Thermo King Precedent C-600 Refrigeration Unit, TK486V25 Engine, X430L Compressor, SR-4 Controller Operator's Manual
Below you will find brief information for Refrigeration Unit Precedent C-600, Engine TK486V25, Compressor X430L, Controller SR-4. The Precedent C-600 is a one piece, self-contained, diesel powered, air cooling/heating unit designed for transport refrigeration. It features the quiet running Thermo King TK486V25 engine and the Thermo King X-430 reciprocating compressor. It is available in two models: Standard and SmartPower. The Standard model offers cooling and heating on diesel engine operation, while the SmartPower model adds electric standby operation for added flexibility. Both models utilize the SMART REEFER 4 (SR-4) programmable microprocessor controller for easy operation and monitoring.
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Ingersoll Rand’s Climate Solutions sector delivers energy-effi cient HVACR solutions for customers globally. Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy effi cient 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.
Ingersoll Rand’s Climate Solutions sector delivers energy-effi cient HVACR solutions for customers globally. Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy effi cient 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.
Operator’s Manual
Precedent™
C-600
TK 55692-2-OP (Rev. 2, 12/15)
Operator’s Manual
Precedent™
C-600
TK 55692-2-OP (Rev. 2, 12/15)
Precedent
TM
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
(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
Both Numerical Setpoints and Named Products . 50
Changing the Setpoint - Numerical Setpoint . . . . 51
Changing the Setpoint - Named Product . . . . . . . 55
Starting the Diesel Engine . . . . . . . . . . . . . . . . . . . . . 60
Starting the Electric Motor . . . . . . . . . . . . . . . . . . . . . 61
Switching from Diesel to Electric . . . . . . . . . . . . . . . . 62
Switching from Electric to Diesel . . . . . . . . . . . . . . . . 63
Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . . 64
Terminating a Defrost Cycle . . . . . . . . . . . . . . . . . . . . 67
Selecting Cycle Sentry or Continuous Mode . . . . . . . 67
Using the Gauges Key . . . . . . . . . . . . . . . . . . . . . . . . 71
Gauges Available . . . . . . . . . . . . . . . . . . . . . . . . . 71
Using The Sensors Key . . . . . . . . . . . . . . . . . . . . . . . 73
Sensors Available . . . . . . . . . . . . . . . . . . . . . . . . 74
Using the Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . 75
Pretrip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Performing a Pretrip Test . . . . . . . . . . . . . . . . . . . 78
Flash Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Flash Drive Icon . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Selecting the Flash Drive Menu from the Main Menu
(If Already Connected) . . . . . . . . . . . . . . . . . . . . . . . . 84
Removing the Flash Drive . . . . . . . . . . . . . . . . . . . . . 85
4
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 Service-
Watch 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
Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
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
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Maintenance Inspection Schedule . . . . . . . . . . . . 193
Serial Number Locations . . . . . . . . . . . . . . . . . . . . 198
Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . . 201
Recover Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . 202
Proposition 65 Warning . . . . . . . . . . . . . . . . . . . . . 203
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
6
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.
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.
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.
7
8
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.
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.
This warranty covers the following emission-related parts and components:
• Fuel Injection System
• Intake Manifold
• Exhaust Manifold
• Miscellaneous hoses, clamps, connectors and sealing devices used in the above systems.
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
During the emission warranty period, if a defect in material or workmanship of a warranted part or component is found,
Thermo King will provide:
• 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
During the emission warranty period, the owner is responsible for:
• 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.
Limitations
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.
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 O
FF
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.
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.
12
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.
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.
First Aid
First Aid–Refrigerant
Eyes:
For contact with liquid, immediately flush eyes with large amounts of water. Get prompt medical attention.
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
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.
Ingestion:
Do not induce vomiting. Immediately contact local poison control center or physician.
14
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.
Figure 1: Fan Warning
AMA1581
AMA1579
AMA1580
Figure 2: High Voltage Warning
NOTE: See Figure 3 and Figure 4 for high voltage
component locations.
15
Safety Precautions
1
7
2
6
8
9
9
3
4
5
1. Condenser Motors 4. High Voltage Control Box
2. Evaporator Motor 5. AC Generator
3. High Voltage
Distribution Box
6. Electric Standby Motor &
Power Receptacle
(SmartPower Option)
Figure 3: High Voltage Component Locations (Front)
7.
Evaporator Motor
8.
High Voltage Heater
Strips
9.
High Voltage Junction
Box
All ORANGE conduiting contains High Voltage
Figure 4: High Voltage Component Locations (Rear)
16
Do Not Use Ether Starting Aids
Figure 5: Do Not Use Ether Starting Aids
(Near Engine)
Safety Precautions
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.
SmartPower
TM
Option:
Cooling and heating on diesel engine operation and electric standby operation.
See the following Features and Options.
18
Figure 6: C-600 Front View
Features and Options
The following chart lists key design features and options.
l Standard Features m Option/Factory installed o Option/Dealer Installed
Precedent C-600 Key Features & Options
SMART REEFER SR-4 Controller
SmartPower Electric Standby
SmartPower High-Output
SmartPower Prep Package
OptiSet Plus
ETV (Electronic Throttling Valve)
ServiceWatch Data Logger
CargoWatch Data Logger
CargoLink Sensor Kits
CargoLink Wireless Sensors
EMI-3000
High-Capacity Condenser Coil l l m l l m m l m / o m / o l l
Unit Description
Precedent C-600 Key Features & Options
Easy-access door design
Composite Exterior Panels
Long-Life Coolant/Silicone Hoses
Remote Status Display
Standard Unit Color White
Standard Grille Color Black
Directional Air Delivery
Vibration Isolation System
Aluminum Undermount Fuel Tank 50 Gal.
(186 Liter)
Fuel Level Sensor
Severe Duty Package
Fuel Tanks with Ultrasonic Fuel level
Sensor
Electric Fuel Heater
Frost Plug Heater
Alternator, 65 Amp, 12 Vdc
Appearance Packages l l m m m m m m l l l m / o l l l l
19
Unit Description
Precedent C-600 Key Features & Options
Fresh Air Exchange
Anti-Siphon Device
REB Wireless Communication Platform
TracKing Telematics
PrimAir bulkhead and duct system
Rear Remote Control
Humidity Sensor
Battery Charger
Reliamax Battery,
12 Volt, Wet Cell
EON Battery,
12 Volt, Dry Cell
Remote Electric Power Receptacle m m m m / o o o o m o o m
Diesel Engine
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.
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:
• EMI 3000-Hour Cyclonic Air Cleaner Assembly and Air
Cleaner Element
• EMI 5-Micron 3000-Hour Fuel Filter
• EMI 3000-Hour Dual Element Oil Filter
• API Rating CI-4 Mineral Oil
• 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.
NOTE: Units equipped with the EMI 3000 package do require regular inspection in accordance with Thermo King's maintenance recommendations.
NOTE: EMI 3000 oil filters and EMI 3000 air cleaners are
NOT interchangeable with older style oil filters and air cleaners.
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.
Electronic Throttling Valve
The ETV provides enhanced control of the refrigeration system as follows:
• Allows the refrigeration system to fully utilize the power capabilities of the engine under varying conditions
• 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.
22
Unit Description
SMART REEFER
TM
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.
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:
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
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-SENTRY
TM
Start-Stop
Controls
The CYCLE-SENTRY Start-Stop fuel saving system provides optimum operating economy.
WARNING: The unit can start at any time without warning. Press the O
FF
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.
24
Data Logging
There are two separate data loggers. The data is downloaded through the USB ports on the front of the control box.
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.
USB Ports:
:
• 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.
• The PC Computer Only USB Port allows a PC Computer to be connected to the unit via a standard USB Cable.
Unit Description
ON
OFF
THERMO KING
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
SR4
Smart Reefer 4
MICRO
PROCESSOR
ON
OFF
USB PORT
FLASH DRIVE ONLY
1
2
USB PORT
PC COMPUTER ONLY
1.
Flash Drive Only USB Port
2.
PC Computer Only USB Port
Figure 9: USB Ports
25
Unit Description
OptiSet
TM
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.
