Truck Refrigeration

OPERATION & SERVICE MANUALFor The

Neos™ 100STruck Refrigeration Units

62-11848 Rev B

OPERATION & SERVICE MANUALFor The

Neos™ 100S

Truck Refrigeration Units

© 2017 Carrier Corporation ● Printed in USA September 2017

i 62-11848

TABLE OF CONTENTSPARAGRAPH NUMBER PAGE

SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.1 GENERAL SAFETY NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2 FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.3 OPERATING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.4 MAINTENANCE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.5 REFRIGERANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21.6 SPECIFIC WARNING AND CAUTION STATEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1.1 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.1.2 Noise Level Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.3 CONDENSING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.3.1 Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.3.2 Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12.3.3 Hot Gas Solenoid Valve (HGS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.3.4 Condenser Pressure Control Valve (HGS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.3.5 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.3.6 Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.3.7 High Pressure Switch (HP1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.3.8 Condenser Pressure Control Switch (HP2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.4 EVAPORATOR SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.4.1 Thermostatic Expansion Valve (TXV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.4.2 Compressor Pressure Regulating Valve (CPR) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.4.3 Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.4.4 Low Pressure Switch (LP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.5 SYSTEM OPERATING CONTROLS AND COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82.6 UNIT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.6.1 Compressor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82.6.2 Refrigeration System Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82.6.3 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92.6.4 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.7 SAFETY DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102.8 REFRIGERATION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2.8.1 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112.8.2 Heat And Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.1 STANDBY MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.2 CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.2.2 Microprocessor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23.2.3 Cab Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.3 STARTING-UP THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43.3.1 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43.3.2 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

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3.4 STOPPING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43.5 SETPOINT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53.6 MANUAL DEFROST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53.7 CHANGING DEFROST PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53.8 ALARM DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.8.1 Accessing Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63.8.2 Clearing Passive Alarms and the Maintenance Interval Message SE . . . . . . . . . 3-63.8.3 Low Battery Voltage Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.9 CHECKING THE SOFTWARE VERSION AND HOURMETER . . . . . . . . . . . . . . . . . . . . . . . . 3-63.10 PRODUCT LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73.11 RECOMMENDED TRANSPORT TEMPERATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83.12 MICROPROCESSOR CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.12.1 Functional Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8CONTROL LOGIC AND TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14.1.1 Perishable Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14.1.2 Frozen Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.2 DEFROST CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24.3 MINIMUM OFF TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15.1 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15.2 INSTALLING MANIFOLD GAUGE SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.2.1 Preparing Manifold Gauge/Hose Set For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35.2.2 Connecting Manifold Gauge/Hose Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35.2.3 Removing the Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.3 REMOVING THE REFRIGERANT CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45.3.1 Removing Complete Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.4 REFRIGERANT LEAK CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55.5 EVACUATION AND DEHYDRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

5.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55.5.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55.5.3 Procedure For Evacuation And Dehydrating System . . . . . . . . . . . . . . . . . . . . . . 5-5

5.6 CHARGING THE REFRIGERATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65.6.1 Checking The Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65.6.2 Installing A Complete Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65.6.3 Installing a Partial Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5.7 CHECKING FOR NON-CONDENSABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75.8 CHECKING AND REPLACING FILTER-DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5.8.1 Checking Filter-Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75.8.2 Replacing The Filter-Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5.9 HIGH PRESSURE (HP1) AND CONDENSER PRESSURE (HP2) SWITCHES . . . . . . . . . . . 5-75.9.1 Removing Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75.9.2 Checking Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5.10 HOT GAS SOLENOID VALVE (HGS1), CONDENSER PRESSURE CONTROL VALVE (HGS2) AND QUENCH VALVE 5-8

5.10.1 Replacing the Solenoid Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85.10.2 Replacing Valve Internal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

5.11 ADJUSTING THE COMPRESSOR PRESSURE REGULATING VALVE (CPR) . . . . . . . . . . . 5-9

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5.12 THERMOSTATIC EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95.12.1 Replacing expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105.12.2 Measuring Superheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.13 DIAGNOSTIC TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105.14 MICROPROCESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115.15 EVAPORATOR COIL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115.16 CONDENSER COIL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16.2 REFRIGERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2.1 Unit Will Not Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26.2.2 Unit Runs But Has Insufficient Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26.2.3 Unit Operates Long or Continuously in Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36.2.4 Unit Will Not Heat or Heating Insufficient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36.2.5 Defrost Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36.2.6 Abnormal Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36.2.7 Abnormal Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46.2.8 Cab Command Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46.2.9 No Evaporator Air Flow or Restricted Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46.2.10 Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56.2.11 Malfunction Hot Gas Solenoid, Condenser Pressure Regulating Valve, or Quench Valve 6-5

WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDEX-1

v 62-11848

LIST OF ILLUSTRATIONSFIGURE NUMBER Page

Figure 2.1 Main Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3Figure 2.2 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4Figure 2.3 Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5Figure 2.4 Microprocessor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5Figure 2.5 Standby Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6Figure 2.6 Cab Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8Figure 2.7 Refrigeration Circuit - Cooling Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12Figure 2.8 Refrigeration Circuit - Heating and Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13Figure 3.1 Cab Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2Figure 3.2 Green Light Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3Figure 4.1 Operating Sequence - Perishable Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1Figure 4.2 Operating Sequence - Frozen Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2Figure 5.1 Manifold Gauge Set (R-134a) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3Figure 5.2 Vacuum Pump Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4Figure 5.3 Procedure for Adding a Complete Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6Figure 5.4 Typical Switch Setup for Testing Pressure Switches HP 1 and HP2 . . . . . . . . . . . . . . . . . . . . . . 5–8Figure 5.5 Hot Gas Valve, Condenser Pressure Control Valve, Quench Valve (Hot Gas Valve Shown) . . . 5–8Figure 5.6 Compressor Pressure Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9Figure 5.7 Thermostatic Expansion Valve Bulb and Thermocouple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10Figure 5.8 CAB Command Diagnostic Tool (CTD P/N 07-00440-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10

62-11848 vi

LIST OF TABLESTABLE NUMBER Page

Table 2–1 Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2Table 2–2 Additional Support Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2Table 3–1 Malfunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6Table 5–1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1Table 5–2 Service Category Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2Table 5–3 R-134a Temperature Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12Table 6–1 Alarm Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1Table 6–2 Mechanical Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2

1-1 62-11848

SECTION 1SAFETY SUMMARY

This manual contains safety and service instructions to follow in order to prevent any accident. Before using thisrefrigeration unit, read carefully all safety information explained in this manual and indicated on the product. Besure that everybody who will use this refrigeration unit has been trained to use it in a safe way.

1.1 GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in thismanual. They are recommended precautions that must be understood and applied during operation and mainte-nance of the equipment covered herein. The general safety notices are presented in the following four sectionslabeled: First Aid, Operating Precautions, Maintenance Precautions, and Refrigerants. A listing of the specificwarnings and cautions appearing elsewhere in the manual follows the general safety notices.

Your Carrier Transicold refrigeration unit has been designed with the safety of the operator in mind. During normaloperation, all moving parts are fully enclosed to help prevent injury. During all pre-trip inspections, daily inspec-tions, and problem troubleshooting, you may be exposed to moving parts. Stay clear of all moving parts when theunit is in operation and when the ON/OFF switch is in the ON position.

1.2 FIRST AID

No injury, no matter how slight, should go unattended. Always obtain first aid or medical attention immediately.

Refrigerant Inhalation: Put the victim in the open air. Administer oxygen or artificial respiration if necessary. Do notadminister adrenaline or similar medicines.

Refrigerant Contact With Eyes: Rinse thoroughly with water for at least 15 minutes and then consult a doctor.

Refrigerant Contact With Skin: Immediately rinse your skin thoroughly with water.

Cooling Oil: Avoid prolonged or repeated contact with the skin. Wash carefully after handling.

1.3 OPERATING PRECAUTIONS

Always wear safety glasses. Hearing protection is recommended while unit is running.

Always keep your hands, hair, clothing and tools clear of the evaporator and condenser fans.

No work should be performed on the unit until the unit is turned off and the battery power supply is disconnected.

Always work in pairs. Never work on the equipment alone.

In case of severe vibration or unusual noise, stop the unit and investigate.

1.4 MAINTENANCE PRECAUTIONS

Beware of unannounced starting of the unit. This unit is equipped with Auto-Start. Be aware that the unit may startat any time without warning.

