Envirotainer RAP t2 User manual

RAP container,
140007R-()
Doc No. MO-RAP-3062
Version 21
www.envirotainer.com
RAP t2 container
Operations Manual
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

Record of revision
RECORD OF REVISION
VER. NO. REVISION
21 REVISED:
• The structure and content of the manual have been revised to increase usability.
Chapters have been rearranged and renamed and information has been moved
between chapters. Texts and illustrations have been revised, rearranged and
supplemented. These changes are not described in any more detail in the revi-
sion history unless specifications have been changed, completely new informa-
tion has been added or entire chapters have been removed.
•2.1.2 Symbols on the container: New chapter.
• Former 2.5 Exposure to high humidity: Removed chapter.
•3.1 Orientation conventions: New chapter.
•3.2 Overview: New chapter.
•3.4 Attachment points for security seals: New chapter.
•3.7 Operating conditions: Added information about container performance in
relation to different ambient temperatures.
•3.8 Battery duration: New chapter.
•4.4.2 Mounting or removing batteries: Clarified that only 8 batteries are neces-
sary during pre-conditioning with dry ice.
•4.4.3.2 Dry ice best practices: New chapter.
•4.4.3.3 Using wrapped or unwrapped dry ice (info moved from 7. Dry ice ta-
bles): Revised the recommendation for set temp + 5 °C; wrapped dry ice shall
now be used for ambient temperatures of +10 to +20 °C.
•4.4.4.2 Pre-condition the container: Clarified that only 8 batteries are neces-
sary for pre-conditioning using dry ice.
•4.4.6 Loading cargo: Added instruction to replace the batteries used during pre-
conditioning with dry ice.
•4.4.10.10 Check date of next control unit verification: Revised information
about when verification must be performed.
•5. Troubleshooting: Converted the chapter to table format and supplemented
the information.
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

Record of revision
RECORD OF REVISION
VER. NO. REVISION
REVISED, CONTINUED:
•7. Dry ice tables:
• Revised the table for set temperature +5 °C.
• Removed the table for set temperature +15 °C.
•8. Technical specification:
• Changed the definition of the door opening dimensions from (L x H) to (W x H).
• Changed the definition of the main loading space dimensions from (L x W x H)
to (Lload x Wload x Hload).
• Changed the definition of the additional loading space dimensions from
(L x W x H) to (l x w x h).
• Corrected the height of the additional loading space.
• Corrected the door opening dimensions in inches (switched place on existing
dimensions).
• Former 8 Alerts and alarms: Removed chapter (information incorporated into 5.
Troubleshooting).
•8.1 Definition of dimensions: New chapter defining what is the length (L), width
(W) and height (H) of the container.
•8.2 Loading space:
• Clarified that the additional loading space is not recommended for use.
• Removed dimensions that are already presented in 8. Technical
specification.
• Former 11.1 External dimensions: Removed chapter.
• Former 13 RAP t2 container checklist: Removed chapter. New checklists avail-
able in 4.1 Preparing a shipment,4.2 Shipping and 4.3 Finishing a shipment.
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

Intentionally left blank
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

TABLE OF CONTENTS
1. INTRODUCTION.......................................................................................................................... 1
1.1 Intended use............................................................................................................................1
1.2 Manufacturer............................................................................................................................1
1.3 Contact....................................................................................................................................1
1.4 How to use the manual .............................................................................................................1
2. SAFETY......................................................................................................................................... 2
2.1 Symbols ..................................................................................................................................2
2.1.1 Symbols in the manual ................................................................................................2
2.1.2 Symbols on the container.............................................................................................3
2.2 Safety instructions ....................................................................................................................4
2.2.1 General ......................................................................................................................4
2.2.2 Handling dry ice ..........................................................................................................4
2.2.3 Lifting the container .....................................................................................................5
3. CONTAINER DESCRIPTION..................................................................................................... 6
3.1 Orientation conventions ............................................................................................................6
3.2 Overview .................................................................................................................................7
3.3 Refrigeration system operation ..................................................................................................8
3.4 Attachment points for security seals...........................................................................................9
3.5 Temperature control capacity.....................................................................................................9
3.6 Loading capacity ....................................................................................................................10
3.7 Operating conditions...............................................................................................................10
3.8 Battery duration......................................................................................................................12
4. USING THE CONTAINER ........................................................................................................ 13
4.1 Preparing a shipment..............................................................................................................14
4.2 Shipping ................................................................................................................................15
4.3 Finishing a shipment...............................................................................................................16
→
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

