61888-4

Safety advisories appear throughout this manual as required. Your personal safety and the proper operation of this unit depend upon the strict observance of these precautions. The four types of advisories are defined as follows:

Electrical Precautions

• The possibility of serious or fatal injury from electrical shock exists when servicing a refrigeration unit. Extreme care must be used when working with a refrigeration unit that is connected to its power source.

• Extreme care must be used even if the unit is not running. Lethal voltage potentials can exist at the unit power cord, inside the control box, inside any high voltage junction box, at the motors and within the wiring harnesses.

• In general, disconnect the units power cord before repairing or changing any electrical components.

• Even though the controller is turned off, one of the phases is still live and represents a potential danger of electrocution.

• Disconnect power at Main Circuit Breaker and remove power plug from the high voltage socket. Lock-out-tag out as required.

Precautions must be taken to prevent electrostatic discharge while servicing the microprocessor controller and related components. The risk of significant damage to the electronic components of the unit is possible if these precautionary measures are not followed. The primary risk potential results from the failure to wear adequate electrostatic discharge preventive equipment when handling and servicing the controller. The second cause results from electric welding on the unit and container chassis without taking precautionary steps.

Electric welding can cause serious damage to electronic circuits when performed on any portion of the refrigeration unit, genset, container, or container chassis with the refrigeration unit attached. It is necessary to verify that welding currents are not allowed to flow through the electronic circuits of the unit. The procedures below MUST be strictly followed when servicing units to avoid damage or destruction of the microprocessor.

1. Disconnect the battery connections (if equipped) and lock out - tag out the unit according to local regulations.

2. Disconnect all power to or from the refrigeration unit or genset.

3. Disconnect all quick-disconnect wire harnesses from the back of the controller.

4. Switch all of the electrical circuit breakers in the control box to the Off position.

5. When steps 1 through 5 are complete, weld the unit and/or container using normal welding procedures. Keep ground return electrode as close to the area to be welded as practical. This will reduce the likelihood of stray welding currents passing through any electrical or electronic circuits.

6. When welding is complete, restore the unit power cables, wiring, and circuit breakers to their normal condition.

REFRIGERANT

• Eyes: For contact with liquid, immediately flush eyes with large amounts of water and get prompt medical attention.

• Skin: Flush area with large amounts of warm water. Do not apply heat. Remove contaminated clothing and shoes. Wrap burns with dry, sterile, bulky dressing to protect from infection. Get prompt medical attention. Wash contaminated clothing before reuse.

• Inhalation: Move victim to fresh air and use Cardiopulmonary Resuscitation (CPR) or mouth-to-mouth resuscitation to restore breathing, if necessary. Stay with victim until emergency personnel arrive.

• Frost Bite: In the event of frost bite, the objectives of First Aid are to protect the frozen area from further injury, warm the affected area rapidly, and to maintain respiration.

REFRIGERANT OIL

• Eyes: Immediately flush with large amounts of water for at least 15 minutes. Get prompt medical attention.

• Skin: Remove contaminated clothing. Wash thoroughly with soap and water. Get medical attention if irritation persists.

• Inhalation: Move victim to fresh air and use Cardiopulmonary Resuscitation (CPR) or mouth-to-mouth resuscitation to restore breathing, if necessary. Stay with victim until emergency personnel arrive.

• Ingestion: Do not induce vomiting. Immediately contact local poison control center or physician.

ENGINE COOLANT

• Eyes: Immediately flush with large amounts of water for at least 15 minutes. Get prompt medical attention.

• Skin: Remove contaminated clothing. Wash thoroughly with soap and water. Get medical attention if irritation persists.

• Ingestion: Do not induce vomiting. Immediately contact local poison control center or physician.

BATTERY ACID

• Eyes: Immediately flush with large amounts of water for at least 15 minutes. Get prompt medical attention. Wash skin with soap and water.

• Skin: Immediately remove contaminated clothing. Wash skin with large volumes of water, for at least 15 minutes. Wash skin with soap and water. Do not apply fatty compounds. Seek immediate medical assistance.

• Inhalation: Provide fresh air. Rinse mouth and nose with water. Seek immediate medical assistance.

• Ingestion: If the injured person is fully conscious: make the person drink extensive amounts of milk. Do not induce vomiting. Take the injured person immediately to a hospital.

ELECTRICAL SHOCK

Take IMMEDIATE action after a person has received an electrical shock. Get quick medical assistance, if possible.

The source of the shock must be quickly stopped, by either shutting off the power or removing the victim. If the power cannot be shut off, the wire should be cut with a non-conductive tool, such as a wood-handle axe or thickly insulated cable cutters. Rescuers should wear insulated gloves and safety glasses and avoid looking at wires being cut. The ensuing flash can cause burns and blindness.

If the victim must be removed from a live circuit, pull the victim away with a non-conductive material. Use wood, rope, a belt or coat to pull or push the victim away from the current. DO NOT TOUCH the victim. You will receive a shock from current flowing through the victim’s body. After separating the victim from power source, immediately check for signs of a pulse and respiration. If no pulse is present, start Cardiopulmonary Resuscitation (CPR). If a pulse is present, respiration might be restored by using mouth-to-mouth resuscitation. Call for emergency medical assistance.

ASPHYXIATION

Move victim to fresh air and use Cardiopulmonary Resuscitation (CPR) or mouth-to-mouth resuscitation to restore breathing, if necessary. Stay with victim until emergency personnel arrive.

Serial number decals, refrigerant type decals, and warning decals appear on all Thermo King® equipment. These decals provide information that may be needed to service or repair the unit. Service technicians should read and follow the instructions on all warning decals.

Nameplate and Warning Locations

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Serial numbers can be found on the component’s nameplate.

• Electric Motor: Attached to the motor housing.

• Compressor: On front of the compressor.

• Unit: On unit frame in power cord storage compartment.

• Controller: On top of controller.

Units are all-electric, single-piece, refrigeration units with bottom air supply. The unit is designed to cool and heat ISO1496-2 refrigerated containers for shipboard or overland transit (Intermodal), as well as land based stationary storage. The unit mounts in the front wall of the container. Forklift pockets are provided for installation and removal of the unit.

