Technical Training

for Dealers

2021­2022

FRIGOBLOCK
BASIC TRAINING

Brussels
FRIGOBLOCK PRODUCT RANGE
Components

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Technical Training
Technical Training
ALTERNATOR

Technical Training
G- Alternator characteristics

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Technical Training
Notes

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Notes

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Notes

Technical Training
Notes

Technical Training
MAINTENANCE REPORT 1

- G-alternator
- AW-alternator
- Tractor unit

Maintenance interval:
A-maintenance: Additional scope every 6 months (more than 100,000 km or 3,000 operating hours a year)
B-maintenance: Regular maintenance every 12 months (less than 100,000 Km or 3,000 operating hours a year)

Customer Dealer Service mechanic

Site Location Date

Vehicle type Alternator type Total op. Hours

FIN Alternator sl. No. Mileage
Inverter-filter sl.No. Registration Number

Idle speed _____ rpm Wirh refrigeration unit running

Item Maintenance Status

To do: 1. Checking mechanical attachment and
good or Comments
operating state
1.1 A B bad / corr.

1.1.1 X X Engine/alternator pulley bolts

1.1.2 X X Alternator mount chassis bolts

1.1.3 X X Alternator / alternator support, oil pan support bolts

1.1.4 X X Shock absorber or belt tensioner bolts

Shock absorber or belt tensioner function test / visual

1.1.5 X X
inspection for leaks

1.1.6 X X Alternator alignment / tilt

1.1.7 X X Check alternator condensing water drain (open)

1.1.8 X Check alternator V-belt state

1.1.9 X Replace alternator V-belt

Item Maintenance Status
To do: 2. Alternator good or Comment
1.2 A B bad / corr.

Visual inspection: alternator electr. Connection, terminal

1.2.1 X X
board, cable routes and terminations

Clean slip ring housing of abraded carbon

1.2.2 X X (G alternator)

1.2.3 X X Inspect terminal box and alternator cover seal

Inspect carbon brushes, replace if necessary

1.2.4 X X (G alternator, at no less than 50 % wear)

Inspect carbon brush holders for firm seating / function (G

1.2.5 X X
alternator)

1.2.6 X X Inspect slip ring state (G alternator)

1.2.7 X X Measure diodes (G alternator)

1.2.8 X X Inspect fastening of series resistance (G alternator)

1.2.9 X X Inspect alternator bearings for damage

1.2.10 X Grease alternator bearings (see "Grease" instruction)

Inspect alternator cooling water lines for leaks (AW

1.2.11 X X
alternators)

Item Maintenance
Status
To do in addition: 3. General Checks good or Comment
1.3 A B bad / corr.

1.3.1 X X Remote control / display indicator lamps

1.3.2 X X Clean refrigeration inverter filter

1.3.3 X X Clean plug connector pins

1.3.4 X X Inspect plug connector for moisture

Inspect sealing of the fuse near the alternator and the
1.3.7 X X
cable gland (SZM or WAB only)

Inspect setting of motor protection switch of the fuse near

1.3.8 X X
the alternator (SZM or WAB with G alternator only)

Item Maintenance
To do: 4. G alternator characteristic
1.4 A B

Idle V at 50 Hz Full throttle

V Hz V Hz
X X
without refrigerator
with refrigerator

Item Maintenance
Todo: 5. Analysis with FRIGOCENTER AW alternator
1.5 A B

Alternator idling at _____ rpm Alternator full throttle at _____ rpm

V Hz L index %
X X
without refrigerator
with refrigerator
 Item Maintenance Status
To be done: 6. Check / update software counts good or Comment
1.6 A B bad / corr.

1.6.1 X X ES controller iInverter filter

1.6.2 X X Inverter p.c.b.(inverter filter)

1.6.3 X X RCU (driver's ca)

Item Maintenance Status good or bad

To do: 7. Finalisation Comment
1.7 A B / corr.

1.7.1 X X CAN fault rate with refrigeration unit running _____% in alternator mode

1.7.2 X X Read out, assess and store diagnostic memory

Observe additional statutory inspections (owner's duty).

Electrical safety check

1.9. Other instructions / remarks / repair work

Next maintenance Service workshop

Date Date / signature

MAINTENANCE REPORT 2
- Inverter-controlled refrigeration unit - Conventional refrigeration units / Inverter filter / R units

Maintenance interval: A maintenance: additional scope every 6 months (more than 100,000 Km or 3,000 operating hours a year) B maintenance:
Regular maintenance every 12 months (less than 100,000 Km or 3,000 operating hours a year)

Customer Dealer Service mechanic

Site Location Date

Refrig. unit type Total operating hours Sl No. - RE1

Registration No. Mileage Sl. No. - RE2
FIN Unit sl. No. Sl. No. - RE3
Sl. No. - RE4
Sl. No. - DL

Maintenance To do 1. Function test of FRIGOBLOCK and

Status good or
Item additional components Comments
A B bad / corr.
C=Chamber

Sense of rotation
2.1.1 X X C1 C2 C3 C4
(alternator mode)

Cooling (mains
2.1.2 X X C1 C2 C3 C4
mode)

Sense of rotation
2.1.3 X X C1 C2 C3 C4
(mains mode)

2.1.4 X X Temperature setting C1 C2 C3 C4

Deforst (mains
2.1.5 X X C1 C2 C3 C4
mode)

Heating (mains
2.1.6 X X C1 C2 C3 C4
mode)

2.1.7 X X Indicator lamps C1 C2 C3 C4

Item Maintenance Status good or

To do: 2. Cleaning Comments
2.2 A B bad / corr.

2.2.1 X X Clean condenser / evaporator

2.2.2 X X Clean cooling water cooler (i units

2.2.3 X X Clean plug connector pins

Clean condensing water drain holes: Mains-0-

2.2.4 X X
alternator control cabinet
Item Maintenance
Status good or
To do: 3. Mechanical checks Comments
bad / corr.
2.3 A B

Check screws / bolts for firm seating

- Refrigerating units at frame, mounting
frame, at superstructure
- fan wheels
2.3.1 X
- compressor and compressor motor to
base fram
- base frame to housing
- RE baseframe to roof

Check compressor cover bolts for correct

2.3.2 X
tightening torque

2.3.3 X Check compressor motor V-belt state / pre-tension

2.3.4 X Replace compressor motor V-belt

Grease bearings: compressor motor and fan
2.3.5 X
motor
2.3.6 X X Inspect flow through defrost water line
Inverter cooling water circulation: Check cooling
2.3.7 X X
water level, inspect cooling water system for leaks
2.3.8 X X Hydraulic tilting system function test

Item Maintenance
Status good or
To do: 4. Electrics Comments
2.4 A B bad / corr.

2.4.1 X X Visual check of all electrical parts

Check motor protection switch setting (not for i
2.4.2 X
units)
2.4.3 X Check cable routes for chafe marks, firm seating
Retighten screws / bolts an contactors and
2.4.4 X X
switches
Inspect plug connections in control box for firm
2.4.5 X X
seating
2.4.6 X X Inspect plug connectors for leaks
Inspect control boxes, including cable glands, for
2.4.7 X X
intactness

Item Maintenance
Status good or
To do: 5. Refrigeration system checks Comments
2.5 A B bad / corr.

