Daikin LXE10E-1 User manual

TR03-06
(2003.12.00200)NK
$5,00
DAIKIN CONTAINER
LXE10E-1
TR 03-06
Service Manual
Head Office. Umeda Center Bldg., 4-12, Nakazakinishi 2-chome, Kita-ku, Osaka, 530-8323 Japan.
Tel: [phone] (From overseas 81-6-6373-4338)
Fax: [phone] (From overseas 81-6-6373-7297)
Tokyo Office. Tokyo Opera City Tower 12F. 3-20-2 Nishi-Shinjuku, Shinjuku-ku, Tokyo 163-1412, Japan.
Tel: [phone] (From overseas 81-3-5353-7860)
Fax: [phone] (From overseas 81-3-5353-7913)
Marine type Container Refrigeration Unit Service Manual LXE10E-1
Container Refrigeration Unit
Marine type
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1
Please read the contents of this manual prior to operation of the unit.
In addition, refer to the manuals listed below:
●Parts List
●Operation Manual of Personal Computer Software
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CONTENTS
3.10.1 Chart indication mode ........................3-57
3.10.2 P code (Pull down time indication).....3-59
3.10.3 Chartless code display function..........3-60
3.10.3.1 List of chartless codes.................3-60
3.10.3.2 H-code.........................................3-61
3.10.3.3 d-code: ........................................3-63
3.11 Communication modem............................3-64
4. Service and Maintenance.................................4-1
4.1 Maintenance service.....................................4-1
4.1.1 Collection of refrigerant..........................4-1
4.1.2 Gauge manifold......................................4-1
4.1.3 Automatic pump down............................4-3
4.1.4 Refrigerant recovery and charge............4-5
4.2 Main components and maintenance.............4-9
4.2.1 Scroll compressor...................................4-9
4.2.2 Fan and fan motor................................4-15
4.2.3 PT and CT board (EC9756) .................4-16
4.2.4 Electronic expansion valve...................4-17
4.2.5 Thermostatic expansion valve..............4-18
4.2.6 Suction modulation valve .....................4-19
4.2.7 Drier......................................................4-20
4.2.8 Solenoid valve......................................4-21
4.2.9 Discharge pressure regulating valve....4-22
4.2.10 Check valve........................................4-22
4.2.11 High-pressure switch (HPS)...............4-23
4.2.12 Low pressure transducer (LPT)..........4-23
4.2.13 High pressure transducer (HPT) ........4-24
4.2.14 Water pressure switch (WPS)............4-24
4.2.15 Humidity sensor..................................4-24
4.2.16 Ventilation port opening degree sensor
(FA sensor) ........................................4-25
4.2.17
Air-cooled condenser and evaporator ...4-25
4.2.18 Water cooled condenser ....................4-26
4.2.19 Fusible plug........................................4-26
4.2.20 Liquid/moisture indicator ....................4-26
4.2.21 Evacuation and dehydrating...............4-27
5. Additional Devices............................................5-1
5.1 USDA transportation.....................................5-1
5.1.1 Type of USDA sensor/receptacle...........5-1
5.1.2 Initial setting ...........................................5-1
5.1.3 USDA sensor calibration........................5-1
5.1.4 USDA transportation requirement..........5-1
5.1.5 USDA report...........................................5-1
6. Troubleshooting................................................6-1
6.1 Refrigeration system and electrical system...6-1
6.2 Alarm codes on electronic controller.............6-5
6.3 Troubleshooting for automatic PTI (J-code) ...6-10
6.4 Emergency operation..................................6-12
6.4.1 Emergency operation of controller .......6-12
6.4.2 Short circuit operation of controller.......6-13
6.4.3 Opening adjustment of electronic
expansion valve....................................6-14
6.4.4 Emergency operation of suction
modulating valve ..................................6-15
6.4.5 Automatic Back up for supply / return air
temperature sensors ............................6-16
7. Appendix............................................................7-1
7.1 Standard tightening torques for bolts............7-1
7.2 Standard tightening torques for flare nuts.....7-1
7.3 Standard tightening torque for stop valve .....7-1
7.4
Resistance of motor coil and solenoid valve coil ...7-2
7.5 Standard tightening torque for electronic
expansion valve coil (EV coil) .......................7-2
7.6 HFC134a, temperature-vapor pressure
characteristics table ......................................7-3
7.7 Temperature sensor characteristics table.....7-4
7.8 Temperature sensor characteristics table DCHS ...7-5
7.9
High pressure transducer characteristics table ...7-5
7.10
Low pressure transducer characteristics table .7-5
7.11 Piping diagram............................................7-6
