SERVICE MANUAL

CITIMAX SERIES
500, 700

CARRIER TRANSICOLD DIVISION

No.1235, Yecheng Road, Shanghai, China
 TABLE OF CONTENTS
SECTION 1 ............................................................................................................................................ 4
SAFETY INSTRUCTIONS ..................................................................................................................... 4
SECTION 2 ............................................................................................................................................ 7
DESCRIPTION....................................................................................................................................... 7
2.1 INTRODUCTION ...................................................................................................................... 7
2.2 COMPRESSOR REFERENCE DATA.................................................................................... 15
2.3 REFRIGERATION SYSTEM DATA....................................................................................... 15
2.4 ELECTRICAL DATA ............................................................................................................... 16
2.5 TORQUE VALUES ................................................................................................................. 16
2.6 SAFETY DEVICES ................................................................................................................. 17
2.6.1 Fuses ............................................................................................................................ 18
2.7 CAB Control description ......................................................................................................... 19
2.7.1 Operation principal ....................................................................................................... 19
2.7.2 to start the unit .............................................................................................................. 20
2.7.3 to stop the unit .............................................................................................................. 20
2.7.4 to change setpoint temperature ................................................................................... 20
2.7.5 to change defrost parameters ...................................................................................... 20
2.7.6 to display other data (alarms, software version, box Tº).............................................. 21
2.7.7 to change default parameters ...................................................................................... 21
2.7.8 Fault alarm display ....................................................................................................... 21
2.8 COMPRESSOR PRESSURE REGULATING VALVE ............................................................ 23
2.9 HOT GAS SOLENOID – HGV (TWO-WAY) ........................................................................... 23
2.10 CONDENSER CLOSING SOLENOID –MHV (TWO-WAY) ................................................. 23
2.11 REFRIGERANT CIRCUIT DURING COOLING ................................................................... 23
2.12 REFRIGERANT CIRCUIT DURING HEAT AND DEFROST ............................................... 23
SECTION 3 .......................................................................................................................................... 32
OPERATION ........................................................................................................................................ 32
3.1 CONTROL AND STARTING UP ............................................................................................ 32
3.1.1 Start and stop the unit .................................................................................................. 32
3.1.2 Compressor start up intervals ...................................................................................... 32
3.1.3 COOLING ..................................................................................................................... 33
3.1.4 HEATING...................................................................................................................... 33
3.1.5 DEFROST .................................................................................................................... 34
3.2 control of fan and valves......................................................................................................... 34
SECTION 4 .......................................................................................................................................... 35
SERVICE.............................................................................................................................................. 35
4.1 UNIT MAINTENANCE ............................................................................................................ 35
4.1.1 Unit maintenance schedules ........................................................................................ 35
4.1.2 Description of maintenance operations........................................................................ 35
4.2 BELT MAINTENANCE AND ADJUSTMENT ......................................................................... 36
4.2.1 Belt tension gauge (compressor) ................................................................................. 36
4.3 REMOVING THE REFRIGERANT CHARGE ........................................................................ 37
4.4 REFRIGERANT LEAK CHECKING ....................................................................................... 37
4.5 EVACUATION AND DEHYDRATION .................................................................................... 37
4.5.1 General ......................................................................................................................... 37
4.5.2 Preparation ................................................................................................................... 37
4.5.3 Evacuation and dehydration procedure ....................................................................... 38
4.6 CHARGING THE REFRIGERATION SYSTEM ..................................................................... 39
4.6.1 Installing a complete charge ........................................................................................ 39
4.6.2 Adding a partial charge ................................................................................................ 39

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 4.6.3 Checking the refrigerant charge ................................................................................... 39
4.7 REPLACING THE COMPRESSOR ....................................................................................... 39
4.8 CHECKING AND REPLACING FILTER DRIER .................................................................... 40
4.9 CHECKING AND REPLACING HIGH PRESSURE CUTOUT SWITCH ............................... 40
4.9.1 Replacing high pressure cutout switch ........................................................................ 40
4.9.2 Checking high pressure cutout switch ......................................................................... 40
4.10. CHECKING AND REPLACING FAN MOTOR BRUSHES .................................................. 41
4.11 EVAPORATOR COIL-CLEANING ....................................................................................... 41
4.12 CONDENSER COIL-CLEANING ......................................................................................... 41
4.13 HOT GAS (TWO-WAY) SOLENOID AND CONDENSER CLOSING SOLENOID (TWO WAY)
...................................................................................................................................................... 42
4.13.1 Replacing solenoid coil .............................................................................................. 42
4.13.2 Replacing solenoid valve internal parts ..................................................................... 42
4.14 ADJUSTING THE COMPRESSOR PRESSURE REGULATING VALVE (CPR) ............... 42
4.15 THERMOSTATIC EXPANSION VALVE .............................................................................. 43
4.16 MICROPROCESSOR ........................................................................................................... 44
SECTION 5 .......................................................................................................................................... 47
TROUBLE SHOOTING ....................................................................................................................... 47
5.1 REFRIGERATION .................................................................................................................. 47
5.1.1 Unit will not cool ........................................................................................................... 47
5.1.2 Unit runs but has insufficient cooling ........................................................................... 47
5.1.3 Unit operates long or continuously in cooling .............................................................. 47
5.1.4 Unit will not heat or heating insufficient........................................................................ 48
5.1.5 Defrost malfunction ...................................................................................................... 48
5.1.6 Abnormal pressure ....................................................................................................... 48
5.1.7 Abnormal noise ............................................................................................................ 49
5.1.8 Cab command malfunction .......................................................................................... 49
5.1.9 No evaporator air flow or restricted air flow ................................................................. 49
5.1.10 Expansion valve malfunction..................................................................................... 50
5.1.11 Malfunction hot gas (two-way) solenoid ..................................................................... 50
5.2 Fault alarm ............................................................................................................................. 51
5.2.1 EE alarm ....................................................................................................................... 51
5.2.2 BAT alarm ..................................................................................................................... 52
5.2.3 Err alarm ....................................................................................................................... 52
5.2.4 A01/A02 alarm .............................................................................................................. 53
5.2.5 A04 alarm ..................................................................................................................... 54
5.2.6 A06 alarm ..................................................................................................................... 54
5.2.7 A07 alarm ..................................................................................................................... 55
5.2.8 A09 alarm ..................................................................................................................... 55
5.2.9 A11 alarm ..................................................................................................................... 56
SECTION 6 .......................................................................................................................................... 57
EXTRACT FROM MATERIAL SAFETY DATA BULLETIN ................................................................. 57
6.1 POE OIL.................................................................................................................................. 57
6.2 FORANE R404A/R134a ......................................................................................................... 59
SECTION 7 .......................................................................................................................................... 62
ELECTRICAL SCHEMATIC WIRING DIAGRAMS.............................................................................. 62

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 SECTION 1
SAFETY INSTRUCTIONS

This manual contains safety and service instructions to follow in order to prevent any accident.
Stickers have been placed on the product for your safety.

BEFORE USING THIS REFRIGERANT UNIT, read carefully all safety

information explained in this manual and indicated on the product. Be sure
that everybody who will use this refrigeration unit has been trained to use it in
a safe way.
DURING THE USE OR MAINTENANCE OF THIS
REFRIGERATION UNIT, the notes on safety are to be considered.

Personal Protective Equipment:

Always use adequate Personal Protective Equipment before doing anything
on this refrigerant unit, as explained in this manual.

Working at height:
Take all necessary safety precautions when accessing this refrigeration unit:
use safe ladders, working platforms with appropriate guards.

Belts and fans:

This refrigeration unit is equipped with Auto–start / stop, it
may start at any time and without warning.
When the unit is running beware of belts and fans that are
moving.
Before servicing refrigeration unit, make sure the main
power is on the DISCONNECTION position. Ensure the
unit will not restart. Lock–out / Tag–out can be performed
as described above.
When there is protective structure (fan grid or guard for
example) make sure they are in place. Never remove them
when the refrigeration unit is running. Always keep your
hands, body parts, clothes, hairs and tools far from moving
parts.

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 Electricity:
When this refrigeration unit is running in electrical operation, some devices
are powered up especially in the electrical control box.
Before servicing refrigeration unit, make sure the main power is on the
DISCONNECTION position. Ensure this refrigeration unit is disconnected
from battery. Lock–out / Tag–out can be performed as described above.
Before working in the electrical control box, it is required to control the
lack of tension.
WHEN IT IS NECESSARY TO WORK IN THE ELECTRICAL
CONTROL BOX UNDER TENSION, PEOPLE MUST BE QUALIFIED
FOR WORKS UNDER LOW OR HIGH VOLTAGE.
Always use adequate tools and Personal Protective Equipment when
working on electrical devices: safety gloves and safety glasses.

