Variable refrigerant flow system 4-way cassette indoor unit series (36 pages)
Summary of Contents for Ingersoll-Rand Thermo King CRR DF MPC2000ID
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Maintenance Manual CRR DF MPC2000 SB-210+ SB-210+ SB-210+ CRR DF MPC2000ID Additional text information Additional text information Additional text information to be placed here to be placed here to be placed here CRR DF MP 3000 TK 5XXXX-X-PL TK 5XXXX-X-PL TK 5XXXX-X-PL TK 50134-4-MM (Rev.
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The maintenance information in this manual covers unit models: CRR-40 DF with MPC2000 CRR-40 DF with MPC2000ID CRR-40 DF with MP3000 For further information, refer to: CRR DF Parts Manual TK50262 Diagnosing Thermo King Container Refrigeration Systems TK41166 Electrostatic Discharge (ESD) Training Guide TK40282 Evacuation Station Operation and Field Application TK40612...
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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.
Introduction CRR DF Model Features Features X=Included X X X 460-380V/3Ph 60-50 Hz, 18.3 m (60 ft) Power Cable and Plug X X X 32 Amp Main Power Circuit Breaker X X X Automatic Phase Selection Control X X X Three Evaporator Fans with 2-Speed Motors X X X One 1-speed Condenser Fan Motor X –...
Safety Precautions General Practices 1. ALWAYS WEAR GOGGLES OR SAFETY GLASSES. Refrigerant liquid and battery acid can permanently damage the eyes (see First Aid under Refrigerant Oil). 2. Never close the compressor discharge valve with the unit in operation. Never operate the unit with the discharge valve closed.
Safety Precautions Refrigerant Oil Observe the following precautions when working with or around refrigerant oil: • Do not allow refrigerant oil to contact your eyes. • Do not allow prolonged or repeated contact with skin or clothing. • To prevent irritation, you should wash thoroughly immediately after handling refrigerant oil. Rubber gloves are recommended when handling Polyol Ester based refrigerant oil.
Safety Precautions First Aid IMMEDIATE action must be initiated after a person has received an electrical shock. Obtain immediate medical assistance if available. The source of shock must be immediately removed by either shutting down the power or removing the victim from the source.
Safety Precautions 6. If a defective controller is to be returned for repair, it should be returned in the same static protective packing materials from which the replacement component was removed. 7. After servicing the circuit board and any other circuits, the wiring should be checked for possible errors before restoring power.
Service Guide Every 1,000 Annual/ Pre-Trip Hours Yearly Inspect/Service These Items Electrical • Perform a controller Pretrip Inspection (PTI) check. • • • Visually check condenser fan and evaporator fan rotation. • • • Visually inspect electrical contacts for damage or loose connections. •...
Specifications Full Cool Operation Net Cooling Capacity* 460V, 3 Phase, 60 Hz Power 380V, 3 Phase, 50 Hz Power Return air to evaporator coil Net Cooling Capacity Power Consp Net Cooling Capacity Power Consp inlet Watts Kcal/hr BTU/hr kW @460V Watts Kcal/hr BTU/hr kW @460V...
Specifications R-23 Refrigeration System Compressor Model No. ZM18K4E-TFD-N275, Hermetic Scroll Refrigerant Charge Evacuated System 3.2 Kg (7.05 lb) R-23 Add Partial Charge by Pressure Charge to 1700 kPa, 17.00 bar, 247 psig Compressor Oil Capacity 1.77 liter (60 oz.)* Compressor Oil Type Polyol Ester Based Type (required), TK Part No.
Specifications Physical Specifications Base Unit Weight (net): CRR-40 DF MPC2000 610 Kg (1344 lb) CRR-40 DF MPC2000ID 610 Kg (1344 lb) CRR-40 DF MP3000 610 Kg (1344 lb) Unit Dimensions Width 2025.5 mm (79.75 in.) Height 2235.2 mm (88.00 in.) Depth 420.0 mm (16.54 in.) from back of flange Compressor Torque —...
Unit Description General Description Model CRR DF units are all-electric, single-piece, refrigeration units with bottom air supply. Each unit is designed for long distance, shipboard or overland transport of deep frozen or frozen cargoes. Each unit mounts in the front wall of the container. Fork lift pockets are provided for installation and removal of the unit.
