Carrier PrimeLINE - Troubleshooting

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6–1 T-362

SECTION 6

TROUBLESHOOTING

Figure 6.1 Unit Troubleshooting Sequence

Start

Troubleshooting

Unit

configured

correctly?

Pass

Pre-trip

inspection?

Active

Alarms?

Correct

software

version?

Did

Evaporator

fans start?

Operating

pressures

normal?

Check Power

Supply

Install Latest

Software

Revision

Load correct

unit

configuration

See alarm

details &

repair

Correct

all faults

Yes

Correct

Refrigerant

issue

Unit OK

Yes

Refer to Connect Power Procedure

Refer to Controller Software Section

Refer to Configuration Software (Variables)

Refer to Controller Alarm Indications

Refer to Pre-Trip Diagnostics

Refer to Refrigeration Service

Check Power

Supply

Unit does

self test?

Section 5.2

Section 4.2.1

Section 4.4

Section 4.5

Section 7.3

Section 4.2

Main Page

Table of Contents4
Description23
3.1 General Description23
Refrigeration Unit - Front Section23
Figure 3.1 Refrigeration Unit - Front Section23
Compressor Section24
Air-Cooled Condenser Section24
Figure 3.2 Compressor Section24
Figure 3.3 Condenser Section with "C" Shape Coil (Pids < NT3000)25
Figure 3.4 Condenser Section, with MCHE and Steel Receiver (Pids NT3000 to NT3099)26
Figure 3.5 Condenser Section, with MCHE and Aluminum Receiver (Pids > NT3100)27
Water-Cooled Condenser Section28
Figure 3.6 Tube in Shell Water-Cooled Condenser28
Fresh Air Makeup Vent29
Evaporator Section29
Figure 3.7 Brazed Plate Water-Cooled Condenser29
Figure 3.8 Evaporator Section30
Figure 3.9 Evaporator Section - Primeline ONE31
Control Box Section32
Communications Interface Module32
Figure 3.10 Control Box Section32
3.2 Refrigeration System Data33
Table 3-1 Refrigeration System Data33
3.3 Electrical Data34
Table 3-2 Electrical Data34
3.4 Safety and Protective Devices35
Electronic Expansion Valve (EEV)35
Table 3-3 Safety and Protective Devices35
Figure 3.11 Refrigeration Circuit Schematic - Standard Operation37
Figure 3.12 Refrigeration Circuit Schematic - Economized Operation38
Figure 3.13 Refrigeration Circuit Schematic - Water-Cooled Condenser (Tube in Shell)39
Figure 3.14 Refrigeration Circuit Schematic - Water-Cooled Condenser (Brazed Plate)40
Microprocessor41
4.1 Temperature Control Microprocessor System41
Controller41
Display Module and Keypad41
Figure 4.1 Controller41
Figure 4.2 Display Module and Keypad41
Table 4-1 Display Module Leds42
Table 4-2 Keypad Function42
4.2 Controller Software43
Configuration Software (Cnf Variables)43
Table 4-3 Controller Configuration Variables43
Operational Software (CD Function Codes)44
Table 4-4 Controller Function Codes45
4.3 Modes of Operation59
Start up - Compressor Phase Sequence59
Start up - Compressor Bump Start59
Perishable Mode Temperature Control59
Perishable Pulldown59
Perishable Steady State59
Perishable Idle, Air Circulation59
Perishable Heating60
Perishable Dehumidification60
Figure 4.3 Controller Operation - Perishable Mode60
Perishable Dehumidification - Bulb Mode61
Perishable Economy61
Perishable Mode Cooling - Sequence of Operation62
Figure 4.4 Perishable Mode Cooling62
Perishable Mode Heating - Sequence of Operation63
Perishable Mode - Trim Heat63
Frozen Mode - Temperature Control63
Frozen Steady State63
Figure 4.5 Perishable Mode Heating63
Frozen Idle Mode64
Frozen "Heat" Mode64
Frozen Economy Mode64
Frozen Mode Cooling - Sequence of Operation64
Figure 4.6 Controller Operation - Frozen Mode64
Defrost65
Figure 4.7 Frozen Mode65
Defrost Operation66
Defrost Related Settings67
Figure 4.8 Defrost67
Protection Modes of Operation68
QUEST Mode68
4.4 Controller Alarms69
Table 4-5 Alarm Indications and Descriptions70
4.5 Pre-Trip Diagnostics82
Controller Pre-Trip Test Codes82
Table 4-6 Controller Pre-Trip Test Codes82
4.6 Datacorder88
Datacorder Description88
Datacorder Configuration Software89
Table 4-7 Datacorder Configuration Variables89
Table 4-8 Sensor Configuration90
Datacorder Operational Software91
Table 4-9 Datacorder Function Code Assignments92
Datacorder Power up93
Datacorder Alarms93
Table 4-10 Datacorder Alarm Indications94
Pre-Trip Data Recording95
Table 4-11 Datacorder Pre-Trip Result Records95
Datacorder Communications96
USDA Cold Treatment97
Figure 4.9 Datacorder Configuration Screen97
Figure 4.10 Datacorder Probe Calibration Screen98
ISO Trip Header99
Figure 4.11 Datacorder Probe Calibration Screen99
Figure 4.12 Datacorder Systems Tool Screen99
Operation101
5.1 Inspection101
5.2 Connect Power101
Connecting to 380/460 VAC Power101
Connecting to 190/230 VAC Power101
5.3 Adjust Fresh Air Makeup Vent102
Upper Fresh Air Makeup Vent102
Figure 5.1 Autotransformer102
Lower Fresh Air Makeup Vent103
