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This manual is published for informational purposes only and the information so provided should
not be considered as all-inclusive or covering all contingencies. If further information is required,
Thermo King Corporation should be consulted.

Sale of product shown in this manual is subject to Thermo King’s terms and conditions
including, but not limited to, the Thermo King Limited Express Warranty. Such terms and
conditions are available upon request. Thermo King’s warranty will not apply to any
equipment which has been “so repaired or altered outside the manufacturer’s plants 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 course of dealing or usage of
trade, are made regarding the information, recommendations, and descriptions
contained herein. Manufacturer is not responsible and will not be held liable in contract
or in tort (including negligence) for any special, indirect or consequential damages,
including injury or damage caused to vehicles, contents or persons, by reason of the
installation of any Thermo King product or its mechanical failure.

For further information, refer to:

CRR-40 119, 800 MPC2000ID Parts Manual for Maersk

Diagnosing Thermo King Container Refrigeration Systems

Electrostatic Discharge (ESD) Training Guide

Evacuation Station Operation and Field Application

Tool Catalog

TK 50680

TK 41166

TK 40282

TK 40612

TK 5955

The information in this manual is provided to assist owners, operators and service people in the proper
upkeep and maintenance of Thermo King units.

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Содержание CRR-40 119

Страница 1: ...CRR 40 119 172 800 for Maersk Sealand TK 50743 4 MM Rev 5 11 03 Copyright 2003 Thermo King Corp Minneapolis MN USA Printed in USA...

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

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

Страница 4: ......

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

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

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

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

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

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

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

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

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

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

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

Страница 16: ...Safety Precautions 16...

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

Страница 18: ...Service Guide 18...

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

Страница 20: ...Model Features 20...

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

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

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

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

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

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

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

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

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

Страница 30: ...lange Height 2235 2 mm 88 00 in E Gasket Height 2140 mm 84 25 in F Unit Height 2094 mm 82 44 in G Gasket Depth 72 mm 2 83 in from back of flange H Maximum Protrusion 37 mm 1 46 in from back of flange...

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

Страница 32: ...Specifications 32...

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

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

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

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

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

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

Страница 39: ...tor Drain Hose 2 Fill Cap 3 Water Tank Heater 4 Tank Overflow Hose 5 Drain Cock 6 Water Tank 7 Water Filter 8 Water Supply Hose 9 Air Compressor 10 Liquid Spray Nozzle Figure 6 Humidity System Option...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 65: ...Off switch ON 1 Press the DEFROST key If the unit operating conditions allow a manual defrost e g evaporator coil temperature is less than 18 C 56 F the unit enters defrost as the Defrost and Heat LE...

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

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

Страница 68: ...entered in the LCD display is correct before proceeding 5 Press and hold the F4 key until the cursor stops flashing The new setpoint is recorded in the controller and appears in the LCD display 6 Pres...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 94: ...logger memory may be viewed on the LCD display Event Examples Controller alarm status alarms set cleared Main power On Off status humidity On Off temperature setpoint and main power Hz 12 Vdc battery...

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

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

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

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

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

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

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

Страница 102: ...ge clears when test is complete Controller displays new message if test indicates a sensor is defective 4 Supply Right Hand Problem Sensor Disabled Indicates Controller disables sensor due to open or...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 119: ...larm occurs 115 Probe Error Check Alarm Occurs during Pretrip PTI test or Probe Test failed in Chilled mode Temperature difference between return air and evaporator coil sensors is too high 1 5 C 2 7...

Страница 120: ...MP 3000a Controller 120...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 147: ...alkaline cleaner with a pH of 9 5 to 10 5 For example a 2 3 solution of SIMPLE GREEN would make a suitable cleaning solution Apply the solution using a pressure spray wash type apparatus Spray the con...

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

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

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

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

Страница 152: ...mpressor Repair or replace compressor Condenser fan motor does not operate Unit in Heat or Defrost Check indicator lights If unit is in Heat or Defrost unit operation is normal no remedy required Unit...

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

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

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

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

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

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

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

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

Страница 161: ...161 MPC2000 Wiring Schematic...

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

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

Страница 164: ...164 MPC2000 WCC Wiring Schematic...

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

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

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

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

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

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

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