Maintenance Manual

Maintenance Manual
Maintenance Manual
CSR40SL-143
Prepared for OOCL
TK 50836-4-MM (Rev. 2/00)
Copyright ©2000, Thermo King Corporation, Minneapolis, MN, U.S.A.
Printed in U.S.A.
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.
Smart Reefer 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
About This Manual
Other Reference Manuals
CSR Semi-Hermetic Model Features
Safety Precautions
General Practices
Refrigerant
Refrigerant Oil
Electrical
General Safety Practices for Servicing Units
(or Containers) Equipped with a
Microprocessor Controller
Unit Decals
Serial Number Locations
Service Guide
Specifications
System Net Cooling Capacity – Full Cool
CSR40SL Models – Air Cooled Condensing
System Net Heating Capacity
Evaporator Airflow
CSR40SL Models
Electrical System
Refrigeration System
R-404A Temperature Pressure Relationships
Normal R-404A System Operating Pressures
Dehumidify System (Option)
Thermoguard® µP-D Controller
Physical Specifications
Metric Hardware Torque Charts
v
v
v
vi
vii
vii
vii
viii
viii
ix
x
x
xi
1-1
1-1
1-1
1-1
1-1
1-1
1-2
1-3
1-4
1-5
1-5
1-6
1-8
1-9
Unit Description
2-1
Unit Features
2-1
Unit Options
2-2
Operating Modes
2-2
Unit Illustrations
2-3 to 2-8
Typical Unit Front View
2-3
CSR40SL Evaporator Section — Front View 2-4
Semi-hermetic Refrigeration System
2-5
Scroll Compressor
2-6
Control Box – Door Open
2-7
Typical Unit Back View
2-8
Operating Instructions
Unit Controls
Unit Instruments
Unit Protection Devices
Pretrip Inspection
Starting the Unit and Adjusting the
Controller Setpoint
Loading Procedure
Post Load Procedure
Post Trip Procedure
µP-D Controller
3-1
3-1
3-1
3-2
3-3
3-4
3-4
3-4
3-4
4-1
Controller Description
Controller Display Menus
Software Version Display
Active Option Displays
Pause Mode Displays
View Menu
Pretrip Menu
Test Menu
Guarded Access Menu
Program Menu
Menu Display Definitions
4-1
4-3
4-3
4-3
4-4
4-4
4-4
4-4
4-4
4-4
4-4
CSR40SL Semi-Hermetic, February 2000
ii
Table of Contents
Status Indicator LEDs and Alarm Codes
Pause Alarms
Data Logging and Downloading Data
General Theory of Operation
Chill Loads
Frozen Loads
Automatic Phase Selection
Compressor Liquid Injection
Modulation Valve Setting (PCVAL)
Evaporator Fan Control
Condenser Fan Control
Sensor Check
Power Limit
Economy Mode Operation
Sequence of Operation
Unit Start-up
Operating Mode Function Chart — Standard
Operation
Operating Mode Function Chart — Optional
Feature Operation
Continuous Temperature Control Operation
Defrost
Reviewing Software Version and Configuration
Displaying Alternate Fahrenheit (F) or
Celsius (C) Temperatures
Displaying Alternate Controlling (Supply or
Return) Air Sensor Temperatures
Changing the Setpoint
Initiating a Manual Defrost
Initiating a Full Pretrip
Entering a Start of Trip Marker
Displaying and Clearing Alarm Codes
Controller Menu Operating Instructions
Menu View Functions
Navigating the Menu View Screens
GRADE Submenu
LOG Submenu
Menu Pretrip Functions
Performing an Extended, Full or Single
Pretrip Test from the Pretrip Menu
Menu Test Functions
4-6
4-7
4-8
4-8
4-8
4-9
4-9
4-9
4-9
4-9
4-9
4-10
4-10
4-11
4-11
4-11
4-12
4-13
4-13
4-16
4-17
4-17
4-18
4-18
4-19
4-19
4-20
4-20
4-21
4-21
4-21
4-22
4-22
4-25
Menu Guard Functions
4-29
Navigating Menu Guard Screens
4-29
Setting the Unit Configuration and
Customer Configuration Numbers
4-30
Setting the Container Identification Number 4-30
Setting the Unit Serial Number
4-31
Setting the Time and Date
4-31
Setting the Compressor and On Time
Hourmeters
4-32
Setting the User Hourmeter Types, User
Hourmeter Thresholds and User
Hourmeters
4-32
Setting the Sensor Grades
4-33
Changing the Display Units (C/F)
4-35
Menu Program Functions
4-36
USDA Sensors
4-36
PULP Sensor (Option)
4-37
Economy Mode
4-38
Dehumidify Mode (Option)
4-39
Humidify Mode (Option)
4-39
Bulb Mode (Option)
4-40
Power Reduction Mode
4-41
Controller Emergency Bypass Procedure
4-42
Output Module
4-43
Thermo Bus Tap
4-43
Power Module
4-43
Replacing the µP-D Controller
4-44
Temperature Sensors
4-44
Diagnosis and Repair
4-45
Alarm Codes, Descriptions and
Corrective Actions
4-46 to 4-66
Electrical Maintenance
Unit Wiring
High Pressure Cutout Switch
Condenser Fan and Evaporator Fan Rotation
Electric Heaters
5-1
5-1
5-1
5-2
5-2
4-26
4-27
CSR40SL Semi-Hermetic, February 2000
Table of Contents
Refrigeration System Diagnosis and Service
Service Tools
Gauge Manifold Valve Positions
Gauge Manifold Set Attachment and Purging
Checking Compressor Oil
Refrigerant Charge
Refrigerant Leak Test Procedure
Using Pressurized Nitrogen
Refrigerant Recovery from Semi-hermetic
Refrigeration Systems
Evacuation and Cleanup of the
Refrigeration System
Charging the System with Refrigerant
Modulation Valve Repair or Replacement
Compressor Replacement
Condenser Coil Replacement
Filter Drier/In-line Filter Replacement
Expansion Valve Replacement
Heat Exchanger Replacement
Receiver Tank Replacement
High Pressure Cutout Switch, Condenser Fan
Speed Pressure Switch, or Compressor
Discharge Temperature Sensor Replacement
Warm Gas Bypass Valve, Liquid Injection Valve
or Dehumidify Valve (Option) Replacement
Structural/Accessory Maintenance
Mounting Bolts
Unit Inspection
Condenser Coil
Evaporator Coil
Defrost Drains
Fresh Air Exchange System
Evaporator Fan Location
Condenser Fan Location
Saginomiya (Model SKM) Recording Thermometer (Option)
Battery
Recording Chart Replacement
Marking System Calibration
Power Element Assembly Replacement
Timer (Quartz Motor and Reducing Gear
Replacement
Battery Voltage Indicator
iii
6-1
6-1
6-2
6-2
6-4
6-5
6-6
6-6
6-7
6-8
6-12
6-12
6-14
6-15
6-16
6-16
6-17
6-17
6-18
6-18
7-1
7-1
7-1
7-1
7-1
7-2
7-2
7-2
7-3
7-3
7-3
7-4
7-4
7-4
7-5
7-5
Diagnosis
8-1
Mechanical Diagnosis
Refrigeration Diagnosis
Electrical, Refrigeration and µP-D Menu
Flow Diagrams
8-1
8-5
9-1
Electrical Schematic with Circuit Tracing
9-1
460/380 Vac Power Supply to Unit
9-1
External 12 Vdc Battery Power Supply
9-2
Microprocessor Awakened from Sleep Mode 9-3
12.5 Vdc Control Circuit, Sensor Circuits,
Modulation Valve Circuit and Water
Pressure Circuit (Option)
9-4
24 Vac Control Circuit
9-5
Dehumidify System, Humidify System,
Water Pressure Switch, USDA
Temperature Sensor, Pulp Sensor and
Chart Recorder Circuits (Options)
9-6
Cool Mode – Chill Load (Setpoint at -9.9 C
[14.1 F] or Above); Condenser Fan ON;
Power Monitor Limiting Unit Power
Consumption; Economy Mode OFF
9-7
Cool Mode – Chill Load (Setpoint at -9.9 C
[14.1 F] or Above); Condenser Fan ON;
Economy Mode OFF
9-8
Modulation Mode – Chill Load (Setpoint at
-9.9 C [14.1 F] or Above); Condenser
Fan ON; Economy Mode OFF;
Temperature Out-of-range
9-9
Modulation Mode – Chill Load (Setpoint at
-9.9 C [14.1 F] or Above); Condenser
Fan ON; Economy Mode OFF;
Temperature In-range; Dehumidify ON
with Humidity 1-5% Above Humidity
Setpoint
9-10
Modulation Mode – Chill Load (Setpoint at
-9.9 C [14.1 F] or Above); Condenser
Fan ON; Economy Mode OFF;
Temperature In-range; Dehumidify ON
with Humidity 5% or More Above
Humidity Setpoint
9-11
Modulation Mode – Chill Load (Setpoint at
-9.9 C [14.1 F] or Above); Condenser
Fan OFF; Economy Mode ON;
Temperature In-range
9-12
CSR40SL Semi-Hermetic, February 2000
iv
Table of Contents
Modulation Mode – Chill Load (Setpoint at
-9.9 C [14.1 F] or Above); Condenser
Fan OFF; Economy Mode ON;
Temperature In-range; Warm Gas
Bypass Valve ON
9-13
Null Mode – Chill Load (Setpoint at -9.9 C
[14.1 F] or Above) Condenser Fan ON;
Economy Mode OFF
9-14
Heat Mode – Chill Load (Setpoint at -9.9 C
[14.1 F] or Above); Economy Mode
OFF; Temperature In-range
9-15
Cool Mode – Frozen Load (Setpoint at -10.0 C
[14.0 F] or Below); Condenser Fan ON;
Container Return Air Temperature Above
-10.0 C [14.0 F]; Power Monitor Limiting
Unit Power Consumption; Economy
Mode OFF
9-16
Cool Mode – Frozen Load (Setpoint at -10.0 C
[14.0 F] or Below); Condenser Fan ON;
Container Return Air Temperature Below
-10.0 C [14.0 F]; Economy Mode OFF;
Temperature In-range
9-17
Null Mode – Frozen Load (Setpoint at -10.0 C
[14.0 F] or Below) Condenser Fan OFF;
Economy Mode OFF
Null Mode – Frozen Load (Setpoint at -10.0 C
[14.0 F] or Below) Condenser Fan OFF;
Economy Mode ON
Defrost
CSR40SL Wiring Schematic
CSR40SL Wiring Diagram
Refrigeration System Schematics:
Refrigeration System Components
Full Cool Flow and Pressure Diagram
Modulation Cool Flow and Pressure Diagram
Dehumidification Flow and Pressure Diagram
µP-D Menu Flow Diagram
9-18
9-19
9-20
9-21
9-22
9-23
9-24
9-25
9-26
9-27
CSR40SL Semi-Hermetic, February 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-40 PS Models
CSR40SL-143
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
System Number
917143
Other Reference Manuals
For detailed descriptions of our refrigeration systems or microprocessor controllers, see the appropriate manual or
Thermoguard µP-D Microprocessor Controller Diagnosis
Manual. For further information refer to:
Parts Manuals
CSR40-143 Parts List
TK 50192
CSR-20 & CSR-40, October 1999
vi
CSR Semi-Hermetic Model Features
Introduction
X
–
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
–
–
X
–
–
X
–
–
–
–
–
–
–
–
X
–
–
–
–
–
–
MODEL
CSR40SL - 143
CSR Semi-Hermetic Model Features
FEATURES
X = Included; O = Option
460-380V/3Ph/60-50 Hz, 18.3 m (60 ft) Power Cable and Plug
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
Automatic Phase Selection Control
25 Amp Main Power Circuit Breaker
Slimline Frame
Flanged Scroll Compressor w/4.48 kW (6.0 Hp) Motor
Suction and Discharge Line Service Valves
Compressor Liquid Injection System
Warm Gas Bypass Valve System
Modulation Valve
Refrigerant R-404A w/Polyol Ester Compressor Oil (TK P/N 203-433)
Receiver Tank with Two Moisture Indicating Sight Glasses
µP-D Controller with Proportional-integral Differential (PID) Capacity Control
Controller Emergency Bypass Module
USDA Cold Treatment Temperature Recording
Three Evaporator Fans with 2-Speed Motors
Fresh Air Exchange System
CO2 Sampling Port
One 1-Speed Condenser Fan Motor
Auxiliary Battery and Battery Charger
Bulb Mode Operation
Data Retrieval Receptacle, Standard (5-Pin Deutsch)
Data Retrieval Receptacle, 5-Pin Threaded Cannon
Data Retrieval Receptacle, 15-Pin RS232
Dehumidify Control
Humidity System
Power Line Communications, Standard (Thermo King Modem)
Power Line Communications, Thermo King Integrated Remote Monitor Unit (IRMU)
Power Line Communications, RTE Modem
Power Line Communications, Sabroe Control Modem
Pressure Gauge, Discharge
Pressure Gauge, Suction
Recorder, Partlow
Recorder, Saginomiya
Remote Monitoring Plug (4-Pin)
TRANSFRESH® Provision
TRANSFRESH® Purge Port
TRANSFRESH® System, Complete
Thermistor Lead
Water-Cooled Condenser-Receiver Tank
CSR40SL Semi-Hermetic, February 2000
Safety Precautions
General Practices
Refrigerant
1.
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.
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.
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.
CSR40SL Semi-Hermetic, February 2000
viii
Refrigerant Oil
Safety Precautions
4.
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.
5.
6.
7.
Do not make any rapid moves when working on high voltage circuits. If a tool or other object falls, do not attempt
to grab it. People do not contact high voltage wires on
purpose. It occurs from an unplanned movement.
Treat all wires and connections as high voltage until a
meter and wiring diagram show otherwise.
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 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.
CSR40SL Semi-Hermetic, February 2000
Safety Precautions
General Safety Precautions for Servicing Controllers
General Safety Precautions for Servicing
Units (or Containers) Equipped with a
Microprocessor Controller
Precautions must be taken to prevent electrostatic discharge
when servicing the µP-D microprocessor, output module 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 microprocessor. The second cause
results from electric welding on the unit and container chassis
without taking precautionary steps.
Controller Repair
When servicing the microprocessor, 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
solid-state integrated circuit components. The following procedures must be rigidly adhered to when servicing these units
to avoid microprocessor 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 microprocessor’s
ground terminal. These straps are available at most electronic equipment 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 materials until ready for installation.
6. If a defective microprocessor 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 restoring power.
ix
Welding of Units or Containers
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 µP-D controller. Also disconnect the wire
harness from the Output module.
3. If the unit is equipped with a Remote Monitor Module
(RMM) or Integrated Remote Monitor Unit (IRMU), disconnect all wire harnesses from the RMM/IRMU circuit
board.
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, wire harnesses and circuit breakers must be
restored to their normal condition.
CSR40SL Semi-Hermetic, February 2000
x
Unit Decals
Safety Precautions
Unit Decals
Serial Number Locations
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.
Electric Motors: Nameplate attached to the motor housing.
Compressor: Nameplate on front of the compressor.
Unit: Nameplate on unit frame in power cord storage compartment.
µP-D Controller: Nameplate on back of controller.
Unit Nameplate Location
CSR40SL Semi-Hermetic, February 2000
Service Guide
Pretrip
Every
1,000
Hours
Annual/
Yearly
Inspect/Service These Items
Electrical
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Perform a controller Full Pretrip Test to check the electrical and refrigeration systems.
Perform a controller Extended Pretrip Test.
Visually check condenser fan and evaporator fan rotation.
Visually inspect electrical contacts for damage or loose connections.
Visually inspect wire harness for damaged wires or connections.
Download the data logger and check data for correct logging.
Check calibration of graded sensors.
Refrigeration
•
•
•
•
•
•
•
•
•
Check refrigerant charge.
Check compressor oil level.
Check for proper discharge and suction pressures.
Check filter drier/in-line filter for a restriction or corrosion.
Structural
•
•
•
•
•
•
•
•
Visually inspect unit for damaged, loose or broken parts.
Tighten unit, compressor and fan motor mounting bolts.
Clean entire unit including condenser and evaporator coils and defrost drains.
CSR40SL Semi-Hermetic, February 2000
1
Specifications
System Net Cooling Capacity — Full Cool
CSR40SL Models — Air Cooled Condensing*
Return air to
460/230V, 3 Phase, 60 Hz Power
evaporator
Net Cooling Capacity
Power Consp
coil inlet
Watts
Kcal/hr BTU/hr
kW @460V
21.1 C (70 F) 12,660
10,890
43,200
9.8
1.7 C (35 F)
9,100
7,825
31,050
8.9
-17.8 C (0 F)
5,300
4,555
18,075
6.1
-28.9 C (-20 F) 3,470
2,980
11,830
5.8
380/190V, 3 Phase, 50 Hz Power
Net Cooling Capacity
Power Consp
Watts
Kcal/hr
BTU/hr
kW @380V
10,130
8,715
34,575
7.6
7,280
6,260
24,845
6.9
4,240
3,645
14,470
4.9
2,775
2,385
9,470
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
CSR40SL
460/230V, 3 Phase, 60 Hz Power
Heating Capacity
Watts
Kcal/hr
BTU/hr
5,880
5,060
20,070
380/190V, 3 Phase, 50 Hz Power
Heating Capacity
Watts
Kcal/hr
BTU/hr
4,900
4,215
16,720
*System net heating capacity includes electric resistance rods and fan heat.
Evaporator Airflow
CSR40SL Models
External Static
Pressure (water
column)
0 mm (0 in.)
10 mm (0.4 in.)
20 mm (0.8 in.)
30 mm (1.2 in.)
40 mm (1.6 in.)
460/230V, 3 Phase, 60 Hz Power
High Speed
Low Speed
3
3
3
m /hr
ft /min
m /hr
ft3/min
5,820
3,430
2,800
1,650
5,055
2,975
1,400
825
4,365
2,570
—
—
3,440
2,025
—
—
2,615
1,540
—
—
380/190V, 3 Phase, 50 Hz Power
High Speed
Low Speed
3
3
3
m /hr
ft /min
m /hr
ft3/min
4,860
2,860
2,590
1,525
3,940
2,320
510
300
3,040
1,790
—
—
2,140
1,260
—
—
—
—
—
—
CSR40SL Semi-Hermetic, February 2000
1-2
Electrical System
Specifications
Electrical System
Compressor Motor:
Type
Kilowatts
Horsepower
RPM
Locked Rotor Amps
Condenser Fan Motor:
Type
Kilowatts
Horsepower
RPM
Full Load Amps
Locked Rotor Amps
Evaporator Fan Motors:
Type
Number: CSR40SL
Kilowatts
Horsepower
RPM (Each): High Speed
Low Speed
Full Load Amps (Each): High Speed
Low Speed
Locked Rotor Amps: High Speed
Low Speed
Electric Resistance Heater Rods:
Type
Number
Watts (Each)
Current Draw (Amps)
Control Circuit Voltage
Auxiliary Battery (Option)
460/380V, 60/50 Hz, 3 Phase
4.48 kW @ 460V, 60 Hz
6.0 hp @ 460V, 60 Hz
3550 rpm @ 460V, 60 Hz
70 amps @ 460V, 60 Hz
460/380V, 60/50 Hz, 3 Phase
0.37 kW @ 460V, 60 Hz
0.50 hp @ 460V, 60 Hz
1145 rpm @ 460V, 60 Hz
0.9 amps @ 460V, 60 Hz; 1.0 amps @ 380V, 50 Hz
4.0 amps @ 460V, 60 Hz; 4.0 amps @ 380V, 50 Hz
460/380V, 60/50 Hz, 3 Phase
3
0.75 kW @ 460V, 60 Hz
1.0 hp @ 460V, 60 Hz
3450 rpm @ 460V, 60 Hz
1725 rpm @ 460V, 60 Hz
1.2 amps @ 460V, 60 Hz
0.5 amps @ 460V, 60 Hz
10.3 amps @ 460V, 60 Hz
2.9 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 contactor
24 Vac
12 Vdc, 7 or 12 amp hour
CSR40SL Semi-Hermetic, February 2000
Specifications
Refrigeration System
1-3
Refrigeration System
Compressor Model No.:
Refrigerant Charge:
Compressor Oil Capacity
Compressor Oil Type
High Pressure Cutout Switch:
CSR40SL
Cutout
Cutin
High Pressure Relief Valve:
Relief Pressure
Reset
Liquid Injection Control:
Compressor Start
Power Limit or Modulation Cool
Compressor Discharge Temperature Control
Liquid Injection Valve (Compressor):
Voltage
Current
Cold Resistance
Warm Gas Bypass Solenoid Valve:
Voltage
Current
Cold Resistance
Modulation Valve:
Voltage
Current Draw
Resistance
ZM18K4E-TFD-276, Scroll
4.1 Kg (9.0 lb) R-404A
1.77 liter (60 oz.)***
Polyol Ester Based Type (required), TK Part No. 203-433****
3243 +/- 48 kPa, 32.43 +/- 0.48 bar, 470 +/- 7 psig
2588 +/- 262 kPa, 25.88 +/- 2.62 bar, 375 +/- 38 psig
3447 +520/-104 kPa, 34.47 +5.20/-1.04 bar, 500 +75/-15 psig
2758 kPa, 27.58 bar, 400 psig
Liquid injection valve opens for 5 minutes on each compressor start
Liquid injection valve opens continuously during Power Limit and
Modulation Cool modes
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)
24 Vac
0.85 amps
5.6 ohms
24 Vac
0.85 amps
5.6 ohms
12 Vdc
0 to 0.4 amperes, valve open
0.4 to 1.4 amperes, valve modulates to close
Above 1.4 amperes, valve closed
7.6 ohms 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
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!
CSR40SL Semi-Hermetic, February 2000
1-4
R-404A Temperature Pressure Relationship
Specifications
R-404A Temperature Pressure Relationship — Vapor Pressure
Temp. Temp.
o
o
F
C
-50
-48
-46
-44
-42
-40
-38
-36
-34
-32
-30
-28
-26
-24
-22
-20
-18
-16
-14
-12
-10
-8
-6
-4
-2
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
-45.6
-44.4
-43.3
-42.2
-41.1
-40.0
-38.9
-37.8
-36.7
-35.6
-34.4
-33.3
-32.2
-31.1
-30.0
-28.9
-27.8
-26.7
-25.6
-24.4
-23.3
-22.2
-21.1
-20.0
-18.9
-17.8
-16.7
-15.6
-14.4
-13.3
-12.2
-11.1
-10.0
-8.9
-7.8
-6.7
-5.6
-4.4
-3.3
-2.2
-1.1
0.0
1.1
2.2
3.3
4.4
5.6
6.7
7.8
8.9
10
kPa
Bar
Psig
0
6.2
13.8
18.6
24.8
31.0
37.9
44.8
52.4
60.0
68.3
76.5
84.8
93.8
102.7
112.4
122.0
132.4
142.7
153.8
164.8
176.5
188.2
200.6
213.1
226.2
240.0
253.7
268.2
283.4
298.6
314.4
331.0
347.5
364.8
382.7
400.6
419.9
439.2
458.5
479.2
499.9
521.3
543.3
566.1
589.5
613.7
637.8
663.3
688.8
715.0
0
0.06
0.14
0.19
0.25
0.31
0.38
0.45
0.52
0.60
0.68
0.77
0.85
0.94
1.03
1.12
1.22
1.32
1.43
1.54
1.65
1.77
1.88
2.01
2.13
2.26
2.40
2.54
2.68
2.83
2.99
3.14
3.31
3.48
3.65
3.83
4.01
4.20
4.39
4.59
4.79
5.00
5.21
5.43
5.66
5.90
6.14
6.38
6.63
6.89
7.15
0
0.9
2.0
2.7
3.6
4.5
5.5
6.5
7.6
8.7
9.9
11.1
12.3
13.6
14.9
16.3
17.7
19.2
20.7
22.3
23.9
25.6
27.3
29.1
30.9
32.8
34.8
36.8
38.9
41.1
43.3
45.6
48.0
50.4
52.9
55.5
58.1
60.9
63.7
66.5
69.5
72.5
75.6
78.8
82.1
85.5
89.0
92.5
96.2
99.9
103.7
Temp. Temp.
o
o
F
C
52
54
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
114
116
118
120
122
124
126
128
130
132
134
136
138
140
142
144
146
148
150
11.1
12.2
13.3
14.4
15.6
16.7
17.8
18.9
20
21.1
22.2
23.3
24.4
25.6
26.7
27.8
28.9
30
31.1
32.2
33.3
34.4
35.6
36.7
37.8
38.9
40
41.1
42.2
43.3
44.4
45.6
46.7
47.8
48.9
50
51.1
52.2
53.3
54.4
55.6
56.7
57.8
58.9
60
61.1
62.2
63.3
64.4
65.6
kPa
Bar
Psig
742.6
770.2
798.4
827.4
857.1
888.1
919.1
950.8
983.9
1017.0
1051.5
1086.6
1122.5
1159.1
1196.3
1234.9
1273.5
1313.5
1354.9
1396.2
1439.0
1482.4
1526.6
1572.1
1618.3
1665.1
1713.4
1763.1
1812.7
1863.7
1916.1
1969.2
2023.7
2078.8
2135.4
2192.6
2251.2
2311.2
2371.9
2433.9
2496.9
2561.5
2627.0
2693.2
2761.5
2830.4
2900.7
2972.4
3045.5
3120.0
7.43
7.70
7.98
8.27
8.57
8.88
9.19
9.51
9.84
10.17
10.52
10.87
11.23
11.59
11.96
12.35
12.74
13.14
13.55
13.96
14.39
14.82
15.27
15.72
16.18
16.65
17.13
17.63
18.13
18.64
19.16
19.69
20.24
20.79
21.35
21.93
22.51
23.11
23.72
24.34
24.97
25.62
26.27
26.93
27.62
28.30
29.01
29.72
30.46
31.20
107.7
111.7
115.8
120.0
124.3
128.8
133.3
137.9
142.7
147.5
152.5
157.6
162.8
168.1
173.5
179.1
184.7
190.5
196.5
202.5
208.7
215.0
221.4
228.0
234.7
241.5
248.5
255.7
262.9
270.3
277.9
285.6
293.5
301.5
309.7
318.0
326.5
335.2
344.0
353.0
362.1
371.5
381.0
390.6
400.5
410.5
420.7
431.1
441.7
452.5
CSR40SL Semi-Hermetic, February 2000
Specifications
Normal R-404A System Operating Pressures
1-5
Normal R-404A System Operating Pressures (Scroll Compressor)
Container
Temp.
21 C (70 F)
2 C (35 F)
-18 C (0 F)
-29 C (-20 F)
Operating Ambient
Mode
Temp.
Cool
27 to 38 C,
80 to 100 F
16 to 27 C,
60 to 80 F
Cool
27 to 38 C,
80 to 100 F
16 to 27 C,
60 to 80 F
Cool
27 to 38 C,
80 to 100 F
16 to 27 C,
60 to 80 F
Cool
27 to 38 C,
80 to 100 F
16 to 27 C,
60 to 80 F
Suction Pressure
Discharge Pressure
410 to 670 kPa, 4.10 to 6.70 bar,
59 to 97 psig
400 to 600 kPa, 4.00 to 6.00 bar,
58 to 87 psig
385 to 425 kPa, 3.85 to 4.25 bar,
56 to 62 psig
345 to 385 kPa, 3.45 to 3.85 bar,
50 to 56 psig
214 to 228 kPa, 2.14 to 2.28 bar,
31 to 33 psig
200 to 215 kPa, 2.00 to 2.15 bar,
29 to 31 psig
145 to 160 kPa, 1.45 to 1.60 bar,
21 to 23 psig
130 to 145 kPa, 1.30 to 1.45 bar,
19 to 21 psig
2140 to 2650 kPa, 21.40 to 26.50 bar,
310 to 385 psig
1725 to 2140 kPa, 17.25 to 21.40 bar,
250 to 310 psig
1860 to 2380 kPa, 18.60 to 23.80 bar,
270 to 345 psig
1450 to 1860 kPa, 14.50 to 18.60 bar,
210 to 270 psig**
1515 to 2035 kPa, 15.15 to 20.35 bar,
220 to 295 psig**
1100 to 1515 kPa, 11.00 to 15.15 bar,
160 to 220 psig**
1450 to 1965 kPa, 14.50 to 19.65 bar,
210 to 285 psig**
1035 to 1450 kPa, 10.35 to 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 70 and 450 kPa, .70 and 4.50 bar, 10
and 65 psig depending upon the percent (%) modulation.
**Discharge pressure is determined by condenser fan cycling.
Dehumidify System (Option)
Dehumidify System (Option):
Turn Mode ON and OFF
Control Range (HUMSP) Setting
Humidity Sensor:
Accuracy:
Output Range:
Set from HUMID screen of the Program menu of the controller
50% to 100% Relative Humidity
+/- 1.5% between 55% and 75% Relative Humidity
+/- 3.0% between 75% and 95% Relative Humidity
4 to 20 milliamps
1% Relative Humidity = 0.2 milliamp
CSR40SL Semi-Hermetic, February 2000
1-6
µP-D Controller
Specifications
Thermoguard® µP-D Controller
Temperature Controller:
Type
Setpoint Range
Digital Temperature Display
Output Module
Thermo Bus PC Board
Power Module PC Board
Controller Software (Original Equipment): Version
Unit Configuration (CFG U)
Customer Configuration (CFG C)
Defrost Initiation
Evaporator Coil Sensor
Demand Defrost
Defrost Timer: Chill Mode*
Defrost Timer: Frozen Mode*
Thermoguard® µP-D microprocessor with digital thermostat, thermometer and fault indicator monitor
-30.0 to +30.0 C (-22.0 to +86.0 F)
-40.0 to +130.0 C (-40.0 to +266.0 F)
Energizes and de-energizes unit contactors and solenoids in
response to serial communications commands from the µP-D controller. Indicator LEDs on the Output Module indicate an output is
energized. RXD and TXD indicator LEDs alternately flash to show
the communications connection is good. If one or both of the RXD
and TXD LEDs do NOT flash, the communications connection is
open or defective.
Transfers the serial communications commands from the µP-D controller to the Output Module.
Supplies low voltage control power to the µP-D controller, Output
Module and modulation valve. Fuses provide current overload protection to unit control circuits.
See controller identification decal
See controller identification decal
See controller identification decal
Coil must be below 10 C (50 F) to initiate defrost by demand, timer
or manual switch
Demand defrost function initiates defrost when the return air and
refrigeration systems conditions indicate the presence of frost or ice
• Default: Every 3 hours until two timed defrosts occur without a
demand defrost in between. Then defrost interval increases 1 hour
every other timed defrost interval. Maximum time interval is 8
hours
• Customer Configuration C5: Standard default times but maximum
time interval is 6 hours on chill loads.
• Customer Configuration C6: 2 hour initial defrost, then maximum
time interval is 6 hours on chill loads.
• Default: Every 6 hours until two timed defrosts occur without a
demand defrost in between. Then defrost interval increases 2
hours each timed defrost interval. Maximum time interval is 24
hours
• Customer Configuration C5: Standard default times but maximum
time interval is 12 hours on frozen loads.
• Customer Configuration C6: 2 hour initial defrost, then maximum
time interval is 6 hours on frozen loads.
*Timed defrost intervals reset to initial value after a manual defrost, after the unit has been OFF for 48 hours and after a setpoint
change from Chill to Frozen mode or Frozen to Chill mode.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Specifications
1-7
Thermoguard® µP-D Controller (Continued)
Defrost Termination:
Evaporator Coil Sensor*
Interval Timer**
Time/Temperature Function
Power Off
Evaporator Over Temperature Protection
Bulb Mode (Option)***:
Defrost Termination Temperature (BDFTT) Setting
Evaporator Fan Speed Settings
Economy Mode (Standard Feature):
Description
Set to ON for Fresh Loads
Set to ON for Frozen Loads
Turn Mode ON and OFF
ECMIN Temperature
ECMAX Temperature
Power Reduction Mode (Standard Feature):
Power Reduction (PWRED) Settings
Pulp Mode (Option)****:
Control Settings
USDA Mode (Standard Feature):
Turn Mode ON and OFF
Operation
Chill mode: Terminates defrost when coil sensor temperature rises
to 30 C (86.0 F)
Frozen mode: Terminates defrost when coil sensor temperature
rises to 18 C (64.4 F)
Terminates defrost 90 minutes after initiation if coil sensor has not
terminated defrost
If the evaporator coil sensor exceeds 8 C (46 F) for 10 minutes, the
controller terminates defrost (Frozen Mode Only)
Turning unit On/Off switch OFF terminates defrost
Operates only when unit is in Heat or Defrost modes: Opens heater
contactor at 38 C (100 F). Opens phase select contactor to shut
down all unit operation and initiate an alarm at 50 C (122 F)
4 to 30 C (40 to 86 F)
High Speed only; Low Speed only; or Cycle (fans will cycle
between low and high speeds every 60 minutes)
Reduces power consumption by reducing evaporator fan operation
Evaporator fans operate on low speed whenever the container temperature is In-range
Evaporator fans stop during Null mode. Controller operates fans
for 5 minutes every 45 minutes to circulate container air
Set from ECON screen of the Program menu of the controller
2.0 C (3.6 F) default setting; Adjustable from 0 to 10 C (0 to 18 F)
in Menu Guard
1.0 C (1.8 F) default setting; Adjustable from 0 to 10 C (0 to 18 F)
in Menu Guard
0 = OFF; 1 = 10% Power Reduction; 2 = 20% Power Reduction;
3= 30% Power Reduction
OFF or ON (Controller records Pulp Sensor temperature)
Set from USDA screen of the Program menu of the controller
Controller automatically detects sensors to initiate data logging.
However, USDA sensors must be ice bath calibrated to accurately
record temperature
*If the evaporator coil sensor fails, the controller terminates defrost when the return air (top) sensor rises to 18 C (64.4 F).
**If both the evaporator coil and return air (top) sensors fail, the interval timer terminates defrost 60 minutes after initiation.
***Unit must be equipped with dehumidify system.
****Sensor must be installed and calibrated.
CSR40SL Semi-Hermetic, February 2000
1-8
Physical Specifications
Specifications
Physical Specifications
Fresh Air Exchange Venting System (Adjustable):
CSR40SL
Evaporator Fan Blade Specifications:
CSR40SL: Diameter
Pitch
Recording Thermometer Options:
Type
Type
Weight (net):
CSR40SL Base Unit
Recorder (Partlow or Saginomiya) Option
Unit Dimensions:
A = Flange Width
B = Gasket Width
C = Unit Width
D = Flange Height
E = Gasket Height
F = Unit Height
G = Gasket Depth
H = Maximum Protrusion
I = Unit Depth: CSR-40SL
0 to 285 m3/hr (0 to 168 ft3/min.) @ 60 Hz
0 to 236 m3/hr (0 to 139 ft3/min.) @ 50 Hz
312 mm (12.25 in.)
25o
31-Day Saginomiya SKM, battery driven recording chart
31-Day Partlow, spring wound recording thermometer
402 Kg (885 lb)
5.9 Kg (13 lb)
2025.5 mm (79.74 in.)
1935 mm (76.18 in.)
1894 mm (74.57 in.)
2235.2 mm (88.00 in.)
2140 mm (84.25 in.)
2094 mm (82.44 in.)
72 mm (2.83 in.) from back of flange
37 mm (1.46 in.) from back of flange
378.0 mm (14.88 in.) from back of flange
CSR40SL Semi-Hermetic, February 2000
Specifications
Metric Hardware Torque Charts
1-9
Metric Hardware Torque Charts
Bolt Size
Bolt Type
and Class*
HH – CL 5.8
HH – CL 8.8
HH – CL 10.9
HH – CL 12.9
HH – SS (2)
M6
M8
M10
M12
N.m (Ft.-lb.)
N.m (Ft.-lb.)
N.m (Ft.-lb.)
N.m (Ft.-lb.)
6-9 (4-7)
12-16 (9-12)
27-34 (20-25)
48-61 (35-40)
10-13 (7-10)
20-27 (15-20)
41-47 (30-35)
75-88 (55-65)
14-17 (10-13)
27-34 (20-25)
54-68 (40-50)
102-122 (75-90)
17-21 (12-16)
41-47 (30-35)
68-81 (50-60)
122-149 (90-110)
10-13 (7-10)
20-27 (15-20)
41-47 (30-35)
75-88 (55-65)
M14
M16
M18
M22
N.m (Ft.-lb.)
N.m (Ft.-lb.)
N.m (Ft.-lb.)
N.m (Ft.-lb.)
75-88 (55-65)
115-135 (85-100)
177-216 (130-160)
339-406 (250-300)
Bolt Size
Bolt Type
and Class*
HH – CL 5.8
HH – CL 8.8
HH – CL 10.9
HH – CL 12.9
HH – SS (2)
115-135 (85-100)
177-216 (130-160)
271-339 (200-250)
475-610 (350-450)
136-176 (100-130)
224-298 (180-220)
393-474 (290-350)
678- 813 (500-600)
177-216 (130-160)
285-352 (210-260)
448-542 (330-400)
881-1016 (650-750)
115-135 (85-100)
177-216 (130-160)
271-339 (200-250)
475-610 (350-450)
*HH = Hex Head, CL = Class.
CSR40SL Semi-Hermetic, February 2000
2
Unit Description
Unit Features
Model CSR40SL units are all-electric, single-piece, refrigeration units with bottom 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. CSR40SL units
feature a slimline frame (see “Physical Specifications” on page
1-9). 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
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. 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 compressor, condenser
fan and evaporator fan motor operation.
Unit features include a flanged scroll compressor with a
liquid injection system; 2-speed evaporator fans; a fresh air
exchange system; and a Thermoguard® µP-D microprocessor
controller with indicator LEDs. The µP-D controller controls,
monitors and records unit operation using supply air, return air,
evaporator coil, condenser coil, ambient and compressor discharge temperature sensors. For additional unit feature information, see “CSR Semi-Hermetic Model Features” on page vi of
the Introduction.
Scroll Compressor with Liquid Injection Cooling
System
The refrigeration unit includes a scroll compressor (one stationary and one orbiting member) with ambient compensated
internal overload and high temperature protectors, and a refrigerant injection system.
Dual Speed Evaporator Fans
CSR40SL models are equipped with 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 return air temperatures
of -9.9 C (14.1 F) and above. At return air temperatures 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.
Thermoguard® µP-D Controller
The µP-D controller incorporates refrigeration system component control, thermostat, digital thermometer, fault indicator
and data recording capabilities into one self-contained package. The µP-D controller provides accurate air temperature
control of perishable and frozen cargo.
The controller features a weather tight, corrosion resistance enclosure. Two large alpha-numeric digital displays are
backlit and tilted for easy viewing. Ten control keys provide
quick access to unit operating information and easy completion of setpoint, manual defrost, pretrip and start-of-trip programming.