4.4 Operating instructions.............................................................................................................17
4.4.1 Lifting and moving the container .................................................................................17
4.4.2 Mounting or removing batteries ..................................................................................19
4.4.3 Handling dry ice ........................................................................................................20
4.4.4 Pre-conditioning cargo and container..........................................................................22
4.4.5 Recording temperatures ............................................................................................24
4.4.6 Loading cargo...........................................................................................................25
4.4.7 Handling the container during shipment ......................................................................30
4.4.8 Unloading the container.............................................................................................31
4.4.9 Storing the container .................................................................................................32
4.4.10 Operating the control unit...........................................................................................33
5. TROUBLESHOOTING.............................................................................................................. 43
5.1 Alerts.....................................................................................................................................43
5.1.1 Control unit type 2 .....................................................................................................43
5.2 Alarms...................................................................................................................................44
5.2.1 Control unit type 1 .....................................................................................................44
5.2.2 Control unit type 2 .....................................................................................................44
5.3 Hardware...............................................................................................................................45
6. CALCULATING DRY ICE AMOUNTS.................................................................................... 49
6.1 Calculate dry ice amount for container pre-conditioning .............................................................50
6.2 Calculate dry ice amount for container shipment .......................................................................51
7. DRY ICE TABLES...................................................................................................................... 52
7.1 Set temperature +5°C .............................................................................................................52
7.2 Set temperature -20°C............................................................................................................52
8. TECHNICAL SPECIFICATION................................................................................................ 53
8.1 Definition of dimensions ..........................................................................................................54
8.2 Loading space........................................................................................................................55
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

1. Introduction
1. INTRODUCTION
This manual provides information for personnel involved in the operation of Envirotainer container series RAP t2
and is published by Envirotainer AB without warranty.
1.1 INTENDED USE
The RAP t2 is a temperature controlled air cargo container designed to transport temperature controlled
products with temperature ranges below -18 °C (-1 °F), from +2 to +8 °C (+36 to +47 °F) and from +2 to +25 °C
(+36 to +77 °F). It is intended for use in aircrafts, trucks and trains. The container may also be transported by
ship when empty or loaded with non temperature sensitive cargo.
The container can be used indoors or outdoors. Operating conditions when transporting temperature sensitive
cargo are stated in 3.7 Operating conditions.
The container may only be handled and operated by trained personnel, and in accordance with the instructions
given in this manual. Operational limitations regarding maximum gross weight and ambient temperatures stated
in 8. Technical specification must not be exceeded.
If applicable, the use of the container must follow the "IATA Dangerous Goods Regulations".
1.2 MANUFACTURER
The container is manufactured and provided by:
Envirotainer Engineering AB
Staffans väg 2A
SE-192 78 Sollentuna
SWEDEN
1.3 CONTACT
For contact information to our operations centers, refer to www.envirotainer.com.
For questions regarding this manual or the container, send an e-mail to [e-mail].
1.4 HOW TO USE THE MANUAL
Before handling and operating the container, carefully read and understand chapter 2. Safety, and get
acquainted with the container and the operating conditions in chapter 3. Container description.
When handling the container before, during and after shipment*, follow the checklists in chapters
4.1 Preparing a shipment,4.2 Shipping and 4.3 Finishing a shipment to make sure that all necessary
measures for a successful shipment are taken. The checklists contain references to relevant operating
instructions.
If any problem should arise, refer to chapter 5. Troubleshooting for possible solutions.
* Definitions of the three shipment stages are found in 4. Using the container.
1 (56)
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

2. Safety
2. SAFETY
This chapter contains safety instructions and explanations of safety related symbols in the manual and on the
container. For safe handling of the container, make sure to read the instructions before use, and pay attention to
the warning stickers attached to the container.
2.1 SYMBOLS
2.1.1 SYMBOLS IN THE MANUAL
The following symbols are used in the manual:
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.
NOTE!
Practical information or tips on how to perform a procedure.
2 (56)
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

