Thermo King Precedent S-600M refrigeration system 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.
PrecedentTM
S-600M
TK 55747-2-OP (Rev. 1, 12/14)
©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.
PrecedentTM
S-600M
TK 55747-2-OP (Rev. 1, 12/14)
PrecedentTM
S-600M
TK 55747-2-OP (Rev. 1, 12/14)
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
EPA Emission Control System Warranty Statement 8
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . .
General Safety Practices . . . . . . . . . . . . . . . . . . . . . .
Automatic Start/Stop Operation . . . . . . . . . . . . . . . . .
Electrical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Installation and Cable Routing . . . . . . . . . . . .
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
First Aid–Refrigerant . . . . . . . . . . . . . . . . . . . . . . .
First Aid–Refrigerant Oil . . . . . . . . . . . . . . . . . . . .
Safety Decals and Locations . . . . . . . . . . . . . . . . . . .
11
11
12
12
13
14
15
15
15
15
16
Unit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Features and Options . . . . . . . . . . . . . . . . . . . . . . . . .
Diesel Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
19
20
21
ELC (Extended Life Coolant) . . . . . . . . . . . . . . . . . . . .22
EMI 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Thermo King X430L Reciprocating Compressor . . . . .23
Electronic Throttling Valve . . . . . . . . . . . . . . . . . . . . . .23
Remote Evaporators . . . . . . . . . . . . . . . . . . . . . . . . . .24
SMART REEFER 4 Multi-Temp (SR-4 MT) Control
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
CYCLE-SENTRY Start-Stop Controls . . . . . . . . . .26
Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
OptiSet Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
FreshSet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Opening the Front Doors . . . . . . . . . . . . . . . . . . . . . . .30
Engine Compartment Components . . . . . . . . . . . . . . .31
Unit Protection Devices . . . . . . . . . . . . . . . . . . . . . . . .31
Base Controller Fuses . . . . . . . . . . . . . . . . . . . . . .32
Expansion Module Fuses . . . . . . . . . . . . . . . . . . .33
ECU Interface Board Fuses . . . . . . . . . . . . . . . . .34
Battery Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
3
Remote Status Display (Optional) . . . . . . . . . . . . . . 35
Manual Pretrip Inspection
(Before Starting the Unit) . . . . . . . . . . . . . . . . . . . . . 38
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . 40
SMART REEFER 4 (SR-4 MT) Controller Overview . . 40
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Control Panel Display . . . . . . . . . . . . . . . . . . . . . . 41
Display Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Zone Cooling, Heating or Null . . . . . . . . . . . . . . . 43
Zone Level or Unit Level Alarm Codes . . . . . . . . . 44
Hard Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Soft Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Display Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Turning Unit On and Off . . . . . . . . . . . . . . . . . . . . . . . 47
Two Zone Standard Display . . . . . . . . . . . . . . . . . 49
Three Zone Standard Display . . . . . . . . . . . . . . . . 50
Single Zone Control Standard Display . . . . . . . . . 50
Operating the Unit in Single Zone Mode . . . . . . . 51
TemperatureWatch Display . . . . . . . . . . . . . . . . . 52
Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . 53
Turning a Zone ON and Off . . . . . . . . . . . . . . . . . 56
Starting the Diesel Engine . . . . . . . . . . . . . . . . . . 58
4
Starting the Electric Motor . . . . . . . . . . . . . . . . . . .59
Switching from Diesel to Electric . . . . . . . . . . . . . .59
Initiating a Manual Defrost Cycle . . . . . . . . . . . . . .62
Selecting Cycle Sentry or Continuous Mode . . . . .65
Using the Main Menu . . . . . . . . . . . . . . . . . . . . . .69
Main Menu Features . . . . . . . . . . . . . . . . . . . . . . .70
Languages (If Enabled) . . . . . . . . . . . . . . . . . . . . .78
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Sensors Available . . . . . . . . . . . . . . . . . . . . . . . . .98
Data Logger (CargoWatch) . . . . . . . . . . . . . . . . .100
Hourmeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Using the Cycle Sentry Key . . . . . . . . . . . . . . . . .109
Rear Remote Control Panel (Optional) . . . . . . . . .124
Rear Remote Control Panel Functionality . . . . . . . . .124
Rear Remote Control Action Set to Run . . . . . . .124
Rear Remote Control Action Set to STAND BY .125
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Reading a Typical Remote Standard Display . . . . . .129
Remote Control Panel Lockout . . . . . . . . . . . . . . . . .129
Turning the Unit ON or OFF (Configured for STAND BY
Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Turning the Unit On and Off (Configured for RUN
Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Changing the Setpoint . . . . . . . . . . . . . . . . . . . . . . . . 131
Selecting Cycle-Sentry or Continuous Mode . . . . . . . 132
Displaying the Discharge Air Temperature . . . . . . . . 133
Viewing and Clearing Alarm Codes . . . . . . . . . . . . . . 134
Starting a Manual Defrost Cycle . . . . . . . . . . . . . . . . 135
Sending a Start of Trip Marker . . . . . . . . . . . . . . . . . 136
Running a Pretrip Test . . . . . . . . . . . . . . . . . . . . . . . . 137
Loading and Enroute Inspections . . . . . . . . . . . . . 139
Pre-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . . 139
Single Temperature Loading Procedures . . . . . . . . . 141
Post-Loading Inspection . . . . . . . . . . . . . . . . . . . . . . 142
Post Trip Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Inspection Troubleshooting . . . . . . . . . . . . . . . . . 142
Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Control System . . . . . . . . . . . . . . . . . . . . .
Electrical Components . . . . . . . . . . . . . . . . . . . . . . .
Electric Heater Strips . . . . . . . . . . . . . . . . . . . . .
Electrical Standby (SmartPower Units Only) . . . . . .
Electric Motor and Overload Relay . . . . . . . . . .
Standby Power Cord Requirements . . . . . . . . .
Electric Fuel Heater (Optional) . . . . . . . . . . . . . . . . .
177
177
180
181
182
183
186
186
186
187
188
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Maintenance Inspection Schedule . . . . . . . . . . . . 196
Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Alarm Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Clearing Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . 148
Serial Number Locations . . . . . . . . . . . . . . . . . . . . 202
Emergency Cold Line . . . . . . . . . . . . . . . . . . . . . . . 205
5
Recover Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . 206
CALIFORNIA
Proposition 65 Warning . . . . . . . . . . . . . . . . . . . . . 207
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
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
EPA Emission Control System Warranty
Statement
Thermo King warrants to the initial owner and each subsequent
owner that the certified, non-road diesel engine in your unit is:
1.
Designed, built and equipped so as to conform, at the time
of sale, with all applicable regulations adopted by the
United States Environmental Protection Agency (EPA).
2.
Free from defects in materials and workmanship in
specific emission related parts for a period of five years or
3,000 hours of operation, whichever comes first, after date
of delivery to the initial owner.
If an emission-related part or component fails during the
warranty period, it will be repaired or replaced. Any such part
or component repaired or replaced under warranty is warranted
for the warranty period.
8
During the term of this warranty, Thermo King will provide,
through a Thermo King authorized service dealer or other
establishment authorized by Thermo King, repair or
replacement of any warranted part at no charge to the non-road
engine owner.
In emergency, repairs may be performed at any service
establishment, or by the owner, using any replacement part.
Thermo King will reimburse the owner for their expenses,
including diagnostic charges for such emergency repair. These
expenses shall not exceed Thermo King’s suggested retail price
for all warranted parts replaced, and labor changes based on
Thermo King’s recommended time allowance for the warranty
repair and the geographically appropriate hourly labor rate.
EPA Emission Control System Warranty Statement
Any replacement part can be used for maintenance or repairs.
The owner should ensure that such parts are equivalent in
design and durability to genuine Thermo King parts. However,
Thermo King is not liable for parts that are not genuine
Thermo King parts.
If failure of one of these parts or components results in failure
of another part or component, both will be covered by this
warranty.
A part not being available within 30 days or repair not being
completed within 30 days constitutes an emergency.
This warranty is subject to the following:
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.
Thermo King Corporation Responsibilities
This warranty covers the following emission-related parts and
components:
•
Fuel Injection System
•
Intake Manifold
•
Exhaust Manifold
•
Miscellaneous hoses, clamps, connectors and sealing
devices used in the above systems.
Responsibilities
During the emission warranty period, if a defect in material or
workmanship of a warranted part or component is found,
Thermo King will provide:
•
New, remanufactured, or repaired parts or components
required to correct the defect.
NOTE: Items replaced under this warranty become the
property of Thermo King.
•
Labor, during normal working hours, required to make the
warranty repair. This includes diagnosis and labor to
remove and install the engine, if necessary.
9
EPA Emission Control System Warranty Statement
Owner Responsibilities
Limitations
During the emission warranty period, the owner is responsible
for:
Thermo King is not responsible for resultant damages to an
emission-related part or component resulting from:
•
•
Any application or installation Thermo King deems
improper as explained in this Operator’s Manual, or any
other manuals provided for the unit.
•
Attachments, accessory items, or parts not authorized for
use by Thermo King.
•
Improper off-road engine maintenance, repair or abuse.
•
Owner’s unreasonable delay in making the product
available after being notified of a potential product
problem.
The performance of all required maintenance. A warranty
claim will not be denied because the scheduled
maintenance was not performed. However, if the lack of
required maintenance was the reason for the repair, then
the claim will be denied.
•
Premium of overtime cost.
•
Cost to investigate complaints that are not caused by
defects in Thermo King material or workmanship.
•
Providing timely notice of a warrantable failure and
promptly making the product available for repair.
This warranty is in addition to Thermo King’s standard
warranty applicable to the off-road engine product involved.
Remedies under this warranty are limited to the provision of
material and services as specified herein. Thermo King is not
responsible for incidental or consequential damages such as
downtime or loss of engine powered equipment.
10
Safety Precautions
Thermo King recommends that servicing be done only by a
Thermo King dealer. However, you should be aware of several
safety practices. This chapter gives basic safety precautions for
working with Thermo King units and describes the safety
stickers on your unit that you should be familiar with.
General Safety Practices
DANGER: NEVER operate the unit with the
compressor discharge valve closed. Doing so could
cause the compressor to explode, causing death or
serious injury.
WARNING: Always wear goggles or safety glasses
when working with or around the refrigeration system
or battery. Refrigerant or battery acid can cause
permanent damage if it comes in contact with your
eyes.
WARNING: Keep hands and loose clothing clear of
fans and belts at all times when the unit is operating
or when opening or closing compressor service
valves.
WARNING: Exposed coil fins can cause painful
lacerations. Service work on the evaporator or
condenser coils should be done by a certified Thermo
King technician.
WARNING: Do not apply heat to a closed cooling
system. Before applying heat to a cooling system,
drain it. Then flush it with water and drain the water.
Antifreeze contains water and ethylene glycol. The
ethylene glycol is flammable and can ignite if the
antifreeze is heated enough to boil off the water.
11
Safety Precautions
CAUTION: Use extreme caution when drilling holes
in the unit. Drilling into electrical wiring or
refrigerant lines could cause a fire. Do not drill into
structural components.
Automatic Start/Stop Operation
This unit is capable of automatic operation and could start at
any time without warning.
WARNING: The unit can start at any time without
warning. Press the OFF key on the control panel and
place the microprocessor On/Off switch in the Off
position before inspecting or servicing any part of the
unit.
12
Electrical Hazard
DANGER: Dangerous three phase AC electric power
is present whenever the unit is operating in either
Diesel Mode or Electric Mode and whenever the unit
is connected to a source of external standby power.
Voltages of this magnitude can be lethal. Exercise
extreme caution when working on the unit.
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.
13
Safety Precautions
Refrigerant
Although fluorocarbon refrigerants are classified as safe, use
caution when working with refrigerants or in areas where they
are being used.
DANGER: Fluorocarbon refrigerants can produce
toxic gases. In the presence of an open flame or
electrical short, these gases are severe respiratory
irritants CAPABLE OF CAUSING DEATH.
DANGER: Fluorocarbon refrigerants tend to
displace air and can cause oxygen depletion which
could result in DEATH BY SUFFOCATION. Provide
adequate ventilation in enclosed or confined areas.
WARNING: Fluorocarbon refrigerants evaporate
rapidly, freezing anything they contact if accidentally
released into the atmosphere from the liquid state.
14
Safety Precautions
Refrigerant Oil
Observe the following precautions when working with or
around refrigerant oil:
WARNING: Always wear goggles or safety glasses to
protect eyes from refrigerant oil contact.
Skin: Flush areas with large amounts of warm water. Do not
apply heat. Wrap burns with dry, sterile, bulky dressing to
protect from infection or injury. Get prompt medical attention.
Inhalation: Move victim to fresh air and restore breathing if
necessary. Stay with victim until emergency personnel arrive.
First Aid–Refrigerant Oil
WARNING: Protect skin and clothing from
prolonged or repeated contact with refrigerant oil.
Rubber gloves are recommended.
WARNING: Wash thoroughly immediately after
handling refrigerant oil to prevent irritation.
Eyes: Immediately flush eyes with large amounts of water for
at least 15 minutes while holding the eyelids open. Get prompt
medical attention.
Skin: Remove contaminated clothing. Wash thoroughly with
soap and water. Get medical attention if irritation persists.
Inhalation: Move victim to fresh air and restore breathing if
necessary. Stay with victim until emergency personnel arrive.
First Aid
Ingestion: Do not induce vomiting. Immediately contact
local poison control center or physician.
First Aid–Refrigerant
Eyes: For contact with liquid, immediately flush eyes with
large amounts of water. Get prompt medical attention.
15
Safety Precautions
Safety Decals and Locations
Condenser and Evaporator Fans
Be aware of the warning nameplates near the condenser fans
and evaporator fans (example in Figure 1).
AMA1581
Figure 1: Fan Warning
16
High Voltage Components
Various components on the Precedent unit operate using
220/3/60 or 460/3/60 high voltage and are identified by
warning nameplates (examples in Figure 2). All high voltage
wiring is identified by ORANGE conduiting. Be aware of the
locations of these components. Only certified, trained
technicians can service them. See Figures 3 and 4 for high
voltage component locations.
AMA1579
AMA1580
Figure 2: High Voltage Warning
Safety Precautions
1
2
7
3
6
8
9
4
5
1.
Condenser Motors
4. High Voltage Control Box
2.
Evaporator Motor
5. AC Generator
3.
High Voltage Distribution
Box
Electric Standby Motor &
6. Power Receptacle
(SmartPower Option)
Figure 3: High Voltage Component Locations (Front)
7.
8.
Evaporator Motor
9. High Voltage Junction Box
High Voltage Heater Strips All ORANGE conduiting
contains High Voltage
Figure 4: High Voltage Component Locations (Rear)
17
Safety Precautions
Do Not Use Ether Starting Aids
Figure 5: Do Not Use Ether Starting Aids nameplate
located near engine.
18
Unit Description
Unit Overview
The Thermo King Precedent S-600M is a multi-temperature
refrigeration system designed to control the temperatures in
two or three compartments (zones). The system allows any
compartment to be set at any temperature.
In the Precedent S-600M unit the evaporator in the host unit
controls one compartment (Zone 1), and a remote evaporator
controls the other compartment (Zone 2). A unit with three
zones has a second remote evaporator, which controls a third
compartment (Zone 3).
The units feature all-new DDE (Diesel Direct Electric)
architecture, the quiet running Thermo King TKDV6 engine
and the Thermo King X-430 reciprocating compressor.
The S-600M is available in the following models:
Standard: Cooling and heating on diesel engine operation.
SmartPower™ Option: Cooling and heating on diesel engine
operation and electric standby operation.
See the following page for Features and Options.
Figure 6: Front View
19
Unit Description
Features and Options
The following chart lists key design features and options.
l Standard Features
m Option/Factory installed
o Option/Dealer Installed
Precedent S-600M Key Features & Options
SMART REEFER™ SR-4 MT Multi-Temp
Controller
SmartPower™ Electric Standby
Precedent S-600M Key Features & Options
High-Capacity Condenser Coil
l
Easy-access door design
l
Composite Exterior Panels
Long-Life Coolant/Silicone Hoses
l
l
Remote Status Display
l
l
Standard Grille Color Black
Directional Air Delivery
l
l
l
m
Vibration Isolation System
SmartPower High-Output
m
SmartPower Prep Package
OptiSet™ Plus
m
l
Aluminum Undermount Fuel Tank 50 Gal.
(186 Liter)
Ultrasonic Fuel Level Sensor
ETV (Electronic Throttling Valve)
l
ServiceWatch™ Data Logger
l
CargoWatch™ Data Logger
CargoLink™ Sensor Kits
l
m/o
CargoLink Wireless Sensors
m/o
EMI-3000
20
m/o
Standard Unit Color White
l
l
l
Severe Duty Package
Fuel Tank with Ultrasonic Fuel level Sensor
m
o
Electric Fuel Heater
m
Frost Plug Heater
m
Alternator, 65 Amp, 12 Vdc
Appearance Packages
m
m
Unit Description
Diesel Engine
Precedent S-600M Key Features & Options
Fresh Air Exchange
m
Anti-Siphon Device
m
REB Wireless Communication Platform
TracKing Telematics
m
m/o
PrimAir™ bulkhead and duct system
o
Rear Remote Control
o
Humidity Sensor
Battery Charger
o
m
Reliamax Battery,
12 Volt, Wet Cell
o
EON Battery,
12 Volt, Dry Cell
Remote Electric Power Receptacle
The 4-cylinder TK DV6 is a water cooled, direct injection,
turbocharged diesel engine. The engine is coupled directly to
the compressor. A centrifugal clutch transfers power from the
engine to the compressor on Smart Power Units. Belts transmit
power to the AC generator, water pump, and alternator.
o
m
ARA2138
Figure 7: TK DV6 Engine
21
Unit Description
ELC (Extended Life Coolant)
ELC is standard equipment. The maintenance interval for ELC
is five years or 12,000 hours. A nameplate on the coolant
expansion tank identifies units with ELC. The new engine
coolant, Chevron Extended Life Coolant, is RED in color
instead of the previous GREEN or BLUE-GREEN colored
conventional coolants.
CAUTION: Do not add “GREEN” or
“BLUE-GREEN” conventional coolant to cooling
systems using “RED” Extended Life Coolant, except
in an emergency. If conventional coolant is added to
Extended Life Coolant, the coolant must be changed
after 2 years instead of 5 years.
NOTE: The use of 50/50% pre-mixed ELC is recommended
to assure that de-ionized water is being used. If 100% full
strength concentrate is used, de-ionized or distilled water is
recommended instead of tap water to insure the integrity of
the cooling system is maintained.
Figure 8: Extended Life Coolant
nameplate located on expansion tank
22
Unit Description
EMI 3000
EMI 3000 is an extended maintenance interval package. It is
standard equipment. The EMI 3000 package consists of the
following key components:
Thermo King X430L
Reciprocating Compressor
The S-600is equipped with a four cylinder 30.0 cu. in. (492
cm3) displacement Thermo King X430L reciprocating
compressor.
•
EMI 3000-Hour Cyclonic Air Cleaner Assembly and Air
Cleaner Element
•
EMI 5-Micron 3000-Hour Fuel Filter
Electronic Throttling Valve
•
EMI 3000-Hour Dual Element Oil Filter
•
API Rating CI-4 Mineral Oil
The ETV provides enhanced control of the refrigeration system
as follows:
•
Five Year or 12,000 Hour ELC (Extended Life Coolant)
•
The EMI package allows standard maintenance intervals to be
extended to 3,000 hours, or 2 years, whichever occurs first.
Allows the refrigeration system to fully utilize the power
capabilities of the engine under varying conditions
•
NOTE: Units equipped with the EMI 3000 package do
require regular inspection in accordance with Thermo King's
maintenance recommendations.
Provides an additional measure of protection against high
discharge pressures
•
Protects the engine from high coolant temperature
shutdowns
•
Provides a means of precise temperature control.
NOTE: EMI 3000 oil filters and EMI 3000 air cleaners are
NOT interchangeable with older style oil filters and air
cleaners.
23
Unit Description
Remote Evaporators
A Remote Evaporator is mounted on the ceiling of each remote
compartment to provide temperature control for Zone 2 and
Zone 3 (if used). A Remote Evaporator with two fans is called
an S-2. A Remote Evaporator with three fans is called an S-3.
Two remote evaporators can be mounted in the same remote
compartment to provide more capacity.
SMART REEFER 4 Multi-Temp
(SR-4 MT) Control System
The SR-4 MT is a microprocessor control system designed for
transport refrigeration. The SR-4 MT integrates the following
functions: changing setpoint and operating mode, viewing
gauge, sensor and hourmeter readings, initiating defrost cycles,
and viewing and clearing alarms.
