General Description

The MP3000/MP3000a is advanced microprocessor controller that has been specially developed for control and monitoring of refrigeration units. The ontroller contains the following basic features:

1. Eight status indicator LEDs are located in the top LED display and signal the following:

   • Supply (Air Temperature)

   • Return (Air Temperature)

   • Humidity Mode (Inactive on CRR DF units)

   • Compressor (Cooling On)

   • Heat (On during Defrost)

   • Defrost

   • In-Range (Temperature)

   • Alarm

   The Alarm LED flashes ON and OFF continuously when a Check Alarm (Level 2 Alarm) or Shutdown Alarm (Level 1Alarm) occurs. Less serious Log Alarms (Level 3 Alarm) are recorded but do not activate the Alarm LED.

   Check Alarms indicate corrective action should be taken before a problem becomes severe. The unit continues to operate. However, some unit functions may be inhibited.

   Shutdown Alarms indicate the unit operation has been stopped to prevent damage to the unit or cargo. The problem must be corrected and the alarm code acknowledged before the unit can be restarted to resume normal operation.

   Alarm codes are recorded in the controller memory to simplify unit diagnosis procedures. Some alarm codes are only recorded during a Pretrip (PTI) Test. Fault codes are retained by the controller in a non-volatile memory (see alarm codes, type and description below).

   MP3000/MP3000a Controller

   Open

   1.	LED display with Status Indicator LEDs	3.	General purpose keys
   2.	LCD message and menu display	4.	Special function keys

   00	Check	Supply Air Sensor Open Circuit	20	Check	Defrost Time Too Long
   01	Check	Supply Air Sensor Short Circuit	22	Check	Capacity Test 1 Error
   02	Check	Return Air Sensor Open Circuit	23	Check	Capacity Test 2 Error
   03	Check	Return Air Sensor Short Circuit	32	Check	Condenser Air Sensor Open Circuit
   04	Check	Evaporator Coil Sensor Open Circuit	33	Check	Condenser Air Sensor Short Circuit
   05	Check	Evaporator Coil Sensor Short Circuit	34	Check	Ambient Air Sensor Open Circuit
   06	Check	R-134a Compressor Current Too High	35	Check	Ambient Air Sensor Short Circuit
   07	Check	R-134a Compressor Current Too Low	43	Check	Return Air Temperature Too High
   10	Check	Heater Current Too High	52	Check	Probe Error
   11	Check	Heater Current Too Low	56	Shutdo wn	Compressor Temperature Too High
   14	Check	Evaporator Fan Low Speed Current Too High	58	Check	Phase Sensor Error
   15	Check	Evaporator Fan Low Speed Current Too Low	59	Check	Delta Current Error
   16	Check	Condenser Fan Current Too High	97	Log	Compressor Sensor Open Circuit
   17	Check	Condenser Fan Current Too Low	98	Log	Compressor Sensor Short Circuit
   18	Log	Power Supply Phase Error	112	Check	Zero Current Too High
   19	Check	Temperature Too Far from Setpoint

2. LED display with 20.32 mm high characters:

   • Five alpha numeric characters: Numerical hundredths, tens, ones and tenths position, a C for Celsius or F for Fahrenheit for temperature display.

   • LED display shows current control temperature (return or supply). Status LEDs signal sensor temperature shown in LED display. If a sensor is out of range the display shows “+Err” or “-Err”. The ± sign indicates whether the sensor temperature is out of range high or low.

   • The LED display is also used to show the current state of a Pretrip (PTI) test.

3. LCD display with 4 line, 20 character message display:

   • LCD standard display shows setpoint temperature during normal operation information.

   • • LCD display shows controller menu and unit operation information when special keys are pressed.

4. Sixteen general purpose keys are used to enter and scroll through the controller menu tree and message text; initiate a Pretrip test; enter new setpoint temperature; and enter trip information.

   The keyboard supports both numerical and text input. Each key can have more than one meaning. Use the special text keys F1, F2, F3 and F4 to enter text in an information screen:

   • F1 key: Press the F1 key, then press another general purpose key to enter the number shown on the key.

   • F2 key: Press the F2 key, then press another general purpose key to enter the first letter shown on the key.

   • F3 key: Press the F3 key, then press another general purpose key to enter the second letter shown on the key.

   • F4 key: Press the F4 key, then press another general purpose key to enter the third letter shown on the key.

   Note When the F1, F2, F3 or F4 key is pressed to enter a character in the display, the keypad remains on that “character level” until another “level” is selected by pressing the F1, F2, F3 or F4 key.

   Text Input Example: To enter THERMO in an information screen:

   1. Enter “T” by pressing F3 key, then pressing STU key.

   2. Enter “H” by pressing GHI key.

   3. Enter “E” by pressing DEF key.

   4. Enter “R” by pressing F4 key, then pressing PQR key.

   5. Enter “M” by pressing F2 key, then pressing MNO key.

   6. Enter “O” by pressing F4 key, then pressing MNO key.

   General text keys F1, F2, F3 and F4 also include directional arrows for entering and scrolling through the controller Main Menu:

   • F1 key: ESC indicates that pressing the K1 key moves the cursor out of (exits) a menu list.

   • F2 key: FORWARD/UP ARROWS indicate that pressing the K2 key scrolls the cursor forward and/or upward through text boxes and menu lists.

