Table of Contents
COPELAND
Concept of the MP5000
Product Specification
MP-5000
1 SYSTEM OVERVIEW
Cabinet Components
Panel Side Mounted
- ON/OFF Switch
- Retriever Port (USB, Deutsch, or Bridgelight (4 pole Canon), option)
Panel Front/Door Mounted
- Display
- Keyboard
- Signal LEDs
Panel Inside Mounted
- Transformer
- Main Controller
- Battery Package
- Main Circuit Breaker
- 3 Current-Loop Coils
- Contactors for driving the 460VAC components, with Interlock
- RS232 Extension Cable to Cargo Space
Optional Components
- Option Module for Extension Possibilities
- Copeland Modem and/or RMM (ISO 10368 Powerline)
- Third-Party Modem
- Three-Part Exterior Power Handling (3-DIN Space)
2 ENVIRONMENTAL
| Operating Condition Min. Max. Method of Compliance | |||
| Ambient Temperature (Refrigeration Unit Full Operation) | -30°C | 60°C | |
| Ambient Temperature (Refrigeration Unit in Standby Mode. No power consumption.) | -30°C | 70°C | |
| Relative Humidity | 95% (Condensing) | ||
| Salt Mist (Internal Components) | 700 hours | According to SWAAT (ASTM G85 A3) | |
| Salt Mist (Panel) | 1500 hours | According to SWAAT (ASTM G85 A3) | |
| Vibration | IEC 61373:1999- Category 1, Class B per Simulated Long-Life Test | ||
| Frequency Range | 2 Hz | 150 Hz | |
| Total RMS Level | 1.2 | ||
| Duration | 100 min per axis | ||
| Shock | 5g @ 10ms | According to TKS60002, IEC 61373:1999- Category 1, Class B | |
| UV Resistance | According to TKS 28-020, ASTM G155-05a Cycle 7, ASTM G151-10 | ||
| IP Rating | IP56 | IEC 529 | |
| Component Inside Panel | IP20 | IEC 529 |
| Parameter Minimum Maximum Units Method of Compliance | ||||
| Ambient Temperature | -40 | 70 | °C | |
| Relative Humidity | 95 | % | Condensing | |
| Shock | 5g @ 10ms | According to 60068-2-27 Ca |
3 CONFORMANCE
3.1.0 ISO 1496-2:2018
A Thermal Freight Container is specified according to ISO 1496-2:2018, Series 1 Freight Containers — Specification and Testing — Part 2: Thermal Containers. Relevant to the MP-5000 Panel, this standard (ISO 1496-2) refers to the electrical aspects in Section 9 and also to IEC 60947-1:2020 Low-voltage Switchgear and Control Gear – Part 1: General Rules. It also refers to:
- Circuit Breakers: IEC 60947-2
- Switches/Disconnects: IEC 60947-3
- Contactors and Motor Starters: IEC 60947-4
This standard classifies various Thermal Containers for outside ambient temperatures of 50°C. This ambient temperature will be used for the ambient temperature specification of the MP-5000 Panel. This standard also specifies the voltage range, tolerance, frequency, and load capacity. Additionally, this standard does not exclude other relevant standards.
3.1.1 ISO Standards
The MP-5000 Panel shall adhere to the voltage outlet specifications for generators complying with ISO 8528-5:2018, Class G1. EN 60204 makes references to the following ISO Standards:
- EN ISO 12100:2010
- EN ISO 13854:2019
- EN ISO 13857:2019
3.1.2 CE Marking
The MP-5000 Panel shall have CE marking. It must meet the essential requirements of the following Directives:
- RED Directive 2014/53/EU
- EMC Directive 2014/30/EU
- Low Voltage Directive 2014/35/EU
- RoHS Directive 2011/65/EU
- WEEE Directive 2002/96/EU
Based on parts of the following specifications applied:
| Category Standard | |
| Radio | EN 300 328 V2.2.2 (2019-07) |
| EMC | Draft EN 301 489-1 V2.2.3 (2019-11), Draft EN 301 489-17 V3.2.2 (2019-12) |
| To | mEmERee |
| Safety | EN 62368-1:2014 + AC:2015 + A11:2017 |
| EE Fendi EE | |
| Health | EWE 21a:2008 |
(1) Use Severity level 4 for Immunity against surges in EN 61000-4-5:2014.
