Thermo King 098592 Manuals

Manuals and User Guides for Thermo King 098592. We have 1 Thermo King 098592 manual available for free PDF download: Maintenance Manual

Thermo King 098592 Maintenance Manual

Thermo King 098592 Maintenance Manual (264 pages)

MAGNUM+ series

Brand: Thermo King | Category: Refrigerator | Size: 5 MB

Table of Contents

Table of Contents
6
Safety Instructions

11
- General Precautions
  11
- Refrigerant Oil Precautions
  11
- Electrical Precautions
  12
  - Precautions
    12
  - First Aid
    12
  - Low Voltage
    13
- Electrostatic Discharge Precautions
  13
  - Electrostatic Discharge and the Controller
    13
  - Welding of Units or Containers
    14
- Removing Refrigerant Properly
  14
- Identifying Unit Safety and Warning Decals
  16
- Locating Serial Numbers
  16
  - Component Serial Number Identification
    16
Service Guide

17
Specifications

18
Unit Description, Features & Options

24
Controller Description

39
- Controller Back-Up Battery
  39
- Controller Input and Output Signals
  39
- Standard Display
  41
  - Idle Screen
    41
  - Glossary of Mode Descriptions
    43
- Function Keys
  44
- Three Special Function Keys
  45
- MP-4000 Software
  46
- Operating Instructions
  
  56
  - Function Keys
    56
    
    Unit On/Off Key
    57
  - Sequence of Operation
    57
    
    Unit Start-Up
    57
    
    Initiating a Manual Defrost
    57
    
    Pti
    58
    
    Viewing Alarms/Warnings
    59
    
    Display Alternate Fahrenheit (F) or Celsius (C) Temperatures
    59
    
    Changing Setpoint
    59
    
    Main Menu
    59
    
    Controller Back-Up Battery
    60
  - Controller Lockup Issue
    60
  - Emergency Run Mode
    61
    
    Rotation Check
    61
    
    FULL COOL Mode
    63
    
    DEFROST Mode
    64
    
    High or Low Speed Fans Only
    64
- Navigating the Controller Operating Menu
  
  66
  - Icon Menu
    67
  - Menu Scrolling Keys
    68
  - Changing Screen Contrast
    69
  - Data/Values Menu
    70
    
    Mp4000
    70
    
    Data/Values
    70
- Main Menu
  
  70
  - Setpoint/Control Menu
    71
    
    Cold Treatment (CT)
    72
    
    Multiple Temperature Set (MTS)
    72
    
    Optiset
    73
    
    Temperature Setpoint
    73
    
    Controlling Mode
    74
    
    Pull down Selection
    74
    
    Watercool
    75
    
    Humidity Control
    75
    
    Humidity Setpoint
    76
    
    AVL (Air Ventilation Logging)
    76
    
    Fresh Air Vent man - AFAM Mode
    77
    
    AFAM Delay
    78
    
    AFAM Rate
    78
    
    AFAM+ CO2 Max
    79
    
    AFAM+ O2 Min
    79
    
    Smart PTI
    80
  - Alarm List
    80
  - Configuration Menu
    81
    
    Unit Setting
    82
    
    Unit Configuration (Configuration Depends on Unit)
    82
    
    Options
    83
  - Warning List
    81
Table of Contents

84
- Datalogger Menu
  84
- Miscellaneous Settings
  84
- States Menu
  85
- Special Function Keys - User Activated Commands
  86
  - PTI Key
    86
  - Defrost Key
    89
- PTI (Pretrip) Tests
  90
  - Automated Tests
    91
  - Function Test
    91
  - Manual Function Test
    92
- Defrost
  100
- Alarms/Warnings Menu
  101
  - Alarm Code States
    101
  - Alarm/Warning List Menu
    102
  - View the Alarm/Warning List Menu
    102
  - Warning List Menu
    103
  - Alarm List Menu
    104
- Configuration Menu
  106
  - Viewing or Setting Functions
    106
  - Set Date and Time
    108
- Datalogger Menu
  109
  - Viewing the Datalogger Menu
    109
  - Inspect Log
    110
  - Trip Start
    110
  - Set Log Time Interval
    111
- States Menu
  112
- Air Ventilation Logging (AVL)
  114
Starting the AFAM System

116
- Change the AFAM Delay
  118
- Change the AFAM Rate
  118
- Advanced Fresh Air Management Plus (AFAM+) System
  119
- Pulsating Vent Door
  127
  - AFAM+ Door Closes Automatically
    127
  - Pulsating AFAM+ Door
    127
  - AFAM+ Enabled
    127
Operating Theory

128
- Chill Loads: (Setpoint at -9.9 C [14.1 F] and Above)
  128
- Frozen Loads: (Setpoint at -10 C [14 F] and Below)
  128
- Compressor Vapor Injection
  128
- High Temperature Protection
  129
- Power Limit Mode
  129
- Evaporator Fan Control
  129
- Condenser Fan Control
  129
- Probe Test
  130
- Dehumidify Mode
  130
- Continuous Temperature Control Operation
  130
  - Frozen Loads (Controller Setpoint at -10 C [14 F] and Below)
    133
- Compressor Digital Control Valve
  136
- Data Recording and Downloading Data
  137
- Economizer System
  137
- Cold Treatment (CT)
  138
- Multiple Temperature Setpoint (MTS)
  144
- Controller Maintenance
  
