Thermoking Training Manual 50390

CONTAINER
TRAINING MANUAL
TK50390-4-TM (08-01).
Introduction & Safety Precautions
THERMO KING
INGERSOLL-RAND
Introduction
A. Table of Contents
B. Safety Precautions
1. Refrigeration Theory
2. Basic Refrigeration System Operation
3. Container Refrigeration Units & System Diagrams
4. Thermostat Sequence Diagrams
5. Evacuation
6. R12 to R134a Conversion
7. AC Electricity
8. Refrigeration Unit Schematic/Wiring Diagrams
9. Microprocessor Controllers
10. Container Service Bulletins
11. Gen-Set Configurations
12. Gen-Set Control Systems
13. µP-G “Smart” Gen Set Controller
14. Gen Set Schematic/Wiring Diagrams
15. Alternator Test Procedures (Original Control System)
16. Alternator Test Procedures (New Control System)
17. Notes
1
SAFETY PRECAUTIONS Refrigerant

When removing any refrigerant from a unit, use a recovery
General Practices process that prevents or absolutely minimizes the refrigerant
that can escape to the atmosphere. Although fluorocarbon
1. ALWAYS WEAR GOGGLES OR SAFETY GLASSES. refrigerants are classified as safe refrigerants when proper
Refrigerant liquid and battery acid can permanently dam- tools and procedures are used, certain precautions must be
age the eyes (see First Aid under Refrigerant Oil). observed when handling them or servicing a unit in which
they are used. When exposed to the atmosphere in the liquid
2. Never close the compressor discharge valve with the unit state, fluorocarbon refrigerants evaporate rapidly, freezing
in operation. Never operate the unit with the discharge anything they contact.
valve closed.
First Aid
3. Keep your hands, clothing and tools clear of the fans In the event of frost bite, the objectives of First Aid are to pro-
when the refrigeration unit is running. If it is necessary to tect the frozen area from further injury, to warm the affected
run the refrigeration unit with covers removed, be very area rapidly, and to maintain respiration.
careful with tools or meters being used in the area.
Eyes: For contact with liquid, immediately flush eyes with
large amounts of water and get prompt medical attention.
4. Be sure the gauge manifold hoses are in good condition.
Never let them come in contact with a fan motor blade or Skin: Flush area with large amounts of lukewarm water. Do
any hot surface. not apply heat. Remove contaminated clothing and shoes.
Wrap burns with dry, sterile, bulky dressing to protect from
5. Never apply heat to a sealed refrigeration system or con- infection/injury. Get medical attention. Wash contaminated
tainer. clothing before reuse.
Inhalation: Move victim to fresh air and use CPR or mouth-
6. Fluorocarbon refrigerants, in the presence of an open to-mouth ventilation, if necessary. Stay with victim until
flame or electrical arc, produce toxic gases that are severe arrival of emergency medical personnel.
respiratory irritants capable of causing death.
7. Be sure all mounting bolts are tight and are the correct Refrigerant Oil
length for their particular application. Observe the following precautions when working with or
around refrigerant oil: Do not allow refrigerant oil to contact
8. Use extreme caution when drilling holes in the unit. The your eyes. Do not allow prolonged or repeated contact with
holes may weaken structural components. Holes drilled skin or clothing. To prevent irritation, you should wash thor-
into electrical wiring can cause fire or explosion. Holes oughly immediately after handling refrigerant oil. Rubber
drilled into the refrigeration system may release refriger- gloves are recommended when handling Polyol Ester based
ant. refrigerant oil.
9. Use caution when working around exposed coil fins. The First Aid
fins can cause painful lacerations. Eyes: Immediately flush eyes with large amounts of water
for at least 15 minutes while holding the eyelids open. Get
10. Use caution when working with a refrigerant or refrigera- prompt medical attention.
tion system in any closed or confined area with a limited
Skin: Remove contaminated clothing. Wash thoroughly with
air supply (for example, a trailer, container or in the hold
soap and water. Get medical attention if irritation persists.
of a ship). Refrigerant tends to displace air and can cause
oxygen depletion, resulting in suffocation and possible Inhalation: Move victim to fresh air and restore breathing if
death. necessary. Stay with victim until arrival of emergency person-
nel.
Ingestion: Do not induce vomiting. Immediately contact a
local poison control center or physician.
2
ELECTRICAL and safety glasses. Whichever method is used, do not look at

the wire while it is being cut. The ensuing flash can cause
burns and blindness.
High Voltage
When servicing or repairing a refrigeration unit, the possibil- If the victim has to be removed from a live circuit, pull the
ity of serious or even fatal injury from electrical shock exists. victim off with a non-conductive material. Use the victim’s
Extreme care must be used when working with a refrigeration coat, a rope, wood, or loop your belt around the victims leg or
unit that is connected to a source of operating power, even if arm and pull the victim off. DO NOT TOUCH the victim.
the unit is not running. Lethal voltage potentials can exist at You can receive a shock from current flowing through the vic-
the unit power cord, inside the control box, at the motors and tim’s body.
within the wiring harnesses.
After separating the victim from power source, check imme-
Precautions diately for the presence of a pulse and respiration. If a pulse is
1. Be certain the unit On/Off switch is turned OFF before not present, start CPR (Cardio Pulmonary Resuscitation) and
connecting or disconnecting the unit power plug. Never call for emergency medical assistance. If a pulse is present,
attempt to stop the unit by disconnecting the power plug. respiration may be restored by using mouth to-mouth resusci-
2. Be certain the unit power plug is clean and dry before tation, but call for emergency medical assistance.
connecting it to a power source.
3. Use tools with insulated handles that are in good condi- Low Voltage
tion. Never hold metal tools in your hand if exposed,
energized conductors are within reach. Control circuits are low voltage (24 Vac and 12 Vdc). This
4. Do not make any rapid moves when working on high voltage potential is not considered dangerous, but the large
voltage circuits. If a tool or other object falls, do not amount of current available (over 30 amperes) can cause
attempt to grab it. People do not contact high voltage severe bums if shorted to ground.
wires on purpose. It occurs from an unplanned move-
ment. Do not wear jewelry, watch or rings. These items can short
5. Treat all wires and connections as high voltage until a out electrical circuits and cause severe burns to the wearer.
meter and wiring diagram show otherwise.
6. Never work alone on high voltage circuits on the refriger- General Safety Precautions for
ation unit. Another person should always be standing by
in the event of an accident to shut off the refrigeration Servicing Units (or Containers)
unit e refrigeration unit and to aid a victim. Equipped with a Microprocessor
7. Have electrically insulated gloves, cable cutters and
safety glasses available in the immediate vicinity in the
Controller
event of an accident. Precautions must be taken to prevent electrostatic discharge
when servicing the µP-D microprocessor, output module and
First Aid related components. If these precautionary measures are not
IMMEDIATE action must be initiated after a person has followed, the risk of significant damage to the electronic com-
received an electrical shock. Obtain immediate medical assis- ponents of the unit is possible.
tance if available.
The primary risk potential results from the failure to wear
The source of shock must be immediately removed by either adequate electrostatic discharge preventive equipment when
shutting down the power or removing the victim from the handling and servicing the microprocessor. The second cause
source. If it is not possible to shut off the power, the wire results from electric welding on the unit and container chassis
should be cut with either an insulated instrument (e.g., a without taking precautionary steps.
wooden handled axe or cable cutters with heavy insulated
handles) or by a rescuer wearing electrically insulated gloves
3
Controller Repair Welding of Units or Containers

When servicing the microprocessor, it is necessary to ensure Whenever electric welding is to be performed on any portion
that electrostatic discharges are avoided. Potential differences of the refrigeration unit, container or container chassis with
considerably lower than those which produce a small spark the refrigeration unit attached, it is necessary to ensure that
from a finger to a door knob can severely damage or destroy welding currents are NOT allowed to flow through the elec-
solid-state integrated circuit components. The following pro tronic circuits of the unit. These procedures must be rigidly
must be rigidly adhered to when servicing these units to avoid adhered to when servicing these units to avoid damage or
microprocessor damage or destruction. destruction.
1. Disconnect all power to the unit. 1. Disconnect all power to the refrigeration unit.
2. Avoid wearing clothing that generates static electricity 2. Disconnect all quick-disconnect wire harnesses from the
(wool, nylon, polyester, etc.). back of the µP-D controller. Also disconnect the wire
3. Do wear a static discharge wrist strap (TK P/N 204-622) harness from the Output module.
with the lead end connected to the microprocessor’s 3. If the unit is equipped with an Integrated Remote Moni-
ground terminal. These straps are available at most elec- tor Unit (IRMU)/Remote Communications Device
tronic equipment distributors. DO NOT wear these straps (RCD), disconnect all wire harnesses from the IRMU/
with power applied to the unit. RCD circuit board.
4. Avoid contacting the electronic components on the circuit 4. Switch all of the electrical circuit breakers in the control
boards of the unit being serviced. box to the OFF position.
5. Leave the circuit boards in their static proof packing 5. Weld unit and/or container per normal welding proce-
materials until ready for installation. dures. Keep ground return electrode as close to the area
6. If a defective microprocessor is to be returned for repair, to be welded as practical. This will reduce the likelihood
it should be returned in the same static protective packing of stray welding currents passing through any electrical
materials from which the replacement component was or electronic circuits.
removed. 6. When the welding operation is completed, the unit power
7. After servicing the circuit board and any other circuits, cables, wiring and circuit breakers must be restored to
the wiring should be checked for possible errors before their normal condition.
restoring power.
4
SECTION 1
Refrigeration Theory
1-1
Section 2-Basic Refrigeration System Operation
1-2
Section1 - Refrigeration Theory
Refrigeration Fundamentals
Principles of Heat Transfer
In this section you will learn the fundamental principles of heat transfer. These principles are the
foundation for your understanding of temperature control.
Refrigeration and Air Conditioning

Thermo King manufactures and distributes refrigeration and air conditioning systems. The key difference between
refrigeration and air conditioning is the temperature level.
Refrigeration is the process of transferring heat away from an area to

achieve a temperature of approximately 65°F (18°C) or colder. Refrig-
eration is accomplished by Thermo King truck, trailer and marine con-
tainer units.
Air conditioning occurs when heat is transferred away from an area to

maintain a comfortable temperature for most peopleusually 65°F
(18°C) to 75°F (24°C). Thermo King provides air conditioning units
for a variety of applications, including city transit buses, shuttle buses,
and large motor coach applications.
Transport Temperature Control

This manual is focused on the cooling function of tempera-
ture control equipment. But most units are also capable of
heating when necessary to protect cargo in cold ambient con-
ditions. Rather than the terms air conditioning or refrigera-
tion, we prefer the more general term transport temperature
control to describe our business; it includes heating and cool-
ing over a wide temperature range.
1-3
Heat Is Everywhere!
The total absence of heat is 460 degrees below zero Fahrenheit
(-273°C). This is called absolute zero. It is unlikely that you will ever
experience "no heat". Even ice cream at -20°F (-29°C) contains heat
energy. We know this by the simple fact that the ice cream can be
made even colder by removing additional heat energy. Thermo King
units don’t make coldthey remove heat!
Heat enters a temperature controlled compartment from many
sources
• Product that is loaded too warm
• Heat from the sun and high outside temperatures
• Door openings during loading and unloading
• Heat generated by the cargo as it ripens
A Thermo King unit simply removes unwanted heat from a temperature-controlled compartment. If heat is
removed faster than it enters, the compartment gets colder. If heat is removed at the same rate it enters, compart-
ment temperature remains the same.
Thermo King Units Do Not Make COLD! They remove Heat.
Matter, Molecules, and Temperature

Your body and everything around you is made of tiny building blocks called molecules. Unless it's -460 °F (abso-
lute zero), a molecule contains heat energy and is always moving. Warm molecules move faster than cool mole-
cules.
Heat Transfer
Heat energy normally transfers from one molecule to the next. But this movement of heat energy can only occur if
there is a difference in temperature between the two molecules. If two molecules (or any objects, for that matter)
are the same temperature, no heat transfer occurs. Heat energy always moves from higher energy areas (hot) to
lower energy areas (cold).
Heat Always Moves From Hotter To Colder
For example, if you hold an ice cube in your hand, heat energy transfers
from your warm hand to the cool ice. Your hand becomes colder (loses
heat energy) and the ice becomes warmer (gains heat energy).
1-4
The speed of heat transfer from one object to another is affected by the
temperature difference between the two objects. Heat energy travels
fast when there is a great temperature difference between two objects.
For example, that ice cube would melt quickly in boiling water, more
slowly in your hand, and very slowly in a cool refrigerator.
Thermo King unit operation relies on these two principles of heat transfer:
• Heat energy always move from “hotter” to “colder”.
• Heat transfer occurs quickly when there is a large temperature difference between two objects
Methods of Heat Transfer

Three additional principles of heat transfer affect the design and operation of Thermo King unitsradiation, con-
duction and convection.
Radiation
Radiation is a method of heat energy transfer. Radiant energy travels through empty space.
The sun’s energy is an example. Energy from the sun must pass through 93 million miles
of space before reaching our atmosphere. It does not warm the emptiness of outer space; it
only becomes heat energy when absorbed by an object. Even when painted white to help
reflect the sun’s radiant energy, refrigerated trucks, trailers, and containers absorb
unwanted heat energy from the sun.
Conduction
Conduction occurs when heat energy moves through a solid object, through a fluid, or when it moves directly from
one substance to another in direct contact. In our earlier example, heat energy was conducted directly from the
warm hand to the ice cube
If a warm spoon is placed in ice water, heat energy will be quickly conducted from
the spoon to the surrounding water (hot to cold). If a cool spoon is placed in hot
water, heat energy will be quickly conducted from the water to the spoon (hot to
cold).
The principle of conduction moves the sun’s heat energy through the ceiling and
walls of a refrigerated truck or trailer. Although insulation is used in the walls and
ceiling to reduce heat conduction, some heat passes into the refrigerated compart-
ment. Chapter three will help you understand how a Thermo King unit uses the
principle of conduction to move unwanted heat from the inside to the outside of the refrigerated box.
1-5
Convection
Convection is the movement of heat within a moving fluid. The fluid can be a liq-
uid (such as water) or a gas (such as air). For example, in an engine cooling sys-
tem, convection contributes to coolant flow between the engine and radiator.
A pump, fan or blower is often used to increase fluid movement. Thermo King
units include powerful fans to force air movement throughout the temperature
controlled compartment.
Heat Moves by Radiation, Conduction, and Convection
Heat Transfer and Equipment Design

Manufacturers of temperature-controlled enclosures know how to
deal with conduction, radiation and convection. Reflective colors
are often used to minimize the absorbtion of the sun’s radiant
energy. Quality insulation is used to reduce heat transfer (con-
duction) through the walls, floor and ceiling. Door seals are
carefully designed to keep warm, moist air out of the box. And
bus (coach) manufacturers install tinted windows to reduce the
absorption of the sun’s heat by coach interiors.
All of these efforts cannot completely overcome a funda-

mental principle of heat transferheat energy always
moves from hot to cold. Some heat energy will always
manage to move from the warm outside to the cool inside of
a refrigerated compartment.
A Thermo King Unit Primarily Moves Unwanted Heat To The Outside.
1-6
Heat Measurement
Heat measurement is part of our daily lives. When someone says, "It’s too hot today", you understand what
they mean. But the words "hot" and "cold" are relativetheir meaning is defined by the subject at hand.
For example, a hot load of lettuce may be 65°F (18°C), but a hot load of ice cream is 0°F (-18°C). (Ice
cream is normally transported at -20°F/-29°C). Some people would consider a bus coach hot when it’s
75°F (24°C) and cold when it’s 65°F (18°C).
Heat Intensity
A thermometer, scaled in degrees Fahrenheit or degrees Celsius, is commonly
used to measure and communicate heat intensity. If an object contains a great
deal of heat energy, the temperature is high. If an object contains little heat
energy, the temperature is low. The formulas below show how to convert
between the two temperature scales.
____°C x 1.8 + 32 = ____°F ____°F - 32 ÷ 1.8 = ____°C
Heat Quantity
A thermometer can only indicate heat intensityit cannot indicate heat quantity. A candle flame and a camp fire
may be the same temperature (intensity) but the camp fire contains much more heat energy. The quantity of heat
energy is commonly measured with a unit known as the British Thermal Unit (Btu) or the metric equivalent, gram-
calorie. One Btu is the amount of heat required to raise the temperature of one pound of water one degree
Fahrenheit. One gram-calorie is the amount of heat required to raise the temperature of one gram of water one
degree Centigrade.
The heat energy from one paper match is approxi-

mately one Btu (0.252 gram-calories).
The illustration shows how the temperature of one
pound of water is raised from 70°F to 71°F when a
single Btu is added.
One Btu is the amount of heat required

to raise the temperature of one pound of water
one degree Fahrenheit.
These formulas convert between English and metric units of heat.

____Watts x 3.409 = ____BTUs per hour
____ BTUs x 0.252 = ____ kilogram calories (kcal)
____ BTUs ÷ 3.409 = ____ Watts
1-7
Cooling Capacity
To warm an object, add BTUs. To cool an object, remove BTUs. Most Thermo King units can add BTUs in the
operating mode called HEAT. However, they’re usually called upon to remove BTUs in the operating mode called
COOL. The cooling capacity of a Thermo King unit is measured in BTUs per hour (BTU/hr) or in Watts. This is a
measure of the unit's ability, per hour of operation, to move BTUs (or Watts) from the inside to the outside of an
enclosure. For example, a refrigeration unit may be rated at 10,000 Btu's per hour. In one hour, it can move 10,000
Btu's from inside the box to the outside. If the box contained 10,000 pounds of water, the temperature of the water
can be reduced one degree Fahrenheit in one hour. (Remember, one Btu is the amount of heat required to change
the temperature of one pound of water one degree Fahrenheit).
Unit capacity:----------------------------------------------------------------------- 10,000 Btu’s / hr
Cargo:-------------------------------------------------------------------------------- 10,000 lbs. water
Btu’s required to change load temperature one degree Fahrenheit: -------- 10,000 Btu’s
Calculation: ------------------------------------------------------------------------- 10,000 Btu’s÷10,000 Btu/hr unit capacity = 1 hr
To lower the water temperature by 10°F, the unit must be operated for ten hours. (Of course, that assumes that no
additional heat is entering the water through the box walls, floor and ceiling!)
1-8
Specific Heat
You learned that a very specific amount of heat must be moved (one Btu) to change the temperature of one pound
of water one degree Fahrenheit. It is important to know that water does not change temperature as easily as most
other substances. In other words, compared to water, most substances require less heat movement to change tem-
perature.
To compare the “willingness” of various substances to change temperature, substances have been given a numeric
value to compare them to water. This value is called specific heat. Water is the standardthe specific heat of water
is 1.0. The table below provides the specific heat value for several common foods. Note that the specific heat of
bacon is 0.5. This means that bacon absorbs (or releases) heat energy two times easier than water. The specific heat
of butter is 0.33it changes temperature three times easier than water.
Commodity Specific Heat Above Freezing
BTU/Pound/°F
Water 1.00
Watermelons 0.97
Lettuce, iceberg 0.96
Strawberries 0.93
Milk (whole) 0.92
Carrots 0.90
Beef (fresh) 0.75
Cheese, cheddar 0.62
Bacon 0.50
Milk Chocolate 0.41
Butter 0.33
The specific heat value of a perishable load affects the amount of time required to change product temperature.
Referring again to our example, a 10,000 pound load of water can be cooled 1°F in one hour by a unit rated at
10,000 Btu/hr. The same unit will cool 10,000 pounds of carrots ten percent quicker (0.9 hours) because the spe-
cific heat of carrots is 0.9. Carrots change temperature 10% quicker than water. The formula for computing time
required to change load temperature may be written as:
SPECIFIC HEAT x WEIGHT x DEGREES CHANGE = HOUR REQUIRED TO CHANGE
UNIT CAPACITY (Btu’s / hour)
1-9
Heat of Respiration
Melons, strawberries and other fresh produce create heat energy as they ripenheat of respiration. Heat of respi-
ration is calculated in BTUs per hour, per ton. The chart below provides a few common examples.
For example, a ton (2000 pounds) of strawberries, at 32°F, produces 113-158 BTUs per hour. At 40°F, the straw-
berries produce 150-283 BTUs per hour. At 60°F, the same strawberries produce up to 846 BTUs per hour! This
additional heat will extend the time required to lower product temperature. It may take many days to reduce the
temperature of these strawberries to the recommended storage temperature. Unfortunately, the strawberries would
be spoiled beyond recognition before they reached the recommended temperature.
Commodity Heat of Respiration

BTU/Hr/Ton
Asparagus 488-963 @ 40°F
Carrots 146 @ 40°F
Lettuce (head) 113 @ 40°F
Melons (Cantaloupe) 83 @ 40°F
Strawberries 150-283 @ 40°F
Temperature-sensitive products must be at the recommended storage temperature when loaded.

Transport refrigeration units are designed to maintain product temperaturenot lower product
temperature.
The appendix of this manual contains a chart listing moisture content, initial freezing point, and specific heat of
foods.
Heat of Respiration?
Of course, bus passengers can hardly be compared to a load of strawber-
ries. Like strawberries, however, each passenger gives off heatabout 580
BTUs per hour. Add the heat of each passenger to the heat entering when
the doors open and passengers stream in and out. Now add the sun’s heat
coming through the glass and engine heat being conducted through the
coach body. You can see why bus air conditioning requirements range up
to 125,000 BTUs per hour!
1-10
Terms To Remember
Refrigeration
Air Conditioning
Transport Temperature Control
Absolute Zero
Radiation
Conduction
Convection
Heat Transfer
Heat Intensity
Fahrenheit
Celsius
British Thermal Unit (Btu)
Gram-Calories
Watts
Cooling Capacity
Specific Heat
Heat of Respiration
1-11
How Are You Doing So Far?

This is a long chapter with a great deal to remember. Before reading the
rest of this chapter, answer the following questions to review what you’ve
learned.
1. True or False
The main difference between refrigeration and air conditioning is the temperature in the controlled area.
2. What’s the preferred term for the transport heating and cooling business?
a. Transport refrigeration
b. Mobil cooling
c. Transport air conditioning
d. Transport temperature control
3. The total absence of heat is "absolute zero". This temperature is

a. 0°F.
b. 0°C.
c. - 360°F.
d. - 460°F.
4. Heat intensity is measured in

a. degrees.
b. Btu’s.
c. calories.
d. CFM.
5. Which of the following statements is FALSE?

a. Transport temperature control units are designed to maintain product temperature.
b. Heat energy transfers quickly when there is a large temperature difference.
c. Heat energy always moves from colder areas to hotter areas.
d. When produce ripens it creates heat. This is the heat of respiration.
1-12
6. Heat enters a temperature controlled compartment

a. through leaking door seals.
b. when product is being loaded and unloaded.
c. through insulation in the walls, ceiling and floor.
d. All of the above.
7. If heat is removed from a box faster than heat enters the box, box temperature
a. goes up.
b. goes down.
c. remains the same.
8. Which method of heat transfer occurs when heat moves through trailer, truck, or container walls?
a. Conduction
b. Radiation
c. Convection
9. The amount of heat required to raise the temperature of one pound of water one degree Fahrenheit. This is
the definition of
a. British Thermal Unit.
b. specific heat.
c. heat of respiration.
d. ambient temperature.
10. What is the approximate time necessary to reduce this load of bacon one degree Fahrenheit?
a. 30 minutes
b. 50 minutes Product: Bacon
Weight: 1,000 pounds
c. 60 minutes Specific Heat: 0.50
d. 4 hours Unit Capacity: 1,000 Btu’s /Hr.
1-13
Section 1-Refrigerqtion Theory
Latent Heat and Pressure/Temperature

In this section you will learn how "latent heat" and the manipulation of system pressures are fundamental to
system operation.
Latent Heat
Earlier you learned about heat measurement. You learned that the intensity of heat can be measured with a ther-
mometerthis is sensible heat. There is another type of heat that cannot be measured with a thermometerlatent
heat. Latent heat is heat absorbed or released when a substance changes its physical state.
Changing States: SolidLiquidGas
Understanding latent heat is your key to understanding refrigeration systems. To explain this concept, let’s begin
with the physical behavior of something familiarwater!
Water, like many substances, can exist in three physical statessolid, liquid and vapor
(gas). If you add heat to a block of ice it becomes water. It changes from the solid state to
the liquid state. (Some call it a phase change.) If you add enough heat to water, the water
boils and becomes steam. The water changes state from liquid to vapor (gas).
It works the other way, too. If you remove heat from steam (if you cool it), the steam
returns to water. If you continue to remove heat from the water, it becomes ice.
As you add heat to a block of ice, a thermometer will clearly indicate a temperature rise. And as the temperature
rises, the ice will change from solid, to liquid, to vapor. But if you watch the thermometer very carefully, you will
notice something strange. Although you continue to add heat energy, the thermometer stops rising during each
change of state!
During each change of state, the heat is being absorbed to make the phase change possible. This heat, that cannot
be measured on the thermometer, is latent heat. A large amount of latent heat is absorbed or released as a sub-
stance changes state.
Latent Heat Is Absorbed Or Released During A Change Of State.

Latent Heat Cannot Be Measured With A Thermometer.
1-14
This illustration will help you understand how heat energy is used to convert one pound of ice at 0°F (-17.7°C)
to steam at 212 °F (100°C) .
1. We begin with a bock of ice, at 0°F (-17.7°C), weighing one pound (0.45 kilograms). Sixteen BTUs of heat
raises the ice temperature from 0°F (-17.7°C) to 32°F (0°C). The sixteen BTUs added here are called sensible
heat heat energy that can be “sensed” or measured with a thermometer and results in temperature change.
Ice has a specific heat of “0.5”. The BTUs required to raise the temperature 32 degrees is .5 X 32 or 16 BTUs.
2. When the ice temperature reaches 32°F (0°C), it begins to melt. However, the temperature rise stops while 144
additional BTUs are absorbed by the ice. This heat cannot be sensed with a thermometerthis is latent heat.
Latent heat is always involved in a change of state. While the 144 Btu's of latent heat are absorbed, the ice
changes to water.
144 BTUs of latent heat are required to change one pound of ice from solid to liquid.
3. After the ice becomes water, we continue to add Btu's and the water temperature rises. As we add 180 BTUs of
sensible heat, the water temperature steadily rises from 32°F (0°C) to 212°F (100°C).
Remember, one Btu is the amount of heat required to raise the temperature of one pound of water one
degree Fahrenheit. Here we have one pound of water being raised 180 degrees (from 32°F to 212°F).
180 BTUs of sensible heat are absorbed.
4. When the water temperature reaches 212°F (100°C), it begins to boil. However, the temperature rise stops
while 970 additional BTUs are absorbed by the water. 970 BTUs of latent heat are absorbed while water
changes to steam.
970 BTUs of latent heat are required to change one pound of water from liquid to vapor.
5. If we continue adding heat to the steam, the steam becomes super heated. Super heated vapor contains heat
beyond the amount required to maintain it as a vapor. Super heated water vapor is steam with a temperature
above 212°F (100°C).
1-15
Latent Heat of Vaporization

The amount of heat required to make the phase change from liquid to vapor is the latent heat of vaporization. In
the illustration on the previous page, 970 BTUs of latent heat were absorbed (latent heat of vaporization) as the liq-
uid became vapor.
Latent Heat of Condensation

If we reverse the processif we cool the steam until it becomes waterhuge amounts of heat are released. Just as
970 BTUs were absorbed to change liquid to vapor, 970 BTUs are released as vapor cools and returns to the liquid
state. The heat energy released when vapor becomes liquid is the latent heat of condensation.
.
Every change of state absorbs or releases large amounts of heat energy.
All refrigeration units use these two principles to move heat from one place to another. Latent heat of vaporization
is used to absorb large amounts of heat inside the box. Latent heat of condensation is used to release large amounts
of heat outside the box. The evaporator absorbs heat. The condenser releases heat.
1-16
The Pressure/Temperature Relationship

Pressure Affects The Boiling Point of Liquids
At sea level, water in an open container boils at 212°F (100°C). If you increase the heat
source, the water will boil more violently but the water temperature will never rise above
212°F (100°C). This is because the boiling water releases heat with the rising vapor.
.
At sea level, water in an open container boils when it reaches 212°F (100°C).
However, the temperature of water in a closed container can rise above 212°F (100°C).
Trapped vapor builds pressure on the water’s surface. Increased surface pressure raises the
boiling point of liquidthe water must get hotter than 212°F (100°C) before it can boil and
release excess heat energy.
CAUTION!
Boiling liquid in a closed container may cause the container to explode causing serious injury
or death!
Raising The Boiling Point

Raising the boiling point of liquid by pressurizing the container is
a common practice. The automobile uses a special radiator cap
that allows pressure in the cooling system to rise while also pre-
venting excess pressure build-up. Raising the system pressure
(and boiling point) is necessary because automobile cooling sys-
tems often operate at 230°F (110°C) or higher. Non-pressurized
water would violently boil out of the radiator and the engine
would overheat. Simply maintaining a cooling system pressure of 10 psi raises the boiling point to 240°F (115°C).
(The addition of an anti-freeze solution will raise the boiling point even higher.) For every pound of pressure, the
boiling point of water increases approximately 3°F.
.
Raising pressure on a liquid raises the boiling point.
1-17
Section 1-Refrigeration Theory
Lowering The Boiling Point

If raising pressure raises the boiling
point, it stands to reason that lowering
pressure will lower the boiling point.
At sea level, the earth’s atmosphere
presses down on all objects with a force
of 14.7 pounds per square inch (101.3
kPa). At this pressure, the boiling point
of water is 212°F (100°C). As you move higher in the earth’s atmosphere (when you’re climbing a mountain, for
example), atmospheric pressure is reduced. At 5000 feet (1524 meters), atmospheric pressure is only 12.3 psi and
the boiling point is reduced to 203°F (95.1°C). For every 550 feet (167 meters) above sea level, the boiling point
of water is reduced by approximately 1°F.
.
Lowering pressure on a liquid lowers the boiling point.
1-18
Summary: Refrigeration Fundamentals

This chapter has presented you with the fundamental principles used in the operation of all refrigeration
systems. The fundamental principles are:
Heat Can Be Moved

• All refrigeration systems move heat
Heat Moves By Conduction, Convection, and Radiation

• Transport temperature control systems involve all three types of heat transfer
A Change of State Releases or Absorbs Heat Energy

• All refrigeration systems repeatedly use this principle to absorb and release heat
Latent Heat of Condensation

• This principle is applied in the condenser section of all refrigeration systems to release large amounts of heat
energy.
Latent Heat of Evaporation

• This principle is applied in the evaporator section of all refrigeration systems to absorb large amounts of heat
energy.
Boiling Point Is Controlled By Pressure

• Refrigeration systems manipulate the refrigerant’s boiling point to force heat absorption in one area and heat
release in another area.
The next chapter will explain how each of these principles is applied in a simple four-component refrigeration sys-
tem.
1-19
Let’s see how much you remember about sensible heat, latent heat, and the affect of
pressure on boiling points.
1. Sensible heat
a. can be measured with a thermometer.
b. absorbs a large amount of heat energy as liquid changes to gas.
c. absorbs a large amount of heat energy as solid changes to liquid.
d. absorbs a large amount of heat energy as solid changes to gas.
2. Latent heat
a. cannot be measured with a thermometer.
b. absorbs a large amount of heat energy as liquid changes to gas.
c. releases a large amount of heat energy as gas changes to liquid.
d. All of the above.
3. Latent heat of condensation is heat energy

a. released when vapor changes to liquid.
b. absorbed when vapor changes to liquid.
c. absorbed when liquid changes to vapor.
d. absorbed when ice changes to water.
4. Latent heat of vaporization is heat energy

a. released when vapor changes to liquid.
b. absorbed when vapor changes to liquid.
c. absorbed when liquid changes to vapor.
d. absorbed when ice changes to water.
5. True or False
At sea level, atmospheric pressure is 14.7 psi (101.3 kPa) and the boiling point of water is 212°F (100°C).
Reducing the pressure on water will raise its boiling point; increasing pressure will lower the boiling point.
1-20
REFRIGERATION THEORY sea level of 29.2 inches of mercury. At pressures above that,
boiling would not take place. Pressures from 1,500 to 2,000
The table below illustrates the reduction of the boiling point microns are required for effective dehydration.
of water with a reduction of pressure. At normal room tem-
peratures, dehydration by evacuation requires pressures below NOTE: It is important to remember that gauge pressure has
0.40 psia, which means a corresponding vacuum reading at no relationship to absolute pressure.
Pounds Per
Boiling Boiling Inch of
Inches of Square Inch
Temperature Temperature Mercury kPa Microns
Mercury (PSI)
of H20 in F. of H20 in C. Vacuum
(Pressure)
212 F 100 C 0 -0 759,968 29.92 14.696
205 F 96 C 4.92 -16.62 635,000 25.00 12.279

194 F 90 C 9.23 -31.19 525,526 20.69 10.162
176 F 80 C 15.94 -53.87 355,092 13.98 6.866
158 F 70 C 20.72 -70.03 233,680 9.20 4.519
140 F 60 C 24.04 -81.25 149,352 5.88 2.888
122 F 50 C 26.28 -88.82 92,456 3.64 1.788
104 F 40 C 27.75 -93.79 55,118 2.17 1.066
86 F 30 C 28.67 -96.90 35,560 1.25 .614
80 F 26 C 28.92 -97.74 25,400 1.00 .491
76 F 24 C 29.02 -98.08 22,860 .90 .442
72 F 22 C 29.12 -98.42 20,320 .80 .393
69 F 21 C 29.22 -98.76 17,780 .70 .344
64 F 18 C 29.32 -99.10 15,240 .60 .295
59 F 15 C 29.42 -98.43 12,700 .50 .246
53 F 12 C 29.52 -99.77 10,160 .40 .196
45 F 7C 29.62 -100.1 7,620 .30 .147
32 F 0C 29.72 -100.5 4,572 .18 .088
21 F -6 C 29.82 -100.7 2,540 .10 .049
6F -14 C 29.87 -100.9 1,270 .05 .0245

-24 F -31 C 29.91 -101.09 254 .01 .0049
-35 F -37 C 127 .005 .00245
-60 F -51 C 25.4 .001 .00049
-70 F -57 C 12.7 .0005 .00024
-90 F -68 C 2.54 .0001 .000049
1-21
Temperature - Pressure Chart temperatures above those given for the corresponding pres-
sures. This is true of any substance which can exist in liquid
The chart shows the temperature at which this substances will
or gaseous states, but the change-of-state points are different
change from a liquid to a gas, or vice-versa, at various pres-
for each substance. It is by virtue of these properties that
sures. Two important points must be remembered when con-
mechanical refrigeration is possible.
sidering this pressure-temperature relationships; Refrigerant-
12 cannot exist as a gas at temperatures below those given for
corresponding pressures, neither can it exist as a liquid at
R-134a PRESSURE-TEMPERATURE R-404A PRESSURE-TEMPERATURE

RELATIONSHIP RELATIONSHIP
F° C° PSIG kPa F° C° PSIG kPa
-30.0 F -34.4 C 9.7* -32.8 -30.0 F -34.4 C 9.9 68.2
-25.0 F -31.7 C 6.8* -23.0 -25.0 F -31.7 C 12.9 88.9
-20.0 F -28.9 C 3.6* -12.2 -20.0 F -28.9 C 16.3 112.3
-15.0 F -26.1 C 0.0 0.0 -15.0 F -26.1 C 20.0 137.8
-10.0 F -23.3 C 2.0 13.8 -10.0 F -23.3 C 23.9 164.7
-5.0 F -20.6 C 4.1 28.3 -5.0 F -20.6 C 28.2 194.3
0.0 F -17.8 C 6.5 44.8
0.0 F -17.8 C 32.8 226.0
5.0 F -15.0 C 9.1 62.7
5.0 F -15.0 C 37.9 261.1
10.0 F -12.2 C 12.0 82.7
10.0 F -12.2 C 43.3 298.3
15.0 F -9.4 C 15.1 104.1
20.0 F -6.7 C 18.4 126.8 15.0 F -9.4 C 49.2 339.0
25.0 F -3.9 C 22.1 152.4 20.0 F -6.7 C 55.5 382.4
30.0 F -1.1 C 26.1 179.9 25.0 F -3.9 C 62.4 429.9
35.0 F 1.7 C 30.4 209.6 30.0 F -1.1 C 69.5 478.9
40.0 F 4.4 C 35.0 241.3 35.0 F 1.7 C 77.2 531.9
45.0 F 7.2 C 40.0 275.8 40.0 F 4.4 C 85.5 589.1
50.0 F 10.0 C 45.4 312.9 45.0 F 7.2 C 94.3 649.7
55.0 F 12.8 C 51.2 353.0 50.0 F 10.0 C 103.7 714.5
60.0 F 15.6 C 57.4 395.7 55.0 F 12.8 C 113.7 783.4
65.0 F 18.3 C 64.0 441.3
60.0 F 15.6 C 124.3 856.4
70.0 F 21.1 C 71.1 490.2
65.0 F 18.3 C 135.5 933.6
75.0 F 23.9 C 78.6 541.9
70.0 F 21.1 C 147.5 1016.3
80.0 F 26.7 C 86.7 597.7
85.0 F 29.4 C 95.2 656.3 75.0 F 23.9 C 160.2 1103.8
90.0 F 32.2 C 104.3 719.0 80.0 F 26.7 C 173.5 1195.4
95.0 F 35.0 C 113.9 785.2 85.0 F 29.4 C 187.5 1291.9
100.0 F 37.8 C 124.1 855.5 90.0 F 32.2 C 202.5 1395.2
105.0 F 40.6 C 134.9 930.0 95.0 F 35.0 C 218.2 1503.4
110.0 F 43.3 C 146.3 1008.6 100.0 F 37.8 C 234.7 1617.1
115.0 F 46.1 C 158.4 1092.0 105.0 F 40.6 C 252.1 1737.0
120.0 F 48.9 C 171.1 1179.6 110.0 F 43.3 C 270.3 1862.4
115.0 F 46.1 C 289.6 1995.3
*Vacuum (inches Hg) 120.0 F 48.9 C 309.7 2133.8
125.0 F 51.7 C 330.9 2279.9
130.0 F 54.4 C 353.0 2432.2
135.0 F 57.2 C 376.2 2592.0
140.0 F 60.0 C 400.5 2759.4
145.0 F 62.8 C 425.9 2934.5
150.0 F 65.6 C 452.5 3117.7
1-22
Glossary Convection
The method of heat transfer by the circulation of heated por-
Absolute Pressure tions of a fluid. As heat is transferred to a gas, it causes it to
Absolute pressure expressed in pounds per square inch abso- expand. Cooler and more dense air will settle and push the
lute (psia) or kilopascals (kPa) is the pressure existing above a less dense (warmer) air upward.
perfect vacuum.
Dehydration
Ambient Temperature Removing moisture from a refrigeration system or produce.
Ambient temperature is the temperature of the air surrounding
an object. Density
The density of a substance is defined as weight per unit vol-
Atmospheric Pressure ume and is normally expressed in pounds per cubic foot.
The atmosphere surrounding the earth extends many miles Since density is directly related to specific volume, the den-
above the surface of the earth. The weight of that atmosphere sity of a gas may vary greatly with changes in pressure and
pressing down on the earth is relatively constant except for temperature.
minor changes due to changing weather conditions. As a basic
reference for comparison, the atmospheric pressure at sea Desiccant
level has been universally established at 14.7 psi (100 kPa) A chemical used in removal of moisture from refrigerant.
and is equivalent to the pressure exerted by a column of mer- Additional requirements are: Allow oil to pass without affect-
cury 29.92 inches high. ing the efficiency of the desiccant; Remain chemically stable
during operation and idle or storage periods; Retain its origi-
At altitudes above sea level, the depth of the atmospheric nal shape so as not to plug up and restrict the flow of refriger-
blanket surrounding the earth is less; therefore, the atmo- ant.
spheric pressure is less. Evacuation
The removal of air, non-condensable gas and moisture from
Back Seating
inside a refrigerant system through the use of a vacuum pump.
Turning the valve stem all the way out (counter clockwise)
backseats the valve. In this position the valve outlet to the sys- Evaporation
tem is open and the gauge connection closed. A change of state from a liquid to a vapor.
Boiling Point Flash Gas
The temperature at which a liquid vaporizes upon the addition The instantaneous vaporization of refrigerant caused by the
of heat or by the reduction of pressure. reduction of pressure in liquid refrigerant when it passes
British Thermal Unit though a pressure reducing device.
The amount of heat required to produce a temperature change Fluid Flow
of one degree Fahrenheit in one pound of water. In order for a fluid to flow from one point to another, there
must be a difference in pressure between the two points to
Calorie
cause the flow. Fluids may be either liquids or gases. Fluid
The amount of heat required to raise temperature of one gram
flow through pipes or tubing is governed by the pressure
of water one degree Celsius.
exerted on the fluid, the effect of gravity due to the vertical
Capacity rise or fall of the pipe, restrictions in the pipe resisting flow,
Rate of heat transfer measured in tons, BTU per hour, K cal and the viscosity of the fluid.
per hours, or Watts.
Foaming
Change Of State A condition caused by refrigerant boiling out of the compres-
A change from one phase to another, such as a solid to a liquid sor oil.
or liquid to a gas.
Force
Charge Force is a word used to denote total pressure or influence to
The amount and type of refrigerant in a system. cause motion or movement.
Conduction Freeze-up
The method of heat transfer from molecule to molecule. 1. The formation of ice at the expansion valve.
When an object is heated on one end heat will flow to the 2. The formation of a solid ice mass over the evaporator coil
other end. reducing air flow.
1-23
Freeze Point Heat Transmission

The temperature at which a liquid makes a physical change to Any form or combination of heat transfer; usually refers to
a solid. For water this change occurs at 32 F (0 C). conduction, convection or radiation.
Frosting Back Heat Transfer

1. The conditions of frost formation on the suction line dur- Heat always travels from a warm object to a colder one. The
ing the cooling cycle. This happens when the suction line rate of heat travel is in direct proportion to the temperature
temperature is below the dew point. This is a normal con- difference between the two bodies.
dition.
2. The formation of frost on the suction line, accumulator Heat can travel in any of three ways: radiation, conduction, or
tank or any portion of the compressor during the cooling convention.
or heating cycle indicating liquid refrigerant vaporizing
at these locations. This may be abnormal. Ice Melting Capacity
Ice melting effect or equivalent - the refrigeration equal to the
Gas latent heat of fusion of a stated weight of ice at 144 BTU per
A common term for refrigerant in its gaseous state. lb. (42 W).
Heat Insulation (Thermal)

Heat is a form of energy, primarily created by the transforma- The substances used to retard the flow of heat from one area
tion of other types of energy into heat energy. to another. Normally materials that have many small air pock-
ets or resist conduction.
Heat is often defined as energy in transfer, for it is never con-
tent to stand still, but is always moving from a warm body to a Latent Heat
colder body. The terms warmer and colder are only compara- The heat added or removed from a substance that accounts for
tive. Heat exists at any temperature above absolute zero, even a change in state without any measurable change in tempera-
though it may be in extremely small quantities. ture. For some substances there are two conditions where
latent heat is required to make the change of state. They are -
Heat Measurement changing from a solid to a liquid called fusion, and from liq-
The measurement of temperature has no relation to the quan- uid to vapor, or vapor to liquid called vaporization or conden-
tity of heat. A match flame may have the same temperature as sation.
a bonfire, but obviously the quantity of heat given off is vastly
different. When one pound of water boils or evaporates, it absorbs 970
BTU (1023 joules) and to condense one pound of steam to
The basic unit of heat measurement used today in the United water 970 BTU (1023 joules) must be extracted from it.
States is the British Thermal Unit. A BTU is defined as the
amount of heat necessary to raise one pound of water one Latent Heat Fusion
degree Fahrenheit. Its metric equivalent is measured in either A change of substances form a solid to a liquid, or from a liq-
joule or watts. uid to a solid involves the latent heat of fusion.
Heat Measurement (Metric) When one pound of ice melts, it absorbs 144 BTU (151 905
The basic unit of heat measurement in this system will be joules), and if one pound of water is to be frozen into ice, 144
either joule or watts: BTU (151 905 joules) must be removed from the water.
The joule can be defined as a unit of energy or work. The
joule is the work done when the point of application of force Latent Heat Of Sublimation
of one Newton is displaced a distance of one meter in the A change in state directly from a solid to a vapor without
direction of the force. The watt (unit of power). The watt is going through the liquid phase can occur in some substances.
the power that in one second gives rise to energy of one joule. The most common example is the use of “dry ice” or solid
carbon dioxide for cooling.; the same process can occur with
Heat Of Compression ice below the freezing point, and is also utilized is some
The heat of compression is the heat added to the refrigerant freeze-drying processes at extremely low temperatures and
gas as a result of the work energy used in compression. high
vacuums. The latent heat of sublimation equal to the sum of
Heat Of Respiration the latent heat of fusion and the latent heat of evaporation.
The living process in which plants continue to age. Often car-
bon dioxide and water are given off by the product.
1-24
Load PSIA
1. The product that is being refrigerated. Pound per square inch - Absolute.
2. The amount of heat that is being removed by the system.
PSIG
Pressure And Fluid Head Pound per square inch - Gauge.
It is frequently necessary to know the pressure created by a
column of liquid, or possibly the pressure required to force a Purging
column of refrigerant to flow a given vertical distance Releasing a vapor through a refrigeration system, to remove
upwards. contaminants from the system. The common vapors used for
purging are dry nitrogen and refrigerants.
Densities are usually available in terms of pounds per cubic Radiation
foot, and it is convenient to visualize pressure in terms of a Radiation is the transfer of heat by waves similar to light
cube of liquid one foot height, one foot wide, and one foot waves or radio waves. For example, the sun is energy is trans-
deep. Since the base of this cube is 144 square inches, the ferred to the earth by radiation.
average pressure in pounds per square inch is the weight of
the liquid per cubic foot divided by 144. For example, since Saturation Temperature
water weighs approximately 62.4 pounds per cubic foot, the The conditions of temperature and pressure where both liquid
pressure exerted by 1 foot of water is 62.4. (144 =.433 pounds and vapor exist simultaneously is termed saturation. A satu-
per square inch. Then feet of water would exert a pressure of rated liquid or vapor is one at its boiling point, and for water
10 x.433 pounds per square inch. The same relation of height at sea level, the saturation temperature is 212 F (100 C). At
to pressure holds true, no matter what the area of vertical liq- higher pressure, the saturation temperature increases, and
uid column. The pressure exerted by other liquids can be cal- with a decrease in pressure the saturation temperature
culated in exactly the same manner if the density is known. decreases.
Fluid head is a general term used to designate any kind of Saturated Vapor
pressure exerted by a fluid which can be expressed in terms of The condition when a refrigerant has liquid present with the
the height of a column of the given fluid. Hence a pressure of vapor. This occurs in the evaporator when refrigerant is mak-
1 psi may be expressed as being equivalent to a head of 2.31 ing the change from liquid to vapor or in the condenser when
feet of water. (1 psi (.433 psi/ft of water). In air flow through the refrigerant is condensing.
ducts, very small pressures are encountered, and these are Sensible Heat
commonly expressed inches of water. 1 inch of water = Sensible heat is defined as the heat involved in a change of
.433 12 =.036 psi. temperature of a substance. When the temperature of water is
Pressure Drop raised from 32 F (0 C) to 212 F (100 C), an increase in sensi-
The amount of pressure lost while passing through a compo- ble heat content is taking place.
nent. It is the difference between the pressure in and the pres- Short Cycling
sure out. 1. Improper air circulation in a trailer or container causing
Pressure Gauge unit to operate for brief periods.
A pressure gauge is calibrated to read 0 pounds per square 2. Thermostats set with improper differential causing it to
inch when not connected to a pressure producing source. sequence too rapidly from cool to heat or from cool to off
Therefore the absolute pressure of a closed system will position.
always be gauge pressure plus atmospheric pressure. Pres- Slugging
sures below 0 psig are actually negative readings on the The return of liquid refrigerant or oil to the compressor. This
gauge, and are referred to as inches of vacuum. condition will cause knocking and possible damage to com-
Pressure - Temperature Relationship pressor.
The boiling temperature of a liquid is dependent on the pres-
sure being exerted on it. Reducing the pressure reduces the
boiling temperature and increasing the pressure increases the
boiling temperature.
1-25
Specific Gravity Thermodynamics

Specific gravity (sp.gr.) is defined as the ratio of the weight of Thermodynamics is the branch of science dealing with the
a certain volume of a substance as compared to the weight of mechanical action of heat. There are fundamental principles
an equal volume of water. of nature called laws of thermodynamics that govern our
Water is considered to have a specific gravity of one. existence here on earth, several of which are basic in the study
Objects, which float on water, have specific gravity of less of refrigeration.
than one. Objects, which sink in water, have a specific gravity The first and most important of these laws is that energy can
greater than one.Mixtures of salt and water (brine) have spe- neither be created nor destroyed, but can be converted from
cific gravity greater than one. A calcium chloride brine Spe- one type to another.
cific Heat adjusted to freeze at 0 F (-18 C) will have a specific
gravity of 1.18. “Ton” Of Refrigeration Effect
The common unit used to measure refrigeration effect is the
The BTU required to raise the temperature of 1 lb. of a sub- “ton”. This is the amount of heat absorbed in melting one ton
stance 1 F (-17 C). It is expressed in BTU per pound per (2000 lb.) of ice.
degree Fahrenheit or joules per kilogram kelvin. Vapor
Specific Volume Word usually used to denote vaporized refrigerant rather than
Specific volume of a substance is defined as the number of the word gas.
cubic feet occupied by one pound and in the case of liquids Volumetric Efficiency Of The Compressor
and gases, it varies with the temperature and the pressure to Volumetric efficiency is the ratio of the actual volume of
which the fluid is subjected. The volume of a liquid varies refrigerant gas pumped by the compressor to the volume dis-
with temperature, but within the limits of practical refrigera- placed by the compressor.
tion practice, it may be regarded as incompressible.
Watts
Superheated Vapor A term to define the cooling ability of a unit. (Metric equiva-
After a liquid has changed to a vapor, any further heat added lent of BTU.)
to the vapor raises its temperature so long as the pressure to
which it is exposed remains constant. 1 W = 3.42 BTU
Temperature
Temperature is the word used to describe the intensity of heat.
In the United States, temperature is normally measure in
degrees Fahrenheit, but the Celsius scale is widely used in
other parts of the world.
1-26
Boiling Point of Water Varying Pressures
Pounds Per
Temperature Square Inch
F (PSI)
(Pressure)
212 F 100 C 14.696
205 F 96 C 12.279
194 F 90 C 10.162
176 F 80 C 6.866
158 F 70 C 4.519
140 F 60 C 2.888
122 F 50 C 1.788
104 F 40 C 1.066
86 F 30 C .614
80 F 27 C .491
76 F 24 C .442
72 F 22 C .393
69 F 21 C .344
64 F 18 C .295
59 F 15 C .246
53 F 12 C .196
45 F 7C .147
32 F 0C .088
21 F -6 C .049
6F -14 C .0245
-24 F -31 C .0049
-35 F -37 C .00245
-60 F -51 C .00049
-70 F -57 C .00024
-90 F -68 C .000049
1-27
STORAGE CONDITIONS SPECIFIC SPECIFIC

HIGHEST HEAT HEAT LATENT
COMMODITY STORAGE RELATIVE APPROXIMATE WATER FREEZING ABOVE BELOW HEAT OF
(ALPHABETICAL TEMP. HUMIDITY STORAGE CONTENT POINT FREEZING FREEZING FUSION
LISTING) F % LIFE* % F BTU/LB/F BTU/LB/F BTU/LB
Apples 30-40 F (1-5 C) 90 3-8 months 84.1 29.3 F (-1.5C) 0.87 0.45 121
Apricots 31-32 F (-.5-0 C) 90 1-2 weeks 85.4 30.1 F (-1.05C) 0.88 0.46 122
Artichokes (Globe) 31-32 F (-.5-0 C) 95 2 weeks 83.7 29.9 F (-1.16C) 0.87 0.45 120
Asparagus 32-36 F (0 -2 C) 95 2-3 weeks 93.0 30.9 F (-.61C) 0.94 0.48 134
Avocados 45-55 F (7-13 C) 85-90 2-4 weeks 65.4 31.5 F (-.27C) 0.72 0.40 94
Bananas — 85-95 — 74.8 30.6 F (-.77C) 0.80 0.42 108

Beans (Green) 40-45 F (4.4 -7.2 C) 90-95 7-10 days 88.9 30.7 F (-.72C) 0.91 0.47 128
Lima 32-40 F (0-5 C) 90 1 week 66.5 31.0 F (-.55C) 0.73 0.40 94
Beer. keg 35-40 F (2-5 C) — 3-8 weeks 90.2 28.0 F (-2.2C) 0.92 — 129
Bottles. Cans 35-40 F (2-5 C) 65 or below 3-6 months 90.2 — — — —
Beets. topped 32 F (0 C) 95-100 4-6 months 87.6 30.1 F (-1.05C) 0.90 0.46 126
Blackberries 31-32 F (-1-0 C) 95 3 days 84.8 30.5 F (-.83C) 0.88 0.46 122
Blueberries 31-32 F (-1-0 C) 90-95 2 weeks 82.3 29.7 F (-1.27C) 0.86 0.45 118
Bread. baked 0 F (-18 C) — 1-3 months 32-37 16-20 F (-8.8- -6.6C) 0.70 0.34 46-53
Dough 35-40 F (2-5 C) 85-90 3-72 hours 58.0 — 0.75 — —
Broccoli, sprouting 32 F (0 C) 95 10-14 days 89.9 30.9 F (-.61C) 0.92 0.47 130
Brussels Sprouts 32 F (0 C) 95 3-5 weeks 84.9 30.5 F (-.83C) 0.88 0.46 122
Cabbage. late 32 F (0 C) 95-100 3-4 months 92.4 30.4 F (-.88C) 0.94 0.47 132
Carrots. topped. mature 32 F (0 C) 98-100 5-9 months 88.2 29.5 F (-1.38C) 0.90 0.46 126
Cauliflower 32 F (0 C) 95 2-4 weeks 91.7 30.6 F (-.77C) 0.93 0.47 132
Celery 32 F (0 C) 95 1 -2 months 93.7 31.1 F (-.5C) 0.95 0.48 135
Cherries. sour 31-32 F (-1-0 C) 90-95 3-7 days 83.7 29.0 F (-1.6C) 0.87 — 120
Sweet 30-31 F (-2 --1 C) 90-95 2-3 weeks 80.4 28.8 F (-1.7C) 0.84 — —
Chocolate (Coating) 50-65 F (10-18 C) 40-50 2-3 months 55.0 95-85 F (35-29.4C) 0.30 0.55 40
Cocoa 32-40 F (0-5 C) 50-70 1 year. plus — — — — —
Coconuts 32-35 F (0-2 C) 80-85 1-2 months 46.9 30.4 F (-.88C) 0.58 0.34 67
Coffee (Green) 35-37 F (2-7 C) 80-85 2-4 months 10-15 — 0.30 0.24 14-21
Collards 32 F (0 C) 95 10-14 days 86.9 30.6 F (-.77C) 0.90 — —
Corn Sweet (Fresh) 32 F (0 C) 95 4-8 days 73.9 30.9 F (.61C) 0.79 0.42 106
Cranberries 36-40 F (2.2 - 4.4 C) 90-95 2- 4 months 87.4 30.4 F (.88C) 0.90 0.46 124
Cucumbers 50-55 F (10-13 C) 90-95 10-14 days 96.1 31.1F (-.5C) 0.97 0.49 137
Currants 31-32 F -1-0 C) 90-95 10-14 days 84.7 30.2 F (-1C) 0.88 0.45 120
Dairy Products
Cheddar Cheese 40 F (4.4C) 66-70 6 months 37.5 8.0 F (-13.3C) 0.50 0.31 53
Processed Cheese 40 F (4.4 C) 65-70 12 months 39.0 19.0 F (-7.2C) 0.50 0.31 56
Butter 40 F (4.4 C) 75-85 1 month 16.0 -4 F- 31 F (15.5-.55C) 0.60 0.25 23
Cream 35-40 F (2 - 4.4 C) — 2- 3 weeks 55-75 31.0 F (-.55C) 0.66-0.80 0.36-0.42 79-107
Ice Cream -20 to -15 (C) — 3-12 months 58-63 21.0 F (-6.1C) 0.66-0.70 0.37-0.39 86
Milk, Fluid Whole
Pasteurized. Grade A 32-34F (0-1 C) — 2- 4 months 87.0 31.0 F (-.55C) 0.93 0.46 125
Condensed. Sweetened 40 F (4.4 C) — 15 months 28.0 5.0 F (-15C) 0.42 0.28 40
Evaporated 40 F (4.4 C) — 24 months 74.0 29.5 F (-1.38C) 0.79 0.42 106
Dates (Dried) 0 or 32 F (-18 or 0 C) 75 or less 6-12 months 20.0 3.7 F (-15.72C) 0.36 0.26 29
Dewberries 31-32 F (-1-0 C) 90-95 3 days 84.5 29.7 F (-1.27C) 0.88 — —
Dried Fruits 32 F (0 C) 50-60 9-12 months 14-26 — 0.31-0.41 0.26 20-37
Eggplant 45-50 F (7.2 -10 C) 90-95 7-10 days 92.7 30.6 F (-.77C) 0.94 0.48 132
Eggs. shelf 29-31 F (-2-0 C) 80-85 5- 6 months 66.0 28.0 F (-2.2C) 0.73 0.40 96
Shelf. farm cooler 50-55 F (10-13 C) 70-75 2- 3 weeks 66.0 29.0 F (-1.6C) 0.73 0.40 96
Frozen. whole 0 or below (-18 C or below) — 1 year, plus 74.0 28.0 F (-2.2C) 0.73 0.42 106
Endive (Escarole) 32 F (0 C) 95 2- 3 weeks 93.3 31.9 F (-.05C) 0.94 0.48 132
Figs. dried 32-40 F (0 -4.4 C) 50-60 9-12 months 24.0 — 0.39 0.27 34
Fresh 31-32 F (-1-0 C) 85-90 7-10 days 78.0 27.6 F (-2.4C) 0.82 0.43 112
Fish. fresh 33-35 F (.5 -2 C) 90-95 5-15 days 62-85 28.0 F (-2.2C) 0.70-0.86 0.38-0.45 89-122
Smoked 40-50 F (4.4 -10 C) 50-60 6- 8 months — — 0.70 0.39 92
Shellfish. fresh 30-33 F (-1 -.5 C) 85-95 3- 7 days 80-87 28.0 F (-2.2C) 0.83-.90 0.44-0.46 113-125
Furs and Fabrics 34-40 F (1 -4.4 C) 45-55 several years — — — — —
Garlic, dry 32 F (0 C) 65-70 6- 7 months 61.3 30.5 F (-.83C) 0.69 0.40 89

Gooseberries 31-32 F (-1 - 0 C) 90-95 2- 4 weeks 88.9 30.0 F (-1.1C) 0.90 0.46 126
Grapefruit 50-60 F (10 -16 C) 85-90 4- 6 weeks 88.8 30.0 F (-1.1C) 0.91 0.46 126
Grapes. American type 31-32 F (-1 - 0 C) 85-90 2- 8 weeks 81.9 29.7 F (-1.27C) 0.86 0.44 116
European type 30-31 F (-2 -1 C) 90-95 3- 6 months 81.6 28.1 F (-2.16C) 0.86 0.44 116
Greens. leafy 32 F (0 C) 95 10-14 days — — — — —
Guavas 45-50 F (7 - 10 C) 90 2- 3 weeks 83.0 — 0.86 — —
Honey 38-50 F (3 - 10 C) 50-60 1 year. plus 18.0 — 0.35 0.26 26

Horseradish 30-32 F (-2 - 0 C) 95-100 10-12 months 73.4 28.7 F (-1.83C) 0.78 0.42 104
Kale 32 F (0 C) 95 3- 4 months 86.6 31.1 F (-.5C) 0.89 0.46 124

Kohlrabi 32 F (0 C) 95 2- 4 weeks 90.1 30.2 F (-1C) 0.92 0.47 128
Leeks. green 32 F (0 C) 95 1- 3 months 85.4 30.7 F (-.72C) 0.88 0.46 126

Lemons 32 or 50-58 F (0 -10-15C) 85-90 1- 6 months 89.3 29.4 F (-1.4C) 0.91 0.46 127
Lettuce. head 32-34 F (0 - 1.1 C) 95-100 2- 3 weeks 94.8 31.7 F (C) 0.96 0.48 136
Limes 48-50 F (8.8 -10 C) 85-90 8 weeks 86.0 29.1 F (C) 0.89 0.46 122
* Not based on maintaining nutritional value.
1-28
STORAGE CONDITIONS SPECIFIC SPECIFIC

HIGHEST HEAT HEAT LATENT
COMMODITY STORAGE RELATIVE APPROXIMATE WATER FREEZING ABOVE BELOW HEAT OF
(ALPHABETICAL TEMP. HUMIDITY STORAGE CONTENT POINT FREEZING FREEZING FUSION
LISTING) F % LIFE* % F BTU/LB/F BTU/LB/F BTU/LB
Maple Sugar 75-80 F (23.8-26.6 C) 60-65 1 year. plus 5.0 — 0.24 0.21 7
Mangoes 55 F (12.7 C) 85-90 2- 3 weeks 81.4 30.3 F (-.94 C) 0.85 0.44 117
Meat
Bacon, cured (Farm style) 60-65 F (15.5-18.3 C) 85 4- 6 months 13-29 — 0.30-0.43 0.42 18-41
Game. fresh 32 F (0 C) 80-85 1- 6 weeks 47-54 28-29 F (-2.2 - -1.6 C) 0.80 0.38-0.43 115
Beef. fresh 32-34 F (0-1.1 C) 88-92 1- 6 weeks 62-77 28-29 F (-2.2 - -1.6 C) 0.70-0.84 0 89-110
Hams and Shoulders. fresh 32-34 F (0 -1.1 C) 85-90 7-12 days 47-54 28-29 F (-2.2 - -1.6C) 0.58-0.63 0.34-0.36 67-77
Cured 60-65 F (15.5-18.3 C) 50-60 0- 3 years 40-45 — 0.52-0.56 0.32-0.33 57-64
Lamb. fresh 32-34 F (0- 1.1 C) 85-90 5-12 days 60-70 28-29 F (-2.2 - -1.6C) 0.68-0.76 0.38-0.51 85-100
Livers. frozen -10 to 0 F (12.2- -17.7 C) 90-95 3- 4 months 70.0 — 0 0.41 100
Pork fresh 32-34F (0 - 1.1 C) 85-90 3- 7 days 32-44 28-29 F (-2.2 - -1.6C) 0.46-0.55 0.30-0.33 46-63
Smoked Sausage 40-45 F (4.4 - 7.2 C) 85-90 6 months 60.0 — 0.68 0.38 86
Fresh 32 F (0 C) 85-90 1- 2 weeks 65.0 26.0 F (-3.33C) 0.89 0.56 93
Veal. fresh 32-34 F (0 - 1.1 C) 90-95 5-1 0 days 64-70 28-29 F (-2.2- -1.6C) 0.71-0.76 0.39-0.41 92-100
Melons. Cantaloupe 36-40 F (7.2 -10 C) 90-95 5- 1 5 days 92.0 29.9 F (-1.16C) 0.93 0.48 132
Honeydew and Money Ball 45-50 F (4.4 - 10 C) 90-95 3- 4 weeks 92.6 30.3 F (-.94C) 0.94 0.48 132
Watermelons 40-50 F (4.4 - 7.2 C) 80-90 2- 3 weeks 92.1 31.3 F (-.38C) 0.97 0.48 132
Mushrooms 32 F (0 C) 90 3- 4 days 91.1 30.4 F (-.88C) 0.93 0.47 130
Nectarines 31-32 F (-.5 - 0C) 90 2- 4 weeks 81.8 30.4 F (-.88C) 0.90 0.49 119
Nuts (Dried) 32-50 F (0 - 10 C) 65-75 8-12 months 3-6 — 0.22-0.25 0.21-0.22 4-8
Okra 45-50 F (7.2 - 10 C) 90-95 7-10 days 89.8 28.7 F (-1.83C) 0.92 0.46 128
Oleo margarine 35 F (1.66 C) 60-70 1 year, plus 15.5 — 0.32 0.25 22
Olives, fresh 45-50 F (7.22 - 10 C) 85-90 4-6 weeks 75.2 29.4 F (-1.44C) 0.80 0.42 108
Onions (Dry) and Onion sets 32 F (0 C) 65-70 1-8 months 87.5 30.6 F (-.77C) 0.90 0.46 124
Green 32 F (0 C) 95 3- 4 weeks 89.4 30.4 F (-.88C) 0.91 — —
Oranges 32-48 F (0 - 8.8C) 85-90 3-12 weeks 87.2 30.6 F (-.77C) 0.90 0.46 124
Orange Juice. chilled 30-35 F (-1.1 - 1.6 C) — 3- 6 weeks 89.0 — 0.91 0.47 128
Papayas 45 F (7.22 C) 85-90 1- 3 weeks 90.8 30.4 F (-.88C) 0.82 0.47 130
Parsley 32 F (0 C) 95 1 - 2 months 85.1 30.0 F (-1.1C) 0.88 0.45 122
Parsnips 32 F (0 C) 98-100 4-6 months 78.6 30.4 F (-.88C) 0.84 0.44 112
Peaches and Nectarines 31-32 F (-.5 -0 C) 90 2- 4 weeks 89.1 30.3 F (-.94C) 0.90 0.46 124
Pears 29-31 F (-1.6 - -.5C) 90-95 2-7 months 82.7 29.2 F (-1.55C) 0.86 0.45 118
Peas. green 32 F (0 C) 95 1 - 3 weeks 74.3 30.9 F (-.61C) 0.79 0.42 106
Peppers, sweet 45-50 F (7.2 - 10 C) 90-95 2-3 weeks 92.4 30.7 F (-.72C) 0.94 0.47 132
Peppers. Chili (Dry) 32-50 F (0 - 10 C) 60-70 6 months 12.0 — 0.30 0.24 17
Persimmons 30 F (-1.1 C) 90 3-4 months 78.2 28.1 F (-2.16C) 0.84 0.43 112
Pineapples. ripe 45 F (7.2 C) 85-90 2-4 weeks 85.3 30.0 F (-1.11C) 0.88 0.45 122
Plums. including fresh prunes 31-32 F (-.5 - 0 C) 90-95 2-4 weeks 82.3 30.5 F (-.83C) 0.88 0.45 118
Pomegranates 32 F (0 C) 90 2-4 weeks 77.0 26.6 F (-3C) 0.87 0.48 112
Popcorn. unpopped 32-40 F (0 - 4.4 C) 85 4-6 months 13.5 — 0.31 0.24 19
Potatoes. Early crop 50-55 F (10-12.7 C) 90 0-2 months 81.2 30.9 F (-.61C) 0.85 0.44 116
Late crop 38-50 F (3.3 - 10 C) 90 5-8 months 77.8 30.9 F (-.61C) 0.82 0.43 111
Poultry. Fresh Chicken 32 F (0 C) 85-90 1 week 74.0 27.0 F (-2.7C) 0.79 0.42 106
Fresh Goose 32 F (0 C) 85-90 1 week 47.0 27.0 F (-2.7C) 0.57 0.34 67
Fresh Turkey 32 F (0 C) 85-90 1 week 55.0 27.0 F (-2.7C) 0.64 0.37 79
Pumpkins 50-55 F (10 - 12.7C) 70-75 2-3 months 90.5 30.5 F (-.83C) 0.92 0.47 130
Quinces 31-32 F (-.5 - 0 C) 90 2-3 months 85.3 28.4 F (-2C) 0.88 0.45 122
Radishes-Spring. prepackaged 32 F (0 C) 95 3-4 weeks 93.6 30.7 F (-.72C) 0.95 0.48 134
Raisins (dried) 40 F (4.4 C) 60-70 9-12 months 35.0 — 0.47 0.32 43
Rabbits. fresh 32-34 F (0 - 1.1 C) 90-95 1-5 days 68.0 — 0.74 0.40 98
Raspberries. black 31-32 F (-.5 - 0 C) 90-95 2-3 days 81.6 30.0 F (-1.11C) 0.84 0.44 122
Red 31-32 F (-.5 - 0 C) 90-95 2-3 days 84.1 30.9 F (-.61C) 0.87 0.45 121
Rhubarb 32 F (0 C) 95 2-4 weeks 94.9 30.3 F (-.94C) 0.96 0.48 134
Rutabagas 32 F (0 C) 98-100 4-6 months 89.1 30.1 F (-1.05C) 0.91 0.47 127
Salsify 32 F (0 C) 98-100 2-4 months 79.1 30.0 F (-1.1C) 0.83 0.44 113
Spinach 32 F (0 C) 95 10-14 days 92.7 31.5 F (-.27C) 0.94 0.48 132
Squash, summer 32-50 F (0 - 10 C) 85-90 5-14 days 94.0 31.1 F (-.5C) 0.95 0.48 135
Winter 50-55 F (10 - 12.7 C) 70-75 4-6 months 88.6 30.3 F (-.94C) 0.91 0.48 127
Strawberries. fresh 31-32 F (-.5 - 0C) 90-95 5-7 days 89.9 30.6 F (-.77C) 0.92 0.42 129
Sugar. Maple 75-80 F (23.8 - 26.6 C) 60-65 1 year. plus 5.0 — 0.24 0.21 7
Sweet Potatoes 55-60 F (12.7 - 15.5 C) 85-90 4-7 months 68.5 29.7 F (-1.27C) 0.75 0.40 97
Syrup, Maple 31 F (-.55 C) 60-70 1 year plus 35.5 — 0.48 0.31 51
Tangerines 32-38 F (0 - 3.3 C) 85-90 2-4 weeks 87.3 30.1 F (-.55C) 0.90 0.46 125
Tobacco. Cigarettes 35-46 F (1.6 - 7.7 C) 50-55 6 months — 25.0 F (-3.8C) — — —
Cigars 35-50 F (1.6 - 10 C) 60-65 2 months — 25.0 F (-3.8C) — — —
Tomatoes. Mature green 55-70 F (12.7 - 21.1 C) 85-90 1- 3 weeks 93.0 31.0 F (-.55C) 0.95 0.48 134
Firm ripe 45-50 F (7.2 - 10 C) 85-90 4-7 days 94.1 31.1 F (-.5C) 0.94 0.48 134
Turnips. roots 32 F (0 C) 95 4-5 months 91.5 — — — —
Vegetables (mixed) 32-40 F (0 -4.4 C) 90-95 1-4 weeks 90.0 30.0 F (C) 0.90 0.45 130
Yams 60 F (15.5 C) 85-90 3-6 months 73.5 28.5 F (C) 0.79 0.40 105
Yeast. compressed baker’s 31-32 F (-.55 - 0C) — — 70.9 — 0.77 0.41 102
*Not based on maintaining nutritional value. Extracted by permission from 1974 ASHRAE APPLICATIONS HANDBOOK.
1-29
HEAT OF RESPIRATION
Approximate rates of evolution of heat by certain fresh fruits, vegetables and cut flowers
when stored at the temperatures indicated.
COMMODITY BTU PER TON PER HOUR

