TRS Transportkoeling BV

TRS EnergySystems BV
De Scheysloot 71 (Klei-Oost)
2201 GN Noordwijk
Postbus 3088
2220 CB Katwijk
The Netherlands

Tel: +31(0)71-4050070
Fax: +31(0)71-4050071
e-mail: info@trs.eu
internet: www.trs.eu

TR SERIES
REPAIR MANUAL

V2.0 17042013
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Table of Contents

Safety measures .......................................................................................................................... 3

What to do if you come in contact with a coolant ...................................................................... 4

General ....................................................................................................................................... 5

Identification .............................................................................................................................. 6

The unit ...................................................................................................................................... 7

Mains connection ....................................................................................................................... 7

Operation .................................................................................................................................... 8

Setting the temperature............................................................................................................... 8

Functions on the control panel ................................................................................................... 9

How the unit works .................................................................................................................. 10

Maintenance ............................................................................................................................. 11

Warranty ................................................................................................................................... 11

Maintenance program ............................................................................................................... 12

Setting Internal Parameters ...................................................................................................... 13

Alarm codes.............................................................................................................................. 14

Possible faults in TR7000 and solutions .................................................................................. 15

Replacing electric components in the switch box .................................................................... 17

Tables and diagrams ................................................................................................................. 41

Electrical Diagram.................................................................................................................... 42

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Safety measures

1. Read this user manual carefully before using or maintaining the machine.

2. Whenever doing any work on the machine, makes sure that it is not in operation and
switch off the main voltage from the unit.

3. Watch out for sharp edges of the laminates close to the condenser block.

4. If the machine is switched on, be careful that your hands do not come too close to the fan
or drive belts.

5. When the cooling machine is working, certain parts will heat up, such as the condenser,
compressed gas pipe, compressor, etc. Avoid touching these parts.

6. Never turn off the compressor's delivery valve while the unit is switched on.

7. Be very careful with handling the coolant. Any repairs should be carried out by a certified
repair company and according to the legislation applicable in the particular country.

8. If the coolant comes in contact with fire, it creates a gas that spreads an unpleasant odour
and irritates the respiratory system. Avoid inhaling this gas.

9. Never heat a closed cooling circuit with fire or another source of heat.

10. Liquid coolant evaporates immediately when exposed to external air and freezes
everything that it comes in contact with.

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What to do if you come in contact with a coolant

Eyes : If your eyes come in contact with a coolant, rinse them with lots of water and
consult a physician immediately.

Skin : Rinse the affected spot with lots of lukewarm water. Wrap the wound with a
dry, thick and sterile bandage and consult a physician immediately.

Inhaling : Bring the person outside for fresh air. Stay with the person and if needed, help
the person regain his/her normal breathing, and consult a physician
immediately.

If it is necessary to visit a physician, inform him/her that the coolant is CFK R134A.

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General

The manual is intended specifically for using cooling and heating units on tank containers. It
contains instructions for operating the cooling and heating units, safety instructions and
directions for repairing minor failures.

To use your unit over longer periods of time without failures, it is important to have proper
maintenance and service. In addition, this saves on operating costs and gives your machine a
longer lifespan.

This manual provides you with a comprehensive description of how the unit operates. It also
contains solutions to possible problems that might arise. For additional information about
failures and problems, please contact TRS Transportkoeling BV.

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Identification

Each unit can be identified according to a type plate. The type plate contains the following
information:

- Type of cooling machine

- Serial number
- Construction year
- Data about Freon (DuPont's brand name for CFCs, HCFCs and related
compounds)

The type plate is mounted on the outside of the unit, on the left side.
In case of a failure or if you need information, we recommend that you write down the data
that appears on the plate before consulting technical services. That will ensure a more
effective service by them.

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The unit

The TR7000 is a unit that cools and heats (optional). The unit is mounted to the side of the
tank container and it is designed specifically to fit in precisely within the ISO 20" frame of a
tank container. The unit is designed to maintain the temperature of the cargo; the cargo must
have the correct temperature before it is loaded into the container. The TR7000 is powered by
an electric unit from the mains or from a generator.

