Thermo King CSR Series Manual
  1. Manuals
  2. Brands
  3. Thermo King Manuals
  4. Refrigerator
  5. CSR Series
  6. Manual

Thermo King CSR Series Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
CSR
TK 50824-4-MM (Rev. 6, 11/02)
©
Copyright
2002 Thermo King Corp., Minneapolis, MN, U.S.A.
Printed in U.S.A.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the CSR Series and is the answer not in the manual?

Questions and answers

Related Manuals for Thermo King CSR Series

Summary of Contents for Thermo King CSR Series

  • Page 1 TK 50824-4-MM (Rev. 6, 11/02) © Copyright 2002 Thermo King Corp., Minneapolis, MN, U.S.A. Printed in U.S.A.
  • Page 2 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.
  • Page 3 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.

  • Page 5: Table Of Contents

    Table of Contents List of Figures ................11 Safety Precautions .
  • Page 6 Table of Contents MP-3000 Controller ..............55 Controller Description .
  • Page 7 Table of Contents MP-3000 Controller (continued) Datalogger Menu ............... . 95 Viewing the Datalogger Menu .
  • Page 8 Table of Contents Refrigeration Maintenance and Service Operations (continued) Evacuation and Cleanup of the Refrigeration System ..........139 Compressor Oil Color Code .
  • Page 9 Table of Contents Structural/Accessory Maintenance ............151 Mounting Bolts .
  • Page 10 Table of Contents...

  • Page 11: List Of Figures

    List of Figures Figure 1:Nameplate and Warning Locations ........... 16 Figure 2:Physical Specifications .
  • Page 12 List of Figures Figure 50:Evacuation Station and Unit Hook-up ..........141 Figure 51:Constant Pressure Rise After Evacuation Indicates System Leak .

  • Page 13: Safety Precautions

    Safety Precautions General Practices Refrigerant 1. Always wear goggles or safety glasses. When removing any refrigerant from a unit, use a Refrigerant liquid and battery acid can recovery process that prevents or absolutely permanently damage the eyes (see First Aid minimizes the refrigerant that can escape to the under Refrigerant Oil).

  • Page 14: Electrical

    Safety Precautions Use the following First Aid practices if needed. • Never work alone on high voltage circuits on the refrigeration unit. Another person should Immediately flush eyes with large amounts Eyes: always be standing by in the event of an of water for at least 15 minutes while holding the accident to shut off the refrigeration unit and eyelids open.

  • Page 15: Servicing Units (Or Containers) Equipped With A Microprocessor Controller

    Safety Precautions Low Voltage 5. Leave the circuit boards in their static proof packing materials until ready for installation. Control circuits are low voltage (24 Van and 12 Vdc). This voltage potential is not considered 6. If a defective controller is to be returned for dangerous, but the large amount of current repair, it should be returned in the same static available (over 30 amperes) can cause severe...

  • Page 16: Unit Decals

    Serial number decals, refrigerant type decals and • Compressor: Nameplate on front of the ® warning decals appear on all Thermo King compressor. equipment. These decals provide information that may be needed to service or repair unit. Service •...

  • Page 17: Service Guide

    Service Guide Every Annual/ Pre-trip 1,000 Inspect/Service These Items Yearly Hours Electrical • Perform a controller pre-trip inspection (PTI) check. • • • Visually check condenser fan and evaporator fan • • • Visually inspect electrical contacts for damage or loose connections. •...
  • Page 18 Service Guide...

  • Page 19: Specifications

    Specifications System Net Cooling Capacity— Full Cool CSR20SL Models — Air Cooled Condensing* 460/230V, 3 Phase, 60 Hz Power 380/190V, 3 Phase, 50 Hz Power Return air to Net Cooling Capacity Power Consp Net Cooling Capacity Power evaporator coil Consp inlet Watts Kcal/hr...

  • Page 20: Evaporator Airflow

    Specifications Evaporator Airflow Model CSR20SL 460/230V, 3 Phase, 60 Hz Power 380/190V, 3 Phase, 50 Hz Power External Static High Speed Low Speed High Speed Low Speed Pressure (water column) /min /min /min /min 0 mm (0 in.) 4,000 2,350 2,000 1,180 3,300...

  • Page 21: Electrical System

    Specifications Electrical System Compressor Motor: Type 460/380V, 60/50 Hz, 3 Phase Kilowatts 4.48 kW @ 460V, 60 Hz Horsepower 6.0 hp @ 460V, 60 Hz 3550 rpm @ 460V, 60 Hz Locked Rotor Amps 70 amps @ 460V, 60 Hz Condenser Fan Motor: Type 460/380V, 60/50 Hz, 3 Phase...

  • Page 22: Refrigeration System

    Specifications Electrical System (Continued) Electrical Resistance Heater Rods: Type 460/380V, 60/50 Hz, 3 Phase Number Watts (Each) 680 Watts @ 460V, 60 Hz 5 amps total @ 460V across each phase at heater Current Draw (Amps) contractor Control Circuit Voltage: 29 Vac @ 60 Hz 24 Vac @ 50 Hz Evaporator Overheat Switch:...

  • Page 23: Normal R-404A System Operating Pressures (Scroll Compressor)

    Specifications Refrigeration System (Continued) Liquid Injection Valve (Compressor): Voltage 24 Vac Current 0.85 amps Cold Resistance 5.6 ohms Warm Gas Bypass Solenoid Valve: Voltage 24 Vac Current 0.85 amps Cold Resistance 5.6 ohms Stepper Valve Regulating Motor: Voltage 12 Vdc Current Draw 0.13 to 0.21 amperes per winding 0.26 to 0.44 amperes with 2 windings energized...

  • Page 24: Mp-3000 Controller

    Specifications MP-3000 Controller Temperature Controller: MP-3000 microprocessor with thermostat, digital thermometer, Type programming keypad, mode indicators, LED display and LCD display for displaying unit operating and cargo information Setpoint Range -30.0 to +30.0 C (-22.0 to +86.0 F) Digital Temperature Display -60.0 to +80.0 C (-76.0 to +176.0 F) Controller Software (Original Equipment): Version...

  • Page 25: Dehumidify And Humidify Systems (Options)

    Specifications MP-3000 Controller (Continued) Compressor Shutdown Protection (Auto Reset): Stops Compressor 148 C (298 F) Allows Compressor Start 90 C (194 F) Bulb Mode (Option): Flow High: High speed only; Flow Low: Low speed only Evaporator Fan Speed Settings Flow Cycle: Fans will cycle between low and high speed every 60 minutes Defrost Termination Temperature Setting 4 to 30 C (40 to 86 F)

  • Page 26: Physical Specifications

    Specifications Physical Specifications Fresh Air Exchange Venting System (Adjustable): 0 to 160 m /hr (0 to 96 ft /min.) @ 60 Hz CSR20SL 0 to 134 m /hr (0 to 79 ft /min.) @ 50 Hz 0 to 280 m /hr (0 to 165 ft /min.) @ 60 Hz CSR40SL and CSR40...

  • Page 27: Figure 2:Physical Specifications

    Specifications AXA0220 Figure 2: Physical Specifications...

