Head Office. Umeda Center Bldg., 4-12, Nakazaki-Nishi 2-chome, Kita-ku, Osaka, 530-8323 Japan. Tel: 06-6373-4338 Fax: 06-6373-7297 Tokyo Office. JR Shinagawa East Bldg., 10F 18-1, Konan 2-chome, Minato-ku Tokyo, 108-0075 Japan. Tel: 03-6716-0420 Fax: 03-6716-0230 Marine type Container Refrigeration Unit Service Manual・Parts List Optional Functions LXE10E-A27 TR04-05 TR04-05 (2004.XX.000XX)NK Covered Models Regarding the features and operation of the unit, this service manual describes the items which are different from those of the service manual TR01-09A. Different points from service manual NO. Item （Maintenance and Repair） 1☆ Debumidification function Refer to the details in the following pages. 2☆ Trans FRESH (PROVISION) Provided For the ☆marked items, refer to the details in the following pages. 1 1 *Diffirences from standard model service manual (TR01-09A) are marked with ☆ CONTENTS Safety Precautions 3.10 Chartless function.....................................3-56 • Danger.................................................................3 3.10.1 Chart indication function.....................3-56 • Warning................................................................4 3.10.2 P code (Pull down time indication).....3-58 • Caution.................................................................5 3.10.3 Chartless code display function..........3-59 1. Introduction.......................................................1-1 3.10.3.1 List of chartless code...................3-59 1.1 Operation range............................................1-1 3.10.3.2 H-code.........................................3-60 ☆ 1.2 Basic Names of components........................1-1 3.10.3.3 d-code:........................................3-62 1.3 Basic operation of refrigeration unit..............1-2 3.11 Communication modem............................3-63 1.3.1 Starting operation...................................1-2 4. Service and Maintenance.................................4-1 1.3.2 Checking during operation.....................1-3 4.1 Maintenance service.....................................4-1 1.3.3 Procedure after operation.......................1-3 4.1.1 Collection of refrigerant..........................4-1 1.3.4 Adjust the ventilation..............................1-4 4.1.2 Gauge manifold......................................4-1 2. General description..........................................2-1 4.1.3 Automatic pump down............................4-3 2.1 Main specifications........................................2-1 4.1.4 Refrigerant recovery and charge............4-5 2.2 Names of components..................................2-2 4.2 Main components and maintenance.............4-9 2.2.1 Outside...................................................2-2 4.2.1 Scroll compressor...................................4-9 ☆ 2.2.2 Inside......................................................2-4 4.2.2 Fan and fan motor................................4-11 2.2.3 Control box.............................................2-6 4.2.3 PT and CT board (EC9756).................4-12 2.3 Set point of functional parts and protection devices...2-9 ☆ 4.2.4 Electronic expansion valve...................4-14 2.4 Operating pressure and running current.....2-10 4.2.5 Suction modulation valve.....................4-15 ☆2.5 Operation modes and control......................2-14 4.2.6 Drier......................................................4-16 2.5.1 Frozen mode........................................2-15 4.2.7 Solenoid valve......................................4-17 2.5.2 Chilled and partial frozen mode............2-17 4.2.8 Discharge pressure regulating valve....4-18 2.5.3 Defrosting mode...................................2-19 4.2.9 Check valve..........................................4-18 ☆ 2.5.4 Dehumidification mode (Optional)........2-22 4.2.10 High-pressure switch (HPS)...............4-19 2.5.5 Common control...................................2-23 4.2.11 Low pressure transducer (LPT)..........4-19 3. Electronic Controller.........................................3-1 4.2.12 High pressure transducer (HPT)........4-20 3.1 Functiontable................................................3-1 4.2.13 Air-cooled condenser and evaporator...4-20 3.2 Basic operation of electronic controller.........3-3 