7.12 Pilot lamps...................................................7-7
7.13 Fuse protection table...................................7-8
7.14 Schematic wiring diagram.........................7-10
7.15 Stereoscopic wiring diagram.....................7-11
Safety Precautions
• Danger .................................................................3
• Warning................................................................4
• Caution.................................................................5
1. Introduction.......................................................1-1
1.1 Operation range............................................1-1
1.2 Basic Names of components ........................1-1
1.3 Basic operation of refrigeration unit ..............1-2
1.3.1 Operation preparation ............................1-2
1.3.2 Starting operation...................................1-3
1.3.3 Checking during operation .....................1-4
1.3.4 Procedure after operation.......................1-4
1.3.5 Adjust the ventilation..............................1-5
2. General description ..........................................2-1
2.1 Main specifications........................................2-1
2.2 Names of components..................................2-2
2.2.1 Outside...................................................2-2
2.2.2 Inside......................................................2-4
2.2.3 Control box.............................................2-6
2.3
Set point of functional parts and protection devices ...2-9
2.4 Operating pressure and running current.....2-10
2.5 Operation modes and control......................2-14
2.5.1 Frozen mode........................................2-15
2.5.2 Chilled mode ........................................2-17
2.5.3 Defrosting mode...................................2-19
2.5.4 Dehumidification...................................2-22
2.5.5 Common control...................................2-23
3. Electronic Controller.........................................3-1
3.1 Function table................................................3-1
3.2 Basic operation of electronic controller.........3-3
3.2.1 Control panel..........................................3-3
3.2.2 Operation mode and control...................3-5
3.3 Operation procedure.....................................3-6
3.3.1 Operation procedure flow chart..............3-6
3.3.2 Mode operation procedure.....................3-9
1. Current indication mode.........................3-9
2. Operation setting mode........................3-10
3. Battery mode........................................3-11
4. Mode operation ....................................3-12
5. LED display light-OFF mode................3-15
6. Sensor indication mode........................3-16
7. Temperature record scroll mode..........3-19
8. Alarm record scroll mode .....................3-22
3.3.3 Setting flow chart..................................3-24
10. Optional function setting mode...........3-26
11. Basic function setting mode ...............3-27
12. Optional condition setting mode.........3-29
13. Input data mode .................................3-31
14. Controller software download mode...3-32
3.4 Alarm display and back-up function............3-33
3.4.1 Alarm list...............................................3-33
3.4.2 Back-up operation at sensor
malfunction...........................................3-34
3.5 Battery.........................................................3-36
3.5.1 Specifications.......................................3-36
3.5.2 Function................................................3-36
3.5.3 Battery check........................................3-36
3.5.4
Battery replacement (Rechargeable battery) ...3-37
3.6 Information interchange with personal computer ...3-38
3.6.1 Data logging.........................................3-39
3.6.2 Software configuration..........................3-40
3.7 Inspection procedure for the electronic controller ...3-42
3.8 Controller replacement and initial setting....3-43
3.8.1 Controller replacement.........................3-43
3.8.2 Initial setting & operation procedure.....3-44
3.9 PTI (Pre-Trip Inspection) and periodic inspection ...3-45
3.9.1 Inspection item.....................................3-46
3.9.2 Automatic PTI (Pre-Trip Inspection).....3-49
3.9.2.1 PTI selection mode........................3-50
3.9.2.2 Short PTI (S.PTI)...........................3-51
3.9.2.3 Full PTI (F.PTI)..............................3-52
3.9.2.4
Alarm list during PTI (Pre-Trip Inspection) ...3-54
3.9.2.5 Manual check (M.CHECK) ............3-55
3.10 Chartless function .....................................3-57
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3
SAFETY PRECAUTIONS
DANGER
High voltage
Circuit breaker
Modem (optional)
Always turn off the main power supply in the facility (※1)
before inspecting the interior of the control box.
