Operator`s Manual T-1080S SPECTRUM With Standard HMI

Operator`s Manual T-1080S SPECTRUM With Standard HMI
Operator’s Manual
Rand’s(NYSE:IR)
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delivers
cientcomfortable,
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Ingersoll Rand
advancessector
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include
King, the leaderClub
in transport
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Our people
and our
familyThermo
of brands—including
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temperature
control
a providertogether
of energy
cient heating,
ventilating
and of air
Rand®, Thermo
King®and
andTrane,
Trane®—work
to effi
enhance
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airhomes
conditioning
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T-1080S SPECTRUM
With Standard HMI
TK 55709-1-OP (Rev. 1, 09/16)
©2013 Ingersoll-Rand Company
Printed in U.S.A.
Operator’s Manual
Ingersoll Rand (NYSE:IR) advances the quality of life by creating comfortable, sustainable and
efficient environments. Our people and our family of brands—including Club Car®, Ingersoll
Rand®, Thermo King® and Trane®—work together to enhance the quality and comfort of air
in homes and buildings; transport and protect food and perishables; and increase industrial
productivity and efficiency. We are a global business committed to a world of sustainable
progress and enduring results. For more information, visit www.ingersollrand.com.
©2013 Ingersoll-Rand Company
Printed in U.S.A.
T-1080S SPECTRUM
With Standard HMI
TK 55709-1-OP (Rev. 1, 09/16)
T-1080S SPECTRUM
With Standard HMI
TK 55709-1-OP (Rev. 1, 09/16)
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.
2
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Automatic Start/Stop Operation . . . . . . . . . . . . . . . . . . 7
Battery Installation and Cable Routing . . . . . . . . . . . . . 8
Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
First Aid–Refrigerant . . . . . . . . . . . . . . . . . . . . . . . 10
First Aid–Refrigerant Oil . . . . . . . . . . . . . . . . . . . . 10
Safety Decals and Locations . . . . . . . . . . . . . . . . . . . 10
Model 50 Units (Electric Standby) . . . . . . . . . . . . 13
Emission Control . . . . . . . . . . . . . . . . . . . . . . . . . . .
California Emission Control System Warranty
Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Your Warranty Rights And Obligations . . . . . . . . .
Manufacturer’s Warranty Coverage . . . . . . . . . . .
Owner’s Warranty Responsibilities . . . . . . . . . . . .
14
17
17
18
18
Manufacturer Explanation Of Emission Control System
Warranty Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . .19
EPA Emission Control System Warranty Statement . .21
Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Unit Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . .27
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Scroll Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Standard HMI Control Panel . . . . . . . . . . . . . . . . . . . .27
CYCLE-SENTRYTM Start/Stop System . . . . . . . . . . .28
Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
DAS - Data Acquisition System (Optional) . . . . . . . . . .28
CargoLink™ (Optional) . . . . . . . . . . . . . . . . . . . . .29
Electric Standby (Model 50 Units Only) . . . . . . . . . . . .29
3
Table of Contents
Standard Model 50 Features . . . . . . . . . . . . . . . .
Optional Model 50 Features . . . . . . . . . . . . . . . . .
Engine Compartment Components . . . . . . . . . . . . . . .
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . .
29
30
30
31
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SR-3 Truck HMI Controller . . . . . . . . . . . . . . . . . .
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keys and LED Indicators . . . . . . . . . . . . . . . . . . .
The Multi-Temperature Display and Zone
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turning the Unit On and Off . . . . . . . . . . . . . . . . .
The Multi-Temperature Standard Display . . . . . . .
Automatic Zone Scrolling . . . . . . . . . . . . . . . . . . .
Manual Zone Selection Mode . . . . . . . . . . . . . . . .
Turning Zones On and Off . . . . . . . . . . . . . . . . . .
Changing the Zone Setpoint . . . . . . . . . . . . . . . . .
Starting the Diesel Engine . . . . . . . . . . . . . . . . . .
Starting the Electric Motor . . . . . . . . . . . . . . . . . .
Switching From Diesel to Electric . . . . . . . . . . . . .
Switching from Electric to Diesel . . . . . . . . . . . . .
Selecting CYCLE SENTRY or Continuous Mode .
Selecting the High Speed Lock-Out Feature . . . .
Initiating a Zone Manual Defrost Cycle . . . . . . . . .
34
34
35
37
4
43
44
46
47
48
49
50
52
53
54
54
57
58
59
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
SR-3 Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . .62
Sending a Data Logger Start of Trip . . . . . . . . . . .72
Pretrip Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Performing a Pretrip Test . . . . . . . . . . . . . . . . . . .75
Display Brightness . . . . . . . . . . . . . . . . . . . . . . . . .77
Keypad Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Checking Truck HMI Control Panel Serial Number
and Software Revision . . . . . . . . . . . . . . . . . . . . .79
Time and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Electric Standby Operation . . . . . . . . . . . . . . . . . . . .81
Electric Power Receptacle . . . . . . . . . . . . . . . . . . . . . .81
Loading and Enroute Inspections . . . . . . . . . . . . . .83
Pre-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . . .83
Post-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . .84
Enroute Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Inspection Procedure . . . . . . . . . . . . . . . . . . . . . .87
Inspection Troubleshooting . . . . . . . . . . . . . . . . . .87
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Table of Contents
Engine Clutch - Hilliard . . . . . . . . . . . . . . . . . . . . . . . . 94
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Electrical Control System . . . . . . . . . . . . . . . . . . . . . . 95
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . 98
Standby Power Requirements . . . . . . . . . . . . . . 100
Electrical Standby (Model 50 Units Only) . . . . . . . . . 100
Electric Motor and Overload Relay . . . . . . . . . . . 100
Serial Number and Refrigerant Label Locations . 109
Maintenance Inspection Schedule . . . . . . . . . . . . . 101
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Recover Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . 111
Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . . 112
California
Proposition 65 Warning . . . . . . . . . . . . . . . . . . . . . 113
Maintenance Inspection Schedule . . . . . . . . . . . . . 102
5
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.
6
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.
Safety Precautions
Thermo King recommends that all services be performed by a
Thermo King dealer. However, there are several general safety
practices which you should be aware of:
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 is best left to a certified Thermo King
technician.
CAUTION: Use extreme caution when drilling holes
in the unit. Drilling into electrical wiring or
refrigerant lines could cause a fire. Never drill into
structural components.
Automatic Start/Stop Operation
This unit is capable of automatic operation and may start at any
time without prior warning.
WARNING: The unit may start at any time when the
controller is turned on. The controller display lights
up when the controller is turned on.
WARNING: Units equipped with electric standby may
start at any time when the unit is connected to live
electric power and the controller is turned on.
7
Safety Precautions
WARNING: Be sure to press the OFF key to turn the
controller off before opening doors or inspecting any
part of 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!
8
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!
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.
Safety Precautions
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.
Electrical Hazard
CAUTION: Be sure to turn off the high voltage
power supply, and disconnect the electric cable before
working on the unit. Units with electric standby
present a potential electrical hazard.
Refrigerant
Although fluorocarbon refrigerants are classified as safe,
observe caution when working with refrigerants or around
areas where they are being used in the servicing of your unit.
DANGER: Fluorocarbon refrigerants may 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.
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.
9
Safety Precautions
First Aid
Ingestion: Do not induce vomiting. Immediately contact
local poison control center or physician.
First Aid–Refrigerant
Eyes: For contact with liquid, immediately flush eyes with
large amounts of water. Get prompt medical attention.
Safety Decals and Locations
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 arrival of emergency medical
personnel.
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 arrival of emergency
personnel.
10
Figure 1: Antifreeze Caution
(Attached near Expansion Tank fill cap)
Safety Precautions
Figure 2: Clearing Alarms Caution
(Typically located near the HMI Controller)
Figure 3: Belt Caution (Locations vary depending on
model. Decals are located near areas that contain
belts and fans which can cause severe injuries if
hands or clothing become tangled.)
11
Safety Precautions
CAUTION FAN
ACHTUNG VENTILATOR
91-4815
ATTENTION VENTILATEUR
ATTENZIONE VENTILATORE
CUIDADO VENTILADOR
Figure 4: Automatic Start Caution (Locations vary
depending on model. Decals are located near areas
that contain moving parts which can cause severe
injuries if hands or clothing become tangled when the
unit automatically starts.)
12
Figure 5: Fan Caution (Locations vary depending on
model. Decals are located near areas that contain
fans which can cause severe injuries if hands or
clothing become tangled.)
Safety Precautions
Model 50 Units (Electric Standby)
Figure 6: Electrical Hazard (Locations vary
depending on model. Typically located near power
receptacle, high voltage tray cover and interface
board.)
Figure 7: High Voltage Caution
(Located near high voltage box.)
13
Emission Control
In compliance with the California ULG (Utility, Lawn and
Garden) Rules, the following information is provided:
1. Selection Of Fuel Oil: Use diesel fuel only.
2-1. Modification To Any Engine Component:
Modifications to any engine component which many cause
engine exhaust emission output changes are not allowed.
Any engine modification not in compliance with regulation
will be the responsibility of the engine manufacturer, dealer or
customer who made the modification.
2-2. Air Induction System: Air induction system must
remain intact and receive regular prescribed maintenance.
Example: Air cleaner element replacement at required
operation hour interval.
2-3. Exhaust System: Exhaust system must remain intact
and cannot be modified in any manner that will further restrict
exhaust flow.
14
2-4. Fuel Oil System: Fuel oil system must remain intact
and receive regular prescribed maintenance. Example: Fuel
filter replacement at required operation hour interval.
3. Engine Identification: Engines must be identified in a
manner that will determine when they were built and what
regulations they comply with. The engine must be labeled with
an emission control label and the engine family name, both
described below.
Emission Control
a.
Emission control label: a new label, shown in
Figure 8, contains important engine information.
AMA04
b.
Engine Family Name, as assigned by the California
Air Resources Board, identifies engine family group,
by largest displacement, within an engine family, and
is shown in Figure 9.
AMA06
Figure 8: Emission Control Label
Figure 9: Engine Family Name
15
Emission Control
3-1 Emission Control Labels: Emission control labels are
a requirement of the California ULG Rules. In the event the
emission control label provided on the engine is inaccessible,
there will be a supplemental label containing the same
information, provided by the equipment manufacturer, located
in a readily accessible location, shown in Figure 10:
All engine labels and supplementary labels will contain the
following information:
•
Engine Family Name
•
Displacement
•
Manufacturer
The above information, along with the engine serial number,
will be required to obtain proper service information and
correct service repair parts. Figure 11 identifies the engine
model.
Engine Model
TK380F
AMA05
Figure 10: Emission Control Label Location
16
Note: Design parameters to bring engine family
into compliance were utilized; no after treatment
measures incorporated.
Figure 11: Engine Model
Emission Control
4. Emission Control Related Parts: The California ULG
Rules require a manufacturing defect warranty on all emission
control parts, including:
5. Maintenance Schedule: To maintain optimum engine
performance and compliance with the California ULG Rules,
the maintenance schedule must be adhered to.
•
Fuel Injection Pump
•
Fuel Injection Nozzle
•
High Pressure Oil Line
Regular scheduled maintenance is the major key to engine
service life and emission regulation compliance. Scheduled
maintenance requirements must be performed regularly. See
the Maintenance Schedule provided in this Operator’s Manual.
•
Air Cleaner Element1
•
Fuel Filter Element1
•
Air Cleaner Gasket
•
Air Intake Pipe (Manifold) Gasket
•
Muffler Gasket
The warranty period is two years and complete details are
included in the section of this manual titled “California
Emission Control System Warranty Statement, Your Warranty
Rights And Obligations.”
1
Any warranted part which is scheduled for replacement as
required maintenance shall be warranted for the period of time
up to the first scheduled replacement point for that part.
California Emission Control
System Warranty Statement
Your Warranty Rights And
Obligations
The California Air Resources Board and Thermo King are
pleased to explain the California emission control system
warranty on your 1996 and later utility equipment (ULG)
engine. In California, new utility equipment (ULG) engines
must be designed, built, and equipped to meet the state’s
stringent anti-smog standards. Thermo King must warrant the
California emission control system on your utility equipment
17
Emission Control
(ULG) engine for the time listed below, provided there has
been no abuse, neglect or improper maintenance of your utility
equipment (ULG) engine.
