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 Introduction Unit Description About This Manual Unit Features Other Reference Manuals Unit Options CSR Semi-Hermetic Model Features Operating Modes Unit Illustrations 2-3 to 2-8 Typical Unit Front View Safety Precautions CSR40SL Evaporator Section — Front View General Practices Semi-hermetic Refrigeration System Refrigerant Scroll Compressor...
Page 6: Table Of Contents
Table of Contents Status Indicator LEDs and Alarm Codes Menu Guard Functions 4-29 Pause Alarms Navigating Menu Guard Screens 4-29 Data Logging and Downloading Data Setting the Unit Configuration and General Theory of Operation Customer Configuration Numbers 4-30 Chill Loads Setting the Container Identification Number 4-30 Frozen Loads...
Page 7 Table of Contents Refrigeration System Diagnosis and Service Diagnosis Service Tools Mechanical Diagnosis Gauge Manifold Valve Positions Refrigeration Diagnosis Gauge Manifold Set Attachment and Purging Checking Compressor Oil Electrical, Refrigeration and µ µ P-D Menu Refrigerant Charge Refrigerant Leak Test Procedure Flow Diagrams Using Pressurized Nitrogen Electrical Schematic with Circuit Tracing...
Page 8 Table of Contents Modulation Mode – Chill Load (Setpoint at Null Mode – Frozen Load (Setpoint at -10.0 C -9.9 C [14.1 F] or Above); Condenser [14.0 F] or Below) Condenser Fan OFF; Fan OFF; Economy Mode ON; Economy Mode OFF 9-18 Temperature In-range;...
Page 9 Refrigeration Systems TK 41166 operators and service people in the proper upkeep and mainte- Electrostatic Discharge (ESD) nance of Thermo King units. This manual includes mainte- Training Guide TK 40282 nance and diagnosis information for both standard and option- Evacuation Station Operation and Field al unit features.
Page 10 Dehumidify Control – Humidity System – Power Line Communications, Standard (Thermo King Modem) – Power Line Communications, Thermo King Integrated Remote Monitor Unit (IRMU) – Power Line Communications, RTE Modem – Power Line Communications, Sabroe Control Modem – Pressure Gauge, Discharge –...
Page 11 Safety Precautions General Practices Refrigerant ALWAYS WEAR GOGGLES OR SAFETY GLASSES. When removing any refrigerant from a unit, use a recovery Refrigerant liquid and battery acid can permanently dam- process that prevents or absolutely minimizes the refrigerant age the eyes (see First Aid under Refrigerant Oil). that can escape to the atmosphere.
Page 12 viii Refrigerant Oil Safety Precautions 4. Do not make any rapid moves when working on high volt- Refrigerant Oil age circuits. If a tool or other object falls, do not attempt to grab it. People do not contact high voltage wires on Observe the following precautions when working with or purpose.
Page 13 Safety Precautions General Safety Precautions for Servicing Controllers Welding of Units or Containers General Safety Precautions for Servicing Whenever electric welding is to be performed on any portion Units (or Containers) Equipped with a of the refrigeration unit, container or container chassis with the refrigeration unit attached, it is necessary to ensure that weld- Microprocessor Controller ing currents are NOT allowed to flow through the electronic...
Page 14 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 Every Annual/ 1,000 Yearly Pretrip Hours Inspect/Service These Items Electrical • Perform a controller Full Pretrip Test to check the electrical and refrigeration systems. • • Perform a controller Extended Pretrip Test. • • • Visually check condenser fan and evaporator fan rotation. •...
Page 17 Specifications System Net Cooling Capacity — Full Cool CSR40SL Models — Air Cooled Condensing* Return air to 460/230V, 3 Phase, 60 Hz Power 380/190V, 3 Phase, 50 Hz Power evaporator Net Cooling Capacity Power Consp Net Cooling Capacity Power Consp coil inlet Watts Kcal/hr...
Page 18 Electrical System Specifications Electrical System Compressor Motor: Type 460/380V, 60/50 Hz, 3 Phase Kilowatts 4.48 kW @ 460V, 60 Hz Horsepower 6.0 hp @ 460V, 60 Hz 3550 rpm @ 460V, 60 Hz Locked Rotor Amps 70 amps @ 460V, 60 Hz Condenser Fan Motor: Type 460/380V, 60/50 Hz, 3 Phase...
Page 19 Specifications Refrigeration System Refrigeration System Compressor Model No.: ZM18K4E-TFD-276, Scroll Refrigerant Charge: CSR40SL 4.1 Kg (9.0 lb) R-404A Compressor Oil Capacity 1.77 liter (60 oz.)*** Compressor Oil Type Polyol Ester Based Type (required), TK Part No. 203-433**** High Pressure Cutout Switch: Cutout 3243 +/- 48 kPa, 32.43 +/- 0.48 bar, 470 +/- 7 psig Cutin...
Page 20 R-404A Temperature Pressure Relationship Specifications R-404A Temperature Pressure Relationship — Vapor Pressure Temp. Temp. Temp. Temp. Psig Psig -45.6 11.1 742.6 7.43 107.7 -44.4 0.06 12.2 770.2 7.70 111.7 -43.3 13.8 0.14 13.3 798.4 7.98 115.8 -42.2 18.6 0.19 14.4 827.4 8.27 120.0...
Page 21 Specifications Normal R-404A System Operating Pressures Normal R-404A System Operating Pressures (Scroll Compressor) Container Operating Ambient Suction Pressure Discharge Pressure Temp. Mode Temp. 21 C (70 F) Cool 27 to 38 C, 410 to 670 kPa, 4.10 to 6.70 bar, 2140 to 2650 kPa, 21.40 to 26.50 bar, 80 to 100 F 59 to 97 psig...
Page 22 µ µ P-D Controller Specifications µ µ P-D Controller Thermoguard ® µP-D microprocessor with digital thermostat, ther- Temperature Controller: Type Thermoguard ® mometer and fault indicator monitor Setpoint Range -30.0 to +30.0 C (-22.0 to +86.0 F) Digital Temperature Display -40.0 to +130.0 C (-40.0 to +266.0 F) Output Module Energizes and de-energizes unit contactors and solenoids in...
Page 23 µ µ P-D Controller Specifications µ µ P-D Controller (Continued) Thermoguard ® Defrost Termination: Evaporator Coil Sensor* Chill mode: Terminates defrost when coil sensor temperature rises to 30 C (86.0 F) Frozen mode: Terminates defrost when coil sensor temperature rises to 18 C (64.4 F) Interval Timer** Terminates defrost 90 minutes after initiation if coil sensor has not terminated defrost...
