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KLINGE TCR-104-15 Operation, Service And Parts Manual

Tank container refrigeration unit
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MODEL TCR-104-15
TANK CONTAINER REFRIGERATION UNIT
OPERATION, SERVICE AND PARTS MANUAL
Address: 4075 East Market Street York, PA 17402-5100 USA
Telephone: 717-840-4500
Telefax: 717-840-4501
www.klingecorp.com
MANUFACTURED BY KLINGE CORPORATION
UNCONTROLLED WHEN PRINTED
K35-TCR104-15
Rev. J, August 2024

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  • Page 1 MODEL TCR-104-15 TANK CONTAINER REFRIGERATION UNIT OPERATION, SERVICE AND PARTS MANUAL Address: 4075 East Market Street York, PA 17402-5100 USA Telephone: 717-840-4500 Telefax: 717-840-4501 www.klingecorp.com MANUFACTURED BY KLINGE CORPORATION UNCONTROLLED WHEN PRINTED K35-TCR104-15 Rev. J, August 2024...
  • Page 2 UNCONTROLLED IF PRINTED K35-TCR104-15 Rev. J, August 2024...

  • Page 3: Revision Record

    REVISION RECORD Description Date Approved Section 8.3B, corrected Items 31, 32, 2017/03/02 33, added “UNCONTROLLED IF PRINTED” Updated Electrical Schematic, page 15, Section 8.3B, Item 23 was K24-22148- 2017/03/23 00, Item 28 was K24-22269-00, deleted “SUGGESTED SPARE PARTS” page 50 Updated Section 5.2 Safety page 22, Section 8.3A changed Item 1 to 360 2017/11/30...

  • Page 4: Table Of Contents

    Contents Service Request ............................5 Spare Parts Request ..........................5 Use of this Manual ............................. 5 SECTION 1.0 GENERAL DESCRIPTION ....................6 1.1 Compressor ............................6 1.2 Chiller ..............................6 1.3 Glycol Components & System ......................6 1.4 Refrigeration System & Components ....................7 1.5 Piping Schematic ..........................

  • Page 5: Service Request

    Service Request Requests for Service should be directed to the Klinge Service Team. The below link should be used to place all requests for service and will afford the quickest response time. https://klingecorp.com/request-service/ This form will help us determine model and age of the equipment, location, basic details about the issue, who to contact and how to best handle the issues with the equipment.

  • Page 6: Section 1.0 General Description

    SECTION 1.0 GENERAL DESCRIPTION This unit is especially designed for cooling heat transfer fluid, which is used to control the temperature of tank containers. The machine is designed for uses in combination with ethylene glycol, propylene glycol, or synthetic oils where different cargoes dictate a different cooling medium.

  • Page 7: Refrigeration System & Components

    1.3.1 Cleanliness of the Glycol System New cooling systems are typically coated with oil, grease, or protective film during fabrication. Welding byproducts, flux and scale that would not normally cause a problem with a steam system can cause a problem with the glycol heat exchanger – the chiller. Dirt will migrate to the chiller (a plate type heat exchanger) and may block the small gaps between each plate.

  • Page 8: Piping Schematic

    1.5 Piping Schematic UNCONTROLLED IF PRINTED K35-TCR104-15 Rev. J, August 2024...

  • Page 9: Section 2.0 Operation

    SECTION 2.0 OPERATION 2.1 Pre-starting Check The following inspection should be made before the container is loaded as part of a pre-trip inspection. All electrical power to the unit should be disconnected before inspection. 1. Visually check unit for physical damage. 2.
  • Page 10 Both temperature controls are set using the touch pad control panel. The sequence of events or cycles of the unit are governed by the controller in conjunction with the cargo and supply glycol temperature probes and the temperature control settings selected on the touch pad panel. There are two possible control configurations depending on the cargo: 1) For normal cargoes that are not sensitive to local “under-cooling”...
  • Page 11 The energy of the pumping action is transferred to the glycol in the form of heat. Therefore, if for some reason the unit is not cooling it is best to turn the system off to avoid heating up the glycol in the expansion tank from the heat from the pump.
  • Page 12 UNCONTROLLED IF PRINTED K35-TCR104-15 Rev. J, August 2024...