Your California emission control system includes parts such as
the fuel injection pump, the fuel injection nozzle, and the
high-pressure fuel line. Also included are the air filter element
and the fuel filter element which are covered under this
California emission control system warranty only up to the first
scheduled maintenance replacement.
Where a warrantable condition exists, Thermo King will repair
your utility equipment (ULG) engine with California emission
control system parts or components at no cost to you, including
diagnosis, parts and labor.
Manufacturer’s Warranty Coverage
1996 and later utility equipment (ULG) engines: California
emission control system parts and components are warranted
for the period of two years (24 months). If any California
emission control system part or component on your utility
equipment (ULG) engine is defective, the part or component
will be repaired or replaced by Thermo King.
18
Owner’s Warranty Responsibilities
As the utility equipment (ULG) engine owner, you are
responsible for the performance of the required maintenance
listed in this Operator’s Manual. Thermo King recommends
that you retain all receipts covering maintenance on your utility
equipment (ULG) engine, but Thermo King cannot deny
warranty solely for the lack of receipts or your failure to ensure
the performance of all scheduled maintenance.
As the utility equipment (ULG) engine owner, you should be
aware that Thermo King may deny you warranty coverage if
your utility equipment (ULG) engine, or a part or component,
has failed due to abuse, neglect, improper maintenance, or
unapproved modifications.
You are responsible for presenting your utility equipment
(ULG) engine to an authorized Thermo King dealer as soon as
a problem exists. The emission control system parts or
component repairs should be completed in a reasonable
amount of time not to exceed 30 days.
If you have any questions regarding your warranty rights and
responsibilities, contact a Thermo King service representative
at 952-887-2337.
Emission Control
Manufacturer Explanation Of
Emission Control System
Warranty Coverage
at a Thermo King authorized service dealer. To obtain the
phone number of your nearest Thermo King authorized
service dealer, call the Cold Line at: 952-887-2202.
2.
Warranty Period: Any warranted California emission
control system part or component that is not scheduled for
replacement as required maintenance, or that is scheduled
only for regular inspection to the effect of repair or
replacement as necessary, shall be warranted for the
warranty period. Any warranted part that is scheduled for
replacement as required maintenance shall be warranted
for the period of time up to the first scheduled replacement
point for that part or component.
3.
Diagnosis: The owner shall not be charged for diagnostic
labor which leads to the determination that a California
emission control system warranted part or component is
defective, if the diagnostic work is performed at a Thermo
King authorized service dealer.
4.
Consequential Damages: Thermo King is liable for
damages to other engine parts or components caused by
the failure of an emission control system part or
component within the above stated California emission
control system warranty period.
A. Warranty Commencement Date
The California emission control system warranty period begins
on the date the engine or equipment is delivered to the original
retail purchaser.
B. Length Of Coverage
Thermo King warrants to the original purchaser, and each
subsequent purchaser, that the engine emission control system
is free from defects in material and workmanship that cause the
failure of the warranted California emission control system
part or component for a period of two years (24 months)
beginning on the day the utility equipment (ULG) engine is
delivered to the original purchaser.
C. What Is Covered
1.
Repair or Replacement of Parts: Repair or replacement
of any California emission control system warranted part
or component will be performed at no charge to the owner
19
Emission Control
D. What is Not Covered
1.
Failures caused by abuse, neglect, or improper
maintenance.
2.
Add-On or Modified Parts. The use of add-on or modified
parts can be grounds for disallowing a warranty claim.
Thermo King is not liable for failures of emission control
system parts or components caused by the use of add-on or
modified parts.
3.
Use of fuel other than the California Title 13, CCR Section
2282 (g)(3), low sulfur, low aromatic, with a cetane
number of 48 minimum, will nullify this warranty.
call the customer service representative at 888-887-2202 for
the location of the nearest Thermo King authorized service
dealer.
G. Maintenance, Replacement and Repair of Emission
Control System Related Parts
Any Thermo King approved replacement part can be used in
the performance of any warranty maintenance or repairs on
emission control system parts or components, and must be
provided without charge to the owner if the part is still under
the California emission control system warranty.
H. Emission Control System Warranty Parts List
E. How to File a Claim
•
Part Name
Warranty claims for California emission control system parts
or components are to be filed by the Thermo King authorized
servicing dealer on behalf of the engine owner.
•
Fuel Injection Pump
•
Fuel injection Nozzle
•
High Pressure Fuel Oil Line
•
Air Cleaner Element
•
Fuel Filter Element
•
Air Cleaner Gasket
•
Air Intake Pipe (Manifold)
F.
Where to Get Warranty Service
Warranty service or repairs shall be provided at all Thermo
King authorized service dealers. You can generally find dealers
in the Yellow Pages of your regional telephone directory, or
20
Emission Control
•
Gasket Muffler Gasket
I.
Maintenance Statements
The owner is responsible for the performance of the required
maintenance as defined by Thermo King within this Operator’s
Manual.
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 an emergency, repairs can 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.
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 which are not genuine
Thermo King parts.
21
Emission Control
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:
22
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.
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.
Emission Control
•
Premium of overtime cost.
•
Cost to investigate complaints that are not caused by
defect in Thermo King material or workmanship.
•
Providing timely notice of a warrantable failure and
promptly making the product available for repair.
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.
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 with 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.
23
Unit Description
General Description
The T-1080S SPECTRUM™ unit is a microprocessor based
transport temperature control system that uses the SR-3 Truck
HMI microcontroller to manage system functions.
The unit is a self-powered multi-temperature unit for straight
trucks and includes the latest in scroll compressor technology.
The T-1080S condensing unit mounts on the front of the truck
cargo compartment. Remote evaporators are used to control
temperatures in up to three individual cargo compartments.
The T-1080S is designed for use with chlorine free R-404A
refrigerant. Two basic models provide the following:
Model 30: Cooling and hot gas heating on engine operation.
Model 50: Cooling and hot gas heating on engine operation
and electric standby operation. Electric evaporator heaters are
optional.
24
Engine power for the unit is provided by a diesel engine.
Optional electric standby power (Model 50) is provided by an
electric motor. A clutch on the diesel engine isolates the engine
during electric standby operation.
The continuous monitoring function of the microprocessor
optimizes the unit’s performance, reducing fuel consumption
and unit down time. The unit has a self check feature that can
be run before the daily distribution route to identify possible
malfunctions.
The built-in CYCLE-SENTRY, an exclusive Thermo King
feature, automatically starts and stops the unit according to
temperature demands.
Unit Description
Design Features
•
Diesel/Electric Autoswitching (Model 50)
•
Microprocessor Controller, SR-3 Truck
•
Economy Mode
•
Alarm Code Display
•
Fahrenheit and Celsius Scales
•
Continuous System Monitoring
•
Fuel Filter, Spin On
•
CYCLE-SENTRYTM Start/Stop Controls
•
Low Decibel Kit
•
Engine and Electric (Model 50) Hour Display
•
Oil Filter, Full Flow
•
In-Cab Remote
•
Poly-V Belt System with Quiet Channel Technology
•
Smart Defrost
•
R-404A Chlorine-free Refrigerant
•
Symbolic Controller Interface
•
Robotic Welded Steel Frame with Automotive Grade 2
Coat Paint Finish
•
Unit Self Check-pretrip
Scroll Compressor, New Generation TK06
Aerodynamic Thermo Plastic Recyclable Injection
Molded Skins with In-mold Color
•
•
•
ETV (Electronic Throttling Valve)
•
Air Cleaner, Dry Type
•
Stainless Steel Condenser and Evaporator Hardware
•
Alternator, 12 Volt, 120 Amp
•
TK380F Tier 4 Diesel Engine
•
Automatic Phase Correction (Model 50)
•
Top Cover System
•
Bypass Oil Filter
•
Coolant Expansion Tank with Overflow Bottle
25
Unit Description
Unit Options
•
Whisper™ Plus Sound Kit
•
SmartPower™ Electric Standby (standard 230 v/3
phase/60 Hz) 460/3/60, 400/3/50
•
Silicone Hoses
•
Hose Management Channel
•
Hand Held TSR-3 Diagnostic Tool
•
Top Cover and Screen
•
Body Mount Enclosure for HMI
•
Evap Side Screens
•
Rear Remote Control (flush mount)
•
Snow Cover
•
Easy-Read Thermometer
•
Special Finish Paint
•
Remote Indicator Lights
•
Chrome Grills
•
DAS (Data Acquisition System)
•
Door Switch
•
CargoLink™ Wireless Sensors
•
Battery Box
•
Battery (truck)
•
Heat (electric)
•
Engine Block Heater
•
Fuel Tank (30 gal. aluminum side-fill)
•
Quick Oil Drain Kit
26
Engine
Engine power for the T-1080S SPECTRUM is provided by the
TK380F, a three cylinder, EPA Tier 4, special clean and quiet
diesel engine rated at 16.2 continuous horsepower (12.1 kW) at
2200 RPM. A belt drive system transfers energy to the
compressor, unit fans and alternator.
Unit Description
ELC (Extended Life Coolant)
Scroll Compressor
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, Texaco Extended Life Coolant, is Red instead
of the previous Green or Blue-Green coolants.
The unit features the high performance new generation TK06
scroll compressor.
CAUTION: Do not add Green or Blue-Green
coolants to cooling systems that use Red Extended
Life Coolants.
NOTE: The use of 50/50% pre-mixed ELC is recommended
to ensure that deionized water is being used. If 100% full
strength concentrate is used, deionized or distilled water is
recommended instead of tap water to ensure the integrity of
the cooling system is maintained.
Standard HMI Control Panel
The Standard HMI Control Panel (Human/Machine Interface)
is used to operate the unit and display unit information. The
Control Panel is typically located in the vehicle driver's
compartment and communicates with the base controller using
a connection on the interface board.
Clutch
The centrifugal clutch engages fully at 600 ± 100 RPM on
engine operation, constantly turning the compressor, alternator,
and fans at both high and low speed. The clutch isolates the
engine from the belt drive system during electric standby
operation on Model 50 units.
Figure 12: Standard HMI Control Panel
27
Unit Description
CYCLE-SENTRYTM Start/Stop
System
The CYCLE-SENTRY Start/Stop fuel saving system provides
optimum operating economy.
WARNING: Turn the unit off by pressing the OFF key
before opening doors or inspecting any part of the
unit. The unit can start at any time without warning if
it has been turned on by pressing the ON key.
The CYCLE-SENTRY system automatically starts the unit on
microprocessor demand and shuts down the unit when all
demands are satisfied.
The system monitors and maintains the compartment
temperature, the engine block temperature, and battery charge
levels at a point where quick, easy starts are possible.
Defrost
Frost will gradually build up on the evaporator coils as a result
of normal operation. Periodically this frost must be melted to
prevent a loss of cooling and airflow.
28
Defrost is accomplished by passing hot refrigerant gas through
the evaporator coil, thus melting the frost (or ice). Melted frost
drains out of the unit onto the ground through the drain tubes.
The defrost damper closes during defrost to prevent warm air
from entering the cargo area. The optional electric heater strips
are also energized in defrost during electric standby operation.
Defrost can be initiated at any time the evaporator coil
temperature is below 42 F (5.5 C).
There are two methods of defrost initiation:
SR-3 Microprocessor Controller: The Microprocessor
Controller is programmed to automatically initiate timed and
forced defrost cycles. The SR-3 uses temperature sensors to
determine if forced defrost is required.
Manual Defrost: Manual Defrost allows the operator to
initiate a defrost cycle by pressing the DEFROST key. See
“Initiating a Manual Defrost Cycle.”
DAS - Data Acquisition System
(Optional)
The DAS (Data Acquisition System) monitors and records the
temperatures of (up to) six additional sensors. The sensors are
independent from the microprocessor controller and are
Unit Description
normally located in the truck box to monitor load temperatures.
DAS data can be downloaded through a serial port to an IBM®
PC compatible computer. WinTrac™ 4.0 (or higher) software
is used to view and analyze the data. Brief reports can be
printed on a microprinter connected to the serial port.
CargoLink™ (Optional)
DANGER: High voltage AC power is present
whenever the unit is operating in the Electric mode
and whenever the unit is connected to external
standby power. Voltages of this magnitude can be
lethal. Exercise extreme caution when working on the
unit.
