Direct Smart Reefer Microprocessor Control System

Direct Smart Reefer Microprocessor Control System
Direct Smart Reefer
Microprocessor
Control System
Revision 121 XX, 273 XX
Software
TK 52573-EN-18-OD (Rev. 6, 10-08)
Direct Drive Truck Units (ESA)
B-100, V-100, V-200, V-300, V-400, V-500
Diagnostic Manual
Copyright© 2008 Thermo King Barcelona, Spain
Release History
(04-2005)
Original
(08-2006)
Add software revision 273 XX, V-400 MAX 30/50, V-500 MAX 20 1PH, V-500 MAX TC
10/20/30/50 1PH/3PH
(12-2006)
Add software revision 273 XX, B-100 10/20
(03-2007)
Add V-500 AC 10/20
(12-2007)
To replace CB1 by FP and F14 in B-100 units. To replace F20 (5A) by F20 (4A) in all
the units "except B-100"
(04-2008)
To update electrical diagramsfor the V-100/200/300 MAX 10/20/30/50, V-400/500 MAX
20/50, V-500 MAX TC 20/50 and V-500 AC 10/20 units
(10-2008)
Add V-100/20 and V-100 MAX 20/50. To update electrical diagrams for V-100/200/300
MAX 10/20/30/50, V-400/500 MAX 10/20/30/50 and V-500 MAX TC 10/20/30/50 units.
To update F21 and F14. To eliminate DAS connection.
This manual is published for informational purposes only and the information so provided should not be considered as all-inclusive
or covering all contingencies. If further information is required Thermo King Corporation should be consulted.
Sale of product shown in this manual is subject to Thermo King's terms and conditions including, but not limited to, the THERMO
KING LIMITED EXPRESS WARRANTY. Such terms and conditions are available upon request.
Thermo King's warranty will not apply to any equipment which has been "so repaired or altered outside the manufacturers plants as,
in the manufacturers judgment, to effect it's stability".
No warranties, express or implied, including warranties of fitness for a particular purpose or merchantability, or warranties arising
from course of dealing or usage of trade, are made regarding the information, recommendations and descriptions contained herein.
Manufacturer is not responsible and will not be held liable in contract or in tort (including negligence) for any special, indirect or
consequential damages, including injury or damage caused to vehicles, contents or persons, by reason of the installation of any
Thermo King product or its mechanical failure.
ABOUT THIS MANUAL
Because not everyone is familiar with microprocessor-based control systems, please take a few minutes
to read this page. It explains the content and structure of this manual. This will make it easier for you to
find the information you need.
Section 1 - Safety Precautions
This section contains the safety precautions, safety decals and locations and microprocessor cautions.
You should read this material carefully before working on the unit.
Section 2 - System Description
This section includes a complete system hardware description, including special features. It shows you
how the system works in different modes and under various conditions.
Section 3 - Software Description
This section discusses the operation of the software, the programmable features, and the sequence of
operation. Each programmable feature is discussed individually to show you how each works and how
to change the settings.
Section 4 - Operation
This section shows you how to operate the Direct Smart Reefer Microprocessor Controller.
Section 5 - Diagnostics
This section shows you how to diagnosis problems. It includes both alarm code diagnostics and other
symptom diagnostics.
Section 6 - Service Procedures
This section includes step by step procedures to repair and program the Direct Smart Reefer
Microprocessor Controller. They are referenced by the Diagnostics section.
Section 7 - DSR µP Controller Information
This section offers information on the parts of the Direct Smart Reefer Microprocessor Controller,
including identifying components.
Section 8 - Schematics and Wiring Diagrams
This section includes the control schematics and wiring diagrams.
Table of Contents
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DSR μP Controller Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematics and Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Microprocessor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Low Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Typical Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Direct Smart Reefer Microprocessor Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
In-cab Control Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Electronic Control Module (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Electronic Control System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Microprocessors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
PCB 1 and PCB 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Printed Circuit Board I/O Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
System Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
System Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
System Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
System Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Unit Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
External Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Switches and Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Motors and Motor Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Systems and Equipment Covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Software Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Software Revisions and Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Table of Contents
Menu Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Menu Flowcharts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Programmable Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Main Menu and Its Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Hourmeters Menu and Its Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Information Menu and Its Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Installation (Guarded Access) Menu and Its Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
In-cab Control Box Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Keypad Keys and Buzzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Understanding the Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Display Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Reading a Typical Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
The Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Manual Start After an Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Auto Start After an Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Buzzers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Checking the Software Revision. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Viewing and Clearing Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
To View Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
To Clear Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
DSR µP Controller Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DSR µP Controller Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Electrostatic Discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
DSR µP Controller Diagnostic Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Part 1 - Corrective Actions as a Result of Alarm Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Part 2 - Corrective Actions as a Result of Other Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Important Diagnostic Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Service Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Microprocessor Procedures
A02A Recording Existing Microprocessor Settings
A04A Microprocessor Setup
A12A ESD (Electrostatic Discharge) Procedures
A26A Welding on Units Equipped with Microprocessors
A28A Setting Unit Running Time Hourmeters
Printed Circuit Board Procedures
B02A Printed Circuit Board Removal and Replacement
Miscellaneous Procedures
D01A Return Air Temperature Sensor Test
F06A 3 Wire Magnetic Door Switch
H02A Deutsch Connector Repair using Pigtail
H04A Checking Harness Continuity
UH09A Removal and Replacement of the Filter or Fan in an Electronic Control Module
DSR µP Controller Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DSR µP Controller Software Features
and Interchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Schematics and Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
1E26983, Rev. B, B-100 10/20 DSR μP Controller Schematic Diagram
1E26984, Rev. C, B-100 10/20 DSR μP Controller Wiring Diagram
1E23072, Rev. B, V-100, V-200, V-300 MAX 10/30 DSR μP Controller Schematic Diagram
1E23071, Rev. B, V-100, V-200, V-300 MAX 10/30 DSR μP Controller Wiring Diagram
Table of Contents
1E50773, Rev. A, V-100 20/50 DSR μP Controller Schematic Diagram
1E50774, Rev. A, V-100 20/50 DSR μP Controller Wiring Diagram
1E47098, Rev. B, V-200, V-300 MAX 20/50 DSR μP Controller Schematic Diagram
1E47097, Rev. B, V-200, V-300 MAX 20/50 DSR μP Controller Wiring Diagram
1E17674, Rev. A, V-200, V-300 MAX Multi-Temp DSR μP Controller Schematic Diagram
1E17673, Rev. A, V-200, V-300 MAX Multi-Temp DSR μP Controller Wiring Diagram
1E19988, Rev. B, V-400, V-500 MAX 10/30 DSR μP Controller Schematic Diagram
1E19987, Rev. B, V-400, V-500 MAX 10/30 DSR μP Controller Wiring Diagram
1E47148, Rev. B, V-400, V-500 MAX 20/50 DSR μP Controller Schematic Diagram
1E47147, Rev. B, V-400, V-500 MAX 20/50 DSR μP Controller Wiring Diagram
1E29761, Rev. C, V-500 MAX TC 10/30 DSR μP Controller Schematic Diagram
1E29760, Rev. C, V-500 MAX TC 10/30 DSR μP Controller Wiring Diagram
1E47150, Rev. B, V-500 MAX TC 20/50 DSR μP Controller Schematic Diagram
1E47149, Rev. B, V-500 MAX TC 20/50 DSR μP Controller Wiring Diagram
1E47152, Rev. A, V-500 AC 10/20 DSR μP Controller Schematic Diagram
1E47151, Rev. A, V-500 AC 10/20 DSR μP Controller Wiring Diagram
Table of Contents
List of Figures
Figure 2-1: DSR Microprocessor Block Diagram: for Platform 1 Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-2: DSR Microprocessor Controller Block Diagram: for Platform 1 and 2 Units . . . . . . . . . . . . . . . . . . 2-2
Figure 2-3: In-cab Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-4: A Platform 2 ECM configuration, with PCB 2 mounted above PCB 1 . . . . . . . . . . . . . . . . . . . . . . . 2-4
Figure 2-5: Internal Layout of a Platform 1 Electronic Control Module, showing PCB 1 . . . . . . . . . . . . . . . . . . 2-5
Figure 2-6: Internal Layout of a Platform 2 Electronic Control Module, showing PCB 1 and PCB 2 . . . . . . . . . 2-6
Figure 3-1: Temperature vs. Operating Mode Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Figure 3-2: Direct Smart Reefer Microprocessor Controller Menus and Screens . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-3: DSR Main Menu Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-4: DSR Hourmeters Menu Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-5: DSR Information Menu Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3-6: DSR Installation (Guarded Access) Menu Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Figure 4-1: In-cab Control Box, with all icons illuminated in the Standard Display . . . . . . . . . . . . . . . . . . . . . . 4-1
Figure 4-2: The Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Figure 4-3: Typical Standard Display reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Figure 4-4: The Standard Display, with a load compartment temperature of 3°C . . . . . . . . . . . . . . . . . . . . . . . 4-4
Figure 4-5: The Standard Display, with an alarm icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Figure 4-6: The Standard Display, with a setpoint of 10.8 and a declining compartment temperature . . . . . . . 4-5
Figure 4-7: The Standard Display, with a Return Air Alarm and alarm icon . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Figure 4-8: The Standard Display, with main and remote compartment temperature readings . . . . . . . . . . . . . 4-6
Figure 4-9: The Standard Display, with a setpoint of -18°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Figure 4-10: The Standard Display, with a setpoint of 5ºC for the remote compartment . . . . . . . . . . . . . . . . . . 4-8
Figure 4-11: The Standard Display, showing defrost off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Figure 4-12: The Standard Display, showing defrost on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Figure 4-13: The Standard Display, with a setpoint of -15°C and the defrost icon. . . . . . . . . . . . . . . . . . . . . . 4-10
Figure 4-14: The Standard Display, showing the software revision at the Information Menu . . . . . . . . . . . . . 4-10
Figure 4-15: The Standard Display, showing the bAt (Low Battery Voltage) alarm . . . . . . . . . . . . . . . . . . . . . 4-11
List of Figures
THIS PAGE INTENTIONALLY LEFT BLANK
Section 1
Safety Precautions
General Practices ................................. 1 - 1
Refrigerant ............................................ 1 - 1
First Aid
1-1
Refrigeration Oil ................................... 1 - 2
First Aid
1-2
Electrical ............................................... 1 - 2
Microprocessor Service
Welding
Batteries
1-2
1-2
1-2
Electrical Hazards ................................ 1 - 2
High Voltage
First Aid
Low Voltage
1-2
1-3
1-3
Typical Safety Decals........................... 1 - 4
Direct Smart Reefer Microprocessor
Notes ..................................................... 1 - 5
1Section 1 - Safety Precautions
General Practices
Refrigerant
1. Always wear goggles or safety glasses.
Refrigerant and battery acid can permanently
damage the eyes.
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.
2. Keep hands, clothing and tools clear of fans
and belts when the unit is running.
We strictly adhere to a policy that promotes
the recovery and limits the loss of refrigerant
into the atmosphere.
3. Be sure gauge manifold hoses are in good
condition. Never let them come in contact
with belts, fans, pulleys or hot surfaces.
When working on transport refrigeration
systems a recovery process that prevents or
minimizes refrigerant loss to the atmosphere
is required by law. In addition, service
personnel must be aware of European Union,
national, and local regulations governing the
use of refrigerants and certification of
technicians.
4. Never apply heat to a sealed refrigeration
system or container.
5. Refrigerants in the presence of an open
flame produce toxic gases. These gases are
severe respiratory irritants capable of
causing death.
6. Be sure all mounting bolts are the correct
length for the application and are securely
tightened.
When refrigerants are exposed to the
atmosphere in liquid form, they evaporate
rapidly, freezing anything they contact. If they
contact the skin severe frostbite can result. In
the event of frostbite, the objectives of first aid
are to protect the frozen area from additional
injury and to warm it rapidly.
7. Use extreme caution when drilling holes in
the unit. Holes may weaken structural
components. Holes drilled in wiring can
cause fire or explosion. Holes drilled into the
refrigeration system will release refrigerant.
First Aid
8. Use caution when working around exposed
coil fins. The fins can cause painful
lacerations.
1. Warm the frozen area by immersing it in
luke-warm (not hot) water or by covering the
area with warm blankets.
9. Use caution when working with refrigerant
in a closed or confined area with a limited
air supply such as a trailer, container or hold
of a ship. Refrigerant tends to displace air
and can cause oxygen depletion which may
result in unconsciousness or death due to
suffocation.
2. Obtain medical assistance as soon as
possible.
3. If refrigerant contacts the eyes, flush them
with water immediately and obtain medical
assistance as soon as possible.
10. If the air conditioning system is on, the
V-500 AC unit continues running even
though the in-cab control box is off.
(03/07)
1-1
Section 1 - Safety Precautions
Refrigeration Oil
Batteries
When removing a battery from the unit,
ALWAYS disconnect the negative battery
terminal (-) first. Then remove the positive
terminal (+). When RECONNECTING THE
BATTERY TERMINALS, CONNECT THE
POSITIVE TERMINAL (+) FIRST, AND
CONNECT THE NEGATIVE (-) TERMINAL
LAST.
Avoid contact with the eyes. Avoid prolonged
contact with the skin or clothing. Wash hands
thoroughly after handling refrigeration oil to
prevent skin irritation.
First Aid
In case of eye contact, flush immediately with
water for at least 15 minutes. Obtain medical
assistance as soon as possible.
Electrical Hazards
High Voltage
Electrical
Units with optional Electric Standby utilize 115
or 230 volt, single-phase power or 230 to 440
volt three-phase AC power any time the unit is
operating in Electric mode. This voltage
potential is also present any time the unit is
connected to standby power. Extreme care must
be used when working on the unit, as these
voltages are capable of causing serious injury or
death.
Microprocessor Service
Precautions must be taken to prevent
electrostatic discharge when servicing the
microprocessor and related components. A
potential difference less than that required to
produce a small spark between a finger and a
doorknob can cause severe damage to solid
state components. Refer to Service Procedure
A12A,
ESD
(Electrostatic
Discharge)
Procedure in this manual and the Electrostatic
Discharge Training Guide (TK 40282-1) for
additional information.
1. When working on the high voltage circuits, do
not make any rapid movements. Unplanned
movements can cause contact with high voltage.
2. Use tools with insulated handles that are in
good condition. Never hold metal tools in
your hand if exposed high voltage
conductors are within reach.
Welding
Precautions must be taken before welding on
the unit. Refer to Service Procedure A26A,
Welding
on
Units
Equipped
with
Microprocessors in this manual for additional
information.
(03/07)
3. Treat all wires as high voltage wires.
4. Never work alone on high voltage circuits.
Another person should be nearby in case of
accident.
1-2
Section 1 - Safety Precautions
First Aid
Immediate action must be taken after a person
has received an electrical shock. Medical
attention should be summoned as soon as
possible.
The source of electricity must be immediately
removed, either by shutting down the power or
removing the victim from the source.
If the victim must be removed from a live
circuit, pull the victim off with a
non-conductive material. Use the victim's
clothing, a rope, wood or your belt. After
separating the victim from the power source,
immediately check for pulse and respiration. If
a pulse is not present, start CPR
(Cardio-PulmonaryResuscitation) immediately.
If a pulse is present, respiration may be restored
by mouth to mouth resuscitation. Obtain
emergency medical assistance as soon as
possible.
Low Voltage
Control circuits can be 12 volt DC or 24 volt
DC. This voltage potential is not considered
dangerous, but the large amount of current
available can cause severe burns if shorted to
ground.
Do not wear jewelry, watches or rings when
working on the unit. If these items contact an
electrical circuit severe burns may result.
(03/07)
1-3
Section 1 - Safety Precautions
Typical Safety Decals
(03/07)
1-4
Section 1 - Safety Precautions
Direct Smart Reefer
Microprocessor Notes
The following procedures may not be readily
apparent, but must be followed when working
on units equipped with Direct Smart Reefer
microprocessors.
• Never use testers consisting of a battery and
a light bulb to test circuits on any
microprocessor based system.
• Any time the software is changed, perform
Service Procedure A02A, Recording
Existing Microprocessor Settings and
Service Procedure A04A, Microprocessor
Setup
(Programming
the
DSR
Microprocessor).
• Any time an Electronic Control Module
printed circuit board is replaced, perform
Service Procedure B02A, Printed Circuit
Board Removal and Replacement.
• Any time welding is to be done on the unit
or truck, perform Service Procedure A26A,
Welding on Units Equipped with
Microprocessors.
SEE SECTION 5 FOR ADDITIONAL
DETAILS.
(03/07)
1-5
Section 1 - Safety Precautions
THIS PAGE IS INTENTIONALLY BLANK
(03/07)
1-6
Section 2
System Description
Block Diagrams .................................... 2 - 1
General Description ............................. 2 - 3
In-cab Control Box
Electronic Control Module (ECM)
2-3
2-4
Electronic Control System
Components ......................................... 2 - 6
Microprocessors
PCB 1 and PCB 2
Printed Circuit Board I/O Connectors
System Fuses
System Relays
System Inputs
System Outputs
2-6
2-7
2-8
2 - 17
2 - 18
2 - 19
2 - 19
Unit Power........................................... 2 - 20
External Devices................................. 2 - 20
Sensors
Switches and Transducers
Valves
Relays
Motors and Motor Protectors
Clutches
Contactors
Power Sources
Heaters
2 - 20
2 - 20
2 - 21
2 - 22
2 - 22
2 - 22
2 - 23
2 - 23
2 - 23
Systems and Equipment Covered .... 2 - 23
2Section 2 - System Description
Direct Smart Reefer Microprocessor Controller Block Diagram:
for DSR μP Controllers with Platform 1
In-Cab Control Box
Contains:
Standby
Compressor
(provides for
circulation of the
system's refrigerant)
Optional Electrical
Stand-By
(secondary,
electrically-driven
compressor and
power system)
Vehicle
Engine
(drives unit's
compressor and the
electrical system)
Vehicle
Battery
(primary system
power source,
12V or 24V)
Vehicle
Compressor
(provides circulation
of system
refrigerant)
* Controlling (master) microprocessor and
microprocessor software
* LCD Display, with operator and maintainer
screens
* Function keys
* Alarm buzzer
* Digital input and output connectors to the
microprocessor(s) in the Electronic Control
Module
* Power supply circuitry
Electronic Control Module
(located inside the condenser section of the unit)
Contains:
* Slaved microprocessor(s) on PCB 1 and PCB 2
* Fuses, relays, and other discrete electrical
devices on one or two printed circuit boards
* Input/output connections to system switches,
sensors, pilot solenoids, the In-cab Control Box,
and to system sensing and monitoring
components.
* Connectors to analog inputs
* Connectors to Electric Stand-By and other
optional equipment
* Power supply circuitry
Inputs -- Platform
Platform 11
Inputs
Outputs - Platform 1
ReturnReturn
Air Temperature
Battery Voltage
Air Temperature
Electric
Standby
(optional)
Battery
Voltage
Defrost Standby
Termination
Switch
Electric
(optional)
Low Termination
Pressure Cut-Out
Defrost
Switch
High
Low Pressure
PressureTransducer
Cut-Out
Overload
High Pressure
Transducer
Door
Switch
Overload
DoorKey
Switch
Vehicle
Contact
Vehiclemotor
Key protection*
Contact
Thermal
*B-100 units only
Evaporator Fan Motor 1
Evaporator Fan Motor 2
Heaters 1, 2 *
Liquid Injection Switch
Liquid Injection Valve
Clutch 1 or RM power
(B-100 only)
Clutchrelay
1
Host Defrost Hot Gas Solenoid Valve
Heat Pilot Solenoid
Clutch 2 *
Contactor Coil
Condenser Fan Motor 1
Condenser Fan Motor 2 **
* V-200/V-300 units only
** V-400/V-500 units only
Figure 2-1 DSR Microprocessor Block Diagram: for Platform 1 Units
(10/08)
2-1
Section 2 - System Description
Direct Smart Reefer Microprocessor Controller Block Diagram:
for DSR μP Controllers with Platform 1 and Platform 2
In-Cab Control Box
Contains:
Standby
Compressor
(provides for
circulation of the
system's refrigerant)
Optional Electrical
Stand-By
(secondary,
electrically-driven
compressor and
power system)
* Controlling (master) microprocessor and
microprocessor software
* LCD Display, with operator and maintainer
screens
* Function keys
* Alarm buzzer
* Digital input and output connectors to the
microprocessor(s) in the Electronic Control
Module
* Power supply circuitry
Vehicle
Engine
(drives unit's
compressor and the
electrical system)
Vehicle
Battery
(primary system
power source,
12V or 24V)
Vehicle
Compressor
(provides circulation
of system
refrigerant)
Electronic Control Module
(located inside the condenser section of the unit)
Contains:
* Slaved microprocessor(s) on PCB 1 and PCB 2
* Fuses, relays, and other discrete electrical
devices on one or two printed circuit boards
* Input/output connections to system switches,
sensors, pilot solenoids, the In-cab Control Box,
and to system sensing and monitoring
components.
* Connectors to analog inputs
* Connectors to Electric Stand-By and other
optional equipment
* Power supply circuitry
Inputs - Platform 1
Inputs - Platform 1
Outputs - Platform 1
Outputs - Platform 2
Inputs - Platform 2
Return Air Temperature
Temperature
Battery Voltage
Voltage
Battery
Electric Standby (optional)
Termination Switch
Defrost Termination
Switch
Low Pressure Cut-Out
High Pressure Transducer
Overload
Door
Door Switch
Switch
Vehicle
Vehicle Key
Key Condact
Condact
AC Switch***
***V-500 AC units only
Evaporator Fan Motor 1
Evaporator Fan Motor 2
Heaters 1, 2 *
Liquid Injection Switch
Liquid Injection Valve
Clutch 1
Host Defrost Hot Gas Solenoid Valve
Heat Pilot Solenoid
Clutch 2 *
Contactor Coil
Condenser Fan Motor 1
Condenser Fan Motor 2 **
Evaporator Fan Motor 3
Remote Liquid Solenoid Valve
Host Liquid Solenoid Valve
Remote Defrost Hot Gas Solenoid Valve
Heaters 1, 2 **
Suction Line Solenoid***
** V-400/V-500 units only
***V-500 AC units only
Return Air Temperature
Defrost Termination Switch
Door Switch
* V-200/V-300 units only
** V-400/V-500 units only
Figure 2-2 DSR Microprocessor Controller Block Diagram: for Platform 1 and 2 Units
(10/08)
2-2
Section 2 - System Description
General Description
In-Cab Control Box
The In-cab Control Box contains the Electronic
Control
System’s
controlling
(master)
microprocessor, microprocessor software, LCD
display screen, touch-sensitive function keys,
and discrete electronic components. It is usually
mounted on or above the truck instrument
panel. The In-cab Control Box is connected to
the ECM by a cable that contains
communications, voltage, and chassis/ground
wires.
Thermo King units that use the Direct Smart
Reefer Microprocessor Control System
(referred to, throughout the remainder of this
manual, as a DSR μP Controller) are
temperature-control units mounted on smalland medium-sized trucks. Units provide
cooling and defrosting by means of the vehicle
motor or DC motor (in models operating
electrically, the second compressor is driven by
a Electric Standby Motor).
Defrost is accomplished by hot gas. Heat is
provided by the hot gas system and by the
forced-convection air-flow created by the fans.
The DSR μP Controller consists of two main
assemblies: an In-Cab Control Box, located
near the vehicle driver, and an Electronic
Control Box (ECM), located in the condenser
section of the unit. Both assemblies together are
referred to as an Electronic Control System.
Figure 2-3 In-cab Control Box
The In-cab Control Box performs several major
functions:
This section of the manual describes the
Electronic Control System hardware in groups:
• It receives temperature-control and unit
operating inputs from the microprocessor(s)
in the ECM. The ECM can have one or two
printed circuit boards (PCB 1, PCB2), each
containing a microprocessor.
• In-Cab Control Box
• Electronic Control Module
• The In-cab Control Box provides visual
information to the user (vehicle driver or
service personnel) about unit operating
conditions, setpoints, and current load
compartment temperatures.
• Microprocessor
• Printed Circuit Boards PCB 1 and PCB 2
• Input/Output Connectors
• Fuses
• It allows the driver to select setpoint
temperatures, review and respond to alarms,
examine other unit operating conditions, and
set the manual defrost. It allows service
personnel to select operating parameters,
hourmeters, and timers in the Information
Menu and Installation Menu.
• Relays
• External Equipment
(10/08)
2-3
Section 2 - System Description
The unit can be operated by the ECM without
an In-cab Control Box. However, operating
conditions for the unit must be selected with the
In-cab Control Box before it is disconnected
from the ECM.
The ECM microprocessor(s) also receives input
signals from load compartment sensors and
switches, the vehicle battery, engine,
compressor clutches, an optional Electrical
Standby, and solenoid valves. These inputs are
sent to the In-cab Control Box microprocessor,
where it determines if faulty or out-of-range
conditions exist.
Electronic Control Module (ECM)
The ECM, located inside the unit’s condenser,
contains
the
system’s
secondary
microprocessor(s), I/O connectors, output
relays, fuses, LEDs, cooling fan, and discrete
electronic components mounted on one or two
printed circuit boards (platforms). The
microprocessor(s) receives output signals from
the load compartment return air sensor and
electronic thermostat. These signals are sent to
the microprocessor in the In-cab Control Box.
Based on setpoint temperature and other
parameters,
the
In-cab
Control
Box
microprocessor determines when to adjust the
temperature-control state in the main and/or
remote load compartment to Cool, Heat, or Null
mode, or to initiate a Defrost cycle.
The ECM can be configured with a single, large
printed circuit board (PCB 1) that is attached to
the ECM enclosure. This configuration (PCB 1
only) is referred to as Platform 1.
The ECM can also be configured to contain a
smaller, add-on printed circuit board (PCB 2)
that is mounted above PCB 1. PCB 2 consists of
a microprocessor, two I/O connectors, relays,
fuses, and other discrete electronic components.
This configuration (PCB 1 and PCB 2) is
referred to as Platform 1 and 2.
See Figure 2-4 for a Platform 2 configuration,
with the ECM cover removed and PCB 2
mounted above PCB 1. See Figure 2-5 and
Figure 2-6 for typical PCB 1 and PCB 2
layouts.
2
1
Figure 2-4 A Platform 2 ECM configuration, with PCB 2 mounted above PCB 1
(10/08)
2-4
Section 2 - System Description
Callout
Description
1
PCB 2
2
PCB 1
2
1
Figure 2-5 Internal Layout of a Platform 1 Electronic Control Module, showing PCB 1
Callout
Description
1
Connector C-1
2
Connector C-2
(10/08)
2-5
Section 2 - System Description
1
2
3
4
Figure 2-6 Internal Layout of a Platform 2 Electronic Control Module, showing PCB 1 and PCB 2
Callout
Description
1
Connector C-1, PCB 1
2
Connector C-1, PCB 2
3
Connector C-2, PCB 1
4
Connector C-2, PCB 2
Electronic Control System
Components
Microprocessors
The controlling microprocessor in the In-cab
Control Box, and the slaved microprocessor(s)
in the ECM, are the heart of the DSR μP
Controller. The microprocessors accomplish the
following:
The following sub-section describes the main
components of the Electronic Control System:
• Microprocessors
• In general, they monitor and control the
functioning of the refrigeration system
sensors, valves, switches, and motors
• PCB 1 and PCB 2
• Printed Circuit Board I/O Connectors
• The microprocessor(s) on PCB 1 and PCB 2
in the ECM receive input signals from the
controlling microprocessor in the In-cab
Control Box, and from sensors and electrical
components in the load compartment, and
provide output power signals to system
solenoid valves, motors, and heaters
• System Fuses
• Printed Circuit Board Relays
• DSR μP Controller Inputs
• DSR μP Controller Outputs
(10/08)
2-6
Section 2 - System Description
• The microprocessor in the In-cab Control
Box receives information signals from the
ECM microprocessors regarding unit
operations and power. The In-cab
microprocessor send signals to the ECM
microprocessors regarding setpoint and
parameter settings, manual defrost, and the
functioning of the evaporator, condenser,
and other system components
• Changes made at the In-cab Control Box are
processed by the In-cab microprocessor.
Signals are routed to the microprocessor in
PCB 1 and/or PCB 2, which analyzes and
processes the commands. Signals are sent to
the applicable relays on PCB 1 or PCB 2,
which energize solenoid valves or activate
system electrical devices, such as fan
motors, clutches, heaters, etc.
PCB 1 and PCB 2
Printed Circuit Board 1 (PCB 1) and/or Printed
Circuit Board 2 (PCB 2) are located in the
ECM. Each printed circuit board is populated
with a microprocessor and discrete electronic
components, and connected by wires to analog
and digital I/O devices. A PCB, in addition to
physically connecting these components, is an
interface between the microprocessor and the
unit valves, evaporator and condenser fan
motor contactors, heaters, the Data Acquisition
System (which monitors and records the unit
I/O’s, alarms, and temperature-control device
signals), and the In-cab Control Box.
(10/08)
2-7
Section 2 - System Description
Printed Circuit Board I/O Connectors
C-2 Output Connector for the B-100 10
Single Temperature Units, 12V and 24V (PCB
1)
The pins for connectors C-1 (inputs) and C-2
(outputs) on PCB 1 and PCB 2 are different for
each B-100 through V-500 direct-drive truck
unit. These differences are noted in the
following tables.
