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Thermo King 098916, Maintenance Manual

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Thermo King 098916 Maintenance Manual Download Page 39

Unit Description, Features & Options

38

1.

Expansion Valve

7.

Ball Valve

2.

Evaporator Coil

8.

Digital Control Valve

3.

Expansion Valve (Economizer)

9.

Low Pressure Cutout Switch

4.

Condenser Coil

10.

Economizer Heat Exchanger

5.

Water Cooled Condenser Tank

11.

Vapor Injection Solenoid Valve

6.

Scroll Compressor

12.

Dehydrator

Figure 16: Refrigeration System

AJA1986

2

1

10

8

9

6

4

12

3

11

5

7

Summary of Contents for 098916

Page 1: ...of refrigeration and food merchandising solutions Thermo King the leader in transport temperature control and Trane a provider of energy efficient heating ventilating and air conditioning systems buil...

Page 2: ...MAGNUM TK 51122 4 MM Rev 6 02 06 Copyright 2004 Thermo King Corp Minneapolis MN USA Printed in USA...

Page 3: ...r 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 including negligence for any spe...

Page 4: ...ormation 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 Pa...

Page 5: ......

Page 6: ...28 Unit Description Features Options 29 Introduction 29 General Description 29 Scroll Compressor 30 MP 3000a Controller 30 Compressor Digital Control Valve 30 Economizer Heat Exchange System 31 Temper...

Page 7: ...or Advanced Fresh Air Management Plus AFAM Setting 53 Alarms Menu 54 Alarm Types 54 Alarm Code States 54 View the Alarm List Menu 54 Alarm List 56 Data Menu 57 Viewing the Data Menu 57 RMM State Menu...

Page 8: ...Optional 100 Electronic Chart Recorder for MP3000a Controllers 101 Recorder Installation 101 Recorder Setup 102 Main Menu 102 Configuration 102 Operating Theory 105 Chill Loads Setpoint at 9 9 C 14 1...

Page 9: ...ers and Cartridges 129 Use the Correct Refrigerant Recovery Equipment 129 Detecting Leaks 129 Locating Special Service Fittings 129 Perform an Oil Acid Test 130 Isolate the Compressor 130 Working with...

Page 10: ...pecting the Unit 151 Checking the Mounting Bolts 151 Cleaning the Condenser Coil 151 Cleaning the Evaporator Coil 151 Cleaning the Defrost Drains 151 Positioning the Condenser Fan Blade 152 Positionin...

Page 11: ...Table of Contents 10...

Page 12: ...igure 26 Unit On Off Switch 47 Figure 27 Special Function Keys 49 Figure 28 Setpoint Menu 50 Figure 29 Setpoint Menu 52 Figure 30 Setpoint Menu 53 Figure 31 Alarms Menu 54 Figure 32 Data Menu 57 Figur...

Page 13: ...sure 130 Figure 79 Removing Refrigerant 131 Figure 80 Gauge Manifold Closed to Center Port 131 Figure 81 Gauge Manifold Open to Center Port 131 Figure 82 Charging the System 131 Figure 83 Purging Gaug...

Page 14: ...cause oxygen depletion This can result in suffocation and possible death Use caution and follow the manufacturer s suggested practices when using ladders or scaffolds Refrigerant Oil Precautions Obser...

Page 15: ...uch the victim You can receive a shock from current flowing through the victim s body Check immediately for the presence of a pulse and respiration after separating the victim from power source If a p...

Page 16: ...t 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 a...

Page 17: ...ctions on all warning decals See above figure Locating Serial Numbers Serial numbers can be found on the component s nameplate Electric Motor Nameplate Attached to the motor housing Compressor Namepla...

Page 18: ...r fan Visually inspect electrical contacts for damage or loose connections Visually inspect wire harnesses for damage or loose connections Download the data logger and check data for correct logging C...

Page 19: ...Service Guide 18...

Page 20: ...nt air temperature and R 404A MAGNUM MAGNUM SL Models Water Cooled Condensing Return air to evaporator coil inlet 460 230V 3 Phase 60 Hz Power Net Cooling Capacity Power Consump 60 Hz Capacity B hr 60...

Page 21: ...hr BTU hr Watts Kcal hr BTU hr MAGNUM 5 800 4 990 19 800 4 900 4 215 16 720 System net heating capacity includes electric resistance rods and fan heat MAGNUM External Static Pressure water column 460...

Page 22: ...820 Electrical System Specifications Compressor Motor Type 460 380V 60 50 Hz 3 Phase Kilowatts 4 48 kW 460V 60 Hz Horsepower 6 0 hp 460V 60 Hz RPM 3550 RPM 460V 60 Hz Locked Rotor Amps 70 amps 460V 6...

