Sp truck single-temperature gdp compliant (44 pages)
Summary of Contents for Thermo King MAGNUM PLUS 098212
Page 1
Maintenance Manual Container Edition MAGNUM PLUS® ® with MP4000 Revision A T T K K 6 6 0 0 2 2 7 7 5 5 - - 4 4 - - M M M M - - E E N N October 2019...
Page 2
This manual is published for informational purposes only. Thermo King® makes no representations warranties express or implied, with respect to the information recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or covering all contingencies. If further information is required, Thermo King Corporation Service Department should be consulted.
Page 3
Regulations must be observed when working on refrigeration systems. 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.
Table of Contents S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s ................................1 1 2 2 Danger, Warning, Caution, and Notice .
Page 5
T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Condenser Fan Control ............... . . 31 USDA Cold Treatment Temperature Recording (Standard).
T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Low Speed Fans Only............... 55 N N a a v v i i g g a a t t i i n n g g C C o o n n t t r r o o l l l l e e r r O O p p e e r r a a t t i i n n g g M M e e n n u u .
T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s PTI (Pretrip) Tests ................81 Manual Function Test.
Page 8
T T a a b b l l e e o o f f C C o o n n t t e e n n t t s s Chill Loads (Controller Setpoint at -9.9 C [14.1 F] and Above)........99 Cool with Modulation.
Safety Precautions Danger, Warning, Caution, and Notice Thermo King® recommends that all service be performed by a Thermo King dealer and to be aware of several general safety practices. Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this unit depend upon the strict observance of these precautions.
Page 13
S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s D D A A N N G G E E R R R R e e f f r r i i g g e e r r a a n n t t V V a a p p o o r r H H a a z z a a r r d d ! ! D D o o n n o o t t i i n n h h a a l l e e r r e e f f r r i i g g e e r r a a n n t t .
S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s Refrigerant Hazards D D A A N N G G E E R R H H a a z z a a r r d d o o u u s s P P r r e e s s s s u u r r e e s s ! ! A A l l w w a a y y s s s s t t o o r r e e r r e e f f r r i i g g e e r r a a n n t t i i n n p p r r o o p p e e r r c c o o n n t t a a i i n n e e r r s s , , o o u u t t o o f f d d i i r r e e c c t t s s u u n n l l i i g g h h t t a a n n d d a a w w a a y y f f r r o o m m i i n n t t e e n n s s e e h h e e a a t t .
S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s W W A A R R N N I I N N G G H H a a z z a a r r d d o o u u s s V V o o l l t t a a g g e e ! ! T T r r e e a a t t a a l l l l w w i i r r e e s s a a n n d d c c o o n n n n e e c c t t i i o o n n s s a a s s i i f f t t h h e e y y w w e e r r e e h h i i g g h h v v o o l l t t a a g g e e u u n n t t i i l l a a m m e e t t e e r r a a n n d d w w i i r r i i n n g g d d i i a a g g r r a a m m i i n n d d i i c c a a t t e e o o t t h h e e r r w w i i s s e e .
S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s preventive equipment when handling and servicing the controller. The second cause results from electric welding on the unit and container chassis without taking precautionary steps.
Page 17
S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s E E N N G G I I N N E E C C O O O O L L A A N N T T •...
Identifying Unit Safety and Warning Decals Serial number decals, refrigerant type decals, and warning decals appear on all Thermo King® equipment. These decals provide information that may be needed to service or repair the unit. Service technicians should read and follow the instructions on all warning decals.
Page 19
S S a a f f e e t t y y P P r r e e c c a a u u t t i i o o n n s s Label on Controller ID in Controller Controller ID Shown in Datalogger TK 60275-4-MM-EN...
Page 20
Service Guide A closely followed maintenance program will help to keep your Thermo King unit in top operating condition. The following table should be used as a guide when inspecting or servicing components on this unit. Pretrip Every Annual/ Inspect/Service These Items...
Specifications System Net Cooling Capacity - Full Cool Table 1. MAGNUM PLUS Model - Air Cooled Condensing* Return air to evaporator 460/230V, 3 Phase, 60 Hz Power coil inlet Net Cooling Capacity Power Consumption 60 Hz Capacity B/hr 60 Hz Capacity kW 60 Hz Power kW 21.1 C (70 F) 56,700...
S S p p e e c c i i f f i i c c a a t t i i o o n n s s Electrical System Compressor Motor Type 460/380V, 60/50 Hz, 3 Phase Kilowatts 4.48 kW @ 460V, 60 Hz Horsepower 6.0 hp @ 460V, 60 Hz 3550 RPM @ 460V, 60 Hz...
