Envirotainer RAP e2 User manual

This manual is valid for:
RAP container,
P/N 140010R-()
Doc No. MO-RAP-3079
Version 17 www.envirotainer.com
RAP e2 container
Operations Manual
Doc No:
MO-RAP-3079
Revision:
17
State:
Released
Release Date:
2019-04-25
Approved By:
maxf

RECORD OF REVISION
VER. NO. REVISION
Operations Manual RECORD OF REVISION
RAP e2 container
17 REVISED:
• Revised document title and front page image.
• Changed the version number format from 1.7 to 17 to conform ith the document footer
added by Windchill.
• Updated applicable figures ith the ODLN sticker.
•9. Technical Specification: Added “For other aircrafts, alternative operating procedures may
apply” under Other information.
•7.1 Start the Control Unit and 8.2 Infos: Changed the direction of the aeroplane icon in the
display unit images.
• Revised layout of admonitions.
ADDED:
•1.7 ODLN sticker.
Doc No:
MO-RAP-3079
Revision:
17
State:
Released
Release Date:
2019-04-25
Approved By:
maxf

Operations Manual TABLE OF CONTENTS
RAP e2 container
TABLE OF CONTENTS
1. INTRODUCTION.......................................................................................................................... 1
1.1 Scope of the Manual.................................................................................................................1
1.2 Symbols ..................................................................................................................................1
1.3 Safety Instructions....................................................................................................................1
1.4 The Container ..........................................................................................................................2
1.5 Control Unit..............................................................................................................................3
1.6 Charging Unit...........................................................................................................................3
1.7 ODLN sticker ...........................................................................................................................4
2. LIMITS, AMBIENT CONDITIONS............................................................................................. 5
2.1 Pre-conditioning of Cargo..........................................................................................................5
2.2 Minimum Operating Time - fully charged Container .....................................................................5
2.3 Exposure to Ambient Temperature above +30°C (+86°F).............................................................5
2.4 Exposure to Ambient Temperature below -10°C (+14°F)..............................................................6
3. CHARGING................................................................................................................................... 7
3.1 Charging Procedure .................................................................................................................8
3.2 Additional Charging Adapters..................................................................................................10
3.3 Charging with damaged Cable or Cable Winder........................................................................ 11
4. PRE-CONDITIONING ............................................................................................................... 12
4.1 Cargo pre-conditioning............................................................................................................12
4.2 Container pre-conditioning ......................................................................................................13
4.2.1 Pre-conditioning with Container operating in Non-temperature Controlled Area..............13
4.2.2 Pre-condition with a Temperature-controlled Room ...................................................... 13
5. GENERAL CARGO LOADING GUIDELINES ...................................................................... 14
5.1 Cargo loading ........................................................................................................................15
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Doc No:
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Revision:
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Release Date:
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Operations Manual TABLE OF CONTENTS
RAP e2 container
5.2 After Cargo loading.................................................................................................................16
5.2.1 Ambient temperature recording ..................................................................................16
6. GENERAL CONTAINER HANDLING GUIDELINES........................................................... 17
6.1 Forklift Requirements..............................................................................................................17
6.1.1 Lifting the Container from the left or right side ..............................................................17
6.1.2 Lifting the Container from the aft side..........................................................................17
6.1.3 Lifting the container with Electric Pallet Jacks .............................................................. 18
6.2 Roller Beds ............................................................................................................................19
6.3 Ambient Conditions ................................................................................................................19
6.4 Shipment Duration..................................................................................................................19
6.5 Wrapping...............................................................................................................................19
6.6 Ground Transport Precautions.................................................................................................20
6.7 Aircraft Transport Precautions .................................................................................................20
6.8 Unloading ..............................................................................................................................20
6.8.1 After unloading..........................................................................................................20
6.9 Storage .................................................................................................................................20
6.10 Battery Switch ........................................................................................................................21
6.11 Long-time Storage (not in Shipment)........................................................................................21
7. CONTROL UNIT OPERATION................................................................................................ 22
