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Thermo King CRR-20, Руководство по обслуживанию


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CRR-20 & CRR-40, September 1999

Introduction

CRR Features

vii

CRR 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

–

X

–

X

–

X

–

–

–

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

–

–

–

–

–

–

–

–

–

Slimline Frame

X

X

X

X

X

X

X

X

X

3DS Copeland Discus Compressor w/5.60 kW (7.5 Hp) Motor

–

–

–

–

–

–

–

–

–

3DF Copeland Discus Compressor w/5.60 kW (7.5 Hp) Motor

X

X

X

X

X

X

X

X

X

Compressor Liquid Injection System

X

X

X

X

X

X

X

X

X

Suction and Discharge Line Service Valves

X

X

X

X

X

X

X

X

X

Evaporator Pressure Regulator (KVQ Valve)

X

X

X

X

X

X

X

X

X

Refrigerant R-134a w/Polyol Ester Compressor Oil (TK P/N 203-433)

X

X

X

X

X

X

X

X

X

Receiver Tank with Moisture Indicating Sight Glass

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

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

X

X

X

X

One 1-Speed Condenser Fan Motor

–

–

–

–

–

–

X

–

–

Auxiliary Battery and Battery Charger

–

–

–

–

–

–

–

–

–

Bulb Mode Operation

–

–

–

–

–

–

–

–

–

Controlled Atmosphere System

X

X

–

X

X

X

X

X

X

Data Retrieval Receptacle, Standard (5-Pin Duetsch)

–

–

X

–

–

–

–

–

–

Data Retrieval Receptacle, 5-Pin Threaded Cannon

–

–

–

–

–

–

–

–

–

Data Retrieval Receptacle, 15-Pin RS232

X

–

–

–

–

–

–

–

–

Dehumidify Control

–

–

–

–

–

–

–

–

–

High Output Evaporator Airflow

–

–

–

–

–

–

–

–

–

Humidity System

–

–

–

–

–

–

–

–

–

Power Line Communications , Standard (Thermo King Modem)

–

–

–

–

–

–

–

–

–

Power Line Communications , RTE Modem

X

–

–

–

–

–

–

–

–

Power Line Communications , Sabroe Control Modem

–

–

–

–

–

–

–

–

–

Pressure Gauge, Discharge

–

–

–

X

–

–

–

–

–

Pressure Gauge, Suction

–

X

X

–

X

–

–

X

X

Recorder, Partlow

X

–

–

–

–

–

–

–

–

Recorder, Saginomiya

–

–

–

–

–

–

–

–

–

Redundant Supply and Return Sensors 

X  X

–

–

X

–

–

–

–

Remote Monitoring Plug (4-Pin)

–

–

–

–

X

–

–

–

–

TRANSFRESH

®

Provision

–

–

–

–

X

–

–

X

–

TRANSFRESH

®

Purge Port

–

–

–

–

–

–

–

X

–

TRANSFRESH

®

System, Complete

–

X

–

–

–

–

–

–

–

Thermistor Lead

–

–

–

–

–

–

–

–

–

Water-Cooled Condenser-Receiver Tank with Moisture Indicating Sight Glass

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

FEATURES

X = Included

MODEL

Содержание CRR-20

Страница 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...

Страница 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...

Страница 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...

Страница 4: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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