CONTAINER 69NT

SERVICE PROCEDURES

















TABLE OF CONTENTS

1. Troubleshooting tips.
3. Diode testing procedure.
4. Relay testing procedure.
6. Refrigeration component identification.
7. Refrigeration system diagram.
8. Analog control electrical component identification.
10. Microlink control electrical component identification.
12. Microlink 2 & 2i control electrical component identification.
14. Service valves
15. Manifold gauge set installation and removal procedure.
18. Low side pumpdown procedure.
19. O6DR compressor operation test procedure.
20. Compressor oil level test procedure.
22. Superheat test procedure.
24. Analog controller 30 second test procedure.
26. Modulation and quench valve test procedure. (Analog control)
27. Modulation and quench valve test procedure. (Microlink, Microlink 2 & 2i)
28. CSS resistance test procedure. (Analog control)
29. Temperature sensor resistance test procedure. (Analog control)
30. Temperature sensor resistance test procedure. (Microlink, Microlink 2 & 2i)
31. Temperature control simulator module. (Analog control)
33. Motor and heater resistance test procedure.
35. Motor and heater current test procedure.
36. Refrigerant charge level test procedure.
37. Refrigerant charging procedure.
38. Refrigerant color codes
39. Refrigerant recovery procedure.
41. Evacuation procedure.
42. Boiling temperature of water
46. Dual voltage compressor internal resistance readings.




Page 1
TROUBLESHOOTING TIPS


1. Always connect a voltmeter in parallel. When troubleshooting grounded low voltage control
circuits, (24VAC, 12VDC, etc) use a clip-on connection from the meter negative (black) lead to
unit ground. This will leave one hand free to operate switches, etc. Always test the meter setup
on a known voltage before troubleshooting. When troubleshooting high voltage (230VAC,
460VAC, etc) check voltages from phase to phase and not to ground. Check that the meter is on
the proper scale. If unsure, select the highest scale first and then select progressively lower
scales until the value displayed is approximately in the middle of the scale.

2. Ohmmeters are always connected in parallel on de-energized circuits. At least one side (lead) of
the component being tested must be disconnected from the circuit to isolate that component
from the rest of the circuit. Resistance readings must not be taken with power applied to the
component. Always test the ohmmeter by touching the meter leads together to test the meter for
proper operation. It should read 0 ohms (or very low). Check that the meter is on the proper
scale.

3. Always connect DC ammeters in series with the circuit being tested. You must "break" the
circuit and connect the meter in series. The meter becomes part of the circuit under test.

4. To locate a unit problem, operate the unit in all modes of operation: full cool, full cool with
bypass, modulated cooling, air circulation, heat, and defrost. Check the operation of the
modulation valve and the quench valve. Note the suction and discharge pressures in all modes
of operation.

5. When troubleshooting electrical faults, it is necessary to know how the unit operates and what is
supposed to happen. It is suggested that the meter negative (black) lead be first connected to
ground or common. Check the operation of the meter by touching the red meter lead on a
known source of voltage. Starting at he left of the schematic and at supply voltage, work your
way across the schematic towards the circuit load by testing consecutive connection points until
the voltage is not found. The problem or fault in the circuit will be between the points where
voltage was found and where voltage was not found.

Example: If on an analog unit the heat contactor (HR) will not close, first check for control
voltage (24VAC) at mother board terminal T9 then continue to the right towards the load (HR
contactor coil). Test for 24VAC at T8, T10, T11, and C1 on the HR contactor. If voltage is not
found at a test point, the problem lies between that point and the last point tested. Be sure to
check the obvious visual indications such as the LED's on the motherboard.











Page 2
CLAMP-ON AMMETER

The clamp-on ammeter is a small, versatile test instrument used by technicians for measuring AC
current or amps.

The clamp-on ammeter works like a transformer. The wire acts like the primary of the transformer
and the jaws of the ammeter as the secondary. Current through the wire creates lines of force that
induce a current in the jaws. The induced current passes through the meter movement, providing an
indication of how much current is passing through the wire.

When taking a current reading, always start on the highest possible scale and work towards the lower
scale to prevent damage to the meter. Do not cycle a motor off and back on with the meter clamped
onto the motor lead, unless you first set the meter to the highest scale. This will prevent damage
from current surges.

Never clamp the meter around two different wires (phases) at the same time. If currents are flowing
in opposite directions, the meter will read the difference between the two. If current is flowing in the
same direction, the meter will read the sum of the two.

An example of where an ammeter would be used on a refrigeration unit would be to check the amp
draw on the compressor when the unit is operating in the cool mode.




























Page 3
DIODE TESTING PROCEDURE

The diodes used in Carrier Transicold equipment are solid state devices that conduct electrical current in one
direction only. They are used for circuit isolation and arc suppression.

CIRCUIT ISOLATION

When used for circuit isolation, diodes are connected in order to prevent one energized circuit from energizing
another.

An example of this is diode D1, found in the glow plug circuit for the Carrier Transicold diesel powered
generator set model #69GL15-114, drawing #69GL15-1094-RA. Diode D1 is used to prevent the low oil
pressure switch from energizing the glow plugs when the engine is running.

ARC SUPPRESSION

When diodes are used for arc suppression, they are usually connected across inductive loads. An inductive load
is any load made up of a coil of wire.

Examples are: relay coils, solenoid valve coils, speed and run solenoids and unloader coils. When any inductive
load is de-energized, it instantaneously generates a very high voltage spike. This high voltage spike can destroy
the relay contacts that control the load. A relay that has pitted, burnt or welded together contacts may be the
result of a defective arc suppression diode.

TESTING A DIODE

Before a diode can be tested using an ohmmeter, the diode must be isolated from the circuit to which it is
connected.

Using an analog meter

To use an analog volt-ohm-milliammeter (vom) to test diodes, select the ohms R x 1 scale. A good diode
should read very low resistance in one direction and very high in the other direction.

Using a digital meter

Because a digital meter has limited power output in the ohm's scale, it cannot be used to test a diode in the same
way as an analog meter. A good diode tested on the ohms scale on a digital meter would read infinite ohms in
both directions, incorrectly indicating a defective diode. On digital vom's you must use the diode test scale.
When using this scale to test a diode, the meter will read the voltage at which the diode begins to conduct in the
forward direction. A normal reading will usually be .4 to .7 Volts. Very high or very low readings indicate a
defective diode. In the reverse direction, the diode will not conduct and the meter will indicate "OL" or an open
circuit. Any other indication signifies a defective diode.



Page 4
RELAY TESTING PROCEDURE
FOR RELAY (PART #10-00220)


1. Turn the unit off and remove the suspect relay from its socket on the motherboard. Refer to the
diagram below.

2. Check the coil for continuity with an ohmmeter by placing the ohmmeter leads on the coil
terminals. The coil terminals will be labeled "C". A good coil will have a resistance of
approximately 115 ohms. A resistance value of 0 ohms or infinite ohms indicates a defective
coil.

3. Continuity (0 or nearly 0 ohms) should be found between the common (C) and the normally
closed (NC) terminals. The common terminals are numbers 1, 4, and 7. The normally closed
terminals are numbers 2, 5, and 8. Therefore you should measure 0 or nearly 0 ohms between
terminals 1 & 2, 4 & 5, and 7 & 8.

4. No continuity (infinite resistance) should be found between the common (C) and normally open
(NO) terminals. The normally open terminals are 3, 6, and 9. Therefore you should measure
infinite (very high) resistance between terminals 1 & 3, 4 & 6, and 7 & 9.

5. To test the normally open (NO) contacts it is necessary to energize the relay coil. Connect a
12VDC-power supply to the coil terminals. You should be able to see the contacts change
position. Continuity should now be found between the common and normally open terminals
and there should be no continuity between the common and normally closed terminals.

9- NO 6- NO 3- NO
5- NC 8- NC 2- NC
C - 1
C - 7
C - 4
Coil Coil
Legend
NC - Normally Closed
NO - Normally Open
C - Common



Page 5



Page 6
CONTAINER REFRIGERATION COMPONENT IDENTIFICATION


Referring to the following unit refrigeration diagram, locate the designated component on the
unit and write the name and location of that component below.



