Thermo King CRR-20 Maintenance Manual
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Thermo King CRR-20 Maintenance Manual

Thermo King CRR-20 Maintenance Manual

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Maintenance Manual
CRR-20 & CRR-40
with µ µ P-D
TK50094-4-MM (Rev. 5, 9/99)
Copyright ©1999, Thermo King Corporation, Minneapolis, MN, U.S.A.
Printed in U.S.A.

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  • Page 1 Maintenance Manual CRR-20 & CRR-40 with µ µ P-D TK50094-4-MM (Rev. 5, 9/99) Copyright ©1999, Thermo King Corporation, 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 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

    Dual Voltage Option 2-13 Fans – Water Cooled Condensing Option Auxiliary Battery and Battery Charger Option 2-14 with 30 C (86 F) Water Temperature TRANSFRESH System Option 2-15 Humidify System Option 2-16 Typical Unit Back View 2-17 CRR-20 & CRR-40, September 1999...
  • Page 6 4-45 Feature Operation 4-13 Continuous Temperature Control Operation 4-13 Alarm Codes, Descriptions and Defrost 4-16 Corrective Actions 4-46 to 4-64 Reviewing Software Version and Configuration 4-17 Displaying Alternate Fahrenheit (F) or Celsius (C) Temperatures 4-17 CRR-20 & CRR-40, September 1999...
  • Page 7 Integrated Remote Monitor System Circuit (Option) 9-10 Defrost Drains Evaporator Fan Location Dehumidify System, Humidity System, Condenser Fan Location Water Pressure Switch, USDA Fresh Air Exchange System Temperature Sensor, Pulp Sensor and Chart Recorder Circuits (Options) 9-11 CRR-20 & CRR-40, September 1999...
  • Page 8 -9.9 C [14.1 F] or Above); Condenser Fan OFF; Economy Mode ON; Temperature In-range 9-20 Null Mode – Chill Load (Setpoint at -9.9 C [14.1 F] or Above) During Compressor Pump Down (Condenser Fan ON); Economy Mode OFF 9-21 CRR-20 & CRR-40, September 1999...

  • Page 9: Introduction

    CRR-40-136 The information in this manual is provided to assist owners, CRR-40-139 operators and service people in the proper upkeep and mainte- CRR-40-141 nance of Thermo King units. The maintenance information in CRR-40-147 this manual covers unit models: CRR-40-148 CRR-40-150...

  • Page 10: Crr Model Features Vi To

    – – – Humidity System – – – – – – – – – Power Line Communications , Standard (Thermo King Modem) – – – – – – – – – Power Line Communications , RTE Modem – – –...
  • Page 11 – – – Humidity System – – – – – – – – – Power Line Communications , Standard (Thermo King Modem) – – – – – – – – – Power Line Communications , RTE Modem – – –...
  • Page 12 – – – – Humidity System – – – – – – – – – Power Line Communications, Standard (Thermo King Modem) – – – – – – – – – Power Line Communications, RTE Modem – – – –...
  • Page 13 – – – – Humidity System – – – – – – – – – Power Line Communications, Standard (Thermo King Modem) – – – – – – – – – Power Line Communications, RTE Modem – – – –...
  • Page 14 Data Retrieval Receptacle, 15-Pin RS232 Dehumidify Control – High Output Evaporator Airflow – Humidity System – Power Line Communications, Standard (Thermo King Modem) – Power Line Communications, RTE Modem – Power Line Communications, Sabroe Control Modem – Pressure Gauge, Discharge –...

  • Page 15: Safety Precautions

    (for example, a trailer, container or in the hold of a ship). Refrigerant tends to displace air and can cause oxygen depletion, resulting in suffocation and possible death. 11. Use caution and follow the manufacturer’s suggested practices when using ladders or scaffolds. CRR-20 & CRR-40, September 1999...

  • Page 16: Refrigerant Oil

    3. Use tools with insulated handles that are in good condi- out electrical circuits and cause severe burns to the wearer. tion. Never hold metal tools in your hand if exposed, energized conductors are within reach. CRR-20 & CRR-40, September 1999...

  • Page 17: Microprocessor Controller

    7. After servicing the circuit board and any other circuits, the wiring should be checked for possible errors before restor- ing power. CRR-20 & CRR-40, September 1999...

  • Page 18: 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 19: Service Guide

    Clean entire unit including condenser and evaporator coils and defrost drains. Humidify System (Option) • Check water level in water tank. • • • Check humidify system operation. • • Clean water supply filter on water tank. CRR-20 & CRR-40, September 1999...

  • Page 20: Specifications

    -17.8 C (0 F) 4,300 3,700 14,675 3,580 3,080 12,225 -25.0 C (-13 F) 3,000 2,580 10,240 2,500 2,150 8,530 *System net cooling capacity with a 37.8 C (100 F) ambient air temperature and R-134a. CRR-20 & CRR-40, September 1999...

  • Page 21: Models With Three Evaporator Fans - Water Cooled Condensing Option With 37.8 C (100 F) Water Temperature

    Heating Capacity Watts Kcal/hr BTU/hr Watts Kcal/hr BTU/hr CRR-20SL* 5,560 4,780 18,975 4,110 3,535 14,025 CRR-40* 5,880 5,060 20,070 4,900 4,215 16,720 *System net heating capacity for all models includes electric resistance rods and fan heat. CRR-20 & CRR-40, September 1999...

  • Page 22: Evaporator Airflow

    1,530 20 mm (0.8 in.) 2,900 1,710 — — 1,800 1,060 — — 30 mm (1.2 in.) 2,200 1,300 — — 1,100 — — 40 mm (1.6 in.) 1,400 — — — — — — CRR-20 & CRR-40, September 1999...

  • Page 23: Refrigeration System

    **DO NOT use or add standard synthetic or mineral oils to the refrigeration system. If Ester based oil becomes contaminated with moisture or with standard oils, dispose of properly — DO NOT USE! ***Included with Water-Cooled Condenser-Receiver Tank option. CRR-20 & CRR-40, September 1999...

  • Page 24: Normal R-134A System Operating Pressures

    During the Modulation Cool mode, the suction pressure will vary between 140 and -35 kPa, 1.40 and -0.35 bar, 20 psig and 10” Hg vacuum depending upon the percent (%) modulation. **Discharge pressure is determined by condenser fan cycling. CRR-20 & CRR-40, September 1999...

  • Page 25: Thermoguard

    *Timed defrost intervals reset to initial value after a manual defrost, after the unit has been OFF for 48 hours and after a setpoint change from Chill to Frozen mode or Frozen to Chill mode. CRR-20 & CRR-40, September 1999...
  • Page 26 *If the evaporator coil sensor fails, the controller terminates defrost when the return air (top) sensor rises to 18 C (64.4 F). **If both the evaporator coil and return air (top) sensors fail, the interval timer terminates defrost 60 minutes after initiation. ***Unit must be equipped with dehumidify system. ****Sensor must be installed and calibrated. CRR-20 & CRR-40, October 1999...

