This manual is published for informational purposes only. Thermo
King® makes no representations warranties express
or implied, with respect to the information recommendations and descriptions
contained herein. Information provided should not be regarded as all-inclusive
or covering all contingencies. If further information is required,
Thermo King Service Department should be consulted.
Thermo King’s warranty shall not apply to any equipment which
has been so installed, maintained, repaired or altered as, in the
manufacturer’s judgment, to affect its integrity.
Manufacturer shall have no liability to any person or entity
for any personal injury, property damage or any other direct, indirect,
special, or consequential damages whatsoever, arising out of the use
of this manual or any information, recommendations or descriptions
contained herein. The procedures described herein should only be undertaken
by suitably qualified personnel. Failure to implement these procedures
correctly may cause damage to the Thermo King unit or other property
or personal injury.
General Information
The maintenance information
in this manual covers unit models:
Superfreezer CRR-40 DF with MP4000
For further
information, refer to:
Superfreezer
CRR DF Parts Manual
TK 61905
Diagnosing
Thermo King Container Refrigeration Systems
The information in this manual
is provided to assist owners, operators, and service people in the
proper upkeep and maintenance of Thermo King units.
Note For Parts Manual TK 61905 go to Eletronic Parts Catalog and search for Grid
Number 23U91.
Revision History
Revision A
(Apr 2021) New manual format, general updates throughout manual.
Recover Refrigerant
Note In the USA, EPA
Section 608 Certification is required to work on refrigeration systems.
In the EU, local F-gas Regulations must be observed when working on
refrigeration systems.
At Thermo King®, we recognize the need to
preserve the environment and limit the potential harm to the ozone
layer that can result from allowing refrigerant to escape into the
atmosphere.
We strictly adhere to a policy that promotes the recovery and limits
the loss of refrigerant into the atmosphere.
When working on transport temperature control systems, a recovery
process that prevents or minimizes refrigerant loss to the atmosphere
is required by law. In addition, service personnel must be aware of
the applicable European Union, National, Federal, State, and/or Local
regulations governing the use of refrigerants and certification of
technicians. For additional information on regulations and technician
programs, contact your local THERMO KING dealer.
Service Tools - Use the proper service tools. Gauge manifold
sets should include appropriate shutoff valves or disconnects near
the end of each service line.
Recovery Equipment - Recovery equipment must be used. Proper
recovering, storing and recycling of refrigerants is an important
part of all service work.
Service Procedures - Recommended procedures must be used
to minimize refrigerant loss.
Components may be isolated by closing service valves and
performing system pump-downs.
Components unable to be isolated for service must be repaired
only after refrigerant is properly recovered.
R-134a/R-23
Notice
Equipment Damage
Use only Polyolester-based refrigeration compressor oil
in R-134a/R-23 systems. See Thermo King Parts Manual for part number.
Notice
System Contamination
Do not mix Polyolester and standard synthetic compressor
oils. Keep Polyolester compressor oil in tightly sealed containers.
If Polyolester oil becomes contaminated with moisture or standard
oils, dispose of properly–DO NOT USE.
Notice
System Contamination
When servicing Thermo King R-134a/R-23 unit, use only
those service tools certified for and dedicated to R-134a/R-23 refrigerant
and Polyolester compressor oils. Residual non-HFC refrigerants or
oils will contaminate R-134a/R-23 systems. Please check serial# plate
for type and volume of Refrigerant charged. Please do not blend with
other refrigerants than the original charged refrigerant
Chapter 1: Safety Precautions
1.1: Danger, Warning, Caution, and Notice
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:
Danger
Hazard
Indicates an imminently hazardous situation which, if
not avoided, will result in death or serious injury.
Warning
Hazard
Indicates a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
Caution
Hazard
Indicates a potentially hazardous situation which, if
not avoided, could result in minor or moderate injury and unsafe practices.
Notice
Hazard
Indicates a situation that could result in equipment or
property-damage only accidents.
1.2: General Practices
Danger
Hazard of Explosion
Never apply heat to a sealed refrigeration system or container.
Heat increases internal pressure, which might cause an explosion resulting
in death or serious injury.
Danger
Hazardous Gases - Personal Protective Equipment (PPE)
Required
Refrigerant in the presence of an open flame, spark, or
electrical short produces toxic gases that are severe respiratory
irritants which can cause serious injury or possible death. When working
with or around hazardous chemicals, ALWAYS refer to the applicable
Material Data Safety Sheets (MSDS) and OSHA/GHS (Global Harmonized
System of Classification and Labelling of Chemicals) guidelines for
information on allowable personal exposure levels, proper respiratory
protection, and handling instructions.
Danger
Risk of Injury
Keep your hands, clothing, and tools clear of fans and/or
belts when working on a unit that is running or when opening or closing
compressor service valves. Loose clothing might entangle moving pulleys
or belts, causing serious injury or possible death.
Danger
Refrigerant Vapor Hazard
Do not inhale refrigerant. Use caution when working with
refrigerant or a refrigeration system in any confined area with a
limited air supply. Refrigerant displaces air and can cause oxygen
depletion, resulting in suffocation and possible death. When working
with or around hazardous chemicals, ALWAYS refer to the applicable
Material Data Safety Sheets (MSDS) and OSHA/GHS (Global Harmonized
System of Classification and Labelling of Chemicals) guidelines for
information on allowable personal exposure levels, proper respiratory
protection, and handling instructions.
Warning
Hazard of Explosion
Never close the compressor discharge service valve when
the unit is operating. Never operate the unit with the discharge valve
closed (front seated). This condition increases internal pressure,
which can cause an explosion.
Warning
Proper Equipment Condition
Gauge manifold hoses must be in good condition before
using them. Never let them come in contact with moving belts, fans,
pulleys or hot surfaces. Defective gauge equipment can damage components
or cause serious injury.
Warning
Personal Protective Equipment (PPE) Required
Always wear goggles or safety glasses and proper PPE when
working on a unit. Refrigerant liquid, oil, and battery acid can permanently
damage your eyes. When working with or around hazardous chemicals,
ALWAYS refer to the applicable Material Data Safety Sheets (MSDS)
and OSHA/GHS (Global Harmonized System of Classification and Labelling
of Chemicals) guidelines for information on allowable personal exposure
levels, proper respiratory protection, and handling instructions.
Warning
Equipment Damage and Risk of Injury
Never drill holes into the unit unless instructed by Thermo
King. Holes drilled into high voltage cables could cause an electrical
fire, severe personal injury, or even death.
Warning
Risk of Injury
When using ladders to install or service refrigeration
systems, always observe the ladder manufacturer’s safety labels and
warnings. A work platform or scaffolding is the recommended method
for installations and servicing.
Caution
Sharp Edges
Exposed coil fins can cause lacerations. Service work
on the evaporator or condenser coils should only be accomplished by
a certified Thermo King technician.
Notice
Equipment Damage
All unit mounting bolts must be installed, be the correct
length for their application, and torqued to specifications. Missing
bolts, incorrect bolt lengths and improper torque specifications can
damage equipment and void the warranty.
1.3: Refrigerant Hazards
Danger
Hazardous Pressures
Always store refrigerant in proper containers, out of
direct sunlight and away from intense heat. Heat increases pressure
inside storage containers, which can cause them to burst and could
result in severe personal injury.
Danger
Combustible Hazard
Do not use oxygen (O2 ) or compressed air for
leak testing. Oxygen mixed with refrigerant is combustible.
Warning
Hazardous Gases
Do not use a Halide torch. When a flame comes in contact
with refrigerant, toxic gases are produced. These gases can cause
suffocation, even death.
Warning
Personal Protective Equipment (PPE) Required
Refrigerant in a liquid state evaporates rapidly when
exposed to the atmosphere, freezing anything it contacts. Wear butyl
lined gloves and other clothing and eye wear when handling refrigerant
to help prevent frostbite. When working with or around hazardous chemicals,
ALWAYS refer to the applicable Material Data Safety Sheets (MSDS)
and OSHA/GHS (Global Harmonized System of Classification and Labelling
of Chemicals) guidelines for information on allowable personal exposure
levels, proper respiratory protection, and handling instructions.
Notice
Equipment Damage
When being transferred, refrigerant must be in liquid
state to avoid possible equipment damage.
1.4: Electrical Hazards
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.
High Voltage
Danger
Hazardous Voltage
Lethal amounts of voltage are present in some electrical
circuits. Use extreme care when working on the refrigeration unit.
If there is a risk of energized electrical contact, arc, or flash,
technicians MUST put on all PPE in accordance with OSHA, NFPA 70E,
or other local, state, or country-specific requirements for arc flash
protection PRIOR to servicing the unit. NEVER PERFORM ANY SWITCHING,
DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL PPE AND
ARC FLASHING CLOTHING. ELECTRICAL METERS AND EQUIPMENT MUST BE PROPERLY
RATED FOR INTENDED VOLTAGE.
Warning
Hazardous Voltage
Treat all wires and connections as if they were high voltage
until a meter and wiring diagram indicate otherwise. Only use tools
with insulated handles. Never hold uninsulated metal tools near exposed,
energized conductors. If there is a risk of energized electrical contact,
arc, or flash, technicians MUST put on all PPE in accordance with
OSHA, NFPA 70E, or other local, state, or country-specific requirements
for arc flash protection PRIOR to servicing the unit. NEVER PERFORM
ANY SWITCHING, DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL
PPE AND ARC FLASHING CLOTHING. ELECTRICAL METERS AND EQUIPMENT MUST
BE PROPERLY RATED FOR INTENDED VOLTAGE.
Warning
Hazardous Voltage
Never work alone on high voltage circuits in the refrigeration
unit. Another person should be nearby to shut off the unit and provide
aid in the event of an accident. If there is a risk of energized electrical
contact, arc, or flash, technicians MUST put on all PPE in accordance
with OSHA, NFPA 70E, or other local, state, or country-specific requirements
for arc flash protection PRIOR to servicing the unit. NEVER PERFORM
ANY SWITCHING, DISCONNECTING, OR VOLTAGE TESTING WITHOUT PROPER ELECTRICAL
PPE AND ARC FLASHING CLOTHING. ELECTRICAL METERS AND EQUIPMENT MUST
BE PROPERLY RATED FOR INTENDED VOLTAGE.
Warning
Personal Protective Equipment (PPE) Required
In the event of an electrical accident, all required PPE
should be near the work area in accordance with OSHA, NFPE 70E, or
other local, state, or country-specific requirements for a Category
3 risk.
Warning
Hazardous Voltage
The unit On/Off switch must be turned Off before connecting
or disconnecting the standby power plug. Never attempt to stop the
unit by disconnecting the power plug.
Warning
Risk of Injury
The unit power plug must be clean and dry before connecting
it to a power source.
Warning
Risk of Injury
Do not make rapid moves when working on high voltage circuits
in the refrigeration unit. Do not grab for falling tools because you
might accidentally touch a high voltage source.
Low Voltage
Warning
Live Electrical Components
Control circuits are low voltage (24 Vac and 12 Vdc).
This voltage potential is not considered dangerous. Large amount of
current available (over 30 amperes) can cause severe burns if shorted
to ground. Do not wear jewelry, watch or rings. These items can shortcut
electrical circuits and cause severe burns to the wearer.
1.5: Electrostatic Discharge Precautions
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.
Electrostatic Discharge and the Controller
You must avoid electrostatic discharges when servicing the controller.
Solid-state integrated circuit components can be severely damaged
or destroyed with less than a small spark from a finger to metal object.
You must rigidly adhere to the following statements when servicing
these units. This will avoid controller damage or destruction.
Do wear a static discharge wrist strap (refer to Tool Catalog)
with the lead end connected to the controller's ground terminal. These
straps are available at most electronic equipment distributors. Do not wear these straps with power applied to the unit.
Avoid contacting the electronic components on the circuit boards
of the unit being serviced.
Leave the circuit boards in their static proof packing materials
until ready for installation.
Return a defective controller for repair in the same static
protective packing materials from which the replacement component
was removed.
Check the wiring after servicing the unit for possible errors.
Complete this task before restoring power.
1.6: Welding on Refrigeration Units or Containers
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.
Disconnect the battery connections (if equipped) and lock out
- tag out the unit according to local regulations.
Disconnect all power to or from the refrigeration unit or genset.
Disconnect all quick-disconnect wire harnesses from the back
of the controller.
Switch all of the electrical circuit breakers in the control
box to the Off position.
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.
When welding is complete, restore the unit power cables, wiring,
and circuit breakers to their normal condition.
1.7: First Aid
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.
1.8: Identifying Unit Safety and Warning Decals
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
1
Controller Nameplate
2
Unit Nameplate
3
Compressor Nameplate
1.9: Serial Number Location
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.
Component Serial Number Identification
To better identify the different electronic components, our supplier
has changed their serial number labeling on the MP4000 controller
and power module. The label will show part number, date, and sequence.
MP4000 Controller: New label shows controller ID ABS782800212245390
Part number: ABS7828002; Date: 2012 24 wk 1224; Sequence 5390
ID in controller would show 1224-5390
Label on Controller
ID in Controller
Controller ID Shown in Datalogger
Chapter 2: Service Guide
A closely followed maintenance program will help to keep your Thermo
King unit in top operating condition. The following table should be
used as a guide when inspecting or servicing components on this unit.
Pretrip
Every 1,000 Hours
Annual/ Yearly
Inspect/Service These Items
Electrical:
•
Perform a controller pretrip inspection (PTI) check.
•
•
•
Visually check condenser fan and evaporator fan.
•
•
•
Visually inspect electrical contacts for damage or loose connections.
•
•
•
Visually inspect wire harnesses for damage or loose connections.
•
•
Download the data logger and check data for correct logging.
•
Check operation of protection shutdown circuits.
Refrigeration:
•
•
•
Check refrigerant charge.
•
•
Check for proper discharge and suction pressures.
•
Check filter drier/in-line filter for a restriction pressures.
•
Leak test the entire unit.
Structural:
•
•
•
Visually inspect unit for damaged, loose, or broken parts.
•
•
•
Tighten unit, compressor and fan motor mounting bolts.
•
•
Clean entire unit including condenser and evaporator coils
and defrost drains.
Note If a unit has been carrying
cargo which contains a high level of sulphor or phosphorous (e.g.,
garlic, salted fish etc.), it is recommended to clean the evaporator
coil after each trip.
Chapter 3: Specifications
3.1: Full Cool Operation Net Cooling Capacity
CRR DF Model - Air Cooled Condensing*
Return air to evaporator coil inlet
460/230V, 3 Phase, 60 Hz Power
380V, 3 Phase, 50 Hz Power
Net
Cooling Capacity
Power Consumption
Net Cooling Capacity
Power Consumption
Watts Kcal/hr BTU/hr
Watts Kcal/hr BTU/hr
Watts Kcal/hr BTU/hr
kW @460V
Watts Kcal/hr BTU/hr
Watts Kcal/hr BTU/hr
Watts Kcal/hr BTU/hr
kW @380V
-30C (-22F)
8,250
7,094
28,175
16.3
7,112
6,115
24,289
13.6
**-70 C (-94 F)
3,744
3,219
12,786
9.6
3,228
2,775
11,023
7.7
*System net
cooling capacity with a 37.8 C (100 F) ambient air temperature.
**Lowest possible
set-point - provided Box Size is set to 10´ or 20´. -65C would be
lowest possible set-point for Box Size 40´”
3.2: System Net Defrost Heating Capacity
CRR DF Model - System Net Defrost Heating Capacity
Heater Type
460V,
3 Phase, 60 Hz Power
380V,
3 Phase, 50 Hz Power
Heating
Capacity
Heating
Capacity
Watts
Kcal/hr
BTU/hr
Watts
Kcal/hr
BTU/hr
Electric resistance
rods
8,160
7,018
27,850
6,000
5,160
20,475
3.3: Evaporator Airflow
CRR DF Model - Evaporator Airflow*
External
Static Pressure (water column)
460V, 3 Phase, 60 Hz Power
380V, 3 Phase, 50 Hz Power
Low Speed
Low Speed
m3/hr
ft3/min
m3/hr
ft3/min
0 mm (0 in.)
3,700
1,835
2,900
1,708
10 mm (0.4 in.)
3,300
1,943
2,350
1,384
20 mm (0.8 in.)
2,800
1,649
1,750
1,031
30 mm (1.2 in.)
2,300
1,355
1,000
589
*22° pitch fan
blades.
3.4: R-134a Refrigeration System
CRR DF Model - R-134a Refrigeration System
Compressor
Model No.
D3DST-075E-TFD,
Semi-hermetic Reciprocating with
Copeland Discus® Valve Design
Refrigerant Charge
3.5 Kg (7.7 lb)
R-134a
Compressor Oil Capacity
4.6 liter (4.86
qt)*
Compressor Oil Type
Polyol Ester Based
Type (required), TK Part No. 203-433**
Typical System Pressures at 37.8 C
(100 F) Ambient
Standby (Unit Off, Empty Box):
High Side
—
Low Side
—
-30 C (-22 F) Box, Unit Cooling:
High Side
1500 to 1800 kPa,
15.0 to 18.0 bar, 218 to 261 psig
Low Side
60 to 90 kPa, 0.60
to 0.90 bar, 9 to 13 psig
-60 C (-76 F) Box, Unit Cooling:
High Side
1380 to 1500 kPa,
13.8 to 15.0 bar, 200 to 218 psig
Low Side
20 to 50 kPa, 0.20
to 0.50 bar, 3 to 7 psig
High Pressure Cutout Switch
Cutout
2410 ± 68kPa, 24.10
± 0.68 bar, 350 ± 10 psig
Cutin
1640 ± 68kPa, 16.4
± 0.68 bar, 238 ± 10 psig
Fusible Plug (High Pressure Relief)
Relief Temp.
100 C (212 F)
3.5: R-23 Refrigeration System
CRR DF Model - R-23 Refrigeration System
Compressor
Model No.
ZM18K4E-TFD-N275, Hermetic Scroll
Refrigerant
Charge
Evacuated System
Add Partial Charge by Pressure
3.2 Kg (7.05 lb) R-23
Charge
to 1700 kPa, 17.00 bar, 247 psig
Compressor
Oil Capacity
1.77 liter (60 oz.)*
Compressor
Oil Type
Polyol Ester Based Type (required),
TK Part No.
203-433**
Typical System Pressures at 37.8
C (100 F) Ambient
Standby (Unit Off, Empty Box):
High and Low Side
0 C / 32 F
20
C / 68 F
38 C / 100 F
1600
kPa, 16.0 bar, 232 psig
1700 kPa, 17.0 bar, 2247 psig
1800 kPa, 18.0 bar, 261 psig
-30 C (-22
F) Box, Unit Cooling:
High Side
Low Side
2100 to 2300 kPa, 21.0 to 23.0 bar,
305 to 334 psig
250 to 280 kPa, 2.5 to 2.8 bar, 36 to 41 psig
-60 C (-76 F) Box, Unit Cooling:
High Side
Low Side
1400 to 1600 kPa, 14.0 to 16.0 bar,
203 to 232 psig
900 to 1100 kPa, 0.9 to 1.1 bar, 131 to 160
psig
High
Pressure Cutout Switch
Cutout
Cutin
3250 ± 50 kPa, 32.5 ± 0.50 bar, 470
± 7 psig
2590 ± 250 kPa, 25.90 ± 2.5 bar, 375 ± 38 psig
High
Pressure Relief Valve
Relief Pressure
Reset
3447 +520/-104 kPa, 34.47 +5.20/-1.04
bar, 500 +75/-15 psig
2758 kPa, 27.58 bar, 400 psig
*When the
compressor is removed from the unit, oil level should be noted or
the oil removed from the compressor should be measured so that the
same amount of oil can be maintained in the replacement compressor.
**Donot use or add standard synthetic or mineral
oils to the refrigeration system. If Ester based oil becomes contaminated
with moisture or with standard oils, dispose of properly — Donot use!
10 amps nominal
(total) across each phase at the heater contactor
Control
Circuit Voltage:
29 Vac @ 60
Hz; 24 Vac @ 50 Hz
Evaporator
Overheat Switch:
Opens
54 ±3 C (130
±5 F)
Closes
38 ±4C (100 ±8 F)
*CRR DF applications
operates the two-speed evaporator fan motors continuously on low speed.
Evaporator fans stop during defrost.
3.7: Microprocessor Controller
CRR DF Model - Microprocessor Controller
Temperature
Controller:
CRR-40 DF MP4000
MP4000 microprocessor
Description
MP4000 is a
controller module for the Thermo King units. Additional requirements
can be met by means of expansion modules. The MP4000 is solely responsible
for temperature regulation of the reefer container, but other monitoring
equipment can be used in conjunction with the MP4000, such as a chart
recorder.
Setpoint Range
-65.0 to -10.0
C (-85.0 to +14.0 F)
Digital Temperature
Display
-80.0 to +130.0
C (-112.0 to +266.0 F)
Controller
Software (Original Equipment):
See controller
identification decal
Defrost
Initiation:
Evaporator
Coil Sensor Coil
Coil must
be below 18 C (65 F) to initiate defrost by demand, timer or manual
switch.
-Manual Switch or Demand Defrost Initiation: Defrost
cycle starts when technician or controller request defrost initiation.
-Timed Defrost Initiation: Defrost cycle starts 1 minute after
the hour immediately following a defrost timer request for defrost
initiation. For example, if the defrost timer requests a defrost cycle
at 7:35, the defrost cycle will start at 8:01. Datalogger will record
a Defrost event for each interval in which a Defrost cycle is pending
or active (i.e. both the 8:00 and 9:00 data logs).
Demand Defrost
Demand Defrost
function initiates defrost when the temperature difference between
the return air sensor and setpoint increases to a preset value and
a minimum of 6 hours of compressor ON (running) time have elapsed
since the previous defrost; indicating the presence of frost or ice
Defrost Timer:
Frozen Mode
Initially every
12 hours of compressor operation. Then defrost interval increases
6 hours each time a timed defrost occurs without a demand defrost
in between. Maximum time interval in frozen mode is 36 hours of compressor
operation. Defrost timer resets if the unit is Off more than 12 hours
or the setpoint is changed more than 5 C (9 F)
Defrost
Termination:
Evaporator
Coil Sensor
Frozen mode:
Terminates defrost when coil sensor temperature rises to 18 C (64
F) or exceeds 8 C (46 F) for 35 minutes above 440 volts and 45 minutes
below 440 volts
Interval Timer
Terminates
defrost 90 minutes after initiation if coil sensor has not terminated
defrost (120 minutes if power supply is less than 55 Hz)
Time/Temperature
Function
If the evaporator
coil sensor exceeds 8 C (46 F) for 15 minutes, the controller terminates
defrost
Power Off
Turning unit
On/Off switch Off terminates defrost
3.8: Physical Specifications
CRR DF Model - Physical Specifications
Base Unit
Weight (net):
CRR-40 DF MP4000
610 Kg (1344
lb)
Unit Dimensions:
Width
2025.5 mm (79.75
in.)
Height
2235.2 mm (88.00
in.)
Depth
420.0 mm (16.54
in.) from back of flange
3.9: Compressor Torque — 3D Copeland Compressor Bolt Torque
CRR DF Model - Compressor Torque
Bolt Usage
N.m
In.-lb.
Bottom Plate:
Grade 5
45.2
400
Grade 8
59.3
525
Housing Cover
45.2
400
Oil Pump to
Housing Cover
33.9
300
Bearing Cover
to Housing Cover
33.9
300
Stator Cover:
Grade 5
45.2
400
Grade 8
59.3
525
Cylinder Head
59.3
525
Oil Screen
Cover
31.1
275
Crankcase Heater
Plug
45.2
400
Discharge and
Suction Valve:
18 (5/16 in.)
25.4
225
13 (1/2 in.)
56.5
500
Pipe Plug:
6.35 mm (0.25
in.)
33.9
300
3.175 mm (0.125
in.)
22.6
200
Oil Sight Glass:
Grade 5
4.5
40
Grade 8
8.5
75
Terminal Plate
33.9
300
Nut on Top
of Terminal Plate
5.1
45
Nut on Top
of Jumper Bar
9.0
80
3.10: Metric Hardware Torque Charts
Bolt Type and Class*
Bolt
Size
M6 N.m (Ft.-lb.)
M8 N.m (Ft.-lb.)
M10 N.m (Ft.-lb.)
M12 N.m (Ft.-lb.)
HH – CL 5.8
6-9 (4-7)
12-16 (9-12)
27-34 (20-25)
48-61 (35-40)
HH – CL 8.8
10-13 (7-10)
20-27 (15-20)
41-47 (30-35)
75-88 (55-65)
HH – CL 10.9
14-17 (10-13)
27-34 (20-25)
54-68 (40-50)
102-122 (75-90)
HH – CL 12.9
17-21 (12-16)
41-47 (30-35)
68-81 (50-60)
122-149 (90-110)
HH – SS (2)
10-13 (7-10)
20-27 (15-20)
41-47 (30-35)
75-88 (55-65)
*HH = Hex Head, CL = Class
Bolt Type and Class*
Bolt
Size
M14 N.m (Ft.-lb.)
M16 N.m (Ft.-lb.)
M18 N.m (Ft.-lb.)
M22 N.m (Ft.-lb.)
HH – CL 5.8
75-88 (55-65)
115-135 (85-100)
177-216 (130-160)
339-406 (250-300)
HH – CL 8.8
115-135 (85-100)
177-216 (130-160)
271-339 (200-250)
475-610 (350-450)
HH – CL 10.9
136-176 (100-130)
224-298 (180-220)
393-474 (290-350)
678-813 (500-600)
HH – CL 12.9
177-216 (130-160)
285-352 (210-260)
448-542 (330-400)
881-1016 (650-750)
HH – SS (2)
115-135 (85-100)
177-216 (130-160)
271-339 (200-250)
475-610 (350-450)
*HH = Hex Head, CL = Class
Chapter 4: Unit Description
4.1: General Description
Superfreezer Model CRR DF units are all-electric, single-piece,
refrigeration units with bottom air supply. Each unit is designed
for long distance, shipboard or overland transport of deep frozen
or frozen cargoes. Each unit mounts in the front wall of the container.
Fork lift 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 hinged, removable evaporator compartment
door provides easy service access. All operating components except
the evaporator coil and buffer receiver tanks can be replaced from
the front of the unit.
The unit is equipped with an 18.3 m (60 ft) power cable for operation
on 460-380V/3 Ph/60-50 Hz power. For operation on 460-380V/3 Ph/60-50
Hz power, plug the 460-380Vpower cable into the proper power supply.
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 and evaporator fan motor operation.
Unit power cable is stored below the control box in the condenser
section.
CRR DF MP4000 units feature MP4000 microprocessor
controller and a datalogger. Additional features include three evaporator
fans; USDA Cold Treatment Temperature Recording; and a Remote Monitoring
Modem (RMM). For additional unit feature information, see “CRR DF
Model Features” on page v of the Introduction.
Cascade Refrigeration System
The CRR DF unit uses a basic cascade refrigeration system to achieve
to frozen and deep frozen cargo temperatures between -10 C and -70
C (+14 F and -94 F). (-70 C is the Lowest possible set-point provided
the Box Size is set to 10´ or 20´, -65C would be lowest possible set-point
for Box Size of 40´). The CRR DF cascade refrigeration system design
allows shippers to economically carry cargo at deep frozen temperatures
using proven, reliable transport refrigeration system technology.
