/Heat/Defrost/Power Lights2. Manual Defrost Switch3. Compartment ON-OFF Switch (2ST or 3ST)4. Defrost Timer5. Fuse6. Relays7. Diode BlockFigure 6-5. Remote Control Box (For ReversibleUnits)6.7 MICROPROCESSOR CONTROLLERNOTEThe Phoenix Ultra nosemount unitmicroprocessor controller controls allcompartments (Refer to section 1.10).1. Run Relay (Compartment)2. Cool Relay (Compartment)3. Heat Relay (Compartment)4. Cool Light5. Heat Light6. Defrost Light7. Compartment ON-OFF Switch (2ST or 3ST)8. Power Light9. Manual Defrost SwitchFigure 6-4. Remote Control BoxThe Phoenix Ultra microprocessor controller controls upto two remote compartments. The compartments areenabled by the compartment ON-OFF switch located onthe remote control box. When a compartment is enabledthe controller will maintain temperature based onsetpoints entered via the keypad function parameterselections. Two temperature thermistor sensors are usedto monitor the return air of each evaporator.Temperature control is achieved by switching between 4modes: high speed cool, low speed cool, null and highspeed heat.When heating is required the microprocessor willenergize 2HR or 3HR and the speed relay at 1.8_F(1_C)below setpoint. The remote heat relays will bede-energized when the temperature rises above 0.9_F(0.5_C) below setpoint. When the heat relay isde-energized the compartment will stay in null modeuntil the temperature rises greater than 1.8_F (1_C)above setpoint. At this point the controller will energize2CR or 3CR and de-energize the unloaders if possible. Ifthe temperature continues to rise the speed relay will be62-024616-4

energized at 2.5_C above setpoint. If the temperaturefalls below 3.6_F(2_C) above setpoint the speed relay isde-energized and if it falls below 0.5_C abovesetpointthe remote cool relays are de-energized.There are overriding factors which would prevent theremote compartments from cooling or heating. If themain compartment is in heat or defrost then no cool orheat will be allowed in the remote compartments. Inaddition if the unit is being forced to run in low speedremote heat will be locked out.Defrost in the remote compartments will be activatedindependently from the controller. When a remotecompartment is in defrost the controller will energize thespeed solenoid.Start/Stop mode is also available for Multi compartmentunits. A remote compartment can override shutdownafter the minimum run time if the temperature is notwithin ¦ 1.8_F (1_C) of setpoint. A remotecompartment will cause the unit to restart after theminimum off time if temperature is more than ¦ 3.6_F(2_C) from setpoint. The minimum off time can beoverridden if the remote temperature is more than 6_Cfrom setpoint.6.8 SERVICING REMOTE EVAPORATORWARNINGBefore servicing the remote evaporator, removenegative battery cable and tag nosemountstart-run-stop switch to prevent starting.a. Fan Motor or Blade Replacement1. Remove front panel.2. Remove fan guard, loosen fan hub set screw (#10-32x 1/2 lg --- cone point) and remove fan. Remove fanmotor hardware and fan wiring (if required).3. Replace fan motor and fan blade before tighteningfan setscrew, align fan with 1/3 of the fan bladesextending beyond the leaving edge of the housing.Replace fan guard and front panel, test fanoperation.b. Fan Motor Brushes and CommutatorFan motor brushes should be inspected every 1500operating hours. Brushes should be replaced when brushis approximately 1/4I or less in length. Blow out brushholder with low pressure air to remove any carbon dust inholder. Before installing brushes, remove back cover ofmotor and inspect commutator. If commutator is heavilygrooved, polish it using 220 grit sandpaper: do not useemery cloth. Wipe out any accumulation of dust using aclean rag with solvent. Reassemble motor and reinstallbrushes.c. Replacing Tubular Heaters1. Remove front panel.2. Disconnect heater wiring from junction block andspiral wrap.3. Release spring tension on heater and remove fromattaching clip.4. Replace and rewire heater. Reinstall front panel andtest heater operation.6.9 SERVICING LIQUID SOLENOID VALVE (LSV)NOTEThe liquid solenoid valve (LSV) is the samevalve as (SV2). Refer to section 4.19 forservicing.6.10 EVAPORATOR PRESSURE REGULATINGVALVEEvaporator pressure regulating valves offer an efficientmeans of balancing the system capacity and the loadrequirements during periods of low loads andmaintaining different evaporator conditions onmulti-temperature systems. The primary function of thistype of valve is to prevent the evaporator pressure fromfalling below a predetermined value at which the valvehas been set.The valves will automatically throttle the vapor flow fromthe evaporator in order to maintain the desired minimumevaporator pressure. As the load increases, theevaporating pressure will increase above the valve settingand the valve will open further.OperationEvaporator pressure regulating valves respond only tovariations in their inlet pressure (evaporator pressure).The outlet pressure is exerted on the underside of thebellows and on top of the seat disc. Since the effectivearea of the bellows is equal to the area of the port, theoutlet pressure cancels out and the inlet pressure actingon the bottom of the seat disc opposes the adjustablespring force. These two forces are the operating forces ofthe valve. When the evaporator load changes, the valveopens or closes in response to the change in evaporatorpressure.An increase in inlet pressure above the valve settingtends to open the valve. If the load drops, lessrefrigerant is boiled off in the evaporator and theevaporator pressure will decrease. The decrease inevaporator pressure tends to move the valve to a moreclosed position which in turn keeps the evaporatorpressure up. The net result is that the evaporatorpressure does change as the load changes.The operation of a valve of this type is improved by ananti-chatter device built into the valve. Without thisdevice, the valve would be susceptible to compressorpulsations that can greatly reduce the life of a bellows.This feature allows the valve to function at low loadconditions without chattering or other operatingdifficulties.6-5 62-02461

