Home

Copyright© 2003 Thermo King Corp., Minneapolis, MN, USA

Contents

1. 8 7 6 5 3 CIRCUIT BREAKER F m EVAP amp HEATER HARNESS CABLE RETRIEVER 25 AMP CBI Nel NED PLUG FROM CONTROLLER a O BLACK BROWN 5 3810291601 E WIRE CODES os uim d EVAP EVAPORATOR AFA L2 0 WHITES Su 2 COND CONDENSOR 5O 55 voto DER e 3 AMB AMBIENT T d aep ick Sz 4 COMP COMPRESSOR Dist E GRN GRN YEL
2. 3 7 4 3 CIRCUIT BREAKER r4 NOTES LS D EVAP 8 ELATER WIRES EVAP EVAPORATOR O BLACK BROWN 2 COND CONDENSOR 3 AMD AMBIENT 4 COMP COMPRESSOR WHITE BLUE 5 DEF DEFROST L d La s Q RED BLACK 8 VEL YELLOW TRANSFORMER 9 WHI WHITE IT BRN BROW C me 11 BRN BROW COMPRESSOR Qs 12 BLU BLU CONTACTOR 1 gt S 3 A 13 ESV EVAPORATOR SOLENOID VALVE DE Say 14 LSV LIOIUD SOLENOID VALVE i in CT Gp 15 LISV LIQUID INJECTION SOLENOID VALVE laz 0109 Dg D9 oe D 16 HUM HUMIDITY F H Que 17 HPS HIGH PRESSJRE SWITCH D Os E 18 WCC WATER COLD D CONDENSER L ov s o7 s i Se 19 CB CIRCUIT BREAKER IS 8 c co G a KEYPAD e L 8z e HEATER WIR mm TERMINA RED BAND Y ES GREEN BAND INS S ORANGE BAND j BLUE BAND CONTROL BOX CAPA YELLOW BAND DOOR BLACK BAND Nas K3 ip mee EATER GRN GRN YEL imis RED GREEN BANDS oo BLK ORANGE BLU BARIS bu m c YHLLORLBL ACE panos in os J4 BATTERY BLK amp RED A amp 16 THERMISTER YEL WHT wT a REM RED S A REMOTE E MON I TOR MODULE E Aq 48 N USE 2A 28V O y Bk PHASE 2 PHASE Sq WHT E RED FUSE 2A 12V gt BATIERY 7 EL E E RD MP3000 i3 CON ROLLER E D M ERE B la zz Oi 911 916 Hs S O13 912 O11 p 99 48 gr ia 95 4 93 er NORD ss EFI3 uo LEM sis tFI2 C
3. IAB AMP PTIOO OPTION USDA pA EVAPORATOR HEATERS ADD HUMIDITY OPTION MP 3000 RELAY BOARD ADD HUMIDITY OPTION L 460VAC WA 29V X2 x a PITY ATTY 28V P8 PC p D par POWER SUPPLY 24 VOC NTC OPTION USDAI Bar DB por Ba PB bc pa b8 bc Bar b8 AFAM BOARD J30 1 GAS SENSOR BOX 24 VDC J30 2 GND J30 3 RS232 Rx 85232 Tx GAS SENSOR OPTION PA RED TA AM ak Amor SUPPLY AIR SENSOR RH RETURN AIR SENSOR EVAP COIL SENSOR CONDENSER COIL SENSOR COMP DISCH TEMP SENSOR AMBIENT AIR SENSOR HUMIDITY SENSOR RED BRN HUM WHT BLU HUM SUPPLY AIR SENSOR LH KEYPAD KVO JUMPER LPS JUMPER 25 CONDUCTOR BLK 4A J16 4 2 3 4 REMOTE MONITOR MODULE CABLE 2 37 CONDUCTO
4. 2 E F DEFROST TRANSFORMER BOUERRABEL CB SR GTN IND i gt 400V 460V GRN GRN EL 7 LEFT HAND M HEATER AE E Y 7 330 GRHJGRN YEL A YEL TELLO sco 24 voc y is COMPRESSOR lf DO l 3 WHT WHITE TED miei de Laa CONTACTOR St 7 mm Fuse 7 gt BR 9 GREEN RS232 Tx GAS r 6h s COND MOTOR BRN E BROW o fc SENSOR i da ia ds G a l Se aa E E 2 BOX 29V 28V 40Y RISA A E L D E ac x2 xi Go ap Ys 6 i al O l 4 VIV VAPOR INJECTION VALVE p AFAM AFAM CABLE Jipe a BLUE BAND A RED BAND 5 HPS HIGH PRESSURE SWITCH rtm tpm ae a YELLOW BANDE CREEN BAND Es LPS LOW PRESSURE SWITCH Wig yo Fo onavet pup 17 WCC gt WATER COLDED CONDENSER E PER 37a ale BLACK BLACK BAND L 3 8 CB CIRCUIT BREAKER AFAM INTERFACE BOARD PIRSIG L l EATER WIRES kl nor vn TERMINAL BLOCK NOTES x HPS EM peo l VIEW DEPICTS WIRING FOR PTIOO OPTION KEYPAD r Fa WIRING FOR NTC OPTION IS DEPICTED IN GRN GRN YEL amp cu mw T l DETAIL VIEW A SHOWN BELOW eS Lo J2 131 A e cte eS o gt AIR COMPRESSOR ate uet A PO ci NC te Shee n E J eee FI B L l l i 20 AMP F2 Shiz i CONTACTOR 3 20 AMP 43 ENIE N i Seve BLKt CONTROL BOX DOOR Ji3 J12 HEATER arc e ets apo xd o 5 idt Peces ies i roii Y 1 e ol a RED GREEN BANDS og m Mee e EE VY 2 NN V GRN GRN YEL m WESA DO HUI y 3 M Ras ORANGE BLUE BANDS ool ay Poa Ee es ee eee M ped A SENSOR 3
5. 0 0 0 teeta 92 Manual Emergency Control Connections 0 eee eae 93 AFAM System Linkage Adjustment oococcccc teeta 95 Air Exchange System curacion TARTA ea ence 97 Humidify System Option 2 0 nee Im eet 97 Partlow SR Recording ThermoMmeter oooccocococc eens 99 Saginomiya SKM Recording Thermometer 000 cee eee eee eh 100 Power Wire Connections o ia e a a Gln RUE SUR RE Dr EN RUN 103 Chart Recorder Terminals llllllleleeeeee m mun 103 Electronic Chart Recorder Mounting Bolts lleleeleeleele e 103 ARAM Systelm osito dde eu dank don died dsl t 106 Setpoint Menu Screen Flow Diagram lssessee e eh 107 Configuration Menu Screen Flow Diagram essere 109 AFAM Syste Mi simi ata at LACER RUERANS oa es RUFUS Leone kas ROP DECIR IARE AID cen ta ats 110 Chill Load Control Sequence Setpoints at 9 9C 14 1 F and Above 0005 117 Frozen Load Control Sequence Setpoints at 10 C 14 F and below 121 List of Figures Figure 59 Figure 60 Figure 61 Figure 62 Figure 63 Figure 64 Figure 65 Figure 66 Figure 67 Figure 68 Figure 69 Figure 70 Figure 71 Figure 72 Figure 73 Figure 74 Figure 75 Figure 76 Figure 77 Figure 78 Figure 79 Figure 80 Figure 81 Figure 82 Figure 83 Figure 84 10 Condenser Coil Sensor Location ooooococcocco eens 126 2 Fan Evaporator Evaporator D
6. The evaporator fans continue to operate except when Economy mode is ON CRR PS units only e Compressor remains OFF for a minimum of 5 minutes Operating Theory 1 5C 2 7F 10C 1 8 F 2al M ud ed 1 0 C 1 8 F AJA1284 per Increasing Temperature If the compressor stops it must remain OFF for a minimum of 5 minutes When the compressor re starts it must stay ON for a minimum of 5 minutes Figure 58 Frozen Load Control Sequence Setpoints at 10 C 14 F and below Defrost The evaporator coil sensor temperature must be below 18 C 65 F to initiate a Demand Defrost or Manual Defrost The evaporator coil sensor temperature must be below 10 C 50 F to initiate a Timed Defrost Demand defrost function initiates defrost immediately when Temperature difference between the return air sensor and defrost evaporator coil sensor is too large Temperature difference between the left hand and right hand supply air sensors is too large and unit has operated for more than 90 minutes since last defrost Temperature difference between the supply sensors and return air sensor is too large 121 Operating Theory Manual Defrost may be initiated immediately by pressing the Defrost key or by Refcon Remote Monitoring Modem RMM A Timed Defrost always starts at 1 minute past the hour immediately following a defrost timer request for defrost For example if the defrost timer requests a
7. more than 20 seconds Check all fuses Check cable No 1 on relay board Check cable No 1 between controller and relay board Replace relay board Check voltage reading on Defective digital inputs on relay board each phase Indicates One phase on power line is missing Defective fuse on relay board Defective controller NOTE If both alarms 16 and 17 are activated the alarms are caused by a large difference in measured amps Enter Manual Function Test menu and start condenser fan Check the condenser an amps measurement If necessary check the resistance in the motor between CF1 and CF2 CF2 and CF3 and CF1 and CF3 Resistance readings should be equal approximately 25 Ohms Temperature Too Far from Setpoint Check Press SUP RET key to check supply and return Alarm air sensor temperatures COmpare temperatures to evaluate unit cooling capacity and performance Temperature difference should be 4 C to 6 C Open evaporator door Inspect coil for rice or frost and initiate manual defrost if necessary After 75 minutes of operation supply or return air temperature is not in range and does not approach setpoint within preset pulldown rate Indicates ce or frost on evaporator coil P Check refrigerant charge NOTE This alarm can be activated if the supply or return air temperature varies even if the mean temperature does approach setpoint Low refrigerant charge Air exchange vent open too mu
8. 3 DO NOT expose to excessive heat or direct sun light 4 DO NOT drop dent or damage cylinder 5 Use a pressure regulator and a safety pressure relief valve as part of the pressure testing equipment The safety pressure relief valve should be of the non adjustable non tempering type The valve should bypass any time the pressure exceeds its setting Refrigeration Maintenance 6 Open valve slowly use regulators and safety valves that are in good working order 7 The regulator should have two gauges one to read tank pressure the other to read line pressure Properly maintained equipment will allow leak testing purging or dehydration to be done safely CAUTION Nitrogen N is under 15 170 kPa 151 70 bar 2200 psig or greater Pressure is for full cylinder at 21 C 70 F DO NOT use Oxygen O acetylene or any other types of pressurized gas on refrigeration systems or any component of a system Dehydration pressure testing purging and soldering can be accomplished with the use of dry nitrogen N2 The proper equipment and application of equipment is of greatest importance Line Pressure a0 Pressure Regulator Figure 81 Typical Pressurized Gas Bottle with Pressure Regulator and Gauges 147 Refrigeration Maintenance Procedure 1 Attach gauge manifold set refer to Gauge Manifold Set Attachment and Purging for proper procedure for connecting to compressor 2 Close both hand valves
9. Unit Description Features and Options Fresh Air Exchange System The fresh air exchange system removes harmful gases from containers carrying sensitive perishable commodities The fresh air vent is located above the control box The fresh air vent is adjustable to accommodate a variety of frozen and chilled load operating conditions AXA0340 Fresh Air Exchange Vent Figure 4 Fresh Air Exchange Vent Advanced Fresh Air Management AFAM and Advanced Fresh Air Management Plus AFAM Optional An advanced microprocessor controlled fresh air management system provides programmable control of the air exchange rate programmable delayed vent opening automatic closure of the air exchange vent during low ambient conditions e data logging of the air exchange rate and vent opening delay interval The AFAM system includes a door control module vent door and vent grille The MP 3000a controller sends a communication signal to the door control module to position the vent door to the desired position The controller can also be set to delay opening of the fresh air vent for up to 72 hours in 1 hour increments This allows faster product temperature pull down An advanced microprocessor controlled fresh air management system also provides programmable control of the CO levels in the container and data logging of the CO gas level readings 26 The AFAM system includes a gas sensor unit
10. 0 15 to 0 40 bar 5 to 11 in vacuum on the suction pressure gauge 3 5 minutes Then shut the unit down manually with the On Off switch CAUTION Never open the low side to the atmosphere while it is in a vacuum Air and moisture will be drawn in and contaminate the refrigerant system 4 To place the unit back in service open the liquid line service valve and turn the On Off switch ON Refrigeration Maintenance Refrigerant Charge The refrigerant charge should be checked during pretrip and routine maintenance inspections A low charge of refrigerant will cause the container temperature to rise due to the lack of liquid refrigerant at the expansion valve even though the unit is operating in a cooling mode The refrigerant charge can be checked by inspecting the receiver tank sight glasses NOTE See Receiver Tank Sight Glass under Unit Instruments in the Operating Instructions chapter for information about checking the moisture indicator in the sight glass Unit Refrigerant Charge Standard receiver 4 9 kg 10 8 Ib of R 134a e Water cooled condenser receiver 5 2 kg 11 5 Ib of R 134a Checking the Refrigerant Charge 1 Inspect the receiver tank sight glasses with the unit operating in COOL 2 a Standard Receiver Tank e Ifthe balls FLOAT in the sight glass at any time R 134a charge is OK Ifthe balls DO NOT FLOAT R 134a charge is low b Water cooled Condenser receiver Tank with one si
11. Evacuate the low side and compressor see Evacuation and Cleanup of the Refrigeration System in this chapter Back seat the discharge service valve and open the liquid line service valve fully Operate the unit at least thirty minutes and then inspect the oil level in the compressor Add or remove oil if necessary Check the refrigerant charge and add refrigerant if needed Condenser Coil Replacement Removal 1 Recover the refrigerant charge from the unit do NOT vent refrigerant to the atmosphere Remove the condenser fan grille condenser fan blade and condenser fan shroud Remove the condenser coil support brackets from the coil Unsolder the coil inlet and liquid line connections Support the coil and unbolt the condenser coil mounting brackets Slide the coil from the unit Installation 1 2 Clean the tubes for soldering Slide the coil into the unit and install the bolts in the mounting brackets Solder the inlet line and liquid line connections NOTE It is strongly recommended that dry nitrogen be used to purge the system during any solder operations see Using Pressurized Nitrogen in this chapter Pressurize the system and test for leaks see Refrigerant Leak Test Procedure in this chapter If no leaks are found recover the leak test gas see Refrigerant Recovery in this chapter Refrigeration Maintenance Then evacuate the system see Evacuation a
12. e The unit power cables wiring and circuit breakers must be restored to their normal condition when the welding operation is completed Safety Instructions Removing Refrigerant Properly Use a refrigerant recovery process that prevents or absolutely minimizes refrigerant escaping to the atmosphere Fluorocarbon refrigerants are classified as safe refrigerants when proper tools and procedures are used Certain precautions must be observed when handling them or servicing a unit in which they are used Fluorocarbon refrigerants evaporate rapidly freezing anything they contact when exposed to the atmosphere in the liquid state In the event of frost bite attempt to protect the frozen area from further injury warm the affected area rapidly and maintain respiration Eyes For contact with liquid immediately flush eyes with large amounts of water and get prompt medical attention Skin Flush area with large amounts of lukewarm water Do not apply heat Remove contaminated clothing and shoes Wrap burns with dry sterile bulky dressing to protect from infection injury Get medical attention Wash contaminated clothing before reuse Inhalation Move victim to fresh air and use CPR or mouth to mouth ventilation if necessary Stay with victim until arrival of emergency medical personnel 13 Warning Fans start automatically Warning Hot Components Compressor discharge may be hot Warning Hig
13. line 2 Press F2 key to scroll to AFAM DELAY line The current setting 0 appears in the display 3 To enter a new time delay press the F4 key An Enter Arrow appears in the menu line and the current time delay disappears 4 Enter type the new time delay in the LCD display using the general purpose keypad 1 to 72 hours The cursor moves to the right of the screen as each key entry is acknowledged and displayed Operating Instructions WARNING The vent door and motor actuator arm move immediately again when the delay is entered Keep hands and tools away from the air exchange system components to prevent personal injury or unit damage 5 Press and hold the F4 key until the cursor stops flashing The new time delay is recorded in the controller and appears in the LCD display 6 Press ESC key to exit the SETPOINT screen Changing the CO Maximum Setting NOTE The minimum CO rate should be established by shipper The CO rate sets the desired CO level in the container when a gas sensor unit is installed The actual AFAM door position is based on the CO level O level and AFAM delay 1 Press the SETPOINT key The SETPOINT menu appears with the cursor in the TEMP SETP line 2 Press F2 key to scroll to CO line The current rate and units e g 2 5 appears in the display 3 To change the rate press the F4 key An Enter Arrow appears in the menu line and the current
14. 14 Install new chart 105 Operating Instructions AFAM System and AFAM System Operation Advanced Fresh Air Management AFAM System An advanced microprocessor controlled fresh air management system provides programmable control of the air exchange rate programmable delayed vent opening automatic closure of the air exchange vent during low ambient conditions and data logging of the air exchange rate and vent opening delay interval The AFAM system includes a door control module vent door and vent grille The MP 3000a controller sends a communication signal to the door control module to position to vent door to the desired position The controller can also be set to delay opening of the fresh air vent for up to 72 hours in 1 hour increments This allows faster product temperature pulldown The system is precalibrated for air exchange rates of 0 to 280 m3 hr 0 to 165 ft3 min The actual door position is based on the air exchange setting the power supply frequency Hertz and the VFD mode setting CRR PS Models only Vent Door Assembly and Damper Motor Interface Board and Cable Mounts in Control Box Figure 53 AFAM System 106 If the controller identifies a component failure during unit startup an alarm is recorded in the controller display and datalogger memory If a power loss occurs after the AFAM system is turned ON the controller automatically operates the vent door based on the previous AFAM
15. 4 Visually check the linkage alignment The linkage should be straight and touching or almost touching the mechanical stop If the linkage is linkage is binding or jammed against the stop the linkage is too long Disconnect the rod end from the door bracket Shorten the linkage by rotating the rod end on to the L rod additional rotations Shorten linkage until linkage alignment is correct 5 Visually check vent door seal If the vent door is fully closed but the door gasket does not create a tight seal with the air exchange openings the linkage is too short Disconnect the rod end from the door bracket Lengthen linkage by backing rod end off additional rotations Lengthen linkage until door gasket seals tightly against the air exchange openings 6 When linkage is properly adjusted fasten rod end securely to door bracket with pin and cotter pin 96 Fresh Air Exchange System The fresh air exchange system has an adjustable vent door for ventilation The evaporator fans draw in outside air through an air intake and discharge an equal amount of container air through an air outlet NOTE Set the disk or door position to the ventilation rate indicated on the shipping manifest Disk Adjustment Low Ventilation Rates 1 Loosen wing nut on handle assembly 2 Rotate the disk to set the Indicator at the air exchange rate shown on the ventilation scale on the door CRR40 and CRR40SL Models 0 to 125 m3 hr 0 and 75 ft3 mi
16. All CRRAO TNE 508 units with KVQ valve e Position 2 All CSR20 PS CSR40SL PS and CSR40 PS units with a stepper motor valve e Position 3 All CRR40 DF units e Position 4 All CSR40 Magnum units e Position 7 Unit testing and service only Changing Software Selection Dial Position 1 Turn Unit On Off switch OFF 2 Set dial indicator to correct position 3 Turn Unit On Off switch ON New software selection is loaded during controller start up Flash Loading Controller Software Controller software must be flash loaded when software has been revised To flash load software complete the following steps 1 Turn the UNIT ON OFF switch OFF 2 Plug cable from a portable computer with controller software into the data retrieval connector on the control box 3 Press and hold the 7 key and F1 key at the same time LCD display will show FLASHLOAD 4 Press one of the special functions keys to activate controller LCD display on battery power or turn the UNIT ON OFF switch ON NOTE Controller will start in Emergency mode and LCD display will show EMERGENCY MODE if the communications cable is defective or not connected to the download port Secure cable connection to proceed with flash loading of software 124 5 Start flash load program on portable computer 6 Flash loading of new software is complete when FLASH LOADING clears from the LCD display 7 The controller then checks the new software and lo
17. Ambient Air Sensor Short Circuit Check Alarm Occurs during pretrip PTI test only Sensor circuit resistance is lower than 200 ohms Temperature is above 80 C 176 F Indicates Short circuit to sensor Defective or wrong sensor Defective relay board Defective cable No 1 Defective controller 14 on plug J15 Resistance must be 2 000 ohms at 25 C 77 F Check cable no 1 between controller and relay board Check sensor resistance between pins 13 and 14 on plug J15 Resistance must be 2 000 ohms at 25 C 77 F Check cable No 1 between controller and relay board Check sensor resistance between pins 13 and 14 on plug J15 Resistance must be 2 000 ohms at 25 C 77 F Check cable No 1 between controller and relay board Diagnosis Troubleshooting Status Messages Alarm Codes Return Air temperature Too High Check for sensor alarm codes Check Alarm Check supply and return sensor connections and During defrost Return air temperature increases above 40 C 104 F Indicates Defective return or evaporator coil sensor Return and evaporator coil sensor connections are reversed Low Supply Voltage Check Alarm Alarm occurs if line voltage is below 350 volts for 30 minutes If the main power supply voltage to the unit while running drops below 340 VAC the unit will stop running until the voltage increases above 350 VAC If the main power supply voltage on initial unit start up
18. DELAY and AFAM RATE settings when power is restored Setting AFAM System Values WARNING After installing or servicing the AFAM door assembly remove all tools and install the vent grille before starting the AFAM system Failure to replace the vent grille before turning the AFAM system ON may result in personal injury or unit damage The Controlled Atmosphere CA OPTION submenu in the CONFIGURATION menu is factory set to AFAM The controller then adds the AFAM AFAM DELAY and AFAM RATE submenus to the SETPOINT menu If a replacement controller or new software is installed a controller auto configuration will detect the AFAM option when the AFAM door control module is connected to the controller The default setting for the AFAM in the SETPOINT menu is the last value set OFF UNITS or DEMAND The AFAM submenu should be set to UNITS to control the vent door to the fresh air exchange rate setting Starting the AFAM System 1 Press the SETPOINT key The SETPOINT menu appears with the cursor in the TEMP SETP line 2 Press F2 key to scroll to AFAM line 3 To change the mode setting press F4 key Cursor moves to end of menu line and flashes WARNING The vent door and motor actuator arm move immediately when the F4 key is pressed to turn the AFAM system in DEMAND UNITS or OFF Keep hands and tools away from the air exchange system components to prevent personal injury or unit damage Pre
19. Demand Defrost Demand defrost function initiates defrost when Temperature difference between the return air sensor and defrost evaporator coil sensor is too large for 90 minutes Temperature difference between the left hand and right hand supply air sensors is too large and unit has operated for more then 90 minutes since last defrost Temperature difference between the supply air sensors and return air sensor is too large Defrost Timer Chilled Mode Supply Temperature at 5 1 C 41 2 F or above Every 8 hours of compressor operation Supply Temperature at 5 0 C 41 0 F or below Every 2 5 hours of compressor operation Defrost interval increases 0 5 hours each timed defrost interval Defrost synchronization creates step intervals of 3 4 4 5 5 6 6 and 7 hours Maximum time interval in frozen mode is 7 hours Defrost Timer Frozen Mode Every 8 hours of compressor operation Defrost interval increases 2 hours each timed defrost interval Maximum time interval in frozen mode is 24 hours Defrost Timer Reset to Base Time Defrost timer resets if the unit is Off more than 12 hours setpoint is changed more than 5 C 9 F or PTI Pretrip test occurs Defrost Termination Defrost Coil Sensor Chilled mode Terminates defrost when coil sensor temperature rises to 30 C 86 F or exceeds 18 C 65 F for 35 minutes Frozen mode Terminates defrost when coil sensor temperature rises to 30 C 86 F or exceeds 8 C 46 F
20. Electrostatic Discharge Precautions o ooococcocc mmn 12 Electrostatic Discharge and the Controller liliis 12 Welding of Units or Containers 0 2 0 eR Rr menn 13 Removing Refrigerant Properly liliis mh mnn 13 Service Guide AED 15 SEMICE GUIDE sho EMO SR Rx Rice ate ca mdi ala ld ln Pauline neces E ois Skis eau a tan 15 Specifications ir he Ree eee EIER COR Oe GOS a Ms meee d 17 Electrical System nea 050 ene xv Bede PE DER ea ee ee ie 18 Refrigeration Systemie iesire enaena either dane boa Boa EROR O a eee eke ee BPRS 19 Unit Description Features and Options o ooococccccn ee RR I n nnn 25 Introduction ri aem rn O DINER Ue E ROLE Re FM ORE ln a RP RESP RUP Les eet 25 General Description 4 rer UP tg teas Ae ais dite Wh E 25 Semi hermetic Reciprocating Compressor with Liquid Injection Cooling System 000 ee eee 25 MP 3000a Controller Srei m obo bdo st RN RR UR noe Med bed bed ed AT Gere te 25 Dual Speed Evaporator Fans 00 cece eee eee eee 25 Fresh Air Exchange System 0 00 adaa a etn m emm hn 26 Advanced Fresh Air Management AFAM and Advanced Fresh Air Management Plus AFAM Optional 0 0 00 e eee ee eee eee 26 Dehumidification Control System 0 0 0 eet 26 Dual Voltage aces i ORS Ob AER Pee hie ee i a Pe ee eS eee WE 27 Humidification Control System 0 0 ce ete eee ee 27 Pressure Gauge Options 0 0 cee ete 27 Recording Thermomet
21. Fi Misc Functions Controller Software setting and the options installed on the unit Kem im e Emi IW ace AN Menu hum 3 mr DATE TIME o L LL iiu STATUS S F4 Main Menu DATA ALARMS COMMANDS t MISC FUNCTIONS CONFIGURATION DATALOGGER RMM STATE PROGRAM VERSION CARGO DATA C F MODE RUN TIME ESC Submenu F1 Current function setting appears in display Press F3 key to scroll to desired function Press F4 key to change a setting Type a new value or press F3 key to toggle value to desired setting Press and hold F4 key until cursor stops flashing Figure 40 Misc Functions Menu Screen Flow Diagram Setting the Date and Time 1 Press F3 key to enter the menu list Press F2 key to scroll to MISC FUNCTIONS 2 Press F4 key to access the Misc Functions menu Date Time appears in the LCD display 3 Press F4 Key to access the Date Time screen Date Time screen appears with cursor in the Time menu line Display shows time in HH MM SS where H hour M minute and S second 4 Toenter a new time press F4 key with cursor in Time menu line An Enter Arrow appears in the menu line and the previous time disappears 5 Enter new time in HH MM SS format Decimal points must be included in the entry between the hour minute and second NOTE To scroll backward in the Time or Date menu line press and hold the F4 key then press F3 key Press F1 key to retur
22. Indicator LEDs 44 Keypad 43 45 Menu Scrolling Keys 45 Message Display 43 44 Special Function Keys 43 44 Temperature Status Display 43 Text Input 45 Text Input Example 46 Controller Menu Alarm List Menu 48 Commands Menu 48 Configuration Menu 48 Data logger Menu 48 Data Menu 48 Miscellaneous Functions Menu 48 REFCON Remote Monitoring State 48 RMM State 48 Setpoint Menu 48 CRR Operating Mode Function Chart 119 D Damper Motor Assembly Mounting Bracket 26 Damper Motor Housing 26 Data Recording and Downloading Data 113 Defrost 121 Display Alternate Controlling Supply or Return Air Sensor Temperature 57 Displaying Alternate Temperatures 57 E Electric Heaters 129 Electric Heaters Malfunction 129 Electrical System 18 Evaporator Fan Control 115 Fan Rotation 129 F First Aid 12 Fresh Air Management AFAM 26 Frozen Loads Controller Setpoint at 10 C 14 F or Below 118 Functional Inspection 53 G Gas Sensor Assembly 26 Gasket 26 General 11 General Description 25 General Precautions 11 15 General Precautions Safety 11 15 l Initiating a Manual Defrost 56 Interface Board 26 L Linkage Assembly 26 Loading Procedure 55 Low Voltage Safety Instructions 12 M Manual Function Test 71 MP 3000 Controller 26 N Navigating Controller Operating Menu 47 O Operating Instructions 49 Operating Modes 26 118 P Precautions General 11 15 Pressure Gauge Options 27 R Refrigeration System 19 Removing
23. LSV GRN GRN YEL BLU FVAP SOLFNOID VALVE BRN CONDENSER EH COIL BLU SENSOR SLACK 2 KOHM AT 25 C YELLOW RED LIQUID INJECTION C UM ALVE v BRN YELLOW 3 R AUR CFI AMBIENT 7 i M BLU C ers CONDENSER TEMP a waite Ko LH SUPPLY SENSOR 3LACK FR 2 KOHM AT 25 C SUPPLY GRN GRN YELS E AIR AIR SENSOR LH SENSOR RH f 2 KOHM AT 25 C 2 kOHM AT 25 C m s a a Ka f y J CARA ES wy HIGH PRESSURE COMPRESSOR CUTOUT DISCHARGE SWITCH TEMP SENSOR 100 kOHM AT 25 C POWER CORD e MOTOR CONNEC IONS e 1 L 1 400 460 VOLTS DATA COND KV HPS HUM aul 5 GS 7 EM 50 60 Hz USDA 17273 SUPPLY RH DEF RETURN CONDENSER KVG SENSOR EVAP FAN MOTORS TOP VIEW CONDENSOR FAN MOTOR cuo v T D P WIRES POWER RECEPTACLE AMBT COMP LH SUPPLY ROTATION C 0E rotation C S LOW SPEED HGH SPEED A BLK BRN B WHT BLU rN rl EFI EF2 EF3 Gwem EFII EFI2 EFI3 CFI C2 CE RED BLK COMPRESSOR WIRES G GRN GRN YEL Tl 72 T3 ma T13 a oo GRN GRN YEL C GRN GRN YEL RED BLU WHT QOELIBLIO RED BLK H TI EVAPORATOR HHT ABLKO As PRESSURF REGULATOR T4 T715 T8T6 T9 jns rdi DRAWN THERMO K NG PROPR ETARY DATA A ERE SS n THERMO KING THIS DOCUMENT CONTAINS PROPRIETARY CHECKED E S CORPORATION Se
24. Offline Zombie Online Press F3 key to scroll down or forward To Exit a Menu or Text Line Datal M EN ites a pe Datalogger Submenu Inspect Event Log Activate Tripstart Press F1 ESC key A spect temp Log e First function screen Press F3 key to scroll Press F4 key to i i PTI State appears through previous even enter trip start Special Function Keys EN a ert ea pa Press C F key to view alternate temperatur le in LED displ as A 9 gy Speckle DCG y perature scale Isp ay DATALOGGER Calibrate USDA Probe Press F4 key to view next Set Log Time Press F3 Inspect PTI Log Press DEFROST key to initiate a manual defrost Evaporator coil temperature must be below 10C Activate Trip Start Ey Set Log Time screen Press F3 key to scroll through previous logs key to scroll through log interval list Press and thro Press F3 key ugh test result A E of sensors hold F4 key until cursor screens Press SUP RET key to view alternate return supply sensor temperature in Inspect Event Log stops flashing LED display To Lock a LCD Data Screen Display Configuration Each time the 5 key is pressed the display time of the current LCD screen Configuration Submenu Type new value increases by 5 mi nutes Maximum display time is 30 minutes for data screens Menu Unit Type AFAM Opt Chart R o Curen umeo or press F3 key and 100 minutes for manual tests Press F
25. PTI stores volt and amps of all power consuming components PTI stores temperatures logged at both the start and end of Chilled Mode and Frozen Mode capacity tests Press ESC key to exit the PTI Log 65 Operating Instructions Alarms Menu The Alarm List menu displays alarm codes Alarm codes are recorded in the controller memory to simplify unit diagnosis procedures Some alarm codes are only recorded during a Pretrip PTI Test or Function Test Fault codes are retained by the controller in a non volatile memory If the Alarm LED is ON or flashing ON and OFF enter the ALARM LIST to view the alarm code s Alarm Types There are two types of alarms Shutdown Alarm Level 1 Alarm LED flashes and unit stops Shutdown alarms indicate the unit has been stopped to prevent damage to the unit or cargo The condition must be corrected before restarting the unit Alarm code 56 compressor temperature too high is a shutdown alarm Check Alarm Level 2 Alarm LED flashes until alarm is acknowledged Check alarms indicate corrective action should be taken before a problem becomes severe Alarm Code States There are three alarm code states for Shutdown and Check alarms NOT ACTIVE An alarm condition has occurred but no longer exists in the unit Not Active means the condition was corrected and did not recur for 1 hour or the unit On Off switch was turned OFF and then ON When a NOT ACTIVE alarm code is acknowledged F
26. Return Air Sensor 24 Defrost Evaporator Coil Sensor 25 Supply Air Sensor 26 Condenser Coil Sensor 27 Ambient Sensor 28 MP 3000 Controller 29 KVQ Valve Evaporator Pressure Regulator 30 Suction Service Valve 31 Liquid Injection Valve 32 Dehumidify Solenoid Valve Option 33 Humidity Sensor Option 34 Water Cooled Condenser Receiver Tank Option 35 Water Inlet Coupling 36 Water Outlet Coupling 37 Water Pressure Switch WPS Option Orco A a CON NOTE Compressor Discharge Temperature Sensor is mounted in the compressor head on CRR40 196 models 195 Full Cool Flow and Pressure Diagram Flow and Pressure Diagram CRR 40 Full Cool 1 D3DS Compressor Compressor operation has a variable delay on initial start up A sequence start of the compressor occurs when the compressor has been OFF for more than 18 hours High Pressure Cutout Switch HPCO Is a normally CLOSED switch It OPENS at 2240 70 kPa 22 4 0 7 bar 325 10 psig It CLOSES at 1590 70 kPa 15 9 0 7 bar 230 10 psig High Pressure Relief Fusible Plug BLOWS at 100 C 212 F Liquid Line Solenoid LLS Is a normally CLOSED solenoid It OPENS when energized when the compressor operates TET Hw B CERT 8 oea i y Electric Heaters During the DEFROST and HEAT modes the electric heaters are pulsed ON and OFF Condenser Coil Temperature Sensor Controller cycles condenser fan ON typic
27. Setpoint Menu Screen Flow Diagram Changing the Humidity Mode Setting 1 Press the SETPOINT key The SETPOINT menu appears with the cursor in the TEMP SETP line Press F2 key to scroll to HUM CONTROL line To change the mode setting press F4 key Cursor moves to end of menu line and flashes Press F2 key to toggle between OFF and ON With the desired state in the menu line press and hold F4 key until cursor stops flashing New mode setting appears in display Press ESC key to exit the SETPOINT screen Changing the Humidity Setpoint 1 Press the SETPOINT key The SETPOINT menu appears with the cursor in the TEMP SETP line Press F2 key to scroll to HUM SETP line To enter a new setpoint press the F4 key An Enter Arrow appears in the menu line and the current setpoint disappears Enter type the new setpoint in the LCD display using the general purpose keypad The cursor moves to the right of the screen as each key entry is acknowledged and displayed NOTE Always check that the setpoint entered in the LCD display is correct before proceeding Press and hold the F4 key until the cursor stops flashing The new setpoint is recorded in the controller and appears in the LCD display Press ESC key to exit the SETPOINT screen 59 Operating Instructions Advanced Fresh Air Management AFAM or Advanced Fresh Air Management Plus AFAM Door Options A microprocessor cont
28. an alarm is recorded in the controller display and data logger memory If a power loss occurs after the AFAM system is turned ON the controller automatically operates the vent door based on the previous AFAM DELAY and AFAM RATE settings when power is restored X y Se oS F Se gt A o 1 Cotter Pins 6 Vent Motor Linkage Figure 45 AFAM System Linkage Adjustment Operating Instructions Alarm Alarm Code Type 57 Check AFAM Control Module or Motor Error Indicates a frozen or stuck vent door or a problem with the control module or its wiring or the motor current draw is not with limits 68 Check AFAM Gas Analyzer Error Indicates a communication problem with the gas analyzer 69 Check AFAM Gas Analyzer Calibration indicates problem with sensor Description Linkage Installation and Adjustment If the vent door motor linkage assembly or vent door require repair or replacement make sure the linkage is properly adjusted 1 Insert L rod in damper motor linkage so that the eyelet in the rod end aligns with the vent door bracket Install pin shoulder washer and cotter pin to fasten L rod to damper motor linkage 2 Fully thread the rod end onto the L rod Then back off rod end approximately 2 complete rotations 95 Operating Instructions 3 Align the rod end eyelet in the vent door bracket Temporarily insert pin to fasten rod end to door bracket
29. hold the F4 key then the press F3 key To delete text from a previous entry press F4 key and then the SPACE key To start entry over or quickly return to the beginning of the text box press F4 key then EXIT key and then F4 key again When the F1 F2 F3 or F4 key is pressed to enter a character in the display the keypad remains on that character level until another level is selected by pressing the F1 F2 F3 or F4 key 8 Operating Instructions When the desired text entry is complete press F4 key Then press EXIT key The cursor stops flashing and the new text appears in the menu line Repeat steps 5 through 7 until all information has been entered in the Cargo Data screen Press ESC key to exit the Cargo Data screen Changing the Temperature Display Value C F 1 Press F3 key to enter the menu list Press F2 key to scroll to MISC FUNCTIONS Press F4 key to access the Misc Functions menu Date Time appears in the LCD display Press F2 key to scroll to C F MODE Press F4 key to access the C F Mode screen C F Mode screen appears with cursor in the temperature value menu line Display shows C F MODE C where C Celsius and F Fahrenheit To change the temperature value press F4 key Cursor moves to end of menu line and flashes Press F2 key to toggle temperature value in the menu line between C and F With the desired temperature value in the menu
30. the rod end from the door bracket Lengthen linkage by backing rod end off additional rotations Lengthen linkage until door gasket seals tightly against the air exchange openings When linkage is properly adjusted fasten rod end securely to door bracket with pin and cotter pin 61 Operating Instructions Datalogger Menu The Datalogger menu contains a list of functions that display unit operating information recorded in the MP 3000a datalogger The following functions are available Inspect Temperature Log Displays temperature logs by time and date for the Setpoint Supply Controlling Temperature Return USDA1 USDA2 USDA3 and Ambient sensors humidity sensor and event flags Inspect Event Log Displays important event logs by time and date for events such as unit alarms power On Off setpoint change clock reset trip start defrost etc Set Log Time Sets the data log interval 1 minute or 1 2 1 2 or 4 hours Standard Display o o o o o o HUMIDITY COMP HEAT DEFROSTIN RANGE ALARM ela m Lt Main DATA ALARMS COMMANDS MISC FUNCTIONS CONFIGURATION DATALOGGER RMM STATE Activate Tripstart Sets the date and time of the trip start Inspect PTI Log Displays results of last PTI test including component volt and amps data and sensor temperatures Test values are recorded at the start and end of the Chilled and Frozen Mode test Viewing
31. with sharp metal edges 129 Electrical Maintenance 130 Refrigeration Maintenance NOTE The following procedures involve servicing the refrigeration system Some of these service procedures are regulated by Federal and in some cases by State and Local laws All regulated refrigeration service procedures must be performed by an EPA certified technician using approved equipment and complying with all Federal State and Local laws NOTE CRR units feature a large one piece filter drier in line filter The filter drier should not require replacement unless major system contamination requires evacuation and cleanup of the refrigeration system 1 AAA serene Y ES JI CLE H ZA Gun d ITZA WMA 11 0mm 13 0mm C RAS iS Internal Threads for Cap AJA1314 High Pressure Fitting Low Pressure Fitting Figure 63 Service Fittings Specifications Service Tools CAUTION When servicing thermo king R 134a refrigeration systems use only those service tools i e vacuum pump refrigerant recovery equipment gauge hoses and gauge manifold set certified for and dedicated to R 134a refrigerant and Polyol ester based compressor oils Residual non HFC refrigerant or non Ester based oils will contaminate HFC systems Unit Service Fittings Special fittings are used on R 134a systems to prevent mixing of non HFC refrigerants in R 134a units These fittings are located in three p
32. 2 1A 2 3A PTI PART 1 END SUP RET EVA 5 1C 5 0C 5 16 2 3A 2 1A 2 3A operates in cool until the return sensor is ms then 15 C 59 F or 1 hour If the return air temperature is below 5 C 41 F unit operates in heat until return temperature is above 5 C 41 F or 2 hours PTI Part 1 end is recorded in PTI log Readings may vary depending on voltage and temperature RUNNING PTI 0 C 32 F 00 00 00 0 0C 10 0C 10 0C RUNNING PTI 0 C 32 F 00 00 00 0 0C 10 0C 10 0C RUNNING PT DEFROST 00 00 00 18 0C 10 0C 10 0C RUNNING PT 18 C 0 F 00 00 00 18 0C 10 0C 10 0C PTI PASS PRESS KEY 76 Supply temp Supply temp Return temp Return temp Return temp Readings may vary depending on voltage and temperature Unit operates in normal mode with 0 C 32 F setpoint When supply air temperature decreases to setpoint Chill Arrival temperatures are recorded in PTI log Unit operates in normal mode with 0 C 32 F setpoint for 30 minutes after previous test is completed At the end of 30 minutes Chill End temperatures are recorded in PTI log Sensor values for supply LH supply RH return and evaporator sensors are recorded in the event log Unit operates in normal mode with 18C OF setpoint and defrost activated Defrost terminates when evaporator temperature increases to 18C 65F Unit operates in normal mode with 18C OF setpoint When return air temperature
33. 21 1 17 0 21 bar 17 3 psig is provided to the condenser receiver tank the water pressure switch opens This causes the controller to stop condenser fan operation When the water pressure decreases below 35 21 kPa 0 35 0 21 bar 5 3 psig the switch closes causing the controller to place the unit on air cooled condenser fan operation NOTE Water cooled condenser requires a water flow of 19 to 38 l min 5 to 10 gal min Unit Instruments 50 Moisture Indicator Light Green Dry Yellow Wet Outer ring is color coded Compare to indicator Figure 29 Receiver Tank Sight Glass RECEIVER TANK SIGHT GLASS A sight glass on the receiver tank contains three small balls that indicate the level of refrigerant in the tank for checking the refrigerant charge A moisture indicator in the sight glass changes color to indicate the level of moisture in the system Check the color of the indicator against the color decal in the sight glass The dry eye in the sight glass is LIGHT GREEN when the system is dry and YELLOW when the system is wet contains excessive moisture COMPRESSOR OIL SIGHT GLASS A compressor oil sight glass indicates the relative level of compressor oil in the compressor sump SUCTION PRESSURE GAUGE OPTION A suction pressure gauge indicates the refrigerant pressure in the suction line returning to the compressor DISCHARGE PRESSURE GAUGE OPTION A discharge pressure g
34. 4 Amps approx at 400V 5 2A 54A 5 24 5 1 Amps approx at 460V Heater amperes are recorded in PTI log COMPRESSOR TEST With compressor and condenser fan on compressor is 6 7 30 seconds AMB CON EVA operating at 100 percent capacity Amp draw is measured and compared to voltage Compressor 8 0C 15 0C 5 0C amperes are recorded in PTI log If compressor has 91A 90A 94A been off for 18 hours less than 30 seconds on a compressor sequence occurs KVQ VALVE TEST With compressor condensor fan and evaporator fan on 29 240 seconds AMB CON EVA feo An Amp draw diference of 1 2 amps le required 8 0C 25 0C 2 0C 91A 90A 9 1A INJECTION VALVE Liquid injection valve is turned on for 3 seconds off for 3 None 20 seconds TEST seconds and on for 3 second to verify valve operation AMB CON EVA 8 0C 25 0C 2 0C 91A 90A 9 1A Readings may vary depending on voltage and temperature 79 Operating Instructions Manual Function Test The Manual Function Test menu allows technicians to perform specific diagnostic tests on individual components or turn several components on at the same time to perform a system test NOTE When the Manual Function Test menu is entered the UNIT STOPS A technician can then select the control circuit or component to be checked tested from the items shown in the menu With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press F3 key to enter the menu list R
35. 78 8 26 93449 72048 196 Hoop e Ambient sensor must be placed on the bottom 82 4 28 87023 2084 98 5941 plate of the right forklift pocket 86 30 79428 212 100 5574 Compressor sensor must be placed in the 89 6 32 72567 215 6 102 5234 manifold on the discharge tube before the 93 2 34 66365 2192 104 4917 discharge service valve 96 8 36 60752 222 8 106 4623 100 4 38 55668 226 4 108 4348 104 40 51058 230 110 4092 107 6 42 46873 233 6 112 3854 111 2 44 43071 237 2 114 3631 114 8 46 39613 2408 116 3423 1 to 1 2 in 118 4 48 36465 244 4 118 3229 25 to 30 mm asas 122 50 33598 248 120 3047 x ee s Meg ON e E est 132 8 56 26413 258 8 126 2569 136 4 58 24419 2624 128 2430 C Insert Sensor at least 75 mm into coil between tube rows 2 and 3 140 60 22593 266 130 2299 Figure 60 2 Fan Evaporator Evaporator Defrost 143 6 62 20921 269 6 132 2176 Sensor Location 147 2 64 19388 273 2 134 2118 150 8 66 17961 2768 136 1953 154 4 68 16689 280 4 138 1852 126 Es B 11 in 279 mm C AJA1282 Coil Support Brackets Unit Front Insert Sensor at least 75 mm into coil between tube rows 2 and 3 Em uM Figure 61 Evaporator Defrost Sensor Location Diagnosis and Repair If the unit appears to be operating incorrectly view any alarm codes that may be stored in the controller display memory Diagnose and correct the problem associated with each alarm code see Alarm Codes Alarm Types and Corrective Action
36. A Sol il rique fpe vee 104 Configuration sesa Rs 104 AFAM System and AFAM System Operation 0 00 cece eens 106 Advanced Fresh Air Management AFAM System ooccccccccc eee 106 Setting AFAM System Values 0 0 ccc teen eee eee 106 Advanced Fresh Air Management Plus AFAM System 000000 cece eee eee 110 Setting AFAM System Values o oocoococco ttt eee 110 Operating Theory lit nA eA ee ae lak Soak Spach leach Re dere hole RS iia 113 Data Recording and Downloading Data occoccocconcor nen 113 Chill Loads Setpoint at 9 9 C 14 1F and Above 20 cece eee 113 Frozen Loads Setpoint at 10 C 14 F and Below oooocoococooooo 114 KVQ Setting Value and Cool Capacity Value in Data Menu 0 0 eee eee 114 Compressor Liquid Injection sssi rra saa o o Oe e RR m uh 114 Power LimitMode audi e o vem up Dae add 114 Evaporator Fan GOntrol xem actae per CIE EUER Ren RI ti USER Rate LAS S err 115 Condenser Fan Control ooo arar rev a She Pe tie Phe eY eed du en 115 Probe Test fui ti eA ai iste naa Ao E Aleta Aca RASA Ae a EINE US 116 Dehumidify Mode Option 0 0 0 eR RR uh nn 116 Sequence Of Operation er eee oe ck ck On HR SIR SERRE RS E UR Ri dob DRE 116 Continuous Temperature Control Operation 0 cee tees 117 Operating Modes 1 2 ea stand eic EMG ii AG Ray RY E Re NE 118 Chill Loads Controller Setpoint at 9 9 C 14 1 F or Above coccccccccc ee 118