Page 23: ...Cooled Condenser Receiver Tank Option 4 8 Kg 8 8 lb R 404A Compressor Oil Capacity 1 77 liter 60 oz Compressor Oil Type Polyol Ester Based Type required refer to Tool Catalog When the compressor is r...

Page 24: ...to 385 psig 16 to 27 C 60 to 80 F 400 to 600 kPa 4 00 to 6 00 bar 58 to 87 psig 1725 to 2140 kPa 17 25 to 21 40 bar 250 to 310 psig 2 C 35 F Cool 27 to 38 C 80 to 100 F 385 to 425 kPa 3 85 to 4 25 ba...

Page 25: ...e left hand and right hand supply air sensors is too large and unit has operated for 90 minutes since last defrost Temperature difference between the supply air sensors and return air sensor is too la...

Page 26: ...Compressor Start 90 C 194 F Bulb Mode Evaporator Fan Speed Settings Flow High High speed only Flow Low Low speed only Flow Cycle Fans will cycle between low and high speed every 60 minutes Defrost Te...

Page 27: ...GNUM SL Base Unit 402 Kg 885 lb MAGNUM Base Unit 422 Kg 930 lb Full TRANSFRESH Option 13 Kg 28 lb Water cooled Condenser Receiver Option 13 6 Kg 30 lb Unit Dimensions see Figure 2 A Flange Width 2025...

Page 28: ...Specifications 27 Figure 2 Physical Specifications AMA313...

Page 29: ...6 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 75 88 55...

Page 30: ...d with an 18 3 m 60 ft power cable for operation on 460 380V 3 Ph 60 50 Hz power The unit power cable is stored below the control box in the condenser section Each unit is equipped with 460 380V 3 Ph...

Page 31: ...nomizer gas pressure from influencing the cooling capacity of the unit evaporator main suction gas pressure Figure 4 Scroll Compressor MP 3000a Controller The MP 3000a is an advanced microprocessor co...

Page 32: ...ly Air Left Hand Supply Air Right Hand Return Air Evaporator Coil Condenser Coil Compressor Top Cap Ambient Air These sensors are field replaceable Four sensor receptacles are provided three USDA and...

Page 33: ...r fan motor speed based on the setpoint temperature and the Economy mode setting NOTE If Economy mode is on Chill Loads Evaporator fans operate on low speed when container temperature is in range Froz...

Page 34: ...tor Cool Compressor On Defrost and In range conditions Remote Monitoring Modem RMM Optional A REFCON remote monitoring modem is provided to permit remote monitoring via the power cable High speed tran...

Page 35: ...provides the unit with above and below deck operating capabilities Condenser fan control is provided in software or by a Condenser Fan Selection switch or a Water Pressure switch Starting april 2005 w...

Page 36: ...f the fresh air vent for up to 72 hours in 1 hour increments This allows faster product temperature pull down An advanced microprocessor controlled fresh air management system also provides programmab...

Page 37: ...es Options 36 1 2 3 4 5 6 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 Fig...

Page 38: ...annels 3 Fresh Air Inlet 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 U...

Page 39: ...igital Control Valve 3 Expansion Valve Economizer 9 Low Pressure Cutout Switch 4 Condenser Coil 10 Economizer Heat Exchanger 5 Water Cooled Condenser Tank 11 Vapor Injection Solenoid Valve 6 Scroll Co...

Page 40: ...er Plug 19 Control Box 6 LPCO Switch 20 Compressor Cable 7 Heater Spring 21 HPCO Switch 8 Humidity Sensor Harness 22 Digital Valve 9 Condenser Fan Harness 23 Humidity Sensor 10 Condenser Fan Motor 24...

Page 41: ...Unit Description Features Options 40...

Page 42: ...controller menu alarms and messages See the next page for further information Keypad Contain sixteen keys used to Navigate scroll the controller menu Enter change text and numeric characters in the m...

Page 43: ...display unit operating mode or condition The Alarm LED flashes on and off continuously when a Check Alarm or Shutdown Alarm occurs Message Display The Message Display shows setpoint temperature durin...

Page 44: ...m text box Setpoint Menu Alarm List Menu Data Menu REFCON Remote Monitoring RMM State Data logger Menu Miscellaneous Functions Menu Configuration Menu Commands Menu NOTE The screens that display on th...

Page 45: ...r THERMO in an information screen Enter T by pressing the F3 key then pressing STU key Enter H by pressing the GHI key Enter E by pressing the DEF key Enter R by pressing the F4 key then pressing the...