6.11 ADJUSTING EVAPORATOR PRESSUREREGULATING VALVEa. Adjustment0_F (---17. 8_C) Front and 35_F (1. 7_C) RearCompartment Operation1. Connect gauge to evaporator pressure regulatingvalve (EPR) access valve. Remove the cap from theEPR.NOTETo adjust valve, place 1/4I hex wrench size inadjustment screw. A clockwise rotationincreases the valve setting while acounterclockwise rotation decreases the setting.To obtain the desired setting, a pressure gaugeshould be utilized so the effects of anyadjustment may be observed.2. Set front and rear compartment controllers to abovesettings and start unit. When the front compartmentsuction Pressure reaches l8 to 22 Psig (1.3 to 1.5kg/cm@),setrearevaporatorEPR.valveat40Psig2.8kg/cm@ ) . This setting will satisfy the operatingrequirements for most 2 compartment applications.3. However, if the front compartment does not pulldown to 0_F ( --- l7.8_C) within 2 hours, adjust therear evaporator EPR to a higher pressure setting,increasing by 2 psig (0.1 kg/cm) increments.(Adjustment screw turned in a clockwise direction. )Allow temperature to stabilize after each new valveadjustment until the set compartment temperature isreached.4. Conversely, if the front compartment reachescontroller setting of 0_F (---17.8_C) but the rearcompartment does not pull down to 35_F (l.7_C)within 1 hour, adjust the rear evaporator EPR.counterclockwise in 2 psig (0.1 kg/cm@) incrementsuntil the set rear compartment temperature isreached. Allow stabilization of temperature aftereach new adjustment is recommended.EPR adjustments should be made when the ambienttemperature is near summer maximum Adjustmentsmade in cooler ambients may require resetting when thesummer maximum is reached.For other temperature and respective valve pressuresettings, contact Carrier Transicold.b. ServiceSince these valves are hermetic and cannot bedisassembled for inspection and cleaning, they usuallymust be replaced if they become inoperative. However, ifthe valve fails to open, close properly, Or won’t adjust, itis probably due to solder or other foreign materialslodged in the port. It is sometimes possible to dislodgethese materials. by turning the adjustment screw all theway out with the system running.If the valve develops a refrigerant leak around the springhousing, it probably has been overheated duringinstallation or the bellows has failed due to severecompressor pulsations. In either case the valve must bereplaced.6.12 REPLACING OR ADJUSTING GENERATORBELTa. Loosen locknut on adjusting screw (Item 3,Figure 6-6) enough to clear generator V-belt fromthe sheave.b. To remove generator V-belt from drive shaft, followinstructions in section 4.4. (See Figure 4-9)c. After replacing belt, take up on jam nut and locknuton adjusting screw until a belt tension of 60 ft-lbs ismaintained.11. Generator 5kw2. Jam Nut3. Locknut4. Adjusting Screw5. V-BeltFigure 6-6. Generator523462-024616-6