(ALPHABETICAL LISTING) 32 F (0 C) 40 F (4 C) 60 F (16 C)
Apples 20 - 38 46 - 667 125 - 283
Asparagus 245 - 550 488 - 963 917 - 2145
Avocados 550 - 1279
Bananas
Holding 54° 138
Ripening 68° 380
Chilling 70 - 56° 1000
Beans, green or snap 383 - 475 1338 - 1838
Beans, lima 96 - 133 179 - 254 917 - 1142
Beets, topped 112 170 300
Blueberries 54 - 91 83 - 113 313 - 541
Broccoli, sprouting 312 458 - 733 1408 - 2083
Brussels sprouts 137 - 345 275 - 458 550 - 1145
Cabbage 50 71 171
Carrots, topped 87 146 337
Cauliflower 150 - 175 175 - 200 392 - 450
Celery 66 100 341
Cherries 54 - 75 117 - 121 458 - 550
Corn, sweet 300 - 470 442 - 550 1600
Cranberries 25 - 29 38 - 47
Cucumbers 137 - 304
Flowers, cut 480/Sq. Ft Floor Area
Grapefruit 16 - 41 29 - 54 92 - 166
Grapes, American 25 50 14
Grapes, European 13 - 17 29 - 54 92 - 108
Lemons 21 - 38 25 - 79 96 - 208
Lettuce, head 96 113 329
Lettuce, leaf 188 267 600
Melons, cantaloupes 54 83 354

Melons, honeydews 38 - 49 100 - 137
Mushrooms 258 - 400 650 916 (50F)
Okra 504 1317

Onions 29 - 46 34 100
Onions, green 96 - 204 158 - 63 604 - 892
Oranges 17 - 42 54 - 67 154 - 217
Peaches 38 - 58 58 - 83 304 - 388

Pears 29 - 38 367 - 550
Peas, green 342 - 350 55 - 667 1637 - 1854
Peppers, sweet 113 195 354
Plums 27 - 39 38 - 63 100 - 116
Potatoes, immature 108 120 - 283
Potatoes, mature 54 - 75 63 - 108
Raspberries 163 - 229 283 - 354 754 - 929
Spinach 175 - 204 329 - 467 1538 - 1583

Strawberries 113 - 158 150 - 283 650 - 846
Sweet Potatoes 179 -263
Tomatoes, mature green 46 258

Tomatoes, ripe 42 54 233
Turnips 79 92 220
1-30
SECTION 2
Basic Refrigeration
System Operation
2-1
2-2
Section 2-Basic Refrigeratrion System Operation
The Four Component System

This section will help you understand the four basic components of any standard refrigeration system
and how they work together to absorb heat in one place and release it somewhere else.
The basic refrigeration system has four components:
1. compressor
2. condenser
3. evaporator
4. pressure control device (expansion valve).
The Fifth Component

Before we explain each component of the four component system, you should know there is an important fifth
component in every refrigeration systemthe refrigerant! Refrigerant is the "blood" that flows throughout the
system. It is responsible for absorbing heat from inside the box and releasing heat on the outside. Your under-
standing of latent heat and boiling points (from chapter 2) is essential to your understanding of how refrigerant
operates in the system.
There are many types of refrigerants used in transport refrigeration. Each type has unique characteristics, but all
perform the same function in the refrigeration systemrefrigerant is the vehicle that absorbs, carries and releases
heat energy. In a the next chapter, refrigerant types and characteristics will be explained in more detail.
.
Refrigerant is the vehicle that absorbs, carries and releases heat energy.
Refrigerant is the vehicle that absorbs, carries and releases heat energy.
2-3
The Compressor
The compressor performs two important functions:
1. It moves refrigerant through the system to carry heat energy.
2. It creates high pressure on one side of the refrigeration system and low
pressure on the other. These two pressures help control the boiling
point of the refrigerant, causing refrigerant to boil in the evaporator and
condense in the condenser.
The Thermo King compressor is a very high pressure pump capable of

establishing normal operating system pressures above 350 psig (2,413 kPa).
This very high pressure results in very high temperature.
Hot vapor (shown in red) travels from the compres-

sor to the condenser. Refrigerant vapor traveling
through the condenser is normally thirty degrees or
more above ambient temperature. Because the refrig-
erant vapor is very hot, heat energy naturally moves
to the colder ambient air (rememberhotter to
colder!). Even if the ambient temperature is 100°F
(38°C), heat readily transfers from the hot refrigerant
vapor to the cooler outside air. If the compressor is
severely worn and not capable of developing high
pressure (high temperature), little heat transfer will
occur between the condenser and the ambient air.
High pressure is important to good heat transfer from
the condenser to ambient air.
2-4
The Condenser
The condenser is similar to the radiator in an automobile. The automobile’s
radiator transfers heat from the engine to the ambient air. This keeps the
engine cool. In a refrigeration system, the condenser releases heat to the
outside air. The condenser is always on the outside of the refrigerated com-
partment.
The condenser relies on two key principles of heat transfer:
• Heat energy always moves from "hotter" to "colder".
• Heat energy transfers quickly between objects having a large tempera-
ture difference.
The condenser consists of copper tubes to contain the hot refrigerant and
hundreds of delicate fins to transfer heat from the copper tubes to the cool air
passing around the fins. These fins are tightly attached to the copper tubes to
provide excellent heat transfer. They also provide an extremely large surface
area for maximum exposure of heat to the cool ambient air. Copper or alu-
minum fins are used because they are good conductors of heat energy. The
condenser (often called the condenser coil) is a very efficient heat transfer
component.
As the hot refrigerant vapor passes through the condenser, it loses heat and changes from vapor to liquid (it con-
denses.) In chapter two you learned that a large amount of latent heat energy is released as vapor cools and changes
to the liquid state. The condenser makes good use of the Latent Heat of Condensation principle. The boiling point
of refrigerant in the condenser must always be above ambient temperature so that the "cool" ambient air causes the
refrigerant vapor to condense. If the refrigerant vapor fails to condense, only a small amount of heat will transfer
to the ambient air.
Refrigerant vapor condenses in the condenser.
The latent heat of condensation is vital to system efficiency.
2-5
2-6
2-7
The Expansion Valve
.
After passing through the condenser, the high
pressure liquid refrigerant travels to the expansion
valve. The expansion valve restricts and controls
the flow of liquid refrigerant to the evaporator.
This restriction helps maintain high pressure in the
condenser to keep the boiling/condensation point
high (above ambient).
This restriction also allows low pressure to
develop on the outlet side of the expansion valve.
This low pressure reduces refrigerant pressure,
refrigerant temperature, and the refrigerant’s boil-
ing point in the evaporator. The boiling point of
refrigerant in the evaporator can be reduced so
much that refrigerant in the evaporator boils at
temperatures below -20°F (-28.8°C).
The expansion valve assembly constantly responds to changes in evaporator outlet temperature and pressure to pre-
cisely meter the correct amount of refrigerant through the evaporator.
Too much refrigerant will "flood" the evaporator. This will reduce or eliminate the important boiling effect that
must occur for efficient operation. It also may damage the compressor.
Too little refrigerant will not provide the volume of moving refrigerant necessary to absorb large amounts of heat
from the refrigerated compartment.
2-8
The Evaporator
Like the condenser, the evaporator consists of copper tubes and hundreds of delicate fins that transfer heat very
efficiently. While the condenser releases heat to the outside air, the evaporator absorbs heat from the refrigerated
compartment. The evaporator is always inside the refrigerated compartment.
Like the condenser, the evaporator relies on the same two key principles
of heat transfer:
• Heat energy always moves from "hotter" to "colder".
• Heat energy transfers quickly between objects having a large temper-
ature difference.
As low pressure, liquid refrigerant passes through the evaporator, it
absorbs heat from the refrigerated compartment and begins to boil. Even
if the evaporator temperature is well below zero degrees Fahrenheit, the
refrigerant boils and takes full advantage of the principle discussed in
chapter twoLatent Heat of Vaporization. As the refrigerant boils, the
evaporator surface is normally about ten degrees colder than the box air
passing through it. (On bus climate control systems, evaporator tempera-
ture is maintained at approximately 35°F.) Evaporator pressure and
refrigerant boiling point must be lower than the temperature of air pass-
ing through it. (That's opposite to the conditions required in condenser.)
.
Refrigerant liquid evaporates in the evaporator.
The latent heat of evaporation is vital to system efficiency.
2-9
2-10
SECTION 3
Container
Refrigeration
Components & System
Diagrams
3-1
Section 3-Container Refrigeration Unit & System Diagrams
Marine Container Components and Operation

When transporting perishables for many days or weeks at sea, peak performance and absolute reliability
are essential. This chapter will introduce you to marine container unit components and operation.
More Than “Cool Only”

In chapter three you learned about the four-component
refrigeration system. With only four major components,
it’s a cool only system. Marine container refrigeration
systems are actually cool only, but electric resistance heat-
ers are included to provide heat and defrost operation.
This chapter will help you understand the components
added to allow marine container units to cool, heat and
defrost. You’ll also learn about additional components
used to improve system performance.
Product Overview
Over the years, Thermo King has produced several different marine container unit models. The CSR and CRR series
units shown here have been selected as ‘representative’ and will be used to explain system components and compo-
nent functions.
3-2
Marine container units are all electric. Use of a diesel engine is

impractical, undesirable and impossible on most container ships.
While operating on or below deck, marine container units are con-
nected to the ship’s power supply  usually 460 volts, 3-phase, 60
Hertz. On some older model units, 230 volts may also be used as the
unit operating voltage. An available dual voltage transformer option
allows units to operate on either voltage. When off-loaded to shore,
containers must be connected to either shore power as shown here or
to generator power.
When a container is placed on a chassis for land bridge

(over-the-road) transport, a portable generator set provides
the required electrical power to operate the refrigeration
unit. Portable generators are available in three physical con-
figurationsClip-On, Center Mount and Side Mount.
Because the refrigeration system in a container unit provides

"cooling only", electric resistance heaters are used to provide
the necessary heat during the heat and defrost operating
modes.
3-3
Thermo King marine container units are designed for 40-foot or 20-
foot marine containers. Depending on unit model and age, the com-
pressor used may be a Thermo King X426 or X430, a Copeland
3DS/3DF (like the one pictured here), or a Copeland scroll
compressor. Thermo King CRR marine container units use the
Copeland reciprocating compressor; CSR models use the Cope-
land scroll compressor.
CSR scroll compressors have two (2) scrolls, a stationary scroll and an
orbiting scroll, that compress the refrigerant and circulate it throughout
the refrigeration system.
3-4
CRR units reciprocating compressors use pistons and disk type

reed valves to compress the refrigerant and circulate it through-
out the system.
Compared to reciprocating compressors, scroll com-

pressors have only four moving parts, two of which are
shown here. Scrolls are also quieter, significantly
lighter weight and provide more cooling capacity for
their size than comparable reciprocating compressors.
X426/X430 Moving Parts
3-5
The Technology Leader

Over the years, Thermo King has been recognized as the “technology leader” in the marine container industry.
Thermo King has led the way with new components, systems and electronics.
Microprocessor controllers have been the standard on Thermo King container units
since 1984 when the original Thermoguard µP was introduced on the CF-II con-
tainer unit.
Continuous innovation and improvement has kept Thermo King micro-

processors, like the MP-3000, out in front of the competition.
The microprocessors incorporate refrigeration system component con-
trol, thermostat, digital thermometer, fault indication and data recording
capabilities into one self-contained unit.
The MP-3000 controller is mounted in a weather-tight, corrosion-resis-
tant enclosure. A large-character LED display (upper) provides easy
viewing of the control sensor temperature (return or supply air tempera-
ture). A 4-line, 20-character LCD display (lower) shows important data
including setpoint temperature, controller Main Menu tree and impor-
tant unit operating data.
Sixteen general purpose keys are used to enter and scroll through the
controller menu tree and message text; initiate Pretrip and Function
tests; enter new setpoint temperature; and enter trip information.
3-6
Hermetic Refrigeration Systems
For many years, hermetic (sealed) refrigera-

tion systems were thought to be only for sta-
tionary equipment applications, like home
refrigerators. However, in 1998, Thermo
King introduced the CSRthe industry’s first
marine container hermetic system.
In the year 2000, Thermo King became the first reefer unit man-
ufacturer to introduce internal capacity control with a scroll
compressor. The CSR ‘Magnum’ unit’s unique Modulated
Vapor Injection (MVI) scroll compressor has an internal
unloading mechanism that allows variable compressor capacity
from 0% to 100%. Loading and unloading is accomplished by
opening and closing a ‘Pulse Width Modulation (PWM) sole-
noid valve. Opening the valve reduces cooling capacity. The
duration of valve-open time affects how much the cooling
capacity is reduced. The longer the valve is open, the more
cooling capacity is reduced.
3-7
CRR Components
As previously discussed, Thermo King has provided a variety of different models and options over the years to meet
customer requirements. The following illustration provides an overall view of the refrigeration system components
used in the CRR unit.
The following components are unique to the CRR model.

1. 3DS Compressor
12. Condenser Coil Sub-Cooling Circuit
13. Liquid Line Service Valve
16. Liquid Line Solenoid Valve
30. Evaporator Pressure Regulator (KVQ) Valve
35. Condenser Check Valve
3-8
CRR Component Functions

(Item numbers below correspond to the item numbers on the preceding page.)
1. Moves refrigerant and increases refrigerant gas temperature and pressure.
2. Used to add or remove compressor oil.
3. Used for isolating and servicing the discharge side of the compressor.
4. Shuts refrigeration system down in case of high discharge refrigerant pressure.
5. Controls operation of the liquid injection circuit.
6. Prevents liquid refrigerant return to the compressor during the ‘off’ cycle.
7. Causes refrigerant to condense by transferring heat from refrigerant to ambient air flowing through it.
8. Collects condensed refrigerant and stores it during low load conditions and during low side repair.
9. Relieves extremely high-pressure refrigerant from the system.
10. Service fitting used during evacuation and service procedures.
11. Used to determine proper system refrigerant charge level.
12. Provides additional sub-cooling of refrigerant to ensure 100% liquid to the expansion valve.
13. Allows refrigerant to flow from the receiver tank / condenser coil sub-cooling circuit and is used for servicing the
low side.
14. Acts as a filter to remove dirt and debris from the system, absorbs moisture and filters compressor oil.
15. Transfers heat from the high-pressure / temperature liquid to the lower pressure / temperature suction vapor to
maintain cooling capacity and prevent liquid return to the compressor.
16. Used to pump system down before cycling compressor off at set-point making it easier to re-start compressor.
17. Controls / meters refrigerant flow to the evaporator coil during cooling.
18. Senses suction vapor temperature and helps control operation of the expansion valve.
19. Senses evaporator outlet pressure and helps control operation of the expansion valve.
20. Equally distributes refrigerant to each circuit within the evaporator.
21. Absorbs heat from the cargo space into the refrigerant flowing through its tubes / circuits.
22. Provides heat necessary to raise container temperature during the heat mode and melt frost and ice off the evapo-
rator coil during defrost mode.
23. Senses temperature of air returning to the unit from the cargo area and helps control operation of the unit.
24. Senses evaporator coil temperature and is used to control initiation and termination of defrost.
25. Senses temperature of the air being delivered (supplied) to the cargo space.
26. Senses temperature of the condenser coil.
27. Senses temperature of the ambient air.
28. Controls all aspects of unit operation; records and displays data, alarms, events; and is the user interface.
29. Controls (restricts) flow of refrigerant returning to the compressor as a means of controlling (limiting) capacity.
30. Used for isolating and servicing the low side of the compressor.
31. Controls flow of refrigerant to the liquid injection circuit.
32. Optional solenoid valve shuts off half of evaporator coil to remove moisture from the cargo space air.
33. Optional sensor that provides input to microprocessor; controls operation of de-humidify solenoid valve.
34. Causes refrigerant to condense when air-cooled condenser coil/fan is not being used.
35. Allows water to enter during water-cooled condenser operation.
36. Carries water that has absorbed heat of compression and cargo heat.
3-9
CSR Components
The following illustration provides an overall view of the refrigeration system components used in the CSR unit.
The following components are unique to the CSR model.

1. Scroll Compressor
13. Receiver Bypass Valve
29. Modulation Valve
3-10
CSR Component Functions

2. Used to determine proper compressor oil level.
3. Used to add or remove compressor oil.
4. Controls operation of the liquid injection circuit.
5. Shuts refrigeration system down in case of high refrigerant pressure.
6. Controls operation of the condenser fan motor.
7. Used for isolating and servicing the discharge side of the compressor.
11. Used to determine proper system refrigerant charge level.
12. Allows refrigerant to flow from the receiver tank and is used during system service.
13. Allows high pressure refrigerant vapor from receiver tank to enter the suction line to prevent compressor from
operating in a vacuum.
14. Filters and cleans compressor oil.
15. Acts as a filter to remove dirt and debris from the system and absorbs moisture from the system.
16. Transfers heat from the high-pressure / temperature liquid to the lower pressure / temperature suction vapor to
maintain cooling capacity and prevent liquid return to the compressor.
20. Senses evaporator outlet temperature and helps control operation of the expansion valve.
22. Provides heat necessary to raise container temperature during heat mode and melt frost and ice off the evaporator
coil during defrost mode.
26. Senses temperature of the surrounding / outside (ambient) air.
28. Controls all aspects of unit operation; records and displays data, alarms, events; and is the user interface.
29. Controls (restricts) flow of refrigerant returning to compressor as a means of controlling cooling capacity.
30. Controls flow of refrigerant to the liquid injection circuit used to cool the compressor.
31. Used for isolating and servicing the low side of the compressor.
32. Optional solenoid valve shuts off half of evaporator coil to remove moisture from the cargo space air.
33. Optional sensor that provides input to microprocessor and controls operation of dehumidify solenoid valve.
3-11
CSR ‘Magnum’ Container Unit Components

The following illustration provides an overall view of the refrigeration system components used in the CSR MAG-
NUM unit.
The following components are unique to the CSR MAGNUM unit.

1. MVI Scroll Compressor
4. Discharge Process Tube
9. Economizer Heat Exchanger
16. Suction Line Process Tube
17. PWM Valve (Pulse Width Modulation)
18. Vapor Injection Valve (VIV)
19. Economizer Expansion Valve (TXV2)
3-12
CSR ‘Magnum’ Container Unit Components & Operation

Component Functions
2. Protects compressor from overheating and can control operation of the condenser fan motor.
3. Shuts refrigeration system down in case of high refrigerant pressure.
4. Used for adding / removing refrigerant and evacuating the refrigeration system’s high side.
8. Acts as a filter to remove dirt and debris from the system, absorbs moisture from the system and filters and cleans
the compressor oil.
9. Pre-cools liquid refrigerant being delivered to evaporator TXV1.
12. Senses evaporator outlet temperature and helps control operation of the expansion valve.
15. Protects the compressor and system from low refrigerant charge conditions.
16. Used for adding / removing refrigerant and evacuating the refrigeration system’s low side.
17. Controls the physical loading and unloading of the compressor.
18. Controls the flow of refrigerant to the economizer circuit.
19. Controls / meters refrigerant flow to the economizer circuit.
20. Senses economizer heat exchanger outlet pressure and helps control operation of TXV2.
21. Senses economizer heat exchanger outlet temperature and helps control operation of TXV2.
22. Provides heat necessary to raise container temperature during heat mode and melt frost and ice off the evaporator
coil during defrost mode.
23. Controls all aspects of unit operation, records and displays data, alarms, events and is the user interface.
27. Senses temperature of the surrounding / outside (ambient) air.
29. Optional sensor that provides input to microprocessor and controls operation of dehumidify solenoid valve.
30. Optional solenoid valve that shuts off half of evaporator coil to remove moisture in the cargo air space.
3-13
Terms to Remember
Shore Power
Land Bridge
Clip-On
Center-Mount
Side-Mount
Resistance Heaters
CRR
CSR
Scroll Compressor
Hermetic
Modulated Vapor Injection (VI)
PWM Valve
Unloader
3-14
Table 1: Thermo King Models
Model Compressor Refrigerant Controller
CF-II/CF-III X430/X426 R12/R134a µP, µC, µP-A, µP-A+
CF-II 3DS/3DF R12/R134a µP-A, µP-A+
CF-II M39 2DB R404A µP-A+
CRR (TNE) 3DS/3DF R134a MPC2000/µP-D/

MPC2001D
CSR Scroll R404A µP-D

TNE (Sabroe) Scroll R22 MPC2000
CSR PS/PS+ 3DS R134a MP3000
CSR PS/PS+ Scroll R404A MP3000
3-15
CF-II M34, M36
Refrigeration System Components
1. Compressor
2. Discharge Service Valve (DSV)
3. High Pressure Cutout Switch (HPCO)
4. Condenser Coil
5. High Pressure Relief Valve
6. Water Cooled Condenser / Receiver Tank 13
7. Condenser Water Inlet
14
8. Water Pressure Switch (WPS) 19
9. Condenser Water Outlet
10. Receiver Tank Outlet Valve
11. Filter Drier 20 15
12. Liquid Line Solenoid (LLS) 16
17
13. Expansion Valve (TXV)
14. Distributor 22 18
15. Evaporator Coil 21
16. TXV Power Element
17. TXV Equalizer Line
18. Electric Heaters 12
19. Return Air Sensor
20. Coil Sensor 4
3-16
21. Discharge / Supply Air Sensor
22. Controller
23. Low Pressure Cutout Switch (LPCO)
24. Modulation Valve (MV) 11
25. Compound Gauge 23
26. Suction Service Valve (SSV)
5
24
25 8
3 10
7
2 9
26 6
1
AJA478
Flow and Pressure Diagram

CF-II M34, M36
Full Cool
1. Compressor
Compressor operation has a three-(3) second delay on
initial unit start-up or when the unit shifts to a cooling
mode requiring compressor start up.
Is a normally CLOSED switch.
It OPENS (cuts-out) when pressure is 300
± 25/0 PSIG (2068 +172 -0 kPa).
It CLOSES (cuts-in) when pressure is
13
200 ± 20
PSIG (1379 ± 138 kPa).
5. High Pressure Relief Valve OPENS at 500+50/-15 19 14
PSIG (3447 + 345/-104 kPa).
Resets (CLOSES) at 400 PSIG (2758 kPa).
8. Water Pressure Switch (WPS)
Is a normally CLOSED switch, and automatically 20 15
16 17
selects air-cooled OR water-cooled condenser opera-
tion. It OPENS at 17 ± 3 PSIG (117 ± 21 kPa), con-
denser fan stops. 22 18
3-17
It CLOSES at 5 ± 3 PSIG (35 ± 21 kPa), returning the
unit to condenser fan operation. 21
If (CFPS) opens during water cooled operation, the
condenser fan will run.
22. Controller
12
Thermoguard (P-A with digital thermostat,
thermometer and fault indicator monitor. 4
Null Mode Operation
During Null Mode Operation, the compressor does not
run. Condenser fan runs for 2 minutes and stops. Evap- 11
orator blowers are running. (Speed is controlled by the
23
return air sensor temperature.)
5
High pressure gas 24
High pressure liquid
Low pressure gas 8
25 3
Low pressure liquid 10
7
Condensing high pressure gas 2 9
Low pressure vaporizing liquid
26 6
1
AJA479
CF-II M34, M36
Modulated Cool
12. Liquid Line Solenoid (LLS)
Is a normally CLOSED solenoid.
It OPENS when energized.
18. Electric Heaters
During DEFROST operation, the Electric heaters
are energized. The compressor does not run. Evapo-
rator blowers and the condenser fan are off. During
HEAT operation, the Electric Heaters are energized.
The compressor does not run. Condenser fan is off. 13
Evaporator blowers running. (Speed is controlled by
the return air sensor temperature.) 19 14
It OPENS (cuts-out) at 5 to I I in he vacuum (-17 to
-34 kPa). 20 15
16 17
It CLOSES (cuts-in) at 4 to 7 PSIG (28 to 48 kPa).
24. Modulation Valve (MV)
Is a normally OPEN valve. It CLOSES when ener- 22 18
3-18
gized. As the signal strength is increased, the valve
CLOSES more. The controller controls the signal to 21
the valve as it monitors the temperatures and power

limit to the compressor.
12
4
High pressure gas
High pressure liquid 11
Low pressure gas
23
Low pressure liquid
Condensing high pressure gas 5
Low pressure vaporizing liquid 24
Modulated pressure
25 8
3 10
7
2 9
26 6
1
AJA480
CF-II M37, M37.1

Refrigeration System Component
1. Compressor
4. Condenser Fan Pressure Switch (CFPS)
5. Condenser Coil
7. Receiver Tank
12 13
8. Sight Glass
9. Receiver Tank Outlet Valve 14
10. Filter Drier 19
12. Heat Exchanger
13. Expansion Valve (TXV) 20 15
16 17
14. Distributor
15. Evaporator Coil
22 18
16. TXV Power Element
17. TXV Equalizer Line 21
3-19
20. Coil Sensor 11
21. Discharge/Supply Air Sensor 27
22. Controller 5
25. Suction Service Valve (SSV) 10
26. Compressor Head (Discharge
23
Temperature) Sensor (CDTS)
27. Liquid Injection Module (LIM) 6
28. Liquid Injection Valve 26 4
24
w/Restrictor (LIV)
8
3 9
2
25 7
28
1
AJA481
CF-II M37, M37.1
Full Cool
1. Compressor
Compressor operation has a three (3) second
delay on initial unit start-up or when the unit
shifts to cooling mode requiring compressor
start up.
It OPENS (cuts-out) when pressure is 325 + 25
/-0 PSIG (2242 + 172 /0 kPa).
It CLOSES (cuts-in) when pressure is 200 ± 20 12 13
PSIG (1379 ± 138 kPa).
4. Condenser Fan Pressure Switch (CFPS) 19 14
Is a normally closed switch.
It OPENS at 200 ± 7 PSIG
(1379 ± 48 kPa).
It CLOSES at 160 ± 7 PSIG 20 15
(1103 ± 48 kPa).
16 17
OPENS at 500 +50/-15 PSIG 22 18
3-20
(3447+ 345/-104 kPa)
Resets (CLOSES) at 400 PSIG (2758 kPa). 21
22. Controller
Thermoguard (P-A with digital thermostat,
thermometer and fault indicator monitor). 11
27
High pressure gas 5
Low pressure gas
Liquid refrigerant injection
6
26 4
24
8
3 9
2
25 7
28
1
AJA482

CF-II M37, M37.1
Modulated Cool
During DEFROST operation, the Electric Heaters
are energized. The compressor does not run.
Evaporator blowers and the condenser fan are off.
During HEAT operation, the Electric Heaters are
energized. The compressor does not run.
Condenser fan is off. Evaporator blowers running. 12 13
(Speed is controlled by the return air sensor
temperature.) 19 14
Is a normally CLOSED switch. It OPENS (cuts-
out) at 5 to 11 in hg vacuum
20 15
(-17 to-34 kPa). 16
It CLOSES (cuts-in) at 4 to 7 PSIG 17
(28 to 48 kPa).
24. Modulation Valve (MV) 22 18
3-21
Is a normally OPEN valve.
It CLOSES when energized.
21
As the signal strength is increased, the valve
CLOSES more. The controller controls the signal
to the valve as it monitors the temperatures and
11
power limit to the compressor. 27
28. Liquid Injection Valve (LIV) 5
Is a normally CLOSED valve.
It OPENS when energized. The valve is energized
when the compressor head temperature is above
292F (144.4C) or when the modulation valve 10
closes 62% or more (75% or more on temperature
pull down).
23
6
High pressure gas 26 4
24
Low pressure gas 8
Low pressure liquid 3 9
Low pressure vaporizing liquid 25 7
28
1
AJA483
CF-II M19.7, M19.8, M19.9
M37.3, M37.5 Refrigeration System Components
1. Compressor
5. Condenser Coil
7. Receiver Tank (M37.5 has water cooled
12 13
condenser/receiver tank)
8. Sight Glass 14
10. Filter Drier
20 15
12. Heat Exchanger 16 17
14. Distributor 22 18
15. Evaporator Coil
3-22
16. TXV Power Element 21
17. Equalizer Line

18. Electric Heater 11
20. Coil Sensor 5
21. Discharge/Supply Air Sensor
22. Controller
10
25. Compound Gauge (Used on M19.7, M19.8) 23
26. Compressor Head (Discharge
6
Temperature Sensor CDTS) 26 4
27. Liquid Injection Valve w/Restrictor (LIV) 24
28. Compressor Bypass Oil Filter(Used on M19.9 25
8
29. Check Valve
3 9
2
29 7
27
28
1
AJA484

CF-II M19.7, M19.8, M19.9,
M37.3, M37.5
Full Cool
1. Compressor
Compressor operation has a three (3) second delay
on initial unit start-up or when the unit shifts to a
cooling mode requiring compressor start up.
It OPENS (cuts-out) when pressure is 350 ± 10
PSIG (2415 ± 69 kPa). 12 13
It CLOSES (cuts-in) when pressure is 240 ± 10
PSIG (1656 ± 69 kPa).
It OPENS at 200 ± 7 PSIG (1379 ± 48 kPa).
It CLOSES at 160 ± 7 PSIG (1103 ± 48 kPa).
20 15
6. High Pressure Relief Valve 16 17
OPENS at 500 +50 1-15 PSIG (3447+345/-104 kPa).
22 18
22. Controller
3-23
Thermoguard (P-A+ with digital thermostat, 21
thermometer and fault indicator monitor.
Null Mode Operation 11
During Null Mode Operation, the compressor does
not run. Condenser fan runs for 2 minutes and
stops. Evaporator blowers are running. (Speed is 5
controlled by the return air sensor temperature.)
Water Pressure Switch (WPS) (M37.5 only)
Is a normally CLOSED switch, and automatically
10
selects air-cooled OR water-cooled condenser 23
operation. It OPENS at 17 ± 3 PSIG (117 ± 21
kPa), condenser fan stops. It CLOSES at 5 ± 3 6
PSIG (35 ± 21 kPa), returning the unit to condenser 26 4
fan operation. If (CFPS) opens during water cooled
24
operation, the condenser fan will run. 25 8
3 9
High pressure gas Low pressure gas
2
High pressure liquid Low pressure liquid
Condensing high pressure gas
29 7
27 28
Liquid refrigerant injection AJA485
CF-II M19.7, M19.8, M19.9,
M37.3, M37.5
Modulated Cool
During HEAT operation, the Electric Heaters are 12 13
energized. The compressor does not run. Condenser
fan is off. Evaporator blowers running. (Speed is
controlled by the return air temperature.)
19 14
It OPENS (cuts-out) at 5 to 17 in hg vacuum (-17 20 15
16
to -57 kPa). 17
It CLOSES (cuts-in) at I to 7 PSIG (7 to 48 kPa).
24. Modulation Valve (MV) 22 18
3-24
It CLOSES when energized. As the signal strength 21
is increased, the valve CLOSES more. The
controller controls the signal to the valve as it

monitors the temperatures and power limit to the 11
compressor.
27. Liquid Injection Valve (LIV)
5
It OPENS when energized. The valve is energiz
when the compressor head temperature is above 280F
(137.8) or when the modulation valve closes 62%
10
or more (75% or more on temperature pull down).
23
6
24 26 4
High pressure gas
25 8
Low pressure gas 3 9
Low pressure liquid
2
Low pressure vaporizing liquid 29 7
27 28
Liquid refrigerant injection 1
Modulated pressure AJA486
CF-II M38, M39,

M39.2, M39.3
1. Compressor
3. High Pressure Cutout Switch (BPCO)
4. Condenser Coil
6. Receiver Tank
7. Sight Glass
10
9. Filter Drier
10. Heat Exchanger
17 12
12. Distributor
13. Evaporator Coil
18 13
14. TXV Power Element 14 15
15. TXVEqualizer Line
16. Electric Heaters 16
21
3-25
19
18. Coil Sensor 20
19. Discharge/Supply Air Sensor (Squashed)
20. Ambient Sensor
21. Controller
22. Suction Line Solenoid (SLS) 4
25. Compressor Head Discharge 23
9
Temperature Sensor (CDTS)
26. Liquid Injection Valve w/Restrictor (LIV)
27. Condenser Fan Pressure Switch (CFPS) 22
5
25
7
3 8
2
24 6
26
1
AJA487
CF-II M38, M39, M39.2, M39.3
Full Cool
1. Compressor
Compressor operation has a three (3) second delay on
It OPENS (cuts-out) when pressure is 450 ±10 PSIG
(3105 ± 69 kPa).
It CLOSES (cuts-in) when pressure is 375 ± 38 PSIG
(2588 ± 262 kPa). 11
10
OPENS at 500+50/-15 PSIG (3447+345/-104 kPa).
Resets (CLOSES) at 400 PSIG (2759 kPa). 17 12
21. Controller
Thermoguard (P-A+ with digital thermostat,
thermometer and fault indicator monitor.)
18 13
14 15
Null Mode Operation
During Null Mode Operation, the compressor does not
run. Condenser fan runs for 2 minutes and stops. 16
Evaporator blowers are running. (Speed is controlled by 21
3-26
the return air sensor temperature.) 19
Is a normally closed switch.

It OPENS when pressure is 350 ± 10 PSIG
(2415 ± 69 kPa). Fan run in high speed.
It CLOSES when pressure is 280 ± 10 PSIG
(1933 ± 69 kPa). 4
Fan in the OFF mode.
High pressure gas
23
9
Low pressure gas
7
3 8
2
24 6
26
1
AJA488

CF-II M38, M39, M39.2, M39.3
Modulated Cool
During DEFROST operation, the Electric
Heaters are energized. The compressor does
not run. Evaporator blowers and the
condenser fan are off. During HEAT
operation, the Electric Heaters are
Condenser fan is off. Evaporator blowers
running. (Speed is controlled by the return
air sensor temperature.) 10 11
22. Suction Line Solenoid (SLS)
Is a normally CLOSED solenoid. 17 12
It CLOSES when energized. As the signal 18 13
14
strength is increased, the valve CLOSES 15
more. The controller controls the signal to
the valve as it monitors the temperatures 16
21
3-27
and power the limit to the compressor.
26. Liquid Injection Valve (LIV) 19
20
It OPENS when energized. The valve is
energized when the compressor head
temperature is above 280F (137.8C) or
when the modulation valve closes 62% or 4
more (75% or more on temperature pull down).
23
High pressure gas 9
Low pressure gas
22
5
3 8
Modulated pressure
2
24 6
26
1
AJA489
CF-II M40, M40.1 M41
1. Compressor
5. Condenser Coil
7. Water Cooled Condenser / Receiver Tank
8. Condenser Water Inlet
9. Water Pressure Switch (WPS) 14 15
10. Condenser Water Outlet
11. Receiver Tank Outlet Valve 21 16
12. Filter Drier
14. Heat Exchanger 22 17
18
15. Expansion Valve (TXV) 19
16. Distributor
24 20
17. Evaporator Coil
3-28
19. Equalizer Line

13
22. Coil Sensor
5
23. Discharge/Supply Air Sensor
24. Controller
27 12
27. Modulation Valve (MV) 25
29. Compressor Head Discharge 6
Temperature Sensor (CDTS) 29
30. Liquid Injection Valve w/ Restrictor (LIV) 3 4
31. Compressor Bypass Oil Filter 9
(Used on M40. 1, M41) 2 11 8
32. Check Valve 10
28 32 7
30
31
1
AJA490

CF-II M40, M40.1, M41
Full Cool
1. Compressor
Compressor operation has a three-(3) second delay on
It OPENS (cuts-out) when pressure is 350 ± 10 PSIG
(2415 ± 69 kPa).
It CLOSES (cuts-in) when pressure is 240 ± 10 PSIG 15
14
(1656 ± 69 kPa).
Is a normally CLOSED switch. 21 16
6. High Pressure Relief Valve 17
22
OPENS at 500+50/-15 PSIG (3447+345/-104 kPa). 18 19
9. Water Pressure Switch (WPS)
Is a normally CLOSED switch and automatically 24 20
3-29
select air-cooled OR water-cooled condenser 23
operation. It OPENS at 17 ± 3 PSIG (17 ± 21 kPa),
condenser fan stops. It CLOSES at 5 ± 3 PSIG
(35 ± 21 kPa), returning the unit to air cooled 13
condenser fan operation. If (CFPS) opens during water
cooled operation the condenser fan will run.
24. Controller 5
Thermoguard up-A+ with digital thermostat,
27
During Null Mode Operation, the compressor does not 25
run. Condenser fan runs for 2 minutes and stops. 26
Evaporator blowers are running. (Speed is controlled
6
by the return air sensor temperature.)
29
3 4
High pressure gas
9
High pressure liquid 2 11 8
Low pressure gas 10
Low pressure liquid
28 32 7
Liquid refrigerant injection AJA491
CF-II M40, M40.1, M41
Modulated Cool
energized. The compressor does not run. Condenser 14 15
fan is off. Evaporator blowers running. (Speed is
controlled by the return air sensor temperature.) 21 16
It OPENS (cuts-out) at 5 to 17 in hg vacuum 17
(-17 to -57 kPa). 22 18
It CLOSES (cuts-in) at I to 7 PSIG (7 to 48 kPa). 19
Is a normally CLOSED solenoid. It OPENS when 24 20
energized.
23
3-30
Is a normally OPEN valve. It CLOSES when
energized. As the signal strength is increased, the

valve CLOSES more. The controller controls the
13
signal to the valve as it monitors the temperatures
and power limits to the compressor. 5
It OPENS when energized. The valve is energized 27
when the compressor head temperature is above 12
280F (137.8C) or when the modulation valve closes
62% or more (75% or more on temperature pull down.)
25
26
6
3 4
Low pressure gas 9
2 11
10
Low pressure vaporizing liquid 28 32 7
30 31
1
Modulated Pressure
AJA492
CF-II M46.1, M48.1, M49

2. Sight Glass
3. Oil Fill/Drain Fitting
4. Compressor Head Discharge Temperature
(CDTS)
8. Condenser Coil
9. High Pressure Relief Valve 16 17
10. Receiver Tank (M48.1 has water cooled
condenser/receiver tank) 23 18
11. Sight Glass
13. Bypass Valve 24 19 20
21
14. Filter
15. Filter Drier
27 22
3-31
16. Heat Exchanger
17. Expansion Valve (TXV) 25
26
18. Distributor
19. Evaporator Coil
21. Equalizer Line 8
24. Coil Sensor 13
25. Supply Air Sensor 14
26. Ambient Sensor 28
27. Controller 6 5 9
28. Suction Line Solenoid (SLS) 29 4
(Not Used on M48.1) 30
7 11
30. Liquid Injection Valve w/Restrictor (LIV)
31
2 10
3 AJA493 12
1
CF-II M46.1, M48.1, M49
Full Cool
5. High Pressure Cutout Switch (HPCO
It OPENS (cut-out) when pressure is 450± 10 PSIG
(3105±69kPa).
It CLOSES (cut-in) when pressure is 375± 38 PSIG
(2588±262kPa). 16 17
Is a normally CLOSED switch. 23 18
It OPENS at 200±7 PSIG (1379±48 kPa).
It CLOSES at 160±7 PSIG (1103±48 kPa).
OPENS at 500+50/-15 PSIG (3447+345/-104 kPa). 24 19
20 21
Resets (CLOSES) 400 PSIG (2758 kPa).
During DEFROST operation, the Electric Heaters are 27 22
3-32
25 26
Evaporator blowers and condenser fan are off.

Condenser fan is off. Evaporator blowers running in
high speed. 15
27. Controller 8
Electronic Thermoguard MICRO P-D (µP-D) with
digital thermostat, thermometer and indicator monitor.
13
14
28
6 5 9
29 4
30
7
Low pressure gas
3 AJA494 12

CF-II M46.1, M48.1, M49
Modulation Cool
13. Bypass Valve
It OPENS when energized to reduce cooling
capacity when the temperature is close to setpoint.
The Suction Line Solenoid is de-energized
(CLOSED) when the unit is operating in 17
modulation. 16
Is a normally OPEN valve. 23 18
It CLOSES when energized. As the signal
strength is increased, the valve CLOSES more.
The controller controls the signal to the valve as
it monitors the temperatures and power limits to 24 19
20
the compressor. 21
Is a normally CLOSED valve. 27 22
3-33
The valve is energized when the compressor
25
26
head temperature is above 280 F (137.8 C) or
when the modulation valve closes 62% or more
(75% or more on temperature pull down).
15
8
13
14
28
6 5 9
High pressure gas 4
29
30
Low pressure gas
7 11
Low pressure liquid
Liquid refrigerant injection 2 10
Modulated pressure 3 AJA495 12
High pressure gas injection 1
CF-II M37.6, M37.7, M37.9,
M52 M52.1, M53
1. Compressor
4. Compressor Head Discharge
Temperature Sensor (CDTS)
6. Condenser Check Valve (CCV) 15 16
7. Discharge Pressure Regulator Valve (DPRV) 25
8. Condenser Coil 21 17
10. Receiver Tank
11. Sight Glass 22 20
19
13. Filter Drier
14. Liquid Line Solenoid (LSS) 26 24
3-34
15. Heat Exchanger 23
17. Distributor
19. Equalizer Line
20. Evaporator Coil 8
22. Coil Sensor 7
23. Discharge/Supply Air Sensor (Squashed) 28
13
(Used on M53) 27
24. Electric Heaters 29 6
25. Humidity Sensor 9
26. Controller
4
27. Low Pressure Cutout Switch (LPCO) 3 5
11
29. Suction Line Solenoid (SLS) 2 12
30. Liquid Injection Valve w/ Restrictor (LIV)
(Not used on M53) 10
32. Compressor Bypass Oil Filter 30
(Not used on M53) 1
33. Check Valve (Not used on M53) AJA496

CF-II M37.6, M37.7, M37.9,
M52, M52.1, M53
Full Cool
1. Compressor
It OPENS (cut-out) when pressure is 350 ± 10 PSIG
(2415 ± 69 kPa). 15 16
It CLOSES (cut-in) when pressure is 240 ± 10 PSIG
(1656 ± 69 kPa). 25
6. Condenser Check Valve (CCV) 22 20
18
The check valve prevents reverse of liquid refrigerant 19
low back into the compressor in the off cycle.
7. Discharge Pressure Regulator Valve (DPRV) 24
26
The Discharge Pressure Regulator Valve maintains a
3-35
discharge pressure at 70 PSIG (478.4 kPa) into the 23
compressor.
OPENS at 500 ± /-15 PSIG 14
(3447+345/-104 kPa).
Reset (CLOSES) at 400 PSIG (2758 kPa).
26. Controller 8
Thermoguard µP-A+ with digital thermostat,
7
Null Mode Operation
28 13
During Null Mode Operation, the compressor does 27
not run. Condenser fan run for 2 minutes and stops. 29 6
Evaporator blowers are running. (Speed is
9
controlled by the return air sensor temperature.)
High pressure gas 4
3 5
Low pressure gas 2 12
Low pressure liquid
30
1
AJA497
CF-II M37.6, M37.7, M37.9,
M52, M52.1, M53
Modulated Cool
Condenser fan is off. Evaporator blowers running.
(Speed is controlled by the return air temperature.)
27. Low Pressure Cutout Switch (LPCO) 15 16
Is a normally CLOSED switch. 25
It OPENS (cut-out) at 5 to 17 in hg vacuum 17
21
(-17 to -57 kPa).
It CLOSES (cut-in) at 1 to 7 PSIG (7 to 48 kPa).
Is a normally OPEN valve. 22 20
It CLOSES when energized. As the signal strength 18 19
is increased, the valve CLOSES more. The
controller controls the signal to the valve as it
monitors the temperatures and power limit to the 26 24
3-36
compressor. 23
Is a normally CLOSED solenoid. It OPENS when

energized.
The Suction Line Solenoid is de-energized
14
(CLOSED) when the unit is operating in
modulation. 8
It OPENS when energized. The valve is energized 28 7
when the compressor head temperature is above 13
280 F (137.8 C) or when the modulation valve
closes 62% or more (75% or more on temperature 27
pull down.) 29 6
9
High pressure gas
High pressure liquid 3 4 5 11
Low pressure gas
Low pressure liquid 2 12
10
30
Modulated pressure 1
AJA498
TNE 508 w/KVQ Valve

1. Water cooled Compressor
2. Non return valve
3. Condenser coil
4. Copper receiver assembly
5. Shut off valve
6. Drier refrigerant
7. Heat exchanger
8. Liquid solenoid valve
9. TX expansion valve 18
10. Liquid injection solenoid valve 11
11. Evaporator coil 8 3
12. Evaporator pressure regulator (KVQ)
13. Discharge access port
9
14. Suction service 19
10 20
15. Discharge service valve
4
16. Suction service valve
17. Sight glass/moisture indicator
18. De humidity valve (option) 6 17
7 5
19. Schroder valve
3-37
20. Fusible plug
21. Sightglass/moisture indicator
22. Sightglass 12
2
23. Fusible plug
24. Service adapter
25. Adapter incl. schraeder valve 15 13 23
26. High pressure switch
24, 25
27. Condenser
27
14 22
1
26
21
16
AJA499
TNE 508 w/ Unloaders
1. Evaporator coil
2. Condenser coil 1
3. Receiver
4. Dehumidifying solenoid valve
5. TX Expansion valve
6. Drier refrigerant
7. Hand valve
4
8. Indicator moisture
9. Heat exchanger 5
10. Constant pressure regulator
11. Crankcase pressure regulator 13
12. Compressor
13. Liquid solenoid valve
9
14. Non return valve
2
6 7
8
3-38
3
10
11
14
12
AJA500

CRR-40
Cool with Modulation
30. Evaporator Pressure Regulator (KVQ Valve)
Is a normally OPEN actuator valve. It CLOSES (or OPENS)
according to the strength and frequency of a pulsing voltage
signal from the controller. The voltage signal energizes a
heating element in the actuator power element. Increasing the
temperature of the heating element increases the pressure on
the main valve actuator, forcing the valve towards the close
position. Decreasing the temperature of the heating element
decreases the pressure on the main valve actuator, drawing the
valve towards the open position.
It OPENS when energized. When liquid injection is required
the valve is pulsed open and closed on a 60 second cycle.
Liquid injection is controlled by the compressor discharge
temperature.
3-39
High pressure gas
Low pressure gas
Low pressure liquid
Modulated pressure
CRR-40
Full Cool
1. D3DS Compressor
Compressor operation has a variable delay on initial start-up. A
sequence start of the compressor occurs when the compressor has
been OFF for more than 18 hours.
OPENS at 2240 +/- 70 kPa, 22.4 +/- 0.7 bar 325 +/- 10 psig.
It CLOSES at 1590 +/- 70 kPa, 15.9 +/- 0.7 bar, 230 +/- 10 psig.
9. High Pressure Relief (Fusible Plug)
BLOWS at 100 C (212 F).
It opens when energized, when the compressor operates.
22. Electric heaters
During the DEFROST mode, the electrical heaters are pulsed ON
and OFF.The compressor, condenser fan and evaporator fans are
OFF.
During the HEAT mode, the electric heaters are pulsed ON and
OFF. The compressor and condenser fans are OFF. The evapora-
tor fans continoue to operate (evaporator fan speed is determined
by the setpoint and economy mode setting).
28. Controller
3-40
Microprocessor with digital thermostat, thermometer and fault
indicator monitor.
37. Water Pressure Switch (WPS) (HPCO)

It OPENS at 117 +/- 21 kPa, 1.17 +/- 0.21 bar, 17 +/- 3 psig.
It CLOSES at 35 +/- 21 kPa, 0.35 +/- 0.21 bar, 5 +/- 3 psig. 8
High pressure gas
Low pressure gas
Low pressure liquid

CRR-40
Dehumidification
32. Dehumidify Solenoid Valve (DSV)
If the container humidity is 2% or more above the humid-
ity setpoint and the KVQ valve has reduced cooling
capacity
by about 25%, 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 container air.
If the container humidity is 5% or more above the
humidity set-point, and the KVQ valve has closed to
3-41
reducecooling capacity by about 50%, the controller will
pulse the electric heaters ON and OFF. This increases the
cooling
load of the evaporator coil, thereby lowering the
temperature of the entire coil and condensing more
moisture from the container air.
33. Humidity Sensor (rH)
The humidity sensor is located at the top right hand side
of the evaporator fan deck and measures the humidity of
the return air from the cargo space.
High pressure gas
Low pressure gas
Low pressure liquid
CSR-40
1. Scroll compressor
2. Sight Glass
3. Oil Fill / Drain Fitting
4. Compressor Head Discharge Temperature Sensor 33
(CDTS) 19 23
18
8. Condenser Coil (Circular)
18 22
32 25
10. Receiver Tank
11. Receiver Tank Sight Glasses 20
13. Receiver Bypass Valve 17 28
21
14. Compressor Oil Filter
15. Filter Drier (Dehydrator) 13
3-42
9
16. Heat Exchanger
27

18. Distributors
19. Evaporator Coil
20. Expansion Valve Feeler Bulb 16 10
21. Equalizer Line 11
23. Return Air Sensor (RET) 14
24. Evaporator Coil Sensor (ECOIL)
12
25. Supply Air Sensor (SUP)
26. Ambient Sensor (AMBT) 15
27. Condenser Coil Sensor (CCOIL) 5 6 8
28. Controller (µP-D)
26
29. Modulation Valve (MV) AJA505
29
30. Liquid Injection Valve (LIV) with Restrictor 7
32. Dehumidify Solenoid Valve (DSV) (Option)
31
33. Humidity Sensor (rH) (Option)
30 2 3
1

CSR-40
Full Cool
Compressor operation has a delay on initial start-up
when the unit shifts to a cooling mode requiring the
compressor to start up.
5. High Pressure Cutout Switch (HPCO) 33
18 19 23
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, 24
375 ± 38 psig.
18
22
It OPENS at 1855 ± 50 kPa, 16.55 ± 0.5 bar, 240 ± 7 32 25
psig. It CLOSES at 1325 ± 50 kPa, 13.25 ± 0.5 bar, 20
192 ± 7 psig.
OPENS at 3450 +345/-105 kPa, 34.5 +3.45/-1.05 17
bar, 500 +50/-15 psig.
21 28
CLOSES at 2760 kPa, 27.6 bar, 400 psig. 13
3-43
28. Controller (µP-D) 9 11
Thermoguard (µP-D) with digital thermostat,
27
During the Null mode, the compressor does not
operate. If the condenser fan is ON (based on 16 11
condensing pressure) when the unit shifts to Null,
the condenser fan operates for 30 seconds and stops.
Evaporator fans continue to operate (evaporator fan 14
speed is determined by return air temperature and
economy mode setting). 12
15
5 6 8
26
High pressure gas 29 AJA506
Low pressure gas 4
1
CSR-40
Modulation Cool
13. Receiver Bypass Valve
capacity when the temperature is close to setpoint.
22. Electric Heaters 18 19 23
During the defrost mode, the electric heaters are
pulsed ON and OFF. The compressor does not
24
operate. The condenser fan and evaporator fans
remain OFF.
During the HEAT mode, the electric heaters are 18
pulsed ON and OFF. The compressor does not
22
32 25
operate. The condenser fan is OFF. The
evaporator fans continue to operate (evaporatro fan
20
speed is determined by return air temperature and
economy mode setting).
29. Modulation Valve (MV) 21 17 28
Is a normally OPEN valve. 13
It OPENS when energized. When liquid injection
9
3-44
is required, the valve is pulsed open and closed on 11
a 10 second cycle. 27
The valve is energized when the compressor head

temperature is above 138C (280F) or when the 10
modulation valve closes more than 45%.
16
11
14
12
High pressure gas
15 8
5 6
Low pressure gas
Condensing high pressure gas 29 AJA507
Modulated pressure
31
High pressure gas injection 30 2
High pressure gas injection 3
1

CSR-40
Dehumidification
If the container humidity is 5% or more above
setpoint +3% and the temperature is in-range, the
controller will pulse the electric heater ON and
OFF. This increases the cooling load on the
compressor and condenses more moisture from the 33
18 19 23
container air.
Is a normally OPEN valve. 24
If the container humidity is between 1 and 5%
above setpoint and the temperature is
in-range, the controller will energize (CLOSE) the 18 22
normally open solenoid. This closes refrigerant 32
distribution to 50% of the evaporator coil, thereby
25
20
lowering the temperature of the active part of the
coil and condensing more moisture from the
container air.
33. Humidity Sensor (rH) (Option) 21 17 28
The humidity sensor is located at the top right hand 13
3-45
side of the evaporator fan deck and measures the 9
humidity of the return air from the cargo space. 11
27
10
16 11
14
12
15 8
5 6
26 AJA508
Low pressure gas 4
3
1
CSR-20 & CSR-40
Modulation Cool
7. Warm Gas Bypass Valve
capacity when the temperature is close to
setpoint.
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.
It OPENS when energized. When liquid injection
is required, the valve is pulsed open and closed
on a 10 second cycle.
3-46
The valve is energized when the compressor head
temperature is above 138 C (280 F) or when the
modulation valve closes more than 45%.

During the DEFROST mode, the electric heaters
are pulsed ON and OFF. The compressor does
not operate. The condenser fan is OFF. The
evaporator fans continue to operate (evaporator
fan speed is determined by return air temperature
and economy mode setting).
High pressure gas
Low pressure gas
Low pressure liquid
Modulated pressure
High pressure gas injection
High pressure gas injection

CSR-20 & CSR-40
Dehumidification
If the container humidity is 5% or more above the humidity
setpoint, and the temperature is in-range, the controller will
pulse the electric heater ON and OFF in addition to ene
gizing (closing) the dehumidify solenoid valve. This
increases the cooling load on the evaporator coil, thereby
lowering the temperature of the entire coil and condensing
more moisture from the container air.
If the container humidity is between 1 and 5% 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 container air.
27. Humidity Sensor (rH) (Option)
3-47
The humidity sensor is located at the top right hand side of
the evaporator fan deck and measures the humidity of the
return air from the cargo space.
High pressure gas
Low pressure gas
Low pressure liquid
Modulated pressure
CRR DF
3-48
3-49
3-50
3-51
3-52
SECTION 4
Thermostat Sequence
Diagrams
4-1
Section 4-Thermostat Sequence Diagrams
THERMOGUARD MICROPROCESSOR CONTROLLER SEQUENCE
Controller Set Point Controller Set Point

Above 24 F (-4.4 C) Below 24 F (-4.4 C)
Falling Temperature Falling Temperature

High Speed Condenser Fan High Speed Condenser Fan
9.5 F (5.3 C)
Full Cool
8.0 F (4.5 C)
Condenser Fan
Controlled by Full Cool
Pressure Switch
Partial Cool 4.0 F (2.2 C)

Out-of-Range
4.0 F (2.2 C)
Out-of-Range 3.0 F (1.7C)
3.0 F (1.7 C) 3.0 F (1.7 C) In-Range
In-Range
Modulation Cool 1.5 F (0.9 C) 1.5 F (0.9 C)
Set point Null Set point

-1.0 F (-.06 C) Null
Heat
In-Range 2.0 F (-1.1 C)
-3.0 F (-1.7 C)
Out-of-Range
Rising Temperature Rising Temperature

AJA509
OPERATING MODE CONTROL SEQUENCE

CF-II M 19.7,19.8,19.9,19.10 w/uP-A+ Controller
Controller
Controller Set Point
Set Point
Above 24 F (-4.4 C)
Below 24 F (-4.4 C)
Mod. Cool
Part Cool
Full Cool
Full Cool
Defrost
Defrost
Unit Function
Heat
Null
Null
HIGH SPEED EVAPORATOR FAN • • • • •

LOW SPEED EVAPORATOR FAN • •
RETURN AIR SENSOR CONTROL • • • • • • • • •
COMPRESSOR OPERATION* • • • •
HIGH SPEED CONDENSER FAN • •** •** •
LOW SPEED CONDENSER FAN •** •**
SUCTION LINE SOLENOID OPEN • • • • • • •
SUCTION LINE SOLENOID CLOSED (ENERGIZED) • •
MODULATING VALVE OPEN • • •
MODULATING VALVE MODULATING (ENERGIZED) •
ELECTRIC HEATERS “ON” • • •
*Three second delay on initial unit startup or unit shift to cooling.

**Condenser fan operation is controlled by condenser fan switch.
4-2
Software Version 5.00.08 through 5.00.11

Control Sequence Chart for Configuration Block Cb 02
Cool Cool
+9.0 F (5.0 C)1
Modulation Cool
Out-of-Range +4.0 F (+2.2 C)3 Out-of-Range +4.0 F (+2.2 C)3
+3.0 F (+1.7C)3 +3.0 F (+1.7C)3

In-Range
Null
+0.5 F (+.03 C)1
Set point 1 Set point4 +0.5 F (+.03 C)4
In-Range
- 1.0 F (-.06 C)1
Heat2 -2.0 F (-1.1 C)3 Null
In-Range
- 3.0 F (-1.7 C)3

1
Calculated Temperature Differential Using Discharge Sensor
2
Calculated Temperature Differential Using Return Sensor
3 Controlling Air Sensor Temperature
4 Return Air Sensor Temperature
Software Version 5.00.13 through 5.00.15 Control Sequence Chart

Controller Setpoint Above 24 F (-4.4 C) Controller Setpoint Below 24 F (-4.4 C)
Cool Cool
1
+5.4 F (+3.0 C)
Modulation Cool
+4.0 F (+2.2 C)3 +4.0 F (+2.2 C)3
Out-of-Range
3
+3.0 F (+1.7C)3 +3.0 F (+1.7C)
Null
+0.5 F (+.03 C)1 Out-of-Range
+0.5 F (+.03 C)4
Set point1 Set point4
In-Range
-1.0 F (-.06 C)1
Heat2
-2.0 F (-1.1 C)3
In-Range
-3.0 F (-1.7 C)3
Null

1
Calculated Temperature Differential Using Discharge Sensor
2
Calculated Temperature Differential Using Return Sensor CF-II M 14B w/µP Controller
3 Controlling Air Sensor Temperature
4 Return Air Sensor Temperature
4-3
1
A
+4.5 F4
(+2.5 C)
A
+4.5 F5
+3.0 F5
(+2.5 C) +4.5 F6
(+1.7 C)
B (+2.5 C)
C
E +0.5 F +3.0 F6
4 (+0.3 C4) (+1.7 C)
2 +1.8 F6,8
E (+1.0 C)
-1.0 F4 -3.0 F5 -3.6 F6,7
(-0.6 C) D (-1.7 C) (-2.0 C)
-4.5 F5 C
AJA798
(-2.5 C)
3 AJA707
Fresh Load Control Sequence 3
(Setpoints at 14.1 F (-9.9C) and Above)
Frozen Load Control Sequence
A. Cool 1. Decreasing Temperature (Setpoints at 14F (-10C) and Below)
B. Modulation Cool 2. Setpoint Economy Mode ON
C. Null 3. Increasing Temperature
A. Cool 1. Decreasing Temperature
D Heat 4. Calculated Temperature Differential
C. Null 2. Setpoint
E. In Range 5. Supply Air Temperature
E. In-Range 3. Increasing Temperature
6. Return Air Pressure
7. ECMIN (default setting is
1 3.6F (2.0C) below
setpoint) Setting is
adjustable from 0F to
18F (0C to 10C)below
setpoint.
A 8. ECMAX (default setting
is 1.8F (1.0C). Setting is
+4.5 F6 adjustable from 0F to
(+2.5 C) 18F (0C to 10C) above
setpoint.
+3.0 F6
(+1.7 C)
+1.8 F6
E (+1.0 C)
-1.8 F6
(-1.0 C)
C
AJA709
3
(Setpoints at 14F (-10C) and Below)
Economy Mode OFF
A. Cool 1. Decreasing Temperature
C. Null 2. Setpoint
E. In-Range 3. Increasing Temperature
6. Return Air Pressure
4-4
SECTION 5
Evacuation
5-1
Section 5-Evacuation
WHY EVACUATE? HOW DOES AIR AND MOISTURE

Today’s high performance, high efficiency refrigeration sys- CONTAMINATE A
tems become small chemical plants if they are allowed to
operate with the presence of moisture and non condensables.
REFRIGERATION SYSTEM?
• All air contains some amount of water vapor, so when air
enters, so does moisture.
High efficiency refrigeration system + air + moisture = In-
creased maintenance costs and Warranty call backs
• Air will move to the high pressure side of an operating
refrigeration system. The liquid seal keeps it there. It will
Evacuation - not condense but uses up condensing space.
The process of removing moisture and non-condensables
from a refrigeration system. • An operating unit + air = Reduced condensing surface
area.
Non-Condensables - • Reduced condensing surface area = higher discharge

Gases found in our atmosphere such as Nitrogen and Oxygen. pressure, higher discharge temperature and higher com-
A system must be degassed to remove these Non Condens- pression ratio.
ables.
• Oxygen from the air will cause the oil to burn when the
temperature gets high enough.
Moisture -
The water vapor which is present in air and is measured as rel- • Moisture can become present in a refrigeration system
ative humidity. Water vapor must boil off to be removed from from a leak, poor service practices, oil, refrigerant, and
the system. This process is called dehydration. excessive heat.
• Chlorine containing refrigerants will hydrolyze with

DEHYDRATION + DEGASSING = EVACUATION water forming hydrochloric acid and more water.
• Acids have a corrosive effect on metal surfaces and con-

tribute to copper plating bearings and other components
with close tolerances.
5-2
Micron Evacuation Boiling

Microns
1. A Micron is a unit of length equal to one-millionth of a Temperature Inch of Mercury
Vacuum
meter. Of Water - F
2. One inch equals 25,400 microns. 80 F (27 C) 28.92 25,400
76 F (24 C) 29.02 22,860

3. When the vacuum pressure approaches 29.5 in. to 30 in.
on the compound gauge, the gauge is working within the 72 F (22 C) 29.12 20,320
last half inch of pressure, and the readout beyond 29.5 is
not accurate. 69 F (21 C) 29.22 17,780
64 F (18 C) 29.32 15,240

4. The table below not only demonstrates the comparison in
units of measure but dramatically shows the changes in 59 F (15 C) 29.42 12,700
the boiling point of water as the evacuation approaches
the perfect vacuum. This is the main purpose of evacua- 53 F (12 C) 29.52 10,160
tion - to reduce the pressure or vacuum enough to boil or
45 F (7 C) 29.62 7,620
vaporize the water and then pump it out of the system. It
will be noted the compound gauge could not possibly be 32 F (0 C) 29.72 4,572
read to such minute changes in inches of mercury.
21 F (-6 C) 29.82 2,540
6 F (-14 C) 29.87 1,270
-24 F (-31 C) 29.91 254
5-3
TESTING FOR AIR AND OTHER 3. Close the high side gauge valve to isolate the micron
gauge and pump.
NON-CONDENSABLES IN A
THERMO KING CONTAINER 4. Open the receiver tank service valve to a count of four
(4). Then close the valve and count to four (4) again.
REFRIGERATION UNIT
5. Then close the low side gauge valve.
MANIFOLD SET HOOKUP PROCE- 6. Place the sample bottle into the ice bath for 15 to 20 min-
utes. Stir the ice bath occasionally.
DURE
Attach manifold set as follows: NOTE: An ice water bath must be 75% ice in small
pieces and it should completely cover the sample bottle.
1. Connect low side hose to sample bottle. The smaller the sample bottle, the faster the
temperature will equal that of the ice water bath.
2. Connect center hose to receiver tank service valve. 7. Compare the low side gauge reading with your pressure/
temperature chart for 32 F (0 C).
3. Connect high side hose to evacuation pump. R-12 = 30.2 psig (208 kPa)
R-134a = 27.3 psig (188 kPa)
R-404a = 72.5 psig (499.5 kPa)
CAUTION: If hoses are not connected properly, gauge
readings will be inaccurate.
READING MUST BE PLUS/MINUS
ICE BATH TEST PROCEDURE ONE (1) psig (7 kPa)
If pressures exceed specifications, the refrigerant must be
1. Open manifold gauges and evacuate all hoses, manifold
reclaimed and the unit totally evacuated according to proper
and sample bottle to 500 microns.
evacuation procedures. After the system has been evacuated,
leak tested, and recharged with clean refrigerant, reconfirm
CAUTION: Ensure that there are no leaks in the system.
the system operation. If system operation is satisfactory,
return the unit to service.
2. Run the unit to circulate any air that may be in the sys-
tem.
5-4
5
6
1 8
1. Ice Bath 75% Ice 5. Manifold Set

2. Sample Bottle of Refrigerant 6. Receiver Tank
3. Refrigerant 7. Micron Gauge
4. Temperature 32F (0C) 8. Vacuum Pump
Refrigerant Pressures at 32 F (0C)

R-12 = 30.2 psig (208 kPa)
R-134a = 27.3 psig (188 kPa)
R-404a = 72.5 psig (499.5 kPa)
READING MUST BE PLUS/MINUS ONE (1) PSIG (7 kPa)
Ice Bath Sample Method
5-5
SECTION 6
R12 to R134a Conversion
6-1
Section 6-R12 to R134a Conversion
CF UNIT R-12 TO R-134A PROCEDURE

