Thermo King CRR-40 119 Page 44 Manual Download

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Unit Description

AJA1411

Evaporator Grille

Unit Gasket

Top Rear Plate

Bottom Rear Plate

Sensor Connector Assembly
Controller Communications and Data Retrieval Connection
USDA1 Sensor Connection
USDA2 Sensor Connection
USDA3 Sensor Connection
USDA4 Sensor Connection

Figure 11: Unit Back View

Summary of Contents for CRR-40 119

Page 2: ...r purpose or merchantability or warranties arising from course of dealing or usage of trade are made regarding the information recommendations and descriptions contained herein Manufacturer is not res...

Page 3: ...to 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 co...

Page 4: ......

Page 5: ...re Torque Chart 31 Compressor Torque D3D Copeland Compressor Bolt Torque 31 Unit Description 33 General Description 33 Semi Hermetic Reciprocating Compressor with Liquid Injection Cooling System 33 Du...

Page 6: ...etpoint 65 Initiating a Manual Defrost 65 Displaying Alternate Controlling Supply or Return Air Sensor Temperature 65 Displaying Alternate Fahrenheit F or Celsius C Temperatures 66 Navigating the Cont...

Page 7: ...rvice Tools 123 Compressor Discharge and Suction Service Valves 124 Gauge Manifold Valve Positions 125 Gauge Manifold Set With Low Loss Fittings Attachment And Purging 126 Checking Compressor Oil 127...

Page 8: ...s 8 Structural Accessory Maintenance continued Condenser Fan Location 149 Humidify System Option 149 Pretrip Inspection 150 Inspection and Cleaning 150 Diagnosis 151 Index 157 Wiring and Schematic Dia...

Page 9: ...iagram 96 Figure 24 Manual Emergency Control Connections 96 Figure 25 Condenser Coil Sensor Location 100 Figure 26 2 Fan Evaporator Evaporator Defrost Sensor Location 100 Figure 27 Evaporator Defrost...

Page 10: ...List of Figures 10 Figure 50 Air Exchange System 148 Figure 51 Condenser Fan Blade Placement 149 Figure 52 Evaporator Fan Blade Placement 149 Figure 53 Humidify System Option 150...

Page 11: ...frigerant or refrigeration system in any closed or confined area with a limited air supply for example a trailer container or in the hold of a ship Refrigerant tends to displace air and can cause oxyg...

Page 12: ...t is connected to a source of operating power even if the unit is not running Lethal voltage potentials can exist at the unit power cord inside the control box inside any high voltage junction box at...

Page 13: ...of a pulse and respiration If a pulse is not present start CPR Cardio Pulmonary Resuscitation and call for emergency medical assistance If a pulse is present respiration may be restored by using mouth...

Page 14: ...e replacement component was removed 7 After servicing the circuit board and any other circuits the wiring should be checked for possible errors before restoring power Welding of Units or Containers Wh...

Page 15: ...pair the unit Service technicians should read and follow the instructions on all warning decals Serial Number Locations Electric Motors Nameplate attached to the motor housing Compressor Nameplate on...

Page 16: ...Safety Precautions 16...

Page 17: ...the data logger and check data for correct logging Check operation of protection shutdown circuits Refrigeration Check refrigerant charge Check for proper suction pressure Check compressor oil level...

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

Page 19: ...tor X X X X X X Refrigerant R 134a w Polyol Ester Compressor Oil P N 203 433 X X X MPC2000ID Microprocessor Controller with Integral Datalogger X X X MP 3000a Microprocessor Controller with Integral D...

Page 20: ...Model Features 20...

Page 21: ...605 4 820 19 125 5300 W 4 484 3 857 15 304 4 69 System net cooling capacity with a 37 8 C 100 F ambient air temperature and R 134a CRR 40 Models with Two Evaporator Fans Air Cooled Condensing Return...

Page 22: ...sp Net Cooling Capacity Power Consp Watts Kcal hr BTU hr kW 460V Watts Kcal hr BTU hr kW 460V 1 7 C 35 F 12 900 11 095 44 030 9 8 10 320 8 876 35 222 7 93 17 8 C 0 F 6 300 5 418 21 500 5 1 5 040 4 335...