FreshSet
TM
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 O
N
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.
Figure 10: Door Latch Locations
ARA2207
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 O
FF
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.
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.
28
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.
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.
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.
29
Unit Description
F5
F6
F7
F8
F10
F12
F13
F15
F20
F25
F25
Fuse Size Function
F1
F2
F3
F4
5A
15A
40A
None
2A
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
60A Preheat Circuit
(Note 2)
15A High Speed Solenoid Circuit
2A
5A
8X Power for CAN bus
2A Power for CAN bus J12
15A On/Off Relay Circuit
5A 2A Power for CAN bus J13
2A
2A
Status Light Circuit
SR-4 Power Supply Circuit
2A Alternator Sense Circuit
10A Fresh Air Door Circuit
7.5A
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.
30
Unit Description
1
2
3
4
5
1.
Control Box 4.
PC Only USB Poet
2.
HMI Control Panel 5.
Flash Drive Only USB
Port
3.
Microprocessor
On/Off Switch
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.
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 14: Remote Status Display (All LEDs Shown)
32
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
1
2
3
34
1.
Status Indicator
2.
Fuel Level Indicator
Figure 18: Remote Status Display with Fuel Level
1.
Status Indicator
2.
Fuel Level Indicator
3.
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
ON
OFF
THERMO KING
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
SR4
Smart Reefer 4
MICRO
PROCESSOR
ON
OFF
USB PORT
FLASH DRIVE ONLY
USB PORT
PC COMPUTER ONLY
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.
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.
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
O
FF
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.
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.
38
3
1
2
ON
OFF
THERMO KING
35
GAUGES
.8
°F
SENSORS
35
MENU
SR4
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
Figure 21: Control Panel Display and Keys
4
5
Operating Instructions
Display Icons
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:
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.
39
Operating Instructions
Hard Keys
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.
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.
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
•
NEXT
•
+ OR -
•
•
•
CLEAR
HOURMETERS
GAUGES
• SELECT • BACK
•
NO
•
•
EXIT
•
SENSORS
HELP
40
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.
ON
OFF
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.
Figure 22: ON Key
41
Operating Instructions
ON
OFF
ON
OFF
FLASH DRIVE
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.
EXIT
FLASH DRIVE DETECTED
Figure 25: Flash Drive Menu
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.
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:
• 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
• “Send OptiSet Plus files
• RETRIEVE
• “Retrieve OptiSet Plus files
The Flash Drive is also available from the Main Menu.
42
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.
Configurable Soft Keys
When the Standard Display is shown, the default functions of the two center soft keys are GAUGES and SENSORS.
ON
35
GAUGES
°F
.8
SENSORS
35
MENU
OFF
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:
Gauges Pretrip SOT (start of trip)
Sensors Data Logger Hourmeters
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
35
PRETRIP
.8
°F
SOT
OFF
35
MENU
Figure 26: Soft Keys
Figure 27: PRETRIP and SOT
43
Operating Instructions
Display Heater
The HMI Control Panel is equipped with a display heater. This heater is needed to make the display visible in very cold ambient temperatures.
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.
If a Language is Enabled
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
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.
ON
OFF
CURRENT LANGUAGE IS
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 29: + or -, then YES Key
The display will briefly show PROGRAMMING
LANGUAGE - PLEASE WAIT in the new language as shown
Figure 30: New Language
Figure 31: Standard Display, 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.
ON
LOG ALARMS ACTIVE
GO TO MENU TO VIEW
OFF
EXIT
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
ON
OFF
35
GAUGES
.8
°F
SENSORS
35
MENU
Figure 33: Standard Display
46
Turning The Unit Off
Pressing the OFF Key stops unit operation. The unit shuts down immediately and the display briefly shows the power
SYSTEM IS POWERING DOWN
ON
OFF
Operating Instructions
The Standard Display
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
35
GAUGES
°F
.8
SENSORS
35
MENU
OFF
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.
ON
OFF
OFF
Figure 36: Standard Display
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.
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.
48
Operating Instructions
ON
OFF
TEMPERATURE
35
°F
.8
SETPOINT
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.
Changing The Setpoint
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
ON
35
GAUGES
°F
.8
SENSORS
35
MENU
OFF
Figure 38: Setpoint
49
50
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
• A single setpoint temperature may be allowed for the specific named product.
• A numerical setpoint range may be allowed for the specific named product.
ON
PRODUCT
35
GAUGES
°F
.8
SENSORS
35
MENU
OFF
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
ON
35
GAUGES
.8
°F
SENSORS
35
MENU
OFF
Figure 40: Left Soft Key Labeled
“PRODUCT/SETPOINT”
Figure 39: Left Soft Key Labeled “Product”
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.
The setpoint display appears (Figure 41).
CURRENT SETPOINT
ON
35 F
OFF
+
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.
ON
OFF
NEW SETPOINT WILL BE
+
40 F
YES
OK?
NO
Figure 42: Setpoint Changed Using “+” 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
ON
OFF
NEW SETPOINT WILL BE
+
40 F
YES
OK?
NO
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.
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
35
GAUGES
.8
°F
SENSORS
40
MENU
OFF
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
ON
NEW SETPOINT IS
40 F
OFF
Figure 45: Up Arrow
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.
Figure 44: New Setpoint
52
• 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.
Operating Instructions
53
Operating Instructions
ON
OFF
35
GAUGES
.8
°F
SENSORS
35
MENU
ON
OFF
NEW SETPOINT WILL BE
+
40 F
YES
OK?
NO
ON
OFF
NEW SETPOINT IS
40 F
ON
OFF
Setpoint Key
CURRENT SETPOINT
+
35 F
EXIT
+ or - Keys
ON
OFF
NEW SETPOINT WILL BE
+
40 F
YES
OK?
NO
New Setpoint
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
40
MENU
Yes or No Keys
Figure 46: Changing the Setpoint - Numerical Setpoint
54
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).
ON
GRAPEFRUIT, ARIZONA
PRODUCT
59
GAUGES
°F
.8
SENSORS
59
MENU
OFF
Figure 47: Product Displayed
The display briefly shows PRODUCT and then the setpoint
ON
OFF
CURRENT PRODUCT IS
GRAPEFRUIT, ARIZONA
+
EXIT
Figure 48: Setpoint Display
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.
ON
OFF
NEW PRODUCT WILL BE
POTATO, LATE CROP
+
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.
ON
OFF
NEW PRODUCT WILL BE
POTATO, LATE CROP
+
YES
OK?
NO
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.
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.
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).
Figure 50: Yes and No Keys
56
Operating Instructions
ON
OFF
POTATO, LATE CROP
PRODUCT
45
GAUGES
.8
°F
SENSORS
45
MENU
Figure 52: Standard Display
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.
• 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.
57
Operating Instructions
58
ON
OFF
GRAPEFRUIT, ARIZONA
PRODUCT
59
GAUGES
.8
°F
SENSORS
59
MENU
ON
OFF
NEW PRODUCT WILL BE
POTATO, LATE CROP
+
YES
OK?
NO
ON
OFF
NEW NAMED PRODUCT IS
POTATO, LATE CROP
ON
OFF
Product Key
CURRENT PRODUCT IS
GRAPEFRUIT, ARIZONA
+
EXIT
Setpoint Display
ON
OFF
+ or - Keys
NEW PRODUCT WILL BE
POTATO, LATE CROP
+
YES
OK?
NO
Yes or No Keys
If Yes Key Chosen,
ON
Figure 53: Changing the Setpoint, Named Product
New Named Product
OFF
POTATO, LATE CROP
PRODUCT
45
GAUGES
°F
.8
SENSORS
45
MENU
Standard Display
Operating Instructions
Changing the Setpoint - Both
Numerical Setpoint and Named
Product Available
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
PRODUCT/
SETPOINT
35
GAUGES
.8
°F
SENSORS
35
MENU
Figure 54: PRODUCT and SETPOINT are displayed
The NAMED PRODUCT / NUMERIC SETPOINT prompt
will appear as shown (Figure 55).
.
