Operating Manual: CA Reefer Container

Table of contents
2008-01-11
Operating manual
CA reefer container
Dok-ID: Carg-5410 Read the operating instructions before starting work!

Keep for future use!
© Cargofresh AG
An der Strusbek 60-62
D- 22926 Ahrensburg
Tel.: +49 (0) 4102 45 72 60

Fax: +49 (0) 4102 45 75 60
E-Mail: info@cargofresh.com
Internet: www.cargofresh.de
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1 General .................................................................................... 5
1.1 Information about this manual ....................................... 5
1.2 Explanation of symbols .................................................. 6
1.3 Disclaimer ...................................................................... 7
1.4 Copyright........................................................................ 8
1.5 Replacement parts ......................................................... 8
1.6 Warranty terms .............................................................. 9
1.7 Customer service ........................................................... 9
2 Safety .................................................................................... 10

2.1 Responsibility of the owner .......................................... 10
2.2 Personnel requirements............................................... 11
2.2.1 Qualifications ................................................ 11
2.2.2 Unauthorized persons .................................. 12
2.2.3 Instruction ..................................................... 12
2.3 Intended use ................................................................ 13
2.4 Personal protective equipment .................................... 14
2.5 Specific dangers .......................................................... 14
2.6 Safety devices.............................................................. 19
2.7 Safeguarding against restart........................................ 20
2.8 Behavior in the event of danger or accident ................ 21
2.9 Environmental protection ............................................. 22
2.10 Labeling ....................................................................... 22
2.10.1 Warnings ...................................................... 23
3 Technical data ...................................................................... 25

3.1 General information ..................................................... 25
3.2 Connected loads .......................................................... 25
3.3 Operating conditions .................................................... 26
3.4 Performance values ..................................................... 26
3.5 Emissions..................................................................... 26
3.6 Operating materials ..................................................... 27
4 Structure and function ........................................................ 28

4.1 Overview ...................................................................... 28
4.2 Brief description ........................................................... 30
4.3 Process description ..................................................... 31
4.4 Module description ....................................................... 33
4.4.1 Compressor system ..................................... 33
4.4.2 Water separator/cyclone .............................. 34
4.4.3 Air/air cooler with fine filter ........................... 35
4.4.4 Wet membrane ............................................. 36
4.4.5 Adsorption dryer with micro filter .................. 37
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4.4.6 Gas separation membrane ...........................39

4.4.7 Armature group with valves ..........................40
4.4.8 Nozzles .........................................................42
4.4.9 Energy supply ...............................................42
4.4.10 Controller ......................................................43
4.4.11 Sensors .........................................................43
4.4.11.1 Oxygen sensors ........................... 44
4.4.11.2 Moisture/temperature ................... 46
4.4.11.3 Pressure sensor ........................... 47
5 Transport, packing, and storage ........................................48

5.1 Instructions for transport ..............................................48
5.2 Pre-trip inspection ........................................................50
5.3 Transport ......................................................................50
6 Installation and commissioning .........................................52
7 Operation...............................................................................53
7.1 Safety ...........................................................................53
7.2 Activities prior to use ....................................................54
7.2.1 Implementation requirements .......................54
7.3 Switching on .................................................................56
7.4 Operating the CA system .............................................58
7.4.1 Operating the display ....................................59
7.4.2 Specifying setpoints ......................................62
7.4.3 Execute auto PTI ..........................................62
7.5 Decommissioning/unloading ........................................64
7.6 Shutdown in emergency situations ..............................65
7.7 Activities after use ........................................................66
8 Troubleshooting ...................................................................67
8.1 Safety ...........................................................................67
8.2 Fault indications ...........................................................69
8.3 Troubleshooting chart ..................................................71
8.4 Recommissioning after corrected malfunction .............73
9 Maintenance ..........................................................................74
10 Dismantling ...........................................................................75

10.1 Safety ...........................................................................75
10.2 Dismantling ..................................................................76
10.3 Disposal .......................................................................77
11 Index ......................................................................................78
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1 General
1.1 Information about this manual
This manual enables you to handle the system safely and
efficiently.
The manual is a component of the system and must be kept
accessible to personnel in the immediate vicinity of the system at
all times. Personnel must have carefully read and understood this
manual prior to starting all work. The basic prerequisite for safe
work is compliance with all safety instructions and handling
instructions specified in this manual.
In addition the local accident prevention guidelines and general
safety regulations for the system's area of implementation apply.
Illustrations in this manual are provided for basic understanding
and can deviate from the actual model of the system.
In addition to this manual the manuals of the installed components

provided in the appendix also apply.
Service und updates are available directly from the manufacturer

by calling the indicated number or on the website.
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General
1.2 Explanation of symbols

Warnings Warnings are indicated by symbols in this operating manual. The
warnings are introduced by signal words that express the scope of
the hazard.
The warnings must be strictly heeded, you must act prudently to
prevent accidents, personal injury, and property damage.
DANGER!
… indicates an imminent dangerous situation that
can result in death or serious injury if it is not
avoided.
WARNING!
… indicates a possible dangerous situation that can
result in death or serious injury if it is not avoided.
CAUTION!
result in minor injury if it is not avoided.
CAUTION!
result in material damage if it is not avoided.
Tips and recommendations NOTE!

... indicates useful tips and recommendations as
well as information for efficient and trouble-free
operation.
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Special safety instructions The following symbols are used in conjunction with safety
instructions to alert to particular dangers.
DANGER!
Life-threatening danger due to electric shock!
… indicates life-threatening situations due to
electric shock. If the safety instructions are not
heeded there is danger of serious injury or death.
The work that must be executed should only be
performed by a qualified electrician.
1.3 Disclaimer
All information and instructions in this Operating Manual have been
provided under due consideration of applicable guidelines, the
current state of technology, as well as our many years of
experience.
The manufacturer assumes no liability for damages due to:
z Failure to heed the instructions in this manual
z Non-intended use
z Deployment of untrained personnel
z Unauthorized conversions
z Technical changes
z Use of non-approved replacement parts
The actual scope of supply can vary from the explanations and
graphic representations provided in this manual in the case of
special versions, if supplemental order options are desired, or on
the basis of the latest technical changes.
In all other respects the agreed obligations in the delivery contract,
the general terms and conditions, as well as delivery conditions of
the manufacturer, and the statutory regulations valid at the time the
contract was concluded apply.
We reserve the right to make changes in the interest of

enhancements and improvement of the performance
characteristics.
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1.4 Copyright
Treat this operating manual with confidentiality. It has been
exclusively prepared for personnel working with the system.
Provision of the manual to third-parties without written consent
from the manufacturer is prohibited.
NOTE!
Content information, text, drawings, graphics, and
other representations are protected by copyright
and are subject to commercial property rights. Any
improper use is punishable.
Duplication in any form - including excerpts - as well as exploitation
and/or communication of the content are not permitted without a
written declaration from the manufacturer. Actions to the contrary
make damage compensation mandatory. We reserve the right to
enforce additional claims.
1.5 Replacement parts

WARNING!
Injury hazard if the wrong replacement parts
are used!
Incorrect or defective replacement parts can cause
damage, malfunction, or total failure; they can also
impair safety.
Therefore:
– Only use manufacturer's original replacement
parts.
Purchase replacement parts from authorized dealers or direct from

the manufacturer. See page 2 for manufacturer's address.
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1.6 Warranty terms

The guarantee terms are including in the manufacturer's terms and
conditions.
1.7 Customer service

Our customer service organization is available for technical
information.
Information about the responsible contact is available at any time
per telephone, fax, email, or it can be called up via the Internet,
see manufacturer address on page 2.
Our employees are always interested in new information and
experiences associated with the application, and which could prove
valuable in improving our products.
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Safety
2 Safety
This section provides an overview of all the important safety
aspects for optimal protection of personnel, as well as for safe and
trouble-free operation.
Significant hazards can occur if the handling instructions and
safety instructions in this manual are not complied with.
2.1 Responsibility of the owner

The system is used in commercial applications. Consequently the
operator of the system is subject to legal industrial safety
obligations.
In addition to the safety instructions in this manual, generally valid
safety and accident protection guidelines, and environmental
protection guidelines must be heeded and complied with for the
area of implementation of the system. In this regard:
The owner must inform himself of applicable industrial safety
regulations, and in a hazard analysis identify other hazards that
may exist at the installation site of the system due to the special
work conditions. Owner must convert this information relative to
hazards into operating instructions for operation of the system.
The owner must ensure during the entire implementation period
of the system that the operating instructions created by the
owner correspond to the current state of legislation, and if
necessary the owner must adapt these operating instructions.
The owner must clearly regulate and specify responsibilities for
installation, operation, maintenance, and cleaning.
The owner must ensure that all employees who handle the
system have read and understood the operating manual.
In addition, owner must train personnel and inform personnel of
the hazards at regular intervals.
The owner must provide the required protective equipment for
personnel.
Moreover the owner is responsible for ensuring that the system is
always in technically faultless condition; consequently the following
applies:
The owner must ensure that the maintenance intervals
described in this operating manual are observed.
The owner must have all safety devices inspected regularly for
function and for completeness.
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2.2 Personnel requirements

2.2.1 Qualifications
WARNING!
Danger of injury without sufficient qualification!
Improper handling can cause serious injury or
property damage.
Therefore:
– Only have activities performed by personnel
who are qualified to perform these activities.
The following qualifications are cited in the operating manual for
the various activity areas.
Operator/ Instructed person

is a person who has been instructed by the owner relative to the
tasks assigned to him and the possible dangers associated with
improper behavior.
Specialized personnel
Specialized personnel are personnel who thanks to their
specialized training, skills, and experience, as well as
knowledge of the applicable regulations are capable of
executing the tasks assigned to them and of recognizing
possible hazards and avoiding them on their own.
Qualified electrician
is a person who thanks to his specialized training, skills, and
experience, as well as knowledge of the applicable regulations
is capable of executing work on electrical equipment and of
recognizing and avoiding possible hazards on his own.
The qualified electrician is especially trained for the particular
installation site where he is active and knows all relevant
standards and regulations.
Only persons from whom it can be expected that they reliably

execute their work are considered as personnel. Persons whose
capability to react is impaired, for instance through drugs, alcohol,
or medication are not approved.
Comply with age-specific and job-specific regulations that are
applicable at the installation site when selecting personnel.
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2.2.2 Unauthorized persons
WARNING! Danger for unauthorized persons!