Page 46: ...re learning how to navigate the MP3000a Controller Menu It is recommended to fold this menu out and leave it folded out until you become familiar with the controller menu Menu Scrolling Keys Moving th...

Page 47: ...nitoring RMM State Menu screen show current remote monitoring state Offline Zombie or On line Data logger Menu Menu screens in this group display temperature log event log set log time and PTI log Con...

Page 48: ...at setpoint temperatures of 10 C 14 F and below The compressor starts about 10 seconds later and the liquid line solenoid energizes opens if the controller calls for cooling The condenser fan then sta...

Page 49: ...be set from the Setpoint menu See Setpoint Menu under Menu Operating Instructions in this chapter Initiating a Manual Defrost Turn the UNIT ON OFF switch ON Complete the following steps 1 Press the DE...

Page 50: ...renheit or celsius 1 Press and hold the C F key The controller will show both LED and LCD display temperatures in the alternate temperature scale Fahrenheit or Celsius as long as the C F key is depres...

Page 51: ...on the controller are determined by the controller software setting and the options installed on the unit All screens are not present on all units A complete listing of the controller operating menu i...

Page 52: ...aporator fans operate continuously on low speed 5 Press and hold the F4 key until the cursor stops flashing The new mode setting appears in the display When the Bulb mode is active The defrost termina...

Page 53: ...line press and hold the F4 key until cursor stops flashing New mode setting appears in display NOTE On frozen loads the Economy mode also modifies the temperature control algorithm to extend the Null...

Page 54: ...display is correct before proceeding Press and hold the F4 key until the cursor stops flashing The new setpoint is recorded in the controller and appears in the LCD display 5 Press the ESC key to exit...

Page 55: ...l turn off and the alarm code disappears from the alarm list Active An alarm condition has occurred and continues to exist in the unit or the alarm condition occurred within the past 1 hour but does n...

Page 56: ...ust be corrected and the alarm code acknowledged in the Alarm List menu 5 To acknowledge an alarm press F4 while alarm code appears on screen The alarm state will change from Active or Not Active to A...

Page 57: ...t Time Too Long 22 Check Check Capacity Test 1 Error 25 Check Check Evaporator Temperature Test Error 26 Check Vapor Injection Valve Error 27 Check Check Heat Capacity Test Error 31 Check Low Pressure...

Page 58: ...Discharge Pressure Cool Capacity Ambient Temperature High Pressure High Pressure Temperature Compressor Discharge Line Temperature Relative Humidity Battery Voltage Voltage Average 380 460V Power Sup...

Page 59: ...the UNIT ON OFF switch ON and the LCD display showing the standard display setpoint 1 Press the F2 or F3 key to enter the Main menu 2 Press the F2 or F3 key to scroll through Main menu until RMM STATE...

Page 60: ...on an 11 x 17 fold out on the last page of the book Viewing the Datalogger Menu With the UNIT ON OFF switch ON and the LCD display showing the standard display setpoint 1 Press the F2 or F3 key to en...

Page 61: ...r Open B Bulb Mode W Warning in Last Interval C CO2 Active NOTE All event flags that occurred during a log interval are displayed 8 Press the ESC key to exit the Temp Log Inspect Event Log With the UN...

Page 62: ...ts Stirring 10 seconds every 3 minutes during the test procedure is adequate Calibrating the USDA Sensors 1 Insert all USDA sensors in an ice bath see Ice Bath Preparation above NOTE The sensors must...

Page 63: ...n the ACTUAL row 9 Press the ESC key to exit the Calibrate menu Set Trip Start With the UNIT ON OFF switch ON and the LCD display showing the standard display setpoint 1 Press the F2 or F3 key to ente...

Page 64: ...logging of USDA sensors is fixed at 1 hour intervals to comply with USDA requirements A logging test of USDA sensors at 1 minute intervals is possible for 72 minutes USDA data can not be downloaded du...

Page 65: ...t log screens press the F3 key All event logs recorded in the datalogger memory may be viewed on the LCD display Event Examples Controller alarm status alarms set cleared Main power On Off status humi...

Page 66: ...rations screen appears with cursor in the CONTAINER ID menu line 4 Press the F2 or F3 key to scroll cursor to view or reset the desired function Container ID Sets the container identification number E...

Page 67: ...e Sets the condenser fan value to 1 2 HP 3 4 HP or 2 HP Must be manually set Chart R Electronic Chart Recorder Must be manually set to 20 80 F 31 day 30 25 C 31 day 25 25 C 31 day or Not Present Auto...

Page 68: ...hrenheit the controller uses to record and display temperature including historical data A complete listing of the controller operating menu is located on an 11 x 17 fold out on the last page of this...

