Precedent™ C-600 Operator’s Manual
Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
Precedent™
C-600
TK 55692-2-OP (Rev. 2, 12/15)
©2013 Ingersoll-Rand Company
Printed in U.S.A.
Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
©2013 Ingersoll-Rand Company
Printed in U.S.A.
Precedent™
C-600
TK 55692-2-OP (Rev. 2, 12/15)
PrecedentTM
C-600
TK 55692-2-OP (Rev. 2, 12/15)
Copyright© 2013 Thermo King Corp., Minneapolis, MN, USA
Printed in USA
Disclaimer
This manual is published for informational purposes only. Thermo King Corporation makes no
representations or warranties, express or implied, with respect to the information, recommendations
and descriptions contained in this manual and such information, recommendations and descriptions
should not be regarded as all-inclusive or covering all contingencies. In the event you have any
questions or require further information, please contact your local Thermo King dealer.
The procedures described herein should only be undertaken by suitably qualified personnel. Failure to
implement these procedures correctly may cause damage to the Thermo King unit or other property or
personal injury.
Thermo King Corporation and its affiliates shall have no liability in contract or tort (including negligence
and/or strict liability) or otherwise, to any person or entity for any personal injury, property damage or
any other direct, indirect, special or consequential damage or liability whatsoever, arising out of or
resulting from any actions by any person that are contrary to this manual or any of the information,
recommendations or descriptions contained herein or the failure of any person to implement the
procedures described herein correctly or to follow caution and safety decals located on the Thermo
King unit.
Table Of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EPA Emission Control System Warranty Statement 8
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Safety Practices . . . . . . . . . . . . . . . . . . . . . . 11
Automatic Start/Stop Operation . . . . . . . . . . . . . . . . . 12
Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Battery Installation and Cable Routing . . . . . . . . . . . . 12
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
First Aid–Refrigerant . . . . . . . . . . . . . . . . . . . . . . . 14
First Aid–Refrigerant Oil . . . . . . . . . . . . . . . . . . . . 14
Safety Decals and Locations . . . . . . . . . . . . . . . . . . . 15
Condenser and Evaporator Fans . . . . . . . . . . . . . 15
High Voltage Components . . . . . . . . . . . . . . . . . . 15
Do Not Use Ether Starting Aids . . . . . . . . . . . . . . 17
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Features and Options . . . . . . . . . . . . . . . . . . . . . . . . .19
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . .21
EMI 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Thermo King X430L Reciprocating Compressor . . . . .22
Electronic Throttling Valve . . . . . . . . . . . . . . . . . . . . . .22
SMART REEFER 4 (SR-4) Control System . . . . . . . . .23
Diesel Operation . . . . . . . . . . . . . . . . . . . . . . . . . .23
Electric Operation . . . . . . . . . . . . . . . . . . . . . . . . .24
CYCLE-SENTRY Start-Stop Controls . . . . . . . . . . . . .24
Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
OptiSet Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
FreshSet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Opening the Front Doors . . . . . . . . . . . . . . . . . . . . . . .27
Engine Compartment . . . . . . . . . . . . . . . . . . . . . . . . . .28
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . .28
3
Remote Status Display (Optional) . . . . . . . . . . . . . . 32
Manual Pretrip Inspection
(Before Starting the Unit) . . . . . . . . . . . . . . . . . . . . . 35
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . 37
SMART REEFER 4 (SR-4) Controller Overview . . . . . 37
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Control Panel Display . . . . . . . . . . . . . . . . . . . . . . 38
Display Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Hard Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Turning Unit On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
If a Flash Drive is Connected: . . . . . . . . . . . . . . . . 41
Configurable Soft Keys . . . . . . . . . . . . . . . . . . . . . 43
Display Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
If a Language is Enabled . . . . . . . . . . . . . . . . . . . 44
If Log Alarms are Present . . . . . . . . . . . . . . . . . . . 45
Turning The Unit Off . . . . . . . . . . . . . . . . . . . . . . . . . . 47
The Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . 47
The TemperatureWatch Display . . . . . . . . . . . . . . . . . 48
Changing The Setpoint . . . . . . . . . . . . . . . . . . . . . . . . 49
Numerical Setpoints . . . . . . . . . . . . . . . . . . . . . . . 49
Named Products - OptiSet Plus . . . . . . . . . . . . . . 50
4
Both Numerical Setpoints and Named Products .
Changing the Setpoint - Numerical Setpoint . . . .
Changing the Setpoint - Named Product . . . . . . .
Changing the Setpoint - Both Numerical Setpoint
and Named Product Available . . . . . . . . . . . . . . .
Starting the Diesel Engine . . . . . . . . . . . . . . . . . . . . .
Starting the Electric Motor . . . . . . . . . . . . . . . . . . . . .
Switching from Diesel to Electric . . . . . . . . . . . . . . . .
Switching from Electric to Diesel . . . . . . . . . . . . . . . .
Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . .
Terminating a Defrost Cycle . . . . . . . . . . . . . . . . . . . .
Selecting Cycle Sentry or Continuous Mode . . . . . . .
Using the Gauges Key . . . . . . . . . . . . . . . . . . . . . . . .
Gauges Available . . . . . . . . . . . . . . . . . . . . . . . . .
Using The Sensors Key . . . . . . . . . . . . . . . . . . . . . . .
Sensors Available . . . . . . . . . . . . . . . . . . . . . . . .
Using the Main Menu . . . . . . . . . . . . . . . . . . . . . . . . .
Pretrip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performing a Pretrip Test . . . . . . . . . . . . . . . . . . .
Flash Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flash Drive Icon . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting the Flash Drive Menu from the Main Menu
(If Already Connected) . . . . . . . . . . . . . . . . . . . . . . . .
Removing the Flash Drive . . . . . . . . . . . . . . . . . . . . .
50
51
55
59
60
61
62
63
64
67
67
71
71
73
74
75
76
78
83
83
84
85
Languages (If Enabled) . . . . . . . . . . . . . . . . . . . . . . . . 86
Available Languages . . . . . . . . . . . . . . . . . . . . . . 86
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Log Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Check Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Shutdown Alarms . . . . . . . . . . . . . . . . . . . . . . . . . 91
Pretrip Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Clearing Alarm Codes . . . . . . . . . . . . . . . . . . . . . 92
Displaying and Clearing Alarm Codes . . . . . . . . . 93
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Displaying Gauges . . . . . . . . . . . . . . . . . . . . . . . . 98
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Displaying Sensors . . . . . . . . . . . . . . . . . . . . . . . . 99
Data Logger (CargoWatch) . . . . . . . . . . . . . . . . . . . . 100
Sending Start of Trip Marker to CargoWatch and ServiceWatch Data Loggers . . . . . . . . . . . . . . . . . . . . . . . . . 101
Hourmeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Viewing Hourmeters . . . . . . . . . . . . . . . . . . . . . . 104
Mode Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
SmartPower Electric Standby Option . . . . . . . . . 113
Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Clear All ECU Faults . . . . . . . . . . . . . . . . . . . . . . 118
Optional Rear Remote Control Panel . . . . . . . . . . .121
Rear Remote Control Panel Functionality . . . . . . . . .121
Rear Remote Control Action Set to Run . . . . . . .121
Rear Remote Control Action Set to STAND BY .122
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Reading a Typical Remote Standard Display . . .126
Remote Control Panel Lockout . . . . . . . . . . . . . .126
Turning the Unit ON or OFF (Configured for STAND
BY Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Turning the Unit On and Off (Configured for RUN
Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . .128
Selecting Cycle-Sentry or Continuous Mode . . . . . . .129
Displaying the Discharge Air Temperature . . . . . . . .130
Viewing and Clearing Alarm Codes . . . . . . . . . . . . . .131
Starting a Manual Defrost Cycle . . . . . . . . . . . . . . . .132
Sending a Start of Trip Marker . . . . . . . . . . . . . . . . . .133
Running a Pretrip Test . . . . . . . . . . . . . . . . . . . . . . . .134
Loading and Enroute Inspections . . . . . . . . . . . . .136
Pre-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . .136
Post-Loading Inspection . . . . . . . . . . . . . . . . . . . . . .138
Enroute Inspections . . . . . . . . . . . . . . . . . . . . . . . . . .139
5
Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Alarm Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Clearing Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . 145
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Maintenance Inspection Schedule . . . . . . . . . . . . 193
Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Serial Number Locations . . . . . . . . . . . . . . . . . . . . 198
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . 179
Electrical Control System . . . . . . . . . . . . . . . . . . . . . 181
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . 182
Electric Heater Strips . . . . . . . . . . . . . . . . . . . . . . . . . 184
Electrical Standby (Smart Power Units Only) . . . . . . 184
Electric Motor and Overload Relay . . . . . . . . . . . 184
Standby Power Cord Requirements . . . . . . . . . . 185
Electric Fuel Heater (Optional) . . . . . . . . . . . . . . . . . 185
6
Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . . 201
Recover Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . 202
CALIFORNIA
Proposition 65 Warning . . . . . . . . . . . . . . . . . . . . . 203
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Introduction
There is nothing complicated about operating and maintaining
your Thermo King unit, but a few minutes studying this
manual will be time well spent.
Performing pre-trip checks and enroute inspections on a
regular basis will minimize on-the-road operating problems. A
regular maintenance program will also help to keep your unit
in top operating condition. If factory recommended procedures
are followed, you will find that you have purchased the most
efficient and dependable temperature control system available.
IMPORTANT: This manual is published for informational
purposes only and the information furnished herein should
not be considered as all-inclusive or meant to cover all
contingencies. If more information is required, consult your
Thermo King Service Directory for the location and
telephone number of the local dealer.
All service requirements, major and minor, should be handled
by a Thermo King dealer for four very important reasons:
•
They are equipped with the factory recommended tools to
perform all service functions
•
They have factory trained and certified technicians
•
They have genuine Thermo King replacement parts
•
The warranty on your new unit is valid only when the
repair and replacement of component parts is performed
by an authorized Thermo King dealer.
7
EPA Emission Control System Warranty
Statement
Thermo King warrants to the initial owner and each subsequent
owner that the certified, non-road diesel engine in your unit is:
1.
Designed, built and equipped so as to conform, at the time
of sale, with all applicable regulations adopted by the
United States Environmental Protection Agency (EPA).
2.
Free from defects in materials and workmanship in
specific emission related parts for a period of five years or
3,000 hours of operation, whichever comes first, after date
of delivery to the initial owner.
If an emission-related part or component fails during the
warranty period, it will be repaired or replaced. Any such part
or component repaired or replaced under warranty is warranted
for the warranty period.
8
During the term of this warranty, Thermo King will provide,
through a Thermo King authorized service dealer or other
establishment authorized by Thermo King, repair or
replacement of any warranted part at no charge to the non-road
engine owner.
In emergency, repairs may be performed at any service
establishment, or by the owner, using any replacement part.
Thermo King will reimburse the owner for their expenses,
including diagnostic charges for such emergency repair. These
expenses shall not exceed Thermo King’s suggested retail price
for all warranted parts replaced, and labor changes based on
Thermo King’s recommended time allowance for the warranty
repair and the geographically appropriate hourly labor rate.
EPA Emission Control System Warranty Statement
Any replacement part can be used for maintenance or repairs.
The owner should ensure that such parts are equivalent in
design and durability to genuine Thermo King parts. However,
Thermo King is not liable for parts that are not genuine
Thermo King parts.
A part not being available within 30 days or repair not being
completed within 30 days constitutes an emergency.
As a condition of reimbursement, replaced parts and received
invoices must be presented at a place of business of a Thermo
King authorized service dealer or other establishment
authorized by Thermo King.
If failure of one of these parts or components results in failure
of another part or component, both will be covered by this
warranty.
Responsibilities
This warranty is subject to the following:
Thermo King Corporation
Responsibilities
This warranty covers the following emission-related parts and
components:
During the emission warranty period, if a defect in material or
workmanship of a warranted part or component is found,
Thermo King will provide:
•
Fuel Injection System
•
•
Intake Manifold
•
Exhaust Manifold
•
Miscellaneous hoses, clamps, connectors and sealing
devices used in the above systems.
New, remanufactured, or repaired parts or components
required to correct the defect.
NOTE: Items replaced under this warranty become the
property of Thermo King.
•
Labor, during normal working hours, required to make the
warranty repair. This includes diagnosis and labor to
remove and install the engine, if necessary.
9
EPA Emission Control System Warranty Statement
Owner Responsibilities
Limitations
During the emission warranty period, the owner is responsible
for:
Thermo King is not responsible for resultant damages to an
emission-related part or component resulting from:
•
•
Any application or installation Thermo King deems
improper as explained in this Operator’s Manual, or any
other manuals provided for the unit.
•
Attachments, accessory items, or parts not authorized for
use by Thermo King.
•
Improper off-road engine maintenance, repair or abuse.
•
Owner’s unreasonable delay in making the product
available after being notified of a potential product
problem.
The performance of all required maintenance. A warranty
claim will not be denied because the scheduled
maintenance was not performed. However, if the lack of
required maintenance was the reason for the repair, then
the claim will be denied.
•
Premium of overtime cost.
•
Cost to investigate complaints that are not caused by
defects in Thermo King material or workmanship.
•
Providing timely notice of a warrantable failure and
promptly making the product available for repair.
This warranty is in addition to Thermo King’s standard
warranty applicable to the off-road engine product involved.
Remedies under this warranty are limited to the provision of
material and services as specified herein. Thermo King is not
responsible for incidental or consequential damages such as
downtime or loss of engine powered equipment.
10
Safety Precautions
Thermo King recommends that servicing be done only by a
Thermo King dealer. However, you should be aware of several
safety practices. This chapter gives basic safety precautions for
working with Thermo King units and describes the safety
stickers on your unit that you should be familiar with.
General Safety Practices
DANGER: NEVER operate the unit with the
compressor discharge valve closed. Doing so could
cause the compressor to explode, causing death or
serious injury.
WARNING: Always wear goggles or safety glasses
when working with or around the refrigeration system
or battery. Refrigerant or battery acid can cause
permanent damage if it comes in contact with your
eyes.
WARNING: Keep hands and loose clothing clear of
fans and belts at all times when the unit is operating
or when opening or closing compressor service
valves.
WARNING: Exposed coil fins can cause painful
lacerations. Service work on the evaporator or
condenser coils should be done by a certified Thermo
King technician.
WARNING: Do not apply heat to a closed cooling
system. Before applying heat to a cooling system,
drain it. Then flush it with water and drain the water.
Antifreeze contains water and ethylene glycol. The
ethylene glycol is flammable and can ignite if the
antifreeze is heated enough to boil off the water.
CAUTION: Use extreme caution when drilling holes
in the unit. Drilling into electrical wiring or
refrigerant lines could cause a fire. Do not drill into
structural components.
11
Safety Precautions
Automatic Start/Stop Operation
This unit is capable of automatic operation and could start at
any time without warning.
WARNING: The unit can start at any time without
warning. Press the OFF key on the control panel and
place the microprocessor On/Off switch in the Off
position before inspecting or servicing any part of the
unit.
Electrical Hazard
DANGER: Dangerous three phase AC electric power
is present whenever the unit is operating in either
Diesel Mode or Electric Mode and whenever the unit
is connected to a source of external standby power.
Voltages of this magnitude can be lethal. Exercise
extreme caution when working on the unit.
12
Battery Installation and Cable
Routing
WARNING: Improperly installed battery could result
in a fire or explosion. A Thermo King approved
battery must be installed and properly secured to the
battery tray.
WARNING: Improperly installed battery cables could
result in fire or explosion. Battery cables must be
installed, routed and secured properly to prevent
them from rubbing, chaffing or making contact with
hot, sharp or rotating components.
WARNING: Do not attach fuel lines or any
additional wiring harnesses to the battery cables as
this could cause an electrical fire.
CAUTION: Do not connect other manufacturer’s
equipment or accessories to the Thermo King unit.
This could result in severe damage to equipment and
void the warranty.
Safety Precautions
CAUTION: Set all unit electrical controls to the OFF
position before connecting battery cables to the
battery to prevent unit from starting unexpectedly and
causing personal injury.
CAUTION: Always wear protective clothing, gloves
and eye wear when handling and installing batteries.
Battery acid can cause serious burns when exposed to
eyes or skin. If battery acid contacts skin or clothing,
wash immediately with soap and water. If acid enters
your eye, immediately flood it with running cold
water for at least twenty minutes and get medical
attention immediately.
CAUTION: Always cover battery terminals to prevent
them from making contact with metal components
during battery installation. Battery terminals
grounding against metal could cause the battery to
explode.
Refrigerant
Although fluorocarbon refrigerants are classified as safe, use
caution when working with refrigerants or in areas where they
are being used.
DANGER: Fluorocarbon refrigerants can produce
toxic gases. In the presence of an open flame or
electrical short, these gases are severe respiratory
irritants CAPABLE OF CAUSING DEATH.
DANGER: Fluorocarbon refrigerants tend to
displace air and can cause oxygen depletion which
could result in DEATH BY SUFFOCATION. Provide
adequate ventilation in enclosed or confined areas.
WARNING: Fluorocarbon refrigerants evaporate
rapidly, freezing anything they contact if accidentally
released into the atmosphere from the liquid state.
13
Safety Precautions
Refrigerant Oil
Observe the following precautions when working with or
around refrigerant oil:
WARNING: Always wear goggles or safety glasses to
protect eyes from refrigerant oil contact.
Skin: Flush areas with large amounts of warm water. Do not
apply heat. Wrap burns with dry, sterile, bulky dressing to
protect from infection or injury. Get prompt medical attention.
Inhalation: Move victim to fresh air and restore breathing if
necessary. Stay with victim until emergency personnel arrive.
First Aid–Refrigerant Oil
WARNING: Protect skin and clothing from
prolonged or repeated contact with refrigerant oil.
Rubber gloves are recommended.
WARNING: Wash thoroughly immediately after
handling refrigerant oil to prevent irritation.
Eyes: Immediately flush eyes with large amounts of water for
at least 15 minutes while holding the eyelids open. Get prompt
medical attention.
Skin: Remove contaminated clothing. Wash thoroughly with
soap and water. Get medical attention if irritation persists.
Inhalation: Move victim to fresh air and restore breathing if
necessary. Stay with victim until emergency personnel arrive.
First Aid
First Aid–Refrigerant
Eyes: For contact with liquid, immediately flush eyes with
large amounts of water. Get prompt medical attention.
14
Ingestion: Do not induce vomiting. Immediately contact
local poison control center or physician.
Safety Precautions
Safety Decals and Locations
Condenser and Evaporator Fans
Be aware of the warning nameplates near the condenser fans
and evaporator fans (example in Figure 1).
High Voltage Components
Various components on the Precedent unit operate using
220/3/60 or 460/3/60 high voltage and are identified by
warning nameplates (examples in Figure 2). All high voltage
wiring is identified by ORANGE conduiting. Be aware of the
locations of these components. Only certified, trained
technicians can service them.
AMA1579
AMA1580
AMA1581
Figure 1: Fan Warning
Figure 2: High Voltage Warning
NOTE: See Figure 3 and Figure 4 for high voltage
component locations.
15
Safety Precautions
1
7
2
8
6
99
3
4
5
1. Condenser Motors 4. High Voltage Control Box
2. Evaporator Motor 5. AC Generator
3. High Voltage
6. Electric Standby Motor &
Distribution Box
Power Receptacle
(SmartPower Option)
Figure 3: High Voltage Component Locations (Front)
16
7.
8.
Evaporator Motor
9.
High Voltage Junction
Box
High Voltage Heater All ORANGE conduiting
Strips
contains High Voltage
Figure 4: High Voltage Component Locations (Rear)
Safety Precautions
Do Not Use Ether Starting Aids
Figure 5: Do Not Use Ether Starting Aids
(Near Engine)
17
Unit Description
Unit Overview
The Thermo King Precedent C-600 is a one piece,
self-contained, diesel powered, air cooling/heating unit
operating under the control of a SMART REEFER 4 (SR-4)
programmable microprocessor controller. The unit mounts on
the front of the trailer with the evaporator extending through an
opening in the front wall.
The units feature all-new DDE (Diesel Direct Electric)
architecture, the quiet running Thermo King TK486V25
engine and the Thermo King X-430 reciprocating compressor.
The C-600 is available in the following models:
Standard : Cooling and heating on diesel engine operation.
SmartPowerTM Option: Cooling and heating on diesel
engine operation and electric standby operation.
See the following Features and Options.
Figure 6: C-600 Front View
18
Unit Description
Features and Options
The following chart lists key design features and options.
l Standard Features
m Option/Factory installed
Precedent C-600 Key Features & Options
Easy-access door design
l
Composite Exterior Panels
l
Long-Life Coolant/Silicone Hoses
l
Remote Status Display
o Option/Dealer Installed
m/o
Standard Unit Color White
l
Standard Grille Color Black
l
l
Directional Air Delivery
l
m
Vibration Isolation System
l
SmartPower High-Output
m
SmartPower Prep Package
m
OptiSet Plus
l
Aluminum Undermount Fuel Tank 50 Gal.
(186 Liter)
Fuel Level Sensor
Precedent C-600 Key Features & Options
SMART REEFER SR-4 Controller
SmartPower Electric Standby
ETV (Electronic Throttling Valve)
l
ServiceWatch Data Logger
l
CargoWatch Data Logger
l
Severe Duty Package
Fuel Tanks with Ultrasonic Fuel level
Sensor
Electric Fuel Heater
l
l
m
m
m
CargoLink Sensor Kits
m/o
Frost Plug Heater
m
CargoLink Wireless Sensors
m/o
Alternator, 65 Amp, 12 Vdc
m
Appearance Packages
m
EMI-3000
l
High-Capacity Condenser Coil
l
19
Unit Description
Diesel Engine
Precedent C-600 Key Features & Options
Fresh Air Exchange
m
Anti-Siphon Device
m
REB Wireless Communication Platform
m
TracKing Telematics
m/o
PrimAir bulkhead and duct system
o
Rear Remote Control
o
Humidity Sensor
o
Battery Charger
m
Reliamax Battery,
12 Volt, Wet Cell
o
EON Battery,
12 Volt, Dry Cell
Remote Electric Power Receptacle
The 4-cylinder TK486V25 is a water cooled, direct injection
diesel engine. The engine is coupled directly to the compressor
on Standard Units. A centrifugal clutch transfers power from
the engine to the compressor on Smart Power Units. Belts
transmit power to the AC generator, water pump, and
alternator.
o
m
ARA1955
Figure 7: TK486V25 Engine
20
Unit Description
ELC (Extended Life Coolant)
ELC (Extended Life Coolant) is standard equipment. The
maintenance interval for ELC is five years or 12,000 hours. A
nameplate on the coolant expansion tank identifies units with
ELC (see “Safety Decals and Locations”). The new engine
coolant, Chevron Extended Life Coolant, is RED in color
instead of the previous GREEN or BLUE-GREEN colored
conventional coolants.
CAUTION: Do not add “GREEN” or
“BLUE-GREEN” conventional coolant to cooling
systems using “RED” Extended Life Coolant, except
in an emergency. If conventional coolant is added to
Extended Life Coolant, the coolant must be changed
after 2 years instead of 5 years.
NOTE: The use of 50/50% pre-mixed ELC is recommended
to assure that de-ionized water is being used. If 100% full
strength concentrate is used, de-ionized or distilled water is
recommended instead of tap water to insure the integrity of
the cooling system is maintained.
AJA1947
Figure 8: ELC (Extended Life Coolant) Nameplate
(On expansion tank)
21
Unit Description
EMI 3000
EMI 3000 is an extended maintenance interval package. It is
standard equipment. The EMI 3000 package consists of the
following key components:
Thermo King X430L
Reciprocating Compressor
The C-600 is equipped with a four cylinder 30.0 cu. in. (492
cm3) displacement Thermo King X430L reciprocating
compressor.
•
EMI 3000-Hour Cyclonic Air Cleaner Assembly and Air
Cleaner Element
•
EMI 5-Micron 3000-Hour Fuel Filter
Electronic Throttling Valve
•
EMI 3000-Hour Dual Element Oil Filter
•
API Rating CI-4 Mineral Oil
The ETV provides enhanced control of the refrigeration system
as follows:
•
Five Year or 12,000 Hour ELC (Extended Life Coolant)
•
The EMI package allows standard maintenance intervals to be
extended to 3,000 hours, or 2 years, whichever occurs first.
