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Vector 8500
Carrier TRANSICOLD Vector 8500 User Manual
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T
railer & Rail Refrigeration
EVXV
EV
APORA
TOR
EVOT
EVOP
MM
DISTRIBUT
OR
OPERA
TION & SER
VICE MANUAL
For The
VECT
OR 8500
Single-T
emp T
railer and Rail Refrigeration Units
62-1
1640 Rev B Change 09/14
2
Table of Contents
Table of Contents
4
List of Illustrations
14
Figure 1.1 Lockout/Tagout
19
Section 2 - Unit Description
28
Figure 2.8 Light Bar
28
Table 2-1 Model Chart
29
Table 2-2 Additional Support Manuals
29
Figure 2.1 Front View - Refrigeration System Components
30
Figure 2.2 Front View - Engine, Control System & Autofresh Components
31
Figure 2.3 Evaporator Section - Grille Removed
32
Figure 2.4 Control and Standby Boxes
33
Ambient Air Temperature Sensor (AAT)
35
Compressor
35
Compressor Suction Modulation Valve (CSMV)
35
Compressor Switches, Transducers and Sensors
35
Condenser Coil
35
Economizer Circuit
35
Economizer Transducer and Sensor
35
Filter-Drier
35
Liquid Injection Solenoid Valve (LIV)
35
Autofresh Air Exchange
36
Evaporator Expansion Valve (EVXV)
36
Evaporator Section
36
Evaporator Switches, Transducers and Sensors
36
Receiver
36
Automatic Start-Stop
37
Component Description and Location
37
Power Control Module
37
Special Features
37
System Operating Controls and Components
37
Figure 2.5 Power Control Module
38
Main Microprocessor Module
38
SVM Module
38
AC Current Sensor
39
Contactor Control Boards
39
Engine Control Unit (ENCU)
39
High Voltage Transformer (HVT)
39
Microprocessor Status LED
39
Display Module (DM)
40
Display Module Keys
40
Figure 2.7 OGF Module
40
Light Bar
40
Options
40
Overload Ground Fault Module (OGF)
40
Electric Fuel Pump
41
Fuel Heater
41
Fuel Level Sensor
41
Remote Panel
41
Remote Switch(Es)
41
Remote Temperature Sensor
41
Compressor Data
42
Engine Data
42
2.10 Electrical Data
43
Refrigeration System Data
43
2.11 Component Resistance & Current Draw
44
2.12 Safety Devices
45
Economized Mode
45
Refrigeration Circuit During Cooling
45
Standard Mode
45
2.14 Heat and Defrost
46
Figure 2.9 Refrigeration Circuit Standard Mode
46
Liquid Injection Mode
46
Null Mode
46
Figure 2.10 Refrigeration Circuit Economized Mode
47
Section 3 - Operation
48
Display
48
Display Screens
48
Operation
48
Starting Unit
48
Switching Operating State
48
Intelliset
54
Intelliset - Continued
55
Pretrip
56
Changing Setpoint
59
Start-Stop Operation
60
Continuous Operation
61
3.10 Data Recorder
62
Control System Information
62
Data Downloading
62
Data Recording
62
Datalink Data Recorder Power-Up
62
3.11 Manual Defrost
64
3.12 Language Selection
65
3.13 Advanced User
66
3.14 Unit Data
67
Table 3-1 Unit Data
68
3.15 View Active Alarms
70
3.16 View Hour Meters
71
3.17 Functional Parameters
72
Table 3-2 Functional Parameters
73
Sleep Mode
75
3.18 Sleep Mode
76
3.19 Stopping the Unit
78
3.20 Option - Datatrak
78
3.21 Remote Panel
79
Section 4 - Engine and Temperature Control
80
Sequence of Operation - Electrical
80
Engine Control
82
Engine/Electric Operation
82
Figure 4.1 Auto Start Sequence
