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TRANSCRIPT
17 July 2013
Super Freezer Refurbishment Guide (Draft)
1.0.1 General and process chart 1.0.2 Basic requirements on spare parts storage 1.0.3 Visual inspection 1.0.4 Gas sample flame testing (R134a) 1.0.5 R134a system cleanup procedure 1.0.6 Function and operational Check: 1.0.7 Buffer tank modification 1.0.8 Unit cannibalization 1.0.9 Estimation and repairs 1.0.10 Unit reinstallation 1.0.11 Full PTI 1.0.12 Quality managements by shop
Super Freezer Refurbishment
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1.0.1 GENERAL
The purpose of this manual is to standardise the SuperFreezer Containers’
Refurbishment and reporting thereof.
Process chart
Gate in
Visual inspection
R134a Flame test
Lab GCMS test
Estimation
Repair
Cannibalize unit from box
Full PTI
RCD installation Y/N
Releasing
Unit installation onto new box
Buffer tank mod modification
Y/N
Function check New box production
Vacuum & cleaning
R40 great than 0.05% R134a less than 99%
R40 less than 0.05% R134a Great than 99%
Disposal
Above repair limit
Below repair limit
Parts cannibalization from disposed unit for further units’ repairs
Truck unit to MCIQ
Truck new container to depot/shop
Pass
Working in
MCIQ Working in depot/shop
Failed R40
Without R40
Quantity controlling by
MCI
Second flame test
Pass
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1.0.2 Basic requirements on spare parts storage
The shop will at least have following parts in storage before the refurbishment
programme starts along with a good inventory level during the refurbishment
process.
Item Part No: Part description Quantity Remark
1 66-8811 Moisture Indicator , CRR-40 10 SF kit
2 102-796 Compressor, R-23 Super Freezer 10 SF kit
3 506-431 TXV, R-23 Super Freezer 10 SF kit
4 41-4523 HP-Switch , 470 PSIG , R-23 10 SF kit
5 506-421 Filter Drier, R-23 20 SF kit
6 504-1529 Sensor for Deep freezer ONLY 20 SF kit
7 66-9877 Orifice for R-23 TXV 506-431 10 SF kit
8
Adapter Unitor R23 bottle - 1/4
3/8 flare (Refer to following
pictures) 5
Prepared
by shop
9 R-23/KG 9,1KG Bottle
2
bottles
From
Sinochemlt
10
Buffer mod pipes (3/8, 9.52mm,
1.2mm copper) (Refer to following
pictures) 50
Prepared
by shop
11 4x6mm2 Cable 3000 ft From HF
12 104-759 Condensor motors 10 SF using
13
17-
10812-01 CAP,SV VLV (PLAST) 30 PLASTIC
14 66-3015 VALVE CAP ON R23(BRASS) 10 BRASS
15 506-161 CAP-DISCHARGE VALVE, R134A 20
16 66-9873 ADAPTER-SERV-PRESS-HIGH 20
17
12-
01125-02 R23 GAUGE 20
From
Carrier
18 66-1916 VALVE-SUCTION-R23 10
19 66-3942 VALVE-DISCHARGE-R23 10
20 33-2805 GASKET-R23 COMPRESSOR 10
21 78-1167 CONDENSER FAN 10
Remarks
Adapter Unitor R23 bottle - 1/4 3/8 flare, it is used on R23 cylinder for the connection type
change to link with gauges.
Page 4 of 42
Buffer mod pipes - 3/8, 9,52mm(O.D), 1.2MM (W.T) copper pipe
Orifice for R23 TXV, P/N 66-9877, we shall select the new type from ThermoKing with flat
head (in the green bottle) into this refurbishment project.
New type
Old type
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The Circuit breaker to be changed to 7.5 A Fuse during the refurbishment then the
shop shall have following parts in storage at least in following level before the project.
More details of that Fuse modification you can refer to Example A) below.