  • Page 27: Electrical System

    5 amps nominal (total) across each phase at the heater contactor Control Circuit Voltage 24 Vac Auxiliary Battery (Option) 12 Vdc, 7 or 12 amp hour *Use the motor color to identify the motor used in units built between 3/1/99 and 7/31/99. CRR-20 & CRR-40, September 1999...

  • Page 28: Dehumidify And Humidify Systems (Options)

    45 Kg (99 lb) Power Line Communications Option 3.6 Kg (8 lb) Recorder (Partlow or Saginomiya) Option 5.9 Kg (13 lb) TRANSFRESH ® Option 13 Kg (28 lb) Water-cooled Condenser-Receiver Option 13.6 Kg (30 lb) CRR-20 & CRR-40, September 1999...
  • Page 29 CRR-20SL: 335.0 mm (13.18 in.) from back of flange CRR-40SL: 378.0 mm (14.88 in.) from back of flange CRR-40: 420.0 mm (16.54 in.) from back of flange I = Gasket Depth 72 mm (2.83 in.) from back of flange CRR-20 & CRR-40, October 1999...

  • Page 30: Compressor Torque Chart

    56.5 Pipe Plug: 6.35 mm (0.25 in.) 33.9 3.175 mm (0.125 in.) 22.6 Oil Sight Glass: Grade 5 Grade 8 Terminal Plate 33.9 Nut on Top of Terminal Plate Nut on Top of Jumper Bar CRR-20 & CRR-40, September 1999...

  • Page 31: Metric Hardware Torque Charts

    393-474 (290-350) 678- 813 (500-600) HH – CL 12.9 177-216 (130-160) 285-352 (210-260) 448-542 (330-400) 881-1016 (650-750) HH – SS (2) 115-135 (85-100) 177-216 (130-160) 271-339 (200-250) 475-610 (350-450) *HH = Hex Head, CL = Class. CRR-20 & CRR-40, September 1999...

  • Page 32: Unit Description

    A µP-D output module is used by the controller to ener- and a refrigerant injection system. gize and de-energize various contactors and solenoids. An CRR-20 & CRR-40, September 1999...
  • Page 33 The control • Thermo King ISO narrow band power line remote monitor- range setpoint is adjustable between 50% and 100%. ing modem is installed in a self-enclosed box bolted above the compressor compartment.

  • Page 34: Operating Modes

    When the unit is started, two backlit LED displays on the microprocessor illuminate. A sequence start of the required loads occurs during initial start-up of the microprocessor and when a control mode shift requires the compressor to start. CRR-20 & CRR-40, September 1999...
  • Page 35 45 minutes. The unit remains in Null until the return air temperature increases to ECMAX temperature at the expiration of a 45 minute Null state time sequence. The default ECMAX setting is 1.0 C (1.8 F) above setpoint. CRR-20 & CRR-40, September 1999...

  • Page 36: Unit Illustrations

    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 Supply Air Sensor Probe Holder Power Cord Storage Compartment Control Box USDA Receptacle Panel (Access from Inside Container) 10. Fresh Air Exchange Vent CRR-20 & CRR-40, September 1999...

  • Page 37: Unit Options Front View

    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 (Sabroe Control modem inside Control Box) Auxiliary Battery and Batter Charger Option 10. TRANSFRESH Option, Complete CRR-20 & CRR-40, September 1999...

  • Page 38: Evaporator Section For Models With Three Evaporator Fans - Front View

    Evaporator Fan Blade (see “Physical Specifications” on page 1-9 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 2-16 CRR-20 & CRR-40, September 1999...

  • Page 39: 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 1-9 for description) Evaporator Fan Motor Humidity System Compressor (Option), see page 2-16 CRR-20 & CRR-40, September 1999...

  • Page 40: Standard Refrigeration System

    10. Filter Drier (Units before 3/9/99) 11. One-piece Filter Drier/In-line Filter (Units after 3/9/99 and Models with Two Evaporator Fans Only) 12. Condenser Fan Pressure Switch 13. Condenser Check Valve 14. Compressor Discharge Gas Temperature Sensor CRR-20 & CRR-40, September 1999...

  • Page 41: Refrigeration System Options

    1c. Water Pressure Switch 1d. Water Inlet Coupling Water-Cooled Condenser-Receiver Tank Option (After 8/99) 2a. Fusible Plug 2b. Water Outlet Coupling 2c. Water Pressure Switch 2d. Water Inlet Coupling Dehumidify Valve Option (Replaces Standard Tube) CRR-20 & CRR-40, September 1999...

  • Page 42: Control Box - Door Open

    10. Data Retrieval Receptacle (located on bottom of control box on some models) 11. Thermistor Lead Option 12. Main Circuit Breaker 13. CBA Phase Contactor 14. ABC Phase Contactor 15. Current Transformer 16. Compressor Contactor 17. Heater Contactor 18. Evaporator Fan High Speed Contactor 19. µP-D Controller CRR-20 & CRR-40, September 1999...

  • Page 43: Sabroe Or Rte 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 CRR-20 & CRR-40, September 1999...

  • Page 44: Dual Voltage Option

    Unit Description Unit Illustrations 2-13 Dual Voltage Option 15 KVA Transformer 460-380V Power Receptacle Cable Bracket 230-190V Power Cable Power Plug (Option) CRR-20 & CRR-40, September 1999...

  • Page 45: Auxiliary Battery And Battery Charger Option

    2-14 Unit Illustrations Unit Description Auxiliary Battery and Battery Charger Option 12 Vdc Battery Battery Charger Box Battery Charger Terminal Board Battery Charger Cover CRR-20 & CRR-40, September 1999...

  • Page 46: Transfresh System Option

    TRANSFRESH Door Assembly TRANSFRESH Download Port Transformer Assembly mounted in Control Box TRANSFRESH Provision Option includes: • TRANSFRESH Box • A2 Wire Harness to TRANSFRESH Transformer • A3 Wire Harness to TRANSFRESH Download Port • Evaporator Grille CRR-20 & CRR-40, September 1999...

  • Page 47: Humidify System Option

    2-16 Unit Illustrations Unit Description Humidify 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 CRR-20 & CRR-40, September 1999...

  • Page 48: Typical Unit Back View

    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 • USDA3 Sensor Connection CRR-20 & CRR-40, September 1999...

  • Page 49: Operating Instructions

    NOTE: When unit configurations 5015 or 5016 ing the C/F key, and then pressing the ENTER are loaded (CRR-40-52 units), the controller uses key. the compressor discharge temperature and/or CRR-20 & CRR-40, September 1999...

  • Page 50: Unit Instruments

    1.7 C (3.0 F) above set- mation. point and 2.5 C (4.5 F) below setpoint. The controller • Thermo King modem is installed in a self-enclosed box inhibits the out-of-range alarm during defrost. bolted above the compressor.

