Home

MP-4000 Controller

1. TRANSFORMER EVAP EVAPORATOR 400V 460V 2 COND CONDENSOR 3 AMB AMBIENT 4 COMP COMPRESSOR 5 DEF DEFROST CIRCUIT BREAKER 6 RH RIGTH HAND D 25 AMP CBI T LH LEFT HAND D 4 8 YEL YELLOW 8 a 9 WHT WHITE 0 BLK BLAC rr O BLK BRN GREY ifs BR BROW L l 3 3 456 7 8 2 BLU Bil Lalo QIRI L2 O O RED BLU BLK 3 DCV DIGITAL CONTROL VALVE Cini Tes 4 VIV VAPOR INJECTION VALVE Y als lowe es 5 HPS HIGH PRESSURE SWITCH U is DN ES Sc ue Y 16 LPS LOW PRESSURE SWITCH 1 WCC WATER COLDED CONDENSER 8 CB CIRCUIT BREAKER 1 9 AVL AIR VENT LOGGIN 20 HS HIGH SPEED CONTROL BOX DOOR A IS 20 HP HIGH PRESSURE TRANSDUCER pele eee a 21 LP LOW PRESSURE TRANSDUCER i 22 DF DEFROST SIGNAL TRANSFRESH POWER CM 4000 CM pe EE 23 DF DEFROST SIGNAL TRANSFRESH GROUND Lele Selle le 24 P POWER TRANSFRESH EUN 1575 CE 25 P GROUND TRANSFRESH Lasso 26 HS HIGH SPEE BATTERY MODULE esa IL Seon en C joe 05 8121810 i C V HEATER o4 000000 BATT o3 y 123456 amp elsh c BATTERY NTC 02 EEUU HIGH POWER 119 Sa S c2
2. AXA0427 Figure 6 Economizer Heat Exchanger Temperature Sensors Each sensor element is connected to a cable and packaged in a sealed stainless steel tube The temperature signal from the sensor is transmitted through the cable PT 1000 type temperature sensors are used to sense temperatures for the Supply Air Return Air e Evaporator Coil e Condenser Coil e Ambient Air The compressor sensor is of Thermistor type and is located in the top cap of the compressor These sensors are field replaceable Five sensor receptacles are provided three USDA and one cargo temperature Unit Description Features amp Options Fresh Air Exchange System The fresh air exchange system removes harmful gases from containers carrying sensitive perishable commodities The fresh air vent is located above the control box The fresh air vent is adjustable to accommodate a variety of frozen and chilled load operating conditions Fresh Air Exchange Vent Figure 7 Fresh Air Exchange Vent Fresh Air Exchange Recorder Optional The Fresh Air Exchange Recorder detects vent disk movement It automatically displays a value on the Display This value is also logged in the datalogger The entry records the time date and vent opening position It mounts on the fresh air vent door Figure 8 Fresh Air Exchange Recorder 27 Unit Description Features amp Options Receive
3. O o mo Ez om ce LEGEND UE NEU s UMS ANE ES AT ae 23 US as zc CODE DESCRIPTION LOC mo S So 2z lt oe 3 lt zu Sz 8 So eu S gt AVL AIR VENT LOGGIN 6D 2 se gt m ES gt BAT BATTERY 4C 5 Bl CKT BREAKER MAIN 3B D 2 3 3 2 col COMPRESSOR CONTACTOR 4A S S E im e 3 c E m m gt gt CFM CONDENSER FAN MOTOR TA a gt a Ed e Di E Mew Ser s e Maney COMP COMPRESSOR MOTOR m LE Y X Y DV DIGITAL CONTROL VALVE 6D EFM 1 2 EVAPORATOR FAN MOTORS 6A 7A 83 F3 FUSE 20 AMP 5B coe S i goo owe ene c Jl n L L i ak SNe OA EO a oC UN 8 3 A Za So S o 3 3 3 3 F4 FUSE 20 AMP 5B p o o E S gt F5 FUSE 20 AMP 5B 7 q HP HIGH PRESSURE 60 TRANSDUCER R A ee De SARA an E rc Era gen HPS LOW PRESSURE CUT OFF SWITCH 48 3 S x OR A J Kl RELAY PHASE SELECT 1 48 IE e c G a c K2 RELAY PHASE SELECT 2 4B RS485 41 LP LOW PRESSURE TRANSDUCER 6D R 485 43 LPS LOW PRESSURE CUT OFF SWITCH 1D Vunreg 5 ae Tepe AA MP MICRO PROCESSOR 6B 18 GND 6 A SI SOL STATE RELAY EVAP HEATERS 6B l ER 2 SOL STATE RELAY EFMI 6B V_unreg47 gt er o Sg 3 SOL STATE RELAY EFM2 1B 18 4A oo GND o gt Ze 2 4 SOL STATE RELAY CFM 1B m e ss m TFO TRANSFRESH OPTION 3C Ss Be e e i ico m TI TRANSFORMER 3B CHART RECORDER L a viv VAPOR INJECTION VALVE 1D a ae Mx ez So ol OPTION AO Festa 6 S e TUR Al c x gt N AA S ri
4. 142 Diagnosis Troubleshooting Warnings and Alarm Codes Code 124 Alarm Codes Descriptions and Corrective Actions Continued Description _ _ _____________ TCormeefiveAeiien Check Power Module Sensor Replace power module Voltage frequency and current sensor located at the power module has detected a problem Check Supply Air Temperature Probe Check discharge and suction pressure gauge Probe Test detects sensor problem readings and refrigerant charge Check for sensor or evaporator fan alarm codes Open evaporator door Inspect coil for ice or frost and initiate manual defrost if necessary Check for correct evaporator fan motor rotation and operation Check supply and return sensor connections and locations Check Return Air Temperature Probe Check for sensor alarm codes Probe Test detects sensor problem Check supply and return sensor connections and locations Check Evaporator Coil Temperature Probe Check for sensor or evaporator fan alarm Probe Test detects sensor problem codes Open evaporator door Inspect coil for ice or frost and initiate manual defrost if necessary Check for correct evaporator fan rotation and operation Inspect return air grille and cargo load Remove any debris or cargo from blocking return air grille At setpoints below 5 C 41 F maximum air vent setting is not allowed Check discharge and suction pressure gauge readings and check refrigerant cha
5. 0 0 ccc hmm 81 Table of Contents Controller Replacement 81 Electrical Maintenance ii ta a dai 83 Unit Protection Devices o o o oo ete 83 Introduction ii a a a A a ee 83 Main Circuit Breaker ERR er er ee a ee 83 Evaporator Overheat Protection o oooooooo els 83 High Pressure Cutout Switch 2 202 nee nennen hh nenn 83 High Pressure Cutout Manifold 0 00 sonen een 84 High Pressure Cutout Switch Removal 22 2 cece nennen nenn 85 High Pressure Cutout Switch Installation 00 eee Ih 85 Low Pressure Cutout Switch i rirerire rika Ee Er ERE hn hn 86 Low Pressure Cutout Switch Removal 0 0 0 cee hrs 86 Low Pressure Cutout Switch Installation 00 0 0 ccc eee ee 87 Discharge and Low Pressure Sensors Optional 20 000 c eee eee eae 87 Discharge and Low Pressure Sensors Removal 0 00 cece nennen nennen 88 Discharge and Low Pressure Sensor Installation 2 2 222m sonen ee 88 Condenser Fan and Evaporator Fan Rotation 0 02 els 88 Check Condenser Fan Rotation 0 0 0 88 Check Evaporator Fan Rotation llle rn 89 Reversing Power Phase on MAGNUM Units 0 000 0 eens 90 Electric Heaters Malfunction 0 0 0 0 ec een 90 Compressor Discharge Gas Temperature Sensor 0 0000 e eects 91 Compressor Discharge Temperature Sensor Replacement 20 oo 91 Temperature Sensors a 24 04 04 els ra a
6. 1 Press the F4 MENU key Press the F3 key to scroll down to the DATALOGGER Menu 2 Press the F4 ENTER KEY to access the Datalogger menu 3 Press the F2 oR F3 Up Down key to scroll through submenu to SET LOG TIME INTERVAL 4 Press the F4 ENTER KEY to enter Temp Log Display shows the current Log Time interval 5 Press the F4 ENTER KEY again with cursor in LOG TIME menu line to enter a new log interval ARROW appears in menu line 6 Press the F2 oR F3 UP DOWN key to increase or decrease the Log Interval he logging of USDA sensors is fixed at 1 hour intervals to comply with USDA requirements A logging test of USDA sensors at 1 minute intervals is possible for 72 minutes USDA data can not be downloaded during the logging test and can only be viewed on screen After 72 minutes controller returns to previous logging interval and clears USDA test data from data logger memory Main Menu When the correct Log Time appears in the menu line press and hold the F4 ENTER KEY until cursor stops flashing The new Log Time appears in the display Press the F1 key to exit 69 Main Menu States Menu NOTE All screens are NOT present on all units The screens that display on the controller are determined by the Controller Software settings and the options installed on the unit Do O DATA pe SETPOINT COMMAND ALARM LIST WARNING LIST CONFIGURATION PTI DATALOGGER INPUT OUTPUT RMM
7. 56 Main Menu Display Description Possible Duration Brief Function Alarms Time PTI Test press Compressor running loaded 25 to 35 evaporator fan at high speed seconds AMB CON EVA and condenser fan maintaining due qusc 30 35degC for 15 sec An IUD OUS Next the compressor is unloaded and running for 10 sec Amp draw difference is mea sured and expected to be at least 0 9 Amp Con 35C or 1 5 Amp Con 35C SCORN Roce With compressor on loaded 26 Max 90 condenser and evaporator fans seconds AMB CON EVA at high speed are turned on for 8 0C 45 0C 1 0C 94A 90A 94A 30 seconds If condenser fan f 2 f temperature is below 30C 86F then the test is aborted Vapor injection valve is turned on Amp draw difference is measured and verified to be minimum 0 4 amps Evaluating Power Consumption Increase 57 Main Menu Display Description Possible Duration Brief Function Alarms Time PTI Test 58 HIGH PRESSURE CUTOUT TEST CAPACITY TEST APPROACHING 0 TEST Running with compressor fully loaded and with evaporator fan at high speed awaiting high pressure cut out The test is seconds ended if the condenser coil probe reads temperature above 70 C and the HPCO does not occurs The time observing is depending on the startup tem perature and will be increased as long as the condenser tempera ture is increasing After the HPCO the compressor signal is removed and the condenser fan is ac
8. 8 Replace the condenser coil support brackets condenser fan shroud and condenser fan grille 9 Recharge the unit with R 404A see Charging the System with Refrigerant in this chapter Filter Drier In line Filter Replacement Filter Drier In line Filter Removal Remove the filter drier in line filter by performing the following steps l 2 6 Recover the refrigerant charge from the unit Place the new filter drier near the unit for immediate installation Crack both the inlet and outlet nuts on the filter drier Use two wrenches on flare fittings to prevent line damage Separate the filter drier line mountings Remove the filter bracket clamping nuts and bolts Remove the old filter drier from the unit Filter Drier In line Filter Installation Install the filter drier in line filter by performing the following steps l Remove the sealing caps from the new filter drier Apply clean compressor oil to filter drier threads Install new filter drier in unit Finger tighten mounting nuts NOTE To prevent incorrect installation of the dehydrator the inlet and outlet fittings are different sizes Reinstall clamping brackets nut and bolts Tighten the bolts Tighten filter drier inlet and outlet nuts NOTE Always hold the body of the dehydrator or liquid filter near the flange fittings This will prevent twisting the tubing when the nuts are being loosened or tightened
9. 29 C 20 F Cool 16to 27 C 60 130 to 145 kPa 1 30 to 1 45 1035 to 1450 kPa 10 35 to to 80 F bar 19 to 21 psig 14 50 bar 150 to 210 psig Suction and discharge pressures vary too greatly during Modulation Cool to use for evaluating or diagnosing refrigeration System performance During the Modulation Cool mode the suction pressure will vary between 100 and 450 kPa 1 0 and 4 5 bar 15 and 65 psig depending upon the percent percent cooling capacity Discharge pressure is determined by condenser fan cycling 21 Specifications MP 4000 Controller Specifications Temperature Controller Type MP 4000 is a controller module for the Thermo King Magnum Unit Additional requirements can be met by means of expansion modules The MP4000 is solely responsible for temperature regulation of the reefer container but other monitoring equipment can be used in conjunction with the MP 4000 such as a chart recorder Setpoint Range 40 0 to 30 0 C 31 0 to 86 0 F Digital Temperature Display Controller Software Original Equipment 60 0 to 80 0 C 76 0 to 176 0 F Version See controller identification decal Defrost Initiation Evaporator Coil Sensor Manual Switch or Demand Defrost Initiation Coil must be below 18 C 65 F Defrost cycle starts when technician or controller requests defrost initiation Timed Defrost Initiation Coil must be below 4 C 41 F Defrost cycle starts 1 minute a
10. Warnings and Controller Actions Continued ME Warning Message Controller Action Corrective Action Supply Air Temperature Too Low Last defrost gt 90 minutes perform defrost During Chill or Frozen Mode Supply air Controller perform Probe test temperature is too low compared to return air If sensor is still low generates Alarm 128 temperature under operating conditions Indicates Ice or frost on evaporator coil Low heating capacity Incorrect evaporator fan operation Incorrect connection or location of supply or return air sensors Return Air Temperature Too High Last defrost gt 90 minutes perform defrost During Defrost Return air temperature Controller perform Probe test increases above 40 C 104 F If sensor is still high generates Alarm 129 Indicates Defective return or evaporator coil sensor Return and evaporator coil sensor connections are reversed Evaporator Coil Temperature Too High Last defrost gt 90 minutes perform defrost During Chill or Frozen Mode Evaporator coil Controller perform Probe test temperature is too high compared to return air If sensor is still high generates Alarm 130 temperature under operating conditions Indicates Low refrigerant charge Defective evaporator coil or return air sensor Incorrect connection or location of evaporator coil or return air sensor Evaporator Coil Temperature Too Low Last defrost gt 90 minutes perf
11. e Mode Description Descript unit operation e Fl f4 Key Functions ALARM C F SETPOINT MENU Glossary of Symbols A Alarm 2 Pretrip Component Being Tested E Heating efe Evaporator Fan High Speed 4 Dehumidification 3 Defrost Condenser Fan On Compressor On Unloaded Compressor On loaded without Vapour Injection Compressor On loaded with Vapour Injection Evaporator Fan Low Speed Glossary of Mode Descriptions Chilled cooling Chilled cooling is a mode where the Unit setpoint is set to above 10C The function here is to maintain setpoint temperature by controlling the temperature on the supply air The supply air is not allowed to be lower than the setpoint Chilled cooling mode can operate the unit in different modes where the compressor can Controller Description run loaded unloaded loaded and vapor injection depending on the need for cooling capacity The condenser fan will operate in an on off algoritim depending on the temperature on the condenser The evaporator fans will operate in either high or low speed mode depending on the need for capacity Chilled heating Chilled heating is a mode the Unit setpoint is set to above 10C The function here is to maintain setpoint temperature by controlling the tempera ture on the supply air The supply air is not allowed to be lower than the setpoint Chilled heating mode can operate the unit where only the evaporator fan low s
12. fold out on the last page of the book NOTE All screens are NOT present on all units The screens that display on the controller are determined by the Controller Software settings and the options installed on the unit EE DATA SETPOINT COMMAND ALARM LIST WARNING LIST CONFIGURATION Datalogger Menu DATALOGGER Inspect Log Calibrate Probes STATES Set Log Time Interval Figure 34 Datalogger Menu Viewing the Datalogger Menu With the UNIT TURNED ON Allow Unit to start and stabilise and the Display showing the unit status display setpoint 1 Press the F4 MENU key Press the F3 key to scroll down to the DATALOGGER Menu 2 Press the F4 ENTER to access the Datalogger menu 3 Press F2 OR F3 Up Down key to scroll to the desired function INSPECT LOG e CALIBRATE PROBE Optional SET LOG TIME INTERVAL 4 Press F4 ENTER to access the function selected Inspect Log With the UNIT TURNED ON Allow Unit to start and stabilise and the Display showing the unit status display setpoint 1 Press the F4 MENU key Press the F3 key to scroll down to the DATALOGGER Menu 2 Press the F4 ENTER KEY to access the Datalogger menu 3 Press the F2 OR F3 Up Down key to scroll through submenu TO INSPECT LOG 4 Press the F4 ENTER KEY to enter Inspect Log Display shows the Log Time and the most recent event 5 To scroll through test results in the log press the F3 key Event
13. 2 meer mp a rate a dad arant dt 48 Change the Humidity Control Setting 0 0 sasaa aaaeeeaa 48 Change the Humidity Setpoint ore sii ania e a mr 48 Gommands Menu 24254 veg a ae A ee DR as et iud 49 View the Commands Men vxore n Re a ure e E de 49 PTI Brief PTI Function Test Display oooooocoooo rr 49 PII Pretrp Test orien aee See e Dd OR C SE RU te e Ee det cd ded de ERE bog 50 Brief PTI Pretrip Test iocur LI e Od aee in 50 Function Test iae erre Da aa a hob cute ana E Ra c EP ore eta Sf 51 Manual Function Test u 2 3 iena rar rep in hee o e rci P cast i c TR eode 52 Detroit SLE E te ues vd eS ML e EE Ha NUN i SO ta Ea a Es E MM 61 Tip Start cual tere RR bau BV edes Uer LEA Iq Ba de BASEL 61 Alarms VWVarnings Menu 2 202 420 arent ante de D ga ee Bathe na gp sce s 62 Alarm Code States cio er ee ara Lieb ced oen Bee eR eria 62 Alarm Warning kist Menu Led EAR Rx dani Ada date LESER ER Rs eal er e RR en 63 View the Alarm Warning List Menu 0 0 0c hh rns 63 Warning Gist Mente oc de no tote truces o a ae attest led ada e dole a tee tes 64 Alarm Eist Ment 22222 A A ce ENEMIES Ne ee RY eS 64 G nfiguration Menu A te tl tad Be b iue d E ES le 65 Viewing or Setting Functions s rere recreere iadaa een 65 oetiDate arid TIME sees rara rhet ud e Vai de d eta diet Rape Ape apte i RR cnr 66 Datalogger Menu ctore iue a Be ae oe sav e Det deuten AL ERR ade Ba cd 66 Viewing the Datalogger Menu 1 2 0 ec h
14. AVL Option Again if AVL sensor is mounted you can change the setting here USDA Option When USDA sensor is mounted you can change the setting here Auto Configuration View display on or off value factory default off Set value to on to automatically configure unit to installed components Unit Serial ID Is the TK serial number of the unit itself This is a ten digit alpha numeric entry found under the UNIT Serial Number on the Serial Plate on the unit Unit ID A 12 digit alpha numeric unit serial number old system 65 Main Menu Power Module ID An 8 digit alpha numeric power module number found on the power module Date Time Sets the controller time and date Version Displays the current software version loaded in the controller Controller CTRL EPROM and program serial numbers SER NO NOTE MAGNUM units without a container number beginning with MAE MSF or MWC must be set for USDA temperature sensing See USDA Type above 4 To set a new Configuration screen value a Press the F4 ENTER KEY with cursor in the desired menu line b Press the F2 OR F3 Up Down Up Down keys to scroll the value to the desired setting c Press the F4 ENTER KEY and release when the entry is complete Press the F1 key The new value appears in the menu line 5 Repeat steps 3 and 4 to reset additional configuration values 6 Press the F1 key to exit the Configurations screen Set Date and T
15. AVL Position Radiator DATALOGGER STATES Suct Press Disch Press Bat Voltage Bat c Current Bat Temp Board Temp CO2 02 pt1000 Spare Figure 23 Data Menu Main Menu Viewing the Data Menu With the UNIT ON and the Display showing the unit status display 1 Press the F4 MENu key Press the F3 key to scroll down to the Data 2 Press the F4 ENTER KEY to enter the data submenu 3 Press the F3 key to scroll the cursor down through the menu list or F2 to see previous Press the F1 key to exit the submenu Supply View display on or off value factory default off Controller automatically activates when supply sensor is installed for more than 1 minute Setting this value is not necessary Setpoint Menu NOTE All screens are NOT present on all units The screens that display on the controller are determined by the Controller Software settings and the options installed on the unit Setpoint Cooling Setting TEMPERATURE SETPOINT 24 CONTROLLING MODE HumibiTY CONTROL HuMiDITY SETPOINT Figure 24 Setpoint Menu The screens that display on the controller are determined by the controller software setting and the options installed on the unit All screens are not present on all units Temperature Setpoint To change the controller setpoint turn the UNIT On Allow Unit to start and stabilise Complete the following steps 47 Main Menu Pres
16. WARNING Never use a torch or other concentrated heat source to heat the compressor or other refrigeration system component Heat lamps electric heaters or fans can be applied to the compressor crankcase and other parts of the system to increase the temperature of the refrigerant and compressor oil Charging the System with Refrigerant Unit Charging by weight from an Evacuated Condition 1 Close valve V4 2 Open the gas ballast valve located on top of the pump housing behind the handle 3 Stop the vacuum pump 4 Mid seat the discharge valve 5 Connect the refrigerant tank with gauge manifold to the evacuation station see Evacuation Station and Unit Hookup in this chapter 6 Weigh the tank of refrigerant 7 Check the unit data plate for the required weight of refrigerant charge Subtract the amount of the charge to be input to your unit from the total weight of the tank of refrigerant This provides final tank weight after the unit receives a full system refrigerant charge 108 8 Set the refrigerant tank for liquid removal Open the hand valve on the tank 9 Turn the unit off 10 Open the gauge manifold hand valve and charge liquid refrigerant into the system 11 Close the refrigerant tank hand valve when the correct amount by weight of refrigerant has been added or if the system will take no more liquid The unit is now ready to have the evacuation station removed Evacuation Sta
17. e Evaporator fan motor operation Compressor digital valve e Vapor injection valve e Dehumidify valve e Electric heaters e Phase selection 37 Controller Description Tuesday 06 January 2009 14 10 21 rH AVL LoPrs HiPrs ill LE HEATING uM qr sreomr MENU BEN040 Standard Display Function Keys Special Function Keys Figure 16 MP 4000 Controller Display Panel 38 Standard Display The Standard Display is a 4 VGA graphical type display The temperature can be displayed in Celsius or Fahrenheit The standard display will display the controlling sensor and Setpoint The Setpoint will be the low reading with the C or F Once a key is pressed the Standard display will change to the Unit Status Display After 2 min of no key activity the display will return the Standard 0 0 0 0C Figure 17 Standard Display Unit Status Display Tuesday 06 January 2009 14 10 21 0 0 0 0 5 0 rH AvL LoPrs HiPrs add sis CHILLED HEATING Figure 18 Unit Status Display The Unit Status display will show Looking at the display from top to bottom Date and Time Alarm Warning rH Relative Humidity sensor e AVL Door Position e LoPrs Low Pressure Transducer e HiPrs High Pressure Transducer RA Return air sensor SA Supply air sensor SP Setpoint e Mode Icons Compressor ON Heater ON Evap Fan ON e Capacity Bar Graph Percentage of mode 10095 is full on
18. 5 0C 12 0C 15 0C 5 2A 5 1A 52A With condenser fan on amp draw is measured and compared to the expected amp draw in respect to voltage and frequency If the phase amp draw differs more than 1 0 Amp both alarm is set MAGNUM Expected Power Con sumption 1 2 Amps approx at 50 Hz 1 5 Amps approx at 60 Hz Amperes are recorded in PTI log Evaporator fans operate on high speed for maximum 3 minutes Then probe test runs until temperature difference between sensors stops increasing Maximum temperature difference allowed Return Evaporator 1 5C 34 7F return air sensor temperature must be 0 5C 32 9F above evaporator sensor temperature Return Supply 0 8C 33 0F return air sensor temperature must be 0 5C 32 9F above supply air temperature LH Supply RH Supply if equipped 0 5C 32 9F With condenser fan on reverse phase selector relay is energized Condenser fan and compressor reverse current is measured Electric heaters are turned on Amp draw is measured to the expected amp draw in respect to voltage and frequency 4 4 Amps approx at 400V 5 1 Amps approx at 460V Heater amperes are recorded in PTI log If evaporator temperature is below 10C heater remains on until evaporator temperature is above 18C Defrosting until Eva 18C 64F pili 115 116 1 minute 117 minimum to 13 minutes maximum 0 90 Minutes at voltage above 440V 0 120 Minutes at v
19. 94 2 Resistance Values for Compressor Discharge Sensors A Te F C F C L5 s 363886 221105 5091 Capo pene 400 a e 20 107440 265 130 2 279 BE 30 09282 284 140 20217 130 60 21397 s 170 1055 780 Lie 60 10788 wa 100 95 Refrigeration Maintenance Introduction The following procedures involve servicing the refrigeration system Some of these service procedures are regulated by Federal and in some cases by State and Local laws NOTE All regulated refrigeration service procedures must be performed by an EPA certified technician using approved equipment and complying with all Federal State and Local laws Use the Correct Tools CAUTION Use only those service tools certified for and dedicated to R 404A refrigerant and Polyol Ester based compressor oils i e vacuum pump refrigerant recovery equipment gauge hoses and gauge manifold set Residual non HFC refrigerants or non Ester based oils will contaminate HFC systems Use the Correct Vacuum Pump A two stage refer to Tool Catalog three stage or five stage pump is recommended for evacuation Purging the system with dry nitrogen is recommended before evacuation Because residual refrigerant may be present in used vacuum pumps a new vacuum pump should be used and dedicated strictly as an R 404a refrigerant pump Use only recommended vacuum pump oils and change oil after every major evacuation Because vacuum pump o
20. BEN 056 Figure 19 Function Keys FI ALARM key Press to view an explaination for the current alarms present e F2C F key Press to view alternate temperature scale Celsius or Fahrenheit in display F3 SETPOINT key Press to enter Setpoint menu Press F2 Up or F3 Down keys to increase or decrease the Setpoint Press and Hold F4 until you are returned back to the main menu F4 MENU key Press to view the extended Menu for the MP4000 Indicator LEDs Two status indicator LEDs are located just under the F1 F4 function keys Green Led Flashing Temperature approaching in range Solid Temperature In Range Red Led Flashing Alarm present and has not been acknowledged Solid Alarm present and has been acknowledged 40 Three Special Function Keys The Special Function keys are located around the TK Logo These special function key allow the operator to move quickly to perform a specific function Figure 20 Special Function Keys PTI Pre Trip Inspecion k Defrost E Unit On OFF Control Operating Instructions Function Keys Tuesday 06 January 2009 14 27 58 25 jx CHILLED HEATING N THERMO KINC ON OFF Key Tene o eese 7 remos CI spem Figure 21 Function Keys Unit On Off Key ON Unit will operate on Cool or Heat depending on the controller setpoint temperature and the container air temperature OFF The unit will not operate Sequence Of Ope
21. Corrective Actio Evaporator Coil Sensor Open Circuit When the sensor circuit resistance is higher than 100 000 ohms Indicates Open circuit to sensor Defective or wrong sensor Defective power module Defective controller Low evaporator coil temperature Evaporator Coil Sensor Short Circuit When the sensor circuit resistance is lower than 200 ohms Indicates Short circuit to sensor Defective or wrong sensor Defective power module Defective controller Compressor Current Too High e Occurs during pretrip PTI or function test only Compressor power consumption is 25 percent expected current draw above approximately 13 amps or compressor phase current level difference of 10 percent or more depending on ambient temperature Indicates Defective Digital Control valve Defective compressor Defective volt or amp meter on power module Inaccurate ambient condenser or evaporator temperature measurement Out of range power supply Excessive condenser pressure due to air or wrong refrigerant in system or refrigerant over charge Check sensor resistance must be approx 1 000 ohms at 25 C 77 F See Resistance Values for temperature sensors on page 94 Check for damaged sensor wires Check sensor connections at controller Check sensor resistance must be approx 1 000 ohms at 25 C 77 F See Resistance Values for temperature sensors on page 94 Check for damaged sensor wire
22. Keypad e FI F4 Function keys navigate within the Status Display 2Status LED indicators e Special Function keys ON OFF PTI Defrost Controller Back up Battery Every Controller has a Back up Battery This will allow the controller to be energized if the unit is not connected to shore power The technician can change settings in the controller Setpoint etc Press the ON OFF key the controller will energize and stay energized for 25 sec by pressing any of the Menu keys the 25 sec timer will reset to 20 sec Controller Input and Output Signals The MP 4000 microprocessor controls all unit functions to maintain the cargo at the proper temperature The controller also monitors and records system faults and performs pretrip The MP 4000 controller uses advanced solid state integrated circuits to monitor and control unit functions The controller monitors inputs from e Return Air Sensor Supply Air Sensor e Evaporator Coil Sensor e Condenser Coil Sensor Ambient Sensor Humidity Sensor e USDA Spare Sensors 1 2 and 3 Compressor Discharge Line Temperature Sensor High Pressure Cutout Switch Discharge Pressure Sensor Low Pressure Cutout Switch Suction Pressure Sensor e Phase measuring circuits Current measuring circuits e Voltage measuring circuits Output signals from the controller automatically regulate all unit functions including Compressor operation Condenser fan operation
23. 5 to 10 gal min Unit Description Features amp Options Evaporator Access Door Condenser Fan Scroll Compressor Compressor Compartment Control Box Access from Inside Container c A o s o D o na lt x Q N D v c G v 2 c z Q G o na z 2 gt a c o LL c 2 g D LL 31 Unit Description Features amp Options 32 AXA0238 Bottom Rear Plate USDA3 Spare 3 Sensor Connection Cargo Pulp Sensor Connection USDA Receptacle Panel Controller Communications and Data Download Port USDA1 Spare 1 Sensor Connection USDA2 Spare 2 Sensor Connection Figure 13 Unit Back View Unit Description Features amp Options AJA1986 1 Expansion Valve all Valve Evaporator Coil B Digital Control Valve Low Pressure Cutout Switch Condenser Coil 1 Water Cooled Condenser Tank Vapor Injection Solenoid Valve Scroll Compressor Dehydrator Figure 14 Refrigeration System EN Expansion Valve Economize 10 0 Economizer Heat Exchanger 33 Unit Description Features amp Options 34 Thermostat Defrost Termination 5 prosm 120 Compressor cai 5 om SensorHamess Dg S CondenserFan Hamess _ 23 Humaiysonser IS E Figure 15 Electrical Components Unit Description Features amp Options 35 Unit Description Features amp Options Metric Ha
24. Cool mode whenever Return air temperature increases more than 0 2 C 0 36 F above setpoint 77 Operating Theory Return air temperature is above setpoint and the compressor has been off for 30 minutes Controller turns on the Compressor indicator when the compressor is operating Compressor must operate for a minimum of 5 minutes after startup e After initial pull down to setpoint controller keeps the In range LED on as long as the return air temperature remains less than 1 5 C 2 7 F above setpoint Null The controller calls for Null when the return air temperature decreases more than 2 0 C 3 6 F below setpoint The controller stops the compressor and condenser fan and evaporator fan Defrost The evaporator coil sensor temperature must be below 18 C 65 F to initiate a Demand Defrost or Manual Defrost The evaporator coil sensor temperature must be below 4 C 39 F to initiate a Timed Defrost Demand Defrost function initiates Defrost immediately when Temperature difference between the return air sensor and defrost evaporator coil sensor is too large e Temperature difference between the supply sensors and return air sensor is too large Manual Defrost may be initiated immediately by pressing the DEFROST key or by REFCON Remote Monitoring Modem RMM A Timed Defrost always starts at 1 minute past the hour immediately following a defrost timer request for defrost For ex