For efficient transfer of heating or cooling between the cargo and the coolers, it is important
that the cargo remains in motion. This is not necessary during transport.
For questions about the cargo and heat transfer, please contact the TRS service department.

Mains connection

The power current connection for the TR7000 unit has to be a 3-phase network 380V-50Hz or
440V-60Hz with 16A inert fuses. The power current connection of the cooling unit is a c-
form inlet socket 32A-4p-3h. Once the unit is connected to a power current (network or
generator) via an adequately heavy-duty extension cable, the system adjusts itself to the
correct rotating direction by means of the phase monitor.

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Operation

The control panel is located on the rear side of the tank container.
The unit has two positions: the OFF position and the ON position.

1- Switch on the plug on the mains voltage or the generator.

2- Press the On/Off button (for 2 seconds). The display will show OFF. Press once again
on the On/Off button (for 3 seconds). The display will now show the current
temperature.

3- Check the thermostat settings.

4- To switch off the unit, press the On/Off (for 2 seconds). The display will show Off.
After 10 seconds the display will switch off.

Setting the temperature

Adjusting the desired temperature is carried out in the control panel.

Adjusting: 1 – Press 'SET' once.

2 – The set temperature will blink.
3 – By pressing 6 or 7, the new temperature can be set (the display must
blink).
4 – After around 5 seconds, the display will change to the actual
temperature of the new setting.

After changing the setting of the thermostat, this unit will automatically cool or heat
according to the re-adjusted values.
It is important to check the temperature setting regularly.

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Functions on the control panel

The control panel has a number of LEDs. These LEDs make it easy to check the status of the
unit and its operation.

1) Failure LED 9) Option

2) External connection 10) Heating LED
3) Pressing On/Off (for 2 seconds) 11) Option (for several machines)
4) Display 12) Option
5) SET button 13) Option
6) Decrease value 14) LED machine is operational
7) Increase value 15) Cooling LED
8) Option

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How the unit works

- The cooling / heating function of the unit works as follows:

- Adjust the required setting point. After 30 seconds, the unit will start burning the
cooling / heating LED and the unit will start to operate.

- As soon as the set temperature is reached, the unit will stop cooling or heating and
the control LED on the remote control will switch off.

- The unit will also stop cooling / heating if the glycol reaches maximum
differentiation.

- With cooling, reaching the set-point temperature of the glycol differentiation

temperature will operate the pump-down system. The fluid valve will shut and the
compressor will pump out the coolant system until the suction pressure in the
compressor reaches 0 bar.

- As soon as the glycol or product temperature comes within 0.5° of the set point,
the fluid valve will reopen and the unit will cool again until the set point is reached
or the glycol differentiation temperature is reached.

- The glycol pump continues to circulate at all times.

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Maintenance

To guarantee the reliability of the unit, it is recommended to have TRS Transportkoeling

maintain it periodically. Also in case of internal or external failures in the unit, it is
recommended to contact TRS Transportkoeling so that we can provide you with the address
of the nearest TRS Transportkoeling dealer. This will guarantee a proper and fast repair of
your unit.

During maintenance, disconnect the unit from the main voltage and set the main switch on
'Off'.
The unit should undergo maintenance and a CFK check every 12 months in order to guarantee
a good and long lifespan.
Check to glycol level each day. The glycol tank is situated at the right side of the unit, above
the corner of the container.

Warranty
The complete warranty provisions of TRS Transportkoeling can be obtained from a TRS
dealer. TRS provides a 12-month warranty on material and assembly faults. Replacement
and/or repair of parts under this warranty must be carried out by TRS Transportkoeling. It is
also possible to have a certified TRS dealer carry out this work, but prior permission is
required from TRS Transportkoeling.

If you wish to use this warranty option during the warranty period, please contact TRS
Transportkoeling. We will be pleased to assist you.