82
Soft Start (Bump Start)
82
Engine Start-Up Sequence
83
Start-Stop Operation
83
Table 4-1 Engine Preheat Time
83
Transition to High Speed
83
Battery Is Fully Charged - Voltage
84
Engine Coolant Temperature Has Warmed
84
Start-Stop Configuration
84
Stop Parameters
84
Unit Has Run for the Selected Minimum Run Time
84
Battery Is Fully Charged - Amperage
85
Battery Voltage Falls below Selected Configuration Value
85
Compartment Temperature Requirement Is Satisfied
85
Engine Coolant Temperature Drops below Selected Configuration Value
85
Maximum off Time Has Expired
85
Minimum off Time Has Expired
85
Re-Start Parameters
85
Compartment Temperature Has Exceeded the Override Functional Parameter Value
86
Continuous Operation
86
Cool Mode
86
Cool/Heat/Null Mode Switching Logic
86
Heat Mode
86
Null Mode
86
Perishable and Frozen Setpoint Ranges
86
Temperature Control
86
Temperature Determination
86
Autofresh Air Exchange
88
Defrost
88
Defrost Based on Coil Condition
88
Defrost Initiation and Start
88
4.10 User Selected Override Operation
89
Defrost Based on Time
89
Defrost Modes
89
Defrost Termination
89
Supply Air Limit Control
89
Temperature Range Lock 1 & 2
90
Figure 4.2 Range Lock Settings - Non Overlapping
91
Figure 4.3 Range Lock Settings - Overlapping
91
Productshield
92
Cargo Protect Mode
94
Engine Speed Overrides
94
High Discharge Temperature
94
Preprogrammed Software Overrides
94
CSMV Control Overrides
95
Component Test Mode
96
Configuration Settings
96
Figure 5.1 Technician Mode
96
Figure 5.3 Inactive Alarms
96
Inactive Alarms
96
Interface Methods
96
Service Mode
96
Technician Hour Meters
96
Technician Mode
96
Usb Memory Devices
96
Figure 5.2 Technician Hour Meters
98
Figure 5.4 Setting Configurations
100
Data Transfer USB Memory Device
103
PC Mode
104
Downloading Data Files
105
Figure 5.7 Downloading Data Files
105
Figure 5.8 Installing Software
106
Installing Software
106
Figure 5.9 Transferring Configuration Files
107
Transferring Configuration Files
107
Connecting Computer and Control System
108
Figure 5.10 TRU-Tech/Tru-View Connection
108
TRU-Tech
108
Tru-Tech & Tru-View
108
TRU-View
108
Main Microprocessor Replacement & Setup
109
Pre-Replacement Steps
109
Main Microprocessor Module Replacement
110
Main Microprocessor Setup
110
Configurations Via Display Mounted Keys
111
Datalink Data Recorder Via TRU-Tech
111
Functional Parameters Via Display Mounted Keys
111
System Final Checkout
111
Table 5-1 Configuration Settings
113
Messagecenter Messages
126
Table 6-1 Messagecenter Messages
126
Section 7 - Alarm Troubleshooting
130
Introduction
130
Introduction
134
Notes
135
00001 Low Fuel Level Warning
136
Alarms
136
Low Fuel Level Warning
136
00011 Check Engine Oil Pressure
137
Check Engine Oil Pressure
137
00012 High Coolant Temperature
138
00012 High Coolant Temperature
139
00013 High Discharge Pressure
140
High Discharge Pressure
140
00015 Battery Voltage too High
141
Battery Voltage too High
141
00016 Battery Voltage too Low
142
Battery Voltage too Low
142
00017 High Comp Discharge Temp
143
High Comp Discharge Temp
143