25. E TI T E I Lagi cu A DRE AAA i wesen BLK lt 3 o ncm AA qe es LATUS eee notes EUR e Wer pee pcs REDE S jo WIES 2 AMP RIAC oo 0 a c O po ARI l nae ae Jog seo LLL E Hj K LLS Lis Cri momo la IM 4 aS aS ZU LTONDON ees aT 5 a 2 EHZw o HAS 2 3 ara mm aon j oo am ul m ane a WE ce doc ar haa ret s7ss ESA n m 2 Fa gt gt 2 2 RETRIEVER PLUG RETRIEVER PLUG DU Qu Of OM RZ L 4 LI A eS 5 gt m 3 br EN Te A eat ne ales B z IS ISS E a IA et 7 L3 gt x 2 D 5 x 8 2 E A a l N zal mt de LI m Rb ae et bbs es panos dL es s Wee eed mn a EE E DE Ee de ds kL le de Ee gt ol gt ful S E a 5 eo 6 e px He a gt state T le L3 1 e m T a e gl ii l i EARTH 4 No Sell T IPS RO T zu 3 RE i 3 EEE kl ee e Ie ie ic ic c DO z 32352 l vn o 3 ejJOl vi i vo N l I 2 8 EAT RS T 3 2 222 eg m og aso gt o m q Mm oc ES bs tes S H EU mae ooo I o a 4 z 2 la ISESI AS 4 a 2 o6 PN oo I 3l INGERSOLL RAND IS THENISQSE OVERY QFE TSPIEX F ED CAD GENERATED DRAWING A Em d DRAWING AND ALL NHORMACNONONS ARE MH IOE HERE DO NOT MANUALLY UPDATE Ingersoll Rand ZN gt gt lt F SE PROTECTED BY COPYR GHIT ERER OTHER LANS TAND MER Th Ki Q m gt no q BE SUBJECT TO LAWS RESMER DING SPORTING SER mor ermo Ring 2 m e gt gt 83 INFORMATION OUTSIDE OF THE U S THIS DRA
26. EF2 EF2 and EF3 and EF1 and EF3 Resistance readings should be equal High speed about 6 Ohms total of 2 motors Low speed about 20 Ohms total of 2 motors Evaporator Fan High Speed Current Too Low Occurs during pretrip PTI function test or probe test When the evaporator fan power consumption is 25 percent below expected current draw below 1 6 to 2 4 amps depending on voltage ndicates Defective or open fan motor internal over temperature protection switch Defective volt or amp meter on power module Incorrect motor or motor connections Evaporator Fan Low Speed Current Too High e Occurs during pretrip PTI or function test only Evaporator fan power consumption is 25 percent above expected current draw above 1 0 to 2 0 amps depending on voltage Indicates Defective or stuck evaporator fan motor Incorrect motor or motor connections Motor high and low speed connection are interchanged Defective volt or amp meter on power module 136 Open evaporator door and make sure all fans rotate freely Enter Manual Function Test and start evaporator fans on high speed Make sure all fans start on high speed If a motor does not start and is very hot wait 10 minutes for internal over temperature switch to close Check fan motor volts and amps Check volt and ampere meter Open evaporator door and make sure all fans rotate freely Enter Manual Function Test and start evaporator fa
27. EVAPORATOR MOTORS CONDENSER MOTOR AND SATA 9 Do COP Hoo qe D SHO Qum COMPRESSOR MOTOR ARE PROTECTED BY AN 2OAUP 20AMP 20ANP ara INTERNAL KLIXON WHICH CAN DISCONNECT z pop to THE POWER TO THE MOTOR AT HIGH eng Sat N TEMPERATURE ON THE MOTOR EXPANS ON EXPANS ON en zs Sat Q GRN GRN YEL MODULE MODULE 2 le ee A Omega La HEATER HARNESS 2 P 8 P TRANSFRESH OPTION zole Her C AF AM OPT ON SE Y I GRN GRN YEL an mn un PM 4000 Be ei Ye EVAP H l pa m BLE E Ree Are AO PONE amp smom re sr SENSOR BOX 57S EES SMR TEL SESS FI2 pS l 3 8 EFI L EA 2 L To ES GRN GRN YEL COH T RS 232 INTERFACE ESF FB EVAP MOTOR sa EF2 PM 4000 GND re o2 TEST_INDICATOR_PIN 8 EFI EVAP HARNESS B T TE El ie DEFROST POWER COMMUNICATION B BUF PM SOTO 681 3 3V Ss FROM TRANSFRESH BUF _PSEN 96 ol 0 6GND ISO als CF3 N J3 i Jl2 i 7 528 cre ANALOG 3 TERM POWER INLET S o CFI SG SAS AANA B 78 554 el ul re S SEI Re E Ill ES 1 ED Jl ANALOG 2 J9 DIGITAL Ce 6754 732 1 8 5 43 21 AA SEINE O 2 ee er DATA USDA 1 2 3 COMP Ll LEBER UT CHART RECORDER AIR VENT LOGGIN Z COMPRESSOR E i CAE LEE Te WIRES A y SEF F fae TRT di COND A ANALOG y33 53 531 yoaf 15 31 32 97531 WIRES 8 41 2625 Aa 1l COM la 6 4 2 COM Ib 6 4 2 COM 2 8 6 4 2 COM Sf OF 858542 RETRIEVER PLUG LLELE E TTE inum si Te A RK USER DCV VIV BLK RETURN AMBT 525235353 ze E 2322 2552 GND HPS LPS D
28. Examples Controller alarm status alarms set cleared Main power On Off status humidity On Off temperature setpoint and main power Hz e 12 Vdc battery discharge test battery voltage total unit and compressor hours if main power on this event logged at once a day Change temperature setpoint new old setpoint Change RH setpoint new old RH setpoint Main Menu Change RH status On Off e Event log retrieval Temperature log retrieval e Trip start New container ID e PTI start Unit configuration e PTI part 1 end Temperature differences for tests 1 2 3 and heat test e PTI end e Defrost start logged with demand or manual defrost only Defrost end start time 6 Press the F1 key to exit the log Calibrate Probe Optional Setting the USDA Type in the Configuration menu activates spare sensors 1 2 3 and 4 for USDA Cold Treatment Temperature Recording USDA sensor temperatures are recorded in the datalogger memory The USDA sensors should be connected to the controller and located in the load as shown in USDA directives When a USDA sensor is installed the controller will automatically detect each sensor and activate data logging However the USDA Type screen in the Configuration menu must be set to the correct sensor setting and each USDA sensor must be calibrated to comply with USDA temperature recording requirements Calibrate the sensors in an ice bath MAGNUM units equip
29. Frozen Loads Setpoints at 9 9 C Setpoints at 10 C 14 4 F and Above 14 F and Below caer wild Heat Defrost Goo Null Defrost UsitFuncton S HE CETT A Sp a rtr Fans tow Speed I peser Fans OF A ce AE A vires 1 Proportional integral Derivative Supply Air Control Return Air Sensor Control Chill Loads fe lee Far A a RU neon TI EH pine e APR 1 p EEE E REA ee A ETE er el ee ee TEE AAA pnl ee ee en zen 00 A lisse all CREE RR Lm Digital Control Valve Modulating energized 4 pectoeupe e EE PS Eset Restore RUE oron energized 1Setpoint temperature and controlling mode setting determine the evaporator fan speed Normal Operation Chill Loads High or low speed fans Frozen Loads Low speed fans or 3Condenser fan pulses on and off on a 30 second duty cycle to maintain a minimum condenser temperature Chill Loads Controller maintains a minimum 30 no fans C 86 F condenser temperature Frozen Loads Controller maintains a minimum 20 C 68 F condenser temperature 2Vapor injection valve Chill Frozen or Power Limit Mode When the cool capacity is 100 percent Digital Control valve modulates Chill Loads whenever the unit is in a Cooling mode Power Limit whenever the unit is in Power Limit mode Compressor High Temperature Protection When the compressor discharge temperature exceeds 138 C 280 F Dehumidificat
30. PRESSURE CUTOUT CHECK CONDENSER PROBE Water pressure switch is open and the condenser temperature is low HIGH PRESSURE CUTOUT CHECK CONDENSER FAN Water pressure switch is open and the condenser temperature is high HIGH PRESSURE CUTOUT CHECK WATER COOLING Water pressure switch is closed eS Low Pressure Cutout Switch High Pressure Cutout Switch Figure 43 Low and High Pressure Cutout Switches e The controller continues to call for cooling so the compressor will restart when the overload condition is corrected switch resets if power is available e Ifthe switch remains open for 5 minutes the controller also turns on the Alarm indicator and records Alarm 37 Total Power Consumption Too Low 83 Electrical Maintenance High Pressure Cutout Switch Opens 3243 7 kPa 32 43 0 48 bar 470 7 psig e Closes 2586kPa 25 9 bar 375 psig To test the switch rework a gauge manifold per High Pressure Cutout Manifold illustration 84 High Pressure Cutout Manifold 1 Connect the manifold gauge to the compressor discharge service valve with a heavy duty black jacketed thick wall HCA 144 hose with 6024 kPa 60 24 bar 900 psig working pressure rating Operate the unit in Cool by performing a Capacity 100 percent test from the Manual Function Test menu of the controller Relief Valve Adapter Tee Weather Head Figure 44 High Pressure Cutout Manifold 3 Raise the disc
31. Pressurize the refrigeration system and check for leaks see Refrigerant Leak Test Procedure in this chapter Repair leaks if required 10 Refrigeration Maintenance Recover the refrigerant used for the leak test if no leaks were found Evacuate the system see Evacuation and Cleanup of the Refrigeration System in this chapter Recharge the unit with R 404A see Charging the System with Refrigerant in this chapter Perform a controller pretrip test to verify system operation AFA23 l G Figure 70 Filter Drier 111 Refrigeration Maintenance Evaporator Expansion Valve TXV Replacement NOTE TXV can be accessed through the evaporator access door 1 Perform a low side pump down or reclaim charge depending on the unit Release the 2 3 lbs pressure from the low side Open the evaporator access panel Install plywood or heavy cardboard on top of coil on the left and right side This will protect the coil from damage Remove the left side motor and fan and position in right side opening Do not unwire the motor the harness is long enough Remove TXV standoff mount Remove the panel to gain access to the TXV element 112 ppm oo 1 Tube on Suction Line Figure 71 TXV Valve and Element Location 10 11 12 13 14 15 16 17 Cut the one ty band off the insulation around the element Peel back the insulation to expose the clamp holding t
32. Unit Width 1894 mm 74 57 in D Flange Height 2235 2 mm 88 00 in E Gasket Height 2140 mm 84 25 in F Unit Height 2094 mm 82 44 in G Gasket Depth 72 mm 2 83 in from back of flange H Maximum Protrusion 37 mm 1 46 in from back of flange MAGNUM 420 0 mm 16 54 in from back of flange J MANGUM Evaporator Access Door Figure 1 Physical Specifications 24 Unit Description Features amp Options Unit Description Features amp Options Introduction This chapter will briefly describe the following items General Unit Description e Standard Component Descriptions Optional Component Descriptions General Description MAGNUM units are all electric single piece refrigeration units with bottom air supply The unit is designed to cool and heat containers for shipboard or overland transit The unit mounts in the front wall of the container Fork lift pockets are provided for installation and removal of the unit The frame and bulkhead panels are constructed of aluminum and are treated to resist corrosion A removable evaporator compartment door provides service access All components except the evaporator coil and electric heaters can be replaced from the front of the unit Each unit is equipped with an 18 3 m 60 ft power cable for operation on 460 380V 3 Ph 60 50 Hz power The unit power cable is stored below the control box in the condenser section
33. Valve DSV Suction Service Valve SSV Figure 57 Balancing the Pressure AXA0242 Quick Disconnect Access Valve Discharge Service Valve DSV Suction Service Valve SSV Reclaimer 5 fr epi SC Figure 58 Removing Refrigerant AXA0181 Close Hand Valves Figure 59 Gauge Manifold Closed to Center Port AXA0182 Open Hand Valves Figure 60 Gauge Manifold Open to Center Port Refrigeration Maintenance AXA0243 Quick Disconnect Access Valve Discharge Service Valve DSV Suction Service Valve SSV Figure 61 Charging the System Gauge Manifold Set Installation amp Removal Thermo King recommends the use of access valves or self sealing quick disconnect fittings This limits the loss of refrigerant into the atmosphere A separate gauge manifold set with low loss fittings refer to Tool Catalog should be dedicated for use with R 404A only Gauge hoses should also be dedicated to R 404A NOTE Carefully check to ensure that access connections are functioning properly when any of these devices are used Gauge Manifold Set Installation The following procedure purges the gauge hoses The procedure must be followed when using new gauges or hoses for the first time The system should be operating on Cool 10 psig 69 kPa or greater suction pressure when using this procedure to purge the low side hose Gauge hoses may be removed and re installed without additional purging so long as a
34. and surveillance to start up All alarms are turned off Alarm list is cleared All relays are turned off and air vent are closed Testing sensor interface All 00 01 02 Instant sensors must have values within 03 04 05 their measuring range 32 33 34 35 60 97 98 120 121 123 With evaporator fan on low 14 15 5 seconds X X X speed amp draw is measured and compared to the expected amp draw in respect to voltage and frequency MAGNUM MAGNUM 40 SL 1 0 Amps approx at 50 Hz 1 0 Amps approx at 60 Hz MAGNUM 20 SL 1 5 Amps approx at 50 Hz 1 5 Amps approx at 60 Hz Amperes are recorded in the PTI log With evaporator fan on high 12 13 5 seconds X X X speed amp draw is measured and compared to the expected amp draw in respect to voltage and frequency If the minimum phase amp draw is less than 70 of the maximal amp draw both alarm is set MAGNUM MAGNUM 40 SL 2 1 Amps approx at 50 Hz 2 5 Amps approx at 60 Hz MAGNUM 20 SL 2 7 Amps approx at 50 Hz 3 2 Amps approx at 60 Hz Amperes are recorded in PTI log Main Menu Display Description Possible Duration PTI Brief Function Alarms Time PTI Test COND FAN TEST SUP RET EVA 5 2C 5 0C 5 1C 1 3A 1 2A 1 3A PROBE TEST SUP RET EVA 5 1C 5 0C 5 1C 24A 2 3A 2 4A REVERSE PHASE TEST SUP RET EVA 1 3C 1 0C 1 3C 1 3A 1 2A 1 3A HEATER TEST SUP RET EVA 1 3C 1 0C 1 3C 5 2A 5 1A 5 2A DEFROST TEST SUP RET EVA
35. arar Rae da ae RE Sd Roses Rub al RI RE duque 100 Safety Precautions errant e T oE La ek ee me or non SR PER e ds 101 Purge High Side to Low Side 0 0 00 cee eee hh hr 102 Maximum Gas Pressures osi ai enta e e e nee hs 102 Recovering Refrigerant from the System 0 104 Evacuation and Cleanup of the Refrigeration System 00 eect eee 104 Unit Preparation and Hookup o 105 Unit Evacuation 41r Ge a ha eee a ee Re ee A a 106 Pressure Rise Test cenis da maaa a RU ana dies eh Ales nn oe a Rar ter do 3 R BO Bad aa 107 Factors Affecting the Speed of System Evacuation saaana 107 Heat Saves MMM ae el daa dette en hace Ve tak ee koe 108 Charging the System with Refrigerant 0 0 0 ccc eee 108 Unit Charging by weight from an Evacuated Condition 0 000 ee 108 Table of Contents Compressor Replacement 109 Compressor Removal iaa fart die dee eased anda wale ie A gg eas et aa sn 109 Compressor Installation 00000 eee eee 109 Condenser Coil Replacement 110 Filter Drier In line Filter Replacement 111 Evaporator Expansion Valve TXV Replacement 112 Economizer Expansion Valve Replacement 113 Economizer Heat Exchanger Replacement o oooccccoccc eee eee 113 Economizer Heat Exchanger Removal oooccoccocc eee ren 113 Economizer Heat Exchanger installation 0 0 0 e 113 Receiver Tank Water Cooled Condenser Tank Replacement 0000 0c eee
36. component performance Display will show expected current and actual current on phase 1 2 and 3 Press the F4 ENTER KEY again to stop test Display will change component state from on to off System Test test multiple components at the same time 1 Press the F2 oR F3 UP DOWN key to scroll to the first component 2 Press the F4 ENTER KEY to turn the component on 3 Press the F3 key to scroll to select next component Press theF4 ENTER KEY to turn component on 4 Repeat step 3 until all required components are on For example to operate unit in Full Cool mode start the following components Condenser Fan Compressor e Capacity 100 percent e Evaporator High or Low Main Menu 5 Observe current draw and system performance to verify component s performance 6 Press the F4 ENTER KEY again to turn off components individually Or press the F1 key to exit Manual Function Test menu and turn all components off Press the F1 key to exit the Manual Function Test submenu 53 Main Menu Figure 30 PTI Brief PTI Function Tests Display Description Possible Duration Brief Function Alarms Time PTI Test 54 PTI START Activated 0 1A 0 0A 0 1A SENSOR TEST Activated 0 1A 0 0A 0 1A EVAP FAN LOW SPEED TEST SUP RET EVA 5 1C 5 0C 5 1C 1 4A 1 0A 1 1A EVAP FAN HIGH SPEED TEST SUP RET EVA 5 1C 5 0C 5 1C 24A 2 3A 2 4A 1 to 100 seconds Event Log for PTI begins Awaits phase selection
37. compressor start up No alarm is set until Controller determines that unit current draw is too low or supply air temperature is too high Controller automatically activates probe test to check for a defective sensor Message clears when test is complete Controller displays new message if test indicates a sensor is defective Controller clears message on compressor start up No alarm is set until Controller determines that unit current draw is too low or supply air temperature is too high Controller clears message on compressor start up No alarm is set until Controller determines that unit current draw is too low or supply air temperature is too high Controller clears message after compressor start up Diagnosis Troubleshooting Warnings and Alarm Codes Warnings and Controller Actions Continued Scroll Compressor Low Pressure Indicates Low pressure cutout switch is open Possible causes include low refrigerant charge defective low pressure cutout switch or open circuit block TXV or suction line restriction etc Total Current Too High When the unit or component current draw is 25 percent above expected amps for 4 minutes ndicates Digital Control valve malfunction Compressor evaporator fan motor condenser fan motor or heater current too high Defective volt or amp meter on power module Power supply voltage too low Total Current Too Low Compressor Start up Unit or compon
38. controller turns on the Defrost indicator Heat indicator and energizes the solid state turning on the electric heaters The controller terminates the Defrost mode when Evaporator temperature Chill mode Evaporator coil sensor temperature reaches 18 C 65 F e Frozen mode Evaporator coil sensor temperature reaches 18 C 65 F Interval timer Controller terminates defrost after 90 minutes on 60 Hz power 120 on 50 Hz power Alarm Code 20 will be generated if this occurs e Power off Turning UNIT ON OFF switch OFF terminates defrost When the defrost mode is terminated The Heat and Defrost indicators turn off and the solid state is de energized The controller starts the compressor to pre cool the evaporator coil The condenser fan starts if required The controller pre cools the evaporator coil to the supply air temperature or for 3 minutes maximum to minimize heat energy release into the container The controller then starts the evaporator fans Compressor Digital Control Valve The MP 4000 controller pulses the Compressor Digital Control solenoid valve between open and closed positions This provides precise cooling capacity control No pump down function or warm gas bypass control is used in conjunction with the Compressor Digital Control valve AXA0428 Figure 40 Compressor Digital Control Solenoid Valve The Compressor Digital Control valve is normally closed The normally closed positio
39. economizer expansion valve by performing the following steps 2 Clean the inlet and outlet lines for soldering 3 Place new economizer expansion valve in position k AJA1960 Economizer Heat Exchanger Economizer Expansion Valve Vapor Injection Line Feeler Bulb Line Figure 72 Economizer Expansion Valve and Heat Exchanger 4 Solder inlet and outlet line connections to economizer expansion valve Refrigeration Maintenance NOTE Thermo King strongly recommends that dry nitrogen be used to purge the system during any solder operations see Using Pressurized Nitrogen in this chapter 5 Pressurize the refrigeration system and check for leaks see Refrigerant Leak Test Procedure in this chapter 6 Ifno leaks are found recover the refrigerant used for the leak test see Recovering Refrigerant from the System on page 104 7 Evacuate the system see Evacuation and Cleanup of the Refrigeration System in this chapter 8 Locate feeler bulb in former position The feeler bulb must make good contact or operation will be faulty Cover with insulating tape 9 Recharge the unit with R 404A see Charging the System with Refrigerant in this chapter 10 Perform a controller pretrip test to verify system operation and correct feeler bulb installation Economizer Heat Exchanger Replacement Economizer Heat Exchanger Removal Remove the economizer heat exchanger by perf
40. ee duet ed baies dated o Bob dure dyson Dri 92 Installing Temperature Sensors 0 0 00 nennen 92 Testing the Sensors a eae oe diag Cowie dia PCa SER am fens a ea nd RN BUM 93 Resistance Values for Temperature Sensors liliis 94 Refrigeration Maintenance oooocoooorr hh hh mh mnm ehh hn 95 Introdtctlon gt UE TA S e eats tei Led ets tes 95 Use the Correct Tools s isi rr 2 22 Rey ege re e bend oak a ed RU a d Pe d 95 Use the Correct Vacuum PUMP 95 Use Filters and Cartridges ccoo oooooccoorccorn o en eh rh hh hes 95 Use the Correct Refrigerant Recovery Equipment 00 nennen 95 Detecting Leaks 422 ert De A esed eM eed dod dodo de Pg cerdo dod ded ee RO eg 95 Locating Special Serice FINOS ru senate Re epe RI Gk qa Puedes a uo d 95 Perform an Oil Acid Test u en re ead y er hone En does 96 Isolate the Compressor 96 Working with a Gauge Manifold 0 0c m m ems 96 Using a New Gauge Manifold Set 0 0 00 ee hh 96 Gauge Manifold Valve Positions liliis m me ms 96 Gauge Manifold Set Installation amp Removal ooooccccoccoo nh 97 Gauge Manifold Set Installation iili RH eh 97 Removing the Gauge Manifold Set 0 ce rn 98 Checking Refrigerant Charge o ooooccoo eh rrr 99 Receiver Tank Sight Glass ooooomcccoraarr ee hh ee ee heh nhe 99 Leak Testing the Refrigeration System 0 00 ete en 100 Using Pressurized Nitrogen sica
41. eee nennen 114 Tank Removal i254 m edt tel rede duse eed a al a a edle v g 114 Tank Installation u 242 222 220 22 eee Rawal E UP BERGER ERATES LA UR 114 Vapor Injection Valve Replacement liliis rr 115 Compressor Digital Control Valve Replacement 116 Servicing The Unit Erer a ta eae eee SE ee ea ee BE a ee ee es 119 Taking Care of the Structure rysem cen nen 119 Inspecting the Unit osc rc sou do ee rre pee 119 Checking the Mounting Bolts cre serere aotree rer EAA eee 119 Cleaning the Condenser Coil 00 ccc eee hh hr nenn 119 Cleaning the Evaporator Coil 0 0 ce eee eae 119 Cleaning the Defrost Drains 00 cee hh hh hh 119 Positioning the Condenser Fan Blade 0 0 cc n 120 Positioning the Evaporator Fan Blade 0 0 n 120 Servicing the Fresh Air System 0 0 0 0c eae 120 Adjusting the Fresh Air Exchange System 0 0 0 0 120 Diagnosis Troubleshooting Warnings and Alarm Codes 00 0 cece eee eee eee eee 123 Introd ctloni 22 oae IA AA ann ridet n a a eed eo a 123 Controller Diagnostics i wei A HL as ER RM 123 Warnings and Controller Actions 0 0 0 0 00 hs 130 Wiring and Schematic Diagrams Index 00 cee eee hn 145 CONTROLLER MENU GUIDE 1 en eet 152 List Of Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Physical Specificati ns 4 24 509 aug e Brida a SE SR ale en
42. is still live and represents 11 Safety Instructions a potential danger of electrocution Where turning of the unit is not possible for example at voltage measuring or troubleshoot ing follow safety precautions below Turn the unit On Off switch to Off before connecting or disconnecting the unit power plug Never attempt to stop the unit by disconnecting the power plug Becertain the unit power plug is clean and dry before connecting it to a power source Use tools with insulated handles Use tools that are in good condition Never hold metal tools in your hand if exposed energized conductors are within reach Do not make any rapid moves when working with high voltage circuits Do not grab a falling tool or other object People do not contact high voltage wires on purpose It occurs from an unplanned movement e Treat all wires and connections as high voltage until ammeter and wiring diagram show otherwise e Never work alone on high voltage circuits on the refrigeration unit Another person should always be standing by in the event of an accident to shut off the refrigeration unit and to aid a victim Have electrically insulated gloves cable cutters and safety glasses available in the immediate vicinity in the event of an accident First Aid IMMEDIATE action must be initiated after a person has received an electrical shock Obtain immediate medical assistance The source of shock must be immedia
43. releasing the unit for service 81 Controller Maintenance 82 Electrical Maintenance Unit Protection Devices Introduction The unit has numerous protection devices They are described in detail on the following pages Main Circuit Breaker The main power circuit breaker is located in the control box The 25 ampere manual reset circuit breaker is located in the Control Box It protects the 460 380V power supply circuit to the unit electric motors and control system transformer AXA0342 t Main Circuit Breaker Figure 42 Main Circuit Breaker Evaporator Overheat Protection The Heater are protected from overheating surveillance from the supply return and evaporator sensor If one or more reaches 50 C it will automatically terminate the heaters High Pressure Cutout Switch A high pressure cutout switch is located on the compressor discharge service manifold of the compressor If the discharge pressure becomes too high the switch opens the ground circuit to the compressor contactor coil Compressor stops immediately Evaporator and condenser fans continue normal operation Controller determines that a high pressure cutout switch or compressor motor internal overload protector is open when the unit current draw during compressor operation is normal and then decreases by 7 amps for more than 3 seconds e After 1 minute controller VGA display shows a High Pressure Cutout message HIGH
44. section displays actual readings and the expected power consumption 49 Main Menu PTI Pretrip Test CAUTION The Full PTI test should only be performed on an empty container NOTE Units equipped with a water cooled condenser must be set to operate on air cooled condensing to perform a complete system capacity test The MP 4000 controller contains a special Full PTI pretrip test that automatically checks unit refrigeration capacity heating capacity temperature control and individual components including the controller display contactors fans protection devices and sensors The test includes measurement of component power consumption and compares test results to expected values The test takes up to 2 to 2 5 hours to complete depending on the container and ambient temperature NOTE Correct all existing alarm conditions and clear the alarm codes before performing a Full PTI test The controller will automatically clear all existing alarms before beginning the Full PTI test With the UNIT TURNED ON Allow Unit to start and stabilise and the Display showing the unit status display setpoint 1 Press the F4 MENu key Press the F3 key to scroll down to the Commands Menu 2 Press the F4 ENTER KEY to access the Commands menu 3 Press the F2 oR F3 Up Down key to scroll to PTI 4 Press the F4 ENTER KEY to start the PTI test Display shows PTI test currently being performed PTI test ends automatically P
45. the valve fully clockwise c Turn the digital service valve one quarter turn to the right 2 Turn the Unit On Off switch Off 3 Disconnect electrical connections to valve coil 4 Unsolder the liquid line connections to the valve 5 Remove the valve from the unit Digital Control Valve Installation To install the compressor digital control valve perform the following steps 1 Clean the tubes for soldering 2 Place the new valve in position and solder the liquid line connections A CAUTION Use a heat sink or wrap the switch with wet rags to prevent damage to the new switch 3 Perform a leak test see Leak Testing the Refrigeration Repair leak 1f required 4 Check the refrigerant charge see Checking the Refrigerant Charge 5 Reconnect the electrical wires to the valve 6 Perform a controller pretrip test to verify system operation Refrigeration Maintenance Figure 76 Digital Control Valve 117 Refrigeration Maintenance 118 Servicing The Unit Taking Care of the Structure Inspecting the Unit Inspect the unit during unit pretrip inspection and every 1 000 operating hours for loose or broken wires or hardware compressor oil leaks or other physical damage which can affect unit performance and require repair or replacement of parts Checking the Mounting Bolts Check and tighten all unit compressor and fan motor mounting bolts during pretrip inspections and every 1 000 o
46. to the main suction port It also prevents the economizer gas pressure from influencing the cooling capacity of the unit evaporator main suction gas pressure Li Figure 3 Scroll Compressor 26 MP 4000 Controller The MP 4000 is an advanced microprocessor controller that has been specially developed for the control and monitoring of refrigeration units See Controller Description and Operating Chapter for more detailed information 1 BEN074 1 MP 4000 Controller Figure 4 MP 4000 Controller Compressor Digital Control Valve The MP 4000 controller pulses the Compressor Digital Control solenoid valve between open and closed positions This provides precise cooling capacity control No pump down function or warm gas bypass control is used in conjunction with the Compressor Digital Control valve See the General Theory of Operation Chapter for more detailed information AXA0428 Figure 5 Compressor Digital Control Solenoid Valve Economizer Heat Exchange System An economizer heat exchange system replaces the conventional heat exchanger The economizer Heat Exchange system subcools the liquid refrigerant before it reaches the evaporator expansion valve Subcooling liquid refrigerant increases the cooling efficiency and capacity of the evaporator See the General Theory of Operation Chapter for more detailed information
47. vacuum is improved Refrigeration Maintenance Connect the evacuation station and refrigerant tank with gauge manifold optional to the unit as indicated in figure Figure 66 on page 103 Connect evacuation hoses to the compressor suction and discharge service fittings Open Evacuation Station valves V1 V3 and V4 It is only necessary to open valve V2 when a reading on the micron meter is desired This is especially true when starting to evacuate a unit and large amounts of moisture and oil will be passing by the sensor Open the vacuum pump Iso Valve built into the pump housing below the handle It is recommended that the valve be kept open at all times If connecting a refrigerant tank and gauge manifold to the evacuation station close the gauge manifold and refrigerant tank valves to prevent refrigerant from being drawn from the tank 105 Refrigeration Maintenance Unit Evacuation 1 Turn on the vacuum pump Open the gas ballast valve located on top of the pump housing behind the handle the valve is fully open at two turns counterclockwise Evacuate the system to 500 microns to achieve a final equilibrium pressure of 2000 microns or less The final equilibrium pressure is determined with the Thermo King Evacuation Station using the following procedure called a pressure rise test a Evacuate the system using the evacuation station until the vacuum level reaches 1000 microns Then close the gas ballast va
