Thermo King CSR40-149, CSR40-150 User Manual

Maintenance Manual

CSR40-149 & -150

Power Saver

TK 50892-4-MM (Rev. 6/00)

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

Sale of product shown in this Manual is subject to Thermo King’s terms and conditions including, but not limited to, the THERMO KING EXPRESS WARRANTY. Such terms and conditions are available upon request.

Thermo King’s warranty will not apply to any equipment which has been “so repaired or altered outside the manufacturer’s plants as, in the manufacturer’s judgment, to effect its stability.”

No warranties, express or implied, including warranties of fitness for a particular purpose or merchantability, or warranties arising from course of dealing or usage of trade, are made regarding the information, recommendations, and descriptions contained herein. Manufacturer is not responsible and will not be held liable in contract or in tort (including negligence) for any special, indirect or consequential damages, including injury or damage caused to vehicles, contents or persons, by reason of the installation of any Thermo King product or its mechanical failure.

SmartSponge and Thermoguard are trademarks of Thermo King Corporation. All other trademarks are the property of their respective owners.

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.

Table of Contents

Introduction v

About This Manual v Other Reference Manuals v CSR40-149 & -150 PS Model Features vi

Safety Precautions vii

General Practices vii Refrigerant vii Refrigerant Oil viii Electrical viii General Safety Practices for Servicing Units

(or Containers) Equipped with a

Microprocessor Controller ix Unit Decals x Serial Number Locations x

Service Guide xi

Specifications 1-1

System Net Cooling Capacity — Full Cool:

CSR40 PS Models — Air Cooled Condensing 1-1 System Net Heating Capacity 1-1 Evaporator Airflow:

CSR40 PS Models 1-1 Electrical System 1-2 Refrigeration System 1-3 MP-3000 Controller 1-4 Dehumidify and Humidify Systems (Options) 1-5 Physical Specifications 1-6 Metric Hardware Torque Charts 1-7

Unit Description 2-1

Unit Features 2-1 Unit Options 2-2 Operating Modes 2-3 Unit Illustrations 2-4

Typical Unit Front View 2-4 Unit Options Front View 2-5 CSR40 PS Evaporator Section – Front View 2-6 Hermetic Refrigeration System 2-7 MP-3000 Controller 2-8 Unit Control Box 2-9 Humidify System Option 2-10 Advanced Fresh Air Management Option 2-11 Typical Unit Back View 2-12

Operating Instructions 3-1

Unit Controls 3-1 Unit Instruments 3-1 Unit Protection Devices 3-1 Pretrip Inspection 3-3 Starting the Unit and Adjusting the Controller

Setpoint 3-4 Loading Procedure 3-5 Post Load Procedure 3-5 Post Trip Procedure 3-5

MP-3000 Controller 4-1

Controller Description 4-1 Status Indicator LEDs 4-3 Data Recording and Downloading Data 4-3 General Theory of Operation 4-4

Chill Loads 4-4

Frozen Loads 4-5

Modulation Display in Data Menu 4-5

Power Limit Mode 4-5

CSR40-149 & -150 PS Hermetic, June 2000

ii Table of Contents

Compressor Liquid Injection 4-5 Warm Gas Bypass 4-5 Evaporator Fan Control 4-5 Condenser Fan Control 4-6 Economy Mode Operation 4-6 Probe Test 4-6 Dehumidify Mode (Option) 4-7

Sequence of Operation 4-7

Unit Start-up 4-7 Continuous Temperature Control Operation 4-8 Operating Mode Function Chart — Standard

Operation 4-9

Operating Mode Function Chart — Optional

Feature Operation 4-10

Defrost 4-11 Changing the Setpoint 4-12 Initiating a Manual Defrost 4-12 Displaying Alternate Controlling (Supply or

Return) Air Sensor Temperature 4-12 Displaying Alternate Fahrenheit (F) or

Celsius (C) Temperatures 4-13 Navigating the Controller Menu 4-13

General Operating Tips 4-13 Setpoint Menu 4-13

Changing the Setpoint Temperature 4-13

Changing the Economy Mode Setting 4-14

Changing the Humidity Mode Setting 4-14

Changing the Humidity Setpoint 4-14

Changing the Advanced Fresh Air

Management (AFAM) Mode Setting 4-14 Changing the AFAM Delay 4-15 Changing the AFAM Rate 4-15

Data Menu 4-16

Viewing the Data Menu 4-16

Alarms Menu 4-16

Alarm Types 4-16 Alarm Code States 4-17 Viewing the Alarm List Menu 4-17 Alarm List 4-17

Commands Menu 4-18

View the Commands Menu 4-18 Defrost 4-19 Function Test 4-19

CSR PS Function Test Procedure 4-21 Pretrip (PTI) Test 4-20

CSR PS Pretrip (PTI) Test Procedure 4-23 Manual Function Test 4-20 Power Management 4-28

Misc. Functions Menu 4-28

Viewing the Misc. Functions Menu 4-28 Setting the Date and Time 4-28 Changing the Temperature Display