The frame and bulkhead panels are constructed of aluminum and are treated to resist corrosion. A removable evaporator compartment door provides service access. All components except the evaporator coil and electric heaters can be replaced from the front of the unit.

Each unit is equipped with an 18.3 m (60 ft.) power cable for operation on 460-380V/3 Ph/60-50 Hz power. The unit power cable is stored below the control box in the condenser section.

Each unit is equipped with 460-380V/3 Ph/60-50 Hz electric motors. An automatic phase correction system provides the proper electrical phase sequence for condenser fan, evaporator fan and compressor operation.

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Container units features the following components. Each component will be described briefly on the following pages.

The scroll compressor features a digital port and an intermediate suction port.

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The MP4000 is an advanced microprocessor controller that has been specially developed for the control and monitoring of refrigeration units. Refer to (MP4000 Controller) for more detailed information.

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		1	MP4000 Controller

The controller pulses the Compressor Digital Control solenoid valve between open and closed positions. This provides precise cooling capacity control. No pump down function or warm gas bypass control is used in conjunction with the Compressor Digital Control valve. Refer to (Compressor Digital Control Valve) for more detailed information.

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An economizer heat exchange system replaces the conventional heat exchanger. The economizer Heat Exchange system subcools the liquid refrigerant before it reaches the evaporator expansion valve. Subcooling liquid refrigerant increases the cooling efficiency and capacity of the evaporator. Refer to (Economizer System) for more detailed information.

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Each sensor element is connected to a cable and packaged in a sealed stainless steel tube. The temperature signal from the sensor is transmitted through the cable. PT1000 type temperature sensors are used to sense temperatures for the following:

• Supply Air

• Return Air

• Evaporator Coil

• Condenser Coil

• Compressor Discharge Temperature Sensor

• Ambient Air

The fresh air exchange system removes harmful gases from containers carrying sensitive perishable commodities. The fresh air vent is located above the control box. The fresh air vent is adjustable to accommodate a variety of frozen and chilled load operating conditions.

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		1	Fresh Air Exchange Vent

The receiver tank contains a sight glass which has three small balls that indicate the level of refrigerant in the tank for checking the refrigerant charge. A moisture indicator in the sight glass changes color to indicate the level of moisture in the system.

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		1	Moisture Indicator: Light Green = Dry Yellow = Wet
		2	Outer ring is color coded. Compare to indicator.

CFF models are equipped with either 2 or 3 evaporator fans. All models feature 2-speed motors. The evaporator fans operate continuously to circulate air inside the container. The evaporator fans operate on the following:

• High and low speed for chilled cargo at setpoints of -9.9 C (14.1 F) and above.

• Low speed for frozen cargo at setpoints of -10 C (14 F) and below.

The evaporator fan low speed RPM is one-half the high speed RPM. The controller determines evaporator fan motor speed based on the setpoint temperature and the Economy mode setting.

If Non-Optimized mode is on:

• Chill Loads: Evaporator fans operate on high speed.

• Frozen Loads: Evaporator fans operate on low speed.

If Optimized mode is on:

• Chill Loads: Evaporator fans operate on high and low speed - depending on the need for cooling.

• Frozen Loads: Evaporator fans operate on low speed and stops when there is no need for cooling.

The controller also uses a proportional-integral derivative algorithm to control the condenser temperature and ensure a constant liquid pressure at the expansion valve. The condenser fan operates continuously in high ambients. In low ambient conditions, the controller cycles the condenser fan on and off to maintain a minimum condenser temperature. The controller maintains a minimum 30 C (86 F) condenser temperature on Chill loads and a minimum 20 C (68 F) condenser temperature on Frozen loads.

This unit is available with several options that are listed in below. These options are specified when placing the order and are briefly described on the following pages.

Optional Components Open
		1	AVL, AFAM, AFAM+
		2	USDA Sensor Receptacle (Access from Inside Container)
		3	Remote Monitor Modem for Power Line Communications (REFCON control modem inside Control Box)
		4	Suction/Discharge Pressure Transducer

The MP4000 is an advanced microprocessor controller. It has been specially developed for the control and monitoring of refrigeration units. The controller contains the following basic features:

• Temperature/Message Status Display

  • Temperature area: Displays return air sensor, supply air sensor, and setpoint.

  • Message area: Displays alarms, message, and controller menu.

• Keypad

  • F1 - F4 Function keys navigate within the Status Display.

  • Two Status LED indicators.

  • Special function keys: ON/OFF, PTI, Defrost.

The Standard Display is a ¼ VGA graphical type display. The temperature can be displayed in Celsius or Fahrenheit.

The Standard Display will display the controlling sensor and Setpoint. The Setpoint will be the low reading with the C or F.

Once a key is pressed, the Standard Display will change to the Unit Status Display. After two minutes of no key activity, the display will return to the Standard Display.

Standard Display

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Some MP4000 controllers with 2.5.4.0 software are not restarting while changing power sources without turning the unit off. If a controller is found with no display and unit not running, follow this procedure.

1. Unplug the unit or turn OFF the main circuit breaker in the control box.

2. Disconnect the battery found on the back side of the controller.

3. Wait 30 seconds then plug in the battery.

4. Plug in unit or turn the main CB back ON.

5. Turn unit ON by pressing the ON key.

6. Controller will now restart.

Install MP4000 software (3.1.0.0 or later) in the controller before releasing unit. If the unit has 2.5.4.0 software or older, install 3.0.0.0 software before loading 3.1.0.0.

In order to load version 3.1.0.0 or later software, the MP4000 controller needs to have 3.0.0.0 software installed first. Load to SD Card file contains both 3.0.0.0 and 3.1.0.0 or later software.

If the controller has 3.0.0.0 software installed, insert SD card to load 3.1.0.0 or later software.

If the controller has 2.5.4.0 or older software, insert SD to load 3.0.0.0 software. Remove SD card and wait for the unit to shut down, restart, and auto configuration is completed. Reinsert SD card to load 3.1.0.0 or later software.