Refrigerant:
The refrigerant contained in this refrigeration unit can cause frostbite, severe
burns or blindness in case of projection and direct contact with the skin or
eyes. In contact with flame or heat refrigerant generate toxic gas.
Refrigerant handling must be done by qualified people. Keep any flame, any
lighted object or any source of sparks away from the refrigerant unit.
Always use Personal Protective Equipment when handling refrigerant:
safety clothes, safety gloves and safety glasses.

Burning with hot and cold:

When this refrigeration unit is running or even after, different components
can be very cold or hot (exhaust pipe, tubes, coils, receiver, accumulator or
engine for example)
Beware when operating closed from cold or hot components.
Always use adequate safety gloves when doing any maintenance on this
refrigeration unit.

Cuttings:
Beware when handling or operating closed from parts that could be sharp
(coils, evaporators, clamps for example).
Always use adequate safety gloves when doing any maintenance on this
refrigeration unit.

Environment:
Think about protection of environment during all the life of this
refrigeration unit. To prevent environmental damages NEVER release
refrigerant in the atmosphere, NEVER throw coolant, oil, battery and
chemicals in the nature. It must be recuperate and recycle according to
current regulations. When disposing this refrigerant unit do it in an
environmentally sound way and in accordance with current regulations.

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 CAUTION

Under no circumstances should anyone attempt to repair the Logic or Display Boards. Should a
problem develop with these components, contact your nearest Carrier Transicold dealer for
replacement.
Under no circumstances should a technician electrically probe the processor at any point, other
than the connector terminals where the harness attaches. Microprocessor components operate at
different voltage levels and at extremely low current levels. Improper use of voltmeters, jumper
wires, continuity testers, etc. could permanently damage the processor.
Most electronic components are susceptible to damage caused by electrical static discharge
(ESD). In certain cases, the human body can have enough static electricity to cause resultant
damage to the components by touch. This is especially true of the integrated circuits found on the
truck/trailer microprocessor.

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 SECTION 2
DESCRIPTION
2.1 INTRODUCTION

CITIMAX 500 CITIMAX 700

R134a R404A R404A
12V 24V 12V 24V 12V 24V
Fresh Frozen

Table 2-1 shows the configuration of

CITIMAX units, such as refrigerant volume,
compressor type, evaporator and condenser
weight.
The unit is directly driven by the engine of
the vehicle when in operation on the road.
The standard control system is a
microprocessor controller. Once the
controller (remote Command within the cab
of the truck) is set at the desired temperature,
the unit will operate automatically to
CITIMAX 500/700 units are simple, tried maintain the desired temperature within very
and tested design; low-cost purchase and close limits.
operation to equip large and middle size The control system automatically selects
delivery vehicles. cooling and heating cycles as necessary to
It is manufactured as a split system, enabling maintain the desired temperature.
it to adapt to any vehicle and any The evaporator assembly consists of an
configuration. evaporator coil, an expansion valve, one
Please note CITIMAX 500 / 700 are heat exchanger.
available in next versions: The condenser assembly is consist of a
MCHX, a receiver, an accumulator,
condenser fan, hot gas solenoid, injection
valve, CPR, an optional condenser closing
solenoid.
Table 2-1 module table
R-404A Weight
Model compressor
LB KG Evaporator Condenser
CITIMAX 500 R404A 6.17 2.8 TM16 30kg 58kg
CITIMAX 700 R404A 8.82 4.0 TM21 35kg 62kg

R-134a Weight
Model compressor
LB KG Evaporator Condenser
CITIMAX 500 R134a 8.82 4.0 TM21 35kg 58kg

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 8
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 Figure 2-1 CITIMAX 500 condenser

1. Frame 8. MCHX 14．Low pressure switch

2. Harness 9． Accumulator 15．Defrost valve
3. Fan blade 10．Receiver 16. High pressure switch
4. Condenser motor 11．Electrical control box HP2
5. Injection valve 17．High pressure switch
12．Oil separator
6. Sight glass HP1
7. Filter drier 13．CPR

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 Figure 2-2 CITIMAX 500 evaporator

1．Fan blade 5．Distributor

2．Motor
3．Heat exchanger
4．Expansion valve

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 11
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 Figure 2-3 CITIMAX 700 condenser

1. Frame 8. MCHX 14．Low pressure switch

2. Harness 9． Accumulator 15．Defrost valve
3. Fan blade 10．Receiver 16. High pressure switch
4. Condenser motor 11．Electrical control box HP2
5. Injection valve 17．High pressure switch
12．Oil separator
6. Sight glass HP1
7. Filter drier 13．CPR

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 Figure 2-4 CITIMAX 700 evaporator

1．Fan blade 5．Distributor

2．Motor
3．Heat exchanger
4．Expansion valve

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 Figure 2-5 Electrical control box of CITIMAX

1. Relay 4. RAT cable

2. Fuse 5. Control cable
3. PCB board

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2.2 COMPRESSOR REFERENCE DATA
Model TM 16 TM 21 TM21
R404A R404A R134a
Unit type
CITIMAX 500 CITIMAX 700 CITIMAX 500
Discharge volume 163 cc 215cc 215cc
Cylinder number 6 10 10
Weight 7 .1 kg 8.1 kg 8.1kg
Refrigerant oil volume 450 ml 490ml 490ml
Refrigerant oil type POE EAL 68 POE EAL 68 POE EAL 68

2.3 REFRIGERATION SYSTEM g. R134a low pressure switch

DATA
Cutout at: -0.45±0.21bars (-6.5±3psig)
a. Defrost Timer
Cut-in at: 0.45±0.21bars (6.5±3psig)
00: No defrost
h. Refrigerant charge volume
Set defrost intervals:
1h，1.5h，2h，2.5h，3h，4h，5h and 6h. Refer to chart 2-1.
b. R404a High Pressure switch (HP1) i. Compressor Pressure Regulating Valve
(CPR)
Cutout at: 32 bars (465 ±10 psig)
Cut-in at: 25 bars (360 ±10 psig) Adjustment on heat or defrost mode
CPR setting
c. R404a Control Pressure switch (HP2) Model
bar psig
Cutout at: 17 bars (245 ±10 psig) R404
Cut-in at: 22 bars (320 ±10 psig) 2.6(2400rpm) 38±1
CITIMAX 500
d. R404a low pressure switch R404
3.9(2400rpm) 57±1
CITIMAX 700
Cutout at: -0.2 bar (-2.9 psig±3 psi)
Cut-in at: 1 bar (14.5 psig±3 psi) R134a unit without CPR.
e. R134a high pressure switch (HPl) j. Thermostatic expansion valve and
Cutout at: 24.5bars (355±10psig) Orifice
Cut-in at: 20bars (290±10psig) TES2/Orifice nº 3/ (CITIMAX 500 R404A)
f. R134a high pressure control switch TES2/Orifice nº 4/ (CITIMAX 700 R404A)
(HP2) TEN2/Orifice nº 4/ (CITIMAX 500 R134a)

Cutout at: 9bars (130±10psig) k. Quench valve

Cut-in at: 12bars (175±10psig) Opens at: 127ºC (260ºF)
Closes at: 105ºC (212ºF)

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2.4 ELECTRICAL DATA

a. Evaporator fan motors

Operating
Bearing lubrication Horse power Speed
current
12V factory lubricated 93W 8-11A 2800rpm

24V factory lubricated 93W 4-6A 2800rpm

b. Condenser fan motor

Operating
Bearing lubrication Horse power Speed
current
12V factory lubricated 89W 8-10A 2200rpm

24V factory lubricated 89W 4-6A 2200rpm

2.5 TORQUE VALUES

Compressor Evaporator Evaporator Condenser- Condenser Condenser Mounting

pulley fan motor fan blade frame motor fan blade bolts

kg-m 3.0 1.8 1.0 1.0 1.8 2.5 6~8

ft-lb 22 13 7 7 13 18 44~60

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2.6 SAFETY DEVICES
System components are protected from damage caused by unsafe operating conditions by
automatically shutting down the unit when such conditions occur. This is accomplished by the
safety devices listed in Table 2-2.

