Section 5
5.1Inspection (Before Loading)
Beware of unannounced starting of the evaporator and condenser fans. The unit may cycle the fans and compressor unexpectedly as control requirements dictate.
a.If container is empty, check inside for the following:
1.Check channels or “T” bar floor for cleanliness. Channels must be free of debris for proper air circulation.
2.Check container panels, insulation, and door seals for damage. Make permanent or temporary repairs.
3.Visually check evaporator fan motor mounting bolts for proper securement (refer to Section 7.15).
4.Check for visible corrosion on the evaporator stator and fan deck (refer to Section 7.15).
5.Check for dirt or grease on evaporator fan or fan deck and clean if necessary.
6.Check evaporator coil for cleanliness or obstructions. Wash with fresh water (Refer to Section 7.13).
7.Check defrost drain pans and drain lines for obstructions and clear if necessary. Wash with fresh water.
8.Check panels on refrigeration unit for loose bolts and condition of panels. Make sure T.I.R. devices are in place on access panels.
b.Check condenser coil for cleanliness. Wash with fresh water (Refer to Section 7.10).
c.Open control box door. Check for loose electrical connections or hardware.
d.Check color of moisture-liquid indicator.
e.Check oil level in compressor sight glass (if applicable).
Do not attempt to remove power plug(s) before turning OFF start-stop switch (ST), unit circuit breaker(s) and external power source.
Make sure the power plugs are clean and dry before connecting to power receptacle.
5.2.1Connection To 380/460 VAC Power
1.Make sure start-stop switch (ST on control panel) and circuit breaker (CB-1 in the control box) are in position “O” (OFF).
2.Plug the 460VAC (yellow) cable into a de-energized 380/460VAC, 3-phase power source. Energize the power source. Place circuit breaker (CB-1) in position “I” (ON). Close and secure control box door.
5.2.2Connection to 190/230VAC Power (option)
An autotransformer (Figure 5.1) is required to allow operation on nominal 230 volt power. It is fitted with a 230VAC cable and a receptacle to accept the standard 460VAC power plug. The 230 volt cable is black in color while the 460 volt cable is yellow. The transformer may also be equipped with a circuit breaker (CB-2). The transformer is a step-up transformer that will provide 380/460VAC, 3-phase, 50/60 hertz power to the unit when the 230VAC power cable is connected to a 190/230VAC, 3-phase power source.
1.Make sure that the start-stop switch (ST, on control panel) and circuit breakers CB-1 (in the control box and CB-2 (on the transformer) are in position “O” (OFF). Plug in and lock the 460VAC power plug at the receptacle on the transformer.
2.Plug the 230VAC (black) cable into a de-energized 190/230VAC, 3-phase power source. Energize the power source. Set circuit breakers CB-1 and CB2 to position “I” (ON). Close and secure control box door.
5.3Adjust Fresh Air Makeup Vent
The purpose of the fresh air makeup vent is to provide ventilation for commodities that require fresh air circulation. The vent must be closed when transporting frozen foods.
Air exchange depends on static pressure differential, which will vary depending on the container and how the container is loaded.
Units may be equipped with a vent position sensor (VPS). The VPS determines the position of the fresh air vent (upper or lower, as equipped) and sends data to the controller display.
5.3.1Upper Fresh Air Makeup Vent
Two slots and a stop are designed into the Upper Fresh Air disc for air flow adjustments. The first slot allows for a 0 to 30% air flow; the second slot allows for a 30 to 100% air flow.
To adjust the percentage of air flow, loosen the wing nut and rotate the disc until the desired percentage of air flow matches with the arrow. Tighten the wing nut.
To clear the gap between the slots, loosen the wing nut until the disc clears the stop.
Figure 5.2 gives air exchange values for an empty container. Higher values can be expected for a fully loaded container.
Figure 5.2 Make Up Air Flow Chart
The VPS allows the user to determine position of the fresh air vent via Cd45. This function code is accessible via the code select key.
