Operator`s Manual
Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
T-680R / T-880R / T-1080R
T-680S / T-880S / T-1080S
Series with
Premium SR-3 HMI
TK 55667-1-OP (Rev. 1, 02/15)
©2013 Ingersoll-Rand Company
Printed in U.S.A.
Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
©2013 Ingersoll-Rand Company
Printed in U.S.A.
T-680R / T-880R / T-1080R
T-680S / T-880S / T-1080S
Series with
Premium SR-3 HMI
TK 55667-1-OP (Rev. 1, 02/15)
T-680R / T-880R / T-1080R
T-680S / T-880S / T-1080S
Series with
Premium SR-3 HMI
TK 55667-1-OP (Rev. 1, 02/2015)
Copyright© 2013 Thermo King Corp., Minneapolis, MN, USA
Printed in USA
Disclaimer
This manual is published for informational purposes only. Thermo King Corporation makes no
representations or warranties, express or implied, with respect to the information, recommendations
and descriptions contained in this manual and such information, recommendations and descriptions
should not be regarded as all-inclusive or covering all contingencies. In the event you have any
questions or require further information, please contact your local Thermo King dealer.
The procedures described herein should only be undertaken by suitably qualified personnel. Failure to
implement these procedures correctly may cause damage to the Thermo King unit or other property or
personal injury.
Thermo King Corporation and its affiliates shall have no liability in contract or tort (including negligence
and/or strict liability) or otherwise, to any person or entity for any personal injury, property damage or
any other direct, indirect, special or consequential damage or liability whatsoever, arising out of or
resulting from any actions by any person that are contrary to this manual or any of the information,
recommendations or descriptions contained herein or the failure of any person to implement the
procedures described herein correctly or to follow caution and safety decals located on the Thermo
King unit.
2
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Automatic Start/Stop Operation . . . . . . . . . . . . . . . . . . 8
Battery Installation and Cable Routing . . . . . . . . . . . . . 9
Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
First Aid–Refrigerant . . . . . . . . . . . . . . . . . . . . . . . 11
First Aid–Refrigerant Oil . . . . . . . . . . . . . . . . . . . . 11
Safety Decals and Locations . . . . . . . . . . . . . . . . . . . 12
Model 50 Units (Electric Standby) . . . . . . . . . . . . 14
Emission Control . . . . . . . . . . . . . . . . . . . . . . . . . . .
California Emission Control System Warranty
Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Your Warranty Rights And Obligations . . . . . . . . .
Manufacturer’s Warranty Coverage . . . . . . . . . . .
Owner’s Warranty Responsibilities . . . . . . . . . . . .
15
18
18
19
19
Manufacturer Explanation Of Emission Control System
Warranty Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . .20
EPA Emission Control System Warranty Statement . .22
Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Thermo King Corporation Responsibilities . . . . . . . . . .23
Owner Responsibilities . . . . . . . . . . . . . . . . . . . . . . . .23
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Unit Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . .28
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Reciprocating Compressor . . . . . . . . . . . . . . . . . . . . .29
Scroll Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Premium HMI Control Panel . . . . . . . . . . . . . . . . . . . .29
CYCLE-SENTRY Start/Stop System . . . . . . . . . . . . . .30
Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3
Table of Contents
DAS - Data Acquisition System (Optional) . . . . . . . . . 31
CargoLink (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Electric Standby (Model 50 Units Only) . . . . . . . . . . . . 31
Standard Model 50 Features . . . . . . . . . . . . . . . . 32
Optional Model 50 Features . . . . . . . . . . . . . . . . . 32
Engine Compartment Components . . . . . . . . . . . . . . . 32
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . 33
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Premium HMI Control Panel . . . . . . . . . . . . . . . . . 37
Controller Features . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Hard Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Typical soft key functions: . . . . . . . . . . . . . . . . . . . . . . 40
Turning the Unit On and Off . . . . . . . . . . . . . . . . . . . . 41
If More Than One Language is Enabled . . . . . . . . 42
The Standard Display . . . . . . . . . . . . . . . . . . . . . . . . . 44
Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . 45
Starting the Diesel Engine . . . . . . . . . . . . . . . . . . . . . . 47
Starting the Electric Motor . . . . . . . . . . . . . . . . . . . . . . 48
Switching from Diesel to Electric . . . . . . . . . . . . . . . . . 49
Switching from Electric to Diesel . . . . . . . . . . . . . . . . . 50
4
Initiating a Manual Defrost Cycle . . . . . . . . . . . . . . . .
Terminating a Defrost Cycle . . . . . . . . . . . . . . . .
Selecting High Speed Lockout Mode (If Enabled) . . .
Selecting CYCLE-SENTRY or Continuous Mode . . .
Using the Gauges Key . . . . . . . . . . . . . . . . . . . . . . . .
Gauges Available . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Sensors Key . . . . . . . . . . . . . . . . . . . . . . . .
Sensors Available . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using The Main Menu . . . . . . . . . . . . . . . . . . . . . . . .
Main Menu Choices . . . . . . . . . . . . . . . . . . . . . . . . . .
Languages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Log Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prevent Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pretrip Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm Codes When Switching Between Diesel
and Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm Code Notification . . . . . . . . . . . . . . . . . . . . . . .
Clearing Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . .
Displaying and Clearing Alarm Codes. . . . . . . . . . . . .
SR-3 Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
52
52
54
54
55
56
57
57
58
60
62
62
63
63
64
64
65
65
65
66
67
69
Table of Contents
Datalogger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Hourmeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Hourmeter Names and Definitions . . . . . . . . . . . . . . . 80
Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Turn CYCLE-SENTRY On or Off . . . . . . . . . . . . . . . . . 81
Keypad Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Start Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Selecting CYCLE-SENTRY or Continuous Mode . . . . 83
Selecting Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . 85
Pretrip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Pretrip Test Conditions . . . . . . . . . . . . . . . . . . . . . . . . 89
Conditions where Pretrip Tests are not allowed . . . . . 89
Pretrip Test Sequence . . . . . . . . . . . . . . . . . . . . . . . . 90
Pretrip Test Considerations . . . . . . . . . . . . . . . . . . . . . 90
Performing a Pretrip Test . . . . . . . . . . . . . . . . . . . . . . . 91
Diesel/Electric Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Switching from Diesel to Electric - Units equipped
with the Electric Standby option only . . . . . . . . . . . . . 93
Switching from Electric to Diesel - Units equipped
with the Electric Standby option only . . . . . . . . . . . . . 94
Adjust Brightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Loading and Enroute Inspections . . . . . . . . . . . . . .98
Pre-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . . .98
Inspecting the Load . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Enroute Inspections . . . . . . . . . . . . . . . . . . . . . . . . . .100
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Engine Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Reciprocating Compressor . . . . . . . . . . . . . . . . .106
Scroll Compressor . . . . . . . . . . . . . . . . . . . . . . . .107
Electrical Control System . . . . . . . . . . . . . . . . . . . . . .108
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Electrical Components . . . . . . . . . . . . . . . . . . . . . . . .110
SmartPower Electrical Standby
(Model 50 Units Only) . . . . . . . . . . . . . . . . . . . . . . . .112
T-680R, T-680S, T-880R, T-880S Electric Motor
and Overload Relay . . . . . . . . . . . . . . . . . . . . . . .112
T-1080R & T-1080S Electric Motor and Overload
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Electric Heater Strips (Optional) . . . . . . . . . . . . .113
SmartPower Standby Power Requirements . . . .113
5
Table of Contents
Maintenance Inspection Schedule . . . . . . . . . . . . . 114
Recover Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . 130
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . . 131
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
CALIFORNIA Proposition 65 Warning . . . . . . . . . 132
Serial Number and Refrigerant Label Locations . 127
6
Introduction
There is nothing complicated about operating and maintaining
your Thermo King unit, but a few minutes studying this
manual will be time well spent.
Performing pre-trip checks and enroute inspections on a
regular basis will minimize on-the-road operating problems. A
regular maintenance program will also help to keep your unit
in top operating condition. If factory recommended procedures
are followed, you will find that you have purchased the most
efficient and dependable temperature control system available.
IMPORTANT: This manual is published for informational
purposes only and the information furnished herein should
not be considered as all-inclusive or meant to cover all
contingencies. If more information is required, consult your
Thermo King Service Directory for the location and
telephone number of the local dealer.
All service requirements, major and minor, should be handled
by a Thermo King dealer for four very important reasons:
•
They are equipped with the factory recommended tools to
perform all service functions
•
They have factory trained and certified technicians
•
They have genuine Thermo King replacement parts
•
The warranty on your new unit is valid only when the
repair and replacement of component parts is performed
by an authorized Thermo King dealer.
7
Safety Precautions
Thermo King recommends that all services be performed by a
Thermo King dealer. However, there are several general safety
practices which you should be aware of:
WARNING: Always wear goggles or safety glasses
when working with or around the refrigeration
system or battery. Refrigerant or battery acid can
cause permanent damage if it comes in contact with
your eyes.
WARNING: Keep hands and loose clothing clear of
fans and belts at all times when the unit is operating
or when opening or closing compressor service
valves.
WARNING: Exposed coil fins can cause painful
lacerations. Service work on the evaporator or
condenser coils is best left to a certified Thermo King
technician.
8
CAUTION: Use extreme caution when drilling holes
in the unit. Drilling into electrical wiring or
refrigerant lines could cause a fire. Never drill into
structural components.
Automatic Start/Stop Operation
This unit is capable of automatic operation and may start at any
time without prior warning.
WARNING: The unit may start at any time when the
controller is turned on. The controller display lights
up when the controller is turned on.
WARNING: Units equipped with electric standby may
start at any time when the unit is connected to live
electric power and the controller is turned on.
WARNING: Be sure to press the OFF key to turn the
controller off before opening doors or inspecting any
part of the unit.
Safety Precautions
Battery Installation and Cable
Routing
WARNING: Improperly installed battery could
result in a fire or explosion! A Thermo King
approved battery must be installed and properly
secured to the battery tray.
WARNING: Improperly installed battery cables
could result in fire or explosion! Battery cables
must be installed, routed and secured properly to
prevent them from rubbing, chaffing or making
contact with hot, sharp or rotating components.
WARNING: Do not attach fuel lines or any
additional wiring harnesses to the battery cables as
this could cause an electrical fire!
CAUTION: Do not connect other manufacturer’s
equipment or accessories to the Thermo King unit.
This could result in severe damage to equipment
and void the warranty!
CAUTION: Set all unit electrical controls to the
OFF position before connecting battery cables to
the battery to prevent unit from starting
unexpectedly and causing personal injury.
CAUTION: Always wear protective clothing,
gloves and eye wear when handling and installing
batteries. Battery acid can cause serious burns
when exposed to eyes or skin. If battery acid
contacts skin or clothing, wash immediately with
soap and water. If acid enters your eye,
immediately flood it with running cold water for at
least twenty minutes and get medical attention
immediately.
CAUTION: Always cover battery terminals to
prevent them from making contact with metal
components during battery installation. Battery
terminals grounding against metal could cause the
battery to explode.
9
Safety Precautions
Electrical Hazard
CAUTION: Be sure to turn off the high voltage
power supply, and disconnect the electric cable before
working on the unit. Units with electric standby
present a potential electrical hazard.
Refrigerant
Although fluorocarbon refrigerants are classified as safe,
observe caution when working with refrigerants or around
areas where they are being used in the servicing of your unit.
DANGER: Fluorocarbon refrigerants may produce
toxic gases. In the presence of an open flame or
electrical short, these gases are severe respiratory
irritants CAPABLE OF CAUSING DEATH.
DANGER: Fluorocarbon refrigerants tend to
displace air and can cause oxygen depletion which
could result in DEATH BY SUFFOCATION. Provide
adequate ventilation in enclosed or confined areas.
10
WARNING: Fluorocarbon refrigerants evaporate
rapidly, freezing anything they contact if accidentally
released into the atmosphere from the liquid state.
Refrigerant Oil
Observe the following precautions when working with or
around refrigerant oil:
WARNING: Always wear goggles or safety glasses to
protect eyes from refrigerant oil contact.
WARNING: Protect skin and clothing from
prolonged or repeated contact with refrigerant oil.
Rubber gloves are recommended.
WARNING: Wash thoroughly immediately after
handling refrigerant oil to prevent irritation.
Safety Precautions
First Aid
First Aid–Refrigerant
Eyes: For contact with liquid, immediately flush eyes with
large amounts of water. Get prompt medical attention.
Inhalation: Move victim to fresh air and restore breathing if
necessary. Stay with victim until arrival of emergency
personnel.
Ingestion: Do not induce vomiting. Immediately contact
local poison control center or physician.
Skin: Flush areas with large amounts of warm water. Do not
apply heat. Wrap burns with dry, sterile, bulky dressing to
protect from infection or injury. Get prompt medical attention.
Inhalation: Move victim to fresh air and restore breathing if
necessary. Stay with victim until arrival of emergency medical
personnel.
First Aid–Refrigerant Oil
Eyes: Immediately flush eyes with large amounts of water for
at least 15 minutes while holding the eyelids open. Get prompt
medical attention.
Skin: Remove contaminated clothing. Wash thoroughly with
soap and water. Get medical attention if irritation persists.
11
Safety Precautions
Safety Decals and Locations
AKA98
Figure 1: Antifreeze Caution
(Attached near radiator fill cap.)
12
Figure 2: Belt Caution (Locations vary depending on
model. Decals are located near areas that contain
belts and fans which can cause severe injuries if
hands or clothing become tangled.)
Safety Precautions
CAUTION FAN
ACHTUNG VENTILATOR
91-4815
ATTENTION VENTILATEUR
ATTENZIONE VENTILATORE
AKA99
Figure 3: Automatic Start Caution (Locations vary
depending on model. Decals are located near areas
that contain moving parts which can cause severe
injuries if hands or clothing become tangled when the
unit automatically starts.)
CUIDADO VENTILADOR
ARA183
Figure 4: Fan Caution (Locations vary depending on
model. Decals are located near areas that contain
fans which can cause severe injuries if hands or
clothing become tangled.)
13
Safety Precautions
Model 50 Units (Electric Standby)
AKB01
AKB02
Figure 5: Electrical Hazard (Locations vary
depending on model. Typically located near power
receptacle, high voltage tray cover and interface
board.)
14
Figure 6: High Voltage Caution
(Located near high voltage box.)
Emission Control
In compliance with the California ULG (Utility, Lawn and
Garden) Rules, the following information is provided:
1. Selection Of Fuel Oil: Use diesel fuel only.
2-1. Modification To Any Engine Component:
Modifications to any engine component which many cause
engine exhaust emission output changes are not allowed.
Any engine modification not in compliance with regulation
will be the responsibility of the engine manufacturer, dealer or
customer who made the modification.
2-4. Fuel Oil System: Fuel oil system must remain intact
and receive regular prescribed maintenance. Example: Fuel
filter replacement at required operation hour interval.
3. Engine Identification: Engines must be identified in a
manner that will determine when they were built and what
regulations they comply with. The engine must be labeled with
an emission control label and the engine family name, both
described below.
2-2. Air Induction System: Air induction system must
remain intact and receive regular prescribed maintenance.
Example: Air cleaner element replacement at required
operation hour interval.
2-3. Exhaust System: Exhaust system must remain intact
and cannot be modified in any manner that will further restrict
exhaust flow.
15
Emission Control
a.
Emission control label: a new label, shown in
Figure 7, contains important engine information.
AMA04
Engine Family Name, as assigned by the California
Air Resources Board, identifies engine family group,
by largest displacement, within an engine family, and
is shown in Figure 8.
AMA06
Figure 7: Emission Control Label
16
b.
Figure 8: Engine Family Name
Emission Control
3-1 Emission Control Labels: Emission control labels are
a requirement of the California ULG Rules. In the event the
emission control label provided on the engine is inaccessible,
there will be a supplemental label containing the same
information, provided by the equipment manufacturer, located
in a readily accessible location, shown in Figure 9:
All engine labels and supplementary labels will contain the
following information:
•
Engine Family Name
•
Displacement
•
Manufacturer
The above information, along with the engine serial number,
will be required to obtain proper service information and
correct service repair parts. An example list which identifies
the exhaust control system is shown in Figure 10.
AMA05
Figure 9: Emission Control Label Location
1.
Engine Model
3TNV70-TK
Engine Family Name
6YDXL0.85W3N
2.
3TNV76-TK
6YDXL1.11W3N
Note: Design parameters to bring engine family into
compliance were utilized; no after treatment measures
incorporated.