When performing any check of the system, make sure the unit is turned off and the battery power supply is discon-nected. Ensure the unit will not restart. Be sure the unit is turned off before working on motors, controllers, solenoidvalves and electrical control switches. Tag vehicle ignition to prevent accidental energizing of circuit.

Before doing anything on the refrigerant unit, ALWAYS use tools and Personal Protective Equipment in accordancewith Carrier Lock-out/Tag-out procedure. Lock-out / Tag-out can be performed by disconnecting and enclosing thenegative battery cable in diesel mode; and the electrical plug in electrical mode.

Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problemswith the system should be diagnosed, and any necessary repairs performed, by qualified service personnel.

When performing any arc welding on the unit or container, disconnect all wire harness connectors from the micro-processor. Do not remove wire harness from the modules unless you are grounded to the unit frame with a staticsafe wrist strap.

In case of electrical fire, turn unit off and extinguish with CO2 (never use water).

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Take all necessary safety precautions in accordance with regulations in force when accessing this refrigerationunit: use safe ladders, working platforms with appropriate guards.

When the unit is running beware of belts and fans that are moving. When there is a protective structure (fan grid orguard for example) make sure they are in place. Never remove them when the refrigeration unit is running.

When this refrigeration unit is running in electrical operation, some devices are powered up especially in the elec-trical control box.

Always use insulated tools relating to maximum voltage and wear individual protecting equipment (EPI) followingCarrier Logout/ Tag-out procedure.

Before servicing this refrigeration unit, make sure the main power switch is in the OFF position.

Ensure this refrigeration unit is disconnected from the local electrical network. Implement Carrier Logout/ Tag-outprocedure (CTE mandatory Fatality Prevention Review: LO/TO and Electricity). Before working in the electricalcontrol box, it is required to control the absence of tension. Ensure that all capacitors (if any) are discharged beforeservice to avoid electric shock.

WHEN IT IS NECESSARY TO WORK IN THE ELECTRICAL CONTROL BOX UNDER TENSION, PEOPLE MUSTBE QUALIFIED FOR WORK UNDER LOW OR HIGH VOLTAGE.

When this refrigeration unit is running or even after it has been running, different components can be very cold orhot (exhaust pipe, tubes, coils, receiver, accumulator or engine for example). Beware when operating near cold orhot components.

Always use adequate safety gloves when doing any maintenance on this refrigeration unit.

Beware when handling or operating parts that could be sharp (coils, evaporators, clamps for example).

This refrigeration unit may be equipped with a lead-acid type battery. When charging the battery normally, smallamounts of flammable and explosive hydrogen gas are vented.

Projections of acids on the skin or eyes can cause severe burns.

Keep any flame, any lighted object or any source of sparks away from the battery elements.

Always use Personal Protective Equipment when handling and charging battery: safety clothes, safety gloves andsafety glasses.

Respect polarity when connecting a battery.

1.5 REFRIGERANTS

The refrigerant contained in your unit can cause frostbite, severe burns, or blindness when in direct contact withthe skin or eyes. For this reason, and because of legislation regarding the handling of refrigerants during systemservice, we recommend that you contact your nearest Carrier Transicold authorized repair facility whenever yourunit requires refrigeration system service.

Combustibility - Certain HFC & HCFC refrigerants can become combustible when mixed with high concentrationsof air at elevated pressures. This is true of R-134a. So, these refrigerants should not be mixed with air under pres-sure for leak testing or other purposes.

Inhalation Hazards - All refrigerants are hazardous if inhaled in concentrations exceeding the recommended safelimits. The symptoms include: headaches, nausea, sleepiness, lethargy, dizziness and loss of coordination. It canresult in irregular heartbeat, unconsciousness and even death. The proper remedies should be taken to eliminateor reduce the exposures.

Flame Enhancement - If you see a change in the color or size of the torch flame while welding or soldering in thepresence of refrigerant vapors, stop work immediately and ventilate the area. This flame effect only occurs at dan-gerously high concentrations of refrigerant vapors. This could create the inhalation hazards noted above.

Skin & Eye Protection - Contact with “liquid” refrigerants can result in immediate freezing of the tissues, and perma-nent damage or blindness can result. DO NOT handle liquid refrigerants without proper personal protective equip-ment. DO NOT cut into any refrigerant lines under pressure. DO NOT open valves or vent equipment where youmay be sprayed with liquid refrigerant.

Always use Personal Protective equipment when handling refrigerant: safety clothes, safety gloves and safetyglasses.

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1.6 SPECIFIC WARNING AND CAUTION STATEMENTS

To help identify the label hazards on the unit and explain the level of awareness each one carries, an explanation isgiven with the appropriate consequences:

DANGER - means an immediate hazard which WILL result in severe personal injury or death.

WARNING - means to warn against hazards or unsafe conditions which COULD result in severe personal injury ordeath.

CAUTION - means to warn against potential hazard or unsafe practice which could result in minor personal injury,product or property damage.

The statements listed below are applicable to the refrigeration unit and appear elsewhere in this manual. Theserecommended precautions must be understood and applied during operation and maintenance of the equipmentcovered herein.

WARNING!Beware of unannounced starting of the unit. The unit may cycle the fans and compressor unex-pectedly as control requirements dictate. Press the OFF key on the Cab Command.

WARNING!Beware of V-belt and belt-driven components as the unit may start automatically.

WARNING!Ensure power to the unit is OFF, the vehicle engine is OFF, and the negative battery cable isconnected before replacing the compressor.

WARNING!Slowly open the plug on the suction and discharge valves of the new compressor to vent thenitrogen holding charge.

WARNING!Do not use a nitrogen cylinder without a pressure regulator. Cylinder pressure is approxi-mately 2350 psig (160 bars). Do not use oxygen in or near a refrigerant system as an explosionmay occur.

CAUTION!Under no circumstances should anyone attempt to repair the microprocessor components orCab Command! Should a problem develop with these components, contact your nearest Car-rier Transicold dealer for replacement.

CAUTION!If starting a unit for the first time after installation, the compressor pressure regulating valvewill need to be reset.

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CAUTION!If starting a unit for the first time after installation, or starting after adding/removing an optionalfeature, or if Owner’s operating parameters have changed, the Configuration will need to bereset.

CAUTION!Compressor failure will occur if inert gas brazing procedures are not used on units with R-134aand POE oil. For more information see Technical Procedure 98-50553-00 - Inert Gas Brazing.

CAUTION!To prevent trapping liquid refrigerant in the manifold gauge set, be sure set is brought to suc-tion pressure before disconnecting.

CAUTION!When working with refrigerant, use safety glasses and gloves to avoid burns. Hoses and cop-per tubing can be hot when unit is running.

CAUTION!Do not damage or over tighten the enclosing tube assembly. Place all parts in the enclosingtube in proper sequence in order to avoid premature coil burn-out.

CAUTION!Observe proper polarity when installing battery. Negative battery terminal must be grounded.

CAUTION!Under no circumstances should a technician electrically probe the processor at any point,other than the connector terminals where the harness attaches. Microprocessor componentsoperate at different voltage levels and at extremely low current levels. Improper use of voltme-ters, jumper wires, continuity testers, etc. could permanently damage the processor.

CAUTION!Most electronic components are susceptible to damage caused by electrical static discharge(ESD). In certain cases, the human body can have enough static electricity to cause resultantdamage to the components by touch. This is especially true of the integrated circuits found onthe microprocessor. Use proper board handling techniques.

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SECTION 2DESCRIPTION

2.1 INTRODUCTION

This guide has been prepared for the operator of Carrier Transicold refrigeration units to help deliver the load in thebest possible condition. It contains Operating Data, Electrical Data and Service Instructions for the Carrier Transi-cold Model Neos™ 100S truck refrigeration units listed in Table 2–1.Additional support manuals are listed in Table 2–2.Beware of unannounced starting of the unit. The unit may cycle the fans and compressor unexpectedly as controlrequirements dictate. Press the OFF key on the Cab Command.

Your refrigeration unit has been engineered to provide long, trouble-free performance when it is properly operatedand maintained. The checks outlined in this guide will help to minimize on the road problems. In addition, a com-prehensive maintenance program will help to ensure that the unit continues to operate reliably. Such a mainte-nance program will also help to control operating costs, increase the unit's working life, and improve performance.

2.1.1 NameplateEach unit is identified by a nameplate attached to the frame of the unit. The nameplate identifies the completemodel number of the unit, the serial number and some other information.

If a problem occurs, please refer to the information on this plate, and make a note of the model and serial numberbefore calling for assistance. This information will be needed when you contact a technician so that he may prop-erly assist you.