00018 Low Refrigerant Pressure
144
Low Refrigerant Pressure
144
00019 Low Fuel Shutdown
145
00020 Maximum Compressor Alarms
145
Low Fuel Shutdown
145
Maximum Compressor Alarms
145
00021 Technician Reset Required
146
Technician Reset Required
146
00022 Low Suction Superheat
147
Low Suction Superheat
147
00023 A/C Current over Limit
148
00023 A/C Current over Limit
149
00024 Compression Ratio Exceeded
150
Compression Ratio Exceeded
150
00027 High Suction Pressure
151
High Suction Pressure
151
00028 Check Refrigeration System
152
00030 Failed to Run Minimum Time
152
Check Refrigeration System
152
Failed to Run Minimum Time
152
00031 Failed to Start - Auto Mode
153
Failed to Start - Auto Mode
153
00034 Engine Failed to Stop
154
Engine Failed to Stop
154
00035 Check Starter Circuit
155
Check Starter Circuit
155
00036 Check Coolant Temperature
156
00037 Check Low Speed Rpm
156
Check Coolant Temperature
156
Check Low Speed Rpm
156
00038 Check High Speed Rpm
157
Check High Speed Rpm
157
00039 Check Engine Rpm
158
Check Engine Rpm
158
00040 Check Engine Preheat Circuit
159
Check Engine Preheat Circuit
159
00041 Engine Stalled
160
Engine Stalled
160
00051 Alternator (Battery Charger) Not Charging
162
Alternator (Battery Charger) Not Charging
162
00053 Box Temp Out-Of-Range
163
Box Temp Out-Of-Range
163
00054 Defrost Not Complete
165
Defrost Not Complete
165
00055 Check Defrost Air Switch
166
Check Defrost Air Switch
166
00057 Check Remote Switch 1 (Rems1)
167
Check Remote Switch 1 (Rems1)
167
00058 Check Remote Switch 2 (Rems2)
168
Check Remote Switch 2 (Rems2)
168
00059 DATALOGGER (Datalink Data Recorder) NOT RECORDING
169
00060 DATALOGGER (Datalink Data Recorder) TIME WRONG
169
DATALOGGER (Datalink Data Recorder) NOT RECORDING
169
DATALOGGER (Datalink Data Recorder) TIME WRONG
169
00061 Door Open (Ds1)
170
Door Open (Ds1)
170
00073 No Power-Check Power Cord
171
No Power-Check Power Cord
171
00074 Phase Reversed
172
Phase Reversed
172
00075 Comp Motor Overload
173
Comp Motor Overload
173
00076 Condenser Motor Overheated
174
Condenser Motor Overheated
174
00077 Evap Motor Overheated
176
Evap Motor Overheated
176
00084 Check Remote Alarm Light
177
00090 Chk Afa Solenoid Circuit
177
Check Remote Alarm Light
177
Chk Afa Solenoid Circuit
177
00093 Check Startup Buzzer
178
00094 Check Comp Contactor 1
178
Check Startup Buzzer
178
00095 Check Cdcon1 Coil
179
Check Cdcon1 Coil
179
00096 Check Gencoil Coil
180
Check Gencoil Coil
180
00098 Check High Temp Thermostat
181
Check High Temp Thermostat
181
00100 Overload/Ground Fault
182
Overload/Ground Fault
182
00109 Check 1Evcon Coil
183
Check 1Evcon Coil
183
00114 Check Liv Circuit
184
00121 Check Ambient Air Sensor
184
Check Ambient Air Sensor
184
Check Liv Circuit
184
00122 Check Return Air Sensor
185
00123 Check Supply Air Sensor
185
Check Return Air Sensor
185
Check Supply Air Sensor
185
00124 Check Defrost Term 1 Sensor
186
00125 Check Comp Discharge Sensor
186
Check Comp Discharge Sensor
186
Check Defrost Term 1 Sensor
186
00126 Check Fuel Sensor Circuit
187
00127 Check Suction Temp Sensor
187
Check Fuel Sensor Circuit