ON
OFF
NAMED PRODUCT / NUMERIC
SETPOINT?
EXIT NAMED NUMERIC
Figure 55: NAMED PRODUCT / NUMERIC
SETPOINT Prompt
• 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.
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.
ON
OFF
DIESEL ENGINE STARTING
Figure 56: Engine Start Screen
After the engine is started the display returns to the Standard
Display of temperature and setpoint.
60
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.
ON
OFF
ELECTRIC STANDBY DETECTED
DO YOU WISH TO SWITCH TO
ELECTRIC?
YES NO
ON
OFF
PROGRAMMING ELECTRIC
STANDBY
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.
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
62
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.
ON
OFF
ELECTRIC STANDBY NOT DETECTED
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
ON
PROGRAMMING DIESEL MODE
OFF
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.
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
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).
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 63: Press Defrost Key
The display briefly shows [DEFROST], [PROGRAMMING
DEFROST - PLEASE WAIT] and then [DEFROST
ON
DEFROST STARTED
OFF
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
OFF
SET
POINT
GAUGES SENSORS
35
MENU
ON
OFF
DEFROST NOT AVAILABLE
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
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
Yes
ON
OFF
SET
POINT
GAUGES SENSORS
35
MENU
ON
OFF
DEFROST STARTED
No
ON
OFF
DEFROST NOT AVAILABLE
Figure 67: Initiating a Manual Defrost Cycle
66
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
SET
POINT
35
GAUGES
.8
°F
SENSORS
35
MENU
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.
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.
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
67
Operating Instructions
ON
OFF
SET
POINT
35
GAUGES
.8
°F
SENSORS
35
MENU
ON
OFF
PROGRAMMING CONT MODE
PLEASE WAIT
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,
Figure 70: Continuous Mode
The new mode is confirmed for 3 seconds (Figure 71).
ON
NEW SYSTEM MODE IS
CONTINUOUS
OFF
Figure 71: New Mode Confirmed
68
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
.8
°F
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.
Operating Instructions
69
Operating Instructions
70
ON
OFF
35
GAUGES
.8
°F
SENSORS
35
MENU
ON
OFF
35
GAUGES
.8
°F
SENSORS
35
MENU
ON
OFF
PROGRAMMING CONT MODE
PLEASE WAIT
Continuous Mode
Selected
ON
NEW SYSTEM MODE IS
CONTINUOUS
OFF
ON
OFF
35
GAUGES
.8
°F
SENSORS
35
MENU
Figure 73: Selecting Cycle Sentry or Continuous Mode
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.
To access the GAUGES Menu, press the GAUGES Key
ON
OFF
35
GAUGES
.8
°F
SENSORS
35
MENU
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).
ON
OFF
EXIT
BATTERY VOLTAGE
13.
8
LOCK BACK
v
NEXT
Figure 75: Gauge Display Locked
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.
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.
Accessory Battery Voltage:
Displays the voltage at the alternator.
Engine RPM:
Displays the engine speed in RPMs.
Fuel Level Sensor:
Displays the fuel level if a fuel level sensor is installed.
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.
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
• Run Relay Feedback • Spare Output 3
• Alternator Excite
Output
• Spare Output 4
• Defrost Damper
• Heat Output
• Motor RPM
• Spare Digital Input 1
• Spare Output 5
• Fresh Air Exchange
Output
• Fresh Air Exchange
Feedback
• Diesel/Electric Relay
(SmartPower units only)
• Spare Digital Input 2 • Electric Ready Input
(SmartPower units only)
72
Operating Instructions
• Spare Digital Input 3
• Spare Digital Input 4
• Electric overload
(SmartPower units only)
• Hot Gas Bypass (ETV units only)
• Spare Analog Input 1
• Spare Analog Input 2
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.
To access the SENSORS Menu, press the SENSORS Key:
ON
OFF
35
GAUGES
°F
.8
SENSORS
35
MENU
Figure 76: Sensors Key
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)
ON
OFF
CONTROL DISCHARGE AIR TEMPERATURE
48.
3
°F
EXIT LOCK BACK 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.
Sensors Available
Control Return Air Temperature:
Displays the temperature of the control return air sensor.
Display Return Air Temperature:
Displays the temperature of the display return air sensor.
Control Discharge Air Temperature:
Displays the temperature of the control discharge air sensor.
Display Discharge Air Temperature:
Displays the temperature of the display discharge air sensor.
Temperature Differential:
Displays the calculated difference between the control return air sensor and the control discharge air sensor.
Evaporator Coil Temperature:
Displays the temperature of the evaporator coil sensor.
Ambient Air Temperature:
Displays the temperature of the ambient air sensor.
* Spare 1 Temperature:
Displays the temperature of the spare 1 temperature sensor.
* Log Sensor 1:
Displays the temperature of the
CargoWatch Data Logger temperature sensor 1.
* Log Sensor 2:
Displays the temperature of the
CargoWatch Data Logger temperature sensor 2.
* Log Sensor 3:
Displays the temperature of the
CargoWatch Data Logger temperature sensor 3.
* Log Sensor 4:
Displays the temperature of the
CargoWatch Data Logger temperature sensor 4.
* Log Sensor 5:
Displays the temperature of the
CargoWatch Data Logger temperature sensor 5.
* Log Sensor 6:
Displays the temperature of the
CargoWatch Data Logger temperature sensor 6.
Board Temperature Sensor:
Displays the internal temperature of the HMI Control Panel pc board.
* If sensors have been added.
74
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
ON
35
GAUGES
.8
°F
SENSORS
35
MENU
OFF
ON
OFF
MAIN MENU
PRETRIP
LANGUAGE
ALARMS
GAUGES
EXIT SELECT UP DOWN
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
To return to the Standard Display press the EXIT Key.
Figure 79: Pretrip Submenu
Main Menu Choices
Each of these Main Menu choices will be explained in following pages of this chapter:
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.
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
76
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
When performing a Pretrip Test, the following issues should be considered.
• 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.
• Always perform Pretrip Tests with the trailer cargo doors closed to prevent false test failures.
Performing a Pretrip Test
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.
• 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
35
GAUGES
°F
.8
SENSORS
35
MENU
OFF
Figure 80: Menu Key
78
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
ON
OFF
MAIN MENU
PRETRIP
LANGUAGE
ALARMS
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.
ON
OFF
PROGRAMMING PRETRIP MODE
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
NO PRETRIP -- ALARM ACTIVE
OFF
EXIT
Figure 83: Alarms Not Cleared
79
Operating Instructions
If all alarms were cleared, the Pretrip Test display appears
ON
OFF
NON-RUNNING PRETRIP
TEST 1 OF 26
SENSOR CHECK
HOUR
METERS
SENSORS GAUGES
• 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.
ON
RUNNING PRETRIP
TEST 21 OF 26
COOL TEST
OFF
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.
• The soft keys may be used during the Pretrip Test to select the Hourmeter, Gauge or Sensor menus.
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.
80
ON
OFF
EXIT
PRETRIP
PASS
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.
Operating Instructions
81
Operating Instructions
82
ON
OFF
35
GAUGES
°F
.8
SENSORS
35
MENU
ON
OFF
MAIN MENU
PRETRIP
LANGUAGE
ALARMS
GAUGES
EXIT SELECT UP DOWN
ON
OFF
PROGRAMMING PRETRIP MODE
Yes
ON
OFF
NON-RUNNING PRETRIP
TEST 1 OF 26
SENSOR CHECK
SENSORS GAUGES
Alarms Cleared?
ON
No
NO PRETRIP -- ALARM ACTIVE
OFF
EXIT
Exit Pretrip Test, clear alarms, restart Pretrip Test.
ON
OFF
RUNNING PRETRIP
TEST 21 OF 26
COOL TEST
SENSORS GAUGES
ON
OFF EXIT
PRETRIP
PASS
Figure 87: Performing a Pretrip Test
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:
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
• 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.
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.
ON
OFF
SET
POINT
35
GAUGES
°F
.8
SENSORS
35
MENU
Figure 88: Flash Drive Icon
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
35
GAUGES
°F
.8
SENSORS
35
MENU
OFF
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).