2.1.2 Noise Level StickerThis sticker indicates the noise level in Lwa (sound power level).

2.2 GENERAL DESCRIPTIONThe Neos 100S unit is a simple design for operation in smaller delivery vehicles. The unit (Figure 2.1) is manufac-tured as a split system type enabling it to adapt to any vehicle and any configuration. The Neos 100S has the fol-lowing components:

a. Evaporator

b. Host Unit

c. Cab Control

d. Vehicle Battery

e. Main Road Fuse (near vehicle battery)

f. Standby Module (optional)

2.3 CONDENSING SECTIONThe condensing section (see Figure 2.1) contains the condenser fan & coil, filter-drier, hot gas solenoid valve,receiver, and a condenser pressure control valve.

2.3.1 Condenser CoilThe condenser is of the tube and fin type and acts as a heat exchanger in which the compressed refrigerant gas iscondensed into a liquid and lowered in temperature. Air movement over the condenser is provided by a fanmounted in the condensing section.

2.3.2 Filter DrierThe drier is a cylindrical shell containing a drying agent and screen. It is installed in the liquid line and functions tokeep the system clean and remove moisture from the refrigerant.

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Table 2–1 Model Chart

Model No. Description R134A Compressor Condenser Weight Evap. Weight

Neos 100S Road Only 2.2 lbs / 1 kg SD 5H09 105.8 lb (48 kg) 33 lb (15 Kg)

Table 2–2 Additional Support Manuals

Manual Number Equipment Covered Type of Manual

62-11850 Neos 100S Operator’s Manual

62-11852 Neos 100S Part’s List

2-3 62-11848

Figure 2.1 Main Unit Components

1. Condenser Fan2. Nameplate3. Cab Command4. Electric Motor5. Control Box

6. Compressor7. Condenser Coil8. Filter Drier / Receiver9. Hot Gas Valve (HGS1)10. Main Heat Valve (HGS2)

- - - - -

10

5

6

7

84

9

1

2

3

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Figure 2.2 Evaporator

1. Evaporator coil2. Defrost Termination Thermostat (DTT)3. Low Pressure Switch (LP)4. Defrost Element5. Frame

6. Compressor Pressure Regulating Valve (CPR)7. LP Manifold Fitting (CPR adjustment)8. Expansion Valve (TXV)9. LP Manifold Fitting (TXV adjustment)

- - - - -

1

2

3

4

5

6 9 87

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Figure 2.3 Control Box

1. RR - run relay (DC motor)2. RSSP - Relay shunt switch pressure3. RPM - Micro board relay

4. Microprocessor board5. FMC - Fuse for MC protection

- - - - -Figure 2.4 Microprocessor Board

1. Microprocessor fuse 25A2. +12 Vdc3. Micro sticker4. CN2 connector5. Ground

6. Cab Command connector7. CN4 connector (RAT)8. EEPROM9. T selection bridge10. CN3 connector

- - - - -

1

2

3

4

5

12 3 4 5

678910

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Figure 2.5 Standby Module

1. Phase cable (standby plug)2. Neutral cable (standby plug)3. Ground cable (standby plug)4. Ignition key OUT (to the unit)5. Ignition key IN (from the vehicle)

6. - Battery (from battery)7. - Battery (from the unit)8. + Battery (from battery)9. + Battery (from the unit)

- - - - -

123

4 5 6 7 8 9

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2.3.3 Hot Gas Solenoid Valve (HGS1)HGS1 is normally closed and prevents discharge gas from entering the evaporator. The valve opens to allow hotgas refrigerant to be delivered from the compressor to the evaporator during heat or defrost modes.

2.3.4 Condenser Pressure Control Valve (HGS2)The condenser pressure control valve (or condenser closing valve) is a normally open valve that is powered when thecondenser pressure control switch (HP2) is closed. With the solenoid coil de-energized, the valve is in the cool modeand the compressor discharge gas is delivered to the condenser. In the cool mode, heat is removed from the air insidethe truck body and rejected to the surrounding air. With the solenoid coil energized, the valve is in the heat mode andthe compressor discharge gas is diverted to the evaporator and rejected to the air inside the truck body.

2.3.5 Compressor

The compressor withdraws refrigerant gas from the evaporator and delivers it to the condenser at an increased pres-sure. The pressure is such that refrigerant heat can be absorbed by the surrounding air at ordinary temperatures.

2.3.6 ReceiverLiquid refrigerant from the condenser is delivered to the receiver. The receiver serves as a liquid reservoir whenthere are surges due to load changes in the system; as a storage space when pumping down the system and as aliquid seal against the entrance of refrigerant gas into the liquid line.

NOTEIf the receiver king valve is not equipped with a service access port, install a charging connection (Car-rier Transicold P/N 40-60059-02) and (2) clamps (Carrier Transicold P/N 34-60019-02) in the liquidline before continuing with leak checking or charging instructions. (Refer to Figure 5.2.)

2.3.7 High Pressure Switch (HP1)High pressure switch (HP1) is a normally closed switch which monitors the system for high pressure and shutsdown the unit when pressure rises above a predetermined setting. For HP1 settings, see Section 2.6.2.

2.3.8 Condenser Pressure Control Switch (HP2)Condenser pressure control switch (HP2) is a normally open switch which closes to signal the microprocessor toactivate the condenser fan. HP2 also cycles the condenser pressure control valve (HGS2), in addition to the con-denser fan, in order to maintain discharge pressure for heating capacity. For HP2 settings, see Section 2.6.2.

2.4 EVAPORATOR SECTION

The evaporator assembly consists of an evaporator fan, evaporator coil, thermostatic expansion valve, defrost ter-mination thermostat, low pressure switch, and a compressor pressure regulating valve.

2.4.1 Thermostatic Expansion Valve (TXV)The thermostatic expansion valve (TXV) is an automatic device which controls the flow of liquid to the evaporatoraccording to changes in superheat of the refrigerant leaving the evaporator. The thermal expansion valve main-tains a relatively constant degree of superheat in the gas leaving the evaporator regardless of suction pressure.Thus, the valve has a dual function: 1) automatic expansion control and 2) preventing liquid from returning to thecompressor. For TXV superheat settings, see Section 2.6.2. To adjust the TXV, refer to Section 5.12.2.

2.4.2 Compressor Pressure Regulating Valve (CPR)The compressor pressure regulating valve (CPR) is installed on the suction line to regulate the suction pressureentering the compressor. The CPR valve is set to limit the maximum suction pressure. For CPR settings, refer toSection 2.6.2.

2.4.3 Evaporator CoilThe evaporator is of the tube and fin type. The operation of the compressor maintains a reduced pressure withinthe coil. At this reduced pressure, the liquid refrigerant evaporates at a temperature sufficiently low enough toabsorb heat from the air. Air movement over the evaporator is provided by an electric fan.

2.4.4 Low Pressure Switch (LP)The low pressure switch is a normally closed switch which signals the microprocessor to shut down the unit whenthe system is outside the low pressure limit. For LP settings, refer to Section 2.6.2.

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2.5 SYSTEM OPERATING CONTROLS AND COMPONENTS

The unit is furnished with a microprocessor control system. Once the setpoint is entered at the Cab Command, theunit will operate automatically to maintain the desired temperature within very close limits. See Section 3.2.1.

WARNING!Beware of unannounced starting of the evaporator or condenser fans. The unit may cycle fansunexpectedly as control requirements dictate.

CAUTION!Under no circumstances should anyone attempt to repair the microprocessor module or CabCommand! Should a problem develop with these components, contact your nearest CarrierTransicold dealer for replacement.

Figure 2.6 Cab Command

2.6 UNIT SPECIFICATIONS

2.6.1 Compressor Data

2.6.2 Refrigeration System Data

a. Defrost TimerAutomatic triggering or at preset intervals: 0 (Disabled), auto, 1h, 2h, 3h, 4h, 5h, 6h

b. High Pressure Switch (HP1)Cutout at: 355 psig ± 10 psig; Cut-in at: 290 psig ± 10 psig

c. Condenser Pressure Control Switch (HP2)Cutout at: 130 psig ± 10 psig; Cut-in at: 175 psig ± 10 psig

d. Refrigerant chargeRefer to Table 2–1.

