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CRR-20 & CRR-40, September 1999

Introduction

About This Manual

The information in this manual is provided to assist owners,
operators and service people in the proper upkeep and mainte-
nance of Thermo King units. The maintenance information in
this manual covers unit models:

CRR Models with Three Evaporator Fans

CRR-40-52
CRR-40-54
CRR-20SL-63
CRR-40-100
CRR-40-101
CRR-40-102
CRR-40-103
CRR-40-106
CRR-40-107
CRR-40-110
CRR-40-111
CRR-40-112
CRR-40-113
CRR-40-114
CRR-40-116
CRR-40-117
CRR-40-121
CRR-40-123
CRR-20SL-125
CRR-40-126
CRR-40-128
CRR-40-130
CRR-40-131
CRR-40-132
CRR-40-138
CRR-40-142
CRR-40-143
CRR-40-144
CRR-40-145

CRR Models with Two Evaporator Fans

CRR-40-133
CRR-40-136
CRR-40-139
CRR-40-141
CRR-40-147
CRR-40-148
CRR-40-150
CRR-40-151

Other Reference Manuals

For detailed descriptions of our refrigeration systems or micro-
processor controllers, see the appropriate manual or
Thermoguard

µ

P-D Microprocessor Controller Diagnosis

Manual. For further information refer to:

Parts Manuals

CRR-40 & CRR-20 with

µ

P-D

Parts List*

TK50193

CRR-40 & CRR-20

µ

P-D for

Hapag-Lloyd Parts List*

TK50469

CRR P & O Parts List**

TK50528

Operation, Diagnosis and Refrigeration Maintenance

Manuals

Diagnosing Thermo King Container

Refrigeration Systems

TK 41166

Electrostatic Discharge (ESD)

Training Guide

TK 40282

Evacuation Station Operation and Field

Application

TK 40612

PC-PAC™ Software Manual

P/N 204-988

Thermoguard

®

µ

P-D Microprocessor

Controller Operation and
Diagnosis Manual

TK 41230

Tool Catalog

TK 5955

*Models with three evaporator fans.
**Models with two evaporator fans.

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Summary of Contents for CRR-20

Page 1: ...CRR 20 CRR 40 with P D TK50094 4 MM Rev 5 9 99 Maintenance Manual Copyright 1999 Thermo King Corporation Minneapolis MN U S A Printed in U S A...

Page 2: ...lants as in the manufacturer s judgment to effect its stability No warranties express or implied including warranties of fitness for a particular purpose or merchantability or warranties arising from...

Page 3: ...o the atmosphere We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere In addition service personnel must be aware of Federal regulations con...

Page 4: ......

Page 5: ...or Airflow 1 3 CRR 40 Models with Three Evaporator Fans 1 3 High Performance Airflow Option for CRR 40 Models with Three Evaporator Fans 1 3 CRR 40 Models with Two Evaporator Fans 1 3 CRR 20SL Models...

Page 6: ...nheit F or Celsius C Temperatures 4 17 Displaying Alternate Controlling Supply or Return Air Sensor Temperatures 4 18 Changing the Setpoint 4 18 Initiating a Manual Defrost 4 19 Initiating a Full Pret...

Page 7: ...efrost Drains 7 2 Evaporator Fan Location 7 2 Condenser Fan Location 7 2 Fresh Air Exchange System 7 2 Partlow Model SR Recording Thermo meter Option 7 3 Recording Chart Replacement 7 3 Recording Styl...

Page 8: ...ad Setpoint at 9 9 C 14 1 F or Above Condenser Fan OFF Economy Mode ON Temperature In range 9 20 Null Mode Chill Load Setpoint at 9 9 C 14 1 F or Above During Compressor Pump Down Condenser Fan ON Eco...

Page 9: ...40 136 CRR 40 139 CRR 40 141 CRR 40 147 CRR 40 148 CRR 40 150 CRR 40 151 Other Reference Manuals For detailed descriptions of our refrigeration systems or micro processor controllers see the appropria...

Page 10: ...X X X X USDA Cold Treatment Temperature Recording X X X X X X X X X Three Evaporator Fans with 2 Speed Motors X X X X X X X X X Fresh Air Exchange System X X X X X X X X X CO2 Sampling Port X X X X X...

Page 11: ...er Emergency Bypass Module X X X X X X X X X USDA Cold Treatment Temperature Recording X X X X X X X X X Three Evaporator Fans with 2 Speed Motors X X X X X X X X X Fresh Air Exchange System X X X X X...

Page 12: ...X USDA Cold Treatment Temperature Recording X X X X X X X Three Evaporator Fans with 2 Speed Motors X X Two Evaporator Fans with 2 Speed Motors X X X X X X X X X Fresh Air Exchange System X X X X X X...

Page 13: ...X X X X X USDA Cold Treatment Temperature Recording X X X X Three Evaporator Fans with 2 Speed Motors X X X X X Two Evaporator Fans with 2 Speed Motors X X X X X X X X X Fresh Air Exchange System X X...

Page 14: ...Cold Treatment Temperature Recording Three Evaporator Fans with 2 Speed Motors X Two Evaporator Fans with 2 Speed Motors X Fresh Air Exchange System X CO2 Sampling Port X One 1 Speed Condenser Fan Mot...

Page 15: ...nt or refrigera tion system in any closed or confined area with a limited air supply for example a trailer container or in the hold of a ship Refrigerant tends to displace air and can cause oxygen dep...

Page 16: ...t People do not contact high voltage wires on purpose It occurs from an unplanned movement 5 Treat all wires and connections as high voltage until a meter and wiring diagram show otherwise 6 Never wor...

Page 17: ...the unit 4 Avoid contacting the electronic components on the circuit boards of the unit being serviced 5 Leave the circuit boards in their static proof packing mate rials until ready for installation...

