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Ingersoll-Rand Thermo King CRR DF MPC2000, Maintenance Manual

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Ingersoll-Rand Thermo King CRR DF MPC2000 Maintenance Manual Download Page 132

Refrigeration Maintenance and Service Operations

131

Installation

1. Remove the sealing caps from the new dehydrator.

2. 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.

3. Reinstall dehydrator clamping brackets, nut and bolts. Tighten the bolts.

4. Do one of the following:

•

R-134a System:

a. 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.

b. Back seat (open) the liquid line service valve on the inlet side of the dehydrator.

c. Test the dehydrator for leaks (see “Refrigerant Leak Test Procedure” in this chapter).

d. If no leaks are found, place the unit in operation.

•

R-23 System:

a. Pressurize the system and test for leaks (see “Refrigerant Leak Test Procedure” in this chapter).

b. If no leaks are found, recover the leak test gas (see “Refrigerant Recovery” in this chapter).

c. Then evacuate the system (see “Evacuation and Cleanup of the Refrigeration System” in this 

chapter).

d. Recharge the unit with R-23 refrigerant and check the compressor oil level. Add oil if necessary. 

Expansion Valve Replacement (R-134a or R-23 Systems)

Removal

1. 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).

2. 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.

3. Remove insulating tape from expansion valve outlet line.

Summary of Contents for Thermo King CRR DF MPC2000

Page 1: ...rol and Trane a provider of energy efficient heating ventilating and air conditioning systems building and contracting services parts support and advanced controls for commercial buildings and homes SB 210 Additional text information to be placed here TK 5XXXX X PL 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate SB 210 Additional text information to be placed her...

Page 2: ...CRR DF MPC2000 CRR DF MPC2000ID CRR DF MP 3000 TK 50134 4 MM Rev 6 09 2017 Copyright 2017 Ingersoll Rand Climate Solutions EMEA Electronically Printed in Czech Republic ...

Page 3: ...ng from course of dealing or usage of trade are made regarding the information recommendations and descriptions contained herein Manufacturer is not responsible and will not be held liable in contract or in tort including negligence for any special indirect or consequential damages including injury or damage caused to vehicles contents or persons by reason of the installation of any Thermo King pr...

Page 4: ...nto the atmosphere We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere In addition service personnel must be aware of Federal regulations concerning the use of refrigerants and the certification of technicians For additional information on regulations and technician certification programs contact your local Thermo King dealer ...

Page 5: ...4 ...

Page 6: ...ns 25 Compressor Torque 3D Copeland Compressor Bolt Torque 25 Metric Hardware Torque Chart 26 Unit Description 27 General Description 27 Cascade Refrigeration System 27 Microprocessor Controller 28 Datalogger 28 Three Evaporator Fans 28 USDA Cold Treatment Temperature Recording 28 REFCON Remote Monitoring Modem RMM 29 Operating Modes 29 Frozen Loads 29 Operating Instructions 47 Basic Unit Controls...

Page 7: ...ist 86 Alarm Codes Descriptions and Corrective Actions 87 Electrical Maintenance 97 Unit Wiring 97 High Pressure Cutout Switch 97 R 23 High Pressure Cutout Switch 97 R 134a High Pressure Cutout Switch 97 Condenser Fan and Evaporator Fan Rotation 97 Condenser Fan 98 Evaporator Fans 98 Electric Heaters 98 Low Pressure Cutout Switch R 23 System on CRR DF MPC2000ID Units Only 98 Low Pressure Cutout Sw...

Page 8: ...Charging R 23 System with Gas Refrigerant Recovered in 40 Liter 42 qt Refrigerant Bottle from an Evacuated Condition 124 R 23 Final Charging Procedure for Partially Charged Units on Empty Containers 125 R 23 Charging Procedure for Partially Charged Units on Loaded Containers 125 Using Pressurized Nitrogen 126 Safety Precautions 126 Dehydration Pressure Testing Purging and Soldering Procedure 127 C...

Page 9: ...6 Structural Accessory Maintenance 137 Mounting Bolts 137 Unit Inspection 137 Condenser Coil 137 Evaporator Coil 138 Defrost Drains 138 Evaporator Fan Location 138 Condenser Fan Location 138 Vacuum Valve 139 Mechanical Diagnosis 141 Refrigeration System Diagnosis 143 Electrical Refrigeration and Controller Menu Flow Diagrams 147 ...

Page 10: ...gure 20 3 Fan Evaporator Evaporator Defrost Sensor Location 80 Figure 21 Manual Emergency Control Connections 83 Figure 22 R 134a Service Fittings Specifications 101 Figure 23 Service Valve Back Seated 103 Figure 24 Service Valve Open to Port 103 Figure 25 Service Valve Front Seated 103 Figure 26 Balancing R 134a System Pressure 104 Figure 27 Charging the R 134a System 104 Figure 28 Gauge Manifold...

Page 11: ...List of Figures 10 ...

Page 12: ...odem RMM X X X USDA Cold Treatment Temperature Recording Three 3 Sensor X X X D3DS Copeland Discus Compressor w 5 60 kW 7 5 Hp Motor for R 134a Refrigeration Circuit X X X Copper Receiver Tank with Moisture Indicating Sight Glass in R 134a Refrigerant Circuit X X X Suction Pressure Gauge for R 134a Refrigeration Circuit X X X Discharge Pressure Gauge for R 134a Refrigeration Circuit X X X Hermetic...

Page 13: ...Introduction 12 ...

Page 14: ...efrigerant or refrigeration system in any closed or confined area with a limited air supply for example a trailer container or in the hold of a ship Refrigerant tends to displace air and can cause oxygen depletion resulting in suffocation and possible death 11 Use caution and follow the manufacturer s suggested practices when using ladders or scaffolds Refrigerant When removing any refrigerant fro...

Page 15: ...that is connected to a source of operating power 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 Precautions 1 Be certain the unit On Off switch is turned OFF before connecting or disconnecting the unit power plug Never attempt to stop the unit by dis...

Page 16: ...d Do not wear jewelry watch or rings These items can short out electrical circuits and cause severe burns to the wearer General Safety Precautions for Servicing Units or Containers Equipped with a Microprocessor Controller Precautions must be taken to prevent electrostatic discharge when servicing the microprocessor and related components If these precautionary measures are not followed the risk o...