4.2.14 Fusible plug........................................4-21 3.2.1 Control panel..........................................3-3 4.2.15 Liquid/moisture indicator....................4-21 3.2.2 Operation mode and control...................3-5 4.2.16 Evacuation and dehydrating...............4-22 3.3 Operation procedure.....................................3-6 5. Optional Devices...............................................5-1 3.3.1 Operation procedure flow chart..............3-6 5.1 Electronic temperature recorder....................5-1 3.3.2 Mode operation procedure.....................3-9 5.2 USDA transportation.....................................5-3 1. Current (Operation state) indication mode...3-9 5.2.1 Type of USDA sensor/receptacle...........5-3 2. Operation setting mode........................3-10 5.2.2 Initial setting...........................................5-3 3. Battery mode........................................3-11 5.2.3 USDA sensor calibration........................5-3 ☆ 4. Mode operation....................................3-12 5.2.4 USDA transportation requirement..........5-3 5. LED display light-OFF mode................3-14 5.2.5 USDA report...........................................5-3 6. Sensor indication mode........................3-15 ☆5.3 TransFRESH.................................................5-5 7. Temperature record scroll mode..........3-18 6. Troubleshooting................................................6-1 8. Alarm record scroll mode.....................3-21 6.1 Refrigeration system and electrical system...6-1 9. PTI record scroll mode.........................3-23 6.2 Alarm codes on electronic controller.............6-4 3.3.3 Setting flow chart..................................3-24 6.3 Troubleshooting for automatic PTI (J-code)...6-9 10. Optional function setting mode...........3-26 6.4 Diagnosis based on the recording chart......6-11 11. Basic function setting mode...............3-27 6.5 Emergency operation..................................6-14 12. Optional condition setting mode.........3-29 6.5.1 Emergency operation of controller.......6-14 13. Input data mode.................................3-31 6.5.2 Short circuit operation of controller.......6-15 14. Controller software download mode...3-32 6.5.3 Opening adjustment of electronic expansion valve...6-16 3.4 Alarm display and back-up function............3-33 6.5.4 Opening adjustment of suction modulation valve:...6-17 ☆ 3.4.1 Alarm list...............................................3-33 6.5.5 Automatic Back up for supply/ return air 3.4.2 Back-up operation at sensor malfunction...3-34 temperature sensors............................6-18 3.5 Battery.........................................................3-36 6.6 Troubleshooting for automatic PTI (J-code)...6-19 ☆ 3.5.1 Specifications.......................................3-36 7. Appendix............................................................7-1 3.5.2 Function................................................3-37 7.1 Standard tightening torques for bolts............7-1 3.6 Information interchange with personal computer...3-37 7.2 Standard tightening torque for flare nut.........7-1 3.6.1 Data logging.........................................3-38 7.3 Resistance of motor coil and solenoid valve coil...7-1 3.6.2 Software configuration..........................3-39 7.4 HFC134a, temperature-vapor pressure characteristics table...7-2 3.7 Inspection procedure for the electronic controller...3-41 7.5 Temperature conversion table and temperature sensor 3.8 Controller replacement and the initial setting...3-42 (SS/RS/DSS/DRS/RSS/RRS/EIS/EOS/SGS/AMBS) 3.8.1 Controller replacement.........................3-42 characteristics table.............................................7-3 3.8.2 Initial setting & operation procedure.....3-43 7.6 Temperature conversion table and temperature 3.8.3 Initial setting table into spare controller...3-44 sensor (DCHS) characteristics table................7-4 3.9 PTI (Pre-Trip Inspection) and periodic inspection...3-45 7.7 High pressure transducer characteristics table...7-4 3.9.1 Inspection item.....................................3-46 7.8 Low pressure transducer characteristics table...7-4 3.9.2 Automatic PTI(Pre-Trip Inspection).....3-49 ☆7.9 Piping