Related Manuals for Thermo King CRR-40 172
Summarization of Contents
Safety Precautions Overview
General Practices for Safe Operation
General guidelines for safe operation and maintenance of the unit.
Refrigerant Handling Safety
Precautions for handling refrigerants to prevent atmospheric release and personal injury.
First Aid Procedures
Immediate actions for personnel exposed to refrigerant or electrical hazards.
Refrigerant Oil Handling and Electrical Safety
Refrigerant Oil Precautions
Precautions and first aid procedures for working with refrigerant oil.
High Voltage Safety Measures
Specific safety measures to prevent electrical shock when working with high voltage.
Low Voltage Safety
Safety measures for low voltage circuits, highlighting potential burn hazards.
Controller and Welding Safety
Controller Maintenance Safety
Procedures to avoid static discharge when servicing the controller.
Welding Safety Precautions
Guidelines to prevent damage to electronic circuits during welding.
Unit Identification and Service Guide
Unit Decals and Serial Numbers
Information on warning decals and serial number locations for unit identification.
Service Guide Overview
Tabular overview of inspection and maintenance tasks for electrical, refrigeration, and structural systems.
Model Features and Specifications
CRR-40 Model Feature List
Detailed list of features included for specific CRR-40 models.
System Cooling Capacity Specifications
Technical data for system net cooling capacity under various conditions.
Refrigeration System Specifications
Detailed specifications for refrigerant, compressor, and related components.
Controller and Electrical System Specifications
Controller Specifications
Details on controller type, setpoint range, defrost initiation, and timing.
Electrical System Specifications
Technical data for motors, heaters, and control circuit voltage.
Optional Systems and Physical Specifications
Dehumidify and Humidify Systems
Specifications for optional dehumidify and humidify systems.
Physical Specifications
Dimensions, weight, and venting specifications for the unit.
Torque Specifications
Metric Hardware Torque Chart
Torque values for metric hardware based on size and class.
Compressor Bolt Torque
Specific torque values for D3D Copeland compressor bolts.
Unit Description and Operating Modes
General Unit Description
Overview of the unit's design, construction, and power specifications.
Compressor System Details
Details on the semi-hermetic reciprocating compressor and liquid injection system.
Evaporator Fan Operation
Information on dual-speed evaporator fans and their operation based on cargo type.
Microprocessor Controller Overview
Description of the controller's features, display, and operational capabilities.
Operating Modes Explained
Explanation of different operating modes based on setpoint and conditions.
Operating Instructions and Unit Controls
Unit Control Box Functions
Description of the physical controls on the unit's control box.
MPC2000ID/MP-3000a Controller Operation
Explanation of the controller's keypad, display indicators, and operational functions.
Pretrip Inspection Procedures
Steps for performing a visual inspection of the unit before loading cargo.
Starting the Unit and Adjusting Setpoint
Step-by-step instructions for starting the unit and setting the desired temperature.
MP-3000a Controller Features and Menus
Controller Description
Overview of the MP-3000a controller's capabilities, displays, and keypad functions.
Data Recording and Downloading
Details on controller data logging and retrieval of operational data.
General Theory of Operation
Explanation of how the controller monitors inputs and regulates unit functions.
Chill Loads Operation Details
How the controller manages unit operation for chill loads based on setpoints.
MP-3000a Controller Operation Details
Frozen Loads Operation
How the controller manages operation for frozen loads, including Null mode.
Compressor Liquid Injection System
Explanation of the liquid injection system for compressor temperature protection.
Power Limit Mode Explained
How the controller manages power consumption based on unit current and temperature.
MP-3000a Controller Operation Modes
Economy Mode Operation
How the Economy Mode reduces power consumption by adjusting evaporator fan operation.
Chill Loads Operation
Unit operation details for chill loads with setpoints above -9.9 C.
Frozen Loads Operation
Unit operation details for frozen loads with setpoints below -10 C.
MP-3000a Controller Functions and Menus
Probe Test Procedure
How the controller initiates a probe test to check for defective sensors.
Dehumidify Mode Operation
Explanation of the dehumidification system's availability and operation.
Sequence of Operation Overview
Steps involved in the unit's start-up sequence and mode changes.
Continuous Temperature Control
Chill Loads Continuous Control
How the controller regulates operation for precise temperature control in chill loads.
Defrost Operation and Controller Alarms
Defrost Cycle Procedures
Detailed explanation of defrost initiation, termination, and operation modes.
Alarms Menu Overview
Information on the Alarms Menu for viewing and diagnosing alarm codes.
Alarm Code States Explained
Explanation of the different states of alarm codes and their implications.
Controller Command and Test Procedures
Alarm List Details
A comprehensive list of alarm codes, descriptions, and corrective actions.
Commands Menu Functions
Outlines tasks available in the Commands Menu, including Function Test and Pretrip Test.
Brief Pretrip (PTI) Test Procedure
Detailed instructions for performing the Brief Pretrip (PTI) Test.
Controller Test Procedures
Full Pretrip (PTI) Test
Explanation of the Full PTI test's purpose, duration, and procedure.
Function Test Procedures
Instructions for performing the Function Test and CRR Function Tests.
Manual Function Test Guide
Steps for performing manual tests on individual components or system tests.
Controller Settings and Menus
Power Management Settings
Instructions on how to select and adjust power limit and time settings.
Miscellaneous Functions Menu
Description of the Misc. Functions Menu and its available functions.
Setting Date and Time
Detailed procedure for setting the unit's date and time.
Setting Cargo Data
Instructions for entering trip-specific information into the controller.
Controller Configuration and Datalogger
Configuration Menu Options
Explanation of the Configuration Menu for setting unit features and parameters.