AND POLYOLESTER OIL NOTE: PRIOR TO BEGINNING THE CONVERSION,
CONVERSION PERFORM THE FOLLOWING STEPS.
This conversion kit contains the components needed to con- 1. CONFIRM PROPER COMPRESSOR PUMPING
vert a CF series unit with Thermo King X426 or X430 com- ABILITY BY PERFORMING A LOW SIDE PUMP-
pressor from R-l2 to R-134a. Included in the kit are 4 US DOWN AND COMPRESSOR CAPACITY (EFFI-
gallons of polyolester oil. This conversion procedure requires CIENCY) TEST.
three (3) oil flushes using the polyol ester oil and a fourth
(4th) final oil fill. The original R12 oil in the refrigeration sys- 2. CAREFULLY CHECK THE UNIT FOR CORRECT
tem must be diluted so that no more than 2% of the original OPERATION, FULL COOLING CAPACITY AND
oil remains in the system before the forth (4th) and final oil THAT THE SYSTEM IS LEAK FREE.
fill. Compressor mineral and synthetic oils are not compatible
with R-134a and polyolester oil. ALL DEFICIENCIES MUST BE CORRECTED
PRIOR TO BEGINNING THE CONVERSION TO
Thermo King has polyolester oil available in quart and gallon ENSURE RELIABLE RESULTS.
containers for the Thermo King compressor.
P/N 203-426 - 1 US gallon Compliance with applicable environmental and safety regula-
P/N 203-420 - 1 US quart tion standards is essential.
Tool List - Reference 3. Operate unit in full cool with the container temperature
above 50 F (10 C) for one (1 hour) to get the maximum
Van Steenburgh or other U.L. approved refrigerant reclama- amount of oil back to the compressor.
tion system
In ambient conditions below 50 F (10 C) it may be necessary
Thermo King Evacuation Station to use supplemental heat sources to raise the container (box)
110 VAC P/N 204-725 temperature above 50 F (10 C).
220 VAC P/N 204-744
In ambients ABOVE 50 F (10 C) opening the container doors
may be sufficient to keep the unit operating in the full cool
Adapters for the Evacuation Station for use with mode.
R-134a fittings.
High Side Couplers (2 needed)P/N 204-791 4. Leak check unit (repair leaks before continuing).
Low Side CouplerP/N 204-792
Vacuum Pump Oil 1 US GallonP/N 203-419 5. Turn unit off and reclaim R12 with U.L approved recla-
Leak Detector for R-134a refrigerant mation system. Pull system down to 10î vacuum.
12VDC/110 VACP/N 204-756
12VDC/220 VACP/N 204-765 NOTE: While refrigerant is being reclaimed see attachment
Manifold gauge set for R-134aP/N 204-758 on assembly and use of the compressor oil drain and fill
Electronic programmable charging scale tool.
110 VACP/N 204-760
220 VACP/N 204-795 6. With the unit still in a vacuum install the oil drain tool,
Compressor oil sump drain and fill toolP/N 204-750 this will minimize oil spillage.
Oil Sump Adapter (included with 204-750 Kit)
P/N 204-796 7. Return unit pressure to 0 to 2 psig (O to 14 kPa) using dry
125# Cylinder valve adapter (converts 3.4’NPS nitrogen.
on the valve to 1/4” male flare)P/N 204-169
R-134a ACME Coupler (converts 1/4” male flare to 8. FIRST OIL CHANGE. Drain oil from compressor sump.
1/2”male ACME) (permanent application) Refill with 1 US gallon (3.78 liters) of polyolester oil.
P/N 204-793
R-134a ACME Coupler, (converts 1/4” male flare to
1/2” male ACME (with swivel nut)P/N 204-794
6-2
9. Install the following new parts. 15. Charge system with R-134a (see unit data plate for proper
charge weight). Operate the unit at 50 F (10 C) (or above)
• Replace the expansion valve thermostatic element. Hand box temperature for 20 minutes. Turn unit off.
tighten element and then tighten an additional 1/6 turn (1
flat on the nut). 16. Leak check unit (make any repairs as needed).
• Clean suction line and install TXV sensor bulb with new NOTE: While unit is operating between oil changes, install
clamps and insulation wrap. the new decals. See attached CF-11 decal positioning.
17. SECOND OIL CHANGE. Pump down the compressor to
Suggestion: To make the installation of the insulation eas- 0 psig. Adjust pressure to 1 to 2 psig (7-14 kPa) positive.
ier, cut the long strip into 4 short pieces. Drain the compressor oil. Refill with 1 US gallon of new
polyolester oil. Operate unit for 20 minutes at 50 F (10 C)
10. Remove schrader valve depressors from the 1/4î flare fit- (or above) box temperature.
tings on the discharge side of the system only.
18. THIRD OIL CHANGE. Pump down the compressor to 0
11. Install Two Discharge (red) and One Suction (blue) R- psig. Adjust pressure to 1 to 2 psig (7-14 kPa) positive.
134a access fitting using provided Locktight on the Drain the compressor oil. Refill with 1 US gallon of new
threads. polyolester oil. Operate unit for 20 minutes at 50 F (10 C)
(or above) box temperature.
NOTE: Do Not over tighten adapters. The adapters have an 19. FINAL OIL FILL. Pump down the compressor and drain
integral o-ring seal. Torque to 5 to 6 ft/lbs. (60-72 in/lbs.) the oil. Refill the compressor new with polyolester oil to
maximum. the BOTTOM of the sight glass. Operate the unit in full
cool for 20 minutes and check oil level. Oil level should
12. Remove any remaining 1/4î flare fittings and plug the
be 1/2 sight glass. Make adjustments as needed.
hole(s) with 1/8î pipe plug(s) using the provided Lock-
tight on the threads.Install new Oil Fill Plug and O-Ring.
20. Pump down the compressor and remove the oil fill/drain
tool and install the new oil drain plug and o-ring pro-
13. Install new Filter Drier.
vided.
14. Evacuate refrigeration system using the Thermo King
21. Isolate and evacuate the compressor to remove any air
Evacuation Station.
that may have entered the compressor during installation
of the drain plug.
6-3
EXPANSION VALVE “SUPERHEAT PROCEDURE

CHECK”.
NOTE: THIS TEST MUST BE PERFORMED EVEN IF
CAUTION: DO NOT ATTEMPT TO PERFORM THE TXV IS COMPLETELY REPLACED IN ORDER TO
SUPERHEAT CHECK USING UNIT DISCHARGE ENSURE PROPER OPERATION OF THE EQUIPMENT.
(SUPPLY) AND RETURN AIR SENSORS. THE 22. Install an accurately calibrated Compound Gauge as
FOLLOWING PROCEDURE IS THE ONLY ACCURATE close as possible to the outlet of the evaporator coil.
METHOD TO PROPERLY DETERMINE SUPERHEAT.
Note: Newer units have a port in the suction line between
EXAMPLE / R-134a:
the evaporator outlet and the modulation valve for this
Suction Pressure Measured Upstream (before) Mod Valve
purpose.
Suction Pressure = 11 PSIG = 8 Degrees F Saturation Tem-
perature from P/T chart. CAUTION: On older units that DO NOT have this port it
Suction Temperature = 14 F (-10 C) from electronic thermom- may be necessary to connect the compound gauge to the
eter. compressor suction inlet connection. If so, pressure drop
through the Modulation valve will need to be compensated
Calculation: Suction Temperature 14 F (-10 C) for as described in step number 34.
Minus (-) Saturation Temp - 8 F (-22 C)
Equals (=) SUPERHEAT 6 F (-14 C) 23. Install an accurate thermometer sensor (thermocouple or
equivalent) under the TXV insulation on the suction line
Proper Superheat should be 6 F (-14 C). next to the expansion valve sensing bulb and re-install
the insulation as it was before. This prevents the Exist
Purpose: This test confirms the expansion valves setting and sensing bulb from sensing surrounding ambient tempera-
ture and insures its sensing only suction vapor tempera-
operation and must be followed exactly and completely to
ture as it should.
ensure proper operation of the unit.
Note: When installing the thermometer sensing element, be
EXAMPLE / R-134a: Suction Pressure sure lead does not come in contact with the evaporator
Measured at the compressor heaters as the unit will be operated in heat prior to
beginning the procedure and could damage the
Suction Pressure = 10 PSIG = 6 F (-14 C) Saturation Temper-
ature from P/T chart. thermometer sensing element lead.
Suction Temperature = 12 F (-11 C) from electronic thermom- 24. If the evaporator coil is clear of frost and ice, operate the
eter. unit in MAXIMUM COOL with the Thermostat set for 0
F (-18 C). The unit must be operated long enough to
Calculation: Suction Temperature 12 F (-11 C) achieve 0 F (-18 C) Return Air Temperature.
Minus (-) Saturation Temp - 6 F (-21 C)
Equals (=) SUPERHEAT 6 F (-14 C)
Note: If 0 F (-l8 C) cannot be achieved GO TO STEP 30 and
Proper Superheat should be 6 F (-14 C). repeat the initial Low Side Pumpdown, Compressor
Capacity Test and other unit performance tests and repair
Purpose: This test confirms the expansion valves setting and unit as necessary. Once repaired, operate the unit until the
operation and must be followed exactly and completely to
required 0 F (-l8 C) Return Air Temperature is achieved
ensure proper operation of the unit.
before continuing. Repeat step 29.
Equipment Required: 25. Run the unit in the heat mode with the controllers K3
1. Compound Gauge (Evap Fan High) relay removed until 75 F (24 C) return
2. An accurately calibrated Electronic Thermometer. air temperature is achieved and all frost and ice has been
3. R-134a Pressure / Temperature Chart removed from the evaporator coil or no water is draining
from the drain tubes.
6-4
26. After this is complete, replace the K 3 (Evap. Fan High) CAUTION: WHEN ADJUSTING SUPERHEAT, DO NOT
relay and operate the unit in MAXIMUM COOL until ADJUST VALVE STEM ANY MORE THAN ONE (1)
Return Air is 0 F (-18 C) again. COMPLETE TURN (4 FLATS) AT A TIME.
27. With the unit continuing to operate in MAXIMUM If the proper Superheat WAS NOT achieved using the above
COOLING, read the Suction Pressure on the compound procedure further adjustment of the TXV is required. To
gauge and Suction Temperature on the thermometer. adjust the TXV, use the following procedure:
Make several readings approximately every two (2) min-
utes. • If the Superheat is TOO LOW (potential liquid return to
the compressor), turn the valve stem IN (clock wise when
28. If measuring evaporator outlet pressure between the viewed from the stem end) approximately 1/4 turn (1 flat
evaporator coil outlet and modulation valve, skip step 34 on stem). 1/4 turn of the stem provides approximately 1 F
and go to step 35. (0.5 C) change in Superheat.
29. IF MEASURING SUCTION PRESSURE AT THE • REPEAT AS NECESSARY UNTIL THE PROPER
COMPRESSOR, ADD I PSIG to the pressure gauge SUPERHEAT IS ACHIEVED.
reading BEFORE converting that pressure to the corre-
sponding Saturation Temperature using an R-134a Pres- • If the Superheat is TOO HIGH (lack of cooling capacity),
sure / Temperature chart. turn the valve stem OUT (counter clock wise when
viewed from the stem end) approximately 1/4 turn (1 flat
30. Subtract the Saturation Temperature from P/T chart from on stem). 1/4 turn of the stem provides approximately 1 F
the Suction Vapor (Thermometer) Temperature. The dif- (0.5 C) change in Superheat.
ference is the Superheat.
• REPEAT AS NECESSARY UNTIL THE PROPER
Note: If the proper amount of Superheat was achieved using SUPERHEAT IS ACHIEVED.
the above procedures the conversion is complete and the
31. Pre-Trip unit and return to service.
unit may be placed back into service. If the proper amount
of Superheat was not achieved, perform the following
procedures for the conditions obtained.
6-5
1. Inlet
2. Equalizer Line
3. To Distributor
6-6
SECTION 7
AC Electricity
7-1
Section 7-AC Electricity
DEFINITIONS OR TERMS USED IN CURE: The word cure embraces all theoretical and practical
aspects of the term Vulcanization of rubber or neoprene com-
THE WIRE AND CABLE INDUSTRY pounds.
A.S.T.M.: American Society for Testing Materials. CURRENT CARRYING CAPACITY: The current carrying
A.W.G.: American Wire Gauge. The wire gauge universally capacity of an electrical conductor is the maximum current
used in the U.S to designate the size of wire or conductors. the conductor can carry without heating beyond a safe limit.
The number designating wire sizes are retrogressive. The DUPLEX CABLE: A duplex cable is a cable composed of
larger the number the smaller the wire. two insulated conductors twisted together with no sheath or
BRAID: A woven covering of cotton or other type of yarn, outer covering.
used on some types of insulated wires. Braids provide some DIRECTION OF LAY: The direction of lay is the lateral
mechanical strength and serve as a means of polarity identifi- direction in which the strands of a cable run over the top of
cation. the cable as they recede from an observer looking along the
BUNA RUBBER: Man-made rubber used as replacement axis of the cable. This is the same designation used for thread
for natural rubber. direction of screws.
BUNCH STRANDING: A Bunch Strand is a collection of DIELECTRIC: A medium having the required properties that
wires or strands twisted together in the same direction without the energy required to establish an electric field (voltage
regard to geometrical arrangement. stress) is recoverable, in whole, or in part, as electrical energy.
The establishment of the field or voltage stress is accom-
BUTYL RUBBER: Man-made rubber used for special appli- plished by displacement of charging currents. A vacuum is the
cations. Has excellent resistance to heat, sunlight, weather, only known perfect dielectric.
aging and ozone.
DIELECTRIC STRENGTH: The voltage stress required to
C.M.: Circular Mil. puncture a specimen of known thickness, expressed as volts
CABLE: A cable is a standard insulated single conductor or per unit thickness.
an assembly of insulated conductors usually with an outer G.R.S.: Same as Buna Rubber.
covering. Small single conductors are often called wires and
small flexible cables are called cords. There are numerous I.P.C.E.A.: Insulated Power Cable Engineers Association.
deviations from these definitions resulting from traditional INSULATION: Any substance of such low conductivity that
names for items used for a long time. the flow of electrical current through it can usually be
CIRCULAR MIL: The circular mil area of a round conductor neglected.
is obtained by squaring its diameter measured in thousandths INSULATION RESISTANCE: The insulation resistance of
of an inch. For instance, a 0.010 inch wire has an area of 100 an insulated conductor is the resistance offered by its insula-
circular mils: a 0.001 inch wire has an area of 1 circular mil, tion to current flow from impressed d.c.
etc.
JACKET: An outer sheath or covering, extruded or tubed
COMPACT STRANDING: A compact stranded conductor over an insulated conductor, or over an assembly of insulated
is a round or sector conductor having all layers of wires conductors.
within it stranded in the same direction and rolled to the
LAY: The lay or pitch of any helical element of a cable is the
desired shape. The finished conductor has a relatively smooth
axial length of a turn of the helix of that element.
surface and the individual strands are no longer round.
CONCENTRIC STRANDING: A concentric stranded con- LEAD-CURE: A vulcanization process for wires and cables
ductor consists of a central wire or core surrounded by one or during which unvulcanized insulated wires or cables are run
more layers of helically laid wires. Each layer of wires is through a lead press which forms a lead pipe snugly around
applied in the reverse direction to the layer of wires under it. the cable. The lead cure process consists of vulcanizing the
insulated cable while it is enclosed in this tight fitting pipe.
CONDUCTOR: A conductor is a wire or a group of wires When vulcanization is complete, the lead pipe is removed
uninsulated from one another, suitable for transmitting elec- from the cable.
tric current. A conductor may be bare of insulated.
MCM: 1000 Circular Mils.
CORD: A cord is a small very flexible cable, having two or
MIL: “MIL” is a term universally used in the United States to
more conductors insulated from one another, covered by an
measure wire or cable diameters. It is a unit of length equal to
outer sheath or suitable covering.
one-thousandth of an inch.
7-2
N.E.C.: National Electric Code. copper and insulation. It also facilitates soldering the wire to a
terminating connection.
N.E.M.A.: Abbreviation for National Electrical Manufactur-
ers Association. TINSEL: Tinsel wire is an extra flexible conductor made by
wrapping thin flat ribbons on copper or bronze around fine
NEOPRENE: A man-made rubber having superior resis-
cotton or textile yarns of other fibrous materials. This type of
tance to oils, alkalies, acids and most solvents. Has high abra-
conductor has a low current carrying capacity.
sion resistance and will not support combustion.
PLASTIC: A physical condition characterized by permanent TRACER: A means of identifying polarity,e.g., a thread or
change of shape of a material upon application of force. group of threads of contrasting color or size in a braid, a ridge
on insulation surface, a colored stripe on insulation.
ROPE STRANDING: A rope stranded conductor is a
TRIPLEX CABLE: A triplex cable is a cable having three
stranded conductor, formed by cabling together groups of
insulated conductors twisted together without a sheath over
wires which are themselves stranded.
all.
SAFETY FACTOR: The safety factor of assurance of wire
TWIN CABLE: A twin cable is a cable having two insulated
or cable insulation is the ratio of the voltage at which it is
conductors, laid parallel and having a protecting sheath or
tested to that at which it is used or designed for.
jacket over them.
SELENIUM: A finely ground form of an elementary metal:
TWISTED PAIR: A twisted pair comprises two insulated
used as a vulcanizing agent in rubber compounds.
conductors twisted together without a common covering.
SHIELDED CABLES: A shielded cable is a cable in which
the insulated conductor or conductors is/are enclosed within VULCANIZATION: Vulcanization or cure is a permanent
an envelope of conducting material. The shield of conducting chemical and mechanical change in Rubber or Neoprene
metal or other material is so applied that substantially every Compounds. After application of heat and pressure, the com-
point on the surface of the insulation is at ground potential. pound is no longer plastic; but now, has the familiar property
of stretching and returning to its original shape upon the
STRAND: A strand is a single uninsulated wire used in com- application and removal of force.
bination with other strands or groups of strands to form a con-
WIRE: A wire is a rod or filament of drawn metal, usually of
ductor.
circular cross section.
STRANDED CONDUCTOR: A stranded conductor is com-
posed of a group of wires, or a combination of groups of
wires.
ELECTRICAL DEFINITIONS
SYNCHRO-CURE: An improved, perfected method of vul- AMPACITY: Current carrying capacity of conductors
canizing rubber insulated cables, which makes it possible to expressed in amperes.
balance the “cure” of the rubber insulated conductors with the ALTERNATING CURRENT: Alternating current (ac) is
“cure” of the Neoprene or rubber outer sheath. By eliminating current which reverses direction rapidly, flowing back and
the possibility of “over-cure”, maximum physical properties forth in the system with regularity. This reversal of current is
and electrical characteristics are maintained. due to reversal of voltage which occurs at the same frequency.
TELLURIUM: A finely ground form of an elementary metal; In alternating current, any one wire is first positive, then neg-
used as a vulcanizing agent in rubber compounds. ative, then positive and so on. With commercial power, the
change from positive to negative to positive occurs 60 times
THERMOPLASTIC: A physical condition in which the per second resulting in 60 Hertz current.
plasticity is increased by increased temperatures and
decreased by decreased temperatures. Any change of shape ALTERNATOR: An electric generator designed to supply
resulting from the application of force at elevated tempera- alternating current. Some types have a revolving armature and
tures is permanent. in other types a revolving field.
THERMOSETTING: A term applied to any type of material AMPERE: The ampere is the unit of measurement for elec-
which, although originally in a plastic condition, undergoes tric current. It represents the rate at which current flows
permanent change at increased temperature, so that subse- through a resistance of one ohm by a pressure of one volt.
quent changes of shape resulting from applications of force CAPACITOR OR CONDENSER: A capacitor is an electri-
exist only during the period the force is effective and the orig- cal device which causes the current to lead the voltage, oppo-
inal shape is restored when the force is removed. site in effect to inductive reactance. Capacitors are used to
TINNED CONDUCTOR: A bare copper wire with a thin neutralize the objectionable effect of lagging current (induc-
coating of tin. The tin coating acts as a separator between the tive reactance) which overloads the power source. It also acts
7-3
as a low resistance path to ground for currents of radio fre- cotton, enamel and paraffin are called insulators because they
quency thus effectively reducing radio disturbances. are practically non-conducting. However, no material is a per-
fect insulator.
CONDUCTOR: Substances which offer little resistance to
the flow of electric current (such as metals). Silver, copper KVA: The abbreviation of kilovolt-amperes which is the
and aluminum are especially good conductors although no product of the volts times the amperes divided by 1000. This
material is a perfect conductor. Each of the wires lying in the term is used in rating alternating current machinery because
armature slots of an electric generator is referred to as a con- with alternating currents, the product of the volts times the
ductor. amperes usually does not give the true average power. See
Reactance and Power Factor.
CURRENT: The flow of electricity in a circuit (similar to the
flow of water in a pipe). It is expressed in amperes and repre- KVAR: The abbreviation of kilovolt-ampere reactance which
sents an amount of electricity, similar to gallons per minute of is a measurement of reactive power that generates power
water flow, regardless of the pressure (voltage). within induction equipment (motors, transformers, holding
CYCLE: One complete period of flow of alternating current coils, lighting ballasts, etc.).
in both directions. One cycle represents 360×. See Frequency. KW: The abbreviation for kilowatt is a unit of measurement
DIRECT CURRENT: Current (dc) which flows in one direc- of electrical power. A kilowatt (kw) equals 1000 watts and is
tion only. One wire is always positive, the other negative. the product of the volts times the amperes divided by 1000
when used in rating direct current machinery. It is also the
ELECTRICAL GENERATOR: An electrical generator is a term used to indicate true power in an ac circuit.
machine so constructed that when its rotor is driven by an
KILOWATT HOUR: A kilowatt hour is the amount of elec-
engine or other prime mover, a voltage is generated.
trical power represented by 1000 watts for a period of 1 hour.
EXCITER: An exciter is a direct-current generator which Thus a generator which delivered 1000 watts for a period of 1
supplies direct current to excite or magnetize the fields of an hour would have delivered 1 kilowatt hour of electricity.
alternator. An exciter may be a separate machine or be com-
OHM: The ohm is the unit of measurement of electrical resis-
bined with the alternator.
tance and represents the amount of resistance that permits cur-
FARAD: A farad is a measure of electrical capacity of con- rent flow at the rate of one ampere under pressure of one volt.
densers. A microfarad is one-millionth of a farad and is abbre- The resistance (in ohms) equals the pressure (in volts) divided
viated “mfd”. by the current (in amperes).
FREQUENCY: Frequency of alternating current is the num- POWER FACTOR: When the current waves in an alternat-
ber of cycles per second. A 60-Hertz alternating current ing-current circuit coincide exactly in time with the voltage
makes 60 complete cycles of flow back and forth (120 alter- waves, the product of volts times amperes gives volt amperes
nations) per second. A conventional alternator has an even which is true power in watts (or in kw if divided by 1000).
number of field poles arranged in alternate north and south When the current waves lag behind the voltage, due to induc-
polarities. Current flows in one direction in an ac armature tive reactance (or lead due to capacitive reactance), they do
conductor while the conductor is passing a north pole and in not reach their respective peak values at the same time.
the other direction while passing a south pole. The conductor
passes two poles during each cycle. A frequency of 60 Hertz Under such conditions, the product of volts and amperes does
requires the conductor to pass 120 poles per second. In a 6- not give true average watts. Such a product is called volt
pole alternator, the equivalent speed would be 20 revolutions amperes or apparent watts. The factor by which apparent
per second or 1200 revolutions per minute. In a 4-pole alter- watts must be multiplied to give the true watts is know as the
nator, the equivalent speed would be 30 revolutions per sec- power factor (PF).
ond or 1800 revolutions per minute.
HERTZ: A unit of frequency, one cycle per second. Written Power factor depends on the amount of lag or lead, and is the
as 50-Hertz or 60-Hertz current, etc. percentage of apparent watts which represents true watts.
With a power factor of 80%, a fully loaded 5KVA (80% PF)
IMPEDANCE: Effects placed on alternating current by alternator will produce 4KW (true watts). When the rating of
inductive capacities (current lags voltage), capacitor reactance a power unit is stated in KVA at 80% PF, it means that with an
(current leads voltage) and resistance (opposes current but 80% PF load, the generator will generate its rated voltage pro-
does not lag or lead voltage) or any combination of two. It is viding the load does not exceed the KVA rating.
measured in ohms like resistance.
INSULATOR: Substances which offer great resistances to An engine-driven alternator with automatic voltage regula-
the flow of electric current such as glass, porcelain, paper, tion, the KVA rating usually is determined by the maximum
7-4
current which can flow through the windings without injuri- at the rate of one ampere. In a dc circuit or in an ac circuit at
ous overheating or by the ability of the engine or other prime unity (100%) power factor, the number of watts equals the
mover to maintain the normal operating speed. A resistance pressure (in volts) multiplied by the current (in amperes).
load such as lamp bulbs, irons, toasters and similar devices is
a unity power factor load. Motors, transformers and various ELECTRICAL POWER SUPPLY
other devices cause a current wave lag which is expressed in
the power in the power factor of the load. The preceding section dealt with Direct Current power. This
source was primarily from a battery which was maintained by
REACTANCE: Reactance is opposition to the change of cur-
the generator or alternator. This section will deal with alter-
rent flow in an ac circuit. The rapid reversing of alternating
nating current that is supplied to run the motor or operate
current tends to induce voltages that oppose the flow of cur-
other components.
rent in such a manner that the current waves do not coincide
in time with the voltage waves. The opposition of self induc-
Alternating current is different from direct current in that the
tance to the flow of current is called “inductive reactance” and
current flow is constantly reversing in the circuit while direct
causes the current to lag behind the voltage causes the current
current flows only in one direction.
wave to lead the voltage wave. This is called “capacitive reac-
tance.” The unit of measurement for either inductive reac-
The alternating current that is supplied has voltage character-
tance or capacitive reactance is the ohm.
istics as follows:
RESISTANCE: Electrical resistance is opposition to the
flow of electric current and may be compared to the resistance If the electric service is a two-wire system of any voltage, the
of a pipe to the flow of water. All substances have some resis- current will flow first in one direction and then the other
tance but the amount varies with different substances and with direction. The current flow will alternate or charge direction
the same substances under different conditions. at a rate of 120 times a second, or 60 cycles per second. This
cycling or frequency is call Hertz (Hz). In some locations this
RESISTOR: A resistor is a poor conductor used in a circuit
may be only 50 Hz as in European and Asian countries.
to create resistance which limits the amount of current flow. It
may be compared to a valve in a water system.
SINGLE PHASE: A single phase, alternating-current sys-
tem has a single voltage in which voltage reversals occur at
the same time and are of the same alternating polarity
VOLTS
throughout the system.
THREE PHASE: A three phase, alternating-current system
has three individuals circuits or phases. Each phase is timed
so the current alternations of the first phase is 1-3-cycle ZERO 0° 180° 360°
(120°) ahead of the second and 2-3-cycle (240°) ahead of the
third.
VOLTAGE: Voltage is the force, pressure or electromotive
force (EMF) which causes electric current to flow in an elec-
tric circuit. Its unit of measurement is the volt, which repre-
sents the amount of electrical pressure that causes current to
flow at the rate of one ampere through a resistance of one
ohm. Voltage in an electric circuit may be considered as being
similar to water pressure in a pipe or water system.
BASIC ALTERNATING CURRENT
VOLTAGE DROP: The voltage drop in an electrical circuit
is the difference between the voltage at the power source and Electrical power, how does it originate? Many times we over-
the voltage at the point at which electricity is to be used. The look the very basic requirements of electrical power genera-
voltage drop or loss is created by the resistance of the con- tion.
necting conductors.
1. A magnetic field created by one or more permanent mag-
WATT: The watt is the unit of measurement of electrical
nets each having a North and South Pole.
power or rate of work. 746 watts is equivalent to 1 horse-
power. The watt represents the rate at which power is
2. A conductor in effect with the magnetic force.
expended when a pressure of one volt causes current to flow
7-5
3. The conductor traveling through the lines of force. CAUTION:
4. The external conductor to complete the circuit with mod- It should be understand that none of our units are designed to
ifications. These basic requirements are in use in all gen- use the system ground in lieu of the system neutral in control
erators. or power circuits. Units which require a neutral connection
for satisfactory operation will not operate safely and reliably
The magnetic field is maintained using coils which use d.c. if a connection to ground is used in lieu of a connection to
power or permanent magnets for excitation. neutral. Most power companies ground their neutral when
they have one, but this fact does not alter the above.
The field may rotate, as in an alternator, or be stationary as in Whenever the standby system is worked on, the control power
a generator, or may be a combination. transformer leads must be wired as shown on the unit wiring
diagram. This means that they must be wired for proper volt-
A rotating or stationary field virtually has no difference as to age and into the correct supply conductors. They must not be
output. wired from one of the supply phase wires, through the trans-
former, unit circuitry, switches, control contacts to ground.
This is the EXCITATION CIRCUIT. By varying the amount
of excitation, output is changed. With the unit disconnected from the power source, you should
be able to check with an ohmmeter or a “megger” and find no
If a single conductor is in motion through a magnetic field connection between ground and any part of the high voltage
(magnetic lines of force), it has no practical use. system for electric standby.
1. If the number of conductors is increased, the voltage will Conditions within the A.C. Circuit: there are three basic con-
increase. ditions that can take place within any electrical circuit resis-
tance, inductions, and capacitance.
2. If the size of the conductor is increased, the amperage Resistance: With this type of load, the voltage and amper-
will increase. age sine wave are in phase.
This normally accounts for the physical size of any unit. By Inductive: With an inductive load, the voltage leads the
combining the proper turns and size of wire, the manufacturer amperage. This is referred to as lag.
can have any output of voltage and amperage required. Capacitance: With this type of load, the current leads the
voltage. This is referred to as lead.
The movement of the conductor through the lines of force or
the movement of the lines of force around the conductor
makes virtually no difference as to output.
1. The rate at which it moves will set up the cycle (Hertz).

From the base line, the rise of the voltage and amperage
level in the conductor in a positive direction back to its
base line, and now in a negative direction back to the
base line.
2. This smooth transition in the conductor accounts for the

operation of motors, relays, transformers and capacitors.
7-6
ONE CYCLE ONE CYCLE

MAX.
VOLTS
ZERO
0° 90° 180° 270° 360° 90° 180° 270° 360°
VOLTS
These three basic conditions enter into all components one at

a time or in combination.
277 V.
The external conductor accounts for the completion of the cir-
cuit. 480 V. 480 V.
1. If the size of the conductor, or connectors is not sufficient

to maintain adequate flow with no resistance, excessive NEUTRAL
loss will occur. (USUALLY 277 V.
GROUNDED)
2. The addition of heat normally causes more heat, more
slippage, etc. 277 V.
C B
POWER SUPPLIES AVAILABLE PHASE PHASE
FROM ELECTRIC COMPANIES
There are two basic 3-phase systems for supplying industrial 480 V.
power. One system is called WYE, the other DELTA. Neither Figure 1: 480V, 4-Wire, 3-Phase Wye
one is standard. The same system may be used at more than
one nominal voltage. Actual operating voltage is usually
somewhat higher than the nominal voltage. (Figure 1): The neutral wire is usually grounded (to a water
pipe) on such systems and there will be 277 V between any
The most up-to-date but least common system is the 3-phase, phase wire and either the grounded conductor or metal part of
4-wire Wye, sometimes called 4-wire star. Voltages on a nor- the building, conduit system, etc. The system which is preva-
mal 440 V system will be approximately 480 V between any lent in downtown areas of cities, 120/208 V, 3-phase, 4-wire
two of the 3-phase wires, and at the same time approximately Wye is similar.
277 V between any phase wire and the fourth or neutral wire.
7-7
A Four wire Delta 440 V systems provide a so-called neutral

PHASE which will measure 240 V to either the two-phase wires and at
the same time 416 V from neutral to the 3-phase wire. The
neutral is actually in midtap on one 480 V transformer wind-
ing. Two of the phase wires of the 4-wire and 3-phase system
and neutral form a 3-wire, single-phase 240/480 V system.
This neutral may be grounded or not grounded. If the neutral
120 V. 120 V. is grounded, one would measure 240-240-416 from ground to
LIGHTING LIGHTING the phase wires.
208 V. 208 V.
NEUTRAL A
(ALWAYS
GROUNDED)
C 120 V.
LIGHTING B 480 V.
PHASE PHASE
416 V.
208 V.
480 V.
120/280 V, 4-Wire, 3-Phase Wye
The other basic system connection is called Delta and the

electric supply from such a system may be either 3 or 4 wire C
B
Delta. There will normally be 480 V between any two-phase
240 V. 240 V.
wires of a 440 volt Delta system. There is no neutral on the 3
wire system.
A 2
1
1. ONE PHASE WIRE MAY BE

480 V. 480 V. GROUNDED (RARE) FOR “CORNER OF
THE DELTA GROUNDING”
2. THIS WIRE MAY BE GROUNDED
(RARE)
The 4-wire Delta system is very common for “240-120/240 V,

C B 4-wire, 3-phase and 1-phase power.” The wire which has the
highest potential to ground is called the “identified conduc-
480 V. tor” or the “high leg.” This connection is extremely rare on
480 V, 4-Wire, 3-Phase Delta 480 V systems.
7-8
NEC REFERENCE
A
4 WIRE, 240 V.,
SECTION 200-10: “Identification of terminals - All devices
3 PH. DELTA (HIGH LEG)
provided with terminals for the attachment of conductors and
intended for connections to more than one side of the circuit
shall have terminals properly marked for identification...”
240 V. 240 V. SECTION 210-21 (b): “Receptacles connected to circuits

having different voltages, frequencies or type of current (a.c.
or d.c.) on the same premises shall be of such design that
attachment plugs used on such circuits are not interchange-
able.”
SECTION 250-45: “Equipment Connected by Cord and
Plug. Under any of the following conditions, exposed non-
C current carrying metal parts of cord and plug connected
B
equipment, which are liable to become energized, shall be
120 V. 120 V. grounded”:
a. Hazardous location.
b. When operated at more than 150 volts to ground.
NEUTRAL (USUALLY GROUNDED)
SECTION 250-51: “Effective Grounding. The path to
ground from circuits, equipment, and conductor enclosures
The 3-wire 480 V Delta system is very common, but few shall (1) be permanent and continuous and (2) shall have
installations are being made in the more progressive parts of ample carrying capacity to conduct safely any currents liable
the country. Such systems are commonly called “isolated” or to be imposed on it, and (3) shall have impedance sufficiently
“ungrounded” neutral because the system has no neutral wire low to limit the potential above ground and to facilitate the
and normally none of the wires are intentionally grounded. operation of the overcurrent devices in the circuit.”
The voltage between grounded metal parts and any one of the
three-phase wires may be 277 V (for a “perfectly insulated
and balanced” system), 480 V or even higher potentials,
depending on load characteristics, the integrity of the insula-
tion system and a number of other fairly complex factors. In
any event, it is never intended that any control or other power
should be derived from the potential between any phase wire
and ground. Such arrangements are often referred to as “float-
ing” neutral or “floating” ground since the voltage between
ground and phase wires is not tied down and may literally be
any value. The ground wire on all electric standby units is
provided to make sure the frame and other parts of the unit
accessible to the user are never at a potential above ground.
This is to ensure against electric shock, and that is the only
correct use and purpose of the ground connection. This
ground does not have any electrically conducting connection
to the Delta electric system. Usually it terminates on a water SECTION 400-10: “Pull at Joints and Terminals. Flexible
pipe. cords shall be so connected to devices and to fittings that ten-
sion will not be transmitted to joints or terminal screws. This
WIRE DEVICES shall be accomplished by a knot in the cord, winding with
tape, by a special fitting designed for that purpose, or by other
All a.c. electrical components must meet or exceed specifica- approved means which will prevent a pull on the cord from
tion of the National Electrical Code. This is also true of wir- being directly transmitted to joints or terminal screws.”
ing devices.
SECTION 410-52 (d): “Rating and Type (Receptacles,
Cord Connectors and Attachment Plugs). All 15- and 20-
Most recently this is the most obvious change taken from
ampere attachment plugs and connectors shall be so con-
National Electrical Code 1975.
structed that there are no exposed current-carrying parts
7-9
except the prongs, blades or pins. The cover for wire termina-
tions shall be mechanically secured, or an integral of the 2
1 2 1
attachment plug or connector.”
SECTION 410-54: “Receptacles in Damp or Wet Loca-
3 4 4 3
tions.”
a. Damp Locations. A receptacle outlet installed outdoors MALE OUTPUT FEMALE OUTPUT
in a location protected from the weather or in other damp
locations shall have an enclosure for the receptacle which
is weather-proof when the receptacle is covered (attach-
2 2
ment plug cap not inserted and receptacle covers closed).
An installation suitable where exposed to wet location is also 3 4 4 3

suitable for damp locations.
A receptacle outlet may be considered to be in a location pro-

tected for the weather when located under roofed, open 1. Red
porches, canopies, marquees, and the like, so as not to be sub- 2. Green
jected to a beating rain or water run off. 3. White
4. Black
b. Wet location. A receptacle installed outdoors where
exposed to weather or in other wet locations shall be in a
weather-proof enclosure, the integrity of which is not
affected when the receptacle is in use (attachment plug
inserted). TERMINAL USE
IDENTIFICATION
EXCEPTION: An enclosure which is weather-proof only
GREEN Green equipment grounding
when a self-closing receptacle cover is closed may be used
Terminal conductor only (or green w/
for a receptacle installed outdoors where the receptacle is yellow stripe)
not likely to be used with other than portable tools or other
portable equipment not usually left connected to the WHITE White or Grey, system ground or
receptacle indefinitely. Terminal neutral conductor only
“X” Terminal Red, Black, Blue, etc.

NOTE: “Hot” conductors
Twist the strands of wire and simultaneously insert all the “Y” Terminal (No specific lettered terminal is
wires into all proper wiring chambers as noted. for any
specific colored conductor)
Examine cable to be sure you have proper end of cable for
correct alignment of wires and pass cable through cord
clamp and cover of device in the proper direction as AC VOLTMETER OPERATION
illustrated. Ac measuring instruments have different characteristics than
dc instruments have because the ac current flow is constantly
reversing. The procedure for using the ac voltmeter differs
from the dc voltmeter.
1. AC voltage checks taken to ground or chassis common

have little value.
2. AC voltage reading should always be made between the

one or more power supply wires.
7-10
3. AC voltage reading to line ground would be an indication NOTE: Voltage test made at this location should be
of type of power supply from the generator or power compared to nameplate or data plate. If not within the 10%
transformer. Voltage readings should be taken between allowable range, corrective steps must be taken.
lines or across components.
AC AMMETER OPERATION
Before using the ac voltmeter, it should be zeroed, the voltage
selector turned one voltage scale higher than the anticipated Amperage readings on ac circuits are done with a wraparound
voltage the test leads and probes should be in good condition, ammeter.
an electrical shock could be fatal. Then test the circuits by
first checking between legs as shown in the diagram of a This meter converts the strength of the magnetic field around
three-phase system. the wire to a meter reading. The ammeter must be zeroed
before use. The amperage selector should be turned to a scale
CAUTION: Always use a disconnect switch to shut off the higher than anticipated. The procedure for using ac ammeters
power to a unit before working on it. Do not use the plug for is to place the pickup clamp around a single conductor. It will
not read more than one wire at a time because the current will
a switch.
be flowing in both directions at once, and the amperage flow
in the conductors would cancel each other. The pickup clamp
jaws should mate firmly. Any air gap would cause error in
readings. A reading should be taken from each conductor to
check for balance of load.
NOTE: Extremely small amperage readings may be

amplified by the use of multipliers or by taking the
conductor and placing additional loops through the
inductive pickup.
G
ON
WR
Wrong Way to Use AC Ammeter
VM
VM
VM
DISCONNECT SWITCH Reading Divided by 3 Indicates

True Amperage Reading
7-11
POWER SUPPLY EVALUATION

N
If the unit is designed to operate on 230 volts, the minimum/
maximum voltage must be within 10% (of 230 volts or 207
minimum, 253 maximum.
A rule for ac power and components is that all values must be

within 10% of nameplates rating or power supplies. Some
areas have power supplies which have one conductor at a 110 V
220 V
higher voltage. This is defined in Section 10, power require-
ments.
110 V
Further checking should be done between L1-L2, L2-L3, and
L3-L1. All of these readings should be close, as any variance Single-Phase Power Supply
would cause inefficient motor operation. Checking the volt-
ages from the three hot legs L1, L2, L3, to ground will indi-
cate a completed safety ground circuit. If the system is single- L1
phase, the same rule applies except the circuit has only two
wires and safety ground.
L2
NOTE: Any voltage reading between legs that is one half or
less that the required voltage indicates an open circuit and
the wiring or fuses should be corrected before proceeding
with any further testing.
L3
L1
L2
Three-Phase Plug
L1
22
0V
0V
22
Single-Phase Plug
L3 L2 100 V
OR MORE
220 V
Three-Phase Power Supply
7-12
MOTORS INTERNAL WINDING CONNECTIONS

The three-phase motor must have at least three windings, one
WINDING CONSTRUCTION for each phase. The windings may be connected in either
Delta or “Wye” configuration. Most motors have all leads
A.C. motors have several features not found in d.c. motors. exposed as to allow wiring changes.
ONE ONE
CYCLE CYCLE
1. The motor operates on an induction principle with no MAX L1 L2 L3 5A
windings as such on the rotor. VOLTS
2. These rotors are called squirrel cage rotors. The magnetic ZERO
field induced in the loops of these rotors by the rotating VOLTS 0° 90° 180° 270° 360° 90° 180° 270° 360°
magnetic field of the stator drag the rotor around causing

the torque or turning effect of the motor.
2.5
5.0 L1
L3 L2
2.5 2.5
1. When wired in the Delta configuration and power is sup-

plied to the winding, it passes through only one winding.
3. Three-phase induction motors are self-starting. The rota-
tion can be reversed by interchange of any two-power 2. When wired in the Wye configuration and power is sup-
supply wires. plied to the windings, it now passes through two wind-
ings. To have the same amount of output, the voltage
4. The motor operation on single-phase power functions in would have to be changed. This is the basic concept for
the same manner except it requires start winding and the all motors that operate on dual voltage.
addition of start capacitor to cause a phase difference and ONE
CYCLE
ONE
CYCLE
start rotation. Single-phase motors may use a run capaci- MAX L1 L2 L3 5A
VOLTS
tor to improve the power factor and improve on the effi-
ciency of the motor.
ZERO
VOLTS 0° 90° 180° 270° 360° 90° 180° 270° 360°
5A
L1
L3 2.5 L2
2.5
7-13
3. Larger motors may have 9 to 12 or even more external NOTE: There is only one way to wire a motor otherwise
leads. This allows the motor to be wired to different volt- damage could occur: refer to the data plate below for
ages. Proper wire configuration at a 12 lead motor would example.
be:
6. RPM at full load.
NAMEPLATE DATA 7. Frequency.
A. Alternating-Current Single-Phase and Polyphase Squirrel-
Cage Motors, NEMA Standard 8. Number of phases.
1. Manufacturers type and frame designation. 9. Voltage.
2. Horsepower output. 10. Full load amperes.
3. Time rating. 11. Code (locked rotor).
4. Maximum ambient for which motor is designed. 12. For motors equipped with thermal protection, the words
“thermally protected” and, for motors rated more than 1
5. Insulation system designation. (if stator and rotor use dif- horsepower, a type number. (See MG1-171 and MG 1-
ferent classes of insulation system, both insulation sys- 1.72). (For their own convenience, motor manufacturers
tem designations should be given on the nameplate, for may use letters, but not numbers, preceding or following
the stator being given first.) the words “thermally protected” for other identification
purposes.)
CYCLES KVA
PHASE
HZ CODE SERIAL
3 60
K
HORSEPOWER RPM TIME HRS P4 P5 P8

3 1750 24
4 5 6
SER. FAC. INS CL FRAME MAX ABM
1.15 B 182 T 40 7 8 9
VOLTS 1 2 3
230 460
LOWER VOLTAGE LINE
AMPS
9.6 4.8 P4 P5 P6
USER OR CATALOG NUMBER 4 5 6
3065C24G01
MOTOR 7 8 9
STYLE 773B743G01
1 2 3
DRIVE OR
30BC03JPP3 HIGHER VOLTAGE LINE
LOWER BRG.
OPP. DRIVE OR
30BC03JPP3 SBDP MODEL
UPPER BRG.
7-14
NOTE: 10, 11 and 12 are tied 1

2
together internally on 9-wire
systems.
4
5
7 8
10 11
12
10 11 12 10 11 12
4 5 6 4 5 6
7 8 9 7 8 9
1 2 3 1 2 3 2
1
4 5
7
8
2
1 7
8
10 5 10
4 11
11
12
6 12
9
6
3 9 3
7-15
THERMAL OVERLOAD 2. Disk type with automatic reset.

PROTECTORS CAUTION: If the automatic reset type are used, the motor
The Thermal Protectors are often referred to as load or motor may start at any time.
overload protectors. They are used to prevent temperatures
from exceeding the limits for safe operation. This temperature
may be caused by excessive amperage or improper cooling.
The thermal protector operates on the principle of heating of a

bimetal disk or arm. When the heat caused by the excessive
flow of electricity exceeds the rating of the bimetal element, it
will snap open and interrupt the circuit. The thermal overload
may be manual reset or automatically reset.
3. Winding type with automatic reset.
CONTACTORS
Contact material used in the contactor must meet the follow-
ing basic requirements:
1. It must withstand the expected erosion.
2. It must resist sticking or welding.
3. It must withstand the maximum current and peak voltage.
These are a few of the requirements that enter into the life of
1. Manual reset with control circuit interrupt. the contact. Replacement components will require the same
quality.
CAUTION: When used as part of the load circuit, voltage
may be present at the contactor or even to the motor. CONTROL TYPE
The voltage used to control the contactor is normally of low
voltage-12vdc; 24 vdc; or 12 to 25 vac. This is supplied by a
transformer or the battery. The voltage from the transformer
output may be rectified to be compatible with the other com-
ponents within system. If line voltage is use in the contactor
coils, it will be isolated from the remaining circuit by a line
starter actuator.
This device carries high voltage across the contact and the
coil will be supplied low voltage.
NAMEPLATE DATA
The information consists of:
F.L. - Full Load Amps: The maximum amps that the con-
tactor contacts can conduct continuously.
L.R. - Locked Rotor Amps: The maximum amperage
load the contactor contact can conduct for motor start up.
7-16
Coil Voltage: The voltage and type of power for which the MOTOR PROTECTORS
pull in coil is designed.
The motor protectors are of individual line units or of multi-
line units. The protectors have a very high degree of reliabil-
Contact Voltage Ratings: The voltage and amperage for ity. Failures, if at all, most times are caused by open circuits
which the contacts are designed. within the device. Check for opens across the connection with
a voltmeter.
Inductive Per Pole: Amperage for motor operation.
NOTE: When changing voltages, motor protectors must be
Resistive Per Pole: Amperage for heaters. changed.
VM
INDIVIDUAL
LINE UNIT
VM
1. 10-12 VDC
VM
2. 15 AMP - 300 V.
10 AMP - 100 V. Contactor Voltmeter Check
15 AMP - 80 V.
Multi-Line
AC CONTACTOR CHECKS Unit
The contacts conduct between the power supply and the load.
VM
Check for burnt contacts by visual inspection and the voltage
drop across the contact with an ac voltmeter. This must be VM
Low Voltage
done for each contact under load. The lower the voltage read-
Check
ing, the better the contact has completed the circuit.
VM Circuit Protector Voltmeter Check

(Typical of 3)
VM
Contactor Voltmeter Check
7-17
MOTOR EVALUATION CHECKS FULL LOAD AMPERAGE

The electric motor should be checked for starting and running
with the unit on the cool cycle. This will ensure that only the
electric motor is operating and not the electric heater strips SINGLE PHASE THREE PHASE
giving a higher reading than normal.
H.P. 115 V 220 V 220 V 440 V
Any uneven amperage readings between legs of a system 1 16 8 3.6 1.8
indicate a voltage loss or electric motor problem.
1-1/2 20 10 5.2 2.6
The running amperage should be checked against the motor
nameplate information. Another indicator of a motor failure is 2 24 12 6.8 3.4
the starting amperages will be uneven as well as the run amps. 3 34 17 9.6 4.8
The starting current should not exceed five times the running
amperes of the unit. 5 15.2 7.6
7-1/2 22 11
10 28 14
1
2
3
15 42 21
LOCKED ROTOR AMPERAGE
4 SINGLE PHASE THREE PHASE

5 H.P. 115 V 220 V 220 V 440 V
6
1. Line 1 - 3 Amps (Example) 4. T1 1/2 58.8 29 12 6
2. Line 2 - 3 Amps (Example) 5. T2 3/4 82.8 41.4 16.8 8.4
3. Line 3 - 3 Amps (Example) 6. T3
1 96 48 21 10.8
Motor Evaluation Checks
1-1/2 120 60 30 15
Leads T1, T2 and T3 are normally tied together for Wye con- 2 144 72 38 19.8
figurations, or T1 to L2, T2 to L3, T3 to L3 for delta resis-
tance checks between each coil, L1 to T1, etc., would indicate 3 204 102 54 27
short or open. Any continuity from L1,L2, L3 to case with
ohmmeter would indicated GND. 5 90 45
7-1/2 132 66
FULL LOAD AMPERAGE
10 162 84
SINGLE PHASE THREE PHASE 15 240 120
H.P. 115 V 220 V 220 V 440 V
1/2 9.8 4.9 2 1 NOTE: The amperage values given are approximate. The
voltage difference will cause amperage values to vary.
3/4 13.8 6.9 2.8 1.4
7-18
NOTE: A single-phase circuit is usually supplied through

two wires.
440
(220) (220)
TRANSFORMER DEFINITION
A transformer is an electric device without continuously mov-
ing parts, which with electro-magnetic induction transfers
electric energy from one or more circuits to one or more at the
same frequency, usually with changed values of voltage and
current.
(16) (16)
32 V
220
COOLING
Transformers used are of the fry type, self-cooled, which are
cooled by the natural circulation of air.
RATINGS
16 V
Input Voltage: The voltage at which the primary side of the
transformer is designed to operate.
Output Voltage: The voltage at the secondary side of the TRANSFORMER EVALUATION
transformer is designed to maintain at rated load.
CHECKS
Output Ampacity: This is the current-carrying capacity
expressed in amperes. The transformer assembly used is of single-phase type and
can be checked for proper operation with a voltmeter and
Output KVA: This is the voltage x amperage indicating a ammeter. Set the voltmeter on the proper scale and take read-
total output. ings on the primary and secondary side of the transformer. A
line voltage reading should be obtained on the primary side,
CIRCUIT and control voltage should be read on the secondary side. Any
readings not within specification indicate a defective trans-
A single-phase circuit, energized by single alternating electro-
former, power supply, or excessive load on circuit. The watt-
motive force.
7-19
age should be the same on both the primary and secondary by

using the following formula: STRANDED
AMPERAGE
COPPER
Volts X Amps = Watts
The transformer can be checked for Single- Cabled
Size A.W.G.
internal loss or shorting. Conductor Conductor
18 10 7
220 Volts
.075 Amps 16 13 10
VM
L1 (Example)
L2 14 20 15
Primary Side
12 25 20
10 40 25
8 65 35
16 Volts 6 95 45
Secondary Side 4 125
VM 10 Amps (Example)
Ratings: All heaters are rated in watts. The heaters also
16 Volts specify the maximum voltage that may be applied to the
Transformer Evaluation Check heater.
TRANSFORMER LOAD
With 12 Vdc at Voltage at Primary

BATTERY CABLE
Load Amps
120 230 460
1 .13 .06 .03
SIZE A.W.G AMPERAGE
5 .65 .34 .17
No. 4 125
7 .9 .48 .24
No. 1 310
10 1.3 .69 .34
No. 1/0 375
15 2 1.04 .52
NOTE: Size of power cable to maintain a proper voltage to

the unit.
NOTE: The amperage values given are approximate. The
voltage difference will cause amperage values to vary.
RESISTANT HEATERS
Definition: Resistant heaters use wires which oppose the
flow of electricity; this causes the wire to heat excessively.
The heat generated by the wire is conducted to the object.
Circuit: Heater of the type used in our units are of single-
phase type which requires two conductors to each heater. The
back of heaters may be wired. Wye or Delta configuration to
utilize all three phases.
7-20
TYPES OF WIRE AND CABLE AND THEIR APPLICATIONS
Maximum
Type Trade Maximum Voltage Kind of
Operating Outer Covering Application
Letter Designation Rating Insulation
Temperature
SJ SJ 140F (60C) 300 Rubber Same as S Light duty

service
SO SO Power Cord 140F (60C) 600 Rubber Flame and Heavy Duty
Oil-Resistance service
Neoprene
SJO SJ Neoprene 140F (60C) 300 Rubber Same as SO Light Duty
service
-- 300F (149C) 600 Polyurethane -- Wire Harness
-- -- 140F (60C) 100 Chrome Vinyl or Neo- -- Battery Cable
prene
NOTE: The amperage values given are approximate.

HEATER EVALUATION CHECKS The voltage difference will cause amperage values to vary.
Heater strips can be checked by a voltage test and an amper-
age reading of each leg. Most heater strips are of 500 watts to
1000 watts in size. The amperage draw will be about 5 to 8
amps per leg on the heater circuit when using 230 volts. A
low or high reading on one leg may indicate a defective heater
relay or heater strip. L1 - 5 Amps (Example)
Improper heater wiring also gives an unbalance in readings.

For proper wiring of heaters, refer to Service Bulletin #5840.
3 HEATERS WIRED “WYE”
AMPERAGE VM
Watts Each
230 V 460 V
L2 - 5 Amps (Example)
500 3.6 1.8
750 5.4 2.7

1000 7.2 3.6
VM
3 HEATERS WIRED “DELTA”
VM
Watts Each AMPERAGE L3 - 5 Amps (Example)

230 V 460 V
500 3.7 1.8
750 5.7 2.8
1000 7.5 3.76
7-21
GREEN GREEN
RED RED
WHITE
BLACK
WHITE
BLACK
BLK RD
BLK
GRN
WH R
WH
DC+
A single three-phase bridge rectifier uses three terminals for
ac input and one terminal for dc positive output.
Three-Phase The case is the dc negative (chassis ground). This configura-

Rectification - L1 tion can only be used for low-voltage rectification.
Single-Phase Bridge L3
L2
L1
AC
Two single-phase bridges wired as shown can be used with

high voltage because the circuits are isolated from the base of
AC
the rectifier.
DC- L2 DC+
AC
Three-Phase
Rectification - L3
Two, Single-Phase Bridges
7-22
DISADVANTAGES OF D.C. ELECTRICITY COMPARED TO A.C. ELECTRICITY

When commercial use of electricity became wide-spread in the United States, certain disadvantages in using direct current in the
home became apparent. If a commercial direct-current system is used, the voltage must be generated at the level required by the
load. To properly light a 240-volt lamp, for example, the d.c. generator must deliver 240 volts. If a 120-volt lamp is to be sup-
plied power from the 240-volt generator, a resistor or another 120-volt lamp must be placed in series with the 120-volt lamp to
drop the extra 120 volts. When the resistor is used to reduce the voltage, an amount of power equal to that consumed by the lamp
is wasted.
Another disadvantages of the direct-current system becomes evident when the direct current from the generating station must be
transmitted a long distance over wires to the consumer. When this happens, a large amount of power is lost due to the resistance
of the wire. However, this loss can be greatly reduced if the power is transmitted over the lines at a very high voltage level and a
low current level. This is not a practical solution to the power loss in the d.c. system since the load would then have to be oper-
ated at dangerously high voltage. Because of the disadvantages related to transmitting and using direct current, practically all
modern commercial power companies generate and distribute alternating current (a.c.)
Unlike direct voltages, alternating voltages can be stepped up or down by a device called a TRANSFORMER. Use of the trans-
former permits efficient transmission of electrical power over long-distance lines. At the electrical power station, the transformer
output power is at high voltage and low current levels. At the consumer end of the transmission lines, the voltage is stepped
down by a transformer to the value required by the load. Due to its inherent advantages and versatility, alternating current has
replaced direct current in all but few commercial power distribution systems.
CONDUCTORS PARALLEL TO
LINES OF FORCE, EMF MINIMUM DIRECTION OF
CURRENT
ROTATION ROTATION
N N N N
N
(B) S (E) S
(A) S S (C) S (D)
CONDUCTORS CUTTING DIRECTLY CONDUCTORS CUTTING DIRECTLY

DIRECTION OF
ACROSS FIELD, EMF IS MAXIMUM ACROSS FIELD, EMF IS MAXIMUM
CURRENT
EMF
ONE ALTERNATION
(0 - 180°) (180 - 360°)
ZERO
ONE CYCLE
ONE ALTERNATION
AJA515
7-23
CHECKING AC VOLTAGE
AC measuring instruments have different characteristics than dc instruments have because the ac current flow is constantly
reversing. The procedure for using the ac voltmeter differs from the dc voltmeter.
1. AC voltage checks taken to ground or chassis common have little value.
2. AC voltage readings should always be made between the one or more power supply wires.
3. AC voltage readings should be taken between lines or across components.
+ 01 02 03
0
120° 120° 120°
-- VM
AJA271
VM AJA272
VM
7-24
120° 120°
AJA273
120°
Three-phase AC power generation.
+
01 02 03
0
120° 120° 120°
-- AJA274
Waveforms for three-phase voltage.
7-25
PHASE REVERSAL ASSEMBLY FAULT ANALYSIS

THEORY OF OPERATION 1. Verify the electrical connection of the components is
coerce according to the wiring diagram.
Electrically the assembly is an unbalanced three phase wye
connected load. 2. Verify the resistor values and contactor coil resistance
values are correct. Disconnect one coil lead to correctly
Two of the three legs of the wye are an equivalent value, measure the coil resistance. Test the capacitor and each
series connection of a resistor and single phase bridge rectifier bridge rectifier if equipment is available.
connected to a DC contactor coil.
3. Take proper safety precautions and apply three phase
The third leg is a 0.5 (1 MFD - old style) MFD capacitor. voltage to the assembly.
With the component values selected, the circuit wye point is Measure the voltages on the components as indicated in the
shifted away from neutral or zero volts such that unbalanced diagram.
voltages are relatively high on one resistor/contactor coil
phase and relatively low on the other resistor/contactor coil Compare the voltages with the proper voltages as indicated on
phase. The contactor with the higher coil voltage is then ener- the diagram which is appropriate for the applied voltage.
gized.
If the voltage values are correct, the phase reversal assembly
The energized contactor connects the phase voltage straight is good, or the contactor may have a mechanical problem.
thru for positive phase sequence or swaps two of the phases
for negative sequence. Verify proper mechanical operation by manually energizing
each contactor and by verifying both conductors can’t simulta-
neously pull in.
Visually verify that the contactor contacts are good and that
contactor return spring and contact overtravel springs have
normal force and travel. Verify that the movable contacts slide
freely.
Correct electrical voltages and proper contactor operation

indicates the phase reversal assembly will operate normally
7-26
50 HZ VOLTAGE TEST POINTS VERIFICATION

POSITIVE PHASE SEQUENCE APPLIED
VOLTAGE DROP COIL VOLTS
INPUT TEST
VOLTS POINTS VAC TERM VDC
1 .5 1 .5
mfd mfd mfd mfd
460/50 A-B 200 95 BRN-ORG 65 30
3 Phase C-D 245 345
E-F 375 325 RED-BLU 120 100
F-G 165 145
E-G 510 445
380/50 A-B 165 80 BRN-ORG 50 25

3 Phase C-D 200 280
E-F 310 270 RED-BLU 100 85
F-G 140 120
E-G 420 360
360/50 A-B 155 75 BRN-ORG 50 25

3 Phase C-D 190 265
E-F 290 255 RED-BLU 95 80
F-G 130 110
E-G 400 345
7-27

NEGATIVE PHASE SEQUENCE APPLIED
INPUT
TEST POINTS
VOLTS VAC TERM VDC
1 .5 1 .5
mfd mfd mfd mfd
460/50 A-B 375 325 BRN-ORG 120 100
3 Phase C-D 245 345
E-F 200 95 RED-BLU 65 30
F-G 165 145
E-G 510 445
380/50 A-B 310 270 BRN-ORG 100 85

3 Phase C-D 200 280
E-F 165 80 RED-BLU 50 25
F-G 140 120
E-G 420 360
360/50 A-B 290 255 BRN-ORG 95 80

3 Phase C-D 190 265
E-F 155 75 RED-BLU 50 25
F-G 130 110
E-G 400 345
7-28

POSITIVE PHASE SEQUENCE APPLIED
INPUT TEST
1 .5 1 .5
mfd mfd mfd mfd
500/60 A-B 240 130 BRN-ORG 75 40
3 Phase C-D 235 350
E-F 410 360 RED-BLU 130 125
F-G 180 170
E-G 560 510
460/60 A-B 220 120 BRN-ORG 70 35

3 Phase C-D 215 325
E-F 375 330 RED-BLU 120 110
F-G 165 155
E-G 510 465
400/60 A-B 195 105 BRN-ORG 60 30

3 Phase C-D 185 280
E-F 325 290 RED-BLU 105 95
F-G 145 135
E-G 445 400
7-29

NEGATIVE PHASE SEQUENCE APPLIED
INPUT TEST
1 .5 1 .5
mfd mfd mfd mfd
500/60 A-B 410 360 BRN-ORG 130 125
3 Phase C-D 235 350
E-F 240 130 RED-BLU 75 40
F-G 180 170
E-G 560 510
460/60 A-B 375 330 BRN-ORG 120 110

3 Phase C-D 215 325
E-F 220 120 RED-BLU 70 35
F-G 165 155
E-G 510 465
400/60 A-B 325 290 BRN-ORG 105 95

3 Phase C-D 185 280
E-F 195 105 RED-BLU 60 30
F-G 145 135
E-G 445 400
7-30
SECTION 8
Refrigeration Unit
Schematic/Wiring Diagrams
8-1
8-2
Section 9
Microprocessor Controllers
9-1
Section 9-Microprocessor Controllers
MP3000 CONTROLLER
DESCRIPTION
Controller Description
The MP3000 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 indi-
cates 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 tempera-
ture 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 AJA730
text in an information screen:
• F1 key: Press the F1 key, then press another general pur-
pose key to enter the number shown on the key.
• F2 key: Press the F2 key, then press another general pur-
pose key to enter the first letter shown on the key. 1. LED display for TEMPERATURE. Status
• F3 key: Press the F3 key, then press another general pur- indicator LEDs identify controlling sensor
pose key to enter the second letter shown on the key. temperature (return or supply) that appears
• F4 key: Press the F4 key, then press another general pur- in display.
pose key to enter the third letter shown on the key.
NOTE: When the F1, F2, F3 or F4 key is pressed 2. LCD display for SETPOINT, MESSAGES
to enter a character in the display, the keypad and MENU. Use the keypad to scroll
remains on that “character level” until another through messages and the controller menu.
“level” is selected by pressing the F1, F2, F3 or 3. 3. General purpose keys are used to enter
F4 key. text and scroll through menus.
4. Special function keys perform specific

tasks.
9-2
Text Input Example: To enter THERMO in an information • Control circuit fuse and circuit breaker protection: 7 amp
screen: manual reset circuit breaker protects the 24 Vdc
a. Enter “T” by pressing F3 key, then pressing STU key. • control circuit. 2 amp fuse protects the 28V ac control
b. Enter “H” by pressing GHI key. power circuit to the controller. 2 amp fuse protects the
c. Enter “E” by pressing DEF key. battery charger output circuit to the controller.
d. Enter “R” by pressing F4 key, then pressing PQR • Electronics for measuring phase sequence.
key. • Electronics for measuring amperage.
e. Enter “M” by pressing F2 key, then pressing MNO • Electronics for measuring voltage.
key. • Zero current transformer for earth leaking measurement
f. Enter “O” by pressing F4 key, then pressing MNO (option).
key. 8. Replaceable sensors: Return air, left hand supply air,
b. Menu Scrolling: General text keys F1, F2, F3 and right hand supply air, evaporator coil (defrost), condenser
F4 also include directional arrows for entering and coil, ambient air and compressor discharge line tempera-
scrolling through the controller Main Menu: ture sensors are field replaceable. Three (replaceable)
• • F1 key: ESC indicates that pressing the K1 key moves spare sensor receptacles are also provided for USDA
the cursor out of (exits) a menu list. temperature recording.
• • F2 key: FORWARD/UP ARROWS indicate that press- 9. Probe Test (see “Probe Test” in this chapter).
ing the K2 key scrolls the cursor forward and/or upward 10. Defrost cycle control (see “Defrost System” in this chap-
through text boxes and menu lists. ter).
• • F3 key: BACKWARD/DOWN ARROWS indicate that 11. Pretrip (PTI) test capability (see “PTI (Pretrip) Test” in
pressing the K3 key scrolls the cursor backward and/or this chapter).
downward through text boxes and menu lists. 12. Function test capability (see “Function Test” in this chap-
• • F4 key: ENTER ARROW indicates that pressing the K4 ter).
key moves the cursor into the next menu level or into a 13. Data recording capability (see “Data Recording and
menu item text box. Downloading Data” in this chapter).
4. Four special function keys (see illustration on page 1): 14. Electronic phase selection: The microprocessor relay
• C/F key: Press to view alternate temperature scale in board monitors the phase of the power supply to ensure
LED display. proper rotation of the condenser fan and evaporator
• DEFROST key: Press to initiate defrost. Evaporator coil fans.The controller determines the correct phase
temperature must be below 10 C (50 F). sequence for the compressor and energizes the correct
• SUP/RET key: Press to view alternate return/supply sen- compressor contactor.
sor temperature in LED display. 15. Power limit control (see “Power Limit Mode” in this
• SETPOINT key: Press to enter Setpoint Menu. The first chapter)
line of the Setpoint Menu is the setpoint temperature. 16. Sequential component startup control: A sequence star of
• Press F2 or F3 key to scroll up or down through the menu the required loads occurs during initial startup of the con-
list. troller and when a control mode shift requires the com-
NOTE: Press the “5” key to increase the display time of the pressors to start (see “Sequence of Operation” in this
current LCD data screen by 5 minutes. Maximum display chapter).
time is 30 minutes for data screens and 100 minutes for 17. Compressor refrigerant injection cycle control (see Com-
manual tests. pressor Liquid Injection” in this chapter).
5. Status indicator LEDs (see “Status Indicator LEDs and 18. Hourmeters: The MP3000 controller has multiple built-in
Alarm Codes” in this chapter). hourmeters that can be accessed through the Main Menu.
6. Control Transformer: Low voltage control power and 19. Manual emergency control capability. Manual control
ground is supplied to the MP3000 controller and the main settings in the control box allow the unit to operate even
relay board. in the event of a fatal failure of the controller. Manual
7. Main Relay Board: High voltage supply power and low control offers three operating functions: Heat, Defrost
voltage control power and ground are supplied to the and Cool (see “Manual Emergency Mode Operation” in
main relay board. The main relay board contains: this chapter).
• Relays to energize and deenergize unit contactors and 20. Flash memory: Flash program memory allows the appli-
• solenoids. Component relays include the heater, evapora- cation software to be updated without replacing a
tor fan motor, condenser fan motor, and phase reversalre- EPROM chip on the controller. Application software can
lays. be updated in the field using a portable computer and the
• Supply power circuit protection: 20 amp fuses (3) protect MP3000 Loader program. Consequently, the field
the high voltage circuits on the main relay board. installed application software version may have a differ-
9-3
ent revision number and may include control features not Status Indicator LEDs
included in the original factory installed software. If the
operation of your unit differs from the Sequence of Oper- Eight status indicator LEDs are located in the top LED dis-
ation described for the unit in this manual, enter “Misc. play and signal the following:
Functions” in the Main Menu to check that the program • Supply (Air Temperature)
version is correct (see “Menu Operating Instructions” in • Return (Air Temperature)
this chapter). • Humidity Mode (Humidification set to On in Setpoint
21. Display menus: The MP3000 controller contains an menu)
extensive display menu that can be navigated via keypad. • Compressor (Cooling On)
22. The display menu is organized into eight (8) Main • Heat (On)
Menus: • Defrost
• • Setpoint Menu: Menu screens in this group are used to • InRange (Temperature)
enter the temperature setpoint and set the economy mode. • Alarm
Setpoint menu option functions include: set humidify or The indicator LEDs stay ON continuously to indicate sensor
dehumidify operation, enter humidity setpoint, set air- temperature display, unit operating mode or condition. The
flow, set custom airflow, set bulb mode, set AFAM opera- Alarm LED flashes ON and OFF continuously when a Check
tion, set AFAM delay, set AFAM rate, set O 2 Minimum Alarm (Level 2 Alarm) or Shutdown Alarm (Level 1 Alarm)
and set CO 2 Maximum. occurs. Less serious Log Alarms (Level 3 Alarm) are
• Data Menu: Menu screens in this group are used to dis- recorded but do not activate the Alarm LED (see Alarms
play unit operating information including sensor temper- Menu on page 417 for more information).
atures, voltage, current and frequency information.
• Alarm List Menu: Menu screens in this group display a Data Recording and
list of alarm code(s).
• Commands Menu: Menu screens in this group are used to
Downloading Data
activate defrost, function tests, pretrip (PTI) tests and The MP3000 datalogger can record sensor temperatures as
manual function test. well as loss of power, alarms, sensor failure, setpoint change
• Miscellaneous Functions Menu: Menu screens in this and unit shutdown events. All data logs include the time and
• group display date/time, C/F, cargo data, program version date; setpoint temperature; supply, return, ambient, USDA1,
and run time (hourmeters) information. USDA2 and USDA3 sensor temperatures; and humidity sen-
• Configuration Menu: Menu screens in this group display sor. All temperature logs can be viewed from the controller’s
refrigerant type, ingrain setting, container ID, contrast LCD message display.
(screen), language, unit type, reefer type and zero current Data logging intervals are selectable from 1 minute or 1/2,
status. 1, 2 or 4 hours. When a 1 hour logging interval is selected, the
• Datalogger Menu: Menu screens in this group display datalogger memory can store approximately 512 days of
temperature log, event log, set log time and PTI log. information.
• Refcon Remote Monitoring (RMM) State: Menu screen- The logging of USDA sensors is fixed at 1 hour intervals
show current remote monitoring state (Offline, Zombie to comply with USDA requirements. A logging test of USDA
or Online). sensors at 1 minute intervals is possible for 72 minutes.
USDA data can be downloaded during the logging test. After
72 minutes, controller returns to previous logging interval and
clears USDA test data from datalogger memory.
If the unit power supply is disconnected, the datalogger
will continue to register 120 temperature logs (except humid-
ity sensor) when battery voltage is above 11.4 volts. These
will be maintained until the unit is reconnected to power, and
the battery automatically recharged.
Trip data can be retrieved (but not erased) from the datalogger
memory using a DRUII or Smart Sponge handheld data
retriever. DRUII data transfer rate based on a 1 hour log.
interval is about 15 seconds per month of event logs and about