Page 17: ...nit IRMU disconnect all wire harnesses from the RMM IRMU circuit board 4 Switch all of the electrical circuit breakers in the control box to the OFF position 5 Weld unit and or container per 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 circ...

Page 18: ...Safety Precautions 17 Figure 1 Unit Nameplate and Decal Locations BEC851 AXA0343 AXA0344 AXA0345 Unit Nameplate Location ...

Page 19: ...Safety Precautions 18 ...

Page 20: ...he R 134a and R 23 refrigeration circuits Check for proper suction pressure on both the R 134a and R 23 refrigeration circuits Check compressor oil level in both the reciprocating and scroll compressors Check compressor efficiency and pump down R 134a refrigeration system only Check discharge and suction pressures of both the R 134a and R 23 refrigeration circuits Check dehydrator for a restrictio...

Page 21: ...Service Guide 20 ...

Page 22: ...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 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...

Page 23: ... Cooling HighSide 1400 to 1600 kPa 14 0 to 16 0 bar 203 to 232 psig LowSide 900 to 1100 kPa 0 9 to 1 1 bar 131 to 160 psig High Pressure Cutout Switch Cutout 3250 50 kPa 32 5 0 50 bar 470 7 psig Cutin 2590 250 kPa 25 90 2 5 bar 375 38 psig High Pressure Relief Valve Relief Pressure 3447 520 104 kPa 34 47 5 20 1 04 bar 500 75 15 psig Reset 2758 kPa 27 58 bar 400 psig Low Pressure Cutout Switch MPC2...

Page 24: ...60 Hz 1725 rpm 1725 rpm Full Load Amps 60 Hz 3 1 amps 460V 1 25 amps Locked Rotor Amps 60 Hz 25 amps 460V 35 7 amps Evaporator Fan Motors Type 460 380V 60 50 Hz 3 Phase Number 3 Kilowatts 60 Hz Each 0 75 kW Horsepower 60 Hz Each 1 0 hp RPM 60 Hz Each 3450 rpm High Speed 1725 rpm Low Speed Full Load Amps 60 Hz Each 1 4 amps 460V High Speed 0 5 amps 460V Low Speed Locked Rotor Amps 60 Hz 10 3 amps 4...

Page 25: ...le 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 ti...

Page 26: ...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...

Page 27: ...0 60 122 149 90 110 HH SS 2 10 13 7 10 20 27 15 20 41 47 30 35 75 88 55 65 Bolt Type and Class Bolt Size M14 M16 M18 M22 N m Ft lb N m Ft lb N m Ft lb 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...

Page 28: ...nd 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 60 C 14 F and 76 F The CRR DF cascade refrigeration system design allows shippers to economically carry cargo a...

Page 29: ... is used during Defrost mode only Datalogger Units with a MPC2000 or MP3000 controller are also equipped with a separate datalogger The MPC2000ID controller includes an integral datalogger The datalogger can record sensor temperatures as well as loss of power alarms unit operating modes sensor failure setpoint change and unit shutdown indications MPC2000 or MP3000 data recordings are stored in a R...

Page 30: ...ing defrost Cooling until return air temperature decreases to 1 C 1 8 F below setpoint Minimum 15 minute compressor ON running time and 10 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...

Page 31: ...ompartment 2 Heater Access Panel Location 7 Supply Air Sensor Probe Holder 3 Condenser Fan 8 Control Box 4 R 23 Compressor Compartment 9 Vacuum Pressure Valve Location for Box Ventilation 5 R 134a Compressor Compartment Figure 2 Unit Front View 1 2 3 4 5 9 8 7 6 BEC851 ...

Page 32: ...scription 31 1 Evaporator Fan Blade 4 Defrost Evaporator Coil Sensor Location 2 Evaporator Fan Motor 5 Return Air Sensor Probe Holder 3 Evaporator Coil Figure 3 Evaporator Section Front View 1 2 3 4 5 AXA0347 ...

Page 33: ...Unit Description 32 1 Vacuum Valve located behind condenser grille cover earlier 2 Vacuum Valve located behind condenser grille cover current Figure 4 Vacuum Valve AXA0348 BEC851 AXA0421 1 2 ...

Page 34: ...Unit Description 33 1 Control Box 4 Ambient Sensor Location 2 Thermometer Sampling Port 5 Power Plug and Cord 3 Supply Air Sensor Probe Holder Figure 5 Power Cord Storage Compartment 1 2 3 4 5 AXA0349 ...

Page 35: ...r Temperature Display and Status Indicator LEDs 6 Unit On Off Switch 7 Communications Connector for Data Retrieval 3 LCD Display Setpoint Temperature Message and Controller Main Menu Tree Display 8 Circuit Breaker 4 General Purpose Keypad Figure 6 Control Box and Microprocessor Controller 1 2 3 4 5 6 7 8 AXA0422 AXA0351 ...

Page 36: ...No 2 Connection to Main Relay Board 5 Cable No 2 Connection to Controller 14 Phase Sensor Relays 6 Datalogger Cable Connection to Datalogger 15 Evaporator Fan Relay Low Speed 7 Download Cable Connection to Controller 16 Condenser Fan Relay 8 Cable No 1 Connection to Controller 17 Cable No 1 Connection to Main Relay Board 9 MPC2000 Datalogger Figure 7 MPC2000 or MP3000 Controller and Remote Monitor...

Page 37: ...to Controller 12 Cable No 2 Connection to Main Relay Board 5 Cable No 2 Connection to Controller 13 Phase Sensor Relays 6 Download Cable Connection to Controller 14 Evaporator Fan Relay Low Speed 7 Cable No 3 Connection to Controller 15 Condenser Fan Relay 8 Cable No 1 Connection to Controller 16 Cable No 1 Connection to Main Relay Board Figure 8 MPC2000ID and MP3000 Controller and Remote Monitori...

Page 38: ...pressor Contactors 2 2 MPC2000 MPC2000ID or MP3000 Controller 6 R 134a Compressor Contactor 3 Datalogger CRR DF MPC2000 only 7 Main Relay Board 4 32 Ampere Main Power Circuit Breaker 8 12 Vdc Battery Figure 9 Unit Control Box with Door Open 1 2 3 4 5 6 7 8 AXA0355 ...