Page 23: ...w Speed High Speed Low Speed m3 hr ft3 min m3 hr ft3 min m3 hr ft3 min m3 hr ft3 min 0 mm 0 in 7 250 4 270 3 760 2 160 6 000 3 530 2 900 1 700 10 mm 0 4 in 6 960 4 100 2 570 1510 5 500 3 240 1 400 825...

Page 24: ...injection valve opens continuously during Power Limit and Modulation Cool modes Liquid Injection Valve Compressor Voltage 24 Vac Cold Resistance 5 6 ohms Evaporator Pressure Regulator KVQ Valve EPR Ci...

Page 25: ...6 to 20 psig Cool 16 to 27 C 60 to 80 F 95 to 125 kPa 0 95 to 1 25 bar 14 to 18 psig Modulation Cool 27 to 38 C 80 to 100 F Modulation Cool 16 to 27 C 60 to 80 F 18 C 0 F Cool 27 to 38 C 80 to 100 F 3...

Page 26: ...ve i e both the 8 00 and 9 00 data logs Demand Defrost Demand defrost function initiates defrost when Temperature difference between the return air sensor and defrost evaporator coil sensor is too lar...

Page 27: ...st when coil sensor temperature rises to 18 C 65 F or exceeds 8 C 46 F for 25 minutes Interval Timer Terminates defrost after 90 minutes at 60 Hz operation if coil sensor has not terminated defrost 12...

Page 28: ...M 60 Hz 1145 rpm 60 Hz Full Load Amps 0 9 amps 460V 1 0 amps 380V 50 Hz Locked Rotor Amps 4 0 amps 460V 4 4 amps 380V 50 Hz Evaporator Fan Motors Type 460 380V 60 50 Hz 3 Phase Number 3 or 2 Kilowatts...

Page 29: ...o kPa 1 5 CFM psig Humidity Tank Heater 240 600 Vac 55 to 70 Watts at 17 8 C 0 F Water Temperature Humidity Sensor Accuracy 1 5 between 55 and 75 Relative Humidity 3 0 between 75 and 95 Relative Humid...

Page 30: ...lange 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 Protrusion 37 mm 1 46 in from back of flange...

Page 31: ...10 9 136 176 100 130 224 298 180 220 393 474 290 350 678 813 500 600 HH CL 12 9 177 216 130 160 285 352 210 260 448 542 330 400 881 1016 650 750 HH SS 2 115 135 85 100 177 216 130 160 271 339 200 250...

Page 32: ...Specifications 32...

Page 33: ...reciprocating compressor with forced feed lubrication system ambient compensated internal overload and high temperature protectors and a refrigerant injection system Dual Speed Evaporator Fans CRR mo...

Page 34: ...ture logs can be viewed from the controller s LCD message display A high speed serial communication port provides data retrieval using a DRU II or SmartSponge handheld data retriever or a REFCON power...

Page 35: ...han 8 hours or the unit has been on heat or defrost the controller performs a compressor sequence start Chill Loads Controller Setpoint at 9 9 C 14 1 F or Above Temperature control by the controller i...

Page 36: ...compressor 2 Evaporator Access Door 1399 mm 55 04 in Wide with Three Latches Models with Three Evaporator Fans 9 Supply Air Sensor Probe Holder Right Hand behind compressor 3 Heater Access Panel Loca...

Page 37: ...Evaporator Fan Blade 2 Evaporator Fan Motor 3 Return Air Sensor 4 Humidity Sensor Option 5 Humidity System Compressor Option Figure 4 Evaporator Section for Models with Three Evaporator Fans Front Vi...

Page 38: ...1 Return Air Sensor 2 Humidity Sensor Option 3 Evaporator Fan Blade 4 Evaporator Fan Motor 5 Humidity System Compressor Option Figure 5 Evaporator Section for Models with Two Evaporator Fans Front Vie...

Page 39: ...tor 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 Hose 9 Air Compressor 10 Liquid Spray Nozzle Figure 6 Humidity System Option...

Page 40: ...ve 3 Condenser Coil 11 Water Cooled Condenser Receiver Tank CRR 40 119A CRR 40 800 4 Condenser Tank 12 Fusible Plug 5 Compressor 13 Service Port Fitting and Cap 6 Heat Exchanger 14 Water Outlet Coupli...

