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Thermo King CSR Series User Manual

Thermo King CSR Series
189 pages
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CSR
TK 50824-4-MM (Rev. 6, 11/02)
Copyright
©
2002 Thermo King Corp., Minneapolis, MN, U.S.A.
Printed in U.S.A.

Table of Contents

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Thermo King CSR Series Specifications

General IconGeneral
BrandThermo King
ModelCSR Series
CategoryRefrigerator
LanguageEnglish

Summary

Safety Precautions

General Practices

Essential safety guidelines for unit operation and handling.

First Aid Procedures

Procedures for immediate care in case of exposure to hazardous materials or conditions.

Refrigerant Safety Guidelines

Precautions for handling refrigerants to prevent environmental release and personal harm.

Refrigerant Oil Handling

Guidelines for safe handling and preventing contact with refrigerant oil.

Electrical Safety

High Voltage Precautions

Critical safety measures when working with high voltage circuits to prevent electrical shock.

Electrical First Aid

Immediate actions to take following an electrical shock incident.

Controller and Welding Safety

Microprocessor Controller Handling

Procedures to prevent electrostatic discharge (ESD) when servicing electronic components.

Welding Safety Precautions

Guidelines to prevent damage to electronic circuits during welding operations.

Unit Identification and Markings

Unit Decals and Serial Numbers

Information on locating and understanding unit decals and serial number identification.

Service Guide

Maintenance Schedule Overview

Recommended inspection and service intervals for electrical, refrigeration, and structural components.

Specifications

System Cooling and Heating Capacity

Performance data for cooling and heating capacities across different models and conditions.

Evaporator Airflow Rates

Airflow specifications for various models based on external static pressure.

Electrical System Components

Details on motors, voltage, and electrical resistance heater specifications.

Refrigeration System Parameters

Specifications for compressor, refrigerant charge, pressure switches, and control systems.

MP-3000 Controller Specifications

Technical details for the MP-3000 controller, including defrost and humidity functions.

Physical Specifications

Dimensions, weight, and fan blade specifications for various unit models.

Metric Hardware Torque Charts

Torque values for metric bolts and classes used in unit assembly.

Unit Description

General Unit Overview

Description of unit construction, features, and design for container transport.

Scroll Compressor and Liquid Injection

Details on the scroll compressor system and its liquid injection cooling mechanism.

MP-3000 Controller Features

Comprehensive overview of the MP-3000 controller's capabilities, display, keypad, and data logger.

Unit Description - Systems and Options

Evaporator Fan and Air Exchange Systems

Description of dual-speed evaporator fans and the fresh air exchange system functionality.

Unit Options Overview

Explanation of available options like AFAM, AFAM+, Bulb Mode, and Dehumidification Control.

Unit Description - Additional Options

Dual Voltage and Humidification Systems

Details on dual voltage capability and optional humidification control system.

Monitoring and Control Options

Information on pressure gauges, remote monitoring, recording thermometers, and TRANSFRESH systems.

USDA Cold Treatment Recording

Features for monitoring and recording temperatures for USDA cold treatment compliance.

Unit Description - Operating Modes

Water-Cooled Condenser/Receiver Tank

Description of the water-cooled condenser option and its fan control.

Operating Modes Explained

Detailed explanation of Chill Loads and Frozen Loads operating modes based on setpoints.

Operating Instructions

Unit Controls Overview

Description of the UNIT ON/OFF switch and the MP-3000 controller interface, including keys and displays.

MP-3000 Controller Functions

Explanation of controller keys (C/F, RET/SUP, DEFROST, SETPOINT) and status indicator LEDs.

Unit Controls and Instruments

Additional Unit Controls

Details on evaporator overheat switch, water pressure switch, and other unit controls.

Unit Instruments for Monitoring

Description of instruments like oil sight glass, pressure gauges, thermistor, and remote monitor connector.

Unit Protection Devices

Electrical Protection Circuits

Overview of main circuit breakers, control system circuits, and fuses for unit protection.