Page 39: ...uction Pressure Gauge Line Connection 3 Low Pressure Cutout Switch CRR DF MPC2000ID Units Only 2 R 23 Suction Line Figure 10 Low Pressure Cutout Switch in R 23 Refrigeration System CRR DF MPC2000ID Units Only 1 2 3 AXA0357 AXA0423 ...

Page 40: ...uge 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 Figure 11 R 23 Compressor Compartment AXA0423 1 2 3 4 5 7 8 9 10 11 12 6 ...

Page 41: ...alve 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 Figure 12 Additional R 23 Refrigeration System Components AXA0359 AXA0423 AXA0424 1 2 3 4 5 6 ...

Page 42: ...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 Figure 13 R 134a Compressor Compartment AXA0425 10 9 8 7 1 2 3 4 5 6 ...

Page 43: ...nk 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 Figure 14 Additional R 134a Refrigeration System Components and Plate Heat Exchanger 1 3 6 7 2 4 5 8 AXA0363 ...

Page 44: ...munications 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 Figure 15 Unit Back View 1 3 6 7 2 4 5 8 9 AXA0364 AXA0365 ...

Page 45: ...ssure Regulator R 23 System 3 Sensor Connector Assembly 2 Buffer Receiver Tanks 5 Total R 23 System 4 Crankcase Pressure Regulator R 23 System Figure 16 Unit Back View Pressure Regulators and Buffer Tanks AXA0366 AXA0367 AXA0368 1 3 2 4 ...

Page 46: ...Unit Description 45 1 Electric Heaters 3 Expansion Valve Feeler Bulb R 23 System 2 Evaporator Coil R 23 System Figure 17 Unit Back View Electric Heaters and Evaporator Coil AXA0369 AXA0370 1 2 3 AXA0368 ...

Page 47: ...Unit Description 46 ...

Page 48: ...ne the incoming power phase to ensure proper condenser fan evaporator fan and compressor rotation MPC2000 MPC2000ID or MP3000 Controller A MPC2000 MPC2000ID or MP3000 microprocessor controls all unit functions to maintain the cargo at the proper temperature The controller also monitors and records system faults and performs pre trip Keypad Sixteen general purpose keys are used to display informati...

Page 49: ...uses the compressor discharge line temperature sensor to protect the compressor from excessively high operating temperatures If the discharge gas temperature rises above 130 C 266 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 90 C 194 F High Pressure Cutout HPCO Swit...

Page 50: ...larm 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 an...

Page 51: ...ure cutout switch remains open check R 23 system suction and discharge pressures Then check for an obstruction or refrigerant leak in the low or high pressure side of the R 23 refrigeration system NOTE Use only Lower R 23 sight glass to check or add refrigerant on unit unable to maintain 50 to 60 setpoint Pretrip Inspection The following inspections should be made before the container is loaded 1 ...

Page 52: ...he 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 switch OFF Then repeat steps 1 and 2 If the unit still does not start refer to Alarm Codes Descriptions and Cor...

Page 53: ... before beginning the PTI test Press F2 key to enter Main Menu Press F2 or F3 key to scroll up or down in menu to COMMANDS Press F4 key to access COMMANDS menu Press F2 or F3 key to scroll up or down to 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...

Page 54: ...the controller memory by selecting Cargo Data from the MISC FUNCTIONS menu of the controller 5 One half hour after loading initiate a manual defrost cycle Press the DEFROST key The Defrost and Heat LEDs turns ON as the unit enters Defrost Defrost will stop automatically NOTE The evaporator coil temperature must be below 10 C 50 F to allow the unit the enter a defrost cycle If the evaporator coil t...

Page 55: ...p Procedure Trip data recorded by the MPC2000 MPC2000ID or MP3000 datalogger may be down loaded via the communications port on the control box using a DRU II or SmartSponge handheld data retriever or via the REFCON remote monitor system ...

Page 56: ...m LED flashes ON and OFF continuously when a Check Alarm Level 2 Alarm or Shutdown Alarm Level 1Alarm occurs Less serious Log Alarms Level 3 Alarm are recorded but do not activate the Alarm LED Check Alarms indicate corrective action should be taken before a problem becomes severe The unit continues to operate However some unit functions may be inhibited Shutdown Alarms indicate the unit operation...

Page 57: ...Microprocessor Controller 56 1 LED display with Status Indicator LEDs 2 LCD message and menu display 3 General purpose keys 4 Special function keys Figure 18 MPC2000 MPC2000ID and MP3000 Controller ...

Page 58: ...porator Fan Low Speed Current Too Low 16 Check Condenser Fan Current Too High 17 Check Condenser Fan Current Too Low 18 Log Power Supply Phase Error 19 Check Temperature Too Far from Setpoint 20 Check Defrost Time Too Long 22 Check Capacity Test 1 Error 23 Check Capacity Test 2 Error 32 Check Condenser Air Sensor Open Circuit 33 Check Condenser Air Sensor Short Circuit 34 Check Ambient Air Sensor ...

Page 59: ...ter text in an information screen F1 key Press the F1 key then press another general purpose key to enter the number shown on the key F2 key Press the F2 key then press another general purpose key to enter the first letter shown on the key F3 key Press the F3 key then press another general purpose key to enter the second letter shown on the key F4 key Press the F4 key then press another general pu...

Page 60: ...7 amp manual reset circuit breaker protects the 29 Vdc control circuit 2 amp fuse protects the 28 Vac control power circuit to the controller 2 amp fuse protects the battery charger output circuit to the controller Electronics for measuring phase sequence Electronics for measuring amperage Electronics for measuring voltage Zero current transformer for earth leaking measurement 8 Replaceable sensor...

Page 61: ... that can be accessed through the Main Menu 15 Manual emergency control capability Manual control settings in the control box allow the unit to operate even in the event of a fatal failure of the controller Manual control offers three operating functions Heat Defrost and Cool see Manual Emergency Mode Operation in this chapter 16 Flash memory Flash program memory allows the application software to...

Page 62: ...ircuits Current measuring circuits Voltage measuring circuits Output signals from the controller automatically regulate all unit functions including Compressor operation Condenser fan operation Evaporator fan motor operation Liquid line solenoid valve Electric heaters Phase selection Frozen Loads Setpoint at 10 C 14 F and Below NOTE CRR DF units are designed to haul deep frozen cargo only at setpo...