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).
ON
OFF
MAIN MENU
FLASH DRIVE
PRETRIP
LANGUAGES
ALARMS
EXIT SELECT UP DOWN
84
ON
OFF
FLASH DRIVE DETECTED
EXIT DOWN
LOAD
FLASH
LOAD
OPTISET
PLUS
Operating Instructions
ON
OFF
EXIT
FLASH DRIVE REMOVED
HELP
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.
Figure 92: Flash Drive Removed
If the HELP Soft Key is pressed the display shown in Figure 93
will appear.
ON
OFF
FLASH DRIVE REMOVED
PLEASE CHECK THE FLASH DRIVE FOR
PROPER INSERTION – REMOVE AND
REINSERT
EXIT
Figure 93: Help Soft Key Pressed
85
Operating Instructions
Languages (If Enabled)
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.
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.
Available Languages
The following languages are available:
• English • French • Spanish
Selecting an Alternate Language
To select an alternate language, press the MENU Key (Figure
ON
OFF
35
GAUGES
.8
°F
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
ON
OFF
MAIN MENU
PRETRIP
LANGUAGE
ALARMS
GAUGES
EXIT SELECT UP DOWN
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.
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
°F
.8
SENSORS
35
MENU
ON
OFF
MAIN MENU
PRETRIP
LANGUAGE
ALARMS
GAUGES
EXIT SELECT UP DOWN
ON
OFF
NEW LANGUAGE WILL BE
DEUTSCH
+
YES
OK?
NO
ON
HAUPTMENU
SPRACHE
OFF
BEENDEN AUSWHAL WEITER
ON
OFF
SET
POINT
35
MESSGE
RAT
°F
.8
SENSORE
N
35
MENU
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 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).
Figure 101: Select Desired Language
NOTE: All languages in the installed software can be selected using this method.
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
ON
OFF
EXIT
LOG ALARMS ACTIVE
GO TO MENU TO VIEW
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.
ON
OFF
SET
POINT
35
35
MENU GAUGES SENSORS
Shutdown Alarms
If a Shutdown Alarm occurs while the unit is running it will be
indicated by all of the following (Figure 104):
• 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
35
35
MENU GAUGES SENSORS
OFF
Figure 104: Reverse/Normal Video
Figure 103: Alarm Icon
91
Operating Instructions
Pretrip Alarms
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 When Switching Between Diesel and
Electric Mode
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.
Clearing Alarm Codes
Most alarm codes can be cleared conventionally from the
Alarm Menu using the CLEAR Key.
The following control and display sensor alarm codes can only be cleared from the Maintenance Menu or Guarded Access
Menu:
• 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.
92
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.
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
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
OFF
35
GAUGES SENSORS
35
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.
ON
OFF
MAIN MENU
PRETRIP
LANGUAGE
ALARMS
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).
ON
OFF
5
64 x
EXIT
1 OF 2 ALARMS
CHECK AMBIENT TEMP SENSOR
PRETRIP REMINDER
64
CLEAR HELP DOWN
ON
OFF
5
64 x
EXIT
1 OF 2 ALARMS
CHECK AMBIENT TEMP SENSOR
PRETRIP REMINDER
64
CLEAR HELP DOWN
Figure 107: Alarms Menu
If necessary to view all alarms, scroll down using the DOWN
Figure 108: Down Key
If the alarm situation has been resolved press the CLEAR Key
to clear the alarm (Figure 109).
ON
OFF
5
64 x
EXIT
1 OF 2 ALARMS
CHECK AMBIENT TEMP SENSOR
PRETRIP REMINDER
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
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.
ON
OFF
35
GAUGES SENSORS
35
MENU
ON
OFF
64
1 OF 1 ALARMS
PRETRIP REMINDER x
EXIT
64
CLEAR HELP DOWN
Figure 110: Pretrip Reminder
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
Figure 111: Unit Shutdown
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).
ON
66
1 OF 1 ALARMS
LOW ENGINE OIL LEVEL
OFF x
EXIT
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.
LOW ENGINE OIL LEVEL
ON
CHECK ENGINE OIL LEVEL. IF UNIT IS SHUT
DOWN REPAIR IMMEDIATELY. OTHERWISE
REPORT ALARM AT END OF DAY.
OFF
EXIT
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.
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
ON
OFF
EXIT
LOG ALARMS ACTIVE
GO TO MENU TO VIEW
ON
OFF
35
35
MENU GAUGES SENSORS
ON
OFF
35
35
MENU GAUGES SENSORS
ON
OFF
35
35
MENU GAUGES SENSORS
ON
OFF
5
64 x
EXIT
1 OF 2 ALARMS
CHECK AMBIENT TEMP SENSOR
PRETRIP REMINDER
64
CLEAR HELP DOWN
ON
OFF
Operating Instructions
35
35
GAUGES SENSORS MENU
ON
OFF
MAIN MENU
PRETRIP
LANGUAGE
ALARMS
GAUGES
EXIT SELECT UP DOWN
ON
OFF
5
64 x
EXIT
1 OF 2 ALARMS
CHECK AMBIENT TEMP SENSOR
PRETRIP REMINDER
64
CLEAR HELP DOWN
ON
OFF
66
1 OF 1 ALARMS
LOW ENGINE OIL LEVEL x
EXIT
64
CLEAR HELP DOWN
ON
OFF
5
64 x
EXIT
1 OF 2 ALARMS
CHECK AMBIENT TEMP SENSOR
PRETRIP REMINDER
64
CLEAR HELP DOWN
ON
OFF
64
1 OF 1 ALARMS
PRETRIP REMINDER x
EXIT
64
CLEAR HELP DOWN
Figure 114: Displaying and Clearing Alarm Codes
ON
OFF
LOW ENGINE OIL LEVEL
CHECK ENGINE OIL LEVEL. IF UNIT IS SHUT
DOWN REPAIR IMMEDIATELY. OTHERWISE
REPORT ALARM AT END OF DAY.
EXIT
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.
Displaying Gauges
Gauges are displayed using the Gauges Menu. From the
Standard Display, press the MENU Key (Figure 115).
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
ON
OFF
MAIN MENU
PRETRIP
LANGUAGE
ALARMS
GAUGES
EXIT SELECT UP DOWN
ON
OFF
35
GAUGES
°F
.8
SENSORS
35
MENU
Figure 116: Up, Down, Select Keys
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
Figure 115: Menu Key
98
Operating Instructions
ON
OFF
EXIT
BATTERY VOLTAGE
13.
8
LOCK BACK
v
NEXT
Displaying Sensors
Sensors are displayed using the Sensors Menu. From the
Standard Display, press the MENU Key (Figure 118).
ON
35
GAUGES
.8
°F
SENSORS
35
MENU
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.
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
99
Operating Instructions
ON
OFF
CONTROL DISCHARGE AIR TEMPERATURE
48.
3
°F
EXIT LOCK BACK 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.
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
100
Operating Instructions
ON
OFF
35
GAUGES
.8
°F
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).
ON
OFF
GAUGES
SENSORS
DATA LOGGER
MAIN MENU
HOURMETERS
EXIT SELECT UP DOWN
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
ON
OFF
START TRIP
PRINT/VIEW
DATA LOGGER
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.
ON
OFF
PRINT DATA
DELIVERY TICKET
TRIP TICKET
EXIT SELECT UP DOWN
CONTROLLER VERSION NUMBER:
CONTROLLER TYPE:
DATALOGGER VERSION NUMBER:
TEMPERATURE UNITS:
START:
FINISH:
SENSORS:
SETPOINT:
B007
SR2
6512
FAHRENHEIT
05/30/08 08:29:08
05/30/08 09:18:33
2
32.0
Sensor Min Ave Max Last
#1: 35 35 35 35
#2: - - - - - - - - - - - -
SENSOR #1:
SENSOR #2:
LOG SENSOR 1
LOG SENSOR 2
Figure 124: Sample Delivery Ticket
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.