Unit Description Microprocessor Controller MPC2000, MPC2000ID and MP3000 controllers incorporate refrigeration system component control, thermostat, digital thermometer and fault indication capabilities into one self-contained package. Units with a MPC2000 or MP3000 controller are also equipped with a separate datalogger while the MPC2000ID controller includes an integral datalogger.
Unit Description REFCON Remote Monitoring Modem (RMM) 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 datalogger via high speed transmission. Operating Modes NOTE: See Microprocessor Controller chapter for complete sequence of operation.
Unit Description AXA0347 Evaporator Fan Blade Defrost (Evaporator Coil) Sensor Location Evaporator Fan Motor Return Air Sensor Probe Holder Evaporator Coil Figure 3: Evaporator Section — Front View...
Unit Description AXA0349 Control Box Ambient Sensor Location Thermometer Sampling Port Power Plug and Cord Supply Air Sensor Probe Holder Figure 5: Power Cord Storage Compartment...
Unit Description AXA0422 AXA0351 MPC2000, MPC2000ID or MP3000 Controller Special Function Keypad LED Display (Return or Supply Air Temperature Unit On/Off Switch Display and Status Indicator LEDs) Communications Connector for Data LCD Display (Setpoint Temperature, Message and Retrieval Controller Main Menu Tree Display) Circuit Breaker General Purpose Keypad Figure 6: Control Box and Microprocessor Controller...
Unit Description AXA0354 AXA0353 MPC2000ID or MP3000 Controller with Control Power Transformer (28 Vac, 29 Vac, 40 Vac) Integral Datalogger Remote Monitoring Modem 10. Heat Relay RMM Connection Cable Cable No. 3 Connection to Main Relay Board Battery Cable Connection to Controller 12.
Unit Description AXA0355 Remote Monitoring Modem R-23 Scroll Compressor Contactors (2) MPC2000, MPC2000ID or MP3000 Controller R-134a Compressor Contactor Datalogger (CRR DF MPC2000 only) Main Relay Board 32 Ampere Main Power Circuit Breaker 12 Vdc Battery Figure 9: Unit Control Box with Door Open...
Unit Description AXA0363 R-134a Receiver Tank Dehydrator (Filter Drier) Receiver Tank Service Fitting Liquid Line Solenoid Receiver Tank Sight Glass R-134a Expansion Valve Liquid Line Ball (Service) Valve R-23/R-134a Plate Heat Exchanger (behind panel) Figure 14: Additional R-134a Refrigeration System Components and Plate Heat Exchanger...
Unit Description AXA0369 AXA0370 AXA0368 Electric Heaters Expansion Valve Feeler Bulb (R-23 System) Evaporator Coil (R-23 System) Figure 17: Unit Back View — Electric Heaters and Evaporator Coil...
Operating Instructions Basic Unit Controls, Instruments and Protection Devices Unit Control Box ON position. Unit will operate on cool or null depending on the controller setpoint ON/OFF Switch: temperature and the container air temperature. OFF position. The unit will not operate. A 7 ampere manual reset circuit breaker protects the control circuit.
Operating Instructions • Heat (On during defrost) • Defrost • In-Range (Temperature) • Alarm The In-range LED illuminates when the controlling air sensor temperature is less than 3.0 C (5.4 F) above setpoint (standard). The controller maintains the in-range signal during defrost and after defrost for 60 minutes.
Operating Instructions A sight glass on the receiver tank contains three small balls that indicate the Receiver Tank Sight Glass: 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.
Operating Instructions A high pressure relief valve is installed in the receiver tank. The relief valve High Pressure Relief Valve: protects against excessive pressure build-up within the refrigeration system from extraordinary and unforeseen circumstances. The valve is a spring-loaded piston that lifts when refrigerant pressure exceeds 3447 +520/-104 kPa, 34.47 +5.20/-1.04 bar, 500 +75/-15 psig.
Operating Instructions 9. Check vacuum valve for proper operation. 10. Observe the unit for proper operation and functions during Pre-load Operation. Power Selection CAUTION: Power supply connections from the unit to the power source should always be made with the refrigeration unit On/Off switch and the power supply On/Off switch in the OFF position.
Operating Instructions • Enter minus sign first by pressing EXIT key. Then press numeric keys to enter new setpoint. • 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 -10 C and -60 C (14 F and -76 F) or controller will return to the previous setpoint display.