48. voltage percent of compressor motor rating Reduce line voltage to at least 110 Excessive line voltage percent of compressor motor rating Short EIC NENNEN RE Eliminate cause of short Eliminate cause of short cycling METUENTES emm Purge system cycling on high pressure cutout Check condenser airflow condenser fan motor condenser fan Inefficient condenser operation grille condenser fan pressure causing cycling on high pressure switch water pressure switch cutout option water flow rate option and water cooled condenser receiver tank option Loose mounting bolts Tighten mounting bolts Perform controller pretrip test to Oil slugging or refrigerant flooding check refrigerant charge Check back expansion valve adjustment Check compressor for compressor oil Scroll rotating backwards Check Pase curTec aon system and check unit wiring Defective compressor Repair or replace compressor check indicator If unit is in Heat or Unit in Heat or Defrost Defrost unit operation is normal no remedy required check indicator condenser temperature and discharge pressure Condenser temperature Unit in Cool with Low condenser may not require condenser fan temperature operation no remedy required condenser fan also pulses on and off on a 30 second cycle to control condenser temperature If unit is on water cooled condenser operation unit operation is normal Otherwise water pressure switch must be Open for air cooled con
49. 0 temp 18 0C 10 0C 10 0C PTI End are recorded in PTI log and a Trip Start is automatically activated Unit will remain OFF until any key is pressed PTI PASS PRESS Return KEY temp If alarms occurred during PTI Display shows PTI FAIL PRESS KEY Readings may vary depending on voltage and temperature 120 minutes maximum 30 minutes 90 minutes maximum 180 minutes maximum 1 2 3 EM 4 DATA Commands Menu SETPOINT PTI gt Brief PTI COMMAND lt q Functions Test ALARM LIST Manual Functions Test Defrost WARNING LIST Trip Start CONFIGURATION DATALOGGER STATES Figure 31 Commands Menu Defrost With the unit turned on allow unit to start and stabilise and the Display showing the unit status display 1 Press the F4 MENU key Press the F3 key to scroll down to the Commands Menu 2 Press the F4 ENTER KEY to expand this menu 3 Press the F2 or F3 Up Down key to scroll through submenu until Defrost appears in display 4 Press the F4 ENTER KEY to enter DEFROST function Ifthe unit operating conditions allow a manual defrost e g evaporator coil temperature is less than 18 C 56 F the unit enters Defrost The defrost cycle automatically terminates and returns the unit to normal operation Trip Start Main Menu With the UNIT TURNED ON Allow Unit to start and stabilise and the Display showing the unit status display Pres
50. 000 ohms at 25 C 77 F Check for damaged sensor wires Sensor circuit resistance lower than 200 ohms ndicates Short circuit to sensor Check sensor connections at controller Defective or wrong sensor Defective power module Defective controller 119 Digital Control Valve Error Check Digital Valve function Current consumption not correct for valve position 20 Suction Pressure Sensor Check wiring to be correct and connected Indicate a problem exists with this sensor or its Check J1 plug is plugged into MRB wiring The sensor is reading out of the range or Check voltage at J1 pin7 to be 0 5 4 5 volts appears to be open or shorted i f PTI Test e Reading did not decease by 0 15 bar 2 175 psi between compressor on and off Discharge Pressure Sensor Check wiring at J1 to be correct and Indicate a problem exists with this sensor or its connected wiring The sensor is reading out of the range or Check J1plug is plugged into MRB appears to be open or shorted Check voltage at J1 pin4 to be 0 5 4 5 volts PTI Test Reading did not increase by 0 15 bar 2 175 psi between compressor on and off CO2 Sensor Calibration Error e Occurs during pretrip PTI test only Sensor reading is less 17 or gt 2596 Controller Battery Error Check battery and connections Controller detects the battery is not able to recharge e fno physical problem is observed replace battery
51. C With the unit running frozen TESI approaching 18 degC OF Probe readings and time are recorded in the pti log when started and when ended When return air temperature is at 18 degC OF the test is ended If the test is not ended within the time limit the alarm is set Approaching 18C 0F PTI END PTI End are recorded in PTI log 26 Max 90 X X and a Trip Start is seconds automatically activated All alarms are cleared and must be acknowledged by the user Unit awaits an ACCEPT of the just ended test before returning to normal operation PASSED PASSED PASSED FAILED FAILED FAILED Display LED Description Possible Duration Display Alarms Time 59 60 Main Menu Unit operates in normal mode with 0C 32F setpoint for 30 minutes after previous test is completed At the end of RUNNING PTI 30 minutes Chill End temperatures are 0 C 32 F Supply recorded in PTI log Sensor values for 00 00 00 temp supply LH supply RH return and EA evaporator sensors are recorded in the 0 0C 10 0C 10 0C event log RUNNING PTI Unit operates in normal mode with 18C OF setpoint and defrost activated Defrost DEEROST Retum terminates when evaporator temperature 00 00 00 temp increases to 18C 65F 18 0C 10 0C 10 0C Unit operates in normal mode with 18C RUNNING PTI OF setpoint When return air temperature decreases to setpoint Frozen Arrival 18 C O F Return temperatures are recorded in PTI log 00 00 0
52. DO NOT USE When servicing Thermo King R 404A unit use only those service tools certified for and dedicated to R 404A refrigerant and Polyol Ester compressor oils Residual non HFX refrigerants or oils will contaminate R 404A systems Table of Contents ListOfFig res 00 a UE Rue Remex Exe tek A BEE Ee eee ERRAT ER ea ek 9 Safety Instructions 2 sees o gum a eee ee eet nn eee pn 11 General Precautions 3 233 esi testa Eden RR ees A RREEE AERE RS De Pe ek pec WEE EE 11 Refrigerant Oil Precautions 2 0 0 0 hh rh 11 Electrical Precautions a xara re a la apa ea td Dee a 11 POCOS MDC ED 11 First Aldi vn oer Mete EEE Rote E Ea a EIN E t VEM Ie Soc didt ro NN feier 12 Low Voltage s eee lueret bad I eed e eda er ru dde IPSI Pa du 12 Electrostatic Discharge Precautions o ooooccocooo hh 12 Electrostatic Discharge and the Controller 0 0 2 eee tee 12 Welding of Units or Containers estuaar a otee a a E eee eae 13 Removing Refrigerant Properly 20 0 000 ccc etna 13 Identifying Unit Safety and Warning Decals 0 0 0 0 een 15 Locating Serial Numbers ooo 15 Service Guide cv O 17 Selvice GUIAS orsi i aliquan reu idend er Dale 2 v Ran eae gay tapas aa DECR open 17 Specifications iiic ERR e EUREN Hee RUPTURE ORE ee eee cee A 19 Evaporator Airflow Specifications o oooooooooo rn 19 Electrical System Specifications 0 hh 19 Refrigeration System Specifications 0 0 0 eee hh 20 Unit
53. Description Features amp Options 0 0 00 ce en 25 Introduction a ede Re Me a o D E a RE SEE o A A A aor 25 General Description 0 e ia teens 25 Scroll Compressor ais sta Gene fg alas aD RR RS ea Bae hla Ne 26 MP 4000 Controller ci en a en el ie ore ne ae Vinee 26 Compressor Digital Control Valve 2 oo 26 Economizer Heat Exchange System 22m onen een 27 Temperature Sensors x zo Par ana oh ae pel eae nen a ee penal ue aha Dolan ha Ru qnn 27 Fresh Air Exchange System 000 ce nn en 27 Fresh Air Exchange Recorder Optional o ooccooccoooccr nennen 27 Receiver Tank Sight Glass 6 ne hh 28 Evaporaton Fans 7 42 ead rito islas Rec aan ee lec Gad Pes RU datu alea E B MM ake 28 Condenser Fan Control renies dria A Rn hac ee ee 28 UniPOptions a a ula Er eal s E oe ihn E is ite al 29 Recording Thermometer Optional 0 0 0 ccc tte rs 29 Remote Monitoring Modem RMM Optional 0 00 eee ee 29 Suction and Discharge Pressure Sensors Optional 22222 eee 29 Air Ventilation Logging AVL Optional 0 0 0 0 cette nae 29 USDA Cold Treatment Temperature Recording standard 0 000 cee eee 30 Water Cooled Condenser Receiver Tank Optional isses 30 Water Pressure Switch Optional 2 0 0 0 0 cc eee 30 Controller Description a dl nee 37 Controller Description 222mm 37 Controller Back up Battery 2422 un Haar Haan
54. ECAUTIONS BEFORE WELDING ON CONTAINER OR REFRIGERATION UNIT 1 Disconnect all power to the refrigeration unit 2 wre harnesses 3 9 of the electr kers in the control box to the OFF 4 Weld unit and or cont procedures Keep gro pa or elect 5 WI welding operation is compl 1 cables wiring and circuit breakers must be AXA0218 restored to their normal condition Controller Nameplate Unit Nameplate Compressor Nameplate Nameplate and Warning Locations 14 BEN074 Identifying Unit Safety and Warning Decals Serial number decals refrigerant type decals and warning decals appear on all Thermo King equipment These decals provide information that may be needed to service or repair the unit Service technicians should read and follow the instructions on all warning decals See Figure Safety Instructions Locating Serial Numbers Serial numbers can be found on the component s nameplate Electric Motor Nameplate Attached to the motor housing Compressor Nameplate On front of the compressor Unit Nameplate On unit frame in power cord storage compartment e MP 4000 Controller Nameplate On back of controller 15 Safety Instructions 16 Service Guide Service Guide A closely followed maintenance program will help to keep your Thermo King unit in top operating condition The following service guide table should be used as a guide when inspecting or ser
55. EFROST HUMID elt z U UE E GRN GRN COND AIR SUPPLY GD Ingersoll Rand SIZE CODE IDENT NO DWG NO REV D 1E54051 SCALE NONE REF DWG a SHEET 2 OR 2 8 1 6 5 4 3 2 149 Magnum Refrigeration System Components 150 T 1 Low Pressure Vapor Ej 2 Low Pressure Liquid 3 High Pressure Vapor IE 4 High Pressure Liquid ei 5 Stage 1 Sub Cooled High Pressure Liquid TK 52234 2 3 4 CH Rev 0 10 03 TEN 6 Stage 2 Sub Cooled High Pressure Liquid MAGNUM Components 151 AAA602 Discharge Service Valve Pressure Rate Brier on Fe S Economizer Heat Exchanger Evaporator Coil CONTROLLER MENU GUIDE F1 Alarms Menu F2CTOF o F3 SETPOINT F4 MENU Tuesday 06 January 2009 14 27 58 rH AL LoPrs HiPrs RA 6 0 NOTE All screens are NOT present on all units The screen y u C that display on the controller are determined by the Controller Software setting and the options installed on the Data Menu i SA Note When a function key F1 F3 F3 or F4 is pressed MAIN MENU SupplyLH Compressor Voltage Frequency Disch Press Battery c current r C the screen remains at that level until another function key is Supply RH Ambient Current Media Curr Ph 3 Bat Temp e pressed DATA Return Humidity Curr Ph 1 AVL Position CO2 CO2 6 0 SP To Enter a Controller Menu or Use Special Function Key A Ee
56. ETPOINT COMMAND p ALARM LIST WARNING LIST CONFIGURATION Datalogger Menu Inspect Log Calibrate Probes DATALOGGER STATES Set Log Time Interval Figure 35 Datalogger Menu 3 Press the F4 ENTER KEY to access the Datalogger menu 4 Press the F2 OR F3 Up Down key to scroll through submenu to CALIBRATE PROBE 5 Press the F4 enter key to enter Calibrate function The display shows RAW and CORR temperature off sets for each sensor in two rows The controller displays COOR in place of a temperature offset until the sensor comes within 0 3 C 0 5 F above or below 0 C 32 F The controller displays the actual temperature offset when the sensor temperature is within 0 3 C 0 5 F above or below 0 C 32 F 8 NOTE The sensors should be in the ice bath a total of 15 minutes or more to assure the sensor temperature has bottomed out Press the F3 key to release the current actual temperature offsets from the controller memory Observe the sensor temperatures in the CORR row Press the F4 ENTER KEY to accept the new temperature offsets when all sensor offsets read between 0 3 C 0 5 F and 0 3 C 0 5 and have been stable for 5 minutes The controller display will show the new offsets in the RESULT row Press the F1 key to exit the Calibrate menu Set Log Time Interval With the UNIT TURNED ON Allow Unit to start and stabilise and the Display showing the unit status display setpoint
57. Each unit is equipped with 460 380V 3 Ph 60 50 Hz electric motors An automatic phase correction system provides the proper electrical phase sequence for condenser fan evaporator fan and compressor operation Lore e nit The MAGNUM container unit features the following components Each component will be described briefly on the following pages Scroll Compressor Compressor Digital Control Valve e Economizer Heat Exchange System e Temperature Sensors Fresh Air Exchange System Receiver Tank Sight Glass Evaporator Fans e Condenser Fan Control e Suction Discharge Pressure Sensor Optional Remote Monitoring Receptacle Option 4 pin optional Remote Monitoring Modem RMM Optional e USDA Cold Treatment Temperature Recording Optional 25 Unit Description Features amp Options Scroll Compressor The scroll compressor features a digital port and an intermediate suction port Digital Port The digital port provides cooling capacity control The digital port is located at the top of the scroll assembly on the compressor body When energized the Digital Control valve disengages the scroll set This reduces pumping capacity to zero Intermediate Suction Port The intermediate suction port draws suction gas from the economizer heat exchanger into the scroll assembly of the compressor The scroll seals off the suction port This prevents economizer gas from leaking back
58. Function Test and start condenser fan compressor compressor 100 percent and evaporator fans on high speed Check the amps measure ments If necessary check the resistance of the motor windings Heater Current Too High Occurs during pretrip PTI or function test only Heater power consumption is 25 percent above expected current draw above approximately 4 4 amps and 5 1 amps depending on voltage Indicates Incorrect heaters or heater connections Defective volt or amp meter on power module Defective heater element Heater Current Too Low Occurs during pretrip PTI or function test only Heater power consumption is 25 percent pretrip below the expected current draw below approximately 3 2 amps and 3 8 amps depending on voltage Indicates Defective heater element Defective wire connection Incorrect heaters or heater connections Enter Manual Function Test and turn heaters on Check current draw on each phase Current draw should be about 4 4 amps on each phase at 400V 5 1 amps at 460V Check heater resistance Resistance should be about 99 ohms on each leg Enter Manual Function Test and turn heaters on Make sure the heat relay energizes Check current draw on each phase Current draw should be 4 4 on each phase at 400V 5 1 amps at 460V Check heater resistance Resistance should be about 99 ohms on each leg Check volt and ampere meter If both alarms 10 and 11 are activate
59. I test only readings Enter Manual Function Test menu Start the following components together compressor 100 percent compressor and evaporator fans Indicates high Discharge pressure should increase High pressure cutout switch did not respond to and compressor should stop at 2250 kPa 22 5 pressure change within 5 seconds bar 326 psig high pressure cutout switch opens Then start condenser fan Discharge pressure must drop quickly 10 to 20 seconds Defective high pressure cutout switch to 1550 kPa 15 5 bar 225 psig and compressor should start switch closes Compressor Temperature Too High Operate unit on Cool and check discharge and Shutdown Alarm suction pressure gauge readings Compressor discharge line temperature is above 148 C 298 F Compressor stopped until discharge line temperature decreases to normal Compressor does not start within normal time during high pressure cutout switch test Air in refrigeration system Enter Manual Function Test menu and test operate Injection Valve to determine if valve opens energizes Check compressor discharge sensor resistance Resistance must be 100 000 ohms Air in refrigeration system at 25 C 77 F Low refrigerant charge Check discharge line temperature with a Defective compressor or valve plate separate electronic thermometer and compare to HIGH PR TEMP shown in the Data menu of controller Indicates Defective liquid injection sy
60. MAGNUM TK 60275 4 MM Rev 0 09 08 Copyright 2008 Ingersoll Rand Climate Control Technologies European Served Area Printed in Ireland The maintenance information in this manual covers unit models Base Unit MAGNUM 098203 For further information refer to Parts Manuals MAGNUM Parts List TK 54356 Operation Diagnosis and Refrigeration Maintenance Manuals Diagnosing Thermo King Container Refrigeration Systems TK 41166 Electrostatic Discharge ESD Training Guide TK 40282 Evacuation Station Operation and Field Application TK 40612 Tool Catalog TK 5955 The information in this manual is provided to assist owners operators and service people in the proper upkeep and maintenance of Thermo King units This manual is published strictly for informational purposes The information so provided should not be considered as all inclusive or covering all contingencies Thermo King Corporation should be consulted if further information is required Sale of product shown in this manual is subject to Thermo King s terms and conditions This includes but not limited to the Thermo King Limited Express Warranty Such terms and conditions are available upon request Thermo King s warranty will not apply to any equipment which has been so repaired or altered outside the manufacturer s plants as in the manufacturer s judgment to effect its stability No warranties express or implied are made regarding
61. MIDITY BRN OR REDP22 HUM EF3 HEATER SENSOR T HARNESS RN GRN YEE EET MAGNUM 20 DEFROST 7 en HEATERS HEATERS PT 1000 g g H YELLOW BLACK H2 a D H3 ORANGE BLUE a er ee HARNESS Sue DEFROST POWER COMMUNICATION H5 RED GREEN H6 3838 FROM TRANSFRESH 0000 C DATA PLUG um WHITE 9 y 3 Or OD GRN GRN YEL mle Sah 2 mE a i NTC USDA A E GND WHITE E DIGITAL CONTROL VALVE SEA EON LES le VRR CONDENSER ARI YELLOW o IL e l SENSOR USDA er l PT 1000 GND BLACK o 71COND iin 1 z AFAM ACTUATOR AVL OPTION 9 l z wn Apo 1625515601 OPT 10 i CAR2 RED o l l AVL VAPOR INJECTION VALVE gt Lg I USDA3 VH van J V unteg I ab i GRN BRN l GND WH I TE e f 1 ae RS485 RS485 GND GND o AMBIENT j RED BLK l EA le b E P a RED WHT SENSOR i WHT GRN P CAR YELLOW c m 1000 2 l N ae i L SUPPLY PULP E 3 SENSOR GND BLACK B Ko PT 1000 le CAR4 RED On f f 3 A L BLK BLK BLK BLK RED WHT ee N ANE dr S7 b POWER CORD LOW PRESSURE HIGH COMPRESSOR CUTOU PRESSURE MOSS ENSOR SWITCH CUTOUT NTC H NOT USED WITH SWITCH DATA USDA 1 2 3 M on CHART RECORDER ES AIR VENT LOGGIN COMP SIT Es RED es N COMPRESSOR HIGH PRESSURE B HP fo sv wel n TRANSDUCER MOIOR CONNECTIONS WIRES WIRES 400 460 VOLTS N ch EVAP FAN MOTORS Y TOP VIEW en R RECEPI COMPRESSOR Ze CONDENSOR FAN MOTOR gt POWER RECEPTACLE TRANSDUCER MOTOR E os O
62. Press F4 key to select able Press F2 or F3 key to Tess ey to selec CONFIGURATION Unit Setting Contrast FAM increase or decrease a Option Unit Configuration Version Humidity Option digit Press F2 key to scroll 4 m Miscellaneous Controller ID Suction Pressure Option Press F4 to move to NOS tti igi Settings Power Module ID Discharge Pressure Option ne next digt lo naa a 2 a Press and hold F4 key A Unit Serial ID E UI to saveuntil you are the main screen A lt Bz USDA Option returned to the main screen Datalogger Submenu DATALOGGER Datalogger Menu Inspect log Press F4 key Set Log Time Interval Enns to view next screen Press Press F3 key to scroll p g F2 or F3 key to scroll through log interval list Calibrate Probes through all logs Pressand hold F4 key F4 jee aad Set Log Time Interval Moalibrmatelprabesamressics nn stops key to Release Press F4 asning key to Calibrate 2 Fl A States Menu RMM Status F2 PTI RMM en shows Offline Zombie Online m Input Output current status STATES RMM Version Defrost Map Telegrams Received Minutes since last Poll Fl gt 53 152
63. Pressure water salumi Umm Qi mm am 500 2940 3780 205 omman 44m 250 299 ams amsn 350 207 389 149 Electrical System Specifications Compressor Motor Type 460 380V 60 50 Hz 3 Phase Kilowatts 4 48 kW 460V 60 Hz Horsepower 6 0 hp 460V 60 Hz RPM 3550 RPM 460V 60 Hz Locked Rotor Amps 70 amps 460V 60 Hz Condenser Fan Motor Type 460 380V 60 50 Hz 3 Phase 19 Specifications Electrical System Specifications Kilowatts Horsepower Number All Models Motor RPM Full Load Amps Locked Rotor Amps Evaporator Fan Motors Type Kilowatts Horsepower Motor RPM Each High Speed Low Speed Full Load Amps Each High Speed Low Speed Locked Rotor Amps High Speed Low Speed Electrical Resistance Heater Rods Type Number Watts Each Current Draw Amps Control Circuit Voltage 0 55 kW 460V 60 Hz 0 75 hp 460V 60 Hz 1 1725 RPM 460V 60 Hz 1 0 amps 460V 60 Hz 1 0 amps 380V 50 Hz 3 9 amps 460V 60 Hz 3 7 amps 380V 50 Hz 460 380V 60 50 Hz 3 Phase 0 75 kW 460V 60 Hz 1 0 hp 460V 60 Hz 3450 RPM 460V 60 Hz 1725 RPM 460V 60 Hz 1 6 amps 460V 60 Hz 0 8 amps 460V 60 Hz 10 5 amps 460V 60 Hz 9 0 amps 460V 60 Hz 460 380V 60 50 Hz 3 Phase 6 680 Watts 460V 60 Hz 5 amps total 460V across each phase at heater contractor 29 Vac 60 Hz Refrigeration Sys
64. RR RR yh nns 37 Controller Input and Output Signals oooooocooo een e een en n en 37 standard Display soii A ee ee 38 Glossary of Mode Descriptions lllieliee een ms 39 F nctlon Keys uuo adest de ee A fub De he dust he ee 40 Three Special Function Keys oooocoocoorr el hm hh haa 40 Operating Instructions 2 uer rrr IRR kr t rrr rer yr rernm rea 41 E nctlom REVS sao a Ge eus are aa ee erus cian ade muse ee re qd durs 41 Unit ONOM Key cesse Ege dette Rena nn HR ra aU a Rb n OS 41 Sequence Of Operation o 41 Unit Start p 23 2 epe p EUST AI EE NUS d sed o Md eve a OA T SIRE e E ed 41 Viewing Alams Warnlngs rosera aneor a RA pute ARE ERO age alea ER Rb ares 43 Display Alternate Fahrenheit F or Celsius C Temperatures 0 00 cee ee eee 43 Table of Contents Changing Setpoinits our mene teas aie al EX DER ia dk Godlee ee te hte 43 Controller Back up Battery 22 2 cece ee e rh ehh gp 3 Ra de eee 43 Navigating the Controller Operating Menu 2 0 e eee eee KH rn 45 Navigating the Controller Operating Menu 0 0 0 ete eee 45 Menu Scrolling Keys 58 eei bp ana ee he pada eed pa bee Gad deeb 45 Main ITE 47 Data MENU x uoa d apte teat cae idee alae ala detainees eh t eee Ru ad 47 Viewing the Data Menu eiee swi at o E a nen na hh mr hh hh 47 Setpoint Menu as nias a idee ERE ae ae a da Le heh one c ERE ie Neu 47 Temperature Setpoint 0 0 00000 lr ns 47 Controlling ModE 4
65. Reduce the refrigerant pressure to a safe working level when maintenance must be performed on high pressure side components Empty the unit of refrigerant when an unknown amount of charge is in the system and a proper charge is required Empty the unit of contaminated refrigerant when the system has become contaminated NOTE Always refer to specific recovery equipment Operator and Service Manuals Perform the following steps to recover vapor from the system 1 Turn unit off 2 Install a gauge manifold set on the unit uy Attach the service line to the recovery machine and properly purge the lines Set the recovery machine for vapor recovery Mid seat the discharge service valve Turn on the recovery machine PD ae Open back seat both gauge manifold and hand valves 8 Continue to operate the recovery machine until unit pressures drop to 0 kPa 0 bar 0 psig pressure 104 Evacuation and Cleanup of the Refrigeration System A thorough clean up is required whenever contaminants have entered the system This will prevent damage to the compressor The purpose of evacuation is to remove moisture and air from the refrigeration system after a system has been opened to the atmosphere Evacuation must occur before recharging a system with new refrigerant The importance of thorough evacuation and system preparation cannot be over emphasized Even infinitesimal quantities of air or moisture in a system can
66. STATES DEFROST Figure 36 States Menu Screen Flow Diagram PTI Shows Information on the following e Last passed PTI e Last passes Brief PTI e Number of passed PTI s and Brief PTI s Input Output Show s Digital Input Information e Phase Diirection e HPCO LPCO Output Information e Economizer Valve Digital Valve 70 e Heater e Evaporator Fan High Evaporator Fan Low e Condenser Fan Compressor RMM State The RMM Remote Monitoring Modem State menu displays the current communications status with a REFCON system Offline No communication between the controller RMM and a REFCON system Zombie The controller has detected REFCON system master module and is waiting for communication On line The controller RMM is logged in on a REFCON system A complete listing of the controller operating menu is located on an 11 x 17 fold out on the last page of this manual Viewing the RMM State Screen With the UNIT TURNED ON Allow Unit to start and stabilise and the display showing the unit status display 1 Press the F4 MENU KEY to enter the Main menu 2 Press the F2 or F3 Up Down key to scroll through Main menu until you reach States 3 Press the F4 ENTER KEY to access the STATES Menu 4 Press the F2 oR F3 UP DowN key to scroll through Main menu until you reach RMM 5 Press the F4 ENTER KEY to view the RMM states Menu 6 Press the ESC key to exit the RMM State scr
67. Turn the Unit On Off switch Off Disconnect electrical connections to valve coil Unsolder liquid line connections to the valve Remove the valve from the unit 115 Refrigeration Maintenance Valve Installation To install the vapor injection valve perform the following steps 1 Clean the tubes for soldering 2 Place the new valve in position and solder the liquid line connections A CAUTION Use a heat sink or wrap switch with wet rags to prevent damage to new switch 3 Pressurize the refrigeration system and check for leaks see Refrigerant Leak Test Procedure in this chapter Repair leak 1f required 4 Recover the refrigerant used for the leak test if no leaks were found 5 Evacuate the system see Evacuation and Cleanup of the Refrigeration System in this chapter 6 Recharge the unit with R 404A see Charging the System with Refrigerant in this chapter 7 Perform a controller pretrip test to verify system operation NOTE In most cases only the coil requires replacement No other repair is possible on solenoid valves 116 Compressor Digital Control Valve Replacement Digital Control Valve Removal To remove the compressor digital control valve perform the following steps 1 Isolate the compressor and digital valve from the system a Front seat the discharge service valve by turning the valve fully clockwise b Front seat the suction service valve by turning
68. WING TITLE un MAY BE USED ONLY B L Are e d g PURPOSE FOR WHICH T EVER ANB GR TO 66 01 0ct 08 SCHEMATIC DIAGRAM m D o THE RECIPIENT WHOJAGREES THAT IT WILL NOT fs m Z WITHOUT INGERSOLL RAND S PRIOR WRITTEN EE MAGNUM s Se PERMISSION 1 DIS amp TA z j aA OR THE INFORMATION RAE UTEM US o ABOVE OR 2 MAKE APPROVED 2 us RE ER ADT tener DRAN OT 07 Oct 08 SIZE CODE IDENT NO DWG NO REV COPIES MUST BE RET Oct UPON COMPLETION OF T R oi HAVE BEEN PROVIDED GRNUPON ANY EARLIER ENG APPVL D E 54 0 JE A t REQUEST SCALE NONE REF DWG 1E54051 SHEET OF 147 Wiring Diagram Page 1 of 2 8 REVISIONS CHANGE ORDER REV DESCRIPTION DATE APPROVED 524162 A RELEASED 20 Aug 08 OT ETT TII SCRUPBER PARTE TR FR TO EVAP EVAPORATOR L MOTIONS SECTION A Jom RETURN ED RETURN AIR wT QOO D SENSOR PT 1000 l EFTS A l EFI2 BLU OR WHTPI gt HUM EFI HU
69. ample if the defrost timer requests a defrost cycle at 7 35 the defrost cycle will start at 8 01 The datalogger will record a Defrost event for each log interval in which a Defrost cycle is pending or active i e both the 8 00 and 9 00 data logs on 1 hour logging interval 78 On Chill Loads setpoints at 9 9 C 14 1 F and above the conditions for this are e Evaporator Coil Temperature must be below 4 C 41 F to activate the defrost compressor hour timer e There is an interval set for defrosting however the defrost timer is built intelligent it detects whether or not there is ice building up on the coil e fthere is no ice building up on the coil it extends the defrost interval and if there is Ice building up earlier on the coil it reduces the defrost interval The maximum interval is 48 hours On Frozen Loads the initial time interval is 8 hours Two 2 hours are added to the time interval each timed defrost interval Maximum accumulated time interval is 24 hours Defrost timer resets if the unit is off more than 12 hours setpoint is changed more than 5 C 8 9 F or PTI pretrip test occurs NOTE If unit operating conditions do not allow the unit to enter a defrost cycle Defrost Not Activated appears on VGA display when the DEFROST key is pressed When the Defrost mode is initiated Thecontroller stops the compressor condenser fan and evaporator fans e When the compressor stops the
70. ation Maintenance 101 Refrigeration Maintenance Purge High Side to Low Side 1 4 Attach gauge manifold set see Gauge Manifold Set Attachment and Purging for proper procedure for connecting to compressor Close both hand valves on the gauge manifold front seated Connect charging hose to a source of nitrogen Adjust pressure regulator to the proper pressure for the required procedure Purge system high side to low side Maximum Gas Pressures The following procedures should utilize the following maximum gas pressure 102 Leak Testing 1034 to 1200 kPa 10 34 to 12 00 bar 150 174 psig Purging Dehydration 69 to 138 kPa 0 69 to 1 38 bar 10 20 psig Soldering 35 kPa 0 35 bar 5 psig Refrigeration Maintenance Special self sealing quick disconnect couplers are required for R 404A units Gas Ballast Valve Iso Valve e Calibration Standard B emn OSC Figure 66 Evacuation Station and Unit Hook up 103 Refrigeration Maintenance Recovering Refrigerant from the System CAUTION Use only refrigerant recovery equipment approved for and dedicated to R 404A recovery When removing any refrigerant from a Thermo King refrigeration system use a recovery process that prevents or absolutely minimizes the refrigerant escaping to the atmosphere Typical service procedures that require removal of refrigerant from the unit includes the following
71. ats add ges 24 MAGNUMF Unit u aces ee bat er ebenen are ne er 25 ScrollCompressor ia again de ea aan REAL v de aan meer 26 MP 4000 Controller 26 Compressor Digital Control Solenoid Valve o o oococccoooccocoo nenn 26 Economizer Heat Exchanger ssas rer riid adeo a eet een 27 Fresh Air Exchange Vent ile rer 27 Fresh Air Exchange Recorder iscissi cei Tenta er rn 27 Figure 9 Receiver Tank Sight Glass 1 0 0 hh 28 Figure 10 Optional Components llsllleeleell ll rr 29 Figure 11 Water Cooled Condenser Receiver Tank oooococcccoo rn 30 Figure 12 Unit Front View ulelelllellA nennen 31 Figure 13 Umit Back VIEW yaco wear eX peces eA pal atas God kate drap Pateat RO grt 32 Figure 14 Refrigeration System illii rr rn 33 Figure 15 Electrical Components rea a hh 34 Figure 16 MP 4000 Controller Display Panel oooccocccccccc e ae 38 Figure 17 Standard DISplay 24 2 2 Pest emet Pen Rae t a Re XR ox Ee dee Fel a xr oa 38 Figure 18 Unit Status Display 0 0 00 rre 38 Figure 19 F nction Keys i seus nr LANERO e ERROR RE Rae ee dee es 40 Figure 20 Special Function Keys 20 0000 hh 40 Figure 21 Function Keys zo tese Bla ake ales veru pie Pure uos A aee caos 41 Figure 22 MP 4000 Controller Display Panel lisllsseeeeeeee nenn 45 Eigure 23 Data Menu 2 se EE Ee REESE a a BAA do de LA End fo 47 Figure 24 Setpoint Menu 2 ee nn 47 Fi
72. cause severe problems The presence of moisture oxygen and heat can create many forms of damage They can create corrosion sludge copper plating oil breakdown carbon formation and eventual compressor failure Things that will contaminate a system are in order of importance Air With oxygen as a contaminant Oxygen in the air reacts with the oil The oil begins to break down and can eventually lead to carbonization in the compressor and acid buildup The longer this breakdown process goes on the darker the compressor oil becomes until finally the color is black indicating major system contamination Moisture Moisture in a system will cause metal corrosion and metal plating It can freeze in the expansion valve and cause intermittent operational problems It reacts in the oil to begin acid buildup Dirt Dust Metal Particles other Foreign Materials Particles of any kind left to float through the system will cause severe damage to all close tolerance items Do not leave a system open to the infiltration of dirt If you must open a system for any reason seal off the open areas as soon as possible and do not work in a dirty environment Acid Air and moisture cause a chemical breakdown of the oil and or the refrigerant itself The acid will accelerate the deterioration of the softer metals 1 e copper and cause metal plating as the softer material begins to cover the inside of the system If this condition is not st
