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Thermo King CRR DF MPC2000
Ingersoll Rand Thermo King CRR DF MPC2000 Manuals
Manuals and User Guides for Ingersoll Rand Thermo King CRR DF MPC2000. We have
1
Ingersoll Rand Thermo King CRR DF MPC2000 manual available for free PDF download: Maintenance Manual
Ingersoll Rand Thermo King CRR DF MPC2000 Maintenance Manual (165 pages)
Brand:
Ingersoll Rand
| Category:
Refrigerator
| Size: 6 MB
Table of Contents
Table of Contents
6
List of Figures
10
Introduction
12
CRR DF Model Features
12
Safety Precautions
14
General Practices
14
Refrigerant
14
First Aid
14
Refrigerant Oil
15
First Aid
15
Electrical
15
High Voltage
15
General Safety Precautions for Servicing Units (or Containers) Equipped with a Microprocessor Controller
16
Controller Repair
16
Welding of Units or Containers
17
Unit Decals
17
Serial Number Locations
17
Figure 1: Unit Nameplate and Decal Locations
18
Service Guide
20
Specifications
22
Full Cool Operation Net Cooling Capacity
22
System Net Defrost Heating Capacity
22
Evaporator Airflow
22
R-134A Refrigeration System
22
R-23 Refrigeration System
23
Electrical System
24
Microprocessor Controller
25
Physical Specifications
26
Compressor Torque - 3D Copeland Compressor Bolt Torque
26
Metric Hardware Torque Chart
27
Unit Description
28
General Description
28
Cascade Refrigeration System
28
Microprocessor Controller
29
Datalogger
29
Three Evaporator Fans
29
USDA Cold Treatment Temperature Recording
29
REFCON Remote Monitoring Modem (RMM)
30
Operating Modes
30
Frozen Loads
30
Figure 2: Unit Front View
31
Figure 3: Evaporator Section - Front View
32
Figure 4: Vacuum Valve
33
Figure 5: Power Cord Storage Compartment
34
Figure 6: Control Box and Microprocessor Controller
35
Figure 7: MPC2000 or MP3000 Controller and Remote Monitoring Modem
36
Figure 8: MPC2000ID and MP3000 Controller, and Remote Monitoring Modem
37
Figure 9: Unit Control Box with Door Open
38
Figure 10: Low Pressure Cutout Switch in R-23 Refrigeration System (CRR DF MPC2000ID Units Only)
39
Figure 11: R-23 Compressor Compartment
40
Figure 12: Additional R-23 Refrigeration System Components
41
Figure 13: R-134A Compressor Compartment
42
Figure 14: Additional R-134A Refrigeration System Components and Plate Heat Exchanger
43
Figure 15: Unit Back View
44
Figure 16: Unit Back View - Pressure Regulators and Buffer Tanks
45
Figure 17: Unit Back View - Electric Heaters and Evaporator Coil
46
Operating Instructions
48
Basic Unit Controls, Instruments and Protection Devices
48
Unit Control Box
48
MPC2000, MPC2000ID or MP3000 Controller
48
Other
49
R-134A Refrigeration System Controls, Instruments and Protection Devices
49
Refrigeration System Controls, Instruments and Protection Devices
50
Pretrip Inspection
51
Power Selection
52
Pre-Load Operation
52
Pre-Trip Conditions
52
Pre-Trip Checks
52
Loading Procedure
53
Post Load Procedure
54
Starting the Unit on Ship
54
Post Trip Procedure
55
Table of Contents
56
Microprocessor Controller
56
General Description
56
Figure 18: MPC2000, MPC2000ID and MP3000 Controller
57
General Theory of Operation
62
Frozen Loads (Setpoint at -10 C [14 F] and Below)
62
Sequence of Operation
63
Unit Start-Up
63
Figure 19: Frozen Load Control Sequence (Setpoints at -10 C [14 F] and Below)
63
Continuous Temperature Control Operation
64
Changing the Setpoint
65
Initiating a Manual Defrost
66
Displaying Alternate Controlling (Supply or Return) Air Sensor Temperature
66
Displaying Alternate Fahrenheit (F) or Celsius (C) Temperature
66
Menu Operating Instructions
66
Controller Menu
67
Data Menu
67
Alarm List Menu
68
Commands Menu
69
Manual Function Test, DF Units
71
Misc. Functions Menu
71
Configuration Menu
75
MP-3000 Configuration List, DF Units
75
Datalogger Menu
76
RMM State Menu
77
PTI (Pretrip) Test
78
Temperature Sensors
80
Figure 20: 3 Fan Evaporator: Evaporator (Defrost) Sensor Location
81
Manual Emergency Mode Operation
83
Replacing the EPROM Chip (MPC2000 and MP3000 Only)
84
Figure 21: Manual Emergency Control Connections
84
Replacing the Microprocessor Controller
85
Flash Loading Controller Software
86
MPC 2000 ID / MP 3000, Super Freezer "Error Message List
87
Alarm Codes, Descriptions and Corrective Actions
88
Electrical Maintenance
98
Unit Wiring
98
High Pressure Cutout Switch
98
R-134A High Pressure Cutout Switch
98
Condenser Fan and Evaporator Fan Rotation
98
Condenser Fan
99
Evaporator Fans
99
Electric Heaters
99
Low Pressure Cutout Switch (R-23 System on CRR DF MPC2000ID Units Only)
99
Low Pressure Cutout Switch
100
Refrigeration Maintenance and Service Operations
102
Service Tools
102
R-134A Service Fittings and Gauge Manifold Set
102
Figure 22: R-134A Service Fittings Specifications
102
Leak Detection
103
Vacuum Pump
103
System Cleanup