Part description Part No: Remark Quantity
TERMINAL STOP CLIPFIX 35.. 41-3687 100
FUSE, TERMINAL BLOCK...... 41-5105 50
FUSE 7.5AMP 32VDC......... 44-9359 50
Parts listed in above are mostly used on R23 system side but these standard parts on
R134a side and consumable parts shall be purchased in a proper sourcing channel and
kept in a good inventory level during the refurbishment program, like following ones,
Part description Part No: Remark Quantity
TXV-R134A 66-9900 5
MOTOR-EVAPORATOR 104-691 10
CONDENSER COIL 67-1589 5
EVAPORATOR COIL 67-1591 5
VALVE-DISCHARGE-R134A 66-9377 5
VALVE-SUCTION-R134A 66-9149 5
EVAPORATOR FAN 508-165 5
BEARING W6203MSL From SKF 5
BEARING W6205MSL From SKF 5
VALVE-BALL 66-9125 5
COIL VALVE LIQ 41-2399 5
SWITCH-HPCO 41-3250 5
VALVE SERVICE Section (R134a) 66-9149 5
1.0.3 Visual inspection
Please use Appendix I of “Super Freezer refurbishment function inspection
form” (Part A) on to record following checking/inspection actions
New parts
Old Circuit breaker
Page 6 of 42
Before performing RUN TEST the heading of the report must be filled in.
Container ID Number. Prefix always to be included
Unit Serial Number. Read the serial number plate on the reefer unit in
order to identify type of unit and then follow the manual, which cover the particular
type of unit.
UNIT manufactured year. Read the month and year of unit manufactured from
unit serial plate.
RUN TEST Date. Actual date when this RUN Test performed.
Ambient temperature. In degree Celsius (C)
Visual checck
Perform visual check on the machinery to ensure all parts are there
Check unit for leakage and cleanliness.
Inspect the unit for refrigerant leaks (trace of oil, low refrigerant level, and low-
pressure indication on R23 gauges and if any leak point at R-23 receiver inlet-
outlet).
Inspect condenser coil for excessive dirt, clean if necessary.
Inspect the control box including the controller door (that it fits), key pad, main
relay board, display, relays and controller.
Open Evap motor access door to see if any gasket missed or damaged. Check these
three motors are there.
Cleaning only to be done with fresh water at a maximum pressure of 30 Psig or
pressurised air at maximum of 60 Psig.
Check fasteners.
Check that unit mounting bolts compressor suspension bolts and all brackets are in
place and tightened properly.
Check power cable and plug.
1. Visual check power cable and power plug for physical and electrical damages.
2. The section of the cable shall be 4G6.0mm2 from HF (Folsgaard) and length of
cable shall be at least 18 meters and 0 splice.
3. A new one shall be placed with total length of 20 meters connected all way to
CB1 (32 Ampere) in the control box if the unit has one of following,
- Wrong cable used which is not 4G6.0mm2 from HF
- Less than 5 m (16 ft) of the cable is left.
- One or more than 1 splice kits were placed on the cable.
4. The plug shall the brand of “Mennekes” with type of “2175A” or “2175B”.
Replaced with the one from MCI via consumable list where required, P/N 818559A.
5. Power plug must be without any electrical or corrosion damages to the phase
legs and with gasket/safety pin and locking ring intact.
1.0.4 Gas sample flame testing of R134a
Carry out the sample test of R134a system, please refer to Appendix II of “Guide
to Taking a Refrigerant Sample”.
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1.0.5 R134a system cleanup procedure
Those units which have failed the flame test but have passed the lab test for R40 or
with limited R40 (has less than 0.05% R40 in system), it is agreed repairs should
carry on in order to get the units back in to service as following steps.
NOTE: Gauges and hoses used for recharging system MUST be confirmed
clean via Halide flame testing a known clean sample of R134a before
using.
If the units that contain at least 90% 134a gas and are contaminated with 5%
or less 142b
1. Open the container doors, run unit for 30 minutes, and then full cooling mode
(close doors) for at least one hour (-30’C). Monitor compressor temperatures
and shut down if temps exceed normal operating temps.