The microprocessor components are located inside the control
box, which is located inside the lower roadside service door. It
is used to operate the unit. The control panel is mounted on the
face of the control box. It is clearly visible through an opening
in the lower roadside service door.
See “Operating Instructions” in this manual for more
information about the SR-4 MT Controller.
Figure 9: S-3 Remote Evaporator
24
Depending on the air temperature in the trailer, as sensed by
the microprocessor Base Controller, the unit will typically
operate in one of the following modes:
Unit Description
Diesel Operation
Electric Operation
In diesel operation the microprocessor will select the operating
mode from the following:
In electric operation the microprocessor will select the
operating mode from the following:
•
High Speed Cool
•
Cool
•
Low Speed Cool
•
Modulated Cool
•
Low Speed Modulated Cool
•
Null (CYCLE-SENTRY operation only)
•
Null (CYCLE-SENTRY operation only)
•
Modulated Heat (Hot Gas only)
•
Low Speed Modulated Heat
•
Hot Gas Heat
•
Low Speed Heat
•
Full Heat (Hot Gas and Electric Heat)
•
High Speed Heat
•
Defrost (Hot Gas and Electric Heat)
•
Defrost
25
Unit Description
CYCLE-SENTRY Start-Stop Controls
The CYCLE-SENTRY Start-Stop fuel saving system provides
optimum operating economy.
WARNING: The unit can start at any time without
warning. Press the OFF key on the control panel and
place the microprocessor On/Off switch in the Off
position before inspecting or servicing any part of the
unit.
When CYCLE-SENTRY Mode is selected the unit will start
and stop automatically to maintain setpoint, keep the engine
warm and the battery charged. When Continuous Mode is
selected, the unit starts automatically and runs continuously to
maintain setpoint and provide constant airflow.
26
Your Thermo King unit provides a wide range
of control and programming flexibility.
However, pre-programming of the unit SR-4
MT microprocessor may prohibit operation in
certain temperature ranges within some
modes and may also prohibit certain modes
of operation. If you have controller
programming questions, contact your
supervisor or your Thermo King dealer before
requesting service.
Unit Description
Data Logging
There are two separate data loggers. The data is downloaded
through the Flash Drive Only USB port on the front of the
control box using a flash drive and ThermoServ software.
Flash Drive Only USB Port: Standard USB drives that have
been programmed with ThermoServ can be used in the Flash
Drive Only USB Port. Use of a USB drive eliminates the need
for an on-site computer and does not require cables.
The Flash Drive Only USB port can be used to:
• Download the CargoWatch and ServiceWatch Data Loggers.
• Flashload the Base Controller and HMI Control Panel.
1
1.
Flash Drive Only USB Port
Figure 10: HMI Controller and USB Port
27
Unit Description
PC Only USB Port: The PC Only USB Port is a connector
located on the base controller inside the control box. It is used
to connect the controller to a PC with a standard USB to USB
mini cable.
downloaded the CargoWatch data. If optional temperature
sensors are installed, their readings are displayed as Datalogger
Sensor (1-6) Temperature in the sensor readings.
The PC Only USB port can be used to:
OptiSet Plus
•
Upload trailer ID and Unit Serial Number (Must be done
on new units and if new controller is installed.)
•
Data Logger setup.
•
Download the CargoWatch and ServiceWatch Data
Loggers.
•
Flashload the Base Controller and HMI Control Panel.
OptiSet Plus is a group of programmable functions that control
how the unit will operate with specific setpoints or named
products. This assures that when a particular setpoint or named
product is selected, the unit will always operate the same way.
This allows an entire fleet to be configured to match the
customers’ needs. Contact your Thermo King dealer for
information about programming OptiSet Plus.
ServiceWatch: ServiceWatch is standard equipment. It
records operating events, alarm codes and compartment
temperatures as they occur and at preset intervals. This
information is typically used to analyze unit performance.
CargoWatch: CargoWatch data logging requires the
installation of optional sensors. Up to six temperature
sensor/probes and four door switches can be installed.
CargoWatch also logs the setpoint. Use a USB port to
28
FreshSet
FreshSet is included in OptiSet Plus. FreshSet is a demand
base temperature control for fresh products. FreshSet modifies
and adjusts unit airflow operation to control temperature and to
maximize protection of cargo, while keeping operating costs to
a minimum. Contact your Thermo King dealer for information
about programming FreshSet.
Unit Description
Defrost
Frost gradually builds-up on evaporator coils as a result of
normal operation. The unit uses hot refrigerant to defrost the
evaporator coil. Hot refrigerant gas passes through the
evaporator coil and melts the frost. The water flows through
collection drain tubes onto the ground. The methods of defrost
initiation are Automatic, and Manual.
NOTE: The unit will not perform a Manual Defrost Cycle
unless the unit has been turned on with the ON key, the unit
is running in Continuous or CYCLE-SENTRY Mode (or shut
down in CYCLE-SENTRY Null Mode), and the coil
temperature is below 45 F (7 C).
Automatic Defrost: The SR-4 MT automatically initiates
timed or demand defrost cycles. The SR-4 MT microprocessor
can be programmed to initiate timed defrost cycles at intervals
of 2, 4, 6, 8, or 12 hours. Demand defrost cycles occur if the
differences between the return air temperature, discharge air
temperature, and coil temperature exceed certain limits. The
unit can enter defrost cycles as often as every 30 minutes if
required.
Manual Defrost: In Manual Defrost Mode, the operator
initiates a defrost cycle. See “Initiating a Manual Defrost
Cycle.”
29
Unit Description
Opening the Front Doors
Pull the right door latch handle out at a 45 degree angle and
turn it down (clockwise) 90 degrees (see Figure 12) to open the
doors and access the engine compartment. Push the door
closed while holding the door latch handle open and then turn
it up (counterclockwise) 90 degrees to close the door.
ARA2207
Figure 11: Door Latch Location
30
Figure 12: Door Latch Nameplate
Unit Description
Engine Compartment
Components
Operate the unit in high speed cool for approximately 15
minutes to stabilize operating conditions and temperature
before attempting to check the refrigerant.
The following maintenance items can be checked visually.
NOTE: If the ball floats, there is sufficient refrigerant in the
unit for that load at that particular trailer temperature. This
test does not determine if the unit contains a full charge or an
overcharge of refrigerant.
WARNING: The unit can start at any time without
warning. Press the OFF key on the control panel and
place the microprocessor On/Off switch in the Off
position before inspecting any part of the unit.
Compressor Oil Sight Glass: Use this sight glass to check
the compressor oil level. Check the compressor oil when there
is evidence of oil loss (leaks). Refer to the unit Maintenance
Manual for the correct procedure.
Engine Oil Dipstick: Use the engine oil dipstick to check
the engine oil level.
CAUTION: Make sure the engine is turned off before
attempting to check the engine oil.
Receiver Tank Sight Glass: This sight glass indicates the
level of refrigerant in the receiver tank. Refer to the unit
Maintenance Manual for the correct procedure.
Unit Protection Devices
Coolant Level Switch: The coolant level switch closes if
the coolant level drops below an acceptable level. If it stays
closed for a specified time, the microprocessor records alarm
code 37.
Engine Coolant Temperature Sensor:
The microprocessor uses the engine coolant temperature sensor
to monitor the engine coolant temperature. If the engine
coolant temperature rises above an acceptable level, the
microprocessor records alarm code 41 and possibly 18. The
microprocessor might also shut the unit down.
31
Unit Description
High Pressure Cutout Switch: The high pressure cutout
switch (HPCO) is located on the compressor discharge
manifold. If the compressor discharge pressure becomes
excessive, the switch opens the circuit to the run relay to stop
the unit. The microprocessor will record Alarm Code 10.
High Pressure Relief Valve: This valve is designed to
relieve excessive pressure in the refrigeration system. It is
located on the receiver tank. If the high pressure relief valve
opens, much of the refrigerant will be lost. Take the unit to a
Thermo King dealer if this occurs.
Low Oil Level Switch: The low oil level switch closes if the
oil drops below an acceptable level. If it stays closed for a
specified time, the microprocessor shuts the unit down and
records Alarm Code 66.
Low Oil Pressure Switch: The low oil pressure switch
closes if the oil pressure drops below an acceptable level. If it
stays closed for a specified time, the microprocessor shuts the
unit down and records alarm code 19.
Preheat Buzzer: The preheat buzzer sounds when the base
controller energizes the preheat relay. This warns anyone near
the unit that the controller is about to start the engine.
32
Overload Relay—Automatic Reset (SmartPower): An
overload relay protects the standby electric motor. The
overload relay opens the circuit to the electric motor if the
motor overloads for any reason (e.g., low line voltage or
improper power supply) while the unit is on electric standby
operation. The microprocessor will record Alarm Code 90.
Smart FETs: Smart FETs in the microprocessor protect some
circuits and components from an overcurrent condition.
Base Controller Fuses
Fuses, located on the base controller protect various circuits
and components. The base controller is located inside the
control box. Refer to the SR-4 Multi-Temp Microprocessor
Control System Diagnostic Manual TK 55788 for a complete
list of the size and function of the fuses.
Unit Description
Base Controller Fuses
Fuse Size Function
F1
5A
2A Circuit for REB
F2
15A
Power to On/Off Switch
Fuel Solenoid/Starter Circuit (Not
F3
40A
Used)
F4
None No Fuse - Alternator Excite Circuit
F5
60A
Preheat Circuit (Not Used)
High Speed Solenoid Circuit (Not
F6
15A
Used)
F7
2A
8X Circuit for T-Bus
F8
5A
2A Power to T-Bus Connector J12
F10
10A
On/Off Relay Circuit
F12
5A
2A Power to T-Bus Connector J13
F13
2A
Power to Remote Status Light
F15
2A
SR-4 Power Supply
F20
2A
Alternator Sense Circuit
F22
10A
Fresh Air Door Circuit
F25
7.5A
HPCO Switch Circuit
Expansion Module Fuses
Fuses located on the expansion module protect various circuits
and components. Refer to the SR-4 Multi-Temp
Microprocessor Control System Diagnostic Manual TK 55788
for a complete list of the size and function of the fuses.
Expansion Module Fuses
Fuse
Size
Function
FX1
20A
Fan 1 Zone 2
FX2
5A
Damper Motor (If Used)
FX3
20A
Fan 2 Zone 2
FX4
20A
Fan 3 Zone 2
FX5
15A
Drain Hose Heater Zone 2
FX6
20A
Fan 5 Zone 3
FX7
20A
Fan 6 Zone 3
FX8
15A
Drain Hose Heater Zone 3
FX9
20A
Fan 4 Zone 3
FX10
20A
Liquid Line Solenoids Zone 2 and
Zone 3/Hot Gas Solenoids Zone 3
33
Unit Description
Expansion Module Fuses (Continued)
ECU Interface Board Fuses (Continued)
FX11
20A
Hot Gas Solenoid Zone 2/Suction
Line Solenoids Zone 2 and Zone 3
F55
15A
F56
3A
Power Relay
FX30
2A
Spare
F57
5A
Key Switch Relay
FX31
2A
Spare
F58
3A
Key Switch Relay
FX32
5A
Digital Ground
F59
10A
ODB
F60
60A
2A Stud
ECU Interface Board Fuses
Fuses located on the expansion module protect various circuits
and components. Refer to the SR-4 Multi-Temp
Microprocessor Control System Diagnostic Manual TK 55788
for a complete list of the size and function of the fuses.
ECU Interface Board Fuses
Fuse
Size
Function
F51
7.5A
Injectors
F52
7.5A
Injectors
F53
10A
Blowby Heater
F54
10A
Lamda O2
34
Fuel Pump
Battery Fuses
A 100A fuse (FS2) protects the 2 circuit to the base controller.
A 70A fuse (FS2) protects the 2 circuit to the ECU.
A 70A fuse (FS3) protects the 2/8S circuit to the starter relay.
Remote Status Display (Optional)
The remote status display mounts on the cargo box for easy
viewing of the unit’s mode.
Figure 13: Remote Status Display (All LEDs Shown)
The remote status display indicates operating status as follows:
White Status LEDs: Illuminate the “T” portion of the TK
logo when the unit is functioning properly with no alarm
codes.
Figure 14: Normal Operation No Alarms
35
Remote Status Display (Optional)
Amber Status LEDs: Illuminate the “K” portion of the TK
logo when the unit has a check alarm code, but is still
functioning properly. Check the unit as soon as possible to
correct the alarm condition.
Figure 15: Check Alarm
36
White and Amber Status LEDs: The two bottom LEDs in
the “T” (in white) and the four bottom LEDs in the “K” (in
amber) are illuminated when the unit has a shutdown alarm
code and the load integrity is at risk. Correct the alarm
condition immediately.
Figure 16: Shutdown Alarm
Remote Status Display (Optional)
Remote status displays that also show the fuel level or the fuel
level and the box temperature are also available. The number
of white LEDs illuminated in the fuel level indicator show the
fuel level. When the fuel level falls below 10%, only the two
amber LEDs at the top and bottom of the fuel level indicator
are illuminated to indicate the low fuel level.
The temperature display shows the box temperature, except
when the unit is in defrost in which case it displays “dF”.
1
2
2
1
3
1.
2.
Status Indicator
Fuel Level Indicator
Figure 17: Remote Status Display with Fuel Level
1.
2.
3.
Status Indicator
Fuel Level Indicator
Temperature Display
Figure 18: Remote Status Display
with Fuel Level and Temperature
37
Manual Pretrip Inspection
(Before Starting the Unit)
Pretrip inspections are an important part of a preventative
maintenance program designed to minimize operating
problems and breakdowns. Perform this pretrip inspection
before every trip involving refrigerated cargo.
NOTE: Pretrip inspections are not intended to take the place
of regular maintenance inspections.
Fuel: Make sure the diesel fuel supply is adequate to
guarantee engine operation to the next check point. Allow for
maximum fuel consumption of one gallon per hour of engine
operation.
Engine Oil: Check the engine oil level. It should be at the
Full mark when the dipstick is threaded all the way into the oil
pan. Do not overfill.
CAUTION: Turn the engine off before checking the
engine oil level.
38
Engine Coolant: The engine coolant must have antifreeze
protection to -30 F (-34 C). Add coolant if Alarm Code 37 is
active. Check and add coolant to the expansion tank.
WARNING: Do not remove the expansion tank cap
while the coolant is hot.
Battery: Make sure the battery terminals are tight and free of
corrosion.
Belts: Make sure belts are in good condition and adjusted to
the proper tension. For more information about belt tension,
see the Specifications chapter.
Electrical: Check the electrical connections to make sure they
are securely fastened. Wires and terminals should be free of
corrosion, cracks, and moisture.
Structural: Visually inspect the unit for leaks, loose or
broken parts, and other damage.
Manual Pretrip Inspection (Before Starting the Unit)
Coils: Make sure the condenser and evaporator coils are clean
and free of debris.
Cargo Box: Check the interior and exterior of the cargo box
for damage. Any damage to the walls or insulation must be
repaired.
Cargo Doors: Make sure that the cargo doors and weather
seals are in good condition. The doors should latch securely
and the weather seals should fit tightly.
Defrost Drains: Check the defrost drain hoses to make sure
they are open.
39
Operating Instructions
SMART REEFER 4 (SR-4 MT)
Controller Overview
Thermo King has applied the latest advances in computer
technology to develop a device that controls temperature and
unit function, and displays operating information quickly and
accurately.
There is nothing complicated about learning to operate the
SR-4 MT Controller, but you will find that a few minutes
studying the contents of this manual will be time well spent.
WARNING: Do not operate the SR-4 MT until you
are completely familiar with the location and
function of each control.
Figure 19: SR-4 MT Control Panel
40
The microprocessor components are located inside the control
box, which is located inside the lower roadside service door.
The microprocessor is connected to a Human Machine
Operating Instructions
Interface (HMI) Control Panel. It is used to operate the unit.
The USB port is used to retrieve data from the data logging
system.
Microprocessor On/Off Switch: This switch supplies or
removes electrical power to the microprocessor. The
Microprocessor Power Switch is located above HMI Control
Panel. It is hidden when the lower roadside body panel
surrounding the Control Box is closed.
WARNING: The unit can start at any time without
warning. Press the OFF key on the control panel and
place the microprocessor On/Off switch in the Off
position before inspecting or servicing any part of the
unit.
Control Panel
The control panel has a display and eight touch sensitive keys.
The display is capable of showing both text and graphics. The
four keys on the left and right sides of the display are “hard”
(dedicated) keys. The four keys under the display are “soft”
keys. The function of “soft” keys change depending on the
operation being performed. If a soft key is active, its function
will be shown in the display directly above the key.
Control Panel Display
The display presents information to the operator. This
information can include setpoint and temperature for each
zone, unit or zone operating information, gauge readings,
temperatures and other information as selected by the operator.
The default display is called the Standard Display. It is shown
in Figure 20 and will be described in detail later in this chapter.
41
Operating Instructions
3
1
4
2
5
6
Figure 21: Display
1.
On Key (Hard Key)
2.
Off Key (Hard Key)
3.
Display
4.
Defrost Key (Hard Key)
5.
CYCLE-SENTRY/Continuous Mode Key
(Hard Key)
6.
Soft Keys
Figure 20: Control Panel Display and Keys
42
The Standard Display of box temperature and setpoint for 3
zones is shown in Figure 21. The unit is running in Continuous
Mode. Zone 1 has a setpoint of -10°F, and a return air
temperature of -8.2°F. The downward pointing arrow shows
this zone is cooling. Zone 2 has a setpoint of 35°F, and a return
air temperature of 35.1°F. The absence of an arrow indicates
that this zone is in null. Zone 3 has a setpoint of 50°F, and a
return air temperature of 48.8°F. The upward pointing arrow
shows this zone is heating.
Operating Instructions
NOTE: The zone temperature shown is always return air
temperature.
Pressing the soft key under each zone allows the setpoint for
that zone to be changed. In addition, the soft keys under Zone 2
and Zone 3 are used to turn those zones on and off. Pressing the
soft key under MENU accesses the MAIN MENU.
Zone Cooling, Heating or Null
Arrows are used to indicate if a zone is
cooling, heating or in null.
NOTE: Zone 1 is always on when the control system is
powered up.
Display Icons
Display Icons are used to indicate the following:
•
If a zone is cooling, heating or null
•
If the unit is operating in Cycle Sentry or Continuous
Mode
•
If unit level or zone level alarm conditions have occurred.
Figure 22: Cooling, Heating, Null Arrows
Arrows: (At the left side of the display) Figure
22 shows Zone 1 is cooling. If the arrow were
pointing upward Zone 1 would be heating. The
absence of an arrow indicates that a Zone is in
Null.
43
Operating Instructions
CYCLE SENTRY/Continuous Mode Key: If
the Cycle Sentry Icon is present as shown in
Figure 23, the unit is operating in Cycle Sentry
Mode. Absence of the Cycle Sentry Icon indicates
the unit is operating in Continuous Mode.
If the Standard Display is shown, the Cycle
Sentry Icon will appear in the upper right corner of the display
as shown in Figure 23.
Figure 24: Three Zone TemperatureWatch Display Unit in Cycle Sentry Mode
Zone Level or Unit Level Alarm Codes
Figure 23: Cycle Sentry Icon
If the TemperatureWatch Display is shown, the Cycle Sentry
Icon will appear in the lower part of the display as shown in
Figure 24.
44
Alarm Icon: The Alarm Icon is used to indicate
the presence of one or more alarm codes. If the
Alarm Icon is present, an alarm condition has
occurred and an Alarm Code has been set.
Absence of the Alarm Icon indicates no Check,
Prevent or Shutdown Alarm Codes exist.
If a zone level Alarm condition exists, the Alarm Icon will
appear in the offending zone as shown in Figure 25. A Zone
Level Alarm exists in Zone 2.
Operating Instructions
Hard Keys
The keys on either side of the display are dedicated or “hard”
keys (Figure 27). Their function always remains the same.
Figure 25: Zone Level Alarm
If a unit level Alarm condition exists, the Alarm Icon will
appear at the right side of the display as shown in Figure 26.
Figure 27: Hard Keys
ON
On Key: The ON Hard 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 th display shows
the Standard Display of box temperature and
setpoint. For more information see “Turning the
Unit On and Off" later in this section
Figure 26: Unit Level Alarm
45
Operating Instructions
OFF
Off Key: The OFF Hard 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 chapter.
Defrost Key: The DEFROST Hard Key is used
to initiate a manual defrost cycle. For more
information see "Initiating a Manual Defrost
Cycle" later in this chapter.
CYCLE SENTRY: Used to select Cycle Sentry
Mode or Continuous Mode operation if allowed
by OptiSet Plus. For more information see
“Selecting Cycle Sentry or Continuous Mode”
later in this chapter.