Unauthorized persons who do not satisfy the
requirements described here are not aware of the
hazards in the work area.
Therefore:
– Keep unauthorized persons away from the work
area.
– If in doubt speak to these persons and instruct
them to leave the work area.
– Interrupt work as long as unauthorized persons
are in the work area.
2.2.3 Instruction
The owner must instruct personnel on a regular basis. Execution of
the instruction must be logged for better traceability.
Date Last name Type of instruction Instruction Signature

executed by
Fig. 1: Example of an instruction log
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Safety
2.3 Intended use

The device has been designed and constructed exclusively for the
intended use described here.
The system is used exclusively for freshness maintaining

transport of perishables (fruit, vegetables, etc.). The container is
also used for conventional dry transport and refrigerated
transport (also with heat operation).
In its features the container satisfies the applicable standards
and classifications for reefer containers. It is suitable for ocean-
going transport and climate resistant. Containers and CA reefer
systems are manufactured in accordance with internationally
recognized construction guidelines (e.g. Germanischer Lloyd).
The CA reefer container can be handled in any of the world's
harbor container terminals, and it can be transported on all
container ships and reefer connections.
WARNING!
Danger due to non-intended use!
Any use that extends beyond intended use and/or
other use of the system can cause hazardous
situations.
Therefore:
– Only use the system as intended.
– Strictly heed all instructions in this operating
manual.
– Particularly refrain from the following uses of the
system. They are considered as non-intended
use:
– Cooling the goods
– Transport of waste products, bulk goods, or
living creatures
– Use of the container as dwelling or
residence of any kind
Claims of any type due to damage arising from non-intended use

are excluded.
The owner bears sole responsibility for all damages arising from
non-intended use.
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Safety
2.4 Personal protective equipment

Wearing personal protective equipment is required to minimize the
health hazards when working with the device.
Always wear the protective equipment necessary for the
respective task when working with the device.
Heed the instructions that have been posted in the work area.
Always wear For all tasks always wear:
Safety footwear
For protection against heavy falling parts and slipping on slippery
substrates.
For special tasks wear Special protective equipment is required when executing special
tasks. Separate reference is made to this equipment in the specific
chapters. This special protective equipment is explained below:
Protective goggles
To protect the eyes from flying parts and liquid splashes.
Protective gloves
To protect the hands from friction, abrasion, puncture wounds, or
deeper injuries as well as from contract with hot surfaces.
2.5 Specific dangers

Residual risks that have been determined based on a risk analysis
are cited below.
Heed the safety instructions listed here and the warnings in the
other chapters of this manual to reduce health hazards and to
avoid dangerous situations.
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Safety
Electrical current DANGER!

There is an imminent life-threatening hazard if live
parts are touched. Damage to insulation or to
specific components can pose a life-threatening
hazard.
Therefore:
– Immediately switch off the device and have it
repaired if there is damage to the insulation of
the power supply.
– Only a qualified electrician should perform work
on the electrical equipment.
– De-energize the electrical equipment and
ensure that all components are disconnected,
for all tasks on the electrical equipment.
– Prior to performing maintenance, cleaning, and
repair work, switch off the power supply and
and safeguard it from being switched on again.
– Do not bypass fuses or render them inoperable.
Always use the correct amperage when
changing fuses.
– Keep moisture away from live parts. Moisture
can cause short circuits.
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Safety
Fehler! Textmarke nicht WARNING!

definiert.Nitrogen Danger of suffocation due to high
concentration of gas! Danger of freezing if
there is contact with eyes or skin!
Escaping gaseous nitrogen in high concentration
can cause unconsciousness and incapacitate
movement, and cause suffocation.
Contact with eyes or skin can cause the most
serious freeze injuries and induce lasting eye
damage.
Therefore:
– Follow the manufacturer’s instructions provided
in the safety data sheet.
– Keep self-contained respiratory devices on
hand for emergency situations.
– Persons who show signs of suffocation should
be given oxygen immediately with a self-
contained respiratory device, brought into fresh
air, and kept still and warm. Summon a
physician.
– If the person is not breathing initiate first aid
measures with artificial respiration.
– Avoid contact with skin and eyes: When working
with containers, lines or supply devices wear
leather protective gloves and protective goggles
with side shields.
– If there is skin or eye contact rinse immediately
and thoroughly with warm water. Do not rub.
– Quickly remove dampened articles of clothing,
shoes, and stockings, rinse affected body parts
with warm water. Do not rub.
– Do not eat, drink, or smoke when working with
the substance.
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Pneumatic system WARNING!

Danger of injury due to pneumatic energy!
Pneumatic energy can cause serious injury.
Pneumatically powered parts can move
unexpectedly.
If there is damage to specific components air can
escape under high pressure and injure the eyes for
example.
Therefore:
– Only have trained, specialized personnel
perform work on the pneumatic equipment.
– De-pressurize the pneumatic system prior to
starting work on the system. Pay attention to the
pressure accumulators. These units should also
be completely de-pressurized.
– Do not change pressure settings to exceed the
maximum values.
Fan WARNING!
Danger of injury due to rotating parts!
Rotating parts in the fan can cause severe injuries.
Ensure that the impeller is not accessible during
operation.
Therefore:
– Never reach into the running fan!
– Do not open coverings or maintenance lids
during operation!
– Pay attention to afterrun time:
Prior to opening the covers for maintenance
purposes ensure that all parts have come to a
standstill.
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Safety
Suspended loads DANGER!

Life-threatening danger due to suspended
loads!
Falling loads can cause the most serious injuries or
fatal injuries.
Therefore:
– Never step under suspended loads.
– Only move loads under supervision.
– Place the load on the ground when leaving the
workstation.
Fouling and loose objects CAUTION!

There is a danger of stumbling due to fouling
and loose objects!
Fouling and loose objects on the ground pose
slipping and stumbling hazards and can cause
severe injuries.
Therefore:
– Always keep the work area clean.
– Remove objects that are not being used.
– Mark stumbling hazards with a black/yellow
marking tape.
Sharp edges and corners CAUTION!

Injury hazard on edges and corners!
Sharp edges and corners can cause skin abrasions
and cutting injuries.
Therefore:
– Exercise caution when working near sharp
edges and corners.
– If in doubt wear gloves.
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Safety
2.6 Safety devices

WARNING!
Life-threatening danger due to non-functioning
safety devices!
Safety is only ensured if safety devices are intact.
Therefore:
– Prior to starting work ensure that the safety
devices are functional and correctly installed.
– Never render safety devices inoperable.
– Ensure that safety devices such as emergency-
stop devices, rip cords, etc. are always
accessible.
NOTE!
See the chapter "Structure and function" for more
information on the position of the safety devices.
The following safety devices are installed:
Main switch
The main switch is concurrently configured as emergency-stop
switch. Turning the main switch to the "0" position immediately cuts
off the energy supply and thus an emergency-stop of the CA
system is triggered.
Fig. 2: Main switch
WARNING!
Life-threatening danger due to uncontrolled
restart!
Uncontrolled restart can cause severe personal
injury or death!
Therefore:
– Prior to restarting the system ensure that the
cause of the emergency-stop has been
corrected, and that all safety devices are
mounted and functional.
Please note that the CA-system will automatically
restart after an “emergency shutdown“!
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Safety
Safety limit switch as access safeguard

The CA system is equipped with a door contact switch that
prevents the system from working if the container door is open or
not properly shut.
In addition this safety limit switch ensures that the system
immediately stops producing nitrogen if the door is opened without
authorization.
Fig. 3: Door contact switch
Inspection openings
There are inspection openings on enclosed housing parts that can
be used to reach components that are difficult to access when
performing service and maintenance work.
Only open the inspection openings when the system is at a
standstill and the energy supply has been switched off and
safeguarded.
The inspection openings can only be opened with tools. After
performing the work close the inspection openings and re-attach
the all fastening material.
2.7 Safeguarding against restart

