Thermo King CSR40-149 User manual

CSR40-149 & -150

Power Saver

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

Maintenance Manual

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 con-

sequential damages, including injury or damage caused to vehicles, contents or persons, by reason of the installation of any

Thermo King product or its mechanical failure.

SmartSponge and Thermoguard are trademarks of Thermo King Corporation. All other trademarks are the property of their respec-

tive 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 concern-

ing the use of refrigerants and the certification of technicians. For additional

information on regulations and technician certification programs, contact

your local THERMO KING dealer.

CSR40-149 & -150 PS Hermetic, June 2000

Introduction v

About This Manual v

Other Reference Manuals v

CSR40-149 & -150 PS Model Features vi

Safety Precautions vii

General Practices vii

Refrigerant vii

Refrigerant Oil viii

Electrical viii

General Safety Practices for Servicing Units

(or Containers) Equipped with a

Microprocessor Controller ix

Unit Decals x

Serial Number Locations x

Service Guide xi

Specifications 1-1

System Net Cooling Capacity — Full Cool:

CSR40 PS Models — Air Cooled Condensing 1-1

System Net Heating Capacity 1-1

Evaporator Airflow:

CSR40 PS Models 1-1

Electrical System 1-2

Refrigeration System 1-3

MP-3000 Controller 1-4

Dehumidify and Humidify Systems (Options) 1-5

Physical Specifications 1-6

Metric Hardware Torque Charts 1-7

Unit Description 2-1

Unit Features 2-1

Unit Options 2-2

Operating Modes 2-3

Unit Illustrations 2-4

Typical Unit Front View 2-4

Unit Options Front View 2-5

CSR40 PS Evaporator Section – Front View 2-6

Hermetic Refrigeration System 2-7

MP-3000 Controller 2-8

Unit Control Box 2-9

Humidify System Option 2-10

Advanced Fresh Air Management Option 2-11

Typical Unit Back View 2-12

Operating Instructions 3-1

Unit Controls 3-1

Unit Instruments 3-1

Unit Protection Devices 3-1

Pretrip Inspection 3-3

Starting the Unit and Adjusting the Controller

Setpoint 3-4

Loading Procedure 3-5

Post Load Procedure 3-5

Post Trip Procedure 3-5

MP-3000 Controller 4-1

Controller Description 4-1

Status Indicator LEDs 4-3

Data Recording and Downloading Data 4-3

General Theory of Operation 4-4

Chill Loads 4-4

Frozen Loads 4-5

Modulation Display in Data Menu 4-5

Power Limit Mode 4-5

Table of Contents

ii Table of Contents

CSR40-149 & -150 PS Hermetic, June 2000

Compressor Liquid Injection 4-5

Warm Gas Bypass 4-5

Evaporator Fan Control 4-5

Condenser Fan Control 4-6

Economy Mode Operation 4-6

Probe Test 4-6

Dehumidify Mode (Option) 4-7

Sequence of Operation 4-7

Unit Start-up 4-7

Continuous Temperature Control Operation 4-8

Operating Mode Function Chart — Standard

Operation 4-9

Operating Mode Function Chart — Optional

Feature Operation 4-10

Defrost 4-11

Changing the Setpoint 4-12

Initiating a Manual Defrost 4-12

Displaying Alternate Controlling (Supply or

Return) Air Sensor Temperature 4-12

Displaying Alternate Fahrenheit (F) or

Celsius (C) Temperatures 4-13

Navigating the Controller Menu 4-13

General Operating Tips 4-13

Setpoint Menu 4-13

Changing the Setpoint Temperature 4-13

Changing the Economy Mode Setting 4-14

Changing the Humidity Mode Setting 4-14

Changing the Humidity Setpoint 4-14

Changing the Advanced Fresh Air

Management (AFAM) Mode Setting 4-14

Changing the AFAM Delay 4-15

Changing the AFAM Rate 4-15

Data Menu 4-16

Viewing the Data Menu 4-16

Alarms Menu 4-16

Alarm Types 4-16

Alarm Code States 4-17

Viewing the Alarm List Menu 4-17

Alarm List 4-17

Commands Menu 4-18

View the Commands Menu 4-18

Defrost 4-19

Function Test 4-19

CSR PS Function Test Procedure 4-21

Pretrip (PTI) Test 4-20

CSR PS Pretrip (PTI) Test Procedure 4-23

Manual Function Test 4-20

Power Management 4-28

Misc. Functions Menu 4-28

Viewing the Misc. Functions Menu 4-28

Setting the Date and Time 4-28

Changing the Temperature Display

Value (C/F) 4-29

Setting Cargo Data 4-29

Viewing or Setting Run Time 4-30

Configuration Menu 4-30

Viewing or Setting Functions 4-30

Datalogger Menu 4-31

Viewing the Datalogger Menu 4-32

Inspect Temp Log 4-32

Inspect Event Log 4-32

Set Log Time 4-33

Set a Trip Start 4-33

Inspect PTI Log 4-34

RMM State Menu 4-34

Viewing the RMM State Screen 4-34

Manual Emergency Mode Operation 4-34

Replacing the Controller 4-35

Automatic Configuration of Spare

Parts Controller 4-35

Controller Software Selection 4-36

Flash Loading Controller Software 4-36

Temperature Sensors 4-36

Diagnosis and Repair 4-38

Error Messages and Controller Actions 4-39

Alarm Codes, Descriptions and

Corrective Actions 4-42 to 4-61

Electrical Maintenance 5-1

Unit Wiring 5-1

High Pressure Cutout Switch 5-1

Low Pressure Cutout Switch 5-2

