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 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
Fans – Air Cooled Condensing CSR-40 Models with Three Evaporator Power Line Communications 2-12 Fans – Air Cooled Condensing Thermo King Modem (Integrated Remote CSR-40 Models with Two Evaporator Monitor Unit) Option for Fans – Air Cooled Condensing Power Line Communications...
Page 6 Table of Contents Displaying Alternate Controlling (Supply or Operating Instructions Return) Air Sensor Temperatures 4-18 Unit Controls Changing the Setpoint 4-18 Unit Instruments Initiating a Manual Defrost 4-19 Unit Protection Devices Initiating a Full Pretrip 4-19 Pretrip Inspection Entering a Start of Trip Marker 4-20 Displaying and Clearing Alarm Codes 4-20...
Page 7 Table of Contents Evaporator Coil Electrical Maintenance Defrost Drains Unit Wiring Evaporator Fan Location Auxiliary Battery and Battery Charger (Option) Condenser Fan Location High Pressure Cutout Switch Fresh Air Exchange System Condenser Fan and Evaporator Fan Rotation Partlow (Model SR) Recording Thermo- meter (Option) Electric Heaters Integrated Remote Monitor Unit (IRMU) (Option)
Page 8 Table of Contents Dehumidify System, Humidity System, Modulation Mode – Chill Load (Setpoint at Water Pressure Switch, USDA -9.9 C [14.1 F] or Above); Condenser Temperature Sensor, Pulp Sensor and Fan OFF; Economy Mode ON; Chart Recorder Circuits (Options) 9-11 Temperature In-range;...
Page 9: Introduction
Thermoguard µP-D Microprocessor Controller Diagnosis operators and service people in the proper upkeep and mainte- Manual. For further information refer to: nance of Thermo King units. This manual includes mainte- nance and diagnosis information for both standard and option- Parts Manuals al unit features.
Page 10: Csr Model Features Vi To
– Power Line Communications, Standard (Thermo King Modem) – – – – – – – – Power Line Communications, Thermo King Integrated Remote Monitor Unit (IRMU) – – – – – – – – – Power Line Communications, RTE Modem –...
Page 11 Power Line Communications, Standard (Thermo King Modem) – – – – – – – – – Power Line Communications, Thermo King Integrated Remote Monitor Unit (IRMU) – – – – – – – – – Power Line Communications, RTE Modem –...
Page 13: Safety Precautions
Safety Precautions General Practices Refrigerant ALWAYS WEAR GOGGLES OR SAFETY GLASSES. When removing any refrigerant from a unit, use a recovery Refrigerant liquid and battery acid can permanently dam- process that prevents or absolutely minimizes the refrigerant age the eyes (see First Aid under Refrigerant Oil). that can escape to the atmosphere.
Page 14: Refrigerant Oil
Refrigerant Oil Safety Precautions 4. Do not make any rapid moves when working on high volt- Refrigerant Oil age circuits. If a tool or other object falls, do not attempt to grab it. People do not contact high voltage wires on Observe the following precautions when working with or purpose.
Page 15: Microprocessor Controller
Safety Precautions General Safety Precautions for Servicing Controllers Welding of Units or Containers General Safety Precautions for Servicing Whenever electric welding is to be performed on any portion Units (or Containers) Equipped with a of the refrigeration unit, container or container chassis with the refrigeration unit attached, it is necessary to ensure that weld- Microprocessor Controller ing currents are NOT allowed to flow through the electronic...
Page 16: Unit Decals
Serial number decals, refrigerant type decals and warning Electric Motors: Nameplate attached to the motor housing. decals appear on all Thermo King equipment. These decals Compressor: Nameplate on front of the compressor. provide information that may be needed to service or repair the Unit: Nameplate on unit frame in power cord storage compart- unit.
Page 17: Service Guide
Service Guide Every Annual/ 1,000 Yearly Pretrip Hours Inspect/Service These Items Refrigeration • Perform a controller Full Pretrip Test to check the refrigeration and electrical systems. • • Perform a controller Extended Pretrip Test. Electrical • • • Visually inspect condenser fan and evaporator fan rotation. •...
Page 18: Specifications
Specifications System Net Cooling Capacity — Full Cool CSR-20SL Models with Three Evaporator Fans — Air Cooled Condensing* Return air to 460/230V, 3 Phase, 60 Hz Power 380/190V, 3 Phase, 50 Hz Power evaporator Net Cooling Capacity Power Consp Net Cooling Capacity Power Consp coil inlet Watts...
Page 19: Csr-40 Models With Two Evaporator Fans - Air Cooled Condensing
Cooling and Heating Capacity Specifications System Net Cooling Capacity — Full Cool (Continues) CSR-40 Models with Two Evaporator Fans — Air Cooled Condensing* Return air to 460/230V, 3 Phase, 60 Hz Power 380/190V, 3 Phase, 50 Hz Power evaporator Net Cooling Capacity Power Consp Net Cooling Capacity Power Consp...
Page 20: Evaporator Airflow
Specifications Evaporator Airflow Evaporator Airflow CSR-20SL Models with Three Evaporator Fans External Static 460/230V, 3 Phase, 60 Hz Power 380/190V, 3 Phase, 50 Hz Power Pressure (water High Speed Low Speed High Speed Low Speed column) /min /min /min /min 0 mm (0 in.) 4,000 2,350...
Page 21: Refrigeration System
Refrigeration System Specifications Refrigeration System Compressor Model No.: CSR-20SL, CSR-40 & CSR-40SL ZM18K4E-TFD-279, Hermetic Scroll Refrigerant Charge: CSR-20SL, CSR-40 & CSR-40SL 4.1 Kg (9.0 lb) R-404A Water-Cooled Condenser-Receiver Tank (Option) 5.0 Kg (11.0 lb) R-404A Compressor Oil Capacity 1.77 liter (60 oz.) Compressor Oil Type Polyol Ester Based Type (required), TK Part No.
Page 22: Electrical System
Specifications Electrical System Electrical System Compressor Motor: Type 460/380V, 60/50 Hz, 3 Phase Kilowatts (60 Hz) 4.48 kW Horsepower (60 Hz) 6.0 hp RPM (60 Hz) 3550 rpm Locked Rotor Amps (60 Hz) 70 amps — 460V Condenser Fan Motor*: Red Color Finish: Type 460/380V, 60/50 Hz, 3 Phase...
Page 23: Thermoguard
µ µ P-D Microprocessor Specifications µ µ P-D Microprocessor Thermoguard ® µP-D microprocessor with digital thermostat, ther- Temperature Controller: Type Thermoguard ® mometer and fault indicator monitor Setpoint Range -30.0 to +30.0 C (-22.0 to +86.0 F) Digital Temperature Display -40.0 to +130.0 C (-40.0 to +266.0 F) Output Module Energizes and de-energizes unit contactors and solenoids in...
Page 24 µ µ P-D Microprocessor Specifications µ µ P-D Microprocessor (Continued) Thermoguard ® Defrost Termination: Evaporator Coil Sensor* Chill mode: Terminates defrost when coil sensor temperature rises to 30 C (86.0 F) Frozen mode: Terminates defrost when coil sensor temperature rises to 18 C (64.4 F) Interval Timer** Terminates defrost 90 minutes after initiation if coil sensor has not terminated defrost...
Page 25: Dehumidify And Humidify Systems (Options)
Dehumidify and Humidify Systems Specifications Dehumidify and Humidify Systems (Options) Dehumidify System (Option): Turn Mode ON and OFF Set from HUMID screen of the Program menu of the controller Control Range (HUMSP) Setting 50% to 100% Relative Humidity Humidify System (Option): Turn Mode ON and OFF Set from HUMID screen of the Program menu of the controller Operating Temperature Range 0 to 60 C (32 to 140 F)
Page 26 Specifications Physical Specifications Physical Specifications (Continued) Unit Dimensions: A = Flange Width 2025.5 mm (79.74 in.) B = Gasket Width 1935 mm (76.18 in.) C = Unit Width 1894 mm (74.57 in.) D = Flange Height 2235.2 mm (88.00 in.) E = Gasket Height 2140 mm (84.25 in.) F = Unit Height...
Page 27: Metric Hardware Torque Charts
1-10 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)
Page 28: Unit Description
Unit Description Hermetic Scroll Compressor with Liquid Injection General Description Cooling System The refrigeration unit includes a hermetic scroll compressor Model CSR-20SL, CSR-40 and CSR-40SL units are all-elec- (one stationary and one orbiting member) with ambient com- tric, single-piece, refrigeration units with bottom air supply. pensated internal overload and high temperature protectors, Each unit is designed to cool and heat containers for shipboard and a refrigerant injection system.