Use this procedure to run the unit in emergency mode if the Control Module (CM) or Power Module (PM) are found to be defective while under load and no replacement parts are available.

From the Standard Display, press the MENU F4 key to enter the Main Menu as shown below. The Main Menu allows access to several other submenus using the UP F3, DOWN F3, and ENTER F4 keys. The other submenus are described below.

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The Values menu displays general unit operating information including temperature values, pressure values, air values, unit electrical data, etc. A complete listing of the controller operating menu is located on an 11” x 17” foldout in the Diagrams chapter (Diagram Index).

Supply	USDA 3	AVL Position	CO2	Open
Return	CARGO	Bat.c.volt	O2
Evaporator	Voltage	Bat. Curr	Dew Point
Condenser	Current Ph1	Bat. Temp.	Dish Pres
Compressor	Current Ph2	PT1000 spare	Suct Pres
Ambient	Current Ph3	Board Temp	SUPPLY
Humidity	Frequency	Board Volt
USDA 1	Modulation	Sensor Volt
USDA 2	Air Exchange	Radiator

The Alarm menu displays the code conditions. Alarm codes are recorded in the controller memory to simplify unit diagnostic procedures. Some alarm codes are only recorded during a Pretrip (PTI) test or function test. Fault codes are retained by the controller in a non-volatile memory. If the Red LED is on or flashing, enter the Alarm menu to view the alarm.

Display will show either NO ALARMS or the newest ALARM. Alarm indicates corrective action should be taken. Red LED flashes and unit may stop or continue to run based on the alarm. Shutdown alarms are : 18, 51, 56, 127, 146, 147.

Shutdown alarms indicate the unit has been stopped to prevent damage to the unit or cargo. The condition must be corrected before restarting the unit. The Alarm description will be displayed across the top of the status display. To view the alarms press the Alarm key to go to the Alarm List Menu.

1. Press the F4 key to access the Alarm menu. The first alarm code number, alarm state, and alarm description appears in the Display.

   Note Alarm codes are displayed in sequential order, not in order of occurrence.

2. Write down the first code. Then press the F2 or F3 Up/Down key to view next alarm code when more than one code has been recorded.

3. Repeat above step until all alarm codes have been recorded. Press the F2 key to scroll backward to return to a previous code.

4. To clear all alarm codes from the current display list and turn off the Alarm LED, all problems must be corrected and the alarm code “acknowledged” in the Alarm Overview.

5. To acknowledge an alarm, press F4 ACK KEY while code appears on screen. The alarm state will change from Active or Not Active to Acknowledge. If no key is pressed for 30 seconds, the controller returns to previous menu level or Unit status display.

No Alarms or Newest Alarm

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The Message menu displays the code conditions. Messages are recorded in the controller memory to simplify unit diagnostic procedures.

Display will show either NO MESSAGES or the newest MESSAGE. A Message indicates corrective action should be taken before a problem becomes severe. When a Message occurs, the controller will try to determine if the component or input is good or bad. The Message description will be displayed across the top of status display and the Red LED will not be illuminated. If the controls determine the component or input is bad, the Message will become an Alarm.

1. Press the F4 key to access the Message menu. The first alarm code number, alarm state, and alarm description appears in the Display.

   Note Messages are displayed in sequential order, not in order of occurrence.

2. Write down the first message. Then press the F2 or F3 Up/Down key to view next message when more than one message has been recorded.

3. Repeat above step until all messages have been recorded. Press the F2 key to scroll backward to return to a previous message.

4. To clear all messages from the current display list and turn off the Alarm LED, all problems must be corrected and the message “acknowledged” in the Message Overview.

5. To acknowledge a message, press F4 ACK KEY while message appears on screen. The message state will change from Active or Not Active to Acknowledge. If no key is pressed for 30 seconds, the controller returns to previous menu level or Unit status display.

For a complete list of status messages and controller actions, refer to (Status Messages and Controller Actions).

No Messages or Newest Message

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The Configuration menu displays a list of functions that identifies unit operating features and current settings. A complete listing of the controller Configuration menu is located on an 11” x 17” foldout in the Diagrams chapter (Diagram Index).

With the unit turned On, allow it to start and stabilize and the display showing the unit status display:

1. Press the F4 MENU key. Press the F3 key to scroll down to the CONFIG menu.

2. Press the F4 key to expand this menu.

3. Press the F2 OR F3 UP/DOWN key to scroll to view or reset the desired function.

4. To set a new Configuration screen value:

   1. Press the F4 key with cursor in the desired menu line.

   2. Press the F2 OR F3 UP/DOWN key to scroll the value to the desired setting.

   3. Press the F4 key and release when the entry is complete. Press the F1 key. The new value appears in the menu line.

5. Repeat steps 3 and 4 to reset additional configuration values.

6. Press the F1 key to exit the Configurations screen.

Configuration Menu

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This menu allows the user to check Temperature, Event, PTI, Smart, and Runtime logs. Displays results of last PTI, Event, and Temperature test including component volt and amps data and sensor temperatures.

A complete listing of the controller operating menu is located on an 11” x 17” foldout in the Diagrams chapter (Diagram Index).

With the unit turned On, allow it to start and stabilize and the display showing the unit status display (setpoint):

1. Press the F4 MENU key. Press the F3 key to scroll down to the Log View menu. 2. 3. :

2. Press the F4 key to access the Log View menu.

3. Press the F2 or F3 UP/DOWN key to scroll to the desired function.

4. Press the F4 key to access the function selected.

Log View Menu

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Open	Open	Open
Open	Open	Open

This menu displays controller software application version, bootloader version, power module version, serial number, and option file version. It also displays expansion slots if used.

Info Menu

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Pressing the PTI key will access various PTI Commands for selecting a user activated functionality.

• Manual Function Test: Refer to (Manual Function Test) for detailed information.

• Function Test: Refer to (Function Test) for detailed information.

• PTI: Refer to (PTI (Pretrip) Tests) for detailed information.

PTI Menu Screen Open	Manual Function Test Open	Function Test Open
AFAM+ PTI Open	Humidity Sensor PTI Open	Brief PTI Open
Chilled PTI Open	PTI Open	Probe Test Open

Show PTI Info Open

To access the Defrost Menu, turn the unit On and allow the unit to start and stabilize and show the unit status display (setpoint).