Pressure switch function test: HP switch, LP

2.5.1 X X
switch, pressure control switch if necessary

2.5.2 X X Drain radial shaft seal oil space

2.5.3 X Inspect refrigerating oil level

2.5.4 X Inspect sightglass moisture indicator

Evaporation pressure ___ bar, superstructure

2.5.5 X
temp.___°C, outside temp.___°C

Condensation pressure___ bar, superstructure

2.5.6 X
temp.___°C, outside temp.___°C

Check e-valve settings (superheating, MOP if

2.5.7 X
installed)

2.5.8 X Inspect suction pressure controller (if installed)

 Item Maintenance
Status good or
To do: 6.Check / update software counts Comments
bad / corr.
2.6 A B

2.6.1 X X ES controller (refrigeration unit)

2.6.2 X X Inverter board (FK i)

2.6.3 X X DC/DC (FK i)

2.6.4 X X Remote control unit(s)

Item Maintenance Status good

To do: 7. Finalisation Comments
2.7 A B or bad / corr.

2.7.1 X X CAN fault rate with refrigeration unit running _____% in alternator mode

2.7.2 X X Read out, assess and store diagnostic memory

8. Other instructions / remarks / repair work

Observe additional statutory inspections (owner's duty).

Annual leak test according to EU Regulation 517/2014
Annual temperature probe test of the temperature recorders according to DIN EN 13486
Electrical safety check
ATP inspection (if required)

Next maintenance: Service workshop

Date Date / signature

Notes

Technical Training
Notes

Technical Training
 Working instruction
Lubrication of alternators, compressor- and fan
motors

Rotating parts with bearings require regular lubrication with different types of grease. The lubrication plan
below provides an overview of the parts that must be lubricated.
Table 1

Grease Quantity Grease gun

Part part No. Interval Bearings Puffs Gram part No.

Alternator
A 30 12
- G series 22-0069 Annually 30-0566
B 20 8

A 18 7
- AW series 22-0246 Annually 30-0566
B 18 7

Compressor motor
A 15 6
- 3/3.7 kW 07-0070 Annually 00-0025
B 15 6

A 20 8
- 4/5 kW 22-0069 Annually 30-0566
B 20 8

A 25 10
- 6/7.5 kW 22-0069 Annually 30-0566
B 25 10

A 38 15
- 9/11 kW 22-0069 Annually 30-0566
B 38 15

A 38 15
- 8/13 kW 22-0069 Annually 30-0566
B 38 15

A 38 15
- 15 kW 22-0069 Annually 30-0566
B 38 15

A 30 12
Turbofan 07-0070 Annually B 30 12 00-0025
C 40 16

Additional Evaporator
07-0070 Annually A 40 16 00-0025
Type RE

Date: July 10, 2017 Page 1/4

 Working instruction
Lubrication of alternators, compressor- and fan
motors

Grease used

Part No. Designation

22-0069 Grease for alternators

07-0070 Grease for turbofans

Special tools

Part No. Designation

30-0566 Grease gun for alternator and electric motors

00-0025 Grease gun for turbofans

Alternator

Procedure:
- Remove the red dust caps from the A and B bearings.
- Apply grease, part No. 22-0069 (G alternator) or 22-0246 (AW alternator), to the grease nipples
on the A and B sides.
- Supply the prescribed quantity of grease (see Table 1) to bearings A and B.
- After greasing, close the nipples of the A and B bearings with the red dust caps.

Figure 1: Figure 2:
Lubricate the G24 A bearing Lubricate the G24 B bearing

Date: July 10, 2017 Page 2/4

 Working instruction
Lubrication of alternators, compressor- and fan
motors

Compressor motor

Procedure:
- Apply grease, part No. 22-0069, to the grease nipples of the bearings A and B.
- Supply the prescribed quantity of grease (see Table 1) to bearings A and B.

Figure 3: Figure 4:
Lubricate the FK13 compressor motor A bearing Lubricate the FK13 compressor motor B bearing

Figure 5: Figure 6:
Lubricate the EK25 compressor motor A bearing Lubricate the EK25 compressor motor B bearing

Date: July 10, 2017 Page 3/4

 Working instruction
Lubrication of alternators, compressor- and fan
motors

Fan motors

Procedure:
- Apply grease, part No. 07-0070, to the grease nipples of the bearings A, B and C.
- Supply the prescribed quantity of grease (see Table 1) to bearings A, B and C.

Figure 7: Figure 8:
Lubricate the FK13 turbofan A bearing Lubricate the FK13 turbofan B bearing

Figure 9: Figure 10:

Lubricate the FK13 turbofan C bearing Lubricate the FK13 turbofan C bearing

Figure 11:
Lubricate the RE fan motor

Date: July 10, 2017 Page 4/4

MULTI TEMP
Refrigeration

Technical Training
Evaporator Concept

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RE 2 2 - 2

Technical Training
Filling quantities

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Notes

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Notes

Technical Training
Service information 2014/02 Version 2
Date: 06.02.2015
Category: Multi Temp Technology Author: DZ

Subject:
Leaks at Aeroquip refrigeration couplings

Situation:
The design of the Aeroquip couplings has changed. The new couplings halves have new article
numbers (see overview).

A B A
New Design

Old Design

Changes:

A. The end of the thread to the soldered socket (brass adapter) is shorter now. Pressing the O-ring
in the thread end is prevented and a space for the sealing ring is defined.
B. A stop has been added in the area in which the coupling halves are screwed together. The flat
ring seal is now pressed by a defined amount. In this way the flat seal cannot be crushed.

All new multi-compartment units of the FK and HK series are shipped with the new Aeroquip
couplings since 20 January 2015.

Service Information 2014/2 Version 2 - Page 1/7

Construction of the Aeroquip coupling:

Items 1 – 7 Items 8 – 12
Typical male coupling half Typical female coupling half

Article No. Article No. Article No.

Item Description
12 mm 22 mm 28 mm
1 Soldering adapter to machine 13-0013 13-0015 13-0016
2 O-ring 13-0030 13-0031 13-0045
3 Poppet valve assembly Part of item 4 Part of item 4 Part of item 4
4 Body 13-0865 13-0867 13-0869
5 Gasket seal 13-0331 13-0332 13-0333
6 Lock washer 13-0021 13-0021 13-0019
7 Jam nut 13-0034 13-0035 13-0037
8 Union Nut and Body Assembly 13-0866 13-0868 13-0870
9 O-ring n.v. n.v. n.v.
10 Valve & sleeve assembly Part of item 8 Part of item 8 Part of item 8
11 O-ring 13-0030 13-0031 13-0045
12 Soldering adapter to tube 13-0013 13-0015 13-0016

Tightening torques of Aeroquip screw connections:

Union (8) to
Connection (4) to Union (8) to
Screw connection soldering adapter
soldering adapter (1) connection (4)
(12)
Liquid line
25 Nm 25 Nm 50 Nm
(12 mm)
Hot gas line
50 Nm 50 Nm 62 Nm
(22 mm)
Suction gas line
75 Nm 75 Nm 90 Nm
(28 mm)

Service Information 2014/2 Version 2 - Page 2/7

Action:

Where leaks occur at Aeroquip screw couplings, the following should be observed
when new seals are installed:

The O-ring of the hot gas line is made of EPDM. EPDM is not resistant to mineral oil products (oils,
greases and fuels).

 Never install O-rings (items 2 and 11) and flat sealing ring (item 5) in dry state.
 Install a new flat seal (item 5) every time the Aeroquip coupling is opened.