3.1.3 CCC
This is not a requirement for the overall product but applies to one or some components inside it. An additional cost will be incurred for contactors sold in China due to the CCC marking.
3.14 USDA Certification
The CM-5000 Controller must be approved by the USDA for cold treatment cargo temperature logging. Link to cold treatment requirements: USDA Animal and Plant Health Inspection Service – Treatment Manual3.1.5 Shipping
The MP-5000 Panel can be shipped by air freight and, as such, shall comply with the International Civil Aviation Organization (ICAO) standards where applicable. The MP-5000 Panel will include a coin cell Lithium-ion battery and a NI-MH Battery Pack. The use of coin cells and NI-MH battery packs will not pose any difficulties during shipping.
3.15.1 Aftermarket
Anti-static packaging shall be used for aftermarket products.
The requirements according to request section 9.1 are:
The system must operate with a 90% confidence level over a 15-year period, with an 86% reliability, and 99% over the first 5 years, under the following assumption:
- Analytics indicate YITL = 4,000 hours of total operation per annum (i.e., Controller operating).
Several initiatives must be undertaken to reach this target with a clear understanding of the conditions for the request. There must be alignment between the application profile and the specification. The reliability acceleration model requires input from time-to-failure data, which takes time to collect. Therefore, we will establish a baseline and evolve the confidence and reliability numbers in parallel.
4.1 Baseline
Initially, quality and reliability are built upon a baseline:
- Transferring quality and reliability knowledge from the MP-4000. Design improvements are made to the MP-5000 based on lessons learned and known major quality issues.
- DFMEA
- PFMEA
- Testing of MP-5000 according to test standards from the specification.
4.1.0 Improvement MP-4000 vs MP-5000
The table below reflects the major areas where a design change has been made to improve quality or reliability aspects.
| Specifications Description | |
| Code | mp4000 0 | mPso0 000000 |
| Label(s) | |
| Mains Voltage Range | Mains voltage range vs Contactor Special contactor and operation to Contactor coil voltage range can be |
| Coil Voltage Range Limits | Coil voltage range limits on contactor coil adjusted to compensate for wide |
| Additional Information | a Co RN Fre al |
4.2 Reliability Framework
With TK, we agree to the (99R/90C) requirements at 5G with the following caveats:
- TK agrees to provide all system-level qualification results, especially those from shock/vibration sensory testing or field trial results.
- We will collaborate with TK Engineering/Reliability to confirm acceleration factors in order to establish the required test sample quantity and duration.
- We will initiate testing as soon as possible but will inform them that it is unlikely to be concluded before the product launch due to the high number of hours required. Test results will establish the first iteration on the Crow-AMSAA chart.
4.2.0 Lab Test
Lab tests are to be performed based on calculated acceleration factors derived from mechanisms of physics calculations on temperature, vibration, shock, humidity, and corrosion. This will establish initial calculated reliability numbers to demonstrate 5 years at 99%R/90%C, 5G.
4.3 Crow-AMSAA with the Working Together Team
Launch a sensor-equipped pilot fleet and initiate Crow-AMSAA (CA) based reliability growth reviews by the Working Together Team (WTT). Include select end customers whenever possible to gather their input and data. The WTT reviews downloaded data logs, analyzes failure tear-downs, observes port, ship, and depot visits, etc. The CA chart is initiated with test results or the actual performance of the fleet pilot. Beta values are monitored to ensure an adequate reliability growth rate is achieved.