103
Refrigerant Recovery
103
Compressor Oil Acid Test
103
Compressor Discharge and Suction Service Valves
103
Figure 23: Service Valve Back Seated
104
Figure 24: Service Valve Open to Port
104
Figure 25: Service Valve Front Seated
104
Gauge Manifold Valve Positions
105
Figure 26: Balancing R-134A System Pressure
105
Figure 27: Charging the R-134A System
105
Figure 28: Gauge Manifold Closed to Center Port
106
Figure 29: Gauge Manifold Open to Center Port
106
Figure 30: Removing R-134A Refrigerant
106
R-134A Gauge Manifold Set (with Low Loss Fittings) Attachment and Purging
107
R-134A Gauge Manifold Set Installation
107
Figure 31: Removing Refrigerant
108
Figure 32: Purging Gauge Manifold
108
Gauge Manifold Set Removal
109
Service Procedure Guide
109
Typical R-23 and R-134A System Suction and Discharge Pressure Readings
109
Test Procedure
109
Discharge Pressure Regulator Test and Adjustment
110
Checking Compressor Oil
111
Checking the Compressor Oil Level
111
Adding Compressor Oil
111
Figure 33: Discharge Pressure Regulator
111
Removing Excess Compressor Oil
112
Figure 34: Checking Compressor Oil Level
112
Refrigerant Leak Test Procedure
113
Figure 35: Adjusting Compressor Oil Level
113
Low Side Pump down (R-134A Compressor Only)
114
Figure 36: Testing for Refrigerant Leaks
114
Refrigerant Charge Inspection
115
Checking the R-134A Refrigerant Charge
115
Figure 37: R-134A Refrigeration System Receiver Tank
115
Checking the R-23 Refrigerant Charge
116
Figure 38: R-23 Refrigeration System Receiver Tank
116
Refrigerant Recovery
117
R-23 Recovery for System Repair
117
R-134A Vapor Recovery
118
R-134A Liquid Recovery
118
Evacuation and Cleanup of the Refrigeration System
118
Contamination
118
Compressor Oil Color Code
119
Refrigeration System Preparation and Hookup
119
Unit Evacuation
120
Pressure Rise Test
121
Factors Affecting the Speed of System Evacuation
121
Figure 39: Constant Pressure Rise after Evacuation Indicates System Leak
121
Heat Saves Time
122
R-134A Refrigeration System Charging
122
Charging R-134A System with Liquid Refrigerant by Weight (from an Evacuated Condition)
122
Figure 40: Pressure Rise Levels off after Evacuation Indicates Moisture in System
122
R-134A Evacuation Station Removal
123
R-134A Final Charging Procedure for Partially Charged Units
123
R-23 Refrigeration System Charging
124
R-23 Evacuation Station Removal
125
Charging R-23 System with Gas Refrigerant Recovered in 40 Liter (42 Qt.) Refrigerant Bottle(from an Evacuated Condition)
125
Final Charging Procedure for Partially Charged Units on Empty Containers
126
R-23 Charging Procedure for Partially Charged Units on Loaded Containers
126
Using Pressurized Nitrogen
127
Safety Precautions
127
Dehydration, Pressure Testing, Purging and Soldering Procedure
128
Figure 41: Typical Pressurized Gas Bottle with Pressure Regulator and Gauges
128
Compressor Replacement (R-134A or R-23 Systems)
129
Removal
129
Installation
129
Condenser Coil Replacement (R-134A or R-23 Systems)
130
Removal
130
Installation
130
Dehydrator (Filter Drier) Replacement (R-134A or R-23 Systems)
131
Removal
131
Installation
132
Expansion Valve Replacement (R-134A or R-23 Systems)
132
Removal
132
Installation
133
R-23 System Heat Exchanger Replacement
133
Removal
133
Installation
134
R-23 System to R-134A System Plate Heat Exchanger Replacement
134
Removal
134
Receiver Tank Replacement (R-134A or R-23 System)
135
Removal
135
Installation
135
High Pressure Cutout Switch Replacement
135
(R-134A or R-23 System)
135
Installation
136
Liquid Line Solenoid Valve Replacement (R-134A System Only)
136
Removal
136
Table of Contents
137
Low Pressure Cutout Switch Replacement (CRR DF MPC2000ID and MP3000 Units Only)
137
Removal
137
Installation
137
Structural/Accessory Maintenance
138
Mounting Bolts
138
Unit Inspection
138
Condenser Coil
138
Figure 42: Mounting Bolts
138
Evaporator Coil
139
Defrost Drains
139
Evaporator Fan Location
139
Condenser Fan Location
139
Figure 43: Evaporator Fan Blade Placement
139
Vacuum Valve
140
Figure 44: Vacuum Valve
140
Figure 45: Condenser Fan Blade Placement
140
Mechanical Diagnosis
142
Refrigeration System Diagnosis
144
Electrical, Refrigeration and Controller Menu Flow Diagrams
148
Legend of CRR DF Refrigeration System Components
156
CRR DF Refrigeration System Components - Page 2 of 2
157
Legend of CRR DF off Cycle Standby Flow and Pressure Diagram
158
CRR DF off Cycle Standby Flow and Pressure Diagram - Page 2 of 2
159
Legend for CRR DF Full Cool Flow and Pressure Diagram - Page 1 of 2
160
CRR DF Full Cool Flow and Pressure Diagram - Page 2 of 2
161
Legend for CRR DF Evacuation Station and Unit Connections - Page 1 of 2
162
CRR DF Evacuation Station and Unit Connections
163
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