Page 29 General Description Unit Description µ µ P-D Controller Thermoguard Dehumidification Control System Option ® The µP-D controller incorporates refrigeration system compo- An optional dehumidification system lowers the relative nent control, thermostat, digital thermometer, fault indicator humidity in the container to the humidity setpoint. The control and data recording capabilities into one self-contained pack- range setpoint is adjustable between 50% and 100%.
Page 30: Operating Modes
NOTE: See speed transmission reads all controller information. sequence of operation. • Thermo King Integrated Remote Monitor Unit (IRMU) for ISO narrow band power line remote monitoring. The IRMU When the unit is started, two backlit LED displays on the is installed in a self-enclosed box bolted above the compres- microprocessor illuminate.
Page 31 Operating Modes Unit Description Frozen Loads: Controller Setpoint at -10 C (14 F) or Below Temperature control by the controller is based on the return air sensor temperature. The evaporator fans operate on low speed (when container return air sensor temperature drops below -10 C [14 F]).
Page 32: Unit Illustrations
Unit Description Unit Illustrations Typical Unit Front View Evaporator Access Door, 1018 mm (40.08 in.) Wide with Two Latches — Models with Two Evaporator Fans Evaporator Access Door, 1399 mm (55.04 in.) Wide with Three Latches — Models with Three Evaporator Fans Heater Access Panel Location Condenser Fan Compressor Compartment...
Page 33: Unit Options Front View
Unit Illustrations Unit Description Unit Options Front View Power Line Communications, Thermo King Modem (Integrated Remote Monitor Unit) Option Recording Thermometer Option Dual Voltage Option TRANSFRESH Download Receptacle, Option Remote Monitor Plug Option (4-Pin Connector on Bottom or Side of Control Box)
Page 34: Evaporator Section For Models With Three Evaporator Fans - Front View
Unit Description Unit Illustrations Evaporator Section for Models with Three Evaporator Fans — Front View Evaporator Fan Blade (see “Physical Specifications” on page 1-8 for description) Evaporator Fan Motor Return Air Sensing Bulb for Recording Thermometer (Option) Return Air Sensor Humidity Sensor (Option) Humidity System Compressor (Option), see page 2-17 CSR-20 &...
Page 35: Evaporator Section For Models With Two Evaporator Fans - Front View
Unit Illustrations Unit Description Evaporator Section for Models with Two Evaporator Fans — Front View Return Air Sensing Bulb for Recording Thermometer (Option) Return Air Sensor Humidity Sensor (Option) Evaporator Fan Blade (see “Physical Specifications” on page 1-8 for description) Evaporator Fan Motor Humidity System Compressor (Option), see page 2-17 CSR-20 &...
Page 36: Standard Hermetic Refrigeration System
Unit Description Unit Illustrations Standard Hermetic Refrigeration System Evaporator Coil 16. Modulation Valve Heat Exchanger Receiver Tank Tube (Standard) 18. Warm Gas Bypass Solenoid Valve Expansion Valve High Pressure Relief Valve Filter Drier/In-line Filter (One-piece) Liquid Line Piping on Units Built After 7/99 Liquid Line Piping on Units Built Before 7/99 Scroll Compressor 10.
Page 37: Hermetic Refrigeration System Options
2-10 Unit Illustrations Unit Description Hermetic Refrigeration System Options Water-Cooled Condenser-Receiver Tank Option 1a. Water Pressure Switch (Option) 1b. Water Inlet Coupling (Option) 1c. Water Outlet Coupling (Option) Dehumidify Valve Option (Replaces Standard Tube) CSR-20 & CSR-40, September 1999...
Page 38: Control Box - Door Open
Unit Description Unit Illustrations 2-11 Control Box — Door Open Condenser Fan Contactor Evaporator Fan Low Speed Contactor Power Module Control Transformer Thermo Bus Tap Output Module Emergency Bypass Module Remote Monitor Option Relays; 4-Pin plug is located on side of control box Unit On/Off Switch 10.
Page 39: Sabroe Remote Monitor Modem Option For Power Line Communications
2-12 Unit Illustrations Unit Description Sabroe or RTE Remote Monitor Modem Option for Power Line Communications High Voltage Tray in Control Box Modem Plug and Harness Sabroe Controls or RTE Modem CSR-20 & CSR-40, September 1999...
Page 40: Thermo King Modem (Integrated Remote Monitor Unit) Option For Power Line Communications
Unit Description Unit Illustrations 2-13 Thermo King Modem (Integrated Remote Monitor Unit) Option for Power Line Communications Remote Monitor Control Box High Voltage Harness Low Voltage Harness Cover Power Cable Data Communications Harness Low Voltage Filter and Interface PC Board...
Page 41: Integrated Remote Monitor Unit (Irmu) Option For Csr-40-116
2-14 Unit Illustrations Unit Description Integrated Remote Monitor Unit (IRMU) Option for CSR-40-116 Service Tools: A. Circuit Chip Installer B. Circuit Chip Remover C. Electrostatic Discharge Wrist Strap Integrated Circuit Chip Cover Power Cable Remote Monitor PC Board and Mounting Plate Assembly High Voltage Terminal Block Data Connection Terminal Block Remote Monitor Control Box...
Page 42: Auxiliary Battery And Battery Charger Option
Unit Description Unit Illustrations 2-15 Auxiliary Battery and Battery Charger Option 12 Vdc Battery Battery Charger Box Battery Charger Terminal Board Battery Charger Cover CSR-20 & CSR-40, September 1999...
Page 43: Dual Voltage Option
2-16 Unit Illustrations Unit Description Dual Voltage Option 15 KVA Transformer 460-380V Power Receptacle Cable Bracket 230-190V Power Cable Power Plug (Option) CSR-20 & CSR-40, September 1999...
Page 44: Humidity System Option
Unit Description Unit Illustrations 2-17 Humidity System Option Evaporator Drain Hose Fill Cap Water Tank Heater Tank Overflow Hose Drain Cock Water Tank Water Filter Water Supply Hose Air Compressor 10. Liquid Spray Nozzle CSR-20 & CSR-40, September 1999...
Page 45: Transfresh System Options
2-18 Unit Illustrations Unit Description TRANSFRESH System Options TRANSFRESH Scrubber Connection and A5 Wire Harnesses Evaporator Grille TRANSFRESH Door Assembly TRANSFRESH Download Port Transformer Assembly mounted in Control Box TRANSFRESH Provision Option includes: • TRANSFRESH Box • A2 Wire Harness to TRANSFRESH Transformer •...
Page 46: Typical Unit Back View
Unit Description Unit Illustrations 2-19 Typical Unit Back View Evaporator Grille Unit Gasket Top Rear Plate Bottom Rear Plate Sensor Connector Assembly: • Controller Communications and Data Download Port • Cargo (Pulp) Sensor Connection • USDA1 Sensor Connection • USDA2 Sensor Connection •...
Page 47: Operating Instructions
Operating Instructions 6. RET/SUP KEY. Press this key to view the alternate sen- Unit Controls sor temperature (non-controlling sensor) in the controller display. Alternate display shows while the key is pressed. 7. DEFROST KEY. Press this key to prepare the controller Unit Control Box to initiate a manual defrost cycle.
Page 48: Unit Instruments
When the discharge gas tem- mation. perature drops to 132 C (270 F), the controller de-ener- • Thermo King modem is installed in a self-enclosed box gizes the injection valve to stop refrigerant injection. bolted above the compressor.
Page 49: Pretrip Inspection
Operating Instructions Pretrip Inspection play will show “PAUSE ALM82” for 1 second every 10 7. OVERLOAD PROTECTION. The condenser fan motor, seconds. After 5 minutes, the controller attempts to restart evaporator fan motors and compressor motor include the compressor. If the compressor still fails to start, fault internal overload protection with automatic reset.
Page 50 Pretrip Inspection Operating Instructions 9. Optional: Check water level in humidity system tank. 4. Check direction of evaporator airflow (see “Condenser Add only demineralized or distilled water to prevent plug- Fan and Evaporator Fan Rotation” in Electrical ging of the atomizing nozzle. Maintenance chapter of this manual).
Page 51 Operating Instructions Starting the Unit NOTE: PASS or FAIL is recorded in the datalog- Starting the Unit and Adjusting the ger memory and can be viewed through the con- Controller Setpoint troller’s VIEW/LOG/PT1 submenu. For instruc- tions on viewing the VIEW/LOG/PT1 submenu, refer to “Viewing Information in the View Menu”...
Page 52: Loading Procedure
Loading Procedure Operating Instructions Loading Procedure Post Trip Procedure µP-D controller may 1. Make sure the Unit On/Off switch is OFF before opening Trip data recorded by the Thermoguard ® the container doors. (The unit may be operating when be down loaded using PC-PAC™ software via the communi- loading the container from a warehouse with door seals.) cations connection located on the bottom of the control box.