Reference number Component name & location

1. __________________________________________________

2. __________________________________________________

3. __________________________________________________

4. __________________________________________________

5. __________________________________________________

6. __________________________________________________

7. __________________________________________________

8. __________________________________________________

9. __________________________________________________

10. __________________________________________________

11. __________________________________________________

12. __________________________________________________

13. __________________________________________________

14. __________________________________________________

15. __________________________________________________

16. __________________________________________________

17. __________________________________________________

18. __________________________________________________




Page 7




R134a
5
17
16
15
9
10
14
13
11
12
1
18 2
3
4
8
7
6
R12
5
4
17
15
10
3
8
12
14
1
9
2
16
11
13
6
7



Page 8

ANALOG UNIT ELECTRICAL COMPONENT IDENTIFICATION


Symbol Description & location

C __________________________________________________
CB1 __________________________________________________
CB2 __________________________________________________
CF __________________________________________________
CL __________________________________________________
CLT __________________________________________________
CM __________________________________________________
CP __________________________________________________
CSS __________________________________________________
DD __________________________________________________
DHBL __________________________________________________
DIS __________________________________________________
DL __________________________________________________
DPH __________________________________________________
DR __________________________________________________
DTT __________________________________________________
EF __________________________________________________
EM __________________________________________________
ES __________________________________________________
F __________________________________________________
HL __________________________________________________
HPS __________________________________________________
HR __________________________________________________
HTT __________________________________________________



Page 9
IRL __________________________________________________
IRS __________________________________________________
MDS __________________________________________________
QV __________________________________________________
RM __________________________________________________
RTS __________________________________________________
SDS __________________________________________________
SMV __________________________________________________
SSS __________________________________________________
SST __________________________________________________
ST __________________________________________________
STS __________________________________________________
TB __________________________________________________
TC __________________________________________________
TDS __________________________________________________
TH __________________________________________________
TU __________________________________________________
TQ __________________________________________________
TR __________________________________________________
TSS __________________________________________________
VS __________________________________________________
UNIT MODEL NUMBER ___________________________________
UNIT SERIAL NUMBER ___________________________________
REFRIGERANT CHARGE ___________________________________





Page 10
MICROLINK UNIT ELECTRICAL COMPONENT IDENTIFICATION


Symbol Description & location

AMBS __________________________________________________
C __________________________________________________
CB1 __________________________________________________
CB2 __________________________________________________
CF __________________________________________________
CM __________________________________________________
CP __________________________________________________
CPDS __________________________________________________
CPSS __________________________________________________
CSAS __________________________________________________
CT __________________________________________________
DHBL __________________________________________________
DPH __________________________________________________
DTT __________________________________________________
EF __________________________________________________
EM __________________________________________________
ES __________________________________________________
HCS __________________________________________________
HPS __________________________________________________
HR __________________________________________________
HTT __________________________________________________
IC __________________________________________________
MDS __________________________________________________
PP __________________________________________________
PR __________________________________________________



Page 11
PT __________________________________________________
QV __________________________________________________
R __________________________________________________
RM __________________________________________________
RRS __________________________________________________
RTS __________________________________________________
SMV __________________________________________________
SRS __________________________________________________
SSV __________________________________________________
ST __________________________________________________
STS __________________________________________________
TB __________________________________________________
TC __________________________________________________
TE __________________________________________________
TFC __________________________________________________
TI __________________________________________________
TH __________________________________________________
TN __________________________________________________
TQ __________________________________________________
TS __________________________________________________
TV __________________________________________________
WP __________________________________________________
UNIT MODEL NUMBER ___________________________________
UNIT SERIAL NUMBER ___________________________________
REFRIGERANT CHARGE ___________________________________



Page 12
MICROLINK 2 AND MICROLINK 2i UNIT ELECTRICAL COMPONENT IDENTIFICATION


Symbol Description & location

AMBS __________________________________________________
C __________________________________________________
CB1 __________________________________________________
CB2 __________________________________________________
CH __________________________________________________
CI __________________________________________________
CL(C-L) __________________________________________________
CM __________________________________________________
CP __________________________________________________
CPDS __________________________________________________
CPSS __________________________________________________
CPT __________________________________________________
DHBL __________________________________________________
DPH __________________________________________________
DR(TF) __________________________________________________
DTS __________________________________________________
DVM __________________________________________________
EF __________________________________________________
EM __________________________________________________
ES __________________________________________________
HPS __________________________________________________
HR __________________________________________________
HS __________________________________________________
HTT __________________________________________________
HVM(CS) __________________________________________________



Page 13
IC __________________________________________________
MDS __________________________________________________
PR __________________________________________________
RM __________________________________________________
RRS __________________________________________________
RTS __________________________________________________
SMV __________________________________________________
SRS __________________________________________________
SSV __________________________________________________
ST __________________________________________________
STS __________________________________________________
TC __________________________________________________
TE __________________________________________________
TH __________________________________________________
TI __________________________________________________
TN __________________________________________________
TP __________________________________________________
TR __________________________________________________
TS __________________________________________________
VS __________________________________________________
WP __________________________________________________
UNIT MODEL NUMBER ___________________________________
UNIT SERIAL NUMBER ___________________________________
REFRIGERANT CHARGE ___________________________________







Page 14
Service Valves




Page 15

MANIFOLD GAUGE SET INSTALLATION AND REMOVAL PROCEDURE


Before using a manifold gauge set it is important that it be purged. This insures that air and other contaminates
will not be introduced into the refrigeration system. Manifold gauge sets using hoses without self-sealing ends
must be purged every time that they are used. Manifold gauge set hoses with self sealing ends must be purged
or evacuated and charged with refrigerant when: 1) the hoses have been disconnected from the manifold or 2)
they will be used on a refrigeration system with different refrigerant than previously serviced units.

While in use, a manifold gauge set high side hose will fill with condensed liquid refrigerant. When the high
side hose is removed from the compressor discharge service valve, liquid refrigerant will be released. It is
because of this liquid release that the proper procedure for removing the manifold gauge set be followed.

SAFETY GLASSES AND GLOVES SHOULD ALWAYS BE WORN WHEN INSTALLING OR
REMOVING A MANIFOLD GAUGE SET. PLEASE FOLLOW LOCAL ENVIRONMENTAL LAWS
WHEN REFERRING TO THESE INSTRUCTIONS.

TO INSTALL THE CFC MANIFOLD GAUGE SET


Installing CFC manifold gauge sets WITHOUT self-sealing hoses.

1. Remove the valve stem caps from the compressor suction and discharge service valves.
BACKSEAT both valves. Remove the caps from the service ports.

2. Connect the high side hose to the compressor discharge service valve and tighten the hose
connection.

3. Connect the low side hose loosely to the compressor suction service valve port. The center
(utility) hose should be connected loosely to the center "dummy fitting" on the manifold gauge
set.

4. To purge the hoses and manifold, backseat the manifold valves, midseat (slightly open) the
compressor discharge service valve. Refrigerant from the discharge service valve will force air
and contaminants from the manifold and hoses and out through the loosely connected center
hose at he "dummy fitting" and at the suction service valve. After hearing gas escape for a few
seconds tighten the center hose connection at the "dummy fitting" and then at the suction service
valve. Frontseat the manifold gauge set valves to isolate the high and low sides from each other.
Midseat the suction service valve.




Page 16
Installing CFC manifold gauge sets WITH self-sealing hoses.

1. Remove the valve stem caps from the compressor suction and discharge service valves.
BACKSEAT both valves. Remove the caps from the service ports.

If a manifold gauge set is new or was exposed to the atmosphere. Due to repair, it will need to be
evacuated to remove contaminants and air as follows:

a. Midseat both hand valves.
b. Connect the utility hose (yellow) to a vacuum pump.
c. Evacuate to 10 inches of vacuum.
d. Charge with proper refrigerant to a slightly positive pressure of 1.0 psig (0.1 kg/cm2)
e. The gauge set is now ready for use.

2. Connect the high side hose to the discharge service valve port and tighten. Do not connect the
center or the low side hose. Backseat the manifold gauge valves, midseat (slightly open) the
compressor discharge service valve.

If the manifold gauge set has been used on refrigeration equipment with the same
refrigerant and the hoses have not been removed (the gauge set displays internal pressure
on the gauges), skip step 3.

3. To purge air and contaminants from the manifold and hoses, use a 1/4 flare fitting or other
instrument to open, for a few seconds, the self sealing valve in the end of the center hose and
then in the low side hose. This will purge the air from the hoses and manifold and leave the
manifold and hoses full of refrigerant vapor.

