Thermo King MAGNUM PLUS 098212 User manual

Revision A
October 2019 TTKK 6600227755--44--MMMM--EENN
Container Edition
MAGNUM PLUS®® with MP4000
Maintenance Manual

©2019 Trane Technologies TK 60275-4-MM-EN
Introduction
This manual is ublished for informational ur oses only. Thermo King®makes no re resentations warranties ex ress
or im lied, with res ect to the information recommendations and descri tions contained herein. Information rovided
should not be regarded as all-inclusive or covering all contingencies. If further information is required, Thermo King
Cor oration Service De artment should be consulted.
TThheerrmmoo KKiinngg’’ss wwaarrrraannttyy sshhaallll nnoott aa llyy ttoo aannyy eeqquuii mmeenntt wwhhiicchh hhaass bbeeeenn ““ssoo iinnssttaalllleedd,, mmaaiinnttaaiinneedd,, rree aaiirreedd
oorr aalltteerreedd aass,, iinn tthhee mmaannuuffaaccttuurreerr’’ss jjuuddggmmeenntt,, ttoo aaffffeecctt iittss iinntteeggrriittyy..””
MMaannuuffaaccttuurreerr sshhaallll hhaavvee nnoo lliiaabbiilliittyy ttoo aannyy ppeerrssoonn oorr eennttiittyy ffoorr aannyy ppeerrssoonnaall iinnjjuurryy,, pprrooppeerrttyy ddaammaaggee oorr aannyy
ootthheerr ddiirreecctt,, iinnddiirreecctt,, ssppeecciiaall,, oorr ccoonnsseeqquueennttiiaall ddaammaaggeess wwhhaattssooeevveerr,, aarriissiinngg oouutt ooff tthhee uussee ooff tthhiiss mmaannuuaall oorr
aannyy iinnffoorrmmaattiioonn,, rreeccoommmmeennddaattiioonnss oorr ddeessccrriippttiioonnss ccoonnttaaiinneedd hheerreeiinn.. TThhee pprroocceedduurreess ddeessccrriibbeedd hheerreeiinn sshhoouulldd
oonnllyy bbee uunnddeerrttaakkeenn bbyy ssuuiittaabbllyy qquuaalliiffiieedd ppeerrssoonnnneell.. FFaaiilluurree ttoo iimmpplleemmeenntt tthheessee pprroocceedduurreess ccoorrrreeccttllyy mmaayy ccaauussee
ddaammaaggee ttoo tthhee TThheerrmmoo KKiinngg uunniitt oorr ootthheerr pprrooppeerrttyy oorr ppeerrssoonnaall iinnjjuurryy..
General Information
The maintenance information in this manual covers unit models:
MAGNUM PLUS 098212
098216
098218
098219
098223
098580
098581
098582
098583
098585
098586
098587
098588
098589
098590
098591
098592
098593
098594
Base Units 098203
For further information, refer to:
MAGNUM Parts List Parts Manual TK 54356
Diagnosing Thermo King Container Refrigeration Systems TK 41166
Electrostatic Discharge (ESD) Training Guide TK 40282
Evacuation Station Operation and Field Application TK 40612
Tool Catalog TK 5955
The information in this manual is provided to assist owners, operators, and service people in the proper upkeep and maintenance of Thermo
King units.
Revision istory
Revision A (Oct 2019) New manual format, general updates throughout manual.

TK 60275-4-MM-EN 3
Recover Refrigerant
NNoottee In the USA, EPA Section 608 Certification is required to work on refrigeration systems. In the EU, local F-gas
Regulations must be observed when working on refrigeration systems.
At Thermo King®, we recognize the need to reserve the environment and limit the otential harm to the ozone layer
that can result from allowing refrigerant to esca e into the atmos here.
We strictly adhere to a olicy that romotes the recovery and limits the loss of refrigerant into the atmos here.
When working on trans ort tem erature control systems, a recovery rocess that revents or minimizes refrigerant
loss to the atmos here is required by law. In addition, service ersonnel must be aware of the a ro riate Euro ean
Union, National, Federal, State, and/or Local regulations governing the use of refrigerants and certification of
technicians. For additional information on regulations and technician rograms, contact your local THERMO KING
dealer.
SSeerrvviiccee TToooollss - Use the ro er service tools. Gauge manifold sets should include a ro riate shutoff valves or
disconnects near the end of each service line.
RReeccoovveerryy EEqquuii mmeenntt - Recovery equi ment must be used. Pro er recovering, storing and recycling of refrigerants is
an im ortant art of all service work.
SSeerrvviiccee PPrroocceedduurreess - Recommended rocedures must be used to minimize refrigerant loss.
CCoomm oonneennttss mmaayy bbee iissoollaatteedd by closing service valves and erforming system um -downs.
CCoomm oonneennttss uunnaabbllee ttoo bbee iissoollaatteedd for service must be re aired only after refrigerant is ro erly recovered.
R-404A/R-452A
NNOOTTIICCEE
EEqquuii mmeenntt DDaammaaggee!!
UUssee oonnllyy PPoollyyoolleesstteerr--bbaasseedd rreeffrriiggeerraattiioonn ccoomm rreessssoorr ooiill iinn RR--113344aa//RR--440044AA//RR--445522AA ssyysstteemmss.. SSeeee TThheerrmmoo KKiinngg
PPaarrttss MMaannuuaall ffoorr aarrtt nnuummbbeerr..
NNOOTTIICCEE
SSyysstteemm CCoonnttaammiinnaattiioonn!!
DDoo nnoott mmiixx PPoollyyoolleesstteerr aanndd ssttaannddaarrdd ssyynntthheettiicc ccoomm rreessssoorr ooiillss.. KKeeee PPoollyyoolleesstteerr ccoomm rreessssoorr ooiill iinn ttiigghhttllyy
sseeaalleedd ccoonnttaaiinneerrss.. IIff PPoollyyoolleesstteerr ooiill bbeeccoommeess ccoonnttaammiinnaatteedd wwiitthh mmooiissttuurree oorr ssttaannddaarrdd ooiillss,, ddiiss oossee ooff
rroo eerrllyy––DDOO NNOOTT UUSSEE..
NNOOTTIICCEE
SSyysstteemm CCoonnttaammiinnaattiioonn!!
WWhheenn sseerrvviicciinngg TThheerrmmoo KKiinngg RR--113344aa,, RR--2233,, RR--440044AA,, RR--445522AA oorr RR--551133AA uunniittss,, uussee oonnllyy tthhoossee sseerrvviiccee ttoooollss
cceerrttiiffiieedd ffoorr aanndd ddeeddiiccaatteedd ttoo RR--113344aa//RR--2233//RR--440044AA//RR--445522AA//RR--551133AA rreeffrriiggeerraanntt aanndd PPoollyyoolleesstteerr ccoomm rreessssoorr ooiillss..