A µP-D output module is used by the controller to energize and de-energize various contactors and solenoids. An
LED indicator is included in each output circuit to show when
the output is energized. The µP-D output module is located
inside the control box.
Indicator Lights
Indicator lights on the µP-D controller signal Cool,
Modulation, Null, Heat, In-range, Defrost, Supply Air
Temperature, Return Air Temperature, Power Limit and
Alarm.
CSR40SL Semi-Hermetic, February 2000
2-2
Unit Options
USDA Cold Treatment Temperature Recording
The µP-D 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 shipments.
When a USDA sensor is installed, the controller will automatically detect the sensors and activate data logging. The
controller Program menu shows the USDA sensor number in
the left display and “AUTO” in the right display if data logging
is active. However, the USDA program screen MUST be set to
ON, each USDA sensor MUST be calibrated, and each sensor
must be located in the load as shown in USDA directives to
comply with USDA temperature recording requirements.
Unit Options
Dehumidification Control System Option
An optional dehumidification system lowers the relative
humidity in the container to the humidity setpoint. The control
range setpoint is adjustable between 50% and 100%.
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 Saginomiya Recorder is electric motor driven by
a dry cell type battery with a 1 year life expectancy.
Operating Modes
NOTE: See µP-D Controller chapter for complete
sequence of operation.
When the unit is started, two backlit LED displays on the
microprocessor illuminate. A sequence start of the required
loads occurs during initial start-up of the microprocessor and
when a control mode shift requires the compressor to start.
The digital displays indicate the setpoint temperature and the
controlling air sensor temperature as the microprocessor relays
and unit loads energize. 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
Unit Description
dict 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 Chill (Fresh) or Frozen mode. Chill to
Frozen mode transition point is -10 C (14 F).
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.
• Cool
• Modulation Cool
• Null (compressor stops, evaporator fans operate, if condenser fan is ON, it will operate for approximately 30
seconds and then stop)
• Heat (resistance heaters on, evaporator fans operate)
• Defrost (resistance heaters on, evaporator fans stop)
NOTE: If the Economy Mode is set to ON in the
Program menu of the µP-D controller, 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.
Frozen Loads: Controller Setpoint at -10 C (14 F) or
Below
Temperature control by the controller is based on the return air
sensor temperature. The evaporator fans operate on low speed
(when container return air sensor temperature drops below -10
C [14 F]).
• Cool
• Null (compressor stops, evaporator fans operate, if condenser fan is ON, it will operate for approximately 30
seconds and then stop)
• Defrost (resistance heaters on, evaporator fans stop)
NOTE: If the Economy Mode is set to ON in the
Program menu of the µP-D controller, the unit
continues in Cool until the return air temperature
decreases to the ECMIN temperature. The
default ECMIN setting is 2.0 C (3.6 F) below setpoint. After the unit shifts to Null, the evaporator
fans stop. During Economy Mode operation, a
Null state timer automatically starts and operates
the evaporator fans on low speed for 5 minutes
every 45 minutes. The unit remains in Null until
the return air temperature increases to ECMAX
temperature at the expiration of a 45 minute Null
state time sequence. The default ECMAX setting
is 1.0 C (1.8 F) above setpoint.
The µP-D controller uses a proportional-integral derivative (PID) algorithm to provide accurate temperature control in
direct response to load demand. Therefore it is difficult to pre-
CSR40SL Semi-Hermetic, February 2000
Unit Description
Unit Illustrations
2-3
1
2
3
4
10
5
9
6
8
7
Typical Unit Front View
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
CSR40SL: Evaporator Access Door, 1399 mm (55.04 in.) Wide with Three Latches
Heater Access Panel Location
Recording Thermometer Option
Condenser Fan
Compressor Compartment
Supply Air Sensor Probe Holder
Power Cord Storage Compartment
Control Box
USDA Receptacle Panel (Access from Inside Container)
Fresh Air Exchange Vent
CSR40SL Semi-Hermetic, February 2000
2-4
Unit Illustrations
1
2
Unit Description
3
4
5
CSR40SL Evaporator Section — Front View
1.
2.
3.
4.
5.
Evaporator Fan Blade:
• CSR40SL: 312 mm (12.25 in.) diameter, 25o pitch
Evaporator Fan Motor
Return Air Sensing Bulb for Recording Thermometer (Option)
Return Air Sensor
Humidity Sensor (Option)
CSR40SL Semi-Hermetic, February 2000
Unit Description
Unit Illustrations
2-5
1
2
3
4
14
5
13
6
12
7
8
9
11
10
Semi-Hermetic Refrigeration System
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Evaporator Coil
Warm Gas Bypass Solenoid Valve
Dehumidify Valve Option (Replaces Standard Tube)
Tube (Standard)
Expansion Valve
High Pressure Relief Valve
Heat Exchanger
Filter Drier/In-line Filter (One-piece)
Liquid Injection Solenoid Valve
Scroll Compressor
Valve Port for Suction Gauge Option
Condenser Coil
Modulation Valve
Receiver Tank
CSR40SL Semi-Hermetic, February 2000
2-6
Unit Illustrations
Unit Description
1
7
2
6
3
4
5
Scroll Compressor
1.
2.
3.
4.
5.
6.
7.
Compressor Discharge Temperature Sensor
Schrader Service Valve on Suction Line
Schrader Service Valve on Discharge Manifold
Compressor Oil Sight Glass
Compressor Oil Fitting
Discharge Line
High Pressure Cutout Switch
CSR40SL Semi-Hermetic, February 2000
Unit Description
Unit Illustrations
2-7
1
17
2
3
16
15
4
14
5
13
6
12
11
7
10
8
9
Control Box — Door Open
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Condenser Fan Contactor
Evaporator Fan Low Speed Contactor
Power Module
Control Transformer
Thermo Bus Tap
Output Module
Emergency Bypass Module
Unit On/Off Switch
Data Retrieval Receptacle (located on bottom of control box on some models)
Main Circuit Breaker
CBA Phase Contactor
ABC Phase Contactor
Current Transformer
Compressor Contactor
Heater Contactor
Evaporator Fan High Speed Contactor
µP-D Controller
CSR40SL Semi-Hermetic, February 2000
2-8
Unit Illustrations
Unit Description
1
2
3
4
5
Typical Unit Back View
1.
2.
3.
4.
5.
Evaporator Grille
Unit Gasket
Top Rear Plate
Bottom Rear Plate
Sensor Connector Assembly:
• Controller Communications and Data Download Port
• Cargo (Pulp) Sensor Connection
• USDA1 Sensor Connection
• USDA2 Sensor Connection
• USDA3 Sensor Connection
CSR40SL Semi-Hermetic, February 2000
3
Operating Instructions
Unit Controls
Unit Control Box
1. ON/OFF SWITCH.
a. ON position. Unit will operate on cool or heat
depending on the controller setpoint temperature and
the container air temperature.
b. OFF position. The unit will not operate.
µP-D Controller
The Thermoguard® µP-D microprocessor controls all unit
functions to maintain the cargo at the proper temperature. The
controller also monitors and records system faults, limits
power demand and performs pre-trip.
Ten touch sensitive keys are used to display information,
change the setpoint, change the programmable features and
initiate control tasks.
1.
2.
3.
4.
5.
SELECT KEY. Press this key to enter and display
screens from the controller menu.
UP KEY. Press this key to increase the setpoint (and
other settings in the menu), and scroll UP through the
menu display.
DOWN KEY. Press this key to decrease the setpoint (and
other settings in the menu), and scroll DOWN through the
menu display.
ENTER KEY. Press this key to load the setpoint (or other
setting in the menu), and execute other controller tasks.
C/F KEY. Press this key to view temperatures in the controller display in the alternate temperature scale.
Alternate display shows while the key is pressed.
key to LOAD a manual defrost. If the evaporator coil
temperature is below 10 C (50 F), the unit will defrost.
Otherwise the controller will display “DFRST INVAL”
and the unit will continue normal operation.
8. PRETRIP KEY. Press this key to prepare the controller to
initiate an automatic Full Pretrip test. Then press the
ENTER key to LOAD a pretrip test. The controller will
perform a Full Pretrip test if no alarms are present.
9. SOT KEY. Press this key to prepare to place a Start of
Trip marker in the datalogger. Then press the ENTER
key to LOAD the Start of Trip marker.
10. ALARM KEY. Press this key to display alarm codes
when the Alarm LED is lit (or flashing). Press the
DOWN arrow key to view additional alarm codes that
may be present. After viewing, writing down and correcting all alarm conditions, press the ENTER key to clear
alarms.
Unit Instruments
1.
The In-range LED illuminates when the controlling
air sensor temperature is between 1.7 C (3.0 F) above setpoint and 2.5 C (4.5 F) below setpoint. The controller
inhibits the out-of-range alarm during defrost.
NOTE: The C/F units shown on the controller
display can be changed by pressing and holding the C/F key, and then pressing the ENTER
key.
6.
7.
RET/SUP KEY. Press this key to view the alternate sensor temperature (non-controlling sensor) in the controller
display. Alternate display shows while the key is pressed.
DEFROST KEY. Press this key to prepare the controller
to initiate a manual defrost cycle. Then press the ENTER
STATUS INDICATOR LEDs are located on the µP-D
controller and signal the following:
• Cool
• Defrost
• Modulation
• Supply
• Null
• Return
• Heat
• Power Limit
• In-Range
• Alarm
NOTE: The controller will not respond to an outof-range condition for 75 minutes to avoid nuisance alarms.
2.
RECORDING THERMOMETER (OPTION). The
recording thermometer indicates and permanently records
the temperature of the air returning to the evaporator section on a calibrated chart.
CSR40SL Semi-Hermetic, February 2000
3-2
Unit Protection Devices
Operating Instructions
4.
Unit Protection Devices
1.
CIRCUIT BREAKERS. A 25 ampere manual reset circuit
breaker protects the 460/380V power supply circuit to the
unit electric motors and control system transformer. The
main power circuit breaker is located in the control box.
2. FUSES. A number of fuses located in the power module
protect unit circuits and components.
• A 2 amp fuse (F1) protects the circuit to the modulation
valve.
• A 1 amp fuse (F2) protects the bridge light relay (option)
circuit.
• A 1 amp fuse (F3) is unused.
• A 5 amp fuse (F4) protects the circuit that supplies
power to Power Module Board.
• A 1 amp fuse (F5) protects the bridge light (option) circuit.
• A 5 amp fuse (F6) protects the IRMU (option) circuit.
• A 3 amp fuse (F7) protects the TRANSFRESH (option)
circuit.
• A 2 amp fuse (F8) protects the IRMU (option) circuit.
• A 3 amp fuse (F9) protects the chart recorder (option)
circuit.
• A 3 amp fuse (F10) protects the battery charger (option)
power input circuit.
• A 7.5 amp fuse (F11) protects the Output Module circuit.
• A 3 amp fuse (F12) protects the battery pack connector
circuit.
• A 3 amp fuse (F13) protects the battery charger (option)
output circuit.
• A 3 amp fuse (F14) protects the battery (option) circuit.
3. COMPRESSOR DISCHARGE GAS TEMPERATURE
SENSOR. A refrigerant injection system uses the compressor discharge temperature to determine when cold
refrigerant will be injected into the center scroll of the
compressor to protect the compressor from excessively
high operating temperatures. At compressor discharge gas
temperature above 138 C (280 F), the controller energizes
the liquid injection valve. When the discharge gas temperature drops to 132 C (270 F), the controller de-energizes the injection valve to stop refrigerant injection.
If the discharge gas temperature rises above 148 C
(298 F), the controller immediately stops the compressor
and evaporator fans. The condenser fan and phase select
outputs remain energized as the controller operates the
condenser fan to correct the condition. The controller display will show “PAUSE ALM82” for 1 second every 10
seconds. After 5 minutes, the controller attempts to restart
the compressor. If the compressor still fails to start, fault
code 82 (Compressor Head Over Temperature) is generated. The controller will restart the compressor when the
fault condition corrects itself (resets).
5.
6.
7.
8.
EVAPORATOR OVER TEMPERATURE PROTECTION. An evaporator coil sensor monitors coil temperature during heat and defrost modes. If the coil sensor temperature reaches 38 C (100 F), the controller de-energizes
the heater contactor. If the coil sensor reaches 50 C (122
F), the controller also de-energizes the evaporator fan and
phase select contactors; and generates a shutdown Alarm.
Fault code 09 (Evaporator Coil Over Temperature) is displayed on the controller display when the ALARM key is
pressed.
HIGH PRESSURE CUTOUT (HPCO) SWITCH. The
refrigerant high pressure cutout opens, interrupting 24 Vac
control power to the compressor contactor if the compressor discharge pressure rises above 3243 +/- 48 kPa, 32.43
+/- 0.48 bar, 470 +/- 7 psig. This immediately stops the
compressor and evaporator fans. The condenser fan and
phase select outputs remain energized as the controller
operates the condenser fan to correct the condition. The
controller display will show “PAUSE ALM10” for 1 second every 10 seconds.
After 5 minutes, the controller attempts to restart the
compressor. If the compressor fails to start, fault code 10
(High Pressure Cutout) is generated. The controller will
restart the compressor when the fault condition corrects
itself (resets). The high pressure switch resets (closes)
when the pressure drops back to 2588 +/- 262 kPa, 25.88
+/- 2.62 bar, 375 +/- 38 psig.
HIGH PRESSURE RELIEF VALVE. A high pressure
relief valve is installed in the liquid line near the receiver
tank. The relief valve protects against excessive pressure
build-up within the refrigeration system from extraordinary and unforeseen circumstances. The valve is a springloaded piston that lifts when refrigerant pressure exceeds
3447 +520/-104 kPa, 34.47 +5.20/-1.04 bar, 500 +75/-15
psig. The valve is located so that refrigerant pressure
expelled from the valve would be directed away from anyone servicing the unit. The valve will reset when this pressure drops to 2758 kPa, 27.58 bar, 400 psig. The valve is
non-repairable and requires no adjustment. If the valve
fails to reseat properly, recover the refrigerant charge and
replace the valve.
OVERLOAD PROTECTION. The condenser fan motor,
evaporator fan motors and compressor motor include
internal overload protection with automatic reset. If the
compressor motor overload protector opens, the µP-D
controller detects the open motor protector and records
alarm code 50. The controller will attempt to restart the
compressor every 5 minutes.
PHASE SEQUENCE SELECTION. When the On/Off
switch is turned ON, the controller display shows “Phase
Check” while it determines the correct phase sequence.
Phase selection takes 50 to 80 seconds; or more on
extremely noisy power lines. The controller then energizes phase select contactor ABC or CBA to ensure proper condenser fan, evaporator fan and compressor rotation.
CSR40SL Semi-Hermetic, February 2000
Operating Instructions
Pretrip Inspection
NOTE: If the unit does not start, turn the On/Off
switch OFF. Check power supply. Then repeat
step 1. If the unit still does not start, refer to
“Alarm Codes, Descriptions and Corrective
Actions” in the µP-D Controller chapter of this
manual.
Pretrip Inspection
Visual Inspection
The following visual inspections should be made before the
container is loaded:
1. Visually check the unit for physical damage.
2. Check the electrical connections in the unit control box,
making sure they are fastened securely.
3. Check the conditions of wires and terminals. Repair or
replace if necessary.
4. Check the refrigeration system for leaks. Inspect for evidence of oil leaks at all joints and connections.
5. Check the condenser and evaporator coils. Clean if necessary. Use an air or water spray jet directed against the coil
from the air discharge side. Also inspect the condenser
fan grille for damage. If the grille is damaged or missing,
abnormally high head pressure may result. Repair or
replace the grille if necessary.
3-3
2.
3.
4.
5.
Check controller setpoint for proper setting. Adjust if
necessary.
Check the direction of the condenser airflow (see
“Condenser Fan and Evaporator Fan Rotation” in the
Electrical Maintenance chapter of this manual).
Check direction of evaporator airflow (see “Condenser
Fan and Evaporator Fan Rotation” in Electrical
Maintenance chapter of this manual).
Perform a Full (or Extended) Pretrip Test to check the unit
refrigeration and electrical systems for proper operation.
CAUTION: Air or water spray jet pressure should
not be high enough to damage (bend) coil fins.
NOTE: An Extended Pretrip test can take up to 7
hours to complete. To perform an Extended
Pretrip Test, see “Pretrip Tests” in the µP-D
Controller chapter of this manual.
Check the mounting bolts on the unit, compressor and fan
motors. Tighten if necessary.
Clean the defrost drains.
Observe the unit for proper operation and functions during
Pre-load Operation.
To perform a Full Pretrip Test:
• Press the PRETRIP key. The left display flashes
“ENTER” and the right display flashes “PTRIP”.
• Press the ENTER key. “LOAD PTRIP” briefly appears
in the display.
Functional Inspection
To properly perform a Full Pretrip Test on units equipped with
the µP-D controller, the container must be empty with the rear
doors closed.
1. Start the unit (see “Starting the Unit and Adjusting the
Controller Setpoint” on page 3-4). A second sequence
start of the required loads occurs during initial start-up of
the unit.
• Status Indicator LEDs and display turn On and then Off.
• The controller display shows “Phase Check” while it
determines the correct phase sequence. Phase selection
takes 50 to 80 seconds; or more on extremely noisy
power lines. Phase select contactor ABC and the electric
heaters, condenser fan and evaporator fans are energized
for 10 seconds. Phase select contactor ABC is then deenergized. 30 seconds later, phase select contactor CBA
and the electric heaters, condenser fan and evaporator
fans are energized for 10 seconds. The controller then
turns OFF all unit loads and energizes phase select contactor ABC or CBA.
• The setpoint and controlling air sensor temperature are
displayed.
• Controller energizes unit loads, starting the evaporator
fans. The condenser fan may also start (if required).
• If the controller calls for cooling, the compressor motor
starts. If the unit starts in Modulation Cool the modulation valve opens or closes to the required setting.
• If the controller calls for heating, the electric heaters are
energized.
NOTE: If Alarm Code(s) are stored in the controller the display will show “CLEAR ALARM”.
Correct the alarm condition(s) and clear the alarm
code(s) before attempting a Pretrip Test.
6.
7.
8.
• The controller then performs the Full Pretrip Test.
NOTE: If the container temperature is below 0 C
(32 F), the controller places the unit in the HEAT
mode when a Full Pretrip Test is initiated. The
test begins when the container temperature
increases to 0 C (32 F).
• Observe the unit for proper operation and functions during pretrip test.
• If the unit passes the Full Pretrip test, “PTRIP PASS” is
stored in the datalogger memory and the unit returns to
normal operation. A Start of Trip (SOT) marker is also
recorded in the data logger memory when an automatic
Full or Extended Pretrip is successfully completed.
• If an operating problem is encountered during the Full
Pretrip Test, the Alarm LED will turn ON, “PTRIP
FAIL” is stored in the datalogger memory and the unit
returns to normal operation (unless a shutdown fault has
occurred). View and correct any alarm conditions.
Then clear the Alarm Code(s) and repeat the pretrip test.
NOTE: PASS or FAIL is recorded in the datalogger memory and can be viewed through the controller’s VIEW/LOG/PT1 submenu. For instrucCSR40SL Semi-Hermetic, February 2000
3-4
Starting the Unit
Operating Instructions
tions on viewing the VIEW/LOG/PT1 submenu,
refer to “Viewing Information in the View Menu”
in the µP-D Controller chapter of this manual.
decrease the setpoint. The left display flashes “SETPT”
while the right display shows the temperature.
• Wait four seconds for all three digits to appear on the
right display. Make additional setpoint adjustment if
necessary.
• Press the ENTER key when the desired setpoint shows
in the right display. The right display briefly shows
LOAD”. The controller then returns to the Standard
Display (showing new setpoint).
NOTE: If the unit fails a Pretrip Test, the alarm
light turns on. Alarm codes generated during a
Pretrip Test are preceded by a hyphen (-) in the
controller display and the datalogger memory of
the controller.
NOTE: If the ENTER key is not pressed within 10
seconds, the controller will default (return) to the
previous setpoint. If this occurs, repeat step 3.
WARNING: Some unit malfunctions will cause an
Alarm and unit shutdown condition. When the
alarm codes are cleared, the unit will start automatically.
6.
7.
8.
Allow the unit to operate in the cool mode for 30 minutes
before loading the container. This will remove residual
container heat and moisture, and pre-cool the container
interior.
Enter trip ID information into the controller memory using
the PC-PAC™ software (see instructions of PC-PAC™
software).
Set the fresh air vent to the desired air exchange rate.
NOTE: If Dehumidification is turned ON, the
fresh air vent should be closed.
9.
Install a new chart and prepare the recording thermometer
for temperature recording (if so equipped):
• Check the battery charge on the recording thermometer
(Saginomiya recorders).
10. Stop the unit by moving the On/Off switch to the OFF
position.
Loading Procedure
1.
2.
Post Load Procedure
1.
2.
3.
4.
5.
Starting the Unit and Adjusting the
Controller Setpoint
CAUTION: Supply power connections from the unit
to the power source must always be made with the
refrigeration Unit On/Off switch and power supply
On/Off switch in the OFF positions. Never attempt to
start or stop the refrigeration unit with the unit power
cable.
1.
2.
3.
Connect the unit power cord to proper power source:
• 460/380V power cord to 460/380V, 60-50 Hz power
source.
• Turn the power supply On/Off switch ON.
Turn the unit On/Off switch to ON position. Check for
condenser fan and evaporator fan motor operation (see
“Condenser Fan and Evaporator Fan Rotation” in the
Electrical Maintenance chapter of this manual). If the unit
was properly pretripped, correct condenser fan rotation
will also indicate correct evaporator fan rotation.
Adjust controller setpoint to the desired temperature:
• Press the UP or DOWN arrow key to increase or
Make sure the Unit On/Off switch is OFF before opening
the container doors. (The unit may be operating when
loading the container from a warehouse with door seals.)
Spot check and record load temperature while loading.
Especially note any off-temperature product.
Make sure all doors are closed and locked.
Start unit if unit is OFF.
Check controller setpoint for proper setting.
If trip ID information has NOT been entered in the controller, enter it now using the PC-PAC™ software (see
instructions of PC-PAC™ software).
One-half hour after loading, initiate a manual defrost
cycle:
• Press the DEFROST key. The display flashes “ENTER
DFRST”.
• Press the ENTER key. “LOAD DFRST” briefly appears
in the display. The Defrost LED turns ON as the unit
enters Defrost. The controller then returns to the
Standard Display. Defrost will stop automatically.
NOTE: The evaporator coil temperature must be
below 10 C (50 F) to allow the unit to enter a
defrost cycle. If the evaporator coil temperature
is too high, the controller display will show
“DFRST INVAL” (defrost invalid) for 3 seconds.
The controller then returns to the Standard
Display.
Post Trip Procedure
Trip data recorded by the Thermoguard® µP-D controller may
be down loaded using PC-PAC™ software via the communications connection located on the bottom of the control box.
See instructions in PC-PAC™ software manual, TK P/N 204988.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
4
• UP: Press to increase the setpoint or scroll UP through
controller menu.
• DOWN: Press to decrease the setpoint or scroll DOWN
through controller menu.
• ENTER: Press to load the setpoint (or other setting) and
execute other controller tasks.
• C/F (Temperature): Press to view alternate temperature
scale in display.
• RET/SUP (Temperature): Press to view alternate
return/supply sensor temperature.
• DEFROST: Press to prepare to initiate a manual defrost.
• PRETRIP: Press to prepare to initiate a Full Pretrip
Test.
• SOT (Start of Trip): Press to prepare to place Start of
Trip marker in the datalogger.
• ALARM: Press to view alarm codes that are present.
Controller Description
The µP-D controller is a programmable microprocessor that
controls all unit functions to maintain the cargo at the proper
temperature. The controller contains the following basic features:
1. Two digital displays:
• SETPOINT: Five alpha numeric characters: Numerical
tens, ones and tenths position, a C for Celsius or F for
Fahrenheit for temperature display.
• TEMPERATURE: Five alpha numeric characters:
Numerical hundreds, tens, ones and tenths position, a C
for Celsius or F for Fahrenheit for temperature display.
2. Ten control keys:
• SELECT: Press to select prompts and display screens
from controller menu.
COOL
MOD
NULL
HEAT IN RANGE
SETPOINT
TEMPERATURE
❇ ❇ ❇: ❇ ❇
❇ ❇ ❇:❇ ❇
°
°
-
-
-
-
-
2
SELECT
THERMO KING
UP
®
3
DOWN
4
ENTER
-
-
2
3
-
DATA
DATA
1
1
DEFROST SUPPLY RETURN PWRLMT ALARM
5
6
°C
°F
RET
SUP
TEMPERATURE
7
8
9
10
SOT
ALARM
P
DEFROST PRETRIP
4
!
THERMOGUARD µP-D
µP-D Controller
1.
2.
3.
4.
Status Indicator Lights
Setpoint (Left) Display
Temperature (Right) Display
Keypad
CSR40SL Semi-Hermetic, February 2000
4-2
3.
Controller Description
Status indicator LEDs (see “Status Indicator LEDs and
Alarm Codes” in this chapter).
4. Power Module: Low voltage control power and ground
are supplied to the µP-D controller and Output Module.
The Power Module also includes:
• Modulation valve power output terminals.
• Remote monitoring connection is provided by a serial
communications port located on the side of the control
box.
• Control circuit fuse protection:
- 2 amp fuse (F1) protects the circuit to the modulation
valve.
- 1 amp fuse (F2) protects the bridge light relay (option)
circuit.
- 1 amp fuse (F3) protects SPARE circuit terminals.
- 5 amp fuse (F4) protects the circuit that supplies power
to Power Module Board.
- 1 amp fuse (F5) protects the bridge light (option) circuit.
- 5 amp fuse (F6) protects SPARE circuit terminals.
- 3 amp fuse (F7) protects the TRANSFRESH (option)
circuit.
- 2 amp fuse (F8) protects the RMM/IRMU (option) circuit.
- 3 amp fuse (F9) protects SPARE circuit terminals.
- 3 amp fuse (F10) protects the battery charger (option)
power input circuit.
- 7.5 amp fuse (F11) protects the Output Module circuit.
- 3 amp fuse (F12) protects the remote battery connector
circuit.
- 3 amp fuse (F13) protects the battery charger (option)
output circuit.
- 3 amp fuse (F14) protects the battery (option) circuit.
5. Output Module: Output terminals are used to energize
and de-energize unit contactors and solenoids (see
“Output Module” in this chapter).
6. Thermo Bus Tap circuit board: Serial communication
commands are transmitted between the controller and the
Output Module through the Thermo Bus circuit board (see
“Thermo Bus Tap” in this chapter).
7. Replaceable sensors: Return air, supply air, evaporator
coil, condenser coil, ambient air and compressor discharge
gas temperature sensors are field replaceable (see
“Temperature Sensors” in this chapter). Four spare sensor
receptacles are also provided for USDA and PULP temperature recording (optional).
8. Defrost cycle control (see “Defrost” under Sequence of
Operation in this chapter).
9. Internal self-checking/diagnostic capability.
10. Pretrip test capability (see “Full Pretrip Test” under Menu
Test in this chapter).
µP-D Controller
11. Sensor Check test capability (see “Sensor Check” under
General Theory of Operation in this chapter).
12. Data recording capability (see “Data Recording and
Downloading Data” in this chapter).
13. Electronic phase selection (see “Automatic Phase
Selection” under General Theory of Operation in this
chapter).
14. Power limit control (see “Power Limit” under General
Theory of Operation in this chapter).
15. Sequential component start-up control: A sequence start
of the required loads occurs during initial start-up of the
controller and when a control mode shift requires the
compressor to start (see “Sequence of Operation” in this
chapter).
16. Evaporator fan speed and condenser fan operation control
(see “Evaporator Fan Control” and “Condenser Fan
Control” under General Theory of Operation in this chapter).
17. Hourmeters: The µP-D controller has multiple built-in
hourmeters that can be accessed through the Display
Menu.
18. Wake-up (setpoint enable) capability: Pressing the
SELECT key (or connecting a communications cable to the
Data Port on the bottom of the control box) when 12 Vdc
battery power option is present awakens the controller.
This capability provides auxiliary power for setpoint adjustment or downloading of controller data recording memory
when a three phase power source is not available. Battery
power keeps the controller energized for 1 minute unless a
key is pressed on the controller keypad.
NOTE: The battery pack connection is located on
the Power Module Board inside the control box.
19. Compressor refrigerant gas injection cycle control (see
“Compressor Liquid Injection” under General Theory of
Operation in this chapter).
20. Flash memory: Flash program memory allows the application software to be updated without replacing a EPROM
chip on the controller. Application software can be updated in the field using a portable computer and Thermo
King flash loading program. Consequently, the field
installed application software version may have a different
revision number and may include control features not
included in the original factory installed software. If the
operation of your unit differs from the Sequence of
Operation described for your unit (both unit and customer
configuration block numbers) in this manual, check the
unit configuration number and customer configuration
number to be sure the controller is set to the proper unit
and customer configuration (see “Reviewing Application
Software Version” in this chapter).
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Controller Display Menus
4-3
Active Option Displays
Controller Display Menus
The µP-D controller contains an extensive display menu that
can be navigated via keypad. The display menu is organized
into five Main Menus (or groups):
NOTE: See page 9-41 to view a diagram of the complete µP-D menu.
Software Version Display
The application software version, unit configuration number
and customer configuration number display when ENTER key
is depressed for 3 seconds (see “Reviewing Application
Software Version” in this chapter).
Software Version Screen Flow Diagram
Control options that have been turned ON in the Program
menu show for 1 second every 10 seconds in the controller display. For example, the Option Display for the Economy mode
is shown below.
COOL
MOD
NULL
HEAT IN RANGE
DEFROST SUPPLY RETURN PWRLMT ALARM
SETPOINT
TEMPERATURE
DATA
DATA
Option
Economy Mode
Display/Description
“ECON ON”/Economy mode reduces
unit power consumption by reducing evaporator fan operation.
“ECONT XXXXX”/Shows the time
remaining to next controller check of return
air temperature (active only during Null
mode on Frozen Loads).
Humidify Mode “HUM ON”/Humidity system operates to
add moisture to the container as required to
maintain humidity setpoint.
Dehumidify Mode “DEHUM ON”/Dehumidify system operates to remove moisture from the container
as required to maintain humidity setpoint.
Bulb Mode
“BULB ON”/Dehumidify system operates to remove moisture from the container
as required to maintain humidity setpoint.
Bulb mode allows adjustment of evaporator fan speed setting and defrost termination temperature.
“DEHUM XX.X”/Current humidity level
also displays briefly when the Bulb mode
is ON.
Active Options and Pause Mode Screen Flow
Diagram
CSR40SL Semi-Hermetic, February 2000
4-4
µP-D Controller
Controller Display Menus
Pause Mode Displays
WARNING: When the unit is in the PAUSE mode, the
compressor, evaporator fans or condenser fan may
continue to operate or start at any time without
notice.
A Pause mode display appears when the controller interrupts
normal unit operation to perform a check or test. For example,
the Pause mode display for a Shutdown alarm condition is
show below.
COOL
MOD
NULL
HEAT IN RANGE
View Menu
Menu screens in this group are used to display unit operating
information, sensor grades and scrollback data logger data
including controlling sensor temperatures and pretrip test
information. No changes can be made to data in the View
menu.
Pretrip Menu
Menu screens in this group are used to activate pretrip tests
including Extended Pretrip Test, Full Pretrip Test and Single
Pretrip Tests.
DEFROST SUPPLY RETURN PWRLMT ALARM
SETPOINT
TEMPERATURE
DATA
DATA
Test Menu
Menu screens in this group are used to set the unit to specified
operating conditions for system and component diagnostics.
Guarded Access Menu
Pause Condition Display/Description
Phase Check
“PAUSE CHECK”/During initial unit
start-up, the controller checks the power
phase sequence for correct compressor,
condenser fan and evaporator fan rotation.
Sensor Check
“SENSR CHECK”/If the supply and
return air temperature difference is outside
certain limits during cooling and no alarms
are recorded, the controller performs a
Sensor Check test.
“SENSR XXX”/Shows the time remaining on the current Sensor Check test being
performed.
Alarm Shutdown “PAUSE ALMXX”/Stops unit operation
due to a shutdown alarm condition. A 2digit alarm code (“XX”) appears in Pause
display to identify the alarm condition.
Typically the condenser fan continues to
operate while the controller attempts to
correct the condition and restart the unit.
The Pause mode display continues until the
shutdown condition has been corrected.
Access to the menu is protected by a special security code.
Menu screens in Guarded Access are used to set the unit configuration, time and date and sensor grades; enter container ID
number and unit serial number; and change programmable settings via keypad.
Program Menu
Menu screens in this group are used to activate the USDA sensors, Pulp sensor, Economy mode, Dehumidify mode (and
enter humidity setpoint), Bulb mode (and enter defrost termination temperature and evaporator fan motor speed), or Power
Reduction mode.
Menu Display Definitions
Acronym
ALM
ALMXX
ALOGS
AMBT
AMP1
AMP2
AMP3
AMPS
AMTG
AUXV
BEFAN
BDFTT
Definition
Alarm
Alarm 01, 02, 03 ...XX (total number of recorded
alarms).
Data Logs in (P-A+ Format on Auxiliary Battery
Power (Option)
Ambient Temperature Sensor
Total Current Phase A
Total Current Phase B
Total Current Phase C
Amperage
Ambient Temperature Sensor Grade
Auxiliary Battery (Option) Voltage
Bulb Mode Enable Fan
Bulb Mode Defrost Termination Temperature
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
BULB
BVS
C/F
CCOIL
CCTG
CFG C
CFG U
CFH
CFH l
CFH 2
CFH 3
CHRM1
CHS1
CID
CIDXX
CLEAR
CLKV
CNFIG
CNTRL
COOL
CPH
DAY
DEHUM
DFRST
DISPL
DMTCH
DMTFZ
ECOIL
ECON
ECONT
ECOOL
ECMAX
ECMIN
ECTG
EFH
EFH l
EFH 2
EFH 3
EFL
EFL l
EFL 2
EFL 3
ELECT
ENTER
ETEST
EX CH
Bulb Mode Enable
Bypass Valve Solenoid
Temperature Display Mode
Condenser Coil Temperature Sensor
Condenser Coil Sensor Grade
Customer Configuration Setting
Unit Configuration Setting
Condenser Fan High Speed
Condenser Fan High Speed Phase 1 Amps
Condenser Fan High Speed Phase 2 Amps
Condenser Fan High Speed Phase 3 Amps
Compressor 1 On Hours
Compressor 1 Head Temperature
Container Identification Number
Container Identification Character 01, 02, 03
...11 (total number of characters)
Clear
Real Time Clock (Lithium) Battery Voltage
Configuration
Controller Test Submenu
Cool
Compressor High Speed
Current Date Day
Dehumidify Mode
Defrost
Display
Defrost Maximum Time in Chill Mode
Defrost Maximum Time in Frozen Mode
Evaporator Coil Temperature Sensor
Economy Mode Enable
Economy Mode Timer
Extended Cool
Economy Mode Maximum (High Switch Point)
Setting
Economy Mode Minimum (Low Switch Point)
Setting
Evaporator Coil Sensor Grade
Evaporator Fan High Speed
Evaporator Fan High Speed Phase 1 Amps
Evaporator Fan High Speed Phase 2 Amps
Evaporator Fan High Speed Phase 3 Amps
Evaporator Fan Low Speed
Evaporator Fan Low Speed Phase 1 Amps
Evaporator Fan Low Speed Phase 2 Amps
Evaporator Fan Low Speed Phase 3 Amps
Electrical Test Submenu
Enter
Extended Pretrip Test
Extended Chill Mode Pretrip Test
Controller Display Menus
EX DF
EX FZ
FTEST
GEN
GLOGS
GRADE
GUARD
H1TYP
H2TYP
H3TYP
H4TYP
HEAT
HEATR
HERTZ
HOUR
HTR
HTR l
HTR 2
HTR 3
HUMID
HUMSP
INVAL
LIV
LLS
LOAD
MC 5O
MClOO
MENU
MIN
MONTH
NULL
ONHRM
PAUSE
PCCAP
PCHUM
PCVAL
PRGRM
PS 1
PS 2
PTI
PTRIP
PULP
PULP1
PWRED
RCOMP
RDEF
REFRG
4-5
Extended Defrost Pretrip Test
Extended Frozen Mode Pretrip Test
Full Pretrip Test
Generator
Data Logs in Global Table Format on Auxiliary
Battery Power (Option)
Sensor Grade Submenu
Guarded Access Menu
User Hourmeter 1 Type
User Hourmeter 2 Type
User Hourmeter 3 Type
User Hourmeter 4 Type
Heat
Heater
Hertz
Current Time in Hours
Heater
Heater Phase I Amps
Heater Phase 2 Amps
Heater Phase 3 Amps
Humidify/Dehumidify Enable
Humidity Setpoint
Invalid
Liquid Injection Valve
Liquid Line Solenoid Valve
Load
Modulated Cool Mode, 50 Percent Modulation
Modulated Cool Mode, 100 Percent Modulation
Menu
Current Time in Minutes
Current Month
Null Mode
Unit On Hours
Pause Mode
KVQ Valve Status in Percent
Percent Humidity
Modulation Valve Status in Percent
Program Menu
Phase Select Contactor 1 (ABC)
Phase Select Contactor 2 (CBA)
Pretrip Inspection
Pretrip Menu
Pulp Sensor Logging Enable
Pump Temperature Sensor
Power Reduction Mode Setting and Enable
Remote Cool Indicator
Remote Defrost Indicator
Refrigeration Test Submenu
CSR40SL Semi-Hermetic, February 2000
4-6
RET
RETG
RIR
RSP
SENSR
SETPT
SLS
SOT
SPR1
SPR1G
SPR2
SPR2G
SPR3
SPR3G
SPR4
SPR4G
SPR5
SPR5G
STEST
SUP
SUPG
TD
TEMP
TEST
TIME
UHMT1
UHMT2
UHMT3
UHMT4
UHRM1
UHRM2
UHRM3
UHRM4
UNIT
USDA
USDA1
USDA2
USDA3
USN
USNXX
VERSN
VIEW
VOLTS
YEAR
µP-D Controller
Status Indicator LEDs and Alarm Codes
Return Air Temperature Sensor
Return Air Sensor Grade
Remote In-range Indicator
Remote Spare Indicator
Sensor
Setpoint Temperature
Suction Line Solenoid Valve
Start of Trip
Spare Temperature Sensor 1
Spare Sensor 1 Grade
Spare Temperature Sensor 2
Spare Sensor 2 Grade
Spare Temperature Sensor 3
Spare Sensor 3 Grade
Spare Temperature Sensor 4
Spare Sensor 4 Grade
Spare Temperature Sensor 5
Spare Sensor 5 Grade
Single Pretrip Test Submenu
Supply (Discharge) Air Temperature Sensor
Supply Air Sensor Grade
Temperature Differential
Temperature
Test Menu
Current Time 1
User Hourmeter 1 Threshold
User Hourmeter 2 Threshold
User Hourmeter 3 Threshold
User Hourmeter 4 Threshold
User Hourmeter 1 Hours
User Hourmeter 2 Hours
User Hourmeter 3 Hours
User Hourmeter 4 Hours
Unit
USDA Logging Enable
USDA1 Temperature Sensor 1 (USDA Enabled)
USDA2 Temperature Sensor 2 (USDA Enabled)
USDA3 Temperature Sensor 3 (USDA Enabled)
Unit Serial Number
Unit Serial Number Character 01, 02, 03 ...10
(total number of characters)
Software Version
View Menu
Total Voltage
Current Year
Status Indicator LEDs and Alarm Codes
The indicator LEDs stay ON continuously to indicate a unit
operating mode or condition. The Alarm LED stays ON continuously when a Check Alarm occurs. The Alarm LED flashes ON and OFF when a Shutdown Alarm occurs. LEDs are
located on the µP-D controller and signal the following:
• Cool Mode
• Modulation Mode
• Null Mode
• Heat Mode
• In-Range (Temperature)
• Defrost Mode
• Supply (Air Temperature)
• Return (Air Temperature)
• Power Limit Mode
• Alarm
Alarm Codes
Check Alarms indicate corrective action should be taken
before a problem becomes severe. The unit continues to operate. However, some unit functions may be inhibited.