Page 69: ...s in the menu line and the previous date disappears 9 Enter new date in YY MM DD where Y year M month and D day Decimal points must be included in the entry between the year month and day 10 Press the...

Page 70: ...y again When the F1 F2 F3 or F4 key is pressed to enter a character in the display the keypad remains on that character level until another level is selected by pressing the F1 F2 F3 or F4 key 6 When...

Page 71: ...rature control The Test takes approximately 20 25 minutes to complete See Brief PTI Pretrip Test on page 71 Also refer to Full PTI Test above A complete listing of the controller operating menu is loc...

Page 72: ...dly press the F2 or F3 key to scroll through Main menu until COMMANDS appears in LCD display 2 Press the F4 key to access the Commands menu The first command in the submenu appears in the LCD display...

Page 73: ...ator fan on high speed amp draw is measured and compared to voltage and frequency MAGNUM 2 1 Amps approx at 50 Hz 2 5 Amps approx at 60 Hz MAGNUM SL and MAGNUM 20 2 7 Amps approx at 50 Hz 3 2 Amps app...

Page 74: ...Compressor amperes are recorded in PTI log 6 7 20 seconds DIGITAL VALVE TEST AMB CON EVA 8 0C 25 0C 2 0C 9 1A 9 0A 9 1A With compressor on if condenser temperature is above 30C 86F condenser fan is tu...

Page 75: ...ecorded in PTI log None 5 seconds PTI PASS PRESS KEY Unit will remain OFF until any key is pressed If alarms occurred during PTI LCD display shows PTI FAIL PRESS KEY None Readings may vary depending o...

Page 76: ...dly press the F2 or F3 key to scroll through Main menu until COMMANDS appears in LCD display 3 Press the F4 key to access the Commands menu The first command in the submenu appears in the LCD display...

Page 77: ...porator fan on high speed amp draw is measured and compared to voltage and frequency MAGNUM 2 1 Amps approx at 50 Hz 2 5 Amps approx at 60 Hz MAGNUM SL and MAGNUM 20 2 7 Amps approx at 50 Hz 3 2 Amps...

Page 78: ...ESSOR TEST AMB CON EVA 8 0C 15 0C 5 0C 9 1A 9 0A 9 1A With compressor and condenser fan on compressor is operating at 100 percent capacity Amp draw is measured and compared to voltage Compressor amper...

Page 79: ...ious test is completed At the end of 30 minutes Chill End temperatures are recorded in PTI log Sensor values for supply LH supply RH return and evaporator sensors are recorded in the event log None 12...

Page 80: ...the F4 key to access the Commands menu The first command in the submenu appears in the LCD display 3 Press the F2 or F3 key to scroll to FUNCTION TEST 4 Press the F4 key to start the Function test LC...

Page 81: ...ondenser fan and compressor are turned off With evaporator fan on high speed amp draw is measured and compared to voltage and frequency MAGNUM 2 1 Amps approx at 50 Hz 2 5 Amps approx at 60 Hz MAGNUM...

Page 82: ...ensor must read an increasing signal of min 0 15 bars 2 175 psi 6 7 20 seconds DIGITAL VALVE TEST AMB CON EVA 8 0C 25 0C 2 0C 9 1A 9 0A 9 1A With compressor on if condenser temperature is above 30C 86...

Page 83: ...ey to scroll to desired component test CONDENSER SENSOR CHECK LOW SENSOR CHECK HEAT AFAM CLOSE AFAM OPEN EVAP LOW EVAP HIGH VAPOR INJECTION VALVE DIGITAL CONTROL VALVE COMPRESSOR Figure 43 Manual Func...

Page 84: ...N OFF switch ON and the LCD display showing the standard display setpoint 1 Press the F2 or F3 key to enter the menu list Repeatedly press the F2 key to scroll through Main menu until COMMANDS appears...

Page 85: ...tic The main relay board will now control the unit based on the manual control setting NOTE MUST check 2 pin plug location on J501 connections of main relay board to ensure correct unit operation 4 If...

Page 86: ...be set to delay opening of fresh air vent for up to 72 hours in 1 hour increments This allows faster product temperature pull down AFAM Operation The system is pre calibrated for air exchange rates o...

Page 87: ...during unit startup an alarm is recorded 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...

Page 88: ...etting appears in display 6 Press the ESC key to exit the Setpoint screen Figure 47 Setpoint Menu Change the AFAM Delay NOTE The fresh air exchange time delay should be established by the shipper The...

Page 89: ...is based on the AFAM rate and the power supply frequency Hertz 1 Press the SETPOINT key The Setpoint menu appears with the cursor in the TEMP SETP line 2 Press the F2 or F3 key to scroll to AFAM RATE...