Example of a CA chart:
5 DEDICATED IO LIST BASED ON UNIT TYPE
| Type Battery Magnum, Roadrunner, EXV | ||
| Super freezer | Valve output | AC only EVI valve Cooling 2 |
| Digital valve | Liq Line | Digital output |
| AC only | Compressor w/HPCO Switch | Compressor 1 + HPCO1 w/Safety DI EvaFanHigh |
| Compressor 2 + HPCO2 | Digital output | AC only Heater |
| Heater wo/safety | EvaFanLow | EvaFanLow |
| ConFan | ConFanHigh | ate ebredenza |
| wo/safety Phase Direction 2 | Analog output | AC only Compressor variable speed |
| Stepper Motor Drive | AC only | Stepper valve |
| Digital input | AC only | tPCO |
| 0-5V input | Bat/AC AVL | DischPrs2 |
| DischPrs | DischPrs1 | SuctPrs |
| SuctPrs1 | SuctPrsEXV | SuctPrs2 |
| 4-20mA input | AC only | eH |
| PT-1000 | Bat/AC Supply Air | Supply Air |
| Return Air | Evap Coil | Evap Coil |
| Condenser Coil | Cargol | Ambient Air |
| Cargo2 | Spare / Suction Line EXV | Cargo3 |
| NTC | Bat/AC CompTemp | ComplTemp |
| USDA1 | CompTemp2 | Ambient Air |
| USDA2 | Condenser Coil (option) | Cargol |
| USDA3 | Suction Line2 EXV | RS-232 |
| Bat/AC COPELAND MODEM | COPELAND MODEM | 3-party |
| RS-232 | Bat/AC Cargo space for USDA probe | calibration |
| Ext+12VDC | TKFRESH+ | Bat/AC Motor +posFB+(RS485w/pwr) |
| CAModule | AC only | Compres+valve stem press |
| Display | AC | |
| Keyboard | Bat/AC | |
| Signal LED’s | AC only | Power, RESET, Status1, Status2, USB, Wireless Tx |
Note 1: PhaseDirSelection and EvaporatorSpeed contactors must be with mechanical interlock
Additional Features for Magnum+ MP-4000:
- RED: Enhancements added to the existing Magnum+ MP-4000.
- GREEN: Enhancements added to the existing Magnum+ MP-4000 with the option module mounted.
- ORANGE: Features planned for future additions.
Regarding the A2L leak sensor, how should it be addressed?
6 CM-5000 CONTROLLER MODULE
Note: Preliminary Concept of the CM5000 Enclosure
Support for
– Magnum+ / CFF
– Roadrunner EXV
– Super freezer
6.1 1/0 List
| CM-5000 Controller Type Count Function Comments | ||||
| Party Device Plug | RS-485 for Display | 1 | Serial IF to Display with LEDs | 12VDC supply AC + Battery |
| Analog Voltage Input | 3 | 0-5VDC input | 3 wires | AC |
| w/12VDC supply | GND, 12V/5V, Al (100k sink) | |||
| w/12VDC supply | 12V, Al (2,5V@25mA to GND) | |||
| PT1000 | Temperature Probe 2 wire | 6 | AC + Battery | |
| INTC | Temperature Probe 2 wire | 6 | AC + Battery | |
| Digital Output | Valve Output | 3 | 2 wire (2 Valve + Condenser) | AC |
| Digital Output | Contactor Output | 2 | 2 + 2 wire for safety line | AC |
| Analog Output | 0-10VDC output | 1 | 2 wire Output (10mA) | AC with Zero Crossing |
| LEDs | Power on | 3.3V = Green | RESET = RED | AC + Battery |
| STATUS1 | Green | |||
| STATUS2 | Yellow | |||
| Wireless Tx | Blue |
6.2 Input / Output Description
This section specifies the inputs and outputs based on the function.
The specification may apply multiple times and to several modules.
6.2.0 NTC Input
This input is typically used for sensing and documenting the temperature in the cargo space.
Temperature probes are connected to Deutsch plugs in the cargo space and are fed into the Panel.
In the Super Freezer configuration, three PT1000 sensors are used for the Cargo1-3 probes.
For the Compressor, focus on achieving accuracy at high temperatures. For Cargo sensors, prioritize a range from -3°C to 15°C.
Update frequency is less than 5 seconds.
| Min. Typ. Max. Units Range | ||||
| -50 | +50 | °C | Cargo probe measuring range ™ | |
| $0.1 | °C | @ -3°C<tm<+3°C, USDA range | ||
| $0.3 | °C | @-35°C<tm<+70°C | ||
| +0.3 | +4 | °C | @-50°C<tm<-35°C | |
| 220 | pA | Probe current |
6.2.1 PT-1000 input
| Min. Typ. Max. Units Range | |||
| Reefer probe measuring range ™ | -100 | +100 | °C |
| Total measurement error | +0.1 | °C | @-15°C < tm < +15°C |
| Total measurement error | +0.3 | °C | @-70°C < tm < +70°C |
| Total measurement error | +0.5 | °C | @-70°C > tm, tm > +70°C |
| Probe current | 191 | pA | @tm=0°C |
6.2.2 0-5V Pressure and AVL Input
The 0-5V transducer input is used for pressure measurements.
