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Thermo King CRR-20 - CRR-40 With P-D Controller PDF
Thermo King CRR-20 - CRR-40 With P-D Controller PDF
with µP-D
TK 50094-4-MM (Rev. 6, 8/01)
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.”
Model
CRR-20SL-63
CRR-40-100
CRR-40-101
CRR-40-102
CRR-40-103
CRR-40-106
CRR-40-107
CRR-40-52
CRR-40-54
Features
X=Included
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: 15kVA Autotransformer with 460-380V Power Receptacle
– – – X – X – – X
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 – – – – – – Slimline Frame
X X – X X X X X X 3DS Copeland Discus Compressor w/5.60 kW (7.5 Hp) Motor
– – X – – – – – – 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 (Refer to Tool Catalog)
X X X X X X X X X Receiver Tank with Moisture Indicating Sight Glass
ThermoGuard µP-D Controller with Proportional-integral Differential (PID) Capacity
X X X X X X X X X
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 X X – – – – Auxiliary Battery and Battery Charger
– X – – – – – – – Bulb Mode Operation
– – – – – – – X – Controlled Atmosphere System
X – X X X X – X X Data Retrieval Receptacle, Standard (5-Pin Duetsch)
– X – – – – X – – Data Retrieval Receptacle, 5-Pin Threaded Cannon
– – – – – – – – – Data Retrieval Receptacle, 15-Pin RS232
X X – – – – X – – Dehumidify Control
– – – – – – X – – 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
X – – – – – – – – Pressure Gauge, Discharge
X – – X – – – – – Pressure Gauge, Suction
– – – X – – – – X Recorder, Partlow
– – – – – – – – – Recorder, Saginomiya
Model Features
Model
CRR-20SL-63
CRR-40-100
CRR-40-101
CRR-40-102
CRR-40-103
CRR-40-106
CRR-40-107
CRR-40-52
CRR-40-54
Features
X=Included
Model
CRR-40-121
CRR-40-123
CRR-40-110
CRR-40-112
CRR-40-113
CRR-40-114
CRR-40-116
CRR-40-117
CRR-40-111
Features
X=Included
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: 15kVA Autotransformer with 460-380V Power Receptacle
– X – X – X – – –
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 (Refer to Tool Catalog)
X X X X X X X X X Receiver Tank with Moisture Indicating Sight Glass
ThermoGuard µP-D Controller with Proportional-integral Differential (PID) Capacity
X X X X X X X X X
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)
Model Features
Model
CRR-40-121
CRR-40-123
CRR-40-110
CRR-40-112
CRR-40-113
CRR-40-114
CRR-40-116
CRR-40-117
CRR-40-111
Features
X=Included
– – – – 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
Model Features
Model
CRR-40-126
CRR-40-128
CRR-40-130
CRR-40-131
CRR-40-132
CRR-40-133
CRR-40-136
CRR-40-138
Features
X=Included
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: 15kVA Autotransformer with 460-380V Power Receptacle
– – X – – – – – –
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 – – – – – – – – Slimline Frame
– X X X X X X X X 3DS Copeland Discus Compressor w/5.60 kW (7.5 Hp) Motor
X – – – – – – – – 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 (Refer to Tool Catalog)
X X X X X X X X X Receiver Tank with Moisture Indicating Sight Glass
ThermoGuard µP-D Controller with Proportional-integral Differential (PID)
X X X X X X X X X
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 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 X X X CO2 Sampling Port
X X X X X X X X X One 1-speed Condenser Fan Motor
X X – – – – – – X Auxiliary Battery and Battery Charger
– – – – – – – – – Bulb Mode Operation
– – – – – – – – – Controlled Atmosphere System
X X X X X X – – X Data Retrieval Receptacle, Standard (5-Pin Duetsch)
– – – – – – X X – Data Retrieval Receptacle, 5-Pin Threaded Cannon
– – – – – – – – – Data Retrieval Receptacle, 15-Pin RS232
– – – – X X X X – Dehumidify Control
– – – – – – – – – High Output Evaporator Airflow
– – – – – – – X – Humidity System
– – – – – – – – – Power Line Communications, Standard (Thermo King Modem)
– – – – – – – – – Power Line Communications, RTE Modem
– – – – – – – – X Power Line Communications, Sabroe Control Modem
– – – – – – – – – Pressure Gauge, Discharge
– – – – – – – – – Pressure Gauge, Suction
– – – – X X – – X Recorder, Partlow
– – – X – – – – – Recorder, Saginomiya
Model Features
Model
CRR-40-126
CRR-40-128
CRR-40-130
CRR-40-131
CRR-40-132
CRR-40-133
CRR-40-136
CRR-40-138
Features
X=Included
Model
CRR-40-139
CRR-40-141
CRR-40-142
CRR-40-143
CRR-40-144
CRR-40-145
CRR-40-147
CRR-40-148
CRR-40-150
Features
X=Included
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: 15kVA Autotransformer with 460-380V Power Receptacle
– – – X X X – – –
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 (Rfer to Tool Catalog)
X X X X X X X X X Receiver Tank with Moisture Indicating Sight Glass
ThermoGuard µP-D Controller with Proportional-integral Differential (PID) Capacity
X X X X X X X X X
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 – – – 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 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
– – – – – – – X – 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 X X X – – X – X Dehumidify Control
– – – X – – – – – High Output Evaporator Airflow
– – – – – – – – – Humidity System
– – – – – – – – – Power Line Communications, Standard (Thermo King Modem)
– – – – – – – – – Power Line Communications, RTE Modem
X X X – – – – – – Power Line Communications, Sabroe Control Modem
– – – – – – – – – Pressure Gauge, Discharge
– – – – – – – – – Pressure Gauge, Suction
– – X – X – X – X Recorder, Partlow
– X – – – X – – – Recorder, Saginomiya
– – – – – – – X – Redundant Supply and Return Sensors
Model Features
Model
CRR-40-139
CRR-40-141
CRR-40-142
CRR-40-143
CRR-40-144
CRR-40-145
CRR-40-147
CRR-40-148
CRR-40-150
Features
X=Included
Model
CRR-40-151
Features
X=Included
X 460-380V/3Ph 60-50 Hz, 18.3 m (60 ft) Power Cable and Plug
Dual Voltage Feature: 15kVA Autotransformer with 460-380V Power Receptacle and 230-190V/3Ph/60-50 Hz,
–
18.3 m (60 ft) Power Cable and Plug
X Automatic Phase Selection Control
X 25 Amp Main Power Circuit Breaker
– Slimline Frame
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 Compressor Liquid Injection System
X Suction and Discharge Line Service Valves
X Evaporator Pressure Regulator (KVQ Valve)
X Refrigerant R-134a w/Polyol Ester Compressor Oil (Refer to Tool Catalog)
X Receiver Tank with Moisture Indicating Sight Glass
X ThermoGuard µP-D Controller with Proportional-integral Differential (PID) Capacity Control
X Controller Emergency Bypass Module
X USDA 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 Motor
X Auxiliary Battery and Battery Charger
– Bulb Mode Operation
– Controlled Atmosphere System
X Data Retrieval Receptacle, Standard (5-Pin Duetsch)
– 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
– Power Line Communications, Sabroe Control Modem
– Pressure Gauge, Discharge
– Pressure Gauge, Suction
– Recorder, Partlow
X Recorder, Saginomiya
– Redundant Supply and Return Sensors
Model Features
Features
X=Included
– TRANSFRESH® Provision
– TRANSFRESH® Purge Port
– TRANSFRESH® System, Complete
– Thermistor Lead
– Water-Cooled Condenser-Receiver Tank with Moisture Indicating Sight Glass
Safety Precautions
Use the following First Aid practices if needed. • Treat all wires and connections as high
voltage until a meter and wiring diagram show
• Eyes: Immediately flush eyes with large
otherwise.
amounts of water for at least 15 minutes while
holding the eyelids open. Get prompt medical • Never work alone on high voltage circuits on
attention. the refrigeration unit. Another person should
always be standing by in the event of an
• Skin: Remove contaminated clothing. Wash
accident to shut off the refrigeration unit and
thoroughly with soap and water. Get medical
to aid a victim.
attention if irritation persists.
• Have electrically insulated gloves, cable
• Inhalation: Move victim to fresh air and
cutters and safety glasses available in the
restore breathing if necessary. Stay with
immediate vicinity in the event of an accident.
victim until arrival of emergency personnel.
• Ingestion: Do not induce vomiting. Contact a First Aid
local poison control center or physician
Immediate action must be initiated after a person
immediately.
has received an electrical shock. Obtain
immediate medical assistance if available.
Electrical
The source of shock must be immediately
High Voltage removed by either shutting down the power or
removing the victim from the source. If it is not
When servicing or repairing a refrigeration unit, possible to shut off the power, the wire should be
the possibility of serious or even fatal injury from cut with either an insulated instrument (e.g. a
electrical shock exists. Extreme care must be used wooden handled axe or cable cutters with heavy
when working with a refrigeration unit that is insulated handles) or by a rescuer wearing
connected to a source of operating power, even if electrically insulated gloves and safety glasses.
the unit is not running. Lethal voltage potentials Whichever method is used, do not look at the wire
can exist at the unit power cord, inside the control while it is being cut. The ensuing flash can cause
box, inside any high voltage junction box, at the burns and blindness.
motors and within the wiring harnesses.
If the victim has to be removed from a live circuit,
Precautions pull the victim off with a non-conductive material.
Use the victim's coat, a rope, wood, or loop your
• Be certain the unit ON/OFF switch is turned belt around the victim's leg or arm and pull the
Off before connecting or disconnecting the victim off. Do not touch the victim. You can
unit power plug. Never attempt to stop the unit receive a shock from current flowing through the
by disconnecting the power plug. victim's body.
• Be certain the unit power plug is clean and dry After separating the victim from power source,
before connecting it to a power source. check immediately for the presence of a pulse and
• Use tools with insulated handles that are in respiration. If a pulse is not present, start CPR
good condition. Never hold metal tools in (Cardio Pulmonary Resuscitation) and call for
your hand if exposed, energized conductors emergency medical assistance. If a pulse is
are within reach. present, respiration may be restored by using
mouth-to-mouth resuscitation, but call for
• Do not make any rapid moves when working emergency medical assistance.
on high voltage circuits. If a tool or other
object falls, do not attempt to grab it. People
do not contact high voltage wires on purpose.
It occurs from an unplanned movement.
Safety Precautions
Every
Annual/
Pre-Trip 1,000 Inspect/Service These Items
Yearly
Hours
Electrical
• Perform a controller full pre-trip check.
• • Perform a controller extended pre-trip check.
• • • Visually inspect condenser fan and evaporator fan rotation.
Visually inspect electrical 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 sensors.
Refrigeration
• • • Check refrigerant charge.
• • • Check for proper suction pressure.
• • • Check compressor oil level.
Check compressor efficiency and pump down refrigeration
•
system.
• Check liquid filter and dehydrator for a restriction or corrosion.
Structural
• • • Visually inspect Unit for damaged, loose or broken parts.
• • • Tighten unit, compressor and fan motor mounting bolts.
Clean entire unit including condenser and evaporator coils and
• •
defrost drains.
Humidity System (Option)
• Check water level in water tank.
• • • Check humidify system operation.
• • Clean water supply filter on water tank.
Service Guide
Specifications
CRR-40 Models with Three Evaporator Fans — Water Cooled Condensing Option
with 37.8 C (100 F) Water Temperature*
460/230V, 3 Phase, 60 Hz Power 380/190V, 3 Phase, 50 Hz Power
Return air to Net Cooling Capacity Power Net Cooling Capacity Power
evaporator coil Consp Consp
inlet Watts Kcal/hr BTU/hr kW@460V Watts Kcal/hr BTU/hr kW@460V
1.7 C (35 F) 10,900 9,375 37,200 10.2 9,080 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
*System net cooling capacity with a 37.8 C (100 F) water temperature, 30 liter/min. (8 gal./min.) water flow and R-134a.
CRR-40 Models with Three Evaporator Fans — Water Cooled Condensing Option
with 30 C(86 F) Water Temperature*
460/230V, 3 Phase, 60 Hz Power 380/190V, 3 Phase, 50 Hz Power
Return air to Net Cooling Capacity Power Net Cooling Capacity Power
evaporator coil Consp Consp
inlet 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 10,746 9,242 36,675 8.2
-17.8 C (0 F) 6,300 5,418 21,500 5.1 5,250 4,515 17,920 4.2
*System net cooling capacity with a 30 C (86 F) water temperature, 30 liter/min. (8 gal./min.) water flow and R-134a.
Evaporator Airflow
CRR-40 Models with Three Evaporator Fans
External Static 460/230V, 3 Phase, 60 Hz Power 380/190V, 3 Phase, 50 Hz Power
Pressure (water High Speed Low Speed High Speed Low Speed
column) 3
m /hr 3
ft /min 3
m /hr 3
ft /min 3
m /hr 3
ft /min 3
m /hr ft3/min
0 mm (0 in.) 6,470 3,810 3,116 1,835 5,400 3,180 2,600 1,530
10 mm (0.4 in.) 5,640 3,320 1,410 830 4,450 2,620 460 270
20 mm (0.8 in.) 4,770 2,810 — — 3,395 2,000 — —
30 mm (1.2 in.) 3,870 2,280 — — 2,240 1,320 — —
40 mm (1.6 in.) 2,885 1,700 — — 935 550 — —
High Performance Airflow Option for CRR-40 Models with Three Evaporator Fans
External Static 460/230V, 3 Phase, 60 Hz Power 380/190V, 3 Phase, 50 Hz Power
Pressure (water High Speed Low Speed High Speed Low Speed
column) 3
m /hr 3
ft /min 3
m /hr 3
ft /min 3
m /hr 3
ft /min 3
m /hr ft3/min
0 mm (0 in.) 7,200 4,240 3,650 2,148 6,000 3,531 2,870 1,689
10 mm (0.4 in.) 6,920 4,073 2,520 1,483 5,500 3,237 1,400 824
20 mm (0.8 in.) 6,500 3,828 — — 5,000 2,943 — —
30 mm (1.2 in.) 5,850 3,445 — — 4,300 2,531 — —
40 mm (1.6 in.) 5,200 3,060 — — 3,500 2,061 — —
Refrigeration System
Compressor Model No.:
CRR-20SL 3DFT-075X-TFD, Semi-hermetic with Copeland Discus® Valve
CRR-40 3DST-075X-TFD, Semi-hermetic with Copeland Discus® Valve
Refrigerant Charge:
Standard Receiver Tank 4.9 Kg (10.8 lb) R-134a
Water-Cooled Condenser-Receiver Tank (Option) 5.45 Kg (12.0 lb) R-134a (Refer to Tool Catalog)
Compressor Oil Capacity 1.77 liter (60 oz.)*
Compressor Oil Type Polyol Ester Based Type (required) Refer to Tool Catalog
High Pressure Cutout Switch:
All models (Except CRR-20SL-63):
Cutout 2410 ± 70 kPa, 24.10 ± 0.70 bar, 350 ± 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 kPa, 13.80 ± 0.50 bar, 200 ± 7 psig
Close 1100 ± 50 kPa, 11.00 ± 0.50 bar, 160 ± 7 psig
Water Pressure Switch (Option):
Open 117 ± 21 kPa, 1.17 ± 0.20 bar, 17 ± 3 psig
Close 35 ± 21 kPa, 0.35 ± 0.20 bar, 5 ± 3 psig1.00
High Pressure Relief:
Fusible Plug (Standard) Relief Temp. 100 C (212 F)
Relief Valve (Option***): Relief Pressure 3447 +345/-104 kPa, 34.47 +3.45/-1.04 bar, 500 +50/-15 psig
Reset 2758 kPa, 27.58 bar, 400 psig
Liquid Injection Control:
Compressor Start Liquid injection valve opens for 5 minutes on each compressor
start
Power Limit or Modulation Cool Liquid injection valve opens continuously during Power Limit
and Modulation Cool modes
Compressor Discharge Temperature Control Energizes (Opens) Liquid Injection Valve at 138 C (280 F)
De-energizes (Closes) Liquid Injection Valve at 132 C (270 F)
Compressor Shutdown (Auto Reset) at 148 C (298 F)
Liquid Injection Valve (Compressor):
Voltage 24 Vac
Cold Resistance 5.6 ohms
Evaporator Pressure Regulator (KVQ Valve):
EPR Circuit Voltage 24 Vdc
EPR Circuit Resistance 22 ohms
EPRTH (Thermistor) Circuit Resistance 22,000 ohms at 20 C (68 F)
*When the compressor is removed from the unit, oil level should be noted or the oil removed from the compressor should be
measured so that the same amount of oil can be maintained in the replacement compressor.
**Do not use or add standard synthetic or mineral oils to the refrigeration system. If Ester based oil becomes contaminated
with moisture or with standard oils, dispose of properly — Do not use!
***Included with Water-Cooled Condenser-Receiver Tank option.
Specifications
Electrical System
Compressor Motor:
Type 460/380V, 60/50 Hz, 3 Phase
Kilowatts (60 Hz) 5.60 kW
Horsepower (60 Hz) 7.5 hp
RPM (60 Hz) 1750 rpm
Full Load Amps 15.5 amps — 460V; 15.5 amps — 380V
Locked Rotor Amps 83 amps — 460V; 82 to 91 amps — 380V
Condenser Fan Motor*:
Red Color Finish: Type 460/380V, 60/50 Hz, 3 Phase
Kilowatts (60 Hz) 0.56 kW
Horsepower (60 Hz) 0.75 hp
RPM (60 Hz) 1140 rpm
Full Load Amps (60 Hz) 1.3 amps — 460V
Black Color Finish: Type 460/380V, 60/50 Hz, 3 Phase
Kilowatts (60 Hz) 0.37 kW
Horsepower (60 Hz) 0.50 hp
RPM (60 Hz) 1145 rpm
Full Load Amps 0.9 amps — 460V; 1.0 amps — 380V
Locked Rotor Amps 4.0 amps — 460V; 4.4 amps — 380V
Evaporator Fan 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 Hz) (Each) 1.2 amps — 460V, High Speed
0.5 amps — 460V, Low Speed
Black Color Finish: Type 460/380V, 60/50 Hz, 3 Phase
Number 3 or 2
Kilowatts (60 Hz) 0.75 kW
Horsepower (60 Hz) 1.0 hp
RPM (60 Hz) (Each) 3450 rpm, High Speed
1725 rpm, Low Speed
Full Load Amps (60 Hz) (Each) 1.2 amps — 460V, High Speed
0.5 amps — 460V, Low Speed
Locked Rotor Amps (60 Hz) 10.3 amps — 460V
Electric Resistance Heater Rods:
Type 460/380V, 60/50 Hz, 3 Phase
Number 6
Watts (60 Hz) (Each) 680 Watts
Current Draw (Amps) 5 amps nominal (total) across each phase at the heater contactor
Control Circuit Voltage 24 Vac
Auxiliary Battery (Option) 12 Vdc, 7 or 12 amp hour
*Use the motor color to identify the motor used in units built between 3/1/99 and 7/31/99.
Specifications
Physical Specifications
Fresh Air Exchange Venting 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
Evaporator Fan Blade Specifications:
CRR-20SL with Three Evaporator Fans
280 mm (11.02 in.)
Diameter:
Pitch 19o
CRR-40SL with Three Evaporator Fans
312 mm (12.25 in.)
Diameter:
Pitch 25o
CRR-40 with Three Evaporator Fans Diameter: 355 mm (14.0 in.)