RReessiidduuaall nnoonn--HHFFCC rreeffrriiggeerraannttss oorr ooiillss wwiillll ccoonnttaammiinnaattee RR--113344aa//RR--2233//RR--440044AA//RR--445522AA//RR--551133AA ssyysstteemmss..PPlleeaassee
cchheecckk sseerriiaall## llaattee ffoorr ttyy ee aanndd vvoolluummee ooff RReeffrriiggeerraanntt cchhaarrggeedd.. PPlleeaassee ddoo nnoott bblleenndd wwiitthh ootthheerr rreeffrriiggeerraannttss
tthhaann tthhee oorriiggiinnaall cchhaarrggeedd rreeffrriiggeerraanntt
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IInnttrroodduuccttiioonn

4TK 60275-4-MM-EN
SSaaffeettyy PPrreeccaauuttiioonnss .. .. .... .. ........ .. .. .... .. .... .. .... .. ........ .. .. .... .. .... .. .... .. ........ .. .. .... .. .... .. .... .. ........ .. .. .... .. .... .. .... .. ........ .. .. .... .. .... .. 1122
Danger, Warning, Caution, and Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Refrigerant Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LowVoltage............................................................................... 15
Electrostatic Discharge Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrostatic Discharge and the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Welding on Refrigeration Units or Containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FirstAid....................................................................................... 16
Identifying Unit Safety and Warning Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Com onent Serial Number Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SSeerrvviiccee GGuuiiddee .. .. .... .. ...... .... .. ........ .. .... .. ...... .... .. ........ .. .... .. ........ .. .... .. ........ .. .. .... .. .... .. .... .. ...... .... .. ........ .. .... .. ........ .. .. .... .. .... .. 2200
SS eecciiffiiccaattiioonnss .... .... .. ...... .... .. .... .. .. .... .. .... .. .... .. .... .. ...... .... .. ........ .. .... .. ........ .. .. .... .. .... .. .... .. ...... .... .. ........ .. .... .. ........ .. .... .. ........ 2211
System Net Cooling Ca acity - Full Cool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Eva orator Airflow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Refrigeration System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Normal R-404A/R-452A System O erating Pressures (Scroll Com ressor) . . . . . . . . . . . . . . . . . . . . . . . . . . 23
MP4000 Controller S ecifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Physical S ecifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Metric Hardware Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
UUnniitt DDeessccrrii ttiioonn .... .... .. .... .. .... ...... .... .. .... .... .. .... .. .... ...... .... .. .... .. .... .... .. .... .. .... .. .... .... .. .... .. .... .. .... .. .... .... .. .... .. .... ...... .... .. .... .... 2277
General Descri tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Scroll Com ressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DigitalPort ................................................................................ 28
Intermediate Suction Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
MP4000 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Power Module Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Com ressor Digital Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Economizer Heat Exchange System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Tem erature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Fresh Air Exchange System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Receiver Tank Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Eva orator Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Table of Contents

TK 60275-4-MM-EN 5
Condenser Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
USDA Cold Treatment Tem erature Recording (Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
UnitO tions................................................................................... 31
Electronic Chart Recorder (O tional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Remote Monitoring Modem (RMM, RMM+) (O tional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Suction and Discharge Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Water-Cooled Condenser/Receiver Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Air Ventilation Logging (AVL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Advanced Fresh Air Management (AFAM) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
AFAMO eration........................................................................... 32
AFAMVentDoorAssembly.................................................................. 33
Advanced Fresh Air Management Plus (AFAM+) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
CCoonnttrroolllleerr DDeessccrrii ttiioonn .... ........ .. .. .... .. .... .. .... .. ........ .. .. .... .. .... .. .... .. ........ .. .. .... .. .... .. .... .. ...... .... .. ........ .. .... .. ........ .. .. .... .. .... .. 3377
MP4000 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Back-u Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
In ut and Out ut Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Standard Dis lay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Idle Screen and Check Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Unit Status Dis lay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Dis lay Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Mode Descri tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Keys and Indicator LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Function Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
S ecial Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Indicator LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Software Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
OO eerraattiinngg IInnssttrruuccttiioonnss .. .... .. .... .. .... .. ...... .... .. ........ .. .... .. ........ .. .. .... .. .... .. .... .. ........ .. .. .... .. .... .. .... .. ........ .. .. .... .. .... .. .... .. ........ 5500
FunctionKeys ................................................................................. 50
Unit On/Off Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Sequence of O eration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Unit Start-u . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Initiating a Manual Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Pretri Ins ection (PTI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Viewing Alarms/Messages from Standard Dis lay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Dis lay Alternate Fahrenheit (F) or Celsius (C) Tem eratures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Changing Set oint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
MainMenu ................................................................................ 52
Lock Padlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Controller Back-u Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Controller Locku Issue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Emergency Run Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Rotation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
FULL COOL Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DEFROST Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
TTaabbllee ooff CCoonntteennttss

6TK 60275-4-MM-EN
Low S eed Fans Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
NNaavviiggaattiinngg CCoonnttrroolllleerr OO eerraattiinngg MMeennuu ...... .. .... .. ...... .... .. ........ .. .... .. ........ .. .... .. ...... .... .. ........ .. .... .. ........ .. .... .. .. .... .. 5566
Menu Scrolling Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Changing Screen Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
MMaaiinn MMeennuu.. ...... .... .. ........ .. .... .. ........ .. .... .. ...... .... .. ........ .. .... .. ........ .. .. .... .. .... .. .... .. ........ .. .. .... .. .... .. .... .. ........ .. .. .... .. .... .. .... .. ........ 5588
MainMenu.................................................................................... 58
ValuesMenu .................................................................................. 58
ControlsMenu................................................................................. 58
Cold Treatment (CT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Multi le Tem erature Set (MTS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
O tiSet™.................................................................................. 60
Tem erature Set oint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Controlling Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Pull Down Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Water Cooled Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Dehumidify Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Dehumidify Set oint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
AVL (Air Ventilation Logging) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Fresh Air Vent Man - AFAM Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Fresh Air Vent Man - AFAM+ Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
AFAMDelay ............................................................................... 64
AFAMRate ................................................................................ 65
AFAM+ CO2 Max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
AFAM+ O2 Min. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
SmartPTI.................................................................................. 66
Silent Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
AlarmMenu................................................................................... 68
Alarm Code States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
AlarmCodes............................................................................... 69
MessageMenu................................................................................ 69
Configuration Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Unit....................................................................................... 71
O tions ................................................................................... 72
System.................................................................................... 74
Clock...................................................................................... 75
Calibrate .................................................................................. 76
IconMenu................................................................................. 76
LogViewMenu................................................................................ 77
InfoMenu..................................................................................... 78
SS eecciiaall FFuunnccttiioonn KKeeyyss -- UUsseerr AAccttiivvaatteedd CCoommmmaannddss ........ .. .... .. ........ .. .. .... .. .... .. .... .. ........ .. .. .... .. .... .. .... .. ........ 7799
PTIKey ....................................................................................... 79
DefrostKey.................................................................................... 80
TTaabbllee ooff CCoonntteennttss

TK 60275-4-MM-EN 7
PTI (Pretri ) Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Manual Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
AAiirr VVeennttiillaattiioonn LLooggggiinngg ((AAVVLL)) .. .. .... .. .. .... .. .... .. .... .. .... .. ...... .... .. ........ .. .... .. ...... .... .. ........ .. .... .. ........ .. .. .... .. .... .. .... .. ........ 8866
AAddvvaanncceedd FFrreesshh AAiirr MMaannaaggeemmeenntt ((AAFFAAMM)) SSyysstteemm .. ........ .. .... .. ........ .. .. .... .. .... .. .... .. ........ .. .. .... .. .... .. .... .. ........ 8877
Starting the AFAM System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Change the AFAM Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Change the AFAM Rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
AAddvvaanncceedd FFrreesshh AAiirr MMaannaaggeemmeenntt PPlluuss ((AAFFAAMM++)) SSyysstteemm .. ........ .. .... .. ........ .. .... .. ........ .. .. .... .. .... .. .... .. ........ 9900
Set AFAM+ System Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Change the AFAM Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Change the CO2 Minimum and Maximum Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Change the AFAM+ Settings Using O tiSet™.................................................... 92
