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
Dehumidify and Humidify Systems (Options) Status Indicator LEDs Physical Specifications Data Recording and Downloading Data Metric Hardware Torque Charts General Theory of Operation Chill Loads Frozen Loads Modulation Display in Data Menu Power Limit Mode CSR40-149 & -150 PS Hermetic, June 2000...
Page 6 View the Commands Menu 4-18 Defrost 4-19 Function Test 4-19 CSR PS Function Test Procedure 4-21 Pretrip (PTI) Test 4-20 CSR PS Pretrip (PTI) Test Procedure 4-23 Manual Function Test 4-20 Power Management 4-28 CSR40-149 & -150 PS Hermetic, June 2000...
Page 7 Refrigeration System Components Injection Valve or Dehumidify Valve Full Cool Flow and Pressure Diagram (Option) Replacement 6-20 Modulation Cool Flow and Pressure Diagram 9-10 Dehumidification Flow and Pressure Diagram 9-11 MP-3000 Menu Flow Diagram 9-12 CSR40-149 & -150 PS Hermetic, June 2000...
Page 9: Introduction
For detailed descriptions of our refrigeration systems or micro- operators and service people in the proper upkeep and mainte- processor controllers, see the appropriate manual. For further nance of Thermo King units. This manual includes mainte- information refer to: nance and diagnosis information for both standard and option- Operation, Diagnosis and Refrigeration Maintenance al unit features.
Page 10: Csr40-149 & -150 Ps Model Features
– – TRANSFRESH ® Provision – – TRANSFRESH ® Purge Port – – TRANSFRESH ® System, Complete – – Thermistor Lead – – USDA Cold Treatment Temperature Recording – – Water-Cooled Condenser-Receiver Tank CSR40-149 & -150 PS Hermetic, June 2000...
Page 11: Safety Precautions
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. CSR40-149 & -150 PS Hermetic, June 2000...
Page 12: 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. CSR40-149 & -150 PS Hermetic, June 2000...
Page 13: Microprocessor Controller
After servicing the circuit board and any other circuits, the wiring should be checked for possible errors before restor- ing power. CSR40-149 & -150 PS Hermetic, June 2000...
Page 14: 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 15: 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. CSR40-149 & -150 PS Hermetic, June 2000...
Page 17: Specifications
20 mm (0.8 in.) 5,000 2,940 — — 3,750 2,205 — — 30 mm (1.2 in.) 4,430 2,610 — — 2,930 1,725 — — 40 mm (1.6 in.) 3,520 2,070 — — 1,870 1,100 — — CSR40-149 & -150 PS Hermetic, June 2000...
Page 18: Electrical System
24 Vac @ 50 Hz Advanced Fresh Air Management (AFAM) Motor: Voltage 24 Vdc Evaporator Overheat Switch: Opens 54 +/- 3 C (130 +/- 5 F) Closes 38 +/- 4.5 C (100 +/- 8 F) CSR40-149 & -150 PS Hermetic, June 2000...
Page 19: 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! CSR40-149 & -150 PS Hermetic, June 2000...
Page 20: Mp-3000 Controller
24 hours. Defrost Timer: Reset to Base Time Defrost timer resets if the unit is Off more than 12 hours, setpoint is changed more than 5 C (9 F) or PTI Pretrip test occurs. CSR40-149 & -150 PS Hermetic, June 2000...
Page 21: Dehumidify And Humidify Systems (Options)
240-600 Vac; 55 to 70 Watts at -17.8 C (0 F) Water Temperature Humidity Sensor: Accuracy: +/- 1.5% between 55% and 75% Relative Humidity +/- 3.0% between 75% and 95% Relative Humidity Output Range: 4 to 20 milliamps 1% Relative Humidity = 0.2 milliamp CSR40-149 & -150 PS Hermetic, June 2000...
Page 22: Physical Specifications
72 mm (2.83 in.) from back of flange H = Maximum Protrusion 37 mm (1.46 in.) from back of flange I = Unit Depth: CSR40 PS 420.0 mm (16.54 in.) from back of flange CSR40-149 & -150 PS Hermetic, June 2000...
Page 23: Metric Hardware Torque Charts
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. CSR40-149 & -150 PS Hermetic, June 2000...
Page 25: Unit Description
CSR PS models are equipped with either 2 or 3 evaporator fans. All models feature 2-speed motors. The evaporator fans operate Model CSR40-149 & -150 PS units are all-electric, single- continuously to circulate air inside the container. The fans oper- piece, refrigeration units with top air supply.