Shutdown Alarms indicate the unit operation has been
stopped to prevent damage to the unit or cargo. The problem
must be corrected and the alarm code cleared from the controller display before the unit can be restarted to resume normal operation.
Alarm codes are recorded in the controller memory to
simplify unit diagnosis and troubleshooting procedures. The
first 16 fault codes including the most recent fault code are
retained by the controller in a non-volatile memory in order of
their occurrence (see codes, alarm type and alarm description
below). Alarm codes that are recorded during an automatic
Pretrip Test are recorded in the controller memory and displayed with a hyphen (-) preceding the alarm code. Alarm
codes 52 through 58 can only be generated during an automatic Pretrip test (or Fitness test).
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Alarm
Code Type
00
02
Check
03
Check
04
Check
05
06
07
09
10
12
13
14
16
25
37
38
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
Check
Check
Check
Shutdown
Check
Check
Check
Check
Shutdown
Check/
Shutdown
Shutdown
Check
Check
Check
Shutdown
Shutdown
Shutdown
Check
Check
Check
Check
Check/
Shutdown
Check/
Shutdown
Check/
Shutdown
Check/
Shutdown
Check/
Shutdown
Check/
Shutdown
Check/
Shutdown
Check/
Shutdown
Check/
Shutdown
Pause Alarms
Description
No Fault
Ambient Temperature Sensor Failure
Supply Air Temperature Sensor Failure
Evaporator Pressure Regulator (KVQ)
Valve Thermistor Failure
Evaporator Coil Temperature Sensor
Failure
Humidity Sensor Error
Return Air Temperature Sensor Failure
Evaporator Coil Over Temperature
High Pressure Cutout
Temperature Out-of-Range High
Temperature Out-of-Range Low
Defrost Terminated on Time Limit
Digital Input Failure
Return & Supply Temperature Sensor
Failure
Low Refrigerant Level (Option)
Real Time Clock Battery Failure
Spare Sensor 5 Failure (Option)
Customer Configuration Alarm
Frequency Out-of-Range Low
Three Phase Current Imbalance
Frequency Out-of-Range High
USDA Sensor 1 Failure (Option)
USDA Sensor 2 Failure (Option)
USDA Sensor 3 Failure (Option)
Pulp Sensor Failure (Option)
Compressor Current Out-of-Range
(Pretrip)
Unit Current Out-of-Range in Cool Mode
Modulation System Failure (Pretrip)
Heating Current Out-of-Range (Pretrip)
Defrost Current Out-of-Range (Pretrip)
High Speed Evaporator Fan Failure
(Pretrip)
Low Speed Evaporator Fan Failure
(Pretrip)
Condenser Fan Current Out-of-Range
(Pretrip)
Sensor Calibration Failure (Pretrip)
59
60
61
63
64
65
69
Check
Check
Check
Check
Check
Check
Check
70
71
72
73
74
79
81
Check
Check
Check
Check
Check
Check
Check
82
85
92
97
4-7
Datalogger Full (µP-A+)
Datalogger Full (Global)
Real Time Clock Invalid
Bypass Valve Circuit Failure (Pretrip)
Pretrip Preconditioning Failure
Datalog Queuing Error
Dehumidify Valve Circuit Failure
(Pretrip) (Option)
Hourmeter Alarm
User Hourmeter 1 Expired
User Hourmeter 2 Expired
User Hourmeter 3 Expired
User Hourmeter 4 Expired
Datalogger Overflow
Compressor Head Temperature Sensor
Failure
Compressor Head Over Temperature
Compressor Current Out-of-range
Check
Check/
Shutdown
Check
Condenser Fan Sensor Failure
Shutdown Loss of Communications with Output
Module
Pause Alarms
A Pause Alarm (“PAUSE ALMXX”) stops unit operation due
to a shutdown alarm condition. “PAUSE ALMXX” appears
in the display for 1 second every 10 seconds until the condition has been corrected. A 2-digit alarm code (“XX”) in Pause
display identifies the alarm condition. The following Alarm
Codes generate a Pause Alarm display:
• 10, High Pressure Cutout
• 43, Frequency Out-of-Range, Low (low supply voltage)
• 82, Compressor Head Over Temperature
NOTE: “PAUSE ALM43” will also appear in the controller display when the Setpoint Enable function is
activated to download the controller data logger or
change the setpoint.
“PAUSE ALM10”, High Pressure Cutout
The controller immediately stops the compressor and evaporator fans when the high pressure cutout switch opens. The condenser fan and phase select outputs remain energized as the
CSR40SL Semi-Hermetic, February 2000
4-8
µP-D Controller
Data Logging and Downloading Data
controller operates the condenser fan for 5 minutes to correct
the condition. After 5 minutes, the controller attempts to
restart the compressor. If the compressor fails to start due to
high pressure cutout, alarm code 10 is generated. The controller will restart the compressor when the fault condition corrects itself (high pressure switch closes).
The controller also generates alarm code 10 if the high
pressure cutout/restart cycle repeats 3 times within 30 minutes.
“PAUSE ALM43”, Frequency Out-of-Range Low
The controller immediately stops the compressor, evaporator
fans, condenser fan and heaters when a low supply power voltage condition exists. The controller will restart the unit to
resume normal temperature control operation when the supply
voltage returns to normal.
“PAUSE ALM82”, Compressor Head Over Temperature
The controller immediately stops the compressor and evaporator fans when the discharge gas temperature rises above 148 C
(298 F). The condenser fan and phase select outputs remain
energized as the controller operates the condenser fan for 5
minutes to correct the condition. After 5 minutes, the controller attempts to restart the compressor. If the compressor
still fails to start due to compressor head over temperature,
fault code 82 is generated. The controller will restart the compressor when the fault condition corrects itself (resets).
The controller also generates alarm code 82 if the compressor head over temperature cutout/restart cycle repeats 3
times within 30 minutes.
General Theory Of Operation
The µP-D controller uses advanced solid-state integrated circuits to monitor and control all unit functions. The controller
monitors inputs from:
• Return air sensor
• Supply air sensor
• Evaporator coil sensor
• Condenser coil sensor
• Ambient sensor
• USDA (Spare) sensors 1, 2 and 3 (option)
• Pulp sensor (or USDA 4 sensor) (option)
• Humidity sensor (option)
• Compressor discharge temperature sensor
• High pressure cutout switch
• Water pressure switch (water-cooled condenser option)
• Current transformer circuits 1, 2 and 3
Output signals from the controller automatically regulate all
unit functions including:
• Compressor operation
• Condenser fan operation
• Evaporator fan motor speed and operation
• Modulation valve
• Compressor liquid injection valve
• Warm gas bypass solenoid valve
• Dehumidify valve (option)
• Humidity air compressor motor (option)
• Electric heaters
• Bridge light relays for defrost, cool and in-range lights
(option)
• Phase selection contactors ABC and CBA
Chill Loads (Setpoint at -9.9 C [14.1 F] and Above)
Data Logging and Downloading Data
The µP-D controller can record sensor temperatures as well as
loss of power, alarms, unit operating modes, sensor failure,
setpoint change and unit shutdown indications. Logging intervals are selectable from 30 minutes and 1 hour. When a 1
hour logging interval is selected, the datalogger memory can
store approximately 365 days of information.
PC-PAC software downloads and reports the Return,
Supply, Ambient and USDA sensor temperatures as standard.
Connect a portable computer with PC-PAC software to the
communications port on the control box to download trip data.
Trip data can be retrieved (but not erased) from the controller memory using PC-PAC software. Trip data from separate units is denoted by the identification information entered
into the controller at the beginning of the trip by PC-PAC software. Identification data may include the date, container ID
number, operator identification, point of origin, product, setpoint and other information up to a total of 80 characters
(numerals or alphabetical letters). The container ID number is
always resident in the controller memory.
At setpoints of -9.9 C (14.1 F) and above, the controller uses a
proportional-integral derivative capacity control system during
cooling. The system uses a direct acting modulation valve to
provide accurate control of the container temperature in direct
response to load demand.
The modulation valve is installed in the suction line and
controls the amount of refrigerant returning to the compressor.
The modulation valve opens and closes in response to a controller voltage pulse signal. The controller generates the voltage pulse signal based on a calculated temperature differential.
The controller calculates the control temperature differential
based on the setpoint temperature; supply air sensor temperature; modulation temperature range and the pull-down rate.
If the supply air sensor fails, the temperature of the return
air sensor minus 1.4 C (2.5 F) is used for temperature control.
If both sensors fail, the controller will immediately shut down
unit operation (chill load operation only).
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
General Theory of Operation
4-9
Frozen Loads (Setpoint at -10 C [14 F] and Below)
Modulation Valve Setting (PCVAL)
At setpoints of -10 C (14 F) and below, the controller controls
unit operation based on the return air sensor temperature and
setpoint temperature.
The system operates on Full Cool to provide accurate control of frozen cargo. If the return air sensor becomes disconnected or fails while it is being used to control unit operation,
the controller will automatically switch and control unit operation from the supply air sensor plus 4.4 C (7.9 F). If both the
supply and return air sensors fails, the controller will operate
the unit continuously on Cool (frozen load operation only).
The modulation valve controls refrigerant return to the compressor during Modulation Cool. The modulation valve setting is displayed in the View menu under PCVAL. The
PCVAL reading indicates the percent the modulation valve is
closed: 100 =100% closed.
Automatic Phase Selection
The µP-D controller monitors each phase of the power supply
to ensure proper rotation of the condenser and evaporator fans,
and the compressor. During unit start-up, “PAUSE CHECK”
appears in the controller display while the controller determines the correct phase sequence. The controller energizes
phase select contactor ABC and then the electric heaters, condenser fan and evaporator fans. The controller senses the
incoming power phase for 10 seconds and then de-energizes
phase select contactor ABC. 30 seconds later, phase select
contactor CBA is energized with the selectric heaters, condenser fan and evaporator fans. The controller senses the
incoming power phase for another 10 seconds to select the correct phase sequence. The controller then de-energizes all unit
loads and energizes either the ABC or CBA phase select contactor to assure correct compressor, condenser fan and evaporator fan rotation.
Compressor Liquid Injection
During compressor operation, a liquid injection system injects
refrigerant into the suction line to protect the compressor for
excessively high operating temperatures. The controller activates liquid injection when the:
• Compressor starts. The controller turns on liquid injection
for 5 minutes after each compressor startup. Compressor
startups include initial unit start, start after Defrost and start
after Null.
• Modulation valve is energized. The controller turns on liquid
injection continuously during the Modulation Cool and
Power Limit modes.
• Compressor discharge temperature exceeds 138 C (280 F).
Liquid injection stops when the compressor discharge temperature decreases to 132 C (270 F).
When liquid injection is active, the controller energizes
the liquid injection valve continuously. The liquid injection
line injects refrigerant into the center scroll of the compressor.
Evaporator Fan Control
The controller determines evaporator fan motor speed based
on the return air temperature and the Economy mode setting.
• Evaporator fans operate on HIGH speed at return air temperatures of -9.9 C (14.1 F) and above. If the Economy mode is
ON and temperature is In-range, the controller shifts the
evaporator fans to LOW speed.
• Evaporator fans operate on LOW speed at return air temperatures of -10 C (14 F) and below. If the Economy mode is ON
and the unit is in the Null mode, the controller STOPS the
evaporator fans. The controller then operates the evaporator
fans on LOW speed for 5 minutes every 45 minutes as long
as the unit remains in the Null mode.
Condenser Fan Control
The controller cycles the condenser fan between ON and OFF
based the compressor discharge temperature and/or the condenser coil temperature. The controller uses a software algorithm to monitor these temperature sensors and their rate of
temperature change. Therefore, when the condenser fan will
start and stop can not be exactly predicted. However, the condenser fan will typically be ON when:
• The compressor temperature is above 50 C (122 F) and
increasing, or
• The condenser temperature is above 35 C (95F).
NOTE: The condenser fan operates continuously if
either the compressor or condenser temperature
sensor is defective.
CSR40SL Semi-Hermetic, February 2000
4-10
µP-D Controller
General Theory of Operation
Sensor Check
NOTE: If a Sensor Check occurs, check the supply
air sensor position in the probe holder. The supply
air sensor MUST be inserted all the way to the bottom of the probe holder to accurately record the supply air temperature.
During unit operation, the controller constantly monitors the
supply and return air temperatures. If the temperature difference is outside certain limits during cooling and no alarms are
recorded, the controller performs a Sensor Check test.
“SENSR CHECK” appears in the display as the controller turns all loads off except the phase contactor. “SENSR
XXX” appears in the display while the controller energizes the
high speed evaporator fan output for 5 minutes and compares
the supply and return air sensor. If the temperature difference
between the supply and return air sensor is greater than 2.2 C
(3.9 F), the controller places the unit in defrost and resets the
“SENSR XXX” display counter. When defrost is complete,
the controller repeats the sensor check test.
• If the temperature difference between the supply and
return air sensor is less than 2.2 C (3.9 F), the controller
resumes normal operation.
• If the temperature difference between the supply and
return air sensor is greater than 2.2 C (3.9 F) and a defrost
has occurred in the last 30 minutes, the controller attempts
to identify the defective sensor. The controller compares
the supply and return air sensor temperatures to the coil
sensor temperature:
- The controller chooses the sensor with the greatest temperature difference with the coil sensor as the defective
sensor, records an alarm code and takes appropriate
action.
• If the Return Air sensor is defective and the setpoint
is -9.9 C (14.1 F) or above, the controller records
alarm code 7 and resumes normal operation.
• If the Supply Air sensor is defective and the setpoint
is -9.9 C (14.1 F) or above, the controller records
alarm code 3 and uses the return air sensor temperature plus an offset to control unit operation.
• If the Return Air sensor is defective and the setpoint
is -10.0 C (14.0 F) or below, the controller records
alarm code 7 and uses the supply air sensor temperature plus an offset to control unit operation.
• If the Supply Air sensor is defective and the setpoint
is -10.0 C (14.0 F) or below, the controller records
alarm code 3 and resumes normal operation.
- If the temperature difference between both the supply
and return air sensors and the coil sensor is greater than
2.2 C (3.9 F), the controller determines both sensors are
defective, records alarm code 25 and takes appropriate
action:
• If the setpoint is -9.9 C (14.1 F) or above, a unit
shutdown occurs.
• If the setpoint is -10.0 C (14.0 F) or below, the unit
continues to operate on Cool.
Power Limit
The controller also uses current transformers to measure line
voltage as well as unit and component amperage draw.
The controller uses total unit current draw information to
provide power limit control. When the current exceeds a predetermined threshold, the controller limits unit power consumption by sending a voltage pulse to the modulation valve.
The modulation valve closes to restrict the flow of refrigerant
to the compressor to limit the compressor drive motor current
draw to the pre-selected threshold.
Initial Unit Start-up and Normal Operation
Power Limit is active whenever the compressor is ON in both
the Chill and Frozen modes. During start-up, the power limit
percentage is calculated based on the total unit current draw,
the ambient temperature and the power supply voltage. After
unit start-up, the controller also uses condenser coil temperature to calculate the power limit percentage of modulation.
When the power limit percentage of modulation is higher
than the refrigeration control percentage of modulation, the
controller uses the power limit percentage to close the modulation valve. The Power Limit LED also turns ON.
Power Limit Management
A predetermined Power Limit can also be set from “PWRED”
feature in the Program Menu of the controller. A 10%, 20% or
30% power reduction can be selected for 8 hours of unit operation. Because the cooling capacity of the unit may be reduced
when the Power Reduction Mode is active, use of the Power
Reduction Mode should be established by the shipper.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Sequence of Operation
4-11
Economy Mode Operation
The Economy Mode reduces unit power consumption by
reducing evaporator fan operation on both fresh and frozen
loads. The use of the Economy Mode should be established by
the shipper and the type of cargo. The Economy Mode option
is turned on from Setpoint menu of the controller.
NOTE: If the Economy Mode is set to ON, the controller display will show “ECON ON” for 1 second
every 10 seconds.
• Fresh Loads (return air temperatures of -9.9 C (14.1 F) and
above): Evaporator fans operate on low speed whenever the
container temperature is In-range.
• Frozen Loads (return air temperatures of -10 C (14 F) and
below): The evaporator fans stop during the Null mode. A
null state timer automatically re-starts the evaporator fans on
low speed for 5 minutes every 45 minutes.
The Economy Mode also modifies the temperature control
algorithm on frozen loads to extend the Null mode. The unit
continues on Cool operation until return air temperature
reaches ECMIN temperature. Default ECMIN setting is 2.0 C
(3.6 F) below setpoint. ECMIN temperature is adjustable
from 0 to 5 C (0 to 8.9 F) below setpoint through the
Configuration menu of the controller.
The unit remains in Null until the return air temperature
increases to ECMAX temperature at the expiration of a 45
minute Null state time sequence. Default ECMAX setting is
.2 C (0.4 F) above setpoint. ECMAX setting is adjustable
from 0 to 5 C (0 to 8.9 F) above setpoint through the
Configuration menu of the controller.
NOTE: On Frozen loads, supply and return air temperatures may vary considerably during Economy
mode operation due to long periods of no air circulation. On Chill loads, container air temperatures may
vary 1 C to 3 C (1.8 F to 5.4 F) above setpoint in high
ambient temperatures.
Sequence Of Operation
Unit Start-up
A sequence start of the required loads occurs during initial
start-up of the controller. If cooling (or heating) is required,
the unit operates in the cool (or heat) mode until the controlling sensor reaches setpoint.
• When the unit On/Off switch is turned ON, the Status
Indicator LEDs and display turn On and then Off.
• “Phase Check” appears in the controller display while
the controller determines the correct phase sequence.
Phase selection takes 50 to 80 seconds; or more on
extremely noisy power lines. The controller then energizes phase select contactor ABC or CBA.
• The setpoint and controlling air sensor temperature are
displayed.
• The evaporator fan motors start. Evaporator fans operate on high speed at return air temperatures of -9.9 C
(14.1 F) and above (except when Economy mode is ON
and temperature is In-range). Evaporator fans operate
on low speed at return air temperatures of -10 C (14 F)
and below (except during Null with Economy mode
ON).
• The condenser fan motor cycles between ON and OFF
based on a control algorithm. Typically, the condenser
fan will typically be ON when:
- the compressor temperature is above 50 C (122 F)
and increasing, or
- the condenser temperature is above 35 C (95F).
• If the controller calls for cooling, the compressor motor
starts. On Chill Loads, the unit operates in cool until the
supply air temperature reaches setpoint. On Frozen
Loads, the unit operates in cool until the return air temperature reaches 1.0 C (1.8 F) below setpoint.
• The modulation valve remains open during initial startup on cooling.
• Power limit is active when the unit is operating in a
cooling mode. This means the modulation valve may be
energized to reduce the cooling load on the compressor,
thereby reducing total unit power consumption.
• Chill Loads Only: If the controller calls for heating, the
electric heaters are energized. Unit operates in heat until
the supply air temperature reaches setpoint.
• Controller turns ON the In-range LED when the controlling sensor temperature is within 1.7 C (3.0 F) of setpoint.
CSR40SL Semi-Hermetic, February 2000
4-12
µP-D Controller
Sequence of Operation
Operating Mode Function Chart — Standard Operation
Chill Loads
Setpoints at -9.9 C
(14.4 F) and Above
Cool Mod
•
•
Frozen Loads
Setpoints at -10.0 C
(14.0 F) and Below
Null Heat Defr
•
Cool Null
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Defr
•
•
•
•
•
•
•
•
•
•
•
•
Unit Function
Evaporator Fans HIGH SPEED1
Evaporator Fans LOW SPEED1
Evaporator Fans OFF1
Proportional-integral Derivative (Supply Air) Control
Return Air Sensor Control
Evaporator Coil Sensor Control
Compressor ON
Compressor Liquid Injection ON (valve energized)2
Warm Gas Bypass Solenoid Valve OPEN (energized)3
Condenser Fan ON4
Modulation Valve OPEN (de-energized)5
Modulation Valve MODULATING (energized)5
Electric Heaters ON (energized)
1Return air temperature determines the evaporator fan speed (except when Economy Mode is ON):
• At return air temperatures of -9.9 C (14.4 F) and above, the evaporator fans operate on high speed.
• At return air temperatures of -10.0 C (14.0 F) and below, the evaporator fans operate on low speed.
2Controller OPENS (energizes) the liquid injection valve:
• For 5 minutes whenever the compressor starts.
• Continuously when the unit is in Modulation Cool.
• Continuously when the unit is in Power Limit mode.
• When the compressor discharge temperature exceeds 138 C (280 F).
3Controller OPENS (energizes) the warm gas bypass valve:
• When the calculated temperature differential is less than 0.6 C (1.0 F), the controller pulses the bypass valve OPEN and
closed. The amount of OPEN (energized) time increases as the modulation valve closes.
• When the modulation valve is closed (PCVAL = 100%), the bypass valve remains open (energized) continuously.
4Condenser fan operation:
• Cooling Mode: Fan operation is impossible to determine exactly because the controller uses a control algorithm to cycle the
condenser fan between ON and OFF. However, the condenser fan will typically be ON when:
- The compressor discharge temperature is above 50 C (122 F) and increasing, or
- The condenser temperature is above 35 C (95F).
• Null Mode: If the condenser fan was ON when the unit shifted to NULL, it will operate for 30 seconds and stop.
• Water-cooled Condenser Option: When water supply pressure opens the water pressure switch, the controller stops the condenser fan.
NOTE: The condenser fan operates continuously if either the compressor or condenser temperature sensor is defective.
5Modulation valve MODULATES:
• When the Power Limit mode is ON.
• When the calculated temperature differential is less than 2.5 C (4.5 F) above setpoint.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Sequence of Operation
Continuous Temperature Control Operation
Chill Loads — Controller Setpoint at -9.9 C (14.1 F)
and Above
After the unit reaches setpoint on initial start-up operation, the
controller regulates the compressor, modulation valve and
electric heaters based on a CALCULATED 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 sensor temperatures. The controller operates the unit on:
• Cool mode
• Modulation Cool mode
• Null mode
• Heat mode
• Defrost mode
4-13
• Evaporator fans operate on high speed (except when
Economy mode is ON and temperature is In-range) and
continuously circulate air inside the container (except
during defrost).
• Controller display shows the setpoint and supply air temperatures.
• Controller uses a control algorithm to cycle the condenser fan between ON and OFF. Typically, the condenser fan will typically be ON when:
- the compressor temperature is above 50 C (122 F)
and increasing, or
- the condenser temperature is above 35 C (95F).
Cool
• Controller calls for the Cool mode whenever the
Calculated Temperature Differential is more than 2.5 C
(4.5 F) above setpoint.
• Modulation valve is fully open so the unit provides maximum cooling capacity.
• Power limit is active when the unit is operating in the
Cool mode.
Operating Mode Function Chart — Optional Feature Operation
Chill Loads
Setpoints at -9.9 C
(14.4 F) and Above
Cool Mod
•
•
Frozen Loads
Setpoints at -10.0 C
(14.0 F) and Below
Null Heat Defr
•
•
Defr
•
•
•
•
Cool Null
•
•
Unit Function
Economy Mode ON: Evaporator Fans HIGH SPEED1
Economy Mode ON: Evaporator Fans LOW SPEED1
Economy Mode ON: Evaporator Fans OFF1
Dehumidify ON: Dehumidify Valve CLOSED (energized)2
Dehumidify ON: Electric Heaters ON (energized)2
1Economy Mode ON: • On Chill Loads, the evaporator fans operate on low speed when the supply air temperature is In-range.
• On Frozen Loads, the evaporator fans stop during the Null mode when the return air temperature is Inrange. A timer re-starts the evaporator fans on low speed for 5 minutes every 45 minutes. If cooling is
required, the evaporator fans operate until the unit returns to Null mode.
2Dehumidification Option: When the Dehumidify Mode is set to ON, the supply air temperature must be in-range to CLOSE
(energize) the dehumidify valve:
• When the humidity is 1 to 5% above setpoint, the controller CLOSES (energizes) the dehumidify valve.
• When the humidity is more than 5% above setpoint, the controller CLOSES (energizes) the dehumidify valve AND pulses
the electric heaters ON and OFF.
CSR40SL Semi-Hermetic, February 2000
4-14
µP-D Controller
Sequence of Operation
Modulation Cool
• Controller calls for Modulation Cool when the Calculated
Temperature Differential is between 2.5 C (4.5 F) above
setpoint and setpoint (on temperature pull-down).
• Controller opens and closes the modulation valve to regulate the flow of refrigerant to the compressor. The
position of the modulation valve balances the unit cooling capacity against the actual load requirements.
• The warm gas bypass valve pulses open and closed
(energized and de-energized) when the Calculated
Temperature Differential is less than 0.6 C (1.0 F) above
setpoint (on temperature pull-down). The amount of ON
(open) time increases as the modulation valve closes.
The bypass valve is ON (energized) continuously when
the modulation valve is closed 100%.
• After the initial temperature pull-down, the In-range
LED turns OFF if the supply air temperature increases
more than 2.5 C (4.5 F) above setpoint. The supply air
temperature must decrease to 1.7 C (3.0 F) above setpoint
to turn the In-range LED ON again.
Calculated Temperature Differential decreases to 3.1 C
(5.5 F) below setpoint.
On temperature pull-up (and initial start-up), the controller pulses the electric heaters ON and OFF until the
Calculated Temperature Differential increases to setpoint.
• The evaporator fans continue to operate.
• The In-range LED turns OFF if the supply air temperature decreases more than 2.5 C (4.5 F) below setpoint.
The supply air temperature must increase to 1.7 C (3.0 F)
below setpoint to turn the In-range LED ON again.
NOTE: If the supply air sensor temperature
stays out-of-range low for 75 minutes after the
unit is In-range, the controller turns ON the
Alarm LED. Alarm code 13 (a check alarm) is
also recorded in the controller’s memory.
NOTE: If the supply air sensor temperature
stays out-of-range high for 75 minutes after the
unit is In-range, the controller turns ON the
Alarm LED. Alarm code 12 (a check alarm) is
also recorded in the controller’s memory.
Null
• The controller calls for Null when the Calculated
Temperature Differential is between setpoint and 0.6 C
(1.0 F) below setpoint (on temperature pull-down).
• The controller de-energizes the compressor contactor to
stop the compressor.
• If the condenser fan was ON, it will operate for 30 seconds and then stop. If the condenser fan was OFF, it
will remain OFF.
• The evaporator fans continue to operate.
• The controller de-energizes (opens) the modulation
valve and de-energizes (closes) the bypass valve.
Heat
• The electric heaters pulse ON and OFF (energized and
de-energized) when the Calculated Temperature
Differential decreases to 0.6 C (1.0 F) below setpoint
(on temperature pull-down). The amount of ON time
increases as the Calculated Temperature Differential
decreases below setpoint. The electric heaters remain
energized continuously (100% of time) when the
Chill Load Control Sequence (Setpoints at -9.9 C
[14.1 F] and Above)
A.
B.
C.
D.
E.
1.
2.
3.
4.
5.
Cool
Modulation Cool
Null
Heat
In-Range
Decreasing Temperature
Setpoint
Increasing Temperature
Calculated Temperature Differential
Supply Air Temperature
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
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 Cool and Heat modes, and warm gas bypass
valve operation. The controller uses the return air temperature
and setpoint temperature to determine operating mode switch
points. The controller operates the unit on:
• Cool mode
• Null mode
• Defrost mode
• Evaporator fans operate on low speed (after return air
temperature decreases to -10 C [14 F]) and continuously
circulate air inside the container (except during defrost;
or during Null mode with Economy Mode ON).
• Controller display shows the setpoint and return air temperatures.
• Controller uses a control algorithm to cycle the condenser fan between ON and OFF. Typically, the condenser fan will typically be ON when:
- the compressor temperature is above 50 C (122 F)
and increasing, or
- the condenser temperature is above 35 C (95F).
Sequence of Operation
4-15
Cool
• Controller calls for the Cool mode whenever the return
air temperature is more than 1.0 C (1.8 F) above setpoint.
• Power limit is active when the unit is operating in the
Cool mode.
• After the initial temperature pull-down, the In-range
LED turns OFF if the return air temperature increases
more than 2.5 C (4.5 F) above setpoint. The return air
temperature must decrease to 1.7 C (3.0 F) above setpoint
to turn the In-range LED ON again.
NOTE: If the return air sensor temperature goes
out-of-range high for 75 minutes after the unit is
In-range, the controller turns ON the Alarm LED.
Alarm code 12 (a check alarm) is also recorded
in the controller’s memory.
Frozen Load Control Sequence (Setpoints at -10 C
[14 F] and Below) — Economy Mode ON
Frozen Load Control Sequence (Setpoints at -10 C
[14 F] and Below) — Economy Mode OFF
A.
C.
E.
1.
2.
3.
6.
Cool
Null
In-Range
Decreasing Temperature
Setpoint
Increasing Temperature
Return Air Temperature
A.
C.
E.
1.
2.
3.
6.
7.
Cool
Null
In-Range
Decreasing Temperature
Setpoint
Increasing Temperature
Return Air Temperature
ECMIN (default setting is 2.0 C [3.6 F] below setpoint). Setting is adjustable from 0 to 10 C (0 F to 18
F) below setpoint.
8. ECMAX (default setting is 1.0 C [1.8 F] above setpoint). Setting is adjustable from 0 to 10 C (0 F to 18
F) above setpoint.
CSR40SL Semi-Hermetic, February 2000
4-16
Sequence of Operation
Null
• The controller calls for Null when the Return Air
Temperature decreases more than 1.0 C (1.8 F) below
setpoint (on temperature pull-down).
• The controller de-energizes the compressor contactor to
stop the compressor.
• If the condenser fan was ON, it will operate for 30 seconds and then stop. If the condenser fan was OFF, it
will remain OFF.
• The evaporator fans continue to operate in low speed.
Defrost
During the Cool, Modulation Cool or Null modes, the controller initiates the Defrost mode when the evaporator coil sensor temperature is below 10 C (50 F) and:
• Demand Defrost algorithm determines when defrost is
required based on the return air temperature, evaporator coil
temperature, condenser coil temperature and the percent
modulation.
• Internal Defrost Timer calls for defrost based on a timed
defrost interval:
On Chill Loads
- Default: The initial time interval is 3 hours. One (1) hour is
added to the time interval each time two timed defrost
cycles occur without a demand defrost cycle between them.
Maximum accumulated time interval is 8 hours. Time interval resets when the setpoint is adjusted to -10 C (14 F) or
below, when the unit is turned OFF for 48 hours, or when a
manual defrost occurs.
- Customer Configuration C5: Standard default times but
maximum time interval is 6 hours on chill loads.
- Customer Configuration C6: 2 hour initial defrost, then
maximum time interval is 6 hours on chill loads.
On Frozen Loads
- Default: The initial time interval is 8 hours. Two (2) hours
are added to the time interval each time two timed defrost
cycles occur without a demand defrost cycle between them.
Maximum accumulated time interval is 24 hours. Time
interval resets when the setpoint is adjusted to -9.9 C (14.1
F) or above, when the unit is turned OFF for 48 hours, or or
when a manual defrost occurs.
- Customer Configuration C5: Standard default times but
maximum time interval is 12 hours on frozen loads.
- Customer Configuration C6: 2 hour initial defrost, then
maximum time interval is 6 hours on frozen loads.
µP-D Controller
• A manual defrost is initiated (loaded) using the controller
keypad.
NOTE: If unit operating conditions do not allow
the unit to enter a defrost cycle, “DFRST INVAL”
(defrost invalid) appears on the controller display when a manual defrost is initiated (loaded)
using the controller keypad.
NOTE: If the coil sensor fails, the controller substitutes the temperature of the controlling sensor
to determine when a defrost mode may initiated.
When the defrost mode is initiated:
• The controller de-energizes the compressor, evaporator
fan and condenser fan contactors.
• When the compressor stops, the controller turns ON the
Defrost LED and energizes the heater contactor, turning
on the electric heaters.
The controller terminates the defrost mode when:
• Chill mode: Evaporator coil sensor temperature reaches
30 C (86 F).
• Frozen mode: Evaporator coil sensor temperature
reaches 18 C (64.4 F).
• Time/temperature function: Controller terminates
defrost if the evaporator coil sensor rises and remains
above 8 C (46 F) for 10 minutes (Frozen mode only).
• Interval timer: Controller terminates defrost 90 minutes
after initiation if the coil sensor temperature has not terminated defrost. An alarm code will be generated if this
occurs.
NOTE: If the coil sensor fails, the controller substitutes the return air sensor. Defrost is terminated when the return air sensor reaches 18 C
(64.4 F). If both the coil and return air sensors
fail, the controller will terminate defrost 60 minutes after initiation. An alarm code will be generated if this occurs.
• When the controller terminates Defrost, the heater contactor is de-energized. The controller starts the compressor to pre-cool the evaporator coil. The condenser fan
starts if required by the condenser pressure (or temperature on unit configurations 5017, 5018, 5019 or 5020).
The controller energizes the high or low speed evaporator fan contactor (depending on return air temperature)
after the evaporator coil has been pre-cooled to minimize
heat energy release into the container.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Reviewing Software Version and Configuration
NOTE: The unit will operate and control the container temperature if the controller remains programmed to unit configuration “5000” and customer configuration “0”. However, the unit will
not operate customer specific options. See the
decal inside the control box for the correct unit
configuration and customer configuration settings for the unit. To load new configuration
numbers, see MENU GUARD under Menu
Operating Instructions in this chapter.
Reviewing Software Version and
Configuration
The software version, unit configuration number and customer
configuration number are stored in the controller memory. To
view the software version and configuration number, turn the
unit On/Off switch ON:
1. With the Standard Display showing on the controller (i.e.
setpoint and controlling sensor temperature), press and
hold the ENTER key for 3 seconds.
• Display will show the software version for 2 seconds (in
following format:VERSN 11.71).
COOL
MOD
NULL
HEAT IN RANGE
SETPOINT
MOD
NULL
DATA
HEAT IN RANGE
71
DEFROST SUPPLY RETURN PWRLMT ALARM
SETPOINT
TEMPERATURE
DATA
DATA
• Display then shows the customer configuration number
for 2 seconds (replacement controller default setting:
CFG C
0).
COOL
MOD
NULL
HEAT IN RANGE
The display then returns to the Standard Display.
DEFROST SUPPLY RETURN PWRLMT ALARM
• Display then shows the unit configuration number for 2
seconds (replacement controller default setting: CFG U
5000).
COOL
2.
TEMPERATURE
DATA
4-17
DEFROST SUPPLY RETURN PWRLMT ALARM
SETPOINT
TEMPERATURE
DATA
DATA
°C
°F
Displaying Alternate Fahrenheit (F) or
Celsius (C) Temperatures
NOTE: The C/F units shown on the controller display can be changed by pressing and holding the
C/F key, and then pressing the ENTER key.
The controller can display temperatures in Fahrenheit or
Celsius. With the unit On/Off switch ON and the controller
showing a Standard Display:
1. Press and hold the F/C key. The controller will show the
display temperatures in the alternate temperature scale
(Fahrenheit or Celsius) from the temperatures shown on
the display as long as the F/C key is depressed.
2. The display then returns to the original display when the
F/C key is released.
NOTE: The setpoint temperature can be entered in
either F or C using the F/C key. Just press and hold
the F/C key (to display the alternate temperature
scale).
NOTE: The customer configuration MUST also
always be set to the configuration number
shown on the set up decal in the unit control
box. Alarm code 42 (unit configuration alarm) is
displayed if the customer configuration has not
been set to a valid number (other than “0”).
CSR40SL Semi-Hermetic, February 2000
4-18
RET
SUP
µP-D Controller
Displaying Alternate Temperatures
NOTE: The setpoint temperature can be entered
in either oF or oC using the F/C key. Just press
and hold the F/C key (to display the alternate
temperature scale). Press the UP or DOWN key
to scroll to the correct setpoint temperature.
Then press the ENTER key to load the setpoint.
Displaying Alternate Controlling
(Supply or Return) Air Sensor
Temperature
The controller can show either the supply air or return air temperature in the right display. With the unit On/Off switch ON
and the controller showing the Standard Display:
1. Check the indicator LEDs to determine which sensor temperature (supply air or return air) currently appears in the
right display. This is the controlling sensor (supply air
sensor at setpoints of -9.9 C [14.1 F] and above; return air
sensor at setpoints of -10 C [14 F] and below).
2. To view the alternate air sensor temperature, press and
hold the RET/SUP key. The controller will show the temperature of the alternate (non-controlling) air sensor as
long as the RET/SUP key is depressed.
3. The display then returns to the Standard Display when the
RET/SUP key is released.
2.
COOL
Changing the Setpoint
NULL
MOD
NULL
HEAT IN RANGE
SETPOINT
TEMPERATURE
DATA
DATA
MOD
NULL
HEAT IN RANGE
SETPOINT
DEFROST SUPPLY RETURN PWRLMT ALARM
TEMPERATURE
°
°
DATA
DEFROST SUPPLY RETURN PWRLMT ALARM
TEMPERATURE
°
°
DATA
DATA
1.
DEFROST SUPPLY RETURN PWRLMT ALARM
SETPOINT
DATA
COOL
HEAT IN RANGE
The display then returns to the Standard Display (showing
new setpoint).
