CSR PS+ Hermetic

Maintenance Manual
CSR Power Saver and

CSR Power Saver Plus
Hermetic Systems
TK 50825-4-MM (Rev. 3/00)
Copyright ©2000, Thermo King Corporation, Minneapolis, MN, U.S.A.

Printed in U.S.A.
This manual is published for informational purposes only and the information so provided should not be considered as all-inclusive
or covering all contingencies. If further information is required, Thermo King Corporation should be consulted.
Sale of product shown in this Manual is subject to Thermo King’s terms and conditions including, but not limited to, the THERMO
KING EXPRESS WARRANTY. Such terms and conditions are available upon request.
Thermo King’s warranty will not apply to any equipment which has been “so repaired or altered outside the manufacturer’s plants
as, in the manufacturer’s judgment, to effect its stability.”
No warranties, express or implied, including warranties of fitness for a particular purpose or merchantability, or warranties arising
from course of dealing or usage of trade, are made regarding the information, recommendations, and descriptions contained herein.
Manufacturer is not responsible and will not be held liable in contract or in tort (including negligence) for any special, indirect or con-
sequential damages, including injury or damage caused to vehicles, contents or persons, by reason of the installation of any
Thermo King product or its mechanical failure.
SmartSponge and Thermoguard are trademarks of Thermo King Corporation. All other trademarks are the property of their respec-
tive owners.
Recover Refrigerant
At Thermo King we recognize the need to preserve the environment and limit
the potential harm to the ozone layer that can result from allowing refrigerant
to escape into the atmosphere.
We strictly adhere to a policy that promotes the recovery and limits the loss
of refrigerant into the atmosphere.
In addition, service personnel must be aware of Federal regulations concern-

ing the use of refrigerants and the certification of technicians. For additional
information on regulations and technician certification programs, contact
your local THERMO KING dealer.
Table of Contents
Electrical System 1-3

Introduction v
Refrigeration System 1-4
About This Manual v MP-3000 Controller 1-5
Other Reference Manuals v Dehumidify and Humidify Systems (Options) 1-6
CSR PS Hermetic Model Features vi Physical Specifications 1-7
Metric Hardware Torque Charts 1-9
Safety Precautions vii
Unit Description 2-1
General Practices vii
Refrigerant vii Unit Features 2-1
Refrigerant Oil viii Unit Options 2-2
Electrical viii Operating Modes 2-3
General Safety Practices for Servicing Units Unit Illustrations 2-4
(or Containers) Equipped with a Typical Unit Front View 2-4
Microprocessor Controller ix Unit Options Front View 2-5
Unit Decals x CSR20 PS and CSR40SL PS Evaporator
Serial Number Locations x Section – Front View 2-6
CSR40 PS Evaporator Section – Front View 2-7
Humidify System Option 2-8
Service Guide xi
Hermetic Refrigeration System 2-9
MP-3000 Controller 2-10
Unit Control Box 2-11
Specifications 1-1
TRANSFRESH System Options 2-12
System Net Cooling Capacity — Full Cool: Typical Unit Back View 2-13
CSR20 PS Models — Air Cooled Condensing 1-1
CSR40SL PS Models — Air Cooled
Operating Instructions 3-1
Condensing 1-1
CSR40 PS Models — Air Cooled Condensing 1-1 Unit Controls 3-1
System Net Heating Capacity 1-2 Unit Instruments 3-2
Evaporator Airflow: Unit Protection Devices 3-2
CSR20 PS Models 1-2 Pretrip Inspection 3-3
CSR40SL PS Models 1-2 Starting the Unit and Adjusting the Controller
CSR40 PS Models 1-2 Setpoint 3-5
Loading Procedure 3-5
Post Load Procedure 3-5
Post Trip Procedure 3-5
CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

ii Table of Contents
Commands Menu 4-18

MP-3000 Controller 4-1
View the Commands Menu 4-18
Controller Description 4-1 Defrost 4-19
Status Indicator LEDs 4-3 Function Test 4-19
Data Recording and Downloading Data 4-3 CSR PS Function Test Procedure 4-21
General Theory of Operation 4-4 Pretrip (PTI) Test 4-20
Chill Loads 4-4 CSR PS Pretrip (PTI) Test Procedure 4-23
Frozen Loads 4-5 Manual Function Test 4-20
Modulation Display in Data Menu 4-5 Power Management 4-28
Power Limit Mode 4-5 Misc. Functions Menu 4-28
Compressor Liquid Injection 4-5 Viewing the Misc. Functions Menu 4-28
Warm Gas Bypass 4-5 Setting the Date and Time 4-28
Evaporator Fan Control 4-5 Changing the Temperature Display
Condenser Fan Control 4-6 Value (C/F) 4-29
Economy Mode Operation 4-6 Setting Cargo Data 4-29
Probe Test 4-6 Viewing or Setting Run Time 4-30
Dehumidify Mode (Option) 4-7 Configuration Menu 4-30
Sequence of Operation 4-7 Viewing or Setting Functions 4-30
Unit Start-up 4-7 Datalogger Menu 4-31
Continuous Temperature Control Operation 4-8 Viewing the Datalogger Menu 4-32
Operating Mode Function Chart — Standard Inspect Temp Log 4-32
Operation 4-9 Inspect Event Log 4-32
Operating Mode Function Chart — Optional Set Log Time 4-33
Feature Operation 4-10 Set a Trip Start 4-33
Defrost 4-11 Inspect PTI Log 4-34
Changing the Setpoint 4-12 RMM State Menu 4-34
Initiating a Manual Defrost 4-12 Viewing the RMM State Screen 4-34
Displaying Alternate Controlling (Supply or Manual Emergency Mode Operation 4-34
Return) Air Sensor Temperature 4-13 Replacing the Controller 4-35
Displaying Alternate Fahrenheit (F) or Automatic Configuration of Spare
Celsius (C) Temperatures 4-13 Parts Controller 4-35
Navigating the Controller Menu 4-13 Controller Software Selection 4-36
General Operating Tips 4-14 Flash Loading Controller Software 4-36
Setpoint Menu 4-14 Temperature Sensors 4-36
Changing the Setpoint Temperature 4-14 Diagnosis and Repair 4-38
Changing the Economy Mode Setting 4-14 Error Messages and Controller Actions 4-39
Changing the Humidity Mode Setting 4-15 Alarm Codes, Descriptions and
Changing the Humidity Setpoint 4-15 Corrective Actions 4-41 to 4-60
Data Menu 4-15
Viewing the Data Menu 4-15
Alarms Menu 4-16
Alarm Types 4-16
Alarm Code States 4-16
Viewing the Alarm List Menu 4-17
Alarm List 4-17

Table of Contents iii
Electrical Maintenance 5-1 Structural/Accessory Maintenance 7-1

Unit Wiring 5-1 Mounting Bolts 7-1
High Pressure Cutout Switch 5-1 Unit Inspection 7-1
Low Pressure Cutout Switch 5-2 Condenser Coil 7-1
Condenser Fan and Evaporator Fan Rotation 5-2 Evaporator Coil 7-1
Electric Heaters 5-2 Defrost Drains 7-2
Fresh Air Exchange System 7-2
Condenser Fan Location 7-2
Refrigeration System Diagnosis and Service 6-1
Evaporator Fan Location 7-3
Hermetic Refrigeration System Diagnosis Humidify System (Option) 7-3
Procedures 6-1
Hermetic Refrigeration System Visual Inspection
Mechanical Diagnosis 8-1
and Diagnosis Chart 6-3
Hermetic Refrigeration System Service Mechanical Diagnosis 8-1
Procedures 6-4
Service Tools 6-4
Electrical, Refrigeration and MP-3000 Menu Flow
Refrigerant Charge 6-5
Diagrams 9-1
Compressor Oil Charge 6-6
Installing and Removing Piercing Type Service Controller Diagram 9-3
Valves and a Gauge Manifold Set 6-6 Wiring Schematic 9-4
Gauge Manifold Valve Positions 6-8 Main Relay Board Terminal Connections
Refrigerant Leak Test Procedure 6-9 (Page 1 of 3) 9-5
Using Pressurized Nitrogen 6-9 Main Relay Board Terminal Connections
Refrigerant Recovery from Hermetic (Page 2 of 3) 9-6
Refrigeration Systems 6-10 Main Relay Board Terminal Connections
Evacuation and Cleanup of the (Page 3 of 3) 9-7
Refrigeration System 6-11 Refrigeration System Schematics:
Charging the System with Refrigerant 6-15 Refrigeration System Components 9-8
Compressor Replacement 6-15 Full Cool Flow and Pressure Diagram 9-9
Compressor Discharge Temperature Sensor Modulation Cool Flow and Pressure Diagram 9-10
Replacement 6-16 Dehumidification Flow and Pressure Diagram 9-11
Stepper Motor Valve Replacement 6-17 MP-3000 Menu Flow Diagram 9-12
Condenser Coil Replacement 6-17
Filter Drier/In-line Filter Replacement 6-18
Expansion Valve Replacement 6-18
Heat Exchanger Replacement 6-19
Receiver Tank Replacement 6-19
Low or High Pressure Cutout Switch Replacement 6-20
Warm Gas Bypass Solenoid Valve, Liquid
Injection Valve or Dehumidify Valve
(Option) Replacement 6-20

Introduction
Operation, Diagnosis and Refrigeration Maintenance

About This Manual Manuals
The information in this manual is provided to assist owners, Diagnosing Thermo King Container
operators and service people in the proper upkeep and mainte- Refrigeration Systems TK 41166
nance of Thermo King units. This manual includes mainte- Electrostatic Discharge (ESD)
nance and diagnosis information for both standard and option- Training Guide TK 40282
al unit features. Some optional features may not apply to your Evacuation Station Operation and Field
unit. The maintenance information in this manual covers unit Application TK 40612
models: Tool Catalog TK 5955
CSR PS Hermetic Models System Number

CSR40SL-148 Power Saver 917148
Other Reference Manuals

For detailed descriptions of our refrigeration systems or micro-
processor controllers, see the appropriate manual. For further
information refer to:
Parts Manuals
CSR40SL-148 PS Parts List TK 50896

vi CSR PS and CSR PS+ Hermetic Model Features Introduction
CSR PS Hermetic Model Features

CSR40SL-148 PS
MODEL
FEATURES
X = Included
X Slimline Frame
X 460-380V/3Ph/60-50 Hz, 18.3 m (60 ft) Power Cable and Plug
– Dual Voltage Feature: 15 kVA Autotransformer with 460-380V Power Receptacle and 230-190V/3Ph/60-50 Hz, 18.3 m (60 ft)
Power Cable and Plug
X 25 Amp Main Power Circuit Breaker
X Automatic Phase Selection Control
X Hermetic Scroll Compressor w/4.48 kW (6.0 Hp) Motor
X Hermetic Refrigeration System
X Refrigerant R-404A w/Polyol Ester Compressor Oil (TK P/N 203-433)
X Stepper Valve Capacity Control System
X Compressor Liquid Injection System
X Warm Gas Bypass Valve System
X MP-3000 Microprocessor Controller with Integral Datalogger
X Three (3) Evaporator Fans with 2-Speed Motors
– Two (2) Evaporator Fans with 2-Speed Motors
X Fresh Air Exchange System
X Condenser Fan with 1-Speed Motor
X Dehumidify Control
– Pressure Gauge, Discharge
– Pressure Gauge, Suction
– Recorder, Partlow
– Recorder, Saginomiya
X Remote Monitoring Plug (4-Pin)
X TRANSFRESH® Provision
– TRANSFRESH® Purge Port
– TRANSFRESH® System, Complete
– Thermistor Lead
– USDA Cold Treatment Temperature Recording
– Water-Cooled Condenser-Receiver Tank

Safety Precautions
General Practices Refrigerant

1. ALWAYS WEAR GOGGLES OR SAFETY GLASSES. When removing any refrigerant from a unit, use a recovery
Refrigerant liquid and battery acid can permanently dam- process that prevents or absolutely minimizes the refrigerant
age the eyes (see First Aid under Refrigerant Oil). that can escape to the atmosphere. Although fluorocarbon
2. Never close the compressor discharge valve with the unit refrigerants are classified as safe refrigerants when proper
in operation. Never operate the unit with the discharge tools and procedures are used, certain precautions must be
valve closed. observed when handling them or servicing a unit in which they
3. Keep your hands, clothing and tools clear of the fans are used. When exposed to the atmosphere in the liquid state,
when the refrigeration unit is running. If it is necessary to fluorocarbon refrigerants evaporate rapidly, freezing anything
run the refrigeration unit with covers removed, be very they contact.
careful with tools or meters being used in the area.
4. Be sure the gauge manifold hoses are in good condition. First Aid
Never let them come in contact with a fan motor blade or In the event of frost bite, the objectives of First Aid are to pro-
any hot surface. tect the frozen area from further injury, to warm the affected
5. Never apply heat to a sealed refrigeration system or con- area rapidly, and to maintain respiration.
tainer. • EYES: For contact with liquid, immediately flush eyes
6. Fluorocarbon refrigerants, in the presence of an open with large amounts of water and get prompt medical atten-
flame or electrical arc, produce toxic gases that are severe tion.
respiratory irritants capable of causing death. • SKIN: Flush area with large amounts of lukewarm water.
7. Be sure all mounting bolts are tight and are the correct Do not apply heat. Remove contaminated clothing and
length for their particular application. shoes. Wrap burns with dry, sterile, bulky dressing to
8. Use extreme caution when drilling holes in the unit. The protect from infection/injury. Get medical attention.
holes may weaken structural components. Holes drilled into Wash contaminated clothing before reuse.
electrical wiring can cause fire or explosion. Holes drilled • INHALATION: Move victim to fresh air and use CPR or
into the refrigeration system may release refrigerant. mouth-to-mouth ventilation, if necessary. Stay with victim
9. Use caution when working around exposed coil fins. The until arrival of emergency medical personnel.
fins can cause painful lacerations.
10. Use caution when working with a refrigerant or refrigera-
tion system in any closed or confined area with a limited
air supply (for example, a trailer, container or in the hold
of a ship). Refrigerant tends to displace air and can cause
oxygen depletion, resulting in suffocation and possible
death.
11. Use caution and follow the manufacturer’s suggested
practices when using ladders or scaffolds.

viii Refrigerant Oil Safety Precautions
4. Do not make any rapid moves when working on high volt-

Refrigerant Oil age circuits. If a tool or other object falls, do not attempt
to grab it. People do not contact high voltage wires on
Observe the following precautions when working with or
purpose. It occurs from an unplanned movement.
around refrigerant oil:
5. Treat all wires and connections as high voltage until a
• Do not allow refrigerant oil to contact your eyes.
meter and wiring diagram show otherwise.
• Do not allow prolonged or repeated contact with skin or
6. Never work alone on high voltage circuits on the refriger-
clothing.
ation unit. Another person should always be standing by
• To prevent irritation, you should wash thoroughly imme-
in the event of an accident to shut off the refrigeration unit
diately after handling refrigerant oil. Rubber gloves are
and to aid a victim.
recommended when handling Polyol Ester based refriger-
7. Have electrically insulated gloves, cable cutters and safety
ant oil.
glasses available in the immediate vicinity in the event of
an accident.
First Aid
• EYES: Immediately flush eyes with large amounts of
First Aid
water for at least 15 minutes while holding the eyelids
IMMEDIATE action must be initiated after a person has
open. Get prompt medical attention.
received an electrical shock. Obtain immediate medical assis-
• SKIN: Remove contaminated clothing. Wash thoroughly
tance if available.
with soap and water. Get medical attention if irritation
The source of shock must be immediately removed by
persists.
either shutting down the power or removing the victim from
• INHALATION: Move victim to fresh air and restore
the source. If it is not possible to shut off the power, the wire
breathing if necessary. Stay with victim until arrival of
should be cut with either an insulated instrument (e.g., a wood-
emergency personnel.
en handled axe or cable cutters with heavy insulated handles)
• INGESTION: Do not induce vomiting. Contact a local
or by a rescuer wearing electrically insulated gloves and safety
poison control center or physician immediately.
glasses. Whichever method is used, do not look at the wire
while it is being cut. The ensuing flash can cause burns and
blindness.
If the victim has to be removed from a live circuit, pull the
Electrical victim off with a non-conductive material. Use the victim’s
coat, a rope, wood, or loop your belt around the victim’s leg or
High Voltage arm and pull the victim off. DO NOT TOUCH the victim.
When servicing or repairing a refrigeration unit, the possibility You can receive a shock from current flowing through the vic-
of serious or even fatal injury from electrical shock exists. tim’s body.
Extreme care must be used when working with a refrigeration After separating the victim from power source, check
unit that is connected to a source of operating power, even if immediately for the presence of a pulse and respiration. If a
the unit is not running. Lethal voltage potentials can exist at pulse is not present, start CPR (Cardio Pulmonary
the unit power cord, inside the control box, inside any high Resuscitation) and call for emergency medical assistance. If a
voltage junction box, at the motors and within the wiring har- pulse is present, respiration may be restored by using mouth-
nesses. to-mouth resuscitation, but call for emergency medical assis-
tance.
Precautions
1. Be certain the unit On/Off switch is turned OFF before Low Voltage
connecting or disconnecting the unit power plug. Never Control circuits are low voltage (24 Vac and 12 Vdc). This
attempt to stop the unit by disconnecting the power plug. voltage potential is not considered dangerous, but the large
2. Be certain the unit power plug is clean and dry before amount of current available (over 30 amperes) can cause
connecting it to a power source. severe burns if shorted to ground.
3. Use tools with insulated handles that are in good condi- Do not wear jewelry, watch or rings. These items can short
tion. Never hold metal tools in your hand if exposed, out electrical circuits and cause severe burns to the wearer.
energized conductors are within reach.

Safety Precautions General Safety Precautions for Servicing Controllers ix
Welding of Units or Containers

General Safety Precautions for Servicing Whenever electric welding is to be performed on any portion
Units (or Containers) Equipped with a of the refrigeration unit, container or container chassis with the
Microprocessor Controller refrigeration unit attached, it is necessary to ensure that weld-
ing currents are NOT allowed to flow through the electronic
Precautions must be taken to prevent electrostatic discharge circuits of the unit. These procedures must be rigidly adhered
when servicing the MP-3000 microprocessor and related com- to when servicing these units to avoid damage or destruction.
ponents. If these precautionary measures are not followed, the 1. Disconnect all power to the refrigeration unit.
risk of significant damage to the electronic components of the 2. Disconnect all quick-disconnect wire harnesses from the
unit is possible. back of the controller.
The primary risk potential results from the failure to wear 3. If the unit is equipped with an Remote Monitor Modem
adequate electrostatic discharge preventive equipment when (RMM), disconnect all wire harnesses from the RMM.
handling and servicing the controller. The second cause 4. Switch all of the electrical circuit breakers in the control
results from electric welding on the unit and container chassis box to the OFF position.
without taking precautionary steps. 5. Weld unit and/or container per normal welding proce-
dures. Keep ground return electrode as close to the area to
Controller Repair be welded as practical. This will reduce the likelihood of
When servicing the controller, it is necessary to ensure that stray welding currents passing through any electrical or
electrostatic discharges are avoided. Potential differences con- electronic circuits.
siderably lower than those which produce a small spark from a 6. When the welding operation is completed, the unit power
finger to a door knob can severely damage or destroy solid- cables, wiring and circuit breakers must be restored to
state integrated circuit components. The following procedures their normal condition.
must be rigidly adhered to when servicing these units to avoid
controller damage or destruction.
1. Disconnect all power to the unit.
2. Avoid wearing clothing that generates static electricity
(wool, nylon, polyester, etc.).
3. Do wear a static discharge wrist strap (TK P/N 204-622)
with the lead end connected to the controller's ground ter-
minal. These straps are available at most electronic equip-
ment distributors. DO NOT wear these straps with power
applied to the unit.
4. Avoid contacting the electronic components on the circuit
boards of the unit being serviced.
5. Leave the circuit boards in their static proof packing mate-
rials until ready for installation.
6. If a defective controller is to be returned for repair, it
should be returned in the same static protective packing
materials from which the replacement component was
removed.
7. After servicing the circuit board and any other circuits, the
wiring should be checked for possible errors before restor-
ing power.

x Unit Decals Safety Precautions
Unit Decals Serial Number Locations

Serial number decals, refrigerant type decals and warning Electric Motors: Nameplate attached to the motor housing.
decals appear on all Thermo King equipment. These decals Compressor: Nameplate on front of the compressor.
provide information that may be needed to service or repair the Unit: Nameplate on unit frame in power cord storage compart-
unit. Service technicians should read and follow the instruc- ment.
tions on all warning decals. MP-3000 Controller: Nameplate on back of controller.
Unit Nameplate Location

Service Guide
Every Annual/
1,000 Yearly
Pretrip Hours Inspect/Service These Items
Refrigeration
• Perform a controller Full Pretrip Test to check the refrigeration and electrical systems.
• • Perform a controller Extended Pretrip Test.
Electrical
• • • Visually inspect condenser fan and evaporator fan rotation.
• • • Visually inspect electrical contacts for damage or loose connections.
• • • Visually inspect wire harnesses for damaged wires or connections.
• • Download the data logger and check data for correct logging.
• Check operation of protection shutdown circuits.
Structural
• • • Visually inspect unit for damaged, loose or broken parts.
• • • Tighten unit, compressor and fan motor mounting bolts.
• • Clean entire unit including condenser and evaporator coils and defrost drains.
Humidify System (Option)
• Check water level in water tank.
• • • Check humidify system operation.
• • Clean water supply filter on water tank.

1 Specifications
System Net Cooling Capacity — Full Cool
CSR20 PS Models — Air Cooled Condensing*

Return air to 460/230V, 3 Phase, 60 Hz Power 380/190V, 3 Phase, 50 Hz Power
evaporator Net Cooling Capacity Power Consp Net Cooling Capacity Power Consp
coil inlet Watts Kcal/hr BTU/hr kW @460V Watts Kcal/hr BTU/hr kW @380V
21.1 C (70 F) 12,510 10,760 42,695 9.6 10,010 8,610 34,160 7.5
1.7 C (35 F) 8,010 6,890 27,340 8.5 6,410 5,515 21,875 6.9
-17.8 C (0 F) 4,435 3,815 15,135 5.2 3,550 3,055 12,115 4.2
-28.9 C (-20 F) 2,810 2,415 9,590 4.6 2,250 1,935 7,680 3.7
*System net cooling capacity with a 37.8 C (100 F) ambient air temperature and R-404A.
CSR40SL PS Models — Air Cooled Condensing*

21.1 C (70 F) 12,660 10,890 43,200 9.8 10,130 8,715 34,575 7.6
1.7 C (35 F) 9,100 7,825 31,050 8.9 7,280 6,260 24,845 6.9
-17.8 C (0 F) 5,300 4,555 18,075 6.1 4,240 3,645 14,470 4.9
-28.9 C (-20 F) 3,470 2,980 11,830 5.8 2,775 2,385 9,470 4.1
CSR40 PS Models — Air Cooled Condensing*

21.1 C (70 F) 13,660 11,750 46,620 9.7 10,930 9,400 37,300 7.6
1.7 C (35 F) 10,090 8,680 34,440 8.9 8,070 6,940 27,545 6.9
-17.8 C (0 F) 5,945 5,115 20,290 6.0 4,755 4,090 16,230 5.4
-28.9 C (-20 F) 4,000 3,440 13,650 5.6 3,200 2,750 10,920 4.1

1-2 Heating Capacity and Evaporator Airflow Specifications
System Net Heating Capacity*

Heater Type 460/230V, 3 Phase, 60 Hz Power 380/190V, 3 Phase, 50 Hz Power
Heating Capacity Heating Capacity
Watts Kcal/hr BTU/hr Watts Kcal/hr BTU/hr
CSR20 PS 5,880 5,060 20,070 4,900 4,215 16,720
CSR40SL PS 5,880 5,060 20,070 4,900 4,215 16,720
CSR40 PS 5,800 4,990 19,800 4,200 3,610 14,335
*System net heating capacity includes electric resistance rods and fan heat.
Evaporator Airflow
CSR20 PS Models
External Static 460/230V, 3 Phase, 60 Hz Power 380/190V, 3 Phase, 50 Hz Power
Pressure (water High Speed Low Speed High Speed Low Speed
3 3 3
column) m /hr ft /min m /hr ft3/min 3
m /hr 3
ft /min 3
m /hr ft3/min
0 mm (0 in.) 4,000 2,350 2,000 1,180 3,300 1,940 1,650 970
10 mm (0.4 in.) 3,500 2,060 1,450 850 2,600 1,530 900 530
20 mm (0.8 in.) 2,900 1,710 — — 1,800 1,060 — —
30 mm (1.2 in.) 2,200 1,300 — — 1,100 650 — —
40 mm (1.6 in.) 1,400 820 — — — — — —
CSR40SL PS Models
3 3 3
m /hr 3
ft /min 3
m /hr ft3/min
0 mm (0 in.) 5,820 3,430 2,800 1,650 4,860 2,860 2,590 1,525
10 mm (0.4 in.) 5,055 2,975 1,400 825 3,940 2,320 510 300
20 mm (0.8 in.) 4,365 2,570 — — 3,040 1,790 — —
30 mm (1.2 in.) 3,440 2,025 — — 2,140 1,260 — —
40 mm (1.6 in.) 2,615 1,540 — — — — — —
CSR40 PS Models
3 3 3
m /hr 3
ft /min 3
m /hr ft3/min
0 mm (0 in.) 6,560 3,860 3,170 1,865 5,480 3,225 2,710 1,595
10 mm (0.4 in.) 5,820 3,425 1,770 1,040 4,530 2,665 930 545
20 mm (0.8 in.) 5,000 2,940 — — 3,750 2,205 — —
30 mm (1.2 in.) 4,430 2,610 — — 2,930 1,725 — —
40 mm (1.6 in.) 3,520 2,070 — — 1,870 1,100 — —

Specifications Electrical System 1-3
Electrical System
Compressor Motor: Type 460/380V, 60/50 Hz, 3 Phase
Kilowatts 4.48 kW @ 460V, 60 Hz
Horsepower 6.0 hp @ 460V, 60 Hz
RPM 3550 rpm @ 460V, 60 Hz
Locked Rotor Amps 70 amps @ 460V, 60 Hz
Condenser Fan Motor: Type 460/380V, 60/50 Hz, 3 Phase
RPM 1145 rpm @ 460V, 60 Hz
Full Load Amps 0.9 amps @ 460V, 60 Hz; 1.0 amps @ 380V, 50 Hz
Locked Rotor Amps 4.0 amps @ 460V, 60 Hz; 4.0 amps @ 380V, 50 Hz
Evaporator Fan Motors: Type 460/380V, 60/50 Hz, 3 Phase
Number: CSR20 PS 3
CSR40SL PS 3
CSR40 PS 2
RPM (Each): High Speed 3450 rpm @ 460V, 60 Hz
Low Speed 1725 rpm @ 460V, 60 Hz
Full Load Amps (Each): High Speed 1.2 amps @ 460V, 60 Hz
Low Speed 0.5 amps @ 460V, 60 Hz
Locked Rotor Amps: High Speed 10.3 amps @ 460V, 60 Hz
Low Speed 2.9 amps @ 460V, 60 Hz
Electric Resistance Heater Rods: Type 460/380V, 60/50 Hz, 3 Phase
Number 6
Watts (Each) 680 Watts @ 460V, 60 Hz
Current Draw (Amps) 5 amps total @ 460V across each phase at heater contactor
Control Circuit Voltage: 29 Vac @ 60 Hz
24 Vac @ 50 Hz
Evaporator Overheat Switch: Opens 54 +/- 3 C (130 +/- 5 F)
Closes 38 +/- 4.5 C (100 +/- 8 F)

1-4 Refrigeration System Specifications
Refrigeration System
Compressor Model No.: ZM18K4E-TFD-279, Hermetic Scroll
Refrigerant Charge: CSR40SL PS 3.6 Kg (8.0 lb) R-404A
Compressor Oil Capacity 1.77 liter (60 oz.)*
Compressor Oil Type Polyol Ester Based Type (required), TK Part No. 203-433**
High Pressure Cutout Switch: Cutout 3243 +/- 48 kPa, 32.43 +/- 0.48 bar, 470 +/- 7 psig
Cutin 2588 +/- 262 kPa, 25.88 +/- 2.62 bar, 375 +/- 38 psig
Low Pressure Cutout Switch: Cutout +21 to -20 kPa, +0.21 to -0.20 bar, 3 psig to 6” Hg vacuum
Cutin 48 to 90 kPa, 0.48 to 0.90 bar, 7 to 13 psig
High Pressure Relief Valve: Relief Pressure 3447 +520/-104 kPa, 34.47 +5.20/-1.04 bar, 500 +75/-15 psig
Reset 2758 kPa, 27.58 bar, 400 psig
Liquid Injection Control: Compressor Start Liquid injection valve opens for 5 minutes on each compressor start
Power Limit or Modulation Cool Liquid injection valve opens continuously during Power Limit and
Modulation Cool modes
Compressor Discharge Temperature Control Energizes (Opens) Liquid Injection Valve at 138 C (280 F)
De-energizes (Closes) Liquid Injection Valve at 132 C (270 F)
Compressor Shutdown (Auto Reset) at 148 C (298 F)
Liquid Injection Valve (Compressor): Voltage 24 Vac
Current 0.85 amps
Cold Resistance 5.6 ohms
Warm Gas Bypass Solenoid Valve: Voltage 24 Vac
Current 0.85 amps
Cold Resistance 5.6 ohms
Stepper Valve Regulating Motor: Voltage 12 Vdc
Current Draw 0.13 to 0.21 amperes per winding
0.26 to 0.44 amperes with 2 windings energized
Resistance 75 +/- 7.5 ohms across each winding at 24 C (75 F) ambient
*When the compressor is removed from the unit, oil level should be noted or the oil removed from the compressor should be mea-
sured so that the same amount of oil can be maintained in the replacement compressor.
**DO NOT use or add standard synthetic or mineral oils to the refrigeration system. If Ester based oil becomes contaminated with
moisture or with standard oils, dispose of properly — DO NOT USE!

Specifications MP-3000 Controller 1-5
MP-3000 Controller
Temperature Controller: Type MP-3000 microprocessor with thermostat, digital thermometer, pro-
gramming keypad, mode indicators, LED display and LCD display
for displaying unit operating and cargo information
Setpoint Range -29.0 to +29.0 C (-20.2 to +84.2 F)
Digital Temperature Display -60.0 to +80.0 C (-76.0 to +176.0 F)
Controller Software (Original Equipment): Version See controller identification decal
Defrost Initiation Evaporator Coil Sensor - Manual Switch or Demand Defrost Initiation: Coil must be below
18 C (65 F). Defrost cycle starts when technician or controller
request defrost initiation.
- Timed Defrost Initiation: Coil must be below 10 C (50 F).
Defrost cycle starts 1 minute after the hour immediately following
a defrost timer request for defrost initiation. For example, if the
defrost timer requests a defrost cycle at 7:35, the defrost cycle will
start at 8:01. Datalogger will record a Defrost event for each inter-
val in which a Defrost cycle is pending or active (i.e. both the 8:00
and 9:00 data logs).
Demand Defrost Demand defrost function initiates defrost when:
- Temperature difference between the return air sensor and defrost
(evaporator coil) sensor is too large
- Temperature difference between the left hand and right hand sup-
ply air sensors is too large and unit has operated for more than 90
minutes since last defrost
- Temperature difference between the supply air sensors and return
air sensor is too large
Defrost Timer: Chilled mode - Supply Temperature at 5.1 C (41.2 F) or Above: Every 8 hours of
compressor operation.
- Supply Temperature at 5.0 C (41.0 F) or Below: Every 2.5 hours
of compressor operation. Defrost interval increases 0.5 hours each
timed defrost interval. Defrost synchronization creates step inter-
vals of 3, 4, 4, 5, 5, 6, 6 and 7 hours. Maximum time interval in
chilled mode is 7 hours.
Defrost Timer: Frozen mode Every 8 hours of compressor operation. Defrost interval increases 2
hours each timed defrost interval. Maximum time interval in frozen
mode is 24 hours.
Defrost Timer Reset Defrost timer resets if the unit is Off more than 12 hours, setpoint is
changed more than 5 C (9 F) or PTI Pretrip test occurs.

1-6 Dehumidify and Humidify Systems Specifications
MP-3000 Controller (Continued)

Defrost Termination: Defrost (Coil) Sensor Chilled mode: Terminates defrost when coil sensor temperature
rises to 30 C (86 F); or exceeds 18 C (65 F) for 15
minutes
Frozen mode: Terminates defrost when coil sensor temperature
rises to 18 C (65 F); or exceeds 8 C (46 F) for 15
minutes
Termination Timer Terminates defrost after 90 minutes at 60 HZ operation if coil sen-
sor has not terminated defrost (120 minutes at 50 Hz operation)
Power Off Turning unit On/Off switch OFF terminates defrost
Compressor Shutdown Protection (Auto Reset):
Stops Compressor 130 C (266 F)
Allows Compressor Start 90 C (194 F)
Dehumidify and Humidify Systems (Options)

Dehumidify System (Option):
Turn Mode ON and OFF Set from CONTROL line of the Setpoint menu of the controller
Control Range (HUMSP) Setting 50% to 99% Relative Humidity
Humidify System (Option): Turn Mode ON and OFF Set from CONTROL line of the Setpoint menu of the controller
Operating Temperature Range 0 to 60 C (32 to 140 F)
Control Range (HUMSP) Setting 50% to 99% Relative Humidity
Air Compressor Output 2.5 m3/hr @ 0 kPa (1.5 CFM @ 0 psig)
Humidity Tank Heater: 240-600 Vac; 55 to 70 Watts at -17.8 C (0 F) Water Temperature
Humidity Sensor: Accuracy: +/- 1.5% between 55% and 75% Relative Humidity
+/- 3.0% between 75% and 95% Relative Humidity
Output Range: 4 to 20 milliamps
1% Relative Humidity = 0.2 milliamp

Specifications Physical Specifications 1-7
Physical Specifications
Fresh Air Exchange Venting System (Adjustable):
CSR20 PS 0 to 160 m3/hr (0 to 94 ft3/min.) @ 60 Hz
0 to 134 m3/hr (0 to 79 ft3/min.) @ 50 Hz
CSR40SL PS and CSR40 PS 0 to 285 m3/hr (0 to 168 ft3/min.) @ 60 Hz
0 to 236 m3/hr (0 to 139 ft3/min.) @ 50 Hz
Evaporator Fan Blade Specifications:
CSR20 PS: Diameter 280 mm (11.02 in.)
Pitch 19o
Number 3
CSR40SL PS: Diameter 312 mm (12.25 in.)
Pitch 25o
Number 3
CSR40 PS: Diameter 355 mm (14.0 in.)
Pitch 25o
Number 2
Weight (net): CSR20 PS Base Unit 392 Kg (865 lb)
CSR40SL PS Base Unit 402 Kg (885 lb)
CSR40 PS Base Unit 413 Kg (910 lb)
Full TRANSFRESH® Option 13 Kg (28 lb)

1-8 Physical Specifications Specifications
Physical Specifications (Continued)

Unit Dimensions: A = Flange Width 2025.5 mm (79.74 in.)
B = Gasket Width 1935 mm (76.18 in.)
C = Unit Width 1894 mm (74.57 in.)
D = Flange Height 2235.2 mm (88.00 in.)
E = Gasket Height 2140 mm (84.25 in.)
F = Unit Height 2094 mm (82.44 in.)
G = Gasket Depth 72 mm (2.83 in.) from back of flange
H = Maximum Protrusion 37 mm (1.46 in.) from back of flange
I = Unit Depth: CSR20 PS 335.0 mm (13.18 in.) from back of flange
CSR40SL PS 378.0 mm (14.88 in.) from back of flange
CSR40 PS 420.0 mm (16.54 in.) from back of flange

Specifications Metric Hardware Torque Charts 1-9
Metric Hardware Torque Charts

Bolt Size
Bolt Type M6 M8 M10 M12
and Class* N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.)
HH – CL 5.8 6-9 (4-7) 12-16 (9-12) 27-34 (20-25) 48-61 (35-40)
HH – CL 8.8 10-13 (7-10) 20-27 (15-20) 41-47 (30-35) 75-88 (55-65)
HH – CL 10.9 14-17 (10-13) 27-34 (20-25) 54-68 (40-50) 102-122 (75-90)
HH – CL 12.9 17-21 (12-16) 41-47 (30-35) 68-81 (50-60) 122-149 (90-110)
HH – SS (2) 10-13 (7-10) 20-27 (15-20) 41-47 (30-35) 75-88 (55-65)
Bolt Size
Bolt Type M14 M16 M18 M22
and Class* N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.)
HH – CL 5.8 75-88 (55-65) 115-135 (85-100) 177-216 (130-160) 339-406 (250-300)
HH – CL 8.8 115-135 (85-100) 177-216 (130-160) 271-339 (200-250) 475-610 (350-450)
HH – CL 10.9 136-176 (100-130) 224-298 (180-220) 393-474 (290-350) 678- 813 (500-600)
HH – CL 12.9 177-216 (130-160) 285-352 (210-260) 448-542 (330-400) 881-1016 (650-750)
HH – SS (2) 115-135 (85-100) 177-216 (130-160) 271-339 (200-250) 475-610 (350-450)
*HH = Hex Head, CL = Class.