  • Page 51: Unit Protection Devices

    “PAUSE ALM82” for 1 second every 10 +345/-104 kPa, 34.47 +3.45/-1.04 bar, 500 +50/-15 psig. seconds. After 5 minutes, the controller attempts to restart The valve is located so that refrigerant pressure expelled CRR-20 & CRR-40, September 1999...

  • Page 52: Pretrip Inspection

    When water lines manual. Be sure to wait up to 3 minutes for the are disconnected, also check to be sure that the water compressor to start. drains completely from the condenser-receiver tank. CRR-20 & CRR-40, September 1999...
  • Page 53 Pretrip Test, the Alarm LED will turn ON, “PTRIP 11. Stop the unit by moving the On/Off switch to the OFF FAIL” is stored in the datalogger memory and the unit position. returns to normal operation (unless a shutdown fault has CRR-20 & CRR-40, September 1999...

  • Page 54: Loading Procedure

    Trip data recorded by the Thermoguard ® be down loaded using PC-PAC™ software via the communi- cations connection located on the bottom of the control box. See instructions in PC-PAC™ software manual, TK P/N 204- 988. CRR-20 & CRR-40, September 1999...

  • Page 55: 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 CRR-20 & CRR-40, September 1999...

  • Page 56: General Description

    10. Pretrip test capability (see “Full Pretrip Test” under Menu and customer configuration (see “Reviewing Application Test in this chapter). Software Version” in this chapter). 11. Sensor Check test capability (see “Sensor Check” under General Theory of Operation in this chapter). CRR-20 & CRR-40, September 1999...

  • Page 57: Controller Display Menus

    Bulb mode allows adjustment of evapora- tor fan speed setting and defrost termina- tion temperature. “DEHUM XX.X”/Current humidity level also displays briefly when the Bulb mode is ON. Active Options and Pause Mode Screen Flow Diagram CRR-20 & CRR-40, September 1999...

  • Page 58: Pause Mode Displays

    Total Current Phase A AMP2 Total Current Phase B AMP3 Total Current Phase C AMPS Amperage AMTG Ambient Temperature Sensor Grade AUXV Auxiliary Battery (Option) Voltage BEFAN Bulb Mode Enable Fan BDFTT Bulb Mode Defrost Termination Temperature CRR-20 & CRR-40, September 1999...
  • Page 59 Power Reduction Mode Setting and Enable ELECT Electrical Test Submenu RCOMP Remote Cool Indicator ENTER Enter RDEF Remote Defrost Indicator ETEST Extended Pretrip Test REFRG Refrigeration Test Submenu EX CH Extended Chill Mode Pretrip Test Return Air Temperature Sensor CRR-20 & CRR-40, September 1999...

  • Page 60: Status Indicator Leds And Alarm Codes

    USDA3 Temperature Sensor 3 (USDA Enabled) ic Pretrip test (or Fitness test). Unit Serial Number USNXX Unit Serial Number Character 01, 02, 03 ...10 (total number of characters) VERSN Software Version VIEW View Menu VOLTS Total Voltage YEAR Current Year CRR-20 & CRR-40, September 1999...

  • Page 61: Pause Alarms

    The controller immediately stops the compressor and evapora- Check/ Sensor Calibration Failure (Pretrip) tor fans when the high pressure cutout switch opens. The con- Shutdown denser fan and phase select outputs remain energized as the CRR-20 & CRR-40, September 1999...

  • Page 62: Data Logging And Downloading Data

    (chill load operation only). point and other information up to a total of 80 characters (numerals or alphabetical letters). The container ID number is always resident in the controller memory. CRR-20 & CRR-40, September 1999...

  • Page 63: Frozen Loads

    When liquid injection is active, the controller energizes either the compressor or condenser temperature the liquid injection valve continuously. The liquid injection sensor is defective. line injects refrigerant into the suction line between the KVQ valve and the compressor suction service valve. CRR-20 & CRR-40, September 1999...

  • Page 64: Sensor Check

    Power Reduction Mode is active, use of the Power is -10.0 C (14.0 F) or below, the controller records Reduction Mode should be established by the shipper. alarm code 3 and resumes normal operation. CRR-20 & CRR-40, September 1999...

  • Page 65: Economy Mode Operation

    • Controller turns ON the In-range LED when the control- ling sensor temperature is within 1.7 C (3.0 F) of setpoint. CRR-20 & CRR-40, September 1999...

  • Page 66: Operating Mode Function Chart - Standard Operation

    • When the calculated temperature differential is less than 10 C (17.9 F) above setpoint. NOTE: Controller OPENS (energizes) the liquid injection valve when the compressor is ON only if the com- pressor discharge temperature exceeds 138 C (280 F). CRR-20 & CRR-40, September 1999...

  • Page 67: Operating Mode Function Chart - Optional Feature Operation

    ON and OFF. 3 Humidification Option: When the container humidity is more than 2% below the humidity setpoint, the controller operates (ener- gizes) the air compressor to inject atomized water directly into the evaporator supply air stream. CRR-20 & CRR-40, October 1999...
  • Page 68 3.1 C (5.5 F) below setpoint. [14.1 F] and Above) A. Cool B. Modulation Cool C. Null D. Heat E. In-Range 1. Decreasing Temperature 2. Setpoint 3. Increasing Temperature 4. Calculated Temperature Differential 5. Supply Air Temperature CRR-20 & CRR-40, September 1999...
  • Page 69 -10 to 0 C (-18 F to 0 F). 3. Increasing Temperature 8. ECMAX (default setting is +1.0 C [+1.8 F]). Setting 6. Return Air Temperature is adjustable from +10 to 0 C (+18 F to 0 F). CRR-20 & CRR-40, September 1999...

  • Page 70: Defrost

    12 hours on frozen loads. heat energy release into the container. - Customer Configuration C6: 2 hour initial defrost, then maximum time interval is 6 hours on frozen loads. CRR-20 & CRR-40, September 1999...

  • Page 71: Reviewing Software Version And Configuration

    Alarm code 42 (unit configuration alarm) is displayed if the customer configuration has not been set to a valid number (other than “0”). CRR-20 & CRR-40, September 1999...

  • Page 72: Displaying Alternate Controlling (Supply Or Return) Air Sensor Temperatures

    To set the tenths digit, wait 4 sec- onds for all three digits to appear on the display. Make additional setpoint adjustment if necessary. COOL NULL HEAT IN RANGE DEFROST SUPPLY RETURN PWRLMT ALARM SETPOINT TEMPERATURE ° DATA DATA CRR-20 & CRR-40, September 1999...

  • Page 73: Initiating A Manual Defrost

    • If unit operating conditions do NOT allow defrost, the display shows “DFRST INVAL” for 3 seconds. COOL NULL HEAT IN RANGE DEFROST SUPPLY RETURN PWRLMT ALARM SETPOINT TEMPERATURE DATA DATA The controller then returns to the Standard Display. CRR-20 & CRR-40, September 1999...

