Carrier 69NT40-511-1 Service-Handbuch

Models

69NT40-511-1

69NT40-511-199

and

69NT40-521

T-268 Rev G

Container

Refrigeration

Unit

DUE TO THE LARGE NUMBER OF SCHEMATIC

DIAGRAMS CONTAINED IN THIS BOOK, THE

BOOK IS PRESENTED AS TWO FILES.

REFER TO FILE T268--DIAGRAMS FOR THE

CHAPTER 7 ELECTRICAL DIAGRAMS AND

SCHEMATICS

Carrier Transicold Division, Carrier Corporation, P.O. Box 4805, Syracuse, N.Y. 13221

OPERATION AND

SERVICE MANUAL

ECarrier Corporation 1999 SPrinted in U. S. A. 0499

CONTAINER REFRIGERATION UNIT

MODELS

69NT40-511-1

69NT40-511-199

and

69NT40-521

SAFETY SUMMARY

Safety-1 T-268-07

SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this

manual. They are recommended precautions that must be understood and applied during operation and maintenance

of the equipment covered herein. The general safety notices are presented in the following three sections labeled: First

Aid, Operating Precautions and Maintenance Precautions. A listing of the specific warnings and cautions appearing

elsewhere in the manual follows the general safety notices.

FIRST AID

An injury, no matter how slight, should never go unattended. Always obtain first aid ormedical attentionimmediately.

OPERATING PRECAUTIONS

Always wear safety glasses.

Keep hands, clothing and tools clear of the evaporator and condenser fans.

No work should be performed on the unit until all circuit breakers and start-stop switches are turned off, and power

supply is disconnected.

Always work in pairs. Never work on the equipment alone.

In case of severe vibration or unusual noise, stop the unit and investigate.

MAINTENANCE PRECAUTIONS

Beware of unannounced starting of the evaporator and condenser fans. Do not open the condenser fan grille or

evaporator access panels before turning power off, and disconnecting and securing the power plug.

Be sure power is turned off before working on motors, controllers, solenoid valves and electrical control switches. Tag

circuit breaker and power supply to prevent accidental energizing of circuit.

Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems

with the system should be diagnosed, and any necessary repairs performed, by qualified service personnel.

When performing any arc welding on the unit or container, disconnect all wire harness connectors from the modules in

the control box. Do not remove wire harness from the modules unless you are grounded to the unit frame with a

static-safe wrist strap.

In case of electrical fire, open circuit switch and extinguish with CO2(never use water).

Safety-2T-268-07

SPECIFIC WARNING AND CAUTION STATEMENTS

To help identify the label hazards on the Unit and explain the level of awareness each one carries, an explanation is

given with the appropriate consequences:

DANGER -- means an immediate hazard which WILL result in severe personal injury or death.

WARNING -- means to warn against hazards or unsafe conditions which COULD result in severe personal injury or

death.

CAUTION -- means to warn against potential hazard or unsafe practice which COULD result in minor personal injury,

product or property damage.

The statements listed below are applicable to the refrigeration unit and appear elsewhere in this manual. These rec-

ommended precautions must be understood and applied during operation and maintenance of the equipment covered

herein.

WARNING

When servicing the unit, use caution when handling R-134a. The refrigerant when in contact with

high temperatures (about 1000_F) will decompose into highly corrosive and toxic compounds.

WARNING

Be sure to avoid refrigerant coming in contact with the eyes. Should refrigerant come in contact

with the eyes, wash eyes for a minimum of 15 minutes with potable water only. THE USE OF

MINERAL OIL OR REFRIGERANT OILS IS NOT RECOMMENDED.

WARNING

Be sure to avoid refrigerant coming in contact with the skin. Should refrigerant come in contact

with the skin, it should be treated as if the skin had been frostbitten or frozen.

WARNING

Be sure ventilation in the workspace is adequate to keep the concentration of refrigerant below

1000 parts per million. If necessary, use portable blowers.

WARNING

Beware of rotating fan blades and unannounced starting of fans.