Model SD 5H09

Displacement 87cc

No. Cylinders 5

Oil Charge 0.422 pint (200 ml)

Approved Oil Carrier POE #46-60002-02

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e. Compressor Pressure Regulating Valve (CPR) (At end of defrost)10.3 psig

f. Thermostatic Expansion Valve (TXV)Superheat setting at commissioning:14.4°F at box temperature of 32°F (0°C); 7.2°F at box temperature of -4°F (-20°C).

g. Low Pressure switch (LP)Cutout at: -6.5 psig ± 3psig; Cut-in at: +6.5 psig ± 3 psig

2.6.3 Electrical Data

a. Fan Motors

b. Compressor Clutch (CLHR)Amp Draw = 3.75AResistance = 3.2Ω

c. Hot Gas Solenoid Valve (HGS1) CoilAmp Draw = 1.33 AmpResistance = 9.2Ω

d. Condenser Pressure Control Valve (HGS2) CoilAmp Draw = 1.65 AmpResistance = 7.3Ω

Electrical System RequirementsIn order to ensure proper unit and vehicle operation, the vehicle should have an electrical system capableof producing an additional 90 amps of current above the full load current required for the rest of the vehicle(including all accessories).

e. Standby ModuleInput Voltage = 230 VAC 1 phase 50/60hzAmp Draw = 10 Amp ACOutput Voltage = 13.7 VDCOutput Current = 90 Amp DC

2.6.4 Torque Values

Evaporator Fan Motor (EFM) Condenser Fan Motor (CFM)

Bearing Lubrication: Factory Lubricated Bearing Lubrication: Factory Lubricated

Horsepower: 0.1 kw

Operating Amps: 7 to 9 amps Operating Amps: 10 amps

Speed: 2100 rpm (rated) Speed: 3300 rpm (rated)

Assembly ft-lb kg-m

Condenser - frame 7 1.0

Mounting Bolts 44 to 60 6 to 8

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2.7 SAFETY DEVICES

System components are protected from damage caused by unsafe operating conditions by automatically shuttingdown the unit when such conditions occur. This is accomplished by the following fuses and safety devices.

(a) This fuse is located close to the vehicle battery (12 V).

Unsafe Conditions Safety DeviceAutomatic re-start with fault

clearedDevice setting

1 Excessive drop in pressure Automatic reset of lowpressure switch (LP) YESCutout: -5.7 inHG ± 3psig(-0.19 bar)Timer 5 min

2 Excessive current draw on all Microprocessor outputs (Evaporator and Condenser fan)

Electronic relay YES Self-protected opening

3 Excessive current draw Control Circuit Fuse on electronic board NO Self-protected opening

4 Excessive current draw Motor Compressor Fuse YES See electrical wiring diagram

5 Excessive current draw Evaporator and Condenser fan motors

Electronic relay YES Self-protected opening

6 Excessive Compressor discharge pressure

Automatic reset of Highpressure switch (HP1) YES Timer: 5 min

7 Excessive current draw unit in road operation Road Supply Fuse (FMP) NO Opens at 25A (12V)

8 Excessive current draw of Control Circuits Main Road Fuse F1 (a) NO Opens at 40A (12V)

9 Compressor Motor overheat Klixon in Winding NO Self-protected openingopens 234°F (130°C)

10 Clutch malfunction - road (insufficient current draw) Electronic relay YES

Detection of min. thresholdat 750 mA

11 Low battery voltage Microprocessor YES Cut-out/cut-in at 10V

12 Excessive current draw on Ignition Circuit (Neiman) Fuse (F1) NO Opens at 2A

13 Battery cable short protection Fuse (FR1) NO Opens at 125A (12V)

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2.8 REFRIGERATION CIRCUIT

2.8.1 Cooling

(See Figure 2.7)

When cooling, the unit operates as a vapor compression refrigeration system. The main components of the systemare the compressor, air-cooled condenser, thermostatic expansion valve, direct expansion evaporator, and hot gassolenoid (two-way).

The compressor raises the pressure and temperature of the refrigerant and forces it into the condenser tubes.

The condenser fan circulates surrounding air over the outside of the condenser tubes. Heat transfer is thus establishedfrom the refrigerant gas (inside the tubes) to the air ambient (flowing over the tubes). The condenser tubes have finsdesigned to improve the transfer of heat. This removal of heat causes the refrigerant to liquefy; liquid refrigerant flowsfrom the condenser to the receiver.

The refrigerant then flows through the filter-drier, where an absorbent keeps it dry and clean. The refrigerant then flowsthrough a sight glass with moisture indication to the check valve and then to the liquid / gas heat exchanger.

The liquid then flows to the thermostatic expansion valve (with external pressure equalizer) which regulates theflow rate of refrigerant in the evaporator in order to obtain maximum use of the evaporator heat transfer surface.

The evaporator tubes have aluminum fins to increase heat transfer; therefore heat is removed from the air circu-lated through the evaporator. This cold air is circulated throughout the refrigerated compartment to maintain thebox at the desired temperature.

The transfer of heat from the air to the low temperature liquid refrigerant causes the liquid to vaporize. The vapor atlow temperature and pressure enters the heat exchanger then enters the compressor pressure regulating valve(CPR) which regulates refrigerant pressure entering the compressor, where the cycle starts over.

The discharge pressure is regulated with HP2.

2.8.2 Heat And Defrost

(See Figure 2.8)

When refrigerant vapor is compressed to a high pressure and temperature in a compressor, the mechanical energynecessary to operate the compressor is transferred to the gas as it is being compressed. This energy is referred toas the “heat of compression” and is used as the source of heat during the heating or defrost cycle.

When the microprocessor activates heating or defrost, the hot gas solenoid valve (HGS1) energizes and the con-denser pressure control valve (HGS2) energizes, closing the port to the condenser and opening a port which allowsheated refrigerant vapor to flow directly to the evaporator coil.

The main difference between heating and defrosting is that when in heating mode the evaporator fans continue torun thus circulating the air throughout the compartment to heat the product. When in defrost, the evaporator fansstop, thus allowing the heated vapor to defrost any ice build-up on the coil.

When the pressure is above the setting of the condenser pressure control switch (HP2), the condenser pressurecontrol valve (HGS2) is closed to prevent additional pressure rise in the system. When pressure is below the set-ting of the condenser pressure control switch, the valve is opened to pressurize the receiver and force additionalrefrigerant into the system and increase heating capacity.

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Figure 2.7 Refrigeration Circuit - Cooling Cycle

HP2

LP

COMPRESSOR

CONDENSER

RECEIVER

TXV

EVAP.

DRAINPANHEATER

HP1SUCTIONACCESSVALVE

DISCHARGEACCESS VALVE

HIGH PRESSURE VAPORHIGH PRESSURE LIQUIDLIQUID INJECTION LINELOW PRESSURE VAPORLOW PRESSURE LIQUID

KINGVALVE

CPR

FILTER DRIER

SERVICEFITTING

(IF FITTED)

HOT GASSOLENOIDVALVE (HGS1)

COND. PRESS.CONTROL VALVE (HGS2)

2-13 62-11848

Figure 2.8 Refrigeration Circuit - Heating and Defrost Cycle

HP2

LP

COMPRESSOR

CONDENSER

RECEIVER

FILTER DRIER

TXV

EVAP.

DRAINPANHEATER

HP1SUCTIONACCESSVALVE

DISCHARGEACCESS VALVE

HIGH PRESSURE VAPORLIQUID INJECTION LINELOW PRESSURE VAPOR

KINGVALVE

CPR

SERVICEFITTING

HOT GASSOLENOIDVALVE (HGS1)

COND. PRESS.CONTROL VALVE (HGS2)

(IF FITTED)

3-1 62-11848

SECTION 3OPERATION

The Neos 100S unit is an all-electrical unit, powered by the vehicle battery (alternator).

After starting up the refrigeration unit by pressing the ON key, the microprocessor manages the unit regulationaccording to the box temperature needed.

The unit automatically shuts down when the engine is switched off with the ignition key.

The unit can be completely shut down manually by pressing the OFF key on the Cab Command.

3.1 STANDBY MODE

The Neos 100S is powered by a standby module reducing the 230 VAC into 12 Vdc. The power network connec-tion is detected by the standby module which automatically starts up the unit in standby mode.

If the ignition key is switched ON while the unit is connected to the power network, or if the standby plug is connectedwhile the unit is running, a buzzer alarm will sound indicating the double power supply and the unit stops.

For safe, reliable operation in Standby mode, it is important to follow a few guidelines:• ALWAYS check that the unit is OFF (Cab command) before connecting or disconnecting it from the power

source.

• The extension cable and fuse used for network connection must comply with the legislation currently applicable onthe site of use and with the unit specifications as described in the table below:

• The unit connection cable must be fitted with a ground connection. The cable must be connected to earth(ground).

