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Thermo King 098203, Maintenance Manual

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Thermo King 098203 Maintenance Manual Download Page 8

Table of Contents

6

Miscellaneous Settings  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Datalogger Menu  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
States Menu   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Special Function Keys - User Activated Commands  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

PTI Key  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Defrost Key  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

PTI (Pretrip) Tests  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Automated Tests  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Function Test   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Manual Function Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Defrost  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Alarms/Warnings Menu  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Alarm Code States   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Alarm/Warning List Menu  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
View the Alarm/Warning List Menu  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Warning List Menu   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Alarm List Menu   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Configuration Menu  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Viewing or Setting Functions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Set Date and Time   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Datalogger Menu  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Viewing the Datalogger Menu  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Inspect Log  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Trip Start  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Set Log Time Interval   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

States Menu   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Air Ventilation Logging (AVL)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Starting the AFAM System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Change the AFAM Delay   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Change the AFAM Rate   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Advanced Fresh Air Management Plus (AFAM+) System   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Set AFAM+ System Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Change the AFAM Delay   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Change the CO

2

 Minimum and Maximum Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Changing the AFAM+ Settings Using ‘OPTISET’  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Modify Optiset Product Settings  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Testing AFAM+ / AFAM System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
AFAM+ Option Alarm Codes (see manual for further descriptions)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Pulsating Vent Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

AFAM+ Door Closes Automatically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Pulsating AFAM+ Door  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
AFAM+ Enabled  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Operating Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Chill Loads: (Setpoint at -9.9 C [14.1 F] and Above)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Frozen Loads: (Setpoint at -10 C [14 F] and Below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Compressor Vapor Injection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
High Temperature Protection   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Power Limit Mode  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Evaporator Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Condenser Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Probe Test   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Dehumidify Mode   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Continuous Temperature Control Operation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Frozen Loads (Controller Setpoint at -10 C [14 F] and Below):   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Compressor Digital Control Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Economizer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Data Recording and Downloading Data   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Cold Treatment (CT)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Multiple Temperature Setpoint (MTS)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Summary of Contents for 098203

Page 1: ...ed here TK 5XXXX X PL TK 60275 4 MM 2012 Ingersoll Rand Company Printed in U S A 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate Distributed by SB 210 Additional te...

Page 2: ......

Page 3: ...MAGNUM TK 60275 4 MM Rev 3 08 15 Copyright 2012 Ingersoll Rand EMEIA Printed in Ireland...

Page 4: ...s for a particular purpose or merchantability or warranties arising from course of dealing or usage of trade The manufacturer is not responsible and will not be held liable in contract or in tort incl...

Page 5: ...formation on regulations and technician certification programs contact your local Thermo King dealer R 404A WARNING Use only Polyol Ester based refrigeration compressor oil in R 404A See Thermo King P...

Page 6: ...Heat Exchange System 25 Temperature Sensors 25 Fresh Air Exchange System 26 Receiver Tank Sight Glass 26 Evaporator Fans 26 Condenser Fan Control 27 USDA Cold Treatment Temperature Recording standard...

Page 7: ...ation Check 59 FULL COOL Mode 61 DEFROST Mode 62 High or Low Speed Fans Only 62 Navigating the Controller Operating Menu 64 Navigating the Controller Operating Menu 64 Icon Menu 65 Menu Scrolling Keys...

Page 8: ...AFAM System 117 Set AFAM System Values 117 Change the AFAM Delay 119 Change the CO2 Minimum and Maximum Setting 119 Changing the AFAM Settings Using OPTISET 121 Modify Optiset Product Settings 121 Te...

Page 9: ...orator Heater Selection 161 Extended Capacity Heaters 162 Electric Heaters Malfunction 162 Compressor Discharge Gas Temperature Sensor 163 Compressor Discharge Temperature Sensor Replacement 163 Tempe...

Page 10: ...omizer Heat Exchanger installation 196 Receiver Tank Water Cooled Condenser Tank Replacement 197 Tank Removal 197 Tank Installation 197 Vapor Injection Valve Replacement 199 Compressor Digital Control...

Page 11: ...e caution when working around exposed coil fins The fins can cause painful lacerations Use caution when working with a refrigerant or refrigeration system in any closed or confined area with a limited...

Page 12: ...nplanned movement Treat all wires and connections as high voltage until ammeter and wiring diagram show otherwise Never work alone on high voltage circuits on the refrigeration unit Another person sho...

Page 13: ...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...

Page 14: ...circuit breakers must be restored to their normal condition when the welding operation is completed Removing Refrigerant Properly Use a refrigerant recovery process that prevents or absolutely minimiz...

Page 15: ...Safety Instructions 13 Nameplate and Warning Locations 1 Controller Nameplate 2 Unit Nameplate 3 Compressor Nameplate 2 BEN074 AXA0214 AXA0215 AXA0218 AXA0217 AXA0216 1 3...

Page 16: ...ousing Compressor Nameplate On front of the compressor Unit Nameplate On unit frame in power cord storage compartment MP 4000 Controller Nameplate On top of controller Component Serial Number Identifi...

Page 17: ...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...

Page 18: ...230V 3 Phase 60 Hz Power 380 190V 3 Phase 50 Hz Power Heating Capacity Heating Capacity Watts Kcal hr BTU hr Watts Kcal hr BTU hr MAGNUM normal 5 250 4 515 17 914 3 900 3 353 13 300 MAGNUM extended 7...

Page 19: ...V 60 Hz Horsepower 1 0 hp 460V 60 Hz Motor RPM Each High Speed 3450 RPM 460V 60 Hz Low Speed 1725 RPM 460V 60 Hz Full Load Amps Each High Speed 1 6 amps 460V 60 Hz Low Speed 0 8 amps 460V 60 Hz Locked...

Page 20: ...Pa 25 9 2 6 bar 375 38 psig Low Pressure Cutout Switch Cutout 17 to 37 kPa 0 17 to 0 37 bar 5 to 11 in Hg vacuum Cutin 28 to 48 kPa 0 28 to 0 48 bar 4 to 7 psig High Pressure Relief Valve Relief Tempe...