   • F3 key: BACKWARD/DOWN ARROWS indicate that pressing the K3 key scrolls the cursor backward and/or downward through text boxes and menu lists.

   • F4 key: ENTER ARROW indicate that pressing the K4 key moves the cursor into the next menu level or into a menu item text box.

5. Four special keys:

   • C/F key: Press to view alternate temperature scale in LED display.

   • DEFROST key: Press to initiate defrost. Evaporator coil temperature must be below 10 C (50 F).

   • SUP/RET key: Press to view alternate return/supply sensor temperature in LED display.

   • SETPOINT key: Press to show Setpoint temperature line in LCD display for setpoint adjustment.

6. Control Transformer: Low voltage control power and ground is supplied to the microprocessor controller and the main relay board.

7. Main Relay Board: High voltage supply power and low voltage control power and ground are supplied to the main relay board. The main relay board contains:

   • Relays to energize and de-energize unit contactors and solenoids. Component relays include the heater, evaporator fan motor, condenser fan motor, and phase reversal relays.

   • Supply power circuit protection: 20 amp fuses (3) protect the high voltage circuits on the main relay board.

   • Control circuit fuse and circuit breaker protection:

     - 7 amp manual reset circuit breaker protects the 29 Vdc control circuit.

     - 2 amp fuse protects the 28 Vac control power circuit to the controller.

     - 2 amp fuse protects the battery charger output circuit to the controller.

   • Electronics for measuring phase sequence.

   • Electronics for measuring amperage.

   • Electronics for measuring voltage.

   • Zero current transformer for earth leaking measurement.

8. Replaceable sensors: Return air, supply air, evaporator coil (defrost), ambient air, R-134a compressor discharge line and R-23 compressor discharge line temperature sensors are field replaceable. Three (replaceable) spare sensor receptacles are also provided for USDA temperature recording.

9. Defrost cycle control (see “Defrost System” in this chapter).

10. Pretrip (PTI) test capability (see “PTI (Pretrip) Test” in this chapter).

11. Data recording capability: The Datalogger can record sensor temperatures as well as loss of power, alarms, unit operating modes, sensor failure, setpoint change and unit shutdown indications. All data recordings are stored in memory. DRU-II or SmartSponge software downloads and reports the return, supply, ambient and USDA sensor temperatures as standard.

    Logging intervals are selectable from 1 minute and 1/2, 1, 2 or 4 hours. When a 1 hour logging interval is selected, the datalogger memory can store approximately 365 days of information. The logging of USDA sensors is fixed at 1 hour intervals to comply with USDA requirements.

    All data logs include the time and date; setpoint temperature; and supply, return, USDA1, USDA2 and USDA3 sensor temperatures. All temperature logs can be viewed from the controller’s LCD message display.

    If the unit power supply is disconnected, the datalogger will continue to register 168 temperature logs. These will be maintained until the unit is re-connected to power, and the battery automatically re-charged.

    Trip data can be retrieved (but not erased) from the datalogger memory using DRU-II or SmartSponge handheld data retriever; or via the REFCON remote monitor system. The datalogger is also equipped with a high-speed parallel communication port. Data transfer time is approx. 25 seconds for event logs and approx. 70 seconds for temperature logs.

    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.

12. Electronic phase selection: The microprocessor controller monitors the phase of the power supply to ensure proper rotation of the condenser and evaporator fans, and the compressor.

13. Sequential component start-up control: A sequence start of the required loads occurs during initial start-up of the controller and when a control mode shift requires the compressors to start (see “Sequence of Operation” in this chapter).

14. Hourmeters: The microprocessor controller has multiple built-in hourmeters that can be accessed through the Main Menu.

15. Manual emergency control capability. Manual control settings in the control box allow the unit to operate even in the event of a fatal failure of the controller. Manual control offers three operating functions: Heat, Defrost and Cool (see “Manual Emergency Mode Operation” in this chapter).

16. Flash memory: Flash program memory allows the application software to be updated without replacing a EPROM chip on the controller. Application software can be updated in the field using a portable computer and the software Loader program. Consequently, the field installed application software version may have a different revision number and may include control features not included in the original factory installed software. If the operation of your unit differs from the Sequence of Operation described for the unit in this manual, enter “Misc. Functions” in the Main Menu to check that the program version is correct (see “Menu Operating Instructions” in this chapter).

17. Display menus: The microprocessor controller contains an extensive display menu that can be navigated via keypad. The display menu is organized into 7 Main Menus:

    • Data Menu: Menu screens in this group are used to display unit operating information including sensor temperatures, voltage, current and frequency information.

    • Alarm List Menu: Menu screens in this group display a list of alarm code(s).

    • Commands Menu: Menu screens in this group are used to activate defrost, function tests, pretrip (PTI) tests and manual function test.

    • Miscellaneous Functions Menu: Menu screens in this group display date/time, C/F, cargo data, program version and run time (hourmeters) information.

    • Configuration Menu: Menu screens in this group display refrigerant type, in-range setting, container ID, contrast (screen), language, unit type, reefer type and zero current status.

    • Datalogger Menu: Menu screens in this group display temperature log, event log, set log time and PTI log.

    • RMM (Remote Monitoring) State: Menu screen show current remote monitoring state (Offline, Zombie or Online).