37. AJA1337 Evaporator Fan Blade Airflow Direction Evaporator Coil Evaporator Motor 12 mm 0 5 in Figure 84 Evaporator Fan Blade Placement 157 Servicing The Unit 158 Diagnosis Troubleshooting Status Messages Alarm Codes Introduction This chapter includes the following e Introduction to Controller Diagnostics e Troubleshooting charts e Status Messages chart e Alarm Codes chart The charts will help you identify and fix unit problems Controller Diagnostics The MP3000a can be a very helpful diagnostic tool The following menu areas of the MP3000a controller menu will help you diagnose problems occurring with the Magnum unit Alarms Menu The Alarm List menu displays alarm codes Alarm codes are recorded in the controller memory to simplify unit diagnosis procedures Some alarm codes are only recorded during a pretrip PTT test or function test Fault codes are retained by the controller in a non volatile memory Refer to the Alarms Menu in the Operating Instructions Section Brief PTI Test The MP 3000a controller contains a special Brief PTI pretrip test that automatically checks unit refrigeration capacity heating capacity temperature control and individual components including the controller display contactors fans protection devices and sensors The test includes measurement of component power consumption and compares test results to expected values The test takes about 25 30 minutes t
38. C li Sept o2 REVISED amp REDRAWN 24 Feb 03 MOVED COMPRESSER WIRING BEFORE F1 F3 DEL VFO OPTION 505955 E 05 Jan 04 HY CO WAS Jd 506512 30 Mar 04 MF WIRE REWIRED TO T1 X2 LOCATION BATTER CONDE COMPRE EHUMI R WCCS ER y CIRCUIT BREA COMPRESSOR CO SER FA SSOR D SO ATOR 20 20 A COOLE AIR COMP CONT AIR COMP MOTO FA ER OTOR OPTION OPTION MAIN TACTOR MOTOR VALVE COPTION MOTORS 89 1 All Models Except CRR40 303 Wiring Diagram Page 1 of 2 8 7 6 5 4 3 2 rc OP T MI NA O S EVAPORATOR TC OPTION spat SECTION Bw a RETURN RED RETURN AIR FRE SENSOR OVERHEAT pop YELLOW ev SWITCH i 25 C EFIS EFI3 i USDA EF I2 EFI l l EFLI EVAPORATOR dior wir br oM EFL EVAPORATOR BLack EN Ee FAN HUMIDITY BRN OR RED 222 HUM EF3 FAN
39. C 14 1 F and above whenever the container temperature is In range Frozen Loads Controller Setpoint at 10 C 14 F or Below Temperature control by the controller is based on the return air sensor temperature The evaporator fans operate continuously on low speed except during defrost e Cool down to 1 C 1 8F below setpoint Null compressor and condenser fan stops evaporator fans operate e Defrost resistance heaters on evaporator fans stop NOTE If the Economy Mode is set to ON the evaporator fans stop when the unit shifts to Null The controller automatically starts and operates the evaporator fans on low speed for 5 minutes every 45 minutes while the unit remains in Null Operating Theory CRR Operating Mode Function Chart Chill Loads Setpoints at 9 9 Frozen Loads C 14 4 F and Above Setpoints at 10 0 C 14 0 F and Below fCOODWMGG Heat Detreet Cool Null AI ESA AE arre gt 7 poe bue A A O ESA EEE AAA AAA a a EA i E Proportional integral Derivative Supply Air Control A PARE AA O i E A ee ee ee Evaporator Coil Sensor Control EM ee 2 E PEA A pel ae poo AREA gate ne Solana Wave Pen ee a AA PAN rn Condenser Fan ON 3 KVQ Valve MODULATING energized Electric Heaters PULSING or ON energized 5 Dehumidify ON Dehumidify valve pre 2002 CLOSED energized 1 Setpoint temperature and Economy mode setting determine the evaporator fan speed Normal Operation economy Mo
40. Charge in this chapter 151 Refrigeration Maintenance High Pressure Cutout Switch Replacement Removal 1 Close the liquid line service valve and pump down the low side Open the outlet valve slightly to equalize the pressure between 10 and 20 kPa 0 10 and 0 20 bar 1 and 3 psig 2 Front seat the discharge service valve CAUTION Any time the discharge valve is front seated disconnect the unit power source to prevent accidental compressor start up 3 Purge the high pressure from the compressor head through the service port on the discharge line 4 Disconnect the leads from the wire harness and remove the switch from the compressor discharge manifold or remove the sensor from the compressor head Installation 1 Apply a refrigeration locktite sealant to the threads of the switch or sensor 2 Install and tighten the switch or sensor Connect the leads to the wire harness 3 Open discharge service valve slightly to pressurize the compressor head and tube assembly Check for leaks see Refrigerant Leak Test Procedure in this chapter Front seat the discharge service valve 4 If no leaks are found recover the leak test gas see Refrigerant Recovery in this chapter 5 Open the liquid line service valve and compressor discharge service valve and place the unit in operation 152 Liquid Line Solenoid Valve Replacement Removal 1 Close the liquid line service valve and pump down
41. Do not wear jewelry watch or rings These items can shortcut electrical circuits and cause severe burns to the wearer Electrostatic Discharge Precautions Precautions must be taken to prevent electrostatic discharge while servicing the MP 3000a microprocessor and related components The risk of significant damage to the electronic components of the unit is possible if these precautionary measures are not followed The primary risk potential results from the failure to wear adequate electrostatic discharge preventive equipment when handling and servicing the controller The second cause results from electric welding on the unit and container chassis without taking precautionary steps Electrostatic Discharge and the Controller You must avoid electrostatic discharges when servicing the controller Solid state integrated circuit components can be severely damaged or destroyed with less than a small spark from a finger to metal object You must rigidly adhere to the following statements when servicing these units This will avoid controller damage or destruction e Disconnect all power to the unit e Avoid wearing clothing that generates static electricity wool nylon polyester etc Do wear a static discharge wrist strap refer to Tool Catalog with the lead end connected to the controller s ground terminal These straps are available at most electronic equipment distributors Do not wear these straps with power applied
42. Frozen Loads Controller Setpoint at 10 C 14 F or Below 0 cece ene 118 CRR Operating Mode Function Chart 0 0 cect tte eee 119 DetrOStret ens cuadro ii acia dato date tn Rd Aqu RI oie aaa bans 121 Controller Maintenance co Sic Seah eg Bole ee eas SE EL EL ME de exer eee Med Rib REP 123 Replacing the Controller 0 0 0 cette eee 123 Automatic Configuration of Spare Parts Controller llle 123 Controller Software Selection 0 0 0 ete eee 124 Flash Loading Controller Software 0 cette eee 124 Electrical Maintenance 2ocs Ges Bie Vee 9o e ee ee eee 125 Temperature SENSO i ne ieee dete ER ned mE Ss ue REC RE OGG BREE ee aed 125 Diagnosis and Repair iade eave She ee ee mE ER EO E a 127 Unt WIFIFIQ cda ta ether Sah WEE pr tes Cep EVE Sea beguniee ed als Ris bares 127 High Pressure Cutout Switch 0 0 0 0 ett rm mun 127 Condenser Fan and Evaporator Fan Rotation 00 cece tenet eee 128 Check Condenser Fan Rotation 0 00 128 Check Evaporator Fan Rotation 0 0 0 0 c tet e teens 129 Electric Heaters Malfunction l l hh eens 129 Refrigeration Maintenance 0 2 cece ehh Rh hh hh kh hn 131 Service Tools cidcid thew eb M4 Onan eee ae eae be ie mend d d d eet te 131 Compressor Discharge and Suction Service Valves 000 e cece eee eee eee eens 132 Gauge Manifold Valve Positions 0 0 0 mm rh 133 Gauge Manifold Set With Low Loss Fitt
43. Hg vacuum 29C 20 F Cool 27 to 38 C 80 to 100 F 45 to 35 kPa 0 45 to 0 30 bar 14 to 11 Hg vacuum Cool 16 to 27 C 60 to 80 F 50 to 35 kPa 0340 to 0 20 bar 15 to 11 Hg vacuum Suction pressure in Modulation Cool mode will vary between 140 and 35 kPa 1 40 and 0 35 bar 20 psig and 10 Hg vac uum depending on the percent of cooling capacity 20 Specifications MP 3000a Controller Temperature Controller Type MP 3000a microprocessor with thermostat digital thermometer programming keypad mode indicators LED display and LCD display for displaying unit operating and cargo information Setpoint Range 30 0 to 30 0 C 22 to 86 F Digital Temperature Display 60 0 to 80 0 C 76 0 to 176 0 F Controller Software Original Equip Version See controller identification decal Defrost Initiation Evaporator Coil Sensor Manual Switch or Demand Defrost Initiation Coil must be below 18 C 65 F Defrost cycle starts when technician or controller request defrost initiation Timed Defrost Initiation Coil must be below 10 C 50 F Defrost cycle starts 1minute after the hour immediately following a defrost timer request for defrost initiation For example if the defrost timer requests a defrost cycle at 7 35 the defrost cycle will start at 8 01 Datalogger will record a Defrost event for each interval in which a Defrost cycle is pending or active i e both the 8 00 and 9 00 data logs
44. Occurs during Pretrip PTI test or Probe Test failed in CHilled mode Temperature difference between LH supply and RD supply sensors is too high 0 5 C 1 0 F difference maximum Indicates Incorrect temperature reading on one sensor Supply air sensor not placed in air flow stream Check sensor connections Check sensor resistance of each sensor Resistance must be 2 000 ohms at 25 C 77 F Check left hand and right hand supply air sensor locations Check sensor connections Check sensor resistance of each sensor Resistance must be 2 000 ohms at 25 C 77 F Check left hand and right hand supply air sensor locations Check sensor connections Check sensor resistance of each sensor Resistance must be 2 000 ohms at 25 C 77 F Check left hand and right hand supply air sensor locations 183 Diagnosis Troubleshooting Status Messages Alarm Codes 184 Index A Advanced Fresh Air Management Plus AFAM 26 AFAM Description 26 AFAM Description 26 Air Exchange System 26 Alarm Code States 66 Alarm List 67 Alarm Types 66 C Changing the Economy Mode Setting 58 Changing the Humidity Mode Setting 59 Changing the Humidity Setpoint 59 Changing the Setpoint 56 Changing the Setpoint Temperature 58 Chill Loads Controller Setpoint at 9 9 C 14 1 F or Above 118 Commands Menu 68 Condenser Fan Control 115 Rotation 128 Controller Electrostatic Discharge 12 F1 Key 45 F2 Key 45 F3 Key 45 F4 Key 45
45. Off switch Replace or repair as required Adjust controller setpoint Replace compressor contactor Diagnose and replace main relay board or controller Turn unit On Off switch OFF and then ON again Replace high pressure cutout switch Check refrigeration system and correct fault Replace compressor Let compressor cool and controller will reset automatically Check liquid injection valve and compressor temperature sensor If compressor contactor is energized wait 60 minutes for protector to cool and reset Remove compressor head Look for broken valve and jammed parts Replace compressor Check correct wiring against wiring diagram Check line voltage determine location of voltage drop Eliminate cause of high head pressure Check by operating manually Repair or replace Check motor stator connections Check stator winding for continuity If open replace compressor Replace thermal overload protector or compressor Compressor contactor burned out Unit short cycles Noisy unit Condenser fan motor does not operate Diagnosis Troubleshooting Status Messages Alarm Codes Low line voltage Excessive line voltage Short cycling Refrigerant overcharge causing cycling on high pressure cutout Inefficient condenser operation causing cycling on high pressure cutout Insufficient compressor oil Loose mounting bolts Oil slugging or refrigerant flooding back Worn fan motor bearings Faulty
46. Refrigerant Properly 13 Rotation Condenser Fan 128 Rotation Evaporator Fan 129 S Safety Instructions 15 Safety Electrical Precautions 11 Safety Electrostatic Discharge Precautions 12 185 Index Safety Refrigerant Oil Precautions 11 15 Safety Removing Refrigerant 13 Safety Welding 13 Service 15 Service Guide 15 Starting the Unit and Adjusting the Controller Setpoint 52 U Unit Description 25 V Vent Door Assembly 26 Viewing the Alarm List Menu 66 Viewing the Commands Menu 69 Visual Inspection 52 Ww Water Cooled Condenser Description 28 Welding Safety 13 186 Electrical Refrigeration and MP 3000a Menu Flow Diagrams Index Dwg No Drawing Title Page 5D55683 All Models Except CRR40 303 Wiring Schematic 189 5D55684 All Models Except CRR40 303 Wiring Diagram 190 191 Page 1 of 2 5D55262 CRR40 303 Wiring Schematic 192 5D55263 CRR40 303 Wiring Diagram Page 1 of 2 193 194 Refrigeration System Components 195 Full Cool Flow and Pressure Diagram 196 Cool with Modulation Flow and Pressure Diagram 197 Dehumidification Flow and Pressure Diagram 198 MP 3000a Menu Flow Diagram 199 187 Electrical Refrigeration and MP 3000a Menu Flow Diagrams Index 188 ic Wiring Schemat All Models Except CRR40 303 CB 254 BLK BRN NS LI 20 AMP Oo WHT BLU A L2 o SET e RED BLK o Xe o NOH AMP O J Je
47. Sets the container identification number Enter up to 11 characters numbers or letters Control Type Displays container length and unit type In Range Sets the temperature value for the controller s In range LED and datalogger functions factory default 1 5 C 2 7 FJ Enter a value from 0 5 to 5 0 C 0 9 to 8 9 F Contrast Controller automatically regulates black and white contrast value on LCD display according to display temperature Standard setting is 45 Resetting this value is not recommended Unit Type View display value factory default NO HUM Controller automatically activates when a humidity sensor is installed for more than 1 minute Setting this value is not necessary Dehumidification Valve Reefer Type Sets the unit model state to CRR20 PS or CRR40 PS Must be manually set to unit type on unit serial number plate Zero Current View display ON or OFF value factory default ON However no errors occur if a Zero Current transformer 1s not installed and configuration is set to ON Supply LH View display ON or OFF value factory default OFF Controller automatically activates when a left hand supply sensor is installed for more than 1 minute Setting this value is not necessary AFAM Options Sets the Advanced Fresh Air Management System to NONE ANALYZER AFAM or AFAM factory default NONE Controller automatically activates when an AFAM system vent door and or AFAM gas senso
48. Soe ee es ee A oe it ici 50 Starting the Unit and Adjusting the Controller Setpoint llle 52 Pretrip Inspectioh 2 91 noe bh eO ine ed ae aoe Dab iy Tae iG Sled bedded bebe aces 52 Visual INSPECtON uos scan arash xe ded ach RE e Wat pall Re ANE EDAD dui asd ded ad Rois 52 Functional InSpectiony A rte anette ig Fees ee EM aU n RE 53 Table of Contents Operating Instructions continued Sequence Of Operalion curar o Tee en delest aed 54 Loading Procedure cerce oov ae ied a See aed eds Mise ee ar de rs ee 55 Post EoadiProcedute c Cus puce A Yu ope me tae ae Rae ee tte nk A eae Fay 55 Post Trip Procedure sen em ee RR Ae ER E Va ege eee xu ee ed 55 Change the Setpoint 1 4 ia endete rera bep Pea eed a e o iuste Sus ga CR ROS Sq RE o 56 Initiating a Manual Defrost oooooccoo eh hmm hs 56 Display Alternate Controlling Supply or Return Air Sensor Temperature llslls lessen 57 Display Alternate Fahrenheit F or Celsius C Temperatures oooocccccccccn 57 Setpoint Men rcp 58 Changing the Setpoint Temperature 0 0 eet eens 58 Changing the Economy Mode Setting ooccoococcooccn eee 58 Changing the Humidity Mode Setting 0 00 ttt eae 59 Changing the Humidity Setpoint o oooooccocccccco e m 59 Advanced Fresh Air Management AFAM or Advanced Fresh Air Management Plus AFAM Door Options 0 000 e eee eee eee 60 Datalogger Menu cuco tas a ae ei ede epi pl
49. access a menu line to enter information or to load a command or value MAIN MENU DATA TEMP SETP C F SUP RET DEFROST SETPOINT AJA1968 Message Display Menu Scrolling Keys Figure 28 MP 3000a Controller Display Panel 47 Navigating the Controller Operating Menu 48 Display menus The MP 3000a controller contains an extensive display menu that can be navigated via keypad The display menu is organized into eight main menus NOTE The screens that display on the controller are determined by the controller software setting and the options installed on the unit All screens are NOT present on all units Setpoint Menu Menu screens in this group are used to enter the temperature setpoint and set the Economy mode Setpoint menu option functions include set Bulb mode or dehumidify operation and enter humidity setpoint set AFAM set AFAM delay set AFAM rate set O Minimum set CO Maximum and OPTI SET Alarm List Menu Menu screens in this group display a list of alarm code s Data Menu Menu screens in this group are used to display unit operating information including sensor temperatures voltage current and frequency information REFCON Remote Monitoring RMM State Menu screen show current remote monitoring state Offline Zombie or On line e Data logger Menu Menu screens in this group display temperature log event log set log time and PTI log e Configuration Menu Menu screens in
50. alarm codes are documented and problems repaired A permanent record of the alarm codes remains stored in the datalogger memory for retrieval via DRU II or SmartSponge retriever software Enter trip ID information into the controller using the keypad Set the fresh air vent or Advanced Fresh Air Management system to the desired air exchange rate NOTE The air exchange rate should be established by the shipper e AFAM System Set the AFAM screen in the Setpoint Menu to UNITS to control the vent door to the fresh air exchange rate setting Set the AFAM screen to DEMAND to control the vent door to the CO gas level Then set the AFAM DELAY AFAM RATE and CO MAX as required Optional Operate the humidify system see Changing the Humidity Mode Setting NOTE The use of the Humidify option should be established by the shipper a Verify that the air compressor operates and that water is drawn into the atomizing nozzle and injected into the return air stream see Humidify System b Adjust the humidity setpoint Stop the unit by moving the On Off switch to the OFF position Sequence Of Operation Unit Start up A 60 second sequence start of the required loads occurs during initial start up of the controller If cooling or heating is required the unit operates in the cool or heat mode When the unit On Off switch is turned ON the LED display turns On and then Off The setpoint appears briefly
51. an securely tighten five mounting screws 6 Connect the motor wires to the terminal board Make sure the red positive and black negative wire are correctly aligned 7 Check to see that the quartz motor is running Look through the inspection window and make sure the internal flywheel on the quartz motor is revolving 8 Replace the recording platen recording chart and chart nut Lower the recording pen Battery Voltage Indicator The battery voltage indicator is field replaceable If the indicator needle oscillates when the test button is depressed or the needle remains in the red zone when a new battery is installed replace the voltage indicator assembly 1 Remove the knurled chart nut and chart Remove the recording platen 2 Loosen the two terminal screws on the terminal board and remove the voltage indicator wires 3 Loosen the two mounting screws that mount the voltage indicator assembly in the recorder Remove the voltage indicator includes battery holder 4 Install a new voltage indicator Install and securely tighten the two mounting screws 5 Connect the voltage indicator wires to the terminal board Make sure the red positive wire and black negative wire are correctly aligned 6 Reinstall the battery in the battery holder with correct polarity Check the voltage indicator by depressing the test button to make sure the indicator needle is in the blue zone Also check to see that
52. an alternative test component If no leaks are found but the system has lost its refrigerant charge proceed to the next step 6 Close both hand valves on gauge manifold front seated 7 Disconnect the refrigerant charging hose Figure 74 Testing for Refrigerant Leaks 8 Connect the charging hose to a source of nitrogen Adjust the pressure regulator to 1380 kPa 13 80 bar 200 psig See Using Pressurized Nitrogen in this manual chapter CAUTION Nitrogen N2 is under 15 170 kPa 151 70 bar 2200 psig pressure ina full cylinder at 21 C 70 F DO NOT use oxygen acetylene or any other type of pressurized gas in the system 9 Pressurize the system with nitrogen to 1380 kPa 13 80 bar 200 psig 10 Close the supply valve on the nitrogen bottle 11 Use an electronic leak tester to inspect all joints and connections Use a soap solution as an alternative test component NOTE If system leakage is indicated loosen supply line hose fittings to release pressure Repair leakage condition 12 If system repair is necessary recheck system after repairs are completed Low Side Pump Down 1 Install the gauge manifold on the compressor 2 Set the controller setpoint temperature well below the return air temperature and operate the unit in the Cool mode until the temperature stabilizes at least 5 minutes 3 Close the liquid line service valve Allow the unit to operate until it reaches 15 to 40 kPa
53. and heat test e PTI end e Defrost start logged with demand or manual defrost only e Defrost end start time 6 Press ESC key to exit the Event Log Set Log Time With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press F3 key to enter the Main Menu 2 Press F2 key to scroll through menu list until DATALOGGER appears in LCD display 3 Press F4 Key to access the Datalogger menu Inspect Temp Log appears in the LCD display 4 Press F2 or F3 key to scroll through submenu until Set Log Time appears in LCD display 5 Press F4 Key to enter Temp Log LCD display shows the current Log Time interval 64 To enter a new log interval press F4 key again with cursor in Log Time menu line Arrow appears in menu line Press F3 key to scroll through a list of log time intervals Minute 1 2 Hour Hour 2 Hour 4 Hour The logging of USDA sensors is fixed at 1 hour intervals to comply with USDA requirement A logging test of USDA sensors at 1 minute intervals is also possible for 72 minutes USDA data can not be downloaded during the logging test After 72 minutes controller returns to previous logging interval and clears USDA test data from datalogger memory When the correct log time appears in the menu line press and hold F4 key until cursor stops flashing The new Log Time appears in the display Press ESC key to exit
54. and motor actuator arm move immediately when the F4 key is pressed to turn the AFAm system to DEMAND UNITS or OFF Keep hands and tools away from the air exchange system components to prevent personal injury or unit damage 4 Press F2 key to toggle between OFF DEMAND and UNITS OFF Vent door stops in current position AFAM DELAY AFAM RATE and CO MAX settings become blank DEMAND Controller uses the CO gas levels to adjust the vent door position AFAM RATE setting becomes blank UNITS Controller uses the fresh air exchange rate to adjust the vent door position The CO MAX setting becomes blank 5 With DEMAND in the menu line press and hold F4 key until cursor stops flashing DEMAND now appears in display 6 Press ESC key to exit the SETPOINT screen Changing the AFAM Delay NOTE The fresh air exchange time delay should be established by the shipper The AFAM delay setting keeps the fresh air vent closed for a preset time when the unit starts This allows faster product temperature pulldown The AFAM delay can be set from 1 to 72 hours in 1 hour increments NOTE During unit startup the AFAM delay prevents the AFAM door from opening until the delay times out or the container temperature is in range The AFAM delay prevents the AFAM door from opening due to the AFAM Rate O or CO system settings 1 Press the SETPOINT key The SETPOINT menu appears with the cursor in the TEMP SETP
55. and place unit in operation Operate unit and note suction pressure and container temperature to see that feeler bulb is properly installed Refrigeration Maintenance Receiver Tank Replacement Removal 1 Recover the refrigerant charge from the unit see Refrigerant Recovery in this chapter Unsolder the outlet valve on the liquid outlet line Unsolder the liquid line inlet connection Loosen the mounting nuts and remove the tank Remove the adapter with fusible plug service fitting and water fittings option from the receiver tank for installation in new tank Installation 1 Install a new tank in the unit and tighten the mounting bolts Solder the inlet line and outlet valve line with high temperature silver solder 30 silver NOTE It is strongly recommended that dry nitrogen be used to purge the system during any solder operations see Using Pressurized Nitrogen in this chapter NOTE If pressurizing with nitrogen front seat the discharge valve to prevent nitrogen from entering the refrigerant charge CAUTION Any time the discharge valve is front seated disconnect the unit power source to prevent accidental compressor start up 3 Pressurize the refrigeration system and check for leaks see Refrigerant Leak Test Procedure in this chapter Evacuate the system see Evacuation and Cleanup of the Refrigeration System in this chapter Recharge the unit see Refrigerant
56. be tightened to a torque value of 20 to 21 N m 15 to 20 ft lb Tighten unit Mounting Bolts Tighten Compressor Condenser Fan and Evaporator Fan Mounting Bolts Unit Inspection Inspect the unit during unit pretrip inspection and every 1 000 operating hours for loose or broken wires or hardware compressor oil leaks or other physical damage which can affect unit performance and require repair or replacement of parts Figure 82 Mounting Bolts 155 Servicing The Unit Condenser Coil Clean the condenser coil by blowing low pressure compressed air or a medium pressure warm water spray from the inside of the coil outward opposite direction of normal airflow Inspect coil and fins for damage and repair if necessary CAUTION Air pressure or water spray must not be high enough to damage coil fins If a build up of salt or debris is present on the condenser coil the coil should be cleaned using a mild alkaline cleaner with a pH of 9 5 to 10 5 For example a 2 3 solution of SIMPLE GREEN would make a suitable cleaning solution Apply the solution using a pressure spray wash type apparatus Spray the condenser coil thoroughly from both the inside and outside of the coil Always thoroughly rinse the coil with a fresh water spray Also inspect the directional airflow condenser grille for damage This grille directs the condenser airflow out and away from the unit to increase t
57. by the setpoint temperature Setpoint and Controlling Sensors e With a setpoint temperature of 9 9 C 14 1 F and above the controlling sensor is the Supply Air Sensor e With a setpoint temperature of 10 C 14 F and below the controlling sensor is the Return Air Sensor The controller uses a complex proportional integral derivative PID algorithm to provide accurate temperature control in direct response to load demand Therefore it is difficult to predict which operating mode the unit should be in by comparing the setpoint to the return or supply air temperature The unit operates in either the Fresh Chill or Frozen mode Chill to Frozen mode transition point is 10 C 14 F NOTE If the compressor has been OFF for more than 18 hours or the unit has been on heat or defrost the controller performs a compressor sequence start Chill Loads Controller Setpoint at 9 9 C 14 1 F or Above Temperature control by the controller is based on the supply air sensor temperature the setpoint the modulation temperature range and the pull down rate The evaporator fans operate in high speed e Cool with Modulation down to setpoint Null compressor and condenser fan stops evaporator fans operate e Heat resistance heaters on evaporator fans operate 118 e Defrost resistance heaters on evaporator fans stop NOTE If the Economy Mode is set to ON the evaporator fans operate on low speed at set points of 9 9
58. c vELo el pte YELLOW BLACK BANDS ou d pna psc Gack Wes os wid ied l l im l NHT J4 BLK al UI RE A seu eet eu d ue 20 A SENSOR 2 BATTERY BLK amp RED 74 TED YEL heza Pons ero e wat A Bie pal RMN ADD HUMITY OPTION THERMISTER YEL amp WHT 97 RU aHTTe eb vt ma FTT REDE reo O A SENSOR qud WHT ORG ES vee Ej mT pl ORG 1 USDA SENSOR 2 BLK E et BLK REMOTE l me MON TOR l gt REO O T MODULE i FUSE 2A 28V l VELO kj 4 Loz Stk usoa stisoa J BLabo MER PHASE I H oF WHT hos l FUSE 2 12V Lo RED RED Lo EATTERY Lo YEL R DETAIL VIEW A 3 EX IE T 7 PR zi 2 sy OVERHEAT 26 ANIMO EOS SNTE OETION s i REMOTE 2 TA Z SWITCH EL 27 PK3 l y RM OPTION MONITOR D z322 DIS aa E PEUS za Eds EE BATTERY 2 l OO BLACK 222 33 zo 221 ES l VOS SBC 383 pr l B MP3000A 9 RS485 f 18 O17 16 95 Qu 913 12 O11 916 99 8 Pr PE 95 94 O3 y ks i JU RED PRI Lee P5485 i ER ale Lo ae pits CONTROLLER Le ono POr Ll x sl EFI3 Al a gt Dm l gt El SIs EFI2 S e gt ls EN OW e V OD HP il 5 28 Z5 5 ES 38 ON O Uli ee a HIGH S EF3 i an d Ac Ee ET o CONNECTER 2 173 zm 2318 EF2 Spa que Qu Fu Po qs qr Fe 9s qa P3 qo Fi KS S EFI 7 La a 2 22 225 E sik LOW B VIIYYYYx Jee E E J ek 3 E ka 5 c eu I i e o i e og 2 CONDENSER ods eee Say 9 PIN D CONNECTER E ii Sk u3 H RS Zis we is
59. certain that the unit is leak free A unit with less than a full charge of refrigerant should be thoroughly leak tested Any leaks found must be repaired Recover all refrigerants from the unit and reduce the unit pressure to the proper level US Federal Law requires a 17 to 34 kPa 0 17 to 0 34 bar 5 to 10 in vacuum that is dependent upon the recovery equipment used 2 Break vacuum with refrigerant and equalize system pressure to O kPa 0 bar 0 psig Replace the liquid line filter drier 3 Confirm that the Evacuation Station functions properly and determine Blank Off Pressure The Blank Off Pressure of the Vacuum Pump is the deepest vacuum that the vacuum pump can attain when isolated from the rest of the system If a vacuum pump isolated from a system is started and the Micron Meter responds quickly by going to a deep vacuum the operator can be confident that the pump and oil are in good condition If the vacuum pump fails to reach a deep vacuum within 5 minutes the operator should suspect the condition of the oil or the pump It is recommended that the pump oil be changed first to see if the rate of reaching a deep vacuum is improved 4 Connect the Evacuation Station and refrigerant tank with gauge manifold optional to the unit as indicated on the diagram on page 6 10 Connect evacuation hoses to the compressor suction and discharge service fittings and the receiver tank service fitting 5 Open Evacua
60. completes a test of individual components checks unit refrigeration capacity heating capacity and temperature control Also see Brief and Full Pretrip Procedure To Activate a Command Press F4 key to start a Function Test PTI Pre trip Test COMMANDS PTI COMMANDS BRIEF PTI COMMANDS FUNCTION TEST Manual Function Test Submenu First Component Test appears in display Press F2 or F3 key to scroll to the desired component CONDENSER SENSOR CHECK LOW SENSOR CHECK Power Management Submenu Current Power Limit and Power Time appear in display Main Menu Press F3 key to scroll to the desired function DATA Press F4 key Fl Power Limit Press F2 or F3 key to ALARMS scroll to new setting Power Time Type the new time in COMMANDS hours Press and hold F4 key until cursor MISC FUNCTIONS stops flashing CONFIGURATION DATALOGGER RMM STATE Note All screens are not present on all units The Screens that display on the controller are determined by the Controller Software setting and the options installed on the unit Figure 36 Commands Menu Screen Flow Diagram 68 ZERO CURRENT HEAT AFAM CLOSE AFAM OPEN DEHUMIDITY VALVE INJECTION VALVE CAPACITY 100 CAPACITY 50 CAPACITY 25 COMPRESSOR Press F4 key to start and stop test toggle component display between ON and OFF More than one component can be turned ON at a time to perform a f
61. condenser fan motor or heater current too high Defective volt or amp meter on relay board Power supply voltage too low High Pressure Cutout Check Condenser Fan Controller clears message on compressor start up No alarm is set until Controller determines that unit current draw is too low Alarm 37 or supply air temperature is too high Alarm 41 Controller clears message after compressor start up Controller clears message on compressor start up No alarm is set until Controller determines that heater current draw is too high Alarm 10 unit unit current draw is too high Alarm 36 or defrost time is too long Alarm 20 Unit stopped If condition is persent for 30 minutes alarm 51 is generated Enter Manual Function Test menu and test operate each component Check volts and amps to determine which component has high amp draw Check power supply volts Check volt and ampere meter 167 Diagnosis Troubleshooting Status Messages Alarm Codes Message 168 No Total Current Too Low Compressor Start up unit or component current draw is 50 below expected amps for 4 minutes Indicates Defective or open fuse CB 7A Defective or open high pressure cutout switch Defective evaporator high temperature protection switch Defective or open motor internal high temperature protection switch Unit on water cooled condensing with no water flow Defective condenser coil sensor or se
62. defrost cycle at 7 35 the defrost cycle will start at 8 01 The datalogger will record a Defrost event for each log interval in which a Defrost cycle is pending or active i e both the 8 00 and 9 00 data logs on 1 hour logging interval On Chill Loads setpoints at 9 9 C 14 1 F and above the initial time interval is 8 hours of compressor operation at supply air temperatures of 5 1 C 41 2 F or above 2 5 hours of compressor operation at supply air temperatures of 5 0 C 41 0 F or below One half 0 5 hour is added to the time interval each timed defrost interval Defrost synchronization creates step intervals of 3 4 4 5 5 6 6 and 7 hours Maximum time interval is 7 hours On Frozen Loads the initial time interval is 8 hours Two 2 hours are added to the time interval each timed defrost interval Maximum accumulated time interval is 24 hours Defrost timer resets if the unit is Off more than 12 hours setpoint is changed more than 5 C 8 9 F or PTI Pretrip test occurs NOTE If unit operating conditions do not allow the unit to enter a defrost cycle Defrost Not Activated appears on LCD display when the DEFROST key is pressed When the defrost mode is initiated 122 The controller stops the compressor condenser fan and evaporator fans and de energizes the liquid line solenoid valve When the compressor stops the controller turns ON the Defrost LED Heat LED and energizes the heater contactor t
63. depending on type of sensor failure Controller clears message during Defrost mode and when UNIT ON OFF switch is turned OFF Controller uses right hand supply sensor to control unit if left hand sensor is defective Controller uses return sensor plus an offset to control unit if both supply sensors are defective Controller clears message on compressor start up No alarm is set until Controller determines that unit current draw is too low Alarm 37 or supply air temperature is too high Alarm 41 Diagnosis Troubleshooting Status Messages Alarm Codes Status Message Controller Action Indicates Unit stops due to high pressure cutout water pressure switch is closed and condenser temperature is high Compressor High Temperature Indicates Compressor stops because discharge temperature is above 130 C 266 F Message remains in display until discharge temperature decreases to normal Evaporator High Temperature Switch Open Indicates Controller disables electric heaters due to open high temperature switch circuit Possible causes include evaporator temperature over 54 C 130 F defective heater defective evaporator overheat switch open circuit etc Low Supply Voltage O 13 14 Voltage on opwer line is below 340 VAC Total Current Too High Unit or component current draw is 25 above expected amps for 4 minutes Indicates KVQ valve malfunction Compressor evaporator fan motor
64. fan rotation by placing a small cloth or sheet of paper against the condenser fan grille on the front of the unit Proper rotation will blow the cloth or paper away from the grille Improper rotation will hold the cloth or paper against the grille If the condenser fan is rotating backwards see the unit wiring diagram to correct fan motor wiring at the fan motor junction box or condenser fan contactor To correct improper fan rotation reverse any two fan power cord leads at the condenser fan contactor disconnect power supply before reversing leads Do not move the CH ground wire Check Evaporator Fan Rotation Visually inspect the evaporator fan blades for proper rotation Arrows located on the underside of the fan deck indicate the correct direction of rotation Check both high and low speed evaporator fan rotation by performing Evaporator High and Evaporator Low tests from the Manual Function Test menu If an evaporator fans rotate backwards on one or both speeds see the unit wiring diagram to correct motor wiring at the fan motor junction box or evaporator fan contactor disconnect power supply before reversing leads Do not move the ground wire which is labeled CH NOTE Evaporator fan motor wires EF 1 EF2 and EF3 are used on low speed fan operation Wires EF 11 EF 12 and EF13 are used on high speed fan operation Electric Heaters Malfunction Six electric heater elements are located underneath the evaporator
65. feeler bulb improperly mounted poorly insulated or making poor contact Check operating mode indicator LED s Check setpoint indicator lights and Setpoint menu of the controller to verify that Economy Mode is set to ON Tighten connections Check for seized bearings or defective thermal overload protector Repair or replace as necessary Replace motor Replace defective contactor Diagnose and replace evaporator fan relay main relay board or controller Repair leak and recharge Clean points or replace contactor Check valves and pistons Repair or replace liquid line solenoid valve Locate obstruction and repair Defrost or clean evaporator coil Clean or replace expansion valve Replace expansion valve Correct or replace container insulation Repair or replace doors Locate obstruction and repair Replace service gauge Repair or replace valve Correct feeler bulb installation Load temperature too high unit not cooling Diagnosis Troubleshooting Status Messages Alarm Codes Compressor does not operate Shortage of refrigerant Overcharge of refrigerant Air in refrigeration system Defective controller or main relay board Controller setpoint too high Too much compressor oil in system Iced or dirty evaporator coil Restricted lines on high side Plugged filter drier Compressor inefficient Evaporator pressure regulator KVQ valve stuck closed or defective Condenser coil dirty or airflow r
66. foaming of the oil as it leaves the compressor may indicate an excess of refrigerant in the oil Remove the access valve actuator and operate the system for 15 minutes to ensure warm sump Then recheck the oil level 3 When the compressor oil sight glass is 1 2 to 3 4 full remove access valve and replace the cap on the oil pressure fitting 4 Operate the unit and recheck the refrigerant charge level and the oil level before returning the unit to service Refrigerant Leak Test Procedure Use a reliable Halogen leak detector such as model H10G P N 204 712 or 204 756 portable to leak test the refrigeration system Inspect carefully for signs of compressor oil leakage which is the first sign of a leak in the refrigeration system 136 NOTE Due to environmental concerns and personal safety the use of a Halide torch is no longer recommended If refrigerant has leaked or been removed from the unit 1 Check entire system for possible component damage and refrigerant oil loss 2 Attach gauge manifold set refer to Gauge Manifold Set Attachment and Purging for proper procedures 3 Attach refrigerant bottle charging hose to center of gauge manifold and purge charging hose of air 4 Pressurize the system with refrigerant GAS ONLY until 345 kPa 3 45 bar 50 psig vapor pressure is achieved 5 Leak check the system with an electronic leak detector to inspect all joints and connections Use soap solution as
67. for Power Line Communications Refcon control modem 1 Recording Thermometer Option 7 inside control box 2 Suction Pressure Gauge Option USDA Sensor Receptacle Option Access from inside container Discharge Pressure Gauge Option Advanced Fresh Air Management AFAM Option Dual Voltage Option see page 2 13 Humidity System Option 5 Remote Monitor Plug Option 4 Pin Connector on 11 TransFresh Option Complete Side of Control Box ON Thermistor Lead Option Lead inside control box WWW Figure 9 Options Unit Front View 31 Unit Description Features and Options Sensing Bulb Option for Recording Thermometer Return Air Vent Loop for Gas Sensor after 4 01 for AFAM Option 5 Air Compressor for Fumidy System Option Figure 10 Options Evaporator Front View 32 Unit Description Features and Options AJA1903 eB fwavere E CC NN SeneaPonriing CIO me MEE TP Figure 11 Refrigeration System Post 2002 33 Unit Description Features and Options AJA1555 11 1 Liquid Line Solenoid Valve 13 Compressor Discharge Temperature Sensor CRR40 196 Only 2 Liquid Injection Solenoid Valve 14 Compressor Discharge Line Temperature Sensor All models except CRR40 196 Expansion Valve Condenser Coil 4 Tube Standard 16 Standard Receiver Tank with Service Port Fitting and Fusible Plug Dehumidify Valve Pre 2
68. into the manifold s service center line to purge the high and service hoses Remove ACME fitting after purging Close discharge service manifold hand valve fully to center port You are now ready to use the gauge manifold to check system pressures or perform MOST service procedures NOTE These gauges may be removed and reinstalled without additional purging so long as a slight positive pressure remains in the manifold and hoses when removed from the unit Gauge Manifold Set Removal NOTE To ensure minimum refrigerant release to the atmosphere THE SYSTEM SHOULD BE RUNNING However this is not possible in all cases but the same procedure should be followed 1 Rotate discharge hose fitting hand wheel counterclockwise to withdraw the fitting stem from the discharge line port valve Then open both service manifold valves to center port 2 Close the liquid line service valve and pump down the low side Then turn the unit OFF 3 Rotate the discharge fitting hand wheel counterclockwise to depress the port valve stem to equalize pressure at 21 kPa 0 21 bar 3 psig 4 Rotate both coupler hand wheels counterclockwise to close seal the valve port stems to the high and low hoses 5 Remove the gauge lines from the suction and discharge service fittings and cap the service ports 6 Open liquid line service valve and cap valve stem 7 Secure all manifold lines to manifold hose anchors when the manifold is not in u
69. no more liquid The unit is now ready to have the Evacuation Station removed described in the following steps Evacuation Station Removal See following Final Charging Procedure for Partially Charged Units to complete charging procedure Evacuation Station Removal 1 Back seat the discharge service valve 2 Remove the service hose from the refrigerant tank service fitting Cap the receiver tank service port Refrigeration Maintenance 3 Operate the unit in cool mode 4 Open the hand valve at the gauge manifold and read suction pressure 5 Front seat the suction service valve and pump down the system to 21 to 35 kPa 0 21 to 0 35 bar 3 to 5 psig 6 Back seat the suction service valve 7 Remove the hoses from the discharge service valve 8 Install a gauge manifold set e If the unit is fully charged perform a functional check out e Ifthe unit has a partial charge complete the charging process as described below Final Charging Procedure for Partially Charged Units 1 Connect the gauge manifold to the suction line and discharge line service ports Be sure to purge the air from the lines see Gauge Manifold Set Attachment and Purging in the Refrigeration Maintenance chapter of this manual 2 Back seat and crack the discharge service valve 3 Connect a refrigerant tank to the gauge manifold service line 4 Set the refrigerant tank for liquid charging Open the refrigeran
70. on the gauge manifold front seated 3 Connect charging hose to a source of nitrogen Adjust pressure regulator to the proper pressure for the required procedure 4 Purge system high side to low side The following procedures should utilize the following MAXIMUM gas pressure e Leak Testing 1030 to 1200 kPa 10 3 to 12 0 bar 150 175 psig e Purging Dehydration 70 to 140 kPa 0 7 to 1 4 bar 10 20 psig e During Soldering 35 kPa 0 35 bar 5 psig Compressor Replacement Removal 1 Remove the compressor compartment bracket Close the liquid line service valve and pump down the low side to 35 kPa 0 35 bar 10 in vacuum Break the vacuum with nitrogen between 10 and 20 kPa 0 10 and 0 20 bar 1 and 3 psig NOTE If the compressor does not operate or the compressor is unable to pump the low side down the refrigerant charge must be reclaimed before service can be performed on the refrigeration system 2 Front seat the discharge valve CAUTION Any time the discharge valve is front seated disconnect the unit power source to prevent accidental compressor start up 3 Remove discharge service valve suction service valve and liquid injection line from the compressor 4 Disconnect the wire connector for the high pressure cutout switch 148 5 Remove the three phase electric power connection 6 Remove the compressor mounting tray bolts and nuts 7 Slide the compressor from the unit 8 K
71. or Teose connections A Dewnlsad he data foager and check data for correct toaono Pec operation of protection shutdown cros LL rr SSS ATA ga age Cheek compressorofievel Peak for proper discharge and sucton pressures Ice anemias iter fora restriction pressures a Se A Pisa inspect unit for damaged Toose or broken pars Fratton unit compressor and fan motor mounting Bots Fea entire unt including condenser and evaporator coll and defrost drains 15 Service Guide 16 Specifications System Net Cooling Capacity Full Cool Air Cooled Condensing CRR40 Return air to 460 230V 3 Phase 60 Hz Power 380 190V 3 Phase 50 Hz Power NT ra Net Cooling Capacity Net Cooling Capacity Watts Kcal hr BTU hr kW at 460V Watts Kcal hr BTU hr kW at 380V Pomona wee eam pues sss puse Fusco ses sss 20m eo arse ero mee 45 System net cooling capacity with a 37 8 C 100 F ambient air temperature and R 134a Water Cooled Condensing Option with 37 8 C 100 F Water Temp CRR40 pens wats Keam orum aw aaoov Wens keai Brune Rw soo meen roam sss sae 99 ero fram mom sor System net cooling capacity with a 37 8 C 100 F water temperature 30 liter min 8 gal min water flow and R 134a Water Cooled Condensing Option with 30 C 86 F Water Temp CRR40 verd wats Reaine orum araraso
