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69NT40-489-100 Series
Carrier 69NT40-489-100 Series User Manual
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T
−
305 Rev C
OPERA
TION AND SER
VICE
for
EverFresh Controlled Atmosphere
69NT40-489-100 Series
Container Refrigeration Units
r
Container Refrigeration
2
Table of Contents
Safety Summary
5
Controlled Atmosphere (Ca) Safety Considerations
5
Immediate Effects of Breathing Oxygen Deficient Atmospheres
5
Human Response to Oxygen Deficient Atmospheres
5
Controlled Atmosphere (Ca) Safe Container Entry
6
Always
6
Resuscitation
6
Rescue
6
First Aid
6
Entering Container in an Emergency
7
Precautions for Handling Compressed Gas
8
General Safety Notices
10
First Aid
10
Operating Precautions
10
Maintenance Precautions
10
Unit Label Identification
10
Specific Danger, Warning and Caution Statements
11
Table of Contents
16
Part One - - Refrigeration Unit
25
Introduction
25
Configuration Identification
25
Option Description
25
Figure Number
29
Description
29
General Description
29
Refrigeration Unit -- Front Section
29
Upper Fresh Air Makeup Vent
29
Figure 1. Refrigeration Unit -- Front Section
29
Evaporator Section
30
Figure 2. Evaporator Section
30
Compressor Section
31
Figure 3. Compressor Section
31
Air Cooled Condenser Section
32
Figure 4. Condenser Section
32
Water-Cooled Condenser Section
33
Figure 5. Water-Cooled Condenser Section
33
Control Box Section
34
Communications Interface Module
34
Figure 6. Control Box Section
34
Refrigeration System Data
35
Electrical Data
36
Table Number
37
Safety and Protective Devices
37
Table 1. Safety and Protective Devices
37
Refrigeration Circuit
38
Figure 7. Refrigeration Circuit Schematic
39
Microprocessor
41
Temperature Control Microprocessor System
41
Figure 8. Temperature Control System
41
Display Module
42
Figure 10. Display Module
42
Figure 9. Key Pad
42
Key Pad
42
Table 2. Key Pad Function
42
Controller
43
Paragraph Number
43
Refrigeration Controller Software
43
Configuration Software (Configuration Variables)
43
Operational Software (Function Codes)
43
Figure 11. Micro-Link 2I Controller
43
Modes of Operation
44
Temperature Control -- Perishable Mode
44
Evaporator Fan Operation
44
Defrost Interval
44
Failure Action
44
Generator Protection
44
Condenser Pressure Control
44
Arctic Mode
44
Perishable Mode -- Conventional
44
Perishable Mode -- Economy
45
Perishable Mode -- Dehumidification
45
Perishable, Dehumidification -- Bulb Mode
45
Temperature Control -- Frozen Mode
46
Frozen Mode -- Conventional
46
Frozen Mode -- Economy
46
Controller Alarms
46
Unit Pre-Trip Diagnostics
46
Datacorder
47
Description
47
Datacorder Software
47
Sensor Configuration (Dcf02)
48
Table 3. Datacorder Configuration Variables
48
Table 4. Datacorder Standard Configurations
49
Figure 12. Standard Configuration Report
50
Logging Interval (Dcf03)
51
Thermistor Format (Dcf04)
51
Sampling Type (Dcf05 & Dcf06)
51
Alarm Configuration (Dcf07 -- Dcf10)
51
Datacorder Power-Up
51
Pre-Trip Data Recording
51
Datacorder Communications
51
USDA Cold Treatment
52
USDA Cold Treatment Procedure
52
Figure 13. Data Reader
52
Datacorder Alarms
53
Table 5. Controller Configuration Variables
54
Table 6. Controller Function Codes
55
Table 7 Controller Alarm Indications
59
Table 8 Temperature Controller Pre-Trip Test Codes
62