Page 53: Μ Μ P-D Controller
DATA DATA °C °F DOWN ENTER TEMPERATURE DEFROST PRETRIP ALARM SELECT THERMOGUARD µ P-D THERMO KING ® µ µ P-D Controller 1. Status Indicator Lights 2. Setpoint (Left) Display 3. Temperature (Right) Display 4. Keypad CSR-20 & CSR-40, September 1999...
Page 54: General Description
µP-D Controller General Description 3. Status indicator LEDs (see “Status Indicator LEDs and 11. Sensor Check test capability (see “Sensor Check” under General Theory of Operation in this chapter). Alarm Codes” in this chapter). 12. Data recording capability (see “Data Recording and 4.
Page 55: Controller Display Menus
µP-D Controller Controller Display Menus Active Option Displays Controller Display Menus Control options that have been turned ON in the Program The µP-D controller contains an extensive display menu that menu show for 1 second every 10 seconds in the controller dis- can be navigated via keypad.
Page 56: Pause Mode Displays
µP-D Controller Controller Display Menus Pause Mode Displays View Menu Menu screens in this group are used to display unit operating WARNING: When the unit is in the PAUSE mode, the information, sensor grades and scrollback data logger data compressor, evaporator fans or condenser fan may including controlling sensor temperatures and pretrip test continue to operate or start at any time without information.
Page 57 µP-D Controller Controller Display Menus BULB Bulb Mode Enable ETEST Extended Pretrip Test Bypass Valve Solenoid EX CH Extended Chill Mode Pretrip Test Temperature Display Mode EX DF Extended Defrost Pretrip Test CCOIL Condenser Coil Temperature Sensor EX FZ Extended Frozen Mode Pretrip Test CCTG Condenser Coil Sensor Grade FTEST...
Page 58: Status Indicator Leds And Alarm Codes
µP-D Controller Status Indicator LEDs and Alarm Codes PWRED Power Reduction Mode Setting and Enable VERSN Software Version RCOMP Remote Cool Indicator VIEW View Menu RDEF Remote Defrost Indicator VOLTS Total Voltage REFRG Refrigeration Test Submenu YEAR Current Year Return Air Temperature Sensor RETG Return Air Sensor Grade Remote In-range Indicator...
Page 59: Pause Alarms
µP-D Controller Pause Alarms Alarm Check Datalogger Full (Global) Code Type Description Check Real Time Clock Invalid Check Bypass Valve Circuit Failure (Pretrip) No Fault Check Ambient Temperature Sensor Failure Check Pretrip Preconditioning Failure Check Supply Air Temperature Sensor Failure Check Datalog Queuing Error Check...
Page 60: Data Logging And Downloading Data
µP-D Controller Data Logging and Downloading Data the condition. After 5 minutes, the controller attempts to General Theory Of Operation restart the compressor. If the compressor fails to start due to high pressure cutout, alarm code 10 is generated. The con- The µP-D controller uses advanced solid-state integrated cir- troller will restart the compressor when the fault condition cor- cuits to monitor and control all unit functions.
Page 61: Frozen Loads
µP-D Controller General Theory of Operation Frozen Loads (Setpoint at -10 C [14 F] and Below) Modulation Valve Setting (PCVAL) The modulation valve controls refrigerant return to the com- At setpoints of -10 C (14 F) and below, the controller controls pressor during Modulation Cool.
Page 62: Sensor Check
µP-D Controller 4-10 General Theory of Operation Sensor Check - If the temperature difference between both the supply and return air sensors and the coil sensor is greater than NOTE: If a Sensor Check occurs, check the supply 2.2 C (3.9 F), the controller determines both sensors are air sensor position in the probe holder.
Page 63: Economy Mode Operation
µP-D Controller Sequence of Operation 4-11 Economy Mode Operation Sequence Of Operation The Economy Mode reduces unit power consumption by reducing evaporator fan operation on both fresh and frozen Unit Start-up loads. The use of the Economy Mode should be established by the shipper and the type of cargo.
Page 64: Operating Mode Function Chart - Standard Operation
µP-D Controller 4-12 Sequence of Operation Operating Mode Function Chart — Standard Operation Chill Loads Frozen Loads Setpoints at -9.9 C Setpoints at -10.0 C (14.4 F) and Above (14.0 F) and Below Cool Mod Null Heat Defr Cool Null Defr Unit Function Evaporator Fans HIGH SPEED 1...
Page 65: Operating Mode Function Chart - Optional Feature Operation
µP-D Controller Sequence of Operation 4-13 Continuous Temperature Control Operation • Evaporator fans operate on high speed (except when Economy mode is ON and temperature is In-range) and continuously circulate air inside the container (except Chill Loads — Controller Setpoint at -9.9 C (14.1 F) during defrost).
Page 66 µP-D Controller 4-14 Sequence of Operation Modulation Cool Calculated Temperature Differential decreases to 3.1 C • Controller calls for Modulation Cool when the Calculated (5.5 F) below setpoint. Temperature Differential is between 2.5 C (4.5 F) above On temperature pull-up (and initial start-up), the con- setpoint and setpoint (on temperature pull-down).
Page 67 µP-D Controller Sequence of Operation 4-15 Frozen Loads — Controller Setpoint at -10 C (14 F) Cool and Below • Controller calls for the Cool mode whenever the return air temperature is more than 1.0 C (1.8 F) above setpoint. At setpoints of -10 C (14 F) and below, the controller locks out •...
Page 68: Defrost
µP-D Controller 4-16 Sequence of Operation Null • A manual defrost is initiated (loaded) using the controller • The controller calls for Null when the Return Air keypad. Temperature decreases more than 1.0 C (1.8 F) below NOTE: If unit operating conditions do not allow setpoint (on temperature pull-down).
Page 69: Reviewing Software Version And Configuration
µP-D Controller Reviewing Software Version and Configuration 4-17 NOTE: The unit will operate and control the con- Reviewing Software Version and tainer temperature if the controller remains pro- Configuration grammed to unit configuration “5000” and cus- tomer configuration “0”. However, the unit will The software version, unit configuration number and customer not operate customer specific options.
Page 70: Displaying Alternate Controlling (Supply Or Return) Air Sensor Temperatures
µP-D Controller 4-18 Displaying Alternate Temperatures NOTE: The setpoint temperature can be entered Displaying Alternate Controlling in either F or C using the F/C key. Just press (Supply or Return) Air Sensor and hold the F/C key (to display the alternate temperature scale).
Page 71: Initiating A Manual Defrost
µP-D Controller Initiating a Manual Defrost 4-19 Initiating a Manual Defrost Initiating a Full Pretrip With the unit On/Off switch ON: To perform a Full Pretrip test, turn the unit On/Off switch ON: Press the DEFROST key. The display flashes “ENTER NOTE: The controller will not perform an auto- DFRST”.
Page 72: Entering A Start Of Trip Marker
µP-D Controller 4-20 Entering a Start of Trip Marker COOL NULL HEAT IN RANGE DEFROST SUPPLY RETURN PWRLMT ALARM Entering a Start of Trip Marker SETPOINT TEMPERATURE DATA DATA To enter a Start of Trip marker, turn the unit On/Off switch ON or operate the controller using battery power (press the SELECT key): 2.
Page 73: Controller Menu Operating Instructions
µP-D Controller Controller Menu Operating Instructions 4-21 Controller Menu Operating Instructions Menu View Functions NOTE: To view the controller’s menu or download NOTE: Information can ONLY be displayed using the data when external power is disconnected from the View menu. Items can NOT be changed. See “MENU unit, connect a 12 Vdc battery to the battery jack on PRGRM”...
Page 74: Grade Submenu
µP-D Controller 4-22 Menu View Functions NOTE: The controller returns to the Standard 4. Press the UP key until “VIEW GRADE” shows in the Display from a View Menu screen after about 10 display. seconds, or when the SELECT key is pressed 5.
Page 75 µP-D Controller Menu View Functions 4-23 When viewing information in the TEMP or PTI scrollback With the unit On/Off switch ON and the controller show- display, the status indicator LEDs on the controller show the ing the Standard Display: unit operating states that were active (ON) when the data or 1.
Page 76 µP-D Controller 4-24 Menu View Functions To enter the TEMP scrollback submenu: To enter the PTI scrollback submenu: 1. Press the SELECT key with “LOG TEMP” in the display. 1. Press the SELECT key with “LOG PTI” in the display. Display will briefly show “SEARC HINGX”.