Page 26: Unit Options
The con- troller can also be set to delay opening of the fresh air vent for up to 72 hours, in 1-hour increments. This allows faster prod- uct temperature pulldown. CSR40-149 & -150 PS Hermetic, June 2000...
Page 27: Operating Modes
• Defrost (resistance heaters on, evaporator fans stop) NOTE: If the Economy Mode is set to ON, the evaporator fans operate on low speed at set- points of -9.9 C (14.1 F) and above whenever the container temperature is In-range. CSR40-149 & -150 PS Hermetic, June 2000...
Page 28: Unit Illustrations
CSR40 PS: Evaporator Access Door, 1018 mm (40.08 in.) Wide with Two Latches Condenser Fan Compressor Compartment Return Air Sensor Probe Holder Power Cord Storage Compartment Control Box Rear Download and USDA Receptacle Panel (Access from Inside Container) Fresh Air Exchange Vent CSR40-149 & -150 PS Hermetic, June 2000...
Page 29: Unit Options Front View
Unit Description Unit Illustrations Unit Options Front View Recording Thermometer Option Dual Voltage Option Advanced Fresh Air Management (AFAM) Option Humidify System Option CSR40-149 & -150 PS Hermetic, June 2000...
Page 30: Csr40 Ps Evaporator Section - Front View
Evaporator Fan Motor Evaporator Fan Blade: • CSR40 PS: 355 mm (14.0 in.) diameter, 25 pitch Supply Air Sensing Bulb for Recording Thermometer (Option) Supply Air Sensor Humidify System Compressor (Option), see page 2-10 CSR40-149 & -150 PS Hermetic, June 2000...
Page 31: Hermetic Refrigeration System
Scroll Compressor 10. Suction Line Process Tube 11. Low Pressure Cutout Switch 12. Discharge Line Process Tube 13. High Pressure Cutout Switch 14. Condenser Coil 15. High Pressure Relief Valve 16. Receiver Tank CSR40-149 & -150 PS Hermetic, June 2000...
Page 32: Mp-3000 Controller
Special Function Keypad General Purpose Keypad LCD Display (Setpoint Temperature, Message and Controller Main Menu Tree Display) 10. LED Display (Return or Supply Air Temperature Display and Status Indicator LEDs) 11. MP-3000 Controller CSR40-149 & -150 PS Hermetic, June 2000...
Page 33: Unit Control Box
Unit Illustrations Unit Control Box Unit On/Off Switch Communications Connector for Data Retrieval Circuit Breaker Main Relay Board 12 Vdc Battery Control Power Transformer Compressor Contactors (2) 25 Ampere Main Power Circuit Breaker CSR40-149 & -150 PS Hermetic, June 2000...
Page 34: Humidify System Option
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 CSR40-149 & -150 PS Hermetic, June 2000...
Page 35: Advanced Fresh Air Management Option
2-11 Advanced Fresh Air Management (AFAM) Option Gasket Vent Door Assembly Linkage Assembly Damper Motor Housing Damper Motor Assembly Mounting Bracket Stop Bracket, Vent Door Full Open Stop Bracket, Vent Door Closed Grille CSR40-149 & -150 PS Hermetic, June 2000...
Page 36: Typical Unit Back View
Bottom Rear Plate Sensor Connector Assembly: • Controller Communications and Data Download Port • USDA1/Spare 1 Sensor Connection • USDA2/Spare 2 Sensor Connection • USDA3/Spare 3 Sensor Connection • Cargo (Pulp) Sensor Connection CSR40-149 & -150 PS Hermetic, June 2000...
Page 37: Operating Instructions
29 Vac control • Compressor (Cooling On) circuit. This circuit breaker is located in the control box • Heat (On) beside the On/Off switch. • Defrost • In-Range (Temperature) • Alarm CSR40-149 & -150 PS Hermetic, June 2000...
Page 38: Unit Protection Devices
(switch resets) if power is compressor contactor. available. The high pressure switch resets (closes) when the pressure drops to 1590 +/- 70 kPa, 15.9 +/- 0.7 bar, 230 +/- 10 psig. CSR40-149 & -150 PS Hermetic, June 2000...
Page 39: Pretrip Inspection
• Controller energizes unit loads, starting the evaporator PTI test ends automatically. Press any key on the con- fans. The condenser fan may also start (if required). troller to return the unit to normal operation. CSR40-149 & -150 PS Hermetic, June 2000...