2. Attach gauge set to low and high side connections and recover all refrigerant in
a labeled (chlorine various) recovery cylinder. After 3rd shutoff on recovery unit
vacuum switch, close connections and remove recovery machine and cylinder
(gas to be disposed in complying with all applicable regulations, laws,
ordinances and best industry practices in local).
3. Disconnect contaminated gauge set (labeled) and fit clean R134a gauge set
(labeled).
4. Clean R134a system by adding Pressurized dry Nitrogen (N2) used manifold
service gauges from service ports of both section pipe and discharge pipe, then
evacuate N2 from drier inlet and outlet tube.
5. Install new filter drier.
6. Evacuate system using high and low side connectors and leave active for a
minimum 4 hours @ 30 inHg of vacuum.
7. Using virgin R134a refrigerant, certified and tested, scale in the charge as
indicated on unit ID plate.
8. Run the unit for minimum 2 hours in full cool (-25C).
9. Turn off unit and allow stand idle for one hour.
10. Perform flame halide test and advise results.
After that, the STS code of 8936 (with max 6.5 man hours and gas cost as
material cost) would be used into the work order via MERC+.
If the units that contain less than 90% 134a gas and/or more than 5% 142b
1. Open the container doors, run unit for 30 minutes, and then full cooling mode
(close doors) for at least one hour (-30’C). Monitor compressor temperatures
and shut down if temps exceed normal operating temps.
2. Attach gauge set to low and high side connections and using refrigerant
recovery machine, recover all gas into a labeled (chlorine various) recovery
cylinder. After a minimum of three (3) shutoffs on recovery cycling switch,
close connections and remove recovery machine and cylinder. Note: reclaimed
gas to be disposed in complying with all applicable regulations, laws, ordinances
and best industry practices in local.
3. Remove compressor drain plug and drain oil from sump, flush sump to remove
as much residue as feasible.
Page 8 of 42
4. Refresh system with POE per machine specification (Polyol Ester Based type, TK
P/N 203-433).
5. Disconnect contaminated gauge set (labeled chlorinated) and fit clean R134a
gauge set (labeled virgin 134a).
6. Clean R134a system by adding Pressurized dry Nitrogen (N2) used manifold
service gauges from service ports of both section pipe and discharge pipe, then
evacuate N2 from drier inlet and outlet tube.
7. Install new filter drier.
8. Evacuate system using high and low side connectors and two vacuum pumps
and leave active until gauge reads 30 inHg of vacuum, minimum operation
should be 4 hours.
9. Using virgin R134a refrigerant, certified and tested, scale in the correct system
charge as indicated on the ID plate.
10. Run the unit for a minimum of 2 hours in full cool (-25C).
11. Turn off unit and allow standing idle for one hour.
12. Perform flame test and advise customer of results.
After that, the STS code of 8936 (with max 6.5 man hours and gas cost as
material cost) and other STS codes, such as 8933 for Compressor oil
adding, would be used in the work order via MERC+.
1.0.6 Function and operational Check:
Please use Appendix I of “Super Freezer refurbishment function inspection
form” (Part B) to guide and record following checking/inspections to
ensure fol
- There shall not be any loosing or crack or deformation on the fastener
components or structures.
- The painter and primer on the structures, such as copper pipes shall be in one
piece without any damage or loss or missing in accordance with industry
standard.
- Refrigeration system shall be in functional condition
- The wires and circuits shall be in functional condition and without corrosion or
loss or missing.
Turn unit on,
Set/select temperature to a set point that puts the unit in full cool/pull down mode.
Allow unit to start up and run for 15 minutes.
Checklist:
1. Ensure proper rotation of condenser and evaporator fans
2. Ensure R23 compressor suction and discharge pressures are correct
3. Unit is cooling - sensor showing temperature trend towards set point
4. Ensure controller is updated with correct Container number, configuration.
5. No abnormal noise
6. Perform a manual defrost - should unit temperature not be low enough for
defrost to start manually force the heater relay and check the current draw.