• On the 230 V supply, the unit should be connected to a Ground Fault Protection Device.

• Operations on the 230 V supply for the unit must only be carried out by authorized personnel.

• The user is liable for ensuring that the above measures are taken.

3.2 CONTROL SYSTEM

3.2.1 Introduction

CAUTION!Under no circumstances should anyone attempt to service the microprocessor components orCab Command. Should a problem develop with the control system, contact your nearest Car-rier Transicold dealer for replacement components.

The Control System consists of the microprocessor (Figure 2.4), Cab Command (Figure 2.1) and interconnecting wiring.

a. The Microprocessor includes the temperature control software and necessary input/output circuitry to inter-face with the unit controls.

b. The Cab Command is remotely mounted in the truck. The Cab Command includes the LCD display and key-pad. The keypad and display serve to provide user access and readouts of microprocessor information. Theinformation is accessed by keypad selections and viewed on the display.

Maximum Amperage for Operation Equipment

Operating Voltage

230 / 1 / 50 Hz 8 A (1.5 mm2)

230 / 1 / 60 Hz 6, 8 A (1.5 mm2)

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3.2.2 Microprocessor ModuleThe microprocessor controls the following functions:

a. Maintains the box temperature at setpoint by regulating the cooling, heating, off mode and automatic defrost cycles.b. Permanently displays the return air temperature and, on request, the setpoint temperature.c. Digital display and selection of data.

For further details on digital message display, see Section 3.8.

3.2.3 Cab CommandThe Cab Command is mounted in the cab and allows the driver to carry out the control operations listed below:

• Manual start-up and shut-down of the unit• Automatic start-up of the unit• Adjusting the setpoint• Initiating manual defrost

As soon as setpoint temperature has been reached, temperature control is obtained by shut-down and start-up ofthe electro-magnetic clutch. The condenser and evaporator fans cut out at setpoint. When transporting fragileloads such as fresh meat, vegetables and cheese, it is possible to program the microprocessor to obtain continu-ous ventilation by the evaporator while at setpoint.

The driver can display the box temperature, and see whether the setpoint is being maintained by checking thegreen indicator. The indicator lights up red in the event of a malfunction.

When the battery voltage is too low, a fail-safe system shuts down the unit. Unit restart is automatic and time-delayed if the voltage rises to the normal level.

Figure 3.1 Cab Command

a. DisplayThe digital display consists of 3 alphanumeric characters. The default value displayed is the box temperature. The micro-processor enables display of the temperature in either Celsius or Fahrenheit, dependent on jumper position (See Figure2.4). The display also includes settings for defrost operation (dF). The display includes three LEDs described below:

Indicates that the unit is running and whether temperature is displayed in Celsius or Fahrenheit.

Digital Display (3 digits)

Unit operating LED - GREENIndicates the 3 different modes:

ON: Cooling ModeOFF: Null Mode (regulation)Flashing: Heating Mode

Alarm LED - REDFlashes in case of a malfunction.

3-3 62-11848

Unit Operating LEDsGreen Light StatusUnder normal operation, the green LED will indicate the temperature control status as follows:

Figure 3.2 Green Light Status

Red Light StatusWhen an alarm has been detected, the red unit indicating light flashes at 1 Hz. The light will continue to flash at1 Hz until the alarm is cleared. At that point the steady green indicator light will light and the alarm will becomeinactive.

b. KeypadThe keypad consists of six keys that enable the operator to activate various functions, display operating data andmodify operating parameters.

Manual defrost control key.

Unit start-up key

Unit shut-down keyThe unit can also be shut down with the ignition key.

The SET key, together with the + and -- keys, enables display andmodification of unit operating data. The display scrolls through pa-rameters each time the SET key is pressed.

Decrease key to select requested settings in different menus.

Increase key to select requested settings in different menus.

SETPOINT

COOLING

HEATING

Steady greenLED

Green LED isOFF

Green LEDflashing 1 Hz

NULLBAND

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3.3 STARTING-UP THE UNIT

3.3.1 InspectionBefore starting the truck engine check the following:

a. Check condenser coil for cleanliness.b. Check condition of refrigerant hoses.c. Check condition and tension of compressor belt(s).d. Check condition of condenser fan blades and motor.e. Check truck battery fluid level.f. Check truck battery and terminal connections -- clean and tighten as necessary.g. Check defrost water drains from evaporator.h. Check evaporator coil for cleanliness.i. Check condition of evaporator fan blades and motor.

3.3.2 Starting

CAUTION!If starting the unit for the first time after installation, the compressor pressure regulating valvewill need to be reset (refer to Section 5.11)

CAUTION!If starting unit for the first time after installation, or starting after adding/removing an optionalfeature, or if Owners operating parameters have changed the Configuration will need to bereset (refer to Section 3.12)

1. Start the vehicle engine or connect thestandby plug.

2. Press the ON key to start the unit. Start up istime-delayed for 30 seconds. The digital dis-play of the Cab Command displays the boxtemperature.

3. Check that the temperature setpoint is cor-rect by pressing the SET key. The setpointtemperature is highlighted on the digital dis-play.

3.4 STOPPING THE UNIT

1. For a delivery stop, switch off the vehiclewith the ignition key. For a long stop (over 2hrs), press the OFF key.

2

3

1

3-5 62-11848

3.5 SETPOINT ADJUSTMENT

1. Press the SET key to display the setpointtemperature.

2. Press the - key to decrease the setpoint.

3. Press the + key to increase the setpoint.

4. Press the SET key to validate the setpointtemperature and return to the display of boxtemperature.

NOTEIf no key is pressed within 5 seconds of adjusting settings, the system reverts to displaying the boxtemperature. Only validated changes are recorded.

3.6 MANUAL DEFROST

1. Check that box temperature is 40°F (4.4°C)or lower.

2. Press the Manual Defrost key to initiate man-ual defrost.

3.7 CHANGING DEFROST PARAMETERS

1. Press the OFF key to shut down the unit.

2. Press simultaneously the Manual Defrostkey and ON key for 5 seconds to display thelast selected defrost interval.

3. Press the - key to decrease the setpoint.

4. Press the + key to increase the setpoint.

5. Press the SET key to validate the setpointtemperature and return to the display of boxtemperature.

NOTEIf no key is pressed within 5 seconds of adjusting settings, the system reverts to displaying the boxtemperature. Only validated changes are recorded.

3.8 ALARM DISPLAYIn the event of a malfunction, the unit will shut down and the Cab Command will display an error message or alarmmessage. The message will remain displayed until the malfunction is corrected. A listing of the error messages andalarm codes is provided in Table 3–1. There are three types of alarms:

• AXX: Active alarms that cannot be cleared until the malfunction can be corrected. The red LED is flashingrapidly.

• PXX: Passive alarms that stay in memory until the technician clears them. The red LED is flashing slowly.• Direct Display: These alarm messages are displayed instead of temperature read-out as soon as the mal-

function is detected, and remain displayed as long as the malfunction persists. The unit does not run untilthe malfunction has disappeared or been corrected.

1, 42 3

2

2 1

43 5

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3.8.1 Accessing Alarm Messages

1. Press the SET key for 5 seconds. This enables access to the alarm messages.

2. In the event of more than one alarm, press the + or - keys to display them.

3. To scroll through the alarm list, use the + key.

3.8.2 Clearing Passive Alarms and the Maintenance Interval Message SE

1. While displaying either the P** alarm or the SE message, press simultaneously the +, -, and SET keys. Thepassive alarms will clear or the service hourmeter will reset.

3.8.3 Low Battery Voltage AlarmsThere is a 40 second time delay during start-up. After this delay if the battery voltage drops below 10.5V ± 0.5V, themicroprocessor will react 20 seconds later and the unit will go out of temperature control mode. The microproces-sor will check the voltage after another 20 seconds. If battery voltage still has not risen, the unit will remain out oftemperature control mode for another 10 minutes, the battery alarm will be activated and the Cab Command willdisplay the message “bAt”. The unit will return to temperature control mode if battery voltage has risen after 10 min-utes. If the battery voltage has not risen after this 10 minute period, the unit will remain out of temperature controlmode another 2 minutes and the microprocessor will check the battery voltage every 2 minutes. The unit will returnto temperature control mode in its current configuration when battery voltage rises to 10.5V ± 0.5V.