COOL
To change the controller setpoint, turn the unit On/Off switch
ON. With the Standard Display showing on the controller (i.e.
setpoint and controlling sensor temperature):
MOD
NOTE: If the ENTER key is not pressed within 10
seconds, the controller will default (return) to the
previous setpoint. If this occurs, repeat steps 1
and 2.
3.
or
When the desired setpoint appears in the right display,
press the ENTER key. The right display shows “LOAD”.
Press the DOWN or UP arrow key. The left display flashes “SETPT” while the right display shows the changing
setpoint temperature. To set the tenths digit, wait 4 seconds for all three digits to appear on the display. Make
additional setpoint adjustment if necessary.
COOL
MOD
NULL
SETPOINT
HEAT IN RANGE
DEFROST SUPPLY RETURN PWRLMT ALARM
TEMPERATURE
°
DATA
DATA
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Initiating a Manual Defrost
P
Initiating a Manual Defrost
With the unit On/Off switch ON:
1. Press the DEFROST key. The display flashes “ENTER
DFRST”.
COOL
MOD
NULL
HEAT IN RANGE
TEMPERATURE
DATA
DATA
Initiating a Full Pretrip
To perform a Full Pretrip test, turn the unit On/Off switch ON:
NOTE: The controller will not perform an automatic pretrip test until all alarms have been corrected and cleared.
DEFROST SUPPLY RETURN PWRLMT ALARM
SETPOINT
1.
Press the PRETRIP key. The display flashes “ENTER
PTRIP”.
COOL
2.
Press the ENTER key.
• If the unit operating conditions allow a manual defrost
(e.g. evaporator coil temperature is less than 10 C [50
F]), the display briefly shows “LOAD DFRST”. The
unit enters defrost as the Defrost LED turn ON. The
defrost cycle automatically terminates.
COOL
MOD
NULL
HEAT IN RANGE
2.
SETPOINT
TEMPERATURE
DATA
DATA
• If unit operating conditions do NOT allow defrost, the
display shows “DFRST INVAL” for 3 seconds.
3.
NULL
HEAT IN RANGE
NULL
HEAT IN RANGE
DEFROST SUPPLY RETURN PWRLMT ALARM
SETPOINT
TEMPERATURE
DATA
DATA
DEFROST SUPPLY RETURN PWRLMT ALARM
NOTE: If the ENTER key is not pressed within
10 seconds, the controller will default (return) to
the Standard Display.
MOD
MOD
Press the ENTER key. The display briefly shows “LOAD
PTRIP”. The controller then conducts a Full Pretrip Test.
COOL
COOL
4-19
MOD
NULL
HEAT IN RANGE
DEFROST SUPPLY RETURN PWRLMT ALARM
SETPOINT
TEMPERATURE
DATA
DATA
3. When the Pretrip test is complete, the display returns to
the Standard Display (e.g. setpoint and controlling sensor
temperatures). The unit returns to normal operation.
DEFROST SUPPLY RETURN PWRLMT ALARM
SETPOINT
TEMPERATURE
DATA
DATA
The controller then returns to the Standard Display.
CSR40SL Semi-Hermetic, February 2000
4-20
µP-D Controller
Entering a Start of Trip Marker
COOL
MOD
Entering a Start of Trip Marker
To enter a Start of Trip marker, turn the unit On/Off switch
ON or operate the controller using battery power (press the
SELECT key):
1. Press the SOT (Start of Trip) key. The display flashes
“ENTER SOT”.
COOL
2.
MOD
NULL
HEAT IN RANGE
DEFROST SUPPLY RETURN PWRLMT ALARM
SETPOINT
TEMPERATURE
DATA
DATA
2.
3.
4.
MOD
NULL
HEAT IN RANGE
COOL
TEMPERATURE
DATA
DATA
NOTE: If the ENTER key is not pressed within 10
seconds, the controller will default (return) to the
Standard Display.
3.
5.
TEMPERATURE
DATA
DATA
MOD
NULL
HEAT IN RANGE
DEFROST SUPPLY RETURN PWRLMT ALARM
SETPOINT
TEMPERATURE
DATA
DATA
To clear all alarm codes from the current display memory,
press the ENTER key. The display briefly shows
“ALARM CLEAR”.
WARNING: Some unit malfunctions will cause an
Alarm and unit shutdown condition. When the
alarm codes are cleared, the unit will start automatically.
Displaying and Clearing Alarm Codes
COOL
If the Alarm LED is ON or flashing ON and OFF, use the
ALARM key to view the alarm code(s). Turn the unit On/Off
switch ON or operate the controller using battery power (press
the SELECT key):
1. Press the ALARM key.
• The left display shows the number of alarms stored in
memory (e.g. ALM 2).
• The right display shows a two digit code for the most
recent alarm (e.g. 02).
SETPOINT
NOTE: If the ENTER key is not pressed within 10
seconds, the controller will default (return) to the
Standard Display.
The controller then returns to the Standard Display.
!
DEFROST SUPPLY RETURN PWRLMT ALARM
NOTE: Clear the Alarm codes ONLY after the
alarm codes are documented and problems
repaired. Clearing the codes erases them from
the controller Alarm display memory.
DEFROST SUPPLY RETURN PWRLMT ALARM
SETPOINT
HEAT IN RANGE
Write down the first alarm code. Then press the DOWN
key to view the next alarm code.
Repeat step 2 until all alarm codes have been recorded.
After the last alarm code (ALM 1) has been viewed and
recorded, the left display flashes “ENTER” (the code
number of the last alarm still appears in the right display).
Press the ENTER key. The display briefly shows “LOAD
SOT”. The controller inserts a SOT marker in the data
logger memory.
COOL
NULL
6.
MOD
NULL
HEAT IN RANGE
DEFROST SUPPLY RETURN PWRLMT ALARM
SETPOINT
TEMPERATURE
DATA
DATA
The controller then returns to the Standard Display.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Controller Menu Operating Instructions
4-21
Controller Menu Operating Instructions
Menu View Functions
NOTE: To view the controller’s menu or download
data when external power is disconnected from the
unit, connect a 12 Vdc battery to the battery jack on
the Power Module Board inside the control box.
Then press SELECT key or connect a communications cable to the Data Port on the bottom of the control box.
NOTE: Information can ONLY be displayed using the
View menu. Items can NOT be changed. See “MENU
PRGRM” in this chapter for information about setting
control functions.
NOTE: To return to the controller’s Standard Display
from anywhere within the µP-D menu, press the
SELECT key for 3 seconds.
Navigating the Controller Menu:
The µP-D controller menu is divided into five major menus:
• MENU VIEW
• MENU PTRIP
• MENU TEST
• MENU GUARD
• MENU PRGRM
Moving through these five menus and their submenus and
entering commands requires the use of four keys:
The View menu displays general unit operating information
including sensor temperatures, component electrical data, etc.
The View Menu also includes two submenus, Grade and Log.
Navigating the Menu View Screens
With the unit On/Off switch ON and the controller showing
the Standard Display:
1. Press the SELECT key to enter menu (display shows
“MENU <--->”).
COOL
2.
MOD
COOL
or
3.
ENTER key: Press the ENTER key to load a command or value.
DEFROST SUPPLY RETURN PWRLMT ALARM
SETPOINT
TEMPERATURE
DATA
DATA
MOD
NULL
HEAT IN RANGE
DEFROST SUPPLY RETURN PWRLMT ALARM
SETPOINT
TEMPERATURE
DATA
DATA
Press the SELECT key to enter VIEW submenu (display
shows “VIEW <--->”).
COOL
4.
HEAT IN RANGE
Press DOWN key until display shows “MENU VIEW”.
SELECT key: Press the SELECT each time you want
to enter a new menu or submenu; or start a procedure
to load a command or value.
UP or DOWN key: Press the UP or DOWN
key each time you want to scroll up or down
to view another item in a menu or submenu.
NULL
MOD
NULL
HEAT IN RANGE
DEFROST SUPPLY RETURN PWRLMT ALARM
SETPOINT
TEMPERATURE
DATA
DATA
Press the DOWN key to view functions in submenu. Press
the UP key to scroll back through submenu. Display
shows submenu function and value (e.g. “RET 03.7 C”).
NOTE: To lock the current View Menu screen in
the controller display, press the ENTER key. A
colon flashes in the left display to indicate the
screen is locked (the screen remains locked for
15 minutes). Press any key to unlock the display.
CSR40SL Semi-Hermetic, February 2000
4-22
µP-D Controller
Menu View Functions
NOTE: The controller returns to the Standard
Display from a View Menu screen after about 10
seconds, or when the SELECT key is pressed
and held for 3 seconds.
4.
5.
6.
GRADE Submenu
The Grade submenu displays the sensor grade of each sensor
installed on the unit. With the unit On/Off switch ON and the
controller showing the Standard Display:
NOTE: If a sensor grade is set to “0”, it means the
sensor has been ice bath calibrated. Original unit
sensors are ice bath calibrated at the factory. See
“Setting the Sensor Grades” in this chapter for more
information.
NOTE: The controller returns to “GRADE <--->”
screen from a sensor grade screen after about 10
seconds. The controller returns to the Standard
Display after another 10 seconds, or when the
SELECT key is pressed and held for 3 seconds.
LOG Submenu
•
1.
2.
3.
Press the SELECT key to enter menu (display shows
“MENU <--->”.
Press DOWN key until display shows “MENU VIEW”.
Press the SELECT key to enter VIEW submenu (display
shows “VIEW <--->”).
Press the UP key until “VIEW GRADE” shows in the
display.
Press the SELECT key to enter the Grade submenu.
Display will show “GRADE <--->”.
Press DOWN key to view functions in GRADE submenu.
Display shows submenu function and value (e.g. “RETG
5”).
The Log submenu provides two scrollback displays:
- TEMP: Display shows unit operating information
recorded with the last 100 data logs.
- PTI: Display shows “PASS” or “FAIL” and individual test results recorded for the last 4 Full Pretrip
tests.
MENU VIEW Screen Flow Diagram (See Display Acronym Definitions on pages 4-4 to 4-6)
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
When viewing information in the TEMP or PTI scrollback
display, the status indicator LEDs on the controller show the
unit operating states that were active (ON) when the data or
event was recorded. If the Alarm LED is ON, press the
ALARM key to view alarm and/or event information in the
right display (e.g. “03.204”).
If more than one alarm/event is recorded, press the
DOWN key to scroll to the next alarm/event code. Alarms are
identified by the 2 digits furthest to the right of the decimal
point and are always preceded by a “0” (see the Alarm Code
list on page 4-7). Events (e.g. Power Up) are identified by a 3
digit number that always begins with a “2”.
NOTE; The scrollback alarm/event screen display
does NOT identify which alarms are pretrip alarms.
The 3 digit event codes that may appear in the scrollback
alarm/event screen display includes:
Event
Code
201
202
203
204
205
206
207
208
209
210
211
212
Description
Setpoint Change
Power Up
Power Off
Alarm(s) Cleared
Real Time Clock Reset
Start of Trip (SOT) Entered
Text Header Entered
Defrost Initiated
Defrost Terminated
Power Limit Algorithm Active
Pretrip Passed
Pretrip Failed
TEMP (Temperature) Scrollback Information Matrix
*First information screen displayed from the TEMP
Scrollback menu.
Menu View Functions
4-23
With the unit On/Off switch ON and the controller showing the Standard Display:
1. Press the SELECT key to enter menu (display shows
“MENU <--->”).
2. Press DOWN key until display shows “MENU VIEW”.
3. Press the SELECT key to enter VIEW submenu (display
shows “VIEW <--->”).
4. Press the UP key until “VIEW LOG” shows in the display.
5. Press the SELECT key to enter the Log submenu. Display
will show “LOG <--->”.
6. Press DOWN key to view scrollback menu items in LOG
submenu. Display will show “LOG TEMP” or “LOG
PTI”.
7. Press the SELECT key to enter either the “LOG TEMP”
or “LOG PTI”.
TEMP Scrollback Display Items
The TEMP scrollback display contains a lot of information
that may appear confusing at first. After entering the TEMP
display (“001RT 43.8F” appears in display), imagine that the
data is stored in a table. The first column identifies the number
of the Log entry (001, 002, etc.) and the return temperature
entry. Each additional column identifies information about
another sensor or the time of the event.
The TEMP scrollback display shows the following
acronyms and information:
RT Return Air Sensor Temperature
ST Supply Air Sensor Temperature
SP Setpoint Temperature
AT Ambient Sensor Temperature
U1 Spare 1 (USDA 1) Sensor Temperature
U2 Spare 2 (USDA 2) Sensor Temperature
U3 Spare 3 (USDA 3) Sensor Temperature
HM Humidity (%)
PP Pulp Probe Sensor Temperature
YR Year
MO Month
DY Day
TI Time
PTI (Pretrip) Scrollback Information Matrix
*First information screen displayed from the PTI
Scrollback menu.
CSR40SL Semi-Hermetic, February 2000
4-24
Menu View Functions
To enter the TEMP scrollback submenu:
1. Press the SELECT key with “LOG TEMP” in the display.
Display will briefly show “SEARC HINGX”. The display
then shows the last (most recent) data log entry (e.g.
“001RT 43.8F”).
2. Press Up or DOWN key to scroll (up or down) through
the last 100 data log entries of the return air temperature.
3. Press the SELECT key to scroll (to the right) to the next
column of data. The display wraps around from T1 (Time)
screen to RT (Return Temperature) screen. Press the
RET/SUP key to quickly return to the RT (return temperature) display.
NOTE: If a log entry for a sensor was not recorded,
the right display will show “NOLOG”.
NOTE: The controller returns to the “LOG TEMP”
screen from a data log screen after 10 seconds if no
controller key is pressed. The controller returns to
the Standard Display after another 10 seconds, or
when the SELECT key is pressed and held for 3 seconds.
µP-D Controller
To enter the PTI scrollback submenu:
1. Press the SELECT key with “LOG PTI” in the display.
Display will show the result of the last (most recent) Full
Pretrip test (e.g. “PT1 FAIL” or “PT1 PASS”).
2. Press UP key to scroll back through the last 4 Full Pretrip
test entries.
3. Press the SELECT key to scroll (to the right) to the next
individual test result stored with each Full Pretrip test (e.g.
“PT1DS PASS”). Display wraps around the TI (Time)
screen to DS (Display Test) screen. Press the RET/SUP
key to quickly return to the DS (Display Test) screen.
NOTE: If a log entry for a sensor was not recorded, the right display will show “NOLOG”.
NOTE: The controller returns to the “LOG PTI”
screen from a pretrip log screen after 30 seconds. To return to the Standard Display, press
and hold the SELECT key for 3 seconds.
PTI Scrollback Display Items
The PTI scrollback display also contains a lot of information. After entering the PTI display (“PT1 PASS” or “PT1
FAIL” appears), imagine that the data is stored in a table. The
first column identifies the number of the Full Pretrip test (PT1,
PT2, etc.) and the test result (PASS or FAIL). Each additional
column identifies information about an individual test result or
the time of the test.
The PTI scrollback display shows the following acronyms
and information:
DS Display Test Result
AM Amps Test Result
SN Sensors Test Result
HT Heat Test Result
DF Defrost Test Result
CL Cool Test Result
EX Extended Cool Test Result
YR Year
MO Month
DY Day
TI Time
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Menu Pretrip Functions
Menu Pretrip Functions
Three pretrip test menus are available through the PTRIP
Menu of the controller to test the unit’s electrical and refrigeration system components.
1. Extended Pretrip Test: Conducts a comprehensive functional check of unit performance (requires up to 7 hours to
complete on an empty container). Activate an Extended
Pretrip Test (ETEST) from the PTRIP menu. When an
extended pretrip test is complete, unit operation stops.
The Extended Pretrip Test includes:
• Full Pretrip Test: Controller performs all of the tests
used in the Full Pretrip Test (see details below).
• Extended Cool Test: Controller operates unit in cooling
for an extended period to verify system cooling performance. The extended test pulls the container temperature down to 0 C (32 F) and then -18 C (0 F) in two
stages.
2. Full Pretrip Test: Conducts a functional check of unit
operating modes (requires up to 30 minutes to complete
on an empty container). Activate a Full Pretrip Test from
the PTRIP menu; or by pressing the PRETRIP key on the
controller keypad and then pressing the ENTER key.
When a full pretrip test is complete, the unit returns to
normal operation. The Full Pretrip Test includes:
• Display: Controller lights all segments in the display for
visual inspection by technician.
3.
4-25
• Amps: Controller individually energizes all outputs
including fan and compressor motors, and solenoid
valves. The controller checks current draw to verify correct operation.
• Sensors: Controller operates unit to condition all sensors
and then verifies correct sensor calibration.
• Heat Capacity: Controller energizes evaporator fans and
electric heaters to verify correct operation.
• Defrost: Controller energizes electric heaters only to
verify correct defrost operation.
• Cool Capacity: Controller cycles unit through cooling
modes (including modulation) and monitors sensor temperatures to verify correct refrigeration system operation.
Single Pretrip Test: Conducts a functional check of one
of the individual operating modes conducted during a Full
Pretrip Test. Most tests require 1 to 10 minutes to complete. However, COOL may take up to 30 minutes,
SENSR may take up to 45 minutes, and ECOOL may take
up to 7 hours. Activate a Single Pretrip Test from the
PTRIP menu. When a single pretrip test is complete, the
unit returns to normal operation.
NOTE: If a Check Alarm fault occurs during a
pretrip test, the Alarm LED turns ON while the
controller continues the Pretrip test. If a
MENU PRETRIP Screen Flow Diagram (See Display Acronym Definitions on pages 4-4 to 4-6)
CSR40SL Semi-Hermetic, February 2000
4-26
Shutdown Alarm fault occurs during a Pretest
test, the Alarm LED FLASHES and the controller
stops all unit operation. Press the ALARM key to
display any fault codes recorded in the controller
display memory. All alarms that occur during a
pretrip test will have a hyphen (-) in front of the
code number.
Performing an Extended, Full or Single
Pretrip Test from the Pretrip Menu
To perform an Extended, Full or Single Pretrip Test:
1. Turn the unit On/Off switch ON.
NOTE: The controller will not perform an automatic pretrip test until all alarms have been corrected and cleared.
2.
3.
4.
5.
Press the SELECT key to enter menu (display shows
“MENU <--->”.
Press DOWN key until display shows “MENU PTRIP”.
Press the SELECT key to enter PTRIP menu (display
shows “PTRIP <--->”).
Press the DOWN key to view functions in submenu.
Press the UP key to scroll back through submenu.
Display shows PTRIP and submenu function (e.g. “PTRIP
ETEST”).
• To initiate an Extended Pretrip Test:
a.
b.
c.
d.
µP-D Controller
Menu Pretrip Functions
Press the SELECT key with “PTRIP ETEST” in the
display.
Flashing display will show “ENTER PTRIP”.
Press the ENTER key. A flashing display will show
LOAD PTRIP. The controller then conducts an
Extended Pretrip Test.
When the test is complete, the unit shuts down.
• To initiate a Full Pretrip Test:
a.
d.
Press the SELECT key with “PTRIP FTEST” in the
display.
Flashing display will show “ENTER PTRIP”.
Press the ENTER key. A flashing display will show
LOAD PTRIP. The controller then conducts a Full
Pretrip Test.
When the test is complete, the unit shuts down.
•
To initiate a Single Pretrip Test:
a.
Enter STEST submenu by pressing the DOWN key
with “PTRIP STEST” showing in the display.
Display will show “STEST <--->”.
Press the DOWN key to view a test function in
STEST submenu. Flashing display will show
ENTER and test function (e.g. “ENTER HEAT”).
With test function you want in RIGHT display, press
the ENTER key. Left display will show LOAD while
the right display shows the test function selected.
The controller then conducts the Single Pretrip Test
selected.
When the test is complete, the display returns to the
Standard Display. The unit returns to normal operation.
b.
c.
b.
c.
d.
NOTE: When a pretrip test is complete, PASS or
FAIL is recorded in the datalogger memory.
Pretrip test results can then be viewed through
the controller’s VIEW/LOG/PT1 submenu. For
instructions on viewing the VIEW/LOG/PT1 submenu, refer to “Menu View” in this chapter.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Menu Test Functions
Menu Test Functions
•
WARNING: Activating some tests in the Menu Test
section of the controller menu causes the unit compressor and fan motors to start and operate.
The Test Menu allows technicians to perform specific diagnostic tests on the unit including:
• Electrical [ELECT]: Check the main supply power voltage and frequency; or check the ac current draw of the
•
•
4-27
heaters, motors or unit during Full Cool, Modulation 50%,
Modulation 100%, Heat and Defrost.
Refrigeration [REFRG]: Perform system diagnostics and
check supply and return air temperatures during each unit
operating mode.
Controller [CNTRL]: Perform individual control circuit
diagnostics on controller outputs. Valves, solenoids and
contactors can be energized without operating the unit or
starting the related component (e.g. motor).
Generator [GEN]: Check the main supply power voltage
and frequency provided by a genset while the unit is in
Full Cool.
MENU TEST Screen Flow Diagram (See Display Acronym Definitions on pages 4-4 to 4-6)
CSR40SL Semi-Hermetic, February 2000
4-28
NOTE: When the Test Menu is entered, the UNIT
STOPS. A technician can then select the control circuit or component to be checked/tested from the
items shown in the Test Menu.
1.
2.
3.
4.
5.
µP-D Controller
Menu Test Functions
7.
Turn the unit On/Off switch ON.
With the controller showing the Standard Display, press
the SELECT key to enter menu (display shows “MENU
<--->”.
Press DOWN key until display shows “MENU TEST”.
Press the SELECT key to enter TEST submenu (display
shows “TEST <--->”).
Press the DOWN key to view functions in submenu.
Press the UP key to scroll back through submenu. Left
display shows submenu topic “TEST” while the right display shows the sub-submenu topic (e.g. “ELECT”).
NOTE: Unit operation STOPS when display
shows “TEST ELECT”.
6.
Press SELECT key to enter a sub-submenu (display shows
“ELECT <--->”).
8.
Press the DOWN key to view functions in sub-submenu.
Press the UP key to scroll back through sub-submenu.
The display shows the test function (e.g. “AMPS/HTR”).
a. Press SELECT key to view functions in a test subsubmenu or initiate a test.
•
Display shows submenu function and value (e.g.
“HERTZ 60”).
•
Display shows test screen (e.g. HTR OFF”ON”
with HTR and ON flashing).
b. To initiate the test function, press ENTER key.
•
The display shows “HTR “OFF”ON (with HTR
and OFF flashing). The heaters should energize.
•
Inspect controller and output module indicator
LEDs and contactor to confirm operation.
c. To turn the test function OFF, press ENTER key
again.
•
Display will show “HTR OFF”ON” (with HTR
and OFF flashing).
d. Press the UP or DOWN key to scroll to another test
function or the top of the submenu.
Press and hold the SELECT key for 3 seconds to return to
the Standard Display.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Menu Guard Functions
NOTE: An access code is required to enter the
Guard menu to prevent unauthorized personnel from
tampering with the programmable features.
The Guard menu is used to set many programmable features
including:
• Unit Configuration
• Customer Configuration
• Container Identification Number
• Unit Serial Number
• Date and Time
• Unit and Special Hourmeters
• Economy Mode ECMAX and ECMIN
• Change Temperature Display Units (C/F)
• Sensor Grades
The controller turns OFF all control outputs and suspends
normal operation when the Guard menu is entered.
When the Guard Menu is exited, the controller resets and
then restarts the unit. This is necessary to be certain that all
changes in the programmable features are activated.
Menu Guard Functions
4-29
Navigating Menu Guard Screens
With the unit On/Off switch ON and the controller showing
the Standard Display:
1. Press the SELECT key to enter menu (display shows
“MENU <--->”).
2. Press DOWN key until display shows “MENU GUARD”.
3. Press the SELECT key to enter GUARD submenu (display shows “GUARD <--->”).
4. Press the DOWN key. Display shows “GUARD 0000”
with left “0” flashing. A flashing digit indicates the digit
that can be changed.
5. Enter the current access code “0007”.
a. Press and release the SELECT key three times to
scroll the flashing digit (“0”) to the right digit.
b. Press and release the DOWN key three times to scroll
the flashing digit to “7” (display now shows
“GUARD 0007”).
c. Press the ENTER key to load the code and access the
Guard menu. The display will briefly show
“GUARD LOAD” and then show “GMENU <--->”.
MENU TEST Screen Flow Diagram (See Display Acronym Definitions on pages 4-4 to 4-6)
CSR40SL Semi-Hermetic, February 2000
4-30
µP-D Controller
Menu Guard Functions
NOTE: If the correct code is not entered, the display returns to “GUARD <--->”.
6.
Press the DOWN or UP key to scroll through the menu list.
NOTE: If a new controller or new software has
been installed, proceed immediately to “Setting
the Unit Configuration and Customer
Configuration Numbers” below.
NOTE: If no key is pressed, the controller returns
to the “GMENU <--->” display from a Guard Menu
screen after 30 seconds. The display returns to
the Standard Display 10 seconds later.
Setting the Unit Configuration and
Customer Configuration Numbers
1.
2.
3.
From “GMENU <--->” in the Guard menu, press the
DOWN key until the display shows “MENU CNFIG”).
Press the SELECT key to enter Configuration submenu
(display shows “CNFIG <--->”).
Press the DOWN key until display shows “CFG U 5000”
(where “5000” is the default unit configuration when a
new controller or software is loaded).
NOTE: If the Unit Configuration has already
been set, the current number (YYYY format) will
show instead of “5000”. The Unit Configuration
MUST always be set first.
4.
5.
6.
7.
NOTE: If the Customer Configuration has
already been set, the current number (ZZ format)
will show instead of “0”. The Unit Configuration
MUST always be set first. The Customer
Configuration MUST always be set after the Unit
Configuration has been set.
Press the SELECT key to enter the load configuration display (left display flashes “CFG U”).
If the correct unit configuration is not known, check the
setup decal in the control box for the correct Unit
Configuration number. Then press the UP or DOWN key
to scroll to the correct number (number appears in right
display).
Press the ENTER key to load the configuration number
selected. The display will briefly show “CFG U LOAD”
and then show the new CFG U setting in the right display.
Press the DOWN key until display shows “CFG C
0”
(where “0” is the default customer configuration when a
new controller or software is loaded; or the Unit
Configuration is reset).
8.
Press the SELECT key to enter the load configuration display (left display flashes “CFG C”).
9. If the correct customer configuration is not known, check
the setup decal in the control box for the correct Customer
Configuration number. Then press the UP or DOWN key
to scroll to the correct number (number appears in right
display).
10. Press the ENTER key to load the configuration number
selected. The display will briefly show “CFG C LOAD”
and then show the new CFG C setting in the right display.
NOTE: If a new controller or new software has
been installed, proceed immediately to “Setting
the Container Identification Number” below.
Setting the Container Identification Number
1.
2.
3.
4.
From “CFG C ZZ” (where ZZ is your customer configuration number) in the Guard menu, press the DOWN key
until the display shows “CNFIG <--->”.
Press the SELECT key to move back to the Guard submenu (display shows “MENU CNFIG”).
Press the DOWN key until display shows “CID11 XXX”.
Digits in the right display then begin to scroll to the left as
the last two digits in the left display indicate the position
of the number that is being shown in the right display.
Press the SELECT key to enter the load Container
Identification Number display. The left display shows
“CID11” while the 11th digit flashes in the right display.
a. Press the UP or DOWN key to choose a letter (A to
Z), a number (0 to 9) or a blank space.
b. When the desired character appears in the 11th position, press the SELECT key to choose the next position. The left display shows “CID10” while the 10th
digit flashes in the right display.
c. Repeat steps a and b for each character until the
Container Identification Number is entered.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
5.
When all characters in the Container Identification
Number have been entered, press the ENTER key. The
display shows “CID LOAD” and then shows the new
number (left display shows CID11 again as the right display shows the 11th digit and begins to scroll to the left
again. Check to make sure the Container Identification
Number was entered correctly.
Menu Guard Functions
Setting the Date and Time
1.
NOTE: If a new controller or new software has
been installed, proceed immediately to “Setting
the Unit Serial Number” below.
Setting the Unit Serial Number
1.
2.
3.
From “CID 11 XXX” (where the scrolling XXX is your
container identification number) in the Guard menu, press
the DOWN key until display shows “USN11 XXX”.
Digits in the right display then begin to scroll to the left as
the last two digits in the left display indicate the position
of the number that is being shown in the right display.
Press the SELECT key to enter the load Unit Serial
Number display. The left display shows “USN11” while
the 11th digit flashes in the right display.
a. Press the UP or DOWN key to choose a letter (A to
Z), a number (0 to 9) or a blank space.
b. When the desired character appears in the 11th position, press the SELECT key to choose the next position. The left display shows “USN10” while the 10th
digit flashes in the right display.
c. Repeat steps a and b for each character until the Unit
Serial Number is entered.
When all characters in the Unit Serial Number have been
entered, press the ENTER key. The display shows “USN
LOAD” and then shows the new number (left display
shows USN11 again as the right display shows the 11th
digit and begins to scroll to the left again. Check to make
sure Unit Serial Number was entered correctly.
NOTE: If a new controller or new software has
been installed, proceed immediately to “Setting
the Date and Time” below.
4-31
2.
3.
4.
From “USN 11 XXX” (where the scrolling XXX is your
unit serial number) in the Guard menu, press the DOWN
key until the display shows “YEAR 1996”.
a. Press the SELECT key to enter the load Year display
(left display flashes “YEAR”).
b. Press the UP or DOWN key to choose the desired
year.
c. When the desired year shows in the right display,
press the ENTER key. The display shows “YEAR
LOAD” and then shows “YEAR YYYY” (where
“YYYY” is the new year).
If the year is correct, press the DOWN key until the display shows “MONTH
MM” (where “MM” is the
month).
a. Press the SELECT key to enter the load Month display (left display flashes “MONTH”).
b. Press the UP or DOWN key to choose the desired
month.
c. When the desired month shows in the right display,
press the ENTER key. The display shows “MONTH
LOAD” and then shows “MONTH MM” (where
“MM” is the new month).
If the month is correct, press the DOWN key until the display shows “DAY
DD” (where “DD” is the day).
a. Press the SELECT key to enter the load Day display
(left display flashes “DAY”).
b. Press the UP or DOWN key to choose the desired
day.
c. When the desired day shows in the right display,
press the ENTER key. The display shows “DAY
LOAD” and then shows “DAY DD” (where “DD”
is the new day).
If the day is correct, press the DOWN key until the display shows “HOUR
HH” (where “HH” is the hour).
a. Press the SELECT key to enter the load Hour display
(left display flashes “HOUR”).
b. Press the UP or DOWN key to choose the desired
hour.
c. When the desired hour shows in the right display,
press the ENTER key. The display shows “HOUR
LOAD” and then shows “HOUR HH” (where
“HH” is the new hour).
CSR40SL Semi-Hermetic, February 2000
4-32
5.
If the hour is correct, press the DOWN key until the display shows “MIN MM” (where “MM” is the minute).
a. Press the SELECT key to enter the load Minute display (left display flashes “MIN”).
b. Press the UP or DOWN key to choose the desired
minute.
c. When the desired minute shows in the right display,
press the ENTER key. The display shows “MIN
LOAD” and then shows “MIN
MM” (where
“MM” is the new minute).
NOTE: Setting the Compressor, On Time and
User Hourmeters is optional when a new controller or new software has been installed.
However, the Sensor Grades MUST be set. If you
are NOT setting the hourmeters, proceed immediately to “Setting the Sensor Grades”.
Setting the Compressor and On Time
Hourmeters
NOTE: If the values for the Compressor Run Time
Hourmeter (CHRM1) and the Unit On Hourmeter
(ONHRM) can be retrieved from the original controller, the values can be duplicated in the new controller.
1.
From “GMENU <--->” in the Guard menu, press the
DOWN key until the display shows “CHRM1 XXXX”
(where “XXXX” is the number of compressor run hours).
NOTE: If the number of compressor run hours
can not be determined, leave this setting “0000”.
Proceed to step 2.
a.
2.
µP-D Controller
Menu Guard Functions
Press the SELECT key to enter the load Compressor
Hourmeter display (left display flashes “CHRM1”).
b. Press the UP or DOWN key to choose the desired
hour setting.
c. When the desired hours show in the right display,
press the ENTER key. The display shows “CHRM1
LOAD” and then shows “CHRM1 XXXX” (where
“XXXX” is the new compressor run hours).
From “CHRM1 XXXX” in the controller display, press
the DOWN key until the display shows “ONHRM
XXXX” (where “XXXX” is the number of unit on hours).
a.
b.
c.
Press the SELECT key to enter the load Compressor
Hourmeter display (left display flashes “ONHRM”).
Press the UP or DOWN key to choose the desired
hour setting.
When the desired hours show in the right display,
press the ENTER key. The display shows “ONHRM
LOAD” and then shows “ONHRM XXXX” (where
“XXXX” is the new Unit On hours).
Setting the User Hourmeter Types, User
Hourmeter Thresholds and User
Hourmeters
NOTE: The procedure for setting H1TYP, H2TYP,
H3TYP and H4TYP is the same. The procedure for
setting UHMT1, UHMT2, UHMT3 and UHMT4 is the
same. The procedure for setting UHRM1, UHRM2,
UHRM3 and UHRM4 is also the same. However, if
the number of accumulated hours can not be determined, leave UHRM1, UHRM2, UHRM3 and UHRM4
settings at “0000”.
1.
From “GMENU <--->” in the Guard menu, press the
DOWN key until the display shows “H1TYP XX”
(where “XX” is the hourmeter type).
a. Press the SELECT key to enter the load User
Hourmeter Type display (left display flashes
“H1TYP”).
b. Press the UP or DOWN key to choose the desired
type setting.
Type
Code
0
1
2
3
4
5
6
7
8
9
10
11
12
13
Description
Timer Turned OFF
Evaporator Fan Low Speed Run Time
Evaporator Fan High Speed Run Time
Not Used
Condenser Fan High Speed Run Time
Full Cool Mode Run Time
Modulation Cool Mode Run Time
Null Mode Time
Heat Mode Run Time
Defrost Mode Run Time
Warm Gas Bypass ON Time
Power Limit ON Time
Liquid Injection ON Time
Heaters ON Time
NOTE: If the number of unit on hours can not be
determined, leave this setting “0000”.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
c.
2.
3.
When the desired type number shows in the right display, press the ENTER key. The display shows
“H1TYP LOAD” and then shows “H1TYP XXXX”
(where “XXXX” is the new type setting).
From “H1TYP XXXX” in the controller display, press
the DOWN key until the display shows “UHMT1 XX”
(where “XX” is the number of threshold hours).
a. Press the SELECT key to enter the load User
Hourmeter Threshold display (left display flashes
“UHMT1”).
b. Press the UP or DOWN key to choose the desired
threshold setting.
c. When the desired threshold hours show in the right
display, press the ENTER key. The display shows
“UHMT1 LOAD” and then shows “UHMT1 XX”
(where “XX” is the new threshold hours).
From “UHMT1 XX” in the controller display, press the
DOWN key until the display shows “UHRM1 XXXX”
(where “XXXX” is the number of accumulated user
hours).
NOTE: If the number of accumulated user hours
can not be determined, leave this setting “0000”.
a.
b.
c.
Press the SELECT key to enter the load User
Hourmeter display (left display flashes “UHRM1”).
Press the UP or DOWN key to choose the desired
hour setting.
When the desired hours show in the right display,
press the ENTER key. The display shows “UHRM1
LOAD” and then shows “UHRM1 XXXX” (where
“XXXX” is the new accumulated user hours).
Menu Guard Functions
4-33
Setting the Sensor Grades
The Menu Grade submenu (MENU GUARD) displays the sensor grade of each graded sensor installed on the unit.
NOTE: If a sensor grade is set to “0”, it means the
sensor has been ice bath calibrated. Original unit
sensors are ice bath calibrated at the factory and
Thermo King recommends ice bath calibration when
replacing the Return Air, Supply Air and Coil
Temperature Sensors. If an ice bath is NOT available,
the controller should be set to the “grade” stamped
on each individual sensor.
The Ambient Temperature Sensor and Condenser Coil
Temperature Sensor are ungraded sensors and may be calibrated if desired. However, because they are NOT controlling sensors, they do not require calibration. If you do NOT calibrate
these ungraded sensors, the ambient sensor and condenser coil
sensor grades should be set to “5”.
Ice Bath Preparation:
• The ice bath should consist 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.
• Stir the ice bath briskly for one minute before proceeding.
• Insert the sensors to be calibrated in the ice bath. Wait 5
minutes to allow the sensor temperatures to stabilize at 0
C (32 F).
• Stir the ice bath frequently while testing and verify ice
bath temperature with a mercury-in-glass thermometer.
Stirring 10 seconds every 3 minutes during the test procedure is adequate.
NOTE: To set the sensor grades, you will need the
sensor grade number recorded on the setup decal in
the control box. If there is any question about the
actual grade of a sensor, physically check the sensor. The grade will be stamped on the side of the
sensor.
1.
2.
3.
From “GMENU <--->” in the Guard menu, press DOWN
key until display shows “MENU GRADE”.
Press the SELECT key to enter GRADE submenu (display
shows “GRADE <--->”).
Press the DOWN key until “RETG
XX” shows in the
display (where “XX” is the sensor grade).
a. Press the SELECT key to enter the load Sensor Grade
display (left display flashes “RETG”).
CSR40SL Semi-Hermetic, February 2000
4-34
b.
µP-D Controller
Menu Guard Functions
To calibrate the sensor in an ice bath:
•
Press the UP or DOWN key to choose “0” as the
grade setting in the right display.
•
Press the ENTER key. Right display briefly
shows “CALIB” and then the sensor (ice bath)
temperature.
•
When the sensor temperature is within 1.7 C [3
F] above or below 0 C (32 F), the left display
(“RET”) begins to flash.
•
Observe the sensor temperature in the right display. When the temperature has been stable for
5 minutes, press the ENTER key. Right display
briefly shows “LOAD” and then the sensor temperature.
c.
5.
NOTE: The sensor should be in the ice bath
a total of 15 minutes or more to assure the
sensor temperature has bottomed out.
4.
c. To set the sensor grade:
•
Press the UP or DOWN key to choose the
desired grade setting.
•
When the desired grade shows in the right display, press the ENTER key. Right display briefly
shows “LOAD” and then the new sensor grade).
Press the DOWN key until “SUPG
XX” shows in the
display (where “XX” is the sensor grade).
a. Press the SELECT key to enter the load Sensor Grade
display (left display flashes “SUPG”).
b. To calibrate the sensor in an ice bath:
•
Press the UP or DOWN key to choose “0” as the
grade setting in the right display.
•
Press the ENTER key. Right display briefly
shows “CALIB” and then the sensor (ice bath)
temperature.
•
When the sensor temperature is within 1.7 C [3
F] above or below 0 C (32 F), the left display
(“SUP”) begins to flash.