Page 63: ... The evaporator fan motors start Evaporator fans operate continuously in low speed The R 134a compressor and condenser fan then start and the liquid line solenoid energizes opens if the controller calls for cooling The R 23 compressor starts 30 seconds later Unit operates in cool until the controlling sensor reaches 1 0 C 1 8 F below setpoint on initial pull down Controller turns ON the In range L...

Page 64: ...rn 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 10 minutes to prevent rapid cycling between ...

Page 65: ... 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...

Page 66: ...P RET key The controller will show the supply air temperature as long as the SUP RET key is depressed 3 The display then returns to the return air temperature when the SUP RET key is released Displaying Alternate Fahrenheit F or Celsius C Temperature The controller can display temperatures in Fahrenheit or Celsius With the unit On Off switch ON and the controller showing a standard LED Display 1 P...

Page 67: ...to access a menu line to enter information or to load a command or value Data Menu NOTE Information can ONLY be displayed using the Data menu Items can NOT be changed The Data menu displays general unit operating information including sensor temperatures unit electrical data etc Viewing the Data menu With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press F...

Page 68: ...before a problem becomes severe Alarm codes 00 17 18 19 20 22 23 34 35 43 52 58 112 are Check alarms Log Alarm Level 3 Alarm is recorded in datalogger only inspect event log Alarm LED does not flash or turn on Alarm codes 59 97 98 are Log alarms Alarm Code States There are three alarm code states for Shutdown and Check alarms NOT ACTIVE An alarm condition has occurred but no longer exists in the u...

Page 69: ...te will change from ACTIVE or NOT ACTIVE to ACKNOWLEDGE NOTE If no key is pressed for 30 seconds the controller returns to the previous menu level or the LCD Standard Display Commands Menu The Commands menu displays a list of tasks that can be activated The following commands are available Defrost Manual defrost can be initiated When command is activated LCD message display will show ACTIVATED NOT...

Page 70: ...Compressor Evaporator Fan R 23 Compressor Sensor Check Heat Zero Current View value only Sensor Check Sensor Check low speed Probe Test operates high speed evaporator fans only After 5 minutes check the temperatures of the left and right hand supply sensors return sensor and defrost sensor Temperatures should be approximately equal c Component Test Press F4 key to start the component test LCD disp...

Page 71: ...nsor and defrost sensor Temperatures should be approximately equal Misc Functions Menu The Misc Functions menu displays a list of functions that identifies trips and determines how the controller records and displays operating information The following functions are available Date Time Sets the controller time and date C F Mode Sets the temperature value Celsius or Fahrenheit the controller uses t...

Page 72: ...mat Decimal points must be included in the entry between the hour minute and second NOTE To scroll backward in the Time or Date menu line press and hold the F4 key then press F3 key Press F1 key to return keyboard to numerical entry before typing again 6 With the correct time entered in the menu line press F4 key Then press EXIT key to enter time in controller memory Cursor stops blinking and new ...

Page 73: ...argo Data screen appears with cursor in LOC BRT menu line 5 Press F3 key to scroll cursor down through cargo data list LOC BRT CONTENTS DATE Loading Date VOYAGE SHIP LD PORT Loading Port DIS PORT Discharge Port COMMENTS 6 To enter text in a cargo data line press F4 key with cursor in the desired menu line An Enter Arrow appears and the cursor flashes in the selected line Enter type the desired tex...

Page 74: ...or down through cargo data list HEAT R 134a COMPRESSOR EVAPORATOR LOW CONDENSER SCROLL R 23 COMPRESSOR TOTAL 6 To reset an hourmeter or set hours on a replacement controller a Press F4 key with cursor in the desired menu line The Password screen appears b Press F2 key A key password is A F4 key and then EXIT key An Enter Arrow appears in the hourmeter line c Enter the desired run time setting up t...

Page 75: ...nd white contrast value on LCD display according to display temperature Standard setting is 45 Resetting this value is not recommended Zero Current View display ON or OFF value factory default ON However no errors occur if a Zero Current transformer is not installed and configuration is set to ON 5 To set a new Configuration screen value a Press F4 key with cursor in the desired menu line The Pass...

Page 76: ...through Main Menu until DATALOGGER appears in LCD display 3 Press F4 key to access the Datalogger menu The first function appears in the LCD display Inspect Temp Log 4 Press F2 or F3 key to scroll to the desired function Inspect Temp Log Inspect Event Log Inspect PTI Log Set Log Time 5 Press F4 key to access the function selected Inspect Temp Log The Log Time and the Setpoint Supply Return USDA1 U...

Page 77: ...State menu displays the current communications status with a REFCON system Offline No communication between Controller RMM and REFCON system Zombie The controller has detected a REFCON system master module and is waiting for communication Online The Controller RMM is logged in on a REFCON system for online viewing Viewing the RMM State screen With the unit On Off switch ON and the LCD display show...

Page 78: ...lly verify function HPCO functions and full cooling capacity CAUTION The PTI test should only be performed on an empty container CRR Pretrip PTI Test Procedure LED Display Test No LCD Display Shows Approx Amps for 460V 60 Hz Unit Test Description Possible Alarms Duration Time P1 00 Display Test Activated 0 1 A 0 0 A 0 1 A Event Log for PTI begins All alarms are turned OFF Alarm list is cleared All...

Page 79: ...Compressor Test Activated 9 2 A 9 1 A 9 2 A Condenser fan and compressor are turned ON Amp draw is measured and compared to voltage Evaporator temperature and condenser coil temperature are measured and recorded in PTI log If compressor has been OFF for last 18 hours less than 30 seconds ON a compressor sequence start occurs 06 07 14 Seconds Return Temp PTI Running Setpoint 30 C 22 F Unit operates...

Page 80: ... in normal mode with 55 C 67 F setpoint When return air temperature decreases to setpoint sensor temperatures are recorded in PTI log PTI End event is recorded in the PTI log A Trip Start is automatically activated Alarms if any are cleared from data logger However alarms if any remain in alarm list as not active until acknowledged 23 6 Hours Maximum Return Temp PTI PASS Press Any Key If alarms er...

Page 81: ...5337 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 2...