If the repair by replacing the seals as described below fails to eliminate the leak in the
system, the coupling of the leaky line should be replaced as a unit.

Caution:
Take care to maintain meticulous cleanness during the replacement.

1. Evacuate all remaining refrigerant.

2. Separate the Aeroquip coupling.

3. Remove the leaking part (item 4 or 8) from soldering
adapter.

The repair procedure is described by the example of the hose

end.

4. Remove and dispose of the old O-ring. Do not remove the

O-ring with a pointed or sharp tool because the sealing
surface of the O-ring groove may be damaged.
5. Clean soldering adapter with a cleaning cloth.
6. If there are deposits in the thread grooves and / or in the
area of the O-ring groove at the soldering adapters clean
them with a clean brush.

Service Information 2014/2 Version 2 - Page 3/7

 7. Apply a thin film Molykote 111 uniformly in the ring groove
using a suitable tool, e.g., an injector.
8. Smoothen the Molykote 111 with a clean brush.

Caution:
Applying too much Molykote may crush the O-ring when
the coupling half is installed.

9. Apply silicone spray to the O-ring groove of the installer

(improves the sliding action of the O-ring during
installation).
10. Push a new, clean O-ring on the installer.

Caution:
To prevent unwanted elongation, slide the O-ring just
before installation into the ring groove.

11. Using the installer, slide the O-ring (item 11) in the ring
groove of the soldering adapter.
12. Apply a thin film Molykote 111 also to the installed O-ring.

Caution:
After installation, the new O-ring must not be twisted.

Service Information 2014/2 Version 2 - Page 4/7

 13. Manually install the union nut and body to the soldering
adapter until the thread engages fully.
14. Ensure that the O-ring cannot be crushed between the
brass adapter and the union nut.
15. Then tighten to the prescribed torque using a torque
wrench.
16. Remove excess Molykote with a piece of cloth.

Caution:
When tightening the nut, stabilise the soldering adapter
to prevent twisting the pipeline.

Caution:
Check to be sure before assembly that the sealing areas
of the coupling halves are not damaged.

17. Apply some refrigerant oil to the connecting thread before

connecting the two coupling halves.
18. Screw the union nut on the connecting thread carefully
and only hand tight at first.
19. Tighten the connection to the prescribed tightening torque;
hold the connecting thread with a suitable tool if
necessary.
20. To prevent the coupling halves coming lose from the brass
adapters, hold them with a suitable tool while tightening.
21. Make a leak test of the connections.

Caution:
When tightening the union nut on the connecting thread
of the refrigeration device type HK / HD, hold the
hexagon of the connecting thread with a suitable tool;
otherwise the pipeline will be twisted.

Service Information 2014/2 Version 2 - Page 5/7

If needed, we will provide one repair kit free to each service partner. The repair kit can be ordered
from the FRIGOBLOCK part sales.

Additional sets should be ordered as usual:

Article No.: 00-0136 1 set installers (price to be inquired from Parts Sale)
Article No.: 30-0579 1 tube Molykote 111 (price to be inquired from Parts Sale)

Molykote 111 is also as single part available.

Repair kit consists of:

 Article No.: 00-0136

o Installer for soldering adapter 12 mm
o Installer for soldering adapter 22 mm
o Installer for soldering adapter 28 mm

 Article No.: 30-0579

o 1 tube Molykote 111

A Molykote 111 injector should be available on site.

Recommended tools for the installation of Aeroquip-couplings

Tools overview:
1. Torque wrench
2. Combination spanner ZOLL
3. CROW-FOOT-spanners ZOLL

Supplier: e. g. http://www.stahlwille.de/en/products/online-catalogue/

Combination spanner Zoll

sizes:
1“; 11/8“; 13/8“; 15/8“; 13/4“; 17/8“

CROW-FOOT-spanners ZOLL

sizes:
1“; 11/8“ ; 13/16“; 13/8“; 15/8“; 13/4“; 17/8“ ; 2“

Service Information 2014/2 Version 2 - Page 6/7

 Male coupling to machine

Female coupling to refrigerant hose

Male coupling to female coupling

Service Information 2014/2 Version 2 - Page 7/7

Technical Training
Troubleshooting and solution

Possible cause Solution

Condenser pressure ________________________ _____________________

HIGH ________________________ _____________________
________________________ _____________________
________________________ _____________________
________________________ _____________________
________________________ _____________________
________________________ _____________________
________________________ _____________________

Possible cause Solution

Condenser pressure ________________________ _____________________

LOW ________________________ _____________________
________________________ _____________________
________________________ _____________________

Possible cause Solution

Compressor Temperatur ________________________ _____________________

To HIGH ________________________ _____________________
________________________ _____________________
________________________ _____________________
________________________ _____________________

Technical Training
 Possible cause Solution

Compressor Temperatur ________________________ _____________________

To LOW ________________________ _____________________
________________________ _____________________
________________________ _____________________

Possible cause Solution

Filter drier cold, ________________________ _____________________

Frostes, ice up ________________________ _____________________

Possible cause Solution

Bubbles in the sight glass ________________________ _____________________

In front of the expansion ________________________ _____________________
valve ________________________ _____________________

Possible cause Solution

Suction pressure ________________________ _____________________

LOW ________________________ _____________________
________________________ _____________________
________________________ _____________________
________________________ _____________________
________________________ _____________________
________________________ _____________________
________________________ _____________________

Technical Training
 Possible cause Solution

Suction pressure ________________________ _____________________

HIGH ________________________ _____________________
________________________ _____________________
________________________ _____________________

Possible cause Solution

Compressor iced ________________________ _____________________

________________________ _____________________

Technical Training
Replacing the valve plate(s)
Removing the shaft seal:
1) Smear proof and clearly mark the mating cylinder cover and valve plates to avoid mistakes during
installation.
2) Turn out the cylinder head screws
3) Remove the cylinder cover and the top valve plate gasket
4) Remove the valve plate and the bottom valve plate gasket
5) Oil the new gaskets with refrigeration oil before assembling
6) Install the valve plate with the bottom valve plate gasket on the housing.
7) Install the top valve plate gasket with cylinder cover
8) Tighten the screws crosswise in minimum two steps. Observe the sequence for tightening the
cylinder head bolts Screw tightening torque 60 Nm.
9) Change oil filling
10) Evacuate the compressor at both sides
11) Open receiver tank
12) Fill the compressor with refrigerant (and open the suction and high-pressure valves)
13) Make a leak test
14) Make a test run (at least 30 min)
15) Check Oil quantity and quality. Change oil filling or adjust oil level if necessary
16) Retighten the cylinder cover screws again to 60 Nm after the test run
17) Make another leak test.

Technical Training
Changing the shaft seal
1.

2.

3.

4.

5.

6.

7.

Removing the shaft seal:

1) Pull off the belt pulley at the compressor.
2) Take the Woodruff key out of the groove at the shaft end.
3) Remove screws (7) from slide ring cover (6).
4) Remove remaining seal material, seal, slide ring cover (5) from the bearing flange.
The slide ring cover (6) is spring-loaded. Some remaining oil may drain from the shaft
seal compartment.
Collect the oil in a suitable container.