Pitch 19o
CRR-40 High Performance Airflow Diameter: 355 mm (14.0 in.) (Three Evaporator Fans)
Pitch 22o
CRR-40 with Two Evaporator Fans Diameter: 355 mm (14.0 in.)
Pitch 25o
Recording Thermometer Options:
Type 31-Day Saginomiya SKM, battery driven recording chart
Type 31-Day Partlow, spring wound recording thermometer
Weight (net):
CRR-20SL Base Unit 498 Kg (1097 lb)
CRR-40 & CRR-40SL Base Unit 522 Kg (1150 lb)
Dual Voltage Option 45 Kg (99 lb)
Power Line Communications Option 3.6 Kg (8 lb)
Recorder (Partlow or Saginomiya) Option 5.9 Kg (13 lb)
TRANSFRESH Option
®
13 Kg (28 lb)
Water-cooled Condenser-Receiver Option 13.6 Kg (30 lb)
Specifications
Bolt Size
Bolt Type and
M14 M16 M18 M22
Class*
N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.)
HH – CL 5.8 75-88 (55-65) 115-135 (85-100) 177-216 (130-160) 339-406 (250-300)
HH – CL 8.8 115-135 (85-100) 177-216 (130-160) 271-339 (200-250) 475-610 (350-450)
HH – CL 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) 475-610 (350-450)
*HH = Hex Head, CL = Class.
Unit Description
10
5
9
6 8
10
9
1
2
3
8
4
7
2
17
16
6
15
7
8 14
9 13
10 12
11
1. Liquid Line Solenoid Valve 10. Filter Drier (Units before 3/9/99)
One-piece Filter Drier/In-Line Filter (Units after
2. Liquid Injection Solenoid Valve 11.
3/9/99 and Models with Two Evaporator Fans Only)
3. Expansion Valve 12. Condenser Fan Pressure Switch
4. Tube (Standard) 13. Condenser Check Valve
5. Heat Exchanger 14. Compressor Discharge Gas Temperature Sensorol
6. KVQ Valve (Evaporator Pressure Regulator) 15. Condenser Coil
7. High Pressure Cutout Switch 16. Receiver Tank with Service Port and Fusible Plug
8. Liquid Line Service Valve 17. Evaporator Coil
9. In-Line Filter (Units before 3/9/99)
Figure 6: Standard Refrigeration System
Unit Description
1a
1b
1c
1d
2a
4
2b
2c
2d
2 19
18
3 17
16
4 15
5 14
13
6
12
7
11
8
9
10
1. 15 KVA Transformer
2. 460-380V Power Receptacle
3. Cable Bracket
4. 230-190V Power Cable
5. Power Plug (Option)
Figure 10: Dual Voltage Option
Unit Description
1. 12 Vdc Battery
2. Battery Charger Box
3. Battery Charger
4. Terminal Board
5. Battery Charger Cover
Figure 11: Auxiliary Battery and Battery Charger Option
Unit Description
10
2
6
4
5
1. Evaporator Grill
2. Unit Gasket
3. Top Rear Plate
4. Bottom Rear Plate
5. Sensor Connector Assembly:
Controller Communications and Data Download Port
Cargo (Pulp) Sensor Connection
USDA1 Sensor Connection
USDA2 Sensor Connection
USDA3 Sensor Connection
Figure 14: Typical Unit Back View
Unit Description
Operating Instructions
2. Water Pressure Switch (Option). When water 4. Suction Pressure Gauge (Option): A suction
pressure greater than 117 ± 21, 1.17 ± 0.21 pressure gauge indicates the refrigerant
bar, 17 ± 3 psig is provided to the pressure in the suction line returning to the
condenser-receiver tank, the water pressure compressor. See "Normal R-134a System
switch opens. This causes the controller to Suction Pressures" table in the Refrigeration
stop condenser fan operation. When the water Maintenance and Service Operations chapter
pressure decreases below 35 ± 21 kPa, 0.35 ± for normal suction pressure readings.
0.21 bar, 5 ± 3 psig, the switch closes, causing
5. Discharge Pressure Gauge (Option): A
the controller to place the unit on air-cooled
discharge pressure gauge indicates the
condenser fan operation.
refrigerant pressure in the discharge line
NOTE: Water-cooled condenser operation leaving the compressor.
requires a water flow of 19 to 38 l/min.
(5 to 10 gal. min.). 6. Thermistor Lead (Option): A thermistor lead
is located in the unit control box to provide air
temperature verification. The bulb of the
Unit Instruments thermistor lead is attached to the return or
1. Status Indicator LEDs are located on the µP-D supply air sensor in the evaporator section.
controller and signal the following: 7. Remote Monitor Connector, 4-pin (Option): A
• Cool • Defrost
receptacle is provided on the side of the
control box for connecting the ship's 4-pin
• Modulation • Supply
bridge light system to the unit. The connector
• Null • Return
provided circuits for Compressor On, Defrost
• Heat • Power Limit
and in-range. The remote in-range light is
• In-Range • Alarm activated when the controlling air sensor
The in-range LED illuminates when the temperature is between 1.7 C (3 F) above
controlling air sensor temperature is between setpoint and 2.5 C (4.5 F) below set-point.
1.7 C (3 F) above set-point and 2.5 C (4.5 F) 8. Recording Thermometer (Option): The
below setpoint. The controller inhibits the recording thermometer indicates and
out-of-range alarm during defrost. permanently records the temperature of the air
NOTE: The controller will not respond to an returning to the evaporator section on a
out-of-range condition for 75 minutes to calibrated chart.
avoid nuisance alarms. 9. Power Line Communications Modem
2. Receiver Tank Sight Glass: A sight glass on (Option): Several models remote monitoring
the receiver tank contains three small balls modems are available to provide remote
that indicate the level of refrigerant in the tank monitoring via the power cable. High speed
for checking the refrigerant charge. A transmission reads all controller information.
moisture indicator in the sight glass changes • Thermo King modem is installed in a
color to indicate the level of moisture in the self-enclosed box bolted above the
system. Check the color of the indicator compressor.
against the color decal in the sight glass. The
dry eye in the sight glass is Light Green when • Sabroe Controls modem is installed in the
the system is dry and Yellow when the system electrical control box.
is wet (contains excessive moisture). • RTE modem is installed in the electrical
3. Compressor Oil Sight Glass: A compressor oil control box.
sight glass indicates the relative level of
compressor oil in the compressor sump.
Operating Instructions
4. Evaporator Over Temperature Protection: An 7. High Pressure Relief Valve (Option): A high
evaporator coil sensor monitors coil pressure relief valve is installed in the
temperature during Heat and Defrost modes. water-cooled condenser-receiver tank to avoid
If the coil sensor temperature reaches 38 C excessive pressure build-up within the
(100 F), the controller de-energizes the heater refrigeration system from extraordinary and
contactor. If the coil sensor reaches 50 C unforeseen circumstances. The valve is a
(122 F), the controller also de-energizes the spring-loaded piston that lifts when refrigerant
evaporator fan and phase select contactors; pressure exceeds 3447 +345/-104 kPa, 34.47
and generates a shutdown Alarm. Fault code +3.45/-1.04 bar, 500 +50/-15 psig. The valve
09 (Evaporator Coil Over Temperature) is is located so that refrigerant pressure expelled
displayed on the controller display when the from the valve would be directed away from
ALARM key is pressed. anyone servicing the unit. The valve will reset
when this pressure drops to 2758 kPa, 27.58
5. High Pressure Cutout (HPCO) Switch: The
bar, 400 psig. The valve is non repairable and
refrigerant high pressure cutout opens,
requires no adjustment. If the valve fails to
interrupting 24 Vac control power to the
reseat properly, recover the refrigerant charge
compressor contactor if the compressor
and replace the valve.
discharge pressure rises above 2410 ± 70 kPa,
24.10 ± 0.7 bar, 350 ± 10 psig. This 8. Overload Protection: The condenser fan
immediately stops the compressor and motor, evaporator fan motors and compressor
evaporator fans. The condenser fan and phase motor include internal overload protection
select outputs remain energized as the with automatic reset.
controller operates the condenser fan to
9. Phase Sequence Selection: When the ON/OFF
correct the condition. The controller display
switch is turned On, the controller display
will show "PAUSE ALM10" for 1 second
shows "Phase Check" while it determines the
every 10 seconds.
correct phase sequence. Phase selection takes
After 5 minutes, the controller attempts to 50 to 80 seconds; or more on extremely noisy
restart the compressor. If the compressor fails power lines. The controller then energizes
to start, fault code 10 (High Pressure Cutout) phase select contactor ABC or CBA to ensure
is generated. The controller will restart the proper condenser fan, evaporator fan and
compressor when the fault condition corrects compressor rotation.
itself (resets). The high pressure switch resets
(closes) when the pressure drops back to 1655 Pre-Trip Inspection
± 70 kPa, 16.55 ± 0.7 bar, 240 ± 10 psig.
6. Fusible Plug for High Pressure Relief: A Visual Inspection
fusible plug is installed in the standard The following visual inspections should be made
receiver tank to avoid excessive pressure before the container is loaded:
build-up within the refrigeration system from
extraordinary and unforeseen circumstances. 1. Visually check the unit for physical damage.
The plug blows when the plug temperature 2. Check the electrical connections in the unit
reaches 100 C (212 F). The plug is located so control box, making sure they are fastened
that refrigerant pressure expelled from the securely.
valve would be directed away from anyone
servicing the unit. The plug is non-repairable 3. Check the conditions of wires and terminals.
and requires no adjustment. If the plug blows, Repair or replace if necessary.
recover the remaining refrigerant charge and 4. Check the refrigeration system for leaks.
replace the fusible plug. Inspect for evidence if oil leaks at all joints
and connections.
Operating Instructions
5. Check the condenser and evaporator coils. • The controller display shows "Phase
Clean if necessary. Use an air or water spray Check" while it determines the correct
jet directed against the coil from the air phase sequence. Phase selection takes 50
discharge side. Also inspect the condenser fan to 80 seconds; or more on extremely noisy
grille for damage. If the grille is damaged or power lines. Phase select contactor ABC
missing, abnormally high head pressure may and the electric heaters, condenser fan and
result. Repair or replace the grille if necessary. evaporator fans are energized for 10
seconds. Phase select contactor ABC is
CAUTION: Air or water spray jet pressure then de energized, 30 seconds later, phase
should not be high enough to damage select contactor CBA and the electric
(bend) coil fins. heaters, condenser fan and evaporator fans
6. Check the mounting bolts on the unit, are energized for 10 seconds. The
compressor and fan motors. Tighten if controller then turns Off all unit loads and
necessary. energizes phase select contactor ABC or
CBA.
7. Clean the defrost drains.
• The setpoint and controlling air sensor
8. Optional: Inspect water-cooled temperature are displayed.
condenser-receiver tank, water lines and
fittings for water leaks. When water lines are • Controller energizes unit loads, starting
disconnected, also check to be sure that the the evaporator fans. The condenser fan
water drains completely from the may also start (if required).
condenser-receiver tank. • If the controller calls for cooling, the
Report defective fittings and tanks that do not compressor motor starts. If the unit starts
drain to a technician. in Modulation Cool, compressor start-up
9. Optional: Check water level in humidity can be delayed up to 3 minutes while the
system tank. Add only demineralized or evaporator pressure regulator (KVQ)
distilled water to prevent plugging of the valve opens or closes to the required
atomizing nozzle. setting.
10. Observe the unit for proper operation and • If the controller calls for heating, the
functions during Pre-load Operation. electric heaters are energized.
NOTE: If the unit does not start, turn the
Functional Inspection ON/OFF switch Off. Check power supply. Then
To properly perform a full pre-trip test on units repeat step 1. If the unit still does not start, refer
equipped with the uP-D controller, the container to "Alarm Codes, Descriptions and Corrective
must be empty with the rear doors closed. Actions" in the ThermoGuard uP-D Controller
chapter of this manual. Be sure to wait up to 3
1. Start the unit (see "Starting the Unit and minutes for the compressor to start.
Adjusting the Controller Setpoint" on page
67). A second sequence start of the required 2. Check controller setpoint for proper setting.
loads occurs during initial start-up of the unit. Adjust if necessary.
• The status Indicator LEDs and display turn 3. Check the direction of the condenser airflow
On and then Off. (see "Condenser Fan and Evaporator Fan
Rotation" in the Electrical Maintenance
chapter of this manual).
4. Check direction of evaporator airflow (see
"Condenser Fan and Evaporator Fan Rotation"
in Electrical Maintenance chapter of this
manual).
Operating Instructions
5. Perform a full (or extended) pre-trip test and NOTE: PASS or FAIL is recorded in the data
check unit modes while the unit pre-cools: logger memory and can be viewed through the
controller’s View/Log/ PT1 submenu. For
NOTE: An extended pre-trip test can take up to 7
instructions on viewing the View/Log/PT1
hours to complete.
submenu, refer to "Viewing Information in the
• Press the PRE-TRIP key. The left display View Menu" in the ThermoGuard uP-D
flashes "ENTER" and the right display Controller chapter of this manual.
flashes "PTRIP".
NOTE: Clear the Alarm codes ONLY after the
• Press the ENTER key. "LOAD PTRIP" alarm codes are documented and problems
briefly appears in the display. repaired. Clearing the codes erases them from
NOTE: If Alarm Code(s) are stored in the the display memory of the controller. However, a
controller when the ENTER key is pressed, the permanent record of the alarm codes remains
display briefly shows "CLEAR ALARM". The stored in the data logger memory of the
display then returns to the Standard Display. controller for retrieval via PC-Pac™ software.
Correct the alarm condition(s) and clear the WARNING: Some unit malfunctions will
alarm code(s) before attempting a pre-trip test. cause an Alarm and unit shutdown
NOTE: To perform an extended or single condition. When the alarm codes are
pre-trip test, see "Pre-Trip Test" in the cleared, the unit will start automatically.
ThermoGuard µP-D Controller chapter of this 6. Allow the unit to operate in the Cool mode for
manual. 30 minutes before loading the container. This
• The controller then performs the full (or will remove residual container heat and
extended) pre-trip test. moisture, and pre-cool the container interior.
NOTE: If the container temperature is below 0 C 7. Enter trip ID information into the controller
(32 F), the controller places the unit in the Heat memory using the PC-Pac™ software (see
mode when a full or extended pre-trip test is instructions of PC-Pac™ software).
initiated. The test begins when the container
8. Set the fresh air vent to the desired air
temperature increases to 0 C (32 F).
exchange rate.
• ’Observe the unit for proper operation and
NOTE: If Dehumidification is turned On, the
functions during pre-trip test. fresh air vent should be closed.
• If the unit passes the full pre-trip test. 9. Optional: Operate the humidity system (see
"PTRIP PASS" is stored in the data logger "Humidify Mode" on page 115). Verify that
memory and the unit returns to normal the air compressor operates and that water is
operation. A Start of Trip (SOT) marker is drawn into the atomizing nozzle and injected
also recorded in the data logger memory into the return air stream (see "Humidify
when an automatic full or extended System" in this section).
pre-trip is successfully completed.
10. Install a new chart and prepare the recording
• If an operating problem is encountered thermometer for temperature recording (if so
during the full pre-trip test. the Alarm equipped):
LED will turn On, "PTRIP FAIL" is stored
in the data logger memory and the unit • Wind the chart drive on the recording
returns to normal operation (unless a thermometer (Paitlow recorders).
shutdown fault has occurred). View and • Check the battery charge on the recording
correct any alarm conditions. Then clear thermometer (Saginomiya recorders).
the Alarm Code(s) and repeat the pre-trip
test. 11. Stop the unit by moving the ON/OFF switch to
the Off position.
Operating Instructions
2
3
• PRE-TRIP: Press to prepare to initiate a full • 7.5 amp fuse (F11) protects the Output
pre-trip test. Module circuit.
• SOT (Start of Trip): Press to prepare to • 3 amp fuse (F12) protects the remote
place Start of Trip marker in the data battery connector circuit.
logger
• 3 amp fuse (F13) protects the battery
• ALARM: Press to view alarm codes that are charger (option) output circuit.
present.
• 3 amp fuse (F14) protects the battery
3. Status indicator LEDs (see "Status Indicator (option) circuit.
LEDs and Alarm Codes" in this chapter).
5. Output Module: Output terminals are used to
4. Power Module: Low voltage control power energize and de-energize unit contactors and
and ground are supplied to the µP-D controller solenoids (see "Output Module" in this
and Output Module. The Power Module also chapter).
includes:
6. Thermo Bus Tap circuit board: Serial
• KVQ valve power output terminals. communication commands are transmitted
between the controller and the Output Module
• Remote monitoring connection is provided
through the Thermo Bus circuit board (see
by a serial communications port located on
"Thermo Bus Tap" in this chapter).
the side of the control box.
7. Replaceable sensors: Return air, supply air,
• Control circuit fuse protection:
evaporator coil, condenser coil, ambient air
• 2 amp fuse (Fl) protects the circuit to and compressor discharge gas temperature
the KVQ valve. sensors are field replaceable (see
"Temperature Sensors" in this chapter). Four
• 1 amp fuse (F2) protects the bridge
spare sensor receptacles are also provided for
light relay (option) circuit.
USDA and Pulp temperature recording
• 1 amp fuse (F3) protects SPARE (optional).
circuit terminals.
8. Defrost cycle control (see "Defrost" under
• 5 amp fuse (F4) protects the circuit Sequence of Operation in this chapter).
that supplies power to Power Module
9. Internal self-checking/diagnostic capability.
Board.
10. Pre-trip test capability (see "Full Pre-Trip
• 1 amp fuse (F5) protects the bridge
Test" under Menu Test in this chapter).
light (option) circuit.
11. Sensor Check test capability (see "Sensor
• 5 amp fuse (F6) protects SPARE
Check" under General Theory of Operation in
circuit terminals.
this chapter).
• 3 amp fuse (F7) protects the
12. Data recording capability (see "Data
TRANSFRESH® (option) circuit. Recording and Downloading Data" in this
• 2 amp fuse (F8) protects the chapter).
RMMIIRMU (option) circuit. 13. Electronic phase selection (see "Automatic
• 3 amp fuse (F9) protects SPARE Phase Selection" under General Theory of
circuit terminals. Operation in this chapter).
• 3 amp fuse (F10) protects the battery 14. Power limit control (see "Power Limit" under
charger (option) power input circuit. General Theory of Operation in this chapter).
ThermoGuard µP-D Controller
15. Sequential component start-up control: A 20. Flash memory: Flash program memory allows
sequence start of the required loads occurs the application software to be updated without
during initial start-up of the controller and replacing a EPROM chip on the controller.
when a control mode shift requires the Application software can be updated in the
compressor to start (see "Compressor Soft field using a portable computer and Thermo
Start Sequence" under General Theory of King flash loading program. Consequently,
Operation and "Sequence of Operation" in this the field installed application software version
chapter). may have a different revision number and may
include control features not included in the
16. Evaporator fan speed and condenser fan
original factory installed software. If the
operation control (see "Evaporator Fan
operation of your unit differs from the
Control" and "Condenser Fan Control" under
Sequence of Operation described for your unit
General Theory of Operation in this chapter).
