CRR40

CRR DF MPC2000
CRR DF MPC2000ID
CRR DF MP 3000
TK 50134-4-MM (Rev. 5, 06/02)
The maintenance information in this manual covers unit models:
CRR-40 DF with MPC2000
CRR-40 DF with MPC2000ID
CRR-40 DF with MP3000
For further information, refer to:
CRR DF Parts Manual TK50262
Diagnosing Thermo King Container Refrigeration Systems TK41166
Electrostatic Discharge (ESD) Training Guide TK40282
Evacuation Station Operation and Field Application TK40612
Tool Catalog TK5955
The information in this manual is provided to assist owners,
operators and service people in the proper upkeep and
maintenance of Thermo King units.
This manual is published for informational purposes

only and the information so provided should not be
considered as all-inclusive or covering all
contingencies. If further information is required,
Thermo King Corporation should be consulted.
Sale of product shown in this manual is subject to

Thermo King’s terms and conditions including, but
Copyright© 1999 Thermo King Corp., Minneapolis, MN, USA.

Printed in USA.
not limited to, the Thermo King Limited Express
Warranty. Such terms and conditions are available
upon request. Thermo King’s warranty will not
apply to any equipment which has been “so
repaired or altered outside the manufacturer’s
plants as, in the manufacturer’s judgment, to
effect its stability.”
No warranties, express or implied, including

warranties of fitness for a particular purpose or
merchantability, or warranties arising from course
of dealing or usage of trade, are made regarding
the information, recommendations, and
descriptions contained herein. Manufacturer is not
responsible and will not be held liable in contract
or in tort (including negligence) for any special,
indirect or consequential damages, including
injury or damage caused to vehicles, contents or
persons, by reason of the installation of any
Thermo King product or its mechanical failure.
Recover Refrigerant
At Thermo King, we recognize the need to preserve the environment and
limit the potential harm to the ozone layer that can result from allowing
refrigerant to escape into the atmosphere.
We strictly adhere to a policy that promotes the recovery and limits the
loss of refrigerant into the atmosphere.
In addition, service personnel must be aware of Federal regulations

concerning the use of refrigerants and the certification of technicians. For
additional information on regulations and technician certification programs,
contact your local Thermo King dealer.
4
Table of Contents
Listof Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CRR DF Model Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FirstAid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RefrigerantOil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FirstAid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
HighVoltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 General
Safety Precautions for Servicing Units (or Containers) Equipped with a Microprocessor Controller . . 15
Controller Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Welding of Units or Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
UnitDecals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Serial
Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ServiceGuide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Full Cool Operation Net Cooling Capacity* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Net Defrost Heating Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
EvaporatorAirflow** . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 R-
134a Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 R-23
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Compressor Torque — 3D Copeland Compressor Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Metric Hardware Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cascade Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Datalogger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Three Evaporator Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
USDA Cold Treatment Temperature Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
REFCON Remote Monitoring Modem (RMM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
OperatingModes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FrozenLoads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Basic Unit Controls, Instruments and Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
UnitControl Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
MPC2000, MPC2000ID or MP3000 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Other. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 R-
134a Refrigeration System Controls, Instruments and Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 R-23
Refrigeration System Controls, Instruments and Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
PretripInspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Power Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Pre-load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Pre-
Trip Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Pre-Trip
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Loading
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Post Load Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Starting the Unit on Ship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Post Trip Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5
Table of Contents
Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
General Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Frozen Loads (Setpoint at -10 C [14 F] and Below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
UnitStart-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Continuous Temperature Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Initiating a Manual Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Displaying Alternate Controlling (Supply or Return) Air Sensor Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Displaying Alternate Fahrenheit (F) or Celsius (C) Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Menu Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Controller Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
DataMenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
AlarmList Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Commands Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Manual function Test, DF units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Misc. Functions Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
MP-3000 Configuration List, DF Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Datalogger Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
RMMState Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
PTI(Pretrip) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Manual Emergency Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Replacing the EPROM Chip (MPC2000 and MP3000 Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Replacing the Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Flash Loading Controller Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
MPC 2000 ID / MP 3000, Super Freezer "Error message list" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Alarm Codes, Descriptions and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Electrical Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
UnitWiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
R-23 High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
R-134a High Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Condenser Fan and Evaporator Fan Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Evaporator Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Electric Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Low Pressure Cutout Switch (R-23 System on CRR DF MPC2000ID Units Only) . . . . . . . . . . . . . . . . . . . . . . .86
Low Pressure Cutout Switch: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Refrigeration Maintenance and Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
ServiceTools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 R-
134a Service Fittings and Gauge Manifold Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
LeakDetection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
VacuumPump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
SystemCleanup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Refrigerant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Compressor Oil Acid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Compressor Discharge and Suction Service Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Gauge Manifold Valve Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
R-134a Gauge Manifold Set (With Low Loss Fittings) Attachment And Purging . . . . . . . . . . . . . . . . . . . . . . . . .90 R-
134a Gauge Manifold Set Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Gauge Manifold Set Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Service Procedure Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Typical R-23 and R-134a System Suction and Discharge Pressure Readings . . . . . . . . . . . . . . . . . . . . . . . . . .91 Test
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Discharge
Pressure Regulator Test and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
6
Table of Contents
Refrigeration Maintenance and Service Operations (continued)

Checking Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Checking the Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Adding Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Removing Excess Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Refrigerant Leak Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Low Side Pump Down (R-134a Compressor Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Refrigerant Charge Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Checking the R-134a Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Checking the R-23 Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Refrigerant Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
R-23 Recovery for System Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 R-
134a Vapor Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 R-
134a Liquid Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Evacuation and Cleanup of the Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Compressor Oil Color Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Refrigeration System Preparation and Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Unit Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Pressure Rise Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Factors Affecting the Speed of System Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Heat Saves Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
R-134a Refrigeration System Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Charging R-134a System with Liquid Refrigerant by Weight (from an Evacuated Condition) . . . . . . . . . . 102 R-
134a Evacuation Station Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 R-
134a Final Charging Procedure for Partially Charged Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
R-23 Refrigeration System Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 R-
23 Evacuation Station Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Charging R-23 System with Gas Refrigerant Recovered in 40 Liter (42 qt.) Refrigerant Bottle
(from an Evacuated Condition) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 R-
23 Final Charging Procedure for Partially Charged Units on Empty Containers . . . . . . . . . . . . . . . . . . 104 R-23
Charging Procedure for Partially Charged Units on Loaded Containers . . . . . . . . . . . . . . . . . . . . . . 105
Using Pressurized Nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Dehydration, Pressure Testing, Purging and Soldering Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Compressor Replacement (R-134a or R-23 Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Condenser Coil Replacement (R-134a or R-23 Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Dehydrator (Filter Drier) Replacement (R-134a or R-23 Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Expansion Valve Replacement (R-134a or R-23 Systems) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
R-23 System Heat Exchanger Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
R-23 System to R-134a System Plate Heat Exchanger Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Receiver Tank Replacement (R-134a or R-23 System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
High Pressure Cutout Switch Replacement (R-134a or R-23 System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
7
Table of Contents
Refrigeration Maintenance and Service Operations (continued)

Liquid Line Solenoid Valve Replacement (R-134a System Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Low Pressure Cutout Switch Replacement (CRR DF MPC2000ID and MP3000 Units Only) . . . . . . . . . . . . . .113
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Structural/Accessory Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
MountingBolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
UnitInspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
CondenserCoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
EvaporatorCoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
DefrostDrains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Evaporator Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Condenser Fan Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
VacuumValve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Mechanical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Refrigeration System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Electrical, Refrigeration and Controller Menu Flow Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
8
List of Figures
Figure 1: Unit Nameplate and Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 2: Unit Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 3: Evaporator Section — Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 4: Vacuum Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 5: Power Cord Storage Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Figure 6: Control Box and Microprocessor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Figure 7: MPC2000 or MP3000 Controller and Remote Monitoring Modem . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 8: MPC2000ID and MP3000 Controller, and Remote Monitoring Modem . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 9: Unit Control Box with Door Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 10: Low Pressure Cutout Switch in R-23 Refrigeration System (CRR DF MPC2000ID Units Only) . . . . 36
Figure 11: R-23 Compressor Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 12: Additional R-23 Refrigeration System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 13: R-134a Compressor Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 14: Additional R-134a Refrigeration System Components and Plate Heat Exchanger . . . . . . . . . . . . . . 40
Figure 15: Unit Back View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 16: Unit Back View — Pressure Regulators and Buffer Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 17: Unit Back View — Electric Heaters and Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 18: MPC2000, MPC2000ID and MP3000 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 19: Frozen Load Control Sequence (Setpoints at -10 C [14 F] and Below) . . . . . . . . . . . . . . . . . . . . . . . 56
Figure 20: 3 Fan Evaporator: Evaporator (Defrost) Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 21: Manual Emergency Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 22: R-134a Service Fittings Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 23: Service Valve Back Seated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 24: Service Valve Open to Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 25: Service Valve Front Seated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 26: Balancing R-134a System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 27: Charging the R-134a System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 28: Gauge Manifold Closed to Center Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 29: Gauge Manifold Open to Center Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 30: Removing R-134a Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 31: Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 32: Purging Gauge Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 33: Discharge Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 34: Checking Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 35: Adjusting Compressor Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Figure 36: Testing for Refrigerant Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 37: R-134a Refrigeration System Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 38: R-23 Refrigeration System Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 39: Constant Pressure Rise After Evacuation Indicates System Leak . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 40: Pressure Rise Levels Off After Evacuation Indicates Moisture in System . . . . . . . . . . . . . . . . . . . . 101
Figure 41: Typical Pressurized Gas Bottle with Pressure Regulator and Gauges . . . . . . . . . . . . . . . . . . . . . . 106
Figure 42: Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Figure 43: Evaporator Fan Blade Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Figure 44: Vacuum Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Figure 45: Condenser Fan Blade Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
9
List of Figures
10
Introduction
CRR DF Model Features

CRR-40DFMPC2000
CRR-40DFMPC2000ID
CRR-40 DF MP3000
Model
Features
X=Included
X X X 460-380V/3Ph 60-50 Hz, 18.3 m (60 ft) Power Cable and Plug
X X X 32 Amp Main Power Circuit Breaker
X X X Automatic Phase Selection Control
X X X Three Evaporator Fans with 2-Speed Motors
X X X One 1-speed Condenser Fan Motor
X – – MPC2000 Microprocessor Controller
X – – MPC2000 Datalogger
– – X MP3000 Microprocessor Controller
– – X MP3000 Datalogger
– X – MP2000ID Microprocessor Controller with Integral Datalogger
X X X Refcon Remote Monitoring Modem (RMM)
X X X USDA Cold Treatment Temperature Recording — Three (3) Sensor
X X X D3DS Copeland Discus Compressor w/5.60 kW (7.5 Hp) Motor for R-134a Refrigeration Circuit
X X X Copper Receiver Tank with Moisture Indicating Sight Glass in R-134a Refrigerant Circuit
X X X Suction Pressure Gauge for R-134a Refrigeration Circuit
X X X Discharge Pressure Gauge for R-134a Refrigeration Circuit
X X X Hermetic Scroll Compressor w/4.48 kW (6.0 Hp) Motor for R-23 Refrigeration Circuit
– X – Low Pressure Cutout Switch for R-23 Refrigeration Circuit
X X X Stainless Steel Receiver Tank with Moisture Indicating Sight Glass in R-23 Refrigerant Circuit
X X X Suction Pressure Gauge for R-23 Refrigeration Circuit
X X X Discharge Pressure Gauge for R-23 Refrigeration Circuit
11
Introduction
12
Safety Precautions
General Practices Refrigerant

1. ALWAYS WEAR GOGGLES OR SAFETY When removing any refrigerant from a unit, use a
GLASSES. Refrigerant liquid and battery acid recovery process that prevents or absolutely
can permanently damage the eyes (see First minimizes the refrigerant that can escape to the
Aid under Refrigerant Oil). atmosphere. Although fluorocarbon refrigerants
are classified as safe refrigerants when proper
2. Never close the compressor discharge valve tools and procedures are used, certain precautions
with the unit in operation. Never operate the
must be observed when handling them or
unit with the discharge valve closed.
servicing a unit in which they are used. When
3. Keep your hands, clothing and tools clear of the exposed to the atmosphere in the liquid state,
fans when the refrigeration unit is running. If it fluorocarbon refrigerants evaporate rapidly,
is necessary to run the refrigeration unit with freezing anything they contact.
covers removed, be very careful with tools or
meters being used in the area. First Aid
4. Be sure the gauge manifold hoses are in good In the event of frost bite, the objectives of First
condition. Never let them come in contact with Aid are to protect the frozen area from further
a fan motor blade or any hot surface. injury, to warm the affected area rapidly, and to
maintain respiration.
5. Never apply heat to a sealed refrigeration
system or container. · EYES: For contact with liquid, immediately
flush eyes with large amounts of water and get
6. Fluorocarbon refrigerants, in the presence of
prompt medical attention.
an open flame or electrical arc, produce toxic
gases that are severe respiratory irritants · SKIN: Flush area with large amounts of
capable of causing death. lukewarm water. Do not apply heat. Remove
contaminated clothing and shoes. Wrap burns
7. Be sure all mounting bolts are tight and are the
with dry, sterile, bulky dressing to protect from
correct length for their particular application.
infection/injury. Get medical attention. Wash
8. Use extreme caution when drilling holes in the contaminated clothing before reuse.
unit. The holes may weaken structural
· INHALATION: Move victim to fresh air and
components. Holes drilled into electrical
use CPR or mouth-to-mouth ventilation, if
wiring can cause fire or explosion. Holes
necessary. Stay with victim until arrival of
drilled into the refrigeration system may
emergency medical personnel.
release refrigerant.
9. Use caution when working around exposed Refrigerant Oil
coil fins. The fins can cause painful
lacerations. Observe the following precautions when working
with or around refrigerant oil:
10. Use caution when working with a
refrigerant or refrigeration system in any · Do not allow refrigerant oil to contact your
closed or confined area with a limited air eyes.
supply (for example, a trailer, container or in · Do not allow prolonged or repeated contact
the hold of a ship). Refrigerant tends to with skin or clothing.
displace air and can cause oxygen depletion,
resulting in suffocation and possible death. · To prevent irritation, you should wash
thoroughly immediately after handling
11. Use caution and follow the refrigerant oil. Rubber gloves are
manufacturer’s suggested practices when using recommended when handling Polyol Ester
ladders or scaffolds. based refrigerant oil.
13
Safety Precautions
First Aid 5. Treat all wires and connections as high voltage

until a meter and wiring diagram show
· EYES: Immediately flush eyes with large
otherwise.
amounts of water for at least 15 minutes while
holding the eyelids open. Get prompt medical 0. Never work alone on high voltage circuits on
attention. the refrigeration unit. Another person should
always be standing by in the event of an
· SKIN: Remove contaminated clothing. Wash
accident to shut off the refrigeration unit and to
thoroughly with soap and water. Get medical
aid a victim.
attention if irritation persists.
6. Have electrically insulated gloves, cable cutters
· INHALATION: Move victim to fresh air and
and safety glasses available in the immediate
restore breathing if necessary. Stay with victim
vicinity in the event of an accident.
until arrival of emergency personnel.
· INGESTION: Do not induce vomiting. Contact First Aid
a local poison control center or physician
IMMEDIATE action must be initiated after a
immediately.
person has received an electrical shock. Obtain
immediate medical assistance if available.
Electrical
The source of shock must be immediately
High Voltage removed by either shutting down the power or
removing the victim from the source. If it is not
When servicing or repairing a refrigeration unit, possible to shut off the power, the wire should be
the possibility of serious or even fatal injury from cut with either an insulated instrument (e.g., a
electrical shock exists. Extreme care must be used wooden handled axe or cable cutters with heavy
when working with a refrigeration unit that is insulated handles) or by a rescuer wearing
connected to a source of operating power, even if electrically insulated gloves and safety glasses.
the unit is not running. Lethal voltage potentials Whichever method is used, do not look at the wire
can exist at the unit power cord, inside the control while it is being cut. The ensuing flash can cause
box, inside any high voltage junction box, at the burns and blindness.
motors and within the wiring harnesses.
If the victim has to be removed from a live circuit,
Precautions pull the victim off with a non-conductive material.
Use the victim’s coat, a rope, wood, or loop your
1. Be certain the unit On/Off switch is turned belt around the victim’s leg or arm and pull the
OFF before connecting or disconnecting the victim off. DO NOT TOUCH the victim. You can
unit power plug. Never attempt to stop the unit receive a shock from current flowing through the
by disconnecting the power plug. victim’s body.
2. Be certain the unit power plug is clean and dry After separating the victim from power source,
before connecting it to a power source. check immediately for the presence of a pulse and
3. Use tools with insulated handles that are in respiration. If a pulse is not present, start CPR
good condition. Never hold metal tools in your (Cardio Pulmonary Resuscitation) and call for
hand if exposed, energized conductors are emergency medical assistance. If a pulse is
within reach. present, respiration may be restored by using
mouth-to-mouth resuscitation, but call for
4. Do not make any rapid moves when working emergency medical assistance.
on high voltage circuits. If a tool or other
object falls, do not attempt to grab it. People do
not contact high voltage wires on purpose. It
occurs from an unplanned movement.
14
Safety Precautions
Low Voltage 4. Avoid contacting the electronic components on

the circuit boards of the unit being serviced.
Control circuits are low voltage (24 Vac and 12
Vdc). This voltage potential is not considered 0. Leave the circuit boards in their static proof
dangerous, but the large amount of current packing materials until ready for installation.
available (over 30 amperes) can cause severe
5. If a defective controller is to be returned for
burns if shorted to ground.
repair, it should be returned in the same static
Do not wear jewelry, watch or rings. These items protective packing materials from which the
can short out electrical circuits and cause severe replacement component was removed.
burns to the wearer.
6. After servicing the circuit board and any other
circuits, the wiring should be checked for
General Safety Precautions for possible errors before restoring power.
Servicing Units (or Containers)
Equipped with a Welding of Units or Containers
Microprocessor Controller Whenever electric welding is to be performed on
Precautions must be taken to prevent electrostatic any portion of the refrigeration unit, container or
discharge when servicing the microprocessor and container chassis with the refrigeration unit
related components. If these precautionary attached, it is necessary to ensure that welding
measures are not followed, the risk of significant currents are NOT allowed to flow through the
damage to the electronic components of the unit is electronic circuits of the unit. These procedures
possible. must be rigidly adhered to when servicing these
units to avoid damage or destruction.
The primary risk potential results from the failure
to wear adequate electrostatic discharge 1. Disconnect all power to the refrigeration unit.
preventive equipment when handling and 2. Disconnect all quick-disconnect wire harnesses
servicing the controller. The second cause results from the back of the controller.
from electric welding on the unit and container
chassis without taking precautionary steps. 3. If the unit is equipped with an Remote Monitor
Module or Modem (RMM) /Integrated Remote
Controller Repair Monitor Unit (IRMU), disconnect all wire
harnesses from the RMM/IRMU circuit board.
When servicing the controller, it is necessary to
ensure that electrostatic discharges are avoided. 4. Switch all of the electrical circuit breakers in
Potential differences considerably lower than the control box to the OFF position.
those which produce a small spark from a finger 5. Weld unit and/or container per normal welding
to a door knob can severely damage or destroy procedures. Keep ground return electrode as
solid-state integrated circuit components. The close to the area to be welded as practical. This
following procedures must be rigidly adhered to will reduce the likelihood of stray welding
when servicing these units to avoid controller currents passing through any electrical or
damage or destruction. electronic circuits.
1. Disconnect all power to the unit. 6. When the welding operation is completed, the
2. Avoid wearing clothing that generates static unit power cables, wiring and circuit breakers
electricity (wool, nylon, polyester, etc.). must be restored to their normal condition.
3. Do wear a static discharge wrist strap (TK P/N
204-622) with the lead end connected to the
controller’s ground terminal. These straps are
available at most electronic equipment
distributors. DO NOT wear these straps with
power applied to the unit.
15
Safety Precautions
Unit Decals Compressor: Nameplate on front of the

compressor.
Serial number decals, refrigerant type decals and
warning decals appear on all Thermo King Unit: Nameplate on unit frame in power cord
equipment. These decals provide information that storage compartment.
may be needed to service or repair the unit. MPC2000 Controller: Nameplate on back of
Service technicians should read and follow the controller.
instructions on all warning decals.
MPC2000ID Controller: Nameplate on back of
controller.
Serial Number Locations
Electric Motors: Nameplate attached to the MP3000 Controller: Nameplate on back of
motor housing. controller.
Figure 1: Unit Nameplate and Decal Locations
AXA0343
AXA0344
16
AXA0345
Unit Nameplate Location AXA0346
Service Guide
Every
1,000 Annual/
Pre-Trip Hours Yearly Inspect/Service These Items
Electrical
• Perform a controller Pretrip Inspection (PTI) check.
• • • Visually check condenser fan and evaporator fan rotation.
• • • Visually inspect electrical contacts for damage or loose connections.
• • • Visually inspect wire harnesses for damaged wires or connections.
• • Download the datalogger and check data for correct logging.
• Check operation of protection shutdown circuits.
Refrigeration
• • • Check refrigerant charge on both the R-134a and R-23 refrigeration circuits.
Check for proper suction pressure on both the R-134a and R-23 refrigeration
• • •
circuits.
• • • Check compressor oil level in both the reciprocating and scroll compressors.
Check compressor efficiency and pump down R-134a refrigeration system
•
(only).
Check discharge and suction pressures of both the R-134a and R-23
•
refrigeration circuits.
Check dehydrator for a restriction or corrosion on both the R-134a and R-23
•
refrigeration circuits.
Structural
• • • Visually inspect unit for damaged, loose or broken parts.
• • • Tighten unit, compressor and fan motor mounting bolts.
• • • Check operation of vacuum valve.
Clean entire unit including condenser and evaporator coils and defrost
• •
drains.
17
Service Guide
18
Specifications
Full Cool Operation Net Cooling Capacity*

Return air to 460V, 3 Phase, 60 Hz Power 380V, 3 Phase, 50 Hz Power
evaporator coil Net Cooling Capacity Power Consp Net Cooling Capacity Power Consp
inlet Watts Kcal/hr BTU/hr kW @460V Watts Kcal/hr BTU/hr kW @460V
-25 C (-13 F) 10,000 8,600 34,130 17.0 8,300 7,138 28,325 14.1
-55 C (-67 F) 6,000 5,160 20,475 13.0 4,980 4,284 17,000 10.8
*System net cooling capacity with a 37.8 C (100 F) ambient air temperature.
System Net Defrost Heating Capacity

460V, 3 Phase, 60 Hz Power 380V, 3 Phase, 50 Hz Power
Heater Type Heating Capacity Heating Capacity
Watts Kcal/hr BTU/hr Watts Kcal/hr BTU/hr
Electric resistance rods 8,160 7,018 27,850 6,000 5,160 20,475
Evaporator Airflow**
External Static 460V, 3 Phase, 60 Hz Power 380V, 3 Phase, 50 Hz Power
Pressure (water Low Speed Low Speed
column) m3/hr ft3/min m3/hr ft3/min
0 mm (0 in.) 3,700 1,835 2,900 1,708
10 mm (0.4 in.) 3,300 1,943 2,350 1,384
20 mm (0.8 in.) 2,800 1,649 1,750 1,031
30 mm (1.2 in.) 2,300 1,355 1,000 589
**22° pitch fan blades.
R-134a Refrigeration System

Compressor Model No. D3DST-075E-TFD, Semi-hermetic Reciprocating with
Copeland Discus® Valve Design
Refrigerant Charge 3.5 Kg (7.7 lb) R-134a
Compressor Oil Capacity 4.6 liter (4.86 qt)*
Compressor Oil Type Polyol Ester Based Type (required), TK Part No.
203-433**
Typical System Pressures at 37.8 C (100 F) Ambient
Standby (Unit Off, Empty Box): High Side —
Low Side —
-30 C (-22 F) Box, Unit Cooling: High Side 1500 to 1800 kPa, 15.0 to 18.0 bar, 218 to 261 psig
Low Side 60 to 90 kPa, 0.60 to 0.90 bar, 9 to 13 psig
High Pressure Cutout Switch
Cutout 2410 ± 68kPa, 24.10 ± 0.68 bar, 350 ± 10 psig
Cutin 1640 ± 68kPa, 16.4 ± 0.68 bar, 238 ± 10 psig
Fusible Plug (High Pressure Relief) Relief Temp. 100 C (212 F)
19
Specifications
R-23 Refrigeration System

Compressor Model No. ZM18K4E-TFD-N275, Hermetic Scroll
Refrigerant Charge Evacuated System 3.2 Kg (7.05 lb) R-23
Add Partial Charge by Pressure Charge to 1700 kPa, 17.00 bar, 247 psig
Compressor Oil Capacity 1.77 liter (60 oz.)*
Compressor Oil Type Polyol Ester Based Type (required), TK Part No.
203-433**
Typical System Pressures at 37.8 C (100 F) Ambient
Standby(UnitOff,
EmptyBox):Highand 1600 kPa, 16.0 bar, 232 psig
LowSide 1700 kPa, 17.0 bar, 2247 psig
0C/32F20C/68F38 1800 kPa, 18.0 bar, 261 psig
C/100F 2100 to 2300 kPa, 21.0 to 23.0 bar, 305 to 334 psig
High Pressure Cutout Switch
Cutout 3250 ± 50 kPa, 32.5 ± 0.50 bar, 470 ± 7 psig
Cutin 2590 ± 250 kPa, 25.90 ± 2.5 bar, 375 ± 38 psig
High Pressure Relief

3447 +520/-104 kPa, 34.47 +5.20/-1.04 bar, 500 +75/-15
Valve Relief Pressure psig
Reset 2758 kPa, 27.58 bar, 400 psig
Low Pressure Cutout Switch (MPC2000ID Units
Only)
Cutout 0 ± 20 kPa, 0.0 ± 0.2 bar, 6 in. vacuum to 3 psig
Cutin 70 ± 20 kPa, 0.7 ± 0.2 bar, 10 ± 3 psig
*When the compressor is removed from the unit, oil level should be noted or the oil removed from the compressor
should be measured so that the same amount of oil can be maintained in the replacement compressor.
**Do not use or add standard synthetic or mineral oils to the refrigeration system. If Ester based oil becomes
contaminated with moisture or with standard oils, dispose of properly — Do not use!
20
Specifications
Electrical System
R-134a Circuit Compressor Motor:
Type Semi-hermetic Reciprocating
Voltage 460/380V, 60/50 Hz, 3 Phase
Kilowatts (60 Hz) 5.60 kW
Horsepower (60 Hz) 7.5 hp
RPM (60 Hz) 1750 rpm
Full Load Amps 15.5 amps — 460V; 15.5 amps — 380V
Locked Rotor Amps (60 Hz) 83 amps — 460V; 82 to 91 amps — 380V
R-23 Circuit Compressor Motor:
Type Hermetic Scroll
Voltage 460/380V, 60/50 Hz, 3 Phase
Kilowatts (60 Hz) 4.48 kW
Horsepower (60 Hz) 6.0 hp
RPM (60 Hz) 3550 rpm
Full Load Amps (60 Hz) 11 amps — 460V
Locked Rotor Amps (60 Hz) 70 amps — 460V
Condenser Fan Motor:
Type 460/380V, 60/50 Hz, 3 Phase 460/380V, 60/50 Hz
Kilowatts (60 Hz) 1.5 kW 749 Watts
Horsepower (60 Hz) 2.0 hp 0.75 hp
RPM (60 Hz) 1725 rpm 1725 rpm
Full Load Amps (60 Hz) 3.1 amps — 460V 1.25 amps
Locked Rotor Amps (60 Hz) 25 amps — 460V 35.7 amps
Evaporator Fan Motors*:
Type 460/380V, 60/50 Hz, 3 Phase
Number 3
Kilowatts (60 Hz) (Each) 0.75 kW
Horsepower (60 Hz) (Each) 1.0 hp
3450 rpm, High Speed
RPM (60 Hz) (Each)
1725 rpm, Low Speed*
1.4 amps — 460V, High Speed
Full Load Amps (60 Hz) (Each)
0.5 amps — 460V, Low Speed
10.3 amps — 460V, High Speed*
Locked Rotor Amps (60 Hz)
2.9 amps — 460V, Low Speed*
Electric Resistance Heater Rods:
Type 460/380V, 60/50 Hz, 3 Phase
Number 12
Watts (60 Hz) (Each) 680 Watts
10 amps nominal (total) across each phase at the heater
Current Draw (Amps)
contactor
Control Circuit Voltage: 29 Vac @ 60 Hz; 24 Vac @ 50 Hz
Evaporator Overheat Switch:
Opens 54 ±3 C (130 ±5 F)
Closes 38 ±4C (100 ±8 F)
RR DF applications operates the two-speed evaporator fan motors continuously on low speed. Evaporator fans stop
during defrost.
21
Specifications
Microprocessor Controller
Temperature Controller:
CRR-40 DF MPC2000 MPC2000 microprocessor
CRR-40 DF MPC2000ID MPC2000ID microprocessor
CRR-40 DF MP3000 MP3000 microprocessor
MPC2000, MPC2000ID and MP3000 microprocessors
include thermostat, digital thermometer, programming
keypad, mode indicators, LED display and LCD display
Description for displaying unit operating and cargo information.
MPC2000ID microprocessor includes an integral
datalogger. Data logger is furnished separately on units
equipped with MPC2000 and MP3000 microprocessor.
Setpoint Range -60.0 to -10.0 C (-76.0 to +14.0 F)
Digital Temperature Display -80.0 to +130.0 C (-112.0 to +266.0 F)
Controller Software (Original Equipment): See controller identification decal
Defrost Initiation:
Coil must be below 18 C (65 F) to initiate defrost by
demand, timer or manual switch.
- Manual Switch or Demand Defrost Initiation: Defrost
cycle starts when technician or controller request defrost
initiation.
Evaporator Coil Sensor Coil - Timed Defrost Initiation: Defrost cycle starts 1 minute
after the hour immediately following a defrost timer
request for defrost initiation. For example, if the defrost
timer requests a defrost cycle at 7:35, the defrost cycle
will start at 8:01. Datalogger will record a Defrost event for
each interval in which a Defrost cycle is pending or active
(i.e. both the 8:00 and 9:00 data logs).
Demand Defrost function initiates defrost when the
temperature difference between the return air sensor and
setpoint increases to a preset value and a minimum of 6
Demand Defrost
hours of compressor ON (running) time have elapsed
since the previous defrost; indicating the presence of
frost or ice
Initially every 12 hours of compressor operation. Then
defrost interval increases 6 hours each time a timed
defrost occurs without a demand defrost in between.
Defrost Timer: Frozen Mode Maximum time interval in frozen mode is 36 hours of
compressor operation. Defrost timer resets if the unit is
Off more than 12 hours or the setpoint is changed more
than 5 C (9 F)
Defrost Termination:
Frozen mode: Terminates defrost when coil sensor
temperature rises to 18 C (64 F) or exceeds 8 C (46 F) for
Evaporator Coil Sensor
35 minutes above 440 volts and 45 minutes below 440
volts
Terminates defrost 90 minutes after initiation if coil sensor
Interval Timer has not terminated defrost (120 minutes if power supply is
less than 55 Hz)
If the evaporator coil sensor exceeds 8 C (46 F) for 15
Time/Temperature Function
minutes, the controller terminates defrost
Power Off Turning unit On/Off switch Off terminates defrost
22
Specifications
Physical Specifications
Base Unit Weight (net):
CRR-40 DF MPC2000 610 Kg (1344 lb)
CRR-40 DF MPC2000ID 610 Kg (1344 lb)
CRR-40 DF MP3000 610 Kg (1344 lb)
Unit Dimensions
Width 2025.5 mm (79.75 in.)
Height 2235.2 mm (88.00 in.)
Depth 420.0 mm (16.54 in.) from back of flange
Compressor Torque — 3D Copeland Compressor Bolt Torque