Table 9 Datacorder Function Code Assignments
66
Table 10 Datacorder Pre-Trip Result Records
67
Table 11 Datacorder Alarm Indications
68
Operation
69
INSPECTION (before Starting)
69
Connect Power
69
Connection to 380/460 Vac Power
69
Connection To190/230 Vac Power
69
Adjust Fresh Air Makeup Vent
69
Upper Fresh Air Makeup Vent
69
Figure 14. Autotransformer
69
Paragraph Number
70
Connect Water-Cooled Condenser
70
Check Controller Function Codes
70
Connect Remote Monitoring Receptacle
70
Physical Inspection
70
Start--Up Inspection
70
Starting and Stopping Instructions
70
Starting the Unit
70
Stopping the Unit
70
Water--Cooled Condenser with Water Pressure Switch
70
Water-Cooled Condenser with Condenser Fan Switch
70
Complete Inspection
71
Pre-Trip Diagnosis
71
Crankcase Heater
72
Observe Unit Operation
72
Probe Check
72
Sequence of Operation
72
Figure 16. Controller Operation -- Perishable Mode
73
Figure 17. Controller Operation -- Frozen Mode
73
Figure 18. Perishable Mode
74
Figure 19. Perishable Mode Heating
74
Sequence of Operation - - Perishable Mode Cooling
74
Sequence of Operation -- Frozen Mode -- Cooling
74
Sequence of Operation -- Perishable Mode -- Heating
74
Figure 20. Frozen Mode
75
Figure 21. Defrost Mode
75
Sequence of Operation -- Defrost Mode
75
Emergency Bypass Operation
76
Emergency Defrost Operation
76
Emergency Operation
76
Troubleshooting
77
Unit will Not Start or Starts then Stops
77
Unit Operates Long or Continuously in Cooling
77
Unit Runs but Has Insufficient Cooling
78
Unit will Not Heat or Has Insufficient Heating
78
Unit will Not Terminate Heating
78
Unit will Not Defrost Properly
78
Abnormal Pressures (Cooling)
79
Abnormal Noise or Vibrations
79
Refrigeration Controller Malfunction
79
No Evaporator Air Flow or Restricted Air Flow
80
Thermostatic Expansion Valve Malfunction
80
Autotransformer Malfunction
80
Water-Cooled Condenser or Water Pressure Switch
80
Service
81
Section Layout
81
Service Valves
81
Manifold Gage Set
81
Figure 22. Service Valve
81
Figure 23. Manifold Gage Set
81
Figure 24. R-134A Manifold Gage/Hose Set
82
Figure 25. Refrigeration System Service Connections
82
Paragraph Number
83
Evacuation and Dehydration
83
General
83
Preparation
83
Procedure - Complete System
83
Procedure - Partial System
84
Pumping the Unit down
83
Refrigerant Leak Checking
83
Refrigerant Charge
84
Checking the Refrigerant Charge
84
Adding Refrigerant to System (Full Charge)
84
Adding Refrigerant to System (Partial Charge)
84
Figure 26. Compressor Service Connections
84
Compressor
85
Removal and Replacement of Compressor
85
Figure 27. Compressor
85
Compressor Disassembly
86
Figure 28. Exploded View of Valve Plate
86
Figure 29. Bottom Plate Removed
86
Figure 30. Oil Pump and Bearing Head
87
Figure 31. Low Profile Oil Pump
87
Figure 32. Motor End Cover
87
Compressor Reassembly
88
Preparation
88
Figure 33. Equalizing Tube and Lock Screw Assembly
88
Figure 34. Crankshaft Assembly
88
Figure 35. Suction Valve & Positioning Springs
88
Figure 36. Piston Ring
88
Installing the Components
89
Compressor Oil Level
89
Condenser Coil
90
Condenser Fan and Motor Assembly
90
Figure 37. High Pressure Switch Testing
90
High Pressure Switch
90
Replacing High Pressure Switch
90
Checking High Pressure Switch
90
Water Cooled Condenser Cleaning
91
Figure 38. Water-Cooled Condenser Cleaning -- Forced Circulation
92