Page 40: Starting The Unit And Adjusting The Controller
10. Stop the unit by moving the On/Off switch to the OFF NOTE: If the setpoint is not entered within 30 position. seconds, the controller will default (return) to the previous setpoint. If this occurs, repeat step 3. CSR40-149 & -150 PS Hermetic, June 2000...
Page 41: Loading Procedure
NOTE: The evaporator coil temperature must be below 18 C (65 F) to allow the unit the enter a defrost cycle. If the evaporator coil temperature is too high, the LCD display will read “Defrost Not Activated”. CSR40-149 & -150 PS Hermetic, June 2000...
Page 43: Mp3000 Controller
MENU. Use the keypad to scroll through messages F4 key. and the controller menu. 3. General purpose keys are used to enter text and scroll through menus. 4. Special function keys perform specific tasks. CSR40-149 & -150 PS Hermetic, June 2000...
Page 44: Controller Description
19. Manual emergency control capability. Manual control relay board. The main relay board contains: settings in the control box allow the unit to operate even CSR40-149 & -150 PS Hermetic, June 2000...
Page 45: Status Indicator Leds
DRU-II data transfer rate based on a 1 hour log interval is show current remote monitoring state (Offline, Zombie about 15 seconds per month of event logs and about 70 sec- or On-line). onds per month of temperature logs. For example, download- CSR40-149 & -150 PS Hermetic, June 2000...
Page 46: General Theory Of Operation
• Condenser fan operation • Evaporator fan motor operation • Stepper motor valve • Liquid injection valve • Dehumidify valve • Electric heaters • Phase selection CSR40-149 & -150 PS Hermetic, June 2000...
Page 47: Frozen Loads
LOW speed for 5 minutes every 45 minutes as long as the the standard power limit control algorithm. unit remains in the Null mode. NOTE: Setting power management current at 13 amps can be used to provide slow pull-down of loads. CSR40-149 & -150 PS Hermetic, June 2000...
Page 48 ECMIN temperature. Default ECMIN setting is 2.0 C (3.6 F) below setpoint. ECMIN temperature is adjustable from 0 to 5 C (0 to 8.9 F) below setpoint through the Configuration menu of the controller. CSR40-149 & -150 PS Hermetic, June 2000...
Page 49 The controller turns ON the In-range LED when the con- trolling sensor temperature is within 1.5 C (2.7 F) of the setpoint. NOTE: Random time delays during the initial unit start-up minimize peak current draw. CSR40-149 & -150 PS Hermetic, June 2000...
Page 50 0.3 C (0.5 F) of setpoint. • Controller turns ON the Heat LED whenever the heaters are pulsed ON and OFF. CSR40-149 & -150 PS Hermetic, June 2000...
Page 51 • Defrost mode: Controller turn heaters ON until evaporator coil temperature increases to: - Chill Loads: 30 C (86 F) or exceeds 18 C (65 F) for 15 minutes. - Frozen Loads: 18 C (65 F) or exceeds 8 C (46 F) for 15 minutes. CSR40-149 & -150 PS Hermetic, June 2000...
Page 52 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. CSR40-149 & -150 PS Hermetic, June 2000...
Page 53 2. Setpoint 3. Increasing Temperature *If the compressor stops, it must remain OFF for a mini- mum of 5 minutes. When the compressor re-starts, it must stay ON for a minimum of 5 minutes. CSR40-149 & -150 PS Hermetic, June 2000...
Page 54 SUP/RET key. The controller will show the alternate sensor temperature as long as the SUP/RET key is depressed. 3. The display then returns to the controlling sensor tempera- ture when the SUP/RET key is released. CSR40-149 & -150 PS Hermetic, June 2000...
Page 55 See “Changing the Setpoint” on page 4-12. F4 key: Press the F4 key to enter a new menu or sub- menu; to access a menu line to enter information; or to load a command or value. CSR40-149 & -150 PS Hermetic, June 2000...
Page 56 The new setpoint is recorded in the controller and appears in display. in the LCD display. 6. Press ESC key to exit the SETPOINT screen. 6. Press ESC key to exit the SETPOINT screen. CSR40-149 & -150 PS Hermetic, June 2000...
Page 57 • Press F4 key. — CO 2 Maximum • Press F2 key to toggle setting between OFF and ON. • Press and hold F4 key until cursor stops flashing. Setpoint Menu Screen Flow Diagram CSR40-149 & -150 PS Hermetic, June 2000...