Technical Training
Installing the shaft seal:
1) Observe a high level of cleanness.
2) Always replace the complete shaft seal, not only parts. Do not use second-hand parts.
3) Check the contact and sealing faces for dirt and damage before the installation.
4) Apply a thin oil film (compressor oil) to the sealing faces of the slide ring (4), the slide ring cover
(6), the O-ring (3) and the compressor shaft.
5) Install the slide ring (4), O-ring (3) and guide ring (2) as an assembly. The strong bevel of slide ring
(4) should point towards slide ring cover (6).
6) Compression spring (1) should latch audibly in the groove of the crankshaft and the guide ring (2).
7) Install the slide ring cover seal (5) dry, do not soak in oil.
8) Install slide ring cover (6) with the marking “TOP “ up.
9) Tighten the fastening screws (7) uniformly crosswise, Screw tightening torques
M6 = 15 Nm M8 = 34Nm
10) After installation of the shaft seal, make a few turns of the crankshaft by hand, then check the
shaft seal for leaks.
11) Insert the Woodruff key in the groove of the compressor shaft end.
12) Change oil
13) Install the belt pulley and the belt.
14) Make a trial run (at least 30 min)
15) Repeat the leak test

Technical Training
Compressor
Testing the compressor
There are different possibilities of checking the compressor without opening the compressor or the
refrigeration circuit.

Running noise: Many cases of compressor damage can be identified by the sound of the running
compressor. If the compressor is untypically loud or otherwise unnormal, further tests should be
made.

Pressure hold test: The pressure hold test can be made to check the function of the valve plates.
For this test, the refrigeration device should be running for a short while until a pressure difference
has established between high pressure and low pressure. After that, watch the pressure gauges to
see whether pressure is compensated briefly. If it is, the fins of the valve plate are damaged and do
not close completely.

Turning by hand: If wear is advanced inside the compressor, it will not normally be easy to turn it
by hand. To test that, rotate the compressor manually at the shaft end or optionally at the belt pulley.
Normally, the compressor rotates easily by hand. If it is sluggish, high wear can be assumed. To
avoid wrong diagnosis, also see whether high pressure is available at the high pressure side which
makes compressor rotation. Besides, when turning the compressor manually watch out if the rotation
is smooth or jerky.

Technical Training
Compressor damage and its causes
If the compressor must be replaced, find the cause of the failure and repair it if possible. Often, a
defective compressor is the result of the failure of another part of the refrigeration device. Often the
cause of failure can quickly be located by watching the valve plates. Described below are a few
compressor damage patterns and their possible causes.

Damage pattern: Possible cause:

___________________________ ________________________________
___________________________ ________________________________
___________________________ ________________________________
___________________________ ________________________________
___________________________ ________________________________

Damage pattern: Possible cause:

___________________________ ________________________________
___________________________ ________________________________
___________________________ ________________________________
___________________________ ________________________________
___________________________ ________________________________

Technical Training
Damage pattern: Possible cause:
___________________________ ________________________________
___________________________ ________________________________
___________________________ ________________________________
___________________________ ________________________________
___________________________ ________________________________

Damage pattern: Possible cause:

___________________________ ________________________________
___________________________ ________________________________
___________________________ ________________________________
___________________________ ________________________________
___________________________ ________________________________

Technical Training
4-way valve
Troubleshooting at the 4-way valve:
The 4-way valve is currentless in refrigeration mode. When the magnetic coil is energized, the pressures in the
pressure pipe are reversed and the gate valve moves to heating position. Then the 4-way valve is in heating
mode. To check whether the mechanical parts of the valve work properly or the current supply of the pilot valve
is in order, proceed as follows:

Device not heating

1) Pull off the coil of the pilot valve and replace it by a permanent magnet. The 4-way valve is now supplied
with voltage and therefore is in heating mode.
2) Operate the refrigeration device and check whether the evaporator becomes warm.
 If the internal gate valve fails to switch over even at high compressor speed and sufficient
refrigerant, the pilot valve or the valve capillaries are clogged or the slide valve does not move.
 If the device heats properly, either the magnetic coil of the pilot valve or the energy supply to the
magnetic coil are defective.

Device heats constantly

1) Pull off the coil of the pilot valve. This makes the 4-way valve currentless and puts it in refrigeration mode.
2) Operate the refrigeration device and see whether the evaporator cools down.
 If the internal gate valve fails to refrigerate even at high compressor speed and sufficient refrigerant,
the pilot valve or the valve capillaries are clogged or the slide valve does not move.
 If the device refrigerates properly, either the magnetic coil of the pilot valve or the energy supply to
the magnetic coil are defective.

Technical Training
Changing the 4 - way valve
The valve can only be changed as a unit. Depending on the refrigeration device type, it is installed by brazing,
flanging or crimping. When brazed, make sure that no solder or dirt enters the valve.
Place a wet cloth around the valve body to prevent excess heating of the housing. The housing should not be
damaged because the teflon slider is installed in the thin soft copper tube.
Protect the refrigeration device housing from heat when brazing. Keep the burner away from the plastic
material to prevent fire. In new flange connections, the seal is in the flange.

 It is possible to order the 4-way valve as spare part with or without piping. The version with piping is
much simpler to install. Please ask the spare parts dispatch experts.
 Ensure correct seating of the gasket in the flange connections. Before assembly smear the gasket
with refrigeration oil.
 Tighten the flange connection to 15 Nm.
 Be careful not to damage the capillaries by brazing.-After finishing the repair a leakage test of the
repaired area must be carried out as well as to change filter dryer and the refrigerant oil.

Technical Training
Notes

Technical Training
Notes

Technical Training
Technical Training
 ELECTRIC

Technical Training
Components

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Technical Training
Components

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____________________________________
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A1 B1 15 17 ____________________________________
KT ____________________________________
A2 R 16 18 ____________________________________
____________________________________
____________________________________

____________________________________
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D B
____________________________________
K2 &
____________________________________
HE F C
____________________________________
____________________________________
L1
L2
L3

____________________________________

Technical Training
Components

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Technical Training
 1 2 3 4 5 6 7 8 9 10
S4 remote control switch F1 fuse ignition 15A K6 Relais H5 indicator "on"
S7 defrost switch F2 fuse D+ 7,5A G1 FRIGOBLOCK alternator H6 indication defrost
R1 excitation dropping resistor F10 coil temperature switch P1 rectifying diodes
P2 blocking diode
F2 1x2,5mm² dynamo - remote control
D+
gn/ge
− 3x1,5mm² ignition - control panel
F1 1
ignition
1 gn/ ye
sw
rt rt
30
3 3
S7 4
K6 S4 4
87 87b
rt
86
H5 H6 red
K6 85
green
gn/
3 6 1 4 ye 2
7x1,5mm²
alternator - remote control
4 6 1 3 2 gn/ye
(6x2,5mm+6x1+1x4)mm² via M-0-A switching box
to the rigid.
7 10 1 2 3 4 5 6 gn/ye
4 L1 L2 L3 5 7 8
R1 F10
P2 6
9U
10V
11W G1
P1
Remote Control rigid without FRIGOBLOCK Grosskopf GmbH
drawn RS 27.01.1999
temperature / voltage indication modifiy
page 1 von 1 Z.-Nr. 96-2001a
 1 2 3 4 5 6 7 8 9 10
Q1 motor overload protection S1 main - 0 - alternator switch S5 temperature preselect switch type 636H (option) X1 CEE plug X2 terminal strip
Q2 motor overload protection (option) S2 switch low speed type 631H (option) S6 switch remote control unit on (option) R1 resitor 18 kOhm (option) H3 indicator motor overload protection switch (option)
K2 phase rotation relay for mains only (option) S3 switch defrost (optional at addtional FE/RE) QV=Crimpconnection H5−7 chilled 1, chilled 2, df (option) H2 indicator wrong rotation (option)
K3 remote control unit off (option) S4 external off switch (option) P2 blocking diode only when remote control (option) P1 only when automatic slow switching
A
colours
rt=red to the second main - 0- alternator switch (option)
to the Frigoblock/EK (6x2,5+6x1+1x4) mm²
ws=white trailer (6x2,5+6x1+1x4) mm²
gr=grey