Value (C/F) 4-29 Setting Cargo Data 4-29 Viewing or Setting Run Time 4-30

Configuration Menu 4-30

Viewing or Setting Functions 4-30

Datalogger Menu 4-31

Viewing the Datalogger Menu 4-32 Inspect Temp Log 4-32 Inspect Event Log 4-32 Set Log Time 4-33 Set a Trip Start 4-33 Inspect PTI Log 4-34

RMM State Menu 4-34

Viewing the RMM State Screen 4-34

Manual Emergency Mode Operation 4-34 Replacing the Controller 4-35

Automatic Configuration of Spare

Parts Controller 4-35

Controller Software Selection 4-36 Flash Loading Controller Software 4-36 Temperature Sensors 4-36 Diagnosis and Repair 4-38 Error Messages and Controller Actions 4-39 Alarm Codes, Descriptions and

Corrective Actions 4-42 to 4-61

Electrical Maintenance 5-1

Unit Wiring 5-1 High Pressure Cutout Switch 5-1 Low Pressure Cutout Switch 5-2 Condenser Fan and Evaporator Fan Rotation 5-2 Electric Heaters 5-3

CSR40-149 & -150 PS Hermetic, June 2000

Table of Contents iii

Refrigeration System Diagnosis and Service 6-1

Hermetic Refrigeration System Diagnosis

Procedures 6-1

Hermetic Refrigeration System Visual Inspection

and Diagnosis Chart 6-3

Hermetic Refrigeration System Service

Procedures 6-4 Service Tools 6-4 Refrigerant Charge 6-5 Compressor Oil Charge 6-6 Installing and Removing Piercing Type Service

Valves and a Gauge Manifold Set 6-6 Gauge Manifold Valve Positions 6-8 Refrigerant Leak Test Procedure 6-9 Using Pressurized Nitrogen 6-9 Refrigerant Recovery from Hermetic

Refrigeration Systems 6-10 Evacuation and Cleanup of the

Refrigeration System 6-11 Charging the System with Refrigerant 6-15 Compressor Replacement 6-15 Compressor Discharge Temperature Sensor

Replacement 6-16 Stepper Motor Valve Replacement 6-17 Condenser Coil Replacement 6-17 Filter Drier/In-line Filter Replacement 6-18 Expansion Valve Replacement 6-18 Heat Exchanger Replacement 6-19 Receiver Tank Replacement 6-19 Low or High Pressure Cutout Switch Replacement 6-20 Warm Gas Bypass Solenoid Valve, Liquid

Injection Valve or Dehumidify Valve

(Option) Replacement 6-20

Structural/Accessory Maintenance 7-1

Mounting Bolts 7-1 Unit Inspection 7-1 Condenser Coil 7-1 Evaporator Coil 7-1 Defrost Drains 7-2 Condenser Fan Location 7-2 Evaporator Fan Location 7-2 Humidify System (Option) 7-2 Partlow (Model SR) Recording Thermometer

(Option) 7-3

Advanced Fresh Air Management (AFAM) System

(Option) 7-5

Mechanical Diagnosis 8-1

Electrical, Refrigeration and MP-3000 Menu Flow

Diagrams 9-1

Controller Diagram 9-3 Wiring Schematic 9-4 Main Relay Board Terminal Connections

(Page 1 of 3) 9-5

Main Relay Board Terminal Connections

(Page 2 of 3) 9-6

Main Relay Board Terminal Connections

(Page 3 of 3) 9-7

Refrigeration System Schematics:

Refrigeration System Components 9-8 Full Cool Flow and Pressure Diagram 9-9 Modulation Cool Flow and Pressure Diagram 9-10 Dehumidification Flow and Pressure Diagram 9-11

MP-3000 Menu Flow Diagram 9-12

CSR40-149 & -150 PS Hermetic, June 2000

Introduction

About This Manual

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 includes maintenance and diagnosis information for both standard and optional unit features. Some optional features may not apply to your unit. The maintenance information in this manual covers unit models:

CSR PS Hermetic Models System Number

CSR40-149 Power Saver 917149 CSR40-150 Power Saver 917150

Other Reference Manuals

For detailed descriptions of our refrigeration systems or microprocessor controllers, see the appropriate manual. For further information refer to:

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

CSR40-149 & -150 PS Hermetic, June 2000

vi CSR40-149 & -150 PS Model Features Introduction

CSR40-149 & -150 PS Model Features

MODEL

FEATURES

CSR40-149 PS

CSR40-150 PS

– – Slimline Frame X X Top Air Discharge X X 460-380V/3Ph/60-50 Hz, 18.3 m (60 ft) Power Cable and Plug X X Dual Voltage Feature: 15 kVA Autotransformer with 460-380V Power Receptacle and 230-190V/3Ph/60-50 Hz, 18.3 m