72. pulse is increased the pressure pin closes the valve plate an additional amount Due to valve design the flow of refrigerant gas exerts no opening or closing forces on the valve plate allowing very precise operation NOTE If the electrical circuit to the heating element fails the valve moves to the full open position Service of the evaporator pressure regulator valve includes replacement of the actuator assembly or replacement of the valve body 144 Tools Required Digital Multimeter P N 204 615 Actuator Assembly Adjustable Wrench Torque Wrench Heater Circuit Checkout Procedure 1 Unplug the evaporator pressure regulator valve lead wire harness Using a FLUKE multimeter test each lead 4 resistance to ground Low resistance indicates a short is present Repair or replace any damaged or exposed wires Check the heater circuit and thermistor circuit resistance A good heater circuit has a resistance of 20 ohms at 25 C 78 F A good thermistor circuit has a resistance of 20 000 ohms at 25 C 78 F NOTE The ohmmeter will display a slightly higher heater resistance if the valve was energized just prior to testing the circuit resistance To return the unit to service plug the evaporator pressure regulator valve lead connector into the unit wire harness Refrigeration Maintenance Valve Actuator Replacement If the evaporator pressure regulator valve fails to operate properly remove the actua
73. rotation make sure fans are rotating correctly on high speed Check the sensor connections Energize and de energize the bypass valve using Injection Valve in the COntroller Manual Function Test submenu Confirm by sound that the valve energizes and de energizes If the valve does not operate check the valve coil for continuity using a high quality multimeter Check the circuit wiring in plug J11 for continuity using a high quality multimeter and a wiring diagram Check sensor resistance between pins 7 and 8 on plug J15 Resistance must be 2 000 ohms at 25 C 77 F Check cable No 1 between controller and relay board 177 Diagnosis Troubleshooting Status Messages Alarm Codes Condenser Temperature Sensor Short Circuit Check sensor resistance between pins 13 and 178 Check Alarm Sensor circuit resistance higher than 100 000 ohms Temperatures below 70 C 94 F Indicates Sensor circuit resistance lower than 200 ohms Temperature above 80 C 176 F Indicates Short circuit to sensor Defective or wrong sensor Defective relay board Defective cable No 1 Defective controller Ambient Air Sensor Open Circuit Check Alarm Occurs during pretrip PTI test only Sensor circuit resistance is higher than 100 000 ohms Temperature is below 70 C 94 F Indicates Open circuit to sensor Defective or wrong sensor Defective relay board Defective cable No 1 Defective controller
74. shows 70 this means the KVQ valve has closed to reduce system cooling capacity from 100 to 70 a 30 reduction 114 Compressor Sequence Start The controller performs a compressor sequence start when the compressor has not operated for more than 60 seconds within the last 18 hours A compressor sequence start cycles the compressor ON 3 seconds OFF 10 seconds ON 5 seconds OFF 10 seconds ON 7 seconds OFF 10 seconds and then ON continuously Compressor Liquid Injection During compressor operation a liquid injection system injects refrigerant into the suction line to protect the compressor for excessively high operating temperatures Compressor Discharge Temperature Control Chill Mode Only Liquid injection is activated at compressor discharge temperatures between 115 C and 125 C 239 F and 257 F The controller pulses the liquid injection valve open for 2 to 60 seconds every 60 seconds The number of seconds the valve is energized depends on the discharge temperature and the KVQ valve setting Liquid injection is activated when the KVQ Setting is less than 5 C 8 9 F below the return air temperature The controller energizes liquid injection valve for 6 seconds every 60 seconds regardless of the discharge temperature High Temperature Protection e Ifthe discharge gas temperature rises above 130 C 266 F the unit stops immediately The controller turns ON the Alarm LED and records Alarm 56 Compressor Te
75. test time to 10 minutes System Test test multiple components at the same time a Press F2 or F3 key to scroll to the first component b Press F4 key to turn the component ON c Press F3 key to scroll to select next component Press F4 to turn component ON d Repeat step 6c until all required components are ON For example to operate unit in Full Cool mode start the following components e Condenser Fan Compressor e Capacity 100 e Evaporator High or Low e Observe current draw and system performance to verify component s performance f Press F4 key again to turn OFF components individually Or press ESC key to exit Manual Function Test menu and turn ALL components OFF g Press ESC key to exit the Manual Function Test submenu NOTE Controller returns unit to normal operation if no keys are pressed for 10 minutes Pressing 5 key extends test time by 10 minutes each time it is pressed maximum time 100 minutes Pressing any other key resets test time to 10 minutes Power Management Selecting a Power Limit from the Power Limit screen turns ON the power reduction control algorithm that reduces total unit electric power consumption based on the Power Limit and Power Time settings With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press F3 key to enter the menu list Repeatedly press F2 key to scroll through Main Menu until COMMANDS ap
76. the Datalogger Menu With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press the F3 key to enter the Main Menu 2 Press F2 key to scroll through Main Menu until DATALOGGER appears in LCD display Note All screens are not present on all units The screens that display on the Datalogger controller are determined by the Controller Software setting INSPECT TEMP and the options installed on PTI STATE the unit INSPECT PTI CALIBRATE USDA PROBE Datalogger AC TATE TAIP First function screen appears SET LOGITIME INSPECT TEMP LOG t INSPECT EVENT Press F4 key to view next screen Press F3 key to scroll through previous logs of sensors INSPECT EVENT LOG Press F3 key to scroll through previous event logs SET LOG TIME Press F3 key to scroll through log interval list Press and hold F4 key until cursor stops flashing ACTIVATE TRIP START Press F4 key to enter trip start marker INSPECT PTI LOG Press F3 key through test result screens Figure 34 Datalogger Menu Screen Flow Diagram Press F4 key to access the Datalogger menu The first function appears in the LCD display Inspect Temp Log Press F2 or F3 key to scroll to the desired function Inspect Temp Log PTT State 62 Inspect Event Log Set Log Time Activate Tripstart Inspect PTI Log 5 Press F4 key to access the functio
77. the Pretrip test e Controller LED display turns On and then Off Operating Instructions LED display briefly shows setpoint and then displays the controlling return air sensor temperature e Controller senses the incoming power phase and selects the correct power phase to unit components Controller energizes unit loads starting the evaporator fans e Ifthe controller calls for cooling the compressor motor starts and the liquid line solenoid energizes opens If the unit starts in Modulation Cool compressor start up can be delayed up to 3 minutes while the KVQ valve opens or closes to the required setting e On cooling the condenser fan starts as required when the unit is on air cooled condensing operation e Ifthe controller calls for heating the electric heaters are energized Check controller setpoint for proper setting Adjust if necessary NOTE New setpoint must be between 30 C and 30 C 22 F and 86 F or controller will return to the previous setpoint display Check the direction of the condenser airflow see Condenser Fan and Evaporator Fan Rotation in the Electrical Maintenance chapter of this manual NOTE If the compressor fails to start turn the On Off switch OFF Then repeat steps 1 through 3 If the unit still does not start refer to Alarm Codes Descriptions and Corrective Actions in the Controller chapter of this manual Be sure to wait up to 3 minutes for the compre
78. the Temp Log Set a Trip Start With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 2 Press F3 key to enter the Main Menu Press F2 key to scroll through menu list until DATALOGGER appears in LCD display Press F4 key to access the Datalogger menu Inspect Temp Log appears in LCD display Press F2 or F3 key to scroll through submenu until Activate Tripstart appears LCD display Press F4 key to enter Tripstart function The date and time of last trip start appears in the screen Press F4 key again to enter a new start of trip date and time in the log NOTE When a PTI Test is completed controller automatically enters a Tripstart in the log Press ESC key to exit the Datalogger menu Operating Instructions Inspect PTI Log With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 2 Press F3 key to enter the Main Menu Press F2 key to scroll through menu list until DATALOGGER appears in LCD display Press F4 key to access the Datalogger menu Inspect Temp Log appears in the LCD display Press F2 or F3 key to scroll through submenu until Inspect PTI Log appears in LCD display Press F4 key to enter PTI Log LCD display shows the Start Time and PTI test results of the most recent PTI log e To scroll through additional test results in the log press F3 key PTI Examples
79. the low side to 35 kPa 0 35 bar 10 in vacuum Break the vacuum with nitrogen between 10 and 20 kPa 0 10 and 0 20 bar 1 and 3 psig 2 Turn the unit On Off switch OFF Disconnect electrical connections to liquid line solenoid NOTE In most cases only the coil requires replacement No other repair is possible on the liquid line solenoid 3 Unsolder the liquid line connections from the valve 4 Remove the valve from the unit Installation 1 Clean the tubes for soldering 2 Place the new valve in position and solder the connections CAUTION Use a heat sink or wrap the valve with wet rags to prevent damage to the new valve 3 Release a small amount of refrigerant from the receiver tank to pressurize the liquid line Check for leaks see Refrigerant Leak Test Procedure in the Refrigeration Maintenance chapter of this manual 4 Ifno leaks are found recover the leak test gas see Refrigerant Recovery in the Refrigeration Maintenance chapter of this manual 5 Evacuate the low side see Evacuation and Cleanup of the Refrigeration System in the Refrigeration Maintenance chapter of this manual 6 Reconnect the electrical wires to the valve 7 Open the liquid line service valve and place the unit in operation Check the refrigerant charge and add refrigerant as required Liquid Injection Valve Replacement Removal 1 Close the liquid line service valve and pump down the low side t
80. upon completion of AUTO CONFIG test Using Special Features An operator can create a new chart from any date range of data recorded in the datalogger This is extremely valuable if e The original chart is missing e The original chart has been damaged Procedure for Redraw Chart 1 Install new temperature chart in recorder 2 Press the UP or DOWN key to enter menu area 3 Scroll up or down to DATALOGGER menu Press the F4 to enter menu 4 Scroll up or down to SET LOG TIME DATALOGGER SET LOG TIME 2002 01 15 12 35 5 Press the F4 key and the following menu will appear LOG CHART 1 HOUR CHART RECORD RET CHART STATE ONLINE ONLINE 02 01 15 02 01 15 CHART CDM REDRAW FROM REDRAW TO Operating Instructions 6 Scroll up or down to place cursor on REDRAW FROM line Press the F4 7 Date information will now be blank Select date to start record After entering press the F4 and EXIT NOTE Date format YY MM DD 8 Scroll down to place cursor on REDRAW TO line Press the F4 9 Date information will now be blank Select date to end record After entering press the F4 and EXIT NOTE Date format YY MM DD NOTE Do not exceed 31 days This is the limit of the chart 10 Scroll up to place cursor on CHART CMD Press the F4 11 Use up or down to scroll to REDRAW Press the F4 12 Chart will now begin to plot requested date range 13 Remove chart when complete
81. voltage controls disconnect the supply power to the unit before replacing the controller 3 Disconnect battery power connection from the controller top plug on the controller 4 Disconnect the communication cables from the controller and remote monitoring modem option 5 Remove the screws that secure the remote monitoring modem to the controller 6 Remove the screws that secure the controller to the inside of the control box door 7 Remove the controller from the door 8 Install the replacement controller in the door using the existing hardware Connect the keyboard cable to the controller 9 Install the remote monitoring modem option on the back of the controller 10 Connect the communication cables to the remote monitoring modem option and controller 11 Set the software selection switch on the back of the controller to position 1 on MP 3000 controllers only NOTE Be certain that all connector plugs are fully seated CAUTION Be sure to enter the container ID before releasing the unit for service The container ID is required to identify the data downloaded form the controller datalogger via a laptop computer or a REFCON remote communications system NOTE Several programmable features may need to be set to completely configure the unit to customer specifications Adjust any additional programmable settings to customer requirements before releasing the unit for service NOTE If a co
82. 002 Water Cooled Condenser Receiver Tank Option Heat Exchanger Water Outlet Coupling ETT E B mre 000 CA Figure 12 Refrigeration System Pre 2002 34 Unit Description Features and Options o IMPORTANT Remote Monitoring Modem RMM Option Cable No 1 Connection to Controller Communication Cable for RMM Option fal Control Box Cover and Controller Keyboard Decal Control Circuit Fuses 2 ampere 2 10 Special Function Keypad Battery Cable Connection to Controller General Purpose Keypad 5 Cable No 2 Connection to Controller 12 LCD Display Setpoint Temperature Message and Controller Main Menu Tree Display Download Cable Connection to Controller LED Display Return or Supply Air Temperature Display and Status Indicator LED s Cable No 3 Connection to Controller MP 3000a Controller Figure 13 MP 3000a Controller 35 Unit Description Features and Options 1 Unit On Off Switch Interface Board for AFAM Option and AFAM Option 2 Condenser Fan FAN AIR WATER Switch Main Relay Board CRR40 Water Cooled Condenser Units Only Remote Monitor 4 Pin Option CS 12 Vdc 12 Vdo Battery Communications Cable for AFAM Option and Control Power Transformer AFAM Option 5 Circuit Breaker Circuit Breaker Breaker 11 Compressor Contactor o e Contactor Communications Cable for AFAM Option and UI EL M NNNM Main Power Circuit Breaker AFAM Option Figure 14 Unit C
83. 1 ESC key to exit display CONFIG A Cont ID Dehum Valve Gas Analyzer Cargo Probes nos e to toggle value ESC z Zero Current AFAM Uni i to desired lt i Ctrl Type E Evap Type ts Press F4 key to setting In Range Reefer Type Cond Type Auto Config change a setting Supply LH Press and hold Contrast Unit 4 Press F3 key A F4 key until Unit ID key password cursor stops F4key and EXIT flashing key CF SUP RET DEFROST SETPOINT Misc Functions ies F4 key to Menu 5 A change a setting Misc Functions MISC FUNCTIONS Date Time Submenu Type new value or A Sii e Current function setting e a T dad mme especia ln ellas to desired setting Program le ERR Press F3 key to scroll to Press and hold F4 desired function key until cursor Gasol 1 stops flashing Commands Manual Function Test Zero Current Press F4 key to Submenu Heat start and stop test To Activate a i toggle component First Component AFAM Close E gommand Test appears in AFAM Open eua Poe Press F4 to start a display Dehumidity PTI Pretrip Test Press F2 or F3 key Valve MICE COMMANDS EJA as Menu Function Test to scroll to the Injection Valve one component can be turned ON ata AE desired component Capacity 100 time to perform a Condensor Capacity 50 functional test of Brief PTI Test Sensor Check Low Capacity 25 the unit Fun
84. 176F Indicates Short circuit to sensor Defective or wrong sensor Defective relay board Defective cable No 1 Defective controller Evaporator Coil Sensor Short Circuit Check Alarm Sensor circuit resistance lower than 200 ohms Temperature above 80C 176F Indicates Short circuit to sensor Defective or wrong sensor Defective relay board Defective cable No 1 esa Evaporator Coil Sensor Open Circuit Check Alarm Sensor circuit resistance higher than 100 000 ohms Temperature below 70C 94F Indicates Open circuit to sensor Defective or wrong sensor Defective relay board Defective cable No 1 Defective controller Low evaporator coil temperature Defective controller on plug J15 Resistance must be 2 000 ohms at 25C 77F Check cable No 1 between controller and relay board Check sensor resistance between pins 5 and 6 on plug J15 Resistance must be 2 000 ohms at 25C 77F Check cable No 1 between controller and relay board Check evaporator air flow Check sensor resistance between pins 5 and 6 on plug J15 Resistance must be 2 000 ohms at 25C 77F Check cable No 1 between controller and relay board 171 Diagnosis Troubleshooting Status Messages Alarm Codes Compressor Current Too High Check Alarm Check evaporator condenser and ambient Occurs during Pretrip PTI or Function test only Compressor power consumption is 25 above expected current draw above appr
85. 2 F Enter the View menu on the controller display and scroll to the return air temperature RET screen Press the ENTER key to lock the RET screen on the display Wait at least 5 minutes to allow the recording thermometer sensing bulb temperature to stabilize Then compare the RET temperature in the controller display with the recording stylus of the recorder Write down both readings If the average difference is 0 6 C 1 0 F or less DO NOT attempt to recalibrate If the recorder needs recalibration a Place the pen in the recording position lowered against chart b Loosen the lock screw using a small Phillips screw driver c Adjust the setting screw with a small slotted screw driver or a 7 mm 9 32 in open end wrench Rotate the setting screw clockwise until the recording pen temperature reading is 2 to 4 C 4 to 6 F higher than the temperature reading of the test instrument NOTE Turning the setting screw one complete revolution 360 degrees changes the temperature reading of the pen by approximately 5 C 9 F d Then rotate the setting screw counterclockwise to lower the recording pen reading until the pen reading agrees with the RET controller display e Tighten the lock screw 101 Operating Instructions f Wait another 5 minutes while the unit operates on Cool Verify that the recording thermometer reading is stable and agrees with the RET temperature in the controller
86. 3 key to enter the Main Menu Press F2 key to scroll through menu list until DATALOGGER appears in LCD display Press F4 key to access the Datalogger menu Inspect Temp Log appears in LCD display Press F2 or F3 key to scroll through submenu until Activate Tripstart appears LCD display Press F4 key to enter Tripstart function The date and time of last trip start appears in the screen Press F4 key again to enter a new start of trip date and time in the log NOTE When a PTI Test is completed controller automatically enters a Tripstart in the log Press ESC key to exit the Datalogger menu Operating Instructions Inspect PTI Log With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 2 Press F3 key to enter the Main Menu Press F2 key to scroll through menu list until DATALOGGER appears in LCD display Press F4 key to access the Datalogger menu Inspect Temp Log appears in the LCD display Press F2 or F3 key to scroll through submenu until Inspect PTI Log appears in LCD display Press F4 key to enter PTI Log LCD display shows the Start Time and PTI test results of the most recent PTI log e To scroll through additional test results in the log press F3 key PTI Examples PTI stores volt and amps of all power consuming components PTI stores temperatures logged at both the start and end of Chilled Mode and Frozen
87. 3 psig 2 Remove insulating tape from liquid line Disconnect the electrical connections to the dehumidify valve pre 2002 NOTE In most cases only the coil requires replacement No other repair is possible on the liquid injection valve 4 Unsolder the liquid line connections Unbolt and remove the valve from the unit Installation 1 Clean the tubes for soldering 2 Place the new valve in position 3 Solder the liquid line connections CAUTION Use a heat sink or wrap the valve with wet rags to prevent damage to the new valve 4 Pressurize the low side with refrigerant and check for leaks see Refrigerant Leak Test Procedure in this chapter 5 If no leaks are found recover the leak test gas see Refrigerant Recovery in this chapter 6 Evacuate the low side see Evacuation and Cleanup of the Refrigeration System in this chapter 7 Cover liquid lines with insulating tape 8 Reconnect the electrical wires to the valve 9 Open the liquid line service valve and place the unit in operation Check the refrigerant charge and add refrigerant as required 153 Refrigeration Maintenance 154 Servicing The Unit Mounting Bolts Check and tighten all unit compressor and fan motor mounting bolts during pretrip inspections and every 1 000 operating hours Unit mounting bolts should be tightened to a torque value of 204 N m 150 ft lb Compressor and fan motor mounting bolts should
88. 4 key pressed while alarm code appears in LCD display the Alarm LED will turn OFF and the alarm code disappears from the alarm list e ACTIVE An alarm condition has occurred and continues to exist in the unit or the alarm condition occurred within the past 1 hour but does not currently exist in the unit If the alarm condition currently exists in the unit and the alarm code is acknowledged the Alarm LED will stop flashing but remain ON The alarm code state will change to ACKNOWLEDGE in the alarm list 66 Standard Display NOTE All screens are NOT present on all units The screens that display on the controller are determined by the Controller Software setting and the options installed on the unit Alarms Menu View and write down all alarm lt codes Press F2 key to view the next alarm code Clear alarm code by correcting problem and acknowledging the alarm To acknowledge an alarm press F4 key with alarm code in display Figure 35 Alarms Screen Flow Diagram If the alarm condition no longer exists in the unit and the alarm code is acknowledged the Alarm LED will turn OFF and the alarm code disappears from the alarm list e ACKNOWLEDGE An alarm code has been viewed and acknowledged in the alarm list The Alarm LED remains ON but does not flash If the alarm condition is corrected the Alarm LED will turn OFF and the alarm code disappears from the alarm list Viewing the Al
89. 60 380V 60 50 Hz 3 Phase 0 37 kW 9 460V 60 Hz 0 50 hp 460V 60 Hz 1140 rpm 60 Hz 1 0 amps 460V 60 Hz 1 0 amps 9 380V 50 Hz 4 0 amps 460V 60 Hz 4 0 amps 9 380V 50 Hz 460 380V 60 50 Hz 3 Phase 2 0 75 kW 460V 60 Hz 1 0 hp 460V 60 Hz 3450 rpm 2 60 Hz 1725 rpm 2 60 Hz 1 4 amps 9 460V 60 Hz 1 1 amps 9 380V 50 Hz 0 55 amps 9 460V 60 Hz 0 5 amps 9 380V 50 Hz 10 3 amps 460V 60 Hz 2 9 amps 460V 60 Hz 460 380V 60 50 Hz 3 Phase 6 680 Watts 5 amps nominal total across each phase at the heater contactor Specifications Electrical System Control Circuit Voltage 29 Vac 60 Hz 24 Vac 50 Hz Evaporator Overheat Switch Opens 54 3 C 130 5 F Closes 38 4 5 C 100 8 F Refrigeration System Copeland Discus Valve Design Refrigerant Charge Standard Receiver Tank 4 9 Kg 10 8 lb R 134a Polyol Ester Based Type required TK Part No 203 433 High Pressure Cutout Switch Cutout 2240 70 kPa 22 40 0 70 bar 325 10 psig Cutin 1590 kpa 15 90 0 70 bar 230 10 psig Water Pressure Switch Option Open 117 21 kPa 1 17 0 20 bar 17 3 psig Close 35 21 kPa 0 35 0 20 bar 5 3 psig Fusible Plug High Pressure Relief Relief Temp Liquid Injection Control KVQ Setting Less Than 5 C 8 9 F Below the Liquid Injection turns ON 6 seconds every minute regardless Return Air Temperature of compressor discha
90. 7 Figure 48 Figure 49 Figure 50 Figure 51 Figure 52 Figure 53 Figure 54 Figure 55 Figure 56 Figure 57 Figure 58 of Figures Nameplate and Warning Locations 0 cece cette ee eae 14 Physical Specification nos dad haces eae ee aes acted arte acts eae td a Soa ar 23 MP 3000a Controller eis ta eee Gare Se oe ee a 25 Eresh Air Exchange Verter areo nen Ad cheated ded Abe held eh aie dia tae eae 26 Advanced Fresh Air Management AFAM Option 0 0 00 cece eee 26 Water Cooled Condenser Receiver Tank 0000 eee eee ttt eee 28 Unit Front View CORR zie uc Meg eee boa os Pere bas Soe the the eo ee wet 29 Evaporator Front View CRR 1 ee tenet mnn 30 Options Unit Front View 0 0 0 eee eae 31 Options Evaporator Front View llssleseeseeeeel m m eee 32 Refrigeration System Post 2002 0 cee ren 33 Refrigeration System Pre 2002 0 tenet eee eee 34 MP 3000a Gontroller 2 et en hi le i bien uem nbd peg ode be bbe Meet 35 s nitGontrol BOX cei A Hebe oe pbs dee aioe Ee ions 36 Dual Voltage Option unes mI a tha OP be e EORR ia 37 Advanced Fresh Air Management AFAM Option llsleeelee 38 Advanced Fresh Air Management Plus AFAM Option 0 000 c eee eee ee 39 zHumiidity System ODptlon asr sarc cee aad Ada ORE 40 TRANSFRESH Provision Option oococcccccocoo e m mh 41 Unit Back View ss mas antaa See idees ipm DEG mati a
91. A 5 16 5 00 5 1C 2 4A 2 3A 2 4A PROBE TEST SUP RET EVA 5 16 5 0C 5 16 2 4A 2 3A 2 4A AFAM TEST SUP RET EVA 5 1C 5 0C 5 16 2 4A 2 3A 2 4A Event Log for PTI begins All alarms are turned off Alarm list is cleared All relays are turned off and air vent are closed All sensors must have values within their measuring range 5 seconds 99 i 115 116 1 minute 117 minimum Condenser fan and compressor are turned off With evaporator fan on low speed amp draw is measured and compared to voltage and frequency CRR 40 1 0 Amps approx at 50 Hz 1 0 Amps approx at 60 Hz Amperes are recorded in the PTI log Condenser fan and compressor are turned off With evaporator fan on high speed amp draw is measured and compared to voltage and frequency CRR 40 2 1 Amps approx at 50 Hz 2 5 Amps approx at 60 Hz Amperes are recorded in PTI log Evaporator fans operate on high speed for maximum 3 minutes Then probe test runs until temperature difference between sensors stops increasing Maximum to temperature difference allowed 13 minutes Return Evaporator 1 5 C 34 7 F return air sensor maximum temperature must be 0 5 C 32 9 F above evaporator sensor temperature Return Supply 0 8 C 33 0 F return air sensor temperature must be 0 5 C 32 9 F above supply air temperature LH Supply RH Supply if equipped 0 5 C 32 9 F Air vent is opened and verified that the motor is oper
92. A 0 0A 0 1A SENSOR TEST Activated 0 1A 0 0A 0 1A EVAP FAN LOW TEST SUP RET EVA 5 1C 5 0C 5 16 1 1A 1 0A 1 1A EVAP FAN HIGH TEST SUP RET EVA 5 1C 5 0C 5 16 2 4A 2 3A 2 4A PROBE TEST SUP RET EVA 5 1C 5 0C 5 16 2 4A 2 3A 2 4A AFAM TEST SUP RET EVA 5 1C 5 0C 5 16 2 4A 2 3A 2 4A Event Log for PTI begins All alarms are turned off Alarm list is cleared All relays are turned off and air vent are closed 5 seconds m E E All sensors must have values within their measuring range 14 15 10 seconds 12 13 10 seconds 115 116 1 minute 117 minimum Condenser fan and compressor are turned off With evaporator fan on low speed amp draw is measured and compared to voltage and frequency CRR 40 1 0 Amps approx at 50 Hz 1 0 Amps approx at 60 Hz Condenser fan and compressor are turned off With evaporator fan on high speed amp draw is measured and compared to voltage and frequency CRR 40 2 1 Amps approx at 50 Hz 2 5 Amps approx at 60 Hz Amperes are recorded in PTI log Evaporator fans operate on high speed for maximum 3 minutes Then probe test runs until temperature difference between sensors stops increasing Maximum gt to temperature difference allowed 13 minutes Return Evaporator 1 5 C 34 7 F return air sensor marlin temperature must be 0 5 C 32 9 F above evaporator sensor temperature Return Supply 0 8 C 33 0 F return air sensor temperature must be 0 5
93. A high pressure cutout switch is located on the compressor discharge service manifold of the compressor If the discharge pressure becomes too high the switch opens the ground circuit to the compressor contactor coil Compressor STOPS immediately Evaporator and condenser fans continue normal operation Controller determines that a high pressure cutout switch or compressor motor internal overload protector is open when the unit current draw during compressor operation is normal and then decreases by 7 amps for more than 3 seconds e After 1 minute the controller LCD display shows a High Pressure Cutout message after 1 minute High Pressure Cutout Check Condenser Probe Water pressure switch is CLOSED and the condenser temperature is low 127 Electrical Maintenance High Pressure Cutout Check Condenser Fan Water pressure switch is CLOSED and the condenser temperature is high High Pressure Cutout Check Water Cooling Water pressure switch is OPEN e The controller continues to call for cooling so the compressor will restart when the overload condition is corrected switch resets if power 1s available e If the switch remains open for 3 minutes the controller also turns ON the Alarm LED and records Alarm 37 Total Power Consumption Too Low High Pressure Cutout Switch Opens 2240 70 kPa 22 4 0 7 bar 325 10 Psig Closes 1590 70 kPa 15 9 0 7 bar 230 10 Psig To test the swit
94. BAT CIR REMOTE RED BLK CIR BATTERY B_4 amp RED amp THERMISTER YZ 8 WHT 28 MAN ID ON OFF 2C ACTOR 20 044 OTO 2B 0 2C OTOR 2B OTOR 2 2A OID VALVE SA 4C as ooo mm cec m loto Toros Tol MONITOR COM CON sz a 1281 O de THERMISTE3 oat Ea ES A 3 EVA FUSE 2A OV O 922 YEL He SEL iu ES JS 4C ZIS 4C 16H 4A ALAY E 4C RELAY S 5C RELAY A 5C RELAY A 5C IZLAY 5 6C RELAY S 6C 1QUID INJECTIO SA D H 0 N MP 3000 CONTROLLER lototohoSo r m 1QUID SOLE 6A 9 PIN D CONNECT OVERHEAT SW 44 SWITCH UN 2C SWITCH WCC ON O 2C CAB TRANSFORMER 2D V 192 CRR40 303 Wiring Diagram Page 1 of 2 EVAPORATOR SECT ON RETURN RETURN AIR SENSOR 2 k03M AT S OVERHEAT o has y FFI3 ase PEST SWITCH EF 12 EFIZ EEN EVAPORATOR BLY or mer Di l Hum e EFI EVAPORATOR EF3 ESN HUMIDITY iv OR RED bao Hum EF3 FAN FF MOTOR 1 SENSOR Fr MOTOR 2 26 EFI OPTIONAL EA GRN GRN YEL 73 L CORNI GRA YES fF 7 ADE FROST RED WAT i HEATERS HEATERS E j YELLOW BLACK S EVAP amp HEATER HARNESS ORANGE BLUE DATA PLUG YELLOW RED GREEN RED WHITE 3LACK LIGUID SOLENOID VALVE BRN A E YELLOW
95. Blade Specifications CRR40 Diameter 355 mm 14 0 in Pitch 25 Weight net CRR40 526 Kg 1159 Ib Water cooled Condenser Receiver Option 13 6 Kg 30 Ib Unit Dimensions A Flange Width 2025 5 mm 79 74 in B Gasket Width 1935 mm 76 18 in C Unit Width 1894 mm 74 57 in D Flange Height 2235 2 mm 88 00 in E Gasket Height 2140 mm 84 25 in F Unit Height 2094 mm 82 44 in G Gasket Depth 72 mm 2 83 in from back of flange H Maximum Protrusion 37 mm 1 46 in from back of flange Unit Depth CRR 40 420 0 mm 16 54 in from back of flange 22 Specifications Figure 2 Physical Specification Metric Hardware Torque Charts Bolt Type and Bolt Size cm OS MENCIONO ANNO N m Ft Ib N m Ft Ib N m Ft Ib N m Ft Ib WT os Bolt Type Bolt Size and Class wm m ws J w HH Hex Head CL Class 23 Specifications Compressor Torque Chart D3D Copeland Compressor Standard Bolt Torque Bolt Usage Bottom Plate Grade 5 Grade 8 Housing Cover Oil Pump to Housing Cover Bearing Cover to Housing Cover Stator Cover Grade 5 Grade 8 Cylinder head Oil Screen Cover Crankcase Heater Plug Discharge and Suction Valve 18 5 16 in 13 1 2 in Pipe Plug 6 35 mm 0 25 in 3 175mm 0 125 in Oil Sight Glass Grade 5 Grade 8 Terminal Plate Nut on Top of Termin
96. C 32 9 F above supply air temperature LH Supply RH Supply if equipped 0 5 C 32 9 F Air vent is opened and verified that the motor is operating Evaporator fan is started and operating until CO2 value is below 0 5 percent or 20 minutes 57 68 69 10 seconds minimum to 20 minutes maximum Readings may vary depending on voltage and temperature 74 Operating Instructions CRR PTI Full Pretrip Test LCD Display Description Possible Duration Alarms Time COND FAN TEST Condenser fan is turned on 16 17 10 seconds SUP RET EVA Amp draw is measured and compared to voltage and 5 20 5 0C 5 10 frequency 0 8 Amps Maximum Condenser fan amperes are recorded in PTI log 1 3A 1 24 1 3A REVERSE PHASE With condenser fan on reverse phase selector relay is 30 seconds TEST energized Condenser fan and compressor reverse SUP RET EVA current is measured 1 3C 1 0C 1 3C 1 3A 1 2A 1 3A HEAT ELEMENT TEST Electric heaters are turned on 10 11 10 seconds SUP RET EVA Amp draw is measured and compared to voltage 1 3C 1 0C 1 3C 4 4 Amps approx at 400V 5 2A 54A 5 24 5 1 Amps approx at 460V Heater amperes are recorded in PTI log DEFROST TEST If evaporator temperature is below 10 C heater 1 hour SUP RET EVA remains on until evaporator temperature is above maximum 418 C 5 0C 12 0C 15 0C 5 2A 54A 52A PRE COOL HEAT TEST If the return air temperature is above 20 C 68 F unit None 30 to 60 RET EVA operates in cool unti
97. CRR TK 50874 4 MM Rev 6 04 05 Copyright 2003 Thermo King Corp Minneapolis MN USA Printed in USA For further information refer to CRR 40 PS amp PS Parts Manual TK 50961 Diagnosing Thermo King Container Refrigeration Systems TK 41166 Electrostatic Discharge ESD Training Guide TK 40282 Evacuation Station Operation and Field Application TK 40612 Tool Catalog TK 5955 The information in this manual is provided to assist owners operators and service people in the proper upkeep and maintenance of Thermo King units This manual is published for informational purposes only and the information so provided should not be considered as all inclusive or covering all contingencies If further information is required Thermo King Corporation should be consulted Sale of product shown in this manual is subject to Thermo King s terms and conditions including but not limited to the Thermo King Limited Express Warranty Such terms and conditions are available upon request Thermo King s warranty will not apply to any equipment which has been so repaired or altered outside the manufacturer s plants as in the manufacturer s judgment to effect its stability IMPORTANT No warranties express or implied including warranties of fitness for a particular purpose or merchantability or warranties arising from course of dealing or usage of trade are made regarding the information recommendations and descriptions contained h
98. Cable Mounts in Cable Box Figure 56 AFAM System 110 The Controlled Atmosphere CA OPTION submenu in the CONFIGURATION menu is factory set to AFAM The controller then adds the AFAM AFAM DELAY AFAM RATE O MIN and CO MAX submenus to the SETPOINT menu If a replacement controller or new software 1s installed a controller auto configuration will detect the AFAM option when the AFAM door control module and gas sensor are connected to the controller When an auto configuration is performed the controller sets the CA OPTION in the Configuration menu to ANALYZER To operate the AFAM system the CA OPTION must be manually set to AFAM ANALYZER This setting turns on data logging for the CO gas level only The AFAM system does not operate e AFAM This setting turns on the AFAM system to control the CO gas level The controller then adds the CO MAX submenu to the SETPOINT display in addition to the AFAM AFAM DELAY and AFAM RATE submenus The default setting for AFAM in the SETPOINT menu is the last value set OFF UNITS or DEMAND AFAM must be set to DEMAND to control the vent door to the CO gas level Starting the AFAM System 1 Press the SETPOINT key The SETPOINT menu appears with the cursor in the TEMP SETP line 2 Press F2 key to scroll to AFAM line 3 To change the mode setting press F4 key Cursor moves to end of menu line and flashes WARNING The vent door
99. Event Log With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press F3 key to enter the Main Menu 2 Press F2 key to scroll through Main Menu until DATALOGGER appears in LCD display 3 Press F4 Key to access the Datalogger menu Inspect Temp Log appears in the LCD display 4 Press F2 or F3 key to scroll through submenu until Inspect Event Log appears in LCD display 5 Press F4 Key to enter Event Log LCD display shows the Log Time and the most recent event e To scroll through previous event log screens press F3 key All event logs recorded in the datalogger memory may be viewed on the LCD display Event Examples e Controller alarm status alarms set cleared Main power On Off status humidity On Off temperature setpoint and main power Hz e 12 Vdc battery discharge test battery voltage total unit and compressor hours if main power On this event logged at once a day Change temperature setpoint new old setpoint e Change RH setpoint new old RH setpoint e Change RH status On Off e Event log retrieval e Temperature log retrieval e Trip start New container ID 89 Operating Instructions e PTI start Unit configuration e PTI part 1 end Temperature differences for tests 1 2 3 and heat test e PTI end e Defrost start logged with demand or manual defrost only e Defrost end start time 6 Press ESC key to exit t
100. IR position Replace defective switch Tighten connections Check for seized bearings or defective thermal overload protector Repair or replace as necessary Replace motor Replace defective contactor Diagnose and replace condenser fan relay main relay board or controller 161 Diagnosis Troubleshooting Status Messages Alarm Codes Evaporator fan motor s does not operate Unit operating in a vacuum unit not cooling NOTE When unit is in Cool with Modulation or the return air temperature is below 18 C 0 F the suction pressure will be less than 0 kPa 0 bar 0 psig during normal operation 162 Unit on defrost unit in Economy Mode Frozen Load Null mode ONLY Loose line connection Open motor internal thermal overload protector Defective motor Defective low or high speed evaporator fan contactor No low or high speed evaporator fan output signal from controller Shortage of refrigerant Compressor motor contacts frozen Compressor inefficient Defective liquid line solenoid valve Partial obstruction in low side or filter drier Iced or plugged evaporator coil Expansion valve partially closed by ice dirt or wax Expansion valve power element lost its charge Defective container insulation Poor fitting container doors Partial obstruction in high side Suction pressure gauge out of calibration Evaporator pressure regulator KVQ valve stuck closed or defective Expansion valve
101. ISTE CS A qae Se ERE EIS 155 Gondenser Coll i rusas rtp sud ate eile i ae AA RIRs cath ott RSEN INE RAE AE AINE 156 Evaporator Goil i253 222 a be RE teh tie a eus nos idoneos aladdaddadded bas 156 Defrost Draitis 2 33 er e UTR ate anal eae ala BOR MI Sr LR helm A DM IMS T 156 Condenser Fan Location 242426 stereo a ee aE eed Sad eee WS ET ed ed EE Ets 156 Evaporator Fam Location ieo usi RR REERERPERPRI ade Rp S anna omaha sa savas 157 Diagnosis Troubleshooting Status Messages Alarm Codes cease eee er nh rrr 159 A O KPE DE A E Eaa 159 Controller Diagnostics lt ie aa e ET e E AE A A a A EE E E Rh rer 159 Status Messages and Controller Actions 0 00 ett 166 Index ini a E RI xU OG EG ee ex E E a a ee Eum gum qe Tus i ee 185 Electrical Refrigeration and MP 3000a Menu Flow Diagrams Index 00 e cece eee hh mh m hh 187 Controller Menu Guide s bis ves va eed ce e 199 List Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 Figure 45 Figure 46 Figure 4
102. ITTED TO WCC ON OFF COM DISCE SWITCH TEMP SENSOR OPTION RED TON MET A ERMO KING PROPRIETARY DATA ED WITHOUT THE PRIOR WRITTEN THERMO KiNG CORPORATION THE YOU IN CONF DENCE AND TRUST AND 15 WHOLE OR IN PART TO OTHERS OR USED FOR OTHER THAN THE PURPOSE FOR WHICH PERMISSION OF THERMO KING CORPORAT THIS DOCUMENT CONTAINS PROPRIETARY TO BE RETJANED UPON REOLEST IMFORMATIQN OF TRE THERMO KING CORPORATION SONTLNIS WAY NOT BE DISCLOSED IN TRANSMITT SIONS SUP_PY A R 149701 SENSOR RH A l an EASED RED ON WET F 560555 16 Sep 01 n 20 AMP Ff 223 AMP CB ANGED T F 1 5 AMP j o Stason LH 3 K3 502464 LG tete HEATER e yr ESV CORRECTED JII RETJRN A R oooo TE Mg USDA SENSO AMBIENT TEMP SENSOR USDA SENSO USDA SENSO KT PHASE 2 m Fb Pb Sh I 1b BH FOE EK E d CONDENSER COIL SENSOR EVAP COIL E SENSOR CABLE 2 RED TON MET E AA Nu HUMIDITY SENSOR HUM LN EUM SWITCH CONDENSER SENSOR o EVAP COLL SENSOR I K5 EVAP LOW o r3 WHT RED 44 CONDEASER E KEYPAD BLK YEL JESCR LOCATION WHT RED BAT
103. Main Menu 2 Press F2 key to scroll through Main Menu until DATALOGGER appears in LCD display Note All screens are not present on all units The screens that display on the Datalogger controller are determined by the Controller Software setting INSPECT TEMP and the options installed on PTI STATE the unit INSPECT PTI CALIBRATE USDA PROBE Datalogger AC TATE TAIP First function screen appears SET LOGITIME INSPECT TEMP LOG t INSPECT EVENT Press F4 key to view next screen Press F3 key to scroll through previous logs of sensors INSPECT EVENT LOG Press F3 key to scroll through previous event logs SET LOG TIME Press F3 key to scroll through log interval list Press and hold F4 key until cursor stops flashing ACTIVATE TRIP START Press F4 key to enter trip start marker INSPECT PTI LOG Press F3 key through test result screens Figure 42 Datalogger Menu Screen Flow Diagram Press F4 key to access the Datalogger menu The first function appears in the LCD display Inspect Temp Log Press F2 or F3 key to scroll to the desired function Inspect Temp Log PTT State 88 Inspect Event Log Set Log Time Activate Tripstart Inspect PTI Log 5 Press F4 key to access the function selected Inspect Temp Log With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press F2 key to ent
104. Message Display Displays the controller menu alarms and messages See the next page for further information MAIN MENU DATA Keypad Contain sixteen keys used to TEMP SETP _ 22 0 C e Navigate scroll the controller menu e Enter change text and numeric characters in the message display See the next page for further information Special Function Keys Four special function keys are available to quickly move to a specific area of the controller menu See the next page for further information Each of the above areas will be described in detail on the following pages C F SUP RET DEFROST SETPOINT AXA0155 Temperature Status Display Message Display 4 Special Function Keys Keypad 4 Figure 21 MP 3000a Controller Display Panel 43 Controller Description Temperature Status Display The Temperature Status Display consists of two areas A 5 digit LED display that shows the sensor temperature in Fahrenheit or Celsius and 8 status indicator LED s LED Display The LED display shows controlling return or supply sensor temperature The sensor temperature shown in LED display is indicated by status indicator lights If a sensor is out of range the display shows Err or Err The sign indicates whether the sensor temperature is out of range high or low The LED display also shows the test stage of a pretrip PTI or function test AJA1971 Figure 22 Temperature Status Display S
105. Mode capacity tests Press ESC key to exit the PTI Log 91 Operating Instructions RMM State Menu The RMM Remote Monitoring Modem State menu displays the current communications status with a REFCON system Offline No communication between the controller RMM and a REFCON system Zombie The controller has detected a REFCON system master module and is waiting for communication e On line The controller RMM is logged in on a REFCON system Viewing the RMM State Screen With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press the F3 key to enter the Main Menu 2 Press F2 key to scroll through Main Menu until RMM STATE appears in LCD display 3 Press F4 key to access the RMM State screen The screen will show Offline Zombie or On line 4 Press ESC key to exit the RMM State screen 92 Note All screens are not present on all units The Screens that display on the controller are determined by Standard Display the Controller Software setting and the options installed on the unit gt DATALOGGER m CONFIGURATION 18 RMM Status Display sh MISC FUNCTIONS BUE SUUS F1 OFFLINE COMMANDS ZOMBIE ON LINE AJA1329 Figure 43 RMM State Menu Screen Flow Diagram Operating Instructions Manual Emergency Mode Operation In the event of an emergency situation where a failure of the controller oc
106. ONNECTER 2 I 3 M z Kb s m 5 es S Ss es zg tue A Bee See So HG e EFS A A RA REE Sis te EDODOPCCCCC CCCO e fs ter LOW s CF3 9 PIN D CONNECTER Y x Y A oun 5 alo d Wir E e 8 9 B E K4 S CFI YEL Bg CONDENSER E l s T m T Z oorok Os ea qi OF Os OF 91 Q7 0 RE POWER CORD CONNECTER 3 n 9n 9i er 3 8 7 Ey N A L CONDENSER A WIRES CONNECTER EN a SV agnosie Phone ETE BATA PPP PIERCE SS THERMO KING x E E vera oocusci Caria enornicrany SEFERE H CORPORATION 3 I Teese on o te ge et WIR NG DIAGRAM S NDA AET TA o rato E DEE RETURN EL IT 5055232 PH SUPE LY COMP a Ue diui fe nun m WIRES Z PERMISSION oF THERMO KING CORPORATION ases D THERMO KING CORPORATION SERE Me ETE 5055263 e 8 a 3 2ROE_DD Refrigeration System Components CRR 40 Refrigeration System Components 3DS Compressor Oil Fill Drain Fitting Discharge Service Valve High Pressure Cutout Switch Compressor Discharge Line Temperature Sensor Condenser Check Valve Condenser Coil Circular Receiver Tank High Pressure Relief Fusible Plug 10 Receiver Tank Service Fitting or Plug Fitting 11 Sight Glass 12 Condenser Coil Subcooler Circuit 13 Liquid Line Service Valve 14 Dehydrator Filter Drier 15 Heat Exchanger 16 Liquid Line Solenoid LLS 17 Expansion Valve TXV 18 Expansion Valve Feeler Bulb 19 Equalizer Line 20 Distributor 21 Evaporator Coil 22 Electric Heaters 23
107. Off switch is OFF before opening the container doors The unit may be operating when loading the container from a warehouse with door seals 2 Spot check and record load temperature while loading Especially note any off temperature product Operating Instructions Post Load Procedure 1 Make sure all doors are closed and locked 2 Start unit if unit is OFF 3 Check controller setpoint for correct setting 4 Enter trip identification information into the controller memory by selecting Cargo Data from the MISC FUNCTIONS menu of the controller 5 One half hour after loading initiate a manual defrost cycle e Press the DEFROST key The Defrost and Heat LEDs turns ON as the unit enters Defrost Defrost will stop automatically NOTE The evaporator coil temperature must be below 18 C 65 F to allow the unit the enter a defrost cycle If the evaporator coil temperature is too high the LCD display will read Defrost Not Activated Post Trip Procedure Trip data recorded by the MP 3000a datalogger may be down loaded via the communications port on the control box using a DRU II handheld data retriever or a laptop or palmtop computer with SmartSponge software or via the REFCON remote monitor system 55 Operating Instructions Change the Setpoint To change the controller setpoint turn the Unit ON OFF switch ON Complete the following steps 1 Press the SETPOINT key The Setpoint menu ap
108. R ABLE 3 25 CONDUCTOR CABLE CONTROLLER amp RS485 4PKII RS485 A PKI1 2 GND PKIN 3 ORG PKS 6 WHT ORG PKS 7 OPTION CHART RECORDER BATTERY REMOTE MONITORING PLUG OPTION IN RANGE DEFROST COMPRESSOR ON l DEHUMIDIFICATION SOLENOID VALVE COPTION LIQUID SOLENOID VALVE LIQUID INJECTION VALVE OVERHEAT SWITCH WATER COOLED CONDENSER SWITCH OPTION DESCRI PTION REV F Thermo King MATIC DIAGRAM RR MP3000A 5055683 5055684 SHEET WG NO V 1 Di IR Ingersoll Rand SCH CODE IDENT NO SIZE 13 Sept 02 FREESE DO NOT MANUALLY UPDATE APPROVED CAD GENERATED DRAWING M CHECKED ENG APPVL 1994 M THIRO ANGLE PROJECTION INTERPRET DIM AND TOL PER UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES ASME YI4 AND IT 1S TRANSMITTED TO 1 TO BE RETURNED UPON REQUEST UHENT CONTAINS PROPRIETARY ITS CONTENTS MAY NOT BE DISCLOSED IN WHOLE OR IN PART TO OTHERS OR USED FOR OTHER THAN THE PURPOSE PRIOR WRITTEN PERMISSION OF THERMO FOU IN CONFIDENCE AND TRUST FOR WHICH TRANSMITTED WITHOUT THE KING CORPORATION INFORMATION Of THE THERMO KING THERNO KING PROPRIETARY DATA THIS DO THERNO KING CORPORATION ORPCRATION REVISIO P