73. ce compressor excessive amperage draw or Seized or frozen compressor bearings Replace compressor intermittenteyelindonovstiesd Check correct wiring against wiring Improperly wired a diagram l Check line voltage determine Low line voltage location of voltage drop Contacts in compressor contactor not Check by operating manually closing completely Repair or replace Check motor stator connections Check stator winding for continuity If open replace compressor Defective compressor motor internal Replace thermal overload protector thermal overload protector or compressor Refrigerant overcharge or high side Check for restricted filter drier restriction causing cycling on high in line filter or high side or pressure cutout refrigerant overcharge Check condenser airflow condenser fan motor fan blade Inefficient condenser operation condenser grille condenser coil causing cycling on high pressure temperature sensor water pressure cutout Switch option water flow rate option and water cooled condenser receiver tank option Replace defective switch Compressor motor internal thermal overload protection open Open circuit in compressor motor winding 124 Diagnosis Troubleshooting Warnings and Alarm Codes Condition Possible Cause Remedy 7000007 Compressor contactor burned out Unit short cycles Noisy compressor Condenser fan motor does not operate Increase line LN to at least 90 Low line
74. ck power supply volts and amps Check volt and ampere meter Enter Data menu and view voltage reading on each phase Check all fuses on power module Replace power module Check voltage reading on each phase 137 Diagnosis Troubleshooting Warnings and Alarm Codes 138 Alarm Codes Descriptions and Corrective Actions Continued Corrective Action If both alarms 16 and 17 are activated the alarms are caused by a large difference in measured amps Enter Manual Function Test menu and start the condenser fan Check the condenser fan amps measurement If necessary check the resistance in the motor between CF1 and CF2 CF2 and CF3 and CF1 and CF3 Resistance readings should be equal approximately 25 Temperature Too Far From Setpoint After 75 minutes of operation supply or return air temperature is not in range and does not approach setpoint within preset pull down rate Indicates Ice or frost on evaporator coil Low refrigerant charge Air exchange vent open too much Container air leakage doors open Defrost Time Too Long Heat signal has been on for more than 90 minutes on 60 Hz power during Defrost 120 minutes on 50 Hz power Indicates Low power supply voltage Defective heater elements Evaporator fans running during defrost Evaporator sensor placed wrong Capacity Test 1 Error e Occurs during pretrip PTI test only Difference between supply and return air temperature is too small w
75. coil sensor See Evaporator Fan Motor Does Not Evaporator fan does not operate Operate under Mechanical Diagnosis Apply hot wet cloth to expansion Ice plugging expansion valve screen valve Moisture indicated by increase or orifice in suction pressure Replace filter drier Overcharge of refrigerant Purge system Expansion valve open too much Adjust or replace valve Diagnose power module and Defective controller or power module controller Replace defective component Service gauge out of calibration Adjust or replace service gauge Diagnosis Troubleshooting Warnings and Alarm Codes Low suction pressure discharge pressures may drop below Restricted lines se pressures mav drop below Restricted Iines Locate and clear restriction expecte normal readings w en the unit is on Modulation Cool control Plugged filter drier Replace filter drier temperature within 10 C 18 F of Expansion valve closed too much Adjust or replace valve setpoint or in Power Limit mode Expansion valve feeler bulb improperly mounted poorly insulated Correct feeler bulb installation or making poor contact Check evaporator fan motors and Evaporator fans off da control circuit and correct fault Diagnose power module and Defective controller or power module controller Replace defective component Service gauge out of calibration Adjust or replace gauge 129 Diagnosis Troubleshooting Warnings and Alarm Code
76. control temperature within 10 C 18 F of setpoint or in Power Limit mode Possible Cause Compressor does not operate See Mechanical Diagnosis Controller setpoint too high Adjust controller setpoint Defective container insulation or poor E Repair container fitting doors Shortage of refrigerant Repair leak and recharge Overcharge of refrigerant Purge system Air in refrigeration system Evacuate and recharge Check vapor injection valve circuit Vapor injection valve open and compressor discharge temperature sensor Mis Remove compressor oil from Too much compressor oil in system compressor Iced or dirty evaporator coil Defrost or clean evaporator coil Restricted lines on high side Clear restriction Plugged filter drier in line filter Change filter drier Compressor Digital Control Valve Replace defective valve defective Clean condenser coil clear restriction or repair or replace fan motor or condenser fan blade No water flow to water cooled Restore water flow to water cooled condenser condenser receiver tank Defective water pressure switch Option Expansion valve open too much Adjust or replace valve Expansion valve power element lost 2 Replace power element its charge Expansion valve feeler bulb improperly mounted poorly insulated Correct feeler bulb installation or making poor contact Shortage of refrigerant Repair leak and recharge Low ambient air temperature Service gauge out of calibration Re
77. d If not sufficient heat increase with pulsating on the heaters until setpoint is reached BENO37 Operating Theory Frozen Loads Controller Setpoint at 10 C 14 F and Below At setpoints of 10 C 14 F and below the controller locks out the Modulation and Heat modes The controller regulates compressor operation based the return air sensor and setpoint temperatures At setpoints of 10 C 14 F and below the controller operates the unit on Cool mode Null mode Defrost mode electric heaters on evaporator fans off Evaporator fans operate on low speed and continuously circulate air inside the container except during Defrost and in Null mode Controller display shows the return air sensor temperature Controller display shows the setpoint temperature Controller cycles a single speed condenser fan on for 2 to 30 seconds every 30 seconds when the unit is on air cooled condenser operation The amount of on time depends on the condenser coil ambient and compressor discharge temperatures Power limit is active during initial start up and pull down when the unit is cooling at return air temperatures above 10 C 14 F Be es Decreasing Temperature Setpoint Increasing Temperature Figure 39 Frozen Load Control Sequence Setpoints at 10 C 14 F and Below Cool After initial start up and pull down to 2 0 C 3 6 F below setpoint the controller calls for the
78. d the alarms are caused by a large difference in measured amps Enter Manual Function Test menu and start HEAT Check the amps measurements If necessary check the resistance Resistance should be about 99 ohms on each leg 135 Diagnosis Troubleshooting Warnings and Alarm Codes Alarm Codes Descriptions and Corrective Actions Continued Corrective Action 12 Evaporator Fan High Speed Current Too High Occurs during pretrip PTI or function test only When the evaporator fan power consumption is 25 percent above expected current draw above 2 0 to 3 0 amps depending on voltage Indicates Defective or stuck evaporator fan motor Incorrect motor or motor connections Defective volt or amp meter on power module Open evaporator door and make sure all fans rotate freely Enter Manual Function Test and start evaporator fans on high speed Make sure all fans start on high speed Check fan motor volts and amps Check volt and ampere meter If both alarms 12 and 13 or 14 and 15 are activated the alarms are caused by a large difference in measured amps Enter 13 or 14 and 15 are activated the alarms are caused by a large difference in measured amps Enter Manual Function Test menu and operate evaporator fans on low and high speed Check the evaporator fan amps measure ment If necessary check the resistance in the motors High speed between EF11 and EF12 EF12 and EF13 and EF11 and EF13 Low speed between EF 1 and
79. d ground is below 0 8 meg ohms isolate and check the resistance of each individual heater element 5 Check the resistance of each individual heater element a Disconnect and isolate each heater from the circuit in the control box b Check resistance of each heater with an insulation tester between each heater and ground If the resistance between each heater and ground is below 0 8 meg ohms the heater element is defective On a loaded container remove the defective heater from service by disconnecting at the control box If the container is empty remove the evaporator cover from the rear of the unit and replace the heater or correct any defective wiring Repeat step 5a NOTE When repairing heater connections protect the new connections from the ingress of moisture with heat shrink tubing All heaters should be secured to prevent contact with sharp metal edges el amp a Figure 48 Compressor Discharge Temperature Sensor Compressor Discharge Gas Temperature Sensor A refrigerant injection system uses the compressor discharge temperature to protect the compressor from excessively high operating temperatures If the vapor injection valve is off and the compressor discharge gas temperature increases to 138 C 280 F the valve will be turned on When the discharge gas temperature decreases to 132 C 270 F the vapor injection will be turned off unless it is required to be on for other reasons The c
80. d leads at the condenser fan contactor disconnect power supply before reversing leads Do not move the CH ground wire Check Evaporator Fan Rotation Visually inspect the evaporator fan blades for proper rotation Arrows located on the underside of the fan deck indicate the correct direction of rotation Check both high and low speed evaporator fan rotation by performing Evaporator High and Evaporator Low tests from the Manual Function Test menu If an evaporator fans rotate backwards on one or both speeds see the unit wiring diagram to correct motor wiring at the fan motor junction box or evaporator fan contactor disconnect power supply before reversing leads Do not move the ground wire which is labeled CH NOTE Evaporator fan motor wires EF 1 EF2 and EF3 are used on low speed fan operation Wires EF 11 EF12 and EF13 are used on high speed fan operation Electrical Maintenance 89 Electrical Maintenance Reversing Power Phase on MAGNUM Units Use the incoming power cable leads to reverse the power phase This is recommended on MAGNUM units because the Jumper J18 does not reverse power to the scroll compressor This protects against the possibility that the compressor will be out of phase with the condenser and evaporator fans when the unit is plugged into a new power supply To reverse the Power Phase Complete complete the following steps 1 Turn the unit 460 380V main circuit breaker off 2 Disconnec
81. de appears on screen The alarm state will change from Active or Not Active to Acknowledge If no key is pressed for 30 seconds the controller returns to previous menu level or Unit status display NOTE See detailed Alarm Warning Code list complete with corrective actions in the Diagnosing and Troubleshooting Section in the back of the manual 63 Main Menu Warning List Menu Alarm ne j Code ction Warning Action Code Power Error Check 20A Fuses High Pressure Cutout Check Water Cooling Check Capacity Test 1 Error Vapor Injection Valve Error Low Pressure Cutout Error Check Condenser Air Sensor Open Circuit Check Condenser Air Sensor Short Circuit Probe Test Please Wait Check Ambient Air Sensor Open Circuit High Pressure Cutout Check Condenser Probe High Pressure Cutout Check Condenser Fan MM MX EX T eri Compressor High Temperature ree C EN Beer a MC Check Alon switch Alarm List Menu Check Evaporator Coil Sensor Short Circuit 06 Check Compressor Current Too High Check Compressor Current Too Low Check Heater Current Too High 15 Check for Low Voltage Check Probe Error Check High Pressure Cutout Switch Off Error Check High Pressure Cutout Switch On Error Shutdown Compressor Temperature Too High 1 2 3 7 11 12 21 22 23 24 25 26 7 ur 120 Di 122 Re calibrate O Sensor 123 124 128 123 Check Evaporator Coil Temperature Probe 131 Ambien
82. denser operation Water pressure switch Closed Water cooled position Option Defective water pressure switch option Loose line connection Tighten connections Check for seized bearings or Open motor internal thermal overload defective thermal overload protector Repair or replace as necessary Defective motor Replace motor Detective condenser fan contactor Replace defective contactor Diagnose and replace condenser fan relay power module or controller Replace defective switch No condenser fan output signal from controller 125 126 Diagnosis Troubleshooting Warnings and Alarm Codes Condition Evaporator fan motor s does not operate Possible Cause Remedy Unit on defrost pen ee operating mode indicator LEDs Loose line connection Tighten connections Check for seized bearings or Open motor internal thermal overload defective thermal overload protector Repair or replace as necessary Defective motor Replace motor No low or high speed evaporator fan Diagnose and replace output output signal from controller output redul module or controller Diagnosis Troubleshooting Warnings and Alarm Codes Troubleshooting Refrigeration Problems Condition Load temperature too high unit not cooling Head pressure too low NOTE This unit has a digital capacity control system Suction and discharge pressures may drop below expected normal readings when the unit is in Modulation Cool
83. e pra 4 Pressure Test Line to System 5 Safety Valve Pressure Regulator Figure 65 Typical Pressurized Gas Bottle with Pressure Regulator and Gauges Safety Precautions Observe the proper handling of cylinders Always keep protective cap on cylinder when not in use Secure cylinder in proper storage area or fastened to cart Do not expose to excessive heat or direct sun light Do not drop dent or damage cylinder Use a pressure regulator and a safety pressure relief valve as part of the pressure testing equipment The safety pressure relief valve should be of the non adjustable non tempering type The valve should bypass any time the pressure exceeds its setting Open valve slowly use regulators and safety valves that are in good working order The regulator should have two gauges one to read tank pressure the other to read line pressure Properly maintained equipment will allow leak testing purging or dehydration to be done safely CAUTION Nitrogen N is under 15 170 kPa 151 70 bar 2200 psig or greater Pressure is for full cylinder at 21 C 70 F DO NOT use Oxygen O acetylene or any other types of pressurized gas on refrigeration systems or any component of a system Dehydration pressure testing purging and soldering can be accomplished with the use of dry nitrogen N The proper equipment and application of equipment is of greatest importance Refriger
84. e et DLs RETURN AMBT OPTION ROTATION C QE ROTATION C HPS LPS DEFROST HUMID ENTE 8 ERED 8LU BLI GRN GRN COND AIR SUPPLY gt LOW SPEED M IH SPEED C WHT BLK BRN s RED GRN LP ROOMS LOW FRESSURE l GRN YEL A I EFT au CFI if RN ec 6 GRN GRN YEL E C BLK 4 THERMO KING PROPRIETARY DATA CAD GENERATED DRAWING puce rE te T P u P WM tug OO NOT MANUALLY UPDATE dB Ingersoll Rand RED BLU WHT CYEL BLK RED BLIO u CORPORATION IT 1S TRANSMITTED TO DRAWN DATE ermo King TI 1S TO BE RETURNED UPON REQUEST GOPI ee Iota ie WHT BLK egal a ISB UP GEES ers MAGNUM TA TITS T8T6 19 FOR WHICH TRANSMITTED WITHOUT THE 2 PRIOR WRITTEN PERMISSION OF THERMO R RAJ 22 Oct 08 W R NG D AGRAM KING CORPORATION THERMO KING CORPORATION Mr R RAJ 22 Oct 08 SIZE CODE IDENT NO DWG NO REV Tit EA VELA ee D E54051 3 SCALE NONE REF DWG SWESREE Oly ORK oe 148 Wiring Diagram Page 2 of 2 8 7 6 5 y 4 3 2 WIRE CODES
85. e present F1 turn the UNIT ON Allow Unit to start and stabilise Complete the following steps 1 Press the F1 ALarm Kev The Alarm List appears 2 Press the F2 F3 keys to scroll between Alarms that are present 3 Press the F4 key to acknowledge the Alarm Press F1 again to exit NOTE See a full List of Alarm and Warning codes on p 72 of this manual Display Alternate Sit Fahrenheit F or Celsius C Temperatures To view the alarms that are present turn the UNIT ON Allow Unit to start and stabilise F2 Complete the following step The controller can display temperatures in Celsius or Fahrenheit Press the F2 function key display will change to C or F Changing Setpoint To change the controller setpoint turn the UNIT ON Allow Unit to F3 start and stabilise Complete the following steps 1 Press the F3 key at the main screen The Setpoint Change menu appears Operating Instructions 2 Press the F2 F3 keys to scroll the Setpoint Up or down depending on your required Temperature 3 Press and hold the F4 key until you are returned to the main Screen The new setpoint is recorded in the controller and appears in the display NOTE The controller will default return to the previous setpoint if the setpoint is not entered within 30 seconds Repeat steps 1 through 3 if this occurs NOTE Humidity control humidity setpoint and Non Optimised mode can also be set from the Setpoint
86. e unit operates on Full Cool and Null to provide accurate control of frozen cargo The controller uses the return air sensor temperature and setpoint temperature to regulate unit operation If the return air sensor becomes disconnected or fails the controller uses the supply air sensors plus an offset for temperature control Cooling Capacity Display in main screen The percent displayed in the main screen indicates the cool capacity that is currently provided For example when controller display shows 70 percent this means the Digital Control valve is operating to reduce system cooling capacity from 100 percent to 70 percent a 30 percent reduction Power Limit Management Power Limit is active whenever the compressor is on in both the Chill and Frozen modes When the total current draw or the condenser temperature exceeds a predetermined threshold the controller limits unit power consumption by sending a voltage pulse to the Digital Control valve The Digital Control valve then operates to control the compressor This reduces the cooling capacity load on the compressor thereby limiting the compressor motor current draw and the condenser temperature to a predetermined threshold Additional power limit management flexibility is available A maximum total current draw 17 15 or 13 amps and power management time interval can be selected from the Power Management feature of the Commands menu When the power management time inte
87. eck the current settings or enter new settings Change the Humidity Control Setting l Press the F4 Menu key Press the F3 key to scroll down to the Humidity Setting Menu Press the F4 ENTER KEY to expand this menu Press the F2 or F3 Up Down key to scroll between OFF and ON Press and hold the F4 ENTER KEY until the main menu screen appears again Change the Humidity Setpoint l Now press the F3 key to scroll to the Humidity Setpoint line Press the F2 OR F3 Up Down key to increase or decrease the the percentage Humidity Control required NOTE The humidity setpoint should be established by the shipper Always check that the setpoint entered in the Display is correct before proceeding Press and hold the F4 ENTER KEY until the menu screen appears again The new setpoint is recorded in the controller and appears in the display Press the F1 EXIT key to exit the Setpoint screen Main Menu Commands Menu The Commands menu displays a list of tasks that can be activated The following commands are available NOTE All screens are NOT present on all units The screens that display on the controller are determined by the Controller Software settings and the options installed on the unit DATA SETPOINT B PTI P Brief PTI COMMAND lt q Functions Test ALARM LIST Manual Functions Test Defrost WARNING LIST Trip Start CONFIGURATION DATALOGGER STATES Command
88. een Main Menu RMM INFORMATION RMM Status ONLINE Wersion 01020304 Map telegrams recieved 205 Minutes since last poll 1 Figure 37 RMM States Defrost Show s the following Compressor Defrost Timer hours Timer Defrost timer Limit hours 71 Main Menu 72 Operating Theory Chill Loads Setpoint at 9 9 C 14 1 F and Above The unit operates on Cool with Modulation and Heat to provide accurate control of chill loads During Cool with Modulation the controller uses a proportional integral derivative PID algorithm and a Digital Control valve to provide accurate control of the container temperature in direct response to load demand The Digital Control valve engages and disengages the compressor to control capacity The valve opens and closes in response to a controller voltage signal based on a control temperature differential The controller uses the setpoint temperature supply air sensor temperature and pull down rate for the last 10 seconds last 20 seconds and last 180 seconds to calculate the control temperature differential Supply Air Sensor Control Temperature control is provided by using a PT1000 temperature sensor to determine the supply temperature used to calculate the control temperature If the supply air sensors fail the controller uses the temperature of the return air sensor plus an offset for temperature control Frozen Loads Setpoint at 10 C 14 F and Below Th
89. een EF1 and EF2 EF2 and EF3 and EF1 and EF3 Resistance readings should be equal High speed about 6 Ohms total of 2 motors Low speed about 20 Ohms total of 2 motors Condenser Fan Current Too High Occurs during pretrip PTI or function test only When the condenser fan power consumption is 25 percent above expected current draw above 1 5 to 1 9 amps depending on voltage Indicates Defective or stuck condenser fan motor Defective volt or amp meter on power module ncorrect motor or motor connections Condenser Fan Current Too Low Occurs during pretrip PTI or function test only Condenser fan power consumption is 25 percent below expected current draw below 0 5 to 0 7 amps depending on voltage Indicates Defective condenser fan motor relay Defective or open fan motor internal over temperature protection switch Defective volt or amp meter on power module Power Supply Phase Error One or more frequency inputs are missing for more than 20 seconds Indicates One phase on power line is missing Defective fuse on power module Defective digital inputs on power module Defective controller Enter Manual Function Test and start condenser fan Make sure the fan starts Check fan motor volts and amps Check power supply volts and amps Check volt and ampere meter Enter Manual Function Test and start condenser fan Make sure the fan starts Check fan motor volts and amps Che
90. ens that display on the controller are determined by the Controller Software settings and the options installed on the unit mu DATA Commands Menu SETPOINT PTI gt Brief PTI COMMAND lt q Functions Test ALARM LIST Manual Functions Test Defrost WARNING LIST Trip Start CONFIGURATION DATALOGGER STATES Figure 29 Manual Function Test NOTE THE UNIT STOPS when the Manual Function Test menu is entered A technician can then select the control circuit or component to be checked tested from the items shown in the menu Complete the following steps to enter the Manual Function Test menu With the unit turned on allow Unit to start and stabilise and the Display showing the unit status display setpoint 1 Press the F4 MENU key Press the F3 key to scroll down to the Commands Menu 2 Press the F4 ENTER KEY to access the Commands menu 3 Press the F2 oR F3 Up Down key to scroll to MANUAL FUNCTION TEST 4 Press the F4 ENTER KEY to enter the Manual Function Test CONDENSER OFF appears in the Display To test a unit component 1 Press the F2 oR F3 Up Down key to scroll to desired component test PHASE DIRECTION HEATER COMPRESSOR EVAPORATOR FAN HIGH EVAPORATOR FAN LOW CONDENSER FAN ECONOMIZER VALVE DIGITAL VALVE 2 Press the F4 ENTER KEY to start the component test Display will change the component state from off to on Verify
91. ensor During a Probe test the Display shows PROBE TEST PLEASE WAIT The controller operates the unit on high speed evaporator fans only for 5 minutes All sensor temperatures are then compared Sensors with large temperature differences are discarded from the control algorithm The controller then activates the appropriate Alarm codes to identify the defective sensor s Ifno sensors are found defective controller display shows RUNNING WITH HIGH SUPPLY DIFFERENCE warning Sensor errors recorded during a probe test are cleared when the next Defrost is initiated or UNIT On OFF switch is turned OFF NOTE A manual probe test can be performed by a technician by selecting SENSOR CHECK from the Manual Test Function menu Dehumidify Mode During Chill mode operation a dehumidification system is available to reduce the relative humidity in the container to the desired humidity setpoint The Dehumidify mode option is turned on from Setpoint menu of the controller The relative humidity setpoint can be set from 60 to 99 percent from the Setpoint menu NOTE The use of the Dehumidify mode should be established by the shipper Changing the humidity control from off to DEHUM in the setpoint menu activates the dehumidify control algorithm When the Dehumidify mode is on the supply air temperature must be in range to activate dehumidification e When the humidity level is 2 percent or more above setpoint and t
92. ensors include e Supply Air e Return Air Evaporator Coil e Condenser Coil Compressor Discharge Temperature Sensor Ambient Air 92 Installing Temperature Sensors All sensors should be properly installed as follows Supply air sensors must be inserted to the bottom of the sensor tube and completely sealed by the grommet connection Return air sensor installs in a grommet between the evaporator fans Evaporator coil defrost sensor must be placed in the middle of the coil and 75 mm deep between the fins Condenser sensor must be placed on the upper left side of the condenser coil and 70 mm deep between the fins Ambient sensor must be placed on the bottom plate of the right forklift pocket Compressor discharge temperature sensor is attached to compressor head by adhesive See Compressor Discharge Temperature Sensor Replacement in the chapter for Refrigeration System Diagnosis and Service Testing the Sensors The controller constantly monitors the left hand and right hand supply sensors return sensor and defrost evaporator coil sensor to determine when to initiate a demand defrost If a demand defrost is requested and defrost has occurred within the last 90 minutes the controller initiates a probe test to check for a defective sensor During a Probe test the VGA display shows PROBE TEST PLEASE WAIT The controller operates the unit on high speed evaporator fans only for 5 minutes All senso
93. ent current draw is 50 percent below expected amps for 4 minutes Indicates Defective or open high pressure cutout Switch Defective or open motor internal high temperature protection switch Unit on water cooled condensing with no water flow Defective condenser coil sensor or sensor location Supply Air Temperature Too High During Chill or Frozen Mode Supply air temperature is too high compared to return air temperature under operating conditions Indicates Low refrigerant charge Incorrect connection or location of supply or return air sensor Air leakage at supply air sensor cable Ice or frost on evaporator coil Incorrect evaporator fan operation ro Warning Message Controller Action Corrective Action Controller activates Alarm Code 31 after 5 minutes Controller clears message after compressor start up Enter Manual Function Test menu and test operate each component Check volts and amps to determine which component has high amp draw Check power supply volts Check volt and ampere meter Check Display for High Pressure Cutout message Enter Manual Function Test menu and test operate each component Check volts and amps to determine which component has low amp draw Check volt and ampere meter Last defrost 90 minutes perform defrost Controller perform Probe test If sensor is still high generates Alarm 128 131 Diagnosis Troubleshooting Warnings and Alarm Codes
94. ent temperature NOTE Correct all existing alarm conditions and clear the alarm codes before performing a Brief PTI test The controller will automatically clear all existing alarms before beginning the Brief PTI test With the UNIT TURNED ON Allow Unit to start and stabilise and the Display showing the unit status display setpoint 1 Press the F4 MENU key Press the F3 key to scroll down to the Commands Menu 2 Press the F4 ENTER KEY to access the Commands menu 3 Press the F2 oR F3 Up Down key to scroll to Brief PTT 4 Press the F4 ENTER KEY to start the Brief PTI test Display shows PTI test currently being performed PTI test ends automatically Press any key on the controller to return the unit to normal operation See Figure 30 for the Magnum PTI Test Procedure Detailed PTI test results are stored in the MP 4000 Datalogger for later viewing Any alarm codes recorded during the test can be viewed through the controller s Alarm List menu at the end of the test Main Menu Function Test The MP 4000 controller contains a special function test that automatically tests individual components including the controller display sensors condenser fan evaporator fan compressors etc The test includes measurement of component power consumption and compares test results to expected values NOTE All screens are NOT present on all units The screens that display on the controller are determined by the Control
95. erly Use a refrigerant recovery process that prevents or absolutely minimizes refrigerant escaping to the atmosphere Fluorocarbon refrigerants are classified as safe refrigerants when proper tools and procedures are used Certain precautions must be observed when handling them or servicing a unit in which they are used Fluorocarbon refrigerants evaporate rapidly freezing anything they contact when exposed to the atmosphere in the liquid state In the event of frost bite attempt to protect the frozen area from further injury warm the affected area rapidly and maintain respiration e Eyes For contact with liquid immediately flush eyes with large amounts of water and get prompt medical attention Skin Flush area with large amounts of lukewarm water Do not apply heat Remove contaminated clothing and shoes Wrap burns with dry sterile bulky dressing to protect from infection injury Get medical attention Wash contaminated clothing before reuse Inhalation Move victim to fresh air and use CPR or mouth to mouth ventilation if necessary Stay with victim until arrival of emergency medical personnel 13 Safety Instructions Warning Fans start automatically AXA0214 Warning Hot Components Compressor discharge may be hot AXA0215 S Warning High voltage WARNING TURN POWER OFF BEFORE DISCONNECTING DATALOGGER OR CONTROLLER AXA0216 AXA0217 _A WARNING PR