•
Observe the sensor temperature in the right display. When the temperature has been stable for
5 minutes, press the ENTER key. Right display
briefly shows “LOAD” and then the sensor temperature.
NOTE: The sensor should be in the ice bath
a total of 15 minutes or more to assure the
sensor temperature has bottomed out.
To set the sensor grade:
•
Press the UP or DOWN key to choose the
desired grade setting.
•
When the desired grade shows in the right display, press the ENTER key. Right display briefly
shows “LOAD” and then the new sensor grade).
Press the DOWN key until “ECTG
XX” shows in the
display (where “XX” is the sensor grade).
a. Press the SELECT key to enter the load Sensor Grade
display (left display flashes “ECTG”).
b. To calibrate the sensor in an ice bath:
•
Press the UP or DOWN key to choose “0” as the
grade setting in the right display.
•
Press the ENTER key. Right display briefly
shows “CALIB” and then the sensor (ice bath)
temperature.
•
When the sensor temperature is within 1.7 C [3
F] above or below 0 C (32 F), the left display
(“ECT”) begins to flash.
•
Observe the sensor temperature in the right display. When the temperature has been stable for
5 minutes, press the ENTER key. Right display
briefly shows “LOAD” and then the sensor temperature.
NOTE: The sensor should be in the ice bath
a total of 15 minutes or more to assure the
sensor temperature has bottomed out.
c.
6.
To set the sensor grade:
•
Press the UP or DOWN key to choose the
desired grade setting.
•
When the desired grade shows in the right display, press the ENTER key. Right display briefly
shows “LOAD” and then the new sensor grade).
Press the DOWN key until “CCTG
XX” shows in the
display (where “XX” is the sensor grade).
a. Press the SELECT key to enter the load Sensor Grade
display (left display flashes “CCTG”).
b. To calibrate the sensor in an ice bath:
•
Press the UP or DOWN key to choose “0” as the
grade setting in the right display.
•
Press the ENTER key. Right display briefly
shows “CALIB” and then the sensor (ice bath)
temperature.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
•
•
When the sensor temperature is within 1.7 C [3
F] above or below 0 C (32 F), the left display
(“CCT”) begins to flash.
Observe the sensor temperature in the right display. When the temperature has been stable for
5 minutes, press the ENTER key. Right display
briefly shows “LOAD” and then the sensor temperature.
NOTE: The sensor should be in the ice bath
a total of 15 minutes or more to assure the
sensor temperature has bottomed out.
8.
9.
c.
7.
To set the sensor grade:
•
Press the UP or DOWN key to choose the grade
setting “5”.
•
When the desired grade shows in the right display, press the ENTER key. Right display briefly
shows “LOAD” and then the new sensor grade).
Press the DOWN key until “AMTG
XX” shows in the
display (where “XX” is the sensor grade).
a. Press the SELECT key to enter the load Sensor Grade
display (left display flashes “AMTG”).
b. To calibrate the sensor in an ice bath:
•
Press the UP or DOWN key to choose “0” as the
grade setting in the right display.
•
Press the ENTER key. Right display briefly
shows “CALIB” and then the sensor (ice bath)
temperature.
•
When the sensor temperature is within 1.7 C [3
F] above or below 0 C (32 F), the left display
(“AMT”) begins to flash.
•
Observe the sensor temperature in the right display. When the temperature has been stable for
5 minutes, press the ENTER key. Right display
briefly shows “LOAD” and then the sensor temperature.
Menu Guard Functions
NOTE: The sensor should be in the ice bath
a total of 15 minutes or more to assure the
sensor temperature has bottomed out.
c.
4-35
Press the DOWN key until “SPR1G
XX” shows in the
display (where “XX” is the sensor grade).
a. Press the SELECT key to enter the load Sensor Grade
display (left display flashes “SPR1G”).
b. Press the UP or DOWN key to choose the desired
grade setting.
c. When the desired grade shows in the right display,
press the ENTER key. The display shows “SPR1G
LOAD” and then shows “SPR1G XX” (where
“XX” is the new sensor grade).
Repeat step 8 for each additional spare sensor shown on
the setup sheet and installed on the unit.
NOTE: Return controller to the Standard Display
by pressing and holding the SELECT key for 3
seconds. Then enter the MENU VIEW or MENU
GUARD to check the accuracy of all settings.
Changing the Display Units (C/F)
NOTE: The C/F units shown on the controller display can also be changed by pressing and holding
the C/F key, and then pressing the ENTER key.
1.
2.
3.
4.
From “GMENU <--->” in the Guard menu, press the
DOWN key until the display shows “C/F
X”).
Press the SELECT key to enter the load configuration display (left display flashes “C/F”).
Press the UP or DOWN key to scroll to the desired temperature unit (C = Celsius, F = Fahrenheit).
Press the ENTER key to load the configuration unit
selected. The display will briefly show “C/F LOAD”
and then show the new C/F setting in the right display.
NOTE: Return the controller to the Standard
Display by pressing and holding the SELECT key
for 3 seconds. Then check to be sure that the
display shows the correct temperature unit.
To set the sensor grade:
•
Press the UP or DOWN key to choose the grade
setting “5”.
•
When the desired grade shows in the right display, press the ENTER key. Right display briefly
shows “LOAD” and then the new sensor grade).
CSR40SL Semi-Hermetic, February 2000
4-36
µP-D Controller
Menu Program Functions
Menu Program Functions
NOTE: When the unit is OFF, the following options
default to OFF after 48 hours (v11.71 to 11.73 software) or 96 hours (v11.74 and above software): Bulb
Mode, Dehumidify, Economy Mode, Humidify, Pulp
Mode and USDA Mode.
The Program Menu allows technicians to set specific control
functions.
• Turn the unit On-Off switch ON or operate controller
using battery power.
• Press the SELECT key to enter menu (display shows
“MENU <--->”.
• Press DOWN key until display shows “MENU PRGRM”.
• Press the SELECT key to enter PRGRM submenu (display shows “PRGRM <--->”).
• Press and hold the SELECT key for 3 seconds to return to
the Standard Display.
Program Menu List
<---> Top of menu
USDA USDA sensor recording (3 or 4 sensors) On/Off
USDA1 Spare 1 sensor On/Off
USDA2 Spare 2 sensor On/Off
USDA3 Spare 3 sensor On/Off
PULP Pulp recording On/Off
ECON Economy mode On/Off
HUM Dehumidify or Humidify On/Off
– HUMSP = Enter Humidity setpoint (50% to 100%)
BULB Bulb mode On/Off
– BDFTT = Enter Bulb mode defrost termination
temperature
– BEFAN = Enter Bulb mode evaporator fan speed
(high, low or cycle)
PWREDPower Reduction 1, 2 or 3
USDA Sensors
Changing the USDA program screen from OFF to ON activates spare sensors 1, 2 and 3 for USDA Cold Treatment
Temperature Recording. USDA sensor temperatures are
recorded in the data logger 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 the sensors and activate data logging. The controller
Program menu shows the USDA sensor number in the left display and “AUTO” in the right display if data logging is active.
However, the USDA program screen MUST be set to ON and
each USDA sensor MUST be calibrated to comply with
USDA temperature recording requirements. Calibrate the sensors in an ice bath. The µP-D controller requires a USDA sensor, P/N 41-3107.
Ice Bath Preparation
1.
2.
3.
4.
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.
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 while testing and verify ice
bath temperature with a mercury-in-glass thermometer.
Stirring 10 seconds every 3 minutes during the test procedure is adequate.
MENU PROGRAM Screen Flow Diagram (See Display Acronym Definitions on pages 4-4 to 4-6)
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Menu Program Functions
NOTE: The sensors should be in the ice bath
a total of 15 minutes or more to assure the
sensor temperature has bottomed out.
Setting and Calibrating the USDA Sensors
1.
Insert all USDA sensors in an ice bath (see “Ice Bath
Preparation” above).
g.
NOTE: The sensors must be completely
immersed in the ice bath without contacting the
walls of the ice bath container for 5 minutes.
2.
3.
4.
5.
6.
7.
8.
9.
Press the SELECT key to enter menu (display shows
“MENU <--->”.
Press DOWN key until display shows “MENU PRGRM”.
Press the SELECT key to show “PRGRM <--->”.
Press the UP or DOWN key until the display shows the
current “USDA” setting:
• “USDA OFF”
• “USDA ON”
To change the current setting, press SELECT key.
“USDA” will begin to flash in the left display.
Press the UP or DOWN key to scroll the right display to
the desired setting.
To load the new setting, press the ENTER key. The display briefly shows “USDA LOAD”.
When the USDA mode is turned ON, the display then
shows “USDA ON”. Each USDA sensor must now be
calibrated for accurate temperature recording. To calibrate the USDA1 sensor:
a. Press the DOWN key to show “USDA1 ON” in the
display.
b. To calibrate the USDA1 sensor, press the SELECT
key. “USDA1” will begin to flash in the left display.
c. Press the UP or DOWN key to show “CAL” in the
right display.
d. Press the ENTER key. The display briefly shows
“USDA1 CALIB”. The left display then shows
“USDA1” and the right display shows the sensor temperature (“00.0 C”).
e. When USDA1 sensor temperature is within 1.7 C [3
F] above or below 0 C (32 F), the left display
(“USDA1”) begins to flash.
f. Observe the sensor temperature in the right display.
When the temperature has been stable for 5 minutes,
press the ENTER key. The display briefly shows
“USDA1 LOAD”, then “USDA1” and the sensor
temperature (“00.0 C”), and returns to the “USDA1
ON” display.
4-37
Repeat steps 8a through 8f to calibrate the USDA2
and USDA3 sensors.
NOTE: Press and hold the SELECT key for 3 seconds to return to the Standard Display.
PULP Sensor (Option)
Changing the PULP program screen from OFF to ON activates
the PULP (spare 5 sensor) temperature recording. PULP sensor temperatures are recorded in the data logger memory.
The Pulp sensor should be connected to the controller and
located in the load as specified by the customer and/or shipping company. When a PULP sensor is installed, the controller will automatically detect the sensor and activate data
logging. The controller Program menu shows the “PULP” in
the left display and “AUTO” in the right display if data logging is active. However, the PULP program screen MUST be
set to ON and the sensor MUST be calibrated to accurately
record temperature. Calibrate the sensor in an ice bath (see
“Ice Bath Preparation” under USDA Sensors in this chapter).
Setting and Calibrating the Pulp Sensor
1.
Insert Pulp sensor in an ice bath (see “Ice Bath
Preparation” above).
NOTE: The sensor must be completely immersed
in the ice bath without contacting the walls of the
ice bath container for 5 minutes.
2.
3.
4.
5.
6.
7.
Press the SELECT key to enter menu (display shows
“MENU <--->”.
Press the UP key until display shows “MENU PRGRM”.
Press the SELECT key to show “PRGRM <--->”.
Press the UP or DOWN key to show the current “PULP”
setting:
• “PULP OFF”
• “PULP ON”
To change the current setting, press SELECT key.
“PULP” will begin to flash in the left display.
Press the UP or DOWN key to scroll the right display to
the desired setting.
CSR40SL Semi-Hermetic, February 2000
4-38
8.
9.
µP-D Controller
Menu Program Functions
To load the new setting, press the ENTER key. The display briefly shows “PULP LOAD”.
When the PULP mode is turned ON, the display then
shows “PULP ON”. The PULP sensor must now be calibrated for accurate temperature recording. To calibrate
the PULP sensor:
a. To calibrate the PULP sensor, press the SELECT key
while “PULP ON” appears in the display. “PULP”
will begin to flash in the left display.
b. Press the UP or DOWN key to show “CAL” in the
right display.
c. Press the ENTER key. The display briefly shows
“PULP CALIB”. The left display then shows
“PULP1” and the right display shows the sensor temperature (“00.0 C”).
d. When PULP1 sensor temperature is within 1.7 C [3
F] above or below 0 C (32 F), the left display
(“PULP1”) begins to flash.
e. Observe the sensor temperature in the right display.
When the temperature has been stable for 5 minutes,
press the ENTER key. The display briefly shows
“PULP1 LOAD”, then “PULP1” and the sensor temperature (“00.0 C”), and returns to the “PULP ON”
display.
•
•
Chill Loads (return air temperatures of -9.9 C (14.1 F) and
above): Evaporator fans operate on low speed whenever
the container temperature is In-range.
Frozen Loads (return air temperatures of -10 C (14 F) and
below): Unit continues on Cool operation until return air
temperature reaches ECMIN temperature. Default ECMIN
setting is 2.0 C (3.6 F) below setpoint. ECMIN temperature is adjustable from 0 to 10 C (0 to 18 F) below setpoint through the Guard menu of the controller.
The evaporator fans stop during the Null mode (on
frozen loads). A null state timer automatically starts and
operates the evaporator fans on low speed for 5 minutes
every 45 minutes. The unit remains in Null until the
return air temperature increases to ECMAX temperature
and a 45 minute Null state time sequence expires. Default
ECMAX setting is 1.0 C (1.8 F) above setpoint. ECMAX
setting is adjustable from 0 to 10 C (0 to 18 F) above setpoint through the Guard menu of the controller.
NOTE: See “Menu Guard” for detailed information
about changing ECMIN and ECMAX from the default
settings.
Setting the Economy Mode
NOTE: The sensors should be in the ice bath
a total of 15 minutes or more to assure the
sensor temperature has bottomed out.
NOTE: Press and hold the SELECT key for 3 seconds to return to the Standard Display.
Economy Mode
The Economy Mode reduces unit power consumption by
reducing evaporator fan operation. On frozen loads, the
Economy mode also modifies the temperature control algorithm to extend the Null mode. The use of the Economy Mode
should be established by the shipper and the type of cargo.
The Economy Mode option is turned on from Program menu
of the controller.
NOTE: If the Economy Mode is set to ON, the controller display will show “ECON ON” for 1 second
every 10 seconds.
1.
2.
3.
4.
5.
6.
7.
Press the SELECT key to enter menu (display shows
“MENU <--->”.
Press UP key until display shows “MENU PRGRM”.
Press the SELECT key to show “PRGRM <--->”.
Press the UP or DOWN key until the display shows the
current setting:
• “ECON OFF”
• “ECON ON”
To change the current setting, press SELECT key.
“ECON” will begin to flash in the left display.
Press the UP or DOWN key to scroll the right display to
the desired setting.
To load the new setting, press the ENTER key. The display briefly shows “ECON LOAD”. When the Economy
mode is turned ON, the display then shows “ECON ON”.
NOTE: Press and hold the SELECT key for 3 seconds to return to the Standard Display.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Dehumidify Mode (Option)
The Dehumidify Mode reduces the humidity level in the container by condensing more moisture from the container air.
More moisture is condensed from the air by lowering the evaporator coil temperature. The use of the Dehumidify Mode
should be established by the shipper. The Dehumidify Mode
option is turned on from the Program menu of the controller.
NOTE: If the Dehumidify Mode is set to ON, the controller display will show “DEHUM” in the left display
and the container humidity level (e.g. “74.5”) in the
right display for 1 second every 10 seconds.
When the Dehumidify Mode is ON:
• The supply air temperature must be In-range before the
controller will operate the dehumidify function.
• When the dehumidify function is operating (dehumidify
valve energized), the supply air LED will flash ON and
OFF.
• The controller energizes (closes) the dehumidify valve
when the humidity level in the container is between 1%
and 5% above the humidity setpoint. This reduces the
size of the evaporator providing cooling by 50%, causing
the coil to become colder and condense more moisture
from the container air.
• The controller energizes (closes) the dehumidify valve
and pulses the electric heaters ON and OFF when the
humidity level in the container is 5% or more above the
humidity setpoint. This increases the cooling load and
causes the evaporator coil to become even colder, condensing more moisture from the container air.
Setting the Dehumidify Mode
1.
2.
3.
4.
Press the SELECT key to enter menu (display shows
“MENU <--->”.
Press UP key until display shows “MENU PRGRM”.
Press the SELECT key to show “PRGRM <--->”.
Press the UP or DOWN key until the display shows the
current “HUMID” setting:
• “HUMID OFF”.
• “HUMID DEHUM” — Dehumidify option is ON.
• “HUMID HUM” — Humidify option is ON.
NOTE: The Dehumidify and Humidify option
screens do not appear unless the unit is
equipped with the option and the controller is set
to the correct unit configuration. Also, the
Dehumidify and Humidify options can NOT be
turned ON at the same time.
Menu Program Functions
5.
6.
7.
8.
4-39
To change the current setting, press the SELECT key.
“HUMID” will begin to flash in the left display.
Press the UP or DOWN key to scroll the right display to
the desired setting: “DEHUM”, “HUM” or “OFF”.
To load the new setting, press the ENTER key. The display briefly shows “HUMID LOAD”.
When the Dehumidify mode is turned ON, the left display
shows “HUMSP” and the right display shows the current
humidity setpoint in percent (e.g. “85.0”). To change the
humidity setpoint:
a. Press the SELECT key. “HUMSP” will flash in the left
display.
b. Press the UP or DOWN key to adjust the humidity
setpoint to the desired setting (see shipping manifest).
The right display scrolls up or down to the new
humidity setpoint in percent (e.g. “70.0”).
c. To load the new setpoint, press the ENTER key. The
display briefly shows “HUMSP LOAD”. The new
humidity setpoint then shows in the right display (e.g.
“70.0”).
NOTE: Press and hold the SELECT key for 3 seconds to return to the Standard Display.
Humidify Mode (Option)
The Humidify Mode increases the humidity level in the container by injecting atomized water directly into the evaporator
supply air stream. The use of the Humidify Mode should be
established by the shipper. The Humidify Mode option is
turned on from the Program menu of the controller.
NOTE: If the Humidify Mode is set to ON, the controller display will show “HUM” in the left display
and the container humidity level (e.g. “74.5”) in the
right display for 1 second every 10 seconds.
When the Humidify Mode is ON:
• The evaporator fans must be ON before the controller will
operate the humidify function.
• When the humidify function is operating (air compressor
energized), the supply air LED will flash ON and OFF.
• The controller energizes (operates) the air compressor
when the humidity level in the container is more than 2%
below the humidity setpoint. The air compressor atomizes
and injects water into the evaporator supply air stream to
add moisture to the container air.
CSR40SL Semi-Hermetic, February 2000
4-40
µP-D Controller
Menu Program Functions
Setting the Humidify Mode
Bulb Mode (Option)
1.
Changing the Bulb screen from OFF to ON automatically activates the Dehumidify Mode and allows the defrost termination
temperature and evaporator fan speed to be set. The use of the
Bulb Mode should be established by the shipper. When the
Bulb Mode is ON:
• The Dehumidify Mode is ON. See “Dehumidify Mode
(Option)” on page 4-39 for a description of the dehumidify system operation.
• The defrost termination temperature (“BDFTT”) can be
adjusted from 4 to 30 C (40 to 86 F). Lower defrost termination settings may result in less warming of the cargo
during defrost.
• The evaporator fan speed (“BEFAN”) can be set to High
Speed, Low Speed or Cycle (fans cycle between high and
low speed every 60 minutes).
2.
3.
4.
Press the SELECT key to enter menu (display shows
“MENU <--->”.
Press UP key until display shows “MENU PRGRM”.
Press the SELECT key to show “PRGRM <--->”.
Press the UP or DOWN key until the display shows the
current “HUMID” setting:
• “HUMID OFF”.
• “HUMID DEHUM” — Dehumidify option is ON.
• “HUMID HUM” — Humidify option is ON.
NOTE: The Dehumidify and Humidify option
screens do not appear unless the unit is
equipped with the option and the controller is set
to the correct unit configuration. Also, the
Dehumidify (or Bulb) and Humidify options can
NOT be turned ON at the same time.
5.
6.
7.
8.
To change the current setting, press the SELECT key.
“HUMID” will begin to flash in the left display.
Press the UP or DOWN key to scroll the right display to
the desired setting: “DEHUM”, “HUM” or “OFF”.
To load the new setting, press the ENTER key. The display briefly shows “HUMID LOAD”.
When the Humidify mode is turned ON, the left display
shows “HUMSP” and the right display shows the current
humidity setpoint in percent (e.g. “70.0”). To change the
humidity setpoint:
a. Press the SELECT key. “HUMSP” will flash in the left
display.
b. Press the UP or DOWN key to adjust the humidity
setpoint to the desired setting (see shipping manifest).
The right display scrolls up or down to the new
humidity setpoint in percent (e.g. “85.0”).
c. To load the new setpoint, press the ENTER key. The
display briefly shows “HUMSP LOAD”. The new
humidity setpoint then shows in the right display (e.g.
“85.0”).
NOTE: Press and hold the SELECT key for 3 seconds to return to the Standard Display.
NOTE: If the Bulb Mode is set to ON, the controller display will show “BULB ON” for 1 second every 10 seconds. Also, the display will
show “DEHUM” in the left display and the container humidity level (e.g. “74.5”) in the right display for 1 second every 10 seconds. Also, the
Bulb and Humidify options can NOT be turned
ON at the same time.
Setting the Bulb Mode
1.
2.
3.
4.
5.
6.
7.
Press the SELECT key to enter menu (display shows
“MENU <--->”.
Press DOWN key until display shows “MENU PRGRM”.
Press the SELECT key to show “PRGRM <--->”.
Press the UP or DOWN key to show the current setting:
• “BULB OFF”
• “BULB ON”
To change the current setting, press SELECT key.
“BULB” will begin to flash in the left display.
Press the UP or DOWN key to scroll the right display to
the desired setting.
To load the new setting, press the ENTER key. The display briefly shows “BULB LOAD”. When the Bulb
Mode is turned ON, the display then shows “BULB ON”.
NOTE: Setting the Bulb mode to OFF does not
automatically set the Dehumidify mode to OFF
too. To de-activate Dehumidify operation, see
“Dehumidify Mode” earlier in this chapter.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
8.
9.
When the Bulb mode is ON, the defrost termination temperature screen “BDFTT” appears in the Program menu.
To change the defrost termination temperature:
a. With “BULB ON” in the display, press the DOWN
key to scroll to the “BDFTT” screen. The current setting appears in the right display (factory default is
30.0 C (86.0 F).
b. Press the SELECT key. “BDFTT” will flash in the
left display.
c. Press the UP or DOWN key to adjust the defrost termination temperature to the desired setting (see shipping manifest). The right display scrolls up or down
to the new temperature setting (e.g. “20.0”).
d. To load the new temperature, press the ENTER key.
The display briefly shows “BDFTT LOAD”.
e. The display then shows “BEFAN” in the left display
and the current evaporator fan speed selection in the
right display (e.g. “HI”).
When the Bulb mode is ON, the current evaporator fan
speed screen “BEFAN” appears in the Program menu. To
change the fan speed selection:
a. With “BULB ON” in the display, press the DOWN
key to scroll to the “BDFTT” screen. If a new defrost
termination temperature was set, the “BEFAN”
screen already appears. The current setting appears in
the right display (factory default is HI).
b. Press the SELECT key. “BEFAN” will flash in the
left display.
c. Press the UP or DOWN key to adjust the evaporator
fan speed to the desired setting (see shipping manifest): “HI”, “LO” or “CYCLE”.
d. To load the new setting, press the ENTER key. The
display briefly shows “BEFAN LOAD”. The display
then shows “BEFAN” in the left display and the current fan speed selection in the right display (e.g.
“CYCLE”).
NOTE: Press and hold the SELECT key for 3 seconds to return to the Standard Display.
Menu Program Functions
4-41
Power Reduction Mode
Changing the Power Reduction program screen from OFF to
ON activates the power reduction control algorithm that
reduces total unit electric power consumption for 8 hours. The
use of the Power Reduction Mode should be established by the
shipper. When the Power Reduction Mode is ON:
• The controller reduces the electric power consumption by
the percent selected: 10%, 20% or 30%.
NOTE: When the Power Reduction Mode is active,
the controller display will briefly show “PWRED ON”
every 10 seconds.
Setting the Power Reduction Mode
1.
2.
3.
4.
5.
6.
Press the SELECT key to enter menu (display shows
“MENU <--->”.
Press DOWN key until display shows “MENU PRGRM”.
Press the SELECT key to show “PRGRM <--->”.
Press the DOWN key to show the current setting,
“PWRED 0” (OFF); or “PWRED 1”, “PWRED 2”,
“PWRED 3” (ON).
Press SELECT key. “PWRED” will begin to flash.
Press the UP or DOWN key to scroll the right display to
the desired setting:
• 0 = OFF
1 = 10% Power Reduction
2 = 20% Power Reduction
3 = 30% Power Reduction
NOTE: The cooling capacity of the unit may be
reduced when the Power Reduction Mode is
active. The greater the reduction in electric
power (e.g. “2” or “3” setting), the greater the
likelihood of unit cooling capacity reduction. The
use of the Power Reduction Mode should be
established by the shipper.
7.
Press the ENTER key to load the power reduction setting
selected. The display briefly shows “PWRED LOAD”.
Left display then shows “PWRED” and the right display
shows the new power reduction setting (e.g. “1”).
NOTE: Press and hold the SELECT key for 3 seconds to return to the Standard Display.
CSR40SL Semi-Hermetic, February 2000
4-42
µP-D Controller
Controller Emergency Bypass Procedure
COMPLETE stop. Then place the Phase Rotation
switch in the CBA position. Check condenser airflow
again to confirm that air is blowing out from the center of the grille.
Controller Emergency Bypass Procedure
In the event the controller fails or the serial communications
link between the output module and the controller fails, the
output module will operate the unit as follows:
• Chill (Fresh) Loads: Output module STOPS all compressor
and fan motor operation.
• Frozen Loads: Output module operates unit in Full Cool
mode.
In the event of an emergency situation where the Output
Module also fails and replacement parts are not available, the
Emergency Bypass Module may be used to manually control
the unit.
8.
Use the Mode Switch to set unit operation for Evaporator
Fan Only or Full Cool operation.
CAUTION: The unit must be cycled manually to
maintain the desired temperature. Monitor container temperature using the controller display (if
working) or an external thermometer.
WARNING: High voltage (460/380 volts) is present on
the contactors and relays in the control box. To prevent dangerous electrical shock, disconnect the supply power to the unit whenever possible when working in this area.
1.
2.
3.
Turn the Unit On/Off switch to OFF.
Disconnect the unit power cord from the power supply.
Disconnect wire harness connector “C1” from the bottom
of the Output Module and connect it to the bottom of the
Emergency Bypass Module.
NOTE: Make sure the Phase Rotation Switch on
the Emergency Bypass Module is OFF.
4.
5.
6.
7.
Connect the unit power cord to the proper power supply.
Turn the Unit On/Off switch to ON. The VIN LED on the
Emergency Bypass Module will turn ON to indicate
power is available at the module.
Place the Phase Rotation Switch in the ABC position to
start the unit.
a. Place the Mode Switch to Full Cool position to operate compressor and condenser fan. Check condenser
fan airflow. Air should be blowing out from the center of the grille.
b. If air is NOT blowing out from the center of the
grille, place the Phase Rotation switch in the OFF
position. Allow the motors and fans to come to a
Emergency Bypass Module
1.
2.
3.
4.
5.
6.
VIN LED
Mode Switch
High Pressure Cutout (HPCO) LED
24 Vac LED
Phase Rotation Switch
Attach Wire Harness Connector C1 Here
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
9.
High Pressure Cutout (HPCO) and 24 Vac LEDs on the
Emergency Bypass Module turn ON to indicate normal
operation.
• The HPCO LED is ON when the HPCO switch is
closed (normal) and turns OFF when the HPCO
switch is open (high discharge pressure).
• THE 24 Vac LED is ON when 24 volt ac control
power is supplied to the Emergency Bypass Module
for Emergency Bypass unit operation.
NOTE: If emergency bypass procedures are used
under high ambient and high container (load) temperature conditions, a compressor motor shutdown
may occur (indicating the compressor motor internal
overload protector has tripped). Wait a few minutes
to allow the overload protector to cool.
Output Module
4-43
Output Module
The controller uses the output module to energize and de-energize unit contactors and solenoids. Controller commands are
transmitted from the controller to the output module through
the CAN terminal using serial communications commands.
Indicator LEDs on the Output Module turn ON to show an
output is energized. The RXD and TXD LEDs alternately flash
continuously to show the communications connection is good.
If one or both of the RXD and TXD LEDs do NOT flash, the
communications connection is open or defective. The output
module contains no user serviceable parts.
In the event the controller fails or the serial communications link between the output module and the controller fails,
the output module will operate the unit as follows:
• Chill (Fresh) Loads: Output module STOPS all compressor
and fan motor operation.
• Frozen Loads: Output module operates unit in Full Cool
mode.
Thermo Bus Tap
Serial communications commands are transmitted from the µPD controller through the Thermo Bus Tap to the Output Module
on two wires (labeled blue and white). An open or defective
communications circuit is indicated when one or both of the
RXD and TXD LEDs on the Output Module do NOT flash.
In the event the serial communications link between the
output module and the controller fails, the output module will
operate the unit as follows:
• Chill (Fresh) Loads: Output module STOPS all compressor
and fan motor operation.
• Frozen Loads: Output module operates unit in Full Cool
mode.
Power Module
The power module supplies low voltage control power and
ground to the µP-D controller and the Output Module. The
power module also supplies power to the modulation valve circuit and the serial communications line. Fuses on the printed
circuit board provide current overload protection to the unit
control circuits. The power module derives power from the
control power transformer. Always disconnect the main supply
power before working on the power module board.
µP-D Output Module
CSR40SL Semi-Hermetic, February 2000
4-44
Replacing the µP-D Controller
Replacing the µP-D Controller
CAUTION: When replacing a controller, correct unit
operation requires that the Unit Configuration, Customer Configuration and programmable Sensor Grades
be set to the UNIT specific features and sensors.
A replacement controller contains default settings that allow it
to function when installed in a unit. However, CORRECT unit
operation REQUIRES that the Unit Configuration, Customer
Configuration and programmable Sensor Grades be set to the
UNIT specific features and sensors. If this information can not
be recovered from the previous controller, see the unit configuration and sensor grade information on the set up decal located on the control box door. Then program these settings
before releasing the unit for service. See “Menu Guard” section for instructions on programming the controller.
There are many other programmable features that may
need to be set to completely configure the unit to customer
specifications. Customer requirements may include features
such as the container identification number and unit serial
number. Adjust any additional programmable settings to customer requirements before releasing the unit for service.
1. Write down the Unit Configuration Number, Customer
Configuration Number, Container Identification Number,
Hourmeter settings and Sensor Grades on a blank setup
sheet. Recover as much information as possible from the
previous controller. If the previous controller is non-functional, see the setup decal located on the control box door
for the Unit Configuration Number, Customer
Configuration Number and Sensor Grades. The Unit
Serial Number is located on the Unit Nameplate.
2. Turn the unit On/Off switch OFF. Then unplug the unit
power cord from the power supply.
3. Disconnect the wire harness connectors from the back of
the controller.
4. Remove the screws that secure the controller to the control box door.
5. Remove the controller and gasket from the door.
6. Install the replacement controller and gasket in the door
using the existing hardware.
µP-D Controller
7.
Attach the wire harness connectors to the back of the controller.
NOTE: Be certain that all connectors are fully
seated until the connector rings lock.
8.
9.
Plug the unit power cord into the proper power supply.
Turn the unit On/Off switch ON. The unit should start
and the Standard Display should appear on the controller.
CAUTION: Immediately proceed to procedure for
“Setting the Unit Configuration and Customer
Configuration Numbers” in the “Menu Guard” section of this chapter. Alarm code 42 should be present in the display when the Alarm key is pressed.
This indicates that the correct Unit Configuration,
Customer Configuration and Sensor Grades must
still be set.
Temperature Sensors
All sensors should be properly installed:
• Supply sensor installs in the sensor tube next to the control
box. The sensor 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 sensor must be placed in the coil fins
between tube rows 2 and 3 in the middle of the coil.
• Condenser sensor must be placed on the left side of the condenser coil and at lest 70 mm deep between the fins.
CAUTION: Do NOT over tighten the mounting
hardware or the controller may be damaged.
CSR40SL Evaporator Coil (Defrost) Sensor Location
A.
B.
C.
Coil Support Brackets
Unit Front
Insert Sensor at least 75 mm into coil between
Tube Rows 2 and 3
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
• Ambient sensor must be placed on the bottom plate of the
right forklift pocket.
• Compressor discharge temperature sensor must be placed in
the discharge service valve manifold.
Semiconductor Type Sensors
Electronic semiconductor type temperature sensors are used
for:
• Supply Air
• Return Air
• Evaporator Coil
• Condenser Coil
• Ambient Air
Semiconductor sensors can not be checked with an ohmmeter. If an alarm code indicates a sensor failure, check the
sensor by substitution. The supply air, return air and evaporator coil sensors are graded sensors. Graded sensors can also be
ice bath calibrated. The µP-D controller will not operate correctly if the return air, supply air and evaporator coil sensors
are not ice bath calibrated or the correct sensor grades are not
in the controller.
The condenser coil and ambient air sensors are non-graded sensors. Non-graded sensor do not require ice bath calibration.
Diagnosis and Repair
4-45
Diagnosis and Repair
If the unit appears to be operating incorrectly, view any alarm
codes that may be stored in the controller display memory.
Diagnose and correct the problem associated with each alarm
code (see “Alarm Codes, Descriptions and Corrective Actions”
in this chapter).
If you have viewed and corrected these problems and the
unit still appears to be operating incorrectly, eliminate any
possibility that the problem is caused by failure of components
other than the controller.
External Cause Checks
•
•
•
•
Poor contact between male and female connector plugs
(loose connection).
Defective wire harness (broken wires, loose connections).
External electrical causes such as faulty (open or stuck)
contactors.
Malfunction of refrigeration system components.
NOTE: For complete diagnosis and corrective action
information about the controller and unit components, see the Diagnosis Manual for THERMOGUARD µP-D Microprocessor Controller, TK 41230.
Thermistor Type Sensors
Thermistor type temperature sensors are used for:
• Compressor Discharge Gas Temperature Sensor
If an alarm code indicates a failed sensor, check the sensor
by substitution.
Condenser Coil Sensor Location
A.
Insert Sensor into condenser coil between Tube
Rows 1 and 2
CSR40SL Semi-Hermetic, February 2000
4-46
µP-D Controller
Alarm Codes, Descriptions and Corrective Actions
Alarm Codes, Descriptions and Corrective Actions
Code
Description
Corrective Action
00
No Fault
• None Required
02
Ambient Temperature Sensor Failure
(Check Alarm)
• Check the sensor by selecting it using the View
menu. If the display shows [- - - -], the sensor is
defective or the circuit is open or shorted.
• Indicates a problem exists with this sensor
or its wiring. The sensor is reading out-ofrange; or appears to be open or shorted.
• This sensor does NOT require ice bath
calibration.
• Check sensor by substitution. Be sure sensor
polarity is correct.
• Continuity check circuit wiring using a high quality
multimeter. Be sure to maintain the correct polarity
or the sensor will not work.
NOTE: Do NOT use a test light or other instrument; or controller damage may result.
03
Supply Air Temperature Sensor Failure
(Check Alarm)
• Indicates a problem exists with this sensor
or its wiring. The sensor is reading out-ofrange; or appears to be open or shorted.
• Sensor Check test detected an out-of-range
condition.
• This sensor REQUIRES ice bath calibration or
correct sensor grade setup.
NOTE: If the Supply Air sensor is the
controlling sensor when it fails, the
controller continues unit operation
using the Return Air sensor.
• Check the sensor by selecting it using the RET/SUP
key (if necessary). If the display shows [- - - -], the
sensor is defective or the circuit is open or shorted.
• Check sensor for complete insertion into tube.
• Check sensor by substitution. Be sure sensor
polarity is correct. Replacement sensor MUST be
calibrated or sensor grade set.
• Continuity check circuit wiring using a high quality
multimeter. Be sure to maintain correct polarity or
the sensor will not work.
NOTE: Do NOT use a test light or other
instrument; or controller damage may result.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Code
04
Alarm Codes, Descriptions and Corrective Actions
Description
Corrective Action
KVQ Valve Thermistor Error
(Check Alarm)
• Check the KVQ valve thermistor circuit with an
ohmmeter. Good thermistor sensor should read
20,000 ohms at 20 C (78 F).
• Indicates a problem exists with the thermistor
or its wiring.
• If the Thermistor fails, the KVQ valve
actuator must be replaced.
4-47
• Continuity check circuit wiring using a high quality
ohmmeter. Be sure to maintain the correct polarity.
NOTE: Do NOT use a test light or other instrument; or controller damage may result.
NOTE: This valve is not used on CSR units.
05
Evaporator Coil Temperature Sensor Failure
(Check Alarm)
• Indicates a problem exists with this sensor
or its wiring. The sensor is reading out-ofrange; or appears to be open or shorted.
• Sensor Check test detected an out-of-range
condition.
• Controller also generates alarm in a Pretrip
test if the Evaporator Coil Sensor does not
show a decrease in temperature with only
the compressor running.
• Check the sensor by selecting it using the View
menu. If the display shows [- - - -], the sensor is
defective or the circuit is open or shorted.
• Check sensor by substitution. Be sure sensor
polarity is correct. Replacement sensor MUST be
calibrated or sensor grade set.
• Continuity check circuit wiring using a high quality
multimeter. Be sure to maintain the correct polarity
or the sensor will not work.
NOTE: Do NOT use a test light or other
instrument; or controller damage may result.
• If alarm occurs during a Pretrip test, a
dash (-) precedes the alarm code.
• This sensor REQUIRES ice bath calibration or
correct sensor grade setup.
NOTE: If the Evaporator Coil Sensor fails,
the controller continues unit operation using
other sensors and internal timers.
CSR40SL Semi-Hermetic, February 2000
4-48
Code
06
µP-D Controller
Alarm Codes, Descriptions and Corrective Actions
Description
Corrective Action
Humidity Sensor Error
(Check Alarm)
• Check the sensor by selecting it using the View
menu. If the display shows [- - - -], the sensor is
defective or the circuit is open or shorted.
• Indicates a problem exists with this sensor or
its wiring. The sensor is reading out-ofrange; or appears to be open or shorted.
• Check the sensor by substitution. Be sure the sensor polarity is correct.
• Continuity check circuit wiring using a high quality
ohmmeter. Be sure to maintain the correct polarity.
NOTE: Do NOT use a test light or other instrument; or controller damage may result.
07
Return Air Temperature Sensor Failure
(Check Alarm)
• Indicates a problem exists with this sensor
or its wiring. The sensor is reading out-ofrange; or appears to be open or shorted.
• Sensor Check test detected an out-of-range
condition.
• This sensor REQUIRES ice bath calibration or
correct sensor grade setup.
NOTE: If the Return Air sensor is the
controlling sensor when it fails, the
controller continues unit operation
using the Supply Air sensor.
09
Evaporator Coil Over Temperature
(Shutdown Alarm — prevents unit from
operating in Heat or Defrost)
• Check the sensor by selecting it using the RET/SUP
key (if necessary). If the display shows [- - - -], the
sensor is defective or the circuit is open or shorted.