WARNING

Do not use a nitrogen cylinder without a pressure regulator. Never mix refrigerants with air for

leak testing. It has been determined that pressurized, air-rich mixtures of refrigerants and air can

undergo combustion when exposed to an ignition source.

WARNING

Never fill a refrigerant cylinder beyond its rated capacity. Cylinder may rupture due to excessive

pressure when exposed to high temperatures.

WARNING

When starting the unit, be sure that all manual refrigerant valves in the discharge line are open.

Severe damage could occur from extremely high refrigerant pressures.

TABLE OF CONTENTS

iT-268-07

TABLE OF CONTENTS

Section Page

SAFETY SUMMARY Safety-1......................................................

GENERAL SAFETY NOTICES Safety-1..............................................

FIRST AID Safety-1...............................................................

OPERATING PRECAUTIONS Safety-1..............................................

MAINTENANCE PRECAUTIONS Safety-1...........................................

SPECIFIC WARNING AND CAUTION STATEMENTS Safety-2.........................

INTRODUCTION 1-1..........................................................

1.1 INTRODUCTION 1-1...................................................

DESCRIPTION 2-1...........................................................

2.1 GENERAL DESCRIPTION 2-1...........................................

2.2 REFRIGERATION SYSTEM DATA 2-10....................................

2.3 ELECTRICAL DATA 2-11................................................

2.4 POWER AUTOTRANSFORMER (Optional) 2-12............................

2.5 UPPER FRESH AIR MAKEUP VENT 2-13.................................

2.6 LOWER FRESH AIR MAKEUP VENT (Optional) 2-13........................

2.7 REFRIGERATION CIRCUIT WITH RECEIVER 2-14.........................

2.8 REFRIGERATION CIRCUIT WITH THE

WATER-COOLED CONDENSER (Optional) 2-16............................

2.9 WATER-COOLED CONDENSER (Optional) 2-16............................

2.9.1 Water--Cooled Condenser with Water Pressure Switch (WP) 2-16.....

2.9.2 Water-Cooled Condenser with Condenser Fan Switch (CFS) 2-16.....

2.10 SUCTION SOLENOID VALVE 2-18........................................

2.11 REMOTE MONITORING (OPTIONAL) 2-18................................

2.12 SAFETY AND PROTECTIVE DEVICES 2-19...............................

MICROPROCESSOR 3-1......................................................

3.1 MICRO-LINK 2i CONTROLLER MODULE 3-1.............................

3.1.1 Brief Description 3-1............................................

3.1.2 Controller Programming (Memory) Cards 3-2......................

3.1.3 General Layout of the Controller Section 3-4.......................

3.1.4 Controller Function Codes 3-6...................................

3.1.5 Controller Alarms 3-10...........................................

3.1.6 Condenser Pressure Control (CPC) 3-14...........................

3.1.7 Controller Temperature Control 3-14...............................

3.1.7.1 Perishable (Chill) Range Above --10_C(+14_F),

or --5_C(+23_F) Optionally. 3-14.........................

3.1.7.2 Frozen Range Below --10_C(+14_F),

or --5_C(+23_F) Optionally 3-17.........................

3.2 PRE-TRIP DIAGNOSTICS 3-17...........................................

3.2.1 Pre-Trip 3-18....................................................

3.2.2 Pre-Trip Mode 3-19..............................................

3.3 INTEGRATED DataCorder (Optional) 3-24.................................

iiT-268-07

TABLE OF CONTENTS (CONTINUED)

Section Page

3.3.1 Brief Description 3-24............................................

3.3.2 DataCORDER Configuration 3-25.................................

3.3.3 DataCORDER Function Codes 3-26...............................

3.3.4 DataCORDER Alarms 3-27.......................................

3.3.5 Access to DataCORDER Functions 3-29...........................

3.3.6 USDA/ Message Trip Comment 3-31...............................

3.3.7 USDA Recording 3-31...........................................

3.3.8 Pre-Trip Data Recording 3-31.....................................

3.3.9 DataCORDER Communications 3-31..............................

3.3.10 DataCORDER Scrollback 3-32....................................

3.4 USDA COLD TREATMENT PROCEDURE 3-32.............................

OPERATION 4-1.............................................................