Page 18: ...ller Nameplate on back of controller xiv Unit Decals Safety Precautions CRR 20 CRR 40 September 1999 Unit Decals Serial number decals refrigerant type decals and warning decals appear on all Thermo Ki...

Page 19: ...for correct logging Check calibration of graded sensors Refrigeration Check refrigerant charge Check for proper suction pressure Check compressor oil level Check compressor efficiency and pump down r...

Page 20: ...s Kcal hr BTU hr kW 460V Watts Kcal hr BTU hr kW 460V 1 7 C 35 F 11 750 10 105 40 100 10 4 9 750 8 390 33 280 8 6 17 8 C 0 F 6 005 5 170 20 500 5 7 4 985 4 290 17 015 4 7 28 9 C 20 F 3 105 2 670 10 60...

Page 21: ...8 2 17 8 C 0 F 6 300 5 418 21 500 5 1 5 250 4 515 17 920 4 2 CRR 40 Models with Three Evaporator Fans Water Cooled Condensing Option with 30 C 86 F Water Temperature System net cooling capacity with a...

Page 22: ...mm 1 2 in 4 430 2 610 2 930 1 725 40 mm 1 6 in 3 520 2 070 1 870 1 100 CRR 40 Models with Two Evaporator Fans External Static 460 230V 3 Phase 60 Hz Power 380 190V 3 Phase 50 Hz Power Pressure water H...

Page 23: ...10 psig Cutin 1655 70 kPa 16 55 0 70 bar 240 10 psig CRR 20SL 63 Cutout 2240 70 kPa 22 40 0 70 bar 325 10 psig Cutin 1590 70 kPa 15 90 0 70 bar 230 10 psig Condenser Fan Pressure Switch Open 1380 50...

Page 24: ...sig 16 to 27 C 27 to 0 kPa 0 27 to 0 bar 1030 to 1450 kPa 10 30 to 14 50 bar 60 to 80 F 8 Hg vacuum to 0 psig 150 to 210 psig 29 C 20 F Cool 27 to 38 C 45 to 35 kPa 0 45 to 0 35 bar 1030 to 1450 kPa 1...

Page 25: ...Configuration CFG C See controller identification decal Defrost Initiation Evaporator Coil Sensor Coil must be below 10 C 50 F to initiate defrost by demand timer or manual switch Demand Defrost Dema...

Page 26: ...n Set to ON for Fresh Loads Evaporator fans operate on low speed whenever the container tem perature is In range Set to ON for Frozen Loads Evaporator fans stop during Null mode Controller operates fa...

Page 27: ...Motors Red Color Finish Type 460 380V 60 50 Hz 3 Phase Number 3 or 2 Kilowatts 60 Hz Each 0 75 kW Horsepower 60 Hz Each 1 0 hp RPM 60 Hz Each 3450 rpm High Speed 1725 rpm Low Speed Full Load Amps 60...

Page 28: ...nting System Adjustable CRR 20SL 0 to 160 m3 hr 0 to 94 ft3 min 60 Hz 0 to 134 m3 hr 0 to 79 ft3 min 50 Hz CRR 40 CRR 40SL 0 to 285 m3 hr 0 to 168 ft3 min 60 Hz 0 to 236 m3 hr 0 to 139 ft3 min 50 Hz E...

Page 29: ...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 Maximum Protrusion 37 mm 1 46 in from back of flange H Unit Depth CR...

Page 30: ...g Cover 33 9 300 Bearing Cover to housing Cover 33 9 300 Stator Cover Grade 5 45 2 400 Grade 8 59 3 525 Cylinder head 59 3 525 Oil Screen Cover 31 1 275 Crankcase Heater Plug 45 2 400 Discharge and Su...

Page 31: ...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 Size Bolt Type M14 M16 M18 M22 and Class N m Ft lb N m Ft lb N m Ft lb N m Ft lb HH CL 5 8...

Page 32: ...tion unit includes a semi hermetic reciprocating compressor with forced feed lubrication system ambient com pensated internal overload and high temperature protectors and a refrigerant injection syste...

Page 33: ...red This allows the product quality to be maintained for longer periods of time Dual Voltage Option A dual voltage system includes a 15 KVA auto transformer and an 18 3 m 60 ft power cable for operati...

Page 34: ...ce of operation When the unit is started two backlit LED displays on the microprocessor illuminate A sequence start of the required loads occurs during initial start up of the microprocessor and when...

Page 35: ...resistance heaters on evaporator fans stop NOTE If the Economy Mode is set to ON in the Program menu of the P D controller the unit continues in Cool until the return air temperature decreases to the...

Page 36: ...o Evaporator Fans 2 Evaporator Access Door 1399 mm 55 04 in Wide with Three Latches Models with Three Evaporator Fans 3 Heater Access Panel Location 4 Condenser Fan 5 Compressor Compartment 6 Supply A...

Page 37: ...uge Option 4 Dual Voltage Option 5 TRANSFRESH Download Receptacle Option 6 Remote Monitor Plug Option 4 Pin Connector on Side of Control Box 7 Thermistor Lead Option Lead inside Control Box 8 Remote M...

Page 38: ...h Three Evaporator Fans Front View 1 Evaporator Fan Blade see Physical Specifications on page 1 9 for description 2 Evaporator Fan Motor 3 Return Air Sensing Bulb for Recording Thermometer Option 4 Re...

Page 39: ...th Two Evaporator Fans Front View 1 Return Air Sensing Bulb for Recording Thermometer Option 2 Return Air Sensor 3 Humidity Sensor Option 4 Evaporator Fan Blade see Physical Specifications on page 1 9...