※ This is important because high voltage remains at the
circuit breaker and the optionally provided modem even
though the circuit breaker in the control box is turned off.
Always observe the following points before operating or
inspecting a unit.
※1: with 30 Amps circuit breaker
Always turn off the main power supply in the facility (※1)
before disconnecting the power plug.
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Do not touch the condenser fan while power to the
unit is ON.
Before removing the condenser fan cover, turn off the
circuit breaker and disconnect the power plug.
During air-cooled operation : Condenser fan may start
and stop automatically for
the refrigerant high
pressure control.
During water-cooled operation: Condenser fan may start
and stop automatically for
cooling of the control box.
4
WARNING
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5
CAUTION
Before starting the unit, run the generator.
Securely close the control box cover.
Otherwise, it will allow water entry.
Quick-lock lever
Control box cover
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6
CAUTION
Wash the refrigeration unit with fresh water at PTI.
Carefully flush the air-cooled condenser with fresh water to
remove the salt that sticks to it.
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7
Use only exclusive tools for HFC134a. (gauge manifold, charging cylinder, etc)
Do not use any tools for CFC12 or HCFC22.
Service ports with exclusive quick joints for HFC134a are provided in the refrigeration
unit to avoid improper refrigerant or refrigerant oil from entering into the refrigeration
circuit. (Refer to section 4.4.2)
The charging hose and gauge port are not interchangeable with those of previous
models using other refrigerants.
7
CAUTION
Refrigerant and refrigerant oil
Be sure to only charge the unit with refrigerant HFC 134a.
Never attempt to use any other refrigerant (CFC12, HCF22, etc) with the
refrigeration unit.
If any other refrigerant not specified is charged, it may cause problems with the unit.
Use only Daikin specified oil (IDEMITSU, Daphne Hermetic Oil FVC46D) when
replacing the refrigerant oil.
If any other refrigerating machine oil not specified is charged, it may cause problems
with the unit.
Open the oil can, just before charging the oil, and use all the oil in the can once
opened.
Do not leave the can open for 5 hours or longer to avoid moisture entry.
Using any refrigerant oil which has absorbed moisture may cause problems with the
unit.
Moisture Moisture
DAPHNE
HERMETIC OIL
FVC46D
SUNISO
3GS - DI
D
A
P
H
N
E
H
E
R
M
E
T
I
C
O
I
L
F
V
C
4
6
D
S
W
-
4
6
OIL
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8
CLASS 1 SPECIFIED PRODUCT BY
THE HYDROFLUORIC REFRIGERANT RECOVERY LAW
HFC IS USED FOR THIS PRODUCT AS A REFRIGERANT.
(1) EMISSION OF HYDROFLUORIC SUBSTANCES INTO THE ATMOSPHERE
WITHOUT PERMISSION IS PROHIBITED.
(2)RECOVERY OF HYDROFLUORIC SUBSTANCES IS MANDATORY WHEN
SCRAPPING THIS PRODUCT.
(3) THE KIND OF HYDROFLUORIC SUBSTANCE AND ITS AMOUNT ARE STATED IN
THE MANUFACTURER'S LABEL OR THE ADDITIONALLY CHARGED AMOUNT
LABEL.
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1-1
1. Introduction
1.1 OPERATION RANGE
Use the units within the following range.
1.2 BASIC NAMES OF COMPONENTS
Ambient temperature range
Inside temperature range
Cooling water Temperature
Water volume
Pressure
Voltage
Vibration and shock
Operation range
-30˚C to +50˚C (-22˚F to + 122˚F)
-30˚C to +30˚C (-22˚F to + 86˚F)
10˚C ~ 36˚C (50˚F ~ 96.8˚F)
23 ~ 30R/min.