(both unit and customer configuration block
17. Hourmeters: The µP-D controller has multiple numbers) in this manual, check the unit
built-in hourmeters that can be accessed configuration number and customer
through the Display menu. configuration number to be sure the controller
is set to the proper unit and customer
18. Wake-up (setpoint enable) capability: Pressing
configuration (see "Reviewing Application
the SELECT key (or connecting a
Software Version" in this chapter).
communications cable to the Data Port on the
bottom of the control box) when 12 Vdc
battery power option is present awakens the Controller Display Menus
controller. This capability provides auxiliary The µP-D controller contains an extensive display
power for setpoint adjustment or downloading menu that can be navigated via keypad. The
of controller data recording memory when a display menu is organized into five main menus
three phase power source is not available. (or groups):
Battery power keeps the controller energized
for 1 minute unless a key is pressed on the NOTE: See page 227 to view a diagram of the
controller keypad. complete µP-D menu.
Option Display/Description
Economy Mode "ECON ON"/Economy mode
reduces unit power consumption
by reducing evaporator fan
operation.
"ECONT XXXXX"/Shows the
time remaining to next controller
check of return air temperature
(active only during Null mode on
Frozen Loads).
Humidify Mode "HUM ON"/Humidity system
operates to add moisture to the
container as required to maintain
humidity setpoint.
Dehumidify Mode "DEHUM ON"/Dehumidify
system operates to remove
moisture from the container as
required to maintain humidity
setpoint.
Bulb Mode "BULB ON"/Dehumidify system
operates to remove moisture
from the container as required to
maintain humidity setpoint. Bulb
mode allows adjustment of
evaporator fan speed setting and
defrost termination temperature.
Figure 18: Active Options and Pause Screen Flow "DEHUM XX.X"/Current humidity
Diagram level also displays briefly when
the Bulb mode is On.
ThermoGuard µP-D Controller
Test Menu
Menu screens in this group are used to set the unit
to specified operating conditions for system and
Figure 20: Pause Mode Display component diagnostics.
Status Indicator LEDs and hyphen (-) preceding the alarm code. Alarm codes
Alarm Codes 50 through 58 can only be generated during an
automatic pre-trip test (or Fitness test).
Status Indicator LEDs Alarm
Type Description
The indicator LEDs stay On continuously to Code
indicate a unit operating mode or condition. The 00 No Fault
Alarm LED stays On continuously when a Check Ambient Temperature
02 Check
Alarm occurs. The Alarm LED flashes On and Sensor Failure
Off when a Shutdown Alarm occurs. LEDs are Supply Air Temperature
03 Check
located on the µP-D controller and signal the Sensor Failure
following: Evaporator Pressure
04 Check Regulator (KVQ) Valve
• Cool Mode Thermistor Failure
Evaporator Coil
• Modulation Mode 05 Check Temperature Sensor
• Null Mode Failure
06 Check Humidity Sensor Error
• Heat Mode Return Air Temperature
07 Check
• In-Range (Temperature) Sensor Failure
Evaporator Coil Over
• Defrost Mode 09 Shutdown
Temperature
• Supply (Air Temperature) 10 Check High Pressure Cutout
Temperature Out-of-Range
• Return (Air Temperature) 12 Check
High
• Power Limit Mode Temperature Out-of-Range
13 Check
Low
• Alarm Defrost Terminated on
14 Check
Time Limit
Alarm Codes 16 Shutdown Digital Input Failure
Check Alarms indicate corrective action should be Return & Supply
Check/
25 Temperature Sensor
taken before a problem becomes severe. The unit Shutdown
Failure
continues to operate. However, some unit
Low Refrigerant Level
functions may be inhibited. 37 Shutdown
(Option)
Shutdown Alarms indicate the unit operation has Real Time Clock Battery
38 Check
been stopped to prevent damage to the unit or Failure
cargo. The problem must be corrected and the Spare Sensor 5 Failure
41 Check
alarm code cleared from the controller display (Option)
before the unit can be restarted to resume normal Customer Configuration
42 Check
Alarm
operation.
Frequency Out-of-Range
43 Shutdown
Alarm codes are recorded in the controller Low
memory to simplify unit diagnosis and Three Phase Current
44 Shutdown
troubleshooting procedures. The first 16 fault Imbalance
codes including the most recent fault code are Frequency Out-of-Range
45 Shutdown
retained by the controller in a non-volatile High
memory in order of their occurrence (the 46 Check
USDA Sensor 1 Failure
following chart). Alarm codes that are recorded (Option)
during an automatic pre-trip test are recorded in USDA Sensor 2 Failure
47 Check
the controller memory and displayed with a (Option)
USDA Sensor 3 Failure
48 Check
(Option)
ThermoGuard µP-D Controller
Alarm
Type Description Pause Alarms
Code
Pulp Sensor Failure
A Pause Alarm ("PAUSE ALMXX") stops unit
49 Check operation due to a shutdown alarm condition. A
(Option)
Check/ Compressor Current 2-digit alarm code ("XX") appears in Pause
50 display to identify the alarm condition. Typically
Shutdown Out-of-Range (Pre-Trip)
Check/ Unit Current Out-of-Range the condenser fan continues to operate while the
51 controller attempts to correct the condition and
Shutdown in Cool Mode (Pre-Trip)
Check/ KVQ Valve System Failure restart the unit. PAUSE ALMXX appears in the
52
Shutdown (Pre-Trip) display for 1 second every 10 seconds until the
Check/ Heating Current condition has been corrected. The following
53
Shutdown Out-of-Range (Pre-Trip) Alarm Codes generate a Pause Alarm display:
Check/ Defrost Current
54
Shutdown Out-of-Range (Pre-Trip)
• 10, High Pressure Cutout
55
Check/ High Speed Evaporator • 43, Frequency Out-of-Range, Low (low
Shutdown Fan Failure (Pre-Trip) supply voltage)
Check/ Low Speed Evaporator Fan
56 • 82, Compressor Head Over Temperature
Shutdown Failure (Pre-Trip)
Check/ Condenser Fan Current NOTE: "PAUSE ALM43" will also appear in
57
Shutdown Out-of-Range (Pre-Trip) the controller display when the Setpoint Enable
Check/ Sensor Calibration Failure function is activated to download the controller
58
Shutdown (Pre-Trip) data logger or change the setpoint.
Check Data
59 Datalogger Full (µP-A+)
Logger
"PAUSE ALM10", High Pressure
60 Check Datalogger Full (Global)
Cutout
61 Check Real Time Clock Invalid
Bypass Valve Circuit The controller immediately stops the compressor
63 Check and evaporator fans when the high pressure cutout
Failure (Pre-Trip)
Pre-Trip Preconditioning switch opens. The condenser fan and phase select
64 Check outputs remain energized as the controller
Failure
65 Check Datalog Queuing Error operates the condenser fan for 5 minutes to correct
Dehumidify Valve Circuit the condition. After 5 minutes, the controller
69 Check attempts to restart the compressor. If the
Failure (Pre-Trip) (Option)
70 Check Hourmeter Alarm compressor fails to start due to high pressure
71 Check User Hourmeter 1 Expired cutout, alarm code 10 is generated. The controller
72 Check User Hourmeter 2 Expired will restart the compressor when the fault
73 Check User Hourmeter 3 Expired
condition corrects itself (high pressure switch
closes).
74 Check User Hourmeter 4 Expired
79 Check Datalogger Overflow The controller also generates alarm code 10 if the
Compressor Head high pressure cutout/restart cycle repeats 3 times
81 Check Temperature Sensor within 30 minutes.
Failure
Compressor Head Over "PAUSE ALM43", Frequency
82 Check
Temperature
Out-of-Range Low
Check/ Compressor Current
85 The controller immediately stops the compressor,
Shutdown Out-of-Range
Condenser Fan Sensor evaporator fans, condenser fan and heaters when a
92 Check low supply power voltage condition exists. The
Failure
Loss of Communications controller will restart the unit to resume normal
97 Shutdown
with Output Module temperature control operation when the supply
voltage returns to normal.
ThermoGuard µP-D Controller
The µP-D controller can record sensor • Water pressure switch (water-cooled
temperatures as well as loss of power. alarms, unit condenser option)
operating modes, sensor failure, setpoint change • Current transformer circuits 1, 2 and 3
and unit shutdown indications. Logging intervals
are selectable from 30 minutes and 1 hour. When Output signals from the controller automatically
a 1 hour logging interval is selected, the data regulate all unit functions including:
logger memory can store approximately 365 days • Compressor operation
of information.
• Condenser fan operation
PC-PacTM software downloads and reports the
• Evaporator fan motor speed and operation
Return, Supply, Ambient and USDA sensor
temperatures as standard. Connect a portable • Evaporator pressure regulator (KVQ)
computer with PC-PacTM software to the valve
communications port on the control box to • Compressor liquid injection valve
download trip data.
• Liquid line solenoid valve
Trip data can be retrieved (but not erased) from
the controller memory using PC-PacTM software. • Dehumidify valve (option)
Trip data from separate units is denoted by the • Electric heaters
identification information entered into the
controller at the beginning of the trip by • Bridge light relays for defrost, cool and
in-range lights (option)
PC-PacTM software. Identification data may
include the date, container ID number, operator • Phase selection contactors ABC and CBA
identification, point of origin, product, setpoint
and other information up to a total of 80
characters (numerals or alphabetical letters). The
container ID number is always resident in the
controller memory.
ThermoGuard µP-D Controller
Power Limit Management The unit remains in Null until the return air
temperature increases to ECMAX temperature at
A predetermined Power Limit can also be set from
the expiration of a 45 minute Null state time
"PWRED" feature in the Program Menu of the
sequence. Default ECMAX setting is 0.2 C (0.4 F)
controller. A 10%, 20% or 30% power reduction
above setpoint. ECMAX setting is adjustable
can be selected for 8 hours of unit operation.
from 0 to 5 C (0 to 8.9 F) above setpoint through
Because the cooling capacity of the unit may be
the Configuration menu of the controller.
reduced when the Power Reduction mode is
active, use of the Power Reduction mode should NOTE: On Frozen loads, supply and return air
be established by the shipper. temperatures may vary considerably during
Economy mode operation due to long periods of
Economy Mode Operation no air circulation. On Chill loads, container air
temperatures may vary 1 C to 3 C (1.8 F to 5.4 F)
The Economy mode reduces unit power
above setpoint in high ambient temperatures.
consumption by reducing evaporator fan
operation on both fresh and frozen loads. The use
of the Economy mode should be established by Sequence Of Operation
the shipper and the type of cargo. The Economy
mode option is turned on from Setpoint menu of Unit Start-up
the controller. A sequence start of the required loads occurs
NOTE: If the Economy mode is set to On, the during initial start-up of the controller. If cooling
controller display will show "ECON ON" for 1 (or heating) is required, the unit operates in the
second every 10 seconds. cool (or heat) mode until the controlling sensor
reaches setpoint.
• Fresh Loads (return air temperatures of -9.9 C
(14.1 F) and above): Evaporator fans operate • When the unit ON/OFF switch is turned On.
on low speed whenever the container the Status Indicator LEDs and display turn On
temperature is in-range. and then Off.
• Frozen Loads (return air temperatures of -10 C • "Phase Check" appears in the controller
(14 F) and below): The evaporator fans stop display while the controller determines the
during the Null mode. A null slate timer correct phase sequence. Phase selection takes
automatically re-starts the evaporator fans on 50 to 80 seconds; or more on extremely noisy
low speed for 5 minutes every 45 minutes. power lines. The controller then energizes
phase select contactor ABC or CBA.
The Economy mode also modifies the temperature
control algorithm on frozen loads to extend the • The setpoint and controlling air sensor
Null mode. The unit continues on Cool operation temperature are displayed.
until return air temperature reaches ECMIN • The evaporator fan motors start. Evaporator
temperature. Default ECMIN setting is 2 C (3.6 F) fans operate on high speed at return air
below setpoint. ECMIN temperature is adjustable temperatures of -9.9 C (14.1 F) and above
from 0 to 5 C (0 to 8.9 F) below setpoint through (except when Economy mode is On and
the Configuration menu of the controller. temperature is in-range). Evaporator fans
operate on low speed at return air
temperatures of -10 C (14 F) and below
(except during Null with Economy mode On).
• The condenser fan motor also starts if the
condenser fan pressure switch is open
(pressure above 1380 ± 50 kPa, 13.80 ± 0.5
bar, 200 ± 7 psig) and the controller calls for
cooling.
ThermoGuard µP-D Controller
• If the controller calls for cooling, the • If the controller calls for heating, the electric
compressor motor starts and the liquid line heaters are energized. Unit operates in heat
solenoid valve opens (energizes). If the unit until the controlling sensor reaches setpoint.
starts in Modulation Cool, compressor start-up
• Power limit is active when the unit is
can be delayed up to 3 minutes while the
operating in the Cool mode. This means the
evaporator pressure regulator (KVQ) valve
KVQ valve may be energized to reduce the
opens or closes to the required setting. Unit
cooling load on the compressor, thereby
operates in cool and modulation cool until the
reducing total unit power consumption.
controlling sensor reaches setpoint.
• Controller turns On the in-range LED when
the controlling sensor temperature is within
1.7 C (3 F) of setpoint.
Null
• The controller calls for Null when the return
air temperature decreases more than 1 C
(1.8 F) below setpoint (on temperature
pull-down).
• The controller de-energizes the liquid line
solenoid valve to pump down the low side.
• The controller de-energizes the compressor
contactor (to terminate pump down) after 30
seconds.
• If the condenser fan was On, it will operate for
30 seconds and then stop. If the condenser fan
was Off (based on condensing pressure), it
will remain Off.
• The evaporator fans continue to operate in low
speed.
A. Cool
C. Null
E. In-Range
1. Decreasing Temperature
2. Setpoint
3. Increasing Temperature
6. Return Air Temperature
Defrost
During the Cool, Modulation Cool or Null modes,
the controller initiates the Defrost mode when the
evaporator coil sensor temperature is below 10 C
(50 F) and:
A. Cool
• Demand Defrost algorithm determines when
C. Null defrost is required based on the return air
E. In-Range temperature, evaporator coil temperature,
1. Decreasing Temperature condenser coil temperature and the percent
2. Setpoint modulation.
3. Increasing Temperature
• Internal Defrost Timer calls for defrost based
6. Return Air Temperature
on a timed defrost interval:
ECMIN (default setting is -2 C [-3.6 F]). Setting is
7.
adjustable from -10 to 0 C (-18 F to 0 F).
ECMAX (default setting is +1 C [+1.8 F]). Setting
8.
is adjustable from +10 to 0 C (+18 F to 0 F).
Figure 22: Frozen Load Control Sequence
(Setpoints at -10C [14 F] and Below) — Economy
Mode On
ThermoGuard µP-D Controller
Displaying Alternate
Fahrenheit (F) or Celsius (C)
Temperatures
NOTE: The C/F units shown on the controller
display can be changed by pressing and holding
Figure 24: Software Version Display the C/F key, and then pressing the ENTER key.
• Display then shows the unit configuration The controller can display temperatures in
number for 2 seconds (replacement Fahrenheit or Celsius. With the unit ON/OFF
controller default setting: CFG U 5000). switch On and the controller showing a Standard
Display:
1. Press and hold the F/C key. The controller
will show the display temperatures in the
alternate temperature scale (Fahrenheit or
Celsius) from the temperatures shown on the
display as long as the F/C key is depressed.
Figure 25: Unit Configuration Display 2. The display then returns to the original display
when the F/C key is released.
• Display then shows the customer
configuration number for 2 seconds NOTE: The setpoint temperature can be entered
(replacement controller default setting: in either F or C using the F/C key. Just press
CFG C 0). and hold the F/C key (to display the alternate
temperature scale).
Displaying Alternate
Controlling (Supply or Return)
Air Sensor Temperature
The controller can show either the supply air or
return air temperature in the right display. With
the unit ON/OFF switch On and the controller
showing the Standard Display: Figure 28: Setpoint Temperature Display
1. Check the indicator LEDs to determine which NOTE: The setpoint temperature can be entered
sensor temperature (supply air or return air) in either F or C using the F/C key. Just press
currently appears in the right display. This is and hold the F/C key (to display the alternate
the controlling sensor (supply air sensor at temperature scale). Press the UP or DOWN key to
setpoints of -9.9 C (14. 1 F) and above; return scroll to the correct setpoint temperature. Then
air sensor at setpoints of -10 C [14 F] and press the ENTER key to load the setpoint.
below). 2. When the desired setpoint appears in the right
2. To view the alternate air sensor temperature, display, press the ENTER key. The right
press and hold the RET/SUP key. The display shows "LOAD".
controller will show the temperature of the
alternate (non-controlling) air sensor as long
as the RET/SUP key is depressed.
3. The display then returns to the Standard
Display when the RET/SUP key is released.
1. Press the DOWN or UP ARROW key. The left Figure 30: New Setpoint Display
display flashes "SETPT" while the right
display shows the changing setpoint
temperature. To set the tenths digit, wait 4
seconds for all three digits to appear on the
display. Make additional setpoint adjustment
if necessary.
ThermoGuard µP-D Controller
With the unit ON/OFF switch On: To perform a full pre-trip test, turn the unit
ON/OFF switch On:
1. Press the DEFROST key. The display flashes
"ENTER DFRST". NOTE: The controller will not perform an
automatic pre-trip test until all alarms have been
corrected and cleared.
1. Press the PRE-TRIP key. The display flashes
"ENTER PTRIP".
5. To clear all alarm codes from the current Moving through these five menus and their
display memory. press the ENTER key. The submenus and entering commands requires the
display briefly shows "ALARM CLEAR". use of four keys:
WARNING: Some unit malfunctions will SELECT key: Press the SELECT each time
cause an Alarm and unit shutdown you want to enter a new menu or submenu;
condition. When the alarm codes are or start a procedure to load a command or
cleared, the unit will start automatically. value.
UP or DOWN key: Press the UP or
or
DOWN key each time you want to
scroll up or down to view another
item in a menu or submenu.
ENTER key: Press the ENTER key to load a
command or value.
Figure 40: “ALARM CLEAR” Display
Figure 42: Menu View Screen Flow Diagram (See Menu Display Definitions beginning on page 74)
ThermoGuard µP-D Controller
2. Press DOWN key until display shows "MENU 2. Press DOWN key until display shows "MENU
VIEW’. 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
Figure 43: “MENU VIEW” Display submenu. Display will show "GRADE <--->".
3. Press the SELECT key to enter View submenu 6. Press DOWN key to view functions in Grade
(display shows VIEW <--->"). submenu. Display shows submenu function
and value (e.g. "RETG 5").
NOTE: The controller returns to "GRADE
<--->" screen from a sensor grade screen after
about 10 seconds. The controller returns to the
Standard Display after another 10 seconds, or
when the SELECT key is pressed and held for 3
Figure 44: “VIEW” Submenu Display seconds.
NOTE: To lock the current View menu screen in • TEMP: Display shows unit operating
the controller display, press the ENTER key. A information recorded with the last 100
colon flashes in the left display to indicate the data logs.
screen is locked (the screen remains locked for • PTI: Display shows "PASS" or "FAIL" and
15 minutes). Press any key to unlock the display. individual test results recorded for the last
NOTE: The controller returns to the Standard 4 full pre-trip tests.
Display from a View menu screen after about 10 When viewing information in the TEMP or PTI
seconds, or when the SELECT key is pressed and scroll back display, the status indicator LEDs on
held for 3 seconds. the controller show the unit operating states that
were active (ON) when the data or event was
Grade Submenu recorded. If the Alarm LED is On, press the
The Grade submenu displays the sensor grade of ALARM key to view alarm and/or event
each sensor installed on the unit. With the unit information in the right display (e.g. "03.204").