6.13 5KW GENERATOR MAINTENANCEThe 5KW generator require very little preventativemaintenance to insure good performance.1. Belt tension should be maintained at 60 ft-lbs Referto section 6.12.2. The generator is equipped with an air filter locatedunder the black plastic housing at the back of thegenerator. Air is drawn through this filter as thegenerator operates, and keeps all internalcomponents cool. Any restriction caused by a dirtyfilter can result in generator overheating problems.The air filter should be removed and cleaned with warmwater and soap, then rinsed well, at every regularlyscheduled service interval (at least once a year), or morefrequently depending on environmental conditions(more often in dusty conditions), in order to protectagainst over-heating of the capacitor and generatorwindings.When trouble-shooting the 5KW generator, it isimportant to check the internal capacitor, theforward/reverse rotating diodes, and the internalwindings.The forward/reverse rotating diodes are located at thefilter end of the generator. The reverse diode is markedwith a red dot on the solder terminal. The forward diodeis unmarked. A faulty diode will give a short circuit oropen circuit reading in both directions.Generally premature capacitor failure can be attributedto over-speeding or over-heating of the generator. Themaximum speed for the generator is 3600 rpm. Settingengine speed on multi-temp units is critical to properoperation of the generator. The engine speed should beset to 1900 rpm with unit operating in fully loaded highspeed cool mode, with all compartments turned on. Referto Table 6-3 for corresponding generator voltage output.A generator fault finding guide is shown in Figure 6-7.This should be used whenever troubleshooting a problemwith a 5KW generator.6.13.1 Generator FlashingIn the event of voltage output failure, the generator mayhave lost its residual magnetism. This loss can be restoredby “flashing” the generator by following these steps:1. Shut the unit OFF and turn the remote compartmentpower switch OFF.2. Connect an A.C. voltmeter to the generator outputwires at the high voltage fuse block.3. Connect two (2) jumper wires, one to each of thegenerator capacitor terminals.4. Start the unit and run in high speed; leave the remotecompartment power OFF.5. Touch one jumper wire to a 12vdc groundconnection.6. Touch the other jumper wire to a 12vdc positiveconnection.WARNINGThe jumpers should only be connected to 12vdcfornolongerthanone(l)secondinordertoflashthe generator and restore the residualmagnetism required for generator output.7. Observe the voltmeter; the voltage should increaseto approximately 220vac.8. Shut the unit OFF and disconnect the jumper wires.9. Restart the unit; run in high speed and check thegenerator voltage output and rear compartmentheater amperage.Table 6-3. Generator Voltage OutputEngine RPM Generator RPM Volts / HZ.1970 3600 240 /601900 3450 200 /55ROTOR MAIN STATOR PER SECTION AUXILIARY WINDING10.7 Ohms 0.89 Ohms 1.18 OhmsThe rotating diodes can be testedduring this same operation. Thediode(s) must be removed from thecircuittotesteitherdiodeorrotorwinding resistance.Disconnect each lead and testresistance between U1 & U2 andU5 & U6. (Note: unit wiring must bedisconnected from generator forthis test.)Remove the wires from capacitor totest.6-7 62-02461

FAULTOff LoadOn LoadNo OutputVoltageIncorrectVoltageVoltageUnstableNo OutputVoltageIncorrectVoltageVoltageUnstableOverheatingCheckResidualVoltageCheck allStatorResistancesCheckSpeedCheckEngineGoverningCheck Loadfor ShortCircuitCheckSpeedCheckEngineGoverningCheckConnectionsOverLoadInlet orOutletOpeningObstructedCheckCapacitorHot Engineor GeneratorAir CirculatingCheckRotorResistancesCheckRotatingDiodesFigure 6-7. Generator Fault Finding Guide62-024616-8

Table 6-4. 2 Compartment Reversible Multi-Temp Logic ControlCompartment Need FrontFrontEngine2CR2HRFront Rear Heat Cool SpeedUnloaderCool Cool O I I O High OCool Heat O I O I High MCool Null O I O O Micro MCool Defrost O I O O High MHeat Cool Electric O I O High MHeat Heat Hot Gas O O I High MHeat Null Hot Gas O O O Micro MHeat Defrost Hot Gas O O O High MDefrost Cool Hot Gas O O O High ODefrost Heat Hot Gas O O I High ODefrost Null Hot Gas O O O High ODefrost Defrost Hot Gas O O O High ONull Cool O O I O Micro MNull Heat Hot Gas I O I High MNull Null Hot Gas I O O Micro MNull Defrost Hot Gas I O O High MUnder Cool Electric O I O High IUnder Heat O I O I High IUnder Null Electric I O O High IUnder Defrost O I O O High II = Output is ONO = Output is OFFMicro = Micro control on temperature demandM = Control both suction pressure and temperature demand6-9 62-02461

Table 6-5. 3 Compartment Reversible Multi-Temp Logic ControlCompartment Need FrontFrontEngine2CR 2HR 3CR 3HRFront Middle Rear Heat Cool SpeedUnloaderCool Cool Cool O I I O I O High OCool Cool Heat O I I O O I High OCool Cool Null O I I O O O High OCool Cool Defrost O I O O O O High MCool Heat Cool O I O I I O High OCool Heat Heat O I O I O I High MCool Heat Null O I O I O O High MCool Heat Defrost O I O O O O High MCool Null Cool O I O O I O High OCool Null Heat O I O O O I High MCool Null Null O I O O O O Micro MCool Null Defrost O I O O O O High MCool Defrost Cool O I O O O O High MCool Defrost Heat O I O O O O High MCool Defrost Null O I O O O O High MCool Defrost Defrost O I O O O O High MHeat Cool Cool Electric O I O I O High MHeat Cool Heat Electric O I O O I High MHeat Cool Null Electric O I O O O High MHeat Cool Defrost Hot Gas O O O O O High MHeat Heat Cool Electric O O I I O High MHeat Heat Heat Hot Gas O O I O I High MHeat Heat Null Hot Gas O O I O O High MHeat Heat Defrost Hot Gas O O O O O High MHeat Null Cool Electric O O O I O High MHeat Null Heat Hot Gas O O O O I High MHeat Null Null Hot Gas O O O O O Micro MHeat Null Defrost Hot Gas O O O O O High MHeat Defrost Cool Hot Gas O O O O O High MHeat Defrost Heat Hot Gas O O O O O High MHeat Defrost Null Hot Gas O O O O O High MHeat Defrost Defrost Hot Gas O O O O O High MDefrost Cool Cool Hot Gas O O O O O High ODefrost Cool Heat Hot Gas O O O O O High ODefrost Cool Null Hot Gas O O O O O High ODefrost Cool Defrost Hot Gas O O O O O High ODefrost Heat Cool Hot Gas O O O O O High ODefrost Heat Heat Hot Gas O O O O I High ODefrost Heat Null Hot Gas O O O O O High ODefrost Heat Defrost Hot Gas O O O O O High ODefrost Null Cool Hot Gas O O O O O High ODefrost Null Heat Hot Gas O O O O O High ODefrost Null Null Hot Gas O O O O O High ODefrost Null Defrost Hot Gas O O O O O High ODefrost Defrost Cool Hot Gas O O O O O High ODefrost Defrost Heat Hot Gas O O O O O High ODefrost Defrost Null Hot Gas O O O O O High ODefrost Defrost Defrost Hot Gas O O O O O High O62-024616-10

