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Thermo King CSR-20 Series, Maintenance Manual

The Thermo King CSR-20 Series Maintenance Manual is available for free download on our website. This comprehensive manual provides detailed information on how to properly maintain your Thermo King CSR-20 Series unit, ensuring optimal performance and longevity. Download it now and keep your unit running smoothly.

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CSR-20 & CSR-40, September 1999

Introduction

CSR Features

vii

CSR Model Features (Continued)

X

X

X

X

X

X

X

X

X

460-380V/3Ph/60-50 Hz, 18.3 m (60 ft) Power Cable and Plug

–

–

–

–

–

–

–

–

–

Dual Voltage Feature: 15 kVA Autotransformer with 460-380V Power Receptacle and 230-
190V/3Ph/60-50 Hz, 18.3 m (60 ft) Power Cable and Plug

X

X

X

X

X

X

X

X

X

Automatic Phase Selection Control

X

X

X

X

X

X

X

X

X

25 Amp Main Power Circuit Breaker

–

–

X

X

–

–

–

–

X

Slimline Frame

X

X

X

X

X

X

X

X

X

Hermetic Scroll Compressor w/4.48 kW (6.0 Hp) Motor

X

X

X

X

X

X

X

X

X

Hermetic Refrigeration System

X

X

X

X

X

X

X

X

X

Compressor Liquid Injection System

X

X

X

X

X

X

X

X

X

Warm Gas Bypass Valve System

X

X

X

X

X

X

X

X

X

Modulation Valve

X

X

X

X

X

X

X

X

X

Refrigerant R-404A w/Polyol Ester Compressor Oil (TK P/N 203-433)

X

X

X

X

X

X

X

X

X

Receiver Tank

X

X

X

X

X

X

X

X

X

µ

P-D Controller with Proportional-integral Differential (PID) Capacity Control

X

X

X

X

X

X

X

X

X

Controller Emergency Bypass Module

X

X

X

X

X

X

X

X

X

USDA Cold Treatment Temperature Recording

–

–

X

X

–

–

–

–

X

Three Evaporator Fans with 2-Speed Motors

X

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

X

X

X

X

X

X

X

CO2 Sampling Port

X

X

X

X

X

X

X

X

X

One 1-Speed Condenser Fan Motor

–

–

X

X

X

X

–

–

–

Auxiliary Battery and Battery Charger

–

–

–

–

–

–

–

–

–

Bulb Mode Operation

–

–

–

–

–

–

–

–

–

Controlled Atmosphere System

X

X

X

X

X

X

X

X

X

Data Retrieval Receptacle, Standard (5-Pin Duetsch)

–

–

–

–

–

–

–

–

–

Data Retrieval Receptacle, 5-Pin Threaded Cannon

–

–

–

–

–

–

–

–

–

Data Retrieval Receptacle, 15-Pin RS232

X

–

X

–

X

–

–

–

–

Dehumidify Control

–

–

X

X

–

–

–

–

–

Humidity System

–

–

–

–

–

–

–

–

–

Power Line Communications, Standard (Thermo King Modem)

–

–

–

–

–

–

–

–

–

Power Line Communications, Thermo King Integrated Remote Monitor Unit (IRMU)

–

–

–

–

–

–

–

–

–

Power Line Communications, RTE Modem

–

–

X

X

–

–

–

–

–

Power Line Communications, Sabroe Control Modem

–

–

–

–

–

X

–

–

–

Recorder, Partlow

–

X

–

–

–

–

–

X

X

Recorder, Saginomiya

–

–

–

–

–

–

–

–

–

Redundant Supply and Return Sensors 

–

–

–

–

X

X

–

–

–

Remote Monitoring Plug (4-Pin)

–

–

–

–

X

–

–

–

–

TRANSFRESH

®

Provision

–

–

–

–

–

–

–

–

–

TRANSFRESH

®

Purge Port

–

–

X

X

–

–

–

–

–

TRANSFRESH

®

System, Complete

–

–

–

–

X

X

–

–

–

Thermistor Lead

–

–

–

–

–

–

X

–

–

Water-Cooled Condenser-Receiver Tank

CSR-40-128

CSR-40-129

CSR-40SL-130

CSR-20SL-131

CSR-40-134

CSR-40-136

CSR-40-139

CSR-40-140

CSR-40SL-142

FEATURES

X = Included

MODEL

Summary of Contents for CSR-20 Series

Page 1: ...CSR 20 CSR 40 Hermetic with P D TK50622 4 MM Rev 1 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: ...w 1 3 CSR 20SL Models with Three Evaporator Fans 1 3 CSR 40SL Models with Three Evaporator Fans 1 3 CSR 40 Models with Three Evaporator Fans 1 3 CSR 40 Models with Two Evaporator Fans 1 3 Refrigeratio...