Table 2-2 safety devices

Automatic
Unsafe Conditions Safety Devices restart with Device setting
fault cleared
Cutoff：
-0.2±0.19 bar
1. Excessive drop in (R404A)
low pressure switch YES
pressure -0.45±0.21 bar
(R134a)
Timer 5mn
2. Excessive current fuse on electronic board(refer to Table 2-
NO refer to Table 2-3、2-4
draw control circuit 3、2-4)
3. Excessive current
draw evaporator fan Motor fuse(refer to Table 2-3、2-4) No refer to chart 2-3、2-4
motor
4. Excessive current
draw condenser fan Motor fuse(refer to chart 2-3、2-4) No refer to Table 2-3、2-4
motor
Cutoff：
5. Excessive
compressor discharge High pressure switch (HP1) YES 32 bar (R404A)
pressure 24.5 bar (R134a)
Timer 5 mn
Fuse Refer to Table 2-3、2-
6. Current over load NO
(refer to Table 2-3、2-4) 4

7. Clutch malfunction Electronic relay YES Self-protected opening

Cutout/cut-in
8. Low battery
Microprocessor YES 10V for 12V unit
voltage
20V for 24V unit

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2.6.1 Fuses
Table 2-3 Fuse-CITIMAX 500/700 12VDC

Evaporator Evaporator Evaporator Condenser Condenser

CITIMAX Ignition Main Logic
fan motor fan motor fan motor fan fan motor
12VDC switch fuse board
1 2 3 motor1 2

notes (a) (c) (b)

Fuse
500 1A 70A 20A 20A 20A 25A / 10A
capacity
Fuse
700 1A 80A 20A 20A 20A 25A 25A 10A
capacity

Table 2-4 Fuse-CITIMAX 500/700 24VDC

Evaporator Evaporator Evaporator Condenser Condenser

CITIMAX Ignition Main Logic
fan motor fan motor fan motor fan motor fan motor
24VDC switch fuse board
1 2 3 1 2

notes (a) (c) (b)

Fuse
500 1A 50A 15A 15A 15A 20A / 7.5A
capacity
Fuse
700 1A 50A 15A 15A 15A 20A 20A 7.5A
capacity
notes：
(a) The fuse is located near the ignition switch in drive cab.
(b) The fuse is located in electrical control box.
(c) The fuse is located close to the vehicle battery.

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2.7 CAB Control description 7. + key
This functional accessory simplifies all
control operations. From your seat, you 8. OFF key
can carry out all the control operations:
shut-down, automatic start-up, adjusting 9. ON key
the set point, defrost, program to
10. Unit operation display
customize unit operation to your own Green (left half):
requirements, manage error messages in Green led ON : cooling
event of malfunction. mode Green led OFF: null
mode (regulation)
You can display the box temperature and Green led flashing: heating
see whether the set point is being mode
Red : malfunction (right
maintained by checking the green
half)
indicator. The indicator lights up red in
the event of malfunction. When the 2.7.1 Operation principal
battery voltage is too low, a fail-save
CITIMAX 500 / 700 are powered on
safety system shuts down the unit. Unit
Road mode by the vehicle battery
restart is automatic and time-delayed if
(alternator)
the voltage rises to the normal level.
After starting up, the refrigeration unit

by pressing the key, unit start-up

and shut-down are automatic.

An open-type compressor is driven by

the engine of the vehicle. The vehicle
battery (alternator) powers the
evaporator and condenser fans. The unit
automatically shuts down when the
engine is switched off with the ignition
key.
Controller
The unit can be completely shut down
1. Display – 3 digits
2. Standby operation LED manually by pressing the key on
(not used) the cab command.

3. Road operation LED Temperature control

4. Manual defrost key As soon as the set-point temperature has

been reached, temperature control is
5. – key obtained by shut down and start-up of
the electro-magnetic clutch.
6. Set key
Condenser fan is controlled by the
microprocessor and evaporator fan(s) cut

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out during regulation. When transporting
fragile loads such as fresh meat,
vegetables and cheese, it is possible to
program the microprocessor to obtain
continuous ventilation by the evaporator
during regulation.
In the event of difficulty on start up,
check that:
-The main road fuse has not blown. If it
is ok, contact your Carrier Service centre
-The temperature selected by the cab
control has not been affected.

Defrost － Frozen version only 2.7.3 to stop the unit

Defrost operation is fully automatic but
can be manually controlled.
- Defrost cycles are fully controlled by
the integrated microprocessor.
- During the defrost cycle, the
evaporator fan shuts down. The
condenser fan is controlled by the
microprocessor.
- Defrost cycle termination is controlled
by a timer.
- During the defrost cycle, the cab
command display indicates "d F".
Heating – Frozen version only
Heating is provided by hot gas system.
The evaporator fan operates, the
condenser fan is controlled by the
microprocessor.
- For a short stop (ex. delivery): switch
off by the vehicle ignition key.
- For a long stop: press the key.
2.7.4 to change setpoint
temperature
Important
If, when settings are adjusted, no key
is activated within 5 sec. the system
reverts to displaying the box
temperature. All changes made are
recorded.
If the cab command is built into the
vehicle control panel ， the command
unit must be located as far as possible
from the heating ducts. Maximum
temperature of exposure: 70°C.

2.7.2 to start the unit 1. Press the key to display setpoint

temperature.
1. Start the vehicle engine.

2. Start the unit by pressing the 2. Press the or key to change

key. Start-up is time-delayed for 40 the setpoint.
seconds.
3. Press the key to return to box
3. The digital display (1.) of the cab temperature display.
control displays the box temperature.
2.7.5 to change defrost
4. Check the temperature setpoint is parameters
Important
correct by pressing the key. The If, when settings are adjusted, no key
setpoint temperature is highlighted on is activated within 5 sec. the system
the digital display. reverts to displaying the box
temperature. All changes made are
5. Enter a new setpoint if necessary (See recorded.
To change setpoint temperature).

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1. Press the key to shut-down the keys to display minimum setpoint.
unit.
2. Press the or key to change
2. Press simultaneously the AND minimum setpoint: 0°C, -20°C or -29°C
(default value -29°C).
keys during 5 seconds to display
last selected defrost interval. 3. Press the key to display
differential parameter.
3. Press the or key to change
the defrost time: 4. Press the or key to adjust the
10 to 45 mn: increase or decrease time differential value: Dif1 (1°C), Dif2
(10, 15, 20, 25, 30 and 45) (2°C), Dif3 (3°C) (default value Dif2).

4. Press the key to display defrost 5. Press the Key to display

interval: 00: inhibit defrost function. 1 H, evaporator fan operating mode during
1.5H, 2 H, 2.5H, 3h, 4H, 5H and 6 H off-cycle.
5. Press the key to return to box 6. Press the or key to change the
temperature display. evaporator fan operating mode : FOFF
or F On(default value FOFF).
2.7.6 To display other data (alarms,
software version, box Tº)
7. Press the key，to return to box
temperature display.
1. Press the key during 5 seconds
to enable access to malfunction codes 2.7.8 Fault alarm display
(see “Fault alarm display”). a. Access by the SET key
2. Press or key to display
1. Press the key during 5 seconds
alarms.
to access to malfunction codes.
3. Press the key to display 2. Press or key to display alarms.
software version.
3. To scroll through the alarm list, use
4. Press the key to return to box
temperature display the key.
2.7.7. to change default
parameters

1. Press simultaneously the , and

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–ACTIVE malfunctions – AXX

An alarm is active when a problem occurs on the unit, the red LED is flashing speedily.

MALFUNCTION CODE – Red LED flashes

Code Description Unit shutdown Checking
No malfunction – Unit in
A00
operation
Low pressure switch
A01/A02 open/ High pressure
switch open Yes
A04 Clutch compressor fault
A06 Condenser fault No Contact your
A07 Evaporator fan fault No Service Center
Defrost valve (HGV)
A09 No
fault
Liquid injection quench
A10 No
valve fault (INV)
Setpoint adjusted out of
A15 Yes
the range -29°C / +30°C

b. Direct display

Note
Direct display malfunction messages are displayed instead of temperature read-out
as soon as the malfunction is detected, and remain displayed as long as malfunction
persists.
The unit does not run until the malfunction has disappeared or been corrected.