ON/OFF switch On and the controller showing the If more than one alarm/event is recorded, press
Standard Display: the DOWN key to scroll to the next alarm/event
NOTE: If a sensor grade is set to "0", it means code. Alarms are identified by the 2 digits furthest
the sensor has been ice bath calibrated. Original to the right of the decimal point and are always
unit sensors are ice bath calibrated at the preceded by a "0" (see the Alarm Code list.
factory. See "Setting the Sensor Grades" in this Events (e.g. Power Up) are identified by a 3 digit
chapter for more information. number that always begins with a "2".
1. Press the SELECT key to enter menu (display NOTE: The scroll back alarm/event screen
shows "MENU <--->". display does NOT identify which alarms are
pre-trip alarms.
ThermoGuard µP-D Controller
The 3 digit event codes that may appear in the The TEMP scroll back display shows the
scroll back alarm/event screen display includes: following acronyms and information:
Event RT Return Air Sensor Temperature
Description
Code ST Supply Air Sensor Temperature
201 Setpoint Change SP Setpoint Temperature
202 Power Up AT Ambient Sensor Temperature
203 Power Off U1 Spare 1 (USDA 1) Sensor Temperature
204 Alarm(s) Cleared U2 Spare 2 (USDA 2) Sensor Temperature
205 Real Time Clock Reset U3 Spare 3 (USDA 3) Sensor Temperature
206 Start of Trip (SOT) Entered HM Humidity (%)
207 Text Header Entered PP Pulp Probe Sensor Temperature
208 Defrost Initiated YR Year
209 Defrost Terminated MO Month
210 Power Limit Algorithm Active DY Day
211 Pre-Trip Passed TI Time
212 Pre-Trip Failed
To enter the TEMP scroll back submenu:
With the unit ON/OFF switch On and the
controller showing the Standard Display: 1. Press the SELECT key with "LOG TEMP" in
the display. Display will briefly show
1. Press the SELECT key to enter menu (display ’SEARCHINGX". The display then shows the
shows "MENU <--->"). last (most recent) data log entry
2. Press DOWN key until display shows "MENU (e.g. "001RT 43.8F").
VIEW". 2. Press UP or DOWN key to scroll (up or down)
3. Press the SELECT key to enter View submenu through the last 100 data log entries of the
(display shows "VIEW <--->"). return air temperature.
4. Press the UP key until "VIEW LOG" shows in 3. Press the SELECT key to scroll (to the right) to
the display. the next column of data. The display wraps
around from Tl (Time) screen to RT (Return
5. Press the SELECT key to enter the Log Temperature) screen. Press the RET/SUP key
submenu. Display will show "LOG <--->". to quickly return to the RT (return
6. Press DOWN key to view scroll back menu temperature) display.
items in Log submenu. Display will show NOTE: If a log entry for a sensor was not
"LOG TEMP" or "LOG PTI". recorded, the right display will show "NOLOG"
7. Press the SELECT key to enter either the "LOG NOTE: The controller returns to the "LOG
TEMP" or "LOG PTI". TEMP" screen from a data log screen after 10
seconds if no controller key is pressed. The
TEMP Scroll back Display Items controller returns to the Standard Display after
another 10 seconds, or when the SELECT key is
The TEMP scroll back display contains a lot of
pressed and held for 3 seconds.
information that may appear confusing at first.
After entering the TEMP display ("001RT 43.8 F"
appears in display), imagine that the data is stored
in a table. The first column identifies the number
of the Log entry (001. 002. etc.) and the return
temperature entry. Each additional column
identifies information about another sensor or the
time of the event.
ThermoGuard µP-D Controller
PTI Scroll back Display Items To enter the PTI scroll back submenu:
The PTI scroll back display also contains a lot of 1. Press the SELECT key with "LOG PTI in the
information. After entering the PTI display ("PT1 display. Display will show the result of the last
PASS" or "PT1 FAIL appears), imagine that the (most recent) full pre-trip test (e.g. "PTI
data is stored in a table. The first column identities FAILS or "PTI PASS").
the number of the full pre-trip test (PT1, PT2, etc.)
2. Press UP key to scroll back through the last 4
and the test result (PASS or FAIL). Each
full pre-trip test entries.
additional column identifies information about an
individual test result or the time of the test. 3. Press the SELECT key to scroll (to the right) to
the next individual test result stored with each
The PTI scroll back display shows the following
full pre-trip test (e.g. "PT1DS PASS").
acronyms and information:
Display wraps around the TI (Time) screen to
DS Display Test Result DS (Display Test) screen. Press the RET/SUP
AM Amps Test Result key to quickly return to the DS (Display Test)
SN Sensors Test Result screen.
HT Heat Test Result NOTE: If a log entry for a sensor was not
DF Defrost Test Result recorded, the right display will show "NOLOG".
CL Cool Test Result NOTE: The controller returns to the "LOG
EX Extended Cool Test Result PTI" screen from a pre-trip log screen after 30
YR Year seconds. To return to the Standard Display, press
MO Month and hold the SELECT key for 3 seconds.
DY Day
TI Time
TEMP (Temperature) Scroll Back Information PTI (Pre-Trip) Scroll Back Information Matrix
* First information screen displayed from the TEMP * First information screen displayed from the PTI
Scroll Back menu. Scroll Back menu.
Figure 45: Scroll Back Information Matrix
ThermoGuard µP-D Controller
Figure 46: Menu Pre-Trip Screen Flow Diagram (See Menu Display Definitions beginning on page 74)
5. Press the DOWN key to view functions in To initiate a single pre-trip test:
submenu. Press the UP key to scroll back
a. Enter Stest submenu by pressing the
through submenu. Display shows PTRIP and
DOWN key with “PTRIP STEST” showing
submenu function (e.g. "PTRIP ETEST").
in the display. Display will show “STEST
To initiate an extended pre-trip test: <--->".
a. Press the SELECT key with "PTRIP b. Press the DOWN key to view a test function
ETEST" in the display. in Stest submenu. Flashing display will
show “ENTER” and test function (e.g.
b. Flashing display will show "ENTER
"ENTER HEAT").
PTRIP".
c. With test function you want in Right
c. Press the ENTER key. A flashing display
display. press the ENTER key. Left display
will show LOAD PTRIP. The controller
will show LOAD while the right display
then conducts an extended pre-trip test.
shows the test function selected. The
d. When the test is complete. the unit shuts controller then conducts the single pre-trip
down. test selected.
To initiate a full pre-trip test: d. When the test is complete, the display
returns to the Standard Display. The unit
a. Press the SELECT key with "PTRIP
returns to normal operation.
FTEST" in the display.
NOTE: When a pre-trip test is complete, PASS
b. Flashing display will show "ENTER or FAIL is recorded in the data logger memory.
PTRIP". pre-trip test results can then be viewed through
c. Press the ENTER key. A flashing display the controller’s View/Log/PT1 submenu. For
will show “LOAD PTRIP”. The controller instructions on viewing the View/Log/PT1
then conducts a full pre-trip test. submenu, refer to "Menu View" in this chapter.
d. When the test is complete, the unit shuts
down.
ThermoGuard µP-D Controller
• Generator [GEN]: Check the main supply • The display shows "HTR "OFF" On
power voltage and frequency provided by (with HTR and OFF flashing). The
a genset while the unit is in Full Cool. heaters should energize.
NOTE: When the Test menu is entered, the • Inspect controller and output module
UNIT STOPS. A technician can then select the indicator LEDs and contactor to
control circuit or component to be checked/tested confirm operation.
from the items shown in the Test menu. c. To turn the test function Off. press ENTER
1. Turn the unit ON/OFF switch On. key again.
2. With the controller showing the Standard • Display will show "HTR OFF "ON"
Display, press the SELECT key to enter menu (with HTR and OFF flashing).
(display shows "MENU <--->"). d. Press the UP or DOWN key to scroll to
3. Press DOWN key until display shows "MENU another test function or the top of the
TEST". submenu.
4. Press the SELECT key to enter Test submenu 8. Press and hold the SELECT key for 3 seconds
(display shows "TEST <-->"). to return to the Standard Display.
ThermoGuard µP-D Controller
Figure 47: Menu Test Screen Flow Diagram (See Menu Display Definitions on page 74)
ThermoGuard µP-D Controller
Menu Guard Functions b. Press and release the DOWN key three
times to scroll the flashing digit to "7"
NOTE: An access code is required to enter the
Guard menu to prevent unauthorized personnel (display now shows "GUARD 0007").
from tampering with the programmable features. c. Press the ENTER key to load the code and
access the Guard menu. The display will
The Guard menu is used to set many
briefly show "GUARD LOAD" and then
programmable features including:
show "GMENU <--->".
• Unit Configuration
NOTE: If the correct code is not entered, the
• Customer Configuration display returns to "GUARD <--->".
• Container Identification Number 6. Press the DOWN or UP key to scroll through
the menu list.
• Unit Serial Number
NOTE: If a new controller or new software has
• Date and Time been installed, proceed immediately to "Setting
• Unit and Special Hourmeters the Unit Configuration and Customer
Configuration Numbers" below.
• Economy Mode ECMAX and ECMIN
NOTE: If no key is pressed, the controller
• Change Temperature Display Units (C/F) returns to the "GMENU <->" display from a
• Sensor Grades Guard menu screen after 30 seconds. The
display returns to the Standard Display 10
The controller turns Off all control outputs and seconds later.
suspends normal operation when the Guard menu
is entered. Setting the Unit Configuration and
When the Guard menu is exited, the controller Customer Configuration Numbers
resets and then restarts the unit. This is necessary 1. From "GMENU <--->" in the Guard menu,
to be certain that all changes in the programmable press the DOWN key until the display shows
features are activated. MENU CNFIG").
Navigating Menu Guard Screens 2. Press the SELECT key to enter Configuration
submenu (display shows "CNFIG <-->").
With the unit ON/OFF switch On and the
controller showing the Standard Display: 3. Press the DOWN key until display shows "CFG
U 5000" (where "5000" is the default unit
1. Press the SELECT key to enter menu (display configuration when a new controller or
shows "MENU <-->"). software is loaded).
2. Press DOWN key until display shows “MENU NOTE: If the Unit Configuration has already
GUARD”. been set, the current number (YYYY format) will
3. Press the SELECT key to enter Guard submenu show instead of "5000". The Unit Configuration
(display shows "GUARD <--->"). MUST always be set first.
4. Press the DOWN key. Display shows "GUARD 4. Press the SELECT key to enter the load
0000" with left "0" flashing. A flashing digit configuration display (left display flashes
indicates the digit that can be changed. "CFG U",).
5. Enter the current access code "0007". 5. If the correct unit configuration is not known,
check the setup decal in the control box for the
a. Press and release the SELECT key three correct Unit Configuration number. Then
times to scroll the flashing digit ("0") to press the UP or DOWN key to scroll to the
the right digit. correct number (number appears in right
display).
ThermoGuard µP-D Controller
Figure 48: Menu Guard Screen Flow Diagram (See Menu Display Definitions on page 74)
6. Press the ENTER key to load the configuration 8. Press the SELECT key to enter the load
number selected. The display will briefly configuration display (left display flashes
show "CFG U LOAD" and then show the new “CFG C”).
CFG U setting in the right display.
9. If the correct customer configuration is not
7. Press the DOWN key until display shows CFG known, check the setup decal in the control
C 0" (where "0" is the default customer box for the correct Customer Configuration
configuration when a new controller or number. Then press the UP or DOWN key to
software is loaded; or the Unit Configuration scroll to the correct number (number appears
is reset). in right display).
NOTE: If the Customer Configuration has 10. Press the ENTER key to load the configuration
already been set, the current number (ZZ number selected. The display will briefly
format) will show instead of "0". The Unit show "CFG C LOAD" and then show the new
Configuration MUST always be set first. The CFG C setting in the right display.
Customer Configuration MUST always be set
NOTE: A new controller or new software has
after the Unit Configuration has been set.
been installed, proceed immediately to "Setting
the Container Identification Number" below.
ThermoGuard µP-D Controller
c. When the desired year shows in the right 5. If the hour is correct, press the DOWN key until
display. press the ENTER key. The display the display shows “MIN MM” (where "MM"
shows "YEAR LOAD" and then shows is the minute).
"YEAR YYYY" (where "YYYY" is the
a. Press the SELECT key to enter the load
new year).
Minute display (left display flashes
2. If the year is correct, press the DOWN key until "MIN").
the display shows "MONTH MM" (where
b. Press the UP or DOWN key to choose the
"MM" is the month).
desired minute.
a. Press the SELECT key to enter the load
c. When the desired minute shows in the
Month display (left display flashes
right display, press the ENTER key. The
"MONTH").
display shows "MIN LOAD" and then
b. Press the UP or DOWN key to choose the shows "MIN MM" (where "MM" is the
desired month. new minute).
c. When the desired month shows in the right NOTE: Setting the Compressor, On Time and
display, press the ENTER key. The display User Hourmeters is optional when a new
shows "MONTH LOAD" and then shows controller or new software has been installed.
"MONTH MM" (where "MM" is the new However, the Sensor Grades MUST be set. If you
month). are NOT setting the hourmeters, proceed
immediately to "Setting the Sensor Grades"
3. If the month is correct, press the DOWN key
until the display shows "DAY DD" (where
Setting the Compressor and On Time
"DD" is the day).
Hourmeters
a. Press the SELECT key to enter the load NOTE: If the values for the Compressor Run
Day display (left display flashes "DAY"). Time Hourmeter (CHRM1) and the Unit On
b. Press the UP or DOWN key to choose the Hourmeter (ONHRM) can be retrieved from the
desired day. original controller, the values can be duplicated
in the new controller.
c. When the desired day shows in the right
display, press the ENTER key. The display 1. From "GMENU <---> in the Guard menu,
shows "DAY LOAD" and then shows press the DOWN key until the display shows
"DAY DD" (where "DD" is the new day). "CHRM 1 XXXX" (where "XXXX" is the
number of compressor run hours).
4. If the day is correct. press the DOWN key until
the display shows "HOUR HH" (where "HH" NOTE: If the number of compressor run hours
is the hour). cannot be determined, leave this setting "0000".
Proceed to step 2.
a. Press the SELECT key to enter the load
Hour display (left display flashes a. Press the SELECT key to enter the load
"HOUR"). Compressor Hourmeter display (left
display flashes "CHRM1".
b. Press the UP or DOWN key to choose the
desired hour. b. Press the UP or DOWN key to choose the
desired hour setting.
c. When the desired hour shows in the right
display. press the ENTER key, The display c. When the desired hours show in the right
shows "HOUR LOAD" and then shows display, press the ENTER key. The display
"HOUR HH" (where "HH" is the new shows "CHRM1 LOAD" and then shows
hour). "CHRM1 XXXX" (where "XXXX" is the
new compressor run hours).
ThermoGuard µP-D Controller
2. From CHRM 1 XXXX" in the controller b. Press the UP or DOWN key to choose the
display. press the DOWN key until the display desired type setting.
shows "ONHRM XXXX’ (where "XXXX" is
the number of unit on hours). Type
Description
Code
NOTE: If the number of unit on hours cannot be
0 Timer Turned Off
determined, leave this setting "0000".
1 Evaporator Fan Low Speed Run Time
a. Press the SELECT key to enter the load 2 Evaporator Fan High Speed Run Time
Compressor Hourmeter display (left 3 Not Used
display flashes "ONHRM"). 4 Condenser Fan High Speed Run Time
b. Press the UP or DOWN key to choose the 5 Full Cool Mode Run Time
desired hour setting. 6 Modulation Cool Mode Run Time
7 Null Mode Time
c. When the desired hours show in the right
8 Heat Mode Run Time
display, press the ENTER key. The display
shows "ONHRM LOAD" and then shows 9 Defrost Mode Run Time
ONHRM XXXX" (where "XXXX" is the 10 Warm Gas Bypass On Time
new Unit On hours). 11 Power Limit On Time
12 Liquid Injection On Time
Setting the User Hourmeter Types, User 13 Heaters On Time
Hourmeter Thresholds and User
c. When the desired type number shows in
Hourmeters
the right display, press the ENTER key. The
NOTE: The procedure for setting H1TYP, display shows "H1TYP LOAD" and then
H2TYP, H3TYP and H4TYP is the same. The shows "H1TYP XXXX" (where "XXXX"
procedure for setting UHMT1, UHMT2, is the new type setting).
UHMT3 and UHMT4 is the same. The
2. From "HITYP XXXX" in the controller
procedure for setting UHRM1, UHRM2,
display, press the DOWN key until the display
UHRM3 and UHRM4 is also the same.
shows "UHMT1 XX" (where "XX" is the
However, if the number of accumulated hours
number of threshold hours).
cannot be determined, leave UHRM1, UHRM2,
UHRM3 and UHRM4 settings at "0000". a. Press the SELECT key to enter the load
User Hourmeter Threshold display (left
1. From "GMENU <--->" in the Guard menu,
display flashes "UHMTI").
press the DOWN key until the display shows
"H ITYP XX" (where "XX" is the hourmeter b. Press the UP or DOWN key to choose the
type). desired threshold setting.
a. Press the SELECT key to enter the load c. When the desired threshold hours show in
User Hourmeter Type display (left display the right display, press the ENTER key. The
flashes "HITYP"). display shows UHMT1 LOAD" and then
shows "UHMT1 XX" (where "XX" is the
new threshold hours).
ThermoGuard µP-D Controller
b. To calibrate the sensor in an ice bath: • Observe the sensor temperature in the
right display. When the temperature
• Press the UP or DOWN key to choose
has been stable for 5 minutes, press the
"0" as the grade setting in the right
ENTER key. Right display briefly
display.
shows "LOAD" and then the sensor
• Press the ENTER key. Right display temperature.
briefly shows "CALIB" and then the
NOTE: The sensor should be in the ice bath a
sensor (ice bath) temperature. total of 15 minutes or more to assure the sensor
• When the sensor temperature is within temperature has bottomed out.
1.7 C [3 F] above or below 0 C (32 F).
c. To set the sensor grade:
the left display ("RET") begins to
flash. • Press the UP or DOWN key to choose
the desired grade setting.
• Observe the sensor temperature in the
right display. When the temperature • When the desired grade shows in the
has been stable for five minutes, press right display, press the ENTER key.
the ENTER key. Right display briefly Right display briefly shows "LOAD"
shows "LOAD" and then the sensor and then the new sensor grade.
temperature.
5. Press the DOWN key until "ECTG XX" shows
NOTE: The sensor should be in the ice bath a in the display (where "XX" is the sensor
total of 15 minutes or more to assure the sensor grade).
temperature has bottomed out.
a. Press the SELECT key to enter the load
c. To set the sensor grade: Sensor Grade display (left display flashes
"ECTG").
• Press the UP or DOWN key to choose
the desired grade setting. b. To calibrate the sensor in an ice bath:
• When the desired grade shows in the • Press the UP or DOWN key to choose
right display, press the ENTER key. "0" as the grade setting in the right
Right display briefly shows "LOAD" display.
and then the new sensor grade.
• Press the ENTER key. Right display
4. Press the DOWN key until "SUPG XX" shows briefly shows "CALIB" and then the
in the display (where "XX" is the sensor sensor (ice bath) temperature.
grade).
• When the sensor temperature is within
a. Press the SELECT key to enter the load 1.7 C [3 F] above or below 0 C (32 F),
Sensor Grade display (left display flashes the left display ("ECT") begins to
"SUPG"). flash.
b. To calibrate the sensor in an ice bath: • Observe the sensor temperature in the
right display. When the temperature
• Press the UP or DOWN key to choose
has been stable for 5 minutes. press the
"0" as the grade setting in the right
ENTER key. Right display briefly
display.
shows "LOAD" and then the sensor
• Press the ENTER key. Right display temperature.
briefly shows "CALIB" and then the NOTE: The sensor should be in the ice bath a
sensor (ice bath) temperature. total of 15 minutes or more to assure the sensor
• When the sensor temperature is within temperature has bottomed out.