CargoLink™ is a wireless sensor system. The main
components are the coordinator module, interconnect harness,
antenna, and wireless sensors. The coordinator module
receives information from the wireless sensors through the
antenna, and communicates with the controller through the
interconnect harness.
Standard Model 50 Features
Electric Standby (Model 50 Units
Only)
Overload Relay: The overload relay is self-resetting.
The Electric Standby option allows the unit to be operated on
either the diesel engine or external electric power.
Automatic Phase Correction: The control system features
two motor contactors. This allows correct motor rotation
regardless of phase rotation on the incoming power.
The following features are standard equipment on units
equipped with Electric Standby.
Automatic Diesel/Electric Selection: The unit will
automatically switch to electric operation when a power cord is
connected and the standby power is switched On.
Hot Gas Heat: Hot gas heat is utilized on all units.
29
Unit Description
Optional Model 50 Features
The following features are available as options on units
equipped with Electric Standby.
•
Electric Heater Strips
•
Auto Switching
Engine Compartment
Components
Coolant Expansion Tank: The coolant level and
temperature inside the expansion tank are monitored by the
base controller. If the coolant temperature becomes too high or
the level becomes too low, an alarm will occur. The expansion
tank must always be completely full of coolant when cool.
Coolant Overflow Bottle: The overflow bottle captures
coolant expelled from the expansion tank during normal diesel
operation. Coolant returns to expansion tank when the unit is
off and coolant has cooled. Coolant level in the overflow bottle
must always be at or above the FULL COLD mark of the bottle
when cool.
30
The engine must have antifreeze protection to –30 F (–34 C).
Check and add coolant in the expansion tank and overflow
bottle as needed.
CAUTION: Do not remove expansion tank cap while
the coolant is hot.
CAUTION: Do not add Green or Blue-Green
coolants to cooling systems that use Red Extended
Life Coolants.
Engine Oil Dipstick: Use the engine oil dipstick to check
the engine oil level.
Receiver Tank Sight Glass: The receiver tank sight glass
is used to assist in checking the amount of refrigerant in the
system.
Compressor Oil Sight Glass: The compressor oil sight
glass is used to check the relative level of compressor oil in the
compressor sump.
Unit Description
Unit Protection Devices
High Pressure Cutout Switch (HPCO): This normally
closed switch monitors the discharge pressure at the
compressor. It opens on high discharge pressure to shut the unit
down to prevent damage.
Electronic Throttling Valve (ETV): This component is an
electromechanical control device used to limit the suction
pressure to the compressor. The valve is controlled by the
microprocessor controller.
Engine Oil Pressure Switch/Sensor: The engine oil
pressure switch/sensor is located on the filter head above the
bypass oil filter. Engine oil pressure should rise immediately
on starting. If engine oil pressure drops below 10 ± 2 psig (69 ±
14 kPa), the switch/sensor signals the microprocessor to stop
the engine.
Coolant Temperature Sensor: This sensor provides an
engine coolant temperature input to the microprocessor. If the
engine coolant temperature is too high, the controller stops the
unit and records an alarm.
Electric Motor Overload Relay (Model 50): The
overload relay protects the electric standby motor. The
overload relay opens the circuit from the contactor to the
electric motor if the motor overloads for any reason and an
alarm will occur. The relay resets when the alarm code is
cleared.
Fuses: Sizes and functions are described in the Specifications
section of this manual.
Preheat Buzzer: The preheat buzzer sounds when the
CYCLE-SENTRYTM system energizes the glow plugs. This
should warn anyone near the unit that the CYCLE-SENTRYTM
system is about to start the diesel engine.
31
Unit Description
Figure 13: T-1080S SPECTRUM Front View
32
Unit Description
1
2
3
4
5
6
7
8
1.
Engine (dipstick on side of engine)
5.
Alternator
2.
Coolant Overflow Bottle
6.
Compressor
3.
Coolant Expansion Tank
7.
Dehydrator (Filter-Drier)
4.
Electric Motor
8.
On/Off Switch
Figure 14: Main Components in Figure 14
33
Operation
SR-3 Truck HMI Controller
Controller Features
The SR-3 Standard Truck HMI (Human/Machine Interface)
Control Panel is supplied as standard equipment on SR-3
Single Temperature and Multi-Temperature Truck applications.
It is used to operate the unit and display some unit information.
The SR-3 Standard Truck HMI Control Panel communicates
with the base controller via the CAN (Controller Area
Network) bus. It is connected to the base controller via CAN
Connector J14 on the interface board. The SR-3 Standard
Truck HMI Control Panel is typically located in the vehicle
driver’s compartment. It may also be located in the truck
dashboard using a DIN mounting ring or under the dashboard
using an under dash mounting kit.
•
Displays Box Temperature and Setpoint in Fahrenheit or
Celsius
•
Displays Engine Running and Motor Running Hourmeters
•
Indicates the current Zone on Multi-Temperature
Applications
•
Changes unit or Zone Setpoints
•
Selects and Indicates CYCLE-SENTRY or Continuous
Mode Operation
•
Selects and Indicates High Speed Lock-Out Operation
•
Initiates and Indicates a unit or Zone Defrost Cycle
•
Indicates an Alarm Condition Exists, Displays and Clears
Alarms
•
Initiates and Indicates a Pretrip Test
•
Sends a Start of Trip to the ServiceWatch data logger.
•
Changes Display Brightness
Figure 15: SR-3 Truck HMI Controller
34
Operation
•
Shows HMI Control Panel Serial Number and Software
Revision.
•
The SR-3 Standard Truck HMI Control Panel consists of a
display and nine touch-sensitive keys.
•
The display is capable of showing numbers and lighting
several icons. It does not display text, thereby making it
suitable for use with any language.
•
Amber indicator LED’s are located next to each of the four
function keys below the display. The LED will light when
that function is active.
•
A red indicator LED is located between the ON Key and
OFF Key. This indicator will glow if Alarm Code 91
Check Electric Ready Input occurs. It will also glow if a
15 pin Thermo King data cable is connected to the serial
port on the back of the controller.
Display
Display The display presents information to the operator. This
information includes setpoint and box temperature, hourmeter
readings, alarms and several icons as shown below. All display
segments and icons are shown in Figure 16.
Figure 16: Display
The upper row of numbers can display the Box Temperature,
Engine Run Time Hourmeter, Current Zone or Alarm Code(s).
The lower row of numbers can display the Setpoint, Electric
Run Time Hourmeter or Total Number of Alarms. The
meaning of the display icons are shown in the following table.
35
Operation
When this icon is present the upper
display is showing the actual box
temperature inside the truck box.
When this icon is present the lower
display is showing the current setpoint.
When this icon is present the upper
display is showing the diesel engine run
time.
36
When this icon is present the lower
display is showing the electric motor run
time (if the unit equipped with optional
ELECTRIC STANDBY).
When this Alarm Icon is present one or
more alarm conditions have occurred. If
the display is not flashing any alarms
are Check Alarms. If the display is
flashing on and off a shutdown alarm
has occurred and the unit has been shut
down. Immediate action must be taken.
Operation
Keys and LED Indicators
There are nine touch sensitive keys. Some of these keys have
more than one function as shown in Figure 17.
•
The UP ARROW, DOWN ARROW and ENTER Keys are
located at the right side of the display
The primary and secondary uses for each key are shown in the
table below. If a key has more than one use, the primary use is
shown first.
Figure 17: Keys and LED Indicators
•
The ON Key and OFF Key are located at the left side of
the display.
•
A red indicator LED is located between the ON Key and
OFF Key. This indicator will glow if Alarm Code 91
Check Electric Ready Input occurs. It will also light if a 15
pin Thermo King data cable is connected to the serial port
on the back of the controller.
•
There are amber indicator LED’s located next to each of
the four function keys below the display. The LED will
glow amber when that function is active.
37
Operation
ON Key
Primary Use – Pressing the ON Key will turn the unit on.
Secondary Use – When the unit is on and a different display is shown, pressing this key will return to
the Standard Display of box temperature and setpoint.
Secondary Use – When the unit is on, pressing this key and the PRETRIP Key at the same time will
display any alarm codes that are present.
Secondary Use – When the unit is on, pressing and holding this key allows the UP ARROW Key and
DOWN ARROW Key to increase or decrease the display brightness.
Multi-Temp Use – When Manual Zone Selection is active the selected zone can be turned on and off
by simultaneously pressing the ON Key and ENTER Key.
POWER OFF Key
Primary Use – Pressing the OFF Key will turn the unit off.
38
Operation
UP ARROW Key
Primary Use – When the unit is turned on and the Standard Display is shown, pressing the UP
ARROW Key will increase the setpoint.
Secondary Use – When alarms are being displayed, pressing this key will scroll thru the alarms (if
more than one alarm is present).
Secondary Use – While holding ON Key down with the unit turned on, pressing this key will increase
the display brightness (Low, Medium, High).
DOWN ARROW Key
Primary Use – When the unit is turned on and the Standard Display is shown, pressing the DOWN
ARROW Key will decrease the setpoint.
Secondary Use – While holding ON Key down with the unit turned on, pressing this key will decrease
the display brightness (High, Medium, Low).
39
Operation
ENTER Key
Primary Use – If the setpoint has been changed using the UP ARROW Key and/or DOWN ARROW
Key, pressing the ENTER Key enters the setpoint into the base controllers memory.
Secondary Use – When alarms are being displayed, pressing this key will clear the alarm shown on
the display.
Secondary Use – When the unit is turned on, press and hold this key for 5 seconds to send a Start of
Trip (SOT) to the data logger.
Multi-Temp Use – Pressing this key will enable Manual Zone Selection mode and scroll through the
installed zones, one zone at a time. When a zone is manually selected the zone can be turned on or
off, the setpoint can be changed and a manual defrost cycle can be initiated if zone conditions permit.
CYCLE-SENTRY/Continuous Key
Primary Use – If the unit is turned on and is in Continuous Mode, pressing the
CYCLE-SENTRY/CONTINUOUS Key will switch operation to CYCLE-SENTRY Mode and the amber
LED indicator will glow. If the unit is running in CYCLE-SENTRY Mode, pressing this key will switch
operation to Continuous Mode and the amber LED will turn off.
40
Operation
HIGH SPEED LOCK-OUT Key
Primary Use – If the unit is turned on, pressing the HIGH SPEED LOCK-OUT Key will activate High
Speed Lock-Out. The unit will switch to low speed operation and the amber LED indicator will glow. No
further high speed operation is allowed until this feature is turned off. If the High Speed Lockout Timer
is enabled, the unit will automatically return to high speed after a programmed time limit. This feature
is typically used in noise sensitive areas to reduce unit noise.
NOTE: The HIGH SPEED LOCK-OUT Key is only used when the unit is operating in Diesel Mode. The
HIGH SPEED LOCK-OUT Key does not have any effect in Electric Mode operation.
DEFROST Key
Primary Use – If the unit is turned on, pressing the DEFROST Key will initiate a manual defrost cycle if
conditions allow. If the evaporator coil temperature less than 45°F (7°C) the unit will enter a defrost
cycle. The amber LED will flash while the defrost cycle is initialized and will glow during the defrost
cycle. The defrost cycle will terminate automatically and the amber LED will turn off when the
evaporator coil temperature is greater than 52°F (11°C). To manually terminate a defrost cycle turn the
unit off and back on.
Multi-Temp Use – A zone must be selected before initiating a manual defrost cycle.
41
Operation
PRETRIP TEST Key
Primary Use – Pressing and holding the PRETRIP TEST Key for 5 seconds will initiate either a Full
Pretrip Test or Engine Running Pretrip Test so long as no alarm conditions exist. If the Alarm Icon is
glowing, record and clear the alarms before starting the Pretrip Test.
Press and hold the PRETRIP TEST Key for 5 seconds. The amber LED may flash while the Pretrip
Test is initialized and will glow steady while the Pretrip Test is running. When the Pretrip Test is
complete the amber LED will turn off.
• If there are no alarm codes set when the Pretrip Test is complete, the unit passed.
• If there are alarm codes set when the Pretrip Test is complete, the unit failed. Check and correct the
alarm conditions and repeat the test.
• If a shutdown alarm occurred, Alarm Code 28 Pretrip Abort will be set and the unit will be shut
down. Check and correct the alarm conditions and repeat the test.