The CRR DF cascade systems consists of two separate, single-stage
refrigeration systems with different refrigerants. One system is a
low temperature stage system that uses a hermetic scroll compressor
and R-23 refrigerant. The evaporator of the low temperature stage
system cools the cargo air, achieving cargo temperatures down to -70
C (-76 F). (-70 C is the Lowest possible set-point provided the Box
Size is set to 10´ or 20´, -65C would be lowest possible set-point
for Box Size of 40´).
The second system is a high temperature stage system that uses
a semi-hermetic reciprocating compressor and R-134a refrigerant. The
evaporator of the high temperature stage system cools the condenser
of the low temperature stage system through a special plate heat exchanger.
The condenser of the high temperature stage system then transfers
the cargo heat to the ambient air.
R-134a Semi-hermetic Reciprocating Compressor
The R-134a high temperature stage circuit features a semi-hermetic
reciprocating compressor with forced feed lubrication system, ambient
compensated internal overload protection and high temperature protection.
R-23 Hermetic Scroll Compressor
The R-23 low temperature stage circuit features a hermetic scroll
compressor (one stationary and one orbiting member) with ambient compensated
internal overload protection and high temperature protection.
Microprocessor Controller
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.
Power Module Fuses
The PM-4000 Power Module in the unit uses Ultra Fast 20 amp fuses
to protect the power module and are not interchangeable with the MP3000
MRB fuses. The fuses from the MP3000 MRB must never be used in the
PM 4000 Power Module.
Part number for a PM 4000 Power Module fuse (FF 20 amp 500v and
black fuse holder) is: P/N 419286 Fuse & Holder Blk MP4000.
Part number for the MP3000 MRB fuse (F 20 amp 500V and red fuse
holder) is: P/N 419318 Fuse & Holder Red MP3000.
Fuse and fuse holder will be sold together as a kit. Individual
fuse and holder part number for the MP3000 will supersedes to the
kit number once inventory is used up.
Power Module
Fuses
1
MP3000 MRB Red Holder
2
F 20 amp Fuse
3
PM 4000 Power Module Black Holder
4
FF 20 amp Fuse
Three Evaporator Fans
Three evaporator fans operate continuously to circulate air inside
the container. Two-speed fans operate continuously on low speed for
deep frozen and frozen cargo (setpoints of -10 C [+14 F] and below).
USDA Cold Treatment Temperature Recording
The datalogger includes provisions for the use of three USDA sensors.
These sensors allow temperatures in various areas of the load to be
monitored and recorded for United States Department of Agriculture
use in monitoring Cold Treatment shipments. The USDA sensors record
temperatures from -80.0 C to +10 C (-112.0 F to +50.0 F).
REFCON Remote Monitoring Modem (RMM)
A REFCON remote monitoring modem is provided to permit remote monitoring
via the power cable. High speed transmission reads all controller
information. Data can also be retrieved from the datalogger via high
speed transmission.
4.2: Operating Modes
Note See Microprocessor Controller chapter for complete
sequence of operation.
A sequence start of the required loads occurs during initial start-up
of the unit and when a control mode shift requires the compressors
to start. As the controller relays and unit loads energize, the controller
LCD display shows the setpoint temperature. The controller LED display
shows the controlling (return) air sensor temperature.
Frozen Loads
Temperature control by the controller is based on the return air
sensor temperature. The evaporator fans operate continuously on low
speed (except during defrost).
Cooling until return air temperature decreases
to 1 C (1.8 F) below setpoint. Minimum 6 minute compressor ON (running)
time and 6 minute compressor OFF time prevents rapid cycling between
Cool and Null modes.
Null until return air temperature increases to 1 C (1.8 F)
above setpoint. Both compressors and the condenser fan stop while
the evaporator fans operate on low speed during the null mode.
Defrost: Resistance heaters turn ON during defrost while the
evaporator fans stop.
A Demand Defrost can be initiated by the controller when the temperature
difference between the return air sensor and setpoint increases to
a pre-set value and a minimum of 6 hours of compressor ON (running)
time have elapsed since the previous defrost.
A Defrost Timer also initiates defrost every 12 hours. During extended
unit operation, timed defrost intervals increase 6 hours each time
a timed defrost occurs without a demand defrost in between. Maximum
time interval is 36 hours. The Defrost Timer resets if the unit is
OFF more than 12 hours or the setpoint is changed more than 5 C (9
F).
Vacuum
Valve (located behind condenser grille cover), current
Control Box and Microprocessor Controller
1.
Standard Display
3.
Special Function Keys
2.
Function Keys
Refrigeration System
1.
R-23
Suction Pressure Gauge Line Connection
2.
R-23
Suction Line
R-23 Compressor Compartment
1.
R-23 Discharge Pressure Gauge
7.
R-23 Lower Receiver Tank Sight Glass
2.
R-23
Suction Pressure Gauge
8.
Suction
Service Valve
3.
R-23
Scroll Compressor
9.
Suction
Service Fitting
4.
Compressor
Discharge Temperature Sensor
10.
R-23
Receiver Tank
5.
Compressor
Oil Sight Glass
11.
Discharge
Service Valve
6.
Oil Fill Fitting
12.
Discharge Service
Fitting
Additional R-23 Refrigeration System Components
1.
R-23 Compressor Discharge Valve
4.
Receiver Tank
2.
R-23
High Pressure Cutout Switch
5.
Schrader
Valve Service Fitting for R-23 Charging
3.
R-23 Expansion Valve
6.
Receiver Tank Sight
Glass
R-134a Compressor Compartment
1.
Discharge Service Valve
6.
Compressor Oil Sight Glass
2.
R-134a
Discharge Pressure Gauge
7.
Suction
Service Valve
3.
R-134a
Suction Pressure Gauge
8.
Suction
Service Fitting
4.
Compressor
Oil Fill Fitting
9.
R-134a
High Pressure Cutout Switch
5.
R-134a Compressor
10.
Compressor Discharge
Temperature Sensor
Additional R-134a Refrigeration System Components and Plate
Heat Exchanger
1.
R-134a Receiver Tank
5.
Dehydrator (Filter Drier)
2.
Receiver
Tank Service Fitting
6.
Liquid
Line Solenoid
3.
Receiver
Tank Sight Glass
7.
R-134a
Expansion Valve
4.
Liquid Line Ball
(Service) Valve
8.
R-23/R-134a Plate
Heat Exchanger (behind panel)
Unit Back View
1.
Evaporator Grille
6.
Controller Communications and Data Retrieval
Connection
2.
Unit
Gasket
7.
USDA1
Sensor Connection
3.
Top
Rear Plate
8.
USDA2
Sensor Connection
4.
Sensor
Connector Assembly
9.
USDA3
Sensor Connection
5.
Bottom Rear Plate
Unit Back View — Pressure Regulators and Buffer Tanks
1.
Constant Pressure Regulator (R-23 System)
3.
Sensor Connector Assembly
2.
Buffer Receiver
Tanks – 5 Total (R-23 System)
4.
Crankcase Pressure
Regulator (R-23 System)
Unit Back View — Electric Heaters and Evaporator Coil
1.
Electric Heaters
3.
Expansion Valve Feeler Bulb (R-23 System)
2.
Evaporator Coil
(R-23 System)
Chapter 5: Unit Operation
5.1: Basic Unit Controls, Instruments and Protection Devices
MP4000 Controller
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.
Back-up Battery
Every Controller has a Back-up Battery. This will allow the controller
to be energized if the unit is not connected to shore power. The technician
can change settings in the controller - Setpoint, etc.
Press the ON/OFF key, the controller will energize and stay energized
for 25 sec, by pressing any of the Menu keys the 25 sec timer will
reset to 20 sec.
5.2: R-134a Refrigeration System Controls, Instruments and Protection
Devices
Compressor Discharge Line Temperature Sensor: The controller uses the compressor discharge line temperature sensor
to protect the compressor from excessively high operating temperatures.
If the discharge gas temperature rises above 148 C (298 F):
Unit stops immediately; controller activates Alarm LED and
records Alarm 146, Compressor 2 Temperature Too High.
Controller will restart the unit when the sensor temperature
is below 138 C (280 F).
High Pressure Cutout (HPCO) Switch: If the compressor discharge
pressure rises above 2410 ± 68 kPa, 24.1 ± 0.68 bar, 350 ± 10 psig,
the high pressure cutout opens to interrupt the ground circuit to
the compressor contactor:
R-134a compressor STOPS immediately.
Evaporator and condenser fans continue normal operation.
R-23 compressor stops.
R-134a compressor will restart when the overload condition
is corrected (switch closes) as long as power is available. The high
pressure switch resets (closes) when the pressure drops to 1640 ±
68 kPa, 16.4 ± 0.68 bar, 238 ± 10 psig
R-23 compressor will restart 30 seconds after R-134a compressor
restarts.
Suction Pressure Gauge: A suction pressure gauge indicates
the refrigerant pressure in the suction line returning to the compressor.
Discharge Pressure Gauge: A discharge pressure gauge indicates
the refrigerant pressure in the discharge line leaving the compressor.
Operating Instructions 49
Receiver Tank Sight Glass: A sight glass on the receiver
tank contains 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. Check the color of the indicator against the color
decal in the sight glass. The dry eye in the sight glass is LIGHT
GREEN when the system is dry and YELLOW when the system is wet (contains
excessive moisture).
Fusible Plug For High Pressure Relief: A fusible plug is
installed in the R-134a receiver tank to avoid excessive pressure
build-up within the refrigeration system from extraordinary and unforeseen
circumstances. The plug blows when the plug temperature reaches 100
C (212 F). The plug is located so that refrigerant pressure expelled
from the valve would be directed away from anyone servicing the unit.
The plug is non-repairable and requires no adjustment. If the plug
blows, recover the remaining refrigerant charge and replace the fusible
plug.
Compressor Oil Sight Glass: A compressor oil sight glass
indicates the relative level of compressor oil in the compressor sump.
5.3: R-23 Refrigeration System Controls, Instruments and Protection
Devices
Compressor Discharge Line Temperature Sensor: The controller uses the compressor discharge line temperature sensor
to protect the compressor from excessively high operating temperatures.
If the discharge gas temperature rises above 148 C (298 F):
Unit stops immediately; controller activates Alarm LED and
records Alarm 56, Compressor Temperature Too High.
Controller will restart the unit when the sensor temperature
is below 138 C (280 F).
High Pressure Cutout (HPCO) Switch: If the compressor discharge
pressure rises above 3250 ± 50 kPa, 32.5 ± 0.5 bar, 470 ± 7 psig,
the high pressure cutout opens to interrupt the ground circuit to
the compressor contactor:
R-23 compressor STOPS immediately.
Evaporator and condenser fans and R-134a compressor continue
normal operation.
R-23 compressor will restart when the overload condition is
corrected (switch closes) as long as power is available. The high
pressure switch resets (closes) when the pressure drops to 2590 ±
250 kPa, 25.9 ± 2.5 bar, 375 ± 38 psig.
Discharge Pressure Gauge: A discharge pressure gauge indicates
the refrigerant pressure in the discharge line leaving the compressor.
Receiver Tank Sight Glass: Two sight glasses on the R-23
receiver tank contains 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. Check the color of the indicator against the
color decal in the sight glass. The dry eye in the sight glass is
LIGHT GREEN when the system is dry and YELLOW when the system is wet
(contains excessive moisture).
Compressor Oil Sight Glass: A compressor oil sight glass
indicates the relative level of compressor oil in the compressor sump.
High Pressure Relief Valve: A high pressure relief valve
is installed in the receiver tank. The relief valve protects against
excessive pressure build-up within the refrigeration system from extraordinary
and unforeseen circumstances. The valve is a spring-loaded piston
that lifts when refrigerant pressure exceeds 3447 +520/-104 kPa, 34.47
+5.20/-1.04 bar, 500 +75/-15 psig. The valve is located so that refrigerant
pressure expelled from the valve would be directed away from anyone
servicing the unit. The valve will reset when this pressure drops
to 2758 kPa, 27.58 bar, 400 psig. The valve is non-repairable and
requires no adjustment. If the valve fails to reseat properly, recover
the refrigerant charge and replace the valve.
Note Use only Lower R-23 sight glass to check or add
refrigerant on unit unable to maintain -50 to -70 setpoint.
5.4: Power Selection
Caution
Risk of Injury
Power supply connections from the unit to the power source
should always be made with the refrigeration unit On/Off key and the
power supply On/Off key in the OFF position. Never attempt to start
or stop the refrigeration unit using the power cord.
The refrigeration unit is designed to operate on 460/380V, 3 Phase,
60-50 Hz electric power from a 4-wire power source.
To operate the refrigeration unit on 460/380V power, plug the
460/380V power cord into the proper power source.
5.5: Pre-load Operation
Pre-Trip Conditions
To properly perform a Full Pretrip Test, the following conditions
must exist:
Pre-Trip Checks
With unit connected to the proper power supply, turn the power
supply On/Off switch to ON.
Switch refrigeration unit
On/Off key to ON position. A sequence start of the required loads
occursduring initial start-up on cooling:
Controller senses the incoming power phase and selects the
correct power phase to unit components.
Evaporator fan motors start and operate on low speed.
R-134a compressor and condenser fan then start and the liquid
line solenoid energizes (opens).
R-23 compressor starts 30 seconds later.
Note If one or both compressors
fail to start, turn the On/Off key OFF. Then repeat steps 1 and 2.
If the unit still does not start, refer to “Alarm Codes, Descriptions
and Corrective Actions” in the Microprocessor Controller chapter of
this manual. Be sure to wait up to 1 minute for both compressors to
start.
Adjust controller setpoint to the desired temperature:
Note The setpoint temperature can be set between -10 C and
-70 C (14 F and -94 F) in either F or C using the C/F key. Just press
and hold the F/C key (to display the alternate temperature scale).
Press SETPOINT key to display cursor flashing in the “TEMP
SETP” line.
Press F3 key to enter new setpoint.
With correct setpoint in display, press and
hold F4. Controller places new setpoint in controller memory and shows
new setpoint in LCD display.
Note New setpoint must be between -10 C and -70
C (14 F and -94 F) or controller will return to the previous setpoint
display.
Note If the F4 key is not pressed within
30 seconds, the controller will default (return) to the previous setpoint.
If this occurs, repeat step 3.
Check the direction of the condenser airflow (see “Condenser
Fan and Evaporator Fan Rotation” in the Electrical Maintenance chapter
of this manual).
Check direction of evaporator airflow (see “Condenser Fan and
Evaporator Fan Rotation” in Electrical Maintenance chapter of this
manual).
Allow the unit to operate one-half hour before loading. This
will remove residual container heat and moisture, and pre-cool the
container interior.
Perform a Pretrip (PTI) Test and check unit modes while the
unit pre-cools:
Caution
Service procedure
The PTI test should only be performed on an empty container!
Note Correct all existing alarm conditions
and clear the alarm codes before performing a PTI test. The controller
will automatically clear all existing alarms before beginning the
PTI test.
Press PTI key to enter PTI menu.
Select PTI.
Press F4 to start the PTI (Pretrip) Test.
The controller then performs the Pretrip Test.
Observe the unit for proper operation and functions during
pretrip test.
LCD display shows PTI Test currently being performed. PTI test
ends automatically. Press any key on the controller to return the
unit to normal operation.
If an operating problem occurs during the Pretrip Test, the
Alarm LED will turn ON and FLASH. An “E” may also appear in the right
side of the LED display. View and correct any alarm conditions. Then
clear (acknowledge) the Alarm Code(s) and repeat the PTI Test.
Note Clear the Alarm codes ONLY after the alarm
codes are documented and problems repaired. A permanent record of
the alarm codes remains stored in the datalogger memory for retrieval
via DRU-II or SmartSponge handheld data retriever.
top the unit by moving the On/Off key to the OFF position.
5.6: Loading Procedure
Make sure the Unit On/Off key is OFF before opening the container
doors. (The unit may be operating when loading the container from
a warehouse with door seals.)
Spot check and record load temperature while loading. Especially
note any off-temperature product.
5.7: Post Load Procedure
Make sure all doors are closed and locked.
Switch the Unit On/Off key to ON position.
Adjust controller setpoint to the desired temperature:
Note The setpoint temperature can be set between -10 C and
-70 C (14 F and -94 F) in either F or C using the C/F key. Just press
and hold the F/C key (to display the alternate temperature scale).
Note New setpoint must be between -10 C and -70
C (14 F and -94 F) or controller will return to the previous setpoint
display.
Note If the F4 key is not pressed within
30 seconds, the controller will default (return) to the previous setpoint.
If this occurs, repeat step 3.
One-half hour after loading, initiate a manual defrost cycle:
Press the DEFROST key.Select "Start DEFROST"
and press F4 key. The unit enters in Defrost. Defrost will stop automatically.
Note The evaporator coil temperature must be below 18 C (64 F) to allow
the unit the enter a defrost cycle. If the evaporator coil temperature
is too high, the LCD display will read “Defrost Not Activated”.
5.8: Starting the Unit on Ship
Caution
Risk of Injury
Power supply connections from the unit to the power source
should always be made with the refrigeration unit On/Off key and the
power supply On/Off key in the OFF position. Never attempt to start
or stop the refrigeration unit using the power cord.
Connect the unit power cord to proper power source:
460/380V power cord to 460/380V, 60-50 Hz power source.
Turn the power supply On/Off key ON.
Turn the unit On/Off key to ON position. Check
for condenser fan and evaporator fan motor operation (see “Condenser
Fan and Evaporator Fan Rotation” in the Electrical Maintenance chapter
of this manual). If the unit was properly pretripped, correct condenser
fan rotation will also indicate correct evaporator fan rotation.
Check the controller setpoint to make sure it is correct (agrees
with shipping manifest).
Chapter 6: Operating Instructions MP4000
6.1: Function Keys
Function Keys
1
PTI - Pre-trip Inspection
2
Defrost Key
3
ON/OFF Key
F1
Alarm Key
F2
C/F Key
F3
Setpoint Key
F4
Menu Key
Unit On/Off Key
ON - Unit will operate on Cool or Heat depending on the controller
setpoint temperature and the container air temperature.
OFF - The unit will not operate.
6.2: Sequence of Operation
6.2.1: Unit Start-up
Connect unit to 460 Volt shore power or genset.
Turn circuit breaker on at post to apply power to unit. Display
will show date and software revision.
Press and Hold ON/OFF key for two seconds.
Display shows RA, SA, SP
PM 4000 Setup
Power Module Init
Power Module Phase test - Shows heater icon
Power module Ready
Stop Plant
Note Random time delays during the initial unit start-up
minimize peak current draw.
6.2.2: Initiating a Manual Defrost
Turn the UNIT ON. Allow Unit to start and stabilize. Complete
the following steps:
Press the Defrost Special Function key.
If the unit operating conditions allow a manual defrost (e.g.,
evaporator coil temperature is less than 18 C [64 F]), the unit enters
Defrost.
The defrost cycle automatically terminates and returns the
unit to normal operation.
6.2.3: Pretrip Inspection (PTI)
Turn the Unit ON. Allow Unit to start and stabilize. Complete the
following steps:
Press the PTI Special Function key.
Press the F2/F3 keys to scroll down to select from the different
PTI test.
Press the F4 key to ACCEPT and start the PTI or test.
During testing the screen is divided into 3 sections.
Section
1:
Shows the list of tests to be performed and their state.
List of possible states.
Awaiting: the test has not yet been performed.
Testing: the test is ongoing.
Pass: the test has been tested, with the result Pass.
Fail: the test has been tested, with the result Fail.
Skipped: the test is skipped, based on conditions.
Section 2: Additional information, to explain the test,
is shown together with a indication of the time frame.
Section
3: This section displays actual readings and the expected power consumption.
Press the F2/F3 keys to scroll between each of the tests.
PTI test ends automatically. Pressing F1 (Exit) will not stop
the PTI, but will allow the user to view and scroll through other
menu's.Once the PTI is finished you will need to exit the PTI menu
for the unit to go back to normal operation.
Note 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.
6.2.4: Lock Padlock
If PADLOCK is active, the technician must enter the correct key
(number) to unlock the display. PADLOCK OPTION must be selected ON
under the CONFIGURATION/UNIT SETTING for it to be active or visible.
6.2.5: Controller Back-up Battery
Every controller has a back-up battery. This will allow the controller
to be energized if the unit is not connected to shore power. The technician
can change settings in the controller (e.g., Setpoint etc.). Press
the ON/OFF key, the controller will energize and stay energized for
25 seconds. By pressing any of the Menu keys the 25 second timer will
reset to 20 seconds.
6.3: Controller Lockup Issue
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.
Unplug the unit or turn OFF the main circuit breaker in the
control box.
Disconnect the battery found on the back side of the controller.
Wait 30 seconds then plug in the battery.
Plug in unit or turn the main CB back ON.
Turn unit ON by pressing the ON key.
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.
Note The latest
software can be found on the Thermoking.com website under iService/Global
Marine Solution Info Central/Software Updates/MP4000/CM4000 Load to
SD Card.zip. Download the zip file to your computer to unzip it, DO
NOT unzip from the website.
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.
6.4: Emergency Run Mode
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.
Rotation Check
Unplug unit and turn OFF the main circuit breaker (CB) located
in the controller box.
Remove compressor wires CP1, CP2, and CP3 from J5 on the PM
and connect them to the output side (left side) of the main CB. Refer
to Rotation Check as shown below.
Make up 3 16 GA (2 mm) jumper wires 16” long (400 mm), mark
them CF1, CF2, CF3. Connect the wires from J11 terminal on the PM
and connect the other end to the input (left side) of the compressor
contactor. Verify to maintain the wiring 1-1, 2-2, 3-3. Refer to Rotation
Check as shown below.
1
3 CF Wires 16 GA 16 in. long (400 mm)
2
3 Wires 18 GA 3 in. long (75 mm)
Locate J1 connector at top left side of PM and disconnect.
Rotation Check
1
J1 Connector Disconnect from PM
2
CP Wires Connected to Output Side of Main CB
3
CF Wires Connected at J11 and Input Side of Compressor Contactor
Plug unit in and turn CB ON. Observe the condenser fan rotation
to be correct, air out of condenser grille, CCW. If wrong, turn CB
OFF and unplug unit. Swap 2 of the CP wires and recheck for correct
fan rotation.
FULL COOL Mode
Unplug unit and turn off the CB located in the controller box.
Remove the Condenser Motor wires CF1, CF2, and CF3 from the
input side of the compressor contactor, installed during the Rotation
Check. Re-tighten input wires.
Remove the Low Speed Evaporator wires EF1, EF2, and EF3 from
J10 on the PM.
Connect the CF and EF wires to the output side (right side)
of the compressor contactor. Verify to maintain wiring 1-1 2-2 3-3.
Refer to Rotation Check as shown above.
Locate J1 connector top left side of PM. Disconnect J1 connector
from the PM. Install 3 18 GA 3” long jumper wires on the J1 connector.
Leave J1 disconnected during cool mode. Refer to Rotation Check as
shown above.
Pin 1 (wire 29VAC 0) to pin 6 (wire CC1).
Pin 2 (wire 29VAC 1) to pin 3 (wire HPCO-0).
Pin 4 (wire HPCO-1) to pin 5 (wire CC0).
Emergency Run Mode for R134a Compressor:
Remove CC3 wire from Pin 3 J9 (Controller Board) and connect
to PIN 1 J1 (Power Module).
Remove CC2 wire from PIN 4 J9 (Controller Board) and connect
to PIN 2 J1 (Power Module).
Plug unit into, turn main CB ON and OFF to maintain box temperature.
If compressor runs backward but the fans run correct, swap the Red
and White wires on the output side of the compressor contactor.
If unit is running in high ambient with high box temperature, monitor
compressor amperage using a amp probe. Maintain <12 amp by closing
suction service to limit capacity.
1
CP Wires Connected to Output Side of Main CB
3
J1 Connector Disconnect from PM
2
CF and EF Wires Connected to Output of Compressor Contactor
DEFROST Mode
Unplug unit and turn main CB OFF located in the control box.
Locate J1 connector disconnected in the FULL Cool mode. Disconnect
the jumper wire from pin 1 to pin 6.
1
Black Heater Wire Connected to Compressor Contactor Input Side
2
J1 Connector with Pin 1 Wire Disconnected
Disconnect CC3 wire from PIN 1 J1 (Power Module).
Disconnect wires from J7 on the PM and connect
them to the input side (left side) of the compressor contactor.
Plug unit in and turn main CB ON to defrost coil and OFF once
no water is flowing from drains.
Important DO NOT LEAVE
THE HEATERS ON FOR MORE THAN ONE HOUR. When running a unit in Defrost
mode, DO NOT leave unit unattended.
To return to the FULL COOL mode, turn main CB OFF and unplug
the unit. Remove the heater wires from the compressor contactor and
re-tighten the input wires. Reinstall the jumper wire on J1 connector
pin 1 to pin 6.
Low Speed Fans Only
Notice
Cargo Loss
Running the unit with evaporator fans only will add heat
to the box, do not leave unit unattended.
Unplug unit and turn main CB OFF located in the control box.
2. 3. 4. 5.
Locate J1 connector disconnected in the FULL Cool mode. Disconnect
the jumper wire from pin 1 to pin 6.
Disconnect EF1, EF2, EF3 for low speed from J10.
Connect the EF to the output side of the compressor contactor
(left side).
Plug unit in and turn main CB ON and OFF to maintain box temperature.
1
EF Wire Connected to Input Side of Compressor Contactor
2
J1 Connector Disconnected from PM
Chapter 7: Controller Description
7.1: MP4000 Controller
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.
Back-up Battery
Every Controller has a Back-up Battery. This will allow the controller
to be energized if the unit is not connected to shore power. The technician
can change settings in the controller - Setpoint, etc.
Press the ON/OFF key, the controller will energize and stay energized
for 25 sec, by pressing any of the Menu keys the 25 sec timer will
reset to 20 sec.
Input and Output Signals
The MP4000 microprocessor controls all unit functions to maintain
the cargo at the proper temperature. The controller also monitors
and records system faults and performs pretrip.
The MP4000 controller uses advanced solid-state integrated circuits
to monitor and control unit functions. The controller monitors inputs
from:
Return Air Sensor
USDA (Spare) Sensors 1, 2, and 3
Current measuring circuits
Compressor HT feedback signal (R134a)
Supply Air Sensor
High Pressure Cutout Switch/Discharge Pressure Sensor
Voltage measuring circuits
Evaporator Coil Sensor
Suction Pressure Sensor
Compressor Discharge Line LT Temperature Sensor (R23)
Ambient Sensor
Phase measuring circuits
Compressor Discharge Line HT Temperature sensor (R134a)
Output signals from the controller automatically regulate all unit
functions including:
Condenser fan operation
Electric heaters
Compressor LT operation
Liquid Solenoid Valve
Evaporator fan motor operation
Phase selection
Compressor HT operation
MP4000 Display
Panel
1
Standard Display
2
Function Keys
3
Special Function Keys
7.2: Standard Display
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
Idle Screen and Check Symbol
After approximately 30 seconds of inactivity, the display will
go into hibernation and one of the following symbols will be displayed.
Display alternates between the idle screen and the standard display
during this time.
Happy face = everything is OK
Disgruntled face = there is a message
Unhappy face = there is an alarm
The check symbol indicates that a Smart PTI has recently been running
and no problems were found. The checkmark will only be shown in the
normal operation state. This symbol will appear at the left hand corner
of the idle screen display.