Page 21: ...for evaluating or diagnosing refrigeration system performance During the Modulation Cool mode the suction pressure will vary between 100 and 450 kPa 1 0 and 4 5 bar 15 and 65 psig depending upon the...

Page 22: ...timer resets if the unit is off more than 12 hours setpoint is changed more than 5 C 9 F or PTI pretrip test occurs Defrost Termination Defrost Coil Sensor Chilled mode Terminates defrost when coil s...

Page 23: ...8 in C Unit Width 1894 mm 74 57 in D Flange Height 2235 2 mm 88 00 in E Gasket Height 2140 mm 84 25 in F Unit Height 2094 mm 82 44 in G Gasket Depth 72 mm 2 83 in from back of flange H Maximum Protrus...

Page 24: ...ovable evaporator compartment door provides service access All components except the evaporator coil and electric heaters can be replaced from the front of the unit Each unit is equipped with an 18 3...

Page 25: ...uction port Digital Port The digital port provides cooling capacity control The digital port is located at the top of the scroll assembly on the compressor body When energized the Digital Control valv...

Page 26: ...B 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 MP40...

Page 27: ...ols the liquid refrigerant before it reaches the evaporator expansion valve Subcooling liquid refrigerant increases the cooling efficiency and capacity of the evaporator See the General Theory of Oper...

Page 28: ...e refrigerant charge A moisture indicator in the sight glass changes color to indicate the level of moisture in the system Evaporator Fans MAGNUM models are equipped with either 2 or 3 evaporator fans...

Page 29: ...an operates continuously in high ambients In low ambient conditions the controller cycles the condenser fan on and off to maintain a minimum condenser temperature The controller maintains a minimum 30...

Page 30: ...se options are briefly described on the following pages 1 Electronic Chart Recorder Optional 2 AVL AFAM AFAM Options 3 USDA Sensor Receptacle Access from Inside Container Optional 4 Remote Monitor Mod...

Page 31: ...r discharge system pressure The display will show a reading and a bar graph Unit can be configured suction only discharge only or suction and discharge Water Cooled Condenser Receiver Tank Optional A...

Page 32: ...door and vent grille The MP 4000 controller sends a communication signal to the door control module to position vent door to desired position The controller can also be set to delay opening of fresh...

Page 33: ...in the controller display and data logger memory If a power loss occurs after the AFAM system is turned on the controller automatically operates the vent door based on the previous AFAM Delay and AFA...

Page 34: ...es Options 32 1 Evaporator Access Door 2 Condenser Fan 3 Compressor Compartment 4 Scroll Compressor 5 Control Box 6 Rear Download and USDA Receptacle Panel Access from Inside Container Figure 15 Unit...

Page 35: ...nlet 4 Top Rear Plate 5 Bottom Rear Plate 6 USDA Receptacle Panel Controller Communications and Data Download Port USDA1 Spare 1 Sensor Connection USDA2 Spare 2 Sensor Connection USDA3 Spare 3 Sensor...

Page 36: ...lve 2 Evaporator Coil 8 Digital Control Valve 3 Expansion Valve Economizer 9 Low Pressure Cutout Switch 4 Condenser Coil 10 Economizer Heat Exchanger 5 Receiver Tank 11 Vapor Injection Solenoid Valve...

Page 37: ...er Plug 19 Control Box 6 Scroll Compressor 20 Compressor Cable 7 HPCO Switch 21 Liquid Tite Connector 8 Heater Group 22 Cable Connection 9 Condenser Fan Motor 23 Cable Supply 10 Condenser Fan Harness...

Page 38: ...7 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 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...

Page 39: ...ontroller will energize and stay energized for 25 sec by pressing any of the Menu keys the 25 sec timer will reset to 20 sec Controller Input and Output Signals The MP 4000 microprocessor controls all...

Page 40: ...or fan motor operation Compressor digital valve Vapor injection valve Dehumidify valve Electric heaters Phase selection 1 Standard Display 2 Function Keys 3 Special Function Keys Figure 19 MP 4000 Con...

Page 41: ...y Figure 20 Standard Display Idle Screen After approximately 30 seconds of inactivity the display will go into hibernation and one of the following symbols will be displayed Display alternates between...

Page 42: ...e Transducer HiPrs High Pressure Transducer 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 Mo...

Page 43: ...y The condenser fan will operate in an on off algoritim depending on the temperature on the condenser The evaporator fans will operate in either high or low speed mode depending on the need for capaci...

Page 44: ...ither 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...

Page 45: ...nd the TK Logo These special function key allow the operator to move quickly to perform a specific function Figure 23 Special Function Keys Green Led Flashing Temperature approaching in range Solid Te...

Page 46: ...lay Added time delay to key function OOCL Unit Features Added for MAGNUM SL 211 Unit runs non optimized mode OOCL Defrost termination OOCL PTI rules RMM Added for TAL TAL prefixes allowed for the RMM...

Page 47: ...oor will close when Power OFF key is pressed MTS and CT Disabled after PTI After a PTI is completed or unit OFF for 5 days MTS and CT will be disabled RMM Enables for UACU Units MP4000 has the RMM bui...

Page 48: ...ors battery heater will be disabled Compressor Temperature Reading Compressor sensor reading returns to the data menu Heating Element Type Heating element type has been added to CONFIGURATION UNIT CON...

Page 49: ...rs In PADLOCK state no user intervention is allowed Option is found in CONFIGURATION UNIT SETTING PADLOCK OPTION Default is OFF Select PADLOCK OPTION and select ON press hold the F4 key to lock PADLOC...

Page 50: ...fans will run high speed until 9 9C then switch to low speed fans MTS Defaulted OFF on Power OFF MTS setting would default OFF after a power OFF Controller will retain setting until power OFF period...

Page 51: ...frost ends evap fans will run in High speed for 5 sec to remove additional water from coil Humidity and AFAM PTI If Return temperature is 5C Humidity and AFAM will not run Unit will preheat until Retu...

Page 52: ...peration In the past dehumidification was allowed once cargo temperature was in range Now Dehumidification is allowed during pull down Setpoint Change on Battery Reports of setpoint change on battery...