Page 40: ...or Coil 4 Tube Standard 5 Heat Exchanger 6 KVQ Valve Evaporator Pressure Regulator 7 High Pressure Cutout Switch 8 Liquid Line Service Valve 9 In line Filter Units before 3 9 99 10 Filter Drier Units...

Page 41: ...n Before 8 99 1a High Pressure Relief Valve 1b Water Outlet Coupling 1c Water Pressure Switch 1d Water Inlet Coupling 2 Water Cooled Condenser Receiver Tank Option After 8 99 2a Fusible Plug 2b Water...

Page 42: ...or Option Relays 4 Pin plug is located on side of control box bottom of control box on CRR 20SL 63 9 Unit On Off Switch 10 Data Retrieval Receptacle located on bottom of control box on some models 11...

Page 43: ...ions Unit Description CRR 20 CRR 40 September 1999 1 2 3 Sabroe or RTE Remote Monitor Modem Option for Power Line Communications 1 High Voltage Tray in Control Box 2 Modem Plug and Harness 3 Sabroe Co...

Page 44: ...20 CRR 40 September 1999 Unit Description Unit Illustrations 2 13 1 2 3 4 5 Dual Voltage Option 1 15 KVA Transformer 2 460 380V Power Receptacle 3 Cable Bracket 4 230 190V Power Cable 5 Power Plug Opt...

Page 45: ...llustrations Unit Description CRR 20 CRR 40 September 1999 1 2 3 4 5 Auxiliary Battery and Battery Charger Option 1 12 Vdc Battery 2 Battery Charger Box 3 Battery Charger 4 Terminal Board 5 Battery Ch...

Page 46: ...Scrubber Connection and A5 Wire Harnesses 2 Evaporator Grille 3 TRANSFRESH Door Assembly 4 TRANSFRESH Download Port 5 Transformer Assembly mounted in Control Box 6 TRANSFRESH Provision Option include...

Page 47: ...20 CRR 40 September 1999 10 9 8 7 6 1 2 3 4 5 Humidify System Option 1 Evaporator Drain Hose 2 Fill Cap 3 Water Tank Heater 4 Tank Overflow Hose 5 Drain Cock 6 Water Tank 7 Water Filter 8 Water Supply...

Page 48: ...4 5 Typical Unit Back View 1 Evaporator Grille 2 Unit Gasket 3 Top Rear Plate 4 Bottom Rear Plate 5 Sensor Connector Assembly Controller Communications and Data Download Port Cargo Pulp Sensor Connect...

Page 49: ...isplay Alternate display shows while the key is pressed 7 DEFROST KEY Press this key to prepare the controller to initiate a manual defrost cycle Then press the ENTER key to LOAD a manual defrost If t...

Page 50: ...SS A compressor oil sight glass indicates the relative level of compressor oil in the compressor sump 4 SUCTION PRESSURE GAUGE OPTION A suction pressure gauge indicates the refrigerant pressure in the...

Page 51: ...ressor Head Over Temperature is generat ed The controller will restart the compressor when the fault condition corrects itself resets 4 EVAPORATOR OVER TEMPERATURE PROTEC TION An evaporator coil senso...

Page 52: ...hen water lines are disconnected also check to be sure that the water drains completely from the condenser receiver tank Report defective fittings and tanks that do not drain to a technician 9 Optiona...

Page 53: ...d during the Full Pretrip Test the Alarm LED will turn ON PTRIP FAIL is stored in the datalogger memory and the unit returns to normal operation unless a shutdown fault has occurred View and correct a...

Page 54: ...display briefly shows LOAD The controller then returns to the Standard Display showing new setpoint NOTE If the ENTER key is not pressed within 10 seconds the controller will default return to the pre...

Page 55: ...ller menu DOWN Press to decrease the setpoint or scroll DOWN through controller menu ENTER Press to load the setpoint or other setting and execute other controller tasks C F Temperature Press to view...

Page 56: ...r 12 Data recording capability see Data Recording and Downloading Data in this chapter 13 Electronic phase selection see Automatic Phase Selection under General Theory of Operation in this chapter 14...

Page 57: ...Economy Mode ECON ON Economy mode reduces unit power consumption by reducing evap orator fan operation ECONT XXXXX Shows the time remaining to next controller check of return air temperature active on...

Page 58: ...NT TEMPERATURE DATA DATA View Menu Menu screens in this group are used to display unit operating information sensor grades and scrollback data logger data including controlling sensor temperatures and...

Page 59: ...n Low Speed EFL l Evaporator Fan Low Speed Phase 1 Amps EFL 2 Evaporator Fan Low Speed Phase 2 Amps EFL 3 Evaporator Fan Low Speed Phase 3 Amps ELECT Electrical Test Submenu ENTER Enter ETEST Extended...

Page 60: ...iew Menu VOLTS Total Voltage YEAR Current Year Status Indicator LEDs and Alarm Codes The indicator LEDs stay ON continuously to indicate a unit operating mode or condition The Alarm LED stays ON con t...

Page 61: ...rent Out of Range Shutdown Pretrip 58 Check Sensor Calibration Failure Pretrip Shutdown 59 Check Datalogger Full P A 60 Check Datalogger Full Global 61 Check Real Time Clock Invalid 63 Check Bypass Va...

Page 62: ...C software Trip data from sepa rate units is denoted by the identification information entered into the controller at the beginning of the trip by PC PAC soft ware Identification data may include the...

Page 63: ...n the Compressor discharge temperature exceeds 138 C 280 F Liquid injection stops when the compressor discharge tem perature decreases to 132 C 270 F When liquid injection is active the controller ene...

Page 64: ...sensor is defective and the setpoint is 10 0 C 14 0 F or below the controller records alarm code 3 and resumes normal operation If the temperature difference between both the supply and return air sen...