Figure 5.2 Upper Fresh Air Make up Flow Chart103
Vent Position Sensor104
5.4 Connect Water-Cooled Condenser104
Water-Cooled Condenser with Water Pressure Switch104
Water-Cooled Condenser with Condenser Fan Switch104
5.5 Connect Remote Monitoring Receptacle105
5.6 Starting and Stopping Instructions105
Starting the Unit105
Stopping the Unit105
5.7 Start-Up Inspection105
Physical Inspection105
Check Controller Function Codes105
Start Temperature Recorder105
Complete Inspection105
5.8 Pre-Trip Diagnosis106
Prior to Starting a Pre-Trip106
Starting a Pre-Trip106
Displaying Pre-Trip Test Results107
5.9 Probe Diagnostics107
5.10 Optional Operating Modes108
Emergency Bypass Operation108
Tripwise109
Figure 5.3 Diagram of Emergency Bypass Connections109
Figure 5.4 Tripwise Status in Datacorder110
Xtendfresh111
Figure 5.5 Generating Tripwise Summary Report111
Automatic Cold Treatment Mode112
Automatic Setpoint Change Mode113
Quest Mode114
Fuelwise Mode114
Figure 6.1 Unit Troubleshooting Sequence115
Microprocessor Malfunction119
6.10 no Evaporator Air Flow or Restricted Air Flow119
6.11 Xtendfresh Not Operating119
6.12 Electronic Expansion Valve Malfunction119
6.13 Autotransformer Malfunction120
6.14 Water-Cooled Condenser or Water Pressure Switch120
Compressor Operating in Reverse120
Abnormal Temperatures120
Abnormal Currents120
Service121
Section Layout121
Manifold Gauge Set121
Figure 7.1 Manifold Gauge Set121
Evacuating the Manifold Gauge Set122
Service Connections122
Figure 7.2 Manifold Gauge / Hose Set122
Connecting the Manifold Gauge Set123
Removing the Manifold Gauge Set123
Pump down the Unit123
Figure 7.3 Service Valve123
Automatic Pump down124
Manual Pump down124
Refrigerant Leak Checking124
Evacuation and Dehydration125
General125
Preparation125
Evacuate and Dehydrate - Complete System125
Figure 7.4 Refrigeration System Service Connections125
Evacuate and Dehydrate - Partial System126
Checking the Refrigerant Charge126
Adding Refrigerant to System - Full Charge127
Adding Refrigerant to System - Partial Charge127
Converting to R-513A Refrigerant127
Compressor128
Removing and Replacing the Compressor128
Figure 7.5 Compressor Kit129
7.10 High Pressure Switch130
Checking High Pressure Switch130
Figure 7.6 High Pressure Switch Testing130
Replacing High Pressure Switch131
7.11 Condenser Coil131
Condenser Coil Cleaning131
Condenser Coil Removal131
Condenser Coil Preparation132
Figure 7.7 Condenser Fan Position133
Figure 7.8 Water-Cooled Condenser Cleaning - Forced Circulation139
Figure 7.9 Water-Cooled Condenser Cleaning - Gravity Circulation140
Figure 7.10 Heater Arrangement141
Figure 7.11 Evaporator Fan Assembly144
Figure 7.12 Access Panel Torque Pattern145
Figure 7.13 Electronic Expansion Valve (EEV)146
Figure 7.14 Coil View of Economizer Solenoid Valve (ESV)149
Figure 7.15 Economizer Expansion Valve150
Figure 7.16 Adapter and O-Ring151
Figure 7.17 View of Digital Unloader Valve (DUV) Assembly152
Table 7-1 Valve Override Control Displays153
Figure 7.18 Autotransformer154
Figure 7.19 Controller155
Table 7-2 Test Point Descriptions155
Table 7-3 Sensor Resistance - AMBS, DTS, ETS, RRS, RTS, SRS, STS162
Table 7-4 Sensor Resistance - Primeline CPDS163
Figure 7.20 Supply Sensors - Cover Assembly and Sensors164
Figure 7.21 Removing Front Access Panels165
Figure 7.22 Removing Evaporator Motor165
Figure 7.23 Return Sensors - Bracket165
Figure 7.24 Return Sensors - Cutting Wire Ties166
Figure 7.25 Dataline - Probe Calibration166
Figure 7.26 Dataline - Calibrate Sensors Button167
Figure 7.27 Dataline - Enter Service Center Information167
Figure 7.28 Ice Bath168
Figure 7.29 Dataline - Start Cal Button168
Figure 7.30 Dataline - Calibration Results169
Figure 7.31 Sensor Types170
Figure 7.32 Sensor and Cable Splice170
Figure 7.33 STS/SRS Positioning171
Figure 7.34 RRS/RTS Positioning171
Figure 7.35 ETS1/ETS2 Positioning172
Figure 7.36 Compressor Discharge Temperature Sensor172
Figure 7.37 Communications Interface Installation174
Table 7-5 R-134A Refrigerant Pressure Temperature Chart175
Table 7-6 R-513A Refrigerant Pressure Temperature Chart178
Table 7-7 Recommended Bolt Torque Values (Dry, Non-Lubricated for 18-8 Stainless Steel)181
Figure 8.1 LEGEND - Standard Unit Configuration183
Figure 8.2 Schematic Diagram184
Figure 8.3 Unit Wiring Diagram (Sheet 1 of 2)185
Figure 8.4 Unit Wiring Diagram (Sheet 2 of 2)186
Figure 8.5 Legend - Unit with Auto Transformer187
Figure 8.6 Schematic Diagram - Unit with Auto Transformer188
Figure 8.7 Unit Wiring Diagram - Unit with Auto Transformer (Sheet 1 of 2)189
Figure 8.8 Unit Wiring Diagram - Unit with Auto Transformer (Sheet 2 of 2)190

Carrier PrimeLINE - Troubleshooting

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