Figure 39. Water Cooled Condenser Cleaning - Gravity Circulation
92
Checking Superheat
93
Figure 40. Thermostatic Expansion Valve Bulb
93
Figure 41. Hermetic Thermostatic Expansion Valve
93
Figure 42. Hermetic Thermostatic Expansion Valve Brazing Procedure
93
Hermetic Valve Replacement
93
Filter-Drier
92
Thermostatic Expansion Valve
92
Assembly
94
Evaporator Coil Replacement
94
Evaporator Heater Replacement
94
Evaporator Coil and Heater
94
Evaporator Fan and Motor Assembly
94
Figure 43. Evaporator Fan Locating Dimension
94
Evaporator Fan Motor Capacitors
95
When to Check for a Defective Capacitor
95
Removing the Capacitor
95
Checking the Capacitor
95
Figure Number
95
Suction Modulation Valve
95
Precheck Procedure
95
Figure 44. Suction Modulation Valve (SMV)
95
Checking the Stepper Valve
96
Checking the Drive Module
96
Checking the Controller
96
Emergency Repair Procedures
97
DISCHARGE PRESSURE REGULATOR VALVE Check Procedure
97
Figure 45. Jumper Assembly
97
Paragraph Number
98
Autotransformer
98
Controller Trouble-Shooting
98
Figure 46. Controller Section of the Control Box
98
Handling Controller
98
Refrigeration Controller
98
Battery Replacement
99
Controller Programming Procedure
99
Removing and Installing the Controller
99
Sensor Checkout Procedure
99
Temperature Sensor Service
99
Figure 47. Sensor Types
100
Figure 48. Sensor and Cable Splice
100
Sensor Replacement
100
Table 12. Sensor Temperature/Resistance Chart
100
Composite Control Box Repairs
101
Figure 49. Supply Sensor Positioning
101
Figure 50. Return Sensor Positioning
101
Introduction
101
Maintenance of Painted Surfaces
101
Sensor Re-Installation
101
Chips and Holes
102
Cracks
102
Door Hinge Inserts
102
Figure 51. Door Hinge Repair
102
Inserts
102
Table 13. Crack, Chip & Hole Repair Kit
103
Table 14. Insert Repair Kit
103
Table 15. Drill Information
103
Figure 52. Insert Locations
104
Communications Interface Module Installation
105
Figure 53. Communications Interface Installation
105
Power Factor Corrector Capacitors (Pfc)
105
Table 16. Recommended Bolt Torque Values
105
Table 17. Wear Limits for Compressors
106
Table 18. Compressor Torque Values
107
Table 19. R-134A Temperature - Pressure Chart
108
Figure 54. R-134A Compressor Pressure and Motor Current Curves Versus Ambient Temperature
109
Figure 54. R-134A Compressor Pressure and Motor Current Curves Versus Ambient Temperature
110
Part Two - - Controlled Atmosphere System
111
Introduction
111
Figure 55. Basic Schematic for the CA System
111
Description
113
General Description
113
CA Equipment Location -- Front Section
113
Calibration, Gas Charge and Pressurization/Gage Ports
113
Figure 56. Controlled Atmosphere Components -- Front Section
113
CA Components in the Refrigeration Evaporator Section
114
Figure 57. Controlled Atmosphere Components -- Evaporator Section
114
Figure 58. Controlled Atmosphere Components -- Evaporator Fan Deck Section
115
Control Box
116
Figure 59. Controlled Atmosphere Components -- Control Box
116
CA Components in the Refrigeration Condenser Section
117
Figure 60. Controlled Atmosphere Components -- Condenser Section
117
Container Rear Door Section
118
Figure 61. Controlled Atmosphere Components -- Container Rear Door
118
Controlled Atmosphere System Data
119
Electrical Data
119
Controlled Atmosphere (Ca) Flow Circuit
120
Figure 62. Controlled Atmosphere System -- Flow Circuit