1. Press the DEFROST (*) key to open the Defrost Menu.

2. Press the F2 OR F3 UP/DOWN key to scroll to “Start Defrost”.

   Defrost Menu

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3. Press the F4 key to enter DEFROST function. If the unit operating conditions allow a manual defrost (e.g., evaporator coil temperature is less than 18 C [56 F]), the unit enters Defrost.

The defrost cycle automatically terminates and returns the unit to normal operation.

Select Show Defrost Info to display the Defrost Info Screen, which shows information about such as, Compressor Defrost Timer, Timer Defrost Timer Limit, and the Last Defrost as shown below.

Defrost Info Screen

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The MP4000 controller contains special PTI pretrip tests that automatically checks unit refrigeration capacity, heating capacity, temperature control, and individual components including the controller display, contactors, fans, protection devices, and sensors. The test includes measurement of component power consumption and compares test results to expected values.

The Full PTI test takes up to 2 to 12 hours to complete, depending on the container and ambient temperature.

The Brief PTI test takes about 25-30 minutes to complete, depending on the container and ambient temperature.

Detailed PTI test results are stored in the MP4000 Datalogger for later viewing. Any alarm codes recorded during the test can be viewed through the controller’s Alarm List menu at the end of the test.

1. Press the F4 key to enter the main menu. Press the F2 or F3 key to scroll to Config menu and press F4 to expand the menu.

2. Press the F2 or F3 key to scroll to Options menu and press F4 to expand the menu.

3. Press the F2 or F3 key to scroll to Controlled Atmosphere (CA) menu and press F4 to enter the menu.

4. Press the F2 or F3 key to select AFAM and Press and hold F4 to accept the selection.

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5. Press the F1 key several times to return to the standard display.

6. Press the F4 key to enter the main menu. Press the F2 or F3 key to scroll to Controls menu and Press F4 to expand the menu.

7. Press the F2 or F3 key to scroll to Fresh Air Vent Man menu. Press the F4 key to enter the Fresh Air Vent Man menu.

   Warning
   • Risk of Injury
   • The vent door and motor actuator arm move immediately when the F4 key is pressed to turn the AFAM system to AFAM or Off. Keep hands and tools away from the air exchange system components to prevent personal injury or unit damage.

8. Press the F2 or F3 key to scroll between [OFF] and [AFAM].

   • [OFF]: Vent door closes and/or remains closed. AFAM Delay and AFAM Rate settings disappear.

   • [AFAM]: Controller uses enter AFAM DELAY and AFAM RATE time to adjust FAE door to user setting.

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9. Press and hold the F4 key with the desired state in the menu line until you are returned to the Controls menu.

10. Press the F1 key several times to return to the standard display.

The AFAM delay setting keeps the fresh air vent closed for a preset time when the unit starts. This allows faster product temperature pull-down. The AFAM delay can be set from 1 to 72 hours in 1-hour increments.

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		1	Vent Door Assembly and Damper Motor
		2	AFAM+ Expansion Module (Mounts on Back of Controller in Control Box)

1. Press the F4 key to enter the main menu. Press the F2 or F3 key to scroll to Controls menu and Press F4 to expand the menu.

2. Press the F2 or F3 key to scroll to AFAM DELAY.

   Warning
   • Risk of Injury
   • The vent door and motor actuator arm move immediately again when a delay is entered. Keep hands and tools away from the air exchange system components to prevent personal injury or unit damage.

3. Press the F4 key to enter the AFAM DELAY menu. The current setting (“0”) appears in the display.

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4. Press the F2 or F3 key to increase or decrease the time delay.

5. Press and hold the F4 key until returned to the main menu. The new time delay is recorded in the controller and appears in the display.

6. Press the F1 key to exit the Controls menu.

The AFAM rate sets the desired air exchange rate. The actual door position is based on the AFAM rate and the power supply frequency (Hertz).

1. Press the F4 key to enter the main menu. Press the F2 or F3 key to scroll to Controls menu and Press F4 to expand the menu.

2. Press the F2 or F3 key to scroll to AFAM RATE. Press F4 to enter menu. The current rate and units (e.g. “0 CMH”) appears in the display.

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   Warning
   • Risk of Injury
   • The vent door immediately closes and re-opens to the new position when a rate is entered. Keep hands and tools away from the air exchange system components to prevent personal injury or unit damage.

3. Press the F2 or F3 key to increase or decrease the AFAM Rate.

4. Press and hold the F4 key until returned to the main menu. The new rate is recorded in the controller and appears in the display.

The unit operates on Cool with Modulation and Heat to provide accurate control of chill loads. During Cool with Modulation, the controller uses a proportional-integral derivative (PID) algorithm, and a Digital Control valve to provide accurate control of the container temperature in direct response to load demand.

The Digital Control valve engages and disengages the compressor to control capacity. The valve opens and closes in response to a controller voltage signal based on a control temperature differential. The controller uses the setpoint temperature, supply air sensor temperature and pull-down rate for the last 10 seconds, last 20 seconds and last 180 seconds to calculate the control temperature differential.

The unit operates on Full Cool and Null to provide accurate control of frozen cargo. The controller uses the return air sensor temperature and setpoint temperature to regulate unit operation.

If the return air sensor becomes disconnected or fails, the controller uses the supply air sensors plus an offset for temperature control.

During compressor operation, a vapor injection system injects refrigerant into the center scroll of the compressor to provide additional cooling capacity. When vapor injection is active, the controller energizes the vapor injection valve continuously. The controller activates vapor injection when the:

• Chill or Power Limit Mode: When the cool capacity is 100 percent (in the display), the controller energizes the vapor injection valve continuously.

• Compressor discharge temperature exceeds 138 C (280 F). Vapor injection stops when the compressor discharge temperature decreases 6 C (10.7 F).

If the discharge gas temperature rises above 148 C (298 F), the unit stops immediately. The controller turns on the Alarm LED and records Alarm Code 56 (Compressor Temperature Too High) and Alarm Code 146 (Compressor 2 Temperature Too High). The controller will restart the unit when the sensor temperature is below 138 C (280 F).