Page 58 Alarm code 56 (com- — CO 2 pressor temperature too high) is a shutdown alarm. — Fresh Air Exchange Rate — Evaporator Fan Speed — Supply Air Temp, LH Data Menu Screen Flow Diagram CSR40-149 & -150 PS Hermetic, June 2000...
Page 59 Heater Current Too High alarm code. • Clear alarm code by correcting problem and acknowledging the alarm. • To acknowledge an alarm, press F4 key with alarm code in display. Alarms Menu Screen Flow Diagram CSR40-149 & -150 PS Hermetic, June 2000...
Page 60 Compressor Sensor Short Circuit NOT ACTIVATED (evaporator temperature above 18 C Check USDA 1 Sensor Open Circuit [50 F]) or ALREADY ACTIVATED (defrost in Check Zero Current Too High progress). Defrost cycle ends automatically. CSR40-149 & -150 PS Hermetic, June 2000...
Page 61 ON at a time to perform determined by the Controller Software setting cursor stops flashing. a functional test of the unit. and the options installed on the unit. Commands Menu Screen Flow Diagram CSR40-149 & -150 PS Hermetic, June 2000...
Page 62 3. Press F2 or F3 key to scroll to Manual Function Test. Observe current draw and system performance to ver- 4. Press F4 key to enter the Manual Function Test: “CON- ify component(s) performance. DENSER OFF” appears in the LCD display. CSR40-149 & -150 PS Hermetic, June 2000...
Page 63 Amp draw is measured and compared to voltage. Evaporator temperature and condenser coil temperature are measured and stored. NOTE: If the condenser temperature is below 15 C (59 F), the condenser fan remains OFF for this test. CSR40-149 & -150 PS Hermetic, June 2000...
Page 64 0.1 A 0.0 A 0.1 A verify valve operation. Function Test log ends. Alarms (if any) are cleared from data logger. However, alarms (if any) remain in alarm list as not active until acknowledged. CSR40-149 & -150 PS Hermetic, June 2000...
Page 65 1.0 Amps approx. at 60 Hz • CSR20 PS and CSR40SL PS: 1.5 Amps approx. at 50 Hz, 1.6 Amps approx. at 60 Hz Evaporator fan high speed amperes are recorded in PTI log. CSR40-149 & -150 PS Hermetic, June 2000...
Page 66 Condenser fan, compressor and liquid injection 10 Seconds Activated valve remain ON. Stepper valve is closed (set 0.8 A 0.7 A 0.8 A to 100 value) and low pressure cutout is verified to open. CSR40-149 & -150 PS Hermetic, June 2000...
Page 67 50% capacity. on CSR20) Liquid injection valve is turned ON. A difference of approx. 4.5 C (8.0 F) is required between return and supply air temperatures, depending on return air and condenser coil temperatures. CSR40-149 & -150 PS Hermetic, June 2000...
Page 68 If return air temperature is below 5 C (41 F), None Activated evaporator fans operate on high speed and Minutes 7.9 A 7.9 A 7.9 A heaters turn ON. Unit operates until return air Maximum temperature is above 5 C (41 F). CSR40-149 & -150 PS Hermetic, June 2000...
Page 69 If alarms (errors) occurred during PTI test, NONE — Temp. Press (Any) Key LCD display shows PTI FAIL. Press any key to clear display. Unit will remain OFF unit any key is pressed again. CSR40-149 & -150 PS Hermetic, June 2000...
Page 70 7. Press ESC key to exit the Power Management submenu. 4. To enter a new time, press F4 key with cursor in Time menu line. An Enter Arrow appears in the menu line and the previous time disappears. CSR40-149 & -150 PS Hermetic, June 2000...
Page 71 — MISC FUNCTIONS • Press and hold F4 key until — CONFIGURATION cursor stops flashing. — DATALOGGER — RMM STATE Misc. Functions Menu Screen Flow Diagram CSR40-149 & -150 PS Hermetic, June 2000...
Page 72 The new run time appears in the menu line. Repeat steps 5 and 6 to reset additional hourmeters. 7. Press ESC key to exit the Run Time screen. CSR40-149 & -150 PS Hermetic, June 2000...