  • Page 74: Entering A Start Of Trip Marker

    • The left display shows the number of alarms stored in 6. The controller then returns to the Standard Display. memory (e.g. ALM 2). • The right display shows a two digit code for the most recent alarm (e.g. 02). CRR-20 & CRR-40, September 1999...

  • Page 75: Controller Menu Operating Instructions

    NOTE: To lock the current View Menu screen in the controller display, press the ENTER key. A colon flashes in the left display to indicate the screen is locked (the screen remains locked for 15 minutes). Press any key to unlock the display. CRR-20 & CRR-40, September 1999...

  • Page 76: Grade Submenu

    3. Press the SELECT key to enter VIEW submenu (display ual test results recorded for the last 4 Full Pretrip shows “VIEW <--->”). tests. MENU VIEW Screen Flow Diagram (See Display Acronym Definitions on pages 4-4 to 4-6) CRR-20 & CRR-40, September 1999...
  • Page 77 YR Year MO Month DY Day TI Time TEMP (Temperature) Scrollback Information Matrix PTI (Pretrip) Scrollback Information Matrix *First information screen displayed from the PTI Scrollback menu. *First information screen displayed from the TEMP Scrollback menu. CRR-20 & CRR-40, September 1999...
  • Page 78 DS Display Test Result AM Amps Test Result SN Sensors Test Result HT Heat Test Result DF Defrost Test Result CL Cool Test Result EX Extended Cool Test Result YR Year MO Month DY Day TI Time CRR-20 & CRR-40, September 1999...

  • Page 79: Menu Pretrip Functions

    Shutdown Alarm fault occurs during a Pretest • Display: Controller lights all segments in the display for visual inspection by technician. MENU PRETRIP Screen Flow Diagram (See Display Acronym Definitions on pages 4-4 to 4-6) CRR-20 & CRR-40, September 1999...

  • Page 80: Performing An Extended, Full Or Single Pretrip Test From The Pretrip Menu

    “Menu View” in this chapter. Press the ENTER key. A flashing display will show LOAD PTRIP. The controller then conducts an Extended Pretrip Test. When the test is complete, the unit shuts down. CRR-20 & CRR-40, September 1999...

  • Page 81: Menu Test Functions

    Full Cool. MENU TEST Screen Flow Diagram (See Display Acronym Definitions on pages 4-4 to 4-6) CRR-20 & CRR-40, September 1999...
  • Page 82 6. Press SELECT key to enter a sub-submenu (display shows 8. Press and hold the SELECT key for 3 seconds to return to “ELECT <--->”). the Standard Display. CRR-20 & CRR-40, September 1999...

  • Page 83: Menu Guard Functions

    When the Guard Menu is exited, the controller resets and then restarts the unit. This is necessary to be certain that all changes in the programmable features are activated. MENU TEST Screen Flow Diagram (See Display Acronym Definitions on pages 4-4 to 4-6) CRR-20 & CRR-40, September 1999...

  • Page 84: Setting The Unit Configuration And Customer Configuration Numbers

    Repeat steps a and b for each character until the (where “0” is the default customer configuration when a Container Identification Number is entered. new controller or software is loaded; or the Unit Configuration is reset). CRR-20 & CRR-40, September 1999...

  • Page 85: Setting The Unit Serial Number

    “Setting When the desired hour shows in the right display, the Date and Time” below. press the ENTER key. The display shows “HOUR LOAD” and then shows “HOUR HH” (where “HH” is the new hour). CRR-20 & CRR-40, September 1999...

  • Page 86: Setting The Compressor And On Time Hourmeters

    DOWN key until the display shows “ONHRM Heaters ON Time XXXX” (where “XXXX” is the number of unit on hours). NOTE: If the number of unit on hours can not be determined, leave this setting “0000”. CRR-20 & CRR-40, September 1999...

  • Page 87: 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 88 Press the ENTER key. Right display briefly perature. shows “CALIB” and then the sensor (ice bath) NOTE: The sensor should be in the ice bath temperature. a total of 15 minutes or more to assure the sensor temperature has bottomed out. CRR-20 & CRR-40, September 1999...

  • Page 89: Changing The Display Units (C/F)

    Press the UP or DOWN key to choose the grade setting “5”. • When the desired grade shows in the right dis- play, press the ENTER key. Right display briefly shows “LOAD” and then the new sensor grade). CRR-20 & CRR-40, September 1999...

  • Page 90: Menu Program Functions

    – BEFAN = Enter Bulb mode evaporator fan speed (high, low or cycle) PWRED Power Reduction 1, 2 or 3 MENU PROGRAM Screen Flow Diagram (See Display Acronym Definitions on pages 4-4 to 4-6) CRR-20 & CRR-40, September 1999...

  • Page 91: Pulp Sensor (Option)

    (“00.0 C”), and returns to the “USDA1 “PULP” will begin to flash in the left display. ON” display. 7. Press the UP or DOWN key to scroll the right display to the desired setting. CRR-20 & CRR-40, September 1999...

  • Page 92: Economy Mode

    NOTE: Press and hold the SELECT key for 3 sec- NOTE: If the Economy Mode is set to ON, the con- onds to return to the Standard Display. troller display will show “ECON ON” for 1 second every 10 seconds. CRR-20 & CRR-40, September 1999...

  • Page 93: Dehumidify Mode (Option)

    Also, the Dehumidify and Humidify options can NOT be turned ON at the same time. CRR-20 & CRR-40, September 1999...

  • Page 94: Bulb Mode (Option)

    Mode is turned ON, the display then shows “BULB ON”. NOTE: Setting the Bulb mode to OFF does not automatically set the Dehumidify mode to OFF too. To de-activate Dehumidify operation, see “Dehumidify Mode” earlier in this chapter. CRR-20 & CRR-40, September 1999...

  • Page 95: Power Reduction Mode

    The display briefly shows “PWRED LOAD”. Left display then shows “PWRED” and the right display shows the new power reduction setting (e.g. “1”). NOTE: Press and hold the SELECT key for 3 sec- onds to return to the Standard Display. CRR-20 & CRR-40, September 1999...

  • Page 96: Controller Emergency Bypass Procedure

    COMPLETE stop. Then place the Phase Rotation Emergency Bypass Module 1. VIN LED 2. Mode Switch 3. High Pressure Cutout (HPCO) LED 4. 24 Vac LED 5. Phase Rotation Switch 6. Attach Wire Harness Connector C1 Here CRR-20 & CRR-40, September 1999...

  • Page 97: Output Module

    The power module derives power from the con- trol power transformer. Always disconnect the main supply power before working on the power module board. µ µ P-D Output Module CRR-20 & CRR-40, September 1999...

  • Page 98: Replacing The Μp-D Controller

    7. Attach the wire harness connectors to the back of the con- troller. Evaporator Coil Sensor Location — Units with Three Evaporator Fans Coil Support Brackets Unit Front Insert Sensor between Tube Rows 2 and 3 CRR-20 & CRR-40, September 1999...