Compressor Temperature Protection

Explanation of compressor discharge temperature sensing and high-temperature protection mechanisms.

MP-3000 Controller Details

Controller Description and Display

Detailed breakdown of the MP-3000 controller's LED and LCD displays and basic features.

Keypad and Special Function Keys

Explanation of the controller's keypad layout, text input, menu navigation, and special function keys.

MP-3000 Controller - Menus and Status

Controller Display Menus Overview

Overview of the eight main display menus available on the MP-3000 controller.

Status Indicator LEDs Explained

Meaning of the eight status indicator LEDs on the MP-3000 controller display.

MP-3000 Controller - Data and Operation

Data Recording and Downloading

Functions for recording and retrieving unit operating data, alarms, and events.

General Theory of Operation

Explanation of the MP-3000 controller's integrated circuits and regulated unit functions.

MP-3000 Controller - Temperature Control

Chill Loads Operation Details

Detailed description of the Cool with Modulation and Heat modes for chill loads.

Supply Air Sensor Control

How supply air sensors are used for temperature control accuracy and frost protection.

MP-3000 Controller - Load Modes and Protection

Frozen Loads Operation Details

Explanation of Cool, Null, and Defrost modes for frozen loads and modulation display.

Compressor Operation Controls

Details on compressor liquid injection and high-temperature protection features.

MP-3000 Controller - Fan and Condenser Control

Evaporator Fan Control and Economy Mode

How the controller manages evaporator fan speed and economy mode settings.

Condenser Fan Control Strategy

Controller's strategy for managing condenser fan operation based on ambient conditions and load.

Probe Test Procedure

How the controller performs a probe test to check for defective sensors.

MP-3000 Controller - Specialized Modes

Bulb Mode Operation

How Bulb mode controls fan speed and defrost termination during Dehumidification.

Dehumidify Mode Operation

How the dehumidify system reduces relative humidity and its control parameters.

Sequence of Operation: Unit Start-up

Description of the unit's start-up sequence for cooling or heating modes.

MP-3000 Controller - Continuous Operation

Continuous Temperature Control for Chill Loads

How the controller regulates operation for chill loads, including cool mode and modulation.

MP-3000 Controller - Operating Modes Summary

CSR Operating Mode Function Chart

A table summarizing unit functions across different modes for Chill and Frozen Loads.

MP-3000 Controller - Frozen Loads and Heat Modes

Frozen Loads Operation Details

How the controller manages operation for frozen loads, including Cool, Null, and Defrost modes.

Heat Mode Operation

How the controller provides heat by pulsing electric heaters when supply air temperature is low.

MP-3000 Controller - Defrost and Cool Modes

Cool Mode Operation Details

Detailed steps and conditions for the Cool mode operation.

Defrost Mode Initiation and Termination

Procedures for initiating and terminating defrost cycles, including manual defrost.

MP-3000 Controller - Setpoint and Defrost Management

Changing the Setpoint Temperature

Step-by-step guide to changing the temperature setpoint on the MP-3000 controller.

Defrost Initiation and Termination Procedures

How defrost cycles are initiated, terminated, and the controller's actions during defrost.

MP-3000 Controller - Display and Menu Navigation

Displaying Alternate Sensor Temperatures

How to view alternate supply or return air sensor temperatures on the LED display.

Displaying Alternate Temperature Scales

How to switch between Celsius and Fahrenheit temperature displays.

Navigating the Controller Menu Structure

Overview of the MP-3000 controller's main menu structure and navigation keys.

MP-3000 Controller - Menu Operations

Setpoint Menu Functions

List of adjustable settings within the Setpoint menu, including temperature, mode, and AFAM parameters.

General Operating Tips

Useful tips for operating the controller, such as quick temperature changes and power management.

MP-3000 Controller - Setpoint Adjustments

Changing Bulb Mode Settings

How to adjust the Bulb mode settings for evaporator fan speed and defrost termination.

Changing USDA Trip Settings

How to configure USDA trip settings for temperature monitoring and defrost parameters.