4.1 PRE-TRIP INSPECTION (Before Starting) 4-1.............................

4.2 STARTING AND STOPPING INSTRUCTIONS 4-2.........................

4.3 AFTER STARTING INSPECTION 4-2.....................................

4.4 UNIT OPERATION 4-2..................................................

4.4.1 Crankcase Heater 4-2..........................................

4.4.2 Probe Check Initiation 4-2.......................................

4.4.3 Cooling -- Controller Set BELOW --10_C(+14_F), or

-- 5 _C(+23_F) optionally 4-3.....................................

4.4.4 Controller Set ABOVE --10_C(+14_F), or --5_C(+23_F) optionally 4-3

4.4.5 Heating (See Figure 4-4.) 4-10....................................

4.4.6 Defrost 4-12....................................................

4.4.7 Arctic 4-12......................................................

TROUBLESHOOTING 5-1.....................................................

5.1 UNIT WILL NOT START OR STARTS THEN STOPS 5-1....................

5.2 UNIT RUNS BUT HAS INSUFFICIENT COOLING 5-1......................

5.3 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING 5-1............

5.4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING 5-2..............

5.5 UNIT WILL NOT TERMINATE HEATING 5-2..............................

5.6 UNIT WILL NOT DEFROST PROPERLY 5-2..............................

5.7 ABNORMAL PRESSURES (COOLING) 5-3...............................

5.8 ABNORMAL NOISE OR VIBRATIONS 5-3................................

5.9 TEMPERATURE CONTROLLER MALFUNCTION 5-3......................

5.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW 5-3............

5.11 THERMOSTATIC EXPANSION VALVE MALFUNCTION 5-4.................

5.12 POWER AUTOTRANSFORMER MALFUNCTION 5-4......................

5.13 WATER-COOLED CONDENSER OR WATER PRESSURE SWITCH 5-4......

TABLE OF CONTENTS

iii T-268-07

TABLE OF CONTENTS (CONTINUED)

Section Page

SERVICE 6-1................................................................