1.7 C [3 F] above or below 0 C (32 F),
the left display ("SUP") begins to
flash.
ThermoGuard µP-D Controller
c. To set the sensor grade: a. Press the SELECT key to enter the load
Sensor Grade display (left display flashes
• Press the UP or DOWN key to choose
"AMTG").
the desired grade setting.
b. To calibrate the sensor in an ice bath:
• When the desired grade shows in the
right display, press the ENTER key. • Press the UP or DOWN key to choose
Right display briefly shows "LOAD" "0" as the grade setting in the right
and then the new sensor grade. display.
6. Press the DOWN key until "CCTG XX" shows • Press the ENTER key. Right display
in the display (where "XX" is the sensor briefly shows "CALIB" and then the
grade). sensor (ice bath) temperature.
a. Press the SELECT key to enter the load • When the sensor temperature is within
Sensor Grade display (left display flashes 1.7 C [3 F] above or below 0 C (32 F),
"CCTG"). the left display ("AMT") begins to
flash.
b. To calibrate the sensor in an ice bath:
• Observe the sensor temperature in the
• Press the UP or DOWN key to choose
right display. When the temperature
"0" as the grade setting in the right
has been stable for 5 minutes, press the
display.
ENTER key. Right display briefly
• Press the ENTER key. Right display shows "LOAD" and then the sensor
briefly shows "CALIB" and then the temperature.
sensor (ice bath) temperature. NOTE: The sensor should be in the ice bath a
• When the sensor temperature is within total of 15 minutes or more to assure the sensor
1.7 C [3 F] above or below 0 C (32 F), temperature has bottomed out.
the left display ("CCT") begins to c. To set the sensor grade:
flash.
• Press the UP or DOWN key to choose
• Observe the sensor temperature in the the grade setting "5".
right display. When the temperature
has been stable for 5 minutes, press the • When the desired grade shows in the
ENTER key. Right display briefly right display, press the ENTER key.
shows "LOAD" and then the sensor Right display briefly shows "LOAD"
temperature. and then the new sensor grade.
NOTE: The sensor should be in the ice bath a 8. Press the DOWN key until "SPRIG XX" shows
total of 15 minutes or more to assure the sensor in the display (where "XX" is the sensor
temperature has bottomed out. grade).
c. To set the sensor grade: a. Press the SELECT key to enter the load
Sensor Grade display (left display flashes
• Press the UP or DOWN key to chose the
"SPRIG").
grade setting "5".
b. Press the UP or DOWN key to choose the
• When the desired grade shows in the
desired grade setting.
right display, press the ENTER key.
Right display briefly shows "LOAD" c. When the desired grade shows in the right
and then the new sensor grade). display, press the ENTER key. The display
shows "SPRIG LOAD" and then shows
7. Press the DOWN key until "AMTG XX" shows
"SPRIG XX" (where "XX" is the new
in the display (where "XX" is the sensor
sensor grade).
grade).
ThermoGuard µP-D Controller
9. Repeat step 8 for each additional spare sensor • Press and hold the SELECT key for 3
shown on the setup sheet and installed on the seconds to return to the Standard Display.
unit.
Program Menu List
NOTE: Return controller to the Standard <---> Top of menu
Display by pressing and holding the SELECT key USDA sensor recording (3 or 4 sensors)
for 3 seconds. Then enter the Menu View or USDA
On/Off
Menu Guard to check the accuracy of all USDA 1 Spare 1 sensor On/Off
settings. USDA2 Spare 2 sensor On/Off
USDA3 Spare 3 sensor On/Off
Changing the Display Units (C/F)
PULP Pulp recording On/Off
1. From "GMENU <--->" in the Guard menu, ECON Economy mode On/Off
press the DOWN key until the display shows Dehumidify or Humidify On/Off
"C/F X"). HUM HUMSP = Enter Humidity setpoint (50%
2. Press the SELECT key to enter the load to 100%)
configuration display (left display flashes Bulb mode On/Off
"C/F"). BDFTT = Enter Bulb mode defrost
BULB termination temperature
3. Press the UP or DOWN key to scroll to the
BEFAN = Enter Bulb mode evaporator
desired temperature unit (C = Celsius, F =
fan speed (high, low or cycle)
Fahrenheit).
PWRED Power Reduction 1, 2 or 3
4. Press the ENTER key to load the configuration
unit selected. The display will briefly show USDA Sensors
"C/F LOAD" and then show the new C/F
setting in the right display. Changing the USDA program screen from Off to
On activates spare sensors 1, 2 and 3 for USDA
NOTE: Return the controller to the Standard Cold Treatment Temperature Recording. USDA
Display by pressing and holding the SELECT key sensor temperatures arc recorded in the data
for 3 seconds. Then check to be sure that the logger memory.
display shows the correct temperature unit.
The USDA sensors should be connected to the
controller and located in the load as shown in
Menu Program Functions
USDA directives. When a USDA sensor is
NOTE: When the unit is Off, the following installed, the controller will automatically detect
options default to Off after 48 hours (v11.71 to the sensors and activate data logging. The
11.73 software) or 96 hours (v11.74 and above controller Program menu shows the USDA sensor
software): Bulb mode, Dehumidify, Economy number in the left display and "AUTO" in the
mode, Humidify, Pulp mode and USDA mode. right display if data logging is active. However,
The Program menu allows technicians to set the USDA program screen MUST be set to On
specific control functions. and each USDA sensor MUST be calibrated to
comply with USDA temperature recording
• Turn the unit ON/OFF switch On or requirements. Calibrate the sensors in an ice bath.
operate controller using battery power. The µP-D controller requires a USDA sensor
• Press the SELECT key to enter menu (refer to Tool Catalog).
(display shows "MENU <-->".
• Press DOWN key until display shows
"MENU PRGRM'.
• Press the SELECT key to enter Prgrm
submenu (display shows 'PRGRM <--->").
ThermoGuard µP-D Controller
Figure 49: Menu Program Screen Flow Diagram (See Menu Display Definitions beginning on 74)
d. Press the ENTER key. The display briefly Setting and Calibrating the Pulp Sensor
shows "USDA 1 CALIB". The left display
1. Insert Pulp sensor in an ice bath (see "Ice Bath
then shows "USDA 1" and the right
Preparation" under USDA Sensors in this
display shows the sensor temperature
chapter).
("00 C").
NOTE: The sensor must be completely immersed
e. When USDA1 sensor temperature is in the ice bath without contacting the walls of
within 1.7 C (3 F) above or below 0 C the ice bath container for 5 minutes.
(32 F), the left display ("USDA1") begins
to flash. 2. Press the SELECT key to enter menu (display
shows "MENU <---->".
f. Observe the sensor temperature in the
right display. When the temperature has 3. Press the UP key until display shows "MENU
been stable for 5 minutes, press the ENTER PRGRM".
key. The display briefly shows "USDA1 4. Press the SELECT key to show ’PRGRM
LOAD", then "USDA1" and the sensor <--->".
temperature ("00 C"), and returns to the
"USDA 1 On" display. 5. Press the UP or DOWN key to show the current
"PULP" setting:
NOTE: The sensors should be in the ice bath a
total of 15 minutes or more to assure the sensor • "PULP OFF'
temperature has bottomed out.
• "PULP ON"
g. Repeat steps 8a through 8f to calibrate the
6. To change the current setting, press SELECT
USDA2 and USDA3 sensors.
key. "PULP' will begin to flash in the left
NOTE: Press and hold the SELECT key for 3 display.
seconds to return to the Standard Display.
7. Press the UP or DOWN key to scroll the right
Pulp Sensor (Option) display to the desired setting.
Changing the Pulp program screen from Off to On 8. To load the new setting, press the ENTER key.
activates the Pulp (spare 5 sensor) temperature The display briefly shows 'PULP LOAD".
recording. Pulp sensor temperatures are recorded 9. When the Pulp mode is turned On, the display
in the data logger memory. then shows "PULP ON". The Pulp sensor
The Pulp sensor should be connected to the must now be calibrated for accurate
controller and located in the load as specified by temperature recording. To calibrate the Pulp
the customer and/or shipping company. When a sensor:
Pulp sensor is installed, the controller will a. To calibrate the Pulp sensor, press the
automatically detect the sensor and activate data SELECT key while PULP ON" appears in
logging. The controller Program menu shows the the display. "PULP" will begin to flash in
"PULP" in the left display and "AUTO" in the the left display.
right display if data logging is active. However,
the Pulp program screen MUST be set to On and b. Press the UP or DOWN key to show "CAL"
in the right display.
the sensor MUST be calibrated to accurately
record temperature. Calibrate the sensor in an ice c. Press the ENTER key. The display briefly
bath (see "Ice Bath Preparation" under USDA shows "PULP CALIB". The left display
Sensors in this chapter). then shows "PULP1" and the right display
shows the sensor temperature ("00 C").
d. When Pulp1 sensor temperature is within
1.7 C [3 F] above or below 0 C (32 F), the
left display ("PULP1") begins to flash.
ThermoGuard µP-D Controller
e. Observe the sensor temperature in the The evaporator fans stop during the Null mode
right display. When the temperature has (on frozen loads). A null state timer automatically
been stable for 5 minutes, press the ENTER starts and operates the evaporator fans on low
key. The display briefly shows "PULP1 speed for 5 minutes every 45 minutes. The unit
LOAD", then "PULP1" and the sensor remains in Null until the return air temperature
temperature ("00 C"), and returns to the increases to ECMAX temperature and a 45 minute
"PULP ON" display. Null state time sequence expires. Default
NOTE: The sensors should be in the ice bath ECMAX setting is 1 C (1.8 F) above setpoint.
total of 15 minutes or more to assure the sensor ECMAX setting is adjustable from 0 to 10 C (0 to
temperature has bottomed out. 18 F) above set-point through the Guard menu of
the controller.
NOTE: Press and hold the SELECT key for 3
seconds to return to the Standard Display. NOTE: See "Menu Guard" for detailed
information about changing ECMIN and
Economy Mode ECMAX from the default settings.
The Economy mode reduces unit power Setting the Economy Mode
consumption by reducing evaporator fan
operation. On frozen loads, the Economy mode 1. Press the SELECT key to enter menu (display
shows "MENU <-->".
also modifies the temperature control algorithm to
extend the Null mode. The use of the Economy 2. Press UP key until display shows "MENU
mode should be established by the shipper and the PRGRM".
type of cargo. The Economy mode option is
turned on from Program menu of the controller. 3. Press the SELECT key to show "PRGRM
<--->".
NOTE: If the Economy mode is set to On, the
controller display will show "ECON ON" for 1 4. Press the UP or DOWN key until the display
second every 10 seconds. shows the current setting:
Humidify Mode (Option) 4. Press the UP or DOWN key until the display
shows the current "HUMID" setting:
The Humidify mode increases the humidity level
in the container by injecting atomized water • "HUMID OFF".
directly into the evaporator supply air stream. The
• "HUMID DEHUM" — Dehumidify
use of the Humidify mode should be established
option is On.
by the shipper. The Humidify mode option is
turned on from the Program menu of the • "HUMID HUM" — Humidify option is
controller. On.
NOTE: If the Humidify mode is set to On, the NOTE: The Dehumidify and Humidify option
controller display will show "HUM" in the left screens do not appear unless the unit is equipped
display and the container humidity level (e.g. with the option and the controller is set to the
"74.5") in the right display for 1 second every 10 correct unit configuration. Also, the Dehumidify
seconds. (or Bulb) and Humidify options can NOT be
turned On at the same time.
When the Humidify mode is On:
5. To change the current setting, press the
• The evaporator fans must be On before the
SELECT key. "HUMID" will begin to flash in
controller will operate the humidify
the left display.
function.
6. Press the UP or DOWN key to scroll the right
• When the humidify function is operating
display to the desired setting: "DEHUM",
(air compressor energized), the supply air
"HUM" or "OFF".
LED will flash On and Off.
7. To load the new setting, press the ENTER key.
• The controller energizes (operates) the air
The display briefly shows "HUMID LOAD".
compressor when the humidity level in the
container is more than 2% below the 8. When the Humidify mode is turned On, the
humidity setpoint. The air compressor left display shows "HUMSP" and the right
atomizes and injects water into the display shows the current humidity setpoint in
evaporator supply air stream to add percent (e.g. "70.0"). To change the humidity
moisture to the container air. setpoint:
a. Press the SELECT key. "HUMSP" will
Setting the Humidify Mode
flash in the left display.
1. Press the SELECT key to enter menu (display
b. Press the UP or DOWN key to adjust the
shows "MENU <-->".
humidity setpoint to the desired setting
2. Press UP key until display shows "MENU (see shipping manifest). The right display
PRGRM". scrolls up or down to the new humidity
setpoint in percent (e.g. "85.0").
3. Press the SELECT key to show "PRGRM
<--->". c. To load the new setpoint, press the ENTER
key. The display briefly shows "HUMSP
LOAD". The new humidity setpoint then
shows in the right display (e.g. "85.0").
NOTE: Press and hold the SELECT key for 3
seconds to return to the Standard Display.
ThermoGuard µP-D Controller
9. When the Bulb mode is On, the current Setting the Power Reduction Mode
evaporator fan speed screen "BEFAN"
1. Press the SELECT key to enter menu (display
appears in the Program menu. To change the
shows "MENU<--->".
fan speed selection:
2. Press DOWN key until display shows "MENU
a. With "BULB ON" in the display, press the
PRGRM".
DOWN key to scroll to the "BDFTT"
screen. If a new defrost termination 3. Press the SELECT key to show 'PRGRM <-->".
temperature was set, the BEFAN" screen
4. Press the DOWN key to show the current
already appears. The current setting
setting; "PWRED 0" (OFF), "PWRED 1",
appears in the right display (factory
"PWRED 2", or "PWRED 3" (ON).
default is HI).
5. Press SELECT key. "PWRED" will begin to
b. Press the SELECT key. "BEFAN" will flash
flash.
in the left display.
6. Press the UP or DOWN key to scroll the right
c. Press the UP or DOWN key to adjust the
display to the desired setting:
evaporator fan speed to the desired setting
(see shipping manifest): "HI", "LO" or • 0 = Off
"CYCLE".
• 1 = 10% Power Reduction
d. To load the new setting, press the ENTER
• 2 = 20% Power Reduction
key. The display briefly shows "BEFAN
LOAD". The display then shows • 3 = 30% Power Reduction
"BEFAN" in the left display and the NOTE: The cooling capacity of the unit may be
current fan speed selection in the right reduced when the Power Reduction mode is
display (e.g. "CYCLE"). active. The greater the reduction in electric
NOTE: Press and hold the SELECT key for 3 power (e.g. "2" or "3" setting), the greater the
seconds to return to the Standard Display. likelihood of unit cooling capacity reduction.
The use of the Power Reduction mode should be
Power Reduction Mode established by the shipper.
Changing the Power Reduction program screen 7. Press the ENTER key to load the power
from Off to On activates the power reduction reduction setting selected. The display briefly
control algorithm that reduces total unit electric shows "PWRED LOAD". Left display then
power consumption for 8 hours. The use of the shows "PWRED" and the right display shows
Power Reduction mode should be established by the new power reduction setting (e.g. "1").
the shipper. When the Power Reduction mode is NOTE: Press and hold the SELECT key for 3
On: seconds to return to the Standard Display.
• The controller reduces the electric power
consumption by the percent selected: 10%.
20% or 30%.
NOTE: When the Power Reduction mode is
active, the controller display will briefly show
"PWRED ON" every 10 seconds.
ThermoGuard µP-D Controller
Thermo Bus Tap these settings before releasing the unit for service.
See "Menu Guard" section for instructions on
Serial communications commands are transmitted programming the controller.
from the µP-D controller through the Thermo Bus
Tap to the Output Module on two wires (labeled There are many other programmable features that
blue and white). An open or defective may need to be set to completely configure the
communications circuit is indicated when one or unit to customer specifications. Customer
both of the RXD and TXD LEDs on the Output requirements may include features such as the
Module do not flash. container identification number and unit serial
number. Adjust any additional programmable
In the event the serial communications link settings to customer requirements before releasing
between the output module and the controller the unit for service.
fails, the output module will operate the unit as
follows: 1. Write down the Unit Configuration Number,
Customer Configuration Number, Container
• Chill (Fresh) Loads: Output module Identification Number, Hourmeter settings
STOPS all compressor and fan motor and Sensor Grades on a blank setup sheet.
operation. Recover as much information as possible from
• Frozen Loads: Output module operates the previous controller.
unit in Full Cool mode. If the previous controller is non-functional,
see the setup decal located on the control box
Power Module door for the Unit Configuration Number,
Customer Configuration Number and Sensor
The power module supplies low voltage control
Grades. The Unit Serial Number is located on
power and ground to the µP-D controller and the
the Unit Nameplate.
Output Module. The power module also supplies
power to the KVQ valve circuit and the serial 2. Turn the unit ON/OFF switch Off. Then
communications line. Fuses on the printed circuit unplug the unit power cord from the power
board provide current overload protection to the supply.
unit control circuits. The power module derives
power from the control power transformer. 3. Disconnect the wire harness connectors from
the back of the controller.
Always disconnect the main supply power before
working on the power module board. 4. Remove the screws that secure the controller
to the control box door.
Replacing the µP-D Controller 5. Remove the controller and gasket from the
CAUTION: When replacing a controller, door.
correct unit operation requires that the 6. Install the replacement controller and gasket
Unit Configuration, Customer in the door using the existing hardware.
Configuration and programmable Sensor
Grades be set to the UNIT specific CAUTION: Do Not over tighten the
features and sensors. mounting hardware or the controller may
be damaged.
A replacement controller contains default settings
that allow it to function when installed in a unit. 7. Attach the wire harness connectors to the back
However, CORRECT unit operation REQUIRES of the controller.
that the Unit Configuration, Customer NOTE: Be certain that all connectors are fully
Configuration and programmable Sensor Grades seated until the connector rings lock.
be set to the UNIT specific features and sensors. If
this information can not be recovered from the 8. Plug the unit power cord into the proper
previous controller, see the unit configuration and power supply.
sensor grade information on the set up decal
located on the control box door. Then program
ThermoGuard µP-D Controller
9. Turn the unit ON/OFF switch On. The unit Semiconductor Type Sensors
should start and the Standard Display should
Electronic semiconductor type temperature
appear on the controller.
sensors are used for:
CAUTION: Immediately proceed to • Supply Air
procedure for "Setting the Unit
Configuration and Customer • Return Air
Configuration Numbers" in the "Menu • Evaporator Coil
Guard" section of this chapter. Alarm
code 42 should be present in the display • Condenser Coil
when the ALARM key is pressed. This • Ambient Air
indicates that the correct Unit
Configuration, Customer Configuration Semiconductor sensors can not be checked with
and Sensor Grades must still be set. an ohm meter. If an alarm code indicates a sensor
failure, check the sensor by substitution. The
supply air, return air and evaporator coil sensors
Temperature Sensors are graded sensors. Graded sensors can also be ice
All sensors should be properly installed: bath calibrated. The µP-D controller will not
operate correctly if the return air, supply air and
• Supply sensor installs in the sensor tube
evaporator coil sensors are not ice bath calibrated
next to the control box. The sensor must
or the correct sensor grades are not in the
be inserted to the bottom of the sensor
controller.
tube and completely sealed by the
grommet connection. The condenser coil and ambient air sensors are
non-graded sensors. Non-graded sensor do not
• Return air sensor installs in a grommet
require ice bath calibration.
between the evaporator fans.