MP4000 Controller Specifications Temperature Controller Type MP4000 is a controller module for the Thermo King units. Additional requirements can be met by means of expansion modules. The MP4000 is solely responsible for temperature regulation of the reefer container, but other monitoring equipment can be used in conjunction with the MP4000, such as a chart recorder.
Page 24
S S p p e e c c i i f f i i c c a a t t i i o o n n s s Setpoint Range -40.0 to +30.0 C (-31.0 to +86.0 F) -30.0 to +30.0 C (-22.0 to +86.0 F) Digital Temperature Display -60.0 to +80.0 C (-76.0 to +176.0 F) Controller Software (Original Equipment)
S S p p e e c c i i f f i i c c a a t t i i o o n n s s Physical Specifications Table 4. Fresh Air Exchange Venting System (Adjustable) MAGNUM PLUS 0 to 225 m /hr (0 to 168 ft /min.) @ 60 Hz...
S S p p e e c c i i f f i i c c a a t t i i o o n n s s Metric Hardware Torque Charts Bolt Size Bolt Type and Class* M6 N.m (Ft.-lb.) M8 N.m (Ft.-lb.) M10 N.m (Ft.-lb.) M12 N.m (Ft.-lb.)
Unit Description General Description Units are all-electric, single-piece, refrigeration units with bottom air supply. The unit is designed to cool and heat containers for shipboard or overland transit. The unit mounts in the front wall of the container. Fork lift pockets are provided for installation and removal of the unit The frame and bulkhead panels are constructed of aluminum and are treated to resist corrosion.
U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Digital Port The digital port provides cooling capacity control. The digital port is located at the top of the scroll assembly on the compressor body.
U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Part number for the MP3000 MRB fuse (F 20 amp 500V and red fuse holder) is: P/N 419318 Fuse & Holder Red MP3000. Fuse and fuse holder will be sold together as a kit.
U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n • Compressor Discharge Temperature Sensor • Ambient Air Fresh Air Exchange System The fresh air exchange system removes harmful gases from containers carrying sensitive perishable commodities.
Condenser Fan Selection switch or a Water Pressure switch. Starting April 2005, Thermo King has added a shutoff valve on the outlet tube of the water-cooled condenser. Condenser fan switch is a software key. This switch is provided on the control box with the water-cooled condenser option.
U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Vent Door Door Control Module Interface Module Board and Cable (mounts in Control Box) Grille AFAM Vent Door Assembly...
Page 34
U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Unit Front View Evaporator Access Door Condenser Fan Compressor Compartment Scroll Compressor Control Box Rear Download and USDA Receptacle Panel...
Page 35
U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Figure 3. Refrigeration System Expansion Valve Receiver Tank Low Pressure Cutout Switch Evaporator Coil Scroll Compressor Economizer Heat Exchanger...
Page 36
U U n n i i t t D D e e s s c c r r i i p p t t i i o o n n Figure 4. Electrical Components Sensor Kit Heater Group Humidity Sensor Cable Connection Evaporator Fans Condenser Fan Motor...
Controller Description MP4000 Controller The MP4000 is an advanced microprocessor controller. It has been specially developed for the control and monitoring of refrigeration units. The controller contains the following basic features: • Temperature/Message Status Display – Temperature area: Displays return air sensor, supply air sensor, and setpoint. –...
C C o o n n t t r r o o l l l l e e r r D D e e s s c c r r i i p p t t i i o o n n Compressor On Loaded without Vapour Injection Battery Error (Datalogger Battery) Compressor On Loaded with Vapour Injection...
F4 MENU Key: Press to view the extended Menu for the MP4000. Special Function Keys The Special Function keys are located around the Thermo King logo. These special function key allow the operator to move quickly to perform a specific function •...
Operating Instructions Function Keys Function Keys ON/OFF Key Defrost Key PTI - Pre-trip Inspection Alarm Key C/F Key Setpoint Key Menu Key Unit On/Off Key ON - Unit will operate on Cool or Heat depending on the controller setpoint temperature and the container air temperature.
O O p p e e r r a a t t i i n n g g I I n n s s t t r r u u c c t t i i o o n n s s Low Speed Fans Only N N O O T T I I C C E E C C a a r r g g o o L L o o s s s s ! !
Navigating Controller Operating Menu Figure 6. MP4000 Control Panel Display Menu Scrolling Keys Moving through these seven menus, their submenus, and entering commands requires the use of four keys: EXIT - Press the F1 key each time you want to exit a submenu shown in the message display. UP/ DOWN - Press the F2 or F3 key each time you want to scroll up or down in a menu or submenu shown in the Message Display;...