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Maintenance program

To guarantee the reliability of the unit, we recommend maintaining it periodically. Also in

case of failures in the unit in your own country or abroad, we advise you to contact TRS
Transportkoeling so that we can provide you with the address of the nearest TRS
Transportkoeling dealer. This will guarantee a proper and fast repair of your unit. All electric
and technical-cooling activities must be carried out by certified/approved company and
according to the applicable legal regulations of the relevant country.

The warranty covering the unit and repairs will become void if the unit is serviced by anyone
other than an approved TRS Transportkoeling BV dealer. Avoid unnecessary confusion and
malfunctions caused by unprofessional repairs.

Preventive maintenance

After the first two months:

♦ Check all bolts and nuts in the unit

♦ Check the electrical connections
♦ Check to glycol level
♦ Check to coolant level
♦ Check the cooling/heating operations of the unit

Interval: every 6 months:

♦ Check all bolts and nuts in the unit

♦ Check the electrical connections
♦ Check the bearings of the condenser fan motor
♦ Clean the condenser
♦ Check the hose connections
♦ Check the glycol level
♦ Check pump-down system
♦ Check the coolant level
♦ Check the cooling/heating operations of the unit

Interval: every 12 months:

♦ Carry out the items listed in the 'Interval every 6 months'

♦ Check the glycol hoses
♦ Check the glycol pump bearings
♦ Check the leak-tightness of the coolant system according to legal regulations

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SETTING INTERNAL PARAMETERS

- Switch on TR 7000

- Press on the "UP" ▲ and "DOWN" ▼ buttons simultaneously (around 2 sec) to change the internal
parameters.

- Enter the code 352 while pressing "UP/DOWN". Press on the "SET" button for the next digit

- If the code is correct, you can inspect and change the parameters

- Press the "SET" button to read the parameters

- Enter the various parameters by pressing "UP/DOWN".

- To increase the parameter, keep the "SET" button pressed and press on the "UP" ▲ button several
times until you reach the correct value.

- To decrease the parameter, keep the "SET" button pressed and press on the "DOWN" ▼ button
several times until you reach the correct value.

- After 30 seconds the remote control will automatically show the product temperature.

PARAMETER LIST TR 7000

P No. Description Scope Default

P 10 Offset control sensor -10.0…+10.0ºC 0.0ºC
P 11 Offset glycol sensor -10.0…+10.0ºC 0.0ºC
P 12 Read-out control sensor - ºC
P 13 Read-out glycol sensor - ºC
P 14 Read-out of hour meter for cooling - hours
P 15 Read-out of hour meter for heating - hours
P 20 Differentiation regulator 0.1…10.0ºC 0.5ºC
P 21 Minimum adjustable set point -20.0…+80.0ºC -10.0ºC
P 22 Maximum adjustable set point -20.0…+80.0ºC +80.0ºC
P 30 Minimum time between switching cooling on / off 0...240 sec. 15 sec.
Minimum time between transfer from cooling to
P 31 heating or vice versa 0...240 min. 1 min.
P 32 Switching off heating 0 = no, 1 = yes 1
P 40 Glycol temperature difference during cooling -3.0…-25.0ºC -10ºC
P 41 Glycol temperature difference during heating +3.0…+25.0ºC +3.0ºC
P 50 Starting delay of the control print 0… 99 min. 0 min.

The default values are the standard set values. The parameters, which have to be set
depending on the user and type of unit, are: P31, P32, P40 and P 41.
All other changes can affect the operation of the unit and are taken entirely at your own risk.

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Alarm codes

Code Description Possible causes

E1 Product temperature sensor is faulty - Check the resistance of the sensor based on the
table below. In case of deviation, replace the
sensor.

- Check the wiring and connections with plugs.

- Check whether the tank temperature does not

exceed 100°C.
E2 Glycol temperature sensor is faulty - Check the resistance of the sensor based on the
table below. In case of deviation, replace the
sensor.

- Check the wiring and connections with plugs.

- Check whether the glycol temperature does not

exceed 100°C.

E4 Thermal alarm compressor - Check the compressor protection relay in the

compressor. If 1 or 2 red LEDs are burning,
check the amount of Amperes used by the
compressor (~9 A).

- Check the voltage on control print J9 – the

brown wire (24V – DC)

- Check whether connection 5+6 on the control

print is a closed connection.