  • Page 28: Metric Hardware Torque Charts

    Specifications Metric Hardware Torque Charts Bolt Size Bolt Type and Class* N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.) HH – CL 5.8 6-9 (4-7) 12-16 (9-12) 27-34 (20-25) 48-61 (35-40) HH – CL 8.8 10-13 (7-10) 20-27 (15-20) 41-47 (30-35) 75-88 (55-65) HH –...

  • Page 29: Unit Description

    Unit Description General Description control sensor temperature (return or supply air temperature). A 4-line, 20-character LCD display Model CSR20SL, CSR40SL and CSR40 units are (bottom) display shows important data including all-electric, single-piece, refrigeration units with the setpoint temperature, controller main menu bottom air supply.

  • Page 30: Dual Speed Evaporator Fans

    Unit Description A high speed serial communication port provides door control module to position to vent door to the data retrieval using a DRU-II hand-held data desired position. The controller can also be set to retriever or laptop computer with SmartSponge™ delay opening of the fresh air vent for up to 72 software, or a REFCON power line remote hours, in 1-hour increments.

  • Page 31: Dual Voltage

    Unit Description Dual Voltage high ambient temperatures, salt water, humidity, fungus, industrial pollutants, dynamic loading, A dual voltage system includes a 15 KVA auto rain, sand and dust. transformer and an 18.3 m (60 ft.) power cable for operation on 230-190V/3 Ph/60-50 Hz power. The •...

  • Page 32: Water-Cooled Condenser/Receiver Tank

    Unit Description When USDA sensors are installed, the controller be in by comparing the setpoint to the return or will automatically detect each sensor and activate supply air temperature. The unit operates in either data logging. However, the USDA Type screen in the Fresh (Chill) or Frozen mode.

  • Page 33: Figure 3:Typical Unit Front View

    Unit Description AXA0221 CSR20SL & CSR40SL: Evaporator Access Door, 1399 mm (55.04 in.) Wide with three latches CSR40: Evaporator Access Door, 1018 mm (40.08 in.) Wide with two latches Heater Access Panel Location (CSR20SL-144 , CSR20SL-155 , CSR40-145 & CSR40SL-506 Models Only) Condenser Fan Compressor Compartment Supply Air Sensor Probe Holder, Left Hand (Behind Compressor)

  • Page 34: Figure 4:Evaporator Front View - Csr20Sl & Csr40Sl

    Unit Description AXA0222 Evaporator Fan Blade (see “Physical Specifications” on page 26 for description) Evaporator Fan Motor Return Air Sensor Figure 4: Evaporator Front View — CSR20SL & CSR40SL...

  • Page 35: Figure 5:Evaporator Front View - Csr40

    Unit Description AXA0224 Return Air Sensor Evaporator Fan Blade (see “Physical Specifications” on page 26 for description) Evaporate Fan Motor Figure 5: Evaporator Front View — CSR40...

  • Page 36: Figure 6:Options - Unit Front View

    Unit Description AXA0226 Recording Thermometer Option Suction Pressure Gauge Option Discharge Pressure Gauge Option Dual Voltage Option TRANSFRESH Download Receptacle Option, see “TRANSFRESH System, Complete” on page 47 Remote Monitor Plug Option (4-Pin Connector on Side of Control Box) Thermistor Lead Option (Lead inside Control Box) Remote Monitor Modem for Power Line Communications (REFCON control modem inside Control Box) USDA Sensor Receptacle Option (Access from Inside Container) Advanced Fresh Air Management (see “Advanced Fresh Air Management (AFAM) Option”...

  • Page 37: Figure 7:Csr20Sl, Csr20Sl, Csr40Sl & Csr40Sl Options - Evaporator Front View

    Unit Description AXA0227 Sensing Bulb Option for Recording Thermometer (Return Air) Gas Sensor Unit for AFAM+ Option, see page 45 Filter for Gas Sensor for AFAM+ Option Vent Loop for Gas Sensor for AFAM+ Option Air Compressor for Humidity System Option, see 43 Humidity Sensor for Dehumidify Option or Humidity Option Figure 7: CSR20SL, CSR20SL, CSR40SL &...

  • Page 38: Figure 8:Csr40 & Csr40 Options - Evaporator Front View

    Unit Description AXA0228 Sensing Bulb Option for recording Thermometer (Return Air) Gas Sensor Unit for AFAM+ Option, see page 45 Vent Loop for Gas Sensor for AFAM+ Option Filter for Gas Sensor for AFAM+ Option Humidity Sensor for Dehumidify Option or Humidity Option Air Compressor for Humidity System Option, see page 43 Figure 8: CSR40 &...

  • Page 39: Figure 9:Refrigeration System

    Unit Description AXA0229 Evaporator Coil Scroll Compressor (See page 40) Coil/Dehumidify Valve 10. Discharge Tube (After 7/00) Discharge Tube with High Pressure Cutout Expansion Valve (Before 8/00) Heat Exchanger 12. Condenser Coil One-piece Filter Drier/In-line Filter 13. High Pressure Relief Valve Stepper Motor Valve 14.

  • Page 40: Figure 10:Scroll Compressor

    Unit Description AXA0230 Compressor Discharge Temperature Sensor Suction Service Valve (Option) with Service Fitting Compressor Oil Sight Glass Compressor Oil Fitting Discharge Service Valve (Option) with Service Fitting High Pressure Cutout Switch (Units After 7/00) Figure 10: Scroll Compressor...

  • Page 41: Figure 11:Mp-3000 Controller

    Unit Description AXA0231 Remote Monitoring Modem (RMM) Option Cable No. 1 Connection to Controller Communication Cable for RMM Option Control Box Cover and Controller Keyboard Decal Control Circuit Fuses, 2 ampere (2) Special Function Keypad Battery Cable Connection to Controller General Purpose Keypad LCD Display (Setpoint Temperature, Message and Cable No.

  • Page 42: Figure 12:Unit Control Box

    Unit Description AXA0232 Switch Main Relay Board Remote Monitor, 4-Pin (Option) 12 Vdc Battery Communications Connector for Data Retrieval Control Power Transformer Circuit Breaker 10. Compressor Contactors (2) Communications Cable for AFAM Option and 11. 25 Ampere Main Power Circuit Breaker AFAM+ Option Interface Board for AFAM Option and AFAM+ Option Figure 12: Unit Control Box...

  • Page 43: Figure 13:Humidify System Option

    Unit Description AXA0233 Evaporator Drain Hose Water Tank Fill Cap Water Filter Water Tank Heater Water Supply Hose Tank Overflow Hose Air Compressor Drain Cock 10. Liquid Spray Nozzle Figure 13: Humidify System Option...

  • Page 44: Figure 14:Advanced Fresh Air Management (Afam) Option

    Unit Description AXA0234 Gasket Interface Board and Cable (Mounts in Control Box), see page 42 Vent Door Assembly Stop Bracket, Vent Door Full Open Linkage Assembly Stop Bracket, Vent Door Closed Damper Motor Housing Grille Damper Motor Assembly Mounting Bracket Figure 14: Advanced Fresh Air Management (AFAM) Option...

  • Page 45: Figure 15:Advanced Fresh Air Management (Afam+) Option

    Unit Description AXA0235 Gas Sensor Assembly (Mounts in Evaporator), Damper Motor Assembly Mounting Bracket see page 37 or 38 Gasket Interface Board and Cable (Mounts in Control Box), see page 42 Vent Door Assembly Stop Bracket, Vent Door Full Open Linkage Assembly Stop Bracket, Vent Door Closed Damper Motor Housing...