  • Page 99: Diagnosis And Repair

    If an alarm code indicates a failed sensor, check the sensor by substitution. Evaporator Coil Sensor Location — Units with Two Evaporator Fans Coil Support Bracket Unit Front Insert Sensor between Tube Rows 2 and 3 CRR-20 & CRR-40, September 1999...

  • Page 100: Alarm Codes, Descriptions And Corrective Actions 4-46 To

    Be sure to maintain the correct polarity. • If the Thermistor fails, the KVQ valve actuator must be replaced. NOTE: Do NOT use a test light or other instru- ment; or controller damage may result. CRR-20 & CRR-40, September 1999...
  • Page 101 • Continuity check circuit wiring using a high quality ohmmeter. Be sure to maintain the correct polarity. NOTE: Do NOT use a test light or other instru- ment; or controller damage may result. CRR-20 & CRR-40, September 1999...
  • Page 102 • Check for correct water cooled condenser operation (option). • Check for jumper on water pressure switch connec- tors in sensor harness if unit is NOT equipped with a water cooled condenser (option). • Check for a defective high pressure cutout switch. CRR-20 & CRR-40, September 1999...
  • Page 103 • Check for other sensor alarm codes, particularly codes 03 and 07. • Indicates both the return and supply sensors have failed. • Continuity check the wiring to the temperature sen- sors using a wiring diagram and digital multimeter. CRR-20 & CRR-40, September 1999...
  • Page 104 “5000” and customer configuration “0”. However, the unit will NOT valid number (other than “0”). operate customer specific options. See the controller identification decal for the correct unit configuration and customer configuration set- tings. CRR-20 & CRR-40, September 1999...
  • Page 105 • Indicates the frequency of the supply speed. power is high. • If the frequency and voltage of the power supply are correct but the controller displays 1/2 of the correct reading, replace the power module. CRR-20 & CRR-40, September 1999...
  • Page 106 • Continuity check circuit wiring using a high quality multimeter. Be sure to maintain the correct polarity or the sensor will not work. NOTE: Do NOT use a test light or other instru- ment; or controller damage may result. CRR-20 & CRR-40, September 1999...
  • Page 107 Resistance for each winding should be 43 +/- 0.5 ohms. • Check the refrigeration system for excessively high pressures that could cause high compressor current draw. CRR-20 & CRR-40, September 1999...
  • Page 108 Disconnect plug on cur- rent transformer and check the resistance of each primary winding. Resistance for each winding should be 43 +/- 0.5 ohms. • Check the refrigeration system for excessively high pressures. CRR-20 & CRR-40, September 1999...
  • Page 109 Turn unit OFF and discon- nect power supply. Disconnect plug on current transformer and check the resistance of each prima- ry winding. Resistance for each winding should be 43 +/- 0.5 ohms. CRR-20 & CRR-40, September 1999...
  • Page 110 Turn unit OFF and discon- nect power supply. Disconnect plug on current transformer and check the resistance of each prima- ry winding. Resistance for each winding should be 43 +/- 0.5 ohms. CRR-20 & CRR-40, September 1999...
  • Page 111 Disconnect plug on current trans- former and check the resistance of each primary winding. Resistance for each winding should be 43 +/- 0.5 ohms. • Check refrigeration system for obstructions or low refrigerant charge. CRR-20 & CRR-40, September 1999...
  • Page 112 Disconnect plug on current trans- former and check the resistance of each primary winding. Resistance for each winding should be 43 +/- 0.5 ohms. • Check refrigeration system for obstructions or low refrigerant charge. CRR-20 & CRR-40, September 1999...
  • Page 113 • If alarm occurs during a Pretrip test, a dash (-) precedes the alarm code. • Check operation of evaporator fans using “AMPS EFH” in the Electrical Test submenu. Then visually inspect fans for proper rotation and operation. CRR-20 & CRR-40, September 1999...
  • Page 114 • Check the circuit wiring for continuity using a high quality multimeter and a wiring diagram. NOTE: This valve is not used on CRR units. NOTE: Do NOT use a test light or other instru- ment; or controller damage may result. CRR-20 & CRR-40, September 1999...
  • Page 115 NOTE: Do NOT use a test light or other instru- ment; or controller damage may result. 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. CRR-20 & CRR-40, September 1999...
  • Page 116 • Continuity check circuit wiring using a high quality multimeter. Be sure to maintain the correct polarity or the sensor will not work. NOTE: Do NOT use a test light or other instru- ment; or controller damage may result. CRR-20 & CRR-40, September 1999...
  • Page 117 Resistance for each winding should be 43 +/- 0.5 ohms. • Check the refrigeration system for excessively high pressures. • Check the compressor for proper operation. CRR-20 & CRR-40, September 1999...
  • Page 118 Check the cable from the thermo bus tap to the output module. Check thermo bus tap for can terminator resistor R4. • Check controller using the Microprocessor Tester. • Replace the Output Module. CRR-20 & CRR-40, September 1999...

  • Page 119: Electrical Maintenance

    +/- 70 kPa, 24.1 +/- 0.7 bar, 350 +/- 10 psig (2240 +/- 70 kPa, for loose, chaffed or broken wires on the unit; open or short 22.4 +/- 0.7 bar, 325 +/- 10 psig on CRR-20-63); the switch circuits and damaged components on the controller printed cir- opens the R51A circuit: cuit board.

  • Page 120: Condenser Fan And Evaporator Fan Rotation

    Diagnosis Manual for Thermoguard µ µ P-D Microprocessor If the HPCO switch fails to stop compressor operation, replace Controller, TK 41230. the switch and repeat steps 1 through 4. CRR-20 & CRR-40, September 1999...

  • Page 121: Electric Heaters

    • Check resistance with an ohmmeter. NOTE: When repairing heater connections, protect the new connections from the ingress of moisture with heat shrink tubing. All heaters should be secured to prevent contact with sharp metal edges. CRR-20 & CRR-40, September 1999...

  • Page 122: Refrigeration Maintenance And Service Operations

    Some of these service pro- cedures are regulated by Federal, and in some cases, by State and Local laws. CAUTION: When servicing Thermo King R-134a All regulated refrigeration service procedures refrigeration systems, use only those service tools must be performed by an EPA certified technician, (i.e., vacuum pump, refrigerant recovery equipment,...

  • Page 123: Compressor Discharge And Suction Service Valves

    • Open to Service Port: Position for servicing. • Front Seated: To check or remove compressor. WARNING: Do not start unit with discharge valve in FRONT SEATED position. Service Valve Front Seated 1. Full Clockwise CRR-20 & CRR-40, September 1999...

  • Page 124: Gauge Manifold Valve Positions

    1. Quick Disconnect Access Valve 1. Quick Disconnect Access Valve 2. In 2. Discharge Service Valve (DSV) 3. Reclaimer 3. Suction Service Valve (SSV) 4. Out 5. Discharge Service Valve (DSV) 6. Suction Service Valve (SSV) CRR-20 & CRR-40, September 1999...
  • Page 125 Refrigeration Maintenance and Service Operations Gauge Manifold Set (With Low Loss Fittings) Attachment And Purging Thermo King recommends the use of access valves or self- sealing, quick disconnect fittings whenever possible to limit the loss of refrigerant into the atmosphere. A separate gauge manifold set with low loss fittings (P/N 204-758) should be dedicated for use with R-134a only.