Page 82: ...ir Sensors for MPC2000ID and MP3000 Controller Temp F Temp C OHMS Temp F Temp C OHMS 40 40 21309 53 6 12 1680 31 35 16099 57 2 14 1547 22 30 12266 60 8 16 1426 13 25 9425 64 4 18 1316 4 20 7309 68 20 1215 5 15 5691 71 6 22 1173 10 4 12 4919 75 2 24 1040 14 10 4470 78 8 26 962 17 6 8 4066 82 4 28 893 21 2 6 3703 86 30 828 24 8 4 3376 89 6 32 770 28 4 2 3082 93 2 34 715 32 0 2817 96 8 36 665 35 6 2 ...

Page 83: ...it On Off switch to OFF 2 Disconnect the unit power cord from the power supply 2K Sensor Resistance Values for Ambient Air Sensors for MPC2000ID and MP3000 Controller Temp F Temp C OHMS Temp F Temp 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...

Page 84: ...he unit power cord from the power supply 2 Disconnect battery power connection from the controller top plug on the controller 3 Do one of the following MPC2000 and MP3000 Controller Remove the datalogger from the back of the controller by loosening the 4 screws MPC2000ID Controller Remove the back of the controller by loosening the 4 screws The EPROM chip will become visible Do NOT remove the conn...

Page 85: ...cation cables from the controller datalogger and remote monitoring modem 4 Remove the screws that secure the datalogger MPC2000 and MP3000 controller only and remote monitoring modem to the controller 5 Remove the screws that secure the controller to the inside of the control box door 6 Remove the controller from the door 7 Install the replacement controller in the door using the existing hardware...

Page 86: ...the communications cable is defective or not connected to the download port the controller will start in emergency mode and LCD display will show EMERGENCY MODE Secure cable connection to proceed with flash loading of software 5 Start flash load program on portable computer 6 Flash loading of new software is complete when FLASH LOADING clears from the LCD display 7 The controller then checks the n...

Page 87: ... warm gas bypass valve wil not open low refrigeratn charge defective low pressure cutout switch open circuit etc Controller activates Alarm 31 after 5 minutes Controller clears message after compressor start up 13 R134a Compressor High Temperature Indicates Compressor stops because discharge temperature is above 130 C 266 F Compressor remains Off until discharge temperature decreases to 90 C 194 F...

Page 88: ...e No 1 Defective controller Check sensor resistance between pins 1 and 2 on plug J15 Resistance must be 1 000 ohms at 25 C 77 F Check cable No 1 between controller and relay board Check evaporator airflow 01 Supply Air Sensor Short Circuit Check Alarm Sensor circuit resistance lower than 200 ohms Temperature above 80 C 176 F Indicates Open circuit to sensor Defective or wrong sensor Defective rela...

Page 89: ...0 ohms at 25 C 77 F Check cable No 1 between controller and relay board Check evaporator airflow 05 Evaporator Coil Sensor Short Circuit Check Alarm Sensor circuit resistance lower than 200 ohms Temperature above 80 C 176 F Indicates Open circuit to sensor Defective or wrong sensor Defective relay board Defective cable No 1 Defective controller Check sensor resistance between pins 5 and 6 on plug ...

Page 90: ...s higher than approximately 9 amps and lower than 13 amps Indicates Incorrect heaters or heater connections Defective volt or amp meter on relay board Defective heater element Start Manual Function Test and turn heaters ON Check current draw on each phase Current draw should be about 9 0 amps on each phase at 380V 10 4 amps at 460V 11 Heater Current Too Low Check Alarm Occurs during Pretrip PTI on...

Page 91: ...vaporator fan power consumption is lower than approximately 1 0 to 1 2 amps depending on voltage Indicates Defective evaporator fan motor relay Defective or open fan motor internal over temperature protection switch Defective volt or amp meter on relay board Incorrect motor or motor connections Open evaporator door and make sure all fans rotate freely Start Manual Function Test and set evaporator ...

Page 92: ...volt or amp meter on relay board Start Manual Function Test and set condenser fan motor to ON Make sure the fan starts Check fan motor volts and amps Check power supply volts and amps 18 Power Supply Phase Error Log Alarm One or more frequency inputs are missing for more than 20 seconds Indicates One phase on power line is missing Defective fuse on relay board Defective digital inputs on relay boa...

Page 93: ...at low voltage and very low box temperature conditions even under normal operating conditions 22 Capacity Test 1 Error Check Alarm Occurs during pre trip PTI test only Return air temperature does not reach 30 C 22 F within 4 hours Indicates Incorrect refrigeration system operation Container door is open Container is not empty Incorrect connection of return air sensor Open evaporator door and inspe...

Page 94: ...nsor resistance between pins 13 and 14 on plug J15 Resistance must be 1 000 ohms at 25 C 77 F Check cable No 1 between controller and relay board 43 Return Air Temperature Too High Check Alarm Return air temperature increases above 35 C 95 F during defrost Indicates Defective return air or evaporator coil sensor Return air and evaporator coil sensor connections are reversed Check for sensor alarm ...

Page 95: ...e than 0 2 amps Indicates Defective relay board Defective relay board cable No 2 Defective phase relay Start Manual Function Test and view current display for each phase to determine if each phase sensor relay is receiving a signal Change incoming power phase Verify that the phase relays respond correctly 59 Delta Current Error Log Alarm Power consumption is More than 50 above or below Min 0 8 Amp...

Page 96: ...e No 1 Defective controller Check sensor resistance between pins 9 and 10 on plug J15 Resistance must be 100 000 ohms at 25 C 77 F Check cable No 1 between controller and relay board 112 Zero Current Too High Check Alarm Ground zero current circuit 30 milliamps Indicates Defective motor or heater insulation to ground Start Manual Function Test and operate each motor and heater separately Note when...

Page 97: ...Microprocessor Controller 96 ...

Page 98: ...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...

Page 99: ...he ground wire which is labeled CH Electric Heaters Twelve electric heater elements are located underneath the evaporator coil If a heater element is suspected of malfunctioning inspect the connections If the connections appear correct and secure isolate and check the resistance of each individual heater element by disconnecting it from the circuit Check resistance with an ohmmeter NOTE When repai...