  • Page 46: Figure 16:Transfresh Provision Option

    Unit Description AXA0236 TRANSFRESH Box in Evaporator Grille A2 Wire Harness to TRANSFRESH Transformer A3 Wire Harness to TRANSFRESH Download Port Purge Port Figure 16: TRANSFRESH Provision Option...

  • Page 47: Figure 17:Transfresh System, Complete

    Unit Description AXA0237 TRANSFRESH Scrubber Connection and A5 Wire Harnesses Evaporator Grille TRANSFRESH Security Enclosure Transformer Assembly mounted in Control Box TRANSFRESH Download Port Purge Port Figure 17: TRANSFRESH System, Complete...

  • Page 48: Figure 18:Unit Back View - All Models Without Heater Access Door

    Unit Description AXA0238 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 18: Unit Back View —...

  • Page 49: Figure 19:Unit Back View - Models With Heater Access Door (Csr20Sl-144 , Csr40-145, Csr20Sl-155 And Csr40Sl-506)

    Unit Description AXA0239 Evaporator Grille Air Channels 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 19: Unit Back View — Models with Heater Access Door (CSR20SL-144 , CSR40-145, CSR20SL-155 and CSR40SL-506)
  • Page 50 Unit Description...

  • Page 51: Operating Instructions

    Operating Instructions Unit Controls 5. Status Indicator LEDs located in the large LED display signal: Unit Control Box • (Air Temperature) UPPLY Switch: • (Air Temperature) ETURN 1. O position. Unit will operate on Cool or Heat • (Humidification Option UMIDITY depending on the controller setpoint set to On...

  • Page 52: Other Unit Controls

    Operating Instructions Other Unit Controls Unit Instruments 1. Evaporator Overheat Switch: A temperature 1. Compressor Oil Sight Glass: A compressor oil switch near the evaporator coil opens to sight glass indicates the relative level of de-energize the heater contactor if the compressor oil in the compressor sump.

  • Page 53: Unit Protection Devices

    Operating Instructions Unit Protection Devices NOTE: Controller also energizes the liquid injection valve when cooling capacity is 83% 1. Main Circuit: A 25 ampere manual reset or less. Controller de-energizes the valve circuit breaker protects the 460/380V power when cooling capacity is 84% or more. supply circuit to the unit electric motors and b.
  • Page 54 Operating Instructions...

  • Page 55: Mp-3000 Controller

    MP-3000 Controller Controller Description The MPC-3000 is an advanced microprocessor controller that has been specially developed for the control and monitoring of refrigeration units. The controller contains the following basic features: 1. LED display for Temperature: • Five alpha numeric, 20.32 mm high characters: Numerical hundredths, tens, ones and tenths position, a C for Celsius or F for Fahrenheit for temperature display.
  • Page 56 MP-3000 Controller F3 key: Press the F3 key, then press • 4. Four special function keys (see illustration on another general purpose key to enter 55): the second letter shown on the key. • C/F key: Press to view alternate F4 key: Press the F4 key, then press •...
  • Page 57 MP-3000 Controller • Control circuit fuse and circuit breaker 15. Power limit control (see “Power Limit Mode” protection: in this chapter). • 7 amp manual reset circuit breaker 16. Sequential component start-up control: A protects the 24 Vdc control circuit. sequence start of the required loads occurs during initial start-up of the controller and •...

  • Page 58: Status Indicator Leds

    MP-3000 Controller 21. Display menus: The MPC-3000 controller • Data logger Menu: Menu screens in this contains an extensive display menu that can be group display temperature log, event log, navigated via keypad. The display menu is set log time and PTI log. organized into eight main menus: •...

  • Page 59: Data Recording And Downloading Data

    MP-3000 Controller Data Recording and contents, loading data, voyage no., ship, load port, discharge port and comments. The container ID Downloading Data number is stored in the Configuration submenu. The MP-3000 data logger can record sensor temperatures as well as loss of power, alarms, General Theory Of Operation sensor failure, setpoint change and unit shutdown events.

  • Page 60: Chill Loads: (Setpoint At -9.9 C [14.1 F] And Above)

    MP-3000 Controller Chill Loads: (Setpoint at -9.9 C Supply Air Sensor Control [14.1 F] and Above) Temperature control accuracy and protection The unit operates on Cool with Modulation and against frost damage is provided by using two Heat to provide accurate control of chill loads. separate sensors (left hand and right hand) to During Cool with Modulation, the controller uses determine the supply temperature used to...

  • Page 61: Frozen Loads: (Setpoint At -10 C [14 F] And Below)

    MP-3000 Controller Frozen Loads: (Setpoint at -10 C feature of the Commands menu. When the power [14 F] and Below) management time interval expires, the unit returns to the standard power limit control algorithm. The unit operates on Full Cool and Null to NOTE: Setting power management current at 13 provide accurate control of frozen cargo.

  • Page 62: Power Limit Mode

    MP-3000 Controller Power Limit Mode state timer automatically re-starts the evaporator fans on low speed for 5 minutes The controller uses the total unit current and the every 45 minutes. condenser temperature to provide power limit control in both the Chill and Frozen modes. When The Economy mode also modifies the temperature the unit is on water-cooled operation, power limit control algorithm on frozen loads to extend the...

  • Page 63: Bulb Mode (Option)

    MP-3000 Controller During a Probe test, the LCD display shows NOTE: The use of the Dehumidify mode should “PROBE TEST PLEASE WAIT”. The controller be established by the shipper. operates the unit on high speed evaporator fans Changing the Humidify/Dehumidify mode only for 5 minutes.

  • Page 64: Continuous Temperature Control Operation

    MP-3000 Controller • Evaporator fans operate on high speed at • Heat mode (electric heaters pulse on and off setpoints of -9.9 C (14.1 F) and above. on a 60 second duty cycle). • Evaporator fans operate on low speed at •...
  • Page 65 MP-3000 Controller CSR Operating Mode Function Chart Chill Loads Frozen Loads Setpoints at -9.9 C Setpoints at -10 C (14.4 F) and Above (14 F) and Below Cool w/Mod Heat Defrost Cool Null Defrost Unit Function • • Evaporator Fans High Speed •...

  • Page 66: Frozen Loads (Controller Setpoint At -10 C [14 F] And Below)

    MP-3000 Controller • Controller pulses electric heaters on and off Dehumidification Option: When the Dehumidify for additional frost protection if the return air mode is set to On, the supply air temperature must temperature decreases to within 0.3 C (0.5 F) be In-range to close (energize) the of setpoint (see “Chill Loads”...

  • Page 67: Figure 23:Frozen Load Control Sequence (Setpoints At -10 C [14 F] And Below)

    MP-3000 Controller The amount of on time depends on the • After initial pull-down to setpoint, controller condenser coil, ambient and compressor keeps the In-range LED on as long as the discharge temperatures. return air temperature remains less than 1.5 C (2.7 F) above setpoint.

  • Page 68: Changing The Setpoint

    MP-3000 Controller log interval in which a Defrost cycle is • Interval timer: Controller terminates defrost pending or active (i.e. both the 8:00 and 9:00 after 90 minutes on 60 Hz power (120 on data logs on 1 hour logging interval). 50 Hz power).