Page 41: ...noid Valve humidity control normally open Danfass valve 3 Compressor 9 Expansion Valve or use Kit 60 253 for replacement of brass valves 4 Condenser Coil 800 800A B C 10 Solenoid Valve liquid normally...

Page 42: ...0 General Purpose Keypad 4 Cable No 2 Connection to Controller 11 LCD Display Setpoint Temperature Message and Controller Main Menu Tree Display 5 Download Cable Connection to Controller 12 LED Displa...

Page 43: ...Water cooled Condenser Operation Option 2 Communications Connector for Data Retrieval 3 Unit On Off Switch 4 Circuit Breaker 5 Main Relay Board 6 12 Vdc Battery 7 Control Power Transformer 8 Compress...

Page 44: ...2 Unit Gasket 3 Top Rear Plate 4 Bottom Rear Plate 5 Sensor Connector Assembly Controller Communications and Data Retrieval Connection USDA1 Sensor Connection USDA2 Sensor Connection USDA3 Sensor Con...

Page 45: ...te sensor return or supply shows while the key is pressed 4 DEFROST KEY Press this key to initiate a manual defrost cycle If the evaporator coil temperature is below 18 C 65 F the unit will defrost Ot...

Page 46: ...cuit breaker protects the 460 380V power supply circuit to the unit electric motors and control system transformer The main power circuit breaker is located in the control box 2 CONTROL SYSTEM CIRCUIT...

Page 47: ...0 psig If the switch remains open for 5 minutes controller also activates Alarm LED and records Alarm 37 Total Power Consumption Too Low 6 FUSIBLE PLUG FOR HIGH PRESSURE RELIEF A fusible plug is insta...

Page 48: ...compressor motor starts and the liquid line solenoid energizes opens If the unit starts in Modulation Cool compressor start up can be delayed up to 3 minutes while the KVQ valve opens or closes to the...

Page 49: ...controller to return the unit to normal operation If an operating problem occurs during the Pretrip Test the Alarm LED will turn ON and FLASH An E may also appear in the right side of the LED display...

Page 50: ...vious setpoint display NOTE If the F4 key is not pressed within 30 seconds the controller will default return to the previous setpoint If this occurs repeat step 4 Loading Procedure 1 Make sure the Un...

Page 51: ...s are used to enter text and scroll through the controller menu tree a Text Input The keyboard supports both numerical and text input Each key can have more than one meaning Use the special text keys...

Page 52: ...ensor temperature in LED display SETPOINT key Press to enter Setpoint Menu The first line of the Setpoint Menu is the setpoint temperature Press F2 or F3 key to scroll up or down through the menu list...

Page 53: ...r Manual control offers three operating functions Heat Defrost and Cool see Manual Emergency Mode Operation in this chapter 20 Flash memory Flash program memory allows the application software to be u...

Page 54: ...r temperatures as well as loss of power alarms sensor failure setpoint change and unit shutdown events All data logs include the time and date setpoint temperature supply return ambient USDA1 USDA2 an...

Page 55: ...egral derivative PID algorithm and a KVQ valve to provide accurate control of the container temperature in direct response to load demand The KVQ valve is installed in the suction line and controls th...

Page 56: ...controller performs a compressor sequence start when the compressor has not operated for more than 60 seconds within the last 18 hours A compressor sequence start cycles the compressor ON 3 seconds OF...

Page 57: ...and temperature is In range the controller shifts the evaporator fans to LOW speed Evaporator fans operate on LOW speed at setpoints of 10 C 14 F and below If the Economy mode is ON and the unit is in...

Page 58: ...nd defective controller LCD display shows Running with High Supply Difference message Sensor errors recorded during a Probe Test are cleared when the next Defrost is initiated or Unit On Off switch is...

Page 59: ...ontrol Temperature Differential see General Theory of Operation in this chapter for more detail This means the unit operating mode can NOT be predicted based ONLY on the setpoint and supply air temper...

Page 60: ...and Below At setpoints of 10 C 14 F and below the controller locks out the Modulation and Heat modes The controller regulates compressor operation based the return air sensor and setpoint temperatures...