187
Check Suction Temp Sensor
187
00128 Low/Unbalanced A/C Amps
188
00129 Check Eng Coolant Sensor
188
Check Eng Coolant Sensor
188
Low/Unbalanced A/C Amps
188
00130 Check Engine Rpm Sensor
189
Check Engine Rpm Sensor
189
00131 Check Evap Temp Sensor
190
Check Evap Temp Sensor
190
00133 Check Remote Temp Sensor 1
191
00134 Check Remote Temp Sensor 2
191
00135 Check Remote Temp Sensor 3
191
Check Remote Temp Sensor 1
191
Check Remote Temp Sensor 2
191
Check Remote Temp Sensor 3
191
P00141 Pretrip Stopped by User
192
P00151 CHECK GLOW CIRCUIT (this Applies to the Engine Preheater = EPH)
192
P00152 Check Fuel Solenoid Circuit
192
P00153 Check Return Air Sensor
193
P00154 Check Supply Air Sensor
193
P00155 Check Coolant Temp Sensor
193
P00157 Check Battery Current
194
P00158 Check Ambient Air Sensor
194
P00159 Check Defrost Term 1 Sensor
195
P00160 Check Discharge Temp Sensor
195
P00161 Check Suction Temp Sensor
195
P00162 Check Afa Solenoid Circuit
196
P00170 Check Liv Circuit
196
P00173 Check Economizer
196
P00174 Check Low Speed Rpm
197
P00175 Check High Speed Rpm
197
P00177 Check Exv (Evxv) Superheat
198
P00179 Check Liv
198
P00180 Check Suction Mod Valve
199
P00186 Check Evap Outlet Temp
199
P00187 Check Heater 1 Circuit
200
P00188 Check Heater 2 Circuit
202
P00189 Check Evaporator Fan Motor
204
P00190 Check Condenser Fan Motor
206
P00206 Check Condenser Fan Circuit
207
P00207 Check Compressor Contact Circ
207
P00208 Check Generator Contact Circ
208
P00209 Check Standby Cont Circuit
209
00223 Engine Maintenance Due
210
00224 Standby Maintenance Due
210
Engine Maintenance Due
210
Standby Maintenance Due
210
00225 General Maintenance Due
211
00226 Service Soon-Pm #1 Due
211
General Maintenance Due
211
Service Soon-Pm #1 Due
211
00227 Service Soon-Pm #2 Due
212
00228 Service Soon-Pm #3 Due
212
Service Soon-Pm #2 Due
212
Service Soon-Pm #3 Due
212
00229 Service Soon-Pm #4 Due
213
00230 Service Soon-Pm #5 Due
213
Service Soon-Pm #4 Due
213
Service Soon-Pm #5 Due
213
00232 Setpoint Error
214
00233 Model # Error
214
Model # Error
214
Setpoint Error
214
00237 Function Parameters Error
215
Function Parameters Error
215
00238 Configurations Error
216
00245 Cannot Save Setting
217
00246 Eeprom Write Failure
217
Cannot Save Setting
217
Eeprom Write Failure
217
00248 Config Mode / Hp2 Error
218
Config Mode / Hp2 Error
218
00255 Microprocessor Error
219
02000 Update Software
219
Update Software
219
02002 Low Discharge Superheat
220
Low Discharge Superheat
220
03001 Engine Load Calibration
221
Engine Load Calibration
221
04002 High Economizer Superheat
222
High Economizer Superheat
222
05005 Bad F9 Fuse
223
05006 Power Enable Relay Fuse Alarm
223
Bad F9 Fuse
223
Power Enable Relay Fuse Alarm
223
05007 Bad F3 Fuse
224
05008 Bad F10 Fuse
224
Bad F10 Fuse
224
Bad F3 Fuse
224
05009 Check Standby Contactor One (Pscon)
225
Check Standby Contactor One (Pscon)
225
05010 Check Standby Contactor Two (Pscon2)
226
Check Standby Contactor Two (Pscon2)
226
05012 Check Encu Power Circuit
227
Check Encu Power Circuit
227
05014 Check Starter Solenoid Circuit
228