Figure 10: Exhaust Control Systems
17
Emission Control
4. Emission Control Related Parts: The California ULG
Rules require a manufacturing defect warranty on all emission
control parts, including:
5. Maintenance Schedule: To maintain optimum engine
performance and compliance with the California ULG Rules,
the maintenance schedule must be adhered to.
•
Fuel Injection Pump
•
Fuel Injection Nozzle
•
High Pressure Oil Line
Regular scheduled maintenance is the major key to engine
service life and emission regulation compliance. Scheduled
maintenance requirements must be performed regularly. See
the Maintenance Schedule provided in this Operator’s Manual.
•
Air Cleaner Element1
•
Fuel Filter Element1
•
Air Cleaner Gasket
•
Air Intake Pipe (Manifold) Gasket
•
Muffler Gasket
The warranty period is two years and complete details are
included in the section of this manual titled “California
Emission Control System Warranty Statement, Your Warranty
Rights And Obligations.”
1
Any warranted part which is scheduled for replacement as
required maintenance shall be warranted for the period of time
up to the first scheduled replacement point for that part.
18
California Emission Control
System Warranty Statement
Your Warranty Rights And
Obligations
The California Air Resources Board and Thermo King are
pleased to explain the California emission control system
warranty on your 1996 and later utility equipment (ULG)
engine. In California, new utility equipment (ULG) engines
must be designed, built, and equipped to meet the state’s
stringent anti-smog standards. Thermo King must warrant the
California emission control system on your utility equipment
Emission Control
(ULG) engine for the time listed below, provided there has
been no abuse, neglect or improper maintenance of your utility
equipment (ULG) engine.
Your California emission control system includes parts such as
the fuel injection pump, the fuel injection nozzle, and the
high-pressure fuel line. Also included are the air filter element
and the fuel filter element which are covered under this
California emission control system warranty only up to the first
scheduled maintenance replacement.
Where a warrantable condition exists, Thermo King will repair
your utility equipment (ULG) engine with California emission
control system parts or components at no cost to you, including
diagnosis, parts and labor.
Manufacturer’s Warranty Coverage
1996 and later utility equipment (ULG) engines: California
emission control system parts and components are warranted
for the period of two years (24 months). If any California
emission control system part or component on your utility
equipment (ULG) engine is defective, the part or component
will be repaired or replaced by Thermo King.
Owner’s Warranty Responsibilities
As the utility equipment (ULG) engine owner, you are
responsible for the performance of the required maintenance
listed in this Operator’s Manual. Thermo King recommends
that you retain all receipts covering maintenance on your utility
equipment (ULG) engine, but Thermo King cannot deny
warranty solely for the lack of receipts or your failure to ensure
the performance of all scheduled maintenance.
As the utility equipment (ULG) engine owner, you should be
aware that Thermo King may deny you warranty coverage if
your utility equipment (ULG) engine, or a part or component,
has failed due to abuse, neglect, improper maintenance, or
unapproved modifications.
You are responsible for presenting your utility equipment
(ULG) engine to an authorized Thermo King dealer as soon as
a problem exists. The emission control system parts or
component repairs should be completed in a reasonable
amount of time not to exceed 30 days.
If you have any questions regarding your warranty rights and
responsibilities, contact a Thermo King service representative
at 952-887-2337.
19
Emission Control
Manufacturer Explanation Of
Emission Control System
Warranty Coverage
at a Thermo King authorized service dealer. To obtain the
phone number of your nearest Thermo King authorized
service dealer, call the Cold Line at: 952-887-2202.
2.
Warranty Period: Any warranted California emission
control system part or component that is not scheduled for
replacement as required maintenance, or that is scheduled
only for regular inspection to the effect of repair or
replacement as necessary, shall be warranted for the
warranty period. Any warranted part that is scheduled for
replacement as required maintenance shall be warranted
for the period of time up to the first scheduled replacement
point for that part or component.
3.
Diagnosis: The owner shall not be charged for diagnostic
labor which leads to the determination that a California
emission control system warranted part or component is
defective, if the diagnostic work is performed at a Thermo
King authorized service dealer.
4.
Consequential Damages: Thermo King is liable for
damages to other engine parts or components caused by
the failure of an emission control system part or
component within the above stated California emission
control system warranty period.
A. Warranty Commencement Date
The California emission control system warranty period begins
on the date the engine or equipment is delivered to the original
retail purchaser.
B. Length Of Coverage
Thermo King warrants to the original purchaser, and each
subsequent purchaser, that the engine emission control system
is free from defects in material and workmanship that cause the
failure of the warranted California emission control system
part or component for a period of two years (24 months)
beginning on the day the utility equipment (ULG) engine is
delivered to the original purchaser.
C. What Is Covered
1.
20
Repair or Replacement of Parts: Repair or replacement
of any California emission control system warranted part
or component will be performed at no charge to the owner
Emission Control
D. What is Not Covered
1.
Failures caused by abuse, neglect, or improper
maintenance.
2.
Add-On or Modified Parts. The use of add-on or modified
parts can be grounds for disallowing a warranty claim.
Thermo King is not liable for failures of emission control
system parts or components caused by the use of add-on or
modified parts.
G. Maintenance, Replacement and Repair of Emission
Control System Related Parts
Any Thermo King approved replacement part can be used in
the performance of any warranty maintenance or repairs on
emission control system parts or components, and must be
provided without charge to the owner if the part is still under
the California emission control system warranty.
H. Emission Control System Warranty Parts List
•
Part Name
•
•
Fuel Injection Pump
Fuel injection Nozzle
E. How to File a Claim
•
High Pressure Fuel Oil Line
Warranty claims for California emission control system parts
or components are to be filed by the Thermo King authorized
servicing dealer on behalf of the engine owner.
•
Air Cleaner Element
•
•
Fuel Filter Element
Air Cleaner Gasket
F.
•
Air Intake Pipe (Manifold)
•
Gasket Muffler Gasket
I.
Maintenance Statements
3.
Use of fuel other than the California Title 13, CCR Section
2282 (g)(3), low sulfur, low aromatic, with a cetane
number of 48 minimum, will nullify this warranty.
Where to Get Warranty Service
Warranty service or repairs shall be provided at all Thermo
King authorized service dealers. You can generally find dealers
in the Yellow Pages of your regional telephone directory, or
call the customer service representative at 888-887-2202 for
the location of the nearest Thermo King authorized service
dealer.
The owner is responsible for the performance of the required
maintenance as defined by Thermo King within this Operator’s
Manual.
21
Emission Control
EPA Emission Control System
Warranty Statement
Thermo King warrants to the initial owner and each subsequent
owner that the certified non-road diesel engine in your unit is:
1.
Designed, built and equipped so as to conform, at the time
of sale, with all applicable regulations adopted by the
United States Environmental Protection Agency (EPA).
2.
Free from defects in materials and workmanship in
specific, emission-related parts for a period of five years
or 3,000 hours of operation, whichever comes first, after
date of delivery to the initial owner.
If an emission-related part or component fails during the
warranty period, it will be repaired or replaced. Any such part
or component repaired or replaced under warranty is warranted
for the warranty period.
During the term of this warranty, Thermo King will provide,
through a Thermo King authorized service dealer or other
establishment authorized by Thermo King, repair or
replacement of any warranted part at no charge to the non-road
engine owner.
In an emergency, repairs can be performed at any service
establishment, or by the owner, using any replacement part.
Thermo King will reimburse the owner for their expenses,
including diagnostic charges, for such emergency repair. These
expenses shall not exceed Thermo King’s suggested retail price
for all warranted parts replaced, and labor changes based on
Thermo King’s recommended time allowance for the warranty
repair and the geographically appropriate hourly labor rate.
Any replacement part can be used for maintenance or repairs.
The owner should ensure that such parts are equivalent in
design and durability to genuine Thermo King parts. However,
Thermo King is not liable for parts which are not genuine
Thermo King parts.
A part not being available within 30 days or repair not being
completed within 30 days constitutes an emergency.
As a condition of reimbursement, replaced parts and received
invoices must be presented at a place of business of a Thermo
King authorized service dealer or other establishment
authorized by Thermo King.
This warranty covers the following emission-related parts and
components:
•
22
Fuel Injection System
Emission Control
•
Intake Manifold
Owner Responsibilities
•
Exhaust Manifold
•
Miscellaneous hoses, clamps, connectors and sealing
devices used in the above systems.
During the emission warranty period, the owner is responsible
for:
•
The performance of all required maintenance. A warranty
claim will not be denied because the scheduled
maintenance was not performed. However, if the lack of
required maintenance was the reason for the repair, then
the claim will be denied.
•
Premium of overtime cost.
•
Cost to investigate complaints that are not caused by
defect in Thermo King material or workmanship.
•
Providing timely notice of a warrantable failure and
promptly making the product available for repair.
If failure of one of these parts or components results in failure
of another part or component, both will be covered by this
warranty.
Responsibilities
This warranty is subject to the following:
Thermo King Corporation Responsibilities
During the emission warranty period, if a defect in material or
workmanship of a warranted part or component is found,
Thermo King will provide:
• New, remanufactured, or repaired parts or components
required to correct the defect.
NOTE: Items replaced under this warranty become the
property of Thermo King.
•
Labor, during normal working hours, required to make the
warranty repair. This includes diagnosis and labor to
remove and install the engine, if necessary.
Limitations
Thermo King is not responsible for resultant damages to an
emission-related part or component resulting from:
•
Any application or installation Thermo King deems
improper as explained in this Operator’s Manual, or any
other manuals provided with the unit.
23
Emission Control
•
Attachments, accessory items, or parts not authorized for
use by Thermo King.
•
Improper off-road engine maintenance, repair, or abuse.
•
Owner’s unreasonable delay in making the product
available after being notified of a potential product
problem.
This warranty is in addition to Thermo King’s standard
warranty applicable to the off-road engine product involved.
Remedies under this warranty are limited to the provision of
material and services as specified herein. Thermo King is not
responsible for incidental or consequential damages such as
downtime or loss of engine-powered equipment.
24
Unit Description
General Description
Units are offered as Model 30 or Model 50:
This manual covers the following Thermo King models:
Model 30: Cooling and hot gas heating on engine operation.
•
T-680R, T-880R and T-1080R with reciprocating
compressor.
•
T-680S, T-880S and T-1080S with scroll compressor.
Model 50: Cooling and hot gas heating on engine operation
and electric standby operation. Electric evaporator heaters are
optional.
All units are microprocessor based transport temperature
control systems that use the Premium SR-3 Truck HMI
microcontroller to manage system functions.
Engine power for the unit is provided by a diesel engine.
Optional SmartPower electric standby power is provided by an
electric motor. A clutch on the diesel engine isolates the engine
during electric standby operation.
All units are one-piece, front-mounted, diesel powered cooling
and heating systems designed for straight trucks. The unit
mounts on the front of a truck with the evaporator portion
protruding into the box. They are designed for use with
chlorine free refrigerants.
The continuous monitoring function of the SR-3
microprocessor optimizes the unit’s performance, reducing fuel
consumption and unit down time. The unit has a self check
feature that can be run before the daily distribution route to
identify possible malfunctions.
The built-in CYCLE-SENTRY, an exclusive Thermo King
feature, automatically starts and stops the unit according to
temperature demands.
25
Unit Description
Design Features
•
Bypass Oil Filter
•
Microprocessor Controller, SR-3 Truck
•
Coolant Expansion Tank
•
Alarm Code Display
•
Diesel/Electric Autoswitching (Model 50)
•
Battery Voltage Display
•
Economy Mode
•
Continuous System Monitoring
•
Fahrenheit and Celsius Scales
•
Coolant Temperature Display
•
Fuel Filter, Spin On
•
CYCLE-SENTRY™ Start/Stop Controls
•
Low Decibel Kit
•
Engine and Electric (Model 50) Hour Display
•
Oil Filter, Full Flow
•
In-Cab Remote
•
Poly-V Belt System with Quiet Channel Technology
•
Smart Defrost
•
R-404A Chlorine-free Refrigerant
•
Symbolic Controller Interface
•
Robotic Welded Steel Frame with Automotive Grade 2
Coat Paint Finish
•
Unit Self Check-pretrip
•
X214 Compressor (T-680R and T-880R)
•
Aerodynamic Thermo Plastic Recyclable Injection
Molded Skins with In-mold Color
•
X426 Compressor (T-1080R)
•
Air Cleaner, Dry Type
•
TK04 Scroll 4 HP (T-680S and T-880S)
•
Alternator, 12 Volt, 37 Amp
•
TK06 Scroll 6 HP (T-1080S)
•
Automatic Phase Correction (Model 50)
•
ETV (Electronic Throttling Valve)
26
Unit Description
•
Stainless Steel Condenser and Evaporator Hardware
•
Quick Oil Drain Kit
•
TK374F Tier 4 Diesel Engine (T-680R, T-680S, T-880R
and T-880S)
•
Rear Remote Control (flushmount)
•
Remote Indicator Light
•
TK380F Tier 4 Diesel Engine (T-1080R and T-1080S)
•
Snow Cover
•
Telematics
•
Whisper™ Plus Sound Kit
•
Top Cover System
Unit Options
•
Body Mount HMI Enclosure Systems
•
DAS (Data Acquisition System)
•
Door Switch
•
CargoLink™ Wireless Sensors
•
Easy-Read Thermometer
•
Electric Evaporator Heater
•
SmartPower™ Electric Standby Operation (Model 50)
•
Engine Block Heater
•
Fuel Tank
•
Hand-held SR-3 Electronic Diagnostic Tool
•
Hose Management System
27
Unit Description
Engine
Engine power for the T-680R, T-680S,T-880R and T-880S is
provided by the TK374F, a three-cylinder, EPA Tier 4, special
clean and quiet diesel engine rated at 11.7 continuous
horsepower (8.7 kW) at 2200 RPM. A belt drive system
transfers energy to the compressor, unit fans, and alternator.
Engine power for the T-1080R and T-1080S is provided by the
TK380F, a three cylinder, EPA Tier 4, special clean and quiet
diesel engine rated at 16.2 continuous horsepower (12.1 kW) at
2200 RPM. A belt drive system transfers energy to the
compressor, unit fans and alternator.
ELC (Extended Life Coolant)
The maintenance interval for ELC is five years or 12,000
hours. A nameplate on the coolant expansion tank identifies
units with ELC (see “Safety Decals and Locations”). The new
engine coolant, Texaco Extended Life Coolant, is Red instead
of the previous Green or Blue-Green coolants.
ARB108
Figure 11: ELC (Extended Life Coolant) Nameplate
(Located On Expansion Tank In Units Equipped With
ELC)
CAUTION: Do not add Green or Blue-Green
coolants to cooling systems that use Red Extended
Life Coolants.
28
Unit Description
NOTE: The use of 50/50% pre-mixed ELC is recommended
to ensure that deionized water is being used. If 100% full
strength concentrate is used, deionized or distilled water is
recommended instead of tap water to ensure the integrity of
the cooling system is maintained.
Scroll Compressor
Clutch
Premium HMI Control Panel
The centrifugal clutch engages fully at 600 ± 100 RPM on
engine operation, constantly turning the compressor, alternator,
and fans at both high and low speed. The clutch isolates the
engine from the belt drive system during electric standby
operation on Model 50 units.
The Premium Truck HMI (Human/Machine Interface) Control
Panel is available as an option on SR-3 Truck applications. It is
used to operate the unit, display unit information and access all
SR-3 Maintenance and Guarded Access Menus. The Control
Panel is typically located in the vehicle driver's compartment
and communicates with the base controller using a connection
on the interface board.
Reciprocating Compressor
The T-680S and T-880S feature the TK04 scroll compressor.
The T-1080S features the TK06 scroll compressor.
The T-680R and T-880R feature the X214, 2 cylinder
reciprocating compressor with 13.92 cu in (229 cc)
displacement.
The T-1080R features the X426, 4-cylinder reciprocating
compressor with 25.9 cu in (424 cc) displacement.
Figure 12: Premium HMI Control Panel
29
Unit Description
CYCLE-SENTRY™ Start/Stop
System
The CYCLE-SENTRY Start/Stop fuel saving system provides
optimum operating economy.
WARNING: Turn the unit off by pressing the OFF key
before opening doors or inspecting any part of the
unit. The unit can start at any time without warning if
it has been turned on by pressing the ON key.
The CYCLE-SENTRY system automatically starts the unit on
microprocessor demand and shuts down the unit when all
demands are satisfied.