Page 61: ...f 5 minutes after startup Controller turns ON the Compressor LED when the compressor is operating After initial pull down to setpoint controller keeps the In range LED ON as long as the return air tem...

Page 62: ...d injection valve continuously Chill Mode When the KVQ valve setting is less than 5 C 8 9 F below the return air temperature the controller energizes liquid injection valve for 6 seconds every 60 seco...

Page 63: ...ns LOW SPEED1 Economy Mode ON Evaporator Fans OFF1 Dehumidify ON Dehumidify Valve CLOSED energized 2 Dehumidify ON Electric Heaters ON energized 2 Humidify ON Air Compressor ON energized 2 1 Economy M...

Page 64: ...6 6 and 7 hours Maximum time interval is 7 hours On Frozen Loads the initial time interval is 8 hours Two 2 hours are added to the time interval each timed defrost interval Maximum accumulated time in...

Page 65: ...Off switch ON 1 Press the DEFROST key 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 as the Defrost and Heat LE...

Page 66: ...major menus Setpoint Data Alarm List Commands Misc Functions Configuration Datalogger Remote Monitoring RMM State Moving through these eight menus and their submenus and entering commands requires the...

Page 67: ...splay on the controller are determined by the controller model and the unit configuration setting All screens are NOT present on all units Changing the Setpoint Temperature See Changing the Setpoint i...

Page 68: ...entered in the LCD display is correct before proceeding 5 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 6 Pres...

Page 69: ...present on all units NOTE Press the 5 key to lock a Data screen in the LCD display for 5 minutes Press any key to unlock the display NOTE Controller returns to previous menu level or LCD Standard Dis...

Page 70: ...state will change to ACKNOWLEDGE in the alarm list If the alarm condition no longer exists in the unit and the alarm code is acknowledged the Alarm LED will turn OFF and the alarm code disappears fro...

Page 71: ...Speed Current Too High 15 Check Evaporator Fan Low Speed Current Too Low 16 Check Condenser Fan Current Too High 17 Check Condenser Fan Current Too Low 18 Check Power Supply Phase Error 19 Check Temp...

Page 72: ...COMMANDS PTI COMMANDS FUNCTION TEST COMMANDS MANUAL FUNCTION TEST To Activate a Command Manual Function Test Submenu First Component Test appears in display Press F2 or F3 key to scroll to the desire...

Page 73: ...er to return the unit to normal operation Power Management LCD display shows current Power Limit setting and Power Time setting Turn Power Limit feature ON and OFF change power limit setting or change...

Page 74: ...sting alarms before beginning the Brief PTI test With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press F3 key to enter the menu list Repeatedly press F2 key...

Page 75: ...elow 10 C 50 F heat remains on until evaporator sensor reaches 18 C 65 F 20 1 Hour Maximum Pb 04 Evaporator Fan High Activated 2 4A 2 3A 2 4A Condenser fan and compressor are turned Off With evaporato...

Page 76: ...4 5A 4 4A 4 5A With condenser fan off compressor fan starts and operates Compressor stops Condenser fan operates 60 seconds more to lower condenser temperature 54 60Seconds plus 10 Seconds Pb 10 Evapo...

Page 77: ...pressor ON evaporator fans are turned OFF The evaporator coil temperature must decrease to approx 15 C 9 5 F depending on the return air temperature 25 5 minutes Maximum Pb 15 Evaporator Temperature T...

Page 78: ...clear all existing alarms before beginning the Full PTI test With the unit On Off switch ON and the LCD display showing the standard display setpoint 1 Press F3 key to enter the menu list Repeatedly p...

Page 79: ...elow 10 C 50 F heat remains on until evaporator sensor reaches 18 C 65 F 20 1 Hour Maximum P1 04 Evaporator Fan High Activated 2 4A 2 3A 2 4A Condenser fan and compressor are turned Off With evaporato...

Page 80: ...ated 4 5A 4 4A 4 5A With condenser fan off compressor starts and operates Compressor stops Condenser fan operates 60 seconds more to lower condenser temperature 54 60Seconds plus 10 Seconds P1 10 Evap...

Page 81: ...None 120 Minutes Maximum Supply Temp Running PTI Setpoint 0C 32F Unit operates in normal cool mode with 0C 32F setpoint When supply air temperature decreases to setpoint Chill Arrival temperatures are...