  • Page 69: Initiating A Manual Defrost

    MP-3000 Controller 4. Press and hold the F4 key until the cursor 2. To view the alternate (supply or return) air temperature, press and hold the S stops flashing. The new setpoint is recorded in key. the controller and appears in the LCD display. The controller will show the alternate sensor temperature as long as the S key is...

  • Page 70: General Operating Tips

    MP-3000 Controller Setpoint Menu Moving through these eight menus and their submenus and entering commands requires the Pressing the S key displays a list of tasks ETPOINT use of four text keys: and values that can be activated or set: F1 key: Press the F1 key each time you •...

  • Page 71: Changing The Usda Trip Setting

    MP-3000 Controller • “FLOW CYCLE”: Evaporator fans cycle 12. Enter (type) the new setpoint in the LCD between high and low speed every 60 display using the general purpose keypad. The minutes. cursor moves to the right of the screen as each key entry is acknowledged and displayed.

  • Page 72: Figure 24:Setpoint Menu Screen Flow Diagram

    MP-3000 Controller 6. Press the F3 key to scroll to the “DEFROST 7. Press the F3 key to scroll to the “DEFROST TERM” line. TIME” line. a. To enter a new defrost termination a. To enter a new defrost time (interval), temperature, press the F4 key.

  • Page 73: Changing The Economy Mode Setting

    MP-3000 Controller Changing the Economy Mode Changing the Humidity Setpoint Setting 1. Press the S key. The Setpoint menu ETPOINT NOTE: Enter Setpoint temperature before appears with the cursor in the “TEMP SETP” turning on the Economy mode. The controller line.

  • Page 74: Changing The Afam Delay

    MP-3000 Controller AFAM+ Settings 3. To change the mode setting, press F4 key. Cursor moves to end of menu line and flashes. The AFAM option submenu is factory set to AFAM+. The controller then adds the AFAM, WARNING: The vent door and motor AFAM Delay, AFAM Rate, O Min and CO actuator arm move immediately when the...

  • Page 75: Changing The Afam Rate

    MP-3000 Controller 2. Press F2 key to scroll to “AFAM DELAY” Units Rate Setting line. The current setting (“0”) appears in the 0 to 168 Cubic Feet Per Minute display. 0 to 280 Cubic Meters Per Hour 3. To enter a new time delay, press the F4 key. PERCENT 0 to 100 Percent An Enter Arrow appears in the menu line and...

  • Page 76: Changing The Co Maximum Setting

    MP-3000 Controller Changing the CO Maximum Setting 2. Press the F3 key to scroll the cursor down through the menu list. The Data menu displays NOTE: The minimum CO rate should be the following functions: established by the shipper. • Supply Air Temperature, Right Hand The CO rate sets the desired CO...

  • Page 77: Alarms Menu

    MP-3000 Controller NOTE: Press the 5 key to lock a Data screen in Alarms Menu the LCD display for 5 minutes. Press any key to The Alarm List menu displays alarm codes. unlock the display. Alarm codes are recorded in the controller NOTE: Controller returns to previous menu memory to simplify unit diagnosis procedures.

  • Page 78: Viewing The Alarm List Menu

    MP-3000 Controller flashing but remain on. The alarm code NOTE: Alarm codes are displayed in state will change to Acknowledge in the sequential order, not in the order of alarm list. occurrence. • If the alarm condition no longer exists in 2.

  • Page 79: Commands Menu

    MP-3000 Controller Alarm List (Continued) Alarm List (Continued) Alarm Alarm Type Description Type Description Code Code Check Condenser Fan Current Check Check Humidity Sensor Error Check Too High Check AFAM Gas Analyzer Error Check Condenser Fan Current Check Gas Analyzer Calibration Error Check Too Low Log Compressor Sensor Open...
  • Page 80 MP-3000 Controller 1. Press the F1 key to enter the Main menu. 5. Press F4 key to activate the command selected. 2. Press F2 key to scroll through Main menu until “COMMANDS” appears in LCD • “PTI (Pre-trip) TEST”: LCD display display.

  • Page 81: Function Test

    MP-3000 Controller Function Test compressors, etc. The test includes measurement of component power consumption and compares The MP-3000 controller contains a special test results to expected values. function test that automatically tests individual NOTE: The function test does not test the actual components including the controller display, performance of the complete system.
  • Page 82 MP-3000 Controller CSR & Function Test Procedure LCD Display Possible Duration Display (Shows Approx. Amps for Test Description Alarms (Time) (Test No.) 460V, 60 Hz Unit) Event Log for Function Test begins. Display Test All alarms are turned off. F1.00 Activated None 10 Seconds...
  • Page 83 MP-3000 Controller CSR & Function Test Procedure (Continued) LCD Display Possible Duration Display (Shows Approx. Amps for Test Description Alarms (Time) (Test No.) 460V, 60 Hz Unit) Condenser fan and compressor remain on. Liquid injection valve is turned on. Amp draw is measured and verified to be Injection Valve Test a minimum of 0.1 amps higher that test F1.07...

  • Page 84: Pre-Trip (Pti) Test

    MP-3000 Controller Pre-trip (PTI) Test With the U switch O and the LCD display showing the standard display (setpoint): CAUTION: The PTI test should only be 1. Press F3 key to enter the menu list. performed on an empty container! Repeatedly press F2 key to scroll through NOTE: Units equipped with a water-cooled Main menu until “COMMANDS”...
  • Page 85 MP-3000 Controller CSR Pre-trip (PTI) Test Procedure (Continued) LCD Display Possible Duration Display (Shows Approx. Amps for Test Description Alarms (Time) (Test No.) 460V, 60 Hz Unit) Condenser fan and compressor are turned off. With evaporator fan on high speed, Amp draw is measured and compared to voltage and frequency: •...
  • Page 86 MP-3000 Controller CSR Pre-trip (PTI) Test Procedure (Continued) LCD Display Possible Duration Display (Shows Approx. Amps for Test Description Alarms (Time) (Test No.) 460V, 60 Hz Unit) Condenser fan, compressor and liquid Low Pressure Test injection valve remain on. Stepper valve is P1.11 Activated 10 seconds...
  • Page 87 MP-3000 Controller CSR Pre-trip (PTI) Test Procedure (Continued) LCD Display Possible Duration Display (Shows Approx. Amps for Test Description Alarms (Time) (Test No.) 460V, 60 Hz Unit) Stepper valve is almost closed (set to 250 value). With condenser fan on, compressor on liquid injection on, bypass Capacity Test 3 4 Minutes...

  • Page 88: Manual Function Test

    MP-3000 Controller CSR Pre-trip (PTI) Test Procedure (Continued) LCD Display Possible Duration Display (Shows Approx. Amps for Test Description Alarms (Time) (Test No.) 460V, 60 Hz Unit) Unit operates in Normal mode with -18 C (0 F) setpoint. When return air temperature decreases to setpoint, “Frozen Arrival”...

  • Page 89: Power Management

    MP-3000 Controller f. Press F4 key again to turn off components • “DEHUMITY VALVE” individually. Or press ESC key to exit • “BYPASS VALVE” Manual Function Test menu and turn all • “CAPACITY 100%” components off. g. Press ESC key to exit the Manual •...