Unit Status Display
The Unit Status Display will show the following (looking from top
to bottom):
Date and Time / Alarm Warning
LoPrsH Low Pressure Transducer R134a
RA Return air sensor
SA Supply air sensor
SP Setpoint
Mode Icons Compressor ON, Heater ON, Evap Fan ON
Capacity Bar Graph Percentage of mode (100% is full on)
F1 - F4 Key Functions ALARM C/F SETPOINT MENU
Display Icons
Alarm
SmartPTI has
recently been running and no problems found
Pretrip
Inspection / Test in Progress
Controlling Mode Optimized
Heating
Controlling Mode Economy
Evaporator
Fan High Speed
Bluetooth®
Evaporator
Fan Low Speed
Cell Phone
Condenser
Fan On
GPS Signal
Watercooled
RMM
Dehumidification
Battery Full (Datalogger Battery)
Defrost
Battery Charging (Datalogger Battery)
Compressor
On Unloaded
Battery state not known. Temperature
to low or high, charger suspended. (Datalogger Battery)
Compressor
On Loaded without Vapour Injection
Battery Error (Datalogger Battery)
Compressor On Loaded with Vapour Injection
Refrigerant Type
R134a compressor
Super Freezer Unit
Mode Descriptions
Frozen/Cooling Down
Frozen/cooling down mode where the unit setpoint is set to below
-10C. The function here is to maintain setpoint temperature by controlling
the temperature on the return air.
The condenser fan will operate in on. The evaporator fans will
operate in low speed mode.
Defrost
Defrost is a situation where the unit either on demand or timing
is defrosting the evaporator coil. The unit is heating with the heating
elements awaiting 18C on the evaporator sensor.
When the set Defrost termination temperature is reached, the unit
will return to the operation mode depending on the setpoint.
PTI
PTI is a pretrip inspection and is used to diagnose the condition
of the unit. There are a possibility to chose between several type
of PTI´s depending on the test needed to secure the functionality
of the unit.
7.2.1: Viewing Alarms/Messages from Standard Display
To view the alarms that are present, turn the Unit ON. Allow the
Unit to start and stabilize. Complete the following steps:
Press the F1 key. The Alarm List appears.
Press the F2/F3 keys to scroll between Alarms that are present.
Press the F4 key to acknowledge the Alarm. Press F1 again to
exit.
7.2.2: Display Alternate Fahrenheit (F) or Celsius (C) Temperatures
The controller can display temperatures in Celsius or Fahrenheit.
Pressing the F2 function key will change the display to C or F. To
change the display to C or F permanently, press and hold the F2 C/F
key, then confirm “ARE YOU SURE YES or NO”. Some customers do not
allow the display to be change permanently.
7.2.3: Changing Setpoint
To change the controller setpoint, turn the Unit ON. Allow Unit
to start and stabilize. Complete the following steps:
Press the F3 key at the main screen. The Setpoint Change menu
appears.
Press the F2/F3 keys to scroll the Setpoint Up or down - depending
on your required temperature.
Press and hold the F4 key until you are returned to the main
screen. The new setpoint is recorded in the controller and appears
in the display.
Note The controller will default (return)
to the previous setpoint if the setpoint is not entered within 30
seconds. Repeat steps 1 through 3 if this occurs.
Note Defrost Terminate Temp, Defrost Internal, and USDA
Trip can be set from the Setpoint menu. Refer to “Setpoint Menu” under
“Menu Operating Instructions” in this chapter.
7.2.4: Main Menu
To view the main menu, turn the Unit ON. Allow Unit to start and
stabilize. To enter the main menu, Press F4. Refer to (Navigating Controller Operating Menu) for this operation.
7.3: Keys and Indicator LEDs
Function Keys
The function keys are the F1 - F4 keys located below the display.
They allow the operator to move quickly to a specific area of the
information or into the controller menu.
Note Function
keys will change based on what menu is active in the display.
F1 ALARM Key: Press to view an explanation for the current
alarms present.
F2 C/F Key: Press to view alternate temperature scale Celsius
or Fahrenheit in display.
F3 SETPOINT Key: Press to enter Setpoint menu. Press F2 Up
or F3 Down keys to increase or decrease the Setpoint. Press and Hold
F4 until you are returned back to the main menu.
F4 MENU Key: Press to view the extended Menu for the MP4000.
Special Function Keys
The Special Function keys are located around the Thermo King logo.
These special function key allow the operator to move quickly to perform
a specific function
Pre-Trip Inspection
Defrost
Unit On/Off Control
Indicator LEDs
Two status indicator LEDs are located just under the F1 - F4 function
keys.
Green
LED
Flashing
Temperature approaching in-range.
Solid
Temperature in-range.
Red LED
Flashing
Alarm present and has not been acknowledged.
Solid
Alarm present and has been acknowledged.
Chapter 8: Navigating Controller Operating Menu
MP4000 Control Panel Display
Menu Scrolling Keys
Moving through these seven menus, their submenus, and entering
commands requires the use of four keys:
EXIT - Press the F1 key each time you want
to exit a submenu shown in the message display.
UP/ DOWN - Press the F2 or F3 key each time
you want to scroll up or down in a menu or submenu shown in the Message
Display; or scroll forward or backward in a menu line.
ENTER - Press the F4 key to enter a new menu
or submenu.
The MP4000 contains an extensive operating menu. The main menu
is divided into seven major areas that can be navigated via keypad.
Values Menu - Menu screens in this group are used to display
unit operating information including temperature values, pressure
values, air values, unit electrical data, etc., and any input to the
controller.
Controls Menu – Menu screens in this group are used to enter
allowable setpoints.
Alarm Menu - Display a list of alarm code(s) present.
Message Menu - Display a list of message(s) present.
Configuration Menu - Menu screens in this group are used to
change the functionality of the unit operation.
Log View Menu - Menu screens in this group display log information
or log function. Includes: Inspect Log, set Trip Start, and Set Log
Interval.
Info Menu - Menu screens in this group give information on
software version and expansion slots.
A complete listing of the
controller operating menu is located on an 11’ x 17’ fold out in the
Diagrams chapter (Diagram Index). It is designed to
be folded out so you can continuously view it as you are learning
how to navigate the MP4000 Controller Menu. It is recommended to fold
this menu out and leave it folded out until you become familiar with
the controller menu.
Changing Screen Contrast
Change the screen contrast temporarily as follows:
Press and hold the F1 INFO KEY until the Contrast Screen appears.
Press the F2 or F3 UP/DOWN KEYS to scroll the Contrast up or
down.
Press and hold the F4 ACCEPT KEY to confirm the new Contrast
Setting.
Chapter 9: Main Menu
9.1: Main Menu
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.
9.2: Values Menu
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 ().
Note The
screens that are display on the controller are determined by the controller
software setting and the options installed on the unit. All screens
are NOT present on all units.
Defrost
Cond. Press.
Fan R23 Heat 2
Heater
Condenser
Condenser
Fan
R23 Heat 3
Evap
Fan Low
Ambient
Suct.
High T
Bat.
Volt
Condenser
Fan
Comp. High T
Disch.
Low T
Bat.
C. Curr
Compressor
Comp. Low T
Suct.
Low T
Bat.
Temp
Compressor
High T
USDA 1
Voltage
Board
Volt
Phase
Direction Reverse
USDA 2
Frequency
Sensor
Volt
HP
Cut Out
USDA 3
Fan
R23 Heat 1
PM
Temp
LP
Cut Out
9.3: Controls Menu
Note When a submenu is highlighted, pressing the ENTER
F4 key again will open a view showing how the unit is currently set
up. In order to see some of these different selections, turn the option
on and then enter the Controls menu again.
Controls Menu and Controls Overview
9.3.1: Temperature Setpoint
Used to change the controller setpoint. The setpoint can also be
changed from the Unit Status Display by pressing the Setpoint F3 key.
The new setpoint is recorded in the controller datalogger and appears
in the display.
Note The controller will default (return)
to the previous setpoint if the new setpoint is not entered within
30 seconds.
Temperature Setpoint
9.3.2: Defrost Termination
Option lowering defrost termination temp, range 18 to 4°
Defrost Termination
9.4: Alarm Menu
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.
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.
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.
Repeat above step until all alarm codes have been recorded.
Press the F2 key to scroll backward to return to a previous code.
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.
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
Alarm Code States
There are three alarm code states for Shutdown and Check alarms:
Active: A code condition has occurred and continues to exist
in the unit or the code condition occurred within the past one hour
but does not currently exist in the unit.
Not Active: A code condition has occurred but no longer exists
in the unit. Not Active means the code condition was corrected and
did not reoccur for one hour, or the Unit On/Off switch was turned
Off and then On.
Acknowledge: A code condition has been viewed and acknowledged
in the Alarm or Message list. If the Alarm code condition still exists
in the unit, the Red LED will stay on and not flash. If the code condition
is corrected, the Red LED will turn off and the code condition will
disappear from the Alarm/Message list.
A complete listing of the controller operating menu is located
on an 11” x 17” fold out in the Diagrams chapter (Diagram Index).
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.
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.
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.
Repeat above step until all messages have been recorded. Press
the F2 key to scroll backward to return to a previous message.
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.
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.
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 ().
With the unit turned On, allow it to start and stabilize and the
display showing the unit status display:
Press the F4 MENU key. Press the F3 key to scroll down to the
CONFIG menu.
Press the F4 key to expand this menu.
Press the F2 OR F3 UP/DOWN key to scroll to view or reset the
desired function.
To set a new Configuration screen value:
Press the F4 key with cursor in the desired menu line.
Press the F2 OR F3 UP/DOWN key to scroll the value to the desired
setting.
Press the F4 key and release when the entry is complete. Press
the F1 key. The new value appears in the menu line.
Repeat steps 3 and 4 to reset additional configuration values.
Press the F1 key to exit the Configurations screen.
Note Pressing F4 again will display the Overview
screen.
Configuration Menu
Unit
Unit Menu and Unit Overview
In-Range Temperature limit: Sets the temperature value for
the controller’s in-range LED and datalogger functions (factory default
= 1.5 C [2.7 F]). Enter a value from 0.5 to 5.0 C (0.9 to 8.9 F).
This menu is used to turn ON/OFF a Module/Feature, select a particular
option within a module, and tell the controller when a sensor is mounted.
Heater Type: Select from Extended Capacity and Normal Capacity
Condenser Fan Type: condenser fan type 2, ¾ and ½ HP
Evaporator Fan Type: evap motor selection 2 or 3
High Temp Suction Press Sensor: HT system LP pressure transducer
mounted or none
Low Temperature Discharge Press Sensor: LT system HP pressure
transducer mounted or none
Condenser Temperature Sensor: condenser sensor fitted “on or
off”
System
System
Container ID: Sets the container identification number. Enter
up to 11 characters (numbers or letters).
SW Unit Type: Choose Unit Type
Container length: 10, 20, 40, 43 or 45ft.
Container height: Select Standard or High Cube
Unit Serial ID: The TK serial number of the unit itself. This
is a ten digit alphanumeric entry found under the UNIT Serial Number
on the Serial Plate on the unit.
Unit ID: A 12 digit alphanumeric unit serial number (old system).
Controller ID: View and edit the Controller ID.
Power Module ID: An 8 digit alphanumeric number found on the
power module.
Clock
Displays current Date and Time, which can be edited.
Press the F4 key. Press the F3 key to scroll down to the CONFIGURATION
Menu.
Press the F4 key to access the CONFIGURATION menu. Press the
F3 key to scroll down to the Clock Menu.
Press the F4 key to access the Date & Time screen.
Press the F4 key to edit.
Enter new time by: Using F2 or F3 Up/Down to change the digits
and by pressing F4 to move the cursor on to the next digit.
Once you have scrolled the cursor through all the time and
date digits, you get an option to Press the F4 key to save. Press
and hold F4 until the main menu appears.
Press the F2 or F3 UP/DOWN key to scroll to the Configuration
selection and press the F4 key. The Configuration Menu will appear.
Press the F2 or F3 UP/DOWN key to scroll to the Icon Menu selection
and press the F4 key. The Icon Menu will appear as shown below.
To change back to the Classic Menu:
Press the F4 key to display the Icon Menu.
Press the F2 or F3 UP/DOWN key to scroll to the Config selection.
Press the F4 key. The Configuration Menu will appear.
Press the F2 or F3 UP/DOWN key to scroll to the Classic Menu
selection.
Press the F4 key. The Classic Menu will appear.
9.7: Log View Menu
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):
Press the F4 MENU key. Press the F3 key to scroll down to the
Log View menu. 2. 3. :
Press the F4 key to access the Log View menu.
Press the F2 or F3 UP/DOWN key to scroll to the desired function.
Press the F4 key to access the function selected.
Log View Menu
9.8: Info Menu
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
Chapter 10: Special Function Keys - User Activated Commands
10.1: PTI Key
Pressing the PTI key will access various PTI Commands for selecting
a user activated functionality.
The PTI test should only be performed on an empty container!
The CRR DF controller contains a special PTI pretrip
test that automatically checks unit refrigeration capacity, heating
capacity, 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.
Note Correct all existing alarm conditions and clear
the alarm codes before performing a PTI test. The controller will
automatically clear all existing alarms before beginning the PTI test.
During the PTI test, the LED display screen will show:
Alarm LED flashes if an alarm condition occurs during the test.
Note Detailed PTI test results are stored in the 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.
Note Auto PTI test omits HPCO test on R134a and R23 compressor,
and cooling capacity is not verified by minimum temp difference between
supply and return. Manually verify function HPCO functions and full
cooling capacity.
10.3: Defrost Key
To access the Defrost Menu, turn the unit On and allow the unit
to start and stabilize and show the unit status display (setpoint).
Press the DEFROST (*) key to open the Defrost Menu.
Press the F2 OR F3 UP/DOWN key to scroll to “Start Defrost”.
Defrost Menu
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
10.4: PTI (Pretrip) Tests
Notice
Cargo Loss
The PTI tests should only be performed on an empty container.
Note Units equipped with a water-cooled condenser must
be set to operate on air-cooled condensing to perform a complete system
capacity test.
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.
Note Correct all existing alarm conditions and clear the alarm
codes before performing a Full PTI test. The controller will automatically
clear all existing alarms before beginning the Full PTI test.
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.
10.4.1: Manual Function Test
The Manual Function Test menu allows technicians to perform specific
diagnostic tests on individual components or turn several components
on at the same time to perform a system test.
Note THE
UNIT STOPS when the Manual Function Test menu is entered. A technician
can then select the control circuit or component to be checked/tested
from the items shown in the menu.
Complete the following steps to enter the Manual Function Test
menu. With the unit turned On, allow it to start and stabilize and
the display to show the unit status display (setpoint):
Press the PTI key to open the PTI Menu.
Press the F2 OR F3 UP/DOWN key to scroll to “Manual Function
Test”.
Press the F4 key to enter the Manual Function Test Menu.
Unit Component Test
Press the F2 OR F3 UP/DOWN key to scroll to desired component
test:
[PHASE DIRECTION]
[HEATER]
[COMPRESSOR HIGH T] (R134a)
[COMPRESSOR LOW T] (R23)
[EVAPORATOR FAN LOW]
[CONDENSER FAN]
Press the F4 key to start the component test. Display will
change the component state from off to on.
Verify component performance: Display will show expected current
and actual current on phase 1, 2, and 3.
Press the F4 key again to stop test. Display will change component
state from on to off.
System Test (test multiple components at the same time)
Press the F2 OR F3 UP/DOWN key to scroll to the first component.
Press the F4 key to turn the component on
Press the F3 key to scroll to select next component. Press
the F4 key to turn the component on.
Repeat step 3 until all required components are on. For example,
to operate unit in Full Cool mode, start the following components:
Condenser Fan
Compressor
Evaporator Low
Observe current draw and system performance to verify component(s)
performance.
Press the F4 key again to turn off components individually.
Or press the F1 key to exit Manual Function Test menu and turn all
components off.
Press the F1 key to exit the Manual Function Test submenu.
PTI, Brief PTI, Function Tests
Display*
Description
Possible Alarms
Duration (Time)
PTI
Brief PTI
Function Test
PTI START
Activated
0.1A 0.0A 0.1A
Event Log for PTI begins. Awaits phase selection, and surveillance
to start up. All alarms are turned off. Alarm list is cleared. All
relays are turned off and air vent are closed.
18
1 to 100 seconds
X
X
X
SENSOR TEST
Activated
0.1A 0.0A 0.1A
Testing sensor interface, All sensors must have values within
their measuring range.
With evaporator fan on low speed, amp draw is measured and
compared to the expected amp draw, in respect to voltage and frequency:
1.1 Amps approx. at 50 Hz
1.1 Amps approx. at 60 Hz
14, 15
5 seconds
X
X
X
COND FAN TEST
SUP RET EVA
5.2C 5.0C 5.1C
1.3A 1.2A 1.3A
With condenser fan on, amp draw is measured and compared
to the expected amp draw, in respect to voltage and frequency. If
the phase amp draw differs more than 1,0 Amp both alarm is set.
Expected Power Consumption:
1.2 Amps approx. at 50 Hz
1.3 Amps approx. at 60 Hz
Amperes are recorded in the PTI log.
16, 17
5 seconds
X
X
X
PROBE TEST
SUP RET EVA
5.1C 5.0C 5.1C
2.4A 2.3A 2.4A
Evaporator fans operate on low speed for maximum 3 minutes.
Then probe test runs until temperature difference between sensors
stops increasing. Maximum temperature difference allowed:
Return/Evaporator: 1.5C (34.7F); return air sensor temperature
must be 0.5C (32.9F) above evaporator sensor temperature.
Return/Supply: 0.8C (33.0F); return air sensor temperature
must be 0.5C (32.9F) above supply air temperature.
52, 128, 129, 130
1 minute minimum to 13 minutes maximum
X
X
—
REVERSE PHASE TEST
SUP RET EVA
1.3C 1.0C 1.3C
1.3A 1.2A 1.3A
With condenser fan on, reverse phase selector relay is energized.
Condenser fan reverse current is measured.
58
30 seconds
X
X
X
HEATER TEST
SUP RET EVA
1.3C 1.0C 1.3C
5.2A 5.1A 5.2A
Electric heaters are turned on. Amp draw is measured to
the expected amp draw, in respect to voltage and frequency.
9 Amps approx. at 400V
10 Amps approx. at 460V
Amperes are recorded in the PTI log.
10, 11
5 seconds
X
X
X
DEFROST TEST
SUP RET EVA
5.0C 12.0C 15.0C
5.2A 5.1A 5.2A
If evaporator temperature is below +10C, heater remains on
until evaporator temperature is above +18C. Defrosting until EVA
> 18C/64F
20
0-90 Minutes at voltage above 440V 0-120 Minutes at voltage
below 440V
X
—
—
COMPRESSOR R23 TEST
8.0C 15.0C 5.0C
9.1A 9.0A
9.1A
Compressor loaded, and condenser fan activated for 10 sec.
Followed by compressor run alone for 7 sec before the amp draw is
measured and compared to the expected amp draw, in respect to voltage
and frequency. Amperes are recorded in the PTI log. Evaluating
power consumption
6, 7
18 seconds
X
X
X
COMPRESSOR 2 (R134a) FEEDBACK TEST
Running compressor 2 R134a. Checking if feedback signal from
R134a contactor matches the output signal to activate the contactor.
147
25 to 35 seconds
X
X
X
PULLDOWN -30C
Unit operates in normal cool mode with -30 C (-22 F) setpoint.
When return air temperature decreases to setpoint. Sensor temperatures
are recorded in PTI log
23
Max 4 hours
X
-
-
PULLDOWN -60C
Unit operates in normal cool mode with -60 C (-76 F) setpoint.
When return air temperature decreases to setpoint. Sensor temperatures
are recorded in PTI log
22
Max 8 hours
X
-
-
DEFROST TEST
Test is skipped and Fail if either of alarm 4,5,130 is present.
Test is skipped if evaporator temperature is at 5degC or above. With
electric heaters turned on, the test will pass when evaporator temperature
reach 18degC or above. Defrosting until EVA > 18C/64F
4, 5, 20, 130
0 to 90 minutes at voltage above 440V 0 to 120 minutes at voltages
below 440V
X
—
—
PTI END
“PTI End” are recorded in PTI log and a Trip Start is automatically
activated. All alarms are cleared and must be acknowledged by the
user. Unit awaits an ACCEPT of the just ended test before returning
to normal operation.
PASSED - PASSED - PASSED
FAILED - FAILED - FAILED
26
Max 90 seconds
X
X
X
PTI PASS – PRESS KEY
Unit will remain OFF until any key is pressed.
If
alarms occurred during PTI, Display shows “PTI FAIL – PRESS KEY”.
Note Controlling Sensor = Return
None
X
X
X
*Readings may vary depending
on voltage and temperature
10.4.2: Function Test
The MP4000 controller contains a special function test that automatically
tests individual components including the controller display, sensors,
condenser fan, evaporator fan, compressors, etc. The test includes
measurement of component power consumption and compares test results
to expected values.
Note The function test does not test
the actual performance of the complete system. Therefore it is not
a pretrip test and should not be used instead of the PTI test.
With the unit turned On, allow it to start and stabilize and the
display to show the unit status display (setpoint):
Press the PTI KEY to open the PTI Menu.
Press the F2 OR F3 UP/DOWN KEY to scroll to “Function Test”.
Press the F4 key to start the Function Test. Display shows
test currently being performed. The Function Test ends automatically.
Press any key on the controller to return the unit to normal operation.
Any alarm codes recorded during the test can be viewed through
the controller’s Alarm List menu at the end of the test.
Chapter 11: Operating Theory
11.1: Frozen Loads (Setpoint at -10 C [14 F] and Below)
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.
Cooling Capacity Display in Main Screen
The percent displayed in the main screen indicates the cool capacity
that is currently provided.
11.2: High Temperature Protection
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).
11.3: Probe Test
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.
Note A manual probe test can be performed by a technician
by selecting “SENSOR CHECK” from the Manual Test Function menu.
11.4: Continuous Temperature Control Operation
Frozen Loads — Controller Setpoint at -10 C (14 F) and Below
The controller regulates compressor operation based the return
air sensor and setpoint temperatures to determine operating mode switch
points. The controller operates the unit on:
Cool mode
Null mode
Defrost mode
Evaporator fans operate on low speed to continuously circulate
air inside the container (except during defrost).
Controller LED display shows the return air sensor temperature.
Controller LCD display shows the setpoint.
Cool
After initial start-up and pull-down to 1.0 C (1.8 F) below
setpoint, the controller calls for the Cool mode whenever the return
air temperature increases more than 1.0 C (1.8 F) above setpoint.
Unit operates in Cool mode for a minimum of 6 minutes to prevent
rapid cycling between Cool and Null.
After initial pull-down to setpoint, the controller keeps the
In-range LED ON as long as the return air temperature remains less
than 1.5 C (2.7 F) above setpoint.
Null
The controller calls for Null when the Return Air Temperature
decreases more than 1.0 C (1.8 F) below setpoint.
The controller de-energizes the compressor contactors and condenser
fan contactor, stopping the both compressors and the condenser fan.
Units remains in Null mode for a minimum of 6 minutes to prevent
rapid cycling between Cool and Null.
The evaporator fans continue to operate in low speed.
Defrost
During the Cool or Null modes, the controller initiates the Defrost
mode when the evaporator coil sensor temperature is below 18 C (65
F) and:
Demand defrost function determines that defrost is required
when the temperature difference between the return air sensor and
setpoint increases to a preset value and a minimum of 6 hours of compressor
ON (running) time have elapsed since the previous defrost.
A manual defrost is initiated by pressing the Defrost special
function key or by Refcon Remote Monitoring Modem (RMM).
Note If unit operating conditions do not allow the unit to
enter a defrost cycle, “Defrost Not Activated” appears on VGA display
when the DEFROST key is pressed.
A Timed Defrost always starts at 1 minute past the hour immediately
following a defrost timer request for defrost. For example, if the
defrost timer requests a defrost cycle at 7:35, the defrost cycle
will start at 8:01. The datalogger will record a Defrost event for
each log interval in which a Defrost cycle is pending or active (i.e.
both the 8:00 and 9:00 data logs on 1 hour logging interval).
On Frozen Loads, the initial time interval is 12 hours. Six
(6) hours are added to the time interval each time a timed defrost
interval occurs without a demand defrost in between. Maximum accumulated
time interval is 36 hours. Time interval resets to 12 hours when setpoint
is changed more than 5 C (9 F); or if the unit is turned OFF for 12
hours.
When the defrost mode is initiated:
The controller de-energizes both the R-134a and R-23 compressor
contactors, the condenser fan contactor and the evaporator fan contactors;
stopping the compressors, condenser fan and evaporator fans.
When the compressors stop, the controller turns ON the heater
output, turning on the electric heaters.
The controller terminates the defrost mode when:
Frozen mode: Evaporator coil sensor temperature reaches 18
C (65 F).
Time/temperature function: If the evaporator coil sensor exceeds
8 C (47 F) for 15 minutes, the controller terminates defrost.
Interval timer: Controller terminates defrost 90 minutes after
initiation if the coil sensor temperature has not terminated defrost
(120 minutes if power supply is less than 55H). Alarm code 20 will
be generated if this occurs.
When the controller terminates Defrost, the heater contactor
is de-energized. The controller starts the condenser fan and the R-134a
compressor. After 30 seconds, the controller starts the R-23 compressor
and the evaporator fans to minimize heat energy release into the container.
11.5: Data Recording and Downloading Data
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.
Chapter 12: Controller Maintenance
12.1: Controller Door Open and Close Instructions
Open
Insert a flat blade screwdriver into slot on
side of control box door.
Move the screwdriver handle to the left to release
the door catch from the box latch.
With the door catch released, pull door out and open.
Close
Push firmly until a click sound is heard.
With hand, rap the door to confirm it is closed
properly.
12.2: Flashloading Controller Software
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
Verify the SD card is in the un-lock or writeable mode. Small
tab on side slide forward is un-locked.
If card is new, format card so it is clean.
Create a new directory on the SD card titled MP4000. In the
MP4000 directory, create two new sub directories titled Firmware and
Logs.
Copy the command.ini file into the /MP4000 directory of the
SD card.
Copy the latest software file (.strip) into the \ MP4000 \
Firmware sub directory. Refer to ( MP4000 and MP4000/Firmware).
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.
Battery Power Flashload Procedures
Verify the unit is not active (no display).
Insert the SD card, with the latest software, into the slot
on the side of the controller.
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.
When finished the display will shut down and the operation
is finished.
Shore Power Flashload Procedures
Plug unit in and turn unit ON, let unit stabilize.
Insert SD card, with the latest software, into the slot on
the side of the controller.
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%.
Once it shows 100%, unit will shut down and restart. Will show
normal display and perform a AUTO CONFIGURATION, then normal start
sequence.
Remove SD card and release unit.
Note After completing the flashload, check to verify
the new Software/Application Revision and Option File Revision have
been loaded. If not, reinsert the SD card to load the Option File.
If it is still not showing the correct software revisions, turn controller
OFF and back ON and recheck the software revisions.
12.3: MP4000 Test System Tool
The MP4000 Test System Tool has the ability to test the following
components:
Controller Module (CM)
Power Module (PM)
Interconnect Cable
Keypad
Displays
Important As of February 1st, 2012, no failed Controller
Module (CM) or Power Module (PM) will be accepted under Warranty without
a ‘Failed Component’ report accompanying the claim and the part. The
tester program generates this report. If no report is included on
the claim it will be rejected. If no report is included with the part
the part will be returned (at the sending location cost).
