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Thermo King CSR-20 Series - User Manual

Thermo King CSR-20 Series
199 pages
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CSR-20 & CSR-40
Hermetic with
µµ
P-D
TK50622-4-MM (Rev. 1, 9/99)
Maintenance Manual
Copyright ©1999, Thermo King Corporation, Minneapolis, MN, U.S.A.
Printed in U.S.A.

Table of Contents

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Thermo King CSR-20 Series Specifications

General IconGeneral
Phase3
Frequency60 Hz
Operating Voltage208-230V
Heating Capacity20, 000 BTU/hr
Voltage208-230V
RefrigerantR-452A

Summary

Introduction

About This Manual

Provides an overview of the manual's content, scope, and unit models covered.

CSR Model Features

Details the features available across different CSR models.

Safety Precautions

General Practices

Outlines essential safety rules for handling units, tools, and working environment.

Refrigerant

Covers safety procedures, first aid, and environmental considerations for refrigerants.

Refrigerant Oil

Details safety precautions and first aid for handling refrigerant oil.

Electrical

Addresses high voltage and low voltage safety precautions and first aid.

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

Specific safety measures for electronic components to prevent damage from static discharge.

Service Guide

Pretrip Inspection

Lists items to visually inspect before loading a container for maintenance.

Specifications

System Net Cooling Capacity

Provides cooling capacity data for various CSR models under different conditions.

Refrigeration System

Details components like compressor, refrigerant charge, oil, and cutout switches.

Electrical System

Lists specifications for motors, heaters, and control circuit voltages.

Thermoguard µP-D Microprocessor

Describes the controller's features, setpoint range, and output module functions.

Physical Specifications

Provides dimensions, fan blade specs, weight, and thermometer options.

Unit Description

General Description

Overview of unit construction, features, and power supply.

Thermoguard µP-D Controller

Describes the controller's integrated functions, displays, and keys.

Operating Modes

Explains how the unit operates in different modes like Chill, Frozen, and Null.

Operating Instructions

Unit Control Box

Describes the function of the ON/OFF switch.

µP-D Controller Operations

Explains how to use the controller's keys for display and control.

Pretrip Inspection

Outlines visual checks and procedures to be performed before loading.

Starting the Unit and Adjusting the Controller Setpoint

Step-by-step instructions for starting the unit and setting the temperature.

µP-D Controller

General Description

Overview of the controller's basic features and capabilities.

Controller Display Menus

Explains the main menus and keypad functions for navigating the controller.

Status Indicator LEDs and Alarm Codes

Explains the meaning of indicator LEDs and the general function of alarm codes.

General Theory Of Operation

Explains the controller's use of circuits, inputs, and outputs to regulate unit functions.

Economy Mode Operation

How Economy Mode reduces power consumption by controlling evaporator fans.

Defrost

Explains how the unit initiates, operates, and terminates defrost cycles.

Displaying Alternate Fahrenheit (F) or Celsius (C) Temperatures

How to switch between temperature display scales.

Changing the Setpoint

Step-by-step guide to adjusting the temperature setpoint via the controller.

Initiating a Manual Defrost

Procedure for manually starting a defrost cycle using the controller.

Initiating a Full Pretrip

Steps to perform a full pretrip test on the unit.

Displaying and Clearing Alarm Codes

Guide to viewing, recording, and clearing alarm codes from the controller.

Menu Guard Functions

Guide to accessing and navigating the Guard menu with an access code.

Menu Program Functions

Explains activating and setting various modes like USDA, Economy, and Dehumidify.

Electrical Maintenance

Unit Wiring

Instructions for inspecting unit wiring, harnesses, and contactor points.

High Pressure Cutout Switch

Details the function and checking procedure for the high pressure cutout switch.

Condenser Fan and Evaporator Fan Rotation

Procedures for checking fan rotation direction and correcting if necessary.

Integrated Remote Monitor Unit (IRMU) (Option)

Explains the function and diagnosis of the IRMU for remote monitoring.

Refrigeration System Diagnosis and Service

Hermetic Refrigeration System Diagnosis Procedures

Outlines procedures for diagnosing hermetic systems using the Full Pretrip Test.

Use Alarm Codes to Identify and Diagnose Potential Problems

Guide to using alarm codes for diagnosing refrigeration system issues.

Refrigerant Recovery

Procedures for recovering R-404A refrigerant using approved equipment.

Evacuation and Cleanup of the Refrigeration System

Importance and steps for evacuating and cleaning the system to prevent contamination.

Charging the System with Refrigerant

Instructions for charging the system with refrigerant by weight.

Compressor Replacement

Step-by-step guide for removing and installing a compressor.

Modulation Valve Repair or Replacement

Details on repairing or replacing the modulation valve and its components.

Filter Drier;In-line Filter Replacement

Procedures for replacing the combination filter drier/in-line filter.

Structural;Accessory Maintenance

Mounting Bolts

Instructions for tightening unit, compressor, and fan motor mounting bolts.

Unit Inspection

Guidance for inspecting the unit for damage during pretrip and routine checks.

Condenser Coil

Steps for cleaning and inspecting the condenser coil and grille.

Evaporator Coil

Instructions for cleaning and inspecting the evaporator coil and fins.

Humidity System (Option)

Describes the operation, setup, and maintenance of the humidity system.

Mechanical Diagnosis

Compressor does not operate - no amperage draw

Lists possible causes and remedies for a compressor that doesn't start.

Compressor does not operate; excessive amperage draw or intermittent cycling on overload

Troubleshooting for compressors with high amperage or overload cycling issues.

Condenser fan motor does not operate

Diagnosing and resolving issues with the condenser fan motor not operating.

Evaporator fan motor(s) does not operate

Troubleshooting for evaporator fan motors that are not operating.

Electrical, Refrigeration and µP-D Menu Flow Diagrams

460;380 Vac Power Supply to Unit

Schematic showing the 460/380 Vac power supply connection to the unit.

230;190 Vac Power Supply to Unit

Schematic illustrating the 230/190 Vac power supply connection to the unit.

12.5 Vdc Control Circuit, Sensor Circuits, Modulation Valve Circuit and Water Pressure Circuit (Option)

Circuit diagram for control, sensor, modulation valve, and water pressure options.

CSR-20 and CSR-40 Wiring Schematic for All Models with Three Evaporator Fans

Wiring schematic for models with three evaporator fans.

Refrigeration System Components

Diagram identifying major components of the refrigeration system.

Flow and Pressure Diagram CSR-20 & CSR-40 Full Cool

Diagram illustrating the flow and pressures during full cool operation.

µP-D Menu Flow Diagram

Visual representation of the µP-D controller's menu structure and navigation.

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