196 ~ 490kPa (2 ~ 5kg/cm2)
50Hz: 380V/400V/415V, 60Hz: 440V/460V
Voltage fluctuation rate should be within ±10%
2G
Item
10
18
12
11
13
19
14
16
2
5
4
9
17
6781531
qCompressor
wCompressor suction side stop valve
eCompressor disharge side stop valve
rEvaporator
tAir-cooled condenser
yWater cooled condenser
uCooling water inlet Connect these connector
connector when the water cooled
operation is required.
Operation will be changed to
water cooled operation
automatically
iCooling water outlet connector
oEvaporator fan
!0 Condenser fan
!1 Control box
Outside: switch, manual defrost switch, monitoring
receptacle
Inside: circuit breaker
!2 Upper ventilator (Above 80m3/h)
!3 Lower ventilator (Below 80m3/h)
!4 Sampling port (Return) Use this port to measure the
inside return air temperature.
!5 Gas sampling port This is used to measure the
Sampling port (Supply) inside supply air temperature
and inside CO2concentration.
!6 Liquid moisture indicator
!7 Drier
!8 Access panel
!9 Storage space for power cable

































 
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14 3 2
(Outlet joint) (Inlet joint)
1-2
1.3 BASIC OPERATION OF
REFRIGERATION UNIT
Operate the unit by the following
procedure.
1.3.1 Operation preparation
(1) Make sure that the compressor discharge
and suction side stop valves q, ware
opened.
(Refer 1.2 Basic name of components.)
(2) Connect the cooling water piping to joints.
(When the water cooled operation is
required.)
Cooling water piping connection (Air and water
cooled combination unit)
For water-cooled operation, connect the water
piping to feed water.
·Connection method
1. Connect the inlet joint e.
2. Connect the outlet joint r.
·Disconnection method
1. Disconnect the outlet joint r.
2. Disconnect the inlet joint e.
Connect the cooling water joint in the following
method.
Connection method: Insert a joint on the ship side in
the piping joint on the unit side and push it in until
you feel a click.
When connecting or disconnecting the joint, be
careful not to be subject to cooling water splashes.
Piping connection method on cooling water
outlet side
Disconnection method: Pull the joint on the ship side
toward you with Part A of the joint on the female side
pushed and held as shown by the arrow in figure
above. [Note] While in water-cooled operation, do
not attempt to touch the condenser fan by
hand. (The condenser fan turns ON or
OFF to cool the control box.)
Mount on the ship side.
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1-3
t
u
(2) Connect the power plug to the power supply.
Insert the plug tsuited to the power source
voltage, and fasten the plug firmly.
(3) Turn on the main power switch of the power
source facility (outside the unit)
(4) Turn on the circuit breaker y.
(5) Close the control box cover fully.
If it is poorly closed, it will allow water entry.
Check the contact around the packing, and
firmly close the cover. (Refer to the
"CAUTION " on page 5.)
(6) Press the UNIT ON/OFF key u.
Power plug
y
1.3.2 Starting operation
(1) Make sure that power to the unit is on.
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1-4
1.3.3 Checking during operation
1. Check the compressor, fan, pipes, etc. for abnormal noise and vibration.
2. Check the refrigerant for shortage.
3. Check the refrigerant for moisture inclusion.
4. Check operating conditions with the pilot lamps.
Method of check
Visual and auditory
Visual
The moisture indicator colour;
Green: normal
Yellow: abnormal.
Visual
Checking items(precautions)
Visual
During the chilled mode, the bubbles always
appear in the moisture indicator.
Do not charge the refrigerant excessively.
Overcharging can damage the compressor.
1.3.4 Procedure after operation
(1) Turn off the UNIT ON/OFF key e, and turn off
the circuit breaker w.
(2) Close the control box cover tightly.
(3) Stow the power cable.
Disconnect the power plug q, and stow the
power cable directing the plug opening
downward to prevent sea water or rain water
from collecting in the power plug.
q
e
w
Liquid moisture indicator
qPower plug
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CAUTION
Keep the ventilation closed during
transportation of the frozen cargo.