  • Page 90: Misc. Functions Menu

    MP-3000 Controller 6. To change the length of time power limit is NOTE: The Controller Label on the side of the active (On): control box shows the controller serial number and the EPROM version. a. Press F2 key to scroll to Power Time menu line (standard setting = 48 hours).

  • Page 91: Setting The Date And Time

    MP-3000 Controller Note: All screens are not present on all Standard Display units. The screens that display on the controller are determined by the Misc. Functions Controller Software setting and the options installed on the unit. Menu DATE TIME STATUS RUN TIME PROGRAM VERSION Misc Functions...

  • Page 92: Viewing Or Setting Run Time

    MP-3000 Controller Setting Cargo Data 10. With the correct date entered in the menu line, press F4 key. Then press E key to enter 1. Press the F3 key to enter the menu list. Press date in controller memory. Cursor stops F2 key to scroll to “MISC.

  • Page 93: Changing The Temperature Display Value (C/F)

    MP-3000 Controller Configuration Menu 6. When the desired text entry is complete, press F4 key. Then press E key. The cursor stops The Configuration menu displays a list of flashing and the new text appears in the menu functions that identifies unit operating features line.

  • Page 94: Mp-3000 Controller (Continued)

    MP-3000 Controller • “LANGUAGE”: English is only setting • “EVAPORATOR TYPE”: Sets the currently available. evaporator fan value to VFD 2 fan, 3 fan or 2 fan. Must be manually set. • “ECONOMY MAX”: Sets the Economy mode maximum temperature limit (factory •...

  • Page 95: Datalogger Menu

    MP-3000 Controller c. Use the general purpose keypad to enter 6. Repeat steps 4 and 5 to reset additional the desired value; or press the F3 key to configuration values. toggle the value to the desired setting. 7. Press ESC key to exit the Configurations d.

  • Page 96: Viewing The Datalogger Menu

    MP-3000 Controller • Inspect Event Log: Displays important event • To scroll through previous logs of the logs by time and date for events such as unit sensor temperatures currently in the display, press F3 key. All temperature alarms, power On/Off, setpoint change, clock reset, trip start, defrost, etc.

  • Page 97: Inspect Event Log

    MP-3000 Controller Inspect Event Log 5. Press F4 key to enter PTI log. LCD display shows the Start Time and PTI test results of With the U switch O and the LCD the most recent PTI log. display showing the standard display (setpoint): •...

  • Page 98: Set A Trip Start

    MP-3000 Controller USDA temperature recording requirements. • The controller displays “OOR” in place of Calibrate the sensors in an ice bath. CSR units a temperature offset until the sensor comes equipped for NTC style USDA sensors require within 0.3 C (0.5 F) above or below 0 C USDA sensor P/N (refer to Tool Catalog).

  • Page 99: Set Log Time

    MP-3000 Controller Set Log Time 3. Press F2 or F3 key to scroll through submenu until “ACTIVATE TRIPSTART” appears in With the U switch O and the LCD LCD display. display showing the standard display (setpoint): 4. Press F4 key to enter Tripstart function. The 1.

  • Page 100: Rmm State Menu

    MP-3000 Controller • Change RH status (On/Off) Note: All screens are not Standard Display present on all units. The • Event log retrieval screens that display on the controller are determined by the Controller Software • Temperature log retrieval setting and the options installed on the unit.

  • Page 101: Figure 32:Manual Emergency Control Connections

    MP-3000 Controller • Position 4: Not Used 3. Disconnect cable No. 2 from the controller and main relay board (see electrical • Position 5: Defrost: Heaters are activated schematic). The main relay board will now (evaporator fans off). control the unit based on the manual control •...

  • Page 102: Reversing Power Phase On Csr Units

    MP-3000 Controller Reversing Power Phase on CSR WARNING: The unit will automatically Units start and operate if 460/380V power is present at the main relay board when the Use the incoming power cable leads to reverse the controller is disconnected. To prevent power phase.

  • Page 103: Automatic Configuration Of Spare Parts Controller

    MP-3000 Controller NOTE: If a controller from another unit has • Position 3: All CRR40 DF units been installed, see “Controller Software • Position 4: All CSR40 Magnum units Selection” in this chapter to set software selection dial correctly. • Position 7: Unit testing and service only.

  • Page 104: Temperature Sensors

    MP-3000 Controller 7. The controller then checks the new software and loads the new control program into memory. NOTE: If the flash load procedure is interrupted or fails, the controller will continue to use the previous control program. NOTE: Installing new software does not change any configuration settings or the AXA0172 setpoint setting, or erase the data log...

  • Page 105: Figure 35:Condenser Coil Sensor Location

    MP-3000 Controller Resistance Values for Supply, Return, Evaporator Resistance Values for Compressor Coil, Condenser Coil and Ambient Air Sensors Discharge Sensors Temp. Temp. Temp. Temp. Temp. Temp. Temp. Temp Ohms Ohms Ohms Ohms 42618 53.6 3360 1,121,457 9,202 32198 57.2 3094 834,716 7,869...

  • Page 106: Diagnosis And Repair

    MP-3000 Controller 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 Actions”...

  • Page 107: Error Messages And Controller Actions

    MP-3000 Controller Error Messages and Controller than one error message may appear at a time. Press F2 or F3 key to scroll through message Actions displays. The controller displays error messages (In the Miscellaneous Function Menu under Status) on the LCD display for several general faults. More Error Messages and Controller Actions Message Error Message...
  • Page 108 MP-3000 Controller Error Messages and Controller Actions (Continued) Message Error Message Controller Action Running with High Supply Difference • Controller clears message during defrost and when U switch is turned O Indicates: • Temperature difference between the left hand and right hand Supply sensors is too large; even after Probe Test indicates no sensor errors.