Page 53: ...determine correct phase Setpoint of 45 Setpoint allowed for prefix TLTS Range 40 to 45 RMM Option Added prefixes for RMM option WHLU7800011 to WHLU7802502 SmartPTI Thumbs Up changed Have changed the...

Page 54: ...ler has 3 0 0 0 software installed insert SD card to load 3 1 0 0 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 software Alarm 60...

Page 55: ...n BCHU140X BCHU150X BCHU240X BCHU250X DCHU251X BCHU267X BCHU596X Humidity Sensor Alarm 60 Criteria for humidity sensor surveillance have been improved If unit has an Alarm 60 software 3 2 0 0 should b...

Page 56: ...54 Operating Instructions Function Keys 1 ON OFF Key 2 Defrost Key 3 PTI Pre trip Inspection F1 Alarm Key F2 C F Key F3 Setpoint Key F4 Menu Key Figure 24 Function Keys 2 3 1...

Page 57: ...SA SP PM 4000 Setup Power Module Init Power Module Phase test Shows heater icon Power module Ready Stop Plant Unit starts and shows CHILLED COOLING and shows mode of operation NOTE Random time delays...

Page 58: ...d 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...

Page 59: ...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 Changing Setpoint To change the controller setpoint...

Page 60: ...re not restarting while changing power sources without turning unit off If a controller is found with no display and unit not running follow this procedure 1 Unplug the unit or turn OFF the main circu...

Page 61: ...de Use this procedure 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 1 Unpl...

Page 62: ...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 1 J1 Connector Disconn...

Page 63: ...ll 3 18 GA 3 long jumper wires on the J1 connector Leave J1 disconnected during cool mode See Figure 28 on page 60 a Pin 1 wire 29VAC 0 to pin 6 wire CC1 b Pin 2 wire 29VAC 1 to pin 3 wire HPCO 0 c Pi...

Page 64: ...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 High or Low Speed Fans Only 1 Unplug unit and turn main CB...

Page 65: ...Operating Instructions 63 1 EF Wire Connected to Input Side of Compressor Contactor 2 J1 Connector Disconnected from PM Figure 31 High or Low Speed Evap Fans Only Mode 1 2...

Page 66: ...the Controller Operating Menu Navigating the Controller Operating Menu 1 Message Display 2 Menu Scrolling Keys Figure 32 MP 4000 Controller Display Panel 1 2 Early Main Menu Display Later Classic Main...

Page 67: ...e F2 OR F3 UP DOWN key to scroll to the Configuration selection and press the F4 ENTER KEY The Configuration Menu will appear Figure 34 Configuration Menu 3 Press the F2 OR F3 UP DOWN key to scroll to...

Page 68: ...s 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 Messa...

Page 69: ...og set Trip Start and Set Log Interval States Info Menu Menu screens in this group give information on the following Cold treatment CT state Multiple Temperature Setpoint MTS state PTI Input Output RM...

Page 70: ...x 17 foldout on the last page of the book MP4000 NOTE The screens that are display on the controller are determined by the controller software setting and the options installed on the unit All screen...

Page 71: ...hted pressing the ENTER F4 key again will open a view show how the unit is currently set up In order to see some of these different selections you need to turn the option on and then enter the Setpoin...

Page 72: ...e CONFIGURATION OPTIONS CT FEATURE for COLD TREATMENT to be active or visible Figure 43 Cold Treatment Multiple Temperature Set MTS This feature is designed to maintain up to 9 different set points wi...

Page 73: ...for OPTISET to be active or visible Figure 45 Optiset Display Temperature Setpoint Used to change the controller setpoint The setpoint can also be changed from the Unit Status Display by pressing the...

Page 74: ...is intended for dry not alive and or evolving cargo It is only allowed with setpoints at and above 15C 59F Changing the setpoint below that will cause the controlling mode to change to a predefined de...

Page 75: ...off on HPCO and the condenser fan will run as required Figure 49 Watercool Humidity Control During Chill mode operation a dehumidification function is available to reduce the relative humidity in the...

Page 76: ...umidity Setpoint AVL Air Ventilation Logging The Fresh Air Exchange Recorder AVL detects vent disk movement and automatically displays a value in the LCD display for values of 0 to 125 m3 h For settin...

Page 77: ...nformation about setting up AFAM Figure 53 AFAM Mode Fresh Air Vent Man AFAM Mode Can be set to OFF AFAM or AFAM OFF Will override all settings and keep the AFAM door completely closed AFAM Will allow...

Page 78: ...before opening to a desired AFAM Rate or due to gas sensor readings This is selectable form 1 to 48 hours Active in AFAM and AFAM modes Figure 55 AFAM Delay AFAM Rate Use to set AFAM door opens to des...

Page 79: ...e only when AFAM is enabled Selectable from 0 to 25 See Advanced Fresh Air Management Plus AFAM System on page 117 for more information Figure 57 CO2 Max AFAM O2 Min Used to set the lowest level of Ox...

Page 80: ...automatically started to determine next cycle start A menu point and a checkmark symbol provide visual status of the last passed Smart PTI on the controller display All checks are performed during no...

Page 81: ...on page 99 for more information Figure 61 No Warnings or Newest Warning Configuration Menu The Configuration menu is used to select unit configuration settings A complete listing of the controller Co...

Page 82: ...C Padlock Option Select ON OFF Unit Configuration Configuration Depends on Unit Figure 65 Unit Configuration 20 FT Unit Select ON OFF Heater Element Type Select from Extended Capacity and Normal Capac...

Page 83: ...section previously in this chapter for more details on each option AFAM Module Select from None AVL AFAM and AFAM Selecting AFAM also turns Optiset ON Humidity Sensor Select from None Sensor Mounted...

Page 84: ...and Option File Revision Controller ID View and Edit Controller ID Power Module ID View and Edit Power Module ID Unit Serial ID View and Edit Unit Serial Number ID Unit ID View and Edit Unit ID Datalo...