Page 24 Physical Specifications Specifications Physical Specifications Fresh Air Exchange Venting System (Adjustable): CSR40SL 0 to 285 m /hr (0 to 168 ft /min.) @ 60 Hz 0 to 236 m /hr (0 to 139 ft /min.) @ 50 Hz Evaporator Fan Blade Specifications: CSR40SL: Diameter 312 mm (12.25 in.) Pitch...
Page 25 Specifications Metric Hardware Torque Charts Metric Hardware Torque Charts Bolt Size Bolt Type and Class* N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.) HH – CL 5.8 6-9 (4-7) 12-16 (9-12) 27-34 (20-25) 48-61 (35-40) HH – CL 8.8 10-13 (7-10) 20-27 (15-20) 41-47 (30-35) 75-88 (55-65)
Page 27 Unit Description of -9.9 C (14.1 F) and above. At return air temperatures of -10 C Unit Features (14 F) and below, the evaporator fans operate on low speed for frozen cargo. Model CSR40SL units are all-electric, single-piece, refrigera- tion units with bottom air supply. Each unit is designed to cool NOTE: If Economy Mode is ON: and heat containers for shipboard or overland transit.
Page 28 Unit Options Unit Description dict which operating mode the unit should be in by comparing USDA Cold Treatment Temperature Recording The µP-D controller includes provisions for the use of three or the setpoint to the return or supply air temperature. The unit operates in either the Chill (Fresh) or Frozen mode.
Page 29 Unit Description Unit Illustrations Typical Unit Front View CSR40SL: Evaporator Access Door, 1399 mm (55.04 in.) Wide with Three Latches Heater Access Panel Location Recording Thermometer Option Condenser Fan Compressor Compartment Supply Air Sensor Probe Holder Power Cord Storage Compartment Control Box USDA Receptacle Panel (Access from Inside Container) 10.
Page 30 Unit Illustrations Unit Description CSR40SL Evaporator Section — Front View Evaporator Fan Blade: • CSR40SL: 312 mm (12.25 in.) diameter, 25 pitch Evaporator Fan Motor Return Air Sensing Bulb for Recording Thermometer (Option) Return Air Sensor Humidity Sensor (Option) CSR40SL Semi-Hermetic, February 2000...
Page 31 Unit Description Unit Illustrations Semi-Hermetic Refrigeration System Evaporator Coil Warm Gas Bypass Solenoid Valve Dehumidify Valve Option (Replaces Standard Tube) Tube (Standard) Expansion Valve High Pressure Relief Valve Heat Exchanger Filter Drier/In-line Filter (One-piece) Liquid Injection Solenoid Valve 10. Scroll Compressor 11.
Page 32 Unit Illustrations Unit Description Scroll Compressor Compressor Discharge Temperature Sensor Schrader Service Valve on Suction Line Schrader Service Valve on Discharge Manifold Compressor Oil Sight Glass Compressor Oil Fitting Discharge Line High Pressure Cutout Switch CSR40SL Semi-Hermetic, February 2000...
Page 33 Unit Description Unit Illustrations Control Box — Door Open Condenser Fan Contactor Evaporator Fan Low Speed Contactor Power Module Control Transformer Thermo Bus Tap Output Module Emergency Bypass Module Unit On/Off Switch Data Retrieval Receptacle (located on bottom of control box on some models) 10.
Page 34 Unit Illustrations Unit Description Typical Unit Back View Evaporator Grille Unit Gasket Top Rear Plate Bottom Rear Plate Sensor Connector Assembly: • Controller Communications and Data Download Port • Cargo (Pulp) Sensor Connection • USDA1 Sensor Connection • USDA2 Sensor Connection •...
Page 35 Operating Instructions key to LOAD a manual defrost. If the evaporator coil Unit Controls temperature is below 10 C (50 F), the unit will defrost. Otherwise the controller will display “DFRST INVAL” and the unit will continue normal operation. Unit Control Box PRETRIP KEY.
Page 36 Unit Protection Devices Operating Instructions 4. EVAPORATOR OVER TEMPERATURE PROTEC- Unit Protection Devices TION. An evaporator coil sensor monitors coil tempera- ture during heat and defrost modes. If the coil sensor tem- 1. CIRCUIT BREAKERS. A 25 ampere manual reset circuit perature reaches 38 C (100 F), the controller de-energizes breaker protects the 460/380V power supply circuit to the the heater contactor.
Page 37 Operating Instructions Pretrip Inspection NOTE: If the unit does not start, turn the On/Off Pretrip Inspection switch OFF. Check power supply. Then repeat step 1. If the unit still does not start, refer to “Alarm Codes, Descriptions and Corrective Visual Inspection Actions”...
Page 38 Starting the Unit Operating Instructions tions on viewing the VIEW/LOG/PT1 submenu, decrease the setpoint. The left display flashes “SETPT” refer to “Viewing Information in the View Menu” while the right display shows the temperature. in the µ µ P-D Controller chapter of this manual. •...
Page 39 ° ° DATA DATA °C °F DOWN ENTER TEMPERATURE DEFROST PRETRIP ALARM SELECT THERMOGUARD µP-D THERMO KING ® µ µ P-D Controller 1. Status Indicator Lights 2. Setpoint (Left) Display 3. Temperature (Right) Display 4. Keypad CSR40SL Semi-Hermetic, February 2000...
Page 40 µP-D Controller Controller Description 3. Status indicator LEDs (see “Status Indicator LEDs and 11. Sensor Check test capability (see “Sensor Check” under General Theory of Operation in this chapter). Alarm Codes” in this chapter). 12. Data recording capability (see “Data Recording and 4.
Page 41 µP-D Controller Controller Display Menus Active Option Displays Controller Display Menus Control options that have been turned ON in the Program The µP-D controller contains an extensive display menu that menu show for 1 second every 10 seconds in the controller dis- can be navigated via keypad.
Page 42 µP-D Controller Controller Display Menus Pause Mode Displays View Menu Menu screens in this group are used to display unit operating WARNING: When the unit is in the PAUSE mode, the information, sensor grades and scrollback data logger data compressor, evaporator fans or condenser fan may including controlling sensor temperatures and pretrip test continue to operate or start at any time without information.
Page 43 µP-D Controller Controller Display Menus BULB Bulb Mode Enable Bypass Valve Solenoid EX DF Extended Defrost Pretrip Test Temperature Display Mode EX FZ Extended Frozen Mode Pretrip Test CCOIL Condenser Coil Temperature Sensor FTEST Full Pretrip Test CCTG Condenser Coil Sensor Grade Generator CFG C Customer Configuration Setting...