Operating Instructions Post Load Procedure 1. Make sure all doors are closed and locked. 2. Switch the Unit On/Off switch to ON position. 3. Adjust controller setpoint to the desired temperature: NOTE: The setpoint temperature can be set between -10 C and -60 C (14 F and -76 F) in either F or C using the C/F key.
Operating Instructions Post Trip Procedure Trip data recorded by the MPC2000, MPC2000ID or MP3000 datalogger may be down loaded via the communications port on the control box using a DRU-II or SmartSponge handheld data retriever; or via the REFCON remote monitor system.
Microprocessor Controller General Description The MPC2000, MPC2000ID and MP3000 are advanced microprocessor controllers that have been specially developed for control and monitoring of refrigeration units. Each controller contains the following basic features: 1. Eight status indicator LEDs are located in the top LED display and signal the following: •...
Microprocessor Controller LED display with Status Indicator LEDs LCD message and menu display General purpose keys Special function keys Figure 18: MPC2000, MPC2000ID and MP3000 Controller...
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Microprocessor Controller Alarm Code Type Description Check Supply Air Sensor Open Circuit Check Supply Air Sensor Short Circuit Check Return Air Sensor Open Circuit Check Return Air Sensor Short Circuit Check Evaporator Coil Sensor Open Circuit Check Evaporator Coil Sensor Short Circuit Check R-134a Compressor Current Too...
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Microprocessor Controller 2. LED display with 20.32 mm high characters: • Five alpha numeric characters: Numerical hundredths, tens, ones and tenths position, a C for Celsius or F for Fahrenheit for temperature display. • LED display shows current control temperature (return or supply). Status LEDs signal sensor temperature shown in LED display.
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Microprocessor Controller • F3 key: BACKWARD/DOWN ARROWS indicate that pressing the K3 key scrolls the cursor backward and/or downward through text boxes and menu lists. • F4 key: ENTER ARROW indicate that pressing the K4 key moves the cursor into the next menu level or into a menu item text box.
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Microprocessor Controller All data logs include the time and date; setpoint temperature; and supply, return, USDA1, USDA2 and USDA3 sensor temperatures. All temperature logs can be viewed from the controller’s LCD message display. If the unit power supply is disconnected, the datalogger will continue to register 168 temperature logs. These will be maintained until the unit is re-connected to power, and the battery automatically re-charged.
Microprocessor Controller • Datalogger Menu: Menu screens in this group display temperature log, event log, set log time and PTI log. • RMM (Remote Monitoring) State: Menu screen show current remote monitoring state (Offline, Zombie or Online). General Theory of Operation The MPC2000 and MPC2000ID controllers use advanced solid-state integrated circuits to monitor and control unit functions.
Microprocessor Controller 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 is required, the unit operates in the cool mode until the controlling sensor reaches 1.0 C (1.8 F) below setpoint.
Microprocessor Controller Continuous Temperature Control Operation Frozen Loads — Controller Setpoint at -10 C (14 F) and Below The controller regulates compressor operation based the return air sensor and setpoint temperatures to determine operating mode switch points. The controller operates the unit on: •...
Microprocessor Controller • 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 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.
Microprocessor Controller Initiating a Manual Defrost With the unit On/Off switch ON: 1. Press the DEFROST key. • If the unit operating conditions allow a manual defrost (e.g. evaporator coil temperature is less than 10 C [50 F]), the unit enters defrost as the Defrost LED turns ON. •...
Microprocessor Controller Controller Menu Navigating the Controller Menu: The controller Main Menu is divided into seven major menus: • Data • Alarm List • Commands • Misc. Functions • Configuration • Datalogger • RMM (Remote Monitoring Modem) State Moving through these seven menus and their submenus and entering commands requires the use of four text keys: F1 key: Press the F1 key each time you want to exit a submenu and/or retrieve current system data for display.
Microprocessor Controller • Voltage 1 (Main Power Supply) • Voltage 2 (Main Power Supply) • Voltage 3 (Main Power Supply) • Frequency (Main Power Supply) • Zero Current • Current Phase 1 (Main Power Supply) • Current Phase 2 (Main Power Supply) •...
Microprocessor Controller • 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.
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Microprocessor Controller 4. Press F2 or F3 key to scroll to the desired command: • Defrost • PTI (Pretrip) • Manual Function Test 5. Press F4 key to activate the command selected. • Defrost: LCD display shows DEFROST ACTIVATED, NOT ACTIVATED (evaporator temperature above 18 C [50 F]) or ALREADY ACTIVATED (defrost in progress).