Page 77: Menu Pretrip Functions
µP-D Controller Menu Pretrip Functions 4-25 • Amps: Controller individually energizes all outputs Menu Pretrip Functions including fan and compressor motors, and solenoid valves. The controller checks current draw to verify cor- Three pretrip test menus are available through the PTRIP rect operation.
Page 78: Performing An Extended, Full Or Single Pretrip Test From The Pretrip Menu
µP-D Controller 4-26 Menu Pretrip Functions test, the Alarm LED FLASHES and the controller • To initiate a Full Pretrip Test: stops all unit operation. Press the ALARM key to Press the SELECT key with “PTRIP FTEST” in the display any fault codes recorded in the controller display.
Page 79: Menu Test Functions
µP-D Controller Menu Test Functions 4-27 heaters, motors or unit during Full Cool, Modulation 50%, Menu Test Functions Modulation 100%, Heat and Defrost. • Refrigeration [REFRG]: Perform system diagnostics and check supply and return air temperatures during each unit WARNING: Activating some tests in the Menu Test operating mode.
Page 80 µP-D Controller 4-28 Menu Test Functions NOTE: When the Test Menu is entered, the UNIT 7. Press the DOWN key to view functions in sub-submenu. STOPS. A technician can then select the control cir- Press the UP key to scroll back through sub-submenu. cuit or component to be checked/tested from the The display shows the test function (e.g.
Page 81: Menu Guard Functions
µP-D Controller Menu Guard Functions 4-29 Navigating Menu Guard Screens Menu Guard Functions With the unit On/Off switch ON and the controller showing the Standard Display: NOTE: An access code is required to enter the 1. Press the SELECT key to enter menu (display shows Guard menu to prevent unauthorized personnel from “MENU <--->”).
Page 82: Setting The Unit Configuration And Customer Configuration Numbers
µP-D Controller 4-30 Menu Guard Functions NOTE: If the correct code is not entered, the dis- NOTE: If the Customer Configuration has play returns to “GUARD <--->”. already been set, the current number (ZZ format) will show instead of “0”. The Unit Configuration Press the DOWN or UP key to scroll through the menu list.
Page 83: Setting The Unit Serial Number
µP-D Controller Menu Guard Functions 4-31 When all characters in the Container Identification Setting the Date and Time Number have been entered, press the ENTER key. The 1. From “USN 11 XXX” (where the scrolling XXX is your display shows “CID LOAD” and then shows the new unit serial number) in the Guard menu, press the DOWN number (left display shows CID11 again as the right dis- key until the display shows “YEAR 1996”.
Page 84: Setting The Compressor And On Time Hourmeters
µP-D Controller 4-32 Menu Guard Functions 5. If the hour is correct, press the DOWN key until the dis- Press the SELECT key to enter the load Compressor play shows “MIN MM” (where “MM” is the minute). Hourmeter display (left display flashes “ONHRM”). Press the SELECT key to enter the load Minute dis- Press the UP or DOWN key to choose the desired play (left display flashes “MIN”).
Page 85: Setting The Sensor Grades
(where “XX” is the number of threshold hours). sensors are ice bath calibrated at the factory and Press the SELECT key to enter the load User Thermo King recommends ice bath calibration when Hourmeter Threshold display (left display flashes replacing the Return Air, Supply Air and Coil “UHMT1”).
Page 86 µP-D Controller 4-34 Menu Guard Functions To calibrate the sensor in an ice bath: To set the sensor grade: • Press the UP or DOWN key to choose “0” as the • Press the UP or DOWN key to choose the grade setting in the right display.
Page 87: Changing The Display Units (C/F)
µP-D Controller Menu Guard Functions 4-35 • When the sensor temperature is within 1.7 C [3 8. Press the DOWN key until “SPR1G XX” shows in the F] above or below 0 C (32 F), the left display display (where “XX” is the sensor grade). (“CCT”) begins to flash.
Page 88: Menu Program Functions
µP-D Controller 4-36 Menu Program Functions USDA Sensors Menu Program Functions Changing the USDA program screen from OFF to ON acti- vates spare sensors 1, 2 and 3 for USDA Cold Treatment NOTE: When the unit is OFF, the following options Temperature Recording.
Page 89: Pulp Sensor (Option)
µP-D Controller Menu Program Functions 4-37 Setting and Calibrating the USDA Sensors NOTE: The sensors should be in the ice bath a total of 15 minutes or more to assure the Insert all USDA sensors in an ice bath (see “Ice Bath sensor temperature has bottomed out.
Page 90: Economy Mode
µP-D Controller 4-38 Menu Program Functions 8. To load the new setting, press the ENTER key. The dis- • Chill Loads (return air temperatures of -9.9 C (14.1 F) and play briefly shows “PULP LOAD”. above): Evaporator fans operate on low speed whenever 9.
Page 91: Dehumidify Mode (Option)
µP-D Controller Menu Program Functions 4-39 Dehumidify Mode (Option) 5. To change the current setting, press the SELECT key. “HUMID” will begin to flash in the left display. The Dehumidify Mode reduces the humidity level in the con- 6. Press the UP or DOWN key to scroll the right display to tainer by condensing more moisture from the container air.
Page 92: Bulb Mode (Option)
µP-D Controller 4-40 Menu Program Functions Setting the Humidify Mode Bulb Mode (Option) Changing the Bulb screen from OFF to ON automatically acti- 1. Press the SELECT key to enter menu (display shows vates the Dehumidify Mode and allows the defrost termination “MENU <--->”.
Page 93: Power Reduction Mode
µP-D Controller Menu Program Functions 4-41 When the Bulb mode is ON, the defrost termination tem- Power Reduction Mode perature screen “BDFTT” appears in the Program menu. Changing the Power Reduction program screen from OFF to To change the defrost termination temperature: ON activates the power reduction control algorithm that With “BULB ON”...
Page 94: Controller Emergency Bypass Procedure
µP-D Controller 4-42 Controller Emergency Bypass Procedure 8. Use the Mode Switch to set unit operation for Evaporator Controller Emergency Bypass Procedure Fan Only or Full Cool operation. In the event the controller fails or the serial communications CAUTION: The unit must be cycled manually to link between the output module and the controller fails, the maintain the desired temperature.
Page 95: Output Module
µP-D Controller Output Module 4-43 High Pressure Cutout (HPCO) and 24 Vac LEDs on the put is energized. The RXD and TXD LEDs alternately flash Emergency Bypass Module turn ON to indicate normal continuously to show the communications connection is good. operation.
Page 96: Replacing The Μp-D Controller
Replacing the µ µ P-D Controller µP-D Controller 4-44 7. Attach the wire harness connectors to the back of the con- Replacing the µ µ P-D Controller troller. NOTE: Be certain that all connectors are fully CAUTION: When replacing a controller, correct unit seated until the connector rings lock.
Page 97: Diagnosis And Repair
µP-D Controller Diagnosis and Repair 4-45 • Ambient sensor must be placed on the bottom plate of the Diagnosis and Repair right forklift pocket. • Compressor discharge temperature sensor must be placed in If the unit appears to be operating incorrectly, view any alarm the sensor pocket on the top of the compressor.
Page 98: Alarm Codes, Descriptions And Corrective Actions 4-46 To
µP-D Controller 4-46 Alarm Codes, Descriptions and Corrective Actions Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action No Fault • None Required Ambient Temperature Sensor Failure • Check the sensor by selecting it using the View (Check Alarm) menu.
Page 99 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-47 Code Description Corrective Action KVQ Valve Thermistor Error • Check the KVQ valve thermistor circuit with an (Check Alarm) ohmmeter. Good thermistor sensor should read 20,000 ohms at 20 C (78 F). •...
Page 100 µP-D Controller 4-48 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action Humidity Sensor Error • Check the sensor by selecting it using the View (Check Alarm) menu. If the display shows [- - - -], the sensor is defective or the circuit is open or shorted.