  • Page 13: Section 3.0 Electrical Functions

    SECTION 3.0 ELECTRICAL FUNCTIONS 3.1 General Information (Refer to Electrical Schematic) When high voltage power is being fed to the unit and CB1 is in the ON position, power will pass along L1, L2 and L3 to the compressor contactor, transformer, phase sensor and phase contactors. When the phase sensor is energized, PC1 or PC2 will be energized and allow power to the condenser fan contactor and glycol pump.
  • Page 14 When the unit has proper voltage and frequency, it automatically selects correct phase rotation. By putting the unit ON/OFF switch to the ON position, 24 volts will pass to pin no. 5. The phase sensor will switch the 24 volts to pin 6 or 8 to give the motors the proper rotation. Test procedure of phase sensor: 1.

  • Page 15: Electrical Schematic

    3.3 Electrical Schematic UNCONTROLLED IF PRINTED K35-TCR104-15 Rev. J, August 2024...

  • Page 16: Section 4.0 Microprocessor Thermostat

    SECTION 4.0 MICROPROCESSOR THERMOSTAT 4.1 General Information The microprocessor thermostat is an electronic solid-state device consisting of three parts: 1. The microprocessor board. 2. The cargo and glycol temperature probes 3. The display panel. All parts are mounted in the control box except the temperature probes, one of which is mounted in the thermowell of the expansion tank and the other in or on the glycol pipe outlet from the unit.
  • Page 17 4.2.1 General Description The temperature select/display panel consists of three touch pad switches and a three-position alpha- numeric display. See drawing of the front panel. The display normally shows: Cargo temperature as derived from the cargo probe in the expansion tank. The glycol probe temperature can be seen by pushing the switch (GLYCOL TEMP) up.

  • Page 18: Temperature Sensors

    4.3 Temperature Sensors Each temperature sensing probe is a thermistor placed in a sealed metal tube, which is connected to a two- conductor shielded cable. The temperature signal from the probe is connected to the microprocessor board through this cable. The probes are labeled CARGO and GLYCOL but other than length, they are both the identical sensors.

  • Page 19: Microprocessor Thermostat And Data Logger

    WARNING: It is important that the sensors are properly mounted and functioning. Use an ohmmeter to check probes. Zero Ohms resistance indicates a short circuit. An open circuit is indicated by infinite Ohms resistance. Good readings should agree with the chart below: PROBE RESISTANCE CHART Probe at Ambient K-Ohms...

  • Page 20: Microprocessor Control Sequence/ Functionality

    1. Compressor ON (cooling) 2. Condenser fan ON 3. Phase sensor ON (for glycol pump) 4. Connection for Data stream to an external computer to record the data logger (if equipped) 4.5 Microprocessor Control Sequence/ Functionality 4.5.1 Temperature Falling • Compressor cycles off at set point.
  • Page 21 UNCONTROLLED IF PRINTED K35-TCR104-15 Rev. J, August 2024...
  • Page 22 4.5.3 Function Test (Label on right side of thermostat) The thermostat is provided with an automatic function test, which energizes the glycol pump, condenser fan, compressor motor, heater (if equipped), and tests the cargo and glycol probes for open or shorted circuits. During the function test, refer only to the label on the side of the thermostat.

  • Page 23: Section 5.0 Maintenance And Service Instruction

    SECTION 5.0 MAINTENANCE AND SERVICE INSTRUCTION 5.1 General This section provides procedures for establishing preventative maintenance and systematic servicing schedules, which are the keys to successful operation. All service and maintenance procedures should be performed in accordance with Montreal protocol or national equivalent of the American Section 608 of the Clean Air Act.

  • Page 24: Checking Refrigerant Charge

    The roof of the container should only be accessed by trained staff. It is suggested that specific company-based SOP’s be established to monitor and govern this. Also, it is highly recommended that proper fall protection is utilized. Proper securing of internal cargo should be done to company established SOP’s based on the type of cargo being stored and transported.