POINT THE HOSES IN A SAFE DIRECTION WHEN PURGING. PLEASE FOLLOW LOCAL
ENVIRONMENTAL LAWS WHEN REFERRING TO THESE INSTRUCTIONS.

4. Connect the low side hose to the compressor suction service valve port. Connect the center
(utility) hose to the center "dummy fitting" on the manifold gauge set. Midseat the suction
service valve. Frontseat the manifold gauge set valves to isolate the high and low sides from
each other.
















Page 17

Installing HFC (R-134a) manifold gauge sets.

1. Remove the valve stem caps from the compressor suction and discharge service valves.
BACKSEAT both valves. Remove the caps from the service ports.

If a manifold gauge set is new or was exposed to the atmosphere. Due to repair, it will need to be
evacuated to remove contaminants and air as follows:

a. Midseat both hand valves.
b. Connect the utility hose (yellow) to a vacuum pump.
c. Evacuate to 10 inches of vacuum.
d. Charge with R-134a to a slightly positive pressure of 1.0 psig (0.1 kg/cm2)
e. The gauge set is now ready for use.


2. Connect the high side field service coupling (backseated) to the discharge service valve port (or
the manual liquid line valve port, whichever is applicable).

3. Turn the high side field service coupling (red knob) clockwise, which will open the high side of
the system to the gauge set.

4. Connect the low side field service coupling to the suction service valve port.

5. Turn the low side field service coupling (blue knob) clockwise, which will open the low side of
the system to the gauge set.

6. To read system pressures: slightly midseat the discharge and suction service valves and
Frontseat both manifold gauge set hand valves.


TO REMOVE ALL MANIFOLD GAUGE SETS

1. With the compressor running, backseat the compressor discharge service valve.

2. Midseat both valves on the manifold gauge set and allow the pressure in the manifold gauge set
to be drawn down to suction pressure. This procedure for removing the manifold gauge set
allows the liquid that condensed in the high side hose to be returned to the system. This will
leave the manifold gauge set internal pressure equal to suction pressure.

3. Backseat the compressor suction service valve. Backseat both field service couplings, and
remove the couplings from the service ports.

4. Install both service valve stem caps and service port caps (finger-tight only).



Page 18
LOW SIDE PUMPDOWN PROCEDURE

1. Install the manifold gauge set. Start the unit and allow it to run for 15 to 20 minutes.

2. Front seat the manual liquid line valve (king valve).

3. Operate the unit in cool mode until suction pressure reaches a positive pressure of 1.0 psig (0.1
kg/cm). Turn unit off.

WARNING: DO NOT ALLOW THE SYSTEM TO OPERATE IN A VACUUM AS
COMPRESSOR DAMAGE MAY RESULT. PLEASE FOLLOW LOCAL ENVIRONMENTAL
LAWS WHEN REFERRING TO THESE INSTRUCTIONS.

4. Watch suction pressure gauge. Typically the pressure will rise a small amount. Ideally, the
pressure should stabilize at 1 to 2 psig.

5. If the pressure climbs too high it may be necessary to re-start the unit and allow it to run for a
few more seconds. If the suction pressure stabilizes too low (vacuum), momentarily midseat
both valves on the manifold gauge set to allow refrigerant from the high side to enter the low
side through the manifold gauge set.

6. When the pressure is stabilized at 1 to 2 psig, Frontseat the suction service valve. The entire
refrigerant charge is now trapped in the compressor, condenser and receiver sections of the
system. All system components with the exception of the discharge service valve, high side
fusible plug, condenser, suction/liquid heat exchanger, receiver/water cooled condenser and the
king valve can be changed or serviced.

7. After completing repairs, be sure to perform a refrigerant leak check and evacuate and dehydrate
the low side of the system through the service port on the liquid line valve (king valve).

8. To return the unit to service, back seat the liquid line valve and the suction service valve (SSV).



















Page 19
06DR COMPRESSOR OPERATION TEST PROCEDURE


COMPRESSOR HIGH PRESSURE TEST

With the unit operating in cool mode, partially block the condenser airflow. Discharge pressure should rise to at
least 250 psig for systems using R-12 and R-134a. Don't let discharge pressure rise enough to cause the high-
pressure safety to open and shut the unit off. Failure of the compressor to reach high discharge pressures
may indicate worn or broken piston rings, worn or broken valves or defective head gaskets. Inability to
operate at high discharge pressures will reduce refrigerating capacity when ambient temperatures are high.


REASONS FOR FAILURE - Blown cylinder head gasket.
Broken or worn valves.
Flooded starts.
Slugging.
Flooding.
Overcharge/undercharge of oil.
Defective TXV.
Contaminates in the system.




Page 20
CHECKING COMPRESSOR OIL LEVEL


A common error in servicing and maintaining Carrier Transicold container refrigeration equipment is
over charging the refrigeration system with oil. A general statement referring to oil level is; if there is
oil visible in the sight glass, don't add any.

1. Operate the unit in the cooling mode for at least 20 minutes.

2. Check the front oil sight glass on the compressor to ensure that no foaming of the oil is present
after 20 minutes of operation. If the oil is foaming excessively after 20 minutes of operation,
check the refrigerant system for flood-back of liquid refrigerant. Correct this situation before
performing step 3.

3. Turn the unit off to check the oil level. The correct oil level range should be as follows:

28 CFM compressor - 0 to 1/2 of the sightglass
37 CFM compressor - 0 to 3/8 of the sightglass
41 CFM compressor - 0 to 1/8 of the sightglass

Compressor size is identified by the 6th and 7th digit of the model number. Example: model number
06DR2418CC19AC is a 41 CFM compressor.


If the oil level is too high, remove enough to lower the oil level to the proper level. If the oil level is
too low, run the system in heat for 15 to 20 minutes and then in cool for 15 to 20 minutes and recheck.
If the oil level is still low then add oil. This insures that a large amount of oil is not out in the system,
giving an erroneous low reading.


TO REMOVE COMPRESSOR OIL

Install a manifold gauge set. Frontseat (close) the suction service valve. Run the compressor until the
suction pressure falls into a slight vacuum. Turn off the unit and observe the suction pressure. It is
necessary for the pressure to stop at a slight positive pressure of 1 to 2 psig (0.1 to 1.2 kg/cm). If
pressure rises too high, run the compressor for a few more seconds. If the pressure remains too low,
momentarily open both hand valves on the manifold gauge set. This allows some refrigerant from the
high side to pass through the manifold and raise the low side pressure.

When the pressure is correct and stabilized, remove power from the unit and secure the power plug to
avoid accidentally starting the compressor. Front seat the suction and discharge service valves to isolate
the compressor from the system. Carefully relieve the remaining compressor internal pressure by
removing the manifold gauge set hose from the suction service valve. PLEASE FOLLOW LOCAL
ENVIRONMENTAL LAWS WHEN REFERRING TO THESE INSTRUCTIONS. The oil drain
plug can now be safely removed and excess oil drained from the compressor crankcase.





Page 21

TO ADD COMPRESSOR OIL

Use only recommended oils. For R-12 units use mineral oil (Texaco wf32). For R-134a units use POE oil
(Castrol Icematic SW20).

With the compressor running and the suction service valve front seated, oil can be drawn into the suction
service valve through the manifold gauge set. If the center hose (use a hose without a self-sealing valve) is
submerged in a container of compressor oil and the low side manifold valve opened, oil will be drawn through
the manifold and into the compressor.

Be sure to purge the center hose after it is submerged in the oil container.

PLEASE FOLLOW LOCAL ENVIRONMENTAL LAWS WHEN REFERRING TO THESE
INSTRUCTIONS.

To purge the center hose:

1. Attach a manifold gauge set to the compressor and purge if necessary. Midseat the discharge
service valve and Frontseat the suction service valve.

2. Drop the center manifold hose into the compressor oil container. Be sure that the end of the hose
is submerged and remains submerged throughout this procedure.

3. Slightly midseat the high side manifold valve. Refrigerant from the discharge service valve will
force air from the center hose and will bubble into the oil. After a few seconds, Frontseat
(close) the high side manifold valve.

There are oil pumps available for compressor oil containers that will pump oil directly into the suction service
valve. The compressor must be running with the suction service valve midseated. The pump will overcome
suction pressure. Add oil carefully as not to over fill the crankcase.