IMPORTANT: If the Hard Keys are lighted the HMI Control
Panel is powered up, even if the display is off. Typically, this
indicates the CargoWatch Data Logger is active, even when
the unit is turned off.
46
Soft Keys
Figure 28: Soft Keys
The four “soft” keys under the display are
multi-purpose keys (Figure 28). 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.
Operating Instructions
Typical soft key applications:
• ZONE ON/OFF and SETPOINT CHANGE
• MENU
• CLEAR
• NO
• NEXT
• HOURMETERS
• SENSORS
• + OR -
• GAUGES
• EXIT
• SELECT
• BACK
• HELP
Display Heater
The colder the ambient temperature the longer it will take for
the heater to make the display visible on a cold startup. It may
take 10-15 seconds for the display to appear with very cold
temperatures
Turning Unit On and Off
The unit is turned on by pressing the ON hard key (Figure 29)
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.
The HMI control panel is equipped with a display heater. This
heater is needed to make the display visible in cold ambient
temperatures.
NOTE: With Multi-Temp applications, Zone 1 is turned on
any time the host unit is turned on. Zone 1 is turned off when
the host unit is turned off.
The HMI has its own internal temperature sensor for the
display heater. The heater is energized when the unit is turned
on and the ambient temperature is below 29.4°F (-2°C). The
heater turns off when the temperature sensed by the internal
sensor rises above 37.4°F (+3°C). The heater draws from 1.4 to
1.7 amps when energized.
NOTE: With extremely cold ambient temperatures it may
take up to 15 seconds for the display to appear on initial
startup.
47
Operating Instructions
When the unit is ready to run the Standard Display appears.
The 2 Zone display is shown in Figure 31.
ON
OFF
Figure 29: ON Key
Then the startup screen (Figure 30) appears while
communications are established and the unit prepares for
operation.
ON
CONFIGURING SYSTEM
PLEASE WAIT
OFF
Figure 30: Startup Screen
48
Figure 31: 2 Zone display
Pressing the OFF hard key stops unit operation. The controller
shuts down immediately and the display briefly shows the
power down message as shown in Figure 32.
Operating Instructions
Two Zone Standard Display
Figure 32: Power Down
The display briefly shows OFF (Figure 33) and then goes
blank. To start the unit again, press the ON hard key.
Figure 33: OFF Displayed
Figure 34: Two Zone Standard Display
The Standard Display is the default display that appears if no
other display function is selected. A 2 Zone Standard display is
shown here. The 2 Zone Standard Display in Figure 34 shows
the return air temperature and setpoint for two zones. The
absence of the Cycle Sentry Icon at the top of the display
shows that the unit is operating in Continuous mode. The
return air temperature for Zone 1 is -8.2°F with a -10°F
setpoint. The down-pointing arrow indicates that Zone 1 is
cooling. The return air temperature for Zone 2 is 35.8°F with a
35°F setpoint. The down-pointing arrow indicates that Zone 2
is also cooling. The soft key under each zone allows the
49
Operating Instructions
Setpoint for that zone to be changed. In addition, the soft key
under Zone 2 is used to turn that zone on and off. The soft key
labeled MENU allows the Main Menu to be selected.
Three Zone Standard Display
indicates that Zone 1 is cooling. The return air temperature for
Zone 2 is 35.8°F with a 35°F setpoint. The absence of an arrow
indicates that Zone 2 is in Null. The return air temperature for
Zone 3 is 48.8°F with a 50°F setpoint. The up-pointing arrow
indicates that Zone 3 is heating. The soft key under each zone
allows the Setpoint for that zone to be changed. In addition, the
soft keys under Zone 2 and Zone 3 are used to turn those zones
on and off. The soft key labeled MENU allows the Main Menu
to be selected.
Single Zone Control Standard Display
Figure 35: Three Zone Standard Display
The 3 Zone Standard Display adds a third zone. The 3 Zone
Standard Display functions the same way as the 2 Zone
Standard Display, but with another temperature controlled
zone. The absence of the Cycle Sentry Icon at the top of the
display in Figure 35 shows that the unit is operating in
Continuous mode. The return air temperature for Zone 1 is
-8.2°F with a -10°F setpoint. The down-pointing arrow
50
Figure 36: Single Zone Control Standard Display
Operating Instructions
See Figure 36. This feature, if enabled in Guarded Access,
allows Single Zone Control operation to be selected by
choosing the Main Menu and then selecting Single Zone
Control from the Mode submenu. When this feature is selected,
all zones will be forced on and will control to the same selected
setpoint. The Single Zone Control Standard Display functions
the same way as the other Standard Displays. The absence of
the Cycle Sentry Icon at the top of the display shows that the
unit is operating in Continuous mode. The box temperature for
all zones is 35.8°F and all zones are controlling to a 35°F
setpoint. The down-pointing arrow indicates that all zones are
cooling. The soft key labeled Setpoint allows the setpoint for
all zones to be changed. The soft key labeled Menu allows the
Main Menu to be selected.
•
Single Zone Control Mode will appear in the Mode Menu
only if the Single Zone Control feature has been enabled
in the Guarded Access/Main Menu Configuration menu. If
the feature is enabled then Single Zone Control will appear
in the Main Menu/Mode Menu.
•
If Single Zone Control operation is selected then all zones
will be forced on and will control to the same setpoint. The
Zone 1 sensors are used to determine box temperature. All
bulkheads should be taken down to create one large
compartment. With the exception of defrost the operating
mode of each zone evaporator(s) will be same when in this
mode. Unit control is based on the temperature sensors of
one zone (usually Zone 1).
•
If Single Zone Control operation is selected the Single
Zone Standard Display provides only one soft key labeled
Set Point. This allows the setpoint for all zones to be
changed simultaneously.
•
If Single Zone Control operation is selected the individual
zones cannot be turned off. The unit and all zones are
turned On and Off simultaneously using the On and Off
hard keys at the left side of the display.
Operating the Unit in Single Zone
Mode
The following differences exist when operating the unit in
Single Zone Control Mode.
51
Operating Instructions
TemperatureWatch Display
If there is no key activity and no check, prevent, or Shutdown
Alarms are present the TemperatureWatch Display appears 2½
minutes after the last key entry from the Standard Display. The
TemperatureWatch screen (Figure 37) will remain on until any
key is pressed or a check, prevent, or Shutdown Alarm occurs.
The TemperatureWatch Display shows the return air
temperature and setpoint for each zone. Tenths of a degree are
not shown by the TemperatureWatch display. The large
numbers allow unit conditions to be checked from a distance.
Pressing any soft key returns the display to the Standard
Display.
If an alarm condition (other than a Log Alarm) is present the
TemperatureWatch Display will not appear. If an alarm
condition occurs while the TemperatureWatch Display is
present the display will return to the Standard Display. If the
Defrost or Cycle Sentry keys are pressed the display will return
to the TemperatureWatch Display after defrost is initiated or
the operating mode is changed.
In the Three Zone TemperatureWatch display the Menu soft
key label covers the Zone 3 label as shown in Figure 38.
Figure 38: Three Zone TemperatureWatch® Display
Figure 37: Two Zone TemperatureWatch® Display
52
Operating Instructions
If the unit is operating in Cycle Sentry mode the Cycle Sentry
icon will appear near Zone 2 as shown above. If the unit is
operating in Continuous Mode the Cycle Sentry icon will not
be present.
Changing the Setpoint
If the TemperatureWatch display is shown, press any soft key
to return to the Standard Display. From the Standard Display,
press the ZONE soft key for the desired zone. ZONE 1 is
shown below.
Figure 40: Setpoint Display
The "-" and "+" soft keys are used to increase or decrease the
setpoint until the desired setpoint is shown. Here the setpoint
has been changed to 0°F using the "+" soft key.
Figure 39: Zone One
The setpoint display appears as shown in Figure 40.
53
Operating Instructions
Figure 41: Setpoint Changed
Figure 42: YES and NO Keys
The YES and NO soft keys confirm the setpoint change
(Figure 42). When the desired setpoint has been selected using
the "+" and/or "-" soft keys, press the YES soft key to confirm
and load the new setpoint. If the setpoint is changed using the
"+" or "-" soft keys, the change must be confirmed or rejected
by pressing the YES or NO soft key within 10 seconds of
changing the setpoint. A warning beep will sound after 5
seconds as a reminder. Failure to confirm the new setpoint by
pressing Yes or No within 10 seconds of changing the setpoint
will result in no setpoint change. If the setpoint is not
confirmed, then Alarm Code 127 Setpoint Not Entered is set,
to indicate that the setpoint change was not completed.
After the YES soft key has been pressed, the display will
briefly show PROGRAMMING NEW SETPOINT - PLEASE
WAIT. The display then confirms the new setpoint for two
seconds (Figure 43).
54
Operating Instructions
Figure 44: Standard Display, New Setpoint
Figure 43: New Setpoint Confirmation
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 44 that the Zone 1 arrow now
points up, to indicate that Zone 1 is heating.
IMPORTANT: If the setpoint is changed using the "+" or
"-" soft 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 soft key is pressed, the setpoint change made
with the "+" or "-" soft key is accepted, the setpoint
changes, and the display returns to the Standard Display.
•
If the NO soft key is pressed the setpoint change made
with the "+" or "-" soft key is not accepted, the setpoint is
not changed, and the display returns to the Setpoint
Display.
55
Operating Instructions
•
If the YES or NO soft key is not pressed within 10 seconds
of making a change with the "+" or "-" soft key, the
setpoint is not changed and the display returns to the
Setpoint Display. The display briefly shows [SETPOINT
NOT CHANGED] and Alarm Code 127 Setpoint Not
Entered is set, to indicate that the setpoint change was
started but not completed.
To turn Zone 2 or Zone 3 on or off, press the soft key under the
desired zone. Zone 2 is selected in Figure 45.
Turning a Zone ON and Off
Zone 1 will always be turned on any time the unit is turned on.
Zone 2 and Zone 3 (if present) can be turned on and off as
desired.
The state of each zone is retained when the unit is turned off
and on. For example, on a three zone unit if zone 2 is turned off
and Zone 3 is turned on and the unit is turned off, the zone
states remain as they were. When the unit is turned back on
Zone 2 will still be off and Zone 3 will still be on.
NOTE: Units equipped with a remote control may operate in
a slightly different manner. See Optional Flush Mount
Remote Control Panel for additional details.
56
Figure 45: Zone 2 Selected
The Zone 2 setpoint display appears as shown in Figure 46. If
the zone is turned on, the third soft key will be labeled TURN
ZONE OFF. If the zone is turned off, the third soft key will be
labeled TURN ZONE ON. In this case TURN ZONE OFF is
shown.
Operating Instructions
The display briefly shows PROGRAMMING ZONE ON/OFF
- PLEASE WAIT (Figure 48). The display then confirms the
new Zone 2 setting for several seconds.
Figure 46: Zone 2 Setpoint Display
Press the TURN ZONE OFF soft key to turn the zone off.
(Figure 47)
Figure 48: New Zone 2 Setting
The display then returns to the Standard Display showing Zone
2 is off. The setpoint for Zone 2 has been replaced with OFF as
shown in Figure 49 to indicate that the zone is now off.
Figure 47: TURN ZONE OFF soft key
57
Operating Instructions
CAUTION: The engine may start automatically any time the
unit is turned on.
WARNING: Never use starting fluid.
When the engine is preparing to start the HMI control panel
will display the engine start screen, as shown in Figure 50. The
preheat buzzer sounds during the engine preheat and crank
sequence.
Figure 49: Zone Off
Starting the Diesel Engine
Diesel engine preheating and starting is automatic in both
Continuous Mode and Cycle Sentry Mode. The engine will
preheat and start as required when the unit is turned on. If any
keys are being pressed on the HMI control panel prior to the
engine start, the engine preheat and start will be delayed until
10 seconds after the last key is pressed.
NOTE: If the unit is equipped with optional SmartPower
there may be some additional prompts before the engine will
start. See STARTING THE ELECTRIC MOTOR on the
following pages for details.
58
Figure 50: Engine Start Screen
After the engine is started the display returns to the Standard
Display of temperature and setpoint.
Operating Instructions
Starting the Electric Motor
Units equipped with the SmartPower option only.
When standby power is connected and available, 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 51. The
preheat buzzer sounds for 20 seconds before the electric motor
starts.
Figure 51: Motor Start Screen
After the motor is started the display returns to the Standard
Display of temperature and setpoint.
Switching from Diesel to Electric
Units equipped with the SmartPower option only.
If the Electric to Diesel 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.
59
Operating Instructions
If the Electric to Diesel Autoswitch Enabled feature in
Guarded Access is set NO then the prompt screen shown in
Figure 52 will appear when standby power is connected and
available.
Figure 53: Electric Motor Start
Switching from Electric to Diesel
Units equipped with the SmartPower option only.
Figure 52: Electric to Diesel Autoswitch Enabled
feature in Guarded Access Set to NO
Electric Mode operation will briefly be confirmed. If unit
operation is required the electric motor will start as shown in
Figure 53 STARTING THE ELECTRIC MOTOR.
60
If the Diesel to Electric 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.
If the Electric to Diesel Autoswitch Enabled feature in
Guarded Access is set NO then the prompt screen shown in
Figure 54 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.
Operating Instructions
Figure 54: Electric to Diesel Autoswitch Enabled
feature in Guarded Access Set to YES
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.
Figure 55: Prompt Screen
If YES is selected then the display will briefly show the screen
in Figure 56. Then Diesel Mode will briefly be confirmed. If
unit operation is required the diesel engine will start as shown
previously in STARTING THE DIESEL ENGINE.
NOTE: The CLEAR Soft Key will not clear these two alarms.
Then the prompt screen in Figure 55 in will appear.
61
Operating Instructions
To initiate a manual defrost cycle, press the Defrost Key as
shown in Figure 57.
Figure 56: YES Selected
Initiating a Manual Defrost Cycle
Defrost cycles are usually initiated automatically based on time
or demand. Manual defrost is also available
Figure 57: Defrost Key
The display will briefly show [DEFROST]. Then the Zone
Select display appears. Zone 1 selected shown in Figure 58.
Manual defrost is only available if the zone is running and the
zone 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.
NOTE: If the Rail Alternate feature is set ENABLED then a
manual defrost cycle is available with temperatures less than
or equal to 55 F (13 C).
Figure 58: Zone 1 Selected
62
Operating Instructions
The display briefly shows [DEFROST], [PROGRAMMING
DEFROST - PLEASE WAIT] and then [DEFROST
STARTED] (Figure 59).
Figure 60: Bar Indicator
See summary of “Initiating a Manual Defrost Cycle” displays
in Figure 61.
Figure 59: Defrost Started
The display then shows the Defrost display. The bar indicator
shows approximately the percentage of time remaining to
complete the defrost cycle. The bar indicator in Figure 60
shows that the Zone 1 defrost cycle is approximately 25%
complete.
Terminating a Defrost Cycle
The defrost cycle terminates automatically when the coil
temperature is greater than or equal to 58°F (14.5°C) or the
defrost timer expires. Defrost can also be terminated by turning
the unit off and back on.
NOTE: If the Rail Alternate feature is set ENABLED then a
defrost cycle will terminate with temperatures greater than or
equal to 70 F (21 C).
63
Operating Instructions
Defrost Key
Figure 61: Initiating a Manual Defrost Cycle
64
Operating Instructions
Selecting Cycle Sentry or Continuous
Mode
NOTE: Cycle Sentry or Continuous Mode operation can also
be selected from the Main Menu > Mode Menu.
When Cycle Sentry mode is selected the unit will start and stop
automatically to maintain setpoint, keep the engine warm and
the battery charged. When Continuous Mode is selected, the
unit starts automatically and runs continuously to maintain
setpoint and provide constant airflow. Cycle Sentry or
Continuous may not be available from the Mode menu if
OptiSet Plus is in use. The Cycle Sentry/Continuous selection
affects all zones.
If allowed by OptiSet Plus, Cycle Sentry or Continuous Mode
is selected by pressing the Cycle Sentry/Continuous Key
(Figure 62). The unit is currently operating in Continuous
Mode as shown by the absence of the Cycle Sentry Icon.
If the unit is operating in Cycle Sentry Mode,
the Cycle Sentry Icon will appear in the display.
• The Cycle Sentry Icon appears in the upper
right corner of the Standard Display
(Figure 65).
• The Cycle Sentry Icon appears in the lower
right of the TemperatureWatch Display
(Figure 66).
Figure 62: Cycle Sentry/Continuous Key
If the unit is operating in Continuous Mode, pressing the Cycle
Sentry/Continuous Key changes the mode from Continuous
Mode to Cycle Sentry Mode. The display confirms the change,
as shown in Figure 63.
• If the Cycle Sentry Icon is not shown, the
unit is operating in Continuous Mode.
65
Operating Instructions
The display then returns to the Standard Display. In the
example here the unit is running in Cycle Sentry Mode as
shown by the presence of the Cycle Sentry Icon at the upper
right corner of the display (Figure 65).
Figure 63: Mode Change Confirmed
The new mode is confirmed for 2 seconds (Figure 64).
Figure 65: Cycle Sentry Icon, Upper Right Corner
Figure 64: Mode Confirmed
66
Operating Instructions
When the TemperatureWatch Display is shown, the Cycle
Sentry Icon appears in the lower right corner (Figure 66).
Figure 66: Cycle Sentry Icon, Lower Right Corner
Pressing the Cycle Sentry/Continuous key again allows the
operator to change back to Continuous Mode operation.
IMPORTANT: If the unit is in Cycle Sentry null and the
mode is switched to Continuous Mode, the unit will start
automatically.
See summary of “Selecting Cycle Sentry or Continuous Mode”
displays in Figure 67.
67
Operating Instructions
Cycle Sentry/Continuous Key
Figure 67: Selecting Cycle Sentry or Continuous Mode
68
Operating Instructions
Using the Main Menu
The Main Menu contains submenus that allow the operator to
view information and modify unit operation. To access the
Main Menu press the MENU soft key (Figure 68).
Figure 69: UP and DOWN Keys
The Main Menu choices are shown below.
Figure 68: MENU Soft Key
The first Main Menu choice will appear. Press and hold the UP
and DOWN Keys to scroll thru the menu choices (Figure 69).
When the desired selection is shown on the display, press the
SELECT Key to access it. The Pretrip submenu is shown here.
Pretrip
Gauges
Hourmeters
Adjust
Brightness
Language
Sensors
Mode
Time
Alarms
Data
Logger
Electric
Standby
Clear ECU
Faults
To return to the Standard Display press the EXIT Key.
69
Operating Instructions
Main Menu Features
Conditions where Pretrip Tests are not
Allowed
Pretrip
•
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.
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
Test is entered with the unit running in either diesel or electric
mode a Running Pretrip Test is performed. Test results are
reported as PASS, CHECK or FAIL when the Pretrip Test is
completed.
Pretrip Test Conditions
•
Current unit settings are saved and restored at the end of
the Pretrip Test or if the unit is turned off and back on.
•
Pretrip Test can be run in either Diesel or Electric Mode.
•
The unit will auto switch from Diesel Mode to Electric
Mode or from Electric Mode to Diesel Mode during a
Pretrip Test if these features are enabled and the auto
switch conditions occur.
70
Pretrip Test Considerations
When performing a Pretrip Test, the following issues should be
considered.
•
If running a Pretrip Test on a trailer loaded with dry cargo,
insure that proper airflow can occur around the load. If the
load restricts airflow, false test results may occur. Also,
SR-4 units have high refrigeration capacity which results
in rapid temperature changes. Sensitive dry cargo may be
damaged as a result.
•
If running a Pretrip Test on a trailer that has just been
washed down, the extremely high humidity inside the
trailer may result in false test results.
Operating Instructions
•
•
If running a Pretrip Test on a trailer loaded with sensitive
cargo, monitor the load temperature during the test as
normal temperature control is suspended during pre-trip
operation.
•
Zone 1 Cool Check - The ability of the unit to cool in low
speed is checked.
•
Zone 1 Heat Check - The ability of the unit to heat in low
speed is checked.
Always perform Pretrip Tests with the trailer cargo doors
closed to prevent false test failures.
•
Zone 1 Return to Cool Check - The ability of the unit to
return to cool mode is checked
•
Zone 2 Cool Check - The ability of the unit to cool in low
speed is checked.
•
Zone 2 Heat Check - The ability of the unit to heat in low
speed is checked.
•
Zone 2 Return to Cool Check - The ability of the unit to
return to cool mode is checked
•
Zone 3 Cool Check - The ability of the unit to cool in low
speed is checked.
•
Zone 3 Heat Check - The ability of the unit to heat in low
speed is checked.
•
Zone 3 Return to Cool Check - The ability of the unit to
return to cool mode is checked
Pretrip Test Sequence
Pretrip tests proceed in the order shown below. A Full Pretrip
Test is started with the engine or motor not running and
includes all tests. A Running Pretrip Test is started with the
engine or motor running and does not include the Amp Checks
or Engine Start Check.
