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TM 11574A-OI

U.S. MARINE CORPS TECHNICAL MANUAL

OPERATION AND UNIT MAINTENANCE INSTRUCTIONS

WITH ILLUSTRATED PARTS BREAKDOWN

LARGE FIELD REFRIGERATION SYSTEM

4130-01-562-9914

THIS PUBLICATION IS REQUIRED FOR OFFICIAL USE OR FOR ADMINISTRATIVE

OR OPERATIONAL PURPOSES ONLY. DISTRIBUTION IS LIMITED TO U.S.

GOVERNMENT AGENCIES. OTHER REQUESTS FOR THIS DOCUMENT MUST BE

REFERRED TO: COMMANDANT OF THE MARINE CORPS (ARD), WASHINGTON,

D.C. 20380-0001.

DESTRUCTION NOTICE

- FOR UNCLASSIFIED, LIMITED DOCUMENTS, DESTROY

BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTS OR

RECONSTRUCTION OF THE DOCUMENTS.

FOR OFFICIAL USE ONLY

FEBRUARY 2100

PCN 500 115740 00

Summary of content (228 pages)

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TM 11574A-OI U.S. MARINE CORPS TECHNICAL MANUAL OPERATION AND UNIT MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN LARGE FIELD REFRIGERATION SYSTEM 4130-01-562-9914 THIS PUBLICATION IS REQUIRED FOR OFFICIAL USE OR FOR ADMINISTRATIVE OR OPERATIONAL PURPOSES ONLY. DISTRIBUTION IS LIMITED TO U.S. GOVERNMENT AGENCIES. OTHER REQUESTS FOR THIS DOCUMENT MUST BE REFERRED TO: COMMANDANT OF THE MARINE CORPS (ARD), WASHINGTON, D.C. 20380-0001.
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TM 11574A-OI TABLE OF CONTENTS CHAPTER/SECTION PAGE CHAPTER 1 GENERAL INSTRUCTIONS..........................................................................................................1-1 I. GENERAL DESCRIPTION AND SPECIFICATION DATA........................................................................1-1 1-1. SCOPE ......................................................................................................................................1-1 1-2. ORIENTATION ..............................
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TM 11574A-OI CHAPTER/SECTION PAGE V. CONTROLLER AND SOFTWARE FUNCTIONS ..................................................................................2-19 2-13. CHECK CONTROLLER FUNCTION CODES........................................................................2-19 2-14. DATACORDER OPERATION................................................................................................2-20 2-15. PRE-TRIP DIAGNOSIS ......................................................................................
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TM 11574A-OI CHAPTER/SECTION PAGE IV. NATIONAL STOCK NUMBER (NSN) TO MANUFACTURER’S PART NUMBER CROSS REFERENCE.........................................................................................................................................4-8 V. MANUFACTURER’S PART NUMBER TO NSN CROSS REFERENCE .................................................4-8 VI. IDENTIFICATION OF PARTS ................................................................................................................4-9 4-6.
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TM 11574A-OI LIST OF ILLUSTRATIONS Figure 1-1 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 2-14 2-15 2-16 2-17 2-18 2-19 2-20 2-21 2-22 2-23 2-24 2-25 2-26 2-27 2-28 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 3-11 3-12 3-13 iv Title Page ISO Container ...........................................................................................................................................1-2 Refrigeration Unit – Front Section ....................................................................
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TM 11574A-OI LIST OF ILLUSTRATIONS Figure 3-14 3-15 3-16 3-17 3-18 3-19 3-20 3-21 3-22 3-23 3-24 3-25 3-26 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-17 4-18 4-19 4-20 4-21 4-22 4-23 4-24 Title Page Controller Section of the Control Box ......................................................................................................3-33 Sensor Temperature/Resistance Chart ..................................................................................................
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TM 11574A-OI LIST OF TABLES Table 1-1 1-2 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-12 2-13 3-1 3-2 3-3 3-4 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-17 4-18 4-19 4-20 4-21 4-22 4-23 4-24 vi Title Page Table of Leading Particulars......................................................................................................................1-4 Visual Inspection Upon Initial Receipt ...............................................................................
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TM 11574A-OI HOW TO USE THIS MANUAL This manual is designed to provide instructions to perform set-up, operation, and scheduled maintenance procedures on the Large Field Refrigeration System (LFRS). This manual also provides corrective maintenance, troubleshooting, and component adjustment procedures for the refrigeration unit aboard the LFRS. The information contained in this manual is the latest available information at the time of publication.
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TM 11574A -OI SAFETY SUMMARY GENERAL SAFETY PRECAUTIONS This safety summary contains general safety warnings and hazardous material warnings that must be understood and applied during operation and maintenance of the LFRS. Failure to observe these precautions could result in equipment damage and / or serious injury or death to personnel. KEEP AWAY FROM LIVE CIRCUITS Operating personnel must observe safety regulations at all times.
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TM 11574A-OI SPECIFIC SAFETY PRECAUTIONS Warnings used in this manual are repeated here to stress how important they are. Study these warnings carefully; they can save lives. WARNING • When loaded, the refrigerated container is extremely heavy. To prevent injury to personnel and damage to equipment, use a hoist and sling rated at a minimum capacity of 26.45 tons (52,900 lbs./ 24,000 kg).
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TM 11574A -OI WARNING Do not open the condenser fan grille before turning power OFF and disconnecting power plug. WARNING Always turn OFF the unit circuit breakers (CB-1 & CB-2) and disconnect main power supply before working on moving parts. WARNING Make sure power to the unit is OFF and power plug disconnected before servicing capacitor(s). WARNING With power OFF discharge the capacitor before disconnecting the circuit wiring. WARNING Pieces of a broken glass dome may be sharp and cause injury.
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TM 11574A-OI ABBREVIATIONS The following abbreviations are used throughout this manual. Abbreviation Definition AC A BER BTU BTR/hr C cm. CAGEC CPC CFM ft³ Dtd. dBA °C °F DC DTR EA EFM EIR F FSC FSCM ft. Gal GPH GFCI Hz HTT hp hrs ID IAW in.
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TM 11574A -OI ABBREVIATIONS - Continued xii Abbreviation Definition NSN NLT N/A NS No.
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TO 11574A-OI CHAPTER 1 GENERAL INSTRUCTIONS I. GENERAL DESCRIPTION AND SPECIFICATION DATA 1-1. Scope a. The Large Field Refrigeration System (LFRS) is a large, insulated, high payload container system with built in refrigeration. The mission of the LFRS is to provide the capability to transport and store large, perishable cargo in a climate controlled, ISO standard container. b. This technical manual provides operation and maintenance instructions for the LFRS (TAMCN B0049, NSN 4130-01-562-9914).
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TO 11574A OI 1-2.
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TO 11574A-OI 1-3. Physical Description and Specification Data a. ISO Container. The ISO container is a 20 ft long, 8 ft wide, 8 ft tall ISO certified insulated container. Interior electrical lighting system is provided for low light conditions. Collapsible access steps lead to the non-slip roof for easy safe access and an emergency escape hatch is provided for emergency situations. Interior T-grade floors are installed to meet sanitary requirements. b. Refrigeration Unit.
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TO 11574A OI j. Rear Access Doors. The rear access doors provide access to the storage section of the refrigeration unit. The right-hand access door includes an escape hatch. k. Escape Hatch Door. The escape hatch provides a means of escape from the inside of the storage section if the rear access doors are closed while an operator is still inside. Table 1-1. Table of Leading Particulars. ISO CONTAINER Weight: Gross Weight .................................................................................
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TO 11574A-OI Table 1-1. Table of Leading Particulars – Continued. Refrigerant Charge: Charge Requirements ............................................................................................... R-134a Unit Configuration..................................................................................... 3 Row Condenser Receiver ..................................................................................................... 10.8 lbs (4.9 kg) Fusible Plug: Melting Point...........................
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TO 11574A OI Table 1-1. Table of Leading Particulars – Continued. Evaporator Fan Motor(S): 380 VAC, Single Phase, 50 Hz: Full Load Amps High Speed ....................................................................................... 1.6 Full Load Amps Low Speed ........................................................................................ 0.8 Nominal Horsepower High Speed ............................................................................. 0.70 Nominal Horsepower Low Speed..............
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TO 11574A-OI II. PUBLICATION 1-4. Copyright Information Carrier Transicold and Sea Box®, Inc. grant the U.S. Government permission to reprint the information in this Technical Manual (TM) for use by the military services. This permission also includes the right to post the TM on controlled government "limited access" websites.
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TO 11574A OI III. WARRANTY For warranty provisions refer to SI 11574A/11609A-OI. IV. PREPARATION FOR USE 1-10. Visual Inspection Upon Initial Receipt Visually inspect for the following to ensure the LFRS is intact, and there are no broken/damaged items. Table 1-2. Visual Inspection Upon Initial Receipt. Component Inspection/Service EXTERIOR Container Check for damage or corrosion on the container surfaces. Check for structural damage that is a hazard or degrades container performance.
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TO 11574A-OI Table 1-2. Visual Inspection Upon Initial Receipt – Continued. Component Inspection/Service INTERIOR Cargo Doors Inspect cargo doors for obvious damage such as cracks and holes affecting serviceability. Check seals for damage. Lighting Check light for security of components. Container Interior Inspect container floor, walls, and ceiling for punctures and obvious damage. Inspect floor for blocked or clogged drains. 1-11. Initial Checkout and Inventory a.