• Check sensor by substitution. Be sure sensor
polarity is correct. Replacement sensor MUST be
calibrated or sensor grade set.
• Continuity check circuit wiring using a high quality
multimeter. Be sure to maintain the correct polarity
or the sensor will not work.
NOTE: Do NOT use a test light or other
instrument; or controller damage may result.
• Check electric heater rod operation using the
“AMPS HEATR” test in the Electrical Test submenu.
• Check evaporator coil sensor using View Menu.
• Evaporator coil has exceeded high
temperature limit.
• Check airflow over evaporator coil.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Code
10
Alarm Codes, Descriptions and Corrective Actions
Description
Corrective Action
High Pressure Cutout
(Check Alarm)
• Check for a dirty or restricted condenser coil.
• Indicates the high pressure cutout switch
has opened and the condition was not
corrected after 5 minutes (fault condition
prevented unit restart).
NOTE: Controller display shows “PAUSE
ALM10” every 10 seconds while condenser
fan operates to resolve the problem during
unit shutdown.
• Controller also generates alarm if high
pressure cutout/restart cycle recurs 3 times
within 30 minutes.
4-49
• Check for correct condenser fan operation using
“AMPS CFH” test in the Electrical Test submenu.
• Install manifold gauge set and check for correct
high pressure cutout switch operation.
• Check fuse F11 on the power module.
• Continuity check high pressure cutout switch
(identified by blue cable tie) circuit wiring using
a high quality multimeter.
NOTE: Do NOT use a test light or other instrument; or controller damage may result.
• Check for correct water cooled condenser operation
(option).
• Check for jumper on water pressure switch connectors in sensor harness if unit is NOT equipped with a
water cooled condenser (option).
• Check for a defective high pressure cutout switch.
12
Temperature Out-of-Range High
(Check Alarm)
• Check for an open or defective door.
• Check for proper setting of fresh air exchange.
• Indicates the control temperature has
exceeded the allowable temperature and
time duration above the setpoint after
having been in-range.
13
Temperature Out-of-Range Low
(Check Alarm) (Chill Loads ONLY)
• Perform a Full Pretrip Test to check unit operation.
• Perform a Full Pretrip Test to check unit operation.
• Indicates the control temperature has
exceeded the allowable temperature and
time duration below the setpoint after
having been in-range.
CSR40SL Semi-Hermetic, February 2000
4-50
Code
14
µP-D Controller
Alarm Codes, Descriptions and Corrective Actions
Description
Corrective Action
Defrost Terminated by TIme Limit
(Check Alarm)
• Check electric heater rod operation using the
“AMPS HEATR” test in the Electrical Test submenu.
• Indicates the controller terminated a defrost
cycle due to time.
• Check for correct evaporator fan operation using
the “REFRG DFRST” test in the Refrigeration Test
submenu.
• Check evaporator coil sensor for correct operation.
16
25
Digital Input Failure
(Shutdown Alarm)
• Check for other alarms, particularly sensor alarm
codes.
• Indicates one or more digital inputs (sensor,
current transformer, pressure switch, etc.)
is erratic or has failed.
• Check controller using the Microprocessor Tester.
Return and Supply Sensor Failure
(Shutdown Alarm — setpoint at -9.9 C [14.1 F]
or above)
(Check Alarm — setpoint at -10 C [14 F] or
below)
• Check to be sure the sensor lead connector is
securely attached to the controller and the sensor
harness is securely attached to the control box.
• Indicates both the return and supply sensors
have failed.
• Check for other sensor alarm codes, particularly
codes 03 and 07.
• Continuity check the wiring to the temperature sensors using a wiring diagram and digital multimeter.
• Sensor Check test detected an out-of-range
condition.
37
Low Refrigerant Level (Option)
(Shutdown Alarm)
• Check the refrigerant charge and correct as
required.
• Conditions indicate the refrigerant charge
may be low.
NOTE: This function is not used on CSR units.
38
Real Time Clock Battery Failure
(Check Alarm)
• Indicates the clock battery is under voltage or
dead.
NOTE: The data logger may lose its time
setting when unit switch is turned OFF.
• Replace the battery. The battery is located behind a
small access panel on the back of the controller.
Check and reset the date/time settings as required.
NOTE: If the battery is changed with unit On/Off
switch ON, the clock functions may not be lost.
Otherwise, up to 12 hours of datalogger and
hourmeter logs may be lost.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Code
41
Alarm Codes, Descriptions and Corrective Actions
4-51
Description
Corrective Action
Spare Sensor 5 Failure (Option)
(Check Alarm)
• Check the sensor by selecting it using the View
menu. If the display shows [- - - -], the sensor is
defective or the circuit is open or shorted. Be sure
the sensor is securely attached to the connector
inside the unit.
• Indicates a problem exists with this sensor
or its wiring. The sensor is reading out-ofrange; or appears to be open or shorted.
• This sensor does NOT require ice bath
calibration.
• Check the sensor by substitution. Be sure the
sensor polarity is correct.
• Continuity check circuit wiring using a high quality
multimeter. Be sure to maintain the correct polarity
or the sensor will not work.
NOTE: Do NOT use a test light or other instrument; or controller damage may result.
42
Customer Configuration Alarm
(Check Alarm)
• Indicates customer configuration has not been
set. This alarm does not clear unless the
Customer Configuration “CFG C” is set to a
valid number (other than “0”).
43
Frequency Out-of-Range Low
(Check Alarm)
• Indicates the frequency of the supply
power is low.
• Set the customer (and/or unit) configuration number
to the setting required.
NOTE: The unit will operate and control temperature if the controller remains programmed
to unit configuration “5000” and customer
configuration “0”. However, the unit will NOT
operate customer specific options. See the
controller identification decal for the correct unit
configuration and customer configuration settings.
• Check the frequency of the supply power source
and correct as required. If the unit is operating
on generator set power supply, check generator
speed.
• If the frequency and voltage of the power supply are
correct but the controller displays 1/2 of the correct
reading, replace the power module.
CSR40SL Semi-Hermetic, February 2000
4-52
Code
44
µP-D Controller
Alarm Codes, Descriptions and Corrective Actions
Description
Corrective Action
Three Phase Current Imbalance
(Shutdown Alarm)
• Check supply power voltage on all three phases.
Voltage should be present on all three phases and
with 90% below or 110% above the rated voltage.
• Indicates the supply power current is
NOT equal within limits in each of the
three phases.
• Controller also generates alarm if phase
detection circuit was unable to determine
correct phase rotation; or if phase contactor
ABC or CBA fails to pull in or release during
a Pretrip test.
• Check for open circuits in the three phase power
circuits to the fans, heaters and compressor.
• Disconnect supply power and check resistance of
each heater leg. Correct open or shorted heaters.
• Check operation of phase contactors using the
“PS1” and “PS2” tests in the Controller Test
submenu.
• If the frequency and voltage of the power supply are
correct but the controller displays 1/2 of the correct
reading, replace the power module.
• Turn unit OFF and disconnect power supply.
Disconnect plug on current transformer and check
the resistance of each primary winding. Resistance
for each winding should be 43 +/- 0.5 ohms.
• If Alarm Code 10 is also present, check for an open
F11 fuse on the power module.
45
Frequency Out-of-Range High
(Check Alarm)
• Indicates the frequency of the supply
power is high.
• Check the frequency of the supply power source
and correct as required. If the unit is operating on
generator set power supply, check the generator
speed.
• If the frequency and voltage of the power supply are
correct but the controller displays 1/2 of the correct
reading, replace the power module.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Code
46
Alarm Codes, Descriptions and Corrective Actions
4-53
Description
Corrective Action
USDA 1 Sensor Failure (Option)
(Check Alarm)
• Check the sensor by selecting it using the View
menu. If USDA1 display shows [- - - -], the sensor
is defective or the circuit is open or shorted.
• Indicates a problem exists with this sensor
or its wiring. The sensor is reading out-ofrange; or appears to be open or shorted.
• This sensor REQUIRES ice bath calibration.
• Check the sensor by substitution. Be sure the
sensor polarity is correct.
• Continuity check circuit wiring using a high quality
multimeter. Be sure to maintain the correct polarity
or the sensor will not work.
NOTE: Do NOT use a test light or other instrument; or controller damage may result.
47
USDA 2 Sensor Failure (Option)
(Check Alarm)
• Indicates a problem exists with this sensor
or its wiring. The sensor is reading out-ofrange; or appears to be open or shorted.
• This sensor REQUIRES ice bath calibration.
• Check the sensor by selecting it using the View
menu. If USDA2 display shows [- - - -], the sensor
is defective or the circuit is open or shorted.
• Check the sensor by substitution. Be sure the
sensor polarity is correct.
• Continuity check circuit wiring using a high quality
multimeter. Be sure to maintain the correct polarity
or the sensor will not work.
NOTE: Do NOT use a test light or other instrument; or controller damage may result.
48
USDA 3 Sensor Failure (Option)
(Check Alarm)
• Indicates a problem exists with this sensor
or its wiring. The sensor is reading out-ofrange; or appears to be open or shorted.
• This sensor REQUIRES ice bath calibration.
• Check the sensor by selecting it using the View
menu. If USDA3 display shows [- - - -], the sensor
is defective or the circuit is open or shorted.
• Check the sensor by substitution. Be sure the
sensor polarity is correct.
• Continuity check circuit wiring using a high quality
multimeter. Be sure to maintain the correct polarity
or the sensor will not work.
NOTE: Do NOT use a test light or other instrument; or controller damage may result.
CSR40SL Semi-Hermetic, February 2000
4-54
Code
49
µP-D Controller
Alarm Codes, Descriptions and Corrective Actions
Description
Corrective Action
Pulp Sensor Failure (Option)
(Check Alarm)
• Check the sensor by selecting it using the View
menu. If PULP1 display shows [- - - -], the sensor
is defective or the circuit is open or shorted.
• Indicates a problem exists with this sensor
or its wiring. The sensor is reading out-ofrange; or appears to be open or shorted.
• This sensor REQUIRES ice bath calibration.
• Check the sensor by substitution. Be sure the
sensor polarity is correct.
• Continuity check circuit wiring using a high quality
multimeter. Be sure to maintain the correct polarity
or the sensor will not work.
NOTE: Do NOT use a test light or other instrument; or controller damage may result.
50
Compressor Current Out-of-Range
(Pretrip and Normal Operation)
(Check or Shutdown Alarm)
• Check for low supply power voltage.
• Indicates compressor current draw is not within
the high or low limits when the compressor
operates alone.
• Check the compressor current draw with a digital
multimeter. Place unit in Full Cool mode using
“REFRG FC HI” in the Refrigeration Test submenu.
Current draw on each leg should be within 0.3
amperes of each other.
• If alarm occurs during a Pretrip test, a
dash (-) precedes the alarm code.
• Visually inspect the compressor motor overloads
and compressor contactor.
• Also occurs if controller determines that
the compressor motor overload opened
• Check the output module and related circuitry if the
compressor contactor does not energize. Place unit
in Full Cool mode using “REFRG FC HI” in the
Refrigeration Test submenu. Then check to see that
compressor output LED AC11 is ON. Check related
unit wiring as necessary.
• If current draw on each leg is not within 0.3 amperes
of each other, check the current transformer. Turn
unit OFF and disconnect power supply. Disconnect
plug on current transformer and check the resistance of each primary winding. Resistance for each
winding should be 43 +/- 0.5 ohms.
• Check the refrigeration system for excessively high
pressures that could cause high compressor current
draw.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Code
51
Alarm Codes, Descriptions and Corrective Actions
Description
Corrective Action
Unit Current Out-of-Range in COOL Mode
(Check or Shutdown Alarm)
• Check for low supply power voltage.
• Indicates total unit current draw is not within
acceptable limits when the unit is in Cool mode.
NOTE: This is not a Pretrip test alarm.
4-55
• Check the compressor current draw with a digital
multimeter. Place unit in Full Cool mode using
“REFRG FC HI” in the Refrigeration Test submenu.
Current draw on each leg should be within 0.2
amperes of each other. Current draw for
compressor only should be 7 to 11 amperes at
480V.
• Check evaporator fan motor current draw using
“AMPS EFH” and “AMPS EFL” in the Electrical Test
submenu. Current draw for evaporator fans only
should be 2 to 4.5 amperes at 480V. If current draw
is high, check for obstructions to evaporator airflow.
If current draw is low, check for a motor not operating.
• Check condenser fan motor current draw using
“AMPS CFH” in the Electrical Test submenu.
Current draw for condenser fan only should be 1 to
2.3 amperes at 480V. If current draw is high, check
for obstructions to condenser airflow. No current
draw indicates the motor is not operating.
• Check the evaporator fan and condenser fan motors
for free rotation and proper condition.
• Visually inspect evaporator fan, condenser fan and
compressor contactors.
• Check the output module and related circuitry using
“REFRG FC HI” in the Refrigeration Test submenu
to place the unit in Full Cool. Then confirm that output LEDs AC11, AC12 and AC14 are ON.
• If current draw on each leg is not within 0.2 amperes
of each other during compressor current draw test,
check the current transformer. Turn unit OFF and
disconnect power supply. Disconnect plug on current transformer and check the resistance of each
primary winding. Resistance for each winding
should be 43 +/- 0.5 ohms.
• Check the refrigeration system for excessively high
pressures.
CSR40SL Semi-Hermetic, February 2000
4-56
Code
52
µP-D Controller
Alarm Codes, Descriptions and Corrective Actions
Description
Corrective Action
Modulation System Failure (Pretrip)
(Check or Shutdown Alarm)
• Perform a Full Pretrip Test to check modulation
valve operation.
• Indicates modulation valve current draw is not
within limits.
• Check the power module.
• Check controller using the Microprocessor Tester.
• If alarm occurs during a Pretrip test, a
dash (-) precedes the alarm code.
53
Heating Current Out-of-Range (Pretrip)
(Check or Shutdown Alarm)
• Indicates total unit current draw is not within
acceptable limits when the unit is in Heat mode.
• If alarm occurs during a Pretrip test, a
dash (-) precedes the alarm code.
• Check the wiring to modulation valve using
unit wiring diagrams and a digital multimeter.
- Disconnect modulation valve leads and check
circuit resistance. Resistance should be 7.6 ohms
at 24 C (75 F).
• Check for low supply power voltage.
• Check the heater element current draw using the
“REFRG HEAT” test in the Refrigeration Test
submenu. Current draw should be 7 to 14.5
amperes at 480V. Current draw on each leg should
be within 0.2 amperes of each other.
• Visually inspect the heater contactor and evaporator
fan contactors (EFH or EFL).
• Check the output module and related circuitry using
“REFRG HEAT” in the Refrigeration Test submenu
to place the unit in Heat. Then confirm that output
LEDs AC7 and AC12 (or AC8) are ON.
• If current draw on each leg is not within 0.2 amperes
of each other during heater current draw test, check
the current transformer. Turn unit OFF and disconnect power supply. Disconnect plug on current
transformer and check the resistance of each primary winding. Resistance for each winding should be
43 +/- 0.5 ohms.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Code
54
Alarm Codes, Descriptions and Corrective Actions
Description
Corrective Action
Defrost Current Out-of-Range (Pretrip)
(Check or Shutdown Alarm)
• Check for low supply power voltage.
• Indicates total unit current draw is not within
acceptable limits when the unit is in Defrost
mode.
• If alarm occurs during a Pretrip test, a
dash (-) precedes the alarm code.
4-57
• Check the heater element current draw using the
“REFRG DFRST” test in the Refrigeration Test
submenu. Current draw should be 7 to 10 amperes
at 480V. Current draw on each leg should be within
0.2 amperes of each other.
• Visually inspect the heater contactor.
• Check the output module and related circuitry using
“REFRG DFRST” in the Refrigeration Test submenu
to place the unit in Heat. Then confirm that ONLY
output LED AC7 is ON.
• If current draw on each leg is not within 0.2 amperes
of each other during heater current draw test, check
the current transformer. Turn unit OFF and disconnect power supply. Disconnect plug on current
transformer and check the resistance of each primary winding. Resistance for each winding should be
43 +/- 0.5 ohms.
CSR40SL Semi-Hermetic, February 2000
4-58
Code
55
µP-D Controller
Alarm Codes, Descriptions and Corrective Actions
Description
Corrective Action
High Speed Evaporator Fan Failure
(Pretrip) (Check or Shutdown Alarm)
• Check for low supply power voltage.
• Indicates evaporator fan current draw is not
within acceptable limits when fans are in
high speed.
• Controller also generates alarm if cooling
capacity is not sufficient.
• If alarm occurs during a Pretrip test, a
dash (-) precedes the alarm code.
• Check high speed evaporator fan current draw
using “AMPS EFH” in the Electrical Test submenu.
Current draw should be 2 to 4.5 amperes at 480V
for 3 fans. Current draw on each leg should be
within 0.2 amperes of each other.
• If current draw is high, check evaporator fan motors
for free rotation and proper condition. Check
direction of fan rotation (counterclockwise) as shown
by directional arrows. Check for obstructions to
evaporator airflow.
• Visually inspect evaporator fan high speed
contactor.
• If contactor does not energize, check output module
using “AMPS EFH” in the Electrical Test submenu.
Then confirm that output LED AC12 is ON.
• If current draw on each leg is not within 0.2 amperes
of each other during current draw test, check the
current transformer. Turn unit OFF and disconnect
power supply. Disconnect plug on current transformer and check the resistance of each primary
winding. Resistance for each winding should be 43
+/- 0.5 ohms.
• Check refrigeration system for obstructions or low
refrigerant charge.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Code
56
Alarm Codes, Descriptions and Corrective Actions
Description
Corrective Action
Low Speed Evaporator Fan Failure
(Pretrip) (Check or Shutdown Alarm)
• Check for low supply power voltage.
• Indicates evaporator fan current draw is not
within acceptable limits when fans are in
high speed.
• Controller also generates alarm if cooling
capacity is not sufficient.
• If alarm occurs during a Pretrip test, a
dash (-) precedes the alarm code.
4-59
• Check low speed evaporator fan current draw
using “AMPS EFL” in the Electrical Test submenu.
Current draw should be 0.8 to 2 amperes at 480V
for 3 fans. Current draw on each leg should be
within 0.2 amperes of each other.
• If current draw is high, check evaporator fan motors
for free rotation and proper condition. Check
direction of fan rotation (counterclockwise) as shown
by directional arrows. Check for obstructions to
evaporator airflow.
• Visually inspect evaporator fan low speed
contactor.
• If contactor does not energize, check output module
using “AMPS EFH” in the Electrical Test submenu.
Then confirm that output LED AC8 is ON.
• If current draw on each leg is not within 0.2 amperes
of each other during current draw test, check the
current transformer. Turn unit OFF and disconnect
power supply. Disconnect plug on current transformer and check the resistance of each primary
winding. Resistance for each winding should be 43
+/- 0.5 ohms.
• Check refrigeration system for obstructions or low
refrigerant charge.
CSR40SL Semi-Hermetic, February 2000
4-60
Code
57
µP-D Controller
Alarm Codes, Descriptions and Corrective Actions
Description
Corrective Action
Condenser Fan Current Out-of-Range (Pretrip)
(Check or Shutdown Alarm)
• Check for low supply power voltage.
• Indicates condenser fan current draw is not
within acceptable limits when fan is operating.
• If alarm occurs during a Pretrip test, a
dash (-) precedes the alarm code.
• Check condenser fan current draw using “AMPS
CFH” in the Electrical Test submenu. Current
draw should be 1 to 2.3 amperes at 480V. Current
draw on each leg should be within 0.2 amperes
of each other.
• If current draw is high, check condenser fan motor
for free rotation and proper condition. Air should be
out from the condenser fan grille.
• Visually inspect condenser fan contactor.
• If contactor does not energize, check output module
using “AMPS CFH” in the Electrical Test submenu.
Then confirm that output LED AC14 is ON.
• If current draw on each leg is not within 0.2 amperes
of each other during current draw test, check the
current transformer. Turn unit OFF and disconnect
power supply. Disconnect plug on current transformer and check the resistance of each primary
winding. Resistance for each winding should be 43
+/- 0.5 ohms.
58
Sensor Calibration Failure (Pretrip)
(Check or Shutdown Alarm)
• Check for other sensor alarm codes, particularly
codes 03, 05 and/or 07.
• Indicates the Return Air, Supply Air and
Evaporator Coil sensor temperatures are not
within acceptable limits after the evaporator
fans have been ON for a specified time.
• Check for obstructions to evaporator airflow.
• If alarm occurs during a Pretrip test, a
dash (-) precedes the alarm code.
• Check sensor grade calibrations. Compare
controller sensor grade setting in View Menu with
with grade shown on sensor identification decals.
• Check operation of evaporator fans using “AMPS
EFH” in the Electrical Test submenu. Then
visually inspect fans for proper rotation and
operation.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Code
59
60
61
Alarm Codes, Descriptions and Corrective Actions
Description
Corrective Action
µP-A+ Datalogger Full
(Check Alarm)
• Enter a Start of Trip to place a marker in the
controller’s data logger memory.
• Indicates datalogger is full.
• Send a Header to controller’s data logger memory.
Global Datalogger Full
(Check Alarm)
• Enter a Start of Trip to place a marker in the
controller’s data logger memory.
• Indicates datalogger is full.
• Send a Header to controller’s data logger memory.
Real Time Clock Invalid
(Check Alarm)
• Check the battery voltage using “CLKV” in the
View menu. Replace the battery if voltage is
less than 3.3 V. Then reset the date/time settings.
If real time clock can NOT be reset, replace the
controller.
• Indicates real time clock has been corrupted
(due to faulty battery, static discharge, etc.).
Up to 12 hours of datalogger and hourmeter
logs have been lost.
63
4-61
Bypass (Warm Gas) Valve Circuit Failure
(Pretrip) (Check Alarm)
• Indicates a problem with the Bypass Valve
or its wiring.
• If alarm occurs during a Pretrip test, a dash
(-) precedes the alarm code.
• Energize and de-energize the bypass valve using
“BVS” in the Controller Test submenu. Confirm by
sound that the valve energizes and de-energizes.
• If the valve does not operate, check the valve coil
coil for continuity using a high quality multimeter.
• Check the circuit wiring for continuity using a high
quality multimeter and a wiring diagram.
NOTE: Do NOT use a test light or other instrument; or controller damage may result.
CSR40SL Semi-Hermetic, February 2000
4-62
Code
64
µP-D Controller
Alarm Codes, Descriptions and Corrective Actions
Description
Corrective Action
Pretrip Preconditioning Failure
(Check Alarm)
• Check the container to be sure it is not loaded.
• Check unit cooling and heating operation.
• Indicates a heating or cooling problem;
Pretrip Test pre-cooling or pre-heating of the
container was aborted or was not completed
in the time allowed.
• Check the liquid injection system.
• Indicates a Pretrip Test was initiated on a
loaded container.
• Indicates a possible liquid injection system
failure if alarm 82 is also recorded.
• If alarm occurs during a Pretrip test, a dash
(-) precedes the alarm code.
65
Datalog Queuing Error
(Check Alarm)
• Check operation of the real time clock using the
“YEAR”, “MONTH”, “DAY” and “TIME” displays
in the View menu.
• Indicates an error occurred in the datalogger.
• Check for the presence of Alarm Code 61. Check
real time clock battery voltage using “CLKV” in View
menu. Replace battery if voltage is less than 3.3 V.
69
Dehumidify Valve Circuit Failure (Option)
(Pretrip) (Check Alarm)
• Indicates a problem with the Dehumidify Valve
or its wiring.
• If alarm occurs during a Pretrip test, a dash
(-) precedes the alarm code.
• Energize and de-energize the dehumidify valve
using “DEHUM” in the Controller Test submenu.
Confirm by sound that the valve energizes and
de-energizes.
• If the valve does not operate, check the valve coil
coil for continuity using a high quality multimeter.
• Check the circuit wiring for continuity using a high
quality multimeter and a wiring diagram.
NOTE: Do NOT use a test light or other instrument; or controller damage may result.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Code
70
Alarm Codes, Descriptions and Corrective Actions
Description
Corrective Action
Hourmeter Alarm
(Check Alarm)
• The hourmeter exceeded 99,999. Reset the
hourmeter to 0.
4-63
• Indicates a problem with one or more
of the controller’s internal hourmeters.
71
User Hourmeter 1 Expired
(Check Alarm)
• Check the hourmeter type and proceed according to
company requirements. Reset the hourmeter if
required.
• Indicates time set on a user hourmeter has
expired.
72
User Hourmeter 2 Expired
(Check Alarm)
• Check the hourmeter type and proceed according to
company requirements. Reset the hourmeter if
required.
• Indicates time set on a user hourmeter has
expired.
73
User Hourmeter 3 Expired
(Check Alarm)
• Check the hourmeter type and proceed according to
company requirements. Reset the hourmeter if
required.
• Indicates time set on a user hourmeter has
expired.
74
User Hourmeter 4 Expired
(Check Alarm)
• Check the hourmeter type and proceed according to
company requirements. Reset the hourmeter if
required.
• Indicates time set on a user hourmeter has
expired.
79
Data Overflow
(Check Alarm)
• No corrective action possible. This alarm only
serves to indicate an event was not recorded
in the datalogger.
• Indicates an event that occurred was not
recorded by the datalogger.
CSR40SL Semi-Hermetic, February 2000
4-64
Code
81
µP-D Controller
Alarm Codes, Descriptions and Corrective Actions
Description
Corrective Action
Compressor Temperature Sensor Failure
(Check Alarm)
• Check the sensor by selecting it using the View
menu. If the display shows [- - - -], the sensor is
defective or the circuit is open or shorted.
• Indicates a problem exists with this sensor
or its wiring. The sensor is reading out-of
range; or appears to be open or shorted.
• Check the sensor by substitution. Be sure the
sensor polarity is correct.
• Continuity check circuit wiring using a high quality
multimeter. Be sure to maintain the correct polarity
or the sensor will not work.
NOTE: Do NOT use a test light or other instrument; or controller damage may result.
82
Compressor Over Temperature
(Check Alarm)
• Check operation of the liquid injection valve using.
“LIV” in the Controller Test submenu.
• Indicates compressor temperature sensor has
detected a high compressor temperature
condition and the condition was not corrected
after 5 minutes (fault condition prevented unit
restart).
• Check refrigeration system for plugged filter drier,
plugged in-line filter, low or high side obstructions or closed receiver tank outlet valve.
NOTE: Controller display shows “PAUSE
ALM82” every 10 seconds while the
condenser fan operates to resolve the
problem during unit shutdown.
• Controller also generates alarm if high
compressor temperature/restart cycle recurs
3 times within 30 minutes.
CSR40SL Semi-Hermetic, February 2000
µP-D Controller
Code
85
Alarm Codes, Descriptions and Corrective Actions
Description
Corrective Action
Compressor Current Out-of-Range
(Check or Shutdown Alarm)
• Check for low supply power voltage.
• Indicates compressor motor has failed to
start.
4-65
• Check the compressor current draw with a digital
multimeter. Place unit in Full Cool mode using
“REFRG FC HI” in the Refrigeration Test submenu.
Current draw of the compressor only should be 7 to
11 amperes at 480V. Current draw on each leg
should be within 0.3 amperes of each other.
• Visually inspect compressor motor contactor.
• If compressor contactor does not energize, check
output module and related circuits by using “REFRG
FC HI” in the Refrigeration Test submenu to place
the unit in Cool. Then confirm that output LED
AC11 is ON.
• If current draw on each leg is not within 0.3 amperes
of each other during compressor current draw test,
check the current transformer. Turn unit OFF and
disconnect power supply. Disconnect plug on current transformer and check the resistance of each
primary winding. Resistance for each winding
should be 43 +/- 0.5 ohms.
• Check the refrigeration system for excessively high
pressures.
• Check the compressor for proper operation.
CSR40SL Semi-Hermetic, February 2000
4-66
Code
92
µP-D Controller
Alarm Codes, Descriptions and Corrective Actions
Description
Corrective Action
Condenser Fan Sensor Failure
(Check Alarm)
• Check the sensor by selecting it using the View
menu. If the display shows [- - - -], the sensor is
defective or the circuit is open or shorted.
• Indicates a problem exists with this sensor
or its wiring. The sensor is reading out-ofrange; or appears to be open or shorted.
This alarm occurs only if the unit is using
the sensor to control condenser fan operation.
• Check the sensor by substitution. Be sure the
sensor polarity is correct.
• Continuity check circuit wiring using a high quality
multimeter. Be sure to maintain the correct polarity
or the sensor will not work.
NOTE: Do NOT use a test light or other instrument; or controller damage may result.
97
Loss of Communications with Output Module
(Shutdown Alarm)
• Indicates a communications link between the
controller and output module is not functioning.
• Check the RXD and TXD LEDs at the top of the
output module. These LEDs should alternately flash
on a continuous basis to indicate a good
communications link.
• Check the cable from the controller to the thermo
bus tap. Check the cable from the thermo bus tap to
the output module. Check thermo bus tap for can
terminator resistor R4.
• Check controller using the Microprocessor Tester.
• Replace the Output Module.
CSR40SL Semi-Hermetic, February 2000
5
Electrical Maintenance
3.
Unit Wiring
Inspect unit wiring, wire harnesses, and the controller during
pre-trip inspection and every 1,000 operating hours to protect
against unit malfunctions due to open or short circuits. Look
for loose, chaffed or broken wires on the unit; open or short
circuits and damaged components on the controller printed circuit board.
Inspect electrical contactor points for pitting or corrosion
every 1,000 operating hours. Repair or replace as necessary.
High Pressure Cutout Switch
Raise the discharge pressure of the 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 Alarm LED should turn ON.
• The compressor and evaporator fans should STOP
immediately.
• The condenser fan should continue to operate.
NOTE: The discharge pressure should never be
allowed to exceed 3,380 kPa, 33.80 bar, 490 psig.
The high pressure cutout is located on the compressor discharge manifold. If the discharge pressure rises above 3243
+/- 48 kPa, 32.43 +/- 0.48 bar, 470 +/- 7 psig, the switch opens
the R51A circuit:
• The compressor and evaporator fans STOP immediately.
• The condenser fan will continue to operate.
• After 5 minutes, the controller attempts to restart the
compressor.
• If the compressor restarts and operates for 10 minutes
without an overload condition, no alarm is recorded.
• If the overload still exists after 5 minutes, the controller
turns the Alarm LED ON. Also, if the overload condition occurs 3 times within 30 minutes, an alarm is
recorded. Pressing the ALARM key on the controller
will cause alarm code 10 (High Refrigerant Cutout) to
appear on the right display.
• Unit restarts when the overload condition is corrected
(reset) as long as power is available.
To test the switch, rework a gauge manifold per “High
Pressure Cutout Manifold” illustration.
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.
2. Operate the unit in Cool by performing an REFRG/FC HI
(full cool with high speed evaporator fan) test from the
Test Menu of the µP-D controller.
High Pressure Cutout Manifold
1. Relief Valve, P/N 66-6543
2. O-ring, P/N 33-1015
3. Adapter Tee (Weather Head No. 552X3)
CSR40SL Semi-Hermetic, February 2000
5-2
4.
Condenser Fan and Evaporator Fan Rotation
Be sure to remove the cardboard installed in step 3.
NOTE: To clear the HPCO alarm, press the
ALARM key on the controller. Press the DOWN
key until ENTER flashes in the left display. Then
press the ENTER key. The Alarm LED should
turn OFF and the unit re-start.
WARNING: When alarm codes are cleared by
pressing the ENTER key, the unit will start automatically.
If the HPCO switch fails to stop compressor operation, replace
the switch and repeat steps 1 through 4.
Electrical Maintenance
If an evaporator fan rotate backwards on one or both
speeds, refer to 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 EF1, EF2 and EF3
are used on LOW SPEED fan operation. Wires EF11,
EF12 and EF13 are used on HIGH SPEED fan operation.
NOTE: If both the condenser and evaporator fans
rotate backwards, see the Diagnosis Manual for
Thermoguard µP-D Microprocessor Controller, TK
41230.
Condenser Fan and Evaporator Fan Rotation
Electric Heaters
Condenser Fan
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.
NOTE: If unit operating conditions do not require
condenser fan operation, check the condenser fan
rotation by performing an AMPS/CFH (high speed
condenser fan) test from the Test Menu of the µP-D
controller.
Six electric heater elements are located underneath the evaporator coil. If a heater element is suspected of malfunctioning,
inspect the connections:
• If the connections appear correct and secure, isolate and
check the resistance of each individual heater element by
disconnecting it from the circuit.
• Check resistance with an ohmmeter.
NOTE: When repairing heater connections, protect
the new connections from the ingress of moisture
with heat shrink tubing. All heaters should be
secured to prevent contact with sharp metal edges.
If the condenser fan is rotating backwards, refer to the unit
wiring diagram to correct fan motor wiring at the fan motor
junction box or condenser fan contactor. To correct improper
fan rotation, reverse any two fan power cord leads at the condenser fan contactor (disconnect power supply before reversing leads). DO NOT move the CH ground wire.
Evaporator Fans
Visually inspect the evaporator fan blades for proper rotation.
Arrows located on the underside of the fan deck indicate the
correct direction of rotation.
NOTE: Check both High and Low Speed evaporator
fan rotation. Perform an AMPS/EFH (high speed
evaporator fan) test and AMPS/EFL (low speed evaporator fan) test from the Test Menu of the µP-D controller.
CSR40SL Semi-Hermetic, February 2000
6
Refrigeration Maintenance
and Service Operations
NOTE: The following procedures involve servicing
the refrigeration system. Some of these service procedures are regulated by Federal, and in some
cases, by State and Local laws.
All regulated refrigeration service procedures
must be performed by an EPA certified technician,
using approved equipment and complying with all
Federal, State and Local laws.
NOTE: CSR40SL units feature a large, one-piece filter drier/in-line filter. The filter drier should not
require replacement unless major system contamination requires evacuation and cleanup of the refrigeration system.
Service Tools
CAUTION: When servicing Thermo King R-404A
refrigeration systems, use only those service tools
(i.e., vacuum pump, refrigerant recovery equipment,
gauge hoses, and gauge manifold set) certified for
and dedicated to R-404A refrigerant and Polyol Ester
based compressor oils. Residual non-HFC refrigerants or non-Ester based oils will contaminate HFC
systems.
Unit Service Fittings
Special fittings are used on R-404A systems to prevent mixing
of non-HFC refrigerants in R-404A units. These fittings are
located in three places on CSR refrigeration systems:
• Low side near the compressor suction adapter.
• High side on the compressor discharge manifold),
Leak Detection
Leaks can be detected with the use of soap bubbles and with
Halogen leak detectors such as model H10G, P/N 204-712 or
model H10N, P/N 204-756 (portable).
Gauge Manifold Set
A new gauge manifold set (P/N 204-758) should be dedicated
for use with R-404A only. Gauge hoses should also be dedicated to R-404A.
Vacuum Pump
A two-stage (P/N 204-725), 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 oils are highly refined to obtain
low vacuums, failure to follow these recommendations may
result in acidic conditions that will destroy the pump.
Service Fittings Specifications
1. Internal Threads for Cap
2. High Pressure Fitting
3. Low Pressure Fitting
System Cleanup
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.
CSR40SL Semi-Hermetic, February 2000
6-2
Gauge Manifold Valve Positions
Refrigeration Maintenance and Service Operations
Refrigerant Recovery
Use only refrigerant recovery equipment approved for and
dedicated to R-404A recovery.
Compressor Oil Acid Test
Perform an oil acid test (oil test kit P/N 203-457) whenever a
unit has a substantial refrigerant loss, a noisy compressor or
dark/dirty oil.
Recommended Solders
When repairing solder connections, use the same solder that
was used in the manufacturing process:
• Copper to copper, use 15% Silver Solder, P/N 203-364
• Copper to brass or steel, use 35% Silver Solder, P/N 203-366
Use flux, P/N 203-365, with both 15% and 35% silver solder. Other types of leaks such as punctures in tubes and leaks
in coils can best be repaired using 15% silver solder, P/N 203364 (with flux, P/N 203-365).
Gauge Manifold Closed to Center Port
1. Close Hand Valves
NOTE: Thermo King recommends that service procedures use the use the same solder on connections
that was used in the manufacturing process.
Therefore, technicians should obtain the recommended solder and flux from Thermo King.
Gauge Manifold Valve Positions
The gauges indicate low and high side pressures.
Operate one or both hand valves to perform the different service operations.
Gauge Manifold Open to Center Port
1. Open Hand Valves
Gauge Manifold Set Attachment And
Purging
Thermo King recommends the use of access valves or selfsealing, quick disconnect fittings whenever possible to limit
the loss of refrigerant into the atmosphere. A separate gauge
manifold set with low loss fittings (P/N 204-758) should be
dedicated for use with R-404A only. Gauge hoses should also
be dedicated to R-404A.
NOTE: When any of these devices are used, carefully check to ensure that access connections are functioning properly.
Gauge Manifold Set Installation
NOTE: As long as a slight positive pressure remains
in the manifold set and hoses, the gauge manifold
set may be reinstalled without additional purging.
To purge a gauge manifold set and hoses, see
“Gauge Manifold Valve Positions” in this chapter.
1.
Inspect gauge manifold for proper hose and fitting connections. Both the low side (suction) and high side (dis-
Removing Refrigerant
1.
2.
3.
4.
5.
6.
Quick Disconnect Access Valve
Discharge Service Valve (DSV)
Suction Service Valve (SSV)
Reclaimer
In
Out
CSR40SL Semi-Hermetic, February 2000
Refrigeration Maintenance and Service Operations
Gauge Manifold Set Attachment
6-3
charge) hand valves on the gauge manifold should be fully
closed to center port.
2. Clean dirt and moisture from around service access valves
on suction and discharge lines. Remove service port caps.
3. Attach the low side hose (compound gauge) to the access
valve on the suction line finger tight.
4. Attach high side hose (pressure gauge) to the access valve
on the discharge line finger tight.
5. The gauge manifold set is now ready to use to check system pressures and perform MOST service procedures.
Gauge Manifold Set Removal
NOTE: To ensure minimum refrigerant release to the
atmosphere, the compressor should be operating.
While this is not possible in all cases, the same procedure should be followed.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Operate the unit in a cool mode.
Close the refrigerant tank hand valve (if attached to the
gauge manifold set).
Open both manifold hand valves.
Remove the discharge line from the access valve.
Operate the unit in cool mode until the suction pressure
decreases below 385 kPa, 3.85 bar, 50 psig.
Stop the unit.
Remove the suction line from the access valve.
Replace service port caps.
Secure all manifold lines to manifold hose anchors when
the manifold is not in use.