Page 6: ...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 Pretrip 4 19 En...

Page 7: ...arm Gas Bypass Solenoid Valve Liquid Injection Valve or Dehumidify Valve Option Replacement 6 22 Structural Accessory Maintenance 7 1 Mounting Bolts 7 1 Unit Inspection 7 1 Condenser Coil 7 1 Evaporat...

Page 8: ...idity Setpoint 9 19 Modulation Mode Chill Load Setpoint at 9 9 C 14 1 F or Above Condenser Fan OFF Economy Mode ON Temperature In range 9 20 Modulation Mode Chill Load Setpoint at 9 9 C 14 1 F or Abov...

Page 9: ...wo Evaporator Fans CSR 40 118 CSR 40 121 CSR 40 124 CSR 40 125 CSR 40 127 CSR 40 128 CSR 40 129 CSR 40 134 CSR 40 136 CSR 40 139 CSR 40 140 Other Reference Manuals For detailed descriptions of our ref...

Page 10: ...A 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 X X X X X X X...

Page 11: ...Cold Treatment Temperature Recording X X X Three Evaporator Fans with 2 Speed Motors X 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 X X X X X X X...

Page 12: ......

Page 13: ...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 14: ...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 work...

Page 15: ...he 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 6...

Page 16: ...ller Nameplate on back of controller xii Unit Decals Safety Precautions CSR 20 CSR 40 September 1999 Unit Decals Serial number decals refrigerant type decals and warning decals appear on all Thermo Ki...

Page 17: ...contacts for damage or loose connections Visually inspect wire harnesses for damaged wires or connections Download the data logger and check data for correct logging Check calibration of graded sensor...

Page 18: ...Kcal hr BTU hr kW 380V 21 1 C 70 F 12 660 10 890 43 200 10 8 10 545 9 070 35 985 9 0 1 7 C 35 F 9 100 7 825 31 050 8 9 7 580 6 520 25 865 7 4 17 8 C 0 F 5 300 4 555 18 075 6 1 4 415 3 795 15 060 5 1 2...

Page 19: ...80 7 810 30 990 8 5 17 8 C 0 F 5 600 4 816 19 115 5 3 4 665 4 010 15 925 4 4 CSR 40 Models with Three Evaporator Fans Water Cooled Condensing Option with 37 8 C 100 F Water Temperature System net cool...

Page 20: ...5 2 570 3 040 1 790 30 mm 1 2 in 3 440 2 025 2 140 1 260 40 mm 1 6 in 2 615 1 540 CSR 40SL Models with Three Evaporator Fans External Static 460 230V 3 Phase 60 Hz Power 380 190V 3 Phase 50 Hz Power P...

Page 21: ...kPa 1 17 0 20 bar 17 3 psig Close 35 21 kPa 0 35 0 20 bar 5 3 psig High Pressure Relief Valve Relief Pressure 3447 520 104 kPa 34 47 5 20 1 04 bar 500 75 15 psig Reset 2758 kPa 27 58 bar 400 psig Liq...

Page 22: ...inish 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 Hz Each 1 2 amps 46...

Page 23: ...omer 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...

Page 24: ...aporator fan operation 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 C...

Page 25: ...Physical Specifications Fresh Air Exchange Venting System Adjustable CSR 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 CSR 40 CSR 40SL 0 to 285 m3 hr 0 to 168 ft3 min...

Page 26: ...n 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 C...

Page 27: ...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 28: ...Thermoguard P D microprocessor controller with indicator LEDs The P D controller controls monitors and records unit operation using supply air return air evaporator coil condenser coil ambient and com...

Page 29: ...nd datalogging when unit 460 380V supply power is disconnected A regulated battery charger automatically maintains the battery charge when 460 380V power is connected to the unit Dehumidification Cont...

Page 30: ...l water cooled condenser receiver tank provides the unit with above deck and below deck operating capabilities A water pressure switch is provided on the water inlet line con nection When water pressu...

Page 31: ...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 ECMIN temperature T...