MP-3000 Controller - Setpoint Menu Flow

Setpoint Menu Flow Diagram

Visual guide illustrating the flow for setting temperature, humidity, and defrost parameters.

Changing AFAM and CO2 Settings

Procedures for changing AFAM rates and CO2 maximum settings.

MP-3000 Controller - Mode and AFAM Configuration

Changing Economy and Humidity Modes

Steps to enable and configure Economy and Humidity control modes.

Changing AFAM/AFAM+ Settings

Configuration steps for Advanced Fresh Air Management system settings and options.

MP-3000 Controller - AFAM System Operation

AFAM System Configuration and Operation

How to set AFAM+ system values, configure Analyzer mode, and operate AFAM/AFAM+ systems.

Changing the AFAM Delay Setting

Procedure for setting the fresh air exchange time delay for product temperature pull-down.

MP-3000 Controller - AFAM Rate and Gas Settings

Changing the AFAM Rate

How to set the desired air exchange rate for the AFAM system.

Changing the O2 Minimum Setting

Procedure to set the desired Oxygen (O2) level for the AFAM+ system.

MP-3000 Controller - CO2 Setting and Data Menu

Changing the CO2 Maximum Setting

Procedure to set the desired Carbon Dioxide (CO2) level for the AFAM+ system.

Viewing the Data Menu

How to access and view general unit operating information from the Data menu.

MP-3000 Controller - Alarms

Alarms Menu Overview

Description of the Alarms menu, including alarm types and states for diagnosis.

MP-3000 Controller - Alarm List and Viewing

Viewing the Alarm List Menu

Steps to access and view the list of recorded alarm codes.

Understanding Alarm Codes

Explanation of alarm codes, their types, and descriptions for troubleshooting.

MP-3000 Controller - Commands and Tests

Commands Menu Overview

List of available tasks in the Commands menu, including PTI, Power Management, and Function Tests.

Viewing the Commands Menu

Steps to navigate and access the Commands menu on the controller.

MP-3000 Controller - Function and PTI Tests

Function Test Procedure

How to perform a function test to automatically check individual unit components.

Pre-trip (PTI) Test Procedure

Detailed steps for performing a pre-trip test to check unit refrigeration, heating, and control systems.

MP-3000 Controller - Manual Function Test

Manual Function Test Operation

How to perform specific diagnostic tests on individual components or systems.

Power Management Settings

How to select and adjust power limit settings and time intervals for power reduction.

MP-3000 Controller - Miscellaneous Functions

Misc. Functions Menu Overview

List of functions for identifying trips and managing operating information like date, time, and program version.

Viewing and Setting Date/Time

Steps to view and set the controller's date and time accurately.

MP-3000 Controller - Time, Cargo, and Temperature Settings

Viewing or Setting Unit Run Time

Procedures for resetting or setting operating hours for the unit and its components.

Setting Cargo Data Information

How to enter essential trip information such as container ID, contents, and shipping details.

MP-3000 Controller - Configuration and Viewing

Changing Temperature Display Units

How to switch the temperature display between Celsius and Fahrenheit.

Configuration Menu Functions

Overview of available configuration settings for unit features, options, and language.

MP-3000 Controller - Datalogger

Datalogger Menu Overview

List of functions for inspecting temperature logs, event logs, PTI logs, and calibrating USDA probes.

Inspecting Temperature and Event Logs

How to view recorded temperature logs and event flags for unit operation analysis.

MP-3000 Controller - Log and Calibration Procedures

Inspect Event Log Details

How to view event logs for alarms, power status, setpoint changes, and defrost events.

Calibrating USDA Probes

Procedures for calibrating USDA sensors using an ice bath to ensure accurate temperature recording.

MP-3000 Controller - Calibration and Trip Start

Calibrating USDA Sensors

Detailed steps for calibrating USDA sensors in an ice bath to ensure accurate readings.

Setting Trip Start Time and Date

How to activate and log the start time and date for a trip.

MP-3000 Controller - Log and Event Management

Setting Data Log Time Intervals

How to configure the data logging interval for temperature and event logs.