Microprocessor Controller • Repeat component start procedure until all required components are ON. For example, to operate unit in Full Cool mode, start the following components: - Condenser Fan - R-134a Compressor - R-23 Compressor - Evaporator Fans • Observe current draw and system performance. •...
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Microprocessor Controller 1. Press the F3 key to enter the Main Menu. 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.
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Microprocessor Controller 3. 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”. 4. Press F4 key to access the C/F Mode screen. C/F Mode screen appears with cursor in the temperature value menu line.
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Microprocessor Controller 9. Press ESC key to exit the Cargo Data screen. Viewing or Setting Run Time 1. Press the F3 key to enter the Main Menu. 2. Press F2 key to scroll to “MISC. FUNCTIONS”. 3. Press F4 key to access the Misc. Functions menu. “Date Time” appears in the LCD display. Press F2 key to scroll to “RUN TIME”.
Microprocessor Controller Configuration Menu The Configuration menu displays a list of functions that identifies unit operating features and current settings. The following functions are available: MP-3000 Configuration List, DF Units Text Description Default Range IN RANGE In range limit 1,5°C 0,5°C - 5°C CONT ID Container Id...
Microprocessor Controller 6. Repeat steps 4 and 5 to reset additional configuration values. 7. Press ESC key to exit the Cargo Data screen. Datalogger Menu The Datalogger menu contains a list of functions that display unit operating information recorded in the MPC2000 Datalogger or MPC2000ID Integral Datalogger.
Microprocessor Controller • Set Log Time: The current Log Time interval appears in the screen. To enter a new log interval: a. Press F4 key with cursor in Log Time menu line. Cursor moves to the end of the menu line and flashes.
Microprocessor Controller PTI (Pretrip) Test CAUTION: The PTI test should only be performed on an empty container! The CRR DF controller contains a special 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.
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Microprocessor Controller CRR Pretrip (PTI) Test Procedure (Continued) LCD Display Display (Shows Approx. Amps for Possible Duration (Test No.) 460V, 60 Hz Unit) Test Description Alarms (Time) Evaporator fans operate until temperature difference between the return and evaporator sensors, and Probe Test return and supply sensors is less than 60 to 600...
Microprocessor Controller CRR Pretrip (PTI) Test Procedure (Continued) LCD Display Display (Shows Approx. Amps for Possible Duration (Test No.) 460V, 60 Hz Unit) Test Description Alarms (Time) Unit operates in normal mode with -55 C (-67 F) setpoint. When return air temperature decreases to setpoint, sensor temperatures are recorded in PTI log.
Microprocessor Controller AXA0171 Coil support brackets Unit front. Insert sensor at least 75 mm into coil between tube rows 2 and 3 Figure 20: 3 Fan Evaporator: Evaporator (Defrost) Sensor Location Resistance Values for R-134a or R-23 Compressor Discharge Line Sensor Temp.
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Microprocessor Controller Resistance Values for R-134a or R-23 Compressor Discharge Line Sensor Temp. °F Temp. °C OHMS Temp. °F Temp. °C OHMS 118.4 36465 244.4 3229 33598 3047 125.6 30983 251.6 2877 129.2 28595 255.5 2718 132.8 26413 258.8 2569 136.4 24419 262.4...
Microprocessor Controller WARNING: High voltage (460/380 volts) is present on the contactors and relays in the control box. To prevent dangerous electrical shock, disconnect the supply power to the unit whenever possible when working in this area. 3. Disconnect cable no. 2 from the controller and main relay board (see electrical schematic). 4.
Microprocessor Controller 5. Replace security strip. Then carefully mount new EPROM chip and tighten security strip. 6. Place new EPROM chip ID label over old label on the side of the controller to identify new EPROM. 7. Install datalogger (or back cover) mounting screws. 8.
Microprocessor Controller Flash Loading Controller Software Controller software must be flash loaded when software has been revised. To flash load software: 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.
Microprocessor Controller MPC 2000 ID / MP 3000, Super Freezer "Error message list" Error Message Controller Action Power Error, Check 20A Fuses • Controller activates alarm 18 Indicates: • Controller will try to restart unit after 60 minutes. • One or more phases are missing •...
Microprocessor Controller Alarm Codes, Descriptions and Corrective Actions NOTE: NOTE: Sensors used with the MPC2000, MPC2000ID and MP 3000 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.