Bolt Usage N.m In.-lb.
Bottom Plate:
Grade 5 45.2 400
Grade 8 59.3 525
Housing Cover 45.2 400
Oil Pump to Housing Cover 33.9 300
Bearing Cover to Housing Cover 33.9 300
Stator Cover:
Grade 5 45.2 400
Grade 8 59.3 525
Cylinder Head 59.3 525
Oil Screen Cover 31.1 275
Crankcase Heater Plug 45.2 400
Discharge and Suction Valve:
18 (5/16 in.) 25.4 225
13 (1/2 in.) 56.5 500
Pipe Plug:
6.35 mm (0.25 in.) 33.9 300
3.175 mm (0.125 in.) 22.6 200
Oil Sight Glass:
Grade 5 4.5 40
Grade 8 8.5 75
Terminal Plate 33.9 300
Nut on Top of Terminal Plate 5.1 45
Nut on Top of Jumper Bar 9.0 80
23
Specifications
Metric Hardware Torque Chart

Bolt Size
Bolt Type
M6 M8 M10 M12
and Class*
N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.)
HH – CL 5.8 6-9 (4-7) 12-16 (9-12) 27-34 (20-25) 48-61 (35-40)
HH – CL 8.8 10-13 (7-10) 20-27 (15-20) 41-47 (30-35) 75-88 (55-65)
HH – CL 10.9 14-17 (10-13) 27-34 (20-25) 54-68 (40-50) 102-122 (75-90)
HH – CL 12.9 17-21 (12-16) 41-47 (30-35) 68-81 (50-60) 122-149 (90-110)
HH – SS (2) 10-13 (7-10) 20-27 (15-20) 41-47 (30-35) 75-88 (55-65)
Bolt Size
Bolt Type and
M14 M16 M18 M22
Class*
N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.) N.m (Ft.-lb.)
HH – CL 5.8 75-88 (55-65) 115-135 (85-100) 177-216 (130-160) 339-406 (250-300)
HH – CL 8.8 115-135 (85-100) 177-216 (130-160) 271-339 (200-250) 475-610 (350-450)
HH – CL 10.9 136-176 (100-130) 224-298 (180-220) 393-474 (290-350) 678-813 (500-600)
HH – CL 12.9 177-216 (130-160) 285-352 (210-260) 448-542 (330-400) 881-1016 (650-750)
HH – SS (2) 115-135 (85-100) 177-216 (130-160) 271-339 (200-250) 475-610 (350-450)
HH = Hex Head, CL = Class.
24
Unit Description
General Description economically carry cargo at deep frozen

temperatures using proven, reliable transport
Model CRR DF units are all-electric, single-piece, refrigeration system technology.
refrigeration units with bottom air supply. Each unit
is designed for long distance, shipboard or overland The CRR DF cascade systems consists of two
transport of deep frozen or frozen cargoes. Each separate, single-stage refrigeration systems with
unit mounts in the front wall of the container. Fork different refrigerants.One system is a low
lift pockets are provided for installation and temperature stage system that uses a hermetic scroll
removal of the unit. compressor and R-23 refrigerant. The evaporator of
the low temperature stage system cools the cargo
The frame and bulkhead panels are constructed of air, achieving cargo temperatures down to -60 C (-
aluminum and are treated to resist corrosion. A 76 F).
hinged, removable vaporator compartment door
provides easy service access. All operating The second system is a high temperature stage
components except the evaporator coil and buffer system that uses a semi-hermetic reciprocating
receiver tanks can be replaced from the front of the compressor and R-134a refrigerant. The evaporator
unit. of the high temperature stage system cools the
condenser of the low temperature stage system
The unit is equipped with an 18.3 m (60 ft) power through a special plate heat exchanger. The
cable for operation on 460-380V/3 Ph/60-50 Hz condenser of the high temperature stage system
power. For operation on 460-380V/3 Ph/60-50 Hz then transfers the cargo heat to the ambient air.
power, plug the 460-380Vpower cable into the
proper power supply. R-134a Semi-hermetic Reciprocating
Each unit is equipped with 460-380V/3 Ph/60-50 Compressor
Hz electric motors. An automatic phase correction The R-134a high temperature stage circuit features
system provides the proper electrical phase a semi-hermetic reciprocating compressor with
sequence for condenser fan and evaporator fan forced feed lubrication system, ambient
motor operation. Unit power cable is stored below compensated internal overload protection and high
the control box in the condenser section. temperature protection.
CRR DF MPC2000 units feature MPC2000
microprocessor controller and a MPC2000 R-23 Hermetic Scroll Compressor
Datalogger. CRR DF MP3000 units feature The R-23 low temperature stage circuit features a
MP3000 microprocessor controller and a MP3000 hermetic scroll compressor (one stationary and one
Datalogger. CRR DFMPC2000ID units feature a orbiting member) with ambient compensated
MPC2000ID microprocessor controller with internal overload protection and high temperature
integral datalogger. Additional features include protection.
three evaporator fans; USDA Cold Treatment
Temperature Recording; and a Remote Monitoring
Modem (RMM). For additional unit feature
information, see “CRR DF Model Features” on MPC2000, MPC2000ID and MP3000 controllers
page v of the Introduction. incorporate refrigeration system component
control, thermostat, digital thermometer and fault
Cascade Refrigeration System indication capabilities into one self-contained
package. Units with a MPC2000 or MP3000
The CRR DF unit uses a basic cascade refrigeration controller are also equipped with a separate
system to achieve to frozen and deep frozen cargo datalogger while the MPC2000ID controller
temperatures between -10 C and -60 C (+14 F and includes an integral datalogger.
-76 F). The CRR DF cascade refrigeration system
design allows shippers to
25
Unit Description
Each controller mounts in a weather tight, corrosion The datalogger clock is factory set at UTC time. All
resistance enclosure. A large-character LED display data logs include the time and date; setpoint
(top) provides easy viewing of the control sensor temperature; and supply, return, USDA1, USDA2
temperature (return or supply air temperature). A 4- and USDA3 sensor temperatures. All temperature
line, 20-character LCD display (bottom) display logs can be viewed from the controller’s LCD
shows important data including the setpoint message display.
temperature, controller Main Menu tree and
A high speed serial communication port provides
important unit operating data.
data retrieval using a DRU-II or SmartSponge
Sixteen general purpose keys are used to enter and handheld data retriever; or a REFCON power line
scroll through the controller menu tree and message remote monitoring system.
text; initiate Pretrip and Function tests; enter new
setpoint temperature; and enter trip information. Three Evaporator Fans
The keyboard supports both numerical and text
Three evaporator fans operate continuously to
input. Four special keys provide quick access to
circulate air inside the container. Two-speed fans
setpoint temperature change, manual defrost
operate continuously on low speed for deep frozen
initiation, alternate return/supply air temperature
and frozen cargo (setpoints of -10 C [+14 F] and
display, and alternate temperature scale (C/F)
below).
display.
Each control system consists of a MPC2000, USDA Cold Treatment Temperature
MPC2000ID or MP3000 microprocessor Recording
controller, a main relay printed circuit board and
The datalogger includes provisions for the use of
six temperature sensors.
three USDA sensors. These sensors allow
Status indicator LEDs in the LED display signal temperatures in various areas of the load to be
Compressor, Defrost, Heat, In-range, Alarm, monitored and recorded for United States
Supply Temperature display and Return Department of Agriculture use in monitoring Cold
Temperature display. Treatment shipments. The USDA sensors record
temperatures from -80.0 C to +10 C (-112.0 F to
NOTE: Humidity indicator LED is not used on
+50.0 F).
the CRR DF application. Heat indicator LED is
used during Defrost mode only.
REFCON Remote Monitoring
Modem (RMM)
Datalogger
A REFCON remote monitoring modem is provided
Units with a MPC2000 or MP3000 controller are
to permit remote monitoring via the power cable.
also equipped with a separate datalogger. The
High speed transmission reads all controller
MPC2000ID controller includes an integral
information. Data can also be retrieved from the
datalogger. The datalogger can record sensor
datalogger via high speed transmission.
temperatures as well as loss of power, alarms, unit
operating modes, sensor failure, setpoint change
and unit shutdown indications. MPC2000 or Operating Modes
MP3000 data recordings are stored in a RAM NOTE: See Microprocessor Controller chapter
memory that is backed by battery. MPC2000ID for complete sequence of operation.
data recording are stored in a permanent Flash
RAM memory. A sequence start of the required loads occurs during
initial start-up of the unit and when a control mode
Logging intervals are selectable from 1 minute and shift requires the compressors to start. As the
1/2, 1, 2 or 4 hours. When a 1 hour logging interval controller relays and unit loads energize, the
is selected, the datalogger memory can store controller LCD display shows the setpoint
approximately 512 days of information. The temperature. The controller LED display shows the
logging of USDA sensors is fixed at 1 hour controlling (return) air sensor temperature.
intervals to comply with USDA requirements.
26
Unit Description
Frozen Loads
Temperature control by the controller is based on
the return air sensor temperature. The evaporator
fans operate continuously on low speed (except
during defrost).
· Cooling until return air temperature decreases to 1 C (1.8 F) below setpoint. Minimum 15 minute
compressor ON (running) time and 10 minute compressor OFF time prevents rapid cycling between
Cool and Null modes.
· Null until return air temperature increases to 1 C (1.8 F) above setpoint. Both compressors and the
condenser fan stop while the evaporator fans operate on low speed during the null mode.
· Defrost: Resistance heaters turn ON during defrost while the evaporator fans stop.
A Demand Defrost can be initiated by the
controller when the temperature difference
between the return air sensor and setpoint
increases to a pre-set value and a minimum of 6
hours of compressor ON (running) time have
elapsed since the previous defrost.
A Defrost Timer also initiates defrost every 12
hours. During extended unit operation, timed
defrost intervals increase 6 hours each time a
timed defrost occurs without a demand defrost in
between. Maximum time interval is 36 hours. The
Defrost Timer resets if the unit is OFF more than
12 hours or the setpoint is changed more than 5 C
(9 F).
27
Unit Description
2 9
4
8
7
6
AXA0346
1. Evaporator Access Door 6. Power Cord Storage Compartment

2. Heater Access Panel Location 7. Supply Air Sensor Probe Holder
3. Condenser Fan 8. Control Box
4. R-23 Compressor Compartment 9. Vacuum Pressure Valve Location
(for Box Ventilation)
5. R-134a Compressor Compartment
Figure 2: Unit Front View
28
Unit Description
1 2 3 4 5
AXA0347
1. Evaporator Fan Blade 4. Defrost (Evaporator Coil) Sensor Location

2. Evaporator Fan Motor 5. Return Air Sensor Probe Holder
3. Evaporator Coil
Figure 3: Evaporator Section — Front View
29
Unit Description
AXA0346
AXA0421
AXA0348
1. Vacuum Valve (located behind condenser grille cover), earlier

2. Vacuum Valve (located behind condenser grille cover), current
Figure 4: Vacuum Valve
30
Unit Description
AXA0349
1. Control Box 4. Ambient Sensor Location

2. Thermometer Sampling Port 5. Power Plug and Cord
3. Supply Air Sensor Probe Holder
Figure 5: Power Cord Storage Compartment
31
Unit Description
AXA0422
8
AXA0351
1. MPC2000, MPC2000ID or MP3000 Controller 5. Special Function Keypad

2. LED Display (Return or Supply Air Temperature 6. Unit On/Off Switch
Display and Status Indicator LEDs)
7. Communications Connector for Data
3. LCD Display (Setpoint Temperature, Message and Retrieval
Controller Main Menu Tree Display)
8. Circuit Breaker
4. General Purpose Keypad
Figure 6: Control Box and Microprocessor Controller
32
Unit Description
10
7
8 1
1
12
9 13
AXA0419
14
15
16
17
AXA0353
1. Remote Monitoring Modem 10. Control Power Transformer (28 Vac, 29 Vac, 40 Vac)
2. RMM Connection Cable 11. Heat Relay
3. Battery Cable Connection to Controller 12. Datalogger Cable Connection to Main Relay Board
4. MPC2000 or MP3000 Controller 13. Cable No. 2 Connection to Main Relay Board
5. Cable No. 2 Connection to Controller 14. Phase Sensor Relays
6. Datalogger Cable Connection to Datalogger 15. Evaporator Fan Relay – Low Speed
7. Download Cable Connection to Controller 16. Condenser Fan Relay
8. Cable No. 1 Connection to Controller 17. Cable No. 1 Connection to Main Relay Board
9. MPC2000 Datalogger
Figure 7: MPC2000 or MP3000 Controller and Remote Monitoring Modem
33
Unit Description
1
2
9
5
6
10
7 11
12
8
13
AXA0354 14
15
16
AXA0353
1. MPC2000ID or MP3000 Controller with 9. Control Power Transformer (28 Vac, 29 Vac, 40 Vac)
Integral Datalogger
2. Remote Monitoring Modem 10. Heat Relay

3. RMM Connection Cable 11. Cable No. 3 Connection to Main Relay Board
4. Battery Cable Connection to Controller 12. Cable No. 2 Connection to Main Relay Board
5. Cable No. 2 Connection to Controller 13. Phase Sensor Relays
6. Download Cable Connection to Controller 14. Evaporator Fan Relay – Low Speed
7. Cable No. 3 Connection to Controller 15. Condenser Fan Relay
8. Cable No. 1 Connection to Controller 16. Cable No. 1 Connection to Main Relay Board
Figure 8: MPC2000ID and MP3000 Controller, and Remote Monitoring Modem
34
Unit Description
6
1
7
2
3 8
AXA0355
1. Remote Monitoring Modem 5. R-23 Scroll Compressor Contactors (2)

2. MPC2000, MPC2000ID or MP3000 Controller 6. R-134a Compressor Contactor
3. Datalogger (CRR DF MPC2000 only) 7. Main Relay Board
4. 32 Ampere Main Power Circuit Breaker 8. 12 Vdc Battery
Figure 9: Unit Control Box with Door Open
35
Unit Description
AXA0357
AXA0423
1. R-23 Suction Pressure Gauge Line Connection 3. Low Pressure Cutout Switch (CRR DF
MPC2000ID Units Only)
2. R-23 Suction Line
Figure 10: Low Pressure Cutout Switch in R-23 Refrigeration System (CRR DF MPC2000ID Units Only)
36
Unit Description
12
1
3 1
4 10
9
AXA0423
1. R-23 Discharge Pressure Gauge 7. R-23 Lower Receiver Tank Sight Glass
2. R-23 Suction Pressure Gauge 8. Suction Service Valve
3. R-23 Scroll Compressor 9. Suction Service Fitting
4. Compressor Discharge Temperature Sensor 10. R-23 Receiver Tank
5. Compressor Oil Sight Glass 11. Discharge Service Valve
6. Oil Fill Fitting 12. Discharge Service Fitting
Figure 11: R-23 Compressor Compartment
37
Unit Description
AXA0359
3
4
AXA0423
AXA0424
1. R-23 Compressor Discharge Valve 4. Receiver Tank

2. R-23 High Pressure Cutout Switch 5. Schrader Valve Service Fitting for R-23 Charging
3. R-23 Expansion Valve 6. Receiver Tank Sight Glass
Figure 12: Additional R-23 Refrigeration System Components
38
Unit Description
10
3
9
8
5
7
AXA0425
1. Discharge Service Valve 6. Compressor Oil Sight Glass

2. R-134a Discharge Pressure Gauge 7. Suction Service Valve
3. R-134a Suction Pressure Gauge 8. Suction Service Fitting
4. Compressor Oil Fill Fitting 9. R-134a High Pressure Cutout Switch
5. R-134a Compressor 10. Compressor Discharge Temperature Sensor
Figure 13: R-134a Compressor Compartment
39
Unit Description
12 34 56 7 8
AXA0363
1. R-134a Receiver Tank 5. Dehydrator (Filter Drier)

2. Receiver Tank Service Fitting 6. Liquid Line Solenoid
3. Receiver Tank Sight Glass 7. R-134a Expansion Valve
4. Liquid Line Ball (Service) Valve 8. R-23/R-134a Plate Heat Exchanger (behind panel)
Figure 14: Additional R-134a Refrigeration System Components and Plate Heat Exchanger
40
Unit Description
4 8
9
5
AXA0364
AXA0365
1. Evaporator Grille 6. Controller Communications and Data Retrieval Connection

2. Unit Gasket 7. USDA1 Sensor Connection
3. Top Rear Plate 8. USDA2 Sensor Connection
4. Sensor Connector Assembly 9. USDA3 Sensor Connection
5. Bottom Rear Plate
Figure 15: Unit Back View
41
Unit Description
AXA0366
4
1
AXA0368
1. Constant Pressure Regulator (R-23 System) 3. Sensor Connector Assembly

2. Buffer Receiver Tanks – 5 Total (R-23 System) 4. Crankcase Pressure Regulator (R-23 System)
Figure 16: Unit Back View — Pressure Regulators and Buffer Tanks
42
Unit Description
AXA0369 AXA0370
AXA0368
1. Electric Heaters 3. Expansion Valve Feeler Bulb (R-23 System)

2. Evaporator Coil (R-23 System)
Figure 17: Unit Back View — Electric Heaters and Evaporator Coil
43
44
Operating Instructions
Basic Unit Controls, Keypad: Sixteen general purpose keys are used to
Instruments and Protection display information, change the setpoint, change
programmable features and initiate control tasks.
Devices
°C–°F Key: Press this key to view temperatures in
Unit Control Box the LED display in the alternate temperature value.
ON/OFF Switch: ON position. Unit will operate on Alternate value (C or F) shows while the key is
cool or null depending on the controller setpoint pressed.
temperature and the container air temperature. OFF RET/SUP Key: Press this key to view the alternate
position. The unit will not operate. sensor temperature in the LED display. Alternate
Control System Circuit Breaker: A 7 ampere sensor (return or supply) shows while the key is
manual reset circuit breaker protects the control pressed.
circuit. This circuit breaker is located in the Defrost Key: Press this key to initiate a manual
control box beside the On/Off switch. defrost cycle. If the evaporator coil temperature is
Main Circuit Breaker: A 32 ampere manual reset below 10 C (50 F), the unit will defrost. Otherwise
circuit breaker protects the 460/380V power the controller will display “Defrost Not Activated”
supply circuit to the unit electric motors and in the LCD display and the unit will continue
control system transformer. The main power normal operation.
circuit breaker is located in the control box. Setpoint Key: Press this key to change the setpoint.
Fuses: A number of fuses are located on the main Cursor in the LCD display automatically appears
relay board and controller plug to protect unit in the “TEMP SETP” line of the Data menu. See
circuits and components. “Changing the Setpoint” in the Microprocessor
Controller chapter for complete instructions.
· Three 20 amp fuses protect high voltage circuits Status Indicator LEDs: located in the large LED
on the main relay board.
display signal:
· A 2 amp fuse protects the controller’s 28 V · Supply (Air Temperature)
system.
· Return (Air Temperature)
· A 2 amp fuse protects the controller’s battery
charging circuit. · Humidity Mode (Inactive on CRR DF units)
Overload Protection: The condenser fan motor, · Compressor (Cooling On)
evaporator fan motors and compressor motors
include internal overload protection with · Heat (On during defrost)
automatic reset. · Defrost
Phase Sequence Selection: When the On/Off switch · In-Range (Temperature)
is turned ON, phase sensors on the main relay
board determine the incoming power phase to · Alarm
ensure proper condenser fan, evaporator fan and The In-range LED illuminates when the
compressor rotation. controlling air sensor temperature is less than 3.0
C (5.4 F) above setpoint (standard). The
MPC2000, MPC2000ID or MP3000 controller maintains the in-range signal during
Controller defrost and after defrost for 60 minutes.
A MPC2000, MPC2000ID or MP3000 LED Display: Large red LED display shows
microprocessor controls all unit functions to current control temperature during normal
maintain the cargo at the proper temperature. The operation. LED display also shows current test
controller also monitors and records system faults state during a Pretrip (PTI) or Function test.
and performs pre-trip.
45
LCD Display: A 4-lineLCD message display Suction Pressure Gauge: A suction pressure
shows setpoint during normal operation. LCD gauge indicates the refrigerant pressure in the
display also shows controller menu and unit suction line returning to the compressor.
operation information when special keys are Discharge Pressure Gauge: A discharge pressure
pressed. gauge indicates the refrigerant pressure in the
discharge line leaving the compressor.
Other
Receiver Tank Sight Glass: A sight glass on the
Evaporator Overheat Switch: A temperature switch receiver tank contains three small balls that indicate
near the evaporator coil opens to de-energize the the level of refrigerant in the tank for checking the
heater contactor if the evaporator temperature refrigerant charge. A moisture indicator in the sight
reaches 54 C (130 F) during Defrost. The switch glass changes color to indicate the level of moisture
closes (resets) when the evaporator temperature in the system. Check the color of the indicator
decreases to 32 C (90 F). against the color decal in the sight glass. The dry
eye in the sight glass is LIGHT GREEN when the
R-134a Refrigeration System system is dry and YELLOW when the system is
Controls, Instruments and wet (contains excessive moisture).
Protection Devices Fusible Plug For High Pressure Relief: A fusible
Compressor Discharge Line Temperature Sensor: plug is installed in the R-134a receiver tank to
avoid excessive pressure build-up within the
The controller uses the compressor discharge line refrigeration system from extraordinary and
temperature sensor to protect the compressor from unforeseen circumstances. The plug blows when
excessively high operating temperatures. If the the plug temperature reaches 100 C (212 F). The
discharge gas temperature rises above 130 C (266 plug is located so that refrigerant pressure expelled
F): from the valve would be directed away from
· Unit stops immediately; controller activates anyone servicing the unit. The plug is non-
Alarm LED and records Alarm 56, Compressor repairable and requires no adjustment. If the plug
Temperature Too High. blows, recover the remaining refrigerant charge and
replace the fusible plug.
· Controller will restart the unit when the sensor
Compressor Oil Sight Glass: A compressor oil
temperature is below 90 C (194 F).
sight glass indicates the relative level of
High Pressure Cutout (HPCO) Switch: If the compressor oil in the compressor sump.
compressor discharge pressure rises above 2410 ±
68 kPa, 24.1 ± 0.68 bar, 350 ± 10 psig, the high
pressure cutout opens to interrupt the ground circuit R-23 Refrigeration System
to the compressor contactor: Controls, Instruments and
· R-134a compressor STOPS immediately.
Protection Devices
Compressor Discharge Line Temperature Sensor:
· Evaporator and condenser fans continue normal
operation. The controller uses the compressor discharge line
temperature sensor to protect the compressor from
· R-23 compressor stops. excessively high operating temperatures. If the
· R-134a compressor will restart when the discharge gas temperature rises above 138 C (280
overload condition is corrected (switch closes) F):
as long as power is available. The high pressure · Unit stops immediately; controller activates
switch resets (closes) when the pressure drops Alarm LED and records Alarm 56, Compressor
to 1640 ± 68 kPa, 16.4 ± 0.68 bar, 238 ± 10 Temperature Too High.
psig.
· Controller will restart the unit when the sensor
· R-23 compressor will restart 30 seconds after R- temperature is below 138 C (280 F).
134a compressor restarts.
46
High Pressure Cutout (HPCO) Switch: If the located so that refrigerant pressure expelled from
compressor discharge pressure rises above 3250 ± the valve would be directed away from anyone
50 kPa, 32.5 ± 0.5 bar, 470 ± 7 psig, the high servicing the unit. The valve will reset when this
pressure cutout opens to interrupt the ground circuit pressure drops to 2758 kPa, 27.58 bar, 400 psig.
to the compressor contactor: The valve is non-repairable and requires no
· R-23 compressor STOPS immediately. adjustment. If the valve fails to reseat properly,
recover the refrigerant charge and replace the
· Evaporator and condenser fans and R-134a valve.
compressor continue normal operation.
Low Pressure Cutout (LPCO) Switch (CRR DF
· R-23 compressor will restart when the overload MPC2000ID Units Only): If the compressor suction
condition is corrected (switch closes) as long as pressure decreases to 0 ± 20 kPa, 0 ± 0.2 bar,6 in.
power is available. The high pressure switch vacuum to 3 psig; the low pressure cutout opens:
resets (closes) when the pressure drops to 2590 · Both the R-23 compressor and R-134a
± 250 kPa, 25.9 ± 2.5 bar, 375 ± 38 psig. compressor STOP immediately.
NOTE: R 23 protective device auxiliary · Evaporator and condenser fans continue normal
contractor mounted on R 134a contractor operation.
must supply digital signal to MBR J12 pin 1
and 2 before R 23 compressor is aiowed to · R-23 compressor will restart if the low
start. refrigerant condition is corrected (switch closes)
as long as power is available. The low pressure
Suction Pressure Gauge: A suction pressure
switch resets (closes) when the pressure
gauge indicates the refrigerant pressure in the
increases to 70 ± 20 kPa, 0.7 ± 0.2 bar, 10 ± 3
suction line returning to the compressor.
psig.
Discharge Pressure Gauge: A discharge pressure
gauge indicates the refrigerant pressure in the · When R-23 low pressure switch resets, R-23
discharge line leaving the compressor. compressor restarts 30 seconds after R-134a
compressor restarts.
Receiver Tank Sight Glass: Two sight glasses on the
R-23 receiver tank contains three small balls that NOTE: If the low pressure cutout switch
indicate the level of refrigerant in the tank for remains open, check R-23 system suction and
checking the refrigerant charge. A moisture discharge pressures. Then check for an
indicator in the sight glass changes color to indicate obstruction or refrigerant leak in the low or
the level of moisture in the system. Check the color high pressure side of the R-23 refrigeration
of the indicator against the color decal in the sight system.
glass. The dry eye in the sight glass is LIGHT NOTE: Use only Lower R-23 sight glass to
GREEN when the system is dry and YELLOW check or add refrigerant on unit unable to
when the system is wet (contains excessive maintain -50 to -60 setpoint.
moisture).
Compressor Oil Sight Glass: A compressor oil Pretrip Inspection
sight glass indicates the relative level of
compressor oil in the compressor sump. The following inspections should be made before
the container is loaded:
High Pressure Relief Valve: A high pressure relief
valve is installed in the receiver tank. The relief 1. Visually check the unit for physical damage.
valve protects against excessive pressure build-up 2. Check the electrical connections in the unit
within the refrigeration system from extraordinary control box, making sure they are fastened
and unforeseen circumstances. The valve is a spring- securely.
loaded piston that lifts when refrigerant pressure
exceeds 3447 +520/-104 kPa, 34.47 +5.20/-1.04 bar, 3. Check the conditions of wires and terminals.
500 +75/-15 psig. The valve is Repair or replace if necessary.
47
4. Inspect both refrigeration systems for evidence