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
12.4: Controller Replacement
Turn the Unit ON/OFF switch OFF.
Turn the unit 460/380V main circuit breaker off.
Danger
Hazardous Voltage
The unit will automatically start and operate if 460/380V
power is present at the main power module when the controller is disconnected.
Disconnect the supply power to the unit before replacing the controller
to prevent personal injury from rotating machinery or dangerous electrical
shock from high voltage controls.
Disconnect the unit power cord from the power supply.
At the same time, remove the controller
from the door.
Install the replacement controller in
the door.
Connect the keyboard cable to the controller.
Connect the Harness to the controller.
Recheck all connector plugs to verify they are fully seated.
Review the Configuration Menu instructions
in the operating section. Reset information as required.
Review the Miscellaneous Functions Menu
instructions in the operating section. Reset information as required.
Note
Enter the container ID before releasing the unit for service.
The container ID is required to identify the data downloaded from
the controller datalogger.
Several programmable features may need to be set to completely
configure the unit to customer specifications. Adjust any additional
programmable settings to customer requirements before releasing the
unit for service.
Chapter 13: Electrical Maintenance
13.1: Unit Wiring
Inspect unit wiring, wire harnesses, and the controller during
pre-trip inspection and every 1,000 operating hours to protect against
unit malfunctions due to open or short circuits. Look for loose, chaffed
or broken wires on the unit; open or short circuits and damaged components
on the controller printed circuit board.
Inspect electrical contactor points for pitting or corrosion every
1,000 operating hours. Repair or replace as necessary.
13.2: High Pressure Cutout Switch
A high pressure cutout switch is located on the compressor discharge
service manifold of each compressor. If a high pressure cutout switch
is suspected of being defective, replace it with a known good switch.
R-23 High Pressure Cutout Switch
If the R-23 compressor discharge pressure rises above 3250 ± 50
kPa, 32.5 ± 0.5 bar, 470 ± 7 psig, the high pressure cutout opens
to interrupt the ground circuit to the compressor contactor:
R-23 compressor STOPS immediately.
LCD Display Message: No response to R-23 high pressure cutout.
Evaporator and condenser fans and R-134a compressor continue
normal operation.
R-23 compressor will restart when the overload condition is
corrected (switch closes) as long as power is available. The high
pressure switch resets (closes) when the pressure drops to 2590 ±
250 kPa, 25.9 ± 2.5 bar, 375 ± 38 psig.
R-134a High Pressure Cutout Switch
If the R-134a compressor discharge pressure rises above 2410 ±
68 kPa, 24.1 ± 0.68 bar, 350 ± 10 psig, the high pressure cutout opens
to interrupt the ground circuit to the compressor contactor:
R-134a compressor STOPS immediately.
LCD Display Message: R-134a high pressure cutout feedback missing.
Evaporator and condenser fans continue normal operation.
R-23 compressor stops.
R-134a compressor will restart when the overload condition
is corrected (switch closes) as long as power is available. The high
pressure switch resets (closes) when the pressure drops to 1640 ±
68 kPa, 16.4 ± 0.68 bar, 238 ± 10 psig.
R-23 compressor will restart 30 seconds after R-134a compressor
restarts.
13.3: Low Pressure Transducer R23
A low pressure transducer R23 is located on the compressor suction
line. The low pressure transducer R23 stops compressor: -33 to -54
kPa, -0.33 to -0.54 bar, 10 to 16 in. Hg vacuum; starts compressor:
24 to 58 kPa, 0.24 to 0.58 bar, 3.5 to 8.5 psig. If the suction pressure
becomes too low, the low pressure transducer R23 stops compressor.
Compressor stops immediately.
Evaporator and condenser fans continue normal operation.
Compressor will restart if the low refrigerant condition is
corrected as long as power is available. The low pressure transducer
R23 stats the compressor when the pressure increase to 24 to 58 kPa,
0.24 to 0.58 bar, 3.5 to 8.5 psig.
Removal
Disconnect the low pressure transducer R23 wires from the control
box.
Remove the low pressure transducer R23 from the suction line.
The fitting on the suction line has a shrader valve which will prevent
refrigerant leakage.
Installation
Install low pressure transducer R23 in the suction line.
Route wires into the control box and connect to proper terminals.
Perform a controller pretrip test to verify system operation.
13.4: Pressure Transducer (Sensor)
The sensors are located on the discharge or suction tubes near
the compressor. The controller will display the actual discharge or
suction system pressure. The display will show a reading and a bar
graph.
Remove the sensor from the discharge or suction tube. The fitting
on the line has a Schrader valve which will prevent refrigerant leakage.
Installation
Apply Locktite to fitting threads (Red 277).
Install sensor on fitting.
Route wire harness to control box and connect in accordance
with wiring diagram.
13.5: Condenser Fan and Evaporator Fan Rotation
Note If both the condenser fan and evaporator fans are
rotating backwards, diagnose the automatic phase selection system.
Check Condenser Fan Rotation
Check for proper condenser fan rotation by placing a small cloth
or sheet of paper against the condenser fan grille on the front of
the unit. Proper rotation will blow the cloth or paper away from the
grille. Improper rotation will hold the cloth or paper against the
grille.
If the condenser fan is rotating backwards, refer to the unit wiring
diagram to correct fan motor wiring at the fan motor junction box
or condenser fan contactor. To correct improper fan rotation, reverse
any two fan power cord leads at the condenser fan contactor (disconnect
power supply before reversing leads). Do not move the CH ground wire.
Check Evaporator Fan Rotation
Visually inspect the evaporator fan blades for proper rotation.
Arrows located on the underside of the fan deck indicate the correct
direction of rotation.
Check both high and low speed evaporator fan rotation by performing
Evaporator High and Evaporator Low tests from the Manual Function
Test menu.
If an evaporator fan is rotating backwards on one or both speeds,
refer to the unit wiring diagram to correct motor wiring at the fan
motor junction box or evaporator fan contactor (disconnect power supply
before reversing leads). Do not move the ground wire which is labeled
CH.
13.6: Temperature Sensors
Thermistor type temperature sensors are used. Each sensor is connected
to a cable and placed in a sealed stainless steel tube. The temperature
signal from the sensor is transmitted through the cable. Temperature
sensors include the following:
Supply Air
Return Air
Evaporator Coil
Compressor LT Discharge Temperature Sensor
Compressor HT Discharge Temperature Sensor
Ambient Air
1
Temperature Sensors
Sensor Installation
All sensors should be properly installed as follows:
Supply air sensors must be inserted to the bottom of the sensor
tube and completely sealed by the grommet connection.
Return air sensor installs in a grommet between the evaporator
fans.
Evaporator coil (defrost) sensor must be placed in the middle
of the coil and 75 mm deep between the fins.
Ambient sensor must be placed on the bottom plate of the right
forklift pocket.
Compressor discharge pressure transducer is attached to compressor
head by adhesive. Refer to (Pressure Transducer (Sensor)).
Sensor Testing
The controller constantly monitors the left hand and right hand
supply sensors, return sensor and defrost (evaporator coil) sensor
to determine when to initiate a demand defrost. If a demand defrost
is requested and defrost has occurred within the last 90 minutes,
the controller initiates a probe test to check for a defective sensor.
During a Probe test, the VGA display shows [PROBE TEST PLEASE WAIT].
The controller operates the unit on high speed evaporator fans only
for five 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).
Sensor errors recorded during a probe test are cleared when the
next Defrost is initiated or Unit On/Off switch is turned Off.
Note A manual probe test can be performed by a technician
by selecting “SENSOR CHECK” from the Manual Test Function menu.
Evaporator Coil
(Defrost) Sensor Location
A
Coil Support Bracket
B
Front of Unit
C
Insert sensor at least 75 mm into coil between tube rows 2
and 3.
Resistance Values for Temperature Sensors
Sensors are permanently calibrated and can be checked using an
ohmmeter. Ohm readings should agree with the data shown in the following
sensor resistance tables.
Supply, Return, Evaporator Coil
°F
°C
Ohms
°F
°C
Ohms
-40
-40
842,9
53.6
12
1046,8
-31
-35
862,5
57.2
14
1054,6
-22
-30
822,2
60.8
16
1062,4
-13
-25
901,9
64.4
18
1070,2
-4
-20
921,6
68
20
1077,9
5
-15
941,2
71.6
22
1085,7
10.4
-12
956,9
75.2
24
1093,5
14
-10
960,9
78.8
26
1101,2
17.6
-8
968,7
82.4
28
1109,2
21.2
-6
976,5
86
30
1116,7
24.8
-4
984,4
89.6
32
1124,5
28.4
-2
992,2
93.2
34
1132,2
32
0
1000,0
96.8
36
1139,9
35.6
2
1007,8
100.4
38
1147,7
39.2
4
1015,6
104
40
1155,4
42.8
6
1023,4
107.6
42
1163,1
46.4
8
1031,2
111.2
44
1170,8
50
10
1039,0
113
45
1174,7
Ambient Air Sensor
°F
°C
Ohms
°F
°C
Ohms
-40
-40
42618
53.6
12
3360
-31
-35
32198
57.2
14
3094
-22
-30
24532
60.8
16
2852
-13
-25
18850
64.4
18
2632
-4
-20
14618
68
20
2431
5
-15
11383
71.6
22
2347
10.4
-12
9838
75.2
24
2079
14
-10
8941
78.8
26
1925
17.6
-8
8132
82.4
28
1785
21.2
-6
7406
86
30
1657
24.8
-4
6752
89.6
32
1539
28.4
-2
6164
93.2
34
1430
32
0
5634
96.8
36
1330
35.6
2
5155
100.4
38
1239
39.2
4
4721
104
40
1154
42.8
6
4329
107.6
42
1076
46.4
8
3907
111.2
44
1004
50
10
3652
113
45
970
Compressor Discharge Sensors R32
°F
°C
Ohms
°F
°C
Ohms
-13
-25
1,121,457
185
85
9,202
-4
-20
834,716
194
90
7,869
5
-15
627,284
203
95
6,768
14
-10
475,743
212
100
5,848
23
-5
363,986
221
105
5,091
32
0
280,824
230
110
4,446
41
5
218,406
239
115
3,870
50
10
171,166
248
120
3,354
59
15
135,140
257
125
2,924
68
20
107,440
266
130
2,580
77
25
86,000
275
135
2,279
86
30
69,282
284
140
2,021
95
35
56,158
293
145
1,797
104
40
45,812
302
150
1,591
113
45
37,582
311
155
1,393
122
50
30,986
320
160
1,247
131
55
25,680
329
165
1,118
140
60
21,397
338
170
1,015
149
65
17,914
347
175
920
158
70
15,067
356
180
834
167
75
12,728
365
185
748
176
80
10,793
374
190
679
Compressor Discharge Sensors R134a
°F
°C
Ohms
°F
°C
Ohms
32
0
351017
158
70
15502
35.6
2
315288
161.6
72
14410
39.2
4
283558
165.2
74
13405
42.8
6
255337
168.8
76
12479
46.4
8
230210
172.4
78
11625
50
10
207807
176
80
10837
53.6
12
187803
179.6
82
10110
57.2
14
169924
183.2
84
9438
60.8
16
153923
186.8
86
8817
64.4
18
139588
190.4
88
8242
68
20
126729
194
90
7710
71.6
22
115179
197.6
92
7216
75.2
24
104796
201.2
94
6759
78.8
26
95449
204.8
96
6335
82.4
28
87023
208.4
98
5941
86
30
79428
212
100
5574
89.6
32
72567
215.6
102
5234
93.2
34
66365
219.2
104
4917
96.8
36
60752
222.8
106
4623
100.4
38
55668
226.4
108
4348
104
40
51058
230
110
4092
107.6
42
46873
233.6
112
3854
111.2
44
43071
237.2
114
3631
114.8
46
39613
240.8
116
3423
118.4
48
36465
244.4
118
3229
122
50
33598
248
120
3047
125.6
52
30983
251.6
122
2877
129.2
54
28595
255.2
124
2718
132.8
56
26413
258.8
126
2569
136.4
58
24419
262.4
128
2430
140
60
22593
266
130
2299
143.6
62
20921
269.6
132
2176
147.2
64
19388
273.2
134
2118
150.8
66
17961
276.8
136
1953
154.4
68
16689
280.4
138
1852
Chapter 14: Refrigeration Maintenance
14.1: Introduction
The following procedures involve servicing the refrigeration system.
Some of these service procedures are regulated by Federal, and in
some cases, by State and Local laws.
Note In the USA,
EPA Section 608 Certification is required to work on refrigeration
systems, using approved equipment and complying with all Federal,
State, and Local laws. In the EU, local F-gas Regulations must be
observed when working on refrigeration systems.
14.2: Tools
Notice
System Contamination
When servicing Thermo King R-134a, R-23, R-404A, R-452A
or R-513A units, use only those service tools certified for and dedicated
to R-134a/R-23/R-404A/R-452A/R-513A refrigerant and Polyolester compressor
oils. Residual non-HFC refrigerants or oils will contaminate R-134a/R-23/R-404A/R-452A/R-513A
systems.Please check serial# plate for type and volume of Refrigerant
charged. Please do not blend with other refrigerants than the original
charged refrigerant
14.3: Vacuum Pump
A two-stage, three-stage, or five-stage
pump is recommended for evacuation. Purging the system with dry nitrogen
is recommended before evacuation. Because residual refrigerant may
be present in used vacuum pumps, a new vacuum pump should be used
and dedicated strictly as an R-134a refrigerant pump. Use only recommended vacuum
pump oils and change
oil after every major evacuation. Because vacuum pump oils are highly
refined to obtain low vacuums, failure to follow these recommendations
may result in acidic conditions that will destroy the pump.
14.4: Filters and Cartridges
Cleanup devices such as suction line
filters and compressor oil filters may be used if they are properly
cleaned and new filters and cartridges are used. All standard petroleum
and synthetic compressor oils must be removed to prevent the contamination
of R-134a systems.
14.5: Refrigerant Recovery Equipment
Use only refrigerant recovery equipment approved for and dedicated
to HFC refrigeration recovery
14.6: Detecting Leaks
Leaks can be detected with the use of soap bubbles and with Halogen
leak detectors such as model H10G or model H10N (portable).
14.7: Special Service Fittings
Special fittings are used on HFC systems to prevent mixing of non-HFC
refrigerants in HFC units. These fittings are located in three places
on refrigeration systems:
Low side near the compressor suction service valve (or suction
adapter)
High side near the compressor discharge service valve (or discharge
manifold)
Receiver Tank
1
Internal Threads for Cap
2
High Pressure Fitting
3
Low Pressure Fitting
14.8: Oil Acid Test
Perform an oil acid test (refer to Tool Catalog for oil test kit)
whenever a unit has a substantial refrigerant loss, a noisy compressor
or dark/dirty oil.
14.9: Checking Compressor Oil
The compressor oil should be checked during pretrip inspections
and when there is evidence of oil loss (oil leaks) or when components
in the refrigeration system have been removed for service or replacement.
Checking the Compressor Oil Level
Operate the unit on full COOL. After 15 minutes, observe the compressor
oil level. The oil level should be 1/2 to 3/4 full in the sight glass
of both compressors.
Adding Compressor Oil
Install gauge manifold set (refer to “Gauge Manifold Set Attachment
and Purging”).
Do one of the following:
R-134a Compressor: Pump the compressor down (refer to “Low
Side Pump Down”).
R-23 Compressor: Do NOT pump down a scroll compressor. Proceed
to step 4 to add oil to a scroll compressor.
After stopping the compressor, adjust the low side pressure
to 21 kPa, 0.21 bar, 3 psig using the service gauge set. (Pressure
measured at the suction line service port.)
Remove the cap from oil pressure fitting on compressor.
Using a commercial hand pump, force oil in through the oil
pressure fitting. Slowly add oil and allow 5 to 10 minutes for the
oil to flow down through the compressor into the sump. Add Polyol
Ester oil,
When the compressor oil sight glass is 1/2 to 3/4 full, remove
hand pump and replace the cap on the oil pressure fitting.
R-134a Compressor: Open the compressor suction service valve
(or liquid line service valve) and operate the unit. Recheck the refrigerant
charge level and the oil level before returning the unit to service.
Removing Excess Compressor Oil
Install an access valve actuator on the oil pressure fitting.
Operate the unit and remove oil while watching the level in
the compressor sight glass.
Note Heavy foaming of
the oil as it leaves the compressor may indicate an excess of refrigerant
in the oil. Remove the access valve actuator and operate the system
for 15 minutes to ensure warm sump. Then recheck the oil level.
When the compressor oil sight glass is 1/2 to 3/4 full, remove
access valve and replace the cap on the oil pressure fitting.
Operate the unit and recheck the refrigerant charge level and
the oil level before returning the unit to service.
14.10: Isolate Compressor
The discharge suction and digital ball service valves isolate the
compressor from the high and low sides of the refrigeration system.
Compressor isolation is needed for system diagnosis, service, and
repair.
Note The valves are a permanently assembled unit
and must be replaced in total if defective. The only maintenance possible
on the discharge or suction service valve is to periodically tighten
the packing nut or to replace the packing.
Warning
Hazard of Explosion
Do not start unit with discharge valve in front seated
position.
Service Valve
Back Seated (Operating Position)
1
Full Counterclockwise
Service Valve
Open to Port (Servicing Position)
1
1/2 Turn In
Service Valve
Front Seated (Check or Remove Compressor)
1
Full Clockwise
14.11: Service Valve Positions
The suction and discharge service valves provide connections for
the gauge manifold to the compressor for system diagnosis, service,
and repair. Familiarize yourself with these valve positions:
Back-seated: Normal operating position. The service valve
is fully closed:
Valve Fully Counterclockwise (Back-seated)
Front-seated: Checking and removing the compressor. The
service valve is open, and access to the system is closed:
Valve Fully Clockwise (Front-seated)
Danger
Risk of Injury
Anytime the suction service valve or the discharge service
valve is front seated (closed), take precautions to ensure the unit
and the bus will not accidentally start while you are servicing the
system.
Danger
Risk of Injury
If the compressor is operated with the service valves
closed, an explosion may occur that could result in serious injury
or death.
Open to Service Port: Servicing position. Access
to the system and the service ports:
Valve Turned Half Way In (Open to Service Port)
14.12: Gauge Manifold Connections
Before You Proceed
Note This procedure is only for units that contains
R134a refrigerant.
Note To minimize refrigerant loss, use sealing-type
quick connectors. These fittings restrict flow during evacuation.
Read the following before you proceed with a gauge manifold connection.
If a procedure requires the compressor to operate at a suction
pressure below 5 inch vacuum (-17 kPa), place a jumper across the
low pressure cutout switch to prevent compressor shutdown.
Use of the quick disconnect access valve during evacuation
increases the time required to reach the correct micron level.
Gauge Manifold Positions
The gauges indicate low and high side pressures. Operate one or
both hand valves to perform the different service operations:
Hand Valves Open to Center Port
Hand Valves Closed to Center Port
Gauge Connections: Balancing Pressure, Removing Refrigerant,
and Charging System
Balancing Pressure
Removing Refrigerant
Charging the System
14.13: Low Side Pump Down (R-134a Compressor Only)
Note Do NOT pump down a scroll compressor. Reclaim the
refrigerant when servicing the low side or high side of the R-23 refrigeration
system.
Install the gauge manifold on the compressor.
Set the controller setpoint temperature well below the return
air temperature and operate the unit in the Cool mode until the temperature
stabilizes (at least 5 minutes).
Close the receiver tank outlet valve. Allow the unit to operate
until it reaches -15 to -40 kPa, -0.15 to -0.40 bar, 5 to 11 in. vacuum
on the suction pressure gauge (3-5 minutes). Then shut the unit down
manually with the On/Off switch.
Notice
Equipment Damage
To prevent air and moisture contamination, do not open
the low side of system while in vacuum.
To place the unit back in service, open the receiver tank outlet
valve and turn the On/Off switch ON.
14.14: Gauge Manifold Set
Using a New Gauge Manifold Set
A new gauge manifold set and gauge hoses
(refer to Tool Catalog) should be dedicated for use with only R-134a refrigerant.
Gauge Manifold Valve Positions
The gauges indicate low and high side pressures. Operate one or
both hand valves to perform the different service operations.
Balancing the
Pressure
1
Quick Disconnect Access Valve
2
Discharge Service Valve (DSV)
3
Suction Service Valve (SSV)
Removing Refrigerant
1
Quick Disconnect Access Valve
2
Discharge Service Valve (DSV)
3
Suction Service Valve (SSV)
4
Reclaimer
5
In
6
Out
Gauge Manifold
Closed to Center Port
1
Close Hand Valves
Gauge Manifold
Open to Center Port
1
Open Hand Valves
Charging the
System
1
Quick Disconnect Access Valve
2
Discharge Service Valve (DSV)
3
Suction Service Valve (SSV)
14.15: Gauge Manifold Set Installation and Removal
Thermo King recommends the use of access
valves or self-sealing, quick disconnect fittings. This limits the
loss of refrigerant into the atmosphere. A separate gauge manifold
set with low loss fittings (refer to Tool Catalog) should be dedicated
for use with R-134a only. Gauge
hoses should also be dedicated to R-134a.
Note Carefully check to verify that access connections
are functioning properly when any of these devices are used.
Installation
The following procedure purges the gauge hoses. The procedure must
be followed when using new gauges or hoses for the first time. The
system should be operating on Cool (10 psig [69 kPa] or greater suction
pressure) when using this procedure to purge the low side hose. Gauge
hoses may be removed and re-installed without additional purging so
long as a slight positive pressure remains in the manifold and lines.
Inspect gauge manifold for proper hose and fitting connections.
Clean dirt and moisture from around service ports.
Remove small service port caps from suction and discharge
service fittings. Save and reuse the caps and sealing washers or gaskets.
Rotate both hose coupler hand wheels counterclockwise
to back the stem out of the high and low hose fittings. Attach low
hose (compound gauge) to the suction line valve port.
Open the suction service manifold hand valve fully with
69 kPa, 0.69 bar, 10 psig or greater pressure in the low side (unit
operating on Cool). Rotate the suction hose fitting hand wheel clockwise
to open (depress) the suction line port valve to the low hose.
Slowly screw a 1/2 inch ACME fitting into the low loss
fitting on the manifold’s service (center) line to purge the suction
and service hoses. Remove ACME fitting after purging.
Close the suction service manifold hand valve fully to
center port.
Attach high side hose (pressure gauge) to the discharge
service line port.
Open discharge service manifold hand valve fully. Rotate
discharge fitting hand wheel clockwise to open (depress) discharge
line port valve to the high hose.
Slowly screw a 1/2 inch ACME fitting into the manifold’s
service (center) line to purge the high and service hoses. Remove
ACME fitting after purging.
Close discharge service manifold hand valve fully to center
port. You are now ready to use the gauge manifold to check system
pressures or perform most service procedures.
Note These gauges may be removed and reinstalled without
additional purging so long as a slight positive pressure remains in
the manifold and hoses when removed from the unit.
Purging Gauge
Manifold
1
Suction Connection
2
Discharge Connection
Removal
Warning
Personal Protective Equipment (PPE) Required
Protect your eyes from contact with refrigerant oil. The
oil can cause serious eye injuries. Protect skin and clothing from
prolonged or repeated contact with refrigerant oil. To prevent irritation,
wash your hands and clothing thoroughly after handling the oil. Rubber
gloves are recommended. When working with or around hazardous chemicals,
ALWAYS refer to the applicable Material Data Safety Sheets (MSDS)
and OSHA/GHS (Global Harmonized System of Classification and Labelling
of Chemicals) guidelines for information on allowable personal exposure
levels, proper respiratory protection, and handling instructions.
Note THE SYSTEM SHOULD BE RUNNING to verify minimum
refrigerant release to the atmosphere,. However, this is not possible
in all cases, but the same procedure should be followed.
Rotate discharge hose fitting hand wheel counterclockwise
to withdraw the fitting stem from the discharge line port valve. Then
open both service manifold valves to center port.
Operate the unit on Cool using the “CAPACITY 100 percent”
test from the Manual Function Test menu of the controller.
Rotate the suction hose coupler hand wheel counterclockwise
to withdraw the fitting stem from the suction line port valve. Then
turn the unit off.
Remove the gauge lines from the suction and discharge
service fittings and cap the service ports.
Secure all manifold lines to manifold hose anchors when
the manifold is not in use.
14.16: Checking Refrigerant Charge
The refrigerant charge should be checked during pretrip and routine
maintenance inspections. A low charge of refrigerant will cause the
container temperature to rise due to the lack of liquid refrigerant
at the expansion valve even though the unit is operating in a cooling
mode. All units are charged with 5.2 kg (11.4 lbs) refrigerant at the factory. The refrigerant charge can be checked
by inspecting the receiver tank sight glass.
Inspect the receiver tank sight glass with the unit operating
in cool or modulation cool. If the ball floats in the bottom receiver
tank sight glass when the compressor is engaged, the refrigerant charge
level is correct.
Notice
Cargo Loss
When adjusting the controller setpoint to check refrigerant
charge, return controller to the setpoint indicated on the shipping
manifest.
If the ball is not floating in the sight glass, the unit
may be low on refrigerant charge. Adjust the controller setpoint to
operate the unit on cool. Operate the unit on cool for five minutes.
If the ball floats in the receiver tank sight glass, the refrigerant
charge level is correct.
If the ball in the receiver tank sight glass does not
float after operating the unit on cool for five minutes, the unit
is low on refrigerant charge. With the unit operating on cool, add
liquid refrigerant charge. With the unit operating in cool, add liquid
refrigerant until the ball in the receiver tank sight glass floats
in the sight glass.
Note Inspect the unit for refrigerant
leaks with a reliable leak detector if the unit is low on refrigerant
charge.
14.16.1: Checking the R-134a Refrigerant Charge
Inspect the receiver tank sight glass with the unit operating
in COOL. If the balls FLOAT in the receiver tank sight glass, the
R-134a charge level is correct.
If the balls are NOT FLOATING in the sight glass, the unit
MAY be low on R-134a charge. Operate the unit on COOL for 5 minutes.
If the balls float in the receiver tank sight glass, the R-134a charge
level is correct.
If the balls do NOT FLOAT in the receiver tank sight glass
after operating the unit on COOL for 5 minutes, the unit is low on
R-134a charge. With the unit operating on COOL, add liquid R-134a
until the balls FLOAT in the sight glass.
Caution
Service procedure
When adding R-134a to the unit, STOP adding refrigerant
when the balls float near the TOP of the sight glass. Continuing to
add refrigerant after the balls float at the top of the sight glass
will OVERCHARGE the unit. If necessary, recover refrigerant until
the balls no longer float at the top of the sight glass.
R-134a Refrigeration System Receiver Tank
1.
Refrigerant
charge is OK if the ball floats at any time:
If the ball does NOT float, the R-134a refrigeration system
is unit is low on refrigerant
14.16.2: Checking the R-23 Refrigerant Charge
The R-23 refrigerant charge should be checked with the container
empty, the unit OFF and all refrigeration system components above
-5 °C (23 °F). The R-134a compressor must not have been operated within
the past 30 minutes and there must not be frost on the plate-type
R-134a / R-23 heat exchanger tubing.