  • Page 126: Checking Compressor Oil

    Back seat receiver tank outlet valve and cap valve stem. Secure all manifold lines to manifold hose anchors when the manifold is not in use. Adjusting Compressor Oil Level 1. Add and Remove Compressor Oil at the Compressor Oil Fitting CRR-20 & CRR-40, September 1999...

  • Page 127: Refrigerant Leak Test Procedure

    4. Operate the unit and recheck the refrigerant charge level and the oil level before returning the unit to service. Testing for Refrigerant Leaks CRR-20 & CRR-40, September 1999...

  • Page 128: Low Side Pump Down

    To place the unit back in service, open the receiver tank outlet valve and turn the On/Off switch ON. Standard Receiver Tank 1. Sight Glass: Refrigerant charge is OK if ball FLOATS at any time 2. Service Fitting 3. Fusible Plug CRR-20 & CRR-40, September 1999...
  • Page 129 WAY TO TOP of sight glass, the unit is over- charged. Water-Cooled Condenser-Receiver Tank (Before Water-Cooled Condenser-Receiver Tank (After 8/99) 8/99) (Option) (Option) 1. Two Sight Glasses: Normal refrigerant level 1. Single Sight Glass: Refrigerant charge is OK if ball FLOATS at any time CRR-20 & CRR-40, September 1999...

  • Page 130: Evacuation And Cleanup Of The Refrigeration System

    5. Open Evacuation Station valves (V1, V3, and V4). It is only necessary to open valve V2 when a reading on the CRR-20 & CRR-40, September 1999...
  • Page 131 1. Special, self-sealing quick disconnect couplers are required for R-134a units. 2. Gas Ballast Valve 3. Iso Valve 4. Two-stage Vacuum Pump 5. To 220/190 VAC Power 6. Calibration Standard 7. Micron Meter 8. Sensor CRR-20 & CRR-40, September 1999...
  • Page 132 2000 microns or less. The final V4 open, the pump is isolated and the system is held under a equilibrium pressure is determined with the Thermo King vacuum. If the Micron Meter rises, one of the following con- Evacuation Station using the following procedure (called ditions exist.
  • Page 133 The leak must then be located and system still contains too much moisture. eliminated. Dehydration and additional evacuation time are 2. Time required. 3. Pressure (Vacuum) 2. Time 4. Atmospheric Pressure 3. Pressure (Vacuum) 4. Atmospheric Pressure CRR-20 & CRR-40, September 1999...

  • Page 134: Evaporator Pressure Regulator (Kvq) Valve

    Tools Required: increase approximately 170 kPa, 1.7 bar, 25 psig. This • Digital Multimeter (P/N 204-615) will meter liquid refrigerant slowly into the low side. • Actuator Assembly • Adjustable Wrench • Torque Wrench CRR-20 & CRR-40, September 1999...
  • Page 135 2. Threaded Connection sequence. 3. Valve Body 9. Replace cover on actuator assembly. 4. Inlet Tube 5. Valve Plate 6. Outlet Tube 7. Pressure Pin 8. Bellows Assembly 9. Pressure Reservoir 10. Heating Element 11. Terminal Connections CRR-20 & CRR-40, September 1999...

  • Page 136: Refrigerant Recovery

    13. Verify that all personnel are clear and connect main power approved for and dedicated to R-134a recovery. plug to power supply. Place the unit back in service. When removing any refrigerant from a Thermo King refrigera- KVQ Valve Replacement tion system, use a recovery process that prevents or absolutely If the valve body is damaged, replace the entire valve.

  • Page 137: Using Pressurized Nitrogen

    Typical Pressurized Gas Bottle with Pressure Regulator and Gauges 1. Line Pressure 2. Tank Pressure 3. Tank 4. Pressure Test Line to System 5. Safety Valve 6. Pressure Regulator CRR-20 & CRR-40, September 1999...

  • Page 138: Compressor Replacement

    CRR-20 & CRR-40, September 1999...

  • Page 139: Condenser Coil Replacement

    1. Close the liquid line service valve and pump down the low side. Open the outlet valve slightly to equalize the pres- sure to 21 kPa, 0.21 bar, 3 psig. 2. Place the new dehydrator (or in-line filter) near the unit for immediate installation. CRR-20 & CRR-40, September 1999...

  • Page 140: Expansion Valve Replacement

    Locate bulb on the suction line in former position. The feeler bulb must make good contact with the suction line or operation will be faulty. Cover with insulating tape. 9. Open the liquid line service valve and place unit in opera- CRR-20 & CRR-40, September 1999...

  • Page 141: Receiver Tank Replacement

    3. Pressurize the refrigeration system and check for leaks (see “Refrigerant Leak Test Procedure” in this chapter). 4. Evacuate the system (see “Evacuation and Cleanup of the Refrigeration System” in this chapter). Recharge the unit (see “Refrigerant Charge” in this chapter). CRR-20 & CRR-40, September 1999...

  • Page 142: Liquid Line Solenoid Valve

    Check the refrigerant charge and add refriger- Reconnect the electrical wires to the valve. ant as required. Open the liquid line service valve and place the unit in operation. Check the refrigerant charge and add refriger- ant as required. CRR-20 & CRR-40, September 1999...

  • Page 143: Dehumidify Valve (Option) Replacement

    1. Clean the tubes for soldering. 2. Place the new valve in position. 3. Solder the liquid line connections. CAUTION: Use a heat sink or wrap the valve with wet rags to prevent damage to the new valve. CRR-20 & CRR-40, September 1999...

  • Page 144: Structural/Accessory Maintenance

    Inspect coil and fins for damage and repair if necessary. CAUTION: Air pressure must not be high enough to damage coil fins. Mounting Bolts Tighten Unit Mounting Bolts Tighten Compressor, Condenser Fan and Evaporator Fan Mounting Bolts CRR-20 & CRR-40, September 1999...

  • Page 145: Defrost Drains

    The fresh air exchange system has an adjustable vent door that is precalibrated for air exchange rates between 0 and 160 m (0 and 94 ft /min.) on CRR-20 units; 0 and 285 m /hr (0 and 168 ft /min.) on CRR-40 units. The evaporator fans draw in outside air through an air intake and discharge an equal amount of container air through an air outlet.

  • Page 146: Partlow (Model Sr) Recording Thermometer (Option)

    Partlow (SR) Recording Thermometer 1. Knurled Knob 2. Recording Stylus 3. Lifter Arm 4. Allen Screw 5. Set Screw “S” 6. Key Mounting Clip 7. Adjustment Shaft “J” 8. Element Flange Screws “D” 9. Thermal Element 10. Stamping CRR-20 & CRR-40, September 1999...