In the following tables, PCB 1 = Printed Circuit
Board 1, PCB 2 = Printed Circuit Board 2.
C-1 Input Connector for the B-100 10 Single
Temperature Units, 12 V and 24V (PCB 1)
Pin
Wire #
Description
A1
26A
Heat Pilot Solenoid
A2
LPCO
Low Pressure Cut-out Switch
A3
DSW1
Door Switch 1
A4
PNK
Thermostat Sensor
A5
DL2
DAS Comms 2 (RS-232)
A6
CHH
Chassis
A7
BAT
Battery Terminal
A8
03
Battery
B4
BLK
Thermostat Sensor
B5
DL1
DAS Comms 1 (RS-232)
B6
RXD
RX Comms Signal to the
In-cab Control Box (RS-485)
B7
TXD
Wire #
Description
1
EF1-01
Terminal Board (EF1)
2
EF1
Evaporator Fan 1
5
CF1-01
Terminal Board (CF1)
6
CF1
Condenser Fan 1
8
26
Main Compartment Defrost
Hot Gas Solenoid Valve
9
RM
Battery relay
10
PC
Terminal Board
C-1 Input Connector for the V-100, V-200,
and V-300, 10/30 Single Temperature Units,
12 V and 24V (PCB 1)
Pin
Wire #
Description
A1
26A
Heat Pilot Solenoid
A2
LPCO
Low Pressure Cut-out Switch
A3
DSW1
Door Switch 1
A4
PNK
Thermostat Sensor
A6
CHH
Chassis
A7
BAT
Battery Terminal
TX Comms Signal to the
In-cab Control Box (RS-485)
A8
03
Battery
B4
BLK
Thermostat Sensor
B6
RXD
RX Comms Signal to the
In-cab Control Box (RS-485)
B7
TXD
TX Comms Signal to the
In-cab Control Box (RS-485)
C1
12
Defrost Temperature Switch
C3
CHT
Chassis to THPCO
C4
HP
High Pressure to THPCO
C5
5V
5 Volt to THPCO
C6
CH, GND Chassis and Ground to the
In-cab Control Box
C7
9V
C1
12
Defrost Temperature Switch
C2
DK3
DC motor thermal protection
C3
CHT
Chassis to THPCO
C4
HP
High Pressure to THPCO
C5
5V
5 Volt to THPCO
C6
CH, GND Chassis and Ground to the
In-cab Control Box
C7
9V
(10/08)
Pin
9-volts output voltage to the
In-cab Control Box
2-8
9-volts output voltage to the
In-cab Control Box
Section 2 - System Description
C-1 Input Connector for the V-400 and V-500
MAX, 10/30 Single Temperature Units, 12 V
and 24V (PCB 1)
C-2 Output Connector for the V-100, V-200,
and V-300 MAX, 10/30 Single Temperature
Units, 12V and 24V (PCB 1)
Pin
Wire #
Description
Pin
Wire #
Description
C4
HP
High Pressure to THPCO
1
EF1-01
Terminal Board (EF1)
C5
5V
5 Volt to THPCO
2
EF1
Evaporator Fan 1
C6
3
EF2-01
Terminal Board (EF2)
CH, GND Chassis and Ground to the
In-cab Control Box
4
EF2
Evaporator Fan 2
C7
9V
5
CF1-01
Terminal Board (CF1)
6
CF1
Condenser Fan 1
8
26
Main Compartment Defrost
Hot Gas Solenoid Valve
9
CLU1-01/ Liquid Injection Switch
LIS
9
CLU1-01/ Compressor Clutch
CLU1
10
PC
9-volts output voltage to the
In-cab Control Box
C-2 Output Connector for the V-400 and
V-500 MAX, 10/30 Single Temperature Units,
12 V and 24V (PCB 1)
Pin
Wire #
Description
1
EF1-01
Terminal Board (EF1)
Terminal Board
(Power Contactor)
2
EF1
Evaporator Fan Motor 1
3
EF2-01
Terminal Board (EF2)
11
27-01/
27A
Heater 1
4
EF2
Evaporator Fan Motor 2
11
27-01/
27
Heater 2
5
CF1-02
Condenser Fan Motor 1
6
CHG
Chassis Ground
EXR1-01
Terminal Board
8
26
Main Compartment Defrost
Hot Gas Solenoid Valve
9
CLU1-01/ Liquid Injection Switch
LIS
9
CLU1-01/ Compressor Clutch
CLU1
12
C-1 Input Connector for the V-400 and V-500
MAX, 10/30 Single Temperature Units, 12 V
and 24V (PCB 1)
Pin
Wire #
Description
10
PC
Terminal Board
A1
26A
Heat Pilot Solenoid
11
P2
Serial/Parallel
A2
LPCO
Low Pressure Cut-out Switch
12
P1
Condenser Fan Motor 1
A3
DSW1
Door Switch 1
A4
PNK
Thermostat Sensor
A6
CHH
Chassis
A7
BAT
Battery Terminal
A8
03
Battery
B4
BLK
Thermostat Sensor
B6
RXD
RX Comms Signal to the
In-cab Control Box (RS-485)
B7
TXD
TX Comms Signal to the
In-cab Control Box (RS-485)
C1
12
Defrost Temperature Switch
C3
CHT
Chassis to THPCO
(10/08)
2-9
Section 2 - System Description
C-1 Input Connector for the B-100 20 Single
Temperature Units, 1PH, 50Hz, 12 V and 24V
(PCB 1)
C-2 Output Connector for the V-400 and
V-500 MAX, 10/30 Single Temperature Units,
12V and 24V (PCB 2)
Pin
Wire #
Description
3
EF3-01
Terminal Board (EF3)
4
EF3
Evaporator Fan Motor 3
5
CF2-01
Terminal Board
6
CF2-02
Condenser Fan Motor 2
11
27-01/27A Heater 1
11
27-01/27
12
EXPR2-01 Terminal Board
Heater 2
C-1 Input Connector for the V-200 and
V-300 MAX, Bi Temperature Units,
12V and 24V (PCB 2)
Pin
Wire #
Description
A2
LPCO
Low Pressure Cut-out Switch
A3
DSW1
Door Switch 1
A4
PNK
Sensor Thermostat
A5
DL2
DAS Comms 2 (RS-232)
A6
CHH
Chassis
A7
BAT
Battery Terminal
A8
03
Battery
B1
CMC
Compressor Motor Contactor
B2
OL
Overload Relay
B4
BLK
Thermostat Sensor
B5
DL1
DAS Comms 1 (RS-232)
B6
RXD
RXD Comms Signal to the
In-cab Control Box (RS-485)
B7
TXD
TXD Comms Signal to the
In-cab Control Box (RS-485)
Pin
Wire #
Description
3
G
Sensor Thermostat
4
B
Sensor Thermostat
6
DSW2
Door Switch 2
B8
X1
AC/DC power source
11
PS3
Liquid Solenoid Valve
C1
12
Defrost Temperature Switch
10
PS2
Remote Liquid Solenoid
Valve
C2
DK3
DC thermal motor protection
C3
CHT
Chassis to THPCO
12
PS4
Remote Compartment
Defrost Hot Gas Solenoid
Valve
C4
HP
High Pressure to THPCO
C5
5V
5 Volt to THPCO
C6
CH, GND Chassis and Ground to the
In-cab Control Box
C7
9V
9-volts output voltage to the
In-cab Control Box
C8
X4
Transformer
C-2 Input/Output Connector for the V-200
and V-300 MAX, Bi Temperature Units,
12V and 24V (PCB 2)
Pin
Wire #
Description
3
EF3-01
Terminal Board (EF3)
4
EF3
Evaporator Fan Motor 3
7
PC2
Terminal Board
8
DK2
Defrost Temperature Therm.
C-2 Output Connector for the B-100 20
Single Temperature Units, 1 PH, 50Hz, 12 V
and 24V (PCB 1)
C-1 Input Connector for the B-100 20 Single
Temperature Units, 1PH, 50Hz, 12 V and 24V
(PCB 1)
1
EF1-01
Terminal Board
2
EF1
Evaporator Fan Motor 1
5
CF1-01
Terminal Board
6
CF1
Condenser Fan Motor 1
8
26
Main Compartment Defrost
Hot Gas Solenoid Valve
Pin
Wire #
Description
9
RM
Battery relay
A1
26A
Heat Pilot Solenoid
10
PC
Terminal Board
(10/08)
2 - 10
Section 2 - System Description
C-1 Input Connector for the
V-100/V-200/V-300/MAX, 20/50 Single
Temperature Units, 3PH/1PH, 50/60Hz, 12 V
and 24V (PCB 1)
C-2 Output Connector for the
V-100/V-200/V-300/MAX, 20/50 Single
Temperature Units, 3 PH/1PH, 50/60Hz, 12 V
and 24V (PCB 1)
Pin
Wire #
Description
Pin
Wire #
Description
A1
26A
Heat Pilot Solenoid
6
CF1
Condenser Fan Motor 1
A2
LPCO
Low Pressure Cut-out Switch
7
A3
DSW1
Door Switch 1
V-200/300 Compressor Clutch 2
CLU2
A4
PNK
Sensor Thermostat
7
V-100:
CMC
Compressor Motor Contactor
A6
CHH
Chassis
8
26
A7
BAT
Battery Terminal
Main Compartment Defrost
Hot Gas Solenoid Valve
A8
03
Battery
9
B1
CMC
Compressor Motor Contactor
(except V-100)
CLU1-01/ Compressor Clutch
CLU1
9
B2
OL
Overload Relay
CLU1-01/ Liquid Injection Switch
LIS
B4
BLK
Thermostat Sensor
10
PC
Terminal Board
B6
RXD
RXD Comms Signal to the
In-cab Control Box (RS-485)
11
27-01/
27A
Heater 1
B7
TXD
TXD Comms Signal to the
In-cab Control Box (RS-485)
11
27-01/
27
Heater 2
B8
X1
Transformer
12
EXR1-01 Terminal Board
C1
12
Defrost Temperature Switch
C3
CHT
Chassis to THPCO
C4
HP
High Pressure to THPCO
C5
5V
5 Volt to THPCO
C6
CH, GND Chassis and Ground to the
In-cab Control Box
C7
9V
C8
X4
C-1 Input Connector for the V-400 and
V-500 MAX, 20/50 Single Temperature Units,
3 PH/1PH, 50/60Hz, 12 V and 24V (PCB 1)
Pin
Wire #
Description
A1
26A
Heat Pilot Solenoid
9-volts output voltage to the
In-cab Control Box
A2
LPCO
Low Pressure Cut-out Switch
A3
DSW1
Door Switch 1
Transformer
A4
PNK
Sensor Thermostat
A6
CHH
Chassis
A7
BAT
Battery Terminal
A8
03
Battery
B1
CMC
Compressor Motor Contactor
B2
OL
Overload Relay
B4
BLK
Thermostat Sensor
B6
RXD
RXD Comms Signal to the
In-cab Control Box (RS-485)
C-2 Output Connector for the
V-100/V-200/V-300/MAX, 20/50 Single
Temperature Units, 3 PH/1PH, 50/60Hz, 12 V
and 24V (PCB 1)
Pin
Wire #
Description
1
EF1-01
Terminal Board
2
EF1
Evaporator Fan Motor 1
3
EF2-01
Terminal Board (except
V-100)
B7
TXD
TXD Comms Signal to the
In-cab Control Box (RS-485)
4
EF2
Evaporator Fan Motor 2
(except V-100)
B8
X1
Transformer
5
CF1-01
Terminal Board
C1
12
Defrost Temperature Switch
C3
CHT
THPCO to Chassis
(10/08)
2 - 11
Section 2 - System Description
C-1 Input Connector for the V-400 and
V-500 MAX, 20/50 Single Temperature Units,
3 PH/1PH, 50/60Hz, 12 V and 24V (PCB 1)
C-2 Output Connector for the V-400 and
V-500 MAX, 20/50 Single Temperature Units,
3 PH/1PH, 50Hz, 12 V and 24V (PCB 2)
Pin
Wire #
Description
Pin
Wire #
Description
C4
HP
High Pressure to THPCO
11
27-01/27A
Heater 1
C5
5V
5 Volt to THPCO
11
27-01/27
Heater 2
C6
CH, GND Chassis and Ground to the
In-cab Control Box
12
EXPR2-01 Terminal Board
C7
9V
9-volts output voltage to the
In-cab Control Box
C8
X4
Transformer
C-1 Input Connector for the V-500 MAX
10/30, Bi Temperature Units, 12V and 24V
(PCB 1)
C-2 Output Connector for the V-400 and
V-500 MAX, 20/50 Single Temperature Units,
3 PH/1PH, 50/60Hz, 12 V and 24V (PCB 1)
Pin
Wire #
Description
A1
26A
Heat Pilot Solenoid
A2
LPCO
Low Pressure Cut-out Switch
A3
DSW1
Door Switch 1
Pin
Wire #
Description
A4
PNK
Thermostat Sensor
1
EF1-01
Terminal Board (EF1)
A6
CHH
Chassis
2
EF1
Evaporator Fan Motor 1
A7
BAT
Battery Terminal
3
EF2-01
Terminal Board (EF2)
A8
03
Battery
4
EF2
Evaporator Fan Motor 2
B4
BLK
Thermostat Sensor
5
CF1-02
Terminal Board
B6
RXD
6
CHG
Chassis Ground
RX Comms Signal to the
In-cab Control Box (RS-485)
8
26
Main Compartment Defrost
Hot Gas Solenoid Valve
B7
TXD
TX Comms Signal to the
In-cab Control Box (RS-485)
9
CLU1-01/ Compressor Clutch
CLU1
C1
12
Defrost Temperature Switch
C3
CHT
Chassis to THPCO
9
CLU1-01/ Liquid Injection Switch
LIS
C4
HP
High Pressure to THPCO
C5
5V
5 Volt to THPCO
10
PC
Terminal Board
C6
11
P2
Serial/Parallel Condenser
Fan Motor 2
CH, GND Chassis and Ground to the
In-cab Control Box
C7
9V
12
P1
Serial/Parallel Condenser
Fan Motor 1
C-2 Output Connector for the V-500 MAX
10/30, Bi Temperature Units, 12V and 24V
(PCB 1)
C-2 Output Connector for the V-400 and
V-500 MAX, 20/50 Single Temperature Units,
3 PH/1PH, 50Hz, 12 V and 24V (PCB 2)
Pin
Wire #
Description
3
EF3-01
Terminal Board (EF3)
4
EF3
Evaporator Fan Motor 3
5
CF2-01
Terminal Board
6
CF2-02
Condenser Fan Motor 2
(10/08)
9-volts output voltage to the
In-cab Control Box
2 - 12
Pin
Wire #
Description
1
EF1-01
Terminal Board (EF1)
2
EF1
Evaporator Fan 1
3
EF2-01
Terminal Board (EF2)
4
EF2
Evaporator Fan 2
5
CF1-02
Condenser Fan Motor 1
Section 2 - System Description
C-2 Output Connector for the V-500 MAX
10/30, Bi Temperature Units, 12V and 24V
(PCB 1)
C-2 Input/Output Connector for the V-500
MAX 10/30, Bi Temperature Units, 12V and
24V (PCB 2)
Pin
Wire #
Description
Pin
Wire #
Description
6
CHG
Chassis Ground
8
DK2
Defrost Temperature Therm.
8
26
Main Compartment Defrost
Hot Gas Solenoid Valve
11
27-02/27 Heaters 3 and 4
B-27C
9
CLU1-01/ Liquid Injection Switch
LIS
12
EXR2-01 Terminal Board
9
CLU1-01/ Compressor Clutch
CLU1
10
PC
Terminal Board
11
P2
Serial/Parallel
12
P1
Condenser Fan Motor 1
C-1 Input Connector for the V-500 MAX
20/50, Bi Temperature Units, 3 PH/1PH, 12 V
and 24V (PCB 1)
C-1 Input Connector for the V-500 MAX
10/30, Bi Temperature Units, 12V and 24V
(PCB 2)
Pin
Wire #
Description
A1
26A
Heat Pilot Solenoid
A2
LPCO
Low Pressure Cut-out Switch
A3
DSW1
Door Switch 1
A4
PNK
Sensor Thermostat
A6
CHH
Chassis
A7
BAT
Battery Terminal
A8
03
Battery
B1
CMC
Compressor Motor Contactor
B2
OL
Overload Relay
B4
BLK
Thermostat Sensor
Pin
Wire #
Description
3
G
Sensor Thermostat
4
B
Sensor Thermostat
6
DSW2
Door Switch 2
9
27-01/27 Heaters 1 and 2
-27A
11
PS3
Liquid Solenoid Valve
B6
RXD
10
PS2
Remote Liquid Solenoid
Valve
RXD Comms Signal to the
In-cab Control Box (RS-485)
B7
TXD
12
PS4
Remote Compartment
Defrost Hot Gas Solenoid
Valve
TXD Comms Signal to the
In-cab Control Box (RS-485)
B8
X1
Transformer
C1
12
Defrost Temperature Switch
C3
CHT
THPCO to Chassis
C4
HP
High Pressure to THPCO
C5
5V
5 Volt to THPCO
C6
CH, GND Chassis and Ground to the
In-cab Control Box
C7
9V
9-volts output voltage to the
In-cab Control Box
C8
X4
Transformer
C-2 Input/Output Connector for the V-500
MAX 10/30, Bi Temperature Units, 12V and
24V (PCB 2)
Pin
Wire #
Description
1
EF4-01
Terminal Board (EF4)
2
EF4
Evaporator Fan Motor 4
3
EF3-01
Terminal Board (EF3)
4
EF3
Evaporator Fan Motor 3
5
CF2-01
Terminal Board
6
CF2-02
Condenser Fan Motor 2
7
PC2
Terminal Board
(10/08)
C-2 Output Connector for the V-500 MAX
20/50, Bi Temperature Units, 3 PH/1PH, 12 V
and 24V (PCB 1)
Pin
2 - 13
Wire #
Description
Section 2 - System Description
C-2 Output Connector for the V-500 MAX
20/50, Bi Temperature Units, 3 PH/1PH, 12 V
and 24V (PCB 1)
C-2 Input/Output Connector for the V-500
MAX 20/50, Bi Temperature Units, 12V and
24V (PCB 2)
1
EF1-01
Terminal Board
Pin
Wire #
Description
2
EF1
Evaporator Fan Motor 1
3
EF3-01
Terminal Board (EF3)
3
EF2-01
Terminal Board
4
EF3
Evaporator Fan Motor 3
4
EF2
Evaporator Fan Motor 2
5
CF2-01
Terminal Board
5
CF1-02
Condenser Fan Motor 1
6
CF2-02
Condenser Fan Motor 2
6
CHG
Chassis Ground
7
PC2
Terminal Board
8
26
Main Compartment Defrost
Hot Gas Solenoid Valve
8
DK2
Defrost Temperature Therm.
11
9
CLU1-01/ Compressor Clutch
CLU1
27-01/27 Heaters 1 and 2
-27A
12
EXR2-01 Terminal Board
9
CLU1-01/ Liquid Injection Switch
LIS
C-1 Input Connector for the V-500 AC 10
Units, 12 V and 24V (PCB 1)
10
PC
Terminal Board
Pin
Wire #
Description
Pin
Wire #
Description
11
P2
Serial/Parallel
A2
LPCO
Low Pressure Cut-out Switch
12
P1
Condenser Fan Motor 1
A3
DSW1
Door Switch 1
A4
PNK
Thermostat Sensor
A5
DL2
DAS Comms 2 (RS-232)
A6
CHH
Chassis
C-1 Input Connector for the V-500 MAX
20/50, Bi Temperature Units, 12V and 24V
(PCB 2)
A7
BAT
Battery Terminal
Pin
Wire #
Description
A8
03
Battery
3
G
Sensor Thermostat
B3
AC_SW
AC Switch
4
B
Sensor Thermostat
B4
BLK
Thermostat Sensor
6
DSW2
Door Switch 2
B5
DL1
DAS Comms 1 (RS-232)
9
27-02/27 Heaters 3 and 4
B-27C
B6
RXD
RX Comms Signal to the
In-cab Control Box (RS-485)
10
PS2
Remote Liquid Solenoid
Valve
B7
TXD
TX Comms Signal to the
In-cab Control Box (RS-485)
11
PS3
Liquid Solenoid Valve
C1
12
Defrost Temperature Switch
12
PS4
Remote Compartment
Defrost Hot Gas Solenoid
Valve
C3
CHT
Chassis to THPCO
C4
HP
High Pressure to THPCO
C5
5V
5 Volt to THPCO
C6
CH, GND Chassis and Ground to the
In-cab Control Box
C7
9V
C-2 Input/Output Connector for the V-500
MAX 20/50, Bi Temperature Units, 12V and
24V (PCB 2)
Pin
Wire #
Description
1
EF4-01
Terminal Board (EF4)
2
EF4
Evaporator Fan Motor 4
(10/08)
2 - 14
9-volts output voltage to the
In-cab Control Box
Section 2 - System Description
C-2 Output Connector for the V-500 AC, 10
Units, 12 V and 24V (PCB 1)
C-1 Input Connector for the V-500 AC 20,
Units, 3 PH/1PH, 12 V and 24V (PCB 1)
Pin
Wire #
Description
Pin
Wire #
Description
1
EF1-01
Terminal Board (EF1)
A8
03
Battery
2
EF1
Evaporator Fan Motor 1
B1
CMC
Compressor Motor Contactor
3
EF2-01
Terminal Board (EF2)
B2
OL
Overload Relay
4
EF2
Evaporator Fan Motor 2
B3
AC_SW
AC switch
5
CF1-02
Condenser Fan Motor 1
B4
BLK
Thermostat Sensor
6
CHG
Chassis Ground
B5
DL1
DAS Comms 1 (RS-232)
8
26
Main Compartment Defrost
Hot Gas Solenoid Valve
B6
RXD
RXD Comms Signal to the
In-cab Control Box (RS-485)
9
CLU1
Compressor Clutch
B7
TXD
10
PC
Terminal Board
TXD Comms Signal to the
In-cab Control Box (RS-485)
11
P2
Serial/Parallel
B8
X1
Transformer
12
P1
Condenser Fan Motor 1
C1
12
Defrost Temperature Switch
C3
CHT
THPCO to Chassis
C4
HP
High Pressure to THPCO
C5
5V
5 Volt to THPCO
C-1 Input Connector for the V-500 AC 10,
Units, 12V and 24V (PCB 2)
Pin
Wire #
Description
C6
9
33A
PS6, Suction Line (bypass)
Solenoid
CH, GND Chassis and Ground to the
In-cab Control Box
C7
9V
9-volts output voltage to the
In-cab Control Box
C8
X4
Transformer
10
33
PS2, AC Liquid Solenoid
11
B3
PS3 Liquid Solenoid Valve
C-2 Output Connector for the V-500 AC, 20
Units, 3 PH/1PH, 12 V and 24V (PCB 1)
C-2 Input/Output Connector for the V-500 AC
10, Units, 12V and 24V (PCB 2)
Pin
Wire #
Description
Pin
Wire #
Description
3
EF3-01
Terminal Board (EF3)
1
EF1-01
Terminal Board
4
EF3
Evaporator Fan Motor 3
2
EF1
Evaporator Fan Motor 1
5
CF2-01
Terminal Board
3
EF2-01
Terminal Board
6
CF2-02
Condenser Fan Motor 2
4
EF2
Evaporator Fan Motor 2
7
PC2
Terminal Board
5
CF1-02
Condenser Fan Motor 1
6
CHG
Chassis Ground
8
26
Main Compartment Defrost
Hot Gas Solenoid Valve
C-1 Input Connector for the V-500 AC 20,
Units, 3 PH/1PH, 12 V and 24V (PCB 1)
Pin
Wire #
Description
9
CLU1
Compressor Clutch
A2
LPCO
Low Pressure Cut-out Switch
10
PC
Terminal Board
A3
DSW1
Door Switch 1
11
P2
Serial/Parallel
A4
PNK
Sensor Thermostat
12
P1
Condenser Fan Motor 1
A5
DL2
DAS Comms 2 (RS-232)
A6
CHH
Chassis
A7
BAT
Battery Terminal
(10/08)
2 - 15
Section 2 - System Description
C-1 Input Connector for the V-500 AC 20,
Units, 3 PH/1PH, 12V and 24V (PCB 2)
Pin
Wire #
Description
9
33A
PS6, Suction Line (bypass)
Solenoid
10
33
PS2, AC Liquid Solenoid
11
B3
PS3 Liquid Solenoid Valve
C-2 Input/Output Connector for the V-500 AC
20, Units, 3 PH/1PH, 12V and 24V (PCB 2)
Pin
Wire #
Description
3
EF3-01
Terminal Board (EF3)
4
EF3
Evaporator Fan Motor 3
5
CF2-01
Terminal Board
6
CF2-02
Condenser Fan Motor 2
7
PC2
Terminal Board
(10/08)
2 - 16
Section 2 - System Description
System Fuses
Fuse Sizes and Descriptions:
Located on Printed Circuit Board 1 (PCB 1)
or Printed Circuit Board 2 (PCB 2)
The following tables describe the fuses used to
protect relays and other DSR μP Controller
electrical components.
Amps Amps
Fuse # @ 12V @ 24V Description
Fuse Sizes and Descriptions:
Located on Printed Circuit Board 1 (PCB 1)
or Printed Circuit Board 2 (PCB 2)
F11
(PCB 2)
5A
5A
Power supply circuit
F2
(PCB 1)
15A
10A
Condenser Fan 1
(CF1)
F3
(PCB 1)
15A
10A
Evaporator Fan 1
(EF1)
F4
(PCB 1)
15A
10A
Evaporator Fan 2
(EF2)
F5
(PCB 1)
20A
10A
Compressor clutch 1
(CCL1), liquid
injection switch (LIS),
liquid injection valve
(LIV), host defrost hot
solenoid valve (PS1),
compressor motor
contactor (CMC), heat
pilot solenoid (PS5),
compressor clutch 2
(CCL2), RM power
relay****
F6
(PCB 1)
10A
7.5A
15A
10A
Condenser Fan 2
(CF2)
F8
(PCB 2)
20A
10A
Remote liquid
solenoid valve (PS2),
host liquid solenoid
valve (PS3), remote
defrost hot gas
solenoid valve (PS4)
and AC system
suction line solenoid
valve (PS6) *****
F9
(PCB 2)
15A
10A
Evaporator Fan 3
(EF3)
F10
(PCB 2)
15A
10A
Evaporator Fan 4
(EF4)
(10/08)
Heater 1, Heater 2***
(HT1, HT2)
**** For B-100 10/20 units.
***** For V-500 AC 10/20 units.
Fuse Sizes and Descriptions:
Located In the Direct-Drive Vehicle
Fuse
Condenser Fan 1, 2*
(CF1, CF2)
Heater 1, Heater 2**
(HT1, HT2)
F7
(PCB 2)
7.5A
* For V-400, V-500, V-500 MAX single-temperature.
** For V-100, V-200, V-300 MAX, 10/30,
single-temperature, V-300 MAX 20/50 single
temperature, and V-200/V-300 MAX, 10/30, 20/50,
TC
*** For V-400, V-500 MAX, 10/30, 20/50
single-temperature.
Amps Amps
Fuse # @ 12V @ 24V Description
F1
(PCB 1)
10A
Amps @
24V
5A
F21
(except
B-100)
V-100: 30 A
V-100: 30 A Battery Relay
V-200: 40 A
V-200: 40 A
V-300: 40 A
V-300: 40 A
V-400: 50 A
V-400: 50 A
V-500: 50 A
V-500: 50 A
100A
60A
DC power
supply motor
and electrical
circuits.
5A
5A
Wires 01 and
BAT (B-100 only)
F14
5A
Description
F20
(except
B-100)
FP
(B-100
only)
2 - 17
Amps @
12V
Transformer
Section 2 - System Description
System Relays
Relay
No.
RY1
Unit
Type
Relay
No.
OLR
Description
1, 3, 4, 5, Compressor Clutch, Liquid
6, 7, 11 Injection Switch, Liquid
Injection Valve
Unit
Type
Description
4, 5, 7, 9, Overload Relay
11
C1R
5, 7, 11
Switching relay
ER1
8, 9
Switching relay
RM power relay
RM
8, 9
DC motor relay
SR
9, 11
Starter relay
RY1
8,9
RY2
5
Clutch 2
RY2
11
Compressor Motor Contactor
(CMC)
Unit Type:
RY3
4, 5, 7, 9 Compressor Motor Contactor
(CMC)
RY4
1, 3, 4, 5, 6, Host Defrost Hot Gas Solenoid
7, 8, 9, 11 Valve (PS1)
RY5
1, 3, 4, 5, 6, Heat Pilot Sol. (PS 5)
7, 8, 9, 11
4 = V-400 MAX, V-500 MAX 20/50, Single Temp
RY6
1, 3, 4, 5, 6, Condenser Fan
7, 8, 9, 11 Motor 1 (CFM1)
5 = V-200, V-300 MAX 20/50, Single Temp
RY7
1, 3, 4, 5, 6, Evaporator Fan
7, 8, 9, 11 Motor 1 (EFM1)
RY8
1, 3, 4, 5, Evaporator Fan
6, 7
Motor 2 (EFM2)
RY9
1, 5, 11
1 = V-100, V-200, V-300 MAX 10/30, Single Temp
2 = V-200 MAX, V-300 MAX, Bi-Temp
3 = V-400 MAX, V-500 MAX 10/30, Single Temp
6 = V-500 MAX 10/30 Bi-Temp
7 = V-500 MAX 20/50 Bi-Temp
8 = B-100 10
9 = B-100 20
Heater 1, Heater 2
RY9
3, 4, 6, 7 Serial/Parallel
CFM1, CFM2
10= V-500 AC 10/20
RY10
3, 4, 6, 7 Condenser Fan
Motor 2 (CFM2)
11= V-100/MAX/20/50
RY11
2, 6, 7
Remote Liquid Solenoid Valve
(PS2)
RY12
2, 6, 7
Host Liquid Solenoid Valve
(PS3)
RY13
2, 6, 7
Remote Defrost Hot Gas Sol.