Figure 123: Select Key, Print Delivery Ticket
102
ON
PRINT DATA
DELIVERY TICKET
TRIP TICKET
OFF
EXIT SELECT UP DOWN
Figure 125: Select Key, Print Trip Ticket
Operating Instructions
UNIT SERIAL NUMBER:
CONTROLLER SERIAL NUMBER:
TRAILER ID: xxxxxxxxxx
A00021506190T3 xxxxxxxxxx
CONTROLLER VERSION NUMBER:
CONTROLLER TYPE:
DATALOGGER VERSION NUMBER:
TEMPERATURE UNITS:
START:
FINISH:
SENSORS:
SETPOINT:
B007
SR2
6512
FAHRENHEIT
05/30/08 09:50:08
05/30/08 13:07:33
1
32.0
1120
1105
1050
1035
1020
1005
0950
30 - MAY - 2008
1305
1250
35.0
35.2
1235
1220
1205
35.1
35.2
35.1
30 - MAY - 2008
1150
1135
35.0
35.0
35.0
34.9
35.0
35.0
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
35
GAUGES
.8
°F
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
ON
OFF
MAIN MENU
SENSORS
DATA LOGGER
HOURMETERS
MODE
EXIT SELECT UP DOWN
Figure 128: Select Key
104
Operating Instructions
Press the NEXT or PREVIOUS Key to scroll through the
ON
OFF
HOURMETERS
TOTAL UNIT RUN HOURS
TOTAL ENGINE RUN HOURS
833
TOTAL ELECTRIC RUN HOURS
EXIT SELECT UP DOWN
To return to the Main Menu press the EXIT Key. To return to the Standard display press the EXIT Key again.
Hourmeter Names and Definitions
Only configured hourmeters that have been enabled in the
Viewable Hourmeter Setup Menu will be shown:
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
Hourmeter
Name
Total Hours
Definition
Total Run
Time Hours
Total number of hours the unit has been turned on (protection 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
Controller
Power On
Pretrip
Reminder
Engine
Reminder 1
Engine
Reminder 2
Electric
Reminder 1
Electric
Reminder 2
User Programmable - The number of hours before a Total Unit Run Time Maintenance
Reminder 2 occurs.
Total hours the controller and HMI Control
Panel have been turned on.
User Programmable - number of hours before a Pretrip Reminder occurs.
User Programmable - The number of hours before an Engine Run Time Maintenance
Reminder 1 occurs.
User Programmable - The number of hours before an Engine Run Time Maintenance
Reminder 2 occurs.
User Programmable - The number of hours before an Electric Run Time Maintenance
Reminder 1 occurs.
User Programmable - The number of hours before an Electric 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.
Mode Menu
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).
106
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).
When shipped from the factory, only the Cycle
Sentry/Continuous Mode is enabled.
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).
ON
OFF
35
GAUGES
.8
°F
SENSORS
35
MENU
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
ON
OFF
DATA LOGGER
MAIN MENU
HOURMETERS
MODE
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).
ON
OFF
CHANGE MODE
TURN ON CYCLE SENTRY MODE
FAHRENHEIT
KEYPAD LOCKOUT
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
ON
OFF
CHANGE MODE
TURN ON CYCLE SENTRY MODE
FAHRENHEIT
KEYPAD LOCKOUT
START SLEEP MODE
EXIT SELECT UP DOWN
Figure 132: Select, Up, Down Keys
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.
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.
108
Operating Instructions
ON
OFF
CHANGE MODE
TURN OFF CYCLE SENTRY
EXIT SELECT
Select Temperature Units
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).
ON
OFF
CHANGE MODE
TURN ON CYCLE SENTRY MODE
FAHRENHEIT
KEYPAD LOCKOUT
START SLEEP MODE
EXIT SELECT UP DOWN
Figure 134: Select Key
Confirmation screens will appear briefly, the unit will switch to
Continuous Mode operation and the Cycle Sentry Icon will disappear.
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
109
Operating Instructions
ON
OFF
EXIT
TEMPERATURE UNITS
FAHRENHEIT
CELSIUS
SELECT UP DOWN
Figure 136: Up, Down, Select Keys
Temperatures will be displayed in the selected units.
• 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 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.
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).
ON
OFF
CHANGE MODE
TURN ON CYCLE SENTRY MODE
FAHRENHEIT
OPEN FRESH AIR EXCHANGE
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.
110
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).
ON
OFF
CHANGE MODE
TURN ON CYCLE SENTRY MODE
FAHRENHEIT
KEYPAD LOCKOUT
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
ON
KEYPAD LOCKOUT
ARE YOU SURE?
OFF
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
ON
OFF
CHANGE MODE
TURN ON CYCLE SENTRY MODE
FAHRENHEIT
KEYPAD LOCKOUT
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.
112
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
35
GAUGES
.8
°F
SENSORS
35
MENU
Figure 141: Menu Key
From the Main Menu choose Electric Standby and press the
ON
OFF
MAIN MENU
HOURMETERS
MODE
ELECTRIC STANDBY
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.
114
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).
ON
OFF
ELECTRIC STANDBY UNDETECTED
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
ON
OFF
35
GAUGES
.8
°F
SENSORS
35
MENU
Figure 144: Menu Key
From the Main Menu choose Diesel Mode and press the
ON
OFF
MAIN MENU
HOURMETERS
MODE
DIESEL MODE
ADJUST BRIGHTNESS
EXIT SELECT UP DOWN
The new mode is confirmed for 10 seconds. The unit will start and run in Diesel Mode.
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 145: Select Key
116
Operating Instructions
ON
OFF
35
GAUGES
.8
°F
SENSORS
35
MENU
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).
ON
OFF
MAIN MENU
MODE
ELECTRIC STANDBY
ADJUST BRIGHTNESS
TIME
EXIT SELECT UP DOWN
Figure 147: Select Key
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).
ON
OFF
DISPLAY BRIGHTNESS WILL BE
OFF
LOW
MEDIUM
EXIT SELECT UP DOWN
Figure 148: Select Key
To return to the Main Menu press the EXIT Key. To return to the Standard display press the EXIT Key again.
Time
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
35
GAUGES
.8
°F
SENSORS
35
MENU
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.
ON
TIME MENU
01:18 MONDAY 10 DEC 2012
OFF
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
ON
OFF
MAIN MENU
ELECTRIC STANDBY
ADJUST BRIGHTNESS
TIME
CLEAR ALL ECU FAULTS
EXIT SELECT UP DOWN
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.
Clear All ECU Faults
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.
Figure 150: Select Key
118
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 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).
ON
OFF
MAIN MENU
ADJUST BRIGHTNESS
TIME
CLEAR ALL ECU FAULTS
EXIT SELECT UP DOWN
ON
OFF
35
GAUGES
°F
.8
SENSORS
35
MENU
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
ON
OFF
CLEAR ALL ECU FAULTS
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
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
122
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
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.
Turns the unit off.
OFF Key
Up Arrow
Key
Increases setpoint or changes other setting.
Down
Arrow Key
Select Key
Enter Key
Decreases setpoint or changes other setting.
Allows Cycle-Sentry to be turned on and off, displays the discharge air temperature and alarms.
Executes a prompt or loads a new setpoint or other setting.
Pretrip Key Initiates a Pretrip Test.
124
TK Logo
Key
Sends a Start of Trip marker to the data logger.
Defrost Key
Initiates a defrost cycle if 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.
Figure 160: Rear Remote Control Panel
Optional Rear Remote Control Panel
Cool Icon
Heat Icon
This icon appears when the unit is cooling.
This icon appears when the unit is heating.
This icon appears when the unit is in modulation.
Modulation
Icon
Defrost Icon
This icon appears when the unit is defrosting.
Cycle-Sentry
Icon
This icon appears when the unit is operating in Cycle-Sentry mode.
Alarm Icon
Electric
Standby Icon
This icon appears when an alarm condition has been detected.
This icon appears when the unit is operating in the optional electric standby mode.
Setpoint
Icon
Not Used
This icon appears when the setpoint is being shown in the display.
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.