96. etector if the unit is low on R 404A charge Refrigeration Maintenance Receiver Tank Sight Glass The receiver tank contains a sight glass which has three small balls that indicate the level of refrigerant in the tank for checking the refrigerant charge A moisture indicator in the sight glass changes color to indicate the level of moisture in the system Check the color of the indicator against the color decal in the sight glass The dry eye in the sight glass is light green when the system is dry and yellow when the system is wet contains excessive moisture A AXA0371 1 Moisture Indicator Light Green Dry Yellow Wet 2 Outer ring is color coded Compare to indicator Figure 63 Receiver Tank Sight Glass 99 Refrigeration Maintenance Leak Testing the Refrigeration System Use a reliable Halogen leak detector such as model H10G refer to Tool Catalog to leak test the refrigeration system Inspect carefully for signs of compressor oil leakage which is the first sign of a leak in the refrigeration system NOTE Due to environmental concerns and personal safety the use of a Halide torch is no longer recommended If refrigerant has leaked or been removed from the unit 1 Check entire system for possible component damage and refrigerant oil loss 2 Attach gauge manifold set see Gauge Manifold Set Attachment and Purging for proper procedures 3 Attach refrigerant bottle charging hose t
97. evaporator coil defrost sensor temperatures Sensor readings should be the same evaporator coil may be 0 5 C 1 0 F lower due to fan motor heat Open evaporator door and inspect evaporator fan rotation Make sure fans are rotating correctly on low speed Check the sensor connections Enter Manual Function Test menu Start and check current draw of the following components separately and together compressor vapor on condenser fan and evaporator fans high Check discharge and suction pressure readings Also check the refrigerant charge NOTE This alarm can be activated in ambient temperatures below 10 C 14 F even under normal conditions Diagnosis Troubleshooting Warnings and Alarm Codes Alarm Codes Descriptions and Corrective Actions Continued Code Desorption _ __ __________TComeeiveAeiien Vapor Injection Valve Error Check vapor valve function Occurs during pti brief pti and function tests Current consumption not correct for valve position Low Pressure Cutout Error Check discharge and suction pressure gauge Occurs during pretrip PTI test only readings If refrigerant pressures are low check for a restriction and leak check the refrigeration Low refrigerant charge system Indicates Refrigeration system restriction at filter drier or f refrigerant pressures are high check for a expansion valve high refrigerant charge see below Defective low pressure cutout swi
98. fter the hour immediately following a defrost timer request for defrost initiation For example if the defrost timer requests a defrost cycle at 7 35 the defrost cycle will start at 8 01 Datalogger will record a Defrost event for each interval in which a Defrost cycle is pending or active i e both the 8 00 and 9 00 data logs Demand Defrost Demand defrost function initiates defrost when Temperature difference between the return air sensor and defrost evaporator coil sensor is too large for 90 minutes Temperature difference between the supply air sensors and return air sensor is too large Defrost Timer Chilled mode Evaporator Coil Temperature must be below 5C 41 F to activate the defrost compressor hour timer There is an interval set for defrosting however the defrost timer is built intelligent it detects whether or not there is ice building up on the coil If there is no ice building up on the coil it extends the defrost interval and if there is Ice building up earlier on the coil it reduces the defrost interval The maximum interval is 48 hours Frozen mode Every 8 hours of compressor operation Defrost interval increases 2 hours each timed defrost interval Maximum time interval in Frozen mode is 24 hours Reset to Base Time Defrost timer resets if the unit is off more than 12 hours setpoint is changed more than 5 C 9 F or PTI pretrip test occurs Defrost Termination Def
99. g has a leak and must be repaired If the vacuum level remained below 2000 microns for 5 minutes the unit is ready to charge See Charging the System with Refrigerant Pressure Rise Test Evacuate the system and close valve V1 With valves V3 and V4 open the pump is isolated and the system is held under a vacuum If the micron meter rises one of the following conditions exist e Leak Watch the movement of the micron meter needle If the needle continues to rise until it reaches atmospheric pressure it is an indication that a leak exists somewhere in the system When a leak is in a system the vacuum will eventually stabilize at atmospheric pressure see Pressure Rise Test Evaluation in this chapter Moisture When the needle indicates a rise and then stabilizes at a level below atmospheric pressure it is an indication that the system is vacuum tight but is still wet and requires additional dehydration and pumping time See Figure 68 Pressure Rise Levels Off After Evacuation Indicates Moisture in System AXA0191 Close the vacuum valve and watch the movement of vacuum gauge needle If needle continues to rise this is an indication that a leak exists in the unit or connecting line The leak must then be located and eliminated Pressure Vacuum Atmospheric Pressure Figure 67 Constant Pressure Rise After Evacuation Indicates System Leak Refrigeration Maintenance AXA0192 3 Close the vacu
100. guration feature detects the unit options installed on a unit After the initial unit power up the controller turns the Auto Configuration feature off See Replacing the Controller in this chapter for more information A complete listing of the controller operating menu is located on an 11 x 17 fold out on the last page in this manual Main Menu Viewing or Setting Functions With the UNIT TURNED ON Allow Unit to start and stabilise and the display showing the unit status display 1 Press the F4 MENu key Press the F3 key to scroll down to the CONFIGURATION Menu 2 Press the F4 ENTER KEY to expand this menu Press the F2 or F3 Up Down key to scroll cursor to view or reset the desired function Container ID Sets the container identification number Enter up to 11 characters numbers or letters In Range Temperature limit Sets the temperature value for the controller s In range LED and datalogger functions factory default 1 5 C 2 7 F Enter a value from 0 5 to 5 0 C 0 9 to 8 9 F 20 FT Option This tells the controller that this is the option chosen AFAM Option This turns on the AVL option scroll between none and AVL Humidity Option When humidity sensor is mounted you can change the setting here Suction Pressure Option When suction pressure sensor is mounted you can change the setting here Discharge Pressure Option When discharge sensor is mounted changed you can change the setting here
101. gure 25 Commands Meni arg x met Ra RM geek d eae eae ewe Eee ee a 49 Figure 26 PTI Men nme nn en ne rang x Rd eer aed ne ORE HY RU Y RO dd de d 49 Figure 27 Brief PN x ege RR RR A ce Re en 50 Figure 28 Function Test ee Eyes te e A eda e ede Po Ade Dod dee dae edo d a 51 Figure 29 Manual Function Test a sert Er era 6c AEN ERRA nn 52 Figure 30 PTI Brief PTI Function Tests 0 0 00 0c rn 54 Figure 31 Commands Menu occ 61 Figure 32 Alarms Menu 2 0 2 c ec ee ee 9 ed ede RR S eee ee 63 Figure 33 Configuration Menu aras me ti de eee nn 65 Figure 34 Datalogger Menu 66 Figure 35 Datalogger Menu eraru aeri ae aa a e E E a e T E E a A a a A 68 Figure 36 States Menu Screen Flow Diagram 0 0 0 tees 70 Figure 37 RMM States sitas edes sae oe a A EAE Io Sacred E OREI een 71 Figure 38 Chill Load Control Sequence Setpoints at 9 9 C 14 1 F and Above 2 75 Figure 39 Frozen Load Control Sequence Setpoints at 10 C 14 F and Below 77 Figure 40 Compressor Digital Control Solenoid Valve auaa onen seen een nenn 79 Figure 41 Economizer Heat Exchanger ooo 79 Figure 42 Main Circuit Breaker ooooocoooccoo hh 83 Figure 43 Low and High Pressure Cutout Switches 2 2202 onen rennen een 83 Figure 44 High Pressure Cutout Manifold llleieeee 84 Figure 45 Low and High Pressure Cutout Switches 2 2222 seen eae 86 Figure 46 Low and H
102. h rrr 67 Inspect OG Mta 67 Calibrate Probe Opti nal 2 asar bap uten eager e qe e dle anata 67 Set Log Time Interval n eec sirrien ehh eh nn 69 States Men a E Bde OE LULA e is der 70 A A 70 INPUE QU PUE anc feces cones Gada Eres apre ea an ae ala Reb aaa a Fuge an ath ae gag 70 RMM State ree 2 Rhett BEE e ee el ee ats Be aa ee 70 Viewing the RMM State Screen 0 0 nennen 70 Operating TEON eia lee Ss E E eke A Saale pe eels Geena eee 73 Chill Loads Setpoint at 9 9 C 14 1 F and Above 000 cece ee 73 Frozen Loads Setpoint at 10 C 14 F and Below 0 2200 cece ete 73 Compressor Vapor Injection ooooooocoo nennen eee 73 High Temperature Protection o ooooccococ nenn 73 Power Limit Mode 2 beet ende ge b ner dab Be u to perdi 74 Evaporator Fan Control 74 Gondenser Far Control suso arar arena Mia ena ea aa mie eru edue 74 Probe Test ae na eus ato a an bite e mea UAI NEM ies 74 Dehumidify Mode o 2 4 se rr re ee a de et 74 Continuous Temperature Control Operation 22 2 o 75 Frozen Loads Controller Setpoint at 10 C 14 F and Below ooococcccocooooo 77 Compressor Digital Control Valve o ooooooooooooo e m m 79 Economizer System us tado a a AA AAA Steep rn du debt 79 Data Recording and Downloading Data ocooccococc een 80 Controller Maintenance sa A cs Sau ch a E a Pog nea ae Gar np ges MUS 81 Flash Loading Controller Software
103. harge pressure of the 3 compressor by blocking the condenser coil airflow Temporarily cover the compressor compartment control box and power cord storage compartment with cardboard to reduce condenser coil airflow This should increase the discharge pressure enough to cause the switch to open When the switch opens The compressor should stop immediately NOTE The discharge pressure should never be allowed to exceed 3 447 kPa 34 4 bar 500 psig 4 Be sure to remove the cardboard installed in step 3 If the HPCO switch fails to stop compressor operation replace the switch and repeat steps 1 through 4 High Pressure Cutout Switch Removal Remove the high pressure cutout switch by performing the following steps 1 Isolate the compressor from the system a Front seat the discharge service valve by turning the valve fully clockwise b Front seat the suction service valve by turning the valve fully clockwise Turn the digital service valve one quarter turn to the right 2 Recover the refrigerant from the compressor see Recovering Refrigerant from the System 3 Disconnect the high pressure cutout switch wires from the control box 4 Remove the high pressure cutout switch from the compressor flange High Pressure Cutout Switch Installation Install the high pressure cutout switch by performing the following steps 1 Apply Locktite sealant to the threads of the switch 2 Install switch in comp
104. he Digital Control valve has reduced the unit cooling capacity to 85 percent the controller pulses the electric heaters on and off This increases the cooling load on the evaporator coil thereby causing the coil to become even colder and condense more moisture from the container air Continuous Temperature Control Operation Chill Loads Controller Setpoint at 9 9 C 14 1 F and Above The controller regulates the compressor Digital Control valve and electric heaters based on a Control Temperature Differential see General Theory of Operation in this chapter for more detail This means the unit operating mode can not be predicted based only on the setpoint and supply air temperature At setpoints of 9 9 C 14 1 F and above the controller operates the unit on Cool mode with Modulation Controller energizes the vapor injection valve continuously when the cool capacity is 100 percent Heat mode electric heaters pulse on and off on a 60 second duty cycle Defrost mode electric heaters on evaporator fans off Operating Theory AXA0156 Cool with Modulation control temperature A irt differential is above setpoint Heat electric heaters pulse on and off on a 60 second duty cycle if the control temperature differential is below setpoint Figure 38 Chill Load Control Sequence Setpoints at 9 9 C 14 1 F and Above 75 Operating Theory MAGNUM Operating Mode Function Chart
105. he element Loosen the clamp and remove the element from the tube Unsolder the three tubes to the TXV and remove the valve from the unit Prepare the tubes in the unit and on the new TXV for installation Solder in the new TXV Use 15 silver solder 203 364 Pressurize the refrigeration system and check for leaks see Refrigeration Leak Test Procedure in this chapter Repair leak 1f required Evacuate the system see Evacuation and Cleanup of the Refrigeration System in this chapter Install element in tube on suction line Tighten clamp Reapply insulation around bulb and secure with a ty band Install the element access panel and install grommets Install TXV mount Install left side motor and fan Open service valves or recharge unit with R404A see Charging the System with Refrigerant in this chapter Perform a controller pretrip test to verify system operation Economizer Expansion Valve Replacement Economizer Expansion Valve Removal Remove the economizer expansion valve by performing the following steps 1 Recover the refrigerant charge from the unit see Recovering Refrigerant from the System on page 104 2 Unclamp feeler bulb from the suction line in the condenser section 3 Heat and unsolder the inlet and outlet lines from economizer expansion valve unit 4 Remove economizer expansion valve from unit Economizer Expansion Valve Installation 1 Install the
106. ief PTI Test in the Operating Instructions Section Full PTI Test The MP 4000 controller contains a special Full PTI pretrip test that automatically checks unit refrigeration capacity heating capacity temperature control and individual components including the controller display solid state contactor fans protection devices and sensors The test includes measurement of component power consumption and compares test results to expected values The test takes up to 2 to 2 5 hours to complete depending on the container and ambient temperature Refer to the Full PTI Test Menu in the Operating Instructions Section Functions Test The MP 4000 controller contains a special function test that automatically tests individual components including the controller display sensors condenser fan evaporator fan compressors etc The test includes measurement of component power consumption and compares test results to expected values Refer to the Functions Test Menu in the Operating Instructions Section Manual Functions Test The Manual Function Test menu allows technicians to perform specific diagnostic tests on individual components or turn several components on at the same time to perform a system test Refer to the Manual Functions Test Menu in the Operating Instructions Section Data The Data menu displays general unit operating information including sensor temperatures unit electrical data etc Refer to the Data Menu in the Opera
107. igh Pressure Cutout Switches 2 2222 onen rennen re 86 Figure 47 Pressure Sensor Location 0 000 ccc een 87 Figure 48 Compressor Discharge Temperature Sensor 00 lille 91 Figure 49 Temperature Sensors se redo ce nn 92 Figure 50 MAGNUM Evaporator Coil Defrost Sensor Location 0 002 cece eee 93 Figure 51 Condenser Coil Sensor Location 0 0 0 rn 93 Figure 52 Resistance Values for temperature sensors lille 94 Figure 53 Service Fittings Specifications llle eee 95 Figure 54 Service Valve Back Seated ooooccococco hh 96 Figure 55 Service Valve Open to Port 22 teeta 96 Figure 56 Service Valve Front Seated 0 0 ete eae 96 Figure 57 Balancing the Pressure 2 0 5 2 000 cc tee nn 96 Figure 58 Removing Refrigerant 0 0 0 00 teas 97 List Of Figures Figure 59 Figure 60 Figure 61 Figure 62 Figure 63 Figure 64 Figure 65 Figure 66 Figure 67 Figure 68 Figure 69 Figure 70 Figure 71 Figure 72 Figure 73 Figure 74 Figure 75 Figure 76 Figure 77 Figure 78 Figure 79 Figure 80 10 Gauge Manifold Closed to Center Port 97 Gauge Manifold Open to Center Port o ooccococc ae 97 Charging the System 2 3 od aa Bene ee Pare EAEE PERO d Balken are d Mate we 97 Purging Gauge Manifold oaser p 058442 e per pP ee A a a EA 98 Receiver Tank Sight Glass Hs 22H ss nennen EAEE RETE E hh he 99 Test for Refrigeran
108. il the unit is re connected to power and the battery automatically recharged Trip data can be retrieved but not erased from the data logger memory using a LOGMAN II handheld data retriever LOGMAN II PC used on a laptop PC or a REFCON power line remote monitoring system LOGMAN II data transfer rate based on a 1 hour log interval is about 15 seconds per month of event logs and about 70 seconds per month of temperature logs For example downloading 90 days of data logs would take about 95 seconds for event logs only and about 210 seconds for temperature logs only Trip data from separate units is denoted by the identification information entered into the controller at the beginning of the trip via the general purpose keypad Identification data may include the container ID number location B R T contents loading data voyage no ship load port discharge port and comments The container ID number is stored in the Configuration submenu Controller Maintenance Flash Loading Controller Software Controller software must be flash loaded when software has been revised To flash load software complete the following steps 1 Load the New Software on an SD card 2 Open the controller door 3 On the side of the controller there is an SD slot 4 Put the SD card into the slot The controller will automatically upload the software if it is a newer version than the one already in use and restart the unit 5 Remember to en
109. ils are highly refined to obtain low vacuums failure to follow these recommendations may result in acidic conditions that will destroy the pump Use Filters and Cartridges Cleanup devices such as suction line filters and compressor oil filters may be used if they are properly cleaned and new filters and cartridges are used All standard petroleum and synthetic compressor oils must be removed to prevent the contamination of R 404A systems Use the Correct Refrigerant Recovery Equipment Use only refrigerant recovery equipment approved for and dedicated to R 404A recovery Detecting Leaks Leaks can be detected with the use of soap bubbles and with Halogen leak detectors such as model H10G or model H10N portable Locating Special Service Fittings Special fittings are used on HFC systems to prevent mixing of non HFC refrigerants in HFC units These fittings are located in three places on MAGNUM refrigeration systems Low side near the compressor suction service valve or suction adapter e High side near the compressor discharge service valve or discharge manifold Receiver Tank GE Du IZ CEES a 4 6mm 8 2mm 11 2mm 9 FR AZ IS aa d N MAD a N 11 0mm 13 0mm Spr X ROS Internal Threads for Cap High Pressure Fitting Low Pressure Fitting Figure 53 Service Fittings Specifications 95 Refrigeration Maintenance Perform an Oil Acid Test Perform an oil acid tes
110. ime 1 Press the F4 MENU key Press the F3 key to scroll down to the CONFIGURATION Menu 2 Press the F4 ENTER KEY to access the CONFIGURATION menu Press the F3 key to scroll down to the Miscellaneous Settings Menu 3 Press F3 to scroll to the Date Time Menu and 4 Press the F4 ENTER KEY to access the Date Time screen Date Time screen appears 5 Press the F4 ENTER KEY EDIT to edit 6 Enter new time by Using F2 or F3 Up Down to change the digits and by pressing F4 to move the cursor on to the next digit 7 Once you have scrolled the cursor through all the time and date digits you get an option to Press the F4 ENTER KEY to save Press and hold F4 until the main menu appears 66 8 Press the F1 key to exit the Date Time screen Datalogger Menu The Datalogger menu contains a list of functions that display unit operating information recorded in the MP 4000 datalogger The following functions are available Inspect Log Displays results of last PTI Event and Temperature test including component volt and amps data and sensor temperatures Test values are recorded at the start and end of the Chilled and Frozen mode test Calibrate Probe Optional Sets a temperature offset in the controller memory to calibrate each USDA sensor to the controller Set Log Time Interval Sets the data log interval 1 minute or 1 2 1 2 or 4 hours A complete listing of the controller operating menu is located on an 11 x 17
111. ines evaporator fan motor speed based on the setpoint temperature and the mode setting Chill Loads Setpoints of 9 9 C 14 1 F and Above When the Optimised Mode is set to ON the evaporator fans operate on low and high speed When the Non Optimised mode is set to On the evaporator fans operate continuously on high speed Frozen Loads Setpoint at 10 0 C 14 0 F or Below When the Optimised mode is set to On the evaporator fans operate on low speed on and off Condenser Fan Control The controller also uses a proportional integral derivative algorithm to control the condenser temperature and ensure a constant liquid pressure at the expansion valve The condenser fan operates continuously in high ambients In low ambient conditions the controller pulses the condenser fan on and off to maintain a minimum condenser temperature The controller maintains a minimum 30 C 86 F condenser temperature on Chill loads and a minimum 20 C 68 F condenser temperature on Frozen loads To do this the condenser fan pulses Note When the condenser fan is pulsing ON OFF the fan will come on just before the fan stops rotating Probe Test The controller constantly monitors t supply sensor return sensor and evaporator coil sensor to determine when to initiate a demand defrost If a 74 demand defrost is requested and defrost has occurred within last 90 minutes the controller initiates a probe test to check for a defective s
112. ing pretrip and routine maintenance inspections A low charge of refrigerant will cause the container temperature to rise due to the lack of liquid refrigerant at the expansion valve even though the unit is operating in a cooling mode All MAGNUM units are charged with 4 0 kg 8 0 Ibs R 404A refrigerant at the factory The refrigerant charge can be checked by inspecting the receiver tank sight glass 1 Inspect the receiver tank sight glass with the unit operating in cool or modulation cool If the ball floats in the bottom receiver tank sight glass when the compressor is engaged the R 404A charge level is correct 2 Ifthe ball is not floating in the sight glass the unit may be low on R 404A charge Adjust the controller setpoint to operate the unit on cool Operate the unit on cool for 5 minutes If the ball floats in the receiver tank sight glass the R 404A charge level is correct CAUTION When adjusting the controller setpoint to check refrigerant charge be sure to return controller to the setpoint indicated on the shipping manifest 3 Ifthe ball in the receiver tank sight glass does not float after operating the unit on cool for 5 minutes the unit is low on R 404A charge With the unit operating on cool add liquid R 404A charge With the unit operating in cool add liquid R 404A until the ball in the receiver tank sight glass floats in the sight glass NOTE Inspect the unit for refrigerant leaks with a reliable leak d
113. ion When the Dehumidify mode is set to On the supply air temperature must be In range to energize the electric heaters e When the humidity is 2 percent or more above humidity setpoint the controller energizes the heaters sController energizes electric heaters for heat defrost and dehumidification Heat mode compressor off If supply air temperature is too low heaters pulse on and off on a 60 second duty cycle Defrost mode Heaters are on until evaporator coil temperature increases to terminate defrost 76 Cool with Modulation Controller calls for the Cool mode whenever the Control Temperature Differential based on supply air temperature is above setpoint Controller turns on the Compressor indicates when the compressor is operating Controller opens and closes Digital Control valve to control the compressor load The duty cycle of the Digital Control valve balances the unit cooling capacity against the actual load requirements Controller turns the In range LED solid when the supply air sensor temperature is within 1 5 C 2 7 F of setpoint Controller turns on the Heat indicator whenever the heaters are pulsed on and off Heat If the supply air temperature is too low and the Control Temperature Differential is below the setpoint the controller stops the compressor The fans low speed are kept on to determine if fan heat is sufficient to increase temperature to setpoint If not switch to high spee
114. ith high speed evaporator fans less than approximately 4 5 C 8 F When the return air temperature does not reach 18 C 0 F within preset time Indicates ncorrect location of supply or return air sensor Air leakage at supply sensor cable Defective supply or return air sensor Interchanged sensor connections Incorrect evaporator fan rotation or high speed operation Incorrect refrigeration system operation Container side panels defective damaged or leaking Economizer circuit defective Press Sup RET key to check supply and return air sensor temperatures Compare temperatures to evaluate unit cooling capacity and performance Temperature difference should be 4 C to 6 C 39 F 43 F Open evaporator door Inspect coil for ice or frost and initiate manual defrost if necessary Check refrigerant charge NOTE This alarm can be activated if the supply or return air temperature varies even if the mean temperature does approach setpoint Initiate a manual defrost and check amperage draw and evaporator coil temperature Evaluate defrost performance Open evaporator door and check location of evaporator coil sensor NOTE This alarm can be activated at low voltage and very low box temperature conditions even under normal operating conditions Enter Manual Function Test and start evaporator fans on high speed Then select Sensor Checks test and operate fans 2 to 5 minutes Check supply return and
115. ler Software settings and the options installed on the unit Be DATA Commands Menu SETPOINT PTI gt Brief PTI COMMAND lt q Functions Test ALARM LIST Manual Functions Test Defrost WARNING LIST Trip Start CONFIGURATION DATALOGGER STATES Figure 28 Function Test NOTE The function test does not test the actual performance ofthe complete system Therefore it is not a pretrip test and should not be used instead of the PTI test With the UNIT TURNED ON Allow Unit to start and stabilise and the Display showing the unit status display setpoint 1 Press the F4 Menu key Press the F3 key to scroll down to the Commands Menu 2 Press the F4 ENTER KEY to access the Commands menu 3 Press the F2 or F3 Up Down key to scroll to FUNCTION TEST 51 Main Menu 4 Press the F4 ENTER KEY to start the Function test Display shows functional test currently being performed Function test ends automatically Unit automatically returns to normal operation See Figure 30 for the full Function Test Procedure Any alarm codes recorded during the test can be viewed through the controller s Alarm List menu at the end of the test 52 Manual Function Test The Manual Function Test menu allows technicians to perform specific diagnostic tests on individual components or turn several components on at the same time to perform a system test NOTE All screens are NOT present on all units The scre
116. lose discharge service manifold hand valve fully to center port You are now ready to use the gauge manifold to check system pressures or perform most service procedures NOTE These gauges may be removed and reinstalled without additional purging so long as a slight positive pressure remains in the manifold and hoses when removed from the unit Suction Connection Discharge Connection Figure 62 Purging Gauge Manifold Removing the Gauge Manifold Set NOTE THE SYSTEM SHOULD BE RUNNING to ensure minimum refrigerant release to the atmosphere However this is not possible in all cases but the same procedure should be followed l Rotate discharge hose fitting hand wheel counterclockwise to withdraw the fitting stem from the discharge line port valve Then open both service manifold valves to center port Operate the unit on Cool using the CAPACITY 100 percent test from the Manual Function Test menu of the controller A CAUTION Rubber gloves are recommended when handling Ester based compressor oil 3 Rotate the suction hose coupler hand wheel counterclockwise to withdraw the fitting stem from the suction line port valve Then turn the unit off Remove the gauge lines from the suction and discharge service fittings and cap the service ports Secure all manifold lines to manifold hose anchors when the manifold is not in use Checking Refrigerant Charge The refrigerant charge should be checked dur
117. lve b Continue evacuation to 500 microns or until vacuum stabilizes at its lowest level Contamination may delay reaching the lowest level for a period of several hours or more c Close valve V1 to isolate the vacuum pump from the system d Observe the vacuum level on the micron meter When the meter has stabilized the value indicated on the micron meter is the equilibrium pressure This reading must be 2000 microns or less NOTE The presence of refrigerant in the compressor oil may prevent a low vacuum reading from being achieved Compressor oil can continue to outgas for long periods of time 106 If the vacuum level appears to stall above 500 microns back seat the discharge service valve and observe the micron meter A drop in pressure indicates that the compressor oil is out gassing and further evacuation is necessary Anincrease in pressure indicates that a leak exists or there is moisture in the system Perform a pressure rise test and evaluate Close valve V1 when the desired vacuum level has been reached Wait five minutes and read the micron meter e A system that is leak free and dry will remain below 2000 microns for 5 minutes e A system that rises above 2000 microns but stabilizes below atmospheric pressure is probably contaminated with moisture or has refrigerant out gassing from the compressor oil Additional evacuation is required A system that continues to rise without stabilizin
118. menu See Setpoint Menu under Menu Operating Instructions in this chapter MENU Main Menu To view the alarms that are present FA turn the UNIT ON Allow Unit to start and stabilise To enter the main menu Press F4 See next Section on Navigating the Controller Menu p 51 for this operation Controller Back up Battery Every Controller has a Back up Battery This will allow the controller to be energized if the unit is not connected to shore power The technician can change settings in the controller Setpoint etc Press the ON OFF key the controller will energize and stay energized for 25 sec by pressing any of the Menu keys the 25 sec timer will reset to 20 sec 43 Operating Instructions 44 Navigating the Controller Operating Menu Navigating the Controller Operating Menu DATA SETPOINT CONTROL SETTING COMMAND ALARM LIST WARNING LIST CONFIGURATION DATALOGGER STATES Message Display Menu Scrolling Keys Figure 22 MP 4000 Controller Display Panel Menu Scrolling Keys Moving through these eight menus their submenus and entering commands requires the use of four keys EXIT Press the F1 key each time you want to exit a submenu shown in the message display UP DOWN Press the F2 or F3 key EPA each time you want to scroll up or down F3 in a menu or submenu shown in the Message Display or scroll forward or backward in a menu line ENTER P