  • Page 109: Alarm Codes, Descriptions And Corrective Actions

    MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions NOTE: Sensors used with the MP-3000 • Check Alarm (Level 2 Alarm): Alarm light on controller do not require calibration. Check display flashes until alarm is acknowledged. sensor resistance with an ohmmeter. •...
  • Page 110 MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions (Continued) Code Description Corrective Action Return Air Sensor Short Circuit • Check sensor resistance between pins 3 and (Check Alarm) 4 on plug J15. Resistance must be 2,000 ohms at 25 C (77 F). •...
  • Page 111 MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions (Continued) Code Description Corrective Action Compressor Current Too High • Check evaporator, condenser and ambient (Check Alarm) sensor temperatures for correct value (± 5 C [± 9 F]) by viewing Data menu. •...
  • Page 112 MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions (Continued) Code Description Corrective Action Heater Current Too High • Enter Manual Function Test and turn heaters (Check Alarm) on. Check current draw on each phase. Current draw should be about 4.4 amps on •...
  • Page 113 MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions (Continued) Code Description Corrective Action 13** Evaporator Fan High Speed Current Too Low • Open evaporator door and make sure all fans (Check Alarm) rotate freely. • Occurs during pre-trip (PTI), function test or probe •...
  • Page 114 MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions (Continued) Code Description Corrective Action Condenser Fan Current Too High • Enter Manual Function Test and start (Check Alarm) condenser fan. Make sure the fan starts. Check fan motor volts and amps. •...
  • Page 115 MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions (Continued) Code Description Corrective Action Temperature Too Far From Setpoint • Press S key to check supply and return (Check Alarm) air sensor temperatures. Compare temperatures to evaluate unit cooling capacity • After 75 minutes of operation, supply or return air and performance.
  • Page 116 MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions (Continued) Code Description Corrective Action Capacity Test 1 Error • Enter Manual Function Test and start (Check Alarm) evaporator fans on low speed. Then select Sensor Checks test and operate fans 2 to 5 •...
  • Page 117 MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions (Continued) Code Description Corrective Action Capacity Test 3 Error • Enter Manual Function Test and start the (Check Alarm) following components: Condenser fan, evaporator fan (high), compressor and • Occurs during pre-trip (PTI) test only. compressor 25%.
  • Page 118 MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions (Continued) Code Description Corrective Action Stepper Motor Valve Error • Check the wiring to stepper motor valve using unit wiring diagrams and a digital multimeter. • Stepper motor valve current too low or too high •...
  • Page 119 MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions (Continued) Code Description Corrective Action Low Pressure Cutout Error • Check discharge and suction pressure gauge (Check Alarm) readings: • Occurs any time. • If refrigerant pressures are low, check for a restriction and leak check the refrigeration •...
  • Page 120 MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions (Continued) Code Description Corrective Action Condenser Temperature Sensor Open Circuit • Check sensor resistance between pins 7 and (Check Alarm) 8 on plug J15. Resistance must be 2,000 ohms at 25 C (77 F). •...
  • Page 121 MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions (Continued) Code Description Corrective Action Total Current Too High • Enter Manual Function Test menu and test (Alarm) (operate) each component. Check volts and amps to determine which component has high • When the unit or component current draw is 25% amp draw.
  • Page 122 MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions (Continued) Code Description Corrective Action Supply Air Temperature Too Low • Check for sensor or evaporator fan alarm (Check Alarm) codes. • During Chill or Frozen Mode: Supply air • Open evaporator door. Inspect coil for ice or temperature is too low compared to return air frost and initiate manual defrost if necessary.
  • Page 123 MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions (Continued) Code Description Corrective Action Probe Error • Check sensor connections. Check sensor (Check Alarm) resistance of each sensor. Resistance must be 2,000 ohms at 25 C (77 F). • Occurs during pre-trip (PTI) test or probe test failed in Chilled mode.
  • Page 124 MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions (Continued) Code Description Corrective Action Compressor Temperature Too High • Operate unit on Cool and check discharge and (Shutdown Alarm) suction pressure gauge readings. • Compressor discharge line temperature is above • Enter Manual Function Test menu and test 148 C (298 F).
  • Page 125 MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions (Continued) Code Description Corrective Action Humidity Sensor Error • Check sensor connections. (Check Alarm) • Check controller configuration for correct • Occurs during pre-trip (PTI) test only. humidity setting. • Relative humidity reading is not between 20% and •...
  • Page 126 MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions (Continued) Code Description Corrective Action USDA 1 Sensor Open Circuit • Check USDA sensors and sensor (Check Alarm) connections. • Occurs during pre-trip (PTI) test only. • Check cable No. 3 between controller and relay board.

  • Page 127: Electrical Maintenance

    Electrical Maintenance High Pressure Cutout Switch High Pressure Cutout Switch: Opens: 3243 ± 7 kPa, 32.43 ± 0.48 bar, 470 ± 7 A high pressure cutout switch is located on the psig. compressor discharge service manifold of the compressor. If the discharge pressure becomes too Closes: 2758 kPa, 27.58 bar, 400 psig.

  • Page 128: Low Pressure Cutout Switch

    Electrical Maintenance Condenser Fan and Evaporator 3. Raise the discharge pressure of the compressor by blocking the condenser coil Fan Rotation airflow. Temporarily cover the compressor NOTE: If both the condenser fan and compartment, control box and power cord evaporator fans are rotating backwards, storage compartment with cardboard to reduce diagnose the automatic phase selection system.

  • Page 129: Electric Heaters

    Electrical Maintenance Electric Heaters Six electric heater elements are located underneath the evaporator coil. If a heater element is suspected of malfunctioning, check the resistance of each individual heater element: 1. Turn unit power supply off. 2. Remove unit power plug from power supply receptacle.
  • Page 130 Electrical Maintenance...

  • Page 131: Refrigeration Maintenance And Service Operations

    Operations Service Tools NOTE: The following procedures involve servicing the refrigeration system. Some of these CAUTION: When servicing Thermo King service procedures are regulated by Federal, and R-404A refrigeration systems, use only in some cases, by State and Local laws.

  • Page 132: Vacuum Pump

    Refrigeration Maintenance and Service Operations Vacuum Pump • Back Seated: Normal operation position. A two-stage (refer to Tool Catalog), three-stage or • Open to Service Port: Position for servicing. five-stage pump is recommended for evacuation. • Front Seated: To check or remove compressor. Purging the system with dry nitrogen is recommended before evacuation.

  • Page 133: Gauge Manifold Valve Positions

    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. AXA0181 Close Hand Valves Figure 43: Gauge Manifold Closed to Center Port AXA0241 Quick Disconnect Access Valve Discharge Service Valve (DSV)

  • Page 134: Gauge Manifold Set (With Low Loss Fittings) Attachment And Purging

    Purging 8. Attach high side hose (pressure gauge) to the discharge service line port. Thermo King recommends the use of access valves or self-sealing, quick disconnect fittings 9. Open discharge service manifold hand valve whenever possible to limit the loss of refrigerant fully.

  • Page 135: Gauge Manifold Set Removal

    Refrigeration Maintenance and Service Operations Gauge Manifold Set Removal The compressor oil should be checked during pre-trip inspections and when there is evidence of NOTE: To ensure minimum refrigerant release oil loss (oil leaks) or when components in the to the atmosphere, THE SYSTEM SHOULD BE refrigeration system have been removed for RUNNING.

  • Page 136: Adding Compressor Oil

    Refrigeration Maintenance and Service Operations Adding Compressor Oil A pre-trip test should be performed during pre-trip and routine maintenance inspections. A low 1. With the unit off, remove the cap from oil charge of refrigerant will cause the container pressure fitting. temperature to rise due to the lack of liquid 2.

  • Page 137: Using Pressurized Nitrogen

    Refrigeration Maintenance and Service Operations Using Pressurized Nitrogen 3. Attach refrigerant bottle charging hose to center of gauge manifold and purge charging The improper use of high pressure cylinders can hose of air. cause physical damage to components, or 4. Pressurize the system with refrigerant (gas personal injury, or cause stress that would lead to only) until 345 kPa, 3.45 bar, 50 psig vapor failure of components.

  • Page 138: Procedure

    Refrigeration Maintenance and Service Operations 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 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.

  • Page 139: Refrigeration Maintenance And Service Operations (Continued)

    Refrigeration Maintenance and Service Operations Evacuation and Cleanup of the • Acid: Air and moisture cause a chemical breakdown of the oil and/or the refrigerant Refrigeration System itself. The acid will accelerate the Whenever contaminants have entered the system, deterioration of the softer metals (i.e., copper) a thorough clean up is required to prevent damage and cause metal plating as the softer material or loss of compressor.

  • Page 140: Unit Evacuation

    The final equilibrium pressure is determined the operator can be confident that the pump with the Thermo King Evacuation Station and oil are in good condition. If the vacuum using the following procedure (called a...