2 Unit Description
Dual Speed Evaporator Fans

Unit Features CSR PS models are equipped with either 2 or 3 evaporator fans.
Model CSR20 PS, CSR40SL PS and CSR40 PS units are all- All models feature 2-speed motors. The evaporator fans operate
electric, single-piece, refrigeration units with bottom air sup- continuously to circulate air inside the container. The fans oper-
ply. Each unit is designed to cool and heat containers for ship- ate on high speed for perishable cargo at setpoints of -9.9 C
board or overland transit. Each unit mounts in the front wall (14.1 F) and above. At setpoints of -10 C (14 F) and below, the
of the container. CSR20 PS and CSR40SL PS units feature a evaporator fans operate on low speed for frozen cargo.
slimline frame (see “Physical Specifications” on page 1-8).
Fork lift pockets are provided for installation and removal of NOTE: If Economy Mode is ON:
the unit. • Fresh Loads: Evaporator fans operate on low
The frame and bulkhead panels are constructed of alu- speed when container temperature is in-range.
minum and are treated to resist corrosion. A hinged, remov- • Frozen Loads: Evaporator fans stop during the
able evaporator compartment door provides easy service Null mode; controller operates fans on low speed
access. All operating components except the evaporator coil for 5 minutes every 45 minutes.
can be replaced from the front of the unit. A totally sealed,
hermetic refrigeration system minimizes maintenance and ser-
Fresh Air Exchange System
vice.
The fresh air exchange system removes harmful gases from
Each unit is equipped with an 18.3 m (60 ft) power cable
containers carrying sensitive perishable commodities. The
for operation on 460-380V/3 Ph/60-50 Hz power. For opera-
fresh air vent is located above the control box. The fresh air
tion on 460-380V/3 Ph/60-50 Hz power, plug the 460-380V
vent is adjustable to accommodate a variety of cargo and
power cable into the proper power supply. The unit power
chilled load operating conditions. The fresh air vent should be
cable is stored below the control box in the condenser section.
tightly closed when carrying frozen cargo.
Each unit is equipped with 460-380V/3 Ph/60-50 Hz elec-
tric motors. An automatic phase correction system provides
MP-3000 Controller
the proper electrical phase sequence for condenser fan, evapo-
The MP-3000 controller incorporates refrigeration system
rator fan and compressor operation.
component control, thermostat, digital thermometer, fault indi-
Unit features include a hermetic scroll compressor with a
cation and data recording capabilities into one self-contained
liquid injection system; 2-speed evaporator fans; a fresh air
package.
exchange system; and a MP-3000 controller with integral data
The controller mounts in a weather tight, corrosion resis-
logger. For additional unit feature information, see “CSR PS
tance enclosure. A large-character LED display (top) provides
Hermetic Model Features” on page vi of the Introduction.
easy viewing of the control sensor temperature (return or sup-
ply air temperature). A 4-line, 20-character LCD display (bot-
Hermetic Scroll Compressor with Liquid Injection
tom) display shows important data including the setpoint tem-
Cooling System
perature, controller Main Menu tree and important unit operat-
The refrigeration unit includes a hermetic scroll compressor
ing data.
(one stationary and one orbiting member) with ambient com-
pensated internal overload and high temperature protectors,
and a refrigerant injection system.

2-2 Unit Options Unit Description
Sixteen general purpose keys are used to enter and scroll Dual Voltage
through the controller menu tree and message text; initiate A dual voltage system includes a 15 KVA auto transformer
Pretrip and Function tests; enter new setpoint temperature; and and an 18.3 m (60 ft) power cable for operation on 230-
enter trip information. The keyboard supports both numerical 190V/3 Ph/60-50 Hz power. The power cable is stored below
and text input. Four special keys provide quick access to set- the control box in the condenser section.
point temperature change, manual defrost initiation, alternate The 15 KVA auto transformer steps 230/190V power up
return/supply air temperature display, and alternate tempera- to 460/380V. The auto transformer includes a 460-380V/3
ture scale (C/F) display. Ph/60-50 Hz power receptacle.
Status indicator LEDs in the controller display signal For operation on 230/190V power, plug the 460-380V
Compressor, Heat, Defrost, In-range, Alarm, Humidity, unit power cable into the receptacle on the auto transformer.
Supply Temperature display and Return Temperature display. Then plug the 230/190V power cable into a 230-190V power
A datalogger incorporated in the MP-3000 controller supply.
records sensor temperatures as well as loss of power, alarms,
unit operating modes, sensor failure, setpoint change and unit REFCON Remote Monitoring Modem (RMM)
shutdown indications. All data recordings are stored in a A REFCON remote monitoring modem is provided to permit
RAM memory that is backed by battery.
remote monitoring via the power cable. High speed transmis-
Logging intervals are selectable from 1 minute and 1/2, 1,
2 or 4 hours. When a 1 hour logging interval is selected, the sion reads all controller information. Data can also be
datalogger memory can store approximately 512 days of infor- retrieved from the datalogger via high speed transmission.
mation. The logging of USDA sensors is fixed at 1 hour inter-
vals to comply with USDA requirements. TRANSFRESH® Atmosphere Control System Options
The datalogger clock is factory set at UTC time. All data Several TRANSFRESH options are available to meet individ-
logs include the time and date; setpoint temperature; and sup- ual customer needs. The TRANSFRESH system provides a
ply, return, USDA1, USDA2 and USDA3 sensor temperatures. controlled atmosphere within the container. By controlling the
All temperature logs can be viewed from the controller’s LCD container temperature and atmosphere, the respiration rate of
message display. fruit and vegetables can be lowered. This allows the product
A high speed serial communication port provides data quality to be maintained for longer periods of time.
retrieval using a DRU-II hand-held data retriever or laptop • TRANSFRESH Ready: Provisions for the future installation
computer with SmartSponge software, or a REFCON power and use of a TRANSFRESH atmosphere control system are
line remote monitoring system. incorporated in the unit. TRANSFRESH compatible A2
(power/defrost) and A3 (communications) cables (without
connectors) are factory installed.
• Full TRANSFRESH Option: TRANSFRESH system com-
Unit Options ponents are installed for use of a TRANSFRESH atmosphere
control system. In addition to A2 and A3 cables (with con-
USDA Cold Treatment Temperature Recording nectors), the security frame, security enclosure with insula-
The datalogger includes provisions for the use of up to four tion block, TRANSFRESH supplied single purge port, air
USDA sensors. These sensors allow temperatures in various hose and scrubber cable (A5, with connectors) are factory
areas of the load to be monitored and recorded for United installed. Purge port includes a removable plug for charging
States Department of Agriculture use in monitoring Cold the container with a modified atmosphere.
Treatment shipments.
Controlled Atmosphere Option
Dehumidification Control System An optional port injection kit includes two charging ports and
A dehumidification system lowers the relative humidity in the a pressure relief valve to provide a modified atmosphere with-
container to the humidity setpoint. The control range setpoint in the container. By controlling the container temperature and
is adjustable between 50% and 99%. atmosphere, the respiration rate of fruit and vegetables can be
lowered. This allows the product quality to be maintained for
Humidification Control System longer periods of time.
An optional humidification system increases the relative
humidity in the container to the humidity setpoint. The control
range setpoint is adjustable between 50% and 99%.

Unit Description Operating Modes 2-3
Remote Monitoring Receptacle (4-Pin) Option Chill Loads: Controller Setpoint at -9.9 C (14.1 F) or
An optional 4-pin remote monitor connector provides 24 Vac Above
signals for bridge lights that monitor Cool (Compressor On), Temperature control by the controller is based on the supply
Defrost and In-range conditions. air sensor temperature, the setpoint, the modulation tempera-
ture range and the pull-down rate. The evaporator fans operate
Recording Thermometer Options in high speed (except during defrost).
Several models of temperature recorders are available for • Cool with Modulation (down to setpoint)
mounting on the unit. Each temperature recorder is designed • Null (compressor and condenser fan stops, evaporator
to withstand widely varying environments including low and fans operate)
high ambient temperatures, salt water, humidity, fungus, • Heat (resistance heaters on, evaporator fans operate)
industrial pollutants, dynamic loading, rain, sand and dust. • Defrost (resistance heaters on, evaporator fans stop)
• The 31-day Saginomiya Recorder is electric motor driven by
a dry cell type battery with a 1 year life expectancy. NOTE: If the Economy Mode is set to ON, the
• The 31-day Partlow Recorder is mechanically driven by a evaporator fans operate on low speed at set-
spring mechanism. points of -9.9 C (14.1 F) and above whenever the
container temperature is In-range.
Operating Modes Frozen Loads: Controller Setpoint at -10 C (14 F) or

Below
NOTE: See MP-3000 Controller chapter for complete Temperature control by the controller is based on the return air
sequence of operation. sensor temperature. The evaporator fans operate continuously
on low speed (except during defrost).
A sequence start of the required loads occurs during initial • Cool (down to 1 C [1.8 F] below setpoint)
start-up of the unit and when a control mode shift requires the • Null (compressor and condenser fan stops, evaporator
compressors to start. As the controller relays and unit loads fans operate)
energize, the controller LCD display shows the setpoint tem- • Defrost (resistance heaters on, evaporator fans stop)
perature. The controller LED display shows the controlling air
sensor temperature. The controlling sensor is determined by NOTE: If the Economy Mode is set to ON, the
the setpoint temperature: evaporator fans stop when the unit shifts to Null.
Setpoint Controlling Sensor The controller automatically starts and operates
-9.9 C (14.1 F) and above Supply Air Temperature the evaporator fans on low speed for 5 minutes
-10 C (14 F) and below Return Air Temperature every 45 minutes while the unit remains in Null.
The MP-3000 controller uses a proportional-integral
derivative (PID) algorithm to provide accurate temperature
control in direct response to load demand. Therefore it is diffi-
cult to predict which operating mode the unit should be in by
comparing the setpoint to the return or supply air temperature.
The unit operates in either the Fresh (Chill) or Frozen mode.
Chill to Frozen mode transition point is -10 C (14 F).

2-4 Unit Illustrations Unit Description
4
11
5
10
6
9
7
8
Typical Unit Front View

1. CSR20 PS and CSR40SL PS: Evaporator Access Door, 1399 mm (55.04 in.) Wide with Three Latches
2. CSR40 PS: Evaporator Access Door, 1018 mm (40.08 in.) Wide with Two Latches
3. Heater Access Panel Location
4. Condenser Fan
5. Compressor Compartment
6. Supply Air Sensor Probe Holder, Left Hand (Behind Compressor)
7. Supply Air Sensor Probe Holder, Right Hand
8. Power Cord Storage Compartment
9. Control Box
10. Rear Download and USDA Receptacle Panel (Access from Inside Container)
11. Fresh Air Exchange Vent

Unit Description Unit Illustrations 2-5
2
7
3 6
Unit Options Front View

1. Recording Thermometer Option
2. Dual Voltage Option
3. TRANSFRESH Download Receptacle, Option
4. Remote Monitor Plug Option (4-Pin Connector on Bottom or Side of Control Box)
5. Thermistor Lead Option (Lead inside Control Box)
6. REFCON Remote Monitoring (RMM) Modem (Modem inside Control Box)
7. Humidify System Option
8. Full TRANSFRESH Option, CSR40 PS
9. Full TRANSFRESH Option, CSR20 PS and CSR40SL PS

1 2 3 4 5 6
CSR20 PS and CSR40SL PS Evaporator Section — Front View

1. Evaporator Fan Motor
2. Evaporator Fan Blade:
• CSR20 PS: 280 mm (11.02 in.) diameter, 19o pitch
• CSR40SL PS: 312 mm (12.25 in.) diameter, 25o pitch
3. Return Air Sensing Bulb for Recording Thermometer (Option)
4. Return Air Sensor
5. Humidity Sensor (Option)
6. Humidify System Compressor (Option), see page 2-8

1 2 3 4 5 6
CSR40 PS Evaporator Section — Front View

1. Evaporator Fan Motor
2. Evaporator Fan Blade:
• CSR40 PS: 355 mm (14.0 in.) diameter, 25o pitch
3. Return Air Sensing Bulb for Recording Thermometer (Option)
6. Humidify System Compressor (Option), see page 2-8

10
1 7
6
2
Humidify System Option

1. Evaporator Drain Hose
2. Fill Cap
3. Water Tank Heater
4. Tank Overflow Hose
5. Drain Cock
6. Water Tank
7. Water Filter
8. Water Supply Hose
9. Air Compressor
10. Liquid Spray Nozzle

18
1
17
2
16
3
4 15
5
14
6
7 13
8
12
9
11
10
Hermetic Refrigeration System

1. Evaporator Coil 17. Warm Gas Bypass Solenoid Valve
2. Tube (Standard) 18. Dehumidify Valve (Option replaces standard tube)
3. Expansion Valve
4. Heat Exchanger
5. One-piece Filter Drier/In-line Filter
6. Stepper Motor Valve
7. Compressor Discharge Temperature Sensor
8. Liquid Injection Solenoid Valve
9. Scroll Compressor
10. Suction Line Process Tube
11. Low Pressure Cutout Switch
12. Discharge Line Process Tube
13. High Pressure Cutout Switch
14. Condenser Coil
15. High Pressure Relief Valve
16. Receiver Tank

2 13
4 12
5 11
6 10
7
9
Controller and Remote Monitoring Modem

1. Remote Monitoring Modem (Option)
2. RMM Communication Cable (Option)
3. Battery Cable Connection to Controller
4. Cable No. 2 Connection to Controller
5. Download Cable Connection to Controller
8. Control Box Cover and Controller Keyboard Decal
9. Special Function Keypad
10. General Purpose Keypad
11. LCD Display (Setpoint Temperature, Message and Controller Main Menu Tree Display)
12. LED Display (Return or Supply Air Temperature Display and Status Indicator LEDs)
13. MP-3000 Controller

1
4
2
Unit Control Box

1. Unit On/Off Switch
2. Communications Connector for Data Retrieval
3. Circuit Breaker
4. Main Relay Board
5. 12 Vdc Battery
6. Control Power Transformer
7. Compressor Contactors (2)
8. 25 Ampere Main Power Circuit Breaker

TRANSFRESH System Options

1. TRANSFRESH Scrubber Connection and A5 Wire Harnesses
2. Evaporator Grille
3. TRANSFRESH Security Enclosure
4. TRANSFRESH Download Port
5. Transformer Assembly mounted in Control Box
6. TRANSFRESH Ready Option includes:
• A2 Wire Harness (without connectors) from control box to evaporator section
• A3 Wire Harness (without connectors) from condenser section to evaporator section
• Evaporator Grille Access Opening

Typical Unit Back View

1. Evaporator Grille
2. Unit Gasket
3. Top Rear Plate
4. Bottom Rear Plate
5. Sensor Connector Assembly:
• Controller Communications and Data Download Port
• Cargo (Pulp) Sensor Connection
• USDA1 Sensor Connection

3 Operating Instructions
6. STATUS INDICATOR LEDs located in the large LED

Unit Controls display signal:
• Supply (Air Temperature)
• Return (Air Temperature)
Unit Control Box
• Humidity Mode (Humidification Option set to On in
1. UNIT ON/OFF SWITCH.
Setpoint menu)
a. ON position. Unit will operate on cool or heat
• Compressor (Cooling On)
depending on the controller setpoint temperature and
• Heat (On)
the container air temperature.
• Defrost
b. OFF position. The unit will not operate.
• In-Range (Temperature)
• Alarm
MP-3000 Controller
The In-range LED illuminates when the controlling
The MP-3000 microprocessor controls all unit functions to
air sensor temperature is less than 1.5 C (2.7 F) above set-
maintain the cargo at the proper temperature. The controller
point (standard). The controller maintains the in-range
also monitors and records system faults and performs pre-trip.
signal during defrost and after defrost for 60 minutes.
1. KEYPAD. Sixteen general purpose keys are used to dis-
7. LED DISPLAY. Large red LED display shows current
play information, change the setpoint, change programma-
control temperature during normal operation. LED dis-
ble features and initiate control tasks.
play also shows current test state during a Pretrip (PTI) or
2. oC–oF KEY. Press this key to view temperatures in the
Function test.
LED display in the alternate temperature value. Alternate
8. LCD DISPLAY. A 4-line LCD message display shows
value (C or F) shows while the key is pressed.
setpoint during normal operation. LCD display also
3. RET/SUP KEY. Press this key to view the alternate sen-
shows controller menu and unit operation information
sor temperature in the LED display. Alternate sensor
when special keys are pressed.
(return or supply) shows while the key is pressed.
4. DEFROST KEY. Press this key to initiate a manual
Other Unit Controls
defrost cycle. If the evaporator coil temperature is below
1. EVAPORATOR OVERHEAT SWITCH. A temperature
18 C (65 F), the unit will defrost. Otherwise the controller
switch near the evaporator coil opens to de-energize the
will display “Defrost Not Activated” in the LCD display
heater contactor if the evaporator temperature reaches 54
and the unit will continue normal operation.
+/- 3 C (130 +/- 5 F). The switch closes (resets) when the
5. SETPOINT KEY. Press this key to change the setpoint.
evaporator temperature decreases to 38 +/- 4.5 C (100 +/-
Cursor in the LCD display automatically appears in the
8 F).
“TEMP SETP” line of the Data menu. See “Changing the
Setpoint” in the MP-3000 Controller chapter for complete
instructions.

3-2 Unit Instruments Operating Instructions
4. COMPRESSOR DISCHARGE GAS TEMPERATURE

Unit Instruments SENSOR. A refrigerant injection system uses the com-
pressor discharge temperature to determine when cold
1. THERMISTOR LEAD (OPTION). A thermistor lead is
refrigerant will be injected into the center scroll of the
located in the unit control box to provide air temperature
compressor to protect the compressor from excessively
verification. The bulb of the thermistor lead is attached to
high operating temperatures.
the return or supply air sensor in the evaporator section.
a. Chill Mode Liquid Injection:
2. REMOTE MONITOR CONNECTOR, 4-PIN (OPTION).
• Controller energizes the liquid injection valve when
A receptacle is provided on the side of the control box for
compressor discharge gas temperature increases to
connecting the ship’s 4-pin bridge light system to the unit.
138 C (280 F).
The connector provided circuits for Compressor On,
• Controller de-energizes the liquid injection valve to
Defrost and In-range. The remote in-range light is activat-
stop liquid injection when the discharge gas temper-
ed when the controlling air sensor temperature is between
ature decreases to 132 C (270 F).
1.7 C (3.0 F) above setpoint and 2.5 C (4.5 F) below set-
b. High Temperature Protection:
point.
• The controller immediately stops unit operation if
3. RECORDING THERMOMETER (OPTION). The
the discharge gas temperature increases to 148 C
recording thermometer indicates and permanently records
(298 F). The controller activates the Alarm LED
the temperature of the air returning to the evaporator sec-
and records Alarm 56, Compressor Temperature
tion on a calibrated chart.
Too High. The controller restarts the unit when the
4. POWER LINE COMMUNICATIONS MODEM
condition corrects itself.
(OPTION). A REFCON remote monitoring modem is
5. HIGH PRESSURE CUTOUT (HPCO) SWITCH. If the
available to provide remote monitoring via the power
compressor discharge pressure rises above 3243 +/- 7 kPa,
cable. High speed transmission reads all controller infor-
32.43 +/- 0.48 bar, 470 +/- 7 psig, the high pressure cutout
mation.
opens to interrupt the ground circuit to the compressor
contactor:
• Compressor STOPS immediately.
• Evaporator and condenser fans continue normal opera-
Unit Protection Devices tion. Controller determines that a high pressure cutout
1. MAIN CIRCUIT BREAKER. A 25 ampere manual reset switch is open when the unit current draw decreases by 7
circuit breaker protects the 460/380V power supply circuit amps for more than 3 seconds.
to the unit electric motors and control system transformer. • The controller LCD display shows a High Pressure
The main power circuit breaker is located in the control Cutout message: “High Pressure Cutout Check
box. Condenser Probe” or “High Pressure Cutout Check
2. CONTROL SYSTEM CIRCUIT BREAKER. A 7 ampere Condenser Fan”.
manual reset circuit breaker protects the 29 Vac control • After 1 minute, the controller energizes the compressor
circuit. This circuit breaker is located in the control box contactor so the compressor will restart when the over-
beside the On/Off switch. load condition is corrected (switch resets) if power is
3. FUSES. A number of fuses are located on the main relay available. The high pressure switch resets (closes) when
board and controller plug to protect unit circuits and com- the pressure drops to 1590 +/- 70 kPa, 15.9 +/- 0.7 bar,
ponents. 230 +/- 10 psig.
• Three 20 amp fuses protect high voltage circuits on the • If the switch remains open for 5 minutes, controller also
main relay board. activates Alarm LED and records Alarm 37, Total Power
• A 2 amp fuse protects the controller’s 28 V system. Consumption Too Low.
• A 2 amp fuse protects the controller’s battery charging
circuit.

Operating Instructions Pretrip Inspection 3-3
6. LOW PRESSURE CUTOUT (LPCO) SWITCH. If the

compressor discharge pressure decreases to +21 to -21 Pretrip Inspection
kPa, +0.21 to -0.21 bar, 3 psig to 6 in. Hg vacuum; the
low pressure cutout opens:
Visual Inspection
The following inspections should be made before the container
• Evaporator and condenser fans continue normal opera-
is loaded:
tion.
1. Visually check the unit for physical damage.
• Compressor will restart if the low refrigerant condition is
2. Check the electrical connections in the unit control box,
corrected (switch closes) as long as power is available.
making sure they are fastened securely.
The low pressure switch resets (closes) when the pres-
3. Check the conditions of wires and terminals. Repair or
sure increases to 48 to 90 kPa, 0.48 to 0.90 bar, 7 to 13
replace if necessary.
psig.
4. Check the refrigeration system for leaks. Inspect for evi-
dence of oil leaks at all joints and connections.
NOTE: If the low pressure cutout switch remains 5. Check the condenser and evaporator coils. Clean if neces-
open, check for an obstruction or refrigerant leak sary. Use an air or water spray jet directed against the coil
in the low or high pressure side of the refrigera- from the air discharge side. Also inspect the condenser
tion system. fan grille for damage. If the grille is damaged or missing,
abnormally high head pressure may result. Repair or
7. HIGH PRESSURE RELIEF VALVE. A high pressure
replace the grille if necessary.
relief valve is installed in the liquid line between the
receiver tank and filter drier. The relief valve protects
CAUTION: Air or water spray jet pressure should
against excessive pressure build-up within the refrigera-
not be high enough to damage (bend) coil fins.
tion system from extraordinary and unforeseen circum-
stances. The valve is a spring-loaded piston that lifts 6. Check the mounting bolts on the unit, compressor and fan
when refrigerant pressure exceeds 3447 +520/-104 kPa, motors. Tighten if necessary.
34.47 +5.20/-1.04 bar, 500 +75/-15 psig. The valve is 7. Clean the defrost drains.
located so that refrigerant pressure expelled from the 8. Optional: Check water level in humidity system tank.
valve would be directed away from anyone servicing the Add only demineralized or distilled water to prevent plug-
unit. The valve will reset when this pressure drops to 2758 ging of the atomizing nozzle.
kPa, 27.58 bar, 400 psig. The valve is non-repairable and 9. Observe the unit for proper operation and functions during
requires no adjustment. If the valve fails to reseat proper- Pre-load Operation.
ly, recover the refrigerant charge and replace the valve. 10. Check to be sure the container ID that appears in the
8. OVERLOAD PROTECTION. The condenser fan motor, Configuration menu is correct.
evaporator fan motors and compressor motors include
internal overload protection with automatic reset. Functional Inspection
9. PHASE SEQUENCE SELECTION. When the On/Off To properly perform a Full Pretrip Test on units equipped with
switch is turned ON, phase sensors on the main relay a MP-3000 controller, the container must be empty with the
board determine the incoming power phase to ensure the rear doors closed.
correct sure proper condenser fan and evaporator fan rota- 1. Start the unit (see “Starting the Unit and Adjusting the
tion. The controller then determines the correct phase Controller Setpoint” on page 3-5). A second sequence
sequence for the compressor and energizes the correct start of the required loads occurs during the Pretrip test:
compressor contactor. • Controller LED display turns On and then Off.
• LED display briefly shows setpoint and then displays the
controlling (return) air sensor temperature.
• Controller senses the incoming power phase and selects
the correct power phase to unit components.
• Controller energizes unit loads, starting the evaporator
fans. The condenser fan may also start (if required).

3-4 Pretrip Inspection Operating Instructions
• If the controller calls for cooling, the compressor motor • LCD display shows PTI Test currently being performed.
starts. If the unit starts in Modulation Cool the stepper PTI test ends automatically. Press any key on the con-
motor valve opens or closes to the required setting. troller to return the unit to normal operation.
• If the controller calls for heating, the electric heaters are • If an operating problem occurs during the Pretrip Test,
energized. the Alarm LED will turn ON and FLASH. An “E” may
also appear in the right side of the LED display. View
NOTE: If the compressor fails to start, turn the and correct any alarm conditions. Then clear (acknowl-
On/Off switch OFF. Then repeat steps 1 through edge) the Alarm Code(s) and repeat the PTI Test.
3. If the unit still does not start, refer to “Alarm
Codes, Descriptions and Corrective Actions” in NOTE: Clear the Alarm codes ONLY after the
the MP-3000 Controller chapter of this manual. alarm codes are documented and problems
repaired. A permanent record of the alarm codes
2. Check controller setpoint for proper setting. Adjust if remains stored in the datalogger memory for
necessary. retrieval via DRU-II or SmartSponge retriever
software.
NOTE: New setpoint must be between -29 C and
+29 C (-20.2 F and +84.2 F) or controller will 6. Enter trip ID information into the controller using the key-
return to the previous setpoint display. pad.
7. Set the fresh air vent to the desired air exchange rate.
3. Check the direction of the condenser airflow (see
“Condenser Fan and Evaporator Fan Rotation” in the NOTE: If Dehumidification is turned ON, the
Electrical Maintenance chapter of this manual). fresh air vent should be closed.
4. Check direction of evaporator airflow (see “Condenser
Fan and Evaporator Fan Rotation” in Electrical 8. Optional: Operate the humidity system (see “Changing
Maintenance chapter of this manual). the Humidity Mode Setting” on page 4-15). Verify that
5. Perform a Pretrip (PTI) Test to check the unit refrigeration the air compressor operates and that water is drawn into
and electrical systems for proper operation. the atomizing nozzle and injected into the return air
stream (see “Humidify System” on page 7-3).
CAUTION: The PTI test should only be per- 9. Install a new chart and prepare the recording thermometer
formed on an empty container! for temperature recording (if so equipped):
• Wind the chart drive on the recording thermometer
NOTE: Correct all existing alarm conditions and (Partlow recorders).
clear the alarm codes before performing a PTI • Check the battery charge on the recording thermometer
test. The controller will automatically clear all (Saginomiya recorders).
existing alarms before beginning the PTI test. 10. Stop the unit by moving the On/Off switch to the OFF
position.
To perform a PTI test:
• Press F2 key to enter Main Menu.
• Press F2 or F3 key to scroll up or down in menu to
“COMMANDS”.
• Press F4 key to access COMMANDS menu.
• Press F2 or F3 key to scroll up or down to “PTI”.
• Press F4 to start the PTI (Pretrip) Test.
• The controller then performs the Pretrip Test.
• Observe the unit for proper operation and functions dur-
ing pretrip test.

Operating Instructions Starting the Unit 3-5
Starting the Unit and Adjusting the Loading Procedure

Controller Setpoint 1. Make sure the Unit On/Off switch is OFF before opening
the container doors. (The unit may be operating when
CAUTION: Supply power connections from the unit loading the container from a warehouse with door seals.)
to the power source must always be made with the 2. Spot check and record load temperature while loading.
refrigeration Unit On/Off switch and power supply Especially note any off-temperature product.
On/Off switch in the OFF positions. Never attempt to
start or stop the refrigeration unit with the unit power
cable.
Post Load Procedure
1. Verify that the Unit On/Off switch is in OFF position.
2. Connect the unit power cord to proper power source: 1. Make sure all doors are closed and locked.
• 460/380V power cord to 460/380V, 60-50 Hz power 2. Start unit if unit is OFF.
source. 3. Check controller setpoint for proper setting.
• Turn the power supply On/Off switch ON. 4. Enter trip identification information into the controller
3. Switch the Unit On/Off switch to ON position. Check for memory by selecting “Cargo Data” from the MISC
condenser fan and evaporator fan motor operation (see FUNCTIONS menu of the controller.
“Condenser Fan and Evaporator Fan Rotation” in the 5. One-half hour after loading, initiate a manual defrost
Electrical Maintenance chapter of this manual). If the unit cycle:
was properly pretripped, correct condenser fan rotation • Press the DEFROST key. The Defrost and Heat LEDs
will also indicate correct evaporator fan rotation. turns ON as the unit enters Defrost. Defrost will stop
4. Adjust controller setpoint to the desired temperature: automatically.
NOTE: The setpoint temperature can be set NOTE: The evaporator coil temperature must be
between -29 C and +29 C (-20.2 F and +84.2 F) in below 18 C (65 F) to allow the unit the enter a
either oF or oC using the oC/oF key. Just press defrost cycle. If the evaporator coil temperature
and hold the F/C key (to display the alternate is too high, the LCD display will read “Defrost
temperature scale). Not Activated”.
• Press SETPOINT key to display cursor flashing in the

“TEMP SETP” line.
• Press F4 key to activate the setpoint change function. Post Trip Procedure
An Enter Arrow appears in the menu line and the current Trip data recorded by the MP-3000 datalogger may be down
setpoint disappears. loaded via the communications port on the control box using a
• Enter minus sign (if required) first by pressing EXIT DRU-II hand-held data retriever, or laptop computer with
key. Then press numeric keys to enter new setpoint. SmartSponge retriever software; or via the REFCON remote
• With correct setpoint in display, press and hold F4 key monitor system.
until cursor stops flashing. Controller places new set-
point in controller memory and shows new setpoint in
LCD display.
NOTE: New setpoint must be between -29 C and

+29 C (-20.2 F and +84.2 F) or controller will
return to the previous setpoint display.
NOTE: If the setpoint is not entered within 30

seconds, the controller will default (return) to the
previous setpoint. If this occurs, repeat step 3.

4 MP-3000 Controller
Controller Description
The MP-3000 is an advanced microprocessor controller that
has been specially developed for control and monitoring of
refrigeration units. The controller contains the following basic
features:
1. LED display for TEMPERATURE:
• Five alpha numeric, 20.32 mm high characters:
Numerical hundredths, tens, ones and tenths position, a C
for Celsius or F for Fahrenheit for temperature display.
• LED display shows controlling (return or supply) sensor
temperature. Sensor temperature shown in LED display
is indicated by status indicator lights. If a sensor is out
of range the display shows “+Err” or “-Err”. The +/-
sign indicates whether the sensor temperature is out of
range high or low.
• The LED display also shows the test stage of a Pretrip
(PTI) or Function test.
2. LCD display for SETPOINT, MESSAGES and MENU:
• 4 line, 20 character LCD display shows setpoint temper-
ature during normal operation.
• Alarms, messages and the controller menu also appear in
the LCD display when special keys are pressed.
3. Sixteen general purpose keys are used to enter text and
scroll through the controller menu tree.
a. Text Input: The keyboard supports both numerical
and text input. Each key can have more than one mean-
ing. Use the special text keys F1, F2, F3 and F4 to enter
text in an information screen:
• F1 key: Press the F1 key, then press another general
purpose key to enter the number shown on the key.
purpose key to enter the first letter shown on the key.
purpose key to enter the second letter shown on the key.
purpose key to enter the third letter shown on the key. MP3000 Controller
1. LED display for TEMPERATURE. Status indicator
NOTE: When the F1, F2, F3 or F4 key is pressed
LEDs identify controlling sensor temperature (return
to enter a character in the display, the keypad
or supply) that appears in display.
remains on that “character level” until another
2. LCD display for SETPOINT, MESSAGES and
“level” is selected by pressing the F1, F2, F3 or
MENU. Use the keypad to scroll through messages
F4 key.
and the controller menu.
3. General purpose keys are used to enter text and
scroll through menus.
4. Special function keys perform specific tasks.