3.9 CHECKING THE SOFTWARE VERSION AND HOURMETER

1. Start up the unit.

2. Press the SET key for 5 seconds.

3. Press the SET key again to display the EEPROM version number.

4. Press the SET key again to display the hourmeter.

5. Press the SET key to return to box temperature.

Table 3–1 Malfunctions

Code Description Unit ShutdownA00 No malfunction - unit in operation No

A01/A02/A03Low pressure switch open / High pressure switch open / DC electrical motor over heated (displayed alternatively)

Yes

A04 Clutch compressor fault NoA06 Condenser fan fault NoA07 Evaporator fan relay fault No

A09 Defrost valve (HGS1) fault NoA11 Main heat valve (HGS2) fault NoA12 High temperature alarm No

A13 Low temperature alarm NoA14 Defrost alarm > 45 minutes NoA15 Setpoint adjusted out of the range -20°F (-29°C) to + 86°F (30°C) Yes

EE Evaporator temperature probe (open circuit) Yesb A t Battery low voltage alarm Yes

S E Maintenance needed. This is a maintenance alarm that occursevery 1000 hours. Refer to Section 5.1 for more information. No

3-7 62-11848

3.10 PRODUCT LOADING

Before Loading• Pre-cool the inside of the insulated body by lowering the temperature for about 15 minutes.• Evacuate the humidity existing inside the box by carrying out a manual defrost. This can only take place

when enabled by the defrost thermostat (box temperature lower than 37°F (3°C) during pull down and 46°F(10°C) during heating.

• Evaporator fans are protected by safety grills. In the event of heavy duty use of the unit, ice can accumulate onthe grills. It is therefore recommended to clean them regularly by means of a small brush. This operation MUSTbe done only after the unit has been SHUT DOWN.

When Loading• Turn the unit off!

• It is recommended to open doors as little as possible to avoid the intake of hot air and humidity.

• Select the temperature by means of the thermostat, according to the transported goods.

• Check the internal temperature of the goods being loaded (using a probe thermometer).

• Take care not to obstruct the air intakes on the evaporator section and the ventilation ducts.

• Leave a free space of about 2 to 3 inches between the load and the front wall.

• Leave a free space of about 8 inches between the top of the load and the roof.

• Leave a free space of about 8 inches between the floor and the load (gratings, pallets).

• Do not forget to close the doors.

• Before closing the doors, check your load once more and see that nobody is shut inside the box.

NOTEFor stationary utilization, we recommend to place the vehicle in the shade.

CAUTION!Never allow your unit to sit more than a month without running.

Proper air circulation in the insulated box refers to air that can move around and through the load. This is a criticalelement in maintaining product quality during transport. If air cannot circulate completely around the load, hot spotsor top-freeze can occur.

The use of pallets is highly recommended. Pallets, when loaded so air can flow freely through the pallets to returnto the evaporator, help protect the product from heat passing through the floor of the truck. When using pallets, it isimportant to refrain from stacking extra boxes on the floor at the rear of the truck, as this will cut off the airflow.

Product stacking is another important factor in protecting the product. Products that generate heat, such as fruits andvegetables, should be stacked so that the air can flow through the product to remove the heat. This is called "airstacking" the product. Products that do not create heat, such as meats and frozen products, should be stacked tightlyin the center of the box.

All products should be kept away from the sidewalls and ceiling of the cargo area to allow air to flow between thebody and the load. This will prevent heat from filtering through the walls and affecting the product.

It is important to check the temperature of the product being loaded to ensure that it is at the correct temperaturefor transport. The refrigeration unit is designed to maintain the temperature of the product at the temperature atwhich it was loaded; it was not designed to cool a warm product.

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3.11 RECOMMENDED TRANSPORT TEMPERATURESBelow are some general recommendations on product transport temperatures and operating modes for the unit.These are included for reference only. The shipper or receiver may require different set points than those listed.More detailed information can be obtained from a Carrier Transicold dealer.

NOTEIt is essential to shut down the compartment during the periods when the doors are opened, in order tomaintain the temperature of the cargo in the other compartments and keep the unit operating correctly.

3.12 MICROPROCESSOR CONFIGURATION

CAUTION!If starting unit for the first time after installation, or starting after adding/removing an optionalfeature, or if Owner’s operating parameters have changed, the Configuration will need to bereset.

3.12.1 Functional SettingsThe procedure for adjusting the functional parameters is as follows:

1. The temperature display is selectable between Fahrenheit and Celsius. Units are configured for Celsiusfrom the factory. To set the display to Fahrenheit, the selection jumper must be removed and discarded. SeeFigure 2.4.

NOTEThe board contains another set of pins similar to the Degrees C/Degrees F selection jumper, markedas J1. This jumper is not used for unit operation, but it is used during the microprocessor controllermanufacturing process. DO NOT CONNECT THE J1 PINS TOGETHER.

2. The following steps must be performed with the unit OFF:

a. Press the OFF key to shut down the unit.

b. Hold both the Manual Defrost key and ON key momentarily in order to display parameters.

c. Using the + or - keys, modify the parameters.

The defrost duration parameter is displayed. This setting determines the length of time in minutesthe unit will remain in defrost once defrost is initiated. The defrost duration can be selected by scroll-ing through available options (10, 20, 25, 30 or 45 minutes) using the + or - keys. Selection MUSTbe validated by pressing the SET key.

ProductSet Point Range

°F °C

Bananas 56 to 58 13 to 14

Fresh fruits and vegetables 33 to 38 0.5 to 3

Fresh meats and seafood 28 to 32 -2 to 0

Dairy products 33 to 38 0.5 to 3

Ice 15 to 20 -10 to -7

Frozen fruits and vegetables -10 to 0 -23 to -18

Frozen meats and seafood -10 to 0 -23 to -18

Ice cream -20 to -15 -29 to -26

3-9 62-11848

The defrost interval parameter is displayed next. This setting determines the time between defrostsin hours. The defrost interval can be selected by scrolling through available options (0, 1, 1.5, 2, 2.5,3, 4, 5, 6 hours) using the + or - keys. Selection MUST be validated by pressing the SET key.

d. Press the SET key to validate the modified settings.

NOTEIf no buttons are depressed within 5 seconds of pressing the Defrost and On Keys or modifyingparameters, the Cab Command reverts to box temperature display and the configuration procedure isaborted.

3. The next steps must be performed with the unit ON:

a. Press the ON key to start-up the unit.

b. Press the + key, then - key, then Manual Defrost key. All keys should be held momentarily after pressingin the correct sequence.

c. Modify parameters using the + and - keys.

The minimum setpoint parameter is displayed. The minimum setpoint can be selected by scrollingthrough available options [-20°F (-28.9°C), -4°F (-20°C), 32°F (0°C)] using the + or - keys. Factorysetting is -20°F. Selection MUST be validated by pressing the SET key.

The null mode differential temperature is displayed next. This setting determines the temperaturedifference between box temperature and setpoint that controls compressor cycling. The differentialcan be selected by scrolling through available options [1.8°F (1°C), 3.6°F (2°C), or 5.4°F (3°C)]using the + or - keys. Factory setting is 3.6°F (2°C). Selection MUST be validated by pressing theSET key.

The ON/OFF (Continuous airflow) parameter for the evaporator fan is displayed next. This featuredetermines whether the evaporator fan is on or off when the unit cycles off upon reaching setpoint.The factory setting is OFF. Change setting by using the + or - keys. Selection MUST be validated bypressing the SET key

NOTEIf no buttons are depressed within 5 seconds of pressing the ON key or modifying parameters, theCab Command reverts to box temperature display and the configuration procedure is aborted.

d. The return air temperature will be displayed after the above sequence.

4-1 62-11848

SECTION 4CONTROL LOGIC AND TEMPERATURE CONTROL

4.1 SEQUENCE OF OPERATION

General operation sequences for cooling, null, and heating are provided in the following paragraphs. The micropro-cessor automatically selects the mode necessary to maintain box temperature at setpoint.