7. Check alarm list (and alarms in message) to ensure all alarms to be recorded
and clear
Page 9 of 42
8. Carry out a full datalog downloading from the unit and save them in a folder
with the current container ID.
Further inspections,
9. Inspection of the evap and cond motor, to ensure they are free and they are not
noisy or have adverse bearing wear. (Replace the bearing or motor where
required).
10. Ensure all wire harnesses are free from damage and secure. Reworks would
need to be carried out on those units with improper repairs.
11. Inspection of the front Evap service hatch, to ensure that it is serviceable, shuts
firmly and that the seals are in place and serviceable. Replace where required.
12. Make sure d/frost drainage tubes are clear and cleaned.
13. Ensure “cork” tape insulation is in place and secure. (Please refer to example T)
14. Check that the Evap coil heaters are fitted correctly to the Evap coil, and the
wiring is correctly secured.
15. All control sensors are correctly mounted.
16. Ensure the air baffle plate is in place and free from damage.
17. Check the all Switchs, Liq Coil, drier if they are free from damage or corrosion
18. All valve caps, are in place, replace where required. Install boot in switch
ON/OFF and CB. Install cap retrieve connector if it’s missed.
19. Check R23 gauges are in place and free from damage.
20. Inspect the condition of the R134a compressor terminal box and valve plate.
Replace with the new plastic box and stainless steel cover (old type terminal
box) where required. Check R134A valve plate and replaced with cylinder head
bolt, if the bolt is heavy rusty.
21. Check regulators are adjusted correctly. They have been unadjusted in the
majority of the cases and should been check again according procedure. At least
crankcase pressure regulator to keep R-23 compressor with constant pressure.
Operate in Cool for 10 minutes and calibrated gauge, the pressure in low side of R-
23 compressor should read from 40 psi to 45 psi.
22. If the R134a compressor was heavy rusty, a repainting with primer and coating
will be needed.
The function testing together with visual inspection would be estimated
into MERC+ by STS0950 under MODE44 (FUNCTION TEST FOR SF REFURB)
with 0.6 man hours and a material cost under MODE43.
Examples,
A) Circuit breaker to be changed to 7.5 A Fuse
New parts
Old Circuit breaker
Page 10 of 42
41-3276 to be changed to 41-3687, 41-5105, 44-9359
Page 11 of 42
B) CB
Before After Breaker modification
C) ELEC CIRCUIT
Before
Page 12 of 42
After
Page 13 of 42
D) Sensor Wire Reconnection
Before
If the wrong sensor wire
splicing found, we shall re-
splice it again by bushing
with hot melt adhesive
inside as follows.
Page 14 of 42
After
E) HEATER CONTACT
Before
But if we shall replace a new supply
sensor, the wire shall be connected
from the connect point insider
controller box.
Page 15 of 42
After
F) MRB
Page 16 of 42
If the MRB connect port has Copper oxide, please use following cleaner to clean it.
But please replace the connect port if corrosion.
G) R134A HP Switch
Before After
If there is any rotating or shake on
the bolt, the replacement is need.
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H) Relay
Before
After
I) Condensor motor and Coil
Before
Page 18 of 42
After
1140 RPM, Wrong motor
Page 19 of 42
J) EVAP ACCESS DOOR (Heater access plate)
Before
1750 RPM, P/N: 104-759 Correct motor
Page 20 of 42
Proper sealing and air tightness are very important for heater access panel, evaporator access panels. Ensure door lock and sealing of controller door panel are good. Repair if necessary.
After
K) EVAP FAN MOTOR
Page 21 of 42
crack on evaporator fan mounting
L) LIQ COIL
LSV (Liquid line Solenoid Valve) is frequent failure part. Ensure to check/replace new one if necessary.