Page 32: ...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 33: ...ermometer Option 3 Dual Voltage Option 4 TRANSFRESH Download Receptacle Option 5 Remote Monitor Plug Option 4 Pin Connector on Bottom or Side of Control Box 6 Thermistor Lead Option Lead inside Contro...

Page 34: ...h Three Evaporator Fans Front View 1 Evaporator Fan Blade see Physical Specifications on page 1 8 for description 2 Evaporator Fan Motor 3 Return Air Sensing Bulb for Recording Thermometer Option 4 Re...

Page 35: ...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 8...

Page 36: ...Expansion Valve 5 High Pressure Relief Valve 6 Filter Drier In line Filter One piece 7 Liquid Line Piping on Units Built After 7 99 8 Liquid Line Piping on Units Built Before 7 99 9 Scroll Compressor...

Page 37: ...September 1999 Hermetic Refrigeration System Options 1 Water Cooled Condenser Receiver Tank Option 1a Water Pressure Switch Option 1b Water Inlet Coupling Option 1c Water Outlet Coupling Option 2 Dehu...

Page 38: ...dule 8 Remote Monitor Option Relays 4 Pin plug is located on side of control box 9 Unit On Off Switch 10 Data Retrieval Receptacle located on bottom of control box on some models 11 Thermistor Lead Op...

Page 39: ...ions Unit Description CSR 20 CSR 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 40: ...Monitor Unit Option for Power Line Communications 1 Remote Monitor Control Box 2 High Voltage Harness 3 Low Voltage Harness 4 Cover 5 Power Cable 6 Data Communications Harness 7 Low Voltage Filter and...

Page 41: ...U Option for CSR 40 116 1 Service Tools A Circuit Chip Installer B Circuit Chip Remover C Electrostatic Discharge Wrist Strap 2 Integrated Circuit Chip 3 Cover 4 Power Cable 5 Remote Monitor PC Board...

Page 42: ...40 September 1999 Unit Description Unit Illustrations 2 15 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 43: ...Unit Illustrations Unit Description CSR 20 CSR 40 September 1999 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 44: ...Unit Illustrations 2 17 10 9 8 7 6 1 2 3 4 5 Humidity 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 45: ...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 46: ...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 47: ...sor temperature non controlling sensor in the controller display Alternate display shows while the key is pressed 7 DEFROST KEY Press this key to prepare the controller to initiate a manual defrost c...

Page 48: ...nit Protection Devices 1 CIRCUIT BREAKERS A 25 ampere manual reset circuit breaker protects the 460 380V power supply circuit to the unit electric motors and control system transformer The main power...

Page 49: ...e valve is located so that refrigerant pressure expelled from the valve would be directed away from any one servicing the unit The valve will reset when this pres sure drops to 2758 kPa 27 58 bar 400...

Page 50: ...s in the P D Controller chapter of this manual 2 Check controller setpoint for proper setting Adjust if necessary 3 Check the direction of the condenser airflow see Condenser Fan and Evaporator Fan Ro...

Page 51: ...ing thermometer Partlow recorders Check the battery charge on the recording thermometer Saginomiya recorders 11 Stop the unit by moving the On Off switch to the OFF position Starting the Unit and Adju...

Page 52: ...ne half hour after loading initiate a manual defrost cycle Press the DEFROST key The display flashes ENTER DFRST Press the ENTER key LOAD DFRST briefly appears in the display The Defrost LED turns ON...

Page 53: ...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 54: ...Theory of Operation in this chapter 12 Data recording capability see Data Recording and Downloading Data in this chapter 13 Electronic phase selection see Automatic Phase Selection under General Theo...

Page 55: ...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 56: ...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 57: ...High Speed Phase 2 Amps EFH 3 Evaporator Fan High Speed Phase 3 Amps EFL Evaporator Fan Low Speed EFL l Evaporator Fan Low Speed Phase 1 Amps EFL 2 Evaporator Fan Low Speed Phase 2 Amps EFL 3 Evaporat...

Page 58: ...Number Character 01 02 03 10 total number of characters VERSN Software Version VIEW View Menu VOLTS Total Voltage YEAR Current Year Status Indicator LEDs and Alarm Codes The indicator LEDs stay ON co...

Page 59: ...etrip 57 Check Condenser Fan Current 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...

Page 60: ...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 da...

Page 61: ...mpressor start up Compressor start ups include initial unit start start after Defrost and start after Null Modulation valve is energized The controller turns on liquid injection continuously during th...