DANGER!
Life-threatening danger if restarted without
authorization!
When working in the danger zone there is a hazard
of the energy supply being switched on without
authorization. This poses a life-threatening hazard
for persons in the danger zone.
Therefore:
– Comply with the instructions in this chapter for
safeguarding the system from being restarted.
– Always comply with the sequence described
below for safeguarding the system against
being restarted.
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Safety
Switch safeguarded with padlock Safeguarding against re-start:

on: …….. at ..... o'clock. 1. Switch off the energy supply.
DO NOT SWITCH ON 2. If possible safeguard the switch with a lock and attach a sign
The lock should only that is appropriately Fig. 4 legible on the switch.
be switched on by: ………………… 3. The employee cited on the sign should carry the key with him.
after it is ensured that no one is in the
danger zone.
Fig. 4
Switched off 4. If it is not possible to safeguard the switch with a padlock,

on: …….. at ..... o'clock. then set up Fig. 5 an appropriate sign.
DO NOT SWITCH ON 5. After all work has been performed ensure that all persons
The system should only have left the danger zone.
be switched on by: ………………… 6. Ensure that all protective devices are installed and are
functional.
after it is ensured that no one is in the
danger zone. 7. Do not remove the sign until after these precautions have
been taken.
Fig. 5
2.8 Behavior in the event of danger or accident

Preventive measures Always be prepared for accidents or fire!
Keep first aid supplies (first-aid boxes, blankets etc.) and fire
extinguishers close at hand.
Familiarize personnel with accident alarms, first-aid boxes and
rescue equipment.
Keep entry ways clear for rescue vehicles.
In an emergency situation Immediately activate the emergency-stop.

Initiate first-aid measures.
Get people out of the danger zone.
Inform the emergency response team.
Call for rescue service.
Keep entry ways clear for rescue vehicles.
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Safety
2.9 Environmental protection

CAUTION!
Environmental hazard due to incorrect
handling!
Incorrect handling of environmentally hazardous
substances, particularly improper disposal can
cause significant environmental damage.
Therefore:
– Always comply with the instructions cited below.
– If environmentally harmful substances should
inadvertently get into the environment, initiate
suitable measures immediately. If in doubt notify
the responsible municipal authority about the
damage.
The following environmentally harmful substances are used:
Lubricants Lubricants like greases and oils contain toxic substances. Do not
allow such substances to get into waterways. Only have such
substances disposed of by a specialized disposal company.
Refrigerant Refrigerants develop environmentally hazardous decomposition

products when released. Therefore the utmost caution and care is
required when handling refrigerants. Strictly follow the
manufacturer’s instructions provided in the safety data sheet.
Regularly instruct personnel who work with refrigerants about the
possible dangers!
2.10 Labeling
The following symbols and instruction signs are affixed in the work
area. These symbols and instructions refer to the immediate
vicinity in which they are affixed.
WARNING!
Danger of injury due to illegible symbols!
Over time stickers and signs can be become fouled
or can become illegible in some other manner.
Therefore:
– Always keep all safety, warning, and operating
instructions on the device in legible condition.
– Replace damaged signs or stickers
immediately.
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Safety
2.10.1 Warnings
Electric shock
Only qualified electricians should work in the work area that is
identified in this manner.
Unauthorized personnel should not enter the work areas identified
in this manner or open the panel that is identified in this manner.
Danger of suffocating in the load area

The warning sign is located in the load area near the container
doors.
In the load area of the container a highly concentrated nitrogen
atmosphere occurs.
Prior to entering the load area the CA system must be switched off.
The load area should only be entered after a wait time of 5
minutes. A second person must be present for safety purposes.
Fig. 6: Warning sign - load area
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Safety
The adjacent warning sign is affixed to the outside of the container

door.
It warns of a suffocation hazard when opening the container doors
and when entering the load area.
Fig. 7: Warning - container door
Load area delimitation

The sticker shown below indicates that the load area should not be
completely loaded to the ceiling.
A free space near the ceiling must be maintained through which air
can circulate unimpeded.
The arrows indicate the maximum permissible load height.
Fig. 8: Load area delimitation
Warning of dangerous atmospheres behind the flaps

The sticker shown below is located on the outside of the container
on the aggregate side on an inspection flap. It warns that the flap is
under pressure and that there is a life-threatening atmosphere
behind the flap.
Prior to opening the flap the system must have been shut down
and the load atmosphere must contain enough oxygen so that
work can be performed without danger.
Fig. 9: Warning sign on the inspection flap
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Technical data
3 Technical data
3.1 General information
Specification Value Unit
Weight 4800 kg
Length 12.192 m
Width 2.438 m
Height 2.591 m
3.2 Connected loads

Electrical Specification Value Unit
Voltage 380...460 V
Frequency 50...60 Hz
Current consumption, maximum 10 A
Power consumption, maximum 15 kW
Fusing 25 A
Length - power cable with plug 18 m
Pneumatic Specification Value Unit
Operating pressure 7...8 bar
Compressed air requirement, at 460 l/min

least
Temperature 70...95 °C
Quality class in accordance with Class 5

ISO 8573-1
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Technical data
3.3 Operating conditions

Environment Specification Value Unit
Temperature range -15...+45 °C
Relative humidity, maximum 60 %
Maximum implementation height 2500 m ü. NN
Designed for ocean-going in accordance with

transport requirements GI-type test
Duration Specification Value Unit
Maximum continuous operating 1000 Hours

period
Service life ~7 Years
3.4 Performance values

CA system Specification Value Unit
Nitrogen generation N2
at 2% residual oxygen Approx. 8 m3/h
in bypass operation at 3.5% Approx. 12 m3/h
residual nitrogen
Oxygen content at the permeate 36...52 %

output
Cooling system Specification Value Unit
Cooling capacity
at 69.98 °F 11.750 Kcal/h
at 35.06 °F 8.680 Kcal/h
at -17.8 °C 5.115 Kcal/h
3.5 Emissions
Noise emission <70 dB(A)
No further emissions emerge from the CA-system.
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Technical data
3.6 Operating materials

Fuel and Type Fill Unit
operating quantity
materials
Compressor MATTEI F2/RO85 2.5 l

oil
Refrigerant See the operating manual for the Thermo King

cooling system
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Structure and function
4 Structure and function

4.1 Overview
9 1
10
3
6 5 4
Fig. 10: Exterior view (covers partially removed)
1 Cooling fan (Thermo King)* 6 Cyclone

2 Control cabinet (Thermo King)* 7 Scroll compressor (Thermo King)*
3 Power connection 400 V 8 Control cabinet
4 Compressor 9 Control group
5 Oil/air cooler 10 Wet membrane
* Individual components of the Thermo King cooling system are also listed to provide complete information.
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1
2
Fig. 11: Load area view (covers partially removed)
1 Microfilter 4 Fine filter

2 Air/air cooler 5 Wet membrane
3 Gas separating membrane (behind cover) 6 Adsorption dryer
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4.2 Brief description

The CA reefer container consists of a standard ISO ocean
container with integrated cooling system and an additionally
installed CA system (CA = "Controlled Atmosphere") for nitrogen
enrichment in the load area.
For storage and transport of fruit and vegetable food products a
controlled atmosphere has the task of minimizing flavor loss, and
changes in consistency and nutritional values. In addition
metabolic processes are significantly decelerated.
The CA system provides the following:
Refrigeration (in conjunction with the refrigerating machine)
Reduction of oxygen content in the atmosphere
Increase of the nitrogen content via the membrane technology
Control of the humidity via humidification and desiccation
The CA conditions are specified individually for each product.
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4.3 Process description
The CA technology of the CARGOFRESH AG obtains the nitrogen

from the compressed ambient air. The CA system generates the
controlled atmosphere with the aid of the Thermo King refrigerating
machine already installed in the container.
A compressor system (rotation compressor) compresses the
ambient air to a system pressure of 6 to 8 bar. The combined oil /
air cooler cools the oil for lubricating the compressor, and also
compresses the air so that the temperature difference compared
with the environment amounts to 15 K.
The compressed air is subsequently channeled into the cyclone
(water separator) where free water is separated from the
compressed air. Then the compressed air is re-cooled in an air/air
cooler and the precipitating condensation is separated from the
compressed air by a filter.
The compressed air is subject to a final cleaning by the adsorption
dryer. Here the compressed air is virtually completely de-
humidified via zeolites in a molecular sieve.
The dry and clean compressed air is now routed into the gas
separating membrane. This is where the compressed air is
separate into nitrogen on one hand, and the so-called permeat on
the other hand, which to a great extent is comprised of oxygen.
The permeat is released directly into the environment:
The nitrogen is fed into the load area via the control group,
consisting of the measuring sensors and magnetic valves.
The moistening of the container’s interior is done via another

membrane technology. The prepared compressed air is induced
via a wet membrane. It consists of a body with special hollow fibres
which act as selectors for steam. The inside of these hollow fibres
is filled with compressed air, the outside of the hollow fibres
(bypass) is filled or flushed with the produced nitrogen. The
nitrogen jet picks up the moistness and transports it into the
container's interior for moisturizing purposes. That way the
nitrogen’s moisture content is determined, depending on the
desired relative moistness. This is done by switching the
humidification valves.
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Fig. 12: Process Design
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4.4 Module description