of oil leaks at all joints and connections.
Pre-load Operation
NOTE: With empty box and all components in Pre-Trip Conditions
R23 system always verify correct charge in To properly perform a Full Pretrip Test on units
R23 system according to pressure readings equipped with the MPC2000 or MPC2000ID
listed below controller, the following conditions must exist:
5. 5.Check R-23 refrigeration system pressures.
Suction and discharge pressure gauges should Pre-Trip Checks
show 1,600 to 1,800 kPa, 16.0 to 18.0 bar, 232 1. With unit connected to the proper power supply,
to 261 psig in both the high and low side with turn the power supply On/Off switch to ON.
the unit OFF and the container empty.
2. Switch refrigeration unit On/Off switch to ON
6. Check the condenser and evaporator coils. Clean position. A sequence start of the required loads
if necessary. Use an air or water spray jet occurs during initial start-up on cooling:
directed against the coil from the air discharge
side. Also inspect the condenser fan grille for · Controller LED display turns On and then
damage. If the grille is damaged or missing, Off.
abnormally high head pressure may result. · LED display briefly shows setpoint and then
Repair or replace the grille if necessary. displays the controlling (return) air sensor
temperature.
CAUTION: Air or water spray jet pressure
· Controller senses the incoming power phase
should not be high enough to damage
and selects the correct power phase to unit
(bend) coil fins.
components.
7. Check the mounting bolts on the
· Evaporator fan motors start and operate on
unit, compressor and fan motors. Tighten if
low speed.
necessary.
· R-134a compressor and condenser fan then
8. Clean the defrost drains.
start and the liquid line solenoid energizes
9. Check vacuum valve for proper operation. (opens).
10. Observe the unit for proper operation and · R-23 compressor starts 30 seconds later.
functions during Pre-load Operation.
NOTE: If one or both compressors fail to start,
turn the On/Off switch OFF. Then repeat steps 1
Power Selection and 2. If the unit still does not start, refer to
“Alarm Codes, Descriptions and Corrective
CAUTION: Power supply connections Actions” in the Microprocessor Controller
from the unit to the power source should chapter of this manual. Be sure to wait up to 1
always be made with the refrigeration unit minute for both compressors to start.
On/Off switch and the power supply
3. Adjust controller setpoint to the desired
On/Off switch in the OFF position. Never
temperature:
attempt to start or stop the refrigeration
unit using the power cord. NOTE: The setpoint temperature can be set
between -10 C and -60 C (14 F and -76 F) in
The refrigeration unit is designed to operate
either F or C using the C/F key. Just press and
on 460/380V, 3 Phase, 60-50 Hz electric power
hold the F/C key (to display the alternate
from a 4-wire power source.
temperature scale).
· To operate the refrigeration unit on 460/380V
· Press SETPOINT key to display cursor
power, plug the 460/380V power cord into the
flashing in the “TEMP SETP” line
proper power source.
48
• Press F4 key to enter new setpoint. Enter · Press F2 or F3 key to scroll up or down to
Arrow appears in the menu line and the “PTI”.
current setpoint disappears.
· Press F4 to start the PTI (Pretrip) Test.
· Enter minus sign first by pressing EXIT key.
· The controller then performs the Pretrip Test.
Then press numeric keys to enter new
setpoint. · Observe the unit for proper operation and
functions during pretrip test.
· With correct setpoint in display, press and
hold F4 key until cursor stops flashing. · LCD display shows PTI Test currently being
Controller places new setpoint in controller performed. PTI test ends automatically. Press
memory and shows new setpoint in LCD any key on the controller to return the unit to
display. normal operation.
NOTE: New setpoint must be between -10 C · If an operating problem occurs during the
and -60 C (14 F and -76 F) or controller will Pretrip Test, the Alarm LED will turn ON
return to the previous setpoint display. and FLASH. An “E” may also appear in the
right side of the LED display. View and
NOTE: If the F4 key is not pressed within 30
correct any alarm conditions. Then clear
seconds, the controller will default (return) to
(acknowledge) the Alarm Code(s) and repeat
the previous setpoint. If this occurs, repeat step
the PTI Test.
3.
NOTE: Clear the Alarm codes ONLY after the
4. Check the direction of the condenser airflow
alarm codes are documented and problems
(see “Condenser Fan and Evaporator Fan
repaired. A permanent record of the alarm
Rotation” in the Electrical Maintenance chapter
codes remains stored in the datalogger
of this manual).
memory for retrieval via DRU-II or
5. Check direction of evaporator airflow (see SmartSponge handheld data retriever.
“Condenser Fan and Evaporator Fan Rotation”
8. Stop the unit by moving the On/Off switch to the
in Electrical Maintenance chapter of this
OFF position.
manual).
6. Allow the unit to operate one-half hour before Loading Procedure
loading. This will remove residual container
heat and moisture, and pre-cool the container 1. Make sure the Unit On/Off switch is OFF before
interior. opening the container doors. (The unit may be
operating when loading the container from a
7. Perform a Pretrip (PTI) Test and check unit warehouse with door seals.)
modes while the unit pre-cools:
2. Spot check and record load temperature while
CAUTION: The PTI test should only loading. Especially note any off-temperature
be performed on an empty container! product.
NOTE: Correct all existing alarm conditions and Post Load Procedure
clear the alarm codes before performing a PTI test.
The controller will automatically clear all existing
1. Make sure all doors are closed and locked.
alarms before beginning the PTI test. 2. Switch the Unit On/Off switch to ON position.
· Press F2 key to enter Main Menu. 3. Adjust controller setpoint to the desired
temperature:
· Press F2 or F3 key to scroll up or down in
menu to “COMMANDS”.
· Press F4 key to access COMMANDS menu.
49
NOTE: The setpoint temperature can be set Starting the Unit on Ship
between -10 C and -60 C (14 F and -76 F) in
either F or C using the C/F key. Just press and CAUTION: Supply power connections
hold the F/C key (to display the alternate from the refrigeration unit to the power
temperature scale). source must always be made with the
· Press SETPOINT key to display cursor refrigeration Unit On/Off switch and
flashing in the “TEMP SETP” line power supply On/Off switch in the OFF
positions. Never attempt to start or stop
· Press F4 key to enter new setpoint. Enter the refrigeration unit with the unit power
Arrow appears in the menu line and the cable.
current setpoint disappears.
1. Connect the unit power cord to proper power
· Enter minus sign first by pressing EXIT key. source:
Then press numeric keys to enter new
setpoint. · 460/380V power cord to 460/380V, 60-50 Hz
power source.
· With correct setpoint in display, press and
hold F4 key until cursor stops flashing. · Turn the power supply On/Off switch ON.
Controller places new setpoint in controller 2. Turn the unit On/Off switch to ON position.
memory and shows new setpoint in LCD Check for condenser fan and evaporator fan
display. motor operation (see “Condenser Fan and
NOTE: New setpoint must be between -10 C and Evaporator Fan Rotation” in the Electrical
-60 C (14 F and -76 F) or controller will return to Maintenance chapter of this manual). If the unit
the previous setpoint display. was properly pretripped, correct condenser fan
rotation will also indicate correct evaporator fan
NOTE: If the F4 key is not pressed within 30 rotation.
seconds, the controller will default (return) to
the previous setpoint. If this occurs, repeat step 3. Check the controller setpoint to make sure it is
3. correct (agrees with shipping manifest).
0. Enter trip identification information into the
controller memory by selecting “Cargo Data” Post Trip Procedure
from the MISC FUNCTIONS menu of the Trip data recorded by the MPC2000, MPC2000ID
controller. or MP3000 datalogger may be down loaded via the
1. One-half hour after loading, initiate a manual communications port on the control box using a
defrost cycle: DRU-II or SmartSponge handheld data retriever;
or via the REFCON remote monitor system.
· Press the DEFROST key. The Defrost and
Heat LEDs turns ON as the unit enters
Defrost. Defrost will stop automatically.
NOTE: The evaporator coil temperature must be
below 10 C (50 F) to allow the unit the enter a
defrost cycle. If the evaporator coil temperature is
too high, the LCD display will read “Defrost Not
Activated”.
50
General Description Pretrip (PTI) Test. Fault codes are retained by

the controller in a non-volatile memory (see
The MPC2000, MPC2000ID and MP3000 are alarm codes, type and description below).
advanced microprocessor controllers that have
been specially developed for control and
monitoring of refrigeration units. Each controller
contains the following basic features:
1. Eight status indicator LEDs are located in the
top LED display and signal the following:
· Supply (Air Temperature)
· Return (Air Temperature)
· Humidity Mode (Inactive on CRR DF units)
· Compressor (Cooling On)
· Heat (On during Defrost)
· Defrost
· In-Range (Temperature)
· Alarm
The indicator LEDs stay ON continuously to
indicate sensor temperature display, unit
operating mode or condition.
The Alarm LED flashes ON and OFF
continuously when a Check Alarm (Level 2
Alarm) or Shutdown Alarm (Level 1Alarm)
occurs. Less serious Log Alarms (Level 3
Alarm) are recorded but do not activate the
Alarm LED.
Check Alarms indicate corrective action
should be taken before a problem becomes
severe. The unit continues to operate.
However, some unit functions may be
inhibited.
Shutdown Alarms indicate the unit operation
has been stopped to prevent damage to the unit
or cargo. The problem must be corrected and
the alarm code acknowledged before the unit 1. LED display with Status Indicator LEDs
can be restarted to resume normal operation. 2. LCD message and menu display
Alarm codes are recorded in the controller 3. General purpose keys

memory to simplify unit diagnosis procedures. 4. Special function keys
Some alarm codes are only recorded during a Figure 18: MPC2000, MPC2000ID and MP3000
Controller
51
Alarm 2. LED display with 20.32 mm high characters:

Code Type Description
· Five alpha numeric characters: Numerical
00 Check Supply Air Sensor Open Circuit hundredths, tens, ones and tenths position, a
01 Check Supply Air Sensor Short Circuit C for Celsius or F for Fahrenheit for
02 Check Return Air Sensor Open Circuit
temperature display.
03 Check Return Air Sensor Short Circuit · LED display shows current control
Evaporator Coil Sensor Open
temperature (return or supply). Status LEDs
04 Check
Circuit signal sensor temperature shown in LED
display. If a sensor is out of range the
05 Check Evaporator Coil Sensor Short
Circuit
display shows “+Err” or “-Err”. The ± sign
indicates whether the sensor temperature is
06 Check R-134a Compressor Current Too out of range high or low.
High
07 Check R-134a Compressor Current Too · The LED display is also used to show the
Low current state of a Pretrip (PTI) test.
10 Check Heater Current Too High 3. LCD display with 4 line, 20 character message
11 Check Heater Current Too Low display:
14 Check Evaporator Fan Low Speed · LCD standard display shows setpoint
Current Too High temperature during normal operation
15 Check Evaporator Fan Low Speed information.
Current Too Low
· LCD display shows controller menu and
16 Check Condenser Fan Current Too High unit operation information when special
17 Check Condenser Fan Current Too Low keys are pressed.
18 Log Power Supply Phase Error 4. Sixteen general purpose keys are used to enter
19 Check Temperature Too Far from and scroll through the controller menu tree
Setpoint and message text; initiate a Pretrip test; enter
20 Check Defrost Time Too Long
new setpoint temperature; and enter trip
information.
22 Check Capacity Test 1 Error
The keyboard supports both numerical and
23 Check Capacity Test 2 Error
text input. Each key can have more than one
32 Check Condenser Air Sensor Open meaning. Use the special text keys F1, F2, F3
Circuit
and F4 to enter text in an information screen:
33 Check Condenser Air Sensor Short
Circuit · F1 key: Press the F1 key, then press another
general purpose key to enter the number
34 Check Ambient Air Sensor Open Circuit
shown on the key.
35 Check Ambient Air Sensor Short Circuit
· F2 key: Press the F2 key, then press another
43 Check Return Air Temperature Too High
general purpose key to enter the first letter
52 Check Probe Error shown on the key.
56 Shutdo Compressor Temperature Too
wn High
general purpose key to enter the second
58 Check Phase Sensor Error letter shown on the key.
59 Check Delta Current Error
97 Log Compressor Sensor Open Circuit general purpose key to enter the third letter
98 Log Compressor Sensor Short Circuit shown on the key.
112 Check Zero Current Too High
52
NOTE: When the F1, F2, F3 or F4 key is · SUP/RET key: Press to view alternate
pressed to enter a character in the display, the return/supply sensor temperature in LED
keypad remains on that “character level” until display.
another “level” is selected by pressing the F1,
· SETPOINT key: Press to show Setpoint
F2, F3 or F4 key.
temperature line in LCD display for setpoint
Text Input Example: To enter THERMO in adjustment.
an information screen:
6. Control Transformer: Low voltage control
a. Enter “T” by pressing F3 key, then pressing power and ground is supplied to the
STU key. microprocessor controller and the main relay
board.
b. Enter “H” by pressing GHI key.
7. Main Relay Board: High voltage supply power
c. Enter “E” by pressing DEF key.
and low voltage control power and ground are
d. Enter “R” by pressing F4 key, then pressing supplied to the main relay board. The main
PQR key. relay board contains:
e. Enter “M” by pressing F2 key, then pressing · Relays to energize and de-energize unit
MNO key. contactors and solenoids. Component relays
include the heater, evaporator fan motor,
f. Enter “O” by pressing F4 key, then pressing
condenser fan motor, and phase reversal
MNO key.
relays.
General text keys F1, F2, F3 and F4 also
· Supply power circuit protection: 20 amp
include directional arrows for entering and
fuses (3) protect the high voltage circuits on
scrolling through the controller Main Menu:
the main relay board.
· F1 key: ESC indicates that pressing the K1
· Control circuit fuse and circuit breaker
key moves the cursor out of (exits) a menu
protection:
list.
- 7 amp manual reset circuit breaker
· F2 key: FORWARD/UP ARROWS indicate protects the 29 Vdc control circuit. - 2
that pressing the K2 key scrolls the cursor amp fuse protects the 28 Vac control
forward and/or upward through text boxes power circuit to the controller.
and menu lists. - 2 amp fuse protects the battery charger
output circuit to the controller.
· F3 key: BACKWARD/DOWN ARROWS
indicate that pressing the K3 key scrolls the · Electronics for measuring phase sequence.
cursor backward and/or downward through
· Electronics for measuring amperage.
text boxes and menu lists.
· Electronics for measuring voltage.
· F4 key: ENTER ARROW indicate that
pressing the K4 key moves the cursor into · Zero current transformer for earth leaking
the next menu level or into a menu item text measurement.
box.
8. Replaceable sensors: Return air, supply air,
5. Four special keys: evaporator coil (defrost), ambient air, R-134a
compressor discharge line and R-23 compressor
· C/F key: Press to view alternate temperature
discharge line temperature sensors are field
scale in LED display.
replaceable. Three (replaceable) spare sensor
· DEFROST key: Press to initiate defrost. receptacles are also provided for USDA
Evaporator coil temperature must be below temperature recording.
10 C (50 F).
9. Defrost cycle control (see “Defrost System” in
this chapter).
53
10. Pretrip (PTI) test capability (see “PTI (Pretrip) 12. Electronic phase selection: The
Test” in this chapter). microprocessor controller monitors the phase
of the power supply to ensure proper rotation
11. Data recording capability: The MPC2000
of the condenser and evaporator fans, and the
Datalogger and MPC2000ID Integral
compressor.
Datalogger can record sensor temperatures as
well as loss of power, alarms, unit operating 13. Sequential component start-up control: A
modes, sensor failure, setpoint change and unit sequence start of the required loads occurs
shutdown indications. All data recordings are during initial start-up of the controller and when
stored in memory. DRU-II or SmartSponge a control mode shift requires the compressors to
software downloads and reports the return, start (see “Sequence of Operation” in this
supply, ambient and USDA sensor temperatures chapter).
as standard.
14. Hourmeters: The microprocessor controller has
Logging intervals are selectable from 1 minute multiple built-in hourmeters that can be
and 1/2, 1, 2 or 4 hours. When a 1 hour logging accessed through the Main Menu.
interval is selected, the datalogger memory can
15. Manual emergency control capability. Manual
store approximately 365 days of information.
control settings in the control box allow the unit
The logging of USDA sensors is fixed at 1 hour
to operate even in the event of a fatal failure of
intervals to comply with USDA requirements.
the controller. Manual control offers three
All data logs include the time and date; operating functions: Heat, Defrost and Cool (see
setpoint temperature; and supply, return, “Manual Emergency Mode Operation” in this
USDA1, USDA2 and USDA3 sensor chapter).
temperatures. All temperature logs can be
16. Flash memory: Flash program memory allows
viewed from the controller’s LCD message
the application software to be updated without
display.
replacing a EPROM chip on the controller.
If the unit power supply is disconnected, the Application software can be updated in the field
datalogger will continue to register 168 using a portable computer and the MPC2000 or
temperature logs. These will be maintained until MPC2000ID Loader program. Consequently, the
the unit is re-connected to power, and the field installed application software version may
battery automatically re-charged. have a different revision number and may
include control features not included in the
Trip data can be retrieved (but not erased) from
original factory installed software. If the
the datalogger memory using DRU-II or
operation of your unit differs from the Sequence
SmartSponge handheld data retriever; or via the
of Operation described for the unit in this
REFCON remote monitor system. The
manual, enter “Misc. Functions” in the Main
datalogger is also equipped with a high-speed
Menu to check that the program version is
parallel communication port. Data transfer time
correct (see “Menu Operating Instructions” in
is approx. 25 seconds for event logs and approx.
this chapter).
70 seconds for temperature logs.
17. Display menus: The microprocessor controller
Trip data from separate units is denoted by the
contains an extensive display menu that can be
identification information entered into the
navigated via keypad. The display menu is
controller at the beginning of the trip via the
organized into 7 Main Menus:
general purpose keypad. Identification data may
include the container ID number, location • Data Menu: Menu screens in this group are
B.R.T., contents, loading data, voyage no., ship, used to display unit operating information
load port, discharge port and comments. The including sensor temperatures, voltage,
container ID number is stored in the current and frequency information.
Configuration submenu.
54
• Alarm List Menu: Menu screens in this Output signals from the controller automatically
group display a list of alarm code(s). regulate all unit functions including:
· Commands Menu: Menu screens in this · Compressor operation
group are used to activate defrost, function
· Condenser fan operation
tests, pretrip (PTI) tests and manual function
test. · Evaporator fan motor operation
· Miscellaneous Functions Menu: Menu · Liquid line solenoid valve
screens in this group display date/time, C/F,
· Electric heaters
cargo data, program version and run time
(hourmeters) information. · Phase selection
· Configuration Menu: Menu screens in this
group display refrigerant type, in-range Frozen Loads (Setpoint at -10 C
setting, container ID, contrast (screen), [14 F] and Below)
language, unit type, reefer type and zero NOTE: CRR DF units are designed to haul deep
current status. frozen cargo only at setpoints between -10 C (14
F) and -60 C (-76 F).
· Datalogger Menu: Menu screens in this
group display temperature log, event log, set At setpoints of -10 C (14 F) and below, the
log time and PTI log. microprocessor controls unit operation based on
the return air sensor temperature and setpoint
· RMM (Remote Monitoring) State: Menu
temperature.
screen show current remote monitoring state
(Offline, Zombie or Online). The system operates on Full Cool to provide
accurate control of frozen cargo. If the return air
General Theory of Operation sensor becomes disconnected or fails while it is
being used to control unit operation, the controller
The MPC2000 and MPC2000ID controllers use will automatically operate the unit continuously on
advanced solid-state integrated circuits to monitor Full Cool.
and control unit functions. The controller monitors
inputs from: Sequence Of Operation
· Return air sensor
Unit Start-up
· Supply air sensor
A 60 second sequence start of the required loads
· Evaporator coil sensor occurs during initial start-up of the controller. If
· Ambient sensor cooling is required, the unit operates in the cool
mode until the controlling sensor reaches 1.0 C
· USDA (Spare) sensors 1, 2 and 3 (1.8 F) below setpoint.
· R-134a compressor discharge line · When the unit On/Off switch is turned ON, the
temperature sensor LED display turns On and then Off.
· R-23 compressor discharge line temperature · The setpoint appears briefly in the LED display.
sensor
NOTE: When the setpoint appears in the LED
· Phase measuring circuits display, both the Return and Supply LEDs are
· Current measuring circuits lit.
· Voltage measuring circuits · The LED then shows the controlling air sensor
temperature.
55
· The controller senses the incoming power phase Continuous Temperature Control
and selects the correct power phase to unit Operation
components.
Frozen Loads — Controller Setpoint at
· The evaporator fan motors start. Evaporator fans
-10 C (14 F) and Below
operate continuously in low speed.
The controller regulates compressor operation based
· The R-134a compressor and condenser fan then
the return air sensor and setpoint temperatures to
start and the liquid line solenoid energizes
determine operating mode switch points. The
(opens) if the controller calls for cooling.
controller operates the unit on:
· The R-23 compressor starts 30 seconds later.
· Cool mode
· Unit operates in cool until the controlling sensor
· Null mode
reaches 1.0 C (1.8 F) below setpoint on initial
pull down. · Defrost mode
· Controller turns ON the In-range LED when the · Evaporator fans operate on low speed to
controlling sensor temperature reaches 1.5 continuously circulate air inside the container
C (2.7 F) above setpoint on initial pull down. (except during defrost).
· Controller LED display shows the return air
sensor temperature.
· Controller LCD display shows the setpoint. Cool
· After initial start-up and pull-down to 1.0 C (1.8
F) below setpoint, the controller calls for the
Cool mode whenever the return air temperature
increases more than 1.0 C (1.8 F) above setpoint.
· Unit operates in Cool mode for a minimum of 15
minutes to prevent rapid cycling between Cool
and Null.
· After initial pull-down to setpoint, the controller
keeps the In-range LED ON as long as the return
air temperature remains less than 1.5 C (2.7 F)
above setpoint.
Null
Cool: Compressors operate a minimum of

· The controller calls for Null when the Return Air
A.
15 minutes after startup to prevent rapid Temperature decreases more than 1.0 C (1.8 F)
cycling between Cool and Null modes. below setpoint.
B. Null: Compressors are OFF a minimum of · The controller de-energizes the compressor
10 minutes to prevent rapid cycling contactors and condenser fan contactor, stopping
between Cool and Null modes.
the both compressors and the condenser fan.
C. In-Range
· Units remains in Null mode for a minimum of 10
1. Decrease Temperature minutes to prevent rapid cycling between Cool
2. Setpoint and Null.
3. Increasing Temperature
Figure 19: Frozen Load Control Sequence

(Setpoints at -10 C [14 F] and Below)
56
• The evaporator fans continue to operate in low When the defrost mode is initiated:
speed.
· The controller de-energizes both the R-134a and
R-23 compressor contactors, the condenser fan
Defrost
contactor and the evaporator fan contactors;
During the Cool or Null modes, the controller stopping the compressors, condenser fan and
initiates the Defrost mode when the evaporator coil evaporator fans.
sensor temperature is below 18 C (65 F) and:
· When the compressors stop, the controller turns
· Demand defrost function determines that defrost ON the Defrost LED, Heat LED and energizes
is required when the temperature difference the heater contactor, turning on the electric
between the return air sensor and setpoint heaters.
increases to a preset value and a minimum of 6 The controller terminates the defrost mode when:
hours of compressor ON (running) time have
elapsed since the previous defrost. · Frozen mode: Evaporator coil sensor
temperature reaches 18 C (65 F).
· A manual defrost is initiated by pressing the
Defrost special function key or by Refcon
· Time/temperature function: If the evaporator coil
sensor exceeds 8 C (47 F) for 15 minutes, the
Remote Monitoring Modem (RMM).
controller terminates defrost.
NOTE: If unit operating conditions do not aiow
the unit to enter a defrost cycle, “Defrost Not · Interval timer: Controller terminates defrost 90
minutes after initiation if the coil sensor
Activated” appears on LCD display when the
DEFROST key is pressed. temperature has not terminated defrost (120
minutes if power supply is less than 55H). Alarm
· A Timed Defrost always starts at 1 minute past code 20 will be generated if this occurs.
the hour immediately following a defrost timer
request for defrost. For example, if the defrost · When the controller terminates Defrost, the
timer requests a defrost cycle at 7:35, the defrost heater contactor is de-energized. The controller
cycle will start at 8:01. The datalogger will starts the condenser fan and the R-134a
record a Defrost event for each log interval in compressor. After 30 seconds, the controller
which a Defrost cycle is pending or active (i.e. starts the R-23 compressor and the evaporator
both the 8:00 and 9:00 data logs on 1 hour fans to minimize heat energy release into the
logging interval). container.
· On Frozen Loads, the initial time interval is Changing the Setpoint

12 hours. Six (6) hours are added to the time
interval each time a timed defrost interval To change the controller setpoint, turn
occurs without a demand defrost in between. the unit On/Off switch ON. With the
Maximum accumulated time interval is 36 standard LCD message display showing on the
hours. Time interval resets to 12 hours when controller (i.e. setpoint temperature):
setpoint is changed more than 5 C (9 F); or if 1. Press the SETPOINT key. The DATA menu
the unit is turned OFF for 12 hours. appears with the cursor flashing in the “TEMP
SETP” line.
2. Press the F4 key. An Enter Arrow appears in the
menu line and the current setpoint disappears.
3. Enter (type) the new setpoint in the LCD
display using the general purpose keypad. To
enter a minus setpoint, press the EXIT (±) key
first. The cursor moves to the right of the screen
as each key entry is acknowledged and
displayed.
57
NOTE: Always check that the setpoint entered in 1. Check the indicator LEDs to determine which
the LCD display is correct before proceeding. sensor temperature (supply air or return air)
4. Press and hold the F4 key until the cursor stops currently appears in the right display. This is the
controlling sensor (return air sensor at setpoints
flashing. The new setpoint is recorded in the
of -10 C [14 F] and below).
controller and appears briefly in the LED
display. 0. To view the supply air temperature, press and
hold the SUP/RET key. The controller will
NOTE: When the setpoint appears in the LED
show the supply air temperature as long as the
display, both the Return and Supply LEDs are
SUP/RET key is depressed.
lit.
2. The display then returns to the return air
NOTE: If the F4 key is not pressed within 30
temperature when the SUP/RET key is released.
seconds, the controller will default (return) to the
previous setpoint. If this occurs, repeat steps 1
through 4. Displaying Alternate
5. Controller returns to the standard LED Display
Fahrenheit (F) or Celsius
(shows return temperature) within 5 seconds (C) Temperature
and the standard LCD display (showing new The controller can display temperatures
setpoint) within 60 seconds. in Fahrenheit or Celsius. With the unit On/Off
switch ON and the controller showing a standard
Initiating a Manual LED Display:
Defrost 1. Press and hold the C/F key. The controller will
show the LED display temperature in the
alternate temperature scale (Fahrenheit or
With the unit On/Off switch ON: Celsius) from the temperatures shown on the
1. Press the DEFROST key. display as long as the C/F key is depressed.
· If the unit operating conditions allow a 2. The display then returns to the original display
manual defrost (e.g. evaporator coil when the C/F key is released.
temperature is less than 10 C [50 F]), the NOTE: To change the default temperature scale
unit enters defrost as the Defrost LED turns display, see “Changing the Temperature Display
ON. Value (C/F)” under MISC. FUNCTIONS in the
· If unit operating conditions do NOT allow Menu Operating Instructions section in this
defrost, the LCD message display shows chapter.
“DEFROST NOT ACTIVATED”.
2. The defrost cycle automatically terminates.
Menu Operating Instructions
NOTE: To view the controller’s menu or
download data when external power is
Displaying Alternate disconnected from the unit, press a special key:
Controlling (Supply or C/F key, SUP/RET key, DEFROST key or
Return) Air Sensor SETPOINT key. The controller LCD display will
Temperature appear using 12 Vdc battery power.
The controller can show either the supply or
return air temperature in the LED Display. With
the unit On/Off switch ON and the controller
showing the standard LED Display:
58
Controller Menu 2. Press F3 to scroll the cursor down through the