  • Page 25: Non-Condensable Gases

    a. Remove the compressor suction service valve cap and back seat the valve. This closes the charging port. Remove the cap from the port and loosely attach the suction gauge line of a manifold set. Connect the center charging line to refrigerant cylinder and tighten the connection. b.

  • Page 26: Pre-Trip Checklist

    5.9 Pre-Trip Checklist It is important a Pre-Trip Inspection (PTI) be completed prior to each shipment. The TCR-104 PTI form can be found on Klinge’s website at: http://www.klingecorp.com/pti/ UNCONTROLLED IF PRINTED K35-TCR104-15 Rev.

  • Page 27: Section 6.0 Servicing Components

    SECTION 6.0 SERVICING COMPONENTS 6.1 Compressor 6.1.1 Compressor Motor Protection The compressor motor of the TCR-104 is equipped with an internal overload device. This device will break the star-point and stop the compressor if a problem arises which causes the motor to overheat. When the motor cools sufficiently, the overload will reset automatically.
  • Page 28 Caution: Acids are formed during a motor burnout. Use rubber gloves and eye protection when working on the system or handling contaminated parts. When a hermetic motor burnout occurs, the stator winding insulation decomposes forming carbon, water, and acid. To prevent contamination of the refrigerant system and repeat motor failures, definite steps MUST be taken to ensure that the refrigerant circuit is kept clean from contamination.

  • Page 29: Condenser Fan Motor

    After the cleaning procedure is completed, recheck in approximately two weeks to ensure that the system condition and operation is completely satisfactory. 6.2 Condenser Fan Motor This totally enclosed motor is equipped with shielded ball bearings, which require no lubrication. The motor is designed to operate satisfactorily with line voltages, which are within 10% of nameplate values.

  • Page 30: Thermal Expansion Valve

    1. With the motor turned OFF, back seat compressor suction and discharge service valves and attach refrigerant recovery lines to the service ports of both valves. Front seat suction service valve 1½ turns so suction pressure can be read. The recovery lines should come from a manifold gauge since the line will also be used to evacuate the system and perhaps add refrigerant.
  • Page 31 Only make one full turn at a time. It may take approx. 30 minutes after each adjustment before a new balance can be acquired. Note: Refer to the Temperature / Pressure chart when calculating the superheat. 1. Measure the temperature of suction line at the point the bulb is clamped. 2.
  • Page 32 What's Superheat? EXAMPLE your REFRIGERANT TEMPERATURE HERE 52° READS EVAPORATOR COIL 40° A. TO THE SUCTION PRESSURE 66 PSIG at compressor 2 PSI B. ADD ESTIMATED SUCTION LOSS 68 PSIG C. TO OBTAIN SUCTION PRESSURE 12° at bulb SUPERHEAT SUCTION LINE UNCONTROLLED IF PRINTED K35-TCR104-15 Rev.

  • Page 33: Section 7.0 Trouble Shooting

    SECTION 7.0 TROUBLE SHOOTING 7.1 General Information Several components are incorporated into the unit to assist the serviceman in finding the cause of problems concerning the operation and efficiency of the unit. The thermostat cycle being called for is indicated by the LED display. These lights should be used in conjunction with the pressure gauges to determine if certain cycles are operating.

  • Page 34: Trouble Shooting Chart

    7.4 Trouble Shooting Chart The following trouble shooting chart is by no means complete but covers the more general type of problems, which may occur if a breakdown is experienced. PROBLEMS: POSSIBLE CAUSE CORRECTIVE ACTION SUGGESTED Power to unit, but unit will not start Tripped CB1, CB2 or CB3 Reset No control circuit voltage at T1...
  • Page 35 Glycol pump does not run Faulty phase sensor "PS" Replace "PC1" or "PC2" phase changing Replace contactor contactor faulty Condenser fan and glycol pump do not run See — Glycol Pump Does Not Run Condenser fan only will not run "CF"...
  • Page 36 Cooling capacity problem Severe lube oil overcharge Remove excess oil. Check oil level (allow oil level to be within sight glass when compressor is hot and has been running for 10 to 15 minutes). Compressor mechanical problem Replace defective compressor reducing pumping capacity UNIT ELECTRICAL INFORMATION (Amps at 480 Volt 60Hz) Input...