70 seconds per month of temperature logs. For example,
downloading 90 days of data logs would take about 75 sec-
onds
9-4
for event logs only and about 45 seconds for temperature logs Chill Loads (Setpoint at 9.9 C
only.
Trip data from separate units is denoted by the identification [14.1 F] and Above)
information entered into the controller at the beginning of The unit operates on Cool with Modulation and Heat to pro-
the trip via the general purpose keypad. Identification data vide accurate control of chill loads. During Cool with Modu-
may include the container ID number, location B.R.T., con- lation, the controller uses a proportional integral derivative
tent, loading data, voyage no., ship, load port, discharge port (PID) algorithm and a stepper motor valve to provide accurate
and comments. The container ID number is stored in the control of the container temperature in direct response to load
Configuration submenu. demand.
The stepper motor valve is installed in the suction line and
controls the amount of refrigerant returning to the compres-
General Theory Of Operation sor. The valve opens and closes in response to a controller
The MP3000 controller uses advanced solid state integrated voltage signal based on a control temperature differential. The
circuits to monitor and control unit functions. The controller controller uses the setpoint temperature, supply air sensor
monitors inputs from: temperature (left and/or right hand sensors) and pull-down
• Return air sensor rate for the last 10 seconds, last 20 seconds and last 180 sec-
• Supply air sensor, left hand onds to calculate the control temperature differential.
• Supply air sensor, right hand
• Evaporator coil sensor Supply Air Sensor Control
• 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
• Phase measuring circuits lowest supply air sensor temperature.
• Current measuring circuits • At setpoints above 0 C (32 F), the controller uses the
• Voltage measuring circuits average temperature of the left hand and right hand sup-
Output signals from the controller automatically regulate all ply air sensors.
unit functions including: • At setpoints between 1 C and 0 C (30 F and 32 F), the
• Compressor operation controller uses a sliding temperature scale from the low-
• Condenser fan operation est supply air sensor temperature to the average tempera-
• Evaporator fan motor operation ture of the left hand and right hand supply air sensors.
• Liquid line solenoid valve If one supply air sensor fails, the controller uses the tempera-
• Stepper motor valve ture of the other supply air sensor for temperature control. If
• Liquid injection valve 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 tempera-
ture fluctuations to +/ 0.1 C (+/ 0.2 F). Additional frost pro-
tections is provided by pulsing the electric heaters ON and
OFF on a 60 second duty cycle to increase the supply air tem-
perature if the return air temperature decreases to within 0.3 C
(0.5 F) of setpoint.MP3000 Controller
9-5
Frozen Loads (Setpoint at 10 C [14 F] Compressor Liquid Injection

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

The controller uses the total unit current and the condenser During Chill Mode operation, a warm gas bypass system
temperature to provide power limit control in both the Chill diverts refrigerant from the high side to the suction line as the
and Frozen modes. When the unit is on water-cooled opera- supply air temperature decreases toward setpoint. This
tion, power limit control is based on the total unit current reduces unit cooling capacity and increases refrigerant flow
draw only. through the compressor. The controller activates the warm gas
bypass valve when:
Initial Unit Startup and Normal • • Chill Mode: When the modulation percent is 25% or
Operation (Standard) less (in the Data menu display), the controller energizes
Power Limit is active whenever the compressor is ON in both warm gas bypass valve on a 30 second duty cycle. The
the Chill and Frozen modes. When the total current draw or amount of On (open) time increases as the modulation
the condenser temperature exceeds a predetermined threshold, percentage decreases.
the controller limits unit power consumption by sending a
voltage pulse to the stepper motor valve. The stepper motor
valve then closes to restrict the flow of refrigerant to the com- Evaporator Fan Control
pressor. The controller determines evaporator fan motor speed based
This reduces the cooling capacity load on the compressor, on the setpoint temperature and the Economy mode setting.
thereby limiting the compressor motor current draw • Evaporator fans operate on HIGH speed at setpoints of
and the condenser temperature to a predetermined threshold. 9.9 C (14.1 F) and above. If the Economy mode is ON
and temperature is Inrange, the controller shifts the evap-
Power Limit Management
orator fans to LOW speed.
Additional power limit management flexibility is available. A
• Evaporator fans operate on LOW speed at setpoints of
maximum total current draw (17, 15 or 13 amps) and power
10 C (14 F) and below. If the Economy mode is ON and
management time interval can be selected from the Power
the unit is in the Null mode, the controller STOPS the
Management feature of the Commands menu. When the
evaporator fans. The controller then operates the evapo-
power management time interval expires, the unit returns to
rator fans on LOW speed for 5 minutes every 45 minutes
the standard power limit control algorithm.
as long as the unit remains in the Null mode.
NOTE: Setting power management current at 13
amps can be used to provide slow pull-down of
loads.
9-6
Condenser Fan Control The unit remains in Null until the return air temperature
increases to ECMAX temperature at the expiration of a 45
The controller also uses a proportional integral derivative minute Null state time sequence. Default ECMAX setting is.2
algorithm to control the condenser temperature and ensure a C (0.4 F) above setpoint. ECMAX setting is adjustable from 0
constant liquid pressure at the expansion valve. In low ambi- to 5 C (0 to 8.9 F) above setpoint through the Configuration
ent conditions, the controller pulses the condenser fan ON and menu of the controller.
OFF to maintain a minimum condenser temperature. The con- NOTE: On Frozen loads, supply and return air
troller maintains a minimum 30 C (86 F) condenser tempera- temperatures may vary considerably during Economy mode
ture on Chill loads and a minimum 20 C (68 F) condenser operation due to long periods of no air circulation.
temperature on Frozen loads.
Probe Test
Economy Mode Operation
The controller constantly monitors the left hand and right
The Economy Mode reduces unit power consumption by hand supply sensors, return sensor and defrost (evaporator
reducing evaporator fan operation on both chill and frozen coil) sensor to determine when to initiate a demand defrost. If
loads. The use of the Economy Mode should be established a demand defrost is requested and defrost has occurred within
by the shipper and the type of cargo. The Economy Mode last 90 minutes, the controller initiates a Probe Test to check
option is turned on from Setpoint menu of the controller. for a defective sensor.
NOTE: Enter Setpoint temperature before turning ON the During a Probe Test, the LCD display shows “Probe Test
Economy mode. The controller automatically turns the Please Wait”. The controller operates the unit on high speed
Economy mode OFF when the setpoint is changed. evaporator fans only for 5 minutes. All sensor temperatures
Chill Loads (Setpoints of 9.9 C (14.1 F) and Above) are then compared:
Evaporator fans operate on low speed whenever the container • Sensors with large temperature differences are discarded
temperature is Inrange. from the control algorithm. The controller then activate
NOTE: On Chill loads, container air temperatures may vary the appropriate Alarm codes to identify the defective sen-
1 C to 3 C (1.8 F to 5.4 F) above setpoint in high ambient sor(s).
temperatures. • If no sensors are found defective, controller LCD display
shows “Running with High Supply Difference” message.
Frozen Loads (Setpoints of 10 C (14 F) and Below) Sensor errors recorded during a Probe Test are cleared
The evaporator fans stop during the Null mode. A null state when the next Defrost is initiated or Unit On/Off switch
timer automatically restarts the evaporator fans on low speed is turned OFF.
for 5 minutes every 45 minutes. NOTE: A manual Probe Test can be performed by a
The Economy Mode also modifies the temperature control technician by selecting Sensor Check from the Manual Test
algorithm on frozen loads to extend the Null mode. The unit Function menu.
continues on Cool operation until return air temperature
reaches 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 Configu-
ration menu of the controller.
9-7
Dehumidify Mode (Option) SEQUENCE OF OPERATION

During Chill mode operation, a dehumidification system is
available to reduce the relative humidity in the container to Unit Startup
the desired humidity setpoint. The Dehumidify Mode option
is turned on from Setpoint menu of the controller. The relative A 60 second sequence start of the required loads occurs dur-
humidity setpoint can be set from 50 to 99% from the Setpoint ing
menu too. initial startup of the controller. If cooling (or heating) is
Changing the Humidify/Dehumidify Mode program screen required, the unit operates in the cool (or heat) mode.
from OFF to ON activates the dehumidify control algorithm. • When the unit On/Off switch is turned ON, the LED dis-
The use of the Dehumidify Mode should be established by the play turns On and then Off.
shipper. When the Dehumidify Mode is ON, the supply air • The setpoint appears briefly in the LED display.
temperature must be inrange to activate dehumidification: NOTE: When the setpoint appears in the LED display, both
a. When the humidity level is 2% or more above setpoint, the Return and Supply LEDs are lit.
the controller energizes (closes) the dehumidify valve. • The LED then shows the controlling air sensor tempera-
This reduces the size of the evaporator providing cooling ture.
by 50%, causing the coil to become colder and condense • The controller senses the incoming power phase and
more moisture from the container air. selects the correct power phase to unit components.
b. When the humidity level is 5% or more above setpoint, • About 40 seconds after the unit was turned ON, the evap-
the controller also pulses the electric heaters ON and orator fan motors start.
OFF. This increases the cooling load on the evaporator Evaporator fans operate on high speed at setpoints of 9.9
coil, thereby causing the coil to become even colder and C (14.1 F) and above.
condense more moisture from the container air. 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 tempera-
ture 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 Inrange 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
startup minimize peak current draw.
9-8
Continuous Temperature Control • Controller pulses electric heaters ON and OFF for addi-
tional frost protection if the return air temperature
Operation decreases to within 0.3 C (0.5 F) of setpoint.
Chill Loads — Controller Setpoint at 9.9 C (14.1 F)
and Above
The controller regulates the compressor, stepper motor valve
and electric heaters based on a Control Temperature Differen- 1
tial (see “General Theory of Operation” in this chapter for
more detail). This means the unit operating mode can NOT be
predicted based ONLY on the setpoint and supply air temper-
ature. A
At setpoints of 9.9 C (14.1 F) and above, the controller
operates the unit on:
• Cool mode with Modulation
• Controller energizes the liquid injection valve continu-
+1.5C
ously when the modulation percent is 75% or less.
(+2.7)F
• Controller energizes the warm gas bypass valve on a 30
second duty cycle when the modulation percent is 75% or C
less. The amount of ON (open) time increases as the 2
modulation percent decreases.
B
• Heat mode (electric heaters pulse On and Off on a 60 sec-
-1.5C
ond duty cycle)
(-2.7)F
• Defrost mode (electric heaters On, evaporator fans Off)
• Evaporator fans operate on high speed (except when
3
Economy mode is ON and temperature is Inrange) and
continuously circulate air inside the container (except AJA731
during defrost)
• Controller LED display shows the supply air sensor tem-
perature.
• Controller LCD display shows the setpoint temperature. Table 1: Chill Load Control Sequence
• Controller uses the condenser coil temperature and a PID (Setpoints at 9.9 C [14.1 F] and Above)
algorithm to cycle a single speed condenser fan between
ON and OFF on a 30 second duty cycle. A. Cool with Modulation* (control temperature dif-
• Power limit is active when the unit is operating in the ferential is above setpoint)
Cool mode.
B. Heat (electric heaters pulse ON and OFF on a 60
second duty cycle if return air temperature decreases
Cool with Modulation within 0.3 C [0.5 F] of setpoint or supply air temper-
• Controller calls for the Cool mode whenever the Control ature is too low)
Temperature Differential (based on supply air tempera-
C. InRange (based on supply air temperature)
ture) is above setpoint.
1. Decreasing Temperature
• Controller turns ON the Compressor LED when the
2. Setpoint
• compressor is operating.
3. Increasing Temperature
• Controller opens and closes stepper motor valve to regu-
late the flow of refrigerant to the compressor. The posi-
tion of the stepper motor valve balances the unit cooling *NOTE: Controller also energizes liquid injection
capacity against the actual load requirements. valve and warm gas bypass valve as modulation
• Controller turns ON the In-range LED when the supply percent decreases.
air sensor temperature is within 1.5 C (2.7 F) of setpoint.
• Supply air sensor control algorithm increases temperature
control accuracy and protection against frost damage (see
“Chill Loads” under General Theory of Operation in this
chapter).
9-9
Table 2: Operating Mode Function Chart Standard Operation

CHILL LOADS
FROZEN LOADS
SET POINTS AT 9.9
SET POINTS AT 10.0 C
C (14.4 F) and
(14.0 F) and Below
Above
Cool w/Mod Heat Defrost Cool Null Defrost Unit Function
• • Evaporator Fans HIGH SPEED 1
• • Evaporator Fans LOW SPEED 1
• • Evaporator Fans OFF 1
• • 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 ON 4
• •5 Stepper Motor Valve MODULATING (energized)5
• • • • Electric Heaters PULSING or ON (energized)6
1
Setpoint temperature determines the evaporator fan speed except when Economy Mode is ON. When Economy Mode is ON:
• Chill Loads: If supply air temperature is inrange, evaporator fans operate on low speed.
• Frozen Loads: If return air temperature is inrange, evaporator fans stop during Null mode. A null state timer automatically
restarts the fans on low speed for 5 minutes every 45 minutes.
2
Controller 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).
3 Controller 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%).
4
Condenser fan operation is determined by a control algorithm so ON/OFF operation can not be predicted. In low ambient con-
ditions, controller pulses the condenser fan ON and OFF on a 30 second duty cycle to maintain a minimum condenser tempera-
ture:
• 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.
5
Stepper motor valve MODULATES:
• Chill Loads: Whenever the unit is in a cooling mode.
• Power Limit: Whenever the unit is in Power Limit mode.
6
Controller 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.
9-10
Heat • Cool mode

• Controller pulses electric heaters ON and OFF on a 60 • Null mode
second duty cycle for additional frost protection if the
return air temperature decreases to within 0.3 C (0.5 F) of • Defrost mode (electric heaters On, evaporator fans Off)
setpoint.
• Evaporator fans operate on low speed and continuously
• Controller turns ON the Heat LED whenever the heaters
are pulsed ON and OFF. circulate air inside the container (except during defrost;
• If the supply air temperature is too low and the Control or when Economy mode is ON and the unit is in Null
Temperature Differential is above the setpoint, the con-
troller stops the compressor and pulses the electric heat- mode)
ers ON and OFF on a 60 second duty cycle to provide • Controller LED display shows the return air sensor tempera-
heat. The controller pulses the electric heaters ON and
OFF until the supply air temperature increases to set- ture.
point. • Controller LCD display shows the setpoint temperature.
Frozen Loads — Controller Setpoint • Controller uses the condenser coil sensor temperature
at 10 C (14 F) and Below and PID algorithm to cycle a single-space condenser fan
ON and OFF on a 30 second duty cycle.
At setpoints of 10 C (14 F) and below, the controller locks out
the Modulation and Heat modes. The controller regulates • Power limit is active during initial startup and pull-down
compressor operation based the return air sensor and setpoint
temperatures. when the unit is cooling at return air temperatures
At setpoints of 10 C (14 F) and below, the controller above 10 C (14 F).
operates the unit on:
Table 3: Operating Mode Function Chart Optional Feature Operation

CHILL LOADS
FROZEN LOADS
SET POINTS AT 9.9
SET POINTS AT 10.0 C
C (14.4 F) and
(14.0 F) and Below
Above
Cool w/Mod Heat Defrost Cool Null Defrost Unit Function
• • Economy Mode ON: Evaporator Fans HIGH SPEED 1
• • Economy Mode ON: Evaporator Fans LOW SPEED 1
• • Economy Mode ON: Evaporator Fans OFF 1
• • Dehumidify ON:
Dehumidify Valve CLOSED (energized)2
• • Dehumidify ON: Electric Heaters ON (energized)2
• • Humidify ON: Air Compressor ON (energized)3
1
Economy Mode ON:
• On Chill Loads, the evaporator fans operate on low speed when the supply air temperature is Inrange.
• On Frozen Loads, the evaporator fans stop during the Null mode when the return air temperature is Inrange. A timer
restarts 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.
2 Dehumidification Option: When the Dehumidify Mode is set to ON, the supply air temperature must be inrange 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.
3
Humidification Option: When the container humidity is more than 2% below the humidity setpoint, the controller operates
(energizes) the air compressor to inject atomized water directly into the evaporator supply air stream.
9-11
Cool Defrost
• After initial startup and pull-down to 1.0 C (1.8 F) below
setpoint, the controller calls for the Cool mode whenever: The evaporator coil sensor temperature must be below 18 C
Return air temperature increases more than 1.0 C (1.8 F) (65 F) to initiate a Demand Defrost or Manual Defrost. The
above setpoint; or evaporator coil sensor temperature must be below 10 C (50 F)
Compressor has been OFF for 15 minutes (maximum). to initiate a Timed Defrost.
• Controller turns ON the Compressor LED when the com- • Demand defrost function initiates defrost immediately
pressor is operating. when:
• Compressor must operate for a minimum of 5 minutes Temperature difference between the return air sensor and
after startup. defrost (evaporator coil) sensor is too large
• After initial pull-down to setpoint, controller keeps the Temperature difference between the left hand and right
Inrange LED ON as long as the return air temperature hand supply air sensors is too large and unit has operated
remains less than 1.5 C (2.7 F) above setpoint. for more than 90 minutes since last defrost
Temperature difference between the supply sensors and
Null return air sensor is too large.
• The controller calls for Null when the Return Air Tem- • • Manual Defrost may be initiated immediately by press-
perature decreases more than 1.0 C (1.8 F) below set- ing the Defrost key or by Refcon Remote Monitoring
point. Modem (RMM).
• The controller stops the compressor and condenser fan. • A Timed Defrost always starts at 1 minute past the hour
• The evaporator fans continue to operate (except when immediately following a defrost timer request for defrost.
Economy mode is ON). For example, if the defrost timer requests a defrost cycle
• Compressor remains OFF for a minimum of 5 minutes at 7:35, the defrost cycle will start at 8:01. The datalogger
and a maximum of 15 minutes. will record a Defrost event for each log interval in which
a Defrost cycle is pending or active (i.e. both the 8:00 and
1 9:00 data logs on 1 hour logging interval).
On Chill Loads (setpoints at 9.9 C [14.1 F] and above),
the initial time interval is:
• 8 hours of compressor operation at supply air tempera-
A tures of 5.1 C (41.2 F) or above.
+1.5C • 2.5 hours of compressor operation at supply air tempera-
(+2.7F) tures of 5.0 C (41.0 F) or below. One half (0.5) hour is
+1.0C added to the time interval each timed defrost interval.
C (+1.8F) Defrost synchronization creates step intervals of 3, 4, 4,
2 5, 5, 6, 6 and 7 hours. Maximum time interval is 7 hours.
On Frozen Loads, the initial time interval is 8 hours. Two
-1.0C D
(2) hours are added to the time interval each timed
(-
defrost interval. Maximum accumulated time interval is
1.8F)
24 hours.
Defrost timer resets if the unit is Off more than 12 hours,
AJA732 setpoint is changed more than 5 C (8.9 F) or PTI Pretrip
test occurs.
NOTE: If unit operating conditions do not allow the unit to
enter a defrost cycle, “Defrost Not Activated” appears on
A. Cool LCD display when the DEFROST key is pressed.
C. InRange
D. Null
1. Decreasing Temperature
2. Setpoint
3. Increasing Temperature

(Setpoints at 10 C [14 F] and Below)
9-12
When the defrost mode is initiated: Changing the Setpoint

• The controller stops the compressor, condenser fan and
evaporator fans. NOTE: Humidity control, humidity setpoint and
• When the compressor stops, the controller turns ON the economy mode can also be set from the Setpoint
Defrost LED, Heat LED and energizes the heater contac- menu. See “Setpoint Menu” under Menu
tor, turning on the electric heaters. Operating Instructions in this chapter.
To change the controller setpoint, turn the unit On/Off switch
The controller terminates the defrost mode when: ON. With the standard LCD message display showing on the
• Evaporator temperature: controller (i.e. setpoint temperature):
Chill mode: Evaporator coil sensor temperature reaches 1. Press the SETPOINT key. The SETPOINT menu appears
30 C (86 F); or exceeds 18 C (65 F) for 15 minutes. with the cursor in the “TEMP SETP” line.
Frozen mode: Evaporator coil sensor temperature 2. Press the F4 key. An Enter Arrow appears in the menu
reaches 18 C (65 F); or exceeds 8 C (46 F) for 15 min- line and the current setpoint disappears.
utes. 3. Enter (type) the new setpoint in the LCD display using
• Interval timer: Controller terminates defrost after 90 min- the general purpose keypad. To enter a minus setpoint,
utes on 60 Hz power (120 on 50 Hz power). Alarm code press the EXIT (+/) key first. The cursor moves to the
20 will be generated if this occurs. right of the screen as each key entry is acknowledged and
• Power OFF: Turning unit On/Off switch Off terminates- displayed.
defrost.
NOTE: Always check that the setpoint entered in the LCD
When the defrost mode is terminated: display is correct before proceeding.
• The Heat and Defrost LEDs turn OFF and the heater con-
tactors de-energized. The controller starts the compressor 4. Press and hold the F4 key until the cursor stops flashing.
to precool the evaporator coil. The condenser fan starts if The new setpoint is recorded in the controller and
required. appears in the LCD display.
• The controller precools the evaporator coil to the supply
air temperature (or for 3 minutes maximum) to minimize NOTE: If the setpoint is not entered within 30 seconds, the
heat energy release into the container. The liquid injec- controller will default (return) to the previous setpoint. If
tion valve is energized if the modulation percent is 75% this occurs, repeat steps 1 through 4.
or less. The controller then starts the evaporator fans.
9-13
Initiating a Manual Defrost Displaying Alternate Control-

With the unit On/Off switch ON: ling (Supply or Return)
1.Press the DEFROST key. Air Sensor Temperature
• If the unit operating conditions allow a manual defrost
(e.g. evaporator coil temperature is less than 18 C [56F]), The controller can show either the supply or return air temper-
the unit enters defrost as the Defrost and Heat LEDs turn ature in the LED Display. With the unit On/Off switch ON
ON. LCD message display shows “DEFROST ACTI- and the controller showing the standard LED Display:
VATED”. 1. Check the indicator LEDs to determine which sensor
• If unit operating conditions do NOT allow defrost, the temperature (supply air or return air) currently appears in
LCD message display shows “DEFROST NOT ACTI- the right display. This is the controlling sensor.
VATED”. 2. To view the alternate (supply or return) air temperature,
2. The defrost cycle automatically terminates. press and hold the SUP/RET key. The controller will
NOTE: If frost or ice can not be removed from the show the alternate sensor temperature as long as the SUP/
evaporator coil by an automatic defrost cycle, a “timed” RET key is depressed.
defrost of the evaporator coil can be performed: 3. The display then returns to the controlling sensor temper-
• Activate HEAT ON in the Manual Function Test submenu. ature when the SUP/RET key is released.
• Then press “5” key six times. Heaters will be activated for
70 minutes. Unit then returns to normal operation. Displaying Alternate
Fahrenheit (F)
or Celsius (C) Temperatures
The controller can display temperatures in Fahrenheit or
Celsius. With the unit On/Off switch ON and the controller
showing a standard LED Display:
1. Press and hold the C/F key. The controller will show both
the LED and LCD display temperatures in the alternate
temperature scale (Fahrenheit or Celsius) as long as the
C/F key is depressed.
2. The display then returns to the original display when the
C/F key is released.
NOTE: To change the default temperature unit display,
press and hold the C/F key, then press the SETPOINT key
for 1 second.
9-14
Navigating the Controller Menu General Operating Tips

NOTE: To view the controller’s menu or download data • Quickly change display temperature units between C and
when external power is disconnected from the unit, press a F: Press and hold the C/F key, then press the SETPOINT
special key: C/F key, SUP/RET key, DEFROST key or key for 1 second.
SETPOINT key. The controller LCD display will appear • Increase display time for current LCD data screen: Press
using 12 Vdc battery power. the “5” key to increase display time by 5 minutes. Maxi-
The MP3000 Main Menu is divided into seven major menus: mum display time is 30 minutes for data screens and 100
• Setpoint minutes for manual tests.
• Data • Slowly cool (initial pull-down) a warm load: Set power
• Alarm List • management to 13 amps.
• Commands • Password for Configuration changes is “A”: Press F2
• Misc. Functions key, “A” key, F4 key and then EXIT key.
• Configuration • Delay Defrost for 24 hours during unit diagnosis or test-
• Datalogger ing: Press “7” key and F1 key at the same time. Press F3
• Remote Monitoring (RMM) State key to scroll cursor down to DELAY DEF menu line.
Moving through these seven menus and their submenus Then press F4 key, F2 key, “A” key, F4 key and EXIT
and entering commands requires the use of four text keys: key. Cursor moves to end of line and flashes. Press F3
key to toggle OFF to ON. Then press and hold F4 key
until cursor stops flashing.
F1 key: Press the F1 key each time you want • Perform a “timed” defrost of evaporator coil: Activate
to exit a submenu and/or retrieve current sys- HEAT ON in the Manual Function Test submenu. Then
tem data for display. press “5” key six times. Heaters will be activated for 70
F2 or F3 key: Press the F2 or minutes. Unit automatically returns to normal operation.
F3 key each time you want to
scroll up or down to view
another item in a menu or
submenu; or scroll forward
or backward in a menu line.
F4 key: Press the F4 key to
enter a new menu or sub-
menu; to access a menu
line to enter information;
or to load a command or
value.
AJA737
9-15
Setpoint Menu 4. Press F2 key to toggle between OFF and ON.

5. With the desired state in the menu line, press and hold F4
Pressing the SETPOINT key displays a list of tasks and val- key until cursor stops flashing. New mode setting appears
ues that can be activated or set: in display.
• Setpoint Temperature
• Economy Mode NOTE: On frozen loads, the Economy Mode also modifies
• Airflow the temperature control algorithm to extend the Null mode.
• Custom Airflow See “Economy Min.” and “Economy Max.” under
• Bulb Mode Configuration Menu in
• Humidity Control this chapter to check the current settings or
• Humidity Setpoint enter new settings.
• AFAM Control 6. Press ESC key to exit the SETPOINT screen.
• AFAM Delay
• AFAM Rate
• O 2 Minimum Changing the Humidity Mode Setting
• CO2 Maximum 1. Press the SETPOINT key. The SETPOINT menu appears
with the cursor in the “TEMP SETP” line.
Changing the Setpoint Temperature 2. Press F2 key to scroll to “HUM CONTROL” line.
3. To change the mode setting, press F4 key. Cursor moves
See “Changing the Setpoint” on page 12. to end of menu line and flashes.
4. Press F2 key to toggle between OFF and ON.
Changing the Economy Mode Setting 5. With the desired state in the menu line, press and hold F4
key until cursor stops flashing. New mode setting appears
NOTE: Enter Setpoint temperature before turning ON the in display.
Economy mode. The controller automatically turns the 6. Press ESC key to exit the SETPOINT screen.
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. Changing the Humidity Setpoint
2. Press F2 key to scroll to “ECONOMY MODE” line. 1. Press the SETPOINT key. The SETPOINT menu appears
3. To change the mode setting, press F4 key. Cursor moves with the cursor in the “TEMP SETP” line.
to end of menu line and flashes. 2. Press F2 key to scroll to “HUM SETP” line.
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 Screen Flow Diagram
AJA738
9-16
3. To enter a new setpoint, press the F4 key. An Enter • Voltage 3 (Main Power Supply)
Arrow appears in the menu line and the current setpoint- • Frequency (Main Power Supply)
disappears. • Zero Current
4. Enter (type) the new setpoint in the LCD display using • Current Phase 1 (Main Power Supply)
the general purpose keypad. The cursor moves to the • Current Phase 2 (Main Power Supply)
right of the screen as each key entry is acknowledged and • Current Phase 3 (Main Power Supply)
displayed. • O2
NOTE: Always check that the setpoint entered in the LCD • CO 2
display is correct before proceeding. • Fresh Air Exchange Rate
5. Press and hold the F4 key until the cursor stops flashing. • Evaporator Fan Speed
The new setpoint is recorded in the controller and • Supply Air Temperature, Left Hand
appears in the LCD display.
6. Press ESC key to exit the SETPOINT screen. NOTE: Press the “5” key to lock a Data screen in the LCD
display for 5 minutes. Press any key to unlock the display.
Data Menu
NOTE: Controller returns to previous menu level or LCD
NOTE: Information can ONLY be displayed using the
Standard Display after 30 seconds.
Data menu. Items can NOT be changed.
The Data menu displays general unit operating information
including sensor temperatures, unit electrical data, etc. NOTE: All screens are
NOT present on all units.
Viewing the Data Menu The screens that display
on the controller are
With the unit On/Off switch ON and the LCD display show- determined by the Unit
ing the standard display (setpoint): Configuration setting.
1. Press F4 key for directly enter the Data menu. Menu
items appear in LCD display.
2. Press F3 to scroll the cursor down through the menu list.
The Data menu displays the following functions:
• Supply Air Temperature, Right Hand
• Return Air Temperature
• Evaporator Coil (Defrost) Temperature
• Condenser Coil Temperature
• Modulation
• Ambient Temperature
• Low Pressure
• High Pressure
• High Pressure Temperature (Compressor Discharge Line
Temperature)
• Relative Humidity
• Battery Voltage
• Voltage Average (380/460V Power Supply)
• Voltage 1 (Main Power Supply)
• Voltage 2 (Main Power Supply)
AJA739
Data Menu Screen Flow Diagram
9-17
Alarms Menu Alarm Code States

The Alarm List menu displays alarm codes. Alarm codes are There are three alarm code states for Shutdown and Check
recorded in the controller memory to simplify unit diagnosis alarms:
procedures. Some alarm codes are only recorded during a • NOT ACTIVE: An alarm condition has occurred but no
Pretrip (PTI) Test or Function Test. Fault codes are retained • longer exists in the unit. Not Active means the condition
by the controller in a nonvolatile memory. If the Alarm LED was corrected and did not recur for 1 hour; or the unit On/
is ON or flashing ON and OFF, enter the ALARM LIST to Off switch was turned OFF and then ON.
view the alarm code(s). When a NOT ACTIVE alarm code is acknowledged (F4
key pressed while alarm code appears in LCD display),
Alarm Types the Alarm LED will turn OFF and the alarm code disap-
pears from the alarm list.
There are three types of alarms: • ACTIVE: An alarm condition has occurred and continues
• Shutdown Alarm (Level 1): Alarm LED flashes and unit to exist in the unit; or the alarm condition occurred within
stops. Shutdown alarms indicate the unit has been the past 1 hour but does not currently exist in the unit.
stopped to prevent damage to the unit or cargo. The con- If the alarm condition currently exists in the unit and the
dition must be corrected before restarting the unit. Alarm alarm code is acknowledged, the Alarm LED will stop
code 56 (compressor temperature too high) is a shutdown flashing but remain ON. The alarm code state will
alarm. change to ACKNOWLEDGE in the alarm list.
• Check Alarm (Level 2): Alarm LED flashes until alarm is If the alarm condition no longer exists in the unit and the
acknowledged. Check alarms indicate corrective action alarm code is acknowledged, the Alarm LED will turn
should be taken before a problem becomes severe. Alarm OFF and the alarm code disappears from the alarm list.
codes 0017, 18, 19, 20, 2235, 4146, 5254, 58, 60, 99112 • ACKNOWLEDGE: An alarm code has been viewed and
are Check alarms. acknowledged in the alarm list. The Alarm LED remains
• Log Alarm (Level 3): Alarm is recorded in datalogger ON but does not flash.
only (inspect event log). Alarm LED does not flash or If the alarm condition is corrected, the Alarm LED will
turn on. Alarm codes 3637, 59, 97, 98 are Log alarms. turn OFF and the alarm code disappears from the alarm
list.
NOTE: All screens are NOT Viewing the Alarm List Menu
present on all units. The
With the unit On/Off switch ON and the LCD display show-
screens that display on the
ing the standard display (setpoint):
controller are determined by
1. Press F2 key to directly enter the Alarms menu. The first
the Unit Configuration
alarm code number, alarm state and alarm description
setting.
appears in LCD display.
NOTE: Alarm codes are displayed in sequential order, not
in the order of occurrence.
2. Write down the first alarm code. Then press F2 key to
view the next alarm code when more than one alarm code
has been recorded.
3. Repeat step 4 until all alarm codes have been recorded.
To scroll backward to return to a previous alarm code,
press F3 key.
4. To clear all alarm codes from the current display list and
turn off the Alarm LED, all problems must be corrected
and the alarm code “acknowledged” in the Alarm List
menu. NOTE: To acknowledge an alarm, press F4 while
the alarm code appears on the screen. The alarm state will
change from ACTIVE or NOT ACTIVE to ACKNOWL-
EDGE. NOTE: If no key is pressed for 30 seconds, the
AJA740 controller returns to the previous menu level or the LCD
Standard Display.
Alarms Menu Screen Flow Diagram
9-18
Alarm List Table 4: Alarm List
Table 4: Alarm List Alarm

Type Description
Code
Alarm
Type Description 30 Check Bypass (Warm Gas) Valve Error
Code
31 Check Low Pressure Cutout Error
00 Check Supply Air Sensor Open Circuit
32 Check Condenser Air Sensor Open Circuit
01 Check Supply Air Sensor Short Circuit
33 Check Condenser Air Sensor Short Circuit
02 Check Return Air Sensor Open Circuit
34 Check Ambient Air Sensor Open Circuit
03 Check Return Air Sensor Short Circuit
35 Check Ambient Air Sensor Short Circuit
04 Check Evaporator Coil Open Circuit
36 Check Current Too High
05 Check Evaporator Coil Sensor Short Circuit
37 Check Current Too Low
06 Check Compressor Current Too High
41 Check Supply Air Temperature Too High
07 Check Compressor Current Too Low
42 Check Supply Air Temperature Too Low
10 Check Heater Current Too High
43 Check Return Air Temperature Too High
11 Check Heater Current Too Low
45 Check Evaporator Coil Temp Too High
12 Check Evaporator Fan High Speed Current
Too High 46 Check Evaporator Coil Temp Too Low
13 Check Evaporator Fan High Speed Current 52 Check Probe Error
Too Low
53 Check High Pressure Cutout Switch Off
14 Check Evaporator Fan Low Speed Current Error
Too High
54 Check High Pressure Cutout Switch On
15 Check Evaporator Fan Low Speed Current Error
Too Low
56 Shut- Compressor Temperature Too High
16 Check Condenser Fan Current Too High down
17 Check Condenser Fan Current Too Low 58 Check Phase Sensor Error
18 Log Power Supply Phase Error 59 Check Delta Current Error
19 Check Temperature Too Far from Setpoint 60 Check Humidity Sensor Error
20 Check Defrost Time Too Long 97 Log Compressor Sensor Open Circuit
22 Check Capacity Test 1 Error 98 Log Compressor Sensor Short Circuit
23 Check Capacity Test 2 Error 99 Check USDA 1 Sensor Open Circuit
24 Check Capacity Test 3 Error 112 Check Zero Current Too High.
25 Check Evaporator Temperature Test Error
27 Check Heat Capacity Test Error
28 Check Suction Stepper Valve Error

29 Check Liquid Injection Valve Error
9-19
Commands Menu Viewing the Commands Menu

The Commands menu displays a list of tasks that can be acti- With the unit On/Off switch ON and the LCD display show-
vated. The following commands are available: ing the standard display (setpoint):
• Defrost: Manual defrost can be initiated. When command 1. Press the F1 key to enter the Main Menu.
is activated, LCD message display will show ACTI- 2. Press F2 key to scroll through Main Menu until “COM-
VATED, NOT ACTIVATED (evaporator temperature MANDS” appears in LCD display.
above 18 C [50 F]) or ALREADY ACTIVATED (defrost 3. Press F4 key to access the Commands menu. The first
in progress). command in the submenu (Defrost) appears in the LCD
• Function Test: Controller automatically tests the opera- display.
tion of individual unit components. This is not a perfor- 4. Press F2 or F3 key to scroll to the desired command:
mance test of the complete system. See “Function Test” • Defrost
in this chapter for test details. • Function Test
• PTI (Pretrip) Test: Controller automatically completes a • PTI (Pretrip)
test of individual components and checks unit refrigera- • Manual Function Test
tion capacity, heating capacity and temperature control. • Power Management
See “PTI (Pretrip) Test” in this chapter for test details. 5. Press F4 key to activate the command selected.
CAUTION: The PTI test should only be performed on an • Defrost: LCD display shows DEFROST ACTIVATED,
empty container! NOT ACTIVATED (evaporator temperature above 18 C
• Manual Function Test: Controller tests individual compo- [50 F]) or ALREADY ACTIVATED (defrost in
nents selected by the technician for diagnosis. LCD dis- progress). Defrost cycle ends automatically.
play will show expected and actual current of the
component being tested.
• Power Management: Sets the power limit and power
limit activation (“On”) time.
NOTE: All screens are NOT present on all units.

The screens that display on the controller are
determined by the Unit Configuration setting.
Commands Menu Screen Flow Diagram AJA741
9-20
• Function Test: LCD display shows functional test cur- Pretrip (PTI) Test
rently being performed. Function test ends automatically.
Unit automatically returns to normal operation. CAUTION: The PTI test should only be performed on
• PTI (Pretrip): LCD display shows PTI Test currently an empty container!
being performed. PTI test ends automatically. Press any
key on the controller to return the unit to normal opera- NOTE: Units equipped with a water-cooled condenser must
tion. be set to operate on air cooled condensing to perform a
• Manual Function Test: LCD display shows list of unit complete system capacity test.
components. Test the operation of individual components
or turn several components ON at the same time to per- The MP3000 controller contains a special PTI pretrip test that
form a system test. automatically checks unit refrigeration capacity, heating
• Power Management: LCD display shows current Power capacity, temperature control, and individual components
Limit setting and Power Time setting. Turn Power Limit including the controller display, contactors, fans, protection
feature ON and OFF, change power limit setting or devices and sensors. The test includes measurement of com-
change power limit time. ponent power consumption and compares test results to
expected values. The test takes about 2 to 2.5 hours to com-
plete, depending on the container and ambient temperature.
Defrost
For a description of the Defrost function, see “Initiating a NOTE: Correct all existing alarm conditions and
Manual Defrost” on page 13. clear the alarm codes before performing a PTI test.
The controller will automatically clear all existing
alarms before beginning the PTI test.
Function Test
The MP3000 controller contains a special function test that For a detailed description of the PTI Test, see pages 23
automatically tests individual components including the con- through 27. Detailed PTI test results are stored in the MP3000
troller display, sensors, condenser fan, evaporator fan, com- Datalogger for later viewing. Any alarm codes recorded
pressors, etc. The test includes measurement of component during the test can be viewed through the controller’s Alarm
power consumption and compares test results to expected val- List menu at the end of the test.
ues.
For a detailed description of the Function Test, see pages
21and 22. Any alarm codes recorded during the test can
be viewed through the controller’s Alarm List menu at the end
of the test.
NOTE: The Function Test does not test the actual

performance of the complete system. Therefore it is not a
Pretrip test and should not be used instead of the PTI Test.
9-21
LCD Display
LED
(Shows Approx. Possible Duration
Display Test Description
Amps for 460V, Alarms (Time)
(Test No.)
60 Hz Unit)
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 mea- 00, 01, 02, 2 Seconds
Activated suring 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 voltage 14, 15 10 Seconds
Activated 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 voltage 12, 13 10 Seconds
Activated and frequency.
2.4 A 2.3 A 2.4 A • CSR40 PS: 2.2 Amps approx. at 50 Hz,
• CSR20 PS and CSR40SL PS:
3.0 Amps approx. at 50 Hz,
F1.04 Condenser Fan Amp draw is measured and compared to voltage 16, 17 10 Seconds
Activated and frequency: 1.2 Amps Maximum.
0.8A 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 started
0.8 A 0.7 A 0.8A in reverse. Amps measured must be approx.
equal to previous test (F1.04).
F1.06 Compressor Test With condenser fan ON and compressor ON, 06, 07, 31 14 Seconds
Activated compressor is operated at 25% capacity. Amp
7.1 A 7.0 A 7.1 A draw is measured and compared to voltage.
Evaporator temperature and condenser coil tem-
perature are measured and stored.
F1.07 Injection Valve Test Condenser fan and compressor remain ON. Liq- 29, 31 10 Seconds
Activated uid injection valve is turned ON. Amp draw is
7.6 A 7.5 A 7.6 measured and verified to be a minimum of .02
amps higher that test F1.06.
9-22
LCD Display
LED
(Test No.)
60 Hz Unit)
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, com- 30 10 Seconds
Valve Activated pressor is operated at 25% capacity. Liquid
8.3 A 8.2A 8.3A 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 volt- 10, 11 10 Seconds
Activated age:
5.2 A 5.1 A 5.2 A • 4.4 Amps approx. at 400V;
• 5.2 Amps approx. at 460 V.
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 ver-
0.1 A 0.0 A 0.1 A ify 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.
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 with in their mea- 00. 01, 02, 10 Seconds
Activated suring range. 03, 04, 05,
0.1 A 0.0 A 0.1 A When CONTAINER ID begins with MAE, 28, 31, 32,
MSF or MWC prefix, at least 1 USDA sensor 33, 34, 35,
must be installed or USDA No. 1 OPEN alarm 97, 98, 99 112
will be logged.
P1.02 Heat Test Electric heaters are turned ON. 10, 11 10 Seconds
Activated Amp draw is measured and compared to volt-
5.2 A 5.1 A 5.2 A age:
• 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), heat 20 1 Hour
Activated remains on until evaporator sensor reaches _18 Maximum
5.2 A 5.1 A 5.2 A C (65 F).
P1.04 PreCool If the evaporator sensor is above +20 C (68 F), 22 1 Hour
Activated unit operates in Cool until sensor temperature is Maximum
15.2 A 15.2 A 15.2 below +15 C (59 F).
A
9-23
LCD Display
LED
(Test No.)
60 Hz Unit)
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 is
2.4 A 2.3 A 2.4 A measured and compared to voltage and fre-
quency:
• CSR 40 PS: 2.2 Amps approx. at 50 Hz,
• CSR20 PS and CSR40Sl PS:
Evaporator fan high speed amperes are recorded
in PTI log.
P1.06 Probe Test Evaporator fans operate on high speed for 3 52 3 Minutes
Activated minutes. Then probe test runs until temperature Minimum to
2.4 A 2.3 A 2.4 A difference between sensors stops increasing. 13 Minutes
Maximum temperature difference 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
(0.9F)
P1.07 Condenser Fan Condenser fan is turned ON. Amp draw is mea- 16, 17 10 Seconds
Activated sured and compared to voltage and frequency:
0.8 A 0.7 A 0.8 A 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 started
in reverse. Amps measured must be approx.
equal to test P1.07.
P1.09 Compressor Test With condenser fan ON and compressor ON, 06, 07 14 Seconds
Activated compressor is operated at 25% capacity. Amp
7.1 A 7.0 A 7.1 A draw is measured and compared to voltage.
Evaporator temperature and condenser coil tem-
perature are measured and recorded in PTI log.
P1.10 Injection Valve Test Condenser fan and compressor remain ON. Liq- 29 10 Seconds
Activated uid injection valve is turned ON. Amp draw is
7.6 A 7.5 A 7.6 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.
9-24
LCD Display
LED
(Test No.)
60 Hz Unit)
P1.12 Warm Gas Bypass With condenser fan and compressor ON, com- 30 10 Seconds
Valve Activated pressor is operated at 25% capacity. Liquid
8.3 A 8.2 A 8.3 A 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. With 53 10 to 300
Pressure Activated compressor ON, evaporator fan operates on high Seconds
12.2 A 12.0 A 12.2 speed until high pressure cutout occurs, causing
A significant amps drop. Maximum time depends
on condenser coil temperature at start of test.
P1.13 Compress High With compressor OFF, condenser fan starts and 54 3 to 50 Sec-
Pressure Activated operates until compressor starts, causing a sig- onds plus 60
4.5 A 4.4 A 4.5 A nificant amps increase. Compressor is then Seconds
turned OFF. Condenser fan operates 60 seconds
more to lower condenser temperature.
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 is
1.1 A 1.0 A 1.1 A measured and compared to voltage and fre-
quency:
• CSR 40 PS: 0.8 Amps approx. at 50 Hz,
• CSR20 PS and CSR40Sl PS:
P1.15 Capacity Test 1 With condenser fan ON, compressor ON, and 22 3 Minutes
Activated evaporator fans on low speed, stepper valve is (4 Minutes
12.1 A 12.0 A 12.1 set to 50% capacity. Liquid injection valve is on CSR20)
A turned ON. A difference of approx. 4.5 C (8.0 F)
is required between return and supply air tem-
peratures, depending on return air and con-
denser coil temperatures.
P1.16 Capacity Test 2 With condenser fan ON, compressor ON, liquid 23 2 Minutes
Activated injection valve ON and stepper valve set to 50%
13.2 A 13.0 A 13.2 capacity, evaporator fans are changed to high
A speed. A difference of approx. 3.0 C (5.4 F) is
required between return and supply air tempera-
tures, depending on return air and condenser
coil temperatures. However, temperature differ-
ence must be less than in test P1.15.
9-25
LCD Display
LED
(Test No.)
60 Hz Unit)
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 evap- on CSR20)
orator 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 is
7.3 A 7.2 A 7.3 A not at least 0.4 C (0.7 F) above the return air
temperature.
P1.19 Evaporator Stepper valve is set to 50% capacity. With con- 25 5 Minutes
Temperature Test denser fan ON, compressor ON, and liquid Maximum
Activated injection valve ON, evaporator fans are turned
12.3 A 12.1 A 12.3 OFF. The evaporator coil temperature must
A 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. Return/ None 5 Minutes
supply air temperature difference from tests
2.4 A 2.3 A 2.4 A 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 PreHeat If return air temperature is below 5 C (41 F), None 120
Activated evaporator fans operate on high speed and heat- Minutes
7.9 A 7.9 A 7.9 A ers turn ON. Unit operates until return air tem- Maximum
perature is above 5 C (41 F).
Supply PTI Running Unit operates in normal cool mode with 0 Cl (32 23 120
Temp. Setpoint: 0 C (32 F) F) setpoint. When supply air temperature Minutes
decreases to setpoint, “Chill Arrival” tempera- Maximum
tures are recorded in PTI log.
Supply PTI Running Unit operates in normal mode with 0 C (32 F) None 30
Temp Setpoint: 9 C (32 F) setpoint for 30 minutes after previous test is Minutes
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 decreases Minutes
to 18 C (0 F), defrost is initiated. Defrost termi- Maximum
nates when evaporator temperature increases to
18 C (65 F).
9-26
LCD Display
LED
(Test No.)
60 Hz Unit)
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 decreases Minutes
to setpoint, “Frozen Arrival” temperatures are Maximum
recorded in PTi log.
If unit is configured with humidity sensor, rela-

tive 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 mem-
ory.
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, LCD NONE __
Temp. Press (Any) Key display shows PTI FAIL.
Press any key to clear display.
Unit will remain OFF unit any key is pressed

again.
9-27
Manual Function Test a. Press F2 or F3 key to scroll to the first component.

b. Press F4 key to turn the component ON.
The Manual Function Test menu allows technicians to per- c. Press F3 key to scroll to select next component. Press
form specific diagnostic tests on individual components or F4 to turn component ON.
turn several components ON at the same time to perform a d. Repeat step 6c. until all required components are ON.
system test. For example, to operate unit in Full Cool mode, start
NOTE: When the Manual Function Test menu is entered, the following components:
the UNIT STOPS. A technician can then select the control Condenser Fan
circuit or component to be checked/tested from the items Compressor
shown in the menu. Capacity 100%
With the unit On/Off switch ON and the LCD display show- Evaporator High or Low
ing the standard display (setpoint): e. Observe current draw and system performance to ver-
1. Press F2 key to enter the menu list. Repeatedly press F2 ify component(s) performance.
key to scroll through Main Menu until “COMMANDS” f. Press F4 key again to turn OFF components individu-
appears in LCD display. ally. Or press ESC key to exit Manual Function Test
2. Press F4 key to access the Commands menu. The first menu and turn ALL components OFF.
command in the submenu (Defrost) appears in the LCD g. Press ESC key to exit the Manual Function Test sub-
display. menu.
3. Press F2 or F3 key to scroll to Manual Function Test. NOTE: Controller returns unit to normal operation if no
4. Press F4 key to enter the Manual Function Test: “CON- keys are pressed for 10 minutes. Pressing “5” key extends
DENSER OFF” appears in the LCD display. test time by 10 minutes each time it is pressed (maximum
5. • To test a unit component: time = 100 minutes). Pressing any other key resets test time
a. Press F2 or F3 key to scroll to desired component test: to 10 minutes.
Condenser Fan
Compressor
Capacity 25% (Stepper valve position) Power Management
Capacity 50% (Stepper valve position) Selecting a Power Limit from the Power Limit screen turns
Capacity 100% (Stepper valve position) ON the power reduction control algorithm that reduces total
Injection Valve unit electric power consumption based on the Power Limit
Dehumidify Valve and Power Time settings.
Evaporator High With the unit On/Off switch ON and the LCD display
Evaporator Low showing the standard display (setpoint):
Heat 1. Press F2 key to enter the menu list. Repeatedly press F2
Zero Current (View value only) key to scroll through Main Menu until “COMMANDS”
Sensor Checks (Probe Test): Operates high speed appears in LCD display.
evaporator fans only. After 5 minutes, check the tempera- 2. Press F4 key to access the Commands menu. The first
tures of the left and right hand supply sensors, return sen- command in the submenu (Defrost) appears in the LCD-
sor and defrost sensor. Temperatures should be display.
approximately equal. 3. Press F2 or F3 key to scroll to Power Management.
b. Press F4 key to start the component test. LCD display 4. Press F4 key to enter Power Management submenu dis-
will change the component state from OFF to ON. play shows the current Power Limit setting and Power
c. Verify component performance: LCD display will Time setting.
show expected current and actual current on phase 1, 2
and 3.
d. Press F4 key again to stop test. LCD display will
change component state from ON to OFF.
NOTE: Controller returns unit to normal
operation if no keys are pressed for 10 minutes.
Pressing “5” key extends test time by 10 minutes
each time it is pressed (maximum time = 100
minutes). Pressing any other key resets test
time to 10 minutes.
6. • System Test (test multiple components at the same
time):
9-28
5. To activate or change the power limit: Misc. Functions Menu

a. Press F4 key with cursor in the Power Limit menu
line. Cursor moves to end of menu line and flashes. The Misc. Functions menu displays a list of functions that
b. Press F2 or F3 key to scroll to the desired power limit identifies trips and determines how the controller records and
setting: OFF, 13 amps, 15 amps or 17 amps. displays operating information. The following functions are
c. With the desired power limit in the menu line, press available:
and hold F4 key until cursor stops flashing. Cursor • Date Time: Sets the controller time and date. C/F Mode:
stops flashing and new value appears in display. Sets the temperature value (Celsius or Fahrenheit) the
6. To change the length of time power limit is active (ON): controller uses to record and display temperature (includ-
a. Press F2 key to scroll to Power Time menu line (stan- ing historical data).
dard setting = 48 hours). • Cargo Data: Sets important trip information about the
b. Press F4 key with cursor in the Power Time menu line. container and the load in the controller.
An Enter Arrow appears in the menu line and the previ- • Program Version: Displays the current software version
ous time disappears. loaded in the controller: Controller (CTRL), EPROM and
c. Enter new active period in hours. program serial numbers (SER NO).
d. With the correct hours entered in the menu line, press NOTE: The Controller Label on the side of the control box
and hold F4 key until cursor stops flashing. Cursor stops shows the controller serial number and the EPROM
flashing and new value appears in display. version.
7. Press ESC key to exit the Power Management submenu. • Run Time: Displays and sets operating hours for the unit
and components.
Viewing the Misc. Functions Menu

1. Press the F1 key to retrieve current unit performance data
before entering Main Menu.
NOTE: All screens are NOT present on

all units. The screens that display on the
controller are determined by the Unit
Configuration setting.
Misc. Functions Menu Screen Flow Diagram AJA742
9-29
2. Press F2 key to scroll through Main Menu until “MISC. 7. With the correct time entered in the menu line, press F4
FUNCTIONS” appears in LCD display. key. Then press EXIT key to enter time in controller
3. Press F4 key to access the Misc. Functions menu. The memory. Cursor stops blinking and new time appears in
first command in the submenu appears in the LCD dis- display.
play: Date Time. 8. To enter a new date, press F3 key to move cursor to Date
4. 4. Press F2 or F3 key to scroll to the desired function: menu line. Display shows date in and date in
• Date Time “YY.MM.DD” where Y = year, M = month and D = day.
• C/F Mode 9. Press F4 key with cursor in Date menu line. An Enter
• Cargo Data Arrow appears in the menu line and the previous date dis-
• Program Version appears.
• Run Time 10. Enter new date in “YY.MM.DD” where Y = year, M =
5. Press F4 key to access the function selected. month and D = day. Decimal points must be included in
the entry between the year, month and day.
Setting the Date and Time 11. With the correct date entered in the menu line, press F4
key. Then press EXIT key to enter date in controller
1. Press the F1 key to retrieve current unit performance data memory. Cursor stops blinking and new date appears in
before entering Main Menu. the display.
2. Press F2 key to enter the menu list. Press F2 key to scroll 12. Press ESC key to exit the Date Time screen.
to “MISC. FUNCTIONS”.
3. Press F4 key to access the Misc. Functions menu. “Date
Time” appears in the LCD display.
Changing the Temperature Display
4. Press F4 key to access the Date Time screen. Date Time Value (C/F)
screen appears with cursor in the Time menu line. Dis-
play shows time in “HH.MM.SS” where H = hour, M =
minute and S = second.
2. Press F2 key to enter the menu list. Press F2 key to scroll
5. To enter a new time, press F4 key with cursor in Time
to “MISC. FUNCTIONS”.
menu line. An Enter Arrow appears in the menu line and
3. Press F4 key to access the Misc. Functions menu. “Day-
the previous time disappears.
time” appears in the LCD display. Press F2 key to scroll
6. Enter new time in “HH.MM.SS” format. Decimal points
to “C/F MODE”.
must be included in the entry between the hour, minute
4. Press F4 key to access the C/F Mode screen. C/F Mode
and second.
screen appears with cursor in the temperature value menu
NOTE: To scroll backward in the Time or Date menu line,
line. Display shows “C/F MODE o C” where C = Celsius
press and hold the F4 key, then press F3 key. Press F1 key to
and F = Fahrenheit.
return keyboard to “numerical” entry before typing again.
5. To change the temperature value, press F4 key. Cursor
moves to end of menu line and flashes.
6. Press F2 key to toggle temperature value in the menu line
between C and F.
7. With the desired temperature value in the menu line,
press and hold F4 key until cursor stops flashing. Cursor
stops blinking and new temperature value appears in dis-
play.
8. Press ESC key to exit the C/F Mode screen.
9-30
Setting Cargo Data Viewing or Setting Run Time

1. Press the F1 key to retrieve current unit performance data 1. Press the F1 key to retrieve current unit performance data
before entering Main Menu. before entering Main Menu.
2. Press F2 key to enter the menu list. Press F2 key to scroll 2. Press F2 key to enter the menu list. Press F2 key to scroll
to “MISC. FUNCTIONS”. to “MISC. FUNCTIONS”.
3. Press F4 key to access the Misc. Functions menu. “Date 3. Press F4 key to access the Misc. Functions menu. “Date
Time” appears in the LCD display. Press F2 key to scroll Time” appears in the LCD display. Press F2 key to scroll
to “CARGO DATA”. to “RUN TIME”.
4. Press F4 key to access the Cargo Data screen. Cargo Data 4. Press F4 key to access the Run Time screen. The Run
screen appears with cursor in LOC. BRT menu line. Time screen appears with cursor in HEAT menu line.
5. Press F3 key to scroll cursor down through cargo data 5. Press F3 key to scroll cursor down through cargo data
list: list:
LOC. BRT HEAT
CONTENTS COMPRESSOR
DATE (Loading Date) EVAPORATOR HIGH
VOYAGE EVAPORATOR LOW
SHIP CONDENSER
LD PORT (Loading Port) TOTAL
DIS PORT (Discharge Port) 6. To reset an hourmeter or set hours on a replacement con-
COMMENTS troller:
6. To enter text in a cargo data line, press F4 key with cursor a. Press F4 key with cursor in the desired menu line.
in the desired menu line. An Enter Arrow appears and the The Password screen appears.
cursor flashes in the selected line. Enter (type) the desired b. Press F2 key, “A” key (password is “A”), F4 key and
text. When entering information: then EXIT key. An Enter Arrow appears in the hourmeter
• Enter up to 10 characters of text/numbers for each menu- line.
item. c. Enter the desired run time setting (up to 5 characters).
• To scroll backwards in the text box, press and hold the F4 d. When the entry is complete, press and hold the F4 key
key, then the press F3 key. until the cursor stops flashing. The new run time appears
• To delete text from a previous entry, press F4 key and in the menu line.
then the SPACE key. 7. Repeat steps 5 and 6 to reset additional hourmeters.
• To start entry over or quickly return to the beginning of 8. Press ESC key to exit the Run Time screen.
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-
acter in the display, the keypad remains on that “character
level” until another “level” is selected by pressing the F1,
F2, F3 or F4 key.
7. When the desired text entry is complete, press F4 key.
Then press EXIT key. The cursor stops flashing and the
new text appears in the menu line.
8. Repeat steps 5 through 7 until all information has been
entered in the Cargo Data screen.
9. Press ESC key to exit the Cargo Data screen.
9-31
Configuration Menu 3. Press F4 key to access the Configurations screen. Config-

urations screen appears with cursor in the InRange menu
The Configuration menu displays a list of functions that iden- line.
tifies unit operating features and current settings. The follow- 4. Press F3 key to scroll cursor to view or reset the desired
ing functions are available: InRange, Container ID, Contrast, function:
Language, Economy Max, Economy Min, Humidity Option, • InRange: Sets the temperature value for the controller’s
Reefer Type, Zero Current, Supply LH, Controlled Inrange LED and datalogger functions (factory default =
Atmosphere Option, Evaporator Fans, AFAM Setup, Auto 1.5 C [2.7 F]). Enter a value from 0.5 5.0 C (0.9 8.9F).
Configuration and Serial Number. Container ID: Sets the container identification number.
NOTE: When a spare parts controller is installed and Enter up to 11 characters (numbers or letters).
powered up for the first time, an automatic configuration • Contrast: Controller automatically regulates black and
feature detects the unit options installed on a unit. After the white contrast value on LCD display according to display
initial unit power up, the controller turns the Auto temperature. Standard setting is 45. Resetting this value
Configuration feature Off. See “Automatic Configuration of is not recommended. Language: English is only setting
Spare Parts Controller” in this chapter for more currently available.
information. • Economy Max: Sets the Economy mode maximum tem-
perature limit (factory default = 0.2 C). Enter a value
Viewing or Setting Functions from 0 to 5.0 C (0 to 8.9 F).
• Economy Min: Sets the Economy mode minimum tem-
perature limit (factory default = 2.0 C). Enter a value
from 0 to 5.0 C (0 to 8.9 F).
• Humidity Option: View display value (factory default =
NO HUM). Controller automatically activates when a
humidity sensor is installed for more than 1 minute. Set-
through Main Menu until “CONFIGURATIONS”
ting this value is not necessary.
appears in LCD display.
NOTE: All screens are NOT present on all units.The screens that display
on the controller are determined by the Unit Configuration setting.
Configuration Menu Screen Flow Diagram AJA743
9-32
• Reefer Type: Sets the unit model state to CSR20 PS or Datalogger Menu
CSR40SL PS/CSR40 PS. Must be manually set to unit
type on unit serial number plate. The Datalogger menu contains a list of functions that display
• Zero Current: View display ON or OFF value (factory unit operating information recorded in the MP3000 datalog-
default = ON). However, no errors occur if a Zero Cur- ger. The following functions are available:
rent transformer is not installed and configuration is set • Inspect Temperature Log: Displays temperature logs by
to ON. time and date for the Setpoint; Supply (Controlling Tem-
• Supply LH: View display ON or OFF value (factory perature), Return, USDA1, USDA2, USDA3 and Ambi-
default = OFF). Controller automatically activates when ent sensors; humidity sensor; and event flags.
a left hand supply sensor is installed for more than 1 • Inspect Event Log: Displays important event logs by time
minute. Setting this value is not necessary. and date for events such as unit alarms, power On/Off,
• Controlled Atmosphere Option: View display value (fac- setpoint change, clock reset, trip start, defrost, etc.
tory default = NO). Controller automatically activates • Set Log Time: Sets the data log interval (1 minute or 1/2,
when a O 2 or CO 2 sensor is installed for more than one 1, 2 or 4 hours).
minute. • Activate Tripstart: Sets the date and time of the trip start.
• Evaporator Fans: Sets the number of evaporator fans to 2 • Inspect PTI Log: Displays results of last PTI test includ-
or 3. Must be manually set. ing component volt and amps data and sensor tempera-
• AFAM Option: View display ON or OFF value (factory tures. Test values are recorded at the start and end of the
default = ON). Set value to OFF when customer want Chilled and Frozen Mode test.
AFAM door to remain closed.
• Auto Configuration: View display ON or OFF value (fac- Viewing the Datalogger Menu
tory default = OFF). Set value to ON to automatically
configure unit to installed components. See “Automatic
Configuration of Spare Parts Controller” in this chapter
for additional information.
• Serial Number: Sets the unit serial number. Enter up to 11
characters (number or letters). Must be manually set.
through Main Menu until “DATALOGGER” appears in
Required to enable automatic detection of USDA sensors
LCD display.
units with serial number beginning with MAE, MSF or
3. Press F4 key to access the Datalogger menu. The first
MWC prefix.
function appears in the LCD display: Inspect Temp Log.
5. To set a new Configuration screen value:
4. Press F2 or F3 key to scroll to the desired function:
a. Press F4 key with cursor in the desired menu line. The
Inspect Temp Log
Password screen appears.
Inspect Event Log
b. Press F2 key, “A” key (password is “A”), F4 key and
Set Log Time
then EXIT key. An Enter Arrow appears in the hourmeter
Activate Tripstart
line.
Inspect PTI Log
c. Use the general purpose keypad to enter the desired
5. Press F4 key to access the function selected.
value; or press the F3 key to toggle the value to the
desired setting.
d. When the entry is complete, press and hold the F4 Inspect Temp Log
key until the cursor stops flashing. The new value With the unit On/Off switch ON and the LCD display show-
appears in the menu line. ing the standard display (setpoint):
6. Repeat steps 4 and 5 to reset additional configuration val- 1. Press F2 key to enter the menu list. Repeatedly press F2
ues. key to scroll through Main Menu until “DATALOGGER”
7. Press ESC key to exit the Configurations screen. appears in LCD display.
2. Press F4 key to access the Datalogger menu. “Inspect
Temp Log” appears in the LCD display.
3. Press F4 key to enter Temp Log. LCD display shows the
Log Time and the Setpoint, Supply and Return tempera-
tures of the most recent log in the first screen.
9-33
• To scroll through previous logs of the sensor tempera- Inspect Event Log
tures currently in the display, press F3 key. All tempera-
ture logs recorded in the datalogger memory may be With the unit On/Off switch ON and the LCD display show-
viewed on the LCD display. ing the standard display (setpoint):
4. To view additional sensor log and event flag screens, 1. Press F2 key to enter the menu list. Repeatedly press F2
press F4 key again. LCD display shows USDA1, key to scroll through Main Menu until “DATALOGGER”
USDA2, USDA3, Relative Humidity (rH), Ambient, etc. appears in LCD display.
sensor readings, and flags. 2. Press F4 key to access the Datalogger menu. “Inspect
• To scroll through previous logs of the sensor tempera- Temp Log” appears in the LCD display.
tures currently in the display, press F3 key. 3. Press F2 or F3 key to scroll through submenu until
“Inspect Event Log” appears in LCD display.
Event Flags for Temperature Log 4. Press F4 key to enter Event Log. LCD display shows the
T = Tripstart Activated Log Time and the most recent event.
P = Primary Power Off • To scroll through previous event log screens, press F3
D = Defrost in Last Interval key. All event logs recorded in the datalogger memory
O = Temperature Not Inrange may be viewed on the LCD display.
h = Humidity Control Active
E = Evaporator High Temperature Event Examples
H = High Refrigeration Pressure • Controller alarm status (alarms set/cleared)
d = Defrost terminated on time limit • Main power On/Off status (humidity On/Off, temperature
e = Economy mode activated setpoint, and main power Hz)
s = Reefer unit stopped (after PTI) • 12 Vdc battery discharge test (battery voltage, total unit
w = Water-cooled operation (Condenser Fan switch is in and compressor hours if main power On) — this event
the WATER position) logged at once a day
A = Alarm in last interval • Change temperature setpoint (new/old setpoint)
NOTE: All event flags that occurred during a log • Change RH setpoint (new/old RH setpoint)
interval are displayed. • Change RH status (On/Off)
5. Press ESC key to exit the Temp Log. • Event log retrieval
• Temperature log retrieval
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 Screen Flow Diagram AJA744
9-34
• Trip start Set a Trip Start

• New container ID
• PTI start (Unit configuration) With the unit On/Off switch ON and the LCD display show-
• PTI part 1 end (Temperature differences for tests 1, 2, 3 ing the standard display (setpoint):
and heat test 1. Press F2 key to enter the menu list. Repeatedly press F2
• PTI end key to scroll through Main Menu until “DATALOGGER”
• Defrost start (logged with demand or manual defrost appears in LCD display.
only) 2. Press F4 key to access the Datalogger menu. “Inspect
• Defrost end (start time) Temp Log” appears in the LCD display.
5. Press ESC key to exit the Event Log. 3. Press F2 or F3 key to scroll through submenu until “Acti-
vate Tripstart” appears in LCD display.
4. Press F4 key to enter Tripstart function. The date and
Set Log Time time of the last trip start appears in the screen.
With the unit On/Off switch ON and the LCD display show- 5. Press F4 key again to enter a new start of trip date and
ing the standard display (setpoint): time in the log.
1. Press F2 key to enter the menu list. Repeatedly press F2 NOTE: When a PTI Test is completed, the controller
key to scroll through Main Menu until “DATALOGGER” automatically enters a Tripstart in the log.
appears in LCD display. 6. Press ESC key to exit the Datalogger menu.
2. Press F4 key to access the Datalogger menu. “Inspect
Temp Log” appears in the LCD display. Inspect PTI Log
3. Press F2 or F3 key to scroll through submenu until “Set
Log Time” appears in LCD display. With the unit On/Off switch ON and the LCD display show-
4. Press F4 key to enter Temp Log. LCD display shows the ing the standard display (setpoint):
current Log Time interval. 1. Press F2 key to enter the menu list. Repeatedly press F2
5. To enter a new log interval, press F4 key again with cur- key to scroll through Main Menu until “DATALOGGER”
sor in Log Time menu line. Arrow appears in menu line. appears in LCD display.
6. Press F3 key to scroll through a list of log time intervals: 2. Press F4 key to access the Datalogger menu. “Inspect
1 Minute* Temp Log” appears in the LCD display.
1/2 Hour 3. Press F2 or F3 key to scroll through submenu until
1 Hour “Inspect PTI Log” appears in LCD display.
2 Hour 4. Press F4 key to enter PTI Log. LCD display shows the
4 Hour Start Time and PTI test results of the most recent PTI log.
*NOTE: When a 1 Minute Log Test is selected, the • To scroll through additional test results in the log, press
datalogger records unit operating information every minute F3 key.
for 72 minutes. During the 1 Minute Log Test, only the 1 PTI Examples
Minute Log can be retrieved for viewing. The Temperature • PTI stores volt and amps of all power consuming compo-
Log and Event Logs can not be viewed. When the 1 Minute nents
Log Test is complete, the 1 minute log is cleared from the • PTI stores temperatures logged at both the start and end
datalogger memory. The datalogger resumes logging using of Chilled Mode and Frozen Mode capacity tests
the previous log time setting. 5. Press ESC key to exit the PTI Log.
7. When the correct log time appears in the menu line, press
and hold F4 key until cursor stops flashing. The new Log
Time appears in the display.
8. Press ESC key to exit the Temp Log.
9-35
RMM State Menu Manual Emergency Mode Operation

The RMM (Remote Monitoring Modem) State menu displays In the event of an emergency situation where a fatal failure of
the current communications status with a REFCON system: the controller occurs, a manual emergency mode function can
• Offline: No communication between the controller RMM be used to operate the unit. Manual control offers a selection
and a REFCON system. of six operating positions:
• Zombie: The controller has detected a REFCON system • Position 1: Cool 1: Continuous cooling with condenser
master module and is waiting for communication. fan operation and high speed evaporator fan operation.
• Online: The controller RMM is logged in on a REFCON • Position 2: Cool 2: Continuous cooling with condenser
system. fan operation, high speed evaporator fan operation and
continuous liquid injection.
Viewing the RMM State Screen • Position 3: Not Used (Moduload Units Only)
• Position 4: Not Used (Moduload Units Only)
With the unit On/Off switch ON and the LCD display show- • Position 5: Defrost: Heaters are activated (evaporator
ing the standard display (setpoint): fans off).
1. Press the F1 key to retrieve current unit performance data • Position 6: Heat: Evaporator fans operate at high speed to
before entering Main Menu. introduce fan motor heat only into the container (no elec-
2. Press F2 key to enter the menu list. Press F2 key to scroll tric heater operation).
through Main Menu until “RMM STATE” appears in
LCD display. CAUTION: The unit must be cycled manually to
3. Press F4 key to access the RMM State screen. The screen maintain the desired temperature. Monitor container
will show: Offline, Zombie or Online. temperature with an external thermometer.
4. Press ESC key to exit the RMM State screen.
NOTE: The unit cooling capacity on Chill loads can
be reduced by almost closing the suction service
valve when Cool 1 is selected. If the compressor
NOTE: All screens are NOT
overheats, select Cool 2.
present on all units. The
screens that display on the
controller are determined
by the Unit Configuration
setting.
AJA746
AJA745
RMM State Menu Screen Flow Diagram Manual Emergency Control Connections
9-36
To select Manual Control: Replacing the Controller

