KLINGE TCR-104-07 Guide

UNCONTROLLED WHEN PRINTED K35-TCR104-07
REV. E, JUNE 2023
MODEL TCR-104-07: Standard
MODEL TCR-104-08: Remote Electrical Box
MODEL TCR-104-09: With Alarm System &
Version 2 Recorder
MODEL TCR-104-10: Standard W/ Drain – R-404A
MODEL TCR-104-20: Standard W/ Drain – R-452A
CLOSED GLYCOL SYSTEM
(Options)
Heat and Microprocessor Data logging
TANK CONTAINER REFRIGERATION UNIT
OPERATION, SERVICE AND PARTS MANUAL
Address: 4075 East Market Street York, PA 17402-5100 USA
Telephone: [phone] Telefax: 717-840-4501
www.klingecorp.com
Manufactured by KLINGE CORPORATION

UNCONTROLLED WHEN PRINTED K35-TCR104-07
REV. E, JUNE 2023
2

UNCONTROLLED WHEN PRINTED K35-TCR104-07
REV. E, JUNE 2023
3
REVISION RECORD
Rev Description Date Approved
A Numerous changes to content, and format
to bring to current manual standards. 03/26/2018 BES
B Add R-452A as a refrigerant option 3/12/2020 BES
C Updated Glycol Pump Overload range pg 16 10/20/2022 BES
D Updated Section 8.2A, Item 16 3/7/2023 DBG
E Updated receiver part # 11 Section 8.1B 6/14/2023 BES

UNCONTROLLED WHEN PRINTED K35-TCR104-07
REV. E, JUNE 2023
4
Service Request
Requests for Service should be directed to the Klinge Service Team. The below link should be used to
place all requests for service and will afford the quickest response time.
https://klingecorp.com/request-service/
This form will help us determine model and age of the equipment, location, basic details about the
issue, who to contact and how to best handle the issues with the equipment. A service ticket number
will be provided in a response email once the form is received and processed. If the equipment is out
of warranty, charges may apply for extensive technical support.
Additionally, our Service Department can be reached via email at [email protected].
Spare Parts Request
Requests for Spare Parts should be directed to our Parts Department via email at
[email protected].Please have available at the time of the request the Serial Number of the
equipment to ensure that the proper part is provided.
Use of this Manual
The use of this manual is intended for the safe operation of the equipment described. It is therefore
reasoned that persons who have the occasion to use this manual have a knowledge of mechanical and
electrical systems and components addressed by its' contents. However, efforts have been made to
enable persons less familiar with these systems to use this manual.
The equipment may be installed in a number of configurations. Each may have optional items and
differing external details provided by third parties. The specific electrical circuit and pipe diagram are
posted on the unit as decals.
Most external and internal pipework parts are standard commercially available pipe fittings and not
covered here. For external pipe fitting, replace like for like, taking care to replace stainless steel with
stainless steel.
Suggestions as to improvement in content and format are welcome and should be addressed to
[email protected].Corrections and improvements will be included on dated revisions –
the latest of which will be available upon request.

UNCONTROLLED WHEN PRINTED K35-TCR104-07
REV. E, JUNE 2023
5
Table of Contents
Service Request...................................................................................................................................................4
Spare Parts Request.............................................................................................................................................4
Use of this Manual..............................................................................................................................................4
1.0 GENERAL DESCRIPTION............................................................................................................................7
1.1 Compressor..................................................................................................................................................7
1.2 Chiller..........................................................................................................................................................7
1.3 Glycol Components & System.....................................................................................................................7
1.4 Refrigeration System & Components..........................................................................................................8
1.5 Heaters (if equipped)....................................................................................................................................9
1.6 Piping Schematic.......................................................................................................................................10
2.0 OPERATION.................................................................................................................................................11
2.1 Pre-starting Check......................................................................................................................................11
2.2 Starting Check............................................................................................................................................11
2.3 Running Unit..............................................................................................................................................11
3.0 ELECTRICAL FUNCTIONS.......................................................................................................................15
3.1 General Information (Refer to Electrical Schematic)................................................................................15
3.2 Electrical Box.............................................................................................................................................15
3.3 Electrical Schematic...................................................................................................................................17
4.0 MICROPROCESSOR THERMOSTAT........................................................................................................19
4.1 General Information...................................................................................................................................19
4.2 Display Panel.............................................................................................................................................19
4.3 Temperature Sensors..................................................................................................................................21
4.4 Microprocessor Thermostat and Data logger.............................................................................................21
4.5 Microprocessor Control Sequence/ Functionality......................................................................................22
5.0 MAINTENANCE AND SERVICE INSTRUCTION...................................................................................27
5.1 General.......................................................................................................................................................27
5.2 Safety.........................................................................................................................................................27
5.3 Checking Refrigerant Charge.....................................................................................................................28
5.4 Procedure for adding refrigerant................................................................................................................28
5.5 Non-condensable gases..............................................................................................................................29
5.6 Opening the System...................................................................................................................................29
5.7 Testing for Leaks.......................................................................................................................................29
5.8 Evacuating the System...............................................................................................................................30
5.9 Glycol System............................................................................................................................................30
5.10 PTI Form..................................................................................................................................................37

UNCONTROLLED WHEN PRINTED K35-TCR104-07
REV. E, JUNE 2023
6
6.0 SERVICING COMPONENTS......................................................................................................................38
6.1 Compressor................................................................................................................................................38
6.2 Condenser Fan Motor.................................................................................................................................40
6.3 Condenser Fan...........................................................................................................................................41
6.4 Filter Drier Replacement............................................................................................................................41
6.5 High Pressure Switch.................................................................................................................................41
6.6 Thermal Expansion Valve..........................................................................................................................42
7.0 TROUBLE SHOOTING................................................................................................................................45
7.1 General Information...................................................................................................................................45
7.2 Service Components..................................................................................................................................45
7.3 Microprocessor Thermostat.......................................................................................................................45
7.4 Trouble Shooting Chart..............................................................................................................................46
8.0 SERVICE PARTS.........................................................................................................................................51
Suggested Spare Parts.......................................................................................................................................80