  • Page 37: Temperature Pressure Chart

    7.6 Temperature Pressure Chart FOR USE WHEN CONVERTING PRESSURE TO TEMPERATURE WHEN CALCULATING THE SUPERHEAT. R-12 ADDED FOR REFERENCE ONLY. DEGREES DEGREES R-12 R-22 R-502 R-134A R-404A (HP-62) FAHRENHEIT CENTIGRADE PSIG PSIG PSIG PSIG PSIG -45.6 15.4 18.4 -44.4 14.6 17.7 -43.3 13.8...
  • Page 38 DEGREES DEGREES R-12 R-22 R-502 R-134A R-404A (HP-62) FAHRENHEIT CENTIGRADE PSIG PSIG PSIG PSIG PSIG 11.1 48.8 87.3 47.7 12.2 90.8 104.8 50.1 13.3 53.2 94.3 108.6 52.3 14.4 55.4 97.9 112.4 15.6 57.7 101.6 116.4 57.5 16.7 60.1 105.4 120.4 60.1 17.8...

  • Page 39: Section 8 - Service Parts

    SECTION 8 - SERVICE PARTS TCR-104-15 Section 8.1A Unit Front View Section 8.1B Unit Front View with Front Panel Removed Section 8.2A Unit Rear View Section 8.2B Unit Rear View with Fan Guard Removed Section 8.3A Electrical Box Door Section 8.3B Electrical Box Internal Parts Section 8.3C Electrical Box External Parts...
  • Page 40 SECTION 8.1A UNIT FRONT VIEW UNCONTROLLED IF PRINTED K35-TCR104-15 Rev. J, August 2024...
  • Page 41 360-12138-00 COVER TOP 060-15036-00 GRILL CONDENSER WHITE 360-12135-00 ANGLE HEADER ASSEMBLY 360-12134-15 PANEL FRONT ASSEMBLY TCR-104-15 K21-16315-00 FASTENER M12-1.75 SS ANTILUCE K29-17879-02 HINGE SLIP SS 9/32 HOLES WITH PIN K28-10848-03 PLUG BUMPER .5 DIA x 1.25 LONG SYNTHETIC UNCONTROLLED IF PRINTED K35-TCR104-15 Rev.
  • Page 42 SECTION 8.1B UNIT FRONT VIEW WITH FRONT PANEL REMOVED UNCONTROLLED IF PRINTED K35-TCR104-15 Rev. J, August 2024...
  • Page 43 8.1B UNIT FRONT VIEW WITH FRONT PANEL REMOVED ITEM PART NO. DESCRIPTION 360-10737-01 RECEIVER WITH VALVE TCR104 K22-01672-00 VALVE HAND SHUT OFF 1/2 K25-26095-00 CONTROL HP NC OPEN 450 CLOSE 300 360-12137-00 ASSEMBLY COIL CONDENSER K35-04602-00 LABEL CAUTION FAN STARTS AUTOMATICALY UNCONTROLLED IF PRINTED K35-TCR104-15 Rev.
  • Page 44 SECTION 8.2A UNIT REAR VIEW UNCONTROLLED IF PRINTED K35-TCR104-15 Rev. J, August 2024...
  • Page 45 8.2A UNIT REAR VIEW ITEM PART NO. DESCRIPTION 060-14544-00 FAN GUARD TCR-104 WHITE K15-00019-01 COMPRESSOR 2 CYLINDER SERVICE NO VALVES 360-18227-00 TRANSFORMER MODIFIED FOR 36VPS K21-16379-16 CLAMP CONSTANT TORQUE SS 5-3/4 K26-24874-00 FAN 20.75 DIA 7/8 BORE 4 BLADE K24-21158-01 MOTOR 2 HP 1800 RPM 230/460 3P 360-11798-00 HEAT EXCHANGER WITH LABEL...