Page 65: ...peratures Sequence Of Operation Unit Start up A sequence start of the required loads occurs during initial start up of the controller If cooling or heating is required the unit operates in the cool or...

Page 66: ...ans operate on low speed 2Null Mode On Chill Loads the compressor stays ON for 60 seconds to pump down the low side On Frozen Loads the compressor stays ON for 30 seconds to pump down the low side 3Co...

Page 67: ...t provides maximum cooling capacity Power limit is active when the unit is operating in the Cool mode Chill Loads Frozen Loads Setpoints at 9 9 C Setpoints at 10 0 C 14 4 F and Above 14 0 F and Below...

Page 68: ...econds later If the condenser fan was ON it will operate for 30 sec onds and then stop If the condenser fan was OFF based on condensing pressure it will remain OFF The evaporator fans continue to oper...

Page 69: ...ns 5015 or 5016 loaded CRR 40 52 units Cool Controller calls for the Cool mode whenever the return air temperature is more than 1 0 C 1 8 F above setpoint Power limit is active when the unit is operat...

Page 70: ...frost occurs Customer Configuration C5 Standard default times but maximum time interval is 12 hours on frozen loads Customer Configuration C6 2 hour initial defrost then maximum time interval is 6 hou...

Page 71: ...OOL SETPOINT TEMPERATURE DATA DATA IN RANGE DEFROST SUPPLY RETURN PWRLMT ALARM HEAT NULL MOD COOL SETPOINT TEMPERATURE DATA DATA 71 NOTE The unit will operate and control the con tainer temperature if...

Page 72: ...temperature 1 Press the DOWN or UP arrow key The left display flash es SETPT while the right display shows the changing setpoint temperature To set the tenths digit wait 4 sec onds for all three digi...

Page 73: ...HEAT NULL MOD COOL SETPOINT TEMPERATURE DATA DATA IN RANGE DEFROST SUPPLY RETURN PWRLMT ALARM HEAT NULL MOD COOL SETPOINT TEMPERATURE DATA DATA IN RANGE DEFROST SUPPLY RETURN PWRLMT ALARM HEAT NULL M...

Page 74: ...IN RANGE DEFROST SUPPLY RETURN PWRLMT ALARM HEAT NULL MOD COOL SETPOINT TEMPERATURE DATA DATA 2 Write down the first alarm code Then press the DOWN key to view the next alarm code 3 Repeat step 2 unt...

Page 75: ...Menu View Functions NOTE Information can ONLY be displayed using the View menu Items can NOT be changed See MENU PRGRM in this chapter for information about setting control functions The View menu dis...

Page 76: ...until display shows MENU VIEW 3 Press the SELECT key to enter VIEW submenu display shows VIEW 4 Press the UP key until VIEW GRADE shows in the display 5 Press the SELECT key to enter the Grade submen...

Page 77: ...DA 2 Sensor Temperature U3 Spare 3 USDA 3 Sensor Temperature HM Humidity PP Pulp Probe Sensor Temperature YR Year MO Month DY Day TI Time When viewing information in the TEMP or PTI scrollback display...

Page 78: ...imagine that the data is stored in a table The first column identifies the number of the Full Pretrip test PT1 PT2 etc and the test result PASS or FAIL Each additional column identifies information a...

Page 79: ...Full Pretrip Test includes Display Controller lights all segments in the display for visual inspection by technician Amps Controller individually energizes all outputs including fan and compressor mot...

Page 80: ...ng display will show LOAD PTRIP The controller then conducts an Extended Pretrip Test d When the test is complete the unit shuts down To initiate a Full Pretrip Test a Press the SELECT key with PTRIP...

Page 81: ...of the heaters motors or unit during Full Cool Modulation 50 Modulation 100 Heat and Defrost Refrigeration REFRG Perform system diagnostics and check supply and return air temperatures during each uni...

Page 82: ...shows TEST ELECT 6 Press SELECT key to enter a sub submenu display shows ELECT 7 Press the DOWN key to view functions in sub submenu Press the UP key to scroll back through sub submenu The display sh...

Page 83: ...rtain that all changes in the programmable features are activated Navigating Menu Guard Screens With the unit On Off switch ON and the controller showing the Standard Display 1 Press the SELECT key to...

Page 84: ...is reset NOTE If the Customer Configuration has already been set the current number ZZ format will show instead of 0 The Unit Configuration MUST always be set first The Customer Configuration MUST al...

Page 85: ...digit and begins to scroll to the left again Check to make sure Unit Serial Number was entered correctly NOTE If a new controller or new software has been installed proceed immediately to Setting the...

Page 86: ...shows CHRM1 XXXX where XXXX is the new compressor run hours 2 From CHRM1 XXXX in the controller display press the DOWN key until the display shows ONHRM XXXX where XXXX is the number of unit on hours...

Page 87: ...commends ice bath calibration when replacing the Return Air Supply Air and Coil Temperature Sensors If an ice bath is NOT available the controller should be set to the grade stamped on each individual...

Page 88: ...en the sensor tem perature NOTE The sensor should be in the ice bath a total of 15 minutes or more to assure the sensor temperature has bottomed out c To set the sensor grade Press the UP or DOWN key...

Page 89: ...be in the ice bath a total of 15 minutes or more to assure the sensor temperature has bottomed out c To set the sensor grade Press the UP or DOWN key to choose the grade setting 5 When the desired gr...

Page 90: ...USDA Cold Treatment Temperature Recording USDA sensor temperatures are recorded in the data logger memory The USDA sensors should be connected to the controller and located in the load as shown in US...

Page 91: ...display briefly shows USDA1 LOAD then USDA1 and the sensor temperature 00 0 C and returns to the USDA1 ON display NOTE The sensors should be in the ice bath a total of 15 minutes or more to assure th...