Modify O tiSet Product Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Testing AFAM / AFAM+ System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
AFAM+ O tion Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
System O eration Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Alarm Codes and Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
PPuullssaattiinngg VVeenntt DDoooorr.... .. .... .. ...... .... .. .... .. .. .... .. .... .. .... .. .... .. ...... .... .. ........ .. .... .. ........ .. .. .... .. .... .. .... .. ........ .. .. .... .. .... .. .... .. ........ 9966
AFAM+ Door Closes Automatically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Pulsating AFAM+ Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
AFAM+ Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
OO eerraattiinngg TThheeoorryy .... .... .. .. .... .. .... .. .... .. ...... .... .. ........ .. .... .. ........ .. .. .... .. .... .. .... .. ........ .. .. .... .. .... .. .... .. ........ .. .. .... .. .... .. .... .. ........ 9977
Chill Loads (Set oint at -9.9 C [14.1 F] and Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Su ly Air Sensor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Frozen Loads (Set oint at -10 C [14 F] and Below). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Cooling Ca acity Dis lay in Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Com ressor Va or Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
High Tem erature Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Power Limit Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Eva orator Fan Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Chill Loads (Set oints of -9.9 C [14.1 F] and Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Frozen Loads (Set oint at -10.0 C [14.0 F] or Below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Condenser Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
ProbeTest .................................................................................... 98
Dehumidify Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Continuous Tem erature Control O eration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
TTaabbllee ooff CCoonntteennttss

8TK 60275-4-MM-EN
Chill Loads (Controller Set oint at -9.9 C [14.1 F] and Above). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Cool with Modulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Heat......................................................................................101
Frozen Loads (Controller Set oint at -10 C [14 F] and Below) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Cool......................................................................................102
Null......................................................................................102
Defrost...................................................................................102
Com ressor Digital Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Economizer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Data Recording and Downloading Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Cold Treatment (CT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Multi le Tem erature Set oint (MTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
CCoonnttrroolllleerr MMaaiinntteennaannccee..............................................................................................................................................111111
Controller Door O en and Close Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Flashloading Controller Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
MP4000 Test System Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Controller Re lacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
EElleeccttrriiccaall MMaaiinntteennaannccee................................................................................................................................................111155
Unit Protection Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Main Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Eva orator Overheat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
High Pressure Cutout Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
High Pressure Cutout Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
High Pressure Cutout Switch Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Low Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Removal..................................................................................118
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Low Pressure Cutout Switch or Suction Transducer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Discharge and Low Pressure Sensors (O tional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Removal..................................................................................120
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Condenser Fan and Eva orator Fan Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Check Condenser Fan Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Check Eva orator Fan Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Reversing Power Phase on Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Eva orator Heater Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Extended Ca acity Heaters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Electric Heaters Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Com ressor Discharge Tem erature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Re lacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
TTaabbllee ooff CCoonntteennttss

TK 60275-4-MM-EN 9
Tem erature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Sensor Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Resistance Values for Tem erature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
RReeffrriiggeerraattiioonn MMaaiinntteennaannccee ......................................................................................................................................112277
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Tools ........................................................................................127
VacuumPum ................................................................................127
Filters and Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Refrigerant Recovery Equi ment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Detecting Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
S ecial Service Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Oil Acid Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Isolate Com ressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Gauge Manifold Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Using a New Gauge Manifold Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Gauge Manifold Valve Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Gauge Manifold Set Installation & Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Removal..................................................................................132
Checking Refrigerant Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Receiver Tank Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Leak Testing Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Using Pressurized Nitrogen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Purge High Side to Low Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Maximum Gas Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Recovering Refrigerant from System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Evacuation and Cleanu of Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Unit Pre aration and Hooku . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Unit Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Pressure Rise Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Factors Affecting S eed of System Evacuation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Heat Saves Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Charging System with Refrigerant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Unit Charging by Weight (from an Evacuated Condition) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Evacuation Station Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Com ressor Re lacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Removal..................................................................................142
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
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10 TK 60275-4-MM-EN
Condenser Coil Re lacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Removal..................................................................................143
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Filter Drier/In-line Filter Re lacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Removal..................................................................................143
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Eva orator Ex ansion Valve (TXV) Re lacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Economizer Ex ansion Valve Re lacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Removal..................................................................................145
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Economizer Heat Exchanger Re lacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Removal..................................................................................148
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Receiver Tank/ Water-Cooled Condenser Tank Re lacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Removal..................................................................................148
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Va or Injection Valve Re lacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Removal..................................................................................149
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Com ressor Digital Control Valve Re lacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Removal..................................................................................150
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
SSeerrvviicciinngg tthhee UUnniitt ..........................................................................................................................................................115522
Taking Care of the Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Ins ecting Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Checking Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Cleaning the Condenser Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Cleaning the Eva orator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Cleaning the Defrost Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Positioning the Condenser Fan Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Positioning the Eva orator Fan Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Adjusting the Fresh Air Exchange System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
DDiiaaggnnoossttiiccss ........................................................................................................................................................................115555
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
MP4000 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Mechanical Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Refrigeration Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Status Messages and Controller Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Alarm Codes and Corrective Actions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
DDiiaaggrraammss ............................................................................................................................................................................118877
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TK 60275-4-MM-EN 11
Diagram Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
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12 TK 60275-4-MM-EN
Safety Precautions
Danger, Warning, Caution, and Notice
Thermo King®recommends that all service be erformed by a Thermo King dealer and to be aware of several general
safety ractices.
Safety advisories a ear throughout this manual as required. Your ersonal safety and the ro er o eration of this unit
de end u on the strict observance of these recautions. The four ty es of advisories are defined as follows:
DDAANNGGEERR
HHaazzaarrdd!!