Code Description Unit shutdown Checking

Evaporator temperature
EE
probe (open circuit) － Evaporator probe
and connections
Yes － Battery
BAT Battery low voltage alarm voltage/12VDC
alternator/connections

Programming mistake of
Err the maximum setpoint by No － Setpoint
user
Setpoint lower that
--- maximum setpoint but in No － Setpoint
the range -29°C / +30°C

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2.8 COMPRESSOR PRESSURE
REGULATING VALVE
This CPR valve is installed on the suction
line of compressor to limit the suction and
then avoid overloading of compressor. For
CPR settings refer to section 2.3.
The suction pressure is controlled to avoid
overloading engine during high box
temperature operation.
2.9 HOT GAS SOLENOID – HGV
(TWO-WAY)
The hot gas solenoid is normally closed (NC)
and is only powered in defrost and heating
modes and 40 seconds before start-up if box
temperature is higher than –5ºC.
2.10 CONDENSER CLOSING
SOLENOID –MHV (TWO-WAY)
The condenser closing solenoid is normally
open (NO) in cooling mode. It is closed in
defrost and heating mode to increase the
capacity.
2.11 REFRIGERANT CIRCUIT
DURING COOLING
When cooling, 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,
evaporator, and hot gas solenoid (two-way).
The compressor raises the pressure and
temperature of the refrigerant and forces it
into the condenser tubes.
The condenser fan circulates surrounding air
over the outside of the condenser tubes. Heat
transfer is thus established from the
refrigerant gas (inside the tubes) to the air
condenser (flowing over the tubes). The
condenser tubes have fins designed to
improve the transfer of heat. This removal of
heat causes the refrigerant to liquefy; liquid
refrigerant flows from the condenser to the
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receiver. The refrigerant then flows through
the filter-drier, where an absorbent keeps it
dry and clean. The refrigerant then flows
through a sight glass with moisture
indication and then to the liquid / gas heat
exchanger.
The liquid enters to the thermostatic
expansion valve (with external pressure
equalizer) which regulates the flow rate of
refrigerant towards the evaporator in order
to obtain maximum use of the evaporator
heat transfer surface.
The evaporator tubes have aluminium fins to
increase heat transfer; therefore heat is
removed from the air circulated through the
evaporator. This cold air is circulated
throughout the truck to maintain the box at
the desired temperature.
The transfer of heat from the air to the low
temperature liquid refrigerant causes the
liquid to vaporize. The steam at low
temperature and pressure enters the heat
exchanger then enters the compressor
pressure regulating valve (CPR) which
regulates refrigerant pressure entering the
compressor, where the cycle starts over.
The discharge pressure is regulated with
HP2. For refrigerant R404a If P>22 bars
HP2 is switch on and the fan works. When
the pressure decreases at 17 bars, HP2 is
switch off and the fan is off.
For refrigerant R134a If P>12 bars, HP2 is
switch on and the fan works. When the
pressure decreases at 9 bars HP2 is switch
off and the fan is off.
2.12 REFRIGERANT CIRCUIT
DURING HEAT AND DEFROST
When refrigerant vapor is compressed to a
high pressure and temperature in a
compressor, the mechanical energy
necessary to operate the compressor is
transferred to the gas it is being compressed.
This energy is referred to as the heat of
compression and is used as the source of
heat during the defrost and heating mode.
Case 1: With condenser closing solenoid
option.
When the microprocessor activates heating
or defrost, the hot gas HGV (two-way)
solenoid energizes, and (if HP2 is switch off)
the condenser closing solenoid MHV
energizes, closing the port to the condenser
and opening a port which allows heated
refrigerant vapor to flow directly to the
evaporator coil.
Case 2: Without condenser closing solenoid
option.
When the microprocessor activates heating
or defrost, the hot gas solenoid HGV (two-
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way) energizes, opening a port which allows
heated refrigerant vapor to flow directly to
the evaporator coil.
The main difference between heating and
defrosting is that, when in heating mode all
the evaporator fans continue to run, blowing
the air around the heated coils to heat the
product. When defrosting, the evaporator
fans stop, allowing the heated vapor to
defrost any ice build-up there may be.
For refrigerant R404a If P>22 bars HP2 is
switch on; When the pressure decreases at
17 bars, HP2 is switch off.
For refrigerant R134a If P>12 bars, HP2 is
switch on; When the pressure decreases at 9
bars, HP2 is switch off.
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 SECTION 3
OPERATION
Start the vehicle engine
3.1 CONTROL AND STARTING Press the ON key to start the
UP unit (start-up is time-delayed
for 40 seconds). The digital
display of the cab command
displays the box temperature.
Check the temperature set-
point is correct by pressing the
SET key; the set-point
temperature is highlighted on
the digital display.
Enter a new set-point if necessary (see
temperature set-point adjustment).
In the event of difficulty on start-up,
check that:
● The fuses have not blown.
● The temperature selected by the cab

Unit shut-down
3.1.1 Start and stop the unit Turn off the ignition
Check the belt tension of the compressor key or press the OFF
drive belts before starting the unit. key.
Start-up and box temperature
control

3.1.2 Compressor start up intervals

The minimum time between two compressor starts is 5 minutes.
Cooling

Heating

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3.1.3 COOLING
There are two control ranges, Frozen and
Perishable. The frozen range is active with
set points at or below -12°C (+10°F) and the
Perishable range is active at set points above
-12°C (+10°F).
The controller automatically selects the
mode necessary to maintain box temperature
at set point.
3.1.4 HEATING
See section 2.12 for a description of the
heating cycle.
The unit will only heat when the controller
is set above -12°C (+10°F) as the heat relays
are electronically locked out with set points
at or below -12°(+10°F).
The microprocessor automatically selects
the mode necessary to maintain box
temperature at set point. In pull down the
heating modes are as follows (Figure 3-1
and Figure 3-2).

DECREASE IN TEMPERATURE INCREASE IN TEMPERATURE

Figure 3-1 Thermostat operating sequence, set-point higher than –12ºC (+10ºF)

Figure 3-2 Thermostat operating sequence, set-point lower than–12ºC(+10ºF)

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3.1.5 DEFROST
See section 2.12 for a description of heat and defrost cycles.

3.2 control of fan and valves

Table 3-1 Management of fan and valve
HGV HP2
EFM CFM condenser MHV CLHR
hot gas pressure
evaporator fan fan solenoid compressor
solenoid switch
ON OFF OFF OFF ON OPEN
cooling ON
ON OFF OFF ON CLOSED
3mn minimum
ON OFF ON ON ON OPEN
Heating if
set-point OFF
ON if
≥-12ºC ON 1mn ON ON CLOSED
MHV=OFF+1mn
minimum
OFF OFF ON ON ON OPEN
defrost OFF
ON if
OFF 1mn ON ON CLOSED
MHV=OFF+1mn
minimum

Injection valve INV is controlled by discharge temperature, when discharge temperature is more
than 127ºC (260ºF), injection valve switches on, when discharge temperature is less than 105 ºC
(212ºF), injection valve switches off.

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 SECTION 4
SERVICE

Please follow the schedules

Table 4-1 Unit maintenance schedule

Initial Service Service
km Mile
service A B
5000 3000 ■
30000 18000 ■
60000 36000 ■ ■
90000 54000 ■
120000 72000 ■ ■
150000 90000 ■
180000 108000 ■ ■
210000 126000 ■

Refrigerant: type R134a / R404A

4.1 UNIT MAINTENANCE
4.1.1 Unit maintenance schedules
Regular servicing is required in order to
optimize the service life and reliability of
your unit. Service operations are to be
carried out according to the following
schedule.
Road compressor oil type: The
compressors are supplied with CARRIER
POLYOLESTER (POE) oil. The presence of
a sticker indicates that oil-change has been
correctly carried out in our Carrier
Transicold plant.
Oils of PAG type are strictly incompatible
with the operation of our unit: never use oil
other than that approved by Carrier.
Oil analysis: on request, we can analyze
your compressor oil.
To do this, we send a small drum with a
label on which you should indicate: the type
of compressor, the lapse time or mileage
since the last oil change, the type of Carrier
equipment, the date of initial operation.
4.1.2 Description of maintenance
operations

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 •Check the tightness of bolts 4.2.1 Belt tension gauge (compressor)
and screws and that the unit is A belt tension gauge provides an accurate
correctly fastened onto the box.
Initial
•Check pressure leak.
and easy method of adjusting belts to their
service proper tension. Properly adjusted belts give
•Check that the road
compressor RPM long lasting and efficient service. Too much
•Check compressor belt tension. tension shortens belt and bearing life, and
•Clean up battery and battery too little tension causes slippage and exces-
clamps sive belt wear. It is also important to keep
•Check belt compressor tension belts and sheaves free of any foreign
•Replace compressor belt every material which may cause the belts to slip.
3000 hours
•Check refrigerant leaks
The Belt Tension gauge can be used to
Service A •Check all electrical adjust all belts. The readings which we
connections specify for Carrier Transicold units are
•Check the cooling mode applicable only for our belts and application,
•Check the defrost operation as the tension is dependent on the size of the
•Check the operation of the cab belt and distance between sheaves. When
control using this gauge, it should be placed as close
•Clean up condenser coil
as possible to the midpoint between two
•Replace idler pulley bearings if
Service B
any.
sheaves.
•Replace filter drier. When installing a new V-belt the tension
Every year •Clean up the expansion valve should be somewhat higher than specified
orifice filter. and readjusted after allowing the unit to run
•Replace compressor oil - only for some time.
use Polyolester oil (POE)
Every approved by Carrier Transicold.
TWO years •Replace refrigerant.
•Replace orifice expansion
valve

Warning: Battery clamps must be well

positioned and tightened after cleaning up.