The system monitors and maintains the compartment
temperature, the engine block temperature, and battery charge
levels at a point where quick, easy starts are possible.
Defrost
Frost will gradually build up on the evaporator coils as a result
of normal operation. Periodically this frost must be melted to
prevent a loss of cooling and airflow.
Defrost is accomplished by passing hot refrigerant gas through
the evaporator coil, thus melting the frost (or ice). Melted frost
drains out of the unit onto the ground through the drain tubes.
The defrost damper closes during defrost to prevent warm air
from entering the cargo area. The optional electric heater strips
are also energized in defrost during electric standby operation.
Defrost can be initiated at any time the evaporator coil
temperature is below 42 F (5.5 C).
There are two methods of defrost initiation:
SR-3 Microprocessor Controller: The Microprocessor
Controller is programmed to automatically initiate timed and
forced defrost cycles. The SR-3 uses temperature sensors to
determine if forced defrost is required.
Manual Defrost: Manual Defrost allows the operator to
initiate a defrost cycle by pressing the DEFROST key. See
“Initiating a Manual Defrost Cycle.”
30
Unit Description
DAS - Data Acquisition System
(Optional)
The DAS (Data Acquisition System) monitors and records the
temperatures of (up to) six additional sensors. The sensors are
independent from the microprocessor controller and are
normally located in the truck box to monitor load temperatures.
DAS data can be downloaded through a serial port to an IBM®
PC compatible computer. WinTrac™ 4.0 (or higher) software
is used to view and analyze the data. Brief reports can be
printed on a microprinter connected to the serial port.
CargoLink™ (Optional)
CargoLink is a wireless sensor system. The main components
are the coordinator module, interconnect harness, antenna, and
wireless sensors. The coordinator module receives information
from the wireless sensors through the antenna, and
communicates with the controller through the interconnect
harness. Currently, only wireless door switches are available.
Other wireless sensors will be available in the future. Refer to
TK 55151 the Truck and Trailer Edition CargoLink Installation
Manual for information about installing the CargoLink system
and sensors, and troubleshooting problems with the system.
Electric Standby (Model 50 Units
Only)
The Electric Standby option allows the unit to be operated on
either the diesel engine or external electric power.
DANGER: High voltage AC power is present
whenever the unit is operating in the Electric mode
and whenever the unit is connected to external
standby power. Voltages of this magnitude can be
lethal. Exercise extreme caution when working on the
unit.
31
Unit Description
Standard Model 50 Features
The following features are standard equipment on units
equipped with Electric Standby.
Automatic Diesel/Electric Selection: The unit will
automatically switch to electric operation when a power cord is
connected and the standby power is switched On.
Overload Relay: The overload relay is self-resetting.
Hot Gas Heat: Hot gas heat is utilized on all units.
Engine Compartment
Components
Coolant Expansion Tank: The coolant level and
temperature are monitored by the base controller. If the coolant
temperature becomes too high or the level becomes too low, an
alarm will occur.
The engine must have antifreeze protection to –30 F (–34 C).
Check and add coolant in the expansion tank as needed.
Automatic Phase Correction: The control system features
two motor contactors. This allows correct motor rotation
regardless of phase rotation on the incoming power.
CAUTION: Do not remove expansion tank cap
while the coolant is hot.
Optional Model 50 Features
CAUTION: Do not add Green or Blue-Green
coolants to cooling systems that use Red Extended
Life Coolants.
The following features are available as options on units
equipped with Electric Standby.
•
Electric Heater Strips
•
Auto Switching
32
Engine Oil Dipstick: Use the engine oil dipstick to check
the engine oil level.
Unit Description
Receiver Tank Sight Glass: The receiver tank sight glass
is used to assist in checking the amount of refrigerant in the
system.
Compressor Oil Sight Glass: The compressor oil sight
glass is used to check the relative level of compressor oil in the
compressor sump.
Unit Protection Devices
High Pressure Cutout Switch (HPCO): This normally
closed switch monitors the discharge pressure at the
compressor. It opens on high discharge pressure to shut the unit
down to prevent damage.
Suction Pressure Regulator (SPR): This component is a
mechanical control device used to limit the suction pressure to
the compressor. The valve controls suction pressure based on
the actual system pressure. (Scroll compressor units: The SPR
is not used if the unit is equipped with an ETV.)
Electronic Throttling Valve (ETV): (Scroll compressor
units only.) This component is an electromechanical control
device used to limit the suction pressure to the compressor. The
valve is controlled by the microprocessor controller.
Engine Oil Pressure Switch/Sensor: The engine oil
pressure switch/sensor is located on the filter head above the
bypass oil filter. Engine oil pressure should rise immediately
on starting. If engine oil pressure drops below 10 ± 2 psig (69 ±
14 kPa), the switch/sensor signals the microprocessor to stop
the engine.
Preheat Buzzer: The preheat buzzer sounds when the
CYCLE-SENTRY system energizes the glow plugs. This
should warn anyone near the unit that the CYCLE-SENTRY
system is about to start the diesel engine.
Coolant Temperature Sensor: This sensor provides an
engine coolant temperature input to the microprocessor. If the
engine coolant temperature is too high, the controller stops the
unit and records an alarm.
Electric Motor Overload Relay (Model 50): The
overload relay protects the electric standby motor. The
overload relay opens the circuit from the contactor to the
electric motor if the motor overloads for any reason and an
alarm will occur. The relay resets when the alarm code is
cleared.
Fuses: Sizes and functions are described in the Specifications
section of this manual.
33
Unit Description
Figure 13: T-680S Front View (T-680R, T-880S and T-880R are similar)
34
Unit Description
Figure 14: T-1080S Front View (T-1080R is similar)
35
Unit Description
2
3
1
4
5
6
7
8
1.
Engine Oil Dipstick (on side of engine)
5.
Alternator
2.
Engine
6.
Compressor (reciprocating shown)
3.
Coolant Expansion Tank
7.
Dehydrator (Filter-Drier)
4.
Electric Motor
8.
On/Off Switch
Figure 15: Main Components
36
Unit Operation
Premium HMI Control Panel
The Premium Truck HMI (Human/Machine Interface) Control
Panel is available as an option on SR-3 Truck applications. It is
used to operate the unit, display unit information and access all
SR-3 Maintenance and Guarded Access Menus. The Premium
HMI Control Panel communicates with the base controller via
the CAN (Controller Area Network) bus. It is connected to the
base controller via CAN Connector J14 on the interface board.
The Premium HMI Control Panel is typically located in the
vehicle driver's compartment. It may be installed in the truck
instrument panel using a DIN mounting ring or under the
instrument panel using an under dash mounting kit.
Figure 16: Premium HMI Control Panel
The HMI control panel consists of a display and 8
touch-sensitive keys.
The display is capable of showing both text and graphics.
The keys on the left and right sides of the display are dedicated
single function "hard" keys.
The four keys under the display are "soft" keys. The functions
of these soft keys change depending on the operation being
performed. If a soft key is active the current key function is
shown in the display directly above the key.
37
Unit Operation
Controller Features
•
Displays Box Temperature and Setpoint in Fahrenheit or
Celsius
•
Displays Engine Running and Motor Running Hourmeters
•
Changes Setpoint
•
Indicates Alarm Condition Exists
•
Displays and Clears Alarms
•
Selects and Indicates CYCLE-SENTRY or Continuous
Mode Operation
•
Selects and Indicates High Speed Lock-Out Operation
•
Initiates and Indicates a Defrost Cycle
•
Initiates and Indicates a Pretrip Test
•
Sends a Start of Trip to the ServiceWatch data logger.
The Standard Display of box temperature and setpoint is
shown here. The CYCLE-SENTRY Icon in the upper right of
the display shows the unit is running in CYCLE-SENTRY
(Start-Stop) Mode. The unit has a setpoint of 35 F, and an
actual box temperature of 35.8 F. The down-pointing arrow at
the left side of the display shows the unit is cooling.
The four keys under the display are termed "soft" keys. The
functions of these keys change depending on the operation
being performed. The function of each soft key is shown by
labels in the display located directly above each soft key. In the
example shown above, pressing the left soft key accesses the
SETPOINT Menu and pressing the right soft key accesses the
MAIN Menu. The other two soft keys access the GAUGES
menu and SENSORS menu as shown by the labels above the
keys.
Display
The display presents information to the operator. This
information includes setpoint and temperature, unit operating
information, gauge readings, temperatures and other
information as selected by the operator.
38
Figure 17: Display
Unit Operation
Keys
Hard Key
Figure 18: Keys
Hard Keys
The keys on either side of the display are dedicated or "hard"
keys. Their function always remains the same.
Description
This key is used to turn the unit on. First
the display will briefly show the Thermo
King Logo and then the statement
"Configuring System - Please Wait".
When the power-up sequence is
complete the display shows the Standard
Display of box temperature and setpoint.
For more information see "Turning the
Unit On and Off" later in this section.
This key is used to turn the unit off. First
the display will briefly show "System is
Powering Down - Please Wait. Press On
to Resume" and then "Off" will appear
momentarily. When the power-down
sequence is complete the display will be
blank. For more information see "Turning
the Unit On and Off" later in this section.
39
Unit Operation
Hard Key
Description
Soft Keys
This key is used to initiate a manual
defrost cycle. For more information see
"Initiating a Manual Defrost Cycle" later
in this section.
Soft Key
Description
The four "soft" keys under the display
are multi-purpose keys. Their function
changes depending on the operation
being performed. If a soft key is active
the key function is shown in the display
directly above the key. The keys are
numbered from left to right, with Key 1
on the far left and Key 4 on the far right.
This key is used to lock out high speed
operation in noise sensitive areas. For
more information see "Selecting High
Speed Lockout" later in this section.
Typical soft key functions:
Figure 19: Soft Keys
40
•
MENU
•
NEXT
BACK
•
•
YES
+
NO
-
•
SELECT
EXIT
•
CLEAR
HELP
•
•
HOUR METERS
GAUGES
SENSORS
Unit Operation
Turning the Unit On and Off
IMPORTANT: Verify the Base Controller On/Off Switch is
turned on before turning on the HMI Control Panel. The
Base Controller On/Off switch is located on the outside of the
control box side of the unit.
NOTE: With extremely cold ambient temperatures it may
take up to 15 seconds for the display to appear on initial
startup.
If the Premium Truck HMI Control Panel is turned on and the
Base Controller On/Off Switch is turned off, the HMI display
screen will briefly show LOST CONTROLLER POWER. The
HMI will then power down.
The unit is turned on by pressing the ON key and off by
pressing the OFF key. When the ON key is pressed the display
briefly shows the THERMO KING Logo as the display
initializes.
IMPORTANT: The ON key must be held down until the
Thermo King Logo appears as shown in Figure 20. If the ON
key is not held down long enough (approximately ½ second),
the display may flicker but the unit will not start up. If this
occurs, hold the ON key down until the Thermo King logo
appears.
Figure 20: Thermo King Logo
Then the startup screen shown in Figure 21 appears while
communications are established and the unit prepares for
operation.
Figure 21: Startup Screen
41
Unit Operation
If More Than One Language is
Enabled
If more than one language has been enabled, a prompt will
appear to allow the desired language to be chosen as shown
below. Only languages enabled from the Guarded Access
Menu are available. If a different language is desired, press the
NO key as shown in Figure 22.
Figure 23: YES Key
The display will briefly show PROGRAMMING
LANGUAGE - PLEASE WAIT in the new language as shown
in Figure 24.
Figure 22: NO key
The Language menu will appear as shown in Figure 23. Press
the + or - keys to select the desired language. When the desired
language is shown press the YES key to confirm the choice.
Figure 24: Programming Language
The new language is confirmed, and then the Standard Display
will appear in the new language as shown in Figure 25. The
unit is ready to run.
42
Unit Operation
The Language Menu will appear in the current language as
shown in Figure 27. Press the + or - keys to select the desired
language. When the desired language is shown press the YES
key to confirm the choice. Note that all languages in the
installed software can be selected using this method.
Figure 25: Standard Display
Should it be necessary to change to another language at any
time, return to the Standard Display and then press and hold the
first and last soft keys for 5 seconds as shown in Figure 26. The
Standard Display below is shown in Deutsch (German).
Figure 27: Language Menu
When the unit is ready to run the Standard Display appears.
Figure 26: First and Last Soft Keys
Figure 28: Standard Display
43
Unit Operation
Pressing the OFF key stops unit operation. The unit shuts down
immediately and the display briefly shows the power down
message.
The Standard Display
The Standard Display is the default display that appears if no
other display function is selected. The Standard Display shows
the box temperature and setpoint. The box temperature is that
measured by the controlling sensor, usually the return air
sensor. The box temperature in Figure 31 is 35.8 F with a 35 F
setpoint.
Figure 29: Power Down Message
The display briefly shows OFF and then goes blank. To start
the unit again, press the ON key.
Figure 31: Standard Display
The CYCLE-SENTRY Icon in the upper right corner of the
display shows that the unit is operating in CYCLE-SENTRY
Mode. If the CYCLE-SENTRY Icon is not present, the unit is
operating in Continuous Mode.
Figure 30: Off Display
44
The down-pointing arrow indicates that the unit is cooling. If
the unit was heating the arrow would be pointing upward.
Unit Operation
Pressing the left soft key allows the user to change the
SETPOINT, and pressing the right soft key accesses the MAIN
MENU. The other two soft keys access the GAUGES menu
and the SENSORS menu.
Changing the Setpoint
From the Standard Display, press the SETPOINT soft key.
Figure 33: Setpoint Display
The "-" and "+" soft keys are used to increase or decrease the
setpoint until the desire setpoint is shown. In Figure 34 the
setpoint has been changed to 40 F using the "+" key.
Figure 32: SETPOINT Key
The setpoint display appears as shown in Figure 33.
Figure 34: Increase Setpoint
45
Unit Operation
The YES and NO soft keys confirm the setpoint change. When
the desired setpoint has been selected using the "+" and/or "-"
keys, press the YES soft key to confirm and load the new
setpoint. If the setpoint is changed using the "+" or "-" keys,
the change must be confirmed or rejected by pressing the YES
or NO soft key within 10 seconds of changing the setpoint.
After the YES soft key has been pressed, the display briefly
shows PROGRAMMING NEW SETPOINT - PLEASE WAIT.
The display then confirms the new setpoint for several
seconds.
Failure to confirm the new setpoint by pressing YES or NO
within 10 seconds of changing the setpoint will result in no
setpoint change. In addition, Alarm Code 127 Setpoint Not
Entered is set, to indicate that the setpoint change was not
completed.
Figure 36: New Setpoint
Figure 35: Soft Keys
46
If the NO soft key is pressed the display will briefly show
SETPOINT NOT CHANGED and return to the Standard
Display. The Standard Display will show the old setpoint.The
display then returns to the Standard Display showing the new
setpoint. Notice in Figure 37 that the arrow now points up to
indicate that the unit is heating.
Unit Operation
Setpoint Display. The display briefly shows [SETPOINT
NOT CHANGED] and Alarm Code 127 Setpoint Not
Entered is set, to indicate that a setpoint change was
started but not completed.
Starting the Diesel Engine
Figure 37: Standard Display, New Setpoint
IMPORTANT: If the setpoint is changed using the "+" or
"-" keys, the change must be confirmed or rejected by
pressing the YES or NO soft key within 10 seconds of
changing the setpoint.
•
If the YES key is pressed, the setpoint change made with
the "+" or "-" key is accepted, the setpoint changes, and
the display returns to the Standard Display.
•
If the NO key is pressed the setpoint change made with the
"+" or "-" key is not accepted, the setpoint is not changed,
and the display returns to the Standard Display.
•
If either the YES or NO key is not pressed within 10
seconds of making a change with the "+" or "-" key, the
setpoint is not changed, and the display returns to the
Diesel engine preheats and starts are automatic in both
Continuous Mode and CYCLE-SENTRY Mode. The engine
will preheat and start as required when the unit is turned on.
The engine preheat and start will be delayed in
CYCLE-SENTRY mode if there is no current need for the
engine to run. If any keys are being pressed on the HMI control
panel the engine will not preheat and start until 10 seconds
after the last key is pressed
NOTE: If the unit is equipped with optional Electric Standby
there may be some additional prompts before the engine will
start. See STARTING THE ELECTRIC MOTOR on the
following pages for details.
CAUTION: The engine may start automatically any time the
unit is turned on.
WARNING: Never use starting fluid.