Page 100: ...nce 99 Low Pressure Cutout Switch Opens 0 20 kPa 0 0 2 bar 6 in vacuum to 3 Psig Closes 70 20 kPa 0 7 0 2 bar 10 3 Psig If the low pressure cutout switch is suspected of being defective replace it with a known good switch ...

Page 101: ...Electrical Maintenance 100 ...

Page 102: ...t Special fittings are used on the CRR DF R 134a refrigeration circuit to prevent mixing of non HFC refrigerants in the system These fittings are located in three places Low side near the compressor suction service valve 1 Internal Threads for Cap 2 High Pressure Fitting 3 Low Pressure Fitting Figure 22 R 134a Service Fittings Specifications CAUTION R 134a and R 23 are HFC Hydrofluoro carbon refri...

Page 103: ...evices 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 or R 23 refrigeration systems Refrigerant Recovery Use only refrigerant recovery equipment approved for and dedicated to HFC refrigeration recovery ...

Page 104: ...ation Maintenance and Service Operations 103 1 Full Counterclockwise Figure 23 Service Valve Back Seated 1 1 2 Turn In Figure 24 Service Valve Open to Port 1 Full Clockwise Figure 25 Service Valve Front Seated ...

Page 105: ...perate one or both hand valves to perform the different service operations 1 Quick Disconnect Access Valve 2 Discharge Service Valve DSV 3 Suction Service Valve SSV Figure 26 Balancing R 134a System Pressure 1 Quick Disconnect Access Valve 2 Discharge Service Valve DSV 3 Suction Service Valve SSV Figure 27 Charging the R 134a System ...

Page 106: ...ure 28 Gauge Manifold Closed to Center Port 1 Open Hand Valves Figure 29 Gauge Manifold Open to Center Port 1 Quick Disconnect Access Valve 2 In 3 Reclaimer with Receiver Tank 4 Out 5 Discharge Service Valve DSV 6 Suction service Valve SSV Figure 30 Removing R 134a Refrigerant ...

Page 107: ...e service fittings Save and re use the caps and sealing washers or gaskets 4 Rotate both hose coupler hand wheels counterclockwise to back the stem out of the high and low hose fittings Then attach low hose compound gauge to the suction line valve port 5 With 69 kPa 0 69 bar 10 psig or greater pressure in the low side unit operating on Cool open the suction service manifold hand valve fully Then r...

Page 108: ... Suction Service Valve NOTE Use quick disconnect access valves on refrigerant hoses Figure 31 Removing Refrigerant A R 23 Scroll Compressor B R 134a Reciprocating Compressor DSV Discharge Service Valve SSV Suction Service Valve NOTE Use quick disconnect access valves on refrigerant hoses Figure 32 Purging Gauge Manifold A B AMA295 ...

Page 109: ... ports 6 Back seat receiver tank outlet valve and cap valve stem 7 Secure all manifold lines to manifold hose anchors when the manifold is not in use Service Procedure Guide Typical R 23 and R 134a System Suction and Discharge Pressure Readings Test Procedure 1 Operate unit in COOL for 10 minutes or more 2 Maintain discharge pressure shown in table below for a 80 100 F 27 38 C ambient temperature ...

Page 110: ...o achieve the correct setting R 23 Refrigeration System Standby Unit OFF and Cool Operation Container Temp Ambient Temp Suction Pressure Discharge Pressure Standby Unit OFF Empty box 0 C 32 F 1600 kPa 16 0 bar 232 psig 1600 kPa 16 0 bar 232 psig 20 C 68 F 1700 kPa 17 0 bar 247 psig 1700 kPa 17 0 bar 247 psig 38 C 100 F 1800 kPa 18 0 bar 261 psig 1800 kPa 18 0 bar 261 psig Cooling 30 C 22 F 250 280...

Page 111: ...ng 2 Do one of the following a R 134a Compressor Pump the compressor down refer to Low Side Pump Down b R 23 Compressor Do NOT pump down a scroll compressor Proceed to step 4 to add oil to a scroll compressor 1 Protective cap 5 Inlet 2 Adjustment 6 Fitting for checking upstream pressure some models 3 Spring 7 Seat 4 Bellows 8 Outlet Figure 33 Discharge Pressure Regulator CAUTION Use ONLY Polyol Es...

Page 112: ...e 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 1 Install an access valve actuator on the oil pressure fitting 2 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 refr...

Page 113: ...nd refrigerant oil loss 2 Attach gauge manifold set refer to Gauge Manifold Set Attachment and Purging for proper procedures 3 Attach refrigerant bottle charging hose to center of gauge manifold and purge charging hose of air 4 Pressurize the system with refrigerant GAS ONLY until 345 kPa 3 45 bar 50 psig vapor pressure is achieved 5 Leak check the system with an electronic leak detector to inspec...

Page 114: ...r Reclaim the refrigerant when servicing the low side or high side of the R 23 refrigeration system 1 Install the gauge manifold on the compressor 2 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 3 Close the receiver tank outlet valve Allow the unit to operate until it reaches 1...

Page 115: ... the balls FLOAT in the receiver tank sight glass the R 134a charge level is correct 2 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 3 If the balls do NOT FLOAT in the receiver tank sight glass after operating the unit on COOL for 5 m...

Page 116: ... 220 psig the unit cooling capacity will be reduced but the unit should be able to maintain a 55 C to 60 C 62 F to 76 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 ...

Page 117: ...ery 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 R23 cannot be reclaimed by use of reclaim station 1 Prepare an empty refrigerant bottle at lease 40 liters 42 quarts in volume Evacuate bottle if neces...

Page 118: ...ver tank service valve port Attach the service line to the recovery machine and purge the lines 2 Set recovery machine for liquid recovery and turn it ON 3 Open back seat high pressure valve on gauge manifold 4 Operate the recovery machine until the unit system pressures reach approximately 0 kPa 0 bar 0 psig Evacuation and Cleanup of the Refrigeration System Contamination Whenever contaminants ha...

Page 119: ...stem cleanup Refrigeration System Preparation and Hookup 1 Recover all refrigerant from the system 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 2 Break vacuum with refrigerant and equalize system pressure to 0 kPa 0 bar 0 psig Replace the liquid line filter drier 3 Confi...

Page 120: ...est level Contamination may delay reaching the lowest level for a period of several or more hours c Close valve V1 to isolate the vacuum pump from the system d 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 ...