6.1 MANIFOLD GAUGE SET 6-1............................................

6.2 SUCTION AND DISCHARGE SERVICE VALVES 6-4.......................

6.3 PUMPING THE UNIT DOWN 6-4........................................

6.4 REFRIGERANT LEAK CHECKING 6-4...................................

6.5 EVACUATION AND DEHYDRATION 6-5..................................

6.5.1 General 6-5...................................................

6.5.2 Preparation 6-5................................................

6.5.3 Procedure 6-5.................................................

6.6 REFRIGERANT CHARGE 6-5...........................................

6.6.1 Checking the Refrigerant Charge 6-5.............................

6.6.2 Adding Refrigerant to System (Full Charge) 6-8....................

6.6.3 Adding Refrigerant to System (Partial Charge) 6-8..................

6.7 COMPRESSOR -- MODEL 06DR 6-8.....................................

6.7.1 Removal and Replacement of Compressor 6-9.....................

6.8 COMPRESSOR DISASSEMBLY 6-9.....................................

6.9 COMPRESSOR REASSEMBLY 6-13......................................

6.10 COMPRESSOR OIL LEVEL 6-14.........................................

6.11 FILTER-DRIER 6-15.....................................................

6.12 HIGH PRESSURE SWITCH 6-15.........................................

6.12.1 Replacing High Pressure Switch 6-15..............................

6.12.2 Checking High Pressure Switch 6-15..............................

6.13 EVAPORATOR COIL AND HEATER ASSEMBLY 6-16.......................

6.14 EVAPORATOR COIL HEATERS 6-16......................................

6.15 EVAPORATOR FAN AND MOTOR ASSEMBLY 6-16........................

6.16 EVAPORATOR FAN MOTOR CAPACITORS 6-17...........................

6.17 CONDENSER COIL 6-18................................................

6.18 CONDENSER FAN AND MOTOR ASSEMBLY 6-18.........................

6.19 PARTLOW RECORDING THERMOMETER 6-18............................

6.20 SAGINOMIYA RECORDING THERMOMETER 6-20.........................

6.21 MAINTENANCE OF PAINTED SURFACES 6-21............................

6.22 POWER AUTOTRANSFORMER (OPTIONAL) 6-21.........................

6.23 SENSOR CHECKOUT PROCEDURE (AMBS, DTS, RRS, RTS, SRS & STS) 6-21

6.23.1 Checking Sensor (RRS, RTS, SRS or STS) 6-21....................

6.23.2 Replacing Sensor (STS and SRS) 6-22............................

6.23.3 Replacing Sensor (RRS and RTS) 6-23............................

6.23.4 Checking Sensor (AMBS or DTS) 6-24.............................

6.23.5Replacing Sensor (AMBS or DTS) 6-24..............................

6.24 SUCTION SOLENOID VALVE (SSV) 6-25..................................

6.25 SUCTION MODULATION VALVE (SMV) 6-25...............................

ivT-268-07

TABLE OF CONTENTS (CONTINUED)

Section Page

6.26 THERMOSTATIC EXPANSION VALVE 6-26................................

6.27 CONTROLLER/DATACORDER 6-28......................................

6.27.1 Controller/DataCORDER Programming Procedure 6-29..............

6.27.2 Controller Trouble-Shooting 6-29..................................

6.28 WATER-COOLED CONDENSER 6-30.....................................

ELECTRICAL WIRING SCHEMATIC AND DIAGRAMS 7-1........................

7.1 INTRODUCTION 7-1...................................................

INDEX Index-1...................................................................

LIST OF ILLUSTRATIONS

Figure Page

Figure 2-1 Refrigeration Unit -- Front 2-1.......................................

Figure 2-2 Refrigeration Unit -- Rear (Panels Removed) 2-3......................

Figure 2-3 Compressor Section 2-4............................................

Figure 2-4 Condenser Section 2-5.............................................

Figure 2-5 Units with Receiver 2-6.............................................

Figure 2-6 Units with Water-Cooled Condenser 2-7..............................

Figure 2-7 Control Box on Units with a Single-Speed Compressor 2-8.............

Figure 2-8 Control Box on Units with a Two-Speed Compressor (Optional) 2-9......

Figure 2-9 Power Autotransformer (Optional) 2-12................................

Figure 2-10 Refrigeration Circuit with Receiver 2-15................................

Figure 2-11 Refrigeration Circuit with Water-Cooled Condenser (Optional) 2-17.......

Figure 3-1 Micro-Link 2i Controller/DataCORDER Module 3-1.....................

Figure 3-1 Key Pad 3-4......................................................

Figure 3-2 Display Module 3-5................................................

Figure 3-3 Standard Configuration Report Sample 3-34...........................

Figure 3-4 Controller Set Point BELOW --10_C(+14_F), or

-- 5 _C(+23_F) optionally 3-35.........................................

Figure 3-5 Controller Set Point ABOVE --10_C(+14_F), or

-- 5 _C(+23_F) optionally 3-35.........................................

Figure 3-6 Two-Speed Compressor Speed Change Logic -- Perishable Range Only 3-36

Figure 3-7 Two-Speed Compressor Speed Change Logic -- Frozen Range Only 3-37.

Figure 4-1 Cooling in High Speed with Two-Speed Compressor 4-5...............

Figure 4-2 Cooling in Low Speed with Two-Speed Compressor 4-7................

Figure 4-3 Cooling with Single-Speed Compressor 4-9...........................

Figure 4-4 Heating Mode 4-11.................................................

Figure 4-5 Defrost 4-13.......................................................

TABLE OF CONTENTS

vT-268-07

LIST OF ILLUSTRATIONS (CONTINUED)

Figure Page

Figure 6-1 Manifold Gauge Set 6-1............................................

Figure 6-2 R-134a Manifold Gauge Set Connection 6-3..........................

Figure 6-3 Suction or Discharge Service Valve 6-4..............................

Figure 6-4 Vacuum Pump Connections 6-7.....................................

Figure 6-5 Compressor -- Model 06DR 6-9......................................