47
Unit Operation
When the engine is preparing to start the HMI control panel
will display the engine start screen, as shown in Figure 38. The
preheat buzzer sounds during the engine preheat and crank
sequence.
Figure 38: Engine Start Screen
After the engine is started the display returns to the Standard
Display of temperature and setpoint.
Figure 39: Standard Display of Temperature and
Setpoint
48
Starting the Electric Motor
Units equipped with the Electric Standby option only.
Electric motor starting is automatic in both Continuous Mode
and CYCLE-SENTRY Mode. The motor will start as required
when the unit is turned on. If any keys are being pressed on the
HMI control panel prior to the motor start, the motor start will
be delayed until 10 seconds after the last key is pressed.
CAUTION: The motor may start automatically any time the
unit is turned on.
When the motor is preparing to start the HMI control panel will
display the motor start screen, as shown in Figure 40. The
preheat buzzer sounds for 20 seconds before the electric motor
starts.
Figure 40: Motor Start Screen
Unit Operation
After the motor is running the display returns to the Standard
Display of temperature and setpoint.
Figure 42: Prompt Screen, Guarded Access Set to No
Figure 41: Standard Display of Temperature and
Setpoint
If YES is selected then the display will briefly show the screen
in Figure 43.
Switching from Diesel to Electric
Units equipped with the Electric Standby option only.
If the Diesel to Electric Autoswitch Enabled feature in
Guarded Access is set YES then the unit will automatically
switch to Electric Mode operation when standby power is
connected and available.
If the Diesel to Electric Autoswitch Enabled feature in
Guarded Access is set NO then the prompt screen shown in
Figure 42 will appear when standby power is connected and
available.
Figure 43: Prompt Screen, Guarded Access Set to Yes
Electric Mode operation will briefly be confirmed. If unit
operation is required the electric motor will start as shown in
STARTING THE ELECTRIC MOTOR.
49
Unit Operation
Switching from Electric to Diesel
Units equipped with the Electric Standby option only.
If the Electric to Diesel Autoswitch Enabled feature in
Guarded Access is set YES then the unit will automatically
switch to Diesel Mode operation when standby power is turned
off or is no longer available.
Turn the unit off and back on using the OFF and ON Keys.
This will clear Alarm Code 91 Check Electric Ready Input and
Alarm Code 84 Restart Null.
NOTE: The CLEAR Soft Key will not clear these two alarms.
Then the prompt screen shown in Figure 45 will appear.
If the Electric to Diesel Autoswitch Enabled feature in
Guarded Access is set NO then the prompt screen in Figure 44
will appear when standby power is turned off or is no longer
available. Alarm Code 91 Check Electric Ready Input and
Alarm Code 84 Restart Null will both be set.
Figure 45: Prompt Screen, after OFF and ON
If YES is selected then the display will briefly show the screen
in Figure 46. Then Diesel Mode operation will briefly be
confirmed.
Figure 44: Prompt Screen, standby power is turned
off or is no longer available
50
Unit Operation
Figure 46: Display is YES is selected
If unit operation is required the diesel engine will start as
shown previously in STARTING THE DIESEL ENGINE.
Figure 47: Press Defrost Key
The display briefly shows [DEFROST], [PROGRAMMING
DEFROST - PLEASE WAIT] and then [DEFROST
STARTED].
Initiating a Manual Defrost Cycle
Defrost cycles are usually initiated automatically based on time
or demand. Manual defrost is also available.
Manual defrost is available if the unit is running and the
evaporator coil temperature is less than or equal to 45°F (7°C).
Other features such as door switch settings may not allow
manual defrost under some conditions. To initiate a manual
defrost cycle, press the Defrost Key as shown in Figure 47.
Figure 48: Prompt Screen, Guarded Access Set to Yes
51
Unit Operation
The display then shows the Defrost display. The bar indicator
shows approximately how much time remains to complete the
defrost cycle. The bar indicator in Figure 48 shows that the
defrost cycle is about 25% complete.
Selecting High Speed Lockout
Mode (If Enabled)
High speed operation can be locked out in noise sensitive areas
if required.
NOTE: High Speed Lockout Enable must be set to [Enabled]
in the Guarded Access/Programmable Features Menu or this
feature will not be available.
Figure 49: Defrost Display
Terminating a Defrost Cycle
The defrost cycle terminates automatically when the coil
temperature is greater than or equal to 52 F (11 C) or the
defrost timer expires. Defrost can also be terminated by turning
the unit off and back on.
52
IMPORTANT: HIGH SPEED LOCKOUT TIMEOUT: If
High Speed Lockout Mode is selected, the High Speed Inhibit
Timeout feature may be set to return the unit to normal
operation after a set time period has expired. This prevents
extended operation with high speed operation locked out. The
time period may be from 15 minutes to 2 hours. If the time
period is set and is exceeded the unit will return to normal
operation, with high speed operation allowed. If this occurs,
the message HIGH SPEED LOCKOUT ACTIVE at the top of
the display will disappear. If necessary to return to High
Speed Lockout Mode, press the High Speed Lockout Key
again.
Unit Operation
The High Speed Lockout Key is a toggle. If high speed is
currently allowed, then pressing the High Speed Lockout Key
will disable high speed operation. Pressing the High Speed
Lockout Key again will allow high speed operation. To change
the setting, press the High Speed Lockout key as shown below.
Figure 51: PROGRAMMING HIGH SPEED LOCKOUT PLEASE WAIT
Figure 50: High Speed Lockout Key
The change is confirmed by briefly displaying [HIGH SPEED
LOCKOUT ACTIVE] or [HIGH SPEED LOCKOUT
INACTIVE].
The display will briefly show [PROGRAMMING HIGH
SPEED LOCKOUT - PLEASE WAIT].
Figure 52: High Speed Lockout Display
53
Unit Operation
The display will then return to the Standard Display. If High
Speed Lockout is turned on, the message HIGH SPEED
LOCKOUT ACTIVE will be shown at the top of the display.
Figure 53: Standard Display, High Speed Lockout
Active
Pressing the High Speed Lockout key again will turn the
feature off.
Selecting CYCLE-SENTRY or
Continuous Mode
With Thermo King Truck unit applications, CYCLE-SENTRY
Mode or Continuous Mode operation is selected from the Main
Menu - Mode Submenu. See the Main Menu - Mode Submenu
material later in this section for complete details.
54
Using the Gauges Key
The GAUGES key allows the operator to view the unit gauges.
To access the GAUGES menu press the GAUGES key.
Figure 54: Gauges Key
The first gauge display will appear. Press the NEXT and
BACK keys to scroll thru the gauges as desired. The Battery
Voltage Gauge is shown in Figure 55. Press the LOCK key to
lock the selected gauge on the display.
Unit Operation
Coolant Level - Displays the coolant level in the overflow tank
as OK or LOW.
Oil Pressure - Displays the engine oil pressure as OK or LOW.
Oil Level - Displays the engine oil level as OK or LOW.
Amps - Displays the current flow in amps to or from the unit
battery.
Figure 55: Next, Back, Lock Keys
The gauges available are shown in the following list. The order
in which the gauges appear may vary slightly based on
software revision. Not all gauges may appear, depending on
unit configuration and software revision
Battery Voltage - Displays the voltage of the unit battery.
Engine RPM - Displays the engine speed in RPMs.
Discharge Pressure - Displays the unit discharge pressure.
(ETV units only)
To return to the Standard Display press the EXIT key.
Suction Pressure - Displays the unit suction pressure. (ETV
units only)
Gauges Available
ETV Position - Displays the current position of the Electronic
Throttling Valve (ETV). (ETV units only)
NOTE: Not all gauges or I/O states will appear, dependent
upon unit type and configuration
Compressor Temperature - Displays the temperature sensed by
the compressor temperature sensor.
Coolant Temperature - Displays the temperature of the engine
coolant.
I/O (Input/Output State) - Displays the current state of the
input/output devices listed below as ON or OFF.
55
Unit Operation
•
High Speed Relay/Electric Heat
•
Run Relay
•
Run Relay Feedback
•
Alternator Excite Output
•
Defrost Damper
•
Hot Gas Solenoid
•
Alternator Frequency
•
Diesel/Electric Relay (Model 50 units only)
•
Electric Ready Input (Model 50 units only)
•
Electric Overload (Model 50 units only)
•
Condenser Inlet Solenoid
•
Drain Hose Heater
•
Purge Valve
Figure 56: Sensors Key
The first sensor display will appear. Press the NEXT and
BACK keys to scroll thru the sensors as desired. The Discharge
Air Temperature sensor is shown in Figure 57. Press the LOCK
key to lock the current sensor on the display.
Using the Sensors Key
The SENSORS key allows the operator to view the
temperatures read by the unit temperature sensors. To access
the SENSORS menu press the SENSORS key.
56
Figure 57: Next, Back, Lock Keys
Unit Operation
To return to the Standard Display press the EXIT key.
Data Logger Sensor 3 Temperature - Display the temperature
of Data Logger Sensor 3.
Sensors Available
Data Logger Sensor 4 Temperature - Display the temperature
of Data Logger Sensor 4.
Return Air Temperature - Displays the temperature of the
control return air sensor.
Data Logger Sensor 5 Temperature - Display the temperature
of Data Logger Sensor 5.
Discharge Air Temperature - Displays the temperature of the
control discharge air sensor.
Data Logger Sensor 6 Temperature - Display the temperature
of Data Logger Sensor 6
Temperature Differential - Displays the calculated difference
between the control return air sensor and the control discharge
air sensor.
Using The Main Menu
Evaporator Coil Temperature - Displays the temperature of the
evaporator coil sensor.
The Main Menu contains several additional submenus that
allow the operator to view information and modify unit
operation. To access the Main Menu press the MENU key.
The sensors available are shown in the following list.
Ambient Air Temperature - Displays the temperature of the
ambient air sensor.
Data Logger Sensor 1 Temperature - Display the temperature
of Data Logger Sensor 1.
Data Logger Sensor 2 Temperature - Display the temperature
of Data Logger Sensor 2.
57
Unit Operation
See “Main Menu Choices.” For detailed information see the
individual explanations of each submenu item on the following
pages.
To return to the Standard Display press the EXIT key.
Main Menu Choices
Figure 58: Menu Key
The first Main Menu choice will appear. Press the NEXT and
BACK keys to scroll thru the menu choices. When the desired
selection is shown on the display, press the SELECT key to
access it. The Pretrip submenu is shown in Figure 59.
LANGUAGE - If more than one language is enabled, this will
be the first menu item to appear. If only one language is
enabled, this menu will not appear. The Language Menu allows
the operator to select a language from a list of up to 11
languages at one time. All subsequent displays are shown in
the selected language. Three different language packages with
a total of 23 languages are available. English is the default
language and is provided in each of the packages.
ALARMS - Allows the operator to view all alarms, and allows
most alarms to be cleared. If only one language is enabled this
will be the first menu item to appear.
Figure 59: Pretrip Submenu
58
DATA LOGGER - Allows the operator to set a Start of Trip
marker to the ServiceWatch data logger. Also allows a Start of
Trip and Print requests to be sent to the Optional DAS Data
Logger (if installed).
Unit Operation
HOURMETERS - Allows the operator to view the unit
hourmeters that have the view feature enabled in the Guarded
Access menu. If the view feature for a particular hourmeter is
not enabled then that hourmeter will continue to accumulate
time but cannot be viewed from the Main Menu. However, all
hourmeters can be viewed from the Maintenance Menu, even if
they are not enabled.
MODE - Allows the operator to change the unit operating
modes if allowed. Not all modes may appear depending on the
settings selected from the Guarded Access menu and the HMI
Control Panel software version.
•
"Turn Off CYCLE-SENTRY Mode/Turn On
CYCLE-SENTRY Mode (If CYCLE-SENTRY is Off unit
runs in Continuous).
•
Allow Keypad Lockout to be selected.
•
Start Sleep Mode.
ELECTRIC STANDBY - If the Electric Standby option is
present and the Diesel to Electric Auto-switch feature is set
NO, this feature allows the operator to manually select electric
mode operation. This feature does not appear if the unit does
not feature optional Electric Standby or if the Diesel to Electric
Auto-switch feature is set YES.
DIESEL MODE - If a unit equipped with electric standby is
running in electric mode and the Electric to Diesel Auto-switch
feature is set NO, this feature allows the operator to manually
select diesel mode operation. This feature does not appear if
the unit does not feature optional Electric Standby or if the
Electric to Diesel Auto-switch feature is set YES.
ADJUST BRIGHTNESS - Allows the operator to adjust the
HMI Control Panel display backlight intensity as required by
local conditions.
TIME - Allows the operator to view the unit time and date. The
time and date cannot be changed from this menu.
PRETRIP - Allows the operator to start a Pretrip Test. If an
alarm is active, the Pretrip Test is not allowed and the operator
is prompted to clear the alarm(s).
59
Unit Operation
Languages
If the Language feature is enabled, an alternate language can be
selected from the Language Menu. After a new language is
chosen, all subsequent displays will appear in that language. If
the language feature is not enabled this menu does not appear.
The default language is English. Only languages that have
been enabled in Guarded Access will appear. Exercise care
when changing languages, as once changed all HMI Control
panel displays will be in the new language. If the user is not
familiar with the new language, problems may be experienced
returning to the default language.
The languages available are dependent on the HMI control
panel software revision.
•
Languages currently supported by software revision 65xx
are English, Spanish, French, German, Italian, Dutch,
Portuguese, Greek, Turkish, Hebrew and Arabic.
•
Languages currently supported by software revision 66xx
are English, Danish, Russian, Norwegian, Swedish,
Finnish, Polish, Hungarian, Romanian, Bulgarian and
Czech.
60
•
Languages currently supported by software revision 67xx
are English, Japanese and Chinese. Other than the
languages supported, software revisions 65xx, 66xx and
67xx are functionally identical.
To select an alternate language, press the MENU key.
Figure 60: Menu Key
If enabled, the Language Menu is the first menu item to appear
as shown in Figure 61. Press the SELECT key to choose the
Language menu.
Unit Operation
The display will briefly show PROGRAMMING
LANGUAGE - PLEASE WAIT in the new language as shown
in Figure 63.
Figure 61: Select Key
The Language menu will appear as shown in Figure 62. Press
the + or - keys to select the desired language. When the desired
language is shown press the YES key to confirm the choice.
Figure 63: New Language
The new language is confirmed, and then the Standard Display
will appear in the new language as shown in Figure 64. The
unit is ready to run.
Figure 62: + or - Keys, Yes Key
Figure 64: Standard Display in New Language
61
Unit Operation
Repeat the process to select a different language. To select a
different Main Menu item press the NEXT key. To return to the
Standard Display press the EXIT key.
press the YES key to confirm the choice. Note that all
languages in the installed HMI Control Panel software (65xx,
66xx or 67xx) can be selected using this method.
IMPORTANT: If necessary, English and all other languages
in the installed HMI Control Panel software revision may be
accessed from the Standard Display.
Should it be necessary to change to another language at any
time, return to the Standard Display and then press and hold the
first and last soft keys for 5 seconds as shown in Figure 65. The
Standard Display below is shown in Deutsch (German).
Figure 66: Language Menu
Alarms
Alarm Types
Alarms may be one of four types as shown.
Figure 65: Standard Display in New Language
After 5 seconds the Language Menu will appear in the current
language as shown in Figure 66. Press the + or - keys to select
the desired language. When the desired language is shown
62
Unit Operation
Log Alarms
Log Alarms are indicated for 60 seconds each time the unit is
turned on. This level of alarm serves as a notice to take
corrective action before the condition impacts unit
performance. Maintenance items such as maintenance
hourmeter time-outs are log alarms.
When the unit is turned on the display will show the Thermo
King Logo and then the "Configuring System" message. If log
alarm(s) are present the Log Alarm notice will appear on the
display for 60 seconds as shown. The amber K symbol of the
remote indicator alarm light (if installed) will also be on during
this period. The Standard Display will appear and the remote
indicator alarm light will go to the white T symbol after 60
seconds.
NOTE: The Alarm Icon does not appear on startup with log
alarms present.
Figure 67: Log Alarm Notice
NOTE: If required, an engine start may occur while the
display in Figure 67 is shown. This is normal operation.
Check Alarms
Check Alarms are indicated by an Alarm Icon in the display.
The amber K symbol of the remote indicator alarm light (if
installed) will be on. This level of alarm serves as a notice to
take corrective action before a problem becomes severe. The
unit will run with check alarms but some features and functions
may be inhibited.