To supply power to the AVL transducer, a +12VDC source is required.
A +5VDC source is necessary to supply power to the other three transducers. The supply for these inputs can be reconfigured for 12V in software.
6.2.3 OmA to 25mA
6.2.4 Three-Phase Current-Loop Coil with Zero Crossing Detection
An external three-phase current loop coil is used to measure the load current in the system. Its external placement increases flexibility regarding mounting immediately after the circuit breaker. Current measurements are used to optimize the compressor’s maximum capacity, identify correct load changes, calculate expected power consumption, and determine the phase order. The current in all three phases should be measured. The zero crossing is extracted from the current measurement and used by the CPU to determine the frequency and phase rotation. The accuracy should be sufficient to detect load changes and support power consumption calculations.
6.2.5 Analog Output
The analog output can be used to control the VFD (Variable Frequency Drive) compressor drive.
6.2.6 Measuring Mains Voltage
The mains voltage is measured on the secondary side of the transformer. By understanding the winding relationship, the primary power can be calculated. The input voltage must generate a “Power Good” signal as digital input (DI) for the CPU, with a response time of less than 50 ms.
6.2.7 Digital Input
Response time is less than 100 milliseconds.
Test mode input is used to bring the Controller in test mode state.
6.2.7.1 Digital Input – Safety Line Switch
The input serves, besides the reading, as a component for driving the corresponding digital output. When the input is short-circuited, it corresponds to the switch being closed, and the signal is deemed NORMAL. This feature is typically used for safety precautions, such as High-Pressure Cut-Off (HPCO). – Response time: Less than 100ms – Safety function: Less than 50ms
6.2.8 Digital Outputs
The digital outputs are designed to activate valves, contactors, or other external devices. The drive power supplied is AC. The supply for all digital outputs is typically selected among two input voltages, AC1a or AC1b, to accommodate a wide input voltage range. The choice between AC1a and AC1b is determined by the mains voltage and frequency readings and is managed by a switchover relay.
General Specifications:
- Separate protection is provided for each output.
- In the reset state or when the power is off, the output must be off.
- The response time is less than 100ms.
- Consider the impact of shocks on the relay contact set.
Digital Output with Frequent Activation
The number of operations on the various digital outputs dictates the use of a relay or a Solid State Drive (SSD).
Activations: 1,500,000 per year
- One condenser fan modulates every 30 seconds.
- Two valves modulate every 20 seconds.
An SSD should be used.
A two-pin connection per output is required to fully support the connection to the valves.
6.2.8.2 Digital Output with DLI for Safety Line
The contactor relay drives should not exceed 150,000 operations per year.
No Double Pole Single Throw (DPST) relay shall be used.
- One pin output should correspond to the function, with a common connection within the harness to the AC ground.
- Two pins are required for connecting the safety switch for each output.
6.2.8.3 Digital Output
The contactor relay drive should be used for less than 150,000 operations per year.
No DPST relay shall be used.
There should be a single pin output corresponding to the function, with a common connection within the harness to the AC ground.
6.2.9 Stepper Motor Drive
The attached stepper motor is expected to be of the Danfoss ETS 6 type..
6.3 Serial Communication Interfaces
6.3.0 RS232
The interface for a third-party modem or COPELAND modem will include handshake capability. For connections to cargo space, there will be no handshake. Additionally, an RS232 is multiplexed with the RS232 port for cargo space. This port acts as a retriever port and is the default connection. Any activity from the cargo space RS232 port will be detected, and the port will be internally selected. This feature can support the ecosystem for monitoring the Reefer. “`
6.3.1 RS485
6.3.2 RS485 sensor power
Power for external sensors on the RS485 line.
6.3.3 USB
The USB interface is based on a USB Type-C interface. With this type of interface, it is possible to configure the interface as either a Host or a Device. Internally, there is a multiplexer that switches to the correct port (Host or Device) based on the detection at the connection or the internal system setup.
The USB Type-C connection can be extended from the controller to the panel side for external access without needing to open the front door.