Page 101 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-49 Code Description Corrective Action High Pressure Cutout • Check for a dirty or restricted condenser coil. (Check Alarm) • Check for correct condenser fan operation using • Indicates the high pressure cutout switch “AMPS CFH”...
Page 102 µP-D Controller 4-50 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action Defrost Terminated by TIme Limit • Check electric heater rod operation using the (Check Alarm) “AMPS HEATR” test in the Electrical Test submenu. • Indicates the controller terminated a defrost •...
Page 103 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-51 Code Description Corrective Action Spare Sensor 5 Failure (Option) • Check the sensor by selecting it using the View (Check Alarm) menu. If the display shows [- - - -], the sensor is defective or the circuit is open or shorted.
Page 104 µP-D Controller 4-52 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action Three Phase Current Imbalance • Check supply power voltage on all three phases. (Shutdown Alarm) Voltage should be present on all three phases and with 90% below or 110% above the rated voltage. •...
Page 105 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-53 Code Description Corrective Action USDA 1 Sensor Failure (Option) • Check the sensor by selecting it using the View (Check Alarm) menu. If USDA1 display shows [- - - -], the sensor is defective or the circuit is open or shorted.
Page 106 µP-D Controller 4-54 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action Pulp Sensor Failure (Option) • Check the sensor by selecting it using the View (Check Alarm) menu. If PULP1 display shows [- - - -], the sensor is defective or the circuit is open or shorted.
Page 107 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-55 Code Description Corrective Action Unit Current Out-of-Range in COOL Mode • Check for low supply power voltage. (Check or Shutdown Alarm) • Check the compressor current draw with a digital • Indicates total unit current draw is not within multimeter.
Page 108 µP-D Controller 4-56 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action Modulation System Failure (Pretrip) • Perform a Full Pretrip Test to check modulation (Check or Shutdown Alarm) valve operation. • Indicates modulation valve current draw is not •...
Page 109 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-57 Code Description Corrective Action Defrost Current Out-of-Range (Pretrip) • Check for low supply power voltage. (Check or Shutdown Alarm) • Check the heater element current draw using the • Indicates total unit current draw is not within “REFRG DFRST”...
Page 110 µP-D Controller 4-58 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action High Speed Evaporator Fan Failure • Check for low supply power voltage. (Pretrip) (Check or Shutdown Alarm) • Check high speed evaporator fan current draw • Indicates evaporator fan current draw is not using “AMPS EFH”...
Page 111 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-59 Code Description Corrective Action Low Speed Evaporator Fan Failure • Check for low supply power voltage. (Pretrip) (Check or Shutdown Alarm) • Check low speed evaporator fan current draw • Indicates evaporator fan current draw is not using “AMPS EFL”...
Page 112 µP-D Controller 4-60 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action Condenser Fan Current Out-of-Range (Pretrip) • Check for low supply power voltage. (Check or Shutdown Alarm) • Check condenser fan current draw using “AMPS • Indicates condenser fan current draw is not CFH”...
Page 113 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-61 Code Description Corrective Action µ µ P-A+ Datalogger Full • Enter a Start of Trip to place a marker in the (Check Alarm) controller’s data logger memory. • Indicates datalogger is full. •...
Page 114 µP-D Controller 4-62 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action Pretrip Preconditioning Failure • Check the container to be sure it is not loaded. (Check Alarm) • Check unit cooling and heating operation. • Indicates a heating or cooling problem; Pretrip Test pre-cooling or pre-heating of the •...
Page 115 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-63 Code Description Corrective Action Hourmeter Alarm • The hourmeter exceeded 99,999. Reset the (Check Alarm) hourmeter to 0. • Indicates a problem with one or more of the controller’s internal hourmeters. User Hourmeter 1 Expired •...
Page 116 µP-D Controller 4-64 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action Compressor Temperature Sensor Failure • Check the sensor by selecting it using the View (Check Alarm) menu. If the display shows [- - - -], the sensor is defective or the circuit is open or shorted.
Page 117 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-65 Code Description Corrective Action Compressor Current Out-of-Range • Check for low supply power voltage. (Check or Shutdown Alarm) • Check the compressor current draw with a digital • Indicates compressor motor has failed to multimeter.
Page 118 µP-D Controller 4-66 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action Condenser Fan Sensor Failure • Check the sensor by selecting it using the View (Check Alarm) menu. If the display shows [- - - -], the sensor is defective or the circuit is open or shorted.
Page 119: Electrical Maintenance
Electrical Maintenance Unit Wiring High Pressure Cutout Switch Inspect unit wiring, wire harnesses, and the controller during The high pressure cutout is located in the liquid line near the pre-trip inspection and every 1,000 operating hours to protect compressor. If the discharge pressure rises above 3243 +/- 48 against unit malfunctions due to open or short circuits.
Page 120: Condenser Fan And Evaporator Fan Rotation
Condenser Fan and Evaporator Fan Rotation Electrical Maintenance 2. If the high pressure cutout switch fails to reset, clear the Evaporator Fans HPCO alarm (code 10). Press the ALARM key on the Visually inspect the evaporator fan blades for proper rotation. controller.
Page 121: Integrated Remote Monitor Unit (Irmu) (Option)
Electrical Maintenance Integrated Remote Monitor Unit System Integrated Remote Monitor Unit (IRMU) Acronym Description (Option) Communication Control Unit DSEL Deselect An integrated remote monitoring unit box is mounted above IRMU Integrated Remote Monitoring Unit the compressor compartment. The remote monitor unit con- Master Monitor Unit sists of a printed circuit board that gathers information from Remote Monitoring Unit...
Page 122 Integrated Remote Monitor Unit Electrical Maintenance easy to locate because no other devices are connected between Problem 1: MMU Does Not Communicate with the the MMU and CCU. The MMU attempts to communicate with Network the CCU every 10 seconds until it receives a response. •...
Page 123 NET LIST when they are plugged in or do not respond to in that segment of the NET. an operator request message (STATUS, PRETRIP SET- • If OK, consult Thermo King for additional assis- POINT, etc.). tance. • System Operation: The MMU initiates a mapping request •...
Page 124 Integrated Remote Monitor Unit Electrical Maintenance 2. Check for the RXD signal at the IRMU; see Step 2 call- Remote Monitor Unit Replacement out on diagram. 1. Disconnect 46O/380V power supply to the unit. If signal is present, check the connections; repair or 2.
Page 125: Refrigeration System Diagnosis And Service
Refrigeration System Diagnosis and Service NOTE: The following procedures involve servicing System Diagnosis Using the Full Pretrip Test the refrigeration system. Some of these service pro- To verify system performance or diagnosis a unit cooling or cedures are regulated by Federal, and in some heating problem, perform a Full Pretrip Test.
Page 126 Diagnosis Procedures Refrigeration Maintenance and Service Operations After the last alarm code (ALM 1) has been viewed and Specific Refrigeration System Problems recorded, the left display flashes “ENTER” (the code -52 Modulation System Failure (Check or Shutdown number of the last alarm still appears in the right display). Alarm) -63 Bypass (Warm Gas) Valve Circuit Failure (Check NOTE: Clear the Alarm codes ONLY after the...
Page 127: Hermetic Refrigeration System Visual Inspection And Diagnosis Chart