4.4.1 Compressor system
The compressor system generates the necessary process gas
volume flow and establishes the required operating pressure (6 to
8 bar).
The ambient air is taken in via an air filter.
1 Compressor unit
2 Drive motor
The compressor system essentially is comprised of the
compressor unit (1) the drive motor (2) and the oil/air filter (Fig.
14).
Fig. 13: Compressor

Type MATTEI AC 540L Spezial
Permissible rated pressure 10 bar
Operating temperature 70...95 °C
Weight 115 kg
Minimum ambient temperature 3 °C
Maximum ambient temperature 45 °C
Oil fill quantities

Total fill quantity Approx. 2.5 l
Fig. 14: Oil/air cooler Top off quantity 0.1 l
Compressor motor
Rated capacity 4 kW
Rated speed 1460 min-1
Protection class IP 56
Fan motor
Rated capacity 53 W
Rated speed 2785 min-1
Protection class IP 54
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4.4.2 Water separator/cyclone

The condensate is removed from the combined oil/air filter with the
aid of a water separator (cyclone). The condensate is discharged
cyclically via a directly triggered solenoid valve (3).
The capacity of the water separator is approximately 50 m3/h.
1 Compressed air input from the oil/air filter
2 Compressed air output
3 24 V solenoid
Type ZANDER G03 WS
Compressed air connection R 1/2 Inches

Fig. 15: Cyclone
(input/output)
Maximum operating pressure 16 bar
Supply voltage - solenoid valves 24 V DC
Weight 1 kg
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4.4.3 Air/air cooler with fine filter

In accordance with the principle of air/air cooling the compressed
air in the interior of the container is cooled to the transport
temperature reached by the refrigerating machine. Thus the
cooling temperature of the compressed air is independent of the
outside temperature.
With successive cooling of the compressed air additional
condensate occurs that is separated by a fine filter (3).
1 Compressed air input
2 Air/air cooler
3 Fine filter
4 24 V solenoid
Air/air cooler Value Unit
Type HAUGG 92052 L

Fig. 16: Air/air cooler with fine filter
(input/output)
Volume flow 35 m3/h
Output Approximately
410 W
Weight 3 kg
Fine filter Value Unit
Type ZANDER G03 VH

(input/output)
Supply voltage - solenoid valves 24 V DC
Weight 1 kg
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4.4.4 Wet membrane

The treated compressed air gets into the wet membrane via line
(1). It withdraws between 10 and 80% of the relative humidity
1 4
depending on the operating mode. The humidity that is withdrawn
is used to humidify the nitrogen flow, which is channeled through
the wet membrane via lines (2) and (3).
The compressed air flow reaches the adsorption dryer.
Depending on the regulation of the relative moistness in the
container there is the possibility to insert the wet membrane for
moistening the supplied nitrogen in order to raise the relative
2 moistness inside the container or to bypass the wet membrane via
a bypass line.
3
1 Input compressed air
2 Input flush jet / Nitrogen line
3 Output flush jet / Nitrogen line
4 Output compressed air
Wet membrane Value Unit
Manufacturer BEKO
Fig. 17: Wet membrane
Type DRYPOINT M PLUS
membrane dryer

(input/output)
Purge air connection R 1/4 Inches

(Input/output)
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4.4.5 Adsorption dryer with micro filter

Behind the wet membrane (1) an adsorption dryer (2) takes over
2
the subsequent drying of the compressed air.
Adsorption drying is the most common manner of drying
compressed air. Pressure dewpoints under 0 °C are reached with
this purely mechanical process. A molecular sieve is used as
drying agent. The water vapors is bound through molecular
1
adhesion to the large inner surface (up to 700 m2/cm3) of the drying
agent and can then be removed again through various
regeneration processes. Thanks to the highly hygroscopic drying
agent a pressure dewpoint reduction of approximately -40 K is
achieved.
1 Adsorption dryer
2 Microfilter
Fig. 18: Overview - compressed air drying
The implemented heatless adsorption dryer consists of two tanks

that are filled with an adsorption agent molecular sieve 4Å. While
one tank dries the compressed air in the other tank the adsorption
agent is regenerated without pressure by a low partial flow of the
dried air. A valve system ensures time-dependent automatic
switchover.
A total cycle runs for 10 mins and is comprised of the following
factory set times:
4 min regeneration time
1 min pressure build up time
5 min adsorption time
The time-dependent control enables implementation in the
downstream compressed air network without pressure drop.

Fig. 19: Adsorption dryer 3 Desiccant in bulk in 2 tanks
4 24 V solenoid valves
The compressed air dryer work automatically and supplies dry air
continuously. The air coming from the wet membrane flows
through the lower shuttle valve to the adsorbed. At this point the
water vapors are removed from the air by the desiccant. The dry
air then leaves the device via the afterfilter or dust filter on the
adsorber output and via the upper shuttle valve.
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Adsorption dryer Value Unit
Type ZANDER K-MT 04

(input/output)
Supply voltage 24 V DC
Solenoid valves
Weight 25 kg
A partial flow of dried air is fed into the adsorber through the
regeneration nozzle. Here the saturated desiccant dissipates the
water vapor and oil vapors to the de-pressurized air flowing
through, in other words the adsorber is regenerated. The moist
regeneration air is dissipated into the atmosphere via a sound
absorber.
The wear on the desiccant produces a fine particle dust that is

separated from the compressed air by a downstream micro filter.
This filter is only a dust filter.

2 Filter housing with micro filter element
3 Hand discharge
Fig. 20: Microfilter Microfilter Value Unit
Type ZANDER G3XP

(input/output)
Weight 1 kg
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4.4.6 Gas separation membrane

The gas separation membrane splits the compressed air feed into
two flows:
One flow with high nitrogen content (utility air)
A residual gas flow (permeate)
The membrane consists of hollow polymer fibres that through
diffusion cause the enrichment of nitrogen (N2) on the product side
and of oxygen (O2) on the permeate side. The generated air that is
channeled into the container typically has an oxygen content in the
range of 2 to 7%. The residual product of the gas separating
process, the so-called permeate, has an oxygen content of
approximately 3 % by volume.
2 Permeate output
3 N2 output
The gas separating membrane is positioned in the interior of the
cooling container and is located behind the right side flap next to
the cooling aggregate.
Gas separation membrane Value Unit
Type PARKER HiFluxx St 6010
Dimensions 736 x 139 mm

(Length x diameter)
Compressed air connection R 1 Inches
Standard conditions - temperature 20 °C
N2 production at 8 bar 98 %
Fig. 21: Gas separation membrane
Weight 5.5 kg
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4.4.7 Armature group with valves
6
5 4
Fig. 22: Armature group
1 Modulating valve/ motor control valve 5 Nitrogen outlet (to wet membrane)
2 Pressure sensor 6 Nitrogen outlet (direct container)
3 Manometer 7 3/2-ways valve
4 Nitrogen intake (from gas separation 8 Oxygen sensor
membrane)
The nitrogen obtained in the gas separating membrane is fed into

the armature group. With the aid of a modulating valve/ motor
control valve (1) the differential pressure is adjusted and thus the
nitrogen unit is adjusted. The nitrogen pressure and the volume
flow change according to the purity of the nitrogen flow.
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The nitrogen flows at about 7 m3/h after a manual pressure

measurement through the modulating valve and over an oxygen
sensor. The oxygen sensor measures the residual oxygen content
or the purity of the nitrogen flow. The oxygen sensor retroactively
triggers the modulating valve/ motor control valve (1) and thus
influences the purity of the nitrogen.
The regulation and thus the pureness of the nitrogen jet depends
on the oxygen concentration inside the load area which is adjusted
with the “setpoints“.
The nitrogen main jet is lead either directly into the load area by
switching the 3/2-valve or it is transported to the wet membrane as
a flush air jet. The switching of the valve and, connected with that,
the moistening of the nitrogen jet, depends on the conditions and
the settings of the "setpoints” in the container. The route of the
nitrogen jet through the wet membrane is for moistening the air
inside the container, as described in chapter 4.4.4.
In "purge" mode the modulating valve is charged with a higher

setpoint. The nitrogen flow is approximately twice as great in this
mode as it is in standard mode. The purge process is used to
quickly increase the low residual oxygen content in the container,
and also to purge out process gasses such as ethylene and CO2 in
a short time with the high volume of nitrogen.
Armature group Value Unit
Modulating valve/ motor control BUSCHJOST

valve (type) Serie 82880
Pressure sensor/manometer (type) WIKA

Pressuretransmitter OC-1
3/2 valve (type) Bürkert

Type 73
Oxygen sensor (type) SCHUMANN

M1-KLCH
Electric feed line 24 V DC
Temperature range (for 0...60 °C

compressed air)
Line connections T 1/2 Inches

T 1/4
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4.4.8 Nozzles
The compressed air containing nitrogen is distributed in the load
area. This is a three-element nozzle system that consists of the
following components:
Liquid nozzle
Air nozzle
Air diffusion nozzle
The nozzle system is in the load area on the left side of the
adsorption dryer (see arrow in Fig. 23).
Nozzles Value Unit
Manufacturer SPRAYING SYSTEMS
Compressed air connection 1/8 – 1/4 Inches

Fig. 23: Nozzles
(inside/outside)
Diffusion pressure ~3...4 bar
4.4.9 Energy supply

The energy the CA system is supplied via the integrated
refrigeration machine. The refrigeration machine is connected with
a three-phase connector to a 400 V voltage network.
Alternatively the CA system can be supplied with voltage via a
generator (GenSet). The GenSet is used if the container is
transported via truck.
The CA system is configured for a supply voltage of 380...460 V
and a frequency of 50...60 Hz.
The connections of the individual consumers and signal
transmitters are brought together in the control cabinet of the CA
system. From this point the individual components are evaluated
and regulated.
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4.4.10 Controller
The controller of the CA system regulates the residual oxygen
content or the nitrogen content in the atmosphere in the load area,
and also regulates the humidity.
The controller of the CA system has a rotary field detection system.
It can be operated with a right rotary field as well as a left rotary
field. In addition the input voltage is monitored. If the supply
voltage moves outside of the specified voltage range of 380 to 460
V, the system switches off and resumes automatic operation when
the supply voltage returns to the specified range.
A voltage converter generates the control voltage of 24 V DC that
is necessary for system operation.
1 Control panel
2 ON/OFF switch
Fig. 24: Control cabinet 3 Display
The CA system is switched on and off on the control cabinet (2).