1. Turn the Unit On/Off switch to OFF.
2. Disconnect the unit power cord from the power supply. 1. Turn the unit On/Off switch OFF. Then unplug the unit
power cord from the power supply.
WARNING: High voltage (460/380 volts) is present on the 2. Disconnect battery power connection from the controller
contactors and relays in the control box. To prevent (top plug on the controller).
dangerous electrical shock, disconnect the supply power to 3. Disconnect the communication cables from the controller
the unit whenever possible when working in this area. and remote monitoring modem.
4. Remove the screws that secure the remote monitoring
3. Disconnect cable no. 2 from the controller and main relay modem to the controller.
board (see electrical schematic). The main relay board 5. Remove the screws that secure the controller to the inside
will now control the unit based on the manual control set- of the control box door.
ting. 6. Remove the controller from the door.
7. Install the replacement controller in the door using the
NOTE: MUST check 2pin plug location on J501 existing hardware. Connect the keyboard cable to the
connections of main relay board to ensure correct unit controller.
operation. 8. Install the remote monitoring modem on the back of the
controller.
4. If necessary, remove 2pin plug from J501 (see decal on 9. Connect the communication cables to the remote moni-
main relay board) and relocate based on the unit operat- toring modem and controller.
ing mode required. 10. Set the software selection switch on the back of the con-
5. Connect the unit power cord to the proper power supply. troller to position “2”.
6. Turn the Unit On/Off switch to ON. Unit will start and
operate. NOTE: Be certain that all connector plugs are fully seated.
7. Check for correct rotation of condenser fan and evapora-
tor fans. Condenser air should be blowing out from the CAUTION: Be sure to enter the container ID before
center of the grille. Evaporator air should be blowing releasing the unit for service. The container ID is required
down through the evaporator coil. If the fans are running to identify the data downloaded from the controller
backwards, the power supply phase must be changed. To datalogger via a laptop computer or a REFCON remote
reverse power phase: communications system.
a. Turn On/Off switch OFF.
b. Disconnect unit power cord from power supply. NOTE: Several programmable features may need to be set
c. Relocate the phase selector terminal plug from J18 to completely configure the unit to customer specifications.
(see decal on main relay board). Relocate from A to Adjust any additional programmable settings to customer
B (B to A) as required. requirements before releasing the unit for service.
d. Connect unit power cord to the proper power supply.
e. Turn the Unit On/Off switch to ON. Check condenser NOTE: If a controller from another unit has been installed,
and evaporator airflow again to confirm correct see “Controller Software Selection” in this chapter to set
fan rotation. software selection dial correctly.
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.
9-37
power up, the controller turns the Auto Configuration feature Flash Loading Controller Software
Off. The Auto Configuration feature detects the following
options and sets the correct value in Configuration menu: Controller software must be flash loaded when software has
• Number of Supply Air Sensors (1 or 2): Controller been revised. To flash load software:
detects left hand and right supply air sensors. 1. Turn the unit On/Off switch OFF.
• Number of Evaporator Fans (2 or 3) 2. Plug cable from a portable computer with controller soft-
• Dehumidify (On or OFF): If controller detects a humidity ware into the data retrieval connector on the control box.
sensor, it then checks for current draw on a dehumidify 3. Press one of the special functions keys to activate con-
valve. troller LCD display on battery power; or turn the Unit
• Humidification (On or OFF): If controller detects a On/Off switch ON.
humidity sensor, it then checks for current draw on an air 4. Press and hold the “7” key and F1 key at the same time.
compressor. LCD display will show “FLASHLOAD ”.
NOTE: If the communications cable is defective or not

Controller Software Selection connected to the download port, the controller will start in
If a replacement controller was removed from another unit, emergency mode and LCD display will show
“EMERGENCY MODE”. Secure cable connection to
check the small dial located on the back of the controller for proceed with flash loading of software.
the correct software selection. Current active software settings
5. Start flash load program on portable computer.
for dial positions are: 6. Flash loading of new software is complete when
• Position 0: All TNE 508 units with Moduload compressor “FLASH LOADING” clears from the LCD display.
7. The controller then checks the new software and loads
• Position 1: All CRR40/TNE 508 units with KVQ valve the new control program into memory.
• Position 2: All CSR20 PS, CSR40SL PS and CSR40 PS
NOTE: If the flash load procedure is interrupted or
units fails, the controller will continue to use the previous
with a stepper motor valve control program.
• Position 7: Unit testing and service only. NOTE: Installing new software does not change any
Changing Software Selection Dial Position configuration settings or the setpoint setting, or
erase the data log currently stored in the controller.
1. Turn Unit On/Off switch OFF.
2. Set dial indicator to correct position.
3. Turn Unit On/Off switch ON. New software selection is
loaded during controller startup.
9-38
Temperature Sensors CAUTION: Sensors are permanently calibrated and can be

checked using an ohmmeter. Ohm readings should agree
Thermistor type temperature sensors are used. Each sensor is with the data shown in the Sensor resistance tables on page
connected to a shielded cable and placed in a sealed stainless 439 and 440.
steel tube. The temperature signal from the sensor is transmit- All sensors should be properly installed:
ted through the shielded cable. Temperature sensors include: • Supply air sensors must be inserted to the bottom of the
• Supply Air, Left Hand sensor tube and completely sealed by the grommet con-
• Supply Air, Right Hand nection.
• Return Air • Left hand supply sensor installs in the sensor tube behind
• Evaporator Coil the compressor.
• Condenser Coil • Right hand supply sensor installed in the sensor tube next
• Compressor Discharge Line to the control box.
• Ambient Air • Return air sensor installs in a grommet between the evap-
orator fans.
A
Resistance Values for Supply, Return,
Evaporator Coil, Condenser Coil and Ambient
Air Sensors
TEMP. C OHMS TEMP. C OHMS
-40 42618 12 3360
-35 32198 14 3094
-30 24532 16 2852
AJA747
B 11in. (279 mm) C -25 18850 18 2632
-20 14618 20 2431
A. Coil Support Brackets -15 11383 22 2347
-12 9838 24 2079
B. Unit Front 26 1925
-10 8941
C. Insert Sensor at least 75 mm into -8 8132 28 1785
coil between tube rows 2 and 3. -6 7406 30 1657
-4 6752 32 1539
CSR20 PS and CSR40SL PS Evaporator Coil -2 6164 34 1430
(Defrost) Sensor Location 0 5634 36 1330
2 5155 38 1239
4 4721 40 1154
6 4329 42 1076
8 3907 44 1004
10 3652 45 970
A
AJA748 A
B 1 to 1.2 in.
(25 to 30 mm)
A. Coil Support Brackets AJA749

B. Unit Front
C. Insert Sensor at least 75 mm into
coil between tube rows 2 and 3. A. Insert Sensor into condenser coil
Table 5: CSR40 PS Evaporator Coil (Defrost)
Condenser Coil Sensor Location
Sensor Location
9-39
• Evaporator coil (defrost) sensor must be placed in the Diagnosis and Repair
middle of the coil and at least 75 mm deep between the
fins. If the unit appears to be operating incorrectly, view any alarm
• Condenser sensor must be placed on the upper left side of codes that may be stored in the controller display memory.
the condenser coil and at lest 70 mm deep between the Diagnose and correct the problem associated with each alarm
fins. code (see “Alarm Codes, Alarm Types and Corrective
• Ambient sensor must be placed on the bottom plate of the Actions” in this chapter).
right forklift pocket.
• Compressor sensor must be placed in the manifold on the NOTE: Defrost can be delayed for 24 hours during unit
discharge tube before the discharge service valve. diagnosis or testing: Press “7” key and F1 key at the same
time from any controller screen display. Press F3 key to
scroll cursor down to DELAY DEF menu line. Then press
Resistance Values for Compressor Discharge Line F4 key, F2 key, “A” key, F4 key and EXIT key. Cursor
Sensor moves to end of line and flashes. Pressure F3 key to toggle
TEMP. C OHMS TEMP. C OHMS OFF to ON. Then press and hold F4 key until cursor stops
flashing.
0 351017 70 15502
2 315288 72 14410 If you have viewed and corrected these problems and the
4 283558 74 13405 unit still appears to be operating incorrectly, eliminate any
6 255337 76 12479 possibility that the problem is caused by failure of compo-
8 230210 78 11625 nents other than the controller.
10 207807 80 10837
12 187803 82 10110 External Cause Checks
14 169924 84 9438 • Poor contact between male and female connector plugs
16 153923 86 8817 (loose connection).
18 139588 88 8242 • Defective wire harness (broken wires, loose connec-
20 126729 90 7710 tions).
22 115179 92 7216 • External electrical causes such as faulty (open or stuck)
24 104796 94 6759 contactors.
26 95449 96 6335 • Malfunction of refrigeration system components.
28 87023 98 5941
30 79428 100 5574
32 72567 102 5234
34 66365 104 4917
36 60752 106 4623
38 55668 108 4348
40 51058 110 4092
42 46873 112 3854
44 43071 114 3631
46 39613 116 3423
48 36465 118 3229
50 33598 120 3047
52 30983 122 2877
54 28595 124 2718
56 26413 126 2569
58 24419 128 2430
60 22593 130 2299
62 20921 132 2176
64 19388 134 2118
66 17961 136 1953
68 16689 138 1852
9-40
SECTION 10
Container
Service Bulletins
10-1
Section 10-Container Service Bulletins
SERVICE BULLETIN
SUBJECT: Index for Container Service Bulletins

BULLETIN NO. Index
DATE: February 12, 1999
Bulletin No. Subject
C-001 Procedure for Converting Thermo King CF-11 C-018 Supply (Discharge) Air Sensor Position in
Sensor Tube on CSR-40, CRR-40, TNE 508 and
Container Units from R-12 to R-401 B (MP66)
C-002 Compressors Oils TNE 508 SCII Units
C-003 New Pocket Reference Cards C-019 PVC Breather Vent on se 2.2 Engines
C-020 Revised Operating Instructions for
C-004 Unit Sight Glass Balls Sticking on HFC Units,
Thermo King P/N 66-7420 Communications Tester/Amplifier (P/N 204-901)
C-005 Refrigeration System Cleanup When Compressor C-021 CSR and CRR Leak Charts
C-022 Operating Instructions for µP-D Tester, P/N 204-911
Oil is Contaminated (Dark or Discolored)
C-006 Copeland Bypass Oil Filter C-023 Use Separate, Dedicated Service Tools for
(Thermo King P/N 66-7462) -Change Requirements HCFC/CFC Refrigerants and HFC Refrigerants
C-024 µP-D Controller Emergency Bypass Procedure
C-007 Thermo King Expansion Valve (TXV)
Setting: After Unit Conversion from R-12 to R-134a; C-025 Normal Operating System Pressures for CSR Units
All Units Factory Equipped with R-134a; C-026 Auto-Restart Operation on Smart Generator Sets
C-027 Sealed Expansion Valve on Sea-Land CSR Units
All Units Including Standard R-12 Units
C-008 Thermo King Refrigeration System Cleanup C-028 New Dehydrator, P/N 66-9015, for All CF-11
Procedure Series Units
C-029 CSR Versus CRR Service Guide and
C-009 Leak Checking Compressor Shaft Seal on
Thermo King X426 and X430 Compressors Refrigeration System Service Procedures
C-010 µP-A+ Controller Configuration Setting and C-030 Injection Pump Timing Bolt Change to Provide
Positive Fuel Shutoff on CG and SG (Smart)
Minimum Software Version Requirement
C-011 CF-11 Sight Glass Moisture Indicators with Generator Sets
R-134a and R-404A C-031 Thermo King 11.71 (or above) Software Release
C-032 Check Mounting Bolt Torque of Suction Flange
C-012 Operating Instructions for Communications
Tester/Amplifier (P/N 204-901) with Power Connections on CRR Units with “29K” in the Serial
Cable/Battery Number (xxx29Kxxx)
C-033 Procedures for Belt Tension Adjustment on
Connector (P/N204-937)
C-013 Operating Instructions for Communications Thermo King Gensets
Tester/Amplifier (P/N 204-901) with Power C-034 Use the Thermo King EXTRANET Site on the World
Wide Web to View and Download Files for Container
Cable/Battery
Connector (P/N204-938) Products
C-014 µP-G Controller Unit Operating Information for C-035 PC-PAC V3.3 Upgrade Now Available from the Public
CG-11 Generator Sets File Download Center at the Thermo King
C-015 CF-11 Heaters EXTRANET Site
C-037 µP-D Controller Replacement
C-016 CF-11 Condenser Coil Cleaning
C-017 Measuring Compressor Crankshaft End Play C-038 Unit and Customer Configuration Settings for
on Thermo King X426 and X4340 Compressors µP-D Controller
C-039 Unit Health Check for CSR Hermetic
Used in CF-11
and CF-111 Container Refrigeration Units Refrigeration Systems
10-2
SERVICE BULLETIN
SUBJECT: Procedure for Converting Thermo King CF-II Container

Units from R-12 to R-401 B (MP66)
BULLETIN NO. C 001
DATE: December 6, 1996
CAUTION: Only CF-II units that have been 5. Refill the compressor with a charge of Thermo King oil
maintained with genuine Thermo King replacement TK P/N 67-404. For example, a full oil charge for X426
parts should be considered for conversion and X430 compressors is 4 qts. 6 oz. (3.96 liter).
6. Install a new filter drier (dehydrator), TK P/N 66508, in
PRIOR TO CONVERSION CAREFULLY CHECK THE unit.
UNIT FOR CORRECT OPERATION AND FULL 7. Install a new 350 psi (2415 kPa) high pressure cutout
COOLING CAPACITY. ALL UNIT DEFICIENCIES switch, TK P/N 41-1626, in unit.
MUST BE CORRECTED BEFORE CONVERSION. 8. Evacuate the refrigeration system following the proce-
dures in the manual “Principles of Evacuation for Field
COMPLIANCE WITH APPLICABLE ENVIRONMEN- Application”, TK 40612.
TAL AND SAFETY REGULATION STANDARDS IS 9. Charge the unit with R-401B. Add the amount of refrig-
ESSENTIAL. erant shown on the unit nameplate (e.g. 100% of the
R-12 charge).
Parts Required: 10. Operate unit on FULL COOL for 10 minutes and confirm
• R-401 B (MP66) refrigerant; charge only as a liquid that oil level is correct.
• Refrigerant Oil, Alkyl Benzene (AB), TK P/N 67-404 11. Check for leaks and install decals for R-401B (Label P/N
• High Pressure Cutout Switch, TK P/N 41-1626 91-7740) and Thermo King compressor oil P/N 67-404
• Filter Drier, TK P/N 66-508 (Label P/N 91-5887).
• Label for R-401 B, TK P/N 91-7740 12. Correct serial plate to show new refrigerant.
• Label for Alkyl Benzene Oil 67-404, TK P/N 91-5887 13. Check the expansion valve superheat setting. See quick
Tools Required: reference pocket card, TK41085, for step-by-step instruc-
• Refrigerant Recovery Machine tions on verifying expansion valve superheat setting.
• Evacuation Station Superheat reading should be 6 F (3.4 C) on all CF-II
• Gauge Manifold Set units.
• Manual, TK 40612, “Principles of Evacuation for Field
Application”
NOTE Inspect all refrigerant lines. All composition fabric/

rubber type hoses MUST be upgraded to copper tubing,
metal type vibrasorbers, nylon lined refrigerant hoses, etc.
1. Install refrigeration gauge manifold set.
2. Operate the unit in Full Cool with 50 F (10 C) or warmer
air over both the condenser and evaporator coils for 60
minutes. This will return the maximum oil charge to the
compressor.
3. Stop the unit and reclaim the refrigerant.
4. Drain the oil from the compressor.
10-3
SERVICE BULLETIN
SUBJECT: Compressor Oils

BULLETIN NO. C 002
CAUTION: Compressor oils that are NOT LISTED here are NOT ACCEPTABLE for use in Thermo King
CF-II units. Compressor oil that is used in refrigeration equipment manufactured by OTHER COMPANIES is
also NOT ACCEPTABLE for use in Thermo King CF-II units.
TK PIN 203-433, Mobil EAL 22 CC (POE) Oil TK P/N 203-426, Mobil EAL 32 (POE) Oil
• CF-II units equipped with 3DS Copeland compressors • CF-II refrigeration units equipped with an X426 or X430
require polyol ester (POE) oil, TK P/N 203-433. ONLY compressor and R-134a must use a polyol ester (POE)
Mobil EAL Arctic 22 CC compressor oil contains the oil. Both Thermo King polyol ester (POE) oils, TK P/N
additive package required all 3DS Copeland compres- 203-426 and TK P/N 203-433 are approved and recom-
sors. mended for use in X426 and X430 compressors.
CAUTION. DO NOT add or mix ANY other CAUTION: DO NOT use TK PIN 203-426 or 203433
compressor oil to units equipped with a 3DS (POE oils) with R-12 refrigerant.
Copeland compressor. Other Thermo King polyol
ester (POE) oils (i e. TK PIN 203-426) DO NOT CAUTION: DO NOT use TK P/N 203-426 (POE oil) in
contain the Copeland required additive and should a Copeland 3DS compressor
NOT be used.
TK P/N 67-404, Alkyl Benzene (AB) Oil
• Through laboratory and field testing, Thermo King has • CF-II refrigeration units equipped with an X426 or X430
determined that Mobil EAL Arctic 22 CC compressor oil compressor and R-12 use synthetic alkyl benzene (AB)
also performs satisfactorily in CF-II units equipped with oil, TK P/N 67-404.
X426 and X430 compressors and R-134a.
CAUTION: DO NOT use alkyl benzene (AB) oil with
NOTE: TK P/N 203-433 pol ester (POE) oil is R-134a refrigerant. DO NOT use alkyl benzene (AB)
designed for use with HFC refrigerants like R-134a. oil in a Copeland 3DS compressor.
Therefore, this oil is PREFERRED for use in ALL
Thermo King CF-II units that use R-134a.
AJA516
X430 & X426 Compressors with:

Copeland 3DS Compressor: R-12 Use AB Oil, TK P/N 67-404 ONLY;
Use ONLY Polyol Ester Oil R-134a Use POE Oil, TK P/N 203-426 OR
(POE) TK P/N 203-433 POE Oil, TK P/N 203-433
10-4
SERVICE BULLETIN
SUBJECT: New Pocket Reference Cards

BULLETIN NO. C 003
Three (3) Quick Reference Pocket Guide cards have been printed by Thermo King to make dealers and customers more familiar
with proper CF-11 container unit service procedures. All technicians should have one of each card to use for reference. Refer-
ence cards can be ordered from the Thermo King Publications Department, 314 W. 90th Street, Minneapolis, MN 55420.
The quick reference cards are:

• Checking and Adjusting CF-II Expansion Valve Superheat Setting, TK 41085
• Checking Refrigerant Charge on CF-II Units, TK 41081
• Temperature/Pressure Relationship (required for adjusting superheat), TK 40852
de
G ui
et
ock 085
P 41
S ee TK
de
Gui
et
ock 081
P 41
S ee TK
e
uid
tG
c ke 52
o 08
e e P TK4
S
10-5
SERVICE BULLETIN
SUBJECT: Unit Sight Glass Balls Sticking on HFC Units,

Thermo King P/N 66-7420
BULLETIN NO. C 004
DATE: December 6,1996
It has been reported that receiver tank sight glass ball(s) have been “sticking” on some units charged with HFC refrigerant R-
134a. This sticking may occur in a refrigeration system that contains residue. The residue accumulates on the sight glass ball(s),
causing the ball(s) to “stick” to the sight glass (es).
If this sticking occurs on newer units that are under warranty, the sight glass (es) (Thermo King P/N 66-7420) should be changed
and handled as a standard warranty claim.
NOTE: The refrigerant charge level may be verified in a system with a “stuck” sight glass ball by shining a light on the sight
glass to view the refrigerant level.
Two Sight Glass Receiver Tank Single Sight Glass Receiver Tank
10-6
SERVICE BULLETIN
SUBJECT: Copeland Bypass Oil Filter (Thermo King P/N 66-7462)

Change Requirements
BULLETIN NO. C 006
The following new bypass oil filter change guidelines apply

to all Thermo King CF-II units equipped with a COPELAND
COMPRESSOR and a COMPRESSOR BYPASS OIL
FILTER.
When to change the bypass oil filter!

The compressor bypass oil filter, TK P/N 66-7462,
should be changed after a system cleanup or when the com-
pressor oil is contaminated and requires changing (typically
when compressor oil becomes discolored).
NOTE: Refer to Thermo King Container Service

Bulletin No. C 005 regarding dark or discolored oil.
NOTE: Refer to Thermo King Container Service

Bulletin No. C 008 regarding system cleanup.
Copeland 3DS
Compressor
Bypass Oil Filter
10-7
SERVICE BULLETIN
SUBJECT: Thermo King Expansion Valve (TXV) Setting:

• After Unit Conversion from R-12 to R-134a
• ALL Units Factory Equipped with R-134a
• ALL Units Including Standard R-12 Units
BULLETIN NO. C 007
The Expansion Valve (TXV) settings have been changed by After converting a unit from R-12 to R-134a:
some technicians in an attempt to achieve lower box tempera- Use this quick reference pocket card, TK41085, to assure that
tures. This is NOT a recommended Thermo King mainte- the expansion valve is correctly set. After the correct setting is
nance practice! verified, use Loctite on the expansion valve cap threads to
Expansion valves come pre-set from the Thermo King fac- seal cap in place!
tory and rarely require adjustment
One of the times adjustment IS required is after a unit conver- ALL Units Factory Equipped with R-134a:
sion from R-12 to R-134a. Thermo King has created a quick If an expansion valve is suspected of being set incorrectly,
reference pocket guide card “Checking and Adjusting CF- CHECK the setting per the procedure on pocket guide card
11 Expansion Valve Superheat Setting” (TK 41085) which (TK 41085) mentioned above. After the correct setting has
outlines and illustrates the correct method of checking and been verified, use Loctite on the expansion valve cap threads
setting the expansion valve. to seal cap in place!
ALL Units Including Standard R-12 Units:

If an expansion valve is suspected of being set incorrectly,
CHECK the setting per the procedure on pocket guide card
(TK 41085) mentioned above. After the correct setting has
been verified, use Loctite on the expansion valve cap threads
de
ui to seal cap in place!
etG5
k
P o c 4108 Before breaking a cap loose that has been sealed with Loctite,
S ee T K check the unit superheat according to the method outlined on
the quick reference card (TK41085) mentioned above. If it is
absolutely necessary to reset a sealed unit, make sure that you
again reseal the cap with Loctite.
NOTE: Once the expansion valve Is properly adjusted, it

should not be necessary to reset expansion valve superheat!
10-8
SERVICE BULLETIN
SUBJECT: Thermo King Refrigeration System Cleanup Procedure

BULLETIN NO. C 008
The following procedure is required when a Thermo King NOTE: When servicing R-134a refrigeration systems,
equipped unit has had a system failure, which results in severe special self-sealing, quick disconnect fittings for R- 134a are
system contamination. required. If your evacuation station is currently equipped
EVACUATION AND CLEANUP OF THE REFRIGERA- with 1/4” flare fittings, the following R-134a connectors are
TION SYSTEM required. The connectors attach to the R-134a service
fittings on the unit and accept 1/4-flare fittings.
Unit Preparation and Hookup • TK P/N 204-791, R-134a Coupler Red (High Side)
• TK P/N 204-792, R-134a Coupler Blue (Low Side)
CAUTION: Do not attempt to evacuate a unit until 5. Rotate the low loss fitting hand wheels clockwise to open
the unit is leak free. A unit with less than a full (depress) service valve fittings to the service gauge
charge of refrigerant should be thoroughly leak hoses.
tested. Any leaks found must be repaired. 6. Mid-seat the receiver tank outlet valve. Replace valve
stem cap on receiver tank outlet valve.
1. Recover all refrigerant from the unit and reduce the unit 7. Open Evacuation Station valves (Vl, V3, and V4). It is
pressure to the proper level (US Federal Law requires a 5 only necessary to open valve V2 when a reading on the
to 1 0 inch vacuum, depending on the recovery equip- Micron Meter is desired. This is especially true when
ment used). starting to evacuate a unit and large amounts of moisture
2. Break vacuum with nitrogen and equalize system pres- and oil will be passing by the sensor.
sure to 0 psig (O kPa). Replace the filter drier (dehydra- 8. Open the vacuum pump Iso-Valve built into the pump
tor). housing below the handle. It is recommended that the lso-
3. Confirm that the Evacuation Station functions properly Valve be kept open at all times and that the valve Vl be
and determine “Blank Off” Pressure. The “Blank Off” used for isolating the pump from the refrigeration system.
Pressure of the Vacuum Pump is the deepest vacuum that 9. If connecting a refrigerant tank and gauge manifold to the
the vacuum pump can attain when isolated from the rest evacuation station, close the gauge manifold and refriger-
of the system. ant tank valves to prevent refrigerant from being drawn
from the tank.
If a vacuum pump (isolated from a system) is started and
the Micron Meter responds quickly by going to a deep NOTE: If the refrigerant tank and gauge mani-fold hoses
vacuum (200 microns or less), the operator can be confi-
do not have seal-sealing, low loss fittings, be sure to purge
dent that the pump and oil are in good condition. If the
the hoses.
vacuum pump fails to reach a deep vacuum within 5 min-
utes, the pump oil is contaminated or the pump is faulty. 10. Energize the liquid line solenoid valve (if so equipped)
Change the pump oil first to see if the rate of reaching a using a separate 24 Vac power source.
deep vacuum is improved. If necessary, repair or replace
the pump.
4. Connect the Evacuation Station and refrigerant tank with
gauge manifold (optional) to the unit as indicated on the
diagram on the following page. Connect evacuation
hoses to the suction, discharge and receiver tank service
connections.
10-9
Special
self-sealing,
quick connect
V-4 couplers are
required for
Sensor R-134a units
V-3
Micron Meter
V-2
Calibration Standard V-1
Gas Ballast Valve
Iso Valve
Evacuation Station
and Unit Hookup AJA517
Two Stage Vacuum Pump
To 110 VAC or 220 VAC Power
Unit Evacuation When the system reaches 1,000 microns, close the Gas
1. Turn on the Vacuum Pump. Open the Gas Ballast Valve Ballast Valve.
located on top of the pump housing in front of the handle
(the valve is fully open at two turns counterclockwise). Evacuate the system to 500 microns to achieve a final equilib-
rium pressure of 2000 microns or less. The final equilibrium
pressure is determined with the Thermo King Evacuation Sta-
NOTE: The Gas Ballast Valve is opened to purge a small
tion using the following procedure (called a pressure-rise
amount of atmospheric air through the pump’s exhaust
test):
chamber This extra volume of air helps exhaust moisture in
the form of vapor from the pump and will substantially a. Evacuate the system using the Evacuation Station until
extend the life of the pump oil. the vacuum level reaches 1000 microns. Then close the
pump Gas Ballast Valve.
b. Continue evacuation to 500 microns or until vacuum
stabilizes at its lowest level. Contamination may delay
10-10
reaching the lowest level for a period of several or more • system that rises above 2000 microns but stabilizes
hours. below atmospheric pressure is probably contaminated
with moisture or has refrigerant out-gassing from the
c. Close valve Vl to isolate the vacuum pump from the compressor oil. Additional evacuation is required.
system. • A system that continues to rise without stabilizing has a
leak and must be repaired.
d. Observe the vacuum level on the Micron Meter. 5. If the vacuum level remained below 2000 microns for
five minutes, the unit is ready to charge.
When the Meter has stabilized, the value indicated on the
Micron Meter is the equilibrium pressure. This reading must Pressure Rise Test
be 2000 microns or less. 1. Evacuate the system and close valve Vl. With valves V3
and V4 open, the pump is isolated and the system is held
under a vacuum. If the Micron Meter rises, one of the fol-
NOTE: The presence of refrigerant in the compressor oil
lowing conditions exists.
may prevent a low vacuum reading from being achieved
Compressor oil can continue to out-gas for long periods of Leak: Watch the movement of the Micron Meter needle.
time. If the needle continues to rise until it reaches atmospheric
2. If the vacuum level appears to stall above 500 microns, pressure, it is an indication that a leak exists somewhere
back seat the discharge service valve (if so equipped) or in the system. When a leak is in a system, the vacuum
rotate the discharge hose coupler wheel counterclockwise will eventually stabilize at atmospheric pressure. See the
to back the stem out of the discharge service fitting. Then diagram below.
back set the suction service valve (if so equipped) or
rotate the suction hose coupler wheel counterclockwise to Moisture: When the needle indicates a rise and then sta-
back the stem out of the suction service fitting. This iso- bilizes at a level below atmospheric pressure, it is an indi-
lates the compressor from the Micron Meter. Observe the cation that the system is vacuum tight, but is still wet and
Micron Meter. requires additional dehydration and pumping time. See
• A drop in pressure indicates that the compressor oil is the diagram below.
out-gassing and further evacuation is necessary.
• An increase in pressure indicates that a leak exists or Pressure Rise Test Evaluation
there is moisture in the system. Perform a “Pressure Rise
Test” and evaluate. Factors Affecting the Speed of System Evacuation
3. Close valve Vl when desired vacuum level has been It is almost impossible to state the exact amount of time
reached. required to evacuate any system. Some factors that can influ-
4. Wait five minutes and read the Micron Meter. ence evacuation time are listed below.
• A system that is leak free and dry will remain below 2000 • How large the system is
microns for five minutes. • The amount of moisture contained in the system
• The ambient temperature
• Internal restrictions within the system
• External restrictions between the system and the vacuum
Atmospheric pump
Pressure
Atmospheric
Pressure
Vacuum level
stabilizes at
atmospheric pressure
Absolute
Vacuum level
Vacuum
stabilizes below
Time Absolute
atmospheric pressure
Vacuum
Time
Pressure Rise Test Evaluation
10-11
Hose size, both diameter and length, affect evacuation times. 10. Set the refrigerant tank for liquid removal. Open the hand
Laboratory tests show that the evacuation time can be signifi- valve on the tank.
cantly reduced by larger diameter hoses and shorter hoses. To 11. With the unit OFF, open the gauge manifold hand valve
obtain optimum pumping speed, keep hoses as short as possi- and charge liquid refrigerant into the system.
ble and as large in diameter as possible. For example, it takes 12. Close the refrigerant tank hand valve when the correct
eight times as long to pull a given vacuum through a 1/4-inch amount (by weight) of refrigerant has been added or if
(6 mm) diameter hose as it does through a 1/2-inch (12 mm) the system will take no more liquid.
diameter hose. It takes twice as long to pull a vacuum through The unit is now ready to have the Evacuation Station removed
a 6-foot (1.8 m) long hose as it does through a 3-foot (0.9 m) (described in the following steps, “Evacuation Station
long hose. Removal”).
Heat Saves Time

A useful and practical time saver is the application of heat to Evacuation Station Removal
the system. Increasing the temperature of the compressor oil 1. Back seat the receiver outlet and discharge service
and refrigerant will speed up the vaporization of any water valves.
present in the system.
Heat lamps, electric heaters, or blowers can be applied to the 2. Rotate the discharge hose and receiver tank hose coupler
compressor crankcase and other parts of the system to wheels counterclockwise to close the valves.
increase the temperature of the refrigerant and compressor oil.
3. Close the refrigerant tank hand valve.
Unit Charging (from an Evacuated Condition)
1. Close valve V4. 4. Operate the unit in cool mode.
2. Open the Gas Ballast valve. 5. Open the hand valve at the gauge manifold and read suc-
tion pressure.
3. Stop the vacuum pump.
4. Close the suction service valve or rotate the suction hose 6. Close the receiver tank outlet valve and pump down the
coupler wheel counterclockwise to back the stem out of system to 3 to 5 psig (21 to 35 kPa).
the service fitting. This isolates the suction line hose from
the system. 7. Rotate the suction hose coupler wheel counterclockwise
to close valve on suction service fitting. Back seat the
5. The discharge valve and receiver outlet valves remain suction service valve (if so equipped).
mid-seated.
8. Stop the unit. Remove the hoses from the suction, dis-
6. Energize the liquid line solenoid valve (if so equipped) charge, and receiver tank service connections.
using a separate 24 Vac power source.
9. Open the receiver tank outlet valve. Cap the receiver out-
7. If you did not connect the refrigerant tank to the evacua- let service port and valve stem.
tion station prior to evacuation, connect the refrigerant
tank with a gauge manifold to the evacuation station now 10. Install a gauge manifold set and check the refrigerant
as shown in the Evacuation Station and Unit Hookup dia- charge per the procedure on pocket guide card (TK
gram. 41081), “Checking Refrigerant Charge on CF-II Units”.
NOTE: If the refrigerant tank and gauge manifold hoses do • If the unit is fully charged, perform a functional check
not have seal-sealing, low loss fittings, be sure to purge the out.
hoses.
• If the unit has a partial charge, add refrigerant to the unit
8. Weigh the tank of refrigerant. per the procedure on pocket guide card (TK 41081) men-
9. Check the unit data plate for the required weight of tioned above.
refrigerant charge then subtract the amount of the charge
to be input to your unit from the total weight of the tank
of refrigerant. This provides final tank weight after the
unit receives a full system refrigerant charge.
10-12
SERVICE BULLETIN
SUBJECT: Leak Checking Compressor Shaft Seal on Thermo King

X426 and X430 Compressors
BULLETIN NO. C 009
Before changing a compressor seal, the following information must be considered:

• The presence of some oil around the seal plate is normal.
• The technician must be able to differentiate between normal oil seepage which is usually dirty or dusty and a fresh stream of
oil which continues to appear and flow until it drips.
• A seal may gradually leak enough refrigerant to cause a system failure with no evidence of heavy oil seepage.
• The compressor seal on a unit that has not been operated for extended periods of time may leak small amounts of refrigerant.
However, the seal often recovers its normal sealing capability after the unit is operated and lubrication occurs.
• Like other refrigerant leaks, a shaft seal leak can be masked by the presence of oil in the leak passage. It can take as long as
30-45 minutes for the leak to appear in a large enough quantity to be measured.
• A high quality, very accurate leak detection device (TK P/N 204-712, 11 OV) and the discipline to follow proper leak test
procedures are essential. A unit with a low refrigerant charge should be thoroughly leak checked.
How to Leak Check the Compressor Shaft Seal

1. Blow out the seal area to remove any residual refrigerant and remove excess oil with solvent.
2. Calibrate your leak detector (TK P/N 204-712) for the medium setting (1/2 oz./year).
3. Start below the seal plate and slowly move the probe up towards the compressor seal. Avoid getting dirt or oil in the probe.
4. If the leak detector senses a leak on the medium setting, withdraw the probe, allow the leak detector to stabilize and check
again.
5. Re-calibrate the leak detector for the large setting (5 oz./year) and repeat steps 3 and 4.
6. If the leak detector senses a leak on the large setting, the unit should be operated in MAXIMUM COOL for 10 minutes or
more. Stop the unit and blow out the seal plate area. Allow unit to stand for 1/2 hour.
NOTE: This time can be used to leak check the rest of the unit.
7. Repeat steps 2, 3, 4, and 5. If the leak detector does not sense a leak on the large setting, the shaft seal is okay unless a fresh
stream of oil reappeared.
10-13
SERVICE BULLETIN
SUBJECT: µP-A+ Controller Configuration Setting and

Minimum Software Version Requirement
BULLETIN NO. C 010-4
DATE: August 7, 1998
The configuration select function has now been moved into the user “Guarded Access” menu. To change the configuration of the
µP-A+ controller:
NOTE: To set the configuration block using the µP-A + controller keypad, the controller MUST be equipped with software
version 05.00.14 or above.
1. Install a new or remanufactured µP-A+ controller.
2. Connect unit to 230V or 460V main power and turn Unit On/Off switch ON position.
NOTE: If power source is not available, operate the controller using battery power if necessary, connect 12 Vdc battery to
battery jack and press [SELECT] key on controller keypad.
3. a. Determine which security code you must enter to access the Guarded Access submenu.
Code Unit
0007 All units (except those listed for code 0013)
0013 CF-II M32E, M32F, M32G and M32H
b. Determine which configuration number is required for your unit:
Number Customer CF-11 Unit Model Minimum Software Version Required

02 Sea-Land M19.7, M19.9 0.500.15 (or above)
02 Sea-Land M19.8, M19.10 05.00.19 (or above)
03 Boyer Alaska M39.2 05.00.15 (or above)
03 TOYO M38 05.00.15 (or above)
04 Crowley M39 05.00.16 (or above)
05 APL, Dole, Genstar M37.3, M37.5, M37.6, M37.7 05.00.15 (or above)
06 OOCL M32E, M32F, M32G, M32H 05.00.18 (or above)
07 P&O M40, M40.1 05.00.15 (or above)
08 Matson M41, M41.1 05.00.21 (or above)
09 PIL M46 05.00.14 (or above)
09 CPV M37.9 05.00.19 (or above)
09 Young Brothers M51 05.00.14 (or above)
09 Wide Shine M52,M52.1 05.00.15 (or above)
09 Thermocar M54 05.00.14 (or above)
10 OOCL Scroll R404A M42.1 05.00.15 (or above)
11 P&O Scroll R134a M42 05.00.13 (or above)
12 Linden Trans M39.3 05.00.15 (or above)
13 HMM M53, M53.1 05.00.17 (or above)
14 PIL Scroll R 134a M46.1 05.00.20 (or above)
NOTE: The (P-A+ controller must be equipped with the minimum software version (or a more recent version) shown in the table above to
properly regulate unit operation. It is NOT necessary to replace a more recent software version (05.00.21 for example) with a previous version
(05.00.16 for example).
10-14
4. Press [SELECT] key on controller keypad to enter the MAIN MENU. The display will show
5. Press the [DOWN] arrow key to scroll to “GrAc.”
6. Press the [SELECT] key with “GrAc” appearing in the SET POINT display. The display will show “0000” in the TEMP
CODE display with the left digit flashing on and off.
7. Enter Guarded Access code (see step 3a).

a. Press and release the [SELECT] key to move the flashing digit to the digit you want to change.
b. With the digit you want to change flashing, press the [UP] or [DOWN] arrow key to scroll the digit to the correct number.
c. Repeat steps 6a and 6b for each digit you want to change.
8. Press the [ENTER] key with the correct security code entered in the display. The display will show “Cld 6 XXXX”.
9. Press the [UP] or [DOWN] arrow key to scroll to the “Cb XX” display.
10. Press the [SELECT] key with “Cb XX” appearing in the display to change the configuration number. The EDIT LED will
flash.
11. Press the [UP] or [DOWN] arrow key to scroll to the required configuration number (see step 3b).
12. With the required configuration number appearing in the TEMP/CODE display, press [ENTER] key. The display will show
“LOAD” for 3 seconds. The controller will then perform a shutdown and restart. After unit start-up, the controller will return
to display the current set point and controlling air sensor temperature.
13. To verify that the correct configuration block setting was loaded, press the [ENTER] key. The controller will display the
application software version, configuration block version and boot block software version currently stored in the micropro-
cessor memory.
10-15
SERVICE BULLETIN
SUBJECT: CF-11 Sight Glass Moisture Indicators

with R-134a and R-404A
BULLETIN NO. C O11
DATE: January 17,1997
Thermo King Corporation has introduced a new sight glass
with moisture indicator on all CF-II stainless steel receiver Moisture Indicator:
tanks and water-cooled condenser receiver tanks. This sight Light Green = Dry
glass has been developed especially for the lower moisture Yellow = Wet
requirements of refrigeration systems using Polyol Ester
(POE) compressor oil and R-404A or R-134a. Outer Ring is Color Coded.
Compare to Indicator.
NOTE: It is important that service personnel operate the Downfalls Sight Glass (All Brass)
CF-II unit for 2-3 hours before reading the moisture
indicator and determining that moisture is present in a Therefore, to ensure an accurate moisture level reading, oper-
ate the unit for 2-3 hours. This thoroughly circulates refriger-
system.
ant and compressor oil through the system and raises the
Moisture indicators on CF-II units that stand idle for several refrigerant temperature above 100 F (38 C). If the moisture
hours in ambient temperatures below 75 F (24 C) may indi- indicator remains yellow after 2-3 hours of system operation,
cate a wet (yellow eye) condition. This occurs because the replace the filter drier. Then operate the unit 2-3 hours more
solubility of moisture in R134a or R-404A becomes lower as and recheck the moisture indicator. If the moisture indicator
the refrigerant temperature drops. As moisture separates from still remains yellow, evacuate the refrigeration system and
the refrigerant, the sight glass indicator senses this moisture recharge with correct refrigerant.
concentration and may turn slightly yellow.
300
Refrigerant (ppm)
200
Moisture in
Wet
100
Dry
0
(C) 0 5 10 15 20 25 30 35 40 45 50 55 (°C)
(F) 32 41 50 59 68 77 86 95 104 113 122 122 (°F)
Temperature
Danfoss Sight Glass Moisture Level Indication

In Relation to Refrigerant Temperature
10-16
SERVICE BULLETIN
SUBJECT: Operating Instructions for Communications Tester/

Amplifier (PN204-901) with Power Cable/Battery
Connector (PN 204-937)
BULLETIN NO. C 012
DATE: February 5,1997
TOOLS Power Cable/Battery Connector
• Communications Tester/Amplifier Adapter, The Power Cable/Battery Connector provides 12 Vdc power
PN 204-901 from a remote battery pack or the on-board backup battery
• Power Cable/Battery Connector, PN 204-937 through the receptacle located on the microprocessor control-
• Ribbon Cable, PN 204-936 ler (if the unit is equipped with a data logger battery and bat-
tery charger) to the Communications Tester/Amplifier
PURPOSE Adapter.
• Amplify serial communication signals to download data 12 Vdc Power Receptacle
from a µP controller.
• Monitor serial communication signals for µP, µP-A or
µP-A+ controllers; or IRMU or SRMU remote monitor Back
Front
units.
PWR = Power On LED
DESCRIPTION TXD = Transmit Data LED
RXD = Receive Data LED
Figure 1. Communications Test/Amplifier
Communications Tester/Amplifier Adapter
Adapter, PN 204-901
The Communications Tester/Amplifier Adapter contains indi- Remote Battery Pack
cator LEDs that verify proper operation of the serial port cir- Connector
cuitry during serial communications. Socket
• The GREEN POWER LED lights when 12 Vdc power is Controller Battery
supplied to the Communications Tester/Amplifier Connector Socket
Adapter by the VREC circuit of the microprocessor con- Communications Tester/Amplifier
troller, or by the Power Cable/Battery Connector. This Connector Socket
indicates the cable connections are good and 12 Vdc Figure 2. Power Cable/Battery
Connector, PN 204-937
power is available to operate the LEDs on the Communi-
cations Tester/Amplifier Adapter and to amplify signals 15-Pin Male Connector
for communications with UP controllers.
• The GREEN TXD (TRANSMIT) LED lights when
PCPAC software sends a message to the microprocessor
controller. This indicates the laptop computer has suc-
cessfully sent a serial communications signal to the con-
troller.
• The RED RXD (RECEIVE) LED lights when the con-
troller sends a reply signal to the laptop computer. This
indicates the controller has successfully sent a serial com- Ribbon Cable
munications signal (download) to the laptop computer. The Ribbon Cable provides easy installation and viewing of
the Communications Tester/Amplifier Adapter LEDs.
10-17
OPERATING INSTRUCTIONS NOTE: The communications tester/amplifier adapter

Using the Communications Tester/Amplifier with µP MUST be installed in SERIES with the µP controller and
Controllers to Amplify Communications Signals and laptop computer Otherwise, the communications tester/
Monitor Communications amplifier adapter will NOT be able to amplify the
1. Insert the communications tester/amplifier adapter into communications signals.
the 15 pin female serial port connector on the front of a
3. Connect the power cable/battery connector to a 12 Vdc
(P controller. The viewing angle of the tester may be
power source.
adjusted by installing the ribbon cable (supplied with the
tester) on the 15-pin serial port of the controller first.
• If the microprocessor has an on-board backup battery,
Then insert the communications tester/amplifier adapter
insert the controller battery connector plug into the bat-
in a 15-pin female connector on the ribbon cable.
tery socket on the UP controller.
• If the on-board battery is not working or not installed,
NOTE: The communications tester/amplifier adapter may
connect a portable 12 Vdc battery to the battery pack
be plugged in while the controller is powered. connector.
2. Connect the communications cable from a laptop com- 4. Connect the power cable/battery connector lead to the 12
puter to the female connector on the communications Vdc power receptacle on the communications tester/
tester/amplifier adapter as shown in Figure 4. amplifier adapter.
5. Check to see that the communication tester’s PWR indi-
cator is ON to verify 12 Vdc has been supplied to the
communications tester/amplifier adapter.
µP Controller Plug Power Cable/Battery Connector, PN 204-937,

into Battery Receptacle on µP Controller if the
Unit Has a Working, On-Board Backup Battery
Plug the 12 Vdc Power Cable/Battery Connector

Lead into Communications Tester/Amplifier
Adapter after connecting 12 Vdc Power Cable/Bat-
tery Connector to Either the On-Board Backup Bat-
tery Socket on the Controller or a Portable 12 Vdc
Battery
Connect Power Cable/Battery Connector

to Portable 12 Vdc Battery When On-
Board Backup Battery is NOT Working or
NOT Installed
Communications Tester/Amplifier
Adapter, PN 204-901, MUST Be
Ribbon Cable, PN 204-936, for Installed in SERIES with (P Con-
Easy Viewing of Communications troller and Laptop Computer to
Tester/Amplifier LEDs Amplify Communication Signals
Figure 4.
Using Communications Tester/Amplifier
with µP Controllers
Laptop computer and
Communications Cable
10-18
NOTE: The communications tester/amplifier adapter If the RXD or TXD LED does not flicker or stays on con-
MUST receive 12 VDC power from the communications stantly, and you have verified that the communications tester/
signals between a laptop computer and µp controller. amplifier assembly is good on another controller, the UP con-
troller is defective and should be replaced.
If the PWR indicator DOES NOT light, recheck the power
supply. Also, check to be sure the power cable connectors are Using the Communications Tester/Amplifier with
properly connected. µP-A and µP-A+ Controllers to Monitor Communications.
NOTE: The PWR LED MUST light before attempting NOTE: Communication signals between a µP-A or µP-A +
communications with µP controller. controller and a laptop computer do NOT require
6. Initiate a data exchange with the controller. The GREEN amplification.
TXD LED should flicker briefly, indicating that the lap-
1. Install the ribbon cable on the 15-pin female serial port
top computer is sending a signal to the controller. If the
connector on the controller.
data exchange requires a reply from the µP controller, the
RED RXD LED should flicker, indicating that a reply 2. Then insert the communications tester/amplifier in one of
message (download) is being sent by the controller to the the 15-pin female connectors on the ribbon cable.
laptop computer.
7. If the GREEN TXD or RED RXD indicator does not
NOTE: The communications tester/amplifier adapter may
flicker, verify that the laptop computer and communica-
be plugged in while the controller is powered.
tions tester/amplifier assembly are working properly on
another µP controller.
Plug Power Cable/Battery Connector, PN 204-937,

µP-A or µP-A+ into Battery Receptacle on (µP-A or (µP-A + Controller if
Controller the Unit Has a Working, On-Board Backup Battery
If unit ON/OFF Switch Is OFF, Plug the Lead

of the 12 Vdc Cable/Battery Connector, PN
204-937, into the Communications Tester/
Amplifier Adapter after Connecting 12 Vdc
Power Cable/Battery Connector to Either
the On-Board Backup Battery Socket on the
Controller or a Portable 12 Vdc Battery
Connect Power Cable/Battery
Connector to Portable 12 Vdc Bat-
tery When On-Board Backup Bat-
tery Is NOT Working or NOT
Installed
Adapter, PN 204-901, MUST Be Installed
in PARALLEL with (µP-A or (µP-A + Con-
Ribbon Cable, PN 204-936 troller and Laptop Computer to Monitor
Communications
Figure 5.
Using Communications Tester/Amplifier
with µP-A or µP-A + Controllers
Laptop Computer and

10-19
3. Connect the communications cable from a laptop com- 7. Initiate a data exchange with the controller. The GREEN
puter to the OTHER 15-pin female connector on the rib- TXD LED should flicker briefly, indicating that the lap-
bon cable as shown in Figure 5. top computer is sending a RS232 signal to the controller.
If the data exchange requires a reply from the controller, the
NOTE: The communications tester/amplifier adapter RED RXD LED should flicker, indicating that a reply mes-
MUST be installed in PARALLEL with a (µP-A or (µP-A + sage (download) is being sent by the controller to the laptop
controller and the laptop computer Otherwise, the computer.
communications tester/amplifier adapter may INTERFERE 8. If the GREEN TXD or RED RXD indicator does not
flicker, verify that the laptop computer and communica-
with the communication signals and cause a
communications fault. This is because the communication
another µP-A or µP-A + controller.
signals between a (µP-A or (µP-A + controller and a laptop
computer do NOT require amplification. If the RXD or TXD LED does not flicker or stays on con-
stantly, and you have verified that the communications tester/
4. a. If the Unit On/Off switch is ON and the unit is operat- amplifier assembly is good on another controller, the µP-A or
ing, check to see that the communication tester’s PWR µP-A + controller is defective and should be replaced.
LED is ON to verify 12 Vdc has been supplied to the
communications tester/ amplifier adapter through the Using the Communications Tester/Amplifier with
VREC circuit of controller (µP-A or µP-A + controllers IRMU Remote Monitor Units to Monitor Communications
ONLY).
NOTE: Communication signals between a µP-A or µP-A +
NOTE: The communications adapter MUST receive 12
controller and IRMU do NOT require amplification.
VDC power from either the controller or the power cable/
battery connector in older to operate the LEDs. LED 1. To make it easier to view the communications tester/
operation is required to monitor communications. amplifier LEDs, install the ribbon cable on the 15-pin
female serial port connector on the controller.
b. If the Unit On/Off switch is OFF or the unit has been 2. Then insert the communications tester/amplifier adapter
disconnect from a 3-phase power supply, connect the in one of the 15-pin female connectors on the ribbon
power cable/battery connector to a 12 Vdc power source. cable.
• If the microprocessor has an on-board backup battery,
insert the controller battery connector plug into the bat- NOTE: The communications tester/amplifier adapter may
tery socket on the (µP-A or (µP-A + controller. be plugged in while the controller is powered.
connect a portable 12 Vdc battery to the battery pack
NOTE. The communications tester/amplifier adapter MUST
connector.
be installed in PARALLEL with a µP-A or µP-A+ controller
5. Connect the power cable/battery connector lead to the 12
and IRMU Otherwise, the communications tester/
Vdc power receptacle on the communications tester/
amplifier adapter may INTERFERE with the
amplifier adapter.
communications signals and cause a communications fault
This is because the communication signals between a µP-A
cator is ON to verify 12 Vdc has been supplied to the
or µP-A + controller and IRMU do NOT require
communications tester/amplifier adapter.
amplification.
supply. Also check to be sure the power cable connectors are 3. Turn the Unit On/Off switch to ON and operate the unit
properly connected. to establish communications between the controller and
the IRMU.
NOTE: The PWR LED MUST light before attempting to
monitor communications with a µP-A or µP-A + controller.
10-20
µP-A or µP-A +Controller
Communications Tester/Amplifier Adapter, PN 204-901,

MUST Be Installed in PARALLEL with a µP-A or µP-A +
Controller and IRMU to Monitor Communication Signals
Second 15-Pin Connector on Ribbon Cable

MUST BE EMPTY. Connecting a Laptop
Computer and Communications Cable to
THIS Connector Will Disable IRMU
Communication
Ribbon Cable, PN 204-936, for

Easy Viewing of Communications
Tester/Amplifier LEDs
IRMU Remote
Monitor Box
Figure 6. Using Communications Tester/Amplifier with IRMU Remote Monitor Box
4. Check to see that the communication tester’s PWR LED As the controller sends the IRMU a complete download of the
is ON to verify 12 Vdc has been supplied to the commu- data logger memory, the RED RXD LED should flicker, indi-
nications tester/amplifier adapter through the VREC cir- cating the controller is sending a RS232 signal to the IRMU.
cuit of controller (µP-A or µP-A + controllers ONLY).
6. If the RED RXD or GREEN TXD indicator does not
flicker, verify that the communications tester/amplifier
NOTE: The communications tester/amplifier adapter
assembly is working properly on another controller.
MUST receive 12 VDC power from the controller in order to
operate the LEDs. LED operation is required to monitor If the RXD or TXD LED does not flicker or stays on con-
communications. stantly, and you have verified that the communications tester/
amplifier assembly is good on another controller, the control-
5. Approximately 30 seconds after turning the Unit On/Off ler or IRMU is defective and should be replaced.
switch ON, the IRMU requests operating information
from the controller. The GREEN TXD LED should
flicker, indicating the IRMU is sending an RS232 signal
to the controller.
10-21
Plug Power Cable/Battery Connector, Plug the Lead of the 12 Vdc Power Cable/Battery Connec-
PN 204-937, into Battery Receptacle on tor into the communications tester/amplifier adapter after
SRMU Data Pac Communications connecting power cable/battery connector to either the on-
Panel f the Unit has a working, on- board backup battery socket or a portable 12 Vdc battery.
board backup battery.
Connect Power Cable/Battery connector
Ribbon Cable, to portable 12 Vdc battery when on-
PN 204-936 board backup battery is NOT working or
NOT installed.
SRMU Remote Communications Tester/Amplifier
Monitor Box Adapter, PN 204-901, MUST be
Installed in PARALLEL with the SRMU
and Laptop Computer to monitor
communications signals.
Laptop Computer and

Figure 7. Using Communications Tester/Amplifier with SRMU Remote Monitor Box
Using the Communications Tester/Amplifier with 4. Connect the power cable/battery connector to a 12 Vdc
SRMU Remote Monitor Units to Monitor power source.
Communications • If the unit has an on-board backup battery, insert the con-
1. Install the ribbon cable on the 15-pin female serial port troller battery connector plug into the battery socket on
connector on the SRMU Data Pac communications 15- the SRMU Data Pac communications panel in the unit
pin female connector. control box.
2. Connect the communications cable from a laptop com- connect a portable 12 Vdc battery to the battery pack
puter to one of the 15-pin female connectors on the rib- connector.
bon cable.
5. Connect the power cable/battery connector lead to the 12
3. Then insert the communications tester/amplifier in the Vdc power receptacle on the communications tester/
OTHER 15-pin female connector on the ribbon cable as amplifier adapter.
shown in Figure 7.
NOTE: The communications tester/amplifier adapter may cator is ON to verify 12 Vdc has been supplied to the
be plugged in while the controller is powered. communications tester/amplifier adapter.
NOTE: The communications tester/amplifier adapter NOTE: The communications tester/amplifier adapter
MUST be installed in PARALLEL with a unit controller and MUST receive 12 VDC power from the power cable/Battery
laptop computer. Otherwise, The communications tester/ connector in order to operate the LEDs to monitor
amplifier adapter may INTERFERE with the communications. If the PWR indicator DOES NOT light,
communication signals and cause a communications fault. recheck the power supply. Also, check to be sure that the
This is because the communication signals between a laptop power cable connectors are properly connected.
computer and a SRMU do NOT require amplification.
10-22
NOTE: The PWR LED MUST light before attempting to 8. If the RED RXD or GREEN TXD indicator does not
monitor communications. flicker, verify that the laptop computer and communica-
tions tester/amplifier assemblies are working properly on
7. Turn the laptop computer ON and initiate a data another controller.
exchange with the SRMU. The GREEN TXD LED
should flicker briefly, indicating that the laptop computer If the RXD or TXD LED does not flicker or stays on con-
is sending an RS232 signal to the SRMU. stantly, and you have verified that the communications tester/
amplifier assembly is good on another controller, the control-
If the data exchange requires a reply from the SRMU, the ler or SRMU is defective and should be replaced.
RED RXD LED should flicker, indicating that a reply mes-
sage (download) is being sent by the SRMU to the laptop
computer.
10-23
SERVICE BULLETIN
SUBJECT: Operating Instructions for Communications Tester/Amplifier

(PN 204-901) With Power Cable/Battery Connector (PN 204-
938)
BULLETIN NO. C 013
DATE: February 6,1997
TOOLS Power Cable/Battery Connector
• Communications Tester/Amplifier Adapter, PN 204-901 The Power Cable/Battery Connector provides 12 Vdc power
• Power Cable/Battery Connector, PN 204-938 from a portable battery pack or the on-board backup battery
through the receptacle located on the microprocessor control-
PURPOSE ler (if the unit is equipped with a data logger battery and bat-
tery charger) to the Communications Tester/Amplifier
• Amplify serial communication signals to download data
Adapter.
from a µP controller.
12 Vdc Power Receptacle
DESCRIPTION
Communications Tester/Amplifier Adapter
The Communications Tester/Amplifier Adapter contains indi- Front Back

cator LEDs that verify proper operation of the serial port cir- PWR = Power On LED
cuitry during serial communications. TXD = Transmit Data LED
• The GREEN POWER LED lights when 12 Vdc power Figure 1. Communications Tester/Amplifier
is supplied to the Communications Tester/Amplifier Adapter, PN 204-901
Adapter by the VREC circuit of the microprocessor con- RED Lead
12 Vdc Battery Pack
troller, or by the Power Cable/Battery Connector. This (Positive)
Connectors
indicates the cable connections are good and 12 Vdc
power is available to operate the LEDs on the Communi- BLACK Lead
cations Tester/Amplifier Adapter and to amplify signals (Negative)
for communications with (P controllers.
• The GREEN TXD (TRANSMIT) LED lights when

PCPACTM software sends a message to the microproces- Controller Battery
sor controller. This indicates the laptop computer has suc- Connector
cessfully sent a serial communications signal to the
controller. Communications
Tester/Amplifier
• The RED RXD (RECEIVE) LED lights when the con- Connector
troller sends a reply signal to the laptop computer. This
indicates the controller has successfully sent a serial com-
munications signal (download) to the laptop computer.
Figure 2. Power Cable/Battery
Connector, PN 204-938
10-24
OPERATING INSTRUCTIONS 4. Connect the power cable/battery connector to the 12 Vdc

power receptacle on the communications tester/amplifier
Using the Communications Tester/Amplifier adapter.
with µP Controllers to Amplify Communications Signals
1. Insert the communications tester/amplifier adapter into cator is ON to verify 12 Vdc has been supplied to the
the 15 pin female serial port connector on the front of a communications tester/amplifier adapter.
µP controller.
NOTE.- 77ie communications tester/amplifier adapter
NOTE. The communications tester/amplifier adapter may
MUST receive 12 Vdc power from the power cable/battery
be plugged in while the controller is powered.
connector in order to operate the LEDs and amplify the
2. Connect the communications cable from a laptop com- communications signals between a laptop computer and a
puter to the female connector on the communications µP controller
tester/amplifier adapter as shown in Figure 3.
3. Connect the power cable/battery connector to a 12 Vdc supply. Also, check to be sure the power cable connectors are
power source. properly connected.
• If the microprocessor has an on-board backup battery, NOTE: The PWR LED MUST light before attempting
insert the controller battery connector plug into the bat- communications with a µP controller
tery socket on the (µP controller. If the on-board battery
6. Initiate a data exchange with the controller. The GREEN
is not working or not installed, connect a portable 12 Vdc
TXD LED should flicker briefly, indicating the laptop
battery to the battery pack connectors.
computer is sending a signal to the controller.
Plug Power Cable/Battery Connector, PN
204-938, into Battery Receptacle on (µP
µP Controller
Controller if the Unit Has a Working, On-
Board Backup Battery
Connect Power Cable/Battery Con-
nector to Portable 12 Vdc Battery
when On-Board Backup battery Is
NOT Working or NOT Installed
Plug the 12 Vdc Power Cable/Battery Connector

Lead into Communications Tester/Amplifier
Adapter after Connecting 12 Vdc Power Cable/
Battery Connector to Either the On-Board
Communications Tester/Amplifier Backup Socket on the Controller or the portable
Adapter, PN 204-901 12 Vdc Battery
Figure 3.
Using Communications
Tester/Amplifier with
µP Controllers
Laptop Computer and
10-25
If the data exchange requires a reply from the µP controller, NOTE: Communication signals between a (P-A or (P-A+
the RED RXD LED should flicker, indicating that a reply controller and a laptop computer do NOT require
message (download) is being sent by the controller to the lap- amplification.
top computer.
1. Install the laptop computer communications cable
7. If the GREEN TXD or RED RXD indicator does not directly into the 15-pin female serial port connector on
flicker, verify that the laptop computer and communica- the controller.
another µP controller. 2. If the on-board backup battery is not working or not
installed, connect the power cable/battery connector to a
If the RXD or TXD LED does not flicker or stayson con- portable 12 Vdc battery (see Figure 4). Then plug the
stantly, and you have verified that the communications tester/ power cable/battery connector into the battery socket on
amplifier assembly is good on another controller, the µP con- the µP-A or µP-A+ controller.
troller is defective and the power cable/battery connector into
the battery should be replaced.
µP-A or µP-A+ Controller Plug Power Cable/Battery Connector, PN 204-938, into Bat-
tery Receptacle on µP-A or µP-A+ Controller and Connect
the 12 vdc Battery Terminals to Portable 12 Vdc Battery if
On-Board Backup Battery Is NOT Working or NOT Installed
Adapter Is NOT Used
Laptop Computer and Communications Cable

Figure 4. Plugs Directly into 15-Pin Female Serial Port
Using Communications on the Controller
Tester/Amplifier with µP-A or
µP-A+ Controllers
10-26
SERVICE BULLETIN
SUBJECT: CF-11 Heaters

BULLETIN NO. C 015
DATE: August 27,1997
When a container unit is connected to a power outlet pro- d. Test all 3 legs of the heater circuit to a good ground
tected by a ground fault protection device (GFI or RCCD connection. Connect a calibrated 500 Vdc insulation
device), faulty heater connections or insulation may cause the tester between each outgoing heater contractor terminal
protection device to trip during the DEFROST or HEAT and ground.
mode. To diagnose a ground fault protection device that trips
during the HEAT or DEFROST mode: e. If the resistance between any contractor terminal and
ground is below 0.8 meg ohms, visually inspect each
1. Make sure the ground fault protection device has a 30 heater connection and associated wiring.
mA current setting.
4. Inspect the heater connections and wiring if the resistance
2. Test heater element operation. between any contactor terminal and ground is below 0.8
meg ohms.
a. Reconnect the unit power cord to a power outlet
a. Remove the lower front evaporator access cover.
WITHOUT ground fault protection.
b. Inspect the heater connections and wiring. Each con-
b. Operate the unit in the HEAT mode for 20 minutes. nection should be secure. Correct any defective connec-
tion and repeat step 3.
c. Allow the heaters to cool for 10 minutes.
NOTE: When repairing heater connections, protect the new
d. Reconnect the unit to the power outlet WITH ground connections from the ingress of moisture with heat shrink
fault protection. tubing. All heaters should be secured to prevent contact with
sharp metal edges.
e. Operate the unit in HEAT or DEFROST mode. If the
protection device trips again, the heater connections and c. If the connections appear correct and secure, isolate
insulation must be tested. and test each individual heater element.
3. If the protection device repeatedly trips after testing 5. Isolate and check the resistance of each individual heater
heater element operation (step 2), test the insulation of element if the connections appear secure.
each individual heater element: a. Disconnect and isolate each heater. Check the resis-
tance of each heater with an insulation tester between
a. Turn unit power supply OFF. each heater and ground. If the resistance between each
heater and ground is 0.8 Meg ohms, replace the defective
b. Remove unit power plug from power supply recepta- heater.
cle.
NOTE: When replacing heaters or repairing heater
c. Open control box high voltage tray. connections, protect the new connections from the ingress
of moisture with heat Shrink tubing. All heaters should be
secured to prevent contact with sharp metal edges.
10-27
SERVICE BULLETIN
SUBJECT: CF-II Condenser Coil Cleaning

BULLETIN NO. C 016
DATE: August, 1997
The condenser coil on CF-II units should be cleaned every Where CF-II units are repeatedly subjected to excessive
1,000 hours to ensure proper refrigeration system perfor- amounts of salt water spray due to vessel design or unusually
mance and coil protection. heavy sea conditions, Thermo King recommends that the
1,000 hour cleaning interval be reduced to 500 hours.
Use low pressure compressed air or a medium pressure warm
water spray. Direct the air or water spray from the inside of If salt deposits have corroded the condenser coil to the point
the coil outward (opposite direction of normal airflow). where the header plates no longer properly secure the coil
tubes from structural movement, the coil must be replaced.
If a build up of salt is present on the condenser coil, Thermo
King recommends that the coil be cleaned using a mild alka-
line cleaner with a pH of 9.5 to 10.5; Follow any cleaning
solution application with a fresh water rinse.
Commercial cleaners are available. For example, a 2-3% solu-

tion of SIMPLE GREEN” would make a suitable cleaning
solution. Apply the solution using a pressure spray/wash type
apparatus. Spray the condenser coil thoroughly from both the
inside and outside of the coil. Then thoroughly rinse the coil
with a fresh water spray.
10-28
SERVICE BULLETIN
SUBJECT: Measuring Compressor Crankshaft End Play on Thermo

King
X426 and X430 Compressors Used in CF41 and CF-II
Container Refrigeration Units
BULLETIN NO. C 017
The Thermo King Warranty Department has recently received main bearing can have lateral (axial) movement during startup
several “good” X430 compressors that were changed out and shut down. However, the refrigerant pressure and crank-
because of suspicion that excessive crankshaft endplay was shaft torque forces prevent the main bearing from spinning
contributing to a shaft seal leak. The crankshaft endplay on radically during compressor operation.
these compressors was measured and found to be well within
normal limits. NOTE: Crank end play up to OX47 inch (12 mm) has NOT
been shown to be a factor in crankshaft seal leaks in testing
Compressor crankshaft endplay on a warm compressor can be conducted by THERMO KING.
as much as 0.047 inch (1.2 mm) as measured with a dial indi-
cator. As much as, 0.012 inch (0.03mm) of this endplay can Crankshaft endplay should NOT be considered to be factor in
be to the accumulated internal clearances in the crankshaft contributing in a shaft seal leak unless it is correctly measured
main bearings. The balance of this endplay is a result of the and found to be more than 0.047 inch (12 mm).
crankshaft main bearing outer races moving laterally in the
bores in the compressor body and oil pump housing. The following guidelines apply when measuring compressor
crankshaft endplay on X426 and X430 compressors:
This end play is necessary because of the different expansion/
contraction rates between aluminum and steel. Endplay pre- • A dial indicator gauge MUST be used.
vents the compressor from locking up at low ambient temper-
atures. Endplay increases with temperature. This means the • Dial indicator gauge must be securely damped or bolted
to the drive coupling housing or compressor body.
Firmly push crankshaft in towards compressor body as far

as R will travel. Zero the dial indicator gauge. Then firmly
pull crankshaft out and record dial indicator reading.
10-29
Tools Required: 7. Repeat step 6 three times. Then average the three read-
• Wrench and Socket Set ings together obtain an accurate crankshaft endplay mea-
• Soft Hammer or Soft Punch surement.
• Small Pry Bars (2)
• Torque Wrench If total crankshaft end play measures 0.047 inch (1 2 mm) or
• Dial Indicator Gauge with Mounting Adapters less, the crankshaft and compressor bearings are considered to
be in good condition. Thermo King testing has determined
End Play Measurement Procedure that a crankshaft end play of 0.047 inch (1.2 mm) is NOT a
1. Close the receiver tank outlet valve and pump down the factor in crankshaft seal leaks.
low side to 10 inch Hg vacuum (-33.8 kPa).
8. Remove dial indicator from compressor drive housing/
2. Turn unit On/Off switch to Off. Then disconnect the unit seal plate or compressor body.
power cable from the main power source. Close (front
seat) the discharge service valve. Break the vacuum with
NOTE: If the drive housing/seal plate was removed from the
nitrogen between 1 and 3 psig (7 and 21 kPa).
compressor body, refer to Service Bulletin No. 493-1 for
detailed instructions on reassembly of crankshaft seal and
CAUTION: Any time the discharge valve is front seated,
drive housing/seal plate to compressor body. Be sure to
disconnect the unit power source to prevent accidental
observe the following guidelines.
compressor start-up.
• Clean the compressor shaft and housing thoroughly
3. Disconnect motor and slide away from compressor.
before reassembly.
NOTE: Disconnecting the 3-phase motor harness may not
• Use only lintless cloth when handling or cleaning the
be necessary. compressor shaft, housing or seal assembly.
4. Remove drive coupling from compressor shaft.
• Never touch the polished contact surfaces of the crank-
5. Install dial indicator gauge. shaft seal or the seal plate hard ring with your fingers.
• Clamp or bolt the dial indicator gauge to the Compressor • Carefully inspect the contact surfaces of the seal and hard
drive housing/seal plate if no additional service of the ring for any nicks, scratches or foreign material. Use a
compressor or compressor crankshaft seal is planned. lintless cloth and denatured alcohol to remove debris
from the seal or hard ring. Replace any seal or hard ring
• Remove the compressor drive housing/seal plate from the that has been damaged in any way.
compressor body if the compressor crankshaft seal
requires replacement. Then clamp or bolt the dial indica- • Always apply only CLEAN compressor oil to the hard
tor gauge to the drive end of the compressor body. ring and contact surface of the new seal before reassem-
bly of the seal and drive plate.
NOTE: For guidelines on how to determine when a
compressor crankshaft seal should be changed, see
Container Service Bulletin C-009.
6. Measure the crankshaft endplay.
a. Firmly push the crankshaft in towards compressor

body as far as the crankshaft will travel.
b. Set the dial indicator reading to “T.
c. Firmly pull crankshaft outward from compressor body

as tar as the crankshaft will travel. Read dial indicator
and write down the measurement.
10-30
SERVICE BULLETIN
SUBJECT: Supply (Discharge) Air Sensor Position in Sensor Tube

on CSR-40,
CRR-40, TNE 508 and TNE 508 SC1Units
BULLETIN NO: C 018
The supply (discharge) air sensor MUST be fully inserted into NOTE: During Inspection, a black mark should be placed
the sensor tube to achieve accurate supply air temperature on the sensor harness. On subsequent Pretrip Inspections,
control. This is especially important when carrying chilled the black mark will indicate that the sensor position in the
cargo. sensor tube has been checked and is correct.
Failure to fully insert the sensor into the sensor tube can lower Tools Required:
the supply air temperature. Testing has shown that inserting • Black permanent marker
the sensor 10 mm (0.4 in.) short of the sensor tube end can • Ruler
lower the supply air temperature up to 0.3 C (0.5 F); inserting
the sensor 30 mm (1.2 in.) short of the tube end can lower the Supply (Discharge) Air Sensor Position Inspection
supply air temperature up to 1.2C (2.1 F). Procedure
Because it has been reported that the supply air sensor on 1. Loosen and unscrew the supply air sensor retaining cap.
some units has been found NOT to be fully inserted in the
sensor tube, Thermo King recommends that the following 2. Remove the supply air sensor from the sensor tube.
inspection be performed on all CSR-40, CRR-40, TNE 508
and TNE 508 SC1 units during the routine Pretrip Inspection: 3. Measure and place a black mark on the sensor harness
170 mm (6.75 inches) from the end of the sensor bulb.
Mark Sensor Lead
Here with Permanent 4. Firmly slide the sensor back into the sensor tube until the
Black Marker sensor bulb reaches the end of the sensor tube.
5. Replace retaining cap on sensor tube. Tighten securely.