Page 121: ...cuate any system 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 larg...

Page 122: ...ging charge the R 23 system first 1 Close valve V4 2 Open the Gas Ballast valve located on top of the pump housing behind the handle 3 Stop the vacuum pump 4 The discharge valve remains mid seated 5 Connect the refrigerant tank with gauge manifold to the evacuation station see Evacuation Station and Unit Hookup in this chapter 1 Close the vacuum valve and watch the movement of vacuum gauge needle ...

Page 123: ...the refrigerant tank hand valve is closed 3 Operate the unit in cool mode R 23 refrigeration system contains a FULL charge of refrigerant R 134a refrigeration system contains a partial charge of refrigerant 4 Open the hand valve at the gauge manifold and read suction pressure 5 Front seat the suction service valve and pump down the system to 21 to 35 kPa 0 21 to 0 35 bar 3 to 5 psig 6 Back seat th...

Page 124: ...uire charging charge the R 23 system first 1 Close valve V4 2 Open the Gas Ballast valve located on top of the pump housing behind the handle 3 Stop the vacuum pump 4 The discharge valve remains mid seated 5 Connect a refrigerant hose from the refrigerant tank to the service fitting on the receiver tank see Evacuation Station and Unit Hookup in this chapter 6 Weigh the tank of refrigerant 7 Check ...

Page 125: ...eiver tank and discharge valve service fittings 7 Cap all service ports and valve stems Charging R 23 System with Gas Refrigerant Recovered in 40 Liter 42 qt Refrigerant Bottle from an Evacuated Condition 1 Close valve V4 2 Open the Gas Ballast valve located on top of the pump housing behind the handle 3 Stop the vacuum pump 4 Back seat the discharge service valve 5 Connect a refrigerant hose to t...

Page 126: ...3 refrigerant tank 3 Connect the refrigerant hose to the suction line service port Be sure to purge the air from the refrigerant hose 4 Mid seat the suction service valve 5 Set the R 23 refrigerant tank for gas charging Open the refrigerant tank hand valve 6 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 va...

Page 127: ...excessive heat or direct sun light 4 DO NOT drop dent or damage cylinder 5 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 6 Open valve slowly use regulators and safety valves that are in good wor...

Page 128: ...lose both hand valves on the gauge manifold front seated 3 Connect charging hose to a source of nitrogen Adjust pressure regulator to the proper pressure for the required procedure 4 Purge system high side to low side The following procedures should utilize the following MAXIMUM gas pressure Leak Testing 1030 to 1200 kPa 10 3 to 12 0 bar 150 175 psig Purging Dehydration 70 to 140 kPa 0 7 to 1 4 ba...

Page 129: ...ust 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 1 Slide the compressor into the unit Install mounting bolts washers and nuts and tighten 2 Bol...

Page 130: ...ondenser fan blade and condenser fan shroud 3 Remove the condenser coil support brackets from the coil 4 Unsolder the coil inlet and liquid line connections 5 Support the coil and unbolt the condenser coil mounting brackets Slide the coil from the unit Installation 1 Clean the tubes for soldering 2 Slide the coil into the unit and install the bolts in the mounting brackets 3 Solder the inlet line ...

Page 131: ...ant charge from the unit do NOT vent refrigerant to the atmosphere 2 Place the new dehydrator near the unit for immediate installation 3 Remove the filter bracket clamping nuts and bolts 4 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 Unsold...

Page 132: ...en the nuts are being loosened or tightened b Back seat open the liquid line service valve on the inlet side of the dehydrator c Test the dehydrator for leaks see Refrigerant Leak Test Procedure in this chapter d If no leaks are found place the unit in operation R 23 System a Pressurize the system and test for leaks see Refrigerant Leak Test Procedure in this chapter b If no leaks are found recove...

Page 133: ...e low side see Evacuation and Cleanup of the Refrigeration System in this chapter d Cover expansion valve outlet line with insulating tape e Open the liquid line service valve and place the unit in operation f 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 a Pres...

Page 134: ...ee Evacuation and Cleanup of the Refrigeration System in this chapter 8 Recharge the unit see Refrigerant Charge in this chapter R 23 System to R 134a System Plate Heat Exchanger Replacement Removal 1 Recover the refrigerant charge from the both refrigeration systems see Refrigerant Recovery in this chapter 2 Remove the panel that protects the heat exchanger assembly in the power cord storage comp...

Page 135: ...n the unit and tighten the mounting bolts 2 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 refriger...

Page 136: ...ak Test Procedure in this chapter Front seat the discharge service valve 4 If no leaks are found recover the leak test gas see Refrigerant Recovery in this chapter 5 Open the suction service valve and compressor discharge service valve and place the unit in operation Liquid Line Solenoid Valve Replacement R 134a System Only Removal 1 Close the liquid line service valve and pump down the low side t...

Page 137: ...red Low Pressure Cutout Switch Replacement CRR DF MPC2000ID and MP3000 Units Only Removal 1 Recover the R 23 refrigerant charge from the unit see Refrigerant Recovery in this chapter 2 Disconnect the leads from the wire harness 3 Unsolder the low pressure cutout switch from the unit Installation 1 Clean the tube for soldering 2 Place the new switch in position and solder the suction line connectio...

Page 138: ... coil by blowing low pressure compressed air or a medium pressure warm water spray from the inside of the coil outward opposite direction of normal airflow Inspect coil and fins for damage and repair if necessary If a build up of salt or debris is present on the condenser coil the coil should be cleaned using a mild alkaline cleaner with a pH of 9 5 to 10 5 For example a 2 3 solution of SIMPLE GRE...

Page 139: ... be sure the lines remain open Evaporator Fan Location Place fan blade on motor shaft with hub located on the outside of the blade for proper airflow direction When mounting the fan blade and hub assembly on the fanshaft center the assembly in the orifice Position the front top of the fan blade hub 13 mm 0 5 in in from the outer edge of the fan orifice Condenser Fan Location Place fan blade on mot...

Page 140: ... 76 F Check the vacuum valve during the pretrip inspection to make sure the ball inside the valve moves freely 1 Vacuum valve Located behind the condenser grille cover earlier 2 Vacuum valve Located behind the condenser grille cover current Figure 44 Vacuum Valve 1 Airflow Direction 4 Condenser Fan Blade 2 10 mm 0 4 in 5 Condenser Motor 3 Condenser Coil Figure 45 Condenser Fan Blade Placement 1 2 ...