4-2 Controller Description MP-3000 Controller
Text Input Example: To enter THERMO in an informa- • Relays to energize and de-energize unit contactors and
tion screen: solenoids. Component relays include the heater, evapo-
a. Enter “T” by pressing F3 key, then pressing STU key. rator fan motor, condenser fan motor, and phase reversal
b. Enter “H” by pressing GHI key. relays.
c. Enter “E” by pressing DEF key. • Supply power circuit protection:
- 20 amp fuses (3) protect the high voltage circuits on the
d. Enter “R” by pressing F4 key, then pressing PQR
main relay board.
key. • Control circuit fuse and circuit breaker protection:
e. Enter “M” by pressing F2 key, then pressing MNO - 7 amp manual reset circuit breaker protects the 24 Vdc
key. control circuit.
f. Enter “O” by pressing F4 key, then pressing MNO - 2 amp fuse protects the 28V ac control power circuit to
key. the controller.
b. Menu Scrolling: General text keys F1, F2, F3 and
- 2 amp fuse protects the battery charger output circuit to
F4 also include directional arrows for entering and
scrolling through the controller Main Menu: the controller.
• F1 key: ESC indicates that pressing the K1 key moves • Electronics for measuring phase sequence.
the cursor out of (exits) a menu list. • Electronics for measuring amperage.
• F2 key: FORWARD/UP ARROWS indicate that press- • Electronics for measuring voltage.
ing the K2 key scrolls the cursor forward and/or upward • Zero current transformer for earth leaking measurement
through text boxes and menu lists. (option).
• F3 key: BACKWARD/DOWN ARROWS indicate that 8. Replaceable sensors: Return air, left hand supply air,
pressing the K3 key scrolls the cursor backward and/or right hand supply air, evaporator coil (defrost), condenser
downward through text boxes and menu lists. coil, ambient air and compressor discharge line tempera-
• F4 key: ENTER ARROW indicates that pressing the K4 ture sensors are field replaceable. Three (replaceable)
key moves the cursor into the next menu level or into a spare sensor receptacles are also provided for USDA tem-
menu item text box. perature recording.
4. Four special function keys (see illustration on page 4-1): 9. Probe Test (see “Probe Test” in this chapter).
• C/F key: Press to view alternate temperature scale in 10. Defrost cycle control (see “Defrost System” in this chap-
LED display. ter).
• DEFROST key: Press to initiate defrost. Evaporator 11. Pretrip (PTI) test capability (see “PTI (Pretrip) Test” in
coil temperature must be below 10 C (50 F). this chapter).
• SUP/RET key: Press to view alternate return/supply 12. Function test capability (see “Function Test” in this chap-
ter).
sensor temperature in LED display.
13. Data recording capability (see “Data Recording and
• SETPOINT key: Press to enter Setpoint Menu. The Downloading Data” in this chapter).
first line of the Setpoint Menu is the setpoint tempera- 14. Electronic phase selection: The microprocessor relay
ture. Press F2 or F3 key to scroll up or down through board monitors the phase of the power supply to ensure
the menu list. proper rotation of the condenser fan and evaporator fans.
The controller determines the correct phase sequence for
NOTE: Press the “5” key to increase the display the compressor and energizes the correct compressor con-
time of the current LCD data screen by 5 min- tactor.
utes. Maximum display time is 30 minutes for 15. Power limit control (see “Power Limit Mode” in this
data screens and 100 minutes for manual tests. chapter)
16. Sequential component start-up control: A sequence start
5. Status indicator LEDs (see “Status Indicator LEDs and of the required loads occurs during initial start-up of the
controller and when a control mode shift requires the
Alarm Codes” in this chapter).
compressors to start (see “Sequence of Operation” in this
6. Control Transformer: Low voltage control power and
chapter).
ground is supplied to the MP-3000 controller and the main
17. Compressor refrigerant injection cycle control (see
relay board.
“Compressor Liquid Injection” in this chapter).
7. Main Relay Board: High voltage supply power and low
18. Hourmeters: The MP-3000 controller has multiple built-in
voltage control power and ground are supplied to the main
hourmeters that can be accessed through the Main Menu.
relay board. The main relay board contains:

MP-3000 Controller Status Indicator LEDs 4-3
19. Manual emergency control capability. Manual control

settings in the control box allow the unit to operate even Status Indicator LEDs
in the event of a fatal failure of the controller. Manual
control offers three operating functions: Heat, Defrost Eight status indicator LEDs are located in the top LED display
and Cool (see “Manual Emergency Mode Operation” in and signal the following:
this chapter). • Supply (Air Temperature)
20. Flash memory: Flash program memory allows the appli- • Return (Air Temperature)
cation software to be updated without replacing a EPROM • Humidity Mode (Humidification set to On in Setpoint
chip on the controller. Application software can be updat- menu)
ed in the field using a portable computer and the MP-3000 • Compressor (Cooling On)
Loader program. Consequently, the field installed appli- • Heat (On)
cation software version may have a different revision • Defrost
number and may include control features not included in
• In-Range (Temperature)
the original factory installed software. If the operation of
your unit differs from the Sequence of Operation • Alarm
described for the unit in this manual, enter “Misc. The indicator LEDs stay ON continuously to indicate sen-
Functions” in the Main Menu to check that the program sor temperature display, unit operating mode or condition.
version is correct (see “Menu Operating Instructions” in The Alarm LED flashes ON and OFF continuously when
this chapter). a Check Alarm (Level 2 Alarm) or Shutdown Alarm (Level
21. Display menus: The MP-3000 controller contains an 1Alarm) occurs. Less serious Log Alarms (Level 3 Alarm) are
extensive display menu that can be navigated via keypad. recorded but do not activate the Alarm LED (see Alarms Menu
The display menu is organized into eight (8) Main Menus: on page 4-16 for more information).
NOTE: The screens that display on the controller

are determined by the controller model and the
unit configuration setting. All screens are NOT Data Recording and Downloading Data
present on all units.
The MP-3000 datalogger can record sensor temperatures as
• Setpoint Menu: Menu screens in this group are used to well as loss of power, alarms, sensor failure, setpoint change
enter the temperature setpoint and set the economy and unit shutdown events. All data logs include the time and
mode. Setpoint menu option functions include: set date; setpoint temperature; supply, return, ambient, USDA1,
humidify or dehumidify operation, enter humidity set- USDA2 and USDA3 sensor temperatures; and humidity sen-
point, set airflow, set custom airflow, set bulb mode, set sor. All temperature logs can be viewed from the controller’s
AFAM operation, set AFAM delay, set AFAM rate, set LCD message display.
O2 Minimum and set CO2 Maximum. Data logging intervals are selectable from 1 minute or 1/2,
• Data Menu: Menu screens in this group are used to dis- 1, 2 or 4 hours. When a 1 hour logging interval is selected, the
play unit operating information including sensor temper- datalogger memory can store approximately 512 days of infor-
atures, voltage, current and frequency information. mation.
• Alarm List Menu: Menu screens in this group display a The logging of USDA sensors is fixed at 1 hour intervals
list of alarm code(s). to comply with USDA requirements. A logging test of USDA
• Commands Menu: Menu screens in this group are used sensors at 1 minute intervals is possible for 72 minutes.
to activate defrost, function tests, pretrip (PTI) tests and USDA data can be downloaded during the logging test. After
72 minutes, controller returns to previous logging interval and
manual function test.
clears USDA test data from datalogger memory.
• Miscellaneous Functions Menu: Menu screens in this
If the unit power supply is disconnected, the datalogger
group display date/time, C/F, cargo data, program ver-
will continue to register 120 temperature logs (except humidity
sion and run time (hourmeters) information.
sensor) when battery voltage is above 11.4 volts. These will
• Configuration Menu: Menu screens in this group display
be maintained until the unit is re-connected to power, and the
refrigerant type, in-range setting, container ID, contrast
battery automatically re-charged.
(screen), language, unit type, reefer type and zero cur- Trip data can be retrieved (but not erased) from the data-
rent status. logger memory using a DRU-II or SmartSponge handheld data
• Datalogger Menu: Menu screens in this group display retriever, or a REFCON power line remote monitoring system.
temperature log, event log, set log time and PTI log. DRU-II data transfer rate based on a 1 hour log interval is
• Refcon Remote Monitoring (RMM) State: Menu screen about 15 seconds per month of event logs and about 70 sec-
show current remote monitoring state (Offline, Zombie onds per month of temperature logs. For example, download-
or On-line).

4-4 General Theory of Operation MP-3000 Controller
ing 90 days of data logs would take about 75 seconds for event Chill Loads (Setpoint at -9.9 C [14.1 F] and
logs only and about 45 seconds for temperature logs only. Above)
Trip data from separate units is denoted by the identifica-
tion information entered into the controller at the beginning of The unit operates on Cool with Modulation and Heat to
the trip via the general purpose keypad. Identification data provide accurate control of chill loads. During Cool with
may include the container ID number, location B.R.T., con- Modulation, the controller uses a proportional-integral deriva-
tents, loading data, voyage no., ship, load port, discharge port tive (PID) algorithm and a stepper motor valve to provide
and comments. The container ID number is stored in the accurate control of the container temperature in direct response
Configuration submenu. to load demand.
The stepper motor valve is installed in the suction line and
controls the amount of refrigerant returning to the compressor.
The valve opens and closes in response to a controller voltage
General Theory Of Operation signal based on a control temperature differential. The con-
The MP-3000 controller uses advanced solid-state integrated troller uses the setpoint temperature, supply air sensor temper-
circuits to monitor and control unit functions. The controller ature (left and/or right hand sensors) and pull-down rate for the
monitors inputs from: last 10 seconds, last 20 seconds and last 180 seconds to calcu-
• Return air sensor late the control temperature differential.
• Supply air sensor, left hand
• Supply air sensor, right hand Supply Air Sensor Control
• Evaporator coil sensor
• Condenser coil sensor Temperature control accuracy and protection against frost
• Ambient sensor damage is provided by using two separate sensors (left hand
• Humidity sensor and right hand) to determine the supply temperature used to
• USDA (Spare) sensors 1, 2 and 3 calculate the control temperature differential:
• Compressor discharge line temperature sensor • At setpoints below -1 C (30 F), the controller uses the lowest
• Phase measuring circuits supply air sensor temperature.
• Current measuring circuits
• At setpoints above 0 C (32 F), the controller uses the average
• Voltage measuring circuits
temperature of the left hand and right hand supply air sen-
Output signals from the controller automatically regulate all sors.
unit functions including: • At setpoints between -1 C and 0 C (30 F and 32 F), the con-
• Compressor operation troller uses a sliding temperature scale from the lowest sup-
• Condenser fan operation ply air sensor temperature to the average temperature of the
• Evaporator fan motor operation left hand and right hand supply air sensors.
• Liquid line solenoid valve If one supply air sensor fails, the controller uses the tem-
• Stepper motor valve perature of the other supply air sensor for temperature control.
• Liquid injection valve If both supply air sensors fail, the controller uses the tempera-
• Dehumidify valve ture of the return air sensor plus an offset for temperature con-
• Electric heaters
trol.
• Phase selection
Temperature Control Accuracy and Frost Protection
The PID algorithm generally minimizes container temperature
fluctuations to +/- 0.1 C (+/- 0.2 F). Additional frost protec-
tions is provided by pulsing the electric heaters ON and OFF
on a 60 second duty cycle to increase the supply air tempera-
ture if the return air temperature decreases to within 0.3 C (0.5
F) of setpoint. The controller pulses the heater ON for 2 to 60
seconds every 60 seconds. The amount of ON time depends
on the amount of heat required to provide frost protection.

MP-3000 Controller General Theory of Operation 4-5
Frozen Loads (Setpoint at -10 C [14 F] and Compressor Liquid Injection

Below) During compressor operation, a liquid injection system injects
The unit operates on Full Cool and Null to provide accu- refrigerant into the center scroll of the compressor to protect
against excessively high operating temperatures. When liquid
rate control of frozen cargo. The controller uses the return air
injection is active, the controller energizes the liquid injection
sensor temperature and setpoint temperature to regulate unit valve continuously. The controller activates liquid injection
operation. when the:
If the return air sensor becomes disconnected or fails, the • Compressor starts. The controller turns on liquid injection
controller uses the supply air sensors plus an offset for temper- for 5 minutes after each compressor start-up. Compressor
ature control. start-ups include initial unit start, start after Defrost and start
after Null.
Modulation Display in Data Menu • Chill or Power Limit Mode: When the modulation percent is
75% or less (in the Data menu display), the controller ener-
The modulation percent displayed in the Data menu indicates gizes liquid injection valve continuously.
the percent of the total unit capacity that is currently provided. • Compressor discharge temperature exceeds 138 C (280 F).
For example, when controller display shows 70%, this means Liquid injection stops when the compressor discharge tem-
the stepper motor valve has closed to reduce system cooling perature decreases to 132 C (270 F).
capacity from 100% to 70% (a 30% reduction).
Warm Gas Bypass

Power Limit Mode
During Chill Mode operation, a warm gas bypass system
The controller uses the total unit current and the condenser diverts refrigerant from the high side to the suction line as the
temperature to provide power limit control in both the Chill supply air temperature decreases toward setpoint. This
and Frozen modes. When the unit is on water-cooled opera- reduces unit cooling capacity and increases refrigerant flow
tion, power limit control is based on the total unit current draw through the compressor. The controller activates the warm gas
only. bypass valve when:
• Chill Mode: When the modulation percent is 25% or less (in
Initial Unit Start-up and Normal Operation (Standard) the Data menu display), the controller energizes warm gas
Power Limit is active whenever the compressor is ON in both bypass valve on a 30 second duty cycle. The amount of On
the Chill and Frozen modes. When the total current draw or (open) time increases as the modulation percentage decreas-
the condenser temperature exceeds a predetermined threshold, es.
the controller limits unit power consumption by sending a
voltage pulse to the stepper motor valve. The stepper motor Evaporator Fan Control
valve then closes to restrict the flow of refrigerant to the com- The controller determines evaporator fan motor speed based
pressor. This reduces the cooling capacity load on the com-
on the setpoint temperature and the Economy mode setting.
pressor, thereby limiting the compressor motor current draw
and the condenser temperature to a predetermined threshold. • Evaporator fans operate on HIGH speed at setpoints of -9.9 C
(14.1 F) and above. If the Economy mode is ON and temper-
Power Limit Management ature is In-range, the controller shifts the evaporator fans to
LOW speed.
Additional power limit management flexibility is available. A • Evaporator fans operate on LOW speed at setpoints of -10 C
maximum total current draw (17, 15 or 13 amps) and power (14 F) and below. If the Economy mode is ON and the unit
management time interval can be selected from the Power is in the Null mode, the controller STOPS the evaporator
Management feature of the Commands menu. When the fans. The controller then operates the evaporator fans on
power management time interval expires, the unit returns to LOW speed for 5 minutes every 45 minutes as long as the
the standard power limit control algorithm. unit remains in the Null mode.
NOTE: Setting power management current at 13

amps can be used to provide slow pull-down of
loads.

4-6 General Theory of Operation MP-3000 Controller
Condenser Fan Control The unit remains in Null until the return air temperature
The controller also uses a proportional-integral derivative increases to ECMAX temperature at the expiration of a 45
algorithm to control the condenser temperature and ensure a minute Null state time sequence. Default ECMAX setting is .2
constant liquid pressure at the expansion valve. In low ambi- C (0.4 F) above setpoint. ECMAX setting is adjustable from 0
ent conditions, the controller pulses the condenser fan ON and to 5 C (0 to 8.9 F) above setpoint through the Configuration
OFF to maintain a minimum condenser temperature. The con- menu of the controller.
troller maintains a minimum 30 C (86 F) condenser tempera-
ture on Chill loads and a minimum 20 C (68 F) condenser tem- NOTE: On Frozen loads, supply and return air tem-
perature on Frozen loads. peratures may vary considerably during Economy
mode operation due to long periods of no air circula-
tion.
Economy Mode Operation
The Economy Mode reduces unit power consumption by
reducing evaporator fan operation on both chill and frozen Probe Test
loads. The use of the Economy Mode should be established by
The controller constantly monitors the left hand and right hand
the shipper and the type of cargo. The Economy Mode option supply sensors, return sensor and defrost (evaporator coil) sen-
is turned on from Setpoint menu of the controller. sor to determine when to initiate a demand defrost. If a
demand defrost is requested and defrost has occurred within
NOTE: Enter Setpoint temperature before turning last 90 minutes, the controller initiates a Probe Test to check
ON the Economy mode. The controller automatically for a defective sensor.
turns the Economy mode OFF when the setpoint is During a Probe Test, the LCD display shows “ Probe Test
changed. Please Wait”. The controller operates the unit on high speed
evaporator fans only for 5 minutes. All sensor temperatures
are then compared:
Chill Loads (Setpoints of -9.9 C (14.1 F) and Above) • Sensors with large temperature differences are discarded
from the control algorithm. The controller then activates the
Evaporator fans operate on low speed whenever the container appropriate Alarm codes to identify the defective sensor(s).
temperature is In-range. • If no sensors are found defective, controller LCD display
shows “Running with High Supply Difference” message.
NOTE: On Chill loads, container air temperatures Sensor errors recorded during a Probe Test are cleared
may vary 1 C to 3 C (1.8 F to 5.4 F) above setpoint in when the next Defrost is initiated or Unit On/Off switch is
high ambient temperatures. turned OFF.
NOTE: A manual Probe Test can be performed by a

Frozen Loads (Setpoints of -10 C (14 F) and Below)
technician by selecting Sensor Check from the
The evaporator fans stop during the Null mode. A null state Manual Test Function menu.
timer automatically re-starts the evaporator fans on low speed
for 5 minutes every 45 minutes.
The Economy Mode also modifies the temperature control
algorithm on frozen loads to extend the Null mode. The unit
continues on Cool operation until return air temperature reach-
es ECMIN temperature. Default ECMIN setting is 2.0 C (3.6
F) below setpoint. ECMIN temperature is adjustable from 0 to
5 C (0 to 8.9 F) below setpoint through the Configuration
menu of the controller.

MP-3000 Controller Sequence of Operation 4-7
Dehumidify Mode (Option)

During Chill mode operation, a dehumidification system is Sequence Of Operation
available to reduce the relative humidity in the container to the
desired humidity setpoint. The Dehumidify Mode option is
turned on from Setpoint menu of the controller. The relative
Unit Start-up
humidity setpoint can be set from 50 to 99% from the Setpoint A 60 second sequence start of the required loads occurs during
menu too. initial start-up of the controller. If cooling (or heating) is
Changing the Humidify/Dehumidify Mode program required, the unit operates in the cool (or heat) mode.
screen from OFF to ON activates the dehumidify control algo- • When the unit On/Off switch is turned ON, the LED dis-
rithm. The use of the Dehumidify Mode should be established play turns On and then Off.
by the shipper. When the Dehumidify Mode is ON, the supply • The setpoint appears briefly in the LED display.
air temperature must be in-range to activate dehumidification:
a. When the humidity level is 2% or more above setpoint, NOTE: When the setpoint appears in the LED
the controller energizes (closes) the dehumidify valve. display, both the Return and Supply LEDs are lit.
This reduces the size of the evaporator providing cooling
by 50%, causing the coil to become colder and condense • The LED then shows the controlling air sensor tempera-
more moisture from the container air. ture.
b. When the humidity level is 5% or more above setpoint, • The controller senses the incoming power phase and
the controller also pulses the electric heaters ON and OFF. selects the correct power phase to unit components.
This increases the cooling load on the evaporator coil, • About 40 seconds after the unit was turned ON, the evap-
thereby causing the coil to become even colder and con- orator fan motors start.
dense more moisture from the container air. - Evaporator fans operate on high speed at setpoints of -
9.9 C (14.1 F) and above.
- Evaporator fans operate on low speed at setpoint temper-
atures of -10 C (14 F) and below.
• About 10 seconds later, the compressor starts if the con-
troller calls for cooling.
• The condenser fan then starts if the condenser temperature
requires condenser fan operation.
• If the controller calls for heating, the electric heaters are
pulsed On and Off to provide heat.
• The controller turns ON the In-range LED when the con-
trolling sensor temperature is within 1.5 C (2.7 F) of the
setpoint.
NOTE: Random time delays during the initial unit

start-up minimize peak current draw.

4-8 Sequence of Operation MP-3000 Controller
Continuous Temperature Control Operation Heat

• Controller pulses electric heaters ON and OFF on a 60
Chill Loads — Controller Setpoint at -9.9 C (14.1 F) and second duty cycle for additional frost protection if the
Above return air temperature decreases to within 0.3 C (0.5 F)
of setpoint.
The controller regulates the compressor, stepper motor valve • Controller turns ON the Heat LED whenever the heaters
and electric heaters based on a Control Temperature are pulsed ON and OFF.
Differential (see “General Theory of Operation” in this chapter • If the supply air temperature is too low and the Control
for more detail). This means the unit operating mode can Temperature Differential is above the setpoint, the con-
NOT be predicted based ONLY on the setpoint and supply air troller stops the compressor and pulses the electric
temperature. heaters ON and OFF on a 60 second duty cycle to pro-
At setpoints of -9.9 C (14.1 F) and above, the controller vide heat. The controller pulses the electric heaters ON
operates the unit on: and OFF until the supply air temperature increases to
• Cool mode with Modulation setpoint.
• Controller energizes the liquid injection valve continu-
ously when the modulation percent is 75% or less.
• Controller energizes the warm gas bypass valve on a 30
second duty cycle when the modulation percent is 75%
or less. The amount of ON (open) time increases as the
modulation percent decreases.
• Heat mode (electric heaters pulse On and Off on a 60
second duty cycle)
• Defrost mode (electric heaters On, evaporator fans Off)
• Evaporator fans operate on high speed (except when
Economy mode is ON and temperature is In-range) and
continuously circulate air inside the container (except
during defrost)
• Controller LED display shows the supply air sensor tem-
perature.
• Controller LCD display shows the setpoint temperature.
• Controller uses the condenser coil temperature and a PID
algorithm to cycle a single-speed condenser fan between
ON and OFF on a 30 second duty cycle.
• Power limit is active when the unit is operating in the
Cool mode.
Cool with Modulation

• Controller calls for the Cool mode whenever the Control
Temperature Differential (based on supply air tempera- Chill Load Control Sequence (Setpoints at -9.9 C
ture) is above setpoint. [14.1 F] and Above)
• Controller turns ON the Compressor LED when the
compressor is operating. A. Cool with Modulation* (control temperature differen-
• Controller opens and closes stepper motor valve to regu- tial is above setpoint)
late the flow of refrigerant to the compressor. The posi- B. Heat (electric heaters pulse ON and OFF on a 60
tion of the stepper motor valve balances the unit cooling second duty cycle if return air temperature decreases
capacity against the actual load requirements. within 0.3 C [0.5 F] of setpoint or supply air tempera-
• Controller turns ON the In-range LED when the supply ture is too low)
air sensor temperature is within 1.5 C (2.7 F) of setpoint. C. In-Range (based on supply air temperature)
• Supply air sensor control algorithm increases tempera- 1. Decreasing Temperature
ture control accuracy and protection against frost dam- 2. Setpoint
age (see “Chill Loads” under General Theory of 3. Increasing Temperature
Operation in this chapter).
• Controller pulses electric heaters ON and OFF for addi- *NOTE: Controller also energizes liquid injection
tional frost protection if the return air temperature valve and warm gas bypass valve as modulation per-
decreases to within 0.3 C (0.5 F) of setpoint. cent decreases.
• Controller turns ON the Heat LED whenever the heaters
are pulsed ON and OFF.

Operating Mode Function Chart — Standard Operation
Chill Loads Frozen Loads

Setpoints at -9.9 C Setpoints at -10.0 C
(14.4 F) and Above (14.0 F) and Below
Cool w/Mod Heat Defrost Cool Null Defrost Unit Function
• • Evaporator Fans HIGH SPEED1
• • Evaporator Fans LOW SPEED1
• • Evaporator Fans OFF1
• • Proportional-integral Derivative (Supply Air) Control
• • Return Air Sensor Control
• • Evaporator Coil Sensor Control
• • Compressor ON
• • Compressor Liquid Injection ON (valve energized)2
• Warm Gas Bypass Solenoid Valve OPEN (energized)3
• • Condenser Fan ON4
• •5 Stepper Motor Valve MODULATING (energized)5
• • • • Electric Heaters PULSING or ON (energized)6
1Setpoint temperature determines the evaporator fan speed except when Economy Mode is ON. When Economy Mode is ON:
• Chill Loads: If supply air temperature is in-range, evaporator fans operate on low speed.
• Frozen Loads: If return air temperature is in-range, evaporator fans stop during Null mode. A null state timer automatically
re-starts the fans on low speed for 5 minutes every 45 minutes.
2Controller OPENS (energizes) the liquid injection valve continuously:
• For 5 minutes whenever the compressor starts.
• Chill or Power Limit Mode: When the modulation percent is 75% or less.
• When the compressor discharge temperature exceeds 138 C (280 F).
3Controller OPENS (energizes) the warm gas bypass valve on a 30 second duty cycle:
• Chill Mode: When the modulation percent is 25% or less. The amount of OPEN (energized) time increases as the modula-
tion valve closes until the bypass valve remains energized continuously (modulation = 0%).
4Condenser fan operation is determined by a control algorithm so ON/OFF operation can not be predicted. In low ambient condi-
tions, controller pulses the condenser fan ON and OFF on a 30 second duty cycle to maintain a minimum condenser temperature:
• Chill Loads: Controller maintains a minimum 30 C (86 F) condenser temperature.
• Frozen Loads: Controller maintains a minimum 20 C (68 F) condenser temperature.
NOTE: The condenser fan operates continuously if the compressor or condenser temperature sensor is
defective.
5Stepper motor valve MODULATES:
• Chill Loads: Whenever the unit is in a cooling mode.
• Power Limit: Whenever the unit is in Power Limit mode.
6Controller energizes electric heaters for frost protection, heat and defrost modes:
• Frost Protection (during compressor operation): If return air temperature decreases to within 0.3 C (0.5 F) of setpoint, con-
troller PULSES heaters ON and OFF on a 30 second duty cycle.
• Heat mode (compressor OFF): If supply air temperature is too low, the controller PULSES heaters ON and OFF on a 60 sec-
ond duty cycle.
• Defrost mode: Controller turn heaters ON until evaporator coil temperature increases to:
- Chill Loads: 30 C (86 F) or exceeds 18 C (65 F) for 15 minutes.
- Frozen Loads: 18 C (65 F) or exceeds 8 C (46 F) for 15 minutes.

4-10 Sequence of Operation MP-3000 Controller
Frozen Loads — Controller Setpoint at -10 C (14 F) Cool

and Below • After initial start-up and pull-down to 1.0 C (1.8 F) below
setpoint, the controller calls for the Cool mode whenever:
At setpoints of -10 C (14 F) and below, the controller locks out
- Return air temperature increases more than 1.0 C (1.8 F)
the Modulation and Heat modes. The controller regulates
above setpoint; or
compressor operation based the return air sensor and setpoint
- Compressor has been OFF for 15 minutes (maximum).
temperatures.
At setpoints of -10 C (14 F) and below, the controller
• Controller turns ON the Compressor LED when the
operates the unit on:
compressor is operating.
• Cool mode
• Compressor must operate for a minimum of 5 minutes
• Null mode
after startup.
• Defrost mode (electric heaters On, evaporator fans Off)
• After initial pull-down to setpoint, controller keeps the
• Evaporator fans operate on low speed and continuously
In-range LED ON as long as the return air temperature
circulate air inside the container (except during defrost;
remains less than 1.5 C (2.7 F) above setpoint.
or when Economy mode is ON and the unit is in Null
mode)
Null
• Controller LED display shows the return air sensor tem-
• The controller calls for Null when the Return Air
perature.
Temperature decreases more than 1.0 C (1.8 F) below
• Controller LCD display shows the setpoint temperature.
setpoint.
• Controller uses the condenser coil sensor temperature
• The controller stops the compressor and condenser fan.
and PID algorithm to cycle a single-speed condenser fan
• The evaporator fans continue to operate (except when
ON and OFF on a 30 second duty cycle.
Economy mode is ON).
• Power limit is active during initial start-up and pull-
• Compressor remains OFF for a minimum of 5 minutes.
down when the unit is cooling at return air temperatures
above -10 C (14 F).
Operating Mode Function Chart — Optional Feature Operation
Chill Loads Frozen Loads

Setpoints at -9.9 C Setpoints at -10.0 C
(14.4 F) and Above (14.0 F) and Below
Cool w/Mod Heat Defrost Cool Null Defrost Unit Function
Economy Mode ON: Evaporator Fans HIGH SPEED1
• • • Economy Mode ON: Evaporator Fans LOW SPEED1
• • • Economy Mode ON: Evaporator Fans OFF1
• Dehumidify ON: Dehumidify Valve CLOSED (energized)2
• Dehumidify ON: Electric Heaters ON (energized)2
• • Humidify ON: Air Compressor ON (energized)3
1Economy Mode ON: • On Chill Loads, the evaporator fans operate on low speed when the supply air temperature is In-range.
• On Frozen Loads, the evaporator fans stop during the Null mode when the return air temperature is In-
range. A timer re-starts the evaporator fans on low speed for 5 minutes every 45 minutes. If cooling is
required, the evaporator fans operate until the unit returns to Null mode.
2Dehumidification Option: When the Dehumidify Mode is set to ON, the supply air temperature must be in-range to CLOSE
(energize) the dehumidify valve:
• When the humidity is 2% or more above humidity setpoint, the controller CLOSES (energizes) the dehumidify valve.
• When the humidity is more than 5% above humidity setpoint, the controller also pulses the electric heaters ON and OFF.
3Humidification Option: When the container humidity is more than 2% below the humidity setpoint, the controller operates (ener-
gizes) the air compressor to inject atomized water directly into the evaporator supply air stream.

Defrost - On Chill Loads (setpoints at -9.9 C [14.1 F] and above),

The evaporator coil sensor temperature must be below 18 C the initial time interval is:
(65 F) to initiate a Demand Defrost or Manual Defrost. The • 8 hours of compressor operation at supply air tempera-
evaporator coil sensor temperature must be below 10 C (50 F) tures of 5.1 C (41.2 F) or above.
to initiate a Timed Defrost. • 2.5 hours of compressor operation at supply air temper-
• Demand defrost function initiates defrost immediately atures of 5.0 C (41.0 F) or below. One-half (0.5) hour
when: is added to the time interval each timed defrost interval.
- Temperature difference between the return air sensor and Defrost synchronization creates step intervals of 3, 4, 4,
defrost (evaporator coil) sensor is too large 5, 5, 6, 6 and 7 hours. Maximum time interval is 7
- Temperature difference between the left hand and right hours.
hand supply air sensors is too large and unit has operated - On Frozen Loads, the initial time interval is 8 hours.
for more than 90 minutes since last defrost Two (2) hours are added to the time interval each timed
- Temperature difference between the supply sensors and defrost interval. Maximum accumulated time interval is
return air sensor is too large 24 hours.
• Manual Defrost may be initiated immediately by pressing - Defrost timer resets if the unit is Off more than 12 hours,
the Defrost key or by Refcon Remote Monitoring Modem setpoint is changed more than 5 C (8.9 F) or PTI Pretrip
(RMM). test occurs.
• A Timed Defrost always starts at 1 minute past the hour
immediately following a defrost timer request for defrost. NOTE: If unit operating conditions do not allow
For example, if the defrost timer requests a defrost cycle the unit to enter a defrost cycle, “Defrost Not
at 7:35, the defrost cycle will start at 8:01. The datalogger Activated” appears on LCD display when the
will record a Defrost event for each log interval in which a DEFROST key is pressed.
Defrost cycle is pending or active (i.e. both the 8:00 and
9:00 data logs on 1 hour logging interval).
When the defrost mode is initiated:
• The controller stops the compressor, condenser fan and
and evaporator fans.
• When the compressor stops, the controller turns ON the
Defrost LED, Heat LED and energizes the heater contac-
tor, turning on the electric heaters.
The controller terminates the defrost mode when:

• Evaporator temperature:
- Chill mode: Evaporator coil sensor temperature reaches
30 C (86 F); or exceeds 18 C (65 F) for 15 minutes.
- Frozen mode: Evaporator coil sensor temperature
reaches 18 C (65 F); or exceeds 8 C (46 F) for 15 min-
utes.
• Interval timer: Controller terminates defrost after 90 min-
utes on 60 Hz power (120 on 50 Hz power). Alarm code
20 will be generated if this occurs.
• Power OFF: Turning unit On/Off switch Off terminates
defrost.
When the defrost mode is terminated:

Frozen Load Control Sequence (Setpoints at -10 C • The Heat and Defrost LEDs turn OFF and the heater con-
[14 F] and Below) tactor is de-energized. The controller starts the compres-
A. Cool* sor to pre-cool the evaporator coil. The condenser fan
C. In-Range starts if required.
D. Null* • The controller pre-cools the evaporator coil to the supply
1. Decreasing Temperature air temperature (or for 3 minutes maximum) to minimize
2. Setpoint heat energy release into the container. The liquid injec-
3. Increasing Temperature tion valve is energized if the modulation percent is 75% or
less. The controller then starts the evaporator fans.
*If the compressor stops, it must remain OFF for a mini-
mum of 5 minutes. When the compressor re-starts, it
must stay ON for a minimum of 5 minutes.

4-12 Changing the Setpoint MP-3000 Controller
Changing the Setpoint Initiating a Manual Defrost
NOTE: Humidity control, humidity setpoint and With the unit On/Off switch ON:
economy mode can also be set from the Setpoint 1. Press the DEFROST key.
menu. See “Setpoint Menu” under Menu Operating • If the unit operating conditions allow a manual defrost
Instructions in this chapter. (e.g. evaporator coil temperature is less than 18 C [56
F]), the unit enters defrost as the Defrost and Heat LEDs
To change the controller setpoint, turn the unit On/Off switch turn ON. LCD message display shows “DEFROST
ON. With the standard LCD message display showing on the ACTIVATED”.
controller (i.e. setpoint temperature): • If unit operating conditions do NOT allow defrost, the
1. Press the SETPOINT key. The SETPOINT menu appears LCD message display shows “DEFROST NOT ACTI-
with the cursor in the “TEMP SETP” line. VATED”.
2. Press the F4 key. An Enter Arrow appears in the menu 2. The defrost cycle automatically terminates.
line and the current setpoint disappears.
3. Enter (type) the new setpoint in the LCD display using the NOTE: If frost or ice can not be removed from the
general purpose keypad. To enter a minus setpoint, press evaporator coil by an automatic defrost cycle, a
the EXIT (+/-) key first. The cursor moves to the right of “timed” defrost of the evaporator coil can be per-
the screen as each key entry is acknowledged and dis- formed:
played. • Activate HEAT ON in the Manual Function Test sub-
menu.
NOTE: Always check that the setpoint entered in • Then press “5” key six times. Heaters will be acti-
the LCD display is correct before proceeding. vated for 70 minutes. Unit then returns to normal
operation.
4. Press and hold the F4 key until the cursor stops flashing.
The new setpoint is recorded in the controller and appears
in the LCD display.
NOTE: If the setpoint is not entered within 30

seconds, the controller will default (return) to the
previous setpoint. If this occurs, repeat steps 1
through 4.

MP-3000 Controller Displaying Alternate Controlling Air Sensor Temperature 4-13
Displaying Alternate Controlling Navigating the Controller Menu

(Supply or Return) Air Sensor
Temperature NOTE: To view the controller’s menu or download
The controller can show either the supply or return air temper- data when external power is disconnected from the
ature in the LED Display. With the unit On/Off switch ON unit, press a special key: C/F key, SUP/RET key,
and the controller showing the standard LED Display: DEFROST key or SETPOINT key. The controller LCD
1. Check the indicator LEDs to determine which sensor tem- display will appear using 12 Vdc battery power.
perature (supply air or return air) currently appears in the
right display. This is the controlling sensor. The MP-3000 Main Menu is divided into seven major menus:
2. To view the alternate (supply or return) air temperature, • Setpoint
press and hold the SUP/RET key. The controller will • Data
show the alternate sensor temperature as long as the • Alarm List
SUP/RET key is depressed. • Commands
3. The display then returns to the controlling sensor tempera- • Misc. Functions
ture when the SUP/RET key is released. • Configuration
• Datalogger
• Remote Monitoring (RMM) State
Moving through these seven menus and their submenus

Displaying Alternate Fahrenheit (F) or and entering commands requires the use of four text keys:
Celsius (C) Temperatures
The controller can display temperatures in Fahrenheit or F1 key: Press the F1 key each time you want to exit a
Celsius. With the unit On/Off switch ON and the controller submenu and/or retrieve current system data for dis-
showing a standard LED Display: play.
1. Press and hold the C/F key. The controller will show both
the LED and LCD display temperatures in the alternate F2 or F3 key: Press the F2 or F3 key each
temperature scale (Fahrenheit or Celsius) as long as the or time you want to scroll up or down to view
C/F key is depressed. another item in a menu or submenu; or
2. The display then returns to the original display when the scroll forward or backward in a menu line.
C/F key is released.
F4 key: Press the F4 key to enter a new menu or sub-
NOTE: To change the default temperature unit dis- menu; to access a menu line to enter information; or
play, press and hold the C/F key, then press the SET- to load a command or value.
POINT key for 1 second.

4-14 Setpoint Menu MP-3000 Controller
General Operating Tips

• Quickly change display temperature units between C and F:
Setpoint Menu
Press and hold the C/F key, then press the SETPOINT key Pressing the SETPOINT key displays a list of tasks and values
for 1 second. that can be activated or set:
• Increase display time for current LCD data screen: Press the • Setpoint Temperature
“5” key to increase display time by 5 minutes. Maximum • Economy Mode
display time is 30 minutes for data screens and 100 minutes • Airflow
for manual tests. • Custom Airflow
• Slowly cool (initial pull-down) a warm load: Set power • Bulb Mode
management to 13 amps. • Humidity Control
• Password for Configuration changes is “A”: Press F2 key, • Humidity Setpoint
“A” key, F4 key and then EXIT key. • AFAM Control
• Delay Defrost for 24 hours during unit diagnosis or testing: • AFAM Delay
Press “7” key and F1 key at the same time. Press F3 key to • AFAM Rate
scroll cursor down to DELAY DEF menu line. Then press • O2 Minimum
F4 key, F2 key, “A” key, F4 key and EXIT key. Cursor • CO2 Maximum
moves to end of line and flashes. Press F3 key to toggle OFF
to ON. Then press and hold F4 key until cursor stops flash- Changing the Setpoint Temperature
ing.
See “Changing the Setpoint” on page 4-12.
• Perform a “timed” defrost of evaporator coil: Activate
HEAT ON in the Manual Function Test submenu. Then
press “5” key six times. Heaters will be activated for 70 min- Changing the Economy Mode Setting
utes. Unit automatically returns to normal operation.
NOTE: Enter Setpoint temperature before turning
ON the Economy mode. The controller automatically
turns the Economy mode OFF when the setpoint is
changed.
1. Press the SETPOINT key. The SETPOINT menu appears

with the cursor in the “TEMP SETP” line.
2. Press F2 key to scroll to “ECONOMY MODE” line.
3. To change the mode setting, press F4 key. Cursor moves
to end of menu line and flashes.
4. Press F2 key to toggle between OFF and ON.
5. With the desired state in the menu line, press and hold F4
key until cursor stops flashing. New mode setting appears
in display.
NOTE: On frozen loads, the Economy Mode also

modifies the temperature control algorithm to to
extend the Null mode. See “Economy Min.” and
“Economy Max.” under Configuration Menu in
this chapter to check the current settings or
enter new settings.
6. Press ESC key to exit the SETPOINT screen.