119. move compressor discharge temperature sensor from the discharge valve manifold Disconnect the unit from the three phase power supply Remove the three phase electric power connection from the compressor Remove the compressor mounting tray bolts and nuts Slide the compressor from the unit Keep compressor ports covered to prevent dust dirt etc from falling into compressor Compressor Installation Install the compressor by performing the following steps 1 Slide the compressor into the unit Install mounting bolts washers and nuts and tighten Bolt the discharge and suction service valves to the compressor Use a new gasket coated with compressor oil on the discharge valve 10 Refrigeration Maintenance Scroll Compressor Suction Service Valve Discharge Service Valve Figure 69 Scroll Compressor Connect vapor injection line and digital control valve line to compressor body Apply refrigerant locktite to the threads of the compressor discharge temperature sensor Install the switches Pressurize the refrigeration system and check for leaks see Refrigerant Leak Test Procedure in this chapter If no leaks are found recover the refrigerant used for the leak test see Leak Test Procedures in this chapter Evacuate the system see Evacuation and Cleanup of the Refrigeration System in this chapter Connect three phase electric power to the compressor Recharge
120. n provides full cooling capacity When the controller energizes it opens the Compressor Digital Control valve Refrigerant gas flows from the digital port of the compressor back to the suction line This disengages the compressor 100 percent and temporarily reduces the compressor pumping capability The controller uses a proportional integral derivative PID algorithm to provide accurate temperature control This is in direct response to load demand However instead of generating a voltage signal to position a suction line modulation valve to regulate cooling capacity the Operating Theory algorithm establishes a pulse width signal to cycle the Compressor Digital Control valve open and closed on a duty cycle The percent ON time compressor pumping time in the duty cycle equals the cooling capacity percent required to meet the current load demand Remember that the percent ON time defines the time the compressor is engaged The compressor is engaged pumping when the Compressor Digital Control valve is closed OFF Therefore a duty cycle of 100 percent means the compressor is pumping 100 percent of the time and the Compressor Digital Control valve is ON open 0 percent of the time A 60 percent duty cycle means the compressor is pumping 60 percent of the time and the Compressor Digital Control valve is ON open 40 percent of the time Economizer System An economizer heat exchange system replaces the conventional heat e
121. nated To configure a sensor in the unit see Configuration Menu in the Operating Instruction chapter in this manual 87 Electrical Maintenance Discharge and Low Pressure Sensors Removal Remove the discharge or suction sensor by performing the following steps 1 Disconnect the sensor from the control box 2 Remove the sensor from the discharge or suction tube The fitting on the line has a Schrader valve which will prevent refrigerant leakage Discharge and Low Pressure Sensor Installation Install the discharge and low pressure sensor by performing the following steps 1 Apply Locktite to fitting threads Red 277 2 Install sensor on fitting 3 Route wire harness to control box and connect per wiring diagram 88 Condenser Fan and Evaporator Fan Rotation NOTE If both the condenser fan and evaporator fans are rotating backwards diagnose the automatic phase selection system Check Condenser Fan Rotation Check for proper condenser fan rotation by placing a small cloth or sheet of paper against the condenser fan grille on the front of the unit Proper rotation will blow the cloth or paper away from the grille Improper rotation will hold the cloth or paper against the grille If the condenser fan is rotating backwards see the unit wiring diagram to correct fan motor wiring at the fan motor junction box or condenser fan contactor To correct improper fan rotation reverse any two fan power cor
122. ns on Low speed Make sure all fans start on low speed Check fan motor volts and amps Check volt and ampere meter Diagnosis Troubleshooting Warnings and Alarm Codes Alarm Codes Descriptions and Corrective Actions Continued Occurs during pretrip PTI or function test only When the evaporator fan power consumption is 25 percent below expected current draw below 0 6 to 1 2 amps depending on voltage Indicates Defective or open fan motor internal over temperature protection switch Defective volt or amp meter on power module Incorrect motor or motor connections Evaporator Fan Low Speed Current Too Low Open evaporator door and make sure all fans rotate freely Enter Manual Function Test and start evaporator fans on low speed Make sure all fans start on low speed If a motor does not start and is very hot wait 10 minutes for internal over temperature switch to close Check fan motor volts and amps Check volt and ampere meter If both alarms 12 and 13 or 14 and 15 are activated the alarms are caused by a large difference in measured amps Enter 13 or 14 and 15 are activated the alarms are caused by a large difference in measured amps Enter Manual Function Test menu and operate evaporator fans on low and high speed Check the evaporator fan amps measure ment If necessary check the resistance in the motors High speed between EF 11 and EF12 EF12 and EF 13 and EF11 and EF13 Low speed betw
123. o center of gauge manifold and purge charging hose of air 4 Pressurize the system with refrigerant gas only until 345 kPa 3 45 bar 50 psig vapor pressure is achieved 5 Leak check the system with an electronic leak detector to inspect all joints and connections Use soap solution as an alternative test component If no leaks are found but the system has lost its refrigerant charge proceed to the next step 6 Close both hand valves on gauge manifold front seated 7 Disconnect the refrigerant charging hose 8 Connect the charging hose to a source of nitrogen Adjust the pressure regulator to 1380 kPa 13 80 bar 200 psig See Using Pressurized Nitrogen in this chapter 9 Pressurize the system with nitrogen to 1380 kPa 13 80 bar 200 psig 10 Close the supply valve on the nitrogen bottle 11 Use an electronic leak tester to inspect all joints and connections Use a soap solution as an alternative test component 100 NOTE If system leakage is indicated loosen supply line hose fittings to release pressure Repair leakage condition 12 If system repair is necessary recheck system after repairs are completed AXA0186 Figure 64 Test for Refrigerant Leaks Using Pressurized Nitrogen The improper use of high pressure cylinders can cause physical damage to components or personal injury or cause stress that would lead to failure of components AXA0194 an Pe ran Pressur
124. o contact your eyes Rubber gloves are recommended when handling Polyol Ester based refrigerant oil Do not allow prolonged or repeated contact with skin or clothing Immediately wash all exposed skin after handling refrigerant oil Use the following First Aid practices if needed Eyes Immediately flush eyes with large amounts of water Continue flushing for at least 15 minutes while holding the eyelids open Get prompt medical attention Skin Remove contaminated clothing Wash thoroughly with soap and water Get medical attention if irritation persists Inhalation Move victim to fresh air Restore breathing if necessary Stay with victim until arrival of emergency personnel Ingestion Do not induce vomiting Contact a local poison control center or physician immediately Electrical Precautions The possibility of serious or fatal injury from electrical shock exists when servicing a refrigeration unit Extreme care must be used when working with a refrigeration unit that is connected to its power source Extreme care must be used even if the unit is not running Lethal voltage potentials can exist at the unit power cord inside the control box inside any high voltage junction box at the motors and within the wiring harnesses Precautions In general disconnect the units power cord before repairing or changing any electrical components Note that even though the controller is turned off one of the phases
125. oltage below 440V 55 Main Menu Display Description Possible Duration Brief Function Alarms Time PTI Test TEMPERATURE With evaporator fan on high 20 to 180 SUIABIHSOHON speed awaiting the supply return seconds and evaporator temperatures to stabilize Delta SUP RET and Delta RET EVA must be stable within 7 seconds Awaiting temperature stability PRE HEAT TEST Test is skipped if return air tem None Instant to 2 SUP RET EVA perature is at 5degC or above hours 5 1C 5 0C 5 1C With electric heaters turned on 2 3A 2 1A 2 3A and evaporator fan on high speed the test will end when return air temperature is at 5degC or above Heating until 5C 41F PRE COOL TEST If the return air temperature is None Instant to 2 x SUP RET EVA below 15C 68F the test is 5 1C 5 0C 5 1C skipped Unit operates in cool 2 3A 2 1A 2 3A until the return sensor is less then 15C 59F or 1 hour Cooling until 15C 59F VENTILATING If heater or compressor has been None 60 seconds x x x running in the preceding test the unit is ventilated with evaporator fan on high speed Ventilating COMPRESSOR TEST Compressor loaded and con 6 7 18 seconds x x x AMB CON EVA denser fan activated for 10 sec 8 0C 15 0C 5 0C Followed by compressor run 9 1A 90A 9 1A alone for 7 sec before the amp draw is measured and compared to the expected amp draw in respect to voltage and frequency Amperes are recorded in the PTI log Evaluating power consumption
126. ontroller Supply Air Sensor Short Circuit Check sensor resistance must be approx 1 000 ohms at 25 C 77 F See Resistance When the sensor circuit resistance is lower than t Values for temperature sensors on page 94 200 ohms Indicates Check for damaged sensor wires Short circuit to sensor Check sensor connections at controller Defective or wrong sensor Defective power module Defective or wrong sensor Defective controller Return Air Sensor Open Circuit Check sensor resistance must be approx 1 000 ohms at 25 C 77 F See Resistance When the sensor circuit resistance is higher than q Values for temperature sensors on page 94 100 000 ohms Indicates Check for damaged sensor wires Open circuit to sensor Check sensor connections at controller Defective or wrong sensor Defective power module Defective cable No 1 Defective controller Return Air Sensor Short Circuit Check sensor resistance must be approx When the sensor circuit resistance is lower than 1 900 0hms ab 28 9477 F See Resistance Values for temperature sensors on page 94 Indicates BT Check for damaged sensor wires Short circuit to sensor E Check sensor connections at controller Defective or wrong sensor Defective power module Defective controller 133 Diagnosis Troubleshooting Warnings and Alarm Codes 134 Alarm Codes Descriptions and Corrective Actions Continued Description
127. ontroller immediately stops unit operation if the discharge gas temperature increases to 148 C 298 F The controller activates the Alarm indicator and records Alarm Code 56 Compressor Temperature Too High The controller will restart the unit when sensor temperature is below 90 C 194 F Electrical Maintenance Compressor Discharge Temperature Sensor Replacement The compressor discharge temperature sensor is mounted externally on the compressor head To remove 1 Shut off power to system 2 Disconnect the compressor discharge sensor wires from J 15 pins 9 amp 10 located in the control box on the main power module 3 Cut silicone seal under rim of sensor using razor blade Remove old sensor and sensor wires Clean sensor seat using wire brush Blow out all debris using compressed air cb gv we uem Apply 0 25 to 0 5 cc thermal grease to mounting position of new sensor 8 Add a bead of RTV silicone approximately 5 mm in diameter around area 9 Press new sensor into position 10 Route the new sensor wires into the control box Connect wires to J 15 pins 9 amp 10 on the main power module 91 Electrical Maintenance Figure 49 Temperature Sensors Temperature Sensors Thermistor type temperature sensors are used Each sensor is connected to a cable and placed in a sealed stainless steel tube The temperature signal from the sensor is transmitted through the cable Temperature s
128. open continuously when the compressor duty cycle ON time is 100 percent Full Cool High compressor discharge temperature may cause the vapor injection valve to energize open but only while the Compressor Digital Control valve is not energized closed Data Recording and Downloading Data The MP 4000 data logger can record sensor temperatures as well as loss of power alarms sensor failure setpoint change and unit shutdown events All data logs include the time and date setpoint temperature supply return ambient USDA1 USDA2 USDA3 and cargo sensor temperatures and humidity sensor All temperature logs can be viewed from the controller s VGA message display Data logging intervals are selectable for 30 minutes 1 2 or 4 hours When a 1 hour logging interval is selected the data logger memory can store approximately 680 days of information The logging of USDA sensors is fixed at 1 hour intervals to comply with USDA requirements A logging test of USDA sensors at 1 minute intervals is possible for 72 minutes USDA data can not be downloaded during the logging test and can only be viewed on screen After 72 minutes controller returns to previous logging interval and clears USDA test data from data logger memory If the unit power supply is disconnected the data logger will continue to register 120 temperature logs except humidity sensor when battery 80 voltage is above 4 2 volts These will be maintained unt
129. opped it can result in the total destruction of your equipment Unit Preparation and Hookup l CAUTION Do not attempt to evacuate a unit until it is certain that the unit is leak free A unit with less than a full charge of refrigerant should be thoroughly leak tested Any leaks found must be repaired Recover all refrigerants from the unit and reduce the unit pressure to the proper level US Federal Law requires a 17 to 34 kPa 0 17 to 0 34 bar 5 to 10 in vacuum that is dependent upon the recovery equipment used Break vacuum with refrigerant and equalize system pressure to 0 kPa 0 bar 0 psig Replace the liquid line filter drier if necessary NOTE Replace the one piece filter drier when major system contamination requires evacuation and cleanup of the refrigeration system Confirm that the evacuation station functions properly Determine Blank Off pressure The Blank Off pressure of the vacuum pump is the deepest vacuum that the vacuum pump can attain when isolated from the rest of the system The operator can be confident that the pump and oil are in good condition ifa vacuum pump isolated from a system is started and the micron meter responds quickly by going to a deep vacuum If the vacuum pump fails to reach a deep vacuum within 5 minutes the operator should suspect the condition of the oil or the pump It is recommended that the pump oil be changed first to see if the rate of reaching a deep
130. orator Motor 13 mm 0 5 in Figure 79 Evaporator Fan Blade Placement Servicing the Fresh Air System Adjusting the Fresh Air Exchange System The fresh air exchange system has an adjustable vent door for ventilation The evaporator fans draw in outside air through an air intake and discharge an equal amount of container air through an air outlet NOTE Set the disk or door position to the ventilation rate indicated on the shipping manifest Disk Adjustment Low Ventilation Rates To make a disk adjustment perform the following steps 1 Loosen wing nut on handle assembly Figure 80 2 Rotate the disk to set the Indicator at the air exchange rate shown on the ventilation scale on the door e MAGNUM Models 0 225m3 hr 0 154 ft3 min 3 Tighten the wing nut Handle Adjustment High Ventilation Rates To make a handle adjustment perform the following steps 1 Loosen wing nut on handle assembly until handle bracket will rotate over handle 2 Align handle bracket and wing nut over hole in handle assembly and push through handle 3 Pull handle down to lower ventilation door Insert edge of ventilation door in a notch on handle Spring loaded handle holds ventilation door in position Air exchange rate is shown on the handle scale Servicing The Unit x AXA0195 Disk Scale Low Ventilation Rates Disk Assembly with Rate Indicator CO Port Ventilation Door Handle Bracket 6 Wing Nut Figu
131. orm defrost During Chill or Frozen Mode Evaporator coil Controller perform Probe test temperature is too low compared to return air jr sensor is still low generates Alarm 130 temperature under actual operating conditions Controller initiates defrost if no recent defrost Indicates Airflow is blocked in the container Evaporator fans do not operate Fresh air exchange vent open too much on frozen load Defective evaporator coil or return air sensor 132 Diagnosis Troubleshooting Warnings and Alarm Codes Alarm Codes Descriptions and Corrective Actions NOTE Sensors used with the MP 4000 e Shutdown Alarm Level 1 Alarm Alarm controller do not require calibration Check light on display flashes and unit stops Correct sensor resistance with an ohmmeter alarm condition and acknowledge alarm before restarting Check Alarm Level 2 Alarm Alarm light on display flashes until alarm is acknowledged Alarm Codes Descriptions and Corrective Actions Code Description O TCorrecilve Action Supply Air Sensor Open Circuit Check sensor resistance must be approx 1 000 ohms at 25 C 77 F See Resistance When the sensor circuit resistance is higher than i Values for temperature sensors on page 94 100 000 ohms indicates Check for damaged sensor wires Open circuit to left or right hand sensor Check sensor connections at controller Defective or wrong sensor Defective c
132. orming the following steps 1 Recover the refrigerant charge from the unit see Recovering Refrigerant in this chapter 2 Unsolder the two liquid and two suction line connections 3 Unbolt the economizer heat exchanger from the mounting bracket 4 Lift the heat exchanger assembly from the unit Economizer Heat Exchanger installation Install the heat exchanger by performing the following steps 113 Refrigeration Maintenance 1 Bolt the economizer heat exchanger to the mounting bracket in the condenser section 2 Clean the two liquid and two suction lines for soldering 3 Solder the liquid and suction lines to the economizer heat exchanger 4 Pressurize the low side and check for leaks see Refrigerant Leak Test Procedure in this chapter 5 Ifno leaks are found recover the leak test gas see Refrigerant Leak Test Procedure in this chapter 6 Evacuate the low side see Evacuation and Cleanup of the Refrigeration System in this chapter 7 Recharge the unit with R 404A see Charging the System with Refrigerant in this chapter 8 Perform a controller pretrip test to verify system operation NOTE Thermo King strongly recommends that dry nitrogen be used to purge the system during any solder operations see Using Pressurized Nitrogen in this chapter 114 Receiver Tank Water Cooled Condenser Tank Replacement Tank Removal Remove the old tank by pe
133. ped for NTC style USDA sensors require USDA sensor P N refer to Tool Catalog MAGNUM units equipped for PT100 style USDA sensors require USDA sensor P N refer to Tool Catalog Ice Bath Preparation 1 The ice bath should consists of an insulated container full of ice made from distilled water with enough distilled water added to cover the top of the ice during the test A properly filled ice bath should be completely filled with ice all the way to the bottom of the container 67 Main Menu Stir the ice bath briskly for one minute before proceeding Insert the USDA sensors in the ice bath Wait 5 minutes to allow the sensor temperatures to stabilize at 0 C 32 F Stir the ice bath frequently As an option test and verify ice bath temperature with a meter or measuring device meeting your accuracy requirements Stirring 10 seconds every 3 minutes during the test procedure is adequate Calibrating the USDA Sensors l 68 Insert all USDA sensors in an ice bath see Ice Bath Preparation above NOTE The sensors must be completely immersed in the ice bath without contacting the walls of ice bath container for 5 minutes Press the F4 Menu key Press the F3 key to scroll down to the DATALOGGER Menu NOTE All screens are NOT present on all units The screens that display on the controller are determined by the Controller Software settings and the options installed on the unit mu DATA rs S
134. peed is running evaporator high speed is running or evaporator high speed and heat is on Frozen cooling down Frozen cooling down mode where the Unit set point is set to below 10C The function here is to maintain setpoint temperature by controlling the temperature on the return air Frozen cooling down mode can operate the unit in different modes where the compressor is loaded and vapor injection is on off The condenser fan will operate in an on off algoritim depending on the temperature on the condenser The evaporator fans will operate in low speed mode or off Defrost Defrost is a situation where the unit either on demand or timing is defrosting the evaporator coil The unit is heating with the heating elements awaiting 18C on the evaporator sensor When the set Defrost termination temperature is reached the unit will return to the operation mode depending on the setpoint PTI PTI is a pretrip inspection and is used to diagnose the condition of the unit There are a possibility to chose between several type of PTI s depending on the test needed to secure the functionality of the unit 39 Controller Description Function Keys The function keys are the F1 F4 keys located below the display They allow the operator to move quickly to a specific area of the information or into the controller menu Function keys will change based on what menu is active in the display ALARM _ __ciF__ SETPOINT _MENU_
135. perating hours Unit mounting bolts should be tightened to a torque value of 204 Nem 150 ft lb Compressor and fan motor mounting bolts should be tightened to a torque value of 20 to 21 Nem 15 to 20 ft lb BEN074 Tighten Unit Mounting Bolts 2 Tighten Compressor Condenser Fan and Evaporator Fan Mounting Bolts Figure 77 Mounting Bolts Cleaning the Condenser Coil Clean the condenser coil by blowing low pressure compressed air or a medium pressure warm water spray from the inside of the coil outward opposite direction of normal airflow Inspect coil and fins for damage and repair if necessary CAUTION Air pressure or water spray must not be high enough to damage coil fins If a build up of salt or debris is present on the condenser coil the coil should be cleaned using a mild alkaline cleaner with a pH of 9 5 to 10 5 For example a 2 3 percent solution of SIMPLE GREEN would make a suitable cleaning solution Apply the solution using a pressure spray wash type apparatus Spray the condenser coil thoroughly from both the inside and outside of the coil Always thoroughly rinse the coil with a fresh water spray Also inspect the directional airflow condenser grille for damage This grille directs the condenser airflow out and away from the unit to increase the efficiency of the condenser coil by preventing the recirculation short cycling of warm air through the coil Abnormally high head p
136. place gauge Condenser coil dirty or airflow restricted Replace switch 127 Diagnosis Troubleshooting Warnings and Alarm Codes Condition Head pressure too high Possible Cause Refrigerant overcharge Purge system Air in refrigeration system Evacuate and recharge Dirty or restricted condenser coil Clean condenser coil See Condenser Fan Motor Does Not Condenser fan not operating Operate under Mechanical Diagnosis Condenser fan grille damaged or go Repair or replace grille missing Compressor loses oil Refrigerant leak Repair leak and recharge Compressor oil migrates to See Unit Short Cycles under Short cycling S system Mechanical Diagnosis Rapid cycling between Cool Null and Heat modes Hot liquid line Frosted liquid line Frosted or sweating suction line Unit in vacuum frost on expansion valve only High suction pressure 128 Air short cycling through evaporator Check and correct cargo load Diagnose power module and Defective controller or power module controller Replace defective component Short cyclin See Unit Short Cycles under 1509 Mechanical Diagnosis Compressor Digital Control valve Replace valve stuck close or defective Replace filter drier filter drier Expansion valve admitting excess rere ee feeler bulb and adjust refrigerant expansion valve Check defrost circuit including Evaporator coil needs defrosting controller and evaporator
137. plete listing of the controller operating menu is located on an 11 x 17 fold out in the Wiring and Diagram section in the back of the manual see last page in book It is designed to be folded out so you can continuously view it as you are learning how to navigate the MP 4000 Controller Menu It is recommended to fold this menu out and leave it folded out until you become familiar with the controller menu 46 Main Menu Data Menu The Data menu displays general unit operating information including sensor temperatures unit electrical data etc A complete listing of the controller operating menu is located on an 11 x 17 foldout on the last page of the book NOTE Information can ONLY be displayed using the Data menu Items can NOT be changed The screens that display on the controller are determined by the controller software setting and the options installed on the unit All screens are NOT present on all units NOTE All screens are NOT present on all units The screens that display on the controller are determined by the Controller Software settings and the options installed on the unit Supply Return Evaporator Condensor Compressor Ambient Humidity USDA 1 USDA 2 USDA 3 SETPOINT Cargo p Voltage Current Curr Ph 1 Curr Ph 2 Curr Ph 3 m DATA COMMAND ALARM LIST WARNING LIST CONFIGURATION Frequency Modulation Fresh Air E
138. pments When USDA sensors are installed the controller will automatically detect each sensor and activate data logging However the USDA Type screen in the Configuration menu must be set to the correct sensor setting and each USDA sensor must be calibrated to comply with USDA temperature recording requirements Figure 11 Water Cooled Condenser Receiver Tank Water Cooled Condenser Receiver Tank Optional A water cooled condenser receiver provides the unit with above and below deck operating capabilities Condenser fan control is provided in software or by a Condenser Fan Selection switch or a Water Pressure switch Starting april 2005 we have added a shutoff valve on the outlet tube of the water cooled condenser Condenser fan switch is a software key This switch is provided on the control box with the water cooled condenser option Place the Condenser Fan On Off switch in the Water position for water cooled condenser operation 30 Water Pressure Switch Optional When water pressure greater than 117 21 kPa 1 17 0 21 bar 17 3 psig is provided to the condenser receiver tank the water pressure switch closes This causes the controller to stop condenser fan operation When the water pressure decreases below 35 21 kPa 0 35 0 21 bar 5 3 psig the switch opens causing the controller to place the unit on air cooled condenser fan operation Water cooled condenser requires a water flow of 19 to 38 l min
139. po d p bag Cum EN 2 Radiator Fresh Air Ex 02 Condensor Cargo Cur Ph 3 J 1 pt 1 10 a C Press Alarm Key to Quickly view Acknowledge Alarms F1 Ses MESS Battery Voltage Pt 1000 spare TE Press C F key to view alternate temperature scale in LED display F2 Setpoint Menu Enter a Temperature or Activate Humidity Contol Press SETPOINT Key to Quickly change Setpoint F3 Opti Set Bulb Mode Humidity Setpoint Press F4 key Temp Setp o i o SETPOINT MENU Press MENU Key to view the main menu F4 u USDA mp Fes IS key osez Press F2 key to scroll he Watercool AFAM Mode this menu setting between OFF Press DEFROST key to initiate a manual defrost Evaporator F4 a SETPOINT ECaniraling mode AFAM Delay Press F2 or F3 key to and ON coil temperature must be below 10C 50F Ino ema Mm increase or decrease os cdit Ty Press PTI key to quick Start the Pre Trip Inspection PTI F1 Hum Setpoint C02 Max setting until you are returned to Defrost Trm Temp 02 Min es enel S FA ey DU i E a until you are returned To Enter a Submenu a Command or a New Value in a DER to the main screen Text Screen Commands Manual Defrosttest Press F4 key to Press F4 key To Activate a AE Temperature start and stop test 1 ine Command abilisation scroll component To Scroll in a Menu or a Text Line Press F4 to start a First Component Pre Heat Test display between Press F2 key to
140. portional integral derivative algorithm to control the condenser temperature and ensure a constant liquid pressure at the expansion valve The condenser fan operates continuously in high ambients In low ambient conditions the controller cycles the condenser fan on and off to maintain a minimum condenser temperature The controller maintains a minimum 30 C 86 F condenser temperature on Chill loads and a minimum 20 C 68 F condenser temperature on Frozen loads Unit Options This unit is available with several options that are listed in Figure 10 These options are specified when placing the order These options are briefly described on the following pages B LA 1 Recording Thermometer Optional Air Ventilation Logging AVL Water Pressure Switch Optional Remote Monitor Modem for Power Line Communications REFCON control modem inside Control Box Optional USDA Sensor Receptacle Access from Inside Container Optional Suction Discharge Pressure Transducer Optional Figure 10 Optional Components Unit Description Features amp Options Recording Thermometer Optional The recording thermometer indicates and permanently records the temperature of the air returning to the evaporator section on a calibrated chart Several models of temperature recorders are available for mounting on the unit Each temperature recorder is designed to withstand widely varying environments incl
141. r Tank Sight Glass The receiver tank contains a sight glass which has three small balls that indicate the level of refrigerant in the tank for checking the refrigerant charge A moisture indicator in the sight glass changes color to indicate the level of moisture in the system AXA0371 1 Moisture Indicator Light Green Dry Yellow Wet 2 Outer ring is color coded Compare to indicator Figure 9 Receiver Tank Sight Glass Evaporator Fans MAGNUM models are equipped with either 2 or 3 evaporator fans All models feature 2 speed motors The evaporator fans operate continuously to circulate air inside the container The evaporator fans operate on High and low speed for chilled cargo at setpoints of 9 9 C 14 1 F and above Low speed for frozen cargo at setpoints of 10 C 14 F and below 28 The evaporator fan low speed RPM is one half the high speed RPM The controller determines evaporator fan motor speed based on the setpoint temperature and the Economy mode setting NOTE If Non Optimised mode is on Chill Loads Evaporator fans operate on high speed Frozen Loads Evaporator fans operate on low speed NOTE If optimised mode is on Chill Loads Evaporator fans operate on high and low speed depending on the need for cooling Frozen Loads Evaporator fans operate on low speed and stops when there is no need for cooling Condenser Fan Control The controller also uses a pro
