TRANSICOLD

Electra
NEE-43/44

62-10426
 OPERATION AND
SERVICE MANUAL
TRAILER REFRIGERATION UNIT

Electra
NEE-43/44

Carrier Refrigeration Operations

Carrier Transicold Division, Carrier Corporation, P.O. Box 4805, Syracuse, N.Y. 13221 U. S. A.
Carrier Transicold E.T.O. Boite Postale Nr. 16 Franqueville --- Saint--- Pierre 76520 Boos, FRANCE
ã Carrier Corporation 2000 D Printed in U. S. A. 0500
 TABLE OF CONTENTS
SECTION Page

1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 COMPRESSOR DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.3 REFRIGERATION SYSTEM DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4 ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.5 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.6 TEMPERATURE CONTROLLER AND SOLID STATE CONTROL SYSTEM . 1-8
1.7 OPERATING CONTROLS AND INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.8 COMPRESSOR UNLOADERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.9 REFRIGERANT CIRCUIT DURING COOLING . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.10 REFRIGERANT CIRCUIT DURING HEATING AND DEFROSTING . . . . . . . 1-14
2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 PRE-START-UP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 STARTING AND STOPPING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 AFTER STARTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.4 CONTROL CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4.1 Cooling -- Setpoint ABOVE +10_F (--12.2_C) . . . . . . . . . . . . . . . . . . . . 2-2
2.4.2 Cooling -- Setpoint BELOW +10_F (--12.2_C) . . . . . . . . . . . . . . . . . . . . 2-2
2.4.3 Heating (Hot Gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4.4 Electric Heating -- Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.4.5 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 UNIT WILL NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 UNIT STARTS THEN STOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 UNIT WILL NOT COOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.4 UNIT RUNS BUT HAS INSUFFICIENT COOLING . . . . . . . . . . . . . . . . . . . . . . 3-1
3.5 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING . . . . . . . . . . . . 3-1
3.6 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING . . . . . . . . . . . . . 3-2
3.7 DEFROST CYCLE MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.8 ABNORMAL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.8.1 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.8.2 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.9 ABNORMAL NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.10 CONTROL SYSTEM MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.11 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW . . . . . . . . . . . . 3-4
3.12 EXPANSION VALVE MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.13 SOLENOID VALVE MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.14 SOLID STATE CONTROL SYSTEM MALFUNCTION . . . . . . . . . . . . . . . . . . . 3-5
3.15 DIODE MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

i
 TABLE OF CONTENTS (CONT’D)

SECTION Page

4 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 PUMPING THE UNIT DOWN OR
REMOVING THE REFRIGERANT CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 REFRIGERANT LEAK CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 EVACUATION AND DEHYDRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3.3 Procedure for Evacuation and Dehydrating System . . . . . . . . . . . . . . . . 4-2
4.4 ADDING REFRIGERANT TO SYSTEM (FULL CHARGE) . . . . . . . . . . . . . . . . 4-4
4.5 ADDING REFRIGERANT TO SYSTEM (PARTIAL CHARGE) -- R-22 ONLY . 4-4
4.6 REPLACING THE COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.7 CHECKING COMPRESSOR OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.8 COMPRESSOR UNLOADER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.9 SERVICING THE CHECK VALVE -- SERVICEABLE TYPE . . . . . . . . . . . . . . . 4-9
4.10 CHECKING AND REPLACING FILTER-DRIER . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.11 CHECKING AND REPLACING HIGH PRESSURE CUTOUT SWITCHES . . . 4-9
4.11.1 Replacing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.11.2 Checking High Pressure Switch (HP-1 or HP-2) . . . . . . . . . . . . . . . . . . . . 4-10
4.12 REPLACING RECEIVER SIGHT GLASS ASSEMBLY . . . . . . . . . . . . . . . . . . . 4-10
4.13 SERVICING SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.13.1 Solenoid Valves -- Alco SV2/SV3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.13.2 Solenoid Valve -- Sporlan SV1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.14 SOLENOID VALVE SV-1 CHECKOUT PROCEDURE . . . . . . . . . . . . . . . . . . . . 4-13
4.15 CHECKING DEFROST OR HEATING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.16 CHECKING CALIBRATION OF THE DEFROST AIR SWITCH . . . . . . . . . . . . 4-14
4.17 REPLACING THE CONDENSER or EVAPORATOR FAN and MOTOR . . . . . . 4-15
4.18 EVAPORATOR COIL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.19 CONDENSER COIL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.20 THERMOSTATIC EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.21 SERVICING THE SOLID STATE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . 4-18
4.21.1 Unit Checkout Procedure With Test Meter (TCSM) . . . . . . . . . . . . . . . . . . 4-18
4.21.2 Checking and Removing Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.21.3 Checking Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.21.4 Diode Board Checkout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.21.5 Checking Out the Temperature Controller and Diodes . . . . . . . . . . . . . . . . 4-23
4.22 CHECKING THE RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4.23 CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4.24 THERMOMETER CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

ii
 LIST OF ILLUSTRATIONS

FIGURE Page
1-1 Curbside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-2 Roadside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-3 Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1-4 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1-5 Solid State Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-6 Compressor Cylinder Head Unloaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1-7 Compressor Cylinder Head Loaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1-8 R-404A Refrigerant Circuit -- Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1-9 R-22 Refrigerant Circuit -- Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1-10 R-404A Refrigerant Circuit -- Heating and Defrosting . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1-11 R-22 Refrigerant Circuit -- Heating and Defrosting . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

2-1 Temperature Controller Operating Sequence Controller

Set Point ABOVE +10_F (--12_C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-2 Temperature Controller Operating Sequence Controller
Set Point BELOW +10_F (--12_C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

4-1 Vacuum Pump Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4-2 Pressure Switches HP-1 and HP-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-3 Compressor -- Model 06DR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-4 Unloader Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4-5 Check Valve -- Serviceable Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-6 Typical Setup for Testing High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4-7 Solenoid Valves -- Alco SV2 & SV3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4-8 Solenoid Valves -- Sporlan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-9 Defrost Air Switch Test Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4-10 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4-11 Solid State Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-12 Temperature Controller Simulator Module (TCSM) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-13 Relay Circuit Diagram (Shown in De-energized Position) . . . . . . . . . . . . . . . . . . . . . . 4-22
4-14 Diode Board Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-15 Module Tester -- Spectrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-16 Checking Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

LIST OF TABLES
TABLE Page
1-1 Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

4-1 Selector Settings and Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-2 Sensor Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4-3 R-22 Pressure -- Temperature Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4-4 R-404A Temperature--Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

iii
 9
Section 1 - Description

1.1 INTRODUCTION
WARNING: Beware of rotating fan blades and unannounced starting of fans.

Table 1-1. Model Chart

Voltage
Model Refrigerant
Standard Optional
Electra NEE-43 R-404A
190/230 Vac 3ph 50/60hz 380/460 Vac 3ph 50/60hz
Electra NEE-44 R-22

This manual contains Operating Data, Electrical Data and Service Instructions for the refrigeration units
listed in Table 1-1.
The Electra is all electric, one piece, self-contained, fully charged, pre-wired, refrigeration/heating unit for
use on insulated trailers or warehouse applications to maintain cargo temperatures within very close limits.
The model/serial number plate is located on the lower left side of the unit as shown in Figure 1-1.
Units used on warehouse applications are offered with an extended evaporator for a wall thickness up to
sixteen (16) inches (0.46m).
Control power is provided by a single phase transformer which steps down the power source to
approximately 15/17 v-ac. A single phase, full--wave bridge rectifier converts the A.C. voltage to nominal
12 v-dc control power.
The evaporator section and condensing section are permanently connected together by means of an insulated
bulkhead. The evaporator and insulated bulkhead fit into a rectangular opening in the upper portion of the
front wall of the trailer. When installed, the evaporator section is located inside the trailer; the insulated
bulkhead is flush with the front wall of the trailer; and the condensing section is outside and on the front of
the trailer.
The condensing unit consists of a compressor, condenser fan and motor, condenser coil, instrument panel,
refrigerant controls, piping, wiring, and associated components. The evaporator assembly consists of an
evaporator coil, evaporator fan and motor, heat exchanger, expansion valve, two defrost thermostats
(termination switches), defrost air switch, drain pan and drain hoses. Optional electric heaters along with a
heat termination switch may also be installed in the evaporator.
The temperature controller is a Carrier Transicold solid state non-indicating type, controller. (Refer to
Section 1.6). Once the temperature controller is set at desired container temperature, the unit will operate
automatically to maintain the desired temperature within very close limits. The control system
automatically selects cooling, holding or heating as necessary to maintain the desired temperature within the
trailer.
The control box and panel assembly includes manual switches, indicator lights, temperature selector gauges,
fuse (5A), rectifier, capacitor, control transformer, compressor contactor, running time meter and a
mechanical thermometer.
The refrigeration compressor used is a Carrier Model 06DR. The compressor may be equipped with
unloader (Optional). Unloader is used as a compressor capacity control to unload the compressor during
periods of reduced loads. This provides closer temperature control, reduces potential for top freezing and
reduces power required to operate the compressor; thus greatly reducing power consumption.
The compressor is equipped with two external overload protectors and one internal protector.

1-1 62-10426
 Section 1 - Description

1. Serial/Model No. Plate

2. Compressor
3. Discharge Service Valve
4. Discharge Line Check Valve
5. Condenser Coil
6. Liquid Line Solenoid Valve (SV-2)
7. Evaporator Fan and Motor
8. Condenser Fan and Motor
9. Hot Gas Solenoid Valve (SV-3)

Figure 1-1. Curbside

62-10426 1-2
 9
Section 1 - Description

1.Control Panel (See Figure 1-4)

2.Filter-Drier
3.Controller Bulb
4.Thermometer Bulb
5.Expansion Valve
6.Defrost Thermostats (DT)
7.Defrost Air Switch
8.Condenser Pressure Control Valve
9.Bypass Line Check Valve
10.Receiver Sight Glass
11. Receiver Manual Outlet Valve

Figure 1-2. Roadside

1-3 62-10426
 Section 1 - Description

1.Head Pressure Control and High Pressure Cutout Switch

2.Discharge Service Valve
3.Compressor
4.Compressor Sight Glass
5.Suction Service Valve
6.Compressor Overload Relay

Figure 1-3. Front View

62-10426 1-4
 9
Section 1 - Description

5
9
6
7

14 13 12 11
10

1. Suction Gauge 2. Running Time Meter (RTM)

3. Thermometer 4. Temperature Selector
5. Power Light (PL) -- White 6. Defrost Light (DL) -- Amber
7. Heat Light (HL) -- Amber 8. Cool Light (CL) -- White
9. Circuit Breaker 10. Power Receptacle
11. Defrost Test Points 12. Start-Stop Switch (ST)
13. Manual DEfrost Switch (MDS) 14. Electric Heat Switch (EHS) -- Optional

Figure 1-4. Control Panel

1-5 62-10426
 Section 1 - Description

1.2 COMPRESSOR DATA

Compressor Models 06DR
No. Cylinders 6
No. Unloaders 2
Weight 122 kg (270 lbs)
Oil Charge 3.6 L (7.6 pints)

APPROVED COMPRESSOR OIL

Refrigerant Oil
Zerol 150
R-22 (synthetic)
P/N 07-00274
R-404A Mobil Arctic EAL 68

1.3 REFRIGERATION SYSTEM DATA

Refrigeration Charge
Model Refrigeration Charge LB Charge KG
NEE-43 R-404A 28 12.7
NEE-44 R-22 28 12.7

Defrost Air Switch (DA) Initiates Defrost: 1.40 (¦ .07) inch (35 ¦ 1.8 mm) WG
Defrost Termination Temp. (DT) Opens: 55 ¦ 5_F (12 ¦ 3_C)
Closes: 40 ¦ 5_F (4.4 ¦ 3_C)
Defrost Timer 1-1/2, 3, 6, or 12 hours
Expansion Valve Superheat Setting: 8 to 10_F (4.4 to 5.6_C)
Setting at 0_F (--17.8_C) box temperature:
Fusible Plug Setting 208 to 220_F (97.8_ to 104.4_C)
High Pressure Switch (HP1) Model NEE-43 (R404A)
Cutout: 465 ¦ 10 psig (32.7 ¦ 0.7 kg/cm@)
Cut-in: 350 ¦ 10 psig (24.6 ¦ 0.7 kg/cm@)
Model NEE-44 (R22)
Cutout: 428 ¦ 10 psig (30 ¦ 0.7 kg/cm@)
Cut-in: 320 ¦ 10 psig (22.5 ¦ 0.7 kg/cm@)
Head Pressure Control Switch (HP2) Cutout: 350 ¦ 10 psig (24.6 ¦ 0.7 kg/cm@)
Cut-in: 290 ¦ 10 psig (20.4 ¦ 0.7 kg/cm@)
High Temperature Termination Opens: 150 ¦ 5_F (79.4 ¦ 3_C)
Closes: 120 ¦ 5_F (48.9 ¦ 3_C)
Unit Weights (Approximate) 800 lb. (363 kg)