Valve (PS4)
RY14
6
Heater 1, heater 2
RY14
7
Heater 3, heater 4
RY 14
10
AC System Suction Line
Solenoid (PS6)
RY1 to RY9 = located on PCB 1
RY10 to RY19 = located on PCB 2
BATR = located in unit control box
STDR = located in unit control box
OLR = located in unit control box
C1R = located in unit control box
ER1 = located in unit control box
RM = located in condenser unit
SR = located in unit control box
RY17 2, 3, 4, 6, Remote Evaporator Fan 3
7
(EF3)
RY18
6, 7
Remote Evaporator Fan 4
(EF4)
RY19
3, 4, 7
Heater 1, Heater 2
RY19
6
Heater 3, heater 4
BATR 1, 5, 6, 7, Battery Relay
11
STDR
(10/08)
5, 7, 11
Stand-By Relay
2 - 18
Section 2 - System Description
System Inputs
Input
Description
System Outputs
Notes
Output Description
Sensor 1 Return Air Sensor
(Analog) (main evaporator)
Platform 1,
wires PNK,
BLK
CLU1
Vehicle Compressor Clutch
Platform 1
CLU2
Electric Standby Clutch
Platform 1
Sensor 2 Return Air Sensor
(Analog) (remote evaporator)
Platform 1,
wires G, B
RM
Battery relay (B-100 only)
Platform 1
CMC
ACC
(Digital)
On-the-road power to
unit controls.
Platform 1,
wire 03
Compressor Motor
Contactor
BAT
Battery Voltage Level
(Analog)
Platform 1,
wire BAT
Platform 1,
For Electric
Standby
option
PS1
Hot Gas Solenoid (defrost)
Platform 1,
wire 26
Notes
STD BY
(Digital)
Electric Standby Option Platform 1,
wires X1, X4
PS2
DK1
(Digital)
Defrost Termination
(main evaporator)
Platform 1,
wire 12
Liquid Line Solenoid
(on remote evaporator)
Platform 2,
wire 33
PS3
DK2
(Digital)
Defrost Termination
(remote evaporator)
Platform 2,
wire 12A
Liquid Line Solenoid
(on main evaporator)
Platform 2,
wire B3
PS4
LPCO
(Digital)
Low Pressure Cut-Out
Platform 1,
wire LPCO
Hot Gas Solenoid
(defrost, remote
evaporator)
Platform 2,
wire 28
High Pressure
Transducer
Platform 1,
wires HP, 5V,
CHT
(analog)
PS5
Condenser Solenoid (heat)
Platform 1,
wire 26A
PS6
Liquid Line Solenoid
(AC system)
Platform 2
PS7
Pressure Regulating Line
Bypass (on main
evaporator suction line, MT
units)
Platform 2
PS8
Pressure Regulating Line
Bypass (on remote
evaporator suction line, MT
units)
Platform 2
CMCH Compressor Motor Electric
Heat Contactor (for Electric
Standby)
Platform 1
CF1
Condenser Fan 1
Platform 1
CF2
Condenser Fan 2
Platform 2
EF1,
EF2
Evaporator Fan 1, Fan 2
(main compartment)
Platform 1
DAS
Communications with DAS
Platform 1,
wires DL1,
DL2
EF3,
EF4
Evaporator Fan 3, Fan 4
(remote compartment)
Platform 2
EXR1
Extra Relay 1
(used for Drain Heater)
Platform 1
EXR2
Extra Relay 2
(used for Drain Heater)
Platform 2
HP
OL
(Digital)
Overload Electric Motor Platform 1,
wire OL
Protector (Electric
Standby)
DSW1
(Digital)
Door Switch 1
Platform 1,
wire DSW1
DSW2
(Digital)
Door Switch 2
Platform 2,
wire DSW2
EX1
(Digital)
Extra Relay 1 (for drain Platform 1
heater, main compart.)
EX2
(Digital)
Extra Relay 2 (for drain Platform 2
heater, remote
compartment)
DK3
AC_SW
Thermal motor
protection
Platform 1
(B-100 only)
AC Switch
Platform 1
(V-500 AC
only)
NOTE: Inputs are applicable for vehicles with
a single temperature/main load compartment,
or with bi-temperature/main and remote load
compartments.
(10/08)
2 - 19
Section 2 - System Description
External Devices
NOTE: Outputs are applicable for vehicles
with a single temperature/main load
compartment, or with bi-temperature/main
and remote load compartments.
External devices (such as the evaporator return
air temperature sensors, coil temperature
sensor, HP and LPCO switches) provide
temperature-control data to the ECM
microprocessor.
Unit Power
The microprocessor, in turn, energizes outputs
to maintain the desired compartment
temperature; displays information on the In-cab
Control Box display; and protects the unit from
excessive pressures and temperatures.
Unit power is supplied from the vehicle battery.
Device power is supplied through the fuse F21
(FP in B-100 10/20 units) located near the
vehicle battery. Power to the In-cab Control
Box is supplied from the ECM.
The operating characteristics of many of these
devices is dependent on the type of refrigerant
used* and other unit specific requirements. For
the exact operating temperatures and pressures
of these devices, consult the Maintenance
Manual for the specific unit.
An Electric Standby option supplies rectified
DC power from the standby power pack,
whenever a source of standby power is
connected to the unit. Device power is supplied
through the electric relay in the power pack.
Power supply protection is achieved by means
of a fuse located in the primary transformer
(except B-100).
* Single temperature 10 and 20 model units use R-134a
refrigerant; MAX, and MAX TC 10, 20, 30, and 50
model units use R-404A refrigerant.
Sensors
Return Air Temperature Sensor - senses the
temperature of the air returning to the
evaporator coil. For bi-temperature units, the
temperature for both compartments is displayed
on the In-cab Control Box.
Switches and Transducers
Low Pressure Cut-out (LPCO) Switch opens when the refrigerant suction line pressure
falls below a determined pressure and stops unit
operation.
High Pressure Transducer - used to control
the high-pressure circuit of the unit.
(10/08)
2 - 20
Section 2 - System Description
Liquid Injection Switch LIS (MAX units) closes when the temperature of the refrigerant
gas leaving the compressor exceeds a
determined temperature. This information is
used by the microprocessor to energize the
liquid injection valve (LIV). The LIV allows
liquid refrigerant to flow from the liquid line to
the metering orifice that is attached to the
suction line fitting on the compressor. As the
refrigerant passes through the metering orifice,
it expands and evaporates, and cools the suction
gas entering the compressor. This cooling effect
is transferred to the discharge gas leaving the
compressor. When the discharge gas is cooled
to a determined value, the LIS opens and
refrigerant no longer flows through the liquid
injection system.
Liquid Injection Valve LIV (MAX units) energizes to inject liquid refrigerant into the
suction line near the compressor, in order to
cool the compressor and the discharge gas that
is leaving the compressor.
Liquid Solenoid Valve (MAX TC and V-500
AC units) - during a cool cycle, this valve
energizes to inject liquid refrigerant into the
evaporator coil.
Heating Pilot Solenoid Valve (30/50
units) - during the heating cycle, allows hot gas
to flow to the evaporator coil.
Suction Line Solenoid (V-500 AC units).
Cancels the Air Conditioning evaporator KVP
valve function (bypass) to remove power
limiting when the box refrigeration is not
energised.
Defrost Termination Switch (DK 1, DK2) normally closed, DK1 or DK2 opens to stop the
defrost operation in the load compartment
(DK1 for the main load compartment, DK2 for
a remote load compartment).
Expansion Valve - restricts (controls) the flow
of high-pressure liquid coolant into the
evaporator and thereby lowers coolant pressure.
This also lowers coolant temperature and
boiling point allowing for efficient cooling of
the loadcompartment.
Door Switches (DSW1, DSW2) - used to stop
unit operation except in defrost mode, when the
load compartment doors are opened.
KVL suction pressure regulator valve
(V-200/300 20/30/50 MAX, V-500 MAX
single-phase and V-500 AC units) - protects
compressor operation and start-up by impeding
suction pressure from rising too high. The KVL is
mounted in the suction line immediately upstream
of the compressor. The KVL opens when suction
pressure decreases. Normal pressure setting for
this valve is 180 kPa (25 psi).
Overload Switch (OL) - used to protect the
motor from an electrical overload. When this
normally open switch closes, the unit shuts
down.
Thermal protection switch (HTT1, HTT2)
(B-100 only) - opens when engine temperature
exceeds a determined value. This information is
used by the microprocessor to energise the tEP
alarm.
In the V-500 AC unit, it also limits the demand
for power from the Air Conditioning evaporator
to protect the refrigerated box charge. Normal
pressure setting in this case is 37.7 psi (260 kPa).
Valves
Hot Gas Solenoid Valve - during heat and
defrost cycles, this valve energizes to route hot
gas to the evaporator coil.
(10/08)
2 - 21
Section 2 - System Description
KVP Evaporation Pressure Regulation Valve
(MAX TC and V-500 AC units) - installed in
the suction line behind the evaporator, it
regulates evaporation pressure ininstallations
with one or more evaporators and one
compressor. IntheTC units running with
different evaporation pressures, the KVP is
installed behind the evaporator withhighest
pressure.
Overload Relay OLR - protects the electric
motor that drives the Electric Standby
compressor. The overload relay opens the
circuit to the microprocessor (which
de-energizes the motor contactor and the
electric motor) if the motor overloads for any
reason (e.g., low line voltage or an improper
power supply) during Electric Standby
operation.
Check
valve
(MAX
TC,
V-400
MAX/V-500/MAX20/50 and V-500 AC units)
- guarantees proper air circulation in one
direction only. Prevents migration and
condensation from hot evaporator to cold
evaporator in TC units.
ER1 Electric Standby relay (B-100 units
only) - when this relay is energised, power is
disconnected from the battery relay. This
prevents the two power sources for the unit
(battery and electric power supply) from being
connected at the same time.
Check valve (V-200/V300 20/50 units).
Isolates the compressor driven by the truck
motor from the Electric Standby compressor
and prevents compressor oil and refrigerant
from flowing between the two compressors.
RM battery relay (B-100 only) - when this
relay is energised, the unit is powered by
battery.
SR start relay (single-phase units only) when this relay is energised, the starter
capacitor turns on the AC motor.
Relays
Control relays are energized by the
microprocessor(s),
depending
on
I/O
requirements. In turn, the relay energizes its
corresponding specified device, such as a
motor, clutch, pilot solenoid, valve, fan, or
heater. Each relay is fuse-protected.
Motors and Motor Protectors
Evaporator Fan Motor (EFM1, EFM2,
EFM3, EFM4) - draws air across the
evaporator coil during cool or heat operation.
The evaporator fan motor is turned off during
defrost cycles.
Battery Relay BATR (except B-100) - when
this relay is energized, the unit is powered from
the vehicle battery.
Condenser Fan Motor (CFM1, CFM2) turns on, as determined by the condenser fan
pressure switch, to flow air across the
condenser coil during cool and heat operation.
Standby Relay STDR (except B-100) - when
this relay is energized, the unit is powered from
the electric power supply.
Clutches
CR1 switching relay - when this relay is
energized, power is disconnected from the
battery relay. This prevents the two power
sources for the unit (battery and electric power
supply) from being connected at the same time.
(10/08)
Vehicle Compressor Clutch (CCL1) energizes to activate the engine driven
compressor when cooling, heating, or defrost
operation is required.
2 - 22
Section 2 - System Description
Standby Compressor Clutch (CCL2) energizes to activate the motor-driven
compressor when cooling, heating, or defrost
operation is required and the optional Electric
Standby is active.
The information contained in this manual
applies to, but is not limited to, the following
Direct-Drive Truck systems and their associated
evaporators and condensers.
System
Contactors
Compressor Motor Contactor (CMC) - for
units with an Electric Standby option, closes to
provide electrical power to the Vac motor.
Power Sources
Electric Standby - substitutes the vehicle’s
engine-driven compressor with a second,
electrically powered compressor and an
external power source. B-100 units use one
compressor only, driven by a DC motor when in
battery mode or an AC motor when in Electric
Standby mode. This ensures operational
continuity when the vehicle is parked and the
unit is on.
Battery – provides 12 Vdc or 24 Vdc power to
the unit and the ECM. PCB 1 in the ECM
provides between 7.5 and 9 Vdc power to the
In-cab Control Box.
Systems and Equipment
Covered
(10/08)
2 - 23
Evaporator/
Condenser
900182
V-500 MAX TC 10 700239 / 700214 18 - 19 - 20 - 21 - 22
900045
V-500 MAX TC 20 700094 / 700214 3PH
18 - 19 - 20 - 21 - 22
900261
V-500 MAX TC 20 700094 / 700214 1PH
18 - 19 - 20 - 21 - 22
900488
V-500 AC 10
900489
V-500 AC 20 3PH 700926 / 720672
900490
V-500 AC 20 1PH 700927 / 720672
900498
B-100 10
700939 / 700941
900499
B-100 20 1PH
700940 / 700941
900874
V-100 20 1PH
12VDC
701519 / 701521
900875
V-100 20 1PH
24VDC
701520 / 701522
900876
V-100 MAX 20
1PH 12VDC
701529 / 701531
900877
V-100 MAX 20
1PH 24VDC
701530 / 701532
900878
V-100 MAX 50
1PH 12VDC
701543 / 701545
900879
V-100 MAX 50
1PH 24VDC
701544 / 701546
920238
V-200 20
720617 / 720629
920239
V-200 MAX 20
720618 / 720630
920240
V-300 20
720619 / 720631
920241
V-300 MAX 20
720620 / 720632
920242
V-200 10
720625 / 720629
920243
V-200 MAX 10
720626 / 720630
920244
V-300 10
720627 / 720631
920245
V-300 MAX 10
720628 / 720632
920248
V-100 10
720637 / 720639
920249
V-100 MAX 10
720621 / 720638
920271
V-500 10
720727 / 720672
920272
V-500 20 3 PH
720728 / 720672
920273
V-500 20 1PH
720729 / 720672
920274
V-500 MAX 10
720730 / 720670
Heaters
Drain Heater - Consists of two resistors in
parallel that are used to prevent ice build-up in
the evaporator drain pipe. Extra relays EXR1 or
EXR2 can be used to energize the drain heater
when the unit is in Cool, Heat, or Defrost mode,
and when Defrost Termination Switch DK1 or
DK2 is closed (i.e., not activated).
Description
700925 / 720672
Section 2 - System Description
System
Description
Evaporator/
Condenser
920275
V-500 MAX 20
3PH
920276
V-500 MAX 20 1H 720732 / 720670
920277
V-400 MAX 10
720733 / 720671
920278
V-400 MAX 20
720734 / 720671
920282
V-300 MAX TC 20 720673 / 720674
920290
V-200 MAX TC 20 720695 / 720693
920291
V-300 MAX TC 10 720689 / 720690
920292
V-200 MAX TC 10 720692 / 720693
(10/08)
720731 / 720670
2 - 24
Section 3
Software Description
Software Operation .............................. 3 - 1
Software Revisions and Changes
Unit Operation
3-1
3-1
Menu Screens ....................................... 3 - 3
Menu Flowcharts .................................. 3 - 5
Programmable Features .................... 3 - 11
Main Menu and Its Screens ........................ 3 - 11
Hourmeter Menu and Its Screens............... 3 - 14
Information Menu and Its Screens.............. 3 - 15
Installation (Guarded Access) Menu and Its
Screens....................................................... 3 - 16
3Section 3 - Software Description
Software Operation
Options
• The Heat option provides heating by hot gas.
The software that operates the microprocessor
contains a complex set of instructions. The
microprocessor examines the conditions of all
the inputs and compares them to the
instructions contained in the software. The
outputs are then energized, as required, by the
software instructions.
• The Electric Standby option provides a
second compressor driven by an electric
motor (except B-100 units). In B-100 units
the same refrigeration compressor is driven
by an AC motor.
• The TC options provide temperature control
for two-compartment systems.
The operation mode is made by the
microprocessor and software after analyzing all
the input conditions and the setpoint
temperature. For details, see the Temperature
vs. Operating Mode Chart on page 3-3.
Operation
The vehicle engine must be running and the unit
must be turned on. On units with Electric
Standby, connect the external power cord and
the unit switches to Electric mode operation.
Unit operation can be tailored, as required,
using programmable settings that are shown
later is this section.
Software Revisions and Changes
• Parameters in the Installation (Guarded
Access) Menu can be changed by using
Service Procedure A04A.
Cool Mode Operation - Standard Units
When cooling is required (when there is a
requirement to lower the evaporator return air
temperature in the load compartment), the
outputs of the microprocessor energize the
compressor clutch and evaporator fans. In
B-100 units the DC motor and evaporator fans
are energised. The condenser fan is also
energized and turns on when the condenser fan
pressure switch closes, and turns off when the
condenser fan pressure switch opens. In TC and
AC units the liquid solenoid valve is enabled in
the compartment requiring refrigeration to let
the coolant go to the evaporator.
• The current software revision can be
checked by using the Checking the Software
Revision procedure in Section 4, Operation.
Unit Operation
Unit operation is fully automatic. The
compressor is turned on by the vehicle engine
or the battery at start-up. Standard units operate
in Cool mode or Null mode, as required, to
maintain the load compartment temperature at
the setpoint temperature. Defrost cycles occur
manually or automatically, as required.
The unit operates in Cool mode until the
setpoint temperature is reached. The unit then
enters Null mode. When the temperature rises
to a pre-determined number of degrees, the unit
restarts in Cool mode.
If power is shut off, the unit comes back in Null
mode when the unit is restarted. There is a
momentary delay at auto start-up for circuit
protection. For units with Electric Standby,
there are protective delays for the compressor
clutch and electric compressor/electrical motor
contactor.
(10/08)
3-1
Section 3 - Software Description
V-500 units only have a triple-cooling capacity
(TCC) feature that energizes condenser fans
CF1 and CF2 at low, medium, and high
refrigerant pressures. Controlled by the high
pressure (HP) transducer, the applicable relays
(RY6, RY9, RY10) remain closed or are
opened, and operate the condenser fan speeds in
the following manner:
The unit operates in Cool mode until the
setpoint temperature is reached. The unit then
enters Null mode. When the temperature rises a
pre-determined number of degrees, the unit
restarts in Cool mode.
Null Mode Operation - All Units
The unit operates in Null mode when the
setpoint temperature is reached and cooling (or
heating) is not required. All outputs are
de-energized. If the temperature rises a
pre-determined number of degrees, the unit
restarts in Cool mode. If the temperature falls a
pre-determined number of degrees, and a heat
option is present, the unit restarts in Heat mode.
• When HP pressure is less than 180 PSI (low
pressure), RY6, RY9, and RY10 open. CF1
and CF2 receive no voltage and are in Null
state.
• When the HP pressure is between 180 PSI
and 300 PSI (medium pressure), RY9 closes.
CF1 and CF2 become connected in series,
receive low voltage, and operate at low
speed
In addition, the evaporator fans (parameter
EFc) operate during Null mode (except B-100).
Heat Mode
• When the HP pressure is greater than 300
PSI (high pressure), RY6 and RY10 close
and RY9 opens. CF1 and CF2 become
connected in parallel, receive high voltage,
and operate at high speed.
If the Heat mode option is present, the unit
enters Heat mode when the temperature falls a
pre-determined number of degrees below the
setpoint temperature. When heat is required, the
outputs of the microprocessor energize the
evaporator fans. (For units with Electric
Standby, compressor CLU2 and the
Compressor Motor Contactor are energized
when the standby input is high)
Cool Mode Operation - Electric Standby
Units
When cooling is required, the outputs of the
microprocessor energize the electric motor
contactor, standby compressor clutch, and
evaporator fans. (For units with Electric
Standby, compressor CLU2 and the
Compressor Motor Contactor are energized
when the standby input is high). In B-100 units
the AC motor and evaporator fans are
energised.
The unit operates in Heat mode until the
setpoint temperature is reached. The unit then
enters Null mode.
• If the temperature falls a pre-determined
number of degrees, the unit restarts in Heat
mode.
• If the temperature rises a pre-determined
number of degrees, the unit restarts in Cool
mode.
The condenser fan is also energized. The fan
turns on when the condenser fan pressure
switch closes, and turns off when the condenser
fan pressure switch opens. In TC and AC units
the liquid solenoid valve is enabled in the
compartment requiring refrigeration to let the
coolant go to the evaporator.
(10/08)
3-2
Section 3 - Software Description
Defrost Mode Operation - All Units
Defrost is initiated automatically by the
programmable defrost timer, or manually by
means of the In-cab Control Box. If demand
defrost is enabled, a demand defrost cycle
occurs, based on the Defrost Initiation Timer
(DIT) and the Defrost Termination Switch
(DK1 or DK2) being closed. The evaporator
coil temperature must be below 2°C (35°F) to
allow defrost.
When defrost is required, the microprocessor
output energizes the hot gas solenoid to supply
hot refrigerant to the evaporator coil. The
Defrost
Initiation
Timer
(DIT)
has
counted-down its required time-setting, and the
Defrost Termination Switch (DK1 or DK2) is
closed.
Figure 3-1 Temperature vs. Operating Mode
Chart
Menu Screens
The function and data screens for the In-cab
Control Box are divided into four groups or
menus. These menus are:
The unit remains in Defrost mode until the
Defrost Termination Switch setpoint is reached
(that is, when the evaporator coil temperature
rises to 14°C (58°F), or until the Defrost
Termination Timer (DTT) count is completed).
If the evaporator coil temperature does not rise
above 14°C (58°F) within the defrost duration
time limit, the microprocessor terminates the
defrost operation.
• Main Menu
• Hourmeters Menu
• Information Menu
• Installation (Guarded Access) Menu
The startup of the evaporator fans is delayed for
several seconds after Defrost mode ends, to
prevent water from the melting ice from being
sprayed on the load.
Within each menu, certain similar functions,
such as changing hourmeter settings or
parameters, can be accomplished by the driver
or by maintenance personnel.
For details of programmable defrost features,
see the Programmable Features in this section.
(10/08)
See Figure 3-2 for the overall DSR menu
layout, Direct Smart Reefer Microprocessor
Controller Menus and Screens. The illustration
also shows the screens that appear within each
menu, and how they are accessed and exited.
3-3
Section 3 - Software Description
Direct Smart Reefer Microprocessor Controller
Menus and Screens
(viewed at the In-cab Control Box)
Standard
Display
Main Menu
To access: press the Select key. Press the Select key to access each menu screen.
Alarms
(see alarm
codes below)
dEF
Manual Defrost
SP
SP2
Setpoint 1
Setpoint 2
--- C --Comms
Failure
P1E
P2E
OL
bAt
Return Air
Sensor 1
Return Air
Sensor 2
Electric Motor
Overload
Low Battery
Voltage
PSE
tEP (B-100)
dr1
Thermal
Door 1
Protection
High Pressure
Sensor
dr1,dr2
HP
LP
HPCO
LPCO
SOF
tCO
Hot
dr2
Door 1,
Door 2
Door 2
Software
Failure
ECM Temp
ECM Temp
Hourmeters Menu
To access: press and hold the Select key for 3 seconds. Press the Select key to access each menu screen.
HC
Hour Counter
for
Maintenance
tH
Total Hours
CC
EC
Vehicle
Compressor
Hours
Electric
Compressor
Hours
Information Menu
To access: press and hold the Up Arrow + Enter keys for 3 seconds. The Information Menu scrolls automatically.
121 XX
121 XX
273
XX
(all icons)
Display
Test
Software
Version
134, 404
bAt
Refrigerant
Type
Battery
Voltage
xC / tyy
HP
Compartments/
Unit Type
High Pressure
Installation (Guarded Access) Menu
To access: press and hold the Down Arrow + Enter keys for 3 seconds. Press the Up or Down arrow keys to access the screens.
u
diF
SSC
dit
Setpoints
Differential
Soft Start
Cycles
Defrost
Initiation Timer
dAL
HC
Out-of-Range
Alarm
Hour Counter
Initial Value
dtt
EFc
Defrost
Termination
Timer
Evaporator
Fans Constant
Blow
dSP
Door Switches
Present/
Polarity
bE
Buzzer Enable
tu
Pu
Thermostat
Units
Pressure
Units
Figure 3-2 Direct Smart Reefer Microprocessor Controller Menus and Screens
(10/08)
3-4
Section 3 - Software Description
Menu Flowcharts
The following pages include flowcharts of the
four DSR μP Controller menus, as viewed at
the In-cab Control Box. Examine the flowcharts
and become familiar with the sequence of the
screens, before reading detailed descriptions of
the screens in the Programmable Features
section.
Menu Type
Hourmeters Menu
Screens include:
HC (Hour Counter for
Maintenance)
tH (Total Hours)
CC (Vehicle Compressor
Hours)
EC (Electric Compressor
Hours)
The table below describes the four menus; the
screens contained within each menu; and the
keys that you must press to access each menu.
DSR μP Controller Menu Screens
From the
Standard
Display, do the
Menu Type
following:
Main Menu
Information Menu
Screens include:
(all icons) (Display Test)
121 XX, 273 XX (Software
Version)
134, 404 (Refrigerant Type)
bAt (Battery Voltage)
HP (High Pressure)
xC / tyy (Number of
compartments / Unit type)
Press the
Select key
Screens include:
Alarm screens:
P1E (Temp Probe 1 alarm)
P2E (Temp Probe 2 alarm)
OL (Overload alarm)
bAt (Low Battery Voltage
alarm)
HP (HPCO alarm)
LP (LPCO alarm)
PSE (HPCO Pressure Sensor
alarm)
tEP (B-100 only) (Thermal
protection alarm)
dr1 (Door Switch 1 alarm)
dr2 (Door Switch 2 alarm)
tCO (ECM Temperature
Control alarm)
SOF (Software Failure alarm)
- C - (Communications Failure
alarm)
dEF (Manual Defrost)
SP (Setpoint 1)
SP 2 (Setpoint 2)
(10/08)
3-5
From the
Standard
Display, do the
following:
Press and hold
the Select key
for 3 seconds,
then use the
Select key to
access a screen
Press and hold
the Enter and Up
arrow keys for
3 seconds to
enter the
Information Menu,
which scrolls
automatically
through the
screens.
Section 3 - Software Description
Menu Type
Installation (Guarded
Access) Menu
Screens include:
diF (Setpoints Differential)
SSC (Soft Start Cycles)
dit (Defrost Initiation Timer)
dtt (Defrost Termination
Timer)
EFc (Evaporator Fan
Constant Blow)
dAL (Out-of-Range Alarms)
HC (Hour Counter Initial
Value)
dSP (Door Switches
Present/Polarity)
bE (Buzzer Enable)
tu (Thermostat Units)
Pu (Pressure Units)
(10/08)
From the
Standard
Display, do the
following:
Press and hold
the Enter and
Down Arrow keys
for 3 seconds.
To scroll through
the menu press
the UP or
DOWN keys.
3-6
Section 3 - Software Description
Main Menu Screens
In-cab Control Box On/Off
Switch Must be On.
SELECT
Key
Standard
Display
SP2
Setpoint 2
SELECT
Key
SELECT
Key
Alarm Codes
Alarma
Codes
(if present)
(ifCan
present)
include:
Standard
Display
Can include:
P1E (Temperature
Probe1)
P1E (Temperature Probe 1)
P2E(Temperature
(Temperature Probe
P2E
Probe2)2)
OL(Electric
(Electric Motor
Motor Protection
OL
Protection
Switch
Switch Overload)
Overload)
bAt
Voltage)
bAt(Low
(Low Battery
Battery Voltage)
HP (HPCO Switch fault)
HP(LPCO
(HPCO Switch
Switch fault)
LP
fault)
(LPCOpressure
Switch fault)
PSELP
(HPCO
sensor
fault)pressure
PSE (HPCO
tEP (B-100
only)
sensor
fault)(Thermal
alarm)
dr1protection
(Door Switch
Switch
11fault)
dr1
(Door
fault)
dr2
(Door
Switch
dr2 (Door Switch 22fault)
fault)
Hot
(Temperature
Control
Alarm)
tCO
(Temperature
Control
Alarm) failure)
SOF (Software
SOF (Software failure)
- C -(Communications
(Communications Failure)
-Cfailure)
SELECT
Key
dEF
Manual Defrost
SELECT
Key
SP
Setpoint 1
Figure 3-3 DSR Main Menu Screens
(10/08)
3-7
Section 3 - Software Description
Hourmeters Menu
Screens
SELECT
Key
In-cab Control Box On/Off
Switch Must be On.