2.1.2 Symbols on the container
2.1.2 SYMBOLS ON THE CONTAINER
This section contains explanations of safety related symbols and stickers on the container, and information
about where they are found.
Fig. 1 Placement of stickers on the container
Table 1 Stickers on the container
Pos Sticker Explanation
A“Perishables
Handle with care”
Make sure to handle the container carefully, as it contains
perishables.
B“Caution! Watch your fingers!” Risk of crush injury. Be careful when handling the door lock.
The sticker is only applicable for one out of two available door lock
models, and is therefore not applied on all containers.
CODLN sticker The container is labeled with an Operational Damage Limits
Notice (ODLN) sticker, to meet the IATA labelling requirements for
aircraft containers. The ODLN describes the acceptable damage
limits from an airworthiness perspective and can be used for safe
loading onto the aircraft.
Before every lease, the containers are inspected against even
stricter criteria than those stated on the ODLN. Therefore, the
container will never exhibit the level of damage as described on
the ODLN when released from an Envirotainer station.
D“Caution! Dry ice” The lid provides access to the dry ice bunker, which contains dry
ice. Refer to 2.2 Safety instructions for safe handling of dry ice.
→
3 (56)
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

2.2 Safety instructions
Table 1 Stickers on the container (cont'd.)
Pos Sticker Explanation
ERed line The red line indicates an area that must be kept clear in order for
the fan to work properly. Do not load any cargo in this area.
FLoading instruction The sticker contains important loading instructions. Make sure to
follow the instructions during cargo loading.
G“Do not load cargo in the red
area”
The red line indicates the end of the loading space. Do not load
cargo on or outside the red line.
2.2 SAFETY INSTRUCTIONS
For safe handling of the container, read the instructions before use, and pay attention to warning stickers
attached to the container.
2.2.1 GENERAL
WARNING!
Before closing the container doors, make sure that nobody is inside the cargo space.
CAUTION!
Always follow the "IATA Dangerous Goods Regulations" when loading the container. For example, if
transporting dangerous goods such as liquids with low boiling point, special consideration should be given to
the fact that the container may not be able to maintain the temperature in the cargo space in case of low
battery level or malfunction.
CAUTION!
Observe normal precautions when handling locks, doors and lids.
2.2.2 HANDLING DRY ICE
WARNING!
The dry ice used as refrigerant is considered a Class 9 dangerous cargo with the UN identification number
1845 and is described as “Carbon Dioxide, Solid”.
WARNING!
Risk of suffocation! Dry ice sublimates into large amounts of CO2gas. This colorless, odorless gas is heavier
than air and can accumulate and displace oxygen in low areas. Do not enter areas where CO2may have
accumulated without first ventilating the space. When handling dry ice, work as fast as possible, and do not
work alone.
WARNING!
Risk of severe frost bite! Do not allow contact between dry ice and skin or eyes. Dry ice is extremely cold
(-78.5 °C (-109 °F)), and severe frostbite can occur within seconds. Always wear gloves or other insulating
material when handling dry ice.
4 (56)
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

2.2.3 Lifting the container
2.2.3 LIFTING THE CONTAINER
WARNING!
Risk of crush injury! If moving the empty container using forklift, make sure that the forklift is placed so to keep
the container stable. Preferably use slave pallets. The container weighs approximately 450 kg, and the center
of gravity is offset due to the weight of the dry ice bunker.
WARNING!
Risk of crush injury! Do not lift the container using forklift when it is loaded with cargo or dry ice as it may tilt.
The container weighs 450 to 6,033 kg (empty/loaded), and the center of gravity is affected by the weight and
placement of the cargo and dry ice.
5 (56)
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

3. Container description
3. CONTAINER DESCRIPTION
3.1 ORIENTATION CONVENTIONS
Fig. 2 Schematic view of the container with orientation conventions
6 (56)
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

3.2 Overview
3.2 OVERVIEW
Fig. 3 Overview of the container
Table 2 Container features
Pos Name Description
ADry ice bunker lid For insertion and removal of dry ice.
BControl unit For turning the container on/off, changing settings, and viewing
information. Contains a battery compartment holding the batteries
that power the control unit and fans. Can be sealed with a security
seal.
CAir guide Distributes cooled air into the cargo space.
DCooling unit Contains dry ice. Cools the air to keep the cargo space at the
required temperature.
EFan Circulates air in the container via the refrigeration system and air
guides.
FTemperature sensor Monitors the cargo space temperature and sends signals to the
control unit.
GInternal tie-down bracket Attachment point for cargo straps, to secure the cargo.
HSpacer Secures a distance between the cargo and the container walls for
air circulation purposes.
ICargo space Temperature controlled area for cargo.
JDocument pouch For shipping documents, checklists etc.
KStrap handle For handling the container on roller beds.
7 (56)
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