62-10426 1-6
 9
Section 1 - Description

1.4 ELECTRICAL DATA

CB1 Trips at 20 amps
Circuit Breaker 230V -- 50 amps Manual Reset
CB Trips at
460V -- 25 amps Manual Reset
108 amps @ 460 vac
Compressor Motor Locked Load Amps (LRA)
215 amps @ 230 vac
Voltage 230 Vac or 460 Vac, 3 Phase, 50/60 hz
Full Load Amps 3.4/4.6 amps for 230V or 1.7/2.3 for 460 V
Condenser and Horsepower 1 hp
Evaporator
p Fan Speed 1725 rpm
Motors Bearing Lubrication Factory lubricated, additional grease not required.
Rotation Evaporator Motor Counter-clockwise when viewed from shaft end.
Rotation Condenser Motor Clockwise when viewed from shaft end.
Number of Heaters 1
Drain Pan Heaters Rating 400 watts at 230 volts, 1 phase, 60 hertz
Type Band
Number of Heaters 3
1000 watts each @ 240 volts, 1 phase, 60 hertz
Evaporator Coil
Rating or
Heaters 2800 watts each @ 240 volts, 1 phase, 60 hertz
Type Strip
Control Circuit 5 amps (F)
Fuse
Compressor Contactor 2 amps (F2)

1.5 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 1-2.
Table 1-2. Safety Devices
Unsafe Conditions Safety Device Device Setting
Excessive current draw on control transformer Fuse (F) Opens at 5 amps
Excessive current draw on compressor Fuse (F2) Opens at 2 amps
contactor
Excessive current draw on control circuit Circuit Breaker (CB1) Opens at 20 amps
(Automatic Reset)
Excessive compressor motor winding Internal Protector (IPC)
temperature (Automatic Reset)
Excessive compressor motor load current Overload Relays (EPA & EPC) Opens at 347_F (175_C)
(Automatic Reset) Closes at 216_F (102_C)
Excessive condenser fan motor winding Internal Protector (COL)
temperature (Automatic Reset)
Excessive evaporator fan motor winding Internal Protector (EOL)
temperature (Automatic Reset)
Excessive compressor High pressure cutout switch Refer to section 1.3.
discharge pressure (HP-1) automatic reset
Excessive current draw Circuit Breaker (CB) Trips at 50 amps 230V
(Manual Reset) Trips at 25 amps 460V

1-7 62-10426
 Section 1 - Description

1.6 TEMPERATURE CONTROLLER AND SOLID STATE CONTROL SYSTEM

The solid state control system provides an automatic, reliable and a virtually maintenance free system to
control the desired trailer temperature between --20_ and +80_F (28.9 to +26.7_C).

1. Circuit Breaker
2. Run Relay
3. Control Board
4. Temperature Controller Module(TCM)
5. Defrost Relay
6. Heat Relay
7. Diode Assembly
8. Unloader (Speed) Relay

Figure 1-5. Solid State Control System

The control system includes the solid state controller, control board, diode board assembly, circuit breaker,
evaporator fan motor relay (ER), Unloader relay, heat relay (HR) and defrost relay (DR).
The temperature controller consists of: (1) the temperature selector which is a potentiometer (variable
resistor) located on the control panel, (2) the temperature control module which consists of a printed circuit
board and semiconductor devices which are located in the control box, and (3) temperature control sensor
which is located in the evaporator section. The electrical resistance of the sensor changes with temperature
changes.

62-10426 1-8
 9
Section 1 - Description

1.7 OPERATING CONTROLS AND INSTRUMENTS

a. Indicating Lights
S Cool Light (White) illuminated -- indicates unit in cooling mode.
S Defrost Light (Amber) illuminated -- indicates unit in defrost mode. When the unit is in defrost, the heat
light will also be illuminated.
S Heat Light (Amber) illuminated -- indicates unit in heating mode.
S Out-of-Range Light Optional (White) illuminated -- indicates that the box temperature is more than 5_F
(2.8_C) above or below set point..
S Power Light (White) illuminated -- indicates power on.
b. Meter, Running Time (RTM)
This meter designates the total hours and provides an accurate readout of accumulated running time. This
data can be used to establish the proper periodic maintenance schedule.
c. Suction Pressure Gauge
The suction pressure gauge line is connected to the compressor. The purpose of this gauge is used as an
indicator of system operation.
d. Switches
S Electric Heat Switch (Optional) When this switch is placed in the HEAT position, the unit will heat by
electric heat only.
S Manual Defrost Switch (MDS) The manual defrost switch (momentary contact), when held in the DOWN
position is provided so that the system may be placed in the defrost mode manually by the operator. When
this switch is closed, the unit will defrost in the same manner as when on automatic defrost. (Refer to
paragraphs 2.5.4 and 2.6.3.)
S Start--Stop Switch (ST) This switch is a two position switch, START and STOP. With the switch in the
START position, power is supplied to the controls. The switch must be moved manually to the STOP
position.
e. Defrost Timer -- Solid State -- Optional
This timer, located in the control box, is factory set to initiate defrost at 6 hours. The timer includes optional
settings of 1--1/2, 3 or 12 hours which are clearly marked on the solid state printed circuit board. To change
settings, remove wire from the six hour pin and place wire on desired defrost initiation time.
To test defrost circuitry, place jumper wire across the two studs (TP1 and TP2). These two studs are located
on the control box.
The defrost timer will automatically terminate defrost after a maximum of 45 minutes, thus preventing a
“stuck in defrost” condition due to a shorted “Klixon”, loss of freon, or a SV-1 malfunction.
The defrost timer also prevents cycling on defrost by providing minimum of 45 minutes between defrost
cycles.
A pretrip test pin of 84 seconds is provided to quickly test the time function.
CAUTION: Three small wires labeled TP-1, TP-2, and TP-3 are located on the timer. These are
used by the vendor for final test and should not be touched in the field or timer failure may occur.
DO NOT hot wire, ground, or short across these test points.

f. Recycling Delay Timer (RDT)

The purpose of this timer is to prevent short cycling of the compressor. The Recycling Delay Timer ensures a
minimum five minute delay before the compressor restarts.

1-9 62-10426
 Section 1 - Description

1.8 COMPRESSOR UNLOADERS

a. Major Working Parts
1. Solenoid and valve system
2. Spring loaded piston type bypass control valve
3. Spring loaded discharge check valve
b. Unloaded Operation
Pressure from the discharge manifold (Figure 1-6, item 15) passes through the strainer (9) and bleed orifice
(8) to the back of the piston bypass valve (7). Unless bled away, this pressure would tend to close the piston
(6) against the piston spring (5) pressure.
With the solenoid valve (1) energized the solenoid valve stem (2) will open the gas bypass port (3).
Refrigerant pressure will be bled to the suction manifold (10) through the opened gas bypass port . A reduction in
pressure on the piston bypass valve will take place because the rate of bleed through the gas bypass port is
greater than the rate of bleed through the bleed orifice (8).
When the pressure behind the piston has been reduced sufficiently, the valve spring will force the piston
bypass valve back, opening the gas bypass from the discharge manifold to the suction manifold.
Discharge pressure in the discharge manifold will close the discharge piston check valve assembly (14)
isolating the compressor discharge manifold from the individual cylinder bank manifold.
The unloaded cylinder bank will continue to operate fully unloaded until the solenoid valve control device is
de-energized and the gas bypass port is closed.
4
5 7 11
2 3 6

1
10

12
8

9 13

14

15

1. Solenoid Valve 9. Strainer

2. Valve Stem 10. Suction Manifold
3. Gas Bypass Port 11. Cylinder Discharge Valve
4. Spring Guide 12. Valve Plate
5. Spring 13. Cylinder Suction Valve
6. Piston 14. Discharge Piston Check Valve Assembly
7. Piston Bypass Valve 15. Discharge Manifold
8. Bleed Orifice
Figure 1-6. Compressor Cylinder Head Unloaded

62-10426 1-10
 9
Section 1 - Description

c. Loaded Operation
Discharge pressure bleeds from the discharge manifold (Figure 1-7, item 15) through the strainer (9) and (8)
bleed orifice to the solenoid valve stem (2) chamber and the back of the piston bypass valve (7).
With the solenoid valve (1) de-energized the solenoid valve stem will close the gas bypass port (3).
Refrigerant pressure will overcome the bypass valve spring (5) tension and force the piston (6) forward
closing the gas bypass from the discharge manifold to the suction manifold (10).
Cylinder discharge pressure will force open the discharge piston check valve assembly (14). Refrigerant gas
will pass into the compressor discharge manifold.
The loaded cylinder bank will continue to operate fully loaded until the solenoid valve control device is
energized and the gas bypass port is opened.
4
5 7 11
2 3 6

1
10

8 12

9 13

14

15

1. Solenoid Valve 9. Strainer

2. Valve Stem 10. Suction Manifold
3. Gas Bypass Port 11. Cylinder Discharge Valve
4. Spring Guide 12. Valve Plate
5. Spring 13. Cylinder Suction Valve
6. Piston 14. Discharge Piston Check Valve Assembly
7. Piston Bypass Valve 15. Discharge Manifold
8. Bleed Orifice

Figure 1-7. Compressor Cylinder Head Loaded

1-11 62-10426
 Section 1 - Description

1.9 REFRIGERANT CIRCUIT DURING COOLING

(See Figure 1-8 or Figure 1-9)
When cooling, the unit operates as a vapor compression refrigeration system. The main components of the
system are the (1) reciprocating compressor, (2) air-cooled condenser, (3) expansion valve, and (4) direct
expansion evaporator.
The compressor raises the pressure and the temperature of the refrigerant and forces it into the condenser
tubes. The condenser fan circulates surrounding air over the outside of the condenser tubes. The tubes have
fins designed to improve the transfer of heat from the refrigerant gas to the air. This removal of heat causes
the refrigerant to liquefy; thus liquid refrigerant leaves the condenser and flows through the solenoid valve
SV-1 (normally open) and to the receiver.
The receiver stores the additional charge necessary for low ambient operation. The receiver is equipped with
a fusible plug which melts if the refrigerant temperature is abnormally high and releases the refrigerant
charge.
The refrigerant leaves the receiver and flows through the manual receiver shutoff valve (King valve). The
refrigerant then flows through the subcooler. The subcooler occupies a portion of the main condensing coil
surface and gives off further heat to the passing air.
The refrigerant then flows through a filter-drier where an absorbent keeps the refrigerant clean and dry; and
the electrically controlled liquid line solenoid valve (SV-2) which starts or stops the flow of liquid
refrigerant.
In R-404A units the refrigerant flows to the “Liquid/suction” heat exchanger. Here the liquid is further
reduced in temperature by giving off some of its heat to the suction gas.
The liquid then flows to an externally equalized thermostatic expansion valve which reduces the pressure of
the liquid and meters the flow of liquid refrigerant to the evaporator to obtain maximum use of the
evaporator heat transfer surface.
The refrigerant pressure drop caused by the expansion valve is accompanied by a drop in temperature; thus,
the low pressure, low temperature fluid that flows into the evaporator tubes is colder than the air that is
circulated over the evaporator tubes by the evaporator fan. The evaporator tubes have aluminum fins to
increase heat transfer; therefore heat is removed from the air circulated over the evaporator. This cold air is
circulated throughout the trailer to maintain the cargo at the desired temperature.
The transfer of heat from the air to the low temperature liquid refrigerant causes the liquid to vaporize. In
R-22 units this low temperature, low pressure vapor returns to the compressor.
In R-404A units this low temperature, low pressure vapor passes through the “suction line/liquid line” heat
exchanger where it absorbs more heat from the high pressure/high temperature liquid and then returns to the
compressor.
The quench valve (R-22 Only) opens as required to maintain a 245 to 285_F (118 to 141_C) maximum
discharge temperature.

62-10426 1-12
 9
Section 1 - Description

FUSIBLE PLUG
HOT GAS
EXTERNAL EQUALIZER EXPANSION VALVE
BYPASS LINE
EXPANSION
VALVE SHUT-OFF
BULB VALVE
RECEIVER

EVAPORATOR
BYPASS
CHECK
HEAT EXCHANGER VALVE

LIQUID LINE LIQUID

SOLENOID
HOT GAS VALVE (SV2), NC
LINE
DISCHARGE FILTER
SERVICE HP-2 HP-1 DRIER
SUBCOOLER
VALVE
HOT GAS
SOLENOID
(SV3), NC

CONDENSER
SUCTION SERVICE PRESSURE
VALVE CONTROL
SOLENOID
DISCHARGE (SV1), NO
CHECK VALVE
COMPRESSOR
CONDENSER

Figure 1-8. R-404A Refrigerant Circuit -- Cooling

FUSIBLE PLUG
EXTERNAL EQUALIZER EXPANSION VALVE

EXPANSION SHUT-OFF
VALVE BULB VALVE
RECEIVER

SUCTION LINE EVAPORATOR BYPASS

CHECK
VALVE
LIQUID LINE

QUENCH VALVE HOT GAS LIQUID

BYPASS SOLENOID
HOT LINE VALVE (SV2), NC
GAS
QUENCH LINE
DISCHARGE FILTER
VALVE
BULB SERVICE HP-2 HP-1 DRIER
VALVE SUBCOOLER
HOT GAS
SOLENOID
(SV3), NC

SUCTION SERVICE
VALVE

DISCHARGE
CHECK VALVE
COMPRESSOR
CONDENS-
CONDENSER
DISCHARGE LINE ER
PRESSURE
CONTROL
SOLENOID
(SV1), NO
Figure 1-9. R-22 Refrigerant Circuit - Cooling

1-13 62-10426
 Section 1 - Description

1.10 REFRIGERANT CIRCUIT DURING HEATING AND DEFROSTING

(See Figure 1-10 or Figure 1-11 )
When vapor refrigerant is compressed to a high pressure and temperature in a reciprocating compressor, the
mechanical energy necessary to operate the compressor is transferred to the gas as it is being compressed. This
energy is referred to as the “heat of compression” and is used as the source of heat during the heating cycle.
The quench valve (R-22 Only) opens as required to maintain a 265 to 285_F (129 to 141_C) maximum
discharge temperature.
NOTE: Solenoid valve (SV-2) remains open during heating or defrosting to allow additional
refrigerant to be metered into the hot gas cycle (through the expansion valve) providing
additional heating capacity until de-energized by head pressure control switch HP-2.