Page 141: ...Structural Accessory Maintenance 140 ...

Page 142: ...r temperature sensor R 134a refrigerant charge R 23 refrigerant charge Compressor motor internal thermal overload protection open If compressor contactor is energized wait 60 minutes for protector to cool and reset Low suction pressure or defective low pressure cutout on R 23 system CRR DF MPC2000ID Units Only Check R 23 refrigeration system for leaks or and obstruction in the low or high side Rep...

Page 143: ...ion valve adjustment Worn fan motor bearings Replace bearings or motor Faulty compressor Repair or replace compressor Condenser fan motor does not operate Unit in Null Heat or Defrost Check indicator lights If unit is in Null 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...

Page 144: ...struction 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...

Page 145: ...ve power element lost its charge R 134a or R 23 system Replace power element Expansion valve feeler bulb improperly mounted poorly insulated or making poor contact R 134a or R 23 system Correct feeler bulb installation R 134a or R 23 System Head pressure too low Shortage of refrigerant Repair leak and recharge Low ambient air temperature R 134a system only No remedy Service gauge out of calibratio...

Page 146: ...n expansion valve only Ice plugging expansion valve screen or orifice Apply hot wet cloth to expansion valve Moisture indicated by increase in suction pressure Replace dehydrator R 134a or R 23 System High suction pressure Overcharge of refrigerant Purge system Expansion valve open too much Adjust or replace valve Defective controller or main relay board Diagnose main relay board and controller Re...

Page 147: ...Refrigeration System Diagnosis 146 ...

Page 148: ...cal Diagram G 153 5D52335 CRR DF MP3000A Unit Wiring Schematic D 154 Legend of CRR DF Refrigeration System Components 155 CRR DF Refrigeration System Components 156 Legend of CRR DF Off Cycle Standby Flow and Pressure Diagram 157 CRR DF Off Cycle Standby Flow and Pressure Diagram 158 Legend for CRR DF Full Cool Flow and Pressure Diagram 159 CRR DF Full Cool Flow and Pressure Diagram 160 Legend for...

Page 149: ...Electrical Refrigeration and Controller Menu Flow Diagrams 148 This page intentionally left blank ...

Page 150: ...149 CRR DF MPC2000 Controller Diagram ...

Page 151: ...150 CRR DF MPC2000 Main Relay Board Electrical Diagram ...

Page 152: ...151 CRR DF MPC2000 Unit Wiring Schematic Low Speed Winding ...

Page 153: ...152 CRR DF MP3000A Controller Diagram ...

Page 154: ...153 CRR DF MP3000A Main Relay Board Electrical Diagram ...

Page 155: ...154 CRR DF MP3000A Unit Wiring Schematic Low Speed Winding ...

Page 156: ...e 15 Liquid Line Ball Service Valve 16 R 134a Threaded Filter Drier 17 Liquid Line Solenoid 18 R 134a Expansion Valve 19 Equalizer Line 20 Expansion Valve Feeler Bulb 21 Plate Heat Exchanger R 134a R 23 22 Suction Service Valve R 23 Refrigeration Circuit Components 21 Plate Heat Exchanger R 134a R 23 23 R 23 Scroll Compressor 24 Sight Glass 25 Oil Fill Drain Fitting 26 High Discharge Pressure Gaug...

Page 157: ...156 CRR DF Refrigeration System Components Page 2 of 2 ...

Page 158: ... Sight Glass 14 Condenser Coil Outlet Tube 15 Liquid Line Ball Service Valve 16 R 134a Threaded Filter Drier 17 Liquid Line Solenoid 18 R 134a Expansion Valve 19 Equalizer Line 20 Expansion Valve Feeler Bulb 21 Plate Heat Exchanger R 134a R 23 22 Suction Service Valve R 23 Refrigeration Circuit Components 21 Plate Heat Exchanger R 134a R 23 23 R 23 Scroll Compressor 24 Sight Glass 25 Oil Fill Drai...

Page 159: ...158 CRR DF Off Cycle Standby Flow and Pressure Diagram Page 2 of 2 CRR DF Off Cycle Standby Flow and Pressure Diagram ...

Page 160: ...e Fitting 12 R 134a High Pressure Relief Fusible Plug 13 Sight Glass 14 Condenser Coil Outlet Tube 15 Liquid Line Ball Service Valve 16 R 134a Threaded Filter Drier 17 Liquid Line Solenoid 18 R 134a Expansion Valve 19 Equalizer Line 20 Expansion Valve Feeler Bulb 21 Plate Heat Exchanger R 134a R 23 22 Suction Service Valve R 23 Refrigeration Circuit Components 21 Plate Heat Exchanger R 134a R 23 2...

Page 161: ...160 CRR DF Full Cool Flow and Pressure Diagram Page 2 of 2 ...

Page 162: ...pressor Discharge Line Temperature Sensor 6 Low Suction Pressure Gauge 7 High Discharge Pressure Gauge 8 Condenser Check Valve 9 Condenser Coil Outlet Tube 10 Receiver Tank 11 R 134a Receiver Tank Service Fitting 12 R 134a High Pressure Relief Fusible Plug 13 Sight Glass 14 Condenser Coil Outlet Tube 15 Liquid Line Ball Service Valve 16 R 134a Threaded Filter Drier 17 Liquid Line Solenoid 18 R 134...

Page 163: ...162 CRR DR Evacuation Station and Unit Connections Page 2 of 2 ...

Page 164: ...R 23 Compressor Heat Zero Current Sensor Check Sensor Check Low Speed Press F4 key to start and stop test toggle component display between ON and OFF More than one component can be turned ON at a time to perform a functional test of the unit Press F4 key Type the new setpoint Press and hold F4 key until the cursor stops flashing Press SETPOINT key Press F4 key Type the new setpoint Press and hold ...

Page 165: ...rol and Trane a provider of energy efficient heating ventilating and air conditioning systems building and contracting services parts support and advanced controls for commercial buildings and homes SB 210 Additional text information to be placed here TK 5XXXX X PL 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate SB 210 Additional text information to be placed her...

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