• Evaporator coil sensor must be placed in Thermistor Type Sensors
the coil fins between tube rows 2 and 3 in
Thermistor type temperature sensors are used for:
the middle of the coil.
• Compressor Discharge Gas Temperature
• Condenser sensor must be placed on the
Sensor
left side of the condenser coil and at least
70 mm deep between the fins. If an alarm code indicates a failed sensor, check
the sensor by substitution.
• Ambient sensor must be placed on the
bottom plate of the right forklift pocket.
• Compressor discharge gas temperature
sensor must be placed in the back side of
the compressor head.
• Indicates condenser fan current draw is not within • Visually inspect condenser fan contactor.
57
acceptable limits when fan is operating. • If contactor does not energize, check output
• If alarm occurs during a pre-trip test, a dash (-) module using "AMPS CFH" in the Electrical Test
precedes the alarm code. 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
disconnect power supply. Disconnect plug on
current transformer and check the resistance of
each primary winding. Resistance for each
winding should be 43 ± 0.5 ohms.
ThermoGuard µP-D Controller
User Hourmeter 3 Expired (Check Alarm) • Check the hourmeter type and proceed
73 according to company requirements. Reset the
• Indicates time set on a user hourmeter has
hourmeter if required.
expired.
User Hourmeter 4 Expired (Check Alarm) • Check the hourmeter type and proceed
74 according to company requirements. Reset the
• Indicates time set on a user hourmeter has
hourmeter if required.
expired.
Data Overflow (Check Alarm) • No corrective action possible. This alarm only
79 • Indicates an event that occurred was not recorded serves to indicate an event was not recorded in
by the datalogger. the data logger.
• Check the sensor by selecting it using the View
menu. If the display shows [- - - -], the sensor is
defective or the circuit is open or shorted.
Compressor Temperature Sensor Failure (Check • Check the sensor by substitution. Be sure the
Alarm) sensor polarity is correct.
81 • Indicates a problem exists with this sensor or its • Continuity check circuit wiring using a high
wiring. The sensor is reading out-of-range; or quality multimeter. Be sure to maintain the
appears to be open or shorted. correct polarity or the sensor will not work.
NOTE: Do Not use a test light or other
instrument; or controller damage may result.
ThermoGuard µP-D Controller
Electric Heaters
Six electric heater elements are located
underneath the evaporator coil. If a heater element
is suspected of malfunctioning, 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 with an ohmmeter.
NOTE: When repairing heater connections,
protect the new connections from the ingress of
moisture with heat shrink tubing. All heaters
should be secured to prevent contact with sharp
metal edges.
Electrical Maintenance
Refrigeration Maintenance/Service
NOTE: The following procedures involve
servicing the refrigeration system. Some of these
service procedures are regulated by Federal, and
in some cases, by State and Local laws.
All regulated refrigeration service procedures
must be performed by an EPA certified
technician, using approved equipment and
complying with all Federal, State and Local
laws.
NOTE: It is generally good practice to replace
the filter drier whenever the high side is opened
or when the low side is opened for an extended
period of time.
Service Tools
CAUTION: When servicing Thermo King
R-134a refrigeration systems, use only
those service tools (i.e., vacuum pump, 1. Internal Threads for Cap
refrigerant recovery equipment, gauge 2. High Pressure Fitting
hoses, and gauge manifold set) certified 3. Low Pressure Fitting
for and dedicated to R-134a refrigerant
Figure 55: Service Fittings Specifications
and Polyol Ester based compressor oils.
Residual non-HFC refrigerants or Leak Detection
non-Ester based oils will contaminate
HFC systems. Leaks can be detected with the use of soap
bubbles and with Halogen leak detectors such as
Unit Service Fittings model H10G, or model H10N (portable) (refer to
Tool Catalog).
Special fittings are used on R-134a systems to
prevent mixing of non-HFC refrigerants in Gauge Manifold Set
R-134a units. These fittings are located in three
places on CRR refrigeration systems: A new gauge manifold set (Refer to Tool Catalog)
should be dedicated for use with R-134a only.
• Low side near the compressor suction service Gauge hoses should also be dedicated to R-134a.
valve (or suction adapter).
• High side near the compressor discharge
service valve (or discharge manifold).
• High side near the receiver tank outlet valve.
Refrigeration Maintenance/Service
Cleanup devices such as suction line filters and Figure 56: Service Valve Back Seated
compressor oil filters may be used if they are
properly cleaned and new filters and cartridges are
used. All standard petroleum and synthetic
compressor oils must be removed to prevent the
contamination of R-134a systems.
Refrigerant Recovery
Use only refrigerant recovery equipment
approved for and dedicated to R-134a recovery. 1. 1/2 Turn In
Compressor Oil Acid Test Figure 57: Service Valve Open to Port
Gauge Manifold Set (With Low 6. Slowly screw a 1/2 inch ACME fitting into the
Loss Fittings) Attachment and low loss filling on the manifold’s service
(center) line to purge the suction and service
Purging hoses. Remove ACME fitting after purging.
Thermo King recommends the use of access
valves or self-sealing, quick disconnect fittings
whenever possible to limit the loss of refrigerant
into the atmosphere. A separate gauge manifold
set with low loss Fittings (refer to Tool Catalog)
should be dedicated for use with R-134a only.
Gauge hoses should also be dedicated to R-134a.
NOTE: When any of these devices are used,
carefully check to ensure that access
connections are functioning properly.
Gauge Manifold Set Removal The compressor oil should be checked during
pre-trip inspections and when there is evidence of
NOTE: To ensure minimum refrigerant release
to the atmosphere, THE SYSTEM SHOULD BE oil loss (oil leaks) or when components in the
refrigeration system have been removed for
RUNNING. However, this is not possible in all
service or replacement.
cases, but the same procedure should be
followed. To check compressor oil level with an ambient air
1. Rotate discharge hose fitting hand wheel temperature above 10 C (50 F):
counterclockwise to withdraw the fitting stem 1. Install gauge manifold on the compressor.
from the discharge line 7 port valve. Then
open both service manifold valves to center 2. Operate the unit on Cool with a 138 kPa, 1.38
bar, 20 psig minimum suction pressure and a
port.
689 kPa, 6.89 bar, 100 psig discharge pressure
2. Close the receiver tank outlet valve and pump for 15 minutes or more.
down the low side. Then turn the unit Off.
3. After the unit has maintained the above
3. Rotate the discharge fitting hand wheel conditions for 15 minutes, observe the
counterclockwise to depress the port valve compressor oil level. The oil should be 1/2 to
stem to equalize pressure at 21 kPa, 0.21 bar, 3 3/4 up in the sight glass.
psig.
To check compressor oil level with an ambient air
4. Rotate both coupler hand wheels temperature below 10 C (50 P):
counterclockwise to close (seal) the valve port
stems to the high and low hoses. 1. With the evaporator temperature below 10 C
(50 F), initiate a manual defrost to operate the
5. Remove the gauge lines from the suction and unit through a complete defrost cycle.
discharge service fittings and cap the service
ports. 2. After completing the defrost cycle, operate the
unit on Cool for a few minutes.
6. Back seat receiver tank outlet valve and cap
3. After 2 to 3 minutes, observe the oil level. The
valve stem.
oil should be 1/2 to 3/4 up in the sight glass.
7. Secure all manifold lines to manifold hose
If the container is empty, you can operate the unit
anchors when the manifold is not in use.
on the heat cycle instead of the defrost cycle.
4. To place the unit back in service, open the Figure 67: Standard Receiver Tank
receiver tank outlet valve and turn the ON/OFF
switch On.
Refrigeration Maintenance/Service
Evacuation and Cleanup of the • Acid: Air and moisture cause a chemical
Refrigeration System breakdown of the oil and/or the refrigerant
itself. The acid will accelerate the
Contamination deterioration of the softer metals (i.e. copper)
and cause metal plating as the softer material
Whenever contaminants have entered the system, begins to cover the inside of the system. If this
a thorough clean up is required to prevent damage condition is not stopped, it can result in the
or loss of compressor. total destruction of your equipment.
It is well known by the refrigeration service
industry that the purpose of evacuation is to Compressor Oil Color Code
remove moisture and air from the refrigeration Black Oil — indicates carbonization caused by air
system before charging with new refrigerant after in the system.
a system has been opened. The importance of
thorough evacuation and system preparation Brown Oil — indicates copper plating caused by
cannot be over emphasized. Even infinitesimal moisture in the system.
quantities of air or moisture in a system can cause Gray or Metallic Oil — indicates bearing wear or
severe problems. piston scoring.
We know that the presence of moisture, oxygen, NOTE: If the compressor oil is discolored,
and heat under certain conditions can result in perform a compressor oil acid test (Refer to Tool
many forms of damage. Corrosion, sludge, copper Catalog for oil test kit). If the compressor oil
plating, oil breakdown, carbon formation, and shows an acid condition, change the oil, the
eventual compressor failure can be caused by in-line oil filter, the filter drier and perform a
these contaminants. refrigeration system cleanup.
Things that will contaminate a system are (in
order of importance): Unit Preparation and Hookup
• Air: Air with oxygen as a contaminant. CAUTION: Do not attempt to evacuate a
Oxygen in the air reacts with the oil. The oil unit until it is certain that the unit is leak
begins to break down and can eventually lead free. A unit with less than a full charge of
to carbonization in the compressor and acid refrigerant should be thoroughly leak
buildup. The longer this breakdown process tested. Any leaks found must be repaired.
goes on, the darker the compressor oil 1. Recover all refrigerant from the unit and
becomes until finally the color is BLACK reduce the unit pressure to the proper level
indicating major system contamination. (US Federal Law requires a -17 to -34 kPa,
• Moisture: Moisture in a system will cause -0.17 to -0.34 bar, 5 to 10 in. vacuum that is
metal corrosion and metal plating. It can dependent upon the recovery equipment
freeze in the expansion valve and cause used).
intermittent operational problems. It reacts in 2. Break vacuum with refrigerant and equalize
the oil to begin acid buildup. system pressure to 0 kPa, 0 bar, 0 psig.
• Dirt, Dust, Metal Particles, other Foreign Replace the liquid line filter drier.
Materials: Particles of any kind left to float
through the system will cause severe damage
to all close tolerance items. Do not leave a
system open to the in filtration of dirt. If you
must open a system for any reason, seal off the
open areas as soon as possible and do not
work in a dirty environment.
Refrigeration Maintenance/Service
1. Special, Self-sealing quick disconnect couplers are required for R-134a Units.
2. Gas Ballast Valve
3. Iso Valve
4. Two Stage Vacuum Pump
5. To 220/190 Vac Power
6. Calibration Standard
7. Micron Meter
8. Sensor
Figure 70: Evacuation Station and Unit Hook-up
Refrigeration Maintenance/Service
3. Close valve V1 when the desired vacuum Factors Affecting the Speed of
level has been reached. System Evacuation
4. Wait five minutes and read the Micron Meter. It is almost impossible to state the exact amount
of time required to evacuate any system. Some
• A system that is leak free and dry will
factors that can influence evacuation line are
remain below 2000 microns for five
listed below.
minutes.
• System size
• A system that rises above 2000 microns
but stabilizes below atmospheric pressure • Amount of moisture contained in the system
is probably contaminated with moisture or
• Ambient temperature
has refrigerant out-gassing from the
compressor oil. Additional evacuation is • Internal restrictions within the system
required.
• External restrictions between the system and
• A system that continues to rise without the vacuum pump
stabilizing has a leak and must be repaired.
Hose size, both diameter and length, affect
5. If the vacuum level remained below 2000 evacuation times. Laboratory tests show that the
microns for five minutes, the unit is ready to evacuation time can be significantly reduced by
charge. larger diameter hoses and shorter hoses. To obtain
optimum pumping speed, keep hoses as short as
Pressure Rise Test possible and as large in diameter as possible. For
example, it takes eight times as long to pull a
Evacuate the system and close valve V1. With
given vacuum through a 6 mm (1/4 inch) diameter
valves V3 and V4 open, the pump is isolated and
hose as it does through a 13 mm (1/2 inch)
the system is held under a vacuum. If the Micron
diameter hose. It takes twice as long to pull a
Meter rises, one of the following conditions exist.
vacuum through a 2 meter (6 foot) long hose as it
• Leak: Watch the movement of the Micron does through a 1 meter (3 foot) long hose.
Meter needle. If the needle continues to rise
until it reaches atmospheric pressure, it is an Heat Saves Time
indication that a leak exists somewhere in the
A useful and practical time saver is the application
system. When a leak is in a system, the
of heat to the system. Increasing the temperature
vacuum will eventually stabilize at
of the compressor oil and refrigerant will speed up
atmospheric pressure (see "Pressure Rise Test
the vaporization of any water present in the
Evaluation" in this chapter).
system.
• Moisture: When the needle indicates a rise and
then stabilizes at a level below atmospheric WARNING: Never use a torch or other
pressure, it is an indication that the system is concentrated heat source to heat the
vacuum tight, but is still wet and requires compressor or other refrigeration system
additional dehydration and pumping time (see component.
"Pressure Rise Test Evaluation" in this Heat lamps, electric heaters, or fans can be
chapter). applied to the compressor crankcase and other
parts of the system to increase the temperature of
the refrigerant and compressor oil.
Refrigeration Maintenance/Service
4. Set the refrigerant tank for liquid charging. Service of the evaporator pressure regulator valve
Open the refrigerant tank hand valve. includes replacement of the actuator assembly or
replacement of the valve body.
5. Start and operate the unit in the Cool mode.
Tools Required:
6. Read the suction pressure and slowly open the
gauge manifold low pressure hand valve to • Digital Multimeter (Refer toTool Catalog)
permit suction pressure to increase • Actuator Assembly
approximately 170 kPa, 1.7 bar, 25 psig. This
will meter liquid refrigerant slowly into the • Adjustable Wrench
low side. • Torque Wrench
7. Add refrigerant until the receiver tank balls
float at the top of the sight glass. Heater Circuit Checkout Procedure
8. Close the hand valve on the refrigerant tank. 1. Unplug the evaporator pressure regulator
valve lead wire harness.
9. Operate the unit on Cool for 10 minutes and
recheck refrigerant charge. 2. Using a FLUKE multimeter, test each lead (4)
resistance to ground. Low resistance indicates
10. Remove the gauge manifold set. a short is present. Repair or replace any
11. Cap all service ports and valve stems. damaged or exposed wires.
11. Evacuate the low side. 9. If no leaks are found, evacuate the low side
and recover the leak test gas (see "Refrigerant
12. Open the discharge valve. Then open the
Recovery" in the Refrigeration Maintenance
receiver tank outlet valve.
chapter of this manual).
13. Verify that all personnel are clear and connect
10. Plug the heater and thermistor wire harnesses
main power plug to power supply. Place the
into the unit wire harness.
unit back in service.
11. Open the discharge valve. Then open the
KVQ Valve Replacement receiver tank outlet valve.
If the valve body is damaged, replace the entire 12. Verify that all personnel are clear and connect
valve. main power plug to power supply. Start the
unit and check the refrigerant charge. Add
1. Connect the unit’s main power cable to the
refrigerant as required.
main power source and switch the
refrigeration unit’s ON/OFF switch to On.
Refrigerant Recovery
2. Close receiver tank outlet valve and pump
down the low side to 21 kPa, 0.21 bar, 3 psig. CAUTION: Use only refrigerant recovery
equipment approved for and dedicated to
3. Turn the unit ON/OFF switch to Off. Then
R-134a recovery.
disconnect the main power cable from the
main power source. Close (front seat) the When removing any refrigerant from a Thermo
discharge service valve. King refrigeration system, use a recovery process
that prevents or absolutely minimizes the
CAUTION: Any time the discharge valve refrigerant that can escape to the atmosphere.
is front seated, disconnect the unit power Typical service procedures that require removal of
source to prevent accidental compressor refrigerant from the unit include:
start-up.
• To reduce the refrigerant pressure to a safe
4. Unplug the heater and thermistor lead wire working level when maintenance must be
harnesses. performed on high-pressure side components.
5. Unsolder the valve outlet (compressor side) • To empty the unit of refrigerant when an
joint from the suction line. Unsolder the inlet unknown amount of charge is in the system
joint and remove valve. and a proper charge is required.
6. Clean the tubes for soldering. Position the new • To empty the unit of contaminated refrigerant
valve in position in the suction line. when the system has become contaminated.
7. Solder both modulation valve connections. NOTE: Always refer to specific recovery
equipment Operator and Service Manuals.
CAUTION: Use a heat sink or wrap the
valve with wet rags to prevent damage to
the new valve. Vapor Recovery
1. Install a gauge manifold set on the unit. Attach
8. Pressurize the low side and test for refrigerant
the service line to the recovery machine and
leaks (see "Refrigerant Leak Test Procedure"
properly purge the lines. Set the recovery
in the Refrigeration Maintenance chapter of
machine for vapor recovery.
this manual.
2. Keep unit Off and mid-seat the discharge
NOTE: If pressurizing with nitrogen, front seat
the discharge valve to prevent nitrogen from service valve.
entering the refrigerant charge.
Refrigeration Maintenance/Service
3. Turn On the recovery machine and open (back • Use a pressure regulator and a safety pressure
seat) both gauge manifold and hand valves. relief valve as part of the pressure testing
equipment. The safety pressure relief valve
4. Continue to operate the recovery machine
should be of the non-adjustable,
until unit pressures drop to 0 kPa, 0 bar, 0 psig
non-tempering type. The valve should bypass
pressure.
any time the pressure exceeds its setting.
Liquid Recovery • Open valve slowly, use regulators and safety
valves that are in good working order.
1. Install a gauge manifold’s low-pressure line to
the Schrader suction service valve in the • The regulator should have two gauges; one to
suction line (near modulation valve). Attach read tank pressure, the other to read line
the manifold’s high-pressure line to receiver pressure. Properly maintained equipment will
tank outlet valve service port. Attach the allow leak testing, purging, or dehydration to
service line to the recovery machine and purge be done safely.
the lines.
CAUTION: Nitrogen (N2) is under
2. Operate the unit and build discharge pressures 15,170 kPa, 151.70 bar, 2200 psig, or
to approximately 1380 kPa, 13.80 bar, greater. Pressure is for full cylinder at
200 psig. 21 C (70 F). Do Not use Oxygen (O2),
3. Close the receiver tank outlet valve and pump acetylene or any other types of pressurized
down the low-pressure side of the system. gas on refrigeration systems or any
component of a system.
4. Stop the unit.
5. Set recovery machine for liquid recovery and
turn it On.
6. Open (back seat) high-pressure valve on
gauge manifold.
7. Operate the recovery machine until the unit
system pressures reach approximately 0 kPa,
0 bar, 0 psig.
Safety Precautions
Observe the proper handling of cylinders:
• Always keep protective cap on cylinder when
not in use. 1. Line Pressure
• Secure cylinder in proper storage area or 2. Tank Pressure
fastened to can. 3. Tank
4. Pressure Test Line to System
• Do not expose to excessive heat or direct sun 5. Safety Valve
light.