Observe both the suction and discharge pressures. With the unit
OFF, the suction and discharge readings should be equal. The R-23
refrigerant pressure in a fully charged system with the unit OFF will
vary with the ambient temperature:
Ambient Temperature
R-23 System Pressure
0
°C (32 °F)
1600 kPa,
16 bar, 232 psig
20
°C (68 °F)
1700 kPa,
17 bar, 247 psig
38 °C (100 °F)
1800
kPa, 18 bar, 261 psig
R-23 Refrigeration System Receiver Tank
1.
The
bottom sight glass ball will rarely float on a fully charged system
during normal operation.
Check the refrigerant charge based on the R-23 system pressure
with the container empty, the unit OFF and all refrigeration system
components above
Note Use the lower sight glass to check or add refrigerant
only on a operating unit that is unable to maintain a -55 C to -65
C (-62 F to -94 F) low temperature.
Correct Refrigerant Charge: If the R-23 system pressure stabilizes
between 1500 and 2000 kPa, 15 and 20 bar, 220 and 290 psig, the unit
will be fully functional. The R-23 refrigerant charge requires no
adjustment.
Low Refrigerant Charge: If the R-23 system pressure stabilizes
between 1000 and 1500 kPa, 10 and 15 bar, 145 and 220 psig, the unit
cooling capacity will be reduced but the unit should be able to maintain
a -55 C to -70 C (-62 F to -94 F) load temperature. Additional R-23
should be added if possible, but do NOT add by operating the unit.
Over Charge of Refrigerant: If the R-23 system pressure stabilizes
above 2000 kPa, 20 bar, 290 psig, the R-23 system is overcharged and
may cause the compressor to stop on high pressure cutout when started
to precool a warm container. Remove refrigerant until the system pressure
stabilizes at 2000 kPa, 20 bar, 290 psig or below.
Note Use the lower receiver tank sight glass to check
or add refrigerant only on an operating unit that is unable to maintain
a -55 °C to -70 °C (-62 °F to -94 °F) load temperature.
14.17: Receiver Tank Sight Glass
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. Check the color
of the indicator against the color decal in the sight glass. The dry
eye in the sight glass is light green when the system is dry and yellow
when the system is wet (contains excessive moisture).
1
Moisture Indicator:
Light Green = Dry
Yellow
= Wet
2
Outer ring is color coded. Compare to indicator.
14.18: Leak Testing Refrigeration System
Use a reliable Halogen leak detector such as model H10G (refer
to Tool Catalog), to leak test the refrigeration system. Inspect carefully
for signs of compressor oil leakage which is the first sign of a leak
in the refrigeration system.
Note Due to environmental
concerns and personal safety, the use of a Halide torch is no longer
recommended.
If refrigerant has leaked or been removed from the unit:
Check entire system for possible component damage and
refrigerant oil loss.
Attach gauge manifold set (Refer to Gauge Manifold Set for proper procedures).
Attach refrigerant bottle charging hose to center of gauge
manifold and purge charging hose of air.
Pressurize the system with refrigerant (gas only) until
345 kPa, 3.45 bar, 50 psig vapor pressure is achieved.
Leak check the system with an electronic leak detector
to inspect all joints and connections (Use soap solution as an alternative
test component). If no leaks are found but the system has lost its
refrigerant charge, proceed to the next step.
Close both hand valves on gauge manifold (front seated).
Disconnect the refrigerant charging hose.
Connect the charging hose to a source of nitrogen. Adjust
the pressure regulator to 1380 kPa, 13.80 bar, 200 psig. Refer to
(Using Pressurized Nitrogen).
Pressurize the system with nitrogen to 1380 kPa, 13.80
bar, 200 psig.
Close the supply valve on the nitrogen bottle.
Use an electronic leak tester to inspect all joints and
connections. Use a soap solution as an alternative test component.
Note If system leakage is indicated, loosen supply line hose
fittings to release pressure. Repair leakage condition.
If system repair is necessary, recheck system after repairs
are completed.
14.19: Using Pressurized Nitrogen
The improper use of high pressure cylinders can cause physical
damage to components, or personal injury, or cause stress that would
lead to failure of components.
Typical Pressurized
Gas Bottle
1
Line Pressure
2
Tank Pressure
3
Tank
4
Pressure Test Line to System
5
Safety Valve
6
Pressure Regulator
Safety Precautions
Observe the proper handling of cylinders:
Always keep protective cap on cylinder when not in use.
Secure cylinder in proper storage area or fastened to cart.
Do not expose to excessive heat or direct sun light.
Do not drop, dent, or damage cylinder.
Use a pressure regulator and a safety pressure relief valve
as part of the pressure testing equipment. The safety pressure relief
valve should be of the non-adjustable, non-tempering type. The valve
should bypass any time the pressure exceeds its setting.
Open valve slowly; use regulators and safety valves that are
in good working order.
The regulator should have two gauges; one to read tank pressure,
the other to read line pressure. Properly maintained equipment will
allow leak testing, purging, or dehydration to be done safely.
Caution
Risk of Injury
Nitrogen (N2) is under 15,170 kPa, 151.70 bar, 2200 psig, or
greater. Pressure is for full cylinder at 21 C (70 F). DO NOT use
Oxygen (O2), acetylene, or any other types of pressurized gas on refrigeration
systems or any component of a system.
Dehydration, pressure testing, purging, and soldering can be accomplished
with the use of dry nitrogen (N2). The proper equipment and application
of equipment is of greatest importance.
Purge High Side to Low Side
Attach gauge manifold set (Refer to Gauge Manifold Set for proper procedure
for connecting to compressor).
Close both hand valves on the gauge manifold (front seated).
Connect charging hose to a source of nitrogen. Adjust pressure
regulator to the proper pressure for the required procedure.
Purge system high side to low side.
Maximum Gas Pressures
The following procedures should utilize the following maximum gas
pressure:
Leak Testing: 1034 to 1200 kPa, 10.34 to 12.00 bar, 150-174
psig.
Purging/Dehydration: 69 to 138 kPa, 0.69 to 1.38 bar, 10-20
psig.
Soldering: 35 kPa, 0.35 bar, 5 psig.
Evacuation Station and Unit Hook-up
1
Special, self-sealing quick disconnect couplers are required
for R-134a units
3
Iso Valve
5
To 220/190 Vac Power
7
Micron Meter
2
Gas Ballast Valve
4
Two-stage Vacuum Pump
6
Calibration Standard
8
Sensor
14.20: Recovering Refrigerant from System
Notice
Risk of Injury!
Use only refrigerant recovery equipment approved for and
dedicated to R-134A recovery.
When removing any refrigerant from a Thermo King refrigeration
system, use a recovery process that prevents or absolutely minimizes
the refrigerant escaping to the atmosphere. Typical service procedures
that require removal of refrigerant from the unit includes the following:
Reduce the refrigerant pressure to a safe working level when
maintenance must be performed on high-pressure side components.
Empty the unit of refrigerant when an unknown amount of charge
is in the system and a proper charge is required.
Empty the unit of contaminated refrigerant when the system
has become contaminated.
Note Always refer to specific recovery equipment
Operator and Service Manuals.
Perform the following steps to recover vapor from the system.
Turn unit off.
Install a gauge manifold set on the unit.
Attach the service line to the recovery machine and properly
purge the lines.
Set the recovery machine for vapor recovery.
Mid-seat the discharge service valve.
Turn on the recovery machine.
Open (back seat) both gauge manifold and hand valves.
Continue to operate the recovery machine until unit pressures
drop to 0 kPa, 0 bar, 0 psig pressure.
14.20.1: Recovery for System Repair
Because R-23 has high working pressures, it must be recovered from
the refrigeration circuit before any component, except the compressor,
suction pressure gauge and discharge pressure gauge, can be repaired
or replaced. Also, because of the high pressure in R-23 refrigerant
bottles, the recovery of R-23 for re-use in the unit requires an empty
refrigerant bottle at least 40 liters (42 quarts) in volume. The refrigerant
bottle must be clean or dedicated to use with HFC refrigerants only.
Note Due to extremely high pressure in normal ambient
R-23 cannot be reclaimed by use of reclaim station.
Prepare an empty refrigerant bottle at lease 40 liters (42
quarts) in volume. Evacuate bottle if necessary to ensure it is clean.
Connect a refrigerant hose from the bottle to the R-23 compressor
discharge service valve.
Midseat the discharge service valve. Then open the service
valve on the bottle. Wait for 5-10 minutes to allow the pressures
to equalize between the refrigeration system and the bottle. This
will remove approximately 1/2 of the refrigerant charge from the unit.
Start the unit and use the Manual Test function submenu of
the controller to start and operate the R-23 compressor only for approximately
2 minutes. This will quickly transfer most of the remaining R-23 refrigerant
charge to the bottle.
Caution
Equipment Damage
Do not allow the compressor suction pressure to decrease
below 100 kPa, 1.00 bar, 15 psig.
Warning
Equipment Damage
Do not allow the pressure of the bottle to exceed 2500
kPa, 25 bar, 362 psig.
After approximately 2 minutes of R-23 compressor operation,
slowly close the compressor suction service valve. When the compressor
suction pressure decreases below 100 kPa, 1.00 bar, 15 psig, stop
the R-23 compressor and turn the unit OFF.
Close the service valve on the R-23 recovery bottle.
Backseat the discharge service valve. Disconnect the refrigerant
hose from the discharge valve.
With system pressures below 100 kPa, 1.00 bar, 15 psig, the
R-23 system components can be serviced.
If necessary, set a recovery machine for vapor recovery. Connect
the recovery machine to a separate, empty recovery bottle. Keep unit
OFF and mid-seat the discharge service valve. Turn ON the recovery
machine and open the service valve on the recovery machine. Operate
the recovery machine until system pressures drop to 0 kPa, 0 bar,
0 psig pressure.
R-134a Vapor Recovery
Install a gauge manifold set on the R-134a refrigeration system.
Attach the service line to the recovery machine and properly purge
the lines. Set the recovery machine for vapor recovery.
Keep unit OFF and mid-seat the discharge service valve.
Turn ON the recovery machine and open (back seat) both gauge
manifold and hand valves.
Continue to operate the recovery machine until system pressures
drop to 0 kPa, 0 bar, 0 psig pressure.
R-134a Liquid Recovery
Install a gauge manifold’s low-pressure line to the Schrader
suction service valve on the suction service valve of the R-134a compressor.
Attach the manifold’s high-pressure line to R-134a receiver tank service
valve port. Attach the service line to the recovery machine and purge
the lines.
Set recovery machine for liquid recovery and turn it ON.
Open (back seat) high-pressure valve on gauge manifold.
Operate the recovery machine until the unit system pressures
reach approximately 0 kPa, 0 bar, 0 psig.
14.21: Evacuation and Cleanup of Refrigeration System
A thorough clean up is required whenever contaminants have entered
the system. This will prevent damage to the compressor.
The purpose of evacuation is to remove moisture and air from the
refrigeration system after a system has been opened to the atmosphere.
Evacuation must occur before recharging a system with new refrigerant.
The importance of thorough evacuation and system preparation cannot
be over emphasized. Even infinitesimal quantities of air or moisture
in a system can cause severe problems.
The presence of moisture, oxygen, and heat can create many forms
of damage. They can create corrosion, sludge, copper plating, oil
breakdown, carbon formation, and eventual compressor failure.
Things that will contaminate a system are (in order of importance):
Air: With oxygen as a contaminant: Oxygen in the air reacts
with the oil. The oil begins to break down and can eventually lead
to carbonization in the compressor and acid buildup. The longer this
breakdown process goes on, the darker the compressor oil becomes until
finally the color is black indicating major system contamination.
Moisture: Moisture in a system will cause metal corrosion and
metal plating. It can freeze in the expansion valve and cause intermittent
operational problems. It reacts in the oil to begin acid buildup.
Dirt, Dust, Metal Particles, other Foreign Materials: Particles
of any kind left to float through the system will cause severe damage
to all close tolerance items. Do not leave a system open to the infiltration
of dirt. If you must open a system for any reason, seal off the open
areas as soon as possible and do not work in a dirty environment.
Acid: Air and moisture cause a chemical breakdown of the oil
and/or the refrigerant itself. The acid will accelerate the deterioration
of the softer metals (i.e., copper) and cause metal plating as the
softer material begins to cover the inside of the system. If this
condition is not stopped, it can result in the total destruction of
your equipment.
14.21.1: Unit Preparation and Hookup
Caution
Risk of Injury
Do not attempt to evacuate a unit until it is certain
that the unit is leak free. A unit with less than a full charge of
refrigerant should be thoroughly leak tested. Any leaks found must
be repaired.
Recover all refrigerants from the unit and reduce the
unit pressure to the proper level (US Federal Law requires a -17 to
-34 kPa, -0.17 to -0.34 bar, 5 to 10 in. vacuum that is dependent
upon the recovery equipment used).
Break vacuum with refrigerant and equalize system pressure
to 0 kPa, 0 bar, 0 psig. Replace the liquid line filter drier if necessary.
Note Replace the one-piece filter drier when major system
contamination requires evacuation and cleanup of the refrigeration
system.
Confirm that the evacuation station functions properly.
Determine “Blank Off” pressure. The “Blank Off” pressure of the vacuum
pump is the deepest vacuum that the vacuum pump can attain when isolated
from the rest of the system. The operator can be confident that the
pump and oil are in good condition, if a vacuum pump (isolated from
a system) is started and the micron meter responds quickly by going
to a deep vacuum. If the vacuum pump fails to reach a deep vacuum
within 5 minutes, the operator should suspect the condition of the
oil or the pump. It is recommended that the pump oil be changed first
to see if the rate of reaching a deep vacuum is improved.
Connect the evacuation station and refrigerant tank with
gauge manifold (optional) to the unit as indicated in Using Pressurized Nitrogen. Connect evacuation
hoses to the compressor suction and discharge service fittings.
Open Evacuation Station valves (V1, V3, and V4). It is
only necessary to open valve V2 when a reading on the micron meter
is desired. This is especially true when starting to evacuate a unit
and large amounts of moisture and oil will be passing by the sensor.
Open the vacuum pump Iso-Valve™ built
into the pump housing below the handle. It is recommended that the
valve be kept open at all times.
If connecting a refrigerant tank and gauge manifold to
the evacuation station, close the gauge manifold and refrigerant tank
valves to prevent refrigerant from being drawn from the tank.
14.21.2: Unit Evacuation
Turn on the vacuum pump. Open the gas ballast valve located
on top of the pump housing behind the handle (the valve is fully open
at two turns counterclockwise). Evacuate the system to 500 microns
to achieve a final equilibrium pressure of 2000 microns or less. The
final equilibrium pressure is determined with the Thermo King Evacuation
Station using the following procedure (called a pressure rise test):
Evacuate the system using the evacuation station until the
vacuum level reaches 1000 microns. Then close the gas ballast valve.
Continue evacuation to 500 microns or until vacuum stabilizes
at its lowest level. Contamination may delay reaching the lowest level
for a period of several hours or more.
Close valve V1 to isolate the vacuum pump from the system.
Observe the vacuum level on the micron meter.
When the meter has stabilized, the value indicated on the
micron meter is the equilibrium pressure. This reading must be 2000
microns or less.
Note The presence of refrigerant in
the compressor oil may prevent a low vacuum reading from being achieved.
Compressor oil can continue to outgas for long periods of time.
If the vacuum level appears to stall above 500 microns, back
seat the discharge service valve and observe the micron meter.
A drop in pressure indicates that the compressor oil is out-gassing
and further evacuation is necessary.
An increase in pressure indicates that a leak exists or there
is moisture in the system. Perform a pressure rise test and evaluate.
Close valve V1 when the desired vacuum level has been reached.
Wait five minutes and read the micron meter.
A system that is leak free and dry will remain below 2000 microns
for five minutes.
A system that rises above 2000 microns but stabilizes below
atmospheric pressure is probably contaminated with moisture or has
refrigerant out-gassing from the compressor oil. Additional evacuation
is required.
A system that continues to rise without stabilizing has a leak
and must be repaired.
If the vacuum level remained below 2000 microns for five minutes,
the unit is ready to charge. Refer to (Charging System with Refrigerant).
14.21.3: Pressure Rise Test
Evacuate the system and close valve V1. With valves V3 and V4 open,
the pump is isolated and the system is held under a vacuum. If the
micron meter rises, one of the following conditions exist:
Leak: Watch the movement of the micron meter needle. If the
needle continues to rise until it reaches atmospheric pressure, it
is an indication that a leak exists somewhere in the system. When
a leak is in a system, the vacuum will eventually stabilize at atmospheric
pressure. Refer to figure shown below.
1
Close the vacuum valve and watch the movement of vacuum gauge
needle. If needle continues to rise, this is an indication that a
leak exists in the unit or connecting line. The leak must then be
located and eliminated.
2
Time
3
Pressure (Vacuum)
4
Atmospheric Pressure
Moisture: When the needle indicates a rise and then stabilizes
at a level below atmospheric pressure, it is an indication that the
system is vacuum tight, but is still wet and requires additional dehydration
and pumping time. Refer to figure shown below.
1
Close the vacuum valve and watch the movement of vacuum gauge
needle. If needle shows a pressure rise but finally levels off to
a constant pressure, the system still contains too much moisture.
Dehydration and additional evacuation time are required.
2
Time
3
Pressure (Vacuum)
4
Atmospheric Pressure
14.21.4: Factors Affecting Speed of System Evacuation
The time needed to evacuate a system can vary. Some factors that
can influence evacuation time are listed below.
System size
Amount of moisture contained in the system
Ambient temperature
Internal restrictions within the system
External restrictions between the system and the vacuum pump
Hose size, both diameter and length, affect evacuation times. Laboratory
tests show that the evacuation time can be significantly reduced by
larger diameter hoses and shorter hoses. For example, it takes eight
times as long to pull a given vacuum through a 6 mm (1/4 inch) diameter
hose as it does through a 12 mm (1/2 inch) diameter hose. It takes
twice as long to pull a vacuum through a 2 meter (6 foot) long hose
as it does through a 1 meter (3 foot) long hose.
14.21.5: Heat Saves Time
Warning
Hazardous Gases
Never use a torch or other concentrated heat source to
heat the compressor or other refrigeration system component.
The application of heat to the system is a useful and practical
time saver. Increasing the temperature of the compressor oil and refrigerant
will speed up the vaporization of any water present in the system.
Heat lamps, electric heaters, or fans can be applied to the compressor
crankcase and other parts of the system to increase the temperature
of the refrigerant and compressor oil.
14.22: Charging System with Refrigerant
Unit Charging by Weight (from an Evacuated Condition)
Close valve V4.
Open the gas ballast valve (located on top of the pump
housing behind the handle).
Stop the vacuum pump.
Mid-seat the discharge valve.
Connect the refrigerant tank with gauge manifold to the
evacuation station (Refer to Unit Preparation and Hookup).
Weigh the tank of refrigerant.
Check the unit data plate for the required weight of refrigerant
charge. Subtract the amount of the charge to be input to your unit
from the total weight of the tank of refrigerant. This provides final
tank weight after the unit receives a full system refrigerant charge.
Set the refrigerant tank for liquid removal. Open the
hand valve on the tank.
Turn the unit off.
Open the gauge manifold hand valve and charge liquid refrigerant
into the system.
Close the refrigerant tank hand valve when the correct
amount (by weight) of refrigerant has been added or if the system
will take no more liquid. The unit is now ready to have the evacuation
station removed.
Evacuation Station Removal
Back seat the discharge service valves.
Close the high pressure hand valve on the gauge manifold.
Close the refrigerant tank hand valve.
Open the hand valve at the gauge manifold and read suction
pressure.
Operate the unit in Cool mode until the suction pressure
decreases below 385 kPa, 3.85 bar, 50 psig.
Back seat the suction line access service valve.
Stop the unit.
Remove the hoses from the suction and discharge line access
service valves.
Start the unit and perform a controller pretrip test to
verify correct refrigerant charge and unit operation.
14.22.1: R-134a Final Charging Procedure for Partially Charged Units
Note Final charge the R-23 system first when both the
R-134a and R-23 systems require charging.
Connect the gauge manifold to the suction line and discharge
line service ports. Be sure to purge the air from the lines (see “Gauge
Manifold Set Attachment and Purging” in the Refrigeration Maintenance
chapter of this manual).
Back seat and crack the discharge service valve.
Connect a refrigerant tank to the gauge manifold service line.
Caution
Service Procedure
Be sure to add the correct refrigerant to the system.
Set the R-134a refrigerant tank for liquid charging. Open the
refrigerant tank hand valve.
Start and operate the unit in the COOL mode.
Caution
Equipment Damage
Do NOT operate the unit on cooling unless: R-23 refrigeration
system contains a FULL charge of refrigerant. R-134a refrigeration
system contains a partial charge of refrigerant.
Read the suction pressure and slowly open the gauge manifold
low pressure hand valve to permit suction pressure to increase approximately
170 kPa, 1.7 bar, 25 psig. This will meter liquid refrigerant slowly
into the low side.
Add R-134a refrigerant until the receiver tank balls float
at the top of the sight glass.
Close the hand valve on the refrigerant tank.
Operate the unit on COOL for 10 minutes and recheck refrigerant
charge.
Remove the gauge manifold set.
Cap all service ports and valve stems.
Note
Caution
Service Procedure
Be sure to add the correct refrigerant to the system.
14.22.2: Checking the R-23 Refrigerant Charge
The R-23 refrigerant charge should be checked with the container
empty, the unit OFF and all refrigeration system components above
-5 °C (23 °F). The R-134a compressor must not have been operated within
the past 30 minutes and there must not be frost on the plate-type
R-134a / R-23 heat exchanger tubing.
Observe both the suction and discharge pressures. With the unit
OFF, the suction and discharge readings should be equal. The R-23
refrigerant pressure in a fully charged system with the unit OFF will
vary with the ambient temperature:
Ambient Temperature
R-23 System Pressure
0
°C (32 °F)
1600 kPa,
16 bar, 232 psig
20
°C (68 °F)
1700 kPa,
17 bar, 247 psig
38 °C (100 °F)
1800
kPa, 18 bar, 261 psig
R-23 Refrigeration System Receiver Tank
1.
The
bottom sight glass ball will rarely float on a fully charged system
during normal operation.
Check the refrigerant charge based on the R-23 system pressure
with the container empty, the unit OFF and all refrigeration system
components above
Note Use the lower sight glass to check or add refrigerant
only on a operating unit that is unable to maintain a -55 C to -65
C (-62 F to -94 F) low temperature.
Correct Refrigerant Charge: If the R-23 system pressure stabilizes
between 1500 and 2000 kPa, 15 and 20 bar, 220 and 290 psig, the unit
will be fully functional. The R-23 refrigerant charge requires no
adjustment.
Low Refrigerant Charge: If the R-23 system pressure stabilizes
between 1000 and 1500 kPa, 10 and 15 bar, 145 and 220 psig, the unit
cooling capacity will be reduced but the unit should be able to maintain
a -55 C to -70 C (-62 F to -94 F) load temperature. Additional R-23
should be added if possible, but do NOT add by operating the unit.
Over Charge of Refrigerant: If the R-23 system pressure stabilizes
above 2000 kPa, 20 bar, 290 psig, the R-23 system is overcharged and
may cause the compressor to stop on high pressure cutout when started
to precool a warm container. Remove refrigerant until the system pressure
stabilizes at 2000 kPa, 20 bar, 290 psig or below.
Note Use the lower receiver tank sight glass to check
or add refrigerant only on an operating unit that is unable to maintain
a -55 °C to -70 °C (-62 °F to -94 °F) load temperature.
14.22.3: Final Charging Procedure for Partially Charged Units on Empty
Containers R-23
Note The R-23 refrigerant should be charged with the
container empty, the unit OFF and all refrigeration system components
above -5 C (23 F). The R-134a compressor must not have been operated
within the past 30 minutes and there must not be frost on the plate-type
R-134a / R-23 heat exchanger tubing.
Before attempting to add R23 refrigerant with loaded container
check for good cooling capacity by verifying if Suction discharge
pressure is in line with specification.
Connect a refrigerant hose to a R-23 refrigerant tank.
Connect the refrigerant hose to the suction line service port.
Be sure to purge the air from the refrigerant hose.
Mid-seat the suction service valve.
Set the R-23 refrigerant tank for gas charging. Open the refrigerant
tank hand valve.
Observe both the suction and discharge pressures on the unit
gauges. When the unit pressure reaches 1700 kPa, 17 bar, 247 psig,
close the hand valve on the refrigerant tank. With the unit OFF, the
suction and discharge readings should be equal.
The R-23 refrigerant
pressure in the unit during charging with the unit OFF will vary with
the ambient temperature:
Ambient Temperature
R-23 System Pressure
O
°C (32 °F)
1600 kPa,
16 bar, 232 psig
20
°C (68 °F)
1700 kPa,
17 bar, 247 psig
38 °C (100 °F)
1800
kPa, 18 bar, 261 psig
Remove the gauge manifold set.
Cap all service ports and valve stems.
14.22.4: Charging Procedure for Partially Charged Units on Loaded Containers
R-23
Note R-23 refrigerant should be added to an operating unit on a loaded
container only if the unit is unable to maintain a -55 C to -70 C
(-62 F to -94 F) load temperature. The risk of overcharging the system
with R-23 is too large.
Connect a refrigerant hose to a R-23 refrigerant tank.
Connect the refrigerant hose to the receiver tank service fitting.
Be sure to purge the air from the hose.
Set the R-23 refrigerant tank for gas charging. Open the refrigerant
tank hand valve.
Observe the bottom receiver tank sight glass. When refrigerant
is visible in the bottom of the lower sight glass, close the hand
valve on the refrigerant tank.
Note Immediately stop adding refrigerant
when refrigerant is visible in the bottom of the lower sight glass.
Under normal operating conditions, R-23 refrigerant will rarely be
visible in the lower sight glass on a fully charged system.
Remove the refrigerant hose from the receiver tank
Cap the receiver tank service port.
Check and correct the refrigerant charge level after the cargo
has been unloaded and the unit is OFF.
14.23: Compressor Replacement
Removal
Close the suction service valve and pump down the compressor:
R-134a Compressor: Pump down the compressor to -35 kPa, -0.35
bar, 10 in. vacuum.
R-23 Compressor: Pump down the compressor to 0 to 21 kPa, 0.0
to 0.2 bar, 0 to 3 psig.
Caution
Equipment Damage
Do NOT allow the R-23 scroll compressor to operate for
more than 10-20 seconds.
Break the vacuum with nitrogen between 10 and 20 kPa, 0.10
and 0.20 bar, 1 and 3 psig.
Note If the compressor
does not operate, or the compressor is unable to pump the low side
down, the refrigerant charge must be reclaimed before service can
be performed on the refrigeration system.
Front seat the discharge valve.
Caution
Equipment Damage
Any time the discharge valve is front seated, disconnect
the unit power source to prevent accidental compressor start-up.
Remove discharge service valve and suction service valve from
the compressor.
Disconnect the wire connector for the high pressure cutout
switch.
Remove the three-phase electric power connection.
Remove the compressor mounting tray bolts and nuts.
Slide the compressor from the unit.
Keep the compressor ports covered to prevent dust, dirt, etc.,
from falling into the compressor.
Note When the compressor
is removed from the unit, oil level should be noted or the oil removed
from the compressor should be measured so that the same amount of
oil can be added before placing the new compressor or repaired compressor
in the unit.