Secondary Use – When the unit is turned off press and hold this key for 5 seconds to show the HMI
Control Panel Serial Number (in the upper display) and the HMI Control Panel Software Revision (in
the lower display).
42
Operation
The Multi-Temperature Display and
Zone Indicators
Horizontal bars to the left of the box temperature are used to
indicate the zone currently shown on the display. In Figure 18
Zone 3 is being shown on the display.
Figure 18: Display
When one horizontal bar is present at
the left side of the box temperature, then
Zone 1 is being shown on the display.
The display will automatically scroll
through all configured zones, showing
each zone for 10 seconds.
When two horizontal bars are present at
the left side of the box temperature,
then Zone 2 is being shown on the
display. The display will automatically
scroll through all configured zones,
showing each zone for 10 seconds.
When three horizontal bars are present
at the left side of the box temperature,
then Zone 3 is being shown on the
display. The display will automatically
scroll through all configured zones,
showing each zone for 10 seconds.
Zone 3 only appears on units configured
with 3 zones.
IMPORTANT: If the unit is configured as
a 2 zone unit, Zone 3 will still appear in
Automatic Zone Scrolling and Manual
Zone Selection mode. However, Zone 3 is
turned off and cannot be turned on.
43
Operation
In Figure 19, Zone 1 is being shown on the display. The box
temperature in Zone 1 is -8.2°F (-22.3°C) and the setpoint is
-10°F (-23.3°C).
Figure 19: Zone 1
In the screen in Figure 20, Zone 2 is being shown on the
display. The box temperature in Zone 2 is 35.8°F (2.1°C) and
the setpoint is 35°F (1.7°C).
In Figure 21, Zone 3 is being shown on the display. The box
temperature in Zone 3 is 48.8°F (9.3°C) and the setpoint is
50°F (10°C). Zone 3 only appears on units configured with 3
zones.
Figure 21: Zone 3
Turning the Unit On and Off
Verify the Base Controller On/Off switch is in the ON position.
The unit is turned on by pressing the ON Key and off by
pressing the OFF Key. When the ON Key is pressed the display
briefly shows dashes (Figure 22) as the display initializes.
IMPORTANT: If the display flashes on and off continuously
when the ON Key is pressed, check to make sure the Base
Controller On/Off switch is in the ON position.
Figure 20: Zone 2
44
Operation
Figure 22: Dashes Displayed
Figure 23: Hourmeters
Then the unit running time hourmeters are shown for 30
seconds. The diesel engine run time hours and Diesel Icon are
shown in the upper display. If the optional Electric Standby
Feature is installed, the electric motor run time hours and
Electric Icon are shown in Figure 23.
When the unit is ready to run the Standard Display of box
temperature and setpoint appears. The box temperature and
Box Temp Icon are shown in the upper display. The setpoint
and Setpoint Icon are shown in the lower display. On
multi-temperature applications, the Zone indicators are shown
to the left of the box temperature. In Figure 24, the two bars
indicate that Zone 2 is currently being shown. The Zone 2 box
temperature shown in Figure 24 is 35.8°F (2.1°C) with a 35°F
(1.7°C) setpoint.
A Full Pretrip Test is initiated from this display by pressing and
holding the Pretrip Key as shown later in this section.
45
Operation
The Multi-Temperature Standard
Display
The Standard Display is the default display that appears if no
other display function is selected. The Standard Display shows
the current zone box and the temperature and setpoint of that
zone.
Figure 24: Zone 2 Temperature
Pressing the OFF Key stops unit operation. The unit shuts
down immediately and the display briefly shows dashes and
then goes blank. To start the unit again, press the ON Key
(Figure 25).
Figure 25: ON Key
46
Horizontal bars to the left of the box temperature are used to
indicate the zone currently shown on the display. Zone 1 is
shown in Figure 26.
The box temperature is that measured by the return air sensor.
The box temperature and Box Temperature Icon are shown in
the upper display. The setpoint and Setpoint Icon are shown in
the lower display. The box temperature in Figure 26 is -8.2°F
(-22.3°C) with a -10°F (-23.3°C) setpoint.
Figure 26: Box Temperature and Box Temperature
Icon, Setpoint Temperature and Setpoint Icon
Operation
IMPORTANT: If the unit is configured as a 2 zone unit, Zone
3 will still appear in Automatic Zone Scrolling and Manual
Zone Selection mode. However, Zone 3 is turned off and
cannot be turned on.
•
If a zone is in defrost, the LED indicator next to the
Defrost Key will be illuminated when that zone is shown
on the display.
•
If the unit is configured as a 2 zone unit, Zone 3 will still
appear in Automatic Zone Scrolling. However, Zone 3 is
turned off and cannot be turned on.
•
Unit operating conditions are shown by the LED
indicators next to the Cycle Sentry Key, High Speed
Lock-out Key and Pretrip Test Key.
If another display is shown, pressing the ON Key will return
the display to the Standard Display.
Automatic Zone Scrolling
When the Standard Display is shown, the operating conditions
for each zone will automatically be shown for 10 seconds. At
the end of that time, the next zone will appear on the display.
•
If a zone is currently turned on, the box temperature and
setpoint for that zone will be shown.
IMPORTANT: On SR-3 Truck SPECTRUM
Multi-Temperature units, Zone 1 can be turned off while the
unit is running. The unit will continue to run with Zone 1
turned off.
•
In Figure 27, Zone 1 is being shown as indicated by the single
horizontal bar to the left of the box temperature. The box
temperature of -8.2°F (-22.3°C) and setpoint of -10°F
(-23.3°C) indicate that Zone 1 is turned on. Since the Cycle
Sentry LED is turned off, the unit operating in Continuous
Mode. The illuminated LED next to the High Speed Lock-out
Key indicates that high speed operation is locked out. The
absence of the Alarm Icon indicated that no alarm conditions
exist.
If a zone is turned off, dashes will be shown instead of the
box temperature and setpoint for that zone.
47
Operation
Figure 28: Decimal Point
Figure 27: Zone 1 Display
Manual Zone Selection Mode
Manual Zone Selection mode allows the operator to select a
desired zone when the Standard Display is being shown. Once
a zone is selected, the zone can be turned on or off, the zone
setpoint can be changed or a manual defrost cycle can be
initiated.
To manually select a zone when the Standard Display is being
shown, press the Enter Key once. A decimal point will be
illuminated to the right of the Zone 1 horizontal bar as shown
in Figure 28. This indicates that Manual Zone Selection
MODE is active. The unit will remain in Manual Zone
Selection MODE for 30 seconds after the last key press.
48
When Manual Zone Selection MODE is active, pressing the
Enter Key manually scrolls through the zones. When the
desired zone is shown on the display, operation of that zone can
be changed as required.
•
The selected zone can be turned on or off.
•
The selected zone setpoint can be changed.
•
A manual defrost cycle can be initiated in the selected
zone if zone conditions permit.
Operation
Turning Zones On and Off
Each configured zone can be individually turned on or off. The
On and Off state for each zone is maintained even if the unit is
turned off and back on. For example, if Zone 2 is turned off
and the unit is then turned off and back on, Zone 2 will still be
off.
IMPORTANT: At least one zone must be turned on. If all
configured zones but one are turned off, the controller will
not allow the last zone to be turned off.
IMPORTANT: Unlike trailer unit applications, Zone 1 can be
turned off without affecting unit operation, so long as at least
one other zone is turned on.
Figure 29: Zone 2 Selected
When the desired zone is selected, simultaneously press the
ON Key and ENTER Key to turn the zone off. The box
temperature and setpoint show all dashes to indicate the zone is
turned off as shown in Figure 30.
From the Standard Display, press the Enter Key to put the unit
in Manual Zone Selection mode. Press the Enter Key again as
required to select the desired zone. In Figure 29, Zone 2 has
been selected.
Figure 30: Dashes Indicate Zone is Off
49
Operation
Simultaneously pressing the ON Key and ENTER Key again
will turn the selected zone back on as shown in Figure 31.
Figure 32: Zone 2 Selected
Figure 31: Simultaneously Press ON Key and ENTER
Key
Changing the Zone Setpoint
When the desired zone is selected, press the UP ARROW Key
and/or DOWN ARROW Key until the desired setpoint is
shown. In Figure 33, the setpoint has been increased to 40°F
(4.4°C) using the UP ARROW Key.
From the Standard Display, press the Enter Key to put the unit
in Manual Zone Selection mode. Press the Enter Key again as
required to select the desired zone. In Figure 32, Zone 2 has
been selected.
Figure 33: Setpoint Increased
50
Operation
When the desired setpoint has been selected using the UP
ARROW Key and DOWN ARROW Key, the ENTER Key
(Figure 34) must be pressed to confirm and load the new
setpoint.
return to the old setpoint and Alarm Code 127 Setpoint
Not Entered will be set. The Alarm Icon will appear in the
display.
Failure to confirm the new setpoint by pressing the ENTER
Key within 20 seconds of changing the setpoint will result in
no setpoint change. In addition, Alarm Code 127 Setpoint Not
Entered is set, to indicate that the setpoint change was started
but was not completed.
Figure 34: Press Enter Key
The new setpoint of 40°F (4.4°C) will remain on the display
after the ENTER Key has been pressed.
•
•
If the setpoint is changed using the UP ARROW Key and
DOWN ARROW Key, the setpoint display will begin to
flash 10 seconds after the last press of the Up Arrow or
Down Arrow key as a reminder to press the ENTER Key.
The setpoint display will flash for 10 additional seconds. If
at the end of this time the ENTER Key still has not been
pressed to complete the setpoint change, the setpoint will
Figure 35: Alarm Icon Displayed
Notice that the setpoint (Figure 35) has returned to the old
setpoint of 35°F (1.6°C) and the Alarm Icon has lighted
indicating that Alarm Code 127 Setpoint Not Entered is set.
51
Operation
IMPORTANT: If the setpoint is changed using the UP
ARROW Key or DOWN ARROW Key, the change must be
confirmed by pressing the ENTER Key within 20 seconds of
changing the setpoint.
•
If the ENTER Key is pressed, the setpoint change made
with the UP ARROW Key and/or DOWN ARROW Key is
accepted, the setpoint is changed, and the display returns
to the Standard Display showing the new setpoint.
•
If the ENTER Key is not pressed within 20 seconds of
making a change with the UP ARROW Key and/or
DOWN ARROW Key, the setpoint is not changed and the
display returns to the Setpoint Display showing the old
setpoint. Alarm Code 127 Setpoint Not Entered is set and
the Alarm Icon will appear on the display, to indicate that
the setpoint change was started but not completed.
Starting the Diesel Engine
Verify the Base Controller On/Off switch is in the ON position.
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.
52
The engine pre-heat and start sequence will be delayed in
CYCLE-SENTRY mode if there is no current need for the
engine to run.
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 SR-3 Standard Truck
HMI Control Panel will continue to display the Standard
Display as shown in Figure 36. The preheat buzzer at the unit
(located on the unit Interface Board) sounds during the engine
pre-heat and crank sequence.
Operation
When the motor is preparing to start, the SR-3 Standard Truck
HMI Control Panel will continue to show the Standard Display
as shown in Figure 37. The preheat buzzer at the unit (located
on the unit Interface Board) sounds for 20 seconds before the
electric motor starts.
Figure 36: Standard Display
Starting the Electric Motor
Units equipped with the Electric Standby option only.
Verify the Base Controller On/Off switch is in the ON position.
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 in Standby Mode and standby power
is connected.
Figure 37: Standard Display
CAUTION: The motor may start automatically any time the
unit is turned on.
53
Operation
Switching From Diesel to Electric
Switching from Electric to Diesel
IMPORTANT: Applies to units with the Electric Standby
Option only. The operation of this feature can be changed
using the Guarded Access Menu. See the Guarded Access /
Unit Configuration Menu / Diesel to Electric Auto Switch
Enabled feature in the Unit Diagnostic Manual for details.
The Diesel to Electric Auto Switch Enabled feature should be
set YES on units equipped with the Standard Truck HMI
Control panel.
IMPORTANT: Applies to units with the Electric Standby
Option only. The operation of this feature can be changed
using the Guarded Access Menu. See the Guarded Access /
Unit Configuration Menu / Electric to Diesel Auto Switch
Enabled feature in the HMI Diagnostic Manual for details.