(60 ft) Power Cable and Plug X X 25 Amp Main Power Circuit Breaker X X Automatic Phase Selection Control X X Hermetic Scroll Compressor w/4.48 kW (6.0 Hp) Motor X X Hermetic Refrigeration System X X Refrigerant R-404A w/Polyol Ester Compressor Oil (TK P/N 203-433) X X Stepper Valve Capacity Control System X X Compressor Liquid Injection System X X Warm Gas Bypass Valve System X X MP-3000 Microprocessor Controller with Integral Datalogger – – Three (3) Evaporator Fans with 2-Speed Motors X X Two (2) Evaporator Fans with 2-Speed Motors X X Condenser Fan with 1-Speed Motor – – Fresh Air Exchange System X X AFAM — Advanced Fresh Air Management – – Data Retrieval Receptacle, Standard (5-Pin Deutsch) X X Data Retrieval Receptacle, 5-Pin Threaded Cannon – – Data Retrieval Receptacle, 15-Pin RS232 – X Dehumidify Control – X Humidity System – – Pressure Gauge, Discharge – – Pressure Gauge, Suction X X Recorder, Partlow – – Recorder, Saginomiya – – Remote Monitoring Plug (4-Pin)

– – TRANSFRESH – – TRANSFRESH – – TRANSFRESH

Provision

Purge Port

System, Complete – – Thermistor Lead – – USDA Cold Treatment Temperature Recording – – Water-Cooled Condenser-Receiver Tank

X = Included

CSR40-149 & -150 PS Hermetic, June 2000

Safety Precautions

General Practices

1. ALWAYS WEAR GOGGLES OR SAFETY GLASSES. Refrigerant liquid and battery acid can permanently damage the eyes (see First Aid under Refrigerant Oil).

2. Never close the compressor discharge valve with the unit in operation. Never operate the unit with the discharge valve closed.

3. Keep your hands, clothing and tools clear of the fans when the refrigeration unit is running. If it is necessary to run the refrigeration unit with covers removed, be very careful with tools or meters being used in the area.

4. Be sure the gauge manifold hoses are in good condition. Never let them come in contact with a fan motor blade or any hot surface.

5. Never apply heat to a sealed refrigeration system or container.

6. Fluorocarbon refrigerants, in the presence of an open flame or electrical arc, produce toxic gases that are severe respiratory irritants capable of causing death.

7. Be sure all mounting bolts are tight and are the correct length for their particular application.

8. 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.

9. Use caution when working around exposed coil fins. The fins can cause painful lacerations.

10. 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, resulting in suffocation and possible death.

11. Use caution and follow the manufacturer’s suggested practices when using ladders or scaffolds.

Refrigerant

When removing any refrigerant from a unit, use a recovery process that prevents or absolutely minimizes the refrigerant that can escape to the atmosphere. Although 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. When exposed to the atmosphere in the liquid state, fluorocarbon refrigerants evaporate rapidly, freezing anything they contact.

First Aid

In the event of frost bite, the objectives of First Aid are to protect the frozen area from further injury, to warm the affected area rapidly, and to maintain respiration.

• 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.

CSR40-149 & -150 PS Hermetic, June 2000

viii Refrigerant Oil Safety Precautions

4. Do not make any rapid moves when working on high volt-

Refrigerant Oil

Observe the following precautions when working with or around refrigerant oil:

• Do not allow refrigerant oil to contact your eyes.

• Do not allow prolonged or repeated contact with skin or clothing.

• To prevent irritation, you should wash thoroughly immediately after handling refrigerant oil. Rubber gloves are recommended when handling Polyol Ester based refrigerant oil.

First Aid

• EYES: Immediately flush eyes with large amounts of water 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 and 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

High Voltage

When servicing or repairing a refrigeration unit, the possibility of serious or even fatal injury from electrical shock exists. Extreme care must be used when working with a refrigeration unit that is connected to a source of operating power, even if the unit is not running. Lethal voltage potentials can exist at the unit power cord, inside the control box, inside any high voltage junction box, at the motors and within the wiring harnesses.

Precautions

1. Be certain the unit On/Off switch is turned OFF before connecting or disconnecting the unit power plug. Never attempt to stop the unit by disconnecting the power plug.

2. Be certain the unit power plug is clean and dry before connecting it to a power source.

3. Use tools with insulated handles that are in good condition. Never hold metal tools in your hand if exposed, energized conductors are within reach.

age circuits. If a tool or other object falls, do not attempt to grab it. People do not contact high voltage wires on purpose. It occurs from an unplanned movement.

5. Treat all wires and connections as high voltage until a meter and wiring diagram show otherwise.

6. 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.

7. 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 if available.

The source of shock must be immediately removed by

either shutting down the power or removing 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) or by a rescuer wearing electrically insulated gloves and safety glasses. Whichever method is used, do not look at the wire while it is being cut. The ensuing flash can cause burns and blindness.

If the victim has to be removed from a live circuit, pull the

victim off with a non-conductive material. 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.

After separating the victim from power source, check

immediately for the presence of a pulse and respiration. If a pulse is not present, start CPR (Cardio Pulmonary Resuscitation) and call for emergency medical assistance. If a pulse is present, respiration may be restored by using mouthto-mouth resuscitation, but call for emergency medical assistance.