Standard
Display
Standard
Display
Press and hold the
SELECT key
for 3 seconds
SELECT
Key
HC
Hour Counter
SELECT
Key
tH
Total Hours
SELECT
Key
CC
Vehicle orCompressor
battery mode (B-100)
Vehicle
Hours
compressor hours
SELECT
Key
EC
Electric orCompressor
Electric StandbyHours
mode
Electric
(B-100) compressor hours
Figure 3-4 DSR Hourmeters Menu Screens
(10/08)
3-8
Section 3 - Software Description
Info rm atio n M e nu
S cree ns
In-cab C ontrol B ox O n/O ff
S witch M ust be O n.
S tandard
D isplay
P res s and hold the E N T E R
and U p arrow keys for
3 s econds . T he s c reens begin
s c rolling autom atic ally.
(all d isp lay ico n s)
D isplay T est
121 121
XX, 273
X X XX
S oftware V ersion
134, 404
R efrigerant T ype
b At
B attery V oltage
HP
H igh P ressure
xC / tyy
C om partm ents / U nit T ype
S tandard
D isplay
Figure 3-5 DSR Information Menu Screens
(10/08)
3-9
Section 3 - Software Description
Installation (Guarded Access)
Menu Screens
Down Arrow
Key
Down Arrow
Key
EFc
Evaporator Fan
Constant Blow
tu
Thermostat Units
Down Arrow
Key
Down Arrow
Key
diF
Setpoints Differential
dAL
Out-of-Range Alarms
Pu
Pressure Units
Down Arrow
Key
Down Arrow
Key
In-cab Control Box On/Off
Switch Must be On.
Standard
Display
Press and hold the ENTER
and Down arrow keys
for 3 seconds
SSC
Soft Start Cycles
HC
Hour Counter Initial Value
Down Arrow
Key
Down Arrow
Key
dit
Defrost Initiation Timer
dSP
Door Switches
Present/Polarity
Down Arrow
Key
Down Arrow
Key
dtt
Defrost Termination Timer
bE
Buzzer Enable
Down Arrow
Key
Standard
Display
NOTE: The Up Arrow key can be used to
scroll back through the screens.
Figure 3-6 DSR Installation (Guarded Access) Menu Screens
(10/08)
3 - 10
Section 3 - Software Description
Programmable Features
Main Menu and Its Screens
Entering Main Menu
The DSR μP Controller contains a number of
programmable features. These features allow
users to configure their units to their own
requirements, for improved performance and
economy of operation.
1. Press the In-cab Control Box On/Off switch on.
For software version 121 21 and higher, the unit
undergoes a 20-second system check. During
this time, the Standard Display shows the word
CHEck.
When the unit is shipped from the factory, these
features are set to the most commonly used
(default) settings. However, they are easily
changed to satisfy special requirements.
2. After the system check, the return air
temperature setting is displayed at the
Standard Display. For bi-temperature units,
the return air temperature for both load
compartments are displayed.
The following descriptions include all the
programmable features available with the DSR
μP Controller, as equipped with revisions 121
XX or 273 XX software. Features can be
programmed from the following category of
menus and their screens:
3. Press and release the Select key. If an alarm
exists, its code appears in the display. See
the following table for the alarm codes that
can appear.
• Main Menu
4. If there is more than one alarm, other alarm
screens can be viewed, in sequence, by
pressing the Select key and toggling through
the alarms.
• Hourmeters Menu
• Information Menu
The following table, Alarm Codes Displayed in
the Main Menu, describes the alarms that can
exist with the DSR μP Controller. See Section 5
- Diagnostics, for a detailed explanation of an
alarm, its possible causes, and the actions to
take to diagnose the source(s) of the alarm.
• Installation (Guarded Access) Menu
The screens are presented in the order they
appear in each menu category. The default
factory setting for each feature is also shown.
See the Direct Smart Reefer Microprocessor
Controller Menus and Screens flowchart for
reference.
Programming Aids
When programming many features at the same
time, such as during the initial setup of the DSR
μP Controller, it is wise to obtain and complete
a copy of the Setup Sheet shown in Service
Procedure A02A. Be certain that all customer
specified settings are included when completing
this setup sheet. The sheet is used to confirm
each entry, to be certain that the correct settings
are programmed.
(10/08)
3 - 11
Section 3 - Software Description
Alarm Codes Displayed in the Main Menu
Alarm Alarm
Code Description
P1E
Return Air Temperature Sensor in the
main load compartment is faulty.
The temperature reading on the In-cab
Control Box displays [----] when the
Return Air Temperature sensor reading is
out of the readable range. This might be
caused by a short circuit or an open circuit
at the Return Air Temperature sensor.
P2E
For vehicles with a remote load
compartment, this alarm indicates that the
Return Air Temperature Sensor in the
remote compartment is faulty.
For details, see the description for alarm
code P1E.
OL
bAt
For units with an Electric Standby option,
this alarm indicates that there is an
overload in the electric motor protector
switch. The unit shuts down until the
alarm condition is corrected. (The unit is
shut down whether the unit is in Cool,
Heat, or Defrost mode).
Low battery voltage. Battery voltage is
below 10.5 Vdc on 12 V systems, or
below 21 Vdc on 24 volt systems. The unit
shuts down. The battery is possibly
damaged, or a short circuits exists in
battery wires 2 or BAT, or fuse 21.
HP
High Pressure Cut-Out Switch fault. The
unit shuts down when there is excessively
high pressure in the refrigerant circuit.
The unit shuts down, but [HP] and the
alarm icon are displayed on the In-cab
Control Box. When the alarm condition is
corrected, the unit returns to a Null state.
LP
Low Pressure Cut-Out Switch fault. The
unit shuts down when there is excessively
low pressure in the refrigerant circuit. The
unit shuts down, but [LP] and the alarm
icon are displayed on the In-cab Control
Box. When the alarm condition is
corrected, the unit returns to a Null state.
(10/08)
Alarm
Code
3 - 12
Alarm
Description
PSE
HPCO pressure sensor is faulty or
disconnected. This indicates that the
reading from the HP sensor is out of the
readable range (<0.5 V or >4.5V).
The unit remains in its existing mode
(Cool, Heat, Null, Defrost) for a time
determined by the factory-set Pressure
Sensor Error Time Delay Time [PSt]
parameter.
If the alarm continues longer than the
[PSt] time, the unit shuts down.
tEP
(B-100 only) Indicates that the thermal
protection circuit has opened in one of the
two electric standby motors (D.C. or A.C.)
due to engine overheating or circuit
failure.
dr1
Door 1 in Zone 1 is open or door switch
DSW1 is faulty. The audible alarm buzzer
is activated.
∗ If the unit is in Cool or Heat modes when
the alarm occurs, the unit shuts down.
When the door is closed, the unit starts in
Null mode.
∗If the unit is in Defrost mode when the
alarm occurs, it remains in Defrost mode.
dr2
Door 2 in Zone 2 is open or door switch
DSW2 is faulty. The audible alarm buzzer
is activated.
∗ If the unit is in Cool or Heat modes when
the alarm occurs, the unit shuts down.
When the door is closed, the unit starts in
Null mode.
∗ If the unit is in Defrost mode when the
alarm occurs, it remains in Defrost mode.
tCO
The Temperature Cut-Out value for the
Electrical Control Module has been
exceeded
(>85°C [> 185°F]).
The internal temperature of the ECM
might exceed the temperature value
because the internal ECM fan has failed,
or the NTC sensor used to measure the
module temperature is faulty.
If the temperature is exceeded for more
than 30 seconds, the unit shuts down.
SOF
Software failure. The software in the
microprocessor is corrupted. The unit
shuts down. The microprocessor must be
reprogrammed. See Service Procedure
A04A in Section 6.
Section 3 - Software Description
Alarm
Code
-C-
3. For vehicles with two compartments and
bi-temperature functions, the screen displays
[SP2]. This indicates the setpoint for the
return air temperature in the second (remote)
compartment.
To change the [SP2] setting, do the
following:
Alarm
Description
Total communications failure between the
microprocessor in the In-cab Control Box
and the microprocessor(s) in the ECM.
Unit is not able to turn on and operate.
The [- C -] alarm code is not part of the
Main Menu alarms. When a Main Menu
alarm occurs, the In-cab Control Box can
communicate with the ECM, and I/O and
parameter statuses can be checked.
When the [- C -] alarm code occurs, there
are no communications between the
In-cab Control Box and the ECM, and I/O
and parameter statuses cannot be
checked at the In-cab Control Box.
• Press the Up Arrow key to increase the
return air temperature by 1-degree
increments.
• Press the Down Arrow key to decrease the
return air temperature by 1-degree
increments.
Accessing Additional Main Menu Screens
4. Press and release the Select key to return to
the Standard Display.
1. After all (if any) alarms are viewed, press the
Select key, until a flashing [dEF] is viewed.
This indicates the Manual Defrost function. To
change the [deF] setting, press the Enter key,
then use the Up Arrow or Down Arrow keys to
change the defrost setting to ON or OFF.
NOTE: If the Select key is not pressed within
20 seconds to select a new setpoint
temperature, the unit continues to operate at
the original setpoint temperature.
Leaving the Main Menu
2. Press the Select key. An [SP] appears, to
indicate the setpoint temperature for the
return air temperature in the single or
primary load compartment of the vehicle.
To change the [SP] setting, do the following:
Leaving the Main Menu can be accomplished in
several ways.
• Press the Select key until you have toggled
through all of the Main Menu screens.
• Press the Up Arrow key to increase the
return air temperature by 1-degree
increments.
• Turn the unit off and back on. The In-cab
Control Box exits the Main Menu, at any
point in the scrolling sequence, and returns
to the Standard Display.
• Press the Down Arrow key to decrease the
return air temperature by 1-degree
increments.
• Allow the display to time out. The In-cab
Control Box automatically exits the Main
Menu and return to the Standard Display, if
no key is pressed for 20 seconds.
• Press and release the SELECT key to return
to the Standard Display.
NOTE: If the Select key is not pressed within
20 seconds to select a new setpoint
temperature, the unit continues to operate at
the original setpoint temperature.
(10/08)
3 - 13
Section 3 - Software Description
Hourmeters Menu and Its Screens
[CC] (Vehicle or battery mode compressor
hours in B-100 units)
The following paragraphs describe the
hourmeters, their settings and parameters, and
how to program certain hourmeter screens. See
the Direct Smart Reefer Microprocessor
Controller Menus and Screens flowchart for
reference.
Programming Choices - n/a
Unit of Measurement - Tens of hours
Parameter Set By - n/a
Factory setting - n/a
To access the Hourmeters Menu, do the
following:
This hourmeter indicates the total number of
hours that the vehicle compressor has been
operating while on-the-road. This parameter
also indicates the total hours that clutch CLU1
has been engaged. Indicates the total number of
hours the compressor has been in battery mode
operation in B-100 units.
• From the Standard Display, press and hold
the Select key for 3 seconds, then release it.
The first Hourmeters Menu screen, [HC],
appears.
• Press the Select key to access other
Hourmeters Menu screens.
[EC] (Electric Standby compressor hours or
hours compressor has been operating in
Electric Standby mode in B-100 units)
[HC] (Hours Counter for Maintenance)
Programming Choices - 1000 through 5000
Programming Choices - n/a
Unit of Measurement - Tens of hours (e.g.,
150 = 1500 hours)
Unit of Measurement - Tens of hours
Parameter Set By - Maintenance Personnel,
in the Installation (Guarded Access) Menu
Parameter Set By - n/a
Factory setting - n/a
Factory setting - 150
This hourmeter indicates the total number of
hours that the Electric Standby compressor has
been operating, if the unit is equipped with an
Electric Standby option. This parameter also
indicates the total hours that clutch CLU2 has
been engaged while the electric motor is
running. Indicates the total number of hours
the compressor has been in Electric Standby
mode operation in B-100 units.
This hourmeter counts-down the hours
remaining until a maintenance procedure
should occur. The hours remaining value starts
from the value selected by the maintenance
personnel. The [HC] value decreases whenever
the unit is not shut down.
[tH] (Total Hours)
Programming Choices - n/a
Unit of Measurement - Tens of Hours
Parameter Set By: n/a
Factory setting - n/a
This hourmeter indicates the total number of
hours that the unit has been in operation.
(10/08)
3 - 14
Section 3 - Software Description
Leaving the Hourmeters Menu
Leaving the Hourmeters Menu
accomplished in several ways:
[all icons] Display Test
can
be
Programming Choices - none
Unit of Measurement - various temperature
and operational measurements
• Press the Select key until you have toggled
through all of the Hourmeters screens.
Parameter Set By - n/a
• Turn the unit off and back on. The In-cab
Control Box exits the Hourmeters Menu, at
any point in the scrolling sequence, and
returns to the Standard Display.
Factory setting - n/a
This screen displays all of the In-cab Control
Box icons, to indicate that they are functioning
and visible.
• Allow the display to time out. The In-cab
Control Box automatically exits the
Hourmeters Menu and return to the Standard
Display, if no key is pressed for 20 seconds.
[121 XX, 273 XX] Software Version
Programming Choices - current or future
121 XX, 273 XX revisions
Information Menu and Its Screens
Unit of Measurement - alphanumeric
number
The following paragraphs describe the
Information Menu screens that can we viewed.
See the Direct Smart Reefer Microprocessor
Controller Menus and Screens flowchart for
reference.
Parameter Set By - n/a
Factory setting - n/a
This screen displays the revision number of the
software that is currently running the In-cab
Control Box.
To access the Information Menu, do the
following:
• From the Standard Display, press and hold
the Up Arrow key and Enter key for three
seconds, then release them. The first
Information Menu screen, [all icons],
appears.
[134, 404] Refrigerant Type
Programming Choices - 134 or 404
Unit of Measurement - n/a
• The Information Menu screens scroll
automatically from screen-to-screen. Each
screen is displayed for 5 seconds before the
next screen is displayed. After the last
Information screen is shown, the In-cab
Control Box returns to the Standard Display.
(10/08)
Parameter Set By - n/a
Factory setting - 134 or 404
B-100, V-100, V-200, V-300, V-400, and V-500
units are charged with R-134a refrigerant.
R-404A refrigerant is available for use on
MAX, and MAX TC.
3 - 15
Section 3 - Software Description
[bAt] Battery Voltage
[xC / tyy] Number of Compartments / Unit
Type
Programming Choices - n/a
Programming Choices - n/a
Unit of Measurement - volts DC
Unit of Measurement - numerals
Parameter Set By - n/a
Parameter Set By - n/a
Factory setting - n/a
Factory setting - depends on the unit
This screen displays the current voltage of the
vehicle battery.
Displays the number of load compartments for
the vehicle (xC, where x = 1 or 2
compartments), and the unit type (type = 10, 20,
30, or 50).
• For vehicles with 12 Vdc batteries, if the
voltage drops below 10.5 Vdc, the unit shuts
down. A 12 Vdc unit functions within a
voltage range of 10.5 Vdc to 18 Vdc.
Leaving the Information Menu
The Information Menu screens are displayed
automatically. When the sequence of screens is
completed, the In-cab Control Box returns to
the Standard Display.
• For vehicles with 24 Vdc batteries, if the
voltage drops below 21 Vdc, the unit shuts
down. A 24 Vdc unit functions with a
voltage range over 21 Vdc.
Installation (Guarded Access) Menu
and Its Screens
[HP] High Pressure
The following paragraphs describe the unit
parameters that are set at the In-cab Control
Box, their settings, and how to program certain
parameter screens. See the Direct Smart Reefer
Microprocessor Controller Menus and Screens
flowchart for reference.
Programming Choices - n/a
Unit of Measurement - PSIG or BAR, in
decimals
Parameter Set By - n/a
The Installation (Guarded Access) Menu
contains screens that are changed by trained and
authorized DSR μP Controller maintenance
personnel. The parameters shown on these
screens impact many of the primary operating
settings for the unit. Only personnel who are
familiar with the unit and DSR μP Controller
functions are allowed to change the Installation
(Guarded Access) Menu parameters.
Factory setting - P
This screen displays the current pressure
setting, as detected by the HPCO pressure
transducer. The pressure setting is influenced
by the type of refrigerant.
• For units with R-134a: the HPCO opens at
300 PSIG and shuts down the unit. The
HPCO closes when the pressure drops to
200 PSIG.
To change or update the parameter settings in
the Installation (Guarded Access) Menu, see
Service Procedure A04A.
• For units with R-404A: the HPCO opens at
450 PSIG and shuts down the unit. The
HPCO closes when the pressure drops to
375 PSIG.
(10/08)
3 - 16
Section 3 - Software Description
[SSC] Soft Start Cycles
To access the Installation (Guarded Access)
Menu, do the following:
Programming Choices - Off, On
• From the Standard Display, press and hold
the Down Arrow and Enter key for three
seconds, then release it. The first Installation
(Guarded Access) Menu screen, [diF],
appears.
Unit of Measurement - n/a
Parameter Set By - Maintenance Personnel
Factory setting - Off
This parameter allows maintenance personnel
to turn the vehicle compressor clutch CLU1
soft-start operation on or off, during initial
startup of the vehicle engine. A soft start
reduces wear & tear on the clutch. If “On” is
selected, CLU1 is switched on for one-second
every six seconds, for five cycles. After five
cycles, the compressor clutch switches to
continuous operation.
• Use the Up Arrow or Down Arrow key to
toggle through the other Installation
(Guarded Access) Menu screens.
NOTE: Some versions of the Direct Smart
Reefer display the Setpoint Temperature (SP)
as the first Installation (Guarded Access)
Menu screen.
[diF] Setpoint Temperature Differentials
[dit] Defrost Initiation Timer
Programming Choices - 1, 2, 3, 4, 5
Programming Choices - 30 to 480,
increments of 30 minutes
Unit of Measurement - degrees Celsius or
Fahrenheit
Unit of Measurement - minutes
Parameter Set By - Maintenance Personnel
Parameter Set By - Maintenance Personnel
Factory setting - 3 degrees
Factory setting - 240 minutes
This parameter means that when the setpoint
temperature has been reached, and while the
temperature remains between diF Celsius or
Fahrenheit above or below the setpoint, there is
no demand for heating or cooling and the unit
remains in Null mode. This parameter is set in
1-degree increments.
This parameter allows maintenance personnel
to set the Defrost Initiation Timer which, when
it times-out, switches the unit from Cool mode
to Defrost mode. The timer counts all the time
that the unit is in Cool mode. The count resets
when Defrost mode starts.
If the timer is set at 0 (zero), this is a test
position. Defrost mode starts in 15 seconds.
(10/08)
3 - 17
Section 3 - Software Description
[dtt] Defrost Termination Timer
[dAL] Out-of-Range Alarm
Programming Choices - 5 to 50, in
increments of 5 minutes
Programming Choices - 0 (Off), 1 to 10
Unit of Measurement - minutes
Unit of Measurement - degrees Celsius or
Fahrenheit, in 1-degree increments
Parameter Set By - Maintenance Personnel
Parameter Set By - Maintenance Personnel
Factory settings - 45 minutes (except B-100)
or 30 minutes (B-100 only)
Factory setting - 0 degrees Celsius
This parameter allows maintenance personnel
to set the number of degrees that the
temperature can rise above the setpoint
temperature before the temperature display
flashes.
This parameter allows maintenance personnel
to set the Defrost Termination Timer, which
begins counting from the initiation of a Defrost
mode. When the timer times-out, the unit is
switched from Defrost mode to Null mode. The
timer resets at the end of a Defrost mode, or
after the Defrost Termination Timer has
timed-out.
[HC] Hourmeter Initial Value
If the timer is set at 0 (zero), this is a test
position. Defrost mode stops in 15 seconds.
Programming Choices - Software version
121 15 to 121 19: 100 to 500. Software
versions 121 19 and higher: 0 to 5000
[EFc] Evaporator Fans Constant Blow
Unit of Measurement - tens of hours; e.g.,
150 = 1500 hours
Programming Choices - On, Off
Parameter Set By - Maintenance Personnel
Unit of Measurement - n/a
Factory setting - 150 (1500 hours)
Parameter Set By - Maintenance Personnel
This parameter allows maintenance personnel
to set the initial hourmeter value for
maintenance hourmeters. The hours value can
be viewed in the Hourmeters Menu, but can be
changed only in Installation (Guarded Access)
Menu.
Factory setting - Off
This parameter allows maintenance personnel
to set whether the evaporator fans remain on
during Null mode.
• On = the evaporator fans
continuously during Null mode
are
• If the [HC] value had decreased to between
0 and 100 hours, the In-cab Control Box
displays the value for 10 seconds, whenever
the unit is manually turned-on.
on
• Off = the evaporator fans cycle on and off
with the regulators
• If the [HC] value has decreased to 0 hours,
the In-cab Control Box displays a
continuous maintenance icon, to alert the
user that maintenance is required.
(10/08)
3 - 18
Section 3 - Software Description
[dSP] Door Switches Present/Polarity
This parameter allows maintenance personnel
to set the following conditions:
Programming Choices - 0 (normally closed),
1 (normally open), 2 (not present)
• 0 = disable the buzzer so that there is no
audible sound when certain alarm condition
exist
Unit of Measurement - n/a
Parameter Set By - Maintenance Personnel
• 1 = enable the buzzer for normal functioning
Factory setting - 1 (normally open)
• 2 = enable the buzzer to perform normal
functioning, plus to be activated whenever
an In-cab Control Box key is pressed
Door switches DSW1 and DSW2 (for
two-compartment vehicles) are normally closed
switches, and become active (open) when a
door is opened. The unit shuts down when a
door is opened and the unit is in Cool or Heat
mode. The [dSP] parameter allows maintenance
personnel to set the correct polarity, in
accordance with the electrical characteristics of
the door switches that are used on the vehicle.
• 3 = enable the buzzer to become activated
only when an In-cab Control Box key is
pressed.
[tu] Temperature Units
0 = the door switch is a Normally Closed type;
the switch opens when a door is opened
Programming Choices - 0C or 0F
1 = the door switch is a Normally Open type;
the switch closes when a door is opened
Unit of Measurement - tenths of a degree for
degrees C; full degrees for degrees F
2 = door switch(es) is not present.
Parameter Set By - Maintenance Personnel
Factory setting - 0C
This parameter allows maintenance personnel
to set whether the temperature readout on the
In-cab Control Box are displayed as 0C or 0F.
[bE] Buzzer Enable
Programming Choices 0 = (not enabled)
1 = (enabled)
2 = (enabled, and also for when a key is
pressed)
3 = (enabled only when a key is pressed)
[Pu] Pressure Units
Programming Choices - b (BARS) or
P (PSI)
Unit of Measurement - n/a
Unit of Measurement - BARS or PSI
Parameter Set By - Maintenance Personnel
Parameter Set By - Maintenance Personnel
Factory setting - 2 (enabled, and also for
when a key is pressed)
Factory setting - P
This parameter allows maintenance personnel
to set whether the pressure readout on the
In-cab Control Box is displayed in BARS or
PSI.
(10/08)
3 - 19
Section 3 - Software Description
THIS PAGE IS INTENTIONALLY BLANK
(10/08)
3 - 20
Section 4
Operation
In-cab Control Box Features ............... 4 - 1
Keypad
Display
Keypad Keys and Buzzer
4-1
4-1
4-2
Understanding the Display.................. 4 - 2
Display Icons
Reading a Typical Display
4-3
4-3
The Standard Display........................... 4 - 4
Manual Start After an Alarm ................ 4 - 4
Auto Start After an Alarm .................... 4 - 5
Buzzers.................................................. 4 - 6
Changing the Setpoint ......................... 4 - 7
Initiating a Manual Defrost Cycle........ 4 - 9
Checking the Software Revision....... 4 - 10
Viewing and Clearing Alarm Codes.. 4 - 11
To View Alarm Codes
To Clear Alarm Codes
DSR µP Controller Alarm Codes
4 - 11
4 - 11
4 - 12
4Section 4 - Operation
In-cab Control Box Features
The In-cab Control Box contains the main (master) microprocessor, a driver/user LCD display, a
keypad with function keys, integrated circuits, and discrete electrical components. It is typically located
on or near the vehicle’s instrument panel.
Figure 4-1 In-cab Control Box, with all icons illuminated in the Standard Display
Keypad
Display
The five touch-sensitive keys are used to turn
the unit “on” and “off,” change the setpoint
temperature, observe unit operating conditions
and alarm codes, and control or change the
unit’s operating parameters.
The display normally shows the Standard
Display of return air temperature. The display
shown here has all possible segments and icons
lighted.
ATTENTION: If the air conditioning system is on, the V-500 AC unit continues running eventhough
the in-cab control box is off.
(03/07)
4-1
Section 4 - Operation
Keypad Keys and Buzzer
The keys are illuminated any time the unit is turned on. This makes nighttime operation much easier.
On/Off Key
Turns the unit on and off. Always lit (except when the unit is disconnected). Provides a
visual indication that the unit is powered-up.
Select Key
Scrolls through the menu screens.
Up Arrow
Key
Chooses menu screen actions or increases the setpoint temperature or other settings.
Down Arrow Chooses menu screen actions or decreases the setpoint temperature or other settings.
Key
Enter Key
Executes menu screen actions or loads the setpoint temperature or other new settings.
Buzzer
Sounds an audible warning whenever these events occur:
1. When the vehicle battery and the optional Electric Standby power source are
connected simultaneously
2. When the load compartment doors are opened while the unit is operating.
Understanding the Display
The In-cab Control Box, at unit startup and
during normal operation, shows the Standard
Display and the return air temperature(s), as
determined by the Return Air Temperature
sensor(s) in the load compartment(s).
In addition, the icons located at the sides and
bottom of the display indicate the operating
mode of the unit, and indicate if any alarm
codes are present. The display shown here has
all possible display icons turned “on”.
Figure 4-2 The Standard Display
(03/07)
4-2
Section 4 - Operation
Display Icons
0
C
0
F
SP
Cool Icon
Appears when the load compartment is cooling.
Heat Icon
Appears when the load compartment is heating.
Degrees Icon
Indicates whether the on-screen temperature reading is in degrees Celsius (0C) or
degrees Fahrenheit (0F).
Maintenance
Icon
Appears when a user-defined maintenance event should occur.
Defrost Icon
Appears when the evaporator coil is defrosting (the unit is in Defrost mode)
Alarm Icon
Appears when an alarm condition has been detected by the microprocessor.
Electric Icon
Appears when the unit is in Electric Standby mode.
Setpoint Icon
Appears when the setpoint temperature is being shown in the display.
Reading a Typical Display
Figure 4-3 Typical Standard Display reading
Figure 4-3 shows the following information:
• The unit is “on” and is cooling
• The load compartment temperature is
20 degrees Celsius
• No alarm conditions exist.
(03/07)
4-3
Section 4 - Operation
The Standard Display
The Standard Display appears when the unit is turned on and no other functions have been selected. The
return air temperature appears in the display. In Figure 4-4, the display shows a load compartment
temperature of 3 degrees C, and that the unit is cooling the load compartment.
Figure 4-4 The Standard Display, with a load compartment temperature of 3°C
NOTE: For software version 121 21 and higher, the unit undergoes a 20-second system check when the
On/Off switch is turned On. During this time, the Standard Display shows the word CHEck.
Manual Start After an Alarm
When an alarm stops unit operation, the Alarm icon appears on the Standard Display. After the
condition that caused the alarm is corrected, the On/Off key on the In-cab Control Box must be pressed,
in order to start unit operations. See Figure 4-5.
Figure 4-5 The Standard Display, with an alarm icon
NOTE: This information applies only to the OL (Electric Standby overload) alarm and bAt (low
battery voltage) alarm.
(03/07)
4-4
Section 4 - Operation
Auto Start After an Alarm
When an alarm stops unit operation, the Alarm icon appears on the Standard Display. After the
condition that caused the alarm is corrected, the unit starts automatically.
Figure 4-6 The Standard Display, with a setpoint of 10.8 and a declining compartment temperature
For single-temperature units, when a Return Air Sensor alarm [P1E] occurs in the load compartment,
the return air temperature reading on the Standard Display is replaced by the - - - icon. The Alarm icon
also appears. See Figure 4-7.
Figure 4-7 The Standard Display, with a Return Air Alarm and alarm icon
For bi-temperature units, when a Return Air Sensor alarm [P2E] occurs in the remote compartment, the
return air temperature reading for the remote compartment is replaced by the - - - icon. The temperature
reading for the main compartment continues to be displayed. The Alarm icon also appears.
In Figure 4-8, the temperature reading for the main compartment is -10°C. The temperature reading for
the remote compartment has been replaced by - - -. The Alarm icon appears.
(03/07)
4-5
Section 4 - Operation
Figure 4-8 The Standard Display, with main and remote compartment temperature readings
Buzzers
The buzzers are energized when the vehicle battery and the electrical supply are connected
simultaneously (the unit continues running in Standby mode). The buzzers are also energized when the
doors are opened, if this option has been selected.