05016 Check Remote Amber Light
228
Check Remote Amber Light
228
Check Starter Solenoid Circuit
228
05017 Check Eng Preheat Enable Circuit
229
Check Eng Preheat Enable Circuit
229
05018 Check Power Enable Control
230
05019 Check Cdcon2 Coil
230
Check Cdcon2 Coil
230
Check Power Enable Control
230
05020 Check Htr Cntr One
231
Check Htr Cntr One
231
05021 Check Htr Cntr Two
232
Check Htr Cntr Two
232
06000 Condenser Motor2 Overheated
233
Condenser Motor2 Overheated
233
06001 Check Light Bar
235
07000 Economizer Temp Sensor
235
Check Light Bar
235
Economizer Temp Sensor
235
07001 Economizer Press Sensor
236
07006 Suction Pressure Sensor
236
Economizer Press Sensor
236
Suction Pressure Sensor
236
20100 No Comm from Micro to Display
237
No Comm from Micro to Display
237
P11000 Check Condenser Fan Motor 2
237
P13000 Check Condenser Fan 2 Circuit
237
20101 No Comm from Micro to Remote Display
238
No Comm from Micro to Remote Display
238
21100 No Comm from any Board to Main Micro
239
22100 No Comm from Micro to Inpbd1
239
No Comm from any Board to Main Micro
239
No Comm from Micro to Inpbd1
239
22101 Sensor Input Voltage Low Inp1
240
Sensor Input Voltage Low Inp1
240
22102 Sensor Input Voltage High Inp1
241
22103 Input Lost Configuration
241
Input Lost Configuration
241
Sensor Input Voltage High Inp1
241
23100 No Comm from Micro to Outpbd1
242
23101 Output Lost Configuration
242
No Comm from Micro to Outpbd1
242
Output Lost Configuration
242
24100 No Comm from Micro to Ccb1
243
24101 Sensor Input Voltage Low Ccb1
243
No Comm from Micro to Ccb1
243
Sensor Input Voltage Low Ccb1
243
24102 Sensor Input Voltage High Ccb1
244
24200 No Comm from Micro to Ccb2
244
No Comm from Micro to Ccb2
244
Sensor Input Voltage High Ccb1
244
24201 Sensor Input Voltage Low Ccb2
245
24202 Sensor Input Voltage High Ccb2
245
Sensor Input Voltage High Ccb2
245
Sensor Input Voltage Low Ccb2
245
25100 No Comm from Micro to Stp1
246
No Comm from Micro to Stp1
246
25101 Over Current Stp1
247
25102 Check Input Voltage Stp1
247
Check Input Voltage Stp1
247
Over Current Stp1
247
25200 No Comm from Micro to Stp2
248
25201 Over Current Stp2
248
25202 Check Input Voltage Stp2
248
Check Input Voltage Stp2
248
No Comm from Micro to Stp2
248
Over Current Stp2
248
26100 No Comm from Micro to Encu
249
26101 Engine over Heat Encu
249
Engine over Heat Encu
249
No Comm from Micro to Encu
249
26102 Water Temp Low Encu
250
26103 Water Temp High Encu
250
26104 Battery Voltage High Encu
250
Battery Voltage High Encu
250
Water Temp High Encu
250
Water Temp Low Encu
250
26105 Engine Overrun Encu
251
26106 Sensor Supply Voltage 1 Low
251
Engine Overrun Encu
251
Sensor Supply Voltage 1 Low
251
26108 Rack Position Sensor Abnormal
252
26109 Actuator Abnormal Encu
252
Actuator Abnormal Encu
252
Rack Position Sensor Abnormal
252
26110 Engine Speed Sensor Abnormal
253
27200 No Comm from Micro to Comm Module
253
Engine Speed Sensor Abnormal
253
No Comm from Micro to Comm Module
253
Section 8 - Service
254
Pre-Trip Inspection
254
Scheduled Maintenance
254
Section Layout
254
Section 8 - Service
255
Table 8-1 Maintenance Schedule