4.2 BELT MAINTENANCE AND

ADJUSTMENT
Figure 4-1 Belt tension gauge
(Part Number 07-00203)

Belt tension depends on each kit. In each kit

installation instruction, we indicate the belt
tension.

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4.3 REMOVING THE
REFRIGERANT CHARGE
Connect a refrigerant system to the unit to
remove refrigerant charge. Refer to
instruction provided by the manufacture of
the refrigerant recovery system.
4.4 REFRIGERANT LEAK
CHECKING
Once the recovery system is OPEN and
repairs completed, leak check the unit by
proceeding as follows:
a. The recommended procedure for finding
leaks in a system is with a halide torch or
electronic leak detector. Testing joints with
soapsuds is satisfactory only for locating
large leaks.
b. If system is without refrigerant, charge
system with refrigerant to build up pressure
between 2.1 to 3.5bar (30 to 50 psig).
Remove refrigerant cylinder and check for
leak all connections.
c. Remove refrigerant using a refrigerant
recovery system and repair any leaks.
Evacuate and dehydrate the unit. (Refer to
section 4.5) Charge unit with refrigerant.
(Refer to section 4.6)
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NOTE
Important: only the correct
refrigerant cylinder must be
connected to pressurize the system.
Any other gas or vapor will
contaminate the system which will
require additional purging and
evacuation of the high side
(discharge) of the system.
4.5 EVACUATION AND
DEHYDRATION
4.5.1 General
Moisture is the deadly enemy of refrigerant
systems. The presence of moisture in a
refrigeration system can have many
undesirable effects. The most common are
copper plating, acid sludge formation,
“freezing-up” of metering devices by free
water, and formation of acids, resulting in
metal corrosion.
4.5.2 Preparation
a. Evacuate and dehydrate only after
pressure leak test. (Refer to section 4.4).
b. Essential tools to properly evacuate and
dehydrate any system include a good
vacuum pump (5cfm =8m3/h volume
displacement, code 07-00176-01) and a
good vacuum indicator such as a thermo-
couple vacuum gauge (vacuum indicator).
c. Keep the ambient temperature above
15.6°C (60°F) to speed evaporation of
moisture. If ambient temperature is lower
than 15.6°C (60°F), ice might form before
moisture removal is complete. Heat lamps or
alternate sources of heat may be used to
raise system temperature.
NOTE
Use of a compound gauge is not
recommended because of its
inherent inaccuracy.

4.5.3 Evacuation and dehydration
procedure
a. Remove refrigerant using a refrigerant
recovery system.
b. The recommended method to evacuate
and dehydrate the system is to connect three
evacuation hoses to the vacuum pump and
refrigeration unit as shown in Figure 4-2 (do
not use standard service hoses as they are
not suited for evacuation purposes). Also, as
shown, connect an evacuation manifold
with special evacuation hoses
c. Open the vacuum pump and electronic
vacuum gauge valves, start the pump, for a
while, Shut off the pump and check to see if
the vacuum holds. This operation is to test
the evacuation setup for leaks, repair if
necessary.
d. Open the vacuum pump and electronic
vacuum gauge valves again. Evacuate unit
until the electronic vacuum gauge indicates
2000 microns. Close the electronic vacuum
gauge and vacuum pump valves. Shut off
Figure 4-2 evacuation connection method
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the vacuum pump. Wait a few minutes to be
sure the vacuum holds.
e. Break the vacuum with clean dry
refrigerant. Use refrigerant that the unit calls
for. Raise system pressure to
approximately 2 psig.
f. Remove refrigerant using a refrigerant
recovery system.
g. Repeat steps d. to f.
h. Evacuate unit to 500 microns. Close off
vacuum pump valve and stop pump. Wait
five minutes to see if vacuum holds. This
checks for residual moisture and/or leaks.
i. With a vacuum still in the unit, the
refrigerant charge may be drawn into the
system from a refrigerant container on
weight scales. The correct amount of
refrigerant may be added by observing the
scales (see table 2-1).
NOTE
Vacuum duration must be at least 8
hours.

4.6 CHARGING THE
REFRIGERATION SYSTEM
4.6.1 Installing a complete charge
a. Dry the refrigeration circuit and create a
high vacuum (see section 4.5).
b. Place refrigerant cylinder on scale and
connect charging line from cylinder to
manifold. Purge charging line at outlet valve.
Purge charging line at inlet manifold.
c. Note weight of refrigerant cylinder. Be
sure that the unit is stopped during this
operation.
d. Open liquid valve on refrigerant cylinder.
Allow the liquid refrigerant to flow into the
unit until the correct weight of refrigerant
has been added as indicated by scales.
NOTE
It is possible that all liquid may not be
pulled into the circuit, as outlined in
step (d) above. In this case, close the
cylinder valve front seat and start the
unit. Refrigerant will accumulate in
the receiver and liquid of the
refrigerant cylinder will be sucked by
the compressor.
e. When refrigerant cylinder weight (scale)
indicates that the correct charge has been
added, close the manifold valves.
4.6.2 Adding a partial charge
a. Place refrigerant cylinder on scale and
note weight.
b. Connect charging line from the cylinder
to the manifold. Charge proper volume
refrigerant to remove air.
c. Start the unit with the compressor turning
at 2400 rpm.
d. Turn down refrigerant cylinder valve.
e. Add refrigerant by small quantity.
f. Repeat the step 4.6.3.
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NOTE
The refrigerant R404A must be
charged from liquid valve and not
vapor. The refrigerant R404A is a
blend. Charging by the vapor valve
will change the properties of the
refrigerant and affect cooling capacity.
4.6.3 Checking the refrigerant charge
Start unit in cooling mode. Run
approximately ten minutes. Partially block
off air flow to condenser coil so discharge
pressure rise to 22 bars (R404A) or 12bar
（R134a）.
The charge is correct if there are no bubbles
at the liquid line sight glass.
4.7 REPLACING THE
COMPRESSOR
a. Read carefully the following
instructions, strict observance of these
procedures are essential for operator
safety.
● do not switch on compressor with
terminal box open.
● remove terminal box cover only with
power source disconnected.
● before compressor installation, slowly
open the plug on the discharge valve and
vent the nitrogen holding charge.
● ensure that suction and discharge
valves are open before starting the
compressor.
● do not touch the compressor shortly
after stopping as surface temperatures
will be dangerous.
● do not operate the compressor with
hydrocarbon gases.
b. Evacuate the unit. Repeat the steps in
section 4.3.
c. Installation
To install the compressor, reverse the
procedure outlined when removing the
compressor. Refer to section 2.5 for torque
values.
Pump down the unit, see section 4.5 then
charge system, see section 4.6.

4.8 CHECKING AND

REPLACING FILTER DRIER
Checking filter-drier
Check for any obstruction of the filter-drier
by feeling the inlet and outlet connections of
the liquid line on the filter cartridge. If the
temperature of the outlet connection seems
lower than the temperature of the inlet
connection, replace the filter-drier.

Replacing the filter-drier

Remove the drier mounting clip, then
replace the filter-drier.

4.9 CHECKING AND

REPLACING HIGH PRESSURE Figure 4-3 Typical setup for testing high
CUTOUT SWITCH pressure switch HP1, HP2

4.9.1 Replacing high pressure cutout a. Remove switch.

switch b. Connect ohmmeter or continuity light
–Remove defective switch. across switch terminals. Ohmmeter will
–Install the new switch. indicate resistance and continuity light
will be lighted if switch is closed (HP1 /
4.9.2 Checking high pressure cutout or open (HP2) after relieving pressure.
switch c. Connect switch to a cylinder of dry
nitrogen (see Figure 4-3)
d. Set nitrogen pressure regulator higher
than cut-out point on switch being tested.
Pressure switch cut-in points are shown
in sections 2.3.
e. Close valve on cylinder and open bleed-
off valve.
f. Open cylinder valve. Slowly close bleed-
off valve and increase pressure until the
switch opens. If light is used, light will
go out and if an ohmmeter is used, the
meter will indicate open. Open pressure
on gauge. Slowly open bleed-off valve
(to decrease pressure) until switch closes
(light will light or ohmmeter will move).