Main Menu Main Menu From the Standard Display, press the MENU F4 key to enter the Main Menu as shown below. The Main Menu allows access to several other submenus using the UP F3, DOWN F3, and ENTER F4 keys. The other submenus are described below.
M M a a i i n n M M e e n n u u Figure 7. Controls Menu and Controls Overview Cold Treatment (CT) This feature is designed to maintain a temperature below the actual set point for a period of time, (per USDA specifications) and then increase the temperature to the final set point.
M M a a i i n n M M e e n n u u Figure 9. Multiple Temperature Set OptiSet™ ™ Allows all the AFAM variable to be set by selecting a specify commodity. Refer to (“Change the AFAM+ Settings Using OptiSet™,”...
M M a a i i n n M M e e n n u u • Bulb mode LOW: Evaporator fan low speed only. • Bulb mode CYCLE: Evaporator fan cycle - fans will cycle between low and high speed every 60 minutes, starting with the low speed fan operation first for 60 minutes.
M M a a i i n n M M e e n n u u Figure 13. Water Cooled Condenser Dehumidify Control During Chill mode operation, a dehumidification function is available (optional after Sep 2019) to reduce the relative humidity in the container to the desired humidity setpoint.
M M a a i i n n M M e e n n u u Figure 15. Dehumidify Setpoint AVL (Air Ventilation Logging) The Fresh Air Exchange Recorder (AVL) detects vent disk movement and automatically displays a value in the LCD display for values of 0 to 125 m3/h.
M M a a i i n n M M e e n n u u Figure 17. AFAM Mode Fresh Air Vent Man - AFAM+ Mode Can be set to OFF, AFAM, or AFAM+. OFF - Will override all settings and keep the AFAM door completely closed. AFAM - Will allow and air exchange Rate and or Delay to be set.
M M a a i i n n M M e e n n u u Figure 19. AFAM Delay AFAM Rate Use to set AFAM door opens to desired rate, selectable from 0 CMH to 225 CMH. Figure 20. AFAM Rate AFAM+ CO2 Max Used to set the highest level of Carbon Dioxide allowed in the container.
M M a a i i n n M M e e n n u u Figure 21. CO2 Max AFAM+ O2 Min Used to set the lowest level of Oxygen allowed in the container. The AFAM+ door will open or close to maintain this level.
M M a a i i n n M M e e n n u u Figure 23. Smart PTI Silent Mode Silent mode is a way to make the reefer unit silent without manual switching it OFF and ON. The feature is normally used when the reefer unit is located near public areas where the noise from the unit is annoying and not acceptable during ie.
M M a a i i n n M M e e n n u u BEE681 BEE680 BEE680 At the temperature log the flag ‘s’ will be set to indicate the halted operation. Changing the configuration of the mode is documented in the event log. Since the unit is not allowed to operate during the silent period, the normal surveillance is not ongoing.
M M a a i i n n M M e e n n u u Figure 24. No Alarms or Newest Alarm Alarm Code States There are three alarm code states for Shutdown and Check alarms: • Active: A code condition has occurred and continues to exist in the unit or the code condition occurred within the past one hour but does not currently exist in the unit.
M M a a i i n n M M e e n n u u For a complete list of status messages and controller actions, refer to (“Status Messages and Controller Actions,” p. 160). Figure 25. No Messages or Newest Message Configuration Menu The Configuration menu displays a list of functions that identifies unit operating features and current settings.
M M a a i i n n M M e e n n u u Unit Figure 27. Unit Menu and Unit Overview • In-Range Temperature limit: Sets the temperature value for the controller’s in-range LED and datalogger functions (factory default = 1.5 C [2.7 F]).
M M a a i i n n M M e e n n u u Options This menu is used to turn ON/OFF a Module/Feature, select a particular option within a module, and tell the controller when a sensor is mounted. •...
Page 73
M M a a i i n n M M e e n n u u TK 60275-4-MM-EN...
M M a a i i n n M M e e n n u u System N N o o t t e e : : Units without a container number beginning with MAE, MSF, or MWC must be set for USDA temperature sensing. Figure 28.
M M a a i i n n M M e e n n u u Clock Displays current Date and Time, which can be edited. 1. Press the F4 key. Press the F3 key to scroll down to the CONFIGURATION Menu. 2.
M M a a i i n n M M e e n n u u Calibrate Used to calibrate sensor probes. For Cld Treatment refer to “Cold Treatment (CT),” p. 104 Icon Menu 1. Press the F2 or F3 UP/DOWN key to scroll to the Configuration selection and press the F4 key. The Configuration Menu will appear.
M M a a i i n n M M e e n n u u 3. Press the F4 key. The Configuration Menu will appear. 4. Press the F2 or F3 UP/DOWN key to scroll to the Classic Menu selection. 5.