Low Voltage

Control circuits are low voltage (24 Vac and 12 Vdc). This voltage potential is not considered dangerous, but the 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 short

out electrical circuits and cause severe burns to the wearer.

CSR40-149 & -150 PS Hermetic, June 2000

Safety Precautions General Safety Precautions for Servicing Controllers ix

Welding of Units or Containers

General Safety Precautions for Servicing Units (or Containers) Equipped with a Microprocessor Controller

Precautions must be taken to prevent electrostatic discharge when servicing the MP-3000 microprocessor and related components. If these precautionary measures are not followed, the risk of significant damage to the electronic components of the unit is possible.

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.

Controller Repair

When servicing the controller, it is necessary to ensure that electrostatic discharges are avoided. Potential differences considerably lower than those which produce a small spark from a finger to a door knob can severely damage or destroy solidstate integrated circuit components. The following procedures must be rigidly adhered to when servicing these units to avoid controller damage or destruction.

1. Disconnect all power to the unit.

2. Avoid wearing clothing that generates static electricity

(wool, nylon, polyester, etc.).

3. Do wear a static discharge wrist strap (TK P/N 204-622)

with the lead end connected to the controller's ground ter-

minal. These straps are available at most electronic equip-

ment distributors. DO NOT wear these straps with power

applied to the unit.

4. Avoid contacting the electronic components on the circuit

boards of the unit being serviced.

5. Leave the circuit boards in their static proof packing mate-

rials until ready for installation.

6. If a defective controller is to be returned for repair, it

should be returned in the same static protective packing

materials from which the replacement component was

removed.

7. After servicing the circuit board and any other circuits, the

wiring should be checked for possible errors before restor-

ing power.

Whenever electric welding is to be 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. These procedures must be rigidly adhered to when servicing these units to avoid damage or destruction.

1. Disconnect all power to the refrigeration unit.

2. Disconnect all quick-disconnect wire harnesses from the back of the controller.

3. If the unit is equipped with an Remote Monitor Modem (RMM), disconnect all wire harnesses from the RMM.

4. Switch all of the electrical circuit breakers in the control box to the OFF position.

5. 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.

6. When the welding operation is completed, the unit power cables, wiring and circuit breakers must be restored to their normal condition.

CSR40-149 & -150 PS Hermetic, June 2000

x Unit Decals Safety Precautions

Unit 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.

Serial Number Locations

Electric Motors: Nameplate attached to the motor housing. Compressor: Nameplate on front of the compressor. Unit: Nameplate on unit frame in power cord storage compart-

ment. MP-3000 Controller: Nameplate on back of controller.

Unit Nameplate Location

CSR40-149 & -150 PS Hermetic, June 2000

Service Guide

Every Annual/

1,000 Yearly

Pretrip Hours Inspect/Service These Items

Refrigeration

• Perform a controller Pretrip Inspection (PTI) test to check the refrigeration and electri-

cal systems.

Electrical

•••Visually inspect condenser fan and evaporator fan rotation.

•••Visually inspect electrical contacts for damage or loose connections.

•••Visually inspect wire harnesses for damaged wires or connections.

••

•

Download the data logger and check data for correct logging.

Check operation of protection shutdown circuits.

Structural

•••

••

•

•••

••

Visually inspect unit for damaged, loose or broken parts.

Tighten unit, compressor and fan motor mounting bolts.

Clean entire unit including condenser and evaporator coils and defrost drains.

Humidify System (Option)

Check water level in water tank.

Check humidify system operation.

Clean water supply filter on water tank.

CSR40-149 & -150 PS Hermetic, June 2000

1 Specifications

System Net Cooling Capacity — Full Cool

CSR40 PS Models — Air Cooled Condensing*

Return air to 460/230V, 3 Phase, 60 Hz Power 380/190V, 3 Phase, 50 Hz Power

evaporator Net Cooling Capacity Power Consp Net Cooling Capacity Power Consp

coil inlet Watts Kcal/hr BTU/hr kW @460V Watts Kcal/hr BTU/hr kW @380V

21.1 C (70 F) 13,660 11,750 46,620 9.7 10,930 9,400 37,300 7.6

1.7 C (35 F) 10,090 8,680 34,440 8.9 8,070 6,940 27,545 6.9

-17.8 C (0 F) 5,945 5,115 20,290 6.0 4,755 4,090 16,230 5.4

-28.9 C (-20 F) 4,000 3,440 13,650 5.6 3,200 2,750 10,920 4.1

*System net cooling capacity with a 37.8 C (100 F) ambient air temperature and R-404A.

System Net Heating Capacity*

Heater Type 460/230V, 3 Phase, 60 Hz Power 380/190V, 3 Phase, 50 Hz Power

Heating Capacity Heating Capacity

Watts Kcal/hr BTU/hr Watts Kcal/hr BTU/hr

CSR40 PS 5,800 4,990 19,800 4,200 3,610 14,335

*System net heating capacity includes electric resistance rods and fan heat.