When the controller calls for heating, hot gas solenoid valve (SV-3) opens and the condenser pressure
control solenoid valve (SV-1) closes. The condenser coil then fills with refrigerant, and hot gas from the
compressor enters the evaporator. Also the liquid line solenoid valve (SV-2) will remain energized (valve
open) as the head pressure control switch (HP-2) will remain closed until the compressor discharge pressure
increases to cut-out setting (Refer to section 1.3).
Switch HP-2 opens to de-energize the liquid line solenoid valve (SV-2) and the valve closes to stop the flow
of refrigerant to the expansion valve.
When the compressor discharge pressure falls to cut-in setting (refer to section 1.3), pressure switch (HP-2)
closes and in turn energizes the normally closed liquid solenoid valve (SV-2) which opens, allowing refrigerant
from the receiver to enter the evaporator through the expansion valve.
If discharge pressure exceeds pressure settings detailed in section 1.3, pressure cutout switch (HP-1) opens
and the unit will shut down.
The function of the hot gas bypass line is to raise the receiver pressure when the ambient temperature is low
(below 0_F = - 17.8_C) so that refrigerant flows from the receiver to the evaporator when needed.
FUSIBLE PLUG
HOT GAS
EXTERNAL EQUALIZER EXPANSION VALVE
BYPASS LINE
EXPANSION
VALVE SHUT-OFF
BULB VALVE
RECEIVER

EVAPORATOR
BYPASS
CHECK
HEAT EXCHANGER VALVE

LIQUID LINE LIQUID

SOLENOID
HOT GAS VALVE (SV2), NC
LINE
DISCHARGE FILTER
SERVICE HP-2 HP-1 DRIER
SUBCOOLER
VALVE
HOT GAS
SOLENOID
(SV3), NC

CONDENSER
SUCTION SERVICE PRESSURE
VALVE CONTROL
SOLENOID
DISCHARGE (SV1), NO
CHECK VALVE
COMPRESSOR
CONDENSER

Figure 1-10. R-404A Refrigerant Circuit - Heating and Defrosting

62-10426 1-14
 9
Section 1 - Description

FUSIBLE PLUG
EXTERNAL EQUALIZER EXPANSION VALVE

EXPANSION SHUT-OFF
VALVE BULB VALVE
RECEIVER

SUCTION LINE EVAPORATOR BYPASS

CHECK
VALVE
LIQUID LINE

QUENCH VALVE HOT GAS LIQUID

BYPASS SOLENOID
HOT LINE VALVE (SV2), NC
GAS
QUENCH LINE
DISCHARGE FILTER
VALVE
BULB SERVICE HP-2 HP-1 DRIER
VALVE SUBCOOLER
HOT GAS
SOLENOID
(SV3), NC

SUCTION SERVICE
VALVE

DISCHARGE
CHECK VALVE
COMPRESSOR
CONDENS-
CONDENSER
DISCHARGE LINE ER
PRESSURE
CONTROL
SOLENOID
(SV1), NO
Figure 1-11. R-22 Refrigerant Circuit - Heating and Defrosting

1-15 62-10426
 Section 2 - Operation
2.1 PRE-START-UP INSPECTION
WARNING: Beware of rotating fan blades and unannounced starting of fans.

1. Check for loose electrical connections.

2. Check evaporator and condenser coil for cleanliness.
3. Check oil level in compressor sight glass.
4. Check defrost drain pan hoses. (Should be clear of debris.)

2.2 STARTING AND STOPPING INSTRUCTIONS

a. Starting Instructions
1. Make sure the Start-Stop Switch (ST) is in the STOP position.
2. Insert power plug that is connected to the proper power source.
3. Set the temperature controller for desired cargo temperature.
4. Turn the Start-Stop Switch (ST) to the START position. Power light (PL) will be illuminated.
5. Refer to Section 2.3 and complete After Starting Inspection of unit.
b. Stopping Instructions
Place Start-Stop Switch (ST) in the STOP position.

2.3 AFTER STARTING INSPECTION

1. After ten minutes check compressor oil level. (Refer to section 4.7)
2. Check for proper condenser fan rotation.
3. Check for proper evaporator fan rotation.

2-1 62-10426
 Section 2 - Operation

2.4 CONTROL CIRCUIT OPERATION

2.4.1 Cooling -- Setpoint ABOVE +10_
_F (--12.2_
_C)
NOTE
On start--up with the controller bulb temperature +5_F (2.8_C) above set point, the unit will
be in full cooling (compressor six cylinders loaded).
When correct electrical power is applied to the unit (Refer to section 1.1) ,and with the start--stop switch in
the START position, power flows to the power light (PL) which will remain illuminated as long as the unit
has control power.
From the start--stop switch (ST), power flows through circuit breaker (CB1) to power light (PL) and to the
running time meter (RTM). Power also flows from start--stop switch (ST) to the temperature controller
board (TCM).
From CB 1, power also flows through the defrost relay (DR) normally closed (N.C.) contacts, to the
evaporator fan motor relay (ER), which energizes to start the evaporator fan motor (if all safety components
are closed, as shown in section 1.5).
From CB 1, power also flows through the heat relay (HR) normally closed contacts, to the cool light (CL)
which is now illuminated. Also power flows through diode (D6) to energize the liquid line solenoid SV--2,
which mechanically opens to start the refrigerant flow.
If the cargo temperature decreases to +2_F (1.1_C) above the set point, relay SR energizes. If using optional
unloaders, both unloader solenoid valves energize to unload the compressor.
The cool light de-energizes and a circuit is completed to the recycle delay timer contacts (SET). The RDT
internal contacts open to de-energize the compressor contactor. Refer to section 1.7. The evaporator fan
motor continues to run to circulate air throughout the cargo space.
If the box temperature increases to l_F (0. 6_C) above set point, relay HR de-energizes to open the circuit to
the recycle delay timer (RDT), terminal SET. Relays SR and RR are still energized so the compressor restarts
(unloaded if using optional unloaders) if a time period of five minutes have elapsed. The optional unloaders
de-energize on increasing temperature of +2_F (1.l_C).

2.4.2 Cooling -- Setpoint BELOW +10_

_F (--12.2_
_C)
NOTE
Terminal 25 is electronically locked out below +10_F (-- 12.2_C) to prevent energizing the
relay RR.
If the box temperature decreases to +2_F (1.1_C) above set point, relay SR energizes and complete a circuit
to the relay delay timer (RDT) terminal SET. At this time a set of internal contacts open to de-energize the
compressor pilot relay (CPR) and the compressor stops.
The compressor will restart on increasing temperature at 3_F (1.7_C) above set point as relay SR
de-energizes to open the circuit to the RDT terminal SET (providing five minutes have elapsed).

62-10426 2-2
 Section 2 - Operation
2.4.3 Heating (Hot Gas)
Refer to section 1.10 for description on heating cycle.
Setpoints below 10_F (--12_C) heating is locked out. Therefore, it is possible for the box temperature to fall
below setpoint in the frozen range.
NOTE
The unit will only heat when the controller is set above +10_F (--12_C) as the heat relays are
electronically locked out with set points at or below +10_F (--12_C).
The controller automatically selects the mode(s) necessary to maintain box temperature at set point.
If the temperature decreases to set point, heat relay energizes and closes a set of HR contacts, to complete a
circuit to the recycle delay timer (RDT), terminal SET. A set of internal RDT contacts open to remove power
from the compressor pilot relay (CPR) and the compressor stops.
The same set of HR contacts also energize the heat light (HL) circuit, the hot gas solenoid valve SV3 circuit
and the condenser pressure solenoid valve SV1. Valve SV3 opens and valve SV1 closes but does nothing
until the air temperature decreases to 3_F (1.7_C) below set point.
At this time relay SR de-energizes to remove the power from RDT terminal SET and the compressor starts
providing a period of five minutes have elapsed.
The unit will remain in heating until the air temperature increases to 2_F (1.1_C) below set point where
relays SR and RR energize and supply power to the recycle delay timer, terminal SET and the compressor
stops.

2.4.4 Electric Heating -- Optional

NOTES
1. Make sure the electric heat switch (EHS) is placed in the Electric Heat position.

2. The unit will not heat with set points below +10_F (--12.2_C) the heat relay is electronically
locked out to prevent heating.

If the air temperature decreases to set point, the heat relay energizes and HR contacts close to energize the
heat light and the electric heat relay (EHR).
The electric heat relay consists of two sets of normally open contacts which close to energize the heaters and
another set of contacts (normally closed) open to prevent the compressor from starting.
The unit will remain in heating until the air temperature increases to +1_F (0.6_C) above set point where the
heat relay de-energizes. The electric heaters de-energize along with the heat light. The pilot light (PL)
remains illuminated and the evaporator fan continues to run to circulate air through the container.
When the heat relay (HR) de-energizes, the normally closes contacts (EHR) close to energize the compressor
contactor coil (CC). The compressor and condenser fan motor start at this time.
The recycle delay timer delays compressor start--up for a period of five minutes. Refer to section 1.7.

2-3 62-10426
 Section 2 - Operation

2.4.5 Defrost
Refer to section 1.10 for the heat and defrost cycle.
NOTES
1. The evaporator coil temperature must be below 40_F (4.4_C) before the defrost cycle may be
initiated.

2. The defrost cycle is activated independently of the action of temperature controller.

a. Three Methods of Initiating Defrost Are:

1. Defrost may be manually initiated by the manual--defrost switch (MDS) located on the control panel
door.
2. Automatic initiation of the defrost cycle with the defrost air switch (DA). The defrost air switch
(DA) is a differential pressure air switch which measures the differential air pressure across the
evaporator coil. Defrost is initiated when the differential air pressure increases to enough to closing
the DA contacts, such as would happen when excessive frost builds up on the evaporator coil surface.
To manually initiate defrost with the air switch, disconnect the two wire leads to switch and touch together.
3. Automatic initiation of the defrost cycle is accomplished by the optional solid state defrost timer
(SDT). This timer is located in the control box.(Refer to section 1.7)
To test defrost circuitry, place jumper wire across the two studs (TP1 and TP2). These two studs are located
on the control box.
b. Operation
The defrost relay (DR) consists of one set of normally open contacts (N.O.) and two sets of normally closed
contacts (N.C.). When the defrost mode is initiated, power flows to the defrost light (DL) and defrost relay
(DR). Once the defrost relay is energized the system will remain in the defrost cycle (even though the defrost
switch (DA) will open after initiation of the defrost cycle. The unit will remain in defrost until the two
defrost thermostats (DT) open to break the circuit.
Energizing the defrost relay closes one set of N.O. contacts and power flows to energize the defrost light
(DL). Power also flows through diode D12 to energize the heat relay (HR). Power also flows through diode
D1 to the two defrost thermostats (DT) which are wired in parallel. Power flows through the defrost relay
coil (DR) and to the ground. The N.C. contacts open the circuit to de-energize the evaporator fan motor relay
(ER) and the fan stops.
During the defrost cycle, the heat light (HL) and defrost light (DL) are illuminated. Solenoid valves SV--1
and SV--3 are energized.
During the defrost cycle, hot gas also passes through a coil located at the bottom of the drain pan to melt any
ice that may have accumulated, and insures rapid drainage of water.
The two defrost thermostat switches (DT) are located on the evaporator coil (roadside). The thermostat
switches are closed whenever the temperature of the tubes are 40_F (4.4_C) or less. Both switches will open
at 55_F (12.8_C) as the coil defrosts. When the thermostats open, the unit resumes its normal operation.
NOTE
The defrost thermostats are located on the third and fifth return bend (from bottom of coil).