M M a a i i n n M M e e n n u u Info Menu This menu displays controller software application version, bootloader version, power module version, serial number, and option file version. It also displays expansion slots if used. Figure 30.
Special Function Keys - User Activated Commands PTI Key Pressing the PTI key will access various PTI Commands for selecting a user activated functionality. • Manual Function Test: Refer to (“Manual Function Test,” p. 81) for detailed information. • Function Test: Refer to (“Function Test,”...
S S p p e e c c i i a a l l F F u u n n c c t t i i o o n n K K e e y y s s - - U U s s e e r r A A c c t t i i v v a a t t e e d d C C o o m m m m a a n n d d s s Show PTI Info Defrost Key To access the Defrost Menu, turn the unit On and allow the unit to start and stabilize and show the unit status display...
S S p p e e c c i i a a l l F F u u n n c c t t i i o o n n K K e e y y s s - - U U s s e e r r A A c c t t i i v v a a t t e e d d C C o o m m m m a a n n d d s s PTI (Pretrip) Tests N N O O T T I I C C E E C C a a r r g g o o L L o o s s s s ! !
Page 82
S S p p e e c c i i a a l l F F u u n n c c t t i i o o n n K K e e y y s s - - U U s s e e r r A A c c t t i i v v a a t t e e d d C C o o m m m m a a n n d d s s •...
Page 83
S S p p e e c c i i a a l l F F u u n n c c t t i i o o n n K K e e y y s s - - U U s s e e r r A A c c t t i i v v a a t t e e d d C C o o m m m m a a n n d d s s Table 40.
Page 84
S S p p e e c c i i a a l l F F u u n n c c t t i i o o n n K K e e y y s s - - U U s s e e r r A A c c t t i i v v a a t t e e d d C C o o m m m m a a n n d d s s Table 40.
S S p p e e c c i i a a l l F F u u n n c c t t i i o o n n K K e e y y s s - - U U s s e e r r A A c c t t i i v v a a t t e e d d C C o o m m m m a a n n d d s s Table 40.
Page 86
Air Ventilation Logging (AVL) The Air Ventilation Logging option detects vent disk movement and automatically displays a value on the display. This value is also logged in the datalogger. The entry records the time, date, and vent opening position. It is mounted on the fresh air vent door.
Advanced Fresh Air Management (AFAM) System Starting the AFAM System 1. Press the F4 key to enter the main menu. Press the F2 or F3 key to scroll to Config menu and press F4 to expand the menu. 2. Press the F2 or F3 key to scroll to Options menu and press F4 to expand the menu. 3.
A A d d v v a a n n c c e e d d F F r r e e s s h h A A i i r r M M a a n n a a g g e e m m e e n n t t ( ( A A F F A A M M ) ) S S y y s s t t e e m m 9.
A A d d v v a a n n c c e e d d F F r r e e s s h h A A i i r r M M a a n n a a g g e e m m e e n n t t ( ( A A F F A A M M ) ) S S y y s s t t e e m m 4.
Advanced Fresh Air Management Plus (AFAM+) System An advanced microprocessor controlled fresh air management system that provides: • programmable control of the CO2 level in the container • data logging of the CO2 gas level reading • gas sensor unit •...
A A d d v v a a n n c c e e d d F F r r e e s s h h A A i i r r M M a a n n a a g g e e m m e e n n t t P P l l u u s s ( ( A A F F A A M M + + ) ) S S y y s s t t e e m m 9.
A A d d v v a a n n c c e e d d F F r r e e s s h h A A i i r r M M a a n n a a g g e e m m e e n n t t P P l l u u s s ( ( A A F F A A M M + + ) ) S S y y s s t t e e m m The CO2 rate sets the desired CO2 level in the container when a gas sensor unit is installed.
A A d d v v a a n n c c e e d d F F r r e e s s h h A A i i r r M M a a n n a a g g e e m m e e n n t t P P l l u u s s ( ( A A F F A A M M + + ) ) S S y y s s t t e e m m 4.
A A d d v v a a n n c c e e d d F F r r e e s s h h A A i i r r M M a a n n a a g g e e m m e e n n t t P P l l u u s s ( ( A A F F A A M M + + ) ) S S y y s s t t e e m m System Operation Verification If the system appears not to be operating properly, it is best to verify that the controller can recognize if the AFAM+ option is installed.