Refrigeration System Diagnosis and Service Visual Inspection and Diagnosis Chart Hermetic Refrigeration System Visual Inspection and Diagnosis Chart Potential Problem Alarm Codes Inspect/Check for Low Refrigerant Charge -55, -56, -64 and - Defective container insulation (unit not cooling) - Poor fitting container doors - Partial obstruction in high side - Partial obstruction in low side or filter drier - Iced or plugged evaporator coil...
Page 128: Hermetic Refrigeration System Service Procedures
Use only refrigerant recovery equipment approved for and 364 (with flux, P/N 203-365). dedicated to R-404A recovery. NOTE: Thermo King recommends that service proce- Leak Detection dures use the use the same solder on connections Leaks can be detected with the use of soap bubbles and with that was used in the manufacturing process.
Page 129: Refrigerant Charge
Refrigeration System Diagnosis and Service Refrigerant Charge Refrigerant Charge Compressor Oil Charge CSR Hermetic units do not have service valves, fittings or NOTE: CSR Hermetic units do not have service sight glasses installed in the refrigeration system. Therefore, valves, fittings or sight glasses installed in the refrig- the compressor oil level can not be visually inspected.
Page 130: Installing And Removing Piercing Type Service Valves And A Gauge Manifold Set
Piercing Type Service Valves Refrigeration System Diagnosis and Service 3. Attach the low side hose (compound gauge) to the pierc- Installing and Removing Piercing Type ing valve port on the suction process tube finger tight. Service Valves and a Gauge Manifold Set 4.
Page 131: Gauge Manifold Valve Positions
Refrigeration System Diagnosis and Service Gauge Manifold Valve Positions Gauge Manifold Valve Positions The gauges indicate low and high side pressures. Operate one or both hand valves to perform the different ser- vice operations shown below. Gauge Manifold Closed to Center Port 1.
Page 132: Refrigerant Leak Test Procedure
Refrigerant Leak Test Procedure Refrigeration System Diagnosis and Service Purging a Gauge Manifold and Hoses Rotate the discharge hose fitting hand wheel clock- 1. Inspect gauge manifold for proper hose and fitting con- wise to open (depress) the discharge line port valve to nections.
Page 133: Using Pressurized Nitrogen
Refrigeration System Diagnosis and Service Using Pressurized Nitrogen Attach gauge manifold set (refer to “Gauge Manifold Set 8. Connect the charging hose to a source of nitrogen. Adjust Attachment and Purging” for proper procedures). the pressure regulator to 1380 kPa, 13.80 bar, 200 psig. Attach refrigerant bottle charging hose to center of gauge See “Using Pressurized Nitrogen”...
Page 134: Refrigerant Recovery From Hermetic Refrigeration Systems
Dehydration, pressure testing, purging and soldering can be accomplished with the use of dry nitrogen (N 2 ). The prop- When removing any refrigerant from a Thermo King refrigera- er equipment and application of equipment is of greatest tion system, use a recovery process that prevents or absolutely importance.
Page 135: Evacuation And Cleanup Of The Refrigeration System
5 minutes, the operator should suspect the condition of the oil or the pump. Thermo King recommends that the pump oil be changed first to see if the rate of reaching a deep vacuum is improved.
Page 136 6-12 Evacuation and Cleanup of System Refrigeration System Diagnosis and Service Evacuation Station and Unit Hook-up 1. Special, self-sealing quick disconnect couplers are required for R-404A units. 2. Gas Ballast Valve 3. Iso Valve 4. Two-stage Vacuum Pump 5. To 220/190 VAC Power 6.
Page 137 2000 microns or less. The final Evacuate the system and close valve V1. With valves V3 and equilibrium pressure is determined with the Thermo King V4 open, the pump is isolated and the system is held under a Evacuation Station using the following procedure (called vacuum.
Page 138 6-14 Evacuation and Cleanup of System Refrigeration System Diagnosis and Service Factors Affecting the Speed of System Evacuation Heat Saves Time It is almost impossible to state the exact amount of time A useful and practical time saver is the application of heat to required to evacuate any system.
Page 139: Charging The System With Refrigerant
(see “Installing and Removing Piercing Type Service NOTE: Thermo King strongly recommends that Valves and a Gauge Manifold Set” in this chapter). dry nitrogen be used to purge the system during Leak check the process tubes with an electronic leak any solder operations (see “Using Pressurized...
Page 140: Compressor Discharge Temperature Sensor Replacement
6-16 Compressor Temperature Sensor Replacement Refrigeration System Diagnosis and Service 5. Pressurize the refrigeration system and check for leaks 3. Remove sensor wires from main harness and control box. (see “Refrigerant Leak Test Procedure” in this chapter). 4. Use a razor knife to cut the black RTV sealant between 6.
Page 141: Modulation Valve Repair Or Replacement
Refrigeration System Diagnosis and Service Modulation Valve Repair or Replacement 6-17 Coil Checkout Procedure Modulation Valve Repair or Replacement NOTE: In most cases, only the coil requires replace- The modulation valve is used to control the flow of refrigerant ment. to the compressor when the unit is operating in the Modulation mode.
Page 142 6-18 Modulation Valve Repair or Replacement Refrigeration System Diagnosis and Service 6. Place a 1.5 inch wrench on the enclosure tube hex fitting Modulation Valve Replacement and loosen enclosure tube one-half turn. If the valve body is damaged, replace the entire modulation 7.
Page 143: Condenser Coil Replacement
3. Slide the coil into the unit and install the bolts in the mounting brackets. 4. Solder the inlet line and liquid line connections. NOTE: Thermo King strongly recommends that dry nitrogen be used to purge the system during any solder operations (see “Using Pressurized Nitrogen”...
Page 144: Filter Drier/In-Line Filter Replacement
Reinstall clamping brackets, nut and bolts. Tighten the bolts. valve. 6. Pressurize the refrigeration system and check for leaks NOTE: Thermo King strongly recommends that (see “Refrigerant Leak Test Procedure” in this chapter). dry nitrogen be used to purge the system during 7.
Page 145: Heat Exchanger Replacement
Solder the suction inlet and outlet line connections. NOTE: Thermo King strongly recommends that NOTE: Thermo King strongly recommends that dry nitrogen be used to purge the system during dry nitrogen be used to purge the system during any solder operations (see “Using Pressurized...
Page 146: High Pressure Cutout Switch Replacement
6-22 High Pressure Switch Replacement Refrigeration System Diagnosis and Service High Pressure Cutout Switch Replacement Warm Gas Bypass Solenoid Valve, Liquid Injection Valve or Dehumidify Valve (Option) Replacement Removal 1. Recover the refrigerant charge from the unit (see “Refrigerant Recovery” in this chapter). NOTE: In most cases, only the coil requires replace- 2.
Page 147: Structural/Accessory Maintenance
Structural/Accessory Maintenance Mounting Bolts Condenser Coil Check and tighten all unit, compressor, and fan motor mount- Clean the condenser coil by blowing low pressure compressed ing bolts during pretrip inspections and every 1,000 operating air or a medium pressure warm water spray from the inside of hours.
Page 148: Defrost Drains
Defrost Drains Structural/Accessory Maintenance Defrost Drains Clean the defrost drains every 1,000 operating hours to be sure the lines remain open. Evaporator Fan Location Place fan blade on motor shaft with hub located on the outside of the blade for proper airflow direction. When mounting the fan blade and hub assembly on the fanshaft, center the assem- bly in the orifice.
Page 149: Partlow (Model Sr) Recording Thermometer (Option)
Structural/Accessory Maintenance Partlow (Model SR) Recording Thermometer cloth to remove material transferred from the back of the chart Partlow (Model SR) Recording Thermometer to the platen by the pressure of the stylus. (Option) Recording Chart Replacement The 31-day Partlow Recorder is mechanically driven by a 1.
Page 150: Element Replacement
Saginomiya (Model SKM) Recording Thermometer Structural/Accessory Maintenance 7. If the recorder needs recalibration: Saginomiya (Model SKM) Recording Loosen the Allen setscrew (S) using a small slotted Thermometer (Option) screwdriver. Adjust shaft (J) with a 5 mm (3/16 in.) open end The 31-day Saginomiya Recorder is electric motor driven by a wrench until the recording stylus pointer is aligned to dry cell type battery with a 1 year life expectancy.
