Integra 40 Operation & Service Manual
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Integra 40, 1-11 62-10630 DISCHARGE LIQUID SUCTION NORMALLY OPEN NORMALLY CLOSED 26 1 2 3 4 56 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 Quench (Liquid Injection) Valve (BPV) 2 Thermostatic Expansion Valve 3 Heat Exchanger 4 Hot Gas Solenoid Valve (HGS1) 5 Liquid Line Check Valve 6 Sight Glass 7 Filter--Drier 8 Subcooler 9 Manual Shut-off Valve (King Valve) 10 Receiver 11 Condenser 12 Condenser Pressure Control Valve (HGS2) 13 Condenser Pressure Control Switch (HP2) 14 High Pressure Switch (HP1) 15 Relief Valve 16 Standby Discharge Check Valve 17 Standby High Pressure Switch (HP3) 18 Standby Compressor 19 Road Compressor 20 Quench (Liquid Injection) Thermostat (BPT) 21 Oil
Integra 40, 5-1 62-10630 SECTION 5 SCHEMATIC DIAGRAMS WARNING Beware of unannounced starting of the unit. The unit may cycle the fans and operating compressor unexpectedly as control requirements dictate. To ensure unit will not start, place the EMERGENCY SWITCH (see Figure 1-1) in the OFF position. To ensure unit is without power, remove power plug and remove battery negative cable. 5.1 INTRODUCTION Schematic diagrams for the unit models listed in Table 1-1 are provided herein.
Integra 40, 4-262-10630 Figure 4-1. Belt Tension Gauge (Carrier part Number 07--00203--00) Belt tension depends on each kit. Refer to Installation Instructions provided with the kit for belt tension requirements. In each kit installation instruction, we indicate the belt tension (given with belt tension gauge P/N 07-00203-00. When installing a new V-belt the tension should be somewhat higher than specified and readjusted after allowing the unit to run for some time. 4.3 EVAPORATOR COIL CLEANING The use of recycled ca
Integra 40, 4-862-10630 Table 4-3. R-404A Temperature--Pressure Chart Temperature Pressure Temperature Pressure _F _ __ _C Psig Kg/cm 2 Bar _F _C Psig Kg/cm 2 Bar -- 40 -- 40 4.5 0.32 0.31 32 0 72.5 5.10 5.00 -- 35 -- 37 7.1 0.50 0.49 34 1 75.6 5.32 5.21 -- 30 -- 34 9.9 0.70 0.68 36 2 78.8 5.54 5.43 -- 25 -- 32 12.9 0.91 0.89 38 3 82.1 5.77 5.66 -- 20 -- 29 16.3 1.15 1.12 40 4 85.5 6.01 5.90 -- 18 -- 28 17.7 1.24 1.22 42 6 89.0 6.26 6.14 -- 16 -- 27 19.2 1.35 1.32 44 7 92.5 6.50 6.38 -- 14 -- 26 20.7 1.46 1.43 46 8 96.2 6.76 6.63 -- 12 -- 24 22.3 1.57 1.54 48
2-3 62-10630 2.4 STARTING CAUTION Ifstartingunitforthefirsttimeafterinstalla- tion the compressor pressure regulating valve will need to be reset (refer to para- graph 4.15) CAUTION Ifstartingunitforthefirsttimeafterinstalla- tion or starting afteradding/removing of an optional feature or if Owners operating pa- rameters have changed the Configuration will need to
Integra 40, 2-5 62-10630 UNIT VOLTAGE PS12 : unit voltage 12 V PS24 : unit voltage 24 V Press the + and -- keys to change PS12 or PS24. Press the SET key to validate. NUMBER OF EVAPORATOR F AN FAn1 : 1 fan FAn2 : 2 fans FAn3 : 3 fans Press the + and -- keys to change F An1, FAn2 or FAn3. Press the SET key to validate. FAN SPEED SPd-- : 1 st speed mini SPd= == = :2 nd speed medium SPd : 3 rd speed maxi Press the + and -- keys to change SPd--, SPd= or SPd Press the SET key to validate. 2or3ETMODE 2 Et : cool, null 3 Et : cool, null, heat Press the + and -- keys to change 2Etor3Et. Note : 50S : 3 Et 40S without condenser closing valve : 2