diagram..............................................7-5 3.9.2.1 PTI selection mode........................3-50 7.10 Pilot lamps and monitoring circuit...............7-6 3.9.2.2 Short PTI (S.PTI)...........................3-51 7.11 Fuse protection table...................................7-7 3.9.2.3 Full PTI (F.PTI)..............................3-52 7.12 Schematic wiring diagram...........................7-9 ☆ 3.9.2.4 Alarm list during PTI (Pre-Trip Inspection)...3-53 7.13 Stereoscopic wiring diagram.....................7-10 2 3.9.2.5 Manual check (M.CHECK)............3-54 1. Introduction 1.1 OPERATION RANGE Use the units within the following range. Item Operation range Ambient temperature range -30˚C to +50˚C (-22˚F to + 122˚F) Inside temperature range -30˚C to +30˚C (-22˚F to + 86˚F) 50Hz: 380V/400V/415V, 60Hz: 440V/460V Voltage Voltage fluctuation rate should be within ±10% Vibration and shock 2G 1.2 BASIC NAMES OF COMPONENTS 8 11 6 10 4 5 2 9 13 3 7 1 12 q Compressor i Access panel w Air-cooled condenser o Storage space for power cable e Receiver !0 Ventilator r Evaporator !1 Sampling port (Return) Use this port to measure the    t Control box inside return air temperature. Outside: switch, manual defrost switch, monitoring !2 Gas sampling port This is used to measure the       receptacle  Sampling port (Supply) inside supply air temperature     Inside: circuit breaker and inside CO2concentration. y Condenser fan !3 Liquid moisture indicator u Drier 1-1 3 2. General description 2.1 Main specifications Model LXE10E Item Condenser cooling system Air cooled type Controller DECOS3C Power supply AC 3-phase 380V/400V/415V 50Hz, 440V/460V 60Hz Compressor Hermetic scroll type (Motor output: 5.5kW) Evaporator Cross fin coil type Air-cooled condenser Cross fin coil type Evaporator fan Propeller fan Evaporator fan motor Three-phase squirrel-cage induction motor Condenser fan Propeller fan Condenser fan motor Three-phase squirrel-cage induction motor g System Hot-gas defrosting system n sti Initiation Dual timer, on-demand defrost and manual switch o r ef Termination Detecting the temperature of evaporator outlet pipe and return air D Refrigerant flow control Electronic expansion valve Capacity control Capacity control with hot gas bypass and suction modulating valve Circuit breaker, PT/CT board (for over current protection). Compressor thermal protector Protective devices Condenser fan-motor thermal protector /Safety devices Evaporator fan-motor thermal protector High-pressure switch, Fusible plug, Fuse (10A, 5A) Refrigerant (charged amount) R134a : 4.6 (kgf) Refrigerant oil (charged amount) IDEMITSU, Daphne hermetic oil FVC 46D : 2.2(R) Weight 495(kgf) 4 2-1 2.2 Names of components 2.2.1 Outside (cid:2)LXE10E 1 2 3 27 28 4 5 6 26 7 8 25 9 24 23 10 22 11 12 13 21 20 19 18 17 16 15 14 qAccess panel !6Discharge pressure regulating valve (DPR) wThermometer check port (Return air) !7Compressor suction pipe temperature eCondenser fan motor (CFM) sensor (SGS) rHot-gas solenoid valve (HSV) !8Ambient temperature sensor (AMBS) tDefrost solenoid valve (DSV) !9Thermometer check port (Supply air) yDischarge gas by-pass solenoid valve (BSV) @0Compressor (MC) uElectronic expansion valve (EV) @1Discharge pipe temperature sensor iEconomizer solenoid valve (ESV) (DCHS) oInjection solenoid valve (ISV) @2Storage space for power cable !0Air-cooled condenser @3Low pressure transducer (LPT) !1Liquid/moisture indicator @4High pressure transducer (HPT) !2Liquid receiver @5High pressure switch (HPS) !3Drier @6Control box !4Liquid solenoid valve (LSV) @7Ventilation !5Suction modulating valve (SMV) @8Reheat coil solenoid valve (RSV) 2-2 5 2.2.2 Inside (cid:2)LXE10E 10 6 1 7 2 5 8 11 9 4 3 qEvaporator fan motor (EFM) wEvaporator eSupply air temperature sensor (SS) Data recorder supply air temperature sensor (DSS) Recorder supply air temperature sensor (RSS, optional) rEvaporator outlet pipe temperature sensor (EOS) tEvaporator inlet pipe temperature sensor (EIS) yReturn air temperature sensor (RS) Data recorder return air temperature sensor (DRS, optional) Recorder return air temperature sensor (DRS, optional) uUSDA receptacle (optional) iCargo temp. receptacles oP.C. Port receptacles !0Humidity sensor !1Reheat coil 6 2-4 2.2.3 Control box (cid:2)Inside of the control box 4 5 6 7 8 20 9 