The controller uses the total unit current and the condenser temperature to provide power limit control in both the Chill and Frozen modes. When the unit is on water-cooled operation, power limit control is based on the total unit current draw only.

The controller determines evaporator fan motor speed based on the setpoint temperature and the mode setting.

The controller also uses a proportional-integral derivative algorithm to control the condenser temperature and ensure a constant liquid pressure at the expansion valve. The condenser fan operates continuously in high ambients. In low ambient conditions, the controller pulses the condenser fan on and off to maintain a minimum condenser temperature. The controller maintains a minimum 30 C (86 F) condenser temperature on Chill loads and a minimum 20 C (68 F) condenser temperature on Frozen loads. To do this the condenser fan pulses.

The controller constantly monitors t supply sensor, return sensor and evaporator coil sensor to determine when to initiate a demand defrost. If a demand defrost is requested and defrost has occurred within last 90 minutes, the controller initiates a probe test to check for a defective sensor.

During a Probe test, the Display shows “PROBE TEST PLEASE WAIT”. The controller operates the unit on high speed evaporator fans only for 5 minutes. All sensor temperatures are then compared.

• Sensors with large temperature differences are discarded from the control algorithm. The controller then activates the appropriate Alarm codes to identify the defective sensor(s).

• If no sensors are found defective, controller display shows “RUNNING WITH HIGH SUPPLY DIFFERENCE” warning.

Sensor errors recorded during a probe test are cleared when the next Defrost is initiated or UNIT ON/OFF switch is turned OFF.

During Chill mode operation, a dehumidification system is available to reduce the relative humidity in the container to the desired humidity setpoint. The Dehumidify mode option is turned on from Setpoint menu of the controller. The relative humidity setpoint can be set from 60 to 99 percent from the Setpoint menu.

Changing the humidity control from off to DEHUM in the setpoint menu activates the dehumidify control algorithm. When the Dehumidify mode is on, the supply air temperature must be in-range to activate dehumidification.

• When the humidity level is 2 percent or more above setpoint and the Digital Control valve has reduced the unit cooling capacity to 85 percent, the controller pulses the electric heaters on and off. This increases the cooling load on the evaporator coil, thereby causing the coil to become even colder and condense more moisture from the container air.

The Compressor Digital Control valve is normally closed. The normally closed position provides full cooling capacity. When the controller energizes, it opens the Compressor Digital Control valve. Refrigerant gas flows from the digital port of the compressor back to the suction line. This disengages the compressor 100 percent and temporarily reduces the compressor pumping capability.

The controller uses a proportional-integral derivative (PID) algorithm to provide accurate temperature control. This is in direct response to load demand. However, instead of generating a voltage signal to position a suction line modulation valve to regulate cooling capacity, the algorithm establishes a pulse width signal to cycle the Compressor Digital Control valve open and closed on a duty cycle. The percent ON time (compressor pumping time) in the duty cycle equals the cooling capacity percent required to meet the current load demand.

Remember that the percent ON time defines the time the compressor is engaged. The compressor is engaged (pumping) when the Compressor Digital Control valve is closed (OFF). Therefore, a duty cycle of 100 percent means the compressor is pumping 100 percent of the time and the Compressor Digital Control valve is ON (open) 0 percent of the time. A 60 percent duty cycle means the compressor is pumping 60 percent of the time and the Compressor Digital Control valve is ON (open) 40 percent of the time.

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A vapor injection line tee is located in the liquid line between the filter drier/in-line filter and the economizer heat exchanger. A vapor injection valve controls refrigerant flow through the vapor injection line to the economizer expansion valve. When this normally closed valve is energized (open), a portion of liquid refrigerant flows through the economizer expansion valve and evaporates in the inner coiled tube of the economizer. This cools the rest of the liquid refrigerant that flows past the tee and through the economizer to the evaporator coil.

The economizer suction gas continues through the vapor injection circuit and returns to the intermediate suction port of the scroll compressor. Injecting the economizer suction gas into the compressor downstream from the suction port prevents the gas from affecting the suction pressure or cooling capacity of the evaporator coil. However, the economizer suction gas adds its heat and volume to the condenser side of the refrigeration system, increasing the discharge pressure.

Because the economizer system increases system cooling capacity, the vapor injection valve is energized (open) continuously when the compressor duty cycle (ON time) is 100 percent (Full Cool). High compressor discharge temperature may cause the vapor injection valve to energize (open) but only while the Compressor Digital Control valve is not energized (closed).

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The data logger can record sensor temperatures as well as loss of power, alarms, sensor failure, setpoint change and unit shutdown events. All data logs include the time and date; setpoint temperature; supply, return, ambient, USDA1, USDA2, USDA3. All temperature logs can be viewed from the controller’s VGA message display.

Data logging intervals are selectable for 1 minute, 5 minutes, 10 minutes, 15 minutes, 30 minutes, 1 hour. 2 hours or 4 hours.

When a 1 hour logging interval is selected, the data logger memory can store approximately 680 days of information. The logging of USDA sensors is fixed at 1 hour intervals to comply with USDA requirements. A logging test of USDA sensors at 1 minute intervals is possible for 72 minutes. USDA data can not be downloaded during the logging test and can only be viewed on screen. After 72 minutes, controller returns to previous logging interval and clears USDA test data from data logger memory.

If the unit power supply is disconnected, the data logger will continue to register 100 temperature logs when battery voltage is above 4.2 volts. These will be maintained until the unit is re-connected to power, and the battery automatically recharged.

Trip data can be retrieved (but not erased) from the data-logger memory using a LOGMAN II handheld data retriever, LOGMAN II PC used on a laptop PC or a REFCON power line remote monitoring system. LOGMAN II data transfer rate based on a 1 hour log interval is about 15 seconds per month of event logs and about 70 seconds per month of temperature logs. For example, downloading 90 days of data logs would take about 95 seconds for event logs only and about 210 seconds for temperature logs only.