Page 44: Status Indicator Leds And Alarm Codes
µP-D Controller Status Indicator LEDs and Alarm Codes Return Air Temperature Sensor Status Indicator LEDs and Alarm Codes RETG Return Air Sensor Grade Remote In-range Indicator The indicator LEDs stay ON continuously to indicate a unit Remote Spare Indicator operating mode or condition. The Alarm LED stays ON con- SENSR Sensor tinuously when a Check Alarm occurs.
Page 45: Pause Alarms
µP-D Controller Pause Alarms Check Datalogger Full (µP-A+) Alarm Code Type Description Check Datalogger Full (Global) Check Real Time Clock Invalid No Fault Check Ambient Temperature Sensor Failure Check Bypass Valve Circuit Failure (Pretrip) Check Supply Air Temperature Sensor Failure Check Pretrip Preconditioning Failure Check...
Page 46: Data Logging And Downloading Data
µP-D Controller Data Logging and Downloading Data controller operates the condenser fan for 5 minutes to correct General Theory Of Operation the condition. After 5 minutes, the controller attempts to restart the compressor. If the compressor fails to start due to The µP-D controller uses advanced solid-state integrated cir- high pressure cutout, alarm code 10 is generated.
Page 47: Frozen Loads
µP-D Controller General Theory of Operation Frozen Loads (Setpoint at -10 C [14 F] and Below) Modulation Valve Setting (PCVAL) The modulation valve controls refrigerant return to the com- At setpoints of -10 C (14 F) and below, the controller controls pressor during Modulation Cool.
Page 48: Sensor Check
µP-D Controller 4-10 General Theory of Operation - If the temperature difference between both the supply Sensor Check and return air sensors and the coil sensor is greater than 2.2 C (3.9 F), the controller determines both sensors are NOTE: If a Sensor Check occurs, check the supply defective, records alarm code 25 and takes appropriate air sensor position in the probe holder.
Page 49: Economy Mode Operation
µP-D Controller Sequence of Operation 4-11 Economy Mode Operation Sequence Of Operation The Economy Mode reduces unit power consumption by reducing evaporator fan operation on both fresh and frozen Unit Start-up loads. The use of the Economy Mode should be established by the shipper and the type of cargo.
Page 50: Operating Mode Function Chart - Standard Operation
µP-D Controller 4-12 Sequence of Operation Operating Mode Function Chart — Standard Operation Chill Loads Frozen Loads Setpoints at -9.9 C Setpoints at -10.0 C (14.4 F) and Above (14.0 F) and Below Cool Mod Null Heat Defr Cool Null Defr Unit Function •...
Page 51: Operating Mode Function Chart - Optional Feature Operation
µP-D Controller Sequence of Operation 4-13 • Evaporator fans operate on high speed (except when Continuous Temperature Control Operation Economy mode is ON and temperature is In-range) and continuously circulate air inside the container (except Chill Loads — Controller Setpoint at -9.9 C (14.1 F) during defrost).
Page 52 µP-D Controller 4-14 Sequence of Operation Modulation Cool Calculated Temperature Differential decreases to 3.1 C • Controller calls for Modulation Cool when the Calculated (5.5 F) below setpoint. Temperature Differential is between 2.5 C (4.5 F) above On temperature pull-up (and initial start-up), the con- setpoint and setpoint (on temperature pull-down).
Page 53 µP-D Controller Sequence of Operation 4-15 Cool Frozen Loads — Controller Setpoint at -10 C (14 F) and Below • Controller calls for the Cool mode whenever the return air temperature is more than 1.0 C (1.8 F) above setpoint. At setpoints of -10 C (14 F) and below, the controller locks out •...
Page 54: Defrost
µP-D Controller 4-16 Sequence of Operation Null • A manual defrost is initiated (loaded) using the controller • The controller calls for Null when the Return Air keypad. Temperature decreases more than 1.0 C (1.8 F) below NOTE: If unit operating conditions do not allow setpoint (on temperature pull-down).
Page 55: Reviewing Software Version And Configuration
µP-D Controller Reviewing Software Version and Configuration 4-17 NOTE: The unit will operate and control the con- Reviewing Software Version and tainer temperature if the controller remains pro- Configuration grammed to unit configuration “5000” and cus- tomer configuration “0”. However, the unit will The software version, unit configuration number and customer not operate customer specific options.
Page 56: Displaying Alternate Controlling (Supply Or Return) Air Sensor Temperatures
µP-D Controller 4-18 Displaying Alternate Temperatures NOTE: The setpoint temperature can be entered Displaying Alternate Controlling in either F or C using the F/C key. Just press (Supply or Return) Air Sensor and hold the F/C key (to display the alternate temperature scale).
Page 57: Initiating A Manual Defrost
µP-D Controller Initiating a Manual Defrost 4-19 Initiating a Manual Defrost Initiating a Full Pretrip With the unit On/Off switch ON: To perform a Full Pretrip test, turn the unit On/Off switch ON: Press the DEFROST key. The display flashes “ENTER NOTE: The controller will not perform an auto- DFRST”.
Page 58: Entering A Start Of Trip Marker
µP-D Controller 4-20 Entering a Start of Trip Marker COOL NULL HEAT IN RANGE DEFROST SUPPLY RETURN PWRLMT ALARM Entering a Start of Trip Marker SETPOINT TEMPERATURE DATA DATA To enter a Start of Trip marker, turn the unit On/Off switch ON or operate the controller using battery power (press the SELECT key): 2.
Page 59: Controller Menu Operating Instructions
µP-D Controller Controller Menu Operating Instructions 4-21 Controller Menu Operating Instructions Menu View Functions NOTE: To view the controller’s menu or download NOTE: Information can ONLY be displayed using the data when external power is disconnected from the View menu. Items can NOT be changed. See “MENU unit, connect a 12 Vdc battery to the battery jack on PRGRM”...
Page 60: Grade Submenu
µP-D Controller 4-22 Menu View Functions NOTE: The controller returns to the Standard 4. Press the UP key until “VIEW GRADE” shows in the Display from a View Menu screen after about 10 display. seconds, or when the SELECT key is pressed 5.
Page 61 µP-D Controller Menu View Functions 4-23 When viewing information in the TEMP or PTI scrollback With the unit On/Off switch ON and the controller show- display, the status indicator LEDs on the controller show the ing the Standard Display: unit operating states that were active (ON) when the data or Press the SELECT key to enter menu (display shows event was recorded.