IInnddiiccaatteess aann iimmmmiinneennttllyy hhaazzaarrddoouuss ssiittuuaattiioonn wwhhiicchh,, iiff nnoott aavvooiiddeedd,, wwiillll rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy..
WWAARRNNIINNGG
HHaazzaarrdd!!
IInnddiiccaatteess aa ootteennttiiaallllyy hhaazzaarrddoouuss ssiittuuaattiioonn wwhhiicchh,, iiff nnoott aavvooiiddeedd,, ccoouulldd rreessuulltt iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy..
CCAAUUTTIIOONN
HHaazzaarrdd!!
IInnddiiccaatteess aa ootteennttiiaallllyy hhaazzaarrddoouuss ssiittuuaattiioonn wwhhiicchh,, iiff nnoott aavvooiiddeedd,, ccoouulldd rreessuulltt iinn mmiinnoorr oorr mmooddeerraattee iinnjjuurryy aanndd
uunnssaaffee rraaccttiicceess..
NNOOTTIICCEE
HHaazzaarrdd!!
IInnddiiccaatteess aa ssiittuuaattiioonn tthhaatt ccoouulldd rreessuulltt iinn eeqquuii mmeenntt oorr rroo eerrttyy--ddaammaaggee oonnllyy aacccciiddeennttss..
General Practices
DDAANNGGEERR
HHaazzaarrdd ooff EExx lloossiioonn!!
NNeevveerr aa llyy hheeaatt ttoo aa sseeaalleedd rreeffrriiggeerraattiioonn ssyysstteemm oorr ccoonnttaaiinneerr.. HHeeaatt iinnccrreeaasseess iinntteerrnnaall rreessssuurree,, wwhhiicchh mmiigghhtt
ccaauussee aann eexx lloossiioonn rreessuullttiinngg iinn ddeeaatthh oorr sseerriioouuss iinnjjuurryy..
DDAANNGGEERR
HHaazzaarrddoouuss GGaasseess -- PPeerrssoonnaall PPrrootteeccttiivvee EEqquuii mmeenntt ((PPPPEE)) RReeqquuiirreedd!!
RReeffrriiggeerraanntt iinn tthhee rreesseennccee ooff aann oo eenn ffllaammee,, ss aarrkk,, oorr eelleeccttrriiccaall sshhoorrtt rroodduucceess ttooxxiicc ggaasseess tthhaatt aarree sseevveerree
rreess iirraattoorryy iirrrriittaannttss wwhhiicchh ccaann ccaauussee sseerriioouuss iinnjjuurryy oorr oossssiibbllee ddeeaatthh.. WWhheenn wwoorrkkiinngg wwiitthh oorr aarroouunndd hhaazzaarrddoouuss
cchheemmiiccaallss,, AALLWWAAYYSS rreeffeerr ttoo aa rroo rriiaattee MMaatteerriiaall DDaattaa SSaaffeettyy SShheeeettss ((MMSSDDSS)) aanndd OOSSHHAA//GGHHSS ((GGlloobbaall
HHaarrmmoonniizzeedd SSyysstteemm ooff CCllaassssiiffiiccaattiioonn aanndd LLaabbeelllliinngg ooff CChheemmiiccaallss)) gguuiiddeelliinneess ffoorr iinnffoorrmmaattiioonn oonn aalllloowwaabbllee
eerrssoonnaall eexx oossuurree lleevveellss,, rroo eerr rreess iirraattoorryy rrootteeccttiioonn,, aanndd hhaannddlliinngg iinnssttrruuccttiioonnss..
DDAANNGGEERR
RRiisskk ooff IInnjjuurryy!!
KKeeee yyoouurr hhaannddss,, ccllootthhiinngg,, aanndd ttoooollss cclleeaarr ooff ffaannss aanndd//oorr bbeellttss wwhheenn wwoorrkkiinngg oonn aa uunniitt tthhaatt iiss rruunnnniinngg oorr wwhheenn
oo eenniinngg oorr cclloossiinngg ccoomm rreessssoorr sseerrvviiccee vvaallvveess.. LLoooossee ccllootthhiinngg mmiigghhtt eennttaannggllee mmoovviinngg uulllleeyyss oorr bbeellttss,, ccaauussiinngg
sseerriioouuss iinnjjuurryy oorr oossssiibbllee ddeeaatthh..

TK 60275-4-MM-EN 13
DDAANNGGEERR
RReeffrriiggeerraanntt VVaa oorr HHaazzaarrdd!!
DDoo nnoott iinnhhaallee rreeffrriiggeerraanntt.. UUssee ccaauuttiioonn wwhheenn wwoorrkkiinngg wwiitthh rreeffrriiggeerraanntt oorr aa rreeffrriiggeerraattiioonn ssyysstteemm iinn aannyy ccoonnffiinneedd
aarreeaa wwiitthh aa lliimmiitteedd aaiirr ssuu llyy.. RReeffrriiggeerraanntt ddiiss llaacceess aaiirr aanndd ccaann ccaauussee ooxxyyggeenn ddee lleettiioonn,, rreessuullttiinngg iinn
ssuuffffooccaattiioonn aanndd oossssiibbllee ddeeaatthh.. WWhheenn wwoorrkkiinngg wwiitthh oorr aarroouunndd hhaazzaarrddoouuss cchheemmiiccaallss,, AALLWWAAYYSS rreeffeerr ttoo
aa rroo rriiaattee MMaatteerriiaall DDaattaa SSaaffeettyy SShheeeettss ((MMSSDDSS)) aanndd OOSSHHAA//GGHHSS ((GGlloobbaall HHaarrmmoonniizzeedd SSyysstteemm ooff CCllaassssiiffiiccaattiioonn
aanndd LLaabbeelllliinngg ooff CChheemmiiccaallss)) gguuiiddeelliinneess ffoorr iinnffoorrmmaattiioonn oonn aalllloowwaabbllee eerrssoonnaall eexx oossuurree lleevveellss,, rroo eerr
rreess iirraattoorryy rrootteeccttiioonn,, aanndd hhaannddlliinngg iinnssttrruuccttiioonnss..
WWAARRNNIINNGG
HHaazzaarrdd ooff EExx lloossiioonn!!
NNeevveerr cclloossee tthhee ccoomm rreessssoorr ddiisscchhaarrggee sseerrvviiccee vvaallvvee wwhheenn tthhee uunniitt iiss oo eerraattiinngg.. NNeevveerr oo eerraattee tthhee uunniitt wwiitthh
tthhee ddiisscchhaarrggee vvaallvvee cclloosseedd ((ffrroonntt sseeaatteedd)).. TThhiiss ccoonnddiittiioonn iinnccrreeaasseess iinntteerrnnaall rreessssuurree,, wwhhiicchh ccaann ccaauussee aann
eexx lloossiioonn..
WWAARRNNIINNGG
PPrroo eerr EEqquuii mmeenntt CCoonnddiittiioonn!!