Table 6-5. 3 Compartment Reversible Multi-Temp Logic ControlCompartment Need FrontFrontEngine2CR 2HR 3CR 3HRUnloaderFront Middle Rear Heat Cool SpeedNull Cool Cool O O I O I O High MNull Cool Heat O O I O O I High MNull Cool Null O O I O O O Micro MNull Cool Defrost Hot Gas I O O O O High MNull Heat Cool O O O I I O High MNull Heat Heat Hot Gas I O I O I High MNull Heat Null Hot Gas I O I O O High MNull Heat Defrost Hot Gas I O O O O High MNull Null Cool O O O O I O Micro MNull Null Heat Hot Gas I O O O I High MNull Null Null Hot Gas I O O O O Micro MNull Null Defrost Hot Gas I O O O O High MNull Defrost Cool Hot Gas I O O O O High MNull Defrost Heat O O O O O O High MNull Defrost Null O O O O O O High MNull Defrost Defrost O O O O O O High MUnder Cool Cool Electric O I O I O High MUnder Cool Heat Electric O I O O I High MUnder Cool Null Electric O I O O O High MUnder Cool Defrost O I O O O O High IUnder Heat Cool Electric O O I I O High MUnder Heat Heat O I O I O I High IUnder Heat Null Electric I O I O O High IUnder Heat Defrost O I O O O O High IUnder Null Cool Electric O O O I O High MUnder Null Heat Electric I O O O I High IUnder Null Null Electric I O O O O High IUnder Null Defrost O I O O O O High IUnder Defrost Cool O I O O O O High IUnder Defrost Heat O I O O O O High IUnder Defrost Null O I O O O O High IUnder Defrost Defrost O I O O O O High II = Output is ONO = Output is OFFMicro = Micro control on temperature demandM = Control both suction pressure and temperature demand6-11 62-02461

Figure 6-8. Electrical Schematic Wiring Diagram (Multi-Temp) --- Prior to S/N EAE90310998 --- Dwg. No. 62-03893 Rev. A (Sheet 1 of 2)62---024616-12

6-13 62---02461Figure 6-8. Electrical Schematic Wiring Diagram (Multi-Temp) --- Prior to S/N EAE90310998 --- Dwg. No. 62-03893 Rev. A (Sheet 2 of 2)