Installation
Slide the compressor into the unit. Install mounting bolts,
washers and nuts, and tighten.
Bolt the discharge valve to the compressor with a new gasket
lightly coated with compressor oil. Bolt the suction service valve
to the compressor using a new O-ring coated with compressor oil.
Apply refrigerant locktite to the threads of the high pressure
cutout switch. Install the switch and connect the wire connectors.
Connect three-phase electric power to the compressor.
Pressurize the compressor with refrigerant gas:
R-134 compressor with R-134a refrigerant.
R-23 compressor with R-23 refrigerant.
Caution
Equipment Damage
Be sure to add the correct refrigerant to the compressor.
Check for refrigerant leaks around the compressor assembly
and gasket connections.
If no leaks are found, recover the refrigerant used for the
leak test (see “Refrigerant Recovery” in this chapter). Because this
refrigerant gas will contain some air, place it in a contaminated
refrigerant bottle to be reclaimed later.
After all pressure is removed from the compressor, connection
the evacuation equipment.
Evacuate the compressor (see “Evacuation and Cleanup of the
Refrigeration System” in this chapter).
Back seat the discharge service valve and open the suction
service valve fully.
Operate the unit at least thirty minutes and then inspect the
oil level in the compressor. Add or remove oil if necessary.
Caution
Equipment Damage
Do NOT operate the unit on cooling unless both the R-134a
and the R-23 refrigeration systems contain a partial charge of refrigerant.
Check the refrigerant charge and add refrigerant if needed.
14.24: Condenser Coil Replacement
Removal
Recover the refrigerant charge from the unit.
Remove the condenser fan grille, condenser fan blade and
condenser fan shroud.
Remove condenser coil support brackets from coil.
Unsolder coil inlet and liquid line connections.
Support the coil and unbolt the condenser coil mounting
brackets. Slide coil from the unit.
Installation
Clean the tubes for soldering.
Slide the coil into the unit and install the bolts in
the mounting brackets.
Solder the inlet line and liquid line connections.
Important It is strongly recommended that dry nitrogen be
used to purge the system during any solder operations (Refer to Using Pressurized Nitrogen).
Perform a controller pretrip test to verify system operation.
Check compressor oil level.
R-134a System: Close the liquid line service valve and pump
down the low side. Open the outlet valve slightly to equalize the
pressure between 10 and 20 kPa, 0.10 and 0.20 bar, 1 and 3 psig.
R-23 System: Recover the refrigerant charge from the unit (do
NOT vent refrigerant to the atmosphere).
Place the new dehydrator near the unit for immediate installation.
Remove the filter bracket clamping nuts and bolts.
Do one of the following:
R-134a System: Using two wrenches, “crack” both filter drier
line mountings. Use two wrenches on flare fittings to prevent line
damage. Separate the dehydrator line mountings.
R-23 System: Unsolder filter drier from liquid line.
Note Perform the following four procedures as quickly
as possible to prevent contamination.
Remove the old dehydrator from the line.
Installation
Remove the sealing caps from the new dehydrator.
Do one of the following:
R-134a System: Apply clean compressor oil to dehydrator threads.
Assemble new dehydrator to lines. Finger tighten mounting nuts.
R-23 System: Clean tubes for soldering. Position filter drier
in liquid line. Solder filter drier in liquid line.
Note To prevent incorrect installation of the dehydrator,
the inlet and outlet fittings are different sizes.
Reinstall dehydrator clamping brackets, nut and bolts. Tighten
the bolts.
Do one of the following:
R-134a System:
Tighten the dehydrator inlet line mounting nut. Open the liquid
line service valve on the inlet side of the dehydrator slowly to release
a small amount of refrigerant from the receiver tank to purge the
air through the filter. Then tighten the outlet nut.
Note R-134a — When removing or replacing the o-ring nuts on
the dehydrator, always hold the body of the dehydrator near the flange
fittings to prevent twisting the tubing when the nuts are being loosened
or tightened.
Back seat (open) the liquid line service valve on the inlet
side of the dehydrator.
Note TXV can be accessed through the evaporator access
door.
Perform a low side pump down or reclaim charge depending
on the unit. Release the 2-3 lbs pressure from the low side.
Open the evaporator access panel.
Install plywood or heavy cardboard on top of coil on the
left and right side. This will protect the coil from damage.
Remove the left side motor and fan and position in right
side opening. Do not unwire the motor the harness is long enough.
Remove TXV standoff mount.
Remove the panel to gain access to the TXV element.
Cut the one ty band off the insulation around the element.
Peel back the insulation to expose the clamp holding the element.
Loosen the clamp and remove the element from the tube.
Unsolder the three tubes to the TXV and remove the valve
from the unit.
Prepare the tubes in the unit and on the new TXV for installation.
Solder in the new TXV. Use 15% silver solder 203-364.
Perform a controller pretrip test to verify system operation.
1
TXV Mount
2
Access Panel
3
Element
4
Tube on Suction Line
14.27: Expansion Valve Replacement
Removal
Do one of the following:
R-134a System: Close the liquid line service valve and pump
down the low side. Open the outlet valve slightly to equalize the
pressure between 10 and 20 kPa, 0.10 and 0.20 bar, 1 and 3 psig.
R-23 System: Recover the refrigerant charge from the unit (do
NOT vent refrigerant to the atmosphere).
Remove insulating tape and encamp feeler bulb from the suction
line. Note the position of the feeler bulb on the side of the suction
line.
Remove insulating tape from expansion valve outlet line.
Heat and unsolder the equalizer line from expansion valve.
Heat and unsolder the liquid line inlet and outlet connections
to expansion valve.
Remove expansion valve from unit.
Installation
Clean the liquid lines and equalizer lines for soldering.
Place new expansion valve in position in liquid line.
Solder liquid line inlet and outlet line connections to valve.
Solder equalizer line to expansion valve.
Clean the suction line to a bright polished condition. Install
the feeler bulb of new power head in the feeler bulb clamp on the
suction line. Locate bulb on the suction line in former position.
The feeler bulb must make good contact with the suction line or operation
will be faulty. Cover with insulating tape.
Do one of the following:
R-134a System:
Open the liquid line service valve and pressurize the low side.
Test for leaks (see “Refrigerant Leak Test Procedure” in this chapter).
If no leaks are found, recover the leak test gas (see “Refrigerant
Recovery” in this chapter).
Evacuate the low side (see “Evacuation and Cleanup of the Refrigeration
System” in this chapter).
Cover expansion valve outlet line with insulating tape.
Open the liquid line service valve and place the unit in operation.
Operate the unit and note the suction pressure and container
temperature to see that the expansion valve is properly installed
and that the feeler bulb is properly located.
R-23 System:
Pressurize the system with R-23 and test for leaks (see “Refrigerant
Leak Test Procedure” in this chapter).
If no leaks are found, recover the leak test gas (see “Refrigerant
Recovery” in this chapter).
Evacuate the system (see “Evacuation and Cleanup of the Refrigeration
System” in this chapter).
Cover expansion valve outlet line with insulating tape.
Recharge the unit with R-23 refrigerant and check the compressor
oil level. Add oil if necessary.
Operate the unit and note the suction pressure and container
temperature to see that the expansion valve is properly installed
and that the feeler bulb is properly located.
14.28: Heat Exchanger Replacement
Removal
Recover the refrigerant charge from the both refrigeration
systems (see “Refrigerant Recovery” in this chapter).
Remove the panel that protects the heat exchanger assembly
in the power cord storage compartment.
Heat and unsolder all system inlet and outlet line connections.
Remove the heat exchanger assembly from the unit.
Installation
Clean the tubes for soldering.
Place the heat exchanger assembly in the unit and position
in refrigeration system tubing.
Solder all refrigerant line connections.
Note It is strongly recommended that dry nitrogen be used to purge the
system during any solder operations (see “Using Pressurized Nitrogen”
in this chapter).
Note If pressurizing with nitrogen,
front seat the discharge valve to prevent nitrogen from entering the
refrigerant charge.
Caution
Equipment Damage
Any time the discharge valve is front seated, disconnect
the unit power source to prevent accidental compressor start-up.
Do one of the following:
Pressurize the R-134a system on the low side and check for
leaks
Pressurize the R-23 system on the high side and check for leaks.
If no leaks are found, recover the leak test gas from both
systems (see “Refrigerant Recovery” in this chapter).
Evacuate both systems (see “Evacuation and Cleanup of the Refrigeration
System” in this chapter).
Recharge both refrigerant systems (see “Refrigerant Charge”
in this chapter).
14.29: Receiver Tank Replacement
Removal
Recover the refrigerant charge from the unit (see “Refrigerant
Recovery” in this chapter).
Unsolder the outlet valve on the liquid outlet line.
Unsolder the liquid line inlet connection.
Loosen the mounting nuts and remove the tank.
Remove the outlet valve from the receiver tank.
Installation
Install a new tank in the unit and tighten the mounting bolts.
Solder the inlet line and outlet valve line with high temperature
silver solder (30% silver).
Note It is strongly recommended
that dry nitrogen be used to purge the system during any solder operations
(see “Using Pressurized Nitrogen” in this chapter).
Note If pressurizing with nitrogen, front seat the discharge
valve to prevent nitrogen from entering the refrigerant charge.
Caution
Equipment Damage
Any time the discharge valve is front seated, disconnect
the unit power source to prevent accidental compressor start-up.
Pressurize the refrigeration system and check for leaks (see
“Refrigerant Leak Test Procedure” in this chapter).
Evacuate the system (see “Evacuation and Cleanup of the Refrigeration
System” in this chapter).
Recharge the unit (see “Refrigerant Charge” in this chapter).
14.30: High Pressure Cutout Switch Replacement
Removal
Close the suction service valve and pump down the compressor:
R-134a Compressor: Pump down the compressor to -35 kPa, -0.35
bar, 10 in. vacuum.
R-23 Compressor: Pump down the compressor to 0 to 21 kPa, 0.0
to 0.2 bar, 0 to 3 psig.
Open the suction service valve slightly to equalize the pressure
between 10 and 20 kPa, 0.10 and 0.20 bar, 1 and 3 psig.
Front seat the discharge service valve.
Purge the high pressure from the compressor head through the
service port on the discharge line.
Disconnect the leads from the wire harness and remove the switch
from the compressor discharge manifold (or remove the sensor from
the compressor head).
Installation
Apply a refrigeration locktite (sealant) to the threads of
the switch (or sensor).
Install and tighten the switch (or sensor). Connect the leads
to the wire harness.
Open discharge service valve slightly to pressurize the compressor
head and tube assembly. Check for leaks (see “Refrigerant Leak Test
Procedure” in this chapter). Front seat the discharge service valve.
If no leaks are found, recover the leak test gas (see “Refrigerant
Recovery” in this chapter).
Open the suction service valve and compressor discharge service
valve and place the unit in operation.
14.31: Liquid Line Solenoid Valve Replacement (R-134a System Only)
Removal
Close the liquid line service valve and pump down the low side
to -35 kPa, -0.35 bar, 10 in. vacuum. Break the vacuum with nitrogen
between 10 and 20 kPa, 0.10 and 0.20 bar, 1 and 3 psig.
Turn the unit On-Off switch OFF. Disconnect electrical connections
to liquid line solenoid.
Note In most cases, only
the coil requires replacement. No other repair is possible on the
liquid line solenoid.
Unsolder the liquid line connections from the valve.
Remove the valve from the unit.
Installation
Clean the tubes for soldering.
Place the new valve in position and solder the connections.
Notice
Equipment Damage
Use a heat sink, P/N 204-584, or wrap the vibrasorber
with wet rags to prevent damaging the vibrasorber.
Release a small amount of refrigerant from the receiver tank
to pressurize the liquid line. Check for leaks (see “Refrigerant Leak
Test Procedure” in the Refrigeration Maintenance chapter of this manual).
If no leaks are found, recover the leak test gas (see “Refrigerant
Recovery” in the Refrigeration Maintenance chapter of this manual).
Evacuate the low side (see “Evacuation and Cleanup of the Refrigeration
System” in the Refrigeration Maintenance chapter of this manual).
Reconnect the electrical wires to the valve.
Open the liquid line service valve and place the unit in operation.
Check the refrigerant charge and add refrigerant as required.
Chapter 15: Diagnostics
15.1: Introduction
This section includes the following:
Controller Diagnostics
Mechanical Diagnostics
Refrigeration Diagnostics
Status Messages and Controller Actions
Alarm Codes and Corrective Actions
The tables shown will help identify and fix unit problems.
15.2: MP4000 Diagnostics
The MP4000 can be a very helpful diagnostic tool. The following
menu areas of the MP4000 controller will help you diagnose problems
occurring with the unit.
Alarms/Warnings Menu: This menu displays the code conditions.
Alarm/Warning codes are recorded in the controller memory to simplify
unit diagnosis 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 list to view the alarm.
Brief PTI Test: The MP4000 controller contains a special
Brief PTI pretrip test that automatically checks unit refrigeration
capacity, heating capacity, temperature control, and individual components
including the controller display, solid state, contactor, fans, protection
devices and sensors. The test includes measurement of component power
consumption and compares test results to expected values. The test
takes about 25-30 minutes to complete, depending on the container
and ambient temperature. Refer to the Brief PTI Test in the Operating
Instructions Section.
Full PTI Test: The MP4000 controller contains a special
Full PTI pretrip test that automatically checks unit refrigeration
capacity, heating capacity, temperature control, and individual components
including the controller display, solid state, contactor, fans, protection
devices and sensors. The test includes measurement of component power
consumption and compares test results to expected values. The test
takes up to 2 to 12 hours to complete, depending on the container
and ambient temperature. Refer to the Full PTI Test Menu in the Operating
Instructions Section.
Functions Test: The MP4000 controller contains a special
function test that automatically tests individual components including
the controller display, sensors, condenser fan, evaporator fan, compressors,
etc. The test includes measurement of component power consumption
and compares test results to expected values. Refer to the Functions
Test Menu in the Operating Instructions Section.
Manual Functions Test: This menu allows technicians to perform
specific diagnostic tests on individual components or turn several
components on at the same time to perform a system test. Refer to
the Manual Functions Test Menu in the Operating Instructions Section.
Data: This menu displays general unit operating information
including sensor temperatures, unit electrical data, etc. Refer to
the Data Menu in the Operating Instructions Section.
15.3: Mechanical Diagnostics
Condition
Possible Cause
Remedy
Compressor does not operate - no amperage draw.
Controller on; unit start sequence still timing.
Wait up to two minutes for compressor start-up.
No power to unit (condenser and evaporator fans do not operate).
Locate fault and repair: power source, power plug, CB1 main
circuit breaker, motor contactors, motor terminals, motor.
Open in 29 Vac control circuit.
Check fuses and On/Off switch. Replace or repair as required.
Container temperature does not demand compressor operation.
Adjust controller setpoint.
Compressor contactor inoperative.
Replace compressor contactor.
No output signal from controller.
Diagnose and replace power module or controller.
Unit on defrost.
Turn Unit On/Off switch Off and then On again.
Detective high pressure or low pressure cutout switch.
Replace defective switch.
High condenser head pressure causing high pressure cutout.
Check refrigeration system and correct fault.
Defective compressor.
Replace compressor.
Controller shut unit down on Compressor Over Temperature.
Let compressor cool and controller will reset automatically.
Check vapor injection valve and compressor temperature sensor.
Compressor motor internal thermal overload protection open.
If compressor contactor is energized, wait 60 minutes for protector
to cool and reset.
Compressor does not operate - excessive amperage
draw or intermittent cycling on overload.
Rotating scroll stuck. Piston Stuck.
Replace compressor.
Seized or frozen compressor bearings.
Replace compressor.
Improperly wired.
Check/correct wiring against wiring diagram.
Low line voltage.
Check line voltage - determine location of voltage drop.
High head pressure
Eliminate cause of high head pressure.
Contacts in compressor contactor not closing completely.
Check by operating manually. Repair or replace.
Open circuit in compressor motor winding.
Check motor stator connections. Check stator winding for continuity.
If open, replace compressor.
Defective compressor motor internal thermal overload protector.
Replace thermal overload protector or compressor.
Refrigerant overcharge or high side restriction causing cycling
on high pressure cutout.
Check for restricted filter drier, in-line filter or high side;
or refrigerant overcharge.
Inefficient condenser operation causing cycling on high pressure
cutout.
Check condenser airflow, condenser fan motor, fan blade, condenser
grille, condenser coil temperature sensor, water pressure switch (option),
water flow rate (option) and water-cooled condenser-receiver tank
(option).
R 23 compressor not running
Auxiliary contact on R134a open
Check curcuit, replace contact.
Compressor contactor burned out.
Low line voltage.
Increase line voltage to at least 90 percent of compressor
motor rating.
Excessive line voltage.
Reduce line voltage to at least 110 percent of compressor motor
rating.
Short cycling.
Eliminate cause of short cycling.
Unit short cycles.
Controller out of calibration
Check controller software program version; load new software
in controller and recheck unit performance, replace controller
Refrigerant overcharge causing cycling on high pressure cutout.
Purge system.
Inefficient condenser operation causing cycling on high pressure
cutout.
Check condenser airflow, condenser fan motor, condenser fan
grille, condenser fan pressure switch, water pressure switch (option),
water flow rate (option) and water-cooled condenser-receiver tank
(option).
Noisy compressor
Insufficient compressor oil
Check compressor oil level on R-134a and R-23 system. Add oil
to proper level.
Loose mounting bolts.
Tighten mounting bolts.
Oil slugging or refrigerant flooding back.
Perform controller pretrip test to check refrigerant charge.
Check expansion valve adjustment. Check compressor for compressor
oil.
Scroll rotating backwards.
Check phase correction system and check unit wiring.
Worn fan motor bearings
Replace bearings or motor.
Defective compressor.
Repair or replace compressor.
Condenser fan motor does not operate.
Unit in Heat or Defrost.
Check indicator. If unit is in Heat or Defrost, unit operation
is normal (no remedy required).
Loose line connection.
Tighten connections.
Open motor internal thermal overload protector.
Check for seized bearings or defective thermal overload protector.
Repair or replace as necessary.
Defective motor.
Replace motor.
Detective condenser fan contactor.
Replace defective contactor
No condenser fan output signal from controller.
Diagnose and replace condenser fan relay, power module or controller.
Evaporator fan motor(s) does not operate.
Unit on defrost.
Check operating mode indicator LEDs.
Loose line connection.
Tighten connections.
Open motor internal thermal overload protector.
Check for seized bearings or defective thermal overload protector.
Repair or replace as necessary.
Defective motor.
Replace motor.
Defective low speed evaporator fan contactor
Replace defective contactor
No low or high speed evaporator fan output signal from controller
output module.
Diagnose and replace output module or controller.
15.4: Refrigeration Diagnostics
Condition
Possible Cause
Remedy
R-134a or R-23 System Compressor operating in
a vacuum (unit not cooling)
Shortage of refrigerant
Repair leak and recharge
Compressor motor contacts frozen (R-134a compressor only)
Clean points or replace contactor
Defective liquid line solenoid valve
Repair or replace liquid line solenoid valve
Compressor inefficient
Repair or replace liquid line solenoid valve
(R-134a compressor only)
Check valve reeds and pistons
Partial obstruction in low side or dehydrator
Locate obstruction and repair
Iced or plugged evaporator coil
Defrost or clean evaporator coil
Expansion valve partially closed by ice, dirt or wax
Replace expansion valve
Expansion valve power element lost its charge
Replace expansion valve
Defective container insulation
Correct or replace container insulation
Poor fitting container doors
Repair or replace doors
Partial obstruction in high side
Locate obstruction and repair
Suction pressure gauge out of calibration
Replace service gauge
Expansion valve feeler bulb improperly mounted, poorly insulated
or making poor contact
Diagnose main relay board and controller. Replace defective
component
Shortage of refrigerant.
Repair leak and recharge.
Overcharge of refrigerant.
Purge system.
Air in refrigeration system.
Evacuate and recharge.
Vapor injection valve open.
Check vapor injection valve circuit and compressor discharge
temperature sensor.
Too much compressor oil in system.
Remove compressor oil from compressor.
Iced or dirty evaporator coil.
Defrost or clean evaporator coil.
Restricted lines on high side.
Clear restriction.
Plugged filter drier/in-line filter.
Change filter drier.
Compressor inefficient (R-134a system only)
Perform compressor efficiency test. Check valve reeds and pistons
Condenser coil dirty or airflow restricted.
Clean condenser coil, clear restriction, or repair or replace
fan motor or condenser fan blade.
Expansion valve power element lost its charge.
Replace power element.
Expansion valve feeler bulb improperly mounted, poorly insulated
or making poor contact.
Correct feeler bulb installation.
Head pressure too low.
Note This
unit has a digital capacity control system. Suction and discharge
pressures may drop below expected normal readings when the unit is
in Modulation Cool (control temperature within 10 C (18 F) of setpoint
or in Power Limit mode).
Shortage of refrigerant.
Repair leak and recharge.
Low ambient air temperature. (R-134a system only)
No remedy.
Service gauge out of calibration.
Replace gauge.
Compressor suction or discharge valve inefficient (R-134a system
only)
Replace suction reeds and gaskets. Clean valve plate. If defective/restricted
then replace.
Apply hot wet cloth to expansion valve. Moisture indicated
by increase in suction pressure. Replace filter drier.
High suction pressure.
Overcharge of refrigerant.
Purge system.
Expansion valve open too much.
Adjust or replace valve.
Defective controller or power module.
Diagnose power module and controller. Replace defective component.
Service gauge out of calibration.
Adjust or replace service gauge.
Low suction pressure.
Note This unit
has a digital capacity control system. Suction and discharge pressures
may drop below expected normal readings when the unit is in Modulation
Cool (control temperature within 10 C (18 F) of setpoint or in Power
Limit mode).
Shortage of refrigerant.
Repair leak and recharge.
Low ambient air temperature. (R-134a system only)
No remedy.
Iced or dirty evaporator coil. (R-134a system only)
Defrost or clean evaporator coil.
Restricted lines.
Locate and clear restriction.
Plugged filter drier.
Replace filter drier.
Expansion valve closed too much.
Adjust or replace valve.
Expansion valve feeler bulb improperly mounted, poorly insulated
or making poor contact.
Correct feeler bulb installation.
Evaporator fans off.
Check evaporator fan motors and control circuit and correct
fault.
Defective controller or power module.
Diagnose power module and controller. Replace defective component.
Service gauge out of calibration.
Adjust or replace gauge.
15.5: Status Messages and Controller Actions
The controller displays status messages (in Alarms Menu) on the
display for several general faults. More than one status message may
appear at a time. Press the F2 or F3 key to scroll through message
displays.
Status Message
Description
Controller Action/Corrective Action
8
High Pressure Cut Out - Please Wait
When:
Unit stops due to high pressure cutout and the condensing temperature
regulation has activated the condenser fan.
Indicates:
Poor cooling of the refrigerant.
Controller auto clears message 10 minutes after compressor
start-up.
Check for high ambient temperature.
Check condenser fan rotation.
Check for blocked condenser coil.
13
Evaporator High Temperature - Check Heater System
When:
If the state “Hot Evaporator Section” is active and the control
calls for heat, the message is set.
The state “Hot Evaporator Section” is defined either by:
RA probe error and Defrost probe error.
RA, SA, or defrost probe is above 50C.
The message is held by a 60 second timer after the conditions
clear.
Indicates:
Evaporator section temperatures are high.
Supply Air, Return Air, and Defrost indicates high temperature.
Enter Manual Function Test menu and test (operate) heating
element. Check volts and amps to determine problem.
Use DATA menu to evaluate evaporator section sensors.
Use PROBE TEST to evaluate if evaporator sensors are reading
correctly.
14
R134a Compr Fault - Check Feedback
The FB signal does not correspond with the activation signal
of the R134a compressor contactor.
The activation signal may be interrupted due to HPCO (R134a).
Check the R134a discharge temperature and the HPCO switch.
Check wiring to the R134a contactor and the feedback wiring
from the contactor.
20
Low Voltage On Line - Unit Stopped
When:
Low voltage observed, voltage has been below 330 VAC and has
not risen above 340 VAC yet.
After 30 minutes this message will set the low voltage alarm.
Indicates:
Poor quality of power source.
Enter Manual Function Test menu and test (operate) components
to load the power source.
Check volts and amps to help determine the problem.
21
Current Too High - Check Compressor and Fans
When:
The component current draw exceeds expected. 50% above expected
amps for four minutes.
Indicates:
Digital Control valve malfunction.
Compressor, evaporator fans motor, condenser fan motor or heater
current too high.
Defective volt or amp meter on power module.
Power supply voltage too low.
Enter Manual Function Test menu and test (operate) each component.
Check volts and amps to determine which component has high
amp draw.
Check power supply volts.
Check volt and ampere meter.
When the message is set, the current power consumption is logged
in the event log.
22
Current Too Low - Check Compressor and Fans
When:
The component current draw exceeds expected. 50% below expected
for four minutes.
Indicates:
Defective or open high pressure cutout switch.
Defective or open motor internal high temperature protection
switch.
Unit on water-cooled condensing with no water flow.
Defective condenser coil sensor or sensor location.
Check Display for High Pressure Cutout message.
Enter Manual Function Test menu and test (operate) each component.
Check volts and amps to determine which component has low amp
draw.
Check volt and ampere meter.
23
Supply Temperature Too High - Check Sensors
When:
During Chill or Frozen Mode: Supply air temperature is too
high compared to return air temperature under operating conditions.
The state will by time request defrost or/and probe test.
Indicates:
Low refrigerant charge
Incorrect connection or location of supply or return air sensor
Air leakage at supply air sensor cable
Ice or frost on evaporator coil
Incorrect evaporator fan operation
Use DATA menu to inspect readings.
Enter Manual Function Test menu and operate evaporator fan
at high speed to evaluate probe spread.
24
Supply Temperature Too Low - Check Evaporator Coil
When:
During Chill or Frozen Mode: Supply air temperature is too
low compared to return air temperature under operating conditions.
The state will by time request extended defrost, defrost or/and probe
test.
Indicates:
Incorrect connection or location of supply or return air sensor.
Air leakage at supply air sensor cable.
Incorrect evaporator fan operation.
Use DATA menu to inspect readings.
Enter Manual Function Test menu and operate evaporator fan
at high speed to evaluate probe spread.
25
Evaporator Temperature Too High - Check Evaporator Sensor
When:
During Chill or Frozen Mode: Evaporator coil temperature is
too high compared to return air temperature under operating conditions.
Indicates:
Probe spread, misplaced probes.
Use DATA menu to inspect readings.
Enter Manual Function Test menu and operate evaporator fan
at high speed to evaluate probe spread.
26
Evaporator Coil Temperature Too Low - Check Evaporator Sensor
When:
During Chill or Frozen Mode: Evaporator coil temperature is
too low compared to return air temperature under operating conditions.
The state will by time request extended defrost, defrost or/and probe
test.
Indicates:
Ice on the evaporator coil, need for defrost.
Probe error.
Use DATA menu to inspect readings.
Enter Manual Function Test menu and operate evaporator fan
at high speed to evaluate probe spread.
30
High Pressure Cut Out - Please Wait
When:
Unit stop due to high pressure cutout signal from the HPCO
switch.
The message will clear when the input signal indicates normal
condition.
Indicates:
Poor or missing cooling of the refrigerant.
Action:
The state will stop / remove the compressor run signal.