Page 82: ...nction Test on page 82 CRR Function Test LED Display Test No LCD Display ShowsApprox Amps for 460V 60 Hz Unit Test Description Possible Alarms Duration Time F1 00 Display Test Activated 0 1A 0 0A0 1A...

Page 83: ...on Valve Capacity 100 Capacity 50 Capacity 25 Compressor Sensor Checks Probe Test Operates high speed evaporator fans only After 5 minutes check the temperatures of the left and right hand supply sens...

Page 84: ...to the first component b Press F4 key to turn the component ON c Press F3 key to scroll to select next component Press F4 to turn component ON d Repeat step 6c until all required components are ON Fo...

Page 85: ...nd Power Time setting 5 To activate or change the power limit a a Press F4 key with cursor in the Power Limit menu line Cursor moves to end of menu line and flashes b Press F2 or F3 key to scroll to t...

Page 86: ...e container and the load in the controller C F Mode Sets the temperature value Celsius or Fahrenheit the controller uses to record and display temperature including historical data Figure 20 Misc Func...

Page 87: ...the Time or Date menu line press and hold the F4 key then press F3 key Press F1 key to return keyboard to numerical entry before typing again 6 With the correct time entered in the menu line press F4...

Page 88: ...he selected line Enter type the desired text When entering information Enter up to 10 characters of text numbers for each menu item To scroll backwards in the text box press and hold the F4 key then t...

Page 89: ...re value in the menu line between C and F 6 With the desired temperature value in the menu line press and hold F4 key until cursor stops flashing Cursor stops blinking and new temperature value appear...

Page 90: ...roll cursor to view or reset the desired function Container ID Sets the container identification number Enter up to 11 characters numbers or letters In Range Sets the temperature value for the control...

Page 91: ...value 9factory default off Set value to on to automatically configure unit to installed components See Automatic Configuration of Spare Parts Controller in this chapter for additional information Uni...

Page 92: ...display 3 Press F4 key to access the Datalogger menu The first function appears in the LCD display Inspect Temp Log 4 Press F2 or F3 key to scroll to the desired function Inspect Temp Log PTI State In...

Page 93: ...WATER position A Alarm in last interval NOTE All event flags that occurred during a log interval are displayed 6 Press ESC key to exit the Temp Log Inspect Event Log With the unit On Off switch ON and...

Page 94: ...logger memory may be viewed on the LCD display 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...

Page 95: ...sor stops flashing The new Log Time appears in the display 9 Press ESC key to exit the Temp Log Set a Trip Start With the unit On Off switch ON and the LCD display showing the standard display setpoin...

Page 96: ...f switch ON and the LCD display showing the standard display setpoint 1 Press the F3 key to enter the Main Menu 2 Press F2 key to scroll through Main Menu until RMM STATE appears in LCD display 3 Pres...

Page 97: ...changed To reverse power phase a Turn On Off switch OFF b Disconnect unit power cord from power supply c Relocate the phase selector terminal plug from J18 see decal on main relay board Relocate from...

Page 98: ...cation On or OFF If controller detects a humidity sensor it then checks for current draw on an air compressor Controller Software Selection If a replacement controller was removed from another unit ch...

Page 99: ...ld be properly installed Supply air sensors must be inserted to the bottom of the sensor tube and completely sealed by the grommet connection Left hand supply sensor installs in the sensor tube behind...

Page 100: ...88 8242 68 20 126729 194 90 7710 71 6 22 115179 197 6 92 7216 75 2 24 104796 201 2 94 6759 78 8 26 95449 204 8 96 6335 82 4 28 87023 208 4 98 5941 86 30 79428 212 100 5574 89 6 32 72567 215 6 102 5234...

Page 101: ...r stops flashing If you have viewed and corrected these problems and the unit still appears to be operating incorrectly eliminate any possibility that the problem is caused by failure of components ot...

Page 102: ...ge clears when test is complete Controller 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...

Page 103: ...expansion valve etc Controller clears message during defrost and when Unit On Off switch is turned OFF 9 High Pressure Cutout Check Condenser Fan Indicates Unit stops due to high pressure cutout cond...