Page 73 — MISC FUNCTIONS setting. — AFAM Setup — CONFIGURATION • Press and hold F4 key until — Auto Configuration — DATALOGGER cursor stops flashing. — Serial Number — RMM STATE Configuration Menu Screen Flow Diagram CSR40-149 & -150 PS Hermetic, June 2000...
Page 74 • Defrost end (start time) D = Defrost in Last Interval O = Temperature Not In-range 6. Press ESC key to exit the Event Log. h = Humidity Control Active E = Evaporator High Temperature CSR40-149 & -150 PS Hermetic, June 2000...
Page 75 - Activate Tripstart: Press F4 — MISC FUNCTIONS key to enter trip start marker. — CONFIGURATION - Inspect PTI Log: Press F3 key — DATALOGGER through test result screens. — RMM STATE Datalogger Menu Screen Flow Diagram CSR40-149 & -150 PS Hermetic, June 2000...
Page 76 — DATA — ALARMS — COMMANDS — MISC FUNCTIONS — CONFIGURATION — DATALOGGER RMM Status — RMM STATE Display shows current status: • Offline • Zombie • On-line RMM State Menu Screen Flow Diagram CSR40-149 & -150 PS Hermetic, June 2000...
Page 77 After the initial unit Manual Emergency Control Connections powerup, the controller turns the Auto Configuration feature Off. CSR40-149 & -150 PS Hermetic, June 2000...
Page 78 Start flash load program on portable computer. 35.6 5155 100.4 1239 6. Flash loading of new software is complete when “FLASH 39.2 4721 1154 LOADING” clears from the LCD display. 42.8 4329 107.6 1076 46.4 3907 111.2 1004 3652 CSR40-149 & -150 PS Hermetic, June 2000...
Page 79 Insert Sensor into condenser coil between Tube Rows 1 and 2 CSR40 PS Evaporator Coil (Defrost) Sensor Location Coil Support Bracket Unit Front Insert Sensor at least 75 mm into coil between Tube Rows 2 and 3 CSR40-149 & -150 PS Hermetic, June 2000...
Page 80 Then press F4 key, F2 key, “A” key, F4 key and EXIT key. Cursor moves to end of line and flashes. Pressure F3 key to toggle OFF to ON. Then press and hold F4 key until cursor stops flashing. CSR40-149 & -150 PS Hermetic, June 2000...
Page 81 • Controller uses right hand supply sensor to control unit if left hand sensor is defective. • Controller uses return sensor plus an offset to control unit if both supply sensors are defective. CSR40-149 & -150 PS Hermetic, June 2000...
Page 82 KVQ/CRR40 PS, CSR40 PS or CSR40 Magnum unit. Correct by turning Unit On/Off switch OFF. Then set controller software switch to correct position. See Controller Software Selection on page 4-36. CSR40-149 & -150 PS Hermetic, June 2000...
Page 83 • Possible causes include evaporator unit current draw is too high (alarm 36), or defrost temperature over 54 C (130 F), defective time is too long (alarm 20). heater, defective evaporator overheat switch, open circuit, etc. CSR40-149 & -150 PS Hermetic, June 2000...
Page 84 • Check cable No. 1 between controller and relay • Temperature below -70 C (-94 F). board. • Indicates: - Open circuit to sensor - Defective or wrong sensor - Defective relay board - Defective cable No. 1 - Defective controller CSR40-149 & -150 PS Hermetic, June 2000...
Page 85 • Check cable No. 1 between controller and relay • Temperature above 80 C (176 F). board. • Indicates: - Short circuit to sensor - Defective or wrong sensor - Defective relay board - Defective cable No. 1 - Defective controller CSR40-149 & -150 PS Hermetic, June 2000...
Page 86 *NOTE: If both alarms 06 and 07 are activated, the alarms are caused by a large difference in measured amps. Enter Function Test and start condenser fan, compressor, compressor 100% and evaporator fans on HIGH speed. Check the amps measurements. If necessary, check the resistance of the motor windings. CSR40-149 & -150 PS Hermetic, June 2000...
Page 87 Enter Manual Function Test menu and start HEAT. Check the amps measurements. If necessary, check the resistance between H1 and H2, H2 and H3, and H1 and H3. Resistance should be about 99 ohms on each leg. **See note on next page. CSR40-149 & -150 PS Hermetic, June 2000...
Page 88 EF11 and EF12, EF12 and EF13, and EF11 and EF13; Low speed between EF1 and EF2, EF2 and EF3, and EF1 and EF3. Resistance readings should be equal: High speed about 6 Ohms, total of 2 motors; Low speed about 20 Ohms, total of 2 motors. CSR40-149 & -150 PS Hermetic, June 2000...