The operator makes the required settings on the control panel (1)
via the membrane keypad.
NOTE!
More detailed information concerning system wiring
and the electrical connection of the specific
components are in the circuit diagram of the
system provided in the appendix.
4.4.11 Sensors
Different process parameters are monitored and controlled via
sensors on the CA system.
A microcontroller has the task of regulating the function of the
overall system based on the data supplied by the sensors.
The measuring sensors permanently monitor the actual status
during operation by comparing the actual status with the target
status. The essential measuring data such as oxygen content and
moisture content in the container, operating pressure of the system
as well as purity of the nitrogen produced are continuously
recorded in the data memory of the microcontroller. It is possible to
read out the data with a laptop.
In addition to the sensor system presented below the CA system
also has additional signal transmitters that have an influence on
proper operation and an influence on the safety functions to protect
both the operator and the system.
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4.4.11.1 Oxygen sensors
A total of two oxygen sensors are in the CA system.
1 Water separator
2 Oxygen sensor
3 Carbon dioxide sensor
The first sensor is placed on the (Æ armature group) and has the
task of measuring the oxygen content of the atmosphere produced
and introduced into the container.
The second oxygen container (2) is located in a separate plastic
Fig. 25: Oxygen sensor housing that is integrated on the front side of the cooling system.
The oxygen sensor is located on the right side next to the water
separator (1). This sensor records captures the oxygen values
inside the container and thus is an essential process monitoring
element.
In addition depending on the model type of the CA system a
carbon dioxide sensor (3) can be integrated below the oxygen
sensor (2).
The carbon dioxide sensors have an output signal from 0 to 10 V
and do not require a supply voltage. The signal of each sensor is
sent directly to the PLC controller for signal processing.
Oxygen sensor Value Unit
Manufacturer SCHUMAN
Type M1-KLCH
System Zirconium dioxide
Output voltage range 0...10 V
Temperature range (operation) -15...+50 °C
Measuring range 0.1...25.0 % by vol.
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Carbon dioxide sensor Value Unit

(optional)
Manufacturer SCHUMANN
System Infrared gas measuring cell
Output voltage range 0...2 V
Measuring range 0,1...25,0 % by vol.
Supply voltage max. 10 V DC
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Field
4.4.11.2 Moisture/temperature
Fig. 26: Moisture/temperature sensor interior
The integrated moisture/temperature sensor (Fehler!

Verweisquelle konnte nicht gefunden werden.) is located in the
load area behind the vent flap of the cooling aggregate. If the
temperature in the container falls below the value of 0 °C the CA
system detects that frozen goods are being transported and
switches off automatically.
Moisture/temperature sensor Value Unit
Manufacturer EE Elektronik
Type EE 21, wall mount
Electrical connection 24 V DC
The second temperature sensor (Fehler! Verweisquelle konnte

nicht gefunden werden.) measures the ambient temperature. If
this temperature drops to a value below -15 °C the system
switches off. At temperatures < -15 °C the CA system should not
be operated as some components are damaged.
If the ambient temperature increases to approximately +1 °C the
CA system switches on again automatically.
Fig. 27: Temperature sensor exterior
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4.4.11.3 Pressure sensor
The pressure sensor (1) is located in the (Æ armature group)

above the control cabinet of the CA system. In addition to the
process relevant electric pressure sensor a mechanical pressure
display is also integrated to enable the operator to quickly assess if
the compressor system is functioning properly.
1 Pressure sensor
2 Manometer
Pressure sensor Value Unit
Manufacturer WIKA
Type OC-1
Fig. 28: Pressure sensor
Electrical connection 24 V DC
Output voltage 0...10 V
Tolerance ± 0.5 bar
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CA reefer container
Transport, packing, and storage
5 Transport, packing, and storage

NOTE!
Installation and commissioning is executed exclusively
by manufacturer's employees or by persons
authorized by manufacturer.
The CA reefer container is frequently transported as
subsequent use.
Strictly heed the instructions listed below in this
regard.
Normally the CA reefer container is transported as follows:

On sea-going ships
On trucks
On railway freight cars
For the transport the container must be adequately secured in
accordance with the applicable regulations provided by the
transport company.
The owner must ensure that these regulations are complied with.
5.1 Instructions for transport

Transport CAUTION!
Unauthorized transport can cause damage!
Significant material damage can occur if the
system is transported improperly by untrained
personnel.
Therefore:
– Only trained personnel should load and unload
the container.
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Suspended loads WARNING!

Life-threatening danger due to suspended
loads!
When lifting loads there is a life-threatening hazard
due to falling parts or parts swinging out of control.
Therefore:
– Never step under suspended loads.
– Comply with the instructions concerning the
intended attachment points.
– Do not attach lifting tackle to projecting machine
parts or to the eyes of attached components;
ensure that the lifting tackle is firmly seated.
– Only use approved lifting devices and lifting
tackle with sufficient bearing capacity.
– Do not use rope and belts that are torn or
frayed.
– Do not place ropes and belts on sharp edges
and corners, do not knot or twist ropes and
belts.
Eccentric center of gravity WARNING!

Eccentric center of gravity poses a danger of
falling!
A loaded container can have an eccentric center of
gravity. If attached incorrectly the container can tip
and cause life-threatening injuries.
Therefore:
– Only lift the container with a suitable transport
device.
– Attach the crane hook in such a manner that it
is located above the center of gravity.
– Carefully raise the container and see if it tips. If
necessary change the attachment.
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5.2 Pre-trip inspection

Prior to any transport with the CA reefer container your Reefer
Service must perform a pre-trip inspection (PTI). In this process the
essential CA components are tested for visible damage functional
disturbances (electrical and mechanical).
The controller of the CA system has an automatic PTI similar to
that of the cooling system, which automatically performs a check of
the essential system components. Execution of the PTI is
described in chapter 7 "Operation".
In addition prior to each transport the lines connecting the CA
components must be checked for leaks.
A regular PTI must also be executed for the refrigerating machine.
See the specifications provided by the manufacturer of the
refrigerating machine in this regard.
5.3 Transport
The CA reefer container is usually raised, loaded, and unloaded
with suitable harbor cranes or lifting vehicles that have been
especially designed for this purpose.
The owner must comply with the regulations that apply for these
transport devices.
NOTE!
The load process should only be executed by
personnel with adequate training!
Crane transport The container can be directly transported with a crane under the
following conditions:
Crane and lifting gear must be designed for the weight of the
container.
The operator must be authorized to operate the crane.
Attachment:
1. Attach the ropes or multi-point suspensions Fig. 29
appropriately.
2. Ensure that the container hangs straight; pay attention to
Fig. 29 possible eccentric center of gravity.
3. Start the transport.
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Transporting pallets with the The CA reefer container can be directly transported with a crane
forklift under the following conditions:
The forklift must be configured appropriately for the weight and
size of the container.
The operator must be authorized to operate the forklift.
Attachment:
1. Drive the forks under the container so that they are centered
on the transverse side.
2. Drive in the forks until they protrude on the opposite side.
3. If there is an eccentric center of gravity, ensure that the
container cannot tip.
4. Raise the container and start the transport.
NOTE!
If the container is empty it can also be raised from
the front side. In this case pay particular attention
to the tip hazard!
Container storage Only store containers under the following conditions:

Do not expose to aggressive media.
Storage temperature: -15...+50 °C.
Relative humidity: max. 99 %
For longer periods of storage (> 3 months) regularly check the
general status of all parts. Touch up or reapply anti-corrosion
agents as needed.
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Installation and commissioning
6 Installation and commissioning