•
Amp Checks - Each electrical control component is
energized and the current drawn is confirmed as within
specification.
•
Engine Start - The Engine will start automatically.
•
Defrost - If the coil temperature is below 45°F (7°C), a
defrost cycle is initiated.
•
RPM Check - The engine RPM in high and low speed is
checked during the Cool Check.
71
Operating Instructions
•
Report Test Results - When the Pretrip Test is completed
the test results are reported as PASS, CHECK or FAIL. If
test results are CHECK or FAIL alarm codes will exist to
direct the technician to the source of the problem.
Performing a Pretrip Test
If a Pretrip Test is initiated with the engine shut down a Full
Pretrip Test will be performed. If a Pretrip Test is initiated with
the engine or motor running a Running Pretrip Test is
performed.
•
Before initiating a Pretrip Test, clear all alarm codes.
•
To stop a Pretrip Test at any time turn the unit off.
Pretrip Tests are initiated using the Pretrip Menu (or the Pretrip
Key if present). From the Standard Display, press the MENU
Key (Figure 70).
72
Figure 70: Pretrip Initiated - MENU Key
NOTE: If the Pretrip Key is used to start a Pretrip Test, the
Main Menu is not shown when the key is pressed. The display
will show [Programming Pretrip Mode] as shown in Figure
72.
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Pretrip Menu. When the Pretrip Menu is
shown press the SELECT Key to start a Pretrip Test (Figure
71).
Operating Instructions
Figure 71: UP, DOWN, SELECT
Figure 72: Programming Pretrip Mode
The display will briefly show PROGRAMMING PRETRIP
MODE (Figure 72). If the unit is not running a Full Pretrip Test
will be initiated. If the unit is running in either diesel or electric
mode a Running Pretrip Test will be performed.
If all alarms were not cleared a prompt appears as shown in
Figure 73. Exit the Pretrip Test, clear all alarms and repeat the
Pretrip Test.
73
Operating Instructions
Figure 73: Alarm Active
If all alarms were cleared, the Pretrip Test display appears
(Figure 74).
•
The top line of the display indicates the unit is performing
the non-running portion of the Pretrip Test.
•
The second line measures test progress. The number of
tests completed of the total number of tests to be
performed is shown. In the example above the unit is
performing Test 1 of 26, Sensor Check.
•
The soft keys may be used during the Pretrip Test to select
the Hourmeter, Gauge or Sensor menus.
•
To stop a Pretrip Test at any time turn the unit off. This
will generate Alarm Code 28 Pretrip Abort. Other alarm
codes may also be generated. This is normal when the
Pretrip Test is halted before completion.
When the non-running tests are complete the unit will start
automatically and continue with the Running Pretrip Test. In
the example shown in Figure 75 the unit is in the Running
Pretrip and is performing Test 21 of 26, Cool Test.
Figure 74: Pretrip Test
74
Operating Instructions
Figure 75: Cool Test
When all tests are complete, the results are reported as PASS,
CHECK or FAIL (Figure 76). If the results are CHECK or
FAIL, the accompanying alarm codes will direct the technician
to the cause of the problem
Figure 76: Pretrip Pass
If the Pretrip Test results are CHECK or FAIL the problem
should be diagnosed and corrected before the unit is released
for service.
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
See summary of “Performing a Pretrip Tes displays in Figure
77 and Figure 78.
75
Operating Instructions
See Figure 78
Alarms Cleared?
Yes
No
Exit Pretrip Test, clear alarms,
restart Pretrip Test.
Figure 77: Performing a Pretrip Test (1)
76
Operating Instructions
From Figure 77
Figure 78: Performing a Pretrip Test (2)
77
Operating Instructions
Languages (If Enabled)
Selecting an Alternate Language
If more than one language is enabled from the Guarded Access
> Language Menu, this menu item will appear. If only one
language is enabled, this menu will not appear. The Language
Menu allows the operator to select a language from a list of
enabled languages. All subsequent displays are shown in the
selected language. English is the default language. See the
Guarded Access Language Setup Menu in Section 3 of the
SR-4 Multi-Temp Microprocessor Control System Diagnostic
Manual TK 55788 for details.
To select an alternate language, press the MENU Key (Figure
79).
If Languages are not enabled from the Guarded Access Menu,
this feature will not appear in the Main Menu.
IMPORTANT: Exercise care when changing languages, as
once changed all HMI Control Panel displays will be in the
new language.
Available Languages
The following languages are available:
English (Enabled), Spanish (Disabled), French (Disabled)
78
Figure 79: Select Languages - MENU Key
The Main Menu will appear. If more than one language is
enabled, the Language Menu will appear as a main Menu
selection. Press the UP or DOWN Key as required to choose
the Language Menu. When the Language Menu is shown press
the SELECT Key to select the Language menu (Figure 80).
Operating Instructions
Figure 80: UP, DOWN. SELECT Keys
The Language menu will appear as shown in Figure 81. Press
the + or - Keys to select the desired language. Only languages
enabled from the Guarded Access Menu are available. When
the desired language is shown press the YES Key to confirm
the choice.
Figure 81: Language Menu
The display will briefly show PROGRAMMING
LANGUAGE - PLEASE WAIT in the new language. The
display will then return to the Main Menu, but will show the
new language. Spanish is shown in Figure 82.
79
Operating Instructions
Figure 82: New Language
Repeat the process to select a different language. To select a
different Main Menu item press the NEXT (SIGUIENTE) Key.
To return to the Standard Display press the EXIT (SALIDA)
Key. All displays will now be in the new language. Español
(Spanish) is shown in Figure 83.
See summary of “Performing a Pretrip Tes displays in Figure
84.
80
Figure 83: Spanish
Operating Instructions
Figure 84: Languages (If Enabled)
Language Menu Quick Access
Should it be necessary at any time to change to English or any
other installed language, return to the Standard Display and
then press and hold the first and last soft keys for 5 seconds as
shown in Figure 85. The Standard Display here is shown in
Español (Spanish).
81
Operating Instructions
Figure 85: First, Last Keys
After 5 seconds the Language Menu will appear in the current
language as shown in Figure 86. Press the + or - Keys to select
the desired language. When the desired language is shown
press the SI (YES) Key to confirm the choice.
82
Figure 86: Language Menu
Note that all languages available in the installed software can
be selected using this method.
Operating Instructions
Alarms
The Alarm Menu allows the operator to view any active
alarms, and allows most alarms to be cleared.
See “Alarms” on page 83 for a table that lists the alarm codes.
Refer to the SR-4 Multi-Temp Microprocessor Control System
Diagnostic Manual TK 55788 for more information about
alarm codes and their diagnosis.
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 off after 30 seconds.
NOTE: The Alarm Icon does not appear on startup with Log
Alarms present.
Log Alarms
Log Alarms are indicated for 30 seconds each time the unit is
turned on. This level of alarm serves as a notice to take
corrective action before a problem becomes severe.
Maintenance items such as maintenance hourmeter time-outs
are Log Alarms. The TemperatureWatch screen is not disabled
if only Log Alarm(s) are active.
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 30 seconds as shown in Figure 87. The remote
Figure 87: Log Alarm Notice
Check Alarms
Check Alarms are indicated by a steady alarm icon at the side
of the display. If the alarm is specific to a zone then a smaller
alarm icon will appear next to the affected zone. This level of
alarm serves as a notice to take corrective action before a
problem becomes severe. The unit will run with Check Alarms
83
Operating Instructions
but some features and functions may be inhibited. The
TemperatureWatch screen is disabled if a Check Alarm is
active.
Unit Level Check Alarms
Zone Level Check Alarms
If the alarm is zone specific, the Alarm Icon will appear in the
offending zone as shown in Figure 89. An alarm exists in
Zone 2.
If the alarm is unit specific, the Alarm Icon will appear at the
right side of the display as shown in Figure 88. Both Zone
Specific and Unit Specific Alarms can exist at the same time.
Figure 89: Alarm for Zone 2
Unit Level Prevent Alarms
Figure 88: Alarm Icon
84
Prevent Alarms are also indicated by a steady alarm icon at the
side of the display. 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
and then restart. If the unit is in a temporary shutdown, Alarm
Code 84 Restart Null will be present along with the associated
Operating Instructions
Prevent Alarm. In most cases the unit will restart with reduced
performance to determine if continued operation is possible. If
the alarm does not reoccur with reduced performance then the
unit will then return to full performance. If the unit is operating
with reduced performance Alarm Code 85 Forced Unit
Operation may also be present under some conditions. In
general, if the alarm condition re-occurs a defined number of
times then the alarm is set as a Shutdown Alarm and no further
restarts are possible. The TemperatureWatch screen is disabled
if a Unit Level Prevent Alarm is active.
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.
Shutdown Alarms
If a Shutdown Alarm occurs while the unit is running it will be
indicated by all of the following (Figure 90):
•
The Alarm Icon will appear.
•
The display, backlight and optional remote alarm light will
flash on and off.
•
The display will switch from normal video to reverse
video and back to normal video. (Light areas become dark
and dark areas become light.)
Zone Level Prevent Alarms
A Zone Level Prevent Alarm will force the affected zone into a
temporary shutdown, but allow the unit to continue to run as
required by the host unit or other zones. A small alarm icon
will appear next to the affected zone. If zone Prevent Alarms
occur in all zones then the unit will be forced into a unit level
prevent shut down. The TemperatureWatch screen is disabled
if a Zone Level Prevent Alarm is active.
Figure 90: Shutdown Alarm Screen
85
Operating Instructions
Unit Level Shutdown Alarms
Unit Level Shutdown Alarms will force the unit into shutdown.
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). The TemperatureWatch screen is disabled if a Unit
Level Shutdown Alarm is active.
Zone Level Shutdown Alarms
A zone Shutdown Alarm will force the affected zone to
shutdown, but allow the unit to continue to run as required by
the host unit or other zones. A small alarm icon will appear
next to the affected zone and blink with a period of ½ second
on - ½ second off. If zone Shutdown Alarms occur in all zones
then the unit will shut down and Alarm Code 114 Multiple
Alarms - Can Not Run will be set.
Pretrip Alarms
If an alarm occurs during a Pretrip Test the alarm code will be
displayed as Pretrip Alarm XX, where XX is the alarm code.
86
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.
Operating Instructions
Clearing Alarm Codes
•
Most alarm codes can be cleared conventionally from the
Alarm Menu using the CLEAR Key.
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.
The following control and display sensor alarm codes can only
be cleared from the Maintenance Menu or Guarded Access
Menu:
•
Alarm Code 03 Check Control Return Air Sensor
•
Alarm Code 04 Check Control Discharge Air Sensor
•
Alarm Code 203 Check Display Return Air Sensor
•
Alarm Code 204 Check Display Discharge Air Sensor
The following alarm codes clear automatically:
•
Alarm Code 64 Pretrip Reminder - Clears when a Pretrip
Test is performed.
•
Alarm Code 84 Restart Null - Clears when the unit is no
longer in a restart null due to a Prevent Alarm.
•
Alarm Code 85 Forced Unit Operation - Clears when the
unit is no longer running in a forced mode due to a Prevent
Alarm.
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. See the Limited Alarm Restarts feature in
Section 3 of the SR-4 Multi-Temp Microprocessor Control
System Diagnostic Manual TK 55788 for details.
•
Alarm Code 10 High Discharge Pressure
•
Alarm Code 23 Cooling Cycle Fault
•
Alarm Code 24 Heating Cycle Fault
•
Alarm Code 32 Refrigeration Capacity Low
87
Operating Instructions
Displaying and Clearing Alarm Codes
Alarms are displayed and cleared using the Alarm Menu. From
the Standard Display, press the MENU Key (Figure 91).
Figure 92: SELECT Key
Figure 91: MENU Key
The Main Menu will appear. Press the UP or DOWN Key
(Figure 92) as required to choose the Alarms Menu. When the
Alarms Menu is shown press the SELECT Key to select the
Alarms menu.
88
The number of alarms (if more than one) and a list of the
alarms with the most recent alarm first will be shown. In the
example in Figure 93, there are two alarms. The most recent is
Alarm Code 5 Check Ambient Temp Sensor.
Operating Instructions
If the alarm situation has been resolved press the CLEAR Key
to clear the alarm (Figure 95).
Figure 93: Two Active Alarms
If necessary to view all alarms, scroll down using the DOWN
Key (Figure 94).
Figure 95: CLEAR Key
The display will briefly show CLEARING ALARM 5 PLEASE WAIT. Then the Alarm Menu will reappear (Figure
96).
Note that Alarm Code 64 Pretrip Reminder cannot be cleared
using the CLEAR Key. This alarm will clear automatically
when a Pretrip Test is run
Figure 94: DOWN Key
89
Operating Instructions
Figure 96: Alarm Menu
If a serious condition occurs, the unit will be shut down to
prevent damage to the unit or the load. If this occurs, the Alarm
Icon will appear (Figure 97), the display and backlight will
flash on and off.
Figure 97: Alarm Screen
The Alarm Menu display will display the Shutdown Alarm
Code. For additional information regarding the alarm shown
on the display, press the HELP Key (Figure 98).
Figure 98: HELP Key
90
Operating Instructions
A help message will appear. Press the EXIT Key (Figure 99) to
return to the Alarms Menu. 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.
Figure 99: EXIT Key
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
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.
91
Operating Instructions
See Figure 101
Figure 100: Displaying and Clearing Alarm Codes (1)
92
From Figure 100
Operating Instructions
Figure 101: Displaying and Clearing Alarm Codes (2)
93
Operating Instructions
SR-4 Precedent Alarm Codes
For a complete list of SR-4 Precedent Alarm Codes see the
table at the end of this chapter.
Gauges
The Gauges Menu allows the operator to view the unit gauges
and I/O conditions. The unit gauges can be viewed from the
Main Menu and Maintenance Menu.
Figure 102: MENU Key
Displaying Gauges
Gauges are displayed using the Gauges Menu. From the
Standard Display, press the MENU Key (Figure 102).
94
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Gauges Menu. When the Gauges Menu
is selected, press the SELECT Key to choose the Gauges menu
(Figure 103).
Operating Instructions
Figure 103: SELECT, UP, Down Keys
The first gauge display will appear. Press the NEXT and
BACK Keys to scroll thru the gauges and I/O conditions.
Pressing the LOCK Key will lock the current gauge on the
display (Figure 104).
Figure 104: LOCK, NEXT, BACK Keys
The gauges and I/O conditions available are shown below. Not
all gauges or I/O conditions may appear depending on unit
configuration and software revision.
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
Gauges Available
NOTE: Not all gauges may appear, dependent upon software
revision, unit type and configuration.
Coolant Temperature - Displays the temperature of the
engine coolant.
95
Operating Instructions
Coolant Level - Displays the coolant level in the overflow
tank as OK or LOW.
I/O (Input/Output) State Submenu - Displays the current
control state of the I/O device listed below as ON or OFF.
Engine Oil Pressure - Displays the engine oil pressure as OK
or LOW.
•
High Speed Relay
•
Run Relay
Engine Oil Level - Displays the engine oil level as OK or
LOW.
•
Run Relay Feedback
•
Alternator Excite Output
•
Fresh Air Exchange Output
Battery Voltage - Displays the voltage of the unit battery.
•
Fresh Air Exchange Feedback
Engine RPM - Displays the engine speed in RPMs.
•
Spare Digital Input 1, 2, 3,4
Fuel Level Sensor - Display the fuel level if configured.
•
Spare Analog Input 1, 2
Discharge Pressure - Displays the unit discharge pressure.
•
Spare Output 1, 2, 3, 4, 5
Suction Pressure - Displays the unit suction pressure.
•
Condenser Inlet Solenoid
ETV Position - Displays ETV Position if configured.
•
Receiver Tank Inlet Pressure Solenoid
I/O (Input/Output State) - Displays the current control state
of the I/O devices listed below as ON or OFF.
•
Purge Valve
•
Liquid Line Solenoid Zone 1
NOTE: Not all gauges may appear, dependent upon software
revision, unit type and configuration.
•
Hot Gas Solenoid Zone 1
•
Suction Line Solenoid Zone 1
Amps - Displays the current flow in amps to or from the unit
battery.
96
Operating Instructions
•
Liquid Line Solenoid Zone 2
Displaying Sensors
•
Hot Gas Solenoid Zone 2
•
Suction Line Solenoid Zone 2
Sensors are displayed using the Sensors Menu. From the
Standard Display, press the MENU Key (Figure 105)
•
Drain Hose Heater Zone 2
•
Liquid Line Solenoid Zone 3
•
Hot Gas Solenoid Zone 3
•
Suction Line Solenoid Zone 3
•
Drain Hose Heater Zone 3
•
Fan Output Zone 2
•
Fan Output Zone 3
•
Diesel/Electric Relay
•
Electric Ready Input
•
Electric Overload
Figure 105: MENU Key
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Sensors Menu. When the Sensors Menu
is selected, press the SELECT Key to choose the Sensors menu
(Figure 106).
Sensors
The Sensors Menu allows the operator to view the unit and
CargoWatch Data Logger temperature sensors. The sensors can
be viewed from the Main Menu or Maintenance Menu.
97
Operating Instructions
Figure 106: SELECT, UP, Down Keys
The first sensors display will appear. Press the NEXT and
BACK Keys to scroll thru the gauges and I/O conditions.
Pressing the LOCK Key will lock the current gauge on the
display (Figure 107).
Figure 107: LOCK Key
The sensors available are shown below.
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
Sensors Available
Zone 1 Return Air Temperature - Displays the temperature
of the Zone 1 Return Air Sensor.
Zone 1 Discharge Air Temperature - Displays the
temperature of the Zone 1 Discharge Air Sensor.
Zone 1 Temperature Differential - Displays the Zone 1
Temperature Differential.
98
Operating Instructions
Zone 1 Evaporator Coil Temperature - Displays the
temperature of the Zone 1 Evaporator Coil sensor.
Spare 1 Temperature - Displays the temperature of the Spare
1 temperature sensor.
Zone 2 Return Air Temperature - Displays the temperature
of the Zone 2 Return Air Sensor.
Spare 2 Temperature - Displays the temperature of the Spare
2 temperature sensor.
Zone 2 Discharge Air Temperature - Displays the
temperature of the Zone 2 Discharge Air Sensor.
Spare 3 Temperature - Displays the temperature of the Spare
3 temperature sensor.
Zone 2 Temperature Differential - Displays the Zone 2
Temperature Differential.
Data Logger Sensor 1 Temperature - Displays the
temperature of the CargoWatch Data Logger 1 temp sensor.
Zone 2 Evaporator Coil Temperature - Displays the
temperature of the Zone 2 Evaporator Coil sensor.
Data Logger Sensor 2 Temperature - Displays the
temperature of the CargoWatch Data Logger 2 temp sensor.
Zone 3 Return Air Temperature - Displays the temperature
of the Zone 3 Return Air Sensor.
Data Logger Sensor 3 Temperature - Displays the
temperature of the CargoWatch Data Logger 3 temp sensor.
Zone 3 Discharge Air Temperature - Displays the
temperature of the Zone 3 Discharge Air Sensor.
Data Logger Sensor 4 Temperature - Displays the
temperature of the CargoWatch Data Logger 4 temp sensor.
Zone 3 Temperature Differential - Displays the Zone 3
Temperature Differential.
Data Logger Sensor 5 Temperature - Displays the
temperature of the CargoWatch Data Logger 5 temp sensor.
Zone 3 Evaporator Coil Temperature - Displays the
temperature of the Zone 3 Evaporator Coil sensor.
Data Logger Sensor 6 Temperature - Displays the
temperature of the CargoWatch Data Logger 6 temp sensor.
Ambient Air Temperature - Displays the temperature of the
ambient air temperature sensor.
Board Temperature Sensor - Displays the temperature of the
HMI control panel PC board.
99
Operating Instructions
Data Logger (CargoWatch)
The CargoWatch Data Logger is physically located in the HMI
Control Panel. It can support up to 6 optional temperature
sensors.
When shipped from the factory, CargoWatch sensors 1 and 2
are turned on to be logged and CargoWatch sensors 3 through 6
are turned off. Also, digital input 1 is turned on to be logged
and digital inputs 2 through 4 are turned off. Sensors and
digital inputs can be turned on, off and configured using the
CargoWatch menu in Guarded Access or with Wintrac. The
CargoWatch Data Logger can also be configured using the
USB Flash Drive OptiSet Plus Feature.
A Start of Trip can be sent to the unit ServiceWatch and
CargoWatch Data Loggers. In addition, the CargoWatch Data
Logger contents can be printed with a hand-held printer.
The ServiceWatch and CargoWatch Data Logger are accessed
using the Data Logger Menu. From the Standard Display, press
the MENU Key (Figure 108).