Balancing the Pressure
1. Quick Disconnect Access Valve
2. Discharge Service Valve (DSV)
3. Suction Service Valve (SSV)
Charging the System
1. Quick Disconnect Access Valve
2. Discharge Service Valve (DSV)
3. Suction Service Valve (SSV)
Purging Gauge Manifold
1. Suction Connection
2. Discharge Connection
CSR40SL Semi-Hermetic, February 2000
6-4
Checking Compressor Oil
Checking Compressor Oil
CAUTION:
• Use ONLY Polyol Ester based refrigeration compressor oil, P/N 203-433.
• DO NOT mix Polyol Ester based and standard synthetic compressor oils.
• Rubber gloves are recommended when handling
Ester based compressor oil.
• Keep Polyol Ester based compressor oil in tightly
sealed containers. If Ester based oil becomes contaminated with moisture or standard oils, dispose of
properly — DO NOT USE!
The compressor oil should be checked during pretrip inspections and when there is evidence of oil loss (oil leaks) or when
components in the refrigeration system have been removed for
service or replacement.
To check compressor oil level with an ambient air
temperature above 10 C (50 F)
Install gauge manifold on the compressor. Operate the unit on
COOL with a 138 kPa, 1.38 bar, 20 psig minimum suction
pressure and a 689 kPa, 6.89 bar, 100 psig discharge pressure
for 15 minutes or more. If necessary, place the unit in Cool
using the “REFRG/FC HI” test from the Test Menu of the µPD controller. After the unit has maintained the above conditions for 15 minutes, observe the compressor oil level. The oil
should be 1/2 to 3/4 up in the sight glass.
Refrigeration Maintenance and Service Operations
Adding Compressor Oil
1. With the unit OFF, remove the cap from oil pressure fitting.
2. Using a commercial hand pump, force oil in through the
oil pressure fitting. Slowly add oil. Add Polyol Ester oil,
P/N 203-433 ONLY!
3. When the compressor oil sight glass is 1/2 to 3/4 full,
remove hand pump and replace the cap on the oil pressure
fitting.
4. Start and operate the unit on COOL using the
“REFRG/FC HI” test from the Test Menu of the µP-D
controller. Recheck the oil level and refrigerant charge
level before returning the unit to service.
Removing Excess Compressor Oil
1. Install an access valve actuator on the oil pressure fitting.
2. Operate the unit on Cool using the “REFRG/FC HI” test
from the Test Menu of the µP-D controller. Remove oil
while watching the level in the compressor sight glass.
NOTE: Heavy foaming of the oil as it leaves the
compressor may indicate an excess of refrigerant in the oil. Remove the access valve actuator
and operate the system for 15 minutes to ensure
warm sump. Then recheck the oil level.
3.
4.
When the compressor oil sight glass is 1/2 to 3/4 full,
remove access valve and replace the cap on the oil pressure fitting.
Operate the unit and recheck the oil level before returning
the unit to service.
To check compressor oil level with an ambient air
temperature below 10 C (50 F)
With the evaporator temperature below 10 C (50 F), press the
Manual Defrost switch to operate the unit through a complete
DEFROST CYCLE. After completing the defrost cycle, operate the unit on COOL for a few minutes using the “REFRG/FC
HI” test from the Test Menu of the µP-D controller. After 2 to
3 minutes, observe the oil level. The oil should be 1/2 to 3/4
up in the sight glass.
If the container is empty, you can operate the unit on the
heat cycle instead of the defrost cycle.
Adjusting Compressor Oil Level
1. Add and Remove Compressor Oil at the Compressor
Oil Fitting
CSR40SL Semi-Hermetic, February 2000
Refrigeration Maintenance and Service Operations
Refrigerant Charge
NOTE: CSR Hermetic units do not have service
valves, fittings or sight glasses installed in the refrigeration system. Therefore, the refrigerant charge
level can not be visually inspected.
Perform a controller Pretrip Test to determine that a CSR
Hermetic refrigeration system contains an adequate charge of
refrigerant for cooling. If the unit passes the the Pretrip Test,
the refrigerant charge is OK.
A Pretrip Test should be performed during 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.
Unit Refrigerant Charge:
• CSR40SL: 4.1 kg (9.0 lb) R-404A
Unit Health Check Procedure
Unit cooling performance may not be affected by a marginally
low refrigerant charge (1 to 3 lbs [0.5 to 1.4 kg] low) under all
ambient operating conditions. Consequently, a unit with a
slightly low refrigerant charge may pass a Pretrip Test. To
Refrigerant Charge
6-5
accurately determine the cooling performance and refrigerant
charge level, operate the unit on Full Cool for 15 minutes or
more:
1. Adjust the setpoint well below the ambient temperature to
force the unit to Full Cool. The Modulation Cool and
Power Limit functions must be OFF.
2. After 15 minutes, check the temperature difference (dT)
across the evaporator coil.
a. Press the SELECT key to enter the controller menu
(display shows “MENU <--->”).
b. Press the DOWN key until display shows “MENU
VIEW”.
c. Press the SELECT key to enter the VIEW submenu
(display shows “VIEW <--->”).
d. Press the DOWN key to view “TD” value (e.g. “TD
-03.7 C)” in the display.
3. Compare the unit dT to the expected values in table
below. If dT is below the value in the “possible low
refrigerant charge” column, visually inspect the unit for
signs of frosted or iced evaporator coil, low or high
obstruction in the refrigeration system, plugged expansion
valve and a loose or defective expansion valve feeler bulb
before concluding the unit is low on refrigerant.
NOTE: Inspect the unit for refrigerant leaks with a
reliable leak detector if the unit is suspected of being
low on R-404A charge.
Unit Health Check Table — Determining Possible Low R-404A Charge
Power
Supply
Ambient
Temp.
38 oC (100 oF)
460V,
3 Phase,
60Hz
27 oC (80 F)
16 oC (60 oF)
38 oC (100 oF)
380V,
3 Phase,
50Hz
27 oC (80 oF)
16 oC (60 oF)
Return Air
Temp.
-29 oC (-20 oF)
-18 oC (0 oF)
-1 oC (30 oF)
10 oC (50 oF)
-29 oC (-20 oF)
-18 oC (0 oF)
-1 oC (30 oF)
10 oC (50 oF)
-29 oC (-20 oF)
-18 oC (0 oF)
-1 oC (30 oF)
10 oC (50 oF)
-29 oC (-20 oF)
-18 oC (0 oF)
-1 oC (30 oF)
10 oC (50 oF)
-29 oC (-20 oF)
-18 oC (0 oF)
-1 oC (30 oF)
10 oC (50 oF)
-29 oC (-20 oF)
-18 oC (0 oF)
-1 oC (30 oF)
10 oC (50 oF)
Expected dT: Return Temp.
minus right hand supply temp.
-2.2 oC
(-4.0 oF)
o
-4.3 C
(-7.7 oF)
-3.9 oC
(-7.0 oF)
o
-5.6 C
(-10.1 oF)
o
-3.0 C
(-5.4 oF)
o
-4.8 C
(-8.6 oF)
-3.8 oC
(-6.9 oF)
o
-6.7 C
(-12.0 oF)
o
-3.0 C
(-5.4 oF)
o
-4.6 C
(-8.3 oF)
-4.5 oC
(-8.1 oF)
o
-6.5 C
(-11.7 oF)
o
-2.1 C
(-3.8 oF)
o
-4.2 C
(-7.5 oF)
-3.9 oC
(-7.0 oF)
o
-5.7 C
(-10.2 oF)
o
-3.0 C
(-5.4 oF)
o
-4.8 C
(-8.6 oF)
-4.3 oC
(-7.7 oF)
o
-6.4 C
(-11.5 oF)
o
-3.0 C
(-5.4 oF)
o
-4.9 C
(-8.8 oF)
-4.7 oC
(-8.5 oF)
o
-5.6 C
(-10.1 oF)
dT less than figure listed below
indicates possible low R-404A charge
-1.7 oC
(-3.0 oF)
o
-3.2 C
(-5.8 oF)
-2.9 oC
(-5.3 oF)
o
-4.2 C
(-7.6 oF)
o
-2.3 C
(-4.1 oF)
o
-3.6 C
(-6.5 oF)
-2.9 oC
(-5.2 oF)
o
-5.0 C
(-9.0 oF)
o
-2.3 C
(-4.1 oF)
o
-3.5 C
(-6.2 oF)
-3.4 oC
(-6.1 oF)
o
-4.9 C
(-8.8 oF)
o
-1.6 C
(-2.9 oF)
o
-3.1 C
(-5.6 oF)
-2.9 oC
(-5.3 oF)
o
-4.3 C
(-7.7 oF)
o
-2.3 C
(-4.1 oF)
o
-3.6 C
(-6.5 oF)
-3.2 oC
(-5.8 oF)
o
-4.8 C
(-8.6 oF)
o
-2.3 C
(-4.1 oF)
o
-3.7 C
(-6.6 oF)
-3.5 oC
(-6.4 oF)
o
-4.2 C
(-7.6 oF)
CSR40SL Semi-Hermetic, February 2000
6-6
Refrigerant Leak Test Procedure
Refrigeration Maintenance and Service Operations
9.
Refrigerant Leak Test Procedure
Use a reliable Halogen leak detector such as model H10G, P/N
204-712 or 204-756 (portable), 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 (refer to “Gauge Manifold Set
Attachment and Purging” for proper procedures).
3. Attach refrigerant bottle charging hose to 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 manual chapter.
CAUTION: Nitrogen (N2 ) is under 15,170 kPa,
151.70 bar, 2200 psig pressure in a full cylinder
at 21 C (70 F). DO NOT use oxygen, acetylene or
any other type of pressurized gas in the system.
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.)
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.
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.
Safety Precautions
Observe the proper handling of cylinders:
1. Always keep protective cap on cylinder when not in use.
2. Secure cylinder in proper storage area or fastened to cart.
3. DO NOT expose to excessive heat or direct sun light.
4. DO NOT drop, dent, or damage cylinder.
5. 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.
6. Open valve slowly; use regulators and safety valves that
are in good working order.
7. 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 (N2 ) 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 (O2), 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 (N2 ). The proper equipment and application of equipment is of greatest
importance.
Procedure
1. Attach gauge manifold set (refer to “Gauge Manifold Set
Attachment and Purging” for proper procedure for connecting to compressor).
Testing for Refrigerant Leaks
CSR40SL Semi-Hermetic, February 2000
Refrigeration Maintenance and Service Operations
2.
3.
4.
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.
The following procedures should utilize the following
MAXIMUM gas pressure:
• 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.
Refrigerant Recovery
6-7
Refrigerant Recovery from Semi-Hermetic
Refrigeration Systems
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 that can escape to the atmosphere.
Typical service procedures that require removal of refrigerant
from the unit include:
• To empty the unit of refrigerant when an unknown
amount of charge is in the system and a correct charge is
required.
• To empty the unit of contaminated refrigerant when the
system has become contaminated. Place this refrigerant
gas in a contaminated refrigerant bottle to be reclaimed
later.
• To remove a leak test charge from the refrigeration system. Because this refrigerant gas will contain some air,
place it in a contaminated refrigerant bottle to be
reclaimed later.
NOTE: Always refer to specific recovery equipment
Operator and Service Manuals.
Vapor Recovery
1. Disconnect unit from 3-phase power supply.
2. Install gauge manifold set on service access valves on the
discharge and suction lines in the compressor compartment. Attach the service line to the recovery machine and
properly purge the lines.
3. Set the recovery machine for vapor recovery.
NOTE: CSR Semi-hermetic units do not have
service valves installed in the refrigeration system. Therefore, only vapor recovery of the refrigerant charge is possible.
4.
5.
Turn ON the recovery machine and open (back seat) both
service access valves.
Continue to operate the recovery machine until unit pressures drop to 0 kPa, 0 bar, 0 psig pressure.
Typical Pressurized Gas Bottle with Pressure
Regulator and Gauges
1.
2.
3.
4.
5.
6.
Line Pressure
Tank Pressure
Tank
Pressure Test Line to System
Safety Valve
Pressure Regulator
CSR40SL Semi-Hermetic, February 2000
6-8
Evacuation and Cleanup of System
Evacuation and Cleanup of the
Refrigeration System
Contamination
Whenever contaminants have entered the system, a thorough
clean up is required to prevent damage or loss of compressor.
It is well known by the refrigeration service industry that
the purpose of evacuation is to remove moisture and air from
the refrigeration system before charging with new refrigerant
after a system has been opened. The importance of thorough
evacuation and system preparation cannot be over emphasized.
Even infinitesimal quantities of air or moisture in a system can
cause severe problems.
We know that the presence of moisture, oxygen, and heat
under certain conditions can result in many forms of damage.
Corrosion, sludge, copper plating, oil breakdown, carbon formation, and eventual compressor failure can be caused by
these contaminants.
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 (i.e., copper) and
cause metal plating as the softer material begins to cover
the inside of the system. If this condition is not stopped, it
can result in the total destruction of your equipment.
Refrigeration Maintenance and Service Operations
Compressor Oil Color Code
BLACK OIL — indicates carbonization caused by air in the
system.
BROWN OIL — indicates copper plating caused by moisture
in the system.
GRAY OR METALLIC OIL — indicates bearing wear or piston scoring.
NOTE: If the compressor oil is discolored, perform a
compressor oil acid test (oil test kit P/N 203-457). If
the compressor oil shows an acid condition, change
the oil, the in-line oil filter, the filter drier and perform
a refrigeration system cleanup.
Unit Preparation and Hookup
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.
1.
2.
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 filter drier if necessary.
NOTE: Hermetic units feature a large, one-piece
filter drier/in-line filter. The filter drier should not
require replacement unless major system contamination requires evacuation and cleanup of the
refrigeration system.
3.
Confirm that the Evacuation Station functions properly
and 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.
If a vacuum pump (isolated from a system) is started
and the Micron Meter responds quickly by going to a deep
vacuum, the operator can be confident that the pump and
oil are in good condition. 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 vacuum is improved.
CSR40SL Semi-Hermetic, February 2000
Refrigeration Maintenance and Service Operations
Evacuation and Cleanup of System
6-9
Evacuation Station and Unit Hook-up
1.
2.
3.
4.
5.
6.
7.
8.
Special, self-sealing quick disconnect couplers are required for R-404A units.
Gas Ballast Valve
Iso Valve
Two-stage Vacuum Pump
To 220/190 VAC Power
Calibration Standard
Micron Meter
Sensor
CSR40SL Semi-Hermetic, February 2000
6-10
4.
5.
6.
7.
Evacuation and Cleanup of System
Connect the Evacuation Station and refrigerant tank with
gauge manifold (optional) to the unit as indicated on the
diagram on page 6-9. Connect evacuation hoses to the
compressor suction and discharge service lines and the
receiver tank outlet valve.
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.
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 Valve,
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
or more hours.
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.
Refrigeration Maintenance and Service Operations
2.
3.
4.
5.
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.
• An increase 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.
• A system that is leak free and dry will remain below
2000 microns for five minutes.
• 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 stabilizing has
a leak and must be repaired.
If the vacuum level remained below 2000 microns for five
minutes, the unit is ready to charge. See “Charging the
System with Refrigerant” on page 6-12.
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.
• 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 graph,
“Constant Pressure Rise After Evacuation Indicates
System Leak”, page 6-11).
• 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
graph, “Pressure Rise Levels Off After Evacuation
Indicates Moisture in System”, page 6-11).
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.
CSR40SL Semi-Hermetic, February 2000
Refrigeration Maintenance and Service Operations
Factors Affecting the Speed of System Evacuation
It is almost impossible to state the exact amount of time
required to evacuate any system. Some factors that can influence evacuation time are listed below.
• System size
• Amount of moisture contained in the system
• 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. To obtain optimum pumping speed, keep hoses as short
as possible and as large in diameter as possible. For example,
it takes eight times as long to pull a given vacuum through a 6
mm (0.25 in.) diameter hose as it does through a 13 mm (0.5
in.) diameter hose. It takes twice as long to pull a vacuum
through a 2 meter (6 ft) long hose as it does through a 1 meter
(3 ft) long hose.
Evacuation and Cleanup of System
6-11
Heat Saves Time
A useful and practical time saver is the application of heat to
the system. Increasing the temperature of the compressor oil
and refrigerant will speed up the vaporization of any water
present in the system.
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.
Constant Pressure Rise After Evacuation Indicates
System Leak
Pressure Rise Levels Off After Evacuation Indicates
Moisture in System
1. 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.
2. Time
3. Pressure (Vacuum)
4. Atmospheric Pressure
1. Close the vacuum 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.
2. Time
3. Pressure (Vacuum)
4. Atmospheric Pressure
CSR40SL Semi-Hermetic, February 2000
6-12
Charging the System with Refrigerant
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. Connect the refrigerant tank with gauge manifold to the
evacuation station (see “Evacuation Station and Unit
Hookup” on page 6-9).
5. Weigh the tank of refrigerant.
6. Check unit data plate for the required weight of refrigerant
charge. Then subtract the unit charge weight from the
total weight of the refrigerant tank. This provides the
final tank weight after the unit receives a full refrigerant
charge.
7. Set the refrigerant tank for liquid removal. Open the hand
valve on the tank.
8. With the unit OFF, open the gauge manifold hand valve
and charge liquid refrigerant into the system.
9. 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 Station Removal
1. Close the high pressure hand valve on the gauge manifold.
2. Close the refrigerant tank hand valve.
3. Open the hand valve at the gauge manifold and read suction pressure.
4. Operate the unit in cool mode until the suction pressure
decreases below 385 kPa, 3.85 bar, 50 psig.
5. Stop the unit.
6. Remove the hoses from the suction and and discharge line
service access valves. Install caps on service valves.
7. Leak check the process tubes with an electronic leak
detector.
8. Start the unit and perform a controller Pretrip Test to verify correct refrigerant charge and unit operation.
Refrigeration Maintenance and Service Operations
Modulation Valve Repair or Replacement
The modulation valve is used to control the flow of refrigerant
to the compressor when the unit is operating in the Modulation
mode. As the supply air temperature approaches setpoint, the
controller sends an electrical signal to the coil of the valve.
The armature overcomes the spring tension and the valve closes a precise amount. This throttles the suction gas returning to
the compressor and reduces cooling capacity. As the signal is
increased, the valve closes an additional amount. Due to valve
design, the flow of refrigerant gas exerts no opening or closing
forces on the valve spool allowing very precise operation.
Service of the modulation valve includes replacement of
the coil, replacement of the enclosing tube assembly or
replacement of the complete valve.
Tools Required:
• Digital Multimeter (P/N 204-615)
• Modulation Valve Coil (P/N 44-5175) or Modulation Valve
Repair Kit (P/N 60-203) (kit includes coil)
• Scissors (with duct tape), pocket knife or other thin-pointed
instrument
• Adjustable Wrench
• 1.5 inch Wrench
• Torque Wrench
Coil Checkout Procedure
NOTE: In most cases, only the coil requires replacement.
1.
2.
3.
Unplug the modulation valve coil lead wire harness.
Using a FLUKE multimeter, test each lead resistance to
ground. Low resistance indicates a short is present.
Repair or replace any damaged or exposed wires.
Check the coil resistance. If the coil resistance is below 5
ohms, replace the coil (good coils have a resistance of 7.6
ohms at 25 C (77 F) or 6.9 ohms at 4.4 C (40 F).
NOTE: The ohmmeter will display a higher coil
resistance if the modulation valve was energized
for a long period of time just prior to testing the
coil resistance.
4.
To return the unit to service, plug the modulation valve
lead connector into the unit wire harness.
CSR40SL Semi-Hermetic, February 2000
Refrigeration Maintenance and Service Operations
Modulation Valve Repair
6-13
Enclosure Tube Replacement
Replacing the Enclosure Tube Assembly
If the modulation fails to operate properly, remove the coil
housing and inspect the solenoid coil sleeve and enclosure tube
assembly for rust or corrosion. Rust or corrosion can damage
the enclosure tube, preventing the piston inside the tube from
opening and closing the valve properly. If the solenoid coil
sleeve is badly corroded, replace the entire enclosure tube and
coil assembly.
CAUTION: When replacing the enclosing tube
assembly, DO NOT remove the valve piston, top
return spring or bottom return spring from the valve
body. These components must be factory installed
and adjusted to ensure proper valve operation.
1.
2.
3.
4.
5.
6.
7.
Remove the compressor compartment bracket.
Recover the refrigerant charge from the unit (see
“Refrigerant Recovery” in this chapter).
Disconnect the unit from the three-phase power supply.
Unplug the coil lead wire harness.
Remove the coil, coil sleeve and bottom housing plate
from the enclosure tube.
Place a 1.5 inch wrench on the enclosure tube hex fitting
and loosen enclosure tube one-half turn.
Hold scissors or other thin-pointed instrument in one hand
while you unscrew enclosure tube using other hand. After
approximately five full turns, the enclosure tube threads
should be free of the modulation valve body. Lift enclosure tube slightly and retain valve piston in valve body by
carefully inserting scissors through top return spring
above boss on piston.
Modulation Valve
Modulation Valve
1.
2.
3.
4.
5.
6.
7.
8.
9.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Top Nut
O-ring
Coil Housing
Coil Sleeve
Electric Coil
Bottom Plate
Enclosure Tube
Closing Spring
Valve Body
Outlet
Inlet
Enclosure Tube
Armature
Electric Coil
Piston
Closing Spring
Valve Seats
Opening Spring
CSR40SL Semi-Hermetic, February 2000
6-14
8.
Compressor Replacement
Hold valve piston in valve body with scissors while you
finish removing the enclosure tube. Immediately insert
new enclosure tube carefully over piston top. When you
are ready to thread new enclosure tube into valve body,
remove scissors from piston boss and top spring.
Refrigeration Maintenance and Service Operations
7.
Solder both modulation valve connections.
CAUTION: Use a heat sink or wrap the valve with
wet rags to prevent damage to the new valve.
8.
NOTE: If the piston is removed from its bottom
seat in the valve body, the entire modulation
valve must be replaced to ensure proper operation of the modulation valve. Attempting to
reseat the piston in the bottom of the valve body
will damage the bottom return spring and the
valve will no longer operate properly.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Thread new enclosure tube into valve body until it is hand
tight. Then tighten 1/6 turn more with a 1.5 inch wrench.
Place new bottom coil housing plate over enclosure tube.
Place new coil and coil sleeve on enclosure tube.
Place new outer and top coil housing plates over enclosure.
Place new o-ring and coil nut on enclosure tube and
torque to 4.1 N.m (3 ft-lb). Plug coil wire harness into unit
wire harness.
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 “Refrigerant Recovery” in this chapter).
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). Then perform a controller Pretrip Test to verify system operation and correct
feeler bulb installation.
Modulation Valve Replacement
If the valve body is damaged, replace the entire modulation
valve.
1. Remove the compressor compartment bracket.
2. Recover the refrigerant charge from the unit (see
“Refrigerant Recovery” in this chapter).
3. Disconnect the unit from the three-phase power supply.
4. Unplug the coil lead wire harness.
5. Unsolder the compressor side modulation valve joints
from the suction line. Unsolder and remove modulation
valve.
6. Clean the tubes for soldering. Position the new valve in
position in the suction line.
Pressurize the refrigeration system and check for leaks
(see “Refrigerant Leak Test Procedure” in this chapter).
9. If no leaks are found, recover the refrigerant used for the
leak test (see “Refrigerant Recovery” in this chapter).
10. Evacuate the system (see “Evacuation and Cleanup of the
Refrigeration System” in this chapter).
11. Plug the coil wire harness into the unit wire harness.
12. Recharge the unit with R-404A (see “Refrigerant Charge” in
this chapter). Then perform a controller Pretrip Test to
verify system operation and correct feeler bulb installation.
Compressor Replacement
Removal
1. Remove the compressor compartment bracket.
2. Recover the refrigerant charge from the unit (see
“Refrigerant Recovery” in this chapter).
3. Disconnect the unit from the three-phase power supply.
4. Disconnect discharge line, suction line and liquid injection
valve line connections from the compressor.
5. Remove the high pressure cutout switch and compressor
discharge temperature sensor from the discharge valve
manifold.
6. Remove the three-phase electric power connection from
the compressor.
7. Remove the compressor mounting tray bolts and nuts.
8. Slide the compressor from the unit.
9. Keep the compressor ports covered to prevent dust, dirt,
etc., from falling into the compressor.
10. Drain and measure the compressor oil that remains in the
compressor.
NOTE: The compressor oil must be removed
from the compressor and measured so that the
same amount of oil can be added before placing
the new compressor or repaired compressor in
the unit.
CSR40SL Semi-Hermetic, February 2000
Refrigeration Maintenance and Service Operations
Installation
1. Add new compressor oil to the new compressor. Add an
amount equal to the amount removed from the old compressor.
CAUTION: Use ONLY Polyol Ester based refrigeration compressor oil, P/N 203-433. Keep
Polyol Ester based compressor oil in tightly
sealed containers. If Ester based oil becomes
contaminated with moisture or standard oils, dispose of properly — DO NOT USE!
2.
3.
4.
5.
6.
7.
8.
9.
Slide the compressor into the unit. Install mounting bolts,
washers and nuts, and tighten.
Bolt the discharge line, suction line and liquid injection
valve line connections to the compressor. Use a new gasket coated with compressor oil on the discharge valve.
Apply refrigerant locktite to the threads of the high pressure cutout switch and compressor discharge temperature
sensor. Install the switch and sensor.
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 “Refrigerant Recovery” 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 the unit with R-404A (see “Charging the System
with Refrigerant” in this chapter). Then perform a controller Pretrip Test to verify system operation. Check
compressor oil level sight glass.
Condenser Coil Replacement
6-15
Condenser Coil Replacement
Removal
1. Recover the refrigerant charge from the unit (see
“Refrigerant Recovery” in this chapter).
2. Remove the condenser fan grille, condenser fan blade and
condenser fan shroud.
3. Remove the condenser coil support brackets from the coil.
4. Unsolder the liquid inlet and outlet connections.
5. Support the coil and unbolt the condenser coil mounting
brackets. Slide the coil from the unit.
Installation
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 is strongly recommended that dry
nitrogen be used to purge the system during any
solder operations (see “Using Pressurized
Nitrogen” in this chapter).
4.
5.
6.
7.
8.
9.
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 “Refrigerant Recovery” in this chapter).
Evacuate the system (see “Evacuation and Cleanup of the
Refrigeration System” in this chapter).
Replace the condenser coil support brackets, condenser
fan shroud and condenser fan grille.
Recharge the unit with R-404A (see “Charging the System
with Refrigerant” in this chapter).
Perform a controller Pretrip Test to verify system operation. Check compressor oil level using sight glass on the
compressor.
CSR40SL Semi-Hermetic, February 2000
6-16
Filter Drier/In-line Filter Replacement
Refrigeration Maintenance and Service Operations
Filter Drier/In-line Filter Replacement
Expansion Valve Replacement
NOTE: CSR Hermetic units use a one-piece, combination filter drier/in-line filter, P/N 66-9306.
NOTE: CSR semi-hermetic units use a nonadjustable, factory sealed expansion valve. Do NOT
attempt to remove the seal or adjust the valve.
Removal
1. Recover the refrigerant charge from the unit (see
“Refrigerant Recovery” in this chapter).
2. Unsolder the filter drier inlet and outlet connections.
3. Remove the filter bracket clamping nuts and bolts.
4. Remove the old filter drier from the unit.
Installation
1. Clean the liquid line tubes for soldering.
2. Remove the sealing caps from the new filter drier/in-line
filter.
3. Place new filter drier in position.
NOTE: To prevent incorrect installation of the
dehydrator (or in-line filter), the inlet and outlet
fittings are different sizes.
4.
5.
6.
7.
8.
9.
Solder inlet and outlet connections.
Reinstall clamping brackets, nut and bolts. Tighten the bolts.
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 “Refrigerant Recovery” in this chapter).
Evacuate the system (see “Evacuation and Cleanup of the
Refrigeration System” in this chapter).
Recharge the unit with R-404A (see “Refrigerant Charge” in
this chapter). Then perform a controller Pretrip Test to
verify system operation.
Removal
1. Recover the refrigerant charge from the unit (see
“Refrigerant Recovery” in this chapter).
2. Remove insulating tape and unclamp feeler bulb from the
suction line in the condenser section. Note the position of
the feeler bulb on the side of the suction line.
3. Remove insulating tape from expansion valve outlet line.
4. Heat and unsolder the equalizer line from expansion
valve.
5. Heat and unsolder the liquid line inlet and outlet connections to expansion valve in condenser section.
6. Remove expansion valve from unit.
Installation
1. Clean the liquid lines and equalizer lines for soldering.
2. Place new expansion valve in position in liquid line.
3. Solder liquid line inlet and outlet line connections to
valve.
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).
4.
5.
Solder equalizer line to expansion valve.
Pressurize the refrigeration system and check for leaks
(see “Refrigerant Leak Test Procedure” in this chapter).
6. If no leaks are found, recover the refrigerant used for the
leak test (see “Refrigerant Recovery” in this chapter).
7. Evacuate the system (see “Evacuation and Cleanup of the
Refrigeration System” in this chapter).
8. Clean the suction line to a bright polished condition.
Install the feeler bulb of new power head in the feeler bulb
clamp on the suction line. Locate bulb on the suction line
in former position. The feeler bulb must make good contact with the suction line or operation will be faulty.
Cover with insulating tape.
9. Cover expansion valve outlet line with insulating tape.
10. Recharge the unit with R-404A (see “Charging the System
with Refrigerant” in this chapter).
11. Perform a controller Pretrip Test to verify system operation and correct feeler bulb installation.
CSR40SL Semi-Hermetic, February 2000
Refrigeration Maintenance and Service Operations
Heat Exchanger Replacement
6-17
Heat Exchanger Replacement
Receiver Tank Replacement
Removal
1. Recover the refrigerant charge from the unit (see
“Refrigerant Recovery” in this chapter).
2. Remove the “U” mounting clamps that hold the heat
exchanger assembly to the wall of the condenser section.
3. Unsolder the liquid inlet and outlet line connections.
4. Note position of feeler bulb on the side of the suction line.
Remove tape and feeler bulb from the suction line.
5. Unsolder the suction inlet and outlet line connections.
6. Lift the heat exchanger assembly from the unit.
Removal
1. Recover the refrigerant charge from the unit (see
“Refrigerant Recovery” in this chapter).
2. Unsolder the liquid inlet, liquid outlet and warm gas
bypass valve line connections.
3. Loosen the mounting nuts and remove the tank.
4. Remove the water fittings (option) and water pressure
switch (option) from the receiver tank for installation in
new tank.
Installation
1. Clean the tubes for soldering.
2. Place the heat exchanger assembly in the unit and install
the mounting hardware.
3. Solder the suction inlet and outlet line connections.
Installation
1. Install a new tank in the unit and tighten the mounting
bolts.
2. Solder the inlet line, outlet line and warm gas bypass line
connections.
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).
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.
4.
5.
Solder the liquid inlet and outlet line connections.
Pressurize the refrigeration system and check for leaks
(see “Refrigerant Leak Test Procedure” in this chapter).
6. If no leaks are found, recover the refrigerant used for the
leak test (see “Refrigerant Recovery” in this chapter).
7. Evacuate the system (see “Evacuation and Cleanup of the
Refrigeration System” in this chapter).
8. Clean suction line to a bright polished condition. Install
feeler bulb in the feeler bulb clamps on the suction line.
Locate bulb on the suction line in former position. The
feeler bulb must make good contact with the suction line
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.
4.
5.
6.
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 “Refrigerant Recovery” in this chapter).
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). Then perform a controller Pretrip Test to verify system operation.
CSR40SL Semi-Hermetic, February 2000
6-18
High Pressure Switch Replacement
Refrigeration Maintenance and Service Operations
High Pressure Cutout Switch or
Compressor Discharge Temperature Sensor
Replacement
Warm Gas Bypass Valve, Liquid Injection
Valve or Dehumidify Valve (Option)
Replacement
Removal
1. Front seat the compressor suction service valve and discharge service valve.
NOTE: In most cases, only the coil requires replacement. No other repair is possible on solenoid
valves.
CAUTION: Any time the discharge valve is front
seated, disconnect the unit power source to prevent accidental compressor start-up.
2.
4.
Purge the high pressure from the compressor head through
the service port on the discharge line.
Disconnect the leads from the wire harness and remove
the defective switch (or sensor) from the compressor discharge manifold.
Installation
1. Apply a refrigeration locktite (sealant) to the threads of
the switch (or sensor).
2. Install and tighten the switch (or sensor). Connect the
leads to the wire harness.
3. Open discharge service valve slightly to pressurize the
compressor head and tube assembly. Check for leaks (see
“Refrigerant Leak Test Procedure” in this chapter). Front
seat the discharge service valve.
4. If no leaks are found, recover the leak test gas (see
“Refrigerant Recovery” in this chapter).
5. Open the suction service valve and discharge service
valve.
6. Perform a controller Pretrip Test to verify system operation.
Removal
1. Recover the refrigerant charge from the unit (see
“Refrigerant Recovery” in this chapter).
2. Turn the unit On-Off switch OFF. Disconnect electrical
connections to valve coil.
3. Dehumidify valve: Remove insulating tape from liquid
line.
4. Unsolder the liquid line connections to the valve.
5. Remove the valve from the unit.
Installation
1. Clean the tubes for soldering.
2. Place the new valve in position and solder the liquid line
connections.
CAUTION: Use a heat sink or wrap the valve with
wet rags to prevent damage to the new valve.
3.
4.
5.
6.
7.
Pressurize the low side with refrigerant 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 “Refrigerant Recovery” in this chapter).
Evacuate the system (see “Evacuation and Cleanup of the
Refrigeration System” in this chapter).
Reconnect the electrical wires to the valve.
Recharge the unit with R-404A (see “Charging the System
with Refrigerant” in this chapter). Then perform a controller Pretrip Test to verify system operation.
CSR40SL Semi-Hermetic, February 2000
7
Structural/Accessory
Maintenance
Mounting Bolts
Condenser Coil
Check and tighten all unit, compressor, and fan motor mounting bolts during pretrip inspections and every 1,000 operating
hours. Unit mounting bolts should be tightened to a torque
value of 204 N.m (150 ft-lb). Compressor and fan motor
mounting bolts should be tightened to a torque value of 20 to
21 N.m (15 to 20 ft-lb).
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.
Unit Inspection
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.
1
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% 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 pressures may result
if this special condenser grille is damaged or missing.
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.
2
CAUTION: Air pressure must not be high enough to
damage coil fins.
Mounting Bolts
1.
2.
Tighten Unit Mounting Bolts
Tighten Compressor, Condenser Fan and
Evaporator Fan Mounting Bolts
CSR40SL Semi-Hermetic, February 2000
7-2
Defrost Drains
Structural/Accessory Maintenance
3.
Defrost Drains
Clean the defrost drains every 1,000 operating hours to be sure
the lines remain open.
4.
5.
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.
Disk Adjustment: Low Ventilation Rates
1. Loosen wing nut on handle assembly.
2. Rotate the disk to set the Indicator at the rate shown on the
ventilation scale on the door. Set the Indicator to the ventilation rate indicated on the shipping manifest.
- CSR40SL Models: 0 to 125 m3/hr (0 and 75 ft3/min.)
3. Tighten the wing nut.
Align handle bracket and wing nut over hole in handle
assembly and push through handle.
Pull handle down to lower ventilation door. Insert edge of
ventilation door in handle notch. Air exchange rate is
shown on the handle scale. Set the door position to the
ventilation rate indicated on the shipping manifest.
- CSR40SL Models: 150 to 280 m3/hr (90 to 165 ft3/min.)
Spring loaded handle holds ventilation door in position.
Evaporator Fan Location
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) of the fan blade hub
13 mm (0.5 in.) in from the outer edge of the fan orifice.
Handle Adjustment: High Ventilation Rates
1. Loosen wing nut on handle assembly until handle bracket
will rotate over handle.
2. Rotate the handle bracket 90 degrees.
1
2
3
4
5
6
7
Air Exchange System
1.
2.
3.
4.
5.
Ventilation Rate Scale: Low Ventilation Rates
Disk Assembly with Rate Indicator
CO2 Port
Ventilation Door
Handle Assembly with Ventilation Rate Scale: High
Ventilation Rates
3
150 to 280 m /hr (0 to ft3/min)
6. Handle Bracket
7. Wing Nut
Condenser Fan Blade Placement
1.
2.
3.
4.
5.
Airflow Direction
10 mm (0.4 in.)
Condenser Coil
Condenser Fan Blade
Condenser Motor
CSR40SL Semi-Hermetic, February 2000
Structural/Accessory Maintenance
Condenser Fan Location
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.
Saginomiya (Model SKM) Recording
Thermometer (Option)
Condenser Fan Location
7-3
• Blue Zone — Battery good. If the indicator needle remains
in the blue zone when the test button is depressed, the battery
has sufficient power to operate the recorder.
• White Zone — Replace battery within 30 days. If the indicator needle remains in the white zone when the test button is
depressed during a pretrip inspection, replace the battery.
Although the battery may operate the recorder up to 30 more
days, replacing the battery before it is completely dead is recommended.
• Red Zone — Dead battery. If the indicator needle remains in
the red zone when the test button is depressed, the battery is
dead and must be replaced.
The 31-day Saginomiya Recorder is electric motor driven by a
dry cell type battery with a 1 year life expectancy. The sensor
bulb is mounted in the evaporator to record the return air temperature.
The recording thermometer should be inspected and
cleaned to ensure that the stylus produces smooth clean lines
and records accurate temperature readings.
Battery
The recording chart is driven by a battery-powered quartz
motor and reducing gear. The battery charge should be
checked during unit pretrip inspection or once a month. To
check the battery charge, press the button the voltage indicator:
Saginomiya (SKM) Recording Thermometer
Evaporator Fan Blade Placement
1.
2.
3.
4.
5.
Evaporator Fan Blade
Airflow Direction
Evaporator Coil
Evaporator Motor
13 mm (0.5 in.)
1. Recording Chart
2. Chart Nut
3. Battery
4. Test Button
5. Battery Voltage Indicator
6. Power Element Assembly
7. Setting Screw (Calibration)
8. Lock Screw (Calibration)
9. Recording Pen
10. Lifting Arm
11. Time Scale Plate
12. Terminal Board
13. Quartz Motor and Reducing Gear Assembly
14. Recording Platen
CSR40SL Semi-Hermetic, February 2000
7-4
Saginomiya (Model SKM) Recording Thermometer
To replace the battery:
1. Raise the stylus away from the chart by rotating the pen
lift gear clockwise 30 degrees and releasing the lifting
arm. The pen will remain in the raised position. Remove
the knurled chart nut from the drive shaft and remove the
chart.
2. Loosen the four setscrews that hold the recording platen in
the recorder. The setscrews do not remove from the
recorder base.
3. Rotate the recording platen counterclockwise and remove
the platen.
4. Remove the battery from the recorder.
5. Install a new battery in the recorder making sure the battery’s positive (+) and negative (-) poles are correctly
aligned.