1.3.5 Adjust the ventilation
Adjust the opening of the lower or upper
ventilator according to the cargo.
When the ventilation amount is 80 m3/h or more,
use the upper ventilator to adjust the amount.
When the amount is not more than 80 m3/h, use
the lower ventilator cover for the adjustment.
Air inlet Ventilation cover
Handle
Air outlet
Air inlet
Air outlet
Nameplate
Upper ventilator (80~250m3/h)
When ventilation is not required (frozen mode),
set the handle to "CLOSE". When ventilation is required (chilled mode), slide the handle upward.
※ Set the arrow mark of the ventilation at the
graduation on the scale to adjust the
ventilation as desired according to the cargo.
1-5
Air inlet
Ventilation
cover
Handle
Air outlet
"CLOSE" "OPEN"
When ventilation is not
required (frozen mode),
set the handle to
"CLOSE".
When ventilation is
required (chilled
mode), slide the
handle upward.
Lower ventilator (0~80m3/h)
※By pressing the key on the operation panel, the ventilation amount will be displayed.
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1-6
CAUTION
Be sure to make the zero-point adjustment of the ventilation cover (if the ventilation
amount is not more than 80 m3/h) at each PTI.
<Zero point adjustment procedure>
While the unit is running, move the ventilation port to a fully closed position manually to
set the ventilation port to "closed state" (i.e., CLOSE setting mode), thus making
automatic zero-point adjustment of ventilation amount through the difference from that at a
position for the ventilation port to start port.
Use the or key while in manual check
selection mode to set the ventilation port to
CLOSE setting mode (in which the LCD screen
displays "FA CAL". Then, press the key, and
the current value of sensor sliding amount will be
displayed.
Pressing and holding the key for a period of 3
seconds while the sliding amount is displayed will
make it possible to reset the sliding amount to "0".
Ventilation port
CLOSE setting
Condenser fan
motor
operating time
Controller
software version
COMP. DEFROST IN RANGE DE-HUMID.
SUPPLY
RETURN
ALARM
R.H.
Press and hold
the key for
a period of 3
seconds.
※Caution for lower ventirator opening
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2-1
2. General description
2.1 Main specifications
Model
Item LXE10E-1
Condenser cooling system Air cooled type
Controller DECOS3d
Power supply AC 3-phase 380V/400V/415V 50Hz, 440V/460V 60Hz
Compressor Hermetic scroll type (Motor output: 5.5kW)
Evaporator Cross fin coil type
Water-cooled condenser Shell and coil type
Evaporator fan Propeller fan
Evaporator fan motor Three-phase squirrel-cage induction motor
Condenser fan Propeller fan
Condenser fan motor Three-phase squirrel-cage induction motor
Defrosting
Hot-gas defrosting system
Dual timer, on-demand defrost and manual switch
Detecting the temperature of evaporator outlet pipe and return air
Electronic expansion valve
Capacity control Capacity control with hot gas bypass and suction modulating valve
Protective devices
/Safety devices
Circuit breaker, PT/CT board (for over current protection).
