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MAGNUM+
TK 60275-4-MM (Rev. 1, 11/10)
Copyright© 2008 Ingersoll Rand Climate Control Technologies - European Served Area
Printed in Ireland
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2
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This manual is published strictly for informational purposes. The information so provided should
not be considered as all-inclusive or covering all contingencies. Thermo King Corporation
should be consulted if further information is required.
Sale of product shown in this manual is subject to Thermo King’s terms and conditions.
This includes, but 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, are made regarding the information,
recommendations, and descriptions contained herein. This includes warranties of
fitness for a particular purpose or merchantability, or warranties arising from course of
dealing or usage of trade. The manufacturer is not responsible and will not be held liable
in contract or in tort (including negligence) for any special, indirect or consequential
damages. This includes injury or damage caused to vehicles, contents or persons, by
reason of the installation of any Thermo King product or its mechanical failure.
The maintenance information in this manual covers unit models:
Base Unit
MAGNUM+ 098203
For further information, refer to:
Parts Manuals
MAGNUM Parts List TK 54356
Operation, Diagnosis and Refrigeration Maintenance Manuals
Diagnosing Thermo King Container Refrigeration Systems TK 41166
Electrostatic Discharge (ESD) Training Guide TK 40282
Evacuation Station Operation and Field Application TK 40612
Tool Catalog TK 5955
The information in this manual is provided to assist owners, operators and service people in the proper
upkeep and maintenance of Thermo King units.
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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.
R-404A
WARNING: Use only Polyol Ester-based refrigeration compressor oil in
R-404A. See Thermo King Parts Manual for part number.
Do not mix Polyol Ester and standard synthetic compressor oils. Keep Polyol
Ester compressor oil in tightly sealed containers. If Polyol Ester oil becomes
contaminated with moisture or standard oils, dispose of properly–DO NOT USE.
When servicing Thermo King R-404A unit, use only those service tools certified
for and dedicated to R-404A refrigerant and Polyol Ester compressor oils.
Residual non-HFX refrigerants or oils will contaminate R-404A systems.
Page 10 of 166
List Of Figures
10
Figure 59: Resistance Values for temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Figure 60: Service Fittings Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Figure 61: Service Valve Back Seated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Figure 62: Service Valve Open to Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Figure 63: Service Valve Front Seated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Figure 64: Balancing the Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Figure 65: Removing Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Figure 66: Gauge Manifold Closed to Center Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Figure 67: Gauge Manifold Open to Center Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Figure 68: Charging the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Figure 69: Purging Gauge Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Figure 70: Receiver Tank Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Figure 71: Test for Refrigerant Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Figure 72: Typical Pressurized Gas Bottle with Pressure Regulator and Gauges . . . . . . . . . . . . . . . . . . . . . .112
Figure 73: Evacuation Station and Unit Hook-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Figure 74: Constant Pressure Rise After Evacuation Indicates System Leak . . . . . . . . . . . . . . . . . . . . . . . . . .119
Figure 75: Pressure Rise Levels Off After Evacuation Indicates Moisture in System . . . . . . . . . . . . . . . . . . . .119
Figure 76: Scroll Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Figure 77: Filter Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Figure 78: TXV Valve and Element Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Figure 79: Economizer Expansion Valve and Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Figure 80: Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Figure 81: Water-Cooled Condenser Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Figure 82: Vapor Injection Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Figure 83: Digital Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Figure 84: Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Figure 85: Condenser Fan Blade Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Figure 86: Evaporator Fan Blade Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Figure 87: Air Exchange System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Page 11 of 166
11
Safety Instructions
General Precautions
• Always wear goggles or safety glasses.
Refrigerant liquid and battery acid can
permanently damage the eyes.
• Never operate the unit with the discharge
valve closed. Never close the compressor
discharge valve with the unit in operation.
• Keep your hands, clothing and tools clear of
the fans when the refrigeration unit is running.
If it is necessary to run the refrigeration unit
with covers removed, be very careful with
tools or meters being used in the area.
• Check the condition of the gauge manifold
hoses. Never let the hoses come in contact
with a fan motor blade or any hot surface.
• Never apply heat to a sealed refrigeration
system or container.
• Fluorocarbon refrigerants produce toxic gases
in the presence of an open flame or electrical
arc. The gases are severe respiratory irritants
capable of causing death.
• Firmly tighten all mounting bolts. Check each
bolt for correct length for their particular
application.
• Use extreme caution when drilling holes in the
unit. The holes may weaken structural
components. Holes drilled into electrical
wiring can cause fire or explosion. Holes
drilled into the refrigeration system may
release refrigerant.
• Use caution when working around exposed
coil fins. The fins can cause painful
lacerations.
• Use caution when working with a refrigerant
or refrigeration system in any closed or
confined area with a limited air supply (for
example, a trailer, container or in the hold of a
ship). Refrigerant tends to displace air and can
cause oxygen depletion. This can result in
suffocation and possible death.
• Use caution and follow the manufacturer’s
suggested practices when using ladders or
scaffolds.
Refrigerant Oil Precautions
Observe the following precautions when working
with or around refrigerant oil:
• Do not allow refrigerant oil to contact your
eyes.
• Rubber gloves are recommended when
handling Polyol Ester based refrigerant oil.
• Do not allow prolonged or repeated contact
with skin or clothing.
• Immediately wash all exposed skin after
handling refrigerant oil.
Use the following First Aid practices if needed.
Eyes: Immediately flush eyes with large amounts
of water. Continue flushing for at least 15 minutes
while holding the eyelids open. Get prompt
medical attention.
Skin: Remove contaminated clothing. Wash
thoroughly with soap and water. Get medical
attention if irritation persists.
Inhalation: Move victim to fresh air. Restore
breathing if necessary. Stay with victim until
arrival of emergency personnel.
Ingestion: Do not induce vomiting. Contact a
local poison control center or physician
immediately.
Electrical Precautions
The possibility of serious or fatal injury from
electrical shock exists when servicing a
refrigeration unit. Extreme care must be used
when working with a refrigeration unit that is
connected to its power source. Extreme care must
be used even if the unit is not running. Lethal
voltage potentials can exist at the unit power cord,
inside the control box, inside any high voltage
junction box, at the motors and within the wiring
harnesses.
Precautions
In general disconnect the units power cord before
repairing or changing any electrical
components.
Note that even though the controller is turned off,
one of the phases is still live and represents
Page 12 of 166
Safety Instructions
12
a potential danger of electrocution
Where turning of the unit is not possible (for
example at voltage measuring or troubleshoot- ing), follow safety precautions below.
• Turn the unit On/Off switch to Off before
connecting or disconnecting the unit power
plug. Never attempt to stop the unit by
disconnecting the power plug.
• Be certain the unit power plug is clean and dry
before connecting it to a power source.
• Use tools with insulated handles. Use tools
that are in good condition. Never hold metal
tools in your hand if exposed, energized
conductors are within reach.
• Do not make any rapid moves when working
with high voltage circuits. Do not grab a
falling tool or other object. People do not
contact high voltage wires on purpose. It
occurs from an unplanned movement.
• Treat all wires and connections as high
voltage until ammeter and wiring diagram
show otherwise.
• Never work alone on high voltage circuits on
the refrigeration unit. Another person should
always be standing by in the event of an
accident to shut off the refrigeration unit and
to aid a victim.
• Have electrically insulated gloves, cable
cutters and safety glasses available in the
immediate vicinity in the event of an accident.