Evaporator Airflow

CSR40 PS Models

External Static 460/230V, 3 Phase, 60 Hz Power 380/190V, 3 Phase, 50 Hz Power

Pressure (water High Speed Low Speed High Speed Low Speed

column) m3/hr ft3/min m3/hr ft3/min m3/hr ft3/min m3/hr ft3/min

0 mm (0 in.) 6,560 3,860 3,170 1,865 5,480 3,225 2,710 1,595

10 mm (0.4 in.) 5,820 3,425 1,770 1,040 4,530 2,665 930 545

20 mm (0.8 in.) 5,000 2,940 — — 3,750 2,205 — —

30 mm (1.2 in.) 4,430 2,610 — — 2,930 1,725 — —

40 mm (1.6 in.) 3,520 2,070 — — 1,870 1,100 — —

CSR40-149 & -150 PS Hermetic, June 2000

1-2 Electrical System Specifications

Electrical System

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

Kilowatts 0.37 kW @ 460V, 60 Hz

Horsepower 0.50 hp @ 460V, 60 Hz

RPM 1140 rpm @ 460V, 60 Hz

Full Load Amps 1.0 amps @ 460V, 60 Hz; 1.0 amps @ 380V, 50 Hz

Locked Rotor Amps 4.0 amps @ 460V, 60 Hz; 4.0 amps @ 380V, 50 Hz

Evaporator Fan Motors: Type 460/380V, 60/50 Hz, 3 Phase

Number: CSR40 PS 2

Kilowatts 0.75 kW @ 460V, 60 Hz

Horsepower 1.0 hp @ 460V, 60 Hz

RPM (Each): High Speed 3450 rpm @ 460V, 60 Hz

Low Speed 1725 rpm @ 460V, 60 Hz

Full Load Amps (Each): High Speed 1.1 amps @ 460V, 60 Hz

Low Speed 0.55 amps @ 460V, 60 Hz

Locked Rotor Amps: High Speed 10.3 amps @ 460V, 60 Hz

Low Speed 2.9 amps @ 460V, 60 Hz

Electric Resistance Heater Rods: Type 460/380V, 60/50 Hz, 3 Phase

Number 6

Watts (Each) 680 Watts @ 460V, 60 Hz

Current Draw (Amps) 5 amps total @ 460V across each phase at heater contactor

Control Circuit Voltage: 29 Vac @ 60 Hz

24 Vac @ 50 Hz

Advanced Fresh Air Management (AFAM) Motor:

Voltage 24 Vdc

Evaporator Overheat Switch: Opens 54 +/- 3 C (130 +/- 5 F)

Closes 38 +/- 4.5 C (100 +/- 8 F)

CSR40-149 & -150 PS Hermetic, June 2000

Specifications Refrigeration System 1-3

Refrigeration System

Compressor Model No.: ZM18K4E-TFD-279, Hermetic Scroll

Refrigerant Charge: CSR40 PS 3.6 Kg (8.0 lb) R-404A

Compressor Oil Capacity 1.77 liter (60 oz.)*

Compressor Oil Type Polyol Ester Based Type (required), TK Part No. 203-433**

High Pressure Cutout Switch: Cutout 3243 +/- 48 kPa, 32.43 +/- 0.48 bar, 470 +/- 7 psig

Cutin 2588 +/- 262 kPa, 25.88 +/- 2.62 bar, 375 +/- 38 psig

Low Pressure Cutout Switch: Cutout +21 to -20 kPa, +0.21 to -0.20 bar, 3 psig to 6” Hg vacuum

Cutin 48 to 90 kPa, 0.48 to 0.90 bar, 7 to 13 psig

High Pressure Relief Valve: Relief Pressure 3447 +520/-104 kPa, 34.47 +5.20/-1.04 bar, 500 +75/-15 psig

Reset 2758 kPa, 27.58 bar, 400 psig

Liquid Injection Control: Compressor Start Liquid injection valve opens for 5 minutes on each compressor start

Power Limit or Modulation Cool Liquid injection valve opens continuously during Power Limit and

Modulation Cool modes

Compressor Discharge Temperature Control Energizes (Opens) Liquid Injection Valve at 138 C (280 F)

De-energizes (Closes) Liquid Injection Valve at 132 C (270 F)

Compressor Shutdown (Auto Reset) at 148 C (298 F)

Liquid Injection Valve (Compressor): Voltage 24 Vac

Current 0.85 amps

Cold Resistance 5.6 ohms

Warm Gas Bypass Solenoid Valve: Voltage 24 Vac

Current 0.85 amps

Cold Resistance 5.6 ohms

Stepper Valve Regulating Motor: Voltage 12 Vdc

Current Draw 0.13 to 0.21 amperes per winding

0.26 to 0.44 amperes with 2 windings energized

Resistance 75 +/- 7.5 ohms across each winding at 24 C (75 F) ambient

*When the compressor is removed from the unit, oil level should be noted or the oil removed from the compressor should be mea-

sured 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!