Page 85: ...on any Special features selected Figure 69 States Menu Cold Treatment CT State Multiple Temperature Setpoint MTS State PTI Input Output RMM RMM Defrost Water Cooled Condenser Runtime Counters Expansio...

Page 86: ...y will open up for selecting a user activated functionality Pressing PTI key or DEFROST key alone WILL NOT ACTIVATE THE FUNCTION PTI Key Figure 70 PTI Menu Screen No Action Manual Function Test See Ma...

Page 87: ...n Test See Automated Tests on page 89 and Function Test on page 89 for more information Figure 72 Function Test Screen AFAM PTI Figure 73 AFAM PTI Test Screen Humidity Sensor PTI Figure 74 Humidity Se...

Page 88: ...PTI See Automated Tests on page 89 for more information Figure 75 Brief PTI Test Screen Chilled PTI Figure 76 Chilled PTI Test Screen PTI See PTI Pretrip Tests on page 88 for more information Figure...

Page 89: ...Main Menu 87 Probe Test Figure 78 Probe Test Screen Show PTI Info Figure 79 PTI Information Screen Defrost Key See Defrost on page 98 for more information Figure 80 Defrost Menu Screen...

Page 90: ...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 With th...

Page 91: ...ime frame Section 3 This section displays actual readings and the expected power consumption Function Test The MP 4000 controller contains a special function test that automatically tests individual c...

Page 92: ...rt and stabilize and the Display to show the unit status display setpoint 1 Press the PTI KEY to open the PTI Menu 2 Press the F2 OR F3 UP DOWN KEY to scroll to Manual Function Test 3 Press the F4 ENT...

Page 93: ...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 v...

Page 94: ...n sumption 1 2 Amps approx at 50 Hz 1 5 Amps approx at 60 Hz Amperes are recorded in 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 high...

Page 95: ...Delta RET EVA must be stable within 7 seconds Awaiting temperature stability None 20 to 180 seconds X X PRE HEAT TEST SUP RET EVA 5 1C 5 0C 5 1C 2 3A 2 1A 2 3A Test is skipped if return air tem peratu...

Page 96: ...r fan maintaining 30 35degC for 15 sec Next the compressor is unloaded and running for 10 sec Amp draw difference is mea sured and expected to be at least 0 9 Amp Con 35C or 1 5 Amp Con 35C 119 25 to...

Page 97: ...ssor is also activated The test will then look for when the HPCO gets back to normal in maximal 60 seconds Awaiting HPCO Compressor stop 53 54 Max 200 seconds X X CAPACITY TEST With compressor fully l...

Page 98: ...to 120 minutes at voltages below 440V X X X PULLDOWN TO 18 C TEST With the unit running frozen approaching 18 deg C 0F Probe readings and time are recorded in the pti log when started and when ended...

Page 99: ...erates in normal mode with 18C 0F setpoint and defrost activated Defrost terminates when evaporator temperature increases to 18C 65F 20 30 minutes RUNNING PTI 18 C 0 F 00 00 00 18 0C 10 0C 10 0C Retur...

Page 100: ...R 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 t...

Page 101: ...ption 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 Alarm Code States There are three alarm code states for Shutdown and Ch...

Page 102: ...han one code has been recorded 3 Repeat above step until all alarm codes have been recorded Press the F2 key to scroll backward to return to a previous code 4 To clear all alarm codes from the current...

Page 103: ...or Coil 25 Evaporator Temperature Too High Check Evaporator Sensor 26 Evaporator Temperature Too Low Check Evaporator Sensor 27 System Low Pressure Check Refrigerant Charge 28 Frozen Setpoint Check Ai...

Page 104: ...r Supply Phase Error 19 Temperature Too Far From Setpoint 20 Defrost Time Too Long 22 Capacity Test 1 Error 23 Capacity Test 2 Error 26 Vapor Injection Error 31 Low Pressure Cut Out 32 Condenser Tempe...

Page 105: ...ture Probe Error 129 Return Air Temperature Probe Error 130 Evaporator Coil Temperature Probe Error 131 Ambient Condenser Temperature Probe Error 132 Power Module Sensor Error 133 Power Module Network...

Page 106: ...he display showing the unit status display 1 Press the F4 MENU key Press the F3 key to scroll down to the CONFIGURATION Menu 2 Press the F4 ENTER KEY to expand this menu 3 Press the F2 OR F3 UP DOWN k...

Page 107: ...sor is mounted you can change the setting here Discharge Pressure Sensor When discharge sensor is mounted changed you can change the setting here AVL Sensor Again if AVL sensor is mounted you can chan...

Page 108: ...NFIGURATION menu Press the F3 key to scroll down to the Miscellaneous Settings Menu 3 Press F3 to scroll to the Date Time Menu and 4 Press the F4 ENTER KEY to access the Date Time screen Date Time scr...

Page 109: ...ating menu is located on an 11 x 17 fold out on the last page of the book Figure 89 Datalogger Menu Viewing the Datalogger Menu With the UNIT TURNED ON Allow Unit to start and stabilize and the Displa...

Page 110: ...n the log press the F3 key Event Examples Controller alarm status alarms set cleared Main power On Off status humidity On Off temperature setpoint and main power Hz 12 Vdc battery discharge test batte...

Page 111: ...ess the Datalogger menu 3 Press the F2 OR F3 UP DOWN key to scroll through submenu to SET LOG TIME INTERVAL 4 Press the F4 ENTER KEY to enter Temp Log Display shows the current Log Time interval 5 Pre...

Page 112: ...put Shows Digital Input Information Phase Direction HPCO LPCO Cold Treatment CT State Multiple Temperature Setpoint MTS State PTI INPUT OUTPUT RMM RMM Defrost Water Cooled Condenser Runtime Counters E...

Page 113: ...in on a REFCON system A complete listing of the controller operating menu is located on an 11 x 17 fold out on the last page of this manual Viewing the RMM State Screen With the UNIT TURNED ON Allow U...

Page 114: ...ion Logging AVL The Air Ventilation Logging option detects vent disk movement and automatically displays a value on the Display This value is also logged in the datalogger The entry records the time d...