Consider the reliability of an external connection and the additional cost.
6.3.3.1 USB Host
Host for USB flash memory.
6.3.3.2 USB Device
Device used for PC connection.
6.4 Wireless Communication
The MP-5000 Panel is equipped with short-range wireless communication via Bluetooth LE 5.0.
The radio is mounted in the CM-5000 and includes an internal antenna. The range is limited since it is inside the panel, but it is sufficient for a user standing directly in front of the refrigeration unit. The goal is to reach reefers stacked three units high.
The purpose is to enhance serviceability for the user with a service app, eliminating the need for a wired connection.
xx: Please refer to test reports.
Notes:
Please note that changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions:
- This device may not cause harmful interference, and
- This device must accept any interference received, including interference that may cause undesired operation.
This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment. This equipment should be installed and operated with a minimum distance of 20 cm between the radiator and your body.
This device complies with Industry Canada licence-exempt RSS standard(s). Operation is subject to the following two conditions:
- This device may not cause interference, and
- This device must accept any interference, including interference that may cause undesired operation of the device.
Le présent appareil est conforme aux CNR d’Industrie Canada applicables aux appareils radio exempts de licence. L’exploitation est autorisée aux deux conditions suivantes :
- L’appareil ne doit pas produire de brouillage, et
- L’utilisateur de l’appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage est susceptible d’en compromettre le fonctionnement.
This equipment complies with IC RSS-102 radiation exposure limits set forth for an uncontrolled environment. This equipment should be installed and operated with a minimum distance of 20 cm between the radiator and your body.
Ce matériel est conforme aux limites de dose d’exposition aux rayonnements CNR-102 énoncées pour un environnement non contrôlé. Cet équipement devrait être installé et exploité avec une distance minimale de 20 cm entre le radiateur et votre corps.
6.5 Power Input / Output
6.5.0 AC Power Input for DO Outputs
The power provided to DO outputs will nominally be 24 Vac with a tolerance of ±5 Vac. One end of the supply will be referenced to the Earth/chassis of the Panel. To accommodate a wide input voltage range, a step-up winding can be switched in or out depending on the voltage measured by the system. The winding will be engaged when the power input voltage is low. The threshold limits for switching, as well as the time prior to switching, will be set by the software. The position will be decided based on the power-up voltage and frequency conditions.
6.5.1 24VAC Power Supply Input
This supply is for the controller internal use only. This supply input shall have double fuses avoiding false current flow.
6.6 Battery Pack Interface and Capacity
6.6.0 Battery Pack Interface
A battery pack is required for data logging and housekeeping of the Controller when in power-off mode. The Controller is designed to interface with a NiMH nominal 7.2V battery pack. The battery pack must be replaceable. The system’s leakage current must be minimized to preserve battery capacity.
6.6.1 Battery Charge
The controller will perform battery charging based on voltage and current only. Charging the battery will be conducted with consideration for the battery’s lifetime.
6.6.2 Battery Discharge
The controller can discharge the battery through a software-controlled passive load. The discharge feature is used for the detection of the presence of a battery pack and for capacity evaluation. The discharge load will not drain the battery when it is not in use.
6.6.3 Battery Capacity
To accommodate different use cases, various capacity sizes of the battery pack can be defined if they align with the charging capabilities. The battery interface is designed to handle capacities up to 2000mAh at 7.2V. The NiMH battery capacity depends on the temperature range during operation and storage.
6.7 Features in Battery Mode and Wakeup
6.7.0 Battery Run
When operating on battery power, without mains power applied, the following features must be active:
- All analog inputs for sensors, such as pt1000, NTC, 0-5V, and 0-25mA.
- All communication interfaces, including USB interfaces.
- Power supply for 0-5V, 0-25mA, and RS485.
- Display and keyboard.
- Stepper motor operation.
- All components of the software, including the “software update” feature.
6.7.1 Battery Wakeup and Hold
The activation of the battery run must be achievable by:
- Pressing a key (just one key).
- RTCalarm.
- RS232 RX activity from the cargo space or modem.
- Software (to handle short mains power dropouts).
The software must be able to identify the source of the wakeup. Moreover, it must be possible to disable future battery wake-up through software control to prevent battery drainage.