6. Pressure Regulator
• Do not drop, dent, or damage cylinder. Figure 74: Typical Pressurized Gas Bottle with
Pressure Regulator and Gauges
Refrigeration Maintenance/Service
Dehydration, pressure testing, purging and 3. Remove discharge service valve, suction
soldering can be accomplished with the use of dry service valve and liquid injection line from the
nitrogen (N2). The proper equipment and compressor.
application of equipment is of greatest 4. Disconnect the wire connector for the high
importance. pressure cutout switch, condenser pressure
switch, and compressor discharge temperature
Procedure sensor.
1. Attach gauge manifold set (refer to "Gauge 5. Remove the three-phase electric power
Manifold Set Attachment and Purging" for connection.
proper procedure for connecting to
compressor). 6. Remove the compressor mounting tray bolts
and nuts.
2. Close both hand valves on the gauge manifold
(front seated). 7. Slide the compressor from the unit.
3. Connect charging hose to a source of nitrogen. 8. Keep the compressor ports covered to prevent
Adjust pressure regulator to the proper dust, dirt, etc., from falling into the
pressure for the required procedure. compressor.
4. Purge system high side to low side. NOTE: When the compressor is removed from
the unit, oil level should be noted or the oil
The following procedures should utilize the removed from the compressor should be
following MAXIMUM gas pressure: measured so that the same amount of oil can be
• Leak Testing: 1030 to 1200kPa, 10.3 to added before placing the new compressor or
12.0 bar, 150-175psig. repaired compressor in the unit.
• Purging/Dehydration: 70 to 140 kPa, 0.7 to Installation
1.4 bar, 10-20 psig.
1. Slide the compressor into the unit. Install
• Soldering: 35 kPa, 0.35 bar, 5 psig. mounting bolts, washers and nuts, and tighten.
2. Bolt the discharge valve to the compressor
Compressor Replacement with a new gasket lightly coated with
compressor oil. Bolt the suction service valve
Removal to the compressor using a new o-ring coated
1. Remove the compressor compartment bracket. with compressor oil.
Close the liquid line service valve and pump
3. Apply refrigerant locktite to the threads of the
down the low side to -35 kPa, -0.35 bar, 10 in.
switches. Install the switches. Connect the
vacuum. Break the vacuum with nitrogen
wire connectors for the condenser fan pressure
between 10 and 20 kPa, 0.10 and 0.20 bar, 1
switch, high pressure cutout switch, and
and 3 psig.
compressor discharge temperature sensor.
NOTE: If the compressor does not operate, or
the compressor is unable to pump the low side 4. Connect liquid injection line to compressor
down, the refrigerant charge must be reclaimed body.
before service can be performed on the 5. Connect three-phase electric power to the
refrigeration system. compressor.
2. Front seat the discharge valve. 6. Pressurize the compressor with refrigerant gas
(same gas as that used in the system). Check
CAUTION: Any time the discharge valve
for refrigerant leaks around the compressor
is front seated, disconnect the unit power
assembly and gasket connections.
source to prevent accidental compressor
start-up.
Refrigeration Maintenance/Service
7. If no leaks are found, recover the refrigerant 3. Solder the inlet line and liquid line
used for the leak test (see "Refrigerant connections.
Recovery" in this chapter). Because this NOTE: It is strongly recommended that dry
refrigerant gas will contain some air, place it nitrogen be used to purge the system during any
in a contaminated refrigerant bottle to be solder operations (see "Using Pressurized
reclaimed later. Nitrogen" in this chapter).
8. After all pressure is removed from the low 4. Pressurize the system and test for leaks (see
side and compressor, hook up your evacuation "Refrigerant Leak Test Procedure" in this
equipment. chapter).
9. Evacuate the low side and compressor (see 5. If no leaks are found, recover the leak test gas
"Evacuation and Cleanup of the Refrigeration (see "Refrigerant Recovery" in this chapter).
System" in this chapter).
6. Then evacuate the system (see "Evacuation
10. Back seat the discharge service valve and and Cleanup of the Refrigeration System" in
open the liquid line service valve fully. this chapter).
11. Operate the unit at least thirty minutes and 7. Replace the condenser coil support brackets,
then inspect the oil level in the compressor. condenser fan shroud and condenser fan grille.
Add or remove oil if necessary.
8. Recharge the unit with R-134a refrigerant and
12. Check the refrigerant charge and add check the compressor oil level. Add oil if
refrigerant if needed. necessary.
Heat Exchanger Replacement 5. Pressurize the low side and check for leaks
(see "Refrigerant Leak Test Procedure" in this
Removal chapter).
1. Close the liquid line service valve and pump 6. If no leaks are found, recover the leak test gas
down the low side to -35 kPa, -0.35 bar, 10 in. (see ’’Refrigerant Recovery" in this chapter).
vacuum. Break the vacuum with nitrogen 7. Evacuate the low side (see "Evacuation and
between 10 and 20 kPa, 0.10 and 0.20 bar, 1 Cleanup of the Refrigeration System" in this
and 3 psig. chapter).
2. Remove the "U" mounting clamps that hold 8. Clean suction line to a bright polished
the heat exchanger assembly to the wall of the condition. Install feeler bulb in the feeler bulb
condenser section. clamps on the suction line. Locale bulb on the
3. Heat and unsolder liquid inlet and outlet line suction line in former position. The feeler bulb
connections. must make good contact with the suction line
or operation will be faulty. Cover with
4. Note position of feeler bulb on the side of the insulating tape.
suction line. Un-tape and remove the feeler
bulb from the suction line. 9. Open the liquid line service valve and place
unit in operation. Operate unit and note
5. Heat and unsolder the suction line suction pressure and container temperature to
connections. see that feeler bulb is properly installed.
6. Lift the heat exchanger assembly from the
unit. Receiver Tank Replacement
Installation Removal
1. Clean the tubes for soldering. 1. Recover the refrigerant charge from the unit
2. Place the heat exchanger assembly in the unit (see "Refrigerant Recovery" in this chapter).
and install the mounting hardware. 2. Unsolder the outlet valve on the liquid outlet
3. Solder the suction line connections. line.
NOTE: It is strongly recommended that dry 3. Unsolder the liquid line inlet connection.
nitrogen be used to purge the system during any 4. Loosen the mounting nuts and remove the
solder operations (see "Using Pressurized tank.
Nitrogen" in this chapter).
5. Remove the adapter with fusible plug (or
NOTE: If pressurizing with nitrogen, front seat relief valve), service fitting, water fittings
the discharge valve to prevent nitrogen from (option) and water pressure switch (option)
entering the refrigerant charge. from the receiver tank for installation in new
CAUTION: Any time the discharge valve tank.
is front seated, disconnect the unit power
source to prevent accidental compressor
start-up.
4. Solder the liquid line connections.
Refrigeration Maintenance/Service
CAUTION: Any time the discharge valve 3. Unsolder the liquid line connections from the
is front seated, disconnect the unit power valve.
source to prevent accidental compressor 4. Remove the valve from the unit.
start-up.
Refrigeration Maintenance/Service
Installation Installation
1. Clean the tubes for soldering. 1. Clean the tubes for soldering.
2. Place the new valve in position and solder the 2. Place the new valve in position.
connections.
3. Solder the liquid line connections.
CAUTION: Use a heat sink or wrap the
CAUTION: Use a heat sink or wrap the
valve with wet rags to prevent damage to
valve with wet rags to prevent damage to
the new valve.
the new valve.
3. Release a small amount of refrigerant from the
4. Pressurize the low side with refrigerant and
receiver tank to pressurize the liquid line.
check for leaks (see "Refrigerant Leak Test
Check for leaks (see “Refrigerant Leak Test
Procedure" in this chapter).
Procedure” in the Refrigeration Maintenance
chapter of this manual). 5. If no leaks are found, recover the leak test gas
(see "Refrigerant Recovery" in this chapter).
4. If no leaks are found, recover the leak test gas
(see “Refrigerant Recovery” in the 6. Evacuate the low side (see "Evacuation and
Refrigeration Maintenance chapter of this Cleanup of the Refrigeration System" in this
manual). chapter).
5. Evacuate the low side (see “Evacuation and 7. Reconnect the electrical wires to the valve.
Cleanup of the Refrigeration System” in the
8. Open the liquid line service valve and place
Refrigeration Maintenance chapter of this
the unit in operation. Check the refrigerant
manual).
charge and add refrigerant as required.
6. Reconnect the electrical wires to the valve.
7. Open the liquid line service valve and place Dehumidify Valve (Option)
the unit in operation. Check the refrigerant Replacement
charge and add refrigerant as required.
Removal
Liquid Injection Valve 1. Close the liquid line service valve and pump
Replacement down the low side to -35 kPa, -0.35 bar, 10 in.
vacuum. Break the vacuum with nitrogen
Removal between 10 and 20 kPa, 0.10 and 0.20 bar, 1
and 3 psig.
1. Close the liquid line service valve and pump
down the low side to -35 kPa, -0.35 bar, 10 in. 2. Remove insulating tape from liquid line.
vacuum. Break the vacuum with nitrogen
3. Disconnect the electrical connections to the
between 10 and 20 kPa. 0.10 and 0.20 bar, 1
dehumidify valve.
and 3 psig.
NOTE: In most cases, only the coil requires
2. Disconnect the unit power source from the
replacement. No other repair is possible on the
unit. Disconnect the electrical connections to
liquid injection valve.
the liquid injection valve.
4. Unsolder the liquid line connections.
NOTE: In most cases, only the coil requires
replacement. No other repair is possible on the 5. Unbolt and remove the valve from the unit.
liquid injection valve.
3. Unsolder the liquid line connections.
4. Unbolt and remove the valve from the unit.
Refrigeration Maintenance/Service
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 wrap the
valve with wet rags to prevent damage to
the new valve.
4. Pressurize the low side with refrigerant and
check for leaks (see "Refrigerant Leak Test
Procedure" in this chapter).
5. If no leaks are found, recover the leak test gas
(see "Refrigerant Recovery" in this chapter).
6. Evacuate the low side (see "Evacuation and
Cleanup of the Refrigeration System" in this
chapter).
7. Cover liquid lines with insulating tape.
8. Reconnect the electrical wires to the valve.
9. Open the liquid line service valve and place
the unit in operation. Check the refrigerant
charge and add refrigerant as required.
Structural/Accessory Maintenance
2 Evaporator Coil
Clean the evaporator coil by blowing low pressure
compressed air from the bottom side of the coil
upward (opposite direction of normal airflow).
Inspect coil and fins for damage and repair if
necessary.
CAUTION: Air pressure must not be high
1. Tighten Unit Mounting Bolts
enough to damage coil fins.
Tighten Compressor, Condenser Fan and
2.
Evaporator Fan Mounting Bolts
Figure 75: Mounting Bolts
Structural/Accessory Maintenance
Defrost Drains
Clean the defrost drains every 1,000 operating
hours to be sure the lines remain open.
Place fan blade on motor shaft with hub located 3. Evaporator Coil
on the outside of the blade for proper airflow 4. Evaporator Motor
direction. When mounting the fan blade and hub 5. 13 mm (0.5 in.)
assembly on the fanshaft, center the assembly in Figure 77: Evaporator Fan Blade Placement
the orifice. Position the front of the fan blade
10 mm (0.4 in.) in from the outer edge of the fan
orifice.
1. Airflow Direction
2. 10 mm (0.4 in.)
1 3. Condenser Coil
4. Condenser Fan Blade
2 5. Condenser Motor
Figure 78: Condenser Fan Blade Placement
1. Knurled Knob
2. Recording Stylus
3. Lifter Arm
4. Allen Screw
5. Set Screw “S”
6. Key Mounting Clip
7. Adjustment Shaft “J”
8. Element Flange Screws “D”
9. Thermal Element
10. Stamping
Figure 79: Partlow (SR) Recording Thermometer
Structural/Accessory Maintenance
• Blue Zone — Battery good. If the indicator 9. Replace the recording chart and chart nut on
needle remains in the blue zone when the test the chart drive shaft and tighten the chart nut
button is depressed, the battery has sufficient finger tight.
power to operate the recorder.
10. Lower the pen by rotating the lifting arm
• White Zone — Replace battery within 30 counterclockwise and push the pen against the
days. If the indicator needle remains in the chart.
white zone when the test button is depressed
during a pre-trip inspection, replace the
battery. Although the battery may operate the
recorder up to 30 more days, replacing the
battery before it is completely dead is
recommended.
• Red Zone — Dead battery. If the indicator
needle remains in the red zone when the test
button is depressed, the battery is dead and
must be replaced.
To replace the battery:
1. Raise the stylus away from the chart by
rotating the pen lift gear clockwise 30 degrees
and releasing the lifting arm. The pen will
remain in the raised position. Remove the
knurled chart nut from the drive shaft and
remove the chart.
2. Loosen the four setscrews that hold the
recording platen in the recorder. The setscrews 1. Recording Chart
do not remove from the recorder base. 2. Chart Nut
3. Rotate the recording platen counterclockwise 3. Battery
and remove the platen. 4. Test Button
5. Battery Voltage Indicator
4. Remove the battery from the recorder.
6. Power Element Assembly
5. Install a new battery in the recorder making 7. Setting Screw (Calibration)
sure the battery’s positive (+) and negative (-) 8. Lock Screw (Calibration)
poles are correctly aligned. 9. Recording Pen
6. Press the button on the voltage indicator to 10. Lifting Arm
make sure the indicator needle is the in blue 11. Time Scale Plate
zone. 12. Terminal Board
13. Quartz Motor and Reducing Gear Assembly
7. Check to see that the quartz motor is running.
Look through the inspection window and 14. Recording Platen
make sure the internal flywheel on the quartz Figure 80: Saginomiya (SKM) Recording
motor is revolving. Thermometer
Humidify System (Option) If the Humidify mode is set to On, the controller
display will show “HUM” in the left display and
The Humidify mode increases the humidity level the container humidity level (e.g. “74.5”) in the
in the container by injecting atomized water right display for 1 second every 10 seconds. When
directly into the evaporator supply air stream. The the humidify function is operating (air compressor
use of the Humidify mode should be established energized), the supply air LED will flash On and
by the shipper. The Humidify mode option is Off.
turned on from the Program menu of the
controller. See “Humidify Mode” on page 115 to The controller energizes (operates) the air
set the Humidify system to On. compressor when the humidity level in the
container is more than 2% below the humidity
setpoint. The air compressor atomizes and injects
water into the evaporator supply air stream to add
moisture to the container air.
The evaporator drain hoses are routed to the water
tank to replenish the water level during unit
operation. However, water usage will vary
depending upon the load and ambient conditions.
An overflow hose on the water tank removes
excess water when particularly wet loads are
transported or when the humidify system is not
operating.
NOTE: Only demineralized or distilled water
should be used to prevent plugging of the
atomizing nozzle.
Pre-Trip Inspection
The following items should be inspected before
loading the container:
• Check the water level in the water tank to
maintain an adequate water supply.
Water Supply Hose and Atomizing Nozzle: • Check humidify system operation by starting
1. Inspect every 1,000 hours and clean if the unit, setting the Humidify mode to On and
necessary.
adjusting the humidify setpoint (HUMSP)
Filter: Inspect every 1,000 hours and clean if more than 2% above the current humidity
2.
necessary.
level in the container. Verify that the air
3. Air Compressor: Inspect once a year.
compressor operates and that water is drawn
Water Tank: into the atomizing nozzle and injected into the
• Pre-trip Inspection: Check the water level. return air stream.
4.
• Every 1,000 Hours: Inspect the water tank
and clean if necessary.
Water Tank Heater: Check for correct operation
5.
in ambient temperatures below 4 C (40 F).
6. Drain Cock
Figure 81: Humidify System (Option)
Structural/Accessory Maintenance
Mechanical Diagnosis
Condition Possible Cause Remedy
Compressor does not operate Controller On; unit start sequence still Wait up to 3 minutes for compressor
— no amperage draw. timing start-up
Locate fault and repair: power source,
No power to unit (condenser and power plug, CB1 main circuit breaker,
evaporator fans do not operate) motor contactor, motor terminals,
motor
Check fuses and ON/OFF switch.
Open in 24 Vac control circuit
Replace or repair as required
Container temperature does not
Adjust controller setpoint
demand compressor operation
Compressor contactor inoperative Replace compressor contactor
No output signal from controller output Diagnose and replace output module
module or controller
Turn unit ON/OFF switch Off and then
Unit on defrost
On again
Detective high pressure cutout switch Replace high pressure cutout switch
High condenser head pressure Check refrigeration system and
causing high pressure cutout correct fault
Defective compressor Replace compressor
Let compressor cool and controller
Controller shut unit down on
will reset automatically. Check liquid
Compressor Over Temperature
injection valve and compressor
(fault code 82)
temperature sensor
If compressor contactor is energized,
Compressor motor internal thermal
wait 60 minutes for protector to cool
overload protection open
and reset.
Compressor does not operate; Remove compressor head. Look for
Piston stuck
excessive amperage draw or broken valve and jammed parts
intermittent cycling on overload Seized or frozen compressor bearings Replace compressor
NOTE: Controller soft starts Check/correct wiring against wiring
Improperly wired
the compressor after a heat or diagram
defrost cycle, or when the unit Check line voltage - determine
Low line voltage
has been off for more than 8 location of voltage drop
hours. See "Sequence of Eliminate cause of high head
High head pressure
pressure
Operation" in ThermoGuard
µP-D Controller chapter. Contacts in compressor contactor not Check by operating manually. Repair
closing completely or replace
Check motor stator connections.