menu list. The Data menu displays the
Navigating the Controller Menu:
following functions:
The controller Main Menu is divided into seven
· Setpoint Temperature
major menus:
· Supply Air Temperature
· Data
· Return Air Temperature
· Alarm List
· Evaporator Coil (Defrost) Temperature
· Commands
· R-23 Compressor Discharge Line
· Misc. Functions
Temperature
· Configuration
· Ambient Temperature
· Datalogger
· High Pressure Temperature (R-134a
· RMM (Remote Monitoring Modem) State Compressor Discharge Line Temperature)
Moving through these seven menus and their · Battery Voltage
submenus and entering commands requires the
· Voltage Average (380/460V Power Supply)
use of four text keys:
· Voltage 1 (Main Power Supply)
F1 key: Press the F1 key each time you
want to exit a submenu and/or retrieve · Voltage 2 (Main Power Supply)
current system data for display.
· Voltage 3 (Main Power Supply)
F2 or F3 key: Press the F2 or
or F3 key each time you want to
· Frequency (Main Power Supply)
scroll up or down to view another · Zero Current
item in a menu or submenu; or scroll forward
· Current Phase 1 (Main Power Supply)
or backward in a menu line.
F4 key: Press the F4 key to enter a new · Current Phase 2 (Main Power Supply)
menu or submenu; to access a menu line · Current Phase 3 (Main Power Supply)
to enter information; or to load a
command or value. 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
NOTE: Information can ONLY be displayed
or LCD Standard Display after 30 seconds.
using the Data menu. Items can NOT be
changed.
Alarm List Menu
The Data menu displays general unit operating
The Alarm List menu displays alarm codes. If the
information including sensor temperatures, unit
Alarm LED is ON or flashing ON and OFF, enter
electrical data, etc.
the ALARM LIST to view the alarm code(s).
Viewing the Data menu:
Alarm Types
With the unit On/Off switch ON and the LCD
display showing the standard display (setpoint): There are three types of alarms:
1. Press F4 key for directly enter the Data menu. Shutdown Alarm (Level 1): Alarm LED flashes and
Menu items appear in LCD display. unit stops. Shutdown alarms indicate the unit has
been stopped to prevent damage to the unit or
59
cargo. The condition must be corrected before · If the alarm condition is corrected, the Alarm
restarting the unit. Alarm code 56 (Compressor LED will turn OFF and the alarm code
Temperature Too High) is a shutdown alarm. disappears from the alarm list.
Check Alarm (Level 2): Alarm LED flashes until
alarm is acknowledged. Check alarms indicate Viewing the Alarm List menu:
corrective action should be taken before a problem With the unit On/Off switch ON and the LCD
becomes severe. Alarm codes 00-17, 18, 19, 20, display showing the standard display (setpoint):
22, 23, 34, 35, 43, 52, 58, 112 are Check alarms.
1. Press F2 key to directly enter the Alarms menu.
Log Alarm (Level 3): Alarm is recorded in The first alarm code number, alarm state and
datalogger only (inspect event log). Alarm LED alarm description appears in LCD display.
does not flash or turn on. Alarm codes 59, 97, 98
are Log alarms. NOTE: Alarm codes are displayed in sequential
order, not in the order of occurrence.
Alarm Code States 2. Write down the first alarm code. Then press F2
There are three alarm code states for Shutdown key to view the next alarm code when more than
and Check alarms: one alarm code has been recorded.
· NOT ACTIVE: An alarm condition has occurred 3. Repeat step 4 until all alarm codes have been
but no longer exists in the unit. Not Active recorded. To scroll backward to return to a
means the condition was corrected and did not previous alarm code, press F3 key.
recur for 1 hour; or the unit On/Off switch was 4. To clear all alarm codes from the current display
turned OFF and then ON. list and turn off the Alarm LED, all problems must
· When a NOT ACTIVE alarm code is be corrected and the alarm code “acknowledged”
acknowledged (F4 key pressed while alarm in the Alarm List menu.
code appears in LCD display), the Alarm NOTE: To acknowledge an alarm, press F4
LED will turn OFF and the alarm code while the alarm code appears on the screen. The
disappears from the alarm list. alarm state will change from ACTIVE or NOT
· ACTIVE: An alarm condition has occurred and ACTIVE to ACKNOWLEDGE.
continues to exist in the unit; or the alarm NOTE: If no key is pressed for 30 seconds, the
condition occurred within the past 1 hour but controller returns to the previous menu level or
does not currently exist in the unit. the LCD Standard Display.
· If the alarm condition currently exists in the
unit and the alarm code is acknowledged, the Commands Menu
Alarm LED will stop flashing but remain The Commands menu displays a list of tasks that
ON. The alarm code state will change to can be activated. The following commands are
ACKNOWLEDGE in the alarm list. available:
· If the alarm condition no longer exists in the · Defrost: Manual defrost can be initiated. When
unit and the alarm code is acknowledged, the command is activated, LCD message display will
Alarm LED will turn OFF and the alarm show ACTIVATED, NOT ACTIVATED
code disappears from the alarm list. (evaporator temperature above 18 C [50 F]) or
· ACKNOWLEDGE: An alarm code has been ALREADY ACTIVATED (defrost in progress).
viewed and acknowledged in the alarm list. The · PTI (Pretrip) Test: Controller automatically
Alarm LED remains ON but does not flash. completes a test of individual components and
checks unit refrigeration capacity, heating
60
capacity, temperature control and defrost. a. Controller displays the first component that
See “PTI (Pretrip) Test” in this chapter for test appears in the Manual Function submenu
details. list: CONDENSER OFF.
0. Press F2 or F3 key to scroll to desired
CAUTION: The PTI test should only component test:
be performed on an empty container!
· Condenser Fan:
· Manual Function Test: Controller tests
· Compressor:
individual components selected by the
technician for diagnosis. LCD display will show · Evaporator Fan:
expected and actual current of the component
· R-23 Compressor
being tested.
· Sensor Check.
Viewing the Commands menu:
· Heat:
· Zero Current (View value only):
display showing the standard display (setpoint):
· ·Sensor Check:
1. Press the F3 key to enter the Main Menu.
· ·Sensor Check low speed (Probe Test),
2. Press F2 key to scroll through Main Menu until operates high speed evaporator fans only.
“COMMANDS” appears in LCD display.
After 5 minutes check the temperatures
3. Press F4 key to access the Commands menu. of the left and right hand supply sensors,
The first command in the submenu (Defrost) return sensor and defrost sensor.
appears in the LCD display. Temperatures should be approximately
equal.
4. Press F2 or F3 key to scroll to the desired
command: c. Component Test:
· Defrost · Press F4 key to start the component test.
LCD display will change the component
· PTI (Pretrip)
state from OFF to ON and show
· Manual Function Test expected current and actual current on
phase 1, 2 and 3.
5. Press F4 key to activate the command
selected. · Press F4 key again to stop test. LCD
display will change component state
· Defrost: LCD display shows DEFROST
from ON to OFF.
ACTIVATED, NOT ACTIVATED
(evaporator temperature above 18 C [50 F]) d. System Test (Multiple Components): More
or ALREADY ACTIVATED (defrost in than one component can be turned ON at a
progress). Defrost cycle ends automatically. time to perform a functional test of the
unit.
· PTI (Pretrip): LCD display shows PTI Test
currently being performed. PTI test ends · Press F4 key to start the component.
automatically. Press any key on the LCD display shows component ON.
controller to return the unit to normal
· Press F3 key to scroll to select next
operation.
component. Press F4 to start the
· Manual Function Test: component. LCD display shows
component ON.
61
· Repeat component start procedure until · C/F Mode: Sets the temperature value (Celsius
all required components are ON. For or Fahrenheit) the controller uses to record and
example, to operate unit in Full Cool display temperature (including historical data).
mode, start the following components:
· Cargo Data: Sets important trip information
- Condenser Fan
about the container and the load in the
- R-134a Compressor
controller.
- R-23 Compressor
- Evaporator Fans · Program Version: Displays the current software
version loaded in the controller: controller
· Observe current draw and system
(CTRL), emergency (EMERG) and program
performance.
(SER NO) serial numbers.
· When diagnosis is complete, press F4
NOTE: The program version serial numbers
key to turn OFF components individually.
should be written down on the Controller decal
Press ESC key to exit Manual Function
located on the side of the control box.
Test menu and turn ALL components
OFF. · Run Time: Displays and sets operating hours for
the unit and components.
e. Press ESC key to exit the Manual
Function Test submenu.
Viewing the Misc. Functions menu:
Manual function Test, DF units With the unit On/Off switch ON and the LCD
Menu list:
1. Press the F3 key to enter the Main Menu. Press
· Condenser Fan:
F2 key to scroll through Main Menu until
· Compressor: “MISC. FUNCTIONS” appears in LCD display.
· Evaporator Fan: 2. Press F4 key to access the Misc. Functions
menu. The first command in the submenu
· R23 Compressor:
appears in the LCD display: Date Time.
· Sensor Check.
3. Press F2 or F3 key to scroll to the desired
· Heat: function:
· Zero Current (View value only): · Date Time
· Sensor Check: · C/F Mode
· Sensor Check low speed (Probe Test), operates · Cargo Data
high speed evaporator fans only. After 5 minutes
· Program Version
check the temperatures of the left and right hand
supply sensors, return sensor and defrost sensor. · Run Time
Temperatures should be approximately equal.
4. Press F4 key to access the function selected.
Misc. Functions Menu Setting the Date and Time
The Misc. Functions menu displays a list of
1. Press the F3 key to entering Main Menu. Press
functions that identifies trips and determines how
F2 key to scroll to “MISC. FUNCTIONS”.
the controller records and displays operating
information. The following functions are available: 2. Press F4 key to access the Misc. Functions
menu. “Date Time” appears in the LCD display.
· Date Time: Sets the controller time and date.
62
3. Press F4 key to access the Date Time screen. 3. Press F4 key to access the Misc. Functions
Date Time screen appears with cursor in the menu. “Date Time” appears in the LCD display.
Time menu line. Display shows time in Press F2 key to scroll to “C/F MODE”.
“HH.MM.SS” where H = hour, M = minute and
0. Press F4 key to access the C/F Mode screen.
S = second.
C/F Mode screen appears with cursor in the
4. To enter a new time, press F4 key with cursor in temperature value menu line. Display shows
Time menu line. An Enter Arrow appears in the “C/F MODE of” where C = Celsius and F =
menu line and the previous time disappears. Fahrenheit.
5. Enter new time in “HH.MM.SS” format. 4. To change the temperature value, press F4 key.
Decimal points must be included in the entry Cursor moves to end of menu line and flashes.
between the hour, minute and second.
5. Press F2 key to toggle temperature value in the
NOTE: To scroll backward in the Time or Date menu line between C and F.
menu line, press and hold the F4 key, then press
6. With the desired temperature value in the menu
F3 key. Press F1 key to return keyboard to
line, press and hold F4 key until cursor stops
“numerical” entry before typing again.
flashing. Cursor stops blinking and new
6. With the correct time entered in the menu line, temperature value appears in display.
press F4 key. Then press EXIT key to enter time
7. Press ESC key to exit the C/F Mode screen.
in controller memory. Cursor stops blinking and
new time appears in display.
Setting Cargo Data
7. To enter a new date, press F3 key to move
cursor to Date menu line. Display shows date in
and date in “YY.MM.DD” where Y = year, 2. Press F2 key to scroll to “MISC.
M = month and D = day. FUNCTIONS”.
8. Press F4 key with cursor in Date menu line. An 3. Press F4 key to access the Misc. Functions
Enter Arrow appears in the menu line and the menu. “Date Time” appears in the LCD display.
previous date disappears. Press F2 key to scroll to “CARGO DATA”.
9. Enter new date in “YY.MM.DD” where Y = 4. Press F4 key to access the Cargo Data screen.
year, M = month and D = day. Decimal points Cargo Data screen appears with cursor in LOC.
must be included in the entry between the year, BRT menu line.
month and day.
5. Press F3 key to scroll cursor down through
10. With the correct date entered in the menu cargo data list: - LOC. BRT
line, press F4 key. Then press EXIT key to enter
· CONTENTS
date in controller memory. Cursor stops
blinking and new date appears in the display. · DATE (Loading Date)
11. Press ESC key to exit the Date Time screen. · VOYAGE
· SHIP
Changing the Temperature Display Value
(C/F) · LD PORT (Loading Port)
1. Press the F3 key to enter the Main Menu. · DIS PORT (Discharge Port)
2. Press F2 key to scroll to “MISC. · COMMENTS
FUNCTIONS”.
63
6. To enter text in a cargo data line, press F4 key 0. Press F4 key to access the Run Time screen.
with cursor in the desired menu line. An Enter The Run Time screen appears with cursor in
Arrow appears and the cursor flashes in the HEAT menu line.
selected line. Enter (type) the desired text.
0. Press F3 key to scroll cursor down through
When entering information:
cargo data list: - HEAT
· Enter up to 10 characters of text/numbers for · R-134a COMPRESSOR
each menu item.
· EVAPORATOR LOW
· To scroll backwards in the text box, press
and hold the F4 key, then the press F3 key. · CONDENSER
· To delete text from a previous entry, press · SCROLL (R-23) COMPRESSOR
F4 key and then the SPACE key.
· TOTAL
· To start entry over or quickly return to the
6. To reset an hourmeter or set hours on a
beginning of the text box, press F4 key, then
replacement controller:
EXIT key and then F4 key again.
a. Press F4 key with cursor in the desired menu
· When the F1, F2, F3 or F4 key is pressed to
line. The Password screen appears.
enter a character in the display, the keypad
remains on that “character level” until b. Press F2 key, “A” key (password is “A”), F4
another “level” is selected by pressing the key and then EXIT key. An Enter Arrow
F1, F2, F3 or F4 key. appears in the hourmeter line.
7. When the desired text entry is complete, press F4 c. Enter the desired run time setting (up to 5
key. Then press EXIT key. The cursor stops characters).
flashing and the new text appears in the menu
d. When the entry is complete, press and hold
line.
the F4 key until the cursor stops flashing.
8. Repeat steps 5 through 7 until all information The new run time appears in the menu line.
has been entered in the Cargo Data screen.
7. Repeat steps 5 and 6 to reset additional
9. Press ESC key to exit the Cargo Data screen. hourmeters.
8. Press ESC key to exit the Cargo Data screen.
Viewing or Setting Run Time
2. Press F2 key to scroll to “MISC.
FUNCTIONS”.
3. Press F4 key to access the Misc. Functions
menu. “Date Time” appears in the LCD display.
Press F2 key to scroll to “RUN TIME”.
64
Configuration Menu
The Configuration menu displays a list of
functions that identifies unit operating features
and current settings. The following functions are
available:
MP-3000 Configuration List, DF Units

Text Description Default Range
IN RANGE In range limit 1,5°C 0,5°C - 5°C
CONT ID Container Id LOSUxxxxxxx Must be valid
CONTRAST The LCD contrast 45 0 - 255
LANGUAGE The used language GB GB
ZERO CURR Zero current measuring On On/Off
USDA TYPE Usda probe set up 3 PT100 3 PT100 / 3 THERM / 4 THERM
CHART R. Chart recorder option Not Present Not Present/ +/-25C 31dy
AUTO CONFIG Auto configuration wanted On On/Off
UNIT # Reefer unit identification 9x any char
Viewing or Setting Functions in the Misc. · Contrast: Controller automatically regulates

Functions menu: black and white contrast value on LCD
display according to display temperature.
Standard setting is 45. Resetting this value is
not recommended.
· Zero Current: View display ON or OFF
2. Press F2 key to scroll through Main Menu until value (factory default = ON). However, no
“CONFIGURATIONS” appears in LCD errors occur if a Zero Current transformer is
display. not installed and configuration is set to ON.
3. Press F4 key to access the Configurations 5. To set a new Configuration screen value:
screen. Configurations screen appears with
a. Press F4 key with cursor in the desired menu
cursor in the In-Range menu line.
line. The Password screen appears.
4. Press F3 key to scroll cursor to view or reset the
b. Press F2 key, “A” key (password is “A”), F4
desired function:
key and then EXIT key. An Enter Arrow
· In-Range: Sets the temperature value for the appears in the hourmeter line.
controller’s In-range LED and datalogger
c. Use the general purpose keypad to enter the
functions (factory default = 1.5
desired value; or press the F3 key to toggle
C [2.7 F]). Enter a value from 0.5 to 5.0 C
the value to the desired setting.
(0.9 to 8.9 F).
d. When the entry is complete, press and hold
· Container ID: Sets the container
the F4 key until the cursor stops flashing.
identification number. Enter up to 11
The new value appears in the menu line.
characters (numbers or letters).
65
6. Repeat steps 4 and 5 to reset additional · Inspect Temp Log: The Log Time and the
configuration values. Setpoint, Supply, Return, USDA1, USDA2
and USDA3 temperatures appear in the first
7. Press ESC key to exit the Cargo Data screen.
screen.
Datalogger Menu · Press the F4 key to view additional
sensor log screens: Ambient sensor
The Datalogger menu contains a list of functions
temperature and flags.
that display unit operating information recorded in
the MPC2000 Datalogger or MPC2000ID Integral · Press the F3 key to scroll through
Datalogger. The following functions are available: previous logs of the sensor temperatures
Inspect Temperature Log: Displays temperature currently in the display. All temperature
logs by time and date for the Setpoint; and the logs recorded in the datalogger memory
Supply, Return, USDA1, USDA2, USDA3 and may be viewed on the LCD display.
Ambient sensors. NOTE: Logging temperature range is -90 C to
Inspect Event Log: Displays important event logs +10 C (-130 F to +50 F). If temperature is greater
by time and date for events such as unit alarms, than +10 C (+50 F), LED display shows “+Err”
power On/Off, setpoint change, clock reset, trip and LCD display shows “Sensor Short” message.
start, defrost, etc. If temperature is less than -90 C (-130 F), LED
display shows “-Err” and LCD display shows
Inspect PTI Log: Displays results of last PTI test
“Sensor Open” message.
including component volt and amps data and
sensor temperatures. Test values are recorded at · Inspect Event Log: The Log Time and most
the start and end of the Frozen Mode test. recent Event appear in the first screen.
Set Log Time: Sets the data log interval (1 minutes · Press the F3 key to scroll previous event
or 1/2, 1, 2 or 4 hours). log screens.
Viewing the Datalogger menu: · Inspect PTI Log: The Start Time and PTI
test results appear in the first screen.
display showing the standard display (setpoint): · Press the F3 key to scroll through
additional test results items in the log.
· Set Log Time: The current Log Time interval
2. Press F2 key to scroll through Main Menu until appears in the screen. To enter a new log
“DATALOGGER” appears in LCD display. interval:
3. Press F4 key to access the Datalogger menu. a. Press F4 key with cursor in Log Time menu
The first function appears in the LCD display: line. Cursor moves to the end of the menu
Inspect Temp Log. line and flashes.
4. Press F2 or F3 key to scroll to the desired b. Press F3 key to scroll through a list of log
function: time intervals:
· Inspect Temp Log · 1 Minute
· Inspect Event Log · 1/2 Hour
· Inspect PTI Log · 1 Hour
· Set Log Time · 2 Hour
5. Press F4 key to access the function selected. · 4 Hour
66
c. When the correct log time appears in the PTI (Pretrip) Test
menu line, press and hold F4 key until
cursor stops flashing. The new Log Time CAUTION: The PTI test should only
appears in the display. be performed on an empty container!
6. Press ESC key to exit any screen in the
Datalogger menu. The CRR DF controller contains a special PTI
pretrip test that automatically checks unit
RMM State Menu refrigeration capacity, heating capacity,
temperature control, and individual components
The RMM (Remote Monitoring Modem) State including the controller display, contactors, fans,
menu displays the current communications status protection devices and sensors. The test includes
with a REFCON system: measurement of component power consumption
· Offline: No communication between Controller- and compares test results to expected values.
RMM and REFCON system. NOTE: Correct all existing alarm conditions and
· Zombie: The controller has detected a REFCON clear the alarm codes before performing a PTI
system master module and is waiting for test. The controller will automatically clear all
communication. existing alarms before beginning the PTI test.
· Online: The Controller-RMM is logged-in on a During the PTI test, the LED display screen will
REFCON system for online viewing. show:
· “P1” for PTI test and the current step of the test
Viewing the RMM State screen: (e.g. “01”).
With the unit On/Off switch ON and the LCD · Alarm LED flashes if an alarm condition occurs
display showing the standard display (setpoint): during the test.
1. Press the F1 key to retrieve current unit NOTE: Detailed PTI test results are stored in the
performance data before entering Main Menu. Datalogger for later viewing. Any alarm codes
2. Press F2 key to enter the menu list. Press F2 recorded during the test can be viewed through
key to scroll through Main Menu until “RMM the controller’s Alarm List menu at the end of the
STATE” appears in LCD display. test.
3. Press F4 key to access the RMM State screen. NOTE: Auto PTI test omits HPCO test on R134a
The screen will show: Offline, Zombie or and R23 compressor, and cooling capacity is not
Online. verified by minimum temp difference between
supply and return. Manually verify function
4. Press ESC key to exit the RMM State screen. HPCO functions and full cooling capacity.
CRR Pretrip (PTI) Test Procedure

LED LCD Display
Display (Shows Approx. Amps for Possible Duration
(Test No.) 460V, 60 Hz Unit) Test Description Alarms (Time)
Display Test Event Log for PTI begins. All alarms are
P1.00 Activated turned OFF. Alarm list is cleared. All None 10 Seconds
0.1 A 0.0 A 0.1 A lights and bars in display turn ON.
00, 01, 02,
Sensor Test All sensors must have values within their 03, 04, 05,
P1.01 Activated measuring range. Power supply voltage 32, 33, 34, 10 Seconds
0.1 A 0.0 A 0.1 A and frequency must be Ok. 35, 97, 98,
112
67
CRR Pretrip (PTI) Test Procedure (Continued)

LED LCD Display
Electric heaters are turned ON. Amp
draw is measured and compared to
Heat Test voltage:
P1.02 Activated · 8.8 Amps approx. at 400V; 10, 11 10 Seconds
10.4 A 10.3 A 10.4 A
· 10.2 Amps approx. at 460V.
Amperes are recorded in PTI log.
Defrost If evaporator sensor is below +10 C (50
1 Hour
P1.03 Activated F), heat remains on until evaporator 20
Maximum
10.4 A 10.3 A 10.4 A sensor reaches +18 C (65 F).
Condenser fan and compressor are
turned OFF. With evaporator fan on high
Evaporator Fan High speed, Amp draw is measured and
P1.04 Activated compared to voltage and frequency: 12, 13 10 Seconds
1.6 A 1.5 A 1.6 A · 1.2 Amps approx. at 50 Hz, 1.6 Amps
approx. at 60 Hz Amperes are recorded
in PTI log.
Evaporator fans operate until
temperature difference between the
return and evaporator sensors, and
Probe Test
return and supply sensors is less than 60 to 600
P1.05 Activated 52
3.0 (5.4 F). Return sensor temperature Seconds
1.6 A 1.5 A 1.6 A
must be 0.5 C (1.0 F) above both the
evaporator and supply sensor
temperatures.
Condenser fan is turned ON. Amp draw
Condenser Fan
is measured and compared to voltage
P1.06 Activated 16, 17 10 Seconds
and frequency: Condenser fan amperes
2.2 A 2.1 A 2.2 A
are recorded in PTI log.
Condenser fan stops. Reverse phase
selector relay is energized and
Reverse Phase
condenser motor is started in reverse for
P1.07 Activated 58 30 Seconds
2 seconds. Amp draw difference
2.2 A 2.1 A 2.2 A
between correct and wrong motor
rotation must be less than 0.2 amps.
Condenser fan and compressor are
turned ON. Amp draw is measured and
compared to voltage. Evaporator
Compressor Test temperature and condenser coil
P1.08 Activated temperature are measured and recorded 06, 07 14 Seconds
9.2 A 9.1 A 9.2 A in PTI log.
If compressor has been OFF for last 18
hours (less than 30 seconds ON), a
compressor sequence start occurs.
Unit operates in normal cool mode with
-30 C (-22 F) setpoint. When return air
Return PTI Running 4 Hours
temperature decreases to setpoint 22
Temp. Setpoint: -30 C (-22 F) Maximum
sensor temperatures are recorded in
PTI log.
68
CRR Pretrip (PTI) Test Procedure (Continued)

LED LCD Display
Unit operates in normal mode with -55 C
(-67 F). When return temperature
PTI Running decreases to -55 C (-67 F), defrost is
Return 90 Minutes
Defrost activated: activated. When evaporator temperature 20
Temp. Maximum
-55 C (-67 F) increases to 18 C (65 F), defrost
terminates and sensor temperatures are
recorded in PTI log.
Unit operates in normal mode with -55 C
(-67 F) setpoint. When return air
temperature decreases to setpoint,
sensor temperatures are recorded in PTI
log.
Return PTI Running “PTI End” event is recorded in the PTI 6 Hours
23
Temp. Setpoint: -55 C (-67 F) log. A Trip Start is automatically Maximum
activated.
Alarms (if any) are cleared from data
logger. However, alarms (if any) remain
in alarm list as not active until
acknowledged.
If alarms (errors) occurred during PTI
test, LCD display shows PTI FAIL. Press
Return PTI PASS: any key to clear display. None —
Temp. Press (Any) Key
Unit will remain OFF unit any key is
pressed again.
Temperature Sensors
CAUTION: It is important that the
Thermistor type temperature sensors are used. temperature sensors are properly
Each sensor is connected to a cable and placed in mounted. Sensors are permanently
a sealed stainless steel tube. The temperature calibrated and can be checked using an
signal from the sensor is transmitted through the ohmmeter. Ohm readings should agree
cable. Temperature sensors include: with specific data as shown in the
· Supply Air foiowing Sensor resistance tables.
· Return Air When positioning the evaporator coil (defrost)
sensor in the coil, make sure it is placed at least 75
· Evaporator Coil mm deep and in the middle of the evaporator coil.
· R-134a Compressor Discharge Line NOTE: K ohm sensors used in standard CSR &
· R-23 Compressor Discharge Line CRR units are not interchangeable with 1K ohm
type sensors used as supply, return and Evap
· Ambient Air sensors in DF units.
69
Resistance Values for R-134a or R-23 Compressor Discharge Line Sensor
96.8 36 60752 222.8 106 4623

100.4 38 55668 226.4 108 4348
104 40 51058 230 110 4092
107.6 42 46873 233.6 112 3854
111.2 44 43071 237.2 114 3631
114.8 46 39613 240.8 116 3423
AXA0171
118.4 48 36465 244.4 118 3229
122 50 33598 248 120 3047
125.6 52 30983 251.6 122 2877
A. Coil support brackets 129.2 54 28595 255.5 124 2718
B. Unit front. 132.8 56 26413 258.8 126 2569
C. Insert sensor at least 75 mm into coil 136.4 58 24419 262.4 128 2430
between tube rows 2 and 3
140 60 22593 266 130 2299
Figure 20: 3 Fan Evaporator: Evaporator (Defrost)
Sensor Location 143.6 62 20921 269.6 132 2176
147.2 64 19388 273.2 134 2118
Resistance Values for R-134a or R-23 150.8 66 17961 276.8 136 1953
Compressor Discharge Line Sensor 154.4 68 16689 280.4 138 1852
Temp. Temp. OHMS Temp. Temp. OHMS
°F °C °F °C
1K Sensor Resistance Values for
Supply, Return, Evaporator Coil and
32 0 351017 158 70 15502 Air Sensors for MPC2000ID and
35.6 2 315288 161.6 72 14410 MP3000 Controller
39.2 4 283558 165.2 74 13405 Temp. Temp. OHMS Temp. Temp. OHMS
°F °C °F °C
42.8 6 255337 168.8 76 12479
-40 -40 21309 53.6 12 1680
46.4 8 230210 172.4 78 11625
-31 -35 16099 57.2 14 1547
50 10 207807 176 80 10837
-22 -30 12266 60.8 16 1426
53.6 12 187803 179.6 82 10110
-13 -25 9425 64.4 18 1316
57.2 14 169924 183.2 84 9438
-4 -20 7309 68 20 1215
60.8 16 153923 186.8 86 8817
5 -15 5691 71.6 22 1173
64.4 18 139588 190.4 88 8242
10.4 -12 4919 75.2 24 1040
68 20 126729 194 90 7710
14 -10 4470 78.8 26 962
71.6 22 115179 197.6 92 7216
17.6 -8 4066 82.4 28 893
75.2 24 104796 201.2 94 6759
21.2 -6 3703 86 30 828
78.8 26 95449 204.8 96 6335
24.8 -4 3376 89.6 32 770
82.4 28 87023 208.4 98 5941
28.4 -2 3082 93.2 34 715
86 30 79428 212 100 5574
32 0 2817 96.8 36 665
89.6 32 72567 215.6 102 5234
35.6 2 2577 100.4 38 619
93.2 34 66365 219.2 104 4917
39.2 4 2360 104 40 577
70
1K Sensor Resistance Values for · Defrost: Heaters are activated for defrost
Supply, Return, Evaporator Coil and (evaporator fans off).
Air Sensors for MPC2000ID and
· Evap Fan: Evaporator fans are activated.
MP3000 Controller
42.8 6 2165 107.6 42 538 CAUTION: The unit must be cycled
46.4 8 1953 111.2 44 502 manually to maintain the desired
50 10 1826 113 45 485
temperature. Monitor container
temperature with an external
thermometer.
2K Sensor Resistance Values for
Ambient Air Sensors for MPC2000ID To select Manual Control:
and MP3000 Controller 1. Turn the Unit On/Off switch to OFF.
Temp. Temp. OHMS Temp. Temp. OHMS
°F °C °F °C 2. Disconnect the unit power cord from the power
supply.
-40 -40 42618 53.6 12 3360
-31 -35 32198 57.2 14 3094 WARNING: High voltage (460/380 volts)
is present on the contactors and relays in
-22 -30 24532 60.8 16 2852
the control box. To prevent dangerous
-13 -25 18850 64.4 18 2632 electrical shock, disconnect the supply
-4 -20 14618 68 20 2431 power to the unit whenever possible when
working in this area.
5 -15 11383 71.6 22 2347
10.4 -12 9838 75.2 24 2079 3. Disconnect cable no. 2 from the controller and
main relay board (see electrical schematic).
14 -10 8941 78.8 26 1925
17.6 -8 8132 82.4 28 1785 4. Disconnect the 2-pin plug from J501 (see decal
on main relay board). Re-locate plug according
21.2 -6 7406 86 30 1657
to the function required: Defrost or Cool.
24.8 -4 6752 89.6 32 1539
5. Connect the unit power cord to the proper
28.4 -2 6164 93.2 34 1430
power supply.
32 0 5634 96.8 36 1330
6. Turn the Unit On/Off switch to ON. Unit will
35.6 2 5155 100.4 38 1239 start and operate.
39.2 4 4721 104 40 1154
7. Check for correct rotation of condenser fan and
42.8 6 4329 107.6 42 1076 evaporator fans. Condenser air should be
46.4 8 3907 111.2 44 1004 blowing out from the center of the grille.
50 10 3652 113 45 970
Evaporator air should be blowing down through
the evaporator coil. If the fans are running
backwards, the power supply phase must be
Manual Emergency Mode changed.
Operation
In the event of an emergency situation where a
fatal failure of the controller occurs, a manual
emergency mode function can be used to operate
the unit. Manual control offers a selection of three
fixed operating functions:
· Cooling (frozen): Both compressors, the
condenser fan and the evaporator fans operate
continuously. The liquid line solenoid is
energized with the R-134a compressor.
71
6. Place new EPROM chip ID label over old label

on the side of the controller to identify new
EPROM.
0. Install datalogger (or back cover) mounting
screws.
7. Connect battery power plug to top of controller.
NOTE: The EPROM replacement will lead to a
total loss of the software, thus software has to be
downloaded.
Figure 21: Manual Emergency Control Connections
CAUTION: EPROM chip replacement

Replacing the EPROM Chip will lead to a total loss of software.
(MPC2000 and MP3000 Only) Immediately proceed to procedure for
To replace the EPROM chip in the controller: “Loading Controller Software” in this
chapter.
1. Turn the unit On/Off switch OFF. Then unplug
the unit power cord from the power supply.
Replacing the
WARNING: High voltage (460/380 volts) Microprocessor Controller
is present on the contactors and relays in
NOTE: There are several programmable
the control box. To prevent dangerous
features that may need to be set to completely
electrical shock, disconnect the supply
configure the unit to customer specifications.
power to the unit whenever possible when
Customer requirements may include features
working in this area.
such as the container identification number.
2. Disconnect battery power Adjust any additional programmable settings to
connection from the controller (top plug on the customer requirements before releasing the unit
controller). for service.
3. Do one of the following: 1. Turn the unit On/Off switch OFF. Then unplug
the unit power cord from the power supply.
· MPC2000 and MP3000 Controller: Remove
the datalogger from the back of the 2. Disconnect battery power connection from the
controller by loosening the 4 screws. controller (top plug on the controller).
· MPC2000ID Controller: Remove the back 3. Disconnect the communication cables from the
of the controller by loosening the 4 screws. controller, datalogger and remote monitoring
modem.
The EPROM chip will become visible. Do
NOT remove the connection between 4. Remove the screws that secure the datalogger
controller and datalogger. (MPC2000 and MP3000 controller only) and
remote monitoring modem to the controller.
NOTE: An anti-static wrist strap and EPROM
chip insertion tool should be used during this 5. Remove the screws that secure the controller to
procedure. the inside of the control box door.
4. Cut the EPROM security strip and carefully 6. Remove the controller from the door.
remove EPROM chip. 7. Install the replacement controller in the door
5. Replace security strip. Then carefully mount using the existing hardware. Connect the
new EPROM chip and tighten security strip. keyboard cable to the controller.
72
8. Install the datalogger (MPC2000 and MP3000 Flash Loading Controller

controller only) and remote monitoring modem Software
to back of the controller.
Controller software must be flash loaded when
9. Connect the communication cables to the software has been revised. To flash load software:
datalogger, remote monitoring modem and
controller. 1. Turn the unit On/Off switch OFF.
NOTE: Be certain that all connector plugs are 2. Plug cable from a portable computer with
fully seated. controller software into the data retrieval
connector on the control box.
CAUTION: Be sure to enter the container 3. Press one of the special functions keys to
ID before releasing the unit for service. activate controller LCD display on battery
The container ID is required to identify the power; or turn the Unit On/Off switch ON.
data downloaded from the controller
datalogger via a laptop computer or a 4. Press and hold the “7” key and F1 key at the
REFCON remote communications system. same time. LCD display will show
“FLASHLOAD”.
CAUTION: Immediately proceed to NOTE: If the communications cable is defective
procedure for “Loading Controller or not connected to the download port, the
Software” in this chapter. controller will start in emergency mode and LCD
display will show “EMERGENCY MODE”.
Secure cable connection to proceed with flash
loading of software.
5. Start flash load program on portable computer.
6. Flash loading of new software is complete when
“FLASH LOADING” clears from the LCD
display.
7. The controller then checks the new software
and loads the new control program into
memory.
NOTE: If the flash load procedure is interrupted
or fails, the controller will continue to use the
previous control program.
NOTE: Installing new software does not change
any configuration settings or the setpoint setting,
or erase the data log currently stored in the
controller.
73
MPC 2000 ID / MP 3000, Super Freezer "Error message list"