Page 104: ...nt Check volts and amps to determine which component has low amp draw Check volt and ampere meter 23 Supply Air Temperature Too High Check Alarm During Chill or Frozen Mode Supply air temperature is t...

Page 105: ...sensor connections are reversed Check for sensor alarm codes Check supply and return sensor connections and locations 26 Evaporator Coil Temperature Too Low Check Alarm During Chill or Frozen Mode Eva...

Page 106: ...J15 and between pins 7 and 8 on plug J14 Resistance must be 2 000 ohms at 25C 77F Check cable No 1 and cable No 3 between the controller and relay board Check evaporator air flow 01 Supply Air Sensor...

Page 107: ...emperature below 70C 94F Indicates Open circuit to sensor Defective or wrong sensor Defective relay board Defective cable No 1 Defective controller Low evaporator coil temperature Check sensor resista...

Page 108: ...ve compressor relay Defective volt or amp meter on relay board Low refrigerant charge Defective compressor or valve plate Enter Manual Function Test menu Start and check current draw of the following...

Page 109: ...es Defective or stuck evaporator fan motor Incorrect motor or motor connections Defective volt or amp meter on relay board Open evaporator door and make sure all fans rotate freely Enter Manual Functi...

Page 110: ...all fans rotate freely Enter Manual Function Test and start evaporator fans on LOW speed Make sure all fans start on low speed if a motor does not start and is very hot wait 10 minutes for internal o...

Page 111: ...lay board Replace relay board Check voltage reading on each phase NOTE If both alarms 16 and 17 are activated the alarms are caused by a large difference in measured amps Enter Manual Function Test me...

Page 112: ...Indicates Incorrect location of supply or return air sensor Air leakage at supply sensor cable Defective supply or return air sensor Interchanged sensor connections incorrect evaporator fan rotation o...

Page 113: ...nd inspect evaporator fan rotation Make sure fans are rotating correctly on high speed Check the sensor connections Enter Manual Function Test menu Start and check current draw of the following compon...

Page 114: ...rn air sensor Interchanged sensor connections Defective heater elements Incorrect evaporator fan rotation or high speed operation Container side panels defective damaged or leaking Enter Manual Functi...

Page 115: ...4 Ambient Air Sensor Open Circuit Check Alarm Sensor circuit resistance higher than 100 000 ohms Temperature below 70 C 94 F Indicates Open circuit to sensor Defective or wrong sensor Defective relay...

Page 116: ...test Indicates Faulty compressor contactor or control circuit Low refrigerant charge Defective high pressure cutout switch Strong winds causing cooling of condenser coil in low ambient conditions Che...

Page 117: ...compressor high temperature protection is not active 58 Phase Sensor Error Check Alarm Occurs during Pretrip PRI or Function test only During Phase Sensor Test amperage difference between correct and...

Page 118: ...Check USDA sensors and sensor connections Check cable No 3 between controller and relay board 109 KVQ Sensor Open Circuit Check Alarm Sensor circuit resistance higher than 10 000 000 ohms Indicates Op...

Page 119: ...larm occurs 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...

Page 120: ...MP 3000a Controller 120...

Page 121: ...aw during compressor operation is normal and then decreases by 7 amps for more than 3 seconds After 1 minute the controller LCD display shows a High Pressure Cutout message after 1 minute High Pressur...

Page 122: ...lle If the condenser fan is rotating backwards refer to the unit wiring diagram to correct fan motor wiring at the fan motor junction box or condenser fan contactor To correct improper fan rotation re...

Page 123: ...ems Low side near the compressor suction service valve or suction adapter High side near the compressor discharge service valve or discharge manifold High side on the receiver tank Leak Detection Leak...

Page 124: ...ystems Refrigerant Recovery Use only refrigerant recovery equipment approved for and dedicated to R 134a recovery Compressor Oil Acid Test Perform an oil acid test oil test kit P N 203 457 whenever a...

Page 125: ...rvice Valve SSV Figure 33 Balancing the Pressure 1 Quick Disconnect Access Valve 2 In 3 Recliner 4 Out 5 Discharge Service Valve DSV 6 Suction Service Valve SSV Figure 34 Removing Refrigerant AJA1311...