63
Unit Operation
Shutdown Alarms
Prevent Alarms
Shutdown alarms will be set if continued operation could cause
damage to the unit or the load. Shutdown Alarms are indicated
by the following:
Prevent Alarms are also indicated by a steady Alarm Icon in
the display. The remote indicator alarm light (if installed) will
be on. The unit will attempt to resolve the situation as shown
below.
•
The Alarm Icon will appear in the display.
•
The display and backlight will flash on and off.
•
The display will switch from normal video to reverse
video and back to normal video. (Light areas become dark
and dark areas become light.)
•
The remote indicator alarm light (if installed) will display
only a row of LEDs at the bottom.
Shutdown alarms will force the unit into shutdown to prevent
potential damage to the unit or load. The unit will remain in
shutdown until the shutdown alarm is manually cleared.
Exceptions are some engine and electric shutdown alarms that
become log alarms when switched to the alternate operating
mode (diesel to electric or electric to diesel).
64
•
The unit will be temporarily shut down if a Prevent Alarm
is active.
•
The unit will remain shut down for a timed restart interval
or until the fault conditions are corrected.
•
If the unit is in a temporary shutdown, Alarm Code 84
Restart Null will be present along with the associated
Prevent Alarm.
•
The unit will restart and run (in most cases with forced
reduced performance) to determine if continued operation
is possible. The unit will run in this manner for a timed
interval. If the unit is running with forced reduced
performance, Alarm Code 85 Forced Unit Operation will
also be present under some conditions.
•
If the alarm does not reoccur during the timed running
interval with reduced performance, the unit will return to
full performance to determine if continued operation is
Unit Operation
possible. The unit will run in this manner for a timed
interval. If the unit is successfully able to return to full
performance for the timed interval without the alarm
re-occurring, the alarm is auto cleared and the unit will run
normally.
•
All Prevent Alarm events and conditions are logged by the
ServiceWatch Data Logger.
•
In general, if the alarm condition re-occurs a defined
number of times, the alarm is set as a shutdown alarm and
no further restarts are possible.
NOTE: If the Restart After Shutdown feature in the Guarded
Access Menu is set for CONTINUOUS, then an unlimited
number of restart attempts are allowed.
Pretrip Alarm Codes
If an alarm occurs during a Pretrip Test the alarm code will be
displayed as Pretrip Alarm XX, where XX is the alarm code.
Alarm Codes When Switching Between
Diesel and Electric
If a shutdown alarm occurs that affects only diesel mode
operation and the unit is switched to electric, the diesel mode
shutdown alarm becomes an electric mode log alarm. This
allows the unit to run in electric mode without clearing the
shutdown alarm that is preventing diesel mode operation. If the
unit is switched back to diesel mode, the alarm again become a
diesel mode shutdown alarm and prevents unit operation.
In the same manner, if a shutdown alarm occurs that affects
only electric mode operation and the unit is switched to diesel,
the electric mode shutdown alarm becomes a diesel mode log
alarm to allow diesel mode operation. If the unit is switched
back to electric mode, the alarm reverts to an electric mode
shutdown alarm and prevents unit operation. If the unit is
configured for electric to diesel autoswitch, it automatically
starts and runs in diesel mode if an electric shutdown occurs.
Alarm Code Notification
The Alarm Icon used in previous Thermo King controllers has
been incorporated. If a Check alarm condition occurs the
Alarm Icon will appear in the display as shown in Figure 68.
65
Unit Operation
The following control and display sensor alarm codes can only
be cleared from the Maintenance Menu or Guarded Access
Menu:
•
Alarm Code 03 Check Control Return Air Sensor
•
Alarm Code 04 Check Control Discharge Air Sensor
The following alarm codes clear automatically.
Figure 68: Alarm Icon
If a Shutdown Alarm occurs it will be indicated by all of the
following:
•
Alarm Code 64 Pretrip Reminder - Clears when a Pretrip
Test is performed.
•
Alarm Code 84 Restart Null - Clears when the unit is no
longer in a restart null due to a Prevent Alarm.
1.
The Alarm Icon will appear.
2.
The display and backlight will flash on and off.
•
3.
The display will switch from normal video to reverse
video and back to normal video. (Light areas become dark
and dark areas become light.)
Alarm Code 85 Forced Unit Operation - Clears when the
unit is no longer running in a forced mode due to a Prevent
Alarm.
•
Alarm Code 91 Check Electric Ready Input - Clears
automatically when the unit starts running.
•
Alarm Code 92 Sensor Grades Not Set - Clears when the
sensor grade is changed from 5H.
Clearing Alarm Codes
Most alarm codes can be cleared conventionally from the
Alarm Menu using the CLEAR key.
66
Unit Operation
If the Limited Alarm Restarts feature is enabled the following
additional alarm codes may only be cleared from the Guarded
Access Menu. If this is the case, the CLEAR soft key will not
appear if the alarms are displayed from the Main Menu or the
Maintenance Menu.
•
Alarm Code 10 High Discharge Pressure
•
Alarm Code 23 Cooling Cycle Fault
•
Alarm Code 24 Heating Cycle Fault
•
Alarm Code 32 Refrigeration Capacity Low
Displaying and Clearing Alarm Codes
Alarms are displayed and cleared using the Alarm Menu. From
the Standard Display, press the MENU key.
Figure 69: Menu Key
The Language Menu or Alarms Menu will appear. If the
Language Menu appears press the NEXT key to show the
Alarm Menu. When the Alarms Menu is shown press the
SELECT key.
Figure 70: Select Key
The Alarm Display will appear. If no alarms are present NO
ALARMS will be shown.
Figure 71: No Alarms
67
Unit Operation
If alarms are present, the quantity of alarms (if more than one)
and the most recent alarm code number will be shown. In the
example in Figure 72, there are two alarms present. The most
recent is Alarm Code 5 (Figure 73). It indicates a problem with
the ambient temperature sensor.
Figure 73: Next Key
Figure 72: Alarm Code 6
After the alarm situation is resolved press the CLEAR key to
clear the alarm. For additional information regarding the alarm
shown on the display, press the HELP key. To display the next
alarm, press the NEXT key.
68
If a serious condition occurs, the unit will be shut down to
prevent damage to the unit or the load. If this occurs, the
display will show that the unit is shut down and display the
alarm code that caused the shutdown. In the example in Figure
74, the unit is shut down due to low oil level. For additional
information regarding the alarm shown on the display, press
the HELP key.
Unit Operation
Figure 74: Help Key
A help message will appear. For the alarm shown in Figure 74,
the message "CHECK OIL LEVEL. IF UNIT IS SHUT
DOWN, REPAIR IMMEDIATELY. OTHERWISE, REPORT
ALARM AT END OF THE DAY" will be shown on the
display. Check the oil level and add oil as required, clear the
alarm and restart the engine.
•
If an alarm cannot be cleared from the Main menu, the
Clear key will not appear. These alarms must be cleared
from the Maintenance or Guarded Access Menus.
•
All alarms must be viewed before any of the alarms can be
cleared.
SR-3 Alarm Codes
NOTE: Not all alarm codes are used with all applications.
Code
No Alarms Exist
2
Check Evaporator
Coil Sensor
To select a different Main Menu item press the NEXT key. To
return to the Standard Display press the EXIT key.
Important Alarm Notes
•
If an alarm will not clear, it may still exist. If the alarm is
not corrected, it will not clear or may be immediately set
again.
Description
0
3
4
Operator Help
Manually monitor load
temperature. Report
alarm at end of the day.
Manually monitor load
temperature. Report
alarm at end of the day.
Manually monitor load
Check (Control)
temperature. Report
Discharge Air Sensor
alarm at end of the day.
Check (Control)
Return Air Sensor
69
Unit Operation
Code
Description
Operator Help
5
Check Ambient Air
Sensor
Report alarm at end of
the day.
6
Check Coolant Temp Report alarm at end of
Sensor
the day.
7
Check Engine RPM
Sensor
9
High Evaporator
Temperature
10
11
12
70
Report alarm at end of
the day.
Manually monitor load
temperature. Report
alarm at end of the day.
High Discharge
Pressure
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Unit Controlling on
Alternate Sensor
Manually monitor load
temperature. Report
alarm at end of the day.
Sensor or Digital
Input Shutdown
The indicated zone is not
longer able to operate
and has been shut down.
Repair immediately.
Code
Description
Operator Help
13
Sensor Check
Manually monitor load
temperature. Report
alarm at end of the day.
15
If unit is shut down repair
Check Glow Plugs or immediately. Otherwise,
report alarm at end of the
Intake Air Heater
day.
17
Engine Failed to
Crank
18
19
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
If unit is shut down repair
High Engine Coolant immediately. Otherwise,
report alarm at end of the
Temperature
day.
Low Engine Oil
Pressure
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Unit Operation
Code
Description
20
If unit is shut down repair
immediately. Otherwise,
Engine Failed to Start
report alarm at end of the
day.
21
Manually monitor load
Cooling Cycle Check temperature. Report
alarm at end of the day.
22
23
24
25
Operator Help
Manually monitor load
Heating Cycle Check temperature. Report
alarm at end of the day.
The indicated zone is not
Cooling Cycle Fault longer able to operate
and has been shut down.
Heating Cycle Fault
The indicated zone is not
longer able to operate
and has been shut down.
Alternator Check
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Code
Description
Operator Help
26
Check Refrigeration
Capacity
Manually monitor load
temperature. Report
alarm at end of the day.
28
Pretrip or Self Check Report alarm at end of
Abort
the day.
29
Defrost Damper
Circuit Check
30
Defrost Damper
Stuck
31
Check Oil Pressure
Switch
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
32
Refrigeration
Capacity Low
The indicated zone is not
longer able to operate
and has been shut down.
Repair immediately.
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
71
Unit Operation
Code
33
35
36
37
Description
Operator Help
Check Engine RPM
Report alarm at end of
the day.
Check Run Relay
Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
If unit is shut down repair
Electric Motor Failed immediately. Otherwise,
report alarm at end of the
to Run
day.
Check Engine
Report alarm at end of
Coolant Level
the day.
38
Electric Phase
Reversed
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
39
Check Water Valve
Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
72
Code
Description
Operator Help
40
Check High Speed
Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
41
If unit is shut down repair
immediately. Otherwise,
Check Engine
Coolant Temperature report alarm at end of the
day.
Unit Forced to Low
Speed
Unit Forced to Low
Speed Modulation
Report alarm at end of
the day.
Report alarm at end of
the day.
44
Check Fuel System
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
45
Hot Gas or Hot Gas
Bypass Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
42
43
Unit Operation
Code
Description
Operator Help
46
Check Air Flow
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
48
If unit is shut down repair
immediately. Otherwise,
Check Belts or Clutch
report alarm at end of the
day.
50
Reset Clock
52
54
Check Heat Circuit
Test Mode Timeout
Report alarm at end of
the day.
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Service Test or Interface
Board Test timed out
after 15 minutes. Report
alarm at end of the day.
Code
Description
Operator Help
61
Low Battery Voltage
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
62
Ammeter Out of
Calibration
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Report alarm at end of
the day.
63
Engine Stopped
64
Pretrip Reminder
66
Check engine oil level. If
unit is shut down repair
Low Engine Oil Level immediately. Otherwise,
report alarm at end of the
day.
73
Unit Operation
Code
Description
Operator Help
67
Check Liquid Line
Solenoid Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
68
Internal Controller
Fault Code
Report alarm at end of
the day.
70
Hourmeter Failure
74
Controller Reset to
Defaults
Report alarm at end of
the day.
Report alarm at end of
the day.
Code
Description
Operator Help
81
High Compressor
Temp
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
82
High Compressor
Temp Shutdown
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
83
Low Engine Coolant
Temperature
84
Restart Null
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Report alarm at end of
the day.
77
Controller EPROM
Checksum Failure
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
79
Internal Data Logger
Overflow
Report alarm at end of
the day.
85
Forced Unit
Operation
Report alarm at end of
the day.
80
Check Compressor
Temp Sensor
Report alarm at end of
the day.
86
Check Discharge
Pressure Sensor
Report alarm at end of
the day.
87
Check Suction
Pressure Sensor
Report alarm at end of
the day.
74
Unit Operation
Code
89
90
91
92
93
Description
Operator Help
Check Electronic
Throttling Valve
Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Electric Overload
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
If unit is shut down repair
Check Electric Ready immediately. Otherwise,
report alarm at end of the
Input
day.
Sensor Grades Not
Report alarm at end of
Set
the day.
Low Compressor
Suction Pressure
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Code
Description
Operator Help
94
Check Loader #1
Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
95
Check Loader #2
Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Check engine fuel level.
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Report alarm at end of
the day.
96
Low Fuel Level
98
Check Fuel Level
Sensor
99
High Compressor
Pressure Ratio
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
108
Door Open Timeout
Close Doors. Report
alarm at end of the day.
75
Unit Operation
Code
Description
Operator Help
111
Unit Not Configured
Correctly
Report alarm at end of
the day.
Check Electric Heat
Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
113
114
115
If unit is shut down repair
Multiple Alarms - Can immediately. Otherwise,
report alarm at end of the
Not Run
day.
If unit is shut down repair
Check High Pressure immediately. Otherwise,
report alarm at end of the
Cut Out Switch
day.
116
Check High Pressure Report alarm at end of
Cut In Switch
the day.
117
Auto Switch from
Diesel to Electric
Report alarm at end of
the day.
118
Auto Switch from
Electric to Diesel
Report alarm at end of
the day.
76
Code
Description
Operator Help
120
Check Alternator
Excite Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
121
Check Liquid
Injection Circuit
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
122
127
If unit is shut down repair
Check Diesel/Electric immediately. Otherwise,
report alarm at end of the
Circuit
day.
Be sure the setpoint is
Setpoint Not Entered set to the required
temperature.
128
Engine Run Time
Maintenance
Reminder #1
Report alarm at end of
the day.
129
Engine Run Time
Maintenance
Reminder #2
Report alarm at end of
the day.
Unit Operation
Code
Description
130
Electric Run Time
Maintenance
Reminder #1
Report alarm at end of
the day.
131
Electric Run Time
Maintenance
Reminder #2
Report alarm at end of
the day.
132
133
Total Unit Run Time
Maintenance
Reminder #1
Total Unit Run Time
Maintenance
Reminder #2
Operator Help
Code
Description
Operator Help
141
Autoswitch Diesel to
Electric Disabled
Report alarm at end of
the day.
145
Loss of Controller
"On" Feedback
Signal
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Report alarm at end of
the day.
146
Software Version
Mismatch
Report alarm at end of
the day.
148
134
Controller Power On
Hours
Report alarm at end of
the day.
135
Check Spare Digital
Inputs
Report alarm at end of
the day.
136
Check Spare Digital
Outputs
Report alarm at end of
the day.
137
Check Damper Motor Report alarm at end of
Heater Output
the day.
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
Autoswitch Electric to Report alarm at end of
Diesel Disabled
the day.
149
Alarm Not Identified
If unit is shut down repair
immediately. Otherwise,
report alarm at end of the
day.
150
Out of Range Low
Manually monitor load
temperature. Report
alarm at end of the day.
77
Unit Operation
Code
Description
Operator Help
151
Out of Range High
Manually monitor load
temperature. Report
alarm at end of the day.
203
Check Display
Return Air Sensor
Manually monitor load
temperature. Report
alarm at end of the day.
204
Manually monitor load
Check Display
temperature. Report
Discharge Air Sensor
alarm at end of the day.
The ServiceWatch Data Logger and DAS Data Logger (if
equipped) are accessed using the Data Logger Menu. From the
Standard Display, press the MENU key.
Figure 75: Menu Key
Datalogger
The unit can be equipped with an optional DAS Data Logger if
desired.
The Language Menu or Alarm Menu will appear. Press the
NEXT key as required to display the Data Logger Menu. When
the Data Logger Menu is shown press the SELECT key.
A Start of Trip marker can be sent to the unit ServiceWatch
Data Logger and the optional DAS Data Logger (if equipped).
If equipped with the optional DAS Data Logger, the most
recent DAS trip record can be printed. The most recent trip is
defined as the trip following the last Start of Trip marker sent
to the data logger.
Figure 76: Select Key
78
Unit Operation
The first feature that appears is the Start of Trip. To send a Start
of Trip to the ServiceWatch Data Logger and DAS Data
Logger (if equipped), press the SELECT key to select the
feature, and then press it again to send the Start of Trip. The
display will briefly show START OF TRIP COMPLETE to
confirm that a Start of Trip marker was set in the data
logger(s).