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TO 11574A OI 1-15. Installation and Relocation a. Siting. (1) Transport. The refrigerated container system is designed for highway, railway and water transport of perishable materials. Transport the refrigerated container system only on equipment compatible with DTR 4500.9-R and MCO P4600.7_ transport requirements. (2) Fixed Site.
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TO 11574A-OI (7) Once power is connected there are no additional adjustments required. Grounding of the unit is accomplished through the power cable connections and the unit is commissioned before leaving the factory eliminating the need for initial adjustments to the equipment. d. Installation Checkout. After installation perform a general inspection to verify proper siting and connection.
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TO 11574A OI (8) The container may now be transported. (9) If refrigerated container will be operated off external power, connect refrigerated unit power cable to power source. V. PREPARATION FOR STORAGE 1-16. Preparation for Limited Storage and Reshipment There are no specific procedures for limited storage and reshipment of the LFRS. 1-17. Preparation for Long Term Storage There are no specific procedures for long term storage of the LFRS. VI. DESTRUCTION TO PREVENT ENEMY USE a.
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TM 11574A-OI CHAPTER 2 OPERATING INSTRUCTIONS I. SYSTEM CONTROLS AND COMPONENTS 2-1. System Components 11 1 10 9 2 8 3 4 7 6 5 1. Access Panel for Evaporator Fan #1 (EFM) Thermostatic Expansion Valve (TXV) and Heater Termination Thermostat (HTT) 2. Fork Lift Pockets 3. Control Box 4. Condenser Coils 5. Compressor 6. Unit Serial Number, Model Number, and Parts Identification Number (PID) Plate 7. Condenser Fan Interrogator Connector (Front Left) 8. Document Holder 9. Fresh Air Makeup Vent 10.
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TM 11574A-OI 4 3 5 6 2 1 7 8 9 TXV BULB (UNDER INSULATION) 11 10 1. Evaporator Fan Motor #1 2. Return Recorder Sensor (RRS) / Return Temperature Sensor (RTS) 3. Humidity Sensor 4. Evaporator Fan Motor #2 5. Heater Termination Thermostat 6. 7. 8. 9. 10. 11. Defrost Temperature Sensor Evaporator Coil Hermetic Thermostatic Expansion Valve TXV Bulb Routing Evaporator Coil Heaters Heat Exchanger Figure 2-2. Refrigeration Unit – Center Access.
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TM 11574A-OI 1 5 6 7 2 10 9 3 11 4 12 8 20 13 14 15 19 16 18 17 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Autotransformer Power Cables Compressor Sight Glass View Port Compressor Guard Supply Temperature Sensor Supply Recorder Sensor Ambient Sensor Discharge Service Valve Discharge Temperature Sensor Discharge Pressure Regulating Valve 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
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TM 11574A-OI 6 7 5 2 4 3 1 8 15 9 10 11 12 13 14 1. 2. 3. 4. 5. 6. 7. 8. Grille and Venturi Assembly Condenser Fan Key Condenser Fan Motor Condenser Coil Cover Condenser Coil Condenser Motor Mounting Bracket Receiver 9. 10. 11. 12. 13. 14. 15. Sight Glass Fusible Plug (Rupture Disc – Alternate) Condenser Pressure Transducer Sight Glass/Moisture Indicator Filter-Drier Liquid Line Service Valve Quench Valve Figure 2-4. Condenser Section.
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TM 11574A-OI 2 1 14 1. 2. 3. 4. 5. 6. 7. 13 4 3 12 11 5 10 Compressor Contactor Fuses Heater Contactor Display Module Controller/DataCORDER Module (Controller) Key Pad Start-Stop Switch 9 8. 9. 10. 11. 12. 13. 14. 8 6 7 Controller Battery Pack Control Transformer Evaporator Fan Contactor – E1 Evaporator Fan Contactor – S1 Condenser Fan Contactor Circuit Breaker – 460V Current Sensor Module Figure 2-5. Control Box Section.
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TM 11574A-OI 1 2 7 6 3 4 5 1. 2. 3. 4. Cargo Doors Pressure Relief Port Escape Hatch Door Handle 5. Door Lanyard 6. Locking Cam 7. Fold Up Steps Figure 2-6. Rear Doors.
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TM 11574A-OI 2-2. System Controls a. Details for operating controls and indicators Large Field Refrigerated System (LFRS) and associated components are given in Table 2-1 and shown in Figure 2-9 through Figure 2-13. Table 2-1. Operating Controls and Indicators 1 2 Item No.
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TM 11574A-OI 1 2 3 4 5 6 7 8 9 10 11 Figure 2-7. RU Controller Control Panel. LEGEND 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 2-8 Code Select Pre-Trip Alarm List Manual Defrost/Interval Enter Arrow Up Arrow Down Return/Supply Degrees C / Degrees F Battery Power ALT.
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TM 11574A-OI Table 2-1. Operating Controls and Indicators - Continued Item No. 1 2 3 Description START/STOP Selector Switch ON (START) Indicator OFF (STOP) Indicator Type Component Electrical Function Selects RU operational condition. Electrical Indicates RU ON condition. Electrical Indicates RU OFF condition 1 2 3 Figure 2-8. START/STOP Switch. LEGEND 1. 2. 3.
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TM 11574A-OI Table 2-1. Operating Controls and Indicators - Continued 1 Item No. Description COOL (White LED) Type Component Electrical 2 Heat (Orange LED) Electrical 3 Defrost (Orange LED) In-Range (Green LED) Electrical 5 Alarm (Red LED) Electrical 6 Supply (Yellow LED) Electrical 7 Return (Yellow LED) Electrical 8 SETPOINT/Code Electrical 9 AIR TEMPERATURE/ Data Electrical 4 2-10 Electrical Function LED energized when refrigerant compressor is energized.
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TM 11574A-OI 2 1 3 4 5 6 7 9 8 Figure 2-9. START/STOP Switch. LEGEND 1. 2. 3. 4. 5. 6. 7. 8. 9.
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TM 11574A-OI Table 2-1. Operating Controls and Indicators - Continued Item No. 1 2 Description Circuit Breaker Selector Switch Circuit Breaker ID plate Type Component Electrical Function Selects circuit breaker condition. Electrical Identifies circuit breaker and indicates circuit breaker ON condition. 2 1 Figure 2-10. Circuit Breaker. LEGEND 1. 2.
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TM 11574A-OI Table 2-1. Operating Controls and Indicators - Continued Item No. 1 Description Light Switch Type Component Electrical Function Controls condition of interior light. Switch to Left = OFF Switch to Center = ON (Takes power from main power) Switch to Right = ON (Takes power from 110 V) 1 Figure 2-11. Interior Lighting. LEGEND 1.
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TM 11574A-OI II. THEORY OF OPERATION 2-3. Theory Of Operation The Large Field Refrigerated System (LFRS) is a climate controlled, insulated container system comprised of an electrically powered refrigeration/freezing/heating unit and a 20-ft. ISO compliant, insulated container. 2-4. 20 Foot Insulated Container The insulated container is designed and built to the requirements of ISO 1496-2 standards.
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TM 11574A-OI 2-7. Perishable Mode Heating If the air temperature decreases 0.9 F (0.5 C) below the set point, the system enters heating mode. The controller closes the contacts to energize the heaters. The HEAT light is illuminated. The evaporator fan circulates the warm air throughout the container. When the temperature reaches 0.4 F (0.2 C) the contact opens to de-energize the heaters. The HEAT light is also deenergized. The evaporator fan continues to circulate air throughout the container. 2-8.
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TM 11574A-OI III. PRE-OPERATING PROCEDURES 2-10. General This section contains theory of operation, startup, normal operation and shutdown procedures for the Large Field Refrigerated System and associated components. Two personnel are the minimum number recommended to safely and efficiently setup the Large Field Refrigerated System (LFRS). 2-11.
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TM 11574A-OI IV. OPERATING CHECKS 2-12. Before, During, and After Operation Checks WARNING Beware of unexpected starting of the fans motors. The unit may cycle the fan motors as control requirements dictate. Table 2-2. Before, During, and After Operation Checks Interval Item Action EXTERIOR Before Cargo Doors Inspect hardware for bent or broken door release handles. Before Rear Doors Inspect hardware for bent or broken door release handles.
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TM 11574A-OI Interval Item Action INTERIOR Before Cargo Doors Inspect cargo doors for obvious damage such as cracks and holes affecting serviceability. Check seals for damage. Before Lights Check light for security of components. Before Floor Inspect container floor for punctures and obvious damage. Inspect floor for blocked or clogged drains. EXTERIOR During Refrigeration Unit Ensure Refrigeration unit is operational.
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TM 11574A-OI V. CONTROLLER AND SOFTWARE FUNCTIONS 2-13. Check Controller Function Codes The controller software is a custom designed program that is subdivided into the configuration software and the operational software. The controller software performs the following functions: a. Control supply or return air temperature to required limits, provide modulated refrigeration control, electric heat control and defrost.
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TM 11574A-OI 2-14. DataCORDER Operation a. DataCORDER. (1) Description. The Carrier Transicold “DataCORDER” software is integrated into the controller and serves to eliminate the temperature recorder and paper chart. The DataCORDER functions may be accessed by keypad selections and viewed on the display module. The unit is also fitted with interrogation connections (see Figure 2-24), which may be used with the Carrier Transicold Data Reader to download data.
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TM 11574A-OI (2) DataCORDER Software. The DataCORDER Software is subdivided into the configuration software, operational software and the Data Memory. (a) Operational Software The operational software reads and interprets inputs for use by the configuration software. The inputs are labeled Function Codes. There are 35 functions (see Table 2-8), which the operator may access to examine the current input data or stored data. To access these codes, do the following: 1. Press the ALT. MODE & CODE SELECT keys.
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TM 11574A-OI NOTE The DataCORDER software uses the supply and return recorder sensors. The temperature control software uses the supply and return temperature sensors. (b) Generic Mode The generic recording mode allows user selection of the network data points to be recorded. The user may select up to a total of eight data points for recording. A list of the data points available for recording follows.
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TM 11574A-OI (4) Logging Interval (dCF03). The user may configure four time intervals between data recordings. Data is logged at exact intervals in accordance with the real-time clock. The clock is factory set at Greenwich Mean Time. (5) Thermistor Format (dCF04). The user may configure the format in which the thermistor readings are recorded. The low resolution is a 1 byte format and the normal resolution is a 2 byte format. The low resolution requires less memory and records temperature in 0.45 F (0.