option when
FE/RE hotgas
(heating detection)
br=brown
bl=blue
li=lila

control voltage 24V

SL

defrost indication
defrost
cooling detection
core

core gn/ge
core 1 + 2
core 3 + 4
core 5 + 6
core 7
core

core
temperature chilled 2

core

(genset speed and

compressor)
core 11

core
core 8
temperature df

core 10

core 9
gn=green

control voltage. 400V

B ge=yellow
sw=black or when only 2 preselection
core 9

core 1 + 2
core 3 + 4
core 5 + 6
core 7
core 10
core 11
only when
add. FE

core gn/ge
core 8
only when DL

4 1 thermostats are fitted in

L3 change-over switch type 636
gr must be used instead of the
control
current cooling X2/8 X2/9 switch type 644
L2 2 (df-thermostat option) not when

defrost
indication
X2/5 24 V detection DL or
QV4 FE
X2/7 or L1 3 4
X2/2 X2/1 X2/6
option S6

df
chilled 2
chilled1
1 QV5 QV QV
12 1 3 chilled 1 -
S2 2 4 5 chilled 2 -df
S3 S6 K3 P2 2
H5 H6 H7
P1
13 A1
3 4 1 3 6

defrost
2 4

(heating
detection)
K3 S5
A2 2 5
S4 option
X2/3 S4 S4 else set a type 644 H

df
X2/4

chilled1
bridge

chilled 2
C rt
sw
1 3 5 13
21

P1 only when SL>L

sw QV1 QV1 QV3
core 3
core 1 5x 1,5mm²
14 22 5x 1,5mm²
Q1 D B 1 3 5 13

(genset speed and

compressor)
QV3 21
R1
I I I
K2 18 KOhm
C H3

K2 only option
else set a bridge
2 4 6 H2
Q2
X2/10 22
SA-Option sw sw solenoid
sw I I I
drive motor QV2
D core 2
5x 1,5mm² 2 4 6 14

only when
additonal FE/RE
QV2
L1 L2 L3 3 1

S1

Attention not when more compartment vehicle

2
K2 & Ub Ua Vb Va Wb Wa 4
If the indicators H2, S2 and H3 are in an other switching box
and no core is avaible in the FRIGOBLOCK cable an
extra cable 5 x 1,5 mm² must be made to the other switching box

HE F N gn/ge

sw
1mm²

E X1
CEE L1
L1
CEE L2
L2
L3 PE
PE
N

9
11
core 8

core 7
core 8

core 10
core 11
core 12

core 12

defrost
indication
core 1 + 2

core gn/ge
core 5 + 6

core 3 + 4

core 12 SL> L
voltage 24V
option DL

core 9 option
F

option core
when drawbar combination
from alternator (6x2,5+6x1+1x4)mm²
op. temp
op. DL

option core
when rigid and drawbar
combination
op. add. FE core 12

main - 0 - alternator Grosskopf G m b H

(Option for system) drawn De 06.05.2009
page1 of 2 Z.-Nr. 96-1612i
modify
 1 2 3 4 5 6 7 8 9 10
M1 compressor motor K1 contactor compressor B1 switching thermometer F3 fuse transformer C D)&)/ .3+5.1*)E: 3E+)6.701.58 B&)0+2 7#,++3+-)6.701.58
M2 fan motor K2 contactor fan B2 defrost thermostat F4 fuse heating H1 indicator cooling (blue) '( %&)*+3:=012+-)>;+5)< +5/+0)
P1 control rectifier K3 contactor heating / defrost X1 terminal strip F @):**101.5:3)/:,+0=)0;+-2./0:0/);+:015< H2 indicator fan (green) 6+3/+)/+0):?-1*< +8)3.--=)@ /A)0-:13+-)&!/
P2-5 blocking diode S1 control current switch X2 plug 3 + 10 pins F6 low pressure switch H3 indicator heating (yellow)
T1 transformer S2 defrost push button X3 terminal box near the evaporator F7 high pressure switch H4 indicator operation (green)
E1 electric heating 9 %)*-: 15)315+);+:015< )6.701.58 F1 coil temperatur switch M1 F8 safety thermostat No. 06-0176
'%% ( )*+,-./0)012 +-)+3+40-.514)6.701.58) F2 coil temperature switch M2
X2 Frigoblock cable (6x2,5+6x1+1x4mm²) 7 x 1,5 mm² when
sw
sw A1 FK8 without plug
sw core 1+2 L1 when FK8 core 1
sw A2 core 3+4 L2
sw when FK8 core 2
sw A3
sw core 5+6 L3 when FK8 core 3
sw B8 core 8 control voltage 400V when FK8 core 5
X1/5 rt B7 core 7 control voltage 24V when FK8 core 6
gr B2 core 12 genset speed + FE/RE (option) (when use FK8 core 7,
ws X1/4 ws B9 core 9 then use 12x1,5 cable)
tempfeeler
rt rt B1 core 11 SL
Attention! 1 B3
When DL use a fuse size B4
depending on transformer S1 B5
2 B10 core 10 defrost when FK8 core 4
400/12-24V H4
or 4mm² gn/ge PE PE when FK8 core gn/ge
X1/6 green/yellow
F3 _ rt
T1 +
R1
P1 F8 1
br or
br sw S2
gr X1/7
FK8 1x1,5mm² or 2 X1/19 colours
FK11-FK/HK13 2 x 1,5mm² rt rt=red
FK25 2x2,5mm² II 1 I 1 or
3K 13 ws=white
B1 K3
3 2 gn
17
gr=grey

KT22
bl 14
K3
21
ge or
or br=brown
22 X1/14
21 18 bl=blue
K2
1 3 5 bl
22 li=lila
K3 X1/8
1 3 5 1 3 5
bl or
gn=green
2 4 6
K1 K2 P2 ge=yellow
X1/17
2 4 6 2 4 6 F4 bl
X1/20 sw=black
X1/9 12 8 core
core 4 5 6 core 1 2 3 X3/8
ND 1 K3 ge ge B2 terminal X3/8
X3/ 4 5 6 F5
F6 P< bl 11
and X3/10 not
4 when HK
X3/10

FK8, FK11+HK
X3/ 1 2 3 X1/10
10 core

E2 not when
M 3M 2
X1/18
3 1
X1/2 gn or
KT21 P3 P4 P5
E1 ge
ge or
X1/3 A1

KT22
X1/15
X1/16
KT21 only when genset, A2 R
else set a bridge bl 1 ge ge
H1 H2 H3
A1 A1 A1 or
F1 F2
K1 MV1 K2 K3 15
X3/7 X3/9 A2 A2 A2