Figure 162: Remote Lock Out Display
126
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
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
Figure 164: Standard Display
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: 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 166: Press Enter Key
IMPORTANT: Confirm that the correct setpoint is set.
Figure 167: Press Select Key
2.
Use the Up and Down Arrow Keys to chose either YES or nO. Yes = Cycle Sentry Mode. nO = Continuous Mode.
129
Optional Rear Remote Control Panel
Figure 168: Press Up or Down Arrow Keys
3.
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.
Displaying the Discharge Air
Temperature
The discharge air temperature can be shown using the Select
Key.
1.
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.
Figure 169: Press Enter Key
4.
The display will then return to the Remote Standard
Display.
130
Figure 170: Press Select Key Twice
2.
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.
The defrost cycle will terminate automatically.
132
Optional Rear Remote Control Panel
Sending a Start of Trip Marker
A Start of Trip marker can be sent to the data loggers using the
TK Logo Key.
1.
Press the TK Logo Key. The Start of Trip [EnTEr SOt] prompt will appear in the display.
2.
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.
Figure 177: Press TK Logo Key
Figure 178: Press Enter 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:
• 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.
136
Loading and Enroute Inspections
8
7
9
6
ADZ30
5
1
4
2
3
1.
Correct load height (trailers without chutes)
2.
Tight doors and gaskets
3.
Good air circulation around load
4.
Proper cargo temperature (prior to loading)
5.
Interior/exterior walls and insulation in good condition
6.
Clear defrost drains
7.
Good outside air circulation
8.
Unit inspection
9.
Tight seals
Figure 183: Loading Considerations
137
Loading and Enroute Inspections
Post-Loading Inspection
Post-loading inspections ensure the cargo has been loaded properly. To perform a post-load inspection:
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.
4.
Close or supervise the closing of the cargo box doors.
Make sure they are securely locked.
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.
138
Loading and Enroute Inspections
Enroute Inspections
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.
Initiate a manual defrost cycle after each enroute inspection.
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.
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.
3.
Immediately contact the nearest Thermo King Service
Center or your company office.
4.
Take all necessary steps to protect and maintain proper load temperature.
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
Problem
A return air temperature reading is not within desired temperature range of the setpoint.
Inspection Troubleshooting
Cause
The unit has not had time to cool down to correct temperature.
Remedy
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 or has just completed a defrost cycle.
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.
The evaporator is plugged with frost.
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.
140
Problem
Loading and Enroute Inspections
Cause Remedy
Improper air circulation in the cargo compartment.
Inspect the unit and cargo compartment to determine if the evaporator fan(s) are working and properly circulating the air. Poor air circulation may be due 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.
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
142
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
SET
POINT
35
35
MENU GAUGES SENSORS
ON
OFF
EXIT
LOG ALARMS ACTIVE
GO TO MENU TO VIEW
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.
Figure 185: Alarm Display
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.
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
35
MENU GAUGES SENSORS
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.
144
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.
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.
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.
145
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
Level Of
Action
00 No Alarms Exist
2 Evaporator Coil Sensor
3 Control Return Air Sensor
4 Control Discharge Air Sensor
5 Ambient Air Sensor
6 Coolant Temp Sensor
7 Engine RPM Sensor
9 High Evaporator Temperature
None required
Manually monitor load temperature with independent thermometer. Report alarm at end of day.
Manually monitor load temperature with independent thermometer. Report alarm at end of day.
Manually monitor load temperature with independent thermometer. Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Manually monitor load temperature. Report alarm at end of the day.
X
X
X
X
X
X
X
X
146
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
Level Of
Action
10
11
13
17
18
19
High Discharge Pressure
Unit Controlling on Alternate
Sensor
12 Sensor or Digital Input Shutdown
Sensor Calibration Check
Engine Failed to Crank
High Engine Coolant
Temperature
Low Engine Oil Pressure
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
Manually monitor load temperature with independent thermometer. Report alarm at end of day.
The indicated zone is no longer able to operate and has been shut down. Repair immediately.
Manually monitor load temperature with independent thermometer. Report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown repair immediately. Otherwise, report alarm at end of day.
It unit is shutdown repair immediately. Otherwise report alarm at end of day.
X
X
X
X
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.
Code Description Corrective Action
Level Of
Action
20 Engine Failed to Start
21 Cooling Cycle Check
22 Heating Cycle Check
23 Cooling Cycle Fault
24 Heating Cycle Fault
25 Alternator Check
26 Refrigeration Capacity
148
If unit is shutdown repair immediately. Otherwise, report alarm at end of day.
Manually monitor load temperature with independent thermometer. Report alarm at end of day.
Manually monitor load temperature with independent thermometer. Report alarm at end of day.
The indicated zone is no longer able to operate and has been shut down. Repair immediately.
The indicated zone is no longer able to operate and has been shut down. Repair immediately.
If unit is shutdown repair immediately. Otherwise, report alarm at end of day.
Manually monitor load temperature with independent thermometer. Report alarm at end of day.
X
X
X
X
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.
Code Description Corrective Action
Level Of
Action
28 Pretrip Abort
29 Defrost Damper Circuit
30 Defrost Damper Stuck
31 Oil Pressure Switch
32 Refrigeration Capacity Low
33 Check Engine RPM
35 Run Relay Circuit
Report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown repair immediately. Otherwise, report alarm at end of day.
The indicated zone is no longer able to operate and has been shut down. Repair immediately.
Report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
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.
Code Description Corrective Action
Level Of
Action
36 Electric Motor Failed to Run
37 Engine Coolant Level
38 Electric Phase Reversed
39 Water Valve Circuit
40 High Speed Circuit
41
Check Engine Coolant
Temperature
42 Unit Forced to Low Speed
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
Check coolant level, add as needed. Report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
Report alarm at end of day.
X
X
X
X
X
X
X
150
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
Level Of
Action
43
Unit Forced to Low Speed
Modulation
44 Check Fuel System
45
Hot Gas Bypass or Hot Gas
Bypass Circuit
46 Check Air Flow
48 Check Belts/Clutch
50 Reset Clock
52 Heat Circuit
Report alarm at end of day.
Refill fuel tank.
If unit is shutdown repair immediately. Otherwise, report alarm at end of day.
If unit is shut down repair immediately. Otherwise, report alarm at end of the day. Cargo may be restricting air flow, check load.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
Report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
X
X
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.
Code Description Corrective Action
Level Of
Action
54 Test Mode Time-out
56 Host Evap Fan Low Speed
57 Host Evap Fan High Speed
61 Low Battery Voltage
62 Ammeter Out of Calibration
63 Engine Stopped
64 Pretrip Reminder
Service Test or Interface Board Test time out after 15 minutes. Report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
Report alarm at end of day.
X
X
X
X
X
X
X
152
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
Level Of
Action
65
Abnormal Temperature
Differential
66 Low Engine Oil Level
67 Liquid Line Solenoid Circuit
68 Internal Controller Fault
70 Hourmeter Failure
74 Controller Reset to Defaults
79 Internal Data Logger Overflow
80 Compressor Temp Sensor
82
High Compressor Temperature
Shutdown
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day
Check engine oil level. If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
Report alarm at end of day.
If unit is shutdown repair immediately. Otherwise, report alarm at end of day.
X
X
X
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.
Code Description Corrective Action
Level Of
Action
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.
85 Forced Unit Operation
86 Discharge Pressure Sensor
Report alarm at end of day.
Report alarm at end of day.
87 Suction Pressure Sensor
89
Report alarm at end of day.
Check Electronic Throttling Valve
Circuit
If unit is shutdown repair immediately. Otherwise, report alarm at end of day.
90
91
92
Electric Overload
Electric Ready Input
Sensor Grades Not Set
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
Report alarm at end of day.
X
X
X
X
X
X
X
X
X
154
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
Level Of
Action
93
96
98
Low Compressor Suction
Pressure
Low Fuel Level
Fuel Level Sensor
99 High Compressor Pressure Ratio
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
Check engine fuel level and add fuel. If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
Report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
105
106
Receiver Tank Pressure Solenoid
Circuit
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
Purge Valve Circuit
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
107 Condenser Inlet Solenoid Circuit
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
X
X
X
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.