7.1 Start the Control Unit ..............................................................................................................22
7.2 Setting Temperature ...............................................................................................................23
7.3 Checking Operation Mode.......................................................................................................23
7.4 Battery Level Check................................................................................................................24
7.5 Functional Test.......................................................................................................................24
7.6 Verification of the Temperature control system ..........................................................................25
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Operations Manual TABLE OF CONTENTS
RAP e2 container
7.7 Info button and seal of control unit ...........................................................................................26
8. OPERATION MODES, INFOS, ALERTS AND ALARMS ................................................... 27
8.1 Operation Modes....................................................................................................................27
8.1.1 Cooling Powerstep X .................................................................................................27
8.1.2 Heating Powerstep X.................................................................................................27
8.1.3 Defrosting Powerstep 2 .............................................................................................27
8.2 Infos ......................................................................................................................................28
8.2.1 Info “Preconditioning" ................................................................................................28
8.2.2 Info “Pre-charging, please wait"..................................................................................28
8.3 Alerts.....................................................................................................................................29
8.3.1 Alert "Batteries at 30% Charge Level" .........................................................................29
8.3.2 Alert “Container stopped, charging required" ...............................................................29
8.3.3 Alert “System too warm, charging prolonged" ..............................................................29
8.3.4 Alert "Inside Temp out of Spec" ..................................................................................30
8.3.5 Alert "Ambient Temp out of Spec" ...............................................................................30
8.4 Alarms...................................................................................................................................31
9. TECHNICAL SPECIFICATION................................................................................................ 32
9.1 Loading Space .......................................................................................................................33
10. TROUBLESHOOTING.............................................................................................................. 34
10.1 No Display .............................................................................................................................34
10.2 Batteries do not charge ...........................................................................................................35
10.3 Alerts.....................................................................................................................................36
10.3.1 Temperature too warm...............................................................................................36
10.3.2 Temperature too cold.................................................................................................37
(Proceed on next page!)
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Operations Manual TABLE OF CONTENTS
RAP e2 container
10.3.3 Ambient Temperature out of Spec...............................................................................38
10.3.4 If an adapter is lost ....................................................................................................38
11. RAP E2 CONTAINER CHECKLIST........................................................................................ 39
Doc No:
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Revision:
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Operations Manual 1. INTRODUCTION
RAP e2 container
1. INTRODUCTION
1.1 SCOPE OF THE MANUAL
This manual provides information for personnel involved in the handling and transport of
Envirotainer container series RAP e2 and is published by Envirotainer AB ithout arranty.
If there are questions regarding this manual or the container, send an e-mail to
[email protected].
To get in contact ith one of our operations centers, please refer to our ebsite
.envirotainer.com.
1.2 SYMBOLS
DANG R!
Indicates an immediate danger that will lead to death or serious injury if necessary measures are
not taken.
WARNING!
Indicates a possible danger that can lead to death or serious injury if necessary measures are not
taken.
CAUTION!
Indicates a possible hazard that can lead to injury or material / equipment damage if necessary
measures are not taken.
NOT !
Practical information or tips on how to perform a procedure.
1.3 SAFETY INSTRUCTIONS
• The design minimizes hazards to personnel and equipment during use. No material used in
the construction constitutes a risk to the health of the personnel involved. All structural and
mechanical components are free of sharp edges. Every attempt has been made to anticipate
potential dangers and build in protections to prevent injury to personnel.
• Normal precautions should be observed hen handling locks, doors and lids. Wherever
necessary, arning stickers or texts ill be attached to the container as a arning to users and
ground handler personnel.
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1 (40)
Doc No:
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Operations Manual 1. INTRODUCTION
RAP e2 container
• Al ays follo the "IATA Dangerous Goods Regulations" hen loading the container. The
container must not be connected to the electrical outlet inside an airplane.
• Normal precautions should be observed hen charging the container. Do not charge the
container outdoors or in a damp, moist environments because of the risk for electric shocks.
1.4 THE CONTAINER
• The RAP e2 container is a temperature controlled air cargo container used to transport
temperature sensitive cargo in the refrigerated and controlled room temperature ranges.
• The container consists of t o primary parts: the cargo space and the refrigeration system
(refer to Fig. 1 ). The refrigeration system is controlled by a control unit and po ered by
internal, rechargeable batteries.