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TM 11574A-OI During DataCORDER power-up, while using battery-pack power, the controller will perform a hardware voltage check on the battery. If the hardware check passes, the Controller will energize and perform a software battery voltage check before DataCORDER logging. If either test fails, the real-time clock battery power-up will be disabled until the next AC power cycle. Further DataCORDER temperature logging will be prohibited until that time.
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TM 11574A-OI Figure 2-13. Standard Configuration Report.
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TM 11574A-OI Figure 2-14. Data Reader. (b) DataBANKTM Card The DataBANKTM card is a PCMCIA card that interfaces with the controller through the programming slot and can download data at a much faster rate when compared to the PC or DataReader. Files downloaded to the DataBANK card files are accessible through an Omni PC Card Drive. The files can then be viewed using the DataLine software. (c) DataLine The DataLINE software for a personal computer is supplied on both floppy disks and CD.
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TM 11574A-OI To clear the alarm list: 1. 2. 3. 4. Press the ALT. MODE & ALARM LIST keys. Press the UP/DOWN ARROW key until “CLEAr” is displayed. Press the ENTER key. The alarm list will clear and “-- -- -- -- -- ” will be displayed. Press the ALARM LIST key. “AL” will show on the left display and “ -- -- -- -- -- ” on the right display when there are no alarms in the list. 5. Upon clearing of the Alarm Queue, the Alarm light will be turned off.
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TM 11574A-OI Table 2-6 Controller Function Codes Code No.
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TM 11574A-OI Table 2-6 Controller Function Codes - Continued Code No. Cd25 Cd26 TITLE DESCRIPTION Compressor Run Time Remaining Until Defrost Defrost Temperature Sensor Reading This code displays the time remaining until the unit goes into defrost (in tenths of an hour). This value is based on the actual accumulated compressor running time. Defrost temperature sensor reading is displayed. Configurable Functions NOTE Cd27 Function codes Cd27 through Cd37 are user-selectable functions.
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TM 11574A-OI Table 2-6 Controller Function Codes – Continued Code No.
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TM 11574A-OI Table 2-7 Controller Alarm Indications Code No. AL11 AL12 AL20 AL21 AL22 AL24 AL25 AL26 AL27 AL50 AL51 AL52 TITLE DESCRIPTION Alarm 11 is applicable to units with Single Evaporator Fan Capability (CnF32 set to Evaporator Motor 1 1EFO) only. The alarm is triggered if the evaporator fan motor #1 internal protector IP Trip opens. If the alarm is active, probe check is deactivated.
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TM 11574A-OI Table 2-7 Controller Alarm Indications - Continued Code No. AL53 AL54 TITLE DESCRIPTION Alarm 53 is caused by the battery pack charge being too low to provide sufficient power for battery-backed recording. Renew replaceable batteries.
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TM 11574A-OI Table 2-7 Controller Alarm Indications - Continued Code No. AL63 AL64 AL65 AL66 AL68 AL69 TITLE Current Over Limit Discharge Temperature Over Limit Discharge Pressure Transducer Failure Suction Pressure Transducer Failure Condenser Pressure Transducer Failure Suction Temperature Sensor Failure DESCRIPTION Alarm 63 is triggered by the current limiting system.
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TM 11574A-OI Table 2-7 Controller Alarm Indications - Continued Code No. TITLE DESCRIPTION ERROR EER 1 – Program Memory EER 2 -- Watchdog time-out EER 3 -- N/A EER 4 -- N/A EER 6 -- IO Board failure N/A The Controller’s Analog to Digital (A-D) converter has failed. Internal program/update failure. EER 7 -- Controller failure Internal version/firmware incompatible. EER 8--DataCorder failure Internal DataCorder memory failure.
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TM 11574A-OI Table 2-8 Controller Pre-Trip Test Codes Code No. TITLE DESCRIPTION NOTE P P1-0 P1-1 P2-0 P2-1 P3 “Auto” or “Auto1” menu includes the: P, P1, P2, P3, P4, P5, P6 and rSLts. “Auto2” menu includes P, P1, P2, P3, P4, P5, P6, P7, P8, P9, P10 and rSLts.“Auto3 menu includes P, P1, P2, P3, P4, P5, P6, P7, P8 and rSLts All lights and display segments will be energized for five seconds at the start of the Pre-Trip Initiated pre-trip.
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TM 11574A-OI Table 2-8 Controller Pre-Trip Test Codes - Continued Code No. TITLE DESCRIPTION Requirements: For units equipped with secondary supply probe only. Pass/Fail Criteria: The temperature difference between primary and secondary probe (supply) is compared. P5-1 NOTE Supply Probe Test If this test fails, “P5-1” and FAIL will be displayed. If both Probe tests (this and the SUPPLY/ RETURN TEST) pass, because of the multiple tests, the display will read ’P 5’ ’PASS’.
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TM 11574A-OI Table 2-8 Controller Pre-Trip Test Codes - Continued Code No. TITLE DESCRIPTION Note, this test is skipped if the unit does NOT have: A compressor discharge sensor (CPDS). A discharge pressure transducer (DPT). Condenser pressure transducer (CPT). In addition, this test is skipped if: The sensed ambient temperature is less than 45 F (7 C). The return air temperature is less than 0F (-17.8 C).
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TM 11574A-OI Table 2-8 Controller Pre-Trip Test Codes - Continued Code No. TITLE P8-2 Perishable Mode Maintain Temperature Test P9-0 Defrost Test P100 Frozen Mode Setup Test P101 Frozen Mode (Pull Down) Test P102 Frozen Mode Maintain Temperature Test 2-38 DESCRIPTION Requirements: Test P8-1 must pass for this test to execute. Setup: The left display will read “P8-2,” and the right display will show the supply air temperature. A 60 minute timer is started.
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TM 11574A-OI Table 2-9 DataCORDER Function Code Assignments NOTE Inapplicable Functions Display “---------” To Access: Press ALT. MODE key Code No. dC1 dC2 dC6-13 TITLE Recorder Supply Temperature Recorder Return Temperature Network Data Points 1-8 DESCRIPTION Current reading of the supply recorder sensor. Current reading of the return recorder sensor. Current values of the network data points (as configured).
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TM 11574A-OI Table 2-10 DataCORDER Pre-Trip Result Records Test No.
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TM 11574A-OI Table 2-11 DataCORDER Alarm Indications To Access: Press ALT. MODE key Code No. dAL70 TITLE Recorder Supply Temperature Out of Range DESCRIPTION The supply recorder sensor reading is outside of the range of -58 F to +158 F (-50 C to 70 C) or, the probe check logic has determined there is a fault with this sensor. NOTE dAL71 Recorder Return Temperature Out of Range The P5 Pre-Trip test must be run to inactivate the alarm.
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TM 11574A-OI 2-15. Pre-Trip Diagnosis CAUTION Pre-trip Inspection should not be performed with critical temperature cargoes in the container. Pre-Trip diagnosis provides automatic testing of the unit components using internal measurements and comparison logic. The program will provide a “PASS” or “FAIL” display to indicate test results. The testing begins with access to a pre-trip selection menu.
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TM 11574A-OI CAUTION When a failure occurs during automatic testing the unit will suspend operation awaiting operator intervention. When an automatic test fails, it will be repeated once. A repeated test failure will cause “FAIL” to be shown on the right display, with the corresponding test number to the left. The user may then press the DOWN ARROW to repeat the test, the UP ARROW to skip to the next test or the PRE-TRIP key to terminate testing.
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TM 11574A-OI V. NORMAL OPERATING PROCEDURES 2-16. Modes of Operation The operational software responds to various inputs. These inputs come from the temperature and pressure sensors, the temperature set point, the settings of the configuration variables, and the function code assignments. The action taken by the operational software will change if any one of the inputs changes. Overall interaction of the inputs is described as a “mode” of operation.
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TM 11574A-OI f. Condenser Pressure Control. When configuration variable CnF14 is set to “In,” the condenser pressure control logic is activated to maintain discharge pressures above 130 psig when the ambient temperature is low. The logic turns the condenser fan on or off in accordance with the condenser pressure transducer reading (refer to Table 2-4). The function is enabled when the following conditions are met: 1. The ambient sensor reading is less than or equal to 80 F (27 C), and 2.
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TM 11574A-OI i. Temperature Control -- Frozen Mode. With configuration variable CnF26 set to -10 C, the frozen mode of operation is active with set points at or below +14 F (-10 C). With the variable set to +23 F (-5 C), the frozen mode is active at or below +23 F (-5 C).
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TM 11574A-OI 2-17. Startup a. Power Connections. WARNING Beware of unannounced starting of the evaporator and condenser fans. The unit may cycle the fans and compressor unexpectedly as control requirements dictate. WARNING Do not attempt to remove power plug(s) before turning OFF start-stop switch (ST), unit circuit breaker(s) and external power source. WARNING Make sure the power plugs are clean and dry before connecting to any power receptacle.
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TM 11574A-OI Figure 2-15. Autotransformer. LEGEND 1. 2. 3. Dual Voltage Modular Autotransformer Circuit Breaker (CB-2) 230V 460 VAC Power Receptacle b. Adjusting Fresh Air Makeup Vent. The purpose of the fresh air makeup vent is to provide ventilation for commodities that require fresh air circulation. The vent must be closed when transporting frozen foods. Air exchange depends on static pressure differential, which will vary depending on the container and how the container is loaded.
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TM 11574A-OI c. Starting the Unit. Do not attempt to remove power plug(s) before turning OFF start-stop switch (ST), unit circuit breaker(s) and external power source. (1) With power properly applied and the fresh air damper set connected (refer to paragraphs 217a and 2-17b), place the START-STOP switch to “I” (ON). (2) Continue with Start Up Inspection (refer to paragraph 2-17d). d. Startup Inspection. (1) Physical Inspection. (a) Perform before operation checks in accordance with table 2-12.