# Error Message Controller Action
1 Power Error, Check 20A Fuses · Controller activates alarm 18
Indicates: · Controller will try to restart unit after 60
minutes.
· One or more phases are missing
· Compressor is able to draw amps on all
phases while heater lacks amps on one or more
phases
10 Cond probe found, please change type · None. On CRR40 DF units, condenser
sensor input must be left open.
Indicates:
· Controller is set for CRR40 DF and start-
up is initiated on a KVQ/CRR PS, CSR PS or
CSR Magnum unit. Correct by turning Un it
On/Off switch Off. Then set controller software
switch to correct position. See controller
software selection.
11 Scroll Compressor, High Temperature · Controller clears message after
compressor start up.
Indicates:
· Compressor stops because discharge
temperature is above 140 c (284 F). Message
remains in display until discharge temperature
decreases to normal.
12 Scroll Compressor, Low Pressure · Controller activates Alarm 31 after 5
minutes.
Indicates:
· Low pressure cutout switch is open.
· Controller clears message after
compressor start up.
· Possible causes include stepper motor
valve will not open, warm gas bypass valve wil
not open, low refrigeratn charge, defective low
pressure cutout switch, open circuit, etc.
13 R134a Compressor, High Temperature · Controller actrivates Alarm 56.
Indicates: · Controller clears message when
compressor temperature decreases below
· Compressor stops because discharge
130 C (266 F). However, compressor
temperature is above 130 C (266 F).
remains off until discharge temperature
Compressor remains Off until discharge
decreases to 90 C (194 F).
temperature decreases to 90 C (194 F)
14 Evaporator High Temperature Switch Open · Controller clears message when high
temperature switch closes.
Indicates:
· Controller disables electric heaters due to
· NO alarm is set until Controller
determines that heater current draw is too
open high temperature switch circuit.
high (alarm 10), unit current draw is too high
· Possible causes include evaporator (alarm 36), or defrost time is too long (alarm
temperature over 54 C (130 F), defective 20).
heater, defective evaporator overheat switch,
open circuit, etc.
15 R134a Compressor Fault · Check to be certain 134a compressor
is running
· Feedback from 134a Compressor is Missing
· Check continuity through 134a
auxiliary contactor on Main Relay Board plug
J12.
74
Alarm Codes, Descriptions and · Check Alarm (Level 2 Alarm): Alarm light on
Corrective Actions display flashes until alarm is acknowledged.
NOTE: NOTE: Sensors used with the MPC2000, · Event Log (Level 3 Alarm): Alarm is recorded in
MPC2000ID and MP 3000 Controller do not datalogger only (inspect event log).
require calibration. Check sensor resistance with
an ohmmeter.
· Shutdown Alarm (Level 1 Alarm): Alarm light
on display flashes and unit stops. Correct alarm
condition and acknowledge alarm before
restarting.
Code Description Corrective Action
Supply
00 Air Sensor Open Circuit
(Check Alarm)
· Sensor circuit resistance higher than 100,000
ohms.
· Temperature below -80 C (-112 F).
· Indicates:
· Open circuit to sensor
· Defective or wrong sensor
· Defective relay board
· Defective cable No. 1
· Defective controller
01
02
· Check sensor resistance between pins 1
and 2 on plug J15. Resistance must be 1,000
ohms at 25 C (77 F).
· Check cable No. 1 between controller and
relay board.
· Check evaporator airflow.

and 2 on plug J15. Resistance must be 1000
relay board.

and 4 on plug J15. Resistance must be 1000
Supply Air Sensor Short Circuit
· Check cable
(Check No. 1 between controller and
Alarm)
relay board.
· Sensor circuit resistance lower than 200 ohms.
· Temperature above 80 C (176 F).
· Indicates:
Return Air Sensor Open Circuit
(Check Alarm)
· Sensor circuit resistance higher than
100,000 ohms.
· Indicates:
75

03 Return Air Sensor Short Circuit · Check sensor resistance between pins 3
(Check Alarm) and 4 on plug J15. Resistance must be 1000 ohms
at 25 C (77 F).
· Sensor circuit resistance lower than 200
ohms. · Check cable No. 1 between controller and
relay board.
· Indicates:
04 Evaporator Coil Sensor Open Circuit · Check sensor resistance between pins 5
(Check Alarm) and 6 on plug J15. Resistance must be 1,000
· Sensor circuit resistance higher than 100,000
relay board.
· Indicates:
· Check evaporator airflow.

· Low evaporator coil temperature
05 Evaporator Coil Sensor Short Circuit · Check sensor resistance between pins 5
ohms. ·Check cable No. 1 between controller and relay.
· Indicates:
06* R-134 Compressor Current Too High · Start “Manual Function Test”. Make sure
(Check Alarm) the compressor and condenser fan are operating.
Check compressor volts and amps.
· Occurs during Pretrip (PTI) only.
· Compressor power consumption is higher than · Check power supply volts.
approximately 13 amps. · Check ambient sensor.
· Indicates:
· Defective compressor or valve plate
· Defective volt or amp meter on relay
board
· Inaccurate ambient temperature
measurement
· Out of range power supply
76

R-134 Compressor Current Too Low
07*
(Check Alarm)
· Compressor power consumption is higher than
approximately 7 amps.
· Indicates:
· Defective or open fuse CB 6A, high
pressure cutout switch or connection in plug
J19 between pins 7 & 8
· No signal on plug J11 on pin 8
· Defective compressor relay
board
· Low R-134a refrigerant charge
· Defective R-134a compressor or valve
10*
11*
· Start “Manual Function Test”.
Make sure the compressor relay energizes. If
relay does NOT energize and the LED above
the compressor relay is NOT ON, check for a
defective cable No. 2, main relay board or
controller.
· Check discharge and suction pressure
gauge readings on R-134a system. Evaluate
readings based on current cargo and ambient
temperatures.
· Check compressor volts and amps.
· Check power supply volts.
*If both alarms 06 and 07 are activated, the alarms are caused by a large difference in measured amps. Start “Manual
Function Test” and start the R-134a compressor and condenser fan. Check the compressor amps measurement. If
necessary, check the resistance of the compressor motor windings.
Heater Current Too High
(Check Alarm)
· Heater power consumption is higher than
approximately 9 amps and lower than 13 amps.
· Indicates:
· Incorrect heaters or heater connections
· Defective volt or amp meter on relay board
· Defective heater element
Heater Current Too Low
(Check Alarm)
· Heater power consumption is lower than
approximately 6 to 9 amps, depending on voltage.
· Indicates:
· Incorrect heaters or heater connections
· Defective heater elements or heat relay
· Defective wire connections
· Defective high evaporator temperature
switch
· Start “Manual Function Test” and turn

heaters ON. Check current draw on each phase.
Current draw should be about 9.0 amps on each
phase at 380V (10.4 amps at 460V).
· Start “Manual Function Test” and turn

heaters ON. Check current draw on each phase.
Current draw should be 4.5 amps on each phase
at 380V.
· If heat relay fails to energize, check
evaporator high temperature switch. Switch
should be closed at temperatures below 54 C
(130 F); there should be continuity between pins 5
& 6 in plug J19.
· Check power supply volts and amps.
· Check heater element resistance between
H1 and H2, H2 and H3, and H1 and H3.
Resistance readings should be equal
(approximately 50 ohms).
*If both alarms 10 and 11 are activated, the alarms are caused by a large difference in measured amps. Start “Manual
Function Test” and energize the heaters. Check the heater amps measurement. If necessary, isolate and check the
resistance of each individual heater element.
77

Evaporator
14* Fan Low Speed Current Too High
(Check Alarm)
· Evaporator fan power consumption is
higher than approximately 2.6 to 2.9 amps,
depending on voltage.
· Indicates:
· Defective or stuck evaporator fan motor
· Incorrect motor or motor connections
· Motor high and low speed connection are
interchanged
board
15*
· Open evaporator door and make sure all
fans rotate freely.
· Start “Manual Function Test” and set
evaporator motors to low speed. Make sure all
fans start on low speed.
· Check fan motor volts and amps.
Evaporator Fan Low Speed Current Too Low

(Check Alarm)
· Evaporator fan power consumption is lower
than approximately 1.0 to 1.2 amps, depending on
voltage.
· Indicates:
· Defective evaporator fan motor relay
· Defective or open fan motor internal over
temperature protection switch
board
· Open evaporator door and make sure all
fans rotate freely.
evaporator motors to low speed. Make sure all
fans start on low speed.
*If both alarms 14 and 15 are activated, the alarms are caused by a large difference in measured amps. Start
“Manual Function Test” and start the evaporator fans. Check the evaporator fan amps measurement. If
necessary, check the resistance in the motors between L1, L2 and L3, and L1 and L3. Resistance readings
should be equal (approximately 30 Ohms, total of 3 motors).
78
Description Condenser Fan Current Too High

(Check Alarm)
· Condenser fan power consumption is
higher than approximately 1.25 amps, depending
on voltage
· Indicates:
· Defective or stuck condenser fan motor
· Defective volt or amp meter on relay board
Corrective Action
condenser fan motor to ON. Make sure the fan
starts.
Code
16*
Condenser Fan Current Too Low

(Check Alarm)
· 17*
Condenser fan power consumption is lower
condenser fan motor to ON. Make sure the fan
than approximately 0.7 amps, depending on
starts.
voltage).
· Indicates:
· Defective condenser fan motor relay

· Defective or open fan motor internal over

temperature protection switch
Power Supply Phase Error

(Log Alarm)
· One or more frequency inputs are missing
for18more than 20 seconds. · Enter “Data” menu and view voltage
· Indicates: reading on each phase.
· One phase on power line is missing · Check all fuses. Check cable No. 1 on
relay board.
· Defective fuse on relay board
· Replace relay board. Check voltage
· Defective digital inputs on relay board reading on each phase.
*If both alarms 16 and 17 are activated, the alarms are
caused by a large difference in measured amps. Start
“Manual Function Test” and start the condenser fan. Check
the condenser fan amps measurement. If necessary, check
the resistance in the motor between L1 and L2, L2 and L3, and L1 and L3. Resistance readings should be equal
(approximately 10 Ohms).
79

19 Temperature Too Far from Setpoint · Press SUP/RET key to check supply and
(Check Alarm) return air sensor temperatures. Compare
temperatures to evaluate unit cooling capacity
· After 80 minutes of operation, return air
and performance. Temperature difference
temperature is not in-range and does not
should be 4 C to 6 C.
approach setpoint by 0.1 C/hr.
· Indicates:
· Open evaporator door. Inspect coil for ice
or frost and initiate manual defrost if necessary.
· Ice or frost on evaporator coil
· Check refrigerant charge of R-23 and R-
· Low refrigerant charge 134a systems.
· Container air leakage (doors open)
NOTE: This alarm can be activated if the
supply or temperature does approach
setpoint.
20 Defrost Time Too Long · Initiate a manual defrost and check amperage
(Check Alarm) draw and evaporator coil temperature. Evaluate
defrost performance.
· Heat signal has been on for more than 90
minutes (120 minutes if power supply below 55 · Open evaporator door and check location of
Hz) during Defrost. evaporator coil sensor.
· Indicates: NOTE: This alarm can be activated at low
· Defective heater elements voltage and very low box temperature
· Defective heat relay conditions, even under normal operating
· Evaporator sensor placed wrong
conditions.
22 Capacity Test 1 Error · Open evaporator door and inspect evaporator fan
(Check Alarm) rotation. Make sure fans are rotating correctly on
low speed.
· Occurs during pre-trip (PTI) test only.
· Return air temperature does not reach -30 C (22 · Operate unit on Cool and check discharge and
suction pressure gauge readings on both the R-
F) within 4 hours.
23 and R-134a refrigeration systems. Check the
· Indicates: refrigerant charge of the R-23 and R-134a
· Incorrect refrigeration system operation systems.
· Container door is open · Check the return sensor connections.
· Container is not empty

· Incorrect connection of return air sensor
23 Capacity Test 2 Error · Open evaporator door and inspect
(Check Alarm) evaporator fan rotation. Make sure fans are
rotating correctly on low speed.
· Occurs during pre-trip (PTI) test only.
· Return air temperature does not reach -55 C (-67 · Operate unit on Cool and check discharge
F) within 6 hours. and suction pressure gauge readings on both the
R-23 and R-134a refrigeration systems. Check the
· Indicates: refrigerant charge of the R-23 and R-134a
· Incorrect refrigeration system operation systems.
· Container door is open · Check the return sensor connections.
· Container is not empty

· Incorrect connection of return air sensor
80

34 Ambient Air Sensor Open Circuit · Check sensor resistance between pins 13
· Sensor circuit resistance is higher than 100,000
relay board.
· Temperature is below -70 C (-94 F).
· Indicates:
35 Ambient Air Sensor Short Circuit · Check sensor resistance between pins 13
· Sensor circuit resistance is lower than 200 ohms.
· Temperature is above 80 C (176 F).
relay board.
· Indicates:
· Short circuit to sensor
43 Return Air Temperature Too High · Check for sensor alarm codes.
(Check Alarm)
· Check supply and return sensor
· Return air temperature increases above 35 C (95 connections and locations.
F) during defrost.
· Indicates:
· Defective return air or evaporator coil
sensor
· Return air and evaporator coil sensor
connections are reversed
52 · Probe Error (Check Alarm) · Check sensor connections. Check sensor
resistance of each sensor. Resistance must be
· Occurs during Pretrip (PTI) test only.
1,000 ohms at 25 C (77 F).
· Temperature difference between supply air,•
return air or evaporator coil sensor is too high (3 C
· Check supply air sensor locations.
maximum)
· Indicates:
· Indication error on one of the sensors
· Supply air sensor not placed in airflow
stream
81

56 Compressor Temperature Too High · Operate unit on Cool and check discharge
(Shutdown Alarm) and suction pressure gauge readings on R-134a
refrigeration system. Check refrigerant charge of
· R-134a compressor discharge line temperature is
R-134a system and R-23 system.
above 130 C (266 F). R-134a compressor
operation should resume when discharge line · Check sensor resistance. Resistance must
temperature decreases below 90 C (194 F); or R- be 100,000 ohms at 25 C (77 F).
23 compressor discharge line temperature is · Check discharge line temperature with a
above 138 C (280 F). R-23 compressor operation separate electronic thermometer and compare to
should resume when discharge line temperature “HIGH PR TEMP” showing in the View submenu of
decreases below 138 C (280 F). controller for both the R-134a compressor and the
· Indicates: R-23 compressor.
· Air in refrigeration system
· Low refrigerant charge in R-134a system
· R-134a Only: Defective compressor or
valve plate
· Wrong or defective sensor
58 Phase Sensor Error · Start “Manual Function Test” and view
(Check Alarm) current display for each phase to determine if
each phase sensor relay is receiving a signal.
· Occurs during Pre-trip (PTI) test only.
Change incoming power phase. Verify that the
· During Phase Sensor Test, amperage difference phase relays respond correctly.
between correct and wrong condenser fan rotation
is more than 0.2 amps.
· Indicates:
· Defective relay board cable No. 2
· Defective phase relay
59 Delta Current Error · Start manual function test one by one to
(Log Alarm) verify correct current draw for all components and
current draw reading of 0 Amp when component
· Power consumption is More than 50%
is disengaged.
above or below (Min 0,8 Amp).
· Indicates:
· Open connection on one phase of power
supply to a 3-phase unit component including R-
134a compressor or R-23 compressor.
97 Compressor Sensor Open Circuit · Check sensor resistance between pins 9
(Log Alarm) and 10 on plug J15 for R-134a compressor sensor
and between pins 11 and 12 on plug J15 for R-23
· Sensor circuit resistance is higher than
compressor. Resistance must be 100,000 ohms at
10,000,000 ohms on R-134a or R-23 compressor.
25 C (77 F).
· Indicates: relay board.
NOTE: Unit will operate normally without
· Defective or wrong sensor compressor sensor. However, controller
· Defective relay board compressor high temperature protection is
· Defective cable No. 1 not active.
82

98 Compressor Sensor Short Circuit · Check sensor resistance between pins 9
(Log Alarm) and 10 on plug J15. Resistance must be 100,000
relay board.
· Indicates:
· Short circuit to sensor
112 Zero Current Too · Start “Manual Function Test” and operate each
High (Check Alarm) motor and heater separately. Note when alarm
occurs.
· Ground (zero current) circuit 30 milliamps.
· Indicates:
· Defective motor or heater insulation to ground
83
84
Electrical Maintenance
Unit Wiring · LCD Display Message: R-134a high pressure

cutout feedback missing.
Inspect unit wiring, wire harnesses, and the
controller during pre-trip inspection and every · Evaporator and condenser fans continue
1,000 operating hours to protect against unit normal operation.
malfunctions due to open or short circuits. Look · R-23 compressor stops.
for loose, chaffed or broken wires on the unit;
open or short circuits and damaged components · R-134a compressor will restart when the
on the controller printed circuit board. overload condition is corrected (switch closes)
as long as power is available. The high
Inspect electrical contactor points for pitting or pressure switch resets (closes) when the
corrosion every 1,000 operating hours. Repair or pressure drops to 1640 ± 68 kPa, 16.4 ± 0.68
replace as necessary. bar, 238 ± 10 psig.
High Pressure Cutout Switch · R-23 compressor will restart 30 seconds after
R-134a compressor restarts.
A high pressure cutout switch is located on the
compressor discharge service manifold of each
compressor. If a high pressure cutout switch is
Condenser Fan and Evaporator
suspected of being defective, replace it with a Fan Rotation
known good switch. NOTE: If both the condenser fan and evaporator
fans are rotating backwards, diagnose the
R-23 High Pressure Cutout Switch automatic phase selection system for Alarm Code
18.
If the R-23 compressor discharge pressure rises
above 3250 ± 50 kPa, 32.5 ± 0.5 bar, 470 ± 7 psig,
the high pressure cutout opens to interrupt the Condenser Fan
ground circuit to the compressor contactor: Check for proper condenser fan rotation by
placing a small cloth or sheet of paper against the
· R-23 compressor STOPS immediately.
condenser fan grille on the front of the unit.
· LCD Display Message: No response to R-23 Proper rotation will blow the cloth or paper away
high pressure cutout. from the grille. Improper rotation will hold the
cloth or paper against the grille.
· Evaporator and condenser fans and R-134a
compressor continue normal operation. If the condenser fan is rotating backwards, refer to
the unit wiring diagram to correct fan motor
· R-23 compressor will restart when the
wiring at the fan motor junction box or condenser
overload condition is corrected (switch
fan contactor. To correct improper fan rotation,
closes) as long as power is available. The
reverse any two fan power cord leads at the
high pressure switch resets (closes) when the
condenser fan contactor (disconnect power supply
pressure drops to 2590 ± 250 kPa, 25.9 ± 2.5
before reversing leads). DO NOT move the CH
bar, 375 ± 38 psig.
ground wire.
R-134a High Pressure Cutout Evaporator Fans
Switch
Visually inspect the evaporator fan blades for
If the R-134a compressor discharge pressure rises
proper rotation. Arrows located on the underside
above 2410 ± 68 kPa, 24.1 ± 0.68 bar, 350 ± 10
of the fan deck indicate the correct direction of
psig, the high pressure cutout opens to interrupt
rotation.
the ground circuit to the compressor contactor:
If an evaporator fans rotate backwards, refer to the
· R-134a compressor STOPS immediately.
unit wiring diagram to correct motor wiring at the
fan motor junction box or evaporator fan
85
Electrical Maintenance
contactor (disconnect power supply before Low Pressure Cutout Switch:

reversing leads). (DO NOT move the ground wire
Opens: 0 ± 20 kPa, 0 ± 0.2 bar, 6 in. vacuum to
which is labeled CH.)
3 Psig
Electric Heaters Closes: 70 ± 20 kPa, 0.7 ± 0.2 bar, 10 ± 3 Psig
Twelve electric heater elements are located If the low pressure cutout switch is suspected of
underneath the evaporator coil. If a heater element being defective, replace it with a known good
is suspected of malfunctioning, inspect the switch.
connections:
· If the connections appear correct and secure,
isolate and check the resistance of each
individual heater element by disconnecting it
from the circuit.
· Check resistance with an ohmmeter.
NOTE: When repairing heater 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.
Low Pressure Cutout Switch (R-

23 System on CRR DF
MPC2000ID Units Only)
A low pressure cutout switch is located on the R-
23 compressor suction line. If the R-23 suction
pressure becomes too low, the switch opens to
stop both compressors:
· LCD Display Message: R-23 Low Pressure
Cutout.
· Evaporator and condenser fans continue
normal operation.
· R-134a compressor will restart if the low
refrigerant condition is corrected (switch
closes) as long as power is available. The low
pressure switch resets (closes) when the
pressure increases to 70 ± 20 kPa, 0.7 ± 0.2
bar, 10 ± 3 psig.
· When R-23 low pressure switch resets, R-23
compressor restarts 30 seconds after R-134a
compressor restarts.
86
Refrigeration Maintenance and Service
Operations
NOTE: The following procedures involve Service Tools
servicing the refrigeration system. Some of these
service procedures are regulated by Federal, and CAUTION: R-134a and R-23 are HFC
in some cases, by State and Local laws. (Hydrofluoro-carbon) refrigerants. When
servicing the CRR DF refrigeration
All regulated refrigeration service procedures systems, use only those service tools (i.e.,
must be performed by an EPA certified vacuum pump, refrigerant recovery
technician, using approved equipment and equipment, gauge hoses, and gauge
complying with all Federal, State and Local manifold set) certified for and dedicated
laws. to HFC refrigerants and Polyol Ester
NOTE: It is generally good practice to replace based compressor oils. Residual non-
the filter drier whenever the high side is opened HFC refrigerants or non-Ester based oils
or when the low side is opened for an extended will contaminate HFC systems. Separate
period of time. service tools should be dedicated to R-
134a and R-23 refrigerant systems.
R-134a Service Fittings and Gauge

Manifold Set
Special fittings are used on the CRR DF R-134a
refrigeration circuit to prevent mixing of non-HFC
refrigerants in the system. These fittings are
located in three places:
· Low side near the compressor suction service
valve,
· High side near the compressor discharge
service valve,
· High side on the receiver tank.
An R-134a gauge manifold set (P/N 204-758)
should be dedicated for use with R-134a (HFC)
refrigerant only.
Leak Detection
1. Internal Threads for Cap
Leaks can be detected with the use of soap
2. High Pressure Fitting bubbles and with Halogen leak detectors such as
3. Low Pressure Fitting model H10G, P/N 204-712 or model H10N, P/N
204-756 (portable).
Figure 22: R-134a Service Fittings Specifications
Vacuum Pump
A two-stage (P/N 204-725), three-stage or five-
stage pump is recommended for evacuation.
Purging the system with dry nitrogen is
recommended before evacuation. Because residual
refrigerant may be present in used vacuum pumps,
a new vacuum pump should be
87
Refrigeration Maintenance and Service Operations
used and dedicated strictly as an HFC refrigerant pump. Use only recommended vacuum pump oils and
change oil after every major evacuation.
Because vacuum pump oils are highly refined to obtain 1. Full Counterclockwise
low vacuums, failure to follow these recommendations
Figure 23: Service Valve Back Seated
may result in acidic conditions that will destroy the
pump.
1. 1/2 Turn In
Figure 24: Service Valve Open to Port
System Cleanup
Cleanup devices such as suction line filters and 1. Full Clockwise
compressor oil filters may be used if they are properly Figure 25: Service Valve Front Seated
cleaned and new filters and cartridges are used. All
standard petroleum and synthetic compressor oils must
be removed to prevent the contamination of R-134a or
R-23 refrigeration systems.
Refrigerant Recovery
Use only refrigerant recovery equipment approved for
and dedicated to HFC refrigeration recovery.
Compressor Oil Acid Test

Perform an oil acid test (oil test kit P/N 203-457)
whenever a unit has a substantial refrigerant loss, a
noisy compressor or dark/dirty oil.
Compressor Discharge and

Suction Service Valves
The discharge and suction valves isolate the
compressor from the high and low sides of the
refrigeration system for system diagnosis, service and
repair.
NOTE: The only maintenance possible on the
discharge or suction service valve is to periodically
tighten the packing nut or to replace the packing. The
valves are a permanently assembled unit and must be
replaced in total if defective.
· Back Seated: Normal operation position.
· Open to Service Port: Position for servicing.
· Front Seated: To check or remove compressor.
WARNING: Do not start unit with discharge valve in FRONT SEATED position.
88
1. Close Hand Valves

Figure 28: Gauge Manifold Closed to Center Port
Gauge Manifold Valve Positions
The gauges indicate low and high side pressures.
Operate one or both hand valves to perform the
different service operations.
1. Quick Disconnect Access Valve

2. Discharge Service Valve (DSV)
3. Suction Service Valve (SSV)
Figure 26: Balancing R-134a System Pressure 1. Open Hand Valves

Figure 29: Gauge Manifold Open to Center Port
1. Quick Disconnect Access Valve

Figure 30: Removing R-134a2.Refrigerant
In
3. Reclaimer with Receiver Tank
1. Quick Disconnect Access Valve 4. Out
2. Discharge Service Valve (DSV) 89
5. Discharge Service Valve (DSV)
3. Suction Service Valve (SSV) 6. Suction service Valve (SSV)
Figure 27: Charging the R-134a System
R-134a Gauge Manifold Set valve fully. Then rotate the suction hose fitting
(With Low Loss Fittings) hand wheel clockwise to open (depress) the
Attachment And Purging suction line port valve to the low hose.
Thermo King recommends the use of access 0. Slowly screw a 1/2 inch ACME fitting into the
valves or self-sealing, quick disconnect fittings low loss fitting on the manifold’s service
whenever possible to limit the loss of refrigerant (center) line to purge the suction and service
into the atmosphere. A separate gauge manifold hoses. Remove ACME fitting after purging.
set with low loss fittings (P/N 204-758) should be 1. Close the suction service manifold hand valve
dedicated for use with HFC refrigerants only. fully to center port.
Gauge hoses should also be dedicated to HFC
refrigerant. 2. Attach high side hose (pressure gauge) to the
discharge service line port.
NOTE: When any of these devices are used,
carefully check to ensure that access 3. Open discharge service manifold hand valve
connections are functioning properly. fully. Then rotate discharge fitting hand wheel
clockwise to open (depress) discharge line port
valve to the high hose.
R-134a Gauge Manifold Set
Installation 4. Slowly screw a 1/2 inch ACME fitting into the
NOTE: The following procedure purges the manifold’s service (center) line to purge the
gauge hoses and must be followed when using high and service hoses. Remove ACME fitting
new gauges or hoses for the first time. The after purging.
system should be operating on Cool (10 psig [69 5. Close discharge service manifold hand valve
kPa] or greater suction pressure) when using fully to center port. You are now ready to use
this procedure to purge the low side hose. Gauge the gauge manifold to check system pressures
hoses may be removed and re-installed without or perform MOST service procedures.
additional purging so long as a slight positive
pressure remains in the manifold and lines when
removed from the unit.
CAUTION: Due to extremely high

pressure in normal ambient, R23 cannot
be reclaimed by use of reclaim station.
1. Inspect gauge manifold for proper hose and
fitting connections.
2. Clean dirt and moisture from around service AMA295
ports.
A B
3. Remove small service port caps from suction
and discharge service fittings. Save and re-use
the caps and sealing washers or gaskets. A. R-134a Reciprocating Compressor
B. Reclaimer
4. Rotate both hose coupler hand wheels
counterclockwise to back the stem out of the DSV = Discharge Service Valve
high and low hose fittings. Then attach low SSV = Suction Service Valve
hose (compound gauge) to the suction line
NOTE: Use quick disconnect access
valve port.
valves on refrigerant hoses.
5. With 69 kPa, 0.69 bar, 10 psig or greater Figure 31: Removing Refrigerant
pressure in the low side (unit operating on
Cool), open the suction service manifold hand
90
3. Rotate the discharge fitting hand wheel

counterclockwise to depress the port valve
stem to equalize pressure at 21 kPa, 0.21 bar,
3 psig.
0. Rotate both coupler hand wheels
counterclockwise to close (seal) the valve port
stems to the high and low hoses.
4. Remove the gauge lines from the suction and
discharge service fittings and cap the service
ports.
5. Back seat receiver tank outlet valve and cap
valve stem.
6. Secure all manifold lines to manifold hose
anchors when the manifold is not in use.
Service Procedure Guide