(03/07)
4-6
Section 4 - Operation
Changing the Setpoint
Figure 4-9 The Standard Display, with a setpoint of -18°C
NOTE: The V-500 AC series works in the same way as single-temperature units.
For Single-Temperament Units
1. Press the On/Off key to turn the unit on.
2. Press the Select key twice to choose the setpoint display. The Setpoint icon SP and the current
setpoint temperature appear. See Figure 4-9.
3. Press the Up Arrow key or Down Arrow key to select a higher or lower setpoint. Each time an arrow
key is pressed, the temperature changes by 1 degree.
NOTE: If the Select key is not pressed within 20 seconds to select a new setpoint temperature, the
unit continues to operate at the original Setpoint temperature.
4. Press and release the Select key. The Standard Display appears on the screen.
(03/07)
4-7
Section 4 - Operation
For Bi-Temperament Units (with Main and Remote Compartments)
Figure 4-10 The Standard Display, with a setpoint of 5ºC for the remote compartment
For the Main Load Compartment of a Bi-Temperature Unit
1. Press the On/Off key to turn the unit on.
2. Press the Select key twice to choose the setpoint display. The setpoint icon SP and the current
setpoint temperature appear. See Figure 4-9.
3. Press the Up Arrow key or Down Arrow key to select a higher or lower setpoint. Each time an arrow
key is pressed, the temperature changes by 1 degree.
NOTE: If the Select key is not pressed within 20 seconds to select a new setpoint temperature, the
unit continues to operate at the original Setpoint temperature.
For The Remote Load Compartment of a Bi-Temperature Unit
1. Press and release the Select key. The remote compartment setpoint temperature setting screen appears.
2. The current setpoint temperature for the remote compartment and the letters SP2 appear on the
display. See Figure 4-10.
3. Press the Up Arrow key or Down Arrow key to select a higher or lower setpoint. Each time an arrow
key is pressed, the temperature changes by 1 degree.
4. Press and release the Select key. The Standard Display appears on the screen.
NOTE: If the Select key is not pressed within 20 seconds to select a new setpoint temperature, the
unit continues to operate at the original Setpoint temperature.
(03/07)
4-8
Section 4 - Operation
Initiating a Manual Defrost Cycle
Figure 4-11 The Standard Display, showing defrost off
CAUTION: Before initiating a manual defrost, make sure that the unit is not already in manual
defrost. Check to see if the defrost icon appears on the Standard Display.
NOTE: If the unit is not running, or if the coil temperature is not below 2°C, the request for
a manual defrost is ignored.
1. The unit must be running and the evaporator coil temperature must be below 2°C. Press and release the
Select key once. [dEF] appears (flashing) on the screen, with the letters OFF. See Figure 4-11.
2. Press the Enter key and either the Up Arrow or Down Arrow key. The letters On appears on the
screen. This means that the manual defrost is activated. See Figure 4-12.
Figure 4-12 The Standard Display, showing defrost on
(03/07)
4-9
Section 4 - Operation
3. Press the Select key two times, to return to the Standard Display. (Press the Select key three times for
bi-temperature units). The round defrost icon appears when the defrost cycle begins. See
Figure 4-13.
Figure 4-13 The Standard Display, with a setpoint of -15°C and the defrost icon
4. A defrost cycle terminates automatically, in accordance with the [dtt] time set at the Parameters
screen. See Section 3 for a description of the [dtt] parameter.
Checking the Software Revision
Figure 4-14 The Standard Display, showing the software revision at the Information Menu
1. Make sure that the unit is on and the Standard Display is showing.
2. Press and hold both the Up Arrow and Enter keys for three seconds. The first Information Menu
screen, [all icons], appears. See Figure 4-14.
3. The Information Menu scrolls automatically. The second screen to appears indicates the software
version. The numbers 121 XX or 273 XX are shown, where “XX” indicates software version 121 15
(273 02) or higher for the DSR µP Controller microprocessor.
(03/07)
4 - 10
Section 4 - Operation
Viewing and Clearing Alarm Codes
Figure 4-15 The Standard Display, showing the bAt (Low Battery Voltage) alarm
If the Alarm icon is present, one or more alarms have been detected.
To View Alarm Codes
The alarm code shown in Figure 4-15 is for
alarm code bAt (Low Battery Voltage).
NOTE: See the table on the following page for
a list of DSR µP Controller alarm codes. In
Section 3, see the table named Alarm Codes
Displayed in the Main Menu for detailed
descriptions of DSR µP Controller alarm
codes.
To Clear Alarm Codes
• Correct the cause of the alarm code.
• Press the Select key to remove the alarm
code.
If the Alarm icon is present, press the Select
key once to show the Alarm screen. The most
recent alarm code is shown on the display.
If more than one alarm code is present, press
the Select key to clear each alarm code
individually.
• If no alarm conditions have occurred, the
Alarm icon does not appear. (If the Select
key is pressed, the Alarm screen does not
appear).
• If more than one alarm code exists, each is
displayed for several seconds.
(03/07)
4 - 11
Section 4 - Operation
DSR µP Controller Alarm Codes
The following table indicates the alarm codes that the DSR µP Controller can experience. All of the
alarm codes can appear on the display of the In-cab Control Box. In Section 3, see the table entitled
Alarm Codes Displayed in the Main Menu for a description of each alarm code.
Alarm
Code
Auto or
Manual
Restart
After Alarm
is Cleared
P1E
Auto
When [----] appears: indicates that the return air temperature in the main load
compartment is outside of the readable range.
P2E
Auto
When [----] appears: indicates that the return air temperature in the remote load
compartment is outside of the readable range.
OL
Manual
Electric Standby electric motor protector overload.
bAt
Manual
Low battery voltage.
HP
Auto
High Pressure in refrigeration system failure (HPCO fault).
LP
Auto
Low Pressure in refrigeration system failure (LPCO fault).
PSE
Auto
High Pressure sensor fault.
tEP
Auto
Thermal protection alarm (B-100 only)
dr1
Auto
Door open or Door Switch 1 faulty.
dr2
Auto
Door open or Door Switch 2 faulty.
tCO
Auto
Electronic Control Module internal temperature exceeds specified limit.
SOF
Auto
Microprocessor software failure.
-C-
-------
Communications failure between the In-Cab Control Box and the ECM.
(03/07)
Description
4 - 12
Section 5
Diagnostics
DSR µP Controller Notes ..................... 5 - 1
Electrostatic Discharge ....................... 5 - 1
DSR µP Controller Diagnostic Hints... 5 - 2
Part 1 - Corrective Actions as a
Result of Alarm Codes......................... 5 - 2
Part 2 - Corrective Actions as a
Result of Other Symptoms ................ 5 - 10
Important Diagnostic Considerations
5 - 10
5Section 5 - Diagnostics
DSR μP Controller Notes
Electrostatic Discharge
The following procedures might not be not
readily apparent, but must be followed when
working on units equipped with DSR μP
Controller microprocessors.
The DSR μP Controller printed circuit board(s)
and In-cab Control Box can be damaged by
electrostatic discharge. Any time that work is
performed directly on the printed circuit boards,
do the following:
• Turn off the unit before connecting or
disconnecting the vehicle battery
• Use an ESD wrist strap, as shown in Service
Procedure A12A, ESD (Electrostatic
Discharge) Procedure.
• Never use testers, consisting of a battery and
a light bulb, to test circuits on any
microprocessor-based equipment
• Keep all printed circuit boards in anti-static
bags at all times.
• Any time the microprocessor is replaced, use
these Service Procedures:
• Protect all defective printed circuit boards
and In-cab Control Boxes from physical
damage by placing them in the shipping
carton supplied with the replacement. They
will be returned for failure analysis and
possible re-manufacture.
– A02A - Recording Existing
Microprocessor Settings
– A04A - Microprocessor Setup
(Programming the DSR Microprocessor)
– A12A - ESD (Electrostatic Discharge)
Procedure
– A26A - Welding on Units Equipped with
Microprocessors
– A28A - Setting Unit Running Time
Hourmeters
(12/07)
5-1
Section 5 - Diagnostics
DSR μP Controller Diagnostic
Hints
Part 1 - Corrective Actions as
a Result of Alarm Codes
Section 5 is devoted to diagnostic routines
designed to help the technician quickly identify
the cause of a problem and repair it, using the
correct tools, information, and procedures. It is
important that the required procedures be
followed exactly. Failure to do so might result
in an incomplete repair.
In Section 3, see the table entitled Alarm Codes
Displayed in the Main Menu for a description of
the DSR μP Controller alarm codes. In Section
4, see the sub-section entitled DSR μP
Controller Alarm Codes for a description of the
types of alarm codes that the DSR μP
Controller can experience.
The remaining material is divided into two
parts. The first part suggests corrective actions
as a result of alarm codes. The second part
suggests corrective actions as a result of other
symptoms.
In order to properly service the DSR μP
Controller, the cautions listed at the front of
this section must be followed carefully.
The following hints might prove helpful when
working on the PCBs.
• Record all alarm codes for reference.
• Clear all alarm codes before testing the unit.
• Be certain all printed circuit board and wire
harness connectors are securely in place.
• Be certain all programmable features are
restored to the customers specifications, as
shown in the procedures.
(12/07)
5-2
Section 5 - Diagnostics
ALARM CODES, THEIR CAUSES AND CORRECTIVE ACTIONS
Code
P1E, P2E
Cause or Explanation
Corrective Action (check in order shown)
Return Air Temperature Sensor
Fault
(P1E = Main Load Compartment)
(P2E = Remote Load
Compartment, if applicable)
1. Check the Return Air Temperature sensor by checking
the Standard Display.
- If the Standard Display shows [----], the return air
temperature is outside of the readable range. The
Return Air Temperature sensor might be defective, or
the circuit is open or has shorted.
A problem exists with the Return Air
2.
Check
the sensor connector at the sensor for damage
Temperature sensor (temperature
or
a
broken
wire.
probe) or its wiring. The sensor is a
thermistor-type sensor and can be 3. With the Return Air Temperature sensor disconnected,
check the sensor with an ohmmeter. Sensor resistance
checked with an ohmmeter. The
should be about as shown below for each temperature:
sensor is located in the return air
stream before the evaporator coil.
The wiring is part of the sensor
Temp
Resistance
Temp
Resistance
harness.
(deg. C)
(kOhms)
(deg. C)
(kOhms)
4.
5.
6.
7.
(12/07)
-25
86.43
45
4.911
-20
67.77
50
4.160
-15
53.41
55
3.536
-10
42.47
60
3.020
-5
33.90
65
2.588
0
27.28
70
2.228
5
22.05
75
1.924
10
17.96
80
1.668
15
14.69
85
1.451
20
12.09
90
1.266
25
10.00
95
1.108
30
8.313
100
0.9731
35
6.940
105
0.8572
40
5.827
110
0.7576
Reconnect the sensor to the wiring harness.
Remove connector C-1 from PCB 1, and remove the
cable from the connector. Check pins A4 and B4 for a
pushed pin, loose pin crimp, or broken wire. As
needed, squeeze the pins together for better contact.
With the sensor connected and using a voltmeter,
check the voltage of the harness wires at pins A4
(PNK) and B4 (BLK) of C-1 connector on PCB 1. The
voltage should be +5 Vdc. If +5 Vdc is not present, the
microprocessor might be malfunctioning.
If the microprocessor is assumed to be functioning,
disconnect the C-1 connector from PCB 1 and
disconnect the suspected bad sensor. Using a Fluke
meter set for ohms, check for shorts to chassis ground
at the PNK and BLK wires of the suspected sensor. If a
short exists, examine the wiring harness for splits, cut
wiring, or corrosion. Repair or replace the wire.
Disconnect the sensor and temporarily connect a new
sensor. Run the unit in Cool and Heat modes. If the
new sensor displays correctly on the In-cab Control
Box, the removed sensor is malfunctioning.
5-3
Section 5 - Diagnostics
ALARM CODES, THEIR CAUSES AND CORRECTIVE ACTIONS (continued)
Code
Cause or Explanation
P1E, P2E
(continued)
OL
8. If the resistance of the sensor and harness is correct,
replace the microprocessor. If the problem persists,
replace PCB 1 and re-install the original
microprocessor.
9. Check the sensor, using Service Procedure D01A.
Electric Standby Overload
DANGER: High voltage is present
any time the unit is connected to
Electric Standby power. Death or
serious injury could result from
unsafe or improper handling of
the Electric Standby equipment.
The optional Electric Standby
electric motor protector has tripped
on single-phase units, or the
overload relay has tripped on
three-phase units. This alarm is
cleared automatically whenever the
unit is turned off and back on, using
the In-cab Control Box On/Off key or
when the Electric Standby power
source is turned off and on.
bAt
(12/07)
Corrective Action (check in order shown)
1. Allow the motor protector or overload relay several
minutes to cool. Turn the unit off and back on to clear
the alarm.
2. Check the voltage on all phases of the motor, to be
sure it is within specification.
3. Check for excessive drive motor current. Check the
nameplate on the motor for the full-load amperage
rating. Correct any condition contributing to excessive
motor load.
4. Check the refrigeration system for any problems that
might cause an overload condition.
5. Check the setting of Electric Standby relay STDR. It
should be 10% greater than the full load amperage
rating of the motor.
6. Check the continuity of the wire between overload
relay OL and pin B2, connector C-1 on PCB 1. See
Service Procedure H04A.
7. Check for continuity between overload relay terminals
97 and 98. The contacts should be Normally Closed.
See Service Procedure H04A.
8. Check the CHX circuit for continuity to chassis ground.
Low Battery Voltage
(alarm does not occur if the unit
is in Electric Standby mode)
1. Check that the cables to the battery (BAT and CHA)
are tightly attached to the battery terminals.
2. Check the battery terminals for corrosion. The vehicle
battery might be discharged or its electrolytic cells
NOTE: This alarm code can occur
might be damaged or leaking.
if the unit is rapidly switched on
3.
Check the operation of the truck alternator. Make sure
and off. Wait 5-10 seconds after
that
the belt is properly adjusted.
switching the unit off before
turning it back on.
4. At the battery, use a voltmeter or multi-meter to check
the voltage.
- For 12V units, the voltage must be between 10.5 Vdc
and 15.0 Vdc.
- For 24V units, the voltage must be between 21 Vdc
and 30 Vdc.
5. At connector C-1 on PCB 1, check pins A6 (CHH) and
A7 (BAT) for a pushed pin.
5-4
Section 5 - Diagnostics
ALARM CODES, THEIR CAUSES AND CORRECTIVE ACTIONS (continued)
Code
HP
Cause or Explanation
High Discharge Pressure
Corrective Action (check in order shown)
1. This alarm indicates that the refrigerant discharge
pressure, as sensed by the transducer, is excessively
high.
When the discharge pressure rises above the specified
value, the transducer opens the circuit to the
compressor clutch and stops compressor (and unit)
operations.
The transducer is connected to PCB 1 at connector
C-1, pin C4 (high pressure), and C-1, pin C5 (5V
power). Check for a pushed pin, loose pin crimp, or
broken wire.
2. Check for obstructions, debris, or dirt on the condenser
coil and condenser fans. (Obstructions can increase
the discharge pressure).
3. Check for a slipping or broken condenser fan belt. (A
malfunctioning condenser fan contributes to increased
discharge pressure).
4. Check the AMP connector on the transducer for a
pushed pin or missing pin wedge, loose pin crimp, or
broken wire. See Service Procedure H02A.
5. Check for a defective transducer. The switch is a
Normally Closed component (it opens when there is
excessive discharge pressure).
6. Check the refrigeration system for high discharge
pressure and correct the condition, as required.
7. Connect a pressure gauge to the high-pressure side of
the unit, with the unit operating. Check the high
pressure reading at the gauge. At the Information
Menu screen of the In-cab Control Box, check the
high-pressure reading. Verify that the high-pressure
reading at the Information Menu screen is the same as
the high-pressure reading at the pressure gauge. If
not:
• Determine if the voltage between 5V-CHT is
approximately 5V. If the voltage is higher, check
point 4.
•
If point 4 is OK, connect directly from transducer to
ECM with external wires.
•
Determine that ground bolts are correctly fitted and
there is continuity between them and wire CHH.
Check that frame surface for ground bolts is clean of
painting and check that a special star washer is
installed.
8. If a problem persists, replace the DSR μP controller
(12/07)
5-5
Section 5 - Diagnostics
ALARM CODES, THEIR CAUSES AND CORRECTIVE ACTIONS (continued)
Code
LP
PSE
Cause or Explanation
Corrective Action (check in order shown)
Low Suction Pressure
1. This alarm indicates that the suction pressure, as
sensed by the Low Pressure Cut-Out (LPCO) switch,
is excessively low. When the suction pressure falls
below the specified value, the LPCO opens the circuit
to the compressor clutch and stops compressor (and
unit) operations.
The LPCO is connected to PCB 1 at connector C-1,
pin A2. Check for a pushed pin, loose pin crimp, or
broken wire.
2. Check compressor and unit operation for cause of the
low suction pressure. Check for possible obstruction in
the suction line or a lack of heat exchange in the
evaporator.
3. Inspect for blocked or dirty evaporator coil (causing
reduced volume of refrigerant reaching the evaporator
and contributing to reduced suction).
4. Determine if there is increased amperage draw at the
LPCO, for indication of a defective LPCO switch.
5. Check ground bolts and continuity between the
grounds and CHH (pin A6, connect C-1)
High Pressure Sensor Fault
1. This alarm code indicates that the signal from the HP
sensor is outside of the readable range (<0.5 Vdc [at 0
psi] or >4.5 Vdc [at 500 psi]), and that a fault exists
with the high discharge pressure sensor.
2. Inspect for a blocked or dirty condenser coil.
3. Inspect for a faulty High Pressure transducer.
4. Check that pin C4 at connector C-1 on PCB 1 is
connected (check for a pushed pin or loose pin crimp),
not corroded, and is not obstructed by dirt.
5. Observe the continuity between CHT (pin C2,
connector C-1) and the ground bolts.
6. Make sure that the voltage between pins C3 and C4 on
connector C-1 corresponds to the table below.
Pressure
(PSI)
130
180
200
300
450
Output Voltage
(HP-CHT) (V)
1.4
1.8
1.9
2.7
3.9
7. Check for +5 volts at pin C5, connector C-1 on PCB 1.
8. If the problem persists, replace the terminals in the
connectors of the ECM and the transducer.
9. Outside the main harness, connect the transducer
directly to the ECM.
(12/07)
5-6
Section 5 - Diagnostics
ALARM CODES, THEIR CAUSES AND CORRECTIVE ACTIONS (continued)
Code
Cause or Explanation
tEP
Thermal protection alarm
(B-100 only)
Corrective Action (check in order shown)
1. This alarm code indicates that the thermal protection
circuit has opened in one of the two Electric Standby
motors (D.C. or A.C.) due to engine overheating or
circuit failure.
2. If alarm persists, use a multimeter to check voltage
between the R1K resistance posts (located in aerial
connector next to the ECM).
• If 12 or 24 VDC, check the voltage at PCB 1 between
connector C-1, pin C2 (DK3), and connector C-1, pin
C6 (CH). If 0 VDC, test for continuity between R1K
resistance and pin C2. If 12 or 24 VDC, replace PCB1,
using Service Procedure B02A. Perform complete
microprocessor setup using Service Procedure A04A.
• If 0 VDC, go to Item 3.
3. Determine which motor matches the open thermal
protection circuit. In B-100 10 units this will be possible
only in the D.C. motor.
4. If circuit is open, disconnect C-40 connector in DC
motor and measure thermal switch continuity:
• Test brushes, pulley and correct belt alignment.
• Check refrigeration system for any problems that might
cause DC motor overheating.
• If problem persists, replace DC motor using procedure
shown in Direct Drive Units (DSR) Service Manual TK
52979-18-BD. Chapter B-100 10/20.
5. Disconnect C-2 connector in AC motor and measure
thermal switch continuity, if circuit is open.
• Test pulley and correct belt alignment.
• Check refrigeration system for any problems that might
cause AC motor overheating.
• If problem persists, replace AC motor using procedure
shown in Direct Drive Units (DSR) Maintenance
Manual TK 52979-18-BD. Chapter B-100 10/20.
(12/07)
5-7
Section 5 - Diagnostics
ALARM CODES, THEIR CAUSES AND CORRECTIVE ACTIONS (continued)
Code
dr1, dr2
tCO
Cause or Explanation
Corrective Action (check in order shown)
Door Open/Door Switch Failure
1. This alarm indicates one or more of the following:
- A door is open. Check if the door is open and close it.
- Wire DSW1 between door switch 1 and PCB 1, or
wire DSW2 between door switch 2 and PCB 2, is
defective. Remove the applicable door switch and
check the wire to the switch for voltage of +5 Vdc.
- There is a short to chassis ground at CHW (PCB 1),
or at CH (PCB 2).
- Voltage at A3 of connector C-1 on PCB 1, or pin 6 of
connector C-1 on PCB 2, is faulty.
2. Confirm that the load compartment doors are closed.
Check the In-cab Control Box screen. If the [dr1] or
[dr2] alarm codes still appear, check the DSW1 and
DSW2 door switches for damage, cut or broken wires,
corrosion, or misalignment.
3. Check the polarity setting at the Installation (Guarded
Access) Menu. Make sure that the polarity for a
Normally Closed door switch is 0, and that the polarity
for a Normally Open door switch is 1.
Electronic Control Module
Internal Temperature Exceeds
Limit
1. This alarm indicates that the microprocessor has detected
an excessively high (>85°C) temperature inside the ECM
enclosure. The built-in fan might be malfunctioning or not
functioning.
2. Check the cable between the fan and PCB 1. Look for
cuts, abrasion, and other damage. Check for a secure
connection to C6-1 on PCB 1 and at the fan motor.
3. Check the fan for a broken blade. Check for a
“burned” smell, indicating that the fan motor has
burned out. Remove and replace the fan and/or filter,
using Service Procedure UH09A.
SOF
(12/07)
Microprocessor Software Failure
1. This alarm code indicates the In-cab Control Box
microprocessor has become defective, or that the
software has become corrupted.
2. If the software is corrupt, the microprocessor must be
reprogrammed. Complete the microprocessor setup
using Service Procedure A04A.
3. If the ECM microprocessor is corrupted or damaged,
replace the microprocessor by replacing PCB1 and/or
PCB 2, using Service Procedure B02A. Complete the
microprocessor setup, using Service Procedure A04A.
5-8
Section 5 - Diagnostics
ALARM CODES, THEIR CAUSES AND CORRECTIVE ACTIONS (continued)
Code
-C-
(12/07)
Cause or Explanation
Corrective Action (check in order shown)
Communications Failure,
1. Check the cable between PCB 1 and the In-cab
Microprocessor to In-cab Control
Control Box. Look for a loose connector or damage to
Box.
the cable. Look for disconnected wires or damaged
pins on the cable, at connector C-1 on PCB 1, or at the
connector on the In-can Control Box. Look for dirt or
debris at all connectors.
2. Using a multimeter, check the voltage at PCB 1
between connector C-1, pin C7 (9V), and connector
C-1, pin C6 (CH). Minimum voltage = 7.5 Vdc.
Maximum voltage = 9 Vdc.
3. Check the continuity of all wires from PCB 1 to the
In-cab Control Box: black wire at connector C-1, pin B6
(RDX, comms); blue wire at connector C-1, pin B7
(TXD, comms); yellow/green wire at connector C-1, pin
C6 (CH, ground); red wire at connector C-1, pin C7
(9V, In-cab power supply); and shield wire at connector
C-1, pin C6 (GND, shield). See Service Procedure
H04A.
4. Remove and replace the In-cab Control Box. If the
replacement does not function, replace PCB 1.
5-9
Section 5 - Diagnostics
Part 2 - Corrective Actions as
a Result of Other Symptoms
Important Diagnostic Considerations
• In some cases, replacement of PCB 1 and/or
PCB 2 is suggested. If replacing the printed
circuit board corrects the problem, recheck
the new printed circuit board and the
original printed circuit board, as the original
printed circuit board might not have been
defective.
A problem with the unit might exist without
generating an alarm code. The following pages
are suggested corrective actions to be taken
when dealing with these symptoms. They have
been broken into sections for ease in locating
specific symptoms.
(12/07)
• When performing diagnostics, consider if
the problem is caused by the refrigeration
system rather than the controls.
5 - 10
Section 5 - Diagnostics
UNIT WILL NOT OPERATE - VEHICLE POWER
Symptom
Cause
Corrective Action
Unit will not operate on Vehicle ignition switch is not on Turn the vehicle ignition switch on.
vehicle power and the
In-cab Control Box
display remains blank.
Blown ignition power fuse F 21. Check 40-amp ignition power fuse F21, located
near the vehicle battery.
Dead or disconnected vehicle
battery.
Service the vehicle battery.
Defective or disconnected
In-Cab Control Box.
Verify that cable is connected between PCB 1 in the
ECM and the In-Cab Control Box.
No voltage in BAT (pin A7,
Check the continuity between the ECM side and the
connector C-1) and/or 03
battery side. If no continuity, repair the wiring.
(pinA8, connector C-1) in the
ECM, even with the ignition on.
Loose or disconnected printed Check PCB 1 and/or PCB 2 connectors C1 and C2,
circuit board connector.
to be sure they are attached securely.
Defective microprocessor or
printed circuit board.
Unit will not operate on Blown unit power fuse F21
vehicle power, but the
In-Cab Control Box
display turns on.
Replace the In-cab Control Box. Setup the
replacement In-cab Control Box in accordance with
Service Procedure A04A.
Check 40-amp unit power fuse F21, located near
the vehicle battery.
Loose or disconnected printed Check PCB1 and/or PCB 2 connectors C1 and C2,
circuit board connector.
to be sure they are attached securely.
(12/07)
No voltage in wire 2A
Check 40-amp unit power fuse F21 and BATR
relay. Replace, if necessary.
Defective microprocessor or
printed circuit board.
Replace In-cab Control Box or
PCB 1 and/or PCB 2. Setup the replacement
printed circuit board in accordance with Service
Procedure A04A.
5 - 11
Section 5 - Diagnostics
UNIT NOT COOLING - VEHICLE POWER
Symptom
Cause
Corrective Action
Vehicle compressor
clutch does not
engage.
Vehicle not running or unit not
turned on.
Start vehicle and turn unit on. Be sure that the
setpoint and the load compartment temperature
requires a Cool or Heat mode.
Blown unit power fuse F21.
Check 40-amp unit power fuse F21 located near
the vehicle battery.
Discharge pressure is above
HPCO value or the Low
Pressure Cut-Out switch is
open.
Verify that the discharge pressure is under the
HPCO value, and that the Low Pressure Cut-Out
switch is closed.
Defective wiring harness or
loose connector for CLU1-01
and CLU2 circuit.
Check wiring and connections for CLU1-01 and
CLU2 circuit. Using the schematic diagram, check
splice 2.
Defective microprocessor or
printed circuit board.
Replace PCB 1. Setup the replacement printed
circuit board in accordance with Service Procedure
A04A.
Blown vehicle compressor
clutch fuse F5.
Check power fuse F5 (20A for 12V units; 10A for
24V units) located on PCB 1. Check vehicle
compressor clutch for shorted coil.
Loose or defective CLU1-01
and CLU2 circuit to
compressor clutch.
Check the CLU1-01 and CLU2 circuit to vehicle
compressor clutch.
Open vehicle compressor
clutch coil or defective clutch.
Check continuity of vehicle compressor clutch coil.
See Service Procedure H04A.
Refrigerant system problem.
Check refrigerant system. Check for level
refrigerant level
Defective compressor
Determine if the compressor is defective. Replace
it, if necessary.
Vehicle compressor
clutch is engaged, but
unit is not cooling.
(12/07)
5 - 12
Section 5 - Diagnostics
UNIT NOT HEATING - VEHICLE POWER
Symptom
Cause
Corrective Action
Vehicle compressor
clutch does not
engage.
Vehicle not running or unit not
turned on.
Start vehicle and turn unit on. Be sure that the
setpoint and the load compartment temperature
requires a Cool or Heat mode.
Blown unit power fuse F21.
Check 40-amp unit power fuse F21 located near
the vehicle battery.
Discharge pressure is above
HPCO value or the Low
Pressure Cut-Out switch is
open.
Verify that the discharge pressure is under the
HPCO value, and that the Low Pressure Cut-Out
switch is closed.
Defective wiring harness or
loose connector for CLU1-01
and CLU2 circuit.
Check wiring and connections for CLU1-01 and
CLU2 circuit. Using the schematic diagram, check
splice 2.
Defective microprocessor or
printed circuit board.
Replace PCB 1. Setup the replacement printed
circuit board in accordance with Service Procedure
A04A.
Blown vehicle compressor
clutch fuse F5.
Check power fuse F5 (20A for 12V units; 10A for
24V units) located on PCB 1. Check vehicle
compressor clutch for shorted coil.
Loose or defective CLU1-01
and CLU2 circuit to
compressor clutch.
Check the CLU1-01 and CLU2 circuit to vehicle
compressor clutch.
Open vehicle compressor
clutch coil or defective clutch.
Check continuity of vehicle compressor clutch coil.
See Service Procedure H04A.
Refrigerant system problem.