Page 62: ...Return Air sensor is defective and the setpoint is 10 0 C 14 0 F or below the controller records alarm code 7 and uses the supply air sensor temper ature plus an offset to control unit operation If t...

Page 63: ...ration 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 heat mode until the cont...

Page 64: ...mode When the compressor discharge temperature exceeds 138 C 280 F 3Controller OPENS energizes the warm gas bypass valve When the calculated temperature differential is less than 0 6 C 1 0 F the contr...

Page 65: ...ower 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 Cool Mod Null Heat Defr Cool Null Def...

Page 66: ...ntroller de energizes the compressor contactor to stop the compressor If the condenser fan was ON it will operate for 30 sec onds and then stop If the condenser fan was OFF it will remain OFF The evap...

Page 67: ...return air temperature is more than 1 0 C 1 8 F above setpoint Power limit is active when the unit is operating in the Cool mode After the initial temperature pull down the In range LED turns OFF if t...

Page 68: ...times but maximum time interval is 12 hours on frozen loads Customer Configuration C6 2 hour initial defrost then maximum time interval is 6 hours on frozen loads A manual defrost is initiated loaded...

Page 69: ...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 70: ...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 71: ...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 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ...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 82: ...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 83: ...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 84: ...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 85: ...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 86: ...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 87: ...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 88: ...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 89: ...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 90: ...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 91: ...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 92: ...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 93: ...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 94: ...e 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 Turn the Unit On Off switch to ON The VIN LED on the Emergen...

Page 95: ...e The output module contains no user serviceable parts In the event the controller fails or the serial communica tions link between the output module and the controller fails the output module will op...

Page 96: ...Number and Sensor Grades The Unit Serial Number is located on the Unit Nameplate 2 Turn the unit On Off switch OFF Then unplug the unit power cord from the power supply 3 Disconnect the wire harness c...

Page 97: ...do not require ice bath calibra tion Thermistor Type Sensors Thermistor type temperature sensors are used for Compressor Discharge Gas Temperature Sensor If an alarm code indicates a failed sensor ch...

Page 98: ...t light or other instru ment or controller damage may result 03 Supply Air Temperature Sensor Failure Check the sensor by selecting it using the RET SUP Check Alarm key if necessary If the display sho...

Page 99: ...sor 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 t...

Page 100: ...s 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 to be open or shorted polarity is...

Page 101: ...instrument or controller damage may result Controller also generates alarm if high Check for correct water cooled condenser operation pressure cutout restart cycle recurs 3 times option within 30 minu...

Page 102: ...t at 9 9 C 14 1 F securely attached to the controller and the sensor or above harness is securely attached to the control box Check Alarm setpoint at 10 C 14 F or below Check for other sensor alarm co...

Page 103: ...ment or controller damage may result 42 Customer Configuration Alarm Set the customer and or unit configuration number Check Alarm to the setting required Indicates customer configuration has not been...

Page 104: ...BA fails to pull in or release during Check operation of phase contactors using the a Pretrip test PS1 and PS2 tests in the Controller Test submenu If the frequency and voltage of the power supply are...

Page 105: ...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 106: ...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 leg should be with...

Page 107: ...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 1 to 2 3 amperes at 480V If current...

Page 108: ...Check the heater element current draw using the Indicates total unit current draw is not within REFRG HEAT test in the Refrigeration Test acceptable limits when the unit is in Heat mode submenu Curre...

Page 109: ...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 110: ...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 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: ...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 113: ...3 3 V Then reset the 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 hour...

Page 114: ...f the real time clock using the Check Alarm YEAR MONTH DAY and TIME displays in the View menu Indicates an error occurred in the datalogger Check for the presence of Alarm Code 61 Check real time cloc...

Page 115: ...ype and proceed according to Check Alarm company requirements Reset the hourmeter if required Indicates time set on a user hourmeter has expired 73 User Hourmeter 3 Expired Check the hourmeter type an...

Page 116: ...the correct polarity or the sensor will not work NOTE Do NOT use a test light or other instru ment or controller damage may result 82 Compressor Over Temperature Check operation of the liquid injectio...

Page 117: ...ot energize check output module and related circuits by using REFRG FC HI in the Refrigeration Test submenu to place the unit in Cool Then confirm that output LED AC11 is ON If current draw on each le...