E5 Glycol pump alarm - Check the glycol level

- Check whether the glycol pump operates.

- Check the pump with regard to voltage on the

relay board (380V ~ 50Hz )

- Check whether connection 7+8 on the control

print is a closed connection.

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Possible faults in TR7000 and solutions

Remote control:

All the LEDs on the display are burning.

- Moisture in the remote control unit

Solution: Dismantle the remote control, remove the screws from the rear side, and carefully
slide the print out of the housing via the front part. Check whether the print is moist. Allow
the print to dry and try once again to connect it. If the problem is not solved, you will have to
mount a new remote control unit.

Only 2 stripes appear in the display

- No data signal from the control print

Solution: Check the plug connection behind the remote control. Check the plug/wiring on the
control print. Check whether wires No. 3 or 4 between the remote control and the control print
are not broken or create a short-cut.
If all this is in order, then the remote control or the control print is defective.

No display

- Check in the switch box whether the phase monitor is active. [The phase monitor is only
active if it receives 3 phases (L1 to L3), the Direction LED and OK LED are constantly
burning, and the Power LED is blinking.] If that's the case, check whether the LEDs on the
control print are blinking. If they are not blinking, then fuse F1 is broken or the relay on the
print plate is defective. If this is not the case, then you should check the voltage on the print.
- If the LEDs on the print plate do blink (red or green), then check whether the F2 fuse is
broken. If this fuse is OK, check whether there is any 24V DC current between print
connection 26+27. If you find current here, then the remote control is switched off (press 2
seconds on the On/Off button). If that is not the case, then the remote control is defective.
- Check whether the engine protection is not switched off.

Display indicates cooling function, but the compressor/glycol pump do not operate and you
get error code E5

- The rotating direction network guard does not function.

Solution: Check whether LED is burning when rotating either clockwise or counter-
clockwise. Check whether there is 24V through-put (DC) on the rotating direction. If so, then
the network guard is defective. If this is not the case, then check whether there is 24V (DC)
on J9 of the control print.

- Phase for reverse relay on the relay print is defective.

Solution: Replace the relay print.

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Compressor:

Compressor switches off when switching on the 2nd condenser fan

- Low pressure switch is not functioning properly.

Solution: Check at which pressure the compressor switches off. At -0.3 bar, the low pressure
switch usually has to close the fluid valve and to switch off the compressor relay.
If the relay is switched off already above 0 bar, then the low pressure switch needs to be
replaced.
- There is too little coolant; check the unit for any possible leakage.
- The thermostatic expansion valve is defective; check the functioning of the valve.
Compressor switches out at high external temperature

- Condenser fan pressure switch does not function.

Solution: Check whether the 2nd condenser fan switches on at 14 bar pressure. If that's not the
case, first check whether the condenser fan is not defective and whether the relay print does
drive the fan. If all that is in order, then the condenser fan pressure switch is defective (on the
fluid vessel).

Compressor relay does not switch on

If the compressor does not switch on, but the cooling indication light on the remote control
does burn, then you have to check the following:
- Check whether there is 24V DC at point 29 on the control print.
- Subsequently, check whether there is 24V DC on the A1 connection of the compressor
relay.
If this is in order, then the compressor relay is defective and must be replaced.

If the compressor does not switch on and the cooling indication light does not burn, then you
have to check the following
- Is the product or glycol on the right temperature?
- Check whether there is 24V DC at point 32.
- Check whether the fluid valve opens (you can check this by removing the coil of the
valve; if it functions well, you will hear a ticking sound).
- Check whether connection 9/10 and 11/12 are closed connections. If one of these two
is an open connection, this indicates to a failure in the coolant or a pressure switch
failure. In both cases, this must be checked and repaired by a certified technical
cooling firm.

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Replacing electric components in the switch box

TR 7000 TR 12000

03 06 04 05 02 01

Pos Article # Description Page

01 10672100 Transformer 18
02 10179750 Thermal regulator 19
03 10501500 Control print 20
04 10113000 Relay 21
05 10505250 Phase - monitor 22
06 10501600 Relay board 23
10501100 Remote control 24

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The transformer

A C

Removing the transformer

- Remove the cables from connector A + B.