NOTE!
Installation and commissioning is executed
exclusively by manufacturer's employees or by
persons authorized by manufacturer.
NOTE!
As the operator please make sure that the area of the
CA-system being worked on is sufficiently illuminated!
WARNING!
Danger due to defective installation and
commissioning!
Installation and initial start-up require trained and
qualified personnel with plenty of experience (see
2.2.1).
Installation and commissioning require trained,
specialized personnel with adequate experience.
Installation errors can cause life-threatening
situations or significant material damage.
Therefore:
– Only have manufacturer's personnel perform
installation and commissioning work.
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Operation
7 Operation
7.1 Safety
Personal protective equipment Wear the following protective equipment for all operating tasks:
Protective gloves
Safety footwear
Basics WARNING!
Danger of injury due to improper operation!
Improper operation can cause serious injury or
property damage.
Therefore:
– Execute all operating steps in accordance with
the information in this operating manual.
– Prior to starting work ensure that all covers and
safety devices are installed and functioning
properly.
– Never render a safety device inoperable during
operation.
– Ensure order and cleanliness in the work area!
Parts and tools that are lying loose or on top of
each other are accident hazards!
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Operation
7.2 Activities prior to use

7.2.1 Implementation requirements
To commission the CA container the following requirements must
be satisfied:
The container must be on a level and stable substrate. The
maximum incline of 5° should not be exceeded.
The maximum deployment height above sea level is 2500
meters.
Do not place the container directly in front of a heat source.
This applies particularly for the front side with cooling system
and CA system.
The maximum ambient temperature for the cooling system and
CA system is 45 °C.
A stable power supply with a capacity of 15 kW must be
ensured.
The container must be completely loaded before starting the CA
system. The transport goods should only be stacked in the
container to the permissible height. A sticker in the load area
indicates the permissible load height.
Fig. 30: Load area delimitation
Prior to switching on the CA system the doors of the container

as well as all inspection flaps must be closed and firmly locked.
Connecting the CA/cooling system

Only operate the entire system if power is connected or if there is a
power aggregate (GenSet). The connection is executed via the
connecting cable of the cooling system, with which both systems
are supplied in common.
1. Ensure that the main switch of the CA system and the the
main switch of the cooling system are on "OFF".
2. Connect the CA system with the connecting cable of the
cooling device to a 400 V three-phase voltage source.
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Operation
Using the GenSet

1. The GenSet is bolted onto the outside of the container on the
system side See the manufacturer's guidelines in this regard.
2. Connect the power cable to the GenSet.
CAUTION!
Overvoltage can cause damage!
The system can be damaged if operated at
voltages other than the specified supply voltage.
Therefore:
– Check the voltage generated by GenSet before
establishing a connection with the power
connector of the CA/ cooling system.
CA system connection Value Unit

specifications
Supply voltage 380...460 V

(3-phase)
Frequency 50...60 Hz
Fusing 25 A
Maximum power consumption 15 kW
Length - power cable with plug Approximately m

18
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Operation
7.3 Switching on
DANGER!
A life-threatening danger exists if live components
are touched.
DANGER!
Danger of suffocation due to nitrogen!
The access flap for the evaporator and the fans of
the refrigerating machine are under pressure when
the device is operating. The nitrogen atmosphere in
the container can cause suffocation if the flap is
opened without authorization. Moreover the flap
can fly open under high pressure and cause severe
injuries.
Therefore:
– Prior to switching on the CA system close the
access flap of the evaporator.
– Do not open the access flap during operation.
– Only open the flap 15 minutes after the system
has been switched off.
– After opening the flap maintain a minimum
distance of 0.5 m to the opening and do not put
stick you head into the evaporator section.
In the CA reefer container a total of two main systems are installed:

The CA system
The Thermo King cooling system
1. To operate the system for the "Controlled Atmosphere" (CA)

setup, first switch on the cooling system and then switch on
the CA system.
CAUTION!
Component damage!
Do not switch on the CA function at transport
temperatures below 0 °C, as this can cause
damage to components installed in the container.
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Operation
NOTE!
See the operating steps provided in the
manufacturer's operating manual for the operating
steps of the Thermo King.
Pure cooling operation

The container can also be operated in pure cooling operation
without CA function.
1. Switch off the CA system to change the system to cooling
mode.
If the CA system is switched off operation in the temperature range
specified by the manufacturer of the cooling device is easily
possible.
NOTE!
The ventilation flap of the cooling system is
mechanically locked from at the factory, opening
the flap in combination with CA operation is not
permitted. If operation of the cooling system is
planned without CA system and with utilization of
the ventilation flap notify the Reefer Service so that
the tear-off bolt on the ventilation flap is removed.
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Operation
7.4 Operating the CA system

1 ON/OFF switch
2 Operating status bar diagram
3 Number pad with LED operating states
4 Display O2 Cargo with alarm and operating status LED
1. Switch the CA system on using the ON/OFF switch.
NOTE!
The CA system can only start when the container
doors and the maintenance flap are closed and
locked.
Fig. 31: Control cabinet

The controller switches the compressor on with a delay of
approximately 30 s if the prerequisites for CA production are
satisfied.
CAUTION!
Frost danger!
If there is heavy frost individual system
components can be damaged.
Therefore:
– Avoid cold starts under -10 °C.
2. Make setting on the system via the operator keypad.
NOTE!
The temperature, humidity, and residual oxygen
values depend on the goods being transported.
Check the freight documents or the sender's
recommendations for the freight-specific values.
The display shows the settings of the system. Error messages are
also shown on the display. A visualization of the operating state is
shown on the display via the bar graph or via the LED below the
display.
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Operation
The following operating states are displayed:
Display Status cargo value (O2 content)
6 Cargo value "in range" of the specified setpoint
5 Cargo value below the setpoint
7; 8; 9 Cargo value above the specified setpoint
The cargo value for the O2 content in the container is shown in the
view window above the display. If there is a system fault all LEDs
flash.
7.4.1 Operating the display

In basic status the system shows the current operating status of
the system on the display. This includes the following displays:
"System is ON/OFF"
Pressure
O2 production
O2 cargo value
Relative humidity in the form of a bar graph
1 Bar graph for display of operating states

Fig. 32: Display operation 2 Operating buttons
3 Number pad with LED to display operating states
1. Press the enter key (Fig. 33) to go to the second display level.
In the second display level you can call the following values:
CO2 value
Temperature - container
Fig. 33: Enter key
Outside temperature
Operating status "Purge"
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Operation
2. Press the "F3" key (Fig. 34) to go to the next level.

This level shows the main menu of the CA system.
Fig. 34: Key "F3"
3. Use the enter key (Fig. 35) to further intervene in the system.
Press the key to call the following points in succession:
Settings
Configuration
Fig. 35: Enter key Time
Auto PTI
Setpoints
NOTE!
An asterisk on the right side indicates the currently
selected submenu.
4. Press the arrow keys (Fig. 36) to select the desired menu
item.
5. Use the number pad (Fig. 32/3) to change and reset numeric
values.
NOTE!
Fig. 36: Arrow keys
Be aware that the change/settings of setpoints is
protected by a code!
6. Press the "F3" key (Fig. 37), if you want to display the current
error.
7. Press the "F3" again to call the index of previously occurred
errors.
Fig. 37: Key "F3" The error display enables fast analysis in the event of malfunction.
8. Press the "F1" key to return to the previous display level.
Fig. 38: Key "F1"
The menu tree of the CA system below shows operation of the display.
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Operation
Fig. 39: Menu structure
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Operation
7.4.2 Specifying setpoints
NOTE!
Note that you can enter a humidity setpoint on the
Thermo King controller!
The following setpoints can be specified on the CA controller:

Oxygen content in the container
Relative humidity in the container
Carbon dioxide content in the container (optional)
These setpoints are preset and can only be changed by service
personnel or authorized personnel. Accessibility to the menu item
for specifying setpoints is protected by a code.
7.4.3 Execute auto PTI

To execute AUTO PTI, proceed as follows:
1. In the main menu select the sub-item "AUTO PTI".
2. Confirm the selection with the enter key (Fig. 40).
The following screen will be displayed:
Fig. 40: Enter key
Start Auto PTI
Last auto PTI
Result of the last auto PTI
3. Use the arrow keys (Fig. 41) to select the menu item "Start
Auto PTI" and confirm with the enter key (Fig. 40).
The system will prompt you to select the following items:
"Auto PTI Start 1 = Yes"
"2 = No"
Fig. 41: Arrow keys
4. Press key 1 (Fig. 42) on the number pad to start the process.
The AUTO PTI then proceeds to execute a total of 14 individual

tests in which the CA system components are checked.
Fig. 42: Key "1" At the start of the respective test the name of the test is shown,
e.g. "CHECK COMPRESSOR".
Upon conclusion each individual test is either confirmed with:
"PTI 1/14 OK" or with
"PTI 1/14 FAILURE" the system indicates failure.
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Operation
The following tests will be performed:
No. Designation
1 CHECK COMPRESSOR
2 CHECK PRESSURE
3 CHECK OX PROD
4 CHECK FLUSHING
5 CHECK CYCLONE I (1)
6 CHECK CYCLONE I (2)
7 CHECK FILTER I (1)
8 CHECK FILTER I (2)
9 CHECK FILTER II (1)
10 CHECK FILTER II (2)
11 CHECK HUMIDITY
12 CHECK FLUSHING II
13 CHECK HUMIDITY II
14 CHECK PRESSURE II
After conclusion of the AUTO PTI the evaluation of all 14 tests is