Allows the refrigeration system to fully utilize the power
capabilities of the engine under varying conditions
•
NOTE: Units equipped with the EMI 3000 package do
require regular inspection in accordance with Thermo King's
maintenance recommendations.
Provides an additional measure of protection against high
discharge pressures
•
Protects the engine from high coolant temperature
shutdowns
•
Provides a means of precise temperature control.
NOTE: EMI 3000 oil filters and EMI 3000 air cleaners are
NOT interchangeable with older style oil filters and air
cleaners.
22
Unit Description
SMART REEFERTM 4 (SR-4)
Control System
The SR-4 is a microprocessor control system designed for
transport refrigeration. The SR-4 integrates the following
functions: changing setpoint and operating mode, viewing
gauge, sensor and hourmeter readings, initiating defrost cycles,
and viewing and clearing alarms.
The microprocessor components are located inside the control
box, which is located inside the lower roadside service door. It
is used to operate the unit. The control panel is mounted on the
face of the control box. It is clearly visible through an opening
in the lower roadside service door.
See “Operating Instructions” for more information about the
SR-4 Controller.
Diesel Operation
In diesel operation the microprocessor will select the operating
mode from the following:
•
High Speed Cool
•
Low Speed Cool
•
Low Speed Modulated Cool
•
Null (CYCLE-SENTRY operation only)
•
Low Speed Modulated Heat
•
Low Speed Heat
•
High Speed Heat
•
Defrost
Depending on the air temperature in the trailer, as sensed by
the microprocessor Base Controller, the unit will typically
operate in one of the following modes:
23
Unit Description
Electric Operation
In electric operation the microprocessor will select the
operating mode from the following:
•
Cool
•
Modulated Cool
•
Null (CYCLE-SENTRY operation only)
•
Modulated Heat (Hot Gas only)
•
Hot Gas Heat
•
Full Heat (Hot Gas and Electric Heat)
•
Defrost (Hot Gas and Electric Heat)
CYCLE-SENTRYTM Start-Stop
Controls
The CYCLE-SENTRY Start-Stop fuel saving system provides
optimum operating economy.
24
WARNING: The unit can start at any time without
warning. Press the OFF key on the control panel and
place the microprocessor On/Off switch in the Off
position before inspecting or servicing any part of the
unit.
When CYCLE-SENTRY Mode is selected the unit will start
and stop automatically to maintain setpoint, keep the engine
warm and the battery charged. When Continuous Mode is
selected, the unit starts automatically and runs continuously to
maintain setpoint and provide constant airflow.
Your Thermo King unit provides a wide range of
control and programming flexibility. However,
pre-programming of the unit SR-4 microprocessor
may prohibit operation in certain temperature ranges
within some modes and may also prohibit certain
modes of operation. If you have controller
programming questions, contact your supervisor or
your Thermo King dealer before requesting service.
Unit Description
Data Logging
There are two separate data loggers. The data is downloaded
through the USB ports on the front of the control box.
MICRO
PROCESSOR
ON
OFF
ServiceWatch™: ServiceWatch is standard equipment. It
records operating events, alarm codes and compartment
temperatures as they occur and at preset intervals. This
information is typically used to analyze unit performance.
CargoWatch™: CargoWatch data logging requires the
installation of optional sensors. Up to six temperature
sensor/probes and four door switches can be installed.
CargoWatch also logs the setpoint. Use a USB port to
downloaded the CargoWatch data. If optional temperature
sensors are installed, their readings are displayed as Datalogger
Sensor (1-6) Temperature in the sensor readings.
1
THERMO KING
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
USB PORT
FLASH DRIVE ONLY
MENU
2
SR4
Smart Reefer 4
USB PORT
PC COMPUTER ONLY
USB Ports: :
1.
Flash Drive Only USB Port
•
2.
PC Computer Only USB Port
•
The Flash Drive Only USB Port allows a USB Flash Drive
that has been properly configured using the ThermoServ™
Service Tool to be connected to the unit.
Figure 9: USB Ports
The PC Computer Only USB Port allows a PC Computer
to be connected to the unit via a standard USB Cable.
25
Unit Description
OptiSetTM Plus
OptiSet Plus is a group of programmable functions that control
how the unit will operate with specific setpoints or named
products. This assures that when a particular setpoint or named
product is selected, the unit will always operate the same way.
This allows an entire fleet to be configured to match the
customers’ needs. Contact your Thermo King dealer for
information about programming OptiSet Plus.
FreshSetTM
FreshSet is included in OptiSet Plus. FreshSet is a demand
base temperature control for fresh products. FreshSet modifies
and adjusts unit airflow operation to control temperature and to
maximize protection of cargo, while keeping operating costs to
a minimum. Contact your Thermo King dealer for information
about programming FreshSet.
Defrost
Frost gradually builds-up on evaporator coils as a result of
normal operation. The unit uses hot refrigerant to defrost the
evaporator coil. Hot refrigerant gas passes through the
evaporator coil and melts the frost. The water flows through
collection drain tubes onto the ground. The methods of defrost
initiation are Automatic, and Manual.
Automatic Defrost: The SR-4 automatically initiates timed
or demand defrost cycles. The SR-4 microprocessor can be
programmed to initiate timed defrost cycles at intervals of 2, 4,
6, 8, or 12 hours. Demand defrost cycles occur if the
differences between the return air temperature, discharge air
temperature, and coil temperature exceed certain limits. The
unit can enter defrost cycles as often as every 30 minutes if
required.
Manual Defrost: In Manual Defrost Mode, the operator
initiates a defrost cycle. See “Initiating a Manual Defrost
Cycle.”
NOTE: The unit will not perform a Manual Defrost Cycle
unless the unit has been turned on with the ON key, the unit
is running in Continuous or CYCLE-SENTRY Mode (or shut
down in CYCLE-SENTRY Null Mode), and the coil
temperature is below 45 F (7 C).
26
Unit Description
Opening the Front Doors
Pull the right door handle to unlatch the doors and access the
engine compartment. Do not push the doors closed while
holding the door latch handle open or the door will not close
properly.
ARA2207
Figure 10: Door Latch Locations
Figure 11: Door Latch Nameplate
27
Unit Description
Engine Compartment
The following maintenance items can be checked visually.
WARNING: The unit can start at any time without
warning. Press the OFF key on the control panel and
place the microprocessor On/Off switch in the Off
position before inspecting any part of the unit.
Compressor Oil Sight Glass: Use this sight glass to check
the compressor oil level. Check the compressor oil when there
is evidence of oil loss (leaks). Refer to the unit Maintenance
Manual for the correct procedure.
Engine Oil Dipstick: Use the engine oil dipstick to check
the engine oil level.
CAUTION: Make sure the engine is turned off before
attempting to check the engine oil.
Receiver Tank Sight Glass: This sight glass indicates the
level of refrigerant in the receiver tank. Refer to the unit
Maintenance Manual for the correct procedure.
28
Operate the unit in high speed cool for approximately 15
minutes to stabilize operating conditions and temperature
before attempting to check the refrigerant.
NOTE: If the ball floats, there is sufficient refrigerant in the
unit for that load at that particular trailer temperature. This
test does not determine if the unit contains a full charge or an
overcharge of refrigerant.
Unit Protection Devices
Coolant Level Switch: The coolant level switch closes if
the coolant level drops below an acceptable level. If it stays
closed for a specified time, the microprocessor records alarm
code 37.
Engine Coolant Temperature Sensor:
The microprocessor uses the engine coolant temperature sensor
to monitor the engine coolant temperature. If the engine
coolant temperature rises above an acceptable level, the
microprocessor records alarm code 41 and possibly 18. The
microprocessor might also shut the unit down.
Unit Description
High Pressure Cutout Switch: The high pressure cutout
switch (HPCO) is located on the compressor discharge
manifold. If the compressor discharge pressure becomes
excessive, the switch opens the circuit to the run relay to stop
the unit. The microprocessor will record Alarm Code 10.
High Pressure Relief Valve: This valve is designed to
relieve excessive pressure in the refrigeration system. It is
located on the receiver tank. If the high pressure relief valve
opens, much of the refrigerant will be lost. Take the unit to a
Thermo King dealer if this occurs.
Low Oil Level Switch: The low oil level switch closes if the
oil drops below an acceptable level. If it stays closed for a
specified time, the microprocessor shuts the unit down and
records Alarm Code 66.
Overload Relay—Automatic Reset (SmartPower): An
overload relay protects the standby electric motor. The
overload relay opens the circuit to the electric motor if the
motor overloads for any reason (e.g., low line voltage or
improper power supply) while the unit is on electric standby
operation. The microprocessor will record Alarm Code 90.
Smart FETs: Smart FETs in the microprocessor protect some
circuits and components from an overcurrent condition.
Fuses: A number of fuses, located on the microprocessor,
protect various circuits and components. The microprocessor is
located inside the control box. Refer to the appropriate
Microprocessor Controller Diagnostic Manual for more
information about the fuses.
Low Oil Pressure Switch: The low oil pressure switch
closes if the oil pressure drops below an acceptable level. If it
stays closed for a specified time, the microprocessor shuts the
unit down and records alarm code 19.
Preheat Buzzer: The preheat buzzer sounds when the base
controller energizes the preheat relay. This warns anyone near
the unit that the controller is about to start the engine.
29
Unit Description
Fuse
F1
F2
F3
F4
Size
5A
15A
40A
None
F5
F6
F7
F8
F10
F12
F13
F15
F20
F25
F25
2A
60A
15A
2A
5A
15A
5A
2A
2A
2A
10A
7.5A
30
Function
2A Power for REB
On/Off Switch Circuit
Fuel Solenoid/Starter Circuit
No Fuse - All Bosch and Thermo King
Alternators (Note 1)
2A Fuse - All Prestolite Alternators
Preheat Circuit (Note 2)
High Speed Solenoid Circuit
8X Power for CAN bus
2A Power for CAN bus J12
On/Off Relay Circuit
2A Power for CAN bus J13
Status Light Circuit
SR-4 Power Supply Circuit
Alternator Sense Circuit
Fresh Air Door Circuit
High Pressure Cutout Circuit
NOTE: Fuse F4 must be in place for Prestolite alternators to
charge. Fuse F4 must be removed for Bosch and Thermo
King alternators. Service Parts Base Controllers are shipped
without the F4 fuse
NOTE: The F5 preheat fuse is a “slow blow” type fuse. It is
designed for use with the Yanmar trailer engine air
pre-heater. Always replace the fuse with the TK specified
fuse.
Unit Description
1
3
2
4
5
1.
Control Box
4.
2.
HMI Control Panel 5.
3.
Microprocessor
On/Off Switch
PC Only USB Poet
Flash Drive Only USB
Port
Figure 12: Control Box With Service Door Open
Figure 13: SR-4 Controller
31
Remote Status Display (Optional)
The remote status display mounts on the cargo box for easy
viewing of the unit’s mode.
Figure 14: Remote Status Display (All LEDs Shown)
32
The remote status display indicates operating status as follows:
White Status LEDs: Illuminate the “T” portion of the TK
logo when the unit is functioning properly with no alarm
codes.
Figure 15: Normal Operation No Alarms
Remote Status Display (Optional)
Amber Status LEDs: Illuminate the “K” portion of the TK
logo when the unit has a check alarm code, but is still
functioning properly. Check the unit as soon as possible to
correct the alarm condition.
White and Amber Status LEDs: The two bottom LEDs in
the “T” (in white) and the four bottom LEDs in the “K” (in
amber) are illuminated when the unit has a shutdown alarm
code and the load integrity is at risk. Correct the alarm
condition immediately.
Figure 16: Check Alarm
Figure 17: Shutdown Alarm
33
Remote Status Display (Optional)
Remote status displays that also show the fuel level or the fuel
level and the box temperature are also available. The number
of white LEDs illuminated in the fuel level indicator show the
fuel level. When the fuel level falls below 10%, only the two
amber LEDs at the top and bottom of the fuel level indicator
are illuminated to indicate the low fuel level.
The temperature display shows the box temperature, except
when the unit is in defrost in which case it displays “dF”.
1
2
2
1
3
1.
2.
Status Indicator
Fuel Level Indicator
Figure 18: Remote Status Display with Fuel Level
34
1.
2.
3.
Status Indicator
Fuel Level Indicator
Temperature Display
Figure 19: Remote Status Display
with Fuel Level and Temperature
Manual Pretrip Inspection
(Before Starting the Unit)
Pretrip inspections are an important part of a preventative
maintenance program designed to minimize operating
problems and breakdowns. Perform this pretrip inspection
before every trip involving refrigerated cargo.
NOTE: Pretrip inspections are not intended to take the place
of regular maintenance inspections.
Fuel: Make sure the diesel fuel supply is adequate to
guarantee engine operation to the next check point. Allow for
maximum fuel consumption of one gallon per hour of engine
operation.
Engine Oil: Check the engine oil level. It should be at the
Full mark when the dipstick is threaded all the way into the oil
pan. Do not overfill.
CAUTION: Turn the engine off before checking the
engine oil level.
Engine Coolant: The engine coolant must have antifreeze
protection to -30 F (-34 C). Add coolant if Alarm Code 37 is
active. Check and add coolant to the expansion tank.
WARNING: Do not remove the expansion tank cap
while the coolant is hot.
Battery: Make sure the battery terminals are tight and free of
corrosion.
Belts: Make sure belts are in good condition and adjusted to
the proper tension. For more information about belt tension,
see the Specifications chapter.
Electrical: Check the electrical connections to make sure they
are securely fastened. Wires and terminals should be free of
corrosion, cracks, and moisture.
Structural: Visually inspect the unit for leaks, loose or
broken parts, and other damage.
35
Manual Pretrip Inspection (Before Starting the Unit)
Coils: Make sure the condenser and evaporator coils are clean
and free of debris.
Cargo Box: Check the interior and exterior of the cargo box
for damage. Any damage to the walls or insulation must be
repaired.
Cargo Doors: Make sure that the cargo doors and weather
seals are in good condition. The doors should latch securely
and the weather seals should fit tightly.
Defrost Drains: Check the defrost drain hoses to make sure
they are open.
36
Operating Instructions
SMART REEFER 4 (SR-4)
Controller Overview
Thermo King has applied the latest advances in computer
technology to develop a device that controls temperature and
unit function, and displays operating information quickly and
accurately.
MICRO
PROCESSOR
ON
OFF
THERMO KING
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
USB PORT
FLASH DRIVE ONLY
There is nothing complicated about learning to operate the
SR-4 Controller, but you will find that a few minutes studying
the contents of this manual will be time well spent.
MENU
SR4
Smart Reefer 4
USB PORT
PC COMPUTER ONLY
WARNING: Do not operate the SR-4 until you are
completely familiar with the location and function of
each control.
Figure 20: SR-4 Control Panel
37
Operating Instructions
The microprocessor components are located inside the control
box, which is located inside the lower roadside service door.
The microprocessor is connected to a Human Machine
Interface (HMI) Control Panel. It is used to operate the unit.
The USB ports are used to retrieve data from the data logging
system.
Microprocessor On/Off Switch: This switch supplies or
removes electrical power to the microprocessor. The
Microprocessor Power Switch is located above HMI Control
Panel. It is hidden when the lower roadside body panel
surrounding the Control Box is closed.
WARNING: The unit can start at any time without
warning. Press the OFF key on the control panel and
place the microprocessor On/Off switch in the Off
position before inspecting or servicing any part of the
unit.
38
Control Panel
The control panel has a display and eight touch sensitive keys.
The display is capable of showing both text and graphics. The
four keys on the left and right sides of the display are “hard”
(dedicated) keys. The four keys under the display are “soft”
keys. The function of “soft” keys change depending on the
operation being performed. If a soft key is active, its function
will be shown in the display directly above the key.
Control Panel Display
The display is used to supply unit information to the operator.
This information includes setpoint, current box temperature
operating information, unit gauge readings, system
temperatures and other information as selected by the operator.
The default display is called the Standard Display. It is shown
in Figure 21 and will be described in detail later in this chapter.
Operating Instructions
Display Icons
3
THERMO KING
1
ON
2
OFF
SET
POINT
35
°F
.8
GAUGES
SENSORS
35
MENU
SR4
4
5
Display symbols or Icons are used to present additional unit
information
Down-Pointing Arrow: (At the left side of the
display) Shows the unit is cooling. If the arrow
were pointing upward the unit would be heating.
CYCLE SENTRY/Continuous Mode Key:
Smart Reefer 4
6
1.
On Key (Hard Key)
2.
Off Key (Hard Key)
3.
Display
4.
Defrost Key (Hard Key)
5.
CYCLE-SENTRY/Continuous Mode Key
(Hard Key)
6.
Soft Keys
The unit is running in Cycle Sentry Mode as
shown by the Cycle Sentry Icon in the upper right
corner of the display. If the Cycle Sentry icon is
not present, the unit is running in Continuous
Mode.
USB: The USB Icon in the upper left corner of
the display will appear when a USB device is
connected to either of the USB Ports on the Unit
Control Panel.
Figure 21: Control Panel Display and Keys
39
Operating Instructions
Hard Keys
CYCLE SENTRY: Used to select Cycle Sentry
Mode or Continuous Mode operation if allowed
by OptiSet Plus. For more information see
“Selecting Cycle Sentry or Continuous Mode”
later in this section.
The keys on either side of the display are dedicated or “hard”
keys. Their function always remains the same.
ON
OFF
On Key: Used to turn the unit on. First the
display will briefly show the Thermo King Logo
and then the statement “Configuring System Please Wait”. When the power-up sequence is
complete the display shows the Standard Display
of box temperature and setpoint.
Off Key: Used to turn the unit off. First the
display will briefly show “System is Powering
Down - Please Wait. Press On to Resume” and
then “Off” will appear momentarily. When the
power-down sequence is complete the display
will be blank. For more information see “Turning
the Unit On and Off” later in this section.
Defrost Key: Press this key to initiate a Manual
Defrost cycle.
40
Soft Keys
The four “soft” keys under the display are
multi-purpose keys. Their function changes
depending on the operation being performed. If a
soft key is active the key function is shown in the
display directly above the key. The keys are
numbered from left to right, with Key 1 on the far
left and Key 4 on the far right.
Typical soft key applications:
• MENU
• CLEAR
• NO
• NEXT
• HOURMETERS
• SENSORS
• + OR -
• GAUGES
• EXIT
• SELECT
• BACK
• HELP
Operating Instructions
Turning Unit On
The unit is turned on by pressing the ON Key (Figure 22) and
off by pressing the OFF Key. When the On Key is pressed the
display briefly shows the THERMO KING Logo as the display
initializes.
IMPORTANT: The ON Key must be held down until the
Thermo King Logo appears. If the ON Key is not held down
long enough (approximately ½ second), the display may
flicker but the unit will not start up. If this occurs, hold the
ON Key down until the Thermo King logo appears.
NOTE: With extremely cold ambient temperatures it may
take up to 15 seconds for the display to appear on initial
startup.
Then the startup screen (Figure 23) appears while
communications are established and the unit prepares for
operation.
ON
CONFIGURING SYSTEM
PLEASE WAIT
OFF
Figure 23: Startup Screen
If a Flash Drive is Connected:
If a properly configured USB Flash Drive is inserted in the
Flash Drive Only USB Port on the Control Panel when the unit
is turned on, the display (Figure 24) will briefly show FLASH
DRIVE.
ON
OFF
Figure 22: ON Key
41
Operating Instructions
ON
IMPORTANT: The engine start is not delayed by the Flash
Drive Menu shown above. The engine start prompt will
appear and the engine will start. After the engine is started
the display will return to the Flash Drive Menu or the
Standard Display.
FLASH DRIVE
OFF
Figure 24: Flash Drive
Then FLASH DRIVE DETECTED and the Flash Drive Menu
will appear on the display (Figure 25). The display will be
shown for about 30 seconds and then the Standard Display will
appear. To go to the Standard Display immediately press the
EXIT Soft Key.
ON
If a properly configured USB Flash Drive is connected to the
USB Flash Drive connector, this feature allows the operator to
select the desired Flash Drive function. If enabled when the
Flash Drive was configured, the following functions may be
available:
•
•
FLASH DRIVE DETECTED
•
OFF
EXIT
DOWN
LOAD
FLASH
LOAD
OPTISET
PLUS
DOWNLOAD
•
“Download the ServiceWatch Data Logger
•
“Download the CargoWatch Data Logger
FLASHLOAD
•
“Flash load Base Controller Software
•
“Flash load HMI Control Panel Software
OPTISET PLUS
•
SEND
•
•
Figure 25: Flash Drive Menu
42
“Send OptiSet Plus files
RETRIEVE
•
“Retrieve OptiSet Plus files
The Flash Drive is also available from the Main Menu.
Operating Instructions
The Flash Drive Menu will time out about 30 seconds after the
engine starts. When the Flash Drive Menu times out, the
Standard Display will appear. To go to the Standard Display
immediately press the EXIT Key.
The functions of these two keys can be changed as required for
customer convenience. The functions of these two soft keys on
the Standard Display can be re-assigned to any of the following
functions using the Guarded Access > Main Menu
Configuration menu:
Configurable Soft Keys
Gauges
Pretrip
SOT (start of trip)
When the Standard Display is shown, the default functions of
the two center soft keys are GAUGES and SENSORS.
(Figure 26)
Sensors
Data Logger
Hourmeters
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
The GAUGES and SENSORS functions are always available
from the Maintenance Menu.
In the example shown in Figure 27, the soft key functions from
the Standard Display have been changed to PRETRIP and SOT
(Start of Trip marker). The GAUGES and SENSORS functions
are always available from the Maintenance Menu.
ON
Figure 26: Soft Keys
OFF
SET
POINT
35
PRETRIP
°F
.8
SOT
35
MENU
Figure 27: PRETRIP and SOT
43
Operating Instructions
Display Heater
If a Language is Enabled
The HMI Control Panel is equipped with a display heater. This
heater is needed to make the display visible in very cold
ambient temperatures.
If more than one language has been enabled from the Guarded
Access Language Menu, a prompt will appear to allow the
desired language to be chosen as shown below. Only languages
specifically enabled from the Guarded Access Menu are
available. If a different language is desired, press the NO Key
(Figure 28).
The HMI has its own internal temperature sensor for the
display heater. The heater is energized when the unit is turned
on and the ambient temperature is below 29.4 F (-2 C). The
heater turns off when the temperature sensed by the internal
sensor rises above 37.4 F (+3 C). The heater draws from 1.4 to
1.7 amps when energized.
The colder the ambient temperature the longer it will take for
the heater to make the display visible on a cold startup. It may
take 10-15 seconds for the display to appear with extremely
cold temperatures.
IMPORTANT: The engine start is not delayed by the
language prompt shown below. The prompt will appear for 10
seconds and then the engine will start. After the engine is
started the display will return to the prompt shown.
CURRENT LANGUAGE IS
ON
OFF
ENGLISH
YES
OK?
NO
Figure 28: NO Key
44
Operating Instructions
The Language menu will appear as shown in Figure 29. Press
the + or - Keys to select the desired language. When the
desired language is shown press the YES Key to confirm the
choice.
The new language is confirmed, and then the Standard Display
will appear in the new language as shown in Figure 31. The
unit is ready to run.
Figure 31: Standard Display, New Language
Figure 29: + or -, then YES Key
The display will briefly show PROGRAMMING
LANGUAGE - PLEASE WAIT in the new language as shown
in Figure 30.
Figure 30: New Language
If Log Alarms are Present
Log Alarms are indicated for 60 seconds each time the unit is
turned on. This level of alarm serves as a notice to take
corrective action before a problem becomes severe.
Maintenance items such as maintenance hourmeter time-outs
are log alarms. The Temperature Watch screen is not disabled
if only log alarm(s) are active.
If log alarm(s) are present the Log Alarm notice shown in
Figure 32 will appear on the display for 60 seconds. The
remote indicator alarm light (if installed) will also be on during
this period. After 60 seconds the Standard Display will appear
45
Operating Instructions
and the remote indicator alarm light will go off. Pressing the
EXIT soft key (Figure 32) will return to the Standard Display
immediately.