Page 115: ...figuration screen Figure 92 AVL Operating Instructions The following automatically occurs when the vent recorder is enabled in the configurations menu and the vent door changes position 1 The LCD scre...

Page 116: ...display 6 Press the MENU F4 key to enter the main menu Press the F2 or F3 key to scroll to Setpoint Control Menu and Press F4 to expand the menu 7 Press the F2 or F3 key to scroll to Fresh Air Vent Ma...

Page 117: ...PLE TEMPERATURE SET MTS OPTISET AFAM ONLY TEMPERATURE SETPOINT CONTROLLING MODE PULL DOWN SELECTION WATERCOOL HUMIDITY CONTROL HUMIDITY SETPOINT AVL OPEN VALVE DEFROST TERMINATION TEMPERATURE DEFROST...

Page 118: ...etting 0 appears in the display 4 Press the F2 OR F3 key to increase or decrease the time delay 5 Press and hold the F4 key until you are returned to the main menu The new time delay is recorded in th...

Page 119: ...er or new software is installed a controller auto configuration will detect the AFAM option when the AFAM door control module and gas sensor are connected to the controller AFAM This setting turns on...

Page 120: ...key to enter the Fresh Air Vent Man menu 9 Press the F2 or F3 key to scroll between OFF AFAM and AFAM OFF Vent door closes and or remains closed AFAM Delay and CO2 Max settings disappear AFAM Controll...

Page 121: ...The AFAM delay prevents the AFAM door from opening due to the AFAM Rate or CO2 system settings Change the CO2 Minimum and Maximum Setting NOTE The minimum CO2 rate should be established by the shippe...

Page 122: ...immediately again when the rate is entered Keep hands and tools away from the air exchange system components to prevent personal injury or unit damage Setpoint Control COLD TREATMENT CT MULTIPLE TEMPE...

Page 123: ...oduct to CUSTOM This signifies that some or all of the settings have been changed Modify Optiset Product Settings 1 Press the MENU F4 key to enter the main menu Press the F2 or F3 key to scroll to Set...

Page 124: ...manual for further descriptions Code 122 O2 Sensor Calibration Error PTI Only if equipped Code 124 Power module sensor Error How to verify System Operation If the system appears not to be operating pr...

Page 125: ...upply voltages and communication wring to the two components Also verify that the AFAM Expansion Module is firmly attached to the back of the controller Figure 102 AFAM Schematic Diagram Alarm Codes a...

Page 126: ...or Short If no alarm has been generated the system most likely has not communicated with or is verifying communications with the analyzer Follow action for Stale Atmosphere steps noted above If fault...

Page 127: ...5 CMH When door is closed the display will read PULSATING AFAM XXX SEC TO DOOR OPEN When door is open the display will read PULSATING AFAM DOOR OPEN When the AFAM door opens it remains open for min of...

Page 128: ...t for temperature control Cooling Capacity Display in main screen The percent displayed in the main screen indicates the cool capacity that is currently provided For example when controller display sh...

Page 129: ...rmined by the controller Once the setpoint has been reached the evaporator fans usually run in low speed as long as the temperature is near the setpoint If the controller determines it is necessary th...

Page 130: ...he controller The relative humidity setpoint can be set from 60 to 99 percent from the Setpoint menu NOTE The use of the Dehumidify mode should be established by the shipper Changing the humidity cont...

Page 131: ...eat electric heaters pulse on and off on a 60 second duty cycle if the control temperature differential is below setpoint C In range based on supply air temperature 1 Decreasing Temperature 2 Setpoint...

Page 132: ...is set to On the supply air temperature must be In range to energize the electric heaters When the humidity is 2 percent or more above humidity setpoint the controller energizes the heaters 5Controlle...

Page 133: ...switch to high speed If not sufficient heat increase with pulsating on the heaters until setpoint is reached Frozen Loads Controller Setpoint at 10 C 14 F and Below At setpoints of 10 C 14 F and below...

Page 134: ...ating Compressor must operate for a minimum of 5 minutes after startup After initial pull down to setpoint controller keeps the In range LED on as long as the return air temperature remains less than...

Page 135: ...he defrost timer is built intelligent it detects whether or not there is ice building up on the coil If there is no ice building up on the coil it extends the defrost interval and if there is Ice buil...

Page 136: ...flows from the digital port of the compressor back to the suction line This disengages the compressor 100 percent and temporarily reduces the compressor pumping capability The controller uses a propor...

Page 137: ...e economizer system increases system cooling capacity the vapor injection valve is energized open continuously when the compressor duty cycle ON time is 100 percent Full Cool High compressor discharge...

Page 138: ...d comments The container ID number is stored in the Configuration submenu Cold Treatment CT This feature is designed to maintain a temperature below the actual setpoint for a period of time per USDA s...

Page 139: ...mperature readings are logged in the datalogger 2005 04 27 11 33 KBD Cold Treatment Activity Option made possible not yet activated 2005 04 27 11 33 KBD Cold Treatment Activity C t set point 0 0C 2005...

Page 140: ...temperature recording requirements Calibrate the sensors in an ice bath MAGNUM units equipped for NTC style USDA sensors require USDA sensor P N refer to Tool Catalog MAGNUM units equipped for PT100...

Page 141: ...croll down to the SENSOR Menu 5 Press the F4 ENTER key to access the SENSOR Menu Figure 110 Sensor Menu 6 Press the F3 key to scroll down to CALIBRATE PROBES 7 Press the F4 enter key to enter Calibrat...

Page 142: ...sor temperatures in the CORR row 9 Press the F4 ENTER KEY to accept the new temperature offsets when all sensor offsets read between 0 3 C 0 5 F and 0 3 C 0 5 and have been stable for 5 minutes The co...

Page 143: ...illance during cold treatment During the CT period all USDA sensors can fail and the CT period will continue The fail state will be shown in the temperature log If all 3 probes fail the period will co...

Page 144: ...start approaching the first setpoint The next setpoint will be approached within the maximum capabilities of the unit as if a user manually has changed the setpoint The timing for any period will sta...