Page 62 µP-D Controller 4-24 Menu View Functions To enter the TEMP scrollback submenu: To enter the PTI scrollback submenu: 1. Press the SELECT key with “LOG TEMP” in the display. 1. Press the SELECT key with “LOG PTI” in the display. Display will briefly show “SEARC HINGX”.
Page 63: Menu Pretrip Functions
µP-D Controller Menu Pretrip Functions 4-25 • Amps: Controller individually energizes all outputs Menu Pretrip Functions including fan and compressor motors, and solenoid valves. The controller checks current draw to verify cor- Three pretrip test menus are available through the PTRIP rect operation.
Page 64: Performing An Extended, Full Or Single Pretrip Test From The Pretrip Menu
µP-D Controller 4-26 Menu Pretrip Functions Shutdown Alarm fault occurs during a Pretest • To initiate a Full Pretrip Test: test, the Alarm LED FLASHES and the controller Press the SELECT key with “PTRIP FTEST” in the stops all unit operation. Press the ALARM key to display.
Page 65: Menu Test Functions
µP-D Controller Menu Test Functions 4-27 heaters, motors or unit during Full Cool, Modulation 50%, Menu Test Functions Modulation 100%, Heat and Defrost. • Refrigeration [REFRG]: Perform system diagnostics and check supply and return air temperatures during each unit WARNING: Activating some tests in the Menu Test operating mode.
Page 66 µP-D Controller 4-28 Menu Test Functions NOTE: When the Test Menu is entered, the UNIT 7. Press the DOWN key to view functions in sub-submenu. STOPS. A technician can then select the control cir- Press the UP key to scroll back through sub-submenu. cuit or component to be checked/tested from the The display shows the test function (e.g.
Page 67: Menu Guard Functions
µP-D Controller Menu Guard Functions 4-29 Navigating Menu Guard Screens Menu Guard Functions With the unit On/Off switch ON and the controller showing the Standard Display: NOTE: An access code is required to enter the Press the SELECT key to enter menu (display shows Guard menu to prevent unauthorized personnel from “MENU <--->”).
Page 68: Setting The Unit Configuration And Customer Configuration Numbers
µP-D Controller 4-30 Menu Guard Functions NOTE: If the correct code is not entered, the dis- NOTE: If the Customer Configuration has play returns to “GUARD <--->”. already been set, the current number (ZZ format) will show instead of “0”. The Unit Configuration Press the DOWN or UP key to scroll through the menu list.
Page 69: Setting The Unit Serial Number
µP-D Controller Menu Guard Functions 4-31 When all characters in the Container Identification Setting the Date and Time Number have been entered, press the ENTER key. The From “USN 11 XXX” (where the scrolling XXX is your display shows “CID LOAD” and then shows the new unit serial number) in the Guard menu, press the DOWN number (left display shows CID11 again as the right dis- key until the display shows “YEAR 1996”.
Page 70: Setting The Compressor And On Time Hourmeters
µP-D Controller 4-32 Menu Guard Functions 5. If the hour is correct, press the DOWN key until the dis- Press the SELECT key to enter the load Compressor play shows “MIN MM” (where “MM” is the minute). Hourmeter display (left display flashes “ONHRM”). Press the SELECT key to enter the load Minute dis- Press the UP or DOWN key to choose the desired play (left display flashes “MIN”).
Page 71: 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 72 µP-D Controller 4-34 Menu Guard Functions To calibrate the sensor in an ice bath: To set the sensor grade: • Press the UP or DOWN key to choose “0” as the • Press the UP or DOWN key to choose the grade setting in the right display.
Page 73: Changing The Display Units (C/F)
µP-D Controller Menu Guard Functions 4-35 • When the sensor temperature is within 1.7 C [3 Press the DOWN key until “SPR1G XX” shows in the F] above or below 0 C (32 F), the left display display (where “XX” is the sensor grade). (“CCT”) begins to flash.
Page 74: Menu Program Functions
µP-D Controller 4-36 Menu Program Functions USDA Sensors Menu Program Functions Changing the USDA program screen from OFF to ON acti- vates spare sensors 1, 2 and 3 for USDA Cold Treatment NOTE: When the unit is OFF, the following options Temperature Recording.
Page 75: Pulp Sensor (Option)
µP-D Controller Menu Program Functions 4-37 NOTE: The sensors should be in the ice bath Setting and Calibrating the USDA Sensors a total of 15 minutes or more to assure the Insert all USDA sensors in an ice bath (see “Ice Bath sensor temperature has bottomed out.
Page 76: Economy Mode
µP-D Controller 4-38 Menu Program Functions 8. To load the new setting, press the ENTER key. The dis- • Chill Loads (return air temperatures of -9.9 C (14.1 F) and play briefly shows “PULP LOAD”. above): Evaporator fans operate on low speed whenever 9.
Page 77: Dehumidify Mode (Option)
µP-D Controller Menu Program Functions 4-39 5. To change the current setting, press the SELECT key. Dehumidify Mode (Option) “HUMID” will begin to flash in the left display. The Dehumidify Mode reduces the humidity level in the con- 6. Press the UP or DOWN key to scroll the right display to tainer by condensing more moisture from the container air.
Page 78: Bulb Mode (Option)
µP-D Controller 4-40 Menu Program Functions Setting the Humidify Mode Bulb Mode (Option) Changing the Bulb screen from OFF to ON automatically acti- 1. Press the SELECT key to enter menu (display shows vates the Dehumidify Mode and allows the defrost termination “MENU <--->”.
Page 79: Power Reduction Mode
µP-D Controller Menu Program Functions 4-41 When the Bulb mode is ON, the defrost termination tem- Power Reduction Mode perature screen “BDFTT” appears in the Program menu. Changing the Power Reduction program screen from OFF to To change the defrost termination temperature: ON activates the power reduction control algorithm that With “BULB ON”...
Page 80: Controller Emergency Bypass Procedure
µP-D Controller 4-42 Controller Emergency Bypass Procedure COMPLETE stop. Then place the Phase Rotation Controller Emergency Bypass Procedure switch in the CBA position. Check condenser airflow again to confirm that air is blowing out from the cen- In the event the controller fails or the serial communications ter of the grille.
Page 81: Output Module
µP-D Controller Output Module 4-43 High Pressure Cutout (HPCO) and 24 Vac LEDs on the Output Module Emergency Bypass Module turn ON to indicate normal operation. The controller uses the output module to energize and de-ener- • The HPCO LED is ON when the HPCO switch is gize unit contactors and solenoids.
Page 82: Replacing The Μp-D Controller
Replacing the µ µ P-D Controller µP-D Controller 4-44 7. Attach the wire harness connectors to the back of the con- Replacing the µ µ P-D Controller troller. NOTE: Be certain that all connectors are fully CAUTION: When replacing a controller, correct unit seated until the connector rings lock.