LOG ALARMS ACTIVE
ON
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
GO TO MENU TO VIEW
OFF
EXIT
Figure 33: Standard Display
Figure 32: Log Alarms Active
NOTE: The Alarm Icon does not appear on startup with
log alarms present.
When the unit is ready to run the Standard Display
appears(Figure 33).
46
Operating Instructions
Turning The Unit Off
The Standard Display
Pressing the OFF Key stops unit operation. The unit shuts
down immediately and the display briefly shows the power
down message (Figure 34).
The Standard Display is the default display that appears if no
other display function is selected. The Standard Display shows
the box temperature and setpoint. The box temperature is that
measured by the controlling sensor, usually the return air
sensor. The box temperature in Figure 36 is 35.8 F (2.1 C) with
a 35 F (1.7 C) setpoint.
ON
SYSTEM IS POWERING DOWN
OFF
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
Figure 34: Power Down Message
The display briefly shows OFF (Figure 35) and then goes
blank. To start the unit again, press the ON Key.
Figure 36: Standard Display
ON
OFF
OFF
The down-pointing arrow at the left side of the
display shows the unit is cooling. If the arrow
were pointing upward the unit would be heating.
Figure 35: Display Shows OFF
47
Operating Instructions
The unit is running in Cycle Sentry Mode as
shown by the Cycle Sentry Icon in the upper right
corner of the display. If the Cycle Sentry icon is
not present, the unit would be running in
Continuous Mode.
The USB Icon in the upper left corner of the
display will appear when a USB Flash Drive is
connected to the Flash Drive Only USB Port or a
PC computer is connected to the PC Only USB
Port on the Unit Control Panel.
Pressing the left soft key allows the user to change the
SETPOINT, and pressing the right soft key accesses the MAIN
MENU. The other two soft keys access the GAUGES menu
and the SENSORS menu.
NOTE: The functions of the GAUGES and SENSORS soft
keys may be re-assigned to better suit customer requirements.
The GAUGES and SENSORS functions are always available
from the Maintenance Menu.
48
The TemperatureWatch Display
The TemperatureWatch Display appears 2 ½ minutes after the
Standard Display appears so long as there is no key activity
and no check, prevent or shutdown alarms are present. The
TemperatureWatch Display will remain on until any key is
pressed or a check, prevent or shutdown alarm occurs.
The TemperatureWatch Display shows the box temperature
and setpoint. The large numbers allow unit conditions to be
checked from a distance. The box temperature is that measured
by the controlling sensor, usually the return air sensor. The box
temperature in Figure 37 is 35.8 F (2.1 C) with a 35 F (1.7 C)
setpoint. The Cycle Sentry icon in the upper right corner of the
display shows that the unit is operating in Cycle Sentry Mode.
If the Cycle Sentry icon is not present, the unit is running in
Continuous Mode. The down-pointing arrow indicates that the
unit is cooling. Pressing any soft key returns the display to the
Standard Display.
Operating Instructions
Changing The Setpoint
35
TEMPERATURE
ON
OFF
SETPOINT
°F
.8
35
MENU
Figure 37: TemperatureWatch Display
If an alarm condition (other than a log alarm) is present, the
TemperatureWatch Display will not appear. If an alarm
condition occurs while the TemperatureWatch Display is
present the display will return to the Standard Display to
indicate that an alarm condition has occurred.
If the Defrost Key or Cycle Sentry Key is pressed, the display
will return to the TemperatureWatch Display immediately after
the defrost cycle is initiated or the operating mode is changed.
The Setpoint is changed from the Standard Display. If the
TemperatureWatch display is present, press any key to return to
the Standard Display.
IMPORTANT: If OptiSet Plus is in use there are several
possible options when changing the setpoint.
Numerical Setpoints
If OptiSet Plus is not in use or if only Numerical Setpoints are
enabled the left soft key will be labeled SETPOINT (Figure
38).
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
Figure 38: Setpoint
49
Operating Instructions
Named Products - OptiSet Plus
OptiSet Plus allows the use of Named Products such as
APPLES or BANANAS in place of a numerical setpoint. If
only named products are enabled the left soft key will be
labeled PRODUCT (Figure 39).
•
A single setpoint temperature may be allowed for the
specific named product.
•
A numerical setpoint range may be allowed for the
specific named product.
Both Numerical Setpoints and Named
Products
OptiSet Plus can allow the use of both Numerical Setpoints and
Named Products. If both numerical setpoints and named
products are enabled the left soft key will be labeled
PRODUCT/SETPOINT (Figure 40).
ON
OFF
ON
OFF
35
PRODUCT
GAUGES
°F
.8
SENSORS
35
PRODUCT/
SETPOINT
GAUGES
°F
.8
SENSORS
35
MENU
35
MENU
Figure 40: Left Soft Key Labeled
“PRODUCT/SETPOINT”
Figure 39: Left Soft Key Labeled “Product”
50
Operating Instructions
Changing the Setpoint - Numerical
Setpoint
If the Temperature Watch display is shown, press any soft key
to return to the Standard Display. From the Standard Display,
press the SETPOINT Key.
NEW SETPOINT WILL BE
ON
OFF
40 F
+/- TO CHANGE
-
+
YES
OK?
NO
The setpoint display appears (Figure 41).
CURRENT SETPOINT
ON
OFF
35 F
+/- TO CHANGE
-
+
Figure 42: Setpoint Changed Using “+” Key
EXIT
Figure 41: Setpoint Display
The “-” and “+” Keys are used to increase or decrease the
setpoint until the desired setpoint is shown. In Figure 42 the
setpoint has been changed to 40 F using the “+” Key.
The YES and NO Keys (Figure 43) confirm the setpoint
change. When the desired setpoint has been selected using the
“+” and/or “-” Keys, press the YES Key to confirm and load
the new setpoint. If the setpoint is changed using the “+” or “-”
Keys, the change must be confirmed or rejected by pressing the
YES or NO Key within 10 seconds of changing the setpoint. A
warning beep will sound for 5 seconds as a reminder.
Failure to confirm the new setpoint by pressing Yes or No
within 10 seconds of changing the setpoint will result in no
setpoint change. In addition, Alarm Code 127 Setpoint Not
Entered is set, to indicate that a setpoint change was initiated
but not completed.
51
Operating Instructions
If the NO Key is pressed the display will briefly show
SETPOINT NOT CHANGED and return to the Standard
Display. The Standard Display will show the old setpoint.
NEW SETPOINT WILL BE
ON
OFF
40 F
+/- TO CHANGE
-
+
YES
OK?
NO
Figure 43: Yes and No Keys
After the YES Key has been pressed, the display briefly shows
PROGRAMMING NEW SETPOINT - PLEASE WAIT. The
display then confirms the new setpoint for several seconds
(Figure 44):
The display then returns to the Standard Display showing the
new setpoint. Notice in Figure 45 that the arrow now points up
to indicate that the unit is heating.
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
40
MENU
Figure 45: Up Arrow
NEW SETPOINT IS
ON
40 F
OFF
Figure 44: New Setpoint
52
IMPORTANT: If the setpoint is changed using the “+” or “-”
Keys, the change must be confirmed or rejected by pressing
the YES or NO Key within 10 seconds of changing the
setpoint.
Operating Instructions
•
If the YES Key is pressed, the setpoint change made with
the “+” or “-” Key is accepted, the setpoint changes, and
the display returns to the Standard Display.
•
If the NO Key is pressed the setpoint change made with
the “+” or “-” Key is not accepted, the setpoint is not
changed, and the display returns to the Standard Display.
•
If the YES or NO Key is not pressed within 10 seconds of
making a change with the “+” or “-” Key, the setpoint is
not changed and the display returns to the Standard
Display. The display briefly shows [SETPOINT NOT
CHANGED] and Alarm Code 127 Setpoint Not Entered is
set, to indicate that a setpoint change was initiated but not
completed.
See Figure 46 for an overview of the Changing the Setpoint Numerical Setpoint procedure.
53
Operating Instructions
NEW SETPOINT WILL BE
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
Setpoint Key
ON
OFF
+/- TO CHANGE
-
OFF
-
+
YES
OK?
NO
40 F
OFF
New Setpoint
NEW SETPOINT WILL BE
ON
35 F
+/- TO CHANGE
+
+ or - Keys
CURRENT SETPOINT
ON
NEW SETPOINT IS
ON
40 F
EXIT
OFF
40 F
+/- TO CHANGE
-
+
YES
ON
OK?
NO
OFF
SET
POINT
35
Yes or No Keys
Figure 46: Changing the Setpoint - Numerical Setpoint
54
GAUGES
°F
.8
SENSORS
40
MENU
Operating Instructions
Changing the Setpoint - Named
Product
If the Temperature Watch display is shown, press any soft key
to return to the Standard Display. From the Standard Display,
press the PRODUCT Key. Note that PRODUCT is displayed in
place of SETPOINT (Figure 47).
CURRENT PRODUCT IS
ON
OFF
OFF
59
PRODUCT
GAUGES
°F
.8
SENSORS
-
+
EXIT
Figure 48: Setpoint Display
GRAPEFRUIT, ARIZONA
ON
GRAPEFRUIT, ARIZONA
+/- TO CHANGE
59
MENU
The “-” and “+” Keys are used to change the Named Product
until the desired product is shown. In Figure 49 the product has
been changed to Potato, Late Crop.
NEW PRODUCT WILL BE
Figure 47: Product Displayed
The display briefly shows PRODUCT and then the setpoint
display appears (Figure 48).
ON
OFF
POTATO, LATE CROP
+/- TO CHANGE
-
+
YES
OK?
NO
Figure 49: Named Product
55
Operating Instructions
The YES and NO Keys confirm the product change (Figure
50). When the desired product has been selected using the “+”
and/or “-” Keys, press the YES Key to confirm and load the
new product. If the product is changed using the “+” or “-”
Keys, the change must be confirmed or rejected by pressing the
YES or NO Key within 10 seconds of changing the product. A
warning beep will sound for 5 seconds as a reminder.
Failure to confirm the new product by pressing Yes or No
within 10 seconds of changing the product will result in no
product change. In addition, Alarm Code 127 Setpoint Not
Entered is set, to indicate that the product change was initiated
but not completed.
OFF
POTATO, LATE CROP
+/- TO CHANGE
-
+
YES
OK?
NO
Figure 50: Yes and No Keys
56
NEW NAMED PRODUCT IS
ON
POTATO, LATE CROP
OFF
Figure 51: New Named Product
If the NO Key is pressed the display will briefly show
SETPOINT NOT CHANGED and return to the Standard
Display. The Standard Display will show the old setpoint.
NEW PRODUCT WILL BE
ON
After the YES Key has been pressed, the display briefly shows
PROGRAMMING NAMED PRODUCT - PLEASE WAIT.
The display then confirms the new setpoint for several
seconds.
The display then returns to the Standard Display showing the
new named product. Notice that the arrow points down, to
indicate that the unit is cooling (Figure 52).
Operating Instructions
•
POTATO, LATE CROP
ON
OFF
45
PRODUCT
GAUGES
°F
.8
SENSORS
45
MENU
Figure 52: Standard Display
If the YES or NO Key is not pressed within 10 seconds of
making a change with the “+” or “-” Key, the product is
not changed and the display returns to the Standard
Display. The display briefly shows [SETPOINT NOT
CHANGED] and Alarm Code 127 Setpoint Not Entered is
set, to indicate that the product change was initiated but
not completed.
See Figure 53 for an overview of the Changing the Setpoint Named Product procedure.
IMPORTANT: If the named product is changed using the
“+” or “-” Keys, the change must be confirmed or rejected by
pressing the YES or NO Key within 10 seconds of changing
the named product.
•
If the YES Key is pressed, the product change made with
the “+” or “-” Key is accepted, the product changes, and
the display returns to the Standard Display.
•
If the NO Key is pressed the product change made with
the “+” or “-” Key is not accepted, the product is not
changed, and the display returns to the Standard Display.
57
Operating Instructions
GRAPEFRUIT, ARIZONA
59
ON
OFF
PRODUCT
GAUGES
°F
.8
NEW PRODUCT WILL BE
59
SENSORS
MENU
ON
OFF
Product Key
+/- TO CHANGE
-
OFF
-
+
Setpoint Display
OK?
POTATO, LATE CROP
NO
OFF
EXIT
OFF
POTATO, LATE CROP
ON
POTATO, LATE CROP
+/- TO CHANGE
-
+
YES
OK?
NO
OFF
45
PRODUCT
Yes or No Keys
Figure 53: Changing the Setpoint, Named Product
58
New Named Product
If Yes Key Chosen,
NEW PRODUCT WILL BE
ON
GRAPEFRUIT, ARIZONA
+/- TO CHANGE
+
YES
+ or - Keys
CURRENT PRODUCT IS
ON
NEW NAMED PRODUCT IS
ON
POTATO, LATE CROP
GAUGES
°F
.8
SENSORS
45
MENU
Standard Display
Operating Instructions
Changing the Setpoint - Both
Numerical Setpoint and Named
Product Available
.
ON
If the Temperature Watch display is shown, press any soft key
to return to the Standard Display. From the Standard Display,
press the SETPOINT Key. Note that both PRODUCT and
SETPOINT are displayed as shown (Figure 54).
ON
OFF
35
PRODUCT/
SETPOINT
GAUGES
OFF
NAMED PRODUCT / NUMERIC
SETPOINT?
EXIT
NAMED
NUMERIC
Figure 55: NAMED PRODUCT / NUMERIC
SETPOINT Prompt
°F
.8
SENSORS
35
•
Press the NUMERIC Soft Key to proceed with Changing
the Setpoint - Numeric Setpoint change as previously
shown.
•
Press the NAMED Soft Key to proceed with Changing the
Setpoint - Named Product change as shown previously.
•
Press the EXIT Soft Key to return to the Standard Display.
MENU
Figure 54: PRODUCT and SETPOINT are displayed
The NAMED PRODUCT / NUMERIC SETPOINT prompt
will appear as shown (Figure 55).
59
Operating Instructions
Starting the Diesel Engine
Diesel engine preheats and starts are automatic in both
Continuous Mode and Cycle Sentry Mode. The engine will
preheat and start as required when the unit is turned on. The
engine preheat and start will be delayed in Cycle Sentry Mode
if there is no current need for the engine to run. If any keys are
being pressed on the HMI Control Panel the engine will not
preheat and start until 10 seconds after the last key is pressed.
NOTE: If the unit is equipped with optional Electric Standby
there may be some additional prompts before the engine will
start. See STARTING THE ELECTRIC MOTOR on the
following pages for details.
CAUTION: The engine may start automatically any time the
unit is turned on.
WARNING: Never use starting fluid.
When the engine is preparing to start the HMI Control Panel
will display the engine start screen (Figure 56). The preheat
buzzer sounds during the engine preheat and crank sequence.
60
ON
DIESEL ENGINE STARTING
OFF
Figure 56: Engine Start Screen
After the engine is started the display returns to the Standard
Display of temperature and setpoint.
Operating Instructions
Starting the Electric Motor
Units equipped with the SmartPower option only.
Electric Power Receptacle: The electric power receptacle
is used to connect the unit to an appropriate electric power
source for electric standby operation (Figure 57). The electric
power receptacle is usually mounted on the trailer below the
HMI Control Panel. Make sure the unit and the power supply
are turned off before connecting or disconnecting a power
cord.
Electric motor starting is automatic in both Continuous Mode
and Cycle Sentry Mode. The motor will start as required when
the unit is turned on. If any keys are being pressed on the HMI
Control Panel prior to the motor start, the motor start will be
delayed until 10 seconds after the last key is pressed.
CAUTION: The motor may start automatically any time the
unit is turned on.
Figure 57: Electric Power Receptacle
When the motor is preparing to start the HMI Control Panel
will display the motor start screen (Figure 58). The preheat
buzzer sounds for 20 seconds before the electric motor starts.
ON
ELECTRIC MOTOR STARTING
OFF
Figure 58: Motor Start Screen
61
Operating Instructions
Switching from Diesel to Electric
Units equipped with the SmartPower option only.
If the Diesel to Electric Auto-Switch Enabled feature in
Guarded Access is set YES then the unit will automatically
switch to Electric Mode operation when standby power is
connected and available.
If the Diesel to Electric Auto-Switch Enabled feature in
Guarded Access is set NO then the prompt screen (Figure 59)
will appear when standby power is connected and available.
ELECTRIC STANDBY DETECTED
ON
OFF
DO YOU WISH TO SWITCH TO
ELECTRIC?
YES
NO
Figure 59: Standby Power Connected
If NO is selected, then the unit will continue to operate in
Diesel Mode. If YES is selected then the display will briefly
show the screen in Figure 60.
62
ON
PROGRAMMING ELECTRIC
STANDBY
OFF
PLEASE WAIT
Figure 60: YES Selected
Electric Mode operation will briefly be confirmed. If unit
operation is required the electric motor will start as shown
previously under STARTING THE ELECTRIC MOTOR.
If the Diesel to Electric Auto-Switch Enabled feature in
Guarded Access is set NO then the unit can also be switched
from Diesel Mode to Electric Mode operation using the
Electric Standby Selection from the Main Menu as shown later
in this section.
Operating Instructions
Switching from Electric to Diesel
Units equipped with the SMARTPOWER option only.
If the Electric to Diesel Auto-Switch Enabled feature in
Guarded Access is set YES then the unit will automatically
switch to Diesel Mode operation when standby power is turned
off or is no longer available.
If the Electric to Diesel Auto-Switch Enabled feature in
Guarded Access is set NO and standby power is disconnected
or fails, the unit will not automatically switch to Diesel Mode.
This is primarily designed to prevent unauthorized diesel
engine starts when the truck is indoors or on a ferry where
engine operation is strictly prohibited. If the Electric to Diesel
Auto-Switch Enabled feature in Guarded Access is set NO then
the prompt screen (Figure 61) will appear when standby power
is turned off or is no longer available.
ELECTRIC STANDBY NOT DETECTED
ON
OFF
DO YOU WISH TO SWITCH TO
DIESEL?
YES
NO
Figure 61: Standby Power is Off
If YES is selected then the display will briefly show the screen
in Figure 62.
ON
OFF
PROGRAMMING DIESEL MODE
PLEASE WAIT
Figure 62: Yes Selected
63
Operating Instructions
Diesel Mode operation will briefly be confirmed. If unit
operation is required the diesel engine will start as shown
previously under STARTING THE DIESEL ENGINE.
If the Electric to Diesel Auto-Switch Enabled feature in
Guarded Access is set NO then the unit can also be switched
from Diesel Mode to Electric Mode operation using the Diesel
Selection from the Main Menu as shown later in this section.
Initiating a Manual Defrost Cycle
Defrost cycles are usually initiated automatically based on time
or demand. Manual defrost is also available
Manual defrost is available if the unit is running and the
evaporator coil temperature is less than or equal to 45 F (7 C).
NOTE: If the Rail Alternate feature is set YES defrost is
allowed with an evaporator coil temperature less than or
equal to 55 F (13 C).
ON
OFF
SET
POINT
35
GAUGES
°F
.8
35
SENSORS
MENU
Figure 63: Press Defrost Key
The display briefly shows [DEFROST], [PROGRAMMING
DEFROST - PLEASE WAIT] and then [DEFROST
STARTED] (Figure 64).
ON
DEFROST STARTED
OFF
Other features such as door switch settings may not allow
manual defrost under some conditions. To initiate a manual
defrost cycle, press the Defrost Key (Figure 63).
Figure 64: Defrost Started
64
Operating Instructions
The display then shows the Defrost display. The bar indicator
shows approximately how much time remains to complete the
defrost cycle. The bar indicator shows that the defrost cycle is
about 25% complete (Figure 65).
ON
DEFROST NOT AVAILABLE
OFF
ON
OFF
35
SET
POINT
GAUGES
SENSORS
MENU
Figure 66: Defrost Not Available
See Figure 67 for an overview of the Initiating a Manual
Defrost Cycle procedure.
Figure 65: Bar Indicator
If conditions do not allow a defrost cycle, the display shown in
Figure 66 will briefly appear. The display will then return to
the Standard Display.
65
Operating Instructions
ON
OFF
ON
SET
POINT
35
GAUGES
°F
.8
35
SENSORS
MENU
ON
Yes
DEFROST STARTED
OFF
ON
OFF
35
SET
POINT
GAUGES
SENSORS
DEFROST NOT AVAILABLE
OFF
No
Figure 67: Initiating a Manual Defrost Cycle
66
MENU
Operating Instructions
Terminating a Defrost Cycle
The defrost cycle terminates automatically when the coil
temperature is greater than or equal to 58 F (14 C) or the
defrost timer expires. Defrost can also be terminated by turning
the unit off and back on.
NOTE: If Rail Alternate is set YES the defrost cycle
terminates at 70 F (21 C) or if the defrost timer expires.
If the unit is operating in Cycle Sentry Mode, the Cycle Sentry
Icon will be present in the upper right corner of the display as
shown below. If the Cycle Sentry Icon (Figure 68) is not
present the unit is operating in Continuous Mode.
ON
OFF
Selecting Cycle Sentry or
Continuous Mode
When Cycle Sentry Mode is selected the unit will start and stop
automatically to maintain setpoint, keep the engine warm and
the battery charged. When Continuous Mode is selected, the
unit starts automatically and runs continuously to maintain
setpoint and provide constant airflow.
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
Figure 68: Cycle Sentry Icon
If allowed by OptiSet Plus, Cycle Sentry Mode or Continuous
Mode is selected by pressing the Cycle Sentry/Continuous Key
as shown in Figure 69.
IMPORTANT: Cycle Sentry or Continuous Mode may not be
selectable if OptiSet Plus is in use.
See Figure 73 for an overview of the Selecting Cycle Sentry
or Continuous Mode procedure.
67
Operating Instructions
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
Figure 69: Cycle Sentry/Continuous Key
NOTE: Cycle Sentry Mode or Continuous Mode can also be
selected using the Main Menu > Mode Submenu.
If the unit is in Cycle Sentry Mode, pressing the Cycle
Sentry/Continuous Key changes the mode from Cycle Sentry
Mode to Continuous Mode. The display confirms the change,
as shown in Figure 70.
ON
OFF
PROGRAMMING CONT MODE
PLEASE WAIT
Figure 70: Continuous Mode
The new mode is confirmed for 3 seconds (Figure 71).
ON
OFF
NEW SYSTEM MODE IS
CONTINUOUS
Figure 71: New Mode Confirmed
68
Operating Instructions
The display then returns to the Standard Display. In the
example shown in Figure 72 the absence of the Cycle Sentry
Icon indicates that the unit is running in Continuous Mode.
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
Figure 72: Cycle Sentry Icon Not Shown =
Continuous Mode
Pressing the Cycle Sentry/Continuous Key again allows the
operator to change back to Cycle Sentry Mode operation.
IMPORTANT: If the unit is in Cycle Sentry Null and the
mode is switched to Continuous Mode, the unit will start
automatically.
IMPORTANT: Cycle Sentry or Continuous Mode may not be
selectable if OptiSet Plus is in use.
69
Operating Instructions
ON
OFF
SET
POINT
35
GAUGES
°F
.8
35
SENSORS
MENU
ON
OFF
PROGRAMMING CONT MODE
PLEASE WAIT
ON
OFF
SET
POINT
35
Continuous Mode
Selected
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
ON
OFF
NEW SYSTEM MODE IS
CONTINUOUS
Figure 73: Selecting Cycle Sentry or Continuous Mode
70
GAUGES
°F
.8
SENSORS
35
MENU
Operating Instructions
Using the Gauges Key
The GAUGES Key allows the operator to view the unit
gauges. If the function of this key has been reassigned, the
GAUGES Menu is also available in the Maintenance Menu.
BATTERY VOLTAGE
13.8
ON
OFF
EXIT
LOCK
BACK
v
NEXT
To access the GAUGES Menu, press the GAUGES Key
(Figure 74).
Figure 75: Gauge Display Locked
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
The gauges and I/O conditions available are shown on the next
page. Not all gauges or I/O conditions may appear depending
on unit configuration and software revision.
To return to the Standard Display press the EXIT Key.
Figure 74: Gauges Key
The first gauge display will appear. Press the NEXT and
BACK Keys to scroll through the gauges. Pressing the LOCK
Key will lock the current gauge on the display (Figure 75).