- Remove the 4 fastening screws near point C.
- After removing the bolts, the transformer comes loose from the foundation plate and
can be replaced.

Mounting / connecting the transformer

- Mount the transformer by means of the 4 bolts on the foundation plate.

- Mount the 2 brown wires ( B ) to the connector on connections 0 and 400V.
- Mount the 2 yellow wires ( A ) to connections 0 and 20V

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The thermal regulator

E A C

B D

Removing the thermal regulator

- Mark and remove the wiring from connection points A + B.

- Remove end-stop C from the DIN rail.
- Remove the regulator by inserting a small screwdriver into blocking device D,
pushing it slightly downward and at the same time turning the DIN rail to one side.

Mounting / connecting the regulator

- Before mounting a new regulator, you first have to put its top part into the DIN rail
and afterwards to press the lower side unto the rail.
- If the regulator is fixed well on the rail, then you have to affix the end-stop C.
- Reconnect the wiring on A + B and screw these tightly with the correct torque.
- Set the dial (E) of the regulator to 18 and press the start button.

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The control print

C A A C

B
D

C A B C

Removing the print

- Remove the cable lugs A from the print (mark any lugs if necessary).
- Remove the terminal blocks B from the print (leave the wires in the terminal blocks).
- Remove the 5 screws at point C.

Mounting / connecting the print

- Check the description on the e-prom located at point D (TRS TR7000 V1.08).
- Affix the print plate with 5 screws (C).
- Mount the terminal blocks (B).
- Mount the cable lugs (A) unto the print plate.
- Attention! When mounting a new print plate, the parameters and the set point
should be recheck and/or reset.

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Compressor/heating relay

B
A

D C

Dismounting the relay

- Remove the blue wire out of A2 and the orange wire out of A1 (point A).
- Mark and remove the brown/black wires out of connection point B.
- Mark and remove the red wires out of connection point C.
- Remove the screws located at point D.

Mounting / connecting the relay

- Mount the relay with 2 screws in point D.

- Mount the red wires unto relay connection C.
- Mount the brown/black wires unto relay connection B.
- Mount the blue wire unto A2 and the orange wire unto A1 (point A).
- Tighten the bolts of the relay with the correct torque.

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The phase monitor

B D

Dismounting the phase monitor

- Mark and remove the phase wiring located at point A.

- Mark and remove the hook-up wiring located at point B.
- Remove the end stop C.
- Put a flat screwdriver in the recess (D) and turn the phase monitor upwards to remove
it from the rail.

Mounting / connecting the phase monitor

- First put the top side of the monitor on the rail and then push the bottom unto the rail.
Check whether the monitor is clipped on the rail.
- Return the end stop C unto the rail and put it against the monitor. You can affix the
end stop by tightening the bolt in the centre.
- Remount the wiring at point B.
- Remount the wiring at point A.
- Connect the power supply of the unit and check the operation of the monitor.

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The relay board

A D

C B

Removing the relay board

- Dismount the control print (see page 4).

- Remove the 5 screws A and move the ground plate.
- Mark and remove the 6 green plugs B from the print.
- Remove the 3 screws located at point C.
- Unscrew the 5 spacer sleeves D and remove the relay board from the switchbox.

Mounting / connecting the relay board

- Put the relay board in the switchbox and affix it using the spacer sleeves D.
- Mount the 3 screws at point C.
- Return the 6 green plugs B unto the relay board and check whether the wiring is not
touching anything.
- Screw the ground plate tightly using the 5 screws A.
- Return the control print (see page 4.)

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Replacing the remote control

A C B

Dismounting the remote control

- Remove the 4 mounting bolts A of the panel and take the entire unit out of the control
box.
- Loosen the nut B and take the connector plug out of the remote control.
- Dismount the fastening plates C and slide the remote control out of the panel.