CSR40-149 & -150 PS Hermetic, June 2000

1-4 MP-3000 Controller Specifications

MP-3000 Controller

Temperature Controller: Type MP-3000 microprocessor with thermostat, digital thermometer, pro-

gramming keypad, mode indicators, LED display and LCD display

for displaying unit operating and cargo information

Setpoint Range -29.0 to +29.0 C (-20.2 to +84.2 F)

Digital Temperature Display -60.0 to +80.0 C (-76.0 to +176.0 F)

Controller Software (Original Equipment): 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

request defrost initiation.

- Timed Defrost Initiation: Coil must be below 10 C (50 F).

Defrost cycle starts 1 minute after 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 inter-

val 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

- Temperature difference between the supply air sensor and return

air sensor is too large

Defrost Timer: Chilled mode - Supply Temperature at 5.1 C (41.2 F) or Above: Every 8 hours of

compressor operation.

- Supply Temperature at 5.0 C (41.0 F) or Below: Every 2.5 hours

of compressor operation. Defrost interval increases 0.5 hours each

timed defrost interval. Defrost synchronization creates step inter-

vals of 3, 4, 4, 5, 5, 6, 6 and 7 hours. Maximum time interval in

chilled mode is 7 hours.

Defrost Timer: 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.

Defrost Timer: 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.

CSR40-149 & -150 PS Hermetic, June 2000

Specifications Dehumidify and Humidify Systems 1-5

MP-3000 Controller (Continued)

Defrost Termination: Defrost (Coil) Sensor Chilled mode: Terminates defrost when coil sensor temperature

rises to 30 C (86 F); or exceeds 18 C (65 F) for 15

minutes

Frozen mode: Terminates defrost when coil sensor temperature

rises to 18 C (65 F); or exceeds 8 C (46 F) for 15

minutes

Termination Timer Terminates defrost after 90 minutes at 60 HZ operation if coil sen-

sor has not terminated defrost (120 minutes at 50 Hz operation)

Power Off Turning unit On/Off switch OFF terminates defrost

Compressor Shutdown Protection (Auto Reset):

Stops Compressor 130 C (266 F)

Allows Compressor Start 90 C (194 F)

Dehumidify and Humidify Systems (Options)

Dehumidify System (Option):

Turn Mode ON and OFF Set from CONTROL line of the Setpoint menu of the controller

Control Range (HUMSP) Setting 50% to 99% Relative Humidity

Humidify System (Option): Turn Mode ON and OFF Set from CONTROL line of the Setpoint menu of the controller

Operating Temperature Range 0 to 60 C (32 to 140 F)

Control Range (HUMSP) Setting 50% to 99% Relative Humidity

Air Compressor Output 2.5 m3/hr @ 0 kPa (1.5 CFM @ 0 psig)

Humidity Tank Heater: 240-600 Vac; 55 to 70 Watts at -17.8 C (0 F) Water Temperature

Humidity Sensor: Accuracy: +/- 1.5% between 55% and 75% Relative Humidity

+/- 3.0% between 75% and 95% Relative Humidity

Output Range: 4 to 20 milliamps

1% Relative Humidity = 0.2 milliamp

CSR40-149 & -150 PS Hermetic, June 2000

1-6 Physical Specifications Specifications

Physical Specifications

Advanced Fresh Air Management (AFAM)

Exchange Rate: CSR40 PS 0 to 285 m3/hr (0 to 168 ft3/min.) @ 60 Hz

0 to 236 m3/hr (0 to 139 ft3/min.) @ 50 Hz

Evaporator Fan Blade Specifications:

CSR40 PS Top Air Discharge: Diameter 355 mm (14.0 in.)

Pitch 25

Number 2

Weight (net): CSR40 PS Base Unit 413 Kg (910 lb)

Dual Voltage Option 45 Kg (99 lb)

Power Line Communications Option 3.6 Kg (8 lb)

Recorder (Partlow or Saginomiya) Option 5.9 Kg (13 lb)

Full TRANSFRESH®Option 13 Kg (28 lb)

Unit Dimensions: A = Flange Width 2025.5 mm (79.74 in.)

B = Gasket Width 1935 mm (76.18 in.)

C = Unit Width 1894 mm (74.57 in.)

D = Flange Height 2235.2 mm (88.00 in.)

E = Gasket Height 2140 mm (84.25 in.)

F = Unit Height 2094 mm (82.44 in.)

G = Gasket Depth 72 mm (2.83 in.) from back of flange

H = Maximum Protrusion 37 mm (1.46 in.) from back of flange

I = Unit Depth: CSR40 PS 420.0 mm (16.54 in.) from back of flange

CSR40-149 & -150 PS Hermetic, June 2000

Specifications Metric Hardware Torque Charts 1-7

Metric Hardware Torque Charts

Bolt Size

Bolt Type M6 M8 M10 M12

and Class* N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.)

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

Bolt Type M14 M16 M18 M22

and Class* N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.)