UNCONTROLLED WHEN PRINTED K35-TCR104-07
REV. E, JUNE 2023
7
1.0 GENERAL DESCRIPTION
This unit is specially designed for cooling heat transfer fluid, which is used to control the temperature
of tank containers.
The machine is designed for uses in combination with ethylene glycol, propylene glycol, or synthetic
oils where different cargoes dictate a different cooling medium. Ethylene glycol is commonly used
with most chemical cargoes. Propylene glycol is used with foods and synthetic oils are used for high
and low temperature cargoes. With due consideration for non-metallic pipe connections a mixture of
diphenylethane and alkylated aromatics, can be used for very low temperatures if required.
The basic equipment of the standard configuration of the TCR-104 includes the following:
a discus compressor using R-404A or R-452A,
a plate chiller section,
a circulating pump,
provision for an optional 5kW heater (not fitted here)
A detailed description of the system follows.
An adjustable thermostat and two probes monitor the temperature of the cargo in the tank and the
glycol system. The thermostat is then linked in the electromechanical system to control operation of
the pump, compressor, suction-throttling valve, and fan.
The connection to the tank’s circulating system is made with the necessary components, built into the
tank and supplied by the tank builder.
1.1 Compressor
Compressor is a Copeland discus compressor, specifically designed for transport operation. The
compressor is supplied with a deep oil sump to provide larger oil capacity. Protection from salt
atmosphere is provided by a double coating of Pit guard paint. The compressor, which has been
available since 1988, is rugged and has many new high-tech features. The shaft is impregnated with
Teflon to provide lubrication should the compressor lose lubrication for a short period of time, the
valve seats are made of a permeable material which permits the compressor to obtain optimum seating
after the first 72 hours of operation.
1.2 Chiller
The chiller is a solid, brazed plate unit construction producing a very compact rugged heat exchanger.
This stack plate type construction, using the very latest in continuous vacuum brazing technology, is
more compact, efficient, reliable, and maintenance-free than ordinary units.
1.3 Glycol Components & System
The glycol system is a closed system. The glycol is not exposed to the air. This is accomplished by
using a buffer tank with a bladder to allow for the expansion and contraction of the glycol as
temperatures change. No air can get into the system, as would be the case with a naturally aspirated
expansion tank.

UNCONTROLLED WHEN PRINTED K35-TCR104-07
REV. E, JUNE 2023
8
Air in the system would promote corrosion and could get trapped. This could cause noisy, inefficient
operation and energy waste. The result would be loss of pump performance and corrosion of
equipment.
The bladder in the expansion tank has air or nitrogen on one side and system glycol on the other. The
gas is pressurized to 0.8 Bar (12 psig). This maintains a system pressure of 0.8 Bar (12 psi).
The system has a fill valve set at 0.8 Bar (12 psi). This allows the system to be filled to exactly 0.8
Bar (12 psi) glycol pressure automatically. Each glycol system is equipped with an air purger and
float vent which automatically purge the air out of the system and expel it into the atmosphere. This
removes any air, which may be in the glycol when the system is filled. The system also has a safety
pressure relief valve, which is set at 3.5 Bar (50 psi).
The glycol pump is powered by a 1½ H.P. TEFC motor at 3450 RPM. The motor is slightly over
sized. At no time will the pump load exceed 1½ H.P.
1.3.1 Cleanliness of the Glycol System
New cooling systems are typically coated with oil, grease, or protective film during fabrication.
Welding by products, flux and scale that would not normally cause a problem with a steam system can
cause a problem with the glycol heat exchanger – the chiller.
Dirt will migrate to the chiller (a plate type heat exchanger) and may block the small gaps between
each plate. Because of this, thoroughly cleaning the new system is important.
A solution of 1 to 2% trisodium phosphate can be used with water for flushing the cooling pipes.
The system volume can be calculated at this stage by metering in the cleaning material.
This cleaning should be completed prior to connecting the TCR-104 unit.
We suggest that a gauze or muslin cloth be used to filter and observe the output of the cleaning
medium. Use the lack of returning dirt as a guide to cleanliness.
NOTE: As it is an inherently closed loop system, the unit purposely does not have the restriction of an
in-line filter in the glycol line and depends on the system being cleaned at the initial charge filling.
1.4 Refrigeration System & Components
In addition to the compressor and chiller the refrigeration system includes thermal expansion valve
(TXV), drier, sight glass, condenser coil, receiver, pressure switch and heat exchanger/suction
accumulator.
The suction pressure-regulating valve prevents the suction pressure from increasing above a pre-
determined value. This prevents the compressor motor and engine generator set from being
overloaded at pull down conditions on high ambient days.
The heat exchanger/suction accumulator prevents liquid slugging of the compressor and uses the cold
suction gas to sub-cool the liquid line.

UNCONTROLLED WHEN PRINTED K35-TCR104-07
REV. E, JUNE 2023
9
The receiver is equipped with (2) sight glasses. The bottom sight glass should be filled and the ball
floating during normal operation.
1.5 Heaters (if equipped)
The immersion heaters are 3 phase heaters for operation on 480-volt 3 phase power. At 480 Volts, the
power is 5kW. These heaters must be submerged at all times when in operation.
There is a safety thermal release permanently set to 110°C. If tripped this device opens all 3 legs of
the heater assembly.

UNCONTROLLED WHEN PRINTED K35-TCR104-07
REV. E, JUNE 2023
10
1.6 Piping Schematic