Trip data from separate units is denoted by the identification information entered into the controller at the beginning of the trip via the general purpose keypad. Identification data may include the container ID number, location B.R.T., contents, loading data, voyage no., ship, load port, discharge port and comments. The container ID number is stored in the Configuration submenu.

This feature is designed to maintain a temperature below the actual setpoint for a period of time (per USDA specifications), and then increase the temperature to the final setpoint. If at any time one of the USDA sensor temperature reading goes above the USDA Max the CT period will begin again.

To document the CT, a set of events and temperatures are recorded in the datalogger. When the CT has passed the controlling setpoint will be increased at slow rate to the final setpoint.

Controller Settings

• CT Temperature Setpoint - Setpoint temperature used during the CT period.

• CT Period - Number of days and/or hours accepted by the USDA max limit, to pass the CT period.

• CT MAX USDA Temperature - Maximum allowed USDA sensor temperature during the CT period.

• CT Final Temperature Setpoint - Final setpoint temperature after the CT passes.

• CT Heatup - Delay interval between each 0.1 C increase (normally 1 hour).

Trip Action and Unit Mode

• Container is prepared with CT settings and transported to be loaded. If the unit is running the container will pre-cooled.

• If unit is equipped with the UDSA sensors, once all the sensor temperature readings deceases to or below the USDA Max the CT period will start.

• Cargo is loaded and USDA sensors are placed in the cargo per the USDA specification.

• USDA sensor readings will increase to cargo temperature and a running CT period will be canceled. Pull down of the cargo temperature begins.

• Once all the USDA sensor temperature readings decease to or below the USDA Max the real CT period will start.

• If any of the USDA sensor temperature readings go above the USDA Max, the CT period will be canceled and the above action will repeat.

• When the specified number of days has finished the controlling setpoint is increase, 0.1 C per hour, until the final setpoint is reached.

During the CT a set of events and temperature readings are logged in the datalogger.

Unit Requirements

To activate CT the unit must have:

• 1 - 3 UDSA or Cargo sensors

• Battery (Battery is required for off power logging)

Activating Cold Treatment

Go to the Configuration > Options Menu enter CT Feature and turn it ON.

Calibrate Probe (Optional)

Setting the USDA Type in the Configuration menu activates spare sensors 1, 2, 3, and 4 for USDA Cold Treatment Temperature Recording. USDA sensor temperatures are recorded in the datalogger memory.

The USDA sensors should be connected to the controller and located in the load as shown in USDA directives. When a USDA sensor is installed, the controller will automatically detect each sensor and activate data logging. However, the USDA Type screen in the Configuration menu must be set to the correct sensor setting and each USDA sensor must be calibrated to comply with USDA temperature recording requirements. Calibrate the sensors in an ice bath. Units equipped for NTC style USDA sensors require USDA sensor P/N (refer to Tool Catalog). Units equipped for PT100 style USDA sensors require USDA sensor P/N (refer to Tool Catalog)

Ice Bath Preparation

1. The ice bath should consists of an insulated container full of ice made from distilled water with enough distilled water added to cover the top of the ice during the test. A properly filled ice bath should be completely filled with ice all the way to the bottom of the container.

2. Stir the ice bath briskly for one minute before proceeding.

3. Insert the USDA sensors in the ice bath. Wait five minutes to allow the sensor temperatures to stabilize at 0 C (32 F).

4. Stir the ice bath frequently. As an option, test and verify ice bath temperature with a meter or measuring device meeting your accuracy requirements. Stirring 10 seconds every three minutes during the test procedure is adequate.

Calibrating the USDA Sensors

1. Insert all USDA sensors in an ice bath (see “Ice Bath Preparation” above).

   Note The sensors must be completely immersed in the ice bath without contacting the walls of ice bath container for five minutes.

2. Press the F4 MENU key. Press the F3 key to scroll down to the CONFIGURATION Menu.

3. Press the F4 ENTER KEY to access the CONFIGURATION menu.

4. Press the F2 OR F3 UP/DOWN key to scroll to scroll down to the SENSOR Menu.

5. Press the F4 ENTER key to access the SENSOR Menu.

6. Press the F3 key to scroll down to CALIBRATE PROBES.

7. Press the F4 enter key to enter Calibrate function. The display shows [RAW] and [CORR] temperature off-sets for each sensor in two rows.

   The controller displays [COOR] in place of a temperature offset until the sensor comes within 0.3 C (0.5 F) above or below 0 C (32 F).

   The controller displays the actual temperature offset when the sensor temperature is within 0.3 C (0.5 F) above or below 0 C (32 F).

   Note The sensors should be in the ice bath a total of 15 minutes or more to assure the sensor temperature has bottomed out.

8. Press the F3 key to release the current actual temperature offsets from the controller memory. Observe the sensor temperatures in the [CORR] row.

9. Press the F4 ENTER KEY to accept the new temperature offsets when all sensor offsets read between + 0.3 C (+0.5 F) and - 0.3 C (-0.5) and have been stable for five minutes. The controller display will show the new offsets in the [RESULT] row.

10. Press the F1 key to exit the Calibrate menu.

Starting Cold Treatment

1. Go to the Setpoint/Control and enter Cold Treatment (CT).

2. Display will show the Cold Treatment setting list, scroll up and down to edit and enter the settings per the load specifications.

   Note Once Cold Treatment has been started, it must be stopped to change any of the settings.

3. Select EXIT. The Standard Display will appear showing “CT In Progress”. CT is activated and the trip begins.

Stopping Cold Treatment

1. Press the CT Key.

2. Scroll down to ABORT CT - PRESS >STOP< and press STOP.

3. The Standard Display will appear and “CT In Progress” will disappear from the display.

Passed Cold Treatment - must be acknowledged: To verify the user observes the passed display, Acknowledge CT will be displayed until it is acknowledged by pressing the CT Key and them pressing the ACK Key.

Surveillance during cold treatment: During the CT period all USDA sensors can fail and the CT period will continue. The fail state will be shown in the temperature log. If all three probes fail, the period will continue based on time only.

RMM / Refcon: The RMM at no time during the CT is able to change any of the CT settings The RMM interface will show the final temperature as setpoint through out the trip, even when the period is running and another setpoint is used.