MP-3000 Controller Data Menu 4-15
Changing the Humidity Mode Setting

1. Press the SETPOINT key. The SETPOINT menu appears
Data Menu
with the cursor in the “TEMP SETP” line.
2. Press F2 key to scroll to “HUM CONTROL” line. NOTE: Information can ONLY be displayed using the
3. To change the mode setting, press F4 key. Cursor moves Data menu. Items can NOT be changed.
to end of menu line and flashes.
4. Press F2 key to toggle between OFF and ON. The Data menu displays general unit operating information
5. With the desired state in the menu line, press and hold F4 including sensor temperatures, unit electrical data, etc.
key until cursor stops flashing. New mode setting appears
in display. Viewing the Data Menu
6. Press ESC key to exit the SETPOINT screen.
With the unit On/Off switch ON and the LCD display showing
the standard display (setpoint):
Changing the Humidity Setpoint 1. Press F4 key to directly enter the Data menu. Menu items
1. Press the SETPOINT key. The SETPOINT menu appears appear in LCD display.
with the cursor in the “TEMP SETP” line. 2. Press F3 to scroll the cursor down through the menu list.
2. Press F2 key to scroll to “HUM SETP” line. The Data menu displays the following functions:
3. To enter a new setpoint, press the F4 key. An Enter • Supply Air Temperature, Right Hand
Arrow appears in the menu line and the current setpoint • Return Air Temperature
disappears. • Evaporator Coil (Defrost) Temperature
4. Enter (type) the new setpoint in the LCD display using the • Condenser Coil Temperature
general purpose keypad. The cursor moves to the right of • Modulation
the screen as each key entry is acknowledged and dis- • Ambient Temperature
played. • Low Pressure
• High Pressure
NOTE: Always check that the setpoint entered in • High Pressure Temperature (Compressor Discharge Line
the LCD display is correct before proceeding. Temperature)
• Relative Humidity
5. Press and hold the F4 key until the cursor stops flashing. • Battery Voltage
The new setpoint is recorded in the controller and appears • Voltage Average (380/460V Power Supply)
in the LCD display. • Voltage 1 (Main Power Supply)
6. Press ESC key to exit the SETPOINT screen. • Voltage 2 (Main Power Supply)
• Voltage 3 (Main Power Supply)
• Frequency (Main Power Supply)
• Zero Current
• Current Phase 1 (Main Power Supply)
Standard Display NOTE: All screens are NOT present on all units.
The screens that display on the controller are
determined by the Unit Configuration setting.
Setpoint Menu
— Setpoint Temperature
— Economy Mode
Enter a Temperature or
— Airflow
Humidity Setpoint
— Custom Airflow
• Press F4 key.
— Bulb Mode
• Type the new setpoint.
— Humidity Control
• Press and hold F4 key until
— Humidity Setpoint
cursor stops flashing.
— AFAM Control
— AFAM Delay
Activate Humidity Control or
— AFAM Rate
Economy Mode
— O2 Minimum
• Press F4 key.
— CO2 Maximum
• Press F2 key to toggle setting
between OFF and ON.
Setpoint Menu Screen Flow Diagram

4-16 Alarms Menu MP-3000 Controller
• Current Phase 2 (Main Power Supply)

• Current Phase 3 (Main Power Supply) Alarms Menu
• O2
The Alarm List menu displays alarm codes. Alarm codes are
• CO2
recorded in the controller memory to simplify unit diagnosis
• Fresh Air Exchange Rate
procedures. Some alarm codes are only recorded during a
• Evaporator Fan Speed
Pretrip (PTI) Test or Function Test. Fault codes are retained
• Supply Air Temperature, Left Hand
by the controller in a non-volatile memory. If the Alarm LED
is ON or flashing ON and OFF, enter the ALARM LIST to
NOTE: Press the “5” key to lock a Data screen in view the alarm code(s).
the LCD display for 5 minutes. Press any key to
unlock the display.
Alarm Types
NOTE: Controller returns to previous menu level There are three types of alarms:
or LCD Standard Display after 30 seconds. • Shutdown Alarm (Level 1): Alarm LED flashes and unit
stops. Shutdown alarms indicate the unit has been stopped to
prevent damage to the unit or cargo. The condition must be
corrected before restarting the unit. Alarm code 56 (com-
pressor temperature too high) is a shutdown alarm.
• Check Alarm (Level 2): Alarm LED flashes until alarm is
acknowledged. Check alarms indicate corrective action
should be taken before a problem becomes severe. Alarm
codes 00-17, 18, 19, 20, 22-35, 41-46, 52-54, 58, 60, 99-112
Standard Display are Check alarms.
• Log Alarm (Level 3): Alarm is recorded in datalogger only
(inspect event log). Alarm LED does not flash or turn on.
NOTE: All screens are NOT Alarm codes 36-37, 59, 97, 98 are Log alarms.
present on all units. The
screens that display on the
controller are determined Alarm Code States
by the Unit Configuration There are three alarm code states for Shutdown and Check
setting.
alarms:
• NOT ACTIVE: An alarm condition has occurred but no
longer exists in the unit. Not Active means the condition was
corrected and did not recur for 1 hour; or the unit On/Off
Data Menu
switch was turned OFF and then ON.
- When a NOT ACTIVE alarm code is acknowledged (F4
— Supply Air Temp, RH
— Return Air Temp
key pressed while alarm code appears in LCD display),
— Defrost (Evap Coil) Temp the Alarm LED will turn OFF and the alarm code disap-
— Condenser Coil Temp pears from the alarm list.
— Modulation • ACTIVE: An alarm condition has occurred and continues to
— Ambient Temp exist in the unit; or the alarm condition occurred within the
— Low Pressure
— High Pressure
past 1 hour but does not currently exist in the unit.
— High Pressure Temp - If the alarm condition currently exists in the unit and the
— Relative Humidity alarm code is acknowledged, the Alarm LED will stop
— Battery Voltage flashing but remain ON. The alarm code state will
— Voltage Average change to ACKNOWLEDGE in the alarm list.
— Voltage 1
— Voltage 2
- If the alarm condition no longer exists in the unit and the
— Voltage 3 alarm code is acknowledged, the Alarm LED will turn
— Frequency OFF and the alarm code disappears from the alarm list.
— Zero Current
— Current Phase 1
— Current Phase 2
— Current Phase 3
— O2
— CO2
— Fresh Air Exchange Rate
— Evaporator Fan Speed
— Supply Air Temp, LH
Data Menu Screen Flow Diagram

MP-3000 Controller Alarms Menu 4-17
• ACKNOWLEDGE: An alarm code has been viewed and NOTE: To acknowledge an alarm, press F4 while
acknowledged in the alarm list. The Alarm LED remains ON the alarm code appears on the screen. The
but does not flash. alarm state will change from ACTIVE or NOT
- If the alarm condition is corrected, the Alarm LED will ACTIVE to ACKNOWLEDGE.
turn OFF and the alarm code disappears from the alarm
list. NOTE: If no key is pressed for 30 seconds, the
controller returns to the previous menu level or
Viewing the Alarm List Menu the LCD Standard Display.
1. Press F2 key to directly enter the Alarms menu. The first Alarm List
alarm code number, alarm state and alarm description Alarm
appears in LCD display. Code Type Description
00 Check Supply Air Sensor Open Circuit
NOTE: Alarm codes are displayed in sequential 01 Check Supply Air Sensor Short Circuit
order, not in the order of occurrence. 02 Check Return Air Sensor Open Circuit
03 Check Return Air Sensor Short Circuit
2. Write down the first alarm code. Then press F2 key to 04 Check Evaporator Coil Open Circuit
view the next alarm code when more than one alarm code 05 Check Evaporator Coil Sensor Short Circuit
has been recorded. 06 Check Compressor Current Too High
3. Repeat step 4 until all alarm codes have been recorded. 07 Check Compressor Current Too Low
To scroll backward to return to a previous alarm code, 10 Check Heater Current Too High
press F3 key. 11 Check Heater Current Too Low
4. To clear all alarm codes from the current display list and 12 Check Evaporator Fan High Speed Current
turn off the Alarm LED, all problems must be corrected Too High
and the alarm code “acknowledged” in the Alarm List 13 Check Evaporator Fan High Speed Current
menu. Too Low
14 Check Evaporator Fan Low Speed Current Too
High
15 Check Evaporator Fan Low Speed Current Too
Low
16 Check Condenser Fan Current Too High
17 Check Condenser Fan Current Too Low
Standard Display
18 Log Power Supply Phase Error
19 Check Temperature Too Far from Setpoint
20 Check Defrost Time Too Long
NOTE: All screens are NOT 22 Check Capacity Test 1 Error
present on all units. The 23 Check Capacity Test 2 Error
screens that display on the
controller are determined
24 Check Capacity Test 3 Error
by the Unit Configuration 25 Check Evaporator Temperature Test Error
setting. 27 Check Heat Capacity Test Error
28 Check Suction Stepper Valve Error
29 Check Liquid Injection Valve Error
30 Check Bypass (Warm Gas) Valve Error
Alarms Menu
• View and write down all alarm
codes.
• Press F2 key to view the next
alarm code.
• Clear alarm code by correcting
problem and acknowledging
the alarm.
• To acknowledge an alarm,
press F4 key with alarm code in
display.
Alarms Menu Screen Flow Diagram

4-18 Commands Menu MP-3000 Controller
31 Check Low Pressure Cutout Error

32 Check Condenser Air Sensor Open Circuit Commands Menu
33 Check Condenser Air Sensor Short Circuit
The Commands menu displays a list of tasks that can be acti-
34 Check Ambient Air Sensor Open Circuit
vated. The following commands are available:
35 Check Ambient Air Sensor Short Circuit
• Defrost: Manual defrost can be initiated. When command is
36 Check Current Too High
activated, LCD message display will show ACTIVATED,
37 Check Current Too Low
NOT ACTIVATED (evaporator temperature above 18 C [50
41 Check Supply Air Temperature Too High
F]) or ALREADY ACTIVATED (defrost in progress).
42 Check Supply Air Temperature Too Low
• Function Test: Controller automatically tests the operation
43 Check Return Air Temperature Too High
of individual unit components. This is not a performance test
45 Check Evaporator Coil Temperature Too High
of the complete system. See “Function Test” in this chapter
46 Check Evaporator Coil Temperature Too Low
for test details.
52 Check Probe Error
• PTI (Pretrip) Test: Controller automatically completes a test
53 Check High Pressure Cutout Switch Off Error
of individual components and checks unit refrigeration
54 Check High Pressure Cutout Switch On Error
capacity, heating capacity and temperature control. See
56 Shutdown Compressor Temperature Too High
“PTI (Pretrip) Test” in this chapter for test details.
58 Check Phase Sensor Error
59 Check Delta Current Error
CAUTION: The PTI test should only be per-
60 Check Humidity Sensor Error
formed on an empty container!
97 Log Compressor Sensor Open Circuit
98 Log Compressor Sensor Short Circuit
• Manual Function Test: Controller tests individual compo-
99 Check USDA 1 Sensor Open Circuit
nents selected by the technician for diagnosis. LCD display
112 Check Zero Current Too High
will show expected and actual current of the component
being tested.
• Power Management: Sets the power limit and power limit
activation (“On”) time.
Viewing the Commands Menu

1. Press the F3 key to enter the Main Menu.
2. Press F2 key to scroll through Main Menu until “COM-
MANDS” appears in LCD display.
3. Press F4 key to access the Commands menu. The first
command in the submenu (Defrost) appears in the LCD
display.
4. Press F2 or F3 key to scroll to the desired command:
• Defrost
• Function Test
• PTI (Pretrip)
• Manual Function Test
• Power Management
5. Press F4 key to activate the command selected.
• Defrost: LCD display shows DEFROST ACTIVATED,
NOT ACTIVATED (evaporator temperature above 18 C
[50 F]) or ALREADY ACTIVATED (defrost in
progress). Defrost cycle ends automatically.

MP-3000 Controller Commands Menu 4-19
• Function Test: LCD display shows functional test cur- Function Test
rently being performed. Function test ends automatical- The MP-3000 controller contains a special function test that
ly. Unit automatically returns to normal operation. automatically tests individual components including the con-
• PTI (Pretrip): LCD display shows PTI Test currently troller display, sensors, condenser fan, evaporator fan, com-
being performed. PTI test ends automatically. Press any pressors, etc. The test includes measurement of component
key on the controller to return the unit to normal opera- power consumption and compares test results to expected val-
tion. ues.
• Manual Function Test: LCD display shows list of unit For a detailed description of the Function Test, see pages
components. Test the operation of individual compo- 4-21 and 4-22. Any alarm codes recorded during the test can
nents or turn several components ON at the same time to be viewed through the controller’s Alarm List menu at the end
perform a system test. of the test.
• Power Management: LCD display shows current Power
Limit setting and Power Time setting. Turn Power Limit NOTE: The Function Test does not test the actual
feature ON and OFF, change power limit setting or performance of the complete system. Therefore it is
change power limit time. not a Pretrip test and should not be used instead of
the PTI Test.
Defrost
For a description of the Defrost function, see “Initiating a
Manual Defrost” on page 4-12.
Standard Display To Activate a Command

• Press F4 key to start a:
- Manual Defrost
- Function Test
Commands Menu - PTI (Pretrip) Test
— Defrost
— Function Test
Manual Function
— PTI (Pretrip) Test
Test Submenu
— Manual Function Test
— Power Management • First Component Test appears
in display.
• Press F2 or F3 key to scroll to
to the desired component:
- Condenser Fan
MAIN MENU - Compressor
- Capacity 25%
— DATA - Capacity 50%
- Capacity 100%
— ALARMS Power Management Submenu
- Injection Valve
— COMMANDS • Current Power Limit and Power - Dehumidify Valve
— MISC FUNCTIONS Time appear in display. - Evaporator High
• Press F3 key to scroll to - Evaporator Low
— CONFIGURATION desired - Heat
— DATALOGGER function. - Zero Current
• Press F4 key. - Sensor Checks
— RMM STATE
- Power Limit: Press F2 or F3 • Press F4 key to start and stop
key to scroll to new setting. test (toggle component display
NOTE: All screens are NOT present on all units. - Power Time: Type the new between ON and OFF).
The screens that display on the controller are time in hours. • More than one component can
determined by the Unit Configuration setting. • Press and hold F4 key until be turned ON at a time to perform
cursor stops flashing. a functional test of the unit.
Commands Menu Screen Flow Diagram

Pretrip (PTI) Test 5. • To test a unit component:

a. Press F2 or F3 key to scroll to desired component
CAUTION: The PTI test should only be performed on test:
an empty container! - Condenser Fan
- Compressor
NOTE: Units equipped with a water-cooled con- - Capacity 25% (Stepper valve position)
denser must be set to operate on air-cooled con- - Capacity 50% (Stepper valve position)
densing to perform a complete system capacity test. - Capacity 100% (Stepper valve position)
- Injection Valve
The MP-3000 controller contains a special PTI pretrip test that - Dehumidify Valve
automatically checks unit refrigeration capacity, heating - Evaporator High
capacity, temperature control, and individual components - Evaporator Low
including the controller display, contactors, fans, protection - Heat
devices and sensors. The test includes measurement of com- - Zero Current (View value only)
ponent power consumption and compares test results to - Sensor Checks (Probe Test): Operates high speed
expected values. The test takes about 2 to 2.5 hours to com- evaporator fans only. After 5 minutes, check the
plete, depending on the container and ambient temperature. temperatures of the left and right hand supply sen-
sors, return sensor and defrost sensor. Temperatures
NOTE: Correct all existing alarm conditions and should be approximately equal.
clear the alarm codes before performing a PTI test. b. Press F4 key to start the component test. LCD dis-
The controller will automatically clear all existing play will change the component state from OFF to
alarms before beginning the PTI test. ON.
c. Verify component performance: LCD display will
For a detailed description of the PTI Test, see pages 4-23 show expected current and actual current on phase 1,
through 4-27. Detailed PTI test results are stored in the MP- 2 and 3.
3000 Datalogger for later viewing. Any alarm codes recorded d. Press F4 key again to stop test. LCD display will
during the test can be viewed through the controller’s Alarm change component state from ON to OFF.
List menu at the end of the test.
NOTE: Controller returns unit to normal opera-
tion if no keys are pressed for 10 minutes.
Manual Function Test Pressing “5” key extends test time by 10 minutes
The Manual Function Test menu allows technicians to perform each time it is pressed (maximum time = 100
specific diagnostic tests on individual components or turn sev- minutes). Pressing any other key resets test
eral components ON at the same time to perform a system test. time to 10 minutes.
NOTE: When the Manual Function Test menu is 6. • System Test (test multiple components at the same
entered, the UNIT STOPS. A technician can then time):
select the control circuit or component to be a. Press F2 or F3 key to scroll to the first component.
checked/tested from the items shown in the menu. b. Press F4 key to turn the component ON.
c. Press F3 key to scroll to select next component. Press
With the unit On/Off switch ON and the LCD display showing F4 to turn component ON.
the standard display (setpoint): d. Repeat step 6c. until all required components are ON.
1. Press F3 key to enter the menu list. Repeatedly press F2 For example, to operate unit in Full Cool mode, start
key to scroll through Main Menu until “COMMANDS” the following components:
appears in LCD display. - Condenser Fan
2. Press F4 key to access the Commands menu. The first - Compressor
command in the submenu (Defrost) appears in the LCD - Capacity 100%
display. - Evaporator High or Low
3. Press F2 or F3 key to scroll to Manual Function Test. e. Observe current draw and system performance to ver-
4. Press F4 key to enter the Manual Function Test: “CON- ify component(s) performance.
DENSER OFF” appears in the LCD display.

CSR PS Function Test Procedure
LCD Display
LED (Shows Approx.
Display Amps for 460V, Possible Duration
(Test No.) 60 Hz Unit) Test Description Alarms (Time)
F1.00 Display Test Event Log for Function Test begins. None 10 Seconds
Activated All alarms are turned OFF.
0.1 A 0.0 A 0.1 A Alarm list is cleared.
All lights and bars in display turn ON.
F1.01 Sensor Test All sensors must have values within their 00, 01, 02, 2 Seconds
Activated measuring range. 03, 04, 05,
0.1 A 0.0 A 0.1 A 28, 31, 32,
33, 34, 35,
97, 98, 112
F1.02 Evaporator Fan Low Amp draw is measured and compared to 14, 15 10 Seconds
Activated voltage and frequency.
1.1 A 1.0 A 1.1 A • CSR40 PS: 0.8 Amps approx. at 50 Hz,
1.1 Amps approx. at 60 Hz
• CSR20 PS and CSR40SL PS:
1.2 Amps approx. at 50 Hz,
F1.03 Evaporator Fan High Amp draw is measured and compared to 12, 13 10 Seconds
Activated voltage and frequency:
2.4 A 2.3 A 2.4 A • CSR40 PS: 2.2 Amps approx. at 50 Hz,
F1.04 Condenser Fan Amp draw is measured and compared to 16, 17 10 Seconds
Activated voltage and frequency: 1.2 Amps Maximum.
0.8 A 0.7 A 0.8 A
F1.05 Reverse Phase Condenser fan stops. Reverse phase selector 58 30 Seconds
Activated relay is energized and condenser motor is
0.8 A 0.7 A 0.8 A started in reverse for 2 seconds. Amp draw
difference between correct and wrong motor
rotation must be less than 0.2 amps.
F1.06 Compressor Test With condenser fan ON and compressor ON, 06, 07, 31 14 Seconds
Activated compressor is operated at 25% capacity.
7.1 A 7.0 A 7.1 A Amp draw is measured and compared to
voltage. Evaporator temperature and condenser
coil temperature are measured and stored.
F1.07 Injection Valve Test Condenser fan and compressor remain ON. 29, 31 10 Seconds
Activated Liquid injection valve is turned ON.
7.6 A 7.5 A 7.6 A Amp draw is measured and verified to be a
minimum of 0.2 amps higher that test F1.06.

CSR PS Function Test Procedure (Continued)
LCD Display
LED (Shows Approx.
F1.08 Low Pressure Test Condenser fan, compressor and liquid injection 31 10 Seconds
Activated valve remain ON. Stepper valve is closed and
0.8 A 0.7 A 0.8 A low pressure cutout is verified to open.
F1.09 Warm Gas Bypass With condenser fan and compressor ON, 30 10 Seconds
Valve Activated compressor is operated at 25% capacity.
8.3 A 8.2 A 8.3 A Liquid injection valve is OFF.
Bypass valve is turned ON. Amp draw
measured and verified to be a minimum
of 0.2 amps higher that test F1.06.
F1.10 Heat Test Amp draw is measured and compared to voltage: 10, 11 10 Seconds
Activated • 4.4 Amps approx. at 400V;
5.2 A 5.1 A 5.2 A • 5.1 Amps approx. at 460V.
F1.11 Humidify Valve Test Dehumidify valve is turned ON for 2 seconds, None 6 Seconds
Activated OFF for 2 seconds and ON for 2 seconds to
0.1 A 0.0 A 0.1 A verify valve operation.
Function Test log ends.
Alarms (if any) are cleared from data logger.
However, alarms (if any) remain in alarm list
as not active until acknowledged.

CSR PS Pretrip (PTI) Test Procedure
LCD Display
LED (Shows Approx.
P1.00 Display Test Event Log for PTI begins. None 10 Seconds
Activated All alarms are turned OFF.
0.1 A 0.0 A 0.1 A Alarm list is cleared.
All lights and bars in display turn ON.
P1.01 Sensor Test All sensors must have values within their 00, 01, 02, 10 Seconds
Activated measuring range. 03, 04, 05,
0.1 A 0.0 A 0.1 A When CONTAINER ID begins with MAE, MSF 28, 31, 32,
or MWC prefix, at least 1 USDA sensor must 33, 34, 35,
be installed or USDA No. 1 OPEN alarm 97, 98, 99
will be logged. 112
P1.02 Heat Test Electric heaters are turned ON. 10, 11 10 Seconds
Activated Amp draw is measured and compared to voltage:
5.2 A 5.1 A 5.2 A • 4.4 Amps approx. at 400V;
• 5.1 Amps approx. at 460V.
Heater amperes are recorded in PTI log.
P1.03 Defrost If evaporator sensor is below +10 C (50 F), 20 1 Hour

Activated heat remains on until evaporator sensor Maximum
5.2 A 5.1 A 5.2 A reaches +18 C (65 F).
P1.04 Pre-Cool If the evaporator sensor is above +20 C (68 F), 22 1 Hour
Activated unit operates in Cool until sensor temperature Maximum
15.2 A 15.1 A 15.2 A is below +15 C (59 F).
P1.05 Evaporator Fan High Condenser fan and compressor are turned OFF. 12, 13 10 Seconds
Activated With evaporator fan on high speed, Amp draw
2.4 A 2.3 A 2.4 A is measured and compared to voltage and
frequency:
• CSR40 PS: 2.2 Amps approx. at 50 Hz,
Evaporator fan high speed amperes are
recorded in PTI log.

CSR PS Pretrip (PTI) Test Procedure (Continued)
LCD Display
LED (Shows Approx.
P1.06 Probe Test Evaporator fans operate on high speed for 52 3 Minutes
Activated 3 minutes. Then probe test runs until Minimum
2.4 A 2.3 A 2.4 A temperature difference between sensors stops to
increasing. Maximum temperature difference 13 Minutes
allowed: Maximum
• Return/Evaporator: 1.5 C (2.7 F); return air
sensor temperature must be 0.5 C (1.0 F)
above evaporator sensor temperature
• Return/Supply: 0.8 C (1.4 F); return air
sensor temperature must be 0.5 C (1.0 F)
above supply air temperature
• LH Supply/RH Supply (if equipped):
0.5 C (0.9 F)
P1.07 Condenser Fan Condenser fan is turned ON. 16, 17 10 Seconds

Activated Amp draw is measured and compared to
0.8 A 0.7 A 0.8 A voltage and frequency: 1.2 Amps Maximum.
Condenser fan amperes are recorded in
PTI log.
P1.08 Reverse Phase Condenser fan stops. Reverse phase selector 58 30 Seconds
Activated relay is energized and condenser motor is
0.8 A 0.7 A 0.8 A started in reverse for 2 seconds. Amp draw
difference between correct and wrong motor
rotation must be less than 0.2 amps.
P1.09 Compressor Test With condenser fan ON and compressor ON, 06, 07 14 Seconds
Activated compressor is operated at 25% capacity.
7.1 A 7.0 A 7.1 A Amp draw is measured and compared to
voltage. Evaporator temperature and condenser
coil temperature are measured and recorded
in PTI log.
P1.10 Injection Valve Test Condenser fan and compressor remain ON. 29 10 Seconds
Activated Liquid injection valve is turned ON.
7.6 A 7.5 A 7.6 A Amp draw is measured and verified to be a
minimum of 0.2 amps higher that test P1.09.
P1.11 Low Pressure Test Condenser fan, compressor and liquid injection 31 10 Seconds
Activated valve remain ON. Stepper valve is closed and
0.8 A 0.7 A 0.8 A low pressure cutout is verified to open.

LCD Display
LED (Shows Approx.
P1.12 Warm Gas Bypass With condenser fan and compressor ON, 30 10 Seconds
Valve Activated compressor is operated at 25% capacity.
8.3 A 8.2 A 8.3 A Liquid injection valve is OFF.
Bypass valve is turned ON. Amp draw
measured and verified to be a minimum
of 0.2 amps higher that test P1.09.
P1.13 Compressor High Stepper valve opened to 50% capacity. 53 10 to 300

Pressure Activated With compressor ON, evaporator fan operates Seconds
12.2 A 12.0 A 12.2 A on high speed until high pressure cutout occurs,
causing significant amps drop.
Maximum time depends on condenser coil
temperature at start of test.
P1.13 Compressor High With compressor OFF, condenser fan starts 54 3 to 50

Pressure Activated and operates until compressor starts, causing Seconds
4.5 A 4.4 A 4.5 A a significant amps increase.
Compressor is then turned OFF. Condenser plus
fan operates 60 seconds more to lower 60
condenser temperature. Seconds
P1.14 Evaporator Fan Low Condenser fan and compressor are turned OFF. 14, 15 10 Seconds
Activated With evaporator fan on low speed, Amp draw
1.1 A 1.0 A 1.1 A is measured and compared to voltage and
frequency:
• CSR40 PS: 0.8 Amps approx. at 50 Hz,
P1.15 Capacity Test 1 With condenser fan ON, compressor ON, 22 3 Minutes
Activated and evaporator fans on low speed, (4 Minutes
12.1 A 12.0 A 12.1 A stepper valve is set to 50% capacity. on CSR20)
Liquid injection valve is turned ON.
A difference of approx. 4.5 C (8.0 F) is required
between return and supply air temperatures,
depending on return air and condenser coil
temperatures.

LCD Display
LED (Shows Approx.
P1.16 Capacity Test 2 With condenser fan ON, compressor ON, 23 2 Minutes
Activated liquid injection valve ON and stepper valve
13.2 A 13.0 A 13.2 A set to 50% capacity, evaporator fans are
changed to high speed. A difference of
approx. 3.0 C (5.4 F) is required between
return and supply air temperatures,
depending on return air and condenser coil
temperatures. However, temperature difference
must be less than in test P1.15.
P1.17 Capacity Test 3 Stepper valve is almost closed (set to 250 24 4 Minutes
Activated value). With condenser fan ON, compressor ON (5 Minutes
11.2 A 11.1 A 11.2 A liquid injection ON, bypass valve ON and on CSR20)
evaporator fans on high speed, alarm is
recorded if temperature difference exceeds:
• CSR40 PS: 1.5 C (2.7 F)
• CSR20 PS and CSR40SL PS: 3.0 C (5.4 F)
P1.18 Heat Test With heaters ON and evaporator fans on high 27 4 Minutes
Activated speed, alarm is recorded if supply temperature
7.3 A 7.2 A 7.3 A is not at least 0.4 C (0.7 F) above the return air
temperature.
P1.19 Evaporator Stepper valve is set to 50% capacity. 25 5 Minutes

Temperature Test With condenser fan ON, compressor ON, Maximum
Activated and liquid injection valve ON, evaporator fans
12.3 A 12.1 A 12.3 A are turned OFF. The evaporator coil
temperature must decrease to approx. -15 C
(+5 F), depending on the return air temperature.
P1.21 PTI Part 1 End “PTI Part 1 End” is recorded in PTI log. None 5 Minutes
Return/supply air temperature difference from
2.4 A 2.3 A 2.4 A tests P1.15, P1.16, P1.17 and P1.18 are
recorded in PTI log.
Condenser fan and compressor stop.
Evaporator fans start and operate on high speed.
P1.22 Pre-Heat If return air temperature is below 5 C (41 F), None 120
Activated evaporator fans operate on high speed and Minutes
7.9 A 7.9 A 7.9 A heaters turn ON. Unit operates until return air Maximum
temperature is above 5 C (41 F).

LCD Display
LED (Shows Approx.
Supply PTI Running Unit operates in normal cool mode with 0 C 23 120
Temp. Setpoint: 0 C (32 F) (32 F) setpoint. When supply air temperature Minutes
decreases to setpoint, “Chill Arrival” Maximum
temperatures are recorded in PTI log.
Supply PTI Running Unit operates in normal mode with 0 C (32 F) None 30
Temp. Setpoint: 0 C (32 F) setpoint for 30 minutes after previous test Minutes
is completed. At the end of 30 minutes,
“Chill End” temperatures are recorded in PTI log.
Return Defrost Activated Unit operates in normal mode with -18 C (0 F) 20 90

Temp. 4.5 A 4.4 A 4.5 A setpoint. When return air temperature Minutes
decreases to -18 C (0 F), defrost is initiated. Maximum
Defrost terminates when evaporator
temperature increases to 18 C (65 F).
Return PTI Running Unit operates in normal mode with -18 C (0 F) 22, 60 180
Temp. Setpoint: -18 C (0 F) setpoint. When return air temperature Minutes
decreases to setpoint, “Frozen Arrival” Maximum
temperatures are recorded in PTI log.
If unit is configured with humidity sensor,

relative humidity must be between 20% and
95% or a Humidity Sensor alarm is recorded and
stored in the PTI log.
“PTI End” is recorded in the PTI log.

A Trip Start is automatically activated.
Current load port, discharge port, comment,

and USDA entries are cleared from controller
memory.
Alarms (if any) are cleared from data logger.

However, alarms (if any) remain in alarm list
as not active until acknowledged.
Return PTI PASS: If alarms (errors) occurred during PTI test, NONE —
Temp. Press (Any) Key LCD display shows PTI FAIL.
Press any key to clear display.
Unit will remain OFF unit any key is

pressed again.

4-28 Misc. Functions Menu MP-3000 Controller
f. Press F4 key again to turn OFF components individu-

ally. Or press ESC key to exit Manual Function Test Misc. Functions Menu
menu and turn ALL components OFF.
The Misc. Functions menu displays a list of functions that
g. Press ESC key to exit the Manual Function Test sub-
identifies trips and determines how the controller records and
menu.
displays operating information. The following functions are
available:
NOTE: Controller returns unit to normal opera- • Date Time: Sets the controller time and date.
tion if no keys are pressed for 10 minutes. • C/F Mode: Sets the temperature value (Celsius or
Pressing “5” key extends test time by 10 minutes Fahrenheit) the controller uses to record and display tempera-
each time it is pressed (maximum time = 100 ture (including historical data).
minutes). Pressing any other key resets test • Cargo Data: Sets important trip information about the con-
time to 10 minutes. tainer and the load in the controller.
• Program Version: Displays the current software version
loaded in the controller: Controller (CTRL), EPROM and
Power Management program serial numbers (SER NO).
Selecting a Power Limit from the Power Limit screen turns
ON the power reduction control algorithm that reduces total NOTE: The Controller Label on the side of the
unit electric power consumption based on the Power Limit and control box shows the controller serial number
Power Time settings. and the EPROM version.
With the unit On/Off switch ON and the LCD display
showing the standard display (setpoint): • Run Time: Displays and sets operating hours for the unit and
1. Press F3 key to enter the menu list. Repeatedly press F2 components.
key to scroll through Main Menu until “COMMANDS”
appears in LCD display. Viewing the Misc. Functions Menu
2. Press F4 key to access the Commands menu. The first
display.
1. Press F3 key to enter the menu list. Press F2 key to scroll
3. Press F2 or F3 key to scroll to Power Management.
through Main Menu until “MISC. FUNCTIONS” appears
4. Press F4 key to enter Power Management submenu. LCD
in LCD display.
display shows the current Power Limit setting and Power
2. Press F4 key to access the Misc. Functions menu. The
Time setting.
first command in the submenu appears in the LCD dis-
5. To activate or change the power limit:
play: Date Time.
a. Press F4 key with cursor in the Power Limit menu
3. Press F2 or F3 key to scroll to the desired function:
line. Cursor moves to end of menu line and flashes.
• Date Time
b. Press F2 or F3 key to scroll to the desired power limit
• C/F Mode
setting: OFF, 13 amps, 15 amps or 17 amps.
• Cargo Data
c. With the desired power limit in the menu line, press
• Program Version
and hold F4 key until cursor stops flashing. Cursor
• Run Time
stops flashing and new value appears in display.
4. Press F4 key to access the function selected.
6 To change the length of time power limit is active (ON):
a. Press F2 key to scroll to Power Time menu line (stan-
dard setting = 48 hours). Setting the Date and Time
b. Press F4 key with cursor in the Power Time menu 1. Press F3 key to enter the menu list. Press F2 key to scroll
line. An Enter Arrow appears in the menu line and to “MISC. FUNCTIONS”.
the previous time disappears. 2. Press F4 key to access the Misc. Functions menu. “Date
c. Enter new active period in hours. Time” appears in the LCD display.
d. With the correct hours entered in the menu line, press 3. Press F4 key to access the Date Time screen. Date Time
and hold F4 key until cursor stops flashing. Cursor screen appears with cursor in the Time menu line.
stops flashing and new value appears in display. Display shows time in “HH.MM.SS” where H = hour, M
7. Press ESC key to exit the Power Management submenu. = minute and S = second.
4. To enter a new time, press F4 key with cursor in Time
menu line. An Enter Arrow appears in the menu line and
the previous time disappears.

MP-3000 Controller Misc. Functions Menu 4-29
5. Enter new time in “HH.MM.SS” format. Decimal points Changing the Temperature Display Value
must be included in the entry between the hour, minute (C/F)
and second.
to “MISC. FUNCTIONS”.
NOTE: To scroll backward in the Time or Date
2. Press F4 key to access the Misc. Functions menu. “Date
menu line, press and hold the F4 key, then press
Time” appears in the LCD display. Press F2 key to scroll
F3 key. Press F1 key to return keyboard to
to “C/F MODE”.
“numerical” entry before typing again.
3. Press F4 key to access the C/F Mode screen. C/F Mode
screen appears with cursor in the temperature value menu
6. With the correct time entered in the menu line, press F4
line. Display shows “C/F MODE o
C” where C =
key. Then press EXIT key to enter time in controller
Celsius and F = Fahrenheit.
memory. Cursor stops blinking and new time appears in
4. To change the temperature value, press F4 key. Cursor
display.
moves to end of menu line and flashes.
7. To enter a new date, press F3 key to move cursor to Date
5. Press F2 key to toggle temperature value in the menu line
menu line. Display shows date in and date in
between C and F.
“YY.MM.DD” where Y = year, M = month and D = day.
6. With the desired temperature value in the menu line, press
8. Press F4 key with cursor in Date menu line. An Enter
and hold F4 key until cursor stops flashing. Cursor stops
Arrow appears in the menu line and the previous date dis-
blinking and new temperature value appears in display.
appears.
7. Press ESC key to exit the C/F Mode screen.
9. Enter new date in “YY.MM.DD” where Y = year, M =
month and D = day. Decimal points must be included in
the entry between the year, month and day. Setting Cargo Data
10. With the correct date entered in the menu line, press F4 1. Press F3 key to enter the menu list. Press F2 key to scroll
key. Then press EXIT key to enter date in controller to “MISC. FUNCTIONS”.
memory. Cursor stops blinking and new date appears in 2. Press F4 key to access the Misc. Functions menu. “Date
the display. Time” appears in the LCD display. Press F2 key to scroll
11. Press ESC key to exit the Date Time screen. to “CARGO DATA”.
3. Press F4 key to access the Cargo Data screen. Cargo Data
screen appears with cursor in LOC. BRT menu line.
4. Press F3 key to scroll cursor down through cargo data list:
- LOC. BRT
- CONTENTS
Standard Display
NOTE: All screens are NOT present on all units.

