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MAGNUM PLUS 098580
Thermo King MAGNUM PLUS 098580 User Manual
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MAGNUM
PLUS
®
®
with
MP4000
Maintenance
Manual
2
Table of Contents
Table of Contents
4
A a I I R R V V E E N N T T I I L L a a T T I I O O N N L L O O G G G G I I N N G G ( ( a a V V L
6
A a D D V V a a N N C C E E D D F F R R E E S S H H a a I I R R M M a a N N a a G G E E M M E E N N T T ( ( a a F F a a M M ) ) S S y y S S T T E E M
7
S S P P E E C C I I a a L L F F U U N N C C T T I I O O N N K K E E y y S S - - U U S S E E R R a a C C T T I I V V a a T T E E D D C C O O M M M M a a N N D D S
9
Danger, Warning, Caution, and Notice
12
General Practices
12
Refrigerant Hazards
14
Electrical Hazards
14
High Voltage
14
Low Voltage
15
Electrostatic Discharge Precautions
15
Electrostatic Discharge and the Controller
16
Welding on Refrigeration Units or Containers
16
First Aid
16
Identifying Unit Safety and Warning Decals
18
Serial Number Location
18
Component Serial Number Identification
18
S S E E R R V V I I C C E E G G U U I I D D E
21
S S P P E E C C I I F F I I C C a a T T I I O O N N S
21
System Net Cooling Capacity - Full Cool
21
Evaporator Airflow
21
Electrical System
22
Refrigeration System
22
Normal R-404A/R-452A System Operating Pressures (Scroll Compressor)
23
MP4000 Controller Specifications
23
Physical Specifications
25
Metric Hardware Torque Charts
26
General Description
27
Scroll Compressor
27
Digital Port
28
Intermediate Suction Port
28
MP4000 Controller
28
Power Module Fuses
28
Compressor Digital Control Valve
29
Economizer Heat Exchange System
29
Temperature Sensors
29
Fresh Air Exchange System
30
Receiver Tank Sight Glass
30
Evaporator Fans
30
Condenser Fan Control
31
USDA Cold Treatment Temperature Recording (Standard)
31
Unit Options
31
Electronic Chart Recorder (Optional)
31
Remote Monitoring Modem (RMM, RMM+) (Optional)
32
Suction and Discharge Pressure Sensors
32
Water-Cooled Condenser/Receiver Tank
32
Air Ventilation Logging (AVL)
32
Advanced Fresh Air Management (AFAM) System
32
AFAM Operation
32
AFAM Vent Door Assembly
33
Advanced Fresh Air Management Plus (AFAM+) System
33
MP4000 Controller
37
Back-Up Battery
37
Input and Output Signals
37
Standard Display
37
Idle Screen and Check Symbol
38
Unit Status Display
38
Display Icons
39
Mode Descriptions
40
Keys and Indicator Leds
40
Function Keys
40
Special Function Keys
41
Indicator Leds
41
Software Versions
42
Function Keys
50
Unit On/Off Key
50
Sequence of Operation
50
Unit Start-Up
50
Initiating a Manual Defrost
51
Pretrip Inspection (PTI)
51
Viewing Alarms/Messages from Standard Display
51
Display Alternate Fahrenheit (F) or Celsius (C) Temperatures
51
Changing Setpoint
51
Main Menu
52
Lock Padlock
52
Controller Back-Up Battery
52
Controller Lockup Issue
52
Emergency Run Mode
52
Rotation Check
52
FULL COOL Mode
53
DEFROST Mode
54
Low Speed Fans Only
55
Menu Scrolling Keys
56
Changing Screen Contrast
57
Main Menu
58
Values Menu
58
Controls Menu
58
Cold Treatment (CT)
59
Multiple Temperature Set (MTS)
59
Optiset
60
Temperature Setpoint
60
Controlling Mode
60
Pull down Selection
61
Water Cooled Condenser
61
Dehumidify Control
62
Dehumidify Setpoint
62
AVL (Air Ventilation Logging)
63
Fresh Air Vent man - AFAM Mode
63
Fresh Air Vent man - AFAM+ Mode
64
AFAM Delay
64
AFAM Rate
65
AFAM+ CO2 Max
65
AFAM+ O2 Min
66
Smart PTI
66
Silent Mode
67
Alarm Menu
68
Alarm Code States
69
Alarm Codes
69
Message Menu
69
Configuration Menu
70
Unit
71
Options
72
System
74
Clock
75
Calibrate
76
Icon Menu
76
Log View Menu
77
Info Menu
78
PTI Key
79
Defrost Key
80
PTI (Pretrip) Tests
81
Manual Function Test
81
Function Test
85
Starting the AFAM System
87
Change the AFAM Delay
88
Change the AFAM Rate
89
Set AFAM+ System Values
90
Change the AFAM Delay
91
Change the CO2 Minimum and Maximum Setting
91
Change the AFAM+ Settings Using Optiset
92
Modify Optiset Product Settings
93
Testing AFAM / AFAM+ System
93
AFAM+ Option Alarm Codes
93
System Operation Verification
94
Alarm Codes and Actions
94
AFAM+ Door Closes Automatically