Datalogger Menu Functions
Description of the Datalogger Menu functions for accessing recorded data.
Viewing Temperature Logs
How to access and view temperature logs for various sensors and events.
Controller Log Operations
Setting Data Log Intervals
How to set the data logging interval for recording unit information.
Setting Trip Start Marker
Procedure for marking the start of a trip in the datalogger.
Inspecting PTI Test Log
How to view the results of the last Pretrip (PTI) Test.
RMM Status and Manual Emergency Operation
Viewing RMM State Screen
How to check the communication status with the REFCON system.
Manual Emergency Mode Operation
Procedures for operating the unit manually in emergency situations.
Controller Replacement and Software
Replacing the Controller Unit
Step-by-step guide for removing and installing a replacement controller.
Controller Software Selection
How to select the correct software for a replacement controller based on dial position.
Flash Loading Controller Software
Procedure for updating the controller software using a portable computer.
Temperature Sensor Installation
Temperature Sensor Details
Information on the types of thermistor sensors used and their proper installation.
Diagnosis and Repair Procedures
General Diagnosis and Repair Steps
Guidance on troubleshooting unit malfunctions by checking alarms and external factors.
External Cause Checks
Common external issues that can cause unit malfunctions, like connector problems.
Status Messages and Controller Actions
Explanation of status messages displayed by the controller and corresponding actions.
Controller Status Messages and Alarms
Detailed Status Messages Table
A table detailing status messages, their indications, and controller actions.
Alarm Code Descriptions
A comprehensive list of alarm codes, their descriptions, and corrective actions.
Alarm Codes and Corrective Actions
Compressor Current Alarms
Causes and corrective actions for high or low compressor current draw.
Heater Current Alarms
Causes and corrective actions for high or low heater current draw.
Evaporator Fan Current Alarms
Causes and corrective actions for evaporator fan current draw issues.
Condenser Fan Current Alarms
Causes and corrective actions for condenser fan current draw issues.
Alarm Codes and System Faults
Power Supply Phase Error
Causes and corrective actions for power supply phase errors.
Temperature Deviation Alarms
Causes and corrective actions when temperature deviates significantly from setpoint.
Capacity Test Alarms
Causes and corrective actions for errors during capacity tests.
Electrical Maintenance Procedures
Unit Wiring Inspection
Guidelines for inspecting unit wiring and harnesses for damage or faults.
High Pressure Cutout Switch
Description of the high pressure cutout switch, its operation, and testing.
Fan Rotation Checks
Instructions for checking the rotation direction of condenser and evaporator fans.
Refrigeration System Maintenance
Service Tools and Fittings
List of recommended tools and special fittings for R-134a systems.
Leak Detection Methods
Methods for detecting refrigerant leaks using soap bubbles or Halogen detectors.
Vacuum Pump Procedures
Guidelines for using vacuum pumps for system evacuation.
Refrigerant Recovery Procedures
Guidelines for safely removing refrigerant from the system.
Compressor Oil and Refrigerant Charge
Checking Compressor Oil Level
Procedures for checking compressor oil level under different ambient conditions.
Adding Compressor Oil
Instructions for adding the correct type of compressor oil.
Refrigerant Charge Check
How to check the refrigerant charge by inspecting receiver tank sight glasses.
System Evacuation and Charging
Evacuation and Cleanup of Refrigeration System
Procedures for system cleaning, identifying contaminants, and their effects.
Unit Evacuation Steps
Detailed steps for evacuating the system to achieve the required vacuum level.
Unit Charging Procedure
Step-by-step guide for charging the refrigeration system with refrigerant.
Component Replacement Procedures
Evaporator Pressure Regulator (KVQ) Valve
Explanation of the KVQ valve's function, operation, and service requirements.
KVQ Valve Replacement
Detailed steps for removing, installing, and testing the KVQ valve.
Liquid Line Solenoid Valve Replacement
Steps for removing and installing the liquid line solenoid valve.
Liquid Injection Valve Replacement
Procedures for removing and installing the liquid injection valve.
Dehumidify Valve Replacement
Step-by-step instructions for replacing the dehumidify valve.
Structural and Accessory Maintenance
Mounting Bolts Check and Tightening
Instructions for checking and tightening unit, compressor, and fan motor mounting bolts.
Unit Inspection Guidelines
Guidelines for inspecting the unit for damage, leaks, or performance issues.
Condenser Coil Cleaning
Procedures for cleaning the condenser coil, including using alkaline cleaners.
Evaporator Coil Cleaning
Instructions for cleaning the evaporator coil using compressed air or water.
Accessory System Maintenance
Defrost Drains Cleaning
Procedure for cleaning defrost drains to ensure they remain open.
Fresh Air Exchange System Adjustment
Explanation of the fresh air exchange system and adjusting ventilation rate.
Pretrip Inspection for Humidify System
Steps for inspecting the humidify system during a pretrip check.
Humidify System Inspection and Cleaning
Periodic servicing and cleaning of humidify system components.
Mechanical Diagnosis Guide
Compressor Mechanical Diagnosis
Troubleshooting for compressor issues, including no amperage draw and overload cycling.
Condenser Fan Motor Diagnosis
Troubleshooting for condenser fan motor not operating, including heat/defrost modes.
Unit Not Cooling Diagnosis
Troubleshooting steps when the unit is in vacuum but not cooling effectively.
System Diagnosis and Troubleshooting
Head Pressure Issues
Troubleshooting for low or high head pressure, considering modulation and power limit.
Frosted or Sweating Suction Line
Troubleshooting for frosted or sweating suction lines, related to expansion valve.
Low Suction Pressure Diagnosis
Troubleshooting steps for low suction pressure, considering capacity control.
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