109. THE AO KING P WIRING DIAGRAM MINNEAPOLIS MINNESOTA USA YOU IN CONFIDENCE AND TRUST AND IS APPROVED TO GE RETURNED UPON REQUEST ITS WHOLE OR IN PARS TO OTHERS OR USED CRR REF 5D55262 TOR OTHER THAN THE PURPOSE FOR WHich APPROVED H1 sssoas 19NYH 282 10 vr 65 JAF L0691 04543138 SNOISIAJY TRANSMITTED wITEOUT THE PRIOR WRITTEN PERMISSION OF THERMO KING CORPORATION Tle DRAWING NUMBER dV S L 3504 old 9 10 10 da5 31 THIS PAINT e THERMO KING CORPORATION SUPERSEDES ANY eee Bye aa Sates 5055263 2 PROE_DD LIC 0312398902 AS J IO zo unr co HI eorzas 193 CRR40 303 Wiring Diagram Page 2 of 2
110. Y p o 2 KOHM AT 25 C 2 KOHN AT 25 C g 3 DATA PLUG B KVQ VALVE T S ES YELLOW R BRN ln 361 GRN f 3 f i m BLK BLK RED WHT BLACK wT o4 ye N J QU YEN A HIGH PRESSURE COMPRESSOR CUTOUT DISCHARGE SWITCH TEMP SENSOR 100 KOHM AT 25 C POWER CORD Os O6 00 0 9 100 460 VOLTS DATA COND KVO HPS DHY LIV ANA ES l FON 50760 Hz USDA 1 2 3 SUPPLY RH DEF RETURN LSV KVG treed TOP VIEW CONDENSOR FAN MOTOR gt GAS AFAM AMBT COMP LH SUPPLY POWER RECEPTACLE CHART RECORDEA HUM ROTATION C OG RoTaTION QR A PBLK BRN el e 7 LOW SPEED A HIGH SPEED COMPRESSOR c2 EFI EF2 EF e ie EFII EF I2 EFIS BU RS 2 MOTOR GRN YEL CFI CF2 Cra en C RED 8LK COMPRESSOR oe WIRES A G GRN GRN YEL Tl T2 73 TH T13 GRILO NEEL RED BLU CWHT OELABLIO RED SLO n E I TS 7272 22 TET TZ rr BE EORR T12 2 lalea aleae mimm THERMO KING PROPRIETARY DATA J PIERCE Sep 02 QIHTIBLEO Zala F ae Ria E S ENA m Anes tenes GwEenTo CORPORATION iT US Es alo nena Moes icon WIRING DIAGRAM ou a a seein meas es 3 3 3 E al contenta war mor Be brscuoseo ru REF 5455683 1 85l EJZ S F esol m f o Met Rer dede mem CRR d TH TI 113 an zS esa st BLS AI mission or remo kias conronari n pa E 3 5 ERE 5 THERMO KING CORPORATION AECI Ale TAT TAE 5D 5 5 6 84 6 8 T 6 5 4 3 2 PROE_DD 190 All Models Except CRR40 303 Wiring Diagram Page 2 of 2
111. Z ereronerqr 97 0 opor 93 02 a Wwe ecl inaa POWER CORD dixe zl 5 14 et qme Ea 35 12 I Be om A CONNECTER 3 CONDENSER i i LH SUPPLY WIRES Y I I O DHV o7 DATE a O 2 isi O E THERNG KING PROPRIETARY CATA J PIERCE 30 Jul 02 EZ THERMO KING HECK CORPORATION m va C maano a serm m esr 2e WIRING DIAGRAM AAR o CONNECTER DATA CONDENSER PS S M UU ret a l USDA 172 3 UPPLY RH f CO TO BE RETURNED UPON REQUEST ITS aa GAS AFAM COMP AMBT LH SUPPLY Z MASLE OR IA PART TO OTHERS OR USED aera CRR REF 5035083 CHART RECORDER KVO HUM A SE utum e Na M MELLE BER ECRIRE T Z PAIS oF Titio rias cot in H D THERMO KING CORPORATION SATE Me a SEDIT 5055684 G L 8 7 6 5 4 3 2 PROE_DD 191 CRR40 303 Wiring Schematic C PROE DD ZERO A CURRENT Jl SENSOR 20 amp BLK BRY or ET F2 20 AMP WHT BLI T S 3 20 AMP E REDIBL AT eX p 7 6 460 380V 50 60Hz 3 H POWER IMIENEAPOLIS MINNESOTA USA THERMO KING CORPORAT ON ORAW NG NUMBER 5D55262 SCHEMATIC coe ABOVAC c RA I DESTROY SAME APPROVED APPROVED on VEL BLK WET RED ITs VV ISO r Dees a cd IT 18 TRANSM
112. aa a ae RAG RS BEE eR EUR 42 MP 3000a Controller Display Panel 0 0c cee eee 43 Temperature Status Display i sec ucria ses a ta a D a e nn 44 Message Display o ena n EO Dates Seeks Ee he he het nA 44 Special Function Keys sacs eua tise VE tte inlets taeda ib dla a Pale ale Re aaa 44 Menu Scrolling Keys on Keypad 0 oococccccco I 45 TEXEKOYS ON Keypad a th Woe ap ave A Weite eda aud adi 45 VOX Siete ors sem Ur A HERES PR E PE UAE 46 MP 3000a Controller Display Panel ooococcoccoccno III 47 Receiver Tank Sight Glass oooo oooococcrccr er 50 Control Circuit FUSES 6i ener tg eS A A LT RORIS ELE RE DETENER 51 Special Function Keys na oo emp e ter ete pee Be ede a Re edad EE Rea 57 Setpoint Menu Screen Flow Diagram ssesseeleele nee eee 59 AFAM System Linkage Adjustment oococccccc nn 60 Datalogger Menu Screen Flow Diagram o oococcoccccco en 62 Alarms Screen Flow Diagram ooococcococ nn 66 Commands Menu Screen Flow Diagram oooococccccccc nen 68 Brie TE Test 2i isi ete hU b b Nude See ee quse demde a 70 FUER Tl Test su scere cR cr chee DR ORI rie Re Eee Das pete puis ate quidc a fed as AUN LE eg 73 Function Testini aie cree ne pe MR A hedge xe 77 Misc Functions Menu Screen Flow Diagram 0 0 e eee ete eee 83 Configuration Menu Screen Flow Diagram 0 0 00 87 Datalogger Menu Screen Flow Diagram 0 0 eee ete teen eee 88 RMM State Menu Screen Flow Diagram
113. ads the new control program into memory NOTE If the flash load procedure is interrupted or fails on a MP3000a the controller will stay in the flash mode until correctly flash loaded If the flash load procedure is interrupted or fails on a MP3000 the controller will continue to use the previous control program NOTE Installing new software does not change any configuration settings or the setpoint setting or erase the data log currently stored in the controller Electrical Maintenance Temperature Sensors Resistance Values for Supply Return Thermistor type temperature sensors are used Evaporator Coil Condenser Coil and Ambient Each sensor is connected to a shielded cable and Air Sensors placed in a sealed stainless steel tube The Temp Temp OHMS Temp Temp OHM temperature signal from the sensor is transmitted F C F C S through the shielded cable Temperature sensors 40 40 42618 53 6 12 3360 iehida 31 35 32198 572 14 3094 Supply Air Left Hand 22 30 24532 608 16 2852 Supply Air Right Hand 18 25 18850 64 4 18 2632 e Return Air 4 20 14618 68 20 2431 Evaporator Coil 5 15 11383 71 6 22 2347 10 4 12 9838 75 2 24 2079 e Condenser Coil 14 10 8941 78 8 26 1925 Compressor Discharge Temperature 176 3 8132 82 4 28 1785 Ambient Air 214 2 6 7406 86 30 1657 CAUTION Sensors are permanently 24 8 4 6752 89 6 32 1539 calibrated and can be checked using an 28 4 P 6164 93 2 34 1430 ohmmeter Ohm reading
114. al Plate Nut on Top of Jumper Bar 24 Unit Description Features and Options Introduction This chapter will briefly describe the following items e General Unit Description Standard Component Descriptions e Optional Component Descriptions General Description CRR units are all electric single piece refrigeration units with bottom air supply Each unit is designed to cool and heat containers for shipboard or overland transit of deep frozen chilled or heated cargoes Each unit mounts in the front wall of the container Fork lift pockets are provided for installation and removal of the unit The frame and bulkhead panels are constructed of aluminum and are treated to resist corrosion A hinged removable evaporator compartment door provides easy service access All operating components except the evaporator coil and electric heaters can be replaced from the front of the unit The unit is equipped with an 18 3 m 60 ft power cable for operation on 460 380V 3 Ph 60 50 Hz power For operation on 460 380V 3 Ph 60 50 Hz power plug the 460 380V power cable into the proper power supply Each unit is equipped with 460 380V 3 Ph 60 50 Hz electric motors An automatic phase correction system provides the proper electrical phase sequence for condenser fan and evaporator fan motor operation Unit power cable is stored below the control box in the condenser section Unit features include a semi hermetic reciprocatin
115. ally terminates NOTE A timed defrost of the evaporator coil can be performed if frost or ice can not be removed from the evaporator coil by an automatic defrost cycle Activate HEAT ON in the Manual Function Test submenu Press the 5 key six times Heaters will be activated for 70 minutes Unit then returns to normal operation Display Alternate Controlling Supply or Return Air Sensor Temperature The controller can show either the supply or return air temperature in the LED Display Turn Unit ON OFF switch ON Complete the following steps to display alternate controlling temperature 1 Check the indicator LEDs to determine which sensor temperature supply air or return air currently appears in the right display This is the controlling sensor 2 To view the alternate supply or return air temperature press and hold the SuP RET key The controller will show the alternate sensor temperature as long as the SuP RET key is depressed 3 The display then returns to controlling sensor temperature when SuP RET key is released Display Alternate Fahrenheit F or Celsius C Temperatures The controller can display temperatures in Celsius or Fahrenheit Turn the UNIT ON OFF switch ON and complete the following steps to display in fahrenheit or celsius Press and hold the C F key The controller will show both LED and LCD display temperatures in the alternate temperature scale Fahrenheit or Celsius a
116. ally when the con denser coil temperature is above 35 C 95 F MP 3000 Controller Microprocessor with digital thermostat thermometer and fault indicator monitor Water Pressure Switch WPS HPCO Is a normally CLOSED switch It OPENS at 117 21 kPa 1 17 0 21 bar 17 3 psig It CLOSES at 35 21 kPa 0 35 0 21 bar 5 3 psig High pressure gas High pressure liquid Low pressure gas Low pressure liquid Condensing high pressure gas Low pressure vaporizing liquid ETT FE RARA Liquid refrigerant injection 196 Cool with Modulation Flow and Pressure Diagram Flow and Pressure Diagram CRR 40 Cool with Modulation or Power Limit 29 Evaporator Pressure Regulator KVQ Valve Is anormally OPEN actuator valve It CLOSES or OPENS according to the strength and frequency of a pulsing voltage sig nal from the controller The voltage signal energizes a heating element in the actuator power element Increasing the tempera ture of the heating element increases the pressure on the main valve actuator forcing the valve towards the closed position Decreasing the temperature of the heating element decreases the pressure on the main valve actuator drawing the valve towards the open position Liquid Injection Valve LIV Is anormally CLOSED valve It OPENS when energized When liquid injection is required the valve is pulsed open and closed on a 60 second cycle Liquid injection is controlled by th
117. an offset for temperature control 113 Operating Theory Temperature Control Accuracy and Frost Protection The PID algorithm generally minimizes container temperature fluctuations to 0 1 C 0 2 F Additional frost protections is provided by pulsing the electric heaters ON and OFF to increase the supply air temperature if the return air temperature decreases to within 0 3 C 0 5 F of setpoint The controller pulses the heater ON for 2 to 60 seconds every 60 seconds The amount of ON time depends on the amount of heat required to provide frost protection Frozen Loads Setpoint at 10 C 14 F and Below The unit operates on Full Cool and Null to provide accurate control of frozen cargo The controller uses the return air sensor temperature and setpoint temperature to regulate unit operation If the return air sensor becomes disconnected or fails the controller uses the supply air sensors plus an offset for temperature control KVQ Setting Value and Cool Capacity Value in Data Menu The KVQ Setting value displayed in the Data menu indicates the evaporating temperature the KVQ valve uses to control refrigerant return to the compressor During maximum cooling capacity operation the K VQ Setting value may range between 40 C and 60 C 40 F and 76 F The Cool Capacity value displayed in the Data menu indicates the percent of the total unit capacity that is currently provided For example when controller display
118. aneous Functions Menu Configuration Menu Commands Menu NOTE The screens that display on the controller are determined by the controller software setting and the options installed on the unit All screens are NOT present on all units Text Input The keyboard supports both numerical and text input Each key can have more than one meaning Use the special text keys F1 F2 F3 and F4 to enter text in an information screen AJA1978 Figure 26 Text Keys on Keypad F1 key Press the F1 key then press another general purpose key to enter the number shown on the key F2 key Press the F2 key then press another general purpose key to enter the first letter shown on the key F3 key Press the F3 key then press another general purpose key to enter the second letter shown on the key F4 key Press the F4 key then press another general purpose key to enter the third letter shown on the key NOTE When the F1 F2 F3 or F4 key is pressed to enter a character in the display the keypad remains on that character level until another level is selected by pressing the F1 F2 F3or F4 key 45 Controller Description Text Input Example The following paragraph gives an example of how to enter text to an informational screen To enter THERMO in an information screen 46 Enter T by pressing the F3 key then pressing STU key Enter H by pressing the GHI key Enter E by pressing th
119. anual Function Test menu and start HEAT Check the amps measurement If necessary check the resistance between H1 and H2 H2 and H3 and H1 and H3 resistance should be about 99 ohms on each leg See note on next page Evaporator Fan high Speed Current Too Low Check Alarm Occurs during Pretrip PTI Function test or Probe test Evaporator fan power consumption is 25 below expected current draw below 1 5 to 2 3 amps depending on voltage Indicates Defective evaporator fan motor relay Defective or open fan motor internal over temperature protection switch Defective volt or amp meter on relay board Incorrect motor or motor connections Open evaporator door and make sure all fans rotate freely Enter manual Function Test and start evaporator fans on HIGH speed Make sure all fans start on high speed If a motor does not start and is very hot wait 10 minutes for internal over temperature switch to close Check fan motor volts and amps Check volt and ampere meter 173 Diagnosis Troubleshooting Status Messages Alarm Codes Evaporator Fan Low Speed Current Too High Check Alarm Occurs during Pretrip PTI or Function test only Evaporator fan power consumption is 25 above expected current draw above 2 8 to 4 0 amps depending on voltage Indicates Defective or stuck evaporator fan motor ncorrect motor or motor connections Motor high and low speed connection are interchanged Def
120. arm List Menu With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press F2 key to directly enter the Alarms menu The first alarm code number alarm state and alarm description appears in LCD display NOTE Alarm codes are displayed in sequential order not in the order of occurrence 2 Write down the first alarm code Then press F2 key to view the next alarm code when more than one alarm code has been recorded 3 Repeat step 2 until all alarm codes have been recorded To scroll backward to return to a previous alarm code press F3 key To clear all alarm codes from the current display list and turn off the Alarm LED all problems must be corrected and the alarm code acknowledged in the Alarm List menu NOTE To acknowledge an alarm press F4 while the alarm code appears on the screen The alarm state will change from ACTIVE or NOT ACTIVE to ACKNOWLEDGE NOTE If no key is pressed for 30 seconds the controller returns to the previous menu level or the LCD Standard Display Alarm List Alarm Type Description Code 00 Check Supply Air Sensor Open Circuit 01 Check Supply Air Sensor Short Circuit 02 Check Return Air Sensor Open Circuit 03 Check Return Air Sensor Short Circuit 04 Check Evaporator Coil Open Circuit 05 Check Evaporator Coil Sensor Short Circuit 06 Check Compressor Current Too High 07 Check Compressor Current Too Low 10 Check Heater Current Too Hig
121. arm in last interval NOTE All event flags that occurred during a log interval are displayed 6 Press ESC key to exit the Temp Log Inspect Event Log With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press F3 key to enter the Main Menu 2 Press F2 key to scroll through Main Menu until DATALOGGER appears in LCD display 3 Press F4 Key to access the Datalogger menu Inspect Temp Log appears in the LCD display 4 Press F2 or F3 key to scroll through submenu until Inspect Event Log appears in LCD display 5 Press F4 Key to enter Event Log LCD display shows the Log Time and the most recent event e To scroll through previous event log screens press F3 key All event logs recorded in the datalogger memory may be viewed on the LCD display Event Examples e Controller alarm status alarms set cleared Main power On Off status humidity On Off temperature setpoint and main power Hz e 12 Vdc battery discharge test battery voltage total unit and compressor hours if main power On this event logged at once a day Change temperature setpoint new old setpoint e Change RH setpoint new old RH setpoint e Change RH status On Off e Event log retrieval e Temperature log retrieval e Trip start New container ID 63 Operating Instructions e PTI start Unit configuration e PTI part 1 end Temperature differences for tests 1 2 3
122. arn asalawu Y WIR gear eee 62 Viewing the Datalogger Menu 2 0 cee teens 62 Inspect Tempi Logi teoria oe eed aed PEGE ee ela ea teeta 63 Inspect Event EOg vss a e A 6544 ale iA eee ele eee eee ee eels 63 set Log Times co e kde ee e IR ee DRE IRE Ye Ye Ye CAE dad 64 Seta Trip Stat ec NN 65 Inspect A BN E D 65 Alarms Menu uk hu n Pe Rm terii ODE ERE RUM NE RE NO ON RN E Res KTE ELS E opus e n 66 Alarm Types P 66 Al rm Code States se cocer TR Sy ae acia dt tees s aet 66 Viewing the Alarm List Menu sssseeeee RR mme hh 66 Alarm Lists et sce ed ureters ppb hy bey S ed etd Spee ond EPEETPES MERE UD ab xn CE med n 67 Commands Menu sessed eaae Atos ae ee dc dd ae We de Fe ee vee 68 Viewing the Commands Menu 0 00 c eee hm hh 69 Brief P TI Pretrip Test m ga woke siri dori coher Rade Ri a MS a RD 70 PTL Eull Pretrip LeSt uz rcp pRIG da A ee eee oe ERE eS 73 FUNCION pestine resan a de il dete dene al wag eee eid seine art aaa ees 77 Manual Function Test sce deca e Bie ee ga than ma fede imu eerie oa mie qun 80 Power Management o 81 Mise Functions Menu aiii Sa ey bee a A ee ie a de eee ce eee esas 82 Viewing the Misc Functions Menu 00 cee 82 Setting the Date ANA Time 4 oec a Pee eek A lis 83 Viewing or Setting Run Time 1 2 tetas 84 setting Cargo Dt Leia quud ERE CERE ERR e ee wu 85 Changing the Temperature Display Value C F 0 ce
123. ating Evaporator fan is started and operating until CO2 value is below 0 5 percent or 20 minutes 57 68 69 10 seconds minimum to 20 minutes maximum Readings may vary depending on voltage and temperature COND FAN TEST SUP RET EVA 5 2C 5 0C 5 1C Condenser fan is turned on 10 seconds Amp draw is measured and compared to voltage and frequency 0 8 Amps maximum Condenser fan amperes are recorded in PTI log 1 3A 1 2A 1 3A 71 Operating Instructions CRR Brief PTI Test LCD Display Description Possible Duration Alarms Time REVERSE PHASE TEST SUP RET EVA 1 3C 1 00 1 36 1 3A 1 2A 1 3A HEAT ELEMENT TEST SUP RET EVA 1 3C 1 0C 1 3C 5 2A 54A 52A PRE COOL HEAT TEST SUP RET EVA 5 1C 5 0C 5 1C 2 3A 24A 2 3A COMPRESSOR TEST AMB CON EVA 8 0C 15 0C 5 0C 91A 9 0A 9 1A KVQ VALVE TEST AMB CON EVA 8 0C 25 0C 2 0C 91A 90A 9 1A COMP HI PRESS TEST AMB CON EVA 8 0C 45 0C 1 0C 91A 90A 9 1A CAPACITY 1 TEST SUP RET EVA 5 1C 5 0C 5 16 2 3A 244A 2 3A INJECTION VALVE TEST AMB CON EVA 8 0C 25 0C 2 0C 91A 90A 9 1A With condenser fan on reverse phase selector relay is energized Condenser fan and compressor reverse current is measured Electric heaters are turned on Amp draw is measured and compared to voltage 4 4 Amps approx at 400V 5 1 Amps approx at 460V Heater amperes are recorded in PTI log If the return air temperature is above 20 C 68 F unit operates
124. auge indicates the refrigerant pressure in the discharge line leaving the compressor RECORDING THERMOMETER OPTION The recording thermometer indicates and permanently records the temperature of the supply air leaving the evaporator section on a calibrated chart POWER LINE COMMUNICATIONS MODEM OPTION A REFCON remote monitoring modem is available to provide remote monitoring via the power cable High speed transmission reads all controller information Unit Protection Devices 1 MAIN CIRCUIT BREAKER A 25 ampere manual reset circuit breaker protects the 460 380V power supply circuit to the unit electric motors and control system transformer The main power circuit breaker is located in the control box CONTROL SYSTEM CIRCUIT BREAKER A 7 ampere manual reset circuit breaker or a 7 ampere ATO fuse protects the 29 Vac control circuit The circuit breaker is located in the control box beside the On Off switch The ATO fuse is located inside the control box on the right side wall FUSES A number of fuses are located on the main relay board and controller to protect unit circuits and components e Three 20 amp fuses protect high voltage circuits on the main relay board A 2 amp fuse protects the controller s 28 Vac system e A 2 amp fuse protects the controller s battery charging circuit 4 COMPRESSOR DISCHARGE LINE TEMPERATURE SENSOR The controller uses the compressor discharge line temperature sensor to pr
125. ause metal corrosion and metal plating It can freeze in the expansion valve and cause intermittent operational problems It reacts in the oil to begin acid buildup e DIRT DUST METAL PARTICLES OTHER FOREIGN MATERIALS Particles of any kind left to float through the system will cause severe damage to all close tolerance items Do not leave a system open to the infiltration of dirt If you must open a system for any reason seal off the open areas as soon as possible and DO NOT work in a dirty environment e ACID Air and moisture cause a chemical breakdown of the oil and or the refrigerant itself The acid will accelerate the deterioration of the softer metals 1 e copper and cause metal plating as the softer material begins to cover the inside of the system If this condition is not stopped it can result in the total destruction of your equipment Compressor Oil Color Code BLACK OIL indicates carbonization caused by air in the system BROWN OIL indicates copper plating caused by moisture in the system GRAY OR METALLIC OIL indicates bearing wear or piston scoring NOTE If the compressor oil is discolored perform a compressor oil acid test oil test kit P N 203 457 If the compressor oil shows an acid condition change the oil and the filter drier Then perform a refrigeration system cleanup Refrigeration Maintenance Unit Preparation and Hookup CAUTION Do not attempt to evacuate a unit until it is
126. blished by the shipper Changing the Humidify Dehumidify Mode program screen from OFF to ON activates the dehumidify control algorithm When the Dehumidify Mode is ON the supply air temperature must be in range to activate dehumidification 116 1 When the humidity level is 2 or more above setpoint and the KVQ valve has reduced the unit cooling capacity by about 25 the controller energizes closes the dehumidify valve pre 2002 This reduces the size of the evaporator providing cooling by 50 causing the coil to become colder and condense more moisture from the container air 2 When the humidity level is 5 or more above setpoint or if the unit does not have a dehumidity valve and the KVQ valve has reduced the unit cooling capacity by about 50 40 at setpoint temperatures below 5 C 41 F the controller also pulses the electric heaters ON and OFF This increases the cooling load on the evaporator coil thereby causing the coil to become even colder and condense more moisture from the container air Sequence Of Operation Unit Start up A 60 second sequence start of the required loads occurs during initial start up of the controller If cooling or heating is required the unit operates in the cool or heat mode When the unit On Off switch is turned ON the LED display turns On and then Off e The setpoint appears briefly in the LED display NOTE When the setpoint appears in the LED display both the Ret
127. cable to recorder as shown below 004086009 6 Pin 6 24Vac orange white Pin 7 24Vac orange Figure 51 Chart Recorder Terminals Mount recorder into enclosure using bolts provided or existing ones removed Mechanical installation is complete Proceed to SETUP section Figure 52 Electronic Chart Recorder Mounting Bolts 103 Operating Instructions Recorder Setup Once the recorder is installed it needs to be added to the unit configuration Connect unit to main power and turn ON NOTE Software version 01122300 or above is required to add the electronic recorder Flashload software as necessary 1 Press the UP or DOWN key to enter menu area 2 Scroll up or down to CONFIGURATION menu Press F4 to enter menu Main Menu Configuration 2002 01 15 12 35 3 Scroll up or down to find CHART R NOT PRESENT below is only an example of where item is located COND TYPE 1 2HP FAN USDA TYPE 3 PT100 CHART R NOT PRESENT AUTO CONFIG OFF 104 Press the F4 to select CHART R NOT PRESENT Enter password Password is A NOTE To enter password Press F2 key press A key press F4 key press EXIT key Scroll up or down to select chart type being used Press and hold F4 for 5 seconds Chart Types Available 25 25 C 31 day 25 30 C 31 day 80 20 F 31 day Controller will now enter AUTO CONFIG test as unit configuration has been changed Setup is complete
128. ccess the Commands menu The first command in the submenu appears in the LCD display 3 Press the F2 or F3 key to scroll to Brief PTI TEST 4 Press the F4 key to start the Brief PTI test LCD display shows PTI test currently being performed PTI test ends automatically Press any key on the controller to return the unit to normal operation 70 See the following CRR Brief Pretrip PTT Test Procedure for a detailed description of the PTI Test Detailed PTI test results are stored in the MP 3000a Datalogger for later viewing Any alarm codes recorded during the test can be viewed through the controller s Alarm List menu at the end of the test NOTE All screens are NOT present on all units The screens that display on the Ce controller are determined by the Controller Software 0000 settings and the options S88 installed on the unit 0000 0008 pong n EA By MAIN MENU ALARMS DATA RMM STATE DATALOGGER CONFIGURATION MISC FUNCTIONS Commands Menu F4 COMMANDS PTI Test Power Management Manual Function Test EN Brief PTI Test z1 A Function Test Figure 37 Brief PTI Test Operating Instructions CRR Brief PTI Test LCD Display Description Possible Duration Alarms Time PTI START Activated 0 1A 0 0A 0 1A SENSOR TEST Activated 0 1A 0 0A 0 1A EVAP FAN LOW TEST SUP RET EVA 5 16 5 00 5 1C 1 1A 1 0A 1 1A EVAP FAN HIGH TEST SUP RET EV
129. ce RI 85 Configuration MENU nhe retur p rer goatee eka RR a ed aue e esa ated a 86 Viewing or Setting Functions lllieeseeeeeeee mh 86 Datalogger Men tira ia a ia al qp xt gd Se eit 88 Viewing the Datalogger Menu 0 2 0 ec RR 3r 88 Inspect Temp LO s rca reri pee tite ade VERDE petala Med wee as 89 Inspect Event Log ille nime uw etr ore Ra Xu xara E YI YE IE TEE UE EIE ete 89 Set Log Times 222 stb e a A uon PONENS denne Ae AE la puteus 90 Seta Trip Start osse eared A dra E E ene a GAA We ene ne dre n Ped ea ie 91 InspecEP TEEOQ Grace taste D o dd e RETE ue yeu d ae d ae ee eee 91 RMM State i e a a A A AA a ata 92 Viewing the RMM State Screen ocooocccccco hh 92 Manual Emergency Mode Operation oooocccocccoo tenets 93 Advanced Fresh Air Management AFAM or Advanced Fresh Air Management Plus AFAM Door Options 0 00 ce eee eee eee 94 Fresh Air Exchange System 0 00 cece lh mmn 96 Humidify System Option 0 0 0 enn ete 97 Partlow Model SR Recording Thermometer Option liliis 98 Saginomiya Model SKM Recording Thermometer Option 0 00 e eee eee ee 100 Electronic Chart Recorder for MP3000a Controllers 1 2 2 0 llli 103 Table of Contents Operating Instructions continued Recorder Installatiom ic ae cia aed an epe eid Ad a AS Ren Pisin mee o esr tla acess 103 Recorder Setup xcu fee erue Sanden a AA te Se ey 104 Main Mendy 2 3 E E E iii
130. ch Container air leakage doors open 175 Diagnosis Troubleshooting Status Messages Alarm Codes Defrost Time Too Long Check Alarm Heat signal has been ON for more than 90 minutes on 60 Hz power during Defrost 120 minutes on 50 Hz power Indicates Low power supply voltage Defective heater elements Defective evaporator high temperature protection switch Defective heat relay Evaporator fans running during defrost Evaporator sensor placed wrong esten Capacity Test 1 Error Check Alarm Occurs during Pretrip PTI test only Difference between supply and return air temperature is too small with low speed evaporator fans less than approximately 4 5C 8 F Return air temperature does not reach 18C 0 F within preset time Indicates ncorrect location of supply or return air sensor Air leakage at supply sensor cable Defective supply or return air sensor Interchanged sensor connections incorrect evaporator fan rotation or high speed operation Incorrect refrigeration system operation Container side panels defective damaged or leaking Evaporator Temperature Test Error Check Alarm Occurs during Pretrip PTI test only Evaporator coil temperature too high with no evaporator fans running above about 15 C 5 F Indicates Evaporator coil sensor is not in contact with evaporator coil Return and evaporator coil sensor connections are interchanged Expansion valve
131. ch rework a gauge manifold per High Pressure Cutout Manifold illustration Relief Valve P N 66 6543 O ring P N 33 1015 Adapter Tee Weather Head No 55 2X3 Figure 62 High Pressure Cutout Manifold 128 High Pressure Cutout Manifold 1 Connect the manifold gauge to the compressor discharge service valve with a heavy duty black jacketed thick wall HCA 144 hose with 6024 kPa 60 24 bar 900 psig working pressure rating 2 Operate the unit in Cool by performing an Capacity 100 test from the Manual Function Test menu of the controller 3 Raise the discharge pressure of the compressor by blocking the condenser coil airflow Temporarily cover the compressor compartment control box and power cord storage compartment with cardboard to reduce condenser coil airflow This should increase the discharge pressure enough to cause the switch to open When the switch opens The compressor and evaporator fans should STOP immediately NOTE The discharge pressure should never be allowed to exceed 2 760 kPa 27 6 bar 400 psig 4 Be sure to remove the cardboard installed in step 3 If the HPCO switch fails to stop compressor operation replace the switch and repeat steps 1 through 4 Condenser Fan and Evaporator Fan Rotation NOTE If both the condenser fan and evaporator fans are rotating backwards diagnose the automatic phase selection system Check Condenser Fan Rotation Check for proper condenser
132. coil If a heater element is suspected of malfunctioning check the resistance of each individual heater element by performing the following procedure 1 Turn unit power supply off 2 Remove unit power plug from power supply receptacle 3 Open the control box door 4 Test the insulation of each individual heater element a Test all 3 legs of the heater circuit to a good ground connection Connect a calibrated 500 Vdc insulation tester between each outgoing heater contactor terminal and ground b Ifthe resistance between any contactor terminal and ground is below 0 8 meg ohms isolate and check the resistance of each individual heater element S Electrical Maintenance Check the resistance of each individual heater element a Disconnect and isolate each heater from the circuit in the control box b Check resistance of each heater with an insulation tester between each heater and ground If the resistance between each heater and ground is below 0 8 meg ohms the heater element is defective On a loaded container remove the defective heater from service by disconnecting at the control box If the container is empty remove the evaporator cover from the rear of the unit and replace the heater or correct any defective wiring Repeat step 5a NOTE When repairing heater connections protect the new connections from the ingress of moisture with heat shrink tubing All heaters should be secured to prevent contact
133. compressor Unit in Heat or Defrost Unit in Cool with Low condenser temperature Water Pressure switch OPEN or Condenser Fan switch in WATER position Defective water pressure switch option Loose line connection Open motor internal thermal overload protector Defective motor Defective condenser fan contactor No condenser fan output signal from controller Increase line voltage to at least 90 of compressor motor rating Reduce line voltage to at least 110 of compressor motor rating Eliminate cause of short cycling Purge system Check condenser airflow condenser fan motor condenser fan grille water pressure switch option water flow rate option and water cooled condenser receiver tank optional Add oil to proper level Tighten mounting bolts Add oil or refrigerant charge Check expansion valve adjustment Replace bearings or motor Repair or replace compressor Check indicator lights If unit is in Heat or Defrost unit operation is normal no remedy required Check indicator lights condenser temperature and discharge pressure Condenser temperature may not require condenser fan operation no remedy required condenser fan also pulses On and Off on a 30 second cycle to control condenser temperature If unit is on water cooled condenser operation unit operation is normal For air cooled condenser operation water pressure switch must be CLOSED or Condenser Fan switch must be in FAN A
134. compressor discharge pressure rises above 2240 70 kPa 22 4 0 7 bar 325 10 psig the high pressure cutout opens to interrupt the ground circuit to the compressor contactor e Compressor STOPS immediately e Evaporator and condenser fans continue normal operation Controller determines that a high pressure cutout switch is open when the unit current draw decreases by 7 amps for more than 3 seconds e The controller LCD display shows a High Pressure Cutout message in the Misc Function Status menu High Pressure Cutout Check Condenser Probe or High Pressure Cutout Check Condenser Fan e The controller continues to call for cooling so the compressor will restart when the high pressure condition is corrected switch resets if power is available The high pressure switch resets closes when the pressure drops to 1590 70 kPa 15 9 0 7 bar 230 10 psig e Ifthe switch remains open for 5 minutes controller also activates Alarm LED and records Alarm 37 Total Power Consumption Too Low 51 Operating Instructions 6 FUSIBLE PLUG FOR HIGH PRESSURE RELIEF A fusible plug is installed in the receiver tank to avoid excessive pressure build up within the refrigeration system from extraordinary and unforeseen circumstances The plug blows when the plug temperature reaches 100 C 212 F The plug is located so that refrigerant pressure expelled from the valve would be directed away from anyone servicing th
135. condenser and evaporator coils Clean if necessary Use an air or water spray jet directed against the coil from the air discharge side Also inspect the condenser fan grille for damage If the grille is damaged or missing abnormally high head pressure may result Repair or replace the grille if necessary CAUTION Air or water spray jet pressure should not be high enough to damage bend coil fins Check the mounting bolts on the unit compressor and fan motors Tighten if necessary Clean the defrost drains Optional Inspect water cooled condenser receiver tank water lines and fittings for water leaks When water lines are disconnected also check to be sure that the water drains completely from the condenser receiver tank Report defective fittings and tanks that do not drain to a technician Optional Check water level in humidity system tank Add only demineralized or distilled water to prevent plugging of the atomizing nozzle Observe the unit for proper operation and functions during Pre load Operation Check to be sure the container ID that appears in the Configuration menu is correct Functional Inspection To properly perform a Full Pretrip Test on units equipped with a MP 3000a controller the container must be empty with the rear doors closed 1 Start the unit see Starting the Unit and Adjusting the Controller Setpoint on page 3 5 A second sequence start of the required loads occurs during
136. conds Plus 30 seconds Operating Instructions CRR Brief PTI Test LCD Display Description Possible Duration Alarms Time PTI PART 1 END SUP RET EVA 5 1C 5 0C 5 16 2 3A 24A 2 3A PTI PASS PRESS KEY FAIL PRESS KEY PTI Part 1 end is recorded in PTI log Unit will remain OFF until any key is pressed If alarms occurred during PTI LCD display shows PTI Readings may vary depending on voltage and temperature PTI Full Pretrip Test CAUTION The Full PTI test should only be performed on an empty container NOTE Units equipped with a water cooled condenser must be set to operate on air cooled condensing to perform a complete system capacity test The MP 3000a controller contains a special Full PTI pretrip test that automatically checks unit refrigeration capacity heating capacity temperature control and individual components including the controller display contactors fans protection devices and sensors The test includes measurement of component power consumption and compares test results to expected values The test takes up to 2 to 2 5 hours to complete depending on the container and ambient temperature NOTE Correct all existing alarm conditions and clear the alarm codes before performing a Full PTI test The controller will automatically clear all existing alarms before beginning the Full PTI test With the Unit ON OFF switch ON and the LCD display showing the standard displa
137. cron Meter When the Meter has stabilized the value indicated on the Micron Meter is the equilibrium pressure This reading must be 2000 microns or less NOTE The presence of refrigerant in the compressor oil may prevent a low vacuum reading from being achieved Compressor oil can continue to outgas for long periods of time 2 Ifthe vacuum level appears to stall above 500 microns back seat the discharge service valve and observe the Micron Meter 140 e A drop in pressure indicates that the compressor oil is out gassing and further evacuation is necessary An increase in pressure indicates that a leak exists or there is moisture in the system Perform a Pressure Rise Test and evaluate 3 Close valve V1 when the desired vacuum level has been reached 4 Wait five minutes and read the Micron Meter A system that is leak free and dry will remain below 2000 microns for five minutes e A system that rises above 2000 microns but stabilizes below atmospheric pressure is probably contaminated with moisture or has refrigerant out gassing from the compressor oil Additional evacuation is required e A system that continues to rise without stabilizing has a leak and must be repaired 5 Ifthe vacuum level remained below 2000 microns for five minutes the unit is ready to charge Pressure Rise Test Evacuate the system and close valve V1 With valves V3 and V4 open the pump is isolated and the system is hel
138. ction Test Sensor Check 1 Manual Function Test Power Management Power Management Sls m Power Limit Press F2 or Current Power Limit and F3 key to scroll to new Power Time appear in setting display Press F3 key to scroll to desired function 199 Power Time Type the new time in hours Press and hold F4 key until cursor stops flashing e Press F4 key
139. cuit 30 milliamps Indicates Defective motor or heater insulation to ground 182 Check cable No 3 between controller and relay board Check sensor resistance between pins 11 and 12 on plug J15 Resistance must be 20 000 ohms at 25 C 77 F Check cable No 1 between controller and relay board Check sensor resistance between pins 9 and 10 on plug J15 Resistance must be 100 000 ohms at 25 C 77 F Check cable No 1 between controller and relay board Carefully inspect actuator If actuator is hot check that the actuator sensor has been mounted correctly in p ins 11 and 12 on plug J15 If actuator is not hot check resistance between pins 5 and 6 on plug J11 Resistance must be about 17 Ohms Check voltage from pins 5 and 6 relays 2 and 3 Check cable No 2 between controller and relay board Enter Manual Function Test manual and test operate each motor and heater separately not when alarm occurs Diagnosis Troubleshooting Status Messages Alarm Codes Probe Error Check Alarm Occurs during Pretrip PTI test or Probe Test failed in Chilled mode Temperature difference between return air and evaporator coil sensors is too high 1 5 C 2 7 F difference maximum Probe Error Check Alarm Occurs during Pretrip PTI test or Probe Test failed in CHilled mode Temperature difference between return air and supply air sensors is too high 0 8 C 1 5 F Probe Error Check Alarm
140. curs a manual emergency mode function can be used to operate the unit However the unit must be manually cycled ON and OFF using the unit 460 380V main circuit breaker This is because manual control disconnects both the controller and Unit On Off switch from the main relay board Manual control offers a selection of six operating positions Position 1 Cool 1 Continuous cooling with condenser fan operation and high speed evaporator fan operation Position 2 Cool 2 Continuous cooling with condenser fan operation high speed evaporator fan operation and continuous liquid injection Position 3 Not in Use Position 4 Not in Use Position 5 Defrost Heaters are activated evaporator fans off Position 6 Heat Evaporator fans operate at high speed to introduce fan motor heat only into the container no electric heater operation CAUTION The unit must be cycled ON and OFF manually to maintain the desired temperature Use the 460 380V main circuit breaker to start and stop the unit monitor container temperature with an external thermometer NOTE The unit cooling capacity on Chill loads can be reduced by almost closing the suction service valve when Cool 1 is selected If the compressor overheats select Cool 2 MANUAL CONTROL 1 COOL 1 4 NOT IN USE 2 COOL 2 5 DEFROST 3 NOT IN USE 6 HEAT 509 1174 3A87370H01 REVA AJA1292 Decal for J501 jumper B Decal for J18 jumper Figure 44 Manual Emergency Contro
141. d EF1 and EF3 Resistance readings should be equal High speed about 6 Ohms total of 2 motors Low speed about 20 Ohms total of 2 motors Enter Manual Function Test and start condenser fan make sure the fan starts Check fan motor volts and amps Condenser Fan Current Too High Check Alarm Occurs during Pretrip PTI or Function test only Condenser fan power consumption is 2596 above expected current draw above 1 5 to 1 9 amps depending on voltage Check power supply volts and amps Check volts and ampere meter Indicates Defective or stuck condenser fan motor Defective volt or amp meter on relay board ncorrect motor or motor connections 174 Diagnosis Troubleshooting Status Messages Alarm Codes 17 Condenser Fan Current Too Low Check Alarm Enter Manual Function Test and start condenser Occurs during Pretrip PTI or Function test only fan Make sure the fan starts Check fan motor volts and amps Condenser fan power consumption is 2596 below Check d expected current draw below 0 5 to 0 7 amps eck power supply volts and amps depending on voltage Check volt and ampere meter Indicates Defective condenser fan motor relay Defective or open fan motor internal over temperature protection switch Defective volt or amp meter on relay board Power Supply Phase Error Check Alarm Enter Data menu and view voltage reading on One or more frequency inputs are missing for each phase
142. d under a vacuum If the Micron Meter rises one of the following conditions exist Leak Watch the movement of the Micron Meter needle If the needle continues to rise until it reaches atmospheric pressure it is an indication that a leak exists somewhere in the system When a leak is in a system the vacuum will eventually stabilize at atmospheric pressure see graph Constant Pressure Rise After Evacuation Indicates System Leak below Refrigeration Maintenance required for R 134a units e Gestatestvave TE a TwoseesveeumPune EN Senso Figure 77 Evacuation Station and Unit Hook Up 141 Refrigeration Maintenance Moisture When the needle indicates a rise and then stabilizes at a level below atmospheric pressure it is an indication that the system is vacuum tight but is still wet and requires additional dehydration and pumping time see graph Pressure Rise Levels Off After Evacuation Indicates Moisture in System below Factors Affecting the Speed of System Evacuation It is almost impossible to state the exact amount of time required to evacuate any system Some factors that can influence evacuation time are listed below e System size e Amount of moisture contained in the system e Ambient temperature e Internal restrictions withi
143. datalogger memory If the unit power supply is disconnected the datalogger will continue to register 120 temperature logs except humidity sensor when battery voltage is above 11 4 volts These will be maintained until the unit is re connected to power and the battery automatically re charged Trip data can be retrieved but not erased from the datalogger memory using a DRU II or SmartSponge handheld data retriever or a REFCON power line remote monitoring system DRU II data transfer rate based on a 1 hour log interval is about 15 seconds per month of event logs and about 70 seconds per month of temperature logs For example downloading 90 days of data logs would take about 95 seconds for event logs only and about 210 seconds for temperature logs only Trip data from separate units is denoted by the identification information entered into the controller at the beginning of the trip via the general purpose keypad Identification data may include the container ID number location B R T contents loading data voyage no ship load port discharge port and comments The container ID number is stored in the Configuration submenu Chill Loads Setpoint at 9 9 C 14 1F and Above The unit operates on Cool with Modulation and Heat to provide accurate control of chill loads During Cool with Modulation the controller uses a proportional integral derivative PID algorithm and a KVQ valve to provide accurate control of the co
144. de set to OFF Chill Loads HIGH speed fans Frozen Loads LOW speed fans Economy Mode Operation Economy Mode set to ON Chill Loads Fans switch from HIGH speed to LOW speed when temperature is in range Frozen Loads LOW speed fans during cooling Fans are OFF during Null mode but operate on LOW speed for 5 minutes every 45 minutes 2 Liquid injection valve Chill Mode When the KVQ valve setting is less than 5 C 8 9 F below the return air temperature the controller energizes liquid injection valve for 6 seconds every 60 seconds regardless of the compressor discharge temperature Compressor High Temperature Protection When discharge temperature is between 115 C and 125 C 239 F and 257 F the valve pulses open on a 60 second duty cycle Valve energizes open for 2 to 60 seconds depending on the discharge temperature and the KVQ valve setting 3 Condenser fan pulses ON and OFF on a 30 second duty cycle to maintain a minimum condenser temperature Chill Loads Controller maintains a minimum30 C 86 F condenser temperature Frozen Loads Controller maintains a minimum 20 C 68 F condenser temperature NOTE Condenser fan does not operate when COndenser Fan Switch is on WATER or when the water pressure switch option is OPEN 4KVQ valve MODULATES whenever unit is in a Power Limit mode or is cooling at setpoints 9 9 C 14 4 F and above 119 Operating Theory 5 Controller energizes electric heaters for