Page 95
A A d d v v a a n n c c e e d d F F r r e e s s h h A A i i r r M M a a n n a a g g e e m m e e n n t t P P l l u u s s ( ( A A F F A A M M + + ) ) S S y y s s t t e e m m N N O O T T I I C C E E E E q q u u i i p p m m e e n n t t D D a a m m a a g g e e ! ! I I f f t t h h e e i i n n l l e e t t / / o o u u t t l l e e t t t t u u b b e e s s o o r r f f i i l l t t e e r r n n e e e e d d t t o o b b e e c c l l e e a a r r e e d d , , d d i i s s c c o o n n n n e e c c t t f f r r o o m m t t h h e e g g a a s s a a n n a a l l y y z z e e r r B B E E F F O O R R E E p p u u r r g g i i n n g g a a i i r r...
Pulsating Vent Door AFAM+ Door Closes Automatically On units equipped with the AFAM option, a harness from J_B12 to the on/off switch, and a container prefix of HLXU. If the AFAM door is open it will close automatically if the on/off switch is turned off. Unit and controller will shut off and the AFAM door will be power close.
Operating Theory Chill Loads (Setpoint at -9.9 C [14.1 F] and Above) The unit operates on Cool with Modulation and Heat to provide accurate control of chill loads. During Cool with Modulation, the controller uses a proportional-integral derivative (PID) algorithm, and a Digital Control valve to provide accurate control of the container temperature in direct response to load demand.
O O p p e e r r a a t t i i n n g g T T h h e e o o r r y y Chill Loads (Setpoints of -9.9 C [14.1 F] and Above) When the Optimized Mode is set to ON, the evaporator fans operate on low and high speed as needed to maintain the setpoint and save energy.
O O p p e e r r a a t t i i n n g g T T h h e e o o r r y y Continuous Temperature Control Operation Chill Loads (Controller Setpoint at -9.9 C [14.1 F] and Above) The controller regulates the compressor, digital control valve, and electric heaters based on a Control Temperature Differential (Refer to “Compressor Digital Control Valve,”...
Page 100
O O p p e e r r a a t t i i n n g g T T h h e e o o r r y y Table 41. CFF Operating Mode Function Chart (continued) Chill Loads Setpoints at -9.9 C Frozen Loads Setpoints (14.4 F) and Above at -10 C (14 F) and...
O O p p e e r r a a t t i i n n g g T T h h e e o o r r y y Cool with Modulation • Controller calls for the Cool mode whenever the Control Temperature Differential (based on supply air temperature) is above setpoint.
O O p p e e r r a a t t i i n n g g T T h h e e o o r r y y Cool • After initial start-up and pull-down to 2.0 C (3.6 F) below setpoint, the controller calls for the Cool mode whenever: –...
O O p p e e r r a a t t i i n n g g T T h h e e o o r r y y • The Heat and Defrost indicators turn off and the solid state is de-energized. The controller starts the compressor to pre-cool the evaporator coil.
O O p p e e r r a a t t i i n n g g T T h h e e o o r r y y Data Recording and Downloading Data The data logger can record sensor temperatures as well as loss of power, alarms, sensor failure, setpoint change and unit shutdown events.
Page 105
O O p p e e r r a a t t i i n n g g T T h h e e o o r r y y Figure 34. Details of CT Log Commodity is loaded Final set point Commodity reached Pre-cool...
Page 106
O O p p e e r r a a t t i i n n g g T T h h e e o o r r y y USDA Type screen in the Configuration menu must be set to the correct sensor setting and each USDA sensor must be calibrated to comply with USDA temperature recording requirements.
O O p p e e r r a a t t i i n n g g T T h h e e o o r r y y S S u u r r v v e e i i l l l l a a n n c c e e d d u u r r i i n n g g c c o o l l d d t t r r e e a a t t m m e e n n t t : : During the CT period all USDA sensors can fail and the CT period will continue. The fail state will be shown in the temperature log.
Page 108
O O p p e e r r a a t t i i n n g g T T h h e e o o r r y y S S t t a a r r t t i i n n g g a a n n d d S S e e t t t t i i n n g g M M u u l l t t i i p p l l e e T T e e m m p p e e r r a a t t u u r r e e S S e e t t p p o o i i n n t t 1.
Page 109
O O p p e e r r a a t t i i n n g g T T h h e e o o r r y y 5. The following screen will appear. Repeat steps 3 and 4 for Setpoint 2 and Period 2, and for each additional setpoint that is required.
Page 110
O O p p e e r r a a t t i i n n g g T T h h e e o o r r y y 3. The Standard Display will appear and “MTS - Approaching setting 1” will disappear. After stopping MTS, the unit will continue running with the last MTS setpoint in action.
Controller Maintenance Controller Door Open and Close Instructions O O p p e e n n Insert a flat blade screwdriver into slot Move the screwdriver handle to the left With the door catch released, pull door on side of control box door. to release the door catch from the box out and open.