Page 145: ...N Figure 116 Turn MTS Feature On Starting and Setting Multiple Temperature Setpoint 1 Go to the Setpoint Control and enter Multiple Temp Set MTS 2 The display will show the Multiple Temperature Setpoi...

Page 146: ...4 Select MTS Period 1 and press EDIT The following screen will appear Press UP and or DOWN to change the period to the desired setting and Press and hold ACCEPT to enter that period Figure 119 Setting...

Page 147: ...isplay Showing MTS In Process Stopping Multiple Temperature Setpoint 1 Press the MTS Key 2 Scroll down to ABORT MTS PRESS STOP and press STOP Figure 122 Stopping MTS 3 The Standard Display will appear...

Page 148: ...l unit surveillance is kept Associated interfaces RMM REFCON The RMM must at no time during the journey be able of changing any involving parameters and settings on the controller The RMM interface wi...

Page 149: ...1 Insert a flat blade screwdriver into slot on side of control box door 2 Move the screwdriver handle to the left to release the door catch from the box latch 3 With the door catch released pull door...

Page 150: ...ual was published is CM4000 3 2 0 0 w 3 2 3 0 sip Load to SD Card zip SD Card Setup structure 1 Make sure the SD card is in the un lock or writeable mode Small tab on side slide forward is un locked 2...

Page 151: ...Figure 124 Removable Disk E MP4000 command ini 3 18 2010 Figure 124 MP4000 Figure 125 Removable Disk E MP4000 Firmware CM4000_3 2 0 0_140822 strip Logs Downloads will appear here command ini 3 18 2010...

Page 152: ...t on the side of the controller 3 Activate the display using battery power by pushing the ON OFF button If the software on the SD card is newer then what is on the controller the upload will take plac...

Page 153: ...ar from date of purchase by Emerson Controls To order a replacement test plug please provide the following information 1 Part number of plug to be replaced 2 Original purchase date of test tool and se...

Page 154: ...ion Menu instructions in the operating section Reset information as required 10 Review the Misc Functions Menu instructions in the operating section Reset information as required NOTE Be sure to enter...

Page 155: ...discharge service manifold of the compressor If the discharge pressure becomes too high the switch opens the ground circuit to the compressor contactor coil Compressor stops immediately Evaporator an...

Page 156: ...inutes the controller also turns on the Alarm indicator and records Alarm 37 Total Power Consumption Too Low High Pressure Cutout Switch Opens 3243 7 kPa 32 43 0 48 bar 470 7 psig Closes 2586kPa 25 9...

Page 157: ...e discharge pressure should never be allowed to exceed 3 447 kPa 34 4 bar 500 psig 4 Be sure to remove the cardboard installed in step 3 NOTE If the HPCO switch fails to stop compressor operation repl...

Page 158: ...f the Refrigeration System 5 Route wires into the control box and connect to proper terminals 6 Back seat the discharge service valve by turning the valve fully counter clockwise 7 Back seat the sucti...

Page 159: ...28 to 48 kPa 0 28 to 0 48 bar 4 to 7 psig Low Pressure Cutout Switch Opens 17 to 37 kPa 0 17 to 0 37 bar 5 to 11 in Hg vacuum Closes 28 to 48 kPa 0 28 to 0 48 bar 4 to 7 psig Low Pressure Cutout Swit...

Page 160: ...3 Perform a controller pretrip test to verify system operation Low Pressure Cutout Switch or Suction Transducer Configuration These units could have either a Low Pressure Cutout switch 41 4473 or a S...

Page 161: ...to J1 pins 7 8 9 a White wire to pin 7 b Red wire to pin 8 c Black wire to pin 9 7 Secure harness 8 Start unit press F4 to enter Menu Press F3 to scroll down to CONFIGURATION press F4 to enter Press F...

Page 162: ...iagnose 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 fro...

Page 163: ...n by turning the unit 460 380V main circuit breaker on and the Unit turned On and allow Unit to start and stabilize 6 Check condenser airflow again to confirm correct fan rotation Evaporator Heater Se...

Page 164: ...ation of each individual heater element a Test all 3 legs of the heater circuit to a good ground connection Connect a calibrated 500 Vdc insulation tester between each outgoing heater contactor termin...

Page 165: ...nd records Alarm Code 56 Compressor Temperature Too High The controller will restart the unit when sensor temperature is below 90 C 194 F Compressor Discharge Temperature Sensor Replacement The compre...

Page 166: ...s 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 Supply Ai...

Page 167: ...s and Service Testing the Sensors 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...

Page 168: ...it Front C Insert Sensor at least 75 mm into coil between Tube Rows 2 and 3 Figure 143 MAGNUM Evaporator Coil Defrost Sensor Location A Insert Sensor into condenser coil between Tube Rows 1 and 2 Figu...

Page 169: ...temperature sensors Temp F Temp C Ohms Temp F Temp 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...

Page 170: ...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...

Page 171: ...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 synth...

Page 172: ...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 va...

Page 173: ...use with only R 404refrigerant Gauge Manifold Valve Positions The gauges indicate low and high side pressures Operate one or both hand valves to perform the different service operations 1 Full Counter...

Page 174: ...alve 2 Discharge Service Valve DSV 3 Suction Service Valve SSV Figure 150 Balancing the Pressure 1 Quick Disconnect Access Valve 2 Discharge Service Valve DSV 3 Suction Service Valve SSV 4 Reclaimer 5...

Page 175: ...re 152 Gauge Manifold Closed to Center Port 1 Open Hand Valves Figure 153 Gauge Manifold Open to Center Port 1 Quick Disconnect Access Valve 2 Discharge Service Valve DSV 3 Suction Service Valve SSV F...

Page 176: ...e 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 5 Open the suction service manifol...

Page 177: ...the service ports 5 Secure all manifold lines to manifold hose anchors when the manifold is not in use Checking Refrigerant Charge The refrigerant charge should be checked during pretrip and routine...

Page 178: ...leaks with a reliable leak detector if the unit is low on R 404A charge Receiver Tank Sight Glass The receiver tank contains a sight glass which has three small balls that indicate the level of refri...