62-10426 2-4
 Section 2 - Operation
FALLING TEMPERATURE RISING TEMPERATURE

+5_F (+2.8_C)
6 Cylinder
+4_F (+2.2_C)
COOL 6 Cylinder
COOL
+3_F (+1.7_C)

+2_F (+1.1_C)
2 Cylinder COOL
2 Cylinder
COOL +1_F (+0.6_C)

SET POINT Unit OFF

STOP
Unit OFF --1_F (--0.6_C)
STOP
--2_F (--1.1_C)

--3_F (--1.7_C) 6 Cylinder

HEAT
6 Cylinder
HEAT

Figure 2-1. Temperature Controller Operating Sequence

Controller Set Point ABOVE +10_F (--12_C)
FALLING TEMPERATURE RISING TEMPERATURE

+5_F (+2.8_C)
6 Cylinder 6 Cylinder
+4_F (+2.2_C)
COOL COOL
+3_F (+1.7_C)

+2_F (+1.1_C)

+1_F (+0.6_C)

SET POINT Unit OFF

STOP
Unit OFF --1_F (--0.6_C)
STOP
--2_F (--1.1_C)

--3_F (--1.7_C)

Figure 2-2. Temperature Controller Operating Sequence

Controller Set Point BELOW +10_F (--12_C)

2-5 62-10426
 Section 3 --- Troubleshooting
TROUBLESHOOTING

INDICATION/ REFERENCE
POSSIBLE CAUSES
TROUBLE SECTION
3.1 UNIT WILL NOT START
No control power, power light No power to unit Check
OFF Control transformer defective Replace
Rectifier defective 4.22
Choke coil defective Replace
Defective fuse Replace
Circuit breaker defective Replace

3.2 UNIT STARTS THEN STOPS

Refrigeration system High pressure cutout switch 3.8
Defective fuse Replace
Circuit breaker tripped Check
Defective recycle delay timer 1.7

3.3 UNIT WILL NOT COOL

Compressor malfunction Low line voltage 1.1
Single phasing Check
Shorted or grounded motor windings 4.6
Compressor defective 4.6

Cool light ON but unit will not cool Defective recycle delay timer 1.7
Temperature controller malfunction 3.10
Solenoid valve malfunction 3.13
Compressor defective 4.6

3.4 UNIT RUNS BUT HAS INSUFFICIENT COOLING

Compressor Compressor valves defective 4.6
Unloader malfunction 4.8
Refrigeration system Abnormal pressure 3.8
Unloader malfunction 4.8
Expansion valve malfunction 3.12
No or restricted evaporator airflow 3.11

3.5 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING

Trailer Hot Load Allow time to
pull down
Defective box insulation or air leak Correct

Refrigeration system Abnormal pressure 3.8

Temperature controller malfunction 3.10

Compressor Defective 4.6

3-1 62-10426
 Section 3 --- Troubleshooting
INDICATION/ REFERENCE
POSSIBLE CAUSES
TROUBLE SECTION
3.6 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING
Heat light on, but unit has Head pressure control switch (HP-2) defective 4.11
insufficient heat Abnormal pressure 3.8
Evaporator fan motor malfunction 4.17
Solenoid valve malfunction 3.13
1/4” check valve (bypass) defective 4.9
Compressor defective 4.6
Electric heater, switches or relay defective Replace
3.7 DEFROST CYCLE MALFUNCTION
Will not initiate defrost Defrost air switch (DA) out of calibration 4.16
automatically Defrost thermostats (DT) open or defective 4.15
Defrost air switch (DA) defective 4.15 & 4.16
Loose terminal connections Tighten
Defrost relay defective Replace
Air sensing tubes defective or disconnected Check
Will not initiate defrost manually Defective 1 amp diode (D1) 4.21.4
Loose terminal connections Tighten
Defrost thermostats (DT) open or defective Replace
Defrost relay defective Replace
Manual defrost switch defective Replace

Initiates but does not defrost Solenoid valve malfunction 3.13

Defrost relay (DR) defective Replace
Heat relay defective Replace
Frequent defrost Defrost air switch (DA) out of adjustment 4.15 & 4.16
Wet load Normal
Does not terminate or Defrost thermostats (DT) shorted closed 4.15
cycles on defrost Head pressure control switch (HP-2) defective 4.11
Low refrigerant charge 4.5
Defrost air switch (DA) out of adjustment 4.15 & 4.16
Manual defrost switch defective Replace

62-10426 3-2
 Section 3 --- Troubleshooting
INDICATION/ REFERENCE
POSSIBLE CAUSES
TROUBLE SECTION
3.8 ABNORMAL PRESSURE
3.8.1 Cooling
High discharge pressure Quench valve malfunction (R-22) Replace
Condenser coil dirty 4.19
Condenser fan motor defective 4.17
Discharge check valve restricted 4.9
Noncondensibles or refrigerant overcharge Replace
Solenoid valve (SV-1) malfunction 4.14
Low discharge pressure Compressor valves(s) worn or broken 4.6

High suction pressure Compressor valves(s) worn or broken 4.6

Compressor gasket(s) defective 4.6
Solenoid valve (SV-3) malfunction 4.13

Low suction pressure Suction service valve partially closed Open

King valve partially closed Open
Filter-drier partially plugged 4.10
Low refrigerant charge 4.5
Expansion valve malfunction 3.12
No evaporator air flow or restricted air flow 3.11
Excessive frost on coil 4.15
Solenoid valve (SV-2) defective 4.13

Suction and discharge Compressor valves defective 4.6

pressures tend to equalize Heat exchanger defective (R-404A) Replace
when unit is operating

3.8.2 Heating
High discharge pressure Solenoid valves (SV-1 or SV-3) malfunction 3.13
Condenser fan or motor defective 4.17
Noncondensibles in system Check
Head pressure control switch (HP-2) defective (closed) 4.11
Low discharge pressure Compressor valve(s) worn or broken 4.6
Head pressure control switch (HP-2) defective (open) 4.11
Solenoid valve (SV-1) malfunction 3.13
Low refrigerant charge 4.5

Low suction pressure Refrigerant shortage 4.5

Solenoid (SV-1 or SV-2) malfunction 4.13
Expansion valve malfunction 3.12
Defective HP-2 4.11

3-3 62-10426
 Section 3 --- Troubleshooting
INDICATION/ REFERENCE
POSSIBLE CAUSES
TROUBLE SECTION
3.9 ABNORMAL NOISE
Compressor Loose mounting bolts Tighten
Worn bearings 4.6
Worn or broken valves 4.6
Liquid slugging 3.12
Insufficient oil 4.7

Condenser or Loose or striking shroud Check

evaporator fan Bearings defective 4.17
Bent shaft 4.17

3.10 CONTROL SYSTEM MALFUNCTION

Will not control Defective wiring Replace
Temperature selector malfunction 3.14
Controller malfunction 4.21

3.11 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW

Evaporator coil blocked Frost on coil 4.15
Dirty coil 4.18

No or partial evaporator Evaporator fan loose or motor defective 4.17

air flow Evaporator fan rotating backwards 4.17
Evaporator air flow blocked in trailer (box) Check
Relay ER defective Replace

3.12 EXPANSION VALVE MALFUNCTION

Low suction pressure with Low refrigerant charge 4.2/4.5
high superheat External equalizer line plugged Clean
Ice formation at valve seat 4.3
Wax, oil or dirt plugging valve or orifice 4.20
Broken capillary 4.20
Power assembly failure or partial Replace
Loss of element/bulb charge Replace
Superheat setting too high 4.20

Low superheat and liquid Superheat setting too low 4.20

slugging in compressor External equalizer line plugged Open
Ice holding valve open 4.3
Foreign material in valve Clean
Pin and seat of expansion valve eroded or
held open by foreign material 4.20

Fluctuating suction Improper bulb location or installation 4.20

pressure Low superheat setting 4.20

High superheat Broken capillary 4.20

62-10426 3-4
 Section 3 --- Troubleshooting
INDICATION/ REFERENCE
POSSIBLE CAUSES
TROUBLE SECTION
3.13 SOLENOID VALVE MALFUNCTION
Solenoid valve does not No power to valve Check
function properly Improper wiring or loose connections Check
Coil defective 4.13
Valve improperly assembled 4.13
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 4.13
c. Bent or dented enclosing tub 4.13
Solenoid valve closes but Foreign material lodged under seat Clean
refrigerant continues to flow Defective seat Replace

3.14 SOLID STATE CONTROL SYSTEM MALFUNCTION

Will not control Control board defective 4.21.2
Diode defective 4.21.4
Temperature selector malfunction 4.21.1
Temperature sensor defective 4.21.1
Relay defective 4.21.3

3.15 DIODE MALFUNCTION

Cool light stays on in heat and Diode D6 defective 4.21.4
defrost as long as SV-2 is
energized
Unit goes into defrost when Diode D12 defective 4.21.4
controller calls for heat
Unit will not defrost Diode D1 or D12 defective 4.21.4

3-5 62-10426
 SECTION 4 SERVICE
WARNING: Beware of rotating fan blades and unannounced starting of fans.

CAUTION: Unit with R404A and POE oil, the use of inert gas brazing procedures is mandatory;
otherwise compressor failure will occur.

NOTE
To avoid damage to the earth’s ozone layer, use a refrigerant recovery system whenever
removing refrigerant. When working with refrigerants you must comply with all local
government environmental laws, U.S.A. EPA section 608.

4.1 PUMPING THE UNIT DOWN OR

REMOVING THE REFRIGERANT CHARGE
a. Pumping the Unit Down
To service the filter-drier, liquid line solenoid valve (SV-2), expansion valve, quench valve or evaporator
coil, pump most of refrigerant into condenser coil and receiver as follows:
1. Backseat suction and discharge service valve (turn counterclockwise) to close off gauge connection
and attach manifold gauges to valves.
2. Open valves two turns (clockwise). Purge gauge line.
3. Close the receiver outlet (king) valve by turning clockwise. Start unit and run in cooling. Place
Start-stop switch in the STOP position when unit reaches 1 psig (0.1 kg/cm@).
4. Frontseat (close) suction service valve and the refrigerant will be trapped between the compressor
suction service valve and the manual shutoff (King) valve.
5. Before opening up any part of the system, a slight positive pressure should be indicated on the
pressure gauge.
6. When opening up the refrigerant system, certain parts may frost. Allow the part to warm to ambient
temperature before dismantling. This avoids internal condensation which puts moisture in the
system.
7. Open (backseat) King valve and midseat suction service valve.
8. Leak check connections with a leak detector. (Refer to section 4.2)
9. Start the unit in cooling and check for noncondensibles.
10. Check the refrigerant charge. (Refer to section 4.4.f)
NOTE
Store the refrigerant charge in an evacuated container if the system must be opened
between the compressor discharge valve and receiver.
Whenever the system is opened, it must be evacuated and dehydrated. (Refer to section
4.3)
b. Removing the Refrigerant Charge
Connect a refrigerant recovery system to the unit to remove refrigerant charge. Refer to instruction provided
by the manufacture of the refrigerant recovery system.

4-1 62-10426
 SECTION 4 SERVICE
4.2 REFRIGERANT LEAK CHECKING
a. If system was opened and repairs completed, leak check the unit.
b. 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.
c. If system is without refrigerant, charge system with refrigerant to build up pressure between 30 to 50
psig (2.1 to 3.5 kg/cm@). Remove refrigerant drum and leak check all connections.
NOTE
It must be emphasized that only the correct refrigerant drum 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.
d. Remove refrigerant using a refrigerant recovery system and repair any leaks. Evacuate and
dehydrate the unit. (Refer to section 4.3) Charge unit with refrigerant. (Refer to section 4.4)

4.3 EVACUATION AND DEHYDRATION

4.3.1 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.

4.3.2 Preparation
a. Evacuate and dehydrate only after pressure leak test. (Refer to section 4.2)
b. Essential tools to properly evacuate and dehydrate any system include a good vacuum pump (5 cfm =
8m#H volume displacement, P/N 07-00176-01) and a good vacuum indicator such as a
thermocouple vacuum gauge (vacuum indicator). (Available through Robinair Manufacturing,
Montpelier, Ohio, Part Number 14010.)
NOTE
It is not recommended using a compound gauge because of its inherent inaccuracy.
c. Keep the ambient temperature above 60_F (15.6_C) to speed evaporation of moisture. If ambient
temperature is lower than 60_F (15.6_C), ice might form before moisture removal is complete. Heat
lamps or alternate sources of heat may be used to raise system temperature.

4.3.3 Procedure for Evacuation and Dehydrating System

a. Remove refrigerant using a refrigerant recovery system.
b. The recommended method to evacuate and dehydrate the system is to connect three evacuation hoses
(Do not use standard service hoses, as they are not suited for evacuation purposes.) as shown in
Figure 4-1 to the vacuum pump and refrigeration unit. Also, as shown, connect a evacuation
manifold, with evacuation hoses only, to the vacuum pump, electronic vacuum gauge, and
refrigerant recovery system.
c. With the unit service valves closed (back seated) and the vacuum pump and electronic vacuum gauge
valves open, start the pump and draw a deep vacuum. 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. Midseat the refrigerant system service valves.