Page 112
C C o o n n t t r r o o l l l l e e r r M M a a i i n n t t e e n n a a n n c c e e / MP4000 / command.ini 3/18/2010 / Logs (Downloads will appear here) / Firmware CM4000_3.2.0.0_140822.strip Figure 36.
Electrical Maintenance Unit Protection Devices Main Circuit Breaker The main power circuit breaker is located in the control box. The 25 ampere manual reset circuit breaker is located in the Control Box. It protects the 460/380V power supply circuit to the unit electric motors and control system transformer.
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Low Pressure Cutout Switch A low pressure cutout switch is located on the compressor suction line.
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e If an evaporator fan is rotating backwards on one or both speeds, refer to the unit wiring diagram to correct motor wiring at the fan motor junction box or evaporator fan contactor (disconnect power supply before reversing leads).
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Six Short Length Heaters (680 Watts Each) Three Longer Heaters (1360 or 2000 Watts Each) Extended Capacity Heaters...
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e the evaporator cover from the rear of the unit and replace the heater or correct any defective wiring.
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Sensor Testing The controller constantly monitors the left hand and right hand supply sensors, return sensor and defrost (evaporator coil) sensor to determine when to initiate a demand defrost.
Page 126
E E l l e e c c t t r r i i c c a a l l M M a a i i n n t t e e n n a a n n c c e e Table 43.
Refrigeration Maintenance Introduction The following procedures involve servicing the refrigeration system. Some of these service procedures are regulated by Federal, and in some cases, by State and Local laws. N N o o t t e e : : In the USA, EPA Section 608 Certification is required to work on refrigeration systems, using approved equipment and complying with all Federal, State, and Local laws.
R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e Service Valve Open to Port (Servicing Position) 1/2 Turn In Service Valve Front Seated (Check or Remove...
Page 130
R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e Removing Refrigerant Quick Disconnect Access Valve Discharge Service Valve (DSV)
Gauge Manifold Set Installation & Removal Thermo King recommends the use of access valves or self-sealing, quick disconnect fittings. This limits the loss of refrigerant into the atmosphere. A separate gauge manifold set with low loss fittings (refer to Tool Catalog) should be dedicated for use with R-404A/R-452A only.
R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e Purging Gauge Manifold Suction Connection Discharge Connection...
R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e Using Pressurized Nitrogen The improper use of high pressure cylinders can cause physical damage to components, or personal injury, or cause stress that would lead to failure of components.
R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e 4.
Page 137
R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e Special, self-sealing quick disconnect Iso Valve To 220/190 Vac Power...
U U s s e e o o n n l l y y r r e e f f r r i i g g e e r r a a n n t t r r e e c c o o v v e e r r y y e e q q u u i i p p m m e e n n t t a a p p p p r r o o v v e e d d f f o o r r a a n n d d d d e e d d i i c c a a t t e e d d t t o o R R - - 1 1 3 3 4 4 A A r r e e c c o o v v e e r r y y . . When removing any refrigerant from a Thermo King refrigeration system, use a recovery process that prevents or absolutely minimizes the refrigerant escaping to the atmosphere.
Evacuate the system to 500 microns to achieve a final equilibrium pressure of 2000 microns or less. The final equilibrium pressure is determined with the Thermo King Evacuation Station using the following procedure (called a pressure rise test): a.
R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e Scroll Compressor Suction Service Valve Discharge Service Valve...
3. Solder inlet and outlet line connections to economizer expansion valve and clean solder connections with baking soda. Apply black paint to area to prevent corrosion. N N o o t t e e : : Thermo King strongly recommends that dry nitrogen be used to purge the system during any solder operations (Refer to “Using Pressurized Nitrogen,”...
Page 147
R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e Apply heat transfer paste to bulb holder before installing TXV bulb.
2. Clean the two liquid and two suction lines for soldering. I I m m p p o o r r t t a a n n t t : : Thermo King strongly recommends that dry nitrogen be used to purge the system during any solder operations (Refer to “Using Pressurized Nitrogen,”...
R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e N N O O T T I I C C E E E E q q u u i i p p m m e e n n t t D D a a m m a a g g e e ! ! U U s s e e a a h h e e a a t t s s i i n n k k o o r r w w r r a a p p s s w w i i t t c c h h w w i i t t h h w w e e t t r r a a g g s s t t o o p p r r e e v v e e n n t t d d a a m m a a g g e e t t o o n n e e w w s s w w i i t t c c h h .