Figure 78: Select Key
Pressing the EXIT key returns the display to the Main Menu.
Hourmeters
Figure 77: Start of Trip
Hourmeters are displayed using the Hourmeter Menu. Only
hourmeters enabled in the Guarded Access Menu will be
shown. From the Standard Display, press the MENU key.
NOTE: The start of trip marker is sent to both the
ServiceWatch Data Logger and DAS Data Logger (if
equipped).
Press the NEXT key to select the PRINT feature. The PRINT
screen will appear. Press the SELECT key to print the most
recent trip record to the optional remote printer.
Figure 79: Menu Key
79
Unit Operation
The Language Menu or Alarm Menu will appear. Press the
NEXT key as required to display the Hourmeter Menu. When
the Hourmeter Menu is shown press the SELECT key. The
Hourmeter Display will appear.
Hourmeter names and definitions are shown in the table below
in the order they appear. Only hourmeters enabled in the
Guarded Access Menu will be shown. To return to the Standard
Display, press the EXIT key.
Hourmeter Names and Definitions
Total Hours: Total number of hours the unit has been turned
on (protection hours).
Figure 80: Hourmeter Display
Press the NEXT or PREVIOUS key to scroll through the
enabled hourmeters.
Total Run Time Hours: Total number of hours the unit has
run in both diesel and electric mode.
Engine Hours: Total number of hours the unit has run in
diesel mode.
Electric Run Hours: Total number of hours the unit has run
in electric mode.
Total Run Reminder 1: User Programmable - The number
of hours before a Total Unit Run Time Maintenance Reminder
1 occurs.
Figure 81: Scroll Through Hourmeters
80
Total Run Reminder 2: User Programmable - The number
of hours before a Total Unit Run Time Maintenance Reminder
2 occurs.
Unit Operation
Controller Power On: Total hours the controller and HMI
control panel have been turned on.
Pretrip Reminder : User Programmable - number of hours
before a Pretrip Reminder occurs.
Engine Reminder 1: User Programmable - The number of
hours before an Engine Run Time Maintenance Reminder 1
occurs.
Mode
Various operating modes can be selected using the Mode
menu. Not all modes may be available, depending on settings
of other programmable features. The following modes may be
available.
Turn CYCLE-SENTRY On or Off
Engine Reminder 2: User Programmable - The number of
hours before an Engine Run Time Maintenance Reminder 2
occurs.
CYCLE-SENTRY Mode can be turned On or Off. If
CYCLE-SENTRY Mode is turned Off then unit will run in
Continuous mode.
Electric Reminder 1: User Programmable - The number of
hours before an Electric Run Time Maintenance Reminder 1
occurs.
Keypad Lockout
Electric Reminder 2: User Programmable - The number of
hours before an Electric Run Time Maintenance Reminder 2
occurs.
IMPORTANT: If a programmable hourmeter is not enabled
or the view for that hourmeter is not turned on it will not
appear in the display sequence.
If enabled in Guarded Access, the keypad can be locked to
prevent unauthorized use. If the keypad is locked only the ON
and OFF keys function. The keypad will remain locked even if
the unit is turned Off and back on. If Keypad Lockout is active,
press and hold any soft key for 5 seconds to deactivate the
feature.
81
Unit Operation
Start Sleep Mode
If enabled in Guarded Access, Sleep Mode is used to keep the
engine warm and the battery charged when the unit is not in
use. When the unit is in Sleep Mode the display will show
"SLEEP" and the current time. When Sleep Mode is entered
the unit will start and run to confirm proper battery charge
level and engine temperature.
IMPORTANT: While in Sleep Mode the unit will not monitor
or maintain setpoint and load temperature. Fuel level should
be monitored as the unit may run periodically, particularly in
cold weather.
Hour to Wake Up: This feature allows the hour the unit is to
wake up to be specified.
Minute to Wake Up: This feature allows the minute the unit
is to wake up to be specified.
Run Pretrip on Wakeup: This feature allows a Pretrip Test
to be automatically run when the unit wakes up.
Mode changes are made using the Mode Menu. From the
Standard Display, press the MENU key.
The following features are available in Sleep Mode.
Program Wakeup Time: This feature allows a wakeup time
to be specified. When the selected time is reached the unit will
start and resume normal operation.
If a Wakeup Time is selected the following features are
available:
Day to Wake Up: This feature allows the day of the week the
unit is to wake up to be specified.
82
Figure 82: Menu Key
The Language Menu or Alarm Menu will appear. Press the
NEXT key as required to show the Mode Menu. When the
Mode Menu is shown press the SELECT key.
Unit Operation
Selecting CYCLE-SENTRY or
Continuous Mode
Figure 83: Select Key
The first mode change screen will appear. To choose that
function, press the SELECT key. To Scroll thru the Mode
Menu press the NEXT key.
When CYCLE-SENTRY mode is selected the unit will start
and stop automatically to maintain setpoint, keep the engine
warm and the battery charged. When Continuous Mode is
selected, the unit will start automatically and run continuously
to maintain setpoint and provide constant airflow. From the
Standard Display, press the MENU key.
.
Figure 85: Menu Key
Figure 84: Select and Next Keys
The Language Menu or Alarm Menu will appear. Press the
NEXT key as required to display the Mode Menu. When the
Mode Menu is shown press the SELECT key.
83
Unit Operation
Figure 86: Select Key
The Turn Off/Turn On CYCLE-SENTRY screen will appear.
In the display shown below, the unit is operating in
CYCLE-SENTRY mode. Turning CYCLE-SENTRY mode off
will result in the unit running in Continuous mode.
Figure 88: Select Key
The display will confirm the change as shown below.
Figure 89: Mode Change Confirmed
The new mode is then confirmed for 10 seconds.
Figure 87: Turn Off/Turn On CYCLE-SENTRY Screen
Pressing the Select key will change the mode from
CYCLE-SENTRY to Continuous.
84
Unit Operation
Selecting Sleep Mode
Figure 90: Mode Confirmed
The display then returns to the Mode Menu. In the example
here the unit is currently running in Continuous mode. Pressing
the Select key again allows the operator to change back to
CYCLE-SENTRY mode operation.
Figure 91: Mode Menu
IMPORTANT: If the unit is in CYCLE-SENTRY null and the
mode is switched to Continuous Mode, the unit will start
automatically.
Normal CYCLE-SENTRY mode starts and stops the unit as
required to maintain the desired setpoint temperature, maintain
the unit battery in a charged condition and keep the unit engine
warm in cold ambient conditions. Sleep mode does not
consider setpoint or maintain cargo temperatures - it only
keeps the engine warm and the unit battery charged. This is
useful in extremely cold weather or when the unit is to be out
of service for an extended time. Sleep mode operates in both
Diesel mode and Electric mode. In Diesel mode the unit will
start and stop as required to maintain engine temperature and
battery charge. In Electric mode the unit starts and stops as
necessary to maintain battery charge only.
When Sleep mode is entered, the operator can program an
automatic Wake-up Time up to a week away. Using this
feature, the unit will automatically restart and run normally at
the determined time. If a Wake-up Time is programmed the
operator can also program an automatic Pretrip Test when the
unit restarts.
Sleep Mode is turned On and Off using the Mode Menu. From
the Standard Display, press the MENU key.
85
Unit Operation
.
Figure 92: Menu Key
The Language Menu or Alarm Menu will appear. Press the
NEXT key as required to show the Mode Menu. When the
Mode Menu is shown press the SELECT key.
Figure 94: Sleep Mode Menu
The screen shown in Figure 95 will appear.
Figure 95: Start of Sleep Mode Menu
Figure 93: Select Key
Press the Next key as required to display the Sleep Mode
prompt. Press the Select key to choose the Sleep Mode menu.
86
The operator can now choose a Sleep Mode Wake-up Time or
simply enter Sleep Mode immediately. If NO is pressed the
unit will immediately enter Sleep Mode.
Unit Operation
To enter a Wake-up Time, verify the unit clock is set properly.
Then press the YES key at the Sleep Mode menu.
Figure 96: Select No to Enter Sleep Mode
The display will show SLEEP and the unit will start and stop as
required to keep the engine warm and/or the battery charged.
Sleep mode does not consider setpoint or maintain cargo
temperatures. To exit Sleep Mode press the EXIT key or turn
the unit off and back on. The unit will resume normal operation
and control to setpoint.
Figure 97: Sleep Mode Display
Figure 98: Yes Key
The display will prompt the operator for the DAY the unit is to
restart in normal operation. In Figure 99 Monday has been
chosen. Press the YES key to confirm the DAY.
Figure 99: Day Unit is to Restart
87
Unit Operation
The display will now prompt the operator for the Hour the unit
is to restart in normal operation. In Figure 100 4:00 am has
been chosen. Press the YES key to confirm the HOUR. Note
that 24 hour "military time" is used.
Figure 100: Confirm Hour
The display will now prompt the operator for the MINUTE the
unit is to restart in normal operation. In Figure 101 4:30 am has
been chosen. Press the YES key to confirm the MINUTE.
The display will now prompt for a Pretrip Test on Wake-up.
Press the YES key to perform a Pretrip Test on Wake-up. If the
No key is pressed the unit will resume normal operation on
Wake-up.
Figure 102: Press Yes Key for Pretrip Test
The display will show SLEEP and the unit will start and stop as
required to keep the engine warm and/or the battery charged.
Sleep mode does not consider setpoint or maintain cargo
temperatures.
NOTE: The unit may start when sleep is enabled to bring
battery charge level and engine temperature up to minimum
level. It will shut down and then maintain minimum levels.
Figure 101: Confirm Minute
88
Unit Operation
Test is entered with the unit running in either diesel or electric
mode a Running Pretrip Test is performed, but the device amps
checks are not performed. Test results are reported as PASS,
CHECK or FAIL when the Pretrip Test is completed. If an
alarm occurs during a Pretrip Test the alarm code will be
displayed as Pretrip Alarm XX, where XX is the alarm code.
Figure 103: Sleep Mode
Pretrip Test Conditions
•
The unit will restart at the programmed time (in this example
4:30 am) and perform a Pretrip Test (if selected). After the
Pretrip Test is complete the test results will be displayed and
the unit will resume normal operation and control to setpoint.
To exit Sleep Mode before the selected Wake-up time press the
EXIT key or turn the unit off and back on. The unit will resume
normal operation and control to setpoint.
Pretrip
A Pretrip Test verifies unit operation. This display allows a
Pretrip Test to be selected and initiated by the operator. If the
Pretrip Test is entered with the unit shut down a Full Pretrip
Test with device amp checks will be performed. If the Pretrip
•
•
Current unit settings are saved and restored at the end of
the Pretrip Test or if the unit is turned off and back on.
Pretrip Test can be run in either Diesel or Electric Mode.
The unit will auto switch from Diesel Mode to Electric
Mode or from Electric Mode to Diesel Mode during a
Pretrip Test if these features are enabled and the auto
switch conditions occur.
Conditions where Pretrip Tests are not
allowed
•
If any shutdown alarms are present. Pretrip tests are
allowed with some Check and Log alarms.
•
If the unit is in Sleep Mode.
•
If the unit is in Service Test Mode, Interface Board Test
Mode or Evacuation Mode.
89
Unit Operation
Pretrip Test Sequence
Pretrip Test Considerations
Pretrip tests proceed in the order shown below. A Full Pretrip
Test includes all tests. A Running Pretrip Test is started with
the engine or motor running and does not include the Amp
Checks or Engine Start Check.
When performing a Pretrip Test, the following issues should be
considered.
•
Amp Checks - Each electrical control component is
energized and the current drawn is confirmed as within
specification.
•
Engine Start - The Engine will start automatically.
•
Defrost - If the coil temperature is below 45 F (7 C), a
defrost cycle is initiated.
•
RPM Check - The engine RPM in high and low speed is
checked during the Cool Check.
•
Cool Check - The ability of the unit to cool in low speed is
checked.
•
Heat Check - The ability of the unit to heat in low speed is
checked.
•
Report Test Results - The test results are reported as PASS,
CHECK or FAIL when the Pretrip Test is completed. If
test results are CHECK or FAIL alarm codes will exist to
direct the technician to the source of the problem.
90
•
If running a Pretrip Test on a truck or trailer loaded with
dry cargo, insure that proper airflow can occur around the
load. If the load restricts airflow, false test results may
occur. Also, SR-3 units have high refrigeration capacity
which results in rapid temperature changes. Sensitive dry
cargo may be damaged as a result.
•
If running a Pretrip Test on a truck or trailer that has just
been washed down, the extremely high humidity inside the
truck or trailer may result in false test results.
•
If running a Pretrip Test on a truck or trailer loaded with
sensitive cargo, monitor the load temperature during the
test as normal temperature control is suspended during a
Pretrip Test.
•
Always perform Pretrip Tests with the truck or trailer
cargo doors closed to prevent false test failures.
Unit Operation
Performing a Pretrip Test
If a Pretrip Test is initiated with the engine shut down a Full
Pretrip Test will be performed. If a Pretrip Test is initiated with
the engine or motor running a Running Pretrip Test is
performed.
•
Before initiating a Pretrip Test, clear all alarm codes.
•
To stop a Pretrip Test at any time, turn the unit off. Alarm
Code 28 Pretrip Abort will be set. Other alarms may also
be set, depending upon test in progress when the test was
terminated.
Pretrip Tests are initiated using the Pretrip Menu. From the
Standard Display, press the MENU key.
.
Figure 104: Menu Key
The Language Menu or Alarm Menu will appear. Press the
NEXT key as required to display the Pretrip Menu. When the
Pretrip Menu is shown press the SELECT key.
Figure 105: Select Key
If the unit is not running a Full Pretrip Test will be initiated. If
the unit is running in either diesel or electric mode a Running
Pretrip will be performed.
Figure 106: Running Pretrip
91
Unit Operation
If all alarms were not cleared a prompt appears as shown in
Figure 107. Exit the Pretrip Test, clear all alarms and restart the
Pretrip Test.
Figure 107: No Pretrip Prompt
If no alarms are present, the Pretrip Test display appears.
•
The top line of the display indicates the unit is performing
the non-running portion of the Pretrip Test.
•
The second line measures test progress. The number of
tests completed of the total number of tests to be
performed is shown. In Figure 108 the unit is performing
Test 1 of 26, Sensor Check.
•
The soft keys may be used during the Pretrip Test to select
the Hourmeter, Gauge or Sensor menus.
•
To stop a Pretrip Test at any time turn the unit off. This
will generate Alarm Code 28 Pretrip Abort. Other alarm
codes may also be generated. This is normal when the
Pretrip Test is halted before completion.
When the non-running tests are complete the unit will start
automatically and continue with the Running Pretrip Test. In
the example in Figure 109 the unit is in the Running Pretrip
and is performing Test 21 of 26, Cool Test.
Figure 108: Pretrip Test Display
92
Unit Operation
If the Pretrip Test results are CHECK or FAIL the problem
should be diagnosed and corrected before the unit is released
for service.
Diesel/Electric Menu
Figure 109: Performing Cool Test
When all tests are complete, the results are reported as PASS,
CHECK or FAIL. If the results are CHECK or FAIL, the
accompanying alarm codes will direct the technician to the
cause of the problem.
The Diesel Mode/Electric Standby menu allows the operator to
manually select diesel or electric mode operation. The unit can
also be programmed to automatically select electric mode
operation when standby power is available and to
automatically select diesel mode operation if standby power
fails or is removed. If the unit is programmed to switch
automatically from diesel to electric and electric to diesel these
screens do not appear.
Switching from Diesel to Electric - Units
equipped with the Electric Standby option
only
Figure 110: Pass, Check or Fail
If the Diesel to Electric Autoswitch Enabled feature in
Guarded Access is set YES then the unit will automatically
switch to Electric Mode operation when standby power is
connected and available.
93
Unit Operation
If the Diesel to Electric Autoswitch Enabled feature in
Guarded Access is set NO then the prompt screen shown in
Figure 111 will appear when standby power is connected and
available.
Switching from Electric to Diesel - Units
equipped with the Electric Standby option
only
If the Electric to Diesel Autoswitch Enabled feature in
Guarded Access is set YES then the unit will automatically
switch to Diesel Mode operation when standby power is turned
off or is no longer available.
Figure 111: Standby Power connected & available
If YES is selected then the display will briefly show the screen
in Figure 112.