100
Figure 108: MENU Key
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Data Logger Menu. When the Data
Logger Menu is selected, press the SELECT Key to choose the
Data Logger menu (Figure 109).
Operating Instructions
Figure 109: SELECT Key
The Data Logger Menu will appear.
Sending Start of Trip Marker to CargoWatch and
ServiceWatch Data Loggers
To send a Start of Trip marker to the CargoWatch and
ServiceWatch Data Loggers press the SELECT Key. The
display will briefly show START OF TRIP COMPLETE to
confirm that a Start of Trip marker was set in the CargoWatch
Data Logger (Figure 110).
Figure 110: SELECT Key, START OF TRIP COMPLETE
NOTE: The start of trip marker is sent to both the
CargoWatch and ServiceWatch data loggers.
Printing CargoWatch Data Logger Reports
Connect an appropriate printer to the printer port. Press the
DOWN Key to select the PRINT / VIEW feature and press the
SELECT Key to choose Print/View.
101
Operating Instructions
Figure 111: PRINT / VIEW, SELECT
Figure 112: Delivery Ticket
The Print Data Menu will appear (Figure 112). The first Print
Data Menu allows the operator to print a Delivery Ticket using
a hand held printer. Pressing the SELECT Key will print the
ticket. The Delivery Ticket is a short ticket that shows delivery
specific details including the current temperature.
Pressing the DOWN Key allows the operator to print a Trip
Ticket using a hand held printer. Press the SELECT Key to
print the ticket. The Trip Ticket is a long ticket that shows
details for the current trip including a temperature history. The
Trip Ticket is also called a Journey Ticket.
102
Operating Instructions
Figure 113: Trip Ticket, SELECT
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
103
Operating Instructions
Hourmeters
The Hourmeters Menu allows the operator to view the unit
hourmeters that have the view feature enabled in the Guarded
Access menu. If the view feature for a particular hourmeter is
not enabled then that hourmeter will continue to accumulate
time but cannot be viewed from the Main Menu. However, all
hourmeters can be viewed from the Maintenance Menu, even if
they are not enabled. The hourmeters shown below are
implemented.
Viewing Hourmeters
Only Hourmeters that have been enabled in Guarded Access
are shown from the Main Menu. The Hourmeters can be
viewed only.
Hourmeters are displayed using the Hourmeter Display. From
the Standard Display, press the MENU Key (Figure 114).
104
Figure 114: MENU Key
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Hourmeter Menu. When the Hourmeter
Menu is selected, press the SELECT Key to choose the
Hourmeter Menu (Figure 115).
Operating Instructions
Hourmeter names and definitions are shown in the following
table in the order they appear. Only hourmeters enabled in the
Guarded Access Menu will be shown. To return to the Standard
Display, press the EXIT Key.
When shipped from the factory, only these hourmeters are
enabled for viewing from the Main Menu.
Figure 115: Hourmeter Menu
Press the NEXT or PREVIOUS Key to scroll through the
hourmeters.
•
Total Unit Run Hours
•
Total Engine Run Hours
•
Total Electric Run Hours
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
Hourmeter Names and Definitions
Only configured hourmeters that have been enabled in the
Guarded Access > Hourmeter Setup > Viewable Hourmeter
Setup Menu will be shown.
Figure 116: Scroll Hourmeters
105
Operating Instructions
Hourmeter Name
Definition
Engine Reminder 1
User Programmable
Total Hours
Total number of hours the unit has
been turned on (protection hours).
The number of hours before an
Engine Run Time Maintenance
Reminder 1 occurs.
Engine Reminder 2
User Programmable - The number of
hours before an Engine Run Time
Maintenance Reminder 2 occurs.
Electric Reminder 1
User Programmable - The number of
hours before an Electric Run Time
Maintenance Reminder 1 occurs.
Electric Reminder 2
User Programmable - The number of
hours before an Electric Run Time
Maintenance Reminder 2 occurs.
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.
Total Run Reminder 2
User Programmable - The number of
hours before a Total Unit Run Time
Maintenance Reminder 2 occurs.
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.
106
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.
Operating Instructions
Mode
•
The Mode Menu allows the operator to change the unit
operating modes that have been enabled in Guarded Access.
Only Operating Modes that have been enabled from the
Guarded Access > Main Menu Configuration Menu will be
shown.
When shipped from the factory, only the Cycle
Sentry/Continuous Mode feature is enabled.
•
Turns Off Cycle Sentry Mode/Turns On Cycle Sentry
Mode (If Cycle Sentry is turned Off unit runs in
Continuous). Note that selecting Cycle Sentry Mode or
Continuous Mode can also be accomplished using the
Cycle Sentry Hard Key to the right of the display.
•
Allows Single Zone Control to be selected (if enabled
from the Guarded Access > Main Menu Configuration
Menu).
•
Allows temperatures to be displayed in either Fahrenheit
or Celsius degrees (if enabled from the Guarded Access >
Main Menu Configuration Menu).
•
Allows Keypad Lockout to be selected (if enabled from
the Guarded Access > Main Menu Configuration Menu).
Allows Sleep Mode to be set up and started (if enabled
from the Guarded Access > Main Menu Configuration
Menu).
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
Using the Change Mode Menu
Mode changes are made using the Mode Menu. From the
Standard Display, press the MENU Key (Figure 117).
Figure 117: MENU Key
107
Operating Instructions
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Mode Menu (Figure 118). When the
Mode Menu is selected, press the SELECT Key to choose the
Mode Menu.
Figure 119: Change Mode Menu
•
Possible mode selections are shown on the following
pages.
Figure 118: MODE Menu
•
The first enabled Change Mode Menu selection will appear
(Figure 119). To choose that function, press the SELECT Soft
Key. To Scroll through the enabled features in the Change
Mode Menu, press the UP and DOWN Soft Keys.
Only those modes that have been enabled in Guarded
Access > Main Menu Configuration will appear. Only the
Cycle Sentry/Continuous Mode is enabled on factory
units.
•
To return to the Standard Display press the EXIT Key.
108
Operating Instructions
Turn Cycle Sentry On or Off
Using the Cycle Sentry Key
Cycle Sentry can be turned on and off either by using the Cycle
Sentry hard key at the lower right side of the display or from
the Main Menu.
If allowed by OptiSet Plus, Cycle Sentry Mode or Continuous
Mode is selected by pressing the Cycle Sentry Key as shown in
Figure 121.
IMPORTANT: If the unit is in Cycle Sentry Null and the
mode is switched to Continuous Mode, the unit will start
automatically.
If the unit is operating in Cycle Sentry Mode, the Cycle Sentry
Icon will be present in the upper right corner of the display as
shown in Figure 120. If the Cycle Sentry Icon is not present the
unit is operating in Continuous Mode.
Figure 121: Cycle Sentry Key
Using the Main Menu
From the Main Menu > Change Mode menu choose Turn
On/Off Cycle Sentry Mode and press the SELECT Soft Key.
Figure 120: Cycle Sentry Icon
109
Operating Instructions
Figure 122: SELECT Soft Key
Figure 123: SELECT Soft Key
If the unit is running in Cycle Sentry Mode, press the SELECT
Soft Key to turn off Cycle Sentry Mode as shown in Figure
123.
Confirmation screens will appear briefly, the unit will switch to
Continuous Mode operation and the Cycle Sentry Icon will
disappear.
•
To turn Cycle Sentry back on press the SELECT Key
again.
•
To leave this menu without changing the setting, press the
EXIT Soft Key. To return to the Standard Display press the
EXIT Soft Key again.
IMPORTANT: If the unit is in Cycle Sentry Null and the
mode is switched to Continuous Mode, the unit will start
automatically.
110
Operating Instructions
Single Zone Control - Multi Zone Control
The following differences exist when operating the unit in
Single Zone Control Mode.
•
Single Zone Control Mode will appear in the Mode Menu
only if the Single Zone Control feature has been enabled
in the Guarded Access > Main Menu Configuration menu.
If the feature is enabled then Single Zone Control will
appear in the Main Menu > Mode Menu.
•
If Single Zone Control operation is selected then all zones
will be forced on and will control to the same setpoint. All
bulkheads should be taken down to create one large
compartment. With the exception of defrost, the operating
mode of each zone evaporator(s) will be same when in this
mode. Unit control is based on the temperature sensors of
one zone (usually Zone 1).
Figure 124: Setpoint
•
If Single Zone Control operation is selected the Single
Zone Standard Display provides one soft key labeled Set
Point as shown in Figure 124. This allows the setpoint for
all zones to be changed simultaneously.
•
If Single Zone Control operation is selected the individual
zones cannot be turned off. The unit and all zones are
turned On and Off simultaneously using the On and Off
hard keys at the left side of the display.
111
Operating Instructions
Select Temperature Units
If this feature enabled in Guarded Access > Main Menu
Configuration, the operator can select temperature units to be
displayed as either degrees Fahrenheit or degrees Celsius.
From the Main Menu > Change Mode menu choose Fahrenheit
or Celsius and press the SELECT Soft Key.
Figure 126: SELECT Soft Key
Temperatures will be displayed in the selected units.
•
Figure 125: SELECT Soft Key
Choose the desired Temperature Units using the UP and
DOWN Soft Keys and press the SELECT Soft Key to select
the choice.
112
To leave this menu without changing the setting, press the
EXIT Soft Key. To return to the Standard Display press the
EXIT Soft Key again.
Keypad Lockout
If enabled in Guarded Access > Main Menu Configuration, the
keypad can be locked to prevent unauthorized use. If the
keypad is locked, only the On Key and Off Key function. The
keypad will remain locked even if the unit is turned off and
back on. If Keypad Lockout is active, press and hold any soft
Operating Instructions
key for 5 seconds to deactivate the feature. To turn the feature
on, from the Change Mode menu choose Keypad Lockout and
press the SELECT Soft Key (Figure 127).
Figure 128: YES and NO Soft Keys
Figure 127: SELECT Soft Key
A Confirmation Request will appear. To activate Keypad
Lockout press the YES Soft Key. To leave this menu without
turning the Keypad Lockout feature on, press the NO Soft Key
(Figure 128).
If the YES Soft Key was pressed Keypad Lockout is active.
Repeat the process to turn the Keypad Lockout feature off.
•
If the keypad is locked, only the On Key and Off Key
function. The keypad will remain locked even if the unit is
turned off and back on.
•
If Keypad Lockout is active, press and hold any soft key
for 5 seconds to deactivate the feature.
•
To return to the Standard Display press the EXIT Soft Key
again.
113
Operating Instructions
Start Sleep Mode
If this feature enabled in Guarded Access > Main Menu
Configuration, the operator can set up and start set Sleep Mode
from the Mode Menu. Sleep Mode is used to keep the engine
warm and the battery charged when the unit is not in use. When
the unit is Sleep Mode the display will show "SLEEP" and the
current time. To turn the feature on, from the Change Mode
menu choose Start Sleep Mode and press the SELECT Soft
Key (Figure 129).
•
Program Wakeup Time This feature allows a wakeup
time to be specified. When the selected time is reached the
unit will start and resume normal operation.
If a Wakeup Time is selected the following features are
available:
•
Day to Wake Up This feature allows the day the unit is to
wake up to be specified.
•
Hour to Wake Up This feature allows the hour the unit
is to wake up to be specified.
•
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.
Smart Power™ Electric Standby Option
Figure 129: SELECT Soft Key
The following features are available in Sleep Mode. Follow the
display prompts to select and set the features.
114
The Diesel/Electric Standby selection from the Main Menu
allows the operator to manually select diesel or electric mode
operation on units equipped with the electric standby Smart
Power option. The unit can also be programmed to
automatically switch to Electric Mode operation when standby
power is available and to automatically switch to Diesel Mode
Operating Instructions
operation if standby power fails or is removed. If the unit is
programmed to automatically switch from diesel to electric
and/or electric to diesel the associated screens do not appear.
•
If the unit is currently operating in Diesel Mode the
ELECTRIC STANDBY selection will appear in the Main
Menu.
•
If the unit is currently operating in Electric Mode the
DIESEL MODE selection will appear in the Main Menu.
Diesel Mode Operation
If a unit equipped with the electric standby Smart Power option
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 electric standby Smart Power option is not
installed or if the Electric to Diesel Auto-switch feature is set
YES.
Electric Mode Operation
Switching from Diesel to Electric
If a unit equipped with the electric standby Smart Power option
is running in Diesel Mode, the Diesel to Electric Auto-switch
feature is set NO and the unit is connected to a source of
standby power, this feature allows the operator to manually
select electric mode operation. This feature does not appear if
the electric standby Smart Power option is not installed or if
the Diesel to Electric Auto-switch feature is set YES.
If the unit is running in Diesel Mode and the Guarded Access >
Diesel to Electric Autoswitch Enabled feature is set YES then
the unit will automatically switch to Electric Mode operation
when standby power is connected and available. The screens
shown in Figure 130 and Figure will not appear.
If the unit is running in Diesel Mode and the Guarded Access >
Diesel to Electric Autoswitch Enabled feature is set NO, the
unit can be switched to Electric Mode using the Electric
Standby selection from the Main Menu.
From the Standard Display, press the MENU Key (Figure 130).
115
Operating Instructions
If the unit has standby power available and is turned on, the
electric standby run screen will appear. The new mode is
confirmed for 10 seconds. The unit will start and run in
Electric Mode. If electric standby power is not available or
fails, the display will prompt for a return to Diesel Mode as
shown below.
Figure 130: MENU Key
From the Main Menu choose Electric Standby and press the
SELECT Soft Key (Figure 131).
Any engine related Shutdown Alarms become Log Alarms
when the unit is switched to Electric Mode operation. If the
unit is switched back to Diesel Mode these alarms again
become Shutdown Alarms.
Electric Standby Power Fails or is
Disconnected
If the electric standby power source fails or is disconnected and
manual switching to Diesel Mode is selected, the unit will
prompt for a switch to Diesel Mode (Figure 132).
Figure 131: SELECT Soft Key
116
Operating Instructions
Switching from Electric to Diesel
If the unit is running in Electric Mode and the Guarded Access
> Electric to Diesel Autoswitch Enabled feature is set YES
then the unit will automatically switch to Diesel Mode
operation when standby power is no longer available. The
screens shown below will not appear.
Figure 132: Prompt For Switch to Diesel Mode
•
Pressing the YES Soft Key will switch unit operation back
to Diesel Mode.
•
Pressing the NO Soft Key will allow the unit to remain in
Electric Mode even though standby power is not available.
If the Diesel to Guarded Access > Electric Autoswitch Enabled
feature is set NO and standby power is disconnected or fails,
the unit will not automatically switch to Diesel mode. This is
primarily designed to prevent unauthorized diesel engine starts
when the truck is indoors or on a ferry where engine operation
is strictly prohibited.
From the Standard Display, press the MENU Key (Figure 133).
The unit will not run and Alarm Code 91 Check Electric Ready
Input will be set as a prevent alarm.
117
Operating Instructions
The new mode is confirmed for 10 seconds. The unit will start
and run in Diesel Mode.
Any Electric Standby related Shutdown Alarms become Log
Alarms when the unit is switched to Diesel Mode operation. If
the unit is switched back to Electric Mode these alarms again
become Shutdown Alarms.
Adjust Brightness
Figure 133: MENU Key
From the Main Menu choose Diesel Mode and press the
SELECT Soft Key (Figure 134).
The brightness of the HMI Control Panel display can be
adjusted to allow for changing ambient light conditions. The
choices available to the operator are HIGH, MEDIUM, LOW
and OFF. OFF actually results in a very dim screen suitable for
low light conditions.
Display brightness is adjusted using the Adjust Brightness
Menu. From the Standard Display, press the MENU Key.
Figure 134: SELECT Soft Key
118
Operating Instructions
Figure 135: MENU Key.
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Adjust Brightness Menu (Figure 136).
When the Adjust Brightness is selected, press the SELECT
Key to choose the Adjust Brightness.
Figure 136: Adjust Brightness Menu
The Display Brightness menu will appear as shown below.
Press the UP or DOWN Soft Keys to select the desired display
brightness. When the desired brightness is shown press the
SELECT Soft Key to confirm the choice(Figure 137).
119
Operating Instructions
Figure 137: SELECT Soft Key
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
Time
The Time and Date held by the HMI Control Panel can be
checked. Time and Date cannot be changed from the Main
Menu. The time and date is accessed using the Main Menu.
From the Standard Display, press the MENU Key (Figure 138).
120
Figure 138: MENU Key.
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Time Menu (Figure 139). When the
Time Menu is selected, press the SELECT Key to choose the
Time Menu.
Operating Instructions
Figure 139: SELECT, UP, DOWN Keys
The date and time held in the HMI Control Panel will be shown
on the display (Figure 140). Time and Date cannot be changed
from the Main Menu.
Figure 140: Date and Time
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
Clear All ECU Faults
Pressing this key will clear all existing Engine Control Unit
(ECU) Fault Codes on units equipped with an ECU. This may
allow continued unit operation should an ECU fault code result
in engine shutdown.
“Any Thermo King Alarm Codes associated with the Engine
Control Unit (ECU) Fault Codes will also be cleared.
121
Operating Instructions
"The Thermo King Alarm Codes and Engine Control Unit
(ECU) Fault Codes that were cleared can be viewed in the
ServiceWatch and ECU Data Loggers.
Engine Control Unit (ECU) Fault Codes are cleared using the
Clear All ECU Faults Menu. From the Standard Display, press
the MENU Key (Figure 141).
Figure 142: Clear All ECU Faults Menu
The Clear All ECU Faults Prompt will appear. To clear all
Engine Control Unit (ECU) Faults and associated Thermo
King Faults press the CLEAR Soft Key.
Figure 141: MENU Key
The Main Menu will appear. Press the UP or DOWN Key as
required to choose the Clear All ECU Faults Menu. When the
Clear All ECU Faults Menu is selected, press the SELECT
Key to choose the Clear All ECU Faults Menu (Figure 142).
122
Operating Instructions
Figure 143: CLEAR Soft Key.
All Engine Control Unit (ECU) Faults and associated Thermo
King Faults will be cleared.
To return to the Main Menu press the EXIT Key. To return to
the Standard display press the EXIT Key again.
123
Rear Remote Control Panel (Optional)
The optional Rear Remote Control Panel is connected to the
control system and is used to operate the unit from a remote
location, typically at the rear of the trailer. In the illustration
below all display segments are turned on.
Rear Remote Control Panel
Functionality
The Rear Remote Control Panel functions that are available to
the user are determined by the setting of the Rear Remote
Control Action features in the Guarded Access / Unit
Configuration Menu. The Rear Remote Control Action can be
set to either RUN or STAND BY.
When the unit is turned on at the Rear Remote Control Panel
either the Standard Display or [STAnd by] will appear on the
display.
Figure 144: Rear Remote Control Panel
Rear Remote Control Action Set to
Run
If the Rear Remote Control Action is set to RUN the Standard
Display will be present on the Rear Remote Control Panel and
the unit will start and run when the Rear Remote Control Panel
ON Key is pressed. Pressing the Rear Remote Control Panel
OFF Key will turn the unit off.
124
Rear Remote Control Panel (Optional)
If the control system is powered up from the Rear Remote
Control Panel the Standard Display will appear in both the
Rear Remote Control Panel display and the unit Control Panel
display. When set to RUN the Rear Remote Control Panel
allows the following:
•
Turn the unit on and off
•
Unit will start and run
•
Change the Setpoint
•
Select Cycle-Sentry or Continuous Mode
•
Display discharge air temperature
•
Display and clear alarm codes
•
Initiate a manual defrost cycle
•
Send a Start of Trip marker to the ServiceWatch and
CargoWatch Data Loggers
•
Initiate a Pretrip Test
Rear Remote Control Action Set to
STAND BY
If the Rear Remote Control Action is set to STAND BY,
pressing the Rear Remote Control Panel ON Key will power
up the control system, but the unit will not start and run.
Pressing the Rear Remote Control Panel OFF Key will turn the
unit off. The Control Panel on the unit must be used to start and
stop unit operation.
In addition to turning the unit on and off, when set to STAND
BY the Rear Remote Control Panel allows the following:
•
Turn the unit on and off
•
Unit will not start and run
•
Change the Setpoint
•
Select Cycle Sentry or Continuous Mode (unless
prevented by OptiSet Plus)
•
Display discharge air temperature
•
Display and clear alarm codes
•
Send a Start of Trip marker to the ServiceWatch and
CargoWatch Data Loggers
125
Rear Remote Control Panel (Optional)
When in STAND BY, the unit will not start and run and a
defrost cycle or Pretrip Test cannot be started.
If the control system is powered up from the remote control
panel a stand by message will appear in both the remote control
panel display and the unit Control Panel display as shown in
Figure 145 and Figure 146.