First Aid
IMMEDIATE action must be initiated after a
person has received an electrical shock. Obtain
immediate medical assistance.
The source of shock must be immediately
removed. Shut down the power or remove the
victim from the source. If it is not possible to shut
off the power, the wire should be cut with either
an insulated instrument (e.g., a wooden handled
axe or cable cutters with heavy insulated handles).
A rescuer wearing electrically insulated gloves
and safety glasses could also cut the wire. Do not
look at the wire while it is being cut. The ensuing
flash can cause burns and blindness.
Pull the victim off with a non-conductive material
if the victim has to be removed from a live circuit.
Use the victim’s coat, a rope, wood, or loop your
belt around the victim’s leg or arm and pull the
victim off. Do not touch the victim. You can
receive a shock from current flowing through the
victim’s body.
Check immediately for the presence of a pulse and
respiration after separating the victim from power
source. If a pulse is not present, start CPR (Cardio
Pulmonary Resuscitation) and call for emergency
medical assistance. Respiration may also be
restored by using mouth-to-mouth resuscitation.
Low Voltage
Control circuits are low voltage (24 Vac and 12
Vdc). This voltage potential is not considered
dangerous. Large amount of current available
(over 30 amperes) can cause severe burns if
shorted to ground. Do not wear jewelry, watch or
rings. These items can shortcut electrical circuits
and cause severe burns to the wearer.
Electrostatic Discharge
Precautions
Precautions must be taken to prevent electrostatic
discharge while servicing the MP-3000a
microprocessor and related components. The risk
of significant damage to the electronic
components of the unit is possible if these
precautionary measures are not followed. The
primary risk potential results from the failure to
wear adequate electrostatic discharge preventive
equipment when handling and servicing the
controller. The second cause results from electric
welding on the unit and container chassis without
taking precautionary steps.
Electrostatic Discharge and the
Controller
You must avoid electrostatic discharges when
servicing the controller. Solid-state integrated
circuit components can be severely damaged or
destroyed with less than a small spark from a
finger to metal object. You must rigidly adhere to
the following statements when servicing these
units. This will avoid controller damage or
destruction.
Page 13 of 166
Safety Instructions
13
• Disconnect all power to the unit.
• Avoid wearing clothing that generates static
electricity (wool, nylon, polyester, etc.).
• Do wear a static discharge wrist strap (refer to
Tool Catalog) 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.
• Avoid contacting the electronic components
on the circuit boards of the unit being
serviced.
• Leave the circuit boards in their static proof
packing materials until ready for installation.
• Return a defective controller for repair in the
same static protective packing materials from
which the replacement component was
removed.
• Check the wiring after servicing the unit for
possible errors. Complete this task before
restoring power.
Welding of Units or Containers
Electric welding can cause serious damage to
electronic circuits when performed on any portion
of the refrigeration unit, container or container
chassis with the refrigeration unit attached. It is
necessary to ensure that welding currents are not
allowed to flow through the electronic circuits of
the unit. The following statements must be rigidly
adhered to when servicing these units to avoid
damage or destruction.
• Disconnect all power to the refrigeration unit.
• Disconnect all quick-disconnect wire
harnesses from the back of the controller.
• Disconnect all wire harnesses from the
Remote Monitor Modem (RMM).
• Switch all of the electrical circuit breakers in
the control box to the Off position.
• Weld unit and/or container per normal
welding procedures. Keep ground return
electrode as close to the area to be welded as
practical. This will reduce the likelihood of
stray welding currents passing through any
electrical or electronic circuits.
• The unit power cables, wiring and circuit
breakers must be restored to their normal
condition when the welding operation is
completed.
Removing Refrigerant Properly
Use a refrigerant recovery process that prevents or
absolutely minimizes refrigerant escaping to the
atmosphere. Fluorocarbon refrigerants are
classified as safe refrigerants when proper tools
and procedures are used. Certain precautions must
be observed when handling them or servicing a
unit in which they are used.
Fluorocarbon refrigerants evaporate rapidly,
freezing anything they contact when exposed to
the atmosphere in the liquid state. In the event of
frost bite, attempt to protect the frozen area from
further injury, warm the affected area rapidly, and
maintain respiration.
• Eyes: For contact with liquid, immediately
flush eyes with large amounts of water and get
prompt medical attention.
• Skin: Flush area with large amounts of
lukewarm water. Do not apply heat. Remove
contaminated clothing and shoes. Wrap burns
with dry, sterile, bulky dressing to protect
from infection/injury. Get medical attention.
Wash contaminated clothing before reuse.
• Inhalation: Move victim to fresh air and use
CPR or mouth-to-mouth ventilation, if
necessary. Stay with victim until arrival of
emergency medical personnel.
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Safety Instructions
14
Nameplate and Warning Locations
1. Controller Nameplate
2. Unit Nameplate
3. Compressor Nameplate
2
BEN074
AXA0214
AXA0215
AXA0218
AXA0217
AXA0216
1
3
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Safety Instructions
15
Identifying Unit Safety and
Warning Decals
Serial number decals, refrigerant type decals and
warning decals appear on all Thermo King®
equipment. These decals provide information that
may be needed to service or repair the unit.
Service technicians should read and follow the
instructions on all warning decals. See Figure .
Locating Serial Numbers
Serial numbers can be found on the component’s
nameplate.
• Electric Motor Nameplate: Attached to the
motor housing.
• Compressor Nameplate: On front of the
compressor.
• Unit Nameplate: On unit frame in power cord
storage compartment.
• MP-4000 Controller Nameplate: On back of
controller.
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Safety Instructions
16
Page 17 of 166
17
Service Guide
Service Guide
A closely followed maintenance program will help to keep your Thermo King unit in top operating
condition.
The following service guide table should be used as a guide when inspecting or servicing components on
this unit.
NOTE: If a unit has been carrying cargo which
contains a high level of sulphor or phosphorous
(e.g. garlic, salted fish etc.), it is recommended
that clean evaporator coil after each trip.
Pretrip
Every
1,000
Hours
Annual/
Yearly Inspect/Service These Items
Electrical
• Perform a controller pretrip inspection (PTI) check.
• • • Visually check condenser fan and evaporator fan.
• • • Visually inspect electrical contacts for damage or loose connections.
• • • Visually inspect wire harnesses for damage or loose connections.
• • Download the data logger and check data for correct logging.
• Check operation of protection shutdown circuits.
Refrigeration
• • • Check refrigerant charge.
• • Check for proper discharge and suction pressures.
• Check filter drier/in-line filter for a restriction pressures.
Structural
• • • Visually inspect unit for damaged, loose or broken parts.
• • • Tighten unit, compressor and fan motor mounting bolts.
• • Clean entire unit including condenser and evaporator coils, and defrost drains.
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Service Guide
18
Page 19 of 166
19
Specifications
System Net Cooling Capacity— Full Cool
Evaporator Airflow Specifications
MAGNUM+ Model — Air Cooled
Condensing*
Return air to
evaporator coil
inlet
460/230V, 3 Phase, 60 Hz Power
Net Cooling Capacity Power
Consump
60 Hz
Capacity
B/hr
60 Hz
Capacity
kW
60 Hz Power
kW
21.1 C (70 F) 56,700 16.603 11.55
1.7 C (35 F) 40, 945 11.990 11.03
-17.8 C (0 F) 24,785 7.258 7.57
-29 C (-20 F) 17, 215 5,041 6.6
-35 C (-31 F) 14,000 4.104 6.03
*System net cooling capacity with a 38 C (100 F) ambient air
temperature and R-404A.