121
Fresh Air Makeup Vent
122
Safety and Protective Devices
122
Table 20. Controlled Atmosphere Safety and Protective Devices
122
Microprocessor
123
Controlled Atmosphere Controller Module
123
Brief Description
123
Figure 63. Controlled Atmosphere Controller Module
123
CA Controller Programming (Memory) Card
124
Figure 64. CA Controller Key Pad
124
General Layout of the CA Controller Section
124
Figure 65 CA Controller Display Module
125
CA Controller Function and Data Codes
126
Table 22. CA Controller Function Code Assignments
126
CA Controller Alarms
128
Configuration Software (Configuration Variables)
128
Table 23. CA Controller Configuration Variables
128
Table 24. CA Controller Alarm Indications
129
Controller CA Control
130
Paragraph Number
131
Ca Pre-Trip Diagnostics
131
Pre-Trip
131
Pre-Trip Mode
133
Table 25. Controlled Atmosphere Pre-Trip Test Codes
133
Operation
135
CONTROLLED ATMOSPHERE (CA) PRE-TRIP INSPECTION (before Starting)
135
Controlled Atmosphere (Ca) Starting and Stopping Instructions
135
Start--Up Inspection
136
Controlled Atmosphere Set Point Selection
137
Controlled Atmosphere System Operation
137
Controlled Atmosphere (Ca) System Container Venting Procedure
137
Figure 66 Emergency Bypass for the Door Interlock System
138
Troubleshooting
139
Controlled Atmosphere (Ca) System will Not Start
139
Controlled Atmosphere (Ca) System Malfunction
139
Service
141
Maintenance Schedule
141
Air Compressor
142
Air Compressor Service (P/N 18--00052)
142
Figure 67. Typical Air Compressor
143
Figure 68. Puller Backing Plate
143
Figure 69. Air Compressor (P/N 18--00052) Exploded View
144
Air Compressor Assembly (P/N 18--00052)
145
Air Compressor Service (P/N 18--00099)
146
Figure 70 Cylinder Head Removal
146
Figure 71 O--Ring Installation
146
Figure 72 Puller Plate Positioning
148
Figure 73 Puller Installation
148
Figure 74 C--Stand Positioning
149
Figure 75 Rod Assembly Positioning
149
Figure 76 Rod Pusher Installation
149
Figure 77. Air Compressor (P/N 18/00099) Exploded View
150
Air Intake Filter
151
Figure 78. Membrane Air Filter Assembly
151
Figure 79. Air Intake Filter Assembly
151
Membrane Air Filter
151
Air Sample Filter
152
Carbon Dioxide Sensor
152
Figure 80. Solenoid Manifold Valve and Sensor Assemblies
152
Oxygen Sensor
152
Figure 81. Carbon Dioxide Sensor
153
Nitrogen Membrane Separator
153
Figure 82. Nitrogen Membrane Separator
154
Container Curtain
155
Figure 83. Installation of Container Curtain
155
Controlled Atmosphere (Ca) Controller Module
156
Programming Procedure
157
Troubleshooting
157
Figure 84. Controlled Atmosphere Ml2I Control Box
158
Solenoid Valve
156
Part Three -- Electrical Wiring Schematics and Diagrams
159
Introduction
159
Figure 85. Legend
159
Figure 86. Schematic Diagram
160
Figure 87. Schematic Diagram -- Humidity
161
Figure Number
161
Figure 88. Wiring Diagram
162
Introduction
165
Figure 89. LEGEND -- CA
166
Figure 90. Electrical Schematic -- CA
167
Figure 91. Electrical Wiring Diagram -- Controlled Atmosphere
169
Figure 92. Electrical Schematic
171
Figure 93. Electrical Wiring Diagram
173
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Carrier 69NT40-489-100 Series Specifications
General
Brand
Carrier
Model
69NT40-489-100 Series
Category
Refrigerator
Language
English
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