Mounting / connecting the remote control

- Slide the new remote control into the panel and affix it using the fastening plates C.
- Connect the connector B and tighten the nut (Attention! The connector fits just in one
way).
- Return the entire unit into the control box and affix it using the 4 bolts.
- Start the unit and check the operation and settings of the unit.

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Replacing electrical components

04

01

03

02

Pos Article # Description Page

01 10505500 Switchbox
02 25099056 Glycol pump 27
03 10778400 Flow switch 28
04 20326000 Coil magnetic valve 29

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02 01

03

Pos Article # Description Page

01 10654000 Condenser fan 30
02 15169300 Compressor 31
03 15132250 Screw element 9kW 34

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The glycol pump

D A F A

C B E

Dismounting the glycol pump

- Close the ball valves on the tank (if present) and put a receptacle under the unit near
the glycol pump.
- Remove the hose clips A.
- Carefully slide the hoses off the glycol pump. Attention! When removing the hoses,
glycol will flow out of the hoses and/or the glycol pump.
- Remove the glycol temperature sensor B from the adapter by loosening the nut.
- Remove the 4 nuts from the foot of the glycol pump C.
- Remove cover D to gain access to the wiring.
- Mark the wires E and remove these from the connecting block.
- Remove the pump from the unit, including the hose connectors that are present.

Mounting /connecting the glycol pump

- Mount the hose connectors to the new pump.

- Connect the green wires E in the correct place in the connecting block.
- Mount the yellow/green wire unto the earth connection.
- Treat the connection against corrosion and close the terminal box D.
- Affix the pump using the 4 bolts/nuts C.
- Mount the glycol temperature sensor to the adapter B.
- Connect the hoses to the hose connectors and affix these using the hose clips A.
- Open the ball valves (if present) and bleed the system by loosening blind plug F. As
soon as liquid flows along the blind plug, it should be tightened again. Start the unit
and check the rotating direction of the pump. The rotating direction should be counter-
clockwise viewed from the fan casing on the pump.

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The flow switch

A B C

Dismounting the flow switch

- Close the ball valves on the tank (if present) and put a receptacle under the connection
of the outlet.
- Loosen the hose clips and unscrew the hose connector from connector A (Attention!
When loosening the hose, glycol may flow out of it).
- Remove connecting plug B by completely unscrewing the screw in the centre.
- Remove nuts C from the connector.

E D
- Remove the hose from the hose connector and loosen hose connector D and
connection E from the flow switch.

Mounting the flow switch

- Mount hose connector D and connection E into the flow switch using sealing
compound.
- Mount the hose unto the hose connector and put the flow switch in back of the glycol
pump.
- Affix the connector using the 2 bolts C.
- Connect plug B to the flow switch and tighten it.
- Screw hose connector A in the connector using sealing compound, return the hose and
affix it using the hose clips.
- Open the ball valves and start the unit. Check for any error codes.

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Coil magnetic valve

B A

Dismount the coil magnetic valve

- Remove the guard by lifting cover A.

- Remove screw B from the connecting plug before disconnecting the plug.
- Slide the coil from the spindle.

Mounting / connecting the coil

- Check whether the spindle is clean before mounting the new coil. If the spindle is
oxidized or damaged, the valve should be overhauled (see ‘Replacing cooling
technical / fluid valve’).
- Slide the coil over the spindle and connect plug B.
- If the coil is in the correct position, block it on the spindle using guard A.

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The condenser fan

C D B A

Dismounting the fan

- Remove the wiring of the fan that should be replaced from connector A. (Connector
CR1 for fan 1, CR2 for fan 2). Remove the cables from the switchbox.
- Remove the 4 fastening nuts B with which the fan cage is attached to the condenser
and slide it to the stud bolts in its entirety.
- When the unit is disassembled, the fan can be removed via the rear side. If the unit is
still assembled, the fan can be removed via opening C at the bottom.
- Remove the 4 fastening nuts D to detach the fan from the cage.