Page 151: Recording Chart Replacement
Structural/Accessory Maintenance Saginomiya (Model SKM) Recording Thermometer Check to see that the quartz motor is running. Look Recording Chart Replacement through the inspection window and make sure the internal 1. To change the charts, raise the stylus away from the chart flywheel on the quartz motor is revolving.
Page 152: Power Element Assembly Replacement
Saginomiya (Model SKM) Recording Thermometer Structural/Accessory Maintenance Then rotate the setting screw counterclockwise to 6. Connect the motor wires to the terminal board. Make sure lower the recording pen reading until the pen reading the red positive (+) and black negative (-) wire are correct- agrees with the “RET”...
Page 153: Humidity System (Option)
Structural/Accessory Maintenance Humidity System If the Humidify Mode is set to ON, the controller display Humidity System (Option) will show “HUM” in the left display and the container humidi- ty level (e.g. “74.5”) in the right display for 1 second every 10 The Humidify Mode increases the humidity level in the con- seconds.
Page 154: Mechanical Diagnosis
Mechanical Diagnosis Mechanical Diagnosis Condition Possible Cause Remedy Compressor does not Controller ON; unit start Wait up to 2 minutes for compressor operate — no amperage sequence still timing start-up draw No power to unit (condenser and Check and repair: power source, evaporator fans do not operate) power plug, CB1 main circuit breaker, motor contactor, motor terminals, motor...
Page 155 Mechanical Diagnosis Condition Possible Cause Remedy Compressor does not Defective compressor Replace compressor operate — no amperage draw (continued) Controller shut unit down on Let compressor cool and controller will Compressor Over Temperature reset automatically. Check liquid injection (alarm code 82) valve and compressor temperature sensor Compressor motor internal thermal If compressor contactor is energized, wait...
Page 156 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 µP-D Microprocessor Unit short cycles...
Page 157 Mechanical Diagnosis Condition Possible Cause Remedy Condenser fan motor does Unit in Null, Heat or Defrost Check indicator lights. If unit is in not operate Null, Heat or Defrost, unit operation is normal (no remedy required) Unit in Cool or Modulation Check indicator lights and condenser pres- sure in View menu of µP-D controller.
Page 158 Mechanical Diagnosis Condition Possible Cause Remedy Evaporator fan motor(s) Unit on defrost Check operating mode indicator lights does not operate Unit in Economy Mode (Frozen Load; Check setpoint, indicator lights and Program menu of µP-D controller to verify Null mode ONLY) that Economy Mode is set to ON Loose line connection Tighten connections...
Page 159: Electrical, Refrigeration And Μ Μ P-D Menu Flow Diagrams
9 Electrical, Refrigeration and µ µ P-D Menu Flow Diagrams 460/380 Vac Power Supply to Unit Typical model shown with three evaporator fans. CSR-20 & CSR-40, September 1999...
Page 160: 230/190 Vac Power Supply To Unit
µP-D Menu Flow Diagrams Schematic Circuit Tracings Electrical, Refrigeration and 230/190 Vac Power Supply to Unit Typical model shown with three evaporator fans. CSR-20 & CSR-40, September 1999...
Page 161: External 12 Vdc Battery Power Supply
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings External 12 Vdc Battery Power Supply 1, 2 Typical model shown with three evaporator fans. Requires on-board 12 Vdc battery or an external 12 Vdc battery connected to battery jack on Power Module Board inside control box.
Page 162: Microprocessor Awakened From Sleep Mode
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings Microprocessor Awakened from Sleep Mode (when external power is disconnected from unit) When external power is disconnected from unit, microprocessor operation requires an on-board 12 Vdc battery, or an external 12 Vdc battery connected to the battery jack on Power Module Board inside control box. Then press SELECT key or connect communications cable to Data Port on bottom of control box.
Page 163: Vdc Control Circuit, Sensor Circuits, Modulation Valve Circuit And Water Pressure Circuit (Option)
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings 12.5 Vdc Control Circuit, Sensor Circuits, Modulation Valve Circuit and Water Pressure Circuit (Option) Typical model shown with three evaporator fans. CSR-20 & CSR-40, September 1999...
Page 164: Vac Control Circuit
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings 24 Vac Control Circuit Typical model shown with three evaporator fans. CSR-20 & CSR-40, September 1999...
Page 165: Setpoint Enable Battery And Battery Charger Circuit (Option)
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings Setpoint Enable Battery and Battery Charger Circuit (Option) Typical model shown with three evaporator fans. CSR-20 & CSR-40, September 1999...
Page 166: Remote Monitor Receptacle (4-Pin) For Bridge Lights Circuit (Option)
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings Remote Monitor Receptacle (4-pin) for Bridge Lights Circuit (Option) Typical model shown with three evaporator fans. CSR-20 & CSR-40, September 1999...
Page 167: Transfresh Atmosphere Control System Circuit (Option)
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings TRANSFRESH Atmosphere Control System Circuit (Option) ® Typical model shown with three evaporator fans. CSR-20 & CSR-40, September 1999...
Page 168: Integrated Remote Monitor System Circuit (Option)
Electrical, Refrigeration and µP-D Menu Flow Diagrams 9-10 Schematic Circuit Tracings Integrated Remote Monitor System Circuit (Option) Typical model shown with three evaporator fans. CSR-20 & CSR-40, September 1999...
Page 169 Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings 9-11 Dehumidify System, Humidity System, Water Pressure Switch, USDA Temperature Sensor, Pulp Sensor and Chart Recorder Circuits (Options) Typical model shown with three evaporator fans. CSR-20 & CSR-40, September 1999...
Page 170: Cool Mode - Chill Load
Electrical, Refrigeration and µP-D Menu Flow Diagrams 9-12 Schematic Circuit Tracings Cool Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Water-Cooled Condenser Operation ; Power Monitor Limiting Unit Power Consumption; Economy Mode OFF Typical model shown with three evaporator fans. When the water pressure switch opens on units with an optional water-cooled condenser-receiver tank, the con- denser fan does not operate.
Page 171 Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings 9-13 Cool Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan ON ; Power Monitor Limiting Unit Power Consumption; Economy Mode OFF Typical model shown with three evaporator fans. A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above 50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
Page 172 Electrical, Refrigeration and µP-D Menu Flow Diagrams 9-14 Schematic Circuit Tracings Cool Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan ON ; Economy Mode OFF Typical model shown with three evaporator fans. A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above 50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
Page 173: Cool Mode - Chill Load
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings 9-15 Cool Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan ON ; Economy Mode OFF; Humidify Mode (Option) ON with container humidity above humidity setpoint Typical model shown with three evaporator fans.
Page 174 Electrical, Refrigeration and µP-D Menu Flow Diagrams 9-16 Schematic Circuit Tracings Cool Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan ON ; Economy Mode OFF; Humidify Mode (Option) ON with container humidity more than 2% below the humidity setpoint Typical model shown with three evaporator fans.
Page 175: Modulation Mode - Chill Load
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings 9-17 Modulation Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan ON ; Economy Mode OFF; Temperature Out-of-range Typical model shown with three evaporator fans. A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above 50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
Page 176: Modulation Mode - Chill Load