Scroll Compressor
A. R-23 Scroll Compressor (R-23 Refrigeration System)
B. R-134a Reciprocating Compressor
Procedure Repair/Service Action
DSV = Discharge Service Valve
Reclaim Open the high side of the
SSV = Suction Service Valve Refrigerant refrigeration system.
NOTE: Use quick disconnect access Reclaim Open the low side of the
valves on refrigerant hoses. Refrigerant refrigeration system.
Figure 32: Purging Gauge Manifold
NOTE: These gauges may be removed and Reciprocating Compressor

reinstalled without additional purging so long as (R-134a Refrigeration System)
a slight positive pressure remains in the manifold Procedure Repair/Service Action
and hoses when removed from the unit.
Reclaim Open the high side of the
Refrigerant refrigeration system.
Gauge Manifold Set Removal Low Side Open the low side of the
NOTE: To ensure minimum refrigerant release Pump Down refrigeration system.
to the atmosphere, THE SYSTEM SHOULD BE
RUNNING. However, this is not possible in all
cases, but the same procedure should be
Typical R-23 and R-134a
followed. System Suction and Discharge
Pressure Readings
1. Rotate discharge hose fitting hand wheel
counterclockwise to withdraw the fitting stem Test Procedure
from the discharge line port valve. Then open
both service manifold valves to center port. 1. Operate unit in COOL for 10 minutes or more.
2. Close the receiver tank outlet valve and pump 2. Maintain discharge pressure (shown in table
down the low side. Then turn the unit OFF. below) for a 80-100 F (27-38 C) ambient
temperature by covering the condenser coil.
91
3. Compare unit suction pressure with R-134a Refrigeration System —

approximate expected reading (shown in table Cool Operation
below).
Container Ambient Suction Discharge
4.Temp.
A cool, moist
Temp.line is normal. A frosted
Pressure or
Pressure
abnormally0 to
Standby
dry38line
C
and out-of-range
—
pressures
—
indicate
(Unit a (32
OFF, problem
to 100in
F)the refrigeration system.
Empty box)
NOTE: Control condenser air flow to maintain
Cooling: temperature
condenser 27 to 38 C (R-134a
60-90 System)
kPa 1500-1800
near a
-30 C (80 to 100 F) 0.6-0.9
27-38oC (80-100oF) ambient while barreading
kPa
(-22 F) 9-13 psig 15.0-18.0
discharge and suction pressures. bar
218-261
NOTE: With empty box and all components in R23
system always verify correct charge in R23psig
system
according
Cooling: to 27
pressure
to 38 Creadings
20-50listed
kPa below
1380-1500
-60 C (80 to 100 F) 0.2-0.5 bar kPa
R-23
(-76 F)Refrigeration System
3-7 psig — Standby
13.80-15.0
(Unit OFF) and Cool Operation bar
200-218 psig
Container Ambient Suction Discharge

“= Inches of Hg Vacuum
Temp. Temp. Pressure Pressure
Standby 0 C (32 F) 1600 kPa 1600 kPa
(Unit OFF, 16.0 bar 16.0 bar Discharge Pressure Regulator Test
Empty 232 psig 232 psig and Adjustment
box)
Regulators are preset at the factory and adjustment
20 C (68 F) 1700 kPa 1700 kPa should not be required. If adjustment is necessary, use
17.0 bar 17.0 bar the following procedure:
247 psig 247 psig
38 C (100 F) 1800 kPa 1800 kPa Install a calibrated gauge manifold on the
18.0 bar 18.0 bar discharge service fitting downstream of the
261 psig 261 psig pressure regulator.
Cooling: 250 - 280 2100 - Operate in Cool for 10 minutes.
-30 C (- kPa 2300 kPa
22 F)
2.5-2.8 bar
21 - 23 bar Read the valve setting on the gauge manifold. The
305 - 334 correct setting is 280 kPa (2.8 bar; 41 psi).
36 - 41 psig
psig
Remove the protective cap. Use a hex key to turn
Cooling: 900 - 1100 1400 -
-60 C (- kPa 1600 kPa adjustment screw in to increase or reduce the setting as
76 F) 14 - 16 bar necessary to achieve the correct setting.
.9 - 1.1 bar
13 - 16 psig 203 - 232
psig
92
1
Checking the Compressor Oil Level
2
3 Operate the unit on full COOL. After 15 minutes,
4 observe the compressor oil level. The oil level
should be 1/2 to 3/4 full in the sight glass of both
5 compressors.
6
Adding Compressor Oil
7 1. Install gauge manifold set (refer to “Gauge
8 Manifold Set Attachment and Purging”).
2. Do one of the following:
1. Protective cap a. R-134a Compressor: Pump the compressor
2. Adjustment down (refer to “Low Side Pump Down”).
3. Spring b. R-23 Compressor: Do NOT pump down a
4. Bellows scroll compressor. Proceed to step 4 to add
5. Inlet oil to a scroll compressor.
6. Fitting for checking upstream
pressure (some models)
7. Seat
8. Outlet
Figure 33: Discharge Pressure Regulator
Checking Compressor Oil

CAUTION:
· Use ONLY Polyol Ester based

refrigeration compressor oil, P/N 203-433.
· DO NOT mix Polyol Ester based
and standard synthetic compressor oils.
· Rubber gloves are recommended
when
handling Ester based compressor oil. 1. Normal R-134a and R-23 compressor oil
level: Sight glass is 1/4 to 3/4 full.
· Keep Polyol Ester based
compressor oil in tightly sealed containers. Figure 34: Checking Compressor Oil Level
If Ester based oil becomes contaminated
with moisture or standard oils, dispose of 3. After stopping the compressor, adjust the low
properly — DO NOT USE! side pressure to 21 kPa, 0.21 bar, 3 psig using
The compressor oil should be checked during the service gauge set. (Pressure measured at
pretrip inspections and when there is evidence of the suction line service port.)
oil loss (oil leaks) or when components in the 4. Remove the cap from oil pressure fitting on
refrigeration system have been removed for compressor.
service or replacement.
93
5. Using a commercial hand pump, force oil in Refrigerant Leak Test

through the oil pressure fitting. Slowly add oil Procedure
and allow 5 to 10 minutes for the oil to flow
down through the compressor into the sump. Use a reliable Halogen leak detector such as
Add Polyol Ester oil, P/N 203-433 ONLY! model H10G, P/N 204-712 or 204-756 (portable),
to leak test the refrigeration system. Inspect
6. When the compressor oil sight glass is 1/2 to carefully for signs of compressor oil leakage
3/4 full, remove hand pump and replace the which is the first sign of a leak in the refrigeration
cap on the oil pressure fitting. system.
7. R-134a Compressor: Open the compressor NOTE: Due to environmental concerns and
suction service valve (or liquid line service personal safety, the use of a Halide torch is
valve) and operate the unit. Recheck the no longer recommended.
refrigerant charge level and the oil level before
returning the unit to service. If refrigerant has leaked or been removed from
the R-134a or R-23 refrigeration system:
Removing Excess Compressor Oil 1. Check entire system for possible component
1. Install an access valve actuator on the oil damage and refrigerant oil loss.
pressure fitting. 2. Attach gauge manifold set (refer to “Gauge
2. Operate the unit and remove oil while Manifold Set Attachment and Purging” for
watching the level in the compressor sight proper procedures).
glass. 3. Attach refrigerant bottle charging hose to
NOTE: Heavy foaming of the oil as it leaves the center of gauge manifold and purge charging
compressor may indicate an excess of refrigerant hose of air.
in the oil. Remove the access valve actuator and 4. Pressurize the system with refrigerant (GAS
operate the system for 15 minutes to ensure warm ONLY) until 345 kPa, 3.45 bar, 50 psig vapor
sump. Then recheck the oil level. pressure is achieved.
3. When the compressor oil sight glass is 1/2 to 5. Leak check the system with an electronic leak
3/4 full, remove access valve and replace the detector to inspect all joints and connections.
cap on the oil pressure fitting. (Use soap solution as an alternative test
4. Operate the unit and recheck the refrigerant component.)
charge level and the oil level before returning
the unit to service. If no leaks are found but the system has lost its
refrigerant charge, proceed to the next step.
6. Close both hand valves on gauge manifold
(front seated).
7. Disconnect the refrigerant charging hose.
1. Add and Remove Compressor Oil at the

Compressor Oil Fitting
Figure 35: Adjusting Compressor Oil Level
94
2. Set the controller setpoint temperature well

below the return air temperature and operate
the unit in the Cool mode until the temperature
stabilizes (at least 5 minutes).
0. Close the receiver tank outlet valve. Allow the
unit to operate until it reaches -15 to -40 kPa,
-0.15 to -0.40 bar, 5 to 11 in. vacuum on the
suction pressure gauge (3-5 minutes). Then
shut the unit down manually with the On/Off
switch.
CAUTION: Never open the low side to the

atmosphere while it is in a vacuum. Air
and moisture will be drawn in and
contaminate the refrigerant system.
Figure 36: Testing for Refrigerant Leaks
3. To place the unit back in service, open the
8. Connect the charging hose to a source of receiver tank outlet valve and turn the On/Off
nitrogen. Adjust the pressure regulator to 1380 switch ON.
kPa, 13.80 bar, 200 psig. See “Using
Pressurized Nitrogen” in this manual chapter.
Refrigerant Charge Inspection
CAUTION: Nitrogen (N2) is under The refrigerant charge should be checked during
15,170 kPa, 151.70 bar, 2200 psig pressure pretrip and routine maintenance inspections. A
in a full cylinder at 21 C (70 F). DO NOT low charge of refrigerant will cause the container
use oxygen, acetylene or any other type of temperature to rise due to the lack of liquid
pressurized gas in the system. refrigerant at the expansion valve even though the
unit is operating in a cooling mode. If the unit is
9. Pressurize the system with nitrogen to 1380
low on R-134a charge, inspect the unit for
kPa, 13.80 bar, 200 psig.
refrigerant leaks with a reliable leak detector.
0. Close the supply valve on the nitrogen bottle.
· R-134a Refrigeration System Charge: 3.5 Kg
0. Use an electronic leak tester to inspect all (7.7 lb)
joints and connections. (Use a soap solution
· R-23 Refrigeration System Charge: 3.2 Kg
as an alternative test component.)
(7.05 lb)
NOTE: If a system leak is indicated, loosen
NOTE: See “Receiver Tank Sight Glass” under
supply line hose fittings to release pressure.
Unit Instruments in the Operating Instructions
Repair leakage condition.
chapter for information about checking the
1. If system repair is necessary, recheck system moisture indicator in the sight glass.
after repairs are completed.
Checking the R-134a Refrigerant
Low Side Pump Down (R-134a Charge
Compressor Only) 1. Inspect the receiver tank sight glass with the
unit operating in COOL. If the balls FLOAT in
NOTE: Do NOT pump down a scroll
the receiver tank sight glass, the R-134a charge
compressor. Reclaim the refrigerant when
level is correct.
servicing the low side or high side of the R-23
refrigeration system.
1. Install the gauge manifold on the compressor.
95
2. If the balls are NOT FLOATING in the sight been operated within the past 30 minutes and
glass, the unit MAY be low on R-134a charge. there must not be frost on the plate-type R-134a /
Operate the unit on COOL for 5 minutes. If the R-23 heat exchanger tubing.
balls float in the receiver tank sight glass, the
Observe both the suction and discharge pressures.
R-134a charge level is correct.
With the unit OFF, the suction and discharge
3. If the balls do NOT FLOAT in the receiver readings should be equal. The R-23 refrigerant
tank sight glass after operating the unit on pressure in a fully charged system with the unit
COOL for 5 minutes, the unit is low on R- OFF will vary with the ambient temperature:
134a charge. With the unit operating on
COOL, add liquid R-134a until the balls Ambient Temperature R-23 System Pressure
FLOAT in the sight glass. O C (32 F) 1600 kPa, 16 bar, 232 psig
20 C (68 F) 1700 kPa, 17 bar, 247 psig
CAUTION: When adding R-134a to the 38 C (100 F) 1800 kPa, 18 bar, 261 psig
unit, STOP adding refrigerant when the
balls float near the TOP of the sight glass.
Continuing to add refrigerant after the
balls float at the top of the sight glass will
OVERCHARGE the unit. If necessary,
recover refrigerant until the balls no
longer float at the top of the sight glass.
1. The bottom sight glass ball will rarely float

on a fully charged system during normal
operation.
· Check the refrigerant charge based
on the R-23 system pressure with the
1. Refrigerant charge is OK if the ball floats container empty, the unit OFF and all
at any time: refrigeration system components above
· If the ball does NOT float, the R-134a NOTE: Use the lower sight glass to check
refrigeration system is unit is low on or add refrigerant only on a operating
refrigerant
unit that is unable to maintain a -55 C to
Figure 37: R-134a Refrigeration System -65 C (-62 F to -76 F) low temperature.
Receiver Tank
Figure 38: R-23 Refrigeration System
Receiver Tank
Checking the R-23 Refrigerant
Charge · Correct Refrigerant Charge: If the R-23
The R-23 refrigerant charge should be checked system pressure stabilizes between 1500 and
with the container empty, the unit OFF and all 2000 kPa, 15 and 20 bar, 220 and 290 psig,
refrigeration system components above -5 C (23 the unit will be fully functional. The R-23
F). The R-134a compressor must not have refrigerant charge requires no adjustment.
96
• Low Refrigerant Charge: If the R-23 system R-23 Recovery for System Repair
pressure stabilizes between 1000 and 1500 Because R-23 has high working pressures, it must
kPa, 10 and 15 bar, 145 and 220 psig, the unit be recovered from the refrigeration circuit before
cooling capacity will be reduced but the unit any component, except the compressor, suction
should be able to maintain a -55 C to -60 C (-
pressure gauge and discharge pressure gauge, can
62 F to -76 F) load temperature. Additional R-
be repaired or replaced. Also, because of the high
23 should be added if possible, but do NOT
pressure in R-23 refrigerant bottles, the recovery
add by operating the unit.
of R-23 for re-use in the unit requires an empty
· Over Charge of Refrigerant: If the R-23 refrigerant bottle at least 40 liters (42 quarts) in
system pressure stabilizes above 2000 kPa, 20 volume. The refrigerant bottle must be clean or
bar, 290 psig, the R-23 system is overcharged dedicated to use with HFC refrigerants only.
and may cause the compressor to stop on high
NOTE: Due to extremely high pressure in
pressure cutout when started to precool a
normal ambient R23 cannot be reclaimed by use
warm container. Remove refrigerant until the
of reclaim station.
system pressure stabilizes at 2000 kPa, 20 bar,
290 psig or below. 1. Prepare an empty refrigerant bottle at lease 40
liters (42 quarts) in volume. Evacuate bottle if
NOTE: Use the lower receiver tank sight glass to
necessary to ensure it is clean.
check or add refrigerant only on an operating
unit that is unable to maintain a -55 C to -60 C (- 2. Connect a refrigerant hose from the bottle to
62 F to -76 F) load temperature. See “R-23 the R-23 compressor discharge service valve.
Charging Procedure for Partially Charged Units
3. Midseat the discharge service valve. Then open
on Loaded Containers” on page 105.
the service valve on the bottle. Wait for 5-10
minutes to allow the pressures to equalize
Refrigerant Recovery between the refrigeration system and the
bottle. This will remove approximately 1/2 of
CAUTION: Use only refrigerant recovery the refrigerant charge from the unit.
equipment approved for and dedicated to
4. Start the unit and use the Manual Test function
HFC refrigerants.
submenu of the controller to start and operate
When removing any refrigerant from a Thermo the R-23 compressor only for approximately 2
King refrigeration system, use a recovery process minutes. This will quickly transfer most of the
that prevents or absolutely minimizes the remaining R-23 refrigerant charge to the
refrigerant that can escape to the atmosphere. bottle.
Typical service procedures that require removal of
refrigerant from the unit include: CAUTION: Do not allow the compressor
· To reduce the refrigerant pressure to a safe suction pressure to decrease below 100
working level when maintenance must be kPa, 1.00 bar, 15 psig.
performed on high-pressure side components. WARNING: Do not allow the pressure of
· To empty a system of refrigerant when an the bottle to exceed 2500 kPa, 25 bar, 362
unknown amount of charge is in the system psig.
and a proper charge is required. 5. After approximately 2 minutes of R-23
· To empty a system of contaminated refrigerant compressor operation, slowly close the
when the system has become contaminated. compressor suction service valve. When the
compressor suction pressure decreases below
NOTE: Always refer to specific recovery
100 kPa, 1.00 bar, 15 psig, stop the R-23
equipment Operator and Service Manuals.
compressor and turn the unit OFF.
6. Close the service valve on the R-23 recovery
bottle.
97
7. Backseat the discharge service valve. Evacuation and Cleanup of the

Disconnect the refrigerant hose from the Refrigeration System
discharge valve.
8. With system pressures below 100 kPa, 1.00 Contamination
bar, 15 psig, the R-23 system components can Whenever contaminants have entered the system,
be serviced. a thorough clean up is required to prevent damage
If necessary, set a recovery machine for vapor or loss of compressor.
recovery. Connect the recovery machine to a It is well known by the refrigeration service
separate, empty recovery bottle. Keep unit OFF industry that the purpose of evacuation is to
and mid-seat the discharge service valve. Turn remove moisture and air from the refrigeration
ON the recovery machine and open the service system before charging with new refrigerant after
valve on the recovery machine. Operate the a system has been opened. The importance of
recovery machine until system pressures drop to thorough evacuation and system preparation
0 kPa, 0 bar, 0 psig pressure. cannot be over emphasized. Even infinitesimal
quantities of air or moisture in a system can cause
R-134a Vapor Recovery severe problems.
1. Install a gauge manifold set on the R-134a We know that the presence of moisture, oxygen,
refrigeration system. Attach the service line to and heat under certain conditions can result in
the recovery machine and properly purge the many forms of damage. Corrosion, sludge, copper
lines. Set the recovery machine for vapor plating, oil breakdown, carbon formation, and
recovery. eventual compressor failure can be caused by
2. Keep unit OFF and mid-seat the discharge these contaminants.
service valve. Things that will contaminate a system are (in
3. Turn ON the recovery machine and open order of importance):
(back seat) both gauge manifold and hand · AIR — with oxygen as a contaminant. Oxygen
valves. in the air reacts with the oil. The oil begins to
4. Continue to operate the recovery machine break down and can eventually lead to
until system pressures drop to 0 kPa, 0 bar, 0 carbonization in the compressor and acid
psig pressure. buildup. The longer this breakdown process
goes on, the darker the compressor oil becomes
R-134a Liquid Recovery until finally the color is BLACK indicating
major system contamination.
1. Install a gauge manifold’s low-pressure line to
the Schrader suction service valve on the · MOISTURE. Moisture in a system will cause
suction service valve of the R-134a metal corrosion and metal plating. It can freeze
compressor. Attach the manifold’s high- in the expansion valve and cause intermittent
pressure line to R-134a receiver tank service operational problems. It reacts in the oil to
valve port. Attach the service line to the begin acid buildup.
recovery machine and purge the lines. · DIRT, DUST, METAL PARTICLES, OTHER
2. Set recovery machine for liquid recovery and FOREIGN MATERIALS. Particles of any kind
turn it ON. left to float through the system will cause
severe damage to all close tolerance items. Do
3. Open (back seat) high-pressure valve on not leave a system open to the infiltration of
gauge manifold. dirt. If you must open a system for any reason,
4. Operate the recovery machine until the unit seal off the open areas as soon as possible and
system pressures reach approximately 0 kPa, DO NOT work in a dirty environment.
0 bar, 0 psig.
98
• ACID. Air and moisture cause a chemical If a vacuum pump (isolated from a system) is
breakdown of the oil and/or the refrigerant started and the Micron Meter responds quickly
itself. The acid will accelerate the by going to a deep vacuum, the operator can
deterioration of the softer metals (i.e., copper) be confident that the pump and oil are in good
and cause metal plating as the softer material condition. If the vacuum pump fails to reach a
begins to cover the inside of the system. If this deep vacuum within 5 minutes, the operator
condition is not stopped, it can result in the should suspect the condition of the oil or the
total destruction of your equipment. pump. It is recommended that the pump oil be
changed first to see if the rate of reaching a
Compressor Oil Color Code deep vacuum is improved.
BLACK OIL — indicates carbonization caused 0. Connect the Evacuation Station and
by air in the system. refrigerant tank with gauge manifold
(optional) to the unit. Connect evacuation
BROWN OIL — indicates copper plating caused
hoses to the compressor suction and discharge
by moisture in the system.
service lines and the receiver tank outlet
GRAY OR METALLIC OIL — indicates bearing valve.
wear or piston scoring.
1. Mid-seat the receiver tank outlet valve.
NOTE: If the compressor oil is discolored,
2. Replace valve stem cap on the receiver tank
perform a compressor oil acid test (oil test kit
outlet valve.
P/N 203-457). If the compressor oil shows an
acid condition, change the oil, the in-line oil 3. Open Evacuation Station valves (V1, V3, and
filter, the filter drier and perform a refrigeration V4). It is only necessary to open valve V2
system cleanup. when a reading on the Micron Meter is
desired. This is especially true when starting to
Refrigeration System Preparation evacuate a unit and large amounts of moisture
and Hookup and oil will be passing by the sensor.
4. Open the vacuum pump Iso-ValveTM built
CAUTION: Do not attempt to evacuate a into the pump housing below the handle. It is
refrigeration system until it is certain that recommended that the valve be kept open at
the system is leak free. A system with less all times.
than a full charge of refrigerant should be
thoroughly leak tested. Any leaks found 5. If connecting a refrigerant tank and gauge
must be repaired. manifold to the evacuation station, close the
gauge manifold and refrigerant tank valves to
1. Recover all refrigerant from the system and prevent refrigerant from being drawn from the
reduce the unit pressure to the proper level tank.
(US Federal Law requires a -17 to -34 kPa,
-0.17 to -0.34 bar, 5 to 10 in.vacuum that is Unit Evacuation
dependent upon the recovery equipment
used). 1. Turn on the Vacuum Pump. Open the Gas
Ballast Valve located on top of the pump
2. Break vacuum with refrigerant and equalize housing behind the handle (the valve is fully
system pressure to 0 kPa, 0 bar, 0 psig. open at two turns counterclockwise). Evacuate
Replace the liquid line filter drier. the system to 500 microns to achieve a final
3. Confirm that the Evacuation Station functions equilibrium pressure of 2000 microns or less.
properly and determine “Blank Off” Pressure. The final equilibrium pressure is determined
The Blank Off Pressure of the Vacuum Pump with the Thermo King Evacuation Station
is the deepest vacuum that the vacuum pump using the following procedure (called a
can attain when isolated from the rest of the pressure-rise test):
system.
99
a. Evacuate the system using the Evacuation 5. If the vacuum level remained below 2000
Station until the vacuum level reaches microns for five minutes, the unit is ready to
1000 microns. Then close the Gas Ballast charge.
Valve.
b. Continue evacuation to 500 microns or until Pressure Rise Test
vacuum stabilizes at its lowest level. Evacuate the system and close valve V1. With
Contamination may delay reaching the valves V3 and V4 open, the pump is isolated and
lowest level for a period of several or more the system is held under a vacuum. If the Micron
hours. Meter rises, one of the following conditions exist.
c. Close valve V1 to isolate the vacuum pump Leak: Watch the movement of the Micron Meter
from the system. needle. If the needle continues to rise until it
reaches atmospheric pressure, it is an indication
d. Observe the vacuum level on the Micron that a leak exists somewhere in the system. When
Meter. a leak is in a system, the vacuum will eventually
When the Meter has stabilized, the value indicated stabilize at atmospheric pressure.
on the Micron Meter is the equilibrium pressure. Moisture: When the needle indicates a rise and
This reading must be 2000 microns or less. then stabilizes at a level below atmospheric
NOTE: The presence of refrigerant in the pressure, it is an indication that the system is
compressor oil may prevent a low vacuum vacuum tight, but is still wet and requires
reading from being achieved. Compressor oil additional dehydration and pumping time (see
can continue to outgas for long periods of time. “Pressure Rise Test Evaluation” below).
2. If the vacuum level appears to stall above 500 Factors Affecting the Speed of
microns, back seat the discharge service valve System Evacuation
and observe the Micron Meter.
It is almost impossible to state the exact amount
· A drop in pressure indicates that the of time required to evacuate any system. Some
compressor oil is out-gassing and further factors that can influence evacuation time are
evacuation is necessary. listed below.
· An increase in pressure indicates that a leak · System size
exists or there is moisture in the system.
Perform a “Pressure Rise Test” and · Amount of moisture contained in the system
evaluate. · Ambient temperature
3. Close valve V1 when the desired vacuum level · Internal restrictions within the system
has been reached.
· External restrictions between the system and
4. Wait five minutes and read the Micron Meter. the vacuum pump
· A system that is leak free and dry will
remain below 2000 microns for five
minutes.
· A system that rises above 2000 microns but
stabilizes below atmospheric pressure is
probably contaminated with moisture or
has refrigerant out-gassing from the
compressor oil. Additional evacuation is
required.
· A system that continues to rise without
stabilizing has a leak and must be repaired.
100
Hose size, both diameter and length, affect evacuation times.

Laboratory tests show that the evacuation time can be
significantly reduced by larger diameter hoses and shorter hoses. To
obtain optimum pumping speed, keep hoses as short as possible and as
large in diameter as possible. For example, it takes eight times as long
to pull a given vacuum through a 1/4 inch diameter hose as it does
through a 1/2 inch diameter hose. It takes twice as long to pull a vacuum
through a 6 foot long hose as it does through a 3 foot long hose.
1. Close the vacuum valve and watch the

movement of vacuum gauge needle. If
needle shows a pressure rise but finally
1. Close the vacuum valve and watch the levels off to a constant pressure, the system
movement of vacuum gauge needle. If needle still contains too much moisture.
continues to rise, this is an indication that a Dehydration and additional evacuation time
leak exists in the unit or connecting line. The are required.
leak must then be located and eliminated.
2. Time
2. Time
3. Pressure (Vacuum)
3. Pressure (Vacuum)
4. Atmospheric Pressure
4. Atmospheric Pressure
Figure 40: Pressure Rise Levels Off After
Figure 39: Constant Pressure Rise After Evacuation Indicates Moisture in System
Evacuation Indicates System Leak
Heat Saves Time
A useful and practical time saver is the
application of heat to the system. Increasing the
temperature of the compressor oil and refrigerant
will speed up the vaporization of any water
present in the system.
WARNING: Never use a torch or other

concentrated heat source to heat the
compressor or other refrigeration system
component.
Heat lamps, electric heaters, or fans can be
applied to the compressor crankcase and other
parts of the system to increase the temperature of
the refrigerant and compressor oil.
101
R-134a Refrigeration System R-134a Evacuation Station Removal

Charging 1. Make sure the discharge service valve is back
seated.
Charging R-134a System with
Liquid Refrigerant by Weight (from 2. Make sure the refrigerant tank hand valve is
an Evacuated Condition) closed.
NOTE: When both the R-134a and R-23 systems 3. Operate the unit in cool mode.
require charging, charge the R-23 system first.
CAUTION: Do NOT operate the unit on