Condenser fan-motor thermal protector
Evaporator fan-motor thermal protector
High-pressure switch, Fusible plug, Fuse (10A, 5A)
Refrigerant (charged amount) R134a : 5.4 (kg)
Refrigerant oil (charged amount) IDEMITSU, Daphne hermetic oil FVC 46D : 2.2(R)
Weight LXE10E-1 : 505(kg)
System
Initiation
Termination
Refrigerant flow control
Compressor thermal protector
Air-cooled condenser Cross fin coil type
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2-2
2.2 Names of components
2.2.1 Outside
●LXE10E-1
qCompressor
wCompressor suction side stop valve
eCompressor disharge side stop valve
rEvaporator
tAir-cooled condenser
yWater cooled condenser
uCooling water inlet connector
iCooling water outlet connector
oEvaporator fan
!0 Condenser fan
!1 Control box
!2 Upper ventilator (Above 80m3/h)
!3 Lower ventilator (Below 80m3/h)
!4 Sampling port (Return)
!5 Gas sampling port Sampling port (Supply)
!6 Liquid moisture indicator
!7 Drier
!8 Access panel
!9 Storage space for power cable
@0 Discharge gas by-pass solenoid valve (BSV)
@1 Capillary solenoid valve (CSV)
@2 Defrost solenoid valve (DSV)
@3 Economizer solenoid valve (ESV)
@4 Electronic expansion valve (EV)
@5 Hot-gas solenoid valve (HSV)
@6 Injection solenoid valve (ISV)
@7 Liquid solenoid valve (LSV)
@8 Reheat coil solenoid valve (RSV)
@9 Discharge pressure regulating valve (DPR)
#0 Suction modulating valve (SMV)
#1 Thermostatic expansion valve (TEV)
#2 Ambient temperature sensor (AMBS)
#3 Discharge pipe temperature sensor (DCHS)
#4 High pressure switch (HPS)
#5 High pressure transducer (HPT)
#6 Low pressure transducer (LPT)
#7 Compressor suction pipe temperature sensor (SGS)
3133 15 32 372
24
22
12
10
35
14
11
13
19
18 9
4
5
16
31
23
26
277 68
34
17
29
20
36
30
25
28
21
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2-3
●LXE10E-1
· Detail of solenoid valves
EV
Liquid
Moisture
Indicator
ISV
ESV
TEV
HSV BSV DSVRSVCSV
LPT
DCHS
HPT
HPS
Sensor
Valve
Service
Port wqrte
Drier
AMBS
CSSV
CDSV SGS SMV
LSV DPR
WPS
[Valve]
BSV :Bypass Solenoid Valve
CDSV:Compressor Discharge Stop Valve
CSSV:Compressor Suction Stop Valve
CSV :Capillary Solenoid Valve
DSV :Defrost Solenoid Valve
DPR :Discharge Pressure Regulator Valve
EV :Electronic Expansion Valve
ESV :Economizer Solenoid Valve
ISV :Injection Solenoid Valve
LSV :Liquid Solenoid Valve
RSV :Reheater Solenoid Valve
for dehumidification control
SMV :Suction Modulation Valve
TEV :Thermostatic Expansion Valve
[Sensor]
AMBS:Ambient Air Temperature Sensor
DCHS:Discharge Gas Temperature Sensor
HPS :High Pressure Switch
HPT :High Pressure Tranceducer
LPT :Low Pressure Tranceducer
SGS :Suction Pipe Temperature Sensor
WPS :Water Pressure Sensor
·Detail of compressor and refrigerant control devices
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2-4
2.2.2 Inside
●LXE10E-1
qEvaporator fan motor (EFM)
wEvaporator
eSupply air temperature sensor (SS)
Data recorder supply air temperature sensor (DSS)
rEvaporator outlet pipe temperature sensor (EOS)
tEvaporator inlet pipe temperature sensor (EIS)
yReturn air temperature sensor (RS)
Data recorder return air temperature sensor (DRS, optional)
uUSDA receptacle
iCargo temp. receptacles
oP.C. Port receptacles
!0 Humidity sensor
!1 Reheat coil
10 6 1
8
9
3
7
5
4
2
11
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2-5
※Reheater for
Dehumidification Control
Evaporator Drain Pan Heater PCR, Indoor
(Personal
Computor
Receptacle)
USDA1
USDA2
USDA3
CTR
EIS
EOS
RS/DRS
HuS
[Sensor]
CTR :Cargo Temperature Receptacle
DRS :Return Air Temperature Sensor for Datacorder
DSS :Supply Air Temperature Sensor for Datacorder
EIS :Evaporator Inlet Temperature Sensor
EOS :Evaporator Outlet Temperature Sensor
HuS :Humidity Sensor
RS :Return Air Temperature Sensor
SS :Supply Air Temperature Sensor
USDA 1:USDA Receptacle 1
USDA 2:USDA Receptacle 2
USDA 3:USDA Receptacle 3
·Inside Detail
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