shown with "OK" or "FAILURE.
5. Press the "F1" key (Fig. 43) repeatedly to return to the main
menu.
NOTE!
Fig. 43: Key "F1"
The results of the last PTI can be viewed via the
appropriate menu item "Last Auto PTI".
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Operation
7.5 Decommissioning/unloading
When the CA container reaches its destination it must be
unloaded.
NOTE!
The following operating steps must be followed in
the sequence specified!
1. Switch the CA system off using the ON/OFF switch on the

control cabinet.
NOTE!
Let the cooling system continue to run so that a
quick exchange of air can take place.
2. Open both door wings of the container wide. When opening

the doors move behind the door wings and do not enter the
load area!
DANGER!
Life-threatening hazard due to nitrogen!
After switching off the CA system an atmosphere
containing nitrogen prevails in the load area of the
container, which can cause suffocation if directly
inhaled.
Therefore:
– After opening the doors wait for at least 10
minutes until sufficient outside air has flowed
into the load area.
After a wait time of at least 10 minutes the air in the load area has
been so enriched with oxygen that there is no longer danger for
operating personnel.
3. Switch the cooling system off using the ON/OFF switch on the
control cabinet.
4. Unplug the power plug to prevent unauthorized start up of the
cooling / CA system.
5. Start the unloading process.
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Operation
7.6 Shutdown in emergency situations

In dangerous situations machine movements and nitrogen
production must be stopped as quickly as possible and the energy
supply must be switched off.
Shutdown in emergency situations In case of danger proceed as follows:

1. Immediately switch off the CA system via the main switch or
unplug the power plug.
2. Inform the responsible parties at the implementation site.
3. If there are injuries/fire call a physician and possibly the fire
department.
4. Get persons out of the danger zone, initiate first-aid
measures.
5. Safeguarding the main power supply of the CA-system (power
plug) against restart
6. Keep entry ways clear for rescue vehicles.
After the rescue measures 7 Depending on the seriousness of the emergency situation,
inform the responsible government agencies.
8 Assign specialized personal to resolve the malfunction.
WARNING!
authorization!
There is a life-threatening hazard for all persons in
the danger zone if the machine is restarted.
Therefore:
– Prior to restarting ensure that no one is in the
danger zone.
9. Prior to starting up the machine again check and ensure that
all safety devices are installed and functioning.
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Operation
7.7 Activities after use

After unloading the container the comply with the following
instructions.
1. Clean the container area with suitable cleaning agents, such
as wash reagents or citric acid.
NOTE!
Ensure that the container is hygienically clean
before it is filled again.
2. After cleaning allow the container to cool down and dry off.
NOTE!
Prior to recommissioning after a longer term
shutdown period (after approximately a half year) in
your own interest have a major inspection
performed by the Reefer Service.
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Troubleshooting
8 Troubleshooting
Possible causes for faults and the tasks to correct these faults are
described in the following chapter.
If faults occur more frequently, the maintenance intervals must be
shortened in accordance with the actual load.
Contact the manufacturer if there are faults that cannot be
corrected by following the instructions below; see the service
address on page 2.
8.1 Safety
Personnel The fault correction work described here can be executed by
the operator unless otherwise indicated.
Some tasks should only be executed by especially trained,
specialized personnel, or exclusively by the manufacturer;
special reference will be made in each case in the description of
the specific maintenance tasks.
Only qualified electricians should perform work on the electrical
equipment.
Personal protective equipment Wear the following protective equipment for all maintenance work:
Protective gloves
Protective goggles
Safety footwear
Basics WARNING!
Injury hazard posed by improper fault
correction!
Improper fault correction can cause serious injury
or property damage.
Therefore:
– Prior to starting work ensure that there is
adequate free space for installation.
– Ensure order and cleanliness at the installation
location! Parts and tools that are lying loose or
on top of each other are accident hazards!
– If components have been removed, ensure that
they are properly re-installed, that all fastening
elements are re-installed, and that all threaded
connections are tightened with the specified
torque.
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Troubleshooting
Electrical equipment DANGER!

There is a life-threatening hazard when touching
live components. Switched-on electrical
components can move unexpectedly and can
cause serious injuries.
Therefore:
– Prior to starting work switch off the power
supply and safeguard it from being re-started.
Loading area DANGER!

Life-threatening hazard due to lack of oxygen!
After operation of the CA system the oxygen
content in the container may have sunk to 2%.
There is a suffocation hazard.
Therefore:
– Prior to all performing all repair work on the
components inside the cooling system and the
CA system ensure that the container was
adequately ventilated.
Oxygen sensors WARNING!

Danger of burning due to heated sensors!
In operation the head area of the oxygen sensor
heats to 150 °C. There is a danger of burning!
Therefore:
– Prior to working on the oxygen sensor, or in the
area of the oxygen sensor always allow sensor
heads to cool until they can be safely handled.
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Troubleshooting
Safeguarding against restart DANGER!

authorization!
When correcting faults there is danger of the
energy supply being switched on without
authorization. This poses a life-threatening hazard
for persons in the danger zone.
Therefore:
– Prior to starting work switch off the system and
safeguard it from being switched on again.
Behavior in the event of fault The following always applies:

1. For faults that pose a direct danger for personnel and or
property immediately execute the emergency-stop function.
2. Determine the cause of the fault.
3. If correction of the fault requires work in the danger zone,
switch off the device and safeguard it against being restarted.
4. Immediately inform the responsible parties at the installation
site of the fault.
5. Depending on the type of fault, either have authorized
specialized personnel correct the fault, or correct it yourself.
NOTE!
The fault table provided below lists personnel who
are authorized to correct the fault.
8.2 Fault indications

Malfunction messages of the CA system are indicated by the red
LED on the control cabinet.
Error messages are shown in the display under the menu item
"Current errors".
There is a fundamental distinction between malfunctions of the CA

system or malfunctions of the Thermo King cooling system.
NOTE!
Malfunctions of the cooling system are described in
detail in the manual provided for the Thermo King.
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Troubleshooting
When operating the CA system it is important that the cooling

system works trouble-free.
A positive effect on the load can only be achieved in conjunction
with the cooling.
Consequently there is a connection between the controllers of the
CA system and those of the cooling system via which the function
is queried by the CA system.
This signal is implemented via the two compressor contactors in
the Thermo King control cabinet. An auxiliary switched is placed on
this cabinet which reports the cooling compressor operation to the
CA controller.
NOTE!
If the compressor of the cooling system is not
operated for a longer period of time (30 minutes)
then the CA system assumes there is a malfunction
and switches itself off automatically.
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Troubleshooting
8.3 Troubleshooting chart

Malfunction Error source Possible cause Fault correction Corrected by
Total device
System cannot Voltage supply Power plug is not Check the control Operator
be switched-off inserted or is not inserted voltage
correctly; feed cable is
interrupted.
No mains voltage
present at the power
outlet.
Fuses in the system
have tripped.
CA system
Nothing on the Display, voltage Display defective; Change display; Qualified

display supply connecting plug has fasten the plug on the electrician
become detached from MC, press the reset
the MC; button on the MC,
MC defective, 24 V not Replace the MC.
supplied. Switch on/replace the
fuse (24 V).
Display: Compressor fuse Compressor motor is Switch on the safety Operator

has tripped. defective; compressor is cutout; ensure that the Qualified
jammed; fuse defective. compressor as moves electrician
freely; replace motor.
Red LED
Flashing LED
The safety cutout Compressor motor is Switch on the safety Operator

for the fan motor defective; fan is jammed; cutout, ensure that the Qualified
has tripped. fuse defective. fan moves freely; electrician
change motor.
Red LED
Flashing LED
Door contact Container door is open; Close the container Operator

switch; wiring door contact switch is door; repair/replace Service
defective; wiring is loose. the door contact
switch; check the Qualified
wiring. electrician
Red LED
Flashing LED
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Troubleshooting
Compressor; Oil level too low; ambient Top off oil; replace the Operator
Wiring temperature too high; temperature switch; Qualified
temperature switch switch on the safety electrician
defective; fan motor does cutout of the fan
Red LED not work; wiring on the motor; replace the fan
Flashing LED MC. motor; check the
wiring.
O2 sensor; Cable break O2 sensor; Replace cable; Service

Measured value Sensor plug has tripped Fasten the plug; Qualified
amplifier; on the control cabinet or Replace the sensor; electrician
Wiring sensor; Apply voltage on the
Red LED Sensor defective; no measured value
Flashing LED voltage on the measured amplifier; replace
value amplifier. measured value
amplifier.
Moisture sensor; Cable break, moisture Replace cable; fasten Service

Wiring sensor; sensor plug has plug; replace sensor; Qualified
become detached on the establish power electrician
control cabinet or on the supply.
Red LED sensor, sensor defective,
Flashing LED no voltage on the sensor.
Phase detection Overvoltage/ Check the voltage Service