Condenser Fan and Evaporator Fan Rotation 5-2

Electric Heaters 5-3

CSR40-149 & -150 PS Hermetic, June 2000

Table of Contents iii

Refrigeration System Diagnosis and Service 6-1

Hermetic Refrigeration System Diagnosis

Procedures 6-1

Hermetic Refrigeration System Visual Inspection

and Diagnosis Chart 6-3

Hermetic Refrigeration System Service

Procedures 6-4

Service Tools 6-4

Refrigerant Charge 6-5

Compressor Oil Charge 6-6

Installing and Removing Piercing Type Service

Valves and a Gauge Manifold Set 6-6

Gauge Manifold Valve Positions 6-8

Refrigerant Leak Test Procedure 6-9

Using Pressurized Nitrogen 6-9

Refrigerant Recovery from Hermetic

Refrigeration Systems 6-10

Evacuation and Cleanup of the

Refrigeration System 6-11

Charging the System with Refrigerant 6-15

Compressor Replacement 6-15

Compressor Discharge Temperature Sensor

Replacement 6-16

Stepper Motor Valve Replacement 6-17

Condenser Coil Replacement 6-17

Filter Drier/In-line Filter Replacement 6-18

Expansion Valve Replacement 6-18

Heat Exchanger Replacement 6-19

Receiver Tank Replacement 6-19

Low or High Pressure Cutout Switch Replacement 6-20

Warm Gas Bypass Solenoid Valve, Liquid

Injection Valve or Dehumidify Valve

(Option) Replacement 6-20

Structural/Accessory Maintenance 7-1

Mounting Bolts 7-1

Unit Inspection 7-1

Condenser Coil 7-1

Evaporator Coil 7-1

Defrost Drains 7-2

Condenser Fan Location 7-2

Evaporator Fan Location 7-2

Humidify System (Option) 7-2

Partlow (Model SR) Recording Thermometer

(Option) 7-3

Advanced Fresh Air Management (AFAM) System

(Option) 7-5

Mechanical Diagnosis 8-1

Electrical, Refrigeration and MP-3000 Menu Flow

Diagrams 9-1

Controller Diagram 9-3

Wiring Schematic 9-4

Main Relay Board Terminal Connections

(Page 1 of 3) 9-5

Main Relay Board Terminal Connections

(Page 2 of 3) 9-6

Main Relay Board Terminal Connections

(Page 3 of 3) 9-7

Refrigeration System Schematics:

Refrigeration System Components 9-8

Full Cool Flow and Pressure Diagram 9-9

Modulation Cool Flow and Pressure Diagram 9-10

Dehumidification Flow and Pressure Diagram 9-11

MP-3000 Menu Flow Diagram 9-12

CSR40-149 & -150 PS Hermetic, June 2000

Introduction

About This Manual

The information in this manual is provided to assist owners,

operators and service people in the proper upkeep and mainte-

nance of Thermo King units. This manual includes mainte-

nance and diagnosis information for both standard and option-

al unit features. Some optional features may not apply to your

unit. The maintenance information in this manual covers unit

models:

CSR PS Hermetic Models System Number

CSR40-149 Power Saver 917149

CSR40-150 Power Saver 917150

Other Reference Manuals

For detailed descriptions of our refrigeration systems or micro-

processor controllers, see the appropriate manual. For further

information refer to:

Operation, Diagnosis and Refrigeration Maintenance

Manuals

Diagnosing Thermo King Container

Refrigeration Systems TK 41166

Electrostatic Discharge (ESD)

Training Guide TK 40282

Evacuation Station Operation and Field

Application TK 40612

Tool Catalog TK 5955

vi CSR40-149 & -150 PS Model Features Introduction

CSR40-149 & -150 PS Hermetic, June 2000

CSR40-149 & -150 PS Model Features

– – Slimline Frame

X X Top Air Discharge

X X 460-380V/3Ph/60-50 Hz, 18.3 m (60 ft) Power Cable and Plug

X X Dual Voltage Feature: 15 kVA Autotransformer with 460-380V Power Receptacle and 230-190V/3Ph/60-50 Hz, 18.3 m

(60 ft) Power Cable and Plug

X X 25 Amp Main Power Circuit Breaker

X X Automatic Phase Selection Control

X X Hermetic Scroll Compressor w/4.48 kW (6.0 Hp) Motor

X X Hermetic Refrigeration System

X X Refrigerant R-404A w/Polyol Ester Compressor Oil (TK P/N 203-433)

X X Stepper Valve Capacity Control System

X X Compressor Liquid Injection System

X X Warm Gas Bypass Valve System

X X MP-3000 Microprocessor Controller with Integral Datalogger

– – Three (3) Evaporator Fans with 2-Speed Motors

X X Two (2) Evaporator Fans with 2-Speed Motors

X X Condenser Fan with 1-Speed Motor

– – Fresh Air Exchange System

X X AFAM — Advanced Fresh Air Management

– – Data Retrieval Receptacle, Standard (5-Pin Deutsch)

X X Data Retrieval Receptacle, 5-Pin Threaded Cannon

– – Data Retrieval Receptacle, 15-Pin RS232

– X Dehumidify Control

– X Humidity System

– – Pressure Gauge, Discharge

– – Pressure Gauge, Suction

X X Recorder, Partlow

– – Recorder, Saginomiya

– – Remote Monitoring Plug (4-Pin)

– – TRANSFRESH®Provision

– – TRANSFRESH®Purge Port

– – TRANSFRESH®System, Complete

– – Thermistor Lead

– – USDA Cold Treatment Temperature Recording

– – Water-Cooled Condenser-Receiver Tank

CSR40-149 PS

CSR40-150 PS

FEATURES

X = Included

MODEL

This manual suits for next models

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