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Microprocessor Controller Code Description Corrective Action Return Air Sensor Short Circuit • Check sensor resistance between pins 3 and 4 (Check Alarm) on plug J15. Resistance must be 1000 ohms at 25 C (77 F). • Sensor circuit resistance lower than 200 ohms. •...
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Microprocessor Controller Code Description Corrective Action R-134 Compressor Current Too Low • Start “Manual Function Test”. (Check Alarm) Make sure the compressor relay energizes. If relay does NOT energize and the LED above • Occurs during Pretrip (PTI) only. the compressor relay is NOT ON, check for a •...
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Microprocessor Controller Code Description Corrective Action Evaporator Fan Low Speed Current Too High • Open evaporator door and make sure all fans (Check Alarm) rotate freely. • Occurs during Pretrip (PTI) only. • Start “Manual Function Test” and set evaporator motors to low speed.
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Microprocessor Controller Code Description Corrective Action Condenser Fan Current Too High • Start “Manual Function Test” and set condenser (Check Alarm) fan motor to ON. Make sure the fan starts. • Occurs during Pretrip (PTI) only. • Check fan motor volts and amps. •...
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Microprocessor Controller Code Description Corrective Action Temperature Too Far from Setpoint • Press SUP/RET key to check supply and return (Check Alarm) air sensor temperatures. Compare temperatures to evaluate unit cooling capacity • After 80 minutes of operation, return air and performance.
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Microprocessor Controller Code Description Corrective Action Ambient Air Sensor Open Circuit • Check sensor resistance between pins 13 and (Check Alarm) 14 on plug J15. Resistance must be 1,000 ohms at 25 C (77 F). • Sensor circuit resistance is higher than 100,000 ohms.
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Microprocessor Controller Code Description Corrective Action Compressor Temperature Too High • Operate unit on Cool and check discharge and (Shutdown Alarm) suction pressure gauge readings on R-134a refrigeration system. Check refrigerant charge • R-134a compressor discharge line temperature of R-134a system and R-23 system. is above 130 C (266 F).
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Microprocessor Controller Code Description Corrective Action Compressor Sensor Short Circuit • Check sensor resistance between pins 9 and (Log Alarm) 10 on plug J15. Resistance must be 100,000 ohms at 25 C (77 F). • Sensor circuit resistance lower than 200 ohms. •...
Electrical Maintenance 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.
Electrical Maintenance Condenser Fan Check for proper condenser 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.
Electrical Maintenance Low Pressure Cutout Switch: Opens: 0 ± 20 kPa, 0 ± 0.2 bar, 6 in. vacuum to 3 Psig Closes: 70 ± 20 kPa, 0.7 ± 0.2 bar, 10 ± 3 Psig If the low pressure cutout switch is suspected of being defective, replace it with a known good switch.
Refrigeration Maintenance and Service Operations 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.
Refrigeration Maintenance and Service Operations • High side near the compressor discharge service valve, • High side on the receiver tank. An R-134a gauge manifold set (P/N 204-758) should be dedicated for use with R-134a (HFC) refrigerant only. 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).
Refrigeration Maintenance and Service Operations Full Counterclockwise Figure 23: Service Valve Back Seated 1/2 Turn In Figure 24: Service Valve Open to Port Full Clockwise Figure 25: Service Valve Front Seated...
Refrigeration Maintenance and Service Operations Gauge Manifold Valve Positions The gauges indicate low and high side pressures. Operate one or both hand valves to perform the different service operations. Quick Disconnect Access Valve Discharge Service Valve (DSV) Suction Service Valve (SSV) Figure 26: Balancing R-134a System Pressure Quick Disconnect Access Valve Discharge Service Valve (DSV)
Refrigeration Maintenance and Service Operations Close Hand Valves Figure 28: Gauge Manifold Closed to Center Port Open Hand Valves Figure 29: Gauge Manifold Open to Center Port Quick Disconnect Access Valve Reclaimer with Receiver Tank Discharge Service Valve (DSV) Suction service Valve (SSV) Figure 30: Removing R-134a Refrigerant...
Refrigeration Maintenance and Service Operations R-134a 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 HFC refrigerants only.
Refrigeration Maintenance and Service Operations 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.
Refrigeration Maintenance and Service Operations NOTE: With empty box and all components in R23 system always verify correct charge in R23 system according to pressure readings listed below R-23 Refrigeration System — Standby (Unit OFF) and Cool Operation Container Temp. Ambient Temp.
