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Thermo King CRR-40 800 User Manual

Thermo King CRR-40 800
170 pages
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CRR-40 119, 172
& 800 for
Maersk Sealand
TK 50743-4-MM (Rev. 5, 11/03)
Copyright© 2003 Thermo King Corp., Minneapolis, MN, USA.
Printed in USA.

Table of Contents

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Thermo King CRR-40 800 Specifications

General IconGeneral
BrandThermo King
ModelCRR-40 800
CategoryHeat Pump
LanguageEnglish

Summary

Recover Refrigerant Procedures

Safety Precautions

Refrigerant Handling and First Aid

Precautions, properties, and first aid for handling refrigerants.

Refrigerant Oil Handling and First Aid

Precautions and first aid for handling refrigerant oil.

Electrical Safety Guidelines

Guidelines for working safely with high and low voltage electrical components.

Controller and Component Safety

Precautions for servicing controllers and preventing damage from ESD and welding.

Specifications

System Net Cooling Capacity

Cooling capacity data for CRR-40 models under different conditions.

Refrigeration System Specifications

Compressor and Related Components Specs

Details about the compressor model, oil, and high pressure cutout switch.

System Suction Pressures

Controller Operation

Defrost Termination Conditions

Conditions that terminate the defrost cycle, based on sensors and timers.

Electrical System Specifications

Compressor Motor Specifications

Electrical specifications for the compressor motor, including type, power, and amps.

Unit Description

Compressor System Details

Description of the compressor and its liquid injection cooling system.

Microprocessor Controller Overview

Overview of the microprocessor controller's capabilities and display features.

Operating Modes

Operating Instructions

Controller Interface and Display

Explanation of the controller keypad, LED, and LCD display functions.

Unit Protection Devices Explanation

Overview of unit protection devices like circuit breakers and fuses.

Pretrip Inspection Procedures

Steps for performing a visual inspection before loading the container.

Functional Inspection Procedures

Steps for performing a functional test on units with MPC2000ID or MP-3000a controllers.

Starting Unit and Adjusting Setpoint

Procedures for starting the unit and setting the controller temperature setpoint.

MP-3000a Controller Details

Controller Alarms and Status Handling

How the controller displays and handles alarms and status messages.

Data Recording and Downloading Procedures

How the controller records and allows download of operational data.

MP-3000a Controller Functions

General Theory of Operation

How the controller uses integrated circuits to monitor and control unit functions.

Chill Loads Operation Logic

How the controller manages chill loads based on setpoints and supply air.

Compressor Liquid Injection Operation

How liquid injection protects the compressor from high temperatures.

High Temperature Protection Logic

Controller actions for high compressor discharge temperatures.

Probe Test Procedure

How the controller performs a probe test to check sensors.

Continuous Temperature Control: Chill Loads

How the controller maintains temperature in chill loads mode.

Frozen Loads Operation Logic

How the controller manages frozen loads, locking out modulation and heat modes.

Defrost Operations

Defrost Initiation Methods

Conditions and methods for initiating defrost cycles.

Defrost Mode Termination Conditions

Conditions that cause the defrost mode to terminate.

Changing the Setpoint Procedure

Step-by-step instructions for changing the controller setpoint.

Initiating a Manual Defrost

How to manually initiate a defrost cycle.

Alarms Menu

Alarms Menu Overview

How to access and view alarm codes recorded by the controller.

Alarm Types and States Explained

Explanation of different alarm types and their states (active, not active).

Viewing the Alarm List Menu

Steps to view the list of recorded alarm codes.

Commands Menu

Function Test Procedures

How to perform automated tests on individual unit components.

Pretrip (PTI) Test Procedures

How to initiate and perform Pretrip (PTI) tests for unit diagnostics.

Manual Function Test Submenu Navigation

How to select and perform tests on individual components manually.

Brief Pretrip (PTI) Test

Brief PTI Test Procedure Details

Detailed steps, possible alarms, and durations for the Brief PTI test.

Full Pretrip (PTI) Test

Full PTI Test Procedure Details

Detailed steps, possible alarms, and durations for the Full PTI test.

Function Test Procedures

Configuration Menu

Datalogger Menu

Manual Emergency Mode Operation

Replacing the Controller

Controller Replacement Steps

Step-by-step procedure for replacing the unit's controller.

Diagnosis and Repair

Status Messages and Controller Actions

Explanation of status messages displayed by the controller and their corresponding actions.

Status Messages and Controller Actions Table

Table detailing status messages, their indications, and controller actions.

Alarm Code Descriptions and Corrective Actions

Detailed list of alarm codes, their descriptions, and corrective actions.

Electrical Maintenance

High Pressure Cutout Switch

Description and testing procedure for the high pressure cutout switch.

High Pressure Cutout Manifold Testing

Procedure for testing the high pressure cutout switch using a gauge manifold.

Refrigeration Maintenance and Service Operations

Refrigerant Leak Test Procedure

Methods and steps for performing a refrigerant leak test.

Refrigerant Charge Check Procedure

How to check the refrigerant charge using receiver tank sight glasses.

Checking Refrigerant Charge with Sight Glasses

Detailed steps for checking refrigerant charge with sight glasses.

Evacuation and Cleanup of Refrigeration System

Unit Evacuation Procedure

Detailed steps for evacuating the refrigeration system to the required vacuum level.

Pressure Rise Test Procedure

How to perform a pressure rise test to check for leaks or moisture.

Unit Charging Procedure

Steps for charging the system with refrigerant from an evacuated condition.

Final Charging Procedure for Partially Charged Units

Procedure for completing the refrigerant charge for partially charged units.

Evaporator Pressure Regulator (KVQ) Valve

KVQ Valve Replacement

KVQ Valve Replacement Procedure

Complete procedure for replacing the KVQ valve body.

Refrigerant Recovery Operations

Refrigerant Recovery Precautions

Cautions and procedures for using refrigerant recovery equipment.

Compressor Replacement

Compressor Removal Steps

Steps for removing the compressor from the unit.

Compressor Installation Steps

Steps for installing a new or repaired compressor.

Condenser Coil Replacement

Dehydrator (Filter Drier) Replacement Procedure

Heat Exchanger Replacement Procedure

Receiver Tank Replacement

High Pressure Cutout Switch Replacement

Liquid Line Solenoid Valve Replacement

Liquid Injection Valve Replacement

Dehumidify Valve Replacement

Structural/Accessory Maintenance

Pretrip Inspection Checklist

Items to inspect before loading the container.

Diagnosis: Mechanical Issues

Compressor Not Operating (No Amperage Draw)

Troubleshooting steps for a compressor with no amperage draw.

Compressor Not Operating (Excessive Amperage/Cycling)

Troubleshooting steps for a compressor with excessive amperage or overload cycling.

Compressor Contactor Burnout Troubleshooting

Troubleshooting for a burned-out compressor contactor.

Unit Short Cycling Troubleshooting

Troubleshooting steps for a unit that is short cycling.

Condenser Fan Motor Not Operating Troubleshooting

Troubleshooting for a condenser fan motor that is not operating.

Evaporator Fan Motor(s) Not Operating Troubleshooting

Troubleshooting for evaporator fan motors that are not operating.

Unit Vacuum (Not Cooling) Troubleshooting

Troubleshooting steps when the unit is in vacuum and not cooling.

Load Temperature Too High (Not Cooling) Troubleshooting

Troubleshooting steps for high load temperatures when the unit is not cooling.

Head Pressure Too Low Diagnosis

Troubleshooting for low head pressure conditions.

Head Pressure Too High Diagnosis

Troubleshooting for high head pressure conditions.

Compressor Oil Loss Diagnosis

Troubleshooting for compressor oil loss or migration.

Frosted or Sweating Suction Line Diagnosis

Troubleshooting for frosted or sweating suction lines.

Unit Vacuum with Expansion Valve Frost Diagnosis

Troubleshooting for frost on the expansion valve when the unit is in vacuum.

High Suction Pressure Diagnosis

Troubleshooting for high suction pressure.

Low Suction Pressure Diagnosis

Troubleshooting for low suction pressure conditions.

Full Cool Flow and Pressure Diagram

Cool with Modulation Flow Diagram

MPC2000ID Controller Menu Flow Diagram

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