Mounting / connecting the fan

- Mount the fan unto the cage using bolts D that are greased with Loctite.
- Slide the fan cage over the stud bolts and affix it using the washer and self-locking
nuts B.
- Lead the cable to the switchbox and connect the wiring to the corresponding connecter
A.
- Start the unit and check the rotating direction of the fan (fan sucks in air through the
condenser). If needed, the rotating direction can be changed by switching the 2 wires
in connecter A.

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The compressor

A B B C

Dismounting the compressor

- Remove the switchbox (only for TR7000XL / TR12000).

- Open cover A using a matching key and remove the hinge bolts to remove the cover
completely.
- Mark wires B and remove these from the terminal block and the compressor.
- Mark and remove the wires from the protective relays C.

D D F G E

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- Remove valve caps D and check whether the valves are completely turned out.
- Remove the cap of the connection point E for measuring and connect a meter set.
- Turn the valves completely inside to block the coolant system and start with emptying
out the remaining quantity of coolant that is still in the compressor.
- When the compressor is completely empty (no more coolant), the socket screws G can
be removed, which results in loosening the valves out of the compressor.

H H

- Remove bolts and nuts H, so that the compressor can be taken out of the unit.
- Pay attention to the weight of the compressor: it is 90 kg! Use suitable lifting tools!

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Mounting / connecting the compressor

I J

Attention! A new compressor is delivered under pressure of nitrogen. The compressor

should be pressure-free before you start to remove/mount components.

- Remove blind plugs J from the new compressor and pressure switches I from the old
compressor. Place the pressure switches in the new compressor using sealing
compound. Transfer the turnbuckles to the new terminal box.
- Don’t let moisture and dirt penetrate the compressor – Don’t leave it standing open for
a long time.
- Put the compressor in the unit and affix it using the 4 bolts/nuts H.
- Mount the compressor valves; use the new gaskets that are supplied.
- Pressurize the compressor with nitrogen for 2 hours and check for any leakage.
- Reconnect wires B and C to the compressor terminal box and treat it against
corrosion.
- Return the cover unto the terminal box and close it with key A.
- If the pressure in the compressor is still the same after 1 hour, the nitrogen can be
blown off and the compressor should be brought to vacuum (at least to 2000 micron),
which should be maintained for 30 minutes.
- If the vacuum test is OK, you can turn out the valve, so that the compressor can fill
with coolant.
- Start the unit and check the quantity of coolant in the sight-glass. If needed, add new
coolant to the compressor via the suction connection.
- First close the valve of the pressure valve (by turning out the valve completely) and
suck the meter set empty via the suction connection. Finally the suction valve can be
closed completely and the meter set can be removed.
- Cover connecting point E using the corresponding blind caps.

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The heating element

B A C

Dismounting the element

- Close the ball valves of the glycol system on the tank (if present).
- Put a receptacle near the element.
- Remove blind nut A to remove protective cover B.
- Remove the wiring of the element by unscrewing nut C off it.

- Remove the element by unscrewing it.

Mounting / connecting the element

- Remove the residue of the old gasket of the heating tube.

- Affix the element in the heating tube including a new gasket.
- Affix the wiring under nuts C of the 3 element connections.
- Treat the connections against corrosion before returning the protective cover B.
- Affix the protective cover using blind nut A.
- Open the ball valves before starting the unit.

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Replacing technical cooling components

Attention! This may only be carried out by a certified technical cooling company according to
the legislation applicable in the particular country.

1 2

4 5 6

Pos Article # Description Page

01 20360000 Fluid vessel 35
02 20164500 Dryer 36
03 20165980 Air valve 37
04 90446132 Low pressure switch 38
05 90442907 High pressure switch 38
06 15107660 Condenser 39

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The fluid vessel

B
A

Dismounting the fluid vessel

- In case of a mounted unit, the switchbox should be loosened. This can be done by
removing the 4 socket screws A (only for TR7000).
- Ensure that all coolant is sucked out of the unit before starting the technical cooling
activities.
- Loosen nut B to remove the fluid faucet.
- Solder the fluid pipe C so that is comes loose of the fluid vessel.
- Remove the fastening nut at the bottom to take out the fluid vessel.

Mounting the fluid vessel

- First, the far end of the vessel’s feeding pipe should be heated and flared (see photo)
to mount the new vessel.