Refrigeration Maintenance and Service Operations Normal R-134a and R-23 compressor oil level: Sight glass is 1/4 to 3/4 full. Figure 34: Checking Compressor Oil Level 3. After stopping the compressor, adjust the low side pressure to 21 kPa, 0.21 bar, 3 psig using the service gauge set.
Refrigeration Maintenance and Service Operations Add and Remove Compressor Oil at the Compressor Oil Fitting Figure 35: Adjusting Compressor Oil Level 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.
Refrigeration Maintenance and Service Operations Figure 36: 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 in a full cylinder at 21 C (70 F).
Refrigeration Maintenance and Service Operations Refrigerant Charge Inspection 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.
Refrigeration Maintenance and Service Operations Checking the R-23 Refrigerant Charge The R-23 refrigerant charge should be checked with the container empty, the unit OFF and all refrigeration system components above -5 C (23 F). The R-134a compressor must not have been operated within the past 30 minutes and there must not be frost on the plate-type R-134a / R-23 heat exchanger tubing.
Refrigeration Maintenance and Service Operations NOTE: Use the lower receiver tank sight glass to check or add refrigerant only on an operating unit that is unable to maintain a -55 C to -60 C (-62 F to -76 F) load temperature. See “R-23 Charging Procedure for Partially Charged Units on Loaded Containers”...
Refrigeration Maintenance and Service Operations 6. Close the service valve on the R-23 recovery bottle. 7. Backseat the discharge service valve. Disconnect the refrigerant hose from the discharge valve. 8. With system pressures below 100 kPa, 1.00 bar, 15 psig, the R-23 system components can be serviced.
Refrigeration Maintenance and Service Operations • MOISTURE. Moisture in a system will cause 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. • DIRT, DUST, METAL PARTICLES, OTHER FOREIGN MATERIALS.
Refrigeration Maintenance and Service Operations 7. Open Evacuation 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.
Refrigeration Maintenance and Service Operations Pressure Rise Test Evacuate the system and close valve V1. With valves V3 and V4 open, the pump is isolated and the system is held under a vacuum. If the Micron Meter rises, one of the following conditions exist. Watch the movement of the Micron Meter needle.
Refrigeration Maintenance and Service Operations Close the vacuum valve and watch the movement of vacuum gauge needle. If needle shows a pressure rise but finally levels off to a constant pressure, the system still contains too much moisture. Dehydration and additional evacuation time are required.
Refrigeration Maintenance and Service Operations CAUTION: Be sure to add the correct refrigerant to the system. 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.
Refrigeration Maintenance and Service Operations CAUTION: Be sure to add the correct refrigerant to the system. 4. Set the R-134a refrigerant tank for liquid charging. Open the refrigerant tank hand valve. 5. Start and operate the unit in the COOL mode. CAUTION: Do NOT operate the unit on cooling unless: •...
Refrigeration Maintenance and Service Operations NOTE: If a scale is not available, the R-23 system can be accurately charged by pressure. Add refrigerant to the receiver tank until the unit suction and discharge pressure gauges indicate 1700 kPa, 17 bar, 247 psig. 8.
Refrigeration Maintenance and Service Operations 10. Close the refrigerant tank hand valve. 11. Back seat the suction service valve. Then stop the compressor. 12. Remove the hoses from the receiver outlet and discharge service valves. Cap the receiver outlet service port. 13.
Refrigeration Maintenance and Service Operations 3. Set the R-23 refrigerant tank for gas charging. Open the refrigerant tank hand valve. 4. Observe the bottom receiver tank sight glass. When refrigerant is visible in the bottom of the lower sight glass, close the hand valve on the refrigerant tank. CAUTION: Immediately stop adding refrigerant when refrigerant is visible in the bottom of the lower sight glass.
Refrigeration Maintenance and Service Operations Dehydration, Pressure Testing, Purging and Soldering Procedure 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. 1. Attach gauge manifold set (refer to “Gauge Manifold Set Attachment and Purging” for proper procedure for connecting to compressor).
Refrigeration Maintenance and Service Operations Compressor Replacement (R-134a or R-23 Systems) Removal 1. Close the suction service valve and pump down the compressor: • R-134a Compressor: Pump down the compressor to -35 kPa, -0.35 bar, 10 in. vacuum. • R-23 Compressor: Pump down the compressor to 0 to 21 kPa, 0.0 to 0.2 bar, 0 to 3 psig. CAUTION: Do NOT allow the R-23 scroll compressor to operate for more than 10-20 seconds.