If the Electric to Diesel Autoswitch Enabled feature in
Guarded Access is set NO then the prompt screen shown in
Figure 113 will appear when standby power is turned off or is
no longer available. Alarm Code 91 Check Electric Ready
Input and Alarm Code 84 Restart Null will both be set.
Figure 112: Display when YES is selected
Electric Mode operation will briefly be confirmed. If unit
operation is required the electric motor will start as shown
previously in STARTING THE ELECTRIC MOTOR.
94
Figure 113: Display when Standby Power not
available
Unit Operation
Turn the unit off and back on using the OFF and ON Keys.
This will clear Alarm Code 91 Check Electric Ready Input and
Alarm Code 84 Restart Null. NOTE: The CLEAR Soft Key
will not clear these two alarms. Then the prompt screen shown
in Figure 114 will appear.
Figure 115: Display when YES is selected
If unit operation is required the diesel engine will start as
shown previously in STARTING THE DIESEL ENGINE.
Figure 114: Prompt for Switch to Diesel
If YES is selected then the display will briefly show the screen
in Figure 115. Then Diesel Mode operation will briefly be
confirmed.
Adjust Brightness
The brightness of the HMI Control Panel display can be
adjusted to allow for changing ambient light conditions. The
choices available to the operator are HIGH, MEDIUM, LOW
and OFF. OFF actually results in a very dim screen suitable for
low light conditions.
Display brightness is adjusted using the Adjust Brightness
Menu. From the Standard Display, press the MENU key.
95
Unit Operation
The Display Brightness menu will appear as shown below.
Press the + or - keys to select the desired display brightness.
When the desired brightness is shown press the YES key to
confirm the choice.
.
Figure 116: Menu Key
The Language Menu or Alarm Menu will appear. Press the
NEXT key as required to display the Adjust Brightness Menu.
When the Adjust Brightness Menu is shown press the SELECT
key.
Figure 117: Select Key
Figure 118: + and - Keys
The display will briefly show ADJUSTING BRIGHTNESS PLEASE WAIT.
Figure 119: Adjusting Brightness
The display brightness is changed to the new setting.
96
Unit Operation
Time
The system time and date is viewed using the Main Menu.
Time and Date cannot be changed from the Main Menu. From
the Standard Display, press the MENU key.
.
Figure 121: Select Key
The current time and date will appear.
Figure 120: Menu Key
The Language Menu or Alarm Menu will appear. Press the
NEXT key as required to display the Time Menu. When the
Time Menu is shown press the SELECT key.
Figure 122: + and - Keys
97
Loading and Enroute Inspections
Thermo King refrigeration units are designed to maintain the
required temperature for the product being carried during its
time in transit. Because of the unit’s unique design, special care
is required during loading to prevent cargo spoilage.
4.
Pre-Loading Inspection
1.
Inspect all door seals, including vent doors, for condition
and a tight seal with no air leakage.
2.
Inspect the cargo compartment inside and out for damaged
or loose skin and insulation.
3.
Inspect the inside of the cargo compartment for damaged
walls, air ducts, floor channels or “T” flooring, clogged
defrost drain tubes, and clogged or damaged floor
channels which could block the air return, creating
isolated areas in the load that are warmer than the desired
temperature.
98
Pre-cool the cargo compartment. Adjust the setpoint to the
desired cargo temperature and allow the unit to run a
minimum of 30 to 60 minutes (longer if possible) before
loading. Check to be certain the setpoint temperature is
correct for the cargo.
Pre-cooling before loading will remove residual heat and
moisture from the cargo compartment and prepare it to
receive the refrigerated load. Pre-cooling also provides a
good test of the refrigeration system.
5.
Make sure products are pre-cooled to the proper
temperature before loading. Any variance should be noted
on the manifest.
6.
Supervise product loading to make sure that there is
sufficient air space around and through the load so air flow
is not restricted.
Loading and Enroute Inspections
Inspecting the Load
3.
Never assume that the product has been loaded properly. Watch
for and perform the following tasks. It takes only a few
minutes and could save you or your employer considerable
time and money later on.
While inspecting to see that the cargo is loaded properly,
make sure the evaporator inlets and outlets are not
blocked.
4.
Close or supervise the closing of the cargo compartment
doors. Make sure they are securely locked.
1.
5.
Check to make sure the unit setpoint is set at the desired
temperature as listed on the manifest.
6.
If the unit was stopped, restart using the appropriate
starting procedure outlined in this manual.
7.
Repeat the after-start inspection.
8.
Defrost the unit 30 minutes after loading by starting a
manual defrost cycle.
Make sure the unit is off before opening the cargo
compartment doors. During operation, the unit blows out
refrigerated air, and draws in outside air.
NOTE: The unit can be run with the doors open if the
truck is backed into a refrigerated warehouse with tight
door seals.
2.
Perform a final check of the load temperature. If the load
is too hot or too cold, make a final notation on the
manifest.
CAUTION: Make sure cargo is pre-cooled to the
proper temperature before loading. The unit is
designed to maintain temperature, not cool an
above-temperature load.
99
Loading and Enroute Inspections
Enroute Inspections
NOTE: Enroute inspections are recommended every four
hours for the prevention of damage to the cargo.
1.
Note the setpoint to make certain no one has altered the
setting since picking up the load.
2.
Note the return air temperature reading. It should be
within the desired temperature range. If the return air
temperature reading is not within the desired temperature
range, it indicates one of the following:
a.
b.
The unit has not had sufficient time to pull down the
temperature. Refer to log, if possible, for history of
load (for example, above temperature load, properly
pre-cooled cargo compartment, length of time on
road).
The unit is in defrost or has just completed defrost.
NOTE: You can cancel defrost by turning the unit off,
then restarting the unit.
100
c.
The evaporator is plugged with frost. Initiate a manual
defrost cycle. The defrost cycle will be automatically
terminated.
d.
Improper air circulation within the cargo
compartment. Inspect the cargo compartment (if
possible) to determine if the evaporator fans are
working and properly circulating the air. Poor air
circulation can be due to improper loading of the
cargo or shifting of the load, or the fan belt slipping.
WARNING: The unit may START automatically AT
ANY TIME while it is turned ON. Make sure to turn
the unit OFF before opening unit doors or inspecting
any part of the unit.
e.
The unit did not start automatically. If the unit
cranked without starting, determine and correct the
cause for not starting.
Loading and Enroute Inspections
f.
The unit may have a low refrigerant charge. If liquid
is not showing in the unit receiver tank sight glass, the
refrigerant charge may be low. Adding refrigerant or
repairing the refrigeration system requires a
competent mechanic. Refer such problems to the
nearest Thermo King dealer or authorized Service
Center, or call the Thermo King Cold Line telephone
number shown on the inside back cover of this
manual for referral.
NOTE: If the temperature in the compartment is not
within the desired temperature range, repeat the Enroute
Inspection every 30 minutes until the compartment
temperature comes within the desired temperature range.
CAUTION: Stop the unit if the compartment
temperature remains outside the desired temperature
range from the setpoint on two consecutive 30 minute
inspections. Contact the nearest Thermo King
Service Center or your company office immediately.
Take all necessary steps to protect and maintain
proper load temperature.
3.
Initiate a Manual Defrost cycle after each Enroute
Inspection.
101
Specifications
Engine
Model:
T-680R, T-680S, T-880R & T-880S
T-1080R & T-1080S
Fuel Type
TK374F (Tier 4)
TK380F (Tier 4)
No. 2 Diesel fuel under normal conditions
No. 1 Diesel fuel is acceptable cold weather fuel
Oil Capacity:T-680S and T-880S
Crankcase & Oil Filter 9.0 quarts (8.5 liters)
T-680S and T-880S w/Bypass Oil Filter 10.0 quarts (9.5 liters) Fill to full mark on dipstick
T-1080R & T-1080S Crankcase & Oil Filter
T-1080R & T-1080S w/Bypass Oil Filter
12.0 quarts (11.4 liters)
13.0 quarts (12.3 liters) Fill to full mark on dipstick
Oil Type
API Classification CI-4 or better
(ACEA Rating E3 or better for Europe)
Oil Viscosity
14 F to 122 F (-10 C to 50 C): SAE 15W-40 (Synthetic)
5 to 104 F (-15 to 40 C): SAE 15W-40
-13 to 104 F (-25 to 40 C): SAE 10W-40
-13 to 86 F (-25 to 30 C): SAE 10W-30
-22 to 122 F (-30 to 50 C): SAE 5W-40 (Synthetic)
Below -22 F (-30 C): SAE 0W-30 (Synthetic)
102
Specifications
Engine (Continued)
Engine rpm:
Low Speed Operation
1625 ± 25 rpm
High Speed Operation Reciprocating Compressor: 2200 ± 25 rpm
Scroll Compressor: 2200 ± 25 rpm
Engine Oil Pressure
20 to 50 psig (138 to 345 kPa) in low speed
40 to 60 psig (276 to 414 kPa) in high speed
Intake Valve Clearance
0.006 to 0.010 in. (0.15 to 0.25 mm)
Exhaust Valve Clearance
0.006 to 0.010 in. (0.15 to 0.25 mm)
Valve Setting Temperature
70 F (21 C)
Fuel Injection Timing
16 ± 1 degrees BTDC
Injection Nozzle Pressure
1784 to 1929 psig (12,300 to 13,300 kPa)
Low Oil Pressure Switch/Sensor
10 ± 2 psig (69 ± 14 kPa)—shutdown
High Coolant Temperature Sensor
220 ± 5 F (104 ± 3 C)—shutdown
Engine Thermostat
160 F (71 C)
103
Specifications
Engine (Continued)
Engine Coolant Type
ELC (Extended Life Coolant), which is “RED”
Use a 50/50 concentration of any of the following
equivalents:
Chevron Dex-Cool
Texaco ELC
Havoline Dex-Cool®
Havoline XLC for Europe
Shell Dexcool®
Shell Rotella
Saturn/General Motors Dex-Cool®
Caterpillar ELC
Detroit Diesel POWERCOOL® Plus
CAUTION: Do not add “GREEN” or “BLUE-GREEN”
conventional coolant to cooling systems using “RED”
Extended Life Coolant, except in an emergency. If
conventional coolant is added to Extended Life
Coolant, the coolant must be changed after 2 years
instead of 5 years.
104
Specifications
Engine (Continued)
Coolant System Capacity:
T-680R, T-680S, T-880R, T-880S
T-1080R, T-1080S
4.5 quarts (4.3 liters) with coolant expansion tank
6.5 quarts (6.2 liters) with coolant expansion tank
Coolant Expansion Tank Cap Pressure
15 psig (103 kPa)
Belt Tension
Belt
Tension No. on TK Gauge
P/N 204-427
New Belt
Field Reset
Water Pump Belt
40
40
Engine/Electric Motor (Jackshaft) –
Static Belt Tensioner
81
77
Electric Motor (Jackshaft)/Compressor
Frequency Gauge P/N 204-1903
Setting Where Applicable
New Belt
Field Reset
62 Hz
55 Hz
Automatically tensioned by tensioner position. See “Belts” in
appropriate Maintenance Manual Chapter.
105
Specifications
Engine Clutch
Engagement
600 ± 100 RPM
Dynamic Torque
66 ft-lb (89.5 N•m) minimum @ 1600 RPM
Refrigeration System
Reciprocating Compressor
Unit Model:
T-680R and T-880R
T-1080R
Compressor Model:
Thermo King X214
Thermo King X426
Refrigerant Charge: T-680R
T-880R
T-1080R
8.0 lb (3.6 kg) R-404A
8.5 lb (3.9 kg) R-404A
9.0 lb (4.1 kg) R-404A
*Compressor Oil Charge:
X214 in T-680R and T-880R
X426 in T-1080R
3.2 quarts (3.0 liters)
4.3 quarts (4.1 liters)
Compressor Oil Type
Ester base P/N 203-513 required
106
Specifications
Refrigeration System
Suction Pressure Regulator Valve Setting:
T-680R
T-880R
T-1080R
High Pressure Cutout Switch:
Open
Close
28 to 31 psig (193 to 214 kPa)
35 to 37 psig (241 to 255 kPa)
21 to 23 psig (145 to 159 kPa)
470 ± 7 psig (3241 ± 48 kPa)
375 ± 38 psig (2586 ± 262 kPa)
* When the compressor is removed from the unit, oil level should be noted or the oil removed from the
compressor should be measured. This is to be sure that the same amount of oil can be added before placing the
replacement compressor in the unit.
Scroll Compressor
Unit Model:
T-680S and T-880S
T-1080S
Compressor Model:
TK04 Scroll 4 HP
TK06 Scroll 6 HP
Refrigerant Charge:
T-680S and T-880S
T-1080S
*Compressor Oil Charge
7.0 lb (3.2 kg) R-404A
7.5 lb (3.4 kg) R-404A
2.0 quarts (1.9 liters)
107
Specifications
Refrigeration System
Compressor Oil Type
Ester base P/N 203-516 required for Scroll compressor
Discharge Pressure Regulator Valve Setting
350 ± 5 psig (2413 ± 34 kPa)
High Pressure Cutout Switch:
470 ± 7 psig (3241 ± 48 kPa)
375 ± 38 psig (2586 ± 262 kPa)
Open
Close
* When the compressor is removed from the unit, oil level should be noted or the oil removed from the
compressor should be measured. This is to be sure that the same amount of oil can be added before placing the
replacement compressor in the unit.
Electrical Control System
Control System Voltage
12.5 Vdc
Battery Charging System
12 volt, 37 amp, brush type, Thermo King alternator
Voltage Regulator Setting
13.8 to 14.4 volts @ 77 F (25 C)
NOTE: Fuse F4 (Bypass resistor for Prestolite Alternator) must be removed for the Thermo King
Alternator.
108
Specifications
Fuses
Fuse
Size
Function
F2
15A
Power to On/Off Switch
F3
40A
Fuel Sol Pull-In/Starter Circuit
F4
None
2A
No Fuse - All Bosch and Thermo King Alternators
2A Fuse - All Prestolite Alternators
F5
40A
Preheat Circuit
F6
15A
Damper and High Speed Circuits
F7
2A
8XP Circuit - Controller On Feedback to HMI
F8
5A
2A Power to CAN Connector J12
F9
5A
2A Power to CAN Connector J14
F10
10A
8X Power (Install fuse in right position)
F12
5A
2A Power to CAN Connector J13
F13
2A
8FC Circuit (Remote Status Light/Optional Power)
F20
2A
Alternator Sense
F21
60A
Main Fuse (2 Circuit)
109
Specifications
Fuses (Continued)
Fuse
Size
Function
F25
7.5A
HPCO Switch Circuit
F26
5A
Power to CAN Connector J98
F4 Remove fuse F4 for units with Australian Bosch or Thermo King Alternators. Install fuse F4 for units with
Prestolite Alternator.
F10 When fuse F10 is installed in the right position the On/Off keys on the HMI turn the unit on and off. When
fuse F10 is installed in the left position the unit will start and run without the HMI control panel.
Electrical Components
Component
Current Draw (Amps)
at 12.5 Vdc
Resistance
(Ohms)
4.3
2.3 ± 0.2
35 to 45
0.5
0.2 to 0.3
24 to 29
High Speed (Throttle) Solenoid
3.3
3.8
Damper Solenoid
5.7
2.2
Glow Plugs (3) Each
Fuel Solenoid:
110
Pull In Coil
Hold In Coil
Specifications
Electrical Components (Continued)
Component
Current Draw (Amps)
at 12.5 Vdc
Resistance
(Ohms)
Condenser Inlet Solenoid (CIS)
1.8
6.9
Hot Gas Solenoid (HGS)
1.1
11.3
Purge Valve (PV)
1.1
11.3
Liquid Injection Solenoid (LIS) (Scroll Compressor
only)
1.1
11.3
Electronic Throttling Valve (ETV) if used:
Coil A (Red [EVA] and Blue [EVB] Wires)
Coil B (Black [EVC] and White [EVD] Wires)
—
—
20 to 35
20 to 35
Starter Motor (No Load Bench Test)
90
111
Specifications
SmartPower Electrical Standby (Model 50 Units Only)
T-680R, T-680S, T-880R, T-880S Electric Motor and Overload Relay
Voltage/Phase/Frequency
Horsepower
Kilowatts
rpm
Full Load
(amps)
Overload Relay
Setting (amps)
230/3/50
6.0
4.5
1460
17.0
19
230/3/60
7.2
5.4
1765
19.4
22
400/3/50
6.0
4.5
1460
9.8
11
460/3/60
7.2
5.4
1765
9.7
11
T-1080R & T-1080S Electric Motor and Overload Relay
Voltage/Phase/Frequency
Horsepower
Kilowatts
rpm
Full Load
(amps)
Overload Relay
Setting (amps)
230/3/50
10.0
7.5
1460
22.5
25
230/3/60
12.0
8.9
1750
28.8
32
400/3/50
10.0
7.5
1460
17.0
16
460/3/60
12.0
8.9
1750
14.4
16
112
Specifications
Electric Heater Strips (Optional)
Number
3
Watts
750 watts (each)
Resistance
71 ohms (each)
SmartPower Standby Power Requirements
Supply Circuit Breaker:
T-680R, T-680S, T-880R & T-880S
230/3/60
30 amps
T-1080R & T-1080S
230/3/60
All 380-460/3/50-60
50 amps
20 amps
Extension Cord Size:
Up to 50 ft—10 gauge
75 ft—8 gauge
113
Maintenance Inspection Schedule
A closely followed maintenance program will help to keep
your Thermo King unit in top operating condition. The
following general schedule is provided to assist in monitoring
that maintenance.