Page 179: ...0 psig vapor pressure is achieved 5 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 foun...

Page 180: ...ssure 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 pressu...

Page 181: ...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 Maximum Gas Pressures The...

Page 182: ...k disconnect couplers are required for R 404A units 2 Gas Ballast Valve 3 Iso Valve 4 Two stage Vacuum Pump 5 To 220 190 VAC Power 6 Calibration Standard 7 Micron Meter 8 Sensor Figure 159 Evacuation...

Page 183: ...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...

Page 184: ...y 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 acce...

Page 185: ...valve b 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 c Close valve V1 to i...

Page 186: ...ure see Pressure Rise Test Evaluation in this chapter 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...

Page 187: ...ong hose as it does through a 1 meter 3 foot long hose Heat Saves Time The application of heat to the system is a useful and practical time saver Increasing the temperature of the compressor oil and r...

Page 188: ...the tank 9 Turn the unit off 10 Open the gauge manifold hand valve and charge liquid refrigerant into the system 11 Close the refrigerant tank hand valve when the correct amount by weight of refrigera...

Page 189: ...discharge service valve suction service valve digital control valve line and vapor injection valve line from the compressor 5 Remove compressor discharge temperature sensor from the discharge valve ma...

Page 190: ...chapter 6 If no leaks are found recover the refrigerant used for the leak test see Leak Test Procedures in this chapter 7 Evacuate the system see Evacuation and Cleanup of the Refrigeration System in...

Page 191: ...o the unit and install the bolts in the mounting brackets 3 Solder the inlet line and liquid line connections NOTE It s strongly recommended that dry nitrogen be used to purge the system during any so...

Page 192: ...pressor oil to filter drier threads 3 Install new filter drier in unit Finger tighten mounting nuts NOTE To prevent incorrect installation of the dehydrator the inlet and outlet fittings are different...

Page 193: ...Refrigeration Maintenance 191 Figure 163 Filter Drier...

Page 194: ...Remove the panel to gain access to the TXV element 7 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 rem...

Page 195: ...unit does perform a low side pump down and isolate the low side by closing the compressor service valves If the unit does not have an outlet valve recover the refrigerant charge from the unit see Reco...

Page 196: ...the leak test see Recovering Refrigerant from the System on page 181 6 Evacuate the system or the low side see Evacuation and Cleanup of the Refrigeration System in this chapter 7 Locate feeler bulb i...

Page 197: ...Economizer Heat Exchanger Replacement Economizer Heat Exchanger Removal Remove the economizer heat exchanger by performing the following steps 1 Recover the refrigerant charge from the unit see Recove...

Page 198: ...check for leaks see Refrigerant Leak Test Procedure in this chapter 5 If no leaks are found recover the leak test gas see Refrigerant Leak Test Procedure in this chapter 6 Evacuate the low side see Ev...

Page 199: ...ing bolts 2 Solder the inlet line and outlet line connections NOTE It is strongly recommended that dry nitrogen be used to purge the system during any solder operations see Using Pressurized Nitrogen...

Page 200: ...Refrigeration Maintenance 198 Figure 169 Receiver Tank Figure 170 Water Cooled Condenser Tank...

Page 201: ...ent No other repair is possible on solenoid valves Valve Removal To remove the vapor injection valve perform the following steps 1 Recover the refrigerant charge from the unit 2 Turn the Unit On Off s...

Page 202: ...e the compressor digital control valve perform the following steps 1 Isolate the compressor and digital valve from the system a Front seat the discharge service valve by turning the valve fully clockw...

Page 203: ...electrical wires to the valve 6 Perform a controller pretrip test to verify system operation 1 Discharge Service Valve 2 Suction Service Valve 3 Compressor 4 Digital Service Valve 5 Digital Control Va...

Page 204: ...lacement of parts Checking the Mounting Bolts Check and tighten all unit compressor and fan motor mounting bolts during pretrip inspections and every 1 000 operating hours Unit mounting bolts should b...

Page 205: ...the unit to increase the efficiency of the condenser coil by preventing the recirculation short cycling of warm air through the coil Abnormally high head pressures may result if this special condense...

Page 206: ...flow 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 fa...

Page 207: ...perform the following steps 1 Loosen wing nut on handle Bracket Figure 176 2 Rotate the disk to set the Indicator at the air exchange rate shown on the ventilation scale on the door MAGNUM Models 0 2...

Page 208: ...a notch on handle Spring loaded handle holds ventilation door in position Air exchange rate is shown on the handle scale Figure 176 Air Exchange System 1 Disk Scale Low Ventilation Rates 2 Disk Assem...

Page 209: ...ainer and ambient temperature Refer to the Brief PTI Test in the Operating Instructions Section Full PTI Test The MP 4000 controller contains a special Full PTI pretrip test that automatically checks...

Page 210: ...r 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...

Page 211: ...iring 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 re...

Page 212: ...ection 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...

Page 213: ...er Change filter drier Compressor Digital Control Valve defective Replace defective valve Condenser coil dirty or airflow restricted Clean condenser coil clear restriction or repair or replace fan mot...

Page 214: ...rt Cycles under Mechanical Diagnosis Compressor Digital Control valve stuck close or defective Replace valve Hot liquid line Shortage of refrigerant Repair or recharge Expansion valve open too wide Ad...

Page 215: ...dirty evaporator coil 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 E...

Page 216: ...utes after compressor start up Check location of condenser probe 8 High Pressure Cut Out Please Wait When Unit stops due to high pressure cutout and the condensing temperature regulation has activated...

Page 217: ...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 wa...

Page 218: ...emperature 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...

Page 219: ...is related to the capacity surveillance system which observes the reefer machine capability to create a temperature drop between return air and supply air when expected to be running at high capacity...

Page 220: ...air through the coil and blow air out through the grill 31 HPCO Timer Hold Please Wait When The warning is a timer based warning to protect the compressor from starting at high pressure The warning w...

Page 221: ...ction etc Action The state will stop remove the compressor run signal This state will activate and hold warning 33 as long as the input signal indicates LPCO Controller activates Alarm Code 31 after 5...