142. r circuit resistance is higher than 100 000 ohms Indicates Open circuit to sensor Defective or wrong sensor Defective power module Defective controller Ambient Air Sensor Short Circuit Occurs during pretrip PTI test only Sensor circuit resistance is lower than 200 ohms Indicates Short circuit to sensor Defective or wrong sensor Defective power module Defective controller above 40 C 104 F Indicates Defective return or evaporator coil sensor Return and evaporator coil sensor connections are reversed Low Supply Voltage Alarm occurs if line voltage is below 350 volts for 30 minutes Ifthe main power supply voltage to the unit while running drops below 340 VAC the unit will stop running until the voltage increases above 350 VAC If the main power supply voltage on initial unit start up is below 350 VAC the unit will not start If the voltage remains below 350 VAC for 30 minutes Alarm 51 Low Voltage will occur Probe Error Occurs during pretrip PTI test or probe test failed in Chilled mode Temperature difference between return air and evaporator coil sensors is too high 1 5 C 2 7 F difference maximum Return Air temperature Too High During defrost Return air temperature increases 140 Check sensor resistance must be 1 000 ohms at 25 C 77 F Check for damaged sensor wires Check sensor connections at controller Check sensor
143. r temperatures are then compared Sensors with large temperature differences are discarded from the control algorithm The controller then activates the appropriate Alarm codes to identify the defective sensor s Sensor errors recorded during a probe test are cleared when the next Defrost is initiated or Unit On Off switch is turned Off NOTE A manual probe test can be performed by a technician by selecting SENSOR CHECK from the Manual Test Function menu Electrical Maintenance A l Z AXA0172 B 1 to 1 2 in 25 to 30 mm Coil Support Bracket IB Unit Front Insert Sensor at least 75 mm into coil between Tube Rows 2 and 3 Figure 50 MAGNUM Evaporator Coil Defrost Sensor Location AXA0173 a A Insert Sensor into condenser coil between Tube Rows 1 and 2 Figure 51 Condenser Coil Sensor Location Electrical Maintenance Resistance Values for Temperature Sensors Sensors are permanently calibrated and can be checked using an ohmmeter Ohm readings should agree with the data shown in the following Sensor resistance tables 1 Resistance Values for Supply Return Evaporator Coil Condenser Coil and Ambient Air Sensors Figure 52 Resistance Values for temperature sensors ELM King a 1e 4 3 sns e m pre n pars e 0657 824 28 1082 paz e ores 30 mer o 1000 958 30 28 1024 1075 42 rast 354 8 0912 2 41 708
144. ration Unit Start up Connect unit to 460 Volt shore power or genset Turn circuit breaker on at post to apply power to unit e Display will show Johnson Controls Test Memory Passed Start Application Display will go blank with just status bar Display Thermo King Logo Please Wait Loading Screen go blank Press and Hold ON OFF key for 2 seconds e Display shows RA SA SP PM 4000 Setup Power Module Init Power Module Phase test Shows heater icon Power module Ready Stop Plant Unit starts and shows CHILLED COOLING and shows mode of operation NOTE Random time delays during the initial unit start up minimize peak current draw 41 Operating Instructions Initiating a Manual Defrost Turn the UNIT ON Allow Unit to start and stabilise Complete the following steps 1 Press the DEFROST Special Function key Ifthe unit operating conditions allow a manual defrost e g evaporator coil temperature is less than 18 C 56 F the unit enters Defrost rH 4vL LoPrs HiPrs 0 0 0 0 0 0 SA 0 0 Ne Fie SP 6 0 DEFROST AWAITING EVAP O O 18 0 C ALARM CIF SETPOINT MENU 2 The defrost cycle automatically terminates and returns the unit to normal operation 42 PTI Turn the UNIT ON Allow Unit to start and stabilise Complete the following steps 1 Press the PTI Special Function key During testing the screen is divided into 3 sec tion
145. rdware Torque Charts Bolt Size Bolt Type M8 M10 M12 and Class N m Ft Ib N m Ft Ib N m Ft Ib HH CL 5 8 6 9 4 7 12 16 9 12 27 34 20 25 48 61 35 40 HH CL 8 8 10 13 7 10 20 27 15 20 41 47 30 35 75 88 55 65 HH CL 10 9 14 17 10 13 27 34 20 25 54 68 40 50 102 122 75 90 HH CL 12 9 17 21 12 16 41 47 30 35 68 81 50 60 122 149 90 110 HH SS 2 10 13 7 10 20 27 15 20 41 47 30 35 75 88 55 65 Bolt Size Boll Type and M14 M16 M18 Class N m Ft Ib N m Ft Ib N m Ft Ib HH CL 5 8 75 88 55 65 115 135 85 100 177 216 130 160 339 406 250 300 HH CL8 8 115 135 85 100 177 216 130 160 271 339 200 250 475 610 350 450 HH CL 10 9 136 176 100 130 224 298 180 220 393 474 290 350 678 813 500 600 HH CL 12 9 177 216 130 160 285 352 210 260 448 542 330 400 881 1016 650 750 HH SS 2 115 135 85 100 177 216 130 160 271 339 200 250 475 610 350 450 HH Hex Head CL Class 36 Controller Description Controller Description The MP 4000 is an advanced microprocessor controller It has been specially developed for the control and monitoring of refrigeration units The controller contains the following basic features Temperature Message Status Display Temperature area Displays Return air sensor Supply air sensor and Setpoint Message area Displays Alarms Message and Controller menu
146. re 80 Air Exchange System 121 Servicing The Unit 122 Diagnosis Troubleshooting Warnings and Alarm Codes Introduction This chapter includes the following e Introduction to Controller Diagnostics e Troubleshooting charts Warnings chart Alarm Codes chart The charts will help you identify and fix unit problems Controller Diagnostics The MP4000 can be a very helpful diagnostic tool The following menu areas of the MP4000 controller menu will help you diagnose problems occurring with the Magnum unit Alarms Warnings Menu The Alarm Warning list menu displays the code conditions Alarm Warning codes are recorded in the controller memory to simplify unit diagnosis procedures Some alarm codes are only recorded during a Pretrip PTI test or function test Fault codes are retained by the controller in a non volatile memory If the Red LED is on or flashing enter the alarm list to view the alarm Brief PTI Test The MP 4000 controller contains a special Brief PTI pretrip test that automatically checks unit refrigeration capacity heating capacity temperature control and individual components including the controller display solid state contactor fans protection devices and sensors The test includes measurement of component power consumption and compares test results to expected values The test takes about 25 30 minutes to complete depending on the container and ambient temperature Refer to the Br
147. re Cutout Switch Removal Low Pressure Cutout Switch High Pressure Cutout Switch Discharge Service Valve Suction Service Valve Figure 46 Low and High Pressure Cutout Switches Remove the low pressure cutout switch by performing the following steps 1 Disconnect the low pressure cutout switch wires from the control box 2 Remove the low pressure cutout switch from the suction line The fitting on the suction line has a shrader valve which will prevent refrigerant leakage Electrical Maintenance Low Pressure Cutout Switch Installation Install the low pressure cutout switch by performing the following steps 1 Install low pressure cutout switch in the suction line 2 Route wires into the control box and connect to proper terminals 3 Perform a controller pretrip test to verify system operation AAAG16 Suction Pressure Sensor Discharge Pressure Sensor Suction Service Valve Discharge Service Valve Figure 47 Pressure Sensor Location Discharge and Low Pressure Sensors Optional The unit can be configured discharge only suction only or discharge and suction The sensors are located on the discharge or suction tubes near the compressor The controller will display the actual discharge or suction system pressure The display will show a reading and a bar graph If the unit is configured with a suction sensor the LPCO will be elimi
148. recting problem and CONFIGURATION acknowledging the alarm DATALOGGER To acknowledge an alarm press F4 key with STATES alarm code in display Figure 32 Alarms Menu View the Alarm Warning List Menu The Alarm Warning list menu displays the code conditions Alarm Warning codes are recorded in the controller memory to simplify unit diagnosis procedures Some alarm codes are only recorded during a Pretrip PTT test or function test Fault codes are retained by the controller in a non volatile memory If the Red LED is on or flashing enter the alarm list to view the alarm With the unit turned on allow unit to start and stabilise and the Display showing the unit status display setpoint 1 Press the F1 key to directly enter Alarms Warning menu The first alarm code number alarm state and alarm description appears in Display Main Menu NOTE Alarm codes are displayed in sequential order not in order of occurrence 2 Write down the first code Then press the F2 or F3 Up Down key to view next alarm code when more than one code has been recorded 3 Repeat above step until all alarm codes have been recorded Press the F2 key to scroll backward to return to a previous code 4 To clear all alarm codes from the current display list and turn off the Alarm LED all problems must be corrected and the alarm code acknowledged in the Alarm List menu 5 To acknowledge an alarm warning press F4 ACCEPT KEY while co
149. refrigeration unit with covers removed be very careful with tools or meters being used in the area e Check the condition of the gauge manifold hoses Never let the hoses come in contact with a fan motor blade or any hot surface e Never apply heat to a sealed refrigeration system or container e Fluorocarbon refrigerants produce toxic gases in the presence of an open flame or electrical arc The gases are severe respiratory irritants capable of causing death Firmly tighten all mounting bolts Check each bolt for correct length for their particular application e Use extreme caution when drilling holes in the unit The holes may weaken structural components Holes drilled into electrical wiring can cause fire or explosion Holes drilled into the refrigeration system may release refrigerant e Use caution when working around exposed coil fins The fins can cause painful lacerations e Use caution when working with a refrigerant or refrigeration system in any closed or confined area with a limited air supply for example a trailer container or in the hold of a ship Refrigerant tends to displace air and can cause oxygen depletion This can result in suffocation and possible death e Use caution and follow the manufacturer s suggested practices when using ladders or scaffolds Refrigerant Oil Precautions Observe the following precautions when working with or around refrigerant oil e Do not allow refrigerant oil t
150. resistance must be 1 000 ohms at 25 C 77 F Check for damaged sensor wires Check sensor connections at controller Check for sensor alarm codes Check supply and return sensor connections and locations Check line voltage of power source Refer to the electrical specifications in the Specifications Section for correct power Source requirements Check sensor connections Check sensor resistance of each sensor Resistance must be 1 000 ohms at 25 C 77 F Diagnosis Troubleshooting Warnings and Alarm Codes Alarm Codes Descriptions and Corrective Actions Continued Code Description _____________TComecveAetin High Pressure Cutout Switch Off Error Check discharge and suction pressure gauge Occurs during pretrip PTI test only readings and check refrigerant charge Enter Manual Function Test menu Start the following components together compressor 100 percent compressor and evaporator fans Indicates high Discharge pressure should increase Faulty compressor contactor or control circuit and compressor should stop at 2250 kPa 22 5 bar 326 psig high pressure cutout switch opens Compressor does not stop during high pressure cutout switch test Low refrigerant charge Defective high pressure cutout switch Strong winds causing cooling of condenser coil in low ambient conditions High Pressure Cutout Switch On Error Check discharge and suction pressure gauge Occurs during pretrip PT
151. ress any key on the controller to return the unit to normal operation See Figure 30 for the Magnum PTI Test Procedure Detailed PTI test results are stored in the MP 4000 Datalogger for later viewing Any alarm codes recorded during the test can be viewed through the controller s Alarm List menu at the end of the test 50 Brief PTI Pretrip Test CAUTION The Brief PTI test should only be performed on an empty container NOTE Units equipped with a water cooled condenser must be set to operate on air cooled condensing to perform a complete system capacity test NOTE All screens are NOT present on all units The screens that display on the controller are determined by the Controller Software settings and the options installed on the unit Bd DATA Commands Menu SETPOINT PTI gt _ Brief PTI COMMAND 4 Functions Test ALARM LIST Manual Functions Test Defrost WARNING LIST Trip Start CONFIGURATION DATALOGGER STATES Figure 27 Brief PTI The MP 4000 controller contains a special Brief PTI pretrip test that automatically checks unit refrigeration capacity heating capacity temperature control and individual components including the controller display contactors fans protection devices and sensors The test includes measurement of component power consumption and compares test results to expected values The test takes about 25 30 minutes to complete depending on the container and ambi
152. ress the F4 key to enter a EE new menu or submenu The MP 4000 contains an extensive operating menu The menu is navigated via the controller keypad The Main menu is divided into eight major areas that can be navigated via keypad Data Menu Menu screens in this group are used to display unit operating information including sensor temperatures voltage current and frequency information e Setpoint Menu Menu screens in this group are used to enter the temperature setpoint and set between Optimised Non Optimised mode Setpoint menu option functions include set Humidity Control operation and enter humidity setpoint Commands Menu Menu screens in this group are used to activate pretrip PTI or brief PTI tests function tests manual function tests and power management Alarm List Menu Display a list of alarm code s present Warnings List Menu Display a list of warning code s present Configuration Menu Menu screens in this group display a Unit setting in range setting container ID b contrast screen language unit type reefer type evaporator type condenser type USDA type and other unit settings c miscellaneous settings Unit ID s Date Time 45 Navigating the Controller Operating Menu Data logger Menu Menu screens in this group display Inspect log set log interval calibrate probes States Menu Gives information on the following PTI Input Output RMM Defrost A com
153. ressor flange Electrical Maintenance Pressurize the compressor with refrigerant and check for leaks Evacuate the compressor see Evacuation and Cleanup of the Refrigeration System 85 Electrical Maintenance Low Pressure Cutout Switch High Pressure Cutout Switch Discharge Service Valve Suction Service Valve Figure 45 Low and High Pressure Cutout Switches 5 Route wires into the control box and connect to proper terminals 6 Back seat the discharge service valve by turning the valve fully counter clockwise 7 Back seat the suction service valve by turning the valve fully counter clockwise 8 Turn the digital service valve one quarter turn to the left 9 Perform a controller pretrip test to verify system operation 86 Low Pressure Cutout Switch A low pressure cutout switch is located on the compressor suction line If the suction pressure becomes too low the switch opens to stop the compressor Compressor stops immediately Evaporator and condenser fans continue normal operation Compressor will restart if the low refrigerant condition is corrected switch closes as long as power is available The low pressure switch resets closes when the pressure increases to 28 to 48 kPa 0 28 to 0 48 bar 4 to 7 psig Low Pressure Cutout Switch Opens 17 to 37 kPa 0 17 to 0 37 bar 5 to 11 in Hg vacuum Closes 28 to 48 kPa 0 28 to 0 48 bar 4 to 7 psig Low Pressu
154. ressures may result if this special condenser grille is damaged or missing Cleaning the Evaporator Coil Clean the evaporator coil by blowing low pressure compressed air from the bottom side of the coil upward opposite direction of normal airflow Inspect coil and fins for damage and repair if necessary A CAUTION Air pressure must not be high enough to damage coil fins Cleaning the Defrost Drains Clean the defrost drains every 1 000 operating hours to be sure the lines remain open 119 Servicing The Unit Positioning the Condenser Fan Blade Place fan blade on motor shaft with hub located on the outside of the blade for proper airflow direction When mounting the fan blade and hub assembly on the fanshaft center the assembly in the orifice Position the front of the fan blade 10 mm 0 4 in in from the outer edge of the fan orifice BEN041 i Airflow Direction 10 mm 0 4 in Condenser Coil Condenser Fan Blade Condenser Motor Figure 78 Condenser Fan Blade Placement Positioning the Evaporator Fan Blade Place fan blade on motor shaft with hub located on the outside of the blade for proper airflow direction When mounting the fan blade and hub assembly on the fanshaft center the assembly in the orifice Position the front top ofthe fan blade hub 13 mm 0 5 in in from the outer edge of the fan orifice 120 3 4 BEN042 Evaporator Fan Blade Airflow Direction Evaporator Coil Evap
155. rforming the following steps 1 Recover the refrigerant charge from the unit 2 Unsolder the liquid inlet and liquid outlet valve line connections 3 Loosen the mounting nuts and remove the tank Tank Installation Install the new tank by performing the following steps 1 Install a new tank in the unit and tighten the mounting bolts 2 Solder the inlet line and outlet line connections NOTE It is strongly recommended that dry nitrogen be used to purge the system during any solder operations see Using Pressurized Nitrogen in this chapter 3 Pressurize the refrigeration system and check for leaks see Refrigerant Leak Test Procedure in this chapter 4 Ifno leaks are found recover the refrigerant used for the leak test 5 Evacuate the system see Evacuation and Cleanup of the Refrigeration System in this chapter 6 Recharge the unit with R 404A see Charging the System with Refrigerant in this chapter 7 Perform a controller pretrip test to verify system operation Figure 74 Water Cooled Condenser Tank Refrigeration Maintenance AJA2032 Figure 75 Vapor Injection Valve Vapor Injection Valve Replacement NOTE In most cases only the coil requires replacement No other repair is possible on solenoid valves Valve Removal To remove the vapor injection valve perform the following steps l 2 Recover the refrigerant charge from the unit
156. rge Check evaporator coil and return air sensor connections and locations Check AMB Condenser Temperature Probe Error Check for sensor alarm codes Probetest detects inconsistency between Check supply and return sensor connections ambient and condensor sensor and locations 143 Diagnosis Troubleshooting Warnings and Alarm Codes 144 Wiring and Schematic Diagrams Index Dwg No Drawing Title Page 1654052 Wiring Schematic 147 1654051 Wiring Diagram 148 149 MAGNUM Refrigeration System Components 150 MP 4000 Menu Flow Diagram 152 145 Wiring and Schematic Diagrams Index 146 Wiring Schematic B 8 1 6 5 4 3 2
157. rost Coil Sensor Chilled mode Terminates defrost when coil sensor temperature rises to 18 C 65 F Frozen mode Terminates defrost when coil sensor temperature rises to 18 C 65 F Termination Timer Terminates defrost after 90 minutes at 60 HZ operation if coil sensor has not terminated defrost 120 minutes at 50 Hz operation Power Off 22 Turning Unit On Off switch Off terminates defrost Specifications MP 4000 Controller Specifications Continued Compressor Shutdown Protection Auto Reset Stops Compressor 148 C 298 F Allows Compressor Start Bulb Mode 90 C 194 F Evaporator Fan Speed Settings Flow High High speed only Flow Low Low speed only Flow Cycle Fans will cycle between low and high speed every 60 minutes Defrost Termination Temperature Setting Physical Specifications Fresh Air Exchange Venting System Adjustable 4 to 30 C 40 to 86 F MAGNUM Evaporator Fan Blade Specifications 0 to 225 m3 hr 0 to 168 ft min 60 Hz 0 to 185 m3 hr 0 to 139 ft min 50 Hz MAGNUM Diameter 355 mm 14 0 in Pitch 25 Number of Fans Weight net 2 MAGNUM Base Unit 380 Kg 875 Ib Water cooled Condenser Receiver Option 13 6 Kg 30 Ib 23 Specifications ri n n H H AMA313 Unit Dimensions A Flange Width 2025 5 mm 79 74 in B Gasket Width 1935 mm 76 18 in C
158. rval expires the unit returns to the standard power limit control algorithm NOTE Setting power management current at 13 amps can be used to provide slow pull down of loads Compressor Vapor Injection During compressor operation a vapor injection system injects refrigerant into the center scroll of the compressor to provide additional cooling capacity When vapor injection is active the controller energizes the vapor injection valve continuously The controller activates vapor injection when the Chill or Power Limit Mode When the cool capacity is 100 percent in the display the controller energizes the vapor injection valve continuously Compressor discharge temperature exceeds 138 C 280 F Vapor injection stops when the compressor discharge temperature decreases 6 C 10 7 F High Temperature Protection If the discharge gas temperature rises above 148 C 298 F the unit stops immediately The controller turns on the Alarm LED and records Alarm Code 56 Compressor Temperature Too High The controller will restart the unit when the sensor temperature is below 90 C 194 F 73 Operating Theory Power Limit Mode The controller uses the total unit current and the condenser temperature to provide power limit control in both the Chill and Frozen modes When the unit is on water cooled operation power limit control is based on the total unit current draw only Evaporator Fan Control The controller determ
159. s Check sensor connections at controller Check evaporator condenser and ambient sensor temperatures for correct value 5 C 9 F by viewing Data menu Enter Manual Function Test menu Start and check current draw of the following components separately and together compressor compressor 100 percent condenser fan and evaporator fan high and low Check volt and ampere meter Check power supply volts Diagnosis Troubleshooting Warnings and Alarm Codes Alarm Codes Descriptions and Corrective Actions Continued Code Description _ _ _ ___________ TComeeiiveActon 07 Compressor Current Too Low Occurs during pretrip PTI or function test only Compressor power consumption is 25 percent below expected current draw below approximately 9 amps Indicates Defective or open high pressure cutout switch Defective compressor relay Defective volt or amp meter on power module Low refrigerant charge Defective compressor Enter Manual Function Test menu Start and check current draw of the following components separately and together compressor compressor 25 percent condenser fan and evaporator fan high and low Check discharge and suction pressure gauge readings Evaluate readings based on current cargo and ambient temperatures Check volt and ampere meter Check power supply volts If both Alarms 06 and 07 are activated the alarms are caused by a large difference in measured amps Enter
160. s Section 1 Showing the list of test to be performed and there state List of possible states Awaiting the test has not yet been per formed Testing the test is ongoing Pass the test has been tested with the result Pass Fail the test has been tested with the result Fail Skipped the test is skipped based on con ditions Section 2 Additional information to explain the test is shown together with a indication of the time frame Section 3 This section displays actual readings and the expected power consumption Condenser fan test Reverse phase test Heater test Defrost test Temperature stabilization Pre heating Pre cooling awaiting Ventilating Defrost test Defrosting until 18C 64F Time 168 min O max 5400 5 34 5 34 5 34 Exp 5 34 456 04 53 0Hz Sup 32 0F Ret 32 0F Eva 32 0F Con 32 0F Amb 32 0F EXIT 2 Press the F2 F3 keys to scroll between each of the tests 3 PTI test ends automatically Pressing F1 Exit will not stop the PTI but will allow the user to view and scroll through other menu s Once the PTI is finished you will need to exit the PTI menu for the unit to go back to normal operation NOTE Detailed PTI test results are stored in the MP 4000 Datalogger for later viewing Any alarm codes recorded during the test can be viewed through the controller s Alarm List menu at the end of the test Viewing ALARM _ Alarms Warnings To view the alarms that ar
161. s Warnings and Controller Actions The controller displays Warnings In the Alarms Menu on the Display for several general faults More than one status message may appear at a time Press the F2 or F3 key to scroll through message displays Warnings and Controller Actions Warning Message Controller Action Corrective Action Power Error Check 20A Fuses Indicates One or more phases are missing Compressor is able to draw amps on all phases while heater lacks amps on one or more phases High Pressure Cutout Check Water Cooling Indicates Unit stops due to high pressure cutout and water pressure switch is open Probe Test Please Wait Indicates 3 Incorrect temperature difference between Supply or Return Air Sensor for 10 minutes with evaporator fan amps OK High Pressure Cutout Check Condenser Probe Indicates Units stops due to high pressure cutout water pressure switch is closed and condenser temperature is low High Pressure Cutout Check Condenser Fan Indicates Unit stops due to high pressure cutout water pressure switch is closed and condenser temperature is high Scroll Compressor High Temperature Indicates Compressor stops because discharge temperature is above 148 C 300 F Message remains in display until discharge temperature decreases to normal 130 Controller activates Alarm 18 Controller will try to restart unit after 60 minutes Controller clears message on
162. s Menu Figure 25 Commands Menu View the Commands Menu With the UNIT TURNED ON Having allowed Unit to start and stabilise Display showing unit status display setpoint 1 Press the F4 MENU key Press the F3 key to scroll down to the Commands Menu 2 Press the F4 ENTER key to expand this menu 3 Press the F2 oR F3 Up Down key to scroll to desired command 4 Press the F4 ENTER KEY to activate command selected PTI Brief PTI Function Test Display This Screen shows the different states of the PTI Brief PTI and Function Tests Preparation Sensor test Evaporator fan low speed test Evaporator fan high speed test Probe test Condenser fan test Reverse phase test Heater test Evaporator fan low speed test Comparing against expected value Time 1 min 5 max 5 1 24 1 24 1 24 Exp 1 24 456 04 53 0Hz Sup 0 0C Ret 0 0C Eva 0 0C Con 0 0C Amb 0 0C Figure 26 PTI Menu The Screen is divided into three sections Section 1 Shows the list of test to be performed and there state List of possible states 1 Awaiting the test has not yet been performed 2 Testing the test is ongoing 3 Pass the test has been tested with the result Pass 4 Fail the test has been tested with the result Fail 5 Skipped the test is skipped based on conditions Section 2 Additional information to explain the test is shown together with a indication of the time frame Section 3 This
163. s the F4 Menu key Press the F3 key to scroll down to the Commands Menu Press the F4 ENTER KEY to expand this menu Press the F2 or F3 Up Down key to scroll through submenu until TRIP START appears in display Press the F4 ENTER KEY to enter Tripstart function The date and time of the last trip start appears in the screen 61 Main Menu 5 Press the F4 ENTER KEY again to enter a new start of trip date and time in the log NOTE When a PTI test is completed the controller automatically enters a Tripstart in the log 6 Press the F1 key to exit the Commands menu 62 Alarms Warnings Menu There are two types of alerts Warnings Warning indicates corrective action should be taken before a problem becomes severe When a Warning occurs the controller will try to determine if the component or input is good or bad The Warning description will be displayed across the top of status display and the Red LED will not be turned on If the controls determine the component or input is bad the Warning will become an Alarm Alarms Alarm indicates corrective action should be taken Red LED flashes and unit may stop or continue to base on the alarm Alarm 56 Compressor Temperature too high is a Shutdown alarm Shutdown alarms indicate the unit has been stopped to prevent damage to the unit or cargo The condition must be corrected before restarting the unit The Alarm description will be displayed across the top of the sta
164. s the MENU key Press the F3 key to scroll down to the Temperature Setpoint Menu Press the F4 ENTER KEY to expand this menu Press the F2 F3 Up Down keys to move the Setpoint Up or down depending on your required Temperature Press and hold the F4 ENTER KEY until you are returned to the sub menu The new setpoint is recorded in the controller and appears in the display NOTE The controller will default return to the previous setpoint if the setpoint is not entered within 30 seconds Repeat steps 1 through 3 if this occurs Controlling Modes Optimised The default Mode for the new Magnum for temperature and fan control Non Optimised The default Mode for the original Magnum for temperature and fan control Change the Optimised Non Optimised Mode Setting NOTE Enter Setpoint temperature before turning on the Non Optimised mode The controller automatically turns the Non Optimised mode off when the setpoint is changed 1 Press the F4 SETPOINT key at the main screen The Setpoint Change menu appears 2 Press the F2 F3 Up Down keys to scroll between Non Optimised and Optimised Mode 3 Press and hold the F4 ENTER KEY until you are 48 returned to the main Screen The new mode is recorded in the controller NOTE On frozen loads the Non Optimised mode also modifies the temperature control algorithm to extend the Null mode See In Range Temperature Limit under Configuration Menu in this chapter to ch
165. scroll up or backward COMMAND Brief PTI Pretrip Test appears in Pre Cool Test ON and OFF Brie retrip display Press F3 key to scroll down or forward Test zu Ho o Compressor Test More than Press or ey rat one component can To Exit a Menu or Text Line PTI Pretrip Test to scroll io the Comes Biehl esi be turned ON ata Press F1 key LN Function Test desired component Compressor Econ Test deep perform a Manual Funcion f Sensor Test Pressure Sensor Test unctional test o Test Evap Fan Low HPCO Test neun To Lock a LCD Data Screen Display lt Fi Boo Ran IET Capacity Test RER Trip Start Cond Fan Test Approaching 0 Test Maximum display time is 30 minutes for data screens and 100 Miainleining O Tesi minutes for manual tests Press F1 key to exit display Probe Test een Reverse Phase Test Heater Test Pulldown to 18 C Test Alarms Menu Clear alarm code by correcting problem and acknowledging the alarm View and write down all alarm code ALARM LIST To acknowledge an alarm Press F2 key to view gt a the next alarm code press F4 key with alarm code in display Container ID Set Time Date In Range eeu Ut Press F4 key to select lt _ Bs Temperature Limit AFAM Option this menu Pulsating Press F4 key again to To Select an option in the F2 Configuration I AFAM edit Unit Configuration Menu Menu Date Time Vari