145. decreases to setpoint Frozen Arrival temperatures are recorded in PTI log PTI End are recorded in PTI log and a Trip Start is automatically activated Unit will remain OFF until any key is pressed If alarms occurred during PTI LCD display shows PTI FAIL PRESS KEY 30 to 60 seconds 1 or 2 hours maximum 5 seconds 120 minutes maximum 30 minutes maximum 90 minutes 180 minutes maximum Function Test The MP 3000a controller contains a special function test that automatically tests individual components including the controller display sensors condenser fan evaporator fan compressors etc The test includes measurement of component power consumption and compares test results to expected values NOTE The function test does not test the actual performance of the complete system Therefore it is not a pretrip test and should not be used instead of the PTI test With the Unit ON OFF switch ON and the LCD display showing the standard display setpoint 1 Press the F2 or F3 key to enter the menu list Repeatedly press F2 key to scroll through Main menu until COMMANDS appears in LCD display 2 Press the F4 key to access the Commands menu The first command in the submenu appears in the LCD display 3 Press the F2 or F3 key to scroll to FUNCTION TEST 4 Press the F4 key to start the Function test LCD display shows functional test currently being performed Function tes
146. display g Press any key to unlock the controller display screen Power Element Assembly Replacement The recording thermometer s power element is field replace able To replace the element assembly 1 Raise the stylus away from the chart Remove the knurled chart nut and chart 2 Remove the recording platen 3 Loosen five mounting screws that mount the capillary holding plate and element assembly in the recorder Remove the power element assembly includes recording pen assembly 4 Remove the old sensing bulb and capillary from the unit 5 Install the new sensing bulb and capillary in the unit The capillary of the new thermal element may be bent but DO NOT bend the bulb 6 Install the capillary in the recorder and securely tighten five mounting screws 7 Replace the recording platen recording chart and chart nut Lower the recording pen 8 Check the calibration of the recorder Recalibrate the recorder if necessary Timer Quartz Motor and Reducing Gear Replacement The quartz motor is field replaceable To replace the motor and reducing gear assembly 1 Raise the stylus away from the chart Remove the knurled chart nut and chart 2 Remove the recording platen 3 Loosen the two terminal screws on the terminal board and remove the motor wires 102 4 Loosen the five screws that mount the motor assembly in the recorder Remove the motor assembly 5 Install new motor assembly Install
147. does not open enough or opens too much 176 Initiate a manual defrost and check amperage draw and evaporator coil temperature Evaluate defrost performance Open evaporator door and check location of evaporator coil sensor NOTE This alarm can be activated at low voltage and very low box temperature conditions even under normal operating conditions Enter Manual Function Test and start evaporator fans on LOW speed Then select Sensor Checks test and operate fans 2 to 5 minutes Check supply return and evaporator coil defrost sensor temperatures Sensor readings should be the same evaporator coil may be 0 5 C 1 0 F lower due to fan motor heat NOTE This sensor check does not detect air leakage around the sensor cables Open evaporator door and inspect evaporator fan rotation Make sure fans are rotating correctly on low speed Check the sensor connections Enter Manual Function Test menu Start and check current draw of the following components separately and together compressor compressor 100 condenser fan and evaporator fans low Check discharge and suction pressure readings Also check the refrigerant charge NOTE This alarm can be activated in ambient temperatures below 10 C 14 F even under normal conditions Check evaporator coil sensor location Check evaporator coil sensor and return air sensor connections Check expansion valve superheat setting Diagnosis Troubleshoo
148. e DEF key Enter R by pressing the F4 key then pressing the PQR key Enter M by pressing the F2 key then pressing the MNO key Enter O by pressing the F4 key then pressing the MNO key Figure 27 Text Keys Navigating the Controller Operating Menu Navigating the Controller Operating Menu The MP 3000a contains an extensive operating menu The menu is navigated via the controller keypad The Main menu is divided into eight major areas e Setpoint e Alarm List e Data RMM State e Datalogger e Configuration e Misc Functions e Commands A complete listing of the controller operating menu is located on an 11 x 17 fold out in the Wiring and Diagram section in the back of the manual see last page in book It is designed to be folded out so you can continuously view it as you are learning how to navigate the MP3000a Controller Menu It is recommended to fold this menu out and leave it folded out until you become familiar with the controller menu Menu Scrolling Keys Moving through these eight menus their submenus and entering commands requires the use of four keys Press the F1 key each time you want to F1 J exit a submenu shown in the message display Press the F2 or F3 key each time you want to scroll up or down in a menu or submenu shown in the Message Display or scroll forward or backward in a menu line F4 key Press the F4 key to enter a new F4 J menu or submenu to
149. e Ee E oa ars 155 Condenser Fan Blade Placement 00 0 cece ete eee eee 156 Evaporator Fan Blade Placement 0 00 e eee ett ete 157 Safety Instructions General Precautions e Always wear goggles or safety glasses Refrigerant liquid and battery acid can permanently damage the eyes e Never operate the unit with the discharge valve closed Never close the compressor discharge valve with the unit in operation e Keep your hands clothing and tools clear of the fans when the refrigeration unit is running If it is necessary to run the refrigeration unit with covers removed be very careful with tools or meters being used in the area e Check the condition of the gauge manifold hoses Never let the hoses come in contact with a fan motor blade or any hot surface e Never apply heat to a sealed refrigeration system or container e Fluorocarbon refrigerants produce toxic gases in the presence of an open flame or electrical arc The gases are severe respiratory irritants capable of causing death e Firmly tighten all mounting bolts Check each bolt for correct length for their particular application e Use extreme caution when drilling holes in the unit The holes may weaken structural components Holes drilled into electrical wiring can cause fire or explosion Holes drilled into the refrigeration system may release refrigerant e Use caution when working around exposed coil fins The fins can cause painful
150. e compressor discharge tempera ture and the temperature control algorithm High pressure gas High pressure liquid Low pressure gas Low pressure liquid Condensing high pressure gas o Low pressure vaporizing liquid Liquid refrigerant injection Modulated pressure 197 Dehumidification Flow and Pressure Diagram Flow and Pressure Diagram CRR 40 Dehumidification NOTE At setpoints below 5 C 41F dehumidification is not energized 32 Dehumidify Solenoid Valve DSV Is anormally OPEN valve If the container humidity is 2 or more above the humidity set point and the KVQ valve has reduced cooling capacity by about 25 the controller will energize CLOSE the normally open sole noid This closes refrigerant distribution to 50 of the evaporator coil thereby lowering the temperature of the active part of the coil and condensing more moisture from the container air Electric Heaters If the container humidity is 5 or more above the humidity set point and the KVQ valve has closed to reduce cooling capacity by about 50 the controller will pulse the electric heaters ON and OFF in addition to energizing closing the dehumidify sole noid valve This increases the cooling load on the evaporator coil thereby lowering the temperature of the entire coil and condens ing more moisture from the container air Humidity Sensor rH The humidity sensor is located at the top right hand side of the evaporator fan deck a
151. e high evaporator temperature switch Defective heater element or heat relay Defective wire connection Incorrect heaters or heater connections Evaporator Fan high Speed Current Too High Check Alarm Occurs during Pretrip PTI or Function test only Evaporator fan power consumption is 2596 above expected current draw above 2 0 to 3 0 amps depending on voltage Indicates Defective or stuck evaporator fan motor ncorrect motor or motor connections Defective volt or amp meter on relay board Enter Manual Function Test and turn heaters ON Make sure the heat relay energizes Check current draw on each phase Current draw should be 4 4 on each phase at 400V 5 1 amps at 460V If heat relay fails to energize check evaporator high temperature switch Switch should be closed at temperatures below 54c 130F there should be continuity between pins 5 and 6 in plug J19 Check cable No 2 between controller and relay board Check heater resistance between H1 and H2 H2 and H3 and H1 and H3 Resistance should be about 99 ohms on each leg Check volt and ampere meter Open evaporator door and make sure all fans rotate freely Enter Manual Function Test and start evaporator fans on High speed Make sure all fans start on high speed Check fan motor volts and amps Check volt and ampere meter NOTE If both alarms 10 and 11 are activated the alarms are caused by a large difference in measured amps Enter M
152. e needle If needle shows a pressure rise but finally levels off to a much moisture Dehydration and additional evacuation time are required Pressure Vacuum Atmospheric Pressure Figure 79 Pressure Rise Levels Off after Evacuation Indicates Moisture in System Heat lamps electric heaters or fans can be applied to the compressor crankcase and other parts of the system to increase the temperature of the refrigerant and compressor oil Unit Charging from an Evacuated Condition 1 Close valve V4 2 Open the Gas Ballast valve located on top of the pump housing behind the handle 3 Stop the vacuum pump 4 The discharge valve remains mid seated 5 Connect the refrigerant tank with gauge manifold to the evacuation station see Evacuation Station and Unit Hookup in this chapter 6 Weigh the tank of refrigerant 7 Check the unit data plate for the required weight of refrigerant charge then subtract the amount of the charge to be input to your unit from the total weight of the tank of refrigerant This provides final tank weight after the unit receives a full system refrigerant charge 8 Set the refrigerant tank for liquid removal Open the hand valve on the tank 9 With the unit OFF open the gauge manifold hand valve and charge liquid refrigerant into the system 10 Close the refrigerant tank hand valve when the correct amount by weight of refrigerant has been added or if the system will take
153. e out of calibration Compressor suction or discharge valve inefficient Refrigerant overcharge Air in refrigeration system Dirty or restricted condenser coil Condenser fan not operating Condenser fan grille damaged or missing Condenser fan grille damaged or missing Condenser fan blade damaged High ambient air temperature Restricted filter drier or high side Defective high pressure gauge Repair leak and recharge No remedy Replace gauge Clean or replace leaking valve plates Purge system Evacuate and recharge Clean condenser coil See Condenser fan motor does not operate under Mechanical Diagnosis Repair or replace Repair or replace grille Replace fan blade No remedy Replace filter drier or clear restriction Replace service gauge Compressor loses oil Refrigerant leak Repair leak and recharge Compressor oil migrates to Short cycling system Rapid cycling between Cool Air short cycling through evaporator and Heat modes Defective controller or main relay board Short Cycling Evaporator pressure regulator KVQ valve stuck closed or defective See Unit short cycles under Mechanical Diagnosis Check and correct cargo load Diagnose main relay board and controller Replace defective component See Unit short cycles under Mechanical Diagnosis Repair or replace valve Hot liquid line Shortage of refrigerant Repair or recharge Expansion valve open too wide Adjust or replace expans
154. e recording platen on the recorder base and rotate clockwise to view setscrews Tighten four set screws that hold the platen in the recorder Replace the recording chart and chart nut on the chart drive shaft and tighten the chart nut finger tight Lower the pen by rotating the lifting arm counterclock wise and push the pen against the chart Recording Chart Replacement 1 To change the charts raise the stylus away from the chart by rotating the pen lifting arm clockwise 30 degrees and releasing the lifting arm The pen will remain in the raised position Remove the knurled chart nut from the drive shaft and remove the chart Install the new chart in the slot on the platen and on the chart drive shaft Position the chart edge under three hold down flanges Replace the chant nut loosely and rotate the chart so that the correct date and time are indicated by the arrow on the time scale plate Finally hold the recording chart in position and tighten the chart nut finger tight Lower the pen by rotating the lifting arm counterclock wise and pushing the pen against the chart Operating Instructions Marking System Calibration 1 Visually inspect the recording thermometer sensing bulb located in the evaporator near the return air grille Make sure it is securely fastened and clear of debris Start the unit and adjust the temperature setpoint to 0 C 32 F Operate the unit until the return air temperature reaches 0 C 3
155. e unit The plug is non repairable and requires no adjustment If the plug blows recover the remaining refrigerant charge and replace the fusible plug OVERLOAD PROTECTION The condenser fan motor evaporator fan motors and compressor motors include internal overload protection with automatic reset PHASE SEQUENCE SELECTION When the On Off switch is turned ON phase sensors on the main relay board determine the incoming power phase to ensure proper condenser and evaporator fan rotation Starting the Unit and Adjusting the Controller Setpoint A CAUTION Supply power connections 1 52 from the unit to the power source must always be made with the refrigeration Unit On Off switch and power supply Connect the unit power cord to proper power source e 460 380V power cord to 460 380V 60 50 Hz power source e For operation on 230 190V power insert the 460 380V power plug into the dual voltage transformer receptacle Then connect the 230 190V power cord to a 230 190V 60 50 Hz power source Turn the power supply On Off switch ON Switch the Unit On Off switch to ON position Check for condenser fan and evaporator fan motor operation see Condenser Fan and Evaporator Fan Rotation in the Electrical Maintenance chapter of this manual If the unit was properly pretripped correct condenser fan rotation will also indicate correct evaporator fan rotation Adjust controller setpoint to the desired temperatu
156. e valve to prevent nitrogen from entering the refrigerant charge 9 If no leaks are found evacuate the low side and recover the leak test gas see Refrigerant Recovery in the Refrigeration Maintenance chapter of this manual 10 Plug the heater and thermistor wire harnesses into the unit wire harness 1 Open the discharge valve Then open the liquid line service valve 146 12 Verify that all personnel are clear and connect main power plug to power supply Start the unit and check the refrigerant charge Add refrigerant as required Refrigerant Recovery CAUTION Use only refrigerant recovery equipment approved for and dedicated to R 134a recovery When removing any refrigerant from a Thermo King refrigeration system use a recovery process that prevents or absolutely minimizes the refrigerant that can escape to the atmosphere Typical service procedures that require removal of refrigerant from the unit include To reduce the refrigerant pressure to a safe working level when maintenance must be performed on high pressure side components To empty the unit of refrigerant when an unknown amount of charge is in the system and a proper charge is required e To empty the unit of contaminated refrigerant when the system has become contaminated NOTE Always refer to specific recovery equipment Operator and Service Manuals Vapor Recovery 1 Install a gauge manifold set on the unit Attach the ser
157. ective volt or amp meter on relay board Evaporator Fan Low Speed Current Too Low Check Alarm Occurs during Pretrip PTI or Function test only Evaporator fan power consumption is 25 below expected current draw below 0 6 to 1 2 amps depending on voltage Indicates Defective evaporator fan motor relay Defective or open fan motor internal over temperature protection switch Defective volt or amp meter on relay board Incorrect motor or motor connections Open evaporator door and make sure all fans rotate freely Enter Manual Function Test and start evaporator fans on LOW speed Make sure all fans start on low speed Check fan motor volts and amps Check volt and ampere meter Open evaporator door and make sure all fans rotate freely Enter Manual Function Test and start evaporator fans on LOW speed Make sure all fans start on low speed if a motor does not start and is very hot wait 10 minutes for internal over temperature Switch to close Check fan motor volts and amps Check volt and ampere meter NOTE If both alarms 12 and 13 or 14 and 15 are activated the alarms are caused by a large difference in measured amps Enter manual Function Test menu and operate evaporator fans on low and high speed Check the evaporator fan amps measurement If necessary check the resistance in the motors High speed between EF11 and EF12 EF12 and EF13 and EF11 and EF13 Low speed between EF1 and EF2 EF2 and EF3 an
158. eep the compressor ports covered to prevent dust dirt etc from falling into the compressor NOTE When the compressor is removed from the unit oil level should be noted or the oil removed from the compressor should be measured so that the same amount of oil can be added before placing the new compressor or repaired compressor in the unit Installation 1 Slide the compressor into the unit Install mounting bolts washers and nuts and tighten 2 Bolt the discharge valve to the compressor with a new gasket lightly coated with compressor oil Bolt the suction service valve to the compressor using a new O ring coated with compressor oil 3 Apply refrigerant locktite to the threads of the switches Install the switches Connect the wire connectors for the high pressure cutout switch 4 Connect liquid injection line to compressor body 5 Connect three phase electric power to the compressor 6 Pressurize the compressor with refrigerant gas same gas as that used in the system Check for refrigerant leaks around the compressor assembly and gasket connections 7 Tf no leaks are found recover the refrigerant used for the leak test see Refrigerant Recovery in this chapter Because this refrigerant gas will contain some air place it in a contaminated refrigerant bottle to be reclaimed later 8 After all pressure is removed from the low side and compressor hook up your evacuation equipment 10 11 12
159. efrost Sensor Location 2 0 00 cece eee eee 126 Evaporator Defrost Sensor Location 0 0 0 0 c cece teens 127 High Pressure Cutout Manifold 0 0c eet ete 128 Service Fittings Specifications 0 6 cts 131 Service Valve Back Seated o erigo era era cette teens 132 Service Valve Open to Port 0 ete 132 Service Valve Front Seated 20 0 cece tenes 132 Balancing the Pressure oooooccoocco tees 133 Removing Refrigerate rien e e e r ae tte teen E 133 Gauge manifold Closed to Center Port 0 cece ee 133 Gauge Manifold Open to Center Port llli 133 Charging the System 00 cee eh mr rh m 133 Purging Ga ge Manifold se ose ber eue a br Ee ERR RR A ee add 134 Adjusting Compressor Oil Level o ooocococcccoc RR A 135 Testing for Refrigerant Leaks 0 0 cece hh 136 Standard Receiver Tank 0 02 cee etn hm 138 Water Cooled Condenser Receiver Tank with One Sight Glass 000 e eee eee 138 Evacuation Station and Unit Hook Up 0 0 0 cette eee 141 Constant Pressure Rise after Evacuation Indicates System Leak 00000 e eee eae 142 Pressure Rise Levels Off after Evacuation Indicates Moisture in System ss 142 KVQ Valve uut erm eh at ee PRAE RR RUE NOR IN desi Ires de qu qe qued 145 Typical Pressurized Gas Bottle with Pressure Regulator and Gauges LL 147 Mounting Bolts stro Seen A ihe e p ue x
160. en connection on one phase of power supply to a motor or heater element Operate unit on Cool and check discharge and suction pressure gauge readings Enter Manual Function Test menu and test operate Injection Valve to determine if valve opens energizes Check compressor discharge sensor resistance Resistance must be 100 000 ohms at 25 C 77 F Check discharge line temperature with a separate electronic thermometer and compare to HIGH PR TEMP shown in the Data menu of controller NOTE Unit will operate normally without compressor sensor However controller compressor high temperature protection is not active Visually inspect the vent door and linkage for ice or obstruction Check for proper linkage adjustment Check wiring connections to the AFAM circuit board for continuity using a high quality multimeter Check motor winding for continuity using a high quality multimeter Start a Function Test During step F1 05 check whether the phase relays on relay board receive a signal LED energizes Verify that the relays respond and shift to reverse phase Enter Manual Function Test menu and test operate each 3 phase component to locate defective connection Diagnosis Troubleshooting Status Messages Alarm Codes Humidity Sensor Error Check Alarm Occurs during Pretrip PTI test only Relative humidity reading not between 20 and 95 Indicates e Sensor disconnected Wrong control
161. ent from the recorder case Care must be taken not to bend the hex shaft which extends from the recorder case 2 Remove the old sensing bulb and capillary from the unit 99 Operating Instructions 3 Install the new sensing bulb and capillary in the unit The capillary of the new thermal element may be bent but DO NOT bend the bulb 4 Install a new thermal element in the recorder case 5 Replace the element flange screws D and tighten securely 6 Check the calibration of the recorder Recalibrate the recorder if necessary Saginomiya Model SKM Recording Thermometer Option The 31 day Saginomiya Recorder is electric motor driven by a dry cell type battery with a 1 year life expectancy The sensor bulb is mounted in the evaporator to record the return air temperature The recording thermometer should be inspected and cleaned to ensure that the stylus produces smooth clean lines and records accurate temperature readings Battery The recording chart is driven by a battery powered quartz motor and reducing gear The battery charge should be checked during unit pretrip inspection or once a month To check the battery charge press the button the voltage indicator e Blue Zone Battery good If the indicator needle remains in the blue zone when the test button is depressed the battery has sufficient power to operate the recorder White Zone Replace battery within 30 days If the indicator needle
162. enter the Main Menu 2 Press F2 key to scroll through Main Menu until CONFIGURATIONS appears in LCD display 3 Press F4 key to access the Configurations screen Configurations screen appears with cursor in the In Range menu line 4 Press F3 key to scroll cursor to AFAM UNITS 5 To set a new value press F4 key The Password screen appears Operating Instructions 6 Enter the password Press F2 key A key 8 When the desired value appears in the display password is A F4 key and then EXIT key press and hold the F4 key until the cursor An Enter Arrow appears in the hourmeter line stops flashing The new value appears in the menu line 7 Press the F3 key to toggle the value to the desired setting default is M3 9 Press ESC key to exit the Configurations y screen M3 Cubic Meters per Hour e CF Cubic Feet per Minute PERCENT Note All screens are not present on all units The screens that display on the x controller are determined by the Standard Display Configuration Controller Software setting and the Menu options installed on the unit CONTAINER ID IN RANGE CONTRAST UNIT TYPE DEHUM VALVE 7 4 Configuration ESC Submenu REEFER TYPE F1 Current function setting appears in display ZERO CURRENT Press F4 key to change a setting SUPPLY LH Press F2 key A key password F4 key and Exit key AFAM OPTION Type a new value or pres
163. epartment of Agriculture use in monitoring Cold Treatment shipments 28 Figure 6 Water Cooled Condenser Receiver Tank Water Cooled Condenser Receiver Tank Optional A water cooled condenser receiver provides the unit with above and below deck operating capabilities Condenser fan control can be provided by a Condenser Fan Selection switch or a Water Pressure switch The Condenser Fan switch is provided on the control box with the water cooled condenser option Place the Condenser Fan On Off switch in the Water position for water cooled condenser operation Unit Description Features and Options AJA1550 1 Evaporator Access Door 40 08 in Wide with two Power Cord Storage Compartment latches Models with two evaporator fans Condenser Fan Fan Condenser Fan ss Control Box aaa Control Box Box 3 Compressor Compartment Rear Download and USDA Receptacle Panel Access from inside container Supply Air Sensor Probe Holder Left Hand Fresh Air Exchange Vent Next to compressor 5 Supply Air Sensor Probe Holder Right Hand Figure 7 Unit L View CRR 29 Unit Description Features and Options AJA1551 Return Air Sensor Evaporator Fan Blade Evaporator Fan Motor Figure 8 Evaporator Front View CRR 30 Unit Description Features and Options AJA1553 Remote Monitor Modem
164. epeatedly press F2 key to scroll through Main Menu until COMMANDS appears in LCD display 2 Press F4 key to access the Commands menu The first command in the submenu Defrost appears in the LCD display 3 Press F2 or F3 key to scroll to Manual Function Test 4 Press F4 key to enter the Manual Function Test CONDENSER OFF appears in the LCD display 5 To test a unit component a Press F2 or F3 key to scroll to desired component test Condenser Sensor Check Low Sensor Check Zero Current Heat e AFAM Close e AFAM Open e Dehumidity Valve e Injection Valve e Capacity 100 e Capacity 50 e Capacity 25 80 Compressor Sensor Checks Probe Test Operates high speed evaporator fans only After 5 minutes check the temperatures of the left and right hand supply sensors return sensor and defrost sensor Temperatures should be approximately equal b Press F4 key to start the component test LCD display will change the component state from OFF to ON c Verify component performance LCD display will show expected current and actual current on phase 1 2 and 3 d Press F4 key again to stop test LCD display will change component state from ON to OFF NOTE Controller returns unit to normal operation if no keys are pressed for 10 minutes Pressing 5 key extends test time by 10 minutes each time it is pressed maximum time 100 minutes Pressing any other key resets
165. er Option 0 00 cece teens 27 Remote Monitoring Modem RMM Optional 0 00 6 eect eens 27 Remote Monitoring Receptacle Option 4 Pin Optional 00 cece eee eee 28 TRANSFRESH Atmosphere Control System Options 00 000 cece cee eee 28 USDA Cold Treatment Temperature Recording 2 00 0 cee eee teens 28 Water Cooled Condenser Receiver Tank Optional naana cece eee eee 28 Controller Description ore rn a ee eee ree ee 43 Controller Description 00 eem PRIM ec EE REPRE E ieee bade eed oe ted ned ede ie 43 Temperature Status Display 2x5 a Rr does diate diets E ie pale aed edad ACER RR 44 Message Displays xr A A A eh ee A Pe Red rete ue RN XM 44 Four Special Function Keys uu ia ied deeds teeta LER Ran DEUX RA aN aes 44 Keypad hanced dupe de SS e Ai Pe tee aaah ab daa Meats ad 4 45 Navigating the Controller Operating Menu 0 600 cece e eee eee eee hn 47 Navigating the Controller Operating Menu 0 2 0 etna 47 Menu Scrolling Keys ecne eii a a a a E A eR RR RR RH hh hh 47 Operating Instr ctions 1 11 11 1 ee eee eet eae elt te e nra ema tme emp cele 49 Unit Control BOX ut ure REM IMS EP Ate gata RC IM ied in e es 49 MP 3000a Controll t 54 153 a2c2 and anata nal a a e Ra p dn hu un Bee eae Pale DART ERN 49 Other Unit Controls ii 24 0 40 Impr NE e eeu ke es a s IN ERR EE 50 UNItINStUMENTS s za entree acted A AS ue Eua S RS 50 Unit Protection Devices i e vci we
166. er the menu list 2 Press F2 key to scroll through Main Menu until DATALOGGER appears in LCD display 3 Press F4 key to access the Datalogger menu Inspect Temp Log appears in the LCD display 4 Press F4 key to enter Temp Log LCD display shows the Log Time and the Setpoint Supply and Return temperatures of the most recent log in the first screen e To scroll through previous logs of the sensor temperatures currently in the display press F3 key All temperature logs recorded in the datalogger memory may be viewed on the LCD display 5 To view additional sensor log and event flag screens press F4 key again LCD display shows USDAI USDA2 USDA3 Relative Humidity rH Ambient etc e To scroll through previous logs of the sensor temperatures currently in the display press F3 key Event Flags for Temperature Log T Tripstart Activated P Primary Power Off D Defrost in Last Interval O Temperature Not In range h Humidity Control Active E Evaporator High Temperature H High Refrigeration Pressure d Defrost terminated on time limit e Economy mode activated s Reefer unit stopped after PTT w Water cooled operation water pressure switch is OPEN or Condenser Fan Switch is in WATER position Operating Instructions A Alarm in last interval NOTE All event flags that occurred during a log interval are displayed 6 Press ESC key to exit the Temp Log Inspect
167. er to operate the stylus with the door open for the purpose of checking or zeroing the control the lifter arm can be locked in this lowered position by pushing down on the lifter arm shaft and rotating the arm on its pivot point If the lifter arm does not retract away from the stylus when the door is closed reposition the arm on the shaft by loosening the Allen screw on the lifter arm 4 Hold the recording chart in position and tighten the chart nut finger tight 5 Lower the pen by rotating the lifting arm counterclock wise and pushing the pen against the chart If there is insufficient pressure on the stylus to mark the chart care fully grip the pivot end of the stylus warm where it is riveted to the stamping with a pair of long nosed pliers Bend the stamping toward the instrument Care must be used not to bend the stylus arm but only the stamping to which it is attached Marking System Calibration 1 Visually inspect the recording thermometer sensing bulb located in the evaporator near the supply air grille Make sure it is securely fastened and clear of debris 2 Start the unit and adjust the temperature setpoint to 0 C 32 F Operate the unit until the supply air temperature reaches 0 C 32 F Enter the Data menu on the controller display and view the supply air temperature screen Press the 5 key two times to lock the screen on the display for 10 minutes 3 Wait at least 5 minutes to allow the recording ther
168. erein Manufacturer is not responsible and will not be held liable in contract or in tort including negligence for any special indirect or consequential damages including injury or damage caused to vehicles contents or persons by reason of the installation of any Thermo King product or its mechanical failure Recover Refrigerant At Thermo King we recognize the need to preserve the environment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape into the atmosphere We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere In addition service personnel must be aware of Federal regulations concerning the use of refrigerants and the certification of technicians For additional information on regulations and technician certification programs contact your local Thermo King dealer Table of Contents able ot Contents 2 tits Sah ea ERU ALIA a ei Stee iie E 5 List Of Figures ite vee ee Reg ERR bebe tbe dbo bobo e a e ms 9 Safety Instructions iode A ee iO REOR Ris Rare II bare 11 General Precautions 2 22 4 224 la eM aia a ee te ei e rca 11 Refrigerant Oil Precaution v yu aud et eo AA PIN RP RE ERE Re Ra kate ARR Rs 11 Electrical Precautions zx prp ecb IRI Rie EST wa hee Ree ee Ter ED BW XE 11 PEecautlorns scchacksERimiazpAT pA hun ue ache hen au Leu acia 11 diccre 12 BOW Voltage s Ram RERO RR AED DM CEU RE AiO 12
169. estricted No water flow to water cooled condenser Defective water pressure switch option Expansion valve open too much Expansion valve power element lost its charge Expansion valve feeler bulb improperly mounted poorly insulated or making poor contact See Mechanical Diagnosis Repair leak and recharge Purge system Evacuate and recharge Diagnose main relay board and controller Replace defective component Adjust controller setpoint Remove compressor oil from compressor Defrost or clean evaporator coil Clear restriction Change filter drier Perform compressor efficiency test Check valves and pistons Repair or replace valve Clean condenser coil clear restriction or repair or replace fan motor or condenser fan blade Restore water flow to water cooled condenser receiver tank turn Condenser Fan switch to FAN AIR position or check water pressure switch option Replace switch Adjust or replace valve Replace power element Correct feeler bulb installation 163 Diagnosis Troubleshooting Status Messages Alarm Codes Head pressure too low NOTE This unit has a suction modulation capacity control system Suction and discharge pressures may drop below expected normal readings when the unit is in Modulation Cool control temperature within 10 C 18 F of setpoint or in Power Limit mode Head pressure too high Shortage of refrigerant Low ambient air temperature Service gaug
170. eting the defrost cycle operate the unit on COOL for a few minutes After 2 to 3 minutes observe the oil level The oil should be 1 2 to 3 4 up in the sight glass If the container is empty you can operate the unit on the heat cycle instead of the defrost cycle Adding Compressor Oil 1 Install gauge manifold set refer to Gauge Manifold Set Attachment and Purging Pump the compressor down refer to Low Side Pump Down 135 Refrigeration Maintenance 2 After stopping the compressor adjust the low side pressure to 21 kPa 0 21 bar 3 psig using the service gauge set Pressure measured at the suction line service port 3 Remove the cap from oil pressure fitting on oil pump 4 Using a commercial hand pump force oil in through the oil pressure fitting Slowly add oil and allow 5 to 10 minutes for the oil to flow down through the compressor into the sump Add Polyol Ester oil P N 203 433 ONLY 5 When the compressor oil sight glass is 1 2 to 3 4 full remove hand pump and replace the cap on the oil pressure fitting 6 Open the compressor suction service valve or liquid line service valve and operate the unit Recheck the refrigerant charge level and the oil level before returning the unit to service Removing Excess Compressor Oil Install an access valve actuator on the oil pressure fitting 2 Operate the unit and remove oil while watching the level in the compressor sight glass NOTE Heavy
171. f an accident First Aid IMMEDIATE action must be initiated after a person has received an electrical shock Obtain immediate medical assistance The source of shock must be immediately removed Shut down the power or remove the victim from the source If it is not possible to shut off the power the wire should be cut with either an insulated instrument e g a wooden handled axe or cable cutters with heavy insulated handles A rescuer wearing electrically insulated gloves and safety glasses could also cut the wire Do not look at the wire while it is being cut The ensuing flash can cause burns and blindness Pull the victim off with a non conductive material if the victim has to be removed from a live circuit Use the victim s coat a rope wood or loop your belt around the victim s leg or arm and pull the victim off Do not touch the victim You can receive a shock from current flowing through the victim s body 12 Check immediately for the presence of a pulse and respiration after separating the victim from power source If a pulse is not present start CPR Cardio Pulmonary Resuscitation and call for emergency medical assistance Respiration may also be restored by using mouth to mouth resuscitation Low Voltage Control circuits are low voltage 24 Vac and 12 Vdc This voltage potential is not considered dangerous Large amount of current available over 30 amperes can cause severe burns if shorted to ground
172. f feeler bulb on the side of the suction line Un tape and remove the feeler bulb from the suction line Heat and unsolder the suction line connections Lift the heat exchanger assembly from the unit Installation Clean the tubes for soldering Place the heat exchanger assembly in the unit and install the mounting hardware Solder the suction line connections NOTE It is strongly recommended that dry nitrogen be used to purge the system during any solder operations see Using Pressurized Nitrogen in this chapter If pressurizing with nitrogen front seat the discharge valve to prevent nitrogen from entering the refrigerant charge CAUTION Any time the discharge valve is front seated disconnect the unit power source the prevent accidental compressor start up Solder the liquid line connections Pressurize the low side and check for leaks see Refrigerant Leak Test Procedure in this chapter If no leaks are found recover the leak test gas see Refrigerant Recovery in this chapter Evacuate the low side see Evacuation and Cleanup of the Refrigeration System in this chapter Clean suction line to a bright polished condition Install feeler bulb in the feeler bulb clamps on the suction line Locate bulb on the suction line in former position The feeler bulb must make good contact with the suction line or operation will be faulty Cover with insulating tape Open the liquid line service valve
173. for 35 minutes Interval Timer Terminates defrost after 90 minutes at 60 hz operation if coil sensor has not terminated defrost 120 minutes at 50 Hz operation Power Off Turning unit On Off switch OFF terminates defrost Compressor Shutdown Auto Reset Stops Compressor 130 C 266 F Allows Compressor Start 90 C 194 F 21 Specifications Dehumidify and Humidify Systems Options Dehumidify System Turn Mode ON and OFF Set from CONTROL line of the Setpoint menu of the controller Control Range 50 to 98 Relative Humidity Setpoint Range HUMSP Setpoint adjustable from 50 to 98 Relative Humidity Humidify System Option Turn Mode ON and OFF Set from CONTROL line of the Setpoint menu of the controller Operating Temperature Range 0 to 60 C 82 to 140 F Control Range 50 to 98 Relative Humidity Setpoint Range HUMSP Setpoint adjustable from 50 to 98 Relative Humidity Air Compressor Output 2 5 m3 hr O 0 kPa 1 5 CFM 0 psig Humidity Tank Heater 240 600 Vac 55 to 70 Watts at 17 8 C 0 F Water Temperature Humidity Sensor Option Accuracy 1 5 between 55 and 75 Relative Humidity 3 0 between 75 and 95 Relative Humidity Output Range 4 to 20 milliamps 1 Relative Humidity 0 2 milliamp Physical Specifications Fresh Air Exchange Venting System Adjustable CRR40 0 to 280 m hr o to 165 ft min 60 Hz 0 to 232 m hr 0 to 136 ft min 50 hz Evaporator Fan
174. frost protection heat defrost and dehumidificatione Frost Protection cooling If return air temperature is within 0 3 C 0 5 F of setpoint heaters PULSE ON and OFF on a 60 second duty cycle Heat mode compressor OFF If supply air temperature is tool low heaters PULSE ON and OFF on a 60 second duty cycle Defrost mode Heaters are ON until evaporator coil temperature increases to terminate defrost 6 Dehumidification Option Dehumidify valve pre 2002 CLOSES energizes when humidity is more than 2 above setpoint and the KVQ valve has reduced cooling capacity by about 25 Electric heaters are also pulsed ON and OFF by controller when humidify is more than 5 above setpoint and the KVQ valve has reduced cooling capacity by about 50 40 at setpoint temperatures below 5 C 41 F Cool with Modulation 120 Controller calls for the Cool mode whenever the Control Temperature Differential based on supply air temperature is above setpoint Controller turns ON the Compressor LED when the compressor is operating Controller opens and closes KVQ valve to regulate the flow of refrigerant to the compressor The position of the valve balances the unit cooling capacity against the actual load requirements Controller turns ON the In range LED when the supply air sensor temperature is within 1 5 C 2 7 F of setpoint Supply air sensor control algorithm increases temperature control accuracy and protection agai
175. g compressor with a liquid injection system a microprocessor controller with integral data logger 2 speed evaporator fans and a fresh air exchange system Semi hermetic Reciprocating Compressor with Liquid Injection Cooling System The refrigeration unit includes a semi hermetic reciprocating compressor with forced feed lubrication system ambient compensated internal overload and high temperature protectors and a refrigerant injection system MP 3000a Controller The MP 3000a is an advanced microprocessor controller that has been specially developed for the control and monitoring of refrigeration units See Controller Description and Operating Chapter for more detailed information 1 AXA0340 MP 3000a Controller Figure 3 MP 3000a Controller Dual Speed Evaporator Fans All CRR40 models feature 2 speed motors The evaporator fans operate continuously to circulate air inside the container The fans operate on high speed for perishable cargo at set points of 9 9 C 14 1 F and above At setpoints of 10 C 14 F and below the evaporator fans operate on low speed for frozen cargo The evaporator fan low speed rpm is one half the high speed rpm NOTE If Economy Mode is ON Fresh Loads Evaporator fans operate on low speed when container temperature is in range Frozen Loads Evaporator fans stop during the Null mode controller operates fans on low speed for 5 minutes every 45 minutes 25
176. g so long as a slight positive pressure remains in the manifold and lines when removed from the unit 1 Inspect gauge manifold for proper hose and fitting connections 2 Clean dirt and moisture from around service ports 3 Remove small service port caps from suction and discharge service fittings Save and re use the caps and sealing washers or gaskets 4 Rotate both hose coupler hand wheels counterclockwise to back the stem out of the high and low hose fittings Then attach low hose compound gauge to the suction line valve port 5 With 69 kPa 0 69 bar 10 psig or greater pressure in the low side unit operating on Cool open the suction service manifold hand valve fully Then rotate the suction hose fitting hand wheel clockwise to open depress the suction line port valve to the low hose 6 Slowly screw a 1 2 inch ACME fitting into the low loss fitting on the manifold s service center line to purge the suction and service hoses Remove ACME fitting after purging 134 10 11 Suction Connection Discharge Connection Figure 72 Purging Gauge Manifold Close the suction service manifold hand valve fully to center port Attach high side hose pressure gauge to the discharge service line port Open discharge service manifold hand valve fully Then rotate discharge fitting hand wheel clockwise to open depress discharge line port valve to the high hose Slowly screw a 1 2 inch ACME fitting
177. gement feature of the Commands menu When the power management time interval expires the unit returns to the standard power limit control algorithm NOTE Setting power management current at 13 amps can be used to provide slow pull down of loads Operating Theory Evaporator Fan Control The controller determines evaporator fan motor speed based on the setpoint temperature and the Economy mode setting Chill Loads Setpoints of 9 9 C 14 1 F and Above When the Economy mode is set to Off the evaporator fans operate continuously on high speed Frozen Loads Setpoint at 10 0 C 14 0 F or Below NOTE When the Economy mode is set to Off the evaporator fans operate on low speed Low speed RPM is one half the high speed RPM Condenser Fan Control The controller also uses a proportional integral derivative algorithm to control the condenser temperature and ensure a constant liquid pressure at the expansion valve The condenser fan operates continuously in high ambients In low ambient conditions the controller pulses the condenser fan on and off to maintain a minimum condenser temperature The controller maintains a minimum 30 C 86 F condenser temperature on Chill loads and a minimum 20 C 68 F condenser temperature on Frozen loads 115 Operating Theory Probe Test The controller constantly monitors the left hand and right hand supply sensors return sensor and defrost evaporator coil sensor to determine w
178. ght glass e Ifthe balls FLOAT in the sight glass at any time R 134a charge is OK Ifthe balls DO NOT FLOAT R 134a charge may be low 137 Refrigeration Maintenance 1 Sight Glass Refrigerant charge is OK if ball floats at any time Fusible Plug Figure 75 Standard Receiver Tank 3 Operate the uniton MAXIMUM COOL for 5 minutes If necessary place the unit in COOL using the Manual Function Test menu start compressor condenser fan evaporator fans high or low and compressor 100 a Standard Receiver Tank e If the balls FLOAT in the sight glass at any time the R 134a charge is OK b Water cooled Condenser receiver Tank with one sight glass Ifthe balls DO NOT FLOAT in the sight glass at any time the R 134a charge is low e Ifthe balls FLOAT ALL THE WAY TO TOP of sight glass the unit is overcharged NOTE Inspect the unit for refrigerant leaks with a reliable leak detector if the unit is low on R 134a charge CAUTION When adding R 134a to the unit be careful not to OVERCHARGE the unit Standard Receiver Tank When the balls float in the middle of the sight glass stop adding refrigerant Water cooled Condenser receiver Tank When the balls in the sight glass float stop adding refrigerant 138 Refrigerant Level Air cooled Condenser Operation The refrigerant charge is OK if balls FLOAT at any time Water cooled Condenser Operation It is normal for the balls to float at t