GGaauuggee mmaanniiffoolldd hhoosseess mmuusstt bbee iinn ggoooodd ccoonnddiittiioonn bbeeffoorree uussiinngg tthheemm.. NNeevveerr lleett tthheemm ccoommee iinn ccoonnttaacctt wwiitthh
mmoovviinngg bbeellttss,, ffaannss,, uulllleeyyss oorr hhoott ssuurrffaacceess.. DDeeffeeccttiivvee ggaauuggee eeqquuii mmeenntt ccaann ddaammaaggee ccoomm oonneennttss oorr ccaauussee
sseerriioouuss iinnjjuurryy..
WWAARRNNIINNGG
PPeerrssoonnaall PPrrootteeccttiivvee EEqquuii mmeenntt ((PPPPEE)) RReeqquuiirreedd!!
AAllwwaayyss wweeaarr ggoogggglleess oorr ssaaffeettyy ggllaasssseess aanndd rroo eerr PPPPEE wwhheenn wwoorrkkiinngg oonn aa uunniitt.. RReeffrriiggeerraanntt lliiqquuiidd,, ooiill,, aanndd
bbaatttteerryy aacciidd ccaann eerrmmaanneennttllyy ddaammaaggee yyoouurr eeyyeess.. WWhheenn wwoorrkkiinngg wwiitthh oorr aarroouunndd hhaazzaarrddoouuss cchheemmiiccaallss,,
AALLWWAAYYSS rreeffeerr ttoo aa rroo rriiaattee MMaatteerriiaall DDaattaa SSaaffeettyy SShheeeettss ((MMSSDDSS)) aanndd OOSSHHAA//GGHHSS ((GGlloobbaall HHaarrmmoonniizzeedd SSyysstteemm
ooff CCllaassssiiffiiccaattiioonn aanndd LLaabbeelllliinngg ooff CChheemmiiccaallss)) gguuiiddeelliinneess ffoorr iinnffoorrmmaattiioonn oonn aalllloowwaabbllee eerrssoonnaall eexx oossuurree
lleevveellss,, rroo eerr rreess iirraattoorryy rrootteeccttiioonn,, aanndd hhaannddlliinngg iinnssttrruuccttiioonnss..
WWAARRNNIINNGG
EEqquuii mmeenntt DDaammaaggee aanndd RRiisskk ooff IInnjjuurryy!!
NNeevveerr ddrriillll hhoolleess iinnttoo tthhee uunniitt uunnlleessss iinnssttrruucctteedd bbyy TThheerrmmoo KKiinngg.. HHoolleess ddrriilllleedd iinnttoo hhiigghh vvoollttaaggee ccaabblleess ccoouulldd
ccaauussee aann eelleeccttrriiccaall ffiirree,, sseevveerree eerrssoonnaall iinnjjuurryy,, oorr eevveenn ddeeaatthh..
WWAARRNNIINNGG
RRiisskk ooff IInnjjuurryy!!
WWhheenn uussiinngg llaaddddeerrss ttoo iinnssttaallll oorr sseerrvviiccee rreeffrriiggeerraattiioonn ssyysstteemmss,, aallwwaayyss oobbsseerrvvee tthhee llaaddddeerr mmaannuuffaaccttuurreerr’’ss
ssaaffeettyy llaabbeellss aanndd wwaarrnniinnggss.. AA wwoorrkk llaattffoorrmm oorr ssccaaffffoollddiinngg iiss tthhee rreeccoommmmeennddeedd mmeetthhoodd ffoorr iinnssttaallllaattiioonnss aanndd
sseerrvviicciinngg..
CCAAUUTTIIOONN
SShhaarr EEddggeess!!
EExx oosseedd ccooiill ffiinnss ccaann ccaauussee llaacceerraattiioonnss.. SSeerrvviiccee wwoorrkk oonn tthhee eevvaa oorraattoorr oorr ccoonnddeennsseerr ccooiillss sshhoouulldd oonnllyy bbee
aaccccoomm lliisshheedd bbyy aa cceerrttiiffiieedd TThheerrmmoo KKiinngg tteecchhnniicciiaann..
NNOOTTIICCEE
EEqquuii mmeenntt DDaammaaggee!!
AAllll uunniitt mmoouunnttiinngg bboollttss mmuusstt bbee iinnssttaalllleedd,, bbee tthhee ccoorrrreecctt lleennggtthh ffoorr tthheeiirr aa lliiccaattiioonn,, aanndd ttoorrqquueedd ttoo
ss eecciiffiiccaattiioonnss.. MMiissssiinngg bboollttss,, iinnccoorrrreecctt bboolltt lleennggtthhss aanndd iimm rroo eerr ttoorrqquuee ss eecciiffiiccaattiioonnss ccaann ddaammaaggee
eeqquuii mmeenntt aanndd vvooiidd tthhee wwaarrrraannttyy..
SSaaffeettyy PPrreeccaauuttiioonnss

14 TK 60275-4-MM-EN
Refrigerant azards
DDAANNGGEERR
HHaazzaarrddoouuss PPrreessssuurreess!!
AAllwwaayyss ssttoorree rreeffrriiggeerraanntt iinn rroo eerr ccoonnttaaiinneerrss,, oouutt ooff ddiirreecctt ssuunnlliigghhtt aanndd aawwaayy ffrroomm iinntteennssee hheeaatt.. HHeeaatt
iinnccrreeaasseess rreessssuurree iinnssiiddee ssttoorraaggee ccoonnttaaiinneerrss,, wwhhiicchh ccaann ccaauussee tthheemm ttoo bbuurrsstt aanndd ccoouulldd rreessuulltt iinn sseevveerree
eerrssoonnaall iinnjjuurryy..
DDAANNGGEERR
CCoommbbuussttiibbllee HHaazzaarrdd!!
DDoo nnoott uussee ooxxyyggeenn ((OO22 )) oorr ccoomm rreesssseedd aaiirr ffoorr lleeaakk tteessttiinngg.. OOxxyyggeenn mmiixxeedd wwiitthh rreeffrriiggeerraanntt iiss ccoommbbuussttiibbllee..
WWAARRNNIINNGG
HHaazzaarrddoouuss GGaasseess!!
DDoo nnoott uussee aa HHaalliiddee ttoorrcchh.. WWhheenn aa ffllaammee ccoommeess iinn ccoonnttaacctt wwiitthh rreeffrriiggeerraanntt,, ttooxxiicc ggaasseess aarree rroodduucceedd.. TThheessee
ggaasseess ccaann ccaauussee ssuuffffooccaattiioonn,, eevveenn ddeeaatthh..
WWAARRNNIINNGG
PPeerrssoonnaall PPrrootteeccttiivvee EEqquuii mmeenntt ((PPPPEE)) RReeqquuiirreedd!!