Economy mode: Running economy mode either manually or automatically by the AVL, will automatically be set to OFF during CT pull down and period. After the CT period ends the economy mode is reinstated (starting from warm up phase).

Associated tools: LogView must be updated to Version 5.8.2.0 to report the cold treatment events.

Various actions: When the user activates the cold treatment, a trips start mark and event is automatically made.

To be able of transporting a commodity under the best possible temperature scheme, the MP4000 is capable of controlling the temperature through a set of temperatures.

The scheme is defined by user pre programmed temperature setpoints and time periods.

The fix point list for the temperature scheme programming allows for up to nine different sets of temperatures and periods.

• Nine sets of temperature setpoints.

• Eight sets of timing in between the nine setpoints.

Trip Actions and States

• The container is prepared, initiated with setpoints and parameters for the journey and transported to the loading location. The refrigeration unit will, if powered, start approaching the first setpoint.

• The next setpoint will be approached within the maximum capabilities of the unit, as if a user manually has changed the setpoint.

• The timing for any period will start when the supply air approach for the setpoint is within the IN RANGE setting. The timing will not stop or restart even though the supply air gets out range.

• The temperature setting will be kept through the specified period and when the period ends the next set of parameters will be activated.

During the treatment a set of events is made together with the temperature logging to document the journey.

Activating Multiple Temperature Setpoint

Go to the Configuration > Options Menu enter MULTIPLE SETPOINT (MTS) and choose SELECTABLE.

Open

Starting and Setting Multiple Temperature Setpoint

1. Go to the Controls menu and enter MTS/CT.

2. The display will show the Multiple Setpoint selection. Select MULTIPLE SETPOINT and press CONFIRM.

   Open

3. The following screen will appear. Press UP and/or DOWN to change the setpoint to the desired setting, then press and hold CONFIRM to enter the setpoint.

   Open

4. Select MTS Period 1 and press CONFIRM. The following screen will appear. Press UP and/or DOWN to change the period to the desired setting, then press and hold CONFIRM to enter that period.

   Open

5. The following screen will appear. Repeat steps 3 and 4 for Setpoint 2 and Period 2, and for each additional setpoint that is required. Leave the Period Setting at “MTS END” for the final period.

   Open

6. Select BACK as necessary. The Standard Display will appear showing “MTS - Approaching setting 1” indicating MTS is active.

   Open

Stopping Multiple Temperature Setpoint

1. Go to the Controls menu and enter MTS/CT.

2. The display will show the Multiple Setpoint selection. Select NONE and press and hold ACCEPT.

   Open

3. The Standard Display will appear and “MTS - Approaching setting 1” will disappear. After stopping MTS, the unit will continue running with the last MTS setpoint in action.

   Open

Surveillance during the multi-temperature setting trip: During the treatment the normal unit surveillance is kept.

Associated interfaces RMM / REFCON: The RMM must at no time during the journey be able of changing any involving parameters and settings on the controller. The RMM interface will show the ending final/last set point through out the trip, even when setting 1 or 2 etc. is running as active with another set point in use.

Associated tools: LogView must be updated to Version 5.8.2.0 to report the Multi-Temperature Setting events.

Various actions: When the user activates the treatment, a trips start mark and event is automatically made.

Open

Insert a flat blade screwdriver into slot on side of control box door. Open

Move the screwdriver handle to the left to release the door catch from the box latch. Open

With the door catch released, pull door out and open. Open

Close

Push firmly until a click sound is heard. Open

With hand, rap the door to confirm it is closed properly. Open

Controller software must be flashloaded when software has been revised. Flashload software using the following procedure.

Download the latest software file from Global Marine Solution Info Central site/Software Update/MP4000. The CM4000 zip file will contain the latest software and command.ini file. Unzip them to a local drive.

SD Card Setup Structure

1. Verify the SD card is in the un-lock or writeable mode. Small tab on side slide forward is un-locked.

2. If card is new, format card so it is clean.

3. Create a new directory on the SD card titled MP4000. In the MP4000 directory, create two new sub directories titled Firmware and Logs.

4. Copy the command.ini file into the /MP4000 directory of the SD card.

5. Copy the latest software file (.strip) into the \ MP4000 \ Firmware sub directory. Refer to ( MP4000 and MP4000/Firmware).

   / MP4000 / command.ini 3/18/2010 / Logs (Downloads will appear here) / Firmware CM4000_3.2.0.0_140822.strip

MP4000

Open

MP4000/Firmware

Open

Software File Format SIP

In version 3.0.0.0 the SIP file format was introduced for adding options like RMM to the unit. Version 3.1.0.0 120612 and later were released in this SIP format (e.g., CM4000_3.1.0.0.120612.srip.sip). In order to load version 3.1.0.0 or later software, the MP4000 controller needs to have 3.0.0.0 software installed first. Load to SD Card file contains both 3.0.0.0 and 3.1.0.0 or later software.

If controller has 3.0.0.0 software installed, insert SD card to load 3.1.0.0 or later. If controller has 2.5.4.0 or older software, insert SD to load 3.0.0.0 software, then reinsert SD card to load 3.1.0.0 or later software.

The MP4000 controller can be flashloaded using battery power or shore power. If the SD Card is not configured correctly, the MP4000 will display Command files not found.

Open

Battery Power Flashload Procedures

1. Verify the unit is not active (no display).

2. Insert the SD card, with the latest software, into the slot on the side of the controller.

3. Activate the display using battery power by pushing the ON/OFF button. If the software on the SD card is newer then what is on the controller, the upload will take place and progress can be shown on the display.

4. When finished the display will shut down and the operation is finished.

Shore Power Flashload Procedures

1. Plug unit in and turn unit ON, let unit stabilize.

2. Insert SD card, with the latest software, into the slot on the side of the controller.

3. If the software on the SD card is newer then what is on the controller the display will show, PLEASE WAIT… EXACTING COMMAND FILE, then UPDATE FIRMWARE, then PREPARING, then UPDATING FIRMWARE 0-100%.