Page 22
SUPERHEAT TEST PROCEDURE


1. Check the calibration of the manifold test set gauges, especially the suction gauge. Adjust if
necessary.
2. Install an accurate gauge to the suction service port.
3. Firmly attach a temperature-sensing device to the evaporator coil outlet line at or near the TXV
bulb location and insulate the area.
4. Start the unit and set to operate in cool mode for a minimum of 20 minutes. The system must
stabilize with the compressor operating on all 6 cylinders and the High Side pressure at the
following minimum levels - 150 psig for R-134a and 200 psig for R-22.
5. Note the suction gauge reading and the temperature at the TXV sensing bulb (the refrigerant
vapor temperature). Record both readings.
6. Repeat step 6 at least five times at two to three minute intervals and record the information.
7. After recording the five readings, calculate the superheat for each set of readings.
8. Using a pressure - temperature chart determine the saturation temperature at the suction pressure
recorded.
9. To determine superheat, subtract the saturation temperature determined above, from the
temperature measured at the TXV bulb.
10. Average the five superheat figures calculated above and compare to the specification for the
unit.
REFER TO OPERATION AND SERVICE MANUAL FOR CORRECT SUPERHEAT.
SEE SAMPLE SUPERHEAT CHECKSHEET ON FOLLOWING PAGE.






Page 23

SUPERHEAT CHECK SHEET

Suction Pressure
(Taken at Suction
Service Valve)
Thermometer
Reading at TXV
Bulb
Saturated Suction
Temperature
(From P/T Chart)
Superheat = TXV
Bulb Temp. Minus
Saturation Temp.
BARS
PSIG
C
F
C
F
C
F
BARS
PSIG
C
F
C
F
C
F
BARS
PSIG
C
F
C
F
C
F
BARS
PSIG
C
F
C
F
C
F
BARS
PSIG
C
F
C
F
C
F
Total the (5)
Readings
C
F
Average
Superheat
C
F

VEHICLE INFORMATION:
IDENTIFICATION NUMBER ______________________________
HUB MILAGE ______________________________
DATE ______________________________
REFER TO OPERATION AND SERVICE MANUAL FOR CORRECT SUPERHEAT.



Page 24
THE ANALOG CONTROLLER 30 SECOND TEST

TO TEST THE FROZEN PROGRAM:

1. Install manifold gauge set. Rotate the temperature set station (CSS) to its full counter-clockwise
position. Start the unit and allow the system to stabilize.

2. Using one hand, depress and hold the time delay switch (TDS) while holding the temperature
simulator switch (TSS) in the -17.8 C (0 F) position. Using the other hand, slowly rotate the
CSS clockwise. The following events should occur at approximately the CSS setpoints
indicated:

Start (TC) on
-19.8 C (-3.6 F) (IRS) on, In-range light on
-17.5 C (0.5 F) (TC) off, Compressor and condenser off
-15.8 C (3.6 F) (IRS) off, In-range light off
-10 C (14 F) (TH) on, Heaters on, (TU) on

3. Reversing the procedure, rotate the CSS counter-clockwise and the following should occur:

Start (TH) on, Heaters on
-10 C (14 F) (TH) off, Heaters off, (TU) off)
-15.8 C (3.6 F) (IRS) on, In-range light on
-18 C (0.4 F) (TC) on, Compressor and condenser on
-19.8 C (-3.6 F) (IRS) off, In-range off

TO TEST THE CHILL OR PERISHABLE PROGRAM:

1. Install manifold gauge set. Rotate the CSS to its full counter-clockwise position. Start the unit
and allow the system to stabilize.

2. Using one hand, depress and hold the TDS while holding the TSS in the 0 C (32 F) position.
Slowly rotate the CSS clockwise. The following events should occur at approximately the CSS
setpoints indicated:

Start (TC) on, Compressor and condenser on
-10 C (14 F) (TU) on, Utility relay on
Approx. -5 C (23 F) (TQ) on, Modulation occurs
-2 C (28 F) (IRS) on, In-range light on
+0.25 C (32.5 F) (TC) off, Compressor and condenser off
+1 C (34 F) (TH) on, Heaters on
+2 C (36 F) (IRS) off, In-range light off




Page 25
3. Reversing the procedure, rotate the CSS counter-clockwise and the following should occur:

Start (TH) on, Heaters on
+2 C (36 F) (IRS) on, In-range light on
+0.5 C (33 F) (TH) off, Heaters off
-0.25 C (31.5 F) (TC) on, Compressor and condenser on
-2 C (28 F) (IRS) off, In-range off
Approx. -5 C (23 F) (TQ) off, Modulation stops
-10 C (14 F) (TU) off, Utility relay off

The quench relay (TQ) will be energized at 50% or more modulation.



Page 26
ANALOG CONTROL SUCTION MODULATION and QUENCH VALVE TEST PROCEDURE

FOR ANALOG CONTROLLED UNITS


1. Install the manifold gauge set. Turn the unit on, set the temperature set station (CSS) to -18 C
(0 F) and allow system pressures to stabilize.


2. Using one hand, hold the time delay switch (TDS) in and the temperature simulator switch
(TSS) in the 0 C (32 F) position.


3. Starting with CSS in the full counter clockwise position, with your other hand, slowly rotate the
CSS clockwise. If the modulation circuit is functioning properly you will notice a change in the
sound of the compressor and a significant drop in suction pressure as the modulation valve
begins to close as CSS approaches 0 C (32 F). As the CSS approaches the 0 C (32 F) position,
the suction pressure should be approximately 10-20 inches of mercury vacuum. At this time if a
clamp on ammeter is monitoring compressor current, it should drop to a reading below 10 amp.


4. To check the temperature controller's electrical signal to the modulation valve, connect a DC
voltmeter between motherboard terminals T12 (DC common) and T14. Repeat the procedure
above. When the reading is 0.2 VDC or less the modulation valve is fully open. As the voltage
increases, the modulation valve is closing. This may be confirmed by watching the suction
pressure gauge fall as the voltage to the modulation valve increases. A reading of 1.2 to 1.4
VDC indicates a fully closed modulation valve. This voltage reading is equal to modulation
valve current.


5. To check the operation of the quench valve, repeat the procedures of steps 2 and 3 above, while
touching the quench line on the suction line side of the quench valve. When the temperature
controller's electrical signal to the modulation valve exceeds 0.62 amps the TQ relay will be
energized (TQ LED on). This energizes the quench valve, causing it to open. This may be
confirmed by noting a significant drop in the temperature of the quench line and a slight increase
in suction pressure.

If the SMV coil is defective and open, TQ will not be energized and the quench valve will
fail to function.



Page 27
SUCTION MODULATION VALVE and QUENCH VALVE TEST PROCEDURE

FOR MICROLINK, MICROLINK 2 AND MICROLINK 2I CONTROLLED UNITS


1. Install the manifold gauge set. Turn the unit on. Using the keypad, set the set point to a
temperature significantly below the container temperature. This will cause the unit to run in
cool mode.


2. At start up the microprocessor may close the suction modulation valve (SMV). The modulation
valve will be allowed to open at a rate of 1% per second until fully open. This can be viewed by
displaying code 01. Code 01 will indicate the percent of opening of the SMV as directed by the
microprocessor. It does not mean that the SMV operated correctly as the circuit is not
monitored directly.


3. The correct operation of the SMV can be checked by two methods:

START THE UNIT IN COOL MODE WITH THE SETPOINT 5 C TO 10 C BELOW
THE CONTAINER TEMPERATURE. AFTER THE SYSTEM HAS STABILIZED,
CHANGE THE SETPOINT TO EQUAL THE CONTAINER TEMPERATURE.

a. Watch the suction gauge pressure drop into a vacuum when the SMV closes
after the setpoint is set to a temperature equal to the container temperature.

b. Using a clamp on ammeter, monitor compressor current. After the setpoint is set
to a temperature equal to the container temperature the compressor current will
usually fall below 10 amps. This drop in compressor current indicates that the
SMV closed.

4. To check the operation of the quench valve (electric solenoid operated quench valve with a
Microlink control), monitor code 02. The operation of the quench valve is indicated as "open"
or "closed". When the electrical current through the suction modulation valve solenoid coil
exceeds 0.62 amps (when 47% open or less is indicated by code 01) the quench valve will be
energized. This may be confirmed by noting a significant drop in the temperature of the quench
line and a slight increase in suction pressure. Power to the quench valve can be confirmed by
reading the voltage at TB9. There should be 24 VAC at TB9 anytime code 02 indicates "open".

If the SMV coil is defective and open, the quench valve will fail to function and the
Microlink will fail the pretrip tests P6-2 (QV test) and P6-3 (SMV closed).