  • Page 141: Figure 50:Evacuation Station And Unit Hook-Up

    Refrigeration Maintenance and Service Operations AXA0246 Special, self-sealing quick disconnect couplers are required for R-404A units. Gas Ballast Valve Iso Valve Two-stage Vacuum Pump To 220/190 VAC Power Calibration Standard Micron Meter Sensor Figure 50: Evacuation Station and Unit Hook-up...

  • Page 142: Pressure Rise Test

    Refrigeration Maintenance and Service Operations 2. If the vacuum level appears to stall above additional dehydration and pumping time. See 500 microns, back seat the discharge service Figure 52 “Pressure Rise Levels Off After valve and observe the micron meter. Evacuation Indicates Moisture in System”.

  • Page 143: Factors Affecting The Speed Of System Evacuation

    Refrigeration Maintenance and Service Operations Factors Affecting the Speed of Charging the System with System Evacuation Refrigerant It is almost impossible to state the exact amount Unit Charging by weight (from an of time required to evacuate any system. Some Evacuated Condition) factors that can influence evacuation time are listed below.

  • Page 144: Stepper Motor Valve Replacement

    Refrigeration Maintenance and Service Operations 6. Back seat the suction line access service 9. If no leaks are found, recover the refrigerant valve. used for the leak test (see “Refrigerant Recovery” in this chapter). 7. Stop the unit. 10. Evacuate the system (see “Evacuation and 8.

  • Page 145: Installation

    Refrigeration Maintenance and Service Operations Installation Condenser Coil Replacement 1. Add new compressor oil to the new Removal compressor. Add an amount equal to the amount removed from the old compressor. 1. Recover the refrigerant charge from the unit (see “Refrigerant Recovery” in this chapter). CAUTION: Use ONLY Polyol Ester based 2.

  • Page 146: Filter Drier/In-Line Filter Replacement

    Refrigeration Maintenance and Service Operations Filter Drier/In-line Filter 8. Evacuate the system (see “Evacuation and Cleanup of the Refrigeration System” in this Replacement chapter). Removal 9. Recharge the unit with R-404A (see “Charging the System with Refrigerant” in 1. Recover the refrigerant charge from the unit this chapter).

  • Page 147: Heat Exchanger Replacement

    Refrigeration Maintenance and Service Operations 3. Solder liquid line inlet and outlet line connections to valve. NOTE: Thermo King strongly recommended that dry nitrogen be used to purge the system during any solder operations (see “Using Pressurized Nitrogen” in this chapter).

  • Page 148: Installation

    Refrigeration Maintenance and Service Operations Installation Installation 1. Clean the tubes for soldering. 1. Install a new tank in the unit and tighten the mounting bolts. 2. Place the heat exchanger assembly in the unit and install the mounting hardware. 2.

  • Page 149: Installation

    Refrigeration Maintenance and Service Operations Installation 2. Purge the high pressure from the compressor head through the service port on the discharge 1. Clean the tubes for soldering. line. 2. Place the new valve in position. and solder the 3. Disconnect the leads from the wire harness connections.
  • Page 150 Refrigeration Maintenance and Service Operations 6. Reconnect the electrical wires to the valve. 7. Recharge the unit with R-404A (see “Charging the System with Refrigerant” in this chapter). 8. Perform a controller pre-trip test to verify system operation.

  • Page 151: Structural/Accessory Maintenance

    Structural/Accessory Maintenance Mounting Bolts Condenser Coil Check and tighten all unit, compressor, and fan Clean the condenser coil by blowing low pressure motor mounting bolts during pre-trip inspections compressed air or a medium pressure warm water and every 1,000 operating hours. Unit mounting spray from the inside of the coil outward (opposite bolts should be tightened to a torque value of direction of normal airflow).

  • Page 152: Condenser Fan Location

    Structural/Accessory Maintenance 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 fanshaft, 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.

  • Page 153: Handle Adjustment: High Ventilation Rates

    Structural/Accessory Maintenance Advanced Fresh Air 3. Tighten the wing nut. Management (AFAM) or Handle Adjustment: High Ventilation Advanced Fresh Air Rates Management Plus (AFAM+) 1. Loosen wing nut on handle assembly until Door (Options) handle bracket will rotate over handle. A microprocessor controlled AFAM or AFAM+ 2.

  • Page 154: Humidify System (Option)

    Structural/Accessory Maintenance AXA0249 Cotter Pins Shoulder Washer Rod End AXA0200 L-Rod Vent Motor Linkage Water Supply Hose and Atomizing Nozzle: Inspect every 1,000 hours and clean if Figure 58: AFAM System Linkage Adjustment necessary. Humidify System (Option) Filter: Inspect every 1,000 hours and clean if necessary.

  • Page 155: Pre-Trip Inspection

    Structural/Accessory Maintenance Partlow (Model SR) Recording The evaporator drain hoses are routed to the water tank to replenish the water level during unit Thermometer (Option) operation. However, water usage will vary The 31-day Partlow Recorder is mechanically depending upon the load and ambient conditions. driven by a spring wound mechanism.

  • Page 156: Marking System Calibration

    Structural/Accessory Maintenance 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).

  • Page 157: Element Replacement

    Structural/Accessory Maintenance Element Replacement The thermal element is field replaceable. To replace the element: 1. Remove element flange screws (D) and withdraw the thermal element from the recorder case. Care must be taken not to bend the hex shaft which extends from the recorder case.

  • Page 158: Battery

    Structural/Accessory Maintenance Battery 7. Check to see that the quartz motor is running. Look through the inspection window and The recording chart is driven by a make sure the internal flywheel on the quartz battery-powered quartz motor and reducing gear. motor is revolving.

  • Page 159: Power Element Assembly Replacement

    Structural/Accessory Maintenance 3. Wait at least 5 minutes to allow the recording 3. Loosen five mounting screws that mount the thermometer sensing bulb temperature to capillary holding plate and element assembly stabilize. Then compare the “RET” in the recorder. Remove the power element temperature in the controller display with the assembly (includes recording pen assembly).

  • Page 160: Battery Voltage Indicator

    Structural/Accessory Maintenance 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.

  • Page 161: Diagnosis

    Diagnosis Mechanical Diagnosis Condition Possible Cause Remedy Compressor does not operate— Controller on; unit start sequence still Wait up to 2minutes for compressor no amperage draw timing start-up Locate fault and repair: power No power to unit (condenser and source, power plug, CB1 main evaporator fans do not operate) circuit breaker, motor contactor, motor terminals, motor...
  • Page 162 Diagnosis Condition Possible Cause Remedy Compressor contactor burned Increase line voltage to at least 90% Low line voltage of compressor motor rating Reduce line voltage to at least 110% Excessive line voltage of compressor motor rating Short cycling Eliminate cause of short cycling Unit short cycles Refrigerant overcharge causing Purge system...