The vent position will display for 30 seconds whenever motion corresponding to 5CMH (3CFM) or greater is detected. It will scroll in intervals of 5CMH (3CFM). Scrolling to Cd45 will display the Fresh Air Vent Position.
The position of the vent will be recorded in the DataCORDER whenever the unit is running under AC power and any of the following:
Trip start
On every power cycle
Midnight
Manual change greater than 5 CMH (3 CFM) and remains in that position for at least four minutes
The user has four minutes to make necessary adjustments to the vent setting. This time calculation begins on the initial movement of the sensor. The vent can be moved to any position within the four minutes. On completion of the first four minutes, the vent is required to remain stable for the next four minutes. If vent position changes are detected during the four minute stability period, an alarm will be generated. This provides the user with the ability to change the vent setting without generating multiple events in the DataCORDER.
5.4Connect Remote Monitoring Receptacle
If remote monitoring is required, connect remote monitor plug at the unit receptacle, see Figure 3.5.
When the remote monitor plug is connected to the remote monitoring receptacle, the following remote circuits are energized:
CIRCUIT |
FUNCTION |
|---|---|
Sockets B to A |
Energizes remote cool light |
Sockets C to A |
Energizes remote defrost light |
Sockets D to A |
Energizes remote in-range light |
5.5Starting and Stopping Instructions
Make sure that the unit circuit breaker(s) (CB-1 & CB-2) and the START-STOP switch (ST) are in the “O” (OFF) position before connecting to any electrical power source.
a.With power properly applied, the fresh air vent in proper position, place the START−STOP switch to “I” (ON), see Figure 3.5.
b.The Controller Function Codes for the container ID (Cd40), software version (Cd18) and unit model number (Cd20) will be displayed in sequence.
c.Continue with Start Up Inspection (refer to Section 5.6).
To stop the unit, place the START-STOP switch in position “O” (OFF).
a.Check rotation of condenser and evaporator fans.
b.Check compressor oil level (refer to Section 7.8.6).
5.6.2Check Controller Function Codes
Check and, if required, reset controller Function Codes (Cd27 through Cd39) in accordance with desired operating parameters (refer to Section 4.2.2).
5.6.3Start Temperature Recorder
DataCORDER
a.Check and, if required, set the DataCORDER Configuration in accordance with desired recording parameter. Refer to Section 4.8.2.
b.Enter a “Trip Start.” To enter a “Trip Start,” do the following:
1.Depress the ALT MODE key. When the left display shows, dC, depress the ENTER key.
2.Scroll to Code dC30.
3.Depress and hold the ENTER key for five seconds.
4.The “Trip Start” event will be entered in the DataCORDER.
Allow unit to run for five minutes to stabilize conditions and perform a pre-trip diagnosis in accordance with Section 5.7.
Pre-trip inspection should not be performed with critical temperature cargoes in the container.
When Pre−Trip key is pressed, economy, dehumidification and bulb mode will be deactivated. At the completion of Pre−Trip activity, economy, dehumidification and bulb mode must be reactivated.
Pre-Trip diagnostics provides automatic testing of the unit components using internal measurements and comparison logic. The program will provide a “PASS” or “FAIL” display to indicate test results.
The testing begins with access to a Pre-trip selection menu. The user may have the option of selecting one of three automatic tests.
These tests will automatically perform a series of individual Pre-trip tests. The user may also scroll down to select any of the individual tests.
When only the short sequence is configured, it will appear as “AUtO” in the display. Otherwise “AUtO1” will indicate the short sequence and “AUtO2” will indicate the long sequence. The test short sequence will run tests P0 through P6. The long test sequence will run tests P0 through P10.
A detailed description of the Pre-trip test codes is listed in Table 4–7. If no selection is made, the Pre-trip menu selection process will terminate automatically. However, dehumidification and bulb mode must be reactivated manually if required.