6.8 Display Interface
The CM-5000 features a display interface with RS485 communication. Termination is internally fixed on the CM-5000. The /Key_wakeup is an input to the CM-5000, which remains constantly active and is pulled up to a 3.3V level. When a specified key on the front door keypad is pressed, this input is pulled low, initiating a wakeup of the controller.
6.9 Watchdog
The system must include an external watchdog circuit.
6.10 Battery Coin Cell
The CM-5000 contains a lithium coin cell battery for Real-Time Clock power backup. The battery size is CR2032 with a capacity of 210mAh.
6.11 LED Indications
The five LED indicators provide a quick status overview of the CM-5000:
- The System RESET LED will be lit if the supply to the CPU system is too low or if the external watchdog is activated.
- The USB LED will indicate activity when connected.
- Status LED 1 and LED 2 are used to indicate activity.
- The Bluetooth LE transmit LED shows that wireless transmission is active.
6.12 Connectors
6.12.0.1 Dual Level with Crimp and Locking Connector
This type of connection should be used for the battery interface to avoid incorrect connection of the positive and negative wires on the battery pack. A 4.2mm double-level high-density connector, one position (two poles), will be used. The male and female components must be similar to the Molex Mini-Fit Jr. series, Dual Row, 4.2mm with a flammability class of UL94-V0. 
6.12.0.2 Screw Connectors
A 3.81 mm connector series will be used for general interfaces. The components should be similar to Weidmuller SC 3.81/90F, SCD 3.81/90F, SCZ 3.81/180F. 
To avoid incorrect connections, use coding: Accessory coding plugs must be inserted into the base male connectors, and the corresponding notch/tab on the female connector must be cut off to fit the coding.
6.13 Connection list
6.14 Enclosure of CM5000
6.14.0 Position Inside the Box
- Positioned vertically
- Secured at the bottom of the metal bottom box
- Fixed with screws
- The main controller must be available as a separate spare part
- The assembly of the electronics inside the plastic container must facilitate production and ensure resistance to vibrations and shocks (as described elsewhere in this document).
- Enclosure IP: IP20
6.14.1 Internal PCB Layout (Concept)
6.14.2 Material
- Materials used are the same as similar EMR Main Controllers: PC or PC-ASA
- The unit is tested and passes with a 30-second duration with flaming drips allowed under UL-94-HB (minimum). It is preferable to achieve UL-94-V0 standards.
- Must be constructed of fire-retardant materials
- The material must withstand the marine environment, as described elsewhere in this document
6.14.3 Fixing into the Panel
- It is preferable to use screws for quick assembly and replacement in case of failure
- Use Phillips head self-tapping screws (standard)
6.14.4 Connectors
- The connectors must be easily accessible during both the production assembly phase and field replacement (service).
- Connectors must have a mechanical retention type to resist vibrations and shocks. Preferably, this retention should be secured with screws. Latch retainers are acceptable if they are robust.
6.14.5 Labelling
The enclosure exterior must have a label displaying the identification information and main data of the product, complying with approval requirements.
7 OM-5000 Option Module
7.1 OM-5000 System Overview TK FRESH+
7.2 OM-5000 System Overview TK FRESH+ and ActiveCA
7.3 OM-5000 System Enclosure Outline and Mounting
Follow the same concept as for the CM-5000.
Note: The size and shape of the module are indicative.
- Support for TK FRESH+
- Support for ActiveCA
- Optional RS-232
- Bridge light
7.4 I/O List
| OM-5000 Option Module | |||
| Type | Count | Function Comments | Pins |
| RS-232 w/ Handshake | 5 | ||
| RS-485 | 2 | ||
| TK FRESH+ I/O | RS-485 | 2 | |
| Sensor power | 2 | ||
| Analog input | 1 | ||
| 12 | |||
| Input Power | 2 | ||
| Motor driver | 2 | ||
| Feedback | 2 | ||
| 4x LED | 0 | ||
| Bridge light | |||
| Relays | 4 | ||
| ActiveCA — Module | |||
| 24-29Vac | 3 | ||
| Digital output | 2 | Contactor / Heater output AC | |
| Digital output | 4 | Valve outputs AC |
7.5 Input / Output Description
This section specifies the inputs and outputs based on functionality. Where the specification differs from the CM-5000 Specification, this will be specified in this section.