Integra 40, 4-1 62-10630 SECTION 4 SERVICE WARNING Beware of unannounced starting of the unit. The unit may cycle the fans and operating compressor unexpectedly as control requirements dictate. To ensure unit will not start, place the EMERGENCY SWITCH (see Figure 1-1) in the OFF position. To ensure unit is without power, remove power plug and remove battery negative cable. 4.1 PREVENTATIVE MAINTENANCE Regular servicing is required in order to optimize thelife andreliabilityofyourunit.Therecommendedscheduled maintenance intervals and categories are provided
Integra 40, Safety-2 62--10630 SWITCH (see Figure 1-1) in the OFF position. To ensure unit is without power, remove power plug and remove battery negative cable. WARNING Ensure powerto theunit is OFF and powerplug is disconnected or vehicle engineis OFF andnega- tive battery cable is disconnected before replacing the compressor. WARNING Do not use a nitrogen cylinder without a pressure regulator. (See Figure 4-3.) Cylinder pressure is approximately 2350 psi (160 bar). Do not use oxygen in or near a refrigerant system as an explosion may occur. C
1-9 62-10630 Table 1-3 Safety Devices -- Microprocessor controller Unsafe Conditions Safety Device Automatic restart with fault cleared Device setting 1 Excessive drop in pressure Automatic reset of low pressure switch YES Cutout : --2.9 psig (-0.2 bar) Timer 5 mn 2 Excessive current draw on all mi- croprocessor outputs (evaporator and condenser fan) Electroni
Integra 40, 3-4 62-10630 Table 3-2 Mechanical Indications -- Continued INDICATION/TROUBLE POSSIBLE CAUSES REFERENCE SECTION 3.2.6 Abnormal Pressure 3.2.6.1 Cooling High discharge pressure Condenser coil dirty Noncondensibles or refrigerant overcharge Condenser fan/motor defective 4.4 4.10.1 4.13 Low discharge pressure Compressor defective Hot gas solenoid malfunction Low refrigerant charge 4.11 4.14 4.10.1 High suction pressure Compressor defective Hot gas solenoid malfunction Compressor pressure regulator misadjusted (CPR) 4.11 4.14 4.15 Low suction pressure Filter–drier partially plugged Low refrigerant charge Expansion valve malfunction No evaporator air flow or restricted air
Integra 40, 1-1 62-10630 SECTION 1 DESCRIPTION 1.1 INTRODUCTION WARNING Beware of unannounced starting of the unit.Theunitmaycyclethefansandoperat- ingcompressor unexpectedlyascontrolre- quirements dictate. This manual contains Operating Data, Electrical Data and Service Instructions for the Carrier Transicold Model 40S and 50S truck refrigeration units listed in Table 1-1. The unit (Figure 1-1) is of the split syst em type with the condenser mounted outside the truck body, evaporator mounted in the body, and a CAB COMMAND control center mounted in the drivers compartment. Two types of compressor drive ar
Integra 40, 4-5 62-10630 4.10.3 Adding A Partial Charge a. Place refrigerant cylinder on scale and note weight. b. Connect charging line from the cylinder to the receiv- er valve. Purge the line at the cylinder valve. c. Start the unit with the road compressor turning at 2400 rpm. d. Front seat the liquid line service valve. CAUTION Refrigerant R404A mustbe charged asaliq- uid. Refrigerant R404A is a blend. Charging as a vapor will change the properties of the refrigerant. e. Add a small quantity of refrigerant. f. Back seat the receiver valve. g. Fo
4-462-10630 1 2 3 4 5 6 4 4 1 Refrigerant Recovery Unit 2 Refrigerant Cylinder 3 Evacuation Manifold 4Valve 5 Vacuum Pump 6 Electronic Vacuum Gauge Figure 4-2. Vacuum Pump Connection g. Remove refrigerant using a refrigerant recovery sys- tem. h. Repeat steps e. to g. i. If required, remove the copper tubing and install a new filter--drier . Evacuate unit to 500 micro