62-10426 4-2
 SECTION 4 SERVICE

10

11
1. Refrigerant Recovery Unit
2. Refrigerant Cylinder
3. Evacuation Manifold
7 9 4. Valve
5. Vacuum Pump
6. Vacuum Gauge
7. King Valve
12 8. Receiver
13 9. Condenser
10. Evaporator
4 4
11. Discharge Valve
12. Suction Valve
3 13. Compressor

1
4
6

2 5
Figure 4-1. Vacuum Pump Connection

e. Then open the vacuum pump and electronic vacuum gauge valves, if they are not already open. Start
the vacuum pump. Evacuate unit until the electronic vacuum gauge indicates 2000 microns. Close
the electronic vacuum gauge and vacuum pump valves. Shut off the vacuum pump. Wait a few
minutes to be sure the vacuum holds.
f. Break the vacuum with clean dry refrigerant. Use refrigerant that the unit calls for. Raise system
pressure to approximately 2 psig.
g. Remove refrigerant using a refrigerant recovery system.
h. Repeat steps e through g one time.
i. 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.
j. 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.
(Refer to section 4.4)

4-3 62-10426
 SECTION 4 SERVICE
4.4 ADDING REFRIGERANT TO SYSTEM (FULL CHARGE)
a. Dehydrate unit and leave in deep vacuum. (Refer to section 4.3)
b. Place drum of refrigerant on scale and connect charging line from drum to king valve. Purge
charging line at outlet valve.
c. Note weight of drum and refrigerant.
d. Open liquid valve on drum. Open king valve half way and allow the liquid refrigerant to flow into the
unit until the correct weight of refrigerant has been added as indicated by scales. Correct charge will
be found in section 1.3.
NOTE
It is possible that all liquid may not be pulled into the receiver, as outlined in step d. In this
case, frontseat the receiver outlet valve (king valve) and the liquid will be pulled into the
system. Unit must be operating in the cooling mode.
e. When drum weight (scale) indicates that the correct charge has been added, close liquid line valve on
drum and backseat the king valve.
f. Start unit in cooling mode. Run approximately ten minutes. Partially block off air flow to condenser
coil so discharge pressure rises to 230 psig (16 kg/cm@).
Refrigerant should appear at center line of lower receiver sight glass. If charge is inadequate, add refrigerant
charge (per section 4.5).

4.5 ADDING REFRIGERANT TO SYSTEM (PARTIAL CHARGE) -- R-22 ONLY

CAUTION: Do not vapor charge R-404A. Only liquid charging through the liquid line king valve is
acceptable.

a. Place drum of refrigerant on scale and note weight. Backseat suction service valve and connect
charging line between suction valve port and drum. Open VAPOR valve on drum and purge charging
line.
b. Run the unit in cooling for ten minutes and then partially block off air flow to condenser coil so
discharge pressure will rise 10 psig (0.7 kg/cm@). Refrigerant should appear at center line of the
lower receiver sight glass . If charge is inadequate, add refrigerant charge with condenser coil still
blocked.
c. Open suction service valve three turns. Add charge until level appears at center line of the lower
receiver sight glass.
d. Backseat (close) suction service valve. Close vapor valve on refrigerant drum, noting weight. Vent
charging line and replace all caps.
e. Start unit and check for noncondensibles.

62-10426 4-4
 SECTION 4 SERVICE
4.6 REPLACING THE COMPRESSOR
If compressor is inoperative and unit still has refrigerant pressure, frontseat suction and discharge service
valves to trap most of the refrigerant in the unit.
If compressor runs, pump down the unit. (Refer to section 4.1.a)
a. Slowly release compressor pressure to a recovery system.
b. Remove bolts from suction and discharge service valve flanges.
c. Disconnect wiring to unloader valve assemblies and the wiring to the high pressure cutout switches
(HP-1 and HP-2). Identify wiring and switches if necessary. (See Figure 4-2)
d. Disconnect ground strap from frame.
e. Remove wiring from compressor terminals.
f. Remove compressor junction box.
g. Attach sling or other device to the compressor.
h. Remove compressor mounting bolts, two spacers and remove compressor from unit.
i. Drain oil from defective compressor before shipping.
j. The original unloader valves must be transferred to the replacement compressor. The plug
arrangement removed from the replacement is installed in the original compressor as a seal. If piston
is stuck, it may be extracted by threading socket head cap screw into top of piston. A small teflon seat
ring at bottom of piston must be removed.
NOTE
The service replacement compressor is sold without shutoff valves (but with valve pads)
and terminal box. Customer should retain the original capacity control valves for use on
replacement compressor. Check oil level in service replacement compressor.
k. Remove the complete high pressure switch assembly (HP-1 and HP-2) (See Figure 4-2) and install
on new compressor after checking switch settings.
HP-1
HP-2

Figure 4-2. Pressure Switches HP-1 and HP-2

l. Install compressor in unit by reversing step 4.6.c through n. It is recommended using new locknuts
when replacing compressor. Torque bolts to a value of 46 ft/lb (6.4 mkg). Install new gaskets on
service valves and tighten bolts uniformly.
m. Attach two lines (with hand valves near vacuum pump) to the suction and discharge service valves.
Dehydrate and evacuate compressor to 500 microns (29.90” Hg vacuum = 75.9 cm Hg vacuum).
Turn off valves on both lines to pump.
n. Fully backseat (open) both suction and discharge service valves.
o. Remove vacuum pump lines and install manifold gauges.
p. Start unit and check for noncondensibles.
q. Check refrigerant level (section 4.5.b.)
r. Check compressor oil level. (Refer to section 4.7) Add oil if necessary.
s. Check compressor unloader operation. (Refer to section 4.8)
t. Check refrigerant cycles. (Refer to section 2)

4-5 62-10426
 SECTION 4 SERVICE
4.7 CHECKING COMPRESSOR OIL LEVEL
a. To Check the Oil Level in the Compressor:
1. Operate the unit in cooling for at least 20 minutes.
2. Check the oil sight glass on the compressor to ensure that no foaming of the oil is present after 20
minutes of operation. If the oil is foaming excessively after 20 minutes of operation, check the
refrigerant system for flood-back of liquid refrigerant. Correct this situation before performing step
3.
3. Turn unit OFF and the correct oil level is between 1/4 and 1/2 of sight glass.
b. Adding Oil with Compressor in System
Two methods for adding oil are the oil pump method and closed system method.
1. Oil Pump Method
One compressor oil pump that may be purchased is a Robinair, part no. 14388. This oil pump adapts to a one
U.S. gallon (3.785 liters) metal refrigeration oil container and pumps 2-1/2 ounces (0.0725 liters) per stroke
when connected to the oil fill (item4, Figure 4-3). Also there is no need to remove pump from can after each
use.
When the compressor is in operation, the pump check valve prevents the loss of refrigerant, while allowing
servicemen to develop sufficient pressure to overcome the operating suction pressure to add oil as necessary.
Backseat suction service valve and connect oil charging hose to oil fill (item4, Figure 4-3). Purge the oil hose
at oil pump. Add oil as necessary (Refer to section 1.2).
2. Closed System Method
In an emergency where an oil pump is not available, oil may be drawn into the compressor through the
suction service valve.
CAUTION: Extreme care must be taken to ensure the manifold common connection remains
immersed in oil at all times. Otherwise air and moisture will be drawn into the compressor.

Connect the suction connection of the gauge manifold to the compressor suction service valve port, and
immerse the common connection of the gauge manifold in an open container of refrigeration oil. Crack the
suction service valve and gauge valve to vent a small amount of refrigerant through the common connection
and the oil to purge the lines of air. Close the gauge manifold valve.
With the unit running, frontseat the suction service valve and pull a vacuum in the compressor crankcase.
SLOWLY crack the suction gauge manifold valve and oil will flow through the suction service valve into the
compressor. Add oil as necessary (Refer to section 1.2).

62-10426 4-6
 SECTION 4 SERVICE
1 13 12
1. Discharge Service Valve
2 2. Unloader Solenoid
11 3. Cylinder Head
3
4. Oil Pump
4 5. Oil Level Sight Glass
6. Oil Drain Plug
7. Bottom Plate
8. Oil Fill Plug
5 9. Serial No. Plate
10. Motor End Cover
11. Suction Service Valve
6 12. Low Pressure Connection
13. High Pressure Connection
7 8 9 10

Figure 4-3. Compressor - Model 06DR

c. Adding Oil to Service Replacement Compressor

Service replacement compressors may or may not be shipped with oil.
If compressor is without oil:
Add correct oil charge (Refer to section 1.2) through the suction service valve flange cavity or by removing
the oil fill plug (See Figure 4-3)
d. To remove oil from the compressor:
1. Close suction service valve (frontseat) and pump unit down to 2 to 4 psig (0.1 to 0.3 kg/cm@).
Frontseat discharge service valve and slowly bleed remaining refrigerant.
2. Remove the oil drain plug from the compressor and drain the proper amount of oil. Replace the plug
securely back into the compressor.
3. Open service valves and run unit to check oil level, repeat as required to ensure proper oil level.

4.8 COMPRESSOR UNLOADER VALVE

The compressor unloaders (located on the compressor cylinder heads) are controlled by relays UFR,URR
and the temperature controller. (Refer to section 1.8)
a. Checkout Procedure
The controller prevents both unloaders (UF and UR) from energizing when the controller is set below +10_F
(--12.2_C).
1. Connect manifold gauges to the compressor suction and discharge service valves and start unit in
cooling with the trailer temperature at least 5_F (2.8_C) above set point and the compressor will be
fully loaded (both unloader coils are de-energized). Note suction pressure.
2. Remove wiring from the front unloader coil. Place electrical tape over wire terminals.
3. Set controller upscale (cooler to warmer). This mechanically simulates falling temperature.
Approximately 2_F (1.1_C) below box temperature the unloader coils will energize, but only the
rear unloader valve will unload. Note suction pressure, a rise of approximately 3 psig (0.2 kg/cm@)
will be noted on the suction pressure gauge.
4. Reconnect wiring on the front unloader. The front unloader will retract and an additional 3 psig (0.2
kg/cm@) rise on the suction gauge will be noted. Compressor is now fully unloaded and only the top
bank is loaded (two cylinders).

4-7 62-10426
 SECTION 4 SERVICE
5. Reverse the above procedure to check out compressor loading. Suction pressure will drop with this
test.
NOTE
If either unloader coil energizes and the suction pressure does not change, the unloader
assembly must be checked.
b. Solenoid Coil Replacement
NOTE
The coil may be removed without pumping the unit down.
1. Disconnect leads. Remove retainer. Lift off coil. (See Figure 4-4)
2. Verify coil type, voltage and frequency of old and new coil. This information appears on the coil
housing.
3. Place new coil over enclosing tube, retainer and connect wiring.
1
2 1. Retainer
2. Coil Assembly
3 3. Installation/RemovalTool
4 4. Enclosing TubeCollar
5 5. “O” Ring
6. Enclosing Tube
6
12 7. Plunger Spring
7 8. Plunger Assembly
8 13 9. Gasket
9 10. Valve Body
10 11. Gasket
11 12. Bolt
13. Gasket, Bolt
14 14. Piston Ring

Figure 4-4. Unloader Solenoid Valve

c. Replacing Solenoid Valve Internal Parts (See Figure 4-4)

1. Pump down the unit. Frontseat both service valves to isolate the compressor.
2. Remove coil retainer, and coil.
3. Remove enclosing tube collar (item 4, Figure 4-4) using installation/removal tool supplied with
repair kit (item 3).
4. Check plunger for restriction due to: (a) Corroded or worn parts; (b) Foreign material lodged in
valve; (c) Bent or dented enclosing tube.
5. Install new parts. Do not over tighten enclosing tube assembly. Torque to a value of 100 inch pounds
(1.15 mkg).
6. Remove supplied installation/removal tool. Install coil, voltage plate, and retainer.
7. Evacuate and dehydrate the compressor. (Refer to section 4.6.p through 4.6.w.)
8. Start unit and check unloader operation (Refer to section 4.8.a).

62-10426 4-8
 SECTION 4 SERVICE
4.9 SERVICING THE CHECK VALVE -- SERVICEABLE TYPE
The check valve allows the hot gas to travel in one direction only.
The function of the condenser coil bypass is to raise the receiver pressure when the ambient temperature is
low so that refrigerant can flow from the receiver to the evaporator when the unit is in heating or defrost.