Page 89 Enter Manual Function Test menu and start the condenser fan. Check the condenser fan amps measurement. If necessary, check the resistance in the motor between CF1 and CF2, CF2 and CF3, and CF1 and CF3. Resistance readings should be equal (approximately 25 Ohms). CSR40-149 & -150 PS Hermetic, June 2000...
Page 90 NOTE: This alarm can be activated at low voltage protection switch and very low box temperature conditions, even under - Defective heat relay normal operating conditions. - Evaporator fans running during defrost - Evaporator sensor placed wrong CSR40-149 & -150 PS Hermetic, June 2000...
Page 91 (low). Check the refrigerant charge using the “Unit Health Check Procedure” on page 6-5. NOTE: This alarm can be activated in ambient tem- peratures below -10 C (14 F), even under normal con- ditions. CSR40-149 & -150 PS Hermetic, June 2000...
Page 92 (high). Check leaking the refrigerant charge using the “Unit Health Check Procedure” on page 6-5. NOTE: Alarm can be activated in ambient tempera- tures below -10 C (14 F), even under normal condi- tions. CSR40-149 & -150 PS Hermetic, June 2000...
Page 93 • Indicates: - Evaporator coil sensor is not in contact with evaporator coil - Return and evaporator coil sensor connections are interchanged - Expansion valve does not open enough or opens too much CSR40-149 & -150 PS Hermetic, June 2000...
Page 94 - Faulty bypass valve or circuit for continuity using a high quality multimeter. • Check the circuit wiring in plug J11 for continuity using a high quality multimeter and a wiring dia- gram. CSR40-149 & -150 PS Hermetic, June 2000...
Page 95 • Check cable No. 1 between controller and relay • Temperature below -70 C (-94 F). board. • Indicates: - Open circuit to sensor - Defective or wrong sensor - Defective relay board - Defective cable No. 1 - Defective controller CSR40-149 & -150 PS Hermetic, June 2000...
Page 96 • Check cable No. 1 between controller and relay • Temperature above 80 C (176 F). board. • Indicates: - Short circuit to sensor - Defective or wrong sensor - Defective relay board - Defective cable No. 1 - Defective controller CSR40-149 & -150 PS Hermetic, June 2000...
Page 97 - Air leakage at supply air sensor cable • Check supply and return sensor connections and - Ice or frost on evaporator coil locations. - Incorrect evaporator fan operation CSR40-149 & -150 PS Hermetic, June 2000...
Page 98 • Check the refrigerant charge using the “Unit Health • Indicates: Check Procedure” on page 6-5. - Low refrigerant charge. - Defective evaporator coil or return air sensor - Incorrect connection or location of evaporator coil or return air sensor CSR40-149 & -150 PS Hermetic, June 2000...
Page 99 • Temperature difference between LH supply and RH supply sensors is too high (0.5 C [1.0 F] difference maximum) • Indicates: - Incorrect temperature reading on one sensor - Supply air sensor not placed in airflow stream CSR40-149 & -150 PS Hermetic, June 2000...
Page 100 - High pressure cutout switch did not respond (switch closes). to pressure change within 5 seconds - Air in refrigeration system - Defective high pressure cutout switch CSR40-149 & -150 PS Hermetic, June 2000...
Page 101 • During Phase Sensor Test, amperage difference between correct and wrong condenser fan rotation is more than 0.2 amps. • Indicates: - Defective phase relay - Defective relay board - Defective relay board cable No. 2 CSR40-149 & -150 PS Hermetic, June 2000...
Page 102 NOTE: Unit will operate normally without compressor - Defective or wrong sensor sensor. However, controller compressor high - Defective relay board temperature protection is not active. - Defective cable No. 1 - Defective controller CSR40-149 & -150 PS Hermetic, June 2000...
Page 103 • Enter Manual Function Test menu and test (operate) (Check Alarm) each motor and heater separately. Note when alarm occurs. • Ground (zero current) circuit 30 milliamps. • Indicates: - Defective motor or heater insulation to ground CSR40-149 & -150 PS Hermetic, June 2000...
Page 105 Compressor will restart when the overload condition is corrected (switch closes) as long as power is available. High Pressure Cutout Manifold 1. Relief Valve, P/N 66-6543 2. O-ring, P/N 33-1015 3. Adapter Tee (Weather Head No. 552X3) CSR40-149 & -150 PS Hermetic, June 2000...