After first week of operation:
For more specific detail, see the maintenance manual for your
unit and to the PreTrip Inspection chapter in this manual.
•
Check belt tension.
•
Tighten unit mounting bolts.
•
Check coolant level.
•
Check refrigerant oil level.
•
Check refrigerant level
l
Pretrip
1,200
Hours
2,000
Hours
Inspect/Service These Items
Annual/
3,000
Hours
Microprocessor
•
Run pretrip test (see “Pretrip Test” in Operating Instructions Chapter).
Engine
•
•
114
Check fuel supply.
•
Check engine oil level.
Maintenance Inspection Schedule
2,000
Hours
1,200
Hours
•
•
Check condition of belts.
•
•
Check engine oil pressure hot, on high speed.
•
•
•
Annual/
3,000
Hours
Inspect/Service These Items
Pretrip
•
Listen for unusual noises, vibrations, etc.
•
Check air cleaner hose for damage.
•
Inspect and clean electric fuel pump filter.
•
Dry air cleaner. Replace air cleaner element at 2,000 hours or 1 year
(whichever occurs first)
•
Change EMI 2000 (black) fuel filter.
•
Change engine oil and oil filters (hot). Requires oil with API Rating CI-4
or better (ACEA Rating E3 for Europe) and EMI 2000 bypass oil filter.
•
Check restraining mount (snubber) pre-load adjustment.
•
Drain water from fuel tank and check vent.
•
Check and adjust engine speeds (high and low speed).
•
Check condition of engine mounts.
115
Maintenance Inspection Schedule
Pretrip
1,200
Hours
2,000
Hours
* Based on EPA 40 CFR Part 89.
116
Annual/
3,000
Hours
Inspect/Service These Items
•
Maintain year round antifreeze protection at –30 F (–34 C).
•
Test fuel injection nozzles at least every 3,000 hours.*
—
Replace the fuel return lines between fuel injection nozzles every 10,000
hours or sooner as required.
—
Change ELC (red) engine coolant every 5 years or 12,000 hours. Units
equipped with ELC have an ELC nameplate on the expansion tank.
Maintenance Inspection Schedule
Pretrip
1,200
Hours
2,000
Hours
Inspect/Service These Items
Annual/
3,000
Hours
Electrical
•
Check controller for alarms.
•
Run pretrip test
•
Check battery voltage.
•
Inspect battery terminals and electrolyte level.
•
Inspect wire harness for damaged wires or connections.
•
Inspect alternator bearings and brushes.**
•
Inspect electric motor bearings (Model 50).**
** With belt removed, spin bearings by hand. Listen for noise (bearings roll freely).
117
Maintenance Inspection Schedule
Pretrip
1,200
Hours
2,000
Hours
Inspect/Service These Items
Annual/
3,000
Hours
Refrigeration
•
•
Check refrigerant level.
•
Check compressor oil level.
•
Check suction pressure regulator setting on Defrost or Heat.
•
Check discharge and suction pressures.
•
Check compressor efficiency.
—
118
Replace dehydrator and compressor oil filter every two (2) years.
Maintenance Inspection Schedule
Pretrip
1,200
Hours
2,000
Hours
Inspect/Service These Items
Annual/
3,000
Hours
Structural
•
•
Visually inspect unit for fluid leaks.
•
•
Visually inspect unit for damaged, loose or broken parts (includes air
ducts and bulkheads).
•
•
•
•
Inspect clutch for shoe and anchor bushing wear with a mirror. Check
bearings.**
•
Inspect idlers, fan shafts and jackshaft (if so equipped) for leakage and
bearing wear.**
•
Clean entire unit including condenser coils, evaporator coils, and defrost
drains.
•
Check all unit, fuel tank, engine, and electric motor mounting bolts,
brackets, lines, hoses, etc.
** With belt removed, spin bearings by hand. Listen for noise (bearings roll freely).
119
Warranty
Terms of the Thermo King Warranty are available on request.
Please reference document TK 50047 for the Thermo King
Self-Powered Truck Unit Warranty.
120
Glossary
This glossary is published for informational purposes only and
the information being furnished herein should not be
considered as all-inclusive or meant to cover all contingencies.
NOTE: Additional terms not found in the glossary may be
located in the index section of this manual.
accumulator: A device located in the suction line to collect
liquid refrigerant and meter it safety back to the compressor as
gas.
ambient air temperature: Temperature of the air
surrounding an object.
amp: Abbreviation for ampere. The basic measuring unit of
electrical current.
bar: A metric unit of pressure. 1 bar = 100 kPa = 14.5 psi.
Battery Sentry: Part of the CYCLE-SENTRY™ system. The
Battery Sentry module monitors alternator charge rate and will
keep the unit running until the battery is adequately charged.
box temperature: The temperature within a
temperature-controlled compartment.
Btu (british thermal unit): The quantity of heat required to
raise the temperature of one pound of water by one degree
Fahrenheit. 1 Btu = 252 calories.
bulkhead: 1) return air bulkhead. A metal or plastic “wall”
placed at the front of the box to prevent loading of product
tightly against the Thermo King unit. (Loading too close to the
unit restricts air flow and system efficiency.) 2) bulkhead
divider. A thick, insulated “wall” used to separate
compartments of a multi-temperature truck or trailer.
calorie: The amount of heat required to raise temperature of
one gram of water one degree Celsius. 1 calorie = 0.004 Btu.
Celsius: The metric unit of temperature measurement. The
preferred alternate to the term centigrade. Abbreviated “C.”
centigrade. See Celsius.
121
Glossary
CFC: Chlorofluorocarbon. A chlorine-based refrigerant
consisting of chlorine, fluorine and carbon. Example: R12. In
many countries it is illegal to release this type of refrigerant to
the atmosphere because chlorine damages the earth’s
atmosphere. CFC refrigerants are not used in modern Thermo
King units.
circuit breaker: A thermal device that automatically
interrupts an electrical circuit when the current in the circuit
exceeds the predetermined amperage rating of the breaker. See
amp.
coil: A cooling or heating element made of pipe or tube,
formed into a helical or serpentine shape, that may be equipped
with thin metal fins to aid heat transfer.
cold curtains: Flexible vinyl curtains used to reduce air
exchange between the refrigerated compartment and the
outside during door openings.
compound gauge: A gauge calibrated in psig (or kPa) to
measure pressure, and in inches of mercury (Kg/cm2) to
measure vacuum.
compressor: The refrigeration component that compresses
refrigerant vapor and creates refrigerant flow.
122
condenser: An arrangement of tubing in which the
vaporized and compressed refrigerant is liquefied as heat is
removed.
cycles per second: See Hertz.
damper door: A door on the evaporator section that closes
during defrost to prevent hot air from entering the refrigerated
cargo compartment.
data logger: An electronic device that monitors and stores
unit operating and temperature data for later review. Examples:
DMS, DAS, DRS and AccuTrac.
defrost: The removal of accumulated ice from an evaporator
coil. Periodic defrost is necessary when the evaporator coil is
operating below freezing. Defrost is required more frequently
when the air passing through the evaporator has a high
moisture content.
defrost termination switch: A component that terminates
defrost operation at a specific temperature.
defrost timer: A solid state module that initiates defrost at
selected intervals. Also establishes a maximum defrost
duration if normal circuits malfunction.
Glossary
dehydrator: A device used to remove moisture from
refrigerant. Also called a drier.
discharge air temperature: The temperature of air leaving
the evaporator.
drier: See dehydrator.
ERC: Extended Remote Unit Control. (Door switches) An
option on Thermo King multi-temperature units to improve
temperature control when doors are opened during delivery.
When a compartment door is opened, the refrigeration unit for
that compartment may be forced to NULL, defrost, or some
other mode. Opening a compartment door may also affect the
operating mode of other compartments. ERC systems are
connected in a variety of ways to meet customer needs.
ETV (Electronic Throttling Valve) : A device used with a
microprocessor to precisely control the refrigeration system.
evaporator: The part of the refrigeration system that absorbs
heat during the cooling cycle.
F: See Fahrenheit.
Fahrenheit: A unit of temperature measurement used in the
United States. Abbreviated “F.”
freeze up: 1) Failure of a refrigeration system to operate
normally due to moisture in the refrigerant and the formation
of ice at the expansion valve. The expansion valve may be
frozen shut or open, causing improper unit operation in either
case. 2) The formation of a solid ice mass over the evaporator
coil reducing air flow.
fuse: An electrical safety device (typically a cartridge)
inserted into an electrical circuit. It contains material that will
melt or break when the current is increased beyond a specific
value. When this occurs, the circuit is opened and electrical
current flow is stopped.
fusible link: An electrical safety device (typically a short
piece of wire) inserted into an electrical circuit. The wire melts
or breaks when the current is increased beyond a specific
value. When this occurs, the circuit is opened and electrical
current flow is stopped.
HCFC: Hydrochlorofluorocarbon. A chlorine-based
refrigerant containing hydrogen, chlorine, fluorine and carbon.
Example: R22. Because chlorine damages the earth’s
atmosphere, in many countries, it is illegal to release this type
of refrigerant to the atmosphere. HCFC refrigerants are not
used in modern Thermo King units.
123
Glossary
Hertz: A unit of frequency equal to one cycle per second.
Abbreviated “Hz.”
HFC: A refrigerant consisting of hydrogen, fluorine and
carbon. Examples: R134a and 404A. HFC refrigerants contain
no chlorine and are, therefore, considered “safe” for the
environment.
high pressure relief valve: A safety valve on the
refrigeration system that allows refrigerant to escape from the
system if pressure exceeds a predetermined value.
hp (horsepower): A unit of power equivalent to 746 watts
or 550 foot-pounds per second.
HPCO (High Pressure Cut Out Switch): A
pressure-operated switch that opens to stop unit operation
when discharge pressure reaches a predetermined maximum.
kPa: Kilopascals. A metric unit of pressure. 1 kPa = 0.01 bar =
0.145 psi.
load: 1) The product being refrigerated and transported.
2) The amount of heat being removed by the refrigeration
system. (For example, a compressor is under a heavy heat load
when expected to cool a very warm box.)
124
LPCO (Low Pressure Cut Out Switch): A
pressure-operated switch that opens to stop unit operation
when suction pressure reaches a predetermined minimum.
modulation: An optional system that reduces load (product)
dehydration and avoids “top freeze.”
movable bulkhead: A thick, insulated, portable wall-like
device used to compartmentalize a temperature-controlled
truck or trailer. See bulkhead.
Multi-Temp: A Thermo King truck or trailer unit capable of
maintaining different set-points in multiple compartments.
no. 1 diesel fuel: A grade of diesel fuel formulated to
prevent “jelling” in low ambient temperatures.
no. 2 diesel fuel: A grade of diesel fuel formulated for
moderate to warm ambient temperatures.
ohm: An electrical unit measuring the amount of resistance
(opposition to the current flow) in an electrical circuit.
pre-cooling: 1) To cool down an empty box
(temperature-controlled area) to the desired load temperature
prior to loading. 2) To cool cargo to a desired temperature
before loading.
Glossary
pre-heat: The heating of diesel engine glow plugs prior to
start-up. Some engines use an intake manifold heater rather
than glow plugs.
pre-trip inspection: Checking the operation of a
refrigeration system before loading.
psi: Pounds per square inch. A unit of pressure.
1 psi = 0.069 bar = 6.89 kPa.
return air bulkhead: A structure (metal or plastic) mounted
in the front of a trailer and designed to prevent restriction of
return air flow to the Thermo King unit due to improper
loading. See bulkhead.
return air temperature: The temperature of the air
returning to the evaporator. See box temperature.
rpm: Revolutions per minute.
psig: Pounds per Square Inch Gauge. Pressure in pounds per
square inch as displayed by a gauge calibrated to zero when
open to the atmosphere.
setpoint: The temperature selected on a thermostat or
microprocessor controller. This is normally the desired box
temperature.
receiver tank: A refrigerant storage device included in
nearly all Thermo King units.
short cycling: When a refrigeration unit cycles between the
heat and cool modes more often than normal.
refrigerant: The medium of heat transfer in a refrigeration
system which absorbs heat by evaporating at a low temperature
and releases heat by condensing at a higher temperature.
sight glass: A system component that permits visual
inspection of oil or refrigerant level and condition.
refrigerant oil: A special oil used to lubricate compressors in
refrigeration systems.
remote evaporator: A separate evaporator unit located in a
second or third compartment of a multi-temperature truck or
trailer unit.
thermostat: A device that controls unit modes of operation to
maintain a selected box temperature.
top freeze: When the top portion of perishable cargo is
damaged by freezing temperatures discharged from the
refrigeration unit. This may occur near the front of the box
when product is placed too close to the cold, discharge air flow.
125
Glossary
Vac (volts alternating current): An electric current that
reverses direction at regularly recurring intervals.
Vdc (volts direct current): An electric current that flows in
one direction only and is constant in value.
volts: The basic measuring unit of electrical potential.
watt: The basic measuring unit of electrical power.
126
Serial Number and Refrigerant Label
Locations
Write the unit model and unit serial number in the spaces
provided in the following Emergency Cold Line chapter. This
information is needed to service the unit.
AMA832
Figure 124: Scroll Compressor Serial Number
Location,
Figure 123: Engine Serial Number Location
127
Serial Number and Refrigerant Label Locations
AQA183
Figure 125: X214 Reciprocating Compressor Serial
Number Location
128
Figure 126: X426 Reciprocating Compressor Serial
Number Location
Serial Number and Refrigerant Label Locations
1
2
Figure 128: Laminated Unit Serial Number Plate
AMA833
1.
Unit Serial Plate
2.
Refrigerant Type
Figure 127: Label Locations
Figure 129: Refrigerant Type Label
129
Recover Refrigerant
At Thermo King, we recognize the need to preserve the environment
and limit the potential harm to the ozone layer that can result from
allowing refrigerant to escape into the atmosphere.
We strictly adhere to a policy that promotes the recovery and limits
the loss of refrigerant into the atmosphere.
In addition, service personnel must be aware of Federal regulations
concerning the use of refrigerants and the certification of technicians.
For additional information on regulations and technician certification
programs, contact your local THERMO KING dealer.
130
Emergency Cold Line
If you can’t get your rig rolling, and you have tried the Thermo
King North American Service Directory (available from any
Thermo King dealer) to reach a dealer without success, then
call the Toll Free Emergency Cold Line Number
(888) 887-2202.
The answering service at the factory will assist you in reaching
a dealer to get the help you need. The Cold Line is answered 24
hours a day by personnel who will do their best to get you
quick service at an authorized Thermo King Dealer.
AMA1585
131
CALIFORNIA
Proposition 65 Warning
Diesel exhaust is a chemical known to
the State of California to cause cancer.
132
Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
T-680R / T-880R / T-1080R
T-680S / T-880S / T-1080S
Series with
Premium SR-3 HMI
TK 55667-1-OP (Rev. 1, 02/15)
©2013 Ingersoll-Rand Company
Printed in U.S.A.
Operator’s Manual
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Thermo King, the leader in transport
temperature control and Trane, a provider of energy efficient heating, ventilating and
air conditioning systems, building and contracting services, parts support and advanced
controls for commercial buildings and homes.
©2013 Ingersoll-Rand Company
Printed in U.S.A.
T-680R / T-880R / T-1080R
T-680S / T-880S / T-1080S
Series with
Premium SR-3 HMI
TK 55667-1-OP (Rev. 1, 02/15)
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