Refrigeration Maintenance and Service Operations 6. Check for refrigerant leaks around the compressor assembly and gasket connections. 7. If 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.
Refrigeration Maintenance and Service Operations Dehydrator (Filter Drier) Replacement (R-134a or R-23 Systems) Removal 1. Do one of the following: • R-134a System: 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. •...
Refrigeration Maintenance and Service Operations Installation 1. Remove the sealing caps from the new dehydrator. 2. Do one of the following: • R-134a System: Apply clean compressor oil to dehydrator threads. Assemble new dehydrator to lines. Finger tighten mounting nuts. •...
Refrigeration Maintenance and Service Operations 4. Heat and unsolder the equalizer line from expansion valve. 5. Heat and unsolder the liquid line inlet and outlet connections to expansion valve. 6. Remove expansion valve from unit. Installation 1. Clean the liquid lines and equalizer lines for soldering. 2.
Refrigeration Maintenance and Service Operations 3. Heat and unsolder liquid inlet and outlet line connections. 4. Heat and unsolder the suction line connections. 5. Lift the heat exchanger assembly from the unit. Installation 1. Clean the tubes for soldering. 2. Place the heat exchanger assembly in the unit and install the mounting hardware. 3.
Refrigeration Maintenance and Service Operations CAUTION: Any time the discharge valve is front seated, disconnect the unit power source to prevent accidental compressor start-up. 4. Do one of the following: • Pressurize the R-134a system on the low side and check for leaks •...
Refrigeration Maintenance and Service Operations • R-134a Compressor: Pump down the compressor to -35 kPa, -0.35 bar, 10 in. vacuum. • R-23 Compressor: Pump down the compressor to 0 to 21 kPa, 0.0 to 0.2 bar, 0 to 3 psig. CAUTION: Do NOT allow the R-23 scroll compressor to operate for more than 10-20 seconds.
Refrigeration Maintenance and Service Operations 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”...
Structural/Accessory Maintenance 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 be tightened to a torque value of 20 to 21 N.m (15 to 20 ft-lb).
Structural/Accessory Maintenance Also inspect the directional airflow condenser grille for damage. This grille directs the condenser airflow out and away from the unit to increase the 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.
Structural/Accessory Maintenance Vacuum Valve The vacuum valve draws outside air into the container to prevent the container from developing negative atmospheric pressure as the cargo temperature decreases toward -60 C (-76 F). Check the vacuum valve during the pretrip inspection to make sure the ball inside the valve moves freely. AXA0421 AXA0426 Vacuum valve (Located behind the...
Mechanical Diagnosis Condition Possible Cause Remedy One or Both Compressors Controller on; unit start sequence still Wait at least 1 minute for both do not operate — no timing compressors to start amperage draw No power to unit (condenser and Locate fault and repair: power source, evaporator fans do not operate) power plug, main circuit breaker, motor...
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Mechanical Diagnosis Condition Possible Cause Remedy Compressor contactor Low line voltage Increase line voltage to at least 90% of burned out compressor motor rating Excessive line voltage Reduce line voltage to at least 110% of compressor motor rating Short cycling Eliminate cause of short cycling Unit short cycles Controller out of calibration...
Refrigeration System Diagnosis Condition Possible Cause Remedy R-134a or R-23 System Shortage of refrigerant Repair leak and recharge Compressor operating in Compressor motor contacts frozen Clean points or replace contactor a vacuum (R-134a compressor only) (unit not cooling) Defective liquid line solenoid valve Repair or replace liquid line solenoid valve Compressor inefficient...
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Refrigeration System Diagnosis Condition Possible Cause Remedy Load temperature too high One or both compressors do not operate See "Mechanical Diagnosis" and unit (unit not cooling) wiring schematic Shortage of refrigerant Repair leak and recharge (R-134a or R-23 system) Overcharge of refrigerant Purge system (R-134a or R-23 system) Air in system...
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Refrigeration System Diagnosis Condition Possible Cause Remedy Rapid cycling between Air short cycling through evaporator Check and correct cargo load Cool and Null modes Defective controller or main relay board Diagnose main relay board and controller. Replace defective component Short cycling See "Unit Short Cycles"...
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