System Net Heating Capacity*
460/230V, 3 Phase, 60 Hz Power 380/190V, 3 Phase, 50 Hz Power
Heating Capacity Heating Capacity
Watts Kcal/hr BTU/hr Watts Kcal/hr BTU/hr
MAGNUM+ 5,250 4,515 17914 3,900 3,353 13,300
*System net heating capacity includes electric resistance rods and fan heat.
MAGNUM+
External Static
Pressure (water
column)
460/230V, 3 Phase, 60 Hz Power 380/190V, 3 Phase, 50 Hz Power
High Speed Low Speed High Speed Low Speed
m3/hr ft3/min m3/hr ft3/min m3/hr ft3/min m3/hr ft3/min
0 mm (0 in.) 6,560 3,860 3,170 1,865 5,480 3,225 2,710 1,595
10 mm (0.4 in.) 5,820 3,425 1,770 1,040 4,530 2,665 930 545
20 mm (0.8 in.) 5,000 2,940 — — 3,750 2,205 — —
30 mm (1.2 in.) 4,430 2,610 — — 2,930 1,725 — —
40 mm (1.6 in.) 3,520 2,070 — — 1,870 1,100 — —
Electrical System Specifications
Compressor Motor:
Type 460/380V, 60/50 Hz, 3 Phase
Kilowatts 4.48 kW @ 460V, 60 Hz
Horsepower 6.0 hp @ 460V, 60 Hz
RPM 3550 RPM @ 460V, 60 Hz
Locked Rotor Amps 70 amps @ 460V, 60 Hz
Condenser Fan Motor:
Type 460/380V, 60/50 Hz, 3 Phase
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Specifications
20
Kilowatts 0.55 kW @ 460V, 60 Hz
Horsepower 0.75 hp @ 460V, 60 Hz
Number: All Models 1
Motor:
RPM 1725 RPM @ 460V, 60 Hz
Full Load Amps 1.0 amps @ 460V, 60 Hz; 1.0 amps @ 380V, 50 Hz
Locked Rotor Amps 3.9 amps @ 460V, 60 Hz; 3.7 amps @ 380V, 50 Hz
Evaporator Fan Motors:
Type 460/380V, 60/50 Hz, 3 Phase
Kilowatts 0.75 kW @ 460V, 60 Hz
Horsepower 1.0 hp @ 460V, 60 Hz
Motor:
RPM (Each): High Speed 3450 RPM @ 460V, 60 Hz
Low Speed 1725 RPM @ 460V, 60 Hz
Full Load Amps (Each): High Speed 1.6 amps @ 460V, 60 Hz
Low Speed 0.8 amps @ 460V, 60 Hz
Locked Rotor Amps: High Speed 10.5 amps @ 460V, 60 Hz
Low Speed 9.0 amps @ 460V, 60 Hz
Electrical Resistance Heater Rods:
Type 460/380V, 60/50 Hz, 3 Phase
Number 6
Watts (Each) 680 Watts @ 460V, 60 Hz
Current Draw (Amps) 5 amps total @ 460V across each phase at heater contractor
Control Circuit Voltage:
29 Vac @ 60 Hz
Refrigeration System Specifications
Compressor:
Model No.: ZMD18KVE-TFD-277, Scroll
Refrigerant Charge:
MAGNUM+ 4.0 Kg (8.0 lb.) R-404A
Compressor Oil Capacity 1.77 liter (60 oz.)*
Compressor Oil Type: Polyol Ester Based Type (required), (refer to Tool Catalog)**
*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!
High Pressure Cutout Switch:
Cutout 3240 ± 48 kPa, 32.4 ± 0.5 bar, 470 ± 7 psig
Cutin 2586 ± 262 kPa, 25.9 ± 2.6 bar, 375 ± 38 psig
Low Pressure Cutout Switch:
Cutout -17 to -37 kPa, -0.17 to -0.37 bar, 5 to 11 in. Hg vacuum
Cutin 28 to 48 kPa, 0.28 to 0.48 bar, 4 to 7 psig
High Pressure Relief Valve:
Relief Temperature 99 C, 210 F
Electrical System Specifications
Page 21 of 166
Specifications
21
Vapor Injection Control:
Modulation Cool or Power Limit
Vapor injection valve is energized (open) continuously when
the compressor duty cycle (ON time) is 100 percent (Full
Cool). High compressor discharge temperature may cause
the vapor injection valve to energize (open) but only while
the Compressor Digital Control valve is not energized
(closed).
Compressor Discharge Temperature Control:
Vapor Injection Valve Energizes (Opens) 138 C (280 F)
Vapor Injection Valve De-energizes (Closes) 6 C (10.7 F) below energize temperature
(132 C [123 F])
Compressor Shutdown (Auto Reset) 148 C (298 F)
Vapor Injection Valve (Compressor):
Voltage 24 Vac
Current 0.85 amps
Cold Resistance 5.6 ohms
Compressor Digital Control Valve:
Voltage 24 Vac
Current Draw 0.85 amps
Normal R-404A System Operating Pressures (Scroll Compressor)
Container Temp. Operating
Mode
Ambient
Temp. Suction Pressure Discharge Pressure
21 C (70 F) Cool
27 to 38 C, 80
to 100 F
410 to 670 kPa, 4.10 to 6.70
bar, 59 to 97 psig
2140 to 2650 kPa, 21.40 to
26.50 bar, 310 to 385 psig
16 to 27 C, 60
to 80 F
400 to 600 kPa, 4.00 to 6.00
bar, 58 to 87 psig
1725 to 2140 kPa, 17.25 to
21.40 bar, 250 to 310 psig
2 C (35 F) Cool
27 to 38 C, 80
to 100 F
385 to 425 kPa, 3.85 to 4.25
bar, 56 to 62 psig
1860 to 2380 kPa, 18.60 to
23.80 bar, 270 to 345 psig
16 to 27 C, 60
to 80 F
345 to 385 kPa, 3.45 to 3.85
bar, 50 to 56 psig
1450 to 1860 kPa, 14.50 to
18.60 bar, 210 to 270 psig**
-18 C (0 F) Cool
27 to 38 C, 80
to 100 F
214 to 228 kPa, 2.14 to 2.28
bar, 31 to 33 psig
1515 to 2035 kPa, 15.15 to
20.35 bar, 220 to 295 psig**
16 to 27 C, 60
to 80 F
200 to 215 kPa, 2.00 to 2.15
bar, 29 to 31 psig
1100 to 1515 kPa, 11.00 to
15.15 bar, 160 to 220 psig**
-29 C (-20 F) Cool
27 to 38 C, 80
to 100 F
145 to 160 kPa, 1.45 to 1.60
bar, 21 to 23 psig
1450 to 1965 kPa, 14.50 to
19.65 bar, 210 to 285 psig**
16 to 27 C, 60
to 80 F
130 to 145 kPa, 1.30 to 1.45
bar, 19 to 21 psig
1035 to 1450 kPa, 10.35 to
14.50 bar, 150 to 210 psig**
Suction and discharge pressures vary too greatly during Modulation Cool to use for evaluating or diagnosing refrigeration
system performance. During the Modulation Cool mode, the suction pressure will vary between 100 and 450 kPa, 1.0 and 4.5
bar, 15 and 65 psig depending upon the percent (percent) cooling capacity.