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4.10. CHECKING AND
REPLACING FAN MOTOR
BRUSHES
The fan motor brushes should be checked
periodically for cleanliness and wear to
maintain proper operation of the fan motors.
Figure 4-4 Fan motor brushes
To check brushes proceed as follows:
a. With unit off and battery disconnected,
remove brush cap (item 1; 2 per motor).
See Figure 4-4.
b. Remove brushes (item 2; 2 per motor)
and check the length of the brush. If the
length is less than 1/4 inch (6 mm) the
brushes should be replaced (after
checking collector).
c. Blow out the brush holder with low
pressure air to remove any carbon dust
in the holder. This dust could prevent a
good contact between the brushes and
collector.
d. Remove the back cover of the motor and
inspect the collector. If the commutator
is heavily grooved, polish it using fine
sandpaper; do not use abrasive paper.
Wipe out any accumulation of greasy
material using a clean rag dampened
with solvent. Reassemble the motor;
install new brushes and replace cap.
4.11 EVAPORATOR COIL-
CLEANING
The use of recycled cardboard cartons is
increasing. The recycled cardboard cartons
create much more fiber dust during transport
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than “new” cartons. The fiber dust and
particles are drawn into the evaporator
where they lodge between the evaporator
fins. If the coil is not cleaned on a regular
basis, sometimes as often as after each trip,
the accumulation can be great enough to
restrict air flow, cause coil icing, repetitive
defrosts and loss of unit capacity. Due to the
“washing” action of normal defrost the fiber
dust and particles may not be visible on the
face of the coil but may accumulate deep
within.
It is recommended to clean the evaporator
coil on a regular basis, not only to remove
cardboard dust, but to remove any grease oil
film which sometimes coats the fins and
prevents water from draining into the drain
pan.
Cardboard fiber particles after being wetted
and dried several times can be very hard to
remove. Therefore, several washings may be
necessary.
a. Spray coil with a mild detergent solution
such as any good commercial-grade
automatic dish washer detergent and let the
solution stand for a few minutes. Reverse
flush (opposite normal air flow) with clean
water at mild pressure. A garden hose with
spray nozzle is usually sufficient. Make sure
drain lines are clean.
b. Run unit until defrost mode be initiated to
check for proper draining from drain pan.
4.12 CONDENSER COIL-
CLEANING
Remove all foreign material from the
condenser coil by reversing the normal air
flow. (Air is pulled in through the front and
discharges over the unit.) Compressed air or
water may be used as a cleaning agent. It
may be necessary to use warm water mixed
with any good commercial dishwasher
detergent. Rinse coil with fresh water if a
detergent is used.
4.13 HOT GAS (TWO-WAY)
SOLENOID AND CONDENSER
CLOSING SOLENOID (TWO
WAY)
4.13.1 Replacing solenoid coil
It is not necessary to pump the unit down to
replace the coil (see Figure 4-5).
a. Remove coil snap cap, voltage plate and
coil assembly. Disconnect leads and remove
coil junction box if necessary.
b. Verify coil type, voltage and frequency.
This information appears on the coil voltage
plate and the coil housing.
c. Place new coil over enclosing tube and
then install voltage plate and snap cap.
Figure 4-5 Hot gas (two-way) solenoid or
Condenser closing solenoid (Two-way)
4.13.2 Replacing solenoid valve
internal parts
If the hot gas solenoid is to be replaced, or if
a service operation is scheduled on the
internal components of the valve, the
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refrigerant must be evacuated.
a. Remove and store the refrigerant charge
in an evacuated container (see section
4.3).
b. Remove coil snap cap, voltage cover and
coil assembly. Remove the valve body
head.
c. Check for foreign material in valve body.
d. Check for damaged plunger and O-ring.
If O-ring is to be replaced, always put
refrigerant oil on O-rings before
installing.
e. Tighten enclosing tube. If the valve has
been removed from the circuit, check for
eventual leaks.
f. Install coil assembly, voltage cover and
snap cap.
g. Evacuate and dehydrate the circuit.
h. Install a complete refrigerant charge.
i. Start unit and check operation.
4.14 ADJUSTING THE
COMPRESSOR PRESSURE
REGULATING VALVE (CPR)
The CPR valve is not factory pre-set and
need adjustment. It is necessary to adjust the
valve during commission, proceed with the
following outline:
When adjusting the CPR valve, the unit
must be running in heating or defrost mode.
This will ensure a suction pressure above the
proper CPR setting.
Figure 4-6 Compressor pressure
regulating valve
To adjust the CPR valve, proceed as
follows :
a. Install a low-pressure gauge.
b. Remove cap (item 1) from CPR valve.
c. With an 8 mm Allen wrench, loosen the
jam nut (Figure 4-6, item 2.).
d. Using the 8 mm Allen wrench, adjust the
setting screw. To raise the suction
pressure turn the set ting screw (item 3.)
clockwise; to lower the suction pressure,
turn the setting screw counterclockwise.
Refer to section 2.3 for CPR valve
setting.
e. When the setting has been adjusted,
tighten the jam nut securely against the
setting screw (item3.). This will prevent
any movement of the setting screw due
to vibrations in the unit. Replace the cap.
4.15 THERMOSTATIC
EXPANSION VALVE
MOP expansion valve characteristics:
–Rule: in order to avoid the compressor
overcharge, a MOP expansion valve
(expansion valve with limited flow) is used.
–Operating: this kind of expansion valve can
not open more than MOP setpoint. Any
temperature increase of the sensor can not
open more the expansion valve.
The thermal expansion valve is an automatic
device which maintains constant superheat
of the refrigerant gas leaving the evaporator
regardless of suction pressure. The valve
functions are: (a) automatic response of
refrigerant flow to match the evaporator load
and (b) prevention of liquid refrigerant
entering the compressor. Unless the valve is
defective, it requires adjustment, but
maintenance must be done every year in
order to clean the orifice filter.
a. Replacing expansion valve
1. Remove refrigerant charge.
2. Remove insulation from expansion valve
bulb and then remove bulb from suction
line.
3. Loosen inlet nut and unbraze equalizer
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line and outlet line from expansion valve.
4. The thermal bulb is located below the
center of the suction line. This area must be
clean to ensure positive bulb contact. Strap
thermal bulb to suction line and insulate
both.
5. Braze the equalizer tubes to expansion
valve.
6. Evacuate by placing vacuum pump on
suction and receiver tank service valve.
7. Recharge unit.
8. Check superheat.
b. Measuring superheat
NOTE
The expansion valve and bulb
location are shown in Figure 4-7.
1. Remove insulation from expansion valve
bulb and suction line.
2. Loosen one TXV bulb clamp and make
sure area under clamp (above TXV bulb)
is clean.
3. Place thermocouple above (parallel)
TXV bulb and then secure loosened
clamp making sure both bulbs are firmly
secured to suction line as shown in
Figure 4-7.
Figure 4-7 Thermostatic expansion valve
bulb and thermocouple
4. Connect an accurate gauge to the ¼”
port on the suction service valve.
5. Run unit until stabilize, set controller
temperature lower 5.5ºC than box
 temperature.
6. From the temperature/pressure table,
determine the saturation temperature
corresponding to the evaporator outlet
pressure.
7. Note the temperature of the suction gas
at the expansion valve bulb.
8. Subtract the saturation temperature
determined in Step 7 from the average
temperature measured in Step 6. The
difference is the superheat of the suction
gas.
4.16 MICROPROCESSOR
Although there is less danger of electrical
static discharge ESD damage in the outdoor
environment, where the processor is likely
to be handled, proper board handling
techniques should always be stressed.
Boards should always be handled by their
edges, in much the same way one would
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handle a photograph. This not only
precludes the possibility of ESD damage,
but also lowers the possibility of physical
damage to the electronic components.
Although the microprocessor boards are
fairly rugged when assembled, they are
more fragile when separated and should
always be handled carefully.
When welding is required on the unit frame,
or on the front area of the trailer, ALL
wiring to the microprocessor MUST be
disconnected. When welding is per formed
on other areas of the truck and van, the
welder ground connection MUST be in close
proximity to the area being welded. It is also
a good practice to remove both battery
cables before wedding on either the unit
frame or the truck to prevent possible
damage to other components such as the
alternator and voltage regulator.
 Table 4-2 R404A temperature-pressure