Page 118: ...the correct polarity or the sensor will not work NOTE Do NOT use a test light or other instru ment or controller damage may result 97 Loss of Communications with Output Module Check the RXD and TXD L...

Page 119: ...k the battery charger for proper operation High Pressure Cutout Switch The high pressure cutout is located in the liquid line near the compressor If the discharge pressure rises above 3243 48 kPa 32 4...

Page 120: ...ord leads at the con denser fan contactor disconnect power supply before revers ing leads DO NOT move the CH ground wire Evaporator Fans Visually inspect the evaporator fan blades for proper rotation...

Page 121: ...tes and unit shutdown due to a fault to be transmitted to a remote computer for viewing It also per mits the operator to request additional information or take action to initiate defrost change the cu...

Page 122: ...r initiated request message CONTAINER NO NOT FOUND IN NET or NO RESPONSE FROM CONTAINER NO appears on the MMU upper screen check Container No to ensure it is correct Check for the letter O instead of...

Page 123: ...ted to the MMU If container does not communicate replace the IRMU b If power is not OK determine location of power interruption and correct the problem 2 If several containers demonstrate symptoms ref...

Page 124: ...and the operator determines the remote monitoring unit is faulty the complete remote monitoring unit circuit board must be replaced No other repair is possible Remote Monitor Unit Replacement 1 Discon...

Page 125: ...ify unit performance and operation If the unit still fails to cool properly identify and diagnose all poten tial refrigeration system problems before opening the refrigera tion system System Diagnosis...

Page 126: ...isplay flashes ENTER the code number of the last alarm still appears in the right display NOTE Clear the Alarm codes ONLY after the alarm codes are documented and problems repaired Clearing the codes...

Page 127: ...g Restricted airflow through the evaporator coil Dry warm suction line Restricted filter drier Shortage of refrigerant Inspect refrigeration system for signs of oil loss Locate and repair leak Expansi...

Page 128: ...ttings P N 204 761 6 ft 1 8 m blue hose P N 204 762 6 ft 1 8 m red hose P N 204 763 6 ft 1 8 m yellow hose or Use a Gauge Manifold set equipped with 1 4 gauge hoses with R 134a suction and discharge c...

Page 129: ...R 404A to the unit be care ful not to OVERCHARGE the unit Compressor Oil Charge CSR Hermetic units do not have service valves fittings or sight glasses installed in the refrigeration system Therefore...

Page 130: ...nspect gauge manifold for proper hose and fitting con nections Both the low side suction and high side dis charge hand valves on the gauge manifold should be fully closed to center port 2 Clean dirt a...

Page 131: ...ns shown below Gauge Manifold Closed to Center Port 1 Close Hand Valves Charging the System 1 Quick Disconnect Access Valve 2 Discharge Service Valve DSV 3 Suction Service Valve SSV Gauge Manifold Ope...

Page 132: ...side hose pressure gauge to the port on the discharge line service valve Purge the high side hose a Open the high side discharge hand valve on the gauge manifold fully to center port b Rotate the dis...

Page 133: ...o inspect all joints and con nections Use a soap solution as an alternative test com ponent NOTE If system leakage is indicated loosen supply line hose fittings to release pressure Repair leakage cond...

Page 134: ...ervice lines to the ser vice access valves and recovery machine and properly purge the lines 3 Set the recovery machine for vapor recovery NOTE CSR Hermetic units do not have service valves or fitting...

Page 135: ...celer ate the deterioration of the softer metals i e copper and cause metal plating as the softer material begins to cover the inside of the system If this condition is not stopped it can result in th...

Page 136: ...rvice CSR 20 CSR 40 September 1999 Evacuation Station and Unit Hook up 1 Special self sealing quick disconnect couplers are required for R 404A units 2 Gas Ballast Valve 3 Iso Valve 4 Two stage Vacuum...

Page 137: ...ust be 2000 microns or less NOTE The presence of refrigerant in the com pressor oil may prevent a low vacuum reading from being achieved Compressor oil can contin ue to outgas for long periods of time...

Page 138: ...long hose Heat Saves Time A useful and practical time saver is the application of heat to the system Increasing the temperature of the compressor oil and refrigerant will speed up the vaporization of...

Page 139: ...remove piercing type access service valves from unit see Installing and Removing Piercing Type Service Valves and a Gauge Manifold Set in this chapter 9 Leak check the process tubes with an electronic...