KT22
HD br br 2
core 7 9 core br br br br
F7 P> 16
1 2
br br
X1/12 X1/11
X1/1
K1 2 4 6 K2 2 4 6 K3 2 4 6 X1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
M1 M2 E1/E2 ground KT21 R1 F8 F6 MV1, F7 B2 K22T
S1 MV1
X3 1 2 3 4 5 6 7 8 9 10 11 12 N F8
E1/E2 M2 F2 B2 F2 B2 ground
defrost timer electronic option
FK 8 - FK 25, HK11 - HK13 with electrical heating Grosskopf G m b H
*-:> #H+ !" #!$ #%!!&
7:< +)&)G)& 2 .*1,= Z.- Nr. 96-1228 j
Notes

Technical Training
 Thermostat

Example 1:

Chilled 1: 15°C
Chilled 2: 2°C
Deep frozen: -20°C
Chilled 1 selected, RAT = 20°C

Example 2:

Chilled 1: 15°C
Chilled 2: 2°C
Deep frozen: -20°C
Chilled 1 selected, RAT = 10°C
 Thermostat

Example 3:

Chilled 1: 15°C
Chilled 2: 2°C
Deep frozen: -20°C
Chilled 2 selected, RAT = 10°C

Example 4:

Chilled 1: 15°C
Chilled 2: 2°C
Deep frozen: -20°C
Deep frozen selected, RAT = 10°C
Delayed heating timer

Deep frozen Thermostat

 Q1 motor overload protection
PE
L3
L2
L1
N

X1
main - 0 - alternator

K2
HE F

&

option
X2/7
1mm²
option core

sw
9
when drawbar combination
core
option core 11 only when defrost indication
defrost
when rigid and drawbar additonal FE/RE
indication
combination
defrost
indication
Attention not when more compartment vehicle option when
core 9 option core 9 FE/RE hotgas
(heating detection)

X2/3
SA-Option
(heating

X2/10
detection)
CEE L1
CEE L2

core
(genset speed and (genset speed and

S1 main - 0 - alternator switch

compressor) compressor)

core 10 core 10

or
X2/4

to the Frigoblock/EK (6x2,5+6x1+1x4) mm²

defrost defrost

core gn/ge core gn/ge

from alternator (6x2,5+6x1+1x4)mm²

P1
P1 only when SL>L
core 12 SL> L
core 11

X2/5

gr
SL

S2
Ub

or
Q1
sw

rt
L1

core 1 + 2
Ua Vb

core 1 + 2
2

L1
core 3 + 4

L2
sw
L2

core 3 + 4 core 5 + 6
Va Wb

5
6

L3
S3
14

13
L3

sw

2
core 5 + 6
Wa 4

21
22

S6
S4

13

12 1
2
core 8
sw
3

X2/2
control voltage. 400V
K2 only option
else set a bridge
S4

K3
4

3
K2
D

core 7
1

control voltage 24V

core 7
X2/1
24 V
current
control
solenoid

bridge
else set a
S4 option
drive motor

P2
C

B
2

core 8
1
S6
sw

voltage 24V
drawn De

option DL
modify

S1

core
2
5
K3

cooling detection
X2/6
PE

detection
cooling
A2

A1
QV1

X1 CEE plug
chilled 2 -df
chilled 1 -
18 KOhm
R1
5x 1,5mm²
core 1

S5
type 644 H

core
3
QV1

df
5x 1,5mm²
core 2

4
QV2

QV2

temperature df
H2

X2/8 X2/9

chilled 2
2

chilled1
1

core
3

4
Grosskopf G m b H

5
N

temperature chilled 2
6
06.05.2009

5x 1,5mm²
core 3
QV3

QV3
H3

chilled1
H5

2
gn/ge

1 thermostats are fitted in

(df-thermostat option)
switch type 644
must be used instead of the
change-over switch type 636

when only 2 preselection

df
H6

If the indicators H2, S2 and H3 are in an other switching box

and no core is avaible in the FRIGOBLOCK cable an
H7

extra cable 5 x 1,5 mm² must be made to the other switching box chilled 2
to the second main - 0- alternator switch (option)
trailer (6x2,5+6x1+1x4) mm²
page1 of 2

Q2

core 1 + 2
2

core 3 + 4
4 6

3 5

core 5 + 6
X2 terminal strip

core 8 core 7
13
14

21
22

core gn/ge
QV4

core 11 core 10
QV5
Z.-Nr. 96-1612i

op. temp core 12 core 9

not when
FE
DL or

core 11
QV

op. add. FE core 12 only when

add. FE
QV

op. DL core 12 core 8

only when DL
Notes

Technical Training
Technical Training
 R-Unit

Technical Training
Notes

Technical Training
Notes

Technical Training
Components

____________________________________
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____________________________________
____________________________________
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____________________________________
____________________________________

____________________________________
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____________________________________
____________________________________
____________________________________
____________________________________
____________________________________

____________________________________
____________________________________
____________________________________
____________________________________
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Technical Training
Components

____________________________________
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____________________________________

____________________________________ ____________________________________
____________________________________ ____________________________________
____________________________________ ____________________________________
____________________________________ ____________________________________
____________________________________ ____________________________________
____________________________________ ____________________________________
____________________________________ ____________________________________

Technical Training
CAN BUS Address ranges
Standard – ID
Inverter-Filter (incl. Controller 27-0028)
Advanced 1
refrigeration unit rigid
switching box rigid (incl. Controller 27-0028)
remote control (HMI) in driver cabin (rigid)
remote control (HMI) in MOA box (rigid)
remote control (HMI) in compartment (rigid)
refrigeration unit I/O cards (rigid)
Advanced 2

refrigeration unit trailer

switching box trailer (incl. Controller 27-0028)
remote control (HMI) in driver cabin (trailer)
remote control (HMI) in MOA box (trailer)
remote control (HMI) in compartment (trailer)
refrigeration unit I / O cards (trailer)

ID0 = I/0-card compartment 1, ID1 = I/0-card compartment 2

ID2 = I/0-card compartment 3, ID3 = I/0-card compartment 4
ID6 = I/0-card diesel genset, ID7 = I/0-card refrigeration unit
ID8 = I/0-card FK/HK/EK /Inverter Filter, ID10 = HMI drivers cab
ID11 = HMI MOA box, ID12 = HMI body
ID15 = Controller 27-0028

Technical Training
CAN-Bus: ID addresses of the components
ID0 = I/0-card compartment 1, ID1 = I/0-card compartment 2

ID2 = I/0-card compartment 3, ID3 = I/0-card compartment 4

ID6 = I/0-card diesel genset, ID7 = I/0-card refrigeration unit

ID8 = I/0-card FK/HK/EK / Inverter Filter, ID10 = HMI drivers cab

ID11 = HMI MOA box ID12 = HMI body

ID15 = Controller 27-0028

Technical Training
CAN BUS Adressing
Technical Training
CAN BUS Adressing

Technical Training
CAN BUS Adressing
Technical Training
CAN BUS Adressing

Technical Training
CAN BUS Adressing
Technical Training
CAN BUS Adressing

Technical Training
CAN BUS Adressing
Technical Training
 R-Unit
Schematic

Technical Training
 remote HMI controller for ridig and drawbar for HMI controller
remote HMI controller for ridig and

ws 0,25mm² ws 0,25mm²
CAN L CAN L

ON
JP1 CAN

rigid
HMI controller
ON
JP1 CAN

rigid
HMI controll
bl 0,5mm² bl 0,5mm²
GND GND
br 0,25mm² br 0,25mm²
CAN H CAN H

OFF
OFF

rt 0,5mm² rt 0,5mm²
KL 15 KL 15
sw 0,5mm² sw 0,5mm²
KL 30 KL 30

KL. 15 KL. 15
gr 0,35mm² gr 0,35mm²
IN7 IN7
KL. 15 KL. 15
br 0,5mm² br 0,5mm²
IO2 IO2
KL. 15 KL. 15
1 2 3 4 5 6 7 8 9 10 12