Page 106 If the low pressure cutout switch is suspected of being are used on LOW SPEED fan operation. Wires EF11, defective, replace it with a known good switch. EF12 and EF13 are used on HIGH SPEED fan opera- tion. CSR40-149 & -150 PS Hermetic, June 2000...
Page 107 0.8 meg ohms, isolate and check the with heat shrink tubing. All heaters should be resistance of each individual heater element. secured to prevent contact with sharp metal edges. CSR40-149 & -150 PS Hermetic, June 2000...
Page 109 10. Repeat step 9 until all alarm codes have been recorded. tem. WARNING: Some unit malfunctions will cause an Alarm and unit shutdown condition. When the alarm codes are cleared, the unit will start auto- matically. CSR40-149 & -150 PS Hermetic, June 2000...
Page 110 -46 Evaporator Coil Temperature Too Low (Check Alarm) -53 High Pressure Cutout Switch Off Error (Check Alarm) -54 High Pressure Cutout Switch On Error (Check Alarm) -56 Compressor Temperature Too High (Shutdown Alarm) CSR40-149 & -150 PS Hermetic, June 2000...
Page 111 - Air in refrigeration system - Overcharge of refrigerant: Install service valves and gauge manifold set. Check system operating pressures. After all other components have been checked, remove refrigerant charge and weight in new charge CSR40-149 & -150 PS Hermetic, June 2000...
Page 112 Perform an oil acid test (oil test kit P/N 203-457) whenever a 404A only. Piercing type service valves require that the gauge unit has a substantial refrigerant loss, a noisy compressor or manifold set connect to 1/4” flare fittings: dark/dirty oil. CSR40-149 & -150 PS Hermetic, June 2000...
Page 113 (-5.8 C (50 -6.4 (-11.5 -4.8 (-8.6 C (60 C (-20 -3.0 (-5.4 -2.3 (-4.1 C (0 -4.9 (-8.8 -3.7 (-6.6 C (30 -4.7 (-8.5 -3.5 (-6.4 C (50 -5.6 (-10.1 -4.2 (-7.6 CSR40-149 & -150 PS Hermetic, June 2000...
Page 114 — DO NOT USE! Balancing the Pressure 1. Quick Disconnect Access Valve 2. Discharge Service Valve (DSV) 3. Suction Service Valve (SSV) CSR40-149 & -150 PS Hermetic, June 2000...
Page 115 Charging the System 1. Quick Disconnect Access Valve 1. Quick Disconnect Access Valve 2. Discharge Service Valve (DSV) 2. Discharge Service Valve (DSV) 3. Suction Service Valve (SSV) 3. Suction Service Valve (SSV) CSR40-149 & -150 PS Hermetic, June 2000...
Page 116 Gauge Manifold Closed to Center Port 1. Close Hand Valves Purging Gauge Manifold 1. Quick Disconnect Access Valve Gauge Manifold Open to Center Port 2. Discharge Connection 3. Suction Connection 1. Open Hand Valves CSR40-149 & -150 PS Hermetic, June 2000...
Page 117 Dehydration, pressure testing, purging and soldering can be accomplished with the use of dry nitrogen (N 2 ). The prop- er equipment and application of equipment is of greatest importance. Testing for Refrigerant Leaks CSR40-149 & -150 PS Hermetic, June 2000...
Page 118 R-404A recovery. 3. Connect charging hose to a source of nitrogen. Adjust pressure regulator to the proper pressure for the required When removing any refrigerant from a Thermo King refrigera- procedure. tion system, use a recovery process that prevents or absolutely 4.
Page 119 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 120 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. Calibration Standard 7. Micron Meter 8. Sensor CSR40-149 & -150 PS Hermetic, June 2000...
Page 121 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 122 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 CSR40-149 & -150 PS Hermetic, June 2000...
Page 123 Leak check the process tubes with an electronic leak any solder operations (see “Using Pressurized detector. Nitrogen” in this chapter). 10. Start the unit and perform a controller Pretrip Test to veri- fy correct refrigerant charge and unit operation. CSR40-149 & -150 PS Hermetic, June 2000...
Page 124 CAUTION: Do NOT splice or damage sensor 1. Loosen sensor cap from compressor body by cutting leads or compressor damage will occur. through RTV sealant with razor knife. Cut complete- ly around the cap. CSR40-149 & -150 PS Hermetic, June 2000...