Misc. Functions Menu

— Date Time
— C/F Mode Misc. Functions Submenu
— Cargo Data
• Current function setting appears
— Program Version
in display.
MAIN MENU — Run Time
• Press F3 key to scroll to desired
function.
— DATA • Press F4 key to change a
— ALARMS setting.
• Type new value; or press F3
— COMMANDS key to toggle value to desired
— MISC FUNCTIONS setting.
— CONFIGURATION
— DATALOGGER
— RMM STATE
Misc. Functions Menu Screen Flow Diagram

4-30 Configuration Menu MP-3000 Controller
- DATE (Loading Date)

- VOYAGE Configuration Menu
- SHIP
The Configuration menu displays a list of functions that identi-
- LD PORT (Loading Port)
fies unit operating features and current settings. The following
- DIS PORT (Discharge Port)
functions are available: In-Range, Container ID, Contrast,
- COMMENTS
Language, Economy Max, Economy Min, Humidity Option,
5. To enter text in a cargo data line, press F4 key with cursor
Reefer Type, Zero Current, Supply LH, Controlled
in the desired menu line. An Enter Arrow appears and the
Atmosphere Option, Evaporator Fans, AFAM Setup, Auto
cursor flashes in the selected line. Enter (type) the desired
Configuration and Serial Number.
text. When entering information:
• Enter up to 10 characters of text/numbers for each menu
NOTE: When a spare parts controller is installed and
item.
powered up for the first time, an automatic configu-
• To scroll backwards in the text box, press and hold the
ration feature detects the unit options installed on a
F4 key, then the press F3 key.
unit. After the initial unit powerup, the controller
• To delete text from a previous entry, press F4 key and
turns the Auto Configuration feature Off. See
then the SPACE key.
“Replacing the Controller” in this chapter for more
• To start entry over or quickly return to the beginning of
information.
the text box, press F4 key, then EXIT key and then F4
key again.
• When the F1, F2, F3 or F4 key is pressed to enter a char- Viewing or Setting Functions
acter in the display, the keypad remains on that “charac- With the unit On/Off switch ON and the LCD display showing
ter level” until another “level” is selected by pressing the the standard display (setpoint):
F1, F2, F3 or F4 key. 1. Press the F3 key to enter the Main Menu.
6. When the desired text entry is complete, press F4 key. 2. Press F2 key to scroll through Main Menu until “CON-
Then press EXIT key. The cursor stops flashing and the FIGURATIONS” appears in LCD display.
new text appears in the menu line. 3. Press F4 key to access the Configurations screen.
7. Repeat steps 5 through 7 until all information has been Configurations screen appears with cursor in the In-Range
entered in the Cargo Data screen. menu line.
8. Press ESC key to exit the Cargo Data screen. 4. Press F3 key to scroll cursor to view or reset the desired
function:
Viewing or Setting Run Time • In-Range: Sets the temperature value for the controller’s
In-range LED and datalogger functions (factory default
= 1.5 C [2.7 F]). Enter a value from 0.5 to 5.0 C (0.9 to
to “MISC. FUNCTIONS”.
8.9 F).
2. Press F4 key to access the Misc. Functions menu. “Date
• Container ID: Sets the container identification number.
Time” appears in the LCD display. Press F2 key to scroll
Enter up to 11 characters (numbers or letters).
to “RUN TIME”.
• Contrast: Controller automatically regulates black and
3. Press F4 key to access the Run Time screen. The Run
white contrast value on LCD display according to dis-
Time screen appears with cursor in HEAT menu line.
play temperature. Standard setting is 45. Resetting this
4. Press F3 key to scroll cursor down through cargo data list:
value is not recommended.
- HEAT
• Language: English is only setting currently available.
- COMPRESSOR
• Economy Max: Sets the Economy mode maximum tem-
- EVAPORATOR HIGH
perature limit (factory default = 0.2 C). Enter a value
- EVAPORATOR LOW
from 0 to 5.0 C (0 to 8.9 F).
- CONDENSER
• Economy Min: Sets the Economy mode minimum tem-
- TOTAL
perature limit (factory default = 2.0 C). Enter a value
5. To reset an hourmeter or set hours on a replacement con-
from 0 to 5.0 C (0 to 8.9 F).
troller:
• Humidity Option: View display value (factory default =
a. Press F4 key with cursor in the desired menu line.
NO HUM). Controller automatically activates when a
The Password screen appears.
humidity sensor is installed for more than 1 minute.
b. Press F2 key, “A” key (password is “A”), F4 key and
Setting this value is not necessary.
then EXIT key. An Enter Arrow appears in the
hourmeter line.
c. Enter the desired run time setting (up to 5 characters).
d. When the entry is complete, press and hold the F4
key until the cursor stops flashing. The new run time
appears in the menu line.
6. Repeat steps 5 and 6 to reset additional hourmeters.
7. Press ESC key to exit the Run Time screen.

MP-3000 Controller Datalogger Menu 4-31
• Reefer Type: Sets the unit model state to CSR20 PS or 5. To set a new Configuration screen value:
CSR40SL PS/CSR40 PS. Must be manually set to unit a. Press F4 key with cursor in the desired menu line.
type on unit serial number plate. The Password screen appears.
• Zero Current: View display ON or OFF value (factory b. Press F2 key, “A” key (password is “A”), F4 key and
default = ON). However, no errors occur if a Zero then EXIT key. An Enter Arrow appears in the
Current transformer is not installed and configuration is hourmeter line.
set to ON. c. Use the general purpose keypad to enter the desired
• Supply LH: View display ON or OFF value (factory value; or press the F3 key to toggle the value to the
default = OFF). Controller automatically activates when desired setting.
a left hand supply sensor is installed for more than 1 d. When the entry is complete, press and hold the F4
minute. Setting this value is not necessary. key until the cursor stops flashing. The new value
• Controlled Atmosphere Option: View display value (fac- appears in the menu line.
tory default = NO). Controller automatically activates 6. Repeat steps 4 and 5 to reset additional configuration val-
when a O2 or CO2 sensor is installed for more than one ues.
minute. 7. Press ESC key to exit the Configurations screen.
• Evaporator Fans: Sets the number of evaporator fans to
2 or 3. Must be manually set.
• AFAM Option: View display ON or OFF value (factory
default = ON). Set value to OFF when customer want Datalogger Menu
AFAM door to remain closed.
• Auto Configuration: View display ON or OFF value The Datalogger menu contains a list of functions that display
(factory default = OFF). Set value to ON to automatical- unit operating information recorded in the MP-3000 datalog-
ly configure unit to installed components. See ger. The following functions are available:
“Automatic Configuration of Spare Parts Controller” in • Inspect Temperature Log: Displays temperature logs by
this chapter for additional information. time and date for the Setpoint; Supply (Controlling
• Serial Number: Sets the unit serial number. Enter up to Temperature), Return, USDA1, USDA2, USDA3 and
11 characters (number or letters). Must be manually set. Ambient sensors; humidity sensor; and event flags.
Required to enable automatic detection of USDA sen- • Inspect Event Log: Displays important event logs by time
sors units with serial number beginning with MAE, MSF and date for events such as unit alarms, power On/Off, set-
or MWC prefix. point change, clock reset, trip start, defrost, etc.
Standard Display
NOTE: All screens are NOT present on all units.

Configuration Menu
— In-Range
— Container ID
— Contrast
— Language
Configuration Submenu
— Economy Max.
— Economy Min. • Current function setting
MAIN MENU — Humidity Option appears in display.
— Reefer Type • Press F4 key to change a
— DATA — Zero Current setting.
— ALARMS — Supply LH • Press F2 key, “A” key (pass-
— Controlled Atmosphere word), F4 key and EXIT key.
— COMMANDS Option • Type new value; or press F3
— MISC FUNCTIONS — Evaporator Fans key to toggle value to desired
— AFAM Setup setting.
— CONFIGURATION
— Auto Configuration • Press and hold F4 key until
— DATALOGGER — Serial Number cursor stops flashing.
— RMM STATE
Configuration Menu Screen Flow Diagram

4-32 Datalogger Menu MP-3000 Controller
• Set Log Time: Sets the data log interval (1 minute or 1/2, 1, H = High Refrigeration Pressure
2 or 4 hours). d = Defrost terminated on time limit
• Activate Tripstart: Sets the date and time of the trip start. e = Economy mode activated
• Inspect PTI Log: Displays results of last PTI test including s = Reefer unit stopped (after PTI)
component volt and amps data and sensor temperatures. Test w = Water-cooled operation (Condenser Fan switch is in
values are recorded at the start and end of the Chilled and the WATER position)
Frozen Mode test. A = Alarm in last interval
Viewing the Datalogger Menu NOTE: All event flags that occurred during a log
With the unit On/Off switch ON and the LCD display showing interval are displayed.
6. Press ESC key to exit the Temp Log.
2. Press F2 key to scroll through Main Menu until “DATA-
LOGGER” appears in LCD display. Inspect Event Log
3. Press F4 key to access the Datalogger menu. The first With the unit On/Off switch ON and the LCD display showing
function appears in the LCD display: Inspect Temp Log. the standard display (setpoint):
4. Press F2 or F3 key to scroll to the desired function: 1. Press F3 key to enter the Main Menu.
- Inspect Temp Log 2. Press F2 key to scroll through Main Menu until “DATA-
- Inspect Event Log LOGGER” appears in LCD display.
- Set Log Time 3. Press F4 key to access the Datalogger menu. “Inspect
- Activate Tripstart Temp Log” appears in the LCD display.
- Inspect PTI Log 4. Press F2 or F3 key to scroll through submenu until
5. Press F4 key to access the function selected. “Inspect Event Log” appears in LCD display.
5. Press F4 key to enter Event Log. LCD display shows the
Inspect Temp Log Log Time and the most recent event.
With the unit On/Off switch ON and the LCD display showing • To scroll through previous event log screens, press
the standard display (setpoint): F3 key. All event logs recorded in the datalogger
1. Press F3 key to enter the Main Menu. memory may be viewed on the LCD display.
2. Press F2 key to scroll through Main Menu until “DATA-
Event Examples
LOGGER” appears in LCD display.
• Controller alarm status (alarms set/cleared)
3. Press F4 key to access the Datalogger menu. “Inspect
• Main power On/Off status (humidity On/Off, tempera-
Temp Log” appears in the LCD display.
ture setpoint, and main power Hz)
4. Press F4 key to enter Temp Log. LCD display shows the
• 12 Vdc battery discharge test (battery voltage, total unit
Log Time and the Setpoint, Supply and Return tempera-
and compressor hours if main power On) — this event
tures of the most recent log in the first screen.
logged at once a day
• To scroll through previous logs of the sensor tem-
• Change temperature setpoint (new/old setpoint)
peratures currently in the display, press F3 key. All
• Change RH setpoint (new/old RH setpoint)
temperature logs recorded in the datalogger memory
• Change RH status (On/Off)
may be viewed on the LCD display.
• Event log retrieval
5. To view additional sensor log and event flag screens,
• Temperature log retrieval
press F4 key again. LCD display shows USDA1,
• Trip start
USDA2, USDA3, Relative Humidity (rH), Ambient, etc.
• New container ID
sensor readings, and flags.
• PTI start (Unit configuration)
• To scroll through previous logs of the sensor tem-
• PTI part 1 end (Temperature differences for tests 1, 2, 3
peratures currently in the display, press F3 key.
and heat test
Event Flags for Temperature Log • PTI end
T = Tripstart Activated • Defrost start (logged with demand or manual defrost
P = Primary Power Off only)
D = Defrost in Last Interval • Defrost end (start time)
O = Temperature Not In-range
h = Humidity Control Active 6. Press ESC key to exit the Event Log.
E = Evaporator High Temperature

MP-3000 Controller Datalogger Menu 4-33
Set Log Time cleared from the datalogger memory. The data-
With the unit On/Off switch ON and the LCD display showing logger resumes logging using the previous log
the standard display (setpoint): time setting.
1. Press F3 key to enter the Main Menu.
2. Press F2 key to scroll through menu list until “DATA- 8. When the correct log time appears in the menu line, press
LOGGER” appears in LCD display. and hold F4 key until cursor stops flashing. The new Log
3. Press F4 key to access the Datalogger menu. “Inspect Time appears in the display.
Temp Log” appears in the LCD display. 9. Press ESC key to exit the Temp Log.
4. Press F2 or F3 key to scroll through submenu until “Set
Log Time” appears in LCD display. Set a Trip Start
5. Press F4 key to enter Temp Log. LCD display shows the With the unit On/Off switch ON and the LCD display showing
current Log Time interval. the standard display (setpoint):
6. To enter a new log interval, press F4 key again with cur- 1. Press F3 key to enter the Main Menu.
sor in Log Time menu line. Arrow appears in menu line. 2. Press F2 key to scroll through menu list until “DATA-
7. Press F3 key to scroll through a list of log time intervals: LOGGER” appears in LCD display.
- 1 Minute* 3. Press F4 key to access the Datalogger menu. “Inspect
- 1/2 Hour Temp Log” appears in the LCD display.
- 1 Hour 4. Press F2 or F3 key to scroll through submenu until
- 2 Hour “Activate Tripstart” appears in LCD display.
- 4 Hour 5. Press F4 key to enter Tripstart function. The date and
time of the last trip start appears in the screen.
*NOTE: When a 1 Minute Log Test is selected, 6. Press F4 key again to enter a new start of trip date and
the datalogger records unit operating informa- time in the log.
tion every minute for 72 minutes. During the 1
Minute Log Test, only the 1 Minute Log can be NOTE: When a PTI Test is completed, the con-
retrieved for viewing. The Temperature Log and troller automatically enters a Tripstart in the log.
Event Logs can not be viewed. When the 1
Minute Log Test is complete, the 1 minute log is 7. Press ESC key to exit the Datalogger menu.
Standard Display
NOTE: All screens are NOT present on
all units. The screens that display on
the controller are determined by the
Unit Configuration setting.
Datalogger Menu
— Inspect Temp Log
— Inspect event Log Datalogger Submenu
— Set Log Time • First function screen appears:
— Activate Tripstart - Inspect Temp Log: Press F4
— Inspect PTI Log key to view next screen.
Press F3 key to scroll through
previous logs of sensors.
- Inspect Event Log: Press F3
MAIN MENU key to scroll through previous
event logs.
— DATA - Set Log Time: Press F3 key to
— ALARMS scroll through log interval list.
Press and hold F4 key until
— COMMANDS cursor stops flashing.
— MISC FUNCTIONS - Activate Tripstart: Press F4
key to enter trip start marker.
— CONFIGURATION
- Inspect PTI Log: Press F3 key
— DATALOGGER through test result screens.
— RMM STATE
Datalogger Menu Screen Flow Diagram

4-34 RMM State Menu MP-3000 Controller
Inspect PTI Log

Manual Emergency Mode Operation
the standard display (setpoint): In the event of an emergency situation where a fatal failure of
1. Press F3 key to enter the Main Menu. the controller occurs, a manual emergency mode function can
2. Press F2 key to scroll through menu list until “DATA- be used to operate the unit. Manual control offers a selection
LOGGER” appears in LCD display. of six operating positions:
3. Press F4 key to access the Datalogger menu. “Inspect • Position 1: Cool 1: Continuous cooling with condenser fan
Temp Log” appears in the LCD display. operation and high speed evaporator fan operation.
4. Press F2 or F3 key to scroll through submenu until • Position 2: Cool 2: Continuous cooling with condenser fan
“Inspect PTI Log” appears in LCD display. operation, high speed evaporator fan operation and continu-
5. Press F4 key to enter PTI Log. LCD display shows the ous liquid injection.
Start Time and PTI test results of the most recent PTI log. • Position 3: Not Used (Moduload Units Only)
• To scroll through additional test results in the log, press • Position 4: Not Used (Moduload Units Only)
F3 key. • Position 5: Defrost: Heaters are activated (evaporator fans
off).
PTI Examples • Position 6: Heat: Evaporator fans operate at high speed to
• PTI stores volt and amps of all power consuming com- introduce fan motor heat only into the container (no electric
ponents heater operation).
• PTI stores temperatures logged at both the start and end
of Chilled Mode and Frozen Mode capacity tests CAUTION: The unit must be cycled manually to
maintain the desired temperature. Monitor container
6. Press ESC key to exit the PTI Log. temperature with an external thermometer.
NOTE: The unit cooling capacity on Chill loads can

be reduced by almost closing the suction service
RMM State Menu valve when Cool 1 is selected. If the compressor
overheats, select Cool 2.
The RMM (Remote Monitoring Modem) State menu displays
the current communications status with a REFCON system:
• Offline: No communication between the controller RMM
and a REFCON system. Standard Display
• Zombie: The controller has detected a REFCON system
master module and is waiting for communication.
• On-line: The controller RMM is logged-in on a REFCON NOTE: All screens are NOT
present on all units. The
system. screens that display on the
controller are determined
Viewing the RMM State Screen by the Unit Configuration
setting.
2. Press F2 key to scroll through Main Menu until “RMM
STATE” appears in LCD display.
3. Press F4 key to access the RMM State screen. The screen MAIN MENU
will show: Offline, Zombie or On-line.
4. Press ESC key to exit the RMM State screen. — DATA
— ALARMS
— COMMANDS
— MISC FUNCTIONS
— CONFIGURATION
— DATALOGGER
RMM Status
— RMM STATE
Display shows
current status:
• Offline
• Zombie
• On-line
RMM State Menu Screen Flow Diagram

MP-3000 Controller Replacing the Controller 4-35
To select Manual Control: d. Connect unit power cord to the proper power supply.
1. Turn the Unit On/Off switch to OFF. e. Turn the Unit On/Off switch to ON. Check con-
2. Disconnect the unit power cord from the power supply. denser and evaporator airflow again to confirm cor-
rect fan rotation.
WARNING: High voltage (460/380 volts) is pre-
sent on the contactors and relays in the control
box. To prevent dangerous electrical shock, dis-
connect the supply power to the unit whenever Replacing the Controller
possible when working in this area.
1. Turn the unit On/Off switch OFF. Then unplug the unit
3. Disconnect cable no. 2 from the controller and main relay power cord from the power supply.
board (see electrical schematic). The main relay board will 2. Disconnect battery power connection from the controller
now control the unit based on the manual control setting. (top plug on the controller).
3. Disconnect the communication cables from the controller
NOTE: MUST check 2-pin plug location on J501 and remote monitoring modem.
connections of main relay board to ensure cor- 4. Remove the screws that secure the remote monitoring
rect unit operation. modem to the controller.
5. Remove the screws that secure the controller to the inside
4. If necessary, remove 2-pin plug from J501 (see decal on of the control box door.
main relay board) and re-locate based on the unit operat- 6. Remove the controller from the door.
ing mode required. 7. Install the replacement controller in the door using the
5. Connect the unit power cord to the proper power supply. existing hardware. Connect the keyboard cable to the
6. Turn Unit On/Off switch to ON. Unit will start and operate. controller.
7. Check for correct rotation of condenser fan and evaporator 8. Install the remote monitoring modem on the back of the
fans. Condenser air should be blowing out from the cen- controller.
ter of the grille. Evaporator air should be blowing down 9. Connect the communication cables to the remote monitor-
through the evaporator coil. If the fans are running back- ing modem and controller.
wards, the power supply phase must be changed. To 10. Set the software selection switch on the back of the con-
reverse power phase: troller to position “2”.
a. Turn On/Off switch OFF.
b. Disconnect unit power cord from power supply. NOTE: Be certain that all connector plugs are
c. Relocate the phase selector terminal plug from J18 fully seated.
(see decal on main relay board). Relocate from A to
B (B to A) as required. CAUTION: Be sure to enter the container ID
before releasing the unit for service. The con-
tainer ID is required to identify the data down-
loaded from the controller datalogger via a lap-
top computer or a REFCON remote communica-
tions system.
NOTE: Several programmable features may

need to be set to completely configure the unit to
customer specifications. Adjust any additional
programmable settings to customer require-
ments before releasing the unit for service.
NOTE: If a controller from another unit has been

installed, see “Controller Software Selection” in
this chapter to set software selection dial cor-
rectly.
Automatic Configuration of Spare Parts

Controller
An automatic configuration feature detects the unit options
installed on a unit when a spare parts controller is installed in
the unit and powered up for the first time. After the initial unit
Manual Emergency Control Connections powerup, the controller turns the Auto Configuration feature
Off.

4-36 Controller Software Selection MP-3000 Controller
The Auto Configuration feature detects the following 7. The controller then checks the new software and loads the
options and sets the correct value in Configuration menu: new control program into memory.
• Number of Supply Air Sensors (1 or 2): Controller detects
left hand and right supply air sensors. NOTE: If the flash load procedure is interrupted or
• Number of Evaporator Fans (2 or 3) fails, the controller will continue to use the previous
• Dehumidify (On or OFF): If controller detects a humidity control program.
sensor, it then checks for current draw on a dehumidify
valve. NOTE: Installing new software does not change any
• Humidification (On or OFF): If controller detects a humidity configuration settings or the setpoint setting, or
sensor, it then checks for current draw on an air compressor. erase the data log currently stored in the controller.
Controller Software Selection Temperature Sensors

If a replacement controller was removed from another unit, Thermistor type temperature sensors are used. Each sensor is
check the small dial located on the back of the controller for connected to a shielded cable and placed in a sealed stainless
the correct software selection. Current active software settings steel tube. The temperature signal from the sensor is transmit-
for dial positions are: ted through the shielded cable. Temperature sensors include:
• Position 0: All TNE 508 units with Moduload compressor • Supply Air, Left Hand
• Position 1: All CRR-40/TNE 508 units with KVQ valve • Supply Air, Right Hand
• Position 2: All CSR20 PS, CSR40SL PS and CSR40 PS units • Return Air
with a stepper motor valve • Evaporator Coil
• Position 7: Unit testing and service only. • Condenser Coil
• Compressor Discharge (Top Cap) Temperature
Changing Software Selection Dial Position • Ambient Air
1. Turn Unit On/Off switch OFF.
2. Set dial indicator to correct position. CAUTION: Sensors are permanently calibrated and
3. Turn Unit On/Off switch ON. New software selection is can be checked using an ohmmeter. Ohm readings
loaded during controller start-up. should agree with the data shown in the Sensor
resistance tables on page 4-36 and 4-37.
Flash Loading Controller Software

Controller software must be flash loaded when software has Resistance Values for Supply, Return, Evaporator
been revised. To flash load software: Coil, Condenser Coil and Ambient Air Sensors
1. Turn the unit On/Off switch OFF.
2. Plug cable from a portable computer with controller soft-
ware into the data retrieval connector on the control box. Temp. Temp. Temp. Temp.
3. Press one of the special functions keys to activate con-
o
F o
C OHMS o
F o
C OHMS
troller LCD display on battery power; or turn the Unit -40 -40 42618 53.6 12 3360
On/Off switch ON. -31 -35 32198 57.2 14 3094
4. Press and hold the “7” key and F1 key at the same time. -22 -30 24532 60.8 16 2852
LCD display will show “FLASHLOAD ”. -13 -25 18850 64.4 18 2632
-4 -20 14618 68 20 2431
NOTE: If the communications cable is defective 5 -15 11383 71.6 22 2347
or not connected to the download port, the con- 10.4 -12 9838 75.2 24 2079
troller will start in emergency mode and LCD dis- 14 -10 8941 78.8 26 1925
play will show “EMERGENCY MODE”. Secure 17.6 -8 8132 82.4 28 1785
cable connection to proceed with flash loading 21.2 -6 7406 86 30 1657
of software. 24.8 -4 6752 89.6 32 1539
28.4 -2 6164 93.2 34 1430
5. Start flash load program on portable computer. 32 0 5634 96.8 36 1330
6. Flash loading of new software is complete when “FLASH 35.6 2 5155 100.4 38 1239
LOADING” clears from the LCD display. 39.2 4 4721 104 40 1154
42.8 6 4329 107.6 42 1076
46.4 8 3907 111.2 44 1004
50 10 3652 113 45 970

MP-3000 Controller Temperature Sensors 4-37
All sensors should be properly installed: Resistance Values for Compressor Discharge (Top
• Supply air sensors must be inserted to the bottom of the sen- Cap) Temperature Sensor
sor tube and completely sealed by the grommet connection.
• Left hand supply sensor installs in the sensor tube behind the Temp. Temp. Temp. Temp.
compressor.
o
F o
C OHMS o
F o
C OHMS
• Right hand supply sensor installed in the sensor tube next to -13 -25 1,121,457 185 85 9,202
the control box. -4 -20 834,716 194 90 7,869
• Return air sensor installs in a grommet between the evapora- 5 -15 627,284 203 95 6,768
tor fans. 14 -10 475,743 212 100 5,848
• Evaporator coil (defrost) sensor must be placed in the middle 23 -5 363,986 221 105 5,091
of the coil and at least 75 mm deep between the fins. 32 0 280,824 230 110 4,446
• Condenser sensor must be placed on the upper left side of the 41 5 218,406 239 115 3,870
condenser coil and at lest 70 mm deep between the fins. 50 10 171,166 248 120 3,354
• Ambient sensor must be placed on the bottom plate of the 59 15 135,140 257 125 2,924
right forklift pocket. 68 20 107,440 266 130 2,580
• Compressor sensor must be placed in the manifold on the 77 25 86,000 275 135 2,279
discharge tube before the discharge service valve. 86 30 69,282 284 140 2,021
95 35 56,158 293 145 1,797
104 40 45,812 302 150 1,591
113 45 37,582 311 155 1,393
122 50 30,986 320 160 1,247
131 55 25,680 329 165 1,118
140 60 21,397 338 170 1,015
149 65 17,914 347 175 920
158 70 15,067 356 180 834
167 75 12,728 365 185 748
176 80 10,793 374 190 679
CSR20 PS and CSR40SL PS Evaporator Coil

(Defrost) Sensor Location
A. Coil Support Brackets
B. Unit Front
C. Insert Sensor at least 75 mm into coil between
Tube Rows 2 and 3
Condenser Coil Sensor Location

A. Insert Sensor into condenser coil between Tube
Rows 1 and 2
CSR40 PS Evaporator Coil (Defrost) Sensor

Location
A. Coil Support Bracket
B. Unit Front
C. Insert Sensor at least 75 mm into coil between
Tube Rows 2 and 3

4-38 Diagnosis and Repair MP-3000 Controller
If you have viewed and corrected these problems and the

Diagnosis and Repair unit still appears to be operating incorrectly, eliminate any
possibility that the problem is caused by failure of components
If the unit appears to be operating incorrectly, view any alarm
other than the controller.
codes that may be stored in the controller display memory.
Diagnose and correct the problem associated with each alarm
External Cause Checks
code (see “Alarm Codes, Alarm Types and Corrective
Actions” in this chapter). • Poor contact between male and female connector plugs
(loose connection).
NOTE: Defrost can be delayed for 24 hours during • Defective wire harness (broken wires, loose connections).
unit diagnosis or testing: Press “7” key and F1 key • External electrical causes such as faulty (open or stuck)
at the same time from any controller screen display. contactors.
Press F3 key to scroll cursor down to DELAY DEF • Malfunction of refrigeration system components.
menu line. Then press F4 key, F2 key, “A” key, F4
key and EXIT key. Cursor moves to end of line and
flashes. Pressure F3 key to toggle OFF to ON. Then
press and hold F4 key until cursor stops flashing.

MP-3000 Controller Error Messages and Controller Actions 4-39
Error Messages and Controller Actions

The controller displays error messages in the LCD display for several general faults. More than one error message may appear at a
time. Press F2 or F3 key to scroll through message displays.
Message
No. Error Message Controller Action
1 Power Error, Check 20A Fuses

Indicates: • Controller activates Alarm 18
• One or more phases are missing • Controller will try to restart unit after 60 minutes.
• Compressor is able to draw amps on all
phases while heater lacks amps on one
or more phases.
2 High Pressure Cutout, Check Water Cooling

Indicates: • Controller clears message on compressor start-up.
• Unit stops due to high pressure cutout and • No alarm is set until Controller determines that
condenser fan switch is in WATER position. unit current draw is too low (alarm 37) or
supply air temperature is too high (alarm 41).
3 Probe Test, Please Wait

Indicates: • Controller automatically activates Probe Test to
• Incorrect temperature difference between check for a defective sensor. Message clears
Supply-LH, Supply-RH, or Return air sensor when test is complete.
for 10 minutes with evaporator fan amps ok. • Controller displays new message if test indicates
a sensor is defective.
4 Supply–Right Hand Problem, Sensor

Disabled
• Controller disables sensor due to open or • Controller activates Alarm 00 or 01, depending on
short circuit or sensor failed a Probe Test.. type of sensor failure.
• Controller clears message during Defrost mode
and when Unit On/Off switch is turned OFF.
• Controller uses left hand supply sensor to control
unit if right hand sensor is defective.
• Controller uses return sensor plus an offset to
control unit if both supply sensors are defective.
5 Supply–Left Hand Problem, Sensor Disabled

• Controller disables sensor due to open or • Controller activates Alarm 00 or 01, depending on
short circuit or sensor failed a Probe Test.. type of sensor failure.
• Controller clears message during Defrost mode
and when Unit On/Off switch is turned OFF.
• Controller uses right hand supply sensor to control
unit if left hand sensor is defective.
• Controller uses return sensor plus an offset to
control unit if both supply sensors are defective.

4-40 Error Messages and Controller Actions MP-3000 Controller
Error Messages and Controller Actions (Continued)
Message
No. Error Message Controller Action
6 KVQ Valve Found, Please Change Type

Indicates: None. On Moduload units, KVQ sensor input must
• Controller is set for Moduload and start-up is be left open.
initiated on KVQ unit. Correct by turning
Unit On/Off switch OFF. Then set controller
software switch to position 1.
7 High Pressure Cutout, Check Condenser

Probe
• Units stops due to high pressure cutout, • No alarm is set until Controller determines that
condenser fan switch is in FAN AIR position unit current draw is too low (alarm 37) or
and condenser temperature is low. supply air temperature is too high (alarm 41).
8 Running with High Supply Difference

Indicates: • Controller clears message during defrost and
• Temperature difference between the left hand when Unit On/Off switch is turned OFF.
and right hand Supply sensors is too large;
even after Probe Test indicates no sensor
errors.
• Possible causes include air leak around
sensor cable, low refrigerant charge,
defective expansion valve, etc.
9 High Pressure Cutout, Check Condenser

Fan
• Unit stops due to high pressure cutout, • No alarm is set until Controller determines that
condenser fan switch is in FAN AIR position unit current draw is too low (alarm 37) or
and condenser temperature is high. supply air temperature is too high (alarm 41).

MP-3000 Controller Alarm Codes, Descriptions and Corrective Actions 4-41
Alarm Codes, Descriptions and Corrective Actions
NOTE: Sensors used with the MP-3000 controller do not require calibration. Check sensor resistance with an
ohmmeter.
• Shutdown Alarm (Level 1 Alarm): Alarm light on display flashes and unit stops. Correct alarm condition and
acknowledge alarm before restarting.
• Check Alarm (Level 2 Alarm): Alarm light on display flashes until alarm is acknowledged.
• Event Log (Level 3 Alarm): Alarm is recorded in datalogger only (inspect event log).
Alarm List
Code Description Corrective Action
00 Supply Air Sensor Open Circuit • Identify defective sensor (left hand or right hand) by
(Check Alarm) viewing Data menu.
• Sensor circuit resistance higher than 100,000 • Check sensor resistance between pins 1 and 2 on
ohms. plug J15 and between pins 7 and 8 on plug J14.
• Temperature below -70 C (-94 F). Resistance must be 2,000 ohms at 25 C (77 F).
• Indicates:
- Open circuit to left or right hand sensor • Check cable No. 1 and cable No. 3 between the
- Defective or wrong sensor controller and relay board.
- Defective relay board
- Defective cable No. 1 or cable No. 3 • Check evaporator airflow.
- Defective controller
01 Supply Air Sensor Short Circuit • Identify defective sensor (left hand or right hand) by
(Check Alarm) viewing Data menu.
• Sensor circuit resistance lower than 200 • Check sensor resistance between pins 1 and 2 on
ohms. plug J15 and between pins 7 and 8 on plug J14.
• Temperature below 80 C (176 F). Resistance must be 2,000 ohms at 25 C (77 F).
• Indicates:
- Short circuit to left or right hand sensor • Check cable No. 1 and cable No. 3 between the
- Defective or wrong sensor controller and relay board.
- Defective cable No. 1 or cable No. 3
02 Return Air Sensor Open Circuit • Check sensor resistance between pins 3 and 4 on
(Check Alarm) plug J15. Resistance must be 2,000 ohms at 25 C
(77 F).
• Sensor circuit resistance higher than 100,000
ohms. • Check cable No. 1 between controller and relay
• Temperature below -70 C (-94 F). board.
• Indicates:
- Open circuit to sensor
- Defective or wrong sensor
- Defective cable No. 1

4-42 Alarm Codes, Descriptions and Corrective Actions MP-3000 Controller
03 Return Air Sensor Short Circuit • Check sensor resistance between pins 3 and 4 on
(77 F).
• Sensor circuit resistance lower than 200
• Temperature above 80 C (176 F). board.
• Indicates:
- Short circuit to sensor
04 Evaporator Coil Sensor Open Circuit • Check sensor resistance between pins 5 and 6 on
(77 F).
• Indicates:
- Open circuit to sensor • Check evaporator airflow.
- Low evaporator coil temperature
05 Evaporator Coil Sensor Short Circuit • Check sensor resistance between pins 5 and 6 on
(77 F).
• Indicates:

06* Compressor Current Too High • Check evaporator, condenser and ambient sensor
(Check Alarm) temperatures for correct value (+/- 5 C [+/- 9 F])
by viewing Data menu.
• Occurs during Pretrip (PTI) or Function test only.
• Compressor power consumption is 25% above • Enter Manual Function Test menu. Start and check
expected current draw (above approximately current draw of the following components separately
13 amps); or compressor phase current level and together: compressor, compressor 100%,
difference of 10% or more, depending on condenser fan and evaporator fan (high and low).
ambient temperature.
• Indicates: • Check volt and ampere meter.
- Defective Stepper valve
- Defective compressor or valve plate • Check power supply volts.
- Defective volt or amp meter on relay board
- Inaccurate ambient, condenser or evaporator
temperature measurement
- Out of range power supply
- Excessive condenser pressure due to air
or wrong refrigerant in system, or refrigerant
over charge
07* Compressor Current Too Low • Enter Manual Function Test menu. Start and check
(Check Alarm) current draw of the following components separately
and together: compressor, compressor 25%,
• Occurs during Pretrip (PTI) or Function test only. condenser fan and evaporator fan (high and low).
• Compressor power consumption is 25% below If relay does NOT energize and the LED above the
expected current draw (below approximately 9 compressor relay is NOT ON, check for a defective
amps). cable No. 2, main relay board or controller.
• Indicates:
- Defective or open fuse CB 7A, high pressure • Check volt and ampere meter.
cutout switch or connection in plug J19
between pins 7 & 8 • Check power supply volts.
- No signal on plug J11 on pin 8
- Defective compressor relay • Check the refrigerant charge using the “Unit Health
- Defective volt or amp meter on relay board Check Procedure” on page 6-5.
- Low refrigerant charge
- Defective compressor or valve plate
*NOTE: If both alarms 06 and 07 are activated, the alarms are caused by a large difference in measured amps.
Enter Function Test and start condenser fan, compressor, compressor 100% and evaporator fans on HIGH
speed. Check the amps measurements. If necessary, check the resistance of the motor windings.