179. gure 69 Gauge manifold Closed to Center Port Sl i C AJA1311 Quick Disconnect Access Valve Discharge Service Valve DSV Suction Service Valve SSV Figure 67 Balancing the Pressure AJA1316 Open Hand Valves Figure 70 Gauge Manifold Open to Center Port Quick Disconnect Access Valve 2 In 3 s Een Serio vaes L9 p Figure 68 Removing Refrigerant Quick Disconnect Access Valve Discharge Service Valve DSV Suction Service Valve SSV Figure 71 Charging the System 133 Refrigeration Maintenance Gauge Manifold Set With Low Loss Fittings Attachment And Purging Thermo King recommends the use of access valves or self sealing quick disconnect fittings whenever possible to limit the loss of refrigerant into the atmosphere A separate gauge manifold set with low loss fittings P N 204 758 should be dedicated for use with R 134a only Gauge hoses should also be dedicated to R 134a NOTE When any of these devices are used carefully check to ensure that access connections are functioning properly Gauge Manifold Set Installation NOTE The following procedure purges the gauge hoses and must be followed when using new gauges or hoses for the first time The system should be operating on Cool 10 psig 69 kPa or greater suction pressure when using this procedure to purge the low side hose Gauge hoses may be removed and re installed without additional purgin
180. h 11 Check Heater Current Too Low 12 Check Evaporator Fan high Speed Current Too High 13 Check Evaporator Fan High Speed Current Too Low 14 Check Evaporator Fan Low Speed Current Too High 15 Check Evaporator Fan Low Speed Current Too Low 16 Check Condenser Fan Current Too High 17 Check Condenser Fan Current Too Low 18 Check Power Supply Phase Error 19 Check Temperature Too Far from Setpoint 20 Check Defrost Time Too Long 22 23 24 25 27 29 32 33 34 35 43 52 53 54 56 57 58 59 60 68 69 97 98 99 109 110 111 112 115 116 117 Check Check Check Check Check Check Check Check Check Check Check Check Check Check Shutdown Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Check Operating Instructions Capacity Test 1 Error Capacity Test 2 Error Capacity Test 3 Error Evaporator Temperature Test Error Heat Capacity Test Error Liquid Injection Valve Error Condenser Air Sensor Open Circuit Condenser Air Sensor Short Circuit Ambient Air Sensor Open Circuit Ambient Air Sensor Short Circuit Return Air Temperature Too High Probe Error High Pressure Cutout Switch Off Error High Pressure Cutout Switch On Error Compressor Temperature Too High AFAM Control module or Motor Error Phase Sensor Error Delta Current Error Humidity Sensor Error AFAM Gas Analyzer Error Gas Analy
181. h voltage WARNING TURN POWER OFF BEFORE DISCONNECTING DATALOGGER OR CONTROLLER A WARNING H CONSULT MAINTENANCE MANUAL FOR H PRECAUTIONS BEFORE WELDING ON CONTAINER OR REFRIGERATION UNIT Disconnect all power to the refrigeration unit Disconnect all quick disconnect wire harnesses Switch ali of the electrical circuit breakers in the control box to the OFF position Weld unit and or container per normal welding procedures Keep ground return etectrode as close to tite area to be welded as practical This will reduce the likelihood of stay welding currents passing through any electrical or electronic circuits When the welding operation is completed the unit power cables wiring and circuit breakers must be restored to their normal condition 4 p tn Figure 1 Nameplate and Warning Locations Y i i AUA1 442 en Unit Nameplate Location Service Guide Service Guide The following service guide table should be used as a guide when inspecting or servicing A closely followed maintenance program will components on this unit help to keep your Thermo King unit in top operating condition Inspect Service These Items Perform a controller pretrip inspection PTI check A a eck condenser fan and evaporator an scaly inspect electrical contacts or damage or Teose connections Visa inspect wire hamesses for damage
182. he efficiency of the condenser coil by preventing the recirculation short cycling of warm air through the coil Abnormally high head pressures may result if this special condenser grille is damaged or missing Evaporator Coil Clean the evaporator coil by blowing low pressure compressed air from the bottom side of the coil upward opposite direction of normal airflow Inspect coil and fins for damage and repair if necessary CAUTION Air pressure must not be high enough to damage coil fins Defrost Drains Clean the defrost drains every 1 000 operating hours to be sure the lines remain open 156 Condenser Fan Location Place fan blade on motor shaft with hub located on the outside of the blade for proper airflow direction When mounting the fan blade and hub assembly on the fan shaft center the assembly in the orifice Position the front of the fan blade 10 mm 0 4 in in from the outer edge of the fan orifice AJA1336 Airflow Direction 10 mm 0 4 in Condenser Coil Condenser Fan Blade Condenser Motor Figure 83 Condenser Fan Blade Placement Servicing The Unit Evaporator Fan Location Place fan blade on motor shaft with hub located on the outside of the blade for proper airflow direction When mounting the fan blade and hub assembly on the fanshaft center the assembly in the orifice Position the front top of the fan blade hub 13 mm 0 5 in in from the outer edge of the fan orifice 3 4
183. he Event Log Set Log Time With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press F3 key to enter the Main Menu 2 Press F2 key to scroll through menu list until DATALOGGER appears in LCD display 3 Press F4 Key to access the Datalogger menu Inspect Temp Log appears in the LCD display 4 Press F2 or F3 key to scroll through submenu until Set Log Time appears in LCD display 5 Press F4 Key to enter Temp Log LCD display shows the current Log Time interval 90 To enter a new log interval press F4 key again with cursor in Log Time menu line Arrow appears in menu line Press F3 key to scroll through a list of log time intervals Minute 1 2 Hour Hour 2 Hour 4 Hour The logging of USDA sensors is fixed at 1 hour intervals to comply with USDA requirement A logging test of USDA sensors at 1 minute intervals is also possible for 72 minutes USDA data can not be downloaded during the logging test After 72 minutes controller returns to previous logging interval and clears USDA test data from datalogger memory When the correct log time appears in the menu line press and hold F4 key until cursor stops flashing The new Log Time appears in the display Press ESC key to exit the Temp Log Set a Trip Start With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 2 Press F
184. he top of the sight glass To check the refrigerant charge operate unit on air cooled condenser Figure 76 Water Cooled Condenser Receiver Tank with One Sight Glass Evacuation and Cleanup of the Refrigeration System Contamination Whenever contaminants have entered the system a thorough clean up is required to prevent damage or loss of compressor It is well known by the refrigeration service industry that the purpose of evacuation is to remove moisture and air from the refrigeration system before charging with new refrigerant after a system has been opened The importance of thorough evacuation and system preparation cannot be over emphasized Even infinitesimal quantities of air or moisture in a system can cause severe problems We know that the presence of moisture oxygen and heat under certain conditions can result in many forms of damage Corrosion sludge copper plating oil breakdown carbon formation and eventual compressor failure can be caused by these contaminants Things that will contaminate a system are in order of importance e AIR with oxygen as a contaminant Oxygen in the air reacts with the oil The oil begins to break down and can eventually lead to carbonization in the compressor and acid buildup The longer this breakdown process goes on the darker the compressor oil becomes until finally the color is BLACK indicating major system contamination e MOISTURE Moisture in a system will c
185. hen to initiate a demand defrost If a demand defrost is requested and defrost has occurred within last 90 minutes the controller initiates a Probe Test to check for a defective sensor During a Probe Test the LCD display shows Probe Test Please Wait The controller operates the unit on high speed evaporator fans only for 5 minutes All sensor temperatures are then compared e Sensors with large temperature differences are discarded from the control algorithm The controller then activates the appropriate Alarm codes to identify the defective sensor s e f no sensors are found defective controller LCD display shows Running with High Supply Difference message Sensor errors recorded during a Probe Test are cleared when the next Defrost is initiated or Unit On Off switch is turned OFF NOTE A manual Probe Test can be performed by a technician by selecting Sensor Check from the Manual Test Function menu Dehumidify Mode Option NOTE At setpoints below 5 C 41F dehumidification is not energized During Chill mode operation a dehumidification system is available to reduce the relative humidity in the container to the desired humidity setpoint The Dehumidify Mode option is turned on from Setpoint menu of the controller The relative humidity can then be controlled between 60 and 95 However the setpoint is adjustable from 0 to 99 from the Setpoint menu NOTE The use of the Dehumidify Mode should be esta
186. in cool until the return sensor is less then 15 C 59 F or 1 hour If the return air temperature is below 5 C 41 F unit operates in heat until return temperature is above 5 C 41 F or 2 hours With compressor and condenser fan on compressor is operating at 100 percent capacity Amp draw is measured and compared to voltage Compressor amperes are recorded in PTI log If compressor has been off for last 18 hours less than 30 seconds on a compressor sequence start occurs With compressor condenser fan and evaporator fan on and operating at 100 capacity Capacity is reduced to 25 An amp difference of 1 2 is required With compressor on evaporator fan operates on high speed until high pressure cutout occurs or condenser temperature is above 75 C 167 F Condenser fan starts and operates until compressor starts With condenser fan on compressor on and evaporator fans on high speed cool capacity is set to 100 percent capacity Liquid injection valve is turned on A difference of approx 4 5 C 40 1 F is required between return and supply air temperatures depending on return air and condenser coil temperatures Liquid injection valve is turned on for three seconds off for three seconds and on for three seconds to verify valve operation Readings may vary depending on voltage and temperature 72 10 11 10 seconds 30 to 60 seconds 1 or 2 hours maximum 30 seconds 240 seconds maximum 10 to 60 se
187. in the LED display NOTE When the setpoint appears in the LED display both the Return and Supply LEDs are lit The LED then shows the controlling air sensor temperature The controller senses the incoming power phase and selects the correct power phase to unit components The evaporator fan motors start about 40 seconds after the unit was turned ON Evaporator fans operate on high speed at setpoints of 9 9 C 14 1 F and above Evaporator fans operate on low speed at setpoint temperatures of 10 C 14 F and below e About 10 seconds later the compressor starts and the liquid line solenoid energizes opens if the controller calls for cooling The condenser fan then starts if the condenser temperature requires condenser fan operation On units equipped with a water cooled condenser the water pressure switch must also be CLOSED or the Condenser Fan Switch on FAN AIR position e Ifthe controller calls for heating the electric heaters are pulsed On and Off to provide heat e The controller turns ON the In range LED when the controlling sensor temperature is within 1 5 C 2 7 F of the setpoint NOTE If the compressor has been off for more than 18 hours the controller performs a compressor sequence start See Compressor Sequence Start on page 114 for further details NOTE Random time delays during the initial unit start up minimize peak current draw Loading Procedure 1 Make sure the Unit On
188. ings Attachment And Purging eee eee 134 Checking Compressor Qil ss ao iue sete Bh hath e adi Sloe IE 135 Refrigerant Leak Test Procedure 0 cect nnn teen eeeee 136 Low Side Pump Down ati ee pean sae pe BE Sa Da eee SE ee ee ee es da 137 Refrigerant Charge imita ara Reigate aed blo Aa ii ee Ad a esc 137 Evacuation and Cleanup of the Refrigeration System 0 00 cee eee 138 Evaporator Pressure Regulator KVQ Valve 0 cette en 144 Refrigerant Recovery co 146 Using Pressurized Nitrogen 00 RR 9 hn 147 Compressor Replacement 0 00 ccc hr mre 148 Condenser Coil Replacement a e pai are mr m 149 Filter Drier In line Filter Replacement 0 0 0 0 ccc RII IM 149 Table of Contents Refrigeration Maintenance continued Expansion Valve Replacement 0 0 cece ete teen eens 150 Heat Exchanger Replacement 0 0 cece tenet eens 150 Receiver Tank Replacement 0 0 0 cece eee rr hn 151 High Pressure Cutout Switch Replacement 000 cee ttt 152 Liquid Line Solenoid Valve Replacement 0 000 cece tee e eee 152 Liquid Injection Valve Replacement lssssseseeeee er hmm 153 Dehumidify Valve pre 2002 Replacement 000 cee ttt e 153 Servicing The Unit 22 od ei LII suelo lta eben Sate at tt tape Parada aT da NI 155 Mounting BOlIS 2 2 452 9 LEGE A RR RR RES RR EN ce Roe 155 Unit InspectlOn ux e
189. int menu is the setpoint temperature Press F2 or F3 key to scroll up or down through the menu list NOTE Press the 5 key to increase the display time of the current LCD data screen by 5 minutes Maximum display time is 30 minutes for data screens and 100 minutes for manual tests Keypad The keys are used to scroll through the Controller menu and enter text and numeric characters Menu Scrolling Keys Display menus The MP 3000a controller contains an extensive display menu that can be navigated via the 4 menu scrolling keys on the keypad The display menu is organized into eight main menus General text keys F1 F2 F3 and F4 also include directional arrows for entering and scrolling through the controller Main menu AJA1977 Figure 25 Menu Scrolling Keys on Keypad e F1 key ESC indicates that pressing the F1 key moves the cursor out of exits a menu list e F2key Forward Up Arrows indicate that pressing the F2 key scrolls the cursor forward and or upward through text boxes and menu lists e F3key Backward Down Arrows indicate that pressing the F3 key scrolls the cursor backward and or downward through text boxes and menu lists F4 key Enter Arrow indicates that pressing the F4 key moves the cursor into the next menu level or into a menu item text box e Setpoint Menu Alarm List Menu Data Menu e REFCON Remote Monitoring RMM State Controller Description e Data logger Menu e Miscell
190. ion valve Frosted liquid line 164 Liquid line service valve partially closed or restricted Restricted filter drier Open valve or remove restriction Replace filter drier Unit in vacuum Frost on expansion valve only High suction pressure Low suction pressure NOTE This unit has a suction modulation capacity control system Suction and discharge pressures may drop below expected normal readings when the unit is on Modulation Cool control temperature within 10 C 18 F of setpoint or in Power Limit mode Diagnosis Troubleshooting Status Messages Alarm Codes Frosted or sweating suction Expansion valve admitting excess refrigerant Evaporator coil needs defrosting Evaporator fan does not operate Ice plugging expansion valve screen or orifice Overcharge of refrigerant Expansion valve open too much Defective controller or main relay board Suction pressure gauge out of calibration Shortage of refrigerant Low ambient air temperature Iced or dirty evaporator coil Restricted lines Plugged filter drier Expansion valve closed too much Expansion valve feeler bulb improperly mounted poorly insulated or making poor contact Evaporator fans off Defective controller or main relay board Suction pressure gauge out of calibration Check feeler bulb and adjust expansion valve Check defrost circuit including controller and evaporator coil sensor See Evaporator fan motor does not
191. is below 350 VAC the unit will not start If the voltage remains below 350 VAC for 30 minutes Alarm 51 Low Voltage will occur High Pressure Cutout Switch Off Error Check Alarm Occurs during Pretrip PTI test only Compressor does not stop during high pressure cutout switch test Indicates Faulty compressor contactor or control circuit Low refrigerant charge Defective high pressure cutout switch Strong winds causing cooling of condenser coil in low ambient conditions High Pressure Cutout Switch On Error Check Alarm Occurs during pretrip PTI test only Compressor does not start within normal time during high pressure cutout switch test Indicates High pressure cutout switch did not respond to pressure change within 5 seconds Air in refrigeration system Defective high pressure cutout switch locations Check line voltage of power source Refer to the electrical specifications in the Specifications Section for correct power source requirements Check discharge and suction pressure gauge readings and check refrigerant charge Enter Manual Function Test menu Start the following components together compressor 100 compressor and evaporator fans high Discharge pressure should increase and compressor should stop at 2250 kPa 22 5 bar 326 psig high pressure cutout switch opens Check discharge and suction pressure gauge readings Enter Manual Function Test menu Start the followi
192. l Connections To select Manual Control 1 Turn the unit On Off switch to OFF 2 Turn the unit 460 380V main circuit breaker OFF Then disconnect the unit power cord from the power supply WARNING The unit will automatically start and operate if 460 380V power is present at the main relay board when the controller is disconnected To prevent personal injury from rotating machinery or dangerous electrical shock from high voltage controls disconnect the supply power to the unit before preparing the unit for manual emergency mode operation 3 Disconnect cable no 2 from the controller and main relay board see electrical schematic The main relay board will now control the unit based on the manual control setting NOTE MUST check 2 pin plug location on J501 connections of main relay board to ensure correct unit operation 4 Ifnecessary remove 2 pin plug from J501 see decal on main relay board and re locate based on the unit operating mode required 93 Operating Instructions 5 Connect the unit power cord to the proper power supply 6 Start the unit by turning the unit 460 380V main circuit breaker ON 7 Check for correct rotation of condenser fan and evaporator fans Condenser air should be blowing out from the center of the grille Evaporator air should be blowing down through the evaporator coil If the fans are running backwards the power supply phase must be changed To reverse power phase a T
193. l o en MOTOR 1 SENSOR t2 MOTOR 2 26 aq eee ar d EFI EFI l RN GRN Y d GRN G EL V GRN GRN YED Vi uh j USDA3 i WHITE 5 i D EVA amp HEATER HARNESS i VFD i YELLOW fF DEFROST C l RED WHT M O E RS l PULP E gt f E P ZaLacr ON pg l o TC HEATERS HEATERS E TERME S 2 KOHM AT 25 C l a D i i Ex YELLOW BLACK PC BOARD il I 2i scr terms A Auch E A A Li Ec m eo eic N zi ARAR ena IN eos je d ee n I I 1 E CANAL t Brads ORANGE PUES l it IPTIOD OPTION USDAL l zat Ed l l i l MES Li 1 WHITE l RED GREEN 22 5 d BLACK i AIR RED ua l N L f YELLOW COMPRESSOR wat uu d PORO ie RED 1 MOTOR SUS a trii Lil I m l CEDE Tl WHITE BM cC Lg on l E ee es S RIUBRRSVEL L BLACK l AFAM OPTION WIRING YELLOW gt RED l l l l E DEHUMIDIEICATION VALVE Los BLK Ney OPTION 0 aue FX aix El CHART RECORDER CONDENSES SLACK I BLK OPTION EK l l SENSOR i YELLOW i LIQUID SOLENOID VALVE l L L 2 kOHM AI 29 C ie Fe RED BLK l i E E COND LSY K I a a id BLK z a ec Ger ao PULP E l i LIQUID INJECTION VALVE i l l WHITE BLK i f p L L qan I YELLOW HH Lo a RED WHT RED N WHT cfi AMBIENT l I BLK EN AUR IND M TEMP RED Nul NO ars SENSOR i 2 KOHM AT 250 d l SUPPLY SUPPLY IAE amp E E E zl AIR AIR SENSOR LH SENSOR RH ae TR
194. l the return sensor is less then seconds SUF 15 C 59F or 1 hour 1 or 2 hours 1 1 i ies If the return air temperature is below 5 C 41 F unit maximum 2 3A 2 1A 2 3A operates in heat until return temperature is above 5 C 41 F or 2 hours 240 seconds maximum DIGITAL VALVE TEST With compressor condenser fan and evaporator fan on AMB CON EVA and operating at 100 capacity Capacity is reduced to 25 An Amp difference of 1 2 Amps is required 8 0C 25 0C 2 0C 91A 9 0A 9 1A COMP HI PRESS TEST With compressor on evaporator fan operates on high 53 54 10 to 60 EVA speed until high pressure cutout occurs or condenser seconds BM EON temperature is above 75 C 167 F 20 COMPRESSOR TEST With compressor and condenser fan on compressor is 6 7 30 seconds AMB CON EVA operating at 100 percent capacity Amp draw is measured and compared to voltage Compressor 8 0C 15 0C 5 0C amperes are recorded in PTI log If compressor has 91A 90A 94A been off for last 18 hours less than 30 seconds on a compressor sequence start occurs Plus 30 45 1 e 10C Condenser fan starts and operates until compressor seconds 9 1A 9 0A 9 1A starts Readings may vary depending on voltage and temperature 75 Operating Instructions CRR PTI Full Pretrip Test LCD Display Description Possible Duration Alarms Time PRE COOL HEAT TEST If the return air temperature is above 20 C 68 F unit SUP RET EVA 5 1C 5 0C 5 16 2 3A
195. lacerations e Use caution when working with a refrigerant or refrigeration system in any closed or confined area with a limited air supply for example a trailer container or in the hold of a ship Refrigerant tends to displace air and can cause oxygen depletion This can result in suffocation and possible death Use caution and follow the manufacturer s suggested practices when using ladders or scaffolds Refrigerant Oil Precautions Observe the following precautions when working with or around refrigerant oil Do not allow refrigerant oil to contact your eyes e Rubber gloves are recommended when handling Polyolester based refrigerant oil e Do not allow prolonged or repeated contact with skin or clothing Immediately wash all exposed skin after handling refrigerant oil Use the following First Aid practices if needed Eyes Immediately flush eyes with large amounts of water Continue flushing for at least 15 minutes while holding the eyelids open Get prompt medical attention Skin Remove contaminated clothing Wash thoroughly with soap and water Get medical attention if irritation persists Inhalation Move victim to fresh air Restore breathing if necessary Stay with victim until arrival of emergency personnel Ingestion Do not induce vomiting Contact a local poison control center or physician immediately Electrical Precautions The possibility of serious or fatal injury from electrical sh
196. laces on CRR refrigeration systems Low side near the compressor suction service valve or suction adapter High side near the compressor discharge service valve or discharge manifold e High side on the receiver tank Leak Detection Leaks can be detected with the use of soap bubbles and with Halogen leak detectors such as model H10G P N 204 712 or model H10N P N 204 756 portable Gauge Manifold Set A new gauge manifold set P N 204 758 should be dedicated for use with R 134a only Gauge hoses should also be dedicated to R 134a Vacuum Pump A two stage P N 204 725 three stage or five stage pump is recommended for evacuation Purging the system with dry nitrogen is recommended before evacuation Because residual refrigerant may be present in used vacuum pumps a new vacuum pump should be used and dedicated strictly as an R 134a refrigerant pump Use only recommended vacuum pump oils and change oil after every major evacuation 131 Refrigeration Maintenance Because vacuum pump oils are highly refined to obtain low vacuums failure to follow these recommendations may result in acidic conditions that will destroy the pump System Cleanup Cleanup devices such as suction line filters and compressor oil filters may be used if they are properly cleaned and new filters and cartridges are used All standard petroleum and synthetic compressor oils must be removed to prevent the contamination of R 134a syste
197. lates the compressor KVQ valve and electric heaters based on a Control Temperature Differential see General Theory of Operation in this chapter for more detail This means the unit operating mode can NOT be predicted based ONLY on the setpoint and supply air temperature At setpoints of 9 9 C 14 1 F and above the controller operates the unit on Operating Theory Cool mode with Modulation Heat mode electric heaters pulse On and Off on a 60 second duty cycle e Defrost mode electric heaters On evaporator fans Off AJA1283 A Cool with Modulation control temperature differential is above setpoint Heat electric heaters pulse ON and OFF on a 60 second duty cycle if the return air temperature decreases to 0 3 C 0 5 F above setpoint or the supply air temperature is too low If the compressor stops it must remain OFF for minimum of 5 minutes Figure 57 Chill Load Control Sequence Setpoints at 9 9C 14 1 F and Above 117 Operating Theory Operating Modes NOTE See Controller chapter for complete sequence of operation A sequence start of the required loads occurs during initial start up of the unit and when a control mode shift requires the compressors to start As the controller relays and unit loads energize the controller LCD display shows the setpoint temperature The controller LED display shows the controlling air sensor temperature The controlling sensor is determined
198. ler software configuration Defective sensor AFAM Gas Analyzer Error Check Alarm Gas analyzer circuit resistance is too high or low Indicates e Sensor disconnected Wrong controller software configuration Short circuit to sensor Defective sensor AFAM Gas Analyzer Calibration Check Alarm Indicates problem with sensor Compressor Sensor Open Circuit Check Alarm Sensor circuit resistance higher than 100 000 ohms Temperature below 30 C 22 F Indicates Open circuit to sensor Defective or wrong sensor Defective relay board Defective cable No 1 Defective controller Compressor Sensor Short Circuit Check Alarm Sensor circuit resistance higher than 10 000 000 ohms Indicates Open circuit to sensor Defective or wrong sensor Defective relay board Defective cable No 1 Defective controller Check sensor connections Check controller configuration for correct humidity setting Replace sensor Check sensor connections Check controller configuration for correct AFAM setting Replace sensor Check sensor connections Check controller configuration for correct AFAM setting Replace sensor Check sensor resistance between pins 9 and 10 on plug J15 Resistance must be 100 000 ohms at 25 C 77 F Check cable No 1 between controller and relay board NOTE Unit will operate normally without compressor sensor However controller compressor high temperature protection is
199. line press and hold F4 key until cursor stops flashing Cursor stops blinking and new temperature value appears in display Press ESC key to exit the C F Mode screen 85 Operating Instructions Configuration Menu The Configuration menu displays a list of functions that identifies unit operating features and current settings The following functions are available Container ID Control Type In Range Contrast Language Economy Max Economy Min Unit Type Reefer Type Zero Current Supply LH CA Option Evaporator Type Condenser Type USDA Type AFAM Units AFAM Update time AFAM Update Auto Configuration and Unit NOTE When a spare parts controller is installed and powered up for the first time an automatic configuration feature detects the unit options installed on a unit After the initial unit power up the controller turns the Auto Configuration feature Off See Replacing the Controller in this chapter for more information Viewing or Setting Functions With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press the F3 key to enter the Main Menu 2 Press F2 key to scroll through Main Menu until CONFIGURATIONS appears in LCD display 86 Press F4 key to access the Configurations screen Configurations screen appears with cursor in the Container ID menu line Press F3 key to scroll cursor to view or reset the desired function Container ID
200. matically returns to normal operation Brief PTI Pretrip LCD display shows PTI Test currently being performed Brief PTI test ends automatically Press any key on the controller to return the unit to normal operation 69 Operating Instructions Brief PTI Pretrip Test CAUTION The Brief PTI test should only be performed on an empty container NOTE Units equipped with a water cooled condenser must be set to operate on air cooled condensing to perform a complete system capacity test The MP 3000a controller contains a special Brief PTI pretrip test that automatically checks unit refrigeration capacity heating capacity temperature control and individual components including the controller display contactors fans protection devices and sensors The test includes measurement of component power consumption and compares test results to expected values The test takes about 25 30 minutes to complete depending on the container and ambient temperature NOTE Correct all existing alarm conditions and clear the alarm codes before performing a Brief PTI test The controller will automatically clear all existing alarms before beginning the Brief PTI test With the Unit ON OFF switch ON and the LCD display showing the standard display setpoint 1 Press the F2 or F3 key to enter the menu list Repeatedly press the F2 or F3 key to scroll through Main menu until COMMANDS appears in LCD display 2 Press the F4 key to a
201. mometer sensing bulb temperature to stabilize Then compare the supply air temperature in the controller display with the recording stylus of the recorder Write down both readings 4 If the average difference is 0 6 C 1 0 F or less DO NOT attempt to recalibrate 5 If the recorder need recalibration a Loosen the Allen setscrew S using a small slotted screwdriver b Adjust shaft J with a 5 mm 3 16 in open end wrench until the recording stylus pointer is aligned to the temperature reading that agrees with the supply air temperature in the controller display To decrease the stylus temperature reading turn the shaft to the left clockwise To increase the reading turn the shaft to the right counterclockwise c Tighten Allen setscrew S d Wait another 5 minutes while the unit operates on Cool Verify that the recording thermometer reading is stable and agrees with the supply air temperature in the controller display e Press any key to unlock the controller display screen Operating Instructions AJA1334 Knurled Knob Www E mewwesus Key mounting CLip Element Flange Screws D Thermal Element Stamping Figure 48 Partlow SR Recording Thermometer 2 Adjustment Shaft J cal 2 ES Element Replacement The recording thermometer s thermal element is field replace able To replace the element 1 Remove element flange screws D and withdraw the thermal elem
202. mperature Too High The controller will restart the unit when the sensor temperature is below 90 C 194 F Power Limit Mode The controller uses the total unit current and the condenser temperature to provide power limit control in both the Chill and Frozen modes When the unit is on water cooled operation power limit control is based on the total unit current draw only Initial Unit Start up and Normal Operation Standard Power Limit is active during the compressor start up in both the Chill and Frozen modes During start up the controller partially closes the KVQ valve to reduce the cooling capacity load on the compressor The actual KVQ Setting depends on the condenser temperature but ranges between 10 C and 30 C 5 6 and 16 8 F below the return air temperature The KVQ valve then gradually opens to increase cooling capacity during initial pull down as required When the total current draw or the condenser temperature exceeds a predetermined threshold the controller limits unit power consumption by sending a voltage pulse to the KVQ valve The KVQ valve closes to restrict the flow of refrigerant to the compressor This limits the compressor motor current draw and the condenser temperature to the predetermined threshold Power Limit Management Additional power limit management flexibility is available A maximum total current draw 17 15 or 13 amps and power management time interval can be selected from the Power Mana
203. ms Refrigerant Recovery Use only refrigerant recovery equipment approved for and dedicated to R 134a recovery Compressor Oil Acid Test Perform an oil acid test oil test kit P N 203 457 whenever a unit has a substantial refrigerant loss a noisy compressor or dark dirty oil Compressor Discharge and Suction Service Valves The discharge and suction valves isolate the compressor from the high and low sides of the refrigeration system for system diagnosis service and repair NOTE The only maintenance possible on the discharge or suction service valve is to periodically tighten the packing nut or to replace the packing The valves are a permanently assembled unit and must be replaced in total if defective e Back Seated Normal operation position e Open to Service Port Position for servicing e Front Seated To check or remove compressor 132 WARNING Do not start unit with discharge valve in FRONT SEATED position AJA1320 Full Counterclockwise Figure 64 Service Valve Back Seated 1 2 Turn In Figure 65 Service Valve Open to Port AAA 777 uam 2 AJA1321 Full Clockwise Figure 66 Service Valve Front Seated Refrigeration Maintenance Gauge Manifold Valve Positions The gauges indicate low and high side pressures Operate one or both hand valves to perform the different service operations Close Hand Valves Fi
204. n 3 Tighten the wing nut Handle Adjustment High Ventilation Rates 1 Loosen wing nut on handle assembly until handle bracket will rotate over handle 2 Align handle bracket and wing nut over hole in handle assembly and push through handle Operating Instructions Humidify System Option N o A The Humidify Mode increases the humidity level in the container by injecting atomized water directly into the evaporator supply air stream The tp e use of the Humidify Mode should be established 5 CM ka S by the shipper The Humidify Mode option is turned on from the CONTROL line in the 4 a EM 6 Setpoint menu of the controller See Changing n the Humidity Mode Setting under Setpoint J IS xx 7 Menv on page 4 18 to set the Humidify system d to ON The HUMIDITY LED turns ON when the Humidify Mode is set to ON AJA1333 sce 1 5 ESI ee pa Door Handle Assembly with Scale High Ventilation Rates 6 Handle Bracket DNE Nut Figure 46 Air Exchange System 3 Pull handle down to lower ventilation door Insert edge of ventilation door in a notch on handle Spring loaded handle is shown on the handle scale 4 CRR40and CRR40SL Models 150 225 and 280m 3 hr 90 135 and 165 ft 3 min AJA 330 Water Supply Hose and Atomizing Nozzle Inspect every 1 000 hours Clean if necessary Filter Inspect every 1 000 hours and clean if necessary Air Compressor Inspect once a yea
205. n keyboard to numerical entry before typing again With the correct time entered in the menu line press F4 key Then press EXIT key to enter time in controller memory Cursor stops blinking and new time appears in display To enter a new date press F3 key to move cursor to Date menu line Display shows date in and date in Y Y MM DD where Y year M month and D day Press F4 key with cursor in Date menu line An Enter Arrow appears in the menu line and the previous date disappears 83 Operating Instructions 10 11 Enter new date in Y Y MM DD where Y year M month and D day Decimal points must be included in the entry between the year month and day With the correct date entered in the menu line press F4 key Then press EXIT key to enter date in controller memory Cursor stops blinking and new date appears in the display Press ESC key to exit the Date Time screen Viewing or Setting Run Time 1 84 Press F3 key to enter the menu list Press F2 key to scroll to MISC FUNCTIONS Press F4 key to access the Misc Functions menu Date Time appears in the LCD display Press F2 key to scroll to RUN TIME Press F4 key to access the Run Time screen The Run Time screen appears with cursor in HEAT menu line Press F3 key to scroll cursor down through cargo data list HEAT COMPRESSOR EVAPORATOR HIGH EVAPORATOR LOW CONDENSER TOTAL To rese
206. n remote monitor connector provides 24 Vac signals for bridge lights that monitor Cool Compressor On Defrost and In range conditions TRANSFRESH Atmosphere Control System Options Several TRANSFRESH options are available to meet individual customer needs The TRANSFRESH system provides a controlled atmosphere within the container By controlling the container temperature and atmosphere the respiration rate of fruit and vegetables can be lowered This allows the product quality to be maintained for longer periods of time e TRANSFRESH Ready Provisions for the future installation and use of a TRANSFRESH atmosphere control system are incorporated in the unit TRANSFRESH compatible A2 power defrost and A3 communications cables without connectors are factory installed Full TRANSFRESH Option TRANSFRESH system components are installed for use of a TRANSFRESH atmosphere control system In addition to A2 and A3 cables with connectors the security frame security enclosure with insulation block TRANSFRESH supplied single purge port air hose and scrubber cable A5 with connectors are factory installed Purge port includes a removable plug for charging the container with a modified atmosphere USDA Cold Treatment Temperature Recording The datalogger includes provisions for the use of up to four USDA sensors These sensors allow temperatures in various areas of the load to be monitored and recorded for United States D
207. n selected Inspect Temp Log With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press F2 key to enter the menu list 2 Press F2 key to scroll through Main Menu until DATALOGGER appears in LCD display 3 Press F4 key to access the Datalogger menu Inspect Temp Log appears in the LCD display 4 Press F4 key to enter Temp Log LCD display shows the Log Time and the Setpoint Supply and Return temperatures of the most recent log in the first screen e To scroll through previous logs of the sensor temperatures currently in the display press F3 key All temperature logs recorded in the datalogger memory may be viewed on the LCD display 5 To view additional sensor log and event flag screens press F4 key again LCD display shows USDAI USDA2 USDA3 Relative Humidity rH Ambient etc e To scroll through previous logs of the sensor temperatures currently in the display press F3 key Event Flags for Temperature Log T Tripstart Activated P Primary Power Off D Defrost in Last Interval O Temperature Not In range h Humidity Control Active E Evaporator High Temperature H High Refrigeration Pressure d Defrost terminated on time limit e Economy mode activated s Reefer unit stopped after PTT w Water cooled operation water pressure switch is OPEN or Condenser Fan Switch is in WATER position Operating Instructions A Al
208. n the system External restrictions between the system and the vacuum pump Close the vacuum valve and watch the movement of vacuum gauge needle If needle continues to rise this is an indication that a leak exists in the unit or connecting line The leak must then be located and eliminated Pressure Vacuum Atmospheric Pressure Figure 78 Constant Pressure Rise after Evacuation Indicates System Leak 142 Hose size both diameter and length affect evacuation times Laboratory tests show that the evacuation time can be significantly reduced by larger diameter hoses and shorter hoses To obtain optimum pumping speed keep hoses as short as possible and as large in diameter as possible For example it takes eight times as long to pull a given vacuum through a 6 mm 1 4 inch diameter hose as it does through a 12 mm 1 2 inch diameter hose It takes twice as long to pull a vacuum through a 2 meter 6 foot long hose as it does through a 1 meter 3 foot long hose Heat Saves Time A useful and practical time saver is the application of heat to the system Increasing the temperature of the compressor oil and refrigerant will speed up the vaporization of any water present in the system WARNING Never use a torch or other concentrated heat source to heat the compressor or other refrigeration system component constant pressure the system still contains to 1 Close the vacuum valve and watch the movement of vacuum gaug
209. nd Cleanup of the Refrigeration System in this chapter Replace the condenser coil support brackets condenser fan shroud and condenser fan grille Recharge the unit with R 134a refrigerant and check the compressor oil level Add oil if necessary Filter Drier In line Filter Replacement Removal 1 Close the liquid line service valve and pump down the low side Open the outlet valve slightly to equalize the pressure between 10 and 20 kPa 0 10 and 0 20 bar 1 and 3 psig Place the new filter drier near the unit for immediate installation Using two wrenches crack both filter drier line mountings Use two wrenches on flare fittings to prevent line damage Separate the filter drier line mountings Remove the filter bracket clamping nuts and bolts NOTE Perform the following four procedures as quickly as possible to prevent contamination 6 Remove the old filter drier from the line Installation 1 Remove the sealing caps from the new filter drier 2 Apply clean compressor oil to filter drier threads 3 Assemble new filter drier to lines Finger tighten mounting nuts NOTE To prevent incorrect installation of the filter drier the inlet and outlet fittings are different sizes Reinstall filter drier clamping brackets nut and bolts Tighten the bolts Tighten the filter drier inlet line mounting nut 149 Refrigeration Maintenance 6 Open the liquid line service valve on the inlet
210. nd measures the humidity of the return air from the cargo space High pressure gas High pressure liquid Low pressure gas Low pressure liquid Condensing high pressure gas Low pressure vaporizing liquid Liquid refrigerant injection 198 y i t li t 4 ore D Rame m MP 3000a Menu Flow Diagram NOTE All screens are NOT present on all units The screens that display CONTROLLER MENU GUIDE Setpoint Menu Wem on the controller are determined by the Controller Software settings and a Sn PON piis piii contol the options installed on the unit Opti Set Hum Setp Humidity Setpoint conomy Mode Temp Setp AFAM Press F4 key Press F4 key o o o o o o B Bulb Mode AFAM Delay Type the new setpoint Press F2 key to toggle HUMIDITY COMP HEAT DEFROST IN RANGE ALARM Text Input Use F1 F2 F3 and F4 keys to enter text in information screens E Evap Fan Spd AFAM Rate 1 riam rd ey setting between OFF eu To enter a number Press the F1 key and the desired number key Defrost Trm 02 Min until cursor stops cos i P d hold F4 k To enter 1st letter on a key Press the F2 key and the desired letter key m Economy Mode C02 Max flashing inepta is ey P lt Hum Control sorry To enter 2nd letter on a key Press the F3 key and the desired letter key E PIA VU etii To enter 3rd let
211. ng components together compressor 100 percent compressor and evaporator fans high Discharge pressure should increase and compressor should stop at 2250 kPa 22 5 bar 326 psig high pressure cutout switch opens Then start condenser fan Discharge pressure must drop quickly 10 to 20 seconds to 1550 kPa 15 5 bar 225 psig and compressor should start switch closes 179 Diagnosis Troubleshooting Status Messages Alarm Codes 180 Compressor Temperature Too High Shutdown Alarm Compressor dischage line temperature is above 130 C 266 F COmpressor stopped until discharge line temperature decreases to 90 C 194 F Indicates Air in refrigeration system Low refrigerant charge Defective compressor or valve plate Defective liquid injection system Wrong or defective sensor FAE Device Error Check Alarm Controller is unable to adjust vent door to desired position Indicates Frozen or stuck vent door Defective linkage Defective control module Open circuit to control module or motor Defective motor Phase Sensor Error Check Alarm Occurs during Pretrip PRI or Function test only During Phase Sensor Test amperage difference between correct and wrong condenser fan rotation is more than 0 2 amps Indicates Defective phase relay Defective relay board Defective relay board cable No 2 Delta Current Error Check Alarm 100 ampere difference between current phases Indicates Op
212. not active Check sensor resistance between pins 9 and 10 on plug J15 Resistance must be 100 000 ohms at 25 C 77 F Check cable No 1 between controller and relay board 181 Diagnosis Troubleshooting Status Messages Alarm Codes USDA 1 Sensor Open Circuit Check Alarm Check USDA sensors and sensor connections Occurs during Pretrip PTI test only Container ID starts with MAE MSF or MWC Temperature below 50 C 58 F Indicates All 3 USDA sensors are missing Defective cable No 3 KVQ Sensor Open Circuit Check Alarm Sensor circuit resistance higher than 10 000 000 ohms Indicates Open circuit to sensor Defective or wrong sensor Defective relay board Defective cable No 1 Defective controller Cede KVQ Sensor Short Circuit Check Alarm Sensor circuit resistance lower than 200 ohms Indicates Short circuit to sensor Defective or wrong sensor Defective relay board Defective cable No 1 Defective controller KVQ Heat Error Check Alarm KVQ valve actuation temperature is not in range within preset time Indicates Disconnected CB7A Defective heat element in valve actuator Inaccurate actuator temperature measurement Defective relay board Defective circuit between pin 4 and 6 on plug J11 KVQ actuator requires power from both relays 2 and 3 Defective cable No 2 Defective controller Zero Current Too High Check Alarm Ground zero current cir
213. nozzle and injected into the return air stream Inspection and Cleaning The following items should be periodically serviced Clean and inspect the filter in the water supply hose on the water tank every 1 000 operating hours Clean the filter screen with fresh water and a soft brush e Inspect the water tank water supply line and atomizing nozzle every 1 000 hours and clean if necessary Use fresh water a soft brush and compressed air to clean and blow clear components e Inspect the air compressor for signs of overheating once a year 98 Partlow Model SR Recording Thermometer Option The 31 day Partlow Recorder is mechanically driven by a spring wound mechanism The sensor bulb is mounted in the evaporator to record the supply air temperature The recording thermometer should be inspected and cleaned to ensure that the stylus produces smooth clean lines and records accurate temperature readings When changing charts wipe the stylus and chart platen with a clean damp cloth to remove material transferred from the back of the chart to the platen by the pressure of the stylus Recording Chart Replacement 1 To change the charts remove the knurled chart nut from the drive shaft and remove the chart 2 Install the new chart on the chart drive shaft Position the chart edge under the four clips 3 Replace the chant nut loosely and rotate the chart so that the correct time is indicated by the stylus In ord