- Affix the fluid vessel in the unit using the check nut and washer.
- Solder the fluid pipe C to the vessel (use nitrogen during soldering).
- Put a new Teflon ring in the faucet connection and affix the faucet using nut B.
- Compress the system using nitrogen and check for any leaks.
- Bring the system to vacuum and fill the unit with coolant.

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The Dryer

Dismounting the dryer

- Ensure that the system is not pressurized before carrying out soldering activities!
- Remove mounting bracket A.
- Solder pipelines B so that they come loose from the dryer.
- Remove the dryer.

Mounting the dryer

- Remove the sealing caps from the new dryer.

- Place the dryer in the bracket, while paying attention to the rotating direction C.
- Solder the pipelines to the dryer (use nitrogen during soldering).
- Affix the dryer to the bracket.
- Pressurize the system using nitrogen and check for any leaks.
- Bring the system to vacuum and fill the unit with coolant.

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The thermostatic expansion valve

B
C

Dismounting the valve

- Empty the coolant system before carrying out soldering activities!

- Remove pipe clip A and the pipe insulation near the clip.
- Solder pipelines B so that they come loose from the valve.
- Unscrew the mounting bracket of the sensor and remove it from the suction pipe.

Mounting the valve

- Remove all plastic blind caps from the new valve.

- Tie a damp cloth around the valve (C).
- Solder the valve to the pipelines, while taking care that the cloth remains damp and
does not become hot during soldering, because this can impact the operation of the
valve.
- Mount the sensor to the suction pipe and affix it using the corresponding clip.
- Insulate the pipe leading to the valve and affix it using pipe clip A.

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High/low pressure switch

A C

Dismounting the low (B) / high (C) pressure switch

- Close the compressor faucets and extract the remaining coolant so that the compressor
is not pressurized.
- Open the terminal box of the compressor and remove the wiring of the pressure switch
that should be replaced from the terminal strip.
- Unscrew the pressure switch (B = low pressure; C = high pressure) out of the adapter.

Mounting the pressure switch

- Affix the pressure switch to the adapter.

- Lead the cable through the turnbuckle of the terminal box.
- Connect the wiring with the terminal strip and close the cover.
- Pressurize the compressor using nitrogen and check for any leaks.
- Bring the compressor to vacuum.
- Open the compressor faucets before restarting the unit.
- If needed, add coolant after the repair.

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The condenser

B C

A D

Dismounting the condenser

- Extract all remaining coolant so that the system is not pressurized.

- Dismount the condenser fans A.
- Remove fastening brackets B from the mounting clamp C.
- Solder pipelines D so that they come loose.
- Remove the mounting bolts at the bottom of the condenser.

Mounting the condenser

Attention! A new condenser is delivered under pressure of nitrogen. If it is not

pressurized, it should be pressured first and checked for any leaks.

- Cut the connecting pipes to size and remove excess paint.

- Put the condenser in the unit and affix it using the bottom mounting bolts and the top
fastening brackets.
- Solder the pipes to the condenser (use nitrogen during soldering).
- Put the stud bolts E of the fan in the condenser and return the fans to their place.
- Pressurize the system using nitrogen and check for any leaks.
- Bring the system to vacuum and fill the unit with coolant.
- Start the unit and check whether everything functions.

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Tables and diagrams

1K PTC resistance table sensor

°C
-50 515
-40 567
-30 624
-20 684
-10 747
0 815
10 886
20 961
30 1040
40 1122
50 1209
60 1299
70 1392
80 1490
90 1591

Torque of the bolts

Strength Strength
Ø nominal Pitch
Flat hexagonal category category
spanner
(mm) (mm)
8.8 12.9
M2 0.40 4 0.339 0.582
M4 0.7 7 2.78 4.79
M5 0.8 8 5.5 9.5
M6 1 10 9.5 16.4
M8 1.25 13 23 40
M10 1.5 17 46 79
M12 1.75 19 79 136
M14 2 21 127 219
M16 2 24 198 341

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Electrical Diagram

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