10* Heater Current Too High • Enter Manual Function Test and turn heaters ON.
(Check Alarm) Check current draw on each phase. Current draw
should be about 4.4 amps on each phase at 400V
• Occurs during Pretrip (PTI) or Function test only. (5.1 amps at 460V).
• Heater power consumption is 25% above
expected current draw (above approximately • Check heater resistance between H1 and H2,
4.4 amps and 5.1 amps, depending on voltage). H2 and H3, and H1 and H3. Resistance should be
• Indicates: about 99 ohms on each leg.
- Incorrect heaters or heater connections
- Defective heater element
11* Heater Current Too Low • Enter Manual Function Test and turn heaters ON.
(Check Alarm) Make sure the heat relay energizes. Check current
draw on each phase. Current draw should be 4.4
• Occurs during Pretrip (PTI) or Function test only. on each phase at 400V (5.1 amps at 460V).
• Heater power consumption is 25% below the
expected current draw (below approximately • If heat relay fails to energize, check evaporator high
3.2 amps and 3.8 amps, depending on voltage). temperature switch. Switch should be closed at
• Indicates: temperatures below 54 C (130 F); there should be
- Defective high evaporator temperature switch continuity between pins 5 and 6 in plug J19.
- Defective heater element or heat relay
- Defective wire connection • Check cable No. 2 between controller and relay
- Incorrect heaters or heater connections board.
• Check heater resistance between H1 and H2,

H2 and H3, and H1 and H3. Resistance should be
about 99 ohms on each leg.
• Check volt and ampere meter.
12** Evaporator Fan High Speed Current • Open evaporator door and make sure all fans
Too High (Check Alarm) rotate freely.
• Occurs during Pretrip (PTI) or Function test only. • Enter Manual Function Test and start evaporator
• Evaporator fan power consumption is 25% fans on HIGH speed. Make sure all fans start on
above expected current draw (above 2.8 to 4.0 high speed. Check fan motor volts and amps.
amps, depending on voltage)
- Defective or stuck evaporator fan motor
- Incorrect motor or motor connections
Enter Manual Function Test menu and start HEAT. Check the amps measurements. If necessary, check the
resistance between H1 and H2, H2 and H3, and H1 and H3. Resistance should be about 99 ohms on each leg.
**See note on next page.

13** Evaporator Fan High Speed Current • Open evaporator door and make sure all fans
Too Low (Check Alarm) rotate freely.
• Occurs during Pretrip (PTI), Function test or • Enter Manual Function Test and start evaporator
Probe test. fans on HIGH speed. Make sure all fans start on
• Evaporator fan power consumption is 25% high speed. If a motor does not start and is very
below expected current draw (below 1.6 to 2.4 hot, wait 10 minutes for internal over temperature
amps, depending on voltage). switch to close.
• Indicates:
- Defective evaporator fan motor relay • Check fan motor volts and amps.
- Defective or open fan motor internal over
temperature protection switch • Check volt and ampere meter.
14** Evaporator Fan Low Speed Current • Open evaporator door and make sure all fans
Too High (Check Alarm) rotate freely.
• Evaporator fan power consumption is 25% fans on LOW speed. Make sure all fans start on
above expected current draw (above 1.0 to 2.0 low speed. Check fan motor volts and amps.
amps, depending on voltage).
- Defective or stuck evaporator fan motor
- Motor high and low speed connection are
interchanged
15** Evaporator Fan Low Speed Current • Open evaporator door and make sure all fans
Too Low (Check Alarm) rotate freely.
• Evaporator fan power consumption is 25% fans on LOW speed. Make sure all fans start on
below expected current draw (below 0.6 to 1.2 low speed. If a motor does not start and is very
amps, depending on voltage). hot, wait 10 minutes for internal over temperature
• Indicates: switch to close.
- Defective evaporator fan motor relay
- Defective or open fan motor internal over • Check fan motor volts and amps.
temperature protection switch
- Defective volt or amp meter on relay board • Check volt and ampere meter.
**NOTE: If both alarms 12 and 13; or 14 and 15 are activated, the alarms are caused by a large difference in
measured amps. Enter Manual Function Test menu and operate evaporator fans on low and high speed.
Check the evaporator fan amps measurement. If necessary, check the resistance in the motors: High speed
between EF11 and EF12, EF12 and EF13, and EF11 and EF13; Low speed between EF1 and EF2, EF2 and EF3,
and EF1 and EF3. Resistance readings should be equal: High speed about 6 Ohms, total of 2 motors; Low
speed about 20 Ohms, total of 2 motors.

16* Condenser Fan Current Too High • Enter Manual Function Test and start condenser
(Check Alarm) fan. Make sure the fan starts. Check fan motor
volts and amps.
• Condenser fan power consumption is 25% • Check power supply volts and amps.
above expected current draw (above 1.5 to 1.9
amps, depending on voltage). • Check volt and ampere meter.
• Indicates:
- Defective or stuck condenser fan motor
17* Condenser Fan Current Too Low • Enter Manual Function Test and start condenser
(Check Alarm) fan. Make sure the fan starts. Check fan motor
volts and amps.
• Condenser fan power consumption is 25% • Check power supply volts and amps.
below expected current draw (below 0.5 to 0.7
amps, depending on voltage). • Check volt and ampere meter.
• Indicates:
- Defective condenser fan motor relay
- Defective or open fan motor internal over
18 Power Supply Phase Error • Enter Data menu and view voltage reading on
(Log Alarm) each phase.
• One or more frequence inputs are missing • Check all fuses. Check cable No. 1 on relay board.
for more than 20 seconds.
• Indicates: • Check cable No. 1 between controller and relay
- One phase on power line is missing board.
- Defective fuse on relay board
- Defective digital inputs on relay board • Replace relay board. Check voltage reading on
- Defective controller each phase.
Enter Manual Function Test menu and start the condenser fan. Check the condenser fan amps measurement.
If necessary, check the resistance in the motor between CF1 and CF2, CF2 and CF3, and CF1 and CF3.
Resistance readings should be equal (approximately 25 Ohms).

19 Temperature Too Far from Setpoint • Press SUP/RET key to check supply and return air
(Check Alarm) sensor temperatures. Compare temperatures to
evaluate unit cooling capacity and performance.
• After 75 minutes of operation, supply or return Temperature difference should be 4 C to 6 C.
air temperature is not in-range and does
not approach setpoint within preset • Open evaporator door. Inspect coil for ice or frost
pulldown rate. and initiate manual defrost if necessary.
• Indicates:
- Ice or frost on evaporator coil • Check refrigerant charge
- Air exchange vent open too much
- Container air leakage (doors open) NOTE: This alarm can be activated if the supply or
return air temperature varies, even if the mean
temperature does approach setpoint.
20 Defrost Time Too Long • Initiate a manual defrost and check amperage draw
(Check Alarm) and evaporator coil temperature. Evaluate defrost
performance.
• Heat signal has been ON for more than
90 minutes on 60 Hz power during Defrost • Open evaporator door and check location of
(120 minutes on 50 Hz power). evaporator coil sensor.
• Indicates:
- Low power supply voltage
- Defective heater elements
- Defective evaporator high temperature NOTE: This alarm can be activated at low voltage
protection switch and very low box temperature conditions, even under
- Defective heat relay normal operating conditions.
- Evaporator fans running during defrost
- Evaporator sensor placed wrong

22 Capacity Test 1 Error • Enter Manual Function Test and start evaporator
(Check Alarm) fans on LOW speed. Then select Sensor Checks
test and operate fans 2 to 5 minutes. Check supply,
• Occurs during Pretrip (PTI) test only. return and evaporator coil (defrost) sensor
• Difference between supply and return air temperatures. Sensor readings should be the
temperature is too small with low speed same (evaporator coil may be 0.5 C [1.0 F]
evaporator fans (less than approximately lower due to fan motor heat).
4.5 C [8 F]). NOTE: This sensor check does not detect air
• Return air temperature does not reach -18 C leakage around the sensor cables.
(0 F) within preset time.
• Indicates: • Open evaporator door and inspect evaporator fan
- Incorrect location of supply or return air sensor rotation. Make sure fans are rotating correctly on
- Air leakage at supply sensor cable low speed.
- Defective supply or return air sensor
- Interchanged sensor connections • Check the sensor connections.
- Incorrect evaporator fan rotation or high speed
operation • Enter Manual Function Test menu. Start and check
- Incorrect refrigeration system operation current draw of the following components separately
- Container/side panels defective, damaged or and together: compressor, compressor 100%,
leaking condenser fan and evaporator fans (low). Check
the refrigerant charge using the “Unit Health Check
Procedure” on page 6-5.
NOTE: This alarm can be activated in ambient tem-

peratures below -10 C (14 F), even under normal
conditions.

23 Capacity Test 2 Error • Enter Manual Function Test and start evaporator
(Check Alarm) fans on HIGH speed. Then select Sensor Checks
temperature is too small with high speed same (evaporator coil may be 0.5 C [1.0 F]
evaporator fans (less than approximately 3.0 C lower due to fan motor heat).
(5.4 F); or temperature difference is less
than in test P1.15. NOTE: This sensor check does not detect air
• Return air temperature does not reach 0 C leakage around the sensor cables.
(32 F) within preset time.
• Indicates: • Open evaporator door and inspect evaporator fan
- Incorrect location of supply or return air sensor rotation. Make sure fans are rotating correctly on
- Air leakage at supply, return or defrost high speed.
(evaporator coil) sensor cable
- Defective supply or return air sensor • Check the sensor connections.
- Interchanged sensor connections
- Incorrect evaporator fan rotation or low speed • Enter Manual Function Test menu. Start and check
operation current draw of the following components separately
- Incorrect refrigeration system operation and together: compressor, compressor 100%,
- Container/side panels defective, damaged or condenser fan and evaporator fans (high). Check
leaking the refrigerant charge using the “Unit Health
Check Procedure” on page 6-5.
NOTE: Alarm can be activated in ambient tempera-

tures below -10 C (14 F), even under normal condi-
tions.

24 Capacity Test 3 Error • Enter Manual Function Test and start the following
(Check Alarm) components: Condenser fan, evaporator fan (high),
compressor and compressor 25%. Check to be
• Occurs during Pretrip (PTI) test only. sure the Stepper valve closes.
• Difference between supply and return air
temperature is too high with Stepper valve • Check the supply and return air sensor connections.
almost closed and high speed evaporator
fans (more than 1.5 C [2.7 F]). • Check the supply and return air sensor calibration.
• Indicates:
- Defective Stepper valve • Check expansion valve superheat setting.
- Incorrect location of supply or return air sensor
- Defective supply or return air sensor
- Expansion valve open too much
- Incorrect refrigeration system operation
- Container/side panels defective, damaged or
leaking
25 Evaporator Temperature Test Error • Check evaporator coil sensor location.

(Check Alarm)
• Check evaporator coil sensor and return air sensor
• Occurs during Pretrip (PTI) test only. connections.
• Evaporator coil temperature too high with
no evaporator fans running (above about • Check expansion valve superheat setting.
-15 C [+5 F]).
• Indicates:
- Evaporator coil sensor is not in contact with
evaporator coil
- Return and evaporator coil sensor connections
are interchanged
- Expansion valve does not open enough or
opens too much

27 Heat Capacity Test Error • Enter Manual Function Test and start evaporator
(Check Alarm) fans on HIGH speed. Then select Sensor Checks
temperature too small with high speed same (evaporator coil may be 0.5 C [1.0 F] lower
evaporator fans (less than 0.4 C [0.7 F]). lower due to fan motor heat).
• Indicates: NOTE: This sensor check does not detect air
- Incorrect location of supply or return air sensor leakage around the sensor cables.
- Air leakage at supply, return or evaporator
coil sensor cable • Open evaporator door and inspect evaporator fan.
- Defective supply or return air sensor rotation. Make sure fans are rotating correctly on
- Interchanged sensor connections high speed.
- Defective heater elements
- Incorrect evaporator fan rotation or high speed • Check the sensor connections.
operation
- Container/side panels defective, damaged or
leaking
28 Stepper Motor Valve Error • Check the wiring to stepper motor valve using
unit wiring diagrams and a digital multimeter.
• Stepper motor valve current too low or - Disconnect stepper motor valve leads and check
too high circuit resistance. Resistance should be 75 +/- 7.5
• Indicates: ohms at 24 C (75 F) between red/green and
- Short circuit to valve white/yellow wire leads.
- Faulty stepper motor valve or circuit - Be sure to maintain the correct polarity or valve will
not work.
29 Liquid Injection Valve Error • Energize and de-energize the bypass valve using
(Pretrip) (Check Alarm) “Injection Valve” in the Controller Manual Function
Test submenu. Confirm by sound that the valve
• Occurs during Function or Pretrip (PTI) energizes and de-energizes.
test only.
• Indicates: • If the valve does not operate, check the valve coil
- Faulty bypass valve or circuit for continuity using a high quality multimeter.
• Check the circuit wiring in plug J11 for continuity

using a high quality multimeter and a wiring dia-
gram.

30 Bypass (Warm Gas) Valve Error • Energize and de-energize the bypass valve using
(Pretrip) (Check Alarm) “Bypass Valve” in the Controller Manual Function
Test submenu. Confirm by sound that the valve
• Occurs during Function or Pretrip (PTI) energizes and de-energizes.
test only.
• Indicates: • If the valve does not operate, check the valve coil
- Faulty bypass valve or circuit for continuity using a high quality multimeter.
• Check circuit wiring in plug J11 for continuity using a

high quality multimeter and a wiring diagram.
31 Low Pressure Cutout Error • Check the wiring to stepper motor valve using
(Check Alarm) unit wiring diagrams and a digital multimeter.
- Disconnect stepper motor valve leads and check
• Occurs any time. circuit resistance. Resistance should be 75 +/- 7.5
• Compressor does not stop during Function ohms at 24 C (75 F) between red/green and
or Pretrip (PTI) test. white/yellow wire leads. Be sure to maintain
• Indicates: correct polarity or valve will not work.
- Stepper motor valve will not open
- Bypass (warm gas) valve will not open • Check bypass valve circuit wiring in plug J11 for
(energize) continuity using a high quality multimeter.
- Defective low pressure cutout switch • If the bypass valve does not operate, check valve
coil for continuity using a high quality multimeter.
• Check the refrigerant charge using the “Unit Health

Check Procedure” on page 6-5.
• Continuity check low pressure cutout switch wiring

using a high quality multimeter. Replace switch.
32 Condenser Temperature Sensor Open Circuit • Check sensor resistance between pins 7 and 8 on
(77 F).
• Indicates:

33 Condenser Temperature Sensor Short Circuit • Check sensor resistance between pins 7 and 8 on
(77 F).
• Indicates:
34 Ambient Air Sensor Open Circuit • Check sensor resistance between pins 13 and 14 on
(77 F).
• Indicates:
35 Ambient Air Sensor Short Circuit • Check sensor resistance between pins 13 and 14 on
(77 F).
• Indicates:

36 Total Current Too High • Enter Manual Function Test menu and test (operate)
(Log Alarm) each component. Check volts and amps to
determine which component has high amp draw.
• Unit or component current draw is 25% above
expected amps for 4 minutes. • Check power supply volts.
• Indicates:
- Stepper valve malfunction • Check volt and ampere meter.
- Compressor, evaporator fan motor, condenser
fan motor or heater current too high
- Power supply voltage too low
37 Total Current Too Low • Check LCD display for High Pressure Cutout
(Log Alarm) message.
• Compressor Start-up: Unit or component current • Enter Manual Function Test menu and test (operate)
draw is 50% below expected amps for 4 minutes. each component. Check volts and amps to
• Indicates: determine which component has low amp draw.
- Defective or open fuse CB 7A
- Defective or open high pressure cutout switch • Check volt and ampere meter.
- Defective evaporator high temperature
protection switch
- Defective or open motor internal high
- Unit on water-cooled condensing with no water
flow
- Defective condenser coil sensor or sensor
location
41 Supply Air Temperature Too High • Check the refrigerant charge using the “Unit Health
(Check Alarm) Check Procedure” on page 6-5.
• During Chill or Frozen Mode: Supply air • Check for sensor or evaporator fan alarm codes.
temperature is too high compared to return
air temperature under operating conditions. • Open evaporator door. Inspect coil for ice or frost
• Indicates: and initiate manual defrost if necessary. Check
- Low refrigerant charge for correct evaporator fan motor rotation and
- Incorrect connection or location of supply or operation.
return air sensor
- Air leakage at supply air sensor cable • Check supply and return sensor connections and
- Ice or frost on evaporator coil locations.
- Incorrect evaporator fan operation

42 Supply Air Temperature Too Low • Check for sensor or evaporator fan alarm codes.
(Check Alarm)
• Open evaporator door. Inspect coil for ice or frost
• During Chill or Frozen Mode: Supply air and initiate manual defrost if necessary. Check
temperature is too low compared to return air for correct evaporator fan motor rotation and
temperature under operating conditions. operation.
• Indicates:
- Ice or frost on evaporator coil • Check supply and return sensor connections and
- Low heating capacity locations.
- Incorrect evaporator fan operation
- Incorrect connection or location of supply or
return air sensors
43 Return Air Temperature Too High • Check for sensor alarm codes.
(Check Alarm)
• Check supply and return sensor connections and
• During Defrost: Return air temperature locations.
increases above 40 C (104 F).
• Indicates:
- Defective return or evaporator coil sensor
- Return and evaporator coil sensor connections
are reversed
45 Evaporator Coil Temperature Too High • Check for sensor alarm codes.
(Check Alarm)
• Check evaporator coil and return air sensor
• During Chill or Frozen Mode: Evaporator coil connections and locations.
temperature is too high compared to return air
temperature under operating conditions. • Check the refrigerant charge using the “Unit Health
• Indicates: Check Procedure” on page 6-5.
- Low refrigerant charge.
- Defective evaporator coil or return air sensor
- Incorrect connection or location of evaporator
coil or return air sensor

46 Evaporator Coil Temperature Too Low • Check for sensor or evaporator fan alarm codes.
(Check Alarm)
• Open evaporator door. Inspect coil for ice or frost
• During Chill or Frozen Mode: Evaporator coil and initiate manual defrost if necessary. Check for
temperature is too low compared to return air correct evaporator fan rotation and operation.
temperature under actual operating conditions.
• Controller initiates defrost if no recent defrost. • Inspect return air grille and cargo load. Remove any
• Indicates: debris or cargo from blocking return air grille.
- Airflow is blocked in the container
- Evaporator fans do not operate • At setpoints below 5 C (41 F), maximum air vent
- Fresh air exchange vent open too much on setting is not allowed.
frozen load
- Defective evaporator coil or return air sensor • Check evaporator coil and return air sensor
connections and locations.
52 Probe Error • Check sensor connections. Check sensor

(Check Alarm) resistance of each sensor. Resistance must be
2,000 ohms at 25 C (77 F).
• Occurs during Pretrip (PTI) test or Probe
Test failed in Chilled mode. • Check left hand and right hand supply air sensor
• Temperature difference between return locations.
air and evaporator coil sensors is too
high (1.5 C [2.7 F] difference maximum)
• Temperature difference between return air
and supply air sensors is too high (0.8 C
[1.5 F] difference maximum)
• Temperature difference between LH supply
and RH supply sensors is too high (0.5 C
[1.0 F] difference maximum)
• Indicates:
- Incorrect temperature reading on one sensor
- Supply air sensor not placed in airflow stream

53 High Pressure Cutout Switch Off Error • Enter Manual Function Test menu. Start the
(Check Alarm) following components together: compressor 100%,
compressor and evaporator fans (high). Discharge
• Occurs during Pretrip (PTI) test only. pressure should increase and compressor should
• Compressor does not stop during high stop (high pressure cutout switch opens).
pressure cutout switch test.
• Indicates: • Check the refrigerant charge using the “Unit Health
- Faulty compressor contactor or control circuit Check Procedure” on page 6-5.
- Defective high pressure cutout switch
- Strong winds causing cooling of condenser
coil in low ambient conditions
54 High Pressure Cutout Switch On Error • Enter Manual Function Test menu. Start the
(Check Alarm) following components together: compressor 100%,
compressor and evaporator fans (high). Discharge
• Occurs during Pretrip (PTI) test only. pressure should increase and compressor should
• Compressor does not start within normal time stop (high pressure cutout switch opens). Then
during high pressure cutout switch test. start the condenser fan. Discharge pressure must
• Indicates: decrease quickly and compressor should start
- High pressure cutout switch did not respond (switch closes).
to pressure change within 5 seconds
- Air in refrigeration system
- Defective high pressure cutout switch

56 Compressor Temperature Too High • Check the refrigerant charge using the “Unit Health
(Shutdown Alarm) Check Procedure” on page 6-5.
• Compressor discharge line temperature is • Enter Manual Function Test menu and test (operate)
above 130 C (266 F). Compressor stopped Injection Valve to determine if valve opens
until discharge line temperature decreases (energizes).
to 90 C (194 F);
• Indicates: • Check compressor discharge sensor resistance.
- Air in refrigeration system Resistance must be 100,000 ohms at 25 C (77 F).
- Defective compressor or valve plate • Check discharge line temperature with a separate
- Defective liquid injection system electronic thermometer and compare to “HIGH PR
- Wrong or defective sensor TEMP” shown in the Data menu of controller.
NOTE: Unit will operate normally without compressor

sensor. However, controller compressor high
temperature protection is not active.
58 Phase Sensor Error • Start a Function Test. During step F1.05, check
(Check Alarm) whether the phase relays on relay board receive a
signal (LED energizes). Verify that the relays
• Occurs during Pretrip (PTI) or Function test only. respond and shift to reverse phase.
• During Phase Sensor Test, amperage difference
between correct and wrong condenser fan
rotation is more than 0.2 amps.
• Indicates:
- Defective phase relay
- Defective relay board cable No. 2
59 Delta Current Error • Enter Manual Function Test menu and test (operate)
(Log Alarm) each 3-phase component to locate defective
connection.
• 100% ampere difference between current
phases.
• Indicates:
- Open connection on one phase of power
supply to a motor or heater element

60 Humidity Sensor Error • Check sensor connections.

(Check Alarm)
• Check controller configuration for correct humidity
• Occurs during Pretrip (PTI) test only. setting.
• Relative humidity reading is not between
20% and 95%. • Replace sensor.
• Indicates:
- Sensor disconnected
- Wrong controller software configuration
- Defective sensor
97 Compressor Sensor Open Circuit • Check sensor resistance between pins 9 and 10 on
(Log Alarm) plug J15. Resistance must be 100,000 ohms at
25 C (77 F).
• Indicates:
- Open circuit to sensor NOTE: Unit will operate normally without compressor
- Defective or wrong sensor sensor. However, controller compressor high
- Defective relay board temperature protection is not active.
98 Compressor Sensor Short Circuit • Check sensor resistance between pins 9 and 10 on
(Log Alarm) plug J15. Resistance must be 100,000 ohms at
25 C (77 F).
• Indicates:

99 USDA 1 Sensor Open Circuit • Check USDA sensors and sensor connections.
(Check Alarm)
• Check cable No. 3 between controller and relay
• Occurs during Pretrip (PTI) test only. board.
• Container ID starts with MAE, MSF or MWC.
• Temperature below -50 C (-58 F).
• Indicates:
- All 3 USDA sensors are missing
112 Zero Current Too High • Enter Manual Function Test menu and test (operate)
(Check Alarm) each motor and heater separately. Note when
alarm occurs.
• Ground (zero current) circuit 30 milliamps.
• Indicates:
- Defective motor or heater insulation to
ground

5 Electrical Maintenance
High Pressure Cutout Switch:

Unit Wiring Opens: 3243 +/- 7 kPa, 32.43 +/- 0.48 bar, 470 +/- 7 psig
Closes: 2758 kPa, 27.58 bar, 400 psig
Inspect unit wiring, wire harnesses, and the controller during
pre-trip inspection and every 1,000 operating hours to protect
To test the switch, rework a gauge manifold per “High
against unit malfunctions due to open or short circuits. Look
Pressure Cutout Manifold” illustration.
for loose, chaffed or broken wires on the unit; open or short
circuits and damaged components on the controller printed cir-
High Pressure Cutout Manifold
cuit board.
1. Connect the manifold gauge to the compressor discharge
Inspect electrical contactor points for pitting or corrosion
service valve with a heavy duty, black jacketed thick wall
every 1,000 operating hours. Repair or replace as necessary.
#HCA 144 hose with 6024 kPa, 60.24 bar, 900 psig work-
ing pressure rating.
2. Operate the unit in Cool by performing an Capacity 100%
test from the Manual Function Test menu of the con-
High Pressure Cutout Switch troller.
A high pressure cutout switch is located on the compressor
discharge service manifold of the compressor. If the discharge
pressure becomes too high, the switch opens the ground circuit
to the compressor contactor coil:
• Compressor STOPS immediately. Evaporator and con-
denser fans continue normal operation.
• Controller determines that a high pressure cutout switch or
compressor motor internal overload protector is open
when the unit current draw during compressor operation is
normal and then decreases by 7 amps for more than 3 sec-
onds.
• After 1 minute, controller LCD display shows a High
Pressure Cutout message:
- High Pressure Cutout Check Condenser Probe: Water
pressure switch is CLOSED and the condenser tempera-
ture is low.
- High Pressure Cutout Check Condenser Fan: Water
pressure switch is CLOSED and the condenser tempera-
ture is high.
- High Pressure Cutout Check Water Cooling: Water pres-
sure switch is OPEN.
• After 5 minutes, controller also activates Alarm LED and
records Alarm 37, Total Power Consumption Too Low.
• Compressor will restart when the overload condition is
High Pressure Cutout Manifold

1. Relief Valve, P/N 66-6543
2. O-ring, P/N 33-1015
3. Adapter Tee (Weather Head No. 552X3)

5-2 Low Pressure Cutout Switch Electrical Maintenance
3. Raise the discharge pressure of the compressor by block- front of the unit. Proper rotation will blow the cloth or paper
ing the condenser coil airflow. Temporarily cover the away from the grille. Improper rotation will hold the cloth or
compressor compartment, control box and power cord paper against the grille.
storage compartment with cardboard to reduce condenser If the condenser fan is rotating backwards, refer to the
coil airflow. This should increase the discharge pressure unit wiring diagram to correct fan motor wiring at the fan
enough to cause the switch to open. When the switch motor junction box or condenser fan contactor. To correct
opens: improper fan rotation, reverse any two fan power cord leads at
• The compressor and evaporator fans should STOP the condenser fan contactor (disconnect power supply before
immediately. reversing leads). DO NOT move the CH ground wire.
NOTE: The discharge pressure should never be Evaporator Fans

allowed to exceed 2,760 kPa, 27.6 bar, 400 psig. Visually inspect the evaporator fan blades for proper rotation.
Arrows located on the underside of the fan deck indicate the
4. Be sure to remove the cardboard installed in step 3. correct direction of rotation.
If the HPCO switch fails to stop compressor operation, replace NOTE: Check both High and Low Speed evaporator
the switch and repeat steps 1 through 4. fan rotation by performing Evaporator High and
Evaporator Low tests from the Manual Function Test
menu of the controller.
Low Pressure Cutout Switch If an evaporator fans rotate backwards on one or both
speeds, refer to the unit wiring diagram to correct motor wiring
A low pressure cutout switch is located on the compressor suc-
at the fan motor junction box or evaporator fan contactor (dis-
tion line. If the suction pressure becomes too low, the switch
connect power supply before reversing leads). (DO NOT move
opens to stop the compressors:
the ground wire which is labeled CH.)
• Evaporator and condenser fans continue normal operation.
NOTE: Evaporator fan motor wires EF1, EF2 and EF3
• Compressor will restart if the low refrigerant condition is
are used on LOW SPEED fan operation. Wires EF11,
EF12 and EF13 are used on HIGH SPEED fan opera-
The low pressure switch resets (closes) when the pressure
tion.
increases to 48 to 90 kPa, 0.48 to 0.90 bar, 7 to 13 psig.
Low Pressure Cutout Switch:

Opens: +21 to -21 kPa, +).21 to -0.21 bar, 6 in. Hg vacu-
um to 3 psig Electric Heaters
Closes: 48 to 90 kPa, 0.48 to 0.90 bar, 7 to 13 psig Six electric heater elements are located underneath the evapo-
rator coil. If a heater element is suspected of malfunctioning,
If the low pressure cutout switch is suspected of being inspect the connections:
defective, replace it with a known good switch. • If the connections appear correct and secure, isolate and
check the resistance of each individual heater element by
disconnecting it from the circuit.
• Check resistance with an ohmmeter.
Condenser Fan and Evaporator Fan Rotation
NOTE: When repairing heater connections, protect
the new connections from the ingress of moisture
NOTE: If both the condenser fan and evaporator
with heat shrink tubing. All heaters should be
fans are rotating backwards, diagnose the automatic
secured to prevent contact with sharp metal edges.
phase selection system.
Condenser Fan
Check for proper condenser fan rotation by placing a small
cloth or sheet of paper against the condenser fan grille on the

6 Refrigeration System
Diagnosis and Service
NOTE: The following procedures involve servicing System Diagnosis Using the Pretrip (PTI) Test
the refrigeration system. Some of these service pro- To verify system performance or diagnosis a unit cooling or
cedures are regulated by Federal, and in some heating problem, perform a Pretrip Test.
cases, by State and Local laws. 1. Turn the unit On/Off switch ON.
All regulated refrigeration service procedures 2. Press the F3 key to enter the Main Menu.
must be performed by an EPA certified technician, 3. Press F2 key to scroll through Main Menu until “COM-
using approved equipment and complying with all MANDS” appears in LCD display.
Federal, State and Local laws. 4. Press F4 key to access the Commands menu. The first
NOTE: Hermetic units feature a large, one-piece filter display.
drier/in-line filter. The filter drier should not require 5. Press F2 or F3 key to scroll to PTI (Pretrip).
replacement unless major system contamination 6. Press F4 key to activate the command selected. LCD dis-
requires evacuation and cleanup of the refrigeration play shows PTI Test currently being performed. For a
system. detailed description of the PTI Test, see pages 4-23
through 4-27. PTI test ends automatically.
NOTE: Correct all existing alarm conditions and

Hermetic Refrigeration System Diagnosis clear the alarm codes before performing a PTI
Procedures test. The controller will automatically clear all
existing alarms before beginning the PTI test.
A hermetic refrigeration system is a totally sealed system that
is highly reliable, and virtually leak and tamper proof. • If a Check Alarm fault occurs during a pretrip test,
Consequently, CSR hermetic refrigeration units do not have the Alarm LED turns ON while the controller contin-
service valves, schrader fittings or sight glasses to aid diagno- ues the Pretrip test.
sis and service procedures. Instead, system performance is • If a Shutdown Alarm fault occurs during a Pretest
easily and quickly verified by initiating an automatic Pretrip test, the Alarm LED FLASHES and the controller
(PTI) Test. stops all unit operation.
A Pretrip Test should be performed during pretrip and 7. When the Pretrip test is complete, the display will show
routine maintenance inspections. If the unit fails the Pretrip PTI PASS or PTI FAIL. Press any key to return the unit
Test, view and write down each alarm code. Then identify, to normal operation.
diagnose and correct all potential mechanical and electrical 8. If the Alarm LED is ON or flashing ON and OFF, press
system problems first. If a mechanical or electrical system the F2 key to enter the Alarm menu and view the alarm
problem was detected and corrected, perform another Pretrip code(s).
Test to verify unit performance and operation. If the unit still 9. Write down the alarm code in the display. Then press the
fails to cool properly, identify and diagnose all potential refrig- F2 key to view the next alarm code.
eration system problems before opening the refrigeration sys- 10. Repeat step 9 until all alarm codes have been recorded.
tem.
WARNING: Some unit malfunctions will cause an
Alarm and unit shutdown condition. When the
alarm codes are cleared, the unit will start auto-
matically.

6-2 Diagnosis Procedures Refrigeration Maintenance and Service Operations
Use Alarm Codes to Identify and Diagnose Potential Low Refrigerant Charge
Problems -07 Compressor Current Too Low (Check Alarm)
See “Alarm Codes, Descriptions and Corrective Actions” in -19 Temperature Too Far from Setpoint (Check Alarm)
Chapter 4 of this manual to view a list of problems that may -31 Low Pressure Cutout Error (Check Alarm)
cause the controller to record a specific alarm code. -41 Supply Air Temperature Too High (Check Alarm)
Identify, diagnose and correct any mechanical and electri- -45 Evaporator Coil Temperature Too High (Check Alarm)
cal system problems listed in the “Corrective Action” column -53 High Pressure Cutout Switch Off Error (Check Alarm)
first. If no mechanical or electrical system problems can be -56 Compressor Temperature Too High (Shutdown Alarm)
located; or if all mechanical or electrical system problems have
been corrected but the unit still fails to pass a Full Pretrip Test, Obstruction in the Low Side
identify and diagnose potential refrigeration system problems. -07 Compressor Current Too Low (Check Alarm)
Several alarm codes identify specific refrigeration system -19 Temperature Too Far from Setpoint (Check Alarm)
problems. To simply diagnosis, general refrigeration system -22 Capacity Test 1 Error (Check Alarm)
problems have been grouped into three areas: Low refrigerant -23 Capacity Test 2 Error (Check Alarm)
charge, obstruction in the low or high side and high refrigerant -31 Low Pressure Cutout Error (Check Alarm)
charge. Each alarm code that can be generated by the system -41 Supply Air Temperature Too High (Check Alarm)
problem is then listed and briefly described. Also: -45 Evaporator Coil Temperature Too High (Check Alarm)
• When only one of the alarm codes listed below is record- -53 High Pressure Cutout Switch Off Error (Check Alarm)
ed during a Full Pretrip Test, a mechanical or electrical -56 Compressor Temperature Too High (Shutdown Alarm)
system cause is highly probable.
• When two are more of the alarm codes listed below are Obstruction in the High Side
recorded, the likelihood of a problem inside the refriger- -06 Compressor Current Too High (Check Alarm)
ation system greatly increases.
High Refrigerant Charge
Specific Refrigeration System Problems -06 Compressor Current Too High (Check Alarm)
-06 Compressor Current Too High (Check Alarm)
-07 Compressor Current Too Low (Check Alarm)
-19 Temperature Too Far from Setpoint (Check Alarm) Hermetic Refrigeration System Visual Inspection and
-22 Capacity Test 1 Error (Check Alarm) Diagnosis
-23 Capacity Test 2 Error (Check Alarm) First correct all mechanical or electrical system problems. If
-24 Capacity Test 3 Error (Check Alarm) the alarms codes recorded during a Pretrip Test do not readily
-25 Evaporator Temperature Test Error (Check Alarm) identify a specific refrigeration system problem, then perform
-28 Suction Stepper Valve Error (Check Alarm) a visual inspection of the container and each refrigeration sys-
-29 Liquid Injection Valve Error (Check Alarm) tem component. Refer to the Hermetic Refrigeration System
-30 Bypass (Warm Gas) Valve Error (Check Alarm) Visual Inspection and Diagnosis Chart on page 6-3.
-31 Low Pressure Cutout Error (Check Alarm)
-41 Supply Air Temperature Too High (Check Alarm)
-42 Supply Air Temperature Too Low (Check Alarm)
-43 Return Air Temperature Too High (Check Alarm)
-45 Evaporator Coil Temperature Too High (Check Alarm)
-46 Evaporator Coil Temperature Too Low (Check Alarm)
-53 High Pressure Cutout Switch Off Error (Check Alarm)
-54 High Pressure Cutout Switch On Error (Check Alarm)
-56 Compressor Temperature Too High (Shutdown Alarm)

Refrigeration System Diagnosis and Service Visual Inspection and Diagnosis Chart 6-3
Hermetic Refrigeration System Visual Inspection and Diagnosis Chart
Potential Problem Alarm Codes Inspect/Check for
Low Refrigerant Charge -07, -19, -31, -41, - Defective container insulation
(unit not cooling) -45, -53 and -56 - Poor fitting container doors
- Partial obstruction in high side
- Partial obstruction in low side or filter drier
- Iced or plugged evaporator coil
- Expansion valve feeler bulb improperly mounted, poorly insu-
lated or making poor contact
- Expansion valve power element lost its charge
- Shortage of refrigerant: Inspect refrigeration system for signs
of oil loss. Locate and repair leak.
- Compressor inefficient
- Expansion valve partially closed by ice, dirt or wax
Obstruction in Low or -06, -07, -19, -22, Frosted or sweating suction line:
High Side -23, -31, -41, -45, - Expansion valve admitting excess refrigerant
-53 and -56 - Evaporator coil needs defrosting
- Restricted airflow through the evaporator coil
Dry, warm suction line:

- Restricted filter drier
- Expansion valve partially closed by ice, dirt or wax
- Expansion valve power element lost its charge
- Stepper valve stuck closed
Frosted liquid line:

Hot liquid line:

- Expansion valve open too wide
High Refrigerant Charge -06 - Condenser coil dirty or airflow restricted

- Defective water pressure switch (option)
- Insufficient water flow rate or plugged water-cooled con-
denser-receiver tank (option)
- Restricted lines on high side
- Air in refrigeration system
- Overcharge of refrigerant: Install service valves and gauge
manifold set. Check system operating pressures. After all
other components have been checked, remove refrigerant
charge and weight in new charge

6-4 Service Procedures Refrigeration System Diagnosis and Service
• Use Gauge Manifold, P/N 204-526, and gauge hoses with

Hermetic Refrigeration System Service self-sealing, 1/4 in. fittings:
Procedures - P/N 204-761, 6 ft (1.8 m) blue hose
- P/N 204-762, 6 ft (1.8 m) red hose
• To connect a gauge manifold set or other service tools to the - P/N 204-763, 6 ft (1.8 m) yellow hose, or
the refrigeration system, special piercing type service valves • Use a Gauge Manifold set equipped with 1/4” gauge hoses
must be attached to the discharge and suction line process with R-134a suction and discharge couplers, plus:
tubes. These process tubes are located in the compressor - P/N 66-7181, Suction adapter, 1/4 in. male flare fitting
compartment. to 1/2 in. Acme thread fitting
• When service or maintenance is complete, the hermetic - P/N 66-7179, Discharge adapter, 1/4 in. male flare fitting
refrigeration system must be returned to normal. The suction to 1/2 in. Acme thread fitting
and discharge line process tubes must be carefully sealed and
the service valves must be removed from the system. Vacuum Pump
A two-stage (P/N 204-725), three-stage or five-stage pump is
recommended for evacuation. Purging the system with dry
nitrogen is recommended before evacuation. Because residual
Service Tools refrigerant may be present in used vacuum pumps, a new vacu-
um pump should be used and dedicated strictly as an R-404A
CAUTION: When servicing Thermo King R-404A refrigerant pump. Use only recommended vacuum pump oils
refrigeration systems, use only those service tools and change oil after every major evacuation.
(i.e., vacuum pump, refrigerant recovery equipment, Because vacuum pump oils are highly refined to obtain
gauge hoses, and gauge manifold set) certified for low vacuums, failure to follow these recommendations may
and dedicated to R-404A refrigerant and Polyol Ester result in acidic conditions that will destroy the pump.
based compressor oils. Residual non-HFC refriger-
ants or non-Ester based oils will contaminate HFC System Cleanup
systems. Cleanup devices such as suction line filters and compressor oil
filters may be used if they are properly cleaned and new filters
Refrigeration System Service Valves and cartridges are used. All standard petroleum and synthetic
To service the refrigeration system on CSR hermetic units, compressor oils must be removed to prevent the contamination
special piercing type service valves must be attached to the of R-404A systems.
discharge and suction line process tubes.
Recommended Solders
NOTE: Special fittings may also be needed to con- When repairing solder connections, use the same solder that
nect gauge hoses and other service tools to the spe- was used in the manufacturing process:
cial piercing type service access valves. • Copper to copper, use 15% Silver Solder, P/N 203-364
• Copper to brass or steel, use 35% Silver Solder, P/N 203-366
Use flux, P/N 203-365, with both 15% and 35% silver sol-
Refrigerant Recovery der. Other types of leaks such as punctures in tubes and leaks
Use only refrigerant recovery equipment approved for and in coils can best be repaired using 15% silver solder, P/N 203-
dedicated to R-404A recovery. 364 (with flux, P/N 203-365).
Leak Detection NOTE: Thermo King recommends that service proce-

Leaks can be detected with the use of soap bubbles and with dures use the use the same solder on connections
Halogen leak detectors such as model H10G, P/N 204-712 or that was used in the manufacturing process.
model H10N, P/N 204-756 (portable). Therefore, technicians should obtain the recom-
mended solder and flux from Thermo King.
Gauge Manifold Set
The gauge manifold set should be dedicated for use with R- Compressor Oil Acid Test
404A only. Piercing type service valves require that the gauge Perform an oil acid test (oil test kit P/N 203-457) whenever a
manifold set connect to 1/4” flare fittings: unit has a substantial refrigerant loss, a noisy compressor or
dark/dirty oil.