Page 151
R R e e f f r r i i g g e e r r a a t t i i o o n n M M a a i i n n t t e e n n a a n n c c e e N N O O T T I I C C E E E E q q u u i i p p m m e e n n t t D D a a m m a a g g e e ! ! U U s s e e a a h h e e a a t t s s i i n n k k o o r r w w r r a a p p s s w w i i t t c c h h w w i i t t h h w w e e t t r r a a g g s s t t o o p p r r e e v v e e n n t t d d a a m m a a g g e e t t o o n n e e w w s s w w i i t t c c h h .
Servicing the Unit Taking Care of the Structure Inspecting Unit Inspect the unit during unit pretrip inspection and every 1,000 operating hours for loose or broken wires or hardware, compressor oil leaks, or other physical damage which can affect unit performance and require repair or replacement of parts.
S S e e r r v v i i c c i i n n g g t t h h e e U U n n i i t t Cleaning the Evaporator Coil N N O O T T I I C C E E E E q q u u i i p p m m e e n n t t D D a a m m a a g g e e ! ! T T h h e e a a i i r r p p r r e e s s s s u u r r e e s s h h o o u u l l d d n n o o t t b b e e h h i i g g h h e e n n o o u u g g h h t t o o d d a a m m a a g g e e c c o o i i l l f f i i n n s s .
S S e e r r v v i i c c i i n n g g t t h h e e U U n n i i t t Adjusting the Fresh Air Exchange System The fresh air exchange system has an adjustable vent door for ventilation. The evaporator fans draw in outside air through an air intake and discharge an equal amount of container air through an air outlet.
Diagnostics Introduction This section includes the following: • Controller Diagnostics • Mechanical Diagnostics • Refrigeration Diagnostics • Status Messages and Controller Actions • Alarm Codes and Corrective Actions The tables shown will help identify and fix unit problems. MP4000 Diagnostics The MP4000 can be a very helpful diagnostic tool.
D D i i a a g g n n o o s s t t i i c c s s Mechanical Diagnostics Condition Possible Cause Remedy Compressor does not operate - no amperage Controller on; unit start sequence still timing. Wait up to two minutes for compressor start- draw.
Page 157
D D i i a a g g n n o o s s t t i i c c s s Condition Possible Cause Remedy Compressor contactor burned out. Low line voltage. Increase line voltage to at least 90 percent of compressor motor rating.
D D i i a a g g n n o o s s t t i i c c s s Refrigeration Diagnostics Condition Possible Cause Remedy Load temperature too high - unit not cooling. Compressor does not operate. Refer to (“Mechanical Diagnostics,”...
Page 159
D D i i a a g g n n o o s s t t i i c c s s Condition Possible Cause Remedy Compressor loses oil. Refrigerant leak. Repair leak and recharge. Compressor oil migrates to system. Short cycling.
D D i i a a g g n n o o s s t t i i c c s s Status Messages and Controller Actions The controller displays status messages (in Alarms Menu) on the display for several general faults. More than one status message may appear at a time.
Page 161
D D i i a a g g n n o o s s t t i i c c s s Status Description Controller Action/Corrective Action Message Current Too High - Check Compressor and Fans • Enter Manual Function Test menu and test (operate) each •...
Page 162
D D i i a a g g n n o o s s t t i i c c s s Status Description Controller Action/Corrective Action Message Evaporator Coil Temperature Too Low - Check Evaporator • Use DATA menu to inspect readings. Sensor •...
Page 163
D D i i a a g g n n o o s s t t i i c c s s Status Description Controller Action/Corrective Action Message HPCO Timer Hold - Please Wait • Controller clears message on compressor start-up. •...
Page 164
D D i i a a g g n n o o s s t t i i c c s s Status Description Controller Action/Corrective Action Message Compressor High Temperature • The message clears itself when the compressor • When: temperature is normal.
Page 165
D D i i a a g g n n o o s s t t i i c c s s Status Description Controller Action/Corrective Action Message Power Module Heat Exchanger High Temperature • Check for blocked air flow to the back side of the control •...
D D i i a a g g n n o o s s t t i i c c s s Alarm Codes and Corrective Actions N N o o t t e e : : Sensors used with the MP4000 controller do not require calibration. Check sensor resistance with an ohmmeter. Shutdown Alarm (Level 1 Alarm): Alarm light on display flashes and unit stops.
Page 167
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Return Air Temperature Sensor Open Circuit • Check for damaged sensor wires. • When the sensor circuit resistance is higher than 1300Ω. •...
Page 168
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Evaporator Coil Temperature Sensor Open Circuit • Check for damaged sensor wires. • When the sensor circuit resistance is higher than 1300Ω. •...
Page 169
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Compressor Current Too High • Check evaporator and condenser sensor temperatures for • Occurs during pretrip (PTI) or function test only. correct value (±...