Page 126: ...coupler hand wheels counterclockwise to back the stem out of the high and low hose fittings Then attach low hose compound gauge to the suction line valve port 5 With 69 kPa 0 69 bar 10 psig or greater...

Page 127: ...10 C 50 F Install gauge manifold on the compressor Operate the unit on COOL with a 138 kPa 1 38 bar 20 psig minimum suction pressure and a 689 kPa 6 89 bar 100 psig discharge pressure for 15 minutes...

Page 128: ...oil pressure fitting 4 Operate the unit and recheck the refrigerant charge level and the oil level before returning the unit to service Refrigerant Leak Test Procedure Use a reliable Halogen leak dete...

Page 129: ...of liquid refrigerant at the expansion valve even though the unit is operating in a cooling mode The refrigerant charge can be checked by inspecting the receiver tank sight glasses NOTE See Receiver T...

Page 130: ...NOTE Inspect the unit for refrigerant leaks with a reliable leak detector if the unit is low on R 134a charge 1 Sight Glass Refrigerant charge is OK if ball FLOATS at any time 2 Service Fitting 3 Fusi...

Page 131: ...lve and cause intermittent operational problems It reacts in the oil to begin acid buildup DIRT DUST METAL PARTICLES OTHER FOREIGN MATERIALS Particles of any kind left to float through the system will...

Page 132: ...8 1 AJA1450 1 Special self sealing quick disconnect couplers are required for R 134a units 5 To 220 190 VAC Power 2 Gas Ballast Valve 6 Calibration Standard 3 Iso Valve 7 Micron Meter 4 Two stage Vac...

Page 133: ...or 6 Open the vacuum pump Iso Valve built into the pump housing below the handle It is recommended that the valve be kept open at all times 7 If connecting a refrigerant tank and gauge manifold to the...

Page 134: ...in the system When a leak is in a system the vacuum will eventually stabilize at atmospheric pressure see graph Constant Pressure Rise After Evacuation Indicates System Leak below Moisture When the ne...

Page 135: ...your unit from the total weight of the tank of refrigerant This provides final tank weight after the unit receives a full system refrigerant charge 8 Set the refrigerant tank for liquid removal Open...

Page 136: ...d valve stems Evaporator Pressure Regulator KVQ Valve The evaporator pressure regulator valve is used to control the flow of refrigerant to the compressor when the unit is operating in the Power Limit...

Page 137: ...source and switch the refrigeration unit s On Off switch to ON Close the liquid line service valve and pump down the low side Equalize suction pressure to 21 kPa 0 21 bar 3 psig 3 Turn the unit On Off...

Page 138: ...side and test for refrigerant leaks see Refrigerant Leak Test Procedure in the Refrigeration Maintenance chapter of this manual NOTE If pressurizing with nitrogen front seat the discharge valve to pr...

Page 139: ...y 1 Install a gauge manifold s low pressure line to the service fitting on the suction service valve Attach the manifold s high pressure line to receiver tank service port Attach the service line to t...

Page 140: ...psig Compressor Replacement Removal 1 Remove the compressor compartment bracket Close the liquid line service valve and pump down the low side to 35 kPa 0 35 bar 10 in vacuum Break the vacuum with ni...

Page 141: ...in this chapter Because this refrigerant gas will contain some air place it in a contaminated refrigerant bottle to be reclaimed later 8 After all pressure is removed from the low side and compressor...

Page 142: ...ts Tighten the bolts 5 Tighten the filter drier inlet line mounting nut 6 Open the liquid line service valve on the inlet side of the filter drier slowly to release a small amount of refrigerant from...

Page 143: ...s 4 Note position of feeler bulb on the side of the suction line Un tape and remove the feeler bulb from the suction line 5 Heat and unsolder the suction line connections 6 Lift the heat exchanger ass...

Page 144: ...s chapter High Pressure Cutout Switch Replacement Removal 1 Close the liquid line service valve and pump down the low side Open the outlet valve slightly to equalize the pressure between 10 and 20 kPa...

Page 145: ...vice valve and place the unit in operation Check the refrigerant charge and add refrigerant as required Liquid Injection Valve Replacement Removal 1 Close the liquid line service valve and pump down t...