Page 28

TEMPERATURE SET STATION (CSS) RESISTANCE TEST PROCEDURE

FOR ANALOG CONTROLLED UNITS

1. BEFORE PROCEEDING, TURN UNIT OFF, OPEN CIRCUIT BREAKER(S),
DISCONNECT AND SECURE POWER CORD.

2. Isolate the temperature set station by disconnecting it from the motherboard at plug P8.

PLEASE NOTE: When testing at the plug, always insert the meter probes from the back (wire
side) of the plug. This prevents bending of the plug terminals, which could result in a poor
connection when the plug is replaced on the motherboard.

3. Measure the resistance between CSS 1 (the brown wire) and CSS 3 (the orange wire).
Regardless of the selector setting the resistance should be 1980 to 1988 ohms.

4. Set the selector at the -25 C (-15 F) position. The resistance between CSS 1 and CSS 2 (brown
wire to red wire) should be 324 to 334 ohms. The resistance between CSS 2 and CSS 3 (red
wire to orange wire) should be 1648 to 1656 ohms.

5. Set the selector at the 0 C (32 F) position. The resistance between CSS 1 and CSS 2 (brown
wire to red wire) should be 980 to 988 ohms. The resistance between CSS 2 and CSS 3 (red
wire to orange wire) should be 1000 to 1008 ohms.

6. Set the selector at the 25 C (77 F) position. The resistance between CSS 1 and CSS 2 (brown
wire to red wire) should be 1633 to 1641 ohms. The resistance between CSS 2 and CSS 3 (red
wire to orange wire) should be 347 to 355 ohms.

IF THE MEASURED RESISTANCES ARE FOUND TO BE SIGNIFICANTLY DIFFERENT
THAN THE LISTED VALUES, REPLACE THE TEMPERATURE SET STATION.




Page 29
TEMPERATURE SENSOR RESISTANCE TEST PROCEDURE

FOR ANALOG CONTROLLED UNITS

1. BEFORE PROCEEDING, TURN UNIT OFF, OPEN CIRCUIT BREAKER(S),
DISCONNECT AND SECURE POWER CORD.

2. Isolate the temperature sensor to be tested by disconnecting it from the motherboard at the
appropriate plug. Plug P10 for the supply temperature sensor (STS) or P11 for the return
temperature sensor (RTS).

3. Determine the temperature in the area where the sensor is located. An alternate method is to
place the sensor in a 0 C (32 F) ice bath or measure the temperature at the probe location with a
known standard.

4. Measure the resistance of the sensor by placing the meter leads on the back (wire side) of the
plug. For the STS, use pins 1 & 2 on P10, for the RTS use pins 3 & 4 on P11.

5. Compare the measured resistance value to the SENSOR RESISTANCE chart found on page 28
of the 69NT20/40 SERVICE TRAINING MANUAL.


IF THE MEASURED RESISTANCE IS FOUND TO BE SIGNIFICANTLY DIFFERENT
THAN THE LISTED VALUE, REPLACE THE TEMPERATURE SENSOR.




Page 30
TEMPERATURE SENSOR RESISTANCE TEST PROCEDURE

FOR MICROLINK, MICROLINK 2 AND MICROLINK 2i CONTROLLED UNITS


BEFORE PROCEEDING, TURN UNIT OFF, OPEN CIRCUIT BREAKER(S),
DISCONNECT AND SECURE POWER CORD.

Microlink
The temperature sensors change resistance with temperature. For a microprocessor-controlled unit they may be
either thermistors or RTD's. Temperature probes usually fail shorted or opens.

RTD probes are linear; meaning that the resistance change per degree is the same across the temperature range.
RTD probes vary resistance from 91 ohms to 109 ohms and measure exactly 100 ohms at 32 F (0 C).

Additional temperature sensors may be found on most microprocessor units. They are thermistor type probes
but have a different shape than controlling or recording sensors. The compressor suction sensor (CPSS), the
ambient sensor (AMBS), the defrost temperature sensor (DTS) and the condenser saturation sensor (CSAS) will
measure 32,650 ohms at 32 F (0 C). The compressor discharge sensor (CPDS) will measure 326,500 ohms at
32 F (0 C).

Referring to the schematic and the wiring diagram, the RTS is connected to the Microlink microprocessor at the
PC connector through pins 11 and 20. Before measuring the RTS resistance, it is necessary to isolate it from the
circuit by disconnecting the PC plug from the I/O circuit board connection. After removing the plug, place the
ohmmeter probes in the plug at pins 11 and 20.

DO NOT TAKE ANY RESISTANCE MEASUREMENTS ON THE PC SOCKET MOUNTED ON THE
I/O CIRCUIT BOARD AS DAMAGE TO THE BOARD CAN RESULT.

It is necessary to know the temperature of the sensor before measuring its resistance. An accurate thermometer
can be placed near the sensor or the sensor can be placed in an ice bath. A temperature of 32 F (0 C) can be
obtained by ice bathing the sensor. A thermistor sensor will measure 32,650 ohms (CPDS will measure
326,500 ohms) and an RTD sensor will measure 100 ohms while in an ice bath.

Microlink 2 and Microlink 2i
To check the sensors on a Microlink 2 unit it is necessary to disconnect the EC connector from the back the
microprocessor module and take resistance readings at the EC plug. To check the sensors that attach to the
dataCORDER module it is necessary to disconnect the ED connector from the back of the dataCORDER
module and take resistance readings at the ED plug. Sensors are thermistor type. The temperature of the sensor
must be known before checking the resistance.



Page 31
TEMPERATURE CONTROL SIMULATOR MODULE PROCEDURE

FOR ANALOG CONTROLLED UNITS


WARNING: Do not remove or install any circuit board unless the START-STOP switch
is in the "0" or "OFF" position.

1. Install the manifold gauge set.

2. Remove the temperature control board and replace it with the temperature control simulator
module (TCSM).

3. Place all the TCSM switches (except the valve current switch) in the left (up or away from the
circuit board) position. Place the valve current switch in the center (off) position.

4. Turn the unit on by placing the START-STOP switch in the "ON" position. Check the 24 VAC
warning LED. If illuminated, turn the unit off and check all control wiring to the motherboard,
as this indicates a failure in the 24 VAC supply. If not illuminated, proceed to step 5.

5. At this time only the evaporator fans should be operating. If the unit is equipped with two-speed
evaporator fans, they should be operating in low speed. To test high-speed operation, move the
TU-1 switch to the down position.

6. To test the compressor and condenser fan circuit, move the TC switch to the down position.
The compressor and condenser fan motor should now be operating and the "Cool" lamp should
be illuminated.

7. With the compressor and condenser fan operating, you may test the suction modulation and
quench valves. Move the valve (SMV) current switch to the 50% position. A decrease in
suction pressure should be noted. Move the valve current switch to the MAX position. The
suction pressure should drop into a vacuum. DO NOT leave the switch in the MAX position for
more than 30 seconds unless you move the TU-2 (TQ) switch to the down position. This should
energize the quench valve and you should note a slight increase in suction pressure. RETURN
ALL SWITCHES TO THEIR ORIGINAL POSITION.

8. To test the heater circuit, move the TH switch to the down position. The heater contactor and
"Heat" lamp should be energized. You may test the operation of the individual heaters by
measuring the current draw at the wiring loops provided below the heater contactor. Return the
TH switch to the original position and note that the heaters are turned off.

9. To test the operation of the defrost relay, move the DR switch to the down position. The
evaporator fans should turn off and the defrost lamp should be illuminated. Return the DR
switch to the original position. It will be necessary to turn the unit off to de-energize the DR
relay. The defrost relay will de-energize and the evaporator fans should re-start.





Page 32

10. To test the operation of the In-Range relay, move the In-Range switch to the right (down)
position. The In-Range lamp should be illuminated. Return the In-Range switch to the original
position. The In-Range relay will not de-energize unless you depress the TDS switch.

The following procedures require the use of a digital voltmeter.
11. To test the output of the 12 VDC circuit, place the positive voltmeter lead in test point TP1 and
the negative lead in TP4. The negative lead will remain in this position for the remainder of the
tests. A reading of 11.5 1.2 VDC should be noted on the meter.

12. To test the output of the 9 VDC circuit, remove the positive meter lead from TP1 and place it in
TP2. A reading of 8.5 to 9.5 VDC should be noted on the meter. This reading is the reference
voltage, which will be used in later steps. Make a note of this reading for use at that time. If a
reading of 12 VDC appears on the meter, re-check unit wiring.