6
2
1 5
2
3
4

CAP 4 BOLT

1. Cap 4. Brass/Teflon Seat

2. Copper Washer 5. Body
3. Spring 6. Cover

Figure 4-5. Check Valve -- Serviceable Type

a. To replace check valve, store the refrigerant into an evacuated container. (Refer to section 4.1)
b. Replace necessary parts.
c. Evacuate and dehydrate unit. (Refer to section 4.3)
d. Add refrigerant charge. (Refer to section 4.4)

4.10 CHECKING AND REPLACING FILTER-DRIER

To Check Filter-Drier
Check for a restricted or plugged filter-drier by feeling the liquid line inlet and outlet connections of the drier
cartridge. If the outlet side feels cooler than the inlet side, then the filter-drier should be changed.
To Replace Filter-Drier
a. Pump down the unit per section 4.1. Remove bracket, then replace drier.
b. Check refrigerant level. (Refer to section 4.5.b)

4.11 CHECKING AND REPLACING HIGH PRESSURE CUTOUT SWITCHES

4.11.1 Replacing High Pressure Switch
a. Pump down the unit. (Refer to section 4.1.a) Frontseat both suction and discharge service valves to
isolate compressor.
b. Slowly release compressor pressure through the service valve gauge ports.
c. Disconnect wiring from defective switch. The high pressure switches are located on the top cylinder
head. (See Figure 4-3)
d. Install new cutout switch after verifying switch settings. (Refer to section 4.11.2)
e. Evacuate and dehydrate the compressor. (Refer to section 4.6.p through 4.6.w)

4-9 62-10426
 SECTION 4 SERVICE
4.11.2 Checking High Pressure Switch (HP-1 or HP-2)
WARNING: Do not use a nitrogen cylinder without a pressure regulator. Cylinder pressure is
approximately 2350 psi (165 kg/cm2). Do not use oxygen in or near a refrigerant system as an
explosion may occur. (See Figure 4-6)
1
4
1. Cylinder Valve and Gauge
2 5
2. Pressure Regulator
3. Nitrogen Cylinder
4. Pressure Gauge
(0 to 400 psig = 0 to 28 kg/cm@)
5. Bleed-Off Valve
3 6 6. 1/4 inch Connection

Figure 4-6. Typical Setup for Testing High Pressure Switch

a. Remove switch as outlined in section 4.11.1.

b. Connect ohmmeter or continuity light across switch terminals. Ohmmeter will indicate resistance
and continuity light will be lighted if switch closed after relieving pressure.
c. Connect switch to a cylinder of dry nitrogen. (See Figure 4-6)
d. Set nitrogen pressure regulator higher than cutout point on switch being tested. Pressure switch
cutout and cut-in points are shown in sections 1.3.
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).

4.12 REPLACING RECEIVER SIGHT GLASS ASSEMBLY

NOTE
There are two types of receiver sight glasses. One is the floating ball type (P/N 14-00111),
and the second is the prism type (P/N 14-50023-00); both are interchangeable.
a. Store the refrigerant in an evacuated container. (Refer to section 4.1.b)
b. Unscrew the sight glass assembly. Spread some sealing compound on pipe threads of new sight glass
assembly and install.
c. Leak check receiver sight glass per section 4.2.
d. After leak checking unit, evacuate and dehydrate as outlined in section 4.3.
e. Add refrigerant charge. (Refer to section 4.4)
f. Check for noncondensibles.

62-10426 4-10
 SECTION 4 SERVICE
4.13 SERVICING SOLENOID VALVES
4.13.1 Solenoid Valves -- Alco SV2/SV3
CAUTION: Do not damage or over tighten the enclosing tube assembly. Torque to 200-inch
pounds (2.3 mkg). Also make sure all parts are placed on the enclosing tube in proper sequence
to avoid premature coil burnout.

a. Replacing the Coil

NOTE
The coil may be replaced without removing the refrigerant or pumping the unit down.
1. Disconnect leads, remove coil retainer and coil assembly.
2. Verify coil type, voltage and frequency. This information appears on the coil housing.
3. Place new coil over enclosing tube, retainer and connect wiring.
b. Replacing Solenoid Valve Internal Parts (See Figure 4-7)
The liquid line solenoid valve (SV2) may be serviced by pumping the unit down. (Refer to section 4.1.a)
Remove and store the refrigerant charge in an evacuated container to service hot gas solenoid valve. (Refer
to section 4.1.b)
1. Remove coil retainer and coil assembly from valve. Remove enclosing tube assembly and related
items.
2. Check for foreign material in valve body.
3. Install new parts.
4. Tighten enclosing tube assembly to a torque value of 200 inch pounds (2.3 mkg) and leak check the
valve. (Refer to section 4.2)
5. Install coil assembly and retainer.
6. Start unit and check refrigerant charge per section 4.4.f.
7. Check refrigeration cycles.(Refer to section 2)
1
2

1. Retainer
3 2. Coil Assembly
3. Enclosing Tube Assembly
4. Plunger Assembly
4 5. Gasket
5 6. Piston Assembly
7. Body
8. Bracket Adapter
6
7

Figure 4-7. Solenoid Valves - Alco SV2 & SV3

4-11 62-10426
 SECTION 4 SERVICE
4.13.2 Solenoid Valve -- Sporlan SV1
a. Replacing the Coil
NOTE
The coil may be replaced without removing the refrigerant or pumping the unit down.
1. Remove top locknut, spacer cup and nameplate (SV1). For SV3, remove screw and nameplate.
2. Disconnect wiring and remove coil.
3. Replace coil by reversing steps 1 and 2.
b. Replacing Internal Components (See Figure 4-8)
1. Remove and store the refrigerant charge in an evacuated container. (Refer to section 4.1.b)
2. Remove the top locknut, spacer cup, nameplate, coil assembly and spacer (SV1). For SV3, remove
screw and nameplate.
3. Using a 12 point, 1-3/8 inch box wrench, loosen the enclosing tube locknut and bleed off remaining
refrigerant.
4. Remove enclosing tube and locknut assembly. The gasket is inside the enclosing tube.
5. Remove seat disc from inside of body and check for obstructions and foreign material.
6. Place the seat disc into the valve body with the smaller diameter end facing up.
7. For SV3 install stem and plunger (item 11, Figure 4-8)
8. Place the enclosing tube locknut over the enclosing tube. Install spacer over enclosing tube making
sure it is seated properly in the enclosing tube locknut. Tighten enclosing tube locknut to a torque
value of 20 ft-lb (2.78 mkg). Do not over tighten.
1 1
2 3
3

4 4
1. Locknut/Screw
2. Spacer Cup
5 3. Nameplate
6
4. Coil
6 7 5. Spacer
6. Enclosing Tube Locknut
7 8 7. Enclosing Tube
8. Gasket
8
11 9. Seat Disc
10. Body
9 11. Stem and Plunger
9

10 10
SV-1 SV-3
Figure 4-8. Solenoid Valves - Sporlan
9. Install coil assembly, nameplate and top locknut or screw.
10. Dehydrate and evacuate the system. (Refer to section 4.3) Charge unit with refrigerant per sections
4.4 and 4.5.
11. Start unit and check operation. (Refer to section 2)

62-10426 4-12
 SECTION 4 SERVICE
4.14 SOLENOID VALVE SV-1 CHECKOUT PROCEDURE
To obtain proper heating and defrost, the normally open (N.O.) SV-1 solenoid valve must energize and close
tightly during the heat and defrost cycles. If the valve does not close tightly due to physical damage, foreign
material or wear, refrigerant leakage through the valve can reduce heating capacity.
a. During normal heat or defrost cycles the following conditions will be observed when the valve is
operating properly:
(1) Receiver refrigerant level will drop quickly at the initiation of heating or defrost mode.
(2) Suction pressure will rise slowly to 90--100 psig (6.3 to 7.0 kg/cm@).
(3) Discharge pressure will drop quickly, but begin to rise to a minimum of 250 psig (17.5 kg/cm@)
within 15 to 20 minutes.
b. If suction and discharge pressures remain low and the receiver level does not drop, the valve may be
inoperative and can be checked by the following method.
(1) Verify the solenoid coil has proper voltage and is energized in heating and defrosting.
(2) Connect a discharge pressure gauge to the compressor discharge service valve and connect a
gauge to the liquid line valve (king valve) leaving the receiver tank.
(3) With the trailer temperature at 35_F (1.7_C) or lower, operate the unit in cool and remove or
disconnect the “hot” wire leading to the SV-1 coil.
(4) With a separate 12 vdc positive voltage, energize SV-1 with the unit in cooling and observe the
discharge and receiver pressures. If the valve is closing properly, compressor discharge pressure will begin
to rise and the receiver pressure will remain the same or begin to drop slowly. If the valve is not seating
properly, both discharge and receiver pressure will rise slowly or remain the same.
(5) Operate the unit until discharge pressure reaches 200 psig (14 kg/cm@) and disconnect jumper
wire to SV-1 valve. Discharge and receiver pressure should be within 5 to 15 psig (0.4 to 1.0 kg/cm@) of each
other.

4.15 CHECKING DEFROST OR HEATING CYCLE

NOTE
The evaporator temperature must be 35_F (1.7_C) (approximately 40_F = 4.4_C box
temperature) or lower, before any checks can be made.
a. Hot Gas Solenoid Valve (SV-1 & SV-3) Heating and Defrosting
1. Connect a discharge pressure gauge to the King valve and another gauge to the compressor discharge
service valve. Connect a gauge to the compressor suction service valve.
2. Start unit with controller set at least 10_F = 5.5_C below indicated box temperature to obtain
cooling.
3. When box temperature is below 40_F, push the Manual Defrost Switch (MDS). The hot gas valve
(SV3) will energize and the hot gas line will be warm to touch on either side of the valve.
The condenser pressure control solenoid (SV1) closes and suction pressure will rise approximately 10 to 15
psig (0.70 to 1.05 kg/cm@) after 15 minutes of unit operation. Refer to section 4.14 if unit does not heat
properly.
The unit will remain in defrost until coil temperature increases to 55_F (12.8_C) where the defrost
thermostats open and the unit resumes automatic operation.

4-13 62-10426
 SECTION 4 SERVICE
b. Defrost Air Switch (DA)
1. To check air switch, run unit in cooling and jump across the air switch terminals. This will start the
defrost cycle as it simulates the action of the defrost air switch. Bypassing the switch in this manner
operates all components involved in defrost.
2. Unit should remain in defrost until evaporator coil temperature reaches 55_F (12.8_C). At this point
the two defrost thermostats should open to terminate the defrost cycle. Replace the defrost
thermostats if unit fails to terminate defrost.
3. If the above test indicates satisfactory operation, test defrost air switch (DA) settings using a Dwyer
Magnehelic gauge (P/N 07-00177) or similar instrument. (Refer to section 4.16)
c. Solid State Defrost Timer
Refer to section 1.7 for description.

4.16 CHECKING CALIBRATION OF THE DEFROST AIR SWITCH

2 1. Ohmmeter or Continuity Device

5 2. Adjustment Screw (0.050 socket head size)
3. Low Side Connection
4. Pressure Line or Aspirator Bulb (P/N 07-00177-01)
5. Magnehelic Gauge (P/N 07-00177)
6. High Side Connection
6 3
4
1

Figure 4-9. Defrost Air Switch Test Setup

a. Make sure magnehelic gauge is in proper calibration.

NOTE
The magnehelic gauge may be used in any position, but must be re-zeroed if position of
gauge is changed from vertical to horizontal or vice versa. USE ONLY IN POSITION FOR
WHICH IT IS CALIBRATED.
b. With air switch in vertical position, connect high pressure side of magnehelic gauge to high side
connection of air switch. (See Figure 4-9)
c. Install tee in pressure line to high side connection. Tee should be approximately half-way between
gauge and air switch or an improper reading may result.
d. Attach an ohmmeter to the air switch electrical contacts to check switch action.
NOTE
Use a hand aspirator (P/N 07-00177-01), since blowing into tube by mouth may cause an
incorrect reading.
e. With the gauge reading at zero, apply air pressure very slowly to the air switch. An ohmmeter will
indicate continuity when switch actuates.
f. Refer to section 1.3 for switch settings. If switch fails to actuate at correct gauge reading, adjust
switch by turning adjusting screw clockwise to increase setting or counterclockwise to decrease
setting.
g. Repeat checkout procedure until switch actuates at correct gauge reading.
h. After switch is adjusted, place a small amount of paint or glycerol on the adjusting screw so that
vibration will not change switch setting.

62-10426 4-14
 SECTION 4 SERVICE
4.17 REPLACING THE CONDENSER or EVAPORATOR FAN and MOTOR
WARNING: Beware of rotating fan blades and unannounced starting of fans.

a. Turn OFF unit power and disconnect power plug.

b. Remove 2 screws securing fan to split tapered hub. Place the same 2 screws in the threaded holes of
the hub and use screws as jacking screws to remove fan from hub.
c. Disconnect wiring from motor leads, making sure that wiring is identified. Remove motor mounting
hardware and motor.
d. Lubricate new motor fan shaft with Never-Seez or equal and then install motor per wiring diagram.
e. Install tapered hub on evaporator fan loosely. Locate the fan and key so that 1/3 of the fan extends
beyond the leaving edge of the fan shroud. Secure fan and hub to shaft.
f. Start unit and check refrigeration cycle.

4.18 EVAPORATOR COIL CLEANING

The use of recycled cardboard cartons is increasing and the recycled cardboard cartons create much more
fiber dust during transport 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 or 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. Remove rubber check valves (Kazoo) from drain lines (front of trailer).
b. Spray coil with a mild detergent solution such as Oakite 164 or any good commercial grade
automatic dish washer detergent such as Electrosol or Cascade and let the solution stand for a few
minutes and 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.
c. Run unit until defrost mode can be initiated to check for proper draining from drain pan.