The black mark should just be visible on the sensor har-
ness. If necessary, increase the width of the mark by
marking the harness flush with retaining cap (with cap
fully tightened).
NOTE: A visible black mark on the sensor harness will

indicate that the sensor position has been checked and is
correct.
AJA522
When sensor bulb is completely inserted to

the end of the sensor tube, the black mark
should appear flush with the retaining cap.
10-31
SERVICE BULLETIN
SUBJECT: PVC Breather Vent on se 2.2 Engines

BULLETIN NO. C 019
DATE: November 10, 1997
The PCV valve that regulates the crankcase pressure of the If a new unit has a crankcase pressure significantly over 3
se 2.2 engine can develop excessive pressure in the engine inches W.C. positive, or has blow out of its oil level switch,
crankcase if the atmospheric vent in the cover of the valve is check the atmospheric vent on the PCV cover for blockage.
plugged. A few new units have been found with the vent
plugged with the epoxy clear coat applied to the power pack
at the factory.
Vent Hole May Be Found at the Back, Front or

Either Side Position of the Cover.
Location Depends on How Cover Was
Last Installed.
10-32
SERVICE BULLETIN
SUBJECT: Revised Operating Instructions for Communications

Tester/Amplifier EPSON 204-901)
BULLETIN NO: C 020
DATE: July 31, 1998
Several Communications Tester/Amplifier Adapters, P/N 204901,

have failed in the field due to a burned out diode in the PWR LED If unit is operating on AC power, DO NOT plug a
circuit. Diode failure is believed to occur when: connector socket into this 12 Vdc power receptacle
- The tester/amplifier is connected to a controller operating on AC

power (unit On/Off switch ON); AND
- 12 Vdc power is supplied to the communications tester/ amplifier

from either the unit is on-board battery or a portable external battery Front Back
by the power cable/battery connector.
AJA523 PWR = Power On LED
Thermo King believes the diode is burned open by the unit’s VREC TXD = Transmit Data LED
circuit as it attempts to charge an external battery through the tester/
amplifier. Therefore, it the unit is operating on AC power, DO
NOT plug a power cable/battery connector into the 12 Vdc Figure 1. Communications Tester/Amplifier,
receptacle on the tester/amplifier. P/N 204-901
Unit ON - Operating on 460/380V Unit OFF - 460/380V or 230/220V

Unit Status
or 230/220V Power Power NOT Available
Controller µP µP-A µP-A+ µP µP-A µP-A
Controller Required 12 Vdc from On-board

Battery or External No No No Yes2 Yes3 Yes3
Battery Pack1 to Download
Tester/Amplifier Requires 12 Vdc from On-
board Battery or External Battery Pack1 to No No No Yes4 No No
Operate
Purpose of Using the • Amplify • Monitor • Monitor • Amplify • Monitor • Monitor
Tester/Amplifier Signals Signals Signals Signals Signals Signals
• Monitor w/LEDs w/LEDs • Monitor w/LEDs w/LEDs
Signals Signals
w/LEDs w/LEDs
How to Install Tester/Amplifier Parallel5 Parallel5 Parallel5 Parallel5
1. Use a Power Cable/Battery Connector (P/N 204-937 or 204-938) to supply 12 Vdc power to the controller from an external battery if the unit does NOT
have a working on-board battery.
2. On units equipped with 12 Vdc on-board battery press Set Point Enable switch to activate controller display.
3. With 12 Vdc power supplied to controller, press SELECT key on controller keypad to activate controller display.
4. Use the Tester/Amplifier Connector Socket on the Power Cable/Battery Connector (P/N 204-937 or 204-938) to supply 12 Vdc power to Tester/Amplifier
from an on-board OR external battery.
5. Use a Ribbon Cable (P/N 204-936) to connect Tester/Amplifier in parallel to a download communications cable.
NOTE: To use the Tester/Amplifier to monitor SRMU or IRMU communications, see µP-A+ columns above (monitoring IRMU communications requires that
the unit be operating on 460/380V or 230/220V power).
10-33
SERVICE BULLETIN
SUBJECT: CSR and CRR Leak Charts

BULLETIN NO: C 021
DATE: June 12,1998
CSR and CRR refrigeration system diagrams are attached to Warranty Claim Form Reporting
this bulletin. The diagrams show all current connections for
CSR and CRR units. Use these diagrams to identify and Thermo King continuously monitors the performance and
report all component and joint repair work. reliability of unit components. Therefore it is important to
include the component and joint code number(s) that appear
All O-ring seal and solder connections (except coils) have on the attached refrigeration system schematic on warranty
been labeled. When repairing O-ring seals, apply compressor claim forms when describing any repair work. Forms include:
oil to new seals. When repairing solder connections, use the
same solder that was used in the manufacturing process: • CSR refrigeration system diagram with component and
joint identification tables
• Copper to copper, use 15% Silver Solder, • CRR refrigeration system diagram with component and
PN 203-364 joint identification tables
• Copper to brass or steel, use 35% Silver Solder,
PN 203-366
Use flux, PN 203-365, with both 15% and 35% silver solder.
Other types of leaks such as punctures in tubes and leaks in
coils can best be repaired using 15% silver solder, PN 203-
364 (with flux, PN 203-365).
NOTE: It is important that your service procedures use the

same solder that was used in the manufacturing process. We
therefore strongly recommend that you obtain solder and
flux from Thermo King and that only the recommended
solder and flux be used on specific connections.
10-34
CSR REFRIGERATION SYSTEM

Component and Joint Repair Work Reporting Form
589
8 S
205
159
65
B
177
203 87
AZ 21
6
155
119
9 C
5
D 19 Y
4 106
E
155
W 52
66 19
E 161
W
265
64 P
63 18
49
62
2
105 1 A
154
114 277
266 156 AG
116 61
AC
605
BC
36
593
37
247 G
27
K
25
X 28
1
59
60 AJA524
Component Identification P Receiver tank

A Condenser coil S Distributor
B Evaporator W Sight glass, receiver tank
C Expansion valve X Sight glass, compressor
D Heat exchanger Y High pressure relief valve
E Dehydrator AC Condenser fan press. switch, or plug (1/8” pipe)
G Compressor AG Receiver valve outlet
I Discharge Valve AZ Solenoid valve, hot gas bypass
K Suction valve BC Solenoid valve, demand cool/liquid injection
10-35
Joint Identification 105 Tee to liquid line #4

1 Condenser coil inlet 106 Liquid line to receiver service valve
2 Condenser coil outlet 114 Liquid line to tee
4 Equalizer line to expansion valve 116 Tee to liquid line #3
5 Expansion valve inlet 119 Hot gas solenoid to tube
6 Expansion valve outlet 146 Hot gas tube to solenoid
8 Evaporator coil outlet 153 Suction line to modulation valve
9 Equalizer line to fitting 154 Dehydrator outlet o-ring sleeve
18 Dehydrator outlet 155 Dehydrator inlet o-ring sleeve
19 Dehydrator inlet 156 Liquid line service valve packing
21 Fitting to tube (hot gas/defrost) 157 Modulation valve to suction tube
25 Suction valve stem 159 Tee to liquid line #2
27 Discharge valve manifold 161 Hot gas tube joint
28 Discharge valve to tube 177 Tee to liquid line #1
36 Suction valve mounting 203 Liquid tube to solenoid
37 Suction tube to suction valve 205 Liquid tube to tee
49 Receiver tank outlet 247 Demand cool/liquid injection valve outlet (solder)
52 Receiver tank inlet 265 Modulation valve inlet
59 Discharge valve test port 266 Modulation valve outlet
60 Discharge valve stem 277 Modulation valve
61 Liquid inlet, tube to heat exchanger 589 Evaporator header inlet
62 Liquid outlet, tube to heat exchanger 593 Compressor liquid injection inlet o-ring fitting
63 Heat exchanger liquid inlet (to shell) 605 Demand cool solenoid inlet
64 Heat exchanger liquid outlet (to shell)
65 Heat exchanger suction inlet (to shell)
66 Heat exchanger suction outlet (to shell)
87 Tube to solenoid
Warranty Claim Form Reporting Use flux, PN 203-365, with both 15% and 35% silver solder.
Other types of leaks such as punctures in tubes and leaks in
Thermo King continuously monitors the performance and coils can best be repaired using 15% silver solder, PN 203-
reliability of unit components. Therefore it is important to use 364 (with flux, PN 203-365).
this diagram to identify and report all component and joint
repair work. It is also important to include the component and
NOTE. It is important that your service procedures use the
joint code number(s) on warranty claim forms when describ-
same solder that was used in the manufacturing process We
ing any repair work.
therefore strongly recommend that you obtain solder and
All O-ring seal and solder connections (except coils) have flux from Thermo King and that only the recommended
been labeled. When repairing O-ring seals, apply compressor solder and flux be used on specific connections.
oil to new seals. When repairing solder connections, use the
same solder that was used in the manufacturing process:
• Copper to copper, use 15% Silver Solder, PN 203-364

PN 203-366
10-36
CRR REFRIGERATION SYSTEM

Component and Joint Repair Work Reporting Form
S
S
117
589
AV
118
205
105
116
62
5 BC
C P
6 247
52
114 640
605
B
159
BJ
177
636 W
Y
9
4 A
8 591 49 2
65
64
203
D BL
634
63 635
271 266
277
66
265
28
14
R
637
AG 243 1
235
99
155
639
19 100
156
G
106 59 1
E
BK
18
300
154 60
236 638
61 633
237 607
37
AJA525
AC 239
K
599
262
X
36 25
Component Identification S Distributor

A Condenser coil W Sight glass, receiver tank
B Evaporator X Sight glass, compressor
C Expansion valve Y High pressure relief valve
D Heat exchanger AC Condenser fan press. switch, or plug (1/8” pipe)
E Dehydrator AG Receiver valve outlet
G Compressor AV Solenoid valve, liquid line
I Discharge valve BC Solenoid valve, demand cool/liquid injection
K Suction valve BJ Solenoid valve, dehumidification
P Receiver tank BK Oil filter, in-line
R Check valve BL KVQ valve actuator
10-37
Joint Identification 118 Liquid line solenoid to liquid line

1 Condenser coil inlet 154 Dehydrator outlet o-ring sleeve
2 Condenser coil outlet 155 Dehydrator inlet o-ring sleeve
4 Equalizer line to expansion valve 156 Liquid line service valve packing
5 Expansion valve inlet 159 Tee to liquid line #2
6 Expansion valve outlet 177 Tee to liquid line #1
8 Evaporator coil outlet 203 Liquid tube to solenoid
9 Equalizer line to fitting 205 Liquid tube to tee
14 Heat exchanger to tube 235 Oil filter inlet
18 Dehydrator outlet 237 Oil filter outlet tube to adapter
19 Dehydrator inlet 239 Service valve adapter flange
25 Suction valve stem 243 Suction line
28 Discharge valve to tube 247 Demand cool/liquid injection valve outlet (solder)
36 Suction valve mounting 262 Suction valve to adapter
37 Suction tube to suction valve 265 Modulation (KVQ) valve inlet
49 Receiver tank outlet 266 Modulation (KVQ) valve outlet
52 Receiver tank inlet 271 Suction inlet heat exchanger
59 Discharge valve test port 277 Modulation (KVQ) valve
60 Discharge valve stem 300 Discharge valve flange gasket
61 Liquid inlet, tube to heat exchanger 589 Evaporator header inlet
62 Liquid outlet, tube to heat exchanger 591 Liquid injection tube to suction tube
63 Heat exchanger liquid inlet (to shell) 599 Suction pressure SAE service adapter
64 Heat exchanger liquid outlet (to shell) 605 Demand cool solenoid inlet
65 Heat exchanger suction inlet (to shell) 607 Compressor discharge flange
66 Heat exchanger suction outlet (to shell) 633 Subcooler outlet
99 Tube to condenser check valve 634 Subcooler inlet
100 Condenser check valve to discharge-tube 635 KVQ actuator valve
105 Tee to liquid line #4 636 Dehumidification solenoid valve to liquid tube
106 Liquid line to receiver service valve 637 Oil filter inlet tube to adapter
114 Liquid line to tee 638 Discharge valve to adapter/rotalock
116 Tee to liquid line #3 639 Liquid line service valve outlet
117 Liquid line to liquid line solenoid 640 Receiver tank service fitting
Warranty Claim Form Reporting
Use flux, PN 203-365, with both 15% and 35% silver solder.
Thermo King continuously monitors the performance and Other types of leaks such as punctures in tubes and leaks in
reliability of unit components. Therefore it is important to use coils can best be repaired using 15% silver solder, PN 203-
this diagram to identify and report all component and joint 364 (with flux, PN 203-365).
repair work. It is also important to include the component and
joint code number(s) on warranty claim forms when describ-
NOTE. it is important that your service procedures use the
ing any repair work.
same solder that was used in the manufacturing process We
All 0-ring seal and solder connections (except coils) have therefore strongly recommend that you obtain solder and
been labeled. When repairing O-ring seals, apply compressor flux from Thermo King and that only the recommended
oil to new seals. When repairing solder connections, use the solder and flux be used on specific connections.
same solder that was used in the manufacturing process:
• Copper to copper, use 15% Silver Solder, PN 203-364
PN 203-366
10-38
SERVICE BULLETIN
SUBJECT: Operating Instructions for µP-D Tester, P/N 204-911

BULLETIN NO: C 022
DATE: July 31, 1998
TOOLS • Test 2: Automatically tests controller operation. Control-
• µP-D Tester, P/N 204-911 ler display shows PASS or FAIL when test is complete. If
• Optional: Use 12 Vdc power cable/battery connector, TK FAIL appears in the display, press ALARM key to view
P/N 204-938, or make a power cable. Construct cable failure codes. Failure codes are listed at the end of this
from a plug connector (5.0 mm OD/2.5 mm ID) for a bulletin.
Switchcraft #712A jack, red and black wire, and battery
clips. Make sure the red positive lead is connected to the If the controller has been removed from the unit, the µP-D
center terminal of the plug and the positive (+) terminal tester can be used to:
of the power supply. Reversed polarity will damage the
controller. • View the controller Main Menu after the completion of
• Optional: 12 Vdc power supply or battery Test 1. Use the Enter, Select, Up and Down keys on the
controller keypad to view and record the Software Ver-
PURPOSE sion, Unit Configuration, Customer Configuration, pro-
Perform a functional test of the µP-D controller. The µP-D grammable Sensor Grades and Hourmeter settings before
tester, P/N 204-911, performs two tests: replacing the controller.
• Test 1: Uses controller keys to activate display segments • Down load a data log file from the controller.
and mode LEDs to verify keypad and display operation.
RS232 15-Pin Connector LED on 37-Pin Connector Turns On During Test 1

for Down Loading a Data and Flashes On and Off Toward the End of Test 2
Log File or Flash Loading to Indicate Communications with the Controller
Controller Software
Connect POWER IN
Connector to Unit Wire
Harness Connector
Removed from
Connector “A” on AJA526
Back of Controller
RED Lead (Positive)

BLACK Lead (Negative)
Optional Power Cable, P/N 204-938
Figure 1. Connecting a Tester, P/N 204-911, to a µP-D Controller That Has Been Disconnected
from the Unit Wire Harnesses
10-39
• Flash load new software into the controller. Failure

• PASS means the controller should be considered good. Description
Code
• FAIL means the controller should be considered defec- 01 Return Air Temperature LM235 Input Failure
tive. Press the ALARM key to view failure codes. Left
02 Supply Air Temperature LM235 Input Failure
display will show “ALMXX” where XX = number of
03 Evaporator Temperature LM235 Input Failure
failure codes. Right display will show “S-YY” where YY
= failure code. To scroll through the failure codes, press 04 Condenser Temperature LM235 Input Failure
the UP and DOWN keys. Failure codes are listed at the 05 Ambient Air Temperature LM235 Input Failure
end of this bulletin. 06 USDA 1 Temperature LM235 Input Failure
• Turn the Tester 3-position switch to OFF. Wait at least 2 07 USDA 2 Temperature LM235 Input Failure
seconds before repeating Test 1 or Test 2. 08 USDA 3 Temperature LM235 Input Failure
09 Spare 4 Temperature LM235 Input Failure
NOTE: Failure codes can NOT be cleared by pressing the 10 Pulp Temperature LM235 Input Failure
ENTER key on the controller. 11 Compressor 1 Thermistor Input Failure
12 Compressor 2 Thermistor Input Failure
Disconnect the µP-D Tester from the Controller
13 Auxiliary Gel Cell Signal Conditioning Input Failure
14 Vrect Signal Conditioning Input Failure
1. Turn the 3-position Tester switch to OFF.
2. Remove power supply from the µP-D Tester. 15 Lithium Battery Signal Conditioning Input Failure
• Disconnect the POWER IN connector from the unit 16 Pressure Transducer 1 Signal Conditioning Input
wiring harness, or Failure
• Unplug the optional power connector from the receptacle 17 Pressure Transducer 2 Signal Conditioning Input
on bottom of tester. Failure
3. Disconnect all 4 tester wire harness connectors from the 18 Current Transformer 1 Signal Conditioning Input
back of the controller. Failure
4. If the µP-D controller passes Test 1 and Test 2, connect 19 Current Transformer 2 Signal Conditioning Input
the control box harness connectors to the back of the Failure
controller. 20 Current Transformer 3 Signal Conditioning Input
Failure
21 Modulation Valve Output Signal Failure
22 Compressor Low Oil Pressure DC Digital Input
Failure
23 Water Pressure Switch DC Digital Input Failure
24 Condenser Fan DC Digital Input Failure
25 Low Suction Pressure DC Digital Input Failure
26 Spare 1 DC Digital Input Failure
27 HPCO Input AC Digital Input Failure
28 HPCO Output AC Digital Input Failure
29 Future AC1
30 Future AC2
31 VINPUT-2 Failure
32 AUX GEL CELL Failure
33 SWITCHED VIN Failure
34 Communications Failure
35 GDT Remapped/Not Implemented Warning
NOTE: If this Failure Code exists other Failure
Codes may not be valid.
36 Humidity Input 0-20 ma Failure
37 On Board LM235 Temperature Sensor Failure
38 KVQ Valve Thermistor Failure
10-40
TEST PROCEDURE All Display Segments and

Decimal Point Above Key
Controller Key
Connect the µP-D Tester to the Controller Turn ON; Plus the
Pressed
Following Mode LED
1. Turn the unit On/Off switch OFF. Turns ON
• The controller display should be blank. Select key Cool LED
2. Open the control box door. Disconnect all 4 wire harness
Up key Modulation LED
connectors from the back of the controller.
Down key Null LED
WARNING: High voltage (460/380 volts) is present on the Enter key Heat LED
contactors and relays in the control box. Exercise care when °F / °C key In Range LED
working In the control box to prevent dangerous electrical Ret/Sup key Defrost LED
shock. Defrost key Supply LED
3. Turn the 3-position Tester switch to OFF. Connect all 4 Pretrip key Return LED
connectors from the tester wire harness to the back of the SOT key Power Limit LED
controller. Match the letters on the identification labels of Alarm key Alarm LED
the tester connectors to the letters beside the female con-
nectors on the back of the controller (see Figure 1).
4. • If AC power is available to the unit, connect the 3. When the ALARM key is pressed, Test 1 ends 3 seconds
POWER IN connector to the unit wiring harness. Attach later.
POWER IN connector to wire harness connector • Test 1 is complete when the controller display shows the
removed from connector A on the back of the controller Standard Display (setpoint temperature and controlling
in step 2 above. This supplies 13.6 Vdc power to the air sensor temperature).
tester. 4. Turn the 3-position Tester switch to OFF.
• If AC power is NOT available to the unit, a 13.6 Vdc Perform Test 2
power supply or battery and an optional power cable 1. Turn the 3-position Tester switch to TEST 2.
must be used. Use power cable/ battery connector P/N
204-938, or construct a power cable (see description NOTE: Tester 3-position switch must be OFF for at least 2
under Tools Required on page 1). Attach the power cable
seconds before starting Test 2.
to a 13.6 Vdc power source or battery. Then plug the
power connector into the receptacle on bottom of tester. • All mode LEDs and display segments turn ON for 10
seconds. Inspect the display to make sure all segments,
Perform Test 1
decimal points and mode LEDs are lit.
1. Turn the 3-position Tester switch to TEST 1. The
• After 10 seconds, the left display will show “TEST”.
controller display will turn on and show “KEY TEST”.
Numbers 1 through 15 appear in the right display during
2. Starting with the SELECT key, press each key on the
the automatic test. The test takes about 30 seconds.
controller keypad.
NOTE: If a failure occurs during Test 2, the Alarm LED
NOTE: Press the ALARM key last because pressing this key
turns ON.
ends Test 1.
2. When Test 2 is compete, the controller display shows
• When a key is pressed, all 14 segments plus the decimal
PASS or FAIL.
point of the digit directly above the key will turn ON. The
mode LED directly above the key also turns ON. Inspect
NOTE: If an Intermittent controller failure is suspected,
each digit to make sure all segments, decimal point and
mode LED are lit. leave the 3-position Tester switch in the TEST 2 position for
several minutes. The 15 step test sequence for Test 2
automatically repeats in the background as long as the
switch is in the TEST 2 position. If a failure occurs on a
later test, the controller display will change to show FAIL
and the test sequence is ended.
10-41
SERVICE BULLETIN
SUBJECT: Use Separate, Dedicated Service Tools for HCFC/CFC

Refrigerants and HFC Refrigerants
BULLETIN NO: C 023
DATE: August 7,1998
Dedicated Service Tools for HCFC/CFC Dedicated Service Tools for HFC Refrigerant,
Refrigerants (R-1 2, R-22 and R-401 B) (R-134a and R-404A)
When servicing Thermo King refrigeration systems that con- When servicing Thermo King refrigeration systems that con-
tain R-12, R-22 or R-401B refrigerants, use only those service tain R-134a or R-404A refrigerants, use only those service
tools certified for and dedicated to HCFC and CFC refriger- tools certified for and dedicated to HFC refrigerants. The
ants. The same gauge manifold set or recovery equipment can same gauge manifold set or recovery equipment can be used
be used on each of these refrigerants because R-12, R-22 and on each of these refrigerants because R-134a and R-404A
R-401B contain similar chemical compounds and require the contain similar chemical compounds and require the use of
use of mineral oil or alkyl benzene compressor oil. polyolester compressor oil.
CAUTION: Residual HFC refrigerants or ester based oils CAUTION: Residual HCFC/CFC refrigerants, or mineral
will contaminate HCFC and CFC systems or alkyl benzene oils will contaminate HFC systems.
Service tools that should be dedicated to HCFC/CFC systems Service tools that should be dedicated to HFC systems
include: include:
• Gauge Manifold Set
• Refrigerant Recovery Equipment • Gauge Manifold Set
• Vacuum Pump • Refrigerant Recovery Equipment
• System Cleanup devices including service hoses, valves, • Vacuum Pump
suction line filters. • System Cleanup devices including service hoses, valves,
suction line filters.
Use One Dedicated Set of

Tools for R-12, R-22 and
R-401 B Systems
Use Another Dedicated

Set of Service Tools for
R-134a and R-404A
Systems
Recovery
Machine AJA527
10-42
SERVICE BULLETIN
SUBJECT: µP-D Controller Emergency Bypass Procedure

BULLETIN NO. C 024
Use the Emergency Bypass Switch to manually control unit
operation if the µP-D controller or output module fails.
NOTE: If the output module fails, the unit will stop

immediately. If the µP-D controller fails but the output
module is ok, the output module will:
• Immediately stop the unit on Fresh Loads,
• Continue unit operation in Cool on Frozen Loads.
Use the Emergency Bypass Switch to take manual control of
the unit.
1. Turn the Unit On/Off switch to OFF.

2. Turn the power supply OFF. Disconnect the unit power
cord from the power supply.
WARNING:, High voltage (460/380 volts) is present on the

contactors and relays in the control box To prevent
dangerous electrical shock when working in the control box,
disconnect the power supply to the unit whenever possible.
AJA528
3. Disconnect wire harness connector “C1” from the bottom Disconnect the C1 harness from bottom of the Output Module.
of the Output Module. Then connect “C1” to the bottom Then connect it to the bottom of the Emergency Bypass Switch
of the Emergency Bypass Switch assembly. assembly.
VIN LED glows when Emergency
power is available to Emergency Bypass
NOTE: Make sure the Phase Rotation Switch on the Bypass Switch Switch
Emergency Bypass Module is OFF
VIN
Use Mode Switch to
4. Connect the unit power cord to the proper power supply. manually control unit to Mode Fan
maintain the desired SW Only
Turn power supply ON. temperature
5. Turn the Unit On/Off switch ON. Full
Cool
• The VIN LED will glow to indicate power is available at HPCO and 24 VAC
the Emergency Bypass Switch. LEDs glow when
conditions are normal HPCO
6. Place the Phase Rotation Switch in the ABC position to
start the unit.
24
7. Place the Mode Switch to Full cool position to operate Use Phase Rotation switch to achieve
VAC
ABC
compressor and condenser fan. correct unit air flow and motor rotation
Off
AJA529
• Check condenser fan airflow. Air should be blowing out Phase
CBA
from the center of the grill. Rotation
• If air is NOT blowing out from the center of the grille, Emergency Bypass Switch Assembly
place the Phase Rotation switch in the OFF position.
10-43
Allow the motors and fans to come to a COMPLETE stop. NOTE: If emergency bypass procedures are used under
Then place the Phase Rotation switch in the CBA position. high ambient and high container (load) temperature
Check condenser airflow again to confirm that air is blowing conditions, a compressor motor shutdown may occur
out from the center of the grille. (indicating the compressor motor internal overload
protector has tripped). Wait a few minutes to allow the
8. Use the Mode Switch to set unit operation for Evaporator
overload protector to cool.
Fan Only or Full Cool operation.
The unit is equipped with a suction modulation capacity con-
CAUTION: The unit does not control to setpoint during trol system to control system cooling capacity and limit com-
emergency bypass switch use The unit must be cycled pressor motor current draw. If the unit shuts down due to the
manually to maintain the desired temperature Monitor the overload protector tripping during emergency bypass proce-
container temperature using the controller display (if dure operation, restrict refrigerant flow to the compressor
using the receiver tank outlet valve. Manually close the valve
working) or an external thermometer
and then open the valve 1/4 turn. Restart the unit. Check com-
9. High pressure cutout (HPCO) and 24 Vac LEDs on the pressor motor current draw. The motor should draw 14 to 15
Emergency Bypass Module turn ON to indicate normal amps. Adjust the receiver tank outlet valve slightly if neces-
operation. sary to raise or lower current draw to 14 to 15 amps.
• HPCO LED is ON when the HPCO switch is closed (nor-
mal). If the HPCO switch opens (high discharge pres-
sure), the LED will turn OFF.
• 24 VAC LED is ON when 24 volt ac control power is
supplied to the Emergency Bypass Switch.
10-44
SERVICE BULLETIN
SUBJECT: Normal Operating System Pressures for

CSR Units
BULLETIN NO. C 025
DATE: August 7,1998
CSR refrigeration system operating pressures vary with the Suction and discharge pressures vary too greatly during Mod-
operating conditions and cooling load. The suction and dis- ulation Cool to use for evaluating or diagnosing refrigeration
charge pressures listed below are typical for the conditions system performance.
shown during the Full Cool mode.
Normal R-404A System Suction Pressures (CSR Scroll Compressor)
Container Operating Ambient Suction Pressure Discharge Pressure

Temp. Mode Temp.
21 C (70 F) Cool 27 to 38 C, 410 to 670 kPa, 4.10 to 4.70 bar, 1965 to 2140 kPa, 19.65 to 21.40 bar,
80 to 100 F 59 to 97 psig 285 to 310 psig
16 to 27 C, 400 to 600 kPa, 3.45 to 3.93 bar, 1725 to 2140 kPa, 17.25 to 21.40 bar,
2 C (35 F) Cool 27 to 38 C, 385 to 425 kPa, 3.85 to 4.25 bar, 1860 to 2380 kPa, 18.60 to 23.80 bar,
-18 C (0 F) Cool 27 to 38 C, 214 to 228 kPa, 2.14 to 2.28 bar, 1520 to 2035 kPa, 15.20 to 20.35 bar,
-29 C (-20 F) Cool 27 to 38 C, 145 to 159 kPa, 1.45 to 1.59 bar, 1450 to 1965 kPa, 14.50 to 19.65 bar,
10-45
SERVICE BULLETIN
SUBJECT: Auto-Restart Operation on Smart Generator Sets

BULLETIN NO. C 026
This is to remind all personnel that they MUST ALWAYS • Automatic unit restart attempt 20 minutes after:
turn the generator set On/Off switch OFF before attempting to - High engine water temperature shutdown
service or repair the unit. - Engine failure to start
- Check fuel alarm shutdown
WARNING: With the unit On/Off switch “ON”. Generator - 230/460V alternator overload shutdown
sets equipped with an auto-restart system or µP-G controller - An unknown condition shutdown
may start at any time without prior warning. - Low engine oil pressure shutdown (optional)
• Delayed alternator excitation for 15 seconds, or until
An Auto-Restart mode feature may make up to engine coolant temperature increases to 90 F (32 C)
3 attempts every 20 minutes to restart the unit after (optional)
a shutdown has occurred. This restart mode will continue Starting the Unit
until the unit has been successfully restarted or until the Before starting the generator set, make sure the refrigeration
battery is low. unit switch is OFF and the refrigeration unit power cord is
The µP-G controller is a one-piece, self contained micropro- connected to the generator set receptacle.
cessor for diesel generator sets. This system automatically NOTE Time delays In the automatic starting system may
starts the generator set and provides: require up to 3 minutes for the engine to preheat and start,
• Automatic unit preheat and engine start-up during initial and the generator to deliver power to the electrical
start-up or delayed restart receptacle.
• Variable glow plug preheat time The engine must operate for at least 15 seconds before
• Automatic Pre-trip Test capability the generator exciter field (and battery charging) is
• Unit shutdown protection due to high engine coolant energized and power is delivered to the receptacle
temperature, low engine oil pressure, low engine oil level
1. Place the generator set On/Off switch to ON.
or 230/460V alternator overload
• Microprocessor LCD fields will turn ON and OFF.
• After a few seconds, the warning buzzer sounds as the
Display glow plugs automatically preheat for 1 to 120 seconds,
depending on the engine temperature (5 seconds at 150 F
Mode [65 C] to 120 seconds at -20 F [-29 C]).
Description • At the end of the preheat period, the engine will begin
cranking. The glow plugs remain energized during the
Alarm Icon
cranking period. If the engine does not start after 25-30
seconds of cranking, the cranking cycle terminates.
NOTE: Unit will repeat the automatic start sequence up to 3

Keypad times. If engine fails to start, an ALARM Icon will appear
on controller display to indicate a malfunction has
occurred. If left unattended with the unit On/Off switch ON,
the unit will attempt to restart after 20 minutes.
AJA530
10-46
2. If the engine fails to start, press the ALARM key on 3. 3. To attempt another unit start-up, turn the On-Off switch
the controller keypad to view all alarm codes. Place the ON. Then clear all Alarm codes from the controller dis-
On-Off switch in the OFF position. Then determine and play to repeat starting procedure. To clear alarm codes:
correct the cause for not starting. • Press the DOWN key until all alarm codes have been
viewed and written down.
Alarm Codes: • When the last alarm code (ALM 1) appears in the con-
troller display, the display alternately flashes “ENTER”.
06 Water Temperature Sensor Failure • Press the ENTER key to clear all alarm codes from the
07 Engine RPM Sensor current display memory. The display briefly shows
15 Preheat Circuit Check “ALARM CLR”.
16 Digital Input Failure
17 Engine Failed to Crank NOTE: Clear the Alarm codes ONLY after the alarm codes
18 High Engine Water Temperature are documented and problems repaired Clearing the codes
erases them from the controller Alarm display memory.
19 Low Engine Oil Pressure
20 Engine Failed to Start NOTE: If the ENTER key is not pressed within 10 seconds,
25 Low Output Volts the controller will default (return) to the Standard Display.
31 Oil Pressure Sensor
Additional operating information about the µP-G controller
35 Run Relay Circuit
can be found in Container Bulletin C-014, µP-G Controller
37 Coolant Level Alarm Unit Operating Information for Generator Sets”.
41 Engine Water Temperature Check
43 Frequency Out of Range - Low
44 Fuel System Check
45 Frequency Out of Range - High
46 Check Air Filter
51 Alternator Overload Alarm
61 Low Battery Alarm, Low Battery Alarm during Crank,
or High Battery Alarm
63 Engine Stopped - Reason Unknown
66 Low Engine Oil Level
69 Field Relay (Exciter) Circuit Check
70 Any Hourmeter or Counter Exceeds Limits
71 Hourmeter 1 Exceeds Threshold
72 Hourmeter 2 Exceeds Threshold
74 Control Reverted to Default Settings
88 Microprocessor Internal Error
99 Restart Null
10-47
SERVICE BULLETIN
SUBJECT: Sealed Expansion Valve on Sea-Land CSR Units

BULLETIN NO. C 027
DATE: August 7,1998
The expansion valve on all Sea-Land CSR units was perma- If expansion valve operation is determined to be faulty, the
nently sealed at the factory. Therefore any attempt to remove valve must be replaced. Order expansion valve P/N 66-8976.
the cover from the valve stem will permanently damage the
valve.
The expansion valve, P/N 66-8976, on all Sea-Land CSR units

must be replaced when defective or out of adjustments.
AJA531
Sea-Land CSR Refrigerant Piping and Expansion Valve
10-48
SERVICE BULLETIN
SUBJECT: New Dehydrator, P/N 66-9015, for ALL CF-II Series Units
BULLETIN NO. C 028
A new dehydrator, P/N 66-9015, is now available for use on all CF-II refrigeration systems. The new dehydrator features a black,
double coat paint finish to improve corrosion resistance in marine applications.
Dehydrator 66-9015 replaces dehydrator 66-508. All Container Dealers should begin stocking this new dehydrator immediately.
Container Unit Model Use Dehydrator P/N

CF-II and CF-III Units 66-9015* (Replaces 66-508)
CRR Smart Reefer Units 66-8473*
CRR Units 506-129
CSR Smart Reefer Units 66-8767*
These dehydrators feature an improved corrosion resistant finish.
10-49
SERVICE BULLETIN
SUBJECT: CSR Versus CRR Service Guide and Refrigeration

System
Service Procedures
BULLETIN NO. C 029
With thousands of CSR and CRR Smart Reefer(r) units now CSR units use advanced scroll compressor technology with
in service throughout the world, service technicians must R-404A refrigerant. With just 4 moving parts, scroll technol-
remember that CSR units have different service guidelines ogy maximizes pumping efficiency. Furthermore, radial and
and refrigeration system service procedures than CRR units. axial compliance combine with the centrifugal force of scroll
technology so scroll members maintain continuous contact to
CRR units use the Copeland 3DS reciprocating compressor actually “wear- in” rather than wear out. Consequently, per-
with R-134a refrigerant. Most technicians have years of expe- forming a compressor capacity and pump down test is not
rience with this package and probably received their basic necessary on a scroll compressor, and in fact may actually
refrigeration system service training on a unit using semi-her- damage the internal scroll set. Also, scroll compressors are
metic, reciprocating compressor technology. Technicians hermetically sealed, eliminating frequent replacement of the
learned that the pumping efficiency of the pistons and dis- dehydrator.
charge valves in the compressor could be periodically
checked using a compressor capacity (efficiency) and pump When dehydrator replacement is necessary, do NOT pump the
down test. Also, replacement of the dehydrator on systems system down below 0 psig (0 kPa, 0 bar).
with semi-hermetic reciprocating compressors allows the sys-
tem to be “pumped down” to 10” to 15” Hg vacuum (-35 to Refer to the charts below for more detailed information about
-50 kPa, -0.35 to -0.50 bar). the differences in service guidelines and repair procedures
between CSR and CRR Smart Reefer(r) units.
CSR Unit CRR Unit Service Interval Guide

Every Annual/ Every Annual/
1,000 Yearly 1,000 Yearly
Pretrip Hours Pretrip Hours Inspect/Service These Refrigeration System Items
Yes Yes Yes Yes Yes Yes Check refrigerant charge.
Yes Yes Yes Yes Yes Yes Check for proper discharge and suction pressure.
Yes Yes Yes Yes Yes Yes Check compressor oil level.
-- -- No1 -- -- Yes Check compressor efficiency and pump down refrigeration system.
-- -- No1 -- -- No Replace dehydrator2.
Yes Yes Yes Yes Yes Yes Check liquid filter and dehydrator2 for a restriction or corrosion.
1CAUTION: DO NOT pump a scroll compressor into a vacuum to perform maintenance or service.
2
Replace the dehydrator whenever the high side Is opened, or when the low side is opened for an extended period of time.
Procedure
CSR Unit CRR Unit Item or Repair/Service
Scroll Compressor Reciprocating Compressor Compressor Type
Reclaim Refrigerant Reclaim Refrigerant Open the high side of the refrigeration system.
Reclaim Refrigerant Low Side Pump Down Open the low side of the refrigeration system.
10-50
SERVICE BULLETIN
SUBJECT: Injection Pump Timing Bolt Change to Provide

Positive Fuel
Shutoff on CG and SG (Smart) Generator Sets
BULLETIN NO. C 030
DATE: November 20,1998
There have been some field reports that Generator Set units Timing Bolt Replacement Procedure
built after 3/1/98 do not shut down. This is due to a recent 1. Turn the Unit On-Off switch to OFF.
modification in the cam profile and rackset adjustment by the
engine manufacturer. These modifications increased the fuel WARNING: Disconnect the battery cables at the battery to
pressure to the plunger chamber. prevent the unit from accidentally starting.
This condition can be corrected by installing a new (shorter) 2. Remove the timing bolt from the end of the
the timing bolt. The timing bolt is located at the back of the injection pump. The timing bolt is located between the injec-
pump between the injection lines. The shorter bolt increases tion lines.
the volume in the plunger chamber, thereby reducing the fuel
pressure. 3. Install new BLACK timing bolt and COPPER lock
washer in injection pump. Tighten timing bolt to 17 ft-lb
This rework affects Generator Set units manufactured (23 N•m).
between 3/1/98 and 9/1/98. Units built after 9/1/98 have been
reworked at the factory. Check for a BLACK timing bolt and 4. Reconnect battery cables and start the unit.
COPPER washer to identify fuel pumps that has been modi-
fied to correct the fuel shutdown problem. 5. Check the engine speed setting. Loosen the jam nut on
the speed adjustment screw and set engine speed:
Tools Required: • 1800 +/- 10 rpm at Full Load (Alternator Output)
- Wrench and Socket Set • 1950 +/- 10 rpm at No Load
- New Timing Bolt and Copper Washer
NOTE: Parts for this rework are available through the

Service Department. call (612) 887-2620.
After timing bolt is installed,

check and adjust engine speed.
To set speed, loosening jam nut
and turn speed adjustment screw.
Install new BLACK timing bolt and COPPER

flatwasher. Torque bolt to 17 ft-lb (23 N-m).
AJA532 se 2.2 Injection Pump
10-51
SERVICE BULLETIN
SUBJECT: Thermo King 11.71 (or above) Software

Release
BULLETIN NO. C 031
DATE: January 11, 1999
This is to advise all reefer locations of the campaign rework • New low voltage alarm: Controller now de-energizes unit
program being done by Thermo King on CSR and CRR units. contactors to stop compressor, fan motor and heater oper-
This campaign is being done by designated Thermo King ation when a supply power low voltage condition exists.
dealers and will: Controller display will show “Pause Alm43” when power
• Upgrade µP-D controller to 11.71 or above software supply voltage is low. When supply voltage returns to
• Install capacitor module in unit control box normal, the controller restarts the unit to resume normal
• Relocate the evaporator coil sensor (if necessary) temperature control operation.
11.72 Software Upgrade Features

NOTE: “Pause AIM43” will also appear in controller
The 11.72 software upgrade includes items required for
display when the Setpoint Enable function is activated to
water-cooled condenser and hermetic compressor applica-
tions only. download the controller data logger memory or change the
setpoint.
11.71 Software Upgrade Features
• New liquid injection algorithm: The controller now turns
The 11.71 software upgrade includes items that increase the
on liquid injection for 5 minutes after each compressor
accuracy of automatic phase selection and automatic pretrip
startup (includes initial unit start, start after defrost and
tests, and improve unit performance. The following list of
start after Null). The controller also energizes liquid
upgrade features includes some items that will be evident to
injection continuously during the modulation mode.
technicians during unit startup and operation:
• New compressor motor internal overload detection: The
• Improved automatic phase selection algorithm: Control-
controller now detects a compressor motor internal over-
ler display now shows “Phase Check” during initial star-
load shutdown and de-energizes the compressor contac-
tup as controller energizes the heaters, condenser fan and
tor and evaporator fan contactors. The controller will try
evaporator fans to select correct phase sequence. The
to restart the compressor on 5 minute intervals. If the
original 15 second start sequence now takes 50 to 80 sec-
compressor is unable to restart within 2 hours, alarm code
onds. It may take longer if the power phase is extremely
“50” (Compressor Current Out-of-Range) is recorded.
noisy.
Previously alarm code “-50” could only be generated dur-
• Improved automatic pretrip test algorithm: During a Full
ing an automatic Pretrip Test.
or Extended Pretrip Test, the controller pre-cools or pre-
heats the container as required to achieve a 32 F (0 C)
container return air temperature before starting the cool- NOTE: A hyphen (-) precedes an alarm code thatis
ing capacity test. If the unit is unable to cool or heat the generated during an automatic Pretrip Test.
container to achieve 32 F (0 C) within 4 hours, alarm • New automatic detection of USDA and Pulp sensors: The
code “-64” (Pretrip Precondition alarm) is recorded. The controller now automatically activates data logging of the
new pretrip algorithm also includes load protection that USDA and Pulp sensor temperatures when the sensors
prevents the unit from performing a Full Pretrip Test on a are installed. However, technicians must still activate
loaded container. (turn ON) USDA or PULP temperature recording via the
NOTE: A hyphen (-) precedes an alarm code that is controller keypad to calibrate the sensors and to activate
generated during an automatic Pretrip Test. the sensor alarm feature.
10-52
• New Celsius or Fahrenheit temperature display selection Additional software changes:

via “hot keys” on keypad: The temperature units shown - Data logging of sensor calibration offsets has been added.
in the controller display can now be quickly changed. - Display of the evaporator coil sensor has been added to the
Just press and hold the C/F key, and then press the scroll menu when the unit is in the Refrigeration Test mode.
ENTER key This changes the temperature display units - Digital Input (MENU DIGIN) items have been deleted from
from Fahrenheit to Celsius, or Celsius to Fahrenheit. the control test menu.
New Capacitor Module

NOTE: Alternate temperature units (Celsius or Fahrenheit)
A capacitor module is being installed in the circuit between
may still be temporarily viewed on the controller display by
µP-D controller and current transformer module to improve
pressing and holding the C/F key only.
phase selection on “noisy” power lines.
CAUTION: Always check the temperature unit scale that New Evaporator Coil Sensor Location
appears in the controller display when changing the The evaporator coil sensor is being relocated to increase coil
setpoint, The setpoint temperature MUST be entered using temperature sensing accuracy.
the temperature unit scale shown on the shipping manifest.
Coil Sensors New Location

(inserted between rows 2 Old Location (inserted between
and 3 from front of unit) rows 1 and 2 from front of unit)
Unit Back
Coil Support
Brackets (2)
AJA533
Unit Front 11 in. (279.4 mm) 1.5 in. (38.1 mm)
CSR and CRR Evaporator Coil Sensor Location (Top View)
10-53
SERVICE BULLETIN
SUBJECT: Check Mounting Bolt Torque of Suction Flange

Connections on CRR Units with "29K" in the Serial
Number (xxx29Kxxx)
BULLETIN NO. C 032
DATE: July 23,1999
It has been reported that some CRR units have been found 1
with an under-torqued suction flange connection. Units that
have been found with an undertorqued flange on the suction
side all have "291K" in the middle of the serial number:
"xxx29Kxxx". Thermo King recommends that the suction 2
flange bolts be checked and torqued during a Pretrip Inspec-
tion.
A total of six bolts should be re-torqued to assure a

tight suction flange connection:
1. 4 Bolts Mounting Flange Collar to Valve:

Torque to 14 to 16 N.m (10 to 12 ft-lb).
NOTE. Tighten bolts in a ’X’ Pattern.

2. 2 Bolts Mounting Flange to Compressor Body:
Torque to 58 to 64 N.rn (43 to 47 ft-lb).
Mark or paint the suction flange bolts to indicate that the bolts have
been checked and torqued.
AJA583
10-54
SERVICE BULLETIN
SUBJECT: Procedures for Belt Tension Adjustment on

Thermo King Gensets
BULLETIN NO. C 033
CAUTION: Do not over-tension belts. Correct tension is
critical to smooth unit operation.
The belt tensions shown in the table below should be used to maxi-
mize belt life on Thermo King Gensets. CG11 gensets use special WARNING., Do not attempt to adjust belts with the unit
"A" type belts that minimize belt wrap on the pulleys for longer belt
operating.
life.
The following guidelines apply when adjusting the Adjusting Fan/Water Pump Belt Tension on Units
belt tension on Thermo King Gensets: with Sliding Pulley on Fan or Crankshaft Pulley
1. Remove bolts from adjustable pulley:
• All belt tensions should be checked using belt tension
gauge P/N 204-427. • Units with sliding pulley on crankshaft, remove bolts
from the crankshaft pulley.
• Belt tension should be checked when the belt is cold.
Fan Pulley
• To minimize time spent installing and removing shims on
adjustable pulleys, install the new belt using all the shims
Check Tension
provided with the unit (including any extra shims located
Here with Belt
on the outer face of the pulley). Check belt tension. If Gauge or Allow
necessary, remove shims to achieve correct tension. Place 0.75 to 1.0 inch
extra shims on outer face of the pulley. (19 to 25 mm)
Deflection
NOTE. When adjusting the belt tension using shims and
adjustable pulleys, the belt may still feet loose when the belt
Crankshaft Pulley AJA534
tension gauge indicates the correct tension. Allow 0.75 to
1.0 inch deflection with 6 to 9 lb (3 to 4 kg) of force. Fan/Water Pump Belt with Sliding Pulley on Fan or
• Do not attempt to remove or install belts without loosen- Crankshaft Pulley
ing adjustments. Belts that are installed by prying over
pulleys will fail prematurely due to internal cord damage.
Fan/Water Pump Belt Tension Adjustment Information
Belt Tension* Belt Deflection
Belt Adjustment Unit Date of Belt Stationary Sliding Shims
New or 6 - 9 lb (3 -4 kg)
Method Manufacture P/N Pulley P/N Pulley P/N P/N (Qty)
Field Reset of Force
Crankshaft Pulley After 2/96 78-1011 15 to 35 0.75 to 1.0 inch 77-2390 77-2385 77-2386 (6)
(19 to 25 mm) 77-2387 (1)
Crankshaft Pulley Before 2/96 78-943 15 to 35 0.75 to 1.0 inch 77-2260 77-263 77-2261 (6)
(19 to 25 mm) 77-2262 (1)
Fan Pulley -- 78-943 15 to 35 0.75 to 1.0 inch 77-2225 77-1187 77-1285 (5)
(19 to 25 mm) 77-2164 (1)
Idler Pulley -- 78-429 15 to 35 0.75 to 1.0 inch -- -- --
(19 to 25 mm)
10-55
Idler Pulley -- 78-667 15 to 35 0.75 to 1.0 inch -- -- --

w/Eyebolt (19 to 25 mm)
* Using belt tension gauge, TK P/N 204-427.
• Units with sliding pulley on fan, remove bolts from the

fan pulley. 5. Tighten the idler bracket support nut and bolt.
2. Remove the sliding pulley section.
3. Add or remove shims as necessary (see Belt Tension

Adjustment Information table for shim part numbers). Fan Pulley Idler Pulley Fan
4. Install belt on the pulley. Replace sliding pulley section

and tighten pulley mounting bolts. Check Tension
Here with Belt
Gauge or Allow
5. Check tension on belt span between the fan pulley and 0.75 to 1.0 inch
crankshaft pulley. (19 to 25 mm)
• Belt tension gauge should read 15 to 35; or Deflection
• Belt deflection should be 0.75 to 1.0 inch (19 to 25 mm)
with 9 lb (4 kg) of pressure.
Crankshaft Pulley
AJA535
6. Place any extra shims on the outer face of the sliding pul-
ley. Fan/Water Pump Belt with Idler Pulley Adjustment
Adjusting the Fan/Water Pump Belt Tension on

Units with Idler Pulley Adjustment Idler Pulley Idler Pulley Water Pump
Support Bracket Pulley
1. Loosen idler pulley adjustment nut.
Idler Pulley
2. Adjust the idler to change belt tension. Support Bracket
Bolt and Nut
3. Tighten locking nut on the idler pulley.
Eyebolt and
4. Check tension on belt span between the fan pump pulley Locking Nut
and crankshaft pulley.
• Belt tension gauge should read 15 to 35; or Check Tension Here
• Belt deflection should be 0.75 to 1.0 inch (19 to 25 mm) with Belt Gauge or
with 9 lb (4 kg) of pressure. Allow 0.75 to 1.0 inch
(19 to 25 mm) Deflection
Adjusting Fan/Water Pump Belt Tension on Units
with Idler Pulley and Eyebolt Adjustment Crankshaft Pulley
AJA536
1. Loosen idler pulley support bracket nut and bolt (nut

Fan/Water Pump Belt with Idler Pulley
located behind bracket).
and Eyebolt Adjustment
2. Adjust the eyebolt to change belt tension.
3. Check tension on belt span between the idler pulley pul-

ley and crankshaft pulley.
• Belt tension gauge should read 15 to 35; or
• Belt deflection should be 0.75 to 1.0 inch (19 to 25 mm)
with 9 lb (4 kg) of pressure.
4. When belt tension is correct, tighten locking nut on eye-

bolt.
10-56
SERVICE BULLETIN
SUBJECT: Use the Thermo King EXTRANET Site on the World

Wide Web to View and Download Files for Container
Products
BULLETIN NO. C 034
Now dealers and designated customers can view or download service bulletins and other container service and product information from the
World Wide Web. The "www.thermoking.com" site provides service bulletins, maintenance manuals and microprocessor software from a
"password protected" EXTRANET area of the Thermo King web site. To begin viewing and downloading information from the web site, apply
for a password today! See instructions on how to registration below, how to view or download files on page 6 and how to download Acrobat
Reader on page 10.
NOTE. Documents on the EXTRANET are stored in a ".pdf" file format You must have Acrobat Reader Installed on your computer to
open and view these documents Acrobat Reader is required whether you view and print documents online, or download Me documents for
viewing and printing.
Additional regions of information on the Thermo King web site include:
• DEALERS: This region allows visitors to simply point and click on a geographical location for a directory of dealer addresses,
telephone numbers and hours of operation.
• PRODUCTS: This region details the features of Thermo King Truck, Trailer, Sea-going Container and Bus Transport Refrig-
eration units including heating and cooing capacity, as well as power consumption.
• FEATURES: This region select stories from Thermo King customer newsletters.
• ABOUT US: This region details the company history, manufacturing plant and parts warehouse locations and recent news
releases.
• CONTACT US: Use this region to
request product information from the
Thermo King Webmaster.
• CAREER OPPORTUNITIES: This
region fists Thermo King employment
opportunities.
How to Register for Password

Access to the Thermo King
EXTRANET
1. Start the Internet Browser on your

computer.
Go to "wwwThermoking.corri". The
Thermo King home page will appear.
Click on "EXTRANET".
AJA537
10-57
2. The EXTRANET log in screen

appears.
To apply for EXTRANET access, click

on "create an account".
AJA538
3. The Registration screen appears.
Complete the form. Check your entries

for accuracy.
Then select the information

"Resources" you want to access for
viewing or downloading.
Then click on "Register".
Select the information

"Resources" you want
to access here.
AJA539
10-58
4. The "Thanks for registering!" screen

appears when your application has
been successfully entered.
NOTE: You must CONFIRM your

EXTRANETapplication submission
within 48 hours. Go to step 5 now, or
when you are ready to confirm your
application.
AJA540
5. When you apply for an EXTRANET

account a "TK Extranet Registra-
tion" Email is immediately sent to
the E-mail address on your applica-
tion.
Start the E-mail software on your com-
puter and open the letter.
The letter lists the EXTRANET features

you have requested access to use and
issues you a temporary password.
Write down the password.
AJA541
10-59

computer.
Go to "www.thermoking.com" again.
The Thermo King home page will appear.
7. When the EXTRANET Log In

screen appears, log in by entering
your "user name" and the "pass-
word" assigned to you in your "TK
Extranet Registration" Email
letter.
Then click the "LOG IN" button.
AJA542
8. The EXTRANET home page

appears.
Click on "My Profile"
AJA543
10-60
9. When the My Profile screen

appears, complete the form.
To change an entry, highlight the appro-

priate text box and "delete" the existing
text. Then type your new entry.
NOTE. Thermo King recommends that

you enter a new password. The
password must be 6 to 8 characters
(letters or numbers) You must click on
the "SAVE" button before you exit the
"My Profile" screen to change the
password. Remember your password.
Check your profile entries for accuracy.
Then click on "Save".
NOTE: You must Log in and complete

your EXTRANET profile to CONFIRM AJA544
your application request within 48
hours of submitting your online
registration.
10. The Thermo King customer service

team will review your EXTRANET
account request, and appropriate
access permissions as soon as pos-
sible. Please allow 7 to 10 business
days for account approval.
Click on "Log Out" to end your

EXTRANET session.
10-61
How to View or Download Files on

the Thermo King Extranet
computer.
Go to “www.thermoking.com”. The
2. Click on "EXTRANET".
3. When the EXTRANET Log In

screen appears, type your user
name and password. Use the pass-
word issued in your "TK Extranet
Registration" Email. If you changed
your password, use the password
you entered and saved in the "My
Profile" screen.
Then click the "LOG IN" button.
AJA542

appears.
Click on "Files" to view the EXTRA-

NET directory.
NOTE: The "Welcome to Thermo

King’s Extranet!" page will state
whether or not the internet browser on
your computer meets the web site’s
requirements. If not, a message above
the middle of the page will indicate that
you need to upgrade your internet
browser. If you need to upgrade your
browser software, hot link buttons for
Microsoft and Netscape software will
appear at the bottom of the page.
AJA543
10-62
5. A new sub-directory or file list will

appear.
Click on the sub-directory you Want to

view (for example, Container, Bulletins/
Service).
Continue to click through the EXTRA-

NET Directory until the file, or file list
you want appears.
AJA557
6. You can view files online or down-

load files to view later on your com-
puter.
• Online Viewing:
a. Click the left mouse button on the

diskette icon.
NOTE. If the left mouse button is

clicked on the file name, the directory
list and file names are redisplayed in
another format.
b. Your Internet Browser should
automatically start Acrobat Reader
on your computer and then display
the file you selected.
NOTE You can print documents
while viewing them online If your
computer is connected to a printer.
c. Click the "Back" button to return
to the EXTRANET directory to
view another document.
CAUTION: Do not click "File/Close"
in the browser menu unless you want to
end your internet session. Clicking on
"File/Close" will close the Internet
browser on your computer, disconnect-
ing you from the Thermo King EXTRA- AJA558
NET web site.
10-63
• Downloading a File:
NOTE To assure that all your

documents contain the latest updates,
Thermo King recommends viewing and
printing documents online.
a. Click the right mouse button on
the diskette icon. A context menu
appears.
CAUTION: Do NOT right click on the

file name. If the right mouse button is
clicked on the file name, a text file of
the web page will download to your
computer.
b. Click the left mouse button on
"Save Target As".
AJA559
c. The File Download and the Save As

windows appear.
Select where (drive and directory) you

want to save the file you are going to
download.
Check the File Name text box to make

sure the correct file has been selected.
Documents like service bulletins, main-
tenance manuals and instruction sheets
must include the file name extension
".pdf".
NOTE: When you download flies,

Thermo King recommends that you do
not change the file name.
Then click “Save”.
AJA562
10-64
d. A copy of the file you selected will

download to your computer.
When the file download is complete,

click "Close" to exit the download task
and return to the EXTRANET directory.
AJA563
10-65
How to Download Acrobat Reader

for Viewing EXTRANET Docu-
ments
If you do not have Acrobat Reader
installed on your computer, you can
download Acrobat Reader for free.
1. Click on the "Get Acrobat

Reader" hot link button that
appears at the bottom of each
EXTRANET file list.
AJA564
2. A web link takes you to the Adobe®

Acrobat Reader web site.
Follow the web site instructions to

download a free copy of Acrobat Reader
to your computer.
AJA565
10-66
SERVICE BULLETIN
SUBJECT: PC-PAC V3.3 Upgrade Now Available from the

Public File Download Center at the Thermo King
EXTRANET Site
BULLETIN NO. C 035
Now dealers and customers can download an upgrade copy of PC-PAC V3.3 from the World Wide Web. The "www.thermoking.com" site pro-
vides a "Public File Download Center" hot link on the EXTRANET area of the Thermo King web site. The PC-PAC V3.3 upgrade can be
downloaded without applying for an EXTRANET account or logging into the EXTRANET home page. See instructions on how to download
the PC-PAC V3.3 installation file and installation instructions on page 2; and how to download Acrobat Reader on page 4.
NOTE. You must have Acrobat Reader installed on your computer to open and view the PC-PAC installation instructions.
Acrobat Reader is required whether you view and print documents online, or download the documents for viewing and
printing.
PC-PAC V3.3.NEW FEATURES AND IMPROVEMENTS included in Upgrade Software:
• New Set Header menu includes
Send Header A PLUS LOGGER
function and Send Header GDL
LOGGER function. Use "Send
Header A PLUS LOGGER" to send
headers to µP, µP-A and µP-A con- DOWNLOAD THE
trollers; and µP-D controllers that
will be downloaded using PC-PAC
2.0 or a power line communications
system. Use "Send Header GDL
PCPAC V3.3
LOGGER" to send headers to µP-D
controllers that will be downloaded
with PC-PAC 3.2 or higher.
PATCH TO UPGRADE
• Improved support for µP-D reports.
PCPAC V3.2
Sensor names for supply and return
air sensors and setpoint can not be
changed.
Version 3.3 of PC-PAC software is fully
compatible with (and will handle all data
files produced by) previous versions of
PC-PAC. It is fully compatible with the NOTE. The PC-PAC V3.3 download
following Thermo King container micro- patch will NOT update PC-PAC V2.0 or
processor controllers and data logging
systems:
earlier. You must have PC-PAC V3.2
• µP-D Microprocessor Controllers installed on your computer to upgrade
• µP-A Microprocessor Controllers to PC-PAC V3.3.
• µP-A Microprocessor Controllers
• µP, Microprocessor Controllers
• SRMU Data Logging System
10-67
How to Download PC-PAC V3.3

Upgrade Software and Installation
Instructions

computer.
Go to "www.thermoking.com" The
AJA537
2. The "EXTRANET" log in screen

appears.
To download public files, click on

"Public File Download Center" hot
link located near the top of the screen.
AJA538
10-68

appears.
Click on the directory "Files". A new

sub-directory or file list will appear.
Continue to click through the Directory

(e.g. Extranet/Custom/ Files/Container/
PC Pac Patch) until the "PC Pac Patch"
file list appears.
AJA566
4. Download the PcPac V3.3 Upgrade

installation file to your computer
a. Click the right mouse button on

the diskette icon for the file
"PcPac3.3UPgrade.exe"

file name. If the right mouse button Is
clicked on the file name, a text file of
the web page will download to your
computer.
b. A context menu appears. Click
the left mouse button on "Save
Target As".
AJA567
10-69

windows appear.

download.

NOTE: Changing the File Name is not

recommended.
Then click "Save".
AJA568


click "Close" to exit the download task.
AJA569
10-70
5. Download the PcPac V3.3 Upgrade

installation instructions to your
computer
a. Click the right mouse button on the

diskette icon for the file "pcpin-
str.pdf".

file name. If the right mouse button is
clicked on the file name a text file of the
web page will download to your com-
puter
b. A context menu appears. Click the

left mouse button on "Save Target As".
AJA567

windows appear.

download.