  • Page 46 SECTION 8.2B UNIT REAR VIEW WITH FAN GUARD REMOVED UNCONTROLLED IF PRINTED K35-TCR104-15 Rev. J, August 2024...
  • Page 47 8.2B UNIT REAR VIEW WITH FAN GUARD REMOVED ITEM PART NO. DESCRIPTION 060-15031-00 PLENUM CONDENSER FAN WELD WHITE K26-22196-00 INDICATOR MOISTURE 1/2 MFL 1/2 FFL K26-24906-00 FILTER/DRIER 1/2MFL HC WITH LABEL K26-25025-00 CHILLER GLYCOL 5 TON 360-13460-00 VALVE RELIEF 50 PSI KIT 1/2MPT (INCLUDES ITEMS 23, 34, 25 &...
  • Page 48 SECTION 8.3A ELECTRICAL BOX DOOR UNCONTROLLED IF PRINTED K35-TCR104-15 Rev. J, August 2024...
  • Page 49 8.3A ELECTRICAL BOX DOOR ITEM PART NO. DESCRIPTION 360-15140-15 DOOR ASSEMBLY (INCLUDES ITEMS 2 THRU 12) K35-05899-00 LABEL DANGER HIGH VOLTAGE 1.5x3 K28-10847-04 GROMMET INSERT .875 HOLE SIZE K28-10813-00 STRIP SPONGE 3/8x7/8 SOFT CLOSED 6 FT K28-10945-00 WINDOW DOOR ELECTRICAL BOX K29-17880-01 HINGE SLIP SS 9/32 HOLES SOCKET 060-09113-00...
  • Page 50 SECTION 8.3B ELECTRICAL BOX INTERNAL PARTS UNCONTROLLED IF PRINTED K35-TCR104-15 Rev. J, August 2024...
  • Page 51 8.3B ELECTRICAL BOX INTERNAL PARTS ITEM PART NO. DESCRIPTION 360-15134-15 BOX ELECTRICAL (INCLUDES ITEMS 1 & 17 THRU 41) K25-26404-00 TRANSFORMER 180VA 460V 110/24/12 LAB K25-26488-04 BLOCK TERMINAL STRIP 4P 360-12473-22 BATTERY CHARGER TCR-104 (LOCATED BEHIND PANEL) K25-26488-10 BLOCK TERMINAL STRIP 10P K25-26550-02 JUMPER TERM STRIP 8-18GA 2P K25-26550-03...
  • Page 52 SECTION 8.3C ELECTRICAL BOX EXTERNAL PARTS UNCONTROLLED IF PRINTED K35-TCR104-15 Rev. J, August 2024...
  • Page 53 8.3C ELECTRICAL BOX EXTERNAL PARTS ITEM PART NO. DESCRIPTION 060-10748-00 BRACKET HINGE ELECTRICAL BOX K21-16313-00 FASTENER BABY ANTILUSE M8x1.25 060-10820-00 RETAINER ELECTRICAL BOX SS PASS & POLISH 060-09113-00 INSULATOR HINGE (ONE FOR EACH HINGE) K29-17880-01 HINGE SLIP SS 9/32 HOLES SOCKET K29-17879-02 HINGE SLIP SS 9/32 HOLES WITH PIN 360-13807-00...

  • Page 54: Suggested Spare Parts

    Suggested Spare Parts REEFER ELEC BOX ITEM PART NO. DESCRIPTION 360-10829-00 BASE THERMOSTAT CABLE RIBBON SHLD 18” 10 WIRES 360-12540-01 360-13460-00 VALVE RELIEF ¾ MPT 50 PSI KIT 360-13807-00 KIT THERMOSTAT PROBE UNIVERSAL K22-06950-01 VALVE SUCTION PRESS REG 1-1/8 SHORT K24-22144-00 SWITCH TOGGLE 3PST ON-OFF K24-17239-00...

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