214. nsing can be provided by the water cooled condenser NOTE Water cooled condenser requires a water flow of 19 to 38 l min 5 to 10 gal min when Condenser Fan On Off switch is on WATER MP 3000a Controller The MP 3000a microprocessor controls all unit functions to maintain the cargo at the proper temperature The controller also monitors and records system faults and performs pre trip 1 KEYPAD Sixteen general purpose keys are used to display information change the setpoint change programmable features and initiate control tasks 2 C F KEY Press this key to view temperatures in the LED display in the alternate temperature value Alternate value C or F shows while the key is pressed 3 SUP RET KEY Press this key to view the alternate sensor temperature in the LED display Alternate sensor return or supply shows while the key is pressed 4 DEFROST KEY Press this key to initiate a manual defrost cycle If the evaporator coil temperature is below 18 C 65 F the unit will defrost and the controller will display Defrost Activated in the LCD display If the unit is not below 18 c 65 F the controller will display Defrost Not Activated in the LCD display and the unit will continue normal operation 5 SETPOINT KEY Press this key to change the setpoint Cursor in the LCD display automatically appears in the TEMP SETP line of the Data menu See Changing the Setpoint in the MP 3000a Co
215. nsor locations Supply Air Temperature Too High During Chill or Frozen Mode Supply air temperature is too high compared to return air temperature under operating conditions Indicates Low refrigerant charge Incorrect connection or location of supply or return air sensor Air leakage at supply air sensor cable Ice or frost on evaporator coil Incorrect evaporator fan operation Supply Air Temperature Too Low During Chill or Frozen Mode Supply air temperature is too low compared to return air temperature under operating conditions Indicates Ice or frost on evaporator coil Low heating capacity Incorrect evaporator fan operation Incorrect connection or location of supply or return air sensors Return Air Temperature Too High During Defrost Return air temperature increases above 40 C 104 F Indicates Defective return or evaporator coil sensor Return and evaporator coil sensor connections are reversed Status Message Controller Action Check LCD display for High Pressure Cutout message Enter Manual FUnction Test menu and test operate each component Check volts and amps to determine which component has low amp draw Check volt and ampere meter Check discharge an suction pressure gauge readings and refrigerant charge Check for sensor or evaporator fan alarm codes Open evaporator door Inspect coil for ice or frost and initiate manual defrost if necessary Check for correct evaporator fan mot
216. nst frost damage see Chill Loads under General Theory of Operation in this chapter Controller pulses electric heaters ON and OFF for additional frost protection if the return air temperature decreases to within 0 3 C 0 5 F of setpoint see Chill Loads under General Theory of Operation in this chapter Controller turns ON the Heat LED whenever the heaters are pulsed ON and OFF Heat e Ifthe supply air temperature is too low and the calculated KVQ valve setting is above the setpoint the controller stops the compressor de energizes the liquid line solenoid and pulses the electric heaters ON for 2 to 60 seconds every 60 seconds to provide heat The amount of ON time depends on the amount of heat required to gradually increase the supply air temperature to setpoint Frozen Loads Controller Setpoint at 10 C 14 F and Below At setpoints of 10 C 14 F and below the controller locks out the Modulation and Heat modes The controller regulates compressor operation based the return air sensor and setpoint temperatures At setpoints of 10 C 14 F and below the controller operates the unit on e Cool mode Null mode e Defrost mode electric heaters On evaporator fans Off e Evaporator fans operate continuously on low speed except when Economy mode is ON and the unit is in the Null mode and continuously circulate air inside the container except during defrost e Controller LED display shows the
217. ntainer temperature in direct response to load demand The KVQ valve is installed in the suction line and controls the amount of refrigerant returning to the compressor The valve opens and closes in response to a controller voltage signal based on a control temperature differential The controller uses the setpoint temperature supply air sensor temperature left and or right hand sensors and pull down rate for the last 10 seconds last 20 seconds and last 180 seconds to calculate the control temperature differential Supply Air Sensor Control Temperature control accuracy and protection against frost damage is provided by using two separate sensors left hand and right hand to determine the supply temperature used to calculate the control temperature differential e At setpoints below 1 C 30 F the controller uses the lowest supply air sensor temperature e At setpoints above O C 32 F the controller uses the average temperature of the left hand and right hand supply air sensors e At setpoints between 1 C and 0 C 30 F and 32 F the controller uses a sliding temperature scale from the lowest supply air sensor temperature to the average temperature of the left hand and right hand supply air sensors If one supply air sensor fails the controller uses the temperature of the other supply air sensor for temperature control If both supply air sensors fail the controller uses the temperature of the return air sensor plus
218. ntroller chapter for complete instructions STATUS INDICATOR LEDs located in the large LED display signal e Supply Air Temperature Return Air Temperature Humidity Mode Humidification Option set to On in e Setpoint menu Compressor Cooling On e Heat On e Defrost n Range Temperature Alarm The In range LED illuminates when the controlling air sensor temperature is less than 1 5C 2 7 F above setpoint standard The controller maintains the in range signal during defrost and after defrost for 60 minutes If the controlling air sensor temperature goes out of range the controller maintains the in range signal for 5 more minutes 7 LED DISPLAY Large red LED display shows current control temperature during normal operation LED display also shows current test state during a Pretrip PTI or Function test 8 LCD DISPLAY A 4 line LCD message display shows setpoint during normal operation LCD display also shows controller menu and unit operation information when special keys are pressed 49 Operating Instructions Other Unit Controls 1 EVAPORATOR OVERHEAT SWITCH A temperature switch near the evaporator coil opens to de energize the heater contactor if the evaporator temperature reaches 54 3 C 130 5 E The switch closes resets when the evaporator temperature decreases to 38 4 5 C 100 8 F WATER PRESSURE SWITCH OPTION When water pressure greater than 117
219. ntroller from another unit has been installed see Controller Software Selection in this chapter to set software selection dial correctly Automatic Configuration of Spare Parts Controller An automatic configuration feature detects the unit options installed on a unit when a spare parts controller is installed When the controller is powered up for the first time the controller turns the Auto Configuration feature On After the initial unit power up the controller turns the Auto Configuration feature Off The Auto Configuration feature detects the following options and sets the correct value in Configuration menu Number of Supply Air Sensors 1 or 2 Controller detects left hand and right supply air sensors Number of Evaporator Fans 2 or 3 e Dehumidify On or OFF If controller detects a humidity sensor it then checks for current draw on a Dehumidify valve pre 2002 e Humidification On or OFF If controller detects a humidity sensor it then checks for current draw on an air compressor NOTE Automatic configuration will not detect NTC type USDA sensors 123 Controller Maintenance Controller Software Selection If a replacement controller was removed from another unit check the small dial located on the back of the controller for the correct software selection Current active software settings for dial positions are e Position 0 All TNE 508 units with Module load compressor Position 1
220. nu line 6 7 Repeat steps 4 and 5 to reset additional configuration values Press ESC key to exit the Configurations screen 87 Operating Instructions Datalogger Menu The Datalogger menu contains a list of functions that display unit operating information recorded in the MP 3000a datalogger The following functions are available Inspect Temperature Log Displays temperature logs by time and date for the Setpoint Supply Controlling Temperature Return USDA1 USDA2 USDA3 and Ambient sensors humidity sensor and event flags Inspect Event Log Displays important event logs by time and date for events such as unit alarms power On Off setpoint change clock reset trip start defrost etc Set Log Time Sets the data log interval 1 minute or 1 2 1 2 or 4 hours Standard Display o o o o o o HUMIDITY COMP HEAT DEFROSTIN RANGE ALARM ela m Lt Main DATA ALARMS COMMANDS MISC FUNCTIONS CONFIGURATION DATALOGGER RMM STATE Activate Tripstart Sets the date and time of the trip start Inspect PTI Log Displays results of last PTI test including component volt and amps data and sensor temperatures Test values are recorded at the start and end of the Chilled and Frozen Mode test Viewing the Datalogger Menu With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press the F3 key to enter the
221. o 35 kPa 0 35 bar 10 in vacuum Break the vacuum with nitrogen between 10 and 20 kPa 0 10 and 0 20 bar 1 and 3 psig 2 Disconnect the unit power source from the unit Disconnect the electrical connections to the liquid injection valve NOTE In most cases only the coil requires replacement No other repair is possible on the liquid injection valve 3 Unsolder the liquid line connections 4 Unbolt and remove the valve from the unit Installation 1 Clean the tubes for soldering 2 Place the new valve in position 3 Solder the liquid line connections CAUTION Use a heat sink or wrap the valve with wet rags to prevent damage to the new valve 4 Pressurize the low side with refrigerant and check for leaks see Refrigerant Leak Test Procedure in this chapter 5 Ifno leaks are found recover the leak test gas see Refrigerant Recovery in this chapter 6 Evacuate the low side see Evacuation and Cleanup of the Refrigeration System in this chapter 7 Reconnect the electrical wires to the valve 8 Open the liquid line service valve and place the unit in operation Check the refrigerant charge and add refrigerant as required Refrigeration Maintenance Dehumidify Valve pre 2002 Replacement Removal 1 Close the liquid line service valve and pump down the low side to 35 kPa 0 35 bar 10 in vacuum Break the vacuum with nitrogen between 10 and 20 kPa 0 10 and 0 20 bar 1 and
222. o complete depending on the container and ambient temperature Refer to the Brief PTI Test in the Operating Instructions Section Full PTI Test The MP 3000a controller contains a special Full PTI pretrip test that automatically checks unit refrigeration capacity heating capacity temperature control and individual components including the controller display contactors fans protection devices and sensors The test includes measurement of component power consumption and compares test results to expected values The test takes up to 2 to 2 5 hours to complete depending on the container and ambient temperature Refer to the Full PTI Test Menu in the Operating Instructions Section Functions Test The MP 3000a controller contains a special function test that automatically tests individual components including the controller display sensors condenser fan evaporator fan compressors etc The test includes measurement of component power consumption and compares test results to expected values Refer to the Functions Test Menu in the Operating Instructions Section Manual Functions Test The Manual Function Test menu allows technicians to perform specific diagnostic tests on individual components or turn several components on at the same time to perform a system test Refer to the Manual Functions Test Menu in the Operating Instructions Section Data The Data menu displays general unit operating information including sensor tempera
223. ock exists when servicing a refrigeration unit Extreme care must be used when working with a refrigeration unit that is connected to its power source Extreme care must be used even if the unit is not running Lethal voltage potentials can exist at the unit power cord inside the control box inside any high voltage junction box at the motors and within the wiring harnesses Precautions Turn the unit On Off switch to Off before connecting or disconnecting the unit power plug Never attempt to stop the unit by disconnecting the power plug Safety Instructions e Becertain the unit power plug is clean and dry before connecting it to a power source e Use tools with insulated handles Use tools that are in good condition Never hold metal tools in your hand if exposed energized conductors are within reach e Do not make any rapid moves when working with high voltage circuits Do not grab a falling tool or other object People do not contact high voltage wires on purpose It occurs from an unplanned movement e Treat all wires and connections as high voltage until ammeter and wiring diagram show otherwise e Never work alone on high voltage circuits on the refrigeration unit Another person should always be standing by in the event of an accident to shut off the refrigeration unit and to aid a victim Have electrically insulated gloves cable cutters and safety glasses available in the immediate vicinity in the event o
224. older liquid line inlet and outlet line connections to valve Solder equalizer line to expansion valve Clean the suction line to a bright polished condition Install the feeler bulb of new power head in the feeler bulb clamp on the suction line Locate bulb on the suction line in former position The feeler bulb must make good contact with the suction line or operation will be faulty Cover with insulating tape Pressurize the low side and test for leaks see Refrigerant Leak Test Procedure in this chapter If no leaks are found recover the leak test gas see Refrigerant Recovery in this chapter Evacuate the low side see Evacuation and Cleanup of the Refrigeration System in this chapter Cover expansion valve outlet line with insulating tape Open the liquid line service valve and place the unit in operation Operate the unit and note the suction pressure and container temperature to see that the expansion valve is properly installed and that the feeler bulb is properly located Heat Exchanger Replacement Removal 1 Close the liquid line service valve and pump down the low side to 35 kPa 0 35 bar 10 in vacuum Break the vacuum with nitrogen between 10 and 20 kPa 0 10 and 0 20 bar 1 and 3 psig Remove the U mounting clamps that hold the heat exchanger assembly to the wall of the condenser section Heat and unsolder liquid inlet and outlet line connections Note position o
225. oller Return Air Sensor Open Circuit Check Alarm Sensor circuit resistance higher than 100 000 ohms Temperature below 70C 94F Indicates Open circuit to sensor Defective or wrong sensor Defective relay board Defective cable No 1 Defective controller 170 Check Alarm Level 2 Alarm Alarm light on display flashes until alarm is acknowledged Event Log Level 3 Alarm Alarm is recorded in datalogger only inspect event log Identify defective sensor left hand or right hand by viewing Data menu Check sensor resistance between pins 1 and 2 on plug J15 and between pins 7 and 8 on plug J14 Resistance must be 2 000 ohms at 25C 77F Check cable No 1 and cable No 3 between the controller and relay board Check evaporator air flow Identify defective sensor left hand or right hand by viewing Data menu Check sensor resistance between pins 1 and 2 on plug J15 and between pins 7 and 8 on plug J14 Resistance must be 2 000 ohms at 25C 77F Check cable No 1 and cable No 3 between the controller and relay board Check sensor resistance between pins 3 and 4 on plug j15 Resistance must be 2 000 ohms at 25C 77F Check cable No 1 between controller and relay board Diagnosis Troubleshooting Status Messages Alarm Codes Return Air Sensor Short Circuit Check Alarm Check sensor resistance between pins 3and 4 Sensor circuit resistance lower than 200 ohms Temperature above 80C
226. on of PT100 type USDA sensors on units with serial numbers beginning with MAE MSF or MWC prefix Unit ID An 11 digit alpha numeric container number Note All screens are not present on all units The screens that display on the controller are determined by the Controller Software setting and Menu the options installed on the unit CONT ID IN RANGE al L CONTRAST F4 r UNIT TYPE z x DEHUM VALVE ee REEFER TYPE ESC uomenu F1 Current function setting ZERO CURR appears in display Press F4 key to change a SUPPLY LH setting Press F2 key A key AFAM OPT password F4 key and Exit HF G ANALYZER key Type a new value or press F3 EVAP TYPE key to toggle value to desired I COND TYPE setting Press and hold F4 key until CARGO PROBES cursor stops flashing CHART R AFAM UNITS H AUTO CONFIG UNIT I UNIT ID Figure 41 Configuration Menu Screen Flow Diagram 5 To set a new Configuration screen value a Press F4 key with cursor in the desired menu line The Password screen appears Press F2 key A key password is A F4 key and then EXIT key An Enter Arrow appears in the hourmeter line Use the general purpose keypad to enter the desired value or press the F3 key to toggle the value to the desired setting When the entry is complete press the F4 key and release Press the exit key The new value appears in the me
227. ontrol Box 36 Unit Description Features and Options AJA1558 1 15 KVA Transformer 460 380V Power Receptacle Cable Bracket Cable Bracket Early Units 230 190V Power Cable mg Power Plug Option Figure 15 Dual Voltage Option 37 Unit Description Features and Options nf na Haf E VEM eee ua Tani eo ql Lane ne lt l l a d 11 f pi DE A o E NA M gt F en fj jd f 4 AL la Des Ss 7 AJA1559 Gasket 6 Interface Board and Cable Mounts in Control Box Vent Door Assembly Stop Bracket Vent Door Full Open Linkage Assembly 8 Stop Bracket Vent Door Closed Damper uar ous sme CS Figure 16 Advanced Fresh Air Management AFAM Option 38 Unit Description Features and Options Y FEAT _ TADA Ae FBS Saar Ata FONO AJA1560 Gas Sensor Assembly Mounts in Evaporator 6 Damper Motor Assembly Mounting Bracket Box Vent Door Assembl
228. operate under Mechanical Diagnosis Apply hot wet cloth to expansion valve Moisture indicated by increase in suction pressure Replace filter drier Purge system Adjust or replace valve Diagnose main relay board and controller Replace defective component Adjust or replace service gauge Repair leak and recharge No remedy Defrost or clean evaporator coil Locate and clear restriction Replace filter drier Adjust or replace valve Correct feeler bulb installation Check evaporator fan motors and control circuit and correct fault Diagnose main relay board and controller Replace defective component Adjust or replace gauge 165 Diagnosis Troubleshooting Status Messages Alarm Codes Status Messages and Controller Actions The controller displays status messages in the Miscellaneous Functions Menu under Status on the LCD display for several general faults More than one status message may appear at a time Press F2 or F3 key to scroll through message displays Power Error Check 20A Fuses Indicates One or more phases are missing Compressor is able to draw amps on all phases while heater lacks amps on one or more phases High Pressure Cutout Check Water Cooling Indicates Unit stops due to high pressure cutout and water pressure switch is open Probe Test Please Wait Indicates Incorrect temperature difference between Supply LH Supply RH or Return Air Sensor for 10 minutes with evaporat
229. or fan amps OK Supply Right Hand Problem Sensor Disabled Indicates Controller disables sensor due to open or short circuit or sensor failed a Probe Test N la Hand Problem Sensor Disabled Indicates Controller disables sensor due to open or short circuit or sensor failed a Probe Test High Pressure Cutout Check Condenser Probe Indicates o 1 5 7 166 Units stops due to high pressure cutout water pressure switch is closed and condenser temperature is low Status Message Controller Action Controller activates Alarm 18 Controller will try to restart unit after 60 minutes Controller clears message on compressor start up No alarm is set until Controller determines that unit current draw is too low Alarm 37 or supply air temperature is too high Alarm 41 Controller automatically activates probe test to check for a defective sensor Message clears when test is complete Controller displays new message if test indicates a sensor is defective Controller activates Alarm 52 Controller activates Alarm 00 or 01 depending on type of sensor failure Controller clears message during Defrost mode and when Unit ON OFF switch is turned Orr Controller uses left hand supply sensor to control unit if right hand sensor is defective Controller uses return sensor plus an offset to control unit if both supply sensors are defective Controller activates Alarm 52 Controller activates Alarm 00 or 01
230. or rotation and operation Check supply and return sensor connections and locations Check for sensor or evaporator fan alarm codes Open evaporator door Inspect coil for ice or frost and initiate manual defrost if necessary Check for correct evaporator fan motor rotation and operation Check supply and return sensor connections and locations Check for sensor alarm codes Check supply and return sensor connections and locations Diagnosis Troubleshooting Status Messages Alarm Codes Evaporator Coil Temperature Too High During Chill or Frozen Mode Evaporator coil temperature is too high compared to return air temperature under operating conditions Indicates Low refrigerant charge Defective evaporator coil or return air sensor incorrect connection or location of evaporator coil or return air sensor Evaporator Coil Temperature Too Low During Chill or Frozen Mode Evaporator coil temperature is tool low compared to return air temperature under actual operating conditions Controller initiates defrost if not recent defrost Indicates Air flow is blocked in the container Evaporator fans do not operate Fresh air exchange vent open too much on frozen load Defective evaporator coil or return air sensor Status Message Controller Action Check for sensor alarm codes Check discharge and suction pressure gauge readings and check refrigerant charge Check evaporator coil and retu
231. otect the compressor from excessively high operating temperatures and activate liquid injection during Chill mode setpoints at 9 9 C 10 1 F and above a High Temperature Protection e The controller immediately stops unit operation if the discharge gas temperature increases to 130 C 266 F The controller turn ON the Alarm LED and records Alarm 56 Compressor Temperature Too High The controller restarts the unit when the sensor temperature is below 90 C 194 F b Compressor Discharge Temperature Control Chill Mode Only Controller energizes the liquid injection valve when compressor discharge gas temperatures are between 115 C and 125 C 239 F and 257 F The controller pulses the liquid injection valve open and closed on a 1 minute duty cycle For example the valve may be energized for 15 seconds and de energized for 45 seconds Number of seconds the valve is energized is based on the discharge temperature and the KVQ valve setting Controller energizes the liquid injection valve when the KVQ Setting less than 5 C 8 9 F below the return air temperature The controller energizes liquid injection valve for 6 seconds every 60 seconds regardless of the discharge temperature Operating Instructions K K S naa b AJA1566 28 Vac Control Circuit Fuse 2 ampere 28 Vac Control Circuit Fuse 2 ampere Figure 30 Control Circuit Fuses HIGH PRESSURE CUTOUT HPCO SWITCH If the
232. oximately 13 amps or compressor phase current level difference of 1096 or more depending on ambient temperature Indicates Defective KVQ valve Defective compressor or valve plate Defective volt or amp meter on relay board Inaccurate ambient condenser or evaporator temperature measurement Out of range power supply Excessive condenser pressure due to air or wrong refrigerant in system or refrigerant over charge Compressor Current Too Low Check Alarm Occurs during Pretrip PTI or Function test only Compressor power consumption is 2596 below expected current draw below approximately 9 amps Indicates Defective or open fuse CB 7A high pressure cutout switch or connection in plug j19 between pins 7 amp 8 No signal on plug J11 on pin 8 Defective compressor relay Defective volt or amp meter on relay board Low refrigerant charge Defective compressor or valve plate sensor temperatures for correct value C 9F by viewing Data menu Enter Manual Function Test menu Start and check current draw of the following components separately and together compressor compressor 100 condenser fan and evaporator fan high and low Check volt and ampere meter Check power supply volts Enter Manual Function Test menu Start and check current draw of the following components separately and together compressor compressor 25 condenser fan and evaporator fan high and low If relay does NOT energi
233. pears in LCD display 2 Press F4 key to access the Commands menu The first command in the submenu Defrost appears in the LCD display 3 Press F2 or F3 key to scroll to Power Management 4 Press F4 key to enter Power Management submenu LCD display shows the current Power Limit setting and Power Time setting 5 To activate or change the power limit a a Press F4 key with cursor in the Power Limit menu line Cursor moves to end of menu line and flashes b Press F2 or F3 key to scroll to the desired power limit setting OFF 13 amps 15 amps or 17 amps c With the desired power limit in the menu line press and hold F4 key until cursor stops flashing Cursor stops flashing and new value appears in display Operating Instructions To change the length of time power limit is active ON a a Press F2 key to scroll to Power Time menu line standard setting 48 hours b Press F4 key with cursor in the Power Time menu line An Enter Arrow appears in the menu line and the previous time disappears c Enter new active period in hours d With the correct hours entered in the menu line press and hold F4 key until cursor stops flashing Cursor stops flashing and new value appears in display Press ESC key to exit the Power Management submenu 81 Operating Instructions Misc Functions Menu The Misc Functions menu displays a list of functions that identifies trips and determines how the controlle
234. pears with the cursor in the TEMP SETP line Press the F4 key An Enter Arrow appears in the menu line and the current setpoint disappears Enter type the new setpoint in the LCD display using the general purpose keypad Press the Exit key first to enter a minus setpoint The cursor moves to the right of the screen as each key entry is acknowledged and displayed NOTE Always check that the setpoint entered in the LCD display is correct before proceeding Press and hold the F4 key until the cursor stops flashing The new setpoint is recorded in the controller and appears in the LCD display NOTE The controller will default return to the previous setpoint if the setpoint is not entered within 30 seconds Repeat steps 1 through 4 if this occurs NOTE Humidity control humidity setpoint and Economy mode can also be set from the Setpoint menu See Setpoint Menu under Menu Operating Instructions in this chapter 56 Initiating a Manual Defrost Turn the UniT ON OFF switch ON Complete the following steps Press the DEFROST key e Ifthe unit operating conditions allow a manual defrost e g evaporator coil temperature is less than 18 C 56 F the unit enters Defrost as the Defrost and Heat LEDs turn on LCD message display shows DEFROST ACTIVATED e Ifunit operating conditions do not allow defrost the LCD message display shows DEFROST NOT ACTIVATED The defrost cycle automatic
235. ptional humidification system increases the relative humidity in the container to the humidity setpoint The control range is 50 to 98 while the setpoint is adjustable between 50 and 98 Pressure Gauge Options A high pressure gauge is available to indicate condenser high side pressure A low pressure gauge is available to indicate compressor suction low side pressure Unit Description Features and Options Recording Thermometer Option Several models of temperature recorders are available for mounting on the unit Each temperature recorder is designed to withstand widely varying environments including low and high ambient temperatures salt water humidity fungus industrial pollutants dynamic loading rain sand and dust e The 31 day Saginomiya Recorder is electric motor driven by a dry cell type battery with a 1 year life expectancy The 31 day Partlow Recorder is mechanically driven by a spring mechanism On top air discharge units the recording thermometer records supply air temperature e Partlow Recorder Sensor only Remote Monitoring Modem RMM Optional A REFCON remote monitoring modem is provided to permit remote monitoring via the power cable High speed transmission reads all controller information Data can also be retrieved from the data logger via high speed transmission 27 Unit Description Features and Options Remote Monitoring Receptacle Option 4 Pin Optional An optional 4 pi
236. r Water Tanks Pretrip Inspection Check water level Every 1 000 Hours Inspect water tank Clean if necessary 5 Water Tank Heater Check for correct operation in ambient temperatures below 4 C 40 F fe panto Figure 47 Humidify System Option 97 Operating Instructions The controller energizes operates the air compressor when the humidity level in the container is more than 2 below the humidity setpoint The air compressor atomizes and injects water into the evaporator supply air stream to add moisture to the container air The evaporator drain hoses are routed to the water tank to replenish the water level during unit operation However water usage will vary depending upon the load and ambient conditions An overflow hose on the water tank removes excess water when particularly wet loads are transported or when the humidify system is not operating NOTE Only demineralized or distilled water should be used to prevent plugging of the atomizing nozzle Pretrip Inspection The following items should be inspected before loading the container e Check the water level in the water tank to maintain an adequate water supply Check humidify system operation by starting the unit setting the Humidify mode to ON and adjusting the humidify setpoint HUMSP more than 2 above the current humidity level in the container Verify that the air compressor operates and that water is drawn into the atomizing
237. r fan and compressor are turned off With evaporator fan on low speed amp draw is measured and compared to voltage and frequency CRR 40 1 0 Amps approx at 50 Hz 1 0 Amps approx at 60 Hz Amperes are recorded in the PTI log Condenser fan and compressor are turned off With evaporator fan on high speed amp draw is measured and compared to voltage and frequency CRR 40 2 1 Amps approx at 50 Hz 2 5 Amps approx at 60 Hz Amperes are recorded in PTI log Air vent is opened and verified that the motor is operating Evaporator fan is started and operating until CO2 value is below 0 5 percent or 20 minutes Condenser fan is turned on Amp draw is measured and compared to voltage and frequency 0 8 Amps maximum Condenser fan amperes are recorded in PTI log Readings may vary depending on voltage and temperature REVERSE PHASE TEST SUP RET EVA 1 3C 1 0C 1 3C 1 3A 1 2A 1 3A 78 With condenser fan on reverse phase selector relay is energized Condenser fan and compressor reverse current is measured 12 18 57 68 69 16 17 Duration Time 2 seconds 5 seconds 10 seconds minimum to 20 minutes maximum 10 seconds 30 seconds Operating Instructions CRR Function Test LCD Display Description Possible Duration Alarms Time HEAT ELEMENT TEST Electric heaters are turned on 10 11 10 seconds SUP RET EVA Amp draw is measured and compared to voltage 1 3C 1 0C 1 3C 4
238. r is installed for more than one minute Setting this value is not necessary However to calibrate the gas sensor unit the container must be opened and aired out for at least 15 minutes Then close container doors and manually set CA Option to ANALYZER ANALYZER turns on data logging of gas sensor readings only Gas Analyzer Evaporator Type Sets the evaporator fan value Must be manually set Condenser Type Sets the condenser fan value to 1 2 HP 2 HP or 3 4 HP Must be manually set Chart R Shows Not Present 20 F to 80 F 31 day 30 C to 25 C 31 day 25 C to 25 C 31 day e AFAM UNITS Sets the AFAM system units to CF cubic feet per minute M3 cubic meters per hour or PERCENT default is M3 e Auto Configuration View display ON or OFF value factory default OFF Set value to ON to automatically configure unit to installed Standard Display el F4 eB lt lt esc fet F1 F3 1 F2 a Main Menu ESC DATA F1 I ALARMS I COMMANDS F3 MISC FUNCTIONS I CONFIGURATION DATALOGGER RMM STATE Configuration Operating Instructions components See Automatic Configuration of Spare Parts Controller in this chapter for additional information Unit Sets the unit serial number Enter up to 11 characters number or letters Serial number must be manually set Serial number is required to enable automatic detecti
239. r records and displays operating information The following functions are available Date Time Sets the controller time and date Run Time Displays and sets operating hours for the unit and components Program Version Displays the current software version loaded in the controller Controller CTRL EPROM and program serial numbers SER NO NOTE The Controller Label on the side of the control box shows the controller serial number and the EPROM version Cargo Data Sets important trip information about the container and the load in the controller C F Mode Sets the temperature value Celsius or Fahrenheit the controller uses to record and display temperature including historical data 82 Viewing the Misc Functions Menu With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press F3 key to enter the menu list Press F2 key to scroll through Main Menu until MISC FUNCTIONS appears in LCD display 2 Press F4 key to access the Misc Functions menu The first command in the submenu appears in the LCD display Date Time 3 Press F2 or F3 key to scroll to the desired function e Date Time e Run Time e Program Version e Cargo Data e C F Mode 4 Press F4 key to access the function selected Standard Display Operating Instructions Note All screens are not present on all units The screens that display on the l E g controller are determined by the
240. rate disappears 4 Enter type the new rate in the LCD display using the general purpose keypad 0 to 25 WARNING Vent door and motor actuator arm may move immediately again when the rate is entered Keep hands and tools away from the air exchange system components to prevent personal injury or unit damage IMPORTANT Press and hold the F4 key until cursor stops flashing The new rate is recorded in the controller and appears in the LCD display 111 Operating Instructions 112 Operating Theory Data Recording and Downloading Data The MP 3000a datalogger can record sensor temperatures as well as loss of power alarms sensor failure setpoint change and unit shutdown events All data logs include the time and date setpoint temperature supply return ambient USDA1 USDA2 and USDA3 sensor temperatures and humidity sensor All temperature logs can be viewed from the controller s LCD message display Data logging interval is selectable from 1 minute or 1 2 1 2 or 4 hours When a 1 hour logging interval is selected the datalogger memory can store approximately 680 days of information The logging of USDA sensors is fixed at 1 hour intervals to comply with USDA requirements A logging test of USDA sensors at 1 minute intervals is also possible for 72 minutes USDA data can not be downloaded during the logging test After 72 minutes controller returns to previous logging interval and clears USDA test data from
241. re NOTE The setpoint temperature can be set between 30 C and 30 C 22 F and 86 F in either F or C using the C F key Just press and hold the F C key to display the alternate temperature scale e Press SETPOINT key to display cursor flashing in the TEMP SETP line e Press F4 key to enter new setpoint Enter Arrow appears in the menu line and the current setpoint disappears Enter minus sign first by pressing EXIT key Then press numeric keys to enter new setpoint e With correct setpoint in display press and hold F4 key until cursor stops flashing Controller places new setpoint in controller memory and shows new setpoint in LCD display NOTE New setpoint must be between 30 C and 30 C 22 F and 86 F or controller will return to the previous setpoint display NOTE If the F4 key is not pressed within 30 seconds the controller will default return to the previous setpoint If this occurs repeat step 4 Pretrip Inspection Visual Inspection The following inspections should be made before the container is loaded Visually check the unit for physical damage Check the electrical connections in the unit control box making sure they are fastened securely Check the conditions of wires and terminals Repair or replace if necessary 4 6 10 11 Check the refrigeration system for leaks Inspect for evidence of oil leaks at all joints and connections Check the
242. reens are not present on all units The screens that display on the controller are determined by the controller software setting and the options installed on the unit Setpoint Menu OPTI SET TEMP SETP BULB MODE EVAP FAN SPD DEFROST TRM ECONOMY MODE EVAP FAN SPD HUMIDITY CONTROL HUMIDITY SETPOINT AFAM AFAM DELAY AFAM RATE CO MAXIMUM Figure 54 Setpoint Menu Screen Flow Diagram Setting or Delta T Press F4 key Type the new setpoint or setting Press and hold F4 key until cursor stops flashing Activate Bulb USDA Trip Economy or Humidity Control Mode Press F4 key Press F2 key to toggle setting between off and on Press and hold F4 key until cursor stops flashing 107 Operating Instructions 2 Press F2 key to scroll to AFAM DELAY line The current setting 0 appears in the display 3 To enter a new time delay press the F4 key An Enter Arrow appears in the menu line and current time delay disappears 4 Enter type new time delay in the LCD display using general purpose keypad 1 to 72 hours The cursor moves to right of the screen as each key entry is acknowledged and displayed WARNING The vent door and motor actuator arm move immediately again when delay is entered Keep hands and tools away from air exchange system components to prevent personal injury or unit damage 5 Press and hold the F4 key
243. remains in the white zone when the test button is depressed during a pretrip inspection replace the battery Although the battery may operate the recorder up to 30 more days replacing the battery before it is completely dead is recommended e Red Zone Dead battery If the indicator needle remains in the red zone when the test button is depressed the battery is dead and must be replaced 100 AJA1335 1 Recording Chart Power Element Assembly Leak Seren Caraion B mew Figure 49 Saginomiya SKM Recording Thermometer To replace the battery 1 Raise the stylus away from the chart by rotating the pen lift gear clockwise 30 degrees and releasing the lifting arm The pen will remain in the raised position Remove the knurled chart nut from the drive shaft and remove the chart Loosen the four setscrews that hold the recording platen in the recorder The setscrews do not remove from the recorder base 10 Rotate the recording platen counterclockwise and remove the platen Remove the battery from the recorder Install a new battery in the recorder making sure the battery s positive and negative poles are correctly aligned Press the button on the voltage indicator to make sure the indicator needle is the in blue zone Check to see that the quartz motor is running Look through the inspection window and make sure the internal flywheel on the quartz motor is revolving Replace th
244. return air sensor temperature e Controller LCD display shows the setpoint temperature e Controller cycles a single speed condenser fan ON for 2 to 30 seconds every 30 seconds when the unit is on air cooled condenser operation optional Condenser Fan Switch on FAN AIR or water pressure switch closed The amount of ON time depends on the condenser coil ambient and compressor discharge temperatures NOTE When water is supplied to the water cooled condenser receiver the water pressure switch OPENS to prevent condenser fan operation Power limit is active during initial start up and pull down when the unit is cooling at return air temperatures above 10 C 14 F Cool e After initial start up and pull down to 1 0 C 1 8 F below setpoint the controller calls for the Cool mode whenever the Return air temperature increases more than 1 0 C 1 8 F above setpoint Compressor must operate for a minimum of 5 minutes after startup Controller turns ON the Compressor LED when the compressor is operating e After initial pull down to setpoint controller keeps the In range LED ON as long as the return air temperature remains less than 1 5 C 2 7 F above setpoint Null e The controller calls for Null when the Return Air Temperature decreases more than 1 0 C 1 8 F below setpoint The controller stops the compressor and condenser fan e The controller also de energizes closes the liquid line solenoid valve
245. rge temperature Compressor Discharge Temperature Control Liquid injection activated at compressor discharge temperatures between 115 C and 125 C 239 F and 257 F depending on KVQ valve setting Liquid Injection Valve Compressor Voltage 24 Vac Cold Resistance 5 6 ohms Evaporator Pressure Regulator KVQ Valve EPR Circuit Voltage 24 Vdc EPR Circuit Resistance 22 ohms EPRTH Thermistor Circuit Resistance 22 000 ohms at 20 C 68 F When the compressor is removed from the unit oil level should be noted or the oil removed from the compressor should be measured so that the same amount of oil can be maintained in the replacement compressor DO NOT use or add standard synthetic or mineral oils to the refrigeration system If Ester based oil becomes contaminated with moisture or with standard oils dispose of properly DO NOT USE 19 Specifications Normal R 134a System Suction Pressures D3DS Copeland Reciprocating Compressor Temperature Mode Cool 27 to 38 C 80 to 100 F 110 to 140 kPa 1 10 to 1 40 bar 16 to 20 psig Modulation Cool 27 to 38 C 80 to 100 F Cool 27 to 38 C 80 to 100 F 50 to 75 kPa 0 50 to 0 75 bar 7 to 11 psig Modulation Cool 27 to 38 C 80 to 100 F Modulation Cool 16 to 27 C 60 to 80 F 18 C 0 F Cool 27 to 38 C 80 to 100 F 30 to 15 kPa 0 30 to 0 15 bar 9 to 5 Hg vacuum Cool 16 to 27 C 60 to 80 F 35 to 25 kPa 0 35 to 0 25 bar 11 to 7
246. rn air sensor connections and locations Check for sensor or evaporator fan alarm codes Open evaporator door Inspect coil for ice or frost and initiate manual defrost if necessary Check for correct evaporator fan rotation and operation Inspect return air flow and cargo load Remove any debris or cargo from blocking return air grille At setpoints below 5 C 41 F maximum air vent setting is not allowed Check evaporator coil and return air sensor connections and locations 169 Diagnosis Troubleshooting Status Messages Alarm Codes Alarm Codes Descriptions and Corrective Actions NOTE Sensors used with the MP 3000a controller do not require calibration Check sensor resistance with an ohmmeter Shutdown Alarm Level 1 Alarm Alarm light on display flashes and unit stops Correct alarm condition and acknowledge alarm before restarting Supply Air Sensor Open Circuit Check Alarm Sensor circuit resistance higher than 100 000 ohms Temperature below 70C 94F Indicates Open circuit to left or right hand sensor Defective or wrong sensor Defective relay board Defective cable No 1 or cable No 3 Defective controller Supply Air Sensor Short Circuit Check Alarm Sensor circuit resistance lower than 200 ohms Temperature below 80C 176 F Indicates Short circuit to left or right hand sensor Defective or wrong sensor Defective relay board Defective cable No 1 or cable No 3 Defective contr
247. rolled AFAM or AFAM door provides programmable control of the air exchange rate The vent door is adjusted to the desired position by a vent door motor and linkage assembly The system is precalibrated for air exchange rates of 0 to 280 m 3 hr 0 to 165 ft 3 min The use of the AFAM or AFAM option should be established by the shipper WARNING After installing or servicing the AFAM door remove all tools and install the vent grille before starting the AFAM or AFAM system Failure to replace the vent grille before turning the AFAM or AFAM system ON may result in personal injury or unit damage The default setting for AFAM in the SETPOINT menu is the last value set OFF UNITS or DEMAND The AFAM submenu should be set to UNITS to control the vent door to the fresh air exchange rate setting If the controller identifies a component failure during unit startup an alarm is recorded in the controller display and data logger memory If a power loss occurs after the AFAM system is turned ON the controller automatically operates the vent door based on the previous AFAM DELAY and AFAM RATE settings when power is restored 60 N 3 E XN See e San Sea ae eer EU EEL NE eter eed IA 1 Cotter Pins 6 Vent Motor Linkage Figure 33 AFAM System Linkage Adjustment Alarm Alarm Code Type Description 57 Check AFAM Control Module or Motor Error Indicates a frozen or