Check refrigerant system. Check for level
refrigerant level
Defective compressor
Determine if the compressor is defective. Replace
it, if necessary.
Vehicle compressor
clutch is engaged but
vehicle is not heating.
(12/07)
5 - 13
Section 5 - Diagnostics
UNIT WILL NOT DEFROST - VEHICLE POWER
Symptom
Cause
Corrective Action
Unit does not defrost.
Vehicle not running or unit not
turned on.
Start vehicle and turn unit on.
Initiate a manual defrost cycle
using the Main Menu.
Press the Select key until the display briefly shows
[dEF]. The defrost icon should appear. As desired,
press the Enter key, then the Up or Down arrow
key, to change the defrost setting in 1-degree
Celsius increments.
Defrost Initiation Time [dit] is
not set or set to an incorrect
time.
In the Installation (Guarded Access) Menu, scroll to
the [dit] parameter screen. Check if the time (factory
default = 240 minutes) is too short or too long
between defrost initiation cycles. Change the time
setting, as required.
For units with older versions of Switch off the unit with the Direct Smart Reefer,
software revision 121 21: The before switching off the vehicle.
unit has been switched off
using the vehicle key.
If compressor clutch is not energized troubleshoot
Vehicle compressor clutch
as shown under UNIT NOT COOLING - VEHICLE
must be energized and
compressor must be operating. POWER.
Defrost klixon (DK) wire 12 not Inspect the wiring and connector and make sure
connected in the ECM (at pin that DK wire 12 is securely connected.
C1, connector C-1)
Defrost klixon (DK) is defective Inspect the klixon for defects. Replace the klixon,
as required.
Compressor is
running, hot gas
solenoid is not
energized.
Blown hot gas solenoid fuse
F5.
NOTE: If the unit is
equipped with option
defrost drain heaters
they turn on and off
with the hot gas
solenoid.
(12/07)
5 - 14
Check hot gas solenoid fuse F5 (20A for 12V units,
10A for 24V units), located on PCB 1. Check hot
gas solenoid coil for short to ground. If present,
check defrost drain heaters for short to ground.
Section 5 - Diagnostics
UNIT WILL NOT DEFROST - VEHICLE POWER (continued)
Symptom
Cause
Corrective Action
Compressor is
Loose or defective wire 26 to
running, hot gas
hot gas solenoid.
solenoid is not
energized (continued).
Check wire 26 to the hot gas solenoid, PS1. Check
the pin connections at PCB 1 connector C-2, pin 8
for crimps or loose connections.
NOTE: If the unit is
equipped with option
defrost drain heaters
they turn on and off
with the hot gas
solenoid.
Defective hot gas solenoid,
PS1.
Check hot gas solenoid PS1 for proper operation.
Open hot gas solenoid
Check the continuity of the hot gas solenoid coil.
See Service Procedure H04A.
Not output voltage to the hot
gas solenoid (wire 26)
Check wire 26. Replace PCB 1, as required.
Compressor is
Refrigerant system problem.
running, hot gas valve
is energized, but unit is
not defrosting.
Evaporator fan(s) stuck on.
(12/07)
5 - 15
Check refrigerant system.
Check operation of evaporator fans EF1 and EF2.
Check the [EFc] Evaporator Fans Constant Blow
parameter at the Installation (Guarded Access)
Menu. Change the parameter setting from On to Off
(changing to Off causes the evaporator fans to
cycle on/off with Cool, Heat, and Null mode
changes)
Section 5 - Diagnostics
EVAPORATOR FANS DO NOT OPERATE - VEHICLE POWER
The unit is equipped with 1, 2, or 3 evaporator fans. These fans operate in Cool, Heat and Null (if the
Evaporator Fan Constant Blow [EFc] feature is set to [on].
Symptom
Cause
Corrective Action
Evaporator fans
Vehicle not running or unit not
should be running, but turned on.
are not.
Start vehicle and turn unit on. Be sure conditions
require evaporator fans to be operating.
Blown unit power fuse F21.
Check 40-amp unit power fuse F21 located near
the vehicle battery.
Defective wiring harness or
loose connector for EF1 and
EF2 circuits.
Check wiring and connections for EF1 and EF2
circuits.
Defective evaporator fan relays Replace PCB 1.
on PCB 1.
Blown evaporator fan fuse F3
and F4 on PCB1. (Fuse F9 on
PCB2 is for units with
evaporator fan EF3)
Check 15A/12V or 10A/24V evaporator fan fuses
F3 and F4 (and F9), located on the printed circuit
board. Check evaporator fan motors EFM1 and
EFM2 for short to ground. For units with EF3, check
evaporator fan motor EFM3 for short to ground.
Open evaporator fan motors.
Check the continuity of the evaporator fan motors.
See Service Procedure H04A.
Loose or defective EF1, EF2, Check the EF1, EF2, or EF3 circuit to the
or EF3 circuit to the evaporator evaporator fan motors.
fan motors.
Defective microprocessor.
Replace PCB 1 and/or PCB 2.
In vehicles with 2
The microprocessor has been
zones (compartments), programmed for the wrong
or vehicles with
unit.
V-400/V-500 units, not
all of the evaporator
fans are operating.
(12/07)
5 - 16
Check the DSR microprocessor parameters.
Section 5 - Diagnostics
CONDENSER FANS DO NOT OPERATE - VEHICLE POWER
The unit is equipped with 1 or 2 condenser fans. These fans operate in Cool mode when the condenser fan
pressure switch is closed.
Symptom
Cause
Corrective Action
Condenser fans
should be running but
are not.
Vehicle not running or unit not
turned on.
Start vehicle and turn unit on. Be sure conditions
require condenser fans to be operating.
Blown unit power fuse F21.
Check 40-amp unit power fuse F21 located near
the vehicle battery.
Defective wiring harness or
loose connector for CF1-01
circuit (for units with CFM1) or
CF1-02 (for units with CFM2)
circuits.
Check wiring and connections for the CF1-01 or
CF1-02 circuits.
Discharge pressure is greater
than CFP (180 psi) but fan is
not energised.
Enter cab control information Menu and display HP
value; test that pressure reading is correct, using
gauge. Check refrigeration system and replace high
pressure transducer, if applicable.
Defective condenser fan relay
RY6 on PCB 1, or RY10 on
PCB 2. (See the unit’s wiring
diagram for the correct relay
number, or see the table in
Section 2 entitled System
Relays.
Replace PCB 1 or PCB 2.
Defective microprocessor.
Replace PCB 1 and/or PCB 2.
For V-400/V-500 units
only: only one
condenser fan is
operating.
The microprocessor has been
programmed for the wrong
unit.
Check the DSR microprocessor parameters. As
necessary, reprogram the microprocessor, using
Service Procedure A04A.
Condenser fans
should be running but
are not.
Blown condenser fan fuse F2 Check the 15A/12V and 10A/24V condenser fan
on PCB 1, and/or F7 on PCB 2. fuses F2 and F6 on PCB 1, and/or F7 on PCB 2.
See the applicable electric
Check condenser fan motors for short to ground.
schematic for the unit, or the
table in Section 2 entitled Fuse
Sizes and Descriptions:
Located on Printed Circuit
Board 1 (PCB 1) or Printed
Circuit Board 2 (PCB 2)
(12/07)
5 - 17
Section 5 - Diagnostics
CONDENSER FANS DO NOT OPERATE - VEHICLE POWER (continued)
The unit is equipped with 1 or 2 condenser fans. These fans operate in Cool mode when the condenser fan
pressure switch is closed.
Symptom
Cause
Corrective Action
Condenser fans
should be running but
are not (continued).
Open condenser fan motor
circuits.
Check continuity of condenser fan motors CFM1
and CFM2. See Service Procedure H04A.
Loose or defective CF1-02 and Check the CF1-02 circuit to
CF2-02 circuits to the
CFM1, and the CF2-02 circuit to CFM2.
condenser fan motors.
UNIT WILL NOT OPERATE - BATTERY DRIVEN (B-100)
Symptom
Cause
Corrective Action
Unit does not operate
and the In-cab Control
Box screen remains
blank.
Vehicle ignition switch is not on Turn vehicle ignition switch on.
Blown FP power ignition fuse.
Check FP power ignition fuse (100A in 12V units;
60A in 24V units), located near vehicle battery.
Replace, if necessary.
Dead or disconnected vehicle
battery.
Service vehicle battery.
Defective or disconnected
In-cab Control Box
Verify that cable is connected between PCB 1 in the
ECM and the In-cab Control Box.
No voltage in BAT (pin A7,
Check continuity between ECM side and battery
connector C-1) and/or 03
side. If no continuity, repair wiring.
(pinA8, connector C-1) in the
ECM, even with the ignition on.
Loose or disconnected printed Check connectors C1 and C2 on PCB 1 to ensure
circuit board connector.
they are securely attached
Defective microprocessor or
printed circuit board.
(12/07)
5 - 18
Replace In-cab Control Box. Setup replacement
In-cab Control Box in accordance with Service
Procedure A04A.
Section 5 - Diagnostics
UNIT WILL NOT OPERATE - BATTERY DRIVEN (B-100) (continued)
Symptom
Cause
Corrective Action
Unit does not operate Blown FP power ignition fuse.
but In-cab Control Box
screen remains lit.
Check FP power ignition fuse (100A in 12V units;
60A in 24V units), located near vehicle battery.
Replace, if necessary.
Loose or disconnected printed Check connectors C1 and C2 on PCB 1 to ensure
circuit board connector.
they are securely attached.
No voltage in RM relay
connector 30.
Check FP power ignition fuse (100A in 12V units;
60A in 24V units) and RM relay. Replace, if
necessary.
Defective microprocessor or
printed circuit board.
Replace in-Cab Control Box or PCB 1. Setup
replacement printed circuit board in accordance
with Service Procedure A04A.
UNIT NOT COOLING - BATTERY DRIVEN (B-100)
Symptom
Cause
Corrective Action
Compressor does not
operate.
Vehicle not operating or unit
not turned on.
Start vehicle and turn unit on. Make sure setpoint
and load compartment temperature requires a Cool
or Heat mode.
Blown FP power ignition fuse.
Check FP power ignition fuse (100A in 12V units;
60A in 24V units), located near vehicle battery.
Replace, if necessary.
Discharge pressure is above
HPCO value or the Low
Pressure Cut-Out switch is
open.
Verify that the discharge pressure is under the
HPCO value, and that the Low Pressure Cut-Out
switch is closed.
Defective wiring harness or a Check RM circuit wiring and connections.
loose connector for RM circuit.
(12/07)
Defective microprocessor or
printed circuit board.
Replace PCB 1. Setup replacement printed circuit
board in accordance with Service Procedure A04A.
Blown F5 fuse.
Check power F5 fuse (20A for 12V units; 10A for
24V units) located on PCB 1.
5 - 19
Section 5 - Diagnostics
UNIT NOT COOLING - BATTERY DRIVEN (B-100) (continued)
Symptom
Cause
Corrective Action
Compressor does not
operate (continued).
Refrigeration system problem
Check refrigeration system.
Check refrigerant level
Faulty compressor.
Determine if the compressor is defective. Replace,
if necessary. Use procedure shown in Direct Drive
Units (DSR) Maintenance Manual TK
52979-18-BD. Chapter B-100 10/20
Defective DC power supply.
Check brushes and replace, as applicable.
Determine if DC power supply is defective and
replace, if necessary. Use procedure shown in
Direct Drive Units (DSR) Maintenance Manual TK
52979-18-BD. Chapter B-100 10/20
DC power belt incorrectly
mounted or defective.
Test DC motor belt and replace, if necessary. Use
procedure shown in Direct Drive Units (DSR)
Maintenance Manual TK 52979-18-BD. Chapter
B-100 10/20
UNIT WILL NOT DEFROST - BATTERY DRIVEN (B-100)
Symptom
Cause
Corrective Action
Unit does not defrost.
Vehicle not running or unit not
turned on.
Start vehicle and turn unit on.
Initiate a manual defrost cycle
using the Main Menu.
Press the Select key until [dEF] is briefly displayed
on screen. The defrost icon should appear.
Accordingly, press the Enter key, then the Up or
Down arrow key, to change settings. This will
change the defrost setting in 1-degree Celsius
increments.
Defrost Initiation Time [dit] is
not set or set incorrectly.
In the Installation (Guarded Access) Menu, scroll to
the [dit] parameter screen. Check if setting (factory
default = 240 minutes) is too short or too long
between defrost initiation cycles. Change time
settings, as required.
Defrost klixon (DK) wire 12 not Check wiring and connector and make sure that DK
connected to the ECM (at pin wire 12 is securely connected.
C1, connector C-1).
Defrost klixon (DK) is defective Check klixon for defects. Replace klixon, as
required.
(12/07)
5 - 20
Section 5 - Diagnostics
UNIT WILL NOT DEFROST - BATTERY DRIVEN (B-100) (continued)
Symptom
Cause
Corrective Action
Compressor is
running; hot gas
solenoid is not
energised.
Hot gas solenoid F5 fuse
blown.
Check hot gas solenoid F5 fuse (20A for 12V units,
10A for 24V units), located on PCB 1. Check hot
gas solenoid coil for short circuit to ground.
Loose or defective wire 26 to
hot gas solenoid.
Check wire 26 to the hot gas solenoid, PS1. Check
pin connections at PCB 1 connector C-2, pin 8 for
crimps or loose connections.
Defective hot gas solenoid,
PS1.
Check hot gas solenoid PS1 for proper operation.
Open hot gas solenoid
Test hot gas solenoid coil continuity. See Service
Procedure H04A.
No output voltage to hot gas
solenoid (wire 26)
Check wire 26. Replace PCB 1, as required.
Refrigeration system problem.
Check refrigeration system.
Compressor is
running, hot gas valve
is energised, but unit
is not defrosting.
Evaporator fan is locked in ON Check EFM evaporator fan operating hours. Check
position.
[EFc] evaporator fan constant blow parameter in
Installation (Guarded Access) Menu. Change the
parameter setting On to Off, which causes the
evaporator fan to alternate between On and Off
positions with Cool, Heat, and Null mode changes.
(12/07)
5 - 21
Section 5 - Diagnostics
EVAPORATOR FAN WILL NOT OPERATE - BATTERY DRIVEN (B-100)
The unit is equipped with 1 evaporator fan. This fan operates in Cool, Heat and Null modes (if evaporator fan
constant blow [EFc] function is set to [on].
Symptom
Cause
Corrective Action
Evaporator fan should
be running but is not.
Vehicle not running or unit not
turned on.
Start vehicle and turn unit on. Make sure conditions
require evaporator fans to be operating.
Blown FP power ignition fuse.
Check FP power ignition fuse (100A in 12V units;
60A in 24V units), located near vehicle battery.
Replace, if necessary.
Defective wiring harness or a
loose connector for EFM
circuit.
Check EFM circuit wiring and connections
Defective evaporator fan relay
on PCB 1.
Replace PCB 1.
Evaporator fan F3 fuse blown
on PCB1.
Check 15A/12V or 10A/24V evaporator fan F3 fuse,
located on the printed circuit board. Check EFM
evaporator fan Electric Standby motor for short
circuit to ground.
Electric Standby evaporator
fan motor open.
Check Electric Standby evaporator fan motor
continuity. See Service Procedure H04A.
Loose or defective EFM circuit Check Electric Standby evaporator fan motor EFM
to Electric Standby evaporator circuit.
fan motor.
Defective microprocessor.
Replace PCB 1.
CONDENSER FAN WILL NOT OPERATE - BATTERY DRIVEN (B-100)
The unit is equipped with 1 condenser fan. This fan operates in Cool mode when the condenser fan pressure
switch is closed.
Symptom
Cause
Corrective Action
Condenser fan should
be running but is not.
Vehicle not running or unit not
turned on.
Start vehicle and turn unit on. Make sure conditions
require condenser fans to be operating.
Blown FP power ignition fuse.
Check FP power ignition fuse (100A in 12V units;
60A in 24V units), located near vehicle battery.
Replace, if necessary.
Defective wiring harness or
loose connectors for CF1
circuit.
Check CF1 circuit wiring and connections
(12/07)
5 - 22
Section 5 - Diagnostics
CONDENSER FAN WILL NOT OPERATE - BATTERY DRIVEN (B-100) (continued)
Symptom
Cause
Corrective Action
Condenser fan should
be running but is not
(continued).
Discharge pressure is greater
than CFP (180 psi) but fan is
not energised.
Enter cab control information Menu and display HP
value; test that pressure reading is correct, using
gauge. Check refrigeration system and replace high
pressure transducer, if applicable.
Defective RY6 condenser fan
relay on PCB 1. (See unit
wiring diagram for the correct
relay number or see System
Relays table in Section 2.)
Replace PCB 1.
Defective microprocessor.
Replace PCB 1.
Condenser fan F2 fuse blown Check PCB 1 15A/12V or 10A/24V condenser fan
on PCB1. See electric
F2 fuse, respectively. Test Electric Standby
schematic for the unit or Sizes condenser fan motor for short circuit to ground.
and description of fuses
located on printed circuit board
1 (PCB1) or printed circuit
board 2 (PDB 2) table in
Section 2.
Condenser fan motor capacitor Check Electric Standby CFM condenser fan motor
circuit open.
continuity. See Service Procedure H04A.
Defective wiring harness or
loose connectors for CF1
circuit.
Check CF1 circuit wiring and connections
UNIT WILL NOT OPERATE - ELECTRIC STANDBY POWER (except B-100 20)
Symptom
Cause
Corrective Action
Unit will not operate on Unit not connected to Standby
Electric Standby power power or Standby power is
and the In-cab Control turned off.
Box display remains
blank.
Blown transformer primary
fuse F20.
(12/07)
Connect power cord. Verify that the Electric
Standby power is turned on and is the correct
voltage.
Check transformer primary fuse F20 (5A for 12V
and 24V units).
5 - 23
Section 5 - Diagnostics
UNIT WILL NOT OPERATE - ELECTRIC STANDBY POWER (except B-100 20) (continued)
Symptom
Cause
Corrective Action
Unit will not operate on Defective bridge rectifier.
Electric Standby power
and the In-cab Control
Box display remains
blank. (continued).
Check the bridge rectifier, using a digital multimeter.
See the schematic diagram for the voltage
requirements at the 12V or 24V bridge connections.
Defective step-down
transformer.
Check transformer continuity. See Service
Procedure H04A.
Defective voltage in the X1 and Determine if the voltage at X1 and X4 is 12 Vac or
X4 wires (pins B8 and C8,
24 Vac.
connector C-1)
Pins X1 and X4 are misaligned Examine the terminals. Bend the pins into
or fit incorrectly on connector
alignment or replace the connector, as necessary.
C-1
Defective or disconnected
In-cab Control Box
Verify cable is connected at the ECM and the In-cab
Control Box.
Loose or disconnected PCB 1
and/or PCB 2 connector.
Check connectors C-1 and C-2 on PCB 1 and/or
PCB 2 to be sure they are attached securely.
Defective ECM
Replace the ECM.
Unit will not operate on Defective Electric Standby
Electric Standby power power pack or circuitry
but In-cab Control Box
turns on.
Check Electric Standby relay STDR for functioning.
Check the connection of wire 2RA between STDR
and battery terminal board TB.
Defective In-cab Control Box
microprocessor, or PCB 1
and/or PCB 2.
Check the C1R relay. Replace the In-cab Control
Box or PCB 1 and/or PCB 2.
UNIT NOT COOLING - ELECTRIC STANDBY POWER (except B-100 20)
Symptom
Cause
Corrective Action
Electric Standby motor Power cord not plugged in or
is not running,
unit not turned on.
compressor clutch
does not engage.
Defective bridge rectifier.
(12/07)
Connect the power cord and turn the unit on. Make
sure that the setpoint and load compartment
temperature requires Cool mode.
Check the bridge rectifier, using a digital multimeter.
5 - 24
Section 5 - Diagnostics
UNIT NOT COOLING - ELECTRIC STANDBY POWER (except B-100 20) (continued)
Symptom
Cause
Corrective Action
Electric Standby motor Defective step-down
is not running,
transformer
compressor clutch
does not engage
(continued).
Check the continuity of the transformer. See
Service Procedure H04A, Checking Harness
Continuity.
Blown transformer fuse
Check transformer fuse F20.
Defective electric relay STDR
Check electric relay STDR, located in the Electric
Standby power pack.
Discharge pressure above the Verify that the discharge pressure is below the
HPCO value, or Low Pressure HPCO value and that the LPCO is closed.
Cut-Out switch is open
Defective wiring harness or
loose connector for the CLU2
circuit.
Check wiring and connections for the CLU2 circuit.
Defective wiring harness or a
loose connector for the CMC
circuit
Inspect the wiring and connections for the CMC
circuit.
Defective microprocessor or
printed circuit board(s).
Replace the PCB 1 and/or PCB 2. Setup the
replacement printed circuit board in accordance
with Service Procedure A04A.
Electric Standby motor Open Electric Standby
is running,
compressor clutch coil or
compressor clutch
defective clutch.
does not engage.
Check the continuity of the Electric Standby
compressor clutch coil. See Service Procedure
H04A.
NOTE: It can take 15
seconds or more after
the Electric Standby
motor starts for the
Electric Standby clutch
to become energized.
Defective wiring harness or
loose connector for CLU2
circuit
(12/07)
5 - 25
Inspect the wiring and connector for the CLU2
circuit.
Section 5 - Diagnostics
UNIT NOT COOLING - ELECTRIC STANDBY POWER (except B-100 20) (continued)
Symptom
Cause
Corrective Action
Electric Standby motor Loose or defective 2RA circuit
is running,
to the Electric Standby motor
compressor clutch
contactor.
does not engage
(continued).
Check the 2RA circuit to the Electric Standby motor
contactor.
NOTE: It can take 15
seconds or more after
the Electric Standby
motor starts for the
Electric Standby clutch
to become energized.
Electric Standby motor Open Compressor Motor
is not running, and the Contactor (CMC).
compressor clutch
does engage.
Electric Standby
compressor clutch is
engaged, but the unit
is not cooling.
Check continuity on the CMC at wires L1/T1A and
L2/T2A for single-phase units, and at wires L1/T1B,
L2/T2B, and L3/T3B for 3-phase units. See Service
Procedure H04A.
Open or defective L1, L2,
and/or L3 wire to the CMC.
Check that wiring is connected. Check wires L1, L2,
and/or L3 for shorts, abrasions, or damage.
Defective CMC wire
connection from the ECM (pin
B1, connector C-1)
Inspect pin B1 at connector C-1 on the ECM. Check
for bent or missing pin. Replace connector C-1, as
necessary.
Electric Standby motor
overload relay OLR has
tripped.
Turn unit off, allow overload relay to cool and turn
the unit back on to reset the overload relay. Check
motor operation to determine cause for overload
relay tripping.
There is a problem with the
refrigeration system.
Check the Return Air Temperature sensors and
setpoint, check the refrigerant level, check the
evaporator and condenser for obstructions or
not-functioning valves.
UNIT NOT HEATING - ELECTRIC STANDBY POWER
Symptom
Cause
Corrective Action
Electric Standby motor Power cord not plugged in or
is not running,
unit not turned on.
compressor clutch
does not engage.
(12/07)
5 - 26
Connect the power cord and turn the unit on. Make
sure that the setpoint and load compartment
temperature requires Heat mode.
Section 5 - Diagnostics
UNIT NOT HEATING - ELECTRIC STANDBY POWER (continued)
Symptom
Cause
Corrective Action
Electric Standby motor Defective bridge rectifier.
is not running,
compressor clutch
does not engage
(continued).
Check the bridge rectifier, using a digital multimeter.
Defective step-down
transformer
Check the continuity of the transformer. See
Service Procedure H04A.
Blown transformer fuse
Check transformer fuse F20.
Defective electric relay STDR
Check electric relay STDR, located in the Electric
Standby power pack.
Discharge pressure above the Verify that the discharge pressure is below the
HPCO value, or Low Pressure HPCO value and that the LPCO is closed.
Cut-Out switch is open
Defective wiring harness or
loose connector for the CLU2
circuit.
Check wiring and connections for the CLU2 circuit.
Defective wiring harness or a
loose connector for the CMC
circuit
Inspect the wiring and connections for the CMC
circuit.
Defective microprocessor or
printed circuit board(s).
Replace the PCB 1 and/or PCB 2. Setup the
replacement printed circuit board in accordance
with Service Procedure A04A.
Electric Standby motor Open Electric Standby
is running,
compressor clutch coil or
compressor clutch
defective clutch.
does not engage.
Check the continuity of the Electric Standby
compressor clutch coil. See Service Procedure
H04A.
NOTE: It can take 15
seconds or more after
the Electric Standby
motor starts for the
Electric Standby clutch
to become energized.
(12/07)
5 - 27
Section 5 - Diagnostics
UNIT NOT HEATING - ELECTRIC STANDBY POWER (continued)
Symptom
Cause
Corrective Action
Electric Standby motor Defective wiring harness or
is running,
loose connector for CLU2
compressor clutch
circuit
does not engage
(continued).
Inspect the wiring and connector for the CLU2
circuit.
NOTE: It can take 15
seconds or more after
the Electric Standby
motor starts for the
Electric Standby clutch
to become energized.
Loose or defective 2RA circuit
to the Electric Standby motor
contactor.
Electric Standby motor Open Compressor Motor
is not running, and the Contactor (CMC).
compressor clutch
does engage.
Electric Standby
compressor clutch is
engaged, but the unit
is not heating.
(12/07)
Check the 2RA circuit to the Electric Standby motor
contactor.
Check continuity on the CMC at wires L1/T1A and
L2/T2A for single-phase units, and at wires L1/T1B,
L2/T2B, and L3/T3B for 3-phase units. See Service
Procedure H04A.
Open or defective L1, L2,
and/or L3 wire to the CMC.
Check that wiring is connected. Check wires L1, L2,
and/or L3 for shorts, abrasions, or damage.
Defective CMC wire
connection from the ECM (pin
B1, connector C-1)
Inspect pin B1 at connector C-1 on the ECM. Check
for bent or missing pin. Replace connector C-1, as
necessary.
Electric Standby motor
overload relay OLR has
tripped.
Turn unit off, allow overload relay to cool and turn
the unit back on to reset the overload relay. Check
motor operation to determine cause for overload
relay tripping.
There is a problem with the
refrigeration system.
Check the Return Air Temperature sensors and
setpoint, check the refrigerant level, check the
evaporator and condenser for obstructions or
not-functioning valves.
Check the parameters map
Download the suitable parameters map
5 - 28
Section 5 - Diagnostics
UNIT WILL NOT DEFROST - ELECTRIC STANDBY POWER (except B-100 20)
Symptom
Cause
Corrective Action
Unit does not defrost.
Power cord not plugged in or
unit not turned on.
Connect power cord and turn unit on.
Initiate a manual defrost cycle
using the Select and Enter
Keys.
Press the Select key until the display briefly shows
[dEF]. The defrost icon should appear. As desired,
press the Enter key, then the Up or Down arrow
key, to change the defrost setting in 1-degree
Celsius increments.
Defrost Initiation Time [dit] is
not set or set to an incorrect
time.
In the Installation (Guarded Access) Menu, scroll to
the [dit] parameter screen. Check if the time (factory
default = 240 minutes) is too short or too long
between defrost initiation cycles. Change the time
setting, as required.
For units with older versions of Switch off the unit with the Direct Smart Reefer,
software revision 121 21: The before switching off the vehicle.
unit has been switched off
using the vehicle key.
If electric standby compressor clutch is not
Electric standby compressor
clutch must be energized and energized, troubleshoot as shown in the
compressor must be operating. diagnostics section entitled UNIT NOT COOLING ELECTRIC STANDBY POWER (except B-100 20).
Defrost klixon (DK) wire 12 is Inspect the wiring and the terminals. Make sure that
not connected to the ECM (pin DK wire 12 is securely connected.
C1, connector C-1)
Compressor is
running, hot gas
solenoid is not
energized.
(12/07)
Klixon DK is defective
Replace klixon DK.
Defective step-down
transformer.
Check transformer continuity. See Service
Procedure H04A.
Defective wiring harness or
loose connector for 26 circuit.
Check wiring and connections for the 26 circuit.
Defective microprocessor at
PCB 1 and/or PCB 2.
Replace PCB 1 and/or PCB 2.
5 - 29
Section 5 - Diagnostics
UNIT WILL NOT DEFROST - ELECTRIC STANDBY POWER (except B-100 20) (continued)
Symptom
Cause
Corrective Action
Compressor is
Blown host hot gas solenoid
running, hot gas
fuse F5 or remote hot gas
solenoid is not
solenoid fuse F8.
energized (continued).
Check host hot gas solenoid fuse F5 on PCB 1,
and/or remote hot gas solenoid fuse F8 on PCB 2.
Check hot gas solenoid coil for short to ground. If
present, check defrost drain heaters for short to
ground.
Open hot gas solenoid coil.
Check continuity of hot gas solenoid coil. See
Service Procedure H04A.
Defective hot gas solenoid.
Check hot gas solenoid PS1 (host) or PS4 (remote)
for proper operation.
Loose or defective 26 circuit to Check the 26 circuit to hot gas solenoid PS1 (on
hot gas solenoid.
PCB 1), or the 28 circuit to hot gas solenoid PS4
(on PCB 2).