The state will overrule regulation of the condenser fan and
starts the fan.
This state will activate and hold message 31 as long as the
input signal indicates HPCO.
Controller clears message on compressor start-up.
No direct alarm action based on this situation.
If the state continues:
Check for airflow through the condenser coil, air flow might
be blocked.
Check for condenser fan rotation and direction, must suction
air through the coil and blow air out through the grill.
31
HPCO Timer Hold - Please Wait
When:
The message is timer based to protect the compressor from starting
at high pressure. The message will go away when the holding time after
HPCO gets normal has run out.
Indicates:
HPCO present or has just been present.
Action:
The state will stop / remove the compressor run signal.
The state will overrule regulation of the condenser fan and
starts the fan.
This state will activate and hold message 31 as long as the
input signal indicates HPCO.
Controller clears message on compressor start-up.
No direct alarm action based on this situation.
If the state continues:
Check for airflow through the condenser coil, air flow might
be blocked.
Check for condenser fan rotation and direction, must suction
air through the coil and blow air out through the grill.
32
Low Pressure Cut Out - Please Wait
When:
Unit stops due to low pressure cutout signal from the HPCO
switch or the suction pressure reading (if present).
If suction pressure sensor is mounted the signal level for
LPCO is below -0.27 bar to activate LPCO state and above +0.38 bar
to clear the state.
The message will clear when the input signal indicates normal
condition.
Indicates:
Possible causes include low refrigerant charge, defective low
pressure cutout switch or open circuit, block TXV or suction line
restriction etc.
Action:
The state will stop / remove the compressor run signal.
This state will activate and hold status message 33 as long
as the input signal indicates LPCO.
Controller activates Alarm Code 31 after five minutes.
Controller clears message after compressor start-up.
33
LPCO Timer Hold - Please Wait
When:
The message is timer based to protect the compressor from starting
before the pressure has risen from low pressure. The message will
clear when the holding time after LPCO gets normal has run out.
Indicates:
LPCO present or has just been present.
Controller clears message on compressor start-up.
No direct alarm action based on this situation.
34
Compressor Too High Temperature Timer – Please Wait
When:
If the compressor temperature gets above 148C, the message
is set.
The message will clear when the compressor temperature has
been below 137C for 60 seconds.
The message will (also) clear when the compressor temperature
gets below 132C.
Indicates:
Compressor stops because discharge temperature is above 148
C (300 F). Message remains in display until discharge temperature
decreases to normal.
Action:
The state will stop / remove the compressor run signal.
The state will overrule regulation of the condenser fan and
starts the fan.
The message clears itself when the compressor temperature is
normal.
35
Compressor High Temperature
When:
If the compressor temperature gets above 138C, the message
is set.
The message will clear when the compressor temperature gets
below 132C.
Action:
Compressor running at high discharge temperature results in
economizer/vapor injection will be active until discharge temperature
decreases to normal.
In temperature log the state will be represented by the char
‘c’ (small c).
The message clears itself when the compressor temperature is
normal.
38
High Voltage On Line
When:
High voltage observed, voltage has been above 515 Vac. The
message will clear when voltage gets below 500 Vac.
Indicates:
When the message is set, a power line value log is made in
the event log, i.e., “CURR: 0.2A PH1: 0.2A PH2: 0.2A PH3: 0.3A VOLT:
529V FREQ: 63Hz “.
Enter Manual Function Test menu and test (operate) components
to load the power source.
Check volts and amps to help determine the problem.
Possible cause for the problem is a wild running generator
set.
39
Battery Charger/Heater - Check Battery
When:
The data logger battery charger reports battery charging suspended
due to low temperature and the battery internal heater has been on
for two hours, the message is set.
Indicates:
Fault in the data logger battery circuit.
Check for battery position, placement, and wiring.
40
12V Sensor PSU Problem
When:
If the sensor supply (+ 12 Vdc) for the humidity or pressure
transducers is not able of supplying the 12 Vdc.
Indicates:
Too high load on the sensor supply.
Check humidity sensor or transducer.
41
Power Module Heat Exchanger High Temperature
When:
If the power module heat exchanger temperature gets above 95C
the heating element is bypassed and not energized. Since activating
the heating element is the far most heat applying solid state switch,
activating is bypassed to reduce temperature.
Indicates:
High temperature surrounding the control box.
Poor cooling to the back side of the control box.
Check for blocked air flow to the back side of the control
box.
Ambient temperature may be high.
45
Wall Clock Failure
When:
Occurs if the wall clock has been stopped or restarted as a
result of insufficiently voltage.
The wall clock battery must be replaced.
46
Battery Needs Charging
When:
Low battery voltage observed. The battery voltage has been
below 3.7V. The voltage must be above 2.5V to trigger the message.
Leave the unit on (could be standby mode) for four hours to
charge the battery.
48
R134a Comp Too High Temp Timer - Please Wait
When:
If the R134a compressor temperature gets above 148 C (300 F)
the warning is set.
The warning will go away when the compressor temperature has
been below 137C for 60 seconds.
Indicates:
Compressor stops because discharge temperature is too high.
Message remains in display until discharge temperature decreases
to normal.
Action
The state will stop / remove the compressor run signal.
The state will overrule regulation of the condenser fan and
starts the fan.
The warning clears itself when the compressor temperature gets
normal.
15.6: Alarm Codes and Corrective Actions
Note Sensors used with the MP4000 controller do not
require calibration. Check sensor resistance with an ohmmeter.
Shutdown Alarm (Level 1 Alarm): Alarm light on display flashes
and unit stops. Correct alarm condition and acknowledge alarm before
restarting.
Check Alarm (Level 2 Alarm): Alarm light on display flashes until
alarm is acknowledged.
Code
Description
Corrective Action
00
Supply Air Temperature Sensor Open Circuit
When the sensor circuit resistance is higher than 1300Ω.
Indicates:
Open circuit.
Defective or wrong sensor.
Defective wiring.
Defective controller.
Check for damaged sensor wires.
Check sensor connections at controller.
The sensor is a pt1000 – 2 wire sensor, connected to the MP-4000
at connector J3 pin 1 and 2. CM-4000 upper left connector J3, 17 pin
wide, pin number 1 is the right pin, seen at the backside of the controller.
The 2 sensor wires can be switched without affecting the measurement.
Disconnect the sensor, use an Ohm (Ω) measuring device, measure
the electrical resistance between the two sensor wires.
The sensor can’t be examined without disconnecting it.
The electrical resistance towards chassis must be above meg
ohm (MΩ) range.
The sensor is a pt1000 – positive temperature coefficient,
which means that the electrical resistance of the sensor increases
with temperature.
The sensor is defined to be 1000Ω@ 0°C.
Normal condition measuring with disconnected sensor is 960Ω@-10°C,
1000Ω@0°C, 1039Ω@+10°C, 1058Ω@+15°C, 1078Ω@+20°C.
The valid measuring limit for this pt1000 sensor is -100°C
(602Ω) +75°C (approx 1300Ω).
01
Supply Air Temperature Sensor Short Circuit
When the sensor circuit resistance is lower than 602Ω.
Indicates:
Short circuit.
Defective or wrong sensor.
Defective wiring.
Defective controller.
Check for damaged sensor wires.
Check sensor connections at controller.
The sensor is a pt1000 – 2 wire sensor, connected to the MP-4000
at connector J3 pin 1 and 2. CM-4000 upper left connector J3, 17 pin
wide, pin number 1 is the right pin, seen at the backside of the controller.
The 2 sensor wires can be switched without affecting the measurement.
Disconnect the sensor, use an Ohm (Ω) measuring device, measure
the electrical resistance between the two sensor wires.
The sensor can’t be examined without disconnecting it.
The electrical resistance towards chassis must be above meg
ohm (MΩ) range.
The sensor is a pt1000 – positive temperature coefficient,
which means that the electrical resistance of the sensor increases
with temperature.
The sensor is defined to be 1000Ω@ 0°C.
Normal condition measuring with disconnected sensor is 960Ω@-10°C,
1000Ω@0°C, 1039Ω@+10°C, 1058Ω@+15°C, 1078Ω@+20°C.
The valid measuring limit for this pt1000 sensor is -100°C
(602Ω) +75°C (approx 1300Ω).
02
Return Air Temperature Sensor Open Circuit
When the sensor circuit resistance is higher than 1300Ω.
Indicates:
Open circuit.
Defective or wrong sensor.
Defective wiring.
Defective controller.
Check for damaged sensor wires.
Check sensor connections at controller.
The sensor is a pt1000 – 2 wire sensor, connected to the MP-4000
at connector J3 pin 3 and 4. CM-4000 upper left connector J3, 17 pin
wide, pin number 1 is the right pin, seen at the backside of the controller.
The 2 sensor wires can be switched without affecting the measurement.
Disconnect the sensor, use an Ohm (Ω) measuring device, measure
the electrical resistance between the two sensor wires.
The sensor can’t be examined without disconnecting it.
The electrical resistance towards chassis must be above meg
ohm (MΩ) range.
The sensor is a pt1000 – positive temperature coefficient,
which means that the electrical resistance of the sensor increases
with temperature.
The sensor is defined to be 1000Ω@ 0°C.
Normal condition measuring with disconnected sensor is 960Ω@-10°C,
1000Ω@0°C, 1039Ω@+10°C, 1058Ω@+15°C, 1078Ω@+20°C.
The valid measuring limit for this pt1000 sensor is -100°C
(602Ω) +75°C (approx 1300Ω).
03
Return Air Temperature Sensor Short Circuit
When the sensor circuit resistance is lower than 602Ω.
Indicates:
Short circuit.
Defective or wrong sensor.
Defective wiring.
Defective controller.
Check for damaged sensor wires.
Check sensor connections at controller.
The sensor is a pt1000 – 2 wire sensor, connected to the MP-4000
at connector J3 pin 3 and 4. CM-4000 upper left connector J3, 17 pin
wide, pin number 1 is the right pin, seen at the backside of the controller.
The 2 sensor wires can be switched without affecting the measurement.
Disconnect the sensor, use an Ohm (Ω) measuring device, measure
the electrical resistance between the two sensor wires.
The sensor can’t be examined without disconnecting it.
The electrical resistance towards chassis must be above meg
ohm (MΩ) range.
The sensor is a pt1000 – positive temperature coefficient,
which means that the electrical resistance of the sensor increases
with temperature.
The sensor is defined to be 1000Ω@ 0°C.
Normal condition measuring with disconnected sensor is 960Ω@-10°C,
1000Ω@0°C, 1039Ω@+10°C, 1058Ω@+15°C, 1078Ω@+20°C.
The valid measuring limit for this pt1000 sensor is -100°C
(602Ω) +75°C (approx 1300Ω).
04
Evaporator Coil Temperature Sensor Open Circuit
When the sensor circuit resistance is higher than 1300Ω.
Indicates:
Open circuit.
Defective or wrong sensor.
Defective wiring.
Defective controller.
Check for damaged sensor wires.
Check sensor connections at controller.
The sensor is a pt1000 – 2 wire sensor, connected to the MP-4000
at connector J3 pin 5 and 6. CM-4000 upper left connector J3, 17 pin
wide, pin number 1 is the right pin, seen at the backside of the controller.
The 2 sensor wires can be switched without affecting the measurement.
Disconnect the sensor, use an Ohm (Ω) measuring device, measure
the electrical resistance between the two sensor wires.
The sensor can’t be examined without disconnecting it.
The electrical resistance towards chassis must be above meg
ohm (MΩ) range.
The sensor is a pt1000 – positive temperature coefficient,
which means that the electrical resistance of the sensor increases
with temperature.
The sensor is defined to be 1000Ω@ 0°C.
Normal condition measuring with disconnected sensor is 960Ω@-10°C,
1000Ω@0°C, 1039Ω@+10°C, 1058Ω@+15°C, 1078Ω@+20°C.
The valid measuring limit for this pt1000 sensor is -100°C
(602Ω) +75°C (approx 1300Ω).
05
Evaporator Coil Temperature Sensor Short Circuit
When the sensor circuit resistance is lower than 602Ω.
Indicates:
Short circuit.
Defective or wrong sensor.
Defective wiring.
Defective controller.
Check for damaged sensor wires.
Check sensor connections at controller.
The sensor is a pt1000 – 2 wire sensor, connected to the MP-4000
at connector J3 pin 5 and 6. CM-4000 upper left connector J3, 17 pin
wide, pin number 1 is the right pin, seen at the backside of the controller.
The 2 sensor wires can be switched without affecting the measurement.
Disconnect the sensor, use an Ohm (Ω) measuring device, measure
the electrical resistance between the two sensor wires.
The sensor can’t be examined without disconnecting it.
The electrical resistance towards chassis must be above meg
ohm (MΩ) range.
The sensor is a pt1000 – positive temperature coefficient,
which means that the electrical resistance of the sensor increases
with temperature.
The sensor is defined to be 1000Ω@ 0°C.
Normal condition measuring with disconnected sensor is 960Ω@-10°C,
1000Ω@0°C, 1039Ω@+10°C, 1058Ω@+15°C, 1078Ω@+20°C.
The valid measuring limit for this pt1000 sensor is -100°C
(602Ω) +75°C (approx 1300Ω).
06
Compressor Current Too High
Occurs during pretrip (PTI) or function test only.
During compressor test, if Compressor power consumption is
25% above expected current draw or compressor phase current level
differs 33% or more.
If both alarm #6 and #7 is active this indicates too high phase
difference.
Expected compressor current is a function of the surrounding
conditions.
Indicates:
Defective Digital Control valve.
Defective compressor.
Defective volt or amp meter on power module.
Inaccurate ambient, condenser or evaporator temperature measurement.
Excessive condenser pressure due to air or wrong refrigerant
in system, or refrigerant over charge.
Check evaporator and condenser sensor temperatures for correct
value (± 5 C [± 9 F]) by viewing Data menu.
To determine the current draw measurement, enter Manual Function
Test menu. Start and check current draw of the following components
separately and together: compressor, compressor full loaded, condenser
fan and evaporator fan (high or low).
Check power supply volts on all three phases.
07
Compressor Current Too Low
Occurs during pretrip (PTI) or function test only.
During compressor test, if Compressor power consumption is
25% below expected current draw or compressor phase current level
differs 33% or more.
If both alarm #6 and #7 is active this indicates too high phase
difference.
Expected compressor current is a function of the surrounding
conditions.
Indicates:
Defective or open high pressure cutout switch.
Defective or open low pressure cutout switch or transmitter
if mounted.
Defective compressor relay.
Defective volt or amp meter on power module.
Low refrigerant charge.
Defective compressor.
Defective volt or amp meter on power module.
Inaccurate condenser or evaporator temperature measurement.
Defective or open compressor motor internal over temperature
protection switch.
Check evaporator, condenser sensor temperatures for correct
value (± 5 °C [± 9 F]) by viewing Data menu.
To determine the current draw measurement, enter Manual Function
Test menu. Start and check current draw of the following components
separately and together: compressor, compressor full loaded, condenser
fan and evaporator fan (high or low).
Check discharge and suction pressure gauge readings.
Check power supply volts on all three phases.
10
Heater Current Too High
Occurs during pretrip (PTI) or function test only.
Heater power consumption is 25% above expected current draw
or phase current level differs 33% or more.
If both alarm #10 and #11 is active this indicates too high
phase difference.
Expected heater current is a function of the heating element
resistance and the power supply voltage.
The unit may be equipped with extended heating capability.
Normal heating element 4kw@460VAC - above approximately 6,3
Amp / 5,3 Amp.
Extended heating element 6kw@460VAC - above approximately 9,4Amp
/ 8,1Amp.
Indicates:
Enter Manual Function Test and turn heaters on. Check current
draw on each phase. Evaluate current draw in relation to expected
values.
Enter configuration menu and check the heating element setting.
Check heater resistance.
The electrical resistance towards chassis must be above meg
ohm (MΩ) range.
Normal heating element 4kw@460VAC
expects 5,0Amp@460VAC.
expects 4,3Amp@400VAC.
expected resistance 99Ω on each leg.
Extended heating element 6kw@460VAC
expects 7,5Amp@460VAC.
expects 6,5Amp@400VAC.
expected resistance 66Ω on each leg.
11
Heater Current Too Low
Occurs during pretrip (PTI) or function test only.
Heater power consumption is 25% below expected current draw
or phase current level differs 33% or more.
If both alarm #10 and #11 is active this indicates too high
phase difference.
Expected heater current is a function of the heating element
resistance and the power supply voltage.
The unit+ may be equipped with extended heating capability.
Normal heating element 4kw@460VAC:
below approximately 3,7Amp / 3,2Amp.
Extended heating element 6kw@460VAC:
below approximately 5,6Amp / 4,8Amp.
Indicates:
Incorrect heaters or heater connections.
Defective heating element.
Defective volt or amp meter on power module.
Enter Manual Function Test and turn heaters on. Check current
draw on each phase. Evaluate current draw in relation to expected
values.
Enter configuration menu and check the heating element setting.
Check heater resistance.
The electrical resistance towards chassis must be above meg
ohm (MΩ) range.
Normal heating element 4kw@460VAC:
expects 5,0Amp@460VAC
expects 4,3Amp@400VAC
expected resistance 99Ω on each leg.
Extended heating element 6kw@460VAC:
expects 7,5Amp@460VAC
expects 6,5Amp@400VAC
expected resistance 66Ω on each leg.
12
Evaporator Fan High Speed Current Too High
Occurs during pretrip (PTI) or function test only.
Fan power consumption is 33% above expected current draw or
phase current level differs 33% or more.
If both alarm #12 and #13 is active this indicates too high
phase difference.
Expected fan current is a function of the power line frequency
and the supply voltage.
With 20’ setting above approximately:
3,4Amp@400VAC/50Hz
4,2Amp@460VAC/60Hz
With 40’ setting above approximately:
2,7Amp@400VAC/50Hz
3,4Amp@460VAC/60Hz
Indicates:
Defective or stuck evaporator fan motor.
Incorrect motor or motor connections.
Defective volt or amp meter on power module.
Open evaporator door and make sure all fans rotate freely.
Enter Manual Function Test and start evaporator fans on high
speed. Make sure all fans start on high speed. Check fan motor volts
and amps.
With 20’ setting expect:
2,4Amp@400VAC/50Hz
3,1Amp@460VAC/60Hz
With 40’ setting expect:
1,8Amp@400VAC/50Hz
2,4Amp@460VAC/60Hz
13
Evaporator Fan High Speed Current Too Low
Occurs during pretrip (PTI) or function test only.
Fan power consumption is 33% below expected current draw or
phase current level differs 33% or more.
If both alarm #12 and #13 is active this indicates too high
phase difference.
Expected fan current is a function of the power line frequency
and the supply voltage.
With 20’ setting below approximately:
1,4Amp@400VAC/50Hz
2,0Amp@460VAC/60Hz
With 40’ setting below approximately:
0,9Amp@400VAC/50Hz
1,4Amp@460VAC/60Hz
Indicates:
Defective or open fan motor internal over temperature protection
switch.
Incorrect motor or motor connections.
Defective volt or amp meter on power module.
Open evaporator door and make sure all fans rotate freely.
Enter Manual Function Test and start evaporator fans on high
speed. Make sure all fans start on high speed. If a motor does not
start and is very hot, wait 10 minutes for internal over temperature
switch to close.
Enter Manual Function Test and start evaporator fans on high
speed. Make sure all fans start on high speed. Check fan motor volts
and amps.
With 20’ setting expect:
2,4Amp@400VAC/50Hz
3,1Amp@460VAC/60Hz
With 40’ setting expect:
1,8Amp@400VAC/50Hz
2,4Amp@460VAC/60Hz
14
Evaporator Fan Low Speed Current Too High
Occurs during pretrip (PTI) or function test only.
Fan power consumption is 33% above expected current draw or
phase current level differs 33% or more.
If both alarm #14 and #15 is active this indicates too high
phase difference.
Expected fan current is a function of the power line frequency
and the supply voltage.
With 20’ setting above approximately:
1,0Amp@400VAC/50Hz
1,2Amp@460VAC/60Hz
With 40’ setting above approximately:
1,0Amp@400VAC/50Hz
1,2Amp@460VAC/60Hz
Indicates:
Defective or stuck evaporator fan motor.
Incorrect motor or motor connections.
Defective volt or amp meter on power module.
Open evaporator door and make sure all fans rotate freely.
Enter Manual Function Test and start evaporator fans on Low
speed. Make sure all fans start on low speed. Check fan motor volts
and amps.
With 20’ setting expect:
0,8Amp@400VAC/50Hz
0,9Amp@460VAC/60Hz
With 40’ setting expect:
0,8Amp@400VAC/50Hz
0,9Amp@460VAC/60Hz
15
Evaporator Fan Low Speed Current Too Low
Occurs during pretrip (PTI) or function test only.
Fan power consumption is 33% below expected current draw or
phase current level differs 33% or more.
If both alarm #14 and #15 is active this indicates too high
phase difference.
Expected fan current is a function of the power line frequency
and the supply voltage.
With 20’ setting below approximately:
0,5Amp@400VAC/50Hz
0,6Amp@460VAC/60Hz
With 40’ setting below approximately:
0,5Amp@400VAC/50Hz
0,6Amp@460VAC/60Hz
Indicates:
Defective or open fan motor internal over temperature protection
switch.
Incorrect motor or motor connections.
Defective volt or amp meter on power module.
Open evaporator door and make sure all fans rotate freely.
Enter Manual Function Test and start evaporator fans on low
speed. Make sure all fans start on low speed. If a motor does not
start and is very hot, wait 10 minutes for internal over temperature
switch to close.
Enter Manual Function Test and start evaporator fans on high
speed. Make sure all fans start on high speed. Check fan motor volts
and amps.
With 20’ setting expect:
0,8Amp@400VAC/50Hz
0,9Amp@460VAC/60Hz
With 40’ setting expect:
0,8Amp@400VAC/50Hz
0,9Amp@460VAC/60Hz
16
Condenser Fan Current Too High
Occurs during pretrip (PTI) or function test only.
Fan power consumption is 33% above expected current draw or
phase current level differs 33% or more.
If both alarm #16 and #17 is active this indicates too high
phase difference.
Expected fan current is a function of the power line frequency
and the supply voltage.
Above approximately:
1,5Amp@400VAC/50Hz
1,8Amp@460VAC/60Hz
Indicates:
Defective or stuck condenser fan motor.
Incorrect motor or motor connections.
Defective volt or amp meter on power module.
Enter Manual Function Test and start condenser fan. Make sure
the fan starts.
Check fan motor volts and amps.
Expect:
1,0Amp@400VAC/50Hz
1,2Amp@460VAC/60Hz
17
Condenser Fan Current Too Low
Occurs during pretrip (PTI) or function test only.
Fan power consumption is 33% below expected current draw or
phase current level differs 33% or more.
If both alarm #16 and #17 is active this indicates too high
phase difference.
Expected fan current is a function of the power line frequency
and the supply voltage.
Above approximately:
0,5Amp@400VAC/50Hz
0,6Amp@460VAC/60Hz
Indicates:
Defective condenser fan motor relay.
Incorrect motor or motor connections.
Defective or open fan motor internal over temperature protection
switch.
Defective volt or amp meter on power module.
Enter Manual Function Test and start condenser fan. Make sure
the fan starts.
Check fan motor volts and amps.
Expect:
1,0Amp@400VAC/50Hz
1,2Amp@460VAC/60Hz
18
Power Supply Phase Error
Shutdown Alarm
The power module is not capable of detecting the rotation direction.
Indicates:
Phase(s) missing at the power supply line.
Defective fuse at power module.
Power module failure.
Heating element problem (used for current load to decide the
rotation direction).
Check fuses on the power module.
Check power line voltage on all three phases.
Use the tester to detect the problem.
Replace power module.
19
Temperature Too Far From Set Point
Occurs during Normal Run only.
After 75 minutes of operation, supply or return air temperature
is not in-range and does not approach setpoint within preset pull-down
rate.
Indicates:
Ice or frost on evaporator coil.
Low refrigerant charge.
Air exchange vent open too much.
Container air leakage (doors open).
Use DATA menu to check supply and return air sensor temperatures.
Compare temperatures to evaluate unit cooling capacity and
performance.
Temperature difference should be 4 C to 6 C (7.2 F to 10.8
F).
Open evaporator door. Inspect coil for ice or frost and initiate
manual defrost if necessary.
Check refrigerant charge.
Note This alarm can be activated if the supply
or return air temperature varies, even if the mean temperature does
approach setpoint.
20
Defrost Duration Too Long
May occur during any defrost.
Heat signal has been on for too long.
Time limit is 90 minutes with supply voltage above 440VAC and
120 minutes below 440VAC.
Indicates:
Low power supply voltage.
Defective heater elements.
Evaporator fans running during defrost.
Evaporator sensor placed wrong.
Initiate a manual defrost and check amperage draw and evaporator
coil temperature. Evaluate defrost performance.
Open evaporator door and check location of evaporator coil
sensor.
Note This alarm can be activated at low voltage
and very low box temperature conditions, even under normal operating
conditions.
22
Capacity Test 1 Error
Occurs during pretrip (PTI) test only.
Difference between supply and return air temperature is too
small with high speed evaporator fans (less than approximately 4.5
C [8 F]).
When the return air temperature does not reach -60 C (-76 F)
within preset time.
Indicates:
Incorrect location of supply or return air sensor.
Air leakage at supply sensor cable.
Defective supply or return air sensor.
Interchanged sensor connections.
Incorrect evaporator fan rotation or high speed operation.
Incorrect refrigeration system operation.
Container/side panels defective, damaged or leaking.
Economizer circuit defective.
Enter Manual Function Test and start evaporator fans on high
speed and let operate fans for 5 minutes. Check supply, return and
evaporator coil (defrost) sensor temperatures. Sensor readings should
be the same (evaporator coil may be 0.5 C [1.0 F] lower due to fan
motor heat).
Open evaporator door and inspect evaporator fan rotation. Make
sure fans are rotating correctly on high speed.
Check the sensor connections.
Enter Manual Function Test menu. Start and check current draw
of the following components separately and together: compressor, vapor
on, condenser fan and evaporator fans (high). Check discharge and
suction pressure readings. Also check the refrigerant charge.
Note This alarm can be activated in ambient temperatures
below -10 C (14 F), even under normal conditions.
23
Capacity Test 2 Error
Occurs during pretrip (PTI) test only.
When the supply air temperature does not reach –30 °C (–22
F) within preset time.
Indicates:
Incorrect location of supply air sensor.
Air leakage at supply sensor cable.
Defective supply air sensor.
Interchanged sensor connections.
Incorrect evaporator fan rotation or high speed operation.
Incorrect refrigeration system operation.
Container/side panels defective, damaged or leaking.
Air exchange vent open too much.
Low refrigerant charge.
Cooling circuit defective.
Enter Manual Function Test and start evaporator fans on high
speed and let operate fans for five minutes. Check supply, return
and evaporator coil (defrost) sensor temperatures. Sensor readings
should be the same (supply air may be 0.5 °C [1.0 F] higher due to
fan motor heat).
Open evaporator door and inspect evaporator fan rotation. Make
sure fans are rotating correctly on low and high speed.
Check the sensor connections.
Enter Manual Function Test menu. Start and check current draw
of the following components separately and together: compressor, vapor
on, condenser fan and evaporator fans (high). Check discharge and
suction pressure readings. Also check the refrigerant charge.
31
Low Pressure Cut Out
If low pressure switch is mounted.