Documents like service bulletins, main-
tenance manuals and instruction sheets
must include the file name extension
".pdf".
Then click "Save".
AJA568
10-71


click "Close" to exit the download task.
AJA570
How to Download Acrobat

Reader for Viewing EXTRANET
Documents
If you do not have Acrobat Reader

installed on your computer, you can
download Acrobat Reader for free.
1. Click on the "Get Acrobat

Reader" hot link button that
appears at the bottom of each
EXTRANET file list.
AJA566
2. A web link takes you to the

Adobe@ Acrobat Reader web site.
Follow the web site instructions to

download a free copy of Acrobat Reader
to your computer.
AJA565
10-72
SERVICE BULLETIN
SUBJECT: µP-D Controller Replacement

BULLETIN NO. C 037
A replacement controller contains the most current software Step 1: Determine Correct Controller Configuration
version and default settings that allow it to function when and Sensor Grade Information
installed in a unit. However, CORRECT unit operation To obtain the correct unit configuration, customer configura-
REQUIRES that the Unit Configuration, Customer Configu- tion and sensor grade information for a unit:
ration and programmable Sensor Grades be set to the UNIT a. See the Controller Setup Decal located inside the control
specific features and sensors. box door. This decal will contain the most accurate setup
information for the unit.
NOTE. When alarm code 42 is present, unit operating
CONTROLLER SETUP INFORMATION -
features are limited but the unit will operate in the Coot and
DO NOT REMOVE
Heat modes to control the container temperature. Alarm
DESCRIPTION DISPLAY SETTING CHANGES
code 42 indicates that the Unit Configuration and Customer Software Revision REV
Configuration must still be set to activate UNIT specific Unit Configuration CFG U
Custom Configuration CFG C
features.
Supply Sensor Grade SUP G
Return Sensor Grade RET G
µP-D Controller Replacement Guidelines Evap Sensor Grade ECT G
1. Determine and record correct controller configuration
Sensors Grades of 0 have been Ice
and sensor grade information: Water Calibrated
• Unit Configuration: CFG U_________________
• Customer Configuration: CFG C _______________ AJA571
• RET G ________
• SUP G ________ b. If the Controller Setup Decal is missing from the control
• ECT G ________ box, recover the Unit Configuration, Customer Configuration
2. Replace the controller. and programmable Sensor Grades from the previous control-
3. Program controller setup information: ler.
• Unit and customer configuration settings
• Sensor grade settings NOTE: See the Controller chapter in the unit maintenance
• Controller date and time (GMT) manual for instructions on:
• Container identification number • Reviewing Software Version and Configuration.
• Unit serial number • Menu View Functions to view GRADE submenu and
• Compressor and On Time hourmeters hourmeter readings.
4. Perform unit Pretrip test before returning unit to service.
c. If this information can not be recovered from the previous
controller (and the Controller Setup Decal is missing):
• See Container Service Bulletin C-038 to obtain the cor-
rect unit configuration and customer configuration set-
tings.
• Remove the return air, supply air and evaporator coil sen-
sors from their probe holders and read the grade stamped
on the side of the sensor to obtain the correct sensor
grades.
10-73
Step 2: Replace the Controller Step 3: Program Controller Setup Information

a. Disconnect the unit power cord from the power supply. Proceed immediately to enter controller settings. The follow-
ing information MUST be set:
b. Disconnect all wire harness connectors from the back of • Unit and Customer Configuration Numbers
the controller. • Sensor Grades
• Date and Time (GMT)
c. Remove the screws that secure the controller to the control • Container Identification Number
box door. • Unit Serial Number
d. Remove the controller and gasket from the door. Place the Setting the following information is optional:
old controller in the anti-static bag. • Compressor and On Time Hourmeters
e. Install the replacement controller and gasket in the door NOTE: See the Controller chapter of the unit maintenance
using the existing hardware. manual for instructions on: Menu Guard Functions to set
the Unit and Customer Configuration Numbers, Sensors
CAUTION. Do NOT over tighten the mounting hardware or Grades, Time and Date, Container Identification Number,
the controller may be damaged. Unit Serial Number, Compressor Hourmeter and On Time
f. Attach the wire harness connectors to the back of the con- Hourmeter
troller.
Step 4: Perform a Unit Pretrip Test
Perform a Pretrip Test to verify correct unit operation.
NOTE. Be certain that all connectors are fully seated until
the connector rings lock.
g. Plug the unit power cord into the proper power supply.
h. Turn the unit On/Off switch ON. The unit should start and
the Standard Display should appear on the controller.
NOTE. Alarm code 42 will be present in the display when

the ALARM key is pressed This indicates that the correct
Unit Configuration and Customer Configuration must still
be set.
10-74
SERVICE BULLETIN
SUBJECT: Unit and Customer Configuration Settings for µPD

Controller
BULLETIN NO. C 038
A replacement controller contains the most current software missing from the unit control box, refer to unit model list
version and default settings that allow it to function when below to obtain the correct unit configuration and customer
installed in a unit. However, CORRECT unit operation configuration settings.
REQUIRES that the Unit Configuration, Customer Configu- NOTE. See the Controller chapter of the unit maintenance
ration and programmable Sensor Grades be set to the UNIT manual for instructions on µP-D controller replacement.
specific features and sensors. If this information can not be
recovered from the previous controller and the Controller
Setup Decal is missing from the unit control box. Refer to
CF-II Units with µP-D Controller CRR Units with µP-D Controller
Unit Unit Customer
Model Configuration Configuration Unit Unit Customer
CF-II M37.8 5004 1 Model Configuration Configuration
CF-II M48.1 5008 1 CRR40-52 5015 10
CF-II M49 5008 7 CRR40-54 5013 9
CRR20-64 5013 9
CSR Units with µP-D Controller CRR20-794 5014 3
CRR40-100 5014 5
Unit Unit Customer CRR40-101 5014 3
Model Configuration Configuration CRR40-102 5009 6
CSR40-4 5009 5 CRR40-103 5013 9
CSR40-42 5009 8 CRR40SL-104 5014 2
CSR40-46 5010 7 CRR40-106 5014 2
CSR40-47 5010 7 CRR40-107 5014 8
CSR40-57 5009 4 CRR40-110 5013 9
CSR40-66 5010 7 CRR40-111 5013 9
CSR40-67 5010 4 CRR40-112 5014 8
CSR40-100 5011 7 CRR40-113 5014 14
CSR40-101 5010 7 CRR40-114 5014 4
CSR40-102 5009 6 CRR40-121 5014 5
CSR40-103 5013 9 CRR40-123 5014 14
CSR40-104 5010 2 CRR40-124 5014 2
CSR40-109 5009 7 CRR20SL-125 5014 3
CSR40-110 5009 6 CRR40-126 5014 3
CSR40SL-111 5017 9 CRR40-128 5014 1
CSR40-112 5009 10 CRR-40-133 5013 9
(Continued on next page)
(Continued on next page)
10-75
CSR Units with µP-D Controller (Continued) CRR Units with µP-D Controller (Continued)
Unit Unit Customer Unit Unit Customer

Model Configuration Configuration Model Configuration Configuration
CSR40-113 5009 7 CRR40-136 5022 9
CSR40-114 5009 5 CRR40-138 5014 14
CSR40-115 5009 5 CRR40-140 5014 14
CSR40-116 5017 5 CRR40-141 5013 9
CSR40-117 5012 5 CRR40-148 5014 2
CSR40-118 5020 7 CRR40-154 5014 7
CSR40-119 5018 7 CRR40-160 5013 14
CSR40-120 5020 7
CSR40-121 5018 3
CSR40-122 5020 7
CSR40-123 5019 4
CSR40-125 5009 7
CSR40SL-126 5017 7
CSR40-128 5017 9
CSR40-129 5018 14
CSR40SL-130 5019 7
CSR20SL-131 5019 7
CSR40-133 5009 14
CSR40-134 5017 3
CSR40SL-136 5017 7
CSR40SL-143 5017 4
10-76
SERVICE BULLETIN
SUBJECT: Unit Health Check for CSR Hermetic Refrigeration Systems
BULLETIN NO. C 039

DATE: March 14, 2000
CSR Hermetic units do not have service valves, fittings or To Check dT on Units with MP-3000 Controller:
sight glasses installed in the refrigeration system. Therefore, a a. Press F4 key to directly enter the Data menu. Read:
controller Pretrip Test is used to determine that a CSR Her- • Supply Air Temperature, Right Hand
metic refrigeration system contains an adequate charge of • Return Air Temperature
refrigerant for cooling. If the unit passes the Pretrip Test, the b. Subtract the supply air temperature (right hand) from the
refrigerant charge is generally OK. However, unit cooling return air temperature to determine dT.
performance may not be affected by a marginally low refrig-
erant charge (1 to 3 lbs [0.5 to 1.4 kg] low) under all ambient NO TE: Press the “5” key to lock a Data screen in the LCD
operating conditions. To accurately determine the cooling per- display for 5 minutes. Press any key to unlock the display.
formance and refrigerant charge level, operate the unit on Full
Cool for 15 minutes or more: NOTE. Controller returns to previous menu level or
1. Adjust setpoint well below the ambient temperature to Standard Display after 30 seconds.
force unit to Full Cool. The Modulation Cool and Power
Limit functions must be OFF. To Check dT on Units with P-D Controller:
2. After 15 minutes, check the temperature difference (dT) a. Press the SELECT key to enter controller menu (display
across the evaporator coil. shows “MENU < --- >”).
3. Compare the unit dT to the expected values in table b. Press DOWN key until display shows “MENU VIEW”.
below. If dT is less than the value in the “possible low c. Press the SELECT key to enter VIEW submenu (display
refrigerant charge” column, visually inspect the unit for shows “VIEW < --- >”).
signs of a frosted or iced evaporator coil, low side d. Press the DOWN key to view “TD” value (e.g.”TD -03.7
obstruction in the refrigeration system, plugged expan- C”) in display.
sion valve, or a loose or defective expansion valve feeler
bulb before concluding the unit is low on refrigerant. NO TE: To lock the current Hew Menu screen in the
controller display press the ENTER key. A colon flashes in
NOTE: A negative (-) dT indicates the unit is cooling. A the left display to indicate the screen is locked (the screen
positive (+) dT indicates the unit is heating. remains locked for 15 minutes). Press any key to unlock the
display
NOTE. Inspect the unit for refrigerant leaks with a reliable
leak detector If the unit is suspected of being low on R404A NO TE: The controller returns to the Standard Display from
charge. a View Menu screen after about 10 seconds.
Refer to the Unit Health Check Table on the following page.
10-77
Table 1: Unit Health Check Table- Determining Possible Low R-404A Charge
Expected dT: dT less than figure

Power Ambient Return Air Return Temp. minus listed below indicates
Supply Temp. Temp. supply temp. (right possible low R-404A
hand) charge
38°C (100°F) -29°C (-20°F) -2.2°C (4.0°F) -1.7°C (-3.0°F)

-18°C (0°F) -4.3°C (-7.7°F) -3.2°C (-5.8°F)
-1°C (30°F) -3.9°C (-7.0°F) -2.9°C (-5.3°F)
10°C (50°F) -5.6°C (-10.1°F) -4.2°C (-7.6°F)
460V 27°C (80°F) -29°C (-20°F) -3.0°C (-5.4°F) -2.3°C (4.1°F)

3 Phase, -18°C (0°F) -4.8°C (-8.6°F) -3.6°C (-6.5°F)
60Hz -1°C (30°F) -3.8°C (-6.9°F) -2.9°C (-5.2°F)
10°C (50°F) -6.7°C (-12.0°F) -5.0°C (-9.0°F)
16°C (60°F) -29°C (-20°F) -3.0°C (-5.4°F) -2.3°C (4.1°F)

-18°C (0°F) -4.6°C (-8.3°F) -3.5°C (-6.2°F)
-1°C (30°F) -4.5°C (-8.1°F) -3.4°C (-6.1°F)
10°C (50°F) -6.5°C (-11.7°F) -4.9°C (-8.8°F)
38°C (100°F) -29°C (-20°F) -2.1°C (-3.8°F) -1.7°C (-2.9°F)

-18°C (0°F) -4.2°C (-7.5°F) -3.2°C (-5.6°F)
-1°C (30°F) -3.9°C (-7.0°F) -2.9°C (-5.3°F)
10°C (50°F) -5.7°C (-10.2°F) -4.2°C (-7.7°F)
380V 27°C (80°F) -29°C (-20°F) -3.0°C (-5.4°F) -2.3°C (-4.1°F)

3 Phase, -18°C (0°F) -4.8°C (-8.6°F) -3.6°C (-6.5°F)
50Hz -1°C (30°F) -4.3°C (-7.7°F) -3.2°C (-5.8°F)
10°C (50°F) -6.4°C (-11.5°F) -4.8°C (-8.6°F)
16°C (60°F) -29°C (-20°F) -3.0°C (-5.4°F) -2.3°C (-4.1°F)

-18°C (0°F) -4.9°C (-8.8°F) -3.7°C (-6.6°F)
-1°C (30°F) -4.7°C (-8.5°F) -3.5°C (-6.4°F)
10°C (50°F) -5.6°C (-10.1°F) -4.2°C (-7.6°F)
10-78
SERVICE BULLETIN
SUBJECT: Real Time Clock Batteries on µP-A, µP-A+ and µP-D

Controllers Not In Service
BULLETIN NO. C 040
This bulletin concerns the removal, storage and

installation of the real time clock battery in µP-A,
µP-A+ and µP-D controllers.
Several reports have been received that a controller
has been damaged by a leaking battery during
extended storage outside of a unit. Over time, any
battery may potentially corrode and leak, damaging
sensitive electronic components.
When storing µP-A, µP-A+ and µP-D controllers
and/or relay boards outside the unit, remove the Real Time Clock Battery Location in
µP-D Controllers
real time clock battery to prevent possible damage
to a printed circuit board.
When the controller or printed circuit board is
returned to service, install the real time clock
battery and set the controller’s Date, Time,
Container ID and other information.
Real Time Clock Battery Location in

µP-A+ Controllers
Real Time Clock Battery Location in

µP-A Controllers
10-79
Tools Required: NOTE: The Date, Time and other information

can also be entered using SmartSponge™
• Static Ground Wrist Strap, P/N 204-622
software. Detailed instructions can be found in
• 3.6 Volt Replacement Battery, P/N 203-439 (for the SmartSponge Help file or SmartSponge Users
installation in controllers being placed in Guide.
service)
Set µP-A/µP-A+ Container ID Number, TIme
• SmartSponge™ or PC-Pac Communications
and Date
Software
1. Install the controller) or printed circuit board) in
Real Time Clock Battery Removal or the unit.
Installation 2. Turn the Unit On/Off switch ON.
With the controller or printed circuit board
3. Verify the controller software version and
removed from the unit or packaging:
configuration settings by pressing the ENTER
1. Place a static ground wrist strap on your wrist key. Compare the information that appears in
and connect the strap to the ground terminal on the controller display with the Setup decal
the controller or circuit board. located in the control box.
2. Remove the battery access cover from the NOTE: If a Setup decal is not available, see
controller: Container Service Bulletin C-010-4 or above (or
consult a Thermo King factory representative) to
• µP-A Controller - Remove 6 mounting determine the correct software version and
screws from the rear cover panel. configuration number for the unit.
• µP-A+ Controller - Remove button plug 4. Enter the Guarded Access (“GrAc”) menu
from rear cover panel. (access is code “0007” or “0013”).
• µP-D Controller - Remove 2 mounting 5. Press the DOWN or UP key to scroll through he
screws from the battery access panel on the menu list tot he desire submenu.
back of the controller.
6. If the Configuration Block Selection (”Cb”)
3. Remove (or install) the battery, 3.6 V P/N 203- viewed in step 3 was incorrect, scroll to the
439. Configuration Block Selection line. Then enter
4. Replace the battery access cover. the correct Configuration Block Selection.
7. Scroll to the Container Identification Number
(“Cld”) line. Enter the correct Container ID
Set the Controller’s Date, Time, Number.
Container ID and Other Information 8. Scroll to the Time and Date (CLo”) line. Enter
The instructions below enter the Date, Time and the correct Hour, Minute, Day, Month and Year.
other information from the controller keypad. NOTE: Setting the Compressor On Time is
Detailed instructions can be found in the Controller optional when a new controller is installed.
chapter of the unit maintenance manual.
10-80
Set the µP-D COntroller’s Unit 6. If the Unit or Customer Configuration setting
COnfiguration, Customer Configuration, viewed in step 3 was incorrect, enter the
Container ID Number, Unit Serial Number, Configuration submenu (CNFIG <-->”). Then
Date and Time enter the correct Unit Configuration (“CFG U”)
Customer Configuration (“CFG C”) numbers.
1. Install the controller (or printed circuit board) in
the unit. NOTE: The Unit COnfiguration MUST always be
set first. Check the Setup Decal in the control box
2. Turn the Unit On/Off switch ON.
for the correct configuration numbers.
3. Verify the controller software version and
7. Return to the GUARD submenu and scroll until
configuration settings by pressing and holding
the display shows “CID11 XX”. ENter the
the ENTER key for 3 seconds. COmpare the
correct Container ID Number.
information that appears in the controller
display with the Setup decal located in the 8. From the GUARD submenu, scroll until the
control box. display shows “USN11 XXX”. ENter the
correct Unit Serial Number.
NOTE: If a Setup decal is not available, see
Container Service Bulletin C-010-4 or above (or 9. Return to the GUARD submenu and scroll until
consult a Thermo King factory representative) to the display shows “YEAR 1996”. Enter the
determine the correct software version and correct Year, Month, Hour and Minute.
configuration number for the unit.
NOTE: Setting the Compressor, On Time and
4. Enter the GUARD submenu (access is code User Hourmeters is optional when a new
“0007” or “0013”). controller or new software has been installed.
However, the Sensor Grades MUST be set. FOr
5. Press the DOWN or UP key to scroll through
detailed instructions, see “Setting the Sensor
the menu list to the desired submenu.
Grades” in the Controller chapter of the unit
maintenance manual.
10-81
SERVICE BULLETIN
SUBJECT: Manual Emergency Mode Operation or Replacement of

MP-300 Controllers
BULLETIN NO. C 040
This is to remind all personnel that they Must Manual Emergency Mode Operation
Always disconnect the unit power cord from the
In the event of an emergency situation where a
power supply before attempting to disconnect or
failure of the controller occurs, a manual
replace a MP-3000 controller.
emergency mode function can be used to operate
WARNING: The unit will automatically start and
the unit. However, the unit must be manually
operate if 460/380V power is present at the main
cycled ON and OFF using the unit460/380V main
relay board and Cable No. 2 is disconnected from
circuit breaker. This is because manual control
the controller. TO prevent personal injury from
disconnects both the controller and Unit On/Off
rotating machinery or dangerous electrical shock
switch from the main relay board.
from high voltage controls, disconnect the supply
power to the unit. Then proceed to replace the NOTE: On CSR units, both the 460/380V main
controller or prepare the unit for manual circuit breaker and the Unit On/Off switch must
emergency mode operation. be used to cycle the unit ON and OFF. The unit
On/Off switch must be ON to operate the scroll
Remote
compressor.
Monitoring MP-3000
Modem
Manual control offers a selection of six operating
Controller
positions. Refer tot he Manual COntrol decal in the
unit control box or the unit Maintenance Manual to
set the J501 Jumper for the desired unit operating
mode.
NOTE: CRR units and CSR units use different
J501 Jumper positions to provide cooling on
emergency mode operation.
Cable No. 2
The unit must by cycled ON and OFF manually to
maintain the desired temperature. Use the 460/
380V main circuit breaker to start and stop the unit.
Monitor container temperature with an external
thermometer.
NOTE: The unit cooling capacity on Chill loads
can be reduced by almost closing the suction
service valve when Cool 1 is selected. If the
MP-3000 Controller compressor overheats, select Cool 2.
10-82
1. To select Manual Control, turn the unit On/Off

switch to OFF> J501
Jumper
2. Turn the unit 460/380V main circuit breaker Decal for
OFF. Then disconnect the unit power cord from CRR Units
the power supply.

WARNING: The unit will automatically start and
operate if 460/380V power is present at the main
relay board when the controller is disconnected.
To prevent personal injury from rotating
machinery or dangerous electrical shock from
high voltage controls, disconnect the supply power
to the unit before preparing the unit for manual J18 Jumper
Decal
emergency mode operation.
3. Disconnect cable no. 2 from the controller and
main relay board (see electrical schematic). The
main relay board will now control the unit
based on the manual control setting.
CRR Decals for Manual Emergency Control
NOTE: you MUST check 2-pin plug location on
J501 connections of main relay board to ensure
Reversing Power Phase on CRR Units
correct unit operation.
On CRR units, use Jumper J18 to reverse the power
4. if necessary, remove 2-pin plug from J501 (see
phase.
decal on main relay board) and re-locate based
on the unit operating mode required. Refer to 1. Turn the unit 460/380V main circuit breaker
the Manual Control decal in the unit control OFF.
box.
2. Disconnect unit power cord from power supply.
5. Connect the unit power cord to the proper
3. Relocate the phase selector terminal plug from
power supply.
J18 (see decal on main relay board). Relocate
6. Start the unit by turning the unit 460/380V main from A to B (B to A) as required.
circuit breaker ON.
4. Connect unit power cord to proper power
NOTE: On CSR units, both the 460/380V main supply.
circuit breaker and the Unit On/Off switch must
be used to cycle the unit ON and OFF. The Unit 5. Start the unit again by turning the unit 460/
On/Off switch must be ON to operate the scroll 380V main circuit breaker ON. Check
compressor. condenser airflow again to confirm correct fan
rotation.
7. Check for correct rotation of condenser fan.
COndenser air should be blowing out form the Reversing power Phase on CSR Units
center of the grille. If the fan is running
backwards, the power supply phase must be On CSR units, use incoming power cable leads to
change. reverse the power phase. This is recommended on
CSR units because the Jumper J18 does not reverse
power to the scroll compressor. Using the incoming
power cable leads therefore protects against the
10-83
possibility that the compressor will be out of phase

with the condenser and evaporator fans when the J501 Jumper
unit is plugged into new power supply. Decal for CSR
Units
1. Turn the unit 460/380V main circuit breaker
OFF.
2. Disconnect unit power cord from power supply.
3. Relocate the position of the white and black
incoming power cord leads at the 460/380V
main circuit breaker.
4. Connect unit power cord to proper power J18 Jumper
supply. Decal
5. Start the unit again by turning the unit 460/

380V main circuit breaker ON and the unit On/
Off switch ON. CHeck condenser airflow again
to confirm correct fan rotation.
CSR Decals for Manual Emergency Control
10-84
SERVICE BULLETIN
SUBJECT: Replacement Procedure for New Style Power Cord

for Scroll Compressor
BULLETIN NO. C 042
DATE: January 12, 2001
Compressor Power Cord Replacement
All scroll compressors in units built after 9/15/00

include a new style compressor power cord. The
power cord requires the use of a new dielectric
grease during service or replacement.
Thermo King recommends that this special grease
and a new gasket be used when replacing a
compressor or repairing a new style compressor PN Where Used
power cord connection. The grease, gasket and a
new grounding screw and washer are provided in 40-781* Units with µP-D Controller
Power Cord Grease Kit, P/N 40-779. 40-782* CRR DF Units
Thermo King also recommends that this special 40-786* Units with MP-3000 Controller
grease and a new gasket be used when replacing an
*Kits include a power cord, grease, gasket and a
old style compressor power cord with a new style new grounding screw and washer
cord. Three power cord kits are available from
Service Parts. These kits will supersede old power
cord part numbers.
Power Plug LIberally Coat Inner and
Outer Surfaces of New
Gasket with Grease
Place a Small
Amount of Grease
in the COnnector
Terminal Holes
Coat the Gasket on

Ground Screw
Terminal Box
and Washer
Cover with Grease
10-85
Replacing an Old Style Compressor NOTE: All visible grease residue should be
Power Cord removed.
When replacing an old style compressor power 8. Install the new sealing gasket (orange) on the
cord with a new style cord, follow this procedure: compressor receptacle.
1. Make sure the unit On/Off switch is OFF. 9. Cut open a corner of the grease packet.
Liberally coat the inner and outer surfaces of
2. Make sure the 460/230V unit power cord has the gasket with grease. Also coat the boot
been disconnected from the power supply. surfaces and terminal spades with grease.
WARNING: To prevent against personal injury
from dangerous electrical shock from high 10. place a small amount of grease in the connector
voltage controls, disconnect the supply power to terminal holes of the power cord.
the unit before working on the compressor power 11. Lightly push the power cord connector onto the
cord. terminal spades and into the gasket. then slide
3. Remove the terminal box cover. the connector into the terminal box slot.
4. Remove the ground screw and disconnect the 12. Connect the ground wire using the new screw
ground wire. Then unplug power plug from the and washer.
compressor receptacle. 13. Lightly coat the gasket on their terminal box
5. Remove the old sealing gasket (orange) and cover with grease.
discard. If a foam rubber gasket is present 14. Install the terminal box cover.
between the sealing gasket and the compressor
body, it must also be removed and discarded.
6. Wipe the old grease from compressor’s
electrical connections with a dry rag.
7. Wipe down the electrical connections again
using a rag and common cleaning solvent. Any
common solvent such as paint thinner, lacquer
thinner or mineral spirits is sufficient.
10-86
SERVICE BULLETIN
SUBJECT: Setting µP-G Version 0200 Software for Use on Gensets

Equipped with Isuzu or Yanmar Engines
BULLETIN NO. C 043
This bulleting concerns the correct setting of the Setting Version 0200 Software for Use with
new “Engine Selection” screen in all units equipped an Isuzu or Yanmar Engine
µP-G controllers and EPROM chips with version NOTE: Version 0100 software does not contain
“0200” software.
the Engine Select screen and therefore should be
NOTE: The µP-G controller and EPROM chip only be used on a unit equipped with a di 2.2 or se
are sold separately by Service Parts. 2.2 (Isuzu) engine.
EPROM chip PN 40-751 (now available from 1. Make sure the unit On/Off switch is ON and the
Service Parts) is factory programmed with version LCD display shows the standard display
“0200” software. This software is factory set (voltage output).
(Engine Selection screen shows “YAnEN/YES”) to
2. Press SELECT key to access the Guard menu.
control Gensets equipped with a TK 486 (Yanmar)
engine. The Engine Selection screen MUST be set 3. Enter the current access code “0007” to access
to “YAnEN/No” when EPROM Chip No. 40-751 is the Guard menu.
installed on a Genset wit a di 2.2 or se 2.2 (Isuzu)
4. Enter the current access code “0007” to access
engine.
the Guard menu. The display will show
“GUArd/---”.
Viewing the Software Version
5. Press the DOWN key until the display shows
The software version is stored in the controller
“YAnEN/YES” (where “YES” means the
memory. To check the software version:
feature is set for a TK 486 (Yanmar) engine).
1. Make sure the unit On/Off switch is ON and the
LCD display shows the standard display
(voltage output).
2. Press the ENTER key for 3 seconds. The
display shows the software version (“0100/rEv”
or “0200/rEv”) for 3 seconds.
10-87
1. Turn the unit On/Off switch OFF to stop the

unit.
EPROM Chip,
PN 40-751 2. Disconnect the refrigeration unit from the
generator.
3. Turn the unit On/Off switch ON to restart the
µP-G Controller,
PN 45-1797
unit.
4. Check the output voltage at the genset plug.
Check the voltage between the three phases. All
three phases should be within 3% of each other.
Determine the average voltage reading between
the three phases.
5. From “GUArd/__” in the Guard menu, press
the DOWN key until the display shows
“XXXX/CAL” (where “XXXX” is the current
µP-G Controller and EPROM Chip voltage reading).
6. Press the SELECT key to enter the load Engine 6. Press the SELECT key to enter the load
Select display. Bottom display flashes “YES”. Voltmeter Calibration display. Bottom display
flashes “CAL”
7. Press the UP or DOWN key to choose the
desired engine setting: 7. Press the UP or DOWN key to adjust the top
display reading to the average voltage reading
• nO=di 2.2 or se 2.2 (Isuzu) engine determined in Step 1.
• YES=TK 486 (Yanmar) engine 8. When the correct voltage reading shows in the
8. When the desired engine setting shows in the top display, press the ENTER key. The display
bottom display, press the ENTER key. The flashes “LOAd” and then shows “XXX/CAL”
display flashes “LOAd” and then shows (where “XXX” is the new voltage reading).
“YAnEN/XXX” (where “XXX” is the new
setting).
CAUTION: If a new controller or new software

(or chip) has been installed, proceed immediately
to calibrating the Voltmeter; below.
Voltmeter Calibration
The Voltmeter Calibration feature calibrates the
controller to the alternator output. The controller
voltmeter should be calibrated whenever a new
controller is installed in the unit or when the
controller is suspected of displaying inaccurate
readings.
NOTE: Version 0100 software does not contain
the Voltmeter Calibration screen.
10-88
Screen Flow Diagram for Menu
10-89
SERVICE BULLETIN
SUBJECT: Extended Maintenance Interval (EMI 3000) Package for

Gensets Equipped with Yanmar Engines
BULLETIN NO. C 044
DATE: February 22, 2001
Thermo King Corporation will phase in extended the EMI 3000 package do require regular
Maintenance Interval (EMI 3000) packages on new inspection in accordance with Thermo King pretrip
Gensets during the first quarter of 2001. Because inspection and maintenance recommendations.
maintenance intervals have an important impact on CAUTION: With both EMI 3000 and standard
unit operating costs, introduction of the EMI 3000 (non-EMI 3000) units operating in the field, there
package will result in lower total unit life cycle are several important rules to remember:
cost. The genset EMI 3000 package will be
• Extended Life Coolant (ELC) is RED in color
implemented on units with serial number
while conventional coolant is GREEN or
02136H8528 and later. The package includes:
BLUE-GREEN.
• New 5 year or 12,000 Hour Extended Life
• Do NOT add “RED” coolant to cooling systems
Coolant (ELC)
using “GREEN” or “BLUE-GREEN” coolant.
• New EMI 3000 Water Pump, P/N 11-9442
• Do NOT add “GREEN” or “BLUE-GREEN”
(includes HNBR elastomer seals and EPDM
coolant to cooling systems using “RED”
O-rings)
coolant.
• New EMI 3000 Dual Element Oil Filter, P/
• The EMI 3000 oil filter is NOT interchangeable
N 11-9182 (identified by black and gold
with previous oil filters.
colors)
• New EMI 3000 Dual Element Oil Filter EMI 3000 Components
Head, P/N 11-9354
Extended Life Coolant and EMI 3000 Water Pump
• New EMI 3000 API Rating CG-4 Mineral
A decal tag on the coolant expansion tank will
Oil
identify units with extended life coolant (ELC).
• New EMI 3000 Fuel Filter, p/N 11-9342 ELC extends the coolant change interval up to
(identified by black and gold colors) 12,000 hours or 5 years.
EMI 3000 equipped units are identified by a ELC requires a water pump with HNBR elastomer
“Texaco ELC” decal tag on the coolant expansion seal bellows and EPDM elastomer O-rings.
tank, and gold and black colored oil and fuel filters. therefore ELC should not be used on older units
The EMI 3000 package allows standard genset with standard water pumps. All Yanmar (TK 486)
maintenance intervals to be extended to 3000 engines with serial number L16553 and after
hours. However, please note that units equipped include a new EMI 3000 water pump for use with
with extended life coolant.
10-90
• Detroit Diesel POWERCOOL Plus.

NOTE: Use a plycol refractometer to accurately
determine the freeze point and concentration of
engine coolant (Anti-Freeze) solution. A
refractometer works with both extended life and
conventional coolants.
EMI 3000 Dual Element Oil Filter and Oil

Filter Head
All Yanmar (TK 486) engines with serial number
ELC Compatible Water Pump 11-9442 L32024 and after include and EMI 3000 oil filter
head (P/N 11-9354) and gasket (P/N 33-2931). EMI
Thermo King ships all water-cooled engines from 3000 dual element oil filter (P/N 11-9182) and API
the factory with a 50% antifreeze concentrate and rated CG-4 mineral oil. These components are
50% water mixture in the cooling system. ELC required to extend the maintenance interval to 3000
coolants are available in 100% full strength hours.
concentrate or (pre-mixed) 50/50 mixture. Thermo
King recommends the use of 50/50 pre-mixed ELC The EMI 3000 oil filter (identified by black and
coolant to assure that de-ionized water is used. ELC gold colors) is NOT interchangeable with the
100% concentrate must be mixed (50/50) with de- previous oil filters. The EMI 3000 oil filter head,
ionized or distilled water (NOT tap water) to ensure gasket and oil filter can be retrofitted on previous
cooling system integrity. Yanmar (TK486) engines.
The following Extended Life Coolants are API service category CG-4 describes oils for use in
approved by Thermo King for use in ELC units for high-speed four-stroke-cycle diesel engines used in
five years or 12,000 hours: both heavy-duty on-highway (0.05% wt sulfur fuel)
and off-highway (less than.5% wt sulfur fuel)
• Texaco ELC #16445 (100% concentrate) applications. CG-4 oils provide effective control
• Texaco ELC #16447 (premixed 50/50% over high-temperature piston deposits, wear,
mixture) corrosion, foaming, oxidation stability, and soot
accumulation. CG-4 (or better) mineral oil can be
• Havoline Dex-Cool #7994 (100% used in older units. However, an EMI 3000 oil filter
concentrate0 (and oil filter head) is required to extend
• Havoline Dex-Cool #7995 (premixed 50/ recommended maintenance intervals to 3,000
50% mixture hours.
• Shell Dexcool #94040
• Shell Rotella #94041
• Havoline XLC #30379 (100% concentrate,
Europe)
• Havoline XLC #33013 (premixed 50/50%
mixture, Europe)
• Saturn/General Motors Dex-Cool
• Caterpillar ELC
10-91
EMI 3000 Fuel Filter

The new EMI 3000 fuel filter is required to extend
the maintenance interval to 3000 hours. It can be
interchanged with fuel filters used on previous
Thermo King gensets.
Upgrading Older Gensets

ESOC Plug Extended life coolant can NOT be used in older
Gensets with a Yanmar (TK486) engine unless the
engine is retrofitted with a new water pump, (P/N
EMI 3000 Dual Element Oil Filter Head 11-9354 11-9442) and related parts. The seal bellows and O-
rings in conventional water pumps used on older
Gensets are not compatible with ELC.
NOTE: Older gensets with an Isuzu engine can
not be converted to Extended Life Coolant until
an ELC compatible water pump becomes
available later this year.
NOTE: Yanmar (TK 486) engines with serial
number L16553 and later are equipped with an
ELC compatible water pump for use with ELC. If
an emergency requires that one of these engines
EMI 3000 Dual Element Oil FIlter 11-91892 be changed from RED to GREEN coolant (or
back again), the cooling system must be flushed
until all traces of the original coolant dye are
gone and the discharge water is clear. They system
can then be filled with replacement coolant.
Changing a Unit to Extended Life Coolant

(or Back Again)
1. Drain the current coolant and flush the entire
cooling system with HOT water.
2. Refill the cooling system with HOT water.
EMI Fuel Filter 11-9342 3. Start the unit and run the engine with the
NOTE: The new oil filter head is equipped with a thermostat OPEN until the engine reaches
threaded port to accept an ESOC operating temperature. This will allow the
(Environmentally Safe Oil Change) fitting for water to circulate through the entire cooling
quick oil changes. system.
4. stop the unit and drain the water from the
cooling system.
10-92
5. Continue to flush and refill the entire cooling Converting a Storage Tank to Extended Life
system with HOT water until all traces of Coolant
previous coolant dye are gone and the discharge
Thermo King recommends that coolant storage
fluid (water) is clear.
tanks be thoroughly cleaned before using them to
6. Fill the cooling system with appropriate coolant hold extended life coolant. Use hot water as a
mixture. flushing agent. Any silicate get or deposits on the
NOTE: Thermo King recommends the use of 50/ bottom of the tank or associated piping must be
50% pre-mixed extended life coolant to assure physically removed with methods such as steam,
that de-ionized water is being used. 100% scraping or sand blasting. Flushing with hot water
concentrate extended life coolant must be mixed should continue until any traces of dye from
(50/50) with de-ionized or distilled water (NOT tap previous conventional coolants are gone, and the
water) to ensure cooling system integrity. discharge water is clear. Tanks and piping should be
inspected to assure they clean and dry. The storage
Retrofitting a Unit for Extended Life facility is then ready to be filled with Extended Life
Coolant Coolant (ELC), which is silicate free and can be
stored up to five years.
To retrofit a genset manufactured before serial
number 02136H8528 to extended life coolant. The use of soaps, commercial cleaners, solvents or
flushing agents to clean storage tanks or equipment
• Retrofit the water pump assembly on TK 486 cooling systems is NOT recommended. Cleaning
engines with serial number before L16553 to agents are corrosive by nature. Failure to remove
ELC compatible water pump P/N 11-9442 all of the agent will contaminate the coolant stored
• Thoroughly flush unit cooling system and in the tank. Coolant contaminated with a cleaning
convert to extended life coolant. See “Changing agent will likely cause corrosion in the cooling
a Unit to Extended Life Coolant” instructions system of a unit.
above.
Retrofitting a Unit to EMI 3000 Package for

3,000 Hour Maintenance Intervals
To retrofit a genset manufactured before serial
number 02136H8528 to an EMI 3000 package to
achieve 3,00 hour maintenance intervals:
• Retrofit the unit for ELC. See “Changing a Unit
to Extended Life Coolant” instructions above
• Retrofit the oil filter head assembly on TK 486
engines with serial number before L32024 to oil
filter head P/N 11-9182
• Convert to EMI 3000 dual element oil filter P/N
11-9354
• Thoroughly drain engine oil and convert to API
rated CG-4 (or better) mineral oil
• Convert to EMI 3000 fuel filter P/N 11-9342.
10-93
10-94
Section 11
Gen-Set
Configurations
Section 11-Gen-Set Configurations
THERMO KING
GENERATOR SETS
MODEL DESCRIPTION CONTROL SYSTEM VOLTS

SG2000 All µP-G Micro 460-230 or *Dual
SGCM ‘Smart’ Center Mount µP-G Micro 460, 230 or Dual
SGCO ‘Smart’ Clip-On µP-G Micro 460, 230 Only
SGSM ‘Smart’ Side Mount µP-G Micro 460, 230 or Dual
CGCM Standard Center Mount PC Board 460, 230 or Dual
CGCO Standard Clip-On PC Board 460, 230 Only
CGSM Standard Side Mount PC Board 460, 230 or Dual
CG-II Standard Center Discreet Components 460, 230 or **Dual
**Clip-On or Side Mount

** Note: 125 Gallon Clip-On * Not available on Clip-On
Single Voltage Only ** Note: 125 Gallon Clip-On
Single Voltage Only
11-2
Section 12
Gen-Set
Control Systems
Section 12-Gen-Set Control Systems
‘CURRENT’ PRODUCTION
CONTROL SYSTEMS
µP G ‘Smart’ ‘Standard” PC Board
AJA235
AJA572
‘PAST’ PRODUCTION
CONTROL SYSTEMS
Most CG-II / Early CG Series
AJA573
12-2
µP-G CONTROLLER
Controller Features
• Automatic unit restart attempt 20 minutes after:
• High engine water temperature shutdown

• Engine failure to start
• Check fuel alarm shutdown
• 230/460 V generator overload shutdown
• Unknown condition shutdown
• Low engine oil pressure shutdown (optional)
• Delayed generator excitation for 15 seconds, or until engine

coolant temperature increases to 90 F (32 C) (optional)
AJA265
µP-G CONTROLLER
Controller Features
1. LCD display
2. Alarm Indicator Functions
3. Programming Keypad
AJA265
12-3
µP-G CONTROLLER
Controller Features
1
2
3 1. LCD Fields
4 2. Alarm Icon
5 3. Select Key
6 4. Up Arrow Key
5. Down Arrow Key
7
6. Enter Key
7. Alarm Key
8 8. Unit On/Off Switch
9. Alarm Indicator Light
9 10. Unit On Indicator Light
AJA265
10
µP-G CONTROLLER
Controller Operation THERMOGUARD µP-G
• Standard (default) µP-G

display screen shows output
voltage. AJA704
THERMOGUARD µP-G
• When Output Frequency is on

the display, frequency is on
large display, units (HZ) on AJA238
bottom display: AJA265
• Controller displays returns to the current submenu screen if no key is

pressed for 10 seconds
12-4
STANDARD CONTROLLER
Features -- Controls & Instrumentation
1
4
1. Hourmeter
2 2. Ammeter
3. On/Off Switch
5
4. Engine Shutdown LED
3 5. Unit ON Indicator Light
6 6. Preheat-Start Switch
AJA235
1
2
1. Oil Pressure Gauge
2. Engine Coolant Gauge
AJA236
Standard (Original
Electro/Mechanical Style)
Control System
• On/Off Switch • Options:

• Start/Preheat Switch - Voltmeter
• Engine Cutout Switch - Frequency meter
• Alternator Reset Switch connector
• Gauges: - Main output circuit
- engine hour meter breaker
- coolant temperature
- oil pressure
- ammeter
• Safety Shutdowns for:
- High coolant temperature
- Low oil pressure
- Generator overload
AJA573
12-5
TEST INSTRUMENTS
• AC-DC Voltmeter
-- 2.5 to 500 V Range + / - 2% Max. Error
• AC Induction Ammeter (Amprobe)
• DC Ammeter (i.e. TK p/n 204-449)
• Ohmmeter
• Megohmmeter (Megger)
• 1073 Light Bulb / Socket Assembly.
• Two (2) Alligator Clips AJA574
Alternator Test Equipment

• Motorola Alternator Adapter
PRELIM. CHECKS / FAULTS
• Preliminary Checks
-- Engine Problems
-- Voltage Output @ Plug (All Phases - 3% Max. Diff.)
-- Battery Conditions
-- Plug Connections
• Fault Categories
-- Won’t Pick Up Load
-- Tries but Labors Causing Overload Shutdown
-- Control (Safety) Module Shuts Unit Down w/NO Overload
-- Output Voltage Too High
12-6
‘THE TESTS’
• Test 1 - Determines Fault Area
-- Alternator or Excitation
• Test 2 - VR & ‘Initial Excitation Circuit’
• Test 3 - Power Bridge Rect. & Transformer
• Test 4 - Booster Circuit Output
• Test 5 - Battery Charging Circuit
‘THE TESTS’ CON’T
• Test 6 Individual Diodes & Bridge Rectifiers
Test A - Diodes Test B - Diodes

Ohmmeter
Checking Reverse
Ohmmeter Checking for Forward
Leakage Resistance Conductance
Reads high resistance. Good diode reads 1/2 to

Little or no movement 2/3 upscale.
or pointer
LEAD
LEAD
• Test 7 Exciter ‘Field’ Circuit
Exciter
Main Rotor
Field
OHM
METER
F-1 Exciter F-2
Field
AJA575
12-7
‘THE TESTS’ CON’T
• Test 8 - Main Alternator / Stator
Rotation (Main) Field

Alternator Stator
Main
Field Exciter
Rotor
OHM
METER
F1 F2
Exciter
Field
Checking Main Field Winding
Main
• Rotation Field Field Exciter
Rotor
• Rotating Rectifier OHM

METER
F1 F2
Exciter
Field
Checking Main Field Winding
Disconnect Main Alternator AJA576
Red Lead
12-8
Section 13
µP-G ‘Smart’
Gen Set Controller
Section 13-µP-G ‘Smart” Gen Set Controller
µP-G Microprocessor Controller • Provides engine shutdown protection after unit shutdown
due to low engine oil pressure, low engine oil level, low
Description battery, low fuel, or run relay circuit failure.
The µP-G controller is a one-piece, self contained micropro-
cessor for diesel generator sets. This system automatically The Microprocessor contains the following basic features:
starts the generator set provides:
1. Two digital displays on front panel:
Automatic pre-trip test of the engine and alternator, provides • LARGE DATA DISPLAY: Five digits (numerical hun-
alarm and shutdown protection for the engine and alternator; dreds, tens, ones, tenths and hundredths position).
and restarts the generator set after a unit shutdown due to an • SMALL DATA DISPLAY: Three digits (numerical
unknown condition, high engine water temperature or 230/ tens, ones and tenths position).
460V alternator overload. 2. Alarm icon appears when the Microprocessor has
detected an alarm condition.
If a unit shutdown results from a low engine oil pressure or 4. Keypad:
low engine oil level condition, the Genset Control Module a. ALARM Key: Display fault code readout on digital
places the unit in a protection engine shutdown and does NOT display.
attempt to restart the unit. b. ENTER KEY: Enter menu information and
commands.
• Automatic unit preheat and engine startup during initial c. DOWN ARROW Key: Scroll down through MENU
startup or delayed restart display.
• Variable glow plug preheat time d. UP ARROW Key: Scroll up through MENU
• Automatic Pre-trip Test capability display.
• Automatic unit restart 20 minutes after unit shutdown e. SELECT Key: Places you in (enters) the MENU list
due to an unknown condition, high engine water tempera- and selects items for display, change or calibration.
ture, low engine oil pressure, engine failure to start,
check fuel alarm shutdown, or 230/460V alternator over-
load.
Display
Normally shows the Output Voltage. All segments and icons
are shown in the illustration. It will be blank when the unit
On/Off switch is OFF.
Mode Description
The Alarm description indicates alarms.
Icon
An alarm icon appears next to the Alarm description if an
alarm condition occurs.
Keypad
Alarm Key. Displays fault code readout.
Enter Key. Enters/initiates new settings.
Down Arrow Key. Scrolls down through MENU display.
Up Arrow Key. Scrolls up through MENU display.
Select Key. Places you in (enters) the MENU list and selects
AJA265
items for display or change.
13-2
Section 13-µP-G ‘Smart’ Gen Set Controller
5. Internal self-checking/diagnostic capability. VIEW MENU Functions

6. Pre-trip test capability. 1. Press . Display shows MEnU / ---.
7. Data recording capability with retrieval via computer. 2. Press until display shows VIEW.
8. Flash program memory. 3. Press . Display will show VIEW / ---.
9. Application software version display when [ENTER] 4. Press to view functions in submenu. Press to
key is pressed and held for 3 seconds. scroll back through submenu. Display shows submenu func-
10. Microprocessor Inputs: tion and value.
Run Relay Enabled Example:60
Engine Oil Level Sensor HZ
Engine Oil Pressure Switch
Preheat Feedback VIEW MENU LIST
Coolant Level Sensor VIEW / --- Top of Menu
Air Filter Switch 60 / HZ Output Frequency
Excitation Feedback 180.0F / Ent Engine Temperature
Voltage Regulator 50 / OIL Oil Pressure
Flywheel Sensor 1800 / rPM Engine Speed
11. Microprocessor Outputs: 13.8 / bAT Battery Volts
Run Relay 2.5 / Fld Field Current
Field Relay 00000 / rHr Run Hours
Start Relay
Preheat Relay PTRIP Menu Functions
On Light
Alarm Light NOTE: The microprocessor will not perform an automatic
12. Alarm Codes: pre-trip test until all alarms have been corrected and
06 Water Temperature Sensor Failure
cleared.
07 Engine RMP Sensor
15 Preheat Circuit Check 1. Press . Display shows MEnU / ---.
16 Digital Input Failure 2. Press until display shows PtrlP.
17 Engine Failed to Crank 3. Press . Flashing display will show EntEr / PrE.
18 High Engine Water Temperature 4. Press Flashing display will show LOAd / PrE.
19 Low Engine Oil Pressure 5. Display shows following screens as microprocessor per-
20 Engine Failed to Start forms automatic pretrip test.
25 Low Output Volts 6. When pretrip test is complete, displays shows PASS or
31 Oil Pressure Sensor FAIL. Press to clear pretrip test message and return
35 Run Relay Circuit to standard screen. View and correct any alarm codes
37 Coolant Level Alarm recorded before placing unit in service.
41 Engine Water Temperature Check
43 Frequency Out of Range — Low MENU PTRIP LIST
44 Fuel System Check 88888 / 88 Display Test
45 Frequency Out of Range — High OLS / PrE Oil Level Switch Test
46 Check Air Filter OPS / PrE Oil Pressure Sensor Test
51 Alternator Overload Alarm LOP / PrE Oil Pressure Switch Test
61 Low Battery Alarm, Low Battery Alarm during UtS / PrE Coolant Temperature Test
Crank, or High Battery Alarm FUS / PrE RPM Sensor Test
63 Engine Stopped — Reason Unknown Phr / PrE Preheat Relay Test
66 Low Engine Oil Level rr / PrE Run Relay Test
69 Exciter Circuit Check vr / PrE Volt Regulator Test
70 Any Hourmeter or Counter Exceeds Limits Sr / PrE Start Relay Test
71 Hourmeter 1 Exceeds Threshold Fr / PrE Field Relay Test
72 Hourmeter 2 Exceeds Threshold OPS / PrE Oil Pressure Sensor Test
74 Control Revert to Default Settings LOP / PrE Oil Pressure Switch Test
88 Microprocessor Internal Error rPN / PrE RPM Sensor Test
99 Restart Null AC / PrE Output Volts Test
13-3
TEST Menu Functions PROGRAM Menu Functions

1. Press . Display shows MEnU / ---. 1. Press . Display shows MEnU / ---.
2. Press until display shows tESt. 2. Press until display shows PrGrn.
3. Press . Display will show tESt / ---. 3. Press . Display will show PrGrn / ---.
4. Press . Display will show CntrL / tSt. 4. Press to view functions in submenu. Press to
5. Press . Display will show CntrL / ---. scroll back through submenus. Display shows submenu
6. Press until the test function you want shows in the function and current value (for example, DEFI 6).
display (for example, OL / o “l” [“l” flashing]). 5. To change a value:
7. a. Press with OL / 0 “l” (“l” flashing) in display. a. Press until program function you want shows
Display will show OL / “0” l (“0” flashing). The micro- in display (for example, F / dEG).
processor output for the On Light should be now be ON. b. Press with F / dEG in display.
b. Press with OL / “0” l (“0” flashing) in display. c. Display will show “F” / dEG (with “F” flashing).
Display will show OL / 0 “l” (“l” flashing). The micro-
d. Press or until RIGHT display shows
processor output for the On Light should now be OFF.
the NEW value you want to enter
8. To exit test, wait 30 seconds; or press or
until display shows CntrL / ---. Then press . Dis- (for example, “C” / dEG).
play will return to show CntrL / tSt. Press to e. Press . Display will show LOAD.
scroll TEST / ---. Press to exit to TEST screen. f. Display returns to show NEW current value (C, for
Press to return to standard display. example) and the program function (dEG, for
example).
TEST MENU LIST
PROGRAM MENU LIST
AL / 0 l Alarm Light Test
C or F / dEG Set degrees F or C
OL / 0 l On Light Test
PSI, BARS, or
PHr / 0 l Preheat Relay Test
kPA / OIL Set oil pressure units
rr / 0 l Run Relay Test
Sr / 0 l Start Relay Test
Fr / 0 l Field Relay Test Viewing Application Software Version
1. Press the for 3 seconds.
• Display will show application software version
for 3 seconds.
GUARD Menu Functions
Example: 10.00 rEv
---- Access code required to enter GUARD menu.
13-4
µP-G Controller Alarm Table
Alarm
Code Type Cause or Explanation
*06 Check Water Temperature Sensor Failure: This alarm indicates the water temp sensor has gone
out of range (below -40(C to 130(C) or is reading an open or shorted connection.
*Pretrip: During the pretrip test the above fault conditions for the water temp sensor occur.
*07 Check Engine RPM sensor: This alarm occurs if:
• The engine rpm was < 40 during crank, but the engine developed oil pressure > 5 psi 7
seconds after the starter de-energized.
• The engine is running, the rpm is < 800, the oil pressure is > 5 psi. This condition must
occur for one minute.
*Pretrip: During the pretrip test the RPM sensor either showed RPMs when the engine was
not running, or didn’t show RPMs when the engine should have been running.
*15 LOG/Check Preheat Circuit Check:
• If the glow plug preheat relay output is energized but the preheat digital input is low a
check alarm will be generated.
• If the preheat output is energized and the battery volts are
< 9.0V for 3 seconds a log alarm will be generated. If this occurs the unit will attempt to
start without the preheat.
*Pretrip: A check alarm will be produced if during the pretrip test the preheat circuit failed
with either condition.
16 Check Digital Input Failure: The digital inputs have been changing once a second for the last 100
seconds. This condition indicates noise on the line, a loose connection, or a bad sensor.
*17 Check/Shut- Engine Failed to Crank: If the engine failed to achieve 40 rpm within 3 seconds of starter
down energized and the oil pressure is < 5 psi 7 seconds after the starter is de-energized a check
alarm is generated. The unit will try and start 2 more times. If after a third attempt the unit
still doesn’t start the check alarm becomes a shutdown alarm.
*Pretrip: During the pretrip test the unit failed to crank by not reaching the above condi-
tions.
*18 Shutdown High Engine Water Temp: This alarm occurs with the engine running, the water temp sen-
sor not in the fail mode, and the water temp exceeds 225°F for 25 seconds. If the above con-
dition occurs the unit will generate a shutdown alarm and shutdown the unit until the water
temp drops < 190°F. The unit will then try to restart after 20 minutes.
*Pretrip: During the pretrip test the above fault conditions for the water temp occur.
13-5
Alarm
*19 Check/Shut- Low Engine Oil Pressure: This alarm occurs when the engine is running, the oil level is
down high, and the oil pressure reading < 15 psi for water temps above 50F (10 C) or the oil pres-
sure hasn’t increase 5 psi from the non-running oil pressure for water temps below 50F (10
C). If the above conditions last for 30 seconds and the low oil pressure switch is high then a
check alarm will be produced. If the above condition occurs for 30 seconds and the low oil
pressure switch is low then a shutdown alarm will be produced and the unit will look at the
user programmable Low Oil Pressure Restart value. If this value is <OFF> then the unit will
remain off. If this value is <ON> then the unit will try to restart after 20 minutes.
*Pretrip: A shutdown alarm will be generated if during the pretrip test the above fault con-
ditions for oil pressure occur.
*20 Check/Shut- Engine Failed To Start: The rpm was > 40, but did not achieve 800 rpm within 30 seconds
down and did not develop oil pressure > 5 psi 7 seconds after the starter de-energized. If this con-
dition occurs the unit will generate a check level alarm and make two more attempts to
restart the unit. If the unit still does not start it will then try to restart after 20 minutes.
*Pretrip: A shutdown alarm will be generated if during the pretrip test the above fault con-
ditions occur.
*25 Check Low Output Voltage: The field relay is energized but the output voltage < 180 for 30
seconds.
*Pretrip: During the pretrip test the above fault conditions for output voltage occur.
*31 Check Oil Pressure Sensor: An alarm is generated if the engine is stopped and the oil pressure is >
10 psi. An alarm is also generated if the engine is running and the oil pressure is < 10 psi
and the oil pressure switch is high and oil level is high for 10 seconds.
*Pretrip: During the pretrip test the above fault conditions for the oil pressure sensor occur.
*35 Shutdown Run Relay Circuit:
• If after energizing the run relay but before the starter is activated, the run relay feedback
digital input is low. Three attempts 4 seconds on, 2 seconds off will be made to energize
the run relay and obtain a high run relay feedback digital input. An alarm is
generated after the third unsuccessful attempt.
• The run relay is not energized and the run relay feedback digital input is high indicating
a hot wire on the fuel solenoid.
• If running the run relay feedback drop out the unit will go into shutdown.
*Pretrip: During the pretrip test the run relay is energized and the run relay feedback
digital input is low.
*37 Check Coolant Level Alarm: The coolant level digital input is low for 30 seconds.
*Pretrip: During the pretrip test the above fault conditions for the coolant level sensor
occur.
41 Check Engine Water Temperature Check: Engine water temperature is 215 F (102 C) for 2 min-
utes while the unit is running.
13-6
Alarm
*43 Check Frequency Out of Range-Low: The engine is running and the output frequency is < 45 Hz
(engine rpm < 1350) for 10 seconds.
*Pretrip: During the pretrip test the above fault conditions for output frequency occur.
44 Shutdown Fuel System Check: The engine rpm’s have dipped below 1050 and have stayed below
1075 for 80 seconds. This will generate an alarm and the unit will then try to restart after 20
minutes.
*45 Check Frequency Out of Range-High: The engine is running and the output frequency is > 70 Hz
(engine rpm > 2100) for 10 seconds.
*Pretrip: During the pretrip test the above fault conditions for output frequency occur.
46 Check Check Air Filter: Engine is running and the digital input AF is low for 10 seconds.
*51 Shutdown Alternator Overload Alarm: The unit is running and the field current exceeds 4 amps for
15 seconds or exceeds 6 amps for 5 seconds. This will generate an alarm and the unit will
then try to restart after 20 minutes.
*Pretrip: During the pretrip test the above fault conditions for the field current occur.
*61 Log/Check Low Battery Alarm:
• When the engine is in preheat the battery volts are < 9.0V for 3 seconds. This is a log
alarm and if it occurs the preheat output will de-energize and a start will be attempted
without preheat.
• The battery volts are < 12.2 for 3 minutes while the unit is not running, this is a check
alarm that may occur when in a restart null.
*Pretrip: During the pretrip test the above fault conditions for the battery occur.
*61 Shutdown Low Battery Alarm: The unit has attempted a start and the controller has reset itself before
the start could be completed.
*Pretrip: During the pretrip test the above fault conditions for the unit occur.
61 Check High Battery Check: When running the battery volts are > 16.0 V for 3 minutes.
63 Check Engine Stopped - Reason Unknown: The engine is not running, it used to be running and
it should still be running. This will generate an alarm and the unit will then make three
attempts to restart. If restart is unsuccessful the unit will again try to restart after 20 minutes.
*66 Shutdown Low Engine Oil Level: The engine is running and the oil level has been low for 3 minutes.
No restart attempts will be made.
*Pretrip: During the pretrip test engine oil level digital input is low.
*69 Check Field Relay Circuit: The field relay is energized and the field current is <.25 amps for 10
seconds.
*Pretrip: During the pretrip test the above fault conditions for the field relay occur.
70 Check Hour Meter Exceeds Limits: One or more of the hour meters has exceeded 99,999 hours
or one or both of the restart counters has exceeded 9999. The hourmeter or counter that
caused the alarm will be reset.
13-7
Alarm
71 Check Hour Meter Exceeds Limits: Programmable hour meter 1 has exceeded set limit.
Clearing this code will also reset the hourmeter 1.
72 Check Hour Meter Exceeds Limits: Programmable hour meter 2 has exceeded set limit.
Clearing this code will also reset the hourmeter 2.
74 IM_Shutdown Control Reverted to Default Settings: The controller has reverted to factory
programmable settings. This will occur with a chip change in the controller or a controller
cold start was performed.
88 Log Shutdown Microprocessor Fault Alarm: The microprocessor has found a fault condition
with either its RAM or EEprom. If this alarm occurs twice the unit should be sent in for
repair.
99 Check Restart Null: The unit has been shutdown but the controller is monitoring conditions and
will try to restart after 20 minutes.
Notes:
* = Pretrip Alarm
1) The phrase “restart after 20 minutes” refers to the auto-restart mode where the unit will make up to three attempts every 20
minutes to restart the unit after a shutdown has occurred. This restart mode continues until the unit has been successfully
restarted or until a code 61 is generated due to low battery.
13-8
µP-G Acronyms
Acronym Definition
AC Alternating current or Volts A.C. (typically)
AL_01 Alarm 01
rEv Revision, software (typically)
MEnU Menu menu or submenu prompt
PtrIP Pretrip menu or submenu prompt
tESt Test menu or submenu prompt
GUArd Guard menu or submenu prompt
PrGrM Program menu or submenu prompt
vIEW View menu or submenu prompt
dEG Degree
F Fahrenheit
C Celsius
OIL Oil pressure
PSI Pounds per square inch
bArS Bars
kPa Kilo Pascals
HZ Hertz
Ent Engine temperature
rPM Revolutions per minute
bAt Battery volts D.C.
Fld Field current D.C. amps
rHr Run hourmeter
EntEr Prompt for key stroke
PrE Pretrip mode
LOAd Load of data into micro controller
OLS Oil level switch
OPS Oil pressure sensor
LOP Low oil pressure switch
UtS Water temperature sensor
FUS Flywheel sensor
Phr Preheat relay
rr Run relay
vr Voltage regulator
Sr Start relay
Fr Field relay
PASS Pass result after pretrip
FAIL Fail result during pretrip
13-9
CHECh Check alarm after pretrip

CntrL Control test menu or submenu
AL Alarm light
OL On light
Ht1 Programmable hourmeter #1 threshold
Ht2 Programmable hourmeter #2 threshold
HM1 Programmable hourmeter #1 hours
HM2 Programmable hourmeter #2 hours
EOH Engine off hours (while rHr is running)
rSL Restarts since last power up
St Restarts total for unit
LOPrS Low oil pressure restart option
dLYSt Delayed field relay energization option
13-10
Section 14
Gen-Set
Schematic/Wiring Diagrams
Section 14-Gen-Set Schematic/Wiring Diagrams
14-2
Section 15
Gen-Set
Alternator Procedures
(Original Control System)
Section 15-Gen-Set Alternator Procedures (Original Control System)
This alternator consists of three principal components: the The build up continues until the voltage and amperage
main alternator, the integral direct connected exciter, and an reaches the rated amount at which the voltage regulator
externally mounted excitation control system. decreases field current, and the alternator maintains the
proper output voltage.
The main alternator may be subdivided into the 4-pole main
rotating field and the main stator winding. The exciter control system used with this generator differs
slightly from previous Thermo King control systems in that
The main rotating field, the rotating rectifier and the exciter only one booster bridge rectifier is used. This will not sub-
armature are all mounted on a common shaft. Output of the stantially alter test procedures that were utilized for previous
exciter is rectified by the shaft mounted rotating bridge recti- control systems.
fier to provide main alternator rotating field excitation.
Dual Voltage Alternator
The externally mounted excitation control system is energized The generator set is factory wired for 460V power output.
from the battery through a voltage regulator. The output from Alternator output can be changed to 230V by changing power
the main winding is stepped down by the power transformer cable wire connections at the terminal strips in the Exciter
and rectified by power bridge and added to the initial current Control Box.
supplied by the On-Off switch to build up alternator output.
Rotor Assembly
DC AC
Rotating Rotating Exciter

Main Field Rectifier
Magnetic Magnetic
Coupling Coupling
Stator Assembly
Volts
Exciter Field
Alternator
(FLD)
Stator (ALT)
Exciter Package DC Low

Overload Voltage
Amperes
Prot.
AC Excitation
High Voltage
60 Hz Control &
Charging To Engine Safety Devices
DC Low V.
System To Battery
AC Load 3
Phase 60 Hz
15-2
AJA710
FUNCTION OF COMPONENTS IN
VR
EXCITER CONTROL SYSTEM The Voltage Regulator measures the power bridge output
voltage (RED terminal) and supplies exciter field current to
BR1 the GREEN (GRN) field circuit as required to maintain volt-
Bridge Rectifier I rectifies current from the power transformer age (and main generator output) at the desired level.
to charge the battery and supply exciter circuit.
SCR The voltage regulator also maintains a potential at the output

Silicon Controlled Rectifier. Used to divert current trans- of the power bridge suitable for the charge requirements of
former Output to ground during field or excitation control the unit battery and engine electrical controls.
malfunction. Also completes resistor circuit from the reset TRF-I
switch allowing the engine to shut down on malfunction. Power Transformer, 3-phase transformer wired in parallel
MOV with the output of the alternator. As the voltage from the alter-
Metal Oxide Varistor is a transient voltage suppression device nator rises, so does the output side of the power transformer.
to protect the SCR against unnecessary turn-on which would After rectification, this voltage is sensed by the voltage regu-
shut down the unit. lator which then controls alternator output.
15-3
AJA711
DI D6
Diode I protects the Preheat/Start switch from negative tran- Diode 6 isolates alternator excitation system from the battery
sient voltages caused by arcing at the starter solenoid. when the unit is shut down (necessary to avoid drain on bat-
tery when -unit is OFF). Permits battery charging current to
D2 pass from power bridge to ammeter and then back to the bat-
Diode 2 protects the On-Off switch from negative transient tery.
voltages caused by arcing at the fuel shutoff solenoid.
D7
D3 Diode 7 isolates engine oil and water safety switch devices
Diode 3 diverts current bridge output into battery whenever from the exciter control.
the alternator reset circuit breaker opens, and suppresses
destructive voltage transients. D8
Diode 8 isolates and protects regulator from high voltages
D4 which are normally developed across field during motor starts
Diode 4 prevents the battery charging current from bypassing or under heavy overload. Also allows regulator to control
the positive temperature coefficient (PTC) charge limiting field voltage during normal operation.
resistors.
D9
D5 Diode 9 isolates the exciter circuitry from the 12 Vdc control
Diode 5 prevents feedback from power bridge output to voltage when the low oil pressure and high water temperature
engine controls, fuel solenoid, etc. (necessary in order to shut switches are open. Provides a path for field excitation to be
machine down). Permits flow of initial excitation current shunted to ground after the excitation circuit breaker opens
needed for building up normal alternator output voltage. and the silicon controlled rectifier (SCR) has been turned on.
D10
Diode 10 isolates the current bridge from the voltage regula-
tor output and from the transients generated in the field coils.
Allows current bridge output to control field voltage during
motor starts and overload conditions.
15-4
CB1 BR2
Circuit Breaker 1 is located in the field circuit. When the gen- Current Bridge Rectifier (BR2) rectifies the ac output of the
erator set is overloaded, the field current increases to a point current transformer. This current is then used for dc excitation
that trips the circuit breaker. Field current is then diverted current through the orange wire, through diode D10 and into
through D3 to the battery charging circuit. When this hap- Fl. During an overload, this output increases greatly and is
pens, a voltage is present across resistors R4 and R5 which used to boost alternator output.
form a voltage divider for the gate of the SCR. This turns the
SCR on, allowing current to flow from the current bridge and TRF-2
the 20 circuit to ground. With current flowing in the 20 cir- Current transformer. Senses an abrupt increase in current
cuit, the resistor on the reset switch heats and trips the switch demand on the alternator. This in turn sends an increased cur-
shutting down the entire circuit. rent flow through the current rectifier by passing the voltage
regulator going directly to the alternator field winding.
CB2
Circuit Breaker 2 is electrically located between the reset RI &R2
switch normally closed contacts and On-Off switch. The cir- The Positive Temperature Coefficient (PTC) resistors are
cuit breaker trips open if the dc control circuits overload. charge rate control devices that prevents the charge demand of
a discharged unit battery from influencing the voltage output
of the main generator.
15-5
ALTERNATOR FUNCTION The design of the current transformer limits the amount of
transformer current output to less than the field requirement to
A. Starting Excitation maintain normal alternator voltage. Therefore, the alternator
The initial excitation for the alternator is supplied by turning output voltage would tend to be low. The voltage regulator
the On-Off switch to the ON position. Current flows from the then senses a low alternator output voltage. It takes current
unit battery through the No. 2 wire, the ammeter, the fusible from the power transformer (TRF-1) and rectifier (BR1) and
link, diode D4, the safety switch (SSW), CB2, the On-Off adds to the field current to bring the alternator output voltage
switch, the 8-wire, and diode D5 to the RED lead of the volt- up to normal.
age regulator. The regulator sends the current out on the
GREEN wire through diode D8 to Fl. Fl sends the current to If the alternator output voltages rise above the predetermined
the exciter field to build voltage in the stator windings. The limit, the power transformer will reflect this rise in its output
current then travels through F2 and CB1 to ground. voltage. The voltage regulator sensing the higher voltage will
then reduce the exciter current to the field winding. This
B. Running Excitation and Control reduces exciter current to the main alternator field, reducing
Once the alternator is excited by the unit battery and the the alternator output.
engine is running, excitation is provided by the alternator
itself. In essence, a 12 Vdc automotive-type voltage regulator is
controlling a 15 KW ac alternator by taking a sample of the
The magnetic field that was formed in the exciter field stator alternator output, reducing the voltage, rectifying it and send-
winding, by battery current, induces a current in the exciter ing it to the field.
rotating winding. This current is changed from threephase ac
to dc by the rotating rectifier. The dc current is transferred to C. Temporary Overload
the main alternator field winding. The main alternator field For temporary overloads (such as refrigeration unit start up),
now becomes magnetic. the excitation control system utilizes the current (boost) trans-
former (TRF-2) and rectifier (BR2) to handle the overload.
The magnetic field formed in the main field winding now When the alternator output current is normal, the current
induces a voltage in the alternator stator windings. This volt- transformer is supplying a portion of the current used to excite
age is either 230 Vac or 460 Vac, 3-phase, depending on stator the alternator field. When an overload occurs, the increased
connections. current flow from the alternator through the current trans-
former causes an immediate increase in current transformer
It is sent out of the alternator stator leads to the power plug output. This increased output overrides the voltage regulator
and then to the load. The power transformer (TRF-1) is output and boosts the output of the alternator to handle the
tapped into the alternator stator leads. The transformer reads temporary overload.
the alternator output voltage and steps this voltage down to
D. Battery Charging
around 12 Vac (1/20th of output voltage). This current is fed
The unit battery is recharged using current from the power
through the power bridge rectifier (BRI), rectified to dc cur-
bridge rectifier. Current flows from the rectifier bridge
rent and is sent into the IA circuit, and some of it goes to the
through the IA wire and through diode D6.
voltage regulator.
The current is then divided between two wires, 2AI and 2A2
The voltage regulator RED lead is connected to the IA circuit,
and then through two RI and R2 resistors. These limit the
and it utilizes power bridge output to measure alternator volt-
amount of current that a battery, in a discharge state, can
age. It also uses the power bridge current output as a source of
receive from the system. If a battery will accept large amounts
exciter current rather than using the unit battery.
of current, the voltage from the power bridge rectifier will be
lowered, and the voltage regulator would sense the reduction
A portion of running excitation is actually supplied by the
and increase exciter current to the alternator field causing an
current transformer (TRF-2) and current rectifier (BR2). The
over-voltage condition in the alternator.
current transformer is designed to produce output current in
direct relation to the mount of current flowing from the alter-
Two wires are used in parallel (2AI-2A2) to reduce the
nator to the load. The output current is rectified by the current
amount of current transferred through the pin connector.
bridge (BR2) and then used as field current.
15-6
E. Overload Shutdown If the overload breaker trips, it indicates one of the following:
The overload shutdown circuit utilizes a silicon-controlled
rectifier (SCR) in conjunction with the reset switch (SSW). 1. There is a malfunction in the load causing the load to fail
to start or to draw single phase current.
If an overload condition becomes more than temporary, the
reduction in alternator output voltage due to the overload 2. The engine speed or power is low due to improper speed
causes an increase in field current to a point (greater than 3.25 adjustment, fuel supply problems or other mechanical
amps) at -which the field circuit breaker (CB1) opens, discon- conditions while the generator is supplying -motor start-
necting the field circuit from ground. Field current is then ing current to the load.
diverted through D3 to the battery charging circuit.
3. Internal component failure in the excitation control sys-
When this happens, a voltage is present across resistors R4 tem, resulting in excessive field current. This includes
and R5 which form a voltage divider for the gate of the SCR. possible malfunction of protective elements in the excita-
This turns the SCR on. The SCR acting like a switch, allows tion control.
current to flow through the 20 circuit to ground. The resistor
on the reset switch heats up and trips the switches normally 4. Failure in the alternator rotating elements (exciter arma-
closed contacts open, de-energizing the fuel solenoid to stop ture, rotating diode assemblies or main field) can cause
the engine. the regulator to supply excessive exciter field current.
The SCR also provides a path to ground for the output of the
current bridge rectifier. This is done to prevent high voltages
building in and causing damage to the current transformer.
15-7
Alternator Diagnosis The test instruments required:
PRELIMINARY CHECKS 1. AC-DC voltmeter 2.5 V to 500 V ranges ((2% max.