13. To test the temperature set station place the positive meter lead in TP3. The test the selector, at
least three readings must be taken. For the first reading set the selector at one end of it's
operating range, for example, -20 C. Compare the reading to the SELECTOR SET POINT
SIGNAL VOLTAGES chart on page 29 in the 69NT20/40 SERVICE TRAINING MANUAL.
Use the appropriate column based on the reference voltage measured in step 12. Repeat the test
with the selector at various setpoints throughout it's operating range. A good component will
display voltages very close to the chart value.

14. To test the temperature sensors it is first necessary to determine the temperature in the area
where the sensor is located. To test the supply temperature sensor, place the positive meter lead
in TP5. Compare the reading to the SENSOR D.C. VOLTAGES chart on page 27 in the
69NT20/40 SERVICE TRAINING MANUAL. For the return temperature sensor, move the
positive meter lead to TP6. A good sensor will display a voltage close to the chart value.

15. Turn unit off and re-install temperature control board.

AS THERE IS NO CALIBRATION ADJUSTMENT ON THE TEMPERATURE
CONTROL SYSTEM; DEFECTIVE COMPONENTS SHOULD BE REPLACED TO
INSURE ACCURATE TEMPERATURE CONTROL.



Page 33
MOTOR AND HEATER RESISTANCE TEST

ALL POWER SHOULD BE REMOVED FROM THE UNIT BEFORE PROCEEDING.

It is possible to test the static condition of all the motors and the heaters in the unit by reading the
resistance of the device at the contactor connections. All readings are taken at load side terminals.

If the unit is equipped with dual voltage by switch (VS), take the resistance readings with VS in both
the high voltage (460) and the low voltage (230) positions.

A resistance reading from each terminal to unit ground should also be taken to check for insulation
breakdown. An ohmmeter can be used but a more realistic reading can be taken using a Megger.
Meggers use high voltage, typically 500 VDC, while ohmmeters use 1 or 2 VDC.


TESTING THE COMPRESSOR

VS = 230 VS = 460

1 TO 2 ________ ________ 1 TO GND ________

1 TO 3 ________ ________ 2 TO GND ________

2 TO 3 ________ ________ 3 TO GND ________


TESTING THE CONDENSER FAN MOTOR

VS = 230 VS = 460

1 TO 3 ________ ________ 1 TO GND ________

3 TO GND ________

TESTING THE HEATERS

VS = 230 VS = 460

1 TO 2 ________ ________ 1 TO GND ________

1 TO 3 ________ ________ 2 TO GND ________

2 TO 3 ________ ________ 3 TO GND ________




Page 34
TESTING THE EVAPORATOR FAN MOTORS

VS = 230 VS = 460

1 TO 2 ________ ________ 1 TO GND ________

1 TO 3 ________ ________ 2 TO GND ________

2 TO 3 ________ ________ 3 TO GND ________



Page 35
MOTOR AND HEATER CURRENT TEST

It is possible to measure the operating current of all the motors and the heaters in the unit by using a
clamp on ammeter on the "wire loops" on the high voltage contactor connections at the load side
terminals. Current readings while operating on 230 VAC will be approximately 2 times readings for
460 VAC.

WHEN TAKING CURRENT READINGS WITH A CLAMP ON AMMETER, INSURE THAT
ALL LOOPS OF WIRE THAT ARE CONNECTED TO A CONTACTOR TERMINAL PASS
THROUGH THE CLAMP JAWS.

When running the unit in cool, it is possible to read the current drawn by the compressor, evaporator
fans and the condenser fan. The compressor current will depend on the position of the suction
modulation valve, pressures and temperatures. The heaters current can be measured while operating in
heat, defrost or dehumidification modes.

TESTING THE COMPRESSOR TESTING THE CONDENSER FAN MOTOR

VS = 230 VS = 460 VS = 230 VS = 460

1 ________ ________ 1 ________ ________

2 ________ ________ 3 ________ ________

3 ________ ________

TESTING THE HEATERS

VS = 230 VS = 460

1 ________ ________

2 ________ ________

3 ________ ________

TESTING THE EVAPORATOR FAN MOTORS

VS = 230 VS = 460

1 ________ ________

2 ________ ________

3 ________ ________





Page 36

REFRIGERANT CHARGE TESTING PROCEDURE


To insure proper refrigerating capacity, a refrigeration system must have the proper charge.

An under charged system may display low suction and discharge pressures. A semi-hermetic compressor may
overheat as cool refrigerant returning from the evaporator is used to cool the compressor motor. An under
charged system will have a low refrigerating capacity.

An over charged system may have extremely high discharge pressures. Pressures may be high enough to cause
system damage. The compressor discharge temperature may cause the oil to break down. Acids and sludge
formed by the oil break down may damage the compressor. An over charged system may also have a low
refrigerating capacity.

Before checking the refrigerant charge level on a 69NT20/40 container refrigeration unit, set the controller set
point to -13F (-25C) to ensure that the suction modulation valve is fully open. The unit must be running in
cool mode and the container temperature must be at 0 C (32 F) or below.

Partially block the condenser airflow and raise discharge pressure to at least 185 to 195 psig for R-12 and R-
134a. For high ambient temperatures this may not be necessary.

On units without a water-cooled condenser or a receiver, the sight glass/moisture indicator should be clear or
have an occasional bubble.

NOTE: DO NOT ADD REFRIGERANT JUST BECAUSE BUBBLES ARE SEEN IN THE SIGHT GLASS.
THE ONLY SURE WAY TO TELL HOW MUCH CHARGE IS IN A UNIT IS TO REMOVE THE
REFRIGERANT AND WEIGH IT.

On units with a water-cooled condenser, the refrigerant level should be 1/2 the water-cooled condenser sight
glass.

On units with a receiver, there are 2 sight glasses. The bottom sight glass should not be empty and the top sight
glass should not be full.




Page 37
REFRIGERANT CHARGING PROCEDURE


Refrigerant charging may be performed using one of two methods, fully charging an evacuated system and
partial charging.

FULLY CHARGING A REFRIGERATION SYSTEM

A refrigeration system needs to be fully charged if it is evacuated. A Carrier Transicold container refrigeration
system is fully charged using liquid refrigerant, through the liquid line valve (king valve) with the unit off.

Normally the full amount can be charged without warming the refrigerant container. With the refrigerant
container on a scale, carefully weigh in the correct amount. Connect the refrigerant container to the king
valve and purge the hose to remove any air. Midseat the king valve and open the refrigerant container liquid
valve (disposable refrigerant containers must be inverted). The correct refrigerant charge can be found on the
unit nameplate that is attached to the bulkhead at the left of the compressor.


PARTIAL CHARGING A REFRIGERATION SYSTEM

It is necessary to partially charge a refrigeration system when the refrigerant charge is found to be low, or the
complete charge could not be introduced into the unit as described above.
A partial charge is introduced into the system through the suction service valve in vapor form only. With
the refrigerant container on a scale, carefully weigh in a small amount and then recheck the charge.
Connect the refrigerant container to the suction service valve and purge air from the hose. With the compressor
running, allow vapor refrigerant to enter the system.

When charging is completed, check the system charge using the correct procedure. Adjust as necessary.





Page 38
REMOVING EXCESS CHARGE

If a refrigeration system is found to contain an excess refrigerant charge the excess must be removed to insure
safe and proper operation.

Excess refrigerant is removed in liquid form through the king valve with the unit operating in cool mode and the
compressor running. Attach a refrigerant container to the king valve using a manifold gauge set. Connect the
high side hose to the king valve and the low side hose to the suction service valve. Midseat (open) the suction
service valve. The center hose is connected to the refrigerant container. Purge the hoses of air. PLEASE
FOLLOW LOCAL ENVIRONMENTAL LAWS WHEN REFERRING TO THESE INSTRUCTIONS.
Midseat the king valve and only open the high side hand valve on the manifold gauge set. The low side hand
valve on the manifold gauge set must be Frontseated and closed. Open the valve on the refrigerant container and
allow the system high side pressure to force liquid refrigerant into the refrigerant container. With the refrigerant
container on a scale, carefully remove a small amount and then recheck the charge.

When the unit charge is correct, close the refrigerant container valve, backseat and close the king valve and
open both hand valves on the manifold gauge set. This will allow the compressor (the system should be
running in cool mode) to draw any liquid refrigerant from the hoses into the unit.