Electrical, Refrigeration and µP-D Menu Flow Diagrams 9-18 Schematic Circuit Tracings Modulation Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan ON ; Economy Mode OFF; Temperature In-range; Dehumidify ON with Humidity 1-5% Above Humidity Setpoint Typical model shown with three evaporator fans.
Page 177 Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings 9-19 Modulation Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan ON ; Economy Mode OFF; Temperature In-range; Dehumidify ON with Humidity 5% or More Above Humidity Setpoint Typical model shown with three evaporator fans.
Page 178: Temperature In-Range
Electrical, Refrigeration and µP-D Menu Flow Diagrams 9-20 Schematic Circuit Tracings Modulation Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan OFF ; Economy Mode ; Temperature In-range Typical model shown with three evaporator fans. A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above 50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
Page 179 Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings 9-21 Modulation Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan OFF ; Economy Mode ; Temperature In-range, Warm Gas Bypass Valve ON Typical model shown with three evaporator fans. A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above 50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
Page 180: Null Mode - Chill Load (Setpoint At -9.9 C [14.1 F] Or Above) Condenser Fan On; Economy Mode Off
Electrical, Refrigeration and µP-D Menu Flow Diagrams 9-22 Schematic Circuit Tracings Null Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above), Condenser Fan ON ; Economy Mode OFF Typical model shown with three evaporator fans. The controller stops the compressor. If the condenser fan was ON, it will operate for 30 seconds and then stop. CSR-20 &...
Page 181: Heat Mode - Chill Load (Setpoint At -9.9 C [14.1 F] Or Above); Economy Mode Off; Temperature In-Range
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings 9-23 Heat Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Economy Mode OFF; Temperature In-range 1, 2 Typical model shown with three evaporator fans. Electric heaters pulse ON and OFF during the Heat mode. The amount of ON time increases from 0% at a Calculated Temperature Differential of 0.6 C (1.0 F) below setpoint to 100% at a Calculated Temperature Differential of 3.1 C (5.5 F) below setpoint.
Page 182: Cool Mode - Frozen Load
Electrical, Refrigeration and µP-D Menu Flow Diagrams 9-24 Schematic Circuit Tracings Cool Mode — Frozen Load (Setpoint at -10.0 C [14.0 F] or Below); Condenser Fan ON ; Container Return Air Temperature Above -10.0 C (14.0 F); Power Monitor Limiting Unit Power Consumption; Economy Mode OFF Typical model shown with three evaporator fans.
Page 183: Cool Mode - Frozen Load
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings 9-25 Cool Mode — Frozen Load (Setpoint at -10.0 C [14.0 F] or Below); Condenser Fan ON ; Container Return Air Temperature Below -10.0 C (14.0 F); Economy Mode OFF; Temperature In-Range Typical model shown with three evaporator fans.
Page 184: Null Mode - Frozen Load (Setpoint At -10.0 C [14.0 F] Or Below) Condenser Fan Off; Economy Mode Off
Electrical, Refrigeration and µP-D Menu Flow Diagrams 9-26 Schematic Circuit Tracings Null Mode — Frozen Load (Setpoint at -10.0 C [14.0 F] or Below); Condenser Fan OFF ; Economy Mode OFF Typical model shown with three evaporator fans. Controller stops the compressor. If the condenser fan was ON, it will operate for 30 seconds and then stop. CSR-20 &...
Page 185: Null Mode - Frozen Load (Setpoint At -10.0 C [14.0 F] Or Below) Condenser Fan Off; Economy Mode On
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings 9-27 Null Mode — Frozen Load (Setpoint at -10.0 C [14.0 F] or Below); Condenser Fan OFF ; Economy Mode ON Typical model shown with three evaporator fans. Controller stops the compressor. If the condenser fan was ON, it will operate for 30 seconds and then stop. Evaporator fans stop during Null mode when Economy Mode is set to ON in the Program menu of the µP-D con- troller.
Page 186: Defrost
Electrical, Refrigeration and µP-D Menu Flow Diagrams 9-28 Defrost Typical model shown with three evaporator fans. CSR-20 & CSR-40, September 1999...
Page 187: Csr-40 Wiring Schematic For All Models With Three Evaporator Fans
Electrical, Refrigeration and µP-D Menu Flow Diagrams CSR-20 and CSR-40 Wiring Schematic for All Models with Three Evaporator Fans 9-29 CSR-20 & CSR-40, September 1999...
Page 188 Electrical, Refrigeration and µP-D Menu Flow Diagrams CSR-20 and CSR-40 Wiring Diagram for All Models with Three Evaporator Fans — Page 1 of 3 9-30 CSR-20 & CSR-40, September 1999...
Page 189 Electrical, Refrigeration and µP-D Menu Flow Diagrams CSR-20 and CSR-40 Wiring Diagram for All Models with Three Evaporator Fans — Page 2 of 3 9-31 CSR-20 & CSR-40, September 1999...
Page 190 Electrical, Refrigeration and µP-D Menu Flow Diagrams CSR-20 and CSR-40 Wiring Diagram for All Models with Three Evaporator Fans — Page 3 of 3 9-32 CSR-20 & CSR-40, September 1999...
Page 191: Csr-40 Wiring Schematic For All Models With Two Evaporator Fans
Electrical, Refrigeration and µP-D Menu Flow Diagrams CSR-20 and CSR-40 Wiring Schematic for All Models with Two Evaporator Fans 9-33 CSR-20 & CSR-40, September 1999...
Page 192 Electrical, Refrigeration and µP-D Menu Flow Diagrams CSR-20 and CSR-40 Wiring Diagram for All Models with Two Evaporator Fans — Page 1 of 3 9-34 CSR-20 & CSR-40, September 1999...
Page 193 Electrical, Refrigeration and µP-D Menu Flow Diagrams CSR-20 and CSR-40 Wiring Diagram for All Models with Two Evaporator Fans — Page 2 of 3 9-35 CSR-20 & CSR-40, September 1999...
Page 194 Electrical, Refrigeration and µP-D Menu Flow Diagrams CSR-20 and CSR-40 Wiring Diagram for All Models with Two Evaporator Fans — Page 3 of 3 9-36 CSR-20 & CSR-40, September 1999...
Page 195: Refrigeration System Components
Electrical, Refrigeration and µP-D Menu Flow Diagrams Refrigeration Schematic: Components 9-37 CSR-20 & CSR-40 Refrigeration System Components Scroll Compressor Compressor Discharge Temperature Sensor (CDTS) High Pressure Cutout Switch (HPCO) Discharge Line Process Tube Condenser Coil (Circular) Receiver Tank Warm Gas Bypass Valve High Pressure Relief Valve Filter Drier/In-line Filter 10.
Page 196 Electrical, Refrigeration and µP-D Menu Flow Diagrams Refrigeration Schematic: Full Cool 9-38 Flow and Pressure Diagram CSR-20 & CSR-40 Full Cool Scroll Compressor Compressor operation has a delay on initial start-up when the unit shifts to a cooling mode requiring the compressor to start-up. Compressor Discharge (Head) Temperature Sensor (CHS1) Controller cycles condenser fan ON typically when the compressor discharge temperature is above 50 C (122 F) and increasing.
Page 197 Electrical, Refrigeration and µP-D Menu Flow Diagrams Refrigeration Schematic: Modulation Cool 9-39 Flow and Pressure Diagram CSR-20 & CSR-40 Modulation Cool Warm Gas Bypass Valve Is a normally CLOSED solenoid. It OPENS when energized to reduce cooling capacity when the tem- perature is close to setpoint.
Page 198 Electrical, Refrigeration and µP-D Menu Flow Diagrams Refrigeration Schematic: Dehumidification 9-40 Flow and Pressure Diagram CSR-20 & CSR-40 Dehumidification 19. Electric Heaters If the container humidity is 5% or more above the humidity setpoint, and the temperature is in-range, the controller will pulse the electric heaters ON and OFF in addition to energizing (closing) the dehumidify solenoid valve.
Page 199 Active Option and Pause Mode Displays Standard Display NOTE: The screens that display on the con- — ECON troller are determined by the Unit Configura- COOL NULL HEAT IN RANGE DEFROST SUPPLY RETURN PWRLMT ALARM View Menu — ECONT XXXX 1 SETPOINT TEMPERATURE °...

This manual is also suitable for:

Csr-40 series Csr-40-116 Csr-40-122 Csr-40-123 Csr-40sl-126 Csr-40sl-130 ... Show all

Thermo King CSR-20 Series Maintenance Manual

Introduction

Safety Precautions

Service Guide

Specifications

Unit Description

II

Operating Instructions

Μ Μ P-D Controller

Electrical Maintenance

Refrigeration System Diagnosis and Service

Structural/Accessory Maintenance

Mechanical Diagnosis

Electrical, Refrigeration and Μ Μ P-D Menu Flow Diagrams

Quick Links

Need help?

Questions and answers

Related Manuals for Thermo King CSR-20 Series

Summary of Contents for Thermo King CSR-20 Series

This manual is also suitable for:

Table of Contents