Diesel to Electric Auto Switch Enabled set YES
(Default): If this feature is set YES, the unit will switch
automatically from Diesel Mode to Electric Mode when
standby power is connected and present.
Diesel to Electric Auto Switch Enabled set NO: The
Diesel to Electric Auto Switch Enabled feature should not be
set NO on units equipped with the Standard Truck HMI
Control panel.
Electric to Diesel Auto Switch Enabled feature set
YES : If this feature is set YES, the unit will switch
automatically from Electric Mode to Diesel Mode when
standby power is removed or fails.
Electric to Diesel Auto Switch Enabled feature set NO
(Default) : If the unit is operating in Electric Mode 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 unit is operating in Electric Mode and standby power is
disconnected or fails, Alarm Code 91 Check Electric Ready
Input will be set. The red LED between the ON key and OFF
54
Operation
Key will glow, the Alarm Icon will glow and the box
temperature and setpoint displays will disappear as shown in
Figure 38.
Figure 39: Alarm Code Cleared, Unit in Diesel Mode
Figure 38: Alarm Icon
IMPORTANT: If the unit is running in Electric Mode and
electric standby power is lost and then restored, Alarm Code
91 Check Electric Ready Input will be automatically cleared
and the unit will restart in Electric Mode.
IMPORTANT: When the display shown in Figure 39 is
present, do not press the Standard Truck HMI Control Panel
OFF Key to turn the unit off. Press the Standard Truck HMI
Control Panel ON Key twice to clear Alarm Code 91 Check
Electric Ready Input and turn the unit back on in Diesel
Mode.
Preferred Method for Manually Switching from Electric
Mode to Diesel Mode.
1.
Press the Standard Truck HMI Control Panel OFF Key to
turn the unit off.
2.
Turn off the standby power and disconnect the cord.
3.
Press the Standard Truck HMI Control Panel ON Key to
turn the unit on. The Hourmeters display will briefly
appear and then the screen will appear as shown in Figure
40.
55
Operation
Figure 40: Alarm Code Displayed
4.
Press the Standard Truck HMI Control Panel ON Key
twice to clear Alarm Code 91 Check Electric Ready Input
and turn the unit back on in Diesel Mode.
IMPORTANT: When the display shown in Figure 41 is
present, do not press the Standard Truck HMI Control Panel
OFF Key to turn the unit off. Press the Standard Truck HMI
Control Panel ON Key twice to clear Alarm Code 91. Check
Electric Ready Input and turn the unit back on in Diesel
Mode.
56
Figure 41: Press ON Key to Clear Alarm and Turn Unit
ON in Diesel Mode
If the Standard Truck HMI Control Panel OFF Key is pressed
when the display shown in Figure 41 is present, the unit will
turn off and the display will be blank. To restart the unit in
Diesel Mode, proceed as follows:
•
Press the Standard Truck HMI Control Panel ON Key. The
Hourmeters display and a blinking Alarm Icon will appear.
•
When the Hourmeters display and a blinking Alarm Icon
is shown, press the Standard Truck HMI Control Panel ON
Key again. The display will go blank but the blinking
Alarm Icon will remain on and blinking.
Operation
•
When the display goes blank and the blinking Alarm Icon
is shown, press the Standard Truck HMI Control Panel ON
Key again. The box temperature and setpoint will appear,
the blinking Alarm Icon will disappear and the unit will
start in Diesel Mode.
The unit shown below in Figure 42 is running in CYCLE
SENTRY Mode.
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 to provide constant airflow throughout the truck
box.
CYCLE SENTRY Mode or Continuous Mode is selected by
pressing the CYCLE SENTRY/CONTINUOUS Key when the
unit is turned on. If the unit is running in Continuous Mode,
pressing this key will switch operation to CYCLE SENTRY
Mode and the amber LED indicator will glow. If the unit is
running in CYCLE SENTRY Mode, pressing this key will
switch operation to Continuous Mode and the amber LED will
turn off.
Figure 42: CYCLE SENTRY Mode
CAUTION: The engine may start automatically any time the
unit is turned on.
CAUTION: If the unit is in CYCLE SENTRY null and the
mode is switched to Continuous Mode, the unit will start
automatically.
57
Operation
Selecting the High Speed Lock-Out
Feature
If the High Speed Lock-Out feature is enabled and turned on,
the unit will run only in low speed until the High Speed
Lock-Out feature is turned off or the High Speed Lock-Out
Timer is exceeded. This feature is typically used in noise
sensitive areas to reduce unit engine noise.
High Speed Lock-Out is turned on or off by pressing the HIGH
SPEED LOCK-OUT Key when the unit is turned on. Pressing
this key will turn High Speed Lock-Out on, pressing it again
will turn High Speed Lock-Out off. If High Speed Lock-Out is
turned on, unit will switch to low speed operation and the
amber LED inductor will glow. No further high speed
operation is allowed until this feature is turned off or the High
Speed Lock-Out Timer is exceeded.
IMPORTANT: HIGH SPEED LOCK-OUT TIMER: If High
Speed Lock-Out Mode is selected, the High Speed Inhibit
Timeout feature may be enabled to return the unit to normal
operation after a set time period has expired. This prevents
unintended extended operation with high speed operation
locked out. The time period may be set from 15 minutes to 2
hours. If a time period is set and exceeded, the unit will
return to normal operation with high speed operation allowed
and the amber LED indicator will turn off. If necessary to
return to High Speed Lock-Out Mode, press the HIGH
SPEED LOCK-OUT Key again.
The unit shown in Figure 43 has High Speed Lock-out turned
on.
Figure 43: High Speed Lock-Out Turned On
58
Operation
NOTE: The HIGH SPEED LOCK-OUT Key is only used
when the unit is operating in Diesel Mode. The HIGH
SPEED LOCK-OUT Key does not have any effect in Electric
Mode operation.
Initiating a Zone Manual Defrost Cycle
Defrost cycles are usually initiated automatically based on time
or demand. Manual defrost may also be available. Defrost is
only available if the unit is running and the evaporator coil
temperature is less than 45°F (7°C). Other features such as
door switch settings may not allow manual defrost under some
conditions.
Figure 44: Zone 2 Selected
To initiate a manual defrost cycle in the selected zone, press the
DEFROST Key as shown below. If zone conditions allow, the
zone will enter a defrost cycle and the amber LED next to the
DEFROST Key will glow (Figure 45).
From the Standard Display, press the Enter Key to put the unit
in Manual Zone Selection mode. Press the Enter Key again as
required to select the desired zone. In Figure 44, Zone 2 has
been selected.
Figure 45: Amber LED
59
Operation
IMPORTANT: During the defrost cycle, the box temperature
of the zone in defrost will rise toward 50°F (10°C) (Figure
46). This is normal and is caused by the defrost cycle
warming the evaporator coil. Since the damper door is closed
during the defrost cycle, this warm air is not allowed to pass
into the truck box.
Alarms
Alarm Code Notification: If an alarm condition occurs, the
Alarm Icon will appear on the display. If the alarm is a Check
Alarm, the Alarm Icon will turn on but the unit will continue to
run. If the alarm is a Shutdown Alarm, the Alarm Icon and the
display will flash on and off and the unit will shut down. If the
alarm is zone specific, the zone indicator (Figure 47) will be
present to show which zone has the alarm condition.
Figure 46: Box Temperature of Zone in Defrost
Terminating a Defrost Cycle: The defrost cycle terminates
automatically when the evaporator coil temperature is greater
than or equal to 52°F (11°C) or the defrost timer expires. When
the defrost cycle is completed the amber LED next to the
DEFROST Key will turn off. Defrost can also be terminated by
turning the unit off and back on.
60
Figure 47: Alarm Icon
Displaying Alarm Codes: Alarm Codes are displayed by
simultaneously pressing and holding the ON Key and
PRETRIP TEST Key (Figure 48).
Operation
Unit Alarm Codes: Unit alarms affect the operation of the
entire unit. The Alarm Display shown above indicates that
Alarm Code 50 Reset Clock exists and that there is only one
alarm condition present.
Figure 48: ON and PRE TRIP TEST Keys
The Alarm Display will appear as shown in Figure 49.
Figure 49: Alarm Display
Zone Specific Alarm Codes: If an alarm condition is
specific to a zone, the zone indicator will be present to identify
the zone experiencing the alarm condition. The Alarm Display
shown in Figure 50 indicates that Alarm Code 127 Setpoint
Not Entered exists in Zone 2. It also shows that a total of three
alarm conditions exist.
Figure 50: Alarm Code 127
Multiple Alarm Codes: If more than one alarm code has
been set, they are displayed with the most recent alarm shown
first. Use the UP ARROW Key to scroll through the alarms.
61
Operation
Clearing Alarm Codes: After the alarm situation is
resolved, press the ENTER Key to clear the alarm code
currently being shown. When all alarms have been cleared the
display will show all zeros to indicate that no alarm codes exist
(Figure 51).
•
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
•
Some alarms cannot be cleared using the Standard Truck
HMI Control Panel. These alarms must be cleared by
maintenance personnel from the Maintenance or Guarded
Access Menus.
•
Alarm Code 91 Check Electric Ready Input is cleared by
turning the unit off and back on. See SWITCHING FROM
ELECTRIC TO DIESEL in this chapter.
SR-3 Alarm Codes
Figure 51: All Zeros, No Alarm Codes Exist
The display will return to the Standard Display about 30
seconds after all alarms have been cleared.
Important Alarm Notes
•
62
All alarms must be viewed before any of the alarms can be
cleared.
NOTE: Not all alarm codes are used with all applications.
Code
Description
0
No Alarms Exist
2
Check Evaporator
Coil Sensor
Operator Help
Manually monitor load
temperature. Report
alarm at end of the day.
Operation
Code
Description
Operator Help
3
Check (Control)
Return Air Sensor
Manually monitor load
temperature. Report
alarm at end of the day.
4
Check (Control)
Discharge Air
Sensor
Manually monitor load
temperature. Report
alarm at end of the day.
Check Ambient Air
Sensor
Report alarm at end of
the day.
5
6
Check Coolant Temp Report alarm at end of
Sensor
the day.
7
Check Engine RPM
Sensor
Report alarm at end of
the day.
9
High Evaporator
Temperature
Manually monitor load
temperature. Report
alarm at end of the day.
Code
Description
Operator Help
10
High Discharge
Pressure
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
11
Unit Controlling on
Alternate Sensor
Manually monitor load
temperature. Report
alarm at end of the day.
12
Sensor or Digital
Input Shutdown
The indicated zone is
not longer able to
operate and has been
shut down. Repair
immediately.
13
Sensor Check
Manually monitor load
temperature. Report
alarm at end of the day.
15
Check Glow Plugs or If unit is shut down
Intake Air Heater
repair immediately.
Otherwise, report alarm
at end of the day.
63
Operation
Code
Description
Operator Help
Code
Description
17
Engine Failed to
Crank
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
22
Heating Cycle Check Manually monitor load
temperature. Report
alarm at end of the day.
23
Cooling Cycle Fault
18
High Engine Coolant
Temperature
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
The indicated zone is
not longer able to
operate and has been
shut down.
24
Heating Cycle Fault
19
Low Engine Oil
Pressure
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
The indicated zone is
not longer able to
operate and has been
shut down.
25
Alternator Check
20
Engine Failed to
Start
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.
26
21
Cooling Cycle Check Manually monitor load
temperature. Report
alarm at end of the day.
Check Refrigeration
Capacity
Manually monitor load
temperature. Report
alarm at end of the day.
64
Operator Help
Operation
Code
Description
Operator Help
Code
Description
Operator Help
28
Pretrip or Self Check
Abort
Report alarm at end of
the day.
33
Check Engine RPM
Report alarm at end of
the day.
29
Defrost Damper
Circuit Check
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
35
Check Run Relay
Circuit
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
30
Defrost Damper
Stuck
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
36
Electric Motor Failed
to Run
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
31
Check Oil Pressure
Switch
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
37
Check Engine
Coolant Level
Report alarm at end of
the day.
38
Electric Phase
Reversed
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
32
Refrigeration
Capacity Low
The indicated zone is
not longer able to
operate and has been
shut down. Repair
immediately.