ZONE SYMBOL DESCRIPTIONK2 A AmmeterL2 ALT AlternatorL8 ARL Auto Restart Light (Light Bar)J7, F9 ARR Auto Restart RelayA8 ATS Ambient Temperature SensorN1 BTY BatteryA9 CDT Compressor Discharge Temperature SensorP6 CL Cool Light (Light Bar)J14, M14 2/3CL Cool Light (Remote Light)P8 CLH ClutchH12,J12,P4,Q9 2CR/8 Cool Relay (2nd Compartment)L12,M12,P10,R4 3CR/8 Cool Relay (3rd Compartment)F5 DA Defrost Air SwitchJ14,N14 2/3DA Defrost Air Switch (2nd/3rd Compartment)I3---7,J16,M16,P11,Q10 DC Diode CardN3,F9 DER Diesel Electric RelayF1, J9, K5, O5, R2 DK Datalink (Optional)P7 DL Defrost Light (Light Bar)J15,N15 2/3DL Defrost Light (Remote Light)F13,F15,G16 2/3DP Drain Pan Heater (2nd/3rd Compartment)F8,N7 DR Defrost RelayI13---15,L13---15 2/3DR Defrost Relay (2nd/3rd Compartment)F4 DTT Defrost ThermostatI15,L15 2/3DT Defrost Thermostat (2nd/3rd Compartment)J11,N11 2/3EM Evaporator Motors (2nd/3rd Compartment)H11,J13 2EMR Evaporator Motor Relay (2nd Compartment)L11,M13 3EMR Evaporator Motor Relay (3rd Compartment)L2 Fl Fuse (Maxi---fuse) (80 Ampere)I9 F2 Fuse (20 Ampere) (Optional)I3 F3 Fuse (25 Ampere)I5 F4 Fuse (15 Ampere)I6 F5 Fuse (7.5 Ampere)I8 F6 Fuse (5 Ampere)I2 F7 Fuse (30 Ampere)I1 F8 Fuse (30 Ampere)D1 F9 Fuse (5 Ampere)A13,A15 F10 Fuse (30 Ampere)A14,A16 F11 Fuse (30 Ampere)L9 FH Fuel Heater (Optional)J9, R3 FHR Fuel Heater Relay (Optional)L9 FHT Fuel Heater Thermostat (Optional)L9 FL Fault Light (Light Bar And Door)F12, J8 FR Fault RelayO2 FP Fuel Pump (Optional)P2 FS Fuel SolenoidA14,A16 GEN GeneratorL5 GP Glow PlugF6,J4 GPR Glow Plug RelayC1,E1, F4---12, G2---7,I9---11, HC High Current Box PlugK1 --- 9,O3 --- 8,R2ZONE SYMBOL DESCRIPTIONE14,E15,F16 2/3HE Heater Electric (2nd/3rd Compartment)P6 HL Heat Light (Light Bar)H16,L16 2/3HL Heat Light (2nd/3rd Compartment)F6 HP1 High Pressure Cut-Out-Switch (N.C.)R4 HP2 High Pressure Cut-Out-Control (N.C.)F9,N8 HR1 Heat Relay #1F8,N6,N7 HR2 Heat Relay #2F11,J6 HR3 Heat Relay #3F10,N4 HR4 Heat Relay #4H16, I 16, L16, P11,Q10 2/3HR Heat Relay (2nd/3rd Compartment)D13,D15 2HT High Temp. Thermostat #2 (2nd Compartment)D15 3HT High Temp. Thermostat #3 (3rd Compartment)B13,B15, I16 2HVR High Voltage Relay (2nd Compartment)B15,M16 3HVR High Voltage Relay (3rd Compartment)J12,N12 2/3LSV Liquid Solenoid Valve (2nd/3rd Comp.)I14,L14 2/3MDS Manual Defrost Switch (2nd/3rd Comp.)H10 MGC Manual Glow/CrankD2/12 MP Microprocessor BoardE2 OP Oil Pressure Safety Switch (N.O.)F11,J7 OR Out Of Range RelayL7 ORL Out Of Range Light (Light Bar)H12,L12 2/3PL Power Light (2nd/3rd Compartment)I2,M2 PS Power StudA7 RAS Return Air SensorA11,A12 2/3RAS Return Air Sensor (2nd/3rd Compartment)A1 RS Run Stop SwitchF6, J3 RR Run RelayH12,L12,P10,Q9 2/3RR Run Relay (2nd/3rd Compartment)A8 SAS Supply Air Sensor (Optional)L5 SCS Speed Control SolenoidD2 SLP Serial PortP2 SM Starter MotorSP Splice PointSPK Splice PackA6 SPT Suction Pressure TransducerF10,J5 SR Speed RelayM4 SS Starter SolenoidN1 SSC Starter Solenoid ContactorF7, J4 SSR Starter Solenoid RelayN10,P9 2/3ST Start --- Stop SwitchP8 SV1 Con. Pressure Control Valve (N.O.)P4 SV2 Liquid Solenoid Valve (N.C.)L6 SV3 Hot Gas Solenoid Valve (N.C.)P6 SV4 Hot Gas Solenoid Valve (N.C.)L6 UF Unloader FrontF7,J6 UFR Unloader Front RelayP5 UR Unloader RearN4,N5,F8 URR UnloaderRearRelayB4 WTS Water Temperature SensorFigure 6-9. Electrical Schematic Wiring Diagram (Multi-Temp) --- Starting with S/N EAE90310998 --- Dwg. No. 62-03944 (Sheet 1 of 2)62---024616-14

6-15 62---02461Figure 6-9. Electrical Schematic Wiring Diagram (Multi-Temp) --- Starting with S/N EAE90310998 --- Dwg. No. 62-03944 (Sheet 2 of 2)

Figure 6-10. Electrical Schematic Wiring Diagram (Multi-Temp 2 Compartment & 2 Evaps) --- Prior to S/N EAE90310998--- Dwg. No. 62-03894 Rev. A (Sheet 1 of 2)62---024616-16

6-17 62---02461Figure 6-10. Electrical Schematic Wiring Diagram (Multi-Temp 2 Compartment & 2 Evaps) --- Prior to S/N EAE90310998 --- Dwg. No. 62-03894 Rev. A (Sheet 2of2)