4.1.1 Perishable Mode

The unit operates in the perishable mode with set points above 10°F (-12°C).

a. With return air temperature above setpoint and decreasing, the unit will be cooling with the compressor andevaporator fans operating. (See Section 2.8.1 for a description of the refrigeration circuit during cooling.)The condenser fan will operate for the first three minutes after start up then operate under the control of thecondenser pressure control switch (HP2). The green unit operating LED will operate in accordance with Fig-ure 3.2.

b. Once temperature decreases to the setpoint, the unit will then enter the null mode. If the continuous air flowparameter is set to ON, the evaporator fans will continue to operate with all other components OFF. If thecontinuous air flow parameter is OFF, the evaporator fans and all other components will be OFF. A five min-ute delay is required before restart is allowed.

c. If temperature increases during the null mode, the unit will restart in cooling.

d. If temperature continues to decrease, the unit will enter the heating mode with the compressor and evapora-tor fans operating and the hot gas solenoid valve (HGS1) energized (open). The condenser fan and con-denser pressure control valve (HGS2) will operate under the control of the condenser pressure controlswitch (HP2). If the engine coolant option is installed, the optional heaters will also be energized. For adescription of the refrigeration circuit during heat and defrost, See Section 2.8.2.

Figure 4.1 Operating Sequence - Perishable Mode

+5.4º F (+3º C )or +3.6º F (+2º C )or +1.8º F (+1º C)

SETPOINT

--1.8º F (--1º C)or --3.6º F (--2º C)or --5.4º F (--3º C)

(setting)

COOL

UNIT STOPPED

HEAT

62-11848 4-2

4.1.2 Frozen Mode

The unit operates in frozen mode if the set point is below 10°F (-12°C). In this case, the unit switches to two modesof operation, as shown in Figure 4.2.

Figure 4.2 Operating Sequence - Frozen Mode

4.2 DEFROST CYCLEDefrost is an independent cycle overriding cooling and heating functions in order to melt frost and ice from theevaporator when necessary.

Defrost may be initiated automatically by the microprocessor or manually by the operator.

In defrost mode, the microprocessor displays “dF” on the cab command and setpoint is no longer displayed.

During defrost, the evaporator fans shut down and operation of the condenser fan is controlled by the microproces-sor. For a description of the refrigeration circuit during heat and defrost, see Section 2.8.2.

4.3 MINIMUM OFF TIMEOnce the unit has cycled off, it will remain off for the minimum off-time of five minutes. This prevents rapid cyclingdue to changes in air temperature. Air temperature in the box changes rapidly but it takes time for the product tem-perature to change.

+ ºC

SETPOINT

Differential between setpointand box T° decreases

Differential between setpointand box T° increases

COOLCOOL

DEAD BAND

5-1 62-11848

SECTION 5SERVICE

WARNING!Beware of unannounced starting of the unit. The unit may cycle the fans and compressor unex-pectedly as control requirements dictate. Press OFF key on the Cab Command. Verify that it is impossible for the unit to automatically start-up during maintenance.

WARNING!Use proper Lockout/Tagout procedures before inspecting or servicing this unit.

WARNING!All maintenance services must be done by a technician trained on Carrier products respecting all safety and quality standards of Carrier.

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

5.1 MAINTENANCE SCHEDULEA comprehensive maintenance program is required in order to optimize the life and reliability of your unit. The rec-ommended scheduled maintenance intervals and categories are provided in Table 5–1. A service message will appear on the Cab Command display (the running hours of the unit can be found inside the Data menu: 1 on the display = 10 Hrs). Descriptions of the service procedures to be carried out under each category are provided in Table 5–2.

Table 5–1 Maintenance Schedule

Hours displayed Running hours Initial service Service A Service B10 100 X100 1000 X200 2000 X X

300 3000 X400 4000 X500 5000 X X

600 6000 X700 7000 X

62-11848 5-2

NOTECompressor oil: The compressors are supplied with CARRIER POLYOLESTER (POE) oil. The pres-ence of a sticker indicates that the oil change has been correctly carried out in out Carrier Transicoldplant. Oils of PAG type are strictly incompatible with the operation of our units. Never use an oil otherthan that approved by Carrier.

On request, Carrier can analyze your compressor oil. To do this, a small drum is sent with a labelattached. On the label, indicate: the type of compressor, the lapse time or mileage since the last oilchange, the type of Carrier equipment, and the date of initial operation.

Table 5–2 Service Category Descriptions

Initial Service Check the tightness of bolts and screws and verify that the unit is correctly fas-tened onto the box.Check the fixation of the roof-top skin.Check belt tension.Check for refrigerant leaks.Clean the condenser coil.Check electrical motor amperage.Check the gasket pod for air leaks.

Service A Clean up the battery connections and battery clamps.Check and adjust all belts. Replace if needed.Clean up the condenser and evaporator coil.Check for refrigerant leaks on road and standby circuit.Check harness and refrigerant hoses aspect.Check functions parameters and configuration table according to customerapplication.Check the defrost operation. check settings according to customer application,refrigerant control valves. fans stop, and defrost ends automatically.Check the cooling operation in standby and road modes.Check the heating operation in standby and road modes.Check all electrical connections to verify no damage.Check the electrical motor amperage.Check the operation of the cab control.Check and replace the pod gasket if necessary.Clean up the pod (inside).Check the insulation gasket at the condenser opening.Check the insulation gasket at the condenser fan motor opening.

Service B Replace the electrical motor brushes.Check and clean the brushes collector.

Every Year Replace the filter drier.Clean up the expansion orifice filter.

Every Two Years Replace the compressor oil - only use Polyolester oil (POE) approved by Car-rier Transicold.Replace the refrigerant.Replace the filter drier.Replace the orifice expansion valve.

5-3 62-11848

5.2 INSTALLING MANIFOLD GAUGE SET

A manifold gauge/hose set with self-sealing hoses isrequired for service of models covered within this manual.The manifold gauge/hose set is available from CarrierTransicold. (Carrier Transicold P/N 07-00294-00, whichincludes items 1 through 6, Figure 5.1). To perform ser-vice using the manifold gauge/hose set, do the following:

5.2.1 Preparing Manifold Gauge/Hose Set For Use

a. If the manifold gauge/hose set is new or wasexposed to the atmosphere it will need to be evac-uated to remove contaminants and air as follows:

b. Back seat (turn counterclockwise) both field ser-vice couplers (see Figure 5.1) and midseat bothhand valves.

c. Connect the yellow hose to a vacuum pump andan R-134a cylinder.

d. Evacuate to 10 inHg (254 mmHg) and thencharge with R-134a to a slightly positive pres-sure of 1.0 psig (0.07 Bar).

e. Front seat both manifold gauge set hand valvesand disconnect from cylinder. The gauge set isnow ready for use.

5.2.2 Connecting Manifold Gauge/Hose SetTo connect the manifold gauge/hose set for readingpressures, do the following:

a. Connect low side field service coupler to thesuction access valve. (See Figure 5.1.)

b. Turn the field service coupling knob clockwise,which will open the system to the gauge set.

c. Read system pressures.d. Repeat the procedure to connect the other side

of the gauge set to the discharge access valve.

Figure 5.1 Manifold Gauge Set (R-134a)

1. Manifold Gauge Set2. Hose Fitting (0.5-16 Acme)3. Refrigeration and/or Evacuation Hose (SAE J2196/

R-134a)4. Hose Fitting w/O-ring (M14 x 1.5)5. High Side Field Service Coupler6. Low Side Field Service Coupler

- - - - -

5.2.3 Removing the Manifold Gauge Set

1. While the compressor is still ON, turn the high side field service coupler knob counter clockwise to close thesystem to the gauge set.

2. Mid-seat both hand valves on the manifold gauge set and allow the pressure in the manifold gauge set to bedrawn down to low side pressure. This returns any liquid that may be in the high side hose to the system.

CAUTION!To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suc-tion pressure before disconnecting.

3. Turn the low side valve counter clockwise. Remove the couplers from the access valves.

4. Install both access valve caps (finger tight only).

Opened(Backseated )Hand Valve

Closed(Frontseated)Hand Valve

To Low SideAccess Valve

To High SideAccess Valve

(Red Knob)(Blue Knob)

YELLOW

REDBLUE

Low PressureGauge

High PressureGauge

1

2

23

3

4 456

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5.3 REMOVING THE REFRIGERANT CHARGEWhen working with refrigerant use safety glasses and gloves to avoid burns. Hoses and copper tubing can be hotwhen unit is running.

NOTEOnce the system is open, it must be evacuated and dehydrated. (See Section 5.5)

NOTETo avoid damage to the earth’s ozone layer, use a refrigerant recovery system whenever removingrefrigerant.

Connect a refrigerant recovery system (Carrier P/N Diablo - 115V (115V) or 240-V (240V)) to the unit to removerefrigerant charge. (See Figure 5.2.) Refer to instructions provided by the manufacturer of the refrigerant recoverysystem.

5.3.1 Removing Complete ChargeConnect a refrigerant recovery system to the suction and discharge access valves to remove refrigerant charge.Refer to instructions provided by the manufacturer of the refrigerant recovery system.