7.6 I/O for General Functionality
7.6.0 29Vac Input TK Fresh+
The 29Vac is used to power the OM-5000 TK FRESH+. The supply must support internal module power consumption, power for 12Vdc, and contactor drive. The internal supply is not used for 24Vac loads in the ActiveCA option. Estimated power consumption is 10W.
7.6.1 Master / Option Module Communication
RS-485 line to the main controller (CM-5000). The specification is described in the CM-5000 Controller section.
7.6.2 RS-232 w/ Handshake
RS-232 for external options — third-party usage. The specification is described in the CM-5000 Controller section.
7.6.3 RS-485 w/ Sensor Power
RS-485 Modbus with sensor power. The RS-485 must be endpoint terminated at the option module. In the TK FRESH+ configuration, the CO2 and O2 sensors consume 12Vdc / 4W. The supply must not be affected by a short of the DC motor drive.
7.7 I/O for TK FRESH+
7.7.0 DC Motor Drive
Output to drive a DC motor forward or backward, supplying the voltage as +VDC, -VDC, or 0VDC. TK motor spec 1E25515G01. Base motor 36VDC/0.5Amp but operated at 12VDC. Response time is less than 50ms. The output amperage draw must not affect the remaining controller measurements, including power for the attached gas analyzer.
7.7.1 TK FRESH+ Motor Position Feedback
The feedback is represented by two wires holding a 1k + 20k variable resistor reflecting the position.
7.8 I/O for ActiveCA
7.8.0 External 24/29Vac Power Source
The external power source must support power for digital outputs. The input must be prepared for adjustment over a wide input voltage range.
7.8.1 Digital Outputs (DO)
- Four Solid State Outputs are used for valve activation.
- Two Relay Outputs are used to activate external contactors and heaters.
- If a safety line is needed, it must be wired in externally.
7.8.2 Pressure Sensor
One pressure sensor input is specified.
7.8.3 PT1000 Sensor
One PT1000 sensor input is specified. The specifications must be similar to those used in the CM-5000.
7.9 Connectors
Use the same connector type as specified for the CM-5000.
7.10 External PSU for ActiveCA
An external 50/60Hz transformer with two voltage outputs, 24Vac and 5Vac, must be added to support the operation of digital outputs. Mounting and power size to be determined.
7.11 OM-5000 Connection List
8 Other Panel Components
8.1 Main Power Input
8.2 Mains Circuit Breaker
The Circuit Breaker provides protection against current overload and is equipped with a mechanical release, allowing it to function as a main switch. The Circuit Breaker size is selectable between 25A and 32A with C characteristics to handle the maximum inrush current and current consumption for the refrigeration applications covered by this specification. According to the safety standard, the earth wire size must correspond with the circuit breaker size. 
8.3 Current Loop Coil
An external three-phase current loop coil is used to measure the load current in the system. Placing it externally increases flexibility regarding mounting immediately after the Circuit Breaker. 
8.4 Transformer
The mains transformer has two outputs for powering the system components. The wires from the transformer are labeled, and the internal connection is printed on top of the transformer as specified below, along with the output voltage and load capability: 
8.4.0 Label
- L1-L3: 500V
- X – X – X: 24Vac + 5Vac, 100VA
- X – X: 24Vac, 50VA
- Vendor name
- Production year/week code
- Type number: TK part number
Secondary fuse protection:
- Individual protection on digital outputs: 24Vac + 5Vac
- One fuse in each phase on 24Vac power supply.
Mounted on the back wall of the MP-5000 Panel.
8.5 ON/OFF Switch
The ON/OFF switch is used to manually control the power to the Controller. In the OFF position, the switch breaks the 24Vac and 24Vac + 5Vac step-up supplies, turning the system off. This means that no outputs related to high voltage components or safety can be activated, except for power to the OM-5000, which requires AC power to shut down the air inlet when the system is switched off. The ON/OFF switch must be easy for the user to see, access, and operate but must be positioned to avoid accidental activation. 