Page 83: Diagnosis And Repair
µP-D Controller Diagnosis and Repair 4-45 • Ambient sensor must be placed on the bottom plate of the Diagnosis and Repair right forklift pocket. • Compressor discharge temperature sensor must be placed in If the unit appears to be operating incorrectly, view any alarm the discharge service valve manifold.
Page 84: Alarm Codes, Descriptions And Corrective Actions 4-46 To
µP-D Controller 4-46 Alarm Codes, Descriptions and Corrective Actions Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action No Fault • None Required Ambient Temperature Sensor Failure • Check the sensor by selecting it using the View (Check Alarm) menu.
Page 85 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-47 Code Description Corrective Action KVQ Valve Thermistor Error • Check the KVQ valve thermistor circuit with an (Check Alarm) ohmmeter. Good thermistor sensor should read 20,000 ohms at 20 C (78 F). •...
Page 86 µP-D Controller 4-48 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action Humidity Sensor Error • Check the sensor by selecting it using the View (Check Alarm) menu. If the display shows [- - - -], the sensor is defective or the circuit is open or shorted.
Page 87 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-49 Code Description Corrective Action High Pressure Cutout • Check for a dirty or restricted condenser coil. (Check Alarm) • Check for correct condenser fan operation using • Indicates the high pressure cutout switch “AMPS CFH”...
Page 88 µP-D Controller 4-50 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action Defrost Terminated by TIme Limit • Check electric heater rod operation using the (Check Alarm) “AMPS HEATR” test in the Electrical Test submenu. • Indicates the controller terminated a defrost •...
Page 89 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-51 Code Description Corrective Action Spare Sensor 5 Failure (Option) • Check the sensor by selecting it using the View (Check Alarm) menu. If the display shows [- - - -], the sensor is defective or the circuit is open or shorted.
Page 90 µP-D Controller 4-52 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action Three Phase Current Imbalance • Check supply power voltage on all three phases. (Shutdown Alarm) Voltage should be present on all three phases and with 90% below or 110% above the rated voltage. •...
Page 91 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-53 Code Description Corrective Action USDA 1 Sensor Failure (Option) • Check the sensor by selecting it using the View (Check Alarm) menu. If USDA1 display shows [- - - -], the sensor is defective or the circuit is open or shorted.
Page 92 µP-D Controller 4-54 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action Pulp Sensor Failure (Option) • Check the sensor by selecting it using the View (Check Alarm) menu. If PULP1 display shows [- - - -], the sensor is defective or the circuit is open or shorted.
Page 93 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-55 Code Description Corrective Action Unit Current Out-of-Range in COOL Mode • Check for low supply power voltage. (Check or Shutdown Alarm) • Check the compressor current draw with a digital • Indicates total unit current draw is not within multimeter.
Page 94 µP-D Controller 4-56 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action Modulation System Failure (Pretrip) • Perform a Full Pretrip Test to check modulation (Check or Shutdown Alarm) valve operation. • Indicates modulation valve current draw is not •...
Page 95 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-57 Code Description Corrective Action Defrost Current Out-of-Range (Pretrip) • Check for low supply power voltage. (Check or Shutdown Alarm) • Check the heater element current draw using the • Indicates total unit current draw is not within “REFRG DFRST”...
Page 96 µP-D Controller 4-58 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action High Speed Evaporator Fan Failure • Check for low supply power voltage. (Pretrip) (Check or Shutdown Alarm) • Check high speed evaporator fan current draw • Indicates evaporator fan current draw is not using “AMPS EFH”...
Page 97 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-59 Code Description Corrective Action Low Speed Evaporator Fan Failure • Check for low supply power voltage. (Pretrip) (Check or Shutdown Alarm) • Check low speed evaporator fan current draw • Indicates evaporator fan current draw is not using “AMPS EFL”...
Page 98 µP-D Controller 4-60 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action Condenser Fan Current Out-of-Range (Pretrip) • Check for low supply power voltage. (Check or Shutdown Alarm) • Check condenser fan current draw using “AMPS • Indicates condenser fan current draw is not CFH”...
Page 99 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-61 Code Description Corrective Action µ µ P-A+ Datalogger Full • Enter a Start of Trip to place a marker in the (Check Alarm) controller’s data logger memory. • Indicates datalogger is full. •...
Page 100 µP-D Controller 4-62 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action Pretrip Preconditioning Failure • Check the container to be sure it is not loaded. (Check Alarm) • Check unit cooling and heating operation. • Indicates a heating or cooling problem; Pretrip Test pre-cooling or pre-heating of the •...
Page 101 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-63 Code Description Corrective Action Hourmeter Alarm • The hourmeter exceeded 99,999. Reset the (Check Alarm) hourmeter to 0. • Indicates a problem with one or more of the controller’s internal hourmeters. User Hourmeter 1 Expired •...
Page 102 µP-D Controller 4-64 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action Compressor Temperature Sensor Failure • Check the sensor by selecting it using the View (Check Alarm) menu. If the display shows [- - - -], the sensor is defective or the circuit is open or shorted.
Page 103 µP-D Controller Alarm Codes, Descriptions and Corrective Actions 4-65 Code Description Corrective Action Compressor Current Out-of-Range • Check for low supply power voltage. (Check or Shutdown Alarm) • Check the compressor current draw with a digital • Indicates compressor motor has failed to multimeter.
Page 104 µP-D Controller 4-66 Alarm Codes, Descriptions and Corrective Actions Code Description Corrective Action Condenser Fan Sensor Failure • Check the sensor by selecting it using the View (Check Alarm) menu. If the display shows [- - - -], the sensor is defective or the circuit is open or shorted.
Page 105: Electrical Maintenance
Electrical Maintenance Raise the discharge pressure of the compressor by block- Unit Wiring ing the condenser coil airflow. Temporarily cover the compressor compartment, control box and power cord Inspect unit wiring, wire harnesses, and the controller during storage compartment with cardboard to reduce condenser pre-trip inspection and every 1,000 operating hours to protect coil airflow.
Page 106: Condenser Fan And Evaporator Fan Rotation
Condenser Fan and Evaporator Fan Rotation Electrical Maintenance Be sure to remove the cardboard installed in step 3. If an evaporator fan rotate backwards on one or both speeds, refer to the unit wiring diagram to correct motor wiring NOTE: To clear the HPCO alarm, press the at the fan motor junction box or evaporator fan contactor (dis- ALARM key on the controller.