Page 170
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Heater Current Too Low • Enter Manual Function Test and turn heaters on. Check •...
Page 171
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Evaporator Fan High Speed Current Too Low • Open evaporator door and make sure all fans rotate freely. •...
Page 172
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Evaporator Fan Low Speed Current Too Low • Open evaporator door and make sure all fans rotate freely. •...
Page 173
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Power Supply Phase Error • Check fuses on the power module. • Shutdown Alarm •...
Page 174
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Capacity Test 2 Error • Enter Manual Function Test and start evaporator fans on •...
Page 175
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Condenser Coil Temperature Sensor Open Circuit • Check for damaged sensor wires. • When the sensor circuit resistance is above 1785Ω. •...
Page 176
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Ambient Air Temperature Sensor Open Circuit • Check for damaged sensor wires. • When the sensor circuit resistance is above 1785Ω. •...
Page 177
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Return Air Temperature Too Low • Using DATA menu to evaluate sensors. • Occurs during Normal Run only. •...
Page 178
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action High Pressure Switch On Error • Check discharge and suction pressure gauge readings. • Occurs during pretrip (PTI) test only.
Page 179
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Delta Current Error • Enter Manual Function Test menu and test (operate) each • 100% ampere difference between current phases, max 3-phase component to locate defective connection.
Page 180
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Gas Analyzer Error • Redo AFAM+ PTI. • Occurs during Pre-Trip (PTI) test only. •...
Page 181
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Compressor temperature Sensor Open Circuit • Check for damaged sensor wires. • When the sensor circuit resistance is above 1MΩ and the •...
Page 182
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Compressor temperature Sensor Short Circuit • Check for damaged sensor wires. • When the sensor circuit resistance is below 550Ω. •...
Page 183
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Discharge Pressure Sensor Error • Using DATA menu evaluate sensor readings. • Occurs during Normal Run if the sensor is detected to be •...
Page 184
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Supply Air Temperature Sensor Error • Use the DATA menu to detect the failing sensor. •...
Page 185
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Power Module Network Error • Check connection between controller and power module. • The surveillance has not received valid status •...
Page 186
D D i i a a g g n n o o s s t t i i c c s s Code Description Corrective Action Evaporator Section Too Hot • Observe temperature readings to locate the problem. • Occurs if supply air, return air or evaporator coil •...
Page 187
Diagrams Diagram Index Drawing No. Title Page 1E54051 MAGNUM Wiring Diagram Figure 43, p. 188 Figure 44, p. 189 1E54052 MAGNUM Schematic Diagram Figure 45, p. 190 TK 52234 MAGNUM PLUS Refrigeration System Components Figure 46, p. 191 Figure 47, p. 192 MP4000 Menu Flow Diagram Figure 48, p.
Page 188
Figure 43. 1E54051 (Sheet 1 of 2) RELEASED 08/Apr/2019 12:55:38 GMT TK 60275-4-MM-EN...
Page 189
Figure 44. 1E54051 (Sheet 2 of 2) RELEASED 08/Apr/2019 12:55:38 GMT TK 60275-4-MM-EN...
Page 190
Figure 45. 1E54052 (Sheet 1 of 1) RELEASED 08/Apr/2019 12:55:39 GMT TK 60275-4-MM-EN...
Page 191
Figure 46. MAGNUM PLUS Refrigeration System Components Low Pressure Vapor Low Pressure Liquid TK 52234 (2/3)-4-CH (Rev. 0), 10/03 High Pressure Vapor High Pressure Liquid Stage 1 Sub-Cooled High Pressure Liquid Stage 2 Sub-Cooled High Pressure Liquid TK 60275-4-MM-EN...
Page 192
Figure 47. MAGNUM PLUS Components Scroll Compressor Discharge Service Valve High Pressure Switch Condenser Coil Receiver Tank Pressure Relief Sight Glass Drier / Oil Filter Economizer Heat Exchanger 10. Vapor Injection Valve Economizer TXV 12. Evaporator TXV 13. Evaporator Coil 14.
Page 193
Figure 48. MP4000 Controller Menu Guide CONTROLLER MENU GUIDE • F1 ALARM • F2 C/F F3 SETPOINT • F4 MENU • NOTE: All screens are NOT present on all units. The screen Values Menu that display on the controller are determined by the Controller Software setting and the options installed on the Temperature Values Pressure Values...
Page 196
1938. For more information, visit www.thermoking.com or www.tranetechnologies.com. Thermo King has a policy of continuous product and product data improvements and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.
Need help?
Do you have a question about the MAGNUM PLUS 098212 and is the answer not in the manual?
Questions and answers