Table 4-3 Sensor resistance (RAS)

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 Table 4-4 R134a Temperature-pressure

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 SECTION 5
TROUBLE SHOOTING

5.1 REFRIGERATION
5.1.1 Unit will not cool
INDICATION/TROUBLE POSSIBLE CAUSES REFERENCE SECTION
Clutch defective Check
Compressor malfunction Compressor defective 4.7
Belt malfunction Check
Defrost cycle has not terminated 5.1.5
Refrigeration system Abnormal pressure 5.1.6
Hot gas (two-way)solenoid
5.1.11
malfunction

5.1.2 Unit runs but has insufficient cooling

INDICATION/TROUBLE POSSIBLE CAUSES REFERENCE SECTION
Compressor defective 4.7
Compressor
Belt malfunction Check
Abnormal pressure 5.1.6
Refrigeration system Expansion valve malfunction 5.1.10
No or restricted evaporator airflow 5.1.9

5.1.3 Unit operates long or continuously in cooling

INDICATION/TROUBLE POSSIBLE CAUSES REFERENCE SECTION
Hot Load Insufficient pull down time
Box
Defective box insulation or air leak Correct
Abnormal pressure 5.1.6
Refrigeration system
Temperature controller malfunction 2.7

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5.1.4 Unit will not heat or heating insufficient
INDICATION/TROUBLE POSSIBLE CAUSES REFERENCE SECTION
Abnormal pressure 5.1.6
Refrigeration Temperature controller malfunction 2.7
Hot gas (two-way)solenoid
5.1.11
malfunction
Clutch defective Check
Compressor
Compressor defective 4.7

5.1.5 Defrost malfunction

INDICATION/TROUBLE POSSIBLE CAUSES REFERENCE SECTION
Automatic defrost will not Hot gas valve Replace
initiate Electronic board malfunction Check defrost parameters
Manual defrost will not Electronic board defective Replace
initiate Check box temperature Check
Defrost cycle initiates but does Hot gas (two-way)solenoid
5.1.11
not defrost malfunction
Frequent defrost Wet load Check defrost parameters

5.1.6 Abnormal pressure

5.1.6.1 Cooling
REFERENCE
INDICATION/TROUBLE POSSIBLE CAUSES
SECTION
Condenser coil dirty 4.12
High discharge pressure The refrigerant is mixed with other gases or
Replace
refrigerant over charge
Compressor worn or broken 4.7
Hot gas (two way) solenoid malfunction 5.1.11
Low discharge pressure Clutch malfunction Check
Belt malfunction Check
Low refrigerant charge 4.6
CPR valves worn or broken 4.14
High suction pressure
Hot gas (two way) solenoid malfunction 5.1.11
CPR valves worn or broken 4.14
Filter-drier partially plugged 4.8
Low refrigerant charge 4.6
Low suction pressure
Expansion valve malfunction 5.1.10
No evaporator air flow or restricted air flow 5.1.9
Excessive frost on coil Check
Compressor defective 4.7
Suction and discharge
Belt malfunction Check
pressures tend to equalize
when unit is operating Clutch malfunction Check
Hot gas (two way) solenoid malfunction 5.1.11

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5.1.6.2 Heating
REFERENCE
INDICATION/TROUBLE POSSIBLE CAUSES
SECTION
Over charged system 4.6.3
Condenser fan or HP2 pressure switch
4.9.2
High discharge pressure defective
The refrigerant is mixed with other gases Check
Condenser fan defective Check
Compressor worn or broken 4.7
Clutch malfunction Check
Low discharge pressure
Belt malfunction Check
Low charged system 4.6
Low charged system 4.6
Low suction pressure
CPR valve worn or broken 4.14

5.1.7 Abnormal noise

REFERENCE
INDICATION/TROUBLE POSSIBLE CAUSES
SECTION
Loose mounting bolts and belt Tighten
Worn bearings 4.7
Compressor
Liquids lugging 5.1.10
Insufficient oil Check/4.7
Loose mounting bolts Tighten
Condenser or evaporator fan
Bearings defective Replace

5.1.8 Cab command malfunction

REFERENCE
INDICATION/TROUBLE POSSIBLE CAUSES
SECTION
System is out of power Check
Cab command non-
Microprocessor malfunction 4.16
operational
Microprocessor/Cab command cable Change

5.1.9 No evaporator air flow or restricted air flow

REFERENCE
INDICATION/TROUBLE POSSIBLE CAUSES
SECTION
Frost on coil or dirty Check
Evaporator coil blocked
Fan motor malfunction Check
Evaporator fan loose or defective Check
No or partial evaporator air Evaporator fan rotating backwards Check
flow Evaporator air flow blocked in box Check
Fan motor malfunction Check

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5.1.10 Expansion valve malfunction

REFERENCE
POSSIBLE CAUSES
SECTION
External equalizer line plugged Clean
Ice formation at valve seat 4.5
Low suction pressure with high Wax, oil or dirt plugging valve or orifice 4.15
superheat
Broken capillary 4.15
Power assembly failure or partial Replace
Loss of element /bulb charge Replace
Superheat setting too high 4.15
Superheat setting too low 4.15
Low superheat and liquids lugging Choose the wrong type of expansion valve 4.15
in compressor
Improper bulb location or installation 4.15

Improper bulb location or installation 4.15

Fluctuating suction pressure Low superheat setting 4.15
Choose the wrong type of expansion valve Replace

5.1.11 Malfunction hot gas (two-way) solenoid

REFERENCE
INDICATION/TROUBLE POSSIBLE CAUSES
SECTION
No power to valve Check
Improper wiring or loose connections Check
Valve improperly assembled 4.13
Valve does not function properly Coil or coil sleeve improperly assembled 4.13
Movement of plunger restricted due to :
a. Corroded or worn parts
4.13
b. Foreign material lodged in valve
c. Bent or dented enclosing tube
Valve shifts but refrigerant Foreign material lodged under seat 4.13
continues to flow Defective seat Check

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5.2 Fault alarm
Please refer to section 2.7, the following is the way to solve malfunction.

5.2.1 EE alarm

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5.2.2 BAT alarm

5.2.3 Err alarm

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5.2.4 A01/A02 alarm

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5.2.5 A04 alarm

5.2.6 A06 alarm

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5.2.7 A07 alarm

5.2.8 A09 alarm

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5.2.9 A11 alarm

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 SECTION 6
EXTRACT FROM MATERIAL SAFETY DATA BULLETIN
6.1 POE OIL
1. PRODUCT AND COMPANY IDENTIFICATION
CARRIER SHANGHAI

2. FIRST AID MEASURES

EYE CONTACT:
Flush thoroughly with water. If irritation occurs, call a physician.
SKIN CONTACT:
Wash contact areas with soap and water. High pressure accidental injection through the skin
requires immediate medical attention for possible incision, irrigation and/or debridement.
INHALATION:
Not expected to be a problem.
INGESTION:
Not expected to be a problem. However, if greater than 1/2 liter (pint) ingested, seek medical
attention.

3. FIRE-FIGHTING MEASURES
EXTINGUISHING MEDIA:
Carbon dioxide, foam, dry chemical and water fog
SPECIAL FIRE FIGHTING PROCEDURES:
Water or foam may cause frothing. Use water to keep fire exposed containers cool. Water spray
may be used to flush spills away from exposure. Prevent runoff from fire control or dilution from
entering streams, sewers, or drinking water supply.
SPECIAL PROTECTIVE EQUIPMENT:
For fires in enclosed areas, fire fighters must use self-contained breathing apparatus.
UNUSUAL FIRE AND EXPLOSION HAZARDS:
None. Flash point C (F): 232 (450) (ASTM D–92). Flammable limits – LEL: NA, UEL: NA.
NFPA HAZARD ID:
health: 0,
flammability: 1,
reactivity: 0
HAZARDOUS DECOMPOSITION PRODUCTS:
carbon monoxide

4. ACCIDENTAL RELEASE MEASURES

PROCEDURES IF MATERIAL IS RELEASED OR SPILLED:
Small spills can be absorbed with fire retardant treated sawdust, diatomaceous earth, etc.
Contain and remove larger spills for salvage or disposal according to applicable
regulation.
ENVIRONMENTAL PRECAUTIONS:
Prevent spills from entering storm sewers or drains and contact with soil.
PERSONAL PRECAUTIONS:

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see section 6.