ZONE SYMBOL DESCRIPTIONK2 A AmmeterL2 ALT AlternatorL8 ARL Auto Restart Light (Light Bar)J7, F9 ARR Auto Restart RelayA8 ATS Ambient Temperature SensorN1 BTY BatteryA9 CDT Compressor Discharge Temperature SensorP6 CL Cool Light (Light Bar)J14 2CL Cool Light (Remote Light)P8 CLH ClutchI13,J12,P4,Q9 2CR/8 Cool Relay (2nd Compartment)F5 DA Defrost Air SwitchJ14,L14 2/3DA Defrost Air Switch (2nd/3rd Compartment)I3---7,J16,M16,P11,Q10 DC Diode CardN3,F9 DER Diesel Electric RelayF1, J9, K5, O5, R2 DK Datalink (Optional)P7 DL Defrost Light (Light Bar)J15 2DL Defrost Light (Remote Light)E15,G15 2/3DP Drain Pan Heater (2nd/3rd Compartment)F8,N7 DR Defrost RelayI13,I14 2DR Defrost Relay (2nd Compartment)F4 DTT Defrost ThermostatI15,L15 2/3DT Defrost Thermostat (2nd/3rd Compartment)J11,M12 2/3EM Evaporator Motors (2nd/3rd Compartment)I11,J13 2EMR Evaporator Motor Relay (2nd Compartment)J13,L12 3EMR Evaporator Motor Relay (3rd Compartment)L2 Fl Fuse (Maxi---fuse) (80 Ampere)I9 F2 Fuse (20 Ampere) (Optional)I3 F3 Fuse (25 Ampere)I5 F4 Fuse (15 Ampere)I6 F5 Fuse (7.5 Ampere)I8 F6 Fuse (5 Ampere)I2 F7 Fuse (30 Ampere)I1 F8 Fuse (30 Ampere)D1 F9 Fuse (5 Ampere)B14 F10 Fuse (30 Ampere)B15 F11 Fuse (30 Ampere)L9 FH Fuel Heater (Optional)J9, R3 FHR Fuel Heater Relay (Optional)L9 FHT Fuel Heater Thermostat (Optional)L9 FL Fault Light (Light Bar And Door)F12, J8 FR Fault RelayO2 FP Fuel Pump (Optional)P2 FS Fuel SolenoidA15 GEN GeneratorL5 GP Glow PlugF6,J4 GPR Glow Plug RelayC1,E1, F4---12, G2---7,I9---11, HC High Current Box PlugK1 --- 9,O3 --- 8,R2ZONE SYMBOL DESCRIPTIONE15,F15 2/3HE Heater Electric (2nd/3rd Compartment)P6 HL Heat Light (Light Bar)H16 2HL Heat Light (2nd Compartment)F6 HP1 High Pressure Cut-Out-Switch (N.C.)R4 HP2 High Pressure Cut-Out-Control (N.C.)F9,N8 HR1 Heat Relay #1F8,N6,N7 HR2 Heat Relay #2F11,J6 HR3 Heat Relay #3F10,N4 HR4 Heat Relay #4H16, Q10 2HR Heat Relay (2nd Compartment)D14 2HT High Temp. Thermostat #2 (2nd Compartment)D14 3HT High Temp. Thermostat #3 (3rd Compartment)B14, I16 2HVR High Voltage Relay (2nd Compartment)L13 2/3LSV Liquid Solenoid Valve (2nd/3rd Comp.)I14 2MDS Manual Defrost Switch (2nd Comp.)H10 MGC Manual Glow/CrankD2/12 MP Microprocessor BoardE2 OP Oil Pressure Safety Switch (N.O.)F11,J7 OR Out Of Range RelayL7 ORL Out Of Range Light (Light Bar)H12 2PL Power Light (2nd Compartment)I2,M2 PS Power StudA7 RAS Return Air SensorA11 2RAS Return Air Sensor (2nd Compartment)A1 RS Run Stop SwitchF6, J3 RR Run RelayI12,Q9 2RR Run Relay (2nd Compartment)A8 SAS Supply Air Sensor (Optional)L5 SCS Speed Control SolenoidD2 SLP Serial PortP2 SM Starter MotorSP Splice PointSPK Splice PackA6 SPT Suction Pressure TransducerF10,J5 SR Speed RelayM4 SS Starter SolenoidN1 SSC Starter Solenoid ContactorF7, J4 SSR Starter Solenoid RelayN10 2ST Start --- Stop SwitchP8 SV1 Con. Pressure Control Valve (N.O.)P4 SV2 Liquid Solenoid Valve (N.C.)L6 SV3 Hot Gas Solenoid Valve (N.C.)P6 SV4 Hot Gas Solenoid Valve (N.C.)L6 UF Unloader FrontF7,J6 UFR Unloader Front RelayP5 UR Unloader RearN4,N5,F8 URR UnloaderRearRelayB4 WTS Water Temperature SensorFigure 6-11. Electrical Schematic Wiring Diagram (Multi-Temp) --- Starting with S/N EAE90310998 --- Dwg. No. 62-03932 (Sheet 1 of 2)62---024616-18

6-19 62---02461Figure 6-11. Electrical Schematic Wiring Diagram (Multi-Temp) --- Starting with S/N EAE90310998 --- Dwg. No. 62-03932 (Sheet 2 of 2)

Figure 6-12. Electrical Schematic Wiring Diagram (NDA-94 REVERSIBLE Multi-Temp 2 & 3 Compartment) --- Dwg. No. 62-03933 (Sheet 1 of 2)62---024616-20

6-21 62---02461Figure 6-12 Electrical Schematic Wiring Diagram (NDA-94 REVERSIBLE Multi-Temp 2 & 3 Compartment) --- Dwg. No. 62-03933 (Sheet 2 of 2)