Gauges Available
Coolant Temperature: Displays the temperature of the
engine coolant.
Coolant Level: Displays the coolant level in the overflow
tank.
Engine Oil Pressure: Displays the engine oil pressure as
OK or LOW.
71
Operating Instructions
Engine Oil Level Switch: Displays the engine oil level as
OK or LOW.
Amps: Displays the current flow in amps flowing to or from
the unit battery.
Battery Voltage: Displays the voltage of the unit battery.
I/O (Input/Output State): Displays the current state of the
input/output devices listed here:
• High Speed
Relay/Electric Heat
• Spare Output 1
• Run Relay
• Spare Output 2
Accessory Battery Voltage: Displays the voltage at the
alternator.
• Run Relay Feedback
• Spare Output 3
Engine RPM: Displays the engine speed in RPMs.
• Alternator Excite
Output
• Spare Output 4
Fuel Level Sensor: Displays the fuel level if a fuel level
sensor is installed.
• Defrost Damper
• Spare Output 5
• Heat Output
• Fresh Air Exchange
Output
• Motor RPM
• Fresh Air Exchange
Feedback
• Spare Digital Input 1
• Diesel/Electric Relay
(SmartPower units only)
• Spare Digital Input 2
• Electric Ready Input
(SmartPower units only)
Discharge Pressure: Displays the unit discharge pressure.
(ETV units only)
Suction Pressure: Displays the unit suction pressure. (ETV
units only)
ETV Position: Displays the current position of the ETV
valve. (ETV equipped units only)
Fresh Air Exchange: Displays the current position of the
optional Fresh Air Exchange Door.
72
Operating Instructions
• Spare Digital Input 3
• Electric overload
(SmartPower units only)
• Spare Digital Input 4
• Hot Gas Bypass (ETV
units only)
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
• Spare Analog Input 1
• Spare Analog Input 2
Figure 76: Sensors Key
Using The Sensors Key
The SENSORS Key allows the operator to view the unit
gauges. If the function of this key has been reassigned, the
SENSORS Menu is also available in the Maintenance Menu.
The first sensor display will appear. Press the NEXT and
BACK Keys to scroll through the sensors. Pressing the LOCK
Key will lock the current sensor on the display. (Figure 77)
To access the SENSORS Menu, press the SENSORS Key:
CONTROL DISCHARGE AIR TEMPERATURE
ON
OFF
48. 3
EXIT
LOCK
BACK
°F
NEXT
Figure 77: Next, Back, Lock Keys
73
Operating Instructions
The sensors available are shown below.
To return to the Standard Display press the EXIT Key.
* Spare 1 Temperature: Displays the temperature of the
spare 1 temperature sensor.
Sensors Available
* Log Sensor 1: Displays the temperature of the
CargoWatch Data Logger temperature sensor 1.
Control Return Air Temperature: Displays the
temperature of the control return air sensor.
* Log Sensor 2: Displays the temperature of the
CargoWatch Data Logger temperature sensor 2.
Display Return Air Temperature: Displays the
temperature of the display return air sensor.
* Log Sensor 3: Displays the temperature of the
CargoWatch Data Logger temperature sensor 3.
Control Discharge Air Temperature: Displays the
temperature of the control discharge air sensor.
* Log Sensor 4: Displays the temperature of the
CargoWatch Data Logger temperature sensor 4.
Display Discharge Air Temperature: Displays the
temperature of the display discharge air sensor.
* Log Sensor 5: Displays the temperature of the
CargoWatch Data Logger temperature sensor 5.
Temperature Differential: Displays the calculated
difference between the control return air sensor and the control
discharge air sensor.
* Log Sensor 6: Displays the temperature of the
CargoWatch Data Logger temperature sensor 6.
Evaporator Coil Temperature: Displays the temperature
of the evaporator coil sensor.
Ambient Air Temperature: Displays the temperature of the
ambient air sensor.
74
Board Temperature Sensor: Displays the internal
temperature of the HMI Control Panel pc board.
* If sensors have been added.
Operating Instructions
Using the Main Menu
The Main Menu contains several additional submenus that
allow the operator to view information and modify unit
operation. To access the Main Menu press the MENU Key
(Figure 78).
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
MAIN MENU
ON
PRETRIP
LANGUAGE
ALARMS
OFF
GAUGES
EXIT
SELECT
UP
DOWN
Figure 79: Pretrip Submenu
Main Menu Choices
Each of these Main Menu choices will be explained in
following pages of this chapter:
Figure 78: Menu Key
The first Main Menu choice will appear. Press and hold the UP
and DOWN Keys to scroll through the menu choices. When
the desired selection is shown on the display, press the
SELECT Key to access it. The Pretrip submenu is displayed
(Figure 79).
To return to the Standard Display press the EXIT Key.
Pretrip: A Pretrip Test verifies unit operation.
Flash Drive: If a properly configured USB Flash Drive is
currently connected to the USB Port on the unit Control Panel,
the Flash Drive Menu will appear as a Main Menu selection.
Languages (If Enabled): If more than one language is
enabled from the Guarded Access > Language Menu, this
menu item will appear.
75
Operating Instructions
Alarms: The Alarm Menu allows the operator to view any
active alarms, and allows most alarms to be cleared.
Gauges: The Gauges Menu allows the operator to view the
unit gauges and I/O conditions.
Sensors: The Sensors Menu allows the operator to view the
unit and CargoWatch Data Logger temperature sensors.
Data Logger (CargoWatch): The CargoWatch Data Logger
is physically located in the HMI Control Panel. It can support
up to 6 optional temperature sensors.
Hourmeters: The Hourmeters Menu allows the operator to
view the unit hourmeters that have the view feature enabled in
the Guarded Access menu.
Mode: The Mode Menu allows the operator to change the unit
operating modes that have been enabled in Guarded Access.
Keypad Lockout: If enabled in Guarded Access > Main
Menu Configuration, the keypad can be locked to prevent
unauthorized use.
Start Sleep Mode: If this feature enabled in Guarded Access
> Main Menu Configuration, the operator can select and set
Sleep Mode from the Mode Menu.
76
SmartPower™ Electric Standby Option: The
Diesel/Electric Standby selection from the Main Menu allows
the operator to manually select Diesel or Electric Mode
operation on units equipped with the electric standby
SmartPower option.
Adjust Brightness: The brightness of the HMI Control
Panel display can be adjusted to allow for changing ambient
light conditions.
Time: The Time and Date held by the HMI Control Panel can
be checked. Time and Date cannot be changed from the Main
Menu.
Clear All ECU Faults: Pressing this key will clear all
existing Engine Control Unit (ECU) Fault Codes.
Pretrip
Pretrip Test verifies unit operation. This display allows a
Pretrip Test to be selected and initiated by the operator. If the
Pretrip Test is entered with the unit shut down a Full Pretrip
Test with device amp checks will be performed. If the Pretrip
Test is entered with the unit running in either Diesel or Electric
Operating Instructions
Mode a Running Pretrip Test is performed. Test results are
reported as PASS, CHECK or FAIL when the Pretrip Test is
completed.
Pretrip Test Conditions
•
Current unit settings are saved and restored at the end of
the Pretrip Test or if the unit is turned off and back on.
•
Pretrip Test can be run in either Diesel or Electric Mode.
•
The unit will auto switch from Diesel Mode to Electric
Mode or from Electric Mode to Diesel Mode during a
Pretrip Test if these features are enabled and the auto
switch conditions occur.
Conditions where Pretrip Tests are not allowed
•
If any shutdown alarms are present. Pretrip tests are
allowed with some Check and Log alarms.
•
If the unit is in Sleep Mode.
•
If the unit is in Service Test Mode, Output Test Mode or
Evacuation Mode.
Pretrip Test Sequence
Pretrip tests proceed in the order shown below. A Full Pretrip
Test includes all tests. A Running Pretrip Test is started with
the engine or motor running and does not include the Amp
Checks or Engine Start Check.
Amp Checks - Each electrical control component is energized
and the current drawn is confirmed as within specification.
Engine Start - The Engine will start automatically.
Defrost - If the coil temperature is below 45 F (7 C), a defrost
cycle is initiated.
RPM Check - The engine RPM in high and low speed is
checked during the Cool Check.
Cool Check - The ability of the unit to cool in low speed is
checked.
Heat Check - The ability of the unit to heat in low speed is
checked.
Report Test Results - The test results are reported as PASS,
CHECK or FAIL when the Pretrip Test is completed. If test
results are CHECK or FAIL alarm codes will exist to direct the
technician to the source of the problem.
77
Operating Instructions
Pretrip Test Considerations
Performing a Pretrip Test
When performing a Pretrip Test, the following issues should be
considered.
If a Pretrip Test is initiated with the engine shut down a Full
Pretrip Test will be performed. If a Pretrip Test is initiated with
the engine or motor running a Running Pretrip Test is
performed.
•
If running a Pretrip Test on a trailer loaded with dry cargo,
insure that proper airflow can occur around the load. If the
load restricts airflow, false test results may occur. Also,
Precedent units have high refrigeration capacity which
results in rapid temperature changes. Sensitive dry cargo
may be damaged as a result.
•
If running a Pretrip Test on a trailer that has just been
washed down, the extremely high humidity inside the
trailer may result in false test results.
•
If running a Pretrip Test on a trailer loaded with sensitive
cargo, monitor the load temperature during the test as
normal temperature control is suspended during pre-trip
operation.
•
78
Always perform Pretrip Tests with the trailer cargo doors
closed to prevent false test failures.
•
Before initiating a Pretrip Test, clear all alarm codes.
•
To stop a Pretrip Test at any time turn the unit off.
Pretrip Tests are initiated using the Pretrip Menu. From the
Standard Display, press the MENU Key (Figure 80).
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
Figure 80: Menu Key
Operating Instructions
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Pretrip Menu. When the Pretrip Menu is
shown press the SELECT Key to start a Pretrip Test (Figure
81).
ON
PROGRAMMING PRETRIP MODE
OFF
MAIN MENU
ON
PRETRIP
LANGUAGE
ALARMS
OFF
GAUGES
EXIT
SELECT
UP
DOWN
Figure 81: Select Key
The display will briefly show PROGRAMMING PRETRIP
MODE (Figure 82). If the unit is not running a Full Pretrip Test
will be initiated. If the unit is running in either Diesel or
Electric Mode a Running Pretrip Test will be performed.
Figure 82: Programming Trip Mode
If all alarms were not cleared a prompt appears (Figure 83).
Exit the Pretrip Test, clear all alarms and repeat the Pretrip
Test.
ON
OFF
NO PRETRIP -- ALARM ACTIVE
EXIT
Figure 83: Alarms Not Cleared
79
Operating Instructions
If all alarms were cleared, the Pretrip Test display appears
(Figure 84).
NON-RUNNING PRETRIP
TEST 1 OF 26
ON
OFF
SENSOR CHECK
HOUR
METERS
SENSORS
GAUGES
Figure 84: Pretrip Test
•
The top line of the display indicates the unit is performing
the non-running portion of the Pretrip Test.
•
The second line measures test progress. The number of
tests completed of the total number of tests to be
performed is shown. In the example above the unit is
performing Test 1 of 26, Sensor Check.
•
80
The soft keys may be used during the Pretrip Test to select
the Hourmeter, Gauge or Sensor menus.
•
To stop a Pretrip Test at any time turn the unit off. This
will generate Alarm Code 28 Pretrip Abort. Other alarm
codes may also be generated. This is normal when the
Pretrip Test is halted before completion.
When the non-running tests are complete the unit will start
automatically and continue with the Running Pretrip Test. In
the example shown in Figure 85 the unit is in the Running
Pretrip and is performing Test 21 of 26, Cool Test.
RUNNING PRETRIP
TEST 21 OF 26
ON
OFF
COOL TEST
HOUR
METERS
SENSORS
GAUGES
Figure 85: Cool Test
When all tests are complete, the results are reported as PASS,
CHECK or FAIL (Figure 86). If the results are CHECK or
FAIL, the accompanying alarm codes will direct the technician
to the cause of the problem.
Operating Instructions
PRETRIP
PASS
ON
OFF
EXIT
Figure 86: Pretrip Pass
If the Pretrip Test results are CHECK or FAIL the problem
should be diagnosed and corrected by a Thermo King service
technician before the unit is released for service.
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
See Figure 87 for an overview of the Performing a Pretrip
Test procedure.
81
Operating Instructions
Yes
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
ON
PROGRAMMING PRETRIP MODE
OFF
OFF
Alarms Cleared?
NON-RUNNING PRETRIP
TEST 1 OF 26
ON
SENSOR CHECK
HOUR
METERS
SENSORS
GAUGES
RUNNING PRETRIP
TEST 21 OF 26
ON
OFF
COOL TEST
HOUR
METERS
PRETRIP
ON
LANGUAGE
NO PRETRIP -- ALARM ACTIVE
ALARMS
OFF
GAUGES
EXIT
SELECT
UP
DOWN
OFF
EXIT
PRETRIP
PASS
ON
Exit Pretrip Test, clear alarms,
restart Pretrip Test.
Figure 87: Performing a Pretrip Test
82
GAUGES
No
MAIN MENU
ON
SENSORS
OFF
EXIT
Operating Instructions
Flash Drive
If a properly configured USB Flash Drive is currently
connected to the USB Port on the unit Control Panel, the Flash
Drive Menu will appear as a Main Menu selection. If a
properly configured USB Flash Drive is connected to the USB
Flash Drive connector, this feature allows the operator to select
the desired Flash Drive function. If enabled when the Flash
Drive was configured, the following functions may be
available:
Flash Drive Icon
•“The USB Icon (Figure 88) will appear in the
upper left corner of the display as shown below
when a USB Flash Drive is inserted in the USB
Flash Drive USB Port on the Unit Control
Panel.
•“The USB Icon will also appear if a computer
is connected to the USB PC Computer USB
Port on the Unit Control Panel.
Download
•
Download the ServiceWatch Data Logger
•
Download the CargoWatch Data Logger
Flashload
OFF
•
Flash load Base Controller Software
•
Flash load HMI Control Panel Software
OptiSet Plus
•
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
Figure 88: Flash Drive Icon
SEND
•
•
ON
Send OptiSet Plus files
RETRIEVE
•
Retrieve OptiSet Plus files
If a USB Flash Drive is not connected to the unit, this feature
will not appear in the Main Menu.
83
Operating Instructions
Selecting the Flash Drive Menu
from the Main Menu (If Already
Connected)
To select the Flash Drive Menu, press the MENU Key (Figure
89). The Main Menu will appear.
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
Figure 89: Menu Key
If a properly configured USB Flash Drive is connected to the
Flash Drive Only USB Port on the Control Panel, the Flash
Drive Menu will appear as a main Menu selection. Press the
UP or DOWN Key as required to choose the Flash Drive
Menu. When the Flash Drive Menu is shown press the
SELECT Key to select the Flash Drive menu. (Figure 90).
84
MAIN MENU
ON
FLASH DRIVE
PRETRIP
LANGUAGES
OFF
ALARMS
EXIT
SELECT
UP
DOWN
Figure 90: Flash Drive Menu
Flash Drive (If Connected While the Unit is Turned
On)
If a properly configured USB Flash Drive is connected to the
USB Port on the unit Control Panel while the unit is turned on,
a Flash Drive indication will appear for several seconds. Then
the Flash Drive Menu will be shown (Figure 91).
Operating Instructions
ON
OFF
FLASH DRIVE DETECTED
EXIT
DOWN
LOAD
FLASH
LOAD
OPTISET
PLUS
Figure 91: Flash Drive
Removing the Flash Drive
If the Flash Drive is disconnected, the display shown in Figure
92 will appear for 30 seconds and the display will return to the
Standard Display. To return to the Standard Display
immediately press the EXIT Soft Key.
ON
OFF
FLASH DRIVE REMOVED
EXIT
HELP
Figure 92: Flash Drive Removed
If the HELP Soft Key is pressed the display shown in Figure 93
will appear.
FLASH DRIVE REMOVED
ON
OFF
PLEASE CHECK THE FLASH DRIVE FOR
PROPER INSERTION – REMOVE AND
REINSERT
EXIT
Figure 93: Help Soft Key Pressed
85
Operating Instructions
Languages (If Enabled)
Available Languages
If more than one language is enabled from the Guarded Access
> Language Menu, this menu item will appear. If only one
language is enabled, this menu will not appear. The Language
Menu allows the operator to select a language from of enabled
languages. All subsequent displays are shown in the selected
language. English is the default language. See the Guarded
Access Language Setup Menu in the Diagnostic Manual for
technical details.
The following languages are available:
If Languages are not enabled from the Guarded Access Menu,
this feature will not appear in the Main Menu.
IMPORTANT: Exercise care when changing languages, as
once changed all HMI Control Panel displays will be in the
new language.
• English
• French
• Spanish
Selecting an Alternate Language
To select an alternate language, press the MENU Key (Figure
94).
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
Figure 94: Menu Key
The Main Menu will appear. If more than one language is
enabled, the Language Menu will appear as a main Menu
selection (Figure 95). Press the UP or DOWN Key as required
to choose the Language Menu. When the Language Menu is
shown press the SELECT Key to select the Language menu.
86
Operating Instructions
The display will briefly show PROGRAMMING
LANGUAGE - PLEASE WAIT in the new language. The
display will then return to the Language Menu, but will show
the new language. Español (Spanish) is shown in Figure 97.
MAIN MENU
ON
PRETRIP
LANGUAGE
ALARMS
OFF
GAUGES
EXIT
SELECT
UP
DOWN
Figure 95: Main Menu
The Language menu will appear as shown in Figure 96. Press
the + or - Keys to select the desired language. Only languages
enabled from the Guarded Access Menu are available. When
the desired language is shown (example is Español [Spanish])
press the YES Key to confirm the choice.
Figure 97: New Language (Example: Español)
Repeat the process to select a different language. To select a
different Main Menu item press the NEXT (SIGUIENTE) Key.
To return to the Standard Display press the EXIT (SALIDA)
Key.
All displays will now be in the new language. Español
(Spanish) is shown in Figure 98.
Figure 96: Language Menu
87
Operating Instructions
Figure 98: New Language (Example: Español)
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
See Figure 99 for an overview of the Languages selection
procedure.
88
Operating Instructions
ON
OFF
SET
POINT
35
GAUGES
NEW LANGUAGE WILL BE
°F
.8
SENSORS
35
MENU
ON
OFF
-
MAIN MENU
ON
ON
DEUTSCH
USE +/- TO CHANGE
+
YES
OK?
NO
OFF
SET
POINT
35
MESSGE
RAT
°F
.8
SENSORE
N
35
MENU
HAUPTMENU
PRETRIP
ON
LANGUAGE
SPRACHE
ALARMS
OFF
GAUGES
EXIT
SELECT
UP
DOWN
OFF
BEENDEN
AUSWHAL
WEITER
Figure 99: Languages (If Enabled)
89
Operating Instructions
Language Menu Quick Access
Should it be necessary at any time to change to English or any
other installed language, return to the Standard Display and
then press and hold the first and last soft keys for 5 seconds as
shown below. The Standard Display shown in Figure 100 is
Español (Spanish).
Figure 101: Select Desired Language
NOTE: All languages in the installed software can be
selected using this method.
Figure 100: Standard Display in Español
After 5 seconds the Language Menu will appear in the current
language as shown below. Press the + or - Keys to select the
desired language. When the desired language is shown press
the SI (YES) Key to confirm the choice (Figure 101).
Alarms
The Alarm Menu allows the operator to view any active
alarms, and allows most alarms to be cleared.
Log Alarms
If only Log Alarms exist the display shown in Figure 102 will
appear and the optional remote alarm light will light for 30
seconds when the unit is turned on.
90
Operating Instructions
Shutdown Alarms
If a Shutdown Alarm occurs while the unit is running it will be
indicated by all of the following (Figure 104):
LOG ALARMS ACTIVE
ON
GO TO MENU TO VIEW
OFF
EXIT
Figure 102: Log Alarms Exist
Check Alarms
If a Check Alarm condition occurs while the unit is running the
alarm icon will appear in the display as shown in Figure 103.
•
The Alarm Icon will appear.
•
The display, backlight and optional remote alarm light will
flash on and off.
•
The display will switch from normal video to reverse
video and back to normal video. (Light areas become dark
and dark areas become light.)
ON
OFF
ON
OFF
35
SET
POINT
GAUGES
35
SET
POINT
GAUGES
35
SENSORS
MENU
35
SENSORS
MENU
Figure 104: Reverse/Normal Video
Figure 103: Alarm Icon
91
Operating Instructions
Pretrip Alarms
Clearing Alarm Codes
If an alarm occurs during a Pretrip Test the alarm code will be
displayed as Pretrip Alarm XX, where XX is the alarm code.
Most alarm codes can be cleared conventionally from the
Alarm Menu using the CLEAR Key.
Alarm Codes When Switching Between Diesel and
Electric Mode
The following control and display sensor alarm codes can only
be cleared from the Maintenance Menu or Guarded Access
Menu:
If a shutdown alarm occurs that affects only Diesel Mode
operation and the unit is switched to electric, the Diesel Mode
shutdown alarm becomes an Electric Mode log alarm. This
allows the unit to run in Electric Mode without clearing the
shutdown alarm that is preventing Diesel Mode operation. If
the unit is switched back to Diesel Mode, the alarm again
become a Diesel Mode shutdown alarm and prevents unit
operation.
In the same manner, if a shutdown alarm occurs that affects
only Electric Mode operation and the unit is switched to diesel,
the Electric Mode shutdown alarm becomes a Diesel Mode log
alarm to allow Diesel Mode operation. If the unit is switched
back to Electric Mode, the alarm reverts to an Electric Mode
shutdown alarm and prevents unit operation. If the unit is
configured for electric to diesel Auto-Switch, it automatically
starts and runs in Diesel Mode if an electric shutdown occurs.
92
•
Alarm Code 03 Check Control Return Air Sensor
•
Alarm Code 04 Check Control Discharge Air Sensor
•
Alarm Code 203 Check Display Return Air Sensor
•
Alarm Code 204 Check Display Discharge Air Sensor
The following alarm codes clear automatically:
•
Alarm Code 64 Pretrip Reminder - Clears when a Pretrip
Test is performed.
•
Alarm Code 84 Restart Null - Clears when the unit is no
longer in a restart null due to a Prevent Alarm.
•
Alarm Code 85 Forced Unit Operation - Clears when the
unit is no longer running in a forced mode due to a Prevent
Alarm.
Operating Instructions
•
Alarm Code 91 Check Electric Ready Input - Clears
automatically when the unit starts running.
•
Alarm Code 92 Sensor Grades Not Set - Clears when the
sensor grade is changed from 5H.
ON
OFF
If the Limited Alarm Restarts feature is enabled the following
additional alarm codes may only be cleared from the Guarded
Access Menu. If this is the case, the CLEAR soft key will not
appear if the alarms are displayed from the Main Menu or the
Maintenance Menu.
•
Alarm Code 10 High Discharge Pressure
•
Alarm Code 23 Cooling Cycle Fault
•
Alarm Code 24 Heating Cycle Fault
•
Alarm Code 32 Refrigeration Capacity Low
35
SET
POINT
GAUGES
35
SENSORS
MENU
Figure 105: Menu Key
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Alarms Menu (Figure 106). When the
Alarms Menu is shown press the SELECT Key to select the
Alarms menu.
MAIN MENU
Displaying and Clearing Alarm Codes
Alarms are displayed and cleared using the Alarm Menu. From
the Standard Display, press the MENU Key (Figure 105).
ON
PRETRIP
LANGUAGE
ALARMS
OFF
GAUGES
EXIT
SELECT
UP
DOWN
Figure 106: UP/Down, Select Keys
93
Operating Instructions
The number of alarms (if more than one) and a list of the
alarms with the most recent alarm first will be shown. In the
example below, there are two alarms. The most recent is Alarm
Code 5 Check Ambient Temp Sensor (Figure 107).
1 OF 2 ALARMS
ON
5
CHECK AMBIENT TEMP SENSOR
64
PRETRIP REMINDER
64
x
OFF
EXIT
CLEAR
HELP
DOWN
1 OF 2 ALARMS
ON
5
CHECK AMBIENT TEMP SENSOR
64
PRETRIP REMINDER
x
OFF
EXIT
64
CLEAR
HELP
Figure 108: Down Key
DOWN
If the alarm situation has been resolved press the CLEAR Key
to clear the alarm (Figure 109).