65
Operation
Code
Description
Operator Help
Code
Description
Operator Help
39
Check Water Valve
Circuit
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
44
Check Fuel System
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
40
Check High Speed
Circuit
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
45
Hot Gas or Hot Gas
Bypass Circuit
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
41
Check Engine
Coolant
Temperature
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
46
Check Air Flow
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
42
Unit Forced to Low
Speed
Report alarm at end of
the day.
48
Check Belts or
Clutch
43
Unit Forced to Low
Speed Modulation
Report alarm at end of
the day.
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
50
Reset Clock
Report alarm at end of
the day.
66
Operation
Code
Description
Operator Help
Code
Description
Operator Help
52
Check Heat Circuit
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
63
Engine Stopped
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
54
Test Mode Timeout
Service Test or Interface
Board Test timed out
after 15 minutes. Report
alarm at end of the day.
64
Pretrip Reminder
Report alarm at end of
the day.
66
Low Engine Oil
Level
Check engine oil level. If
unit is shut down repair
immediately. Otherwise,
report alarm at end of
the day.
67
Check Liquid Line
Solenoid Circuit
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
68
Internal Controller
Fault Code
Report alarm at end of
the day.
70
Hourmeter Failure
Report alarm at end of
the day.
61
Low Battery Voltage
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
62
Ammeter Out of
Calibration
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
67
Operation
Code
Description
Operator Help
Code
Description
Operator Help
74
Controller Reset to
Defaults
Report alarm at end of
the day.
83
Low Engine Coolant
Temperature
77
Controller EPROM
Checksum Failure
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.
84
Restart Null
Report alarm at end of
the day.
79
Internal Data Logger
Overflow
Report alarm at end of
the day.
85
Forced Unit
Operation
Report alarm at end of
the day.
80
Check Compressor
Temp Sensor
Report alarm at end of
the day.
86
Check Discharge
Pressure Sensor
Report alarm at end of
the day.
81
High Compressor
Temp
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
87
Check Suction
Pressure Sensor
Report alarm at end of
the day.
89
Check Electronic
Throttling Valve
Circuit
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
82
68
High Compressor
Temp Shutdown
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
Operation
Code
Description
Operator Help
Code
Description
Operator Help
90
Electric Overload
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
95
Check Loader #2
Circuit
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
91
Check Electric
Ready Input
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
96
Low Fuel Level
92
Sensor Grades Not
Set
Report alarm at end of
the day.
Check engine fuel level.
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
98
Low Compressor
Suction Pressure
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
Check Fuel Level
Sensor
Report alarm at end of
the day.
99
High Compressor
Pressure Ratio
Check Loader #1
Circuit
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.
108
Door Open Timeout
Close Doors. Report
alarm at end of the day.
111
Unit Not Configured
Correctly
Report alarm at end of
the day.
93
94
69
Operation
Code
Description
Operator Help
Code
Description
Operator Help
113
Check Electric Heat
Circuit
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
120
Check Alternator
Excite Circuit
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
114
Multiple Alarms Can Not Run
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
121
Check Liquid
Injection Circuit
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
115
Check High
Pressure Cut Out
Switch
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
122
Check
Diesel/Electric
Circuit
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
116
Check High
Pressure Cut In
Switch
Report alarm at end of
the day.
127
Setpoint Not Entered Be sure the setpoint is
set to the required
temperature.
117
Auto Switch from
Diesel to Electric
Report alarm at end of
the day.
128
118
Auto Switch from
Electric to Diesel
Report alarm at end of
the day.
Engine Run Time
Maintenance
Reminder #1
70
Report alarm at end of
the day.
Operation
Code
Description
Operator Help
Code
Description
Operator Help
129
Engine Run Time
Maintenance
Reminder #2
Report alarm at end of
the day.
135
Check Spare Digital
Inputs
Report alarm at end of
the day.
136
130
Electric Run Time
Maintenance
Reminder #1
Report alarm at end of
the day.
Check Spare Digital
Outputs
Report alarm at end of
the day.
137
Check Damper
Report alarm at end of
Motor Heater Output the day.
131
Electric Run Time
Maintenance
Reminder #2
Report alarm at end of
the day.
141
Autoswitch Diesel to
Electric Disabled
Report alarm at end of
the day.
132
Total Unit Run Time
Maintenance
Reminder #1
Report alarm at end of
the day.
145
Loss of Controller
"On" Feedback
Signal
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
133
Total Unit Run Time
Maintenance
Reminder #2
Report alarm at end of
the day.
146
Software Version
Mismatch
134
Controller Power On
Hours
Report alarm at end of
the day.
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.
71
Operation
Code
Description
Operator Help
Sending a Data Logger Start of Trip
149
Alarm Not Identified
If unit is shut down
repair immediately.
Otherwise, report alarm
at end of the day.
When the unit is turned on, press and hold the ENTER Key
(Figure 52) for 5 seconds to send a Start of Trip (SOT) marker
to the unit ServiceWatch Data Logger and the optional DAS
Data Logger (if equipped).
150
Out of Range Low
Manually monitor load
temperature. Report
alarm at end of the day.
For additional ServiceWatch Data Logger information, see
Service Procedure A50A in Section 6 of the unit Diagnostic
Manual.
151
Out of Range High
Manually monitor load
temperature. Report
alarm at end of the day.
203
Check Display
Return Air Sensor
Manually monitor load
temperature. Report
alarm at end of the day.
204
Check Display
Discharge Air
Sensor
Manually monitor load
temperature. Report
alarm at end of the day.
Figure 52: ENTER Key
Pretrip Test
A Pretrip Test verifies unit operation. The PRETRIP Key
allows either a Full Pretrip Test or an Engine Running Pretrip
Test to be initiated by the operator.
72
Operation
Pretrip Test Conditions
Pretrip Test Sequence
•
The current unit settings are saved and restored at the end
of the Pretrip Test or if the unit is turned off and back on.
•
The Pretrip Test can be run in either Diesel or Electric
Mode.
Pretrip tests proceed in the order shown below. A Full Pretrip
Test is started with the engine or motor not running and
includes all tests. A Running Pretrip Tests is started with the
engine or motor running and does not include the Amp Checks
or Engine Start Check
•
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.
•
Amp Checks – Each electrical control component is
energized and the current drawn is confirmed as within
specification.
•
Engine Start – The Engine will start automatically.
Conditions where Pretrip Tests are not
allowed
•
Defrost – If the coil temperature is below 45 F (7 C), a
defrost cycle is initiated for that zone.
•
Pretrip Tests are not allowed if any Shutdown alarms are
present.
•
RPM Check – The engine RPM in high and low speed is
checked.
•
Pretrip tests are not allowed with some Check alarms
present.
•
Zone 1 Cool Check – The ability of the unit to cool in low
speed is checked.
•
Zone 1 Heat Check - The ability of the unit to heat in low
speed is checked.
•
Zone 1 Return to Cool Check - The ability of the zone to
return to cool mode is checked.
73
Operation
•
Zone 2 Cool Check - The ability of the zone to cool in low
speed is checked.
•
Zone 2 Heat Check - The ability of the zone to heat in low
speed is checked.
•
Zone 2 Return to Cool Check - The ability of the zone to
return to cool mode is checked.
•
Zone 3 Cool Check - The ability of the zone to cool in low
speed is checked.
•
Zone 3 Heat Check - The ability of the zone to heat in low
speed is checked.
•
•
74
Pretrip Test Considerations
When performing a Pretrip Test, the following issues should be
considered.
•
Whenever possible, run the Pretrip Test with an empty
truck box.
•
Zone 3 Return to Cool Check - The ability of the zone to
return to cool mode is checked.
If running a Pretrip Test on a truck loaded with dry cargo,
insure that proper airflow can occur around the load. If the
load restricts airflow, false test results may occur. Also,
units have high refrigeration capacity which results in
rapid temperature change. Sensitive dry cargo may be
damaged as a result.
•
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.
If running a Pretrip Test on a truck that has just been
washed down, the extremely high humidity inside the
truck box may result in false test results.
•
If running a Pretrip Test on a truck 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 cargo doors closed
to prevent false test results.
Operation
Performing a Pretrip Test
•
The Amps Check Test will be preformed and then the unit
will start automatically. The balance of the tests will be
completed.
•
The Pretrip Test will take about 20 – 30 minutes,
depending on conditions.
Starting a Full Pretrip Test
The Full Pretrip Test must be started with the unit not running.
Turn the unit on and clear all alarm codes. Turn the unit off.
Turn the unit on and wait for the unit running time hourmeters
to be shown on the display. When the unit running time
hourmeters are shown on the display, press and hold the
PRETRIP Key for 5 seconds (Figure 53).
IMPORTANT: The box temperature will vary during the
Pretrip Test. This is normal operation.
•
When the Pretrip Test is complete or if a Shutdown Alarm
occurs, the amber Pretrip LED will turn off.
•
Stopping a Pretrip Test: To stop a Pretrip Test at any
time, press the POWER OFF Key to 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.
Starting a Engine Running Pretrip Test
Figure 53: PRETRIP Key
•
A flashing Pretrip LED indicates that the Pretrip Test is
being initialized. When the Pretrip Test starts, the Pretrip
LED will glow steady amber. The display will show the
Standard Display.
The Engine Running Pretrip Test must be started with the unit
running. Turn the unit on and clear all alarm codes. Allow the
unit to start.
With the unit running, press and hold the PRETRIP Key for 5
seconds (Figure 54).
75
Operation
•
Stopping a Pretrip Test: To stop a Pretrip Test at any
time, press the POWER OFF Key to 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.
Pretrip Test Results
Figure 54: PRETRIP Key
•
A flashing Pretrip LED indicates that the Pretrip Test is
being initialized. When the Pretrip Test starts, the Pretrip
LED will glow steady amber to indicate the test is in
progress. The display will show the Standard Display.
•
The Pretrip Test will take about 20 – 25 minutes,
depending on conditions.
•
IMPORTANT: The box temperature will vary during
the Pretrip Test. This is normal operation.
•
When the Pretrip Test is complete or if a Shutdown Alarm
occurs, the amber Pretrip LED will turn off.
76
Pass Pretrip Test
•
If the unit passes the Pretrip Test, the amber Pretrip Test
LED will turn off at the completion of the test and the unit
will continue to run as required. This signifies that the unit
passed the Pretrip Test.
Fail Pretrip Test with Check Alarms
•
If the unit fails the Pretrip Test with Check alarms, the
Alarm Icon will appear when the alarm condition occurs.
The Pretrip Test will continue to run unless a Shutdown
Alarm occurs.
Operation
•
•
The amber Pretrip Test LED will turn off at the completion
of the test, but the Alarm Icon will remain lit. This
indicates that one or more Check Alarm conditions
occurred during the Pretrip Test. More than one alarm may
be present.
View and record the alarm(s), correct as necessary, clear
the alarm(s) and repeat the Pretrip Test.
Fail Pretrip Test with Shutdown Alarms
•
If the unit fails the Pretrip Test with a Shutdown alarm, the
Alarm Icon will appear when the alarm condition occurs,
the unit will immediately shut down and the amber Pretrip
Test LED will turn off.
•
The Pretrip Test will be aborted.
•
Alarm Code 28 Pretrip Abort will be set along with the
Shutdown Alarm that was detected. This signifies that a
Shutdown Alarm occurred during the Pretrip Test and that
the test was aborted. Other alarms may also be present.
•
Display Brightness
The brightness of the SR-3 Standard Truck HMI Control Panel
display can be adjusted to allow for changing ambient light
conditions. The choices available to the operator are HIGH,
MEDIUM and LOW.
To change the display brightness press and hold the ON key
then press the UP ARROW Key to increase display brightness
and the DOWN ARROW Key to decrease display brightness.
Figure 55: ON Key
View and record the alarm(s), correct as necessary, clear
the alarm(s) and repeat the Pretrip Test.
77
Operation
Keypad Lockout
The Keypad Lockout feature allows the operator to lock the
keypad to prevent tampering. If the Keypad Lockout feature is
turned on, all keys except the ON Key and OFF Key are
prevented from functioning. The unit can still be turned On and
Off, but doing so does not clear Keypad Lockout.
To turn Keypad Lockout on, simultaneously press and hold the
ON Key, CYCLE SENTRY Key and HIGH SPEED
LOCK-OUT Key for 5 seconds. The display shown below in
Figure 56 will appear, with [0 - - - n] replacing the box
temperature. When the three keys are released, the display will
return to the Standard Display of box temperature and setpoint.