Page 92: ...If the Economy Mode is set to ON the con troller display will show ECON ON for 1 second every 10 seconds Chill Loads return air temperatures of 9 9 C 14 1 F and above Evaporator fans operate on low sp...

Page 93: ...s equipped with the option and the controller is set to the correct unit configuration Also the Dehumidify and Humidify options can NOT be turned ON at the same time 5 To change the current setting pr...

Page 94: ...Standard Display Bulb Mode Option Changing the Bulb screen from OFF to ON automatically acti vates the Dehumidify Mode and allows the defrost termination temperature and evaporator fan speed to be se...

Page 95: ...BEFAN in the left display and the cur rent fan speed selection in the right display e g CYCLE NOTE Press and hold the SELECT key for 3 sec onds to return to the Standard Display Power Reduction Mode C...

Page 96: ...e and connect it to the bottom of the Emergency Bypass Module NOTE Make sure the Phase Rotation Switch on the Emergency Bypass Module is OFF 4 Connect the unit power cord to the proper power supply 5...

Page 97: ...munications commands Indicator LEDs on the Output Module turn ON to show an out put is energized The RXD and TXD LEDs alternately flash continuously to show the communications connection is good If on...

Page 98: ...witch OFF Then unplug the unit power cord from the power supply 3 Disconnect the wire harness connectors from the back of the controller 4 Remove the screws that secure the controller to the con trol...

Page 99: ...indicates a failed sensor check the sensor by substitution Diagnosis and Repair If the unit appears to be operating incorrectly view any alarm codes that may be stored in the controller display memory...

Page 100: ...ensor is defective or the circuit is open or shorted Indicates a problem exists with this sensor or its wiring The sensor is reading out of Check sensor by substitution Be sure sensor range or appears...

Page 101: ...aintain the correct polarity the compressor running or the sensor will not work If alarm occurs during a Pretrip test a NOTE Do NOT use a test light or other instru dash precedes the alarm code ment o...

Page 102: ...st submenu operating in Heat or Defrost Check evaporator coil sensor using View Menu Evaporator coil has exceeded high temperature limit Check airflow over evaporator coil 10 High Pressure Cutout Chec...

Page 103: ...test in the Electrical Test submenu Indicates the controller terminated a defrost Check for correct evaporator fan operation using cycle due to time the REFRG DFRST test in the Refrigeration Test subm...

Page 104: ...ive or the circuit is open or shorted Be sure Indicates a problem exists with this sensor the sensor is securely attached to the connector or its wiring The sensor is reading out of inside the unit ra...

Page 105: ...Disconnect supply power and check resistance of detection circuit was unable to determine each heater leg Correct open or shorted heaters correct phase rotation or if phase contactor ABC or CBA fails...

Page 106: ...circuit is open or shorted Indicates a problem exists with this sensor or its wiring The sensor is reading out of Check the sensor by substitution Be sure the range or appears to be open or shorted s...

Page 107: ...timeter Place unit in Full Cool mode using Indicates compressor current draw is not within REFRG FC HI in the Refrigeration Test submenu the high or low limits when the compressor Current draw on each...

Page 108: ...rator airflow If current draw is low check for a motor not operat ing Check condenser fan motor current draw using AMPS CFH in the Electrical Test submenu Current draw for condenser fan only should be...

Page 109: ...low supply power voltage Check or Shutdown Alarm Check the heater element current draw using the Indicates total unit current draw is not within REFRG HEAT test in the Refrigeration Test acceptable li...

Page 110: ...de at 480V Current draw on each leg should be within 0 2 amperes of each other If alarm occurs during a Pretrip test a dash precedes the alarm code Visually inspect the heater contactor Check the outp...

Page 111: ...aw is high check evaporator fan motors for free rotation and proper condition Check If alarm occurs during a Pretrip test a direction of fan rotation counterclockwise as shown dash precedes the alarm...

Page 112: ...aw is high check evaporator fan motors for free rotation and proper condition Check If alarm occurs during a Pretrip test a direction of fan rotation counterclockwise as shown dash precedes the alarm...

Page 113: ...Test submenu Then confirm that output LED AC14 is ON If current draw on each leg is not within 0 2 amperes of each other during current draw test check the current transformer Turn unit OFF and disco...

Page 114: ...date time settings Indicates real time clock has been corrupted If real time clock can NOT be reset replace the due to faulty battery static discharge etc controller Up to 12 hours of datalogger and...

Page 115: ...e View menu Indicates an error occurred in the datalogger Check for the presence of Alarm Code 61 Check real time clock battery voltage using CLKV in View menu Replace battery if voltage is less than...

Page 116: ...meter type and proceed according to Check Alarm company requirements Reset the hourmeter if required Indicates time set on a user hourmeter has expired 79 Data Overflow No corrective action possible T...

Page 117: ...of Range Check for low supply power voltage Check or Shutdown Alarm Check the compressor current draw with a digital Indicates compressor motor has failed to multimeter Place unit in Full Cool mode us...

Page 118: ...fan operation Continuity check circuit wiring using a high quality multimeter Be sure to maintain the correct polarity or the sensor will not work NOTE Do NOT use a test light or other instru ment or...

Page 119: ...eck the battery voltage during the unit pretrip inspec tion The battery is a 12 Vdc 7 or 12 Amp hour Gel Cell The voltage should be 12 4 to 12 7 Vdc If the voltage is 11 5 to 12 39 Vdc the battery mus...

Page 120: ...n alarm codes are cleared by pressing the ENTER key the unit will start auto matically If the HPCO switch fails to stop compressor operation replace the switch and repeat steps 1 through 4 Condenser F...

Page 121: ...tioning inspect the connections If the connections appear correct and secure isolate and check the resistance of each individual heater element by disconnecting it from the circuit Check resistance wi...