**Discharge pressure is determined by condenser fan cycling.
Refrigeration System Specifications (Continued)
Page 22 of 166
Specifications
22
MP-4000 Controller Specifications
Temperature Controller:
Type
MP-4000 is a controller module for the Thermo King Magnum+
Unit. Additional requirements can be met by means of expansion
modules. The MP4000 is solely responsible for temperature
regulation of the reefer container, but other monitoring equipment
can be used in conjunction with the MP 4000 - such as a chart
recorder.
Setpoint Range -40.0 to +30.0 C (-31.0 to +86.0 F)
Digital Temperature Display -60.0 to +80.0 C (-76.0 to +176.0 F)
Controller Software (Original Equipment):
Version See controller identification decal
Defrost Initiation:
Evaporator Coil Sensor
• Manual Switch or Demand Defrost Initiation: Coil must be
below 18 C (65 F). Defrost cycle starts when technician or
controller requests defrost initiation.
• Timed Defrost Initiation: Coil must be below 4 C (41 F). Defrost
cycle starts 1 minute after the hour immediately following a
defrost timer request for defrost initiation. For example, if the
defrost timer requests a defrost cycle at 7:35, the defrost cycle
will start at 8:01. Datalogger will record a Defrost event for each
interval in which a Defrost cycle is pending or active (i.e. both the
8:00 and 9:00 data logs).
Demand Defrost
Demand defrost function initiates defrost when:
• Temperature difference between the return air sensor and
defrost (evaporator coil) sensor is too large for 90 minutes
• Temperature difference between the supply air sensors and
return air sensor is too large
Defrost Timer:
Chilled mode
Evaporator Coil Temperature must be below 5C (41 F) to activate
the defrost compressor hour timer.
There is an interval set for defrosting, however, the defrost timer is
built intelligent - it detects whether or not there is ice building up on
the coil. If there is no ice building up on the coil, it extends the
defrost interval, and if there is Ice building up earlier on the coil it
reduces the defrost interval. The maximum interval is 48 hours.
Frozen mode
Every 8 hours of compressor operation. Defrost interval increases 2
hours each timed defrost interval. Maximum time interval in Frozen
mode is 24 hours.
Reset to Base Time Defrost timer resets if the unit is off more than 12 hours, setpoint is
changed more than 5 C (9 F) or PTI pretrip test occurs.
Defrost Termination:
Defrost (Coil) Sensor
Chilled mode: Terminates defrost when coil sensor temperature
rises to 18 C (65 F).
Frozen mode: Terminates defrost when coil sensor temperature
rises to 18 C (65 F).
Termination Timer Terminates defrost after 90 minutes at 60 HZ operation if coil
sensor has not terminated defrost (120 minutes at 50 Hz operation)
Power Off Turning Unit On/Off switch Off terminates defrost
v
Page 24 of 166
Specifications
24
AMA313
Unit Dimensions:
A = Flange Width 2025.5 mm (79.74 in.)
B = Gasket Width 1935 mm (76.18 in.)
C = Unit Width 1894 mm (74.57 in.)
D = Flange Height 2235.2 mm (88.00 in.)
E = Gasket Height 2140 mm (84.25 in.)
F = Unit Height 2094 mm (82.44 in.)
G = Gasket Depth 72 mm (2.83 in.) from back of flange
H = Maximum Protrusion 37 mm (1.46 in.) from back of flange
I = MAGNUM+ 420.0 mm (16.54 in.) from back of flange
J = MANGUM+ Evaporator Access Door
Figure 1: Physical Specifications
Page 25 of 166
Unit Description, Features & Options
25
Unit Description, Features & Options
Introduction
This chapter will briefly describe the following
items:
• General Unit Description.
• Standard Component Descriptions.
• Optional Component Descriptions.
General Description
MAGNUM units are all-electric, single-piece,
refrigeration units with bottom air supply. The
unit is designed to cool and heat containers for
shipboard or overland transit. The unit mounts in
the front wall of the container. Fork lift pockets
are provided for installation and removal of the
unit.
The frame and bulkhead panels are constructed of
aluminum and are treated to resist corrosion. A
removable evaporator compartment door provides
service access. All components except the
evaporator coil and electric heaters can be
replaced from the front of the unit.
Each unit is equipped with an 18.3 m (60 ft.)
power cable for operation on 460-380V/3
Ph/60-50 Hz power. The unit power cable is
stored below the control box in the condenser
section.
Each unit is equipped with 460-380V/3 Ph/60-50
Hz electric motors. An automatic phase correction
system provides the proper electrical phase
sequence for condenser fan, evaporator fan and
compressor operation.
Figure 2: MAGNUM+ Unit
The MAGNUM+ container unit features the
following components. Each component will be
described briefly on the following pages.:
• Scroll Compressor
• Compressor Digital Control Valve
• Economizer Heat Exchange System
• Temperature Sensors
• Fresh Air Exchange System
• Receiver Tank Sight Glass
• Evaporator Fans
• Condenser Fan Control
• Suction/Discharge Pressure Sensor (Optional)
• Remote Monitoring Receptacle Option (4-pin)
(optional)
• Remote Monitoring Modem (RMM)
(Optional)
• USDA Cold Treatment Temperature
Recording (Optional)
• Advanced Fresh Air Management (AFAM) and
Advanced Fresh Air Management Plus
(AFAM+) (Optional)
BEN074
Page 26 of 166
Unit Description, Features & Options
26
Scroll Compressor
The scroll compressor features a digital port and
an intermediate suction port.
Digital Port
The digital port provides cooling capacity control.
The digital port is located at the top of the scroll
assembly on the compressor body. When
energized, the Digital Control valve disengages
the scroll set. This reduces pumping capacity to
zero.
Intermediate Suction Port
The intermediate suction port draws suction gas
from the economizer heat exchanger into the
scroll assembly of the compressor. The scroll
seals off the suction port. This prevents
economizer gas from leaking back to the main
suction port. It also prevents the economizer gas
pressure from influencing the cooling capacity of
the unit evaporator (main suction gas pressure).
Figure 3: Scroll Compressor
MP-4000 Controller
The MP-4000 is an advanced microprocessor
controller that has been specially developed for
the control and monitoring of refrigeration units.
See “Controller Description and Operating
Chapter” for more detailed information.
Compressor Digital Control
Valve
The MP-4000 controller pulses the Compressor
Digital Control solenoid valve between open and
closed positions. This provides precise cooling
capacity control. No pump down function or
warm gas bypass control is used in conjunction
with the Compressor Digital Control valve. See
the “General Theory of Operation Chapter” for
more detailed information.
Figure 5: Compressor Digital Control Solenoid
Valve
1. MP-4000 Controller
Figure 4: MP-4000 Controller
1
BEN074
AXA0428
Page 27 of 166
Unit Description, Features & Options
27
Economizer Heat Exchange
System
An economizer heat exchange system replaces the
conventional heat exchanger. The economizer
Heat Exchange system subcools the liquid
refrigerant before it reaches the evaporator
expansion valve. Subcooling liquid refrigerant
increases the cooling efficiency and capacity of
the evaporator. See the “General Theory of
Operation Chapter” for more detailed
information.
Figure 6: Economizer Heat Exchanger
Temperature Sensors
Each sensor element is connected to a cable and
packaged in a sealed stainless steel tube. The
temperature signal from the sensor is transmitted
through the cable. PT.1000 type temperature
sensors are used to sense temperatures for the:
• Supply Air
• Return Air
• Evaporator Coil
• Condenser Coil
• Ambient Air
The compressor sensor is of Thermistor type and
is located in the top cap of the compressor.