4. Once it shows 100%, unit will shut down and restart. Will show normal display and perform a AUTO CONFIGURATION, then normal start sequence.

5. Remove SD card and release unit.

The MP4000 Test System Tool has the ability to test the following components:

• Controller Module (CM)

• Power Module (PM)

• Interconnect Cable

• Keypad

• Displays

Open	Tool comes with all necessary test plugs required to perform all tests noted above. Software will be located on the JCI web site. www.myrefcon.com/support/mp-4000-tester/
	The Tool is sold through Emerson Controls.
	Ordering information (Contact) Wilmor Halamani Email: Wilmor.Halamani@Emerson.com Phone 45 70234444 Fax 45 70236044.
	1 MP-4000 Test System (item no. 8232- 010) Delivery terms: ex works Delivery mode: DHL Delivery time: 2-3 days upon receipt of order Payment terms: 14 days net
	Please state purchase order number, invoice address and delivery address when ordering.

In the event of a MP4000 Tester Tool part failure, refer to the following information for replacement.

All of the test plugs are covered under warranty for one (1) year from date of purchase by Emerson Controls. To order a replacement test plug, please provide the following information:

• Part number of plug to be replaced.

• Original purchase date of test tool and serial number.

• Company name and shipping address.

• Contact Thermoking Aftermarket to order.

  Controller Module Test Plugs Analog 2 #J1 1934-001 Analog 3 #J3 1934-002 Analog 1 #J4 1934-003 Digital 1 #J9 1934-004 Com 2=3 J28=J2 1934-005

  Power Module Test Plugs PM test Adaptor #J1 1934-007

  Expansion Module Test Module 1934-006

A high pressure cutout switch is located on the compressor discharge service manifold of the compressor. If the discharge pressure becomes too high, the switch opens the ground circuit to the compressor contactor coil.

• Compressor stops immediately. Evaporator and condenser fans continue normal operation.

• Controller determines that a high pressure cutout switch or compressor motor internal overload protector is open when the unit current draw during compressor operation is normal and then decreases by 7 amps for more than three seconds.

• After one minute, controller VGA display shows a High Pressure Cutout message:

  • “HIGH PRESSURE CUTOUT CHECK CONDENSER PROBE”: Water pressure switch is open and the condenser temperature is low.

  • “HIGH PRESSURE CUTOUT CHECK CONDENSER FAN”: Water pressure switch is open and the condenser temperature is high.

  • “HIGH PRESSURE CUTOUT CHECK WATER COOLING”: Water pressure switch is closed.

  Open
  		1	Low Pressure Cutout Switch
  		2	High Pressure Cutout Switch

• The controller continues to call for cooling so the compressor will restart when the overload condition is corrected (switch resets) if power is available.

• If the switch remains open for five minutes, the controller also turns on the Alarm indicator and records Alarm 37 (Total Power Consumption Too Low).

The high pressure cutout switch opens at 2302 ± 103 kPa, 23.03 ± 1 bar, 334 ± 15 psig, and closes at 1703 kPa, 17.03 bar, 247 psig. To test the switch, rework a gauge manifold in accordance with High Pressure Cutout Manifold.

1. Connect the manifold gauge to the compressor discharge service valve with a heavy duty, black jacketed thick wall #HCA 144 hose with 6024 kPa, 60.24 bar, 900 psig working pressure rating.

2. Operate the unit in Cool by performing a Capacity 100 percent test from the Manual Function Test menu of the controller.

   High Pressure Cutout Manifold Open
   		1	Relief Valve
   		2	O-ring
   		3	Adapter Tee (Weather Head)

3. Raise the discharge pressure f the compressor by blocking the condenser coil airflow. Temporarily cover the compressor compartment, control box and power cord storage compartment with cardboard to reduce condenser coil airflow. This should increase the discharge pressure enough to cause the switch to open. When the switch opens, The compressor should stop immediately.

   Note The discharge pressure should never be allowed to exceed 3,447 kPa, 34.4 bar, 500 psig.

4. Verify removal of the cardboard installed in step 3.

   Note If the HPCO switch fails to stop compressor operation, replace the switch and repeat steps 1 through 4.

Removal

1. Isolate the compressor from the system.

   1. Front seat the discharge service valve by turning the valve fully clockwise.

   2. Front seat the suction service valve by turning the valve fully clockwise. Turn the digital service valve one quarter turn to the right.

2. Recover the refrigerant from the compressor. Refer to (Recovering Refrigerant from System).

3. Disconnect the high pressure cutout switch wires from the control box.

4. Remove the high pressure cutout switch from the compressor flange.

Installation

1. Apply Locktite sealant to the threads of the switch.

2. Install switch in compressor flange.

3. Pressurize the compressor with refrigerant and check for leaks.

4. Evacuate the compressor. Refer to (Evacuation and Cleanup of Refrigeration System).

   Open
   		1	Low Pressure Cutout Switch
   		2	High Pressure Cutout Switch
   		3	Discharge Service Valve
   		4	Suction Service Valve

5. Route wires into the control box and connect to proper terminals.

6. Back seat the discharge service valve by turning the valve fully counter-clockwise.

7. Back seat the suction service valve by turning the valve fully counter-clockwise.

8. Turn the digital service valve one quarter turn to the left.

9. Perform a controller pretrip test to verify system operation.

A low pressure cutout switch is located on the compressor suction line. The low pressure cutout switch opens: -33 to -54 kPa, -0.33 to -0.54 bar, 10 to 16 in. Hg vacuum; closes: 24 to 58 kPa, 0.24 to 0.58 bar, 3.5 to 8.5 psig. If the suction pressure becomes too low, the switch 3opens to stop the compressor.

• Compressor stops immediately.

• Evaporator and condenser fans continue normal operation.

• Compressor will restart if the low refrigerant condition is corrected (switch closes) as long as power is available. The low pressure switch resets (closes) when the pressure increases to 28 to 48 kPa, 0.28 to 0.48 bar, 4 to 7 psig.

These units could have either a Low Pressure Cutout switch or a Suction Transducer installed.

Low Pressure Cutout Switch Installed Open

Suction Transducer Installed Open