RReeffrriiggeerraanntt iinn aa lliiqquuiidd ssttaattee eevvaa oorraatteess rraa iiddllyy wwhheenn eexx oosseedd ttoo tthhee aattmmooss hheerree,, ffrreeeezziinngg aannyytthhiinngg iitt ccoonnttaaccttss..
WWeeaarr bbuuttyyll lliinneedd gglloovveess aanndd ootthheerr ccllootthhiinngg aanndd eeyyee wweeaarr wwhheenn hhaannddlliinngg rreeffrriiggeerraanntt ttoo hheell rreevveenntt ffrroossttbbiittee..
WWhheenn wwoorrkkiinngg wwiitthh oorr aarroouunndd hhaazzaarrddoouuss cchheemmiiccaallss,, AALLWWAAYYSS rreeffeerr ttoo aa rroo rriiaattee MMaatteerriiaall DDaattaa SSaaffeettyy SShheeeettss
((MMSSDDSS)) aanndd OOSSHHAA//GGHHSS ((GGlloobbaall HHaarrmmoonniizzeedd SSyysstteemm ooff CCllaassssiiffiiccaattiioonn aanndd LLaabbeelllliinngg ooff CChheemmiiccaallss)) gguuiiddeelliinneess
ffoorr iinnffoorrmmaattiioonn oonn aalllloowwaabbllee eerrssoonnaall eexx oossuurree lleevveellss,, rroo eerr rreess iirraattoorryy rrootteeccttiioonn,, aanndd hhaannddlliinngg
iinnssttrruuccttiioonnss..
NNOOTTIICCEE
EEqquuii mmeenntt DDaammaaggee!!
WWhheenn bbeeiinngg ttrraannssffeerrrreedd,, rreeffrriiggeerraanntt mmuusstt bbee iinn lliiqquuiidd ssttaattee ttoo aavvooiidd oossssiibbllee eeqquuii mmeenntt ddaammaaggee..
Electrical azards
EElleeccttrriiccaall PPrreeccaauuttiioonnss
• The ossibility of serious or fatal injury from electrical shock exists when servicing a refrigeration unit. Extreme care
must be used when working with a refrigeration unit that is connected to its ower source.
• Extreme care must be used even if the unit is not running. Lethal voltage otentials can exist at the unit ower cord,
inside the control box, inside any high voltage junction box, at the motors and within the wiring harnesses.
• In general, disconnect the units ower cord before re airing or changing any electrical com onents.
• Even though the controller is turned off, one of the hases is still live and re resents a otential danger of
electrocution.
igh Voltage
DDAANNGGEERR
HHaazzaarrddoouuss VVoollttaaggee!!
LLeetthhaall aammoouunnttss ooff vvoollttaaggee aarree rreesseenntt iinn ssoommee eelleeccttrriiccaall cciirrccuuiittss.. UUssee eexxttrreemmee ccaarree wwhheenn wwoorrkkiinngg oonn aann
oo eerraattiinngg rreeffrriiggeerraattiioonn uunniitt.. IIff tthheerree iiss aa rriisskk ooff eenneerrggiizzeedd eelleeccttrriiccaall ccoonnttaacctt,, aarrcc,, oorr ffllaasshh,, tteecchhnniicciiaannss MMUUSSTT uutt
oonn aallll PPPPEE iinn aaccccoorrddaannccee wwiitthh OOSSHHAA,, NNFFPPAA 7700EE,, oorr ootthheerr llooccaall,, ssttaattee,, oorr ccoouunnttrryy--ss eecciiffiicc rreeqquuiirreemmeennttss ffoorr aarrcc
ffllaasshh rrootteeccttiioonn PPRRIIOORR ttoo sseerrvviicciinngg tthhee uunniitt.. NNEEVVEERR PPEERRFFOORRMM AANNYY SSWWIITTCCHHIINNGG,, DDIISSCCOONNNNEECCTTIINNGG,, OORR
VVOOLLTTAAGGEE TTEESSTTIINNGG WWIITTHHOOUUTT PPRROOPPEERR EELLEECCTTRRIICCAALL PPPPEE AANNDD AARRCC FFLLAASSHHIINNGG CCLLOOTTHHIINNGG.. EELLEECCTTRRIICCAALL
MMEETTEERRSS AANNDD EEQQUUIIPPMMEENNTT MMUUSSTT BBEE PPRROOPPEERRLLYY RRAATTEEDD FFOORR IINNTTEENNDDEEDD VVOOLLTTAAGGEE..
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TK 60275-4-MM-EN 15
WWAARRNNIINNGG
HHaazzaarrddoouuss VVoollttaaggee!!
TTrreeaatt aallll wwiirreess aanndd ccoonnnneeccttiioonnss aass iiff tthheeyy wweerree hhiigghh vvoollttaaggee uunnttiill aa mmeetteerr aanndd wwiirriinngg ddiiaaggrraamm iinnddiiccaattee
ootthheerrwwiissee.. OOnnllyy uussee ttoooollss wwiitthh iinnssuullaatteedd hhaannddlleess.. NNeevveerr hhoolldd uunniinnssuullaatteedd mmeettaall ttoooollss nneeaarr eexx oosseedd,, eenneerrggiizzeedd
ccoonndduuccttoorrss.. IIff tthheerree iiss aa rriisskk ooff eenneerrggiizzeedd eelleeccttrriiccaall ccoonnttaacctt,, aarrcc,, oorr ffllaasshh,, tteecchhnniicciiaannss MMUUSSTT uutt oonn aallll PPPPEE iinn
aaccccoorrddaannccee wwiitthh OOSSHHAA,, NNFFPPAA 7700EE,, oorr ootthheerr llooccaall,, ssttaattee,, oorr ccoouunnttrryy--ss eecciiffiicc rreeqquuiirreemmeennttss ffoorr aarrcc ffllaasshh
rrootteeccttiioonn PPRRIIOORR ttoo sseerrvviicciinngg tthhee uunniitt.. NNEEVVEERR PPEERRFFOORRMM AANNYY SSWWIITTCCHHIINNGG,, DDIISSCCOONNNNEECCTTIINNGG,, OORR VVOOLLTTAAGGEE
TTEESSTTIINNGG WWIITTHHOOUUTT PPRROOPPEERR EELLEECCTTRRIICCAALL PPPPEE AANNDD AARRCC FFLLAASSHHIINNGG CCLLOOTTHHIINNGG.. EELLEECCTTRRIICCAALL MMEETTEERRSS AANNDD
EEQQUUIIPPMMEENNTT MMUUSSTT BBEE PPRROOPPEERRLLYY RRAATTEEDD FFOORR IINNTTEENNDDEEDD VVOOLLTTAAGGEE..
WWAARRNNIINNGG
HHaazzaarrddoouuss VVoollttaaggee!!