ZONE SYMBOL DESCRIPTIONZONE SYMBOL DESCRIPTIONK2 A AmmeterL2 ALT AlternatorL8 ARL Auto Restart Light (Light Bar)J7, F9 ARR Auto Restart RelayA8 ATS Ambient Temperature SensorN1 BTY BatteryA9 CDT Compressor Discharge Temperature SensorP6 CL Cool Light (Light Bar)J14 2CL Cool Light (Remote Light)P8 CLH ClutchI13,J12,P4,Q9 2CR/8 Cool Relay (2nd Compartment)F5 DA Defrost Air SwitchJ14,L14 2/3DA Defrost Air Switch (2nd/3rd Compartment)I3---7,J16,M16,P11,Q10 DC Diode CardN3,F9 DER Diesel Electric RelayF1, J9, K5, O5, R2 DK Datalink (Optional)P7 DL Defrost Light (Light Bar)J15 2DL Defrost Light (Remote Light)F15,G15 2/3DP Drain Pan Heater (2nd/3rd Compartment)F8,N7 DR Defrost RelayI13,I14 2DR Defrost Relay (2nd Compartment)F4 DTT Defrost ThermostatI15,L15 2/3DT Defrost Thermostat (2nd/3rd Compartment)J11,M12 2/3EM Evaporator Motors (2nd/3rd Compartment)I11,J13 2EMR Evaporator Motor Relay (2nd Compartment)J13,L12 3EMR Evaporator Motor Relay (3rd Compartment)L2 Fl Fuse (Maxi---fuse) (80 Ampere)I9 F2 Fuse (20 Ampere) (Optional)I3 F3 Fuse (25 Ampere)I5 F4 Fuse (15 Ampere)I6 F5 Fuse (7.5 Ampere)I8 F6 Fuse (5 Ampere)I2 F7 Fuse (30 Ampere)I1 F8 Fuse (30 Ampere)D1 F9 Fuse (5 Ampere)A14 F10 Fuse (30 Ampere)A15 F11 Fuse (30 Ampere)L9 FH Fuel Heater (Optional)J9, R3 FHR Fuel Heater Relay (Optional)L9 FHT Fuel Heater Thermostat (Optional)L9 FL Fault Light (Light Bar And Door)F12, J8 FR Fault RelayO2 FP Fuel Pump (Optional)P2 FS Fuel SolenoidA15 GEN GeneratorL5 GP Glow PlugF6,J4 GPR Glow Plug RelayD15 1HE Heater Electric (Main Unit)E15,F15 2/3HE Heater Electric (2nd/3rd Compartment)P6 HL Heat Light (Light Bar)H16 2HL Heat Light (2nd Compartment)F6 HP1 High Pressure Cut-Out-Switch (N.C.)R4 HP2 High Pressure Cut-Out-Control (N.C.)F9,N8 HR1 Heat Relay #1F8,N6,N7 HR2 Heat Relay #2F11,J6 HR3 Heat Relay #3F10,N4 HR4 Heat Relay #4H16, Q10 2HR Heat Relay (2nd Compartment)C14, D14 1HT High Temp. Thermostat #1 (Main Unit)E14 2HT High Temp. Thermostat #2 (2nd Compartment)F14 3HT High Temp. Thermostat #3 (3rd Compartment)B14, F2 1HVR High Voltage RelayB14, I16 2HVR High Voltage Relay (2nd Compartment)L13 2/3LSV Liquid Solenoid Valve (2nd/3rd Comp.)I14 2MDS Manual Defrost Switch (2nd Comp.)H10 MGC Manual Glow/CrankD2/12 MP Microprocessor BoardE2 OP Oil Pressure Safety Switch (N.O.)F11,J7 OR Out Of Range RelayL7 ORL Out Of Range Light (Light Bar)H12 2PL Power Light (2nd Compartment)I2,M2 PS Power StudA7 RAS Return Air SensorA11 2RAS Return Air Sensor (2nd Compartment)A1 RS Run Stop SwitchF6, J3 RR Run RelayI12,Q9 2RR Run Relay (2nd Compartment)A8 SAS Supply Air Sensor (Optional)L5 SCS Speed Control SolenoidD2 SLP Serial PortP2 SM Starter MotorSP Splice PointSPK Splice PackA6 SPT Suction Pressure TransducerF10,J5 SR Speed RelayM4 SS Starter SolenoidN1 SSC Starter Solenoid ContactorF7, J4 SSR Starter Solenoid RelayN10 2ST Start --- Stop SwitchP8 SV1 Con. Pressure Control Valve (N.O.)P4 SV2 Liquid Solenoid Valve (N.C.)L6 SV3 Hot Gas Solenoid Valve (N.C.)P6 SV4 Hot Gas Solenoid Valve (N.C.)L6 UF Unloader FrontF7,J6 UFR Unloader Front RelayP5 UR Unloader RearN4,N5,F8 URR UnloaderRearRelayB4 WTS Water Temperature SensorC1,E1, F4---12, G2---7,I9---11, HC High Current Box PlugK1 --- 9,O3 --- 8,R2Figure 6-13 Electrical Schematic Wiring Diagram (NDA-94 REVERSIBLE Multi-Temp 2 Compartment & 2 Evaps) --- Dwg. No. 62-03934 (Sheet 1 of 2)62---024616-22