Voltage supply undervoltage of the source. Qualified
supply; phase failure electrician
Red LED
Flashing LED
Temperature Temperature setpoint for Check the deep Service

switch in the deep-freeze is less than freeze setpoint; Qualified
container 0 °C, defective cable. replace cable. electrician
Red LED
Flashing LED
Temperature Ambient temperature Check the ambient Service

switch on the less than -15 °C; temperature; replace Qualified
environment defective cable. cable. electrician
Red LED
Flashing LED
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Troubleshooting
Control cabinet of the Thermo King cooling system
Module cannot Voltage supply Power supply not Insert plug check the Operator
be switched-on. connected or available; supply voltage.
fuses have tripped. Switch on the fuses in
the Thermo King
control cabinet again.
Temperature Thermo King Settings are wrong. Check the settings; Operator
does not drop. controller see the Thermo King
instructions.
8.4 Recommissioning after corrected malfunction

After correcting the fault execute the following steps for re-
commissioning:
1. Acknowledge the fault on the controller.
2. Ensure that that no one is in the danger zone.
3. Start in accordance with the instructions in the chapter
"Operation".
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Maintenance
9 Maintenance
NOTE!
All maintenance work should be performed the
manufacturer or by service companies
commissioned by the manufacturer!
A separate manual is provided for these tasks
which must be referenced when performing these
tasks.
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Dismantling
10 Dismantling
When the end of usage has been reached the system needs to be
dismantled and disposed of in a professional manner and in
compliance with applicable environmental protection regulations.
10.1 Safety
Personnel Only trained, specialized personnel should perform dismantling
work.
Only qualified electricians should perform work on the electrical
equipment.
Basics WARNING!
Improper dismantling poses an injury hazard!
Stored residual energy, sharp-edged components,
points and corners on and in the device, or on the
necessary tools can cause serious injuries.
Therefore:
– Prior to starting work ensure that there is
adequate free space.
– Handle open, sharp-edged components
carefully.
– Ensure order and cleanliness at the workstation!
Parts and tools that are lying loose or on top of
each other are accident hazards!
– Dismantle components properly. Pay attention
to the high dead weight of some of the
components. Use hoist equipment if necessary.
– Secure the components so that they do not fall
down or fall over.
– Consult with the manufacturer if there are
questions.
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Dismantling
Electrical equipment DANGER!

There is a life-threatening hazard when touching
live components. Switched-on electrical
components can move unexpectedly and can
cause serious injuries.
Therefore:
– Prior to dismantling the machine switch off the
electrical supply and permanently disconnect it.
10.2 Dismantling
When dismantling the system for final disposal clean the system
and take it apart in compliance with the applicable industrial safety
and environmental protection regulations.
Prior to disassembling:
Switch off device and safeguard it from being restarted.
Physically disconnect the device from all energy supplies;
discharge stored residual energy.
Remove fuels and auxiliary materials, as well as residual
processing materials and dispose of these items in an
environmentally responsible manner.
NOTE!
In many cases the containers are not scrapped,
rather they are sold to third parties.
NOTE!
See also the chapter on "Dismantling" in the
Thermo King cooling system manual.
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Dismantling
10.3 Disposal
If a return or disposal agreement has not been concluded, then
recycle dismantled components:
Scrap metals.
Recycle plastic elements.
Sort and dispose of the remaining components in accordance
with material condition.
CAUTION!
Improper disposal causes environmental
damage!
Electrical scrap and electronic components,
lubricants, and other auxiliary materials are subject
to treatment as special waste, and should only be
disposed of by approved specialist companies!
In compliance with customary official regulations no special
disposal duties and regulations for hazardous waste need to be
adhered to. Local municipal authorities or specialized disposal
companies provide information on environmentally responsible
disposal.
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Index
11 Index
A G
Accident ............................................................. 22 Gas separation membrane ................................ 40
Adsorption dryer................................................. 38 I
Air/air cooler with fine filter................................. 36 Inspection openings ........................................... 21
Armature group with valves ............................... 41 Instruction........................................................... 12
B Intended use ...................................................... 14
Brief description ................................................. 31 L
C Liability ................................................................. 8
Carbon dioxide sensor ....................................... 45 Loads ................................................................. 19
Compressor system ........................................... 34 Lubricants........................................................... 23
Connection M
connected loads ............................................. 26 Main switch ........................................................ 20
Contacts ............................................................. 10 Maintenance....................................................... 75
Controller ........................................................... 44 Moisture/temperature sensor ............................. 47
Copyright.............................................................. 9 N
Customer service ............................................... 10 Nitrogen.............................................................. 17
D Noise .................................................................. 27
Danger Zone ...................................................... 22 Nozzles .............................................................. 43
Decommissioning/unloading .............................. 65 O
Dismantling .................................................. 76, 77 Operating conditions .......................................... 27
Disposal ............................................................. 78 Operating materials ............................................ 28
E Operating the CA system ................................... 59
Electrical current ................................................ 16 Operating the display ......................................... 60
Emergency-stop ................................................. 66 Operation ........................................................... 54
Emergency-Stop ................................................ 66 Overview ............................................................ 29
Emissions........................................................... 27 Owner................................................................. 11
Energy supply .................................................... 43 Oxygen sensors ................................................. 45
Environmental protection ................................... 23 P
Execute auto PTI ............................................... 63 Packaging .......................................................... 49
F Performance values ........................................... 27
Fan ..................................................................... 18 Personnel
Fault indications ................................................. 70 dismantling ..................................................... 76
Fire ..................................................................... 22 requirements................................................... 12
First Aid .............................................................. 22 troubleshooting ............................................... 68
Fouling ............................................................... 19 Pneumatic system .............................................. 18
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Index
Pressure sensor ................................................. 48 Specialized personnel.........................................12

Pre-trip inspection............................................... 51 Specifying setpoints ............................................63
Process description ............................................ 32 Stickers ...............................................................23
Protective equipment .......................................... 15 Storage .........................................................49, 52
installation ....................................................... 68 Structure .............................................................29
operation ......................................................... 54 Subassemblies ...................................................34
protective gloves ............................................. 15 Switching on .......................................................57
protective goggles ........................................... 15 Symbols
safety footwear................................................ 15 in the manual.....................................................7
Q warnings ..........................................................24
Qualified electrician ............................................ 12 Symbols in the danger area ................................23
R T
Refrigerant .......................................................... 23 Technical data ....................................................26
Replacement parts ............................................... 9 Transport.......................................................49, 51
S forklift ...............................................................52
Safeguarding against restart .............................. 21 with crane ........................................................51
Safety.................................................................. 11 Troubleshooting ..................................................68
general ............................................................ 11 Troubleshooting chart .....................................72
Safety devices .................................................... 20 W
Safety limit switch ............................................... 21 Warranty .............................................................10
Sensors............................................................... 44 Water separator/cyclone .....................................35
Signs ................................................................... 23 Wet membrane ...................................................37
2008-01-11 79

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Table of contents

Dok-ID: Carg-5410 Read the operating instructions before starting work!

Tel.: +49 (0) 4102 45 72 60

2 Safety .................................................................................... 10

3 Technical data ...................................................................... 25

4 Structure and function ........................................................ 28

4.4.6 Gas separation membrane ...........................39

5 Transport, packing, and storage ........................................48

6 Installation and commissioning .........................................52

10 Dismantling ...........................................................................75

11 Index ......................................................................................78

In addition to this manual the manuals of the installed components

Service und updates are available directly from the manufacturer

1.2 Explanation of symbols

Tips and recommendations NOTE!

We reserve the right to make changes in the interest of

1.5 Replacement parts

Purchase replacement parts from authorized dealers or direct from

1.6 Warranty terms

1.7 Customer service

2.1 Responsibility of the owner

2.2 Personnel requirements

 Operator/ Instructed person

Only persons from whom it can be expected that they reliably

2.2.2 Unauthorized persons

WARNING! Danger for unauthorized persons!

Date Last name Type of instruction Instruction Signature

Fig. 1: Example of an instruction log

2.3 Intended use

The system is used exclusively for freshness maintaining

Claims of any type due to damage arising from non-intended use

2.4 Personal protective equipment

Always wear For all tasks always wear:

2.5 Specific dangers

Electrical current DANGER!

Fehler! Textmarke nicht WARNING!

Pneumatic system WARNING!

Suspended loads DANGER!

Fouling and loose objects CAUTION!

Sharp edges and corners CAUTION!

2.6 Safety devices

The following safety devices are installed:

Safety limit switch as access safeguard

Fig. 3: Door contact switch

2.7 Safeguarding against restart

Switch safeguarded with padlock Safeguarding against re-start:

Switched off 4. If it is not possible to safeguard the switch with a padlock,

2.8 Behavior in the event of danger or accident

In an emergency situation  Immediately activate the emergency-stop.

2.9 Environmental protection

The following environmentally harmful substances are used:

Refrigerant Refrigerants develop environmentally hazardous decomposition

Danger of suffocating in the load area

Fig. 6: Warning sign - load area

The adjacent warning sign is affixed to the outside of the container

Fig. 7: Warning - container door

Load area delimitation

Fig. 8: Load area delimitation

Warning of dangerous atmospheres behind the flaps

Fig. 9: Warning sign on the inspection flap

3.2 Connected loads

Current consumption, maximum 10 A

Power consumption, maximum 15 kW

Operator/ Instructed person

In an emergency situation Immediately activate the emergency-stop.