These sensors are field replaceable. Five sensor
receptacles are provided; three USDA and one
cargo temperature.
Fresh Air Exchange System
The fresh air exchange system removes harmful
gases from containers carrying sensitive
perishable commodities. The fresh air vent is
located above the control box. The fresh air vent
is adjustable to accommodate a variety of frozen
and chilled load operating conditions.
Fresh Air Exchange Recorder
(Optional)
The Fresh Air Exchange Recorder detects vent
disk movement. It automatically displays a value
on the Display.This value is also logged in the
datalogger. The entry records the time, date and
vent opening position. It mounts on the fresh air
vent door.
Figure 8: Fresh Air Exchange Recorder
AXA0427 1. Fresh Air Exchange Vent
Figure 7: Fresh Air Exchange Vent
1
BEN075
AJA1964
Page 28 of 166
Unit Description, Features & Options
28
Receiver Tank Sight Glass
The receiver tank contains a sight glass which has
three small balls that indicate the level of
refrigerant in the tank for checking the refrigerant
charge. A moisture indicator in the sight glass
changes color to indicate the level of moisture in
the system.
Evaporator Fans
MAGNUM models are equipped with either 2 or
3 evaporator fans. All models feature 2-speed
motors. The evaporator fans operate continuously
to circulate air inside the container. The
evaporator fans operate on:
• High and low speed for chilled cargo at
setpoints of -9.9 C (14.1 F) and above
• Low speed for frozen cargo at setpoints of
-10 C (14 F) and below
The evaporator fan low speed RPM is one-half the
high speed RPM.
The controller determines evaporator fan motor
speed based on the setpoint temperature and the
Economy mode setting.
NOTE: If Non-Optimised mode is on:
• Chill Loads: Evaporator fans operate on high
speed
• Frozen Loads: Evaporator fans operate on
low speed
NOTE: If optimised mode is on:
• Chill Loads: Evaporator fans operate on high
and low speed - depending on the need for
cooling.
• Frozen Loads: Evaporator fans operate on low
speed and stops when there is no need for
cooling.
Condenser Fan Control
The controller also uses a proportional-integral
derivative algorithm to control the condenser
temperature and ensure a constant liquid pressure
at the expansion valve. The condenser fan
operates continuously in high ambients. In low
ambient conditions, the controller cycles the
condenser fan on and off to maintain a minimum
condenser temperature. The controller maintains a
minimum 30 C (86 F) condenser temperature on
Chill loads and a minimum 20 C (68 F) condenser
temperature on Frozen loads.
1. Moisture Indicator:
Light Green = Dry
Yellow = Wet
2. Outer ring is color coded. Compare to
indicator.
Figure 9: Receiver Tank Sight Glass
AXA0371
Page 29 of 166
Unit Description, Features & Options
29
Unit Options
This unit is available with several options that are
listed in Figure 10. These options are specified
when placing the order. These options are briefly
described on the following pages.
Recording Thermometer (Optional)
The recording thermometer indicates and
permanently records the temperature of the air
returning to the evaporator section on a calibrated
chart.
Several models of temperature recorders are
available for mounting on the unit. Each
temperature recorder is designed to withstand
widely varying environments including low and
high ambient temperatures, salt water, humidity,
fungus, industrial pollutants, dynamic loading,
rain, sand and dust.
Remote Monitoring Modem (RMM)
(Optional)
A REFCON remote monitoring modem is
provided to permit remote monitoring via the
power cable. High speed transmission reads all
controller information. Data can also be retrieved
from the data logger via high speed transmission.
Suction and Discharge Pressure
Sensors (Optional)
Pressure sensors can be added to the unit to
display actual suction or discharge system
pressure. The display will show a reading and a
bar graph. Unit can be configured suction only,
discharge only, or suction and discharge.
Air Ventilation Logging (AVL -
Optional)
AVL is used for detecting and logging the fresh air
exchange position on the manual fresh air vent.
The opening angle of the fresh air vent is con- verted to an output signal from approximately 2-5
volts.
The opening is detected in steps of 5m3/h, from 0
to 125. When opening is greater than 125m3/h the
log will just state that the opening is greater than
125m3/h.
1. Recording Thermometer (Optional)
2. Air Ventilation Logging (AVL)
3. Water Pressure Switch (Optional)
4.
Remote Monitor Modem for Power Line
Communications (REFCON control modem
inside Control Box) (Optional)
5. USDA Sensor Receptacle (Access from Inside
Container) (Optional)
6. Suction/Discharge Pressure Transducer
(Optional)
Figure 10: Optional Components
BEN061
1
6
5
4 3
2
Page 30 of 166
Unit Description, Features & Options
30
USDA Cold Treatment Temperature
Recording (standard)
The MP-4000 controller includes provisions for
the use of three or four USDA sensors. These
sensors allow temperatures in various areas of the
load to be monitored and recorded for United
States Department of Agriculture use in
monitoring Cold Treatment shipments.
When USDA sensors are installed, the controller
will automatically detect each sensor and activate
data logging. However, the USDA Type screen in
the Configuration menu must be set to the correct
sensor setting and each USDA sensor must be
calibrated to comply with USDA temperature
recording requirements.
Figure 11: Water-Cooled Condenser/Receiver Tank
Water-Cooled Condenser/Receiver
Tank (Optional)
A water-cooled condenser/receiver provides the
unit with above and below deck operating
capabilities. Condenser fan control is provided in
software or by a Condenser Fan Selection switch
or a Water Pressure switch. Starting april 2005 we
have added a shutoff valve on the outlet tube of
the water-cooled condenser.
Condenser fan switch is a software key. This
switch is provided on the control box with the
water-cooled condenser option. Place the
Condenser Fan On/Off switch in the Water
position for water-cooled condenser operation.
Water Pressure Switch (Optional)
When water pressure greater than 117 ± 21 kPa,
1.17 ± 0.21 bar, (17 ±3 psig) is provided to the
condenser-receiver tank, the water pressure switch
closes. This causes the controller to stop
condenser fan operation. When the water pressure
decreases below 35 ± 21 kPa, 0.35 ± 0.21 bar, (5 ±
3 psig), the switch opens, causing the controller to
place the unit on air-cooled condenser fan
operation.
Water-cooled condenser requires a water flow of
19 to 38 l/min. (5 to 10 gal./min.).
Advanced Fresh Air Management
(AFAM) System (Optional)
An advanced microprocessor controlled fresh air
management system provides programmable
control of air exchange rate, programmable
delayed vent opening, automatic closure of air
exchange vent during low ambient conditions, and
data logging of air exchange rate and vent opening
delay interval.
The AFAM system includes a door control
module, vent door and vent grille. The MP-4000
controller sends a communication signal to the
door control module to position vent door to
desired position. The controller can also be set to
delay opening of fresh air vent for up to 72 hours
(in 1 hour increments). This allows faster product
temperature pull-down.
AFAM Operation
The system is pre-calibrated for air exchange rates
of 0 to 280 m3/hr. (0 to 165 ft3/min.). The actual
door position is based on the air exchange setting
and the power supply frequency.