Page 90: ...be set to Demand to control the vent door to the CO2 gas level Change the AFAM Delay NOTE The fresh air exchange time delay should be established by the shipper The AFAM delay setting keeps the fresh...

Page 91: ...and units e g 2 5 percent appears in the display 3 To change the rate press the F4 key An Enter Arrow appears in the menu line and the current rate disappears 4 Enter type the new rate in the LCD dis...

Page 92: ...ITS CO2 Max Highest level of Carbon Dioxide allowed in the container The AFAM door will open or close to maintain this level Active only when AFAM is set to DEMAND Settable from 0 25 percent Figure 50...

Page 93: ...y Setpoint Bulb Mode Evaporator Fan Speed Defrost Termination Temperature Economy Mode Humidity Control Humidity Setpoint AFAM DELAY O2 Minimum if applicable CO2 Maximum NOTE Do not modify any of the...

Page 94: ...d by the shipper 14 Press and hold the F4 key until the cursor stops flashing Door will calibrate to open position and the new rate is recorded in the datalogger and appears on the LCD display Changin...

Page 95: ...d on user settings of CO2 and O2 if equipped and AFAM DELAY The FAE door will not open until the container temperature is In Range of setpoint regardless of the CO2 and O2 if applicable readings If th...

Page 96: ...F4 key until entry is complete 7 Press ESC key to begin the Auto Config sequence Once the Auto Config is complete and the AFAM system has been found and configured into controller memory enter the de...

Page 97: ...ery supply to cycle the motor If motor does not move with independent supply motor is defective 5 Defective control module 5 If motor cycles using independent 12 VDC supply the control module is fault...

Page 98: ...or O2 sensor faulty 2 Replace analyzer Code 122 O2 Sensor Calibration Error if equipped PTI Only 1 Stale atmosphere Filter or inlet outlet tubes restricted SEE NOTE BELOW 2 O2 sensor reading 17 or 25...

Page 99: ...e used sometimes for a non AFAM load In this event the vent door must to be able to open to the setting desired by the shipper If the linkage is out of adjustment or misaligned the timing algorithm re...

Page 100: ...Operating Instructions 99 1 With the door fully sealed on the gasket linkage should not touch the top stop and the linkage angle should be towards the unit back wall Figure 52 AFAM Door Adjustment...

Page 101: ...ey to scroll cursor to the AFAM OPTION line 6 Press the F4 key The password line appears 7 Press the F2 key and then the A Key password is A Press the F4 key and then the EXIT key to enter the passwor...

Page 102: ...ble end with connector is controller end Loose wire end goes to recorder 4 Plug the RS 485 plug into controller 5 Connect power wires to battery connector on controller 6 Route recorder cable loose wi...

Page 103: ...een changed 8 Setup is complete upon completion of AUTO CONFIG test Using Special Features An operator can create a new chart from any date range of data recorded in the datalogger This is extremely v...

Page 104: ...the F4 and EXIT NOTE Date format YY MM DD NOTE Do not exceed 31 days This is the limit of the chart 10 Scroll up to place cursor on CHART CMD Press the F4 11 Use up or down to scroll to REDRAW Press...

Page 105: ...Operating Instructions 104...

Page 106: ...or plus an offset for temperature control Frozen Loads Setpoint at 10 C 14 F and Below The unit operates on Full Cool and Null to provide accurate control of frozen cargo The controller uses the retur...

Page 107: ...educing evaporator fan operation on both chill and frozen loads The use of the Economy mode should be established by the shipper and the type of cargo The Economy mode option is turned on from Setpoin...

Page 108: ...ed OFF NOTE A manual probe test can be performed by a technician by selecting SENSOR CHECK from the Manual Test Function menu Bulb Mode The Bulb mode allows the shipper to control the evaporator fan s...

Page 109: ...controller operates the unit on Cool mode with Modulation Controller energizes the vapor injection valve continuously when the cool capacity is 100 percent Heat mode electric heaters pulse on and off...

Page 110: ...modulates Chill Loads whenever the unit is in a Cooling mode Power Limit whenever the unit is in Power Limit mode Dehumidification When the Dehumidify mode is set to On the supply air temperature must...

Page 111: ...on a 60 second duty cycle to provide heat The controller pulses the electric heaters on and off until the supply air temperature increases to setpoint Frozen Loads Controller Setpoint at 10 C 14 F an...

Page 112: ...iates Defrost immediately when Temperature difference between the return air sensor and defrost evaporator coil sensor is too large Temperature difference between the left hand and right hand supply a...

Page 113: ...F switch OFF terminates defrost When the defrost mode is terminated The Heat and Defrost LEDs turn off and the heater contactor is de energized The controller starts the compressor to pre cool the eva...