When the StAnd bY display is shown, press the Select Key to
show the Remote Standard Display. When the remote standard
Display is shown, the setpoint and operating mode can be
changed, the discharge air temperature can be displayed and
alarms can be viewed and cleared. In addition, a Start of Trip
can be sent to the data loggers.
After the last key is pressed, the display will return to the
StAnd bY display shown in Figure 147 in about 10 seconds.
Figure 145: Rear Remote Control Panel Display
Figure 147: Press Select Key
Figure 146: Unit Control Panel Display
126
Rear Remote Control Panel (Optional)
Keypad
The nine touch sensitive keys are used to turn the unit on and
off. They also allow the setpoint to be changed, Cycle Sentry
or Continuous Mode to be selected, Alarm Codes and other
operating data to be displayed and Pretrip Tests and Defrost
Cycles to be performed. A Start of Trip marker can also be sent
to the data loggers.
Figure 148: Rear Remote Control Panel
ON Key
Turns the unit on as determined
by the setting of Rear Remote
Control Action.
OFF Key
Turns the unit off.
Up Arrow
Key
Increases setpoint or changes
other setting.
Down
Arrow Key
Decreases setpoint or changes
other setting.
Select Key
Allows Cycle-Sentry to be turned
on and off, displays the discharge
air temperature and alarms.
Enter Key
Executes a prompt or loads a
new setpoint or other setting.
Pretrip Key Initiates a Pretrip Test.
127
Rear Remote Control Panel (Optional)
TK Logo
Key
Sends a Start of Trip marker to
the data logger.
Defrost Key
Initiates a defrost cycle if
conditions allow.
Display
The display normally shows the Standard Display of return air
temperature and setpoint. The icons on either side of the
display indicate operating modes and alarms. The display
shown here has all possible segments lighted. The display
icons are defined below.
Cool Icon
This icon appears when the unit is
cooling.
Heat Icon
This icon appears when the unit is
heating.
Modulation
Icon
This icon appears when the unit is
in modulation.
This icon appears when the unit is
Defrost Icon
defrosting.
Cycle-Sentry This icon appears when the unit is
Icon
operating in Cycle-Sentry mode.
Alarm Icon
This icon appears when an alarm
condition has been detected.
This icon appears when the unit is
Electric
operating in the optional electric
Standby Icon
standby mode.
This icon appears when the
Setpoint
setpoint is being shown in the
Icon
display.
Not Used
Figure 149: Rear Remote Control Panel
128
This icon appears during a remote
control panel test but is not
currently used.
Rear Remote Control Panel (Optional)
Reading a Typical Remote
Standard Display
The Remote Standard Display shows the temperature and
setpoint. The icons at the sides of the display indicate operating
conditions.
•
The unit is cooling as shown by the icon at the upper left
side of the display.
•
The unit is operating in Cycle Sentry mode as shown by
the icon at the upper right side of the display.
Remote Control Panel Lockout
The remote control panel may be locked out during some
control system functions such as Service Test Mode, Interface
Board Test Mode and while setting programmable features. If
this is the case the display shown in Figure 151 will appear.
The display will return to the Remote Standard Display when
allowed by the control system.
Figure 150: Remote Standard Display
The Remote Standard Display in Figure 150 shows the
following information:
•
The temperature (typically return air temperature) is
35.8°F.
•
The setpoint is 35°F.
Figure 151: Remote Lock Out Display
129
Rear Remote Control Panel (Optional)
Turning the Unit ON or OFF
(Configured for STAND BY
Operation)
The control system is turned on by pressing the ON Key and
off by pressing the OFF Key. When the On Key is pressed the
remote display briefly shows all segments and then StAnd by
as shown in Figure 152. A stand by message will also appear
on the unit Control Panel display. The setpoint can be changed
but the unit will not start and run. Only the Select Key, Enter
Key and Up and Down Arrow Keys are functional. The unit
can be started and run by pressing the unit Control Panel ON
Key.
IMPORTANT: To change the setpoint, press the Select Key to
show the Remote Standard Display. The setpoint can now be
changed as shown on page 131.
130
Figure 152: Stand By Display
Turning the Unit On and Off
(Configured for RUN Operation)
The unit is turned on by pressing the ON key and off by
pressing the OFF key. When the ON key is pressed the remote
display briefly shows all segments and then COn FIg as the
control system initializes. Then the Remote Standard Display
will appear as shown in Figure 153. The unit will start and run
if necessary.
Rear Remote Control Panel (Optional)
Changing the Setpoint
The setpoint can be changed when the Remote Standard
Display is shown.
1.
When the Remote Standard Display is shown, press the
Up or Down Arrow Keys to select the desired setpoint
(Figure 154).
Figure 153: Standard Display
Figure 154: Press Up or Down Arrow Keys
131
Rear Remote Control Panel (Optional)
2.
When the desired setpoint is shown on the display,
immediately press the Enter Key to load the new setpoint.
The display will briefly show [Lod] and then the new
setpoint will reappear in the display.
IMPORTANT: The Enter key (Figure 155) must be pressed
or the setpoint will not be changed. The display will return to
the Standard Display and the setpoint will return to the old
setpoint in about 10 seconds if the Enter Key is not pressed.
Alarm Code 127 Setpoint Not Entered is set, to indicate that
the setpoint change was started but not completed.
Selecting Cycle-Sentry or
Continuous Mode
Cycle Sentry or Continuous Mode operation can be changed
using the Select Key.
1.
When the Remote Standard Display is shown, press the
Select key once to display the Cycle Sentry prompt.
Figure 156: Press Select Key
2.
Figure 155: Press Enter Key
IMPORTANT: Confirm that the correct setpoint is set.
132
Use the Up and Down Arrow Keys to chose either YES or
nO. Yes = Cycle Sentry Mode. nO = Continuous Mode.
Rear Remote Control Panel (Optional)
Displaying the Discharge Air
Temperature
The discharge air temperature can be shown using the Select
Key.
1.
Figure 157: Press Up or Down Arrow Keys
3.
When the Remote Standard Display is shown, press the
Select Key twice. The discharge air temperature will be
shown in the display for about 10 seconds.
When the desired selection is shown, press the Enter Key
(Figure 158) to load the setting. The display will briefly
show [Lod] and then the new selection will briefly appear
in the display.
Figure 159: Press Select Key Twice
2.
The display will then return to the Remote Standard
Display.
Figure 158: Press Enter Key
4.
The display will then return to the Remote Standard
Display.
133
Rear Remote Control Panel (Optional)
Viewing and Clearing Alarm
Codes
Alarm Codes can be displayed and cleared using the Select
Key.
1.
When the Remote Standard Display is shown, press the
Select Key three times. Any alarm codes present will be
shown in the display, with the most recent alarm code
shown first. If no alarm codes are present the display will
show [00].
Figure 161: Press Enter Key
3.
If any additional alarms are present, the next alarm will be
shown. If no other alarms are present the display will
briefly show [00].
Figure 160: Press Select Key Three Times
2.
134
To clear a displayed alarm code, press the Enter Key. The
display will briefly show CLEAr ALm.
Figure 162: No Alarms Display
4.
The display will then return to the Remote Standard
Display.
Rear Remote Control Panel (Optional)
Starting a Manual Defrost Cycle
If conditions allow, a manual defrost cycle can be initiated
using the Defrost Key.
1.
Press the Defrost Key. The defrost prompt [EnTEr dEF]
will appear in the display.
Figure 164: Press Enter Key
3.
The display will return to the Remote Standard Display.
The Defrost Icon will be shown in the display.
Figure 163: Press Defrost Key
2.
When the defrost prompt is shown, press the Enter Key to
start a manual defrost. The display will briefly show
LOAd dEF and then a defrost cycle will begin if
conditions allow.
Figure 165: Defrost Icon Displayed
4.
The defrost cycle will terminate automatically.
135
Rear Remote Control Panel (Optional)
Sending a Start of Trip Marker
2.
A Start of Trip marker can be sent to the data loggers using the
TK Logo Key.
1.
When the Start of Trip prompt is shown, press the Enter
Key to send a Start of Trip marker to the CargoWatch and
ServiceWatch data loggers. The display will briefly show
LOAd SOt.
Press the TK Logo Key. The Start of Trip [EnTEr SOt]
prompt will appear in the display.
Figure 167: Press Enter Key
Figure 166: Press TK Logo Key
136
3.
The display will then return to the Remote Standard
Display.
Rear Remote Control Panel (Optional)
Running a Pretrip Test
A Pretrip Test can be started using the Pretrip Key as long as
the unit is not in STAND BY. If the unit is not running when
the Pretrip Test is started a Full Pretrip Test will be performed.
If the unit is running when the Pretrip Test is started a Running
Pretrip Test will be performed.
1.
Clear any alarm codes as shown previously.
2.
Press the Pretrip Key. The Pretrip [EntEr PrE] prompt will
appear in the display.
3.
When the Pretrip prompt is shown, press the Enter Key to
start a Pretrip Test. The display will briefly show LOAd
PrE. If the unit is not running a Full Pretrip Test will be
performed. If the unit is running a Running Pretrip Test
will be performed.
Figure 169: Press Enter Key
Figure 168: Press Pretrip Key
137
Rear Remote Control Panel (Optional)
4.
When the Pretrip Test is running the display will show PrE
trP. The Control Panel will show the Pretrip Test progress.
Figure 170: Pretrip Display
138
5.
When the Pretrip Test is complete the display will show
PASS, CHEC or FAIL. Pressing the Select Key will return
to the Remote Standard Display.
Figure 171: Pass Pretrip Display
Loading and Enroute Inspections
This chapter describes pre-loading inspection procedures,
single temperature loading procedures, post loading, and
enroute inspection procedures for multi-temperature units.
Thermo King refrigeration units are designed to maintain the
required product load temperature during transit. Follow these
recommended loading and enroute procedures to help
minimize temperature related problems.
NOTE: When in doubt as to the correct refrigeration
requirements and/or loading procedures, call your company
office for instructions.
Pre-Loading Inspection
1.
2.
Make sure the unit is turned off before opening the doors
to minimize frost accumulation on the evaporator coil and
heat gain in the trailer. (Unit may be running when loading
the trailer from a warehouse with door seals.)
Spot check and record load temperature while loading.
Especially note any off-temperature product.
3.
Load the product so that there is adequate space for air
circulation completely around the load. DO NOT block
the evaporator inlets or outlets.
4.
Products should be pre-cooled before loading. Thermo
King transport refrigeration units are designed to maintain
loads at the temperature at which they were loaded.
Transport refrigeration units are not designed to pull hot
loads down to temperature.Verify that the setpoint
temperatures are correct for your cargo. Pre-cool the trailer
as required.
CAUTION: Cargo must be pre-cooled to the proper
temperature before loading. The unit is designed to
maintain temperature, not to bring a product to
temperature.
CAUTION: Push the controller access door firmly
closed after each use. Unit damage can occur in
transit if the door is not properly closed.
139
Loading and Enroute Inspections
1.
Correct load height (trailers without chutes)
1
2.
Tight doors and gaskets
2
3.
Center bulkhead with tight air seals
(multiple compartment trailers)
4.
Good air circulation around load
5.
Proper cargo temperature prior to loading
6.
Interior/exterior walls and insulation in good
condition
7.
Clear defrost drains
8.
Unit inspection
9.
Good outside air circulation
3
10
9
4
8
5
7
ADZ31
6
10. Tight air seals between unit and trailer
Figure 172: Multi-Temperature Loading Considerations
140
Loading and Enroute Inspections
Single Temperature Loading
Procedures
Additional steps must be taken to insure load temperature
requirements are implemented and maintained when a
multi-temp unit is used to refrigerate a single-temperature load.
Trailer loading procedure will be different depending on how
temperature control has established for each trailer
compartment Zone. See “Operating the Unit in Single Zone
Mode” in the Operating Instructions chapter in this manual.
AMA719
Figure 173: Two Compartments, Same Setpoint
Temperature, Bulkheads In Place
In the example in Figure 173, each Zone could be individually
set to 35 F. The evaporator in each compartment will then
control the temperature in that compartment to the same 35 F
setpoint.
NOTE: Using the above method, it is recommended that the
bulkheads that separate each compartment be in place to
isolate the compartments.
Figure 174 shows two Zones that have the same setpoint. The
bulkhead separating the compartments has been removed. The
Host evaporator senses temperature and controls both
evaporators to the temperature setpoint.
AMA720
Figure 174: Two Compartments, Same Setpoint
Temperature, Bulkhead(s) Removed
141
Loading and Enroute Inspections
NOTE: Using Method 2, it is recommended that all
bulkheads be removed to create one large compartment.
Inspection Troubleshooting
1.
If a temperature reading is not within desired temperature
range, refer to the troubleshooting table on the following
pages. Correct problem as required.
2.
Repeat the Enroute Inspection every 30 minutes until the
compartment temperature is within desired temperature
range. Stop the unit if the compartment temperature is not
within desired temperature range on two consecutive 30
minute inspections, especially if the compartment
temperature appears to be moving away from the setpoint.
3.
Immediately contact the nearest Thermo King Service
Center or your company office.
4.
Take all necessary steps to protect and maintain proper
load temperature.
Post-Loading Inspection
1.
Make sure all the doors are closed and locked.
2.
Start the unit if it was shut off to load.
3.
Make sure the setpoints are at the desired settings.
4.
One-half hour after loading, manually initiate a Defrost
cycle. If the evaporator coil sensor temperature is below
45 F (7 C), the unit will Defrost. The microprocessor will
terminate Defrost automatically when the evaporator coil
temperature reaches 58 F (14.5 C) or the unit has been in
the Defrost mode for 30 or 45 minutes (depending on
setting).
Post Trip Checks
1.
Wash the unit.
2.
Check for leaks.
3.
Check for loose or missing hardware.
4.
Check for physical damage to the unit.
142
CAUTION: Stop the unit if the compartment
temperature remains more than the desired
temperature range from the setpoint on two
consecutive 30 minute inspections. Contact the
nearest Thermo King Service Center or your
company office immediately. Take all necessary steps
to protect and maintain proper load temperature.
Loading and Enroute Inspections
Inspection Troubleshooting
Problem
Cause
Remedy
A return air
temperature
reading is not
within desired
temperature
range of the
setpoint.
The unit has not
had time to cool
down to correct
temperature.
Refer to the load log history. Look for above temperature load records,
properly pre-cooled cargo compartment, length of time on road, etc. Correct
as required. Continue monitoring return air temperature until reading is
within desired temperature range of the setpoint.
The unit may have
a low refrigerant
charge.
Check the receiver tank sight glass for refrigerant level. If liquid is not
showing in the receiver tank sight glass, the refrigerant charge may be low.
A competent refrigeration technician is required to add refrigerant or repair
the system. Contact the nearest Thermo King dealer, authorized Service
Center, or call the Thermo King Cold Line for referral. Consult the Table of
Contents for Cold Line information.
The unit is in defrost Monitor the return air temperature after the defrost cycle is completed to see
if the temperature returns to the desired temperature range of the setpoint.
or has just
completed a defrost
cycle.
The evaporator is
plugged with frost.
Initiate a manual defrost cycle. The defrost cycle will automatically terminate
when complete. Continue monitoring return air temperature until reading is
within desired temperature range of the setpoint.
143
Loading and Enroute Inspections
Problem
Cause
A return air
temperature
reading is not
within desired
temperature
range of the
setpoint
(continued)
Inspect the unit and cargo compartment to determine if the evaporator fan(s)
Improper air
are working and properly circulating the air. Poor air circulation may be due
circulation in the
cargo compartment. to improper loading of the cargo, shifting of the load, or fan belt slippage.
Correct as required. Continue monitoring return air temperature until
problem is corrected.
144
Remedy
The unit did not
start automatically.
Determine the cause for not starting. Correct as required. Continue
monitoring return air temperature until reading is within desired temperature
range of the setpoint.
The unit is being
used to cool/heat a
single temperature
load and does not
have the capacity to
cool the entire
trailer.
A multi-temperature unit may not have the cooling or heating capacity to
maintain a specific temperature range throughout an entire trailer. Refer to
the “Single Temperature Loading Considerations” on page 141 for
instructions.
Alarm Codes
Introduction
An alarm code is generated when the microprocessor senses an
abnormal condition. Alarms direct an operator or service
technician to the source of a problem.
Multiple alarms can be present at one time. All generated
alarms will be stored in memory until cleared by the operator.
Document all alarm occurrences and report them to the service
technician.
NOTE: Some alarms (3, 4, 74, 203, and 204) cannot be
cleared in the Alarms Menu, they must be cleared in the
Maintenance Menu or the Guarded Access Menu. Contact
your supervisor or a Thermo King dealer about clearing
those alarms.
IMPORTANT: Always record any Alarm Codes that occur in the order that they occur - as well as any other pertinent
information. This information is extremely valuable to
service personnel.
NOTE: In some cases alarms cannot be cleared, or cannot be
cleared after they have occurred a specified number of times.
If such is the case, these alarms must be cleared by service
personnel. See “Clearing Alarm Codes” on page 148.
Alarm Types
The four types of alarms are described below.
Log Alarms: Log Alarms are indicated by the Log Alarms
screen, which appears for approximately 30 seconds (just
before the Standard Display appears) each time the unit is
turned on. The Alarm Display must be used to view the
existing alarms. This level of alarm serves as a notice to take
corrective action before a problem becomes severe.
Maintenance items such as a maintenance reminder hour meter
reaching its time limit are log alarms.
145
Alarm Codes
LOG ALARMS ACTIVE
ON
ON
GO TO MENU TO VIEW
OFF
EXIT
OFF
35
SET
POINT
GAUGES
35
SENSORS
MENU
Figure 175: Log Alarms Screen
Figure 176: Alarm Display
Check Alarms: Check Alarms are indicated by the Alarm
Display in which the large Alarm Icon will appears on the
Standard Display as shown below in Figure 176. The Alarm
Menu must be used to view the existing alarms. This level of
alarm serves as a notice to take corrective action before a
problem becomes severe. The unit will run with check alarms
but some features and functions may be inhibited.
Prevent Alarms: Prevent Alarms are also indicated by the
Alarm Display as shown in Figure 176. The Alarm Menu must
be used to view the existing alarms. The unit may stop running
and wait a timed interval or until conditions allow and then
restart. If the unit is waiting to restart, Alarm Code 84 Restart
Null will be present along with the Prevent Alarm. In other
cases the unit may restart or run with reduced performance to
determine if continued operation is possible. If the alarm does
not reoccur with reduced performance the unit will then return
to full performance. If the unit is operating with reduced
performance Alarm Code 85 Forced Unit Operation will also
be present.
146
Alarm Codes
Shutdown Alarms: Shutdown Alarms are indicated by the
Alarm Display. Shutdown alarms also cause the display and
backlight to flash on and off, and the display will switch from
normal video to reverse video and back to normal video (light
areas become dark and dark areas become light as shown in
Figure 177). Shutdown alarms force the unit into shutdown.
The unit will remain in shutdown and will not restart until the
shutdown alarm is cleared. Exceptions are some engine and
electric shutdown alarms become that log alarms when
switched to the alternate operating mode (diesel to electric or
electric to diesel).
If a shutdown alarm occurs that affects only diesel mode
operation and the unit is switched to electric (either manually
or automatically), the diesel mode shutdown alarm becomes an
electric mode log alarm. This allows the unit to run in electric
mode without clearing the shutdown alarm that is preventing
diesel mode operation. If the unit is switched back to diesel
mode, the alarm again becomes a diesel mode shutdown alarm
and prevents unit operation. If the unit is configured for
electric to diesel autoswitch, it automatically starts and runs in
diesel mode if an electric shutdown occurs.
In the same manner, if a shutdown alarm occurs that affects
only electric mode operation and the unit is switched to diesel
(either manually or automatically), the electric mode shutdown
alarm becomes a diesel mode log alarm to allow diesel mode
operation. If the unit is switched back to electric mode, the
alarm reverts to an electric mode shutdown alarm and prevents
unit operation.
ON
OFF
35
SET
POINT
GAUGES
35
SENSORS
MENU
Figure 177: Shutdown Alarm Display
Pretrip Alarm Codes
If an alarm occurs during a Pretrip Test the alarm code will be
displayed as Pretrip Alarm XX, where XX is the alarm code.
147
Alarm Codes
Clearing Alarm Codes
Most alarm codes can be cleared conventionally from the
Alarm Menu using the CLEAR Key. See the Operating
Instructions chapter for procedures.
The operator should contact a supervisor or a Thermo King
dealer about clearing alarms using the Guarded Access Menu.
Refer to the table on the following pages for alarm corrective
action.
NOTE: Document all alarm faults and report them to the
service technician.
There are three levels of corrective action that can be taken
when an alarm condition occurs.