  • Page 163: Refrigeration Diagnosis

    Diagnosis Condition Possible Cause Remedy Evaporator fan motor(s) does Check operating mode indicator Unit on defrost not operate LEDs Check setpoint, indicator lights and Unit in Economy mode (Frozen Load; Program menu of µP-D controller to Null mode only) verify that Economy mode is set to Loose line connection Tighten connections Check for seized bearings or...
  • Page 164 Diagnosis Condition Possible Cause Remedy Head pressure too low Shortage of refrigerant Repair leak and recharge Low ambient air temperature No remedy NOTE: This unit has a suction Service gauge out of calibration Replace gauge modulation capacity control system. Suction and discharge pressures may drop below expected normal readings when the unit is in Modulation...
  • Page 165 Diagnosis Condition Possible Cause Remedy Unit in vacuum—frost on Apply hot wet cloth to expansion expansion valve only Ice plugging expansion valve screen valve. Moisture indicated by increase or orifice in suction pressure. Replace filter drier High suction pressure Overcharge of refrigerant Purge system Expansion valve open too much Adjust or replace valve...
  • Page 166 Diagnosis...

  • Page 167: Afam System & Afam

    AFAM System & AFAM+ Advanced Fresh Air If the controller identifies a component failure during unit startup, an alarm is recorded in the Management (AFAM) System controller display and data-logger memory. If a An advanced microprocessor controlled fresh air power loss occurs after the AFAM system is management system provides programmable turned on, the controller automatically operates control of the air exchange rate, programmable...

  • Page 168: Starting The Afam System

    AFAM System & AFAM+ Starting the AFAM System Changing the AFAM Delay NOTE: The fresh air exchange time delay 1. Press the S key. The Setpoint menu ETPOINT should be established by the shipper. appears with the cursor in the “TEMP SETP” line.

  • Page 169: Changing The Afam Rate

    AFAM System & AFAM+ Standard Display Enter a Temperature Setpoint, Humidity Setpoint, Defrost Term. Temp., Defrost Time Setpoint Menu Setting or Delta T OPTI-SET • Press F4 key. TEMP SETP. • Type the new setpoint or setting. • Press and hold F4 key until cursor BULB MODE stops flashing.

  • Page 170: Setting Afam Units In The Configuration Menu

    AFAM System & AFAM+ Setting AFAM Units in the 5. To set a new value, press F4 key. The Configuration Menu Password screen appears. With the U switch O and the LCD 6. Enter the password. Press F2 key, A key (password is “A”), F4 key and then E display showing the standard display (setpoint): key.

  • Page 171: Advanced Fresh Air Management Plus (Afam+) System

    AFAM System & AFAM+ Advanced Fresh Air The default setting for AFAM in the Setpoint menu is the last value set (Off, Units or Demand). Management Plus (AFAM+) AFAM must be set to Demand to control the vent System door to the O and CO gas levels.

  • Page 172: Changing The Afam Delay

    AFAM System & AFAM+ 4. Press F2 key to toggle between “OFF”, 4. Enter (type) the new time delay in the LCD “DEMAND” and “UNITS”. display using the general purpose keypad: 1 to 72 hours. The cursor moves to the right of the •...

  • Page 173: Changing The Co Maximum Setting

    AFAM System & AFAM+ Changing the CO Maximum Setting NOTE: The minimum CO rate should be established by the 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.
  • Page 174 AFAM System & AFAM+...

  • Page 175: Index

    Index Error Messages 107 Accessory Maintenance 151 Evacuation 139 Advanced Fresh Air Management (AFAM) 30, 153 Evaporator Airflow, Specifications 20 Advanced Fresh Air Management (AFAM) System 167 Evaporator Coil 151 Advanced Fresh Air Management Plus (AFAM+) 30, Evaporator Fan Location 152 Evaporator Fan Rotation 128 Advanced Fresh Air Management Plus (AFAM+) Sys- Evaporator Fans 30...
  • Page 176 Index Physical Specifications, Specifications 26 TRANSFRESH 31 Power Limit Management 61 Trip Start 98 Power Limit Mode 61, 62 Power Management 89 Pressure Cutout Switch Replacement 148 Unit Control Box 51 Pressure Gauge Options 31 Unit Controls 51 Pressure Rise Test 142 Unit Decals 16 Pressurized Nitrogen 137 Unit Description 29...

  • Page 177: Wiring And Schematic Diagrams Index

    Wiring and Schematic Diagrams Index Dwg No. Drawing Title Page 5D55643 CSR Wiring Schematic 5D55644 CSR Wiring Diagram 180-181 5D52861 MPC 2000ID/MP3000 Controller High Voltage Wiring Diagram 5D52862 MPC 2000ID/MP3000 Controller Low Voltage Wiring Diagram CSR Wiring Schematic MPC 2000ID/MP3000 Receiver 2 Fan 5D52863 Schematic Diagram CSR Refrigeration System Components...
  • Page 178 Wiring and Schematic Diagrams Index...

  • Page 179: 5D55643 Csr Wiring Schematic

    CSR Wiring Schematic...

  • Page 180: 5D55644 Csr Wiring Diagram

    CSR Wiring Diagram–Page 1 of 2...
  • Page 181 CSR Wiring Diagram–Page 2 of 2...

  • Page 182: 5D52861 Mpc 2000Id/Mp3000 Controller High Voltage Wiring Diagram

    MPC2000ID/MP3000 Controller High Voltage Wiring Diagram...

  • Page 183: 5D52862 Mpc 2000Id/Mp3000 Controller Low Voltage Wiring Diagram

    MPC2000ID/MP3000 Controller Low Voltage Wiring Diagram...

  • Page 184: Csr Wiring Schematic Mpc 2000Id/Mp3000 Receiver 2 Fan Schematic Diagram

    CSR Wiring Schematic MPC 2000ID/MP3000 Receiver 2 Fan Schematic Diagram...

  • Page 185: Csr Refrigeration System Components

    CSR Refrigeration System Components 1. Scroll Compressor 2. Sight Glass 3. Oil Fill / Drain Fitting 4. High Pressure Cutout Switch 5. Compressor Discharge Line Temperature Sensor 6. Discharge Service Valve (Option) 7. Condenser Coil (Circular) 8. Receiver Tank 9. Warm Gas Bypass Valve 10.
  • Page 186 Flow and Pressure Diagram, CSR, Full Cool 1. Scroll Compressor Compressor operation has a delay on initial start-up and when the unit shifts to a cooling mode requiring the compressor to start. 4. High Pressure Cutout Switch (HPCO) Is a normally closed switch. It opens at 3240 ±...

  • Page 187: Flow And Pressure Diagram, Csr

    Flow and Pressure Diagram, CSR, Cool with Modulation (or Power Limit) 9. Warm Gas Bypass Valve Is a normally closed solenoid. It opens when energized to reduce cooling capacity when the Cooling Capacity in the Data menu display is about 50% or less. 18.

  • Page 188: Flow And Pressure Diagram, Csr, Dehumidification

    Flow and Pressure Diagram, CSR, Dehumidification NOTE: At setpoints below 5 C (41 F), the dehumidification is not energized. 29. Coil/Dehumidify Solenoid Valve (DSV) Is a normally open valve. If the container humidity is 2% or more above the humidity setpoint, the temperature is in-range and the Cooling Capacity in the Data menu display is 85% or less;...

  • Page 189: Mp-3000 Menu Flow Diagram

    MP-3000 Menu Flow Diagram...

This manual is also suitable for:

Csr40sl-167 power saverCsr20sl-144 power saverCsr40-145 power saverCsr20sl-155 power saver

Table of Contents

Save PDF