Code Description Corrective Action
Level Of
Action
108 Door Open Time-out
110 Suction Line Solenoid Circuit
111 Unit Not Configured Correctly
112 Remote Fans
113 Electric Heat Circuit
114 Multiple Alarms - Cannot Run
117
Auto switch from Diesel to
Electric
Close Doors. Report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
Report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown repair immediately. Otherwise, report alarm at end of day.
Report alarm at end of day.
X
X
X
X
X
X
X
156
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
Level Of
Action
118
120
121
Auto switch from Electric to
Diesel
Alternator Exciter Circuit
Liquid Injection Circuit
122 Diesel/Electric Relay Circuit
127 Setpoint Not Entered
128
Engine Run Time Maintenance
Reminder #1
129
Engine Run Time Maintenance
Reminder #2
Report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report at end of day.
Be sure the setpoint is set to the required temperature.
Report alarm at end of day.
Report alarm at end of day.
X
X
X
X
X
X
X
157
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
130
131
132
133
Electric Run Time Maintenance
Reminder #1
Electric Run Time Maintenance
Reminder #2
Report alarm at end of day.
Report alarm at end of day.
Total Unit Run Time Maintenance
Reminder #1
Report alarm at end of day.
Total Unit Run Time Maintenance
Reminder #2
Report alarm at end of day.
134 Controller Power On Hours
141
Autoswitch Diesel to Electric
Disabled
143
Report alarm at end of day.
Report alarm at end of the day.
Remote Zone Drain Hose Heater
Output
If unit is shutdown, repair immediately. Otherwise, report at end of day.
X
X
X
X
X
X
X
Level Of
Action
158
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
Level Of
Action
144
145
146
Lost Expansion Module CAN
Communication
If unit is shut down repair immediately. Otherwise, report alarm at end of the day.
Loss of Controller “On” Feedback
Signal
If unit is shut down repair immediately. Otherwise, report alarm at end of the day.
Software Version Mismatch
If unit is shut down repair immediately. Otherwise, report alarm at end of the day.
148
Autoswitch Electric to Diesel
Disabled
Report alarm at end of the day.
150
151
153
Out of Range Low
Out of Range High
Expansion Module Flash Load
Failure
Manually monitor load temperature. Report alarm at end of the day.
Manually monitor load temperature. Report alarm at end of the day.
If unit is shut down repair immediately. Otherwise, report alarm at end of the day.
X
X
X
X
X
X
X
159
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
Level Of
Action
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.
159
160
Check Battery Condition
Lost Radio Expansion Board
(REB) CAN Communication
If unit is shut down repair immediately. Otherwise, report alarm at end of the day.
If unit is shut down repair immediately. Otherwise, report alarm at end of the day.
203
204
Display Return Air Sensor
Display Discharge Air Sensor
Manually monitor load temperature with independent thermometer. Report alarm at end of day.
Manually monitor load temperature with independent thermometer. Report alarm at end of day.
230 Future REB Alarm
231 Future REB Alarm
X
X
X
X
X
X
160
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
Level Of
Action
232 Future REB Alarm
233
REB Transitioning From
Conservative to Full Null
234 Relative Humidity Sensor
251 REB Miss-configured
252
500
Check Fresh Air Exchange
Circuit
Host Evaporator Fan Low Speed
Report alarm at end of the day.
Report alarm at end of the day.
Report alarm at end of the day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
501 Host Evaporator Fan High Speed
502
Host Evaporator Fan RPM
Sensor
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
X
X
X
X
X
X
X
161
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
503
504
505
506
507
508
509
Host Condenser Fan 1 RPM
Sensor
Host Condenser Fan 2 RPM
Sensor
Roadside Condenser Fan Motor
Speed Circuit
Curbside Condenser Fan Motor
Speed Circuit
Digital Scroll Output Circuit
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
Speed Request Communication
Error
Report alarm at end of the day.
Engine Control Unit (ECU) Failed to Enable
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
X
X
X
X
X
X
X
162
Level Of
Action
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
510
511
512
513
514
515
Engine Control Unit (ECU) Run
Signal Failed
Engine Wait to Start Time Delay
Expired
High Compressor Suction
Pressure
Low Compressor Suction Ratio
Minimum ETV Discharge
Superheat Temperature
Minimum ETV Discharge
Superheat Temperature
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
X
X
X
X
X
X
Level Of
Action
163
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
516
I/O Controller to Application
Controller Communication
Failure
517 Check for Water in Fuel System
518
519
520
521
Generator Ground Fault
Check Battery Charger Input
Power
Check Battery Charger Output
Power
Battery Charger
External/Environmental Fault
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
X
X
X
X
X
X
Level Of
Action
164
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
522
523
524
525
526
528
Battery Temperature Sensor
Alarm
Battery Temperature Sensor
Alarm
Generator Operational Limit Vout to Frequency Ratio
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
Generator Frequency Range
Fault
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
Generator Operational Limit
Output Current
527 Reserved
Controller Not Receiving
Messages From Battery Charger
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
X
X
X
X
X
X
X
Level Of
Action
165
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
Level Of
Action
529
530
531
538
539
599
Check Fuel Pump Circuit
Low Pressure Differential
Check Economizer Pressure
Sensor
Engine J1939 CAN Datalink
Degraded
Engine J1939 CAN Datalink
Failed
Engine Service Tool Connected
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report alarm at end of day.
Maintenance information only. Report alarm at end of the day.
600 Check Crankshaft Speed Sensor Report alarm at end of the day.
X
X
X
X
X
X
X
166
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
601 Check Camshaft Speed Sensor Report alarm at end of the day.
602
Check Intake Throttle Position
Sensor
If unit is shut down repair immediately. Otherwise, report alarm at end of the day.
603 Check Exhaust Pressure Sensor f unit is shut down repair immediately. Otherwise, report alarm at end of the day.
604
Check Coolant Temperature
Sensor
Report alarm at end of the day.
605
Check Fresh Air Temperature
Sensor
606 Reserved
Report alarm at end of the day.
607 Check Fuel Temperature Sensor Report alarm at end of the day.
608 Check Rail Pressure Sensor
If unit is shut down repair immediately. Otherwise, report alarm at end of the day.
Level Of
Action
X
X
X
X
X
X
X
X
167
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
Level Of
Action
609 Check Intake Pressure Sensor
If unit is shut down repair immediately. Otherwise, report alarm at end of the day.
610
Check Atmospheric Pressure
Sensor
611 Check Glow Plug Circuit
Report alarm at end of the day.
612
613
614 Check High Pressure Fuel Pump
615
Check Intake Throttle Circuit
Check Injector(s)
Rail Pressure Fault
Report alarm at end of the day.
If unit is shut down repair immediately. Otherwise, report alarm at end of the day.
Report alarm at end of the day.
If unit is shut down repair immediately. Otherwise, report alarm at end of the day.
If unit is shut down repair immediately. Otherwise, report alarm at end of the day.
X
X
X
X
X
X
X
168
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
Level Of
Action
616 Engine Overspeed
617 Internal ECU Fault
618 Check EGR System
619 ECU Main Relay Fault
620 Reserved
621 Reserved
622 Reserved
623 TRU CAN Message Timeout
624
Check Intake Air Temperature
Sensor
If unit is shut down repair immediately. Otherwise, report alarm at end of the day.
If unit is shut down repair immediately. Otherwise, report alarm at end of the day.
Report alarm at end of the day.
Report alarm at end of the day.
Report alarm at end of the day.
Report alarm at end of the day.
X
X
X
X
X
X
169
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Code Description Corrective Action
Level Of
Action
625
626
Check Intake Air Temperature
Sensor
Check Exhaust Temperature
Sensor
699 Unknown ECU Fault
If unit is shut down repair immediately. Otherwise, report alarm at end of the day.
Report alarm at end of the day.
If unit is shut down repair immediately. Otherwise, report alarm at end of the day.
X
X
X
170
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
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.
Remove the red cover from the positive (+) battery terminal on the unit’s battery.