96
Pulsating AFAM+ Door
96
AFAM+ Enabled
96
Chill Loads (Setpoint at -9.9 C [14.1 F] and Above)
97
Supply Air Sensor Control
97
Frozen Loads (Setpoint at -10 C [14 F] and Below)
97
Cooling Capacity Display in Main Screen
97
Compressor Vapor Injection
97
High Temperature Protection
97
Power Limit Mode
97
Evaporator Fan Control
97
Chill Loads (Setpoints of -9.9 C [14.1 F] and Above)
98
Frozen Loads (Setpoint at -10.0 C [14.0 F] or Below)
98
Condenser Fan Control
98
Probe Test
98
Dehumidify Mode
98
Continuous Temperature Control Operation
99
Chill Loads (Controller Setpoint at -9.9 C [14.1 F] and Above)
99
Cool with Modulation
101
Heat
101
Frozen Loads (Controller Setpoint at -10 C [14 F] and Below)
101
Cool
102
Null
102
Defrost
102
Compressor Digital Control Valve
103
Economizer System
103
Data Recording and Downloading Data
104
Cold Treatment (CT)
104
Multiple Temperature Setpoint (MTS)
107
Controller Door Open and Close Instructions
111
Flashloading Controller Software
111
MP4000 Test System Tool
113
Controller Replacement
114
Unit Protection Devices
115
Main Circuit Breaker
115
Evaporator Overheat Protection
115
High Pressure Cutout Switch
115
High Pressure Cutout Manifold
116
High Pressure Cutout Switch Removal/Installation
117
Low Pressure Cutout Switch
118
Removal
118
Installation
118
Low Pressure Cutout Switch or Suction Transducer Configuration
119
Discharge and Low Pressure Sensors (Optional)
120
Removal
120
Installation
120
Condenser Fan and Evaporator Fan Rotation
120
Check Condenser Fan Rotation
120
Check Evaporator Fan Rotation
120
Reversing Power Phase on Units
121
Evaporator Heater Selection
121
Extended Capacity Heaters
122
Electric Heaters Malfunction
122
Compressor Discharge Temperature Sensor
123
Replacement
123
Temperature Sensors
124
Sensor Installation
124
Sensor Testing
125
Resistance Values for Temperature Sensors
125
Introduction
127
Tools
127
Vacuum Pump
127
Filters and Cartridges
127
Refrigerant Recovery Equipment
127
Detecting Leaks
127
Special Service Fittings
127
Oil Acid Test
128
Isolate Compressor
128
Gauge Manifold Set
129
Using a New Gauge Manifold Set
129
Gauge Manifold Valve Positions
129
Gauge Manifold Set Installation & Removal
131
Installation
131
Removal
132
Checking Refrigerant Charge
132
Receiver Tank Sight Glass
133
Leak Testing Refrigeration System
133
Using Pressurized Nitrogen
135
Safety Precautions
135
Purge High Side to Low Side
135
Maximum Gas Pressures
136
Recovering Refrigerant from System
138
Evacuation and Cleanup of Refrigeration System
138
Unit Preparation and Hookup
139
Unit Evacuation
139
Pressure Rise Test
140
Factors Affecting Speed of System Evacuation
140
Heat Saves Time
141
Charging System with Refrigerant
141
Unit Charging by Weight (from an Evacuated Condition)
141
Evacuation Station Removal
141
Compressor Replacement
142
Removal
142
Installation
142
Condenser Coil Replacement
143
Removal
143
Installation
143
Filter Drier/In-Line Filter Replacement
143
Installation
144
Evaporator Expansion Valve (TXV) Replacement
144
Economizer Expansion Valve Replacement
145
Removal
145
Installation
146
Economizer Heat Exchanger Replacement
148
Removal
148
Installation
148
Receiver Tank/ Water-Cooled Condenser Tank Replacement
148
Vapor Injection Valve Replacement
149
Removal
149
Installation
149
Compressor Digital Control Valve Replacement
150
Removal
150
Installation
150
Taking Care of the Structure
152
Inspecting Unit
152
Checking Mounting Bolts
152
Cleaning the Condenser Coil
152
Cleaning the Evaporator Coil
153
Cleaning the Defrost Drains
153
Positioning the Condenser Fan Blade
153
Positioning the Evaporator Fan Blade
153
Adjusting the Fresh Air Exchange System
154
Introduction
155
MP4000 Diagnostics
155
Mechanical Diagnostics
156
Refrigeration Diagnostics
158
Status Messages and Controller Actions
160
Alarm Codes and Corrective Actions
166
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Thermo King MAGNUM PLUS 098580 Specifications
General
Brand
Thermo King
Model
MAGNUM PLUS 098580
Category
Industrial Equipment
Language
English
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