Refrigeration System Diagnosis and Service Refrigerant Charge 6-5
Unit Health Check Procedure

Refrigerant Charge Unit cooling performance may not be affected by a marginally
low refrigerant charge (1 to 3 lbs [0.5 to 1.4 kg] low) under all
NOTE: CSR Hermetic units do not have service ambient operating conditions. Consequently, a unit with a
valves, fittings or sight glasses installed in the refrig- slightly low refrigerant charge may pass a Pretrip Test. The
eration system. Therefore, the refrigerant charge refrigerant charge level of the unit can be accurately deter-
level can not be visually inspected. mined by operating the unit on Cool for 15 minutes or more
and then checking temperature difference (dT) across the
Perform a controller Pretrip Test to determine that a CSR evaporator coil. To check the dT:
Hermetic refrigeration system contains an adequate charge of 1. Press F4 key to directly enter the Data menu. Read:
refrigerant for cooling. If the unit passes the the Pretrip Test, • Supply Air Temperature, Right Hand
the refrigerant charge is generally OK. However, unit cooling • Return Air Temperature
performance may not be affected by a marginally low refriger- 2. Subtract the supply air temperature (right hand) from the
ant charge under all ambient operating conditions. To accu- return air temperature to determine dT.
rately determine the cooling performance and refrigerant 3. Compare the unit dT to the expected values in table
charge level, see the “Unit Health Check” below. below. If dT is below the value in the “possible low
A Pretrip Test should be performed during pretrip and refrigerant charge” column, visually inspect the unit for
routine maintenance inspections. A low charge of refrigerant signs of frosted or iced evaporator coil, low or high
will cause the container temperature to rise due to the lack of obstruction in the refrigeration system, plugged expansion
liquid refrigerant at the expansion valve even though the unit valve and a loose or defective expansion valve feeler bulb
is operating in a cooling mode. Unit refrigerant charge: before concluding the unit is low on refrigerant.
• Standard receiver: 4.1 kg (9.0 lb) of R-404A.
• Water-cooled condenser-receiver: 5.0 kg (11.0 lb) of R- NOTE: Inspect the unit for refrigerant leaks with a
404A. reliable leak detector if the unit is suspected of being
low on R-404A charge.
Unit Health Check Table — Determining Possible Low R-404A Charge
Power Ambient Return Air Expected dT: Return Temp. dT less than figure listed below
Supply Temp. Temp. minus right hand supply temp. indicates possible low R-404A charge
38 oC (100 oF) -29 oC (-20 oF) -2.2 oC (-4.0 oF) -1.7 oC (-3.0 oF)
-18 oC (0 oF) -4.3 C
o
(-7.7 oF) -3.2 C
o
(-5.8 oF)
-1 oC (30 oF) -3.9 oC (-7.0 oF) -2.9 oC (-5.3 oF)
10 oC (50 oF) -5.6 C
o
(-10.1 oF) -4.2 C
o
(-7.6 oF)
460V, 27 oC (80 F) -29 oC (-20 oF) -3.0 C
o
(-5.4 oF) -2.3 C
o
(-4.1 oF)
3 Phase, -18 oC (0 oF) -4.8 C
o
(-8.6 oF) -3.6 C
o
(-6.5 oF)
60Hz -1 oC (30 oF) -3.8 oC (-6.9 oF) -2.9 oC (-5.2 oF)
10 oC (50 oF) -6.7 C
o
(-12.0 oF) -5.0 C
o
(-9.0 oF)
16 oC (60 oF) -29 oC (-20 oF) -3.0 C
o
(-5.4 oF) -2.3 C
o
(-4.1 oF)
-18 oC (0 oF) -4.6 C
o
(-8.3 oF) -3.5 C
o
(-6.2 oF)
-1 oC (30 oF) -4.5 oC (-8.1 oF) -3.4 oC (-6.1 oF)
10 oC (50 oF) -6.5 C
o
(-11.7 oF) -4.9 C
o
(-8.8 oF)
38 oC (100 oF) -29 oC (-20 oF) -2.1 C
o
(-3.8 oF) -1.6 C
o
(-2.9 oF)
-18 oC (0 oF) -4.2 C
o
(-7.5 oF) -3.1 C
o
(-5.6 oF)
-1 oC (30 oF) -3.9 oC (-7.0 oF) -2.9 oC (-5.3 oF)
10 oC (50 oF) -5.7 C
o
(-10.2 oF) -4.3 C
o
(-7.7 oF)
380V, 27 oC (80 oF) -29 oC (-20 oF) -3.0 C
o
(-5.4 oF) -2.3 C
o
(-4.1 oF)
3 Phase, -18 oC (0 oF) -4.8 C
o
(-8.6 oF) -3.6 C
o
(-6.5 oF)
50Hz -1 oC (30 oF) -4.3 oC (-7.7 oF) -3.2 oC (-5.8 oF)
10 oC (50 oF) -6.4 C
o
(-11.5 oF) -4.8 C
o
(-8.6 oF)
16 oC (60 oF) -29 oC (-20 oF) -3.0 C
o
(-5.4 oF) -2.3 C
o
(-4.1 oF)
-18 oC (0 oF) -4.9 C
o
(-8.8 oF) -3.7 C
o
(-6.6 oF)
-1 oC (30 oF) -4.7 oC (-8.5 oF) -3.5 oC (-6.4 oF)
10 oC (50 oF) -5.6 C
o
(-10.1 oF) -4.2 C
o
(-7.6 oF)
6-6 Compressor Oil Charge Refrigeration System Diagnosis and Service
Compressor Oil Charge Installing and Removing Piercing Type

CSR Hermetic units do not have service valves, fittings or Service Valves and a Gauge Manifold Set
sight glasses installed in the refrigeration system. Therefore, To service the refrigeration system on CSR hermetic units,
the compressor oil level can not be visually inspected. To special piercing type service access valves must be attached to
maintain the correct compressor oil level in the unit: the discharge and suction line process tubes. These process
1. Whenever possible, drain and measure the compressor oil tubes are located in the compressor compartment.
from major system components that are removed for ser- When service or maintenance is complete, the hermetic
vice or replacement whenever possible. Major compo- refrigeration system must be returned to normal. The suction
nents include: and discharge line process tubes must be carefully sealed and
- Compressor the service valves must be removed from the system.
- Filter drier
- Heat exchanger Piercing Type Service Valve Installation
- Receiver tank
- Water-cooled condenser-receiver tank NOTE: Before installing any piercing type service
valve, carefully check to ensure that the valve and
NOTE: If the compressor oil is discolored, per- access port connection function properly.
form a compressor oil acid test (oil test kit P/N
1. Stop the unit and allow compressor suction and discharge
203-457). If the compressor oil shows an acid
lines to cool to ambient temperature.
condition, change the oil, the filter drier and per-
2. Inspect piercing type service valves for correct fittings for
form a refrigeration system cleanup.
attachment of gauge manifold hoses, refrigerant recovery
2. Add an amount of new compressor oil equal to the amount equipment, a vacuum pump and other service tools.
removed from the old component. Use only Polyol Ester 3. Remove the compressor compartment bracket.
compressor oil, P/N 203-433. 4. Clean dirt and moisture from the unit’s process tubes.
5. Position the piercing port of the service valve about 13
CAUTION: mm (0.5 in.) from the existing crimp (or end) of the
• Use ONLY Polyol Ester based refrigeration process tube on the suction line.
compressor oil, P/N 203-433. 6. Install and secure the piercing valve on process tube.
• DO NOT mix Polyol Ester based and standard Carefully check to ensure that the piercing valve connec-
synthetic compressor oils. tion on the process tube is secure.
• Rubber gloves are recommended when han- 7. Leak check the service valve connection with an electron-
dling Ester based compressor oil. ic leak detector.
• Keep Polyol Ester based compressor oil in 8. Repeat steps 5 through 7 to install a piercing type service
tightly sealed containers. If Ester based oil valve on the discharge line process tube.
becomes contaminated with moisture or stan-
dard oils, dispose of properly — DO NOT USE!
Balancing the Pressure

1. Quick Disconnect Access Valve
2. Discharge Service Valve (DSV)
3. Suction Service Valve (SSV)

Refrigeration System Diagnosis and Service Piercing Type Service Valves 6-7
Gauge Manifold Set Installation 4. Remove the discharge line from the piercing valve port.
5. Operate the unit in cool mode until the suction pressure
NOTE: As long as a slight positive pressure remains decreases below 385 kPa, 3.85 bar, 50 psig.
in the manifold set and hoses, the gauge manifold 6. Stop the unit.
set may be reinstalled without additional purging. 7. Remove the suction line from the piercing valve port.
To purge a gauge manifold set and hoses, see
“Gauge Manifold Valve Positions” in this chapter. Piercing Type Service Valve Removal
1. Inspect gauge manifold for proper hose and fitting con- NOTE: Before removing a piercing type service
nections. Both the low side (suction) and high side (dis- valve, make sure the unit successfully completes a
charge) hand valves on the gauge manifold should be fully controller Pretrip Test to verify that the refrigerant
closed to center port. charge and unit operation are correct.
2. Clean dirt and moisture from around ports on piercing
valves. Remove service port caps (if required). 1. Carefully crimp the suction line process tube about 13 mm
3. Attach the low side hose (compound gauge) to the pierc- (0.5 in.) from the service access valve to seal and isolate
ing valve port on the suction process tube finger tight. suction line process tube from the service valve.
4. Attach high side hose (pressure gauge) to the piercing
valve port on the discharge process tube finger tight. NOTE: Perform the following three procedures
5. The gauge manifold set is now ready to use to check sys- as quickly as possible to prevent refrigerant
tem pressures and perform MOST service procedures. loss.
Gauge Manifold Set Removal 2. Remove the piercing type service valve from suction
process tube.
NOTE: To ensure minimum refrigerant release to the 3. Cut the end of process tube off where the tube was pierced
atmosphere, the compressor should be operating. by the service valve. This leaves about 13 mm (0.5 in.) of
While this is not possible in all cases, the same pro- process tube open behind the crimp.
cedure should be followed. 4. Fill the open end process tube with high temperature sol-
der.
1. Operate the unit in a cool mode. 5. Repeat steps 1 through 4 to seal the process tube and
2. Close the refrigerant tank hand valve (if attached to the remove the service valve on from the discharge line.
gauge manifold set). 6. Leak check the process tubes with an electronic leak
3. Open both manifold hand valves. detector.
Removing Refrigerant Charging the System

1. Quick Disconnect Access Valve 1. Quick Disconnect Access Valve
2. Discharge Service Valve (DSV) 2. Discharge Service Valve (DSV)
3. Suction Service Valve (SSV) 3. Suction Service Valve (SSV)

6-8 Gauge Manifold Valve Positions Refrigeration System Diagnosis and Service
5. Attach high side hose (pressure gauge) to the port on the

Gauge Manifold Valve Positions discharge line service valve. Purge the high side hose:
a. Open the high side (discharge) hand valve on the
The gauges indicate low and high side pressures.
gauge manifold fully to center port.
Operate one or both hand valves to perform the different ser-
b. Rotate the discharge hose fitting hand wheel clock-
vice operations shown below.
wise to open (depress) the discharge line port valve to
the high side hose.
Purging a Gauge Manifold and Hoses
c. Slowly screw a 1/2 inch ACME fitting into the low
1. Inspect gauge manifold for proper hose and fitting con-
loss fitting on the manifold’s service (center) line to
nections.
purge the discharge and service hoses.
2. Clean dirt and moisture from around service ports on ser-
vice valves. Remove service port caps from service
d. Remove the ACME fitting after purging the discharge
valves (if required).
hose.
3. Rotate both hose coupler hand wheels on the gauge mani-
e. Close the high side (discharge) hand valve on the
fold set counterclockwise to back the stem out of the high
gauge manifold fully to center port.
and low hose fittings.
6. The gauge manifold set is not ready to use to check sys-
4. Attach the low side hose (compound gauge) to the port on
tem pressures and perform MOST service procedures.
the suction line service valve. Purge the low side hose:
a. Open the low side (suction) hand valve on the gauge
manifold fully to center port.
b. With 70 kPa, 0.70 bar, 10 psig or greater pressure in
the low side, rotate the suction hose fitting hand
wheel clockwise to open (depress) the suction line
port valve to the low side hose.
c. Slowly screw a 1/2 inch ACME fitting into the low
loss fitting on the manifold’s service (center) line to
purge the suction and service hoses.
d. Remove the ACME fitting after purging the suction
hose.
e. Close the low side (suction) hand valve on the gauge
manifold fully to center port.
Gauge Manifold Closed to Center Port

1. Close Hand Valves
Purging Gauge Manifold

1. Quick Disconnect Access Valve
2. Discharge Connection Gauge Manifold Open to Center Port
3. Suction Connection
1. Open Hand Valves

Refrigeration System Diagnosis and Service Refrigerant Leak Test Procedure 6-9
at 21 C (70 F). DO NOT use oxygen, acetylene or

Refrigerant Leak Test Procedure any other type of pressurized gas in the system.
Use a reliable Halogen leak detector such as model H10G, P/N
9. Pressurize the system with nitrogen to 1380 kPa, 13.80
204-712 or 204-756 (portable), to leak test the refrigeration
bar, 200 psig.
system. Inspect carefully for signs of compressor oil leakage
10. Close the supply valve on the nitrogen bottle.
which is the first sign of a leak in the refrigeration system.
11. Use an electronic leak tester to inspect all joints and con-
nections. (Use a soap solution as an alternative test com-
NOTE: Due to environmental concerns and personal
ponent.)
safety, the use of a Halide torch is no longer recom-
mended.
NOTE: If system leakage is indicated, loosen
supply line hose fittings to release pressure.
If refrigerant has leaked or been removed from the unit:
Repair leakage condition.
1. Check entire system for possible component damage and
refrigerant oil loss. 12. If system repair is necessary, recheck system after repairs
2. Attach gauge manifold set (refer to “Gauge Manifold Set are completed.
Attachment and Purging” for proper procedures).
3. Attach refrigerant bottle charging hose to center of gauge
manifold and purge charging hose of air.
4. Pressurize the system with refrigerant (GAS ONLY) until
345 kPa, 3.45 bar, 50 psig vapor pressure is achieved.
Using Pressurized Nitrogen
5. Leak check the system with an electronic leak detector to The improper use of high pressure cylinders can cause physi-
inspect all joints and connections. (Use soap solution as cal damage to components, or personal injury, or cause stress
an alternative test component.) that would lead to failure of components.
If no leaks are found but the system has lost its refrig-
erant charge, proceed to the next step. Safety Precautions
6. Close both hand valves on gauge manifold (front seated). Observe the proper handling of cylinders:
7. Disconnect the refrigerant charging hose. 1. Always keep protective cap on cylinder when not in use.
8. Connect the charging hose to a source of nitrogen. Adjust 2. Secure cylinder in proper storage area or fastened to cart.
the pressure regulator to 1380 kPa, 13.80 bar, 200 psig. 3. DO NOT expose to excessive heat or direct sun light.
See “Using Pressurized Nitrogen” in this chapter. 4. DO NOT drop, dent, or damage cylinder.
5. Use a pressure regulator and a safety pressure relief valve
CAUTION: Nitrogen (N2 ) is under 15,170 kPa, as part of the pressure testing equipment. The safety pres-
151.70 bar, 2200 psig pressure in a full cylinder sure relief valve should be of the non-adjustable, non-tem-
pering type. The valve should bypass any time the pres-
sure exceeds its setting.
6. Open valve slowly; use regulators and safety valves that
are in good working order.
7. The regulator should have two gauges; one to read tank
pressure, the other to read line pressure. Properly main-
tained equipment will allow leak testing, purging, or dehy-
dration to be done safely.
CAUTION: Nitrogen (N2 ) is under 15,170 kPa, 151.70

bar, 2200 psig, or greater. Pressure is for full cylin-
der at 21 C (70 F). DO NOT use Oxygen (O2), acety-
lene or any other types of pressurized gas on refrig-
eration systems or any component of a system.
Dehydration, pressure testing, purging and soldering can

be accomplished with the use of dry nitrogen (N2 ). The prop-
er equipment and application of equipment is of greatest
importance.
Testing for Refrigerant Leaks

6-10 Refrigerant Recovery Refrigeration System Diagnosis and Service
Procedure
1. Attach gauge manifold set (refer to “Gauge Manifold Set Refrigerant Recovery from Hermetic
Attachment and Purging” for proper procedure for con- Refrigeration Systems
necting to the unit).
2. Close both hand valves on the gauge manifold (front seat-
Caution: Use only refrigerant recovery equipment
ed).
approved for and dedicated to R-404A recovery.
3. Connect charging hose to a source of nitrogen. Adjust
pressure regulator to the proper pressure for the required
When removing any refrigerant from a Thermo King refrigera-
procedure.
tion system, use a recovery process that prevents or absolutely
4. Purge system high side to low side.
minimizes the refrigerant that can escape to the atmosphere.
Typical service procedures that require removal of refrigerant
MAXIMUM Gas Pressure for Service Procedures
from the unit include:
• Leak Testing: 1034 to 1200 kPa, 10.34 to 12.00 bar, 150-174 psig,
• To empty the unit of refrigerant when an unknown
• Purging/Dehydration: 69 to 138 kPa, 0.69 to 1.38 bar, 10-20 psig,
amount of charge is in the system and a correct charge is
• Soldering: 35 kPa, 0.35 bar, 5 psig.
required.
• To empty the unit of contaminated refrigerant when the
system has become contaminated. Place this refrigerant
gas in a contaminated refrigerant bottle to be reclaimed
later.
• To remove a leak test charge from the refrigeration sys-
tem. Because this refrigerant gas will contain some air,
place it in a contaminated refrigerant bottle to be
reclaimed later.
NOTE: Always refer to specific recovery equipment

Operator and Service Manuals.
Vapor Recovery
1. Disconnect unit from 3-phase power supply.
2. Install piercing type service access valves on the process
tubes located on the discharge and suction lines in the
compressor compartment. Attach service lines to the ser-
vice access valves and recovery machine and properly
purge the lines.
3. Set the recovery machine for vapor recovery.
NOTE: CSR Hermetic units do not have service

valves or fittings installed in the refrigeration
system. Therefore, only vapor recovery of the
refrigerant charge is possible.
4. Turn ON the recovery machine and open (back seat) both

service access valves.
5. Continue to operate the recovery machine until unit pres-
sures drop to 0 kPa, 0 bar, 0 psig pressure.
Typical Pressurized Gas Bottle with Pressure
Regulator and Gauges
1. Line Pressure
2. Tank Pressure
3. Tank
4. Pressure Test Line to System
5. Safety Valve
6. Pressure Regulator

Refrigeration System Diagnosis and Service Evacuation and Cleanup of System 6-11
Compressor Oil Color Code

Evacuation and Cleanup of the BLACK OIL — indicates carbonization caused by air in the
Refrigeration System system.
BROWN OIL — indicates copper plating caused by moisture
in the system.
Contamination
GRAY OR METALLIC OIL — indicates bearing wear or pis-
Whenever contaminants have entered the system, a thorough
ton scoring.
clean up is required to prevent damage or loss of compressor.
It is well known by the refrigeration service industry that
NOTE: If the compressor oil is discolored, perform a
the purpose of evacuation is to remove moisture and air from
compressor oil acid test (oil test kit P/N 203-457). If
the refrigeration system before charging with new refrigerant
the compressor oil shows an acid condition, change
after a system has been opened. The importance of thorough
the oil, the in-line oil filter, the filter drier and perform
evacuation and system preparation cannot be over emphasized.
a refrigeration system cleanup.
Even infinitesimal quantities of air or moisture in a system can
cause severe problems.
We know that the presence of moisture, oxygen, and heat Unit Preparation and Hookup
under certain conditions can result in many forms of damage.
Corrosion, sludge, copper plating, oil breakdown, carbon for- CAUTION: Do not attempt to evacuate a unit until it
mation, and eventual compressor failure can be caused by is certain that the unit is leak free. A unit with less
these contaminants. than a full charge of refrigerant should be thoroughly
Things that will contaminate a system are (in order of leak tested. Any leaks found must be repaired.
importance):
• AIR — with oxygen as a contaminant. 1. Recover all refrigerants from the unit and reduce the unit
Oxygen in the air reacts with the oil. The oil begins to pressure to the proper level (US Federal Law requires a
break down and can eventually lead to carbonization in -17 to -34 kPa, -0.17 to -0.34 bar, 5 to 10 in.vacuum that
the compressor and acid buildup. The longer this break- is dependent upon the recovery equipment used).
down process goes on, the darker the compressor oil 2. Break vacuum with refrigerant and equalize system pres-
becomes until finally the color is BLACK indicating sure to 0 kPa, 0 bar, 0 psig. Replace the liquid line filter
major system contamination. drier if necessary.
• MOISTURE. Moisture in a system will cause metal cor-
rosion and metal plating. It can freeze in the expansion NOTE: Hermetic units feature a large, one-piece
valve and cause intermittent operational problems. It filter drier/in-line filter. The filter drier should not
reacts in the oil to begin acid buildup. require replacement unless major system conta-
• DIRT, DUST, METAL PARTICLES, OTHER FOREIGN mination requires evacuation and cleanup of the
MATERIALS. Particles of any kind left to float through refrigeration system.
the system will cause severe damage to all close tolerance
items. Do not leave a system open to the infiltration of 3. Confirm that the Evacuation Station functions properly
dirt. If you must open a system for any reason, seal off and determine “Blank Off” Pressure. The Blank Off
the open areas as soon as possible and DO NOT work in a Pressure of the Vacuum Pump is the deepest vacuum that
dirty environment. the vacuum pump can attain when isolated from the rest of
• ACID. Air and moisture cause a chemical breakdown of the system.
the oil and/or the refrigerant itself. The acid will acceler- If a vacuum pump (isolated from a system) is started
ate the deterioration of the softer metals (i.e., copper) and and the Micron Meter responds quickly by going to a deep
cause metal plating as the softer material begins to cover vacuum, the operator can be confident that the pump and
the inside of the system. If this condition is not stopped, it oil are in good condition. If the vacuum pump fails to
can result in the total destruction of your equipment. reach a deep vacuum within 5 minutes, the operator should
suspect the condition of the oil or the pump. Thermo King
recommends that the pump oil be changed first to see if the
rate of reaching a deep vacuum is improved.

6-12 Evacuation and Cleanup of System Refrigeration System Diagnosis and Service
Evacuation Station and Unit Hook-up

1. Special, self-sealing quick disconnect couplers are required for R-404A units.
2. Gas Ballast Valve
3. Iso Valve
4. Two-stage Vacuum Pump
5. To 220/190 VAC Power
6. Calibration Standard
7. Micron Meter
8. Sensor

Refrigeration System Diagnosis and Service Evacuation and Cleanup of System 6-13
4. Connect the Evacuation Station and refrigerant tank with 2. If the vacuum level appears to stall above 500 microns,
gauge manifold (optional) to the unit as indicated on the back seat the discharge service access valve and observe
diagram on page 6-12. Connect evacuation hoses to the the Micron Meter.
service access valves on the suction and discharge line • A drop in pressure indicates that the compressor oil is
process tubes. out-gassing and further evacuation is necessary.
5. Open Evacuation Station valves (V1, V3, and V4). Open • An increase in pressure indicates that a leak exists or
valve V2 only when a reading on the Micron Meter is there is moisture in the system. Perform a “Pressure
desired. This is especially true when starting to evacuate Rise Test” and evaluate.
a unit and large amounts of moisture and oil will be pass- 3. Close valve V1 when the desired vacuum level has been
ing by the sensor. reached.
6. Open the vacuum pump Iso-Valve™ built into the pump 4. Wait five minutes and read the Micron Meter.
housing below the handle. Keep the valve be kept open at • A system that is leak free and dry will remain below
all times. 2000 microns for five minutes.
7. If connecting a refrigerant tank and gauge manifold to the • A system that rises above 2000 microns but stabilizes
evacuation station, close the gauge manifold and refriger- below atmospheric pressure is probably contaminated
ant tank valves to prevent refrigerant from being drawn with moisture or has refrigerant out-gassing from the
from the tank. compressor oil. Additional evacuation is required.
• A system that continues to rise without stabilizing has
Unit Evacuation a leak and must be repaired.
1. Turn on the Vacuum Pump. Open the Gas Ballast Valve 5. If the vacuum level remained below 2000 microns for five
located on top of the pump housing behind the handle (the minutes, the unit is ready to charge.
valve is fully open at two turns counterclockwise).
Evacuate the system to 500 microns to achieve a final Pressure Rise Test
equilibrium pressure of 2000 microns or less. The final Evacuate the system and close valve V1. With valves V3 and
equilibrium pressure is determined with the Thermo King V4 open, the pump is isolated and the system is held under a
Evacuation Station using the following procedure (called vacuum. If the Micron Meter rises, one of the following con-
a pressure-rise test): ditions exist.
a. Evacuate the system using the Evacuation Station • Leak: Watch the movement of the Micron Meter
until the vacuum level reaches 1000 microns. Then needle. If the needle continues to rise until it reaches
close the Gas Ballast Valve, atmospheric pressure, it is an indication that a leak
b. Continue evacuation to 500 microns or until vacuum exists somewhere in the system. When a leak is in a
stabilizes at its lowest level. Contamination may system, the vacuum will eventually stabilize at atmos-
delay reaching the lowest level for a period of several pheric pressure (see graph, “Constant Pressure Rise
or more hours. After Evacuation Indicates System Leak”, on page 6-
c. Close valve V1 to isolate the vacuum pump from the 14).
system. • Moisture: When the needle indicates a rise and then
d. Observe the vacuum level on the Micron Meter. stabilizes at a level below atmospheric pressure, it is
an indication that the system is vacuum tight, but is
When the Meter has stabilized, the value indicated on still wet and requires additional dehydration and
the Micron Meter is the equilibrium pressure. This read- pumping time (see graph, “Pressure Rise Levels Off
ing must be 2000 microns or less. After Evacuation Indicates Moisture in System”, on
page 6-14).
NOTE: The presence of refrigerant in the com-
pressor oil may prevent a low vacuum reading
from being achieved. Compressor oil can con-
tinue to outgas for long periods of time.

6-14 Evacuation and Cleanup of System Refrigeration System Diagnosis and Service
Factors Affecting the Speed of System Evacuation Heat Saves Time

It is almost impossible to state the exact amount of time A useful and practical time saver is the application of heat to
required to evacuate any system. Some factors that can influ- the system. Increasing the temperature of the compressor oil
ence evacuation time are listed below. and refrigerant will speed up the vaporization of any water
• System size present in the system.
• Amount of moisture contained in the system
• Ambient temperature WARNING: Never use a torch or other concentrated
• Internal restrictions within the system heat source to heat the compressor or other refriger-
• External restrictions between the system and the vacuum ation system component.
pump
Heat lamps, electric heaters, or fans can be applied to the
Hose size, both diameter and length, affect evacuation compressor crankcase and other parts of the system to increase
times. Laboratory tests show that the evacuation time can be the temperature of the refrigerant and compressor oil.
significantly reduced by larger diameter hoses and shorter
hoses. To obtain optimum pumping speed, keep hoses as short
as possible and as large in diameter as possible. For example,
it takes eight times as long to pull a given vacuum through a 6
mm (0.25 in.) diameter hose as it does through a 13 mm (0.5
in.) diameter hose. It takes twice as long to pull a vacuum
through a 2 meter (6 ft) long hose as it does through a 1 meter
(3 ft) long hose.
Constant Pressure Rise After Evacuation Indicates Pressure Rise Levels Off After Evacuation Indicates
System Leak Moisture in System
1. Close the vacuum valve and watch the movement of 1. Close the vacuum valve and watch the movement of
vacuum gauge needle. If needle continues to rise, vacuum gauge needle. If needle shows a pressure
this is an indication that a leak exists in the unit or rise but finally levels off to a constant pressure, the
connecting line. The leak must then be located and system still contains too much moisture.
eliminated. Dehydration and additional evacuation time are
2. Time required.
3. Pressure (Vacuum) 2. Time
4. Atmospheric Pressure 3. Pressure (Vacuum)
4. Atmospheric Pressure

Refrigeration System Diagnosis and Service Charging the System with Refrigerant 6-15
Charging the System with Refrigerant Compressor Replacement
Unit Charging by Weight (from an Evacuated Removal

Condition) 1. Remove the compressor compartment bracket.
1. Close valve V4. 2. Recover the refrigerant charge from the unit (see
2. Open the Gas Ballast valve (located on top of the pump “Refrigerant Recovery” in this chapter).
housing behind the handle). 3. Disconnect the unit from the three-phase power supply.
3. Stop the vacuum pump. 4. Remove the three-phase electric power connection from
4. The discharge valve and receiver outlet valves remain the compressor.
mid-seated. 5. Unsolder the discharge line, suction line and liquid injec-
5. Connect the refrigerant tank with gauge manifold to the tion line from the compressor.
evacuation station (see “Evacuation Station and Unit 6. Remove the compressor mounting tray bolts and nuts.
Hookup” on page 6-12). 7. Slide the compressor from the unit.
6. Weigh the tank of refrigerant. 8. Keep the compressor ports covered to prevent dust, dirt,
7. Check unit data plate for the required weight of refrigerant etc., from falling into the compressor.
charge. Then subtract the unit charge weight from the 9. Drain and measure the compressor oil that remains in the
total weight of the refrigerant tank. This provides the compressor.
final tank weight after the unit receives a full refrigerant
charge. NOTE: The compressor oil must be removed
8. Set the refrigerant tank for liquid removal. Open the hand from the compressor and measured so that the
valve on the tank. same amount of oil can be added before placing
9. With the unit OFF, open the gauge manifold hand valve the new compressor or repaired compressor in
and charge liquid refrigerant into the system. the unit.
10. Close the refrigerant tank hand valve when the correct
amount (by weight) of refrigerant has been added or if the
system will take no more liquid. Installation
The unit is now ready to have the Evacuation Station 1. Add new compressor oil to the new compressor. Add an
removed. amount equal to the amount removed from the old com-
pressor.
Evacuation Station Removal
1. Close the high pressure hand valve on the gauge manifold. CAUTION: Use ONLY Polyol Ester based refrig-
2. Close the refrigerant tank hand valve. eration compressor oil, P/N 203-433. Keep
3. Open the hand valve at the gauge manifold and read suc- Polyol Ester based compressor oil in tightly
tion pressure. sealed containers. If Ester based oil becomes
4. Operate the unit in cool mode until the suction pressure contaminated with moisture or standard oils, dis-
decreases below 385 kPa, 3.85 bar, 50 psig. pose of properly — DO NOT USE!
5. Back seat the suction line access service valve.
6. Stop the unit. 2. Clean the tubes for soldering.
7. Remove the hoses from the suction and and discharge line 3. Slide the compressor into the unit. Install mounting bolts,
access service valves. washers and nuts, and tighten.
8. Seal and solder the suction and discharge line process 4. Solder the discharge line, suction line and liquid injection
tubes to remove piercing type access service valves from line to the compressor.
unit (see “Installing and Removing Piercing Type Service
Valves and a Gauge Manifold Set” in this chapter). NOTE: Thermo King strongly recommends that
9. Leak check the process tubes with an electronic leak dry nitrogen be used to purge the system during
detector. any solder operations (see “Using Pressurized
10. Start the unit and perform a controller Pretrip Test to veri- Nitrogen” in this chapter).
fy correct refrigerant charge and unit operation.

6-16 Discharge Temperature Sensor Replacement Refrigeration System Diagnosis and Service
5. Pressurize the refrigeration system and check for leaks 5. Remove sensor assembly from compressor.
(see “Refrigerant Leak Test Procedure” in this chapter). 6. Remove all RTV sealant from the compressor body.
6. If no leaks are found, recover the refrigerant used for the
leak test (see “Refrigerant Recovery” in this chapter). Installation
7. Evacuate the system (see “Evacuation and Cleanup of the 1. Apply a heat conducting grease, P/N 203-454, on the
Refrigeration System” in this chapter). sensing element.
8. Connect three-phase electric power to the compressor. 2. Apply a 6 mm (0.25 in.) bead of black RTV silicone
9. Recharge the unit with R-404A (see “Refrigerant Charge” in around the underside of the sensor cap (see sensor illustra-
this chapter). Then perform a controller Pretrip Test to tion below).
verify system operation. 3. Insert sensor into compressor body.
4. Apply another bead of black RTV sealant around the outer
edge of the sensor cap. Smooth and spread the sealant
bead evenly around the edge of the sensor cap with a
Compressor Discharge Temperature Sensor damp cloth.
Replacement 5. Route sensor wires into control box. Connect new sensor
leads (2-pin, white molded connector).
Removal CAUTION: Do NOT splice or damage sensor

1. Disconnect the unit from the three-phase power supply. leads or compressor damage will occur.
2. Open control box door. Disconnect 2-pin, white molded
connector of temperature sensor leads.
3. Remove sensor wires from main harness and control box.
4. Use a razor knife to cut the black RTV sealant between
the compressor body and molded sensor cap.
Preparing Compressor Discharge Temperature

Sensor for Installation
1. Sensor Cap
2. O-ring
3. Apply heat conductive grease on this area of sensor
4. Apply a 6 mm (0.25 in.) bead of RTV silicone around
top of the sensor before inserting sensor into com-
pressor pocket.
5. Route sensor leads into control box.
Removing Compressor Discharge Temperature
Sensor
CAUTION: Do NOT splice or damage sensor
1. Loosen sensor cap from compressor body by cutting leads or compressor damage will occur.
through RTV sealant with razor knife. Cut complete-
ly around the cap.