The switch is OPEN.
If pressure transducer is mounted.
The suction pressure has been measured
below -0,33BarR and has not yet increased above +0,58BarR.
Indicates:
Low refrigerant charge.
Refrigeration system restriction at filter drier or expansion
valve.
Defective low pressure cutout switch.
Defective low pressure transmitter.
Check discharge and suction pressure gauge readings:
If refrigerant pressures are low, check for a restriction and
leak check the refrigeration system.
If refrigerant pressures are high, check for a high refrigerant
charge (see below).
Check for a restriction:
Check for frost on downstream side of the filter drier.
Check for high evaporator superheat using supply air sensor
temperature readings in Data menu or a frost pattern on expansion
valve side of the evaporator coil. A large temperature difference
between the left hand and right hand supply air sensors indicates
a possible evaporator restriction or incorrect superheat.
If low pressure switch is mounted:
Check low pressure cutout switch wiring.
Measure the voltage across the switch, located at J9 pin 6
and pin 5.
Switch closed (normal) voltage is 0VDC.
Switch open (LPCO) voltage is approx. 12VDC.
Replace switch.
If pressure transducer is mounted:
Measure the transducer supply voltage at J1 pin 8 related to
J1 pin 9 (GND). Expects to be approx. 12VDC.
Measure the transducer output voltage at J1 pin 7 related to
J1 pin 9 (GND). Expects to be above 0,5VDC (0BarR = 0,8VDC)
32
Condenser Coil Temperature Sensor Open Circuit
When the sensor circuit resistance is above 1785Ω.
Indicates:
Open circuit.
Defective or wrong sensor.
Defective wiring.
Defective controller.
Check for damaged sensor wires.
Check sensor connections at controller.
The sensor is a pt1000 – 2 wire sensor, connected to the MP-4000
at connector J3 pin 7 and 8. CM-4000 upper left connector J3, 17 pin
wide, pin number 1 is the right pin, seen at the backside of the controller.
The 2 sensor wires can be switched without affecting the measurement.
Disconnect the sensor, use an Ohm (Ω) measuring device, measure
the electrical resistance between the two sensor wires.
The sensor can’t be examined without disconnecting it.
The electrical resistance towards chassis must be above meg
ohm (MΩ) range.
The sensor is a pt1000 – positive temperature coefficient,
which means that the electrical resistance of the sensor increases
with temperature.
The sensor is defined to be 1000Ω@ 0°C.
Normal condition measuring with disconnected sensor is 960Ω@-10°C,
1000Ω@0°C, 1039Ω@+10°C, 1058Ω@+15°C, 1078Ω@+20°C.
The valid measuring limit for this pt1000 sensor is -100°C
(602Ω) +200°C (approx 1758Ω).
33
Condenser Coil Temperature Sensor Short Circuit
When the sensor circuit resistance is below 602Ω.
Indicates:
Open circuit.
Defective or wrong sensor.
Defective wiring.
Defective controller.
Check for damaged sensor wires.
Check sensor connections at controller.
The sensor is a pt1000 – 2 wire sensor, connected to the MP-4000
at connector J3 pin 7 and 8. CM-4000 upper left connector J3, 17 pin
wide, pin number 1 is the right pin, seen at the backside of the controller.
The 2 sensor wires can be switched without affecting the measurement.
Disconnect the sensor, use an Ohm (Ω) measuring device, measure
the electrical resistance between the two sensor wires.
The sensor can’t be examined without disconnecting it.
The electrical resistance towards chassis must be above meg
ohm (MΩ) range.
The sensor is a pt1000 – positive temperature coefficient,
which means that the electrical resistance of the sensor increases
with temperature.
The sensor is defined to be 1000Ω@ 0°C.
Normal condition measuring with disconnected sensor is 960Ω@-10°C,
1000Ω@0°C, 1039Ω@+10°C, 1058Ω@+15°C, 1078Ω@+20°C.
The valid measuring limit for this pt1000 sensor is -100°C
(602Ω) +200°C (approx 1758Ω).
34
Ambient Air Temperature Sensor Open Circuit
When the sensor circuit resistance is above 1785Ω.
Indicates:
Open circuit.
Defective or wrong sensor.
Defective wiring.
Defective controller.
Check for damaged sensor wires.
Check sensor connections at controller.
The sensor is a pt1000 – 2 wire sensor, connected to the MP-4000
at connector J3 pin 9 and 10. CM-4000 upper left connector J3, 17
pin wide, pin number 1 is the right pin, seen at the backside of the
controller.
The 2 sensor wires can be switched without affecting the measurement.
Disconnect the sensor, use an Ohm (Ω) measuring device, measure
the electrical resistance between the two sensor wires.
The sensor can’t be examined without disconnecting it.
The electrical resistance towards chassis must be above meg
ohm (MΩ) range.
The sensor is a pt1000 – positive temperature coefficient,
which means that the electrical resistance of the sensor increases
with temperature.
The sensor is defined to be 1000Ω@ 0°C.
Normal condition measuring with disconnected sensor is 960Ω@-10°C,
1000Ω@0°C, 1039Ω@+10°C, 1058Ω@+15°C, 1078Ω@+20°C.
The valid measuring limit for this pt1000 sensor is -100°C
(602Ω) +200°C (approx 1758Ω).
35
Ambient Air Temperature Sensor Short Circuit
When the sensor circuit resistance is below 602Ω.
Indicates:
Open circuit.
Defective or wrong sensor.
Defective wiring.
Defective controller.
Check for damaged sensor wires.
Check sensor connections at controller.
The sensor is a pt1000 – 2 wire sensor, connected to the MP-4000
at connector J3 pin 9 and 10. CM-4000 upper left connector J3, 17
pin wide, pin number 1 is the right pin, seen at the backside of the
controller.
The 2 sensor wires can be switched without affecting the measurement.
Disconnect the sensor, use an Ohm (Ω) measuring device, measure
the electrical resistance between the two sensor wires.
The sensor can’t be examined without disconnecting it.
The electrical resistance towards chassis must be above meg
ohm (MΩ) range.
The sensor is a pt1000 – positive temperature coefficient,
which means that the electrical resistance of the sensor increases
with temperature.
The sensor is defined to be 1000Ω@ 0°C.
Normal condition measuring with disconnected sensor is 960Ω@-10°C,
1000Ω@0°C, 1039Ω@+10°C, 1058Ω@+15°C, 1078Ω@+20°C.
The valid measuring limit for this pt1000 sensor is -100°C
(602Ω) +200°C (approx 1758Ω).
43
Return Air Temperature Too High
Occurs during defrost.
With dehumidify operation; during defrost the return air temperature
increases above 38 °C (100 F).
Indicates:
Defective return or evaporator coil sensor.
Return and evaporator coil sensor connections are reversed.
Check for sensor alarm codes.
Check supply and return sensor connections and locations.
44
Return Air Temperature Too Low
Occurs during Normal Run only.
Only active with the surveillance active (OOCL option)
During dehumidify operation or if ambient air temperature is
below set point:
If return air temperature is below set point -3C.
Else (other operation range):
If return air temperature is below set point -1C.
The alarm state has to be present for 15 minutes before the
alarm is set.
Indicates:
Container/side panels defective, damaged or leaking.
Using DATA menu to evaluate sensors.
Use PROBE TEST to help determine the problem.
Replace sensor.
51
Power Line Voltage Too Low
Shutdown Alarm
Occurs if line voltage has been below 330VAC and is below 340
volts for 30 minutes.
During the 30 minutes and until voltage gets back above 340VAC
the compressor is stopped, for protecting the unit.
Indicates:
Poor power supply.
Using DATA menu to evaluate the power line quality.
Refer to the electrical specifications in the Specifications
Section for correct power requirements.
52
Probe Error
Occurs during pretrip (PTI) test or probe test in Chilled mode.
Temperature difference between supply and return air is above
1,5C and the system is not capable of pinpointing which probe is failing.
Temperature difference between supply and return air and evaporator
coil is above 1,5C and the system is not capable of pinpointing which
probe is failing.
Indicates:
Sensor error.
Sensor misplacement.
Using MANUAL FUNCTION TEST, ventilate with evaporator fan high
speed and evaluate the readings.
Check sensor connections.
Replace sensor.
Check sensor.
53
High Pressure Switch Off Error
Occurs during pretrip (PTI) test only.
Compressor does not stop during high pressure cutout switch
test.
Indicates:
Faulty compressor contactor or control circuit.
Low refrigerant charge.
Defective high pressure cutout switch.
Strong winds causing cooling of condenser coil in low ambient
conditions.
Check discharge and suction pressure gauge readings and check
refrigerant charge.
Enter Manual Function Test menu.
Start the following components together:
compressor 100 percent, compressor and evaporator fans (high). Discharge
pressure should increase and compressor should stop at 2302 kPa, 23
bar, 334 psig (high pressure cutout switch opens).
54
High Pressure Switch On Error
Occurs during pretrip (PTI) test only.
Compressor does not start within normal time during high pressure
cutout switch test.
Indicates:
High pressure cutout switch did not respond to pressure change
within five seconds.
Air in refrigeration system.
Defective high pressure cutout switch.
Check discharge and suction pressure gauge readings.
Enter Manual Function Test menu.
Start the following components together:
compressor 100 percent, compressor and evaporator fans (high). Discharge
pressure should increase and compressor should stop at 2302 kPa, 23
bar, 334 psig (high pressure cutout switch opens).
Then start condenser fan. Discharge pressure
must drop quickly (10 to 20 seconds) to 1550 kPa, 15.5 bar, 225 psig
and compressor should start (switch closes).
56
Compressor Temperature Too High
Shutdown Alarm
Compressor discharge line temperature is above 148 C (298 F).
Compressor stopped until discharge line temperature decreases to normal.
Indicates:
Air in refrigeration system.
Low refrigerant charge.
Defective compressor.
Defective vapor injection.
Operate unit on Cool and check discharge and suction pressure
gauge readings.
Enter Manual Function Test menu and test (operate) Vapor Injection
Valve to determine if valve opens (energizes).
Check compressor discharge sensor resistance. Resistance must
be approx. 86,000 ohms at 25 C (77 F).
Check discharge line temperature with a separate electronic
thermometer and compare to “HIGH PR TEMP” shown in the Data menu of
controller.
Note Unit will operate normally without compressor
sensor. However, controller compressor high temperature protection
is not active.
58
Phase Sensor Error
Occurs during pretrip (PTI) or function test only.
During Phase Sensor Test, while direction is reversed, the
condenser fan and compressor is tested.
If the current consumption of the condenser fan is below 0,5A
on each phase.
If the current consumption of the compressor is below 2,0A
on each phase.
Indicates:
Defective phase relay.
Defective power module.
Start a Manual Function Test. With reverse phase direction
selected, check the condenser fan runs reversed direction and the
compressor is activated and makes loud noise. Allow only for short
time activation max. 5 sec.
59
Delta Current Error
100% ampere difference between current phases, max reading
must be above 1,5A.
The alarm is protected by a timer which demand the state to
be present for three minutes before the alarm is set.
Indicates:
Open connection on one phase of power supply to a motor or
heater element.
Blown fuse.
Enter Manual Function Test menu and test (operate) each 3-phase
component to locate defective connection.
Check fuses.
97
Compressor temperature Sensor Open Circuit
When the sensor circuit resistance is above 1MΩ and the ambient
air temperature is above -10°C.
Since the sensor is a NTC-type, readings above 1MΩ will occur
when the temperature is below approximately -25°C.
Indicates:
Open circuit.
Defective or wrong sensor.
Defective wiring.
Defective controller.
Check for damaged sensor wires.
Check for sensor connections at controller.
The compressor temperature sensor is a NTC – 2 wire sensor.
The sensor is located/connected to the MP- 4000 at connector J3 pin
13 and 14. CM-4000 upper left connector J3, 17 pin wide, pin number
1 is the right pin, seen at the backside of the controller.
The 2 sensor wires can be switched without affecting the measurement.
Disconnect the sensor, use an Ohm (Ω) measuring device, measure
the electrical resistance between the two sensor wires.
The sensor can’t be examined without disconnecting it.
The electrical resistance towards chassis must be above mega
ohm (MΩ) range.
The sensor is a NTC thermistor type - negative temperature
coefficient, which in this case means that the resistance of the sensor
decreases with temperature.
The sensor is defined to be 86000Ω@ 25°C.
Normal condition measuring with disconnected sensor is:
475kΩ@-10°C
280kΩ@0°C
171kΩ@+10°C
135kΩ@+15°C
107kΩ@+20°C
The valid measuring limit for this sensor is -25°C (approx. 1MΩ)
+185°C (approx. 550Ω).
Note OPEN circuit state may not be reasonable since
open indicates high electrical resistance, which with this type of
sensor is possible at very low temperature. If the Ambient Air Temperature
indicates temperatures above -10°C the sensor is expected not to be
below -25°C and the alarm may be set. If the measured resistance gets
above the limit the reading is replaced with -30°C. The needed protection
compressor temperature vice is at the high temperature end of the
scale.
98
Compressor temperature Sensor Short Circuit
When the sensor circuit resistance is below 550Ω.
Indicates:
Short circuit.
Defective or wrong sensor.
Defective wiring.
Defective controller.
Check for damaged sensor wires.
Check for sensor connections at controller.
The compressor temperature sensor is a NTC – 2 wire sensor.
The sensor is located/connected to the MP- 4000 at connector J3 pin
13 and 14. CM-4000 upper left connector J3, 17 pin wide, pin number
1 is the right pin, seen at the backside of the controller.
The 2 sensor wires can be switched without affecting the measurement.
Disconnect the sensor, use an Ohm (Ω) measuring device, measure
the electrical resistance between the two sensor wires.
The sensor can’t be examined without disconnecting it.
The electrical resistance towards chassis must be above mega
ohm (MΩ) range.
The sensor is a NTC thermistor type - negative temperature
coefficient, which in this case means that the resistance of the sensor
decreases with temperature.
The sensor is defined to be 86000Ω@ 25°C.
Normal condition measuring with disconnected sensor is:
475kΩ@-10°C
280kΩ@0°C
171kΩ@+10°C
135kΩ@+15°C
107kΩ@+20°C
The valid measuring limit for this sensor is -25°C (approx. 1MΩ)
+185°C (approx. 550Ω).
120
Suction Pressure Sensor Error
Occurs during Normal Run if the sensor is detected to be out
of range, open or short circuit.
Occurs during Pre-Trip (PTI) test if the sensor readings do
not act correct during compressor activity.
Expected to decrease 0,15Bar from stopped to compressor running
loaded.
Indicates:
Wrong location of the sensor.
Sensor failure.
Superfreezer:
The sensor is suction pressure for the R23 system.
Using DATA menu evaluate sensor readings.
Check wiring to be correct and connected.
Check J1 plug is plugged into MRB.
Check voltage at J1 pin 1 to be 0.5 – 4.5 VDC.
Replace sensor.
121
Discharge Pressure Sensor Error
Occurs during Normal Run if the sensor is detected to be out
of range, open or short circuit.
Occurs during Pre-Trip (PTI) test if the sensor readings do
not act correct during compressor activity.
Expected to decrease 0,15Bar from stopped to compressor running
loaded.
Indicates:
Wrong location of the sensor.
Sensor failure.
Superfreezer:
The sensor is suction pressure for the R23 system.
Using DATA menu evaluate sensor readings.
Check wiring to be correct and connected.
Check J1 plug is plugged into MRB.
Check voltage at J1 pin 4 to be 0.5 – 4.5 VDC.
Replace sensor.
123
Data logger Battery Error
In cold ambient if the battery heater (battery internal) is
not capable of heating up the battery, ready for charging within 2
hours.
If the battery is not connected.
If the battery voltage is below 3.0VDC.
Using DATA menu to determine the state of the battery. Evaluate
temperature and voltage.
Check the battery physically, dismount and examine wires and
the connection to the controller.
Replace battery.
127
General Unit Error
The surveillance has determined that the unit is not capable
of continue running, and has shut down.
The reason is displayed at the controller main screen, and
is stated at the event next to the alarm event.
Known reason to the shutdown state is:
"SET POINT OUT OF RANGE"
"VOLTAGE OUT OF RANGE"
"POWER LINE PHASE ERROR"
"REGULATION PROBE ERROR"
"COMPRESSOR TEMPERATURE HIGH"
"SET POINT OUT OF RANGE"
The temperature set point is outside valid operation range.
+30°C to -40°C (+35°C with extended range).
Check configurations and settings on the controller.
"VOLTAGE OUT OF RANGE"
The measured voltage is below 330VAC.
Check power line voltage while loaded.
"POWER LINE PHASE ERROR"
The phase detection system detects phase error or not capable
of securing the correct rotation.
Check power line voltage and quality.
"REGULATION PROBE ERROR"
If supply and return air temperature sensor and evaporator
coil temperature sensors ALL indicate OPEN or SHORT circuit, the software
is not capable of determine a reasonable action related to the cargo.
Following steps related to the sensor alarms.
"COMPRESSOR TEMPERATURE HIGH"
The compressor temperature is measured to be above 148°C. The
state will stay until compressor temperature is measured to be below
132°C.
Check refrigerant level and flow through the cooling circuit.
128
Supply Air Temperature Sensor Error
Occurs during Pre-Trip (PTI) test and probe test only.
After ventilation with the evaporator fans.
If the supply and return air temperature sensor differs more
than 1,5C and the return air temperature is within 1,5C of evaporator
coil temperature.
If evaporator coil temperature sensor is failing, if the supply
and return air temperature sensors differs more than 1,5C. Both alarm
129 and 128 will be set.
Indicates:
Failing sensors.
Misplaced sensors.
Failing controller.
Use the DATA menu to detect the failing sensor.
Replace sensors.
Use the tester to determine the problem.
129
Return Air Temperature Sensor Error
Occurs during Pre-Trip (PTI) test and probe test only.
After ventilation with the evaporator fans.
If the supply and return air temperature sensor differs more
than 1,5C and the supply air temperature is within 1,5C of evaporator
coil temperature.
If evaporator coil temperature sensor is failing, if the supply
and return air temperature sensors differs more than 1,5C. Both alarm
129 and 128 will be set.
Indicates:
Failing sensors.
Misplaced sensors.
Failing controller.
Use the DATA menu to detect the failing sensor.
Replace sensors.
Use the tester to determine the problem.
130
Evaporator Coil Temperature Sensor Error
Occurs during Pre-Trip (PTI) test and probe test only.
After ventilation with the evaporator fans.
If the evaporator coil temperature differs more than 1,5C from
the mean value of supply and return air temperature.
Indicates:
Failing sensors.
Misplaced sensors.
Failing controller.
Use the DATA menu to detect the failing sensor.
Replace sensors.
Use the tester to determine the problem.
131
Ambient Air – Condenser Coil Temperature Sensor Error
Occurs during Pre-Trip (PTI) test and probe test only.
After ventilation with the condenser fan.
If the ambient air and condenser coil temperature sensor readings
differs more than 2.5C.
Indicates:
Failing sensors.
Misplaced sensors.
Failing controller.
Use the DATA menu to detect the failing sensor.
Replace sensors.
Use the tester to determine the problem.
132
Power Module Sensor Error
The surveillance continually evaluates the measurements reported
by the power module.
The surveillance includes a timer with a timeout at 60 seconds
before the alarm is set.
Indicates:
Power module located readings outside allowed range.
Use DATA menu to determine the failing reading.
The accepted limit for:
Line AC voltage is 180 to 700VAC.
Power line current is 0mA to 32A.
Radiator temperature is -100C to 200C.
Check for latest software revision.
Use tester to determine the problem.
133
Power Module Network Error
The surveillance has not received valid status communication
from the power module for 10 seconds.
Indicates:
Communication problem.
Check connection between controller and power module.
Use tester to determine the problem.
134
Controller Error
The surveillance has determined the state “controller internal
error”.
Indicates:
The controller is failing one way or another.
Use the tester to determine the problem.
135
Power Module Error
The surveillance has determined the state “Power module error”.
Indicates:
The power module is failing one way or another.
Use the tester to determine the problem.
136
Controller Transducer Circuit Error
The controller is not capable of generating the expected voltage
for the 12V LPCO and transducer sensors, (suction pressure and discharge
pressure, AVL and humidity sensor).
Replace Data logger Battery.
Use the tester to determine the problem.
137
Sensor System Overload
The controller sensor measurement is overloaded.
This situation will probably introduce wrong readings at other
sensors than the one introducing the overload.
Indicates:
Not intended voltage is introduced at one of the sensor inputs.
Transducer, connection or cabling with voltage supply for the
sensor might short circuit this voltage supply onto the measuring
input.
Sensor input which might initiate the problem:
At connector J3:
Humidity sensor (4-20mA type) pin 15-16.
At connector J1:
AVL position pin 1-3.
Discharge pressure pin 4-6.
Suction pressure pin 7-9.
At least one of the sensors circuits holds a short between
sensor voltage and sensor signal.
Problem might be located any were from the connection to the
sensor itself.
Action:
Disconnect sensors and look for a non intended short between
sensor voltage and the sensor line.
The sensor with the problem might show up with its own alarm.
139
Internal File Handling Error
Occurs if the read or write process of nonvolatile information
(i.e., Configuration and settings) fails.
Indicates:
Internal file read or write failure.
Replace controller.
140
Evaporator Section Too Hot
Occurs if supply air, return air or evaporator coil temperature
reads temperature at or above 60C.
Indicates:
Failing heater circuit, hanging output.
Failing evaporator fan.
Observe temperature readings to locate the problem.
Use manual function test to determine the failing component.
Use the tester to determine the problem.
141
Power Module Heat Exchanger Too Hot
Occurs if the power module heat exchanger temperature gets
above 105C.
Since activating the heating element is the far most heat applying
solid state switch, activating is bypassed to reduce temperature.
Indicates:
High temperature surrounding the control box.
Poor cooling to the back side of the control box.
Check for blocked air flow to the back side of the control
box.
Ambient temperature might just be high.
144
Compressor 2 temperature Sensor Open Circuit
Superfreezer only
This sensor is in use with the Superfreezer ‘High Temperature’
compressor (R134a)
When the sensor circuit resistance is above 1MΩ and the ambient
air temperature is above -10°C.
Since the sensor is an NTC-type, readings above 1MΩ will occur
when the temperature is below approximately -25°C.
Indicates:
Open circuit.
Defective or wrong sensor.
Defective wiring.
Defective controller.
Check for damaged sensor wires.
Check for sensor connections at controller.
The compressor temperature sensor is a NTC – 2 wire sensor.
The sensor is located/connected to the MP-4000 at connector J4 pin
7 and 8. CM-4000 low left connector J4, 8 pin wide, pin number 1 is
the right pin, seen at the backside of the controller.
The 2 sensor wires can be switched without affecting the measurement.
Disconnect the sensor, use an Ohm (Ω) measuring device, measure
the electrical resistance between the two sensor wires.
The sensor can’t be examined without disconnecting it.
The electrical resistance towards chassis must be above mega
ohm (MΩ) range.
The sensor is a NTC thermistor type - negative temperature
coefficient, which in this case means that the resistance of the sensor
decreases with temperature.
The sensor is defined to be 100kΩ@ 25°C.
Normal condition measuring with disconnected sensor is
351kΩ@0°C,
208kΩ@+10°C,
127kΩ@+20°C,
79kΩ@+30°C.
The valid measuring limit for this sensor is -25°C (approx.
1MΩ) +185°C (approx. 550Ω).
Note OPEN circuit state may not be reasonable since
open indicates high electrical resistance, which with this type of
sensor is possible at very low temperature. If the Ambient Air Temperature
indicates temperatures above -10°C the sensor is expected not to be
below -25°C and the alarm may be set. If the measured resistance gets
above the limit the reading is replaced with -30°C. The needed protection
compressor temperature vice is at the high temperature end of the
scale.
145
Compressor 2 temperature Sensor Short Circuit
Superfreezer only
This sensor is in use with the Superfreezer ‘High Temperature’
compressor (R134a)
When the sensor circuit resistance is below 550Ω.
Since the sensor is an NTC-type, readings above 1MΩ will occur
when the temperature is below approximately -25°C.
Indicates:
Open circuit.
Defective or wrong sensor.
Defective wiring.
Defective controller.
Check for damaged sensor wires.
Check for sensor connections at controller.
The compressor temperature sensor is a NTC – 2 wire sensor.
The sensor is located/connected to the MP-4000 at connector J4 pin
7 and 8. CM-4000 low left connector J4, 8 pin wide, pin number 1 is
the right pin, seen at the backside of the controller.
The 2 sensor wires can be switched without affecting the measurement.
Disconnect the sensor, use an Ohm (Ω) measuring device, measure
the electrical resistance between the two sensor wires.
The sensor can’t be examined without disconnecting it.
The electrical resistance towards chassis must be above mega
ohm (MΩ) range.
The sensor is a NTC thermistor type - negative temperature
coefficient, which in this case means that the resistance of the sensor
decreases with temperature.
The sensor is defined to be 100kΩ@ 25°C.
Normal condition measuring with disconnected sensor is
351kΩ@0°C,
208kΩ@+10°C,
127kΩ@+20°C,
79kΩ@+30°C.
The valid measuring limit for this sensor is -25°C (approx.
1MΩ) +185°C (approx. 550Ω).
146
Compressor 2 Temperature Too High
Shutdown Alarm
Superfreezer only
Compressor discharge line temperature is above 148 °C (298
F). Compressor stopped until discharge line temperature decreases
to normal.
Indicates:
Air in refrigeration system.
Low refrigerant charge.
Defective compressor.
Not normal ambient condition.
Operate unit and check discharge and suction pressure gauge
readings.
Check refrigerant charge of R-134a system and R-23 system.
Check compressor discharge sensor resistance. Resistance must
be approx. 100k ohms at 25 °C (77 F).
Check discharge line temperature with a separate electronic
thermometer and compare to “HIGH PR TEMP” shown in the Data menu of
controller.
Note Unit will operate normally without compressor
sensor. However, controller compressor high temperature protection
is not active.
147
Compressor 2 Feedback Error
Shutdown Alarm
Superfreezer only
The feedback signal from the R134a compressor contactor is
wrong, does not match the output signal to activate the contactor.
HPCO2 (R134a) is part of the wiring.
Indicates:
HPCO 2 (R134a).
Wiring problem.
Defective contactor.
Verify wiring and activation of contactor.
Check the HPCO switch, must be short in normal operation.
148
Suction 2 Pressure Sensor Error
Superfreezer only
Occurs during Normal Run if the sensor is detected to be out
of range, open or short circuit.
Occurs during Pre-Trip (PTI) test if the sensor readings do
not act correct during compressor activity.
Expected to decrease 0,15Bar from stopped to compressor running
loaded.
Indicates:
Wrong location of the sensor.
Sensor failure.
Using DATA menu evaluate sensor readings.
Check wiring to be correct and connected.
Check J1 plug is plugged into MRB.
Check voltage at J1 pin7 to be 0.5 – 4.5 VDC.
Replace sensor.
157
Data logger Battery Failure
Firmware version 3.3.0 or newer:
Occur if the battery is connected and the battery protection
circuit is activated as a result of overcurrent, over-charge or over-discharge.
Battery voltage must stay below 2.5V after the battery has
been charged for three minutes.
Check the battery physically, dismount and examine wires and
the connection to the controller.
Replace battery.
158
Data logger Battery Test FailureData logger Battery Failure