Figure 107: Alarms Menu
1 OF 2 ALARMS
If necessary to view all alarms, scroll down using the DOWN
Key (Figure 108).
ON
5
CHECK AMBIENT TEMP SENSOR
64
PRETRIP REMINDER
x
OFF
EXIT
64
CLEAR
HELP
DOWN
Figure 109: Clear Key
94
Operating Instructions
The display will briefly show CLEARING ALARM 5 –
PLEASE WAIT. Then the Alarm Menu will reappear
(Figure 110).
Note that Alarm Code 64 Pretrip Reminder cannot be cleared
using the CLEAR Key. This alarm will clear automatically
when a Pretrip Test is run.
OFF
1 OF 1 ALARMS
ON
64
x
OFF
EXIT
64
HELP
SET
POINT
GAUGES
35
SENSORS
MENU
Figure 111: Unit Shutdown
PRETRIP REMINDER
CLEAR
35
ON
DOWN
The Alarm Menu display will display the Shutdown Alarm
Code. For additional information regarding the alarm shown
on the display, press the HELP Key (Figure 112).
1 OF 1 ALARMS
Figure 110: Pretrip Reminder
ON
66
x
If a serious condition occurs, the unit will be shut down to
prevent damage to the unit or the load. If this occurs, the Alarm
Icon will appear, the display and backlight will flash on and
off. (Figure 111)
OFF
EXIT
LOW ENGINE OIL LEVEL
64
CLEAR
HELP
DOWN
Figure 112: Help Key
95
Operating Instructions
A help message will appear. Press the EXIT Key to return to
the Alarms Menu (Figure 113). Check the oil level and add oil
as required, clear the alarm and restart the engine.
Important Alarm Notes
•
If an alarm will not clear, it may still exist. If the alarm is
not corrected, it will not clear or may be immediately set
again.
•
If an alarm cannot be cleared from the Main menu, the
Clear Key will not appear. These alarms must be cleared
from the Maintenance or Guarded Access Menus.
LOW ENGINE OIL LEVEL
ON
OFF
CHECK ENGINE OIL LEVEL. IF UNIT IS SHUT
DOWN REPAIR IMMEDIATELY. OTHERWISE
REPORT ALARM AT END OF DAY.
EXIT
See Figure 114 for an overview of the Displaying and
Clearing Alarm Codes procedure.
Figure 113: Exit Key
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
96
Operating Instructions
LOG ALARMS ACTIVE
ON
35
ON
GO TO MENU TO VIEW
OFF
ON
OFF
ON
OFF
OFF
EXIT
35
SET
POINT
GAUGES
35
SET
POINT
GAUGES
SET
POINT
GAUGES
1 OF 2 ALARMS
35
SENSORS
MENU
ON
35
SENSORS
MENU
PRETRIP REMINDER
ON
LANGUAGE
GAUGES
SELECT
UP
CLEAR
SENSORS
MENU
ON
DOWN
CHECK AMBIENT TEMP SENSOR
PRETRIP REMINDER
EXIT
OFF
ON
64
CHECK AMBIENT TEMP SENSOR
PRETRIP REMINDER
HELP
SET
POINT
GAUGES
66
x
CLEAR
HELP
DOWN
64
DOWN
OFF
EXIT
OFF
ON
64
HELP
MENU
EXIT
LOW ENGINE OIL LEVEL
64
CLEAR
HELP
DOWN
LOW ENGINE OIL LEVEL
PRETRIP REMINDER
CLEAR
35
SENSORS
1 OF 1 ALARMS
ON
64
EXIT
x
CLEAR
OFF
1 OF 1 ALARMS
5
64
x
OFF
DOWN
5
1 OF 2 ALARMS
35
HELP
64
x
EXIT
35
ON
64
EXIT
1 OF 2 ALARMS
PRETRIP
ALARMS
OFF
CHECK AMBIENT TEMP SENSOR
x
OFF
MAIN MENU
ON
5
64
DOWN
OFF
CHECK ENGINE OIL LEVEL. IF UNIT IS SHUT
DOWN REPAIR IMMEDIATELY. OTHERWISE
REPORT ALARM AT END OF DAY.
EXIT
Figure 114: Displaying and Clearing Alarm Codes
97
Operating Instructions
Gauges
The Gauges Menu allows the operator to view the unit gauges
and I/O conditions. The unit gauges can always be viewed
from the Main Menu. This is necessary if the GAUGES Soft
Key on the Standard Display has been reassigned to a different
function.
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Gauges Menu. When the Gauges Menu
is selected, press the SELECT Key to choose the Gauges menu
(Figure 116).
MAIN MENU
ON
PRETRIP
LANGUAGE
ALARMS
Displaying Gauges
OFF
GAUGES
EXIT
SELECT
UP
DOWN
Gauges are displayed using the Gauges Menu. From the
Standard Display, press the MENU Key (Figure 115).
Figure 116: Up, Down, Select Keys
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
Figure 115: Menu Key
98
The first gauge display will appear. Press the NEXT and
BACK Keys to scroll through the gauges and I/O conditions.
Pressing the LOCK Key will lock the current gauge on the
display (Figure 117).
Operating Instructions
Displaying Sensors
BATTERY VOLTAGE
13.8
ON
OFF
EXIT
LOCK
BACK
v
Sensors are displayed using the Sensors Menu. From the
Standard Display, press the MENU Key (Figure 118).
NEXT
ON
OFF
Figure 117: Next, Back, Lock Keys
The gauges and I/O conditions available are described in this
section of the manual. Not all gauges or I/O conditions may
appear depending on unit configuration and software revision.
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
Sensors
The Sensors Menu allows the operator to view the unit and
CargoWatch Data Logger temperature sensors. The sensors can
always be viewed from the Main Menu. This is necessary if the
SENSORS Soft Key on the Standard Display has been
reassigned to a different function.
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
Figure 118: Menu Key
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Sensors Menu. When the Sensors Menu
is selected, press the SELECT Key to choose the Sensors
menu.
The first sensors display will appear. Press the NEXT and
BACK Keys to scroll through the gauges and I/O conditions.
Pressing the LOCK Key will lock the current gauge on the
display (Figure 119).
99
Operating Instructions
CONTROL DISCHARGE AIR TEMPERATURE
ON
OFF
48. 3
EXIT
LOCK
BACK
°F
NEXT
Figure 119: Next, Back, Lock Keys
The sensors available are described in this section of the
manual.
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
Data Logger (CargoWatch)
The CargoWatch Data Logger is physically located in the HMI
Control Panel. It can support up to 6 optional temperature
sensors.
100
When shipped from the factory, CargoWatch sensors 1 and 2
are turned on to be logged and CargoWatch sensors 3 through 6
are turned off. Also, digital input 1 is turned on to be logged
and digital inputs 2 through 4 are turned off. Sensors and
digital inputs can be turned on, off and configured using the
CargoWatch menu in Guarded Access or with Wintrac. The
CargoWatch Data Logger can also be configured using the
USB Flash Drive OptiSet Plus Feature.
A Start of Trip can be sent to the unit ServiceWatch and
CargoWatch Data Loggers. In addition, the CargoWatch Data
Logger contents can be printed with a hand-held printer.
The ServiceWatch and CargoWatch Data Logger are accessed
using the Data Logger Menu. From the Standard Display, press
the MENU Key (Figure 120).
Operating Instructions
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
Figure 120: Standard Screen, Menu Key
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Data Logger Menu. When the Data
Logger Menu is selected, press the SELECT Key to choose the
Data Logger menu (Figure 121).
Sending Start of Trip Marker to
CargoWatch and ServiceWatch
Data Loggers
To send a Start of Trip marker to the CargoWatch and
ServiceWatch Data Loggers press the SELECT Key. The
display will briefly show START OF TRIP COMPLETE to
confirm that a Start of Trip marker was set in the CargoWatch
Data Logger (Figure 122).
DATA LOGGER
ON
OFF
START TRIP
PRINT/VIEW
EXIT
SELECT
UP
DOWN
MAIN MENU
ON
GAUGES
SENSORS
DATA LOGGER
OFF
HOURMETERS
EXIT
SELECT
UP
DOWN
Figure 122: Select Key, Start of Trip Complete
NOTE: The start of trip marker is sent to both the
CargoWatch and ServiceWatch data loggers.
Figure 121: UP, Down, Select Keys
The Data Logger Menu will appear.
101
Operating Instructions
Printing CargoWatch Data Logger Reports
Press the DOWN Key to select the PRINT / VIEW feature and
press the SELECT Key to choose Print/View.
The Print Data Menu will appear. The first Print Data Menu
allows the operator to print a Delivery Ticket using a hand held
printer. Pressing the SELECT Key will print the ticket (Figure
123). The Delivery Ticket is a short ticket that shows delivery
specific details including the current temperature. A sample
Delivery Ticket is shown in Figure 124.
OFF
DELIVERY TICKET
TRIP TICKET
EXIT
SELECT
UP
DOWN
Figure 123: Select Key, Print Delivery Ticket
102
Sensor
#1:
#2:
Min
35
---
SENSOR #1:
SENSOR #2:
Ave
35
---
Max
35
---
Last
35
--LOG SENSOR 1
LOG SENSOR 2
Figure 124: Sample Delivery Ticket
PRINT DATA
ON
B007
CONTROLLER VERSION NUMBER:
SR2
CONTROLLER TYPE:
6512
DATALOGGER VERSION NUMBER:
FAHRENHEIT
TEMPERATURE UNITS:
05/30/08 08:29:08
START:
05/30/08 09:18:33
FINISH:
2
SENSORS:
32.0
SETPOINT:
Pressing the DOWN Key allows the operator to print a Trip
Ticket using a hand held printer. Press the SELECT Key to
print the ticket (Figure 125). The Trip Ticket is a long ticket
that shows details for the current trip including a temperature
history. The Trip Ticket is also called a Journey Ticket. A
sample Trip Ticket is shown in Figure 126.
Operating Instructions
ON
OFF
TRAILER ID:
CONTROLLER VERSION NUMBER:
CONTROLLER TYPE:
DATALOGGER VERSION NUMBER:
TRIP TICKET
EXIT
SELECT
xxxxxxxxxx
A00021506190T3
UNIT SERIAL NUMBER:
CONTROLLER SERIAL NUMBER:
PRINT DATA
DELIVERY TICKET
UP
DOWN
TEMPERATURE UNITS:
START:
FINISH:
SENSORS:
SETPOINT:
Figure 125: Select Key, Print Trip Ticket
xxxxxxxxxx
B007
SR2
6512
FAHRENHEIT
05/30/08 09:50:08
05/30/08 13:07:33
1
32.0
30 - MAY - 2008
1305
35.0
1250
35.2
1235
35.1
1220
35.2
1205
35.1
30 - MAY - 2008
1150
35.0
1135
35.0
1120
35.0
1105
34.9
1050
35.0
1035
35.0
1020
1005
0950
35.0
35.1
35.1
SENSOR #1:
SENSOR #2:
LOG SENSOR 1
LOG SENSOR 2
Figure 126: Sample Trip Ticket
103
Operating Instructions
Hourmeters
The Hourmeters Menu allows the operator to view the unit
hourmeters that have the view feature enabled in the Guarded
Access menu. If the view feature for a particular hourmeter is
not enabled then that hourmeter will continue to accumulate
time but cannot be viewed from the Main Menu. However, all
hourmeters can be viewed from the Maintenance Menu, even if
they are not enabled. The hourmeters shown below are
implemented.
Viewing Hourmeters
Only Hourmeters that have been enabled in Guarded Access
are shown from the Main Menu. The Hourmeters can be
viewed only.
Hourmeters are displayed using the Hourmeter Display. From
the Standard Display, press the MENU Key (Figure 127).
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
Figure 127: Menu Key
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Hourmeter Menu. When the Hourmeter
Menu is selected, press the SELECT Key to choose the
Hourmeter Menu (Figure 128).
MAIN MENU
ON
SENSORS
DATA LOGGER
HOURMETERS
OFF
MODE
EXIT
SELECT
UP
DOWN
Figure 128: Select Key
104
Operating Instructions
Press the NEXT or PREVIOUS Key to scroll through the
hourmeters (Figure 129).
Hourmeter Names and Definitions
HOURMETERS
ON
TOTAL UNIT RUN HOURS
Only configured hourmeters that have been enabled in the
Viewable Hourmeter Setup Menu will be shown:
TOTAL ENGINE RUN HOURS
833
OFF
TOTAL ELECTRIC RUN HOURS
EXIT
SELECT
UP
DOWN
Figure 129: Up/Down Keys
Hourmeter names and definitions are shown in the table on the
next page in the order they appear. Only hourmeters enabled in
the Guarded Access Menu will be shown. To return to the
Standard Display, press the EXIT Key.
When shipped from the factory, only these hourmeters are
enabled for viewing from the Main Menu.
•
Total Unit Run Hours
•
Total Engine Run Hours
•
Total Electric Run Hours
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
Hourmeter
Name
Definition
Total Hours
Total number of hours the unit has been
turned on (protection hours).
Total Run
Time Hours
Total number of hours the unit has run in
both diesel and Electric Mode.
Engine Hours
Total number of hours the unit has run in
Diesel Mode.
Electric Run
Hours
Total number of hours the unit has run in
Electric Mode.
Total Run
Reminder 1
User Programmable - The number of hours
before a Total Unit Run Time Maintenance
Reminder 1 occurs.
105
Operating Instructions
Total Run
Reminder 2
User Programmable - The number of hours
before a Total Unit Run Time Maintenance
Reminder 2 occurs.
IMPORTANT: If a programmable hourmeter is not enabled
or the view for that hourmeter is not turned on it will not
appear in the display sequence.
Controller
Power On
Total hours the controller and HMI Control
Panel have been turned on.
Mode Menu
Pretrip
Reminder
User Programmable - number of hours
before a Pretrip Reminder occurs.
Engine
Reminder 1
User Programmable - The number of hours
before an Engine Run Time Maintenance
Reminder 1 occurs.
Engine
Reminder 2
User Programmable - The number of hours
before an Engine Run Time Maintenance
Reminder 2 occurs.
Electric
Reminder 1
User Programmable - The number of hours
before an Electric Run Time Maintenance
Reminder 1 occurs.
Electric
Reminder 2
User Programmable - The number of hours
before an Electric Run Time Maintenance
Reminder 2 occurs.
106
The Mode Menu allows the operator to change the unit
operating modes that have been enabled in Guarded Access.
Only Operating Modes that have been enabled from the
Guarded Access > Main Menu Configuration Menu will be
shown.
•
Turns Off Cycle Sentry Mode/Turns On Cycle Sentry
Mode (If Cycle Sentry is turned Off unit runs in
Continuous). Note that selecting Cycle Sentry Mode or
Continuous Mode can also be accomplished using the
Cycle Sentry Key to the right of the display.
•
Allows temperature to be displayed in either Fahrenheit or
Celsius degrees (if enabled from the Guarded Access >
Main Menu Configuration Menu).
•
Allows the optional Fresh Air Exchange door to be opened
or closed (if enabled from the Guarded Access >
Hardware Configuration Menu).
Operating Instructions
•
Allows Keypad Lockout to be selected (if enabled from
the Guarded Access > Main Menu Configuration Menu).
•
Start Sleep Mode (if enabled from the Guarded Access >
Main Menu Configuration Menu).
ON
OFF
When shipped from the factory, only the Cycle
Sentry/Continuous Mode is enabled.
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
If OptiSet Plus is in use some modes may not be available.
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
Using the Change Mode Menu
Mode changes are made using the Mode Menu. From the
Standard Display, press the MENU Key (Figure 130).
Figure 130: Menu Key
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Mode Menu. When the Mode Menu is
selected, press the SELECT Key to choose the Mode Menu
(Figure 131).
MAIN MENU
ON
DATA LOGGER
HOURMETERS
MODE
OFF
ELECTRIC STANDBY
EXIT
SELECT
UP
DOWN
Figure 131: Up, Down, Select Keys
107
Operating Instructions
The first enabled Change Mode Menu selection will appear. To
choose that function, press the SELECT Soft Key. To Scroll
through the enabled features in the Change Mode Menu, press
the UP and DOWN Soft Keys (Figure 132).
CHANGE MODE
ON
TURN ON CYCLE SENTRY MODE
FAHRENHEIT
KEYPAD LOCKOUT
OFF
START SLEEP MODE
EXIT
SELECT
UP
DOWN
Turn Cycle Sentry On or Off
Cycle Sentry Mode can be turned On or Off if Cycle Sentry
Mode is allowed by OptiSet Plus. If Cycle Sentry is turned off
the unit runs in Continuous Mode, unless Continuous Mode is
not allowed by OptiSet Plus. Either Cycle Sentry or
Continuous operation can be disabled via OptiSet Plus. From
the Main Menu > Change Mode menu choose Turn On/Off
Cycle Sentry Mode and press the SELECT Soft Key (Figure
133).
CHANGE MODE
Figure 132: Select, Up, Down Keys
ON
TURN ON CYCLE SENTRY MODE
FAHRENHEIT
KEYPAD LOCKOUT
Possible Mode selections are shown later in this section.
•
Only those modes that have been enabled will appear.
Only the Cycle Sentry Menu is enabled on factory units.
•
Not all modes may be available, depending on OptiSet
Plus usage and the settings of other programmable
features.
•
To return to the Standard Display press the EXIT Key.
•
The modes shown on the following pages may be
available.
108
OFF
START SLEEP MODE
EXIT
SELECT
UP
DOWN
Figure 133: Select Key
If the unit is running in Cycle Sentry Mode, press the SELECT
Soft Key (Figure 134) to turn off Cycle Sentry Mode as shown
below.
Operating Instructions
Select Temperature Units
CHANGE MODE
ON
OFF
TURN OFF CYCLE SENTRY
EXIT
SELECT
Figure 134: Select Key
Confirmation screens will appear briefly, the unit will switch to
Continuous Mode operation and the Cycle Sentry Icon will
disappear.
If this feature enabled in Guarded Access > Main Menu
Configuration, the operator can select temperature units to be
displayed as either degrees Fahrenheit or degrees Celsius.
From the Main Menu > Change Mode menu choose Fahrenheit
or Celsius and press the SELECT Soft Key (Figure 135).
CHANGE MODE
ON
TURN ON CYCLE SENTRY MODE
FAHRENHEIT
KEYPAD LOCKOUT
OFF
START SLEEP MODE
EXIT
SELECT
UP
DOWN
To turn Cycle Sentry back on press the SELECT Key again.
To leave this menu without changing the setting, press the
EXIT Soft Key. To return to the Standard Display press the
EXIT Soft Key again.
NOTE: Cycle Sentry Mode can also be turned on and off
using the Cycle Sentry Key on the HMI Control Panel.
Figure 135: Fahrenheit or Celsius, Select Key
Choose the desired Temperature Units using the UP and
DOWN Soft Keys and press the SELECT Soft Key to select
the choice (Figure 136).
109
Operating Instructions
feature is only available with setpoints above 32 F (0 C). The
feature is disabled with setpoints of 32 F (0 C) and below. This
feature may not be available if OptiSet Plus is in use.
TEMPERATURE UNITS
FAHRENHEIT
ON
CELSIUS
OFF
EXIT
SELECT
UP
DOWN
The Fresh Air Exchange feature should be used exactly as
specified by the customer.
From the Change Mode menu choose Open Fresh Air
Exchange and press the SELECT Soft Key (Figure 137).
Figure 136: Up, Down, Select Keys
CHANGE MODE
Temperatures will be displayed in the selected units.
ON
TURN ON CYCLE SENTRY MODE
FAHRENHEIT
OPEN FRESH AIR EXCHANGE
•
To leave this menu without changing the setting, press the
EXIT Soft Key. To return to the Standard Display press the
EXIT Soft Key again.
Fresh Air Exchange Open or Closed
If this option is installed and enabled in Guarded Access >
Main Menu Configuration, the Fresh Air Exchange option
allows fresh outside air to be drawn into the trailer and the
interior air to be exhausted by opening the Fresh Air Exchange
door. This feature is beneficial when hauling loads that release
gas as they ripen, such as potatoes. The Fresh Air Exchange
110
OFF
KEYPAD LOCKOUT
EXIT
SELECT
UP
DOWN
Figure 137: Select Key
The Fresh Air Exchange door will open. To close the Fresh Air
Exchange door press the SELECT Key again.
IMPORTANT: The Fresh Air Exchange feature should be
used exactly as specified by the customer.
Operating Instructions
•
•
•
The Fresh Air Exchange door will only be open when the
unit engine is running. The door will close when the
engine shuts down to preserve unit battery life.
The setting of the Fresh Air Exchange door will survive
power off/power on cycles - if the door is set to “Open” by
the operator it will continue to open any time the engine is
running until it is set to “Close” by the operator.
To leave this menu without changing the setting, press the
EXIT Soft Key. To return to the Standard Display press the
EXIT Soft Key again.
Keypad Lockout
If enabled in Guarded Access > Main Menu Configuration, the
keypad can be locked to prevent unauthorized use. If the
keypad is locked, only the On Key and Off Key function. The
keypad will remain locked even if the unit is turned off and
back on. If Keypad Lockout is active, press and hold any soft
key for 5 seconds to deactivate the feature. To turn the feature
on, from the Change Mode menu choose Keypad Lockout and
press the SELECT Soft Key (Figure 138).
CHANGE MODE
ON
TURN ON CYCLE SENTRY MODE
FAHRENHEIT
KEYPAD LOCKOUT
OFF
START SLEEP MODE
EXIT
SELECT
UP
DOWN
Figure 138: Select Key
A Confirmation Request will appear. To activate Keypad
Lockout press the YES Soft Key. To leave this menu without
turning the Keypad Lockout feature on, press the NO Soft Key
(Figure 139).
KEYPAD LOCKOUT
ON
OFF
ARE YOU SURE?
YES
NO
Figure 139: NO Soft Key
111
Operating Instructions
If the YES Soft Key was pressed Keypad Lockout is active.
Repeat the process to turn the Keypad Lockout feature off.
•
If the keypad is locked, only the On Key and Off Key
function. The keypad will remain locked even if the unit
is turned off and back on.
•
If Keypad Lockout is active, press and hold any soft key
for 5 seconds to deactivate the feature.
•
To return to the Standard Display press the EXIT Soft Key
again.
Start Sleep Mode
If this feature enabled in Guarded Access > Main Menu
Configuration, the operator can select and set Sleep Mode from
the Mode Menu. Sleep Mode is used to keep the engine warm
and the battery charged when the unit is not in use. When the
unit is Sleep Mode the display will show “SLEEP” and the
current time. To turn the feature on, from the Change Mode
menu choose Start Sleep Mode and press the SELECT Soft
Key (Figure 140).
112
CHANGE MODE
ON
TURN ON CYCLE SENTRY MODE
FAHRENHEIT
KEYPAD LOCKOUT
OFF
START SLEEP MODE
EXIT
SELECT
UP
DOWN
Figure 140: Select Soft Key
The following features are available in Sleep Mode. Follow
the display prompts to select and set the features.
•
Program Wakeup Time: This feature allows a wakeup
time to be specified. When the selected time is reached
the unit will start and resume normal operation.
•
If a Wakeup Time is selected the following features
are available:
•
Day to Wake Up: This feature allows the day the unit is to
wake up to be specified.
•
Hour to Wake Up: This feature allows the hour the unit is
to wake up to be specified.
Operating Instructions
•
Minute to Wake Up: This feature allows the minute the
unit is to wake up to be specified.
•
Run Pretrip on Wakeup: This feature allows a Pretrip
Test to be automatically run when the unit wakes up.
SmartPower Electric Standby Option
The Diesel/Electric Standby selection from the Main Menu
allows the operator to manually select diesel or Electric Mode
operation on units equipped with the electric standby
SmartPower option. The unit can also be programmed to
automatically switch to Electric Mode operation when standby
power is available and to automatically switch to Diesel Mode
operation if standby power fails or is removed. If the unit is
programmed to automatically switch from diesel to electric
and/or electric to diesel the associated screens do not appear.