HH – CL 5.8 75-88 (55-65) 115-135 (85-100) 177-216 (130-160) 339-406 (250-300)

HH – CL 8.8 115-135 (85-100) 177-216 (130-160) 271-339 (200-250) 475-610 (350-450)

HH – CL 10.9 136-176 (100-130) 224-298 (180-220) 393-474 (290-350) 678- 813 (500-600)

HH – CL 12.9 177-216 (130-160) 285-352 (210-260) 448-542 (330-400) 881-1016 (650-750)

HH – SS (2) 115-135 (85-100) 177-216 (130-160) 271-339 (200-250) 475-610 (350-450)

*HH = Hex Head, CL = Class.

CSR40-149 & -150 PS Hermetic, June 2000

2 Unit Description

Dual Speed Evaporator Fans

Unit Features

Model CSR40-149 & -150 PS units are all-electric, singlepiece, refrigeration units with top air supply. Each unit is designed to cool and heat containers for shipboard or overland transit. Each 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 hinged, removable evaporator compartment door provides easy service access. All operating components except the evaporator coil and electric heaters can be replaced from the front of the unit. A totally sealed, hermetic refrigeration system minimizes maintenance and service.

Each unit is equipped with an 18.3 m (60 ft) power cable for operation on 460-380V/3 Ph/60-50 Hz power. For operation on 460-380V/3 Ph/60-50 Hz power, plug the 460-380V power cable into the proper power supply. The unit power cable is stored below the control box in the condenser section.

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.

Unit features include a hermetic scroll compressor with a liquid injection system; 2-speed evaporator fans; a fresh air exchange system; and a MP-3000 controller with integral data logger. For additional unit feature information, see “CSR40149 & -150 PS Model Features” on page vi of the Introduction.

Hermetic Scroll Compressor with Liquid Injection Cooling System

The refrigeration unit includes a hermetic scroll compressor (one stationary and one orbiting member) with ambient compensated internal overload and high temperature protectors, and a refrigerant injection system.

CSR PS 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 fans operate on high speed for perishable cargo at setpoints of -9.9 C (14.1 F) and above. At setpoints of -10 C (14 F) and below, the evaporator fans operate on low speed for frozen cargo.

NOTE: If Economy Mode is ON:

• Fresh Loads: Evaporator fans operate on low speed when container temperature is in-range.

• Frozen Loads: Evaporator fans stop during the Null mode; controller operates fans on low speed for 5 minutes every 45 minutes.

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 cargo and chilled load operating conditions. The fresh air vent should be tightly closed when carrying frozen cargo.

MP-3000 Controller

The MP-3000 controller incorporates refrigeration system component control, thermostat, digital thermometer, fault indication and data recording capabilities into one self-contained package.

The controller mounts in a weather tight, corrosion resistance enclosure. A large-character LED display (top) provides easy viewing of the control sensor temperature (return or supply air temperature). A 4-line, 20-character LCD display (bottom) display shows important data including the setpoint temperature, controller Main Menu tree and important unit operating data.

CSR40-149 & -150 PS Hermetic, June 2000

2-2 Unit Options Unit Description

Sixteen general purpose keys are used to enter and scroll through the controller menu tree and message text; initiate Pretrip and Function tests; enter new setpoint temperature; and enter trip information. The keyboard supports both numerical and text input. Four special keys provide quick access to setpoint temperature change, manual defrost initiation, alternate return/supply air temperature display, and alternate temperature scale (C/F) display.

Status indicator LEDs in the controller display signal Compressor, Heat, Defrost, In-range, Alarm, Humidity, Supply Temperature display and Return Temperature display.

A datalogger incorporated in the MP-3000 controller records sensor temperatures as well as loss of power, alarms, unit operating modes, sensor failure, setpoint change and unit shutdown indications. All data recordings are stored in a RAM memory that is backed by battery.

Logging intervals are selectable from 1 minute and 1/2, 1, 2 or 4 hours. When a 1 hour logging interval is selected, the datalogger memory can store approximately 680 days of information. The logging of USDA sensors is fixed at 1 hour intervals to comply with USDA requirements.

The datalogger clock is factory set at UTC time. All data logs include the time and date; setpoint temperature; and supply, return, USDA1, USDA2 and USDA3 sensor temperatures. All temperature logs can be viewed from the controller’s LCD message display.

A high speed serial communication port provides data retrieval using a DRU-II hand-held data retriever or laptop computer with SmartSponge software, or a REFCON power line remote monitoring system.

Unit Options

Advanced Fresh Air Management (AFAM)

An advanced microprocessor controlled fresh air management system provides programmable control of the air exchange rate, programmable delayed vent opening, automatic air exchange lock out for frozen cargo, automatic closure of the air exchange vent when the ambient temperature decreases below the cargo setpoint temperature, and data logging of the air exchange rate and vent opening delay interval.

The AFAM system includes a door control module, vent door, calibration decal and vent grille. The MP-3000 controller sends a communication signal to the door control module to position to vent door to the desired position. The controller can also be set to delay opening of the fresh air vent for up to 72 hours, in 1-hour increments. This allows faster product temperature pulldown.

