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Tuck San’s Reefer Module Repair Workshop
53

Tuck San's Reefer Workshop

Apr 15, 2017

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Tucker Latimer
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Page 1: Tuck San's Reefer Workshop

Tuck San’s Reefer Module Repair Workshop

Page 2: Tuck San's Reefer Workshop

Red Tags We all use them at some time but hate to see them when looking for

spares n’ parts. Too many times have I signed on as reefer to a ship that

only has crates of red tagged modules and no ready to go spares.

It is my hope that this presentation will encourage my fellow Union

Brothers to use their mechanical abilities to effectively rebuild even the

nastiest looking modules. Here we will rebuild the ones in these

pictures.

Page 3: Tuck San's Reefer Workshop
Page 4: Tuck San's Reefer Workshop
Page 5: Tuck San's Reefer Workshop

Tools Wire brushes large and small

Bore brushes

Medium grain crocus cloth

7/16 ¼ drive ratchet and 7/16 nut driver

Long flat head screwdriver

Phillips head screwdriver

5/16 nut driver

Receptacle test equipment

Electrical parts cleaner

226 electrical parts lubricant

111 silicone valve sealant

Page 6: Tuck San's Reefer Workshop

Break it down Most ESL 480V 32Amp modules with mechanical

safety interlocks can be easily broken down. On one

model it is necessary to secure ground pin plunger with a

ty-rap to the on/off plunger or it will spring out and cost

a lot of time reassembling. This module pictured has its

ground pin plunger secured in the interlock and is

assembled in a unit for fast receptacle change out.

Page 7: Tuck San's Reefer Workshop

Step 1

For complete breakdown you will need to unscrew

on/off plunger head with small pipe wrenches after wire

brushing and PB Blasting seam.

Step 2 Remove the 4 bolts securing receptacle to frame

Page 8: Tuck San's Reefer Workshop
Page 9: Tuck San's Reefer Workshop

Step 3 Remove the 2 top screws securing the circuit breaker

handle actuator to on/off plunger rod. The actuator will

slide off with the circuit breaker but if not removing CB

then just remove lower side screw below CB switch

handle and slide it up

Page 10: Tuck San's Reefer Workshop

Step 4

Upper 2 screws securing CB and ground lug connection

plate with ground wire attached

Page 11: Tuck San's Reefer Workshop

Lower 2 screws securing CB and ground pin assembly to

frame

Page 12: Tuck San's Reefer Workshop

Remove the 4 screws securing circuit breaker to frame.

Set aside ground lug and attachment frame. The circuit

breaker is now free to slide up for access to the B phase

wire lug. Loosen lug screws and remove circuit breaker. If

on/off plunger is still in the way, see step 5.

Page 13: Tuck San's Reefer Workshop

Step 5

Remove the 2 pan heads securing ground pin plunger

assembly to frame. The on/off plunger may now be

moved out of way to loosen B phase lug. Lift off circuit

breaker, ground pin plunger assembly and on/off plunger

with sleeve and spring. The receptacle can be removed

anytime the 3 phase CB lugs are loose.

Page 14: Tuck San's Reefer Workshop

The third screw in step 5 picture above the on/off

plunger rod and the 2 pan heads secure the gasket plate

to frame face, sealing the on/off plunger rod. This can be

removed for cleaning and resealing with 111 silicone

valve sealant.

Page 15: Tuck San's Reefer Workshop

Step 6

This is what you are most likely to see. Thus the wire

brushes or, if you have air, a wheel on a gun.

Page 16: Tuck San's Reefer Workshop

And you end up with this.

Page 17: Tuck San's Reefer Workshop

But first check the frame for straightness or warpage or

all that cleaning is a waste of time. We are now ready for

reassembly.

Page 18: Tuck San's Reefer Workshop

Troubleshooting

The red tag and note indicated trouble with module

tripping. The fact that it tripped on a splitter is irrelevant

unless the splitter was at fault which we will never know.

A close inspection of the module will reveal the cause of

tripping.

In this case high resistance through the A phase of the

circuit breaker and water intrusion.

Page 19: Tuck San's Reefer Workshop

But other mechanical wear and improper reassembly

can present problems.

Notice broken edge along bottom of sleeve at top

center of picture. The roll pin holds the sleeve against the

spring pressure which provides safety disconnect of

electrical power. This action opens the circuit breaker if

the plug is removed from receptacle before pulling down

on on/off plunger rod.

This becomes a safety issue if not properly working so

close inspection of these small parts is important. The

Page 20: Tuck San's Reefer Workshop

roll pin can be pushed out with a punch and small

hammer.

This roll pin has sheared ends. The safety release and

interlock are inoperable nor can this module be powered

on.

Page 21: Tuck San's Reefer Workshop

Use of wrong parts in reassembly can compromise

operation and safety. Here improper ground wire

connection will not provide adequate ground protection.

Ring terminal is too large for this application. Securing

screws and ground pin are not proper parts for this

model.

Page 22: Tuck San's Reefer Workshop

The pin on left is the one installed in previous picture.

The pin on right is the correct replacement part.

Page 23: Tuck San's Reefer Workshop

Overheated plugs can melt and warp plastic

receptacles. Bench test receptacles and replace if

necessary.

Page 24: Tuck San's Reefer Workshop

Reassembly

Ok so now we have a clean frame that can provide

water tight seals.