When Keypad Lockout is turned on, only the ON and OFF
Keys are functional. All other keys are locked out. Pressing
any key other than the ON Key and OFF Key will cause the
box temperature to display [0 - - - n]. When the key is released,
the display will return to the Standard Display of box
temperature and setpoint.
To turn Keypad Lockout off, simultaneously press and hold the
ON Key, CYCLE SENTRY Key and HIGH SPEED
LOCK-OUT Key for 5 seconds. The display shown above will
appear, with [0 - - - n] replacing the box temperature. When the
three keys are released, the display will return to the Standard
Display of box temperature and setpoint. All keys will function
normally.
NOTE: With the Standard Truck HMI Control Panel, the
Keypad Lockout feature is present even if the Guarded
Access / Main Menu Configuration / Add Keypad Lockout to
Mode Menu feature is disabled.
Figure 56: [0 - - - n] Replaces Box Temperature
78
Operation
Checking Truck HMI Control Panel
Serial Number and Software Revision
The Standard Truck HMI Control Panel serial number and
software revision can be displayed if necessary. To display the
serial number and software revision press and hold the
PRETRIP key (Figure 57) for 5 seconds when the unit is turned
off.
Figure 58: Software Revision
Time and Date
With all SR-3 control systems, the system time and date is
maintained by the HMI Control Panel.
Figure 57: PRETRIP Key
The HMI Control Panel serial number is shown at the top of
the display and the installed software revision is shown below.
The HMI Control Panel serial number shown below in Figure
58 is 00243 and the software revision is Revision 2201.
The time and date held by the HMI Control Panel cannot be
viewed using the Standard Truck HMI Control Panel. Time and
date can be checked and changed using WinTrac 4.8.1 or later.
Power must be connected to the Standard Truck HMI Control
Panel and the unit must be turned off in order to check or
change the time and date.
1.
Remove the Standard Truck HMI Control Panel as
necessary to gain access to the back of the device.
79
Operation
2.
Turn the unit on to verify that power is available to the
Standard Truck HMI Control Panel. Turn the unit back off.
3.
Remove the back cover from the Standard Truck HMI
Control Panel. 4
4.
Connect a Thermo King 9 to 15 pin serial cable from the
PC computer to the 15 pin connector on the back of the
Standard Truck HMI Control Panel shown in Figure 59.
indicator is not illuminated the time and date cannot be
changed. If the red LED indicator is not illuminated, be
sure the unit is turned off.
Figure 60: Red LED Indicator
Figure 59: “D” Connector
5.
80
When the cable is connected, be sure the red LED
indicator located between Standard Truck HMI Control
Panel POWER ON Key and POWER OFF Key is
illuminated as shown below (Figure 60). If the red LED
6.
Open WinTrac 4.8.1 or later. Earlier versions of WinTrac
will not work.
7.
Select Seek Device.
8.
Use WinTrac to set the time and date. See the WinTrac
Manual for additional information.
9.
When the time and date is set and checked, disconnected
the cable, replace the back cover and reinstall the Standard
Truck HMI Control Panel as necessary.
10. Turn the unit on and perform a ServiceWatch Data Logger
download using WinTrac to verify the time and date are
correct.
Electric Standby Operation
Model 50 units are equipped with Electric Standby. This
feature allows the unit to operate on electric power as well as
be powered by the standard diesel engine.
During Electric Standby operation, power to the unit is
supplied by an electric motor connected to a high voltage
power source. Check the unit for proper power source ratings.
Electric Power Receptacle
The electric power receptacle is used to connect the unit to an
appropriate electric power source for electric standby
operation. Turn the unit OFF before connecting or
disconnecting the power cord.
WARNING: Units equipped with electric standby can
start at any time when the unit is connected to live
electric power and the controller is turned on.
CAUTION: Always turn the electric power supply off
when handling, connecting, or disconnecting high
voltage power cords.
Figure 61: Model 50 Power Receptacle Box
81
Electric Standby Operation
NOTE: The Model 50 control system automatically
determines if diesel or electric power is desired.
See “Starting the Electric Motor” in the Unit Operation chapter
of this manual.
82
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 prevent cargo spoilage.
Pre-Loading Inspection
1.
Products must be pre-cooled before loading. Note any
variances on the manifest.
2.
Inspect door seals and vent doors for condition and tight
seal with no air leakage.
3.
Inspect the cargo compartment inside and out. Look for:
•
Damaged or loose skin and insulation
•
Damaged walls, air ducts, floor channels or “T”
flooring
•
Clogged defrost drain tubes
•
Blocked return air bulkhead.
4.
Inspect bulkheads for a tight fit at ceiling, walls, and floor.
Bulkheads must fit tightly to reduce heat transfer between
compartments.
5.
Pre-cool the cargo compartments: adjust the setpoints for
both compartments and run the unit 30–60 minutes (longer
if possible) before loading.
6.
Supervise product loading to ensure sufficient air space is
maintained around and through the load in both
compartments. Airflow around the cargo must not be
restricted.
NOTE: Loads should be separated from both sides of the
bulkhead by at least 4 in. (100 mm). You can use a pallet
as a spacer.
83
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: You can run the unit with the cargo box doors
open if the truck is backed into a refrigerated warehouse
with tight door seals.
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: Pre-cool cargo to the correct 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.
84
6.
If the unit was stopped, restart using the correct starting
procedure. See the 'Unit Operation” chapter in this
manual.
7.
Repeat the after-start inspection. See the “Unit Operation”
chapter in this manual.
8.
Defrost the unit 30 minutes after loading by starting a
manual defrost cycle.
Loading and Enroute Inspections
1
2
3
4
5
6
7
1.
2.
3.
4.
5.
6.
7.
8.
Unit Inspection
Good Outside Air Circulation
Gaskets Equally Compressed
Clear Defrost Drains
Tight Doors
Good Air Circulation Around Load
Cargo at Proper Temperature Prior
to Loading
Interior and Exterior Walls and
Insulation in Good Condition
8
Figure 62: Loading Considerations
85
Loading and Enroute Inspections
1
2
3
4
1.
2.
3.
4.
5.
6.
6
5
Figure 63: Air Circulation Diagram
86
At Least 48 in. (1219 mm)
Between Air Outlet and Wall
or Bulkhead
Bulkhead Tightly Sealed
Good Air Circulation Around
Load
Rear Compartment
Load Separated from
Bulkhead by 4 in. (100 mm)
Front Compartment
Loading and Enroute Inspections
Enroute Inspections
2.
Repeat the Enroute Inspection every 30 minutes until the
compartment temperature is within the desired
temperature range. Stop the unit if the compartment
temperature is not within 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 the necessary steps to protect and maintain proper
load temperature.
To help prevent damage to the cargo, complete the following
enroute inspection every four hours.
Inspection Procedure
1.
Verify that the setpoints are correct.
2.
Check the return air temperature readings. The
temperature readings should be within the desired
temperature range. If the readings are not within this
range, see the “Inspection Troubleshooting” procedure
below.
3.
Initiate a manual defrost cycle after each enroute
inspection.
Inspection Troubleshooting
1.
If a return air temperature reading is not within the desired
temperature range, refer to the troubleshooting table on the
following pages. Correct the problem as needed.
CAUTION: Stop the unit if the compartment
temperature remains more than 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.
87
Loading and Enroute Inspections
Inspection Troubleshooting
Problem
Cause
A return air
temperature
reading is not
within desired
temperature
range of the
setpoint.
The unit has not had Refer to the load log history. Look for above temperature load records,
time to cool down to properly pre-cooled cargo compartment, length of time on road, etc. Correct
correct temperature. as required. Continue monitoring return air temperature until reading is within
desired temperature range of the setpoint.
The unit may have a Check the receiver tank sight glass for refrigerant level. If liquid is not
showing in the receiver tank sight glass, the refrigerant charge could be low.
low refrigerant
A competent refrigeration technician is required to add refrigerant or repair
charge.
the system. Contact the nearest Thermo King dealer, authorized Service
Center, or call the Thermo King Cold Line for referral. Consult the Table of
Contents for Cold Line information.
The unit is in defrost Monitor the return air temperature after the defrost cycle is completed to see
if the temperature returns to the desired temperature range of the setpoint.
or has just
completed a defrost
cycle.
The evaporator is
Initiate a manual defrost cycle. The defrost cycle will automatically terminate
plugged with frost. when complete. Continue monitoring return air temperature until reading is
within desired temperature range of the setpoint.
88
Remedy
Loading and Enroute Inspections
Inspection Troubleshooting (Continued)
Problem
Cause
Remedy
Inspect the unit and cargo compartment to determine if the evaporator fans
Improper air
are working and properly circulating the air. Poor air circulation may be due
circulation in the
cargo compartment. to improper loading of the cargo, shifting of the load. Correct as required.
Continue monitoring return air temperature until problem is corrected.
WARNING: The unit could start at any time when turned on. Turn the unit off
before opening doors or inspecting any part of the unit.
The unit did not start Determine the cause for not starting. Correct as required. Continue
automatically.
monitoring return air temperature until reading is within desired temperature
range of the setpoint.
89
Specifications
Engine
Model
TK380F (Tier 4)
Fuel Type
No. 2 Diesel fuel under normal conditions
No. 1 Diesel fuel is acceptable cold weather fuel
Oil Capacity:Crankcase & Oil Filter
w/Bypass Oil Filter
12.0 quarts (11.4 liters)
13.0 quarts (12.3 liters) Fill to full mark on dipstick
Oil Type
API Classification CI-4 or better.
API Rating CI or CH, as available, if low sulfur diesel fuel (up to
500ppm sulfur) is used.
(ACEA Rating E3 or better for Europe)
Oil Viscosity
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
-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)
90
Specifications
Engine (Continued)
Engine rpm:Low Speed Operation
High Speed Operation
1625 ± 25 rpm
2200 ± 25 rpm
Engine Oil Pressure
20 to 50 psig (138 to 345 kPa) in low speed
40 to 60 psig (276 to 414 kPa) in high speed
Intake Valve Clearance
0.006 to 0.010 in. (0.15 to 0.25 mm)
Exhaust Valve Clearance
0.006 to 0.010 in. (0.15 to 0.25 mm)
Valve Setting Temperature
70 F (21 C)
Fuel Injection Timing
16 ± 1 degrees BTDC
Injection Nozzle Pressure
1784 to 1929 psig (12,300 to 13,300 kPa)
Low Oil Pressure Switch/Sensor
10 ± 2 psig (69 ± 14 kPa)—shutdown
High Coolant Temperature Sensor
220 ± 5 F (104 ± 3 C)—shutdown
Engine Thermostat
160 F (71 C)
91
Specifications
Engine (Continued)
Engine Coolant Type
ELC (Extended Life Coolant), which is “RED”
Use a 50/50 concentration of any of the following equivalents:
Chevron Dex-Cool
Texaco ELC
Havoline Dex-Cool®
Havoline XLC for Europe
Shell Dexcool®
Shell Rotella
Saturn/General Motors Dex-Cool®
Caterpillar ELC
Detroit Diesel POWERCOOL® Plus
CAUTION: Do not add “GREEN” or “BLUE-GREEN”
conventional coolant to cooling systems using “RED”
Extended Life Coolant, except in an emergency. If
conventional coolant is added to Extended Life Coolant,
the coolant must be changed after 2 years instead of
5 years.
92
Specifications
Engine (Continued)
Units Built Prior to October 2016
Units with coolant expansion tank only.
Coolant System Capacity:
6.5 quarts (6.2 liters)
Coolant Expansion Tank Cap Pressure
15 psig (103 kPa)
7 psig (48 kPa) after November 2015
Units Built After October 2016
Units with coolant expansion tank and overflow bottle.
Coolant System Capacity:
8.36 quarts (7.91 liters)
Coolant Expansion Tank Cap Pressure
10 psig (69 kPa)
93
Specifications
Belt Tension
Belt
Water Pump Belt
Engine/Electric Motor (Jackshaft)
Electric Motor (Jackshaft)/Compressor
Tension No. on TK Gauge P/N 204-427
(Frequency Gauge Setting Where Applicable)
New Belt
Field Reset
40
40
91 (85 Hz)
85 (70 Hz)
Automatically tensioned by tensioner position. See “Belts”
in Maintenance Manual Engine Maintenance Chapter.