• The RAP e2 is a forkliftable LD-9 air cargo container designed to hold four (4) US-pallets
1220 x 1016 mm (48 x 40") or five (5) EURO-pallets 1200 x 800 mm (47,3 x 31,5") of
cargo.
2 (40)
Doc No:
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Release Date:
2019-04-25
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Operations Manual 1. INTRODUCTION
RAP e2 container
1.5 CONTROL UNIT
• The control unit is the user interface for starting the container, setting the temperature,
reading the actual air temperature from the cargo space and other information.
• The control unit also has charging, alert and alarm indicators.
• The control unit is located outside the container on the right side (Fig. 1 ).
Refer to chapter 7. Control Unit Operation
The system indicator (green light) is lit hen the container system is operating.
The charging indicator (blue light) flashes to indicate that charging is in progress and
remains lit hen the charging has been completed.
The alert indicator (yello light) flashes to indicate that the container needs
attention. If the alert indicator is flashing, measures can be taken to continue ith
the shipment.
The alarm indicator (red light) flashes to indicate that a technical part of the
refrigeration system is out of order.
If the alarm indicator is flashing, the container is not functioning properly and the
shipment must be stopped.
Fig. 1
1.6 CHARGING UNIT
• The charging unit is the user interface for charging the internal batteries of the container.
• The charging unit contains a charging cable and adapters for different countries.
• The charging unit is located outside the container on the rear side. (Fig. 1 )
Refer to chapter 3. Charging
3 (40)
Doc No:
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Operations Manual 1. INTRODUCTION
RAP e2 container
1.7 ODLN STICKER
Fig. 2
The container is equipped ith an ODLN (Operational Damage Limits Notice) sticker (Fig. 2 ),
in accordance ith IATA requirements for ULDR aircraft containers. The ODLN sticker
describes the acceptable damage limits for the container from an air orthiness perspective. It is
used by the load master before every flight, to determine if the container is air orthy and hence
safe to load on the aircraft.
After every lease, the container is inspected according to a thorough inspection program. The
damage limits in this inspection program are stricter than the acceptable damage limits specified
on the ODLN sticker. Any damages exceeding the inspection program limits are repaired.
Consequently, a container released from an Envirotainer station ill never exhibit the level of
damages accepted on the ODLN sticker.
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Operations Manual 2. LIMITS, AMBIENT CONDITIONS
RAP e2 container
2. LIMITS, AMBIENT CONDITIONS
• The container is designed to maintain the temperature of the cargo shipped by cooling or
heating the air inside the container.
The following conditions must apply for the container to work properly:
2.1 PRE-CONDITIONING OF CARGO
• The container does not have battery capacity to cool do n or heat up a large quantity of
cargo.
• The container is designed to maintain the temperature of the cargo. It is therefore important
that the cargo is pre-conditioned correctly.
2.2 MINIMUM OPERATING TIME - FULLY CHARGED CONTAINER
• For a +5°C (+41°F) container set temperature the minimum operating time ithout
recharging the batteries is 30 hours provided that the ambient temperature is bet een -10°C
and +30°C (+14°F and +86°F). Ho ever, the operating time ill increase if the ambient
temperature is closer to the container set temperature of the cargo space.
• For other container set temperatures contact Envirotainers Customer Care team for advice:
[email protected]
2.3 EXPOSURE TO AMBIENT TEMPERATURE ABOVE +30°C (+86°F)
The container can maintain the temperature in the loading area even if the ambient temperature
is bet een +30°C and +40°C (+77°F and +104°F), but the battery consumption ill increase,
and the container operating time ill therefore decrease.
For example, if the ambient temperature is +35°C (+95°F) and the container set temperature is
+5°C (+41°F), the container can maintain the temperature but the container operating time ill
be reduced.
NOT !
The container remains operational between +4 °C and +5 °C (+1 4°F and 122°F), but may not
be able to maintain the container set temperature.
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Operations Manual 2. LIMITS, AMBIENT CONDITIONS
RAP e2 container
2.4 EXPOSURE TO AMBIENT TEMPERATURE BELOW -10°C (+14°F)
The container can maintain the temperature in the loading area even though the ambient
temperature is bet een -10°C and -25°C (+14°F and -13°F), but the battery consumption ill
increase, and the container operating time ill therefore decrease.