Page 114: ...gas from affecting the suction pressure or cooling capacity of the evaporator coil However the economizer suction gas adds its heat and volume to the condenser side of the refrigeration system increa...

Page 115: ...ogs would take about 95 seconds for event logs only and about 210 seconds for temperature logs only Trip data from separate units is denoted by the identification information entered into the controll...

Page 116: ...interrupted or fails on a MP3000 the controller will continue to use the previous control program NOTE Installing new software does not change any configuration settings or the setpoint setting or er...

Page 117: ...or service NOTE If a controller from another unit has been installed see Automatic Configuration of Spare Parts Controller in this chapter to set configuration correctly Automatic Configuration of Spa...

Page 118: ...block rail Control Circuit Fuses Two control circuit fuses are located on the controller They protect the unit circuits and components No fuses are present on newer controllers Evaporator Overheat Sw...

Page 119: ...E CUTOUT CHECK CONDENSER PROBE Water pressure switch is open and the condenser temperature is low HIGH PRESSURE CUTOUT CHECK CONDENSER FAN Water pressure switch is open and the condenser temperature i...

Page 120: ...coil airflow Temporarily cover the compressor compartment control box and power cord storage compartment with cardboard to reduce condenser coil airflow This should increase the discharge pressure en...

Page 121: ...Installation Install the high pressure cutout switch by performing the following steps 1 Apply Locktite sealant to the threads of the switch 2 Install switch in compressor flange 3 Pressurize the comp...

Page 122: ...ave a Schrader valve in fitting and will require the refrigerant charge to be recovered from the unit On units built before December 2003 1 Recover the refrigerant charge from the unit see Recovering...

Page 123: ...ischarge only suction only or discharge and suction The sensors are located on the discharge or suction tubes near the compressor The controller will display the actual discharge or suction system pre...

Page 124: ...erse any two fan power cord leads at the condenser fan contactor disconnect power supply before reversing leads Do not move the CH ground wire Check Evaporator Fan Rotation Visually inspect the evapor...

Page 125: ...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 terminal and gr...

Page 126: ...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 compress...

Page 127: ...tely sealed by the grommet connection Left hand supply sensor installs in the sensor tube on the left side of the RH sensor tube Right hand supply sensor installed in the sensor tube on the right side...

Page 128: ...the appropriate Alarm codes to identify the defective sensor s If no sensors are found defective controller LCD display shows RUNNING WITH HIGH SUPPLY DIFFERENCE message Sensor errors recorded during...

Page 129: ...93 2 34 1 430 32 0 5 634 96 8 36 1 330 35 6 2 5 155 100 4 38 1 239 39 2 4 4 721 104 40 1 154 42 8 6 4 329 107 6 42 1 076 46 4 8 3 907 111 2 44 1 004 50 10 3 652 113 45 970 Resistance Values for Compr...

Page 130: ...d 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 contaminat...

Page 131: ...packing Back Seated Normal operation position Open to Service Port Position for servicing Front Seated To check or remove compressor Working with a Gauge Manifold Using a New Gauge Manifold Set A new...

Page 132: ...or the first time The system should be operating on Cool 10 psig 69 kPa or greater suction pressure when using this procedure to purge the low side hose Gauge hoses may be removed and re installed wit...

Page 133: ...Remove ACME fitting after purging 11 Close discharge service manifold hand valve fully to center port You are now ready to use the gauge manifold to check system pressures or perform most service pro...

Page 134: ...the receiver tank sight glass does not float after operating the unit on cool for 5 minutes the unit is low on R 404A charge With the unit operating on cool add liquid R 404A charge With the unit ope...

Page 135: ...aks are found but the system has lost its refrigerant charge proceed to the next step 6 Close both hand valves on gauge manifold front seated 7 Disconnect the refrigerant charging hose 8 Connect the c...

Page 136: ...essure testing purging and soldering can be accomplished with the use of dry nitrogen N2 The proper equipment and application of equipment is of greatest importance Purge High Side to Low Side 1 Attac...

Page 137: ...3 V 4 1 Special self sealing quick 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 Mete...

Page 138: ...a system with new refrigerant The importance of thorough evacuation and system preparation cannot be over emphasized Even infinitesimal quantities of air or moisture in a system can cause severe prob...

Page 139: ...within 5 minutes the operator should suspect the condition of the oil or the pump It is recommended that the pump oil be changed first to see if the rate of reaching a deep vacuum is improved 4 Connec...

Page 140: ...be 2000 microns or less NOTE The presence of refrigerant in the compressor oil may prevent a low vacuum reading from being achieved Compressor oil can continue to outgas for long periods of time 2 If...