Scrolling down to the “rSLts” code and pressing ENTER will allow the user to scroll through the results of the last pre-trip testing run. If no pre-testing has been run (or an individual test has not been run) since the unit was powered up, “−−−−” will be displayed.
To start a Pre-trip test, do the following:
NOTE
1.Prior to starting a Pre−trip test, verify that unit voltage (Cd07) is within tolerance and unit amperage draw (Cd04, Cd05, Cd06) are within expected limits. Otherwise, tests may fail incorrectly.
2.All alarms must be rectified and cleared before starting tests.
3.Pre−trip may also be initiated via communications. The operation is the same as for the keypad initiation described below except that should a test fail, the Pre−trip mode will automatically terminate. When initiated via communications, a Pre−trip test may not be interrupted with an arrow key, but the Pre−trip test can be terminated with the PRE−TRIP key.
a.Press the PRE−TRIP key to accesses the Pre−trip test selection menu.
b.TO RUN AN AUTOMATIC TEST: Scroll through the selections by pressing the UP ARROW or DOWN ARROW keys to display AUTO, AUTO 2 or AUTO 3 as desired and then press the ENTER key.
1.The unit will execute the series of tests without any need for direct user interface. These tests vary in length, depending on the component under test.
2.While tests are running, “P#-#” will appear on the left display, where the #’s indicate the test number and sub-test. The right display will show a countdown time in minutes and seconds, indicating the amount of time remaining in the test.
When a failure occurs during automatic testing the unit will suspend operation awaiting operator intervention.
When an automatic test fails, it will be repeated once . A repeated test failure will cause “FAIL” to be shown on the right display, with the corresponding test number to the left.
The user may then press the DOWN ARROW to repeat the test, the UP ARROW to skip to the next test or the PRE-TRIP key to terminate testing. The unit will wait indefinitely until the user manually enters a command.
When Pre-Trip test Auto 2 runs to completion without being interrupted, the unit will terminate pre-trip and display “Auto 2” “end.” The unit will suspend operation until the user depresses the ENTER key!
When an Auto test runs to completion without a failure, the unit will exit the Pre-trip mode and return to normal control operation.
If configuration variable CnF42 is set to IN, a DataCORDER trip start will be entered. If CnF42 is set to OUT, the trip start will not be entered. However, dehumidification and bulb mode must be reactivated manually if required.
c. TO RUN AN INDIVIDUAL TEST: Scroll through the selections by pressing the UP ARROW or DOWN ARROW keys to display an individual test code. Pressing ENTER when the desired test code is displayed.
1.Individually selected tests, other than the LED/ Display test, will perform the operations necessary to verify the operation of the component. At the conclusion, PASS or FAIL will be displayed.
This message will remain displayed for up to three minutes, during which time a user may select another test. If the three minute time period expires, the unit will terminate pre-trip and return to control mode operation.
2.While the tests are being executed, the user may terminate the pre-trip diagnostics by pressing and holding the PRE-TRIP key.
The unit will then resume normal operation. If the user decides to terminate a test but remain at the test selection menu, the user may press the UP ARROW key. When this is done all test outputs will be de-energized and the test selection menu will be displayed.
3.During Pre−trip testing, current limiting and pressure limiting are both active, except during P−7 (High Pressure Switch Testing) when pressure limiting is turned off.
d. Pre-Trip Test Results
At the end of the pre-trip test selection menu, the message “P,” “rSLts” (pre-trip results) will be displayed. Pressing the ENTER key will allow the user to see the results for all subtests (i.e., 1-0, 1-1, etc).
The results will be displayed as “PASS” or “FAIL” for all the tests run to completion since power up. If a test has not been run since power up, “−−−−−” will be displayed.
Once all pre-test activity is completed, dehumidification and bulb mode must be reactivated manually if required.
A complete temperature probe check is performed during the P5 Pre−trip test. A probe check is also run at the end of a defrost cycle; the defrost light will remain on during this period. If supply probes are within limits and return probes are within limits, the unit will return to normal operation. During normal operation, the controller continuously monitors and compares adjacent temperature probe readings.