IO3
1 2 3 4 5 6 7 8 9 10 12

IO3
KL. 15

ID 1/10
KL. 15
ID 1/10

IN8 IN8
modify OS
drawn OS

gl 0,5mm² gl 0,5mm²
IO4 IO4
gr 0,5mm² gr 0,5mm²
KL. 15 KL. 15
ws 0,5mm² ws 0,5mm²
IN6 IN6
IO1 IO1
KL. 15 KL. 15

IN 5 IN 5
Grosskopf G m b H
07.06.2016

ws 0,25mm²
CAN L
ON
JP1 CAN

bl 0,5mm²
X6

GND
drawbar ID 2/10
HMI controller
X6

br 0,25mm²
CAN H
OFF

rt 0,5mm²
KL 15
sw 0,5mm²
KL 30

KL. 15
gr 0,35mm²
IN7
KL. 15
br 0,5mm²
IO2
KL. 15
IO3
KL. 15
IN8
gl 0,5mm²
IO4
gr 0,5mm²
KL. 15
ws 0,5mm²
IN6
IO1
page 1

KL. 15
IN 5
96-ES-2100
 R1 dropping resistor F31 fuse ignition 20A K31 relay FB "on" Q31 motor overload protection (option) X6 plug HMI
G1 FRIGOBLOCK alternator F32 fuse dynamo D+ 7,5A K32 relay idle speed increase (option)
P1 rectifier diods F33 winding temperature switch
P2 blocking diode F36 fuse permanent positive 10A
P10 blocking diode 10A 01-0216

(MAN 59104) [D+] sw 1,5mm² F32 sw 1,5mm² colours

DAF 1020 rt=red
P10
rt 1,5mm² F36 rt 1,5mm² ws=white
permanent positive +24V
gr=grey
bl 1,5mm² br=brown
(MAN 96) GND
DAF(white) 1 2 3 4 5 6 7 8 9 10 12 bl=blue
(MAN 94) ignition
ws 1,5mm² F31 ws 1,5mm² X6
DAF (red)
li=lila
gn=green
rt ge=yellow
9
bl (3x1+2x0,25 mm²)C sw=black
diagnostic plug 3 4 1 2 3 5
Sub D9 socket ws
2
br
7

shield

rt
br
bl
ws
sw/rt

to m-0-a switch box to rigid.

(6x2,5 + 6x1 + 1x4)mm² (3x1+ 2x0,25 mm² )C

7 8 9 gn/ge
(3x1+

3+4
5+6

1+2
2x0,25 mm²)C
1
3 5 7x0,75 mm²
4 2

red
blue
white
sw/rt

brown
shield
1 3 5 30
86 86
K1 K1 K2
point of separation 87
85 85 point of separation
MAN plug 1 1 2 3 4 5 5 1 3 4 2 MAN plug 2
Q31 MB / DAF plug 1 1 2 3 4 5 11 7 9 10 8 MB / DAF plug 1

gn/ge
3 1 2
7x1,5mm²

red
2 4 6

brown
shield
sw

white

blue
alternator remote control

gn /

3+4
5+6
4 5 6 1

1+2
7 8 9 gn/ge 2 3
ge
7 8 9 1 2 3 4 5 6
(6x2,5+6x1+1x4)mm² gn /
ge
additional switching box m-0-a switch-alternator
only when swap body or tractor unit
4 L1 L2 L3 5 7 8
idle speed increase
R1 truck engine control unit
F33 potential free contact
P2 6 br/ws 1mm²
9U
(MAN 59104)
30
10V P1 note: remove bress bridge from
K2
11W
G1 terminal 7 to terminal 8 87
check if klixon is connected to terminal 7 (MAN 23538)
br/ws 1mm²

HMI remote controller for rigid, contactor technologie Grosskopf G m b H

drawn OS 19.02.2016 OS 16.08.2016
option idle speed increase. G- alternator for rigid and drawbar page 1 96-ES-2001
modify OS 17.05.2016
M1 compressor motor K1 compressor slow X1 switch box F1klixon compressor motor M1 F6 low pressure switch T1 transformer control 01-0236 TE = NTC stainless steel tube 10K Typ 27-0006
K2&3 compressor fast F7 high pressure switch F3 control fuse 5A TK = NTC plastic tube 10K Typ 27-0005
C1 supporting capacitor 4700µF 01-0235
P1 rectifier
P2 blocking diode 3A

L1 motor overload protection

L2 motor overload protection

L3 motor overload protection

control voltage 400V

P2
4mm² gn/ge

rt
control voltage 24V
permanent voltage 24V
100VA transformer br
CAN H
rt ws
CAN L
400/21V bl
GND
C1 gn ge (shield)
F3 _ + connect shield only when rigid.
T1 br ws gr
Else only connect shields together.

+
P1 + H L - ON OFF
+ H L -
CAN CAN IO-module / CAN
x/7 switch box JP1 CAN

permanent
controller
+24V
DIG_I1
+24V
DIG_I2
+24V
DIG_I3
+24V
DIG_I4

+24V
DIG_O1
+24V
DIG_O2
+24V
DIG_O3
+24V
DIG_04

NTC3A
NTC3B
NTC4A
NTC4B

NTC2A
NTC2B

NTC1B

NTC1A
27-0028
core 1 2 7x 3 5 6 core
21
0,75mm²
K2 7x
0,75mm²
22

21 21

K3 K1
1 3 5 1 3 5 1 3 5
22 22
X6/5

outside temperature
when SL
remove bridge
K2 K3 K1

condensation temperature
1

2 4 6 2 4 6 2 4 6 ge ge ge

A1 A1 A1 F1
K1 K2 K3
2

A2 A2 A2

br br
X6/4

br

QV X6/1 2 3
W2 U1
V2 V1
U2 W1

F1

colours
rt=red
ws=white
gr=grey
br=brown
bl=blue
li=lila
gn=green
ge=yellow
X1/1 sw=black

EKxx_R electrical heating (SL) with HMI controller and Grosskopf G m b H

flow chart 17 , 31 drawnOS 26.03.2015
controller 27-0028 page 1 modify OS 22.03.2017 Z.- Nr. 96-ES-4202
M11-11.4 = fan K10 = contactor fan in MOA X10 = terminal box in RE F10 = fuse 10A E12 = electrical heating TE = NTC stainless steel tube 10K type 27-0006
K12 = contactor electrical heating in MOA X12 = terminal box in RE F11-11.4 = klixon fan motor E12.1 = drain line heating TK = NTC plastic tube 10K type 27-0005
K12.1 = contactor drain line heating in MOA electrical heating F12 = fuse electrical heating
F12.1 = thermal 80°C (option)
F12.2 & 12.3 = safety klixon electrical heating
24V
to m-0-a switch module

CAN H
CAN L
GND
400V L3
400V L2
X10/ 2 5
400V L1
F12
F10
Jumper CAN-Bus set at last compartment. Else remove.
- L H + ON OFF
1 3 5 1 3 5 13 23
CAN IO-module /
ID x/0 CAN
JP1 CAN
K10 K12 K12.1