256
Autofresh Fresh Air Exchange
258
Cover And/Or Cover Gaskets
258
External Surface Service
258
Figure 8.1 Automatic Fresh Air Exchange
258
Figure 8.2 Grille Insert Removal and Door Latch Maintenance
258
Grille Insert Removal
258
Solenoid
258
Cable Replacement
259
Display Module
259
Door Latch Maintenance
259
Door Latch Maintenance and Replacement
259
Figure 8.3 Surround Removal
259
Figure 8.4 Door Latch Cable Removal
259
Surround Removal
259
Engine and Engine Related Systems Service
260
Figure 8.5 Fuel System Diagram
260
Fuel System
260
Figure 8.6 Mechanical Fuel Pump
261
Figure 8.7 Electric Fuel Pump
261
Mechanical Fuel Pump Screen
261
Priming the Fuel System
261
Electric Fuel Pump Screen
262
Figure 8.8 Engine Components
262
Spin-On Fuel Filter Replacement
262
Figure 8.9 Suction Side Fuel Filter
263
Fuel Level Sensor (FLS)
263
Suction Side Fuel Filter Replacement
263
Figure 8.10 Fuel Level Sensor
264
Fuel Heater
264
Engine Oil and Oil Filter
265
Figure 8.11 Engine Oil Level
265
Figure 8.12 Oil Drain Tool
265
To Check the Engine Oil Level
265
Figure 8.13 Engine Preheater
266
Figure 8.14 Condenser and Radiator Assemblies
268
Figure 8.15 Water Pump V-Belt
268
Figure 8.16 Engine Crankcase Breather
268
Figure 8.17 Refrigeration System Service
269
Refrigerant System Service
269
Compressor Service
276
Figure 8.18 Compressor Kit
276
Figure 8.19 Compressor Plug Retaining Clip
276
Refrigerant System Component Service
277
Figure 8.20 Condenser/Radiator Assembly
279
Figure 8.21 Economizer Section
280
Figure 8.22 Suction Modulation Valve
281
Figure 8.23 CSMV Coil
281
Figure 8.24 Evaporator Expansion Valve
282
Table 8-2 Expansion Valve Connections
282
Figure 8.25 Evaporator Expansion Valve
283
Figure 8.26 Solenoid Valve
284
Figure 8.27 Testing High Pressure Switch
285
Figure 8.28 Defrost Air Switch Test Setup
286
Electrical System Component Service
287
Figure 8.29 Power Control Module
287
Figure 8.30 CCB Location in Control Box
289
Figure 8.31 CCB Location in Control Box
289
Figure 8.32 Meghommeter Connection to Ground Plate
290
Figure 8.33 Light Bar Connections
291
Figure 8.34 Overload Ground Fault Connections
291
Figure 8.35 Evaporator Blower Assembly
293
Figure 8.36 Condenser Fan Assembly
294
Figure 8.37 Generator / Unidrive Assembly
295
Figure 8.38 Exhaust Connection Disassembly
296
Figure 8.39 Support Tool Secured, Bottom View
296
Figure 8.40 Flywheel Locking Tool
296
Figure 8.41 Generator, Flywheel View
297
Figure 8.42 Guide Rod Installation
297
Figure 8.43 Generator Lifting Tool Installation
297
Figure 8.44 Generator Wires
298
Figure 8.45 Generator/Harness Wire Connections
298
Figure 8.46 Positive Starter Wire Installation
299
Figure 8.47 Compressor Discharge Temperature Sensor
299
Table 8-3 Sensor Resistance
300
Table 8-4 Sensor Resistance (CDTS)
301
Table 8-5 Temperature Pressure Chart
302
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Carrier TRANSICOLD Vector 8500 Specifications
General
Brand
Carrier TRANSICOLD
Model
Vector 8500
Category
Automobile Accessories
Language
English
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