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TM 11574A-OI Table 2-13. Before Operation Checks Interval Item Action EXTERIOR Before Cargo Doors Inspect hardware for bent or broken door release handles. Before Rear Doors Inspect hardware for bent or broken door release handles. Before Refrigeration Unit Check refrigeration unit for security. Install and secure loose or missing mount bolts. Before Evaporator Fan Check for dirt or grease on evaporator fan or fan deck and clean if necessary.
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TM 11574A-OI e. Observe Unit Operations – Probe Check. If the DataCORDER is off or in alarm mode, the controller will revert to a four probe configuration, which includes the DataCORDER supply and return air probes as the secondary controller probes. The controller continuously performs probe diagnosis testing, which compares the four probes. If the probe diagnosis result indicates a probe problem exists, the controller will perform a probe check to identify the probe(s) in error.
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TM 11574A-OI Figure 2-17. Controller Operation – Perishable Mode. Figure 2-18. Controller Operation – Frozen Mode.
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TM 11574A-OI (1) Sequence Of Operation – Perishable Mode Cooling NOTE In the conventional Perishable Mode of Operation, the evaporator motors run in high speed. In the economy Perishable Mode, the fan speed is varied. NOTE In low temperature ambient, the condenser fan will be cycled by the controller to maintain proper condensing pressure.
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TM 11574A-OI (e) compressor and condenser fan motors. The cool light is also de-energized. (f) The evaporator fan motors continue to run to circulate air throughout the container. The in-range light remains illuminated as long as the supply air is within tolerance of set point. (g) When the supply air temperature increases to 0.4 F (0.2 C) above set point and the three minute off time has elapsed, relays TC and TN are energizes to restart the compressor and condenser fan motors.
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TM 11574A-OI (3) Sequence Of Operation – Frozen Mode Cooling NOTE Prior to starting tests, verify that unit voltage (Function Code Cd07) is within tolerance and unit amperage draw (Function Codes Cd04, Cd05, Cd06) is within expected limits. Otherwise, tests may fail incorrectly. All alarms must be rectified and cleared before starting tests.
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TM 11574A-OI (4) Sequence Of Operation – Defrost The defrost cycle may consist of up to three distinct operations. The first is de-icing of the coil, the second is a probe check cycle, and the third is snap freeze. Defrost may be requested by any one of the following methods: The manual defrost function (also manual defrost switch function if equipped) is initiated and ended by the user using the keypad or manual defrost switch (if equipped).
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TM 11574A-OI The processing of a defrost request is controlled by the defrost termination thermostat. The defrost termination thermostat is not a physical component. It is a software point that acts as a thermostat, allowing defrost when it is considered “closed” and preventing or terminating defrost when it is considered “open.
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TM 11574A-OI g. Operation of Temperature Control Microprocessor System. The temperature control Micro-Link 3 microprocessor system (see Figure 2-24) consists of a keypad, display module, control module (controller), and interconnecting wiring. The controller houses the temperature control software and the DataCORDER Software. The temperature control software functions to operate the unit components as required to provide the desired cargo temperature and humidity.
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TM 11574A-OI (1) The keypad (Figure 2-25) is mounted on the right-hand side of the control box. The keypad consists of 11 push button switches that act as the user’s interface with the controller. Descriptions of the switch functions are provided in Table 2-1. Figure 2-24. Keypad. (2) Display Module. The display module (Figure 4-16) consists of five digital displays and seven indicator lights. The indicator lights include: (a) Cool -- White LED: Energized when the refrigerant compressor is energized.
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TM 11574A-OI (f) Return -- Yellow LED: Energized when the return air probe is used for control. When this LED is illuminated, the temperature displayed in the AIRTEMPERATURE display is the reading at the return air probe. (g) Alarm -- Red LED: Energized when there is an active or an inactive shutdown alarm in the alarm queue. Figure 2-25. Display Module. LEGEND KEY 1. 2. Code Select Pre-Trip 3. 4. Alarm List Manual Defrost/Interval 5. Enter 6. Arrow Up 7. Arrow Down 8. Return/Supply 9.
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TM 11574A-OI NOTE The controlling probe in the perishable range will be the SUPPLY air probe and the controlling probe in the frozen range will be the RETURN air probe. (3) Controller. CAUTION Do not remove wire harnesses from controller unless you are grounded to the unit frame with a static safe wrist strap. CAUTION Unplug all controller wire harness connectors before performing arc welding on any part of the container. NOTE Do not attempt to service the controller.
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TM 11574A-OI h. Controller Alarms. Alarm display is an independent controller software function. If an operating parameter is outside of expected range or a component does not return the correct signals back to the controller, an alarm is generated. A listing of the alarms is provided in Table 2-6. The alarm philosophy balances the protection of the refrigeration unit and that of the refrigerated cargo. The action taken when an error is detected always considers the survival of the cargo.
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TM 11574A-OI i. Unit Pre-Trip Diagnostics. Pre-trip diagnostics is an independent controller function that will suspend normal refrigeration controller activities and provide preprogrammed test routines. The test routines include Auto Mode testing, which automatically performs a pre-programmed sequence of tests or Manual Mode testing, which allows the operator to select and run any of the individual tests.
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TM 11574A-OI k. Operating Emergency Escape Door. (1) The emergency escape door provides a means of emergency egress should someone become trapped inside the container. The door can only be opened from the inside. (2) To open the emergency escape door, grasp both spring loaded door handles and pull to the left, disengaging each handle from its locking catch. (3) Swing the emergency escape door outwards. Figure 2-27. Operating Emergency Escape Door.
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TM 11574A-OI l. Operating Interior Lighting. (1) To operate the interior lighting when the system is being powered via the large system power cables, rotate the lighting switch to the center position. (2) If the system is being powered via the 110 VAC power cable, rotate the lighting switch to the far right position. (3) Rotate the lighting switch to the left to turn the interior lighting off. Figure 2-28. Operating the Interior Lighting.
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TM 11574A-OI m. Operating Air Curtain. (1) The air curtain provides a means to enter and exit the container when refrigerated while minimizing the loss of refrigerated air from the interior of the container. (2) To deploy the air curtain, grasp and slide the vertical vanes to the right, closing off the opening to the container. Simply part the vanes when entering and exiting the container. (3) Slide the air curtain fully to the left to move it completely out of the way when entering or exiting with cargo.
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TM 11574A-OI VII. OPERATION UNDER UNUSUAL CONDITIONS 2-20. Unusual Conditions Refer to this section for steps and precautions to take in the event of adverse or unusual environmental conditions. a. Operation in Heavy Rain or Flooding. (1) Keep container doors closed and secure whenever possible. (2) Keep refrigeration unit controller protected from rain. (3) To minimize the effects of flooding or heavy rain, dig a trench around the container to evacuate excess water.
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TM 11574A-OI i. Operation in Mud (1) Keep power cable and plug away from water or excess moisture. Keep plug clear of mud and other particles. (2) Clean floor more frequently. Keep floor free of mud whenever possible. j. Interim Nuclear, Biological, and Chemical (NBC) Decontamination Procedures (1) If chemical or biological contamination is expected, close and secure container door. (2) Close and secure the fresh air make-up vent.
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TM 11574A-OI CHAPTER 3 MAINTENANCE INSTRUCTIONS I. INTRODUCTION 3-1. Scope This chapter of the Technical Manual (TM) contains instructions for Preventive Maintenance Checks and Services (PMCS) for the Large Field Refrigeration System and associated components. Additionally, troubleshooting procedures, corrective maintenance, and component adjustment procedures for the Large Field Refrigeration System are provided. 3-2. Tools Required for Maintenance Procedures Table 3-1. Tool Requirements TAMCN 3-3.
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TM 11574A-OI II. PREVENTIVE MAINTENANCE CHECKS AND SERVICE (PMCS) To ensure the Large Field Refrigeration System is ready for operation at all times, it must be inspected so that defects are discovered and corrected before they result in damage or equipment failure. Any effective preventive maintenance program must begin with instructions to all operators to report all unusual conditions noted during daily checks or actual operation to the appropriate maintenance personnel.
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TM 11574A-OI NOTE Column 3 for the trailer component lists criteria that render the trailer not fully mission capable. Column 4 indicates the specific interval to perform each task. Table 3-2. PMCS Symbols INTERVAL Hourly Weekly Monthly Quarterly Semiannually Annually Other SYMBOLS H W M Q S A O Table 3-3. Preventive Maintenance Checks and Services INTERVAL ITEM / TASK H W Cargo Doors (Exterior) Inspect for broken or missing handle locks. Inspect for broken or missing handle locks.
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TM 11574A-OI Table 3-3. Preventive Maintenance Checks and Services - Continued Container X Inspect for corrosion and condition of paint. Name plates X Inspect for missing, damaged or illegible name plates. Container (Interior) X Check for damage, corrosion, and punctures. Escape door (Interior) X Check for security, damage and missing hardware. 3-6. Preventive Maintenance Tasks a.