Page 38 of 166
Unit Description, Features & Options
38
Page 39 of 166
39
Controller Description
Controller Description
The MP-4000 is an advanced microprocessor
controller. It has been specially developed for the
control and monitoring of refrigeration units. The
controller contains the following basic features:
Temperature/Message Status Display:
• Temperature area. Displays Return air sensor,
Supply air sensor, and Setpoint
• Message area. Displays Alarms, Message and
Controller menu
Keypad:
• F1 – F4 Function keys navigate within the
Status Display
• 2 Status LED indicators
• Special Function keys. ON/OFF, PTI, Defrost
Controller Back-up Battery
Every Controller has a Back-up Battery. This will
allow the controller to be energized if the unit is
not connected to shore power. The technician can
change settings in the controller - Setpoint, etc.
Press the ON/OFF key, the controller will
energize and stay energized for 25 sec, by
pressing any of the Menu keys the 25 sec timer
will reset to 20 sec.
Controller Input and Output Signals
The MP-4000 microprocessor controls all unit
functions to maintain the cargo at the proper
temperature. The controller also monitors and
records system faults and performs pretrip.
The MP-4000 controller uses advanced solid-state
integrated circuits to monitor and control unit
functions. The controller monitors inputs from:
• Return Air Sensor
• Supply Air Sensor
• Evaporator Coil Sensor
• Condenser Coil Sensor
• Ambient Sensor
• Humidity Sensor
• USDA (Spare) Sensors 1, 2 and 3
• Compressor Discharge Line Temperature
Sensor
• High Pressure Cutout Switch/Discharge
Pressure Sensor
• Low Pressure Cutout Switch/Suction Pressure
Sensor
• Phase measuring circuits
• Current measuring circuits
• Voltage measuring circuits
Output signals from the controller automatically
regulate all unit functions including:
• Compressor operation
• Condenser fan operation
• Evaporator fan motor operation
• Compressor digital valve
• Vapor injection valve
• Dehumidify valve
• Electric heaters
• Phase selection
Page 42 of 166
Controller Description
42
When the set Defrost termination temperature is
reached, the unit will return to the operation mode
depending on the setpoint.
PTI
PTI is a pretrip inspection and is used to diagnose
the condition of the unit. There are a possibility to
chose between several type of PTI ́s depending on
the test needed to secure the functionality of the
unit.
Function Keys
The function keys are the F1 - F4 keys located
below the display. They allow the operator to
move quickly to a specific area of the information
or into the controller menu.
Function keys will change based on what menu is
active in the display
Figure 21: Function Keys
• F1 ALARM key: Press to view an
explaination for the current alarms present.
• F2 C/F key: Press to view alternate
temperature scale Celsius or Fahrenheit in
display.
• F3 SETPOINT key: Press to enter Setpoint
menu. Press F2 Up or F3 Down keys to
increase or decrease the Setpoint. Press and
Hold F4 until you are returned back to the
main menu.
• F4 MENU key: Press to view the extended
Menu for the MP4000
Indicator LEDs
Two status indicator LEDs are located just under
the F1-F4 function keys
Green Led Flashing Temperature
approaching in-range
Solid Temperature
In-Range
BEN 056
Red Led Flashing Alarm present and has
not been
acknowledged
Solid Alarm present and has
been acknowledged
Page 43 of 166
Controller Description
43
Three Special Function Keys
The Special Function keys are located around the
TK Logo. These special function key allow the
operator to move quickly to perform a specific
function
Figure 22: Special Function Keys
PTI Pre-Trip Inspecion
* Defrost
ON
OFF
Unit On/OFF Control
Page 56 of 166
Main Menu
54
4. Press the F4 ENTER KEY to start the Function
test. Display shows functional test currently
being performed. Function test ends
automatically. Unit automatically returns to
normal operation.
See Figure 32 for the full Function Test
Procedure. Any alarm codes recorded during the
test can be viewed through the controller’s Alarm
List menu at the end of the test.
Manual Function Test
The Manual Function Test menu allows
technicians to perform specific diagnostic tests on
individual components or turn several
components on at the same time to perform a
system test.
Figure 31: Manual Function Test
NOTE: THE UNIT STOPS when the Manual
Function Test menu is entered. A technician can
then select the control circuit or component to be
checked/tested from the items shown in the
menu.
Complete the following steps to enter the Manual
Function Test menu.
With the unit turned on, allow Unit to start and
stabilise and the Display showing the unit status
display (setpoint):
1. Press the F4 MENU key. Press the F3 key to
scroll down to the Commands Menu.
2. Press the F4 ENTER KEY to access the
Commands menu.
3. Press the F2 OR F3 UP/DOWN key to scroll to
[MANUAL FUNCTION TEST].
SETPOINT
Commands Menu
- PTI
- Brief PTI
- Functions Test
- Manual Functions Test
- Defrost
- Trip Start
DATA
COMMAND
ALARM LIST
WARNING LIST
CONFIGURATION
DATALOGGER
STATES
NOTE: All screens are NOT
present on all units. The
screens that display on the
controller are determined by
the Controller Software
settings and the options
installed on the unit.
Page 57 of 166
Main Menu
55
4. Press the F4 ENTER KEY to enter the Manual
Function Test: [CONDENSER OFF] appears
in the Display.
To test a unit component:
1. Press the F2 OR F3 UP/DOWN key to scroll to
desired component test:
• [PHASE DIRECTION]
• [HEATER]
• [COMPRESSOR]
• [EVAPORATOR FAN HIGH]
• [EVAPORATOR FAN LOW]
• [CONDENSER FAN]
• [ECONOMIZER VALVE]
• [DIGITAL VALVE]
2. Press the F4 ENTER KEY to start the
component test. Display will change the
component state from off to on.
3. Verify component performance: Display will
show expected current and actual current on
phase 1, 2 and 3.
4. Press the F4 ENTER KEY again to stop test.
Display will change component state from on
to off.
System Test (test multiple components at the
same time):
1. Press the F2 OR F3 UP/DOWN key to scroll to
the first component.
2. Press the F4 ENTER KEY to turn the component
on.
3. Press the F3 key to scroll to select next
component. Press theF4 ENTER KEY to turn
component on.
4. Repeat step 3 until all required components
are on. For example, to operate unit in Full
Cool mode, start the following components:
• Condenser Fan
• Compressor
• Capacity 100 percent
• Evaporator High or Low
5. Observe current draw and system performance
to verify component(s) performance.
6. Press the F4 ENTER KEY again to turn off
components individually. Or press the F1 key
to exit Manual Function Test menu and turn
all components off.
Press the F1 key to exit the Manual Function Test
submenu.
Page 58 of 166
Main Menu
56
Figure 32: PTI, Brief PTI, Function Tests
Display* Description Possible
Alarms
Duration
(Time)
PTI Brief
PTI
Function
Test
PTI START
Activated
0.1A 0.0A 0.1A
Event Log for PTI begins.
Awaits phase selection, and
surveillance to start up.
All alarms are turned off. Alarm
list is cleared.
All relays are turned off and air
vent are closed.
18 1 to 100
seconds
X X X
SENSOR TEST
Activated
0.1A 0.0A 0.1A
Testing sensor interface, All
sensors must have values within
their measuring range.
00, 01, 02,
03, 04, 05,
32, 33, 34,
35, 60, 97,
98, 120,
121, 123
Instant X X X
EVAP FAN LOW
SPEED TEST
SUP RET EVA
5.1C 5.0C 5.1C
1.1A 1.0A 1.1A
With evaporator fan on low
speed, amp draw is measured
and compared to the expected
amp draw, in respect to voltage
and frequency:
• MAGNUM+ / MAGNUM+
40’SL:
1.0 Amps approx. at 50 Hz,
1.0 Amps approx. at 60 Hz
• MAGNUM+ 20’SL:
1.5 Amps approx. at 50 Hz,
1.5 Amps approx. at 60 Hz
Amperes are recorded in the PTI
log.