4.19 CONDENSER COIL CLEANING

Remove all foreign material from the condenser coil by reversing the normal air flow. (Air is pulled in
through the front ) 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.

4-15 62-10426
 SECTION 4 SERVICE
4.20 THERMOSTATIC 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 seldom requires any maintenance.
a. Replacing Expansion Valve

1 4

1. Power Assembly
2. Body Flange Gaskets
2 5 3. Seat Gasket
4. Bulb
5. Cage Assembly
6. Body Flange
3 7. Body Flange Screws

Figure 4-10. Thermostatic Expansion Valve

1. Pump down the unit by closing the King valve. (Refer to section 4.1.a)
2. Remove insulation (Presstite) from expansion valve bulb and then remove bulb from suction line.
3. Loosen flare nut and disconnect equalizer line from expansion valve.
4. Remove flange screws and lift off power assembly. Then remove the cage assembly. Check for
foreign material in valve body.
5. The thermal bulb is located below the center of the suction line. This area must be clean to ensure
positive bulb contact. Apply thermal mastic and strap thermal bulb to suction line and insulate both
with Presstite.
6. Install new gaskets and insert cage assembly and install power assembly.
7. Fasten equalizer tube to expansion valve.
8. Evacuate by placing vacuum pump on suction service valve.
9. Open King valve and then check refrigerant level. (Refer to section 4.5.b)
10. Check superheat. (Refer to section 1.3.h)
b. Checking Superheat
NOTE
It is not recommended adjusting expansion valves unless absolutely necessary.
Due to the time involved in adjusting the superheat, replace the valve rather than adjusting it.

62-10426 4-16
 SECTION 4 SERVICE
c. To Measure Superheat
1. Remove Presstite 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.
NOTE
When conducting this test the suction pressure must be 6 psig (0.4 kg/cm@) below
expansion valve maximum operating pressure (MOP). For example: R-22 units use an
expansion valve with a 55 MOP. The recommended test pressure should be below 49
psig(3.44 kg/cm@).
4. Connect an accurate gauge to the 1/4” port on the suction service valve.
5. Run unit until stabilized. Set controller 10_F (5.5_C) below box temperature.
6. From the temperature/pressure chart, 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 6 from the average temperature measured in
Step 7. The difference is the superheat of the suction gas.

4-17 62-10426
 SECTION 4 SERVICE
4.21 SERVICING THE SOLID STATE CONTROL SYSTEM

1. Circuit Breaker
2. Run Relay
3. Control Board
4. Temperature Controller Module(TCM)
5. Defrost Relay
6. Heat Relay
7. Diode Assembly
8. Unloader (Speed) Relay

Figure 4-11 Solid State Control System

4.21.1 Unit Checkout Procedure With Test Meter (TCSM)

a. Equipment Required
1. Multi--Test Meter - Part No. 07--00204
2. Temperature Tester -- Part No. 07--00013
3. Temperature Control Simulator Module (TCSM) -- Part No. 07--00207
NOTES
1. Test points TP1, TP2, TP3, and TP4 on the Temperature Controller Simulator Module (TCSM,
Figure 4-12) do not correspond with terminals on the control board, Figure 4-11 or temperature
selector potentiometer.

2. After replacing controller printed circuit board and all wiring connections are completed, spray
the back of the board with Humiseal, P/N 07--50001. Also, spray back of diode board when
replacing same.

The Temperature Control Simulator Module (TCSM) will operate the unit in all modes by manual switch
operation of the simulator module. The purpose of the TCSM is to quickly check out the system to isolate a
malfunctioning circuit. The simulator replaces the temperature controller module (TCM) (Figure 4-11) and
bypasses the temperature selector (TS, located on the control panel).

62-10426 4-18
 SECTION 4 SERVICE
b. To Use the Simulator:

1. Open cover of control box.

2. Unplug temperature controller module.
(See Figure 4-11.)
3. Plug in Simulator (TCSM).
4. Install gauge manifold to checkout unloaders if so
equipped. (Refer to Section 4.8.)
5. Place simulator switch S1 in high speed, place S2 in
loaded position (if unit is equipped with unloaders)
and place switch S3 in the cool position.
6. Start unit and allow engine to warm up (about ten
minutes). Refer to Section 3 if unit does not cool.
7. Move switch S1 from high speed to low speed.
Compressor will unload if equipped with unloaders.
8. Move switch S1 to high speed and move switch S3 to
heat position. Unit should be in full heating. Refer to
Section 3 if unit does not heat.
9. If equipped with unloaders, watching the suction
gauge, move switch S2 to the unloaded position. A
rise of suction pressure of 3 to 6 psig (1.3 to 1.5
kg/cm@) will be noticed. If not, refer to Section 4.8.
10. Move switch S2 to the loaded Simulator Module
(TCSM) position and a decrease of 3 to 6 psig (1.3 to
1.5 kg/cm@) will be indicated.

Figure 4-12 Temperature Controller Simulator Module (TCSM)

If every test with Simulator TCSM is positive, a malfunction may have occurred with the temperature
controller module (TSM), controller sensor (TCS) or the temperature selector (TS).

4-19 62-10426
 SECTION 4 SERVICE
c. Checking the Temperature Selector Potentiometer (TSP)
NOTE
Test points TP1, TP2, TP3 and TP4 on the Temperature Controller Simulator Module
(TCSM, Figure 4-12) do not correspond with terminals on the control board, Figure 4-11.

The temperature controller simulator module (TCSM), P/N 07--00207, test board procedure checks the
temperature selector for calibration points across two of the three selector wires and the wire connections
from the control board to the selector. If a problem with the selector is suspected, all three wires must be
checked. The selector should be checked for continuity and resistance using a reliable ohmmeter at the
temperature selector connection or test board points as shown in Table 4-1.
If a simulator is not available, the same readings may be obtained by placing one probe of the ohmmeter on
terminal no. 1 on the control board and the other probe on a clean grounding point, preferably, the ground
connection of the selector ground wire at the gauge panel.
Table 4-1. Selector Settings and Resistance
Selector Setting Selector Simulator Board Resistance in Ohms
_F _C Connections Test Points
TSP 1 to TSP 2 TP2 to TP3 300
--20
20 --28.9
28.9 TSP 2 to TSP 3 TP1 to TP2 1700
TSP 1 to TSP 3 TP1 to TP3 2000
TSP 1 to TSP 2 TP2 to TP3 1000
32 0 TSP 2 to TSP 3 TP1 to TP2 1000
TSP 1 to TSP 3 TP1 to TP3 2000
TSP 1 to TSP 2 TP2 to TP3 1560
80 26.7 TSP 2 to TSP 3 TP1 to TP2 440
TSP 1 to TSP 3 TP1 to TP3 2000

In addition to the preceding procedures, a resistance reading should be made from terminal no 9 on the
control board to the selector ground wire connection on selector. Make sure connection is clean to obtain
correct resistance reading. A 2000 Ohms (2K Ohms) resistance should be indicated and should not change,
regardless of the selector setting.
A loose or poor connection and/or a broken wire could give a false indication of a defective selector so all
connections must be checked before replacing the component.

62-10426 4-20
 SECTION 4 SERVICE
d. Temperature Controller Sensor (TCS) Checkout Procedure
Using an accurate ohmmeter and the temperature controller simulator module (TCSM), P/N 07--00207,
check across TP3 and TP4, Figure 4-12 or terminals 6 and 9 on the control board, Figure 4-11 for
resistance values shown in Table 4-2.
Due to variations and inaccuracies in ohmmeters, thermometers or other test equipment, a reading within
2% of the chart value would indicate a good sensor. If a sensor is bad, the resistance reading will usually be
much higher or lower than the resistance values given in Table 4-2.
The Test Board (TCSM) isolates the sensor from the system and provides test points for the resistance
reading. If the test board is not used, at least one lead from the sensor must be disconnected from the unit
electrical system before any reading is taken. Not doing so will result in a false reading. Two preferred
methods of determining the actual test temperature at the sensor, is an ice bath, at 32_F (0_C) or a calibrated
temperature tester.
Table 4-2. Sensor Resistance
Temperature Resistance Temperature Resistance Temperature Resistance
_F _C in Ohms _F _C in Ohms _F _C in Ohms
--20 --28.9 165,000 +14 --10.0 55,300 +48 + 8.9 21,000
--18 --27.8 154,000 +16 -- 8.9 52,100 +50 +10.0 19,900
--16 --26.7 144,300 +18 -- 7.8 49,100 +52 +11.1 18,900
--14 --25.6 134,400 +20 -- 6.7 46,300 +54 +12.2 18,000
--12 --24.4 126,100 +22 -- 5.5 43,600 +56 +13.3 17,000
--10 --23.3 118,300 +24 -- 4.4 41,100 +58 +14.4 16,100
-- 8 --22.2 110,500 +26 -- 3.3 38,800 +60 +15.6 15,300
-- 6 --21.1 103,700 +28 -- 2.2 36,600 +62 +16.7 14,500
-- 4 --20.0 97,100 +30 -- 1.1 34,600 +64 +17.8 13,800
-- 2 --18.9 91,000 +32 0 32,700 +66 +18.9 13,200
0 --17.8 82,800 +34 + 1.1 30,800 +68 +20.0 12,500
+2 --16.7 80,200 +36 + 2.2 29,200 +70 +21.1 11,800
+4 --15.6 75,300 +38 + 3.3 27,600 +72 +22.2 11,300
+6 --14.4 70,800 +40 + 4.4 26,100 +74 +23.3 10,600
+8 --13.3 66,500 +42 + 5.5 24,700 +76 +24.4 10,300
+10 --12.2 62,500 +44 + 6.7 23,400 +78 +25.6 9,800
+12 --11.1 58,800 +46 + 7.8 22,100 +80 +26.7 9,300

NOTE
If tests in paragraph a, b and c are all positive, replace the temperature controller module
(TCM), Figure 4-11.

4.21.2 Checking and Removing Control Board

Failure of components on the control board indicate a possible failure elsewhere in system. Turn unit off and
disconnect power plug. Check board using ohmmeter. A zero resistance connection to ground indicates a
short circuit.
To replace board:
1. Remove four screws (one in each corner). The board may be tilted to one side to check or repair
connections on back of board.
2. Disconnect wiring from defective board and connecting wiring to replacement board using wiring
diagram.

4-21 62-10426
 SECTION 4 SERVICE
4.21.3 Checking Relays

Legend
NC -- Normally Closed
NO -- Normally Open
C -- Common

Figure 4-13. Relay Circuit Diagram (Shown in De-energized Position)

a. If a relay is suspected of being defective, the easiest method is to simply pull the relay (all four relays
are identical) and insert replacement relay.
b. If replacement relay is questionable, remove relay and connect an external 12 vdc power supply to
coil of relay.
With the relay coil energized, continuity should be obtained across normally open (NO) contacts and
no continuity should be obtained across the normally closed (NC) contacts.
c. With the relay de--energized, no continuity should be obtained across relay normally open (NO)
contacts.

4.21.4 Diode Board Checkout Procedure

The diode will permit current flow in one direction, but blocks it in the reverse direction. The direction of the
arrow on the diode case indicates current flow. Current flow, for our purpose here, is always from a positive
(12 vdc) potential to a negative or ground potential.
a. Remove diode board assembly (plug in type) from control board (Figure 4-11) and place board on a
flat surface with the diodes up.
b. Test the diode with a volt--ohm meter set on ohms. Connect leads to each lead of diode. A reading
may or may not be indicated. If a reading is indicated, when reversing the leads there should be no
reading. Inversely, if no reading is indicated the first time, when reversing leads you should see a
reading. This will indicate a good diode. If both readings are the same, diode is faulty.
NOTES
1. Diodes D2, D8, and D12 are arc suppression diodes and will only fail in the open position.

2. The diode board, Figure 4-14, is an universal board, so some diodes will not be used in this
application nor indicated on the schematics or diagrams.

62-10426 4-22
 SECTION 4 SERVICE

Figure 4-14. Diode Board Circuit Diagram

4.21.5 Checking Out the Temperature Controller and Diodes

Figure 4-15. Module Tester - Spectrol

The Temperature Controller and Diode Board Tester provides a fast and accurate method of checking the
controller and diode boards. With the use of this tester, the condition of each board can be determined.
To use the controller and diode board tester, follow these steps:
a. Unfasten the latch, open the lid and pull out the two 12 vdc power leads. Insert the diode assembly
and/or solid state controller into their respective connecting pins. Connect the 12 vdc power leads -
red lead to positive and black to negative (ground) terminals.
b. Move switch S1 to the “Forward” position. Move switch S2 to the “Lamp Test” position. All light
should be illuminated.