Page 140: ...r assembly from compressor 6 Remove all RTV sealant from the compressor body Installation 1 Apply a heat conducting grease P N 203 454 on the sensing element 2 Apply a 6 mm 0 25 in bead of black RTV s...

Page 141: ...is present Repair or replace any damaged or exposed wires 3 Check the coil resistance If the coil resistance is below 5 ohms replace the coil good coils have a resistance of 7 6 ohms at 25 C 77 F or...

Page 142: ...ight Then tighten 1 6 turn more with a 1 5 inch wrench 10 Place new bottom coil housing plate over enclosure tube 11 Place new coil and coil sleeve on enclosure tube 12 Place new outer and top coil ho...

Page 143: ...oil and unbolt the condenser coil mounting brackets Slide the coil from the unit 6 Drain and measure any compressor oil that may be trapped in the condenser coil Installation 1 If compressor oil was d...

Page 144: ...the unit see Refrigerant Recovery in this chapter 2 Remove insulating tape and unclamp feeler bulb from the suction line in the condenser section Note the position of the feeler bulb on the side of th...

Page 145: ...lished condition Install feeler bulb in the feeler bulb clamps on the suction line Locate bulb on the suction line in former position The feeler bulb must make good contact with the suction line or op...

Page 146: ...rip Test to verify system operation Warm Gas Bypass Solenoid Valve Liquid Injection Valve or Dehumidify Valve Option Replacement NOTE In most cases only the coil requires replace ment No other repair...

Page 147: ...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 148: ...e 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 fresh ai...

Page 149: ...ng 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 aga...

Page 150: ...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 151: ...rding 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 32...

Page 152: ...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 153: ...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 154: ...or inoperative 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 ON again Def...

Page 155: ...ly wired Check correct wiring against wiring diagram Low line voltage Check line voltage determine location of voltage drop Contacts in compressor contactor not Check by operating manually Repair or c...

Page 156: ...high side side restriction causing cycling and refrigerant overcharge on high pressure cutout Inefficient condenser operation Check condenser airflow condenser causing cycling on high pressure fan mo...

Page 157: ...d condensing If condenser receiver tank has water operation or water pressure pressure unit operation is normal switch open option Otherwise check water pressure switch circuit to controller Correct d...

Page 158: ...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 overload...

Page 159: ...CSR 20 CSR 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 160: ...9 2 Schematic Circuit Tracings Electrical Refrigeration and P D Menu Flow Diagrams CSR 20 CSR 40 September 1999 1 Typical model shown with three evaporator fans 230 190 Vac Power Supply to Unit1...

Page 161: ...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 162: ...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 163: ...ectrical Refrigeration and P D Menu Flow Diagrams Schematic Circuit Tracings 9 5 1 Typical model shown with three evaporator fans 12 5 Vdc Control Circuit Sensor Circuits Modulation Valve Circuit and...

Page 164: ...9 6 Schematic Circuit Tracings Electrical Refrigeration and P D Menu Flow Diagrams CSR 20 CSR 40 September 1999 1 Typical model shown with three evaporator fans 24 Vac Control Circuit1...

Page 165: ...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 166: ...Circuit Tracings Electrical Refrigeration and P D Menu Flow Diagrams CSR 20 CSR 40 September 1999 1 Typical model shown with three evaporator fans Remote Monitor Receptacle 4 pin for Bridge Lights Ci...

Page 167: ...CSR 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 168: ...Schematic Circuit Tracings Electrical Refrigeration and P D Menu Flow Diagrams CSR 20 CSR 40 September 1999 1 Typical model shown with three evaporator fans Integrated Remote Monitor System Circuit1 O...

Page 169: ...ans Dehumidify System Humidity System Water Pressure Switch USDA Temperature Sensor Pulp Sensor and Chart Recorder Circuits Options CSR 20 CSR 40 September 1999 Electrical Refrigeration and P D Menu F...

Page 170: ...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 171: ...evaporator fans 2 A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above 50 C 122 F and increasing or when the condenser temperature is above 3...

Page 172: ...model shown with three evaporator fans 2 A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above 50 C 122 F and increasing or when the condenser...

Page 173: ...ns 2 A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above 50 C 122 F and increasing or when the condenser temperature is above 35 C 95 F Cool...

Page 174: ...omplex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above 50 C 122 F and increasing or when the condenser temperature is above 35 C 95 F Cool Mode1 C...

Page 175: ...h three evaporator fans 2 A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above 50 C 122 F and increasing or when the condenser temperature is...