Page 222: ...essor temperature gets normal 35 Compressor High Temperature When If the compressor temperature gets above 138C the warning is set The warning will go away when the compressor temperature gets below 1...

Page 223: ...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...

Page 224: ...of the control box Ambient temperature might just be high 42 CA Unit LPCO CA Unit is having too frequent LPCO s 43 CA Unit HPCO CA Unit is having too frequent HPCO s 44 CA Unit OBS CA Unit needs atten...

Page 225: ...nsor 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...

Page 226: ...itched without affecting the measurement Disconnect the sensor use an Ohm measuring device measure the electrical resistance between the two sensor wires The sensor can t be examined without disconnec...

Page 227: ...itched without affecting the measurement Disconnect the sensor use an Ohm measuring device measure the electrical resistance between the two sensor wires The sensor can t be examined without disconnec...

Page 228: ...itched without affecting the measurement Disconnect the sensor use an Ohm measuring device measure the electrical resistance between the two sensor wires The sensor can t be examined without disconnec...

Page 229: ...switched without affecting the measurement Disconnect the sensor use an Ohm measuring device measure the electrical resistance between the two sensor wires The sensor can t be examined without discon...

Page 230: ...ensor is 960 10 C 1000 0 C 1039 10 C 1058 15 C 1078 20 C The valid measuring limit for this pt1000 sensor is 100 C 602 75 C approx 1300 06 Compressor Current Too High Occurs during pretrip PTI or func...

Page 231: ...heck discharge and suction pressure gauge readings Check power supply volts on all 3 phases 10 Heater Current Too High Occurs during pretrip PTI or function test only Heater power consumption is 25 ab...

Page 232: ...460VAC expects 5 0Amp 460VAC expects 4 3Amp 400VAC expected resistance 99 on each leg Extended heating element 6kw 460VAC expects 7 5Amp 460VAC expects 6 5Amp 400VAC expected resistance 66 on each leg...

Page 233: ...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 60...

Page 234: ...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 vol...

Page 235: ...er 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 volta...

Page 236: ...f 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 Incorre...

Page 237: ...nd 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 followin...

Page 238: ...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 temper...

Page 239: ...e switched without affecting the measurement Disconnect the sensor use an Ohm measuring device measure the electrical resistance between the two sensor wires The sensor can t be examined without disco...

Page 240: ...switched without affecting the measurement Disconnect the sensor use an Ohm measuring device measure the electrical resistance between the two sensor wires The sensor can t be examined without disconn...

Page 241: ...ched without affecting the measurement Disconnect the sensor use an Ohm measuring device measure the electrical resistance between the two sensor wires The sensor can t be examined without disconnecti...

Page 242: ...mined without disconnecting it The electrical resistance towards chassis must be above meg ohm M range The sensor is a pt1000 positive temperature coefficient which means that the electrical resistanc...

Page 243: ...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 e...

Page 244: ...nu Start the following components together compressor 100 percent compressor and evaporator fans high Discharge pressure should increase and compressor should stop at 2250 kPa 22 5 bar 326 psig high p...

Page 245: ...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 Sta...

Page 246: ...nction Test Check air vent door functionality Check wiring Check container doors 68 Gas Analyzer Error Occurs during pretrip PTI test only With O2 ON If Both O2 and CO2 sensor reading is not ready and...

Page 247: ...f heating up or create conditions for valid reading Redo the test Replace sensor 71 CO2 Sensor Error Occurs during pretrip PTI test only If the sensor reading is not ready and valid within 10 minutes...

Page 248: ...the two sensor wires The sensor can t be examined without disconnecting it The electrical resistance towards chassis must be above meg ohm M range The sensor is a NTC thermistor type negative tempera...

Page 249: ...the two sensor wires The sensor can t be examined without disconnecting it The electrical resistance towards chassis must be above meg ohm M range The sensor is a NTC thermistor type negative tempera...

Page 250: ...es 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...

Page 251: ...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...

Page 252: ...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 failin...

Page 253: ...perature 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 pow...

Page 254: ...r line The sensor with the problem might show up with its own alarm 138 AVL Sensor Error Occurs if the sensor is detected to be out of range open or short circuit Indicates Sensor failure Using DATA m...

Page 255: ...r flow to the back side of the control box Ambient temperature might just be high 157 Data Logger Battery Failure Firmware version 3 3 0 or newer Occurs if the battery is connected and the battery pro...

Page 256: ...54 Wiring and Schematic Diagrams Index Dwg No Drawing Title Page 1e54052 Wiring Schematic 255 1e54051 Wiring Diagram 256 257 MAGNUM Refrigeration System Components 258 259 MP 4000 Menu Flow Diagram 26...

Page 257: ...255 Schematic Diagram RELEASED 19 Sep 2013...

Page 258: ...256 Wiring Diagram Page 1 of 2 RELEASED 19 Sep 2013...

Page 259: ...257 Wiring Diagram Page 2 of 2 RELEASED 19 Sep 2013...

Page 260: ...geration System Components High Pressure Vapor High Pressure Liquid Low Pressure Liquid Stage 1 Sub Cooled High Pressure Liquid Stage 2 Sub Cooled High Pressure Liquid Low Pressure Vapor TK 52234 2 3...

Page 261: ...Switch 4 Condenser Coil 5 Receiver Tank 6 Pressure Relief 7 Sight Glass 8 Drier Oil Filter 9 Economizer Heat Exchanger 10 Vapor Injection Valve 11 Economizer TXV 12 Evaporator TXV 13 Evaporator Coil...

Page 262: ...next screen Press F2 or F3 key to scroll through all logs Set Log Time Interval Press F3 key to scroll through log interval list Press and hold F4 key until cursor stops flashing DATALOGGER STATES Ma...

Page 263: ......

Page 264: ...ed here TK 5XXXX X PL TK 60275 4 MM 2012 Ingersoll Rand Company Printed in U S A 314 West 90th Street Minneapolis MN 55420 Direct 952 887 2200 Thermo King Corporate Distributed by SB 210 Additional te...

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