1. Close valve V4. cooling unless:
2. Open the Gas Ballast valve (located on top of
the pump housing behind the handle). · R-23 refrigeration system contains a FULL
charge of refrigerant.
3. Stop the vacuum pump.
· R-134a refrigeration system contains a
4. The discharge valve remains mid-seated. partial charge of refrigerant.
5. Connect the refrigerant tank with gauge 4. Open the hand valve at the gauge manifold
manifold to the evacuation station (see and read suction pressure.
“Evacuation Station and Unit Hookup” in this
chapter). 5. Front seat the suction service valve and pump
down the system to 21 to 35 kPa, 0.21 to 0.35
CAUTION: Be sure to add the correct bar, 3 to 5 psig.
refrigerant to the system. 6. Back seat the suction service valve.
6. Weigh the tank of refrigerant. 7. Remove the hoses from the receiver tank
service fitting and discharge service valve.
7. Check the unit data plate for the required
weight of refrigerant charge then subtract the 8. Cap the both service ports and the discharge
amount of the charge to be input to your unit service valve stem.
from the total weight of the tank of refrigerant.
This provides final tank weight after the unit R-134a Final Charging Procedure
receives a full system refrigerant charge. for Partially Charged Units
8. Set the refrigerant tank for liquid. Open the NOTE: Final charge the R-23 system first when
hand valve on the tank. both the R-134a and R-23 systems require
charging.
9. With the unit OFF, open the gauge manifold
hand valve and charge liquid refrigerant into 1. Connect the gauge manifold to the suction line
the system. and discharge line service ports. Be sure to
purge the air from the lines (see “Gauge
10. Close the refrigerant tank hand valve Manifold Set Attachment and Purging” in the
when the correct amount (by weight) of Refrigeration Maintenance chapter of this
refrigerant has been added or if the system will manual).
take no more liquid.
2. Back seat and crack the discharge service
11. Back seat the discharge service valve. valve.
The unit is now ready to have the Evacuation 3. Connect a refrigerant tank to the gauge
Station removed. See R-134a final charging manifold service line.
procedure for partially charged units to complete
charging procedure. CAUTION: Be sure to add the correct
refrigerant to the system.
102
4. Set the R-134a refrigerant tank for liquid 5. Connect a refrigerant hose from the refrigerant
charging. Open the refrigerant tank hand valve. tank to the service fitting on the receiver tank
(see “Evacuation Station and Unit Hookup” in
5. Start and operate the unit in the COOL mode.
this chapter).
CAUTION: Do NOT operate the unit on
CAUTION: Be sure to add the correct
cooling unless:
refrigerant to the system.
· R-23 refrigeration system
contains a FULL charge of refrigerant. 0. Weigh the tank of refrigerant.
· R-134a refrigeration system 1. Check the unit data plate for the required
contains a partial charge of refrigerant. weight of refrigerant charge then subtract the
amount of the charge to be input to your unit
6. Read the suction pressure and from the total weight of the tank of refrigerant.
slowly open the gauge manifold low pressure This provides final tank weight after the unit
hand valve to permit suction pressure to receives a full system refrigerant charge.
increase approximately 170 kPa, 1.7 bar, 25
psig. This will meter liquid refrigerant slowly NOTE: If a scale is not available, the R-23
into the low side. system can be accurately charged by pressure.
Add refrigerant to the receiver tank until the
7. Add R-134a refrigerant until the receiver tank unit suction and discharge pressure gauges
balls float at the top of the sight glass. indicate 1700 kPa, 17 bar, 247 psig.
8. Close the hand valve on the refrigerant tank. 2. Set the refrigerant tank for liquid. Open the
9. Operate the unit on COOL for 10 minutes and hand valve on the tank.
recheck refrigerant charge. 3. With the unit OFF, open the refrigerant tank
10. Remove the gauge manifold set. hand valve and charge liquid refrigerant into
the system.
11. Cap all service ports and valve stems.
4. Close the refrigerant tank hand valve when the
CAUTION: Be sure to return the correct amount (by weight) of refrigerant has
controller to the setpoint indicated on the been added or if the system will take no more
shipping manifest. liquid.
The unit is now ready to have the Evacuation
R-23 Refrigeration System Station removed. See R-23 final charging
procedure for partially charged units to complete
Charging
charging procedure.
Charging R-23 System with Liquid Refrigerant by
Weight (from an Evacuated Condition) R-23 Evacuation Station Removal
NOTE: When both the R-134a and R-23 systems 1. Make sure the discharge service valve is back
require charging, charge the R-23 system first. seated.
1. Close valve V4. 2. Make sure the refrigerant tank hand valve is
2. Open the Gas Ballast valve (located on top of closed.
the pump housing behind the handle). 3. Operate the unit in cool mode.
3. Stop the vacuum pump.
4. The discharge valve remains mid-seated.
103
CAUTION: Do NOT operate the unit b. The recovery bottle pressure (suction
on cooling unless: pressure) decreases to 300 kPa, 3 bar,
44 psig.
· R-23 refrigeration system contains a
FULL charge of refrigerant. 0. Close the refrigerant tank hand valve.
· R-134a refrigeration system contains 1. Back seat the suction service valve. Then stop
a partial charge of refrigerant. the compressor.
4. Front seat the suction service valve and pump 2. Remove the hoses from the receiver outlet and
down the system below 100 kPa, 1.00 bar, 15 discharge service valves. Cap the receiver
psig. outlet service port.
5. Back seat the suction service valve. 3. Wait for the plate-type R-134a / R-23 system
heat exchanger to warm above 0 C (32 F). This
6. Remove the hoses from the receiver tank and can take up to 30 minutes.
discharge valve service fittings.
See R-23 final charging procedure for partially
7. Cap all service ports and valve stems. charged units for empty or loaded containers to
complete charging procedure.
Charging R-23 System with Gas
Refrigerant Recovered in 40 Liter R-23 Final Charging Procedure for
(42 qt.) Refrigerant Bottle (from Partially Charged Units on Empty
an Evacuated Condition) Containers
1. Close valve V4. NOTE: The R-23 refrigerant should be charged
2. Open the Gas Ballast valve (located on top of with the container empty, the unit OFF and all
the pump housing behind the handle). refrigeration system components above -5 C (23
F). The R-134a compressor must not have been
3. Stop the vacuum pump. operated within the past 30 minutes and there
4. Back seat the discharge service valve. must not be frost on the plate-type R-134a / R-23
heat exchanger tubing.
5. Connect a refrigerant hose to the refrigerant
tank and the service fitting on the suction 1. Before attempting to add R23 refrigerant with
service valve. loaded container check for good cooling
capacity by verifying if Suction discharge
6. Midseat the suction service valve. pressure is in line with specification.
7. Open the hand valve on the 40 liter (42 qt.) 2. Connect a refrigerant hose to a R-23
recovery bottle containing R-23 gas.
refrigerant tank.
8. Wait 2 minutes while the gas pressure 3. Connect the refrigerant hose to the suction line
equalizes between the unit and the recovery
service port. Be sure to purge the air from the
bottle of R23 gas.
refrigerant hose.
9. Use the Manual Function Test menu of the 4. Mid-seat the suction service valve.
controller to start the R-23 compressor ONLY.
Operate the R-23 compressor until either: 5. Set the R-23 refrigerant tank for gas charging.
Open the refrigerant tank hand valve.
a. The discharge pressure gauge indicates
approximately 2800 kPa, 28 bar, 400 psig. 6. Observe both the suction and discharge
This method completes the charging pressures on the unit gauges. When the unit
procedure faster by lowering the pressure reaches 1700 kPa, 17 bar, 247 psig,
refrigerant pressure in the buffer tanks; or close the hand valve on the refrigerant tank.
With the unit OFF, the suction and discharge
readings should be equal.
104
The R-23 refrigerant pressure in the unit Using Pressurized Nitrogen

during charging with the unit OFF will vary
with the ambient temperature: The improper use of high pressure cylinders can
cause physical damage to components, or
Ambient Temperature R-23 System Pressure personal injury, or cause stress that would lead to
O C (32 F) 1600 kPa, 16 bar, 232 psig
failure of components.
20 C (68 F) 1700 kPa, 17 bar, 247 psig
Safety Precautions
38 C (100 F) 1800 kPa, 18 bar, 261 psig
Observe the proper handling of cylinders:
7. Remove the gauge manifold set. 1. Always keep protective cap on cylinder when
not in use.
8. Cap all service ports and valve stems.
2. Secure cylinder in proper storage area or
R-23 Charging Procedure for fastened to cart.
Partially Charged Units on Loaded 3. DO NOT expose to excessive heat or direct
Containers sun light.
NOTE: R-23 refrigerant should be added to an
4. DO NOT drop, dent, or damage cylinder.
operating unit on a loaded container only if the
unit is unable to maintain a -55 C to -60 C (-62 5. Use a pressure regulator and a safety pressure
F to -76 F) load temperature. The risk of relief valve as part of the pressure testing
overcharging the system with R-23 is too large. equipment. The safety pressure relief valve
should be of the non-adjustable, non-tempering
1. Connect a refrigerant hose to a R-23
type. The valve should bypass any time the
refrigerant tank.
pressure exceeds its setting.
2. Connect the refrigerant hose to the receiver
6. Open valve slowly; use regulators and safety
tank service fitting. Be sure to purge the air
valves that are in good working order.
from the hose.
7. The regulator should have two gauges; one to
3. Set the R-23 refrigerant tank for gas charging.
read tank pressure, the other to read line
Open the refrigerant tank hand valve.
pressure. Properly maintained equipment will
4. Observe the bottom receiver tank sight glass. allow leak testing, purging, or dehydration to
When refrigerant is visible in the bottom of be done safely.
the lower sight glass, close the hand valve on
the refrigerant tank. CAUTION: Nitrogen (N2) is under 15,170
kPa, 151.70 bar, 2200 psig, or greater.
CAUTION: Immediately stop adding Pressure is for full cylinder at 21 C (70 F).
refrigerant when refrigerant is visible in DO NOT use Oxygen (O2), acetylene or
the bottom of the lower sight glass. Under any other types of pressurized gas on
normal operating conditions, R-23 refrigeration systems or any component of
refrigerant will rarely be visible in the a system.
lower sight glass on a fully charged
system.
5. Remove the refrigerant hose from the receiver
tank
6. Cap the receiver tank service port.
7. Check and correct the refrigerant charge level
after the cargo has been unloaded and the unit
is OFF.
105
Dehydration, Pressure Testing, Purging and Soldering Procedure

Dehydration, pressure testing, purging and soldering
can be accomplished with the use of dry nitrogen (N2).
The proper equipment and application of equipment is 1. Line Pressure
of greatest importance.
2. Tank Pressure
1. Attach gauge manifold set (refer to “Gauge 3. Tank
Manifold Set Attachment and Purging” for proper
4. Pressure Test Line to System
procedure for connecting to compressor).
5. Safety Valve
2. Close both hand valves on the gauge manifold (front
6. Pressure Regulator
seated).
Figure 41: Typical Pressurized Gas Bottle with
3. Connect charging hose to a source of nitrogen. Pressure Regulator and Gauges
Adjust pressure regulator to the proper pressure for
the required procedure.
4. Purge system high side to low side.
The following procedures should utilize the following
MAXIMUM gas pressure:
· Leak Testing: 1030 to 1200 kPa, 10.3 to 12.0 bar,
150-175 psig,
· Purging/Dehydration: 70 to 140 kPa, 0.7 to 1.4 bar,
10-20 psig,
· Soldering: 35 kPa, 0.35 bar, 5 psig.
106
Compressor Replacement (R- NOTE: When the compressor is removed from

134a or R-23 Systems) the unit, oil level should be noted or the oil
removed from the compressor should be
Removal measured so that the same amount of oil can be
added before placing the new compressor or
1. Close the suction service valve and pump repaired compressor in the unit.
down the compressor:
· R-134a Compressor: Pump down the Installation
compressor to -35 kPa, -0.35 bar, 10 in. 1. Slide the compressor into the unit. Install
vacuum. mounting bolts, washers and nuts, and tighten.
· R-23 Compressor: Pump down the 2. Bolt the discharge valve to the compressor
compressor to 0 to 21 kPa, 0.0 to 0.2 bar, 0 with a new gasket lightly coated with
to 3 psig. compressor oil. Bolt the suction service valve
to the compressor using a new O-ring coated
CAUTION: Do NOT aiow the R-23 scroll with compressor oil.
compressor to operate for more than 10-
20 seconds. 3. Apply refrigerant locktite to the threads of the
high pressure cutout switch. Install the switch
2. Break the vacuum with nitrogen between 10 and connect the wire connectors.
and 20 kPa, 0.10 and 0.20 bar, 1 and 3 psig.
4. Connect three-phase electric power to the
NOTE: If the compressor does not operate, or compressor.
the compressor is unable to pump the low side
5. Pressurize the compressor with refrigerant gas:
down, the refrigerant charge must be reclaimed
before service can be performed on the · R-134 compressor with R-134a
refrigeration system. refrigerant.
3. Front seat the discharge valve. · R-23 compressor with R-23 refrigerant.
CAUTION: Any time the discharge valve CAUTION: Be sure to add the correct
is front seated, disconnect the unit power refrigerant to the compressor.
source to prevent accidental compressor
start-up. 6. Check for refrigerant leaks around the
compressor assembly and gasket connections.
4. Remove discharge service valve and suction
service valve from the compressor. 7. If no leaks are found, recover the refrigerant
used for the leak test (see “Refrigerant
5. Disconnect the wire connector for the high Recovery” in this chapter). Because this
pressure cutout switch. refrigerant gas will contain some air, place it in
6. Remove the three-phase electric power a contaminated refrigerant bottle to be
connection. reclaimed later.
7. Remove the compressor mounting tray bolts 8. After all pressure is removed from the
and nuts. compressor, connection the evacuation
equipment.
8. Slide the compressor from the unit.
9. Evacuate the compressor (see “Evacuation and
9. Keep the compressor ports covered to prevent Cleanup of the Refrigeration System” in this
dust, dirt, etc., from falling into the chapter).
compressor.
10. Back seat the discharge service valve and
open the suction service valve fully.
107
11. Operate the unit at least thirty minutes and 0. Then evacuate the system (see “Evacuation
then inspect the oil level in the compressor. and Cleanup of the Refrigeration System” in
Add or remove oil if necessary. this chapter).
0. Replace the condenser coil support brackets,
CAUTION: Do NOT operate the unit condenser fan shroud and condenser fan grille.
on cooling unless both the R-134a and
the R-23 refrigeration systems contain 1. Recharge the unit with R-134a or R23
a partial charge of refrigerant. refrigerant and check the compressor oil level.
Add oil if necessary.
12. Check the refrigerant charge and add
refrigerant if needed.
Dehydrator (Filter Drier)
Condenser Coil Replacement Replacement (R-134a or
(R-134a or R-23 Systems) R-23 Systems)
Removal
Removal
1. Recover the refrigerant charge from the unit
(do NOT vent refrigerant to the atmosphere). · R-134a System: Close the liquid line
service valve and pump down the low side.
2. Remove the condenser fan grille, condenser Open the outlet valve slightly to equalize
fan blade and condenser fan shroud. the pressure between 10 and 20 kPa, 0.10
3. Remove the condenser coil support brackets and 0.20 bar, 1 and 3 psig.
from the coil. · R-23 System: Recover the refrigerant
4. Unsolder the coil inlet and liquid line charge from the unit (do NOT vent
connections. refrigerant to the atmosphere).
5. Support the coil and unbolt the condenser coil 2. Place the new dehydrator near the unit for
mounting brackets. Slide the coil from the immediate installation.
unit.
3. Remove the filter bracket clamping nuts and
bolts.
Installation
1. Clean the tubes for soldering.
· R-134a System: Using two wrenches,
2. Slide the coil into the unit and install the bolts “crack” both filter drier line mountings.
in the mounting brackets. Use two wrenches on flare fittings to
3. Solder the inlet line and liquid line prevent line damage. Separate the
connections. dehydrator line mountings.
NOTE: It is strongly recommended that dry · R-23 System: Unsolder filter drier from
nitrogen be used to purge the system during any liquid line.
solder operations (see “Using Pressurized NOTE: Perform the foiowing four procedures
Nitrogen” in this chapter). as quickly as possible to prevent contamination.
4. Pressurize the system and test for leaks (see 5. Remove the old dehydrator from the line.
“Refrigerant Leak Test Procedure” in this
chapter).
5. If no leaks are found, recover the leak test gas
(see “Refrigerant Recovery” in this chapter).
108
Installation b. If no leaks are found, recover the leak test

gas (see “Refrigerant Recovery” in this
1. Remove the sealing caps from the new
chapter).
dehydrator.
0. Then evacuate the system (see “Evacuation
and Cleanup of the Refrigeration System”
· R-134a System: Apply clean compressor in this chapter).
oil to dehydrator threads. Assemble new
c. Recharge the unit with R-23 refrigerant
dehydrator to lines. Finger tighten
and check the compressor oil level. Add oil
mounting nuts.
if necessary.
· R-23 System: Clean tubes for soldering.
Position filter drier in liquid line. Solder Expansion Valve Replacement
filter drier in liquid line.
(R-134a or R-23 Systems)
NOTE: To prevent incorrect installation of the
dehydrator, the inlet and outlet fittings are Removal
different sizes.
3. Reinstall dehydrator clamping brackets, nut · R-134a System: Close the liquid line
and bolts. Tighten the bolts.
service valve and pump down the low side.
4. Do one of the following: Open the outlet valve slightly to equalize
the pressure between 10 and 20 kPa, 0.10
· R-134a System:
and 0.20 bar, 1 and 3 psig.
a. Tighten the dehydrator inlet line mounting · R-23 System: Recover the refrigerant
nut. Open the liquid line service valve on
charge from the unit (do NOT vent
the inlet side of the dehydrator slowly to
refrigerant to the atmosphere).
release a small amount of refrigerant from
the receiver tank to purge the air through 2. Remove insulating tape and encamp feeler
the filter. Then tighten the outlet nut. bulb from the suction line. Note the position of
the feeler bulb on the side of the suction line.
NOTE: R-134a — When removing or
replacing the o-ring nuts on the dehydrator, 3. Remove insulating tape from expansion valve
always hold the body of the dehydrator near outlet line.
the flange fittings to prevent twisting the
4. Heat and unsolder the equalizer line from
tubing when the nuts are being loosened or
expansion valve.
tightened.
5. Heat and unsolder the liquid line inlet and
b. Back seat (open) the liquid line service outlet connections to expansion valve.
valve on the inlet side of the dehydrator.
6. Remove expansion valve from unit.
c. Test the dehydrator for leaks (see
“Refrigerant Leak Test Procedure” in this Installation
chapter).
1. Clean the liquid lines and equalizer lines for
d. If no leaks are found, place the unit in soldering.
operation.
2. Place new expansion valve in position in liquid
· R-23 System: line.
a. Pressurize the system and test for leaks (see
3. Solder liquid line inlet and outlet line
connections to valve.
chapter).
4. Solder equalizer line to expansion valve.
109
5. Clean the suction line to a bright polished 0. Operate the unit and note the suction
condition. Install the feeler bulb of new power pressure and container temperature to see
head in the feeler bulb clamp on the suction that the expansion valve is properly
line. Locate bulb on the suction line in former installed and that the feeler bulb is
position. The feeler bulb must make good properly located.
contact with the suction line or operation will
be faulty. Cover with insulating tape. R-23 System Heat Exchanger
6. Do one of the following: Replacement
· R-134a System:
Removal
a. Open the liquid line service valve and 1. Recover the refrigerant charge from the system
pressurize the low side. Test for leaks (see (see “Refrigerant Recovery” in this chapter).
chapter). 2. Remove the “U” mounting clamps that hold
the heat exchanger assembly to the wall of the
b. If no leaks are found, recover the leak test condenser section.
chapter). 3. Heat and unsolder liquid inlet and outlet line
connections.
c. Evacuate the low side (see “Evacuation
and Cleanup of the Refrigeration System” 4. Heat and unsolder the suction line
in this chapter). connections.
d. Cover expansion valve outlet line with 5. Lift the heat exchanger assembly from the unit.
insulating tape.
e. Open the liquid line service valve and
Installation
place the unit in operation. 1. Clean the tubes for soldering.
f. Operate the unit and note the suction 2. Place the heat exchanger assembly in the unit
pressure and container temperature to see and install the mounting hardware.
that the expansion valve is properly
3. Solder the suction line connections.
installed and that the feeler bulb is
properly located. NOTE: It is strongly recommended that dry
nitrogen be used to purge the system during any
· R-23 System: solder operations (see “Using Pressurized
a. Pressurize the system with R-23 and test Nitrogen” in this chapter).
for leaks (see “Refrigerant Leak Test NOTE: If pressurizing with nitrogen, front seat
Procedure” in this chapter). the discharge valve to prevent nitrogen from
b. If no leaks are found, recover the leak test entering the refrigerant charge.
chapter). CAUTION: Any time the discharge valve is front
c. Evacuate the system (see “Evacuation and seated, disconnect the unit power source to
Cleanup of the Refrigeration System” in prevent accidental compressor start-up.
this chapter). 4. Solder the liquid line connections.
d. Cover expansion valve outlet line with 5. Pressurize the low side and check for
insulating tape. leaks (see “Refrigerant Leak Test
e. Recharge the unit with R-23 refrigerant Procedure” in this chapter).
and check the compressor oil level. Add oil
if necessary.
110
6. If no leaks are found, recover the leak test gas 4. Do one of the following:
· Pressurize the R-134a system on the low
7. Evacuate the low side (see “Evacuation and side and check for leaks
Cleanup of the Refrigeration System” in this
· Pressurize the R-23 system on the high
chapter).
side and check for leaks.
8. Recharge the unit (see “Refrigerant Charge”
5. If no leaks are found, recover the leak test
in this chapter).
gas from both systems (see “Refrigerant
Recovery” in this chapter).
R-23 System to R-134a System
6. Evacuate both systems (see “Evacuation and
Plate Heat Exchanger Cleanup of the Refrigeration System” in this
Replacement chapter).
Removal 7. Recharge both refrigerant systems (see
“Refrigerant Charge” in this chapter).
1. Recover the refrigerant charge from the both
refrigeration systems (see “Refrigerant
Recovery” in this chapter). Receiver Tank Replacement (R-
134a or R-23 System)
2. Remove the panel that protects the heat
exchanger assembly in the power cord storage
Removal
compartment.
1. Recover the refrigerant charge from the unit
3. Heat and unsolder all system inlet and outlet (see “Refrigerant Recovery” in this chapter).
line connections.
2. Unsolder the outlet valve on the liquid outlet
4. Remove the heat exchanger assembly from line.
the unit.
3. Unsolder the liquid line inlet connection.
Installation 4. Loosen the mounting nuts and remove the
1. Clean the tubes for soldering. tank.
2. Place the heat exchanger assembly in the unit 5. Remove the outlet valve from the receiver
and position in refrigeration system tubing. tank.
3. Solder all refrigerant line connections. Installation
NOTE: It is strongly recommended that dry 1. Install a new tank in the unit and tighten the
nitrogen be used to purge the system during any mounting bolts.
solder operations (see “Using Pressurized
Nitrogen” in this chapter). 2. Solder the inlet line and outlet valve line with
high temperature silver solder (30% silver).
NOTE: If pressurizing with nitrogen, front seat
the discharge valve to prevent nitrogen from NOTE: It is strongly recommended that dry
entering the refrigerant charge. nitrogen be used to purge the system during any
solder operations (see “Using Pressurized
CAUTION: Any time the discharge valve Nitrogen” in this chapter).
is front seated, disconnect the unit power NOTE: If pressurizing with nitrogen, front seat
source to prevent accidental compressor the discharge valve to prevent nitrogen from
start-up. entering the refrigerant charge.
111
CAUTION: Any time the discharge valve 5. Disconnect the leads from the wire harness
is front seated, disconnect the unit power and remove the switch from the compressor
source to prevent accidental compressor discharge manifold (or remove the sensor
start-up. from the compressor head).
3. Pressurize the refrigeration system and check
for leaks (see “Refrigerant Leak Test
Installation
Procedure” in this chapter). 1. Apply a refrigeration locktite (sealant) to the
threads of the switch (or sensor).
4. Evacuate the system (see “Evacuation and
Cleanup of the Refrigeration System” in this 2. Install and tighten the switch (or sensor).
chapter). Connect the leads to the wire harness.
5. Recharge the unit (see “Refrigerant Charge” 3. Open discharge service valve slightly to
in this chapter). pressurize the compressor head and tube
assembly. Check for leaks (see “Refrigerant
High Pressure Cutout Switch Leak Test Procedure” in this chapter). Front
seat the discharge service valve.
Replacement (R-134a or R-23
System) 4. If no leaks are found, recover the leak test gas
Removal 5. Open the suction service valve and
1. Close the suction service valve and pump compressor discharge service valve and place
down the compressor: the unit in operation.
· R-134a Compressor: Pump down the
compressor to -35 kPa, -0.35 bar, 10 in. Liquid Line Solenoid Valve
vacuum. Replacement (R-134a System
· R-23 Compressor: Pump down the Only)
compressor to 0 to 21 kPa, 0.0 to 0.2 bar, 0
to 3 psig.
Removal
1. Close the liquid line service valve and pump
CAUTION: Do NOT aiow the R-23 scroll down the low side to -35 kPa, -0.35 bar, 10 in.
compressor to operate for more than 10- vacuum. Break the vacuum with nitrogen
20 seconds. between 10 and 20 kPa, 0.10 and 0.20 bar, 1
and 3 psig.
2. Open the suction service valve slightly to
equalize the pressure between 10 and 20 kPa, 2. Turn the unit On-Off switch OFF. Disconnect
0.10 and 0.20 bar, 1 and 3 psig. electrical connections to liquid line solenoid.
3. Front seat the discharge service valve. NOTE: In most cases, only the coil requires
replacement. No other repair is possible on the
liquid line solenoid.
CAUTION: Any time the discharge valve
is front seated, disconnect the unit power 3. Unsolder the liquid line connections from the
source to prevent accidental compressor valve.
4. Purge the high pressure from the 4. Remove the valve from the unit.
compressor head through the service port on
the discharge line. Installation
1. Clean the tubes for soldering.
2. Place the new valve in position and solder the
connections.
112
CAUTION: Use a heat sink or wrap Installation

the valve with wet rags to prevent
damage to the new valve. 1. Clean the tube for soldering.
2. Place the new switch in position and
3. Release a small amount of refrigerant from solder the suction line connection.
the receiver tank to pressurize the liquid line.
Check for leaks (see “Refrigerant Leak Test
CAUTION: Use a heat sink or wrap the
Procedure” in the Refrigeration Maintenance
switch with wet rags to prevent damage to
chapter of this manual).
the new switch.
4. If no leaks are found, recover the leak test gas
(see “Refrigerant Recovery” in the 3. Pressurize the refrigeration system and check
Refrigeration Maintenance chapter of this for leaks (see “Refrigerant Leak Test
manual). Procedure” in this chapter).
5. Evacuate the low side (see “Evacuation and 4. Evacuate the system (see “Evacuation and
Cleanup of the Refrigeration System” in the Cleanup of the Refrigeration System” in this
Refrigeration Maintenance chapter of this chapter).
manual). 5. Recharge the unit (see “Refrigerant Charge” in
6. Reconnect the electrical wires to the valve. this chapter).
6. Reconnect the electrical wires to the switch.
7. Open the liquid line service valve and place
the unit in operation. Check the refrigerant
charge and add refrigerant as required.
Low Pressure Cutout Switch

Replacement (CRR DF
MPC2000ID and MP3000 Units
Only)
Removal
1. Recover the R-23 refrigerant charge from the
unit (see “Refrigerant Recovery” in this
chapter).
2. Disconnect the leads from the wire harness.
3. Unsolder the low pressure cutout switch from
the unit.
113
114
Structural/Accessory Maintenance
Mounting Bolts CAUTION: Air pressure or water spray

Check and tighten all unit, compressor, and fan must not be high enough to damage coil
motor mounting bolts during pretrip inspections fins.
and every 1,000 operating hours. Unit mounting If a build up of salt or debris is present on the
bolts should be tightened to a torque value of 204 condenser coil, the coil should be cleaned using a
N.m (150 ft-lb). Compressor and fan motor mild alkaline cleaner with a pH of 9.5 to 10.5. For
mounting bolts should be tightened to a torque example, a 2-3% solution of SIMPLE GREEN®
value of 20 to 21 N.m (15 to 20 ft-lb). would make a suitable cleaning solution. Apply
the solution using a pressure spray/wash type
Unit Inspection apparatus. Spray the condenser coil thoroughly
Inspect the unit during unit pretrip inspection and from both the inside and outside of the coil.
every 1,000 operating hours for loose or broken Always thoroughly rinse the coil with a fresh
wires or hardware, compressor oil leaks, or other water spray.
physical damage which can affect unit Also inspect the directional airflow condenser
performance and require repair or replacement of grille for damage. This grille directs the condenser
parts. airflow out and away from the unit to increase the
efficiency of the condenser coil by preventing the
recirculation (short cycling) of warm air through
the coil. Abnormally high head pressures may
result if this special condenser grille is damaged or
missing.
1
Evaporator Coil
Clean the evaporator coil by blowing low pressure
compressed air from the bottom side of the coil
2
upward (opposite direction of normal airflow).
Inspect coil and fins for damage and repair if
necessary.
CAUTION: Air pressure must not be

high enough to damage coil fins.
AXA0346
1. Tighten Unit Mounting Bolts

Defrost Drains
2. Tighten Compressor, Condenser Fan and Clean the defrost drains every 1,000 operating
Evaporator Fan Mounting Bolts hours to be sure the lines remain open.
Figure 42: Mounting Bolts
Evaporator Fan Location
Condenser Coil Place fan blade on motor shaft with hub located
on the outside of the blade for proper airflow
Clean the condenser coil by blowing low pressure direction. When mounting the fan blade and hub
compressed air or a medium pressure warm water assembly on the fanshaft, center the assembly in
spray from the inside of the coil outward (opposite the orifice. Position the front (top) of the fan blade
direction of normal airflow). Inspect coil and fins hub 13 mm (0.5 in.) in from the outer edge of the
for damage and repair if necessary. fan orifice.
115
Structural/Accessory Maintenance
Condenser Fan Location

Place fan blade on motor shaft with hub located
on the outside of the blade for proper airflow 1
direction. When mounting the fan blade and hub
assembly on the fanshaft, center the assembly in
the orifice. Position the front of the fan blade 10
AXA0421
mm (0.4 in.) in from the outer edge of the fan
orifice.
1. Evaporator Fan Blade

2. Airflow Direction 2
3. Evaporator Coil
4. Evaporator Motor
5. 13 mm (0.5 in.)
Figure 43: Evaporator Fan Blade Placement AXA0426
Vacuum Valve 1. Vacuum valve (Located behind the

condenser grille cover), earlier
The vacuum valve draws outside air into the
2. Vacuum valve (Located behind the
container to prevent the container from
condenser grille cover), current
developing negative atmospheric pressure as the
cargo temperature decreases toward -60 C (-76 Figure 44: Vacuum Valve
F). Check the vacuum valve during the pretrip
inspection to make sure the ball inside the valve
AXA0404
moves freely.
AXA0196
1. Airflow Direction
2. 10 mm (0.4 in.)
3. Condenser Coil
4. Condenser Fan Blade
5. Condenser Motor
Figure 45: Condenser Fan Blade Placement
116
Mechanical Diagnosis
Condition Possible Cause Remedy

One or Both Compressors Controller on; unit start sequence still Wait at least 1 minute for both
do not operate — no timing compressors to start
amperage draw No power to unit (condenser and Locate fault and repair: power source,
evaporator fans do not operate) power plug, main circuit breaker, motor
contactor, motor terminals, motor
Open in 24 Vac control circuit Check fuses and On/Off switch.
Replace or repair as required
Container temperature does not demand Adjust controller setpoint
compressor operation
Compressor contactor inoperative Replace compressor contactor
No output signal from controller Diagnose and replace main relay board
or controller
Unit on defrost Turn Unit On/Off switch Off and then
On again
Detective high pressure cutout switch in Replace defective switch
R-134a or R-23 system
High condenser head pressure causing Check refrigeration system and correct
high pressure cutout on R-134a or R-23 fault
system
Defective R-134a or R-23 compressor Replace compressor
Controller shut unit down on Compressor Let compressor cool and controller will
Over Temperature (fault code 56) reset automatically. Check compressor
temperature sensor, R-134a refrigerant
charge, R-23 refrigerant charge
Compressor motor internal thermal If compressor contactor is
overload protection open energized, wait 60 minutes for
protector to cool and reset.
Low suction pressure or defective low Check R-23 refrigeration system for
pressure cutout on R-23 system (CRR DF leaks or and obstruction in the low or
MPC2000ID Units Only) high side. Replace a defective low
pressure cutout switch
Compressor does not Piston stuck (R-134 System) R-134a System: Remove compressor
operate; excessive Rotating Scroll Stuck (R-23 System) head and look for broken valve and
amperage draw or jammed parts R-23 System: Replace
intermittent cycling on compressor
overload Seized or frozen compressor bearings Replace compressor
Improperly wired Check/correct wiring against wiring
diagram
Low line voltage Check line voltage — determine
location of voltage drop
High head pressure Eliminate cause of high head pressure
Contacts in compressor contactor not Check by operating manually. Repair or
closing completely replace.
Open circuit in compressor motor winding Check motor stator connections. Check
stator winding for continuity. If open,
replace compressor
Defective compressor motor internal Replace thermal overload protector or
thermal overload protector compressor
R 23 compressor not running Auxiliary contact on R134a open Check curcuit, replace contact.
117