3.3 Refrigeration system operation
3.3 REFRIGERATION SYSTEM OPERATION
The required cargo space temperature is set on the control unit, and maintained using cooled air that is
circulated between the cooling unit and the cargo space. Air from the cooling unit is blown into the cargo space
through the air guides in the ceiling. The circulated air is then drawn back into the cooling unit through the
two fans, as indicated with arrows in the figure. The returned air is circulated in a space around the dry ice
bunker for cooling, before being blown back into the cargo space.
Fig. 4 Schematic view of the internal airflow
The fans are controlled by a thermostat in the control unit. The thermostat responds to signals from the
temperature sensor in the cargo space, and turns the fans on or off as required depending on the current
temperature in relation to the set temperature.
The dry ice bunker contains dry ice as refrigerant. The control unit and fans are powered by D-cell alkaline
batteries.
For additional technical data, refer to 8. Technical specification.
8 (56)
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

3.4 Attachment points for security seals
3.4 ATTACHMENT POINTS FOR SECURITY SEALS
The container is equipped with two attachment points for security seals:
• One on the left door lock of the right hand door (A)
• One on the control unit lid (B)
Fig. 5 Attachment points for security seals
Sealing the doors and the control unit lid before shipment can prevent (or help to detect):
• theft or contamination of cargo
• accidental or deliberate tampering with the control unit settings
NOTE!
It is possible to view information on a sealed control unit, but the settings cannot be changed.
Envirotainer recommends sealing at least the doors. If the control unit is sealed, be aware that the battery
compartment is sealed as well, and that the seal must be broken for battery replacements.
Refer to Table 3 for recommended security seal properties per attachment point. Note however that the
effectiveness of a security seal is dependent on the way that it is used, and that procedures for record keeping,
installation, inspection, removal and disposal are required.
Table 3 Recommended security seal properties
Placement Properties
Doors Maximum Ø 4,5 mm (0.18”)
Control unit Ø 2-4 mm (0.08-0.16”)
3.5 TEMPERATURE CONTROL CAPACITY
The container can be set at any temperature between -20 and +20 °C (-4 and +68 °F) with increments of 0.5 °C.
9 (56)
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

3.6 Loading capacity
3.6 LOADING CAPACITY
The RAP t2 is an LD-9 air cargo container designed to hold the following number of standard pallets:
Table 4 Loading capacity
Pallet Max pcs Pallet size
EURO 51200 x 800 mm (47.3 x 31.5")
US 41220 x 1016 mm (48 x 40")
3.7 OPERATING CONDITIONS
The maximum operating time for the container depends on a combination of the available battery power, battery
power consumption rate, type and amount of loaded dry ice, dry ice sublimation rate and ambient conditions.
Therefore, to ensure a successful shipment, the following conditions must apply:
• The cargo and the container must be pre-conditioned to the required set temperature.
Refer to 4.4.4 Pre-conditioning cargo and container.
• The correct set temperature must be set on the control unit.
Refer to 4.4.10 Operating the control unit.
• The required type and amount of dry ice must be used.
Refer to 4.4.3.3 Using wrapped or unwrapped dry ice and 6. Calculating dry ice amounts.
• The container must have sufficient battery power throughout the shipment.
Refer to 4.4.10.6 Check the battery voltage.
• The cargo must be loaded onto pallets, and safely strapped in the container.
Refer to 4.4.6 Loading cargo.
• The container must not be exposed to ambient temperatures outside the recommended range:
• For refrigerated and “do not freeze” cargo: Recommended ambient temperature is
5 to 25 °C (9 to 45 °F) above the set temperature. Avoid exposing the loaded container to temperatures
near or below the set temperature, as the container does not provide heating. Refer to Table 5 for a
description of the container performance at set temperature +5 °C (41 °F) relative to different ambient
temperature ranges.
• For deep frozen cargo: Recommended ambient temperature is maximum 25 °C (45 °F) above the set
temperature.
• For both refrigerated, “do not freeze” and deep frozen cargo: Avoid exposing the loaded container to
direct sunshine and/or extreme temperatures, as it would increase the dry ice consumption rate.
Always take exposure to extreme ambient conditions into account when calculating the required
amount of dry ice.
CAUTION!
Do not use the ambient temperature displayed by the control unit as a reference for verifying ambient
temperature conditions.
→
10 (56)
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