1
Unit
(Discharged)
12-Volt
Battery
2
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.
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.
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).
173
Jump Starting
4
Unit
(Discharged)
12-Volt
Battery
3
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
Number of Cylinders
Cylinder Arrangement
Firing Order
Direction of Rotation
Fuel Type
Oil Capacity
Oil Type
TK486V25 (Tier 4)
4
In-line vertical, number 1 on flywheel end
1-3-4-2
Counterclockwise viewed from flywheel end
No. 2 diesel fuel under normal conditions
No. 1 diesel fuel is acceptable cold weather fuel
12 quarts (11.4 liters) crankcase and oil filter
Fill to full mark on dipstick
API Classification CI-4 or better
ACEA Rating E3 or better for Europe
175
Specifications
Engine (Continued)
Oil Viscosity
Engine rpm:
Engine Oil Pressure
Intake Valve Clearance
Exhaust Valve Clearance
Valve Setting Temperature
Low Speed Operation
High Speed Operation
Low Oil Pressure Switch (Normally Closed)
Engine Coolant Thermostat
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)
1450 ± 25 rpm
2200 ± 25 rpm
18 psig (127 kPa) minimum in low speed
45 to 57 psig (310 to 390 kPa) in high speed
0.006 to 0.010 in. (0.15 to 0.25 mm)
0.006 to 0.010 in. (0.15 to 0.25 mm)
70 F (21 C)
17 ± 3 psig (117 ± 21 kPa)
160 F (71 C)
176
Engine (Continued)
Engine Coolant Type
Coolant System Capacity
Radiator Cap Pressure
Specifications
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.
7.5 quarts (7.1 liters)
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
AC Generator and Alternator Belt - Standard Units:
37 or 65 Amp Alternator
120 Amp Alternator
AC Generator Belt - Smart Power Units and
Standard Units with Optional Battery Charger
Water Pump Belt
New Belt
106 Hz (111 lbs)
121 Hz (144 lbs)
106 Hz (111 lbs)
126 Hz (40 lbs)
Field Reset
92 Hz (84 lbs)
105 Hz (108 lbs)
92 Hz (84 lbs)
118 Hz (32 lbs)
178
Specifications
Belt Tension
Compressor Drive Belt - Smart Power Units Only
12 HP Electric Motor
19 HP Electric Motor
Alternator Belt - Smart Power Units Only:
All Alternators
131 Hz (236 lbs)
150 Hz (300 lbs)
216 Hz (75 lbs)
114 Hz (177 lbs)
130 Hz (223 lbs)
187 Hz (56 lbs)
Refrigeration System
Compressor
Refrigerant Charge—Type
Compressor Oil Charge
Compressor Oil Type
Heat/Defrost Method: Engine Operation
Electric Operation
High Pressure Cutout
Thermo King X430LSC5
14.5 lb (6.6 kg)—R404A
4.3 qt (4.1 liters)*
Polyol Ester type P/N 203-513
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
High Voltage
Battery
Fuses
Battery Charging
Voltage Regulator Setting
12.5 Vdc
230 Vac from AC generator at engine low speed
345 Vac from AC generator at engine high speed
One, group C31, 12 volt, (950 CCA recommended for operation below -15 F [-26 C])
12 volt, 37 amp, brush type, Thermo King Alternator
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
Fuel Solenoid: Pull-in Coil
Hold-in Coil
35 to 45
0.5
High Speed (Throttle) Solenoid
Air Heater
Pilot Solenoid
Electronic Throttling Valve:
Coil A (Red [EVA] and Blue [EVB] Wires)
Coil B (Black [EVC] and White [EVD] Wires)
2.9
89
0.7
—
—
Hot Gas Bypass Valve (if used)
Starter Motor
1.1
350-475*
* On-the-engine cranking check. Bench test is approximately 140 amps.
Resistance—Cold
(Ohms)
0.2 to 0.3
24 to 29
4.3
0.14
17.0
20 to 35
20 to 35
11.1
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
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
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)
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
230/3/60
460/3/60
460/3/60
12.0
12.0
19.0
9.0
9.0
14.2
1760
1760
3500
Full Load
(amps)
31.2
15.6
21.7
Overload Relay
Setting (amps)
34
20
32
Electric Heater Strips
Number
Watts
Resistance
Overload Relay Setting
3
1000 watts (each)
48 ohms (each)
6 amps
184
Standby Power Cord Requirements
Supply Circuit Breaker: 12 HP Motor 230/3/60
12 HP Motor 460/3/60
19 HP Motor 460/3/60
Extension Cord Size: 12 HP Motor 230/3/60
(All 4 conductor, 2000 Vac,
Type W Power Cable)
12 HP Motor 230/3/60
12 HP Motor 460/3/60
19 HP Motor 460/3/60
70 amps
40 amps
60 amps
8 AWG Power Cable, 25 to 50-foot length
6 AWG Power Cable, 75-foot length
10 AWG Power Cable, up to 75-foot length
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.
2FH/2HP Fuse
0.9 to 1.1 ohms
11.4 to 13.9 amps
30 F (-1 C)
75 F (24 C)
20 amps
Specifications
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.
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.
188
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.)
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.
190
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.
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.
receiver tank:
A refrigerant storage device included in nearly all Thermo King units.
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.
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.
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.
setpoint:
The temperature selected on a thermostat or microprocessor controller. This is normally the desired box temperature.
short cycling:
When a refrigeration unit cycles between the heat and cool modes more often than normal.
sight glass:
A system component that permits visual inspection of oil or refrigerant level and condition.
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/
4,500
Hours
Inspect/Service These Items
•
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*
•
•
•
•
•
Annual/
4,500
Hours
•
•
•
•
•
•
Inspect/Service These Items
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.
•
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/
4,500
Hours
Inspect/Service These Items
—
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/
4,500
Hours
Inspect/Service These Items
• •
•
•
•
•
•
•
•
•
•
•
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/
4,500
Hours
Inspect/Service These Items
•
•
•
•
•
•
•
•
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
4
3
ARA793
1.
Unit Serial Number
2.
Bill of Material Number
3.
Unit Model
4.
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
202
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.
CALIFORNIA
Proposition 65 Warning
Diesel exhaust is a chemical known to the State of California to cause cancer.
203
A
automatic start/stop safety precautions 12
B
belt tension, specifications 178
C
CYCLE-SENTRY
D
204
E
ELC (extended life coolant) 21
electrical components, specifications 182
electrical control system, specifications 181
electrical standby, specifications 184
electronic throttling valve (ETV) 22
engine compartment components 28
ETV (electronic throttling valve) 22
extended life coolant (ELC) 21
F
first aid for refrigerant 14 first aid for refrigerant oil 14
front doors
H
high pressure cutout switch 29 high pressure relief valve 29
I
J
L
loading procedures
low oil level switch 29 low oil pressure switch 29
M
maintenance inspection schedule 193
microprocessor On/Off switch 38
O
P
205
R
refrigeration system, specifications 179
S
automatic start/stop operation 12 electrical hazards 12
first aid for refrigerant 14 first aid for refrigerant oil 14
SMART REEFER 2 (SR-2) Controller 23, 37
206
specifications
U
W
Ingersoll Rand’s Climate Solutions sector delivers energy-effi cient HVACR solutions for customers globally. Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy effi cient 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.
Ingersoll Rand’s Climate Solutions sector delivers energy-effi cient HVACR solutions for customers globally. Its world class brands include Thermo King, the leader in transport temperature control and Trane, a provider of energy effi cient 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.
Operator’s Manual
Precedent™
C-600
TK 55692-2-OP (Rev. 2, 12/15)
Operator’s Manual
Precedent™
C-600
TK 55692-2-OP (Rev. 2, 12/15)

Public link updated
The public link to your chat has been updated.
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Key features
- Diesel & Electric Operation
- SMART REEFER 4 Controller
- Cycle-Sentry Start-Stop System
- OptiSet Plus & FreshSet
- Data Logging (ServiceWatch & CargoWatch)
- Automatic & Manual Defrost
- Remote Status Display
- EMI 3000 Package
- Extended Life Coolant