•
If the unit is currently operating in Diesel Mode the
ELECTRIC STANDBY selection will appear in the Main
Menu.
•
If the unit is currently operating in Electric Mode the
Diesel Mode selection will appear in the Main Menu.
Electric Mode Operation
If a unit equipped with the electric standby SmartPower option
is running in Diesel Mode, the Diesel to Electric Auto-Switch
feature is set NO and the unit is connected to a source of
standby power, this feature allows the operator to manually
select Electric Mode operation. This feature does not appear if
the electric standby SmartPower option is not installed or if the
Diesel to Electric Auto-Switch feature is set YES.
Diesel Mode Operation
If a unit equipped with the electric standby SmartPower option
is running in Electric Mode, the Electric to Diesel Auto-Switch
feature is set NO, this feature allows the operator to manually
select Diesel Mode operation. This feature does not appear if
the electric standby SmartPower option is not installed or if the
Electric to Diesel Auto-Switch feature is set YES.
113
Operating Instructions
Switching from Diesel to Electric
If the unit is running in Diesel Mode and the Diesel to Electric
Auto-Switch Enabled feature in Guarded Access is set YES
then the unit will automatically switch to Electric Mode
operation when standby power is connected and available. The
screens shown below will not appear.
If the unit is running in Diesel Mode and the Diesel to Electric
Auto-Switch Enabled feature in Guarded Access is set NO, the
unit can be switched to Electric Mode using the Electric
Standby selection from the Main Menu.
From the Standard Display, press the MENU Key (Figure 141).
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
Figure 141: Menu Key
114
From the Main Menu choose Electric Standby and press the
SELECT Soft Key (Figure 142).
MAIN MENU
ON
HOURMETERS
MODE
ELECTRIC STANDBY
OFF
ADJUST BRIGHTNESS
EXIT
SELECT
UP
DOWN
Figure 142: Select Key
If the unit has standby power available and is turned on, the
electric standby run screen will appear. The new mode is
confirmed for 10 seconds. The unit will start and run in
Electric Mode. If electric standby power is not available or
fails, the display will prompt for a return to Diesel Mode as
shown below.
Any engine related Shutdown Alarms become Log Alarms
when the unit is switched to Electric Mode operation. If the
unit is switched back to Diesel Mode these alarms again
become Shutdown Alarms.
Operating Instructions
Electric Standby Power Fails or is
Disconnected
If the electric standby power source fails or is disconnected and
manual switching to Diesel Mode is selected, the unit will
prompt for a switch to Diesel Mode (Figure 143).
ELECTRIC STANDBY UNDETECTED
ON
OFF
DO YOU WISH TO SWITCH TO
DIESEL?
YES
NO
Switching from Electric to Diesel
If the unit is running in Electric Mode and the Electric to
Diesel Auto-Switch Enabled feature in Guarded Access is set
YES then the unit will automatically switch to Diesel Mode
operation when standby power is no longer available. The
screens shown below will not appear.
If the Diesel to Electric Auto-Switch Enabled feature in
Guarded Access is set NO and standby power is disconnected
or fails, the unit will not automatically switch to Diesel Mode.
This is primarily designed to prevent unauthorized diesel
engine starts when the truck is indoors or on a ferry where
engine operation is strictly prohibited.
From the Standard Display, press the MENU Key (Figure 144).
Figure 143: Diesel Mode Prompt
•
Pressing the YES Soft Key will switch unit operation back
to Diesel Mode.
•
Pressing the NO Soft Key will allow the unit to remain in
Electric Mode even though standby power is not available.
The unit will not run and Alarm Code 91 Check Electric Ready
Input will be set as a prevent alarm.
115
Operating Instructions
The new mode is confirmed for 10 seconds. The unit will start
and run in Diesel Mode.
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
Figure 144: Menu Key
From the Main Menu choose Diesel Mode and press the
SELECT Soft Key (Figure 145).
MAIN MENU
ON
HOURMETERS
MODE
DIESEL MODE
OFF
ADJUST BRIGHTNESS
EXIT
SELECT
UP
DOWN
Figure 145: Select Key
116
Any electric standby related Shutdown Alarms become Log
Alarms when the unit is switched to Diesel Mode operation. If
the unit is switched back to Electric Mode these alarms again
become Shutdown Alarms.
Adjust Brightness
The brightness of the HMI Control Panel display can be
adjusted to allow for changing ambient light conditions. The
choices available to the operator are HIGH, MEDIUM, LOW
and OFF. OFF actually results in a very dim screen suitable for
low light conditions.
Display brightness is adjusted using the Adjust Brightness
Menu. From the Standard Display, press the MENU Key
(Figure 146).
Operating Instructions
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
The Display Brightness menu will appear as shown below.
Press the UP or DOWN Soft Keys to select the desired display
brightness. When the desired brightness is shown press the
SELECT Soft Key to confirm the choice (Figure 148).
MENU
DISPLAY BRIGHTNESS WILL BE
OFF
ON
LOW
MEDIUM
OFF
Figure 146: Menu Key
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Adjust Brightness Menu. When the
Adjust Brightness is selected, press the SELECT Key to
choose the Adjust Brightness (Figure 147).
UP
DOWN
Figure 148: Select Key
MODE
ELECTRIC STANDBY
ADJUST BRIGHTNESS
OFF
SELECT
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
MAIN MENU
ON
EXIT
Time
TIME
EXIT
SELECT
UP
DOWN
Figure 147: Select Key
The Time and Date held by the HMI Control Panel can be
checked. Time and Date cannot be changed from the Main
Menu. The time and date is accessed using the Main Menu.
From the Standard Display, press the MENU Key (Figure 149).
117
Operating Instructions
ON
OFF
SET
POINT
35
°F
.8
GAUGES
SENSORS
35
The date and time held in the HMI Control Panel will be shown
on the display (Figure 151). Time and Date cannot be changed
from the Main Menu.
MENU
TIME MENU
ON
OFF
01:18 MONDAY 10 DEC 2012
EXIT
Figure 149: Menu Key
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Time Menu. When the Time Menu is
selected, press the SELECT Key to choose the Time Menu
(Figure 150).
Figure 151: Date and Time
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
MAIN MENU
ON
ELECTRIC STANDBY
Clear All ECU Faults
ADJUST BRIGHTNESS
TIME
OFF
CLEAR ALL ECU FAULTS
EXIT
SELECT
UP
DOWN
Figure 150: Select Key
118
Pressing this key will clear all existing Engine Control Unit
(ECU) Fault Codes. This may allow continued unit operation
should an ECU fault code result in engine shutdown.
Operating Instructions
•
Any Thermo King Alarm Codes associated with the
Engine Control Unit (ECU) Fault Codes will also be
cleared.
•
The Thermo King Alarm Codes and Engine Control Unit
(ECU) Fault Codes that were cleared can be viewed in the
ServiceWatch and ECU Data Loggers.
Engine Control Unit (ECU) Fault Codes are cleared using the
Clear All ECU Faults Menu. From the Standard Display, press
the MENU Key (Figure 152).
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Clear All ECU Faults Menu. When the
Clear All ECU Faults Menu is selected, press the SELECT
Key to choose the Clear All ECU Faults Menu (Figure 153).
MAIN MENU
ON
ADJUST BRIGHTNESS
TIME
CLEAR ALL ECU FAULTS
OFF
EXIT
SELECT
UP
DOWN
Figure 153: Select Key
The Clear All ECU Faults Prompt will appear. To clear all
Engine Control Unit (ECU) Faults and associated Thermo
King Faults press the CLEAR Soft Key (Figure 154).
Figure 152: Menu key
119
Operating Instructions
CLEAR ALL ECU FAULTS
ON
OFF
CLEAR ALL ECU FAULTS
EXIT
CLEAR
Figure 154: Clear Key
All Engine Control Unit (ECU) Faults and associated Thermo
King Faults will be cleared.
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
120
Optional Rear Remote Control Panel
The optional Rear Remote Control Panel is connected to the
control system and is used to operate the unit from a remote
location, typically at the rear of the trailer. In the illustration
below all display segments are turned on.
Rear Remote Control Panel
Functionality
The Rear Remote Control Panel functions that are available to
the user are determined by the setting of the Rear Remote
Control Action features in the Guarded Access / Unit
Configuration Menu. The Rear Remote Control Action can be
set to either RUN or STAND BY.
When the unit is turned on at the Rear Remote Control Panel
either the Standard Display or [STAnd by] will appear on the
display.
Figure 155: Rear Remote Control Panel
Rear Remote Control Action Set to
Run
If the Rear Remote Control Action is set to RUN the Standard
Display will be present on the Rear Remote Control Panel and
the unit will start and run when the Rear Remote Control Panel
ON Key is pressed. Pressing the Rear Remote Control Panel
OFF Key will turn the unit off.
121
Optional Rear Remote Control Panel
If the control system is powered up from the Rear Remote
Control Panel the Standard Display will appear in both the
Rear Remote Control Panel display and the unit Control Panel
display. When set to RUN the Rear Remote Control Panel
allows the following:
•
Turn the unit on and off
•
Unit will start and run
•
Change the Setpoint
•
Select Cycle-Sentry or Continuous Mode
•
Display discharge air temperature
•
Display and clear alarm codes
•
Initiate a manual defrost cycle
•
Send a Start of Trip marker to the ServiceWatch and
CargoWatch Data Loggers
•
Initiate a Pretrip Test
122
Rear Remote Control Action Set to
STAND BY
If the Rear Remote Control Action is set to STAND BY,
pressing the Rear Remote Control Panel ON Key will power
up the control system, but the unit will not start and run.
Pressing the Rear Remote Control Panel OFF Key will turn the
unit off. The Control Panel on the unit must be used to start and
stop unit operation.
In addition to turning the unit on and off, when set to STAND
BY the Rear Remote Control Panel allows the following:
•
Turn the unit on and off
•
Unit will not start and run
•
Change the Setpoint
•
Select Cycle Sentry or Continuous Mode (unless
prevented by OptiSet Plus)
•
Display discharge air temperature
•
Display and clear alarm codes
•
Send a Start of Trip marker to the ServiceWatch and
CargoWatch Data Loggers
Optional Rear Remote Control Panel
When in STAND BY, the unit will not start and run and a
defrost cycle or Pretrip Test cannot be started.
If the control system is powered up from the remote control
panel a stand by message will appear in both the remote control
panel display and the unit Control Panel display as shown in
Figure 156 and Figure 157.
When the StAnd bY display is shown, press the Select Key to
show the Remote Standard Display. When the remote standard
Display is shown, the setpoint and operating mode can be
changed, the discharge air temperature can be displayed and
alarms can be viewed and cleared. In addition, a Start of Trip
can be sent to the data loggers.
After the last key is pressed, the display will return to the
StAnd bY display shown in Figure 158 in about 10 seconds.
Figure 156: Rear Remote Control Panel Display
Figure 158: Press Select Key
Figure 157: Unit Control Panel Display
123
Optional Rear Remote Control Panel
Keypad
The nine touch sensitive keys are used to turn the unit on and
off. They also allow the setpoint to be changed, Cycle Sentry
or Continuous Mode to be selected, Alarm Codes and other
operating data to be displayed and Pretrip Tests and Defrost
Cycles to be performed. A Start of Trip marker can also be sent
to the data loggers.
Figure 159: Rear Remote Control Panel
ON Key
Turns the unit on as determined
by the setting of Rear Remote
Control Action.
OFF Key
Turns the unit off.
Up Arrow
Key
Increases setpoint or changes
other setting.
Down
Arrow Key
Decreases setpoint or changes
other setting.
Select Key
Allows Cycle-Sentry to be turned
on and off, displays the discharge
air temperature and alarms.
Enter Key
Executes a prompt or loads a
new setpoint or other setting.
Pretrip Key Initiates a Pretrip Test.
124
Optional Rear Remote Control Panel
TK Logo
Key
Sends a Start of Trip marker to
the data logger.
Initiates a defrost cycle if
Defrost Key
conditions allow.
Display
The display normally shows the Standard Display of return air
temperature and setpoint. The icons on either side of the
display indicate operating modes and alarms. The display
shown here has all possible segments lighted. The display
icons are defined below.
Cool Icon
This icon appears when the unit is
cooling.
Heat Icon
This icon appears when the unit is
heating.
Modulation
Icon
This icon appears when the unit is
in modulation.
Defrost Icon
This icon appears when the unit is
defrosting.
Cycle-Sentry This icon appears when the unit is
Icon
operating in Cycle-Sentry mode.
Alarm Icon
This icon appears when an alarm
condition has been detected.
This icon appears when the unit is
Electric
operating in the optional electric
Standby Icon
standby mode.
Figure 160: Rear Remote Control Panel
Setpoint
Icon
This icon appears when the
setpoint is being shown in the
display.
Not Used
This icon appears during a remote
control panel test but is not
currently used.
125
Optional Rear Remote Control Panel
Reading a Typical Remote
Standard Display
The Remote Standard Display shows the temperature and
setpoint. The icons at the sides of the display indicate operating
conditions.
•
The unit is cooling as shown by the icon at the upper left
side of the display.
•
The unit is operating in Cycle Sentry mode as shown by
the icon at the upper right side of the display.
Remote Control Panel Lockout
The remote control panel may be locked out during some
control system functions such as Service Test Mode, Interface
Board Test Mode and while setting programmable features. If
this is the case the display shown in Figure 162 will appear.
The display will return to the Remote Standard Display when
allowed by the control system.
Figure 161: Remote Standard Display
The Remote Standard Display in Figure 161 shows the
following information:
•
The temperature (typically return air temperature) is
35.8°F.
•
The setpoint is 35°F.
126
Figure 162: Remote Lock Out Display
Optional Rear Remote Control Panel
Turning the Unit ON or OFF
(Configured for STAND BY
Operation)
The control system is turned on by pressing the ON Key and
off by pressing the OFF Key. When the On Key is pressed the
remote display briefly shows all segments and then StAnd by
as shown in Figure 163. A stand by message will also appear
on the unit Control Panel display. The setpoint can be changed
but the unit will not start and run. Only the Select Key, Enter
Key and Up and Down Arrow Keys are functional. The unit
can be started and run by pressing the unit Control Panel ON
Key.
IMPORTANT: To change the setpoint, press the Select Key to
show the Remote Standard Display. The setpoint can now be
changed as shown on page 128.
Figure 163: Stand By Display
Turning the Unit On and Off
(Configured for RUN Operation)
The unit is turned on by pressing the ON key and off by
pressing the OFF key. When the ON key is pressed the remote
display briefly shows all segments and then COn FIg as the
control system initializes. Then the Remote Standard Display
will appear as shown in Figure 164. The unit will start and run
if necessary.
127
Optional Rear Remote Control Panel
Changing the Setpoint
The setpoint can be changed when the Remote Standard
Display is shown.
1.
When the Remote Standard Display is shown, press the
Up or Down Arrow Keys to select the desired setpoint
(Figure 165).
Figure 164: Standard Display
Figure 165: Press Up or Down Arrow Keys
128
Optional Rear Remote Control Panel
2.
When the desired setpoint is shown on the display,
immediately press the Enter Key to load the new setpoint.
The display will briefly show [Lod] and then the new
setpoint will reappear in the display.
IMPORTANT: The Enter key (Figure 166) must be pressed
or the setpoint will not be changed. The display will return to
the Standard Display and the setpoint will return to the old
setpoint in about 10 seconds if the Enter Key is not pressed.
Alarm Code 127 Setpoint Not Entered is set, to indicate that
the setpoint change was started but not completed.
Selecting Cycle-Sentry or
Continuous Mode
Cycle Sentry or Continuous Mode operation can be changed
using the Select Key.
1.
When the Remote Standard Display is shown, press the
Select key once to display the Cycle Sentry prompt.
Figure 167: Press Select Key
2.
Figure 166: Press Enter Key
Use the Up and Down Arrow Keys to chose either YES or
nO. Yes = Cycle Sentry Mode. nO = Continuous Mode.
IMPORTANT: Confirm that the correct setpoint is set.
129
Optional Rear Remote Control Panel
Displaying the Discharge Air
Temperature
The discharge air temperature can be shown using the Select
Key.
1.
Figure 168: Press Up or Down Arrow Keys
3.
When the Remote Standard Display is shown, press the
Select Key twice. The discharge air temperature will be
shown in the display for about 10 seconds.
When the desired selection is shown, press the Enter Key
(Figure 169) to load the setting. The display will briefly
show [Lod] and then the new selection will briefly appear
in the display.
Figure 170: Press Select Key Twice
2.
Figure 169: Press Enter Key
4.
130
The display will then return to the Remote Standard
Display.
The display will then return to the Remote Standard
Display.
Optional Rear Remote Control Panel
Viewing and Clearing Alarm
Codes
Alarm Codes can be displayed and cleared using the Select
Key.
1.
When the Remote Standard Display is shown, press the
Select Key three times. Any alarm codes present will be
shown in the display, with the most recent alarm code
shown first. If no alarm codes are present the display will
show [00].
Figure 172: Press Enter Key
3.
If any additional alarms are present, the next alarm will be
shown. If no other alarms are present the display will
briefly show [00].
Figure 171: Press Select Key Three Times
2.
To clear a displayed alarm code, press the Enter Key. The
display will briefly show CLEAr ALm.
Figure 173: No Alarms Display
4.
The display will then return to the Remote Standard
Display.
131
Optional Rear Remote Control Panel
Starting a Manual Defrost Cycle
If conditions allow, a manual defrost cycle can be initiated
using the Defrost Key.
1.
Press the Defrost Key. The defrost prompt [EnTEr dEF]
will appear in the display.
Figure 175: Press Enter Key
3.
The display will return to the Remote Standard Display.
The Defrost Icon will be shown in the display.
Figure 174: Press Defrost Key
2.
When the defrost prompt is shown, press the Enter Key to
start a manual defrost. The display will briefly show
LOAd dEF and then a defrost cycle will begin if
conditions allow.
Figure 176: Defrost Icon Displayed
4.
132
The defrost cycle will terminate automatically.
Optional Rear Remote Control Panel
Sending a Start of Trip Marker
2.
A Start of Trip marker can be sent to the data loggers using the
TK Logo Key.
1.
When the Start of Trip prompt is shown, press the Enter
Key to send a Start of Trip marker to the CargoWatch and
ServiceWatch data loggers. The display will briefly show
LOAd SOt.
Press the TK Logo Key. The Start of Trip [EnTEr SOt]
prompt will appear in the display.
Figure 178: Press Enter Key
Figure 177: Press TK Logo Key
3.
The display will then return to the Remote Standard
Display.
133
Optional Rear Remote Control Panel
Running a Pretrip Test
A Pretrip Test can be started using the Pretrip Key as long as
the unit is not in STAND BY. If the unit is not running when
the Pretrip Test is started a Full Pretrip Test will be performed.
If the unit is running when the Pretrip Test is started a Running
Pretrip Test will be performed.
1.
Clear any alarm codes as shown previously.
2.
Press the Pretrip Key. The Pretrip [EntEr PrE] prompt will
appear in the display.
3.
When the Pretrip prompt is shown, press the Enter Key to
start a Pretrip Test. The display will briefly show LOAd
PrE. If the unit is not running a Full Pretrip Test will be
performed. If the unit is running a Running Pretrip Test
will be performed.
Figure 180: Press Enter Key
Figure 179: Press Pretrip Key
134
Optional Rear Remote Control Panel
4.
When the Pretrip Test is running the display will show PrE
trP. The Control Panel will show the Pretrip Test progress.
5.
When the Pretrip Test is complete the display will show
PASS, CHEC or FAIL. Pressing the Select Key will return
to the Remote Standard Display.
Figure 181: Pretrip Display
Figure 182: Pass Pretrip Display
135
Loading and Enroute Inspections
This chapter describes pre-loading, post loading, and enroute
inspection procedures. Thermo King refrigeration units are
designed to maintain the required product load temperature
during transit. Follow these recommended loading and enroute
procedures to help minimize temperature related problems.
Pre-Loading Inspection
1.
Pre-cool products before loading. Note any variances on
the manifest.
2.
Inspect door seals and vent doors for condition and a tight
seal with no air leakage.
3.
Inspect the trailer inside and out. Look for:
136
•
Damaged or loose trailer skin and insulation
•
Damaged walls, air ducts, floor channels or “T”
flooring
•
Clogged defrost drain tubes
•
Blocked return air bulkhead
4.
Verify that the setpoint temperature is correct for your
cargo. Pre-cool the trailer as required.
5.
Supervise product loading to ensure sufficient air space
around and through the load. Airflow around the cargo
must not be restricted.
NOTE: If the warehouse is not refrigerated, operate the
unit with doors closed until cargo is ready to be loaded.
Then turn off the unit, open cargo doors and load cargo.
When cargo is loaded, close trailer doors and restart the
unit.
The unit can be operated with the cargo box doors open
if the truck is backed into a refrigerated warehouse and
the dock door seals fit tightly around the trailer.
Loading and Enroute Inspections
1
2
9
3
8
4
1.
2.
3.
4.
5.
7
6
5
6.
7.
8.
9.
Correct load height (trailers without chutes)
Tight doors and gaskets
Good air circulation around load
Proper cargo temperature (prior to loading)
Interior/exterior walls and insulation in good
condition
Clear defrost drains
Good outside air circulation
Unit inspection
Tight seals
ADZ30
Figure 183: Loading Considerations
137
Loading and Enroute Inspections
Post-Loading Inspection
4.
Close or supervise the closing of the cargo box doors.
Make sure they are securely locked.
Post-loading inspections ensure the cargo has been loaded
properly. To perform a post-load inspection:
5.
Make sure the setpoint is at the temperature listed on the
manifest.
6.
If the unit was stopped, restart using the correct starting
procedure. See the Operating Instruction chapter in this
manual.
7.
Start a manual defrost cycle 30 minutes after loading. See
the Manual Defrost procedure in this manual.
1.
Inspect the evaporator outlets for blockage.
2.
Turn the unit off before opening the cargo box doors to
maintain efficient operation.
NOTE: The unit can be operated with the cargo box
doors open if the truck is backed into a refrigerated
warehouse and the dock door seals fit tightly around the
trailer.
3.
Perform a final check of the load temperature. If the load
is above or below temperature, make a final notation on
the manifest.
CAUTION: Cargo must be pre-cooled to the proper
temperature before loading. The unit is designed to
maintain temperature, not cool an above-temperature
load.
138
Loading and Enroute Inspections
Enroute Inspections
2.
Repeat the Enroute Inspection every 30 minutes until the
compartment temperature is within the desired
temperature range. Stop the unit if the compartment
temperature is not within the desired temperature range on
two consecutive 30 minute inspections, especially if the
compartment temperature appears to be moving away
from the setpoint.
Complete the following enroute inspection every four hours.
This will help minimize temperature related problems.
Inspection Procedure
1.
Verify setpoint is correct.
2.
Check the return air temperature reading. It should be
within the desired temperature range.
3.
Immediately contact the nearest Thermo King Service
Center or your company office.
3.
Initiate a manual defrost cycle after each enroute
inspection.
4.
Take all necessary steps to protect and maintain proper
load temperature.
Inspection Troubleshooting
1.
If a temperature reading is not within the desired
temperature range, refer to the troubleshooting table on the
following pages. Correct problem as required.
CAUTION: Stop the unit if the compartment
temperature remains higher than the desired
temperature range from the setpoint on two
consecutive 30 minute inspections. Contact the
nearest Thermo King Service Center or your
company office immediately. Take all necessary steps
to protect and maintain proper load temperature.
139
Loading and Enroute Inspections
Inspection Troubleshooting
Problem
Cause
Remedy
A return air
temperature
reading is not
within desired
temperature
range of the
setpoint.
The unit has not
had time to cool
down to correct
temperature.
Refer to the load log history. Look for above temperature load records,
properly pre-cooled cargo compartment, length of time on road, etc. Correct
as required. Continue monitoring return air temperature until the reading is
within the desired temperature range of the setpoint.
The unit may have
a low refrigerant
charge.
Check the receiver tank sight glass for refrigerant level. If liquid is not
showing in the receiver tank sight glass, the refrigerant charge may be low.
A competent refrigeration technician is required to add refrigerant or repair
the system. Contact the nearest Thermo King dealer, authorized Service
Center, or call the Thermo King Cold Line for referral. Consult the Table of
Contents for Cold Line information.