The system is precalibrated for air exchange rates of 0 to 285 m3/hr (0 to 168 ft3/min.). A calibrated decal located inside the air exchange vent compartment can be used to visually verify the air exchange rate setting.

Dehumidification Control System

A dehumidification system lowers the relative humidity in the container to the humidity setpoint. The control range is 50% to 99% while the setpoint is adjustable between 0% and 99%.

Humidification Control System

An optional humidification system increases the relative humidity in the container to the humidity setpoint. The control range is 50% to 99% while the setpoint is adjustable between 0% and 99%.

Dual Voltage

A dual voltage system includes a 15 KVA auto transformer and an 18.3 m (60 ft) power cable for operation on 230190V/3 Ph/60-50 Hz power. The power cable is stored below the control box in the condenser section.

The 15 KVA auto transformer steps 230/190V power up to 460/380V. The auto transformer includes a 460-380V/3 Ph/60-50 Hz power receptacle.

For operation on 230/190V power, plug the 460-380V unit power cable into the receptacle on the auto transformer. Then plug the 230/190V power cable into a 230-190V power supply.

Recording Thermometer Option

Several models of temperature recorders are available for mounting on the unit. Each temperature recorder is designed to withstand widely varying environments including low and high ambient temperatures, salt water, humidity, fungus, industrial pollutants, dynamic loading, rain, sand and dust.

• The 31-day Partlow Recorder is mechanically driven by a

spring mechanism. On top air discharge units, the recording thermometer records supply air temperature.

CSR40-149 & -150 PS Hermetic, June 2000

Unit Description Operating Modes 2-3

Frozen Loads: Controller Setpoint at -10 C (14 F) or

Operating Modes

NOTE: See MP-3000 Controller chapter for complete sequence of operation.

A sequence start of the required loads occurs during initial start-up of the unit and when a control mode shift requires the compressors to start. As the controller relays and unit loads energize, the controller LCD display shows the setpoint temperature. The controller LED display shows the controlling air sensor temperature. The controlling sensor is determined by the setpoint temperature:

Setpoint Controlling Sensor

-9.9 C (14.1 F) and above Supply Air Temperature

-10 C (14 F) and below Return Air Temperature

The MP-3000 controller uses a proportional-integral derivative (PID) algorithm to provide accurate temperature control in direct response to load demand. Therefore it is difficult to predict which operating mode the unit should be in by comparing the setpoint to the return or supply air temperature. The unit operates in either the Fresh (Chill) or Frozen mode. Chill to Frozen mode transition point is -10 C (14 F).

Temperature control by the controller is based on the return air sensor temperature. The evaporator fans operate continuously on low speed (except during defrost).

• Cool (down to 1 C [1.8 F] below setpoint)

• Null (compressor and condenser fan stops, evaporator fans operate)

• Defrost (resistance heaters on, evaporator fans stop)

NOTE: If the Economy Mode is set to ON, the evaporator fans stop when the unit shifts to Null. The controller automatically starts and operates the evaporator fans on low speed for 5 minutes every 45 minutes while the unit remains in Null.

Below

Chill Loads: Controller Setpoint at -9.9 C (14.1 F) or

Above

Temperature control by the controller is based on the supply air sensor temperature, the setpoint, the modulation temperature range and the pull-down rate. The evaporator fans operate in high speed (except during defrost).

• Cool with Modulation (down to setpoint)

• Null (compressor and condenser fan stops, evaporator fans operate)

• Heat (resistance heaters on, evaporator fans operate)

• Defrost (resistance heaters on, evaporator fans stop)

NOTE: If the Economy Mode is set to ON, the evaporator fans operate on low speed at setpoints of -9.9 C (14.1 F) and above whenever the container temperature is In-range.

CSR40-149 & -150 PS Hermetic, June 2000

2-4 Unit Illustrations Unit Description

Typical Unit Front View

1. CSR40 PS: Evaporator Access Door, 1018 mm (40.08 in.) Wide with Two Latches

2. Condenser Fan

3. Compressor Compartment

4. Return Air Sensor Probe Holder

5. Power Cord Storage Compartment

6. Control Box

7. Rear Download and USDA Receptacle Panel (Access from Inside Container)

8. Fresh Air Exchange Vent

CSR40-149 & -150 PS Hermetic, June 2000

Unit Description Unit Illustrations 2-5

Unit Options Front View

1. Recording Thermometer Option

2. Dual Voltage Option

3. Advanced Fresh Air Management (AFAM) Option

4. Humidify System Option

CSR40-149 & -150 PS Hermetic, June 2000

2-6 Unit Illustrations Unit Description

12 3 4 5

CSR40 PS Evaporator Section — Front View

1. Evaporator Fan Motor

2. Evaporator Fan Blade:

• CSR40 PS: 355 mm (14.0 in.) diameter, 25opitch

3. Supply Air Sensing Bulb for Recording Thermometer (Option)

4. Supply Air Sensor

5. Humidify System Compressor (Option), see page 2-10

CSR40-149 & -150 PS Hermetic, June 2000

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