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TM 11574A-OI III. CORRECTIVE MAINTENANCE PROCEDURES 3-7. Corrective Maintenance Tasks (CM) a. Repair the Container. Emergency repairs can be performed to prevent additional damage to container panels. All other container repair is performed by contractor. (1) Emergency Repairs. Damage to the coating of the container panel that does not expose or puncture the lining of the panel should not be repaired.
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TM 11574A-OI b. Repair the Refrigeration System. WARNING Never use air for leak testing. It has been determined that pressurized mixtures of refrigerant and air can undergo combustion when exposed to an ignition source. 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. In the US, refer to EPA section 608. (1) Service Valves.
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TM 11574A-OI (a) Preparing Manifold Gauge/Hose Set For Use If the manifold gauge/hose set is new or was exposed to the atmosphere, it will need to be evacuated to remove contaminants and air as follows: 1 Back seat (turn counterclockwise) both field service couplings (Figure 3-4) and mid seat both hand valves. 2 Connect the yellow hose to a vacuum pump and refrigerant 134a cylinder. 3 Evacuate to 10 inches of vacuum and then charge with R-134a to a slightly positive pressure of 1.0 psig @ (0.1 kg/cm).
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TM 11574A-OI (b) Connecting Manifold Gauge/Hose Set Connection of the manifold gauge/hose set (Figure 3-5) is dependent on the component being serviced. If only the compressor is being serviced, the high side coupling is connected to the discharge service valve. For service of the low side (after pump down), the high side coupling is connected to the liquid line service valve. The center hose connection is brought to the tool being used.
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TM 11574A-OI (c) Removing the Manifold Gauge Set if performed following the steps below: 1 While the compressor is still ON, open (backseat) the high side service valve. 2 Mid seat both hand valves on the manifold gauge set and allow the pressure in the manifold gauge set to be drawn down to suction pressure. This returns any liquid that may be in the high side hose to the system. 3 Open (backseat) the suction service valve.
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TM 11574A-OI (e) Refrigerant leak checking. WARNING Never use air for leak testing. It has been determined that pressurized, air-rich mixtures of refrigerants and air can undergo combustion when exposed to an ignition source. 1 The recommended procedure for finding leaks in a system is with an R-134a electronic leak detector. Testing joints with soapsuds is satisfactory only for locating large leaks.
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TM 11574A-OI (3) Evacuation and dehydration. Moisture is the deadly enemy of refrigeration 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. (a) Preparation.
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TM 11574A-OI 1. 2. 3. 4. 5. Reclaimer Discharge Service Valve Compressor Suction Service Valve Receiver or Condenser 6. Liquid Service Valve 7. Vacuum Pump 8. Electronic Vacuum Gauge 9. Manifold Gauge Set Refrigerant Cylinder Figure 3-5. Compressor Service Connections. (c) Partial system procedure.
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TM 11574A-OI (4) Refrigeration Charge. (a) Checking the refrigerant charge. To check the refrigeration charge, follow the steps below: 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. In the US, refer to EPA section 608. 1 Connect the gauge manifold to the compressor discharge and suction service valves.
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TM 11574A-OI 3 Fully open (backseat) the suction service valve and remove the service port cap. 4 Connect charging line between suction service valve port and cylinder of refrigerant R-134a. Open VAPOR valve. 5 Partially front seat (turn clockwise) the suction service valve and slowly add charge until the refrigerant appears at the proper level. (5) Compressor. WARNING Make sure power to the unit is OFF and power plug disconnected before replacing the compressor.
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TM 11574A-OI 6 Remove compressor and mounting plate. Refer to Refrigeration system data table 11 for weight of compressor. 7 Remove high pressure switch (HPS) from compressor and check operation of switch (refer to Checking high pressure switch section 3-10b(6)). 8 Remove compressor mounting bolts from mounting plate and install mounting plate on replacement compressor. 9 Install replacement compressor terminal wiring kit, following instructions included with kit.
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TM 11574A-OI 1. Discharge Valve Flange 2. High Side Pressure Connection 3. Low Side Pressure Connection 4. Suction Valve Flange 5. Motor End Cover 6. Serial/Model No. Plate 7. Crankcase Heater 8. 9. 10. 11. 12. 13. 14. 15. 16. Bottom Plate Sight Glass Oil Drain Plug Oil Charging Valve Bearing Head Oil Pump Oil Fill Plug Cylinder Head Valve Plate Figure 3-6. Compressor. (c) Checking compressor oil level.
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TM 11574A-OI (d) Compressor cleanup after mild burnout. WARNING Observe all safety precautions while working on system. Avoid contact with refrigerant/oil mixture since acid burns may result. Wear safety glasses and work gloves. NOTE There are two types of burnout cleanup covered in the following section; Mild Burnout and Severe Burnout. Mild burnout is a non-running motor burn with the motor contaminants confined to the compressor.
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TM 11574A-OI 4 Replace liquid line filter with one size larger in capacity than the unit being worked on. 5 Add suction line filter of appropriate size, mounted vertically with pressure taps on both inlet and outlet. 6 Depending on the severity of the burnout, components may need to be changed put or cleaned. 7 Triple evacuate as discussed in the mild burnout procedure. 8 Recharge unit compensating for additional volume in larger liquid line filter drier. 9 Run for one hour minimum.
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TM 11574A-OI (7) Condenser Coil. (a) Condenser coil replacement. The condenser consists of a series of parallel copper tubes expanded into copper fins. The condenser coil must be cleaned with fresh water or steam so the air flow is not restricted. To replace the coil, do the following: WARNING Do not open the condenser fan grille before turning power OFF and disconnecting power plug. 1 Using a refrigerant reclaim system, remove the refrigerant charge. 2 Remove the condenser coil guard.
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TM 11574A-OI 1 Open condenser fan screen guard. 2 Loosen two square head set screws on fan (thread sealer has been applied to set screws at installation). Disconnect wiring from motor junction box. CAUTION Take necessary steps (place plywood over coil or use sling on motor) to prevent motor from falling into condenser coil. 3 Remove motor mounting hardware and replace the motor. It is recommended that new locknuts be used when replacing motor. Connect wiring per wiring diagram.
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TM 11574A-OI NOTE TXV Bulb Clamp is soldered to the suction line. 1. Suction Line 2. Thumbscrew 3. TXV Bulb Clamp 4. TXV Bulb 5. Foam Insulation Figure 3-8. Thermostatic Expansion Valve Bulb. (b) Checking Superheat. To check the superheat function of the thermostatic expansion valve perform the following: NOTE Proper superheat measurement should be completed at 0 F (-17.8 C) container box temperature where possible.
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TM 11574A-OI (c) Expansion valve removal. To remove the expansion valve perform the following: NOTE The TXV is a hermetic valve and does not have adjustable superheat (Figure 3-10). All connections on the hermetic TXV are bi-metallic, copper on the inside and stainless on the outside. All joints on the hermetic TXV (inlet, outlet and equalizer lines) are brazed. Bi-metallic connections heat up very quickly. 1 Pump down the unit per Pumping the unit down paragraph 3-10b(2)(d).
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TM 11574A-OI Figure 3-10. Hermetic Thermostatic Expansion Valve Brazing Procedure. (d) Expansion valve installation. To install the expansion valve perform the following: 1 Braze inlet connection to inlet line (Figure 3-11). 2 Braze outlet connection to outlet line. 3 Braze the equalizer connection to the equalizer line. 4 Reinstall the cushion clamp.
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TM 11574A-OI 7 Unsolder the two coil connections, one at the distributor and the other at the coil header. 8 After defective coil is removed from unit, remove defrost heaters and install on replacement coil. 9 Install coil assembly by reversing above steps. 10 Leak check connections per Refrigeration leak checking paragraph 3-10b(2)(e). Evacuate the unit per Evacuation and dehydration paragraph 3-10b(3), and add refrigerant charge per Refrigeration charge paragraph 3-10b(4).
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TM 11574A-OI 2 Replacing Heat Exchanger. This maintenance procedure does not exist in the commercial manual. It is to be developed at a later date. (12)Evaporator Fan and Motor Assembly NOTE The evaporator fans circulate air throughout the container by pulling air in the top of the unit. The air is forced through the evaporator coil where it is either heated or cooled and then discharged out the bottom of the refrigeration unit into the container.
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TM 11574A-OI 5 Install the evaporator fan assembly in reverse order of removal. Torque the four 1/420 clamp bolts to 70 inch pounds. Apply power momentarily to check for proper fan rotation (refer to Table 1-1). If fan spins backward, then motor wiring or motor is defective. 6 Replace access panel making sure that panel does not leak. Make sure that the T.I.R. locking device is lock wired. 1. 2. 3. 4. 5. Stator Flat washer, 1/4 Bolt, 1/4-20 x 3/4 Locknut, 5/8-18 Flat washer, 5/8 6. 7. 8. 9.
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TM 11574A-OI (13)Evaporator Fan Motor Capacitor Units are equipped with single permanent –split capacitor fan motors. (a) When to Check for a Defective Capacitor. 1 When the fan motor will not change speed, for example: in the conventional perishable mode, the motors should run in high speed. In the economy perishable mode they should switch speeds and in the frozen mode, the motors should run in low speed. NOTE Units are equipped with single permanent-split capacitor fan motors.
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TM 11574A-OI 2 Capacitor analyzer. a. The function of the analyzer is to read the microfarad value of a capacitor and to detect insulation breakdown under load conditions. The important advantages of an analyzer are its ability to locate capacitors that have either failed to hold their microfarad ratings or those that are breaking down internally during operation. It is also useful in identifying capacitors when their microfarad rating marks have become unreadable.