Figure 6-6 Exploded View of Valve Plate 6-10....................................

Figure 6-7 Bottom Plate Removed 6-10.........................................

Figure 6-8 Oil Pump and Bearing Head 6-11.....................................

Figure 6-9 Low Profile Gear Oil Pump 6-11......................................

Figure 6-10 Motor End Cover 6-11...............................................

Figure 6-11 Crankshaft Assembly 6-12...........................................

Figure 6-12 Removing Equalizing Tube and Lock Screw Assembly 6-12..............

Figure 6-13 Terminal Mounting Assembly 6-12....................................

Figure 6-14 Suction Valve & Positioning Springs 6-13..............................

Figure 6-15 Piston Rings 6-13...................................................

Figure 6-16 Compressor Oil Pump End View 6-14.................................

Figure 6-17 Typical Setup for Testing High Pressure Switch 6-15....................

Figure 6-18 Evaporator Fan Assembly 6-17.......................................

Figure 6-19 Partlow Recording Thermometer 6-20................................

Figure 6-20 Saginomiya Recording Thermometer 6-21.............................

Figure 6-21 Supply Sensor Positioning 6-22......................................

Figure 6-22 Sensor (RRS, RTS, SRS or STS) 6-23................................

Figure 6-23 Sensor and Cable Assembly (RRS, RTS, SRS or STS) 6-23.............

Figure 6-24 Return Sensor Positioning 6-24......................................

Figure 6-25 Sensor (AMBS or DTS) 6-24.........................................

Figure 6-26 Sensor and Wire Assembly (AMBS or DTS) 6-24.......................

Figure 6-27 Suction Solenoid Valve (SSV) -- Alco 6-25.............................

Figure 6-28 Suction Modulation Valve (SMV) 6-26.................................

Figure 6-29 Thermostatic Expansion Valve -- Alco 6-27.............................

Figure 6-30 Thermostatic Expansion Valve Bulb 6-27..............................

Figure 6-31 Controller side of the Control Box 6-28................................

Figure 6-32 Water-Cooled Condenser Cleaning -- Forced Circulation 6-31............

Figure 6-33 Water-Cooled Condenser Cleaning -- Gravity Circulation 6-32............

Figure 6-34 R-134a Compressor Pressure and Motor Current Curves Versus

Ambient Temperature 6-37...........................................

Figures 7-1/7-68 Electrical Schematic -- See Model Chart 7-2/7-137.....................

viT-268-07

LIST OF TABLES

Table Page

Table 1-1 Model Chart 1-2...................................................

Table 2-1 Safety and Protective Devices 2-19...................................

Table 3-1 Controller Configuration Variables 3-3................................

Table 3-2 Key Pad Function 3-4..............................................

Table 3-3 Controller Function Code Assignments 3-6...........................

Table 3-4 Controller Alarm Indications 3-11.....................................

Table 3-5 Pre-Trip Test Codes 3-19............................................

Table 3-6 DataCORDER Function Code Assignments 3-26.......................

Table 3-7 DataCORDER Alarm Indications 3-28.................................

Table 3-8 DataCORDER Alarm Configurations 3-29..............................

Table 3-9 DataCorder Standard Configuration 3-30..............................

Table 3-10 DataCORDER Pre-Trip Data 3-33....................................

Table 4-1 Electrical Control Positions -- BELOW --10_C(+14_F), or

-- 5 _C(+23_F) optionally 4-14.........................................

Table 4-2 Electrical Control Positions -- ABOVE --10_C(+14_F), or

-- 5 _C(+23_F) optionally 4-15.........................................

Table 6-1 AMBS, DTS, RRS, RTS, SRS and STS Temperature-Resistance Chart 6-32

Table 6-2 Partlow Bulb Temperature-Resistance Chart 6-32.......................

Table 6-3 Recommended Bolt Torque Values 6-33...............................

Table 6-4 Wear Limits For Compressors 6-33...................................

Table 6-5 Compressor Torque Values 6-34......................................

Table 6-6 Temperature-Pressure Chart -- R-134a 6-35............................

Andere Handbücher für 69NT40-511-1

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