Page 125 Replace the condenser coil support brackets, condenser fan shroud and condenser fan grille. Recharge the unit with R-404A (see “Refrigerant Charge” in this chapter). Then perform a controller Pretrip Test to verify system operation. CSR40-149 & -150 PS Hermetic, June 2000...
Page 126 9. Cover expansion valve outlet line with insulating tape. 10. Recharge the unit with R-404A (see “Refrigerant Charge” in this chapter). Then perform a controller Pretrip Test to verify system operation and correct feeler bulb installa- tion. CSR40-149 & -150 PS Hermetic, June 2000...
Page 127 Cover with insulating tape. 9. Recharge the unit with R-404A (see “Refrigerant Charge” in this chapter). Then perform a controller Pretrip Test to verify system operation and correct feeler bulb installa- tion. CSR40-149 & -150 PS Hermetic, June 2000...
Page 128 7. Recharge the unit with R-404A (see “Refrigerant Charge” in this chapter). Then perform a controller Pretrip Test to this chapter). verify system operation. 8. Perform a controller Pretrip Test to verify system opera- tion. CSR40-149 & -150 PS Hermetic, June 2000...
Page 129 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 CSR40-149 & -150 PS Hermetic, June 2000...
Page 130 1. Evaporator Fan Blade 2. 10 mm (0.4 in.) 2. Airflow Direction 3. Condenser Coil 3. Evaporator Coil 4. Condenser Fan Blade 4. Evaporator Motor 5. Condenser Motor 5. 13 mm (0.5 in.) CSR40-149 & -150 PS Hermetic, June 2000...
Page 131 5. Water Tank Heater: Check for correct operation in it is attached. ambient temperatures below 4 C (40 F). 6. Drain Cock CSR40-149 & -150 PS Hermetic, June 2000...
Page 132 NOT bend the bulb. Install a new thermal element in the recorder case. Replace the element flange screws (D) and tighten secure- Check the calibration of the recorder. Recalibrate the recorder if necessary. CSR40-149 & -150 PS Hermetic, June 2000...
Page 133 L-rod addi- tional rotations. Shorten linkage until linkage alignment is correct. AFAM System Linkage Adjustment 1. Cotter Pins 2. Shoulder Washer 3. Pin 4. Rod End 5. L-Rod 6. Vent Motor Linkage CSR40-149 & -150 PS Hermetic, June 2000...
Page 134 Lengthen linkage until door gasket seals tightly against the air exchange openings. 6. When linkage is properly adjusted, fasten rod end securely to door bracket with pin and cotter pin. CSR40-149 & -150 PS Hermetic, June 2000...
Page 135 Check liquid injection (fault code 56) 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 CSR40-149 & -150 PS Hermetic, June 2000...
Page 136 Refrigerant overcharge causing Purge system cycling on high pressure cutout Inefficient condenser operation Check condenser airflow, condenser causing cycling on high pressure fan motor, fan blade, condenser grille and cutout condenser coil temperature sensor CSR40-149 & -150 PS Hermetic, June 2000...
Page 137 Repair or replace as necessary Defective motor Replace motor Defective condenser fan contactor Replace defective contactor No condenser fan output Diagnose and replace condenser fan relay, signal from controller main relay board, or controller CSR40-149 & -150 PS Hermetic, June 2000...
Page 138 Defective low or high speed Replace defective contactor evaporator fan contactor No low or high speed evaporator Diagnose and replace evaporator fan relay, fan output signal from controller main relay board or controller CSR40-149 & -150 PS Hermetic, June 2000...
Page 139 Main Relay Board Terminal Connections (Page 3 of 3) Refrigeration System Components Full Cool Flow and Pressure Diagram Cool with Modulation Flow and Pressure Diagram 9-10 Dehumidification Flow and Pressure Diagram 9-11 MP-3000 Menu Flow Diagram 9-12 CSR40-149 & -150 PS Hermetic, June 2000...
Page 140 Electrical, Refrigeration and MP-3000 Menu Flow Diagrams This page intentionally left blank. CSR40-149 & -150 PS Hermetic, June 2000...
Page 150 Standard Display NOTE: The screens that display on the controller Keypad Operating Tips are determined by the Unit Configuration setting. All screens are NOT present on all units. Text Input: Use F1, F2, F3 and F4 keys to enter text in information screens: •...

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