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TM 11574A-OI NOTE Carefully listen to the valve. During reset, the valve will make a ratcheting noise that may be heard or felt as it is attempting to close. If this can be heard or felt, it indicates that the controller and drive module are attempting to close the valve, and may serve as a quick indication that the drive module is in working order. 5 During the first few minutes of unit operation, compressor reliability enhancement logic (CREL) may be in effect.
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TM 11574A-OI (15)Checking the Stepper Valve. (a) Checking with ohmmeter 1 Disconnect the 4-pin connector to the stepper SMV. With a reliable digital ohmmeter, check the winding resistance. In normal ambient, the valve should have 72 to 84 ohms measured on the red/green (a-b terminals) and on the white/black (c-d terminals) leads. If an infinite or zero reading occurs, check connections and replace the motor. If near normal or normal reading occurs, proceed to step 3-10b(14)(d) to check out the controller.
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TM 11574A-OI (d) Emergency Repair Procedures. In the event that the SMV system has a failure and replacement components are not readily available, the system can be bypassed by removing the valve piston. To remove the piston, do the following: 1 Perform a low side pump down (refer to Pumping the unit down paragraph 310b(2)(d)). 2 Remove SMV power head by loosening the 2-1/8 inch diameter nut (Figure 3-13) to relieve any pressure and then sliding the power head out.
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TM 11574A-OI Figure 3-13. DPRV Replacement Value Chart. NOTE This test should not be run below 30 F (-1.1 C) or above 120 F (49 C). If the actual differential pressure is close to the replacement differential pressure, it is recommended that the readings be taken several times at two minutes intervals. If valve cap is found to be leaking it may be replaced using cap & O-ring (Carrier Part Number 4050024-00).
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TM 11574A-OI (18)Controller (a) Handling Controller. To safely handle the controller, perform the following steps: CAUTION Do not remove wire harnesses from controller unless you are grounded to the unit frame with a static safe wrist strap. CAUTION Unplug all controller connectors before performing arc welding on any part of the container. NOTE The guidelines and cautions provided herein should be followed when handling the Controller/DataCORDER module.
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TM 11574A-OI Controller Troubleshooting. A group of test points (TP) (Figure 3-15) are provided on the controller for troubleshooting electrical circuits (schematic diagram, Appendix A). A description of the test points follows: NOTE Use a digital voltmeter to measure AC voltage between TPs and ground (TP9), except for TP8. 3-34 1 TP2 This test point enables the user to check if the internal protector for the compressor motor (IP-CP) or high pressure switch is open.
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TM 11574A-OI (b) Removing the Controller. To remove the controller, perform the following steps: 1 Disconnect all front wire harness connectors and move wiring out of way. 2 The lower controller mounting is slotted. Loosen the top mounting screw (Figure 315) and lift up and out. 3 Disconnect the two back connectors (EC) and remove module. 4 When removing the replacement controller from its packaging, note how it is packaged.
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TM 11574A-OI (19)Temperature Sensor Test (a) Temperature Sensor Test. To check the temperature sensor, perform the following steps: 1 Remove the sensor and place in a 32 F (0 C) ice-water bath. The ice-water bath is prepared by filling an insulated container (of sufficient size to completely immerse bulb) with ice cubes or chipped ice, then filling voids between ice with water and agitating until mixture reaches 32 F (0 C) measured on a laboratory thermometer.
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TM 11574A-OI 3 If required, prepare the replacement sensor by cutting sensor wire(s) back 1-/2 in (140 mm). For 3-wire sensors, the black wire should be cut at the middle length and the red/white wire cut to the shorter length (Figure 3-17). Figure 3-16. Sensor Types 4 Prepare the cables by cutting wires to the opposite of the sensor (Figure 3-18). NOTE When installing a single wire color two wire sensor, cut one wire of existing two wire cables 1-1/2 in (40 mm) shorter than the other wire.
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TM 11574A-OI Slide large heat shrink tubing over both splices and shrink. CAUTION Do not allow moisture to enter wire splice area as this may affect the sensor resistance. NOTE The P5 Pre-Trip test must be run to inactivate probe alarms (refer to section 2-15). (c) Temperature Sensor Installation. To install the temperature sensor, perform the following steps: 1 Sensors STS/SRS a 2 Sensor RTS/RRS a 3 To properly position a supply sensor, the sensor must be fully inserted into the probe holder.
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TM 11574A-OI Figure 3-18. Supply Sensor Positioning Figure 3-19.
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TM 11574A-OI Table 3-4. R134a Saturation Temperature – Pressure Chart.
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TM 11574A-OI Figure 3-20. R-134a Compressor Pressure and Motor Current Curves versus Ambient Temperature (Sheet 1 of 2).
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TM 11574A-OI Figure 3-21. R-134a Compressor Pressure and Motor Current Curves versus Ambient Temperature (Sheet 2 of 2). c. Replace the Refrigeration Unit. (1) Replace the refrigeration unit. To replace the refrigeration unit, perform the following steps: (a) To replace the refrigeration unit, loosen and remove the 30 bolts that secure the unit to the container frame. (b) Slide a lifting device rated for the appropriate weight in place under the defective refrigeration unit.
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TM 11574A-OI (c) Support the weight of the refrigeration unit with the lifting device and move out away from the container frame until the power connections are exposed. (d) Disconnect all power cables that run from the container to the refrigeration unit. (e) Move the defective refrigeration unit completely away from the container. (f) Move a new refrigeration unit in position in front of the refrigeration unit bay of the container.
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TM 11574A-OI d. Maintenance of Painted Surfaces The refrigeration unit is protected by a special paint system against the corrosive atmosphere in which it normally operates. However, should the paint system be damaged, the base metal can corrode. In order to protect the refrigeration unit from the highly corrosive sea atmosphere or if the protective paint system is scratched or damaged, clean area to bare metal using a wire brush, emery paper, or equivalent cleaning method.
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TM 11574A-OI 2 3 1 Figure 3-23. Replacing the Glass Dome. (2) Replacing Light Bulb. To replace the interior light bulb follow the steps below: (a) Remove the two screws (Figure 3-29, Item 1) securing the protective cage (Figure 3-29, Item 2) to the lighting assembly. (b) Remove the protective cage and set aside. (c) Remove the glass dome (Figure 3-29, Item 3) and set aside. (d) Unscrew the defective light bulb and discard. (e) Screw a new light bulb into the light socket.
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TM 11574A-OI (3) Replacing Interior Lighting Switch. To replace the interior lighting switch, follow the steps below: (a) To replace the interior lighting switch, remove the screws (Figure 3-30, Item 1) securing the upper switch housing (Figure 3-30, Item 2) to the lower switch housing (Figure 3-30, Item 3). (b) Separate the upper and lower switch housings. (c) Mark and tag all internal wires. (d) Disconnect the wires from the switch assembly mounted to the upper switch housing.
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TM 11574A-OI f. Repairing the Air Curtain (1) To repair one or more damaged interior air curtain vertical vanes (Figure 3-31, Item 1), loosen and remove the three screws, lock washers, and nuts (Figure 3-31, Item 2) that secure the vertical vane to the vane bracket (Figure 3-31, Item 3). Set the hardware aside. (2) Remove the damaged vertical vane and discard. (3) Position a new vertical vane in the vane bracket, aligning the holes in the bracket with those in the vertical vane.
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TM 11574A-OI g. Replacing the Floor Drain (1) To replace a floor drain screen (Figure 3-32, Item 1), pry the edges up around the perimeter with a flat blade screwdriver. (2) Remove the defective screen (Figure 3-32, Item 2). (3) Install the floor drain screen in position and press in place until seated. 1 Figure 3-26. Replacing Floor Drain Screen.
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TM 11574A-OI IV. TROUBLESHOOTING AND FAULT ISOLATION PROCEDURES Troubles or operating malfunctions which may occur on the Large Field Refrigerated System and associated components. After remedial action has been taken, testing of affected equipment shall be carried out to insure that it is serviceable and in satisfactory operating condition. 3-8 Troubleshooting a. Compressor does not run. Step 1 Probable Cause Main power line open. Remedy Replace fuse or reset circuit breaker.
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TM 11574A-OI Step 3 Probable Cause Low refrigerant charge. Remedy Add refrigerant. If fault is not corrected proceed to step 4. 4 Plugged suction strainer. Clean strainer. If fault is not corrected proceed to step 5. 5 c. Defective TXV. Compressor cycles on high pressure control. Step 1 Replace TXV. Probable Cause High pressure control erratic in action. Remedy Check capillary tube for pinches, set control as required. If fault is not corrected proceed to step 2.
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TM 11574A-OI Step 5 Probable Cause Expansion valve setting too high. Remedy Lower setting. If fault is not corrected proceed to step 6. 6 Iced or dirty evaporators. Defrost or clean evaporators. e. Unit operates long or continuously. Step 1 Probable Cause Low refrigerant charge. Remedy Add refrigerant. If fault is not corrected proceed to step 2. 2 Control contacts fused. Replace controls. If fault is not corrected proceed to step 3. 3 Air in system. Recover.
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TM 11574A-OI f. Step 1 System noises. Probable Cause Piping vibration. Remedy Support piping as required, check for plugged liquid line strainer. If fault is not corrected proceed to step 2. 2 Expansion valve hissing. Add refrigerant, check for plugged liquid line strainer. If fault is not corrected proceed to step 3. 3 Compressor noisy. Check valve plates for valve noise, replace compressor (worn bearings), check for loose compressor hold down bolts. If fault is not corrected proceed to step 4.