Page 107: Service Tools
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-404A 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 108: Gauge Manifold Valve Positions
Gauge Manifold Set 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-404A only.
Page 109 Refrigeration Maintenance and Service Operations Gauge Manifold Set Attachment charge) hand valves on the gauge manifold should be fully closed to center port. 2. Clean dirt and moisture from around service access valves on suction and discharge lines. Remove service port caps. Attach the low side hose (compound gauge) to the access valve on the suction line finger tight.
Page 110: Checking Compressor Oil
Checking Compressor Oil Refrigeration Maintenance and Service Operations Adding Compressor Oil Checking Compressor Oil 1. With the unit OFF, remove the cap from oil pressure fit- ting. 2. Using a commercial hand pump, force oil in through the CAUTION: oil pressure fitting. Slowly add oil. Add Polyol Ester oil, •...
Page 111: Refrigerant Charge
Refrigeration Maintenance and Service Operations Refrigerant Charge accurately determine the cooling performance and refrigerant Refrigerant Charge charge level, operate the unit on Full Cool for 15 minutes or more: Adjust the setpoint well below the ambient temperature to NOTE: CSR Hermetic units do not have service force the unit to Full Cool.
Page 112: Refrigerant Leak Test Procedure
Refrigerant Leak Test Procedure Refrigeration Maintenance and Service Operations 9. Pressurize the system with nitrogen to 1380 kPa, 13.80 Refrigerant Leak Test Procedure bar, 200 psig. 10. Close the supply valve on the nitrogen bottle. Use a reliable Halogen leak detector such as model H10G, P/N 11.
Page 113: Refrigerant Recovery From Semi-Hermetic Refrigeration Systems
Purge system high side to low side. approved for and dedicated to R-404A recovery. The following procedures should utilize the following When removing any refrigerant from a Thermo King refrigera- MAXIMUM gas pressure: tion system, use a recovery process that prevents or absolutely •...
Page 114: Evacuation And Cleanup Of The Refrigeration System
Evacuation and Cleanup of System Refrigeration Maintenance and Service Operations Compressor Oil Color Code Evacuation and Cleanup of the BLACK OIL — indicates carbonization caused by air in the Refrigeration System system. BROWN OIL — indicates copper plating caused by moisture in the system.
Page 115 Refrigeration Maintenance and Service Operations Evacuation and Cleanup of System Evacuation Station and Unit Hook-up 1. Special, self-sealing quick disconnect couplers are required for R-404A units. 2. Gas Ballast Valve 3. Iso Valve 4. Two-stage Vacuum Pump 5. To 220/190 VAC Power 6.
Page 116 Evacuate the system to 500 microns to achieve a final equilibrium pressure of 2000 microns or less. The final Pressure Rise Test equilibrium pressure is determined with the Thermo King Evacuate the system and close valve V1. With valves V3 and Evacuation Station using the following procedure (called...
Page 117 Refrigeration Maintenance and Service Operations Evacuation and Cleanup of System 6-11 Factors Affecting the Speed of System Evacuation Heat Saves Time It is almost impossible to state the exact amount of time A useful and practical time saver is the application of heat to required to evacuate any system.
Page 118: Charging The System With Refrigerant
6-12 Charging the System with Refrigerant Refrigeration Maintenance and Service Operations Charging the System with Refrigerant Modulation Valve Repair or Replacement The modulation valve is used to control the flow of refrigerant Unit Charging by Weight (from an Evacuated to the compressor when the unit is operating in the Modulation Condition) mode.
Page 119 Refrigeration Maintenance and Service Operations Modulation Valve Repair 6-13 Replacing the Enclosure Tube Assembly Enclosure Tube Replacement If the modulation fails to operate properly, remove the coil CAUTION: When replacing the enclosing tube housing and inspect the solenoid coil sleeve and enclosure tube assembly, DO NOT remove the valve piston, top assembly for rust or corrosion.
Page 120: Compressor Replacement
6-14 Compressor Replacement Refrigeration Maintenance and Service Operations 8. Hold valve piston in valve body with scissors while you 7. Solder both modulation valve connections. finish removing the enclosure tube. Immediately insert CAUTION: Use a heat sink or wrap the valve with new enclosure tube carefully over piston top.
Page 121: Condenser Coil Replacement
Refrigeration Maintenance and Service Operations Condenser Coil Replacement 6-15 Installation Condenser Coil Replacement Add new compressor oil to the new compressor. Add an amount equal to the amount removed from the old com- pressor. Removal Recover the refrigerant charge from the unit (see CAUTION: Use ONLY Polyol Ester based refrig- “Refrigerant Recovery”...
Page 122: Filter Drier/In-Line Filter Replacement
6-16 Filter Drier/In-line Filter Replacement Refrigeration Maintenance and Service Operations Filter Drier/In-line Filter Replacement Expansion Valve Replacement NOTE: CSR Hermetic units use a one-piece, combi- NOTE: CSR semi-hermetic units use a non- nation filter drier/in-line filter, P/N 66-9306. adjustable, factory sealed expansion valve. Do NOT attempt to remove the seal or adjust the valve.
Page 123: Heat Exchanger Replacement
Solder the suction inlet and outlet line connections. NOTE: Thermo King strongly recommends that NOTE: It is strongly recommended that dry dry nitrogen be used to purge the system during nitrogen be used to purge the system during any any solder operations (see “Using Pressurized...
Page 124: Discharge Temperature Sensor Replacement
6-18 High Pressure Switch Replacement Refrigeration Maintenance and Service Operations High Pressure Cutout Switch or Warm Gas Bypass Valve, Liquid Injection Compressor Discharge Temperature Sensor Valve or Dehumidify Valve (Option) Replacement Replacement Removal NOTE: In most cases, only the coil requires replace- 1.
Page 125: Structural/Accessory Maintenance
Structural/Accessory Maintenance Mounting Bolts Condenser Coil Check and tighten all unit, compressor, and fan motor mount- Clean the condenser coil by blowing low pressure compressed ing bolts during pretrip inspections and every 1,000 operating air or a medium pressure warm water spray from the inside of hours.
Page 126: Defrost Drains
Defrost Drains Structural/Accessory Maintenance 3. Align handle bracket and wing nut over hole in handle Defrost Drains assembly and push through handle. 4. Pull handle down to lower ventilation door. Insert edge of Clean the defrost drains every 1,000 operating hours to be sure ventilation door in handle notch.
Page 127: Condenser Fan Location
Structural/Accessory Maintenance Condenser Fan Location • Blue Zone — Battery good. If the indicator needle remains Condenser Fan Location in the blue zone when the test button is depressed, the battery has sufficient power to operate the recorder. Place fan blade on motor shaft with hub located on the outside •...