6-23 62---02461Figure 6-13 Electrical Schematic Wiring Diagram (NDA-94 REVERSIBLE Multi-Temp 2 Compartment & 2 Evaps) --- Dwg. No. 62-03934 (Sheet 2 of 2)

IndexNumbers5kwGenerator,6-2,6-6,6-7AAir Switch, 1-12, 4-22Alarm Display, 1-24Alternator, 1-34Alternator V --- Belt, 4-7Auto Start/Stop, 1-26Automatic Start, 2-1BBelt tension Gauge, 4-7CCheck Valve, 4-18Clutch/Gearbox V---Belt, 4-8Compressor, 4-14Compressor Data, 1-12Compressor Oil Level, 4-15Compressor Unloader, 1-14, 4-16Condenser Coil, 4-25Configuration of Microprocessor, 4-28Control Circuit Operation ---Engine Drive, 2-2Control Circuit Operation --- Standby Motor, 2-4Controller, 1-19, 4-27Controller Sensor, 4-29Cool Mode, 1-25Cooling, 2-2DDataLink, 1-31DataTrak, 1-28Defrost, 2-3Defrost Air Switch, 1-12, 4-22Defrost Cycle, 1-26, 4-21Defrost Thermostats, 1-12Defrost Timer, 1-12Dehydration, 4-12Digital Display, 1-20EElectrical Schematic, 5-1Engine Air Cleaner, 4-5Engine Air System, 1-13Engine Cooling System, 4-4Engine Crankcase Breather, 4-6Engine Data, 1-12Engine Oil, 1-12Engine Screw Threads, 1-13Evacuation, 4-12Evaporator Coil, 4-25Evaporator Pressure Regulating Valve, 6-5Expansion Valve, 1-12, 4-25FFan Shaft, 4-23Fan Shaft V --- Belt, 4-8Fanshaft Oil, 1-13Filter---Drier, 4-18Fuel Flow Diagram, 1-14Fuel Pump, 4-6Functional Parameters, 1-20Fusible Plug, 1-13GGearbox Clutch, 4-11Gearbox Oil, 1-13Glow Plugs, 4-7HHead Pressure Control Switch, 1-13Heat Mode, 1-25Heating, 2-3Heating Cycle, 4-21High Pressure Switch, 1-13High Pressure Switches, 4-19Index -162-02461

IndexIRemote Evaporator, 6-5Introduction, 1-1KKeypad, 1-19LLiquid Solenoid valve, 6-5Lube Oil Diagram, 1-14Lube Oil Filter, 4-4Lubrication System, 1-12MMaintenance Schedule, 4-1Microprocessor Controller, 1-19, 4-27Multi --- Temp, 6-1Multi---Temp Refrigerant Circuit, 6-3PPhase Sequence, 4-26Pre --- Trip, 1-25Pre --- Trip Inspection, 2-1Priming Fuel System, 4-3Pumping Unit Down, 4-12RReceiver Sight Glass, 4-19Refrigerant Charge, 4-12, 4-13Refrigerant Circuit --- Heating & Defrosting, 1-37Refrigerant Circuit ---Cooling, 1-35Refrigeration Charge, 1-13Refrigeration System Data, 1-12Remote Compartment Operation, 6-4SSafety Devices, 1-13Schematic Wiring Diagram, 5-1Sensor, 4-29Setpoint, 1-20Solenoid Valves, 4-19Speed Control Solenoid, 4-4Standby Clutch, 4-10Standby Motor V---Belts, 4-9Starting Instructions --- Engine Drive, 2-1Starting Instructions --- Standby Motor, 2-2Stopping Instructions --- Engine Drive, 2-1Stopping Instructions --- Standby Motor, 2-2Suction Pressure Transducer, 4-29SV---1 Checkout Procedure, 4-21TThermostatic Expansion Valve, 1-12, 4-25Troubleshooting, 3-1UUltraFresh 2, 1-28Unidrive torque Requirements, 4-29Unit Data, 1-22Unit Weight, 1-13Unloader, 1-14, 4-16VV --- Belts, 4-7WWater Pump V --- Belt, 4-7Wiring Diagram, 5-162-02461Index -2

North AmericaCarrier Transicold700 Olympic DriveAthens, GA 30601 USATel: 1 -706 -357 -7223Fax: 1 -706 -355 -5435Central Americaand MexicoEjercito Nacional No. 418Piso 9, Torre YumalCol. Chapultepec Morales11570 Mexico, D.F.Tel: (5255) 9126.0300Fax: (5255) 9126.0373Carrier Transicold Division,Carrier CorporationTruck/Trailer Products GroupP.O. Box 4805Syracuse, N.Y. 13221 U.S Awww.carrier.transicold.comA member of the United Technologies Corporation family. Stock symbol UTX©2006 Carrier Corporation D PrintedinU.S.A.03/06