For example, if the ambient temperature is -20°C (-4°F) and the container set temperature is +5°
C (+41°F), the container can maintain the temperature but the container operating time ill be
reduced.
NOT !
The container remains operational between -25°C and -3 °C (-13°F and -22°F) but might not be
able to maintain the container set temperature.
6 (40)
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Operations Manual 3. CHARGING
RAP e2 container
3. CHARGING
WARNING!
• Charging must not take place inside an airplane!
• Do not charge the container outdoors or in damp and/or humid environments because of the risk
for electric shocks.
• Caution should be exercised when the container is moved and the electrical cable is fully
extended. In addition please visually inspect the electrical cable for any abnormalities before
connecting it to a power source.
CAUTION!
Always pull out all of the cable when charging, approximately 1 meters (32 ft.). Charging with
part of the cable inside the cable winder can cause damages to the cable winder.
NOT !
• While charging, it is recommended to have the container switched on.
• The time required to charge the container will depend on the battery level at the start of
charging.
• The maximum time needed for charging is 12 hours regardless if the container is operating
while charging.
• During the first hour of charging, the battery level is not updated on the display. As long as the
blue charge indicator is flashing, charging is in progress. The display will switch between
showing Container info and “Info, Pre-charging, Please wait .
• Avoid use of additional extension cable as far as possible. If the use of extension cable is required,
use as short cable as possible and make sure the cross-section of the wires is at least 2.5 mm²
( . 39 inch²).
• For optimal charging, make sure the ambient temperature is in range °C to +2 °C (+32°F to
+68°F). If charging is carried out in temperatures outside this range the charging capacity, and
consequently the resulting battery energy, may be reduced.
• Charging shall not be performed if the ambient temperature is below -2 °C (-4°F) or above
+4 °C (+1 4°F).
• When charging the container, the initial current peak may be high with additional strain on the
supply fuses. Therefore, it shall not be connected to sensitive power grids as it then may cause
flicker.
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Operations Manual 3. CHARGING
RAP e2 container
NOT !
• To avoid overload of power supply fuse, only connect one container per single-phase. The
charging requires 12 W when the container is switched off and 185 W when the container
is operating during charging.
• 11 V supply will as minimum require a 2 A circuit capability.
• 23 V supply will as minimum require a 1 A circuit capability.
3.1 CHARGING PROCEDURE
NOT !
It is recommended to keep the battery switch on, and the container running, during charging.
1. Open the cover of the charging unit.
2. Pull out the cable from the charging unit.
CAUTION!
Pull out all of the cable.
3. The container can be charged either by connecting the blue CEE industry plug to a
suitable socket or by using one of the adapters.
Follo step 4-5if an adapter is to be used. Other ise continue from step 6.
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Operations Manual 3. CHARGING
RAP e2 container
Fig. 3
4. Pull out the adapter case and pick the
appropriate type of adapter (Fig. 3 ).
There are also additional adapters that can
be ordered separately from Envirotainer.
Refer to chapter 3.2 Additional
Charging Adapters
Fig. 4
5. Connect the adapter to the charging cable
(as marked in Fig. 4 ).
(PROCEED ON NEXT PAGE!)
9 (40)
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Operations Manual 3. CHARGING
RAP e2 container
6. Connect the adapter / blue CEE industry plug to the po er supply. The charge indicator
(blue light) on the control unit starts flashing to highlight that charging is in progress.
NOT !
• It may take up to 3 seconds before the charge indicator starts flashing.
• During the first hour of charging, the battery level is not updated on the display. As long as
the blue charge indicator is flashing, charging is in progress.
• During the first hour the display will switch between showing Container info and
“Info, Pre-charging, Please wait .
7. When the charging is complete the blue charging indicator ill illuminate (fixed light) to
indicate that the charging has been completed.
NOT !
The charging indicator may illuminate (fixed light) at 95% battery status.
If fixed light occurs at 95% the batteries are considered fully charged.
8. Disconnect the adapter from the po er supply and disconnect the adapter from the
charging cable.
9. Ensure all five adapters and the cable for recharging have been properly stored in the
charging unit.