Page 146: ...he valve from the unit Installation 1 Clean the tubes for soldering 2 Place the new valve in position 3 Solder the liquid line connections 4 Pressurize the low side with refrigerant and check for leak...

Page 147: ...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 the solution using a pressure spray wash type apparatus Spray the con...

Page 148: ...e disk or door position to the ventilation rate indicated on the shipping manifest Disk Adjustment Low Ventilation Rates 1 Loosen wing nut on handle assembly 2 Rotate the disk to set the Indicator at...

Page 149: ...de of the blade for proper airflow direction When mounting the fan blade and hub assembly on the fanshaft center the assembly in the orifice Position the front of the fan blade 10 mm 0 4 in in from th...

Page 150: ...ressor operates and that water is drawn into the atomizing nozzle and injected into the return air stream Inspection and Cleaning The following items should be periodically serviced Clean and inspect...

Page 151: ...er shut unit down on Compressor Over Temperature fault code 56 Let compressor cool and controller will reset automatically Check liquid injection valve and compressor temperature sensor Compressor mot...

Page 152: ...mpressor 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 required Unit...

Page 153: ...n pressure will be less than 0 kPa 0 bar 0 psig during normal operation Shortage of refrigerant Repair leak and recharge Compressor motor contacts frozen Clean points or replace contactor Compressor i...

Page 154: ...ar restriction Plugged dehydrator Change dehydrator Compressor inefficient Perform compressor efficiency test Check valves and pistons Evaporator pressure regulator KVQ valve stuck closed or defective...

Page 155: ...blade damaged Replace fan blade High ambient air temperature No remedy Restricted filter drier or high side Replace filter drier or clear restriction Defective high pressure gauge Replace service gaug...

Page 156: ...out of calibration Adjust or replace service gauge Low suction pressure NOTE This unit has a suction modulation capacity control system Suction and discharge pressures may drop below expected normal r...

Page 157: ...ter Drier Replacement 142 Diagnosis and Repai 101 Disk Adjustment Low Ventilation Rates 148 Displaying Alternate Controlling Supply or Return Air Sensor Temperature 65 Displaying Alternate Fahrenheit...

Page 158: ...nce and Service Operations 123 Refrigeration System Specifications 24 Replacing the Controller 97 RMM State Men 96 S Safety Precautions 11 Semi Hermetic Reciprocating Compressor with Liquid Injection...

Page 159: ...6 5D51094 MPC2000 Low Voltage Wiring Diagram 157 5D51661 MPC2000 WCC Wiring Schematic 158 Refrigeration System Components 159 Full Cool Flow and Pressure Diagram 160 Cool with Modulation Flow and Pres...

Page 160: ...Wiring and Schematic Diagrams Index 160...

Page 161: ...161 MPC2000 Wiring Schematic...

Page 162: ...162 MPC2000 High Voltage Wiring Diagram...

Page 163: ...163 MPC2000 Low Voltage Wiring Diagram...

Page 164: ...164 MPC2000 WCC Wiring Schematic...

Page 165: ...Liquid Line Service Valve 14 Dehydrator Filter Drier 15 Heat Exchanger 16 Liquid Line Solenoid LLS 17 Expansion Valve TXV 18 Expansion Valve Feeler Bulb 19 Equalizer Line 20 Distributor 21 Evaporator...

Page 166: ...Is a normally CLOSED solenoid It OPENS when energized when the compressor operates 22 Electric Heaters During the DEFROST mode the electric heaters are pulsed ON and OFF The compressor condenser fan...

Page 167: ...e actuator forcing the valve towards the closed position Decreasing the temperature of the heating element decreases the pressure on the main valve actuator drawing the valve towards the open position...

Page 168: ...ner air 22 Electric Heaters If the container humidity is 5 or more above the humidity setpoint and the KVQ valve has closed to reduce cooling capacity by about 50 the controller will pulse the electri...

Page 169: ...Menu Defrost Function Test PTI Pretrip Test Manual Function Test Power Management Alarms Menu View and write down all alarm codes Press F2 key to view the next alarm code Clear alarm code by correcti...

Page 170: ...tion Test Alarms Menu View and write down all alarm odes Press F2 key to view the next larm code Clear alarm code by correcting problem and acknowledging the alarm To acknowledge an alarm press F4 key...

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