Refrigeration System Diagnosis and Service Stepper Motor Valve Replacement 6-17
Stepper Motor Valve Replacement Condenser Coil Replacement

The stepper motor valve is used to control the flow of refriger-
ant to the compressor when the unit is operating in the Removal
Modulation mode. As the supply air temperature approaches 1. Recover the refrigerant charge from the unit (see
setpoint, the controller sends an electrical signal to the stepper “Refrigerant Recovery” in this chapter).
motor to close the valve a precise amount. This throttles the 2. Remove the condenser fan grille, condenser fan blade and
suction gas returning to the compressor and reduces cooling condenser fan shroud.
capacity. 3. Remove the condenser coil support brackets from the coil.
Service of the stepper motor valve includes replacement 4. Unsolder the liquid inlet and outlet connections.
of the complete valve. 5. Support the coil and unbolt the condenser coil mounting
refrigerant Leak Test Procedure” in this chapter). brackets. Slide the coil from the unit.
6. Drain and measure any compressor oil that may be
Replacement trapped in the condenser coil.
1. Remove the compressor compartment bracket.
2. Recover the refrigerant charge from the unit (see Installation
“Refrigerant Recovery” in this chapter). 1. If compressor oil was drained from the condenser coil,
3. Disconnect the unit from the three-phase power supply. add a equal amount of new compressor oil to the new coil.
4. Unplug the motor wire harness.
5. Unsolder the compressor side stepper motor valve joints CAUTION: Use ONLY Polyol Ester based refrig-
from the suction line. Unsolder and remove modulation eration compressor oil, P/N 203-433. Keep
valve. Polyol Ester based compressor oil in tightly
6. Clean the tubes for soldering. Position the new valve in sealed containers. If Ester based oil becomes
position in the suction line. contaminated with moisture or standard oils, dis-
7. Solder both valve connections. pose of properly — DO NOT USE!
CAUTION: Use a heat sink or wrap the valve with 2. Clean the tubes for soldering.
wet rags to prevent damage to the new valve. 3. Slide the coil into the unit and install the bolts in the
mounting brackets.
8. Pressurize the refrigeration system and check for leaks 4. Solder the inlet line and liquid line connections.
(see “Refrigerant Leak Test Procedure” in this chapter).
9. If no leaks are found, recover the refrigerant used for the NOTE: Thermo King strongly recommends that
leak test (see “Refrigerant Recovery” in this chapter). dry nitrogen be used to purge the system during
10. Evacuate the system (see “Evacuation and Cleanup of the any solder operations (see “Using Pressurized
Refrigeration System” in this chapter). Nitrogen” in this chapter).
11. Plug the motor wire harness into the unit wire harness.
12. Recharge the unit with R-404A (see “Charging the System 5. Pressurize the refrigeration system and check for leaks
with Refrigerant” in this chapter). (see “Refrigerant Leak Test Procedure” in this chapter).
13. Perform a controller Pretrip Test to verify system opera- 6. If no leaks are found, recover the refrigerant used for the
tion. leak test (see “Refrigerant Recovery” in this chapter).
7. Evacuate the system (see “Evacuation and Cleanup of the
Refrigeration System” in this chapter).
8. Replace the condenser coil support brackets, condenser
fan shroud and condenser fan grille.
9. Recharge the unit with R-404A (see “Refrigerant Charge” in
this chapter). Then perform a controller Pretrip Test to
verify system operation.

6-18 Filter Drier/In-line Filter Replacement Refrigeration System Diagnosis and Service
Filter Drier/In-line Filter Replacement Expansion Valve Replacement
NOTE: CSR Hermetic units use a one-piece, combi- NOTE: CSR hermetic units use a non-adjustable,
nation filter drier/in-line filter, P/N 66-9306. factory sealed expansion valve. Do NOT attempt to
remove the seal or adjust the valve.
Removal
1. Recover the refrigerant charge from the unit (see Removal
“Refrigerant Recovery” in this chapter). 1. Recover the refrigerant charge from the unit (see
2. Unsolder the filter drier inlet and outlet connections. “Refrigerant Recovery” in this chapter).
3. Remove the filter bracket clamping nuts and bolts. 2. Remove insulating tape and unclamp feeler bulb from the
4. Remove the old filter drier from the unit. suction line in the condenser section. Note the position of
the feeler bulb on the side of the suction line.
Installation 3. Remove insulating tape from expansion valve outlet line.
1. Clean the liquid line tubes for soldering. 4. Heat and unsolder the equalizer line from expansion
2. Remove the sealing caps from the new filter drier/in-line valve.
filter. 5. Heat and unsolder the liquid line inlet and outlet connec-
3. Place new filter drier in position. tions to expansion valve in condenser section.
6. Remove expansion valve from unit.
NOTE: To prevent incorrect installation of the
dehydrator (or in-line filter), the inlet and outlet Installation
fittings are different sizes. 1. Clean the liquid lines and equalizer lines for soldering.
2. Place new expansion valve in position in liquid line.
4. Solder inlet and outlet connections. 3. Solder liquid line inlet and outlet line connections to
5. Reinstall clamping brackets, nut and bolts. Tighten the bolts. valve.
6. Pressurize the refrigeration system and check for leaks
(see “Refrigerant Leak Test Procedure” in this chapter). NOTE: Thermo King strongly recommends that
7. If no leaks are found, recover the refrigerant used for the dry nitrogen be used to purge the system during
leak test (see “Refrigerant Recovery” in this chapter). any solder operations (see “Using Pressurized
8. Evacuate the system (see “Evacuation and Cleanup of the Nitrogen” in this chapter).
9. Recharge the unit with R-404A (see “Refrigerant Charge” in 4. Solder equalizer line to expansion valve.
this chapter). Then perform a controller Pretrip Test to 5. Pressurize the refrigeration system and check for leaks
verify system operation. (see “Refrigerant Leak Test Procedure” in this chapter).
6. If no leaks are found, recover the refrigerant used for the
leak test (see “Refrigerant Recovery” in this chapter).
7. Evacuate the system (see “Evacuation and Cleanup of the
8. Clean the suction line to a bright polished condition.
Install the feeler bulb of new power head in the feeler bulb
clamp on the suction line. Locate bulb on the suction line
in former position. The feeler bulb must make good con-
tact with the suction line or operation will be faulty.
Cover with insulating tape.
9. Cover expansion valve outlet line with insulating tape.
verify system operation and correct feeler bulb installa-
tion.

Refrigeration System Diagnosis and Service Heat Exchanger Replacement 6-19
Heat Exchanger Replacement Receiver Tank Replacement
Removal Removal
1. Recover the refrigerant charge from the unit (see 1. Recover the refrigerant charge from the unit (see
“Refrigerant Recovery” in this chapter). “Refrigerant Recovery” in this chapter).
2. Remove the “U” mounting clamps that hold the heat 2. Unsolder the liquid inlet, liquid outlet and warm gas
exchanger assembly to the wall of the condenser section. bypass valve line connections.
3. Unsolder the liquid inlet and outlet line connections. 3. Loosen the mounting nuts and remove the tank.
4. Note position of feeler bulb on the side of the suction line. 4. Remove the water fittings (option) and water pressure
Un-tape and remove the feeler bulb from the suction line. switch (option) from the receiver tank for installation in
5. Unsolder the suction inlet and outlet line connections. new tank.
6. Lift the heat exchanger assembly from the unit.
Installation
Installation 1. Install a new tank in the unit and tighten the mounting
1. Clean the tubes for soldering. bolts.
2. Place the heat exchanger assembly in the unit and install 2. Solder the inlet line, outlet line and warm gas bypass line
the mounting hardware. connections.
3. Solder the suction inlet and outlet line connections.
NOTE: Thermo King strongly recommends that
NOTE: Thermo King strongly recommends that dry nitrogen be used to purge the system during
dry nitrogen be used to purge the system during any solder operations (see “Using Pressurized
any solder operations (see “Using Pressurized Nitrogen” in this chapter).
Nitrogen” in this chapter).
3. Pressurize the refrigeration system and check for leaks
4. Solder the liquid inlet and outlet line connections. (see “Refrigerant Leak Test Procedure” in this chapter).
5. Pressurize the refrigeration system and check for leaks 4. If no leaks are found, recover the refrigerant used for the
(see “Refrigerant Leak Test Procedure” in this chapter). leak test (see “Refrigerant Recovery” in this chapter).
6. If no leaks are found, recover the refrigerant used for the 5. Evacuate the system (see “Evacuation and Cleanup of the
leak test (see “Refrigerant Recovery” in this chapter). Refrigeration System” in this chapter).
7. Evacuate the system (see “Evacuation and Cleanup of the 6. Recharge the unit with R-404A (see “Refrigerant Charge” in
Refrigeration System” in this chapter). this chapter). Then perform a controller Pretrip Test to
8. Clean suction line to a bright polished condition. Install verify system operation.
feeler bulb in the feeler bulb clamps on the suction line.
Locate bulb on the suction line in former position. The
feeler bulb must make good contact with the suction line
or operation will be faulty. Cover with insulating tape.
verify system operation and correct feeler bulb installa-
tion.

6-20 Low or High Pressure Cutout Switch Replacement Refrigeration System Diagnosis and Service
Low or High Pressure Cutout Switch Warm Gas Bypass Solenoid Valve, Liquid
Replacement Injection Valve or Dehumidify Valve (Option)
Replacement
Removal
1. Recover the refrigerant charge from the unit (see NOTE: In most cases, only the coil requires replace-
“Refrigerant Recovery” in this chapter). ment. No other repair is possible on solenoid
2. Turn the unit On-Off switch OFF. Disconnect electrical valves.
connections to the switch.
3. Unsolder the switch: Removal
• High pressure cutout switch: Unsolder from the liquid 1. Recover the refrigerant charge from the unit (see
line. “Refrigerant Recovery” in this chapter).
• Low pressure cutout switch: Unsolder from the suction 2. Turn the unit On-Off switch OFF. Disconnect electrical
line. connections to valve coil.
3. Dehumidify valve: Remove insulating tape from liquid
Installation line.
1. Clean the tube for soldering. 4. Unsolder the liquid line connections to the valve.
2. Place the new switch in position and solder the connec- 5. Remove the valve from the unit.
tion.
Installation
CAUTION: Use a heat sink or wrap the switch 1. Clean the tubes for soldering.
with wet rags to prevent damage to the new 2. Place the new valve in position and solder the liquid line
switch. connections.
3. Check for refrigerant leaks (see “Refrigerant Leak Test CAUTION: Use a heat sink or wrap the valve with
Procedure” in this chapter). wet rags to prevent damage to the new valve.
• High pressure cutout switch: Pressurize the high side
with refrigerant and check for leaks. 3. Pressurize the low side with refrigerant and check for leaks
• Low pressure cutout switch: Pressurize the low side (see “Refrigerant Leak Test Procedure” in this chapter).
with refrigerant and check for leaks. 4. If no leaks are found, recover the refrigerant used for the
4. If no leaks are found, recover the refrigerant used for the leak test (see “Refrigerant Recovery” in this chapter).
leak test (see “Refrigerant Recovery” in this chapter). 5. Evacuate the system (see “Evacuation and Cleanup of the
5. Evacuate the system (see “Evacuation and Cleanup of the Refrigeration System” in this chapter).
Refrigeration System” in this chapter). 6. Reconnect the electrical wires to the valve.
6. Reconnect the electrical wires to the switch. 7. Recharge the unit with R-404A (see “Refrigerant Charge” in
7. Recharge the unit with R-404A (see “Refrigerant Charge” in this chapter). Then perform a controller Pretrip Test to
this chapter). verify system operation.
8. Perform a controller Pretrip Test to verify system opera-
tion.

7 Structural/Accessory
Maintenance
Mounting Bolts Condenser Coil

Check and tighten all unit, compressor, and fan motor mount- Clean the condenser coil by blowing low pressure compressed
ing bolts during pretrip inspections and every 1,000 operating air or a medium pressure warm water spray from the inside of
hours. Unit mounting bolts should be tightened to a torque the coil outward (opposite direction of normal airflow). Inspect
value of 204 N.m (150 ft-lb). Compressor and fan motor coil and fins for damage and repair if necessary.
mounting bolts should be tightened to a torque value of 20 to
21 N.m (15 to 20 ft-lb). CAUTION: Air pressure or water spray must not be
high enough to damage coil fins.
If a build up of salt or debris is present on the condenser

Unit Inspection coil, the coil should be cleaned using a mild alkaline cleaner
with a pH of 9.5 to 10.5. For example, a 2-3% solution of
Inspect the unit during unit pretrip inspection and every 1,000 SIMPLE GREEN® would make a suitable cleaning solution.
operating hours for loose or broken wires or hardware, com- Apply the solution using a pressure spray/wash type apparatus.
pressor oil leaks, or other physical damage which can affect Spray the condenser coil thoroughly from both the inside and
unit performance and require repair or replacement of parts. outside of the coil. Always thoroughly rinse the coil with a
fresh water spray.
Also inspect the directional airflow condenser grille for
damage. This grille directs the condenser airflow out and
away from the unit to increase the efficiency of the condenser
coil by preventing the recirculation (short cycling) of warm air
through the coil. Abnormally high head pressures may result
1 if this special condenser grille is damaged or missing.
Evaporator Coil
Clean the evaporator coil by blowing low pressure compressed
air from the bottom side of the coil upward (opposite direction
of normal airflow). Inspect coil and fins for damage and repair
if necessary.
2
CAUTION: Air pressure must not be high enough to
damage coil fins.
Mounting Bolts
1. Tighten Unit Mounting Bolts
2. Tighten Compressor, Condenser Fan and
Evaporator Fan Mounting Bolts

7-2 Defrost Drains Structural/Accessory Maintenance
Handle Adjustment: High Ventilation Rates

Defrost Drains 1. Loosen wing nut on handle assembly until handle bracket
Clean the defrost drains every 1,000 operating hours to be sure will rotate over handle.
the lines remain open. 2. Align handle bracket and wing nut over hole in handle
assembly and push through handle.
3. Pull handle down to lower ventilation door. Insert edge of
ventilation door in a notch on handle. Spring loaded han-
dle holds ventilation door in position. Air exchange rate
Fresh Air Exchange System is shown on the handle scale:
The fresh air exchange system has an adjustable vent door for - CSR40and CSR40SL Models: 150 to 280 m3/hr (90 to
ventilation. The evaporator fans draw in outside air through an 165 ft3/min.)
air intake and discharge an equal amount of container air
through an air outlet.
NOTE: Set the disk or door position to the ventila-

tion rate indicated on the shipping manifest. Condenser Fan Location
Disk Adjustment: Low Ventilation Rates Place fan blade on motor shaft with hub located on the outside
1. Loosen wing nut on handle assembly. of the blade for proper airflow direction. When mounting the
2. Rotate the disk to set the Indicator at the air exchange rate fan blade and hub assembly on the fanshaft, center the assem-
shown on the ventilation scale on the door: bly in the orifice. Position the front of the fan blade 10 mm
- CSR40 and CSR40SL Models: 0 to 125 m3/hr (0 and 75 (0.4 in.) in from the outer edge of the fan orifice.
ft3/min.)
3. Tighten the wing nut.
1 2 3 4
Air Exchange System

1. Disk Scale: Low Ventilation Rates
2. Disk Assembly with Rate Indicator
3. CO2 Port
4. Ventilation Door
5. Handle Assembly with Scale: High Ventilation Rates
6. Handle Bracket Condenser Fan Blade Placement
7. Wing Nut
1. Airflow Direction
2. 10 mm (0.4 in.)
3. Condenser Coil
4. Condenser Fan Blade
5. Condenser Motor

Structural/Accessory Maintenance Evaporator Fan Location 7-3
The evaporator drain hoses are routed to the water tank

Evaporator Fan Location to replenish the water level during unit operation. However,
water usage will vary depending upon the load and ambient
Place fan blade on motor shaft with hub located on the outside
conditions. An overflow hose on the water tank removes
of the blade for proper airflow direction. When mounting the
excess water when particularly wet loads are transported or
fan blade and hub assembly on the fanshaft, center the assem-
when the humidify system is not operating.
bly in the orifice. Position the front (top) of the fan blade hub
13 mm (0.5 in.) in from the outer edge of the fan orifice.
NOTE: Only demineralized or distilled water should
be used to prevent plugging of the atomizing nozzle.

The Humidify Mode increases the humidity level in the con-
tainer by injecting atomized water directly into the evaporator
supply air stream. The use of the Humidify Mode should be
established by the shipper. The Humidify Mode option is
turned on from the CONTROL line in the Setpoint menu of
the controller. See “Changing the Humidity Mode Setting”
under “Setpoint Menu” on page 4-15 to set the Humidify sys-
tem to ON. The HUMIDITY LED turns ON when the
Humidify Mode is set to ON.
The controller energizes (operates) the air compressor
when the humidity level in the container is more than 2%
below the humidity setpoint. The air compressor atomizes and
injects water into the evaporator supply air stream to add mois-
ture to the container air.

1. Water Supply Hose and Atomizing Nozzle: Inspect
every 1,000 hours and clean if necessary.
2. Filter: Inspect every 1,000 hours and clean if neces-
sary.
3. Air Compressor: Inspect once a year.
4. Water Tank:
• Pretrip Inspection: Check the water level.
• Every 1,000 Hours: Inspect the water tank and
clean if necessary.
5. Water Tank Heater: Check for correct operation in
ambient temperatures below 4 C (40 F).
Evaporator Fan Blade Placement
6. Drain Cock
1. Evaporator Fan Blade
2. Airflow Direction
3. Evaporator Coil
4. Evaporator Motor
5. 13 mm (0.5 in.)

7-4 Humidify System Structural/Accessory Maintenance
Pretrip Inspection Inspection and Cleaning

The following items should be inspected before loading the The following items should be periodically serviced:
container: • Clean and inspect the filter in the water supply hose on the
• Check the water level in the water tank to maintain an water tank every 1,000 operating hours. Clean the filter
adequate water supply. screen with fresh water and a soft brush.
• Check humidify system operation by starting the unit, set- • Inspect the water tank, water supply line and atomizing
ting the Humidify mode to ON and adjusting the humidify nozzle every 1,000 hours and clean if necessary. Use
setpoint (HUMSP) more than 2% above the current fresh water, a soft brush and compressed air to clean and
humidity level in the container. Verify that the air com- blow clear components.
pressor operates and that water is drawn into the atomiz- • Inspect the air compressor for signs of overheating once a
ing nozzle and injected into the return air stream. year.

8 Mechanical Diagnosis
Mechanical Diagnosis
Condition Possible Cause Remedy
Compressor does not Controller ON; unit start Wait up to 2 minutes for compressor
operate — no amperage sequence still timing start-up
draw
No power to unit (condenser and Locate fault and repair: power source,
evaporator fans do not operate) power plug, main circuit breaker, motor
contactor, motor terminals, motor
Open in 29 Vac Check fuses and On/Off switch. Replace or

control circuit repair as required
Container temperature does not Adjust controller setpoint

demand compressor operation
Compressor contactor inoperative Replace compressor contactor
No output signal from controller Diagnose and replace main relay board or
controller
Unit on defrost Turn unit On/Off switch OFF and then ON

again
Defective high or low pressure Replace defective switch

cutout switch
High condenser head pressure Check refrigeration system and correct

causing high pressure cutout fault
Defective compressor Replace compressor
Controller shut unit down on Let compressor cool and controller will
Compressor Over Temperature reset automatically. Check liquid injection
(fault code 56) valve and compressor temperature sensor
Compressor motor internal thermal If compressor contactor is energized, wait

overload protection open 60 minutes for protector to cool and reset

8-2 Mechanical Diagnosis
Compressor does not Rotating scroll stuck Replace compressor

operate; excessive
amperage draw or Seized or frozen compressor bearings Replace compressor
intermittent cycling
on overload Improperly wired Check/correct wiring against wiring diagram
Low line voltage Check line voltage — determine location of

voltage drop
Contacts in compressor contactor not Check by operating manually. Repair or

closing completely replace
Open circuit in compressor motor Check motor stator connections. Check

winding stator winding for continuity. If open,
replace compressor
Defective compressor motor internal Replace thermal overload protector or

thermal overload protector compressor
Refrigerant overcharge or high Check for restricted filter drier, in-line filter
side restriction causing cycling or high side; or refrigerant overcharge
on high pressure cutout
Inefficient condenser operation Check condenser airflow, condenser

causing cycling on high pressure fan motor, fan blade, condenser grille and
cutout condenser coil temperature sensor
Compressor contactor Low line voltage Increase line voltage to at least 90% of
burned out compressor motor rating
Excessive line voltage Reduce line voltage to at least 110% of

compressor motor rating
Short cycling Eliminate cause of short cycling
Unit short cycles Refrigerant overcharge causing Purge system

cycling on high pressure cutout
Inefficient condenser operation Check condenser airflow, condenser

causing cycling on high pressure fan motor, fan blade, condenser grille and
cutout condenser coil temperature sensor

Mechanical Diagnosis 8-3
Noisy compressor Loose mounting bolts Tighten mounting bolts
Oil slugging or refrigerant flooding Perform controller Pretrip Test to check

back refrigerant charge. Check expansion valve
adjustment. Check compressor for
compressor oil.
Scroll rotating backwards Check phase correction system and check

unit wiring
Defective compressor Repair or replace compressor
Condenser fan motor does Unit in Heat or Defrost Check indicator lights. If unit is in
not operate Heat or Defrost, unit operation is
normal (no remedy required)
Unit in Cool with Low condenser Check indicator lights, condenser

temperature temperature and discharge pressure.
Condenser temperature may not require
condenser fan operation (no remedy
required; condenser fan also pulses On and
Off on a 30 second cycle to control con-
denser temperature)
Loose line connection Tighten connections
Open motor internal thermal Check for seized bearings or defective

overload protector thermal overload protector. Repair or
replace as necessary
Defective motor Replace motor
Defective condenser fan contactor Replace defective contactor
No condenser fan output Diagnose and replace condenser fan relay,

signal from controller main relay board, or controller

8-4 Mechanical Diagnosis
Evaporator fan motor(s) Unit on defrost Check operating mode indicator LEDs
does not operate
Unit in Economy Mode (Frozen Load; Check setpoint, indicator lights and
Null mode ONLY) Setpoint menu of the controller to verify that
Economy Mode is set to ON
Loose line connection Tighten connections
Open motor internal thermal Check for seized bearings or defective

overload protector thermal overload protector. Repair or
replace as necessary
Defective motor Replace motor
Defective low or high speed Replace defective contactor

evaporator fan contactor
No low or high speed evaporator Diagnose and replace evaporator fan relay,
fan output signal from controller main relay board or controller

9 Electrical, Refrigeration
and MP-3000 Menu Flow
Diagrams
Electrical, Refrigeration and MP-3000 Menu Flow

Diagrams 9-1
Controller Diagram 9-3
Wiring Schematic 9-4
Main Relay Board Terminal Connections
(Page 1 of 3) 9-5
(Page 2 of 3) 9-6
(Page 3 of 3) 9-7
Refrigeration System Components 9-8
Full Cool Flow and Pressure Diagram 9-9
Cool with Modulation Flow and Pressure Diagram 9-10
Dehumidification Flow and Pressure Diagram 9-11
MP-3000 Menu Flow Diagram 9-12

9-2 Electrical, Refrigeration and MP-3000 Menu Flow Diagrams
This page intentionally left blank.

Electrical, Refrigeration and MP-3000 Menu Flow Diagrams Controller Diagram 9-3

Electrical, Refrigeration and MP-3000 Menu Flow Diagrams Wiring Schematic 9-4

Electrical, Refrigeration and MP-3000 Menu Flow Diagrams Main Relay Board Terminal Connections (Page 1 of 3) 9-5



Electrical, Refrigeration and MP-3000 Menu Flow Diagrams Refrigeration System Components 9-8
CSR PS
Refrigeration System Components
2. Compressor Discharge Temperature Sensor
3. High Pressure Cutout Switch
4. Discharge Line Process Tube
5. Condenser Coil (Circular)
6. Receiver Tank
7. Warm Gas Bypass Valve
9. Filter Drier/In-line Filter
10. Heat Exchanger
11. Expansion Valve (TXV)
12. Distributors
13. Evaporator Coil
14. Expansion Valve Feeler Bulb
15. Equalizer Line
17. Low Pressure Cutout Switch
18. Suction Line Process Tube
19. Liquid Injection Valve with Restrictor
20. Electric Heaters
22. Evaporator Coil Sensor
23. Supply Air Sensor, Right Hand
24. Supply Air Sensor, Left Hand
25. Ambient Sensor
26. Condenser Coil Sensor
27. Controller (MP-3000)
28. Dehumidify Solenoid Valve (Option)

Electrical, Refrigeration and MP-3000 Menu Flow Diagrams Refrigeration Schematic: Full Cool 9-9
Flow and Pressure Diagram

CSR PS
Full Cool
Compressor operation has a delay on initial start-up and when
the unit shifts to a cooling mode requiring the compressor to start.
2. Compressor Discharge (Head) Temperature Sensor
Controller cycles condenser fan ON typically when the compres-
sor discharge temperature is above 50 C (122 F) and increasing.
3. High Pressure Cutout Switch (HPCO)
Is a normally CLOSED switch.
It OPENS at 3240 +/- 50 kPa, 32.4 +/- 0.5 bar, 470 +/- 7 psig.
It CLOSES at 2590 +/- 260 kPa, 25.9 +/- 2.6 bar, 375 +/- 38 psig.
OPENS at 3450 +520/-105 kPa, 34.5 +5.20/-1.05 bar, 500 +75/-15
psig.
CLOSES at 2760 kPa, 27.6 bar, 400 psig.
17. Low Pressure Cutout Switch (LPCO)
Is a normally OPEN switch.
It OPENS at +21 to -20 kPa, +0.21 to -0.20 bar, 3 psig to 6” Hg
vacuum.
It CLOSES at 48 to 90 kPa, 0.48 to 0.90 bar, 7 to 13 psig
During the DEFROST and HEAT mode, the electric heaters are
pulsed ON and OFF.
26. Condenser Coil Temperature Sensor
Controller cycles condenser fan ON typically when the con-
denser coil temperature is above 35 C (95 F).
27. Controller
MP-3000 with digital thermostat, thermometer and fault indicator
monitor.
High pressure gas
High pressure liquid
Low pressure gas
Low pressure liquid
Condensing high pressure gas
Low pressure vaporizing liquid

Liquid refrigerant injection

Electrical, Refrigeration and MP-3000 Menu Flow Diagrams Refrigeration Schematic: Cool with Modulation 9-10

CSR PS
Cool with Modulation (or Power Limit)
7. Warm Gas Bypass Valve
Is a normally CLOSED solenoid.
It OPENS when energized to reduce cooling capacity when the tem-
perature is close to setpoint.
Is a normally OPEN valve.
It CLOSES when energized. As the signal strength is increased, the
valve closes more. The controller regulates the signal to the valve
based on sensor temperatures and power limit requirements.
19. Liquid Injection Valve
Is a normally CLOSED valve.
It OPENS when energized. When liquid injection is required, the
valve is pulsed open and closed on a 60 second cycle. Liquid injec-
tion is controlled by the compressor discharge temperature and the
temperature control algorithm.
High pressure gas
Low pressure gas
Low pressure liquid

Modulated pressure
High pressure gas injection
High pressure gas injection
Electrical, Refrigeration and MP-3000 Menu Flow Diagrams Refrigeration Schematic: Dehumidification 9-11

CSR PS
Dehumidification
NOTE: At setpoints below 5 C (41F), the dehumidification is not ener-
gized.
28. Dehumidify Solenoid Valve (DSV)

Is a normally OPEN valve.
If the container humidity is 2% or more above the humidity setpoint
and the temperature is in-range, the controller will energize (CLOSE)
the normally open solenoid. This closes refrigerant distribution to
50% of the evaporator coil, thereby lowering the temperature of the
active part of the coil and condensing more moisture from the con-
tainer air.
If the container humidity is 5% or more above the humidity setpoint,
and the temperature is in-range, the controller will pulse the electric
heaters ON and OFF in addition to energizing (closing) the dehumidi-
fy solenoid valve. This increases the cooling load on the evaporator
coil, thereby lowering the temperature of the entire coil and condens-
ing more moisture from the container air.
29. Humidity Sensor (rH) (Option)
The humidity sensor is located at the top right hand side of the evap-
orator fan deck and measures the humidity of the return air from the
cargo space.
High pressure gas
Low pressure gas
Low pressure liquid


Electrical, Refrigeration and MP-3000 Menu Flow Diagrams
Standard Display
NOTE: The screens that display on the controller
are determined by the Unit Configuration setting. Keypad Operating Tips
All screens are NOT present on all units.
Text Input: Use F1, F2, F3 and F4 keys to enter text in information screens:
• To enter a number: Press the F1 key and the desired number key.
Setpoint Menu • To enter 1st letter on a key: Press the F2 key, the desired letter key.
• To enter 2nd letter on a key: Press the F3 key, the desired letter key.
— Setpoint Temperature • To enter 3rd letter on a key: Press the F4 key, the desired letter key.
Enter a Temperature or
— Economy Mode
Humidity Setpoint NOTE: When a function key (F1, F2, F3 or F4) is pressed to enter text,
— Airflow
• Press F4 key. the keypad remains on that “character level” until another function key
— Custom Airflow
• Type the new setpoint. is pressed.
— Bulb Mode
— Humidity Control
cursor stops flashing. To Enter a Controller Menu or Use Special Function Key:
— Humidity Setpoint
— AFAM Control • Press F4 key to directly enter the Data menu.
MAIN MENU Activate Humidity Control • Press F2 key to directly enter the Alarms menu.
— AFAM Delay
or Economy Mode • Press F3 key to directly enter the Main Menu.
— AFAM Rate
• Press F4 key. • Press SETPOINT key to enter Setpoint menu.
— 02 Minimum
• Press F2 key to toggle set- • Press C/F key to view alternate temperature scale in LED display.
— C02 Maximum
ting • Press SUP/RET key to view alternate sensor temperature in LED display.
between OFF and ON. • Press DEFROST key to initiate a manual defrost. Evaporator coil tempera-
• Press and hold F4 key until ture must be below 10 C (50 F).
To Enter a Submenu, a Command or a New Value in a Text Screen:
• Press F4 key.
Data Menu
To Scroll in a Menu or a Text Line:
— DATA — Supply Air Temp, RH • Press F2 key to scroll up or backward.
— Return Air Temp • Press F3 key to scroll down or forward.
— Defrost (Evap Coil) Temp
— Condenser Coil Temp To Exit a Menu or Text Line:
— Modulation • Press F1 (ESC) key.
— Ambient Temp
— Low Pressure Special Function Keys:
— High Pressure • Press C/F key to view alternate temperature scale in LED display.
— High Pressure Temp • Press DEFROST key to initiate a manual defrost. Evaporator coil tempera-
— Relative Humidity ture must be below 10 C (50 F).
Alarms Menu — Battery Voltage • Press SUP/RET key to view alternate return/supply- sensor temperature in
— ALARMS — Voltage Average LED display.
• View and write down all alarm
codes. — Voltage 1
• Press F2 key to view the next — Voltage 2 To Lock a LCD Data Screen Display:
alarm code. — Voltage 3 • Each time the “5” key is pressed, the display time of the current LCD screen
• Clear alarm code by correcting — Frequency increases by 5 minutes. Maximum display time is 30 minutes for data
problem and acknowledging — Zero Current screens and 100 minutes for manual tests. Press F1 (ESC) key to exit dis-
the alarm. — Current Phase 1 play.
• To acknowledge an alarm, — Current Phase 2
press F4 key with alarm code in — Current Phase 3
display. — O2
— CO2
— Fresh Air Exchange Rate
— Evaporator Fan Speed
— Supply Air Temp, LH
To Activate a Command
• Press F4 key to start a:
Commands Menu - Manual Defrost
— COMMANDS - Function Test
— Defrost - PTI (Pretrip) Test
— Function Test
Manual Function Test
— PTI (Pretrip) Test
Submenu
— Manual Function Test
— Power Management • First Component Test appears
Power Management Submenu in display.
• Press F2 or F3 key to scroll to
• Current Power Limit and Power to the desired component:
Time appear in display. - Condenser Fan
• Press F3 key to scroll to - Compressor
Misc. Functions Menu desired - Capacity 25%
— MISC FUNCTIONS — Date Time function. - Capacity 50%
— C/F Mode Misc. Functions Submenu • Press F4 key. - Capacity 100%
— Cargo Data - Power Limit: Press F2 or F3 - Injection Valve
• Current function setting appears key to scroll to new setting.
— Program Version - Dehumidify Valve
in display. - Power Time: Type the new
— Run Time - Evaporator High
• Press F3 key to scroll to desired time in hours. - Evaporator Low
function. • Press and hold F4 key until - Heat
• Press F4 key to change a cursor stops flashing. - Zero Current
setting.
- Sensor Checks
• Type new value; or press F3
• Press F4 key to start and stop
key to toggle value to desired
test (toggle component display
setting.
between ON and OFF).
• More than one component
can be turned ON at a time to
perform a functional test of
the unit.
Configuration Menu
— CONFIGURATION — In-Range
— Container ID
— Contrast
— Language
Configuration Submenu
— Economy Max.
MP-3000 Menu Flow Diagram
— Economy Min. • Current function setting

— Humidity Option appears in display.
Datalogger Menu — Reefer Type • Press F4 key to change a
— DATALOGGER — Inspect Temp Log — Zero Current setting.
— Inspect event Log Datalogger Submenu — Supply LH • Press F2 key, “A” key (pass-
— Set Log Time • First function screen appears: — Controlled Atmosphere word), F4 key and EXIT key.
— Activate Tripstart - Inspect Temp Log: Press F4 Option • Type new value; or press F3
— Inspect PTI Log key to view next screen. — Evaporator Fans key to toggle value to desired
Press F3 key to scroll through — AFAM Setup setting.
previous logs of sensors. — Auto Configuration • Press and hold F4 key until
- Inspect Event Log: Press F3 — Serial Number cursor stops flashing.
key to scroll through previous
event logs.
RMM Status - Set Log Time: Press F3 key to
— RMM STATE scroll through log interval list.
Display shows current Press and hold F4 key until
status: cursor stops flashing.
• Offline - Activate Tripstart: Press F4
• Zombie key to enter trip start marker.
• On-line
9-12
- Inspect PTI Log: Press F3 key

through test result screens.

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Maintenance Manual

CSR Power Saver and

Copyright ©2000, Thermo King Corporation, Minneapolis, MN, U.S.A.

In addition, service personnel must be aware of Federal regulations concern-

Electrical System 1-3

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

Commands Menu 4-18

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

Electrical Maintenance 5-1 Structural/Accessory Maintenance 7-1

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

Operation, Diagnosis and Refrigeration Maintenance

CSR PS Hermetic Models System Number

Other Reference Manuals

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

CSR PS Hermetic Model Features

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

General Practices Refrigerant

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

4. Do not make any rapid moves when working on high volt-

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

Welding of Units or Containers

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

Unit Decals Serial Number Locations

Unit Nameplate Location

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

System Net Cooling Capacity — Full Cool

CSR20 PS Models — Air Cooled Condensing*

CSR40SL PS Models — Air Cooled Condensing*

CSR40 PS Models — Air Cooled Condensing*

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

System Net Heating Capacity*

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

MP-3000 Controller (Continued)

Dehumidify and Humidify Systems (Options)

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

Physical Specifications (Continued)

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

Metric Hardware Torque Charts

*HH = Hex Head, CL = Class.

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

Dual Speed Evaporator Fans

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

Operating Modes Frozen Loads: Controller Setpoint at -10 C (14 F) or

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

Typical Unit Front View

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

Unit Options Front View

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

CSR20 PS and CSR40SL PS Evaporator Section — Front View

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

CSR40 PS Evaporator Section — Front View

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000

Humidify System Option

CSR20 PS, CSR40SL PS & CSR40 PS Hermetic, March 2000