Figure 5.2 Vacuum Pump Connection

1. Refrigerant Recovery Unit2. Suction Valve (Low Side)3. Evacuation Manifold4. Discharge Valve (High Side)5. Refrigerant Cylinder6. Electronic Vacuum Gauge

7. Vacuum Pump8. Vacuum Pump Valve9. King Valve Access Port10. King Valve11. Liquid Line Charging Port

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IF FITTED

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5.4 REFRIGERANT LEAK CHECKINGA refrigerant leak check should always be performed after the system has been opened to replace or repair a com-ponent. To check for leaks in the refrigeration system, perform the following procedure:

NOTEUse only R-134a with dry nitrogen to pressurize the system. Any other gas or vapor will contaminate thesystem which will require additional purging and evacuation of the high side (discharge) of the system.

a. The recommended procedure for finding leaks in a system is with an electronic leak detector. (Carrier P/N 07-00295-00). Testing joints with soap suds is only satisfactory for locating large leaks.

b. Charge system with refrigerant to build up pressure between 30 to 50 psig (2.1 to 3.5 bar). Remove refriger-ant cylinder and leak check all connections.

c. Remove refrigerant using a refrigerant recovery system (See Section 5.3) and repair any leaks. Evacuate anddehydrate the unit. (Refer to Section 5.5.)

5.5 EVACUATION AND DEHYDRATION

5.5.1 GeneralMoisture can seriously damage refrigerant systems. The presence of moisture in a refrigeration system can havemany undesirable effects. The most common are copper plating, acid sludge formation, “freezing-up” of meteringdevices by free water, and formation of acids, resulting in metal corrosion.

5.5.2 Preparationa. Evacuate and dehydrate only after pressure leak test. (Refer to Section 5.4)b. Essential tools to properly evacuate and dehydrate any system include a good vacuum pump (5 cfm =

8m3H volume displacement, P/N07-00176-01) and a good vacuum indicator such as a thermocouple vac-uum gauge. (Carrier P/N 07-00414-00).

NOTEUse of a compound gauge is not recommended because of its inherent inaccuracy.

c. Keep the ambient temperature above 60°F (15.6°C) to speed evaporation of moisture. If ambient tempera-ture is lower than 60°F (15.6°C), ice might form before moisture removal is complete. Heat lamps or alter-nate sources of heat may be used to raise system temperature.

d. Additional time may be saved during a complete system evacuation by replacing the filter-drier with a sec-tion of copper tubing and the appropriate fittings. Installation of a new filter-drier may be performed duringthe charging procedure.

5.5.3 Procedure For Evacuation And Dehydrating Systema. Remove refrigerant using a refrigerant recovery system.b. The recommended method to evacuate and dehydrate the system is to connect three evacuation hoses to

the vacuum pump and refrigeration unit as shown in Figure 5.2. Do not use standard service hoses, as theyare not suited for evacuation purposes. Connect an evacuation manifold, with special evacuation hoses, tothe vacuum pump, electronic vacuum gauge, and to the refrigerant recovery system.

c. Make sure the vacuum gauge valve is closed and the vacuum pump valve is open.d. Test the evacuation system for leaks by back-seating the king valve (or closing the field coupler connected to

the liquid line charging port), turning suction and discharge access valves counter clockwise to close, and draw-ing a deep vacuum with the vacuum pump and gauge valves open. Shut off the pump and check to see if thevacuum holds. Repair leaks if necessary.

e. Mid-seat the king valve or field couple connected to the liquid line charging port. Turn suction and dischargeaccess valves clockwise to open.

f. Open the vacuum pump and electronic vacuum gauge valves, if they are not already open. Start the vacuumpump. Evacuate the unit until the electronic vacuum gauge indicates 2000 microns. Close the electronic vacuumgauge and vacuum pump valves. Shut off the vacuum pump. Wait a few minutes to be sure the vacuum holds.

g. Break the vacuum with nitrogen. Raise system pressure to approximately 2 psig (0.14 Bar).h. Repeat steps f. through h.

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i. Install a new filter-drier. Evacuate the unit to 500 microns. Close off the vacuum pump valve and stop thepump. Wait five minutes to see if the vacuum holds. This checks for residual moisture and/or leaks.

j. With a vacuum still in the unit, the refrigerant charge may be drawn into the system from a refrigerant con-tainer on a scale. See Table 2–1 for correct charge. Continue to Section 5.6.2. for procedure to install acomplete charge.

5.6 CHARGING THE REFRIGERATION SYSTEM

Figure 5.3 Procedure for Adding a Complete Charge

1. Suction Valve (Low Side)2. Manifold Gauge Set3. Discharge Valve (High Side)4. Dead Head Port

5. Refrigerant Cylinder6. King Valve Access Port7. King Valve8. Liquid Line Charging Port

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5.6.1 Checking The Refrigerant Chargea. Start unit in cooling mode and run approximately ten minutes.b. Partially block off air flow to condenser coil so discharge pressure rises to 325 psig (22 Bar).c. The unit is correctly charged when there are no bubbles in the sight glass.

5.6.2 Installing A Complete Charge

NOTEThe ambient (air entering the condenser) air temperature should be above 40°F (4.4°C)

a. Evacuate the refrigeration circuit leave in a deep vacuum. Refer to Section 5.5 for more information.b. Place refrigerant R-134a cylinder on a scale. Connect the discharge gauge field coupler of the manifold test set

to the king valve or liquid line charging port. Connect the suction pressure hose of the manifold gauge set to themanifold dead head port. Connect a charging line between the center tap of the second gauge set and therefrigerant drum. Mid-seat the discharge knob. Open the liquid valve on the drum and purge all hoses. Front-seat the discharge knob. (Refer to Figure 5.3)

c. Note the weight of the refrigerant cylinder.

d. Open the liquid valve on the refrigerant cylinder. Open the king valve or field coupling attached to the liquidline charging port half way and allow the liquid refrigerant to flow into the unit until the correct weight ofrefrigerant has been added as indicated by scale. See Table 2–1 for correct charge.

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e. If the scale indicates the correct charge has been added, close the liquid line valve on the drum and mani-fold valves.

f. Backseat the king valve or field coupler attached to the liquid line charging port. Remove the charging hosesand check charge in accordance with Section 5.6.1.

g. Start the unit and check for non-condensables. Refer to Section 5.7 for more information.

5.6.3 Installing a Partial Charge

There are no partial charges of the Neos 100S unit. If leak is suspected, for instance, all remaining charge shouldbe removed and a complete charge must be performed and then weighted in after repair.

5.7 CHECKING FOR NON-CONDENSABLESTo check for non-condensables, proceed as follows:

a. Stabilize system to equalize pressure between the suction and discharge side of the system.

b. Check temperature at the condenser and receiver.

c. Check pressure at the king valve access port or the liquid line charging port.

d. Check saturation pressure as it corresponds to the condenser/receiver temperature using the Temperature-Pressure Chart, Table 5–3.

e. If gauge reading is 3 psig (0.2 Bar) or more than the calculated P/T pressure in step d., non-condensablesare present.

f. Remove refrigerant using a refrigerant recovery system. Refer to Section 5.3.

g. Evacuate and dehydrate the system. Refer to Section 5.5.

h. Charge the unit. Refer to Section 5.6.

5.8 CHECKING AND REPLACING FILTER-DRIER

5.8.1 Checking Filter-DrierCheck for any obstruction of the filter-drier by feeling the inlet and outlet connections of the liquid line on the filtercartridge. If the temperature of the outlet connection seems lower than the temperature of the inlet connection,replace the filter-drier.

5.8.2 Replacing The Filter-DrierRemove refrigerant charge. See Section 5.3. Remove the drier mounting clip, then replace the filter-drier. Follow-ing drier replacement, evacuate and recharge unit. Refer to Section 5.5 & Section 5.6.

5.9 HIGH PRESSURE (HP1) AND CONDENSER PRESSURE (HP2) SWITCHES

5.9.1 Removing Switch

a. A Schraeder valve is located under each switch to allow removal and installation without removing the refrig-erant charge.

b. Remove the switch and test in accordance with Section 5.9.2.

c. Replace or reinstall the switch.

5.9.2 Checking Pressure Switch

WARNING!Do not use a nitrogen cylinder without a pressure regulator. See Figure 5.4. Cylinder pressureis approximately 2350 psig (160 Bars). Do not use oxygen in or near a refrigerant system as