Page 122: ...ng of non HFC refrigerants in R 134a units These fittings are located in three places on CRR refrigeration systems Low side near the compressor suction service valve or suc tion adapter High side near...

Page 123: ...an oil acid test oil test kit P N 203 457 whenever a unit has a substantial refrigerant loss a noisy compressor or dark dirty oil Compressor Discharge and Suction Service Valves The discharge and suc...

Page 124: ...dicate low and high side pressures Operate one or both hand valves to perform the different ser vice operations Balancing the Pressure 1 Quick Disconnect Access Valve 2 Discharge Service Valve DSV 3 S...

Page 125: ...Gauge hoses may be removed and re installed without additional purging so long as a slight positive pressure remains in the manifold and lines when removed from the unit 1 Inspect gauge manifold for p...

Page 126: ...itting hand wheel counterclockwise to depress the port valve stem to equalize pressure at 21 kPa 0 21 bar 3 psig 4 Rotate both coupler hand wheels counterclockwise to close seal the valve port stems t...

Page 127: ...oil pressure fitting 2 Operate the unit and remove oil while watching the level in the compressor sight glass NOTE Heavy foaming of the oil as it leaves the compressor may indicate an excess of refrig...

Page 128: ...f switch CAUTION Never open the low side to the atmos phere while it is in a vacuum Air and moisture will be drawn in and contaminate the refrigerant system 4 To place the unit back in service open th...

Page 129: ...OAT at any time the R 134a charge is low If the TOP sight glass ball FLOATS ALL THE WAY TO TOP of sight glass the unit is over charged c Water cooled Condenser receiver Tank with one sight glass After...

Page 130: ...al plating as the softer material begins to cover the inside of the system If this condition is not stopped it can result in the total destruction of your equipment Compressor Oil Color Code BLACK OIL...

Page 131: ...erations CRR 20 CRR 40 September 1999 Evacuation Station and Unit Hook up 1 Special self sealing quick disconnect couplers are required for R 134a units 2 Gas Ballast Valve 3 Iso Valve 4 Two stage Vac...

Page 132: ...xists or there is moisture in the system Perform a Pressure Rise Test and evaluate 3 Close valve V1 when the desired vacuum level has been reached 4 Wait five minutes and read the Micron Meter A syste...

Page 133: ...t tank with gauge manifold to the evacuation station see Evacuation Station and Unit Hookup in this chapter 6 Weigh the tank of refrigerant 7 Check the unit data plate for the required weight of refri...

Page 134: ...and slowly open the gauge man ifold low pressure hand valve to permit suction pressure to increase approximately 170 kPa 1 7 bar 25 psig This will meter liquid refrigerant slowly into the low side 7...

Page 135: ...rcuit preventing the valve from operating properly 1 To replace actuator assembly unplug the heater and ther mistor lead wire harnesses 2 Connect the unit s main power cable to the main power source a...

Page 136: ...lve 12 Verify that all personnel are clear and connect main power plug to power supply Start the unit and check the refrig erant charge Add refrigerant as required Refrigerant Recovery Caution Use onl...

Page 137: ...ass any time the pres sure exceeds its setting 6 Open valve slowly use regulators and safety valves that are in good working order 7 The regulator should have two gauges one to read tank pressure the...

Page 138: ...before placing the new compressor or repaired compressor in the unit Installation 1 Slide the compressor into the unit Install mounting bolts washers and nuts and tighten 2 Bolt the discharge valve t...

Page 139: ...equalize the pres sure to 21 kPa 0 21 bar 3 psig 2 Place the new dehydrator or in line filter near the unit for immediate installation 3 Using two wrenches crack both dehydrator or in line filter lin...

Page 140: ...on tainer temperature to see that the expansion valve is prop erly installed and that the feeler bulb is properly located Heat Exchanger Replacement Removal 1 Close the liquid line service valve and p...

Page 141: ...s see Refrigerant Leak Test Procedure in this chapter 4 Evacuate the system see Evacuation and Cleanup of the Refrigeration System in this chapter 5 Recharge the unit see Refrigerant Charge in this ch...

Page 142: ...the Refrigeration Maintenance chapter of this manual 6 Reconnect the electrical wires to the valve 7 Open the liquid line service valve and place the unit in operation Check the refrigerant charge and...

Page 143: ...connections 4 Unbolt and remove the valve from the unit Installation 1 Clean the tubes for soldering 2 Place the new valve in position 3 Solder the liquid line connections CAUTION Use a heat sink or w...

Page 144: ...esent on the condenser coil the coil should be cleaned using a mild alkaline cleaner with a pH of 9 5 to 10 5 For example a 2 3 solution of SIMPLE GREEN would make a suitable cleaning solution Apply t...

Page 145: ...n blade and hub assembly on the fanshaft center the assem bly in the orifice Position the front of the fan blade 10 mm 0 4 in in from the outer edge of the fan orifice Fresh Air Exchange System The fr...

Page 146: ...g the Allen screw on the lifter arm 4 Hold the recording chart in position and tighten the chart nut finger tight 5 Lower the pen by rotating the lifting arm counterclock wise and pushing the pen agai...

Page 147: ...pectancy The sensor bulb is mounted in the evaporator to record the return air tem perature The recording thermometer should be inspected and cleaned to ensure that the stylus produces smooth clean li...

Page 148: ...ording thermometer sensing bulb located in the evaporator near the return air grille Make sure it is securely fastened and clear of debris 2 Start the unit and adjust the temperature setpoint to 0 C 3...

Page 149: ...2 Remove the recording platen 3 Loosen the two terminal screws on the terminal board and remove the motor wires 4 Loosen the five screws that mount the motor assembly in the recorder Remove the motor...