The probe check procedure consists of running the evaporator fans for up to eight minutes in order to compare the readings from the adjacent temperature probes. If a significant difference in temperature readings is detected between probes, a defrost cycle, followed by another probe check may be initiated. Any continued disagreement between probes will prompt the controller to invalidate the failed temperature probe, and the backup probe will be used for temperature control.
In Perishable Mode, both pairs of supply and return probes are monitored for probe disagreement. Probe disagreement is considered a difference of 0.5°C (0.9°F) or greater between the supply air sensors and/ or a difference of 2.0°C (3.6°F) between the return air sensors. Probe disagreement found in either pair can trigger a defrost probe check.
In Frozen Mode, only the controlling probes are considered. Disagreement of the controlling probes can trigger a defrost probe check, which will occur when the difference between the sensors is greater than 2.0°C (3.6°F). Normally, the controlling probes are the return probes but if both return probes are invalidated, the supply probes are used for control purposes. Probe disagreement of the non−controlling probe pair will not trigger a defrost probe check.
If, after the defrost probe check, the supply probes agree and return probes agree, all supply and return sensors are considered valid and the unit returns to normal control.
In the Case of Probe Disagreement:
If the supply probes disagree and the return probes agree, the controller will invalidate the worst supply probe. If the probe check is run as part of Pre−trip P−5, an alarm will be triggered for the invalidated probe. If it is a run time defrost probe check, the invalidated probe will be passed over and no alarm will be triggered. However, if the best supply probe is greater than 1.2°C (2.2°F) difference with respect to its return probes, the best supply probe is also invalidated. If unit is in Perishable Mode, a probe alarm will be triggered for both supply probes.
If the supply probes agree and the return probes disagree, invalidate the worst return probe. If the probe check is being run as part of Pre−trip P−5, an alarm will be triggered for the invalidated probe. If it is a run time defrost probe check, the invalidated probe will be passed over and no alarm will be necessary. If the best return probe is greater than 1.2°C (2.2°F) difference with respect to its supply probes, then the best return probe is also invalidated. If the unit is in perishable mode, a probe alarm will be triggered for both return probes.
5.9Emergency Bypass Operation (option)
Operation by the refrigeration controller may be overridden by use of the EMERGENCY BYPASS switch. The EMERGENCY BYPASS switch functions to bypass the controller in the event of controller failure.
To place the unit in the emergency bypass mode, cut the wire tie installed at the switch mounting and place the EMERGENCY BYPASS switch in the BYPASS position. This will in turn activate the Emergency Bypass System (EBS) control module.
To operate the fans only, the MODE switch must be in the FANS ONLY position and the EMERGENCY BYPASS Switch must be in the ON position.
The EBS module uses the system safety devices (high pressure switch, motor internal protectors, and heat termination thermostat) to protect the system while in Emergency Bypass Mode.
The unit will remain in the full cooling mode as long as the emergency bypass switch is in the BYPASS position and the MODE SWITCH is in the FULL COOL position.
If the cargo is at risk of being damaged by low temperatures, the operator must monitor container temperature and manually cycle operation as required to maintain temperature within required limits.
In the ON position the EBS will be enabled. With the MODE SWITCH in the FULL COOL MODE. The following will occur simultaneously:
1.The EBS switch will enable EBS input.
2.The phase detection circuit will detect the phase rotation and close to provide power to the compressor contactor.
3.The condenser fan contact will close to energize the condenser contactor and provide power to the condenser fan motor.
4.The evaporator fan contact will close to energize the high speed evaporator contactor and provide power to the evaporator fan motor.
5.The EBS electronic module will open the SMV to 100%.
To return the unit to normal operation, place the EBS switch in the NORMAL OPERATION position. When emergency operation is no longer required, re-install the wire tie at the switch mounting.