8.6 Contactors
From a cost perspective, contactors are specified for activating high voltage outputs and phase reversal. Compressor and fan motors depend on the correct phase sequence, and therefore power is fed through the phase reversal contactors. Other outputs are not fed through the phase reversal contactor to avoid unnecessary load and power dissipation. The phase reversal and Evap high/low-speed contactors must have a mechanical interlock function to avoid phase-to-phase short-circuiting. The circuit is designed so only one of the phase relay outputs can be activated at a time. The contactors are mounted on DIN rail and must be oriented so that the movement of the contact sets is perpendicular to the vertical axis of the Reefer to reduce the impact of shocks. At a minimum, 25A contactors must be used for the compressor and the phase reversal. 25A contactors have been chosen for all outputs and phase reversal to optimize spare part handling and serviceability. The voltage for activating the contactors is supplied by the transformer. The controller selects based on the mains voltage and frequency, where it chooses from the base or a step-up voltage winding on the transformer. This selection is made to avoid over-driving and heating up the contactor coil during activation. The contactor is a wearable component, and its lifetime should be considered concerning the number of operations. 
8.7 Heater Element Wire Centre Point
There are no terminals in the MP-5000 Panel for the heater element wires’ center connection, which is not part of the system delivery. The center point for the heater element wires must be connected into a terminal butt splice with a closed end and individual openings. The size must fit the heater element wire sizes. The wires are secured to the harness with strips.
10.1.0 Internal Harness
- As a minimum, the wires must have numeric identification.
- The conductor material must be tinned copper.
- Color: White
- Must adhere to environmental specifications and system voltages concerning temperature and insulation capabilities and must be UL recognized.
The internal harness is specific and not expected to be changed during its lifetime. It should use pluggable screw connectors with lock/fixing where relevant. Fork connections should be used for high current connections on contactors. Bus bars are employed to reduce handling, mounting time, save space in the Panel, increase reliability, and decrease heat dissipation. The drawback is a higher component cost.
10.1.1 External Harness
The external low voltage harness shall have a pluggable connection interface inside the Panel. The external high voltage harness shall connect to already available terminals. External harnesses shall use fork connections for contactors.
10.1.2 Earth Wire
For safety, the earth must be wired internally in the Panel. The size of the earth wire depends on the selection of the circuit breaker’s size. Ground connections must comply with safety regulations applicable to this specification.
11.1 Display DM-5000
The DM-5000 consists of an enclosure with a PBA mounted with a 240×96 dot matrix display module. The PBA is mounted on the front door as depicted below. Two LEDs indicate In Range (green) and Alarm (Red). The DM-5000 has a serial RS485 interface to the CM-5000. The DM-5000 manages input from the keypad (KM-5000) and passes it on to the CM-5000. Below are some of the basic specifications for the 240×96 dot matrix display module. The complete display will be tested according to the environmental and electrical tests specified in this document. 
11.2 Connectors
For interface to the CM-5000, a 3.81 mm connector with 5 poles and fixing is used. For interface to the Keypad, a 2.5mm connector with 7 poles and a lock is used.
11.3 Connection List
Note: The texts and information displayed are only examples and do not represent the real UI update picture based on the existing Visograf 2.0. Mount from the backside of the Door.
11.3.0 Material:
- Same as MP4000: PC ASA (for the non-transparent parts)
- Same material used on similar EMR Main Controller: Transparent PC
The unit is tested and passes with 30 seconds of flaming drips allowed UL-94-HB (minimum). It is preferred to achieve UL-94-V0. It shall be constructed of fire-retardant materials. The material must withstand the marine environment as described elsewhere in this document. It shall provide an interface that can be operated in wet weather. Enclosure IP ratings are as follows:
- From the Frontal Side (LCD Side) and the Metal Door: IP56
- Other Parts Inside the Metal Door: IP20
In front of the LCD, there must be a “robust” transparent protection (like a transparent window).
11.3.1 Fixing into the Panel
It is preferable to use screws for quick assembly and replacement in case of failure. Use Phillips head screws (standard).
11.3.2 Labelling
Outside the enclosure, there must be a label showing the identification information and the main data of the product, which complies with the requirements of approvals.
11.3.3 Tilted Position of the Display
The display of the DM-5000 must be tilted to allow viewing from the ground when the Reefer is positioned in the 3rd level (over two other Reefers) by a distance of 25 feet. The display must be tilted 3° from the vertical surface of the Door.