Page 150: ...is not operating NOTE Only demineralized or distilled water should be used to prevent plugging of the atomizing nozzle Pretrip Inspection The following items should be inspected before loading the con...

Page 151: ...ve Replace compressor contactor No output signal from controller Diagnose and replace output module or output module controller Unit on defrost Turn unit On Off switch OFF and then ON again Defective...

Page 152: ...place Open circuit in compressor motor Check motor stator connections Check winding stator winding for continuity If open replace compressor Defective compressor motor internal Replace thermal overloa...

Page 153: ...operation Option pressure unit operation is normal Unit in Cool or Modulation Check indicator lights and discharge pres sure If condenser head pressure is below 1100 50 kPa 11 0 0 5 bar 160 7 psig un...

Page 154: ...of P D controller to verify that Economy Mode is set to ON Loose line connection Tighten connections Open motor internal thermal Check for seized bearings or defective overload protector thermal overl...

Page 155: ...r plugged evaporator coil Defrost or clean evaporator coil Expansion valve partially closed by Clean or replace expansion valve ice dirt or wax Expansion valve power element lost Replace expansion val...

Page 156: ...ide Clear restriction Plugged dehydrator or in line filter Change dehydrator or in line filter Compressor inefficient Perform compressor efficiency test Check valves and pistons Evaporator pressure re...

Page 157: ...pressure too high Refrigerant overcharge Purge system Air in refrigeration system Evacuate and recharge Dirty or restricted condenser coil Clean condenser coil Defective condenser fan pressure Replac...

Page 158: ...or defective Hot liquid line Shortage of refrigerant Repair or recharge Expansion valve open too wide Adjust or replace expansion valve Frosted liquid line Liquid line service valve partially Open val...

Page 159: ...vaporator coil Defrost or clean evaporator coil Suction and discharge pressures may drop below Restricted lines Locate and clear restriction expected normal readings when the unit is on Plugged dehydr...

Page 160: ...CRR 20 CRR 40 September 1999 9 Electrical Refrigeration and P D Menu Flow Diagrams 460 380 Vac Power Supply to Unit1 1 Typical model shown with three evaporator fans...

Page 161: ...9 2 Schematic Circuit Tracings Electrical Refrigeration and P D Menu Flow Diagrams CRR 20 CRR 40 September 1999 1 Typical model shown with three evaporator fans 230 190 Vac Power Supply to Unit1...

Page 162: ...Flow Diagrams Schematic Circuit Tracings 9 3 1 Typical model shown with three evaporator fans 2 Requires on board 12 Vdc battery or an external 12 Vdc battery connected to battery jack on Power Modul...

Page 163: ...peration requires an on board 12 Vdc battery or an external 12 Vdc battery connected to the battery jack on Power Module Board inside control box Then press SELECT key or connect communications cable...

Page 164: ...Menu Flow Diagrams Schematic Circuit Tracings 9 5 1 Typical model shown with three evaporator fans 12 5 Vdc Control Circuit Sensor Circuits Evaporator Pressure Regulator KVQ Valve Circuit Condenser Fa...

Page 165: ...9 6 Schematic Circuit Tracings Electrical Refrigeration and P D Menu Flow Diagrams CRR 20 CRR 40 September 1999 1 Typical model shown with three evaporator fans 24 Vac Control Circuit1...

Page 166: ...40 September 1999 Electrical Refrigeration and P D Menu Flow Diagrams Schematic Circuit Tracings 9 7 1 Typical model shown with three evaporator fans Setpoint Enable Battery and Battery Charger Circu...

Page 167: ...Circuit Tracings Electrical Refrigeration and P D Menu Flow Diagrams CRR 20 CRR 40 September 1999 1 Typical model shown with three evaporator fans Remote Monitor Receptacle 4 pin for Bridge Lights Ci...

Page 168: ...CRR 40 September 1999 Electrical Refrigeration and P D Menu Flow Diagrams Schematic Circuit Tracings 9 9 1 Typical model shown with three evaporator fans TRANSFRESH Atmosphere Control System Circuit1...

Page 169: ...Schematic Circuit Tracings Electrical Refrigeration and P D Menu Flow Diagrams CRR 20 CRR 40 September 1999 1 Typical model shown with three evaporator fans Integrated Remote Monitor System Circuit1 O...

Page 170: ...ans Dehumidify System Humidity System Water Pressure Switch USDA Temperature Sensor Pulp Sensor and Chart Recorder Circuits Options CRR 20 CRR 40 September 1999 Electrical Refrigeration and P D Menu F...

Page 171: ...optional water cooled condenser receiver tank the con denser fan does not operate When water pressure is disconnected from the condenser receiver tank condenser fan operation resumes Standard units h...

Page 172: ...acings 9 13 1 Typical model shown with three evaporator fans 2 Condenser fan will stop if condenser head pressure decreases to 1100 50 kPa 11 00 0 5 bar 160 7 psig Cool Mode1 Chill Load Setpoint at 9...

Page 173: ...grams CRR 20 CRR 40 September 1999 1 Typical model shown with three evaporator fans 2 Condenser fan will stop if condenser head pressure decreases to 1100 50 kPa 11 00 0 5 bar 160 7 psig Cool Mode1 Ch...

Page 174: ...Typical model shown with three evaporator fans 2 Condenser fan will stop if condenser head pressure decreases to 1100 50 kPa 11 00 0 5 bar 160 7 psig Cool Mode1 Chill Load Setpoint at 9 9 C 14 1 F or...

Page 175: ...model shown with three evaporator fans 2 Condenser fan will stop if condenser head pressure decreases to 1100 50 kPa 11 00 0 5 bar 160 7 psig Cool Mode1 Chill Load Setpoint at 9 9 C 14 1 F or Above C...