  149
  - Controller Door Open and Close Instructions
    149
  - Flash Loading Controller Software
    150
  - MP-4000 Test System Tool
    153
  - Controller Replacement
    154
- Electrical Maintenance
  
  155
  - High Pressure Cutout Switch
    155
  - Unit Protection Devices
    155
    
    Introduction
    155
    
    Main Circuit Breaker
    155
    
    Evaporator Overheat Protection
    155
  - High Pressure Cutout Manifold
    157
  - High Pressure Cutout Switch Removal
    157
    
    High Pressure Cutout Switch Installation
    158
  - Low Pressure Cutout Switch
    159
    
    Low Pressure Cutout Switch Removal
    159
    
    Low Pressure Cutout Switch Installation
    160
  - Low Pressure Cutout Switch or Suction Transducer Configuration
    160
  - Condenser Fan and Evaporator Fan Rotation
    162
    
    Check Condenser Fan Rotation
    162
    
    Check Evaporator Fan Rotation
    162
    
    Reversing Power Phase on MAGNUM Units
    163
  - Discharge and Low Pressure Sensors (Optional)
    162
    
    Discharge and Low Pressure Sensors Removal
    162
    
    Discharge and Low Pressure Sensor Installation
    162
  - Evaporator Heater Selection
    163
    
    Extended Capacity Heaters
    164
    
    Electric Heaters Malfunction
    164
  - Compressor Discharge Gas Temperature Sensor
    165
    
    Compressor Discharge Temperature Sensor Replacement
    165
  - Temperature Sensors
    166
    
    Installing Temperature Sensors
    167
    
    Testing the Sensors
    167
    
    Resistance Values for Temperature Sensors
    169
  - Detecting Leaks
    171
  - Introduction
    171
  - Locating Special Service Fittings
    171
- Refrigeration Maintenance
  
  171
  - Use Filters and Cartridges
    171
  - Use the Correct Refrigerant Recovery Equipment
    171
  - Use the Correct Tools
    171
  - Use the Correct Vacuum Pump
    171
  - Isolate the Compressor
    172
  - Perform an Oil Acid Test
    172
  - Working with a Gauge Manifold
    173
    
    Using a New Gauge Manifold Set
    173
    
    Gauge Manifold Valve Positions
    173
  - Gauge Manifold Set Installation & Removal
    176
    
    Gauge Manifold Set Installation
    176
    
    Removing the Gauge Manifold Set
    177
  - Checking Refrigerant Charge
    177
  - Receiver Tank Sight Glass
    178
  - Leak Testing the Refrigeration System
    179
  - Using Pressurized Nitrogen
    180
    
    Safety Precautions
    180
    
    Purge High Side to Low Side
    181
    
    Maximum Gas Pressures
    181
  - Recovering Refrigerant from the System
    183
Table of Contents

184
- Evacuation and Cleanup of the Refrigeration System
  184
- Unit Preparation and Hookup
  184
- Unit Evacuation
  185
- Pressure Rise Test
  186
- Factors Affecting the Speed of System Evacuation
  187
- Heat Saves Time
  187
- Charging the System with Refrigerant
  188
  - Unit Charging by Weight (from an Evacuated Condition)
    188
- Compressor Replacement
  189
  - Compressor Removal
    189
  - Compressor Installation
    189
- Condenser Coil Replacement
  191
- Filter Drier/In-Line Filter Replacement
  192
- Evaporator Expansion Valve (TXV) Replacement
  194
- Economizer Expansion Valve Replacement
  195
- Economizer Heat Exchanger Replacement
  197
  - Economizer Heat Exchanger Removal
    197
  - Economizer Heat Exchanger Installation
    198
- Receiver Tank/ Water-Cooled Condenser Tank Replacement
  199
  - Tank Removal
    199
  - Tank Installation
    199
- Vapor Injection Valve Replacement
  201
- Compressor Digital Control Valve Replacement
  202
Servicing the Unit

204
- Taking Care of the Structure
  204
  - Inspecting the Unit
    204
  - Checking the Mounting Bolts
    204
  - Cleaning the Condenser Coil
    205
  - Cleaning the Evaporator Coil
    205
  - Cleaning the Defrost Drains
    205
  - Positioning the Condenser Fan Blade
    205
  - Positioning the Evaporator Fan Blade
    206
- Servicing the Fresh Air System
  207
  - Adjusting the Fresh Air Exchange System
    207
- Controller Diagnostics
  209
Diagnosis: Troubleshooting, Warnings and Alarm Codes

209
- Introduction
  209
- Warnings and Controller Actions
  216
Wiring and Schematic Diagrams Index

256
- Controller Menu Guide
  262

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