166. slight positive pressure remains in the manifold and lines 1 Inspect gauge manifold for proper hose and fitting connections 2 Clean dirt and moisture from around service ports 97 Refrigeration Maintenance 10 11 98 Remove small service port caps from suction and discharge service fittings Save and reuse the caps and sealing washers or gaskets Rotate both hose coupler hand wheels counterclockwise to back the stem out of the high and low hose fittings Attach low hose compound gauge to the suction line valve port Open the suction service manifold hand valve fully with 69 kPa 0 69 bar 10 psig or greater pressure in the low side unit operating on Cool Rotate the suction hose fitting hand wheel clockwise to open depress the suction line port valve to the low hose Slowly screw a 1 2 inch ACME fitting into the low loss fitting on the manifold s service center line to purge the suction and service hoses Remove ACME fitting after purging Close the suction service manifold hand valve fully to center port Attach high side hose pressure gauge to the discharge service line port Open discharge service manifold hand valve fully Rotate discharge fitting hand wheel clockwise to open depress discharge line port valve to the high hose Slowly screw a 1 2 inch ACME fitting into the manifold s service center line to purge the high and service hoses Remove ACME fitting after purging C
167. ssor Discharge Temperature Control Vapor Injection Valve Energizes Opens 138 C 280 F 6 C 10 7 F below energize temperature 132 C 123 F Compressor Shutdown Auto Reset 148 C 298 F Vapor Injection Valve Compressor Vapor Injection Valve De energizes Closes Cold Resistance Compressor Digital Control Valve Voltage 24 Vac Current Draw 0 85 amps Normal R 404A System Operating Pressures Scroll Compressor Container Temp Operating Ambient Suction Pressure Discharge Pressure Mode Temp 27 to 38 C 80 410 to 670 kPa 4 10 to 6 70 2140 to 2650 kPa 21 40 to to 100 F bar 59 to 97 psig 26 50 bar 310 to 385 psig 21 C 70 F Cool 16to 27 C 60 400 to 600 kPa 4 00 to 6 00 1725 to 2140 kPa 17 25 to to 80 F bar 58 to 87 psig 21 40 bar 250 to 310 psig 27 to 38 C 80 385 to 425 kPa 3 85 to 4 25 1860 to 2380 kPa 18 60 to to 100 F bar 56 to 62 psig 23 80 bar 270 to 345 psig 2C 35F Cool 16 to 27 C 60 345 to 385 kPa 3 45 to 3 85 1450 to 1860 kPa 14 50 to to 80 F bar 50 to 56 psig 18 60 bar 210 to 270 psig 27 to 38 C 80 214 to 228 kPa 2 14 to 2 28 1515 to 2035 kPa 15 15 to to 100 F bar 31 to 33 psig 20 35 bar 220 to 295 psig 18 C 0 F Cool 16 to 27 C 60 200 to 215 kPa 2 00 to 2 15 1100 to 1515 kPa 11 00 to to 80 F bar 29 to 31 psig 15 15 bar 160 to 220 psig 27 to 38 C 80 145 to 160 kPa 1 45 to 1 60 1450 to 1965 kPa 14 50 to to 100 F bar 21 to 23 psig 19 65 bar 210 to 285 psig
168. stem Wrong or defective sensor NOTE Unit will operate normally without compressor sensor However controller compressor high temperature protection is not active Phase Sensor Error Start a Function Test During step F1 05 check whether the phase relays on power module receive a signal LED energizes During Phase Sensor Test amperage difference Verify that the relays respond and shift to between correct and wrong condenser fan rotation reverse phase is more than 0 2 amps e Occurs during pretrip PTI or function test only Indicates Defective phase relay Defective power module 141 Diagnosis Troubleshooting Warnings and Alarm Codes Alarm Codes Descriptions and Corrective Actions Continued Description recta Action Delta Current Error Enter Manual Function Test menu and test operate each 3 phase component to locate 100 percent ampere difference between current defective connection phases Indicates Open connection on one phase of power supply to a motor or heater element SE i Humidity Sensor Error Check sensor connections e Occurs during pretrip PTI test only Check controller configuration for correct Relative humidity reading is less than 20 percent humidity setting lt Indicates Replace sensor Sensor disconnected Wrong controller software configuration Defective sensor Compressor Sensor Short Circuit Check sensor resistance must be 1
169. sure you still have the correct settings 6 The SD card can be removed when the unit has re started Controller Replacement 1 Turn the UniT ON OFF switch OFF 2 Turn the unit 460 380V main circuit breaker off 3 Disconnect the unit power cord from the power supply WARNING The unit will automatically start and operate if 460 380 V power is present at the main power module when the controller is disconnected Disconnect the supply power to the unit before replacing the controller to prevent personal injury from rotating machinery or dangerous electrical shock from high voltage controls 4 At the same time remove the controller from the door 5 Install the replacement controller in the door 6 Connect the keyboard cable to the controller 7 Connect the Harness to the controller 8 Recheck all connector plugs to ensure they are fully seated 9 Review the Configuration Menu instructions in the operating section Reset information as required 10 Review the Misc Functions Menu instructions in the operating section Reset information as required NOTE Be sure to enter the container ID before releasing the unit for service The container ID is required to identify the data downloaded from the controller datalogger NOTE Several programmable features may need to be set to completely configure the unit to customer specifications Adjust any additional programmable settings to customer requirements before
170. t refer to Tool Catalog for oil test kit whenever a unit has a substantial refrigerant loss a noisy compressor or dark dirty oil Isolate the Compressor The discharge suction and digital ball service valves isolate the compressor from the high and low sides of the refrigeration system compressor isolation is needed for system diagnosis service and repair NOTE The valves are a permanently assembled unit and must be replaced in total if defective The only maintenance possible on the discharge or suction service valve is to periodically tighten the packing nut or to replace the packing e Back Seated Normal operation position e Open to Service Port Position for servicing e Front Seated To check or remove compressor WARNING Do not start unit with discharge valve in Front Seated position AXA0176 Full Counterclockwise Figure 54 Service Valve Back Seated 1 2 Turn in Figure 55 Service Valve Open to Port 96 AA WDR wh PTA AXA0178 Full Clockwise Figure 56 Service Valve Front Seated Working with a Gauge Manifold Using a New Gauge Manifold Set A new gauge manifold set and gauge hoses refer to Tool Catalog should be dedicated for use with only R 404refrigerant Gauge Manifold Valve Positions The gauges indicate low and high side pressures Operate one or both hand valves to perform the different service operations AXA0241 Quick Disconnect Access Valve Discharge Service
171. t Condition Temperature Probe Error 22 26 31 32 33 34 35 43 51 52 53 54 56 58 59 MZ px EN Loc pe HE ope a aa eal ES esl LE ER MEI pe AA A BELIZE ECCE Current Too High Current Too Low Current Too High 0 0 0 0 0 0 1 Check Evaporator Fan Low Speed Current Too Low Check Condenser Fan Current Too High Check Condenser Fan Current Too Low Log Power Supply Phase Error Check Temperature Too Far from 19 Setpoint Check Defrost Time Too Long 64 Configuration Menu The Configuration menu displays a list of functions that identifies unit operating features and current settings The following functions are available NOTE All screens are NOT present on all units The screens that display on the controller are determined by the Controller Software settings and the options installed on the unit Unit Setting Container ID In range temperature limit Unit Configuration A a 20 FT Unit F4 AFAM Otpion DATA gt Humidity Option Suction Pressure SETPOINT Option i 1 Discharge Pressure COMMAND Option AVL Option ALARM LIST USDA Option WARNING LIST Auto Configuration Miscellaneous Settings CONFIGURATION Date Time Contrast DATALOGGER Version STATES Controller ID Power Module ID Unit Serial ID Unit ID Figure 33 Configuration Menu When a spare parts controller is installed and powered up for the first time an automatic confi
172. t Leaks 2 0 ee na hen 100 Typical Pressurized Gas Bottle with Pressure Regulator and Gauges ss 100 Evacuation Station and Unit Hook up 00 0200 103 Constant Pressure Rise After Evacuation Indicates System Leak lilii cee eae 107 Pressure Rise Levels Off After Evacuation Indicates Moisture in System o 107 Scroll Gompressor nn A Cg uted Ain A aes BE eR UNE 109 Filter Diva vtr ds a AR eh a ed A AA aa RA 111 TXV Valve and Element Locati0N o oocooccccoco nn 112 Economizer Expansion Valve and Heat Exchanger o ooocccccccc e eee teens 113 Receiver Tank ai a ds a A di euge eT 115 Water Cooled Condenser Tank o cooocccoo teen nenn 115 Vapor Injection Valve 2 eee nennen 115 Digital Control Valve os exes als ae Sa Alo edd hea aim ed at ee deg datea ails 117 Mounting Bolts 23 22 tek aaa a O AREER RETEN ENUI 119 Condenser Fan Blade Placement 22m ee nn 120 Evaporator Fan Blade Placement o 120 Alt Exchange System cocos re Ae 121 Safety Instructions General Precautions e Always wear goggles or safety glasses Refrigerant liquid and battery acid can permanently damage the eyes Never operate the unit with the discharge valve closed Never close the compressor discharge valve with the unit in operation Keep your hands clothing and tools clear of the fans when the refrigeration unit is running If it is necessary to run the
173. t unit power cord from power supply WARNING The unit will automatically A start and operate if 460 380V power is present at the main power module when the controller is disconnected To prevent personal injury from rotating machinery or dangerous electrical shock from high voltage controls disconnect the supply power to the unit before preparing the unit for manual emergency mode operation 3 Relocate the position of the white and black incoming power cord leads at the 460 380V main circuit breaker 4 Connect unit power cord to proper power supply 5 Start the unit again by turning the unit 460 380V main circuit breaker on and the Unit turned On and allow Unit to start and stabilise 6 Check condenser airflow again to confirm correct fan rotation 90 Electric Heaters Malfunction Six electric heater elements are located underneath the evaporator coil If a heater element is suspected of malfunctioning check the resistance of each individual heater element by performing the following procedure 1 Turn unit power supply off 2 Remove unit power plug from power supply receptacle 997 Open the control box door 4 Test the insulation of each individual heater element a Test all 3 legs of the heater circuit to a good ground connection Connect a calibrated 500 Vdc insulation tester between each outgoing heater contactor terminal and ground b Ifthe resistance between any contactor terminal an
174. tch Check for a restriction Check for frost on down stream side of the filter drier Check for high evaporator superheat using supply air sensor temperature readings in Data menu or a frost pattern on expansion valve side of the evaporator coil A large temperature difference between the left hand and right hand supply air sensors indicates a possible evaporator restriction or incorrect superheat Continuity check low pressure cutout switch wiring using a high quality multimeter Replace switch Condenser Temperature Sensor Open Circuit Check sensor resistance must be 1 000 ohms When the sensor circuit resistance is higher than at 25C 77 F 100 000 ohms Check for damaged sensor wires Indicates Check sensor connections at controller Open circuit to sensor Defective or wrong sensor Defective power module Defective controller Condenser Temperature Sensor Short Circuit Check sensor resistance must be 1 000 ohms at 25 C 77 F Check for damaged sensor wires Sensor circuit resistance is lower than 200 ohms Indicates Open circuit to sensor Check sensor connections at controller Defective or wrong sensor Defective power module Defective controller 139 Diagnosis Troubleshooting Warnings and Alarm Codes Alarm Codes Descriptions and Corrective Actions Continued Description Creative Actio Ambient Air Sensor Open Circuit e Occurs during pretrip PTI test only Senso
175. tely removed Shut down the power or remove the victim from the source If it is not possible to shut off the power the wire should be cut with either an insulated instrument e g a wooden handled axe or cable cutters with heavy insulated handles A rescuer wearing electrically insulated gloves and safety glasses could also cut the wire Do not look at the wire while it is being cut The ensuing flash can cause burns and blindness 12 Pull the victim off with a non conductive material if the victim has to be removed from a live circuit Use the victim s coat a rope wood or loop your belt around the victim s leg or arm and pull the victim off Do not touch the victim You can receive a shock from current flowing through the victim s body Check immediately for the presence of a pulse and respiration after separating the victim from power source If a pulse is not present start CPR Cardio Pulmonary Resuscitation and call for emergency medical assistance Respiration may also be restored by using mouth to mouth resuscitation Low Voltage Control circuits are low voltage 24 Vac and 12 Vdc This voltage potential is not considered dangerous Large amount of current available over 30 amperes can cause severe burns if shorted to ground Do not wear jewelry watch or rings These items can shortcut electrical circuits and cause severe burns to the wearer Electrostatic Discharge Precautions Precautions must be taken
176. tem Specifications Compressor Model No Refrigerant Charge MAGNUM Compressor Oil Capacity Compressor Oil Type ZMD18KVE TFD 277 Scroll 4 0 Kg 8 0 Ib R 404A 1 77 liter 60 oz Polyol Ester Based Type required refer to Tool Catalog When the compressor is removed from the unit oil level should be noted or the oil removed from the compressor should be measured so that the same amount of oil can be maintained in the replacement compressor Do not use or add standard synthetic or mineral oils to the refrigeration system If Ester based oil becomes contaminated with moisture or with standard oils dispose of properly Do Not Use High Pressure Cutout Switch Cutout Cutin Low Pressure Cutout Switch Cutout Cutin High Pressure Relief Valve Relief Temperature 20 3240 48 kPa 32 4 0 5 bar 470 7 psig 2586 262 kPa 25 9 2 6 bar 375 38 psig 17 to 37 kPa 0 17 to 0 37 bar 5 to 11 in Hg vacuum 28 to 48 kPa 0 28 to 0 48 bar 4 to 7 psig 99 C 210 F Specifications Refrigeration System Specifications Continued Vapor Injection Control Vapor injection valve is energized open continuously when the compressor duty cycle ON time is 100 percent Full Cool High compressor discharge temperature may cause the vapor injection valve to energize open but only while the Compressor Digital Control valve is not energized closed Modulation Cool or Power Limit Compre
177. the information recommendations and descriptions contained herein This includes warranties of fitness for a particular purpose or merchantability or warranties arising from course of dealing or usage of trade The manufacturer is not responsible and will not be held liable in contract or in tort including negligence for any special indirect or consequential damages This includes injury or damage caused to vehicles contents or persons by reason of the installation of any Thermo King product or its mechanical failure Recover Refrigerant At Thermo King we recognize the need to preserve the environment and limit the potential harm to the ozone layer that can result from allowing refrigerant to escape into the atmosphere We strictly adhere to a policy that promotes the recovery and limits the loss of refrigerant into the atmosphere In addition service personnel must be aware of Federal regulations concerning the use of refrigerants and the certification of technicians For additional information on regulations and technician certification programs contact your local Thermo King dealer R 404A WARNING Use only Polyol Ester based refrigeration compressor oil in R 404A See Thermo King Parts Manual for part number Do not mix Polyol Ester and standard synthetic compressor oils Keep Polyol Ester compressor oil in tightly sealed containers If Polyol Ester oil becomes contaminated with moisture or standard oils dispose of properly
178. the unit with R 404A see Charging the System with Refrigerant in this chapter Perform a controller pretrip test to verify system operation 109 Refrigeration Maintenance Condenser Coil Replacement Condenser Coil Removal Remove the condenser coil by performing the following steps 1 Recover the refrigerant charge from the unit 2 Remove the condenser fan grille condenser fan blade and condenser fan shroud 3 Remove condenser coil support brackets from coil 4 Unsolder coil inlet and liquid line connections 5 Support the coil and unbolt the condenser coil mounting brackets Slide coil from the unit 110 Condenser Coil Installation Install condenser coil by performing the following steps 1 Clean the tubes for soldering 2 Slide the coil into the unit and install the bolts in the mounting brackets 3 Solder the inlet line and liquid line connections NOTE It s strongly recommended that dry nitrogen be used to purge the system during any solder operations see Using Pressurized Nitrogen in this chapter 4 Perform a controller pretrip test to verify system operation Check compressor oil level 5 Pressurize the system and test for leaks see Refrigerant Leak Test Procedure in this chapter Repair leak if required 6 Recover the leak test gas if no leaks were found 7 Evacuate the system see Evacuation and Cleanup of the Refrigeration System in this chapter
179. ting Instructions Section 123 Diagnosis Troubleshooting Warnings and Alarm Codes Troubleshooting Mechanical Problems Condition Possible Cause Remedy Compressor does not operate Controller on unit start sequence still Wait up to 2 minutes for compressor no amperage draw timing start up Locate fault and repair power source power plug CB1 main circuit breaker motor solid state motor terminals motor fuses on power module Check fuses and On Off switch Open in 29 Vac control circuit Replace or repair as required No power to unit condenser and evaporator fans do not operate Container temperature does not demand compressor operation Compressor contactor inoperative Replace compressor contactor Diagnose and replace power No output signal from controller 9 p P module or controller Turn Unit On Off switch Off and then On again Adjust controller setpoint Unit on defrost Detective high pressure or low pressure cutout switch High condenser head pressure Check refrigeration system and causing high pressure cutout correct fault Defective compressor Replace compressor Let compressor cool and controller Controller shut unit down on will reset automatically Check vapor Compressor Over Temperature injection valve and compressor temperature sensor If compressor contactor is energized wait 60 minutes for protector to cool and reset Compressor does not operate Rotating scroll stuck Repla
180. tion Removal Remove the Evacuation Station by performing the following steps 1 Back seat the discharge service valves 2 Close the high pressure hand valve on the gauge manifold 3 Close the refrigerant tank hand valve 4 Open the hand valve at the gauge manifold and read suction pressure 5 Operate the unit in Cool mode until the suction pressure decreases below 385 kPa 3 85 bar 50 psig 6 Back seat the suction line access service valve 7 Stop the unit 8 Remove the hoses from the suction and discharge line access service valves 9 Start the unit and perform a controller pretrip test to verify correct refrigerant charge and unit operation Compressor Replacement Compressor Removal Remove the compressor by performing the following steps l 2 9 10 Remove the compressor compartment bracket Isolate the compressor from the system a Front seat the discharge service valve by turning the valve fully clockwise b Front seat the suction service valve by turning the valve fully clockwise c Turn the digital service valve one quarter turn to the right See Isolate the Compressor on page 96 for additional information Recover the refrigerant charge from the compressor see Recovering Refrigerant from the System on page 104 Remove discharge service valve suction service valve digital control valve line and vapor injection valve line from the compressor Re
181. tivated to lower the pressure in the condenser When the tempera ture gets below 40 C the compressor is also activated The test will then look for when the HPCO gets back to normal in maximal 60 seconds Awaiting HPCO Compressor stop With compressor fully loaded con seconds for 40 and 240 seconds for denser fan on and evaporator fan at high speed running for the time period At the end of the test is the cooling capability evaluated Evaluating cooling capability Probe readings and time are 23 Max 2 x recorded in the pti log when hours started When supply air temper ature is at 0 degC 32F the test is ended If the test is not ended within the time limit the alarm is set Approaching 0C 32F Main Menu Display Description Possible Duration TI Brief Function Alarms Time P Test T MAINTAINING 0C TEST With the unit running chilled None 30 Minutes x x Non Optimised maintaining 0 degC 32F After 30 minutes the probe readings and time are recorded in the pti log Maintaining 0C 32F DEFROST TEST Test is skipped and Fail if either of 0 to 90 min alarm 4 5 130 is present utes at volt age above 440V 0 to 120 With electric heaters turned on the minutes at Test is skipped if evaporator temper ature is at 5degC or above test will pass when voltages below 440V evaporator temperature reach 18degC or above Defrosting until Eva gt 18C 64F PULLDOWN TO 18
182. to prevent electrostatic discharge while servicing the MP 3000a microprocessor and related components The risk of significant damage to the electronic components of the unit is possible if these precautionary measures are not followed The primary risk potential results from the failure to wear adequate electrostatic discharge preventive equipment when handling and servicing the controller The second cause results from electric welding on the unit and container chassis without taking precautionary steps Electrostatic Discharge and the Controller You must avoid electrostatic discharges when servicing the controller Solid state integrated circuit components can be severely damaged or destroyed with less than a small spark from a finger to metal object You must rigidly adhere to the following statements when servicing these units This will avoid controller damage or destruction e Disconnect all power to the unit e Avoid wearing clothing that generates static electricity wool nylon polyester etc e Do wear a static discharge wrist strap refer to Tool Catalog with the lead end connected to the controller s ground terminal These straps are available at most electronic equipment distributors Do not wear these straps with power applied to the unit e Avoid contacting the electronic components on the circuit boards of the unit being serviced Leave the circuit boards in their static proof packing materials until read
183. tus display To view the alarms press the Alarm key to go to the Alarm List Menu Alarm Code States There are three alarm code states for Shutdown and Check alarms Active A code condition has occurred and continues to exist in the unit or the code condition occurred within the past 1 hour but does not currently exist in the unit Not Active A code condition has occurred but no longer exists in the unit Not Active means the code condition was corrected and did not reoccur for 1 hour or the Unit On Off switch was turned Off and then On Acknowledge A code condition has been viewed and acknowledged in the Alarm or Warning list If the Alarm code condition still exists in the unit the Red LED will stay on and not flash If the code condition is corrected the Red LED will turn off and the code condition will disappear from the Alarm Warning list A complete listing of the controller operating menu is located on an 11 x 17 fold out on the last page of this manual Alarm Warning List Menu NOTE All screens are NOT present on all units The screens that display on the controller are determined by the Controller Software settings and the options installed on the unit Be DATA P p Alarm List Warning List SETPOINT View and write down lt all alarm Warning code COMMAND Press F2 key to view the next alarm warning ALARM LIST code Clear alarm warning WARNING LIST code by cor
184. uding low and high ambient temperatures salt water humidity fungus industrial pollutants dynamic loading rain sand and dust Remote Monitoring Modem RMM Optional A REFCON remote monitoring modem is provided to permit remote monitoring via the power cable High speed transmission reads all controller information Data can also be retrieved from the data logger via high speed transmission Suction and Discharge Pressure Sensors Optional Pressure sensors can be added to the unit to display actual suction or discharge system pressure The display will show a reading and a bar graph Unit can be configured suction only discharge only or suction and discharge Air Ventilation Logging AVL Optional AVL is used for detecting and logging the fresh air exchange position on the manual fresh air vent The opening angle of the fresh air vent is con verted to an output signal from approximately 2 5 volts The opening is detected in steps of 5m3 h from 0 to 125 When opening is greater than 125m3 h the log will just state that the opening is greater than 125m3 h 29 Unit Description Features amp Options USDA Cold Treatment Temperature Recording standard The MP 4000 controller includes provisions for the use of three or four USDA sensors These sensors allow temperatures in various areas of the load to be monitored and recorded for United States Department of Agriculture use in monitoring Cold Treatment shi
185. um valve and watch the movement of vacuum gauge needle If needle shows a pressure rise but finally levels off to a constant pressure the system still contains too much moisture Dehydration and additional evacuation time are required Time Pressure Vacuum Atmospheric Pressure Figure 68 Pressure Rise Levels Off After Evacuation Indicates Moisture in System Factors Affecting the Speed of System Evacuation The time needed to evacuate a system can vary Some factors that can influence evacuation time are listed below System size Amount of moisture contained in the system e Ambient temperature Internal restrictions within the system External restrictions between the system and the vacuum pump Hose size both diameter and length affect evacuation times Laboratory tests show that the evacuation time can be significantly reduced by larger diameter hoses and shorter hoses For example it takes eight times as long to pull a given vacuum through a 6 mm 1 4 inch diameter hose as it does through a 12 mm 1 2 inch diameter hose It takes twice as long to pull a vacuum through a 2 meter 6 foot long hose as it does through a 1 meter 3 foot long hose 107 Refrigeration Maintenance Heat Saves Time The application of heat to the system is a useful and practical time saver Increasing the temperature of the compressor oil and refrigerant will speed up the vaporization of any water present in the system
186. vicing components on this unit Annual Inspect Service These Items Dix Wu ie Perform a controller pretrip inspection PTI check Vewaycekcondenserfanandevaparar am Veualy inspect electrical contacts Tor damage orToose connestons al inspectwire haresses for damage orfoose connections EA ing AE ATA ras 22222222222 LC CIC ek or proper discharge and suction pressures ei iter arerinine iter fora restan pressures HERE RA 2 2 Pisa nspecrunifordamaged Toose orbroken pas PT o Soen ut compressor and fan motor mounting bois aan emire unitintuding condenser and evaporator cols and defrost drains NOTE If a unit has been carrying cargo which contains a high level of sulphor or phosphorous e g garlic salted fish etc it is recommended that clean evaporator coil after each trip 17 Service Guide 18 Specifications System Net Cooling Capacity Full Cool MAGNUM Model Air Cooled Condensing 460 230V 3 Phase 60 Hz Power Return alfo Net Cooling Capacity Consump evaporator coil inlet 60 Hz 60 Hz 60 Hz Power Capacity Capacity kW B hr kW zscuor zs soi ss System net cooling capacity with a 38 C 100 F ambient air temperature and R 404A Evaporator Airflow Specifications System Net Heating Capacity Wars Kear ETUR Wess Kcs BTU System net heating capacity includes electric resistance rods and fan heat MAGNUM External Static
187. xchanger The economizer system subcools the liquid refrigerant before it reaches the evaporator expansion valve Subcooling liquid refrigerant increases the 4 AXA0427 Figure 41 Economizer Heat Exchanger A vapor injection line tee is located in the liquid line between the filter drier in line filter and the economizer heat exchanger A vapor injection valve controls refrigerant flow through the vapor injection line to the economizer expansion valve When this normally closed valve is energized open a portion of liquid refrigerant flows through the economizer expansion valve and evaporates in the inner coiled tube of the economizer This cools the rest of the liquid refrigerant that flows past the tee and through the economizer to the evaporator coil 79 Operating Theory The economizer suction gas continues through the vapor injection circuit and returns to the intermediate suction port of the scroll compressor Injecting the economizer suction gas into the compressor downstream from the suction port prevents the gas from affecting the suction pressure or cooling capacity of the evaporator coil However the economizer suction gas adds its heat and volume to the condenser side of the refrigeration system increasing the discharge pressure Because the economizer system increases system cooling capacity the vapor injection valve is energized
188. y for installation e Return a defective controller for repair in the same static protective packing materials from which the replacement component was removed e Check the wiring after servicing the unit for possible errors Complete this task before restoring power Welding of Units or Containers Electric welding can cause serious damage to electronic circuits when performed on any portion of the refrigeration unit container or container chassis with the refrigeration unit attached It is necessary to ensure that welding currents are not allowed to flow through the electronic circuits of the unit The following statements must be rigidly adhered to when servicing these units to avoid damage or destruction e Disconnect all power to the refrigeration unit e Disconnect all quick disconnect wire harnesses from the back of the controller e Disconnect all wire harnesses from the Remote Monitor Modem RMM Switch all of the electrical circuit breakers in the control box to the Off position e Weld unit and or container per normal welding procedures Keep ground return electrode as close to the area to be welded as practical This will reduce the likelihood of stray welding currents passing through any electrical or electronic circuits Safety Instructions e The unit power cables wiring and circuit breakers must be restored to their normal condition when the welding operation is completed Removing Refrigerant Prop

MP-4000 Controller

Contents

Download Pdf Manuals

Related Search

Related Contents