Page 128: Recording Chart Replacement
Saginomiya (Model SKM) Recording Thermometer Structural/Accessory Maintenance To replace the battery: 3. Wait at least 5 minutes to allow the recording thermome- Raise the stylus away from the chart by rotating the pen ter sensing bulb temperature to stabilize. Then compare lift gear clockwise 30 degrees and releasing the lifting the “RET”...
Page 129: Timer
Structural/Accessory Maintenance Saginomiya (Model SKM) Recording Thermometer Timer (Quartz Motor and Reducing Gear) Battery Voltage Indicator Replacement The battery voltage indicator is field replaceable. If the indica- The quartz motor is field replaceable. To replace the motor tor needle oscillates when the test button is depressed, or the and reducing gear assembly: needle remains in the red zone when a new battery is installed, Raise the stylus away from the chart.
Page 131: Diagnosis
Diagnosis Mechanical Diagnosis Condition Possible Cause Remedy Compressor does not Controller ON; unit start Wait up to 2 minutes for compressor operate — no amperage sequence still timing start-up draw No power to unit (condenser and Check and repair: power source, power evaporator fans do not operate) plug, CB1 main circuit breaker, motor con- tactor, motor terminals, motor...
Page 132 Mechanical Diagnosis Diagnosis Condition Possible Cause Remedy Compressor does not Rotating scroll stuck Replace compressor operate; excessive amperage draw or Seized or frozen compressor bearings Replace compressor intermittent cycling on overload Improperly wired Check/correct wiring against wiring diagram Low line voltage Check line voltage —...
Page 133 Diagnosis Mechanical Diagnosis Condition Possible Cause Remedy Condenser fan motor does Unit in Null, Heat or Defrost Check indicator lights. If unit is in not operate Null, Heat or Defrost, unit operation is normal (no remedy required) Unit in Cool or Modulation Check indicator lights and condenser pres- sure in View menu of µP-D controller.
Page 134 Mechanical Diagnosis Diagnosis Condition Possible Cause Remedy Noisy compressor Loose mounting bolts Tighten mounting bolts Oil slugging or refrigerant flooding Perform controller Pretrip Test to check back refrigerant charge. Check expansion valve adjustment. Check compressor for compressor oil. Scroll rotating backwards Check phase correction system and check unit wiring Defective compressor...
Page 135: Refrigeration Diagnosis
Diagnosis Refrigeration Diagnosis Refrigeration Diagnosis Condition Possible Cause Remedy Load temperature too high Compressor does not operate See “Mechanical Diagnosis” (unit not cooling) Controller setpoint too high Adjust controller setpoint Defective container insulation or Repair container poor fitting doors Shortage of refrigerant Repair leak and recharge Overcharge of refrigerant Purge system...
Page 136 Refrigeration Diagnosis Diagnosis Condition Possible Cause Remedy Head pressure too low Shortage of refrigerant Repair leak and recharge NOTE: This unit has a Low ambient air temperature No remedy suction modulation capacity control system. Service gauge out of calibration Replace gauge Suction and discharge pressures may drop below expected normal readings...
Page 137 Diagnosis Refrigeration Diagnosis Condition Possible Cause Remedy Rapid cycling between Air short cycling through evaporator Check and correct cargo load Cool, Null and Heat Check controller with µP-D Microprocessor modes Defective controller Tester (see Diagnosis Manual, TK 41230) Short cycling See “Unit short cycles”...
Page 138 Refrigeration Diagnosis Diagnosis Condition Possible Cause Remedy Low suction pressure Shortage of refrigerant Repair leak and recharge NOTE: This unit has a Low ambient air temperature No remedy suction modulation capacity control system. Iced or dirty evaporator coil Defrost or clean evaporator coil Suction and discharge pressures may drop below Restricted lines...
Page 139: 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. CSR40SL Semi-Hermetic, February 2000...
Page 140: External 12 Vdc Battery Power Supply
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings External 12 Vdc Battery Power Supply 1, 2 Typical model shown with three evaporator fans. Requires on-board 12 Vdc battery or an external 12 Vdc battery connected to battery jack on Power Module Board inside control box.
Page 141: Microprocessor Awakened From Sleep Mode
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings Microprocessor Awakened from Sleep Mode (when external power is disconnected from unit) When external power is disconnected from unit, microprocessor operation requires an on-board 12 Vdc battery, or an external 12 Vdc battery connected to the battery jack on Power Module Board inside control box. Then press SELECT key or connect communications cable to Data Port on bottom of control box.
Page 142: Vdc Control Circuit, Sensor Circuits, Modulation Valve Circuit And Water Pressure Circuit (Option)
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings 12.5 Vdc Control Circuit, Sensor Circuits, Modulation Valve Circuit and Water Pressure Circuit (Option) Typical model shown with three evaporator fans. CSR40SL Semi-Hermetic, February 2000...
Page 143: 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. CSR40SL Semi-Hermetic, February 2000...
Page 144: Chart Recorder Circuits (Options)
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings Dehumidify System, Humidity System, Water Pressure Switch, USDA Temperature Sensor, Pulp Sensor and Chart Recorder Circuits (Options) Typical model shown with three evaporator fans. CSR40SL Semi-Hermetic, February 2000...
Page 145: Cool Mode - Chill Load (Setpoint At -9.9 C [14.1 F] Or Above); Condenser Fan On; Power Monitor Limiting Unit Power Consumption; Economy Mode Off
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings Cool Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan ON ; Power Monitor Limiting Unit Power Consumption; Economy Mode OFF Typical model shown with three evaporator fans. A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above 50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
Page 146 Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings Cool Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan ON ; Economy Mode OFF Typical model shown with three evaporator fans. A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above 50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
Page 147: Modulation Mode - Chill Load
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings Modulation Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan ON ; Economy Mode OFF; Temperature Out-of-range Typical model shown with three evaporator fans. A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above 50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
Page 148: Modulation Mode - Chill Load
Electrical, Refrigeration and µP-D Menu Flow Diagrams 9-10 Schematic Circuit Tracings Modulation Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan ON ; Economy Mode OFF; Temperature In-range; Dehumidify ON with Humidity 1-5% Above Humidity Setpoint Typical model shown with three evaporator fans.
Page 149 Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings 9-11 Modulation Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan ON ; Economy Mode OFF; Temperature In-range; Dehumidify ON with Humidity 5% or More Above Humidity Setpoint Typical model shown with three evaporator fans.