Engine Clutch - Hilliard
Engagement
600 ± 100 RPM
Dynamic Torque
66 ft-lb (89.5 N•m) minimum @ 1600 RPM
94
Specifications
Refrigeration System
Compressor Model
TK06 Scroll 6 HP
Refrigerant Charge:
Approximately 13.0 lbs (5.9 kg) R-404A
Compressor Oil Charge
2.0 quarts (1.9 liters)
Compressor Oil Type
Ester base P/N 203-516 required for Scroll compressor
Suction Pressure Regulator Valve Setting
26 to 29 psig (179 to 200 kPa)
Discharge Pressure Regulator Valve Setting
350 ± 5 psig (2413 ± 34 kPa)
High Pressure Cutout Switch: Open
Close
470 ± 7 psig (3241 ± 48 kPa)
375 ± 38 psig (2586 ± 262 kPa)
Electrical Control System
Control System Voltage
12.5 Vdc
Battery Charging System
12 volt, 120 amp, brush type, Thermo King alternator
Voltage Regulator Setting
13.8 to 14.4 volts @ 77 F (25 C)
NOTE: Fuse F4 (Bypass resistor for Prestolite Alternator) must be removed for the Thermo King Alternator.
95
Specifications
Fuses
Fuse
Size
Function
F2
15A
Power to On/Off Switch
F3
40A
Fuel Sol Pull-In/Starter Circuit
F4
None
2A
No Fuse - All Bosch and Thermo King Alternators
2A Fuse - All Prestolite Alternators
F5
40A
Preheat Circuit
F6
15A
High Speed Circuits
F7
2A
8XP Circuit - Controller On Feedback to HMI
F8
5A
2A Power to CAN Connector J12
F9
5A
2A Power to CAN Connector J14
F10
10A
8X Power (Install fuse in upper position)
F11
10A
Zone 1 LLS
F12
5A
CAN Connector J13
F13
2A
8FC Circuit (Remote Lights)
96
Specifications
Fuses (Continued)
Fuse
Size
Function
F15
P/S
On/Off Relay
F20
2A
Alternator Sense
F21
60A
Main Fuse (2 Circuit)
F25
7.5A
HPCO/Run Circuit
F4 Remove fuse F4 for Model 30 units with Australian Bosch or Thermo King Alternators. Install fuse F4 for Model 50
units with Prestolite Alternator.
F10 When fuse F10 is installed in the upper position the On/Off keys on the HMI turn the unit on and off. When fuse
F10 is installed in the lower position the unit will start and run without the HMI control panel.
F15 The device identified as F15 is a poly switch. These over-current devices reset automatically and are not
replaceable.
97
Specifications
Electrical Components
Component
Current Draw (Amps)
at 12.5 Vdc
Resistance
(Ohms)
4.3
2.3 ± 0.2
35 to 45
0.5
0.2 to 0.3
24 to 29
High Speed (Throttle) Solenoid
3.3
3.8
Condenser Inlet Solenoid (CIS)
1.8
6.9
Hot Gas Bypass Solenoid (HGBS)
0.8
15.6
Liquid Injection Solenoid (LIS)
1.1
11.3
Purge Valve (PV)
1.1
11.3
Receiver Tank Pressure Solenoid (RTPS)
1.1
11.3
Starter Motor (No Load Bench Test)
90
—
Electronic Throttling Valve (ETV):
- Coil A (Red [EVA] and Blue [EVB] Wires)
- Coil B (Black [EVC] and White [EVD] Wires)
___
___
20 to 35
20 to 35
Hot Gas Solenoids (HGS) - Remote
1.5
8.3
Glow Plugs (3) Each
Fuel Solenoid:Pull In Coil
Hold In Coil
98
Specifications
Electrical Components (Continued)
Component
Current Draw (Amps)
at 12.5 Vdc
Resistance
(Ohms)
Liquid Line Solenoids (LLS) - Remote
1.3
9.6
Suction Line Solenoids (SLS) - Remote
1.3
9.6
Drain Heaters (each) - Remote
2.1
6.0
Fan Motors (each) - Remote
7.3
—
99
Specifications
Electrical Standby (Model 50 Units Only)
Electric Motor and Overload Relay
Voltage/Phase/Frequency
Horsepower
Kilowatts
rpm
Full Load
(amps)
Overload Relay
Setting (amps)
230/3/50
10.0
7.5
1460
22.5
25
208-230/3/60
12.0
8.9
1765
28.8
32
400/3/50
10.0
7.5
1460
17.0
16
460/3/60
12.0
8.9
1765
14.4
16
Standby Power Requirements
Supply Circuit Breaker: 200-230/3/50-60
380-460/3/50-60
50 amps
20 amps
Extension Cord Size:
Up to 50 ft—10 gauge
75 ft—8 gauge
100
Maintenance Inspection Schedule
A closely followed maintenance program will help to keep
your Thermo King unit in top operating condition. The
following general schedule is provided to assist in monitoring
that maintenance.
After first week of operation:
For more specific detail, see the maintenance manual for your
unit and to the PreTrip Inspection chapter in this manual.
•
Check belt tension.
•
Tighten unit mounting bolts.
•
Check coolant level.
•
Check refrigerant oil level.
•
Check refrigerant level.
101
Maintenance Inspection Schedule
Maintenance Inspection Schedule
Pretrip
1,200
Hours
2,000
Hours
Inspect/Service These Items
Annual/
3,000
Hours
Microprocessor
•
Run pretrip test (see “Pretrip Test” in Operating Instructions Chapter).
Engine
•
102
Check fuel supply.
•
•
Check engine oil level.
•
•
Check condition of belts.
•
•
Check engine oil pressure hot, on high speed.
•
•
•
•
Listen for unusual noises, vibrations, etc.
•
Check air cleaner hose for damage.
•
Inspect and clean electric fuel pump filter.
Maintenance Inspection Schedule
Pretrip
1,200
Hours
2,000
Hours
Annual/
3,000
Hours
Inspect/Service These Items
•
Dry air cleaner. Replace air cleaner element at 2,000 hours or 1 year
(whichever occurs first)
•
Change EMI 2000 (black) fuel filter.
•
Change engine oil and oil filters (hot). Requires oil with API Rating CI-4
or better (ACEA Rating E3 for Europe) and EMI 2000 bypass oil filter. If
low sulfur diesel fuel (up to 500ppm sulfur) is used, use engine oil with
API Rating CI or CH, as available.
•
Check restraining mount (snubber) pre-load adjustment.
•
Drain water from fuel tank and check vent.
•
Check and adjust engine speeds (high and low speed).
•
Check condition of engine mounts.
103
Maintenance Inspection Schedule
Pretrip
1,200
Hours
2,000
Hours
Annual/
3,000
Hours
•
Inspect/Service These Items
Check coolant levels (cool)
Coolant Expansion Tank: The expansion tank must always be
completely full of coolant when cool.
Coolant Overflow Bottle: Coolant level in overflow bottle must always
be at or above the FULL COLD mark of the bottle when cool.
* Based on EPA 40 CFR Part 89.
104
•
Maintain year round antifreeze protection at –30 F (–34 C).
•
Test fuel injection nozzles at least every 3,000 hours.*
—
Replace the fuel return lines between fuel injection nozzles every 10,000
hours or sooner as required.
—
Change ELC (red) engine coolant every 5 years or 12,000 hours. Units
equipped with ELC have an ELC nameplate on the expansion tank.
Maintenance Inspection Schedule
Pretrip
1,200
Hours
2,000
Hours
Inspect/Service These Items
Annual/
3,000
Hours
Electrical
•
Check controller for alarms.
•
Run pretrip test
•
Check battery voltage.
•
Inspect battery terminals and electrolyte level.
•
Inspect wire harness for damaged wires or connections.
•
Inspect alternator bearings and brushes.**
•
Inspect electric motor bearings (Model 50).**
** With belt removed, spin bearings by hand. Listen for noise (bearings roll freely).
105
Maintenance Inspection Schedule
Pretrip
1,200
Hours
2,000
Hours
Inspect/Service These Items
Annual/
3,000
Hours
Refrigeration
•
•
Check refrigerant level.
•
Check compressor oil level.
•
Check discharge and suction pressures.
•
Check compressor efficiency.
—
106
Replace dehydrator and compressor oil filter every two (2) years.
Maintenance Inspection Schedule
Pretrip
1,200
Hours
2,000
Hours
Inspect/Service These Items
Annual/
3,000
Hours
Structural
•
•
Visually inspect unit for fluid leaks.
•
•
Visually inspect unit for damaged, loose or broken parts (includes air
ducts and bulkheads).
•
•
•
•
Inspect clutch for shoe and anchor bushing wear with a mirror. Check
bearings.**
•
Inspect idlers and jackshaft (if so equipped) for leakage and bearing
wear.**
•
Clean entire unit including condenser coils, evaporator coils, and defrost
drains.
•
Check all unit, fuel tank, engine, and electric motor mounting bolts,
brackets, lines, hoses, etc.
** With belt removed, spin bearings by hand. Listen for noise (bearings roll freely).
107
Maintenance Inspection Schedule
Pretrip
1,200
Hours
2,000
Hours
Inspect/Service These Items
Annual/
3,000
Hours
Electrical
•
•
Inspect wire harness for damaged wires or connections.
•
Inspect/replace DC fan motors.
Structural
•
•
•
•
•
108
•
Visually inspect unit for fluid leaks.
Visually inspect unit for damaged, loose or broken parts.
•
Clean entire unit including evaporator coils and defrost drains.
•
Check all mounting bolts, brackets, lines, hoses, etc.
Serial Number and Refrigerant Label
Locations
Write the unit model and unit serial number in the spaces
provided in the following Emergency Cold Line chapter. This
information is needed to service the unit.
AMA832
Figure 65: Compressor Serial Number Location
Figure 64: Engine Serial Number Location
109
Serial Number and Refrigerant Label Locations
1
2
Figure 67: Laminated Unit Serial Number Plate
Figure 68: Refrigerant Type Label
1.
Unit Serial Plate
2.
Refrigerant Type
Figure 66: Label Locations
110
•
This label identifies the type of refrigerant in the unit.
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.
111
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.
112
California
Proposition 65 Warning
Diesel exhaust is a chemical known to
the State of California to cause cancer.
113
Warranty
Terms of the Thermo King Warranty are available on request.
Please reference document TK 50047 for the Thermo King
Self-Powered Truck Unit Warranty.
114
Operator’s Manual
Rand’s(NYSE:IR)
Climate Solutions
delivers
cientcomfortable,
HVACR solutions
for and
Ingersoll Rand
advancessector
the quality
of energy-effi
life by creating
sustainable
customers
globally. Its world
class brands
include
King, the leaderClub
in transport
effi
cient environments.
Our people
and our
familyThermo
of brands—including
Car®, Ingersoll
temperature
control
a providertogether
of energy
cient heating,
ventilating
and of air
Rand®, Thermo
King®and
andTrane,
Trane®—work
to effi
enhance
the quality
and comfort
airhomes
conditioning
systems,transport
building and contracting
parts support
and advanced
in
and buildings;
protect foodservices,
and perishables;
and increase
industrial
controls for commercial
buildings
homes.
productivity
and efficiency.
We areand
a global
business committed to a world of sustainable
progress and enduring results. For more information, visit www.ingersollrand.com.
T-1080S SPECTRUM
With Stand HMI
TK 55709-1-OP (Rev. 1, 09/16)
©2013 Ingersoll-Rand Company
Printed in U.S.A.
Operator’s Manual
Ingersoll Rand (NYSE:IR) advances the quality of life by creating comfortable, sustainable and
efficient environments. Our people and our family of brands—including Club Car®, Ingersoll
Rand®, Thermo King® and Trane®—work together to enhance the quality and comfort of air
in homes and buildings; transport and protect food and perishables; and increase industrial
productivity and efficiency. We are a global business committed to a world of sustainable
progress and enduring results. For more information, visit www.ingersollrand.com.
©2013 Ingersoll-Rand Company
Printed in U.S.A.
T-1080S SPECTRUM
With Stand HMI
TK 55709-1-OP (Rev. 1, 09/16)
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