NNeevveerr wwoorrkk aalloonnee oonn hhiigghh vvoollttaaggee cciirrccuuiittss iinn tthhee rreeffrriiggeerraattiioonn uunniitt.. AAnnootthheerr eerrssoonn sshhoouulldd bbee nneeaarrbbyy ttoo sshhuutt
ooffff tthhee uunniitt aanndd rroovviiddee aaiidd iinn tthhee eevveenntt ooff aann aacccciiddeenntt.. IIff tthheerree iiss aa rriisskk ooff eenneerrggiizzeedd eelleeccttrriiccaall ccoonnttaacctt,, aarrcc,, oorr
ffllaasshh,, tteecchhnniicciiaannss MMUUSSTT uutt oonn aallll PPPPEE iinn aaccccoorrddaannccee wwiitthh OOSSHHAA,, NNFFPPAA 7700EE,, oorr ootthheerr llooccaall,, ssttaattee,, oorr ccoouunnttrryy--
ss eecciiffiicc rreeqquuiirreemmeennttss ffoorr aarrcc ffllaasshh rrootteeccttiioonn PPRRIIOORR ttoo sseerrvviicciinngg tthhee uunniitt.. NNEEVVEERR PPEERRFFOORRMM AANNYY SSWWIITTCCHHIINNGG,,
DDIISSCCOONNNNEECCTTIINNGG,, OORR VVOOLLTTAAGGEE TTEESSTTIINNGG WWIITTHHOOUUTT PPRROOPPEERR EELLEECCTTRRIICCAALL PPPPEE AANNDD AARRCC FFLLAASSHHIINNGG
CCLLOOTTHHIINNGG.. EELLEECCTTRRIICCAALL MMEETTEERRSS AANNDD EEQQUUIIPPMMEENNTT MMUUSSTT BBEE PPRROOPPEERRLLYY RRAATTEEDD FFOORR IINNTTEENNDDEEDD VVOOLLTTAAGGEE..
WWAARRNNIINNGG
PPeerrssoonnaall PPrrootteeccttiivvee EEqquuii mmeenntt ((PPPPEE)) RReeqquuiirreedd!!
IInn tthhee eevveenntt ooff aann eelleeccttrriiccaall aacccciiddeenntt,, aallll rreeqquuiirreedd PPPPEE sshhoouulldd bbee nneeaarr tthhee wwoorrkk aarreeaa iinn aaccccoorrddaannccee wwiitthh OOSSHHAA,,
NNFFPPEE 7700EE,, oorr ootthheerr llooccaall,, ssttaattee,, oorr ccoouunnttrryy--ss eecciiffiicc rreeqquuiirreemmeennttss ffoorr aa CCaatteeggoorryy 22 rriisskk..
WWAARRNNIINNGG
HHaazzaarrddoouuss VVoollttaaggee!!
TThhee uunniitt OOnn//OOffff sswwiittcchh mmuusstt bbee ttuurrnneedd OOffff bbeeffoorree ccoonnnneeccttiinngg oorr ddiissccoonnnneeccttiinngg tthhee ssttaannddbbyy oowweerr lluugg.. NNeevveerr
aatttteemm tt ttoo ssttoo tthhee uunniitt bbyy ddiissccoonnnneeccttiinngg tthhee oowweerr lluugg..
WWAARRNNIINNGG
RRiisskk ooff IInnjjuurryy!!
TThhee uunniitt oowweerr lluugg mmuusstt bbee cclleeaann aanndd ddrryy bbeeffoorree ccoonnnneeccttiinngg iitt ttoo aa oowweerr ssoouurrccee..
WWAARRNNIINNGG
RRiisskk ooff IInnjjuurryy!!
DDoo nnoott mmaakkee rraa iidd mmoovveess wwhheenn wwoorrkkiinngg oonn hhiigghh vvoollttaaggee cciirrccuuiittss iinn rreeffrriiggeerraattiioonn uunniittss.. DDoo nnoott ggrraabb ffoorr ffaalllliinngg
ttoooollss bbeeccaauussee yyoouu mmiigghhtt aacccciiddeennttaallllyy ttoouucchh aa hhiigghh vvoollttaaggee ssoouurrccee..
Low Voltage
WWAARRNNIINNGG
LLiivvee EElleeccttrriiccaall CCoomm oonneennttss!!
CCoonnttrrooll cciirrccuuiittss aarree llooww vvoollttaaggee ((2244 VVaacc aanndd 1122 VVddcc)).. TThhiiss vvoollttaaggee ootteennttiiaall iiss nnoott ccoonnssiiddeerreedd ddaannggeerroouuss.. LLaarrggee
aammoouunntt ooff ccuurrrreenntt aavvaaiillaabbllee ((oovveerr 3300 aamm eerreess)) ccaann ccaauussee sseevveerree bbuurrnnss iiff sshhoorrtteedd ttoo ggrroouunndd.. DDoo nnoott wweeaarr
jjeewweellrryy,, wwaattcchh oorr rriinnggss.. TThheessee iitteemmss ccaann sshhoorrttccuutt eelleeccttrriiccaall cciirrccuuiittss aanndd ccaauussee sseevveerree bbuurrnnss ttoo tthhee wweeaarreerr..
Electrostatic Discharge Precautions
Precautions must be taken to revent electrostatic discharge while servicing the micro rocessor controller and related
com onents. The risk of significant damage to the electronic com onents of the unit is ossible if these recautionary
measures are not followed. The rimary risk otential results from the failure to wear adequate electrostatic discharge
SSaaffeettyy PPrreeccaauuttiioonnss

16 TK 60275-4-MM-EN
reventive equi ment when handling and servicing the controller. The second cause results from electric welding on
the unit and container chassis without taking recautionary ste s.
Electrostatic Discharge and the Controller
You must avoid electrostatic discharges when servicing the controller. Solid-state integrated circuit com onents can be
severely damaged or destroyed with less than a small s ark from a finger to metal object. You must rigidly adhere to
the following statements when servicing these units. This will avoid controller damage or destruction.
• Disconnect all ower to the unit.
• Avoid wearing clothing that generates static electricity (wool, nylon, olyester, etc.).
• Do wear a static discharge wrist stra (refer to Tool Catalog) with the lead end connected to the controller's ground
terminal. These stra s are available at most electronic equi ment distributors. Do not wear these stra s with ower
a lied to the unit.
• Avoid contacting the electronic com onents on the circuit boards of the unit being serviced.
• Leave the circuit boards in their static roof acking materials until ready for installation.
• Return a defective controller for re air in the same static rotective acking materials from which the re lacement
com onent was removed.
• Check the wiring after servicing the unit for ossible errors. Com lete this task before restoring ower.
Welding on Refrigeration Units or Containers
Electric welding can cause serious damage to electronic circuits when erformed on any ortion of the refrigeration
unit, genset, container, or container chassis with the refrigeration unit attached. It is necessary to verify that welding
currents are not allowed to flow through the electronic circuits of the unit. The rocedures below MUST be strictly
followed when servicing units to avoid damage or destruction of the micro rocessor.