The unit is in defrost Monitor the return air temperature after the defrost cycle is completed to see
if the temperature returns to the desired temperature range of the setpoint.
or has just
completed a defrost
cycle.
The evaporator is
plugged with frost.
140
Initiate a manual defrost cycle. The defrost cycle will automatically terminate
when complete. Continue monitoring the return air temperature until the
reading is within the desired temperature range of the setpoint.
Loading and Enroute Inspections
Problem
Cause
Remedy
Improper air
Inspect the unit and cargo compartment to determine if the evaporator fan(s)
circulation in the
are working and properly circulating the air. Poor air circulation may be due
cargo compartment. to improper loading of the cargo, shifting of the load, or fan belt slippage.
Correct as required. Continue monitoring return air temperature until
problem is corrected.
The unit did not
start automatically.
Determine the cause for not starting. Correct as required. Continue
monitoring the return air temperature until the reading is within the desired
temperature range of the setpoint.
141
Alarm Codes
Introduction
An alarm code is generated when the microprocessor senses an
abnormal condition. Alarms direct an operator or service
technician to the source of a problem.
Multiple alarms can be present at one time. All generated
alarms will be stored in memory until cleared by the operator.
Document all alarm occurrences and report them to the service
technician.
See “Alarms Menu” in the Operation Instructions Chapter for
information about viewing and clearing alarms.
NOTE: Some alarms (3, 4, 74, 203, and 204) cannot be
cleared in the Alarms Menu, they must be cleared in the
Maintenance Menu or the Guarded Access Menu. Contact
your supervisor or a Thermo King dealer about clearing
those alarms.
142
IMPORTANT: Always record any Alarm Codes that occur in the order that they occur - as well as any other pertinent
information. This information is extremely valuable to
service personnel.
NOTE: In some cases alarms cannot be cleared, or cannot be
cleared after they have occurred a specified number of times.
If such is the case, these alarms must be cleared by service
personnel. See “Clearing Alarm Codes” on page 145.
Alarm Types
The four types of alarms are described below.
Log Alarms: Log Alarms are indicated by the Log Alarms
screen, which appears for approximately 30 seconds (just
before the Standard Display appears) each time the unit is
turned on. The Alarm Display must be used to view the
existing alarms. This level of alarm serves as a notice to take
Alarm Codes
corrective action before a problem becomes severe.
Maintenance items such as a maintenance reminder hour meter
reaching its time limit are log alarms.
ON
OFF
35
SET
POINT
GAUGES
35
SENSORS
MENU
LOG ALARMS ACTIVE
ON
GO TO MENU TO VIEW
OFF
EXIT
Figure 185: Alarm Display
Figure 184: Log Alarms Screen
Check Alarms: Check Alarms are indicated by the Alarm
Display in which the large Alarm Icon will appears on the
Standard Display as shown below in Figure 185. The Alarm
Menu must be used to view the existing alarms. This level of
alarm serves as a notice to take corrective action before a
problem becomes severe. The unit will run with check alarms
but some features and functions may be inhibited.
Prevent Alarms: Prevent Alarms are also indicated by the
Alarm Display as shown in Figure 185. The Alarm Menu must
be used to view the existing alarms. The unit may stop running
and wait a timed interval or until conditions allow and then
restart. If the unit is waiting to restart, Alarm Code 84 Restart
Null will be present along with the Prevent Alarm. In other
cases the unit may restart or run with reduced performance to
determine if continued operation is possible. If the alarm does
not reoccur with reduced performance the unit will then return
to full performance. If the unit is operating with reduced
performance Alarm Code 85 Forced Unit Operation will also
be present.
143
Alarm Codes
Shutdown Alarms: Shutdown Alarms are indicated by the
Alarm Display. Shutdown alarms also cause the display and
backlight to flash on and off, and the display will switch from
normal video to reverse video and back to normal video (light
areas become dark and dark areas become light as shown in
Figure 186). Shutdown alarms force the unit into shutdown.
The unit will remain in shutdown and will not restart until the
shutdown alarm is cleared. Exceptions are some engine and
electric shutdown alarms become that log alarms when
switched to the alternate operating mode (diesel to electric or
electric to diesel).
If a shutdown alarm occurs that affects only Diesel Mode
operation and the unit is switched to electric (either manually
or automatically), the Diesel Mode shutdown alarm becomes
an Electric Mode log alarm. This allows the unit to run in
Electric Mode without clearing the shutdown alarm that is
preventing Diesel Mode operation. If the unit is switched back
to Diesel Mode, the alarm again becomes a Diesel Mode
shutdown alarm and prevents unit operation. If the unit is
configured for electric to diesel autoswitch, it automatically
starts and runs in Diesel Mode if an electric shutdown occurs.
144
In the same manner, if a shutdown alarm occurs that affects
only Electric Mode operation and the unit is switched to diesel
(either manually or automatically), the Electric Mode
shutdown alarm becomes a Diesel Mode log alarm to allow
Diesel Mode operation. If the unit is switched back to Electric
Mode, the alarm reverts to an Electric Mode shutdown alarm
and prevents unit operation.
ON
OFF
35
SET
POINT
GAUGES
35
SENSORS
MENU
Figure 186: Shutdown Alarm Display
Pretrip Alarm Codes
If an alarm occurs during a Pretrip Test the alarm code will be
displayed as Pretrip Alarm XX, where XX is the alarm code.
Alarm Codes
Clearing Alarm Codes
Most alarm codes can be cleared conventionally from the
Alarm Menu using the CLEAR Key. See the Operating
Instructions chapter for procedures.
The operator should contact a supervisor or a Thermo King
dealer about clearing alarms using the Guarded Access Menu.
NOTE: The corrective actions listed in the Operating
Instructions chapter and in the chart on the following pages
are suggestions only. Always consult your company for final
decisions.
NOTE: The chart on the following pages shows all possible
alarm codes for all possible applications. Not all codes will be
applicable to each individual unit.
Refer to the table on the following pages for alarm corrective
action.
NOTE: Document all alarm faults and report them to the
service technician.
There are three levels of corrective action that can be taken
when an alarm condition occurs.
OK To Run: An alarm condition exists but does not affect
unit operation. Corrective action can occur at a later date.
Check As Specified: An alarm condition exists that could
affect unit operation. Follow directions in the Corrective
Action column on the following chart.
Take Immediate Action: An alarm condition exists that
will damage the unit or load. Take immediate action to correct
the problem.
145
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
00
No Alarms Exist
None required
X
2
Evaporator Coil Sensor
Manually monitor load temperature with independent
thermometer. Report alarm at end of day.
X
3
Control Return Air Sensor
Manually monitor load temperature with independent
thermometer. Report alarm at end of day.
X
4
Control Discharge Air Sensor
Manually monitor load temperature with independent
thermometer. Report alarm at end of day.
X
5
Ambient Air Sensor
Report alarm at end of day.
X
6
Coolant Temp Sensor
Report alarm at end of day.
X
7
Engine RPM Sensor
Report alarm at end of day.
X
9
High Evaporator Temperature
Manually monitor load temperature. Report alarm at end of
the day.
146
X
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
10
High Discharge Pressure
If unit is shut down repair immediately. Otherwise, report
alarm at end of day.
11
Unit Controlling on Alternate
Sensor
Manually monitor load temperature with independent
thermometer. Report alarm at end of day.
12
Sensor or Digital Input Shutdown
The indicated zone is no longer able to operate and has
been shut down. Repair immediately.
13
Sensor Calibration Check
Manually monitor load temperature with independent
thermometer. Report alarm at end of day.
X
17
Engine Failed to Crank
If unit is shut down repair immediately. Otherwise, report
alarm at end of day.
X
18
High Engine Coolant
Temperature
If unit is shutdown repair immediately. Otherwise, report
alarm at end of day.
X
19
Low Engine Oil Pressure
It unit is shutdown repair immediately. Otherwise report
alarm at end of day.
X
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
X
X
X
147
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
20
Engine Failed to Start
If unit is shutdown repair immediately. Otherwise, report
alarm at end of day.
X
21
Cooling Cycle Check
Manually monitor load temperature with independent
thermometer. Report alarm at end of day.
X
22
Heating Cycle Check
Manually monitor load temperature with independent
thermometer. Report alarm at end of day.
X
23
Cooling Cycle Fault
The indicated zone is no longer able to operate and has
been shut down. Repair immediately.
X
24
Heating Cycle Fault
The indicated zone is no longer able to operate and has
been shut down. Repair immediately.
X
25
Alternator Check
If unit is shutdown repair immediately. Otherwise, report
alarm at end of day.
X
26
Refrigeration Capacity
Manually monitor load temperature with independent
thermometer. Report alarm at end of day.
X
148
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
28
Pretrip Abort
Report alarm at end of day.
29
Defrost Damper Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
30
Defrost Damper Stuck
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
31
Oil Pressure Switch
If unit is shutdown repair immediately. Otherwise, report
alarm at end of day.
32
Refrigeration Capacity Low
The indicated zone is no longer able to operate and has
been shut down. Repair immediately.
33
Check Engine RPM
Report alarm at end of day.
35
Run Relay Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
X
X
X
X
X
X
X
149
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
36
Electric Motor Failed to Run
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
37
Engine Coolant Level
Check coolant level, add as needed. Report alarm at end of
day.
38
Electric Phase Reversed
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
39
Water Valve Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
40
High Speed Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
41
Check Engine Coolant
Temperature
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
42
Unit Forced to Low Speed
Report alarm at end of day.
X
150
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
X
X
X
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
43
Unit Forced to Low Speed
Modulation
Report alarm at end of day.
44
Check Fuel System
Refill fuel tank.
45
Hot Gas Bypass or Hot Gas
Bypass Circuit
If unit is shutdown repair immediately. Otherwise, report
alarm at end of day.
X
46
Check Air Flow
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day. Cargo may be restricting air flow,
check load.
X
48
Check Belts/Clutch
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
50
Reset Clock
Report alarm at end of day.
52
Heat Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
X
X
X
X
X
151
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
54
Test Mode Time-out
Service Test or Interface Board Test time out after 15
minutes. Report alarm at end of day.
X
56
Host Evap Fan Low Speed
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
57
Host Evap Fan High Speed
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
61
Low Battery Voltage
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
62
Ammeter Out of Calibration
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
63
Engine Stopped
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
64
Pretrip Reminder
Report alarm at end of day.
152
X
X
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
65
Abnormal Temperature
Differential
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day
66
Low Engine Oil Level
Check engine oil level. If unit is shutdown, repair
immediately. Otherwise, report alarm at end of day.
67
Liquid Line Solenoid Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
68
Internal Controller Fault
Report alarm at end of day.
70
Hourmeter Failure
Report alarm at end of day.
X
74
Controller Reset to Defaults
Report alarm at end of day.
X
79
Internal Data Logger Overflow
Report alarm at end of day.
X
80
Compressor Temp Sensor
Report alarm at end of day.
82
High Compressor Temperature
Shutdown
If unit is shutdown repair immediately. Otherwise, report
alarm at end of day.
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
X
X
X
X
X
X
153
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
83
Low Engine Coolant Temperature
If unit is shutdown repair immediately. Otherwise, report
alarm at end of day.
84
Restart Null
Report alarm at end of day.
X
85
Forced Unit Operation
Report alarm at end of day.
X
86
Discharge Pressure Sensor
Report alarm at end of day.
X
87
Suction Pressure Sensor
Report alarm at end of day.
X
89
Check Electronic Throttling Valve If unit is shutdown repair immediately. Otherwise, report
Circuit
alarm at end of day.
90
Electric Overload
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
91
Electric Ready Input
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
92
Sensor Grades Not Set
Report alarm at end of day.
154
X
X
X
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
93
Low Compressor Suction
Pressure
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
96
Low Fuel Level
Check engine fuel level and add fuel. If unit is shutdown,
repair immediately. Otherwise, report alarm at end of day.
98
Fuel Level Sensor
Report alarm at end of day.
99
High Compressor Pressure Ratio
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
105
Receiver Tank Pressure Solenoid If unit is shutdown, repair immediately. Otherwise, report
Circuit
alarm at end of day.
X
106 Purge Valve Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
107 Condenser Inlet Solenoid Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
X
X
X
X
155
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
108 Door Open Time-out
Close Doors. Report alarm at end of day.
X
110
Suction Line Solenoid Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
111
Unit Not Configured Correctly
Report alarm at end of day.
X
112
Remote Fans
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
113
Electric Heat Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
114
Multiple Alarms - Cannot Run
If unit is shutdown repair immediately. Otherwise, report
alarm at end of day.
117
Auto switch from Diesel to
Electric
Report alarm at end of day.
156
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
X
X
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
118
Auto switch from Electric to
Diesel
Report alarm at end of day.
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
X
120 Alternator Exciter Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
121 Liquid Injection Circuit
If unit is shutdown, repair immediately. Otherwise report
alarm at end of day.
X
122 Diesel/Electric Relay Circuit
If unit is shutdown, repair immediately. Otherwise, report at
end of day.
X
127 Setpoint Not Entered
Be sure the setpoint is set to the required temperature.
X
128
Engine Run Time Maintenance
Reminder #1
Report alarm at end of day.
X
129
Engine Run Time Maintenance
Reminder #2
Report alarm at end of day.
X
157
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
130
Electric Run Time Maintenance
Reminder #1
Report alarm at end of day.
X
131
Electric Run Time Maintenance
Reminder #2
Report alarm at end of day.
X
132
Total Unit Run Time Maintenance
Report alarm at end of day.
Reminder #1
X
133
Total Unit Run Time Maintenance
Report alarm at end of day.
Reminder #2
X
134 Controller Power On Hours
Report alarm at end of day.
X
Report alarm at end of the day.
X
141
Autoswitch Diesel to Electric
Disabled
143
Remote Zone Drain Hose Heater If unit is shutdown, repair immediately. Otherwise, report at
Output
end of day.
158
X
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
144
Lost Expansion Module CAN
Communication
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
X
145
Loss of Controller “On” Feedback If unit is shut down repair immediately. Otherwise, report
Signal
alarm at end of the day.
X
146 Software Version Mismatch
148
Autoswitch Electric to Diesel
Disabled
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
X
Report alarm at end of the day.
X
150 Out of Range Low
Manually monitor load temperature. Report alarm at end of
the day.
X
151 Out of Range High
Manually monitor load temperature. Report alarm at end of
the day.
X
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
X
153
Expansion Module Flash Load
Failure
159
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
157 OptiSet Plus Mismatch
Manually monitor load temperature. Report alarm at the end
of the day
158 Primary Software Failed to Load
Report alarm at end of the day.
X
159 Check Battery Condition
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
X
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
X
203 Display Return Air Sensor
Manually monitor load temperature with independent
thermometer. Report alarm at end of day.
X
204 Display Discharge Air Sensor
Manually monitor load temperature with independent
thermometer. Report alarm at end of day.
X
160
Lost Radio Expansion Board
(REB) CAN Communication
230 Future REB Alarm
231 Future REB Alarm
160
X
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
232 Future REB Alarm
233
REB Transitioning From
Conservative to Full Null
234 Relative Humidity Sensor
Report alarm at end of the day.
X
Report alarm at end of the day.
X
251 REB Miss-configured
Report alarm at end of the day.
X
Check Fresh Air Exchange
252
Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
500 Host Evaporator Fan Low Speed
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
501 Host Evaporator Fan High Speed
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
Host Evaporator Fan RPM
Sensor
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
502
161
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
503
Host Condenser Fan 1 RPM
Sensor
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
504
Host Condenser Fan 2 RPM
Sensor
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
505
Roadside Condenser Fan Motor
Speed Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
506
Curbside Condenser Fan Motor
Speed Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
Report alarm at end of the day.
X
507 Digital Scroll Output Circuit
508
Speed Request Communication
Error
509
Engine Control Unit (ECU) Failed If unit is shutdown, repair immediately. Otherwise, report
to Enable
alarm at end of day.
162
X
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
510
Engine Control Unit (ECU) Run
Signal Failed
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
511
Engine Wait to Start Time Delay
Expired
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
512
High Compressor Suction
Pressure
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
513 Low Compressor Suction Ratio
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
514
Minimum ETV Discharge
Superheat Temperature
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
515
Minimum ETV Discharge
Superheat Temperature
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
163
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
I/O Controller to Application
516 Controller Communication
Failure
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
517 Check for Water in Fuel System
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
518 Generator Ground Fault
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
519
Check Battery Charger Input
Power
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
520
Check Battery Charger Output
Power
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
521
Battery Charger
External/Environmental Fault
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
164
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
522
Battery Temperature Sensor
Alarm
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
523
Battery Temperature Sensor
Alarm
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
524
Generator Operational Limit Vout If unit is shutdown, repair immediately. Otherwise, report
to Frequency Ratio
alarm at end of day.
X
525
Generator Frequency Range
Fault
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
526
Generator Operational Limit
Output Current
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
527 Reserved
528
Controller Not Receiving
If unit is shutdown, repair immediately. Otherwise, report
Messages From Battery Charger alarm at end of day.
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
X
X
165
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
529 Check Fuel Pump Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
530 Low Pressure Differential
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
531
Check Economizer Pressure
Sensor
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
538
Engine J1939 CAN Datalink
Degraded
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
539
Engine J1939 CAN Datalink
Failed
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
Maintenance information only. Report alarm at end of the
day.
X
599 Engine Service Tool Connected
600 Check Crankshaft Speed Sensor Report alarm at end of the day.
166
X
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
601 Check Camshaft Speed Sensor
602
Check Intake Throttle Position
Sensor
603 Check Exhaust Pressure Sensor
Report alarm at end of the day.
X
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
X
f unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
X
604
Check Coolant Temperature
Sensor
Report alarm at end of the day.
X
605
Check Fresh Air Temperature
Sensor
Report alarm at end of the day.
X
606 Reserved
X
607 Check Fuel Temperature Sensor Report alarm at end of the day.
X
608 Check Rail Pressure Sensor
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
X
167
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
609 Check Intake Pressure Sensor
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
X
610
Check Atmospheric Pressure
Sensor
Report alarm at end of the day.
X
611
Check Glow Plug Circuit
Report alarm at end of the day.
X
612 Check Intake Throttle Circuit
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
X
613 Check Injector(s)
Report alarm at end of the day.
X
614 Check High Pressure Fuel Pump
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
X
615 Rail Pressure Fault
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
X
168
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
616 Engine Overspeed
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
X
617 Internal ECU Fault
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
X
618 Check EGR System
Report alarm at end of the day.
X
619 ECU Main Relay Fault
Report alarm at end of the day.
X
623 TRU CAN Message Timeout
Report alarm at end of the day.
X
Check Intake Air Temperature
624
Sensor
Report alarm at end of the day.
X
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
620 Reserved
621 Reserved
622 Reserved
169
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
625
Check Intake Air Temperature
Sensor
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
X
626
Check Exhaust Temperature
Sensor
Report alarm at end of the day.
X
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
X
699 Unknown ECU Fault
170
Shut
Down
Level Of
Action
Check
Corrective Action
Ok To
Run
Code Description
Jump Starting
If the battery in a unit is discharged or run down, the unit may
be jump started using jumper cables and another battery or
vehicle. Consider the following precautions and be careful
when jump starting a unit.
WARNING: A battery can be dangerous. A battery
contains a flammable gas that can ignite or
explode. A battery stores enough electricity to burn
you if it discharges quickly. A battery contains
battery acid that can burn you. Always wear
goggles or safety glasses and personal protective
equipment when working with a battery. If you get
battery acid on you, immediately flush it with water
and get medical attention.
CAUTION: Unhook the semi tractor from the
trailer before using the tractor to jump start the
unit on the trailer. The negative ground circuit is
complete when the tractor is hooked to the trailer.
This can cause dangerous sparks when the positive
connection is made at the battery.
IMPORTANT: Make sure to use a 12-volt battery to jump
start the unit. If you are using a vehicle, make sure it has a
12-volt battery with a negative ground system. Do not use a
“hot shot” booster device or a 24-volt source.
Read and understand the following procedure completely
before connecting any jumper cables. Use good jumper cables
made with #2 gauge (or larger) cables.
1.
Make sure the unit is turned off. If you are using a vehicle,
make sure its ignition is also turned off.
2.
Open the front doors on the unit. The battery is located to
the right of the engine.
3.
Check the discharged battery to make sure it is not
damaged or frozen. Do not jump start a damaged or frozen
battery. Check the vent caps to make sure they are tight.
4.
Identify the positive (+) and negative (–) battery terminals.
171
Jump Starting
1
CAUTION: Do not use a match or lighter as a
light near the battery. Use a flashlight. A flame or
a spark can ignite the gas in the battery and cause
it to explode.
5.
2
Unit
(Discharged)
12-Volt
Battery
Remove the red cover from the positive (+) battery
terminal on the unit’s battery.
Good
12-Volt
Battery
Unit
Engine
3
4
1.
Positive (+) Terminal on Unit Battery
2.
Positive (+) Terminal on Good Battery
3.
Negative (–) Terminal on Good Battery
4.
Starter Mounting Bolt on Unit Engine
Figure 187: Sequence for Connecting Jumper Cables
172
Jump Starting
6.
Connect the red positive (+) jumper cable to the positive
(+) battery terminal on the unit’s battery. Do not let the
other end of the jumper cable touch anything that conducts
electricity.
CAUTION: Allowing the positive (+) jumper cable
to short can produce dangerous sparks.
7.
Connect the other end of the red positive (+) jumper cable
to the positive (+) battery terminal on the good battery.
8.
Connect the black negative (–) jumper cable to the
negative (–) battery terminal on the good battery. Do not
let the other end of the jumper cable touch anything that
conducts electricity.
9.
Connect the black negative (–) jumper cable to the lower
starter mounting bolt on the unit’s engine.
CAUTION: Be careful around fans and belts.
Keep your hands away from moving parts when an
engine is running.
11. Turn the unit on and let it start automatically or start it
manually. If the unit will not crank or start, contact a
qualified technician.
NOTE: Some units with microprocessors will show an
alarm code and will not try to start until the battery
voltage is above 10 volts.
12. After the unit starts, remove the jumper cables in reverse
order: black negative (–) from the unit starter mounting
bolt, black negative (–) from the good battery, red positive
(+) from the good battery, and red positive (+) from the
unit battery (that was discharged).
10. If you are using a vehicle to jump start the unit, start the
vehicle and let it run for a few minutes. This will help
charge the discharged battery.
173
Jump Starting
4
3
Unit
(Discharged)
12-Volt
Battery
Good
12-Volt
Battery
Unit
Engine
2
1
1.
Starter Mounting Bolt on Unit Engine
2.
Negative (–) Terminal on Good Battery
3.
Positive (+) Terminal on Good Battery
4.
Positive (+) Terminal on Unit Battery
Figure 188: Sequence for Disconnecting Jumper Cables
174
Specifications
Engine
Model
TK486V25 (Tier 4)
Number of Cylinders
4
Cylinder Arrangement
In-line vertical, number 1 on flywheel end
Firing Order
1-3-4-2
Direction of Rotation
Counterclockwise viewed from flywheel end
Fuel Type
No. 2 diesel fuel under normal conditions
No. 1 diesel fuel is acceptable cold weather fuel
Oil Capacity
12 quarts (11.4 liters) crankcase and oil filter
Fill to full mark on dipstick
Oil Type
API Classification CI-4 or better
ACEA Rating E3 or better for Europe
175
Specifications
Engine (Continued)
14 F to 122 F (-10 C to 50 C): SAE 15W-40 (Synthetic)
5 to 104 F (-15 to 40 C): SAE 15W-40
5 to 104 F (-15 to 40 C): SAE 10W-30 (Synthetic or
Synthetic Blend)
-13 to 104 F (-25 to 40 C): SAE 10W-40
-13 to 86 F (-25 to 30 C): SAE 10W-30
-22 to 122 F (-30 to 50 C): SAE 5W-40 (Synthetic)
Below -22 F (-30 C): SAE 0W-30 (Synthetic)
Oil Viscosity
Engine rpm:
Low Speed Operation
High Speed Operation
1450 ± 25 rpm
2200 ± 25 rpm
Engine Oil Pressure
18 psig (127 kPa) minimum in low speed
45 to 57 psig (310 to 390 kPa) in high speed
Intake Valve Clearance
0.006 to 0.010 in. (0.15 to 0.25 mm)
Exhaust Valve Clearance
0.006 to 0.010 in. (0.15 to 0.25 mm)
Valve Setting Temperature
70 F (21 C)
Low Oil Pressure Switch (Normally Closed)
17 ± 3 psig (117 ± 21 kPa)
Engine Coolant Thermostat
160 F (71 C)
176
Specifications
Engine (Continued)
Engine Coolant Type
ELC (Extended Life Coolant), which is “RED”
Use a 50/50 concentration of any of the following
equivalents:
Chevron Dex-Cool
Texaco ELC
Havoline Dex-Cool®
Havoline XLC for Europe
Shell Dexcool®
Shell Rotella
Saturn/General Motors Dex-Cool®
Caterpillar ELC
Detroit Diesel POWERCOOL® Plus
CAUTION: Do not add “GREEN” or “BLUE-GREEN”
conventional coolant to cooling systems using “RED”
Extended Life Coolant, except in an emergency. If
conventional coolant is added to Extended Life
Coolant, the coolant must be changed after 2 years
instead of 5 years.