4-23 62-10426
 SECTION 4 SERVICE
c. Now, with S1 in the “Forward” position, lights D1 through D14 should be lighted. An unlighted lamp
(excluding D4 and D7) indicates a failure of that diode in the “open” mode. If lights D2 or D14 are
out, hold S4 to the test position for diodes D4 and D7 only. Now if lights D4 or D7 are not lighted,
then diodes D4 or D7 have also failed in the “open” mode.
d. Move switch S1 to the “Reverse” position and if a lamp lights, it indicates that particular diode has
failed in the “shorted” mode.
Leave S1 in the “Reverse” position and move switch S4 to the test position for diodes D4 and D7. If a
lamp lights, it indicates that particular diode has failed in the “shorted” mode.
e. Move switch S1 to the “Forward” position.
f. Set the Temperature Selector (S3) to 32_F (0_C). Turn the simulated load temperature dial (R2) to
the clockwise stop. Gradually turn the dial toward counterclockwise stop to check operational
sequence and calibration in falling load temperature condition, then turn back toward clockwise stop
to check operational sequence and calibration in rising load temperature condition. Heat, low speed,
and unload lamps shall be lighted per Table A.
Table A
Module Output Status
Direction of Dial (R2) Simulated Load Temperature
Unload Low Speed Heat
Above 34_F (+1.1_C) Off Off Off
34 to 33_F (+1.1 to +0.6_C) Lighted Lighted Off
C
Counter--clockwise
t l k i 32.5 to 31.5_F (+0.3 to --0.3_C) Lighted Lighted Lighted
(Falling Load Temperature)
30 to 29_F (--1.1 to 1.7_C) Off Off Lighted
29 or Below (--7_C or Below) Off Off Lighted
Below 29.5_F (below --1.4_C) Off Off Lighted
29.5 to 30.5_F (--1.4 to --0.9_C) Lighted Lighted Lighted
Cl k i
Clockwise 32 to 33_F (0 to +0.6_C) Lighted Lighted Off
(Rising Load Temperature)
34 to 35_F (+1.1. to +1.7_C) Off Off Off
Above 35_F (Above +1.7_C) Off Off Off

g. Turn Temperature Selector (S3) to 11_F (--11.7_C) position. Unload, low speed, and heat lamps shall
be illuminated.
h. Turn Temperature Selector (S3) to 9_F (--12.8_C) position. Low speed light only shall be
illuminated. This tests the heat and unloader lockout operation of the controller.
i. Turn Temperature Selector (S3) to 80_F (+26.7_C) position. Turn Simulated Load temperature dial
(R1) to clockwise stop. Gradually turn the dial toward counterclockwise stop, then back to clockwise
stop. Heat, low speed, and unload lights shall be illuminated per Table B.
Table B
Module Output Status
Position of Knob (R1)
Unload Low Speed Heat
Clockwise Stop Off Off Off
On On Off
On On On
Counterclockwise Stop Off Off On

j. Turn Temperature Selector (S3) to --20_F (--28.9_C) position. Turn Simulated Load Temperature
dial (R1) to clockwise stop. Gradually turn the dial toward counterclockwise stop, then back to
clockwise stop. Heat, low speed and unload lights shall be illuminated per Table C.

62-10426 4-24
 SECTION 4 SERVICE
Table C
Module Output Status
Position of Knob (R1)
Unload Low Speed Heat
Clockwise Stop Off Off Off
Off On Off
Counterclockwise Stop Off On Off

4.22 CHECKING THE RECTIFIER

Since a diode only conducts electricity in one direction, as indicated in Figure 4-16, they may be checked
very easily. Using an ohmmeter, make a normal continuity test. Two readings must be taken with the meter.
After taking first reading, reverse the meter leads and take the second reading. If the diode is good, the
ohmmeter will indicate continuity in one direction but not the other. If continuity cannot be obtained in
either direction, the diode is open or if continuity is obtained in both directions, the diode is shorted out. In
either case the rectifier must be replaced.

METER

Figure 4-16. Checking Rectifier

To Check the Rectifier:
The rectifier is located inside (left side) of the electrical control box.
a. Disconnect the leads from the component taking care not to use any more heat than necessary.
b. Using an ohmmeter and the red dot or plus sign (+) on the component as a reference point, check each
diode in the component as an individual item. Connecting a meter as shown in Figure 4-16, the meter
should read a low resistance. Reversing the leads should indicate a high resistance. If any of the four
diodes are defective (shorted or open), the rectifier must be replaced.

4.23 CHECKING THE CAPACITOR

The capacitor is used as an arc suppression device and should it fail, the result may be premature component
failure.
a. Turn OFF power and disconnect power plug.
b. Use insulated wire (both ends stripped back) to discharge (short) capacitor .
c. Disconnect capacitor leads.
d. Use an ohmmeter on the 0 to 10,000 scale setting. Place meter probes on capacitor terminals. If it
dips to zero or a low resistance and then climbs to a high resistance , the capacitor is probably good.
e. If it dips to zero or a low resistance and stays there, the capacitor is open and needs replacing

4.24 THERMOMETER CALIBRATION

This operation should be done when verifying the controller as a Simpson lead will be attached to the
controller bulb.
a. Depending on thermometer manufacturer, the thermometer lens may be a beveled type, a 1/4 turn
style or a screw-in type (threaded). To adjust thermometer, remove lens and insert small screw driver
in adjustment screw. Turn screw until needle corresponds with Simpson meter reading.

4-25 62-10426
 SECTION 4 SERVICE
Table 4-3. R-22 Pressure - Temperature Chart

TEMPERATURE PRESSURE TEMPERATURE PRESSURE

_F _C Psig Kg/cm@ Bar _F _C Psig Kg/cm@ Bar
---40 ---40 .6 .04 .04 34 1 60.5 4.25 4.17
---36 ---38 2.3 .16 .16 36 2 63.3 4.45 4.36
---32 ---36 4.1 .29 .28 38 3 66.1 4.65 4.56
---28 ---33 6.0 .42 .41 40 4 69 4.85 4.76
---26 ---32 7.0 .49 .48 44 7 75.0 5.27 5.17
---24 ---31 8.1 .57 .56 48 9 81.4 5.72 5.61
---22 ---30 9.2 .65 .63 52 11 88.1 6.19 6.07
---20 ---29 10.3 .72 .71 54 12 91.5 6.43 6.31
---18 ---28 11.5 .81 .79 60 16 102.5 7.21 7.07
---16 ---27 12.7 .89 .88 64 18 110.2 7.75 7.6
---14 ---26 14.0 .98 .97 68 20 118.3 8.32 8.16
---12 ---24 15.2 1.07 1.05 72 22 126.8 8.91 8.74
---10 ---23 16.6 1.17 1.14 76 24 135.7 9.54 9.36
--- 8 ---22 18.0 1.27 1.24 80 27 145 10.19 10.0
--- 6 ---21 19.4 1.36 1.34 84 29 154.7 10.88 10.67
--- 4 ---20 21.0 1.48 1.45 88 31 164.9 11.59 11.37
--- 2 ---19 22.5 1.58 1.55 92 33 175.4 12.33 12.09
0 ---18 24.1 1.69 1.66 96 36 186.5 13.11 12.86
2 ---17 25.7 1.81 1.77 100 38 197.9 13.91 13.64
4 ---16 27.4 1.93 1.89 104 40 209.9 14.76 14.47
6 ---14 29.2 2.05 2.01 108 42 222.3 15.63 15.33
8 ---13 31.0 2.18 2.14 112 44 235.2 16.54 16.22
10 ---12 32.9 2.31 2.27 116 47 248.7 17.49 17.15
12 ---11 34.9 2.45 2.41 120 49 262.6 18.46 18.11
14 ---10 36.9 2.59 2.54 124 51 277.0 19.48 19.10
16 --- 9 39.0 2.74 2.69 128 53 291.8 20.52 20.12
18 --- 8 41.1 2.89 2.83 132 56 307.1 21.59 21.17
20 --- 7 43.3 3.04 2.99 136 58 323.6 22.75 22.31
22 --- 6 45.5 3.2 3.14 140 60 341.3 24.0 23.53
24 --- 4 47.9 3.37 3.3 144 62 359.4 25.27 24.78
26 --- 3 50.2 3.53 3.46 148 64 377.9 26.57 26.06
28 --- 2 52.7 3.71 3.63 152 67 396.6 27.88 27.34
30 --- 1 55.2 3.88 3.81 156 69 415.6 29.22 28.65
32 0 57.8 4.06 3.99 160 71 434.6 30.56 29.96

62-10426 4-26
 SECTION 4 SERVICE
Table 4-4. R-404A Temperature-- Pressure Chart

Temperature Pressure Temperature Pressure

_F _C Psig Kg/cm@ Bar _F _C Psig Kg/cm@ Bar
--40 --40 4.5 0.32 0.31 32 0 72.5 5.10 5.00
--35 --37 7.1 0.50 0.49 34 1 75.6 5.32 5.21
--30 --34 9.9 0.70 0.68 36 2 78.8 5.54 5.43
--25 --32 12.9 0.91 0.89 38 3 82.1 5.77 5.66
--20 --29 16.3 1.15 1.12 40 4 85.5 6.01 5.90
--18 --28 17.7 1.24 1.22 42 6 89.0 6.26 6.14
--16 --27 19.2 1.35 1.32 44 7 92.5 6.50 6.38
--14 --26 20.7 1.46 1.43 46 8 96.2 6.76 6.63
--12 --24 22.3 1.57 1.54 48 9 99.9 7.02 6.89
--10 --23 23.9 1.68 1.65 50 10 103.7 7.29 7.15
--8 --22 25.6 1.80 1.77 55 13 115.4 8.11 7.96
--6 --21 27.3 1.92 1.88 60 16 126.1 8.87 8.69
--4 --20 29.1 2.05 2.01 65 18 137.4 9.66 9.47
--2 --19 30.9 2.17 2.13 70 21 149.4 10.50 10.30
0 --18 32.8 2.31 2.26 75 24 162.1 11.40 11.18
2 --17 34.8 2.45 2.40 80 27 175.5 12.34 12.10
4 --16 36.8 2.59 2.54 85 29 189.6 13.33 13.07
6 --14 38.9 2.73 2.68 90 32 204.5 14.38 14.10
8 --13 41.1 2.89 2.83 95 35 220.2 15.48 15.18
10 --12 43.3 3.04 2.99 100 38 236.8 16.65 16.33
12 --11 45.6 3.21 3.14 105 41 254.2 17.87 17.53
14 --10 48.0 3.37 3.31 110 43 272.4 19.15 18.78
16 --9 50.4 3.54 3.47 115 46 291.6 20.50 20.11
18 --8 52.9 3.72 3.65 120 49 311.8 21.92 21.50
20 --7 55.5 3.90 3.83 125 52 332.9 23.41 22.95
22 --6 58.1 4.08 4.01 130 54 355.0 24.96 24.48
24 --4 60.9 4.28 4.20 135 57 378.1 26.58 26.07
26 --3 63.7 4.48 4.39 140 60 402.3 28.28 27.74
28 --2 66.5 4.68 4.59 145 63 427.6 30.06 29.48
30 --1 69.5 4.89 4.79 150 66 454.0 31.92 31.30

4-27 62-10426
 Index
A H
Air Switch, 1-6, 4-14 Heating, 2-1
Heating Cycle, 4-13
C High Pressure Switch, 1-6
High Pressure Switches, 4-9
Check Valve, 4-9
High Temperature Termination, 1-6
Circuit Breaker, 1-7
Compressor, 4-5
Compressor Data, 1-6
I
Compressor Motor, 1-7 Introduction, 1-1
Compressor Oil Level, 4-6
Compressor Unloader, 1-10, 4-7 O
Condenser Coil, 4-15 Operating Controls and Instruments , 1-9
Condenser Motor, 1-7
Control Circuit Operation --Engine Drive, 2-1 P
Control System, 1-8 Pre--start--up Inspection, 2-1
Controls and Instruments, 1-9 Pumping Unit Down, 4-1
Cooling, 2-1
R
D Receiver Sight Glass, 4-10
Defrost, 2-2 Refrigerant Charge, 4-1, 4-4
Defrost Air Switch, 1-6, 4-14 Refrigerant Circuit -- Heating & Defrosting,
1-14
Defrost Cycle, 4-13
Refrigerant Circuit --Cooling, 1-12
Defrost Thermostats, 1-6
Refrigeration Charge, 1-6
Defrost Timer, 1-6
Refrigeration System Data, 1-6
Dehydration, 4-2
Drain Pan Heaters, 1-7
S
Safety Devices, 1-7
E
Solenoid Valves, 4-11
Electric Heating, 2-2
Starting Instructions -- Engine Drive, 2-1
Electrical Data, 1-7
Stopping Instructions -- Engine Drive, 2-1
Evacuation, 4-2
SV--1 Checkout Procedure, 4-13
Evaporator Coil, 4-15
Evaporator Coil Heater, 1-7
T
Evaporator Motor, 1-7
Temperature Controller and Solid State
Expansion Valve, 1-6, 4-16 Control System, 1-8
Thermostatic Expansion Valve, 1-6, 4-16
F Troubleshooting, 3-1
Fan Shaft, 4-15
Filter--Drier, 4-9 U
Fuse, 1-7 Unit Weight, 1-6
Fusible Plug, 1-6 Unloader, 1-10, 4-7
Index -1
230 Volt
380 Volt
460 Volt
ELECTRIC HEAT
OPTION