Page 141: ...mperature 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...

Page 142: ...ank weight after the unit receives a full system refrigerant charge 8 Set the refrigerant tank for liquid removal Open the hand valve on the tank 9 Turn the unit off 10 Open the gauge manifold hand va...

Page 143: ...from the unit 10 Keep compressor ports covered to prevent dust dirt etc from falling into compressor Compressor Installation Install the compressor by performing the following steps 1 Slide the compre...

Page 144: ...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 145: ...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 sizes 4 Rei...

Page 146: ...emove the element from the tube 8 Unsolder the three tubes to the TXV and remove the valve from the unit 9 Prepare the tubes in the unit and on the new TXV for installation 10 Solder in the new TXV Us...

Page 147: ...operations see Using Pressurized Nitrogen in this chapter 5 Pressurize the refrigeration system and check for leaks see Refrigerant Leak Test Procedure in this chapter 6 If no leaks are found recover...

Page 148: ...mounting bracket in the condenser section 2 Clean the two liquid and two suction lines for soldering 3 Solder the liquid and suction lines to the economizer heat exchanger NOTE Thermo King strongly r...

Page 149: ...ne 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 in this chapter 3 Pressurize th...

Page 150: ...ing steps 1 Clean the tubes for soldering 2 Place the new valve in position and solder the liquid line connections 3 Pressurize the refrigeration system and check for leaks see Refrigerant Leak Test P...

Page 151: ...ctions to the valve 5 Remove the valve from the unit Digital Control Valve Installation To install the compressor digital control valve perform the following steps 1 Clean the tubes for soldering 2 Pl...

Page 152: ...example a 2 3 percent solution of SIMPLE GREEN would make a suitable cleaning solution Apply the solution using a pressure spray wash type apparatus Spray the condenser coil thoroughly from both the...

Page 153: ...resh Air System Adjusting the Fresh Air Exchange System The fresh air exchange system has an adjustable vent door for ventilation The evaporator fans draw in outside air through an air intake and disc...

Page 154: ...in handle assembly and push through handle 3 Pull handle down to lower ventilation door Insert edge of ventilation door in a notch on handle Spring loaded handle holds ventilation door in position Air...

Page 155: ...Servicing The Unit 154...

Page 156: ...t temperature Refer to the Brief PTI Test in the Operating Instructions Section Full PTI Test The MP 3000a controller contains a special Full PTI pretrip test that automatically checks unit refrigerat...

Page 157: ...set automatically Check vapor injection valve and compressor temperature sensor Compressor motor internal thermal overload protection open If compressor contactor is energized wait 60 minutes for prot...

Page 158: ...fective compressor Repair or replace compressor Condenser fan motor does not operate Unit in Heat or Defrost Check indicator lights If unit is in Heat or Defrost unit operation is normal no remedy req...

Page 159: ...hat Economy mode is set to On Loose line connection Tighten connections Open motor internal thermal overload protector Check for seized bearings or defective thermal overload protector Repair or repla...

Page 160: ...ter 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 mo...

Page 161: ...ort 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 A...

Page 162: ...rty 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 Exp...

Page 163: ...r displays new message if test indicates a sensor is defective 4 Supply Right Hand Problem Sensor Disabled Indicates Controller disables sensor due to open or short circuit or sensor failed a Probe Te...

Page 164: ...er sensor input must be left open 11 Scroll Compressor High Temperature Indicates Compressor stops because discharge temperature is above 148 C 300 F Message remains in display until discharge tempera...

Page 165: ...it on water cooled condensing with no water flow Defective condenser coil sensor or sensor location Check LCD display for High Pressure Cutout message Enter Manual Function Test menu and test operate...

Page 166: ...rature under operating conditions Indicates Low refrigerant charge Defective evaporator coil or return air sensor Incorrect connection or location of evaporator coil or return air sensor Check for sen...

Page 167: ...n pins 7 and 8 on plug J14 Resistance must be 2 000 ohms at 25 C 77 F Check cable No 1 and cable No 3 between the controller and relay board Check evaporator airflow 01 Supply Air Sensor Short Circuit...

Page 168: ...Open circuit to sensor Defective or wrong sensor Defective relay board Defective cable No 1 Defective controller Low evaporator coil temperature Check sensor resistance between pins 5 and 6 on plug J...

Page 169: ...unction test only Compressor power consumption is 25 percent below expected current draw below approximately 9 amps Indicates Defective or open fuse CB 7A high pressure cutout switch or connection in...

Page 170: ...d relay board Check heater resistance between H1 and H2 H2 and H3 and H1 and H3 Resistance should be about 99 ohms on each leg Check volt and ampere meter If both alarms 10 and 11 are activated the al...