Refrigerant system problem.
Compressor is
running, hot gas valve
is energized but unit is
not defrosting.
Evaporator fan(s) stuck on.
(12/07)
5 - 30
Check refrigerant system.
Check operation of evaporator fans EF1 and EF2.
Check the [EFc] Evaporator Fans Constant Blow
parameter at the Super Guarded Access Menu.
Change the parameter setting from On to Off
(changing to Off causes the evaporator fans to
cycle on/off with Cool, Heat, and Null mode
changes)
Section 5 - Diagnostics
CONDENSER FANS DO NOT OPERATE - ELECTRIC STANDBY POWER (except B-100 20)
The unit is equipped with 1 or 2 condenser fans. These fans operate in cool mode when the condenser fan
pressure switch is closed
Symptom
Cause
Corrective Action
Condenser fans
should be running but
are not.
Power cord not plugged in or
unit not turned on.
Connect power cord and turn unit on. Be sure
conditions require condenser fans to be operating.
Blown transformer primary
fuse F20.
Check 5A transformer primary fuse, located at wire
H1B to the transformer.
Defective bridge rectifier.
Check bridge rectifier, using a digital multimeter.
See the schematic diagram for the voltage
requirements at the 12V or 24V bridge connections.
Defective step-down
transformer.
Check the continuity of the transformer. See
Service Procedure H04A.
Discharge pressure is greater
than CFP (180 psi) but fan is
not energised.
Enter cab control information Menu and display HP
value; test that pressure reading is correct, using
gauge. Check refrigeration system and replace high
pressure transducer, if applicable.
Defective condenser fan relay
RY6 or RY9 on PCB 1, or
RY10 on PCB 2. (See the
unit’s wiring diagram for the
correct relay number, or see
the table in Section 2 entitled
System Relays.
Replace PCB1 or PCB 2.
Defective microprocessor.
Replace PCB1 and/or PCB2
Blown condenser fan fuses F2
or F6 on PCB1, and/or F7 on
PCB 2. (See the applicable
electric schematic for the unit,
or the table in Section 2
entitled Fuse Sizes and
Descriptions: Located on
Printed Circuit Board 1 (PCB 1)
or Printed Circuit Board 2 (PCB
2)
Check the 15A/12V or 10A/24V condenser fan
fuses F2 and F6 on PCB 1, and/or F7 on PCB 2.
Check the condenser fan motors for short to
ground.
(12/07)
5 - 31
Section 5 - Diagnostics
CONDENSER FANS DO NOT OPERATE - ELECTRIC STANDBY POWER (except B-100 20) (continued)
The unit is equipped with 1 or 2 condenser fans. These fans operate in cool mode when the condenser fan
pressure switch is closed
Symptom
Cause
Corrective Action
Condenser fans
should be running but
are not (continued).
Open condenser fan motors.
Check continuity of condenser fan motors. See
Service Procedure H04A.
Loose or defective CF1-02 and Check the CF1-02 circuit (for units with a single
CF2-02 circuits to condenser
condenser fan) and the CF2-02 circuit (for units with
fan motors.
two condense fans) to condenser fan motors CFM1
and/or CFM2.
For V-400/V-500 units
only: only one
condenser fan is
operating.
The microprocessor has been
programmed for the wrong
unit.
Check the DSR microprocessor parameters. As
necessary, reprogram the microprocessor, using
Service Procedure A04A.
EVAPORATOR FANS DO NOT OPERATE - ELECTRIC STANDBY POWER (except B-100 20)
Symptom
Cause
Corrective Action
Evaporator fans
should be running but
are not.
Power cord not plugged in or
unit not turned on.
Connect power cord and turn unit on. Be sure
conditions require condenser fans to be operating.
Blown transformer primary
fuse F20.
Check 5A transformer primary fuse, located at wire
H1B to the transformer.
Defective bridge rectifier
Check bridge rectifier, using a digital multimeter.
See the schematic diagram for the voltage
requirements at the 12V or 24V bridge connections.
Defective step-down
transformer.
Check the continuity of the transformer. See
Service Procedure H04A.
Defective wiring harness or
loose connector for EF1 or
EF 2 circuits
Check wiring and connections for EF1 and EF2
circuits.
Defective evaporator fan relays Replace PCB 1.
on PCB 1
Blown evaporator fan fuse F3
and F4 on PCB1 (fuse F9 on
PCB 2 is for units with
evaporator fan EF3)
(12/07)
5 - 32
Check 15A/12V or 10A/24V evaporator fan fuses
F3 and F4 (and F9), located on the printed circuit
board. Check evaporator fan motors EFM1 and
EFM2 for short to ground. For units with EF3, check
evaporator fan motor EFM3 for short to ground.
Section 5 - Diagnostics
EVAPORATOR FANS DO NOT OPERATE - ELECTRIC STANDBY POWER (except B-100 20) (continued)
Symptom
Cause
Corrective Action
Evaporator fans
should be running but
are not (continued).
Open evaporator fan motors
Check the continuity of the evaporator fan motors.
Service Procedure H04A.
Loose or defective EF1, EF2,
or EF 3 circuit to the
evaporator fan motors
Check the EF1, EF2, or EF3 circuit to the
evaporator fan motors.
Defective microprocessor
Replace PCB 1 and/or PCB 2.
In vehicles with 2
The microprocessor has been
zones (compartments), programmed for the wrong
or vehicles with
unit.
V-400/V-500 units, not
all of the evaporator
fans are operating.
Check the DSR microprocessor parameters.
UNIT WILL NOT OPERATE - ELECTRIC STANDBY POWER (B-100 20 only)
Symptom
Cause
Corrective Action
Unit will not operate on Unit not connected to Standby
Electric Standby power power or Standby power is
and In-cab Control Box turned off.
display remains blank.
AC/DC SMPS power supply
does not operate.
Connect power cord. Verify that the Electric
Standby power is turned on and is at correct
voltage.
Check voltage between AC/DC SMPS power
supply V+ and V- posts (12 VDC for 12V units, 24
VDC for 24V units). Replace power supply, if
necessary. Check for short circuit between X1, X4,
2RB wires and chassis. AC/DC SMPS power
supply has an auto-protection mechanism that
turns off supply in case of short circuit or overload.
Defective voltage in the X1 and Determine if the voltage at X1 and X4 is 12 VDC or
24 VDC.
X4 wires (pins B8 and C8,
connector C-1)
X1 and X4 pins are misaligned Examine the terminals. Bend pins into alignment or
or incorrectly fitted on
replace the connector, if necessary.
connector C-1
Defective or disconnected
In-cab Control Box
(12/07)
Verify cable is connected at the ECM and the In-cab
Control Box.
5 - 33
Section 5 - Diagnostics
UNIT WILL NOT OPERATE - ELECTRIC STANDBY POWER (B-100 20 only) (continued)
Symptom
Cause
Corrective Action
Unit will not operate on Loose or disconnected PCB1
Electric Standby power connector
and In-cab Control Box
display remains blank
(continued).
Defective ECM
Check connectors C-1 and C-2 on PCB1 to ensure
they are securely attached
Replace ECM.
Unit will not operate on Defective Electric Standby
Electric Standby power power pack or circuitry
but In-cab Control Box
turns on.
Check Electric ER1 Standby relay is operating.
Check 2RB wire connection between ER1 and
SMPS AC/DC power supply.
Defective In-cab Control Box
microprocessor or PCB 1.
Check PC connection between ER1 and PCB1.
Replace In-cab Control Box or PCB 1.
UNIT NOT COOLING - ELECTRIC STANDBY POWER (B-100 20 only)
Symptom
Cause
Corrective Action
AC motor fails to run.
Power cord not plugged in or
unit not turned on.
Connect the power cord and turn the unit on.
Make sure that the setpoint and load compartment
temperature requires Cool mode.
AC/DC SMPS power supply
does not operate.
Check voltage between AC/DC SMPS power
supply V+ and V- posts (12 VDC for 12V units, 24
VDC for 24V units). Replace power supply, if
necessary.
Check for short circuit between X1, X4, 2RB wires
and chassis. AC/DC SMPS power supply has an
auto-protection mechanism that turns off supply in
case of short circuit or overload.
Defective electric ER1 relay.
Check electric ER1 relay, located in the Electric
Standby power pack.
Defective Starter Assembly.
Check SR relay starter as well as CR and CS
condensers.
Discharge pressure is above
HPCO value or the Low
Pressure Cut-Out switch is
open.
Verify that the discharge pressure is below the
HPCO value and that the LPCO is closed.
(12/07)
5 - 34
Section 5 - Diagnostics
UNIT NOT COOLING - ELECTRIC STANDBY POWER (B-100 20 only) (continued)
Symptom
Cause
Corrective Action
AC motor fails to run.
(continued).
Defective CMC Compressor
Motor Contactor.
Check CMC circuit wiring and connections, replace
contactor, if necessary.
Defective microprocessor or
printed circuit board(s).
Replace PCB. Setup replacement printed circuit
board in accordance with Service Procedure A04A.
Defective AC motor.
Determine if AC motor is defective and replace, if
necessary. Use procedure shown in Direct Drive
Units (DSR) Maintenance Manual TK
52979-18-BD. Chapter B-100 10/20
Electric Standby motor
overload relay OLR has
tripped.
Turn unit off, allow overload relay to cool and turn
unit back on to reset overload relay. Check Electric
Standby motor operation to determine cause for
overload relay tripping.
AC motor runs, but
Refrigeration system problem.
unit fails to refrigerate.
Check return air temperature sensors and setpoint,
refrigerant level, evaporator and condenser for
obstructions or non-operating valves.
Faulty compressor.
Determine if compressor is defective. Replace, if
necessary. Use procedure shown in the Direct
Drive Units (DSR) Maintenance Manual TK
52979-18-BD. Chapter B-100 10/20
Defective DC power supply.
Check brushes and replace, if applicable.
Determine if DC power supply is defective and
replace, if necessary. Use procedure shown in
Direct Drive Units (DSR) Maintenance Manual TK
52979-18-BD. Chapter B-100 10/20
DC power belt incorrectly
mounted or defective.
Test DC power supply belt and replace, if
necessary. Use procedure shown in Direct Drive
Units (DSR) Maintenance Manual TK
52979-18-BD. Chapter B-100 10/20
UNIT WILL NOT DEFROST - ELECTRIC STANDBY POWER (B-100 20 only)
Symptom
Cause
Corrective Action
Unit does not defrost.
Power cord not plugged in or
unit not turned on.
Connect the power cord and turn the unit on.
(12/07)
5 - 35
Section 5 - Diagnostics
UNIT WILL NOT DEFROST - ELECTRIC STANDBY POWER (B-100 20 only) (continued)
Symptom
Cause
Corrective Action
Unit does not defrost
(continued).
Initiate a manual defrost cycle
using the Select and Enter
Keys.
Press the Select key until [dEF] is briefly displayed
on screen. The defrost icon should appear.
Accordingly, press the Enter key, then the Up or
Down arrow key, to change settings. This will
change the defrost setting in 1-degree Celsius
increments.
Defrost Initiation Time [dit] is
not set or set incorrectly.
In the Installation (Guarded Access) Menu, scroll to
the [dit] parameter screen. Check if setting (factory
default = 240 minutes) is too short or too long
between defrost initiation cycles. Change the time
setting, as required.
Defrost klixon (DK) wire 12 is Check wiring and terminals. Make sure the DK
not connected to ECM (pin C1, cable 12 is securely connected.
connector C-1)
Compressor is
running; hot gas
solenoid is not
energised.
(12/07)
Klixon DK is defective
Replace klixon DK.
AC/DC SMPS power supply
does not operate.
Check voltage between AC/DC SMPS power
supply V+ and V- posts (12 VDC for 12V units, 24
VDC for 24V units). Replace power supply, if
necessary. Check for short circuit between X1, X4,
2RB wires and chassis. AC/DC SMPS power
supply has an auto-protection mechanism that
turns off supply in case of short circuit or overload.
Defective microprocessor in
PBC 1.
Replace PCB 1.
Hot gas solenoid F5 fuse
blown.
Check host hot gas solenoid F5 fuse on PCB 1.
Check hot gas solenoid coil for short circuit to
ground.
Open hot gas solenoid coil.
Check gas solenoid coil continuity. See Service
Procedure H04A.
Defective hot gas solenoid.
Check hot gas solenoid PS1 (host) for proper
operation.
5 - 36
Section 5 - Diagnostics
UNIT WILL NOT DEFROST - ELECTRIC STANDBY POWER (B-100 20 only) (continued)
Symptom
Cause
Corrective Action
Compressor is
Loose or defective 26 circuit to Check circuit 26 to the hot gas solenoid, PS1 (on
running; hot gas
hot gas solenoid.
PCB 1).
solenoid is not
energised (continued).
Compressor is
running, hot gas valve
is energised, but unit
is not defrosting.
Refrigerant system problem.
Check refrigerant system.
Evaporator fan is locked in ON Check EFM evaporator fan operating hours. Check
position.
[EFc] evaporator fan constant blow parameter at
the Installation (Guarded Access) Menu. Change
the parameter setting On to Off, which causes the
evaporator fan to change the operation of Cool,
Heat, and Null modes.
CONDENSER FAN WILL NOT OPERATE - ELECTRIC STANDBY POWER (B-100 20 only)
The unit is equipped with 1 condenser fan. The fan runs in cooling mode when the condenser fan pressure
switch is closed.
Symptom
Cause
Corrective Action
Condenser fan should
be running but is not.
Power cord not plugged in or
unit not turned on.
Connect the power cord and turn the unit on. Make
sure conditions require condenser fans to be
operating.
Discharge pressure is greater
than CFP (180 psi) but fan is
not energised.
Enter cab control information Menu and display HP
value; test that pressure reading is correct, using
gauge. Check refrigeration system and replace high
pressure transducer, if applicable.
AC/DC SMPS power supply
does not operate.
Check voltage between AC/DC SMPS power
supply V+ and V- posts (12 VDC for 12V units, 24
VDC for 24V units). Replace power supply, if
necessary. Check for short circuit between X1, X4,
2RB wires and chassis. AC/DC SMPS power
supply has an auto-protection mechanism that
turns off supply in case of short circuit or overload.
(12/07)
5 - 37
Section 5 - Diagnostics
CONDENSER FAN WILL NOT OPERATE - ELECTRIC STANDBY POWER (B-100 20 only) (continued)
The unit is equipped with 1 condenser fan. The fan runs in cooling mode when the condenser fan pressure
switch is closed.
Symptom
Cause
Corrective Action
Condenser fan should
be running but is not
(continued).
Defective RY6 condenser fan
relay on PCB 1. (See unit
wiring diagram for the correct
relay number or see System
Relays table in Section 2.)
Replace PCB 1.
Defective microprocessor.
Replace PCB 1.
Condenser fan F2 fuse blown Check PCB 1 15A/12V or 10A/24V condenser fan
on PCB1. See electric
F2 fuse, respectively. Test Electric Standby
schematic for the unit or Sizes condenser fan motor for short circuit to ground.
and description of fuses
located on printed circuit board
1 (PCB1) or printed circuit
board 2 (PDB 2) table in
Section 2.
Condenser fan motor capacitor Check continuity of condenser fan Electric Standby
circuit open.
motors. See Service Procedure H04A.
Defective wiring harness or
loose CF1 circuit connectors.
Check CF1 circuit wiring and connections.
Defective DC power supply.
Check brushes and replace, if applicable.
Determine if DC power supply is defective and
replace, if necessary. Use procedure shown in
Direct Drive Units (DSR) Maintenance Manual TK
52979-18-BD. Chapter B-100 10/20
DC power belt incorrectly
mounted or defective.
Test DC power supply belt and replace, if
necessary. Use procedure shown in Direct Drive
Units (DSR) Maintenance Manual TK
52979-18-BD. Chapter B-100 10/20
EVAPORATOR FAN WILL NOT OPERATE - ELECTRIC STANDBY POWER (B-100 20 only)
Symptom
Cause
Corrective Action
Evaporator fan should
be running but is not.
Power cord not plugged in or
unit not turned on.
Connect the power cord and turn the unit on.
Make sure conditions require condenser fans to be
operating.
(12/07)
5 - 38
Section 5 - Diagnostics
EVAPORATOR FAN WILL NOT OPERATE - ELECTRIC STANDBY POWER (B-100 20 only) (continued)
Symptom
Cause
Corrective Action
Evaporator fan should
be running but is not
(continued).
AC/DC SMPS power supply
does not operate.
Check voltage between AC/DC SMPS power
supply V+ and V- posts (12 VDC for 12V units, 24
VDC for 24V units). Replace power supply, if
necessary. Check for short circuit between X1, X4,
2RB wires and chassis. AC/DC SMPS power
supply has an auto-protection mechanism that
turns off supply in case of short circuit or overload.
Defective wiring harness or a
loose EFM circuit connector
Check EFM circuit wiring and connections
Defective evaporator fan relay
on PCB 1.
Replace PCB 1.
Evaporator fan F3 fuse blown
on PCB1.
Check 15A/12V or 10A/24V evaporator fan F3 fuse,
located on the printed circuit board. Check EFM
evaporator fan Electric Standby motor for short
circuit to ground.
Electric Standby evaporator
fan motor open.
Check Electric Standby evaporator fan motor
continuity. See Service Procedure H04A.
Loose or defective EFM circuit Check evaporator fan Electric Standby EFM circuit.
to Electric Standby evaporator
fan motor.
(12/07)
Defective microprocessor.
Replace PCB 1.
Defective DC power supply.
Check brushes and replace, if applicable.
Determine if DC power supply is defective and
replace, if necessary. Use procedure shown in
Direct Drive Units (DSR) Maintenance Manual TK
52979-18-BD. Chapter B-100 10/20
DC power belt incorrectly
mounted or defective.
Test DC power supply belt and replace, if
necessary. Use procedure shown in Direct Drive
Units (DSR) Maintenance Manual TK
52979-18-BD. Chapter B-100 10/20
5 - 39
Section 5 - Diagnostics
IN-CAB AIR CONDITIONING DOES NOT WORK (V-500 AC only)
Symptom
Cause
Corrective Action
In-cab air conditioning Vehicle not running or unit not
does not cool.
turned on.
Start vehicle and turn unit on.
Unit is working in electric
mode.
AC option is only operational in highway mode.
In-cab air conditioning fan
speed not selected.
Select a fan speed using the truck selector.
AC system liquid solenoid
valve not enabled.
Check the F8 fuse located in PCB2. Check the
wiring (33A) between the PCB2 board (C-1,9) and
the PS6 solenoid valve.
The PCB1 board receives no
signal through the AC-SW
wire.
Check the wiring and that the DSR microprocessor
is properly connected to the truck’s AC module.
The microprocessor has been
programmed for the wrong
unit.
Check the DSR microprocessor parameters. As
necessary, reprogram the microprocessor by using
Maintenance Procedure A04A.
Regulation of the AC system
KVP and KVL valves is
incorrect.
Regulate the valves as described in Installation
Manual TK 60084-ML-18-IM and in the
Maintenance Chapter of the V-500 AC 10/20.
Vehicle’s AC module is
defective.
Have an official brand dealer check the vehicle.
Symptom
Cause
Corrective Action
Intermittent or erratic
operation of the
microprocessor.
Loose printed circuit board
connectors C-1 and/or C-2.
Check the C-1 and/or C-2 connectors on PCB 1
an/or PCB 2 to be sure that they are attached
securely.
Defective wiring harness.
Check wiring harness for damage. Verify all
connections are secure.
ERRATIC OPERATION
(12/07)
5 - 40
Section 5 - Diagnostics
ERRATIC OPERATION (continued)
Symptom
Cause
Corrective Action
Intermittent or erratic
operation of the
microprocessor
(continued).
Loose or broken ground wires
or connections.
Check all ground wires and connections. A
common ground point is located next to the ECM.
Defective microprocessor or
printed circuit board(s)
Replace the In-cab Control Box or PCB1 and/or
PCB 2.
(12/07)
5 - 41
Section 5 - Diagnostics
(12/07)
5 - 42
Section 6
Service Procedures
MICROPROCESSOR PROCEDURES
Number
A02A
A04A
A12A
A26A
A28A
Procedure Title
Recording Existing Microprocessor Settings
Microprocessor Setup
ESD (Electrostatic Discharge) Procedures
Welding on Units Equipped with Microprocessors
Setting Unit Running Time Hourmeters
PRINTED CIRCUIT BOARD PROCEDURES
Number
B02A
Procedure Title
Printed Circuit Board Removal and Replacement
MISCELLANEOUS PROCEDURES
Number
D01A
F06A
H02A
H04A
UH09A
Procedure Title
Return Air Temperature Sensor Test
3 Wire Magnetic Door Switch
Deutsch Connector Repair using Pigtail
Checking Harness Continuity
Removal and Replacement of the Filter or Fan in an Electronic Control Module
Service Procedure A02A
Recording Existing Microprocessor Settings
Where Used
All units equipped with DSR µP Controller microprocessors and Revision 121 21 and 273 XX
software.
Purpose
This procedure should be used to retrieve and record the current settings of a microprocessor. These
settings will then be duplicated in the replacement microprocessor. This must be done prior to
replacement of a microprocessor.
STEP
ACTION
RESULTS
NOTE: It may not be possible
1
2
3
4
5
6
7
8
9
10
11
12
13
14
COMMENTS
to accomplish part or all of this
process with a defective
microprocessor. If not, the
information must be obtained
from customer records.
This copy will be used to
record the information as it is
retrieved.
Obtain a copy of the Setup
Sheet at the end of this
procedure.
Turn the unit on.
The Standard Display appears
on the In-cab Control Box.
Press the Select key once.
The Manual Defrost [dEF]
screen appears.
Press the Select key.
The Setpoint 1 [SP] screen
appears.
Press the Select key.
The Setpoint 2 [SP2] screen
appears.
Press the Select key.
The display returns to the
Standard Display.
Press and hold the Select key The first Hourmeters Menu
for 3 seconds.
screen, Remaining Hours
[HC] appears.
Press the Select key.
The Total Hours [tH] screen
appears.
Press the Select key.
Vehicle compressor hours or
in battery mode for B-100 unit
[CC] display appears.
Press the Select key.
Electric Standby compressor
hours or in Electric Standby
mode for B-100 20 unit [EC]
display appears.
Press the Select key.
The display returns to the
Standard Display.
Press and hold the Up Arrow The Display Test (all icons)
and Enter keys for 3 seconds. screen of the Information
Menu appears.
The Software Revision screen
[121 XX or 273 XX] appears.
1
Record the Manual Defrost
setting on the Setup Sheet.
Record the Setpoint 1 setting
on the Setup Sheet.
Record the Setpoint 2 setting
on the Setup Sheet.
Record the [HC] setting on the
Setup Sheet.
Record the [tH] setting on the
Setup Sheet.
Record the [CC] setting on the
Setup Sheet.
Record the [EC] setting on the
Setup Sheet.
Record the [121 XX or 273
XX] setting on the Setup
Sheet.
P41PA02A - 12/06
Service Procedure A02A
STEP
ACTION
15
16
17
18
19
20
Press and hold the Down
Arrow and Enter keys for
3 seconds.
21
NOTE: In some software
versions, the setpoint
temperature [SP] appears
first.
Press the Down key.
22
Press the Down key.
23
Press the Down key.
24
Press the Down key.
25
Press the Down key.
26
Press the Down key.
27
Press the Down key.
28
Press the Down key.
29
Press the Down key.
30
Press the Down key.
31
Press the Down key.
P41PA02A - 12/06
RESULTS
COMMENTS
The Refrigerant Type [134] or
[404] screen appears.
The Battery Voltage [bAt]
screen appears.
The High Pressure [HP]
screen appears.
The Compartments / Unit
Type [xC/ tyy] screen appears.
The display returns to the
Standard Display.
The Setpoints Differential [diF]
parameter screen of the
Installation (Guarded Access)
Menu appears.
Record the [134] or [404]
setting on the Setup Sheet.
Record the [bAt] setting on the
Setup Sheet.
Record the [HP] setting on the
Setup Sheet.
Record the [xC / tyy] setting
on the Setup Sheet.
The Soft Start Cycles [SSC]
parameter screen appears.
The Defrost Initiation Timer
[dit] parameter screen
appears.
The Defrost Termination Timer
[dtt] parameter screen
appears.
The Evaporator Fans
Constant Blow [EFc]
parameter screen appears.
The Out-of-Range Alarm
[dAL] parameter screen
appears.
The Hour Counter Initial Value
[HC] parameter screen
appears.
The Door Switches
Present/Polarity [dSP]
parameter screen appears.
The Buzzer Enable [bE]
parameter screen appears.
The Thermostat Units [bu]
parameter screen appears.
The Pressure Units [Pu]
parameter screen appears.
The display returns to the
Standard Display.
2
Record the [diF] setting on the
Setup Sheet.
Record the [SSC] setting on
the Setup Sheet.
Record the [dit] setting on the
Setup Sheet.
Record the [dtt] setting on the
Setup Sheet.
Record the [EFc] setting on
the Setup Sheet.
Record the [dAL] setting on
the Setup Sheet.
Record the [HC] setting on the
Setup Sheet.
Record the [dSP] setting on
the Setup Sheet.
Record the [bE] setting on the
Setup Sheet.
Record the [bu] setting on the
Setup Sheet.
Record the [Pu] setting on the
Setup Sheet.
All current microprocessor
settings have been retrieved
and recorded.
Service Procedure A02A
SETUP SHEET
SOFTWARE REVISION
ACCESS KEY
FUNCTION
STANDARD SETTING
RECORDED SETTING
Press "Up Arrow" +
"Enter" and hold for
3 seconds.
Software Revision
appears automatically
when Display Check is
finished
Display Check
---
---
[121 xx, 273 xx]
Software Revision
HOURMETERS ACCESS
ACCESS KEY
FUNCTION
Press and hold "Select" key
for 3 seconds
"Select"
"Select"
"Select"
"Select"
Hourmeters Menu
STANDARD SETTING
[HC]
[tH]
[CC]
[EC]
accumulated hours
accumulated hours
accumulated hours
accumulated hours
ACCESS KEY
FUNCTION
STANDARD SETTING
Press "Up Arrow + "Enter"
and hold for 3 seconds
Information Menu
RECORDED SETTING
INFORMATION MENU
[all icons]
[121 xx, 273 xx]
[134] or [404]
RECORDED SETTING
----134 (for R-134a) or
404 (for R-404A)
Measured voltage
(0-30V)
Measured pressure
(0 to 500 PSIG)
x for the number of
compartments;
yy for unit type
[bAt]
[HP]
[xC / tyy]
INSTALLATION (GUARDED ACCESS) MENU
ACCESS KEY
FUNCTION
Press and hold "Down
Arrow" + "Enter" for
3 seconds
"Down"
"Down"
"Down"
"Down"
"Down"
"Down"
Installation Menu
STANDARD SETTING RECORDED SETTING
[diF]
[SSC]
[dit]
[dtt]
[EFc]
[dAL]
3 Celsius
Off
240
45 (30 in B-100 only)
Off
0
3
P41PA02A - 12/06
Service Procedure A02A
INSTALLATION (GUARDED ACCESS) MENU
ACCESS KEY
FUNCTION
"Down"
"Down"
"Down"
[dSP]
[HC]
[bE]
"Down"
"Down"
[tu]
[Pu]
P41PA02A - 12/06
STANDARD SETTING RECORDED SETTING
1 (normally open)
150 [ = 1500 hours]
2 (enabled and when
pressed)
C (Celsius)
P (PSI)
4
Service Procedure A04A
Microprocessor Setup (Programming the DSR Microprocessor)
Where
All units equipped with a DSR μP Controller microprocessor and revision 121 21 and 273 XX software.
Purpose
This procedure is used to program a DSR microprocessor.
Required Tools
• A PC computer loaded with Wintrac 4.xx software
• Configuration files (downloaded from the Thermo King Information Central Intranet site)
• DSR interface cable, P/N 204-1126
For complete details of programmable features, see Section 3 of this manual.
STEP
1
2
3
4
5
6
ACTION
RESULTS
COMMENTS
Uploading the DSR Controller Software Files
Obtain a completed copy of the
This information on this Setup
Setup Sheet created with
Sheet will be used to set up the
Service Procedure A02A.
DSR microprocessor.
At the PC computer, make sure
Refer to the computer’s system
that decimal point is set correctly
operators manual for guidance.
for the "Regional Settings" of
Windows.
Access the Thermo King
Information Central Intranet site
by accessing
<www.thermoking.com\iService>
At infoCentral, access the
Wintrac files by accessing the
following path: European Served
Area>TK Products>Direct Drive
Units>Wintrac files for Direct
Smart Reefer
At the DSR, disconnect the
In-cab Control Box from its cable
connector.
Connect cable 204-1126 to the
In-cab Control Box and to the
computer serial port:
• Connect the small connector
on cable 204-1126 to the
computer serial port.
• Connect the large connector
on cable 204-1126 to the
In-cab cable connector.
1
P41PA04A - 10/08
Service Procedure A04A
STEP
7
8
9
ACTION
RESULTS
Power-up the truck ignition key
or connect the DSR unit to a
standby power source. (The
DSR controller must have a
source of electrical power, in
order to be programmed).