Page 176: ...rcuit Tracings 9 17 1 Typical model shown with three evaporator fans 2 Condenser fan will stop if condenser head pressure decreases to 1100 50 kPa 11 00 0 5 bar 160 7 psig Modulation Mode1 Chill Load...

Page 177: ...11 00 0 5 bar 160 7 psig 3 Dehumidify Mode is set to ON in the PROGRAM menu of the controller When the unit is in Low Dehumidify opera tion humidity 1 5 above setpoint the dehumidify valve closes ener...

Page 178: ...s set to ON in the PROGRAM menu of the controller When the unit is in High Dehumidify opera tion 5 or more above setpoint the dehumidify valve closes energizes to reduce the size of the evaporator coi...

Page 179: ...nser fan will stop if condenser head pressure decreases to 1100 50 kPa 11 00 0 5 bar 160 7 psig 3 Evaporator fans operate on low speed when Economy Mode is set to ON in the Program menu of the P D con...

Page 180: ...oses de energizes the liquid line solenoid valve while the compressor continues to operate Controller stops compressor to terminate pump down cycle on time limit after 60 seconds If the condenser fan...

Page 181: ...Electrical Refrigeration and P D Menu Flow Diagrams CRR 20 CRR 40 September 1999 1 Typical model shown with three evaporator fans Null Mode1 Chill Load Setpoint at 9 9 C 14 1 F or Above After Compres...

Page 182: ...9 C 14 1 F or Above Economy Mode OFF Temperature In range 1 Typical model shown with three evaporator fans 2 Electric heaters pulse ON and OFF during the Heat mode The amount of ON time increases from...

Page 183: ...shown with three evaporator fans 2 Condenser fan will stop if condenser head pressure decreases to 1100 50 kPa 11 00 0 5 bar 160 7 psig Cool Mode1 Frozen Load Setpoint at 10 0 C 14 0 F or Below Conde...

Page 184: ...ypical model shown with three evaporator fans 2 Condenser fan will stop if condenser head pressure decreases to 1100 50 kPa 11 00 0 5 bar 160 7 psig Cool Mode1 Frozen Load Setpoint at 10 0 C 14 0 F or...

Page 185: ...RR 20 CRR 40 September 1999 1 Typical model shown with three evaporator fans 2 Controller stops the compressor If the condenser fan was ON it will operate for 30 seconds and then stop Null Mode1 Froze...

Page 186: ...Program menu of the P D con troller During Economy Mode operation a Null state timer automatically starts and operates the evaporator fans on low speed for 5 minutes every 45 minutes The unit remains...

Page 187: ...9 28 Electrical Refrigeration and P D Menu Flow Diagrams CRR 20 CRR 40 September 1999 1 Typical model shown with three evaporator fans Defrost1...

Page 188: ...Electrical Refrigeration and P D Menu Flow Diagrams CRR 20 and CRR 40 All Models Except CRR 40 133 CRR 40 139 Wiring Schematic 9 29 CRR 20 CRR 40 September 1999...

Page 189: ...Electrical Refrigeration and P D Menu Flow Diagrams CRR 20 and CRR 40 Wiring Diagram All Models Except CRR 40 133 CRR 40 139 Page 1 of 3 9 30 CRR 20 CRR 40 September 1999...

Page 190: ...Electrical Refrigeration and P D Menu Flow Diagrams CRR 20 and CRR 40 Wiring Diagram All Models Except CRR 40 133 CRR 40 139 Page 2 of 3 9 31 CRR 20 CRR 40 September 1999...

Page 191: ...Electrical Refrigeration and P D Menu Flow Diagrams CRR 20 and CRR 40 Wiring Diagram All Models Except CRR 40 133 CRR 40 139 Page 3 of 3 9 32 CRR 20 CRR 40 September 1999...

Page 192: ...Electrical Refrigeration and P D Menu Flow Diagrams CRR 40 133 CRR 40 139 Wiring Schematic 9 33 CRR 20 CRR 40 September 1999...

Page 193: ...Electrical Refrigeration and P D Menu Flow Diagrams CRR 40 133 CRR 40 139 Wiring Diagram Page 1 of 3 9 34 CRR 20 CRR 40 September 1999...

Page 194: ...Electrical Refrigeration and P D Menu Flow Diagrams CRR 40 133 CRR 40 139 Wiring Diagram Page 2 of 3 9 35 CRR 20 CRR 40 September 1999...

Page 195: ...Electrical Refrigeration and P D Menu Flow Diagrams CRR 40 133 CRR 40 139 Wiring Diagram Page 3 of 3 9 36 CRR 20 CRR 40 September 1999...

Page 196: ...n Valve TXV 19 Expansion Valve Feeler Bulb 20 Equalizer Line 21 Distributor 22 Evaporator Coil 23 Electric Heaters 24 Return Air Sensor RET 25 Evaporator Coil Sensor ECOIL 26 Supply Air Sensor SUP 27...

Page 197: ...e Plug BLOWS at 100 C 212 F 29 Controller P D Thermoguard P D with digital thermostat thermometer and fault indicator monitor Null Mode Operation During the Null mode the compressor does not operate I...

Page 198: ...Q Valve Is a normally OPEN actuator valve It CLOSES or OPENS according to the strength and frequency of a pulsing voltage signal from the controller The voltage signal energizes a heating element in t...

Page 199: ...air 34 Dehumidify Solenoid Valve DSV Option Is a normally OPEN valve If the container humidity is between 1 and 5 above the humidity setpoint and the temperature is in range the controller will energi...

Page 200: ...orms a sensor check test 3PAUSE screen indicates controller has stopped unit operation due to a shutdown alarm Controller restarts unit if alarm condition is corrected 4Screen shows ONLY if spare sens...

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