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TM 11574A-OI i. Hot liquid line. Step 1 j. Step 1 2 k. Step 1 Probable Cause Shortage of refrigerant. Remedy Repair leak and recharge. Frosted liquid line. Probable Cause Remedy Receiver shutoff valve partially closed or restricted. Open valve or remove restiction. Restricted strainer dryer. Replace strainer dryer. If fault is not corrected proceed to step 2. Frosted expansion valve. Probable Cause Ice plugging TXV orifice. Remedy Apply hot wet cloth to TXV.
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TM 11574A-OI l. RU will not start or starts then stops. (1) No power to unit. Step 1 Probable Cause External power source OFF. Remedy Ensure external power source is ON. If fault is not corrected proceed to step 2. 2 Start-Stop switch OFF or defective. Check start-stop switch is in the ON position and not defective. If fault is not corrected proceed to step 3. 3 Circuit breaker tripped or OFF. Check circuit breaker is set to ON. If fault is not corrected proceed to step 4.
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TM 11574A-OI (3) Component(s) not operating. Step Probable Cause 1 Evaporator fan motor internal protector open. Remedy Replace evaporator fan IAW 3-10b(12). If fault is not corrected proceed to step 2. 2 Condenser fan motor internal protector open. Replace condenser fan motor IAW 3-10b(8). If fault is not corrected proceed to step 3. 3 Compressor internal protector open. Replace Compressor internal protector IAW 3-10b(5). If fault is not corrected proceed to step 4. 4 High pressure switch open.
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TM 11574A-OI (2) Refrigeration System. Step 1 Probable Cause Shortage of refrigerant. Remedy Check refrigerant IAW 3-10b(2)(e). Recharge refrigerant IAW 3-10b(4). If fault is not corrected proceed to step 2. 2 Evaporator coil covered with ice. Refer to section 3-11d. If fault is not corrected proceed to step 3. 3 Evaporator coil plugged with debris. Refer to section 3-10b(11). If fault is not corrected proceed to step 4. 4 Evaporator fan(s) rotating backwards.
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TM 11574A-OI (2) Refrigeration System. Step 1 Probable Cause Abnormal pressures. Remedy Refer to section 3-11g. If fault is not corrected proceed to step 2. 2 Controller malfunction. Refer to section 3-11i. If fault is not corrected proceed to step 3. 3 Evaporator fan or motor defective. Refer to section 3-10b(12). If fault is not corrected proceed to step 4. 4 Suction modulation valve malfunction. Refer to section 3-10b(14). If fault is not corrected proceed to step 5.
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TM 11574A-OI (2) No control power. Step 1 Probable Cause Circuit breaker or fuse defective. Remedy Check for blown fuses IAW WP 3-10b(18)(i). Replace blown fuse IAW 3-10b(18)(j) Check for damaged or defective circuit breaker IAW 3-10b(18)(q). If circuit breaker is found to be defective, replace IAW 3-10b(18)(r). If fault is not corrected proceed to step 2. 2 Control transformer defective. Replace control transformer IAW 310b(18)(g). If fault is not corrected proceed to step 3.
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TM 11574A-OI Step 7 Probable Cause Loose terminal connections. Remedy Tighten. If fault is not corrected proceed to step 8. 8 Low line voltage. Refer to table 1-1. If fault is not corrected proceed to step e (1). p. Unit will not terminate heating. (1) Unit fails to stop heating. Step 1 Probable Cause Controller improperly set. Remedy Reset. If fault is not corrected proceed to step 2. 2 Controller malfunction. Refer to section 3-10b(11)(i). If fault is not corrected proceed to step 3.
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TM 11574A-OI Step 5 Probable Cause Heater contactor or coil defective. Remedy Replace contactor or coil IAW 3-10b(11)(b). If fault is not corrected proceed to step f (2). (2) Will not initiate defrost manually. Step 1 Probable Cause Manual defrost switch defective. Remedy Check for defective manual defrost switch IAW 3-10b(11)(c). If necessary, replace manual defrost switch IAW 3-10b(11)(c)1. If fault is not corrected proceed to step 2. 2 Defrost temperature sensor open.
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TM 11574A-OI r. Abnormal pressures (cooling). (1) High discharge pressure. Step 1 Probable Cause Condenser coil dirty. Remedy Refer to section 3-10b(7). If fault is not corrected proceed to step 2. 2 Condenser fan rotating backwards. Refer to section 3-10b(8). If fault is not corrected proceed to step 3. 3 Condenser fan inoperative. Refer to section 3-10b(8). If fault is not corrected proceed to step 4. 4 Refrigerant overcharge or noncondensibles. Refer to section 3-10b(2)(e) and 310b(3)(b).
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TM 11574A-OI Step 5 Probable Cause No evaporator air flow or restricted air flow. Remedy Refer to section 3-10b(11). If fault is not corrected proceed to step 6. 6 Excessive frost on evaporator coil. Refer to section 3-11d. If fault is not corrected proceed to step 7. 7 Evaporator fan(s) rotating backwards. Refer to section 3-10b(11) and 3-10b(12). If fault is not corrected proceed to step 8. 8 Discharge pressure regulator valve defective.
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TM 11574A-OI Step 4 Probable Cause Liquid slugging. Remedy Refer to section 3-10b(10). If fault is not corrected proceed to step 5. 5 Insufficient oil. Refer to section 3-10b(5)(e). If fault is not corrected proceed to step h (2). (2) Condenser or evaporator fan. Step Probable Cause 1 Condenser or Evaporator Fan: Bent, loose or striking venturi. Check and adjust venturi IAW 3-10b(8). Worn motor bearings. Refer to section 3-10b(8) and 3-10b(11).
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TM 11574A-OI u. No evaporator air flow or restricted air flow. (1) Evaporator coil blocked. Step 1 Probable Cause Frost on coil. Remedy Refer to section 3-11d. If fault is not corrected proceed to step 2. 2 Dirty coil. Refer to section 3-10b(11). If fault is not corrected proceed to step j(2). (2) No or partial evaporator air flow. Step Probable Cause 1 Evaporator fan motor internal protector open. Remedy Refer to section 3-10b(12). If fault is not corrected proceed to step 2.
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TM 11574A-OI Step 5 Probable Cause Power assembly failure. Remedy Refer to section 3-10b(10). If fault is not corrected proceed to step 6. 6 Loss of element/bulb charge. Refer to section 3-10b(10). If fault is not corrected proceed to step 7. 7 Broken capillary. Refer to section 3-10b(10). If fault is not corrected proceed to step 8. 8 Foreign material in valve. Refer to section 3-10b(10). If fault is not corrected proceed to k (2). (2) High suction pressure with low superheat.
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TM 11574A-OI w. Autotransformer malfunction. (1) Unit will not start. Step 1 Probable Cause Circuit breaker (CB-1 or CB-2) tripped. Remedy Check circuit breakers IAW 2-17a(2)(b). If fault is not corrected proceed to step 2. 2 Autotransformer defective. Refer to section 3-10b(17). If fault is not corrected proceed to step 3. 3 Power source not turned ON. Check power source IAW 2-17a. If fault is not corrected proceed to step 4. 4 3-66 460 VAC power plug is not inserted into the receptacle.
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TM 11574A-OI 3-9 Troubleshooting Quick Reference 1. Will unit perform 5 sec. self-test? YES ___ NO ___ a. Check container ID # ___________ , b. Software # _________ , c Configuration _________ 2. Enter a perishable range (CHILL) set point. a. After self-test does the evaporator motor contactor (EF) energize? Current level leg 1 _____ Current level leg 2 _____ Current level leg 3 _____ ___ ___ b. 15 sec.
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TM 11574A-OI 6. Turn unit “OFF” a. Unplug the valve from stepper drive module (4 pin plug) and measure resistance of the valve. A – B ________ Ω C – D _______ Ω 7. Turn unit “ON” a. During the first 40 seconds check voltage on the plug from the controller (driver module). A – B ________ VAC C – D _______ VAC 8. Scroll units only. YES NO With unit operating in the cool mode (not at set point), Select code 41. a. Press “ENTER” key to select tIM and set to up to 5 min at 30 sec intervals using arrow keys.
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TM 11574A-OI CHAPTER 4 REPAIR PARTS SECTION SECTION I I. REPAIR PARTS INFORMATION 4-1. Scope This section furnishes complete data, including items used in conjunction with and furnished as part of, or with, the equipment, to enable the user to perform required maintenance and supply support of the equipment described herein. It is comprised of the following parts: Item Identification Listing, Item Number Cross-Reference, National Stock Number (NSN) CrossReference, and Part Number (P/N) Cross-Reference.
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TM 11574A-OI reference designator indicates there is not an illustration for the part. f. Indenture Code (Column 5): This column contains the Indenture Code Letter which indicates the relationship of a line item to the end item or to the preceding component, assembly, or subassembly. Visual indentation of the line item is not shown; however, the Indenture Code Letter will enable the user of the RPL to interpret the relationship of the line item with its next higher assembly. 1.
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TM 11574A-OI 1. The code provides the user with information on each item relative to (1) the method of obtaining the item; for example, by requisition, fabrication or salvage; (2) the lowest maintenance echelon authorized to remove, replace and use the item and the lowest echelon capable to perform complete repair, and (3) disposition action on unserviceable items. 2. Definitions of SMR codes are listed on page viii of the preface.
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TM 11574A-OI SECTION III III. DEFINITIONS AND APPLICATION OF SOURCE, MAINTENANCE, RECOVERABILITY CODES (SMRC) 4-3. Source Codes Source codes are assigned to support items and indicate the manner of acquiring the item for maintenance or overhaul of end items. Source codes are entered in the first and second position of the SMR code. a. SERIES A: ASSEMBLE, COMPLETE ASSEMBLY NOT STOCKED 1.
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TM 11574A-OI echelon. d. SERIES P: PARTS PROCURED, SUPPLY SYSTEM STOCK PA Applied to items procured for the Marine Corps supply system for anticipated or known usage. PB Applied to items for which no usage is anticipated, but procured for the Marine Corps supply system in limited quantity for issuing purposes. PC Applied to items procured for the Marine Corps supply system which would be coded PA except that they are deteriorative in nature.
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TM 11574A-OI Maintenance Codes Maintenance codes are assigned to indicate the levels of maintenance authorized to use and repair support items. The maintenance codes are entered in the third and fourth position of the SMR code. a. (Third Position): The maintenance code entered in the third position will indicate the lowest maintenance level authorized to remove, replace, and use the support item.