Compressor contactor Low line voltage Increase line voltage to at least 90% of
burned out compressor motor rating
Excessive line voltage Reduce line voltage to at least 110% of
compressor motor rating
Short cycling Eliminate cause of short cycling
Unit short cycles Controller out of calibration Check controller software program
version; load new software in controller
and recheck unit performance, replace
controller
Refrigerant overcharge causing cycling Purge system (R-134a or R-23) with
on high pressure cutout cycling compressor
Inefficient condenser operation causing Check condenser airflow, condenser
cycling on high pressure cutout fan motor, condenser fan grille.
If R-23 compressor is cycling off, check
R-134a system operation and
refrigerant charge
Noisy unit Insufficient compressor oil Check compressor oil level on R-134a
and R-23 system. Add oil to proper
level
Loose mounting bolts Tighten mounting bolts
Oil slugging or refrigerant flooding back Add oil or refrigerant charge. Check
expansion valve adjustment.
Worn fan motor bearings Replace bearings or motor
Faulty compressor Repair or replace compressor
Condenser fan motor does Unit in Null, Heat or Defrost Check indicator lights. If unit is in Null,
not operate Heat or Defrost, unit operation is
normal (no remedy required)
Loose line connection Tighten connections
Open motor internal thermal overload Check for seized bearings or defective
protector thermal overload protector. Repair or
replace as necessary
Defective motor Replace motor
Detective condenser fan contactor Replace defective contactor
No condenser fan output signal from Diagnose and replace condenser fan
controller relay, main relay board or controller
Evaporator fan motor(s) Unit on defrost Check operating mode indicator LEDs
does not operate Loose line connection Tighten connections
Open motor internal thermal overload Check for seized bearings or defective
protector thermal overload protector. Repair or
replace as necessary
Defective motor Replace motor
Defective low speed evaporator fan Replace defective contactor
contactor
No low speed evaporator fan output Diagnose and replace evaporator fan
signal from controller relay, main relay board or controller
118
Refrigeration System Diagnosis

R-134a or R-23 System Shortage of refrigerant Repair leak and recharge
Compressor operating in Compressor motor contacts frozen Clean points or replace contactor
a vacuum (R-134a compressor only)
(unit not cooling)
Defective liquid line solenoid valve Repair or replace liquid line solenoid
valve
Compressor inefficient (R- Check valve reeds and pistons
134a compressor only)
Partial obstruction in low side or Locate obstruction and repair
dehydrator
Iced or plugged evaporator coil Defrost or clean evaporator coil
Expansion valve partially closed by ice, Replace expansion valve
dirt or wax
Expansion valve power element lost its Replace expansion valve
charge
Defective container insulation Correct or replace container insulation
Poor fitting container doors Repair or replace doors
Partial obstruction in high side Locate obstruction and repair
Suction pressure gauge out of calibration Replace service gauge
Expansion valve feeler bulb improperly Correct feeler bulb installation
mounted, poorly insulated or making poor
contact
119

Load temperature too high One or both compressors do not operate See "Mechanical Diagnosis" and unit
(unit not cooling) wiring schematic
Shortage of refrigerant Repair leak and recharge
(R-134a or R-23 system)
Overcharge of refrigerant Purge system
Air in system Evacuate and recharge
Controller setpoint too high Adjust controller setpoint
Defective controller or main relay board Diagnose main relay board and
controller. Replace defective component
Too much compressor oil in R-134a or Remove excessive compressor oil from
R-23 system compressor
Iced or dirty evaporator coil Defrost or clean evaporator coil
Restricted lines on high side Clear restriction
Plugged dehydrator (R- Change dehydrator
134a or R-23 system)
Compressor Perform compressor efficiency test.
inefficient (R-134a Check valve reeds and pistons
system
Condenseronly)coil dirty or airflow restricted Clean condenser coil, clear restriction,
or repair or replace fan motor or
condenser fan blade
Expansion valve open too much Adjust or replace valve
Expansion valve power element lost its Replace power element
charge (R-134a or R-23 system)
contact (R-134a or R-23 system)
R-134a or R-23 System: Shortage of refrigerant Repair leak and recharge
Head pressure too low Low ambient air temperature No remedy
(R-134a system only)
Service gauge out of calibration Replace gauge
Compressor suction or discharge valve Replace suction reeds and gaskets.
inefficient (R-134a system only) Clean valve plate. If defective/restricted
then replace.
R-134a or R-23 System: Refrigerant overcharge Purge system
Head pressure too high Air in refrigeration system Evacuate and recharge
Dirty or restricted condenser coil Clean condenser coil
Condenser fan not operating See "Condenser Fan Motor Does Not
Operate" under Mechanical Diagnosis
Condenser fan grille damaged or missing Repair or replace grille
Condenser fan blade damaged Replace fan blade
High ambient air temperature No remedy
Restricted dehydrator or high side Replace dehydrator or clear restriction
Defective high pressure gauge Replace service gauge
R-134a or R-23 System: Refrigerant leak Repair leak and recharge
Compressor loses oil
Compressor oil migrates Short cycling See "Unit Short Cycles" under
to system Mechanical Diagnosis
120

Rapid cycling between Air short cycling through evaporator Check and correct cargo load
Cool and Null modes Defective controller or main relay board Diagnose main relay board and
Short cycling See "Unit Short Cycles" under
R-134a or R-23 System: Shortage of refrigerant Repair or recharge
Hot liquid line Expansion valve open too wide Adjust or replace expansion valve
R-134a or R-23 System: Liquid line service valve partially closed Open valve or remove restriction
Frosted liquid line or restricted
Restricted dehydrator Replace dehydrator
R-134a or R-23 System: Expansion valve admitting excess Check feeler bulb and adjust expansion
Frosted or sweating refrigerant valve or replace
suction line Evaporator coil needs defrosting Check defrost circuit including controller
(R-134a system only) and evaporator coil sensor
Evaporator fan does not operate See "Evaporator Fan Motor Does Not
(R-23 system only) Operate" under Mechanical Diagnosis
and unit wiring schematic
R-134a or R-23 System: Ice plugging expansion valve screen or Apply hot wet cloth to expansion valve.
Unit in vacuum. Frost on orifice Moisture indicated by increase in
expansion valve only suction pressure. Replace dehydrator
R-134a or R-23 System: Overcharge of refrigerant Purge system
High suction pressure Expansion valve open too much Adjust or replace valve
Suction pressure gauge out of calibration Adjust or replace service gauge
R-134a or R-23 System: Shortage of refrigerant Repair leak and recharge
Low suction pressure Low ambient air temperature No remedy
Iced or dirty evaporator coil Defrost or clean evaporator coil
Restricted lines Locate and clear restriction
Plugged dehydrator Replace dehydrator
Expansion valve closed too much Adjust or replace valve
contact
Evaporator fans off Check evaporator fan motors and
(R-23 system only) control circuit and correct fault
controller. Replace defective
component.
Suction pressure gauge out of calibration Adjust or replace gauge
121
122
Electrical, Refrigeration and Controller
Menu Flow Diagrams
Dwg No. Drawing Title Rev. Page

2C33056H01 CRR DF MPC2000 Controller Diagram 1 125
2C33057H01 CRR DF MPC2000 Main Relay Board Electrical Diagram 2 126
2C33059H01 CRR DF MPC2000 Unit Wiring Schematic 1 127
5D52336 CRR DF MPC2000ID Controller Diagram 1 128
5D52338 CRR DF MPC2000ID Main Relay Board Electrical Diagram A 129
5D52335 CRR DF MPC2000ID Unit Wiring Schematic 131
— Legend of CRR DF Refrigeration System Components — 132
— CRR DF Refrigeration System Components — 133
— Legend of CRR DF Off Cycle Standby Flow and Pressure — 134
Diagram
— CRR DF Off Cycle Standby Flow and Pressure Diagram — 135
— Legend for CRR DF Full Cool Flow and Pressure Diagram — 136
— CRR DF Full Cool Flow and Pressure Diagram — 137
— Legend for CRR DF Evacuation Station and Unit Connections — 138
— CRR DF Evacuation Station and Unit Connections — 139
— MPC2000 Menu Flow Diagram — 140
— MPC2000ID Menu Flow Diagram — 141
123
Electrical, Refrigeration and Controller Menu Flow Diagrams
124
CRR DF MPC2000 Controller Diagram — Page 1 of 1
125
CRR DF MPC2000 Main Relay Board Electrical Diagram — Page 1 of 1
126
CRR DF MPC2000 Unit Wiring Schematic — Page 1 of 1
127
CRR DF MPC2000ID Controller Diagram — Page 1 of 1
128
CRR DF MPC2000ID Main Relay Board Electrical Diagram — Page 1 of 1
129
This page intentionally left blank.
130
CRR DF MPC2000ID Unit Wiring Schematic — Page 1 of 1
131
Legend for CRR DF Refrigeration System Components — Page 1 o1 2
Unit Compartments R-23 Refrigeration Circuit Components 21.

A. Evaporator Section Plate Heat Exchanger, R-134a/R-23
B. Condenser Section 0. R-23 Scroll Compressor
1. Sight Glass
Controller and Temperature Sensors 2. Oil Fill / Drain Fitting
5. R-134a Compressor Discharge Line Temperature Sensor 29. 3. High (Discharge) Pressure Gauge
R-23 Compressor Discharge Line Temperature Sensor 4. Discharge Service Valve
48. MPC2000 or MPC2000ID Controller 5. High Pressure Cutout Switch
49. Return Air Sensor 6. R-23 Compressor Discharge Line Temperature Sensor
50. Evaporator Coil Sensor 7. R-23 Condenser Coil Tube (Circular)
51. Supply Air Sensor 8. Receiver Tank
52. Ambient Sensor 9. R-23 Receiver Tank Service Fitting
10. R-23 High Pressure Relief Valve
R-134a Refrigeration Circuit Components 11. Sight Glass
1. R-134a Reciprocating Compressor 12. R-23 Soldered Filter Drier
2. Oil Fill / Drain Fitting 13. Heat Exchanger
3. Discharge Service Valve 14. R-23 Equalizer Line
4. High Pressure Cutout Switch 15. Expansion Valve
5. R-134a Compressor Discharge Line Temperature Sensor 16. Expansion Valve Equalizer Line
6. Low (Suction) Pressure Gauge 17. Expansion Valve Feeler Bulb
7. High (Discharge) Pressure Gauge 18. Distributor
8. Condenser Check Valve 19. Evaporator Coil
9. Condenser Coil Outlet Tube 20. Crankcase Pressure Regulator
10. Receiver Tank 21. Constant Pressure Regulator
11. R-134a Receiver Tank Service Fitting 22. Buffer (Receiver Tanks)
12. R-134a High Pressure Relief (Fusible Plug) 23. Low (Suction) Pressure Gauge
13. Sight Glass 24. Suction Service Valve
14. Condenser Coil Outlet Tube 53. Electric Heaters
15. Liquid Line Ball (Service) Valve 54. Low Pressure Cutout Switch (MPC2000ID Units Only)
16. R-134a Threaded Filter Drier
17. Liquid Line Solenoid
18. R-134a Expansion Valve
19. Equalizer Line
0. Expansion Valve Feeler Bulb
1. Plate Heat Exchanger, R-134a/R-23
2. Suction Service Valve
132
CRR DF Refrigeration System Components — Page 2 of 2
133
Legend for CRR DF Off Cycle Standby Flow and Pressure Diagram — Page 1 of 2
Legend for CRR DF Off Cycle Standby Flow Controller and Temperature R-134a Refrigeration Circuit
and Pressure Diagram Sensors Components
5. R-134a Compressor 1. R-134a Reciprocating Compressor
Discharge Line 2. Oil Fill / Drain Fitting
Temperature Sensor 29. 3. Discharge Service Valve
R-23 Compressor 4. High Pressure Cutout Switch
Discharge Line 5. R-134a Compressor Discharge
Temperature Sensor Line Temperature Sensor
48. MPC2000 or MPC2000ID 6. Low (Suction) Pressure Gauge

Controller 7. High (Discharge) Pressure Gauge
49. Return Air Sensor 8. Condenser Check Valve
50. Evaporator Coil Sensor 9. Condenser Coil Outlet Tube
51. Supply Air Sensor 10. Receiver Tank
Med
52. Ambient Sensor 11. R-134a Receiver Tank Service
Fitting
ium Pressure
12. R-134a High Pressure Relief
Gas Medium (Fusible Plug)
13. Sight Glass
Pressure Liquid
14. Condenser Coil Outlet Tube
Low Pressure Gas 15. Liquid Line Ball (Service) Valve
Medium Pressure Mixture 16. R-134a Threaded Filter Drier
17. Liquid Line Solenoid
(Gas/Liquid) High Pressure Gas
18. R-134a Expansion Valve
(Entire R-23 System) 19. Equalizer Line
21. Plate Heat Exchanger, R-134a/R-
23
Unit Compartments
A. Evaporator Section
B. Condenser Section
R-23 Refrigeration Circuit
Components 21. Plate Heat
Exchanger, R-134a/R-23
0. R-23 Scroll Compressor
1. Sight Glass
2. Oil Fill / Drain Fitting
3. High (Discharge) Pressure Gauge
4. Discharge Service Valve
5. High Pressure Cutout Switch
6. R-23 Compressor Discharge Line
Temperature Sensor
7. R-23 Condenser Coil Tube (Circular)
8. Receiver Tank
9. R-23 Receiver Tank Service Fitting
10. R-23 High Pressure Relief Valve
11. Sight Glass
12. R-23 Soldered Filter Drier
13. Heat Exchanger
14. R-23 Equalizer Line
15. Expansion Valve
16. Expansion Valve Equalizer Line
18. Distributor
19. Evaporator Coil
20. Crankcase Pressure Regulator
21. Constant Pressure Regulator
22. Buffer (Receiver Tanks)
23. Low (Suction) Pressure Gauge
53. Electric Heaters
54. Low Pressure Cutout Switch
(MPC2000ID Units Only)
134
CRR DF Off Cycle Standby Flow and Pressure Diagram — Page 2 of 2
CRR DF Off Cycle Standby Flow and Pressure Diagram
135
Legend for CRR DF Full Cool Flow and Pressure Diagram — Page 1 of 2
Legend for CRR DF Full Cool Flow R-134a Refrigeration Circuit

and Pressure Pressure Vaporizing Components
Diagram
1. R-134a Reciprocating Compressor
Liquid
Unit Compartments 5. R-134a Compressor Discharge Line
Temperature Sensor
A. Evaporator Section
B. Condenser Section 6. Low (Suction) Pressure Gauge
7. High (Discharge) Pressure Gauge
Controller and Temperature
8. Condenser Check Valve
Sensors 9. Condenser Coil Outlet Tube
5. R-134a Compressor Discharge 10. Receiver Tank
Hi
Line Temperature Sensor 29. R-23 11. R-134a Receiver Tank Service
Compressor Discharge Line Fitting
gh Pressure Temperature Sensor 12. R-134a High Pressure Relief
(Fusible Plug)
Gas High 48. MPC2000 or MPC2000ID
Controller
13. Sight Glass
Pressure 49. Return Air Sensor
14. Condenser Coil Outlet Tube
50. Evaporator Coil Sensor
15. Liquid Line Ball (Service) Valve
Liquid
51. Supply Air Sensor 16. R-134a Threaded Filter Drier
Low 52. Ambient Sensor 17. Liquid Line Solenoid
Pressure 18. R-134a Expansion Valve
19. Equalizer Line
Gas Low
Pressure 21. Plate Heat Exchanger, R-134a/R-
23
Liquid
Condensing High
Pressure Gas Low

R-23 21. Constant Pressure
Regulator
Refrigeration
Circuit 22. Buffer (Receiver Tanks)
Components 21. 23. Low (Suction) Pressure
Plate Heat Gauge
Exchanger, R- 24. Suction Service Valve
134a/R-23 53. Electric Heaters
0. R-23 Scroll Compressor 54. Low Pressure Cutout
1. Sight Glass Switch (MPC2000ID Units Only)

3. High (Discharge) Pressure
Gauge
6. R-23 Compressor Discharge
Line Temperature Sensor
7. R-23 Condenser Coil Tube
(Circular)
8. Receiver Tank
9. R-23 Receiver Tank Service
Fitting
10. R-23 High Pressure Relief
Valve
11. Sight Glass
12. R-23 Soldered Filter Drier
13. Heat Exchanger
14. R-23 Equalizer Line
15. Expansion Valve
16. Expansion Valve Equalizer
Line
18. Distributor
19. Evaporator Coil
20. Crankcase Pressure
Regulator
136
CRR DF Full Cool Flow and Pressure Diagram — Page 1 of 2
137
Legend for CRR DF Evacuation Station and Unit Connections — Page 1 of 2
Evacuation Stations s
NOTE: Special, self-sealing quick o 2
disconnect couplers are required for r 9
R-134a systems and R-23 systems.
.
D
Y. R-23 Evacuation Station and Unit i R
Connections
s -
Y1. Scale, R-23 Refrigerant Tank and
Refrigerant Hose Only c 2
Y2. Gas Ballast Valve h 3
Y3. Iso Valve a
Y4. Two-stage Vacuum Pump r C
Y5. To 220/190 VAC Power g o
Y6. Calibration Standard e m
Y7. Micron Meter p
Y8. Sensor L r
i e
n s
Z. R-134a Evacuation Station and Unit
Connections e s
Z1. Scale, R-134a Refrigerant Tank and o
Gauge Manifold T r
Z2. Gas Ballast Valve e
Z3. Iso Valve m D
Z4. Two-stage Vacuum Pump p i
Z5. To 220/190 VAC Power e s
Z6. Calibration Standard r c
Z7. Micron Meter a h
Z8. Sensor t a
u r
Unit Compartments r g
A. Evaporator Section e e
B. Condenser Section
S L
Controller and Temperature Sensors e i
5. R- n n
134a s e
Com o
pres r T
emp R-134a Refrigeration R-23
Circuit Components Refri
eratu
1. R-134a gerati
re Reciprocating on
Sens Compressor
Circui
or 2. Oil Fill / Drain t
Fitting
48. MPC2000 or MPC2000ID Controller Comp
3. Discharge Service onent
49. Return Air Sensor Valve
s 21.
50. Evaporator Coil Sensor 4. High Pressure Plate
51. Supply Air Sensor Cutout Switch
Heat
52. Ambient Sensor 5. R-134a Excha
Compressor Discharge
Line Temperature nger,
Sensor R-
6. Low (Suction) 134a/
Pressure Gauge R-23
7. High (Discharge) 0. R-23 Scroll
Pressure Gauge Compressor
8. Condenser Check 1. Sight Glass
Valve
2. Oil Fill / Drain
9. Condenser Coil Fitting
Outlet Tube 3. High (Discharge)
10. Receiver Tank Pressure Gauge
11. R-134a Receiver 4. Discharge
Tank Service Fitting Service Valve
12. R-134a High 5. High Pressure
Pressure Relief Cutout Switch
(Fusible Plug) 6. R-23 Compressor
13. Sight Glass Discharge Line
Temperature Sensor
14. Condenser Coil
Outlet Tube 7. R-23 Condenser
Coil Tube (Circular)
15. Liquid Line Ball
(Service) Valve 8. Receiver Tank
16. R-134a Threaded 9. R-23 Receiver
Filter Drier Tank Service Fitting
17. Liquid Line 10. R-23 High
Solenoid Pressure Relief Valve
18. R-134a 11. Sight Glass
Expansion Valve 12. R-23 Soldered
19. Equalizer Line Filter Drier
20. Expansion Valve 13. Heat Exchanger
Feeler Bulb
14. R-23 Equalizer
21. Plate Heat Line
Exchanger, R- 15. Expansion Valve
134a/R-23
16. Expansion Valve
22. Suction Service Equalizer Line
Valve
138
18. Distributor
19. Evaporator Coil
20. Crankcase Pressure Regulator
21. Constant Pressure Regulator
22. Buffer (Receiver Tanks)
23. Low (Suction) Pressure Gauge
53. Electric Heaters
54. Low Pressure Cutout Switch
(MPC2000ID Units Only)
MPC2000 Menu Flow Diagram — Page 1 of 1 CRR DR Evacuation Station and Unit Connections — Page 2of 2
Configuration Submenu
Misc
To Manual Function Test Submenu
Act · Current function setting appears in
iva · display.
te Pres · First Component Test appears in display. · Press F4 key to change a setting.
a s F4 key to · Press F2 or F3 key to scroll to · Press F2 key, “A” key
Co start a: - the desired component: (password), F4 key and EXIT key.
Note: All
screens
m Manual - Condenser Fan · Type a new value; or press F3 key to
ma Defrost. - - R-134a Compressor toggle value to desired setting.
that
display
nd Function Test
- PTI (Pretrip)
- R-23 Compressor · Press and hold F4 key until cursor
on the - Capacity 100% stops flashing.
Test - Evaporator Fans
controlle
- Heat
r are
- Zero Current
determin
ed by the · Press F4 key to start and stop test (toggle component
display between ON and OFF).
Unit
Configur
· More than one component can be turned ON at a time to
pe rfo rm a functional test of the unit.
ation
setting. All
screens
are NOT
present on Fu ncti on Test D a t a l o g g e r
all units.
Comm S u b m e n u Configu
ands PTI (Pretrip) Zer
Men u Test ration Cont
· First function screen appears. In- Cur
o
F Manual - Inspect Temp Log: Press F4 key to view next screen. Menu R ainer rent Press F 3
Function Test a
unctions Submenu Defro
key to scroll through previous logs of sensors.
n ID
Data Menu st - Inspect Event Log: Press F3 key to scroll through g previous
event logs. Cont
· C u r r e n t f u n c t i o n s e t t i n g S u p p l y A i r Te m p R e t u r n A i r Te m p - Set Log Time: Press F3 key to scroll through log
e
rast interval list.
a p p e a r s i n d i s p l a y.
· P r e s s F 3 k e y t o s c r o l l t o Defrost (Evap Coil) Temp
Press and hold F4 key until cursor stops flashing.
- Activate Trip Start: Press F4 key to enter trip start marker.
d e s i r e d f u n c t i o n .
· P r e s s F 4 k e y t o c h a n g e a Ambient Temp - Inspect PTI Log: Press F3 key through test result screens.
s e t t i n g .
High Pressure Temp
- Date Time: Type the new setting.
- C/F Mode: Press F2 key to toggle setting. R-23 Compressor Discharge Temp Inspect Temp Log Inspect Event Log Set Log Time
- Cargo Data: Press F3 key to scroll to desired fu n cti o n . B a t t e r y Vo l t a g e Vo l t a g e A v e r a g e
Inspect PTI Log
Entering a Vo l ta g e 1 Vo lta g e 2
New Vo l t a g e 3 F r e q u e n c y
Setpoint Zero Current
· Pres Current Phase 1
s SETPOINT
key. Current Phase 2 Current Phase 3
· Pres
Press F4
s F4 key.
· Typ key. Type
Datalogger Me n u
e the new new
setpoint. setting.
· Pres - Program
Version:
s and hold F4
key until cursor Displays
stops flashing. current
setting · · ·
only. Alarms Press
Clear To
- Run Menu F2
alarm acknowle
Sta Time: code by
nd Press F3 · key to
V view correctin
dge an
alarm,
key to iew and write the g Misc.
ard scroll to problem press F4 C/F Mode
Dis desired down all a next a
and key with Fu
function. larm codes . larm Cargo
pla Press F4 code.
acknowl alarm nctions RM
code i n M Display shows
y key. Type edging t
Menu Date Data
he a larm disp lay. Time Stat current status:
us ·
new
setting. . Program Version Of
fline
·
MAIN MENU
- Press
and hold F4 key until cursor stops flashing. Run Time Zo
mbie
·
CONFIGURATION
O
M
I
S
C DAT
F ALO
COM U GGE RM
MAN N R M
DS C STA
T TE
DATA I
O
N
S
139
140
MPC2000ID Menu Flow Diagram — Page 1 of 1
Note: Configuration
All
To Manual Function Test
scree Submenu
ns Act Submenu
ivat ·
that
ea · Current function setting
displa
Co Press F4 · First Component Test appears in display. appears in display.
y on
the
m key to · Press F2 or F3 key to scroll to · Press F4 key to change a
ma start a: - the desired component: setting.
contr
E nter a nd Manual - Condenser Fan · Press F2 key, “A” key
oller
Temper · Press F4 key.
Defrost. - R-134a Compressor (password), F4 key and EXIT key.
are
· Type the new setpoint.
- - R-23 Compressor · Type a new value; or
deter
mine ature · Press and hold F4 key u n til cursor stops
Function
Test -
- Capacity 100% press F3 key to toggle value to
- Evaporator Fans desired setting.
d by or flashing.
the
PTI - Heat · Press and hold F4 key
Unit Humidi - Zero Current
Confi ty
gurati
on Setpoi
setting. nt
All D
Co F u ncti on Test
a
mm t
and Mi Configu
PTI (Pretrip) a
s Test sc ration Container Zero
Men Curr
ent l
u Manual Fu Menu In-
Ra
ID
Defro Function Test nct nge Contrast o
Data Menu st
g
Setpo ion
Set int S u p p l y A i r Te m p R e t u r n A i r Te m p
s g
Temp
poi eratur Defrost (Evap Coil) Temp Su e
e
nt r
Me Ambient Temp bm
nu High Pressure Temp en
R-23 Compressor Discharge Temp u S
B a t t e r y Vo l t a g e Vo l t a g e Av e r a g e u
Vo lta ge 1 Voltag e 2 · Current function setting b
appears in display.
Vo l t a g e 3 F r e q u e n c y · Press F3 key to scroll to
m
desired function. e
· Press F4 key to change a
n
setting.
- Date Time: Type the new setting. u
- C/F Mode: Press F2 key to toggle
Dat
· · · alo Inspect Temp Log
Alarms Press
Clear To gg
Menu alarm acknowle Inspect Event Log
Standard Display F2 code by er
· V key to correct
dge an
alarm, Me Set Log Time
iew and write view ing p press F4
Misc. Fu C/F Mode nu
down all a l a the roblem key with nctions
rm codes. next and Cargo Data Inspect PTI Log
alarm
alarm acknowl code i n
Men u Date RM
code. Time Program Di splay shows
edging disp lay. M curre nt status:
Stat
the
alarm.
Version Run
us ·
fline
Of
Time
·
mbie
Zo
· O
M CO
I NFI
S GU
C DAT
M F RATI ALO R
AI ALA CO ON GGE M
N MM U M
RMS AND N R
M DA C
EN TA S S
U T T
I A
O T
N
141

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CRR DF MPC2000

This manual is published for informational purposes

Sale of product shown in this manual is subject to

Copyright© 1999 Thermo King Corp., Minneapolis, MN, USA.

No warranties, express or implied, including

In addition, service personnel must be aware of Federal regulations

Refrigeration Maintenance and Service Operations (continued)

Refrigeration Maintenance and Service Operations (continued)

CRR DF Model Features

General Practices Refrigerant

First Aid 5. Treat all wires and connections as high voltage

Low Voltage 4. Avoid contacting the electronic components on

Unit Decals Compressor: Nameplate on front of the

Figure 1: Unit Nameplate and Decal Locations

Full Cool Operation Net Cooling Capacity*

System Net Defrost Heating Capacity

R-134a Refrigeration System

R-23 Refrigeration System

High Pressure Relief

Compressor Torque — 3D Copeland Compressor Bolt Torque

Metric Hardware Torque Chart

General Description economically carry cargo at deep frozen

1. Evaporator Access Door 6. Power Cord Storage Compartment

Figure 2: Unit Front View

1. Evaporator Fan Blade 4. Defrost (Evaporator Coil) Sensor Location

Figure 3: Evaporator Section — Front View

1. Vacuum Valve (located behind condenser grille cover), earlier

Figure 4: Vacuum Valve

1. Control Box 4. Ambient Sensor Location

Figure 5: Power Cord Storage Compartment

1. MPC2000, MPC2000ID or MP3000 Controller 5. Special Function Keypad

Figure 6: Control Box and Microprocessor Controller

Figure 7: MPC2000 or MP3000 Controller and Remote Monitoring Modem

2. Remote Monitoring Modem 10. Heat Relay

Figure 8: MPC2000ID and MP3000 Controller, and Remote Monitoring Modem

1. Remote Monitoring Modem 5. R-23 Scroll Compressor Contactors (2)

Figure 9: Unit Control Box with Door Open

Figure 11: R-23 Compressor Compartment

1. R-23 Compressor Discharge Valve 4. Receiver Tank

Figure 12: Additional R-23 Refrigeration System Components

1. Discharge Service Valve 6. Compressor Oil Sight Glass

Figure 13: R-134a Compressor Compartment

1. R-134a Receiver Tank 5. Dehydrator (Filter Drier)

1. Evaporator Grille 6. Controller Communications and Data Retrieval Connection

Figure 15: Unit Back View

1. Constant Pressure Regulator (R-23 System) 3. Sensor Connector Assembly

1. Electric Heaters 3. Expansion Valve Feeler Bulb (R-23 System)

4. Inspect both refrigeration systems for evidence

General Description Pretrip (PTI) Test. Fault codes are retained by

Alarm codes are recorded in the controller 3. General purpose keys

Alarm 2. LED display with 20.32 mm high characters:

Cool: Compressors operate a minimum of

Figure 19: Frozen Load Control Sequence

· On Frozen Loads, the initial time interval is Changing the Setpoint

Controller Menu 2. Press F3 to scroll the cursor down through the

MP-3000 Configuration List, DF Units

Viewing or Setting Functions in the Misc. · Contrast: Controller automatically regulates

CRR Pretrip (PTI) Test Procedure

CRR Pretrip (PTI) Test Procedure (Continued)