Run the Wintrac software
program
At the Wintrac screen, click on
the Seek Device icon (the truck
graphic)
10
The Communicating screen
appears.
11
Within a few seconds, the VPRS
Controller Settings screen
appears. It displays a table of the
microprocessor configuration
parameters. See the adjacent
illustration.
P41PA04A - 10/08
2
COMMENTS
Service Procedure A04A
STEP
ACTION
12
Click the restore button at the
bottom of the screen.
13
Select the correct file for the unit
and click Open.
14
Click "Yes" when the
confirmation window appears.
15
16
Close Wintrac.
Switch the truck ignition key to
Off or turn off power to the
standby electric power source
17
Turn the unit On/Off switch to
On. Go to the Information Menu
and check if the microprocessor
controller has been correctly
modified.
RESULTS
COMMENTS
A Windows browser appears to
choose the unit file.
The parameters in the DSR
controller are updated.
3
P41PA04A - 10/08
Service Procedure A04A
STEP
1
ACTION
RESULTS
COMMENTS
Saving Parameter Files
To save a file and its parameter settings, in order to upload it to other units with the identical
configuration, perform the following:
Set the parameter as required.
See the adjacent illustration.
2
Click the Save button.
3
The adjacent error message
might appear.
4
If the error message appears,
check the following:
• Check that the DSR controller
is receiving electrical power
• Check that jumpers 1 and 2,
inside the converter, are set
as shown in the adjacent
illustration (see Service
Bulletin 739-G-04 for
additional information).
P41PA04A - 10/08
To upload the file, follow steps 11
through 17 in Uploading the
DSR Controller Software Files.
4
Service Procedure A12A
ESD (Electrostatic Discharge) Procedure
Where Used:
All solid state applications.
Purpose:
To prevent ESD (electrostatic discharge) damage while working on a microprocessor. ESD (electrostatic discharge) is an invisible enemy which can only be counteracted by using good procedures.
Failure to follow stated procedures may result in electronic component failure. Additional information
may be found in the ELECTRO STATIC DISCHARGE (ESD) TRAINING GUIDE TK40282.
STEP
ACTION
1
Obtain and use a wrist strap
when handling a
microprocessor that is not
connected to the unit via the
plugs or is not in an anti-static
bag.
2
Store and ship
microprocessors in the
anti-static bags and protective
packaging.
3
Assume that if these steps are
not followed that damage will
be done to the microprocessor.
RESULTS
COMMENTS
Service Part 204-622. Refer to
ESD Training Guide TK 40282.
1
P41PA12A - 04/05
Service Procedure A12A
THIS PAGE IS INTENTIONALLY BLANK
P41PA12A - 04/05
2
Service Procedure A26A
Welding on Units Equipped with Microprocessors
Where Used
All units equipped with DSR µP Controller microprocessors.
Purpose
To prevent damage to the microprocessor during welding operations. Electric welding generates
extremely high amperage currents which can damage electrical and electronic components. In order to
minimize the possibility of damage the following procedures must be followed.
STEP
ACTION
RESULTS
COMMENTS
Before Welding
1
2
3
4
1
2
3
Turn the unit off.
Disconnect Electric Standby
power, if connected.
Remove the negative battery
cable.
Connect the welder ground
cable as close as possible to the
area where the welding is to be
performed. Move the welder
ground cable, as required.
After Welding is Completed
Reconnect the battery cable.
Connect standby power, if
necessary.
Turn the unit on.
The Standard Display should
appear.
1
P41PA26A - 04/05
Service Procedure A26A
THIS PAGE IS INTENTIONALLY BLANK
P41PA26A - 04/05
2
Service Procedure A28A
Setting Unit Running Time Hourmeters
Where used
All new replacement DSR µP Controller microprocessors only.
Purpose
This procedure should be followed to set the unit running time hourmeters for [HC] (Remaining Hours
Counter).
Setting Hourmeters
STEP
ACTION
RESULTS
COMMENTS
This information on this copy will
be used to set up the
hourmeters.
1
Obtain a completed copy of the
Setup Sheet, shown in Service
Procedure A02A, Recording
Existing Microprocessor
Settings.
2
Turn the unit on.
3
At the Standard Display, press
and hold the Select key for
3 seconds. The first Hourmeters
Menu screen, [HC], appears.
4
Press the Enter key to select the If necessary, change the flashing To reset [HC] and remove the
hourmeter. The two left digits are digit to 0 through 5000, using the service symbol, repeat steps 1 to
3 above.
displayed and the digit on the far Up or Down arrow keys.
left flashes.
5
Press the Enter key to load the The display briefly shows [Lod]
and then the new setting
new value. If no number is
appears.
shown on the Setup Sheet,
consult the customer for a record
of hours that are desired or
recommended before a
maintenance procedure
(inspection, part replacement,
test, etc.) is performed.
The Standard Display appears.
NOTE: To reset the HC symbol from the display, follow steps 3 to 5 only.
1
P41PA28A - 04/05
Service Procedure A28A
THIS PAGE INTENTIONALLY LEFT BLANK
P41PA28A - 04/05
2
Service Procedure B02A
Printed Circuit Board Removal and Replacement
Where Used
All units equipped with DSR μP Controller microprocessors.
Purpose
This procedure should be followed when replacing PCB 1 and /or PCB 2.
STEP
ACTION
1
2
Turn the vehicle ignition off.
Disconnect standby power, if
connected.
Wear an ESD wrist strap.
Connect the lead from the wrist
strap to the unit chassis ground.
RESULTS
COMMENTS
PCB Removal
3
4
5
Proper Electro Static Discharge
procedures must be followed.
See Service Procedure A12A,
ESD (Electrostatic Discharge)
Procedure.
Remove the wiring harness
receptacles from connector C-1
and C-2 on the printed circuit
board(s).
B-100 units: Remove the two
screws 1 that secure the ECM
enclosure to the unit. Remove
ECM from the unit.
1
P41PB02A - 10/08
Service Procedure B02A
STEP
ACTION
6
For V-100 10/30, V-200 and
V-300 units: Remove the three
screws that secure the ECM
enclosure to the unit. Remove
the ECM from the unit.
7
For V-100 20/50: Remove the
routing guide support plate (1)
from the unit by removing the
two bolts that secure the plate to
the unit chassis.
Remove the electric box support
plate (2) from the unit by
removing the three nuts that
secure the plate to the unit
chassis. Remove the ECM from
the unit.
P41PB02A - 10/08
RESULTS
COMMENTS
Service Procedure B02A
STEP
ACTION
8
For V-400/V-500 units: Remove
the three screws that secure the
ECM enclosure to the unit.
Remove the ECM from the unit.
9
Remove the six screws and the
cover from the ECM enclosure.
10
For a Platform 2, remove the
four screws that secure PCB 2 to
the standoffs attached to PCB 1.
Remove PCB 2 from the ECM.
Remove the six screws that
secure PCB 1 to the ECM
enclosure.
Remove PCB 1 from the ECM
enclosure.
11
12
13
RESULTS
COMMENTS
Printed circuit board PCB1 On
Platform 1), or PCB 1 and PCB2
(for Platform 2), are exposed.
PCB Replacement
1
2
3
Position the replacement PCB 1
in the enclosure.
Install the six screws that secure
PCB 1 to the ECM enclosure.
For a Platform 2, install the four
screws that secure PCB 2 to the
standoffs attached to PCB 1.
3
P41PB02A - 10/08
Service Procedure B02A
STEP
4
5
6
7
8
9
10
11
12
13
14
ACTION
RESULTS
Connect the cable that connects
the fan to PCB1.
Position the cover of the ECM
over the printed circuit board(s).
Insert the six screws and tighten.
Connect the power wire to the
screw terminal of PCB 1.
Connect the wire harness
receptacles to connectors C-1
and C-2 of PCB 1 and/or PCB 2.
Place the ECM in the unit. Install
the three screws that secure the
ECM enclosure to the unit.
Remove the ESD wrist strap.
Reconnect the Electric Standby
power, if needed.
Start the unit.
The Standard Display should
appear.
Operate the unit, as required, to
confirm proper operation.
Replace the cover on the ECM
enclosure. Be sure and route the
power wire and In-cab Control
Box cable through the provisions
on the cover.
Route harnesses, as required,
and replace any tie bands that
were removed.
P41PB02A - 10/08
COMMENTS
Be sure no wires or cables are
pinched in the cover.
Service Procedure D01A
Return Air Temperature Sensor Test
Where Used
All DSR µP Controller microprocessors and other solid state controller applications.
Purpose
This procedure is used to confirm the proper operation of Return Air Temperature sensor 1 (Sensor 1),
located in the single or main load compartment, and Return Air Temperature sensor 2 (Sensor 2),
located in the remote load compartment of multi-temp vehicles.
STEP
ACTION
RESULTS
COMMENTS
NOTE: Polarity must be considered when temperature sensors are connected. If the sensors are
connected backwards, the In-cab Control Box display shows [----]. Consult the schematic diagram or
wiring diagram for the unit for the correct connections.
1
2
3
Use the On/Off button on the
In-cab Control Box to turn the
unit off.
Disconnect the applicable
Return Air Temperature sensor
at the plug next to the sensor.
Use the On/Off button on the
In-cab Control Box to turn the
unit on.
1
P41PD01A - 04/05
Service Procedure D01A
STEP
ACTION
RESULTS
4
Check the Standard Display for
the temperature in the main or
remote load compartment.
5
Using a high quality digital
multimeter, check the voltage at
the sensor plug, on the sensor
half of the wire that is still
connected to the printed circuit
board.
If the voltage measured in Step 5 The voltage must be between
is incorrect, check the voltage at 4.90 Vdc and 5.10 Vdc.
the sensor connector at the
ECM, at the following connector
locations:
6
7
Sensor 1 = Printed Circuit Board
1 at connector C-1, pin A4, and
C-1, pin B4.
Sensor 2 = Printed Circuit Board
2 at connector C-1, pin 3, and
C-1, pin 4.
Completely disconnect the
return air temperature sensor
from the ECM. Check the
resistance between wires PNK
and BLK.
P41PD01A - 04/05
COMMENTS
The display should show [----],
meaning that the applicable
Return Air Temperature sensor
(Sensor 1 in the main load
compartment, or Sensor 2 in the
remote load compartment) is
disconnected.
The voltage must be between
If the voltage is correct, replace
4.90 Vdc and 5.10 Vdc.
the sensor.
Depending on the ambient
temperature, the resistance
should be what is indicated in
the Temperature vs. Operating
Mode Chart in Section 3,
Software Description.
2
If the voltage is correct at Step 6,
but incorrect at Step 5, the
problem is in the wiring.
If the voltage is incorrect at
Step 5 and Step 6, the problem
is in the microprocessor.
• If the resistance is OK, and
step 6 is OK, the problem is in
the wiring.
• If the wiring is OK, replace the
return air temperature sensor.
Service Procedure F06A
3 Wire Magnetic Door Switch
Where Used
All 3-wire magnetic door switch applications
Purpose
This information is used to install and wire the 3-wire magnetic door switch.
Door Switch
Magnet
Black = GND = CH wire
White = Output = DS wire
Red = Source of +12V
This distance to be
no more than 19 mm
IMPORTANT INFORMATION: +12 volts is connected to the red wire, and chassis ground is connected
to the black wire, to energize the door switch. When the door is closed no voltage is present on the
white DS wire to the microprocessor. When the door is open +12 volts is present on the white DS wire
to inform the microprocessor that the door is open. The magnet should be no more than 19 mm from the
door switch when the door switch is closed.
1
P41PF06A - 04/05
Service Procedure F06A
Document Control
REVISIONS
Any changes must be verified with all WHERE USED documents to insure correctness.
Date
By
Changes
12/12/96
CA
Original
17/04/05
PAF
English measurements deleted; metric only used for DSR µP Controller microprocessor
application
I41PF06A - 04/05
2
Service Procedure H02A
Deutsch Connector Repair Using Pigtail
Where Used
All units equipped with DSR µP Controller microprocessors.
Purpose
This procedure should be used to repair a broken pin in any of the Deutsch connectors used on the unit.
The service part numbers are shown below.
Deutsch Connectors
Male DEUTSCH pin with pigtail
44-9701
Female DEUTSCH pin with pigtail 44-9700
Repairing Deutsch Connectors
STEP
ACTION
1
Identify the defective pin and
determine if it is male or female.
Obtain the required replacement
pin.
Using a Deutsch Tool (Service
Part Number 204-799), remove
the orange locking wedge from
the front of the connector shell.
Using the Deutsch Tool release
the locking tab in the shell of the
connector and remove the pin.
Cut the wire leading to the
defective pin as close to the pin
as possible.
2
3
4
5
RESULTS
1
COMMENTS
P41PH02A - 04/05
Service Procedure H02A
STEP
ACTION
6
Insert the replacement pin with
short lead into the connector
from the back of the shell.
Check to be sure the pin is fully
seated and locked in the shell.
Re-install the orange locking
wedge from the front side of the
connector shell.
Insert the shrink tubing over the
harness wire and position it far
enough away from the joint that
it does not shrink prematurely
when soldering.
Carefully strip 13 mm of
insulation from the end of the pin
wire and the matching harness
wire.
Twist the ends of the wire
together to create a compact,
mechanically strong connection.
Using a small soldering iron,
solder the connection using rosin
core solder.
Position the shrink tubing over
the connection.
Shrink the tubing in place using
the small soldering iron.
7
8
9
10
11
12
13
14
15
16
RESULTS
See Figure 1.
Trim wire lengths, as required, to
properly fit harness.
See Figure 2.
See Figure 3.
See Figure 4.
See Figure 5.
The connection may be
additionally insulated with
electrical tape, if necessary.
Reinstall the connector on the
mating connector.
Carefully position the harness
and replace any cable ties
removed or missing.
P41PH02A - 04/05
COMMENTS
2
Service Procedure H02A
3
P41PH02A - 04/05
Service Procedure H02A
THIS PAGE IS INTENTIONALLY BLANK
P41PH02A - 04/05
4
Service Procedure H04A
Checking Harness Continuity
Where Used
All DSR µP Controller microprocessors and other solid state controller applications.
Purpose
To illustrate the correct procedures for checking harness continuity on equipment utilizing solid state
devices.
STEP
ACTION
RESULTS
COMMENTS
CAUTION STATEMENTS
1
Do not use battery and light
combinations to check continuity.
2
Use a high quality digital
multimeter such as that
illustrated or an analog meter
with high input impedance.
3
Do not test a circuit to see if it is
energized by tapping the circuit
wire to ground and watching for
a spark.
Using such devices might
present excessive voltage or
current to solid state devices. In
most cases the device will be
damaged or destroyed.
Older analog (needle type meter
movement) meters and some
inexpensive “mechanic tool box”
meters present a large load to
the circuit being tested. This can
significantly alter the meter
reading, especially when
measuring small voltages or
currents.
This will damage solid state
components or blow a fuse.
1
P41PH04A - 04/05
Service Procedure H04A
STEP
ACTION
4
Always wear a grounded wrist
strap when working on exposed
solid state circuits (such as
changing a software IC).
RESULTS
COMMENTS
Failure to use a grounded wrist
strap and/or failure to observe
other ESD (Electrostatic
Discharge) procedures can
result in damage to solid state
components. This damage might
not be immediately noticeable.
See Service Procedure A12A
ESD (Electrostatic Discharge)
Procedure for additional
information on ESD procedures.
GENERAL PROCEDURES
1
2
3
4
Locate the suspect circuit on the
appropriate wiring diagram.
Isolate both ends of the circuit
using the following methods, as
required.
• Disconnect the appropriate
connector at the interface
module.
• Disconnect the device
connector at the device.
• Remove the wire from the
device terminal.
Using jumpers as required,
The meter must show a very low
connect each end of the circuit to resistance (less than 1.0 ohm),
a high quality multimeter.
indicating circuit continuity. If not,
the circuit is open or has
excessive resistance.
Troubleshoot the circuit to
determine the cause using the
wiring diagrams.
After determining that the circuit The meter should indicate an
passes a continuity test, remove open circuit. If continuity is
indicated, the circuit is shorted to
one lead and connect it to
ground. Troubleshoot the circuit
chassis ground to check for a
to determine the cause of the
short to ground.
short using the wiring diagrams.
P41PH04A - 04/05
2
Harness connections might be
determined by consulting the
wiring diagrams.
CAUTION: Failure to isolate
both ends might cause
misleading results.
Be certain the ohmmeter battery
is good and the meter zeros with
the leads held together.
Service Procedure UH09A
Removal and Replacement of the Filter or Fan in an Electronic
Control Module
Where Used
All units equipped with a DSR µP Controller Electronic Control Module (ECM).
Purpose
1. To replace a filter on the ECM enclosure.
2. To replace the ECM fan.
Equipment and Parts Required
• Fan, 40x40x10, DC Co-Axial, TK service code 415480
• Filter, Fan, 40x40, TK service code 923472
• Electrostatic discharge (ESD) strap
• Screwdriver with a plastic handle
Procedure - Removing and Replacing the Filter
STEP
ACTION
RESULTS
COMMENTS
Removal
1
2
3
4
5
6
7
1
2
3
4
5
6
Press the On/Off button the In-cab Control
Box to off.
Disconnect Electric Standby power, if
connected.
Open the unit and locate the ECM.
Remove the six screws that attach the fuse
access cover to the front cover.
Lift the fuse access cover and set it aside.
Remove the four screws that attach the filter
to the fan housing.
Remove the filter and discard it.
Replacement
Position the replacement filter over the fan
housing.
Position the fuse access cover over the filter
and the front cover.
Install the four screws that attach the fuse
access cover to the front cover.
Close the unit.
Turn Elecric Standby power on, if applicable.
Turn the On/Off button the In-cab Control Box
to On.
1
P41UH09A - 04/05
Service Procedure UH09A
Procedure - Removing and Replacing the Fan
STEP
ACTION
RESULTS
COMMENTS
Removal
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
Turn the On/Off button the In-cab
Control Box to off.
Disconnect Electric Standby power,
if connected.
Open the unit and locate the ECM.
Remove the six screws that attach
the fuse access cover to the front
cover.
Remove the fuse access cover and
set it aside.
Remove the four screws that attach
the filter to the fan housing.
Remove the filter and set it aside.
Place an ESD strap on your wrist.
Make sure that the ESD strap
is connected to an ESD mat
or to ground.
Disconnect the fan cable receptacle
from connector CN6-1 on PCB 1
(Platform 1).
Remove the fan and its cable from
the ECM enclosure.
Replacement
Position the replacement fan
assembly over the ECM. Route the
fan cable through the opening in the
front cover.
Make sure the fan screw holes are
aligned with the ECM front cover.
While wearing an ESD strap,
connect the fan cable receptacle to
connector CN6-1 on PCB 1.
Position the filter over the fan.
Make sure the screw holes
are aligned.
Make sure the screws are
tightened.
Install the four screws through the
screw holes in the filter and the fan.
Install the fuse access cover over
the filter/fan assembly and the front
cover.
Install the six screws and tighten.
Close the unit cover.
Connect Electric Standby power, if
applicable.
At the In-cab Control Box, press the
On/Off button to on.
P41PA26A - 04/05
2
Section 7
DSR µP Controller Information
DSR µP Controller Software Features
and Interchange.................................... 7 - 1
7Section 7 - DSR µP Controller Information
DSR µP Controller Software
Features and Interchange
To identify the software version used with your
DSR µP Controller, see Checking the Software
Revision, in Section 4, Operation.
CAUTION: The software of a replacement
microprocessor should always be checked, to
be certain that it is the current software
revision level.
DSR µP Controller Software
Software
Revision
Number
Features
121 15
Field test units
121 19
Production until
August 2004
121 21
Production from Interchange with
September 2004 121 15 and 121 19
273 02
Production from Interchange with
September 2004 121 15, 121 19 and
121 21
273 03
Production from Interchange with
121 15, 121 19,
March 2007
121 21 and 273 02
(12/06)
Interchange With:
Interchange with
121 15
7-1
Section 7 - DSR µP Controller Information
THIS PAGE IS INTENTIONALLY BLANK
(12/06)
7-2
Section 8
Schematics and Wiring Diagrams
Number
Description
1E26983, Rev. B
1E26984, Rev. C
1E23072, Rev. B
1E23071, Rev. B
1E50773, Rev. A
1E50774, Rev. A
1E47098, Rev. B
1E47097, Rev. B
1E17674, Rev. A
1E17673, Rev. A
1E19988, Rev. B
1E19987, Rev. B
1E47148, Rev. B
1E47147, Rev. B
1E29761, Rev. C
1E29760, Rev. C
1E47150, Rev. B
1E47149, Rev. B
1E47152, Rev. A
1E47151, Rev. A
B-100 10/20 DSR μP Controller Schematic Diagram
B-100 10/20 DSR μP Controller Wiring Diagram
V-100, V-200, V-300 MAX 10/30 DSR μP Controller Schematic Diagram
V-100, V-200, V-300 MAX 10/30 DSR μP Controller Wiring Diagram
V-100 MAX 20/50 DSR μP Controller Schematic Diagram
V-100 MAX 20/50 DSR μP Controller Wiring Diagram
V-200, V-300 MAX 20/50 DSR μP Controller Schematic Diagram
V-200, V-300 MAX 20/50 DSR μP Controller Wiring Diagram
V-200, V-300 MAX Multi-Temp DSR μP Controller Schematic Diagram
V-200, V-300 MAX Multi-Temp DSR μP Controller Wiring Diagram
V-400, V-500 MAX 10/30 DSR μP Controller Schematic Diagram
V-400, V-500 MAX 10/30 DSR μP Controller Wiring Diagram
V-400, V-500 MAX 20/50 DSR μP Controller Schematic Diagram
V-400, V-500 MAX 20/50 DSR μP Controller Wiring Diagram
V-500 MAX TC 10/30 DSR μP Controller Schematic Diagram
V-500 MAX TC 10/30 DSR μP Controller Wiring Diagram
V-500 MAX TC 20/50 DSR μP Controller Schematic Diagram
V-500 MAX TC 20/50 DSR μP Controller Wiring Diagram
V-500 AC 10/20 DSR μP Controller Schematic Diagram
V-500 AC 10/20 DSR μP Controller Wiring Diagram
8Section 8 - Schematics and Wiring Diagrams
The following schematic diagrams and wiring diagrams are for B-100, V-100, V-200, V-300, V-400,
and V-500 units that use the DSR μP Controller.
Diagram, Schematic
TK Part Number
Description
1E26983, Rev. B
B-100 10/20, Single Temp, 1PH, 50Hz, 12V/24V
1E23702, Rev. B
V-100/V-200/V-300 MAX, 10/30, Single Temp, 12V/24V
1E50773, Rev. A
V-100 MAX, 20/50, Single Temp, 1PH, 50Hz, 12V/24V
1E47098, Rev. B
V-200/V-300 MAX, 20/50, Single Temp, 12V/24V
1E17674, Rev. A
V-200/V-300 MAX, Bi-Temp, 12V/24V
1E19988, Rev. B
V-400/V-500 MAX, 10/30, Single Temp, 12V/24V
1E47148, Rev. B
V-400/V-500 MAX, 20/50, Single Temp, 3PH, 50Hz, 12V/24V
1E29761, Rev. C
V-500 MAX 10/30, Bi-Temp, 12V/24V
1E47150, Rev. B
V-500 MAX 20/50, Bi-Temp, 1PH/3PH, 50Hz, 12V/24V
1E47152, Rev. A
V-500 AC 10/20, 1PH/3PH, 50Hz, 12V/24V
Diagram, Wiring
TK Part Number
Description
1E26984, Rev. C
B-100 10/20, Single Temp, 1PH, 50Hz, 12V/24V
1E23071, Rev. B
V-100/V-200/V-300 MAX, 10/30, Single Temp, 12V/24V
1E50774, Rev. A
V-100 MAX, 20/50, Single Temp, 1PH, 50Hz, 12V/24V
1E47097, Rev. B
V-200/V-300 MAX, 20/50, Single Temp, 12V/24V
1E17673, Rev. A
V-200/V-300 MAX, Multi-Temp, 12V/24V
1E19987, Rev. B
V-400/V-500 MAX, 10/30, Single Temp, 12V/24V
1E47147, Rev. B
V-400/V-500 MAX, 20/50, Single Temp, 3PH, 50Hz, 12V/24V
1E29760, Rev. C
V-500 MAX 10/30, Bi-Temp, 12V/24V
1E47149, Rev. B
V-500 MAX 20/50, Bi-Temp, 1PH/3PH, 50Hz, 12V/24V
1E47151, Rev. A
V-500 AC 10/20, 1PH/3PH, 50Hz, 12V/24V
(10/08)
8-1
Section 8 - Schematics and Wiring Diagrams
THIS PAGE IS INTENTIONALLY BLANK
(10/08)
8-2
1E26983
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, B-100, 10/20 - Page 1 of 2
8-3
1E26983
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, B-100, 10/20 - Page 2 of 2
8-4
1E26984
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, B-100, 10/20 - Page 1 of 4
8-5
1E26984
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, B-100, 10/20 - Page 2 of 4
8-6
1E26984
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, B-100, 10/20 - Page 3 of 4
8-7
1E26984
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, B-100, 10/20 - Page 4 of 4
8-8
1E23702
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-100, V-200, V-300 MAX, 10/30 - Page 1 of 1
8-9
1E23701
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-100, V-200, V-300 MAX, 10/30 - Page 1 of 1
8-10
1E50773
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-100 MAX, 20/50 - PAGE 1 OF 2
8-11
1E50773
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-100 MAX, 20/50 - PAGE 2 OF 2
8-12
1E50774
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-100 MAX, 20/50 - PAGE 1 OF 3
8-13
1E50774
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-100 MAX, 20/50 - PAGE 2 OF 3
8-14
1E50774
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-100 MAX, 20/50 - PAGE 3 OF 3
8-15
1E47098
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-200, V-300 MAX, 20/50 - PAGE 1 OF 3
8-16
1E47098
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-200, V-300 MAX, 20/50 - PAGE 2 OF 3
8-17
1E47098
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-200, V-300 MAX, 20/50 - PAGE 3 OF 3
8-18
1E47097
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-200, V-300 MAX, 20/50 - PAGE 1 OF 4
8-19
1E47097
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-200, V-300 MAX, 20/50 - PAGE 2 OF 4
8-20
1E47097
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-200, V-300 MAX, 20/50 - PAGE 3 OF 4
8-21
1E47097
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-200, V-300 MAX, 20/50 - PAGE 4 OF 4
8-22
1E17674
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-200, V-300 MAX, MULTI-TEMP - PAGE 1 OF 1
8-23
1E17673
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-200, V-300 MAX, MULTI-TEMP - PAGE 1 OF 1
8-24
1E19988
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-400, V-500 MAX, 10/30 - PAGE 1 OF 2
8-25
1E19988
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-400, V-500 MAX, 10/30 - PAGE 2 OF 2
8-26
1E19987
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-400, V-500 MAX, 10/30 - PAGE 1 OF 2
8-27
1E19987
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-400, V-500 MAX, 10/30 - PAGE 2 OF 2
8-28
1E47148
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-400, V-500 MAX, 20/50 - PAGE 1 OF 4
8-29
1E47148
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-400, V-500 MAX, 20/50 - PAGE 2 OF 4
8-30
1E47148
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-400, V-500 MAX, 20/50 - PAGE 3 OF 4
8-31
1E47148
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-400, V-500 MAX, 20/50 - PAGE 4 OF 4
8-32
1E47147
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-400, V-500 MAX, 20/50 - PAGE 1 OF 5
8-33
1E47147
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-400, V-500 MAX, 20/50 - PAGE 2 OF 5
8-34
1E47147
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-400, V-500 MAX, 20/50 - PAGE 3 OF 5
8-35
1E47147
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-400, V-500 MAX, 20/50 - PAGE 4 OF 5
8-36
1E47147
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-400, V-500 MAX, 20/50 - PAGE 5 OF 5
8-37
1E29761
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-500 MAX TC, 10/30 - PAGE 1 OF 2
8-38
1E29761
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-500 MAX TC, 10/30 - PAGE 2 OF 2
8-39
1E29760
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-500 MAX TC, 10/30 - PAGE 1 OF 2
8-40
1E29760
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-500 MAX TC, 10/30 - PAGE 2 OF 2
8-41
1E47150
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-500 MAX TC, 20/50 - PAGE 1 OF 4
8-42
1E47150
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-500 MAX TC, 20/50 - PAGE 2 OF 4
8-43
1E47150
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-500 MAX TC, 20/50 - PAGE 3 OF 4
8-44
1E47150
DSR MICROPROCESSOR CONTROLLER SCHEMATIC DIAGRAM, V-500 MAX TC, 20/50 - PAGE 4 OF 4
8-45
1E47149
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-500 MAX TC, 20/50 - PAGE 1 OF 5
8-46
1E47149
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-500 MAX TC, 20/50 - PAGE 2 OF 5
8-47
1E47149
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-500 MAX TC, 20/50 - PAGE 3 OF 5
8-48
1E47149
DSR MICROPROCESSOR CONTROLLER WIRING DIAGRAM, V-500 MAX TC, 20/50 - PAGE 4 OF 5
8-49
1E47149
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