OK To Run: An alarm condition exists but does not affect
unit operation. Corrective action can occur at a later date.
Check As Specified: An alarm condition exists that could
affect unit operation. Follow directions in the Corrective
Action column on the following chart.
Take Immediate Action: An alarm condition exists that
will damage the unit or load. Take immediate action to correct
the problem.
148
NOTE: The corrective actions listed in the Operating
Instructions chapter and in the chart on the following pages
are suggestions only. Always consult your company for final
decisions.
NOTE: The chart on the following pages shows all possible
alarm codes for all possible applications. Not all codes will be
applicable to each individual unit.
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
00
2
3
4
No Alarms Exist
No action required
Check Evaporator Coil Sensor
(Zone)
Check (Control) Return Air
Sensor (Zone)
Manually monitor load temperature. Report alarm at end of
day.
Manually monitor load temperature. Report alarm at end of
day.
Check (Control) Discharge Air
Sensor (Zone)
Manually monitor load temperature. Report alarm at end of
day.
X
X
X
X
5
Check Ambient Temp Sensor
Report alarm at end of day.
X
6
Check Coolant Temp Sensor
Report alarm at end of day.
X
7
Check Engine RPM Sensor
High Evaporator Temperature
(Zone)
Report alarm at end of day.
If unit/zone is shut down repair immediately. Otherwise,
report alarm at end of the day.
X
9
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
X
149
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
10
High Discharge Pressure
If unit is shut down repair immediately. Otherwise, report
alarm at end of day.
11
Unit Controlling on Alternate
Sensor (Zone)
Manually monitor load temperature. Report alarm at end of
day.
12
Sensor Shutdown (Zone)
The unit is no longer able to operate and has been shut
down. Repair immediately.
13
Sensor Calibration Check (Zone)
Manually monitor load temperature. Report alarm at end of
day.
17
Engine Failed to Crank
18
High Engine Coolant
Temperature
19
Low Engine Oil Pressure
150
If unit is shut down repair immediately. Otherwise, report
alarm at end of day.
If unit is shutdown repair immediately. Otherwise, report
alarm at end of day.
It unit is shutdown repair immediately. Otherwise report
alarm at end of day.
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
X
X
X
X
X
X
X
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
20
Engine Failed to Start
If unit is shutdown repair immediately. Otherwise, report
alarm at end of day.
X
21
Cooling Cycle Check (Zone)
Manually monitor load temperature. Report alarm at end of
day.
X
22
Heating Cycle Check (Zone)
Manually monitor load temperature. Report alarm at end of
day.
X
23
Cooling Cycle Fault (Zone)
The unit is no longer able to operate and has been shut
down. Repair immediately.
24
Heating Cycle Fault (Zone)
25
Alternator or Battery Charger
Check
The unit is no longer able to operate and has been shut
down. Repair immediately.
If unit is shutdown repair immediately. Otherwise, report
alarm at end of day.
26
Check Refrigeration Capacity
(Zone)
Manually monitor load temperature. Report alarm at end of
day.
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
X
X
X
X
151
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
28
Pretrip Abort
Report alarm at end of day.
31
Check Oil Pressure Switch
If unit is shutdown repair immediately. Otherwise, report
alarm at end of day.
32
Refrigeration Capacity Low
(Zone)
The unit is no longer able to operate and has been shut
down. Repair immediately.
33
35
Check Engine RPM
Check Run Relay Circuit
Report alarm at end of day.
Unit cannot operate and is shutdown. Repair immediately.
36
Electric Motor Failed to Run
Unit cannot operate and is shutdown. Repair immediately.
37
Check Engine Coolant Level
Check engine coolant level. Do not remove the cap if the
engine is hot. Report alarm at end of day.
38
Electric Phase Reversed
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
152
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
X
X
X
X
X
X
X
X
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
40
Check High Speed Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
41
Check Engine Coolant
Temperature
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
42
Unit Forced to Low Speed
Report alarm at end of day.
X
43
44
Unit Forced to Low Speed
Modulation
Check Fuel System
Report alarm at end of day.
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
X
Add fuel as necessary. Report alarm at end of day.
X
45
Check Hot Gas or Hot Gas
Bypass Circuit
If unit is shutdown repair immediately. Otherwise, report
alarm at end of day.
X
46
Check Air Flow
Manually monitor temperature. Report alarm at end of the
day.
X
153
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
48
Check Belts/Clutch
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
49
Check Spare Sensor 1
Report alarm at end of day.
X
50
Reset Clock
Report alarm at end of day.
X
52
Check Heat Circuit
54
Test Mode Timeout
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
Clear alarm and restart unit.
56
Check Host Evap Fan Low
Speed
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
57
Check Host Evap Fan High
Speed
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
61
Low Battery Voltage
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
154
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
X
X
X
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
62
Ammeter Out of Calibration
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
63
Engine Stopped
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
64
Pretrip Reminder
Report alarm at end of day.
65
Abnormal Temperature
Differential (Zone)
66
Low Engine Oil Level
67
Check Liquid Line Solenoid
Circuit (Zone)
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day
Check engine oil level. If unit is shutdown, repair
immediately. Otherwise, report alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
68
Internal Controller Fault Code
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
X
X
X
X
155
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
70
Hourmeter Failure
Report alarm at end of day.
X
74
Controller Reset to Defaults
Report alarm at end of day.
X
79
Internal Data Logger Overflow
Report alarm at end of day.
X
84
85
Restart Null
Forced Unit Operation
Report alarm at end of day.
Report alarm at end of day.
X
X
86
Check Discharge Pressure
Sensor
Report alarm at end of day.
X
87
Check Suction Pressure Sensor
Report alarm at end of day.
X
89
If unit is shutdown repair immediately. Otherwise, report
Check Electronic Throttling Valve
alarm at end of day.
X
90
Electric Overload
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
156
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
Sensor Grades Not Set (Zone)
Report alarm at end of day.
X
93
Low Compressor Suction
Pressure
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
96
98
Low Fuel Level
Check Fuel Level Sensor
Check engine fuel level and add fuel.
Report alarm at end of day.
105
Check Receiver Tank Pressure
Solenoid Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
Check Condenser Inlet Solenoid If unit is shutdown, repair immediately. Otherwise, report
Circuit
alarm at end of day.
X
91
Check Electric Ready Input
92
106 Check Purge Valve Circuit
107
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
X
X
157
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
108
Door Open Time-out (Zone)
Close Doors. Report alarm at end of day.
X
110
Check Suction Line Solenoid
Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
111
Unit Not Configured Correctly
(Zone)
Report alarm at end of day.
112
Check Remote Fans (Zone)
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
113
Check Electric Heat Circuit
(Zone)
Manually monitor temperature. Report alarm at end of day.
X
114
Multiple Alarms - Can not Run
Unit/zone cannot operate and is shut down. Repair
immediately.
117
Auto switch from Diesel to
Electric
Report alarm at end of day.
158
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
X
X
X
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
118
Auto-Switch from Electric to
Diesel
Report alarm at end of day.
X
120 Check Alternator Excite Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
122 Check Diesel/Electric Circuit
If unit is shutdown, repair immediately. Otherwise, report at
end of day.
X
Be sure the setpoint is set to the required temperature.
X
127 Setpoint Not Entered (Zone)
Engine Run Time Maintenance
128
Reminder #1
Engine Run Time Maintenance
129
Reminder #2
130
Electric Run Time Maintenance
Reminder #1
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
Report alarm at end of day.
X
Report alarm at end of day.
X
Report alarm at end of day.
X
159
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
131
Electric Run Time Maintenance
Reminder #2
Report alarm at end of day.
X
132
Total Unit Run Time Maintenance
Report alarm at end of day.
Reminder #1
X
133
Total Unit Run Time Maintenance
Report alarm at end of day.
Reminder #2
X
134
Controller Power On Hours
Report alarm at end of day.
Auto-Switch Diesel to Electric
141
Report alarm at end of the day.
Disabled
Check Remote Zone Drain Hose
Report at end of day.
143
Heater Output (Zone)
144
160
Lost Expansion Module CAN
Communication
Unit cannot operate and is shut down. Repair immediately.
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
X
X
X
X
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
145
Loss of Controller ON Feedback
Signal
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
146 Software Version Mismatch
Report alarm at end of the day.
Auto-Switch Electric to Diesel
148
Disabled
Report alarm at end of the day.
CargoWatch Sensor Out of
Range Low (Zone)
CargoWatch Sensor Out of
151
Range High (Zone)
CargoWatch Sensor Failed
152
(Zone)
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 temperature. Report alarm at end of
day.
150
153
Expansion Module Flash Load
Failure
Report alarm at end of the day.
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
X
X
X
X
X
X
X
161
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
157
OptiSet File Mismatch
Report alarm at the end of the day
X
158
Primary Software Failed to Load
Report alarm at end of the day.
X
159
Check Battery Condition
Report alarm at end of the day.
X
160
203
Lost Radio Expansion Board
Report alarm at end of the day.
(REB) CAN Communication
Check Display Return Air Sensor Manually monitor load temperature. Report alarm at end of
(Zone)
day.
X
X
204
Check Display Discharge Air
Sensor (Zone)
Manually monitor load temperature. Report alarm at end of
day.
233
REB Transitioning From
Conservative to Full Null
Report alarm at end of the day.
X
234
Check Relative Humidity Sensor
Report alarm at end of the day.
Circuit
X
162
X
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
251
Check Radio Expansion Board
Configuration
Report alarm at end of the day.
X
252
Check Auto Fresh Air Exchange
Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
500
Check Host Evaporator Fan Low If unit is shutdown, repair immediately. Otherwise, report
Speed
alarm at end of day.
X
501
Check Host Evaporator Fan High If unit is shutdown, repair immediately. Otherwise, report
Speed
alarm at end of day.
X
Check Roadside Condenser Fan
Motor Speed Circuit
Check Curbside Condenser Fan
506
Motor Speed Circuit
505
508
Speed Request Communication
Error
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
Report alarm at end of the day.
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
X
X
X
163
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
509
Engine Control Unit (ECU) Failed If unit is shutdown, repair immediately. Otherwise, report
to Enable
alarm at end of day.
X
510
Engine Control Unit (ECU) Run
Signal Failed
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
511
Engine Wait to Start Time Delay
Expired
Report alarm at end of day.
516
I/O Controller to Application
Controller Communication
Failure
The unit is no longer able to operate and has been shut
down. Repair immediately.
518
Generator Ground Fault
519
Check Battery Charger Input
Power
164
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
X
X
X
X
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
520
Check Battery Charger Output
Power
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
521
Battery Charger
External/Environmental Faults
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
522
Battery Temperature Sensor
Alarm
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
523
Battery Charger Indicated
Conditions
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
Generator Operational Limit Vout
to Frequency Ratio
Generator Frequency Range
525
Fault
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
Generator Operational Limit
Output Current
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
524
526
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
X
X
X
165
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
528
Failed J1939 CAN
Communication Base
Controller/Battery Charger
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
529
Check Fuel Pump Circuit
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
538
Engine J1939 CAN Datalink
Degraded
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
539
Engine J1939 CAN Datalink
Failed
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day.
X
540
Illegal Engine Operating State
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day
X
542
Battery Charger Fault - Unit
Forced to Low Speed
Maintenance information only. Report alarm at end of day
X
543
Battery Charger Internal Short
Maintenance information only. Report alarm at end of day
X
166
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
544 Battery Charger External Short
Maintenance information only. Report alarm at end of day
X
545
Battery Charger Output Voltage
Exceeded Limit
Maintenance information only. Report alarm at end of day
X
546
Battery Charger Operating Bulk
Voltage out of Range
Maintenance information only. Report alarm at end of day
X
547 AC Bus Phase Loss
Battery Charger Temp Below
Operating Range
Battery Charger AC Input
549
Overvoltage
548
550
Battery Charger Internal
Overvoltage Fault
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day
X
Maintenance information only. Report alarm at end of day
X
Maintenance information only. Report alarm at end of day
X
If unit is shutdown, repair immediately. Otherwise, report
alarm at end of day
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
X
167
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
551
Battery Charger Internal Temp
Sensor Fault
Maintenance information only. Report alarm at end of day
X
552
Battery Charger Charging - Low
Battery
Maintenance information only. Report alarm at end of day
X
553
Battery Charger Operating
Derated Due to High Temp
Maintenance information only. Report alarm at end of day
X
599
800
Engine Service Tool Connected Report alarm at end of the day.
Crankshaft Position Sensor Error Report alarm at end of the day.
X
X
801
Camshaft Position Sensor Error
Report alarm at end of the day.
X
804
Engine Coolant Temperature
Sensor Error
Report alarm at end of the day.
X
807
Fuel Temperature Sensor Error
Report alarm at end of the day.
X
808
Rail Pressure Sensor Error
Report alarm at end of the day.
X
168
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
809 Intake Pressure Sensor Error
Report alarm at end of the day.
X
810
Atmospheric Pressure Sensor
Error
Report alarm at end of the day.
X
811
Glow Plug Circuit
Report alarm at end of the day.
X
Report alarm at end of the day.
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
X
813 General Injector Error
815 Fuel Pressure Regulator Error
X
818 EGR Valve Actuator Error
Report alarm at end of the day.
X
819 ECU Power Relay Error
Report alarm at end of the day.
X
820 Main ECU Relay Error
Report alarm at end of the day.
X
Report alarm at end of the day.
X
825
T1 Air Intake Temperature
Sensor Error
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
169
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
826
T2 Air Intake Temperature
Sensor Error
Report alarm at end of the day.
X
827
EGR Valve Position Sensor Error Report alarm at end of the day.
X
828
Lambda System Error
Report alarm at end of the day.
X
829
830
Engine Communication Error
Air Flow Meter Error
Report alarm at end of the day.
Report alarm at end of the day.
X
X
832
Engine Power Supply Error
Report alarm at end of the day.
X
833
High Pressure Pump Fuel
Metering Unit Error
Report alarm at end of the day.
X
834
Water in Fuel Sensor Error
Report alarm at end of the day.
X
836
838
Major ECU Failures
Intake Air System Error
Report alarm at end of the day.
Report alarm at end of the day.
X
X
839
Engine Speed Error
Report alarm at end of the day.
X
170
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
840 Fuel Injection Energizing Error
Report alarm at end of the day.
X
841 High Pressure Pump Wear
Report alarm at end of the day.
X
Engine Running in Safe Mode 842
Low Speed
Report alarm at end of the day.
X
843 Fuel Injection System Error
844 Failed to Crank
Report alarm at end of the day.
Report alarm at end of the day.
X
X
845 Starter Relay Error
Report alarm at end of the day.
X
846 T50 Switch Error
Report alarm at end of the day.
X
847 Variant Coding Error
Report alarm at end of the day.
X
853 Engine Overspeed (No DTC)
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
X
171
Alarm Codes
Table of Alarm Codes
NOTE: Not all alarm codes are available with all microprocessor controllers or all revisions of software.
854
Engine Protection Self Shutdown
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
X
899
Unknown ECU Fault
If unit is shut down repair immediately. Otherwise, report
alarm at end of the day.
X
172
Shut
Down
Level Of
Action
Check
Operator Action
Ok To
Run
Code Description
Jump Starting
If the battery in a unit is discharged or run down, the unit may
be jump started using jumper cables and another battery or
vehicle. Consider the following precautions and be careful
when jump starting a unit.
WARNING: A battery can be dangerous. A battery
contains a flammable gas that can ignite or
explode. A battery stores enough electricity to burn
you if it discharges quickly. A battery contains
battery acid that can burn you. Always wear
goggles or safety glasses and personal protective
equipment when working with a battery. If you get
battery acid on you, immediately flush it with water
and get medical attention.
CAUTION: Unhook the semi tractor from the
trailer before using the tractor to jump start the
unit on the trailer. The negative ground circuit is
complete when the tractor is hooked to the trailer.
This can cause dangerous sparks when the positive
connection is made at the battery.
IMPORTANT: Make sure to use a 12-volt battery to jump
start the unit. If you are using a vehicle, make sure it has a
12-volt battery with a negative ground system. Do not use a
“hot shot” booster device or a 24-volt source.
Read and understand the following procedure completely
before connecting any jumper cables. Use good jumper cables
made with #2 gauge (or larger) cables.
1.
Make sure the unit is turned off. If you are using a vehicle,
make sure its ignition is also turned off.
2.
Open the front doors on the unit. The battery is located to
the right of the engine.
3.
Check the discharged battery to make sure it is not
damaged or frozen. Do not jump start a damaged or frozen
battery. Check the vent caps to make sure they are tight.
4.
Identify the positive (+) and negative (–) battery terminals.
173
Jump Starting
1
CAUTION: Do not use a match or lighter as a
light near the battery. Use a flashlight. A flame or
a spark can ignite the gas in the battery and cause
it to explode.
5.
2
Unit
(Discharged)
12-Volt
Battery
Remove the red cover from the positive (+) battery
terminal on the unit’s battery.
Good
12-Volt
Battery
Unit
Engine
3
4
1.
Positive (+) Terminal on Unit Battery
2.
Positive (+) Terminal on Good Battery
3.
Negative (–) Terminal on Good Battery
4.
Starter Mounting Bolt on Unit Engine
Figure 178: Sequence for Connecting Jumper Cables
174
Jump Starting
6.
Connect the red positive (+) jumper cable to the positive
(+) battery terminal on the unit’s battery. Do not let the
other end of the jumper cable touch anything that conducts
electricity.
CAUTION: Allowing the positive (+) jumper cable
to short can produce dangerous sparks.
7.
Connect the other end of the red positive (+) jumper cable
to the positive (+) battery terminal on the good battery.
8.
Connect the black negative (–) jumper cable to the
negative (–) battery terminal on the good battery. Do not
let the other end of the jumper cable touch anything that
conducts electricity.
9.
Connect the black negative (–) jumper cable to the lower
starter mounting bolt on the unit’s engine.
CAUTION: Be careful around fans and belts.
Keep your hands away from moving parts when an
engine is running.
11. Turn the unit on and let it start automatically or start it
manually. If the unit will not crank or start, contact a
qualified technician.
NOTE: Some units with microprocessors will show an
alarm code and will not try to start until the battery
voltage is above 10 volts.
12. After the unit starts, remove the jumper cables in reverse
order: black negative (–) from the unit starter mounting
bolt, black negative (–) from the good battery, red positive
(+) from the good battery, and red positive (+) from the
unit battery (that was discharged).
10. If you are using a vehicle to jump start the unit, start the
vehicle and let it run for a few minutes. This will help
charge the discharged battery.
175
Jump Starting
4
3
Unit
(Discharged)
12-Volt
Battery
Good
12-Volt
Battery
Unit
Engine
2
1
1.
Starter Mounting Bolt on Unit Engine
2.
Negative (–) Terminal on Good Battery
3.
Positive (+) Terminal on Good Battery
4.
Positive (+) Terminal on Unit Battery
Figure 179: Sequence for Disconnecting Jumper Cables
176
Specifications
Engine
Model
TKDV6 (Tier 4)
Number of Cylinders
4
Cylinder Arrangement
In-line vertical, number 1 on flywheel end
Firing Order
1-3-4-2
Direction of Rotation
Counterclockwise viewed from flywheel end
Fuel Type
No. 2 diesel fuel under normal conditions
No. 1 diesel fuel is acceptable cold weather fuel
Oil Capacity
12.4 quarts (11.7 liters) crankcase and oil filter
Fill to full mark on dipstick
Oil Type
API Classification CJ-4 or better
177
Specifications
Engine (Continued)
Oil Viscosity:
Recommended
For Other Climates
Engine rpm:
Low Speed Operation
High Speed Operation
10W-30 Delo XLE Syntheblend for -13 to 100 F (-25 C to
38 C)
5W-40 Delo 400LE Full Synthetic for Cold Climates -22 to
122 F (-30 C to 50 C)
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 100 F (-25 to 38 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)
1250 ± 25 rpm
2050 ± 25 rpm
Engine Oil Pressure
60 to 80 psig (414 to 552 kPa) maximum in high speed
Engine Coolant Thermostat
181 F (83 C)
178
Specifications
Engine (Continued)
Engine Coolant Type
ELC (Extended Life Coolant), which is “RED”
Use a 50/50 concentration of any of the following
equivalents:
Chevron Dex-Cool
Texaco ELC
Havoline Dex-Cool®
Havoline XLC for Europe
Shell Dexcool®
Shell Rotella
Saturn/General Motors Dex-Cool®
Caterpillar ELC
Detroit Diesel POWERCOOL® Plus
CAUTION: Do not add “GREEN” or “BLUE-GREEN”
conventional coolant to cooling systems using “RED”
Extended Life Coolant, except in an emergency. If
conventional coolant is added to Extended Life
Coolant, the coolant must be changed after 2 years
instead of 5 years.