6. Press the button on the voltage indicator to make sure the
indicator needle is the in blue zone.
7. Check to see that the quartz motor is running. Look
through the inspection window and make sure the internal
flywheel on the quartz motor is revolving.
8. Replace the recording platen on the recorder base and
rotate clockwise to view setscrews. Tighten four setscrews that hold the platen in the recorder
9. Replace the recording chart and chart nut on the chart
drive shaft and tighten the chart nut finger tight.
10. Lower the pen by rotating the lifting arm counterclockwise and push the pen against the chart.
Recording Chart Replacement
1. To change the charts, raise the stylus away from the chart
by rotating the pen lifting arm clockwise 30 degrees and
releasing the lifting arm. The pen will remain in the
raised position. Remove the knurled chart nut from the
drive shaft and remove the chart.
2. Install the new chart in the slot on the platen and on the
chart drive shaft. Position the chart edge under three
hold-down flanges.
3. Replace the chant nut loosely and rotate the chart so that
the correct date and time are indicated by the arrow on the
time scale plate. Finally hold the recording chart in position and tighten the chart nut finger tight.
4. Lower the pen by rotating the lifting arm counterclockwise and pushing the pen against the chart.
Marking System Calibration
1. Visually inspect the recording thermometer sensing bulb
located in the evaporator near the return air grille. Make
sure it is securely fastened and clear of debris.
2. Start the unit and adjust the temperature setpoint to 0 C
(32 F). Operate the unit until the return air temperature
reaches 0 C (32 F). Enter the View menu on the controller display and scroll to the return air temperature
(“RET”) screen. Press the ENTER key to lock the “RET”
screen on the display.
3.
4.
5.
Structural/Accessory Maintenance
Wait at least 5 minutes to allow the recording thermometer sensing bulb temperature to stabilize. Then compare
the “RET” temperature in the controller display with the
recording stylus of the recorder. Write down both readings.
If the average difference is 0.6 C (1.0 F) or less, DO NOT
attempt to recalibrate.
If the recorder needs recalibration:
a. Place the pen in the recording position (lowered
against chart)
b. Loosen the lock screw using a small Phillips screwdriver.
c. Adjust the setting screw with a small slotted screwdriver or a 7 mm (9/32 in.) open end wrench. Rotate
the setting screw clockwise until the recording pen
temperature reading is 2 to 4 C (4 to 6 F) higher than
the temperature reading of the test instrument.
NOTE: Turning the setting screw one complete
revolution (360 degrees) changes the temperature
reading of the pen by approximately 5 C (9 F).
d.
e.
f.
g.
Then rotate the setting screw counterclockwise to
lower the recording pen reading until the pen reading
agrees with the “RET” controller display.
Tighten the lock screw.
Wait another 5 minutes while the unit operates on
Cool. Verify that the recording thermometer reading
is stable and agrees with the “RET” temperature in
the controller display.
Press any key to unlock the controller display screen.
Power Element Assembly Replacement
The recording thermometer’s power element is field replaceable. To replace the element assembly:
1. Raise the stylus away from the chart. Remove the knurled
chart nut and chart.
2. Remove the recording platen.
3. Loosen five mounting screws that mount the capillary
holding plate and element assembly in the recorder.
Remove the power element assembly (includes recording
pen assembly).
4. Remove the old sensing bulb and capillary from the unit.
5. Install the new sensing bulb and capillary in the unit. The
capillary of the new thermal element may be bent, but DO
NOT bend the bulb.
6. Install the capillary in the recorder and securely tighten
five mounting screws.
7. Replace the recording platen, recording chart and chart
nut. Lower the recording pen.
8. Check the calibration of the recorder. Recalibrate the
recorder if necessary.
CSR40SL Semi-Hermetic, February 2000
Structural/Accessory Maintenance
Saginomiya (Model SKM) Recording Thermometer
Timer (Quartz Motor and Reducing Gear)
Replacement
The quartz motor is field replaceable. To replace the motor
and reducing gear assembly:
1. Raise the stylus away from the chart. Remove the knurled
chart nut and chart.
2. Remove the recording platen.
3. Loosen the two terminal screws on the terminal board and
remove the motor wires.
4. Loosen the five screws that mount the motor assembly in
the recorder. Remove the motor assembly.
5. Install new motor assembly. Install an securely tighten
five mounting screws.
6. Connect the motor wires to the terminal board. Make sure
the red positive (+) and black negative (-) wire are correctly aligned.
7. Check to see that the quartz motor is running. Look
through the inspection window and make sure the internal
flywheel on the quartz motor is revolving.
8. Replace the recording platen, recording chart and chart
nut. Lower the recording pen.
7-5
Battery Voltage Indicator
The battery voltage indicator is field replaceable. If the indicator needle oscillates when the test button is depressed, or the
needle remains in the red zone when a new battery is installed,
replace the voltage indicator assembly:
1. Remove the knurled chart nut and chart. Remove the
recording platen.
2. Loosen the two terminal screws on the terminal board and
remove the voltage indicator wires.
3. Loosen the two mounting screws that mount the voltage
indicator assembly in the recorder. Remove the voltage
indicator (includes battery holder).
4. Install a new voltage indicator. Install and securely tighten the two mounting screws.
5. Connect the voltage indicator wires to the terminal board.
Make sure the red positive (+) wire and black negative (-)
wire are correctly aligned.
6. Reinstall the battery in the battery holder (with correct
polarity). Check the voltage indicator by depressing the
test button to make sure the indicator needle is in the blue
zone. Also check to see that the quartz motor is operating
(flywheel revolving).
7. Replace the recording platen, recording chart and chart
nut. Lower the recording pen.
CSR40SL Semi-Hermetic, February 2000
8
Diagnosis
Mechanical Diagnosis
Condition
Possible Cause
Remedy
Compressor does not
operate — no amperage
draw
Controller ON; unit start
sequence still timing
Wait up to 2 minutes for compressor
start-up
No power to unit (condenser and
evaporator fans do not operate)
Check and repair: power source, power
plug, CB1 main circuit breaker, motor contactor, motor terminals, motor
Open in 24 Vac
control circuit
Check fuses and On/Off switch. Replace or
repair as required
Container temperature does not
demand cooling
Adjust controller setpoint
Compressor contactor inoperative
Replace compressor contactor
No output signal from controller
output module
Diagnose and replace output module or
controller
Unit on defrost
Turn unit On/Off switch OFF and ON again
Defective high pressure cutout switch
Replace high pressure cutout switch
Refrigerant overcharge or high
side restriction causing cycling
on high pressure cutout
Check for restricted filter drier or high side,
and refrigerant overcharge
Inefficient condenser operation
causing cycling on high pressure
cutout
Check condenser airflow, condenser
fan motor, fan blade, condenser grille,
and condenser coil temperature sensor
Controller shut unit down on
Compressor Over Temperature
(alarm code 82)
Let compressor cool and controller will
reset automatically. Check liquid injection
valve and compressor temperature sensor
Compressor motor internal thermal
overload protection open
If compressor contactor is energized, wait
60 minutes for protector to cool and reset.
Defective compressor
Replace compressor
CSR40SL Semi-Hermetic, February 2000
8-2
Mechanical Diagnosis
Diagnosis
Condition
Possible Cause
Remedy
Compressor does not
operate; excessive
amperage draw or
intermittent cycling
on overload
Rotating scroll stuck
Replace compressor
Seized or frozen compressor bearings
Replace compressor
Improperly wired
Check/correct wiring against wiring diagram
Low line voltage
Check line voltage — determine location of
voltage drop
Contacts in compressor contactor not
closing completely
Check by operating manually. Repair or
replace
Open circuit in compressor motor
winding
Check motor stator connections. Check
stator winding for continuity. If open,
replace compressor
Defective compressor motor internal
thermal overload protector
Replace thermal overload protector or
compressor
Refrigerant overcharge or high
side restriction causing cycling
on high pressure cutout
Check for restricted filter drier, in-line filter
or high side; or refrigerant overcharge
Inefficient condenser operation
causing cycling on high pressure
cutout
Check condenser airflow, condenser
fan motor, fan blade, condenser grille,
and condenser coil temperature sensor
Low line voltage
Increase line voltage to at least 90% of
compressor motor rating
Excessive line voltage
Reduce line voltage to at least 110% of
compressor motor rating
Short cycling
Eliminate cause of short cycling
Defective controller
Check controller with µP-D Microprocessor
Tester (see Diagnosis Manual, TK 41230)
Refrigerant overcharge or high
side restriction causing cycling
on high pressure cutout
Check for restricted filter drier, in-line filter
or high side; or refrigerant overcharge
Inefficient condenser operation
causing cycling on high pressure
Check condenser airflow, condenser
fan motor, condenser fan grille and
condenser coil temperature sensor
Compressor contactor
burned out
Unit short cycles
CSR40SL Semi-Hermetic, February 2000
Diagnosis
Mechanical Diagnosis
8-3
Condition
Possible Cause
Remedy
Condenser fan motor does
not operate
Unit in Null, Heat or Defrost
Check indicator lights. If unit is in
Null, Heat or Defrost, unit operation is
normal (no remedy required)
Unit in Cool or Modulation
Check indicator lights and condenser pressure in View menu of µP-D controller. If
condenser coil temperature is below 35 C
(95 F) and the compressor temperature is
below 50 C (122 F), unit operation is normal
(no remedy required)
Loose line connection
Tighten connections
Open motor internal thermal
overload protector
Check for seized bearings or defective
thermal overload protector. Repair or
replace as necessary
Defective motor
Replace motor
Defective high speed condenser fan
contactor
Replace defective contactor
No high speed condenser fan output
signal from controller
Diagnose and replace output module or
controller
Unit on defrost
Check operating mode indicator lights
Unit in Economy Mode (Frozen Load;
Null mode ONLY)
Check setpoint, indicator lights and
Program menu of µP-D controller to verify
that Economy Mode is set to ON
Loose line connection
Tighten connections
Open motor internal thermal
overload protector
Check for seized bearings or defective
thermal overload protector. Repair or
replace as necessary
Defective motor
Replace motor
Defective low or high speed
evaporator fan contactor
Replace defective contactor
No low or high speed evaporator
fan output signal from controller
output module
Diagnose and replace output module or
controller
Evaporator fan motor(s)
does not operate
CSR40SL Semi-Hermetic, February 2000
8-4
Mechanical Diagnosis
Diagnosis
Condition
Possible Cause
Remedy
Noisy compressor
Loose mounting bolts
Tighten mounting bolts
Oil slugging or refrigerant flooding
back
Perform controller Pretrip Test to check
refrigerant charge. Check expansion valve
adjustment. Check compressor for
compressor oil.
Scroll rotating backwards
Check phase correction system and check
unit wiring
Defective compressor
Repair or replace compressor
CSR40SL Semi-Hermetic, February 2000
Diagnosis
Refrigeration Diagnosis
8-5
Refrigeration Diagnosis
Condition
Possible Cause
Remedy
Load temperature too high
(unit not cooling)
Compressor does not operate
See “Mechanical Diagnosis”
Controller setpoint too high
Adjust controller setpoint
Defective container insulation or
poor fitting doors
Repair container
Shortage of refrigerant
Repair leak and recharge
Overcharge of refrigerant
Purge system
Air in refrigeration system
Evacuate and recharge
Liquid injection valve open
Check liquid injection valve circuit and compressor discharge temperature sensor
Warm gas bypass valve open
Check bypass valve circuit
Defective controller
Check controller with µP-D Microprocessor
Tester (see Diagnosis Manual, TK 41230)
Too much compressor oil in system
Remove compressor oil from 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
Modulation valve defective
Repair or replace modulation valve
Condenser coil dirty or airflow
restricted
Clean condenser coil, clear restriction, or
repair or replace fan motor or condenser fan
blade
Expansion valve open too much
Adjust or replace valve
Expansion valve power element lost
its charge
Replace power element
Expansion valve feeler bulb improperly mounted, poorly insulated or
making poor contact
Correct feeler bulb installation
CSR40SL Semi-Hermetic, February 2000
8-6
Refrigeration Diagnosis
Diagnosis
Condition
Possible Cause
Remedy
Head pressure too low
Shortage of refrigerant
Repair leak and recharge
NOTE: This unit has a
suction modulation
capacity control system.
Suction and discharge
pressures may drop below
expected normal readings
when the unit is in
Modulation Cool (control
temperature within 2.5 C
[4.5 F] of setpoint or
in Power Limit mode).
Low ambient air temperature
No remedy
Service gauge out of calibration
Replace gauge
Head pressure too high
Refrigerant overcharge
Purge system
Air in refrigeration system
Evacuate and recharge
Dirty or restricted condenser coil
Clean condenser coil
Condenser fan not operating
See “Condenser fan motor does not operate” under Mechanical Diagnosis
Condenser fan grille damaged or
missing
Repair or replace grille
Condenser fan blade damaged
Replace fan blade
High ambient air temperature
No remedy
Restricted filter drier/in-line filter
or high side
Replace filter drier or clear restriction
Defective service gauge
Replace gauge
Compressor loses oil
Refrigerant leak
Repair leak and recharge
Compressor oil migrates
to system
Short cycling
See “Unit short cycles” under
Mechanical Diagnosis
CSR40SL Semi-Hermetic, February 2000
Diagnosis
Refrigeration Diagnosis
8-7
Condition
Possible Cause
Remedy
Rapid cycling between
Cool, Null and Heat
modes
Air short cycling through evaporator
Check and correct cargo load
Defective controller
Check controller with µP-D Microprocessor
Tester (see Diagnosis Manual, TK 41230)
Short cycling
See “Unit short cycles” under Mechanical
Diagnosis
Modulation Valve not operating
Repair or replace valve
Receiver tank outlet valve partially
closed or restricted
Open valve or remove restriction
Restricted filter drier/in-line filter
Replace filter drier
Expansion valve admitting excess
refrigerant
Check feeler bulb and adjust expansion
valve
Evaporator coil needs defrosting
Check defrost circuit including controller
and evaporator coil sensor
Evaporator fan does not operate
See “Evaporator fan motor does not operate” under Mechanical Diagnosis
Warm gas bypass valve open
Normal when unit is in Modulation and container temperature is near setpoint
Unit in vacuum. Frost on
expansion valve only
Ice plugging expansion valve
screen or orifice
Apply hot wet cloth to expansion valve.
Moisture indicated by increase in suction
pressure. Replace filter drier
High suction pressure
Overcharge of refrigerant
Purge system
Expansion valve open too much
Adjust or replace valve
Controller out of calibration or
defective
Recalibrate or replace controller
Warm gas bypass valve open
Normal when unit is in Modulation and container temperature is near setpoint
Service gauge out of calibration
Adjust or replace service gauge
Frosted liquid line
Frosted or sweating
suction line
CSR40SL Semi-Hermetic, February 2000
8-8
Refrigeration Diagnosis
Diagnosis
Condition
Possible Cause
Remedy
Low suction pressure
Shortage of refrigerant
Repair leak and recharge
NOTE: This unit has a
suction modulation
capacity control system.
Suction and discharge
pressures may drop below
expected normal readings
when the unit is on
Modulation Cool (control
temperature within 2.5 C
[4.5 F] of setpoint or
in Power Limit mode).
Low ambient air temperature
No remedy
Iced or dirty evaporator coil
Defrost or clean evaporator coil
Restricted lines
Locate and clear restriction
Plugged filter drier/in-line filter
Replace filter drier
Expansion valve closed too much
Adjust or replace valve
Expansion valve feeler bulb improperly mounted, poorly insulated or
making poor contact
Correct feeler bulb installation
Evaporator fans off
Check evaporator fan motors and control
circuit and repair
Defective controller
Check controller with µP-D Microprocessor
Tester (see Diagnosis Manual, TK 41230)
Service gauge out of calibration
Adjust or replace gauge
CSR40SL Semi-Hermetic, February 2000
9 Electrical, Refrigeration and
µP-D Menu Flow Diagrams
460/380 Vac Power Supply to Unit1
1
Typical model shown with three evaporator fans.
CSR40SL Semi-Hermetic, February 2000
9-2
Schematic Circuit Tracings
Electrical, Refrigeration and µP-D Menu Flow Diagrams
External 12 Vdc Battery Power Supply1, 2
1
Typical model shown with three evaporator fans.
Requires on-board 12 Vdc battery or an external 12 Vdc battery connected to battery jack on Power Module Board
inside control box.
2
CSR40SL Semi-Hermetic, February 2000
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Schematic Circuit Tracings
9-3
Microprocessor Awakened from Sleep Mode1 (when external power is disconnected from unit)2
1
When external power is disconnected from unit, microprocessor operation requires an on-board 12 Vdc battery, or an
external 12 Vdc battery connected to the battery jack on Power Module Board inside control box. Then press
SELECT key or connect communications cable to Data Port on bottom of control box.
2
Typical model shown with three evaporator fans.
CSR40SL Semi-Hermetic, February 2000
9-4
Schematic Circuit Tracings
Electrical, Refrigeration and µP-D Menu Flow Diagrams
12.5 Vdc Control Circuit, Sensor Circuits, Modulation Valve Circuit and Water Pressure Circuit (Option)1
1
Typical model shown with three evaporator fans.
CSR40SL Semi-Hermetic, February 2000
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Schematic Circuit Tracings
9-5
24 Vac Control Circuit1
1
Typical model shown with three evaporator fans.
CSR40SL Semi-Hermetic, February 2000
9-6
Schematic Circuit Tracings
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Dehumidify System, Humidity System, Water Pressure Switch, USDA Temperature Sensor, Pulp Sensor and
Chart Recorder Circuits (Options)
1
Typical model shown with three evaporator fans.
CSR40SL Semi-Hermetic, February 2000
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Schematic Circuit Tracings
9-7
Cool Mode1 — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan ON2; Power Monitor Limiting
Unit Power Consumption; Economy Mode OFF
1
Typical model shown with three evaporator fans.
A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above
50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
2
CSR40SL Semi-Hermetic, February 2000
9-8
Schematic Circuit Tracings
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Cool Mode1 — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan ON2; Economy Mode OFF
1
Typical model shown with three evaporator fans.
A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above
50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
2
CSR40SL Semi-Hermetic, February 2000
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Schematic Circuit Tracings
9-9
Modulation Mode1 — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan ON2; Economy Mode
OFF; Temperature Out-of-range
1
Typical model shown with three evaporator fans.
A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above
50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
2
CSR40SL Semi-Hermetic, February 2000
9-10
Schematic Circuit Tracings
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Modulation Mode1 — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan ON2; Economy Mode
OFF; Temperature In-range; Dehumidify ON with Humidity 1-5% Above Humidity Setpoint3
1
Typical model shown with three evaporator fans.
A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above
50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
3
Dehumidify Mode is set to ON in the PROGRAM menu of the controller. When the unit is in Low Dehumidify operation (humidity 1-5% above setpoint), the dehumidify valve closes (energizes) to reduce the size of the evaporator coil
used for cooling.
2
CSR40SL Semi-Hermetic, February 2000
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Schematic Circuit Tracings
9-11
Modulation Mode1 — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan ON2; Economy Mode
OFF; Temperature In-range; Dehumidify ON with Humidity 5% or More Above Humidity Setpoint3
1
Typical model shown with three evaporator fans.
A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above
50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
3
Dehumidify Mode is set to ON in the PROGRAM menu of the controller. When the unit is in High Dehumidify operation (5% or more above setpoint), the dehumidify valve closes (energizes) to reduce the size of the evaporator coil
used for cooling and the electric heaters are pulsed ON for a maximum of 15 seconds every 30 seconds.
2
CSR40SL Semi-Hermetic, February 2000
9-12
Schematic Circuit Tracings
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Modulation Mode1 — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan OFF2; Economy Mode
ON3; Temperature In-range
1
Typical model shown with three evaporator fans.
A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above
50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
3
Evaporator fans operate on low speed when Economy Mode is set to ON in the Program menu of the µP-D controller
and the container temperature is In-range.
2
CSR40SL Semi-Hermetic, February 2000
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Schematic Circuit Tracings
9-13
Modulation Mode1 — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Condenser Fan OFF2; Economy Mode
ON3; Temperature In-range, Warm Gas Bypass Valve ON4
1
Typical model shown with three evaporator fans.
A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above
50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
3
Evaporator fans operate on low speed when Economy Mode is set to ON in the Program menu of the µP-D controller
and the container temperature is In-range.
4
Warm gas bypass valve pulses ON and OFF when calculated temperature differential is less than 0.6 C (1.0 F).
2
CSR40SL Semi-Hermetic, February 2000
9-14
Schematic Circuit Tracings
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Null Mode1 — Chill Load (Setpoint at -9.9 C [14.1 F] or Above), Condenser Fan ON2; Economy Mode OFF
1
2
Typical model shown with three evaporator fans.
The controller stops the compressor. If the condenser fan was ON, it will operate for 30 seconds and then stop.
CSR40SL Semi-Hermetic, February 2000
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Schematic Circuit Tracings
9-15
Heat Mode1, 2 — Chill Load (Setpoint at -9.9 C [14.1 F] or Above); Economy Mode OFF; Temperature In-range
1
Typical model shown with three evaporator fans.
Electric heaters pulse ON and OFF during the Heat mode. The amount of ON time increases from 0% at a
Calculated Temperature Differential of 0.6 C (1.0 F) below setpoint to 100% at a Calculated Temperature Differential
of 3.1 C (5.5 F) below setpoint.
2
CSR40SL Semi-Hermetic, February 2000
9-16
Schematic Circuit Tracings
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Cool Mode1 — Frozen Load (Setpoint at -10.0 C [14.0 F] or Below); Condenser Fan ON2; Container Return Air
Temperature Above -10.0 C (14.0 F); Power Monitor Limiting Unit Power Consumption; Economy Mode OFF
1
Typical model shown with three evaporator fans.
A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above
50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
2
CSR40SL Semi-Hermetic, February 2000
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Schematic Circuit Tracings
9-17
Cool Mode1 — Frozen Load (Setpoint at -10.0 C [14.0 F] or Below); Condenser Fan ON2; Container Return Air
Temperature Below -10.0 C (14.0 F); Economy Mode OFF; Temperature In-Range
1
Typical model shown with three evaporator fans.
A complex algorithm will typically turn the condenser fan ON when the compressor discharge temperature is above
50 C (122 F) and increasing, or when the condenser temperature is above 35 C (95 F).
2
CSR40SL Semi-Hermetic, February 2000
9-18
Schematic Circuit Tracings
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Null Mode1 — Frozen Load (Setpoint at -10.0 C [14.0 F] or Below); Condenser Fan OFF2; Economy Mode OFF
1
2
Typical model shown with three evaporator fans.
Controller stops the compressor. If the condenser fan was ON, it will operate for 30 seconds and then stop.
CSR40SL Semi-Hermetic, February 2000
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Schematic Circuit Tracings
9-19
Null Mode1 — Frozen Load (Setpoint at -10.0 C [14.0 F] or Below); Condenser Fan OFF2; Economy Mode ON3
1
Typical model shown with three evaporator fans.
Controller stops the compressor. If the condenser fan was ON, it will operate for 30 seconds and then stop.
3
Evaporator fans stop during Null mode when Economy Mode is set to ON in the Program menu of the µP-D controller. During Economy Mode operation, a Null state timer automatically starts and operates the evaporator fans on
low speed for 5 minutes every 45 minutes. The unit remains in Null until the return air temperature increases to 1.0 C
(1.8 F) above setpoint at the expiration of a 45 minute Null state time sequence.
2
CSR40SL Semi-Hermetic, February 2000
9-20
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Defrost1
1
Typical model shown with three evaporator fans.
CSR40SL Semi-Hermetic, February 2000
Electrical, Refrigeration and µP-D Menu Flow Diagrams
CSR40SL Wiring Schematic
9-21
CSR40SL Semi-Hermetic, February 2000
Electrical, Refrigeration and µP-D Menu Flow Diagrams
CSR40SL Wiring Diagram — Page 1 of 3
9-22
CSR40SL Semi-Hermetic, February 2000
Electrical, Refrigeration and µP-D Menu Flow Diagrams
CSR40SL Wiring Diagram — Page 2 of 3
9-23
CSR40SL Semi-Hermetic, February 2000
Electrical, Refrigeration and µP-D Menu Flow Diagrams
CSR40SL Wiring Diagram — Page 3 of 3
9-24
CSR40SL Semi-Hermetic, February 2000
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Refrigeration Schematic: Components
9-25
CSR40SL
Refrigeration System Components
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Scroll Compressor
Sight Glass
Oil Fill / Drain Fitting
Compressor Discharge Temperature Sensor (CDTS)
High Pressure Cutout Switch (HPCO)
Schrader Valve, Discharge Line
Flange Connection, Discharge Line
Condenser Coil (Circular)
Receiver Tank
Warm Gas Bypass Valve
High Pressure Relief Valve
Filter Drier/In-line Filter
Heat Exchanger
Expansion Valve (TXV)
Distributors
Evaporator Coil
Expansion Valve Feeler Bulb
Equalizer Line
Modulation Valve (MV)
Suction Gauge (Option)
Schrader Valve, Suction Line
Flange Connection, Suction Line
Flange Connection, Injection Line
Liquid Injection Valve (LIV) with Restrictor
Electric Heaters
Return Air Sensor (RET)
Evaporator Coil Sensor (ECOIL)
Supply Air Sensor (SUP)
Ambient Sensor (AMBT)
Condenser Coil Sensor (CCOIL)
Controller (µP-D)
Dehumidify Solenoid Valve (DSV) (Option)
Humidity Sensor (rH) (Option)
CSR40SL Semi-Hermetic, February 2000
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Refrigeration Schematic: Full Cool
9-26
Flow and Pressure Diagram
CSR40SL
Full Cool
1.
Scroll Compressor
Compressor operation has a delay on initial start-up when the unit
shifts to a cooling mode requiring the compressor to start-up.
4.
Compressor Discharge (Head) Temperature Sensor (CHS1)
Controller cycles condenser fan ON typically when the compressor
discharge temperature is above 50 C (122 F) and increasing.
5.
High Pressure Cutout Switch (HPCO)
Is a normally CLOSED switch.
It OPENS at 3240 +/- 50 kPa, 32.4 +/- 0.5 bar, 470 +/- 7 psig.
It CLOSES at 2590 +/- 260 kPa, 25.9 +/- 2.6 bar, 375 +/- 38 psig.
11. High Pressure Relief Valve
OPENS at 3450 +520/-105 kPa, 34.5 +5.20/-1.05 bar, 500 +75/-15
psig.
CLOSES at 2760 kPa, 27.6 bar, 400 psig.
30. Condenser Coil Temperature Sensor (CCOIL)
Controller cycles condenser fan ON typically when the condenser coil
temperature is above 35 C (95 F).
µP-D)
31. Controller (µ
Thermoguard (µP-D) with digital thermostat, thermometer and fault
indicator monitor.
Null Mode Operation
During the Null mode, the compressor does not operate. If the condenser fan is ON when the unit shifts to Null, the condenser fan operates for 30 seconds and stops. Evaporator fans continue to operate
(evaporator fan speed is determined by return air temperature and
economy mode setting).
High pressure gas
High pressure liquid
Low pressure gas
Low pressure liquid
Condensing high pressure gas
Low pressure vaporizing liquid
Liquid refrigerant injection
CSR40SL Semi-Hermetic, February 2000
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Refrigeration Schematic: Modulation Cool
9-27
Flow and Pressure Diagram
CSR40SL
Modulation Cool
10. Warm Gas Bypass Valve
Is a normally CLOSED solenoid.
It OPENS when energized to reduce cooling capacity when the temperature is close to setpoint.
19. Modulation Valve (MV)
Is a normally OPEN valve.
It CLOSES when energized. As the signal strength is increased, the
valve closes more. The controller regulates the signal to the valve
based on sensor temperatures and power limit requirements.
24. Liquid Injection Valve (LIV)
Is a normally CLOSED valve.
It OPENS when energized. When liquid injection is required, the
valve is pulsed open and closed on a 10 second cycle.
The valve is energized when the compressor head temperature is above
138 C (280 F) or when the modulation valve closes more than 45%.
25. Electric Heaters
During the DEFROST mode, the electric heaters are pulsed ON and
OFF. The compressor does not operate. The condenser fan and
evaporator fans remain OFF.
During the HEAT mode, the electric heaters are pulsed ON and OFF.
The compressor does not operate. The condenser fan is OFF. The
evaporator fans continue to operate (evaporator fan speed is determined by return air temperature and economy mode setting).
High pressure gas
High pressure liquid
Low pressure gas
Low pressure liquid
Condensing high pressure gas
Low pressure vaporizing liquid
Liquid refrigerant injection
Modulated pressure
High pressure gas injection
High pressure gas injection
CSR40SL Semi-Hermetic, February 2000
Electrical, Refrigeration and µP-D Menu Flow Diagrams
Refrigeration Schematic: Dehumidification
9-28
Flow and Pressure Diagram
CSR40SL
Dehumidification
32. Dehumidify Solenoid Valve (DSV) (Option)
Is a normally OPEN valve.
If the container humidity is 1% or more above the humidity setpoint
and the temperature is in-range, the controller will energize (CLOSE)
the normally open solenoid. This closes refrigerant distribution to 50%
of the evaporator coil, thereby lowering the temperature of the active
part of the coil and condensing more moisture from the container air.
25. Electric Heaters
If the container humidity is 5% or more above the humidity setpoint,
and the temperature is in-range, the controller will pulse the electric
heaters ON and OFF in addition to energizing (closing) the dehumidify
solenoid valve. This increases the cooling load on the evaporator coil,
thereby lowering the temperature of the entire coil and condensing
more moisture from the container air.
33. Humidity Sensor (rH) (Option)
The humidity sensor is located at the top right hand side of the evaporator fan deck and measures the humidity of the return air from the
cargo space.
High pressure gas
High pressure liquid
Low pressure gas
Low pressure liquid
Condensing high pressure gas
Low pressure vaporizing liquid
Liquid refrigerant injection
Modulated pressure
CSR40SL Semi-Hermetic, February 2000
MOD
DATA
SETPOINT
NULL
°
°
Main Menu
DATA
TEMPERATURE
DEFROST SUPPLY RETURN PWRLMT ALARM
— MENU PRGRM
— MENU GUARD
— MENU TEST
— MENU PTRIP
— MENU VIEW
— MENU < - - - >
HEAT IN RANGE
Standard Display
COOL
<--->
ETEST
FTEST
STEST
to
— PRGRM < - - - >
— USDA
OFF
— USDA1
OFF
— USDA2
OFF
— USDA3
OFF
— PULP
OFF
— HUMSN OFF
— ECON
OFF
— HUMID
OFF
— BULB
OFF
— PWRED
0
Program Menu
Press
to enter
access code.
Display shows
GUARD LOAD, then
GMENU <- - - >.
Press
or
select number.
Press
to scroll
cursor to next digit to
right.
Enter access code7.
— GUARD < - - - >
— GUARD 0 0 0 0
Guard Menu
— TEST < - - - >
— TEST ELECT
— TEST REFRG
— TEST CNTRL
— TEST
GEN
Test Menu
— PTRIP
— PTRIP
— PTRIP
— PTRIP
Pretrip Menu
— VERSN XX.XX
— CFG U YYYY
— CFG C
ZZ
Software
Active Option and Pause Mode Displays
Press
option.
to load
Press
to select
ON (or PWRED
value) in right display.
Press
to enter
Load display. Left
display FLASHES.
— GMENU < - - - >
— MENU CNFIG
— CIDXX (scroll)
— USNXX (scroll)
— YEAR
XXXX
— MONTH
XX
— DAY
XX
— HOUR
XX
— MIN
XX
— CHRM1XXXXX
— ONHRMXXXXX
— H1TYP
XX
— UHMT1
XX
— UHRM1XXXXX
— H2TYP
XX
— UHMT2
XX
— UHRM2XXXXX
— H3TYP
XX
— UHMT3
XX
— UHRM3XXXXX
— H4TYP
XX
— UHMT4 XXXXX
— UHRM4
XX
— ECMAXXXXXX
— ECMIN XXXXX
— ECONT XXXXX
— DMTCH
XX
— DMTFZ
XX
— ALOGS
XXX
— GLOGS XXX
— C/F8
X
— MENU GRADE
Guard Submenu
— REFRG < - - - >
— REFRG FCHI
— REFRG MC50
— REFRG MC100
— REFRG NULL
— REFRG HEAT
— REFRG DFRST
Refrigeration
Test Submenu
— STEST < - - - >
— ENTER DISPL
— ENTER AMPS
— ENTER SENSR
— ENTER HEAT
— ENTER DFRST
— ENTER COOL
— ENTERECOOL
Single Test
Submenu
— ENTER ETEST
or
— ENTER FTEST
• Set calibration for
USDA1, USDA2,
USDA3 and PULP.
• Set HUMSP for
HUMID.
• Set BDFTT and
BEFAN for BULB.
Press
to load
new value.
<--->
FCHI
MC50
MC100
HEAT
DFRST
— GRADE < - - - >
— RETG
XX
— SUPG
XX
— ECTG
XX
— CCTG
XX
— AMTG
XX
— SPR5G
XX
Grade Submenu
Press
to load
selection.
Press
or
to select configuration number.
Press
to enter
load configuration
display.
Press
to start
test. Display shows:
— (TEST) ONOFF
— RET
XXXXX
— SUP
XXXXX
— TD
XXXXX
— ECOIL XXXXX
— (TEST) < - - - >
— UNIT
— UNIT
— UNIT
— UNIT
— UNIT
— UNIT
Unit Amps
Submenu
— VIEW < - - - >
— RET
XXXXX
— SUP
XXXXX
— TD
XXXXX
— ECOIL XXXXX
— CCOIL XXXXX
— AMBT XXXXX
— USDA14XXXXX
— USDA24XXXXX
— USDA34XXXXX
— PULP15 XXXXX
— PCHUM XXXXX
— PCVAL6XXXXX
— VOLTS XXXXX
— HERTZ XXXXX
— AMP1 XXXXX
— AMP2 XXXXX
— AMP3 XXXXX
— AUXV XXXXX
— CLKV XXXXX
— YEAR XXXXX
— MONTH XXXXX
— DAY
XXXXX
— TIME XXXXX
— CHS1 XXXXX
— CHRM1XXXXX
— VIEW GRADE
— VIEW
LOG
View Menu
<--->
TEMP
PTI
OFFON
Press
to load
new grade.
Press
or
to
select new grade.
Press
to enter
load grade display.
— UNIT
Generator Test
— CNTRL < - - - >
— AUTO OFFON
— EFL
OFFON
— EFH OFFON
— CFH OFFON
— CPH OFFON
— PS1
OFFON
— PS2
OFFON
— HTR OFFON
— MC 50 OFFON
— MC100 OFFON
— LIV
OFFON
— BVS OFFON
— LLS
OFFON
— SLS
OFFON
— DEHUMOFFON
— RCOMPOFFON
— RDEF OFFON
— RIR
OFFON
— RSP OFFON
Controller Test
Submenu
Press
to enter
load test display:
— FCHI OFFON
— MC50 OFFON
— MC100 OFFON
— HEAT OFFON
— DFRST OFFON
Press
to enter
load test display:
— HEATROFFON
— EFL
OFFON
— EFH OFFON
— CFH OFFON
— LOG
— LOG
— LOG
Log Submenu
— GRADE < - - - >
— RETG
XX
— SUPG
XX
— ECTG
XX
— CCTG
XX
— AMTG
XX
— SPR5G5
XX
Grade Submenu
Press
to
start refrigeration
unit. Display
shows:
— UNIT ONOFF
— HERTZ
XX
— VOLTS XXXX
— AMP1
XXX
— AMP2
XXX
— AMP3
XXX
— UNIT < - - - >
Press
to
start test. Display
shows:
— (TEST) ONOFF
Press
to
start test. Display
shows:
— (TEST) ONOFF
— AMPS1
XXX
— AMPS2
XXX
— AMPS3
XXX
— VOLTS XXXX
— HERTZ
XX
— (TEST) < - - - >
Press
to
start test. Display
shows:
— (TEST) ONOFF
— AMPS1
XXX
— AMPS2
XXX
— AMPS3
XXX
— VOLTS XXXX
— HERTZ
XX
— (TEST) < - - - >
Press
to display
next TEMP or PTI
result.
Press
or
to
display log entries.
Press
to enter
Scroll Back display.
Display shows:
SEARC HINGX and
then recent log entry.
NOTE: The screens that display on the controller are determined by the Unit Configuration and Customer Configuration settings. All
screens are NOT present on all units.
Footnotes:
1ECON ON time shows ONLY if Economy Mode is ON and unit is in Null on Frozen
Load (setpoint -10.0 C [14 F] or Below).
2SENSR CHECK time shows ONLY when controller performs a sensor check test.
3PAUSE screen indicates controller has stopped unit operation due to a shutdown
alarm. Controller restarts unit if alarm condition is corrected.
4Screen shows ONLY if spare sensor is ON in program menu. If USDA option is ON,
ONLY View Menu shows USDA1, USDA2 and USDA3.
5PULP optional display.
6PCVAL displays on modulation valve systems. PCCAP displays on KVQ valve systems.
7Access code is 0007.
8C/oF units shown on the controller display can also be changed by pressing and holding
the oC/oF key, and then pressing ENTER key.
9When a unit configuration is entered, a customer configuration MUST also be entered.
Press
or
to
select new value.
Press
to enter
load value display.
Press
when all
digits are set correctly
to load new ID.
Press
to select
another digit to change.
Press
or
to
select new letter (A to
Z) or number (0 to 9).
Press
to enter
load value display.
Right display flashes
digit to be changed.
Scrolling display
shows current ID.
— CNFIG < - - - >
— CFG U YYYY9
— CFG C
ZZ
Configuration
Submenu
Press
to enter
load test display:
— FCHI OFFON
— MC50 OFFON
— MC100 OFFON
— NULL OFFON
— HEAT OFFON
— DFRST OFFON
— ELECT < - - - >
— VOLTS XXXX
— HERTZ
XX
— AMPS HEATR
— AMPS
EFL
— AMPS
EFH
— AMPS
CFH
— AMPS
UNIT
Electrical Test
Submenu
Press
to start
a single pretrip
test. Display
shows test time
remaining.
Press
to start
an Extended or
Full Pretrip test.
Display shows test
time remaining.
Display shows Pause Alarm and options
that are ON in Program menu for 1 second
every 10 seconds. Phase and Sensor
check screens show until test is complete.
— ECON
ON
— ECONT XXXX1
— HUM
ON
— DEHUM
ON
— BULB
ON
— PHASE CHECK
— SENSR CHECK
— SENSR
XXX2
— PAUSE ALMXX3
Electrical, Refrigeration and µP-D Menu Flow Diagrams
µP-D Menu Flow Diagram
9-29
CSR40SL Semi-Hermetic, February 2000
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