1. Disconnect the battery connections (if equi ed) and lock out - tag out the unit according to local regulations.
2. Disconnect all ower to or from the refrigeration unit or genset.
3. Disconnect all quick-disconnect wire harnesses from the back of the controller.
4. Switch all of the electrical circuit breakers in the control box to the Off osition.
5. When ste s 1 through 5 are com lete, weld the unit and/or container using normal welding rocedures. Kee
ground return electrode as close to the area to be welded as ractical. This will reduce the likelihood of stray
welding currents assing through any electrical or electronic circuits.
6. When welding is com lete, restore the unit ower cables, wiring, and circuit breakers to their normal condition.
First Aid
RREEFFRRIIGGEERRAANNTT
•EEyyeess:: For contact with liquid, immediately flush eyes with large amounts of water and get rom t medical
attention.
•SSkkiinn:: Flush area with large amounts of warm water. Do not a ly heat. Remove contaminated clothing and shoes.
Wra burns with dry, sterile, bulky dressing to rotect from infection. Get rom t medical attention. Wash
contaminated clothing before reuse.
•IInnhhaallaattiioonn:: Move victim to fresh air and use Cardio Pulmonary Resuscitation (CPR) or mouth-to-mouth
resuscitation to restore breathing, if necessary. Stay with victim until emergency ersonnel arrive.
•FFrroosstt BBiittee:: In the event of frost bite , the objectives of First Aid are to rotect the frozen area from further injury,
warm the affected area ra idly, and to maintain res iration.
RREEFFRRIIGGEERRAANNTT OOIILL
•EEyyeess:: Immediately flush with large amounts of water for at least 15 minutes. Get rom t medical attention.
•SSkkiinn:: Remove contaminated clothing. Wash thoroughly with soa and water. Get medical attention if irritation
ersists.
•IInnhhaallaattiioonn:: Move victim to fresh air and use Cardio Pulmonary Resuscitation (CPR) or mouth-to-mouth
resuscitation to restore breathing, if necessary. Stay with victim until emergency ersonnel arrive.
•IInnggeessttiioonn:: Do not induce vomiting. Immediately contact local oison control center or hysician.
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TK 60275-4-MM-EN 17
EENNGGIINNEE CCOOOOLLAANNTT
•EEyyeess:: Immediately flush with large amounts of water for at least 15 minutes. Get rom t medical attention.
•SSkkiinn:: Remove contaminated clothing. Wash thoroughly with soa and water. Get medical attention if irritation
ersists.
•IInnggeessttiioonn:: Do not induce vomiting. Immediately contact local oison control center or hysician.
BBAATTTTEERRYY AACCIIDD
•EEyyeess:: Immediately flush with large amounts of water for at least 15 minutes. Get rom t medical attention. Wash
skin with soa and water.
•SSkkiinn:: Immediately remove contaminated clothing. Wash skin with large volumes of water, for at least 15 minutes.
Wash skin with soa and water. Do not a ly fatty com ounds. Seek immediate medical assistance.
•IInnhhaallaattiioonn:: Provide fresh air. Rinse mouth and nose with water. Seek immediate medical assistance.
•IInnggeessttiioonn:: If the injured erson is fully conscious: make the erson drink extensive amounts of milk. Do not induce
vomiting. Take the injured erson immediately to a hos ital.
EELLEECCTTRRIICCAALL SSHHOOCCKK
Take IMMEDIATE action after a erson has received an electrical shock. Get quick medical assistance, if ossible.
The source of the shock must be quickly sto ed, by either shutting off the ower or removing the victim. If the ower
cannot be shut off, the wire should be cut with an non-conductive tool, such as a wood-handle axe or thickly insulated
cable cutters. Rescuers should wear insulated gloves and safety glasses, and avoid looking at wires being cut. The
ensuing flash can cause burns and blindness.
If the victim must be removed from a live circuit, ull the victim away with a non-conductive material. Use wood, ro e,
a belt or coat to ull or ush the victim away from the current. DO NOT TOUCH the victim. You will receive a shock from
current flowing through the victim’s body. After se arating the victim from ower source, immediately check for signs
of a ulse and res iration. If no ulse is resent, start Cardio Pulmonary Resuscitation (CPR). If a ulse is resent,
res iration might be restored by using mouth-to-mouth resuscitation. Call for emergency medical assistance.
AASSPPHHYYXXIIAATTIIOONN
Move victim to fresh air and use Cardio Pulmonary Resuscitation (CPR) or mouth-to-mouth resuscitation to restore
breathing, if necessary. Stay with victim until emergency ersonnel arrive.
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18 TK 60275-4-MM-EN
Identifying Unit Safety and Warning Decals
Serial number decals, refrigerant ty e decals, and warning decals a ear on all Thermo King®equi ment. These decals
rovide information that may be needed to service or re air the unit. Service technicians should read and follow the
instructions on all warning decals.
Figure 1. Nameplate and Warning Locations
1 Controller Nameplate
2 Unit Nameplate
3 Compressor Nameplate
Serial Number Location
Serial numbers can be found on the com onent’s name late.
• Electric Motor: Attached to the motor housing.
• Com ressor: On front of the com ressor.
• Unit: On unit frame in ower cord storage com artment.
• Controller: On to of controller.
Component Serial Number Identification
To better identify the different electronic com onents, our su lier has changed their serial number labeling on the
MP4000 controller and ower module. The label will show art number, date, and sequence.
MP4000 Controller: New label shows controller ID ABS782800212245390
Part number: ABS7828002; Date: 2012 24 wk 1224; Sequence 5390
ID in controller would show 1224-5390
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TK 60275-4-MM-EN 19
Label on Controller ID in Controller Controller ID Shown in Datalogger
SSaaffeettyy PPrreeccaauuttiioonnss

20 TK 60275-4-MM-EN
Service Guide
A closely followed maintenance rogram will hel to kee your Thermo King unit in to o erating condition. The
following table should be used as a guide when ins ecting or servicing com onents on this unit.
Pretrip Every
1,000
Hours
Annual/
Yearly
Inspect/Service These Items
Electrical:
• Perform a controller pretrip inspection (PTI) check.
• • • Visually check condenser fan and evaporator fan.
• • • Visually inspect electrical contacts for damage or loose connections.
• • • Visually inspect wire harnesses for damage or loose connections.
• • Download the data logger and check data for correct logging.
•Check operation of protection shutdown circuits.
Refrigeration:
• • • Check refrigerant charge.
• • Check for proper discharge and suction pressures.
•Check filter drier/in-line filter for a restriction pressures.
Structural:
• • • Visually inspect unit for damaged, loose, or broken parts.
• • • Tighten unit, compressor and fan motor mounting bolts.
• • Clean entire unit including condenser and evaporator coils and defrost drains.
Note: If a unit has been carrying cargo which contains a high level of sulphor or phosphorous (e.g., garlic, salted fish etc.),
it is recommended to clean the evaporator coil after each trip.