14, 15 5 seconds X X X
EVAP FAN HIGH
SPEED TEST
SUP RET EVA
5.1C 5.0C 5.1C
2.4A 2.3A 2.4A
With evaporator fan on high
speed, amp draw is measured
and compared to the expected
amp draw, in respect to voltage
and frequency. If the minimum
phase amp draw is less than
70% of the maximal amp draw
both alarm is set.
• MAGNUM / MAGNUM 40’SL:
2.1 Amps approx. at 50 Hz,
2.5 Amps approx. at 60 Hz
• MAGNUM 20’SL:
2.7 Amps approx. at 50 Hz,
3.2 Amps approx. at 60 Hz
Amperes are recorded in PTI log.
12, 13 5 seconds X X X
Page 59 of 166
Main Menu
57
COND FAN TEST
SUP RET EVA
5.2C 5.0C 5.1C
1.3A 1.2A 1.3A
With condenser fan on, amp
draw is measured and compared
to the expected amp draw, in
respect to voltage and frequency.
If the phase amp draw differs
more than 1,0 Amp both alarm is
set.
• MAGNUM+ Expected Power Con- sumption:
1.2 Amps approx. at 50 Hz,
1.5 Amps approx. at 60 Hz
Amperes are recorded in PTI log.
16, 17 5 seconds X X X
PROBE TEST
SUP RET EVA
5.1C 5.0C 5.1C
2.4A 2.3A 2.4A
Evaporator fans operate on high
speed for maximum 3 minutes.
Then probe test runs until
temperature difference between
sensors stops increasing.
Maximum temperature
difference allowed:
• Return/Evaporator: 1.5C (34.7F);
return air sensor temperature must
be 0.5C (32.9F) above evaporator
sensor temperature.
• Return/Supply: 0.8C (33.0F);
return air sensor temperature must
be 0.5C (32.9F) above supply air
temperature.
• LH Supply/RH Supply (if
equipped): 0.5C (32.9F).
115, 116,
117
1 minute
minimum
to
13 minutes
maximum
X X X
REVERSE PHASE
TEST
SUP RET EVA
1.3C 1.0C 1.3C
1.3A 1.2A 1.3A
With condenser fan on, reverse
phase selector relay is
energized. Condenser fan and
compressor reverse current is
measured.
58 30 seconds X X X
HEATER TEST
SUP RET EVA
1.3C 1.0C 1.3C
5.2A 5.1A 5.2A
Electric heaters are turned on.
Amp draw is measured to the
expected amp draw, in respect
to voltage and frequency
• 4.4 Amps approx. at 400V;
• 5.1 Amps approx. at 460V.
Heater amperes are recorded in
PTI log.
10, 11 5 seconds X X X
DEFROST TEST
SUP RET EVA
5.0C 12.0C 15.0C
5.2A 5.1A 5.2A
If evaporator temperature is
below +10C, heater remains on
until evaporator temperature is
above +18C.
Defrosting until Eva. > 18C/64F
20 0-90
Minutes at
voltage
above 440V
0-120
Minutes at
voltage
below 440V
X X -
Display* Description Possible
Alarms
Duration
(Time)
PTI Brief
PTI
Function
Test
Page 60 of 166
Main Menu
58
TEMPERATURE
STABILISATION With evaporator fan on high
speed awaiting the supply, return
and evaporator temperatures to
stabilize.
Delta SUP-RET and Delta
RET-EVA must be stable, within
7 seconds.
Awaiting temperature stability
None 20 to 180
seconds
X X -
PRE HEAT TEST
SUP RET EVA
5.1C 5.0C 5.1C
2.3A 2.1A 2.3A
Test is skipped if return air tem- perature is at 5degC or above.
With electric heaters turned on
and evaporator fan on high
speed, the test will end when
return air temperature is at
5degC or above.
Heating until 5C/41F
None Instant to 2
hours
X X -
PRE COOL TEST
SUP RET EVA
5.1C 5.0C 5.1C
2.3A 2.1A 2.3A
If the return air temperature is
below 15C (68F) the test is
skipped. Unit operates in cool
until the return sensor is less
then +15C (59F) or 1 hour
Cooling until 15C/59F
None Instant to 2
hours
X X -
VENTILATING If heater or compressor has been
running in the preceding test,
the unit is ventilated with
evaporator fan on high speed.
Ventilating
None 60 seconds X X X
COMPRESSOR TEST
AMB CON EVA
8.0C 15.0C 5.0C
9.1A 9.0A 9.1A
Compressor loaded, and con- denser fan activated for 10 sec.
Followed by compressor run
alone for 7 sec before the amp
draw is measured and compared
to the expected amp draw, in
respect to voltage and frequency.
Amperes are recorded in the
PTI log.
Evaluating power consumption
6, 7 18 seconds X X X
Display* Description Possible
Alarms
Duration
(Time)
PTI Brief
PTI
Function
Test
Page 61 of 166
Main Menu
59
COMPRESSOR
DIGITAL TEST
AMB CON EVA
8.0C 25.0C 2.0C
9.1A 9.0A 9.1A
Compressor running loaded,
evaporator fan at high speed,
and condenser fan maintaining
30-35degC for 15 sec.
Next the compressor is unloaded
and running for 10 sec
Amp draw difference is mea- sured and expected to be at least
0,9 Amp (Con > 35C) or 1,5 Amp
(Con < 35C).
119 25 to 35
seconds
X
X
X
COMPRESSOR
ECONOMIZER TEST
AMB CON EVA
8.0C 45.0C 1.0C
9.1A 9.0A 9.1A
With compressor on (loaded),
condenser and evaporator fans
at high speed are turned on for
30 seconds. If condenser fan
temperature is below 30C (86F)
then the test is aborted.
Vapor injection valve is turned
on. Amp draw difference is
measured and verified to be
minimum 0.4 amps.
Evaluating Power Consumption
Increase.
26 Max 90
seconds
X
X
X
Display* Description Possible
Alarms
Duration
(Time)
PTI Brief
PTI
Function
Test
Page 62 of 166
Main Menu
60
HIGH PRESSURE
CUTOUT TEST Running with compressor fully
loaded and with evaporator fan
at high speed, awaiting high
pressure cut out. The test is
ended if the condenser coil
probe reads temperature above
70oC and the HPCO does not
occurs. The time observing is
depending on the startup tem- perature and will be increased as
long as the condenser tempera- ture is increasing.
After the HPCO the compressor
signal is removed and the
condenser fan is activated to
lower the pressure in the
condenser. When the tempera- ture gets below 40oC the
compressor is also activated.
The test will then look for when
the HPCO gets back to normal in
maximal 60 seconds.
Awaiting HPCO - Compressor
stop
53, 54 Max. 200
seconds
X X -
CAPACITY TEST With compressor fully loaded con- denser fan on and evaporator
fan at high speed running for the
time period. At the end of the
test is the cooling capability
evaluated.
Evaluating cooling capability
22 180
seconds for
40’ and 240
seconds for
20’ unit.
- X -
APPROACHING 0
TEST Probe readings and time are
recorded in the pti log when
started. When supply air temper- ature is at 0 degC / 32F the test
is ended. If the test is not ended
within the time limit the alarm is
set.