Integra 40, 1-7 62-10630 1.2 COMPRESSOR REFERENCE DATA Model TM 16 06VM306 06VM307 Displacement 163 cc 113 cc 130 cc No. Cylinders 6 2 2 Weight 7kg 37 kg 47 kg Oil Charge 250 ml 1200 ml 1200 ml Approved oil POE -- Mobil Arctic EAL 68 (Carrier Part Number 46-60002-02) 1.3 REFRIGERATION SYSTEM DATA a. Defrost Timer Automatic triggering or at present intervals : 0, auto, 1h, 2h, 3h, 4h, 5h, 6h b. Defrost Termination Thermostat Opens at: 48_ ¦ 5_F(9_ ¦ 3_C) Closes at: 37_ ¦ 5_F(3_ ¦ 3_C) c. High Pressure Switch (HP1) Cutout at : 465 ¦ 10 psig (32 bar) Cut-in at : 360 ¦ 10 psig (25 bar) d. Condenser Press
Integra 40, 4-7 62-10630 4.15 ADJUSTING THE COMPRESSOR PRESSURE REGULATING VALVE (CPR) When adjusting the compressor pressure regulating valve (CPR) (see Figure 4-6.), the unit must be running in heating or defrost mode. This will ensure a suction pressure above the proper CPR setting. To adjust the CPR valve, proceed as follows : a. Install a gauge on the suction line . b. Remove cap from CPR valve. c. With an 8 mm Allen wrench, loosen the jam nut. d. Usingthe8mmAllenwrench,adjust theset screw .To raise the suction pressure turn the set screw clock- wise; to lower the suction pressure, turn counter- clockwise. Refer to paragraph 1.3 for CPR valve set- ting. e. When the setting has been adjusted, tigh
2-7 62-10630 Table 2-2 Alarm Messages -- Continued Defrost cycle > 45 minutes Setpoint adjusted out of the range -- 29°C/+30°C Evaporator drain line heater (DWR) mal- function Transformer/Rectifier thermal overload (RBT) open Control fault, electric heat (Future) Control fault, multi--temp liquid line valve (Future) Low pressure switch (LPS) open (Standby) Compressor contactor (MC) op
Integra 40, 1-1062-10630 1.7 REFRIGERANT CIRCUIT DURING COOLING When cooling (See Figure 1-7), the unit operates as a vapor compression refrigeration system. The main components of the system are the reciprocating compressor , air-cooled condenser , thermostatic expansion valve and direct expansion evaporator . Thecompressorraisesthepressureand temperatureof the refrigerantand forcesit throughthedischargecheck valve and condenser pressure control valve into the condenser tubes. The discharge check valves prevent reverse flow through the non operating compressor. When operating on the road compressor, the flow also passes through the oil separator where oil is removed and returned
Integra 40, 1-862-10630 c. Compressor Motor Ratings C o n t a c t o r d a t a C on t ac t or d a t a UNIT Voltage Frequency Phase kW HP MRA* LRA* 230 400 230 400 50S 230 / 400 60 Hz 3 1.491 2 11.8 9.8 45.1 26 5 0 S 208 / 230 60 Hz 1 1.491 2 15.6 -- 78.7 -- 4 0 S 230 / 400 60 Hz 3 1.491 2 11.8 9.8 45.1 26 4 0 S 208 / 230 60 Hz 1 1.491 2 15.6 -- 78.7 -- * MRA = Maximum Rotor Amps LRA = Locked Rotor Amps 1.5 TORQUE VALUES Assembly Ft--Lbs N.m Size Standby compressor 4.1 5.5 M10 Evaporator Fan Motor -- Bracket 2.2 3 M4
Integra 40, iii 62--10630 LIST OF ILLUSTRATIONS FIGURE NUMBER Page Figure 1-1 Integra 50S 1-1...................................................................... Figure 1-2 Condenser 1-2....................................................................... Figure 1-3 Control Box 1-3...................................................................... Figure 1-4 Start Box (Single Phase Only) 1-4...................................................... Figure 1-5 Evaporator 3 Fans (Integra 50S) 1-5.................................................... Fig
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