Coolant System Capacity
7.5 quarts (7.1 liters)
Radiator Cap Pressure
15 psig (103 kPa)
177
Specifications
Engine (Continued)
Drive:
Standard Units
Smart Power Units
Direct to compressor; belts to AC generator, alternator, and
water pump
Centrifugal clutch to compressor; belts to electric standby
motor, AC generator, alternator, and water pump
Belt Tension
Belt
New Belt
Field Reset
106 Hz (111 lbs)
121 Hz (144 lbs)
92 Hz (84 lbs)
105 Hz (108 lbs)
AC Generator Belt - Smart Power Units and
Standard Units with Optional Battery Charger
106 Hz (111 lbs)
92 Hz (84 lbs)
Water Pump Belt
126 Hz (40 lbs)
118 Hz (32 lbs)
AC Generator and Alternator Belt - Standard Units:
37 or 65 Amp Alternator
120 Amp Alternator
178
Specifications
Belt Tension
Compressor Drive Belt - Smart Power Units Only
12 HP Electric Motor
19 HP Electric Motor
131 Hz (236 lbs)
150 Hz (300 lbs)
114 Hz (177 lbs)
130 Hz (223 lbs)
Alternator Belt - Smart Power Units Only:
All Alternators
216 Hz (75 lbs)
187 Hz (56 lbs)
Refrigeration System
Compressor
Thermo King X430LSC5
Refrigerant Charge—Type
14.5 lb (6.6 kg)—R404A
Compressor Oil Charge
4.3 qt (4.1 liters)*
Compressor Oil Type
Polyol Ester type P/N 203-513
Heat/Defrost Method:
High Pressure Cutout
Engine Operation
Electric Operation
Hot gas
Hot gas and optional electric heater strips
470 +7/-35 psig (3241 + 48/-241 kPa)
Automatic reset @ 375 ± 38 psig (2586 ± 262 kPa)
179
Specifications
Refrigeration System
* When the compressor is removed from the unit, oil level should be noted or the oil removed from the
compressor should be measured so that the same amount of oil can be added before placing the
replacement compressor in the unit.
180
Specifications
Electrical Control System
Low Voltage
12.5 Vdc
High Voltage
230 Vac from AC generator at engine low speed
345 Vac from AC generator at engine high speed
Battery
One, group C31, 12 volt, (950 CCA recommended for
operation below -15 F [-26 C])
Fuses
See “Fuses” on page 29.
Battery Charging
12 volt, 37 amp, brush type, Thermo King Alternator
Voltage Regulator Setting
13.95 to 14.35 volts @ 77 F (25 C)
181
Specifications
Electrical Components
NOTE: Disconnect components from unit circuit to check resistance.
Component
Current Draw (Amps)
at 12.5 Vdc
Resistance—Cold
(Ohms)
35 to 45
0.5
0.2 to 0.3
24 to 29
High Speed (Throttle) Solenoid
2.9
4.3
Air Heater
89
0.14
Pilot Solenoid
0.7
17.0
Electronic Throttling Valve:
Coil A (Red [EVA] and Blue [EVB] Wires)
Coil B (Black [EVC] and White [EVD] Wires)
—
—
20 to 35
20 to 35
Hot Gas Bypass Valve (if used)
1.1
11.1
Fuel Solenoid:
Starter Motor
Pull-in Coil
Hold-in Coil
350-475*
* On-the-engine cranking check. Bench test is approximately 140 amps.
182
Specifications
Electrical Components
AC Generator
Low Engine Speed (1450 rpm) Output
High Engine Speed (2200 rpm) Output
230 Vac at 54.9 Hz Nominal Vac - Measured Vac, Load
Dependent
345 Vac at 90 Hz Nominal Vac - Measured Vac, Load
Dependent
Fan Motors
Evaporator Fan Motor: Low Speed Power Rating
High Speed Power Rating
High Fan Speed at Low Engine Speed
Low Fan Speed at High Engine Speed
Low Fan Speed at Low Engine Speed
High Speed Current Draw at Low Engine Speed
Low Speed Current Draw at High Engine Speed
Low Speed Current Draw at Low Engine Speed
1.20 hp (0.90 kW)
1.75 hp (1.31 kW)
1700 rpm at low engine speed (1450 rpm)
1800 rpm at high engine speed (2200 rpm)
1180 rpm at low engine speed (1450 rpm)
3.8 amps at low engine speed (1450 rpm)
3.1 amps at high engine speed (2200 rpm)
2.6 amps at low engine speed (1450 rpm)
Condenser Fan Motor (each:
Power Rating
Fan Speed at Low Engine Speed
Fan Speed at High Engine Speed
Current Draw at Low Engine Speed
Current Draw at High Engine Speed
0.50 hp (0.37 kW)
1770 rpm low engine speed (1450 rpm)
2700 rpm at high engine speed (2200 rpm)
1.8 amps (per motor) at low engine speed (1450 rpm)
2.0 amps (per motor) at high engine speed (2200 rpm)
183
Specifications
Electrical Standby (Smart Power Units Only)
NOTE: A transformer is used to convert 460 Vac to 230 Vac in units configured to use electric standby
input voltage of 460 Vac.
Electric Motor and Overload Relay
Voltage/Phase/Frequency
Horsepower
Kilowatts
rpm
Full Load
(amps)
Overload Relay
Setting (amps)
230/3/60
12.0
9.0
1760
31.2
34
460/3/60
12.0
9.0
1760
15.6
20
460/3/60
19.0
14.2
3500
21.7
32
Electric Heater Strips
Number
3
Watts
1000 watts (each)
Resistance
48 ohms (each)
Overload Relay Setting
6 amps
184
Specifications
Standby Power Cord Requirements
Supply Circuit Breaker:
12 HP Motor 230/3/60
70 amps
12 HP Motor 460/3/60
40 amps
19 HP Motor 460/3/60
60 amps
Extension Cord Size:
12 HP Motor 230/3/60
(All 4 conductor, 2000 Vac,
Type W Power Cable)
8 AWG Power Cable, 25 to 50-foot length
12 HP Motor 230/3/60
6 AWG Power Cable, 75-foot length
12 HP Motor 460/3/60
10 AWG Power Cable, up to 75-foot length
19 HP Motor 460/3/60
8 AWG, Power Cable, up to 75-foot length
Electric Fuel Heater (Optional)
Electric Fuel Heater:
Resistance
Current Draw at 12.5 Vdc
Internal Thermostat Minimum Closing Temp.
Internal Thermostat Maximum Opening Temp.
0.9 to 1.1 ohms
11.4 to 13.9 amps
30 F (-1 C)
75 F (24 C)
2FH/2HP Fuse
20 amps
185
Warranty
Terms of the Thermo King Warranty are available on request
from your Thermo King Dealer.
See the “EPA Emission Control System Warranty Statement”
chapter in this manual for the non-road diesel engine in your
unit.
186
Glossary
This glossary is published for informational purposes only and
the information being furnished herein should not be
considered as all-inclusive or meant to cover all contingencies.
NOTE: Additional terms not found in the glossary may be
located in the index section of this manual.
accumulator: A device located in the suction line to collect
liquid refrigerant and meter it safety back to the compressor as
gas.
ambient air temperature: Temperature of the air
surrounding an object.
amp: Abbreviation for ampere. The basic measuring unit of
electrical current.
bar: A metric unit of pressure. 1 bar = 100 kPa = 14.5 psi.
Battery Sentry: Part of the CYCLE-SENTRY™ system. The
Battery Sentry module monitors alternator charge rate and will
keep the unit running until the battery is adequately charged.
box temperature: The temperature within a
temperature-controlled compartment.
Btu (british thermal unit): The quantity of heat required to
raise the temperature of one pound of water by one degree
Fahrenheit. 1 Btu = 252 calories.
bulkhead: 1) return air bulkhead. A metal or plastic “wall”
placed at the front of the box to prevent loading of product
tightly against the Thermo King unit. (Loading too close to the
unit restricts air flow and system efficiency.) 2) bulkhead
divider. A thick, insulated “wall” used to separate
compartments of a multi-temperature truck or trailer.
calorie: The amount of heat required to raise temperature of
one gram of water one degree Celsius. 1 calorie = 0.004 Btu.
Celsius: The metric unit of temperature measurement. The
preferred alternate to the term centigrade. Abbreviated “C.”
centigrade. See Celsius.
187
Glossary
CFC: Chlorofluorocarbon. A chlorine-based refrigerant
consisting of chlorine, fluorine and carbon. Example: R12. In
many countries it is illegal to release this type of refrigerant to
the atmosphere because chlorine damages the earth’s
atmosphere. CFC refrigerants are not used in modern Thermo
King units.
circuit breaker: A thermal device that automatically
interrupts an electrical circuit when the current in the circuit
exceeds the predetermined amperage rating of the breaker. See
amp.
coil: A cooling or heating element made of pipe or tube,
formed into a helical or serpentine shape, that may be equipped
with thin metal fins to aid heat transfer.
cold curtains: Flexible vinyl curtains used to reduce air
exchange between the refrigerated compartment and the
outside during door openings.
compound gauge: A gauge calibrated in psig (or kPa) to
measure pressure, and in inches of mercury (Kg/cm2) to
measure vacuum.
compressor: The refrigeration component that compresses
refrigerant vapor and creates refrigerant flow.
188
condenser: An arrangement of tubing in which the
vaporized and compressed refrigerant is liquefied as heat is
removed.
cycles per second: See Hertz.
damper door: A door on the evaporator section that closes
during defrost to prevent hot air from entering the refrigerated
cargo compartment.
data logger: An electronic device that monitors and stores
unit operating and temperature data for later review. Examples:
DMS, DAS, DRS and AccuTrac.
DE: Dual Evaporator. A multi-temp host unit with two
evaporators capable of refrigerating two separate, longitudinal
compartments.
defrost: The removal of accumulated ice from an evaporator
coil. Periodic defrost is necessary when the evaporator coil is
operating below freezing. Defrost is required more frequently
when the air passing through the evaporator has a high
moisture content.
defrost termination switch: A component that terminates
defrost operation at a specific temperature.
Glossary
defrost timer: A solid state module that initiates defrost at
selected intervals. Also establishes a maximum defrost
duration if normal circuits malfunction.
dehydrator: A device used to remove moisture from
refrigerant. Also called a drier.
discharge air temperature: The temperature of air leaving
the evaporator.
drier: See dehydrator.
ERC: Extended Remote Unit Control. (Door switches) An
option on Thermo King multi-temperature units to improve
temperature control when doors are opened during delivery.
When a compartment door is opened, the refrigeration unit for
that compartment may be forced to NULL, defrost, or some
other mode. Opening a compartment door may also affect the
operating mode of other compartments. ERC systems are
connected in a variety of ways to meet customer needs.
ETV (Electronic Throttling Valve) : A device used with a
microprocessor to precisely control the refrigeration system.
evaporator: The part of the refrigeration system that absorbs
heat during the cooling cycle.
F: See Fahrenheit.
Fahrenheit: A unit of temperature measurement used in the
United States. Abbreviated “F.”
freeze up: 1) Failure of a refrigeration system to operate
normally due to moisture in the refrigerant and the formation
of ice at the expansion valve. The expansion valve may be
frozen shut or open, causing improper unit operation in either
case. 2) The formation of a solid ice mass over the evaporator
coil reducing air flow.
fuse: An electrical safety device (typically a cartridge)
inserted into an electrical circuit. It contains material that will
melt or break when the current is increased beyond a specific
value. When this occurs, the circuit is opened and electrical
current flow is stopped.
fusible link: An electrical safety device (typically a short
piece of wire) inserted into an electrical circuit. The wire melts
or breaks when the current is increased beyond a specific
value. When this occurs, the circuit is opened and electrical
current flow is stopped.
Hertz: A unit of frequency equal to one cycle per second.
Abbreviated “Hz.”
189
Glossary
HFC: A refrigerant consisting of hydrogen, fluorine and
carbon. Examples: R134a and 404A. HFC refrigerants contain
no chlorine and are, therefore, considered “safe” for the
environment.
high pressure relief valve: A safety valve on the
refrigeration system that allows refrigerant to escape from the
system if pressure exceeds a predetermined value.
hp (horsepower): A unit of power equivalent to 746 watts
or 550 foot-pounds per second.
HPCO (High Pressure Cut Out Switch): A
pressure-operated switch that opens to stop unit operation
when discharge pressure reaches a predetermined maximum.
invertible: A multi-temperature truck or trailer unit designed
to allow the placement of deep-frozen cargo in any
compartment. See Multi-Temp.
kPa: Kilopascals. A metric unit of pressure. 1 kPa = 0.01 bar =
0.145 psi.
load: 1) The product being refrigerated and transported.
2) The amount of heat being removed by the refrigeration
system. (For example, a compressor is under a heavy heat load
when expected to cool a very warm box.)
190
LPCO (Low Pressure Cut Out Switch): A
pressure-operated switch that opens to stop unit operation
when suction pressure reaches a predetermined minimum.
modulation: An optional system that reduces load (product)
dehydration and avoids “top freeze.”
movable bulkhead: A thick, insulated, portable wall-like
device used to compartmentalize a temperature-controlled
truck or trailer. See bulkhead.
Multi-Temp: A Thermo King truck or trailer unit capable of
maintaining different set-points in multiple compartments.
no. 1 diesel fuel: A grade of diesel fuel formulated to
prevent “jelling” in low ambient temperatures.
no. 2 diesel fuel: A grade of diesel fuel formulated for
moderate to warm ambient temperatures.
ohm: An electrical unit measuring the amount of resistance
(opposition to the current flow) in an electrical circuit.
pre-cooling: 1) To cool down an empty box
(temperature-controlled area) to the desired load temperature
prior to loading. 2) To cool cargo to a desired temperature
before loading.
Glossary
pre-heat: The heating of diesel engine glow plugs prior to
start-up. Some engines use an intake manifold heater rather
than glow plugs.
pre-trip inspection: Checking the operation of a
refrigeration system before loading.
psi: Pounds per square inch. A unit of pressure.
1 psi = 0.069 bar = 6.89 kPa.
return air bulkhead: A structure (metal or plastic) mounted
in the front of a trailer and designed to prevent restriction of
return air flow to the Thermo King unit due to improper
loading. See bulkhead.
return air temperature: The temperature of the air
returning to the evaporator. See box temperature.
rpm: Revolutions per minute.
psig: Pounds per Square Inch Gauge. Pressure in pounds per
square inch as displayed by a gauge calibrated to zero when
open to the atmosphere.
setpoint: The temperature selected on a thermostat or
microprocessor controller. This is normally the desired box
temperature.
receiver tank: A refrigerant storage device included in
nearly all Thermo King units.
short cycling: When a refrigeration unit cycles between the
heat and cool modes more often than normal.
refrigerant: The medium of heat transfer in a refrigeration
system which absorbs heat by evaporating at a low temperature
and releases heat by condensing at a higher temperature.
sight glass: A system component that permits visual
inspection of oil or refrigerant level and condition.
refrigerant oil: A special oil used to lubricate compressors in
refrigeration systems.
remote evaporator: A separate evaporator unit located in a
second or third compartment of a multi-temperature truck or
trailer unit.
thermostat: A device that controls unit modes of operation to
maintain a selected box temperature.
top freeze: When the top portion of perishable cargo is
damaged by freezing temperatures discharged from the
refrigeration unit. This may occur near the front of the box
when product is placed too close to the cold, discharge air flow.
191
Glossary
Vac (volts alternating current): An electric current that
reverses direction at regularly recurring intervals.
Vdc (volts direct current): An electric current that flows in
one direction only and is constant in value.
volts: The basic measuring unit of electrical potential.
watt: The basic measuring unit of electrical power.
192
Maintenance Inspection Schedule
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
Annual/ Inspect/Service These Items
4,500
Hours
Microprocessor
•
Run Pretrip Test
Engine
•
Check fuel supply.
•
Check engine oil level.
•
•
•
•
Inspect belts for condition and proper tension.
•
•
•
•
Check engine oil pressure hot, on high speed (should display “OK”).
•
•
•
•
Listen for unusual noises, vibrations, etc.
*3,000 hours or two years, whichever occurs first.
** Based on EPA 40 CFR Part 89.
193
Maintenance Inspection Schedule
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
•
•
•
•
Check engine coolant level and antifreeze protection (-30 F [-40 C]).
•
•
•
Drain water from fuel tank and check vent.
•
•
•
Inspect/clean electric fuel pump filter.
•
•
•
Check and adjust engine speeds (high and low speed).
•
•
•
Check condition of drive coupling bushings per Service Bulletin T&T 171.
•
Check engine mounts for wear.
•
Annual/ Inspect/Service These Items
4,500
Hours
•
Replace EMI 3000 air cleaner element at 3,000 hours or two years
(whichever occurs first).
•
Replace fuel filter/water separator.
•
Change engine oil and oil filter (hot). Requires oil with API Rating CI-4 or
better (ACEA Rating E3 for Europe).
Inspect/clean EGR system (valve, piping, and cooler).
*3,000 hours or two years, whichever occurs first.
** Based on EPA 40 CFR Part 89.
194
Maintenance Inspection Schedule
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
Annual/ Inspect/Service These Items
4,500
Hours
•
Adjust engine valve clearance.
Test fuel injection nozzles at least every 3,000 hours. **
Replace fuel return lines between fuel injection nozzles every 10,000
hours.
—
Change ELC (red) engine coolant every 5 years or 12,000 hours. Units
equipped with ELC have an ELC nameplate on the expansion tank.
Electrical
•
•
•
Inspect battery terminals and electrolyte level.
•
•
•
Inspect wire harness for damaged wires or connections.
•
Inspect AC generator and alternator wire connections for tightness.
•
Inspect electric motors.
*3,000 hours or two years, whichever occurs first.
** Based on EPA 40 CFR Part 89.
195
Maintenance Inspection Schedule
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
Annual/ Inspect/Service These Items
4,500
Hours
Refrigeration
•
•
•
•
Check refrigerant level.
•
•
•
Check for proper suction pressure.
•
•
•
Check compressor oil level and condition.
•
Check compressor efficiency and pump down refrigeration system.
•
Empty oil collection container mounted on compressor.
—
Replace dehydrator and check discharge and suction pressure every two
(2) years.
*3,000 hours or two years, whichever occurs first.
** Based on EPA 40 CFR Part 89.
196
Maintenance Inspection Schedule
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
Annual/ Inspect/Service These Items
4,500
Hours
Structural
•
•
•
•
Visually inspect unit for fluid leaks.
•
•
•
•
Visually inspect unit for damaged, loose or broken parts (includes air
ducts and bulkheads).
•
•
•
Inspect idlers for bearing wear (noise).
•
•
•
Clean entire unit including condenser and evaporator coils and defrost
drains.
•
•
•
Check all unit and fuel tank mounting bolts, brackets, lines, hoses, etc.
*3,000 hours or two years, whichever occurs first.
** Based on EPA 40 CFR Part 89.
197
Serial Number Locations
Unit: Nameplates on the evaporator fan housing and on the
roadside of the evaporator.
Engine: See the engine identification plate located on the
engine valve cover.
Compressor: Stamped between the cylinders on the front
end above the oil pump.
Figure 189: Compressor Serial Number Location
198
Serial Number Locations
Figure 190: Engine Serial Number Location
Figure 191: Unit Serial Number Plate Locations
199
Serial Number Locations
1
2
3
4
ARA793
1.
2.
3.
4.
Unit Serial Number
Bill of Material Number
Unit Model
Unit ID
Figure 192: Unit Serial Number Plate
200
Emergency Cold Line
The answering service at the factory will assist you in reaching
a dealer to get the help you need. The Cold Line is answered 24
hours a day by personnel who will do their best to get you
quick service at an authorized Thermo King Dealer.
AMA1585
If you can’t get your rig rolling, and you have tried the Thermo
King North American Service Directory (available from any
Thermo King dealer) to reach a dealer without success, then
call the Toll Free Emergency Cold Line Number
(888) 887-2202.
201
Recover Refrigerant
At Thermo King, we recognize the need to preserve the environment
and limit the potential harm to the ozone layer that can result from
allowing refrigerant to escape into the atmosphere.
We strictly adhere to a policy that promotes the recovery and limits
the loss of refrigerant into the atmosphere.
In addition, service personnel must be aware of Federal regulations
concerning the use of refrigerants and the certification of technicians.
For additional information on regulations and technician certification
programs, contact your local THERMO KING dealer.
202
CALIFORNIA
Proposition 65 Warning
Diesel exhaust is a chemical known to
the State of California to cause cancer.
203
A
alarm codes 142
corrective action 145
types 142
amber status light 33
automatic start/stop safety precautions 12
B
battery inspection 35
belt tension, specifications 178
belts inspection 35
C
coils inspection 36
compressor oil sight glass 28
control panel 38
display 38
keys 40
CYCLE-SENTRY
start-stop controls 24
D
data logging 25
204
defrost 26
defrost drain inspection 36
Defrost key 39, 40, 48, 83
door inspection 36
E
ELC (extended life coolant) 21
electrical components, specifications 182
electrical control system, specifications 181
electrical hazards 12
electrical inspection 35
electrical standby, specifications 184
electronic throttling valve (ETV) 22
Emergency Cold Line 201
EMI 3000 22
engine compartment components 28
engine coolant level 35
engine oil dipstick 28
engine oil level 35
engine, specifications 175
enroute inspections 139
ETV (electronic throttling valve) 22
extended life coolant (ELC) 21
F
first aid for refrigerant 14
first aid for refrigerant oil 14
FreshSet 26
front doors
opening 27
fuel level 35
fuses 29
H
high pressure cutout switch 29
high pressure relief valve 29
HMI control panel 38
I
introduction 7
J
jump starting 171
L
loading procedures
enroute inspections 139
post-loading inspection 138
pre-loading inspection 136
low oil level switch 29
low oil pressure switch 29
M
maintenance inspection schedule 193
manual pretrip inspection 35
microprocessor On/Off switch 38
Mode key 40
O
Off key 39, 40, 48
On key 39, 40, 47
OptiSet Plus 26
overload relay 29
P
post-loading inspection 138
preheat buzzer 29
pre-loading inspection 136
pretrip inspection, manual 35
205
protection devices 28
R
rear remote control panel 121
receiver tank sight glass 28
refrigerant oil safety 14
refrigerant safety 12
refrigeration system, specifications 179
remote status light 32
S
safety precautions 11
automatic start/stop operation 12
electrical hazards 12
first aid for refrigerant 14
first aid for refrigerant oil 14
general safety practices 11
refrigerant 12
refrigerant oil 14
Serial Number Locations 198
smart FETs 29
SMART REEFER 2 (SR-2) Controller 23, 37
206
soft keys 40
specifications
electric fuel heater 185
SR-2 Controller 23, 37
status light, remote 32
structural inspection 35
U
unit description 18
W
warranty 186
Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
Precedent™
C-600
TK 55692-2-OP (Rev. 2, 12/15)
©2013 Ingersoll-Rand Company
Printed in U.S.A.
Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
©2013 Ingersoll-Rand Company
Printed in U.S.A.
Precedent™
C-600
TK 55692-2-OP (Rev. 2, 12/15)
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