Page 25: Tuck San's Reefer Workshop

Reinstall faceplate plunger seal.

Page 26: Tuck San's Reefer Workshop

Receptacle can be installed at any stage of reassembly.

Page 27: Tuck San's Reefer Workshop

If you are not replacing receptacle with a new complete

part make sure you use proper ground connection parts.

Screws, washers and spacers for proper reassembly.

Page 28: Tuck San's Reefer Workshop

Placement of spacers over screw holes in ground pin.

Page 29: Tuck San's Reefer Workshop

Align ground wire connection plate, screws and

washers with spacers and screw into threaded bores of

ground pin.

Page 30: Tuck San's Reefer Workshop

Slide on/off plunger rod through seal bore in face plate.

Slide spring onto plunger till it rests on sleeve. Slide

ground pin plunger interlock unit over on/off plunger till

it rests on spring.

Page 31: Tuck San's Reefer Workshop

Slide receptacle into position with ground pin plunger

inside ground pin bore.

Page 32: Tuck San's Reefer Workshop
Page 33: Tuck San's Reefer Workshop

The circuit breaker can now be installed. Insert the 3

wire leads from receptacle and tighten lugs on circuit

breaker. Make sure the wire leads have a nice helical

spiral to them and no sharp bends like in the yellow A

phase wire. The wires should neatly coil 1 turn as the CB

is lowered into position. They can then be moved out of

the way of moving parts.

The ground pin interlock unit can now be secured to

face plate with the 2 pan head screws into back of gasket

plate on other side.

Slide CB mounting holes over the 4 holes in frame, align

with the 2 holes in ground pin interlock unit frame on

bottom and push a long screw through. Over a washer,

hand tighten nut on backside so CB can be maneuvered

to insert the rest of screws. Refer to Step 5 and Step 4

in Breakdown.

Place ground lug connection plate over the 2 holes at

top of CB with ground lug on left side with a long screw

through lug, plate and CB. The long ground wire from

receptacle feeds up on right side and its terminal is

secured to plate with long screw and washer through

plate and CB.

Page 34: Tuck San's Reefer Workshop
Page 35: Tuck San's Reefer Workshop

.

The 4 mounting screws for the red GD 22K breaker are

larger in diameter than the screws used for the blue GD

22K circuit breaker and are not interchangeable as the

bores through the breakers are different.

With circuit breaker and ground pin interlock unit

securely fastened, replace CB handle actuator.

Page 36: Tuck San's Reefer Workshop

Aligning the circuit breaker handle actuator

The next 6 pictures show the position of the circuit

breaker handle actuator in relation to the circuit breaker

handle and on/off plunger rod. If this is not assembled

properly the module will not power on or off.

The circuit breaker handle is sandwiched between the 2

side screws which provide the lifting force to power on

the module, and the downward force to power off.

Page 37: Tuck San's Reefer Workshop
Page 38: Tuck San's Reefer Workshop
Page 39: Tuck San's Reefer Workshop

Before securing circuit breaker handle actuator, insert

bottom handle lifting screw. With circuit breaker switch

in off position make certain that screw is under switch

handle.

Now the 2 top pan head screws can be loosely inserted

with lock washers.

Then the upper screw is fed through in opposite

direction of lower lifting screw over the top of circuit

breaker switch handle. The upper screw is what forces

the circuit breaker switch handle down, opening the

circuit breaker and disconnecting power to receptacle.

Page 40: Tuck San's Reefer Workshop
Page 41: Tuck San's Reefer Workshop
Page 42: Tuck San's Reefer Workshop
Page 43: Tuck San's Reefer Workshop

The circuit breaker actuator plate is adjustable for most

effective actuating position. Tighten the 2 top plate pan

head screws and turn both side actuating screw’s nuts

until they just touch the plate sides. If overtightened they

will crimp the actuator. The screws should rotate freely.

The on/off plunger head removed in Step 1 can now

be replaced to complete the reassembly.

Page 44: Tuck San's Reefer Workshop
Page 45: Tuck San's Reefer Workshop

Testing

To confirm smooth and proper operation of our rebuilt

module we use a plug with pins extended out from cable

end.

Does the on/off plunger actuate the circuit breaker

closed and open?

Does the interlock release when plug is removed

without pulling down on/off plunger rod?

For continuity through breaker to plug and on/off

plunger to ground pin we use an ohm meter.

For phase to phase and each phase to ground

resistance values we use a megohmeter.

Page 46: Tuck San's Reefer Workshop
Page 47: Tuck San's Reefer Workshop

Measuring phase to ground resistance with meggar set at

1000 Volts

Page 48: Tuck San's Reefer Workshop

Measuring phase to phase resistance with meggar set at

1000 Volts

Page 49: Tuck San's Reefer Workshop

Lubrication and Protection

Use a marine grade grease. Never seize is not a lubricant!

Page 50: Tuck San's Reefer Workshop

Never seize will gum up and seize moving parts. Use

only on threaded joints.

Grease all springs, moving joints and high stress points.

Page 51: Tuck San's Reefer Workshop
Page 52: Tuck San's Reefer Workshop

Gaskets were lubricated with 111

Page 53: Tuck San's Reefer Workshop

And finally external surfaces and ground connection

points are given a coating to extend life of module. Cover

with plastic if stored for long in dirty locations.