Page 176: ...F and increasing or when the condenser temperature is above 35 C 95 F 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 ab...

Page 177: ...rature is above 35 C 95 F 3 Dehumidify Mode is 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 energ...

Page 178: ...ser fan ON when the compressor discharge temperature is above 50 C 122 F and increasing or when the condenser temperature is above 35 C 95 F 3 Evaporator fans operate on low speed when Economy Mode is...

Page 179: ...122 F and increasing or when the condenser temperature is above 35 C 95 F 3 Evaporator fans operate on low speed when Economy Mode is set to ON in the Program menu of the P D controller and the contai...

Page 180: ...s CSR 20 CSR 40 September 1999 1 Typical model shown with three evaporator fans 2 The controller stops the compressor If the condenser fan was ON it will operate for 30 seconds and then stop Null Mode...

Page 181: ...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 182: ...algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above 50 C 122 F and increasing or when the condenser temperature is above 35 C 95 F Cool Mode1 Frozen...

Page 183: ...2 A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above 50 C 122 F and increasing or when the condenser temperature is above 35 C 95 F Cool M...

Page 184: ...ms CSR 20 CSR 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 F...

Page 185: ...p during Null mode when Economy Mode is set to ON in the Program menu of the P D con troller During Economy Mode operation a Null state timer automatically starts and operates the evaporator fans on l...

Page 186: ...9 28 Electrical Refrigeration and P D Menu Flow Diagrams CSR 20 CSR 40 September 1999 1 Typical model shown with three evaporator fans Defrost1...

Page 187: ...Electrical Refrigeration and P D Menu Flow Diagrams CSR 20 and CSR 40 Wiring Schematic for All Models with Three Evaporator Fans 9 29 CSR 20 CSR 40 September 1999...

Page 188: ...Electrical Refrigeration and P D Menu Flow Diagrams CSR 20 and CSR 40 Wiring Diagram for All Models with Three Evaporator Fans Page 1 of 3 9 30 CSR 20 CSR 40 September 1999...

Page 189: ...Electrical Refrigeration and P D Menu Flow Diagrams CSR 20 and CSR 40 Wiring Diagram for All Models with Three Evaporator Fans Page 2 of 3 9 31 CSR 20 CSR 40 September 1999...

Page 190: ...Electrical Refrigeration and P D Menu Flow Diagrams CSR 20 and CSR 40 Wiring Diagram for All Models with Three Evaporator Fans Page 3 of 3 9 32 CSR 20 CSR 40 September 1999...

Page 191: ...Electrical Refrigeration and P D Menu Flow Diagrams CSR 20 and CSR 40 Wiring Schematic for All Models with Two Evaporator Fans 9 33 CSR 20 CSR 40 September 1999...

Page 192: ...Electrical Refrigeration and P D Menu Flow Diagrams CSR 20 and CSR 40 Wiring Diagram for All Models with Two Evaporator Fans Page 1 of 3 9 34 CSR 20 CSR 40 September 1999...

Page 193: ...Electrical Refrigeration and P D Menu Flow Diagrams CSR 20 and CSR 40 Wiring Diagram for All Models with Two Evaporator Fans Page 2 of 3 9 35 CSR 20 CSR 40 September 1999...

Page 194: ...Electrical Refrigeration and P D Menu Flow Diagrams CSR 20 and CSR 40 Wiring Diagram for All Models with Two Evaporator Fans Page 3 of 3 9 36 CSR 20 CSR 40 September 1999...

Page 195: ...ator Coil 14 Expansion Valve Feeler Bulb 15 Equalizer Line 16 Modulation Valve MV 17 Suction Line Process Tube 18 Liquid Injection Valve LIV with Restrictor 19 Electric Heaters 20 Return Air Sensor RE...

Page 196: ...bar 500 75 15 psig CLOSES at 2760 kPa 27 6 bar 400 psig 24 Condenser Coil Temperature Sensor CCOIL Controller cycles condenser fan ON typically when the condenser coil temperature is above 35 C 95 F...

Page 197: ...jection is required the valve is pulsed open and closed on a 10 second cycle The valve is energized when the compressor head temperature is above 138 C 280 F or when the modulation valve closes more t...

Page 198: ...r 26 Dehumidify Solenoid Valve DSV Option Is a normally OPEN valve If the container humidity is between 1 and 5 above the humidity set point and the temperature is in range the controller will energiz...

Page 199: ...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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