3.7 Operating conditions
Table 5 Container performance at set temp +5 °C (41 °F)
Ambient temperature Container performance at set temp +5 °C (41 °F)
High:
> +30 °C (+86 °F)
The container can maintain the container set temperature for a limited time,
but the dry ice and battery consumption rate will increase. It is not
recommended to expose the container to high ambient temperatures due
to risk of hot spots and air segmentation in exposed areas.
Normal (recommended):
+10 to +30 °C (+50 to +86 °F)
Normal container performance.
Low:
< +10 °C (+50 °F)
The container can maintain the container set temperature for a limited time,
but the risk of cold spots close to the cooling unit increases with time,
depending on the amount and type of dry ice used. Low ambient
temperatures are not safe for the cargo.
11 (56)
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

3.8 Battery duration
3.8 BATTERY DURATION
The maximum operating time without changing the batteries is 72 hours. The actual operating time of alkaline
batteries depends on several factors:
• Dry ice amount – When the dry ice amount is low, the container will operate the fans continuously to
increase the cooling effect, leading to faster battery depletion.
• Ambient temperature – When the container is exposed to extreme heat, the fans will need to operate
continuously to maintain the set temperature.
• Battery temperature – Alkaline batteries drain more rapidly when operating at low temperature.
• Battery quality – Some brands perform better than others in the RAP t2 container. For guidance on which
batteries have been found to perform well in the RAP t2 container, or how to plan your shipment, please
contact Envirotainer Customer Service, [e-mail].
In the discharge cycle for an alkaline battery, the voltage initially decreases rapidly. For the RAP t2 container
this can mean that the voltage decreases from 12 V to 10.5 V during the first few hours of operation (see
example in Fig. 6). This is normal and no action is required.
Fig. 6 Graph of battery discharge cycle over time, in battery test case with fans constantly running
12 (56)
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

4. Using the container
4. USING THE CONTAINER
A shipment (B) is defined as all land and air transportation that is required to transfer a loaded container from
the shipper site (A) to the consignee site (C).
Fig. 7 The shipment
Chapters 4.1-4.3 contain three separate checklists, listing the actions to be performed when preparing a
shipment, shipping the container, and finishing the shipment. Follow the applicable checklist, as defined below,
to make sure that all necessary measures for a successful shipment are taken. The checklists contain
references to relevant operating instructions.
•Preparing a shipment: Container handling at the shipper site, from receiving the empty container to
handover of the loaded container.
•Shipping: Container handling during land transportation to and from the airport, and at the airport. To be
performed by forwarders and airport personnel.
•Finishing a shipment: Container handling at the consignee site, from receiving the loaded container to
handover of the empty container.
The checklists may be printed out to make sure that they are completed.
13 (56)
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst

4.1 Preparing a shipment
4.1 PREPARING A SHIPMENT
Before the shipment, the following must be performed:
□ Pre-condition the cargo. Refer to 4.4.4.1 Pre-condition the cargo.
□ Pre-condition the container. Refer to 4.4.4.2 Pre-condition the container.
□ Perform the following according to 4.4.6 Loading cargo:
□ Load and strap the cargo and, for deep frozen products, the dry ice (on top of the cargo).
□ If applicable, move the container from the temperature controlled area.
□ If the container was pre-conditioned in a temperature controlled area:
□ Install batteries and check the battery voltage.
□ Set the temperature.
□ Load dry ice into the dry ice bunker.
□ If the container was pre-conditioned using dry ice: Replace the batteries and check the battery voltage.
□ Confirm that all doors and covers are closed and latched. If required, seal the control unit (type 2).
□ Place any shipping documents or check sheets in the container document pouch.
□ Confirm that the set temp is correct. Refer to 4.4.10 Operating the control unit.
□ Allow the container temperature to stabilize around the set temperature for about one hour.
□ Confirm (on the control unit) that the container is within the required temperature range.
□ Make sure that no alert or alarm is activated. Refer to 4.4.10.7 View activated alerts and alarms.
□ Make sure that the container is not wrapped or covered. Refer to 4.4.7 Handling the container during
shipment.
□ Handle and store the container in an environment where the ambient temperature is within specified
limitations. Refer to 3.7 Operating conditions.
For instructions on moving the container, refer to 4.4.1 Lifting and moving the container.
For instructions on temperature recording, refer to 4.4.5 Recording temperatures.
14 (56)
Doc No:
MO-RAP-3062
Revision:
21
State:
Released
Release Date:
2021-06-24
Approved By:
hanst