BE CERTAIN THAT THE REFRIGERANT CONTAINER IS THE REFILLABLE TYPE AND HAS
THE CAPACITY TO CONTAIN THE REFRIGERANT ABOUT TO BE ADDED TO IT'S
CONTENTS. REFRIGERANT CONTAINERS SHOULD NEVER BE FILLED MORE THAN 80% BY
VOLUME.


REFRIGERANT COLOR CODE SYSTEM


REFRIGERANT CYLINDER COLOR EXPANSION VALVE
COLOR

R-12 WHITE YELLOW
R-22 GREEN GREEN
R-134a LIGHT BLUE BLUE
R-404a ORANGE ORANGE
R-500 YELLOW ORANGE
R-502 PURPLE PURPLE

RECOVERED APPROPRIATE COLOR W/YELLOW SHOULDER OR
GRAY W/YELLOW SHOULDER*

*RECOVERED REFRIGERANT CYLINDERS/DRUMS SHALL BE MARKED AS SHOWN
BELOW IN ONE INCH (25MM) OR LARGER LETTERS/NUMERALS:

RECOVERED REFRIGERANT ____ (ENTER NUMBER)



Page 39
REFRIGERANT RECOVERY PROCEDURE

DO NOT OPERATE AN R-134a COMPRESSOR IN A VACUUM AS LOSS OF LUBRICATION AND
COMPRESSOR DAMAGE CAN RESULT. PLEASE FOLLOW LOCAL ENVIRONMENTAL LAWS
WHEN REFERRING TO THESE INSTRUCTIONS.

Connect a manifold gauge set between the refrigeration unit and the Totalclaim unit. Connect the high side
hose from the manifold gauge set to the unit king valve (manual liquid line valve) and the low side hose from
the manifold gauge set to the compressor suction service valve. The center hose from the manifold gauge set
should have an in line sight glass and be connected to the Totalclaim unit at the bottom hose connection that is
designated as the "black" connection. The king valve and the suction service valve must be mid-seated and the
manifold gauge set hand valves must be front-seated, isolating the center hose from the low side and high side
connections.

If the refrigeration unit is operable, set the Totalclaim recovery system to "liquid" and "recovery" modes
(NOT RECOVERY PLUS) and press the start button. Mid-seat only the high side hand valve on the manifold
gauge set to allow liquid refrigerant to flow from the king valve of the refrigeration unit, through the manifold
gauge set, to the Totalclaim unit. Running the refrigeration unit in cool mode while blocking the condenser
airflow will raise pressure at the king valve and reduce recovery time appreciably. You may run the unit the
entire time you are extracting liquid refrigerant taking care that the compressor does not overheat. When there
is no more liquid being extracted (WATCH THE SIGHT GLASS IN THE CENTER HOSE), turn the
Totalclaim unit off and then back on and select "vapor" and "recovery" modes. When the high and low side
gauges read the same pressure, open the low side hand valve to allow the Totalclaim to draw from both hoses
connected to the unit.

The Totalclaim unit will stop automatically when the refrigerant has been recovered and the refrigeration unit
internal pressure is at a 4-inch mercury vacuum. This method will not remove the same amount as the
"recovery-plus" mode and can take from 10 to 20 minutes, depending upon pressure, temperature and how
much refrigerant is in the refrigeration unit.

IN HIGH AMBIENT TEMPERATURE (ABOVE 85 F), YOU MAY NOT BE ABLE TO GET THE
TOTALCLAIM UNIT TO COMPLETE THE RECOVERY PROCEDURE UNTIL THE TOTALCLAIM
COMPLETES A BOTTLE COOLING PROCEDURE. THIS MAY BE CAUSED BY HIGH STORAGE
BOTTLE PRESSURE. IN THIS CASE, THERE WILL BE NO WAY TO CIRCUMVENT BOTTLE
COOLING MODE AS THIS PROTECTS THE INTERNAL COMPRESSOR FROM DAMAGE. THIS WILL
HAPPEN MORE OFTEN WITH R-22 AND R-502, AS THEY HAVE HIGHER SATURATION
TEMPERATURES.

If the refrigeration unit is inoperable and has not been running for 24 hours, the refrigerant will have
dispersed evenly throughout the unit and will be mostly in vapor form at the king and suction service valves. In
this case set the Totalclaim unit to "vapor" and "Recovery" modes (NOT RECOVERY PLUS) and open both
the low and high sides of the manifold gauge set. In an inoperable refrigeration unit some refrigerant may
migrate to the compressor crankcase and mix with the compressor oil. This refrigerant may be difficult to
remove and may not all be extracted. This can be seen by checking the level of the liquid in the compressor
sight glass. If the level is high, it may indicate refrigerant is mixed with the compressor oil.





Page 40
The Totalclaim unit will stop automatically when the refrigerant has been recovered and the refrigeration unit
internal pressure is at a 4-inch mercury vacuum. This method will not remove the same amount as the
"recovery-plus" mode and can take from 20 to 40 minutes, depending upon pressure, temperature and how
much refrigerant is in the refrigeration unit.



Page 41
REFRIGERATION SYSTEM EVACUATION AND DEHYDRATION PROCEDURE


Proper evacuation and dehydration procedures are imperative when servicing a refrigeration system to ensure
good performance and long compressor life.

The results of improper evacuation may be expensive repairs and loss of service. Non-condensable gases in the
system result in high discharge pressure; moisture may cause ice blockage at the expansion valve; moisture and
refrigerant may react to form an acid. High discharge pressures may cause high discharge temperatures. This
may cause refrigerants and oils to form sludge that can block refrigerant flow in the system or block lubrication
to the compressor bearings. Acid may cause copper plating of the bearing surfaces and eventual compressor
failure.

Proper evacuation begins with a well-maintained vacuum pump. A vacuum pump must be a two-stage pump
and have a rated capacity of three to five cubic feet per minute (CFM). A pump of this capacity is available
from Carrier Transicold Service Parts under part number 07-00176-01. The oil used in the pump will trap some
of the moisture that is removed from the refrigeration system. Moisture trapped in the oil reduces the vacuum
pump efficiency, as the oil is the sealing medium. If left in the pump for extended periods this moisture may
also cause damage to the seals and metal surfaces of the pump. To keep a vacuum pump in top condition,
closely adhere to the manufacturer's maintenance recommendations. At minimum, every three times a vacuum
pump is used, the oil must be changed. Use only vacuum pump oil in vacuum pumps.

To assure good, fast evacuation of the system; use large diameter evacuation hoses. Evacuation hoses are
designed especially for this purpose. Standard charging hoses, like those used on the manifold gauge set, are
made to be very flexible and to minimize leaks under high pressures however, they are not made to prevent
leaks into the hose under vacuum. Evacuation hoses are available from refrigeration suppliers and must be used
for all connections during evacuation. Hoses should be kept as short as possible. The standard manifold gauge
set cannot be used for evacuation, as the internal body porting is too small for good flow at low pressures. A
large manifold gauge set made for evacuation can be used or attach a vacuum manifold directly to the vacuum
pump as shown in the example.

The only way to ensure that a good evacuation has been achieved is through the use of a micron gauge
(electronic vacuum gauge). The compound gauge on a standard manifold is not acceptable. A micron gauge
measures the extremely low absolute pressures that are necessary for removal of moisture from the system. Use
of this gauge is essential in determining the quality of the vacuum. 500 microns, a figure used in evacuation, is
approximately 1/50 of an inch of mercury. This is impossible to read on a standard compound suction pressure
gauge. A micron gauge is available from you local refrigeration supplier.

Evacuation should be performed through three ports in the refrigeration system. On container refrigeration
units the hoses should be connected to the compressor suction and discharge service ports, and to the king valve
service port.
Evacuation Procedure #1 should be performed after a major system repair (e.g. compressor, evaporator, or
condenser replacement). After a minor system repair, (e.g.) replacement of a solenoid valve or the filter/drier)
perform Evacuation Procedure #2.

Be sure to leak check your evacuation setup prior to evacuation. If hoses or seals leak, proper evacuation is
impossible. Repair any leaks found before beginning.



Page 42

Connect the hoses from the refrigeration unit to the evacuation manifold. A refrigerant recovery system is also
connected to the system. If the unit will be swept with dry nitrogen instead of refrigerant, the refrigerant
recovery machine will not be needed. A vacuum gauge thermistor is connected to the manifold gauge set.
The compound gauge on the manifold gauge set will be used to monitor system pressure not vacuum. The
pump is attached as shown.