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TM 11574A-OI Recoverability Codes Recoverability codes are assigned to support items and indicate the disposition action for unserviceable items. The recoverability code is entered in the fifth position of the SMR code. Code Application/Explanation Z Non-reparable item. When unserviceable, condemn and dispose at the maintenance level indicated in position 3. O Reparable item. When uneconomically reparable, condemn at organizational level. F Reparable item.
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TM 11574A-OI SECTION IV IV.
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TM 11574A-OI SECTION VI VI. IDENTIFICATION OF PARTS 4-4. Repair Parts Lists and Illustrations This listing comprises the main part of the RPL. It is arranged in columns which show stock numbers, item identification, and other data necessary to maintain this equipment in an operative condition.
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TM 11574A-OI 3 7 6 4 1 3 7 6 5 4 2 Figure 4-1. RU Mounting Hardware. Table 4-1. RU Mounting Hardware (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI 2 1 4 3 5 6 7 9 8 10 Figure 4-2. Container Components. Table 4-2. Container Components (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO. SMR 4-2 1 XBOZZ 0FXA9 DC2-2 LIGHTING ASSEMBLY EA 2 2 4-2 2 XBOZZ 0FXA9 DC2-2-G GLOBE EA 2 2 4-2 3 XBOZZ 0FXA9 HS202-2 SWITCH ASSEMBLY EA 1 1 4-2 4 XBOZZ 0FXA9 S20-05SD-155F SMALL DOOR ASSY EA 1 1 4-2 5 XBOZZ 0FXA9 555-100 C1.
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TM 11574A-OI 2 1 3 4,5,7 20 7 4 6 22 21 14 Control Box Control Door Box 13 15 16 12 17 11 10 9 8 HINGE ASSEMBLY – SECTIONAL VIEW 23 DOOR ASSEMBLY – PARTIAL BACK VIEW Figure 4-3. Control Box Door.
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TM 11574A-OI Table 4-3. Control Box Door (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI 1 4,5 2 2 3 6,7 9 6,7 6,7 8 Figure 4-4. Control Box. Table 4-4. Control Box (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI 1 2 5 3 4 6 7 9 8 Figure 4-5 Display Module. Table 4-5 Display Module (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI 2,3 1,2 4,5 23 24,25 10 14,19,20,21 34,14,18 11 22 15,16,17 2,3 2,3 12,13,14 8,9 6,7 Figure 4-6. Control Box, Shield Removed.
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TM 11574A-OI Table 4-6. Control Box, Shield Removed (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI 22 21 20 8 1,2,3,4,7 30 15 16 19 5,6 18 14 10,11,12,13 9 11,13,17 NOT SHOWN 23 – Pin Assembly (Connects to ribbon cable) 24 – Kit, Battery Replacement (Located inside controller) 25 – Wire Harness (Connects controller to current sensing transformer) 26 – Wire Harness (Connects display module to controller) 27 – Label, Warning (Located on control box behind controller) 28 – Label, Warning (Located on shields) 29 – Label, Warning (Located on the bottom panel of the control box between th
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TM 11574A-OI Table 4-7. Controller Module (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI 4-20
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TM 11574A-OI 1,2,3,4 5 13 14 11 12 11 16 17,18,19,20,21,22 23 10 15 24 6,7,8 9 25,26,27,28 Figure 4-8. Condenser Fan and Condenser Coil.
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TM 11574A-OI Table 4-8. Condenser Fan and Condenser Coil (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI 16 7,11,12,13 7,8,10 9 6,7,8 18, 19, 20, 21, 22, 23 17 4 5 15 1,2,3 14 Figure 4-9. Compressor Tubing.
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TM 11574A-OI Table 4-9. Compressor Tubing (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI 1,5,6,7,8,9 34 10,32,33 31 10,11,12 29,30 2 27,28 4 26 24,25 3 23 13 11,12,14 5,6,7,15 17 19,20,21,22 16,17 Figure 4-10. Receiver. Table 4-10. Receiver (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI (1) (2) (3) (4) (5) (6) (7) ILLUS PART NUMBER QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO. SMR 4-10 5 PAOZZ 1KCF7 66U1-5361-25 SCREW EA 1 1 4-10 6 PAOZZ 1KCF7 66U1-5321-7 WASHER, FLAT EA 3 3 4-10 7 PAOZZ 1KCF7 34-06053-00 WASHER,MYLAR.25X.75 EA 4 4 4-10 8 PAOZZ 1KCF7 68-86030-00 PROTECTOR, MYLAR EA 1 1 4-10 9 PAOZZ 1KCF7 22-02448-00SV CONNECTOR EA 1 1 4-10 10 PAOZZ 1KCF7 34-00373-05 CLAMP,TUBE (.
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TM 11574A-OI 2 3 2 3 1 (STS) 1 (SRS) 5 4 6,7 Figure 4-11. SRS and STS Section. Table 4-11. SRS and STS Section. (1) (2) (3) (4) (5) (6) (7) ILLUS FIG NO. ITEM NO.
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TM 11574A-OI 9 6 1 6 1 2 10 6 11 3 12 4 6 6,8 5 6 7 Figure 4-12. Thermostatic Expansion Valve. Table 4-12. Thermostatic Expansion Valve (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO. SMR 4-12 1 PAOZZ 1KCF7 14-00273-01 VALVE, HERMETIC TXV EA 1 1 4-12 2 PAOZZ 1KCF7 58-04664-00 INSULATION, TXV BUL EA 2 2 4-12 3 PAOZZ 1KCF7 66U1-3882-3 WIRE TIE EA 2 2 4-12 4 PAOZZ 1KCF7 56-08347-00 TUBE, 0.
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TM 11574A-OI 7 1 2 4 3 5 6 11 12 8 9 10 13 14 Figure 4-13. Fresh Air Makeup Vent.
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TM 11574A-OI Table 4-13. Fresh Air Makeup Vent (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO. SMR 4-13 1 XBOZZ 1KCF7 79-01694-00 PANEL ASSY, W/DISC EA 1 1 4-13 2 XBOZZ 1KCF7 42-00296-01 GASKET, PANEL EA 1 1 4-13 3 XBOZZ 1KCF7 42-00327-00 GASKET, HALFMOON EA 1 1 4-13 4 PAOZZ 1KCF7 34-06053-13 WASHER, MYLAR .
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TM 11574A-OI 5 6 2,3,4 1 2,3,4,7 Figure 4-14. Transformer Panel. Table 4-14. Transformer Panel (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI 2,3,4 1 3,5,6 Figure 4-15. Document Panel. Table 4-15. Document Panel (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI 1 2 3 4 5 6 7 2 8 17 16 3 7 15 9 10 11,12,13,14 18,19,20,21,22,23,24,25 Figure 4-16. Evaporator Fan Assembly.
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TM 11574A-OI Table 4-16. Evaporator Fan Assembly (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI 1 (RRS/RTS) 2,3 4,5 20 24 15 21 22 21 23 6,7,8,9 25 9,10,11,12,13,14 19 18 17 16 Figure 4-17. Evaporator Coil.
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TM 11574A-OI Table 4-17. Evaporator Coil (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI 1 13,14 2 3 3 4 13,14 5,6,7 3 3 8 8 9 9 12 8 8 8,11 10 Figure 4-18. Back Panel Assembly.
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TM 11574A-OI Table 4-18. Back Panel Assembly (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI 1 2 8 14,15,16 3,4,5,6,7 9 12 10 1 3 11 16,17,18,19 Figure 4-19. Compressor.
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TM 11574A-OI Table 4-19. Compressor (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI 1 2,3 Figure 4-20. Compressor Gauges and Transducers. Table 4-20. Compressor Gauges and Transducers (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI 13,17 11,15 12,16 10,14 4,5,6,7, 8,9 1,2,3 Figure 4-21. Voltage Cable. Table 4-21. Voltage Cable (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO. SMR 4-21 1 PAOZZ 1KCF7 34-00373-59 CLAMP,TUBE (.
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TM 11574A-OI 4-21 17 XBOZZ 74545 HBL560P9W PLUG EA 1 4-43 1
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TM 11574A-OI 1 5,6,7,8 2 through 25 23 4,23 8,18, 24,25 2,3 8,17,18, 19 22 12 8,9,13,14, 15,16 20,21 9 10 11 Figure 4-22. Autotransformer.
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TM 11574A-OI Table 4-22. Autotransformer (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI 13 1 12 2 11 3 4 5 6 10 9 8 7 Figure 4-23. RU Labels and Decals.
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TM 11574A-OI Table 4-23. RU Labels and Decals (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI 1, 2, 3, 4 Figure 4-24. Interrogator Receptacle. Table 4-24. Interrogator Receptacle (1) (2) (3) (4) (5) (6) (7) ILLUS QTY QTY PER PER UM ASSY EQUIP FIG NO. ITEM NO.
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TM 11574A-OI APPENDIX A SCHEMATICS A-1
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TM 11574A-OI A-1.
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TM 11574A -OI LEGEND A-3
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TM 11574A-OI A-1.
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TM 11574A -OI LEGEND A-5
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TM 11574A-OI A-2. Schematic Diagram.
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TM 11574A -OI LEGEND A-7
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TM 11574A-OI A-3. Schematic Diagram (Emergency Bypass).
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TM 11574A -OI LEGEND A-9
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TM 11574A-OI A-4. Refrigeration Schematic.
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TM 11574A -OI A-4. Lighting Schematic.
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TM 11574A-OI APPENDIX B MANUFACTURERS CAGE MANUFACTURER CAGE MANUFACTURER 10855 CARRIER CORPORATION DIVISION OF CARRIER TRANSICOLD 6304 THOMPSON RD EAST SYRACUSE, NY 13057-0000 1-315-432-6441 CARRIER TRANSICOLD 700 OLYMPIC DR ATHENS, GA 30601 1-781-246-1400 0FXA9 SEA BOX INC 802 INDUSTRIAL HIGHWAY RIVERTON, NJ 08077-1910 1-856-303-1101 39428 MCMASTER-CARR SUPPLY COMPANY 600 COUNTY LINE RD ELMHURST, IL 60126-2034 1-630-833-0300 1KCF7 74545 HUBBELL INC WIRING DEVICE DIV 185 PLAINS RD MILFORD, CT
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TM 11574A-OI APPENDIX C TROUBLESHOOTING QUICK REFERENCE 1. Will unit perform 5 sec. self-test? YES ___ NO ___ a. Check container ID # ___________ , b. Software # _________ , c Configuration _________ 2. Enter a perishable range (CHILL) set point. a. After self-test does the evaporator motor contactor (EF) energize? Current level leg 1 _____ Current level leg 2 _____ Current level leg 3 _____ ___ ___ b. 15 sec.
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TM 11574A-OI 6. Turn unit “OFF” a. Unplug the valve from stepper drive module (4 pin plug) and measure resistance of the valve. A – B ________ Ω C – D _______ Ω 7. Turn unit “ON” a. During the first 40 seconds check voltage on the plug from the controller (driver module). A – B ________ VAC C – D _______ VAC 8. Scroll units only. YES NO With unit operating in the cool mode (not at set point), Select code 41. a. Press “ENTER” key to select tIM and set to up to 5 min at 30 sec intervals using arrow keys.
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TM 11574A-OI COMPRESSOR DOES NOT RUN • Main power line open – replace fuse or reset circuit breaker • Safety thermostat tripped – reset thermostat • Control stuck open – replace control • Loose terminal connections – check connections • Improperly wired controls - Check wiring and rewire • Low line voltage – Check line voltage. Determine location of voltage drop • Compressor motor defective – Check motor winding for open or short.
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