Page 171: ...and start evaporator fans on Low speed Make sure all fans start on low speed Check fan motor volts and amps Check volt and ampere meter 15 Evaporator Fan Low Speed Current Too Low Check Alarm Occurs d...

Page 172: ...ctive volt or amp meter on relay board Enter Manual Function Test and start condenser fan Make sure the fan starts Check fan motor volts and amps Check power supply volts and amps Check volt and amper...

Page 173: ...rge NOTE This alarm can be activated if the supply or return air temperature varies even if the mean temperature does approach setpoint 20 Defrost Time Too Long Check Alarm Heat signal has been on for...

Page 174: ...or cables Open evaporator door and inspect evaporator fan rotation Make sure fans are rotating correctly on low speed Check the sensor connections Enter Manual Function Test menu Start and check curre...

Page 175: ...ssure Indicates Low pressure has occur from suction transducer sensor Possible causes include low refrigerant charge defective pressure transducer blocked TXV or suction line restriction etc Controlle...

Page 176: ...C 176 F Indicates Short circuit to sensor Defective or wrong sensor Defective relay board Defective cable No 1 Defective controller Check sensor resistance between pins 7 and 8 on plug J15 Resistance...

Page 177: ...340 VAC the unit will stop running until the voltage increases above 350 VAC If the main power supply voltage on initial unit start up is below 350 VAC the unit will not start If the voltage remains...

Page 178: ...m Low refrigerant charge Defective compressor or valve plate Defective liquid injection system Wrong or defective sensor Operate unit on Cool and check discharge and suction pressure gauge readings En...

Page 179: ...perate each 3 phase component to locate defective connection 60 Humidity Sensor Error Check Alarm Occurs during pretrip PTI test only Relative humidity reading is less than 20 percent Indicates Sensor...

Page 180: ...board 115 Probe Error Check Alarm Occurs during pretrip PTI test or probe test failed in Chilled mode Temperature difference between return air and evaporator coil sensors is too high 1 5 C 2 7 F diff...

Page 181: ...e controller and MRB 121 Discharge Pressure Sensor Indicate a problem exists with this sensor or its wiring The sensor is reading out of the range or appears to be open or shorted PTI Test Reading did...

Page 182: ...reTrip Test 70 75 Compressor Cable 39 Compartment 36 Digital Control Valve 30 Digital Control Valve Operating Theory 112 Discharge Gas Temperature Sensor Description 125 Discharge Temperature Sensor R...

Page 183: ...idity 57 Return Air Temperature 57 Supply Air Temperature Left Hand 57 Supply Air Temperature Right Hand 57 Voltage 1 Main Power Supply 57 Voltage 2 57 Voltage 3 57 Voltage Average 57 Data Recording O...

Page 184: ...h 39 Humidity Mode Setting 52 Humidity Sensor 39 Humidity Sensor Harness 39 Humidity Setpoint 53 I Initiating a Manual Defrost 48 In line Filter Installation 144 In line Filter Removal 144 In line Fil...

Page 185: ...5 Schematic and Wiring Diagrams Index 187 Scroll Compressor 30 36 38 39 Sensor Kit 39 Sequence Of Operation 47 108 Serial Number Locations 16 Service 17 Service Guide 17 Servicing The Unit 151 Set Car...

Page 186: ...p 47 USDA Probe Calibrate 60 USDA Receptacle Panel 36 37 39 V Vacuum Pump 129 Vapor Injection 105 Vapor Injection Solenoid Valve 38 Vapor Injection Valve Installation 149 Vapor Injection Valve Removal...

Page 187: ...Index 186...

Page 188: ...187 Wiring and Schematic Diagrams Index Dwg No Drawing Title Page 1E09120 Wiring Schematic 189 1E09121 Wiring Diagram 190 191 MAGNUM Refrigeration System Components 192 MP 3000a Menu Flow Diagram 194...

Page 189: ...Wiring and Schematic Diagrams Index 188...

Page 190: ...189 Wiring Schematic...

Page 191: ...190 Wiring Diagram Page 1 of 2...

Page 192: ...191 Wiring Diagram Page 2 of 2...

Page 193: ...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 194: ...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 195: ...bmenu First Component Test appears in display Press F2 or F3 key to scroll to the desired component Condensor Sensor Check Low Sensor Check Heat AFAM Close AFAM Open Evap Low Evap High Dehumidity Valv...

Page 196: ...of refrigeration and food merchandising solutions Thermo King the leader in transport temperature control and Trane a provider of energy efficient heating ventilating and air conditioning systems buil...

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