Before
Page 22 of 42
After
M) R23 COMPRESSOR
Before
Page 23 of 42
After
N) R134a Compressor terminal box
Before
Page 24 of 42
After
O) R134A Compressor Gasket
Page 25 of 42
P) R134a DRIER
Before
After
Q) Evaporator Coil Section
Ensure no screws/metal parts left on evaporator coil. Surprisingly in some cases, one screw which was left behind had been knocking evaporator coil due to vibration, caused serious leak. Always check/ensure all screws /bolts/nuts are tightened, nothing left on evaporator section.
There are two different types of R134a
compressor gaskets, shops shall purchase both of them from TK on this project.
Page 26 of 42
R) R23 Gauge
Before
Found bolt drop down to evapopator
coil between the unit frame, will cause the evaporator coil broken.
If there are any cracks, pulverization or leakage, the R23 gauge shall be replaced.
Page 27 of 42
High pressure in R23 discharge pressure gauge most of the time. Thus, it is easy to get
leaks at small capillary tube. Ensure to check/repair/ replace new gauge and capillary
tubes to prevent leak.
After
The pipes shall be protected and fasted by both Heat Shrink and protect Tubes to avoid shake damage.
Page 28 of 42
S) R23 HP/LP SVC VALVE
Before
Both discharge and suction gauge on R23 system shall use P/N 12-01125-02 for 500 psig from Carrier.
Page 29 of 42
After
T) R134a LP Service valve
Page 30 of 42
Before after
U) Service cap
Before
After
Page 31 of 42
V) Tube
Before
Page 32 of 42
After
W) Power Cable and plugs
Before
These “cork” tape insulation shall
be supplied by shops.
Page 33 of 42
After
Page 34 of 42
The cable shall be 4G6.0mm2 from HF (Folsgaard), P/N.
The plugs shall be supplied by MCI via consumable parts lis, P/N 818559A.
X) USDA sensors
Before
After
These USDA sensors shall be supplied by MCI via consumable parts list, P/N
818556B (USDA Temperature Sensor, Ø6,0 PT100)
4G6mm2
Page 35 of 42
Y) Evaporator fan motor bearings
Special grease type such as “lithium-soap greases” has been used successfully at the temperatures of minus 60ºF (-51 deg C). However, the grease type used in evaporator fan motor may not be good enough for minus 60 deg C range. We experience frequent evaporator fan motor bearing failure, probably due to grease type which could not work well in very low temperature range for long run. Ensure to check/replace new evaporator fan motor/ball bearings
Page 36 of 42
Z) Grounded heaters , poor connection at heater cables
Poor insulation/grounded heaters are caused by improper wire connections. Check, replace new heaters (if necessary) and insulate connection wires properly.
1.0.7 Buffer tank modification
1. Removal and weighing back in of the R134a gas to ensure the correct charge.
(This action shall be carried out in above mentioned function inspection and
repair process)
2. Removal and weighing back in of the R23 gas to ensure the correct charge.
3. When R23 systems are empty, to perform a leak test with N2. (Nitrogen is under
15,170 kPa, 151.70 bar, 2200 psig pressure in a full cylinder at 21 C (70 F).
4. Replace R23 Filter driers. (The R23 unit is a sweat in type, P/N 506-421).
5. That R23 compound gauges are in place and are working.
6. Inspection of all pipework and paying attention to the known weak areas.
Page 37 of 42
Another weak point which could suffer further fracturing in the future, please
take inspection on that as well.
7. If the buffer tank modification was not carried out on the unit before, a rework
of loop into buffer tank shall be conducted to increase the diameter and number
of loops as follows.
- As part of the rework, change the angle of the pipe from the valve leading
into the loop to the buffer tank.
- Suggested angle is approx 30 degrees instead of 40-45 degrees to alleviate
stress, using 3/8, 9,52mm copper pipe.
- Have the new pipe brazed in to as a posed to on to the buffer tank.
- Straighter pipe entering the buffer tank as opposed to the current angle
- The dry nitrogen (N2) be used to purge the system during any solder
operations and also for the leakage checking after welding.
- Remark in the machinery side with words of “Buffer tank mod done” with
the date and location information.