Before attempting the more complicated diagnosis proce- error).
dures, check the following items to ensure a superficial prob-
lem is not overlooked. 2. AC induction ammeter (amprobe).
NOTE: Further diagnosis is a waste of time until these items 3. DC ammeter (preferably induction type
are checked, since a problem in one of these areas will affect TK No. 204-449).
test results.
4. Ohmmeter.
1. If the generator malfunction is accompanied by excessive
black exhaust smoke and engine lugging, double check 5. Megohmmeter (Megger).
all possible engine problems such as fuel supply, injec-
tion timing, engine speed, restricted air cleaner, etc. 6. 1073 Light Bulb Assembly and Motorola Adapter.
2. Disconnect the refrigeration unit from the generator, and
check the output voltage at the plug. Voltage between the This can be built very quickly. It requires a No. 1073 light
three phases should be between 230 to 250 Vac or 460 to bulb and a matching socket, two alligator type clips and the
500 Vac depending on engine speed and whether the plug off of a discarded voltage regulator. See illustration for
alternator stator is wired for 230 or 460 volt operation. details.
All three phases should be within 3% of each other. If the
voltages appear normal, make sure the refrigeration unit
is not at fault. Reconnect refrigeration unit and run in
Cool mode. Check the amperage draw with an induction
type ammeter (amprobe), and compare it with the load
plate on the refrigeration unit.
3. Check the condition of the generator set battery. A dis-
charged unit battery can give a false signal to the voltage
regulator, causing the generator output voltage to be high.
The unit battery should have a minimum voltage of 12 V.
4. Check all push-in plugs on control circuit for loose pins
or sockets. Make sure all wire terminals are tight. Alternator Test Equipment
5. Check generator circuit breaker for proper operation. Use
an ohmmeter to make sure the circuit through the circuit ALTERNATOR MALFUNCTIONS
breaker is continuous.
Listed below are the categories in which most generator mal-
TEST INSTRUMENTS functions will fall. Following each category are a number of
If the preceding checks did not uncover the cause of the mal- possible component failures that may cause the malfunction.
function, more extensive diagnosis procedures will be Listed with each component is the test used to check the com-
required. The following tests will require various electrical ponent.
test instruments, and the technician performing the tests
should have a good working knowledge of their basic electri- NOTE. Always use Test 1 first to determine if the alternator
cal principles. or the exciter control package is at fault.
The tests are intended to determine whether the source of dif- 1. Generator set will not pick up the load (low or no output
ficulty lies in the generator itself or in the excitation control voltage).
system. Following the procedures carefully will, in many a. Diode D5 is open circuit (Test 2).
cases, avoid unnecessary dismantling and reassembly of the b. Voltage regulator is defective (Test 3).
generator when easily corrected problems may exist in the c. Diode D8 is open circuit (Test 2).
external circuitry. d. Exciter field circuit in alternator is open circuit
(Test 7).
e. Alternator circuit breaker (CBI) is defective (Test 7).
f. Alternator stator, main rotating field, rotating rectifier
or rotating exciter armature is defective (Test 8).
15-8
2. Generator set tries to pick up the load but engine labors d.Exciter field circuit shorted or low resistance
excessively, eventually tripping the alternator circuit (Test 7).
breaker or stopping the engine. e. Defective rotating exciter armature, rotating rectifier,
a. Mechanical problems with engine (see preliminary exciter field circuit or main alternator stator (Test 8).
check 1). f. Engine speed too low. Reset injection pump/ governor
b. Excessive load from refrigeration unit malfunction speed to 1800 (10 rpm at Full Load (60 Hz alternator out-
(see preliminary check 2). put); 1950 ± 10 rpm No Load.
c. Current transformers or current bridge defective 4. Generator set output voltage too high.
(Test 4). a. Unit battery discharged (see preliminary check 3).
d. Diode D8 open circuit (Test 2). b. Voltage regulator defective (Test 2).
e. Defect in rotating field, rotating bridge, alternator main c. Power bridge not functioning (Test 3).
field or alternator stator (Test 8). d. Shorted exciter armature (Test 8).
3. Generator set trips the alternator circuit breaker without 5. Unit battery undercharged.
apparent overload. a. No output from power bridge (Test 3).
a. Power bridge inoperative (Test 3). b. Diode D6 open circuit (Test 5 and 6).
b. Circuit breaker defective (Test 7). c. PTC resistors open circuit (Test 6).
c. Voltage regulator failed in ON position (Test 2).
15-9
TEST NO. 1 5. Attach the free lead of the bulb assembly to Fl. A slight
change in the sound of the engine should be evident as
This test will determine whether the alternator or the excita- alternator voltage and excitation builds up.
tion control system is causing the malfunction. The test
requires the use of the 1073 bulb assembly.
CAUTION: If the engine bogs down or produces black
smoke, there is a short circuit in the alternator or its output
CAUTION: Make sure the generator set is disconnected circuits. In this event, disconnect the light assembly and
from any load and the orange wire is jumpered to ground. shutdown the engine.
Severe damage to the current transformer will occur if the Refer to Tests 7 and 8.
load should attempt to start during this test.
6. Measure alternator output voltages on LI-L2, Ll-L3, and
1. Connect a jumper from orange to ground (CH) on circuit L2-L3. Voltage will normally be between 460 and 500
board during test. volts or 230 to 250 depending on engine s@ and whether
2. Disconnect Fl and F2 leads from the alternator. Using a the alternator stator is wired for 460 or 230 volt opera-
jumper wire, connect F2 to a known good ground. tion.
3. Connect one lead of the light assembly to a known good 7. Low or no output voltage indicates a problem in the
12 Vdc source such as the No. 2 wire at the ammeter. The exciter field coils or the alternator itself. To check alter-
other lead will be used later. nator or field coils, see Tests 7 and 8.
4. Start the engine and make sure speed is 1800 ± 10 rpm at 8. Normal output voltage indicates alternator is almost cer-
Full Load (60 Hz alternator output); 1950 ± 10 rpm No tainly in good condition. (Some machines may exhibit
Load. REMEMBER THAT HAZARDOUS ELECTRI- near normal output voltage with one defective rotating
CAL POTENTIALS will be present on alternator output diode. A defective rotating diode would impair the gener-
terminals on exciter control- The ground (negative) con- ator set motor-starting capabilities.) Ammeter should
nection bypasses all exciter control overload protection, indicate CHARGE. If not, power transformer, power
and CARE MUST BE EXERCISED TO AVOID DAM- bridge BR1 or diode D6 is defective (Tests 4, 6 and 7).
AGE TO THE ALTERNATOR IN THE EVENT THERE
IS AN INTERNAL OR EXTERNAL SHORT CIRCUIT.
15-10
DIS-
CONNECT
CHECK
VOLT
CHECK
VOLT
CHECK
VOLT
TEST NO. 2
Test 2 checks the voltage regulator and also checks the initial 4. Using a dc voltmeter, check for voltage at the following
exciter circuit from the unit battery to the field circuit. locations:
1. Voltage Regulator Quick Test NOTE: Voltage readings may vary slightly depending on
The voltage regulator can be checked quickly by unplug- battery voltage.
ging it from the system and substituting the 1073 bulb
a. No. 8 wire at circuit board ó 12 Vdc
assembly and Motorola adapter plug. If there is at least 9
b. Red wire on circuit board after diode ó 10.5 Vdc
Vdc present, start the generator set engine, and connect
c. Green wire before diode D8 ó 9 Vdc
the light assembly from the red wire to the green wire at
the adapter plug. If the alternator picks up the load and
NOTE. No voltage here indicates open diode D8 (Test 6).
operates normally (alternator output voltage may be
slightly high), the voltage regulator is faulty. Higher voltage indicates the voltage regulator may have
2. Disconnect the No. 8A wire from the safety switch to failed in full-on position or field circuit is open (Test 7).
prevent tripping of the safety switch while the generator 5. Turn the unit switch OFF.
set switch is ON. 6. Reconnect the 20 circuit.
3. Turn the unit switch ON, but DO NOT start the engine. 7. Turn On-Off switch ON and start the generator set.
15-11
8. Start the generator, but do not apply load. Voltages 10. The field circuit amperage can be checked with a dc
should be as follows: ammeter. Under normal load conditions, the field amper-
a. No. 8 wire at circuit board ó 13.5 Vdc age should be between 1.5 to 2.5 amps. If the amperage is
b. Red wire after diode D5 at circuit board ó 14 Vdc too high or too low, recheck the engine speed. If the
c. Green wire before diode D8 ó 5 Vdc speed is correct, replace the regulator. If the amperage is
d. F1 after diode D8 ó 4 Vdc still not correct, check the field circuit (see Test 7).
9. Turn the refrigeration unit on to apply load to alternator.
Voltages should be as follows: CAUTION. The voltage regulator used on the generator TK
a. No. 8 wire at circuit board ó 13Vdc Part No. 44-3345 is not the same as the voltage regulator
b. Red wire after diode D5 at circuit board ó 14Vdc used on 7hermo King over-the-road diesel transport
c. Green wire before diode D8 ó 8 Vdc refrigeration units. The voltage setting is lower on the
d. Fl after diode D8 ó 7.25 Vdc
refrigeration units.
Higher or lower than normal voltages at Fl indicate voltage
regulator failure. Replace the voltage regulator. If alternator
output still is too high or low, or if voltage at Fl is not correct,
check field circuit (see Test 7).
NOTE. A voltage regulator failure in the full ON condition

will cause high alternator voltage and will cause the
alternator circuit breaker to trip from field circuit overload.
15-12
CHECK
VOLT
CHECK
VOLT CHECK
VOLT
TEST NO. 3 3. Start the unit. The voltage should rise to approximately
14.5 volts (depending on batteries state of charge). This
indicates the power bridge and power transformer are
Test 3 checks the power bridge and power transformer. If the functioning.
power bridge fails completely, the voltage regulator will not 4. If the voltage does not rise, using an ac voltmeter, check
receive the normal voltage rise out of BRI. The low voltage the voltage across (XI-X2), (X2-X3), (X3-XI). The cor-
(battery voltage), in the 1A circuit keys the regulator to go to rect voltage is approximately 12 to 13 Vac. This ac read-
full field current and therefore high alternator output voltage, ing will be less than the dc output of the power bridge
eventually tripping the alternator circuit breaker from exces- rectifier. This is normal and is due to the fact that the ac
sive field current and thus shutting the generator set down. A voltmeter does not read the peak voltage of an ac sine
defective power bridge also causes the unit ammeter to show wave but reads an average figure (RMS factor). This phe-
a discharge condition, although the no charge condition can nomenon will usually only occur in a three-phase ac,
be caused by other malfunctions. bridge rectifier combination. If the ac voltage is correct
but the dc output was low or non-existent, replace the
To test the power bridge: power bridge rectifier.
1. Attach a dc voltmeter to the terminal that serves as the If the ac voltage from the power transformer is low or
connection of the two red wires, wire 1A and diode D6. non-existent, replace the power transformer. It is virtually
2. Turn the generator On-Off switch ON, but do not start the impossible to check the ac input to the power transform-
engine. The voltmeter should show a reading of 10 to 11 ers so if the alternator output is near normal or high,
volts (1.5 volts less than battery voltage). assume that the power transformer input is normal.
15-13
CHECK
VOLT
CHECK
VOLT
CHECK
VOLT
TEST NO. 4 4. Attach the bulb assembly lead to the green wire on the
adapter and turn the generator set On-Off switch ON. The
This test checks the output of the booster circuit. The booster voltmeter should show 5 Vdc.
circuit is utilized when the generator starts up a load. 5. Start the generator set engine. The refrigeration unit
should start, and voltage should increase from 5 volts
1. Disconnect the voltage regulator and install the Motorola cranking to 10 to 12 or possibly higher, and then drop
adapter plug in its place. Attach one lead of the bulb back to approximately 7 Vdc as the alternator picks up
assembly to a known good 12 Vdc source (No. 2 wire on and starts the load. If field voltage does not rise as the
the ammeter). The other lead will eventually be con- generator set attempts to start the load or if the load will
nected to the green wire on the Motorola adapter plug. not start, the booster system is not functioning properly.
2. Hook up a dc voltmeter across the green and black wires 6. Turn the refrigeration unit On-Off switch OFF once the
on the adapter plug to measure exciter field voltage as refrigeration unit is running. Turn the refrigeration unit
shown. Voltmeter must have a range of at least 50 volts. back ON, and observe the voltmeter and alternator output
3. Hook up a load (refrigeration unit) to the generator and voltage. Field voltage should rise momentarily as the
turn the refrigeration unit On/Off switch ON. Make sure refrigeration unit starts, and the alternator output voltage
the refrigeration unit thermostat is set below box temper- should not drop below approximately 360 or 190 volts,
ature so the unit will start immediately. depending on how the alternator is wired. If the required
booster voltage is not present, check the current bridge
CAUTION: The generator set is not designed to start a rectifier (Test No. 6).
refrigeration unit from a dead stop, but for this test an 7. If the current bridge rectifier is ok, repeat the test check-
exception is made. ing for ac voltage on (XI-X2), (X2-X3), (X3-XI) at the
booster bridge. If the normal voltage rise (10 to 12 Vac) is
not present from the current transformer, replace the cur-
rent transformer.
15-14
CHECK
VOLT
TEST NO. 5 3. 2AI and 2A2: There will be a small voltage drop across
the RI and R2 resistors (.5 volt). If the voltage reading at
Test 5 checks the battery charging circuit. this point is the same as battery voltage when the genera-
tor set is shut off, the resistors are probably open circuit.
NOTE: Before testing the battery charging circuit, run the The only reliable method of testing the resistors is to
generator set to bring all the components up to normal unsolder both of them from their connections and mea-
operating temperature. sure their resistance with an ohmmeter (.1 ohm at room
temperature).
If the unit ammeter indicates no charge or if the battery is
under charged, test the power bridge (Test 3) to make sure the
N0TE: Ambient temperature and battery charge rate will
bridge is providing adequate voltage to charge the battery
have an affect on the voltage drop across the R1 and R2
(14.6 ± .2 V). If the voltage from the power bridge is correct,
using a dc voltmeter, check the voltages at the following loca- resistors.
tions with the unit running. If the battery discharges while the generator set is not used,
check diode D6 (Test 6). It is probably short circuited. Over-
1. 1A at the junction of the two red wires, diode D6 and 1 charging of the battery is usually caused by a faulty voltage
A, 14.6 ± .2 V. regulator. The voltage regulator controls the ac alternator and
2. Between diode D6 and the R1 and R2 charging resistors, the battery charging voltage so an overcharged battery is usu-
it should be I to.8 volts less than the previous reading, ally accompanied by higher than normal output voltage. If
indicating the diode D6 is conductive. A larger difference this is the case, replace the regulator.
indicates the diode is open circuit.
15-15
TEST NO. 6 Test A -- Diodes
Test No. 6 tests individual diodes and bridge rectifiers. To test 1

Checking Reverse
diodes and bridge rectifiers, one thing must always be kept in Leakage Resistance
mind. The diode or bridge must be isolated from the circuits
that are attached to it. If this is not done, a feedback problem Reads high
can exist, and the ohmmeter may indicate a defective diode resistance. Little or
when in actuality it is not. no movement
of pointer.
CAUTI0N: When unsoldering a diode or bridge rectifier,
use a HOT soldering iron and also hold needle. nose pliers
between rectifier and soldering point to prevent destructive
heating. Bring the connection up to soldering temperature 2
quickly, and remove heat as soon as the solder flows.
1. Testing Diodes 1. Ohmmeter
2. Lead
Use X100 scale on the ohmmeter.
Reject diodes that have excessive leakage (read less than

100,000 ohms) reverse polarity. Reject diodes that read low in
both directions or “Open” in forward direction. Test B -- Diodes 1
Good diodes will have a high resistance reading in one direc- Checking for For-
tion and a low reading when ohmmeter leads are reversed. ward
Conductance
2. Testing Bridge Rectifiers:
a. Unsolder wires from rectifier. Good diode reads
b. Place one ohmmeter lead on RED dot terminal, the 1/2 to 2/3 up scale.
other lead on each ac terminal in turn. The three ohmme-
ter readings should be similar to each other.
c. Reverse lead polarity, and repeat the test. Results
2
should be all similar to test “A” in one polarity direction,
test “B” in the other (ohmmeter leads reversed).
d. Place one ohmmeter lead on the case, the other lead on
each a terminal in turn. Reverse lead polarity and repeat. 1. Ohmmeter
Results should be all similar to test “A” in one instance, 2. Lead
test “B” in the other.
15-16
OHM
METER
TEST NO. 7
Test 7 determines the condition of the exciter field circuit.
1. Measure the resistance of the field circuit (Fl to F2) at the

disconnect plug. The standard value is 2.38 ohms at 77.0
F (25.0 C).
2. Measure Fl or F2 to GND for possible shorted to ground
coils.
3. Reconnect the plug, and check resistance from Fl to
GND. This checks the entire field circuit to ground,
including the circuit breaker. The correct value should be
just slightly above Step 1.
15-17
TEST NO. 8
Test 8 includes testing the main alternator-stator, the rotating
field, the rotating rectifier, and the rotating field armature. All
tests must be made with reliable equipment.
1. Main alternator stator windings.

a. Disconnect the stator leads from the excitation control
package, and check for continuity between the
following pairs: TI-T4, T2-T5, T3-T6, T7-TlO, T8-Tll,
T9-Tl2. The resistance between any of the above pairs
should be 0.107 ± 0.11 ohms at 77.0 F (25.0 C).
A very sensitive instrument (such as a Kelvin bridge) must be

used for resistance readings. A standard ohmmeter will suf-
fice to check continuity.
T2 1
T5 1. Disconnect Main Alternator Field Lead
T11
3. Rotating Exciter Armature.
T8 a.With rectifier leads still disconnected from previous
checks, test between the following combinations of leads:
T1
(CR6-CR4), (CR3-CRI), (CR3-CR2)
T1
(CR6-CR5), (CRS-CR4), (CR2-CR1)
T4
The resistance reading on the ohmmeter for any of the
T7
above combinations of leads should be.64-5 (± 10%)
T7
T10 ohms at 77.0 F (25.0C).
T12 b.Using the megohmmeter, check from each pair of leads
T9 T12
T6
to rotor case.
T11
T3 T8
T9
T6 T5
T3 T2
Alternator Stator
b.Using a megohmmeter, check for insulation breakdown

between each pair of leads.
c.Remove the end bell for the remaining checks.
2. Rotating Rectifier.
Six rectifying diodes mount on the rotating rectifier, three are

positive and three are negative. Checking Exciter Armature
a.Unbolt each of the diode leads.
4. Main Alternator Field.
NOTE: The diodes must be disconnected for testing, or false a. Measure the resistance of the main alternator field.
test readings may occur. Standard value is 2.5 ohms.
b.Measure the main field to rotor or ground with a
b.Disconnect main alternator field leads which connect to megohmmeter.
exciter diode heat sinks.
c.Check each diode in the forward and reverse direction
(refer to Test 6).
15-18
Normally, good insulation has high resistance: poor insula-

tion, relatively low resistance. The actual resistance values
can be higher or lower, depending upon such factors as the
temperature or moisture content of the insulation (resistance
decreases with increase in temperature or moisture). They can
be quite different for a generator tested three days in a row,
yet not mean bad insulation. What really matters is the trend
in readings over a time period, showing lessening resistance
and warning of coming problems. Periodic testing is, there-
fore, your best approach to preventive maintenance.
One of the more popular megohmmeters used in the field

today is the “MeggerO” manufactured by:
Checking Main Field Winding AVO Biddle Instruments
Bluebell, Pennsylvania 19422
Area Code: (215) 646-9200
EMERGENCY OPERATION
Emergency operation of generator set which has a defective They may be contacted for more information on how to use
regulator can be obtained by removing the regulator and con- the megohmmeter for testing or about various types of mego-
necting a No. 1073, No. 1076 or a No. 1034 (with both ele- hmmeters available.
ments wired in parallel) automotive lamp between RED and
adjacent GRN terminals on excitation control connector. This
connection will result in higher than normal voltage when MAINTENANCE PROCEDURES
loaded and will result in overcharged batteries if used for
more than 24 hours. The following paragraphs cover detailed maintenance proce-
dures, including disassembly and assembly of equipment for
If there has been a complete failure of the exciter control necessary component removal and replacement. Many repair
package, the generator set can still be operated by using the or replacement operations can be performed without exten-
1073 light bulb attached to a 12 V source and then to the Fl sive disassembly of the generator.
wire. With no battery charging capabilities from the exciter
control package, the unit battery voltage will eventually drop WARNING: DO NOT attempt adjustments or changes in
to a point at which the engine fuel solenoid will disengage and wiring while a unit is in operation. The unit generates
stop the engine (2 to 4 hours). sufficient voltage to cause severe and possible fatal shock.
Use extreme caution when operating in wet or damp
CAUTION: This is a very dangerous procedure in that the locations.
engine has no safety protection from low oil pressure or
overheat conditions. General Inspection
Inspect the entire unit to see that controls are in order and that
there are no loose nuts, bolts, electrical connections or fit-
MEGOHMMETER tings. Inspect for secure engine to generator mountings.
The use of a megohmmeter can be a valuable addition to the Remove any waste material from area around the unit. Check
repair and maintenance of the generator set. The megohmme- battery connections.
ter is essentially a high-range resistance meter (ohmmeter) Insulation
with a built-in direct current generator. This meter is of spe- Inspect insulation on wires, coils and control components. See
cial construction with both current and voltage coils-enabling that insulation is not frayed, broken or deteriorated. Replace
true ohms to be read directly, independently of the actual volt- wire having damaged insulation.
age applied.
Field Coils, Stator Windings
The meter gives you a direct reading of insulation resistance Visually inspect the field coils and stator wirings, their leads
in “ohms” or “megohms” (I megohm = 1,000,000 ohms). For and connections to determine if they are electrically and
good insulation, the resistance usually reads in the megohm mechanically satisfactory. Look for any evidence of overheat-
range. ing, burned or frayed insulation, loose connections, foreign
matter, etc.
15-19
Generator Housing Impeller Fan

Feel the alternator housing cautiously for abnormal tempera- Visually inspect the impeller fan to ascertain that no vanes are
tures as determined by previous experience with the unit. If missing and that the fan is not encrusted with dirt or other for-
the generator is overheated, check the winding temperature eign matter to the point where it will not function properly.
with thermometer, locate the cause such as lack of ventilation,
overload, etc., and correct the condition or shut down the gen-
erator. Inspect the generator housing for obstruction of air Coupling
pages. Disc type coupling. Inspect to see that coupling bolts are tight
and that the generator is solidly secured to the engine.
Generator Bearing
All alternators covered in this manual are fitted with a lubri-
cated ball bearing which requires no maintenance in normal
service. New grease should be supplied in the cavity behind
the bearing shield every year.
1 2
1. Bearing
2. Apply Grease Here
3. Shield
Bearing and Shield
NOTE. A bearing shield is supplied with an open or non-

shielded bearing. Before assembly apply high quality
bearing grease (Mobil 28 or its equivalent) to the indented
lip of shield.
15-20
1
8 9
2 10 11
3
4
5 12
13
25 6 7
8 14 15 17
16 18
9
19
10
11
12 20
25
23 24
22 21
Alternator Assembly
1. Rotor Assembly 14. Statro and End Bell Assembly

2. Disc - rotor drive 15. Stator - wound
3. Blower - generator 16. Exciter - field
4. Rotor 17. Bell - end
5. Key 18. Stud - bell
6. Spacer - bearing 19. Cover - end bell
7. Bearing/Seal - rotor 20. Screw - mounting end bell cover
8. Exciter - assembly - rotor 21. Gasket - end bell cover
9. Rectifier - positive assembly 22. O-ring
10. Rectifier - negative assembly 23. Screw - retainer
11. Nut - rectifier - mounting 24. Retainer - exciter
12. Screw - mounting rectifier 25. Rotor
13. Screw - mounting bearing
15-21
15-22
Section 16
Gen-Set
Alternator Procedures
(New Control System)
Section 16-Gen-Set Alternator Procedures (New Control System)
This alternator consists of three principal components: the The build-up continues until the voltage and amperage
main alternator, the integral direct-connected exciter, and an reaches the rated amount at which the voltage regulator
externally mounted excitation control system. decreases field current, and the alternator maintains the
proper output voltage.
The main alternator may be subdivided into the 4-pole main
rotating field and the main stator winding. The exciter control system used with this generator differs
from previous Thermo King control systems in that the Genet
The main rotating field, the rotating rectifier and the exciter Control Module circuit board replaces the original safety
armature are all mounted on a common shaft. Output of the devices and the silicon controlled rectifier (SCR) that will
exciter is rectified by the shaft mounted rotating bridge recti- alter some test procedures that were utilized for previous con-
fier to provide main alternator rotating field excitation. trol systems.
The externally mounted excitation control system is energized Dual Voltage Alternator
from the battery through a voltage regulator. The output form The generator set is factory wired for 460V power output. The
the main winding is stepped down by the power transformer alternator output
and rectified by power bridge and added to the initial current can be changed to 230V by changing power cable wire con-
supplied by the On-Off switch to build up alternator output. nections at the terminal
strips in the control box.
Rotor Assembly
DC AC
Rotating Rotating
Rectifier Exciter
Main Field
Magnetic Magnetic
Coupling Coupling
Stator Assembly
Volts
Exciter Field
Alternator
(FLD)
Stator (ALT)
Exciter Package DC Low

Voltage
Amperes Overload
Excitation Prot.
AC
High Voltage Control &
60 Hz
Charging To Engine Safety Devices
System DC Low V.
AC Load 3 To Battery
Phase 60 Hz
16-2
FUNCTION OF COMPONENTS IN TRF-1

Power Transformer, 3-phase transformer wired in parallel
EXCITER CONTROL SYSTEM with the output of the alternator. As the voltage from the alter-
BR1 nator rises, so does the output side of the power transformer.
Bridge Rectifier 1 rectifies current from the power trans- After rectification, this voltage is sensed by the voltage regu-
former to charge the battery and supply the exciter circuit. lator which then controls alternator output.
BR2 TRF-2
Current Bridge Rectifier (BR2) rectifies the ac output of the Current Transformer senses an abrupt increase m current
current transformer. This current is then used for dc excitation demand on the alternator. This in turn sends an increased cur-
current through the orange wire, through diode D3 and into rent flow through the current bridge rectifier by passing the
the exciter field. During an overload, this output increases voltage regulator and going directly to the alternator field
greatly and is used to boost alternator output. winding.
CBI VR
Circuit Breaker 1 is electrically located between the current The Voltage Regulator measures the power bridge output
limiter and On-Off switch. The circuit breaker trips open if voltage (RED wire) and supplies exciter field current (GRN
the dc control circuits overload. wire) to the field circuit as required to maintain voltage (and
main generator output) at the desired level.
The voltage regulator also maintains a potential at the output

of the power bridge suitable for the change requirements of
the unit battery and engine electrical controls.
16-3
D1 D5
Diode 1 protects the Preheat/Start switch from negative tran- Diode 5 prevents feedback from power bridge rectifier BRI to
sient voltages caused by arcing at the starter solenoid. engine controls, fuel solenoid, etc. (necessary m order to shut
machine down). Permits flow of initial excitation needed for
D2 building up normal alternator output voltage.
Diode 2 protects the On-Off switch from negative transient
voltages caused by arcing at the fuel shutoff solenoid. D6
Diode 6 isolates alternator excitation system from the battery
D3 when the unit is shut down (necessary to avoid drain on bat-
Diode 3 (part of bridge rectifier BR3) isolates the bridge recti- tery when unit is OFF). Permits battery charging current to
fier BR2 from the voltage regulator output and from the tran- pass from power bridge rectifier BRI to ammeter and then
sients generated in the field coils. Allows bridge rectifier to back to the battery.
control field voltage during motor starts and overload condi-
tions. D7
Diode 7 isolates and protects regulator from high voltages
D4 which are normally developed across field during motor starts
Diode 4 prevents the battery charging current from by passing or under heavy overload. Also allows regulator to control
the positive temperature coefficient (PTC) charge limiting field voltage during normal operation.
resistors RI and R2.
RI & R2
The Positive Temperature Coefficient (PTC) resistors are
charge rate control devices that prevent the charge demand of
a discharged unit battery from influencing the voltage output
of the main generator.
16-4
ALTERNATOR FUNCTION A portion of running excitation is actually supplied by the

current transformer (TRF-2) and current rectifier (BR2). The
A. Starting Excitation current transformer is designed to produce output current in
direct relation to the amount of current flowing from the alter-
The initial excitation for the alternator is supplied by turning nator to the load. The output current is rectified by the current
the On-Off switch to the ON position. Current flows from the bridge (BR2) and then used as additional field current.
unit battery through the No. 2 wire, the ammeter, the fusible
link, diode D4, CBI, the On-Off switch, and the 8-wire to the The design of the current transformer limits the amount of
Genset Control Module. The Genset Control Module sends transformer current output less than the field requirement to
current through the No. 7A wire and diode D5 to the RED maintain normal alternator voltage. Therefore, the alternator
lead of the voltage regulator. The regulator sends the current output voltage would tend to be low. The voltage regulator
out on the GRN wire through diode D7 (part of bridge recti- then senses a low alternator output voltage. It takes current
fier BR3) to wire F1. Wire Fl sends the current through the from the power transformer (TRF-1) and rectifier (BR1) and
exciter field to build voltage in the stator windings. The cur- adds to the field current to bring the alternator output voltage
rent then travels wire F2 to the Genset Control Module where up to normal.
the circuit is completed to chassis ground by the Field Relay.
Note that the Field Relay does not become energized by the If the alternator output voltages rise above the predetermined
Genset Control Module for about 15 seconds after the engine limit, the power transformer will reflect this rise in its output
starts. voltage. The voltage regulator sensing the higher voltage will
then reduce the exciter current to the field winding. This main
B. Running Excitation and Control alternator field, reducing the alternator output.
Once the alternator is excited by the unit battery, then excita- In essence, a 12 Vdc automotive-type voltage regulator is
tion is provided by the alternator itself. controlling a 15 KW ac alternator by taking a sample of the
alternator output, reducing the voltage and sending it to the
The magnetic field that was formed in the exciter field stator field.
winding by battery current induces a current in the exciter
rotating winding. This current is changed from three-phase ac C. Temporary Overload
to dc by the rotating rectifier. The dc current is transferred to
the main alternator field winding The main alternator field For temporary overloads (such as refrigeration unit start up),
now becomes magnetic. the excitation control system utilizes the current (boost) trans-
former (TRF-2) and rectifier (BR2) to handle the overload.
The magnetic field formed in the main field winding now
induces a voltage in the alternator stator windings. This volt- When the alternator output current is normal, the current
age is either 230 Vac or 460 Vac, 3-phase, depending on stator transformer is supplying a portion of the current used to excite
connections. the alternator field. When an overload occurs, the increased
current flow from the alternator through the current trans-
It is sent out of the a r stator leads to the power plug and then former causes an immediate increase in current transformer
to the load. The power transformer (TRF-1) is tapped into the output This increased output overrides the voltage regulator
alternator stator leads. The transformer reads the alternator output and boosts the output of the alternator to handle the
output volume and steps this voltage down to around 12 Vac temporary overload.
(1/20th of output voltage). This current is fed through the
power bridge rectifier (BR1), rectified to dc current and is
sent into the 1A circuit, and some of it goes to the voltage reg-
ulator.
The voltage regulator RED lead is connected to the 1A cir-

cuit, and it utilizes power bridge output to measure alternator
voltage. It also uses the power bridge current output as a
source of exciter current rather than using the unit battery.
16-5
D. Battery Charging If the Genset Control Module shuts down unit operation, it
indicates one of the following:
The unit battery is recharged using current from the power
bridge rectifier (BRI). Current flows from the rectifier bridge 1. There is a malfunction in the load causing the load to fail
through the 1A wire and through diode D6. to start or to draw single phase current
The current is then divided between two wires, 2A1 and 2A2 2. The engine speed or power is low due to improper speed
and then through two resistors R1 and R2 which have the adjustment, fuel supply problems or other mechanical
characteristics of their resistance increasing in proportion to conditions while the generator is supplying motor start-
temperature. This limits the amount of current that a battery, ing current to the load.
in a discharge state, can receive from the system. If a battery
will accept large amounts of current, the resistors heat up and 3. Internal component failure in the excitation control sys-
their resistance increases. This will limit the amount of bat- tem, resulting in excessive field current. This includes
tery charging current. possible malfunction of protective elements in the excita-
tion control.
E. Overload Shutdown
4. Failure in the alternator rotating elements (exciter arma-
The overload shutdown is provided by the Genset Control ture, rotating diode assemblies or main field) can cause
Module. the regulator to supply excessive exciter field current
If an overload condition becomes more than temporary, the 5. Engine shutdown on low engine oil level, low oil pres-
reduction in alternator output voltage due to the overload sure or high water temperature.
causes the Voltage Regulator (VR) to increase field current
through wire F2 to the Genset Control Module. The module
senses the overload current and then de-energizes the fuel
solenoid to stop the engine.
16-6
Alternator Diagnosis TEST INSTRUMENTS
PRELIMINARY CHECKS If the preceding checks did not uncover the cause of the mal-
function, more extensive diagnosis procedures will be
Before attempting the more complicated diagnosis proce- required. The following tests will require various electrical
dures, check the following items to ensure a superficial prob- test instruments, and the technician performing the tests
lem is not overlooked. should have a good working knowledge of their basic electri-
cal principles.
NOTE: Further diagnosis is a waste of time until these item
are checked, since a problem in one of these areas will The tests are intended to determine whether the source of dif-
influence test results. ficulty lies in the generator itself or in the excitation control
system. Following the procedures carefully will, in many
1. If the generator malfunction is accompanied by excessive cases, avoid unnecessary dismantling and reassembly of the
black exhaust smoke and engine lugging, double check generator when easily corrected problems may exist in the
all possible engine problems such as fuel supply, injec- external circuitry.
tion timing, engine speed, restricted air cleaner, etc.
2. Disconnect the refrigeration unit from the generator and The test instruments required:
check the output voltage at the plug. Voltage between the
three phases should be between 230 to 250 Vac or 460 to 1. AC-DC voltmeter 2-5 V to 500 V ranges
500 Vac depending on engine speed and whether the (±2% max. error).
alternator stator is wired for 230 or 460 volt operation. 2. AC induction ammeter (amprobe).
All three phases should be within 3% of each other. If the 3. DC ammeter (preferably induction type
voltages appear normal, make sure the refrigeration unit TK No. 204-449).
is not at fault. Reconnect refrigeration unit and run in 4. Ohmmeter.
Cool mode. Check the amperage draw with an induction 5. Megohmmeter (Megger).
type ammeter (amprobe), and compare it with the load 6. 1073 Light Bulb Assembly and Motorola Adapter.
plate on the refrigeration unit.
3. Check the condition of the generator set battery. A dis- This can be built very quickly. It requires a No. 1073 light
charged unit battery can increase the voltage regulator bulb and a matching socket, two alligator type clips and the
output, causing the generator output voltage to be high. plug off of discarded voltage regulator. See illustration for
The unit battery should have a minimum voltage of 12 V. details.
4. Check all push-in plugs on control circuit for loose pins
or sockets. Make sure all wire terminals are tight.
Alternator Test Equipment
16-7
ALTERNATOR MALFUNCTIONS 3. Generator set causes the Genset Control Module to shut-
down unit without apparent overload.
Listed below are the categories in which most generator mal- a.Power bridge (BR 1) inoperative (Test 2, 3, 6).
functions will fall. Following each category are a number of b.Voltage regulator (VR) failed in ON position
possible component failures that may cause the malfunction. (Test 2).
Listed with each component is the test used to check the com- c.Exciter field circuit shorted or low resistance
ponent. (Test 2, 7).
d.Defective rotating exciter armature, rotating rectifier,
NOTE: Always use Test 1 first to determine if the alternator exciter field circuit or main alternator stator (Test 8).
or the exciter control package is at fault e.Engine speed too low. Reset injection pump/governor
speed to 1800 (10 rpm at Full Load (60 Hz or output);
1. Generator set will not pick up the load (low or no output 1950 (10 rpm No Load.
voltage).
a. Diode D5 is open circuit (Test 2, 6). 4. Generator set output voltage too high.
b. Voltage regular (VR) is defective (Test 2). a.Unit battery discharged (see preliminary check 3).
c.Diode D7 (part of bridge rectifier BR3) is open circuit b.Voltage regulator (VR) defective (Test 2).
(Test 2, 6). c.Power bridge (BRI) not functioning (Test 2,3,6).
d.Exciter field circuit in alternator is open circuit d.Shorted exciter armature (Test 8).
(Test 2, 7).
e. Genset Control Module is defective (Test 2). 5. Unit battery undercharged.
f. Alternator stator, main rotating field, rotating rectifier a.No output from power bridge (BRI) (Test 2,3,6).
or rotating rectifier exciter armature is defective (Test 8). b.Diode D6 open circuit (Test 2, 3, 5, 6).
c.PTC resistors (RI, R2) open circuit (Test 5).
2. Generator set tries to pick up the load but engine labors
excessively, eventually causing an overload condition
and causing the Genset Control Module to shutdown unit
operation.
a.Mechanical problems with engine (see preliminary
check 1).
b.Excessive load from refrigeration unit malfunction (see
preliminary check 2).
c.Current transformer (TRF2) or current bridge (BR2)
defective (Test 4, 6).
d.Diode D7 open circuit (Test 2, 6).
e. Genset Control Module defective (Test 2).
f. Defect in rotating field, rotating bridge, alternator main
field or alternator stator (Test 8).
16-8
ALTERNATOR TEST PROCEDURES
TEST NO. 1 3. Connect one lead of the light assembly to a known good
12 Vdc source such as the No. 2 wire at the ammeter. The
This test will determine whether the alternator or the excita- other lead will be used later.
tion control system is causing the malfunction. The test
requires the use of the 1073 bulb. 4. Start the engine and make sure speed is 1800 ± 10 rpm at
Full Load (60 Hz alternator output); 1950 ± 10 rpm No
CAUTION: Make sure the generator set is disconnected Load. REMEMBER THAT HAZARDOUS ELECTRI-
from any load and the orange wire is jumpered to ground. CAL POTENTIALS will be present on alternator output
Severe damage to the current transformer will occur if the terminals on exciter control. The ground (negative) con-
load should attempt to start during this test. nection bypasses all exciter control overload protection,
and CARE MUST BE EXERCISED TO AVOID DAM-
1. Connect a jumper from orange to ground (CH) on circuit
AGE TO THE ALTERNATOR IN THE EVENT THERE
board during test.
IS AN INTERNAL OR EXTERNAL SHORT CIRCUIT.
2. Disconnect F1 and F2 leads from the alternator. Using a
jumper wire, connect F2 to a known good ground.
16-9
5. Attach the free lead of the bulb assembly to Fl. A slight 7. Low or no output voltage indicates a problem in the
change in the sound of the engine should be evident as exciter field coils or the alternator itself To check alterna-
alternator voltage and excitation builds up. tor or field coils, see Tests 7 and 8.
CAUTION: If the engine bogs down or produces black 8. Normal output voltage indicates alternator is almost in
smoke, there is a short circuit in the alternator or its output good condition. (Some machines may exhibit near nor-
circuits. In this event, disconnect the light assembly and mal output voltage with one defective rotating diode. A
shutdown the engine. defective rotating diode would impair the generator set
Refer to Test 7 and 8. motor-starting capabilities.) Ammeter should indicate
CHARGE. If not, power transformer, power bridge BR1
6. Measure alternator output voltages on L1-L2, L1-L3 and or diode D6 is defective (Tests 4, 6 and 7).
L2-L3. Voltage will normally be between 460 and 500
volts or 230 to 250 volts depending on engine speed and
whether the alternator stator is wired for 460 or 230 volt
operation.
16-10
CHECK
VOLT
CHECK
VOLT
CHECK
VOLT
CHECK
VOLT
TEST NO. 2 a. No. 8 wire at Genset Control Module -- 12 Vdc

NOTE: No voltage here indicates a failed ammeter, fuse
Test 2 checks the voltage regulator and also checks the initial
link, diode D4, circuit breaker CB1 or On/Off switch.
exciter circuit from the unit battery to the field circuit.
b. No. 7A wire at tenninal board -- 12Vdc
1. Voltage Regulator Quick Test NOTE: No voltage here indicates a failed Power Relay (PR)
The voltage regulator can be checked quickly by unplug- or Genset Control Module.
ging it from the system and substituting the 1073 bulb
assembly and Motorola adapter plug. Start the generator c. No. 1A wire on terminal board -- 11 Vdc
set engine, wait at least 15 seconds and connect the light NOTE: No voltage here indicates a failed diode D5.
assembly from the red wire to the green wire at the d. GRN wire at bridge rectifier BR3 -- 9 Vdc
adapter plug. If the alternator picks up the load and oper- NOTE: No voltage here indicates failed voltage regulator.
ates normally (alternator output voltage may be slightly Higher voltage indicates the voltage regulator may have
high), the voltage regulator is faulty.
failed in full-on position or field circuit is open (Test 7).
2. Unplug the connector labeled CN2 from the Genset Con- e. Wire F1 at terminal board -- 8 Vdc
trol Module to prevent tripping of the safety circuitry NOTE: No voltage here open diode D7 (part of bridge
while the generator set sw@ is ON. rectifier BR3) (Test 6).
3. Turn the unit switch ON, but DO NOT start-t the engine. f. Wire F2 at connector CN1 of Genset Control
Module -- 1 Vdc
4. Wait at least 15 seconds then using.- a dc voltmeter, NOTE: No voltage here may indicate an open field coil
check for voltage at the following locations: winding within the alternator. Higher voltage indicates a de-
energized or faded Field Relay or a failed Genset Control
NOTE: Voltage readings may vary slightly depending on Module.
battery voltage.
16-11
5. Turn the unit switch OFF. 9. Turn the refrigeration unit on to apply load to alternator.
Voltages should be as follows:
6. Reconnect connector CN2 to the Genset Control Module. a.No. 8 wire at circuit board ó 13 Vdc
b.No. 1A wire on terminal board ó 14 Vdc
7. Turn On-Off switch ON and start the generator set. c.GRN wire at bridge rectifier BR3 ó 8 Vdc
d.Wire Fl at terminal board ó 7.25 Vdc
8. Start the generator, but do not apply load. Voltages
should be as follows: Higher or lower normal voltages at F1 indicate voltage regu-
a. No. 8 wire at Genset Control Module ó 13.5 Vdc lator failure. Replace the voltage regulator. If alternator output
b. No. 1A wire on terminal board ó 14 Vdc still is too high or low, or if voltage at Fl is not connect check
c.GRN wire at bridge rectifier BR3 ó 5 Vdc field circuit overload (see Test 7).
d. Wire F1 at terminal board ó 4 Vdc
NOTE: A voltage regulator failure in the full ON condition
NOTE: The above voltages indicate that the alternator will cause high alternator voltage and will cause the Genset
output voltage is stepped down by transformer TRF1 and Control Module to shut the unit down from field circuit
rectified by the power bridge rectifier (BR1) thus increasing overload.
the voltage on wire 1A and causing the voltage regulator
10. The field circuit amperage can be checked with a dc
(VR) output to correctly respond by decreasing its output at
ammeter. Under normal load conditions, the field amper-
the GRN wire. age should be between 1.5 to 2-5 amps. If the amperage
is too high or too low, recheck the engine speed. If the
speed is correct, replace the regulator. If the amperage is
still not correct check the field circuit (see Test 7).
CAUTI0N: The voltage regulator used on the generator TK

Part No. 44-3345 is not the same as the voltage regulator
used on Thermo King over-the-road diesel transport
refrigeration units. The voltage setting is lower on the
refrigeration units.
16-12
CHECK
VOLT
CHECK
VOLT
TEST NO. 3 If the voltage does not rise, using an ac voltmeter, check
the voltage across (XI-X2), (X2-X3), (X3-XI). The correct
Test 3 checks the power bridge (BRI) and power transformer voltage is approximately 12 to 13 Vac. This ac reading will be
(TRF1). If the power bridge fails completely, the voltage reg- less than the dc output of the power bridge rectifier. This is
ulator will not receive the normal voltage rise out of BRI. The normal and is due to the fact that the ac voltmeter does not
low voltage (battery voltage), in the 1A circuit keys the regu- read the peak voltage of an ac sine wave but reads an average
lator to go to full field current and therefore high or output figure (RMS factor). This phenomenon will usually only
voltage, eventually tripping the Genset Control Module from occur in a three-phase ac, bridge rectifier combination. If the
excessive field current and thus shutting the generator set ac voltage is coma but the dc output was low or nonexistent,
down. A defective power bridge also causes the unit ammeter replace the power bridge rectifier (BR1). If the ac voltage
to show a discharge condition, although the no charge condi- from the power transformer is low or nonexistent, replace the
tion can be caused by other malfunctions. power transformer (TRF1). It is virtually impossible to check
the ac input to the power transformers so if the alternator out-
To test the power bridge (BRI): put is near normal or high, assume that the power transformer
1. Attach a dc voltmeter to terminal 1A of the terminal input is normal.
board.
2. Turn the generator On-Off switch ON, but do not start the
engine. The voltmeter should slow a reading of 10 to 11
volts. (1.5 volts less than battery voltage)
3. Start the unit. The voltage should rise to approximately
14.5 volts (depending on batteries state of charge). This
indicates the power bridge (BR1) and power transformer
(TRF1) are functioning.
16-13
CHECK
VOLT
CHECK
VOLT
CHECK
VOLT
TEST NO. 4 2. Hook up a dc voltmeter across the green and black wires
on the adapter plug to measure exciter field voltage as
Test checks the output of the booster circuit. The shown. Voltmeter must have a range of at least 50 volts.
booster circuit is utilized when the generator starts up a
load. 3. Hook up a load (refrigeration unit) to the generator and
turn the refrigeration unit On-Off switch ON. Make sure
1. Disconnect the voltage regulator and install the Motorola the refrigeration unit thermostat is set below box temper-
adapter plug in its place. Attach one lead of the bulb ature so the unit will start immediately.
assembly to a known good 12 Vdc source (No. 2 wire on
the ammeter). The other lead will eventually be con- CAUTION: The generator set is not designed to start a
nected to the green wire on the Motorola adapter plug. refrigeration unit from a dead stop, but for this test an
exception is made.
16-14
4. Attach the bulb assembly lead to the green wire on the 6. Turn the refrigeration unit On-Off switch OFF once the
adapter and turn the generator set On-Off switch ON. The refrigeration unit is running. Turn the refrigeration unit
voltmeter should show 5 Vdc. back ON, and observe the voltmeter and or output volt-
age. Field voltage should rise momentarily as the refrig-
5. Start the generator set engine. The refrigeration should eration unit starts, and the alternator output voltage
start, and voltage should increase from 5 volts cranking should not drop below approximately 360 or 190 volts,
to 10 to 12 or possibly higher, and then drop back to depending on how the rise. If the required booster voltage
approximately 7 Vdc as the alternator picks up and starts is not present, check the current bridge rectifier (BR2)
the load. If field volume does not rise as the generator set (Test No. 6).
attempts to start the load or if the load will not start, the
booster system is not functioning properly. 7. If the current bridge rectifier (BR2) is ok, repeat the test
checking for ac voltage on (XI-X2), (X2-X3), (X3-XI) at
the booster bridge (BR2). If the normal voltage rise (10 to
12 Vac) is not present from the current transformer
(TRF2), replace the current transformer.
16-15
CHECK
VOLT
3. Wire 2A1 at the terminal board: There will be a small

TEST NO. 5 voltage drop across the R1 and R2 resistors (.5 volt). If
Test 5 checks the battery charging circuit. the battery never receives charging current, then the
resistors are probably open circuit. The only reliable
NOTE: Before testing the battery charging circuit, run the method of testing the resistors is to unsolder both of them
generator set to bring all the components up to normal from their connections and measure them from their
resistance with an ohmmeter (.1 ohm at room tempera-
operating temperature.
ture).
If the unit ammeter indicates no charge or if the battery is
under charmed, test the power bridge (BR1) (Test 3) to make NOTE: Ambient temperature and battery charge rate will
sure the bridge is providing adequate voltage to charge the have an affect on the voltage drop across the R1 and R2
battery (14.6 (.2 V). If the voltage from the power bridge is resistor.
correct, using a dc voltmeter, check the volumes at the follow-
ing locations with the unit running. If the battery discharges while the generator set is not used,
check diode D6 (Test 6). It is probably short circuited. Over-
1. Wire 1A at the terminal board ó 14.6 ±.2 V charging of the battery is usually caused by a faulty voltage
2. At diode D6 and the R1 and R2 charging resistors: Volt- regulator. The voltage regulator controls the ac alternator and
age reading should be.8 to 1.0 volts less than the previous the battery charging voltage so an overcharged battery is usu-
reading, indicating the diode D6 is conductive. A larger ally accompanied by higher than normal output voltage. If
difference indicates the diode is open circuit. this is the case, replace the regulator.
16-16
TEST NO. 6 Test A -- Diodes 1

Test No. 6 tests individual diodes and bridge rectifiers. To test Checking Reverse
diodes and bridge rectifiers, one thing must always be kept in Leakage Resistance
mind. The diode or bridge must be isolated from the circuits
that are attached to it. If this is not done, a feedback problem Reads high resis-
can exist, and the ohmmeter may indicate a defective diode tance. Little or no
when in actuality it is not. movement
of pointer.
CAUTION: when unsoldering a diode or bridge rectifier,
use a HOT soldering iron and also hold needle-nose pliers
between rectifier and soldering point to prevent destructive 2
heating. Bring the connection up to soldering temperature
quickly, and remove heat as soon as the solder flows.
1. Ohmmeter
1. Testing Diodes 2. Lead
Use X100 scale on the ohmmeter.
Reject diodes that have excessive leakage (read less than Test B -- Diodes 1
100,000 ohms) reverse polarity. Reject diodes that read low in
both directions or operate in forward direction. Checking for For-
ward
Good diodes will have a high resistance reading in one on and Conductance
a low reading when ohmmeter leads are reversed.
Good diode reads
2. Testing Bridge Rectifiers: 1/2 to 2/3 up scale.
a.Unsolder wires from rectifier.
b. Place one ohmmeter lead on RED dot terminal the
other lead on each ac terminal in turn. The three ohmme-
2
ter readings should be similar to each other.
c. Reverse lead polarity, and repeat the test. Results
should be all similar to test “A” in one polarity direction,
test “B” in the other (ohmmeter leads reversed). 1. Ohmmeter
d. Place one ohmmeter lead on the case, the other lead on 2. Lead
each ac terminal in turn. Reverse lead polarity and repeat
Results should be all similar to test “A” in one instance,
test “B” in the other.
16-17
OHM
METER
AJA581
TEST NO. 7
Test 7 determines the condition of the exciter field circuit.
1. Disconnect the field wires F1 and F2 from the control

box circuitry. Measure the resistance of the field circuit
(F1 to F2). The standard value is 238 ohms at 77 F (25
C).
2. Measure F1 or F2 to GND for possible shorted to ground

coils.
3. Reconnect the field wires.
16-18
TEST NO. 8
Test 8 includes testing the main alternator-stator, the rotating
field, the rotating rectifier, and the rotating field armature. All
tests must be made with reliable
equipment.
1. Main alternator stator windings.

a. Disconnect the stator leads from the excitation control
package, and check for continuity between the following
pairs: TI-T4, T2-T5, T3-T6, T7-T10, T8-T11, T9-TI2.
The resistance between any of the above pairs should be
0.107 (0.11 ohms at 77 F (25 C). 1
1. Disconnect Main Alternator Field Lead
A very sensitive instrument (such as a Kelvin bridge) must be
used for resistance A standard ohmmeter will suffice to check 3. Rotating Exciter Armature
continuity. a.With rectifier leads still disconnected from previous
checks, test between the following combinations of
T2
leads- (CR6-CR4), (CR3-CRI), (CR3-CR2), (CR6-CRS),
T5
T11 (CP,5-CR4), (CR2-CR1)
The resistance reading on the ohmmeter for any of the
T8 above combinations of leads should be.645 (± 10%)
ohms at 77 F (25 C).
T1 T1 b.Using the megohmmeter, check from each pair of leads
to rotor case.
T4 T7
T7
T10 Main
T10 Field Exciter
T12 T12 Rotor
T9 T11 AJA066
T6 T8
T9
T6 T5
T3
T3 T2
Alternator Stator
F1 Exciter F2
b.Using a megohmmeter, check for down between each Field
pair of leads.
c.Remove the end bell for the remaining checks. 4. Main Alternator Field.
a. Measure the resistance of the main alternator field.
2. Rotating Rectifier. Standard value is 2.5 ohms.
Six rectifying diodes mount on the rotating rectifier, three are b. Measure the main field to rotor or ground with a
positive and three are negative. megohmmeter.
a.Unbolt each of the diode leads.
Main
Field Exciter
NOTE: The diodes must be disconnected for testing, or false Rotor
test readings may occur.
b.Disconnect main alternator field leads which connect to
exciter diode heat sinks.
c.Check each diode in the forward and reverse direction
Ohmmeter
(refer to Test 6). Exciter F2
F1
Field
16-19
EMERGENCY OPERATION One of the more popular megohmmeters used in the field
today is the “Megger” manufactured by:
Emergency operation of generator set which has a defective AVO Biddle Instruments
regulator can be obtained by removing the regulator and con- Bluebell, Pennsylvania 19422
necting a No. 1073, No. 1076 or a No. 1034 (with both ele- Area Code: (215) 646-9200
ments wired in parallel) automotive lamp between RED and
adjacent GRN terminals on excitation control connector. This They may be contacted for more information on how to use
connection will result in higher dm normal voltage when the megohmmeter for testing or about various types of mego-
loaded and will result in overcharged batteries if used for hmeters available.
more than 24 hours.
If there has been a complete failure of the exciter control MAINTENANCE PROCEDURES
package, the generator set can still be operated by using the The following paragraphs cover detailed maintenance proce-
1073 light bulb attached to a 12 V source and then to the Fl dures, including disassembly and assembly or equipment for
wire and shorting the F2 wire at the Genset Control Module to necessary component removal and replacement. Many repair
the “CH” ground stud. With no battery charging capabilities or replacement operations can be performed without exten-
from the exciter control package, the unit battery voltage will sive disassembly of the generator.
eventually drop to a point at which the engine fuel solenoid
will disengage and stop the engine (2 to 4 hours). WARNING: DO NOT attempt adjustments or changes in
wiring while a unit is in operation. The unit generates
CAUTI0N: This is a very dangerous procedure in that the sufficient voltage to cause severe and possible fatal shock.
engine has no safety protection from low oil pressure or low Use extreme caution when operating in wet or damp
oil level or overheat conditions, or overload locations.
MEGOHMMETER General Inspection

Inspect the entire unit to see that controls are in order and that
The use of a megohmmeter can be a valuable addition to the there are no loose nuts, bolts, electrical connections or fit-
repair and maintenance of the generator set. The megohmme- tings. Inspect for secure engine to generator mountings.
ter is essentially a high-range resistance meter (ohmmeter) Remove any waste material from area around the unit. Check
with a built-in generator. This meter is of special construction battery connections.
with both current and voltage coil enabling true ohms to be
read directly, independently of the actual voltage applied. Insulation
Insulation on wires, coils and control components. See that
The meter gives you a direct reading of insulation resistance insulation is not frayed, broken deteriorated. Replace wire
in “ohms” or “megohms” (1 megohm = 1,000,000 ohms). For having damaged insulation.
good insulation, the resistance usually reads in the megohm
Field Coils, Stator Windings
range.
Visually inspect the field coils and Stator wirings, their leads
and connections to determine if they are electrically and
Normally, good insulation has high resistance; poor insula-
mechanically satisfactory. Look for any evidence of overheat-
tion, relatively low resistance. The actual resistance values
ing, burned or frayed insulation, loose connections, foreign
can be higher or lower, depending upon such factors as the
matter, etc.
temperature or moisture content of the insulation (resistance
decreases with increase in temperature or moisture). They can
be quite different for a generator tested three days in a row,
yet not mean bad insulation. What really matters is the trend
in readings over a time period, showing lessening resistance
and warning of coming problems. Periodic testing is, there-
fore, your best approach to preventive maintenance.
16-20
1 8 9
2 10 11
3
4
5 12
13
25 6 7
8 14
15 17 18
16
9 19
10
11
20
12
25
23 24
22 21
1. Rotor Assembly 14. Stator and End Bell Assembly

2. Disc - Rotor Drive 15. Stator - Wound
3. Blower - Generator 16. Exciter - Field
4. Rotor - (Includes Items 1,2, 3, 5, thru 12) 17. Bell - End
5. Key 18. Stud - Bell
6. Spacer - Bearing 19. Cover - End Bell
7. Bearing/Seal - Rotor 20. Screw - Mounting End Bell Cover
8. Exciter - Assembly - Rotor 21. Gasket - End Bell Cover
9. Rectifier - Positive Assembly 22. O-ring
10. Rectifier - Negative Assembly 23. Screw - Retainer
11. Nut - Rectifier - Mounting 24. Retainer - Exciter
12. Screw - Mounting Rectifier 25. Rotor
13. Screw - Mounting Bearing
16-21
Generator Housing Bearing and Shield

Feel the alternator housing cautiously for abnormal tempera-
ture as determined by previous experience with the unit. NOTE: A bearing shield is supplied with an open or
nonshielded bearing. Before assembly apply high quality
If the generator is overlie check the winding temperature with bearing grease (Mobil 28 or its equivalent) to the indented
thermometer, locate the cause such as lack of ventilation, lip of shield.
overload, etc., and correct the condition or shut down the gen-
erator. Inspect the generator housing for obstruction of air Impeller Fan
passages. Visually inspect the impeller fan to ascertain that no vanes are
missing and that the fan is not encrusted with dirt or other for-
eign matter to the point where it will not function properly.
Generator Bearing
All alternators covered in this manual are fitted with a lubri-
cated ball bearing which requires no maintenance in normal Coupling
service. New grease should be supplied in the cavity behind Disc type coupling. Inspect to see that coupling bolts are tight
the bearing shield every year. and that the generator is solidly secured to the engine.
1 2
1. Bearing
2. Apply Grease Here
3. Shield
16-22
Section 17
Notes
Section 18-Miscellaneous
17-2
17-3
17-4
17-5
17-6
17-7
17-8
17-9
17-10
Section 8-Refrigeration Unit Schematic/Wiring Diagrams
8-3
8-10
8-11
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
• Press and hold F4 key until
— 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 F1 key to directly enter the Main Menu.
— AFAM Rate
• Press F4 key.
9-1
— 02 Minimum • Press SETPOINT key to enter Setpoint menu.

• 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).
cursor stops flashing.
Section 9- Controller Menu Flow Diagrams
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 • Press SUP/RET key to view alternate return/supply- sensor temperature in
Electrical, Refrigeration, MP-3000 and MPC 2000ID Menu Flow Diagrams
— Battery Voltage
— 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.
— 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 - Inspect PTI Log: Press F3 key
through test result screens.
CSR20 PS, CSR40SL PS & CSR40 PS, January 2000

Standard Display Active Option and Pause Mode Displays
NOTE: The screens that display on the con-
COOL MOD NULL HEAT IN RANGE DEFROST SUPPLY RETURN PWRLMT ALARM
— ECON ON troller are determined by the Unit Configura-
SETPOINT TEMPERATURE
° ° — ECONT XXXX1 View Menu
DATA
tion and Customer Configuration settings. All

DATA
— HUM ON — VIEW < - - - > screens are NOT present on all units.
— DEHUM ON — RET XXXXX
Software — BULB ON — SUP XXXXX
— VERSN XX.XX — PHASE CHECK — TD XXXXX
Grade Submenu
— CFG U YYYY — SENSR CHECK — ECOIL XXXXX
— SENSR XXX2 — CCOIL XXXXX — GRADE < - - - >
— CFG C ZZ
— PAUSE ALMXX3 — AMBT XXXXX — RETG XX
Display shows Pause Alarm and options — USDA14XXXXX — SUPG XX
Main Menu that are ON in Program menu for 1 second — USDA24XXXXX — ECTG XX
— MENU < - - - > every 10 seconds. Phase and Sensor — USDA34XXXXX — CCTG XX
check screens show until test is complete. — PULP15 XXXXX — AMTG XX
— PCHUM XXXXX — SPR5G5 XX
— MENU VIEW
— PCVAL6XXXXX
Pretrip Menu — VOLTS XXXXX
— MENU PTRIP — HERTZ XXXXX
— PTRIP <---> — ENTER ETEST
9-2
Press to start — AMP1 XXXXX

— PTRIP ETEST or
an Extended or — AMP2 XXXXX Log Submenu
— PTRIP FTEST — ENTER FTEST
Full Pretrip test. — AMP3 XXXXX
— PTRIP STEST — LOG <--->
Display shows test — AUXV XXXXX
Single Test — CLKV XXXXX — LOG TEMP Press to enter
time remaining.
Submenu — YEAR XXXXX — LOG PTI Scroll Back display.
Electrical, Refrigeration and µP-D Menu Flow Diagrams
— STEST < - - - > — MONTH XXXXX Display shows:

— ENTER DISPL — DAY XXXXX SEARC HINGX and
— ENTER AMPS — TIME XXXXX then recent log entry.
— ENTER SENSR Press to start — CHS1 XXXXX
Press or to
— ENTER HEAT a single pretrip — CHRM1XXXXX
display log entries.
— ENTER DFRST test. Display — VIEW GRADE
— ENTER COOL shows test time — VIEW LOG Press to display
— ENTERECOOL remaining. next TEMP or PTI
Test Menu result.
— MENU TEST — TEST < - - - >
— TEST ELECT Electrical Test
— TEST REFRG Submenu Press to enter
— TEST CNTRL load test display: Press to
— TEST GEN — ELECT < - - - > — HEATROFFON start test. Display
— VOLTS XXXX — EFL OFFON shows:
— HERTZ XX Unit Amps — EFH OFFON — (TEST) ONOFF
— AMPS HEATR Submenu — CFH OFFON — AMPS1 XXX
Refrigeration — AMPS EFL — AMPS2 XXX
— AMPS EFH — UNIT <--->
Test Submenu — UNIT FCHI — AMPS3 XXX
— AMPS CFH — VOLTS XXXX
— REFRG < - - - > — AMPS UNIT — UNIT MC50
— REFRG FCHI — UNIT MC100 Press to enter — HERTZ XX
— REFRG MC50 — UNIT HEAT load test display: — (TEST) < - - - >
— REFRG MC100 — UNIT DFRST — FCHI OFFON
Press to enter
— REFRG NULL — MC50 OFFON
load test display: Press to
— REFRG HEAT — MC100 OFFON
— FCHI OFFON start test. Display
— REFRG DFRST Press to start — HEAT OFFON
— MC50 OFFON shows:
test. Display shows: — DFRST OFFON
— MC100 OFFON — (TEST) ONOFF
— (TEST) ONOFF
— NULL OFFON — AMPS1 XXX
— RET XXXXX
— HEAT OFFON — AMPS2 XXX
— SUP XXXXX
— DFRST OFFON — AMPS3 XXX
— TD XXXXX
Guard Menu — ECOIL XXXXX Controller Test — VOLTS XXXX
— MENU GUARD Submenu — HERTZ XX
— GUARD < - - - > — (TEST) < - - - >
— GUARD 0 0 0 0 — CNTRL < - - - > — (TEST) < - - - >
— AUTO OFFON
Enter access code7. Guard Submenu — EFL OFFON
Press to scroll — GMENU < - - - > — EFH OFFON
cursor to next digit to — MENU CNFIG — CFH OFFON
right. Configuration — CPH OFFON
— CIDXX (scroll) Press to
Submenu — PS1 OFFON
Press or to — USNXX (scroll) start test. Display
— YEAR XXXX — CNFIG < - - - > — PS2 OFFON
select number. shows:
— MONTH XX — CFG U YYYY9 — HTR OFFON
Press to enter — (TEST) ONOFF
— DAY XX — CFG C ZZ — MC 50 OFFON
access code. — MC100 OFFON
— HOUR XX
Display shows Scrolling display — LIV OFFON
— MIN XX Press to enter
GUARD LOAD, then shows current ID. — BVS OFFON
— CHRM1XXXXX load configuration
GMENU <- - - >. — LLS OFFON
— ONHRMXXXXX Press to enter display.
— H1TYP XX — SLS OFFON
load value display.
— UHMT1 XX Press or — DEHUMOFFON
Right display flashes
— UHRM1XXXXX to select configura- — RCOMPOFFON
digit to be changed.
— H2TYP XX tion number. — RDEF OFFON
— UHMT2 XX Press or to — RIR OFFON
Press to load — RSP OFFON
— UHRM2XXXXX select new letter (A to
selection.
— H3TYP XX Z) or number (0 to 9).
— UHMT3 XX Press to select
— UHRM3XXXXX another digit to change. Generator Test
— H4TYP XX
— UHMT4 XXXXX Press when all — UNIT OFFON Press to
— UHRM4 XX digits are set correctly Grade Submenu start refrigeration
— ECMAXXXXXX to load new ID. unit. Display
— ECMIN XXXXX — GRADE < - - - > shows:
— ECONT XXXXX — RETG XX — UNIT ONOFF
— DMTCH XX Press to enter — SUPG XX Press to enter — HERTZ XX
— DMTFZ XX load value display. — ECTG XX load grade display. — VOLTS XXXX
— ALOGS XXX — CCTG XX — AMP1 XXX
Press or to Press or to
— GLOGS XXX — AMTG XX — AMP2 XXX
select new value. select new grade.
— C/F8 X — SPR5G XX — AMP3 XXX
Program Menu — MENU GRADE Press to load — UNIT < - - - >
new value. Press to load
— MENU PRGRM — PRGRM < - - - > new grade.
— USDA OFF
— USDA1 OFF
— USDA2 OFF Footnotes:
1ECON ON time shows ONLY if Economy Mode is ON and unit is in Null on Frozen
— USDA3 OFF
— PULP OFF Press to enter Load (setpoint -10.0 C [14 F] or Below).
2SENSR CHECK time shows ONLY when controller performs a sensor check test.
— HUMSN OFF Load display. Left
µP-D Menu Flow Diagram
3PAUSE screen indicates controller has stopped unit operation due to a shutdown
— ECON OFF display FLASHES.
alarm. Controller restarts unit if alarm condition is corrected.
— HUMID OFF • Set calibration for 4Screen shows ONLY if spare sensor is ON in program menu. If USDA option is ON,
Press to select
— BULB OFF USDA1, USDA2, ONLY View Menu shows USDA1, USDA2 and USDA3.
ON (or PWRED
— PWRED 0 USDA3 and PULP. 5PULP optional display.
value) in right display. 6PCVAL displays on modulation valve systems. PCCAP displays on KVQ valve systems.
• Set HUMSP for
7Access code is 0007.
Press to load HUMID.
8C/oF units shown on the controller display can also be changed by pressing and holding
option. • Set BDFTT and
the oC/oF key, and then pressing ENTER key.
BEFAN for BULB. 9When a unit configuration is entered, a customer configuration MUST also be entered.
CRR-20 & CRR-40, September 1999

Standard Display
NOTE: The screens that display on the controller
are determined by the Unit Configuration setting.
All screens are NOT present on all units.
Setpoint Menu
— Setpoint Temperature Enter a Temperature or
Humidity Setpoint
• Press F4 key.
• Type the new setpoint.
MAIN MENU
Data Menu
— DATA — Supply Air Temp
— Return Air Temp
9-3
— Defrost (Evap Coil) Temp

— Ambient Temp
— High Pressure Temp
— R-23 Compressor
Discharge Temp
Alarms Menu
— Battery Voltage
ALARMS • View and write down all alarm — Voltage Average
codes.
Electrical, Refrigeration and Controller Menu Flow Diagrams
— Voltage 1
• Press F2 key to view the next — Voltage 2
alarm code. — Voltage 3
• Clear alarm code by correcting — Frequency
problem and acknowledging — Zero Current
the alarm. — Current Phase 1
• To acknowledge an alarm, — Current Phase 2
press F4 key with alarm code in — Current Phase 3
display.
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
• First Component Test appears
in display.
• Press F2 or F3 key to scroll to
to the desired component:
- Condenser Fan
- R-134a Compressor
- R-23 Compressor
Misc. Functions Menu
- Capacity 100%
— MISC FUNCTIONS — Date Time - Evaporator Fans
— C/F Mode Misc. Functions Submenu - Heat
— Cargo Data - Zero Current
• Current function setting appears
— Program Version • Press F4 key to start and stop
in display.
— Run Time test (toggle component display
• Press F3 key to scroll to desired
between ON and OFF).
function.
• More than one component
• Press F4 key to change a
can be turned ON at a time to
setting:
perform a functional test of
- Date Time: Type the new
the unit.
setting.
- C/F Mode: Press F2 key to
toggle setting.
- Cargo Data: Press F3 key to
scroll to desired function.
Press F4 key. Type new
setting.
- Program Version: Displays
current setting only.
- Run Time: Press F3 key to
scroll to desired function.
Press F4 key. Type new
setting.
Configuration Menu
— CONFIGURATION — In-Range
— Container ID Configuration Submenu
— Contrast • Current function setting appears
— Zero Current in display.
• Press F4 key to change a
setting.
• Press F2 key, “A” key (pass-
word), F4 key and EXIT key.
Datalogger Menu • Type new value; or press F3
— DATALOGGER — Inspect Temp Log key to toggle value to desired
— Inspect event Log Datalogger Submenu setting.
— Set Log Time • First function screen appears: • Press and hold F4 key until
— Inspect PTI Log - Inspect Temp Log: Press F4 cursor stops flashing.
key to view next screen.
Press F3 key to scroll through
previous logs of sensors.
- Inspect Event Log: Press F3
CRR DF MPC2000ID Menu Flow Diagram
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 - Inspect PTI Log: Press F3 key
• Zombie through test result screens.
• On-line
CRR DF, February 2000

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14-1
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14-6

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CONTAINER

2. Basic Refrigeration System Operation

3. Container Refrigeration Units & System Diagrams

4. Thermostat Sequence Diagrams

6. R12 to R134a Conversion

8. Refrigeration Unit Schematic/Wiring Diagrams

10. Container Service Bulletins

11. Gen-Set Configurations

12. Gen-Set Control Systems

13. µP-G “Smart” Gen Set Controller

14. Gen Set Schematic/Wiring Diagrams

15. Alternator Test Procedures (Original Control System)

16. Alternator Test Procedures (New Control System)

SAFETY PRECAUTIONS Refrigerant

ELECTRICAL and safety glasses. Whichever method is used, do not look at

Controller Repair Welding of Units or Containers

Principles of Heat Transfer

Refrigeration and Air Conditioning

Refrigeration is the process of transferring heat away from an area to

Air conditioning occurs when heat is transferred away from an area to

Transport Temperature Control

Thermo King Units Do Not Make COLD! They remove Heat.

Matter, Molecules, and Temperature

Heat Always Moves From Hotter To Colder

Methods of Heat Transfer

Heat Moves by Radiation, Conduction, and Convection

Heat Transfer and Equipment Design

All of these efforts cannot completely overcome a funda-

A Thermo King Unit Primarily Moves Unwanted Heat To The Outside.

The heat energy from one paper match is approxi-

One Btu is the amount of heat required

These formulas convert between English and metric units of heat.

Commodity Heat of Respiration

Temperature-sensitive products must be at the recommended storage temperature when loaded.

Transport Temperature Control

British Thermal Unit (Btu)

How Are You Doing So Far?

3. The total absence of heat is "absolute zero". This temperature is

4. Heat intensity is measured in

5. Which of the following statements is FALSE?

6. Heat enters a temperature controlled compartment

Latent Heat and Pressure/Temperature

Changing States: SolidLiquidGas

Latent Heat Is Absorbed Or Released During A Change Of State.

Latent Heat of Vaporization

Latent Heat of Condensation

The Pressure/Temperature Relationship

Raising The Boiling Point

Lowering The Boiling Point

Summary: Refrigeration Fundamentals

Heat Can Be Moved

Heat Moves By Conduction, Convection, and Radiation

A Change of State Releases or Absorbs Heat Energy

Latent Heat of Condensation

Latent Heat of Evaporation

Boiling Point Is Controlled By Pressure

3. Latent heat of condensation is heat energy

4. Latent heat of vaporization is heat energy

212 F 100 C 0 -0 759,968 29.92 14.696

205 F 96 C 4.92 -16.62 635,000 25.00 12.279

176 F 80 C 15.94 -53.87 355,092 13.98 6.866

158 F 70 C 20.72 -70.03 233,680 9.20 4.519

140 F 60 C 24.04 -81.25 149,352 5.88 2.888

122 F 50 C 26.28 -88.82 92,456 3.64 1.788