10 19 22 P35AJK- PAK-61JC PAK-61JC PAK-61JC 18 17 B4P–VH B4P–VH 16 FUSE B5P-VH B3PSVH RA–H341TD 15 21 12 11 (cid:2)Operation panel (Outside of the control box) 1 COMP. DEFROST INRANGED–HUMID SUPPLY ˚C / ˚F (cid:2)Controller ARLEATRUMRN %R H R.H. INSORP5VA+ENRG˚CE21 SUNPD–E5R˚C 321DHAOYUSRS –6–12 –5–10 –4–8 –3–6 –2–4 –1–2 2 DAIKIN ELECTRONICCONTAINER OPERATION SYSTEMDECOS b 3 14 13 11 qController operation panel (EC3, 4) !2Fuse (Fu1-6) wMANUAL DEFROST key !3Rechargeable battery (BAT) eUNIT ON/OFF key !4Voltage indicator rPhase correction contactor (PCC1,2) !5Personal computer receptacle tMagnetic contactor for high speed evaporator fan (EFH) !6Circuit breaker (CB) yMagnetic contactor for low speed evaporator fan (EFL) !7PT/CT board uMagnetic contactor condenser fan (CFC) !8Transformer (TrC), control circuit iReverse phase protection device (RPP) !9Magnetic contactor for compressor (CC) oAdopter PCB (EC6) @0P.C.B for humidity sensor (HUS, optional) !0Terminal block board (TB1) @1Modem (RCD, optional) !1Controller CPU / IO board (EC1, 2) @2Noise filter (NF, optional) 2-6 7 2.3 Set point of functional parts and protection devices Device name Actuation Set point Detection method Symbol ch High-pressure switch OFF 2400kPa (24.47kg/cm2) High-pressure switch HPS wit s ON 1900kPa (19.37kg/cm2) e ur Water pressure switch OFF 98kPa (1.0kg/cm2) Water pressure switch WPS s s Pre (optional) ON 39kPa (0.4kg/cm2) Chilled mode ON +30.0°Cto –2.9°C Set point temperature EC (+86.0°Fto +26.8°F) Partial frozen mode –3.0°Cto –10.0°C Mode selection (+26.6°Fto +14.0°F) Frozen mode –10.1°Cto –30.0°C (+13.8°Fto –22.0°F) Delay Fan Change-over for Hi/Lo ON 10 seconds timer After defrosting 60 seconds Compressor At starting 3 seconds Defrosting on Short ON 4 hours ※1 ati timer niti Long 3, 6, 9, 12, 24 and 99 hours(※2) I Back-up OFF 90 minutes In-range masking 90 minutes ※3 er Out-range guard ON 30 minutes ntroll Defrosting termination set point OFF 30˚C (86°F) Evaporator outlet EOS o Reset tempertature sensor c nic 15˚C (59°F) ※4 Return air temperature RS, DRS o ctr sensor Ele High-pressure control for Condenser fan OFF 800kPa (8.2kg/cm2) ※7 High-pressure transducer HPT (※Frozen only) ON 1000kPa (10.2kg/cm2) Discharge gas Pull down OFF 135˚C (275°F) Discharge gas DCHS temperature LPT>50kpa Reset After 3 minutes elapsed temperature sensor protection LPT≦50kpa OFF 128˚C (262°F) set point Reset After 3 minutes elapsed Overcurrent protection set point (Cutout) OFF 26.0A PT/CT board CT2 Reset After 3 minutes elapsed Current control Control 50Hz: 16.1A PT/CT board CT1 60Hz : 17.4A High pressure control Control 2300 to 2350 kPa High pressure sensor HPT (23.5 to 24.0 kg/cm2) nt Circuit breaker OFF 30A CB e urr Fuse OFF 5A, 10A ※5 Fu C Evaporator fan motor thermal protector OFF 132˚C(270°F) or ot Condenser fan motor thermal protector OFF 135˚C(275°F) MTP M Compressor motor thermal protector OFF 140˚C(284°F) CTP (※1) When Return air (RS) is lower than –20˚C, defrost starts every 6 hours. (※2) When "99" hours is selected, refer to on demand defrost in 2.5.3. (TR01-09A) (※3) When Inside set point is –20.0˚C or Lower, In-range masking is 120min. (※4) If defrost is initiated when inside temperature is out rangle area. (= In-range LED is not light), this condition is added to finish defrost. Refer to "Defrosting termination" in 2.5.3. (TR01-09A) (※5) Refer to "Fuse Protection table" in 7.11. (TR01-09A) (※7) When dehumidification is ON in dehumidification mode, the setting figure may change between 900~2100kPa automatically (Refer to "High Pressure Control" Page 2-17/TR01-09A) 8 2-9 2.4 OPERATION MODES AND CONTROL The relationship between the operation mode and setting temperature is as follows. Operation mode Setting temperature Control sensor Operation description –10.1˚C to –30.0˚C Return air Frozen mode Compressor ON/OFF control (+13.8˚F to –22.0˚F) temperature sensor Capacity control operation Partial frozen –3.0˚C to –10.0˚C Return air with suction modulating valve mode (+26.6˚F to +14˚F) temperature sensor and hot-gas bypass control Capacity control operation +30.0˚C to –2.9˚C Supply air Chilled mode with suction modulating valve (+86˚F to +26.8˚F) temperature sensor and hot-gas bypass control Hot-gas defrosting with Defrosting mode – – refrigerant metering control 2-14 9