248. rs with the cursor in the TEMP SETP line Press F2 key to scroll to ECONOMY MODE line To change the mode setting press F4 key Cursor moves to end of menu line and flashes Press F2 key to toggle between OFF and ON With the desired state in the menu line press and hold F4 key until cursor stops flashing New mode setting appears in display NOTE On frozen loads the Economy Mode also modifies the temperature control algorithm to extend the Null mode See Economy Min and Economy Max under Configuration Menu in this chapter to check the current settings or enter new settings Press ESC key to exit the SETPOINT screen Lemon hh hd nin mE c Standard Display Note All screens are not present on all units The screens that display on the controller are determined by the Controller Software setting and the options installed on the unit EVAP FAN SPD DEFROST TRM ECONOMY MODE HUM CONTROL Operating Instructions Enter a Temperature or Humidity Setpoint F4 Setpoint Menu OPTI SET 4 Press F4 key id Type the new setpoint BULB MODE Press and hold F4 key until cursor stops flashing Activate Humidity Control or economy Mode Press F4 key Press F2 key to toggle setting between off and on HUM SETP Press and hold F4 key until cursor stops flashing AFAM AFAM DELAY AFAM RATE CO MAX Figure 32
249. s in this chapter NOTE Defrost can be delayed for 24 hours during unit diagnosis or testing Press 7 key and Fl key at the same time from any controller screen display Press F3 key to scroll cursor down to DELAY DEF menu line Then press F4 key F2 key A key F4 key and EXIT key Cursor moves to end of line and flashes Pressure F3 key to toggle OFF to ON Then press and hold F4 key until cursor stops flashing If you have viewed and corrected these problems and the unit still appears to be operating incorrectly eliminate any possibility that the problem is caused by failure of components other than the controller Electrical Maintenance External Cause Checks e Poor contact between male and female connector plugs loose connection e Defective wire harness broken wires loose connections e External electrical causes such as faulty open or stuck contactors e Malfunction of refrigeration system components Unit Wiring Inspect unit wiring wire harnesses and the controller during pre trip inspection and every 1 000 operating hours to protect against unit malfunctions due to open or short circuits Look for loose chaffed or broken wires on the unit open or short circuits and damaged components on the controller printed circuit board NOTE Inspect electrical contactor points for pitting or corrosion every 1 000 operating hours Repair or replace as necessary High Pressure Cutout Switch
250. s F3 key to toggle value to desired setting G ANALYZER Press and hold F4 key until cursor stops flashing EVAP TYPE Main Menu COND TYPE CARGO PROBES zr DATA d AFAM UNITS ALARMS AUTO CONFIG COMMANDS UNIT MISC FUNCTIONS UNIT ID CONFIGURATION DATALOGGER RMM STATE Figure 55 Configuration Menu Screen Flow Diagram 109 Operating Instructions Advanced Fresh Air Management Plus AFAM System An advanced microprocessor controlled fresh air management system also provides programmable control of the CO level in the container and data logging of the CO gas level reading The AFAM system includes all AFAM system components plus a gas sensor unit sensor filter sensor vent before 4 01 or vent loop after 4 01 pressure relief valve assembly and single purge port The controller can be set to control the CO level in the container level between 0 to 25 Setting AFAM System Values WARNING After installing or servicing the AFAM door assembly remove all tools and install the vent grille before starting the AFAM system Failure to replace the vent grille before turning the AFAM system ON may result in personal injury or unit damage ey A aoe Gas Sensor Assembly Mounts in Evaporator 2 Vent Door Assembly and Damper Motor 3 Interface Board and
251. s long as the C F key is depressed 2 The display then returns to the original display when the C F key is released To change the default temperature unit display complete the following steps a Press and hold the C F key b Press the Setpoint key for 1 second Operating Instructions o o o o HEAT DEFROST IN RANGE ALARM nr ale MAIN MENU DATA TEMP SETP 220 C F SUP RET DEFROST SETPOINT Sup Ret Key Defrost Key Setpoint Key Figure 31 Special Function Keys 57 Operating Instructions Setpoint Menu Changing the Economy Mode in Pressing the SETPOINT key displays a list of Sett 9 tasks and values that can be activated or set NOTE Enter Setpoint temperature before turning ON the Economy mode The controller Opti Set automatically turns the Economy mode OFF Setpoint Temperature when the setpoint is changed Bulb Mode NOTE Economy Mode is replaced by the VFD evaporator fan system e Evaporator Fan Speed e Defrost Determination Temperature Mode s Economy Mode Humidity Control 2 Humidity Setpoint e AFAM T e AFAM Delay 4 e AFAM Rate 5 e CO Maximum NOTE The screens that display on the controller are determined by the controller software setting and the options installed on the unit All screens are NOT present on all units Changing the Setpoint Temperature See Changing the Setpoint in this chapter 6 58 Press the SETPOINT key The SETPOINT menu appea
252. s should agree with the data shown in the Sensor 9634 96 8 36 1330 Resistance Tables 35 6 5155 100 4 38 1239 0 2 e All sensors should be properly installed 392 Ael 104 40 Te 6 8 4329 107 6 42 1076 Supply air sensors must be inserted to the bottom of the sensor tube and completely 3907 111 2 44 1004 sealed by the grommet connection 50 10 3652 113 45 970 e Left hand supply sensor installs in the sensor tube behind the compressor e Right hand supply sensor installs in the sensor tube next to the control box e Return air sensor installs in a grommet between the evaporator fans 125 Electrical Maintenance Temp Temp OHMS Temp Temp OHM F C F C S 32 0 351017 158 70 15502 35 6 2 315288 161 6 72 14410 39 2 4 283558 165 2 74 13405 42 8 6 255337 168 8 76 12479 o AJA1280 46 4 8 230210 172 4 78 11625 50 10 207807 176 80 10837 A Insert Sensor into condenser coil between tube rows 1 and 2 53 6 12 187803 179 6 82 10110 a r Figure 59 Condenser Coil Sensor Location 57 2 14 169924 183 2 84 9438 60 8 16 153923 186 8 86 8817 Evaporator coil defrost sensor must be placed in the middle of the coil and at least 75 4 4 1 1 190 4 242 6 8 39588 190 88 8 mm deep between the fins 68 20 126729 194 90 7710 e Condenser sensor must be placed on the upper 71 6 22 115179 197 6 92 7216 left side of the condenser coil and at least 70 75 2 24 104796 201 2 94 6759 mm deep between the fins
253. scharge valve Then open the liquid line service valve Figure 80 KVQ Valve 13 Verify that all personnel are clear and connect main power plug to power supply Place the unit back in service 145 Refrigeration Maintenance KVQ Valve Replacement If the valve body is damaged replace the entire valve 1 Connect the unit s main power cable to the main power source Switch the refrigeration unit s On Off switch to ON 2 Close the liquid line service valve and pump down the low side to 21 kPa 0 21 bar 3 psig 3 Turn the unit On Off switch to OFF Then disconnect the main power cable from the main power source Close front seat the discharge service valve CAUTION Any time the discharge valve is front seated disconnect the unit power source to prevent accidental compressor Start up 4 Unplug the heater and thermistor lead wire harnesses 5 Unsolder the valve outlet compressor side joint from the suction line Unsolder the inlet joint and remove valve 6 Clean the tubes for soldering Position the new valve in position in the suction line 7 Solder both KVQ valve connections CAUTION Use a heat sink or wrap the valve with wet rags to prevent damage to the new valve 8 Pressurize the low side and test for refrigerant leaks see Refrigerant Leak Test Procedure in the Refrigeration Maintenance chapter of this manual NOTE If pressurizing with nitrogen front seat the discharg
254. se Checking Compressor Oil CAUTION Use ONLY Polyol Ester based refrigeration compressor oil P N 203 433 DO NOT mix Polyol Ester based and standard synthetic compressor oils CAUTION Rubber gloves are recommended when handling Ester based compressor oil CAUTION Keep Polyol Ester based compressor oil in tightly sealed containers If Ester based oil becomes contaminated with moisture or standard oils dispose of properly DO NOT USE The compressor oil should be checked during pretrip inspections and when there is evidence of oil loss oil leaks or when components in the refrigeration system have been removed for service or replacement Refrigeration Maintenance To check compressor oil level with an ambient air temperature above 10 C 50 F Install gauge manifold on the compressor Operate the unit on COOL with a 138 kPa 1 38 bar 20 psig minimum suction pressure and a 689 kPa 6 89 bar 100 psig discharge pressure for 15 minutes or more After the unit has maintained the above conditions for 15 minutes observe the compressor oil level The oil should be 1 2 to 3 4 up in the sight glass 1 Add and remove compressor oil at the compressor oil fitting Figure 73 Adjusting Compressor Oil Level To check compressor oil level with an ambient air temperature below 10 C 50 F With the evaporator temperature below 10 C 50 F initiate a Manual Defrost to operate the unit through a complete DEFROST CYCLE After compl
255. sensor filter vent loop pressure relief valve assembly and single purge port The controller can be set to maintain a maximum CO level in the container between 0 and 25 percent c ees E e Ser oo TS ce ho aS aa Sei SS Gas Sensor Assembly Mounts in Evaporator Bee ooo EM Vent Door Assembly Damper Motor Housing Damper Motor Assembly Mounting Bracket 7 Interface Board and Cable Mounts in Control Box 8 Stop Bracket Vent Door Full Open 9 Stop Bracket Vent Door Closed o ee Figure 5 Advanced Fresh Air Management AFAM Option 2 3 Linkage Assembly 10 Dehumidification Control System A dehumidification system lowers the relative humidity in the container to the humidity setpoint The control range is 50 to 98 while the setpoint is adjustable between 50 and 98 Dual Voltage A dual voltage system includes a 15 KVA auto transformer and an 18 3 m 60 ft power cable for operation on 230 90V 3 Ph 60 50 Hz power The power cable is stored below the control box in the condenser section The 15 KVA auto transformer steps 230 190V power up to 460 380V The auto transformer includes a 460 380V 3 Ph 60 50 Hz power receptacle For operation on 230 190V power plug the 460 380V unit power cable into the receptacle on the auto transformer Then plug the 230 190V power cable into a 230 190V power supply Humidification Control System An o
256. side of the filter drier slowly to release a small amount of refrigerant from the receiver tank to purge the air through the filter Then tighten the outlet nut NOTE When removing or replacing the o ring nuts on the filter drier always hold the body of the filter drier near the flange fittings to prevent twisting the tubing when the nuts are being loosened or tightened 7 Back seat open the liquid line service valve on the inlet side of the filter drier 8 Test the filter drier for leaks see Refrigerant Leak Test Procedure in this chapter 9 Ifno leaks are found place the unit in operation Expansion Valve Replacement Removal 1 Close the liquid line service valve and pump down the low side to 35 kPa 0 35 bar 10 in vacuum Break the vacuum with nitrogen between 10 and 20 kPa 0 10 and 0 20 bar 1 and 3 psig 2 Remove insulating tape and unclamp feeler bulb from the suction line in the condenser section Note the position of the feeler bulb on the side of the suction line 3 Remove insulating tape from expansion valve outlet line 4 Heat and unsolder the equalizer line from expansion valve 5 Heat and unsolder the liquid line inlet and outlet connections to expansion valve in condenser section 6 Remove expansion valve from unit Installation 1 Clean the liquid lines and equalizer lines for soldering 2 Place new expansion valve in position in liquid line 150 10 11 S
257. ss F2 key to toggle between OFF DEMAND and UNITS OFF Vent door stops in current position AFAM DELAY and AFAM RATE settings become blank If gas sensor unit is installed on unit the CO MAX settings also become blank DEMAND Controller uses the CO gas level to adjust the vent door position UNITS Controller uses the fresh air exchange rate to adjust the vent door position If a gas sensor unit is installed on the unit control of the CO gas level remains OFF Standard Display Operating Instructions 5 With UNITS in the menu line press and hold F4 key until cursor stops flashing UNITS now appears in display 6 Press ESC key to exit the SETPOINT screen Changing the AFAM Delay NOTE The fresh air exchange time delay should be established by the shipper The AFAM delay setting keeps the fresh air vent closed for a preset time when the unit starts This allows faster product temperature pulldown The AFAM delay can be set from 1 to 72 hours in 1 hour increments NOTE During unit startup the AFAM delay prevents the AFAM door from opening until the delay times out The AFAM delay prevents the AFAM door from opening due to the AFAM Rate or CO system settings 1 Press the SETPOINT key The SETPOINT menu appears with the cursor in the TEMP SETP line Enter a Temperature Setpoint Humidity Setpoint Defrost Term F4 Temp Defrost Time Note All sc
258. ssor to start Check direction of evaporator airflow see Condenser Fan and Evaporator Fan Rotation in Electrical Maintenance chapter of this manual Perform a Pretrip PTI Test to check the unit refrigeration and electrical systems for proper operation CAUTION The PTI test should only be performed on an empty container 53 Operating Instructions NOTE Correct all existing alarm conditions and clear the alarm codes before performing a PTI test The controller will automatically clear all existing alarms before beginning the PTI test To perform a PTI test 54 e Press F2 key to enter Main Menu e Press F2 or F3 key to scroll up or down in menu to COMMANDS e Press F4 key to access COMMANDS menu e Press F2 or F3 key to scroll up or down to PTIT e Press F4 to start the PTI Pretrip Test e The controller then performs the Pretrip Test e Observe the unit for proper operation and functions during pretrip test e LCD display shows PTI Test currently being performed e PTI test ends automatically Press any key on the controller to return the unit to normal operation e Ifan operating problem occurs during the Pretrip Test the Alarm LED will turn ON and FLASH An E may also appear in the right side of the LED display View and correct any alarm conditions Then clear acknowledge the Alarm Code s and repeat the PTI Test NOTE Clear the Alarm codes ONLY after the
259. stuck vent door or a problem with the control module or its wiring or the motor current draw is not with limits 68 Check AFAM Gas Analyzer Error Indicates a communication problem with the gas analyzer 69 Check AFAM Gas Analyzer Calibration indicates problem with sensor Linkage Installation and Adjustment If the vent door motor linkage assembly or vent door require repair or replacement make sure the linkage is properly adjusted 1 Insert L rod in damper motor linkage so that the eyelet in the rod end aligns with the vent door bracket Install pin shoulder washer and cotter pin to fasten L rod to damper motor linkage Fully thread the rod end onto the L rod Then back off rod end approximately 2 complete rotations Operating Instructions Align the rod end eyelet in the vent door bracket Temporarily insert pin to fasten rod end to door bracket Visually check the linkage alignment The linkage should be straight and touching or almost touching the mechanical stop If the linkage is linkage is binding or jammed against the stop the linkage is too long Disconnect the rod end from the door bracket Shorten the linkage by rotating the rod end on to the L rod additional rotations Shorten linkage until linkage alignment is correct Visually check vent door seal If the vent door is fully closed but the door gasket does not create a tight seal with the air exchange openings the linkage is too short Disconnect
260. t an hourmeter or set hours on a replacement controller a Press F4 key with cursor in the desired menu line The password screen appears b Press F2 key A key password is A F4 key and then EXIT key An Enter Arrow appears in the hourmeter line c Enter the desired run time setting up to 5 characters d When the entry is complete press and hold the F4 key until the cursor stops flashing The new run time appears in the menu line Repeat steps 5 and 6 to reset additional hourmeters Press ESC key to exit the Run Time screen Setting Cargo Data 1 Press F3 key to enter the menu list Press F2 key to scroll to MISC FUNCTIONS Press F4 key to access the Misc Functions menu Date Time appears in the LCD display Press F2 key to scroll to CARGO DATA Press F4 key to access the Cargo Data screen Cargo Data screen appears with cursor in LOC BRT menu line Press F3 key to scroll cursor down through cargo data list LOC BRT CONTENTS DATE Loading Date VOYAGE SHIP LD PORT Loading Port DIS PORT Discharge Port COMMENTS To enter text in a cargo data line press F4 key with cursor in the desired menu line An Enter Arrow appears and the cursor flashes in the selected line Enter type the desired text When entering information Enter up to 10 characters of text numbers for each menu item To scroll backwards in the text box press and
261. t ends automatically Unit automatically returns to normal operation See CRR Function Test Procedure in the following table for a detailed description of the Function Test Any alarm codes recorded during the test can be viewed through the controller s Alarm List menu at the end of the test Operating Instructions NOTE All screens are NOT present on all units The screens that display on the controller are determined by the Controller Software settings and the options installed on the unit ALARMS DATA RMM STATE DATALOGGER CONFIGURATION MISC FUNCTIONS Commands oe Menu PTI Test lt L A het gemen COMMANDS Function Test _ Manual Function Test Brief PTI Test Y Figure 39 Function Test 77 Operating Instructions LCD Display CRR Function Test Description Possible Alarms 99 FUNCTION TEST START Activated 0 1A 0 0A 0 1A SENSOR TEST Activated 0 1A 0 0A 0 1A EVAP FAN LOW TEST SUP RET EVA 5 1C 5 0C 5 16 1 1A 1 0A 1 1A EVAP FAN HIGH TEST SUP RET EVA 5 1C 5 0C 5 16 2 4A 2 3A 2 4A AFAM TEST SUP RET EVA 5 1C 5 0C 5 16 2 4A 2 3A 2 4A COND FAN TEST SUP RET EVA 5 2C 5 0C 5 1C 1 3A 1 2A 1 3A Event Log for FUNCTION TEST begins All alarms are turned off Alarm list is cleared All relays are turned off and air vent are closed All sensors must have values within their measuring range Condense
262. t tank hand valve 5 Start and operate the unit in the COOL mode 6 Read the suction pressure and slowly open the gauge manifold low pressure hand valve to permit suction pressure to increase approximately 170 kPa 1 7 bar 25 psig This will meter liquid refrigerant slowly into the low side 7 Add refrigerant until the receiver tank balls float in the top sight glass 8 Close the hand valve on the refrigerant tank 9 Operate the unit on COOL for 10 minutes and recheck refrigerant charge 10 Remove the gauge manifold set 143 Refrigeration Maintenance 11 Cap all service ports and valve stems CAUTION If the controller temperature setpoint was lowered to force COOL operation be sure to return the controller to the setpoint indicated on the shipping manifest Evaporator Pressure Regulator KVQ Valve The evaporator pressure regulator valve is used to control the flow of refrigerant to the compressor when the unit is operating in the Power Limit and Modulation Cool modes As the supply air temperature approaches setpoint the controller sends a voltage pulse to a heater in the valve The heater warms a pressure reservoir in the valve actuator As the pressure in the fluid reservoir increases a pressure pin overcomes the spring tension in the bellows closing the valve plate a precise amount This throttles the suction gas returning to the compressor and reduces cooling capacity As the frequency of the voltage
263. tatus Indicator LEDs Eight status indicator LEDs are located along the top of the Temperature Status Display and signal the following Supply Air Temperature Return Air Temperature Humidity Mode Humidification set to On in Setpoint menu Compressor Cooling On e Heat On e Defrost e In range Temperature Alarm The indicator LEDs stay on continuously to indicate sensor temperature display unit operating mode or condition The Alarm LED flashes on and off continuously when a Check Alarm or Shutdown Alarm occurs 44 Message Display The Message Display shows setpoint temperature during normal operation Alarms messages and the controller menu also appear in the LCD display when special keys are pressed MAIN MENU DATA TEMP SETP 22 0C Figure 23 Message Display Four Special Function Keys The following four keys are located at the bottom of your controller These special function keys allow the operator to move quickly to a specific area of information F SUP RET DEFROST SETPOINT Bite 24 Special Function Keys AJA1974 C F key Press to view alternate temperature scale Celsius or Fahrenheit in LED display e DEFROST key Press to initiate defrost Evaporator coil temperature must be below 10 C 50 F SuP RET key Press to view alternate return supply sensor temperature in LED display e SETPOINT key Press to enter Setpoint menu The first line of the Setpo
264. ter on a key Press the F4 key and the desired letter key NOTE When a function key F1 F3 F3 or F4 is pressed to enter text the keypad remains on that character level until another function key is pressed Alarms Menu Clear alarm code by To Enter a Controller Menu or Use Special Function Key Viswisnd white down correcting problem and i knowledging the alarm Press F4 key to directly enter the Data menu ALARMS all alarm code AS a A ESC E To acknowledge an alarm Press F2 key to directly enter the Alarms menu F1 G en ean press F4 key with alarm Press F3 key to directly enter the Main menu code in display MAIN MENU Press SETPOINT key to enter Setpoint menu DATA Press C F Key to view alternate temperature scale in LED display PEEL f Ss gel al Condenser High Press Voltage Frequency Curr Ph 3 TEMP SETP 22 0 Press SUP RET key to view alternate sensor temperature in LED display EAA Supply RH KVQ Setting High Pr Tmp Volt P1 P2 or 02 Press DEFROST key to initiate a manual defrost Evaporator coil DATA re JT Return Cool Cap Hum Val ee XE ERST CO2 temperature must be below 10 C 50 F Evaporator Ambient Bat Voltage 9 mU ereshiAin Ex Evap Fan Speed To Enter a Submenu a Command or a New Value in a Text Screen EY i Press F4 key To Scroll in a Menu or a Text Line RMM Status Press F2 key to scroll up or backward RMM STATE Display shows current status
265. the quartz motor is operating flywheel revolving 7 Replace the recording platen recording chart and chart nut Lower the recording pen January 15 2002 Electronic Chart Recorder for MP3000a Controllers An Electronic Temperature Chart Recorder is available for use in the MP 3000a controlled units The recorder connects to the controller through a RS 485 port on the side of the controller The recorder uses the sensors in the unit for it data chart plotting The charts that are used are any 31 day type charts currently used or available in the industry Recorder Installation Recorder fits in TK enclosure only If OEM Partlow box is installed it must be replaced with TK design box 1 2 3 Turn unit OFF and remove from main power Remove OEM recorder from enclosure Route recorder cable through sensor harness grommet in bottom of control box NOTE Cable end with connector is controller end Loose wire end goes to recorder Plug the RS 485 plug into controller Connect power wires to battery connector on controller PK11 1 RS485 blue PK11 2 RS485 white PK11 3 Signal GND green PK5 6 24Vac orange PK5 7 24Vac orange white Figure 50 Power Wire Connections Operating Instructions Route recorder cable loose wire end through grommet in bottom of recorder enclosure and Timmerman clamp on recorder Ensure exposed length is enough to reach recorder connections Connect
266. this group display refrigerant type in range setting container ID contrast screen language unit type reefer type AFAM option evaporator type condenser type USDA type AFAM units and other unit settings Miscellaneous Functions Menu Menu screens in this group display date time C F cargo data program version and run time hourmeters information e Commands Menu Menu screens in this group are used to activate pretrip PTI tests function tests manual function tests and power management A complete listing of the controller operating menu is located on an 11 x 17 fold out in the Wiring and Diagram section in the back of the manual see last page in book It is designed to be folded out so you can continuously view it as you are learning how to navigate the MP3000a Controller Menu It is recommended to fold this menu out and leave it folded out until you become familiar with the controller menu Operating Instructions Unit Control Box 1 UNIT ON OFF SWITCH a ON position Unit will operate on cool or heat depending on the controller setpoint temperature and the container air temperature b OFF position The unit will not operate 2 CONDENSER FAN SWITCH Water Cooled Condenser Option Model CRR40 303 119 172 800 Only a FAN AIR position Condenser fan operates as required during cooling to provide air cooled condensing b WATER position Condenser fan does NOT operate so refrigerant conde
267. ting Status Messages Alarm Codes Heat Capacity Test Error Check Alarm Enter Manual Function Test and start evaporator Ed Occurs during Pretrip PTI test only Difference between supply and return air temperature too small with high speed evaporator fans less than 0 4 C 0 7F Indicates Incorrect location of supply or return air sensor Air leakage at supply return or evaporator coil sensor cable Defective supply or return air sensor Interchanged sensor connections Defective heater elements Incorrect evaporator fan rotation or high speed operation Container side panels defective damaged or leaking Liquid Injection Valve Error Pretrip Check Alarm Occurs during Function or Pretrip PTI test only Indicates Faulty bypass valve or circuit Condenser Temperature Sensor Open Circuit Check Alarm Sensor circuit resistance higher than 100 000 ohms Temperature below 70 C 94 F Indicates Open circuit to sensor Defective or wrong sensor Defective relay board Defective cable no 1 Defective controller fans on HIGH speed Then select Sensor Checks test and operates fans 2 to 5 minutes Check supply return and evaporator coil defrost sensor temperatures Sensor readings should be the same evaporator coil may be 0 5 C 1 0 F lower due to fan motor heat NOTE this sensor check does not detect air leakage around the sensor cables Open evaporator door and inspect evaporator fan
268. tion Station valves V1 V3 and V4 It is only necessary to open valve V2 when a reading on the Micron Meter is desired This is especially true when starting to evacuate a unit and large amounts of moisture and oil will be passing by the sensor 139 Refrigeration Maintenance 6 Open the vacuum pump Iso Valve built into the pump housing below the handle It is recommended that the valve be kept open at all times 7 If connecting a refrigerant tank and gauge manifold to the evacuation station close the gauge manifold and refrigerant tank valves to prevent refrigerant from being drawn from the tank Unit Evacuation 1 Turn on the Vacuum Pump Open the Gas Ballast Valve located on top of the pump housing behind the handle the valve is fully open at two turns counterclockwise Evacuate the system to 500 microns to achieve a final equilibrium pressure of 2000 microns or less The final equilibrium pressure is determined with the Thermo King Evacuation Station using the following procedure called a pressure rise test a Evacuate the system using the Evacuation Station until the vacuum level reaches 1000 microns Then close the Gas Ballast Valve b Continue evacuation to 500 microns or until vacuum stabilizes at its lowest level Contamination may delay reaching the lowest level for a period of several or more hours c Close valve V1 to isolate the vacuum pump from the system Observe the vacuum level on the Mi
269. to the unit e Avoid contacting the electronic components on the circuit boards of the unit being serviced Leave the circuit boards in their static proof packing materials until ready for installation e Return a defective controller for repair in the same static protective packing materials from which the replacement component was removed e Check the wiring after servicing the unit for possible errors Complete this task before restoring power Welding of Units or Containers Electric welding can cause serious damage to electronic circuits when performed on any portion of the refrigeration unit container or container chassis with the refrigeration unit attached It is necessary to ensure that welding currents are not allowed to flow through the electronic circuits of the unit The following statements must be rigidly adhered to when servicing these units to avoid damage or destruction e Disconnect all power to the refrigeration unit e Disconnect all quick disconnect wire harnesses from the back of the controller Disconnect all wire harnesses from the Remote Monitor Modem RMM e Switch all of the electrical circuit breakers in the control box to the Off position e Weld unit and or container per normal welding procedures Keep ground return electrode as close to the area to be welded as practical This will reduce the likelihood of stray welding currents passing through any electrical or electronic circuits
270. tor cover and inspect the assembly for rust or corrosion Rust or corrosion can damage the actuator or heater circuit preventing the valve from operating properly 1 To replace actuator assembly unplug the heater and thermistor lead wire harnesses 2 Connect the unit s main power cable to the main power source and switch the refrigeration unit s On Off switch to ON Close the liquid line service valve and pump down the low side Equalize suction pressure to 21 kPa 0 21 bar 3 psig 3 Turn the unit On Off switch to OFF Then disconnect the main power cable from the main power source again Close front seat the discharge service valve CAUTION Any time the discharge valve is front seated disconnect the unit power source to prevent accidental compressor start up 4 Inspect the actuator terminals and note the wire connection sequence Then disconnect wire leads 5 Unscrew the actuator assembly from the valve body 6 Immediately insert new actuator assembly in Actuator Assembly valve body y Threaded Connection 7 Thread new actuator into valve body until it is Valve Body hand tight Then tighten to 45 N m 33 ft lb IGITUR Inlet Tube 8 Connect wire leads to actuator terminals in Valve Plate proper sequence EN ES 9 Replace cover on actuator assembly 10 Connect the heater and thermistor lead wire EN Bellows Assembly harnesses s Pressure senor 11 Evacuate the low side Heating Element 12 Open the di
271. tures unit electrical data etc Refer to the Data Menu in the Operating Instructions Section 159 Diagnosis Troubleshooting Status Messages Alarm Codes Mechanical Diagnosis Compressor does not operate no amperage draw Compressor does not operate excessive amperage draw or intermittent cycling on overload NOTE Controller sequence starts the compressor when the unit has been off for more than 18 hours 160 Controller ON unit start sequence still timing No Power to unit condenser and evaporator fans do not operate Open in 29 VAC control circuit Container temperature does not demand compressor operation Compressor contactor inoperative No output signal from controller Unit on defrost Defective high pressure cutout switch High condenser head pressure causing high pressure cutout Defective compressor Controller shut unit down on Compressor Over Temperature fault code 56 Compressor motor internal thermal overload protection open Piston stuck Seized or frozen compressor bearings Improperly wired Low line voltage High head pressure Contacts in compressor contactor not closing completely Open circuit in compressor motor winding Defective compressor motor internal thermal overload protector Wait up to 3 minutes for compressor start up Locate fault and repair power source power plug main circuit breaker motor contactor motor terminals motor Check fuses and On
272. unctional test of the unit Operating Instructions Viewing the Commands Menu With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press the F3 key to enter the Main Menu 2 Press F2 key to scroll through Main Menu until COMMANDS appears in LCD display 3 Press F4 key to access the Commands menu The first command in the submenu PTI Test appears in the LCD display 4 Press F2 or F3 key to scroll to the desired command e PTI Pretrip Power Management e Function Test e Manual Function Test e Brief PTI Pre Trip 5 Press F4 key to activate the command selected e PTI Pretrip LCD display shows PTI Test currently being performed PTI test ends automatically Press any key on the controller to return the unit to normal operation Power Management LCD display shows current Power Limit setting and Power Time setting Turn Power Limit feature ON and OFF change power limit setting or change power limit time Function Test LCD display shows functional test currently being performed Function test ends automatically Unit automatically returns to normal operation Manual Function Test LCD display shows list of unit components Test the operation of individual components or turn several components ON at the same time to perform a system test Function Test LCD display shows functional test currently being performed Function test ends automatically Unit auto
273. until the cursor stops flashing The new time delay is recorded in the controller and appears in the LCD display 6 Press ESC key to exit the SETPOINT screen Changing the AFAM Rate NOTE The fresh air exchange rate should be established by shipper The AFAM rate sets the desired air exchange rate The actual door position is based on the AFAM rate and the power supply frequency Hertz 1 Press the SETPOINT key The SETPOINT menu appears with the cursor in the TEMP SETP line 2 Press F2 key to scroll to AFAM RATE line The current rate and units e g O CFM appears in the display 3 To change the rate press the F4 key An Enter Arrow appears in the menu line and the current rate disappears 4 Enter type the new rate in the LCD display using the general purpose keypad 108 Units Rate Setting CFM 0 to 168 Cubic Feet Per Minute M3H 0 to 280 Cubic Meters Per Hour PERCENT 0 to 100 Percent WARNING The vent door immediately closes and re opens to the new position when a rate is entered Keep hands and tools away from the air exchange system components to prevent personal injury or unit damage 1 Press and hold the F4 key until the cursor stops flashing The new rate is recorded in the controller and appears in the LCD display Setting AFAM Units in the Configuration Menu With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press the F3 key to
274. urn and Supply LEDs are lit The LED then shows the controlling air sensor temperature The controller senses the incoming power phase and selects the correct power phase to unit components e The evaporator fan motors start about 40 seconds after the unit was turned ON Evaporator fans operate on high speed at setpoints of 9 9 C 14 1 F and above Evaporator fans operate on low speed at setpoint temperatures of 10 C 14 F and below e About 10 seconds later the compressor starts and the liquid line solenoid energizes opens if the controller calls for cooling The condenser fan then starts if the condenser temperature requires condenser fan operation On units equipped with a water cooled condenser the water pressure switch must also be CLOSED or the Condenser Fan Switch on FAN AIR position e Ifthe controller calls for heating the electric heaters are pulsed On and Off to provide heat e The controller turns ON the In range LED when the controlling sensor temperature is within 1 5 C 2 7 F of the setpoint NOTE If the compressor has been off for more than 18 hours the controller performs a compressor sequence start See Compressor Sequence Start on page 4 5 for further details NOTE Random time delays during the initial unit start up minimize peak current draw Continuous Temperature Control Operation Chill Loads Controller Setpoint at 9 9 C 14 1 F and Above The controller regu
275. urn the unit 460 380V main circuit breaker OFF b Disconnect unit power cord from power supply c Relocate the phase selector terminal plug from J18 see decal on main relay board Relocate from A to B B to A as required d Connect unit power cord to the proper power supply e Start the unit again by turning the unit 460 380V main circuit breaker ON Check condenser and evaporator air flow again to confirm correct fan rotation 94 Advanced Fresh Air Management AFAM or Advanced Fresh Air Management Plus AFAM Door Options A microprocessor controlled AFAM or AFAM door provides programmable control of the air exchange rate The vent door is adjusted to the desired position by a vent door motor and linkage assembly The system is precalibrated for air exchange rates of 0 to 280 m 3 hr 0 to 165 ft 3 min The use of the AFAM or AFAM option should be established by the shipper WARNING After installing or servicing the AFAM door remove all tools and install the vent grille before starting the AFAM or AFAM system Failure to replace the vent grille before turning the AFAM or AFAM system ON may result in personal injury or unit damage The default setting for AFAM in the SETPOINT menu is the last value set OFF UNITS or DEMAND The AFAM submenu should be set to UNITS to control the vent door to the fresh air exchange rate setting If the controller identifies a component failure during unit startup
276. urning on the electric heaters The controller terminates the defrost mode when Evaporator temperature Chill mode Evaporator coil sensor temperature reaches 30 C 86 F or exceeds 18 C 65 F for 35 minutes Frozen mode Evaporator coil sensor temperature reaches 30 C 86 F or exceeds 8 C 46 F for 35 minutes Interval timer Controller terminates defrost after 90 minutes on 60 Hz power 120 on 50 Hz power Alarm code 20 will be generated if this occurs Power OFF Turning unit On Off switch Off terminates defrost When the defrost mode is terminated The Heat and Defrost LEDs turn OFF and the heater contactor is de energized The controller starts the compressor and energizes the liquid line solenoid to pre cool the evaporator coil The condenser fan starts if required IMPORTANT The controller pre cools the evaporator coil to the supply air temperature or for 3 minutes maximum to minimize heat energy release into the container The controller then starts the evaporator fans Controller Maintenance Replacing the Controller 1 Turn the unit On Off switch OFF 2 Turn the unit 460 380V main circuit breaker OFF Then disconnect the unit power cord from the power supply WARNING The unit will automatically start and operate if 460 380V power is present at the main relay board when the controller is disconnected To prevent personal injury from rotating machinery or dangerous electrical shock form high
277. v Wans keai erue Rw ato DECI em mos wem 3s poss ss mem 7 System net cooling capacity with a 30 C 86 F water temperature 30 liter min 8 gal min water flow and R 134a System Net Heating Capacity Heater Type 460 230V 3 Phase 60 Hz Power 380 190V 3 Phase 50 Hz Power Heating Capacity Heating Capacity Watts Kcal hr BTU hr Watts Kcal hr BTU hr CRR40 PS amp PS 5 800 4 984 19 800 4 814 4 136 16 434 System net heating capacity for all models includes electric resistance rods and fan heat 17 Specifications Evaporator Airflow CRR40 External Static Pressure water column amos e e0 wm zz5 omean ser aero 29 5 gt mms aee a se Electrical System Compressor Motor Type Kilowatts Horsepower RPM Full Load Amps Locked Rotor Amps Condenser Fan Motor Type Kilowatts Horsepower RPM Full Load Amps Locked Rotor Amps Type Number Evaporator Fan Motors Kilowatts Each Horsepower Each RPM Each High Speed Low Speed Full Load Amps Each High Speed Low Speed Locked Rotor Amps High Speed Low Speed Electrical Resistance Heater Rods Type Number Watts 60 Hz Each Current Draw Amps 18 460 380V 60 50 Hz 3 Phase 5 60 kW 9 460V 60 Hz 7 5 hp 9 460V 60 Hz 1750 rpm 60Hz 15 5 amps 460V 60 Hz 15 5 amps 380V 50 Hz 83 amps 460 Hz 82 to 91 amps 380V 50 Hz 4
278. vice line to the recovery machine and properly purge the lines Set the recovery machine for vapor recovery 2 Keep unit OFF and mid seat the discharge service valve 3 Turn ON the recovery machine and open back seat both gauge manifold and hand valves 4 Continue to operate the recovery machine until unit pressures drop to 0 kPa 0 bar 0 psig pressure Liquid Recovery 1 Install a gauge manifold s low pressure line to the service fitting on the suction service valve Attach the manifold s high pressure line to receiver tank service port Attach the service line to the recovery machine and purge the lines 2 Operate the unit and build discharge pressures to approximately 1380 kPa 13 80 bar 200 psig 3 Close the liquid line service valve and pump down the low pressure side of the system 4 Stop the unit 5 Set recovery machine for liquid recovery and turn it ON 6 Open back seat high pressure valve on gauge manifold 7 Operate the recovery machine until the unit system pressures reach approximately 0 kPa 0 bar 0 psig Using Pressurized Nitrogen The improper use of high pressure cylinders can cause physical damage to components or personal injury or cause stress that would lead to failure of components Safety Precautions Observe the proper handling of cylinders 1 Always keep protective cap on cylinder when not in use 2 Secure cylinder in proper storage area or fastened to cart
279. y 8 Stop Bracket Vent Door Full Open Linkage Assembly 9 Stop Bracket Vent Door Closed Figure 17 Advanced Fresh Air Management Plus AFAM Option 39 Unit Description Features and Options D Eao Dan ies 5 aer S Vaer antene s Water Suevo Tank Overow ese 9 Arcomp Figure 18 Humidify System Option 40 AJA1561 Unit Description Features and Options AJA1562 d A2 2 O S g o Q o 2 ul EG x o a I o Ww oc LL e Z lt oc E A2 Wire Harness to TRANSFRESH Transformer A3 Wire Harness to TRANSFRESH Download Port Purge Port Figure 19 TRANSFRESH Provision Option 41 Unit Description Features and Options AJA1563 Evaporator Grille Air Channels Fresh Air Inlet Top Rear Plate Bottom Rear Plate Receptacle Panel Controller Communications and Data Download Port USDA1 Spare 1 Sensor Connection USDA2 Spare 2 Sensor Connection USDA3 Spare 3 Sensor Connection Figure 20 Unit Back View 42 Controller Description Controller Description The MP 3000a is an advanced microprocessor controller It has been specially developed for the control and monitoring of refrigeration units The controller contains the following basic features Temperature Status Display Displays the controlling sensor temperature return or supply Also has 8 status indicator LED s See the next page for further information
280. y setpoint 1 Press the F2 or F3 key to enter the menu list 2 Repeatedly press the F2 or F3 key to scroll through Main menu until COMMANDS appears in LCD display 3 Press the F4 key to access the Commands menu The first command in the submenu appears in the LCD display 4 o Press the F2 or F3 key to scroll to PTI TEST Press the F4 key to start the PTI test LCD display shows PTI test currently being performed PTI test ends automatically Press any key on the controller to return the unit to normal operation NOTE All screens are NOT present on all units The screens that display on the controller are determined by the Controller Software settings and the options installed on the unit EN MAIN MENU ALARMS DATA RMM STATE DATALOGGER CONFIGURATION MISC FUNCTIONS Commands Menu PTI Test Power Management Function Test Manual Function Test Brief PTI Test oa COMMANDS Figure 38 Full PTI Test 73 Operating Instructions See the following pages for the CRR PTI Full Pretrip Test Procedure for a detailed description of the PTI Test Detailed PTI test results are stored Any alarm codes recorded during the test can be viewed through the controller s Alarm List menu at the end of the test in the MP 3000a Datalogger for later viewing CRR PTI Full Pretrip Test LCD Display Description Possible Duration Alarms Time PTI START Activated 0 1
281. ze and the LED above the compressor relay is NOT ON check for a defective cable No 2 main relay board or controller Check discharge and suction pressure gauge readings Evaluate readings based on current cargo and ambient temperatures Check volt and ampere meter Check power supply volts NOTE If both alarms 06 and 07 are activated the alarms are caused by a large difference in measured amps Enter Function Test and start condenser fan compressor compressor 100 and evaporator fans on HIGH speed Check the amps measurements if necessary check the resistance of the motor windings 172 Heater Current Too High Check Alarm Occurs during Pretrip PTI or Function Test Heater power consumption is 2596 above expected current draw above approximately 4 4 amps and 5 1 amps depending on voltage Indicates Incorrect heaters or heater connections Defective volt or amp meter on relay board Defective heater element Enter Manual Function Test and turn heaters ON Check current draw on each phase Current draw should be about 4 4 amps on each phase at 400V 5 1 amps at 460V Check heater resistance between H1 and H2 H2 and H3 and H1 and H3 Resistance should be about 99 ohms on each leg Diagnosis Troubleshooting Status Messages Alarm Codes Heater power consumption is 25 below the expected current draw below approximately 3 2 amps and 3 8 amps depending on voltage Indicates Defectiv
282. zer Calibration Error Compressor Sensor Open Circuit Compressor Sensor Short Circuit USDA 1 Sensor Open Circuit KVQ Sensor Open Circuit KVQ Sensor Short Circuit KVQ Heat Error Zero Current Too High Probe Error Return amp Evaporator Probe Error Return amp Supply Probe Error Supply RH amp Supply LH 67 Operating Instructions Commands Menu The Commands menu displays a list of tasks that can be activated The following commands are available Function Test Controller automatically tests the operation of individual unit components This is not a performance test of the complete system See Function Test in this chapter for test details e PTI Full Pre Trip Test Controller automatically completes a test of individual components checks unit refrigeration capacity heating capacity and temperature control CAUTION The PTI test should only be performed on an empty container Standard Display o o HUMIDITY COMP HEAT DEFROST IN RANGE ALARM o o o o o RETURN ix mr z eo SUPPLY Commands Menu COMMANDS MANUAL FUNCTION TEST COMMANDS POWER MANAGEMENT Power Management Sets the power limit and power limit activation On time Manual Function Test Controller tests individual components selected by the technician for diagnosis LCD display will show expected and actual current of the component being tested Brief PTI Brief Pretrip Test Controller automatically

Download Pdf Manuals

Related Search

Related Contents

Ref. 7150-7150M  TECHNICAL SERVICE MANUAL  Warenwirtschaft (AFS-Kaufmann) - AFS  CONtrôles microbiologiques en hygiène hospitalière  

Copyright © All rights reserved. Failed to retrieve file