5. HANDLING AND STORAGE

STORAGE:
do not store in open or unlabelled containers. Store away from strong oxidizing agents or
combustible material.

6. EXPOSURE CONTROLS / PERSONAL PROTECTION

VENTILATION:
No special requirements under ordinary conditions of use and with adequate ventilation.
RESPIRATORY PROTECTION:
No special requirements under ordinary conditions of use and with adequate ventilation.
EYE PROTECTION:
Normal industrial eye protection practices should be employed.
SKIN PROTECTION:
No special equipment required. However, good personal hygiene practices should always be
followed.

7. STABILITY AND REACTIVITY

HAZARDOUS DECOMPOSITION PRODUCTS:
Carbon monoxide (in case of fire)

8. DISPOSAL CONSIDERATIONS
WASTE DISPOSAL:
EVEN THOUGH THIS PRODUCT IS READILY BIODEGRADABLE, IT MUST NOT BE
INDISCRIMINATELY DISCARDED INTO THE ENVIRONMENT.
This product is suitable for burning in an enclosed, controlled burner for fuel value and for
recycling at an approved facility. In addition, it can be disposed of at an approved waste disposal
facility. Land farming and processing through sewage treatment facilities may be available
disposal options but necessary approvals must first be obtained from appropriate regulatory
authorities. Specific characteristics of the waste at the time of disposal may affect the availability
of the above options.

The complete data sheets are available from Carrier Shanghai on request.

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6.2 FORANE R404A/R134a
1. Refrigerant R404A

1.1 PRODUCT AND COMPANY IDENTIFICATION

CARRIER SHANGHAI

Product name: Forane (R) 404A

Chemical family: hydrofluorocarbons

Chemical formula: CF3CH2F/CF3CH2F/CF3CH3
Chemical name: 1,1,1,2-tetrafluoroethane (HFC-134a)/ Pentafluoroethane (HFC-125)/ 1,1,1-
trifluoroethane (HFC-143a).

1.2 COMPOSITION / INFORMATION ON INGREDIENTS

BLEND OF FORANE 125, 143a, 134a
This product is not hazardous to health as define by the European Union dangerous substances
and preparations directives.

2. Refrigerant R134a：

2.1 PRODUCT AND COMPANY IDENTIFICATION

CARRIER SHANGHAI

Product name: Forane (R) 134a

Chemical family: hydrofluorocarbons
Chemical formula: CH 2 FCF 3
Chemical name: Tetrafluoroethane

R404A and R134a:

3.HAZARDS IDENTIFICATION
EMERGENCY OVERVIEW
Colorless liquified gas with faint ether odor.

WARNING
LIQUID AND GAS UNDER PRESSURE, OVERHEATING AND OVERPRESSURIZING
MAY CAUSE GAS RELEASE OF VIOLENT CYLINDER BURSTING. MAY
DECOMPOSE ON CONTACT WITH FLAMES OR EXTREMELY HOT METAL
SURFACES TO PRODUCE TOXIC AND CORROSIVE PRODUCTS. VAPOR
REDUCES OXYGEN AVAILABLE FOR BREATHING AND IS HEAVIER THAN AIR.
HARMFUL IF INHA LED AND MAY CAUSE HEART IRREGULARITIES,
UNCONSCIOUSNESS OR DEATH. LIQUID CONTACT WITH EYES OR SKIN MAY
CAUSE FROSTBITE.

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POTENTIAL HEALTH, EFFECTS
Skin contact and inhalation are expected to be the primary routes of occupational exposure to
this material. As with most liquified gases, contact with the rapidly volatilizing liquid can cause
frostbite to any tissue. High vapor concentrations are irritating to the eyes and respiratory tract
and may result in central nervous system (CNS) effects such as headache, dizziness, drowsiness
and, in severe exposure, loss of consciousness and death. The dense vapor of this material may
reduce the available oxygen for breathing. Prolonged exposure to an oxygen deficient
atmosphere may be fatal. Inhalation may cause an increase in the sensitivity of the heart to
adrenaline, which could result in irregular or rapid heartbeats. Medical conditions aggravated by
exposure to this material which could result in irregular or rapid heartbeats. Medical conditions
aggravated by exposure to this material include heart disease or compromised heart
function.
4. FIRST AID MEASURES
EYE CONTACT
Immediately flush with plenty of water. Get medical attention if irritation persists.

SKIN CONTACT
Flush exposed skin with lukewarm water (not hot), or use other means to warm skin slowly. Get
medical attention if frostbitten by liquid or if irritation occurs.

INGESTION
Not applicable. Product is a gas at ambient temperatures.

INHALATION
Remove to fresh air. If not breathing, give artificial respiration. If breathing is difficult, give
oxygen. Get medical attention. DO NOT GIVE ADRENALINE, EPINEPHRIN OR
SIMILAR DRUGS FOLLOWING EXPOSURE TO THIS PRODUCT.

5. FIRE FIGHTING MEASURES

EXTINGUISHING MEDIA
Use extinguishing media appropriate to surrounding fire conditions.
FIRE FIGHTING INSTRUCTIONS
Stop the flow of gas if possible. Use water spray on person making shut-off and on containers
and cylinders. Fire fighters and others who may be exposed to products of combustion should
wear full fire fighting turn out gear(full Bunker Gear) and self-contained breathing apparatus.
Fire fighting equipment should be thoroughly decontaminated after use.

FIRE AND EXPLOSION HAZARDS

Some mixtures of HCFCs and / or HFCs, and air or oxygen may be combustible if pressurized
and exposed to extreme heat or flame.

6. ACCIDENTAL RELEASE MEASURES

IN CASE OF SPILL OR LEAK
Use Halogen leak detector or other suitable means to locate leaks or check atmosphere. Keep
upwind. Evacuate enclosed spaces and disperse gas with floor-level forced-air ventilation.
Exhaust vapors outdoors. Do not smoke or operate internal combustion engines. Remove flames
and heating elements.

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7. HANDLING AND STORAGE
HANDLING
Avoid breathing gas. Avoid contact with eyes, skin and clothing. Keep container closed. Use
only with adequate ventilation. Do not enter confined spaces unless adequately ventilated.
STORAGE
Do not apply direct flame to cylinder. Do not store cylinder in direct sun or expose it to heat
above 48ºC (120ºF).
Do not drop or refill this cylinder. Keep away from heat, sparks and flames.

8.EXPOSURE CONTROLS / PERSONAL PROTECTION

EYE / FACE PROTECTION
Where there is potential for eye contact, wear chemical gloggles and have eye flushing
equipment available.
SKIN PROTECTION
Wear appropriate chemical resistant protective clothing and chemical resistant gloves to prevent
skin contact. Consult glove manufacturer to determine appropriate type glove material for given
application. Rinse contaminated skin promptly. Wash contaminated clothing and clean protective
equipment before reuse. Wash skin thoroughly afte r handl0ing.
RESPIRATORY PROTECTION
Avoid breathing gas. When airborne exposure limits are exceeded, use respiratory protection
equipment appropriate to the material and / or its components (full facepiece recommended). For
emergency and other conditions where exposure limit may be significantly exceeded, use an
approved full face positive-pressure, self-contained breathing apparatus or positive-pressure
airline with auxiliary self-contained air supply.

9. STABILITY AND REACTIVITY

INCOMPATIBILITY
Avoid contact with strong alkali or alkaline earth metals, finely powdered metals such as
aluminum, magnesium or zinc and strong oxidizers, since they may react or accelerate
decomposition.
HAZARDOUS DECOMPOSITION PRODUCTS
Thermal decomposition products include hydrogen fluoride, hydrogen chloride, carbon
monoxide, carbon dioxide and chlorine.

10. DISPOSAL CONSIDERATIONS

WASTE DISPOSAL

Recover, reclaim or recycle when practical. Dispose of in accordance with federal, state and
local regulations.

Note : chemical additions to, processing of, or otherwise altering this material may take this
waste management information incomplete, inaccurate, or otherwise inappropriate. Furthermore,
state and local waste disposal requirements may be more restrictive or otherwise different from
federal laws and regulations.

The complete data sheets are available from Carrier Shanghai on request.

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 SECTION 7
ELECTRICAL SCHEMATIC WIRING DIAGRAMS
The following general safety notices supplement the specific warnings and cautions appearing
elsewhere in this manual. They are recommended precautions that must be understood and
applied during operation and maintenance of the equipment covered herein.

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