Before proceeding, it is a good idea to replace the filter drier with a section of copper tubing with the
appropriate fittings.


BOILING TEMPERATURE OF WATER
AT CONVERTED PRESSURES
TEMPERATURE
IN F
TEMPERATURE
IN C
INCHES OF
VACUUM
MICRONS Pounds/Sq. In.
(PRESSURE)
212 100 0.00 759,968 14.696
205 96.1 4.92 535,000 12.279
194 90 9.23 525,526 10.162
176 80 15.94 355,092 6.866
158 70 20.72 233,680 4.519
140 60 24.04 149,352 2.888
122 50 26.68 92,456 1.788
104 40 27.75 55,118 1.066
86 30 28.67 31,750 .614
80 26.7 28.92 25,400 .491
76 24.4 29.02 22,860 .442
72 22.2 29.12 20,320 .393
69 20.6 29.22 17,860 .344
64 17.8 29.32 15,240 .295
59 15 29.42 12,700 .246
53 11.7 29.52 10,160 .196
45 7.2 29.62 7,620 .147
32 0 29.70 5,000 .092
21 -6.1 29.82 2,540 .049
6 -14.4 29.87 1,270 .0245
-24 -31.1 29.91 254 .0049
-35 -37.2 29.915 127 .00245
-60 -51.1 29.919 25.4 .00049
-70 -56.7 29.9195 12.7 .00024
-90 67.8 29.9199 2.54 .000049




Page 43
EVACUATION PROCEDURE #1 (TRIPLE EVACUATION OR DOUBLE SWEEP)

1. Remove any remaining system refrigerant using a refrigerant recovery system.
2. Replace the filter-drier with a section of copper tubing with the appropriate fittings. This action
will help speed the evacuation procedure.
3. Connect the vacuum hoses, vacuum pump, and vacuum gauge and refrigerant recovery unit to
the refrigeration unit.
4. With the unit service valves closed (back seated) and the vacuum pump and the thermistor
(vacuum gauge) valves open, start the pump and draw the manifold and hoses into a very deep
vacuum. Shut off the pump and check to see if the vacuum holds. This is to test the setup for
leaks.
5. Midseat the refrigeration system service valves.
6. With the vacuum pump and the thermistor valves open, start the pump and evacuate to a
pressure below 2000 microns.
7. Close the vacuum pump valve; turn off the vacuum pump. Wait a few minutes to be sure that
the vacuum holds.
8. Close the thermistor valve; closing the thermistor valve protects the thermistor from damage.
Break the vacuum with clean refrigerant or dry nitrogen. Raise the pressure to approximately 2
psig. Monitor the pressure with the compound gauge.
9. Remove the refrigerant using a refrigerant recovery system or discharge the nitrogen to the
atmosphere.
10. REPEAT STEPS 6, 7, 8 and 9 one time.
11. Remove the copper tubing and change the filter-drier. Evacuate to a pressure of 500 microns.
Check that the vacuum holds. If pressure rises, it may indicate that there is a leak or there is
moisture remaining in the system.
12. Charge the system with refrigerant to specification per normal charging procedures.

EVACUATION PROCEDURE #2 (ONE TIME EVACUATION)

1. Remove any remaining system refrigerant using a refrigerant recovery system.
2. Replace the filter drier before evacuating.
3. Install vacuum hoses, vacuum pump, and refrigerant recovery system and micron gauge on the
unit.
4. With the unit service valves closed (back seated) and the vacuum pump and the thermistor valves open,
start the pump and draw the manifold and hoses into a very deep vacuum. Shut off the pump and check
to see if vacuum holds. This is to test the setup for leaks.
5. Start the pump and evacuate to a pressure of 500 microns.
6. Close the vacuum pump and the thermistor valves and turn off the pump. Check that the vacuum holds.
If pressure rises, it may indicate that there is a leak or there is moisture remaining in the system.
7. Charge the system with refrigerant to specification per normal charging procedures.



Page 44
EVACUATION

R12 with QV
1. Refrigerant Recovery Unit
2. Refrigerant Cylinder
3. Evacuation Manifold
4. Valve
5. Vacuum Pump
6. Electronic Vacuum Gauge
7. Liquid Line Valve
8. Condenser Coil
9. Suction Service Valve
10. Compressor
11. Discharge Service Valve
12. Evaporator Coil
12
8
10
11
7
9
4
3
4
4
6
5
1
2



Page 45

REFRIGERANT RECOVERY

R134a with QEV

1. Refrigerant Recovery Unit
2. Refrigerant Cylinder
3. Discharge Pressure Regulator
4. Suction/Liquid Heat Exchanger
5. Condenser Coil
6. Evaporator Coil
7. TXV
8. Liquid Line Valve
9. Quench Expansion Valve

2
1
8
3
6
4
9
5
7



Page 46

69NT40 DUAL VOLTAGE COMPRESSOR INTERNAL RESISTANCE READINGS


NOTE: THESE READINGS ARE FOR A MICROLINK CONTROLLED 69NT40
USING A DUAL VOLTAGE SINGLE SPEED 37 CFM COMPRESSOR AND R-12.


ALL READINGS ARE APPROXIMATE AND MAY VARY FROM UNIT TO UNIT

READINGS FOR A NEW COMPRESSOR OR A USED COMPRESSOR
THAT IS TOTALLY DISCONNECTED FROM UNIT WIRING

CPB-8 TO CPB-9 = 0 (internal motor protector)

CPA-1 TO CPA-2 = .8 RESISTANCE READINGS ARE APPROXIMATE
CPA-1 TO CPA-3 = .8
CPA-2 TO CPA-3 = .8

CPA-4 TO CPB-1 = .4
CPA-5 TO CPB-2 = .4
CPA-6 TO CPB-3 = .4

ERRONEOUS READINGS MAY INDICATE A DEFECTIVE COMPRESSOR OR
MISWIRED OR DEFECTIVE COMPRESSOR TERMINAL BLOCKS

THE RESISTANCE READINGS FOR ALL CPA OR CPB CONNECTIONS SHOULD BE
GREATER THAN 1 MEG TO GROUND.



READINGS WITH COMPRESSOR INSTALLED AND WIRED TO UNIT CONNECTIONS
(CIRCUIT BREAKERS OFF AND UNIT POWER DISCONNECTED)

VS SET TO 460V VS SET TO 230V

C21 TO C22 = 1.6 .4 NOTE: RESISTANCE READINGS MAY
C21 TO C23 = 1.6 .4 VARY GREATLY BECAUSE OF
C22 TO C23 = 1.6 .4 RESISTANCE OF THE VS
CONTACTS.

ERRONEOUS READINGS MAY INDICATE A DEFECTIVE COMPRESSOR, A
DEFECTIVE VS SWITCH OR WRONG OR DAMAGED UNIT WIRING

THE RESISTANCE READINGS FOR C21, C22 OR C23 SHOULD BE GREATER
THAN 1 MEG TO GROUND.



Page 47












Page 48
230 Volt External Connections























Page 49
460 Volt External Connections






















Page 50




SERVICE PROCEDURES CHECKLIST

NAME___________________________

COURSE DATE ___________________

LOCATION ______________________

The following is a list of the service procedures, which you must be capable of performing in order to complete
this course. You must demonstrate, to the instructor, your ability in each area prior to taking the practical final
exam.

PROCEDURE COMPLETED


1. Manifold gauge set installation and removal procedure. _____
2. Low side pumpdown procedure. _____
3. Relay testing procedure. _____
4. O6DR compressor operation test procedure. _____
5. Compressor oil level test procedure. _____
6. Superheat test procedure. _____
7. Analog controller 30 second test procedure. _____
8. Modulation and elec. quench valve test procedure. (Analog) _____
9. Modulation and elec. quench valve test procedure. (Micro) _____
10. CSS resistance test procedure. (Analog control) _____
11. Sensor resistance test procedure. (Analog & micro) _____
12. Temperature control simulator module. (Analog control) _____
13. Motor and heater resistance test procedure. _____
14. Motor and heater current test procedure. _____
15. Refrigerant charge level test procedure. _____


SIGN YOUR NAME AND GIVE TO COURSE INSTRUCTOR WHEN COMPLETED.

STUDENT SIGNATURE __________________________________