Page 150: Temperature In-Range
Electrical, Refrigeration and µP-D Menu Flow Diagrams 9-12 Schematic Circuit Tracings Modulation Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan OFF ; Economy Mode ; Temperature In-range Typical model shown with three evaporator fans. A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above 50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
Page 151 Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings 9-13 Modulation Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan OFF ; Economy Mode ; Temperature In-range, Warm Gas Bypass Valve ON Typical model shown with three evaporator fans. A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above 50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
Page 152: Null Mode - Chill Load (Setpoint At -9.9 C [14.1 F] Or Above) Condenser Fan On; Economy Mode Off
Electrical, Refrigeration and µP-D Menu Flow Diagrams 9-14 Schematic Circuit Tracings Null Mode — Chill Load (Setpoint at -9.9 C [14.1 F] or Above), Condenser Fan ON ; Economy Mode OFF Typical model shown with three evaporator fans. The controller stops the compressor. If the condenser fan was ON, it will operate for 30 seconds and then stop. CSR40SL Semi-Hermetic, February 2000...
Page 153: Heat Mode - Chill Load (Setpoint At -9.9 C [14.1 F] Or Above); Economy Mode Off; Temperature In-Range
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings 9-15 Heat Mode 1, 2 — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Economy Mode OFF; Temperature In-range Typical model shown with three evaporator fans. Electric heaters pulse ON and OFF during the Heat mode. The amount of ON time increases from 0% at a Calculated Temperature Differential of 0.6 C (1.0 F) below setpoint to 100% at a Calculated Temperature Differential of 3.1 C (5.5 F) below setpoint.
Page 154: Cool Mode - Frozen Load
Electrical, Refrigeration and µP-D Menu Flow Diagrams 9-16 Schematic Circuit Tracings Cool Mode — Frozen Load (Setpoint at -10.0 C [14.0 F] or Below); Condenser Fan ON ; Container Return Air Temperature Above -10.0 C (14.0 F); Power Monitor Limiting Unit Power Consumption; Economy Mode OFF Typical model shown with three evaporator fans.
Page 155: Cool Mode - Frozen Load
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings 9-17 Cool Mode — Frozen Load (Setpoint at -10.0 C [14.0 F] or Below); Condenser Fan ON ; Container Return Air Temperature Below -10.0 C (14.0 F); Economy Mode OFF; Temperature In-Range Typical model shown with three evaporator fans.
Page 156: Null Mode - Frozen Load (Setpoint At -10.0 C [14.0 F] Or Below) Condenser Fan Off; Economy Mode Off
Electrical, Refrigeration and µP-D Menu Flow Diagrams 9-18 Schematic Circuit Tracings Null Mode — Frozen Load (Setpoint at -10.0 C [14.0 F] or Below); Condenser Fan OFF ; Economy Mode OFF Typical model shown with three evaporator fans. Controller stops the compressor. If the condenser fan was ON, it will operate for 30 seconds and then stop. CSR40SL Semi-Hermetic, February 2000...
Page 157: Null Mode - Frozen Load (Setpoint At -10.0 C [14.0 F] Or Below) Condenser Fan Off; Economy Mode On
Electrical, Refrigeration and µP-D Menu Flow Diagrams Schematic Circuit Tracings 9-19 Null Mode — Frozen Load (Setpoint at -10.0 C [14.0 F] or Below); Condenser Fan OFF ; Economy Mode ON Typical model shown with three evaporator fans. Controller stops the compressor. If the condenser fan was ON, it will operate for 30 seconds and then stop. Evaporator fans stop during Null mode when Economy Mode is set to ON in the Program menu of the µP-D con- troller.
Page 158: Defrost
Electrical, Refrigeration and µP-D Menu Flow Diagrams 9-20 Defrost Typical model shown with three evaporator fans. CSR40SL Semi-Hermetic, February 2000...
Page 159: Csr40Sl Wiring Schematic
Electrical, Refrigeration and µP-D Menu Flow Diagrams CSR40SL Wiring Schematic 9-21 CSR40SL Semi-Hermetic, February 2000...
Page 160: Csr40Sl Wiring Diagram - Page 1 Of 3
Electrical, Refrigeration and µP-D Menu Flow Diagrams CSR40SL Wiring Diagram — Page 1 of 3 9-22 CSR40SL Semi-Hermetic, February 2000...
Page 161 Electrical, Refrigeration and µP-D Menu Flow Diagrams CSR40SL Wiring Diagram — Page 2 of 3 9-23 CSR40SL Semi-Hermetic, February 2000...
Page 162 Electrical, Refrigeration and µP-D Menu Flow Diagrams CSR40SL Wiring Diagram — Page 3 of 3 9-24 CSR40SL Semi-Hermetic, February 2000...
Page 163: Refrigeration System Components
Electrical, Refrigeration and µP-D Menu Flow Diagrams Refrigeration Schematic: Components 9-25 CSR40SL Refrigeration System Components Scroll Compressor Sight Glass Oil Fill / Drain Fitting Compressor Discharge Temperature Sensor (CDTS) High Pressure Cutout Switch (HPCO) Schrader Valve, Discharge Line Flange Connection, Discharge Line Condenser Coil (Circular) Receiver Tank 10.
Page 164 Electrical, Refrigeration and µP-D Menu Flow Diagrams Refrigeration Schematic: Full Cool 9-26 Flow and Pressure Diagram CSR40SL Full Cool Scroll Compressor Compressor operation has a delay on initial start-up when the unit shifts to a cooling mode requiring the compressor to start-up. Compressor Discharge (Head) Temperature Sensor (CHS1) Controller cycles condenser fan ON typically when the compressor discharge temperature is above 50 C (122 F) and increasing.
Page 165 Electrical, Refrigeration and µP-D Menu Flow Diagrams Refrigeration Schematic: Modulation Cool 9-27 Flow and Pressure Diagram CSR40SL Modulation Cool 10. Warm Gas Bypass Valve Is a normally CLOSED solenoid. It OPENS when energized to reduce cooling capacity when the tem- perature is close to setpoint.
Page 166 Electrical, Refrigeration and µP-D Menu Flow Diagrams Refrigeration Schematic: Dehumidification 9-28 Flow and Pressure Diagram CSR40SL Dehumidification 32. Dehumidify Solenoid Valve (DSV) (Option) Is a normally OPEN valve. If the container humidity is 1% or more above the humidity setpoint and the temperature is in-range, the controller will energize (CLOSE) the normally open solenoid.
Page 167: Μp-D Menu Flow Diagram
µ µ P-D Menu Flow Diagram Electrical, Refrigeration and µP-D Menu Flow Diagrams 9-29 CSR40SL Semi-Hermetic, February 2000...

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