10. Make sure the battery s itch is on.
Refer to chapter 6.10 Battery Switch
3.2 ADDITIONAL CHARGING ADAPTERS
Beside the adapters for different countries included ithin the charging unit; the follo ing
additional adapters can be ordered separately from Envirotainer.
British Standard 546 15A, 3 pins P/N 807W
NEMA 6-15R 15A, 250V P/N 807X
NEMA L15-30P 30A, 250V P/N 807Y
Danish SRAF 1962/DB 16/87 10A, 250V, K-plug P/N 807Z
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Operations Manual 3. CHARGING
RAP e2 container
3.3 CHARGING WITH DAMAGED CABLE OR CABLE WINDER
In the event that the cable or cable inder has been damaged and can no longer be used, the
cable inder may be bypassed for charging.
The recommended procedure is:
1. Open the cover of the charging unit.
Fig. 5
2. Pull out the adapter case. When the
adapter case reaches the stop, continue
pulling the case to reach the CEE industry
plug (Fig. 6 ).
Fig. 6
3. Disconnect the charging cable and
connect the appropriate type of adapter.
4. Connect an extension cable to the adapter.
NOT !
Use as short cable as possible and make sure the cross-section of the wires is at least 2.5 mm²
( . 39 inch²).
11 (40)
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Operations Manual 4. PRE-CONDITIONING
RAP e2 container
4. PRE-CONDITIONING
The cargo and container must be pre-conditioned to the container set temperature prior to
loading. Improper pre-condition ill affect the container's ability to maintain cargo temperature.
4.1 CARGO PRE-CONDITIONING
The cargo must be pre-conditioned to the temperature that is to be maintained during transport.
NOT !
To avoid the risk of temperature deviations, the cargo must be properly pre-conditioned to the
container set temperature.
Cargo temperature recording
• If records must be kept of product temperature, Envirotainer strongly recommends that
temperature recorders are placed as close to the product as possible, preferably inside product
boxes, other ise bet een product boxes.
• The temperature displayed on the control unit is the temperature of the air at the sensor in
the container and ill fluctuate more than the temperature of the product.
12 (40)
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Operations Manual 4. PRE-CONDITIONING
RAP e2 container
4.2 CONTAINER PRE-CONDITIONING
Prior to pre-conditioning, a functional test of the container should be performed.
Refer to chapter 7. Control Unit Operation
There are t o recommended practices for container pre-conditioning:
4.2.1 PRE-CONDITIONING WITH CONTAINER OPERATING IN NON-
TEMPERATURE CONTROLLED AREA
• It is recommended that this type of pre-conditioning is performed ith the container
connected to the po er supply.
• When the container is connected to the po er supply, the heating and cooling equipment
ill run on po er from the po er supply and no battery po er is consumed.
• Pre-conditioning during charging does not affect charging time.
The recommended procedure is:
1. Make sure the container is operating and the container set temperature is correct.
Refer to chapter 7. Control Unit Operation
2. Make sure the doors to the cargo space are closed.
3. Wait until set temp has been reached and the alert "Inside temp out of spec" and info "Pre-
cooling" has disappeared (this can take up to 90 minutes) before loading cargo.
4.2.2 PRE-CONDITION WITH A TEMPERATURE-CONTROLLED ROOM
It is recommended to perform this type of pre-conditioning ith the container s itched off.
The recommended procedure is:
1. Place the container in a temperature-controlled room that is set to the desired temperature.
2. Open the doors to the cargo space.
3. Allo at least one hour for container pre-conditioning before loading the cargo.
13 (40)
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Operations Manual 5. GENERAL CARGO LOADING GUIDELINES
RAP e2 container
5. GENERAL CARGO LOADING GUIDELINES
NOT !
• Load the cargo on pallets to allow proper airflow.
• Do not load cargo between the spacers inside the container walls.
• Ensure that the air inlet at rear end of the cargo space is not blocked by the cargo.
• If the cargo is shrink-wrapped, the pallet base must not be covered in order to allow air flow
along the floor beneath the cargo.
• Ensure proper weight distribution.
• Secure the cargo to the tie-down brackets inside the container as proposed in Fig. 7 . Cargo
which is not properly strapped may shift and obstruct the air flow as well as cause cargo and
container damage.
Fig. 7
14 (40)
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