8. A STS code 8219 can be used into MERC+ with 8 man hours and a
material cost of RMB3000. That material cost will include, a full charge
of R23 gas (worse case) leak testing, N2, R23 f/drier (P/N 506-421) in
fact everything to carry out the repair.
Page 38 of 42
- There is NOT be any further R23 gas cost or R23 f/drier accepted by other
STS codes in the same one unit if it requests the buffer tank modification.
- R23 F/drier (P/N 506-421)’s price (list price USD94.18, about RMB600) shall
be cut off from total material cost with the filter direr part number inputs.
- Each unit has 3.2 kg R23 inside and if the system need full R-23 adding once
leakage, then the material cost shall be 3000 - 600 = 2400 RMB
- If the system has full R23 without any leakage and you just recharge the gas
after recovery, then the material cost shall be input at 3000-600-1500 =
900 RMB to cover other material cost like system recovery/re-charge
actions, N2 using, etc.
Finishing
Page 39 of 42
1.0.8 Unit cannibalization
Remove the unit from the old box with proper equipments and a forklift. Suggest
referring to the manufacturer’s instructions for this risk assessment.
Unit cannibalization can also be carried out before buffer tank modification
checking. That will depend on the repair cost in above compared with repair limit
set in MERC+.
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1.0.9 Estimation and repairs
Submit estimation into MERC+ with current (old) container ID under MODE43 for
Maersk /MCI’s evaluation and then arrange repairs after approval. The repair action
would be conducted together with buffer tank mod modification.
MCI will conduct the evaluation on these to be disposed units to see if any old parts
would be removed from them for further repair using. Shop would use them with a
material cost at 1/5 of list price rather than the part number in MREC+ to cover
their additional action of parts removal and testing.
All these R134a used onto the unit shall be tested by flame halide tester of each
new cylinder. Each Gas usage records shall and filled into Gas Logbook. Please refer
to Appendix III of “R134a flame test guide” for more details on the cylinder
gas flame test.
Shop shall at least have 3 separate Freon recovery machine & cylinders for the gas
recovery and collection. All clean (good) R134a from the unit, which passed unit
samples flame test, would be re-used during repair works by one set of recovery
machine & cylinder. The second set is used for contaminated R134a. The last one
set shall be working for R23 recovery and re-using. Do not mix gases pulled from
different system or cleaning/contaminated units.
Mounting Bolts
Unit mounting bolts should be tightened to a torque value of 204 N.m (150 ft-lb).
Compressor and fan motor mounting bolts should be tightened to a torque value of
20 to 21 N.m (15 to 20 ft-lb).
Cleaning of machinery
After repairs, a cleaning of the machinery side should be carried out and remove all
old labels/stickers, oil smear and impurity. Cleaning only to be done with fresh
water at a maximum pressure of 30 Psig or pressurised air at maximum of 60 Psig.
Insulation
TK recommend the insulation value of compressor and fan motors and heaters to
ground is minimum 1M Ω or more when measure with Mega Ohm meter with 500V
output
Page 41 of 42
Before
After
1.0.10 Unit reinstallation
This action shall be done in MCIQ
1.0.11 Full PTI
Page 42 of 42
Check the unit and box ID to ensure they are in the same. Change the container
number in controller to align with box. The correct software (120608) is in installed
along with the correct Date, Time and Container ID.
Install RCD onto the unit if it was not fitted before. Remove the back up battery
together with wiring inside control box and mounting brackets during RCD installation.
Please refer to Appendix IV of “Maersk RCD Installation Guide Hand-out for
more details.
The normal full PTI process would be followed. Please refer to Appendix V of
“SuperFreezer PTI form”.
The estimation shall be submitted with new container ID into MERC+ for PTI and
RCD installation. STS8940 (FULL PTI FOR SF REFURB ) under MODE44 can be
used for that. Each work order shall be recorded with old container number in the
remark filed for further checking.
1.0.12 Quality managements by shop
Shop should have its own Quality controlling and management team to record and
check each step carried out in the refurbishment. Then the QA documents from the
depot/shop on their work shall be signed off by the person in charge finally.