Approaching 0C/32F
23 Max. 2
hours
X - -
Display* Description Possible
Alarms
Duration
(Time)
PTI Brief
PTI
Function
Test
Page 63 of 166
Main Menu
61
MAINTAINING 0C TEST With the unit running chilled –
Non-Optimised, maintaining 0 degC /
32F.
After 30 minutes the probe readings
and time are recorded in
the pti log.
Maintaining 0C/32F
None 30 Minutes X X -
DEFROST TEST Test is skipped and Fail if either of
alarm 4,5,130 is present.
Test is skipped if evaporator temper- ature is at 5degC or above.
With electric heaters turned on, the
test will pass when
evaporator temperature reach
18degC or above.
Defrosting until Eva. > 18C/64F
4, 5, 20,
130
0 to 90 min- utes at volt- age above
440V
0 to 120
minutes at
voltages
below 440V.
X X X
PULLDOWN TO -18 C
TEST With the unit running frozen,
approaching -18 degC / 0F.
Probe readings and time are
recorded in the pti log when
started and when ended. When
return air temperature is at -18
degC / 0F the test is ended. If the
test is not ended within the time
limit the alarm is set.
Approaching -18C/0F
22 Max. 3
hours
X X -
PTI END “PTI End” are recorded in PTI log
and a Trip Start is
automatically activated.
All alarms are cleared and must
be acknowledged by the user.
Unit awaits an ACCEPT of the
just ended test before returning
to normal operation.
PASSED - PASSED - PASSED
FAILED - FAILED - FAILED
26 Max 90
seconds
X X X
Display* Description Possible
Alarms
Duration
(Time)
PTI Brief
PTI
Function
Test
Display* LED
Display
Description Possible
Alarms
Duration
(Time)
Page 64 of 166
Main Menu
62
RUNNING PTI
0°C / 32°F
00:00:00
0.0C 10.0C 10.0C
Supply
temp.
Unit operates in normal mode with 0C
(32F) setpoint for 30 minutes after
previous test is completed. At the end of
30 minutes, “Chill End” temperatures are
recorded in PTI log. Sensor values for
supply, return and evaporator sensors are
recorded in the event log.
None 120 minutes
maximum
RUNNING PTI
DEFROST
00:00:00
-18.0C 10.0C 10.0C
Return
temp.
Unit operates in normal mode with -18C
(0F) setpoint and defrost activated. Defrost
terminates when evaporator temperature
increases to 18C (65F).
20 30 minutes
RUNNING PTI
-18°C / 0°F
00:00:00
-18.0C 10.0C 10.0C
Return
temp.
Unit operates in normal mode with -18C
(0F) setpoint. When return air temperature
decreases to setpoint, Frozen Arrival”
temperatures are recorded in PTI log.
“PTI End” are recorded in PTI log and a
Trip Start is automatically activated.
22, 60 90 minutes
maximum
PTI PASS – PRESS
KEY
Return
temp.
Unit will remain OFF until any key is
pressed.
If alarms occurred during PTI, Display
shows “PTI FAIL – PRESS KEY”.
None 180 minutes
maximum
* Readings may vary depending on voltage and temperature
Page 68 of 166
Main Menu
66
Warning List Menu
Alarm List Menu
Warning
Code Action
1 Power Error, Check 20A Fuses
2 High Pressure Cutout, Check Water
Cooling
3 Probe Test, Please Wait
7 High Pressure Cutout, Check
Condenser Probe
9 High Pressure Cutout, Check
Condenser Fan
11 Scroll Compressor, High Temperature
12 Scroll Compressor, Low Pressure
21 Total Current Too High
22 Total Current Too Low
23 Supply Air Temperature Too High
24 Supply Air Temperature Too Low
25 Return Air Temperature Too High
26 Evaporator Coil Temperature Too High
27 Evaporator Coil Temperature Too Low
Alarm
Code Action
00 Supply Air Sensor Open Circuit
01 Check Supply Air Sensor Short Circuit
02 Check Return Air Sensor Open Circuit
03 Check Return Air Sensor Short Circuit
04 Check Evaporator Coil Open Circuit
05 Check Evaporator Coil Sensor Short
Circuit
06 Check Compressor Current Too High
07 Check Compressor Current Too Low
10 Check Heater Current Too High
11 Check Heater Current Too Low
12 Check Evaporator Fan High Speed
Current Too High
13 Check Evaporator Fan High Speed
Current Too Low
14 Check Evaporator Fan Low Speed
Current Too High
15 Check Evaporator Fan Low Speed
Current Too Low
16 Check Condenser Fan Current Too High
17 Check Condenser Fan Current Too Low
18 Log Power Supply Phase Error
19 Check Temperature Too Far from
Setpoint
20 Check Defrost Time Too Long
22 Check Capacity Test 1 Error
26 Vapor Injection Valve Error
31 Low Pressure Cutout Error
32 Check Condenser Air Sensor Open
Circuit
33 Check Condenser Air Sensor Short
Circuit
34 Check Ambient Air Sensor Open Circuit
35 Check Ambient Air Sensor Short Circuit
43 Check Return Air Temperature
51 Check for Low Voltage
52 Check Probe Error
53 Check High Pressure Cutout Switch Off
Error
54 Check High Pressure Cutout Switch On
Error
56 Shutdown Compressor Temperature
Too High
58 Check Phase Sensor Error
59 Check Delta Current Error
60 Check Humidity Sensor Error
98 Log Compressor Sensor Short Circuit
119 Digital Valve Error
120 Check Suction Pressure Sensor
121 Check Discharge Pressure Sensor
122 Re-calibrate O2 Sensor
123 Check Datalogger Battery
124 Check Power Module Sensor
128 Check Supply Air Temperature Probe
129 Check Return Air Temperature Probe
130 Check Evaporator Coil Temperature
Probe
131 Ambient Condition Temperature Probe
Error
Alarm
Code Action
Page 110 of 166
Refrigeration Maintenance
108
Perform an Oil Acid Test
Perform an oil acid test (refer to Tool Catalog for
oil test kit) whenever a unit has a substantial
refrigerant loss, a noisy compressor or dark/dirty
oil.
Isolate the Compressor
The discharge suction and digital ball service
valves isolate the compressor from the high and
low sides of the refrigeration system.compressor
isolation is needed for system diagnosis, service
and repair.
NOTE: The valves are a permanently assembled
unit and must be replaced in total if defective.
The only maintenance possible on the discharge
or suction service valve is to periodically tighten
the packing nut or to replace the packing.
• Back Seated: Normal operation position.
• Open to Service Port: Position for servicing.
• Front Seated: To check or remove compressor.
Working with a Gauge Manifold
Using a New Gauge Manifold Set
A new gauge manifold set and gauge hoses (refer
to Tool Catalog) should be dedicated for use with
only R-404refrigerant.
Gauge Manifold Valve Positions
The gauges indicate low and high side pressures.
Operate one or both hand valves to perform the
different service operations.
WARNING: Do not start unit with
discharge valve in Front Seated position.
1. Full Counterclockwise
Figure 61: Service Valve Back Seated
1. 1/2 Turn in
Figure 62: Service Valve Open to Port
AXA0176
AXA0177
1. Full Clockwise
Figure 63: Service Valve Front Seated
1. Quick Disconnect Access Valve
2. Discharge Service Valve (DSV)
3. Suction Service Valve (SSV)
Figure 64: Balancing the Pressure
AXA0178
AXA0241