Inspecting Event Log Entries

Procedures for viewing event logs and understanding event examples.

MP-3000 Controller - Remote Monitoring and Emergency Operation

RMM State Menu and Viewing

How to check the communication status with the REFCON system via the Remote Monitoring Modem.

Manual Emergency Mode Operation

Procedures for operating the unit manually in case of controller failure.

MP-3000 Controller - Maintenance and Configuration

Reversing Power Phase on CSR Units

Steps to reverse power phase for correct fan rotation on CSR units.

Replacing the Controller Unit

Step-by-step guide for replacing the MP-3000 controller, including software selection.

MP-3000 Controller - Software and Configuration

Automatic Controller Configuration

How the controller automatically configures based on installed unit options.

Controller Software Selection Guide

Guide to selecting the correct software for the controller based on unit type and dial position.

Flash Loading Controller Software

Procedures for updating controller software using flash loading.

MP-3000 Controller - Sensor Installation

Temperature Sensors Overview

Description of thermistor sensors used and their typical locations.

Sensor Installation Guidelines

Proper procedures for installing supply air, return air, and evaporator coil sensors.

Sensor Resistance and Placement

Resistance Values for Temperature Sensors

Tables providing resistance values for various sensors at different temperatures.

Condenser Coil Sensor Placement

Specific instructions for locating and positioning the condenser coil sensor.

Diagnosis and Troubleshooting

Mechanical Diagnosis Guide

Table of conditions, possible causes, and remedies for mechanical issues.

Mechanical Diagnosis - Common Issues

Compressor and Condenser Fan Motor Issues

Troubleshooting for compressor contactor burnout, short cycling, noisy operation, and condenser fan motor faults.

Refrigeration Diagnosis - Cooling Issues

Evaporator Fan and Cooling Load Issues

Troubleshooting for evaporator fan faults and unit not cooling due to various refrigerant system issues.

Refrigeration Diagnosis - Pressure and Cycling Issues

Head Pressure and Compressor Oil Issues

Diagnosing low or high head pressure, compressor oil loss, and rapid cycling.

Hot Liquid Line and Frosted Lines

Troubleshooting for issues related to hot liquid lines, frosted lines, and expansion valve problems.

Refrigeration Diagnosis - Vacuum and Suction Issues

Unit Vacuum and Suction Pressure Issues

Diagnosing problems related to vacuum levels, frosted expansion valves, and suction pressure.

AFAM System & AFAM+

Advanced Fresh Air Management (AFAM) System

Description of the AFAM system for programmable air exchange control.

Setting AFAM System Values

How to configure AFAM system settings like units, delay, and rate.

AFAM System Configuration and Control

Starting the AFAM System

Steps to start and operate the AFAM system.

Changing the AFAM Delay Setting

How to adjust the AFAM delay to allow faster product temperature pull-down.

AFAM System - Rate Adjustment

Changing the AFAM Rate

Procedure for setting the desired air exchange rate for the AFAM system.

AFAM System - Configuration Units

Setting AFAM Units in Configuration Menu

How to set AFAM system units (CFM, M3H, PERCENT) within the controller's configuration.

AFAM+ System - O2 and CO2 Control

Advanced Fresh Air Management Plus (AFAM+) System

Overview of the AFAM+ system for controlling O2 and CO2 levels.

Setting AFAM+ System Values

Configuration steps for AFAM+ system, including O2 Min and CO2 Max settings.

Starting the AFAM+ System

Steps to start and operate the AFAM+ system.

AFAM+ System - Delay and O2 Settings

Changing AFAM Delay Setting

Adjusting the AFAM delay to control vent door opening after unit startup.

Changing O2 Minimum Setting

Procedure to set the desired minimum Oxygen (O2) level for the AFAM+ system.

AFAM+ System - CO2 Maximum Setting

Changing the CO2 Maximum Setting

Procedure to set the desired maximum Carbon Dioxide (CO2) level for the AFAM+ system.

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