Open circuit in compressor motor
Check stator winding for continuity. If
winding
open, replace compressor
Defective compressor motor internal Replace thermal overload protector or
thermal overload protector compressor
Compressor contactor burned Increase line voltage to at least 90%
Low line voltage
out of compressor motor rating
Reduce line voltage to at least 110%
Excessive line voltage
of compressor motor rating
Short cycling Eliminate cause of short cycling
Diagnosis
Mechanical Diagnosis
Condition Possible Cause Remedy
Unit short cycles Recalibrate (see Diagnosis Manual
Controller out of calibration for ThermoGuard uP-D
Microprocessor Controller
Refrigerant overcharge causing
Purge system
cycling on high pressure cutout
Check condenser airflow, condenser
fan motor, condenser fan grille,
Inefficient condenser operation
condenser fan pressure switch, water
causing cycling on high pressure
pressure switch (option), water flow
cutout
rate (option) and \ water-cooled
condenser-receiver tank (option)
Noisy Unit Insufficient compressor oil Add oil to proper level
Loose mounting bolts Tighten mounting bolts
Oil slugging or refrigerant flooding Add oil or refrigerant charge. Check
back expansion valve adjustment
Worn fan motor bearings Replace bearings or motor
Faulty compressor Repair or replace compressor
Condenser fan motor does not Check indicator lights. If unit is in Null,
operate Unit in Null, Heat or Defrost Heat or Defrost, unit operation is
normal (no remedy required)
Unit on water-cooled condensing If condenser-receiver tank has water
operation (Option) pressure, unit operation is normal
Check indicator lights and discharge
pressure. If condenser head pressure
Unit in Cool or Modulation is below 1100 ± 50 kPa, 11.0 ± 0.5
bar, 160 ±7 psig, unit operation is
normal (no remedy required)
Defective condenser fan pressure
switch or water pressure switch Replace defective switch
(option)
Loose line connection Tighten connections
Check for seized bearings or
Open motor internal thermal overload
defective thermal overload protector.
protector
Repair or replace as necessary
Defective motor Replace motor
Detective high speed condenser fan
Replace defective contactor
contactor
Diagnose and replace output module
or controller. Disconnect water supply
No high speed condenser fan output
to unit (option) and check water
signal from controller
pressure switch (option) before
replacing controller
Diagnosis
Mechanical Diagnosis
Condition Possible Cause Remedy
Evaporator fan motor(s) does Unit on defrost Check operating mode indicator LEDs
not operate Check setpoint, indicator lights and
Unit in Economy mode
Program menu of µP-D controller to
(Frozen Load; Null mode ONLY)
verify that Economy mode is set to On
Loose line connection Tighten connections
Check for seized bearings or
Open motor internal thermal overload
defective thermal overload protector.
protector
Repair or replace as necessary
Defective motor Replace motor
Defective low or high speed
Replace defective contactor
evaporator fan contactor
No low or high speed evaporator fan
Diagnose and replace output module
output signal from controller output
or controller
module
Diagnosis
Refrigeration Diagnosis
Condition Possible Cause Remedy
Unit operating in a vacuum (unit Shortage of refrigerant Repair leak and recharge
not cooling) Compressor motor contacts frozen Clean points or replace contactor
NOTE: When the unit is in Compressor inefficient Check valves and pistons
Modulation Cool or the return Defective liquid line solenoid valve
Repair or replace liquid line solenoid
air temperature is below -18C valve
(0 F), the suction pressure will Partial obstruction in low side or
Locate obstruction and repair
be less than 0 kPa, 0 bar, 0 dehydrator
psig during normal operation Iced or 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 valve
its charge
Correct or replace container
Defective container insulation
insulation
Poor fitting container doors Repair or replace doors
Partial obstruction in high side Locate obstruction and repair
Service gauge out of calibration Replace service gauge
Evaporator pressure regulator (KVQ)
Repair or replace valve
valve stuck closed or defective
Recalibrate or replace controller (see
Controller out of calibration or
Diagnosis Manual for ThermoGuard
defective
µP-D Microprocessor Controller)
Expansion valve feeler bulb
improperly mounted, poorly insulated Correct feeler bulb installation
or making poor contact
Diagnosis
Refrigeration Diagnosis
Condition Possible Cause Remedy
Load temperature too high (unit Compressor does not operate See "Mechanical Diagnosis"
not cooling) Shortage of refrigerant Repair leak and recharge
Overcharge of refrigerant Purge system
Air in refrigeration system Evacuate and recharge
Recalibrate or replace controller (see
Controller out of calibration or
Diagnosis Manual for ThermoGuard
defective
µP-D Microprocessor Controller)
Controller setpoint too high Adjust controller setpoint
Remove compressor oil from
Too much compressor oil in system
compressor
Iced or dirty evaporator coil Defrost or clean evaporator coil
Restricted lines on high side Clear restriction
Plugged dehydrator or in-line filter Change dehydrator or in-line filter
Perform compressor efficiency test.
Compressor inefficient
Check valves and pistons
Evaporator pressure regulator (KVQ)
Repair or replace valve
valve stuck closed or defective
Clean condenser coil, clear
Condenser coil dirty or airflow
restriction, or repair or replace fan
restricted
motor or condenser fan blade
Defective condenser fan pressure
Replace switch
switch
Defective water pressure switch
Replace switch
(Option)
Insufficient water flow rate or plugged Correct water flow rate or
water-cooled condenser-receiver tank clean/replace condenser-receiver
(option) tank
Expansion valve open too much Adjust or replace valve
Expansion valve power element lost
Replace power element
its charge
Expansion valve feeler bulb
improperly mounted, poorly insulated Correct feeler bulb installation
or making poor contact
Head pressure too low Shortage of refrigerant Repair leak and recharge
NOTE: This unit has a suction Low ambient air temperature No remedy
modulation capacity control Service gauge out of calibration Replace gauge
system. Suction and discharge
pressures may drop below
expected normal readings
Compressor suction or discharge
when the unit is in Modulation valve inefficient
Clean or replace leaking valve plates
Cool (control temperature
within 10 C [18 F] of setpoint
or in Power Limit mode).
Diagnosis
Refrigeration Diagnosis
Condition Possible Cause Remedy
Head 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
Replace switch
switch
Defective water pressure switch
Replace switch
(Option)
Insufficient water flow rate or plugged Correct water flow rate or
water-cooled condenser-receiver tank clean/replace condenser-receiver
(option) tank
See "Condenser Fan Motor Does Not
Condenser fan not operating Operate" under Mechanical
Diagnosis
Condenser fan grille damaged or
Repair or replace grille
missing
Condenser fan blade damaged Replace fan blade
High ambient air temperature No remedy
Replace dehydrator or clear
Restricted dehydrator or high side
restriction
Defective high pressure gauge Replace service gauge
Compressor loses oil Refrigerant leak Repair leak and recharge
Compressor oil migrates to See "Unit Short Cycles" under
Short cycling
system Mechanical Diagnosis
Rapid cycling between Cool, Air short cycling through evaporator Check and correct cargo load
Null and Heat modes Recalibrate or replace controller (see
Controller out of calibration Diagnosis Manual for ThermoGuard
µP-D Microprocessor Controller)
See "Unit Short Cycles" under
Short cycling
Mechanical Diagnosis
Evaporator pressure regulator (KVQ)
Repair or replace valve
valve stuck closed 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 valve or remove restriction
closed or restricted
Restricted dehydrator or in-line filter Replace dehydrator or in-line filter
Frosted or sweating suction Expansion valve admitting excess Check feeler bulb and adjust
line refrigerant expansion valve
Check defrost circuit including
Evaporator coil needs defrosting
controller and evaporator coil sensor
See "Evaporator Fan Motor Does Not
Evaporator fan does not operate Operate" under Mechanical
Diagnosis
Unit in vacuum. Frost on Apply hot wet cloth to expansion
expansion valve only. valve.
Ice plugging expansion valve screen
or orifice Moisture indicated by increase in
suction pressure. Replace
dehydrator
Diagnosis
Refrigeration Diagnosis
Condition Possible Cause Remedy
High suction pressure Overcharge of refrigerant Purge system
Expansion valve open too much Adjust or replace valve
Recalibrate or replace controller (see
Controller out of calibration or
Diagnosis Manual for ThermoGuard
defective
µP-D Microprocessor Controller)
Service gauge out of calibration Adjust or replace service gauge
Low suction pressure Shortage of refrigerant Repair leak and recharge
NOTE: This unit has a suction Low ambient air temperature No remedy
modulation capacity control Iced or dirty evaporator coil Defrost or clean evaporator coil
system. Suction and discharge Restricted lines Locate and clear restriction
pressures may drop below Plugged dehydrator or in-line filter Replace dehydrator or in-line filter
expected normal readings Expansion valve closed too much Adjust or replace valve
when the unit is on Expansion valve feeler bulb
Modulation Cool (control improperly mounted, poorly insulated Correct feeler bulb installation
temperature within 10 C or making poor contact
[18 F] of setpoint or in Power Check evaporator fan motors and
Evaporator fans off
Limit mode). control circuit and correct fault
Recalibrate or replace controller (see
Controller out of calibration or
Diagnosis Manual for ThermoGuard
defective
µP-D Microprocessor Controller)
Service gauge out of calibration Adjust or replace gauge
Diagnosis
Electrical, Refrigeration and µP-D Menu
Flow Diagrams
AXA0098
1
Typical model shown with three evaporator fans.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0099
1
Typical model shown with three evaporator fans.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0100
1
Typical model shown with three evaporator fans.
2
Req8uires on-board 12 Vdc battery or an external 12 Vdc battery connected to battery jack on Power Module Board inside
control box.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0101
1
When external power is disconnected from unit, microprocessor operation 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 to Data Port on bottom of control box.
2
Typical model shown with three evaporator fans.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0102
1
Typical model shown with three evaporator fans.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0103
1
Typical model shown with three evaporator fans.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0104
1
Typical model shown with three evaporator fans.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0105
1
Typical model shown with three evaporator fans.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0106
1
Typical model shown with three evaporator fans.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0107
1
Typical model shown with three evaporator fans.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0108
1
Typical model shown with three evaporator fans.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0109
1
Typical model shown with three evaporator fans.
2
When the water pressure switch opens on units with an optional water-cooled condenser-receiver tank, the condenser fan
does not operate. When water pressure is disconnected from the condenser-receiver tank, condenser fan operation
resumes. Standard units have a jumper wire installed in the water pressure switch harness.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0110
1
Typical model shown with three evaporator fans.
2
Condenser fan will stop if condenser head pressure decreases to 100 ± 50 kPa, 11.00 ± 0.5 bar, 160 ± 7 psig.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0111
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.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0112
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.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0113
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.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0114
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.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0115
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.
3
Dehumidify mode is set to On in the Program menu of the controller. When the unit is in Low Dehumidify operation
(humidity 1-5% above setpoint), the dehumidify valve closes (energizes) to reduce the size of the evaporator coil used for
cooling.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0116
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.
3
Dehumidify mode is set to On in the Program menu of the controller. When the unit is in High Dehumidify operation (5% or
more above setpoint), the dehumidify valve closes (energizes) to reduce the size of the evaporator coil used for cooling and
the electric heaters are pulsed On for a maximum of 15 seconds every 30 seconds.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0117
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.
3
Evaporator fans operate on low speed when Economy mode is set to On in the Program menu of the µP-D controller and
the container temperature is in-range.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0118
1
Typical model shown with three evaporator fans.
2
The microprocessor closes (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 was On, it
will operate for approximately 30 seconds and then stop.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0119
1
Typical model shown with three evaporator fans.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0120
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 0% at a Calculated
Temperature Differential of 0.6 C (1 F) below setpoint to 100% at a Calculated Temperature Differential of 3.1 C (5.5 F)
below setpoint.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0121
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.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0122
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.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0123
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.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
AXA0124
1
Typical model shown with three evaporator fans.
2
Evaporator fans stop during Null mode when Economy mode is set to On is the Program menu of the µP-D controller.
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 in Null until the return air temperature increases to 1 C (1.8 F) above setpoint
at the expiration of a 45 minute Null state time sequence.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Defrost1
AXA0125
1
Typical model shown with three evaporator fans.
Index
A Evacuation 149
Accessory Maintenance 165 Evaporator Airflow, Specifications 33
Air Exchange System 43, 166 Evaporator Coil 165
Alarm Codes 76, 122 Evaporator Fan 80, 138
Evaporator Fan Location 166
B Evaporator Fans 43
Battery 44, 137 Evaporator Pressure Regulator (KVQ) Valve 154
Battery Charger 44, 137 Expansion Valve Replacement 160
C F
Compressor 43 Fittings 141
Compressor Discharge Gas Temperature Sensor Functional Inspection 65
Replacement 162
Compressor Discharge Valve 142 G
Compressor Oil 145 Gauge Manifold Set 141, 144
Compressor Oil Acid Test 142 Gauge Manifold Valve 143
Compressor Replacement 158 General Practices, Safety 25
Compressor Torque, Specifications 42
Condenser Coil 165 H
Condenser Coil Replacement 159 Heat Exchanger Replacement 161
Condenser Fan 80, 138 Heater Circuit 154
Condenser Fan Location 166 High Pressure Cutout Manifold 138
Condenser Fan Speed Pressure Switch Replace- High Pressure Cutout Switch 137
ment 162 High Pressure Cutout Switch Replacement 162
Controlled Atmosphere System 44 Humidification Control System 44
Controller Display 71 Humidify System 172
Controller Emergency Bypass 118
Controller Operation 89 I
Controller Setpoint 67 Indicator Lights 44
Controller, Replacing 120 In-Line Filter Replacement 159
CRR Model Features 13
K
D KVQ Setting 80
Data Logging 78
Defrost Drains 166 L
Dehumidification Control System 44 Leak Detection 141
Dehumidify and Humidify Systems, Specifica- LEDs 76
tions 39 Liquid Injection Valve Replacement 163
Dehumidify Valve Replacement 163 Liquid Line Solenoid Valve Replacement 162
Dehydrator Replacement 159 Loading Procedure 67
Diagnosis, Mechanical 175 Low Side Pump Down 147
Diagnosis, Refrigeration 178
M
Display, Controller 71
Menu Display Definitions 74
Dual Voltage 44
Menu Flow Diagrams 183
E Metric Hardware Torque Chart 42
Electric Heaters 139 Microprocessor Controller, Safety 27
Electrical Diagrams 183 Mounting Bolts 165
Electrical Maintenance 137
N
Electrical System, Specifications 38
Nitrogen 157
Electrical, Safety 26
Index
P U
Physical Specifications 40 Unit Charging 153
Post Load Procedure 67 Unit Control Box 61
Post Trip Procedure 67 Unit Controls 61
Power Line Communications 45 Unit Decals 28
Power Module 120 Unit Description 43
Pressure Gauge 45 Unit Instruments 62
Pressure Rise Test 152 Unit Protection Devices 63
Pre-Trip 98 Unit Wiring 137
Pre-Trip Inspection 64
V
R Vacuum Pump 142
Receiver Tank Replacement 161 Valve Actuator Replacement 155
Recording Thermometer 45 Visual Inspection 64
Recording Thermometer, Partlow 167
Recording Thermometer, Saginomiya 168 W
Recover Refrigerant 4 Water-Cooled Condenser-Receiver 45
Redundant Sensors 45 Welding, Safety 27
Refrigerant Charge 147
Refrigerant Leak Test 146
Refrigerant Oil, Safety 25
Refrigerant Recovery 142, 156
Refrigerant, Safety 25
Refrigeration Diagrams 183
Refrigeration Maintenance 141
Refrigeration System, Specifications 34
Remote Monitoring Receptacle 44
S
Safety Precautions 25
Sensor Check 80
Sequence Of Operation 82
Serial Number Locations 28
Service Guide 29
Service Tools 141
Specifications 31
Starting the Unit 67
Structural Maintenance 165
Suction Service Valve 142
System Cleanup 142
System Net Cooling Capacity, Specifications 31
System Net Heating Capacity, Specifications 32
T
Temperature Recording 44
Temperature Sensors 121
Thermo Bus Tap 120
Wiring and Schematic Diagrams Index
215
CRR Wiring Diagram–Page 1 of 3
216
CRR Wiring Diagram–Page 2 of 3
217
CRR Wiring Diagram–Page 3 of 3
218
CRR Schematic Diagram–Page 1 of 1
219
CRR Wiring Diagram–Page 1 of 3
220
CRR Wiring Diagram–Page 2 of 3
221
CRR Wiring Diagram–Page 3 of 3
222
CRR-20 & CRR-40 Refrigeration System Components
1. 3DS Compressor 21.Distributor
2. Oil Fill / Drain Fitting 22.Evaporator Coil
3. Discharge Service Valve (DSV) 23.Electric Heaters
4. Condenser Fan Pressure Switch 24.Return Air Sensor (RET)
(CFPS)
25.Evaporator Coil Sensor (ECOIL)
5. High Pressure Cutout Switch (HPCO)
26.Supply Air Sensor (SUP)
6. Compressor Head Discharge 27.Condenser Coil Sensor (CCOIL)
Temperature Sensor (CDTS)
28.Ambient Sensor (AMBT)
7. Condenser Coil (Circular)
29.Controller (µP-D)
8. Receiver Tank
30.Evaporator Pressure Regulator (KVQ
9. High Pressure Relief (Fusible Plug) Valve)
10.Receiver Tank Service Fitting
31.Suction Service Valve (SSV)
11.Sight Glass
32.Liquid Injection Valve (LIV)
12.Condenser Coil Subcooler Circuit 33.Condenser Check Valve (CCV)
13.Liquid Line Service Valve
34.Dehumidify Solenoid Valve (DSV)
14.In-Line Filter 1 (Option)
1
Units built after 3/9/99 are all models with two
2
evaporator fans feature a large, one-piece Units built after 8/99 feature a fusible plug and
Filter Drier/In-Line Filter. service fitting located on the tank.
223
CRR-20 & CRR-40 Full Cool Flow and Pressure Diagram
1. 3DS Compressor
Compressor operation has a variable delay on initial start-up when the unit shifts to
a cooling mode requiring the compressor to start.
4. Condenser Fan Pressure Switch (CFPS)
Is a normally Closed switch.
It Opens at 1380 ± 50 kPa, 13.8 ± 7 psig.
It Closes at 1100 ± 50 kPa, 11.0 ± 0.5 bar, 160 ± psig.
5. High Pressure Cutout Switch (HPCO)
Is a normally Closed switch.
It Opens at 2410 ± 70 kPa, 24.1 ± 0.7 bar, 350 ± 10 psig.
It Closes at 1655 ± 70 kPa, 16.5 ± 0.7 bar, 240 ± 10 psig.
*CRR-20-63: at 2240 ± 70 kPa, 22.4 ± 0.7 bar, 325 ± 10 psig.
**CRR-20-63: at 1590 ± 70 kPa, 15.9 ± 0.7 bar, 230 ± 10 psig.
9. High Pressure Relief (Fusible Plug)
Blows at 100 C (212 F).
29. ThermoGuard Controller (µP-D)
ThermoGuard (µP-D) with digital thermostat, thermometer and fault indicator
monitor.
Null Mode Operation
During the Null mode, the compressor does not operate. If the condenser fan is On
(based on condensing pressure) when the unit shifts to Null, the condenser fan
operates for 30 seconds and stops. Evaporator fans continue to operate
(evaporator fan speed is determined by return air temperature and Economy mode
setting).
37. Water Pressure Switch (WPS) (Option)
Is a normally Closed switch.
It Opens at 117 ± 21 kPa, 1.17 ± 1.21 bar, 17 ± 3 psig.
It Closes at 35 ± 21 kPa, 0.35 ± 0.21 bar, 5 ± 3 psig.
40. High Pressure Relief Valve (Before 8/99)
It Opens at 3450 +345/-105 kPa, 34.5 +3.5/-1.0 bar, 500 +50/-15 psig.
It Closes at 2760 kPa, 27.6 bar, 400 psig.
Fusible Plug on Tank (After 8/99)
Blows at 100 C (212 F).
224
CRR-20 & CRR-40 Modulation Cool Flow and Pressure Diagram
17. Liquid Line Solenoid (LLS)
Is a normally Closed solenoid.
It OPENS when energized, when the compressor operates.
23. Electric Heaters
During the Defrost mode, the electric heaters are pulsed On and Off. The
compressor does not operate. The condenser fan and evaporator fans remain Off.
During the Heat mode, the electric heaters are pulsed On and Off. The compressor
does not operate. The condenser fan is Off. The evaporator fans continue to
operate (evaporator fan speed is determined by return air temperature and
Economy mode setting).
30. Evaporator Pressure Regulator (KVQ 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 the actuator power element. Increasing the
temperature of the heating element increases the pressure on the main valve
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.
32. Liquid Injection Valve (LIV)
Is a normally CLOSED valve.
It OPENS when energized. When the liquid injection is required, the valve is pulsed
open and closed on a 10 second cycle.
Liquid injection is controlled by the compressor discharge temperature.
225
CRR-20 & CRR-40 Dehumidification Flow and Pressure Diagram
23. Electric Heaters
If the container humidity is 5% or more above the humidity setpoint, and the
temperature is in-range, the controller will pulse the electric heaters On and Off in
addition to energizing (closing) the dehumidify solenoid valve. This increases the
cooling load on the evaporator coil, thereby lowering the temperature of the entire
coil and condensing more moisture from the container 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 energize (CLOSE) the normally open
solenoid. This closes refrigerant distribution to 50% of the evaporator coil, thereby
lowering the temperature of the active part of the coil and condensing more
moisture from the container air.
35. Humidity Sensor (rH) (Option)
The humidity sensor is located at the top right hand side of the evaporator fan deck
and measures the humidity of the return air from the cargo space.
226
Display Menu Flowchart
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