Coolant System Capacity
7.5 quarts (7.1 liters)
Radiator Cap Pressure
21 psig (145 kPa)
179
Specifications
Engine (Continued)
Drive:
Standard Units
Smart Power Units
Direct to compressor; belts to AC generator and alternator.
Centrifugal clutch to compressor; belts to electric standby
motor, AC generator and alternator.
Belt Tension
Belt
New Belt
Field Reset
Automatic Tensioner
Automatic Tensioner
Alternator Belt - Standard Units
169 Hz (120 lbs)
146 Hz (90 lbs)
Compressor Drive Belt - Smart Power Units Only
12 HP Electric Motor
19 HP Electric Motor
131 Hz (236 lbs)
150 Hz (300 lbs)
114 Hz (177 lbs)
130 Hz (223 lbs)
Alternator Belt - Smart Power Units Only:
216 Hz (75 lbs)
187 Hz (56 lbs)
AC Generator - All Units
180
Specifications
Refrigeration System
Compressor
Thermo King X430LSC5
Refrigerant Charge—Type
Approximately 15.5 lb (7.0 kg)—R404A
Compressor Oil Charge
6.9 qt (6.6 liters)*
Compressor Oil Type
Polyol Ester type P/N 203-513
Heat/Defrost Method:
High Pressure Cutout
Engine Operation
Electric Operation
Hot gas
Hot gas and optional electric heater strips
470 +7/-35 psig (3241 + 48/-241 kPa)
Automatic reset @ 375 ± 38 psig (2586 ± 262 kPa)
* When the compressor is removed from the unit, oil level should be noted or the oil removed from the
compressor should be measured so that the same amount of oil can be added before placing the
replacement compressor in the unit.
181
Specifications
Electrical Control System
Low Voltage
12.5 Vdc
High Voltage
210 Vac from AC generator at engine low speed
345 Vac from AC generator at engine high speed
Battery
One, group C31, 12 volt, (950 CCA recommended for
operation below -15 F [-26 C])
Fuses
See Fuse listing in this manual.
Battery Charging
12 volt, 120 amp, brush type, Thermo King Alternator
Voltage Regulator Setting
13.95 to 14.35 volts @ 77 F (25 C)
182
Specifications
Electrical Components
NOTE: Disconnect components from unit circuit to check resistance.
Component
Current Draw (Amps)
at 12.5 Vdc
Resistance—Cold
(Ohms)
Glow Plugs (4) Each
10
1.3
Condenser Inlet Solenoid
1.3
9.6
Liquid Line Solenoid in Host Unit
1.5
8.3
Liquid Line Solenoids in Remote Units
1.3
9.6
Hot Gas Solenoids
1.5
8.3
Suction Line Solenoids
1.3
9.6
Receiver Tank Pressure Solenoid
0.7
17.0
Purge Valve
0.7
17.0
Electronic Throttling Valve:
Coil A (Red [EVA] and Blue [EVB] Wires)
Coil B (Black [EVC] and White [EVD] Wires)
—
—
20 to 35
20 to 35
Hot Gas Bypass Valve
1.1
11.1
183
Specifications
Electrical Components
Starter Motor
900 maximum
AC Generator
Low Engine Speed (1250 rpm) Output
High Engine Speed (2050 rpm) Output
210 Vac at 54.9 Hz Nominal Vac - Measured Vac, Load
Dependent
345 Vac at 90 Hz Nominal Vac - Measured Vac, Load
Dependent
Fan Motors — Engine Operation
Evaporator Fan Motor: Low Speed Power Rating
High Speed Power Rating
High Fan Speed at Low Engine Speed
Low Fan Speed at High Engine Speed
Low Fan Speed at Low Engine Speed
High Speed Current Draw at Low Engine Speed
Low Speed Current Draw at High Engine Speed
Low Speed Current Draw at Low Engine Speed
184
1.20 hp (0.90 kW)
1.75 hp (1.31 kW)
1600 rpm at low engine speed (1250 rpm)
1750 rpm at high engine speed (2050 rpm)
1050 rpm at low engine speed (1250 rpm)
3.8 amps at low engine speed (1250 rpm)
3.1 amps at high engine speed (2050 rpm)
2.6 amps at low engine speed (1250 rpm)
Specifications
Electrical Components
Condenser Fan Motor (each):
Power Rating
Fan Speed
Fan Speed at High Engine Speed
Current Draw at Low Engine Speed
Current Draw at High Engine Speed
0.50 hp (0.37 kW)
1600 rpm low engine speed (1250 rpm)
2650 rpm at high engine speed (2050 rpm)
1.8 amps (per motor) at low engine speed (1250 rpm)
2.0 amps (per motor) at high engine speed (2050 rpm)
Fan Motors — Electric Standby Operation 230/3/60 or 460/3/60 (Unit transformer reduces 460/3/60 input
voltage to 230/3/60 applied to fan motors.)
Evaporator Fan Motor: Low Speed Power Rating
High Speed Power Rating
High Fan Speed
Low Fan Speed
High Speed Current Draw
Low Speed Current Draw
1.20 hp (0.90 kW)
1.75 hp (1.31 kW)
1750 rpm
1150 rpm)
3.8 amps
2.6 amps
Condenser Fan Motor (each):
0.50 hp (0.37 kW)
1750 rpm
1.8 amps (per motor)
Power Rating
Fan Speed
Current Draw
185
Specifications
Electrical Standby (SmartPower Units Only)
NOTE: A transformer is used to convert 460 Vac to 230 Vac in units configured to use electric standby
input voltage of 460 Vac.
Electric Motor and Overload Relay
Voltage/Phase/Frequency
Horsepower
Kilowatts
rpm
Full Load
(amps)
Overload Relay
Setting (amps)
230/3/60
12.0
9.0
1760
31.2
34
460/3/60
12.0
9.0
1760
15.6
20
460/3/60
19.0
14.2
3500
21.7
32
Electric Heater Strips
Number
3
Watts
1000 watts (each)
Resistance
48 ohms (each)
Overload Relay Setting
6 amps
186
Specifications
Standby Power Cord Requirements
Supply Circuit Breaker:
Extension Cord Size:
12 HP Motor 230/3/60
70 amps
12 HP Motor 460/3/60
40 amps
19 HP Motor 460/3/60
60 amps
12 HP Motor 230/3/60
8 AWG Power Cable, 4-Conductor, 2000V, Type W Power
Cable, 25 to 50-foot length
12 HP Motor 230/3/60
6 AWG Power Cable, 4-Conductor, 2000V, Type W Power
Cable, 75-foot length
12 HP Motor 460/3/60
10 AWG Power Cable, 4-Conductor, 2000V, Type W Power
Cable, up to 75-foot length
19 HP Motor 460/3/60
8 AWG, 4-Conductor, 2000V, Type W Power Cable, up to
75-foot length
187
Specifications
Electric Fuel Heater (Optional)
Electric Fuel Heater:
0.9 to 1.1 ohms
11.4 to 13.9 amps
30 F (-1 C)
75 F (24 C)
2FH/2HP Fuse
20 amps
Resistance
Current Draw at 12.5 Vdc
Internal Thermostat Minimum Closing Temp.
Internal Thermostat Maximum Opening Temp.
188
Warranty
Terms of the Thermo King Warranty are available on request.
Please reference document TK 50046 for the Thermo King
Trailer Unit Warranty.
See the “EPA Emission Control System Warranty Statement”
chapter earlier in this manual for the EPA Emission Control
System Warranty.
189
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.
190
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.
Glossary
CFC: Chlorofluorocarbon. A chlorine-based refrigerant
consisting of chlorine, fluorine and carbon. Example: R12. In
many countries it is illegal to release this type of refrigerant to
the atmosphere because chlorine damages the earth’s
atmosphere. CFC refrigerants are not used in modern Thermo
King units.
circuit breaker: A thermal device that automatically
interrupts an electrical circuit when the current in the circuit
exceeds the predetermined amperage rating of the breaker. See
amp.
coil: A cooling or heating element made of pipe or tube,
formed into a helical or serpentine shape, that may be equipped
with thin metal fins to aid heat transfer.
cold curtains: Flexible vinyl curtains used to reduce air
exchange between the refrigerated compartment and the
outside during door openings.
compound gauge: A gauge calibrated in psig (or kPa) to
measure pressure, and in inches of mercury (Kg/cm2) to
measure vacuum.
compressor: The refrigeration component that compresses
refrigerant vapor and creates refrigerant flow.
condenser: An arrangement of tubing in which the
vaporized and compressed refrigerant is liquefied as heat is
removed.
cycles per second: See Hertz.
damper door: A door on the evaporator section that closes
during defrost to prevent hot air from entering the refrigerated
cargo compartment.
data logger: An electronic device that monitors and stores
unit operating and temperature data for later review. Examples:
DMS, DAS, DRS and AccuTrac.
DE: Dual Evaporator. A multi-temp host unit with two
evaporators capable of refrigerating two separate, longitudinal
compartments.
defrost: The removal of accumulated ice from an evaporator
coil. Periodic defrost is necessary when the evaporator coil is
operating below freezing. Defrost is required more frequently
when the air passing through the evaporator has a high
moisture content.
defrost termination switch: A component that terminates
defrost operation at a specific temperature.
191
Glossary
defrost timer: A solid state module that initiates defrost at
selected intervals. Also establishes a maximum defrost
duration if normal circuits malfunction.
dehydrator: A device used to remove moisture from
refrigerant. Also called a drier.
discharge air temperature: The temperature of air leaving
the evaporator.
drier: See dehydrator.
ERC: Extended Remote Unit Control. (Door switches) An
option on Thermo King multi-temperature units to improve
temperature control when doors are opened during delivery.
When a compartment door is opened, the refrigeration unit for
that compartment may be forced to NULL, defrost, or some
other mode. Opening a compartment door may also affect the
operating mode of other compartments. ERC systems are
connected in a variety of ways to meet customer needs.
ETV (Electronic Throttling Valve) : A device used with a
microprocessor to precisely control the refrigeration system.
evaporator: The part of the refrigeration system that absorbs
heat during the cooling cycle.
192
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.
Glossary
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.
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.
invertible: A multi-temperature truck or trailer unit designed
to allow the placement of deep-frozen cargo in any
compartment. See Multi-Temp.
kPa: Kilopascals. A metric unit of pressure. 1 kPa = 0.01 bar =
0.145 psi.
load: 1) The product being refrigerated and transported.
2) The amount of heat being removed by the refrigeration
system. (For example, a compressor is under a heavy heat load
when expected to cool a very warm box.)
LPCO (Low Pressure Cut Out Switch): A
pressure-operated switch that opens to stop unit operation
when suction pressure reaches a predetermined minimum.
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.
modulation: An optional system that reduces load (product)
dehydration and avoids “top freeze.”
hp (horsepower): A unit of power equivalent to 746 watts
or 550 foot-pounds per second.
movable bulkhead: A thick, insulated, portable wall-like
device used to compartmentalize a temperature-controlled
truck or trailer. See bulkhead.
HPCO (High Pressure Cut Out Switch): A
pressure-operated switch that opens to stop unit operation
when discharge pressure reaches a predetermined maximum.
Multi-Temp: A Thermo King truck or trailer unit capable of
maintaining different set-points in multiple compartments.
193
Glossary
no. 1 diesel fuel: A grade of diesel fuel formulated to
prevent “jelling” in low ambient temperatures.
receiver tank: A refrigerant storage device included in
nearly all Thermo King units.
no. 2 diesel fuel: A grade of diesel fuel formulated for
moderate to warm ambient temperatures.
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.
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.
pre-heat: The heating of diesel engine glow plugs prior to
start-up. Some engines use an intake manifold heater rather
than glow plugs.
pre-trip inspection: Checking the operation of a
refrigeration system before loading.
psi: Pounds per square inch. A unit of pressure.
1 psi = 0.069 bar = 6.89 kPa.
psig: Pounds per Square Inch Gauge. Pressure in pounds per
square inch as displayed by a gauge calibrated to zero when
open to the atmosphere.
194
refrigerant oil: A special oil used to lubricate compressors in
refrigeration systems.
remote evaporator: A separate evaporator unit located in a
second or third compartment of a multi-temperature truck or
trailer unit.
return air bulkhead: A structure (metal or plastic) mounted
in the front of a trailer and designed to prevent restriction of
return air flow to the Thermo King unit due to improper
loading. See bulkhead.
return air temperature: The temperature of the air
returning to the evaporator. See box temperature.
rpm: Revolutions per minute.
setpoint: The temperature selected on a thermostat or
microprocessor controller. This is normally the desired box
temperature.
Glossary
short cycling: When a refrigeration unit cycles between the
heat and cool modes more often than normal.
sight glass: A system component that permits visual
inspection of oil or refrigerant level and condition.
thermostat: A device that controls unit modes of operation to
maintain a selected box temperature.
top freeze: When the top portion of perishable cargo is
damaged by freezing temperatures discharged from the
refrigeration unit. This may occur near the front of the box
when product is placed too close to the cold, discharge air flow.
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.
195
Maintenance Inspection Schedule
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
Annual/ Inspect/Service These Items
4,500
Hours
Microprocessor
•
Run Pretrip Test
Engine
•
Check fuel supply.
•
Check engine oil level.
•
•
•
•
Inspect belts for condition and proper tension.
•
•
•
•
Check engine oil pressure hot, on high speed (should display “OK”).
•
•
•
•
Listen for unusual noises, vibrations, etc.
•
•
•
•
Check engine coolant level and antifreeze protection (-30 F [-40 C]).
•
•
•
Drain water from fuel tank and check vent.
*3,000 hours or two years, whichever occurs first.
196
Maintenance Inspection Schedule
Pretrip
Annual/ Inspect/Service These Items
4,500
Hours
Every
1,500
Hours
Every
3,000
Hours*
•
•
•
Inspect/clean electric fuel pump filter.
•
•
•
Check condition of drive coupling bushings per Service Bulletin T&T 171.
•
Check engine mounts for wear.
•
Replace EMI 3000 air cleaner element at 3,000 hours or two years
(whichever occurs first).
•
Replace EMI 3000 fuel filter/water separator.
•
Change engine oil and oil filter (hot). Requires oil with API Rating CJ-4 or
better.
NOTE: For high biodiesel use (B20) the engine oil and oil filter should be
changed every 1,500 hours.
—
Replace Timing Belt, Water Pump, Belt Tensioner and Idler Pulley with
Timing Belt Kit every 6,000 hours. When replacing the Timing Belt,
inspect the High Pressure Fuel Pump and replace as necessary.
—
Change ELC (red) engine coolant every 5 years or 12,000 hours. Units
equipped with ELC have an ELC nameplate on the expansion tank (see
page 22).
*3,000 hours or two years, whichever occurs first.
197
Maintenance Inspection Schedule
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
Annual/ Inspect/Service These Items
4,500
Hours
Electrical
•
•
•
Inspect battery terminals and electrolyte level.
•
•
•
Inspect wire harness for damaged wires or connections.
•
Inspect AC generator and alternator wire connections for tightness.
•
Inspect electric motors.
•
Inspect and if required re-torque all electrical connections on the
contactors in the Fan Control Box to 15 in-lb (1.7 N•m).
•
Inspect and if required re-torque all electrical connections on the
contactors in the High Voltage Box in Smart Power units. Torque the
connections on the Compressor Motor Contactor, Phase Contactors, and
Overload Relay to 22 in-lb (2.5 N•m). Torque the connections on all other
contactors to 15 in-lb (1.7 N•m).
*3,000 hours or two years, whichever occurs first.
198
Maintenance Inspection Schedule
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
Annual/ Inspect/Service These Items
4,500
Hours
Refrigeration
•
•
•
•
Check refrigerant level.
•
•
•
Check for proper suction pressure.
•
•
•
Check compressor oil level and condition.
•
Check compressor efficiency and pump down refrigeration system.
•
Empty oil collection container mounted on compressor.
—
Replace dehydrator and check discharge and suction pressure every two
(2) years.
*3,000 hours or two years, whichever occurs first.
199
Maintenance Inspection Schedule
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
Annual/ Inspect/Service These Items
4,500
Hours
Structural
•
•
•
•
Visually inspect unit for fluid leaks.
•
•
•
•
Visually inspect unit for damaged, loose or broken parts (includes air
ducts and bulkheads).
•
•
•
Inspect idlers for bearing wear (noise).
•
•
•
Clean entire unit including condenser and evaporator coils and defrost
drains.
•
•
•
Check all unit and fuel tank mounting bolts, brackets, lines, hoses, etc.
Electrical
•
•
•
Inspect wire harness for damaged wires or connections.
•
•
•
Inspect/replace DC fan motors.
Structural
•
•
•
•
Visually inspect unit for fluid leaks.
*3,000 hours or two years, whichever occurs first.
200
Maintenance Inspection Schedule
Annual/ Inspect/Service These Items
4,500
Hours
Pretrip
Every
1,500
Hours
Every
3,000
Hours*
•
•
•
•
Visually inspect unit for damaged, loose, or broken parts.
•
•
•
Clean entire unit including evaporator coils and defrost drains.
•
Check all unit mounting bolts, brackets, lines, hoses, etc.
*3,000 hours or two years, whichever occurs first.
201
Serial Number Locations
Unit: Unit serial number plate is located on the lower
roadside frame near the generator pulley.
Engine: The engine serial number is located on the back of
the engine near the flywheel housing.
Compressor: Stamped between the cylinders on the front
end above the oil pump.
Figure 180: Compressor Serial Number Location
202
Serial Number Locations
1
2
1. On Rear of Evaporator Housing
2. On Frame in Engine Compartment (near battery)
Figure 181: Engine Serial Number Location
(Stamped on back of engine)
Figure 182: Unit Serial Number Plates
203
Serial Number Locations
1
2
3
1.
2.
3.
Unit Serial Number
Unit Model
Bill of Material Number
Figure 183: Laminated Serial Number Plate
204
Emergency Cold Line
The answering service at the factory will assist you in reaching
a dealer to get the help you need. The Cold Line is answered 24
hours a day by personnel who will do their best to get you
quick service at an authorized Thermo King Dealer.
AMA1585
If you can’t get your rig rolling, and you have tried the Thermo
King North American Service Directory (available from any
Thermo King dealer) to reach a dealer without success, then
call the Toll Free Emergency Cold Line Number
(888) 887-2202.
205
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.
206
CALIFORNIA
Proposition 65 Warning
Diesel exhaust is a chemical known to
the State of California to cause cancer.
207
Index
A
alarm codes 145
corrective action 148
types 145
amber status light 36
automatic start/stop safety precautions 12
B
battery inspection 38
belt tension, specifications 180
belts inspection 38
C
coils inspection 39
compressor oil sight glass 31
control panel 41
display 41
keys 45
CYCLE-SENTRY
start-stop controls 26
208
D
data logging 27
defrost 29
defrost drain inspection 39
Defrost key 44, 46
door inspection 39
E
ELC (extended life coolant) 22
electrical components, specifications 183
electrical control system, specifications 182
electrical hazards 12
electrical inspection 38
electrical standby, specifications 186
electronic throttling valve (ETV) 23
Emergency Cold Line 205
EMI 3000 23
engine compartment components 30
engine coolant level 38
Index
engine oil dipstick 31
engine oil level 38
engine, specifications 177
ETV (electronic throttling valve) 23
extended life coolant (ELC) 22
F
first aid for refrigerant 15
first aid for refrigerant oil 15
FreshSet 28
front doors
opening 30
fuel level 38
fuses
base controller 32
H
high pressure cutout switch 32
high pressure relief valve 32
HMI control panel 41
I
introduction 7
J
jump starting 173
L
low oil level switch 32
low oil pressure switch 32
M
maintenance inspection schedule 196
manual pretrip inspection 38
microprocessor On/Off switch 41
Mode key 46
O
Off key 44, 46
On key 43, 45
overload relay 32
P
post-loading inspection 142
preheat buzzer 32
pretrip inspection, manual 38
protection devices 31
209
Index
R
rear remote control panel 124
receiver tank sight glass 31
refrigerant oil safety 15
refrigerant safety 13
refrigeration system, specifications 181
remote status light 35
S
safety precautions 11
automatic start/stop operation 12
electrical hazards 12
first aid for refrigerant 15
first aid for refrigerant oil 15
general safety practices 11
refrigerant 13
refrigerant oil 15
Serial Number Locations 202
smart FETs 32
SMART REEFER 2 (SR-2) Controller 24, 40
soft keys 46
210
specifications
electric fuel heater 188
SR-2 Controller 24, 40
status light, remote 35
structural inspection 38
U
unit description 19
W
warranty 189
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.
PrecedentTM
S-600M
TK 55747-2-OP (Rev. 1, 12/14)
©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.
PrecedentTM
S-600M
TK 55747-2-OP (Rev. 1, 12/14)
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