DIG_O1

DIG_O2

DIG_O3

DIG_04

DIG_I1

DIG_I2

DIG_I3

DIG_I4
NTC2A

NTC2B

NTC3A

NTC3B

NTC4A

NTC4B
NTC1B
NTC1A

+24V

+24V

+24V

+24V

+24V
+24V

+24V
+24V
2 4 6 14 24
2 4 6
F12.1
core 1 2 3 core 1 2 3 core 4 5 core 6 7 core 8
12x0,75mm²
5x2,5mm² 12x0,75mm² 12x0,75mm²

evaporator entrance
12x0,75mm²
X10/ 4 7 10 X12/1 2 3 QV rt

defrost detection
gr
F12.2

evaporator exit
0,5mm²
br sw

expulsion

return air

heating
cooling
rt

1
F12.3
K 10 MV11 MV12 br sw F11-
11.4

2
X10/11
M 11 M 11.1 E12 fan 9
K 12 K 12.1
E12.1
electrical drain line
heating heating
M 11.2
on RE evaporators see
PE heaterbars wiring
on wiring diagram
group 95-18....
M 11.3
module additional-RE_R for refrigeration unit with controller 27-0028, drawn. OS
Grosskopf GmbH
contactor technologie and electrical heating compartment 1 modify
14.11.2016
22.03.2017
page 1 of 3 96-ES-1702a
Notes

Technical Training
CANBus check
Before voltage is fed to the system, the CANBus system must be checked for short circuits.
Proceed as follows:

1. Turn off the ignition and take out the FRIGOBLOCK fuses.
2. Set the MOA switch to alternator.
3. Using a Multimeter, make the following resistance measurements. The measurements can be made at cut-
off points or terminal strip(s) in the MOA.

4. Measurement between CAN-H (brown) and CAN-L (white)

 OL => no terminating resistances activated in the system Underterminated!
 120 Ω => 1 terminating resistance activated in the system Underterminated!
 60 Ω => 2 terminating resistances activated in the system OK (without InverterFilter)
 40 Ω => 3 terminating resistances activated in the system OK (InverterFilter)
 < 40 Ω => more than 3 terminating resistance in the system Overterminated!

5. Measurement between +24V (red) and …

 Ground (blue) => > 10kΩ
 CAN-H (brown) => > 10kΩ
 CAN-L (white) => > 10kΩ
 permanent plus (red/ black) => > 10kΩ

6. Measurement between Ground (blue) and …

 CAN-H (brown) => > 10kΩ
 CAN-L (white) => > 10kΩ
 permanent plus (red/ black) => > 10kΩ

Technical Training
7. Measurement between permanent plus (red/black) and …
 CAN-H (brown) => > 10kΩ
 CAN-L (white) => > 10kΩ

8. Measurement between CAN-H (brown) and …

 CAN-L (white) => > 10kΩ

9. Disconnect the shield of the CANBus cable from GND in the control box of the refrigeration unit and
disconnect the inverter filter from the system, when appropriate.

10.Measure the DC resistance between shield and ground. The resistance should be high-ohm. When it is
lower, a shield is still connected. Locate that ground point and disconnect it.

11. Restore the cable shield connection to GND.

12. Turn back the FRIGOBLOCK fuses and know you can start the Unit.

Technical Training
 FrigoCenter – Helping Guidline

FrigoCenter
Green bar  CAN communication

If not myabe dopple click on the green bar

or check the CAN connection

CAN Overview
Tools – CAN Overview

Change ID of an I/O
card
Choose the right Advanced - Interfaces –
InterfacesID – than change ID by ID

Technical Training
Parameterization
ControllerES
Choose the right Advanced –
Controller/Remote – Set Up ControllerES

Technical Training
Notes

Technical Training
Notes

Technical Training
Notes

Technical Training
Notes

Technical Training
Pressure switch
HP: opens at 42 bar and closes at 32 bar
LP: opens at -0.5 bar and closes at 0.6 bar

Temperature switch

Defrost switch: starts at <0 ° C; ends at > 10 ° C

Alternator safety switch: opens at >150C; closed at <120C
Electric motor Temp. switch: opens at >160°C
Safety switch opens at 60° and closed at 45°

Security components:
F 10 : Generator temperature switch (96-2001a)
Q1: Motor protection switch (96-1612i)
F 1: Motor temperature switch M1 (96-1228j)
F 2: Motor temperature switch M2 (96-1228j)
1. F 6: Low pressure switch (96-1228j)
2. F 7: Hochdruckschalter (95-1228j)
Technical Training
Summary
Preparation How to measure slip ring body
 Carbon particles are conductive.  Use Multimeter
 Blow out the alternator, use brake cleaner spray if necessary.  Disconnected rotor winding

 Blow dry
 Lift the carbon brush spring Terminal to terminal with disconnected Terminal to housing
rotor winding  NO CONTINUITY
 Lift out the carbon brushes  NO CONTINUITY
 Remove the slip ring connection

Visual inspection Brushes

 Brush holder alignment
 Brush spring contact pressure
 Uneven wear
 Brushes have to rest completly and flushed on the slipring
Brush holder Pins Dubo washers
 Brass springs exert  After changing fix  With vibration the pins
constant pressure on with Loctite, also fixed are cleaned , prevents short
carbons. with Brush holder. circuit between carbon brush
holders.

ca.12 mm
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Technical Training
Summary
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Diode Test
Diode strip insulation film insulation  Use Ohmmeter
 Use Ohmmeter  Lift the carbon brushes off the slip ring
One measuring tip at the terminal lug and the other measuring tip at the diode
Note the first measuring: High resistant Ω / low resistant Ω
Red diode strip and housing Terminal and housing
 High resistant Ω  High resistant Ω
 Low resistant Ω :  Low resistant Ω : Change the measuring tip positions
Clean / replace the isulation foil Clean / replace the isulation foil  Opposite of the first measurement , Diode OK
 Both measurements with the same result, Diode defective
0.L 800
k
Technical Training
Summary

How to measure the windings How to measure the windings

How to measure the windings How to measure the windings
 Use insulation meter  Use insulation meter
 Use Ohmmeter  Use insulation meter
 Disconnected every winding  Disconnected every winding
 Disconnected every winding  Disconnected every winding

Rotor: Winding to housing Connection: End winding to End winding

Rotor: Winding terminal to winding terminal Connection: Winding to housing
 NO continuty  No continuty
 Low resistant Ω  No continuty

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Technical Training
Summary
COOL - HEAT COOL - COOL
Technical Training
Summary

OFF - HEAT HEAT - HEAT

Technical Training
Summary
COOL – COOL - HEAT EK COOL - COOL – HEAT FK
Technical Training
Summary

2 Zones General Rule

Cool-Cool: main condenser used as condenser

Heat-Heat: main condenser used as evaporator
Cool-Heat or Heat-Cool:
- the zone in cool used as evaporator
- the zone in heat as condenser
+ Main condenser used for pressure control

Technical Training
Summary Z.-NR. 96-2001a
Z.-Nr. 96-2001a Z.-Nr. 96-2001a
Technical Training
Summary Z.-NR. 96-1612i

Z.-Nr. 96-1612i

Technical Training
Summary Z.-NR. 96-1228j
Z.-Nr. 96-1228j
Technical Training