  • Page 147: Element Replacement

    5. Install a new battery in the recorder making sure the bat- tery’s positive (+) and negative (-) poles are correctly aligned. 6. Press the button on the voltage indicator to make sure the indicator needle is the in blue zone. CRR-20 & CRR-40, September 1999...

  • Page 148: Recording Chart Replacement

    5 C (9 F). 7. Setting Screw (Calibration) 8. Lock Screw (Calibration) 9. Recording Pen 10. Lifting Arm 11. Time Scale Plate 12. Terminal Board 13. Quartz Motor and Reducing Gear Assembly 14. Recording Platen CRR-20 & CRR-40, September 1999...

  • Page 149: Power Element Assembly Replacement

    3. Loosen the two terminal screws on the terminal board and remove the motor wires. 4. Loosen the five screws that mount the motor assembly in the recorder. Remove the motor assembly. 5. Install new motor assembly. Install an securely tighten five mounting screws. CRR-20 & CRR-40, September 1999...

  • Page 150: Humidify System (Option)

    • Pretrip Inspection: Check the water level. • Every 1,000 Hours: Inspect the water tank and clean if necessary. 5. Water Tank Heater: Check for correct operation in ambient temperatures below 4 C (40 F). 6. Drain Cock CRR-20 & CRR-40, September 1999...

  • Page 151: Diagnosis

    Compressor Over Temperature reset automatically. Check liquid injection (fault code 82) valve and compressor temperature sensor Compressor motor internal thermal If compressor contactor is energized, wait overload protection open 60 minutes for protector to cool and reset. CRR-20 & CRR-40, September 1999...
  • Page 152 Inefficient condenser operation Check condenser airflow, condenser causing cycling on high pressure fan motor, condenser fan grille, condenser cutout fan pressure switch, water pressure switch (option), water flow rate (option) and \ water-cooled condenser-receiver tank (option) CRR-20 & CRR-40, September 1999...
  • Page 153 Replace defective contactor contactor No high speed condenser fan output Diagnose and replace output module or signal from controller controller. Disconnect water supply to unit (option) and check water pressure switch (option) before replacing controller CRR-20 & CRR-40, September 1999...
  • Page 154 Defective motor Replace motor Defective low or high speed Replace defective contactor evaporator fan contactor No low or high speed evaporator Diagnose and replace output module or fan output signal from controller controller output module CRR-20 & CRR-40, September 1999...

  • Page 155: Refrigeration Diagnosis

    Controller out of calibration or Recalibrate or replace controller defective (see Diagnosis Manual for Thermoguard µP-D Microprocessor Controller, TK 41230) Expansion valve feeler bulb Correct feeler bulb installation improperly mounted, poorly insulated or making poor contact CRR-20 & CRR-40, September 1999...
  • Page 156 Expansion valve open too much Adjust or replace valve Expansion valve power element lost Replace power element its charge Expansion valve feeler bulb Correct feeler bulb installation improperly mounted, poorly insulated or making poor contact CRR-20 & CRR-40, September 1999...
  • Page 157 Repair or replace grille missing Condenser fan blade damaged Replace fan blade High ambient air temperature No remedy Restricted dehydrator or high side Replace dehydrator or clear restriction Defective high pressure gauge Replace service gauge CRR-20 & CRR-40, September 1999...
  • Page 158 Mechanical Diagnosis Unit in vacuum. Frost on Ice plugging expansion valve Apply hot wet cloth to expansion valve. expansion valve only screen or orifice Moisture indicated by increase in suction pressure. Replace dehydrator CRR-20 & CRR-40, September 1999...
  • Page 159 Check evaporator fan motors and control circuit and correct fault Controller out of calibration or Recalibrate or replace controller defective (see Diagnosis Manual for Thermoguard µP-D Microprocessor Controller, TK 41230) Service gauge out of calibration Adjust or replace gauge CRR-20 & CRR-40, September 1999...

  • Page 160: 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. CRR-20 & CRR-40, September 1999...

  • Page 161: 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. CRR-20 & CRR-40, September 1999...

  • Page 162: External 12 Vdc Battery Power Supply

    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. CRR-20 & CRR-40, September 1999...

  • Page 163: Microprocessor Awakened From Sleep Mode

    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. Typical model shown with three evaporator fans. CRR-20 & CRR-40, September 1999...

  • Page 164: Vdc Control Circuit, Sensor Circuits

    Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings 12.5 Vdc Control Circuit, Sensor Circuits, Evaporator Pressure Regulator (KVQ) Valve Circuit, Condenser Fan Pressure Switch Circuit and Water Pressure Circuit (Option) Typical model shown with three evaporator fans. CRR-20 & CRR-40, September 1999...

  • Page 165: 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. CRR-20 & CRR-40, September 1999...

  • Page 166: 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. CRR-20 & CRR-40, September 1999...

  • Page 167: 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. CRR-20 & CRR-40, September 1999...

  • Page 168: 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. CRR-20 & CRR-40, September 1999...

  • Page 169: 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. CRR-20 & CRR-40, September 1999...

  • Page 170: Dehumidify System, Humidity System, Water Pressure Switch, Usda Temperature Sensor, Pulp Sensor And Chart Recorder Circuits (Options)

    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. CRR-20 & CRR-40, September 1999...

  • Page 171: Cool Mode - Chill Load

    When the water pressure switch opens on units with an optional water-cooled condenser-receiver tank, the con- denser fan does not operate. When water pressure is disconnected from the condenser-receiver tank, condenser fan operation resumes. Standard units have a jumper wire installed in the water pressure switch harness. CRR-20 & CRR-40, September 1999...
  • Page 172 Unit Power Consumption; Economy Mode OFF Typical model shown with three evaporator fans. Condenser fan will stop if condenser head pressure decreases to 1100 +/- 50 kPa, 11.00 +/- 0.5 bar, 160 +/- 7 psig. CRR-20 & CRR-40, September 1999...

  • Page 173: Economy Mode Off

    — 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. Condenser fan will stop if condenser head pressure decreases to 1100 +/- 50 kPa, 11.00 +/- 0.5 bar, 160 +/- 7 psig. CRR-20 & CRR-40, September 1999...

  • Page 174: Cool Mode - Chill Load

    Humidify Mode (Option) ON with container humidity above humidity setpoint Typical model shown with three evaporator fans. Condenser fan will stop if condenser head pressure decreases to 1100 +/- 50 kPa, 11.00 +/- 0.5 bar, 160 +/- 7 psig. CRR-20 & CRR-40, September 1999...
  • Page 175 Humidify Mode (Option) ON with container humidity more than 2% below the humidity setpoint Typical model shown with three evaporator fans. Condenser fan will stop if condenser head pressure decreases to 1100 +/- 50 kPa, 11.00 +/- 0.5 bar, 160 +/- 7 psig. CRR-20 & CRR-40, September 1999...

  • Page 176: Modulation Mode - Chill Load

    ; Economy Mode OFF; Temperature Out-of-range Typical model shown with three evaporator fans. Condenser fan will stop if condenser head pressure decreases to 1100 +/- 50 kPa, 11.00 +/- 0.5 bar, 160 +/- 7 psig. CRR-20 & CRR-40, September 1999...
  • Page 177 Dehumidify Mode is set to ON in the PROGRAM menu of the controller. When the unit is in Low Dehumidify opera- tion (humidity 1-5% above setpoint), the dehumidify valve closes (energizes) to reduce the size of the evaporator coil used for cooling. CRR-20 & CRR-40, September 1999...
  • Page 178 (5% or more above setpoint), the dehumidify valve closes (energizes) to reduce the size of the evaporator coil used for cooling and the electric heaters are pulsed ON for a maximum of 15 seconds every 30 seconds. CRR-20 & CRR-40, September 1999...

  • Page 179: Temperature In-Range

    Condenser fan will stop if condenser head pressure decreases to 1100 +/- 50 kPa, 11.00 +/- 0.5 bar, 160 +/- 7 psig. Evaporator fans operate on low speed when Economy Mode is set to ON in the Program menu of the µP-D controller and the container temperature is In-range. CRR-20 & CRR-40, September 1999...

  • Page 180: Null Mode - Chill Load (Setpoint At -9.9 C [14.1 F] Or Above) During Compressor Pump Down (Condenser Fan On); Economy Mode Off

    The microprocessor closes (de-energizes) the liquid line solenoid valve while the compressor continues to operate. Controller stops compressor to terminate pump down cycle on time limit after 60 seconds. If the condenser fan was ON, it will operate for approximately 30 seconds and then stop. CRR-20 & CRR-40, September 1999...

  • Page 181: Null Mode - Chill Load (Setpoint At -9.9 C [14.1 F] Or Above) After Compressor Pump Down; 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) After Compressor Pump Down; Economy Mode Typical model shown with three evaporator fans. CRR-20 & CRR-40, September 1999...

  • Page 182: Heat Mode - Chill Load (Setpoint At -9.9 C [14.1 F] Or Above); Economy Mode Off; Temperature In-Range

    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. CRR-20 & CRR-40, September 1999...

  • Page 183: Cool Mode - Frozen Load

    Temperature Above -10.0 C (14.0 F); Power Monitor Limiting Unit Power Consumption; Economy Mode OFF Typical model shown with three evaporator fans. Condenser fan will stop if condenser head pressure decreases to 1100 +/- 50 kPa, 11.00 +/- 0.5 bar, 160 +/- 7 psig. CRR-20 & CRR-40, September 1999...
  • Page 184 Temperature Below -10.0 C (14.0 F); Economy Mode OFF; Temperature In-Range Typical model shown with three evaporator fans. Condenser fan will stop if condenser head pressure decreases to 1100 +/- 50 kPa, 11.00 +/- 0.5 bar, 160 +/- 7 psig. CRR-20 & CRR-40, September 1999...

  • Page 185: Mode Off

    — Frozen Load (Setpoint at -10.0 C [14.0 F] or Below); After Compressor Pump Down; 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. CRR-20 & CRR-40, September 1999...

  • Page 186: Null Mode - Frozen Load (Setpoint At -10.0 C [14.0 F] Or Below) After Compressor Pump Down; Economy Mode On

    5 minutes every 45 minutes. The unit remains in Null until the return air temperature increases to 1.0 C (1.8 F) above setpoint at the expiration of a 45 minute Null state time sequence. CRR-20 & CRR-40, September 1999...

  • Page 187: Defrost

    Electrical, Refrigeration and µP-D Menu Flow Diagrams 9-28 Defrost Typical model shown with three evaporator fans. CRR-20 & CRR-40, September 1999...
  • Page 188 Electrical, Refrigeration and µP-D Menu Flow Diagrams CRR-20 and CRR-40 (All Models Except CRR-40-133 & CRR-40-139) Wiring Schematic 9-29 CRR-20 & CRR-40, September 1999...
  • Page 189 Electrical, Refrigeration and µP-D Menu Flow Diagrams CRR-20 and CRR-40 Wiring Diagram (All Models Except CRR-40-133 & CRR-40-139) — Page 1 of 3 9-30 CRR-20 & CRR-40, September 1999...
  • Page 190 Electrical, Refrigeration and µP-D Menu Flow Diagrams CRR-20 and CRR-40 Wiring Diagram (All Models Except CRR-40-133 & CRR-40-139) — Page 2 of 3 9-31 CRR-20 & CRR-40, September 1999...
  • Page 191 Electrical, Refrigeration and µP-D Menu Flow Diagrams CRR-20 and CRR-40 Wiring Diagram (All Models Except CRR-40-133 & CRR-40-139) — Page 3 of 3 9-32 CRR-20 & CRR-40, September 1999...
  • Page 192 Electrical, Refrigeration and µP-D Menu Flow Diagrams CRR-40-133 & CRR-40-139 Wiring Schematic 9-33 CRR-20 & CRR-40, September 1999...
  • Page 193 Electrical, Refrigeration and µP-D Menu Flow Diagrams CRR-40-133 & CRR-40-139 Wiring Diagram — Page 1 of 3 9-34 CRR-20 & CRR-40, September 1999...
  • Page 194 Electrical, Refrigeration and µP-D Menu Flow Diagrams CRR-40-133 & CRR-40-139 Wiring Diagram — Page 2 of 3 9-35 CRR-20 & CRR-40, September 1999...
  • Page 195 Electrical, Refrigeration and µP-D Menu Flow Diagrams CRR-40-133 & CRR-40-139 Wiring Diagram — Page 3 of 3 9-36 CRR-20 & CRR-40, September 1999...

  • Page 196: Refrigeration System Components

    40. High Pressure Relief Valve (Option) *Units built after 3/9/99 and all models with two evaporator fans feature a large, one-piece Filter Drier/In-line Filter. **Units built after 8/99 feature a fusible plug and service fitting located on the tank. CRR-20 & CRR-40, September 1999...
  • Page 197 It CLOSES** at 1655 +/- 70 kPa, 16.5 +/- 0.7 bar, 240 +/- 10 psig. *CRR-20-63: 2240 +/- 70 kPa, 22.4 +/- 0.7 bar, 325 +/- 10 psig. **CRR-20-63: at 1590 +/- 70 kPa, 15.9 +/- 0.7 bar, 230 +/- 10 psig. High Pressure Relief (Fusible Plug) BLOWS at 100 C (212 F).
  • Page 198 10 second cycle. Liquid injection is controlled by the compressor discharge temperature. High pressure gas High pressure liquid Low pressure gas Low pressure liquid Condensing high pressure gas Low pressure vaporizing liquid Liquid refrigerant injection Modulated pressure CRR-20 & CRR-40, September 1999...
  • Page 199 High pressure gas High pressure liquid Low pressure gas Low pressure liquid Condensing high pressure gas Low pressure vaporizing liquid Liquid refrigerant injection Modulated pressure CRR-20 & CRR-40, September 1999...
  • Page 200 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 °...

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