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Thermo King CRR-40 800E - User Manual

Thermo King CRR-40 800E
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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Summary

Safety Precautions

Refrigerant

Safety precautions for handling refrigerants, including evaporation and freezing hazards.

First Aid

Immediate medical response procedures for contact with refrigerants or electrical shock.

Electrical

Safety measures related to electrical systems, emphasizing high voltage hazards.

High Voltage

Specific precautions for working with high voltage circuits and components.

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

Precautions to prevent electrostatic discharge damage to electronic components.

Controller Repair

Procedures to avoid damage during controller servicing, focusing on electrostatic discharge.

Specifications

Refrigeration System

Technical specifications for the unit's refrigeration components, including refrigerant and oil.

Controller

Specifications for the MPC2000ID or MP-3000a controller, including temperature range and defrost parameters.

Metric Hardware Torque Chart

Torque values for various metric bolt sizes and classes used in unit assembly.

Compressor Torque - D3 D Copeland Compressor Bolt Torque

Specific torque values for tightening compressor mounting bolts and covers.

Operating Instructions

Unit Controls

Explanation of the physical unit controls and the microprocessor controller interface.

Unit Protection Devices

Description of safety features like circuit breakers, fuses, and overload protectors.

Pretrip Inspection

Essential pre-operation checks required before loading the container.

Functional Inspection

Tests to verify the correct operation of unit components before starting a trip.

Starting the Unit and Adjusting the Controller Setpoint

Step-by-step guide to starting the unit and setting the desired temperature setpoint.

Loading Procedure

Steps to follow during the container loading process to ensure proper conditions.

Post Load Procedure

Actions to take after the container is loaded, including setting cargo data.

MP-3000 a Controller

Controller Description

Overview of the controller's features, including displays, keypad, and basic functions.

Data Recording and Downloading Data

Details on how the controller logs sensor data, events, and alarms, and how to retrieve it.

Chill Loads (Setpoint at -9.9 C [14.1 F] and Above)

How the controller operates the unit in Cool with Modulation and Heat modes for chill loads.

Frozen Loads (Setpoint at -10 C [14 F] and Below)

How the controller operates the unit in Full Cool and Null modes for frozen loads.

High Temperature Protection

The controller's safety function to stop the unit if discharge gas temperature is too high.

Initial Unit Start-up and Normal Operation (Standard)

Controller behavior during initial unit start-up and normal operation in standard modes.

Defrost

Explanation of defrost cycle initiation, termination, and controller actions.

Changing the Setpoint

Procedure for adjusting the target temperature setpoint via the controller keypad.

Setpoint Menu

Menu for setting temperature, economy mode, humidity control, and other parameters.

Alarms Menu

Menu for displaying and managing alarm codes recorded by the controller.

Commands Menu

Menu for executing various tests and commands, such as Function Test and PTI Test.

Brief Pretrip (PTI) Test

Procedure for performing a brief pre-operation test to check unit functions.

Full Pretrip (PTI) Test

Procedure for performing a comprehensive pre-operation test of the unit's systems.

Function Test

Procedure for testing individual unit components automatically.

Manual Function Test

Procedure for manually testing specific components or groups of components.

Manual Emergency Mode Operation

Procedure for operating the unit manually in emergency situations due to controller failure.

Electrical Maintenance

Refrigeration Maintenance and Service Operations

Refrigerant Recovery

Procedures for safely removing refrigerant, minimizing atmospheric release, and handling contaminated refrigerant.

Checking Compressor Oil

Procedures for checking the compressor oil level under varying ambient temperatures.

Refrigerant Leak Test Procedure

Method for testing the refrigeration system for leaks using electronic detectors or soap solution.

Refrigerant Charge

Information on checking and maintaining the correct refrigerant charge for optimal performance.

Evacuation and Cleanup of the Refrigeration System

Critical procedures for removing contaminants like air and moisture from the system.

Unit Preparation and Hookup

Steps for preparing the unit and connecting service equipment before evacuation.

Unit Evacuation

Procedure for evacuating the system to achieve a specified vacuum level.

Pressure Rise Test

Diagnostic test to identify leaks or moisture in the system by monitoring vacuum pressure rise.

Unit Charging (from an Evacuated Condition)

Procedure for charging the system with refrigerant after it has been evacuated.

KVQ Valve Replacement

Procedure for replacing the KVQ valve body or the entire valve assembly.

Refrigerant Recovery

Procedures for recovering refrigerant safely and minimizing atmospheric release.

Compressor Replacement

Comprehensive guide for removing and installing the compressor unit.

Removal

Steps for safely removing the compressor from the unit, including disconnecting lines and power.

Installation

Steps for installing a new or repaired compressor, including connecting lines and power.

Condenser Coil Replacement

Comprehensive guide for removing and installing the condenser coil.

Dehydrator (Filter Drier) Replacement

Procedure for replacing the dehydrator (filter drier) in the refrigeration system.

Expansion Valve Replacement

Procedure for replacing the expansion valve, including feeler bulb placement.

Heat Exchanger Replacement

Procedure for replacing the heat exchanger assembly.

Receiver Tank Replacement

Procedure for replacing the receiver tank, including transferring fittings.

High Pressure Cutout Switch Replacement

Procedure for replacing the high pressure cutout switch.

Liquid Line Solenoid Valve Replacement

Procedure for replacing the liquid line solenoid valve, focusing on coil replacement.

Liquid Injection Valve Replacement

Procedure for replacing the liquid injection valve, focusing on coil replacement.

Dehumidify Valve Replacement

Procedure for replacing the dehumidify valve, focusing on coil replacement.

Diagnosis

Mechanical Diagnosis

Troubleshooting guide for mechanical issues causing compressor problems, such as no amperage draw or excessive cycling.

Thermo